Mitsibushi Galant Workshop Manual

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00109000812
General . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication . . . . . . . . . . . . .
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . .
Intake and Exhaust . . . . . . . . . . . .
Engine Electrical . . . . . . . . . . . . . . .
Engine and Emission Control . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission . . . . . . . . . . .
Automatic Transmission . . . . . . . .
Front Axle . . . . . . . . . . . . . . . . . . . . . .
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
Wheel and Tyre . . . . . . . . . . . . . . . . .
Power Plant Mount . . . . . . . . . . . . . .
Front Suspension . . . . . . . . . . . . . . .
Rear Suspension . . . . . . . . . . . . . . .
Service Brakes . . . . . . . . . . . . . . . . .
Parking Brakes . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . .
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
WORKSHOP MANUAL
FOREWORD
This Workshop Manual contains procedures for
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and
installation. Use the following manuals in
combination with this manual as required.
TECHNICAL INFORMATION MANUAL
PYDE9604
WORKSHOP MANUAL
ENGINE GROUP PWEEjjjj
(Looseleaf edition)
ELECTRICAL WIRING PHDE9608
BODY REPAIR MANUAL PBDE9609
PARTS CATALOGUE
Sedan B608S107Aj
Wagon B608T507Aj
All information, illustrations and product
descriptions contained in this manual are current
as at the time of publication. We, however, reserve
the right to make changes at any time without prior
notice or obligation.
EMitsubishi Motors Corporation Dec. 1996
Interior and Supplemental
Restraint System (SRS) . . . . . . . . .
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . . .
WARNING!
(1) Improper service or maintenance of any component of the SRS and seat belt with pre-tensioner,
or any SRS-related component, can lead to personal injury or death to service personnel (from
inadvertent firing of the air bag and seat belt with pre-tensioner) or to the driver and passenger
(from rendering the SRS inoperative).
(2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove
the SRS-ECU, air bag module (drivers side and front passengers side), clock spring, side
impact sensor, front seat assembly (side air bag module) and seat belt with pre-tensioner before
drying or baking the vehicle after painting.
SRS-ECU, air bag module, clock spring and side impact sensor: 93_C or more
Seat belt with pre-tensioner: 90_C or more
(3) Service or maintenance of any SRS component and seat belt with pre-tensioner or SRS-related
component must be performed only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
52B - Supplemental Restraint System (SRS), before beginning any service or maintenance
of any component of the SRS and seat belt with pre-tensioner or any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
00-1
GENERAL
CONTENTS 00109000829
HOW TO USE THIS MANUAL 2 . . . . . . . . . . . . . .
Scope of Maintenance, Repair and Servicing
Explanations 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definition of Terms 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Indication of Tightening Torque 2 . . . . . . . . . . . . . . . .
Model Indications 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Explanation of Manual Contents 4 . . . . . . . . . . . . . . .
HOW TO USE
TROUBLESHOOTING/INSPECTION SERVICE
POINTS 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Contents 6 . . . . . . . . . . . . . . . . . . . . .
Diagnosis Function 7 . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Use the Inspection Procedures 9 . . . . . . . .
Connector Measurement Service Points 10 . . . . . . .
Connector Inspection 11 . . . . . . . . . . . . . . . . . . . . . . . .
Inspection Service Points for a Blown Fuse 12 . . .
Points to Note for Intermittent Malfunctions 12 . . . .
VEHICLE IDENTIFICATION 13 . . . . . . . . . . . . . . .
Vehicle Information Code Plate 13 . . . . . . . . . . . . . . .
Models 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Code 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chassis Number 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Model Number 17 . . . . . . . . . . . . . . . . . . . . . . .
MAJOR SPECIFICATIONS 18 . . . . . . . . . . . . . . . .
PRECAUTIONS BEFORE SERVICE 20 . . . . . . .
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
AND SEAT BELT WITH
PRE-TENSIONER 24 . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPORT LOCATIONS FOR LIFTING AND
JACKING 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Positions for a Garage Jack and Axle
Stands 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Positions for a Single-Post Lift or
Double-Post Lift 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Positions and Support Method for an
H-Bar Lift 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD PART/TIGHTENING-TORQUE
TABLE 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL - How to Use This Manual 00-2
HOW TO USE THIS MANUAL 00100010302
SCOPE OF MAINTENANCE, REPAIR
AND SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Note, however,
that for engine and transmission-related component
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and
installation procedures for major components.
For detailed information concerning the inspection,
checking, adjustment, disassembly and reassembly
of the engine, transmission and major components
after they have been removed from the vehicle,
please refer to separate manuals covering the
engine and the transmission.
ON-VEHICLE SERVICE
On-vehicle Service is procedures for performing
inspections and adjustments of particularly
important locations with regard to the construction
and for maintenance and servicing, but other
inspection (for looseness, play, cracking, damage,
etc.) must also be performed.
INSPECTION
Under this title are presented inspection and
checking procedures to be performed by using
special tools and measuring instruments and by
feeling, but, for actual maintenance and servicing
procedures, visual inspections should always be
performed as well.
DEFINITION OF TERMS
STANDARD VALUE
Indicates the value used as the standard for judging
the quality of a part or assembly on inspection
or the value to which the part or assembly is
corrected and adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a
part or assembly on inspection and means the
maximum or minimum value within which the part
or assembly must be kept functionally or in strength.
It is a value established outside the range of
standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be
completed in a shorter time).
CAUTION
Indicates the presentation of information particularly
vital to the worker during the performance of
maintenance and servicing procedures in order to
avoid the possibility of injury to the worker, or
damage to component parts, or a reduction of
component or vehicle function or performance, etc.
INDICATION OF TIGHTENING TORQUE
The tightening torque shown in this manual is a
basic value with a tolerance of 10% except the
following cases when the upper and lower limits
of tightening torque are given.
(1) The tolerance of the basic value is within 10%.
(2) Special bolts or the like are in use.
(3) Special tightening methods are used.
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
2000: Indicates models equipped with the 2,000 mL <4G63> petrol engine.
2500: Indicates models equipped with the 2,500 mL <6A13> petrol engine.
2000D: Indicates models equipped with the 2,000 mL <4D68> diesel engine.
MPI: Indicates the multi-point injection, or engine equipped with the multi-point injection.
SOHC: Indicates an engine with the single overhead camshaft, or models equipped with such an
engine.
M/T: Indicates the manual transmission, or models equipped with the manual transmission.
A/T: Indicates the automatic transmission, or models equipped with the automatic transmission.
A/C: Indicates the air conditioner.
EXPLANATION OF MANUAL CONTENTS
Indicates procedures to be performed
beforethe work in that section is started,
and procedures to be performed after
the work in that section is finished.
Indicates (by symbols) where lubrica-
tion is necessary.
Maintenance and Servicing Procedures
The numbers provided within the diagram indi-
cate the sequence for maintenance and servic-
ing procedures.
D Removal steps:
The part designation number corresponds
to the number in the illustration to indicate
removal steps.
D Disassembly steps:
The part designation number corresponds
to the number in the illustration to indicate
disassembly steps.
D Installation steps:
Specified in case installation is impossible
in reverse order of removal steps. Omitted
if installation is possible in reverse order of
removal steps.
D Reassembly steps:
Specified in case reassembly is impossible
in reverse order of disassembly steps.
Omitted if reassemby is possible in reverse
order of disassembly steps.
Classifications of Major Maintenance/Service Points
When there are major points relative to maintenance and servicing procedures
(suchas essential maintenanceand servicepoints, maintenanceand servicestan-
dard values, information regarding the use of special tools, etc.), these are ar-
ranged together as major maintenance and service points and explained in detail.
AA" : Indicates that there are essential points for removal or disassembly.
"AA : Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for lubrica-
tion and for application of sealants and adhe-
sives is provided, by using symbols, in the dia-
gram of component parts or on the page follow-
ing the component parts page, and explained.
: Grease
(multipurpose grease unless there is a
brand or type specified)
: Sealant or adhesive
: Brake fluid or automatic transmissionfluid
: Engine oil, gear oil or air conditioner com-
pressor oil
: Adhesive tape or butyl rubber tape
Component Diagram
A diagram of the component parts is
provided near the front of each section
in order to give a reader a better under-
standing of the installed condition of
component parts.
Denotes tightening torque.
For bolts and nuts which do not
have a tightening torque listed,
refer to the Standard Parts-
tightening-torque Table.
indicates that there is
a continuity between the termi-
nals.
indicates terminals to
which battery voltage is applied.
Indicates the
section title.
Indicates the
group num-
ber.
Indicates the
page number.
Indicates the
group title.
Denotes non-reus-
able part.
Repair kit or set parts
are shown. (Only very
frequently used parts
are shown.)
Operating procedures, cau-
tions, etc. on removal, installa-
tion, disassembly and reas-
sembly are described.
The title of the page (following
the page on which the diagram
of component parts is pres-
ented) indicating the locations of
lubrication and sealing proce-
dures.
GENERAL - How to Use Troubleshooting/Inspection Service Points 00-6
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE
POINTS 00100020152
Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline
described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems
still follow this outline.
TROUBLESHOOTING CONTENTS
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis
flow is different from that given below, or if additional explanation is required, the details of such
differences or additions will also be listed.
Diagnosis method
Gathering information
from the customer.
Check trouble symptom.
Reoccurs Does not reoccur.
Read the diagnosis code
No diagnosis code
or communication
with MUT-II not
possible
Refer to the INSPECTION
CHART FOR TROUBLE
SYMPTOMS (Refer to
applicable group.)
Diagnosis code
displayed.
Read the diagnosis code
Diagnosis code
displayed.
No diagnosis
code
After taking note of the
malfunction code, erase
the diagnosis code
memory
Recheck trouble symptom.
Diagnosis code
displayed.
Read the diagnosis codes.
No diagnosis
code
Refer to the INSPECTION CHART FOR DIAGNOSIS
CODES (Refer to applicable group.)
INTERMITTENT MALFUNCTIONS (Refer to P.00-12.)
2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS
If verification of the trouble symptoms is difficult, procedures for checking operation and verifying
trouble symptoms are shown.
3. DIAGNOSIS FUNCTION
Details which are different from those in the Diagnosis Function section on the next page are listed.
4. INSPECTION CHART FOR DIAGNOSIS CODES
5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-9 for how
to read the inspection procedures.)
6. INSPECTION CHART FOR TROUBLE SYMPTOMS
If there are trouble symptoms even though the results of inspection using the MUT-II show that all
diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means
of this chart.
7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM
Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection
Chart for Trouble Symptoms. (Refer to P.00-9 for how to read the inspection procedures.)
8. SERVICE DATA REFERENCE TABLE
Inspection items and normal judgement values have been provided in this chart as reference information.
9. CHECK AT ECU TERMINALS
Terminal numbers for the ECU connectors, inspection items and standard values have been provided
in this chart as reference information.
10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE
When there are inspection procedures using an oscilloscope, these are listed here.
DIAGNOSIS FUNCTION
METHOD OF READING DIAGNOSIS CODES
WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and take a
reading of the diagnosis codes.
Caution
Turn off the ignition switch before connecting or
disconnecting the MUT-II.
MUT-II
WHEN USING THE WARNING LAMP
1. Use the special tool to earth No.1 terminal (diagnosis
control terminal) of the diagnosis connector.
2. To check ABS system, remove the valve relay.
NOTE
That is because the valve relay is off and the warning
lamp remains illuminated if there is a fault in the ABS
system.
3. Turn off the ignition switch.
4. Read out a diagnosis code by observing how the warning
lamp flashes.
Applicable systems
System name Warning lamp name
MPI Engine warning lamp
A/T Neutral position indicator lamp
ABS ABS warning lamp
TCL TCL-OFF indicator lamp
Indication of diagnosis code by warning lamp
When the diagnosis code No.24 is output When no diagnosis code is output*
On
Off
1.5 secs. 0.5 sec.
0.5 sec.
Pause
time 3
secs.
Tens
signal
Place
division
2 secs.
Units
signal
On
Off
0.5 sec. <MPI, A/T>
0.25 sec. <ABS>
NOTE
*: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.52 to
be output.
METHOD OF ERASING DIAGNOSIS CODES
WHEN USING THE MUT-II
Connect the MUT-II to the diagnosis connector and erase the diagnosis code.
Caution
Turn off the ignition switch before connecting or disconnecting the MUT-II.
WHEN NOT USING THE MUT-II
(1) Turn the ignition switch to OFF.
(2) After disconnecting the battery cable from the battery ( - ) terminal for 10 seconds or more, reconnect
the cable.
(3) After the engine has warmed up, run it at idle for about 15 minutes.
Diagnosis connector
MB991529
GENERAL - How to Use Troubleshooting/Inspection Service Points
00-9
HOW TO USE THE INSPECTION PROCEDURES
The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors,
components, the ECU and the harnesses between connectors, in that order. These inspection procedures
follow this order, and they first try to discover a problem with a connector or a defective component.
D Indicator does not turn on or off even if control
mode switch is pressed.
D Indicator switch should not be illuminated is
illuminated.
Probable cause
OK
OK
OK
Measure at switch connector A-44
D Disconnect the connector, and measure at the harness
side.
D Voltage between terminal 6 - earth and terminal 8 -
earth
OK: Approx. 5V
OK
NG
Check the following connector. A-44 Repair
OK
Replace the ECS-ECU.
In the above cases, the ECS switch circuit is defective or the indicator
circuit is defective.
CHECKING PROCEDURE 4
2. Indicates inspection carried out using the
MUT-II.
Indicates the operation and inspection proce-
dures.
Indicates the OK judgement conditions.
3. Detailed inspection procedures (methods)
such as component inspection and circuit
inspection are listed on a separate page, and
are given here for reference.
5. Inspect the contact condition at each connector terminal.
(Refer to Connector Inspection Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Caution
After carrying out connector inspection, always be sure to
reconnect the connector as it was before.
6. Confirm that there are trouble symptoms. If trouble symptoms have
disappeared, the connector may have been inserted incorrectly and the
trouble symptom may have disappeared during inspection.
If it seems that trouble symptoms still remain, proceed to the next page of
instructions.
7. If trouble symptoms still remain up to this stage, there is a possibility that there is an
open or short circuit in the harness between the connectors, so check the harness.
Alternatively, the cause may be a defective ECU, so try replacing the ECUand check
if the trouble symptom disappears.
NG
ECU switch component inspection (Refer to P.3-44.)
NG
1. Comments on the diagnosis code or trouble
symptom above.
MUT-II Data list
17 Control mode selection switch
OK: Voltage changes between approx. 0V approx.
2.5V approx. 5V when the switch is operated.
4. Indicates voltage and resistance to be measured at a particular
connector.
(Refer to Connector Measurement Service Points.)
The connector position can be located in the wiring diagram in the
electrical wiring manual by means of this symbol.
Indicates operation and inspection procedures, inspection terminals
and inspection conditions.
Indicates the OK judgement conditions.
HARNESS INSPECTION
Check for an open or short circuit in the harness between the terminals which were defective according
to the connector measurements. Carry out this inspection while referring to the electrical wiring manual.
Here, Check harness between power supply and terminal xx also includes checking for blown fuses.
For inspection service points when there is a blown fuse, refer to Inspection Service Points for a Blown
Fuse.
MEASURES TO TAKE AFTER REPLACING THE ECU
If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure
from the beginning.
CONNECTOR MEASUREMENT SERVICE POINTS
Turn the ignition switch to OFFwhen connecting disconnecting
the connectors, and turn the ignition switch to ON when
measuring if there are no instructions to be contrary.
IF INSPECTING WITH THE CONNECTOR CONNECTED
(WITH CIRCUIT IN A CONDITION OF CONTINUITY)
Waterproof Connectors
Be sure to use the special tool (harness connector). Never
insert a test bar from the harness side, because to do so
will reduce the waterproof performance and result in corrosion.
Ordinary (non-waterproof) Connectors
Check by inserting the test bar from the harness side. Note
that if the connector (control unit, etc.) is too small to permit
insertion of the test bar, it should not be forced; use a special
tool (the extra-thin probe in the harness set for checking
for this purpose.
IF INSPECTING WITH THE CONNECTOR DISCONNECTED
<When Inspecting a Female Pin>
Use the special tool (inspection harness for connector pin
contact pressure in the harness set for inspection).
The inspection harness for connector pin contact pressure
should be used. the test bar should never be forcibly inserted,
as it may cause a defective contact.
<When Inspecting a Male Pin>
Touch the pin directly with the test bar.
Caution
At this time, be careful not to short the connector pins
with the test bars. To do so may damage the circuits
inside the ECU.
Harness connector
Extra-thin probe
Test bar
Connector
Inspection harness
for connector pin
contact pressure
CONNECTOR INSPECTION
VISUAL INSPECTION
D Connector is disconnected or improperly connected
D Connector pins are pulled out
D Due to harness tension at terminal section
D Low contact pressure between male and female terminals
D Lowconnection pressure due to rustedterminals or foreign
matter lodged in terminals
CONNECTOR PIN INSPECTION
If the connector pin stopper is damaged, the terminal
connections (male and female pins) will not be perfect even
if the connector body is connected, and the pins may pull
out of the reverse side of the connector. Therefore, gently
pull the harnesses one by one to make sure that no pins
pull out of the connector.
CONNECTOR ENGAGEMENT INSPECTION
Use the special tool (connector pin connection pressure
inspection harness of the inspection harness set) to inspect
the engagement of the male pins and females pins. (Pin
drawing force : 1 N or more)
Connector disconnected or improperly
connected
Defective connector contact
Harness wire breakage
at terminal section
Low contact pressure
MB991219
INSPECTION SERVICE POINTS FOR A BLOWN
FUSE
Remove the fuse and measure the resistance between the
load side of the fuse and the earth. Set the switches of all
circuits which are connected to this fuse to a condition of
continuity. If the resistance is almost 0 W at this time, there
is a short somewhere between these switches and the load.
If the resistance is not 0 W, there is no short at the present
time, but a momentary short has probably caused the fuse
to blow.
The main causes of a short circuit are the following.
D Harness being clamped by the vehicle body
D Damage to the outer casing of the harness due to wear
or heat
D Water getting into the connector or circuitry
D Human error (mistakenly shorting a circuit, etc.)
POINTS TO NOTE FOR INTERMITTENT
MALFUNCTIONS
Intermittent malfunctions often occur under certain conditions,
and if these conditions can be ascertained, determining the
cause becomes simple. In order to ascertain the conditions
under which an intermittent malfunction occurs, first ask the
customer for details about the driving conditions, weather
conditions, frequency of occurrence and trouble symptoms,
and then try to recreate the trouble symptoms. Next, ascertain
whether the reason why the trouble symptom occurred under
these conditions is due to vibration, temperature or some
other factor. If vibration is thought to be the cause, carry
out the following checks with the connectors and components
to confirm whether the trouble symptom occurs.
The objects to be checked are connectors and components
which are indicated by inspection procedures or given as
probable causes (which generates diagnosis codes or trouble
symptoms.)
D Gently shake the connector up, down and to the left and
right.
D Gently shake the wiring harness up, down and to the
left and right.
D Gently rock each sensor and relay, etc. by hand.
D Gently shake the wiring harness at suspensions and other
moving parts.
NOTE
If determining the cause is difficult, the flight recorder function
of the MUT-II can also be used.
Battery
Fuse
Load
switch
Load
Connector
inspection
0 W
GENERAL - Vehicle Identification 00-13
VEHICLE IDENTIFICATION 00100540085
VEHICLE INFORMATION CODE PLATE
LOCATION
Vehicle information code plate is riveted on the toeboard
inside the engine compartment.
CODE PLATE DESCRIPTION
The plate shows model code, engine model, transmission
model, and body colour code.
No. Item Contents
1 MODEL EA2A EA2A: Vehicle model
SNHEQL6
SNHEQL6: Model series
2 ENGINE 4G63 Engine model
3 EXT B60B Exterior code
4 TRANS
AXLE
F5M42 Transmission code
5 COLOR B60 41H03V B60: Body colour code
INT OPT
41H: Interior code
03V: Equipment code
For monotone colour vehicles, the body colour code shall
be indicated. For two-tone or three-way two-tone colour
vehicles, each colour code only shall be indicated in series.
MODELS 00100030223
<SEDAN>
Model code Engine model Transmission model Fuel supply system
EA2A SNJEQL6 4G63-SOHC(1,997 mL) F5M42(2WD-5M/T) MPI
SNHEQL6
SRHEQL6 F4A42 (2WD-4A/T)
EA5A SNGEQL6 6A13-SOHC (2,497 mL) F5M42(2WD-5M/T) MPI
SRGEQL6 F4A42 (2WD-4A/T)
EA6A SNHFQL6 4D68-SOHC (1,998 mL) F5M42(2WD-5M/T) Electronically
controlled injection
pump
EA2A SNJEQL6C 4G63-SOHC(1,997 mL) F5M42(2WD-5M/T) MPI
SNHEQL6C
SRHEQL6C F4A42 (2WD-4A/T)
1
2
3
4
5
Model code Fuel supply system Transmission model Engine model
EA5A SNGEQL6C 6A13-SOHC (2,497 mL) F5M42(2WD-5M/T) MPI
SRGEQL6C F4A42 (2WD-4A/T)
EA6A SNHFQL6C 4D68-SOHC (1,998 mL) F5M42(2WD-5M/T) Electronically
pump
EA2A SNHEQR6 4G63-SOHC(1,997 mL) F5M42(2WD-5M/T) MPI
SRHEQR6 F4A42 (2WD-4A/T)
EA5A SNGEQR6 6A13-SOHC (2,497 mL) F5M42(2WD-5M/T) MPI
SRGEQR6 F4A42 (2WD-4A/T)
EA6A SNHFQR6 4D68-SOHC (1,998 mL) F5M42(2WD-5M/T) Electronically
pump
<WAGON>
Model code Engine model Transmission model Fuel supply system
EA2W LNJEQL6 4G63-SOHC(1,997 mL) F5M42(2WD-5M/T) MPI
LNHEQL6
LRHEQL6 F4A42 (2WD-4A/T)
EA5W LNGEQL6 6A13-SOHC (2,497 mL) F5M42(2WD-5M/T) MPI
LRGEQL6 F4A42 (2WD-4A/T)
EA6W LNHFQL6 4D68-SOHC (1,998 mL) F5M42(2WD-5M/T) Electronically
pump
EA2W LNJEQL6C 4G63-SOHC(1,997 mL) F5M42(2WD-5M/T) MPI
LNHEQL6C
LRHEQL6C F4A42 (2WD-4A/T)
EA5W LNGEQL6C 6A13-SOHC (2,497 mL) F5M42(2WD-5M/T) MPI
LRGEQL6C F4A42 (2WD-4A/T)
EA6W LNHFQL6C 4D68-SOHC (1,998 mL) F5M42(2WD-5M/T) Electronically
pump
EA2W LNHEQR6 4G63-SOHC(1,997 mL) F5M42(2WD-5M/T) MPI
LRHEQR6 F4A42 (2WD-4A/T)
EA5W LNGEQR6 6A13-SOHC (2,497 mL) F5M42(2WD-5M/T) MPI
LRGEQR6 F4A42 (2WD-4A/T)
EA6W LNHFQR6 4D68-SOHC (1,998 mL) F5M42(2WD-5M/T) Electronically
pump
MODEL CODE 00100040257
No. Items Contents
1 Development EA: MITSUBISHI GALANT
2 Engine type 2: 2,000 mL petrol engine
5: 2,500 mL petrol engine
6: 2,000 mL diesel engine
3 Sort A: Passenger car
W: Wagon
4 Body style S: 4-door sedan
L: 4-door station wagon
5 Transmission type N: 5-speed manual
transmission
R: 4-speed automatic
transmission
6 Trim level J: GLX
H: GLS
G: V6-24
7 Specification engine
feature
E: MPI-SOHC
F: Turbocharger with
intercooler
8 Exhaust system
specification
Q: With catalytic converter
None: Without catalytic
converter
9 Steering wheel location L: Left hand
R: Right hand
10 Destination 6: For Europe
C: Central Europe
1 2 3 4 5 6 7 8 9 10
CHASSIS NUMBER 00100560104
The chassis number is stamped on the toeboard inside the
engine compartment.
1 2 3 4 5 6 7 8 9 11 10
No. Items Contents
1 Fixed figure J Asia
2 Distribution channel M Japan channel
3 Destination A For Europe, right hand drive
B For Europe, left hand drive
4 Body style S 4-door sedan
L 4-door station wagon
5 Transmission type N 5-speed manual transmission
R 4-speed automatic transmission
6 Development order EA GALANT
7 Engine 2 4G63: 1,997 mL petrol engine
5 6A13: 2,498 mL petrol engine
6 4D68: 1,998 mL diesel engine
8 Sort A Passenger car
9 Model year V 1997
10 Plant Z Okazaki Motor Vehicle Works
11 Serial number - -
ENGINE MODEL NUMBER 00100570107
1. The engine model number is stamped at the cylinder
block as shown in the following.
Engine model Engine displacement mL
4G63
6A13
4D68
1,997
2,498
1,998
2. The engine serial number is stamped near the engine
model number.
Engine serial number AA0201 to YY9999
<4G63>
Front of vehicle
Front of vehicle
<6A13>
<4D68>
Front of vehicle
GENERAL - Major Specifications 00-18
MAJOR SPECIFICATIONS 00100080143
<Sedan>
2
5
1
4
8
7 6
3
9
Items
EA2AS
NJEQL6,
NJEQL6C
EA2AS
NHEQL6,
NHEQL6C,
NHEQR6
EA2AS
RHEQL6,
RHEQL6C,
RHEQR6
EA5AS
NGEQL6,
NGEQL6C,
NGEQR6
EA5AS
RGEQL6,
RGEQL6C,
RGEQR6
EA6AS
NHFQL6,
NHFQL6C,
NHFQR6
Vehicle Overall length 1 4,630 4,630 4,630 4,630 4,630 4,630
dimensions
Overall width 2 1,740 1,740 1,740 1,740 1,740 1,740
mm
Overall height
(unladen)
3 1,415 1,415 1,415 1,415 1,415 1,415
Wheelbase 4 2,635 2,635 2,635 2,635 2,635 2,635
Track-front 5 1,510 1,510 1,510 1,510 1,510 1,510
Track-rear 6 1,505 1,505 1,505 1,505 1,505 1,505
Overhang-front 7 930 930 930 930 930 930
Overhang-rear 8 1,065 1,065 1,065 1,065 1,065 1,065
Ground clear-
ance (unladen)
9 150 150 150 150 150 150
Vehicle Kerb weight 1,260 1,280 1,290 1,310 1,300
weight kg
Max. gross vehicle
weight
1,775 1,805 1,795
Max. axle weight
rating-front
925 955 955
Max. axle weight
rating-rear
850 850 840
Seating capacity 5
Engine Model No. 4G63 6A13 4D68
Total displacement
mL
1,997 2,498 1,998
Transmis- Model No. F5M42 F4A42 F5M42 F4A42 F5M42
sion
Type 5-speed manual 4-speed
automatic
5-speed
manual
4-speed
automatic
5-speed
manual
Fuel system Fuel supply
system
Electronically controlled multi-point injection Electroni-
cally con-
trolled fuel
injection
GENERAL - Major Specifications 00-19
<Wagon>
2
5
1
4 8
7
6
3
9
Items
EA2WL
NJEQL6,
NJEQL6C
EA2WL
NHEQL6,
NHEQL6C,
NHEQR6
EA2WL
RHEQL6,
RHEQL6C,
RHEQR6
EA5WL
NGEQL6,
NGEQL6C,
NGEQR6
EA5WL
RGEQL6,
RGEQL6C,
RGEQR6
EA6WL
NHFQL6,
NHFQL6C,
NHFQR6
Vehicle Overall length 1 4,680 4,680 4,680 4,680 4,680 4,680
dimensions
Overall width 2 1,740 1,740 1,740 1,740 1,740 1,740
mm
Overall height
(unladen)
3 1,495 1,495 1,495 1,495 1,495 1,495
Wheelbase 4 2,635 2,635 2,635 2,635 2,635 2,635
Track-front 5 1,510 1,510 1,510 1,510 1,510 1,510
Track-rear 6 1,505 1,505 1,505 1,505 1,505 1,505
Overhang-front 7 930 930 930 930 930 930
Overhang-rear 8 1,115 1,115 1,115 1,115 1,115 1,115
Ground clear-
ance (unladen)
9 150 150 150 150 150 150
Vehicle Kerb weight 1,310 1,310 1,330 1,340 1,360 1,350
weight kg
Max. gross vehicle
weight
1,830 1,860 1,850
Max. axle weight
rating-front
920 950
Max. axle weight
rating-rear
910 910 900
Seating capacity 5
Engine Model No. 4G63 6A13 4D68
Total displacement
mL
1,997 2,498 1,998
Transmis- Model No. F5M42 F4A42 F5M42 F4A42 F5M42
sion
Type 5-speed manual 4-speed
automatic
5-speed
manual
4-speed
automatic
5-speed
manual
Fuel system Fuel supply
system
Electronically controlled multi-point injection Electroni-
cally con-
trolled fuel
injection
GENERAL - Precautions Before Service 00-20
PRECAUTIONS BEFORE SERVICE 00100050229
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), SEAT BELT WITH PRE-TENSIONER
1. Items to follow when servicing SRS
(1) Be sure to read GROUP 52B - Supplemental Restraint System (SRS).
For safe operations, please follow the directions and heed all warnings.
(2) Wait at least 60 seconds after disconnecting the battery cable before doing any further work.
The SRS system is designed to retain enough voltage to deploy the air bag even after the battery
has been disconnected. Serious injury may result from unintended air bag deployment if work
is done on the SRS system immediately after the battery cable is disconnected.
(3) Warning labels must be heeded when servicing or handling SRS components and seat belt with
pre-tensioner. Warning labels are located in the following locations.
D Sun visor
D Glove box
D SRS air bag control unit
D Steering wheel
D Steering gear and linkage
D Air bag module (drivers side and front passengers side)
D Clock spring
D Seat belt with pre-tensioner
D Side air bag module
D Side impact sensor
(4) Always use the designated special tools and test equipment.
(5) Store components removed from the SRS and seat belt with pre-tensioner in a clean and dry
place.
The air bag module and seat belt with pre-tensioner should be stored on a flat surface and
placed so that the pad surface is facing upward.
Do not place anything on top of it.
(6) Never attempt to disassemble or repair the SRS components (SRS air bag control unit, air bag
module, clock spring and side impact sensor) and seat belt with pre-tensioner.
(7) Whenever you finish servicing the SRS and seat belt with pre-tensioner, check the SRS warning
lamp operation to make sure that the system functions properly.
(8) Be sure to deploy the air bag and seat belt with pre-tensioner before disposing of the air bag
module and seat belt with pre-tensioner or disposing of a vehicle equipped with an air bag and
seat belt with pre-tensioner. (Refer to GROUP 52B - Air Bag Module and Seat Belt Pre-tensioner
Disposal Procedures.)
2. Observe the following when carrying out operations on places where SRS components and seat
belt with pre-tensioner are installed, including operations not directly related to the SRS air bag and
seat belt with pre-tensioner.
(1) When removing or installing parts do not allow any impact or shock to the SRS components
and seat belt with pre-tensioner.
(2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove
the SRS components and seat belt with pre-tensioner before drying or baking the vehicle after
painting.
D SRS air bag control unit, air bag module, clock spring and side impact sensor: 93_C or more
D Seat belt with pre-tensioner 90_C or more
After re-installing them, check the SRS warning lamp operation to make sure that the system
functions properly.
SERVICING THE ELECTRICAL SYSTEM
Before replacing a component related to the electrical system
and before undertaking any repair procedures involving the
electrical system, be sure to first disconnect the negative
( - ) cable from the battery in order to avoid damage caused
by short-circuiting.
Caution
Before connectingor disconnectingthe negative ( - ) cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
APPLICATION OF ANTI-CORROSION AGENTS
AND UNDERCOATS
If oil or grease gets onto the oxygen sensor, it will cause
a drop in the performance of the sensor.
Cover the oxygensensor witha protectivecover whenapplying
anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
Pre-inspection condition refers to the condition that the
vehicle must be in before proper engine inspection can be
carried out. If you see the words Set the vehicle to the
pre-inspection condition. in this manual, it means to set the
vehicle to the following condition.
D Engine coolant temperature: 80- 90_C
D Lamps, electric cooling fan and all accessories: OFF
D M/T: Neutral
D A/T: P range
VEHICLE WASHING
If high-pressure car-washing equipment or steamcar-washing
equipment is used to wash the vehicle, be sure to note the
following information in order to avoid damage to plastic
components, etc.
D Spray nozzle distance: Approx. 40 cm or more
D Spray pressure: 3,900 kPa or less
D Spray temperature: 82_C or less
D Time of concentrated spray to one point: within 30 sec.
Approx.
40 cm
MUT-II
Refer to the MUT-II INSTRUCTION MANUAL for instructions
on handling the MUT-II.
Connect the MUT-II to the diagnosis connector as shown
in the illustration.
Caution
Connection and disconnection of the MUT-II should
always be made with the ignition switch in the OFF
position.
IN ORDER TO PREVENT VEHICLES FROM FIRE
Improper installation of electrical or fuel related parts could
cause a fire. In order to retain the high quality and safety
of the vehicle, it is important that any accessories that may
be fitted or modifications/repairs that may be carried out which
involve the electrical or fuel systems, MUST be carried out
in accordance with MMCs information/Instructions.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil will result
in the removal of natural fats fromthe skin, leading to dryness,
irritation and dermatitits. In addition, used engine oil contains
potentially harmful contaminants which may cause skincancer.
Adequate means of skin protection and washing facilities
must be provided.
Recommended Precautions
The most effective precaution is to adapt working practices
which prevent, as far as practicable, the risk of skin contact
with mineral oils, for example by using enclosed systems
for handling used engine oil and by degreasing components,
where practicable, before handling them.
MUT-II
sub-assembly
ROM pack
MUT-II
Other precautions:
D Avoid prolonged and repeated contact with oils,
particularly used engine oils.
D Wear protective clothing, including impervious gloves
where practicable.
D Avoid contaminating clothes, particularly underpants, with
oil.
D Do not put oily rags in pockets, the use of overalls without
pockets will avoid this.
D Do not wear heavily soiled clothing and oil-impregnated
foot-wear. Overalls must be cleaned regularly and kept
separately from personal clothing.
D Where there is a risk of eye contact, eye protection should
be worn, for example, chemical goggles or face shields;
in addition an eye wash facility should be provided.
D Obtain First Aid treatment immediately for open cuts and
wounds.
D Wash regularly with soap and water to ensure all oil is
removed, especially before meals (skin cleansers and
nail brushes will help). After cleaning, the application of
preparations containing lanolin to replace the natural skin
oils is advised.
D Do not use petrol, kerosine, diesel fuel, gas oil, thinners
or solvents for cleaning skin.
D Use barrier creams, applying them before each work
period, to help the removal of oil from the skin after work.
D If skin disorders develop, obtain medical advice without
delay.
GENERAL -
Supplemental Restraint System (SRS)
and Seatbelts with Pre-tensioner
00-24
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEATBELTS
WITH PRE-TENSIONER 00100590073
To improve safety, the SRS and seat belts with
pre-tensioner are available as optional parts. These
systems enhance collision safety by restraining the
front passengers in case of an accident. The SRS
works with the pre-tensioner simultaneously when
a collision is detected.
The SRS consists of four air bag modules, SRS
air bag control unit (SRS-ECU), side impact sensor,
SRS warning lamp and clock spring. The air bags
are located in the centre of the steering wheel,
above the glove box, and built into the front seat
back assemblies. Each air bag has a folded air
bag and an inflator unit. The SRS-ECU under the
floor console monitors the system and has a safing
G sensor and an analog G sensor. The side impact
sensor inside the center pillar monitors any shocks
coming from the side of the vehicle. The warning
lamp on the instrument panel indicates the
operational status of the SRS. The clock spring
is installed in the steering column.
The SRS side air bag deploys if an impact received
at the side of the vehicle is stronger than a certain
set value, in order to protect the upper bodies of
front seat passengers in the event of a collision.
The seat belt pre-tensioner is built into the front
seat belt retractor. Only authorized service
personnel should do work on or around the SRS
components and seat belt with pre-tensioner. Those
service personnel should read this manual carefully
before starting any such work. Extreme care must
be used when servicing the SRS to avoid injury
to the service personnel (by inadvertent deployment
of the air bags or inadvertent operation of the seat
belt with pre-tensioner) or the driver (by rendering
the SRS or the seat belt with pre-tensioner
inoperative).
Diagnosis
connector
Side air bag module
Side impact sensor
Clock spring
Air bag module
(Front passengers side)
Air bag module
(Drivers side)
SRS-ECU
Seat belt with
pre-tensioner
SRS warning lamp
GENERAL -
00-25
SEAT BELT WITH PRE-TENSIONER
The seat belt with pre-tensioner has a pre-tensioner
operating mechanismand aG-sensor whichdetects
the force from an impact built into the seat belt
retractor.
The G-sensor is a mechanical-type sensor which
includes components such as aweight whichmoves
as a result of the impact from a collision, and a
spike which strikes a charge and causes it to
detonate.
Thus the pre-tensioner is equipped with a safety
mechanism to prevent mis-operation during
maintenance operations such as removal and
installation of the seat belt.
The safety mechanism operates automatically
when the retractor top mounting screw is removed
during removal of the seat belt.
When the retractor top mounting screw is removed,
the force of the spring plate causes the tab at the
lower edge of plate (A) to push in the pin of the
G-sensor, which prevents the weight inside the
G-sensor from moving.
At the same time, the retractor bracket and the
top of plate (A) become separated. A stopper is
inserted into the gap thus formed by the force from
a spring to prevent the tab from being removed
from the pin if an outside force is applied to plate
(A).
Stopper
Retractor bracket
Plate (A)
Spring
Spring plate
Tab
Plate (A) (when safety
mechanismis disengaged)
mechanismis engaged)
Stopper
G-sensor structure
Charge
Spike
Pin (when safe-
ty mechanismis
engaged)
Sensor
weight
Tab
Pin
Tab
GENERAL -
00-26
SRS SERVICE PRECAUTIONS 00100600073
1. In order to avoid injury to yourself or others
from accidental deployment of the air bag and
accidental operation of the seat belt with
pre-tensioner during servicing, read and
carefully follow all the precautions and
procedures described in this manual.
2. Do not use any electrical test equipment on
or near SRS components, except those
specified on GROUP 52B.
3. Never Attempt to Repair the Following
Components:
D SRS air bag control unit (SRS-ECU)
D Clock Spring
D Air bag module (Drivers side or front
passengers side)
D Seat belt with Pre-tensioner
NOTE
If any of these components are diagnosed as
faulty, they should only be replaced, in
accordance with the INDIVIDUAL COM-
PONENTS SERVICE procedures in this
manual, starting at page GROUP 52B.
4. After disconnecting the battery cable, wait 60 seconds
or more before proceeding with the following work.
The SRS system is designed to retain enough voltage
to deploy the air bag for a short time even after the
battery has been disconnected, so serious injury may
result from unintended air bag deployment if work
is done on the SRS system immediately after the
battery cables are disconnected.
5. Do not attempt to repair the wiring harness connectors
of the SRS. If any of the connectors are diagnosed as
faulty, replace the wiring harness. If the wires are
diagnosed as faulty, replace or repair the wiring harness
according to the following table.
Insulating tape
Battery
<Vehicles with SRS side air bag>
SRS-ECU connector
<Vehicles without SRS side air bag>
GENERAL -
00-27
SRS-ECU
Terminal No.
Destination of harness Corrective action
1 to 4 - -
5, 6 Dashwiringharness ClockspringAir bagmodule(Drivers
side)
Correct or replace the dashwiring
harness. Replacetheclockspring.
7, 8 Dashwiringharness Air bagmodule(Front passengers side) Correct or replace the dashwiring
9, 10 -
harness.
11 Dash wiring harness Diagnosis connector
12 -
13 Dash wiring harness J unction block (fuse No.4)
15 Dashwiringharness Instrument panel wiringharness SRS
warning lamp
Correct or replace each wiring
harness.
16 to 19 - -
20, 21 Dash wiring harness Earth Correct or replace the dash wring
harness.
SRS-ECU
Terminal No.
1, 2 - -
3 Dash wiring harness Earth Correct or replacethedashwiringharness
4 Dashwiringharness Instrumentpanel wiringharness
SRS warning lamp
Correct or replace each wiring harness.
5, 6 Dash wiring harness Air bag module (Front
Passengers side)
Correctorreplacethedashwiringharness.
7, 8 Dashwiringharness Clock springAir bagmodule
(Drivers side)
Correctorreplacethedashwiringharness.
Replace the clock spring.
9 Dash wiring harness J unction block (fuse No.4) Correctorreplacethedashwiringharness.
10, 11 -
13 -
14, 15 Dash wiring harness Earth
17 to 20 -
21, 22 Dash wiring harness Side air bag module (LH)
23, 24 Dash wiring harness Side air bag module (RH)
GENERAL -
00-28
SRS-ECU
Terminal No.
Corrective action Destination of harness
25 to 33 - Correctorreplacethedashwiringharness.
34, 35, 36 Dash wiring harness Floor wiring harness Side
impact sensor (LH)
Correct or replace each wiring harness
37 to 39 -
impact sensor (RH)
6. Inspection of the SRS-ECU harness connector <vehicles with SRS side air bag>should be carried
out by the following procedure.
Insert the special tool (narrow probe in the harness set) into connector fromharness side (rear side),
and connect the tester to this probe. If any to other than the special tool is used, it may cause
damage to the harness and other components. Furthermore, measurement should not be carried
out by touching the probe directly against the terminals fromthe front of the connector. The terminals
are plated to increase their conductivity, so that if they are touched directly by the probe, the plating
may break, which will cause drops in reliability.
MB991222
SRS-ECU harness connector
SRS-ECU harness connector (rear side)
7. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the
SRS-ECU, air bag module (drivers side and front passengers side), clock spring, side impact sensor,
front seat assembly (side air bag module), and seat belt with pre-tensioner before drying or baking
the vehicle after painting.
D SRS-ECU, air bag module, clock spring, side impact sensor: 93_C or more
D Seat belt with pre-tensioner: 90_C or more
8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to GROUP 52B.)
9. Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected.
10. If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJ URY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.
GENERAL - Support Locations for Lifting and Jacking 00-29
SUPPORT LOCATIONS FOR LIFTING AND JACKING 00100070065
Caution
Do not support the vehicles at locations other than specified supporting points. If do so, this
will cause damage, etc.
SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS
GARAGE JACK
Caution
Never support any point other than the specified one, or it will be deformed.
Notch
Caution
Never support the rear floor crossmember.
AXLE STANDS
Notch
Rubber
Rubber
SUPPORT POSITIONS FOR A
SINGLE-POST LIFT OR DOUBLE-POST
LIFT
Caution
When service procedures require removing rear
suspension, spare tyre and rear bumper, place
additional weight on rear end of vehicle or
anchor vehicle to hoist to prevent tipping of
centre of gravity changes.
DOUBLE-POST LIFT
SINGLE-POST LIFT
Notch Notch
SUPPORT POSITIONS AND SUPPORT METHOD
FOR AN H-BAR LIFT
Caution
When service procedures require removing rear
suspension, fuel tank, spare tyre and rear bumper, place
additional weight on rear end of vehicle or anchor vehicle
to hoist to prevent tipping of centre of gravity changes.
When H-bar lift is used to lift up vehicles, use of metallic
attachment attached to the H-bar lift may cause damage
to the suspension arm etc. Therefore, lift up the vehicle by
the following procedure.
1. Place the vehicle on the H-bar lift (same direction).
2. Place attachments on the H-bar lift at the designated
chassis-support positions. When making the attachments,
refer to the section concerning making them.
Caution
If support is at any location other than the designated
positions, the body or suspension might be deformed
or otherwise damaged, so care should be taken to
support only at the correct (designated) positions.
3. Raise the H-bar lift to the height at which the vehicle
is slightly raised and check to be sure that the vehicle
is correctly and sufficiently secured; then raise the vehicle.
H-bar lift
H-bar lift
A
Chassis-sup-
port position
(side sill) Attachment
H-bar lift
Section A-A
Side sill
Attachment
H-bar lift
A
PREPARATION OF ATTACHMENTS
1. Prepare the blocks (wooden) and nails as shown in the
figure.
Item Dimensions mm Quantity
Block (A) 90 95 1,800 2
Block (B) 60 100 95 4
Block (C) 140 40 95 8
Nail 70 or more 32
Caution
The wood selected for the blocks must be hard.
2. For the (B) blocks and (C) blocks, use a saw and chisel
or similar tool to make grooves of the dimensions shown
in the figure.
3. Make four ATTACHMENTS such as shown in the figure
nailing (B) and (C) blocks so that each (B) blocks is
sandwiches between (C) blocks.
Block (A)
mm
1,800
90
95
Block (B) Block (C)
15
40
60
100
40
20
15
40
140
40
20
40
Block (C)
140
100
Block (C)
Nail
Block (B)
Finished attachment
Movable according
to vehicle width
GENERAL - Standard Part/Tightening-Torque Table 00-33
STANDARD PART/TIGHTENING-TORQUE TABLE 00100110033
Each torque value in the table is a standard value
for tightening under the following conditions.
(1) Bolts, nuts and washers are all made of steel
and plated with zinc.
(2) The threads and bearing surface of bolts and
nuts are all in dry condition.
The values in the table are not applicable:
(1) If toothed washers are inserted.
(2) If plastic parts are fastened.
(3) If bolts are tightened to plastic or die-cast
inserted nuts.
(4) If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque
Thread size Torque Nm
Bolt nominal
diameter (mm)
Pitch (mm) Head mark 4 Head mark 7 Head mark 8
M5 0.8 2.5 4.9 5.9
M6 1.0 4.9 8.8 9.8
M8 1.25 12 22 25
M10 1.25 24 44 52
M12 1.25 41 81 96
M14 1.5 72 137 157
M16 1.5 111 206 235
M18 1.5 167 304 343
M20 1.5 226 412 481
M22 1.5 304 559 647
M24 1.5 392 735 853
Flange bolt and nut tightening torque
Thread size Torque Nm
Bolt nominal
diameter (mm)
Pitch (mm) Head mark 4 Head mark 7 Head mark 8
M6 1.0 4.9 9.8 12
M8 1.25 13 24 28
M10 1.25 26 49 57
M10 1.5 24 44 54
M12 1.25 46 93 103
M12 1.75 42 81 96
NOTES
ENGINE <4G6> 11A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE <6A1> 11B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE <4D6> 11C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11A-1
ENGINE
11A-2
ENGINE <4G6>
GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 3 . . . . . . . . . . . . . . . . .
SEALANTS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 6 . . . . . . . . . . . . . . . . . . . . .
Drive Belt Tension Check and Adjustment 6 . . . . . .
Ignition Timing Check 7 . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Speed Check 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Mixture Check 8 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Pressure Check 9 . . . . . . . . . . . . . . . . .
Manifold Vacuum Check 10 . . . . . . . . . . . . . . . . . . . . .
Lash Adjuster Check 11 . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT PULLEY 15 . . . . . . . . . . . . . . . . . . .
CAMSHAFT AND CAMSHAFT OIL SEAL 16 . . .
OIL PAN 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT OIL SEAL 20 . . . . . . . . . . . . . . . . . .
CYLINDER HEAD GASKET 22 . . . . . . . . . . . . . . . .
TIMING BELT 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING BELT B 30 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ASSEMBLY 33 . . . . . . . . . . . . . . . . . . . . . . .
ENGINE <4G6> - General Information/Service Specifications 11A-3
GENERAL INFORMATION 11100010469
Items 4G63
Total displacement mL 1,997
Bore Stroke mm 85.0 88.0
Compression ratio 10.0
Combustion chamber Pentroof type
Camshaft arrangement SOHC
Intake 8
Number of valve
Exhaust 8
Opening BTDC 11_
Intake
Closing ABDC 53_
Valve timing
Opening BBDC 63_
Exhaust
Closing ATDC 21_
Fuel system Electronically controlled multipoint fuel injection
Rocker arm Roller type
Auto-lash adjuster Equipped
SERVICE SPECIFICATIONS 11100030489
Items Standard value Limit
When checked 294- 490 -
Tension N When a used belt is installed 343- 441 -
Alternator drive When a new belt is installed 490- 686 -
belt
tension When checked 7.7- 12.3 -
Deflection
(Reference When a used belt is installed 8.4- 10.6 -
value) mm
When a new belt is installed 5.9- 7.7 -
Power steering
oil pump and When a new belt is installed 637- 833 -
A/C compressor
drive belt When checked 11.7- 15.3 -
tension
Deflection
mm
When a used belt is installed 12.5- 14.3 -
mm
Basic ignition timing 5_ BTDC2_ -
Ignition timing Approx. 10_BTDC -
ENGINE <4G6> - Service Specifications/Sealants/Special Tools 11A-4
Items Limit Standard value
Idle speed r/min 750 100 -
CO contents % 0.5 or less -
HC contents ppm 100 or less -
Compression pressure (250- 400 r/min) kPa 1,400 Min. 1,060
Compression pressure difference of all cylinder kPa - Max. 100
Intake manifold vacuum kPa - Min. 69
Cylinder head bolt shank length mm - 99.4
Auto-tensioner push rod movement mm Within 1 -
Timing belt tension torque Nm (Reference value) 3.5 -
Auto-tensioner rod protrusion amount mm 3.8 - 4.5 -
Timing belt B tension mm 5 - 7 -
SEALANTS 11100050201
Items Specified sealants Remarks
Rocker cover and cylinder head
Semi-circular packing
3M ATD Part No.8660 or equivalent -
Oil pan
Thermostat case
MITSUBISHI GENUINE PART
MD970389 or equivalent
Semi-drying sealant
Flywheel bolt 3M Stud Locking 4170 or equivalent -
SPECIAL TOOLS 11100060457
Tool Number Name Use
MB991502 MUT-II sub assem-
bly
D Checking the idle speed
D Erasing diagnosis code
MB990767 End yoke holder D Holding the camshaft sprocket
D Holding the crankshaft sprocket
MD998719 or
MD998754
Crankshaft pulley
holder pin
D Holding the camshaft sprocket
D Holding the crankshaft sprocket
ENGINE <4G6> - Special Tools 11A-5
Tool Use Name Number
MD998713 Camshaft oil seal
installer
Press-in of the camshaft oil seal
MD998443 Auto-lash adjuster
holder
Supporting of auto-lash adjuster
MD998727 Oil pan remover Removal of oil pan
MD998781 Flywheel stopper Securing the flywheel
MD998776 Crankshaft rear oil
seal installer
Press-in of the crankshaft rear oil seal
MB990938 Handle Press-in of the crankshaft rear oil seal
MD998767 Tension pulley
socket wrench
Timing belt tension adjustment
GENERAL
SERVICE
TOOL
MZ203827
Engine lifter Supporting the engine assembly during
removal and installation of the transmission
MB991453 Engine hanger
assembly
ENGINE <4G6> - On-vehicle Service 11A-6
ON-VEHICLE SERVICE 11100090432
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Use a belt tension gauge to check that the belt tension is
at the standard value at a point half-way between the two
pulleys as shown in the illustration. In addition, press this
section with a force of 98 N and check that the amount of
belt deflection is at the standard value.
Standard value:
Tension N 294- 490
Deflection (Reference value) mm 7.7- 12.3
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT
1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.
Standard value:
Items When a used
belt is installed
When a new
belt is installed
Tension N 343- 441 490- 686
Deflection (Reference
value) mm
8.4- 10.6 5.9- 7.7
4. Tighten the nut of the alternator pivot bolt.
Tightening torque: 44 Nm
5. Tighten the lock bolt.
6. Tighten the adjusting bolt.
Water pump
pulley
Alternator pulley
Crankshaft pulley
Adjusting bolt
Lock bolt
POWER STEERING OIL PUMP AND AIR CONDITIONER
COMPRESSOR DRIVE BELT TENSION CHECK AND
ADJUSTMENT 11100130127
1. Use a belt tension gauge to check that the belt tension
is at the standard value at a point half-way between the
two pulleys (indicated by an arrow in the illustration).
In addition, press this section with a force of 98 N and
check that the amount of belt deflection is at the standard
value.
Standard value:
Items When
checked
When a
used belt is
installed
When a new
belt is
installed
Tension N 392- 588 441- 539 637- 833
Deflection
(Reference
value) mm
11.7- 15.3 12.5- 14.3 8.8- 11.0
2. If the tension or deflection is outside the standard value,
adjust by the following procedure.
(1) Loosen tensioner pulley fixing nut A.
(2) Adjust the amount of belt deflection using adjusting
bolt B.
(3) Tighten fixing nut A.
(4) Check the belt deflection amount and tension, and
readjust if necessary.
Caution
Check after turning the crankshaft once or more
clockwise (right turn).
IGNITION TIMING CHECK 11100170297
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Connect the MUT-II to the diagnosis connector.
3. Set up a timing light.
4. Start the engine and run at idle.
5. Check that engine idle speed is within the standard value.
Standard value: 750 100 r/min
6. Select No.17 of the MUT-II Actuator test.
<Vehicleswithout A/C>
Oil pumppulley
98 N
Crankshaft
pulley
Tensioner pulley
A
B
98 N
Crankshaft
pulley
Tensioner
pulley
A
B
A/C
compressor
pulley
<VehicleswithA/C>
Oil pump pulley
7. Check that basic ignition timing is within the standard
value.
Standard value: 5_ BTDC2_
8. If the basic ignition timing is outside the standard value,
inspect the MPI system while referring to GROUP 13A
- Troubleshooting.
9. Press the MUT-II clear key (Select a forced driving cancel
mode) to release the Actuator test.
Caution
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this condition
may damage the engine.
10. Check that ignition timing is at the standard value.
Standard value: approx. 10_BTDC
NOTE
1. Ignition timing is variable within about 7_, even
under normal operating.
2. And it is automatically further advanced by about
5_ from standard value at higher altitudes.
IDLE SPEED CHECK 11100350066
condition.
2. Turn the ignition switch to OFF and connect the MUT-II
to the diagnosis connector.
3. Check the basic ignition timing.
4. Run the engine at idle for 2 minutes.
5. Check the idle speed. Select item No. 22 and take a
reading of the idle speed.
NOTE
The idle speed is controlled automatically by the idle speed
control (ISC) system.
6. If the idle speed is outside the standard value, inspect
the MPI components by referring to GROUP 13A -
Troubleshooting.
IDLE MIXTURE CHECK 11100210418
condition.
3. Check that the basic ignition timing is within the standard
value.
4. Run the engine at 2,500 r/min for 2 minutes.
ENGINE <4G6> - On-vehicle Service ENGINE <4G6> - On-vehicle Service 11A-9
5. Set the CO, HC tester.
6. Check the CO contents and the HC contents at idle.
Standard value
CO contents: 0.5% or less
HC contents: 100 ppm or less
7. If there is a deviation from the standard value, check
the following items:
D Diagnosis output
D Closed-loop control (When the closed-loop control
is normal, the output signal of the oxygen sensor
changes between 0- 400 mV and 600- 1,000 mV
at idle.)
D Fuel pressure
D Injector
D Ignition coil, spark plug cable, spark plug
D Leak in the EGR system and in the EGR valve
D Evaporative emission control system
D Compression pressure
NOTE
Replace the three way catalyst when the CO and HC
contents are not within the standard value, even though
the result of the inspection is normal on all items.
COMPRESSION PRESSURE CHECK 11100260499
1. Before inspection, check that the engine oil, starter and
battery are normal. In addition, set the vehicle to the
pre-inspection condition.
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crank angle sensor connector.
NOTE
Doing this will prevent the engine-ECU from carrying out
ignition and fuel injection.
5. Cover the spark plug hole with a shop towel etc., and
after the engine has been cranked, check that no foreign
material is adhering to the shop towel.
Caution
1. Keep away from the spark plug hole when
cranking.
2. If compression is measured with water, oil, fuel,
etc., that has come fromcracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.
6. Set compression gauge to one of the spark plug holes.
7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 250- 400 r/min):
1,400 kPa
Limit (at engine speed of 250- 400 r/min):
Min. 1,060 kPa
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: Max. 100 kPa
9. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the spark plug hole, and repeat
the operations in steps 7 and 8.
(1) If the compression increases after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
(2) If the compression does not rise after oil is added,
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
10. Connect the crank angle sensor connector.
11. Install the spark plugs and spark plug cables.
12. Use the MUT-II to erase the diagnosis codes.
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.
MANIFOLD VACUUM CHECK 11100270409
1. Start the engine and allow it to warm up until the
temperature of the engine coolant reaches 80 to 95_C.
2. Connect a tachometer.
3. Attach a three-way union to the vacuum hose between
the fuel pressure regulator and the air intake plenum,
and connect a vacuum gauge.
4. Start the engine and check that idle speed is within
standard value. Then read off the vacuum gauge.
Limit: Min. 69 kPa
Compression gauge
Vacuum gage
LASH ADJUSTER CHECK 11100290344
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused y
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied (for example,
by shifting from N D).
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or has disappeared,
the cause of the noise was probably that oil sludge had
caused the lash adjusters to become stuck. If this
happens, carry out the following check. If the noise level
does not change, go to step 5.
(1) Let the engine cool down sufficiently.
(2) Turn the crankshaft two full revolutions.
(3) Carry out lash adjuster simple check. (Refer to
P.11A-13.)
D If any of the rocker arms can be pushed down
easily during the lash adjuster simple check,
replace the corresponding lash adjusters.
D If the lash adjuster simple check has been carried
out but all lash adjusters are normal (if none of
the rocker arms could be pushed down easily),
check for some other cause of the problem.
NOTE
You can check whether the lash adjusters are normal
or not by carrying out a leak-down test. (Refer to
the Engine Workshop Manual.)
Caution
Make sure that the air has been fully bled before
installation of a new lash adjuster. (Refer to the
Engine Workshop Manual.)
5. Bleed the air from the lash adjusters. (Refer to P.11A-13.)
6. If the noise does not disappear even after the air has
been bled from the lash adjusters, carry out the following
check.
Carry out lash adjuster simple check. (Refer to P.11A-13.)
D If one of the rocker arms can be pushed down easily
during the lash adjuster simple check, replace the
corresponding lash adjuster.
D If two or more of the rocker arms can be pushed
down easily during the lash adjuster simple check,
the cause may be that the oil passage to the cylinder
head is blocked.
Check for blockages in the oil passage, and clear
the blockages if any are found. If there are no
blockages, replace the lash adjusters.
out but all lash adjusters are normal (if none of the
rocker arms could be pushed down easily), check
for some other cause of the problem.
NOTE
or not by carrying out a leak-down test. (Refer to the
Caution
installation of a newlash adjuster. (Refer to the Engine
Workshop Manual.)
7. Start the engine and check that the abnormal noise has
disappeared. If necessary, bleed the air from the lash
adjusters. (Refer to P.11A-13.)
<LASH ADJUSTER SIMPLE CHECK>
1. Stop the engine.
2. Remove the rocker cover.
3. Set the No.1 cylinder to the compression top dead centre
position.
4. Check the rocker arms indicated by white arrows in the
illustration by the procedures given below.
<Checking an intake-side rocker arm>
Check whether the rocker arm moves downwards when
the part of the rocker arm which touches the top of the
lash adjuster is pushed.
D If the rocker armmoves down easily when it is pushed,
make a note of which is the corresponding lash
adjuster.
D If the rocker arm feels extremely stiff when it is pushed
and does not move down, the lash adjuster is normal,
so check for some other cause of the problem.
<Checking an exhaust-side rocker arm>
NOTE
It will not be possible to depress the Y-shaped rocker
arm at the exhaust valve side if one lash adjuster is
defective but the other one is normal. In such cases,
carry out the following procedure using a thickness gauge.
(1) Check that a thickness gauge with a thickness of
0.1 - 0.2 mm can be inserted easily between the
valve and the lash adjuster.
(2) If the thickness gauge can be inserted easily, make
a note of which is the corresponding lash adjuster.
(3) If the thickness gauge cannot be inserted easily, the
lash adjuster is normal, so check for some other cause
of the problem.
5. Slowly turn the crankshaft 360_ in the clockwise direction.
6. Check the rocker arms indicated by black arrows in the
illustration in the same way as explained in step 4.
<LASH ADJUSTER AIR BLEEDING>
NOTE
(1) If the vehicle is parked on a slope for a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high pressure
chamber when starting the engine.
(2) After parking the vehicle for long periods, the oil drains
out of the oil passage, and it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
(3) If either of the above situations occur, the abnormal
noise can be eliminated by bleeding the air frominside
the lash adjusters.
ENGINE <4G6> - On-vehicle Service ENGINE <4G6> - On-vehicle Service 11A-14
1. Check the engine oil and replenish or replace the oil
if necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
in through the oil screen and will get into the oil
passage.
(2) If the amount of oil is greater than normal, then the
oil will being mixed by the crankshaft and a large
amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
pressure chamber will be compressed when the valve
is open and the lash adjuster will over-compress,
resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation
of the lash adjusters will return to normal.
2. Run the engine at idle for 1 - 3 minutes to let it warm
up.
3. With no load on the engine, repeat the drive pattern shown
in the illustration at left and check if the abnormal noise
disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is probably
not due to air inside the lash adjusters.)
4. After the noise has disappeared, repeat the drive pattern
shown in the illustration at left a further 5 times.
5. Run the engine at idle for 1 - 3 minutes and check that
the noise has disappeared.
Good
High
pressure
chamber
Gradually open the
throttle valve.
Drive pattern for air bleeding
Close the throttle
valve.
Approx.
3,000 r/min.
15
seconds
15
seconds
Idle speed
Once
ENGINE <4G6> - Crankshaft Pulley 11A-15
CRANKSHAFT PULLEY 11200160303
REMOVAL AND INSTALLATION
Pre-removal Operation
D Under Cover Removal
Post-installation Operation
D Drive Belt Tension Adjustment (Refer to P.11A-6.)
D Under Cover Installation
1
2
3
25 Nm
Removal steps
1. Drive belt (Power steering and
A/C)
2. Drive belt (Alternator)
3. Crankshaft pulley
ENGINE <4G6> - Camshaft and Camshaft Oil Seal 11A-16
CAMSHAFT AND CAMSHAFT OIL SEAL 11200190418
Pre-removal and Post-installation Operation
D Air Cleaner Removal and Installation
D Timing Belt Removal and Installation (Refer to
P.11A-26.)
D Relay Box Removal and Installation
8
10 Nm
28- 34 Nm
88 Nm
1
2
5
3
4
9
7
6
(f 3 1 mm)
Sealant:
5
3.4 Nm
Lipsection
Cam section and
journal section
Engine oil
12
12
8
5
14 Nm
11
10
22 Nm
Removal steps
1. Control harness connection
2. Spark plug cable
3. PCV hose connection
4. Rocker cover
5. Camshaft position sensor support
6. Camshaft position sensing cylinder
AA" "CA 7. Camshaft sprocket
"BA 8. Camshaft oil seal
9. Spark plug guide oil seal
AB" "AA 10. Rocker arm and shaft assembly
(intake side)
AB" "AA 11. Rocker arm and shaft assembly
(exhaust side)
12. Camshaft
REMOVAL SERVICE POINTS
AA"CAMSHAFT SPROCKET REMOVAL
AB"ROCKER ARM AND SHAFT ASSEMBLY
REMOVAL
Before removing the rocker arm and shaft assembly, install
the special tools as shown in the illustration so that the lash
adjusters will not fall out.
INSTALLATION SERVICE POINTS
"AA ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
1. Temporarily tighten the rocker shaft with the bolt so that
all rocker arms on the inlet valve side do not push the
valves.
2. Fit the rocker shaft spring from the above and position
it so that it is right angles to the plug guide.
NOTE
Install the rocker shaft spring before installing the rocker
arm and rocker arm shaft on the exhaust side.
3. Remove the special tool for fixing the lash adjuster.
4. Confirm that the rocker shaft notch is in the direction
shown in the diagram.
MB990767
MD998719 or
MD998754
MD998443
"BACAMSHAFT OIL SEAL INSTALLATION
1. Apply engine oil to the camshaft oil seal lip.
2. Use the special tool to press-fit the camshaft oil seal.
"CACAMSHAFT SPROCKET INSTALLATION
Use the special tool to stop the camshaft sprocket from turning
in the same way as was done during removal, and then tighten
the bolts to the specified torque.
MD998713
ENGINE <4G6> - Oil Pan 11A-19
OIL PAN 11200280207
D Engine Oil Draining and Supplying (Refer to GROUP
12 - On-vehicle Service.)
D Oil Level Gauge Removal and Installation
D Front Exhaust Pipe Removal and Installation (Refer
to GROUP 15.)
f 4 1 mm
Bolt
hole
Groove
5
9 Nm
9 Nm
5
2
3
1
Sealant:
4
7 Nm
Removal steps
1. Drain plug
"AA 2. Drain plug gasket
3. Bell housing cover
4. Oil level sensor
AA" 5. Oil pan
REMOVAL SERVICE POINT
AA"OIL PAN REMOVAL
After removing the oil pan mounting bolts, remove the oil
pan with the special tool and a brass bar.
Caution
Perform this slowly to avoid deformation of the oil pan
flange.
INSTALLATION SERVICE POINT
"AADRAIN PLUG GASKET INSTALLATION
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
MD998727 MD998727
Drain plug
gasket
Oil pan side
ENGINE <4G6> - Crankshaft Oil Seal 11A-20
CRANKSHAFT OIL SEAL 11200310135
(Engineoil:
bolt wash-
er surface)
127- 137 Nm
10
5
4
3
2
1
<M/T>
<A/T>
7
9
12
8
11
<M/T> <A/T>
Crankshaft
(Engine oil:
bolt washer
surface)
Crankshaft
9
10
12
5
Sealant: 3M Stud locking 4170 or equivalent
Lip section
Lip section
Engine oil
127- 137 Nm
6
8
Crankshaft front oil seal removal
steps
D Timing belt (Refer to P.11A-26.)
D Crank angle sensor
(Refer to GROUP 16.)
1. Crankshaft sprocket
2. Flange
3. Crankshaft sprocket B
4. Key
"CA 5. Crankshaft front oil seal
Crankshaft rear oil seal removal
steps
D Oil pan (Refer to P.11A-19.)
AA" D Transmission assembly
D Clutch cover and disc <M/T>
6. Crankshaft bushing
AB" "BA 7. Plate <M/T>
AB" "BA 8. Adapter plate
AB" "BA 9. Flywheel <M/T>
AB" "BA 10. Drive plate <A/T>
AB" "BA 11. Adapter plate <M/T>
"AA 12. Crankshaft rear oil seal
ENGINE <4G6> - Crankshaft Oil Seal 11A-21
AA"TRANSMISSION ASSEMBLY REMOVAL
<M/T>:
Refer to GROUP 22.
Caution
Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become
out of balance and damaged.
<A/T>:
Refer to GROUP 23.
AB"PLATE <M/T>/ADAPTER PLATE/FLYWHEEL
<M/T>/DRIVE PLATE <A/T> REMOVAL
Use the special tool to secure the flywheel or drive plate,
and remove the bolts.
"AACRANKSHAFT REAR OIL SEAL INSTALLATION
1. Apply a small mount of engine oil to the entire
circumference of the oil seal lip.
2. Install the oil seal by tapping it as far as the chamfered
position of the oil seal case as shown in the illustration.
"BADRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER
PLATE/PLATE <M/T> INSTALLATION
1. Clean off all sealant, oil and other substances which are
adhering to the threaded bolts, crankshaft thread holes
and the flywheel or drive plate.
2. Apply oil to the bearing surface of the flywheel or drive
plate bolts.
3. Apply oil to the crankshaft thread holes.
4. Apply sealant to the threaded mounting holes.
Specified sealant: 3M Stud locking 4170 or equivalent
5. Use the special tool to hold the flywheel or drive plate
in the same manner as removal, and install the bolt.
"CACRANKSHAFT FRONT OIL SEAL INSTALLATION
1. Apply a small amount of engine oil to the entire
2. Press-fit the oil seal unit it is flush with the oil seal case.
<M/T>
Flywheel
Bolt
MD998781
Crankshaft
rear oil seal
MD990938
MD998776
Crankshaft
ENGINE <4G6> - Cylinder Head Gasket 11A-22
CYLINDER HEAD GASKET 11200400542
D Fuel Discharge Prevention (Refer to GROUP 13A
- On-vehicle Service.)
D Engine Oil Draining (Refer to GROUP 12 -
On-vehicle Service.)
D Thermostat Case Assembly Removal (Refer to
GROUP 14 - Water Hose and Water Pipe.)
D Thermostat Case Assembly Installation (Refer to
D Engine Oil Supplying (Refer to GROUP 12 -
D Accelerator Cable Adjustment (Refer to GROUP
1
8
2
3
4
5
6
7
9
11
Delivery pipe O-ring
Engine oil
10
10
Removal steps
1. Accelerator cable connection
2. Vacuum hose connection
3. Brake booster vacuum hose
connection
5. Throttle position sensor connector
6. Idle speed control connector
7. Injector connector
8. Purge control solenoid valve
connector
9. EGR solenoid valve connector
"CA 10. High-pressure fuel hose connection
11. Fuel return hose connection
(Engine oil)
31 Nm
<Cold engine>
78 Nm 0 Nm 20 Nm + 90_ + 90_
3.4 Nm
26
29
34 Nm
24 Nm
44 Nm
12
13
14
15
16
17
20
21
22
23
24
25
27
28
49 Nm
10 Nm
19
18
12. Radiator upper hose connection
13. PCV hose
14. Ignition coil connector
15. Ignition coil assembly
16. Breather hose
17. Engine coolant temperature sensor
connector
18. Engine coolant temperature gauge
unit connector
19. Camshaft position sensor
20. Water hose connection
21. Heater hose connection
22. Thermostat case assembly
AA" 24. Power steering oil pump and
bracket assembly
25. Front exhaust pipe connection
26. Rocker cover
D Timing belt (Refer to P.11A-26.)
AB" "BA 27. Cylinder head bolt
28. Cylinder head assembly
"AA 29. Cylinder head gasket
AA"POWER STEERING OIL PUMP AND BRACKET
ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
cylinder head assembly, and tie it with a cord.
AB"CYLINDER HEAD BOLT REMOVAL
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head
assembly.
Caution
Because the plug guides cannot be replaced by
themselves, be careful not to damage or deform the plug
guides when removing the cylinder head bolts.
"AACYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting
surface.
2. Install so that the shapes of the cylinder head holes match
the shapes of the respective cylinder head gasket holes.
"BACYLINDER HEAD BOLT INSTALLATION
1. When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
If it is outside the limit, replace the bolts.
Limit (A): 99.4 mm
2. The head bolt washer should be installed with the burred
side caused by tapping out facing upwards.
3. Apply a small amount of engine oil to the thread section
and the washer of the cylinder head bolt.
Intake side
Front of engine
Exhaust side
3 5 10 8 2
1 7 9 6 4
Head bolt
Burred side
Headbolt
washer
(Engine
oil)
Cylinder
head
A
4. Tighten the bolts by the following procedure.
Step Operation Remarks
1 Tighten to 78 Nm. Carry out in the order
shown in the illustration.
2 Fully loosen. Carry out in the reverse
order of that shown in the
illustration.
4 Tighten 90_ of a turn. In the order shown in the
illustration. Mark the head
of the cylinder head bolt
and cylinder head by paint.
illustration. Check that the
painted mark of the head
bolt is lined up with that of
the cylinder head.
Caution
1. Always make a tightening angle just 90_. If it is less
than 90_, the head bolt will be loosened.
2. If it is more than 90_, remove the head bolt and repeat
the procedure from step 1.
"CAHIGH-PRESSURE FUEL HOSE INSTALLATION
1. Apply a small amount of new engine oil to the O-ring.
Caution
Do not let any engine oil get into the delivery pipe.
2. While turning the high-pressure fuel hose to the right
and left, install the delivery pipe, while being careful not
to damage the O-ring. After installing, check that the hose
turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably
being clamped. Disconnect the high-pressure fuel hose
and check the O-ring for damage. After this, re-insert
the delivery pipe and check that the hose turns smoothly.
Intake side
Front of engine
Exhaust side
8 6 1 3 9
10 4 2 5 7
Step 4
90_
Painted mark
Step 5
90_
Painted mark
ENGINE <4G6> - Timing Belt 11A-26
TIMING BELT 11200430473
D Crankshaft Pulley Removal and Installation (Refer
to P.11A-15.)
D Engine Mount Bracket Removal and Installation
(Refer to GROUP 32 - Engine Mounting.)
10- 12 Nm
48 Nm
1
2
5
24 Nm
4
3
9 Nm
Removal steps
1. Timing belt upper cover
2. Timing belt lower cover
"CA D Timing belt tension adjustment
AA" "BA 3. Timing belt
4. Tension pulley
"AA 5. Auto tensioner
AA"TIMING BELT REMOVAL
1. Turn the crankshaft clockwise (right turn) to align each
timing mark and to set the No. 1 cylinder at compression
top dead centre.
Caution
The crankshaft should always be turned only
clockwise.
2. Loosen the tension pulley centre bolt.
3. Move the tension pulley to the water pump side, and
then remove the timing belt.
Caution
If the timing belt is to be re-used, use chalk to mark
(on its flat side) an arrow indicating the clockwise
direction.
"AAAUTO TENSIONER INSTALLATION
1. Apply 98 - 196 N force to the auto tensioner by pressing
it against a metal (cylinder block, etc.), and measure the
movement of the push rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
2. If it is out of the standard value, replace the auto tensioner.
3. Use a press or vice to gently compress the auto tensioner
push rod until pin hole A of the push rod and pin hole
B of the tensioner cylinder are aligned.
Caution
If the compression speed is too fast, the rod may
become damaged, so be sure to carry out this
operation slowly.
Timing mark (Top
of cylinder head)
Timing mark
Camshaft sprocket
Timing mark
Timing mark
Crankshaft
sprocket
Timing mark
Oil pump
sprocket
Centre bolt
Movement
Push rod
Auto tensioner
A B
98N - 196N
A B
4. Once the holes are aligned, insert the set pin.
NOTE
When replacing the auto tensioner with a new part, the
pin will be in the auto tensioner.
5. Install the auto tensioner to the engine.
"BATIMING BELT INSTALLATION
1. Align the timing marks on the camshaft sprocket,
crankshaft sprocket and oil pump sprocket.
2. After aligning the timing mark on the oil pump sprocket,
remove the cylinder block plug and insert a Phillips
screwdriver with a diameter of 8 mm, and check to be
sure that the screwdriver goes in 60 mm or more. If
the screwdriver will only go in 20 - 25 mm before striking
the counterbalance shaft, turn the sprocket once, realign
the timing mark and check that the screwdriver goes in
60 mm or more. The screwdriver should not be taken
out until the timing belt is installed.
3. Install the belt to the crankshaft sprocket, oil pump
sprocket and camshaft sprocket in that order, so that
there is no slackness in the belt tension.
Caution
If the timing belt is re-used, install so that the arrow
marked on it at time of removal is pointing in the
clockwise direction.
4. Set the tension pulley so that the pin holes are at the
top, press the tension pulley lightly against the timing
belt, and then provisionally tighten the fixing bolt.
5. Adjust the timing belt tension.
Set pin
Timing mark (Top
of cylinder head)
Timing mark
Camshaft sprocket
Timing mark
Timing mark
Crankshaft
sprocket
Timing mark
Oil pump
sprocket
Plug
60 mm or
more
8 mm
Screwdriver
Counter-
balance
shaft
Cylinder
block
Fixing bolt
Belt tension side
Pin hole
Belt tension side
"CATIMING BELT TENSION ADJUSTMENT
1. After turning the crankshaft 1/4 of a revolution in the
anticlockwise direction, turn it in the clockwise direction
until the timing marks are aligned.
2. Loosen the tension pulley fixing bolt, and then use the
special tool and a torque wrench to tighten the fixing
bolt to the specified torque while applying tension to the
timing belt.
Standard value: 3.5 Nm <Timing belt tension torque>
Caution
When tightening the fixing bolt, make sure that the
tension pulley does not turn with the bolt.
3. Turn the crankshaft two revolutions in the clockwise
direction so that the timing marks are aligned. After leaving
it for 15 minutes, measure the amount of protrusion of
the auto tensioner.
Standard value (A): 3.8 - 4.5 mm
4. If the amount of protrusion is outside the standard value,
repeat the operation in steps (1) to (3).
5. Check again to be sure that the timing marks of each
sprocket are aligned.
Tension
direction
MD998767
50 Nm
Auto tensioner
A
ENGINE <4G6> - Timing Belt B 11A-30
TIMING BELT B 11200460106
19 Nm
108 - 127 Nm
1
2
3
4
5
Removal steps
1. Timing belt (Refer to P.11A-26.)
AA" "CA 2. Crankshaft sprocket
"BA 3. Flange
4. Timing belt B tensioner
AB" "AA 5. Timing belt B
AA"CRANKSHAFT SPROCKET REMOVAL
AB"TIMING BELT B REMOVAL
Caution
If timing belt B is to be re-used, use chalk to mark
it with an arrow on its flat side indicating the turning
direction (to the right).
MD998719 or MD998754
MB990767
Crankshaft
sprocket
"AATIMING BELT B INSTALLATION, ADJUSTMENT
1. Install timing belt B by the following procedure.
(1) Ensure that crankshaft sprocket B timing mark and
the counterbalance shaft sprocket timing mark are
aligned.
(2) Fit timing belt B over crankshaft sprocket B and
the counterbalance shaft sprocket. Ensure that there
is no slack in the belt.
2. Adjust the tension of timing belt B by the following
procedure.
(1) Temporarily fix the timing belt B tensioner such that
the centre of the tensioner pulley is to the left and
above the centre of the installation bolt, and
temporarily attach the tensioner pulley so that the
flange is toward the front of the engine.
(2) Holding the timing belt B tensioner up with your
finger in the direction of the arrow, place pressure
on the timing belt so that the tension side of the
belt is taut. Now tighten the bolt to fix the tensioner.
Caution
When tightening the bolt, ensure that the tensioner
pulley shaft does not rotate with the bolt. Allowing
it to rotate with the bolt can cause excessive
tension on the belt.
3. To ensure that the tension is correct, depress the belt
(point A) with a finger. If not, adjust.
Standard value: 5 - 7 mm
"BAFLANGE INSTALLATION
When installing, make sure the direction is correct. See figure.
Counterbalance shaft sprocket
Belt tension side
Timing marks
Timing
marks
Crankshaft
sprocket B
Centre of
tensioner
pulley
Centre of installation
bolt
Shaft
Centre of
tensioner
pulley
Centre of
installation
bolt
A
Crankshaft
Crankshaft
sprocket B
Crankshaft
sprocket
Flange
"CACRANKSHAFT SPROCKET INSTALLATION
NOTE
Apply the minimum amount of engine oil to the bearing surface
and thread of the crankshaft bolt.
MD998719 or MD998754
MB990767
Crankshaft
sprocket
ENGINE <4G6> - Engine Assembly 11A-33
ENGINE ASSEMBLY 11200090015
D Engine Coolant Draining
D Thermostat Case Assembly Removal (Refer to
D Front Exhaust Pipe Removal (Refer to GROUP15.)
D Hood Removal (Refer to GROUP 42.)
D Radiator Assembly Removal (Refer to GROUP14.)
D Air Cleaner Removal
D Thermostat Case Assembly Installation (Refer to
D Engine Coolant Supplying
D Front Exhaust Pipe Installation (Refer to GROUP
15.)
D Hood Installation (Refer to GROUP 42.)
D Radiator Assembly Installation (Refer to GROUP
14.)
D Air Cleaner Installation
O-ring Delivery pipe
Engine oil
1
2
3
4
5
6
7
8
9
10
11
10
12
Removal steps
3. Brake booster vacuum hose con-
nection
6. Idle speed control connector
8. Purge control solenoid valve con-
nector
"DA 10. High-pressure fuel hose connection
13
14
15
16
17
18
19
20
21
22
23
24
25
26
49 Nm
57 Nm*
25
98 Nm
A/C)
AA" 15. Power steering oil pump and
bracket assembly
AB" 16. A/C compressor
17. Alternator connector
18. Oil pressure switch connector
unit connector
connector
22. Camshaft position sensor connector
23. Detonation sensor connector
AC" D Transmission assembly
AD" "CA 24. Engine mount bracket
"BA 25. Engine mount stopper
AE" "AA 26. Engine assembly
Caution
Mounting locations marked by * should be provisionally
tightened, and then fully tightened after placing the vehicle
horizontally and loading the full weight of the engine on
the vehicle body.
ASSEMBLY REMOVAL
NOTE
engine assembly, and tie it with a cord.
AB"A/C COMPRESSOR REMOVAL
Disconnect the A/C compressor connector and remove the
compressor from the compressor bracket with the hose still
attached.
NOTE
Place the removed A/C compressor where it will not be a
hindrance when removing and installing the engine assembly,
and tie it with a cord.
AC"TRANSMISSION ASSEMBLY REMOVAL
<M/T>:
Refer to GROUP 22.
Caution
<A/T>:
Refer to GROUP 23.
AD"ENGINE MOUNT BRACKET REMOVAL
1. Support the engine with a garage jack.
2. Remove the special tool which was attached when the
transmission assembly was removed.
3. Hold the engine assembly with a chain block or similar
tool.
4. Place a garage jack against the engine oil pan with a
piece of wood in between, jack up the engine so that
the weight of the engine is no longer being applied to
the engine mount bracket, and then remove the engine
mount bracket.
AE"ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and harness connectors,
etc., are disconnected from the engine, lift the chain block
slowly to remove the engine assembly upward from the engine
compartment.
<M/T>
Flywheel
Bolt
MZ203827
MB991453
"AAENGINE ASSEMBLY INSTALLATION
Install the engine assembly, checking that the cables, hoses,
and harness connectors are not clamped.
"BAENGINE MOUNT STOPPER INSTALLATION
Clamp the engine mount stopper so that the arrow points
in the direction as shown in the diagram.
"CAENGINE MOUNT BRACKET INSTALLATION
piece of wood in between, and install the engine mount
bracket while adjusting the position of the engine.
2. Support the engine with the garage jack.
3. Remove the chain block and support the engine assembly
with the special tool.
"DAHIGH-PRESSURE FUEL HOSE INSTALLATION
Caution
and left, install it to the delivery pipe, while being careful
not to damage the O-ring. After installing, check that the
hose turns smoothly.
Engine side
Dynamic damper
Arrow
Engine
mount
stopper
Engine mount bracket
11B-1
ENGINE <6A1>
SEALANTS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Timing Check 6 . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Speed Check 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Mixture Check 7 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Pressure Check 8 . . . . . . . . . . . . . . . . .
Manifold Vacuum Check 9 . . . . . . . . . . . . . . . . . . . . . .
Lash Adjuster Check 10 . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING BELT 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ASSEMBLY 30 . . . . . . . . . . . . . . . . . . . . . . .
ENGINE <6A1> - General Information/Service Specifications 11B-2
Items 6A13
Combustion chamber Pentroof type
Intake 12
Number of valve
Exhaust 12
Opening BTDC 15_
Intake
Closing ABDC 53_
Valve timing
Opening BBDC 53_
Exhaust
Closing ATDC 15_
Fuel system Electronically controlled multipoint fuel injection
Auto-lash adjuster Equipped
Alternator drive When a new belt is installed 490- 686 -
belt
tension When checked 9.0- 13.0 -
Deflection
value) mm
Power steering
oil pump and When a new belt is installed 784- 980 -
A/C compressor
drive belt When checked 11.0- 15.0 -
tension
Deflection
value) mm
Basic ignition timing 5_ BTDC3_ -
Ignition timing Approx. 7 BTDC -
ENGINE <6A1> - Service Specifications/Sealants/Special Tools 11B-3
CO contents % 0.2 or less -
HC contents ppm 100 or less -
Compression pressure (250- 400 r/min) kPa 1177 Min. 875
Compression pressure difference of all cylinder kPa - Max. 98
Intake manifold vacuum kPa - Min. 60
Auto-tensioner push rod movement mm Within 1 -
Timing belt tension torque Nm 3 -
Auto-tensioner rod protrusion amount mm 3.8 - 4.5 -
Oil pan MITSUBISHI GENUINE PART
Semi-drying sealant
Flywheel bolt or drive plate bolt 3M Stud Locking 4170 or equivalent -
MB991502 MUT-II sub
assembly
Engine idle speed check
Erasing diagnosis code
MB990767 End yoke holder D Holding the camshaft sprocket
D Holding the crankshaft pulley
MD998719 Crankshaft pulley
holder pin
holder pin
ENGINE <6A1> - Special Tools 11B-4
MD998443 Auto-lash adjuster
holder
Supporting of auto-lash adjuster
installer
Press-in of the camshaft oil seal
seal installer
MB990938 Handle Press-in of the crankshaft rear oil seal
MD998767 Tension pulley
socket wrench
Timing belt tension adjustment
MD998717 Crankshaft front
oil seal installer
Press-in of the crankshaft front oil seal
MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate
<A/T>
GENERAL
SERVICE
TOOL
MZ203827
ENGINE <6A1> - Special Tools/On-vehicle Service 11B-5
assembly
Supporting the engine assembly during
ADJUSTMENT
Standard value:
Tension N 294- 490
Deflection (Reference value) mm 9.0- 13.0
1. Loosen the tension pulley fixing nut.
2. Use the adjusting bolt to adjust the belt tension or
deflection to the standard value.
Standard value:
Items When a used
belt is installed
When a new
belt is installed
Tension N 343- 441 490- 686
Deflection (Reference
value) mm
10.0- 12.0 6.8- 8.0
3. Tighten the fixing nut.
Caution
Turn the crankshaft one full rotation or more clockwise
before this check.
Alternator pulley
Tension pulley
Crankshaft pulley
Fixing nut
Adjusting bolt
ENGINE <6A1> - On-vehicle Service 11B-6
POWER STEERING OIL PUMP AND AIR CONDITIONER
1. Use a belt tension gauge to check that the belt tension
is at the standard value at a point half-way between the
two pulleys (indicated by an arrow in the illustration).
In addition, press this section with a force of 98 N and
check that the amount of belt deflection is at the standard
value.
Standard value:
Items When
checked
When a
used belt is
installed
When a new
belt is
installed
Tension N 490 - 686 539 - 637 784 - 980
Deflection
(Reference
value) mm
11.0 - 15.0 12.0 - 14.0 8.0- 12.0
2. If the tension or deflection is outside the standard value,
(2) Adjust the amount of belt deflection using adjusting
bolt B.
(4) Check the belt deflection amount and tension, and
Caution
IGNITION TIMING CHECK 11100170280
condition.
3. Set up a timing light.
5. Check that engine idle speed is within the standard value.
6. Select No.17 of the MUT-II Actuator test.
7. Check that basic ignition timing is within the standard
value.
8. If the basic ignition timing is outside the standard value,
inspect the MPI system while referring to GROUP 13A
- Troubleshooting.
A
B
Power steering
oil pump pulley
Crankshaft
pulley
A/C compressor
pulley
9. Press the MUT-II clear key (Select a forced driving cancel
mode) to release the Actuator test.
Caution
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this condition
may damage the engine.
10. Check that ignition timing is at the standard value.
Standard value: approx. 7_BTDC
NOTE
1. Ignition timing is variable within about 7_, even
under normal operating.
2. And it is automatically further advanced by about
5_ from standard value at higher altitudes.
condition.
3. Check the basic ignition timing. Adjust if necessary.
4. Run the engine at idle for 2 minutes.
5. Check the idle speed. Select item No. 22 and take a
reading of the idle speed.
Curb idle speed: 650 100 r/min
NOTE
The idle speed is controlled automatically by the idle speed
control (ISC) system.
6. If the idle speed is outside the standard value, check
the MPI components by referring to GROUP 13A -
Troubleshooting.
IDLE MIXTURE CHECK 1110020401
condition.
3. Check that the basic ignition timing is within the standard
value.
4. Run the engine at 2,500 r/min for 2 minutes.
5. Set the CO, HC tester.
6. Check the CO contents and the HC contents at idle.
Standard value
CO contents: 0.2% or less
HC contents: 100 ppm or less
the following items:
D Diagnosis output
D Closed-loop control (When the closed-loop control
is normal, the output signal of the oxygen sensor
changes between 0- 400 mV and 600- 1,000 mV
at idle.)
D Fuel pressure
D Injector
D Ignition coil, spark plug cable, spark plug
D Leak in the EGR system and in the EGR valve
NOTE
Replace the three way catalyst when the CO and HC
contents are not within the standard value, even though
the result of the inspection is normal on all items.
1. Before inspection, check that the engine oil, starter and
battery are normal. In addition, set the vehicle to the
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
4. Disconnect the crank angle sensor connector.
NOTE
Doing this will prevent the engine-ECU from carrying out
ignition and fuel injection.
5. Cover the spark plug hole with a shop towel etc., and
Caution
1. Keep away from the spark plug hole when
cranking.
etc., that has come fromcracks inside the cylinder,
out from the spark plug hole, which is dangerous.
Crank angle
sensor connector
6. Set compression gauge to one of the spark plug holes.
7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 250- 400 r/min):
1,177 kPa
Limit (at engine speed of 250- 400 r/min):
Min. 875 kPa
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: Max. 98 kPa
of engine oil through the spark plug hole, and repeat
the operations in steps 7 and 8.
10. Connect the crank angle sensor connector.
11. Install the spark plugs and spark plug cables.
12. Use the MUT-II to erase the diagnosis codes.
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.
MANIFOLD VACUUM CHECK 11100270393
temperature of the engine coolant reaches 80 to 95_C.
2. Connect a tachometer.
3. Attach a three-way union to the vacuum hose between
the fuel pressure regulator and the air intake plenum,
and connect a vacuum gauge.
4. Start the engine and check that idle speed is within the
standard value. Then read off the vacuum gauge.
Limit: Min. 60 kPa
Compression gauge
Vacuum gauge
Fuel pressure regulator
LASH ADJUSTER CHECK 11100290337
If an abnormal noise (knocking) that seems to be coming
from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused y
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied (for example,
by shifting from N D).
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or has disappeared,
the cause of the noise was probably that oil sludge had
caused the lash adjusters to become stuck. If this
happens, carry out the following check. If the noise level
does not change, go to step 5.
(1) Let the engine cool down sufficiently.
(2) Turn the crankshaft two full revolutions.
(3) Carry out lash adjuster simple check. (Refer to
P.11B-12.)
D If any of the rocker arms can be pushed down
easily during the lash adjuster simple check,
replace the corresponding lash adjusters.
out but all lash adjusters are normal (if none of
the rocker arms could be pushed down easily),
check for some other cause of the problem.
NOTE
or not by carrying out a leak-down test. (Refer to
the Engine Workshop Manual.)
Caution
installation of a new lash adjuster. (Refer to the
5. Bleed the air from the lash adjusters. (Refer to P.11B-12.)
6. If the noise does not disappear even after the air has
been bled from the lash adjusters, carry out the following
check.
Carry out lash adjuster simple check. (Refer to P.11B-12.)
D If one of the rocker arms can be pushed down easily
during the lash adjuster simple check, replace the
corresponding lash adjuster.
D If two or more of the rocker arms can be pushed
down easily during the lash adjuster simple check,
the cause may be that the oil passage to the cylinder
head is blocked.
Check for blockages in the oil passage, and clear
the blockages if any are found. If there are no
blockages, replace the lash adjusters.
out but all lash adjusters are normal (if none of the
rocker arms could be pushed down easily), check
for some other cause of the problem.
NOTE
or not by carrying out a leak-down test. (Refer to the
Caution
installation of a newlash adjuster. (Refer to the Engine
Workshop Manual.)
7. Start the engine and check that the abnormal noise has
disappeared. If necessary, bleed the air from the lash
adjusters. (Refer to P.11B-12.)
<LASH ADJUSTER SIMPLE CHECK>
1. Stop the engine.
3. Set the No.1 cylinder to the compression top dead centre
position.
4. Check the rocker arms indicated by white arrows in the
illustration by the procedures given below.
<Checking an intake-side rocker arm>
Check whether the rocker arm moves downwards when
the part of the rocker arm which touches the top of the
lash adjuster is pushed.
D If the rocker armmoves down easily when it is pushed,
make a note of which is the corresponding lash
adjuster.
D If the rocker arm feels extremely stiff when it is pushed
and does not move down, the lash adjuster is normal,
so check for some other cause of the problem.
<Checking an exhaust-side rocker arm>
NOTE
It will not be possible to depress the Y-shaped rocker
arm at the exhaust valve side if one lash adjuster is
defective but the other one is normal. In such cases,
carry out the following procedure using a thickness gauge.
(1) Check that a thickness gauge with a thickness of
0.1 - 0.2 mm can be inserted easily between the
valve and the lash adjuster.
(2) If the thickness gauge can be inserted easily, make
a note of which is the corresponding lash adjuster.
(3) If the thickness gauge cannot be inserted easily, the
lash adjuster is normal, so check for some other cause
of the problem.
5. Slowly turn the crankshaft 360_ in the clockwise direction.
6. Check the rocker arms indicated by black arrows in the
illustration in the same way as explained in step 4.
<LASH ADJUSTER AIR BLEEDING>
NOTE
(1) If the vehicle is parked on a slope for a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high pressure
chamber when starting the engine.
(2) After parking the vehicle for long periods, the oil drains
out of the oil passage, and it takes time for the oil
to be supplied to the lash adjuster, so air can get
into the high pressure chamber.
(3) If either of the above situations occur, the abnormal
noise can be eliminated by bleeding the air frominside
the lash adjusters.
Timing belt side
ENGINE <6A1> - On-vehicle Service ENGINE <6A1> - On-vehicle Service 11B-13
1. Check the engine oil and replenish or replace the oil
if necessary.
NOTE
(1) If there is a only small amount of oil, air will be drawn
in through the oil screen and will get into the oil
passage.
(2) If the amount of oil is greater than normal, then the
oil will being mixed by the crankshaft and a large
amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
pressure chamber will be compressed when the valve
is open and the lash adjuster will over-compress,
resulting in abnormal noise when the valve closes.
This is the same effect as if the valve clearance is
adjusted to be too large by mistake. If the air inside
the lash adjusters is then released, the operation
of the lash adjusters will return to normal.
2. Run the engine at idle for 1 - 3 minutes to let it warm
up.
3. With no load on the engine, repeat the drive pattern shown
in the illustration at left and check if the abnormal noise
disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
level after 30 repetitions or more, the problem is probably
not due to air inside the lash adjusters.)
4. After the noise has disappeared, repeat the drive pattern
shown in the illustration at left a further 5 times.
5. Run the engine at idle for 1 - 3 minutes and check that
the noise has disappeared.
Good
High
pressure
chamber
Gradually open the
throttle valve.
Drive pattern for air bleeding
Close the throttle
valve.
Approx.
3,000 r/min.
15
seconds
15
seconds
Idle speed
Once
ENGINE <6A1> - Crankshaft Pulley 11B-14
D Drive Belt Tension Adjustment (Refer to P.11B-5.)
177- 186 Nm
1
2
3
(Engine oil)
4 5
Removal steps
1. Drive belt (Power steering oil
pump, or A/C compressor and
power steering oil pump)
AA" "AA 3. Crankshaft bolt
4. Washer
AA"CRANKSHAFT BOLT REMOVAL
"AACRANKSHAFT BOLT INSTALLATION
When installing the crankshaft bolt, apply the minimumamount
of engine oil to the bearing surface and thread of the bolt.
MD998719
MB990767
ENGINE <6A1> - Camshaft and Camshaft Oil Seal 11B-15
<Front bank>
D Engine Coolant Draining and Refilling (Refer to
GROUP 14 - On-vehicle Service.)
D Air Intake Hose Assembly Removal and Installation
P.11B-26.)
1
2
3
4
5
6
7
8
9
10
11
12
13
Apply engine oil to all
sliding parts when
installing.
28 - 34 Nm
88 Nm
22 Nm
24 Nm
3.4 Nm
(Engine oil)
5
Removal steps
AA" "DA 1. Radiator upper hose connection
AA" "DA 2. Radiator lower hose connection
3. Blow-by hose connection
6. Spark plug cable
7. Rocker cover
AB" "CA 8. Camshaft sprocket
10. Engine hanger
11. Thrust case
AC" 12. Rocker arm and shaft assembly
"AA 13. Camshaft
<Rear bank>
D Air Intake Plenum Removal and Installation
D Timing Belt Removal and Installation
(Refer to P.11B-26.)
D Distributor Removal and Installation
Apply engine oil to all
sliding parts when
installing.
3.4 Nm
1
2
6
7
9
12
13
8
28 - 34 Nm
88 Nm
Removal steps
1. Breather hose connection
6. Spark plug cable
7. Rocker cover
AB" "CA 8. Camshaft sprocket
AC" 12. Rocker arm and shaft assembly
"AA 13. Camshaft
AA"RADIATOR UPPER HOSE/RADIATOR LOWER
HOSE DISCONNECTION
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.
AB"CAMSHAFT SPROCKET REMOVAL
AC"ROCKER ARM AND SHAFT ASSEMBLY
REMOVAL
1. Install the special tools as shown in the illustration so
that the lash adjusters will not fall out.
2. Loosen the rocker arm and shaft assembly mounting bolt,
and then remove the rocker arm and shaft assembly with
the bolt still attached.
Caution
Never disassemble the rocker arm and shaft
assembly.
"AACAMSHAFT INSTALLATION
Set the camshaft dowel pins so that they are in the position
Caution
Do not mistake the camshafts for the front bank and the
rear bank. The camshaft for the rear bank has a slit with
a width of approximately 4 mm on its rear end.
"BACAMSHAFT OIL SEAL INSTALLATION
1. Apply engine oil to the camshaft oil seal lip.
2. Use the special tool to press-fit the camshaft oil seal.
MB990767
MD998715
MD998443
Approx.
35_
Approx.
35_
<Front bank side> <Rear bank side>
Dowel
pin
Dowel
pin
MD998713
MD991559
MD998713
<Front bank side> <Rear bank side>
"CACAMSHAFT SPROCKET INSTALLATION
Use the special tool to stop the camshaft sprocket from turning
"DARADIATOR LOWER HOSE/RADIATOR UPPER
HOSE CONNECTION
1. Insert each hose as far as the projection of the water
inlet fitting.
2. Align the mating marks on the radiator hose and hose
clamp, and then connect the radiator hose.
Caution
Be sure to install the clamp as far as the old clamp
position.
ENGINE <6A1> - Oil Pan 11B-19
OIL PAN 11200280214
D Engine Oil Draining and Supplying (Refer to GROUP
D Oil Level Gauge Removal and Installation
to GROUP 15.)
D Under Cover Removal and Installation
D Starter Motor Removal and Installation
7 Nm
7 Nm
1
2
3
4
5
39 Nm
44 Nm
44 Nm
7 Nm
Groove
Bolt
hole
Sealant:
7 Nm
5
3
Removal steps
1. Drain plug
AA" 3. Lower oil pan
4. Cover
AA" 5. Upper oil pan
ENGINE <6A1> - Oil Pan 11B-20
AA"LOWER OIL PAN/UPPER OIL PAN REMOVAL
Caution
flange.
MD998727 MD998727
Drain plug
gasket
Oil pan side
ENGINE <6A1> - Crankshaft Oil Seal 11B-21
1
2
3
4
5
6
7
8
9
10
11
<M/T>
<A/T>
<M/T>
(Engine oil:
bolt wash-
er surface)
Crankshaft
<A/T>
(Engine oil:
bolt washer
surface)
Crankshaft
Sealant: 3M Stud Locking
4170 or equivalent
Lip section
Lip section
7
8
10
5
11
Engine oil
93 - 103 Nm
steps
D Timing belt (Refer to P.11B-26.)
2. Crankshaft sensing blade
3. Crankshaft spacer
4. Key
steps
AB" "BA 6. Plate <M/T>
<M/T>:
Refer to GROUP 22.
Caution
<A/T>:
Refer to GROUP 23.
AB"PLATE <M/T>/ADAPTER PLATE/FLYWHEEL
<M/T>/DRIVE PLATE <A/T> REMOVAL
PLATE/PLATE <M/T> INSTALLATION
plate bolts.
<M/T>
Flywheel
Bolt
MD998781
Crankshaft
rear oil seal
MD990938
MD998776
Crankshaft
2. Tap the oil seal unit it is flush with the oil seal case.
Crankshaft
MD998717
MD998717
Oil seal
ENGINE <6A1> - Cylinder Head Gasket 11B-24
D Engine Coolant Draining and Refilling (Refer to
D Air Intake Hose Assembly Removal and Installation
D Radiator Assembly Removal and Installation (Refer
to GROUP 14 - Radiator.)
D Air Intake Plenum and Intake Manifold Removal and
Installation (Refer to GROUP15 - Air Intake Plenum.)
D Engine Cover Removal and Installation
P.11B-26.)
to GROUP 15.)
D Thermostat Case Assembly Removal and Installation
(Refer to GROUP 14 - Water Hoses and Pipes.)
D Water Inlet Pipe Removal and Installation (Refer to
GROUP 14 - Water Hoses and Pipes.)
1
2
3
4
5
6
7
8
9
10
11
3.4 Nm
3.4 Nm
(Engine oil)
35 Nm
10 - 12 Nm
11
4
2
5
9
(Engine oil)
20 Nm + 120_ + 120_
20 Nm + 120_ + 120_
Removal steps
5. Spark plug cable
6. Rocker cover
7. Idler pulley
8. Timing belt rear centre cover
AA" "BA 9. Cylinder head bolt
ENGINE <6A1> - Cylinder Head Gasket 11B-25
AA"CYLINDER HEAD BOLT REMOVAL
assembly.
surface.
2. Install the gasket to thecylinder block with theidentification
mark facing upwards.
Limit (A): 96.4 mm
4. Install the bolts by the following procedure.
(1) Tighten the bolts to 20 Nm in the sequence shown
(2) From the position in (1) above, turn each bolt a further
120_ in the same sequence.
(3) Turn each bolt a further 120_ in the same sequence.
Caution
1) If the tightening angle is less than 120_, that
bolt will not be sufficiently tight.
2) If a bolt is tightened by more than the specified
angle, loosen the bolts and repeat the
procedure from step (1).
Front of
engine
Intake side
<Front bank side> Exhaust side
<Rear bank side>
Exhaust side
Identification mark
Head bolt
Burred side
Head bolt
washer
(Engine
oil)
Cylinder
head
A
Front of
engine
<Front bank side> Exhaust side
Exhaust side
Intake side <Rear bank side>
ENGINE <6A1> - Timing Belt 11B-26
D Crankshaft Pulley Removal and Installation
D Alternator Removal and Installation
10 - 12 Nm
10 - 12 Nm
10 - 12 Nm
24 Nm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
44 Nm
12 Nm
3 Nm
22 Nm
35 Nm
24 Nm
Removal steps
1. Engine cover
2. Engine mount stay
3. Power steering hose clamp bolt
4. Crank angle sensor mounting bolt
5. Oil level gauge assembly
6. Engine hanger
7. Tension pulley bracket assembly
8. Tensioner bracket
9. Timing belt cover (front, upper
right)
10. Timing belt cover (front, upper left)
11. Timing belt cover (front, lower)
12. Flange
"CA D Timing belt tension adjustment
AA" "BA 13. Timing belt
"AA 14. Auto tensioner
AA"TIMING BELT REMOVAL
1. Align each of the timing marks.
2. Loosen the centre bolt of the tension pulley and remove
the timing belt.
Caution
(1) If the timing belt is to be reused, use chalk to
mark it with an arrow on its flat side indicating
the turning direction.
(2) If the timing belt is to be re-used, be careful not
to damage the teeth of the timing belt against
the edges of the camshaft sprocket when
removing the timing belt.
"AAAUTO TENSIONER INSTALLATION
1. Apply 98 - 196 N force to the auto tensioner by pressing
it against a metal (cylinder block, etc.), and measure the
movement of the push rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A - B: Movement
2. If it is out of the standard value, replace the auto tensioner.
3. Use a press or vice to gently compress the auto tensioner
push rod until pin hole A of the push rod and pin hole
B of the tensioner cylinder are aligned.
Caution
If the compression speed is too fast, the rod may
become damaged, so be sure to carry out this
operation slowly.
4. Once the holes are aligned, insert the set pin.
NOTE
When replacing the auto tensioner with a new part, the
pin will be in the auto tensioner.
5. Install the auto tensioner to the engine.
Timing
marks
Tensioner
pulley
Timing belt
Movement
Push rod
Auto tensioner
A B
98 N - 196 N
A B
Set pin
"BATIMING BELT INSTALLATION
1. Check that the timing marks of the both camshaft
sprockets and the crankshaft sprocket are aligned.
NOTE
In this condition, the No.1 cylinder will be in the
compression top dead centre position.
2. Install the timing belt so that there is no slackness on
the tension sides of the belt (A, B, C and D).
Caution
Be careful not to damage the teeth of the timing belt
against the edges of the camshaft sprocket when
installing the timing belt.
NOTE
If reusing the old timing belt, install it so that the arrow
made on the belt during removal is pointing in the direction
of rotation (clockwise).
3. Set the tensioner pulley so that the pin holes are at the
bottom, press the tensioner pulley lightly against the timing
belt, and then provisionally tighten the fixing bolt.
4. Apply force to the rear bank side camshaft sprocket in
the direction of the arrow to apply tension to the tension
sides (A, B, C and D), and check that all of the timing
marks are aligned at this time.
Camshaft
sprocket
Crank-
shaft
sprocket
Timing
marks
Camshaft
sprocket
Rocker cover Rocker cover
Tension side C
Tension side D
Rear
bank
side
camshaft
sprocket
Tension side A Tension side B
Fixing bolt
Pin holes
"CATIMING BELT TENSION ADJUSTMENT
1. After turning the crankshaft 1/4 of a revolution in the
anticlockwise direction, turn it in the clockwise direction
until the timing marks are aligned.
2. Loosen the tensioner pulley fixing bolt, and then use
the special tool and a torque wrench to tighten the fixing
bolt to the specified torque while applying tension to the
timing belt.
Standard value: 3 Nm <Timing belt tension torque>
Caution
When tightening the fixing bolt, make sure that the
tensioner pulley does not turn with the bolt.
3. Turn the crankshaft two revolutions in the clockwise
direction, and after leaving it for 5 minutes or more, check
if the set pin of the auto tensioner can be removed and
inserted easily.
NOTE
If the set pin cannot be inserted easily, the auto tensioner
is good. Check if the amount of protrusion of the auto
tensioner rod is within the standard value.
If the amount of protrusion is outside the standard value,
repeat the procedure in steps 1 to 3
4. Check to be sure that the timing marks of each sprocket
are aligned.
Tensioner
pulley
Tension direction
MD998767
48 Nm
A
ENGINE <6A1> - Engine Assembly 11B-30
D Radiator Removal (Refer to GROUP 14.)
D Engine Cover Removal
D Battery Removal
15.)
D Radiator Installation (Refer to GROUP 14.)
D Engine Cover Installation
D Battery Installation
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
O-ring
Engine oil
9
19
18 Nm
23
24
Removal steps
2. Capacitor connector
4. TPS connector
5. Accelerator pedal position sensor
connector <TCL>
6. ISC connector
7. Control harness connector
8. Distributor connector
connector
unit connector
13. Power steering oil pressure switch
connector
14. Oil pressure harness connector
15. Thermo switch connector
16. Crank angle sensor connector
17. Brake booster vacuum hose con-
nection
"DA 19. High-pressure fuel hose connection
20. Earth cable connection
21. Control harness connector
22. Front harness connector
connector
12 Nm
57 Nm
25
26
27
28
29
30
31
32
34
33
39 Nm
67 Nm
35 Nm
27
33
98 - 118 Nm*
12 Nm
27
A/C)
27. Clamp bolt (Power steering hose
and pipe)
AA" 28. Power steering oil pump assembly
Caution
Mounting locations marked by * should be
provisionally tightened, and then fully tightened
after placing the vehicle horizontally and loading
the full weight of the engine on the vehicle
body.
ASSEMBLY REMOVAL
NOTE
attached.
NOTE
<M/T>:
Refer to GROUP 22.
Caution
<A/T>:
Refer to GROUP 23.
tool.
mount bracket.
compartment.
<M/T>
Flywheel
Bolt
MZ203827
MB991453
"DAHIGH-PRESSURE FUEL HOSE INSTALLATION
Caution
and left, install it to the delivery pipe, while being careful
not to damage the O-ring. After installing, check that the
hose turns smoothly.
Engine side
Dynamic damper
Arrow
Engine
mount
stopper
NOTES
11C-1
ENGINE <4D6>
SEALANTS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Clearance Check and Adjustment 8 . . . . . . . .
Injection Timing Check and Adjustment 10 . . . . . . . .
Idle Speed Check 12 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Pressure Check 12 . . . . . . . . . . . . . . . .
Timing Belt Tension Adjustment 13 . . . . . . . . . . . . . . .
OIL PAN 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING BELT 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMING BELT B 30 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ASSEMBLY 33 . . . . . . . . . . . . . . . . . . . . . . .
ENGINE <4D6> - General Information/Service Specifications 11C-2
Items 4D68
Combustion chamber Vortex chamber type
Number of valve Intake 4
Exhaust 4
Valve timing Intake Opening BTDC 20_
Closing ABDC 48_
Exhaust Opening BBDC 54_
Closing ATDC 22_
Fuel system Distribution type injection pump
Adjusting screw Elephant foot type
Alternator Tension N When checked 343 - 490 -
drive belt
tension When a used belt is installed 392 - 490 -
When a new belt is installed 490 - 588 -
Deflection Centre of belt When checked 8.0 - 10.0 -
(Reference
value) mm
between alternator
pulley and water
pump pulley
When a used belt is
installed
8.0 - 9.4 -
When a new belt is
installed
7.0 - 8.0 -
Centre of belt When checked 7.9 - 9.9 -
between crankshaft
pulley and alternator
pulley
When a used belt is
installed
7.9 - 9.2 -
When a new belt is
installed
6.8 - 7.9 -
ENGINE <4D6> - Service Specifications/Sealants 11C-3
Power Tension N When checked 294 - 490 -
steering oil
pump drive When a used belt is installed 343 - 441 -
belt tension
Deflection When checked 12.6 - 16.3 -
mm
When a used belt is installed 13.4 - 15.3 -
When a new belt is installed 10.0 - 12.6 -
A/C com- Tension N When checked 392 - 588 -
pressor
drive belt When a used belt is installed 441 - 539 -
tension
Deflection When checked 9.2 - 12.0 -
mm
When a used belt is installed 9.8 - 11.2 -
When a new belt is installed 7.0 - 8.6 -
Valve clearance (at hot) Intake valve 0.35 -
mm
Exhaust valve 0.45 -
Injection timing (Dial gauge display value mm) 1 0.03
(10_ATDC)
-
Compression pressure kPa 3,500 Min. 2,560
Compression pressure difference of all cylinder
(at engine speed of 280 r/min) kPa
- Max. 300
Timing belt deflection mm 4 - 5 -
Timing belt B deflection mm 5 - 7 -
Oil pan MITSUBISHI GENUINE PART
Semi-drying sealant
Semi-circular packing and rocker
cover seal, and cylinder head seal
3M ATD Part No.8660 or equivalent
Flywheel bolt or adapter plate bolt 3M Stud Locking 4170 or equivalent -
ENGINE <4D6> - Special Tools 11C-4
MB991502 MUT-II sub
assembly
Idle speed check
MB998720 Prestroke
measuring adapter
Adjustment of the injection timing
MB990767 End yoke holder Holding the camshaft sprocket
holder pin
holder pin
installer
Installing the camshaft oil seal
seal installer
MB990938 Handle
ENGINE <4D6> - Special Tools 11C-5
MD998382 Crankshaft front oil
seal installer
Installing the crankshaft front oil seal
MD998383 Crankshaft front oil
seal guide
MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate
<A/T>
GENERAL
SERVICE
TOOL
MZ203827
MB991453 Engine hanger as-
sembly
ENGINE <4D6> - On-vehicle Service ENGINE <4D6> - On-vehicle Service 11C-6
ADJUSTMENT
Standard value:
Tension N 343 - 490
Deflection (Reference Portion A 8.0 - 10.0
value) mm
Portion B 7.9 - 9.9
1. Loosen the nut of the alternator pivot bolt.
2. Loosen the lock bolt.
3. Use the adjusting bolt to adjust the belt tension and belt
deflection to the standard values.
Standard value:
Items When a
used belt is
installed
When a new
belt is
installed
Tension N 392 - 490 490 - 588
Deflection Portion A 8.0 - 9.4 7.0 - 8.0
(Reference
value) mm
Portion B 7.9 - 9.2 6.8 - 7.9
4. Tighten the lock bolt.
5. Tighten the nut of the alternator pivot bolt.
6. Tighten the adjusting bolt.
Caution
Alternator
pulley
Water pump
pulley
Crankshaft
pulley
A
B
Adjusting bolt
Lock
bolt
Pivot bolt
ENGINE <4D6> - On-vehicle Service 11C-7
POWER STEERING OIL PUMP DRIVE BELT TENSION
CHECK AND ADJUSTMENT 11100110183
1. Check the tension by pulling or pushing at the centre
of the belt between pulleys with a force of 98 N as shown
in the figure. Measure drive belt deflection amount.
Standard value:
Items When
checked
When a
used belt is
installed
When a new
belt is
installed
Tension N 294 - 490 343 - 441 490 - 686
Deflection
(Reference
value) mm
12.6 - 16.3 13.4 - 15.3 10.0 - 12.6
2. If the tension is outside the standard value, adjust by
(1) Loosen oil pump fixing bolts A and B. Check that
the slide bushing at the place where bolt B was
installed is touching the A/C bracket and that there
is no looseness in the oil pump mounting.
(2) While holding a bar or similar tool against the oil
pump body, apply a suitable amount of force to the
belt with your hand to adjust the tension of the belt.
(3) Tighten oil pump fixing bolts A and B in that order.
(4) Check the belt tension, and readjust if necessary.
Caution
Power steering
oil pump pulley
Water pump
pulley
Oil pump
A
B
1. Check the tension by pulling or pushing at the centre
of the belt between pulleys with a force of 98 N as shown
in the figure. Measure drive belt deflection amount.
Standard value:
Items When
checked
When a
used belt is
installed
When a new
belt is
installed
Tension N 392 - 588 441 - 539 637 - 833
Deflection
(Reference
value) mm
9.2 - 12.0 9.8 - 11.2 7.0 - 8.6
2. If the tension is outside the standard value, adjust by
(2) Adjust the belt tension using adjusting bolt B.
(4) Check the belt frequency, tension or deflection, and
Caution
VALVE CLEARANCE CHECK AND
1. Start the engine and allow it to warm up until the engine
coolant temperature reaches 80 to 95 _C.
2. Remove the timing belt upper cover.
4. Remove the glow plug plate and all of the glow plugs.
5. Turn the crankshaft clockwise to align the crankshaft pulley
timing mark and to set the No.1 cylinder or No.4 cylinder
to the compression top dead centre position.
NOTE
Aligning the camshaft sprocket timing mark will set the
No.1 cylinder to the compression top dead centre position.
If the crankshaft is turned one more full revolution from
this position, the No.4 cylinder will be set to the
compression top dead centre position.
A/C compressor
pulley
A
B
Crankshaft
pulley
Camshaft
sprocket
Timing
marks
Timing marks
Crankshaft
pulley
6. Measure the valve clearance in the places indicated by
arrows in the illustration.
Arrow A: When the No.1 cylinder is at compression top
dead centre
Arrow B: When the No.4 cylinder is at compression top
dead centre
Standard value:
When warm When cold (NOTE)
Intake 0.35 mm 0.25 mm
Exhaust 0.45 mm 0.35 mm
NOTE
(1) When inserting the thickness gauge, press the pad
from the opposite side using a flat-tipped screwdriver
or similar tool to make a gap for the thickness gauge
to be inserted.
(2) If you attempt to insert the thickness gauge without
using a flat-tipped screwdriver to make a gap, the
pad will become tilted as shown in the illustration,
and it will not be possible to insert the thickness gauge.
7. If the clearance is outside the standard value, loosen
the lock nut and turn the adjusting screw while using
a thickness gauge to adjust the clearance.
Timing
belt
side
A
B
Pad
Thickness gauge
Flat-tipped
screwdriver
Adjusting
screw
Thickness
gauge
Pad
Thickness
gauge
8. Tighten the lock nut while holding the adjusting screw
with a screwdriver so that it doesnt turn.
9. Turn the crankshaft one full revolution to align the
crankshaft pulley timing mark.
10. Adjust the remaining valves by the same procedure as
in steps 7. - 9. above.
11. Install the glow plugs and the glow plug plate.
12. Install the rocker cover.
13. Install the timing belt upper cover.
INJECTION TIMING CHECK AND
1. Remove all of the glow plugs.
3. Align the timing marks of the camshaft sprocket and set
the No.1 cylinder to the top dead centre position.
4. Remove the timing check plug at the rear of the injection
pump.
5. Install the special tool to the timing check plug hole at
the rear of the injection pump.
6. Connect the dial gauge to the special tool.
Camshaft
sprocket
Timing
marks
Timing marks
Crankshaft
pulley
Timing check plug
MD998720
Dial gauge
7. Turn the crankshaft clockwise to move the No.1 cylinder
approximately 30_ before compression top dead centre.
8. Set the needle of the dial gauge to 0.
9. Check that the needle doesnt move even if the crankshaft
is turned slightly (2 - 3_) in both clockwise and
anti-clockwise direction.
NOTE
If the needle moves, the notch is not positioned properly,
so once again move the No.1 cylinder approximately 30_
before compression top dead centre.
10. Turn the crankshaft clockwise to align the No.1 cylinder
to 10_ ATDC.
11. Check that the value indicated on the dial gauge is at
the standard value.
Standard value: 1 0.03 mm
12. If the value is outside the standard value, adjust the
injection timing by the following procedure.
(1) Loosen the injection pipe union nuts (4 places) on
the injection pump. (Do not remove the union nuts.)
Caution
When loosening the nuts, hold the delivery valve
holders with a spanner so that they dont turn
at the same time.
(2) Loosen the upper mounting nuts and the lower
mounting bolts of the injection pump. (Do not remove
the nut and bolt.)
(3) Tilt the injection pump to the left or right and adjust
the needle on the dial gauge so that the display value
is uniform.
(4) Provisionally tighten the mounting nuts and bolts of
the injection pump.
(5) Repeat steps 7 - 12 to check if the adjustment has
been made correctly.
(6) Tighten the mounting nuts and bolts securely.
(7) Tighten the injection pump union nuts securely.
Caution
When tightening the nuts, hold the delivery valve
holders with a spanner so that they dont turn
at the same time.
13. Remove the special tool.
14. Install a new gasket to the timing check plug.
15. Tighten the timing check plug securely.
Set to 0
Approx.
30_
Timing mark
Set to 10_
ATDC
1 0.03 mm
Nuts
Bolts
When the value is
1 0.03 mm or more
When the value
is 1 0.03 mm
or less
NOTE
Check that the injection timing is normal, and then perform
this check.
condition.
3. Start the engine and check that the idle speed is at the
standard value.
4. If the idle speed is not at the standard value, refer to
GROUP 13E - Troubleshooting.
1. Before inspection, check that the engine oil, starter motor
and battery are normal. In addition, set the vehicle to
the pre-inspection condition.
3. Disconnect the fuel cut solenoid valve connector.
NOTE
Doing this will prevent carrying out fuel injection.
4. Cover the glow plug hole with a shop towel etc., and
Caution
1. Keep away fromthe glowplug hole when cranking.
etc,. that has come fromcracks inside the cylinder,
out from glow plug hole, which is dangerous.
Fuel cut solenoid
valve connector
5. Set compression gauge to one of the glow plug holes.
6. Crank the engine and measure the compression pressure.
Standard value:
3,500 kPa (at engine speed of 280 r/min)
Limit: Min. 2,560 kPa (at engine speed of 280 r/min)
7. Measure the compression pressure for all cylinders, and
check that the pressure differences of the cylinders are
below the limit.
Limit: Max. 300 kPa
of engine oil through the glow plug hole, and repeat the
operations in steps 6 and 7.
9. Connect the fuel cut solenoid valve connector.
TIMING BELT TENSION ADJUSTMENT 11100280174
There are two timing belts: one is the timing belt for the
valve timing, and the other is the timing belt B for driving
the right-side counterbalance shaft.
3. Turn the crankshaft clockwise and check that there is
nothing wrong with the timing belt. Replace the belt if
necessary.
4. Turn the crankshaft clockwise to set the No.1 cylinder
to the compression top dead centre position.
Compression gauge
Adapter
Timing marks
5. Turn the crankshaft anti-clockwise by 1/2 the width of
a camshaft sprocket tooth in order to take up the slack
in the idler pulley belt (the side where the belt is slack).
6. Loosen the timing belt tensioner mounting bolt by 1/4
- 1/3 a turn, and use the force of the tensioner spring
to apply tension to the belt.
7. Turn the crankshaft anti-clockwise again by the width
of three camshaft sprocket teeth.
8. Securely tighten the timing belt tensioner mounting bolt.
9. Turn the crankshaft clockwise to align the timing mark.
10. Press the belt at the point between the camshaft sprocket
and the injection pump sprocket with your index finger
to check the belt deflection.
Standard value: 4.0 - 5.0 mm
11. Install the timing belt upper cover.
1/2 the
width of
a tooth
Timing mark
Timing mark
Timing mark
Width
of 2-1/2
teeth
1/2 the
width of
a tooth
Timing mark
Injection
pump
sprocket
Deflection
Camshaft
sprocket
ENGINE <4D6> - Crankshaft Pulley 11C-15
D Drive Belt Tension Adjustment (Refer to P.11C-6.)
25 Nm
1
2
3
4
Removal steps
1. Drive belt (Power steering)
2. Drive belt (A/C)
ENGINE <4D6> - Camshaft and Camshaft Oil Seal 11C-16
(Refer to P.11C-26.)
D Air Pipe A Removal and Installation
D Vacuum Pump Removal and Installation
Cam section
and journal
section
Lip section
Engine oil
1
2
3
4
5
6
7
8
6 Nm
27 - 31 Nm
19 - 21 Nm
88 Nm
19 - 21 Nm
27 - 31 Nm
19 - 21 Nm
5
8
7
7
Removal steps
2. Control harness
3. Rocker cover
AA" "DA 4. Camshaft sprocket
"CA 5. Camshaft oil seal
"BA 6. Rocker arm and shaft assembly
"AA 7. Camshaft bearing cap
8. Camshaft
ENGINE <4D6> - Camshaft and Camshaft Oil Seal 11C-17
AA"CAMSHAFT SPROCKET REMOVAL
"AACAMSHAFT BEARING CAP INSTALLATION
The cap numbers are embossed on the top surface of the
bearing caps, so install in the order of the numbers. However,
no numbers are embossed on bearing caps 1 and 5.
"BAROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
1. Install the rocker arm and shaft assembly to the bearing
caps.
2. Set the rocker arm springs into the bearing cap indents.
3. Check the valve clearance and adjust if necessary.
(Refer to P.11C-8.)
"CACAMSHAFT OIL SEAL INSTALLATION
circumference of the oil seal lip and camshaft.
2. Use the special tool to tap in the oil seal.
NOTE
The oil seal should be tapped in until the distance from
the end of the camshaft to the end of the oil seal is
"DACAMSHAFT SPROCKET INSTALLATION
Use the special tool to stop the camshaft sprocket fromturning
MB990767
MD998719 or
MD998754
Camshaft sproket
side
Cap No.
Indent
Bearing cap
Oil seal
Camshaft
MD998364
5.5 mm
ENGINE <4D6> - Oil Pan 11C-18
OIL PAN 11200280221
D Front Exhaust Pipe Removal and Installation
D Engine Oil Level Gauge Removal and Insertion
D Engine Oil Draining and Refilling
(Refer to GROUP 12 - On-vehicle Service.)
f4 1 mm
Bolt
hole
Groove
B
Sealant:
BOLT IDENTIFICATION
A: 6 8 mm
B: 6 10 mm
1
2
3
4
5
6
7
29 - 34 Nm
9 Nm
39 Nm
7 Nm
Washer assembled bolt
9 Nm
Flange bolt
10 Nm
A
B
B
B
B
7
7
Removal steps
1. Drain plug
3. Oil filter
4. Engine oil cooler pipe connection
5. Bell housing cover
6. Oil level sensor
AA" 7. Oil pan
ENGINE <4D6> - Oil Pan 11C-19
AA"OIL PAN REMOVAL
Caution
flange.
MD998727 MD998727
Drain plug
gasket
Oil pan side
ENGINE <4D6> - Crankshaft Oil Seal 11C-20
(Engine oil:
bolt washer
surface)
(Engine oil:
bolt washer
surface)
<M/T>
<A/T>
(Engine oil)
Lip section
Lip section
Engine oil
Crankshaft
Crankshaft
Sealant: 3M Stud Locking 4170 or equivalent
1
2
3
4
5
6
7
8
9
10
11
127 - 137 Nm
108 - 127 Nm
127 - 137 Nm
10
6
11
5
9
steps
D Timing belt (Refer to P.11C-26.)
2. Flange
3. Crankshaft sprocket B
4. Key
steps
10. Crankshaft bushing
<M/T>:
Refer to GROUP 22.
Caution
<A/T>:
Refer to GROUP 23.
AB"ADAPTER PLATE/FLYWHEEL <M/T>/DRIVE
PLATE <A/T> REMOVAL
PLATE INSTALLATION
plate bolts.
<M/T>
Flywheel
Bolt
MD998781
Crankshaft
rear oil seal
MD990938
MD998776
Crankshaft
2. Tap the oil seal unit it is flush with the oil seal case.
Crankshaft
Oil seal
MD998382 MD998383
Front
lower
case
ENGINE <4D6> - Cylinder Head Gasket ENGINE <4D6> - Cylinder Head Gasket 11C-23
D Engine Coolant Draining and Refilling
(Refer to GROUP 15 - Intercooler.)
D Vacuum Pump Removal and Installation
D Thermostat Case Assembly Removal and Installation
(Refer to GROUP 14 - Water Hoses and Pipes.)
19 - 21 Nm
13 Nm
88 Nm 0 Nm 39 Nm + 90_ + 90_
O-ring
Engine oil
6 Nm
27 - 31 Nm
12 - 15 Nm
44 Nm
24 Nm 10 - 12 Nm
29 Nm
9 Nm
27 - 31 Nm
27 - 31 Nm
1
2
3
4
5
6
8
9
10
11 12
13
14
15
17
18
19
16
16
20
7
Removal steps
2. Control harness
3. Rocker cover
AA" "DA 4. Fuel injection pipe
5. Camshaft bearing cap
6. Glow plug plate
"CA 7. Rocker arm and shaft assembly
9. Water temperature sensor connector
10. Vacuum air temperature sensor
connector
unit connector
connection
13. Timing belt rear centre cover
14. Front exhaust pipe connection
15. Oil return pipe connection
16. Oil level gauge guide assembly
17. Alternator brace
AB" "BA 18. Cylinder head bolt
11C-24
AA"FUEL INJECTION PIPE REMOVAL
When loosening nuts at injection pipe ends, hold the nut
at other side (delivery holder nut for pump side, nozzle holder
nut at nozzle side) with wrench.
Caution
After disconnecting the injection pipe, plug the opening
so that no foreign particles get inside the pump or into
the injection nozzle.
AB"CYLINDER HEAD BOLT REMOVAL
assembly.
surface.
2. Check the number of identification holes on the cylinder
head gasket that was removed, and select a cylinder
head gasket with the same number of identification holes.
3. Place the cylinder head gasket on top of the cylinder
block so that the identification mark is facing upwards
Limit (A): 119.7 mm
Intake side
Front of engine
Exhaust side
3 5 10 8 2
1 7 9 6 4
Identification holes
Identification mark
Head bolt
Burred side
Headbolt
washer
(Engine
oil)
Cylinder
head
A
ENGINE <4D6> - Cylinder Head Gasket 11C-25
4. Tighten the bolts by the following procedure.
Step Operation Remarks
2 Fully loosen. Carry out in the reverse
order of that shown in the
illustration.
illustration. Mark the head
of the cylinder head bolt
and cylinder head by paint.
illustration. Check that the
painted mark of the head
bolt is lined up with that of
the cylinder head.
Caution
(1) Always make a tightening angle just 90_. If it is less
than 90_, the head bolt will be loosened.
(2) If it is more than 90_, remove the head bolt and repeat
the procedure from step 1.
"CAROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION
1. Install the rocker arm and shaft assembly to the bearing
caps.
2. Set the rocker arm springs into the bearing cap indents.
3. Check the valve clearance and adjust if necessary.
(Refer to P.11C-8.)
"DAFUEL INJECTION PIPE INSTALLATION
When tightening the nuts at both ends of the fuel injection
pipe, hold the delivery holder (for pump side) and the fuel
injection nozzle assembly (for nozzle side) with a wrench,
and tighten the nuts to the specified torque.
Intake side
Front of engine
Exhaust side
8 6 1 3 9
10 4 2 5 7
Step 4
90_
Painted mark
Step 5
90_
Painted mark
Indent
Bearing cap
Fuel injection pipe
Nut
Nozzle holder
ENGINE <4D6> - Timing Belt 11C-26
10 - 12 Nm
9 Nm
25 Nm
23 Nm
19 Nm
10 - 12 Nm
10 - 12 Nm
10 - 12 Nm
9 Nm
10 - 12 Nm
1
2
3
4
5
6
7
Removal steps
1. Water pump pulley
2. A/C tension pulley assembly
AA" 3. Timing belt front upper cover
4. Timing belt front centre cover
5. Timing belt front lower cover
6. Injection pump bracket stay
"BA D Timing belt tension adjustment
AB" "AA 7. Timing belt
AA"TIMING BELT FRONT UPPER COVER
INSTALLATION
Attach protective tape to the engine mount bracket, and then
remove the timing belt front upper cover.
AB"TIMING BELT REMOVAL
1. Align the timing marks.
2. Loosen the installation bolt of the timing belt tensioner.
3. Move the timing belt tensioner downward and loosely
tighten the bolt so that the tensioner doesnt return; then
remove the timing belt.
Caution
If the timing belt is to be re-used, use chalk to mark
(on its flat side) an arrow indicating the clockwise
direction.
Protective tape
Timing marks
Thread diameter
length pitch (mm) Move to the bottom
of the slot.
"AATIMING BELT INSTALLATION
1. Ensure that the timing marks of the camshaft sprocket,
the injection pump sprocket, the crankshaft sprocket, and
the oil pump sprocket are all aligned.
2. Move the timing belt tensioner downward and loosely
tighten the bolt so that the tensioner doesnt return.
3. Install the timing belt onto the crankshaft sprocket, the
timing belt idler, the camshaft sprocket, the injection pump
sprocket, and the oil pump sprocket in that order.
Caution
If the timing belt is reused, install so that the arrow
marked on it at the time of removal is pointing in
the clockwise direction.
"BATIMING BELT TENSION ADJUSTMENT
1. Turn the crankshaft anti-clockwise by a distance
equivalent to 1/2 tooth of the camshaft sprocket in order
to correct looseness at the timing belt idler side.
2. Loosen (by 90_ to 120_ turn) the tensioner installation
bolt previously secured provisionally, taking advantage
of the force of the tensioner spring to provide tension
to the belt.
3. Inaddition, turn thecrankshaft anti-clockwiseby adistance
equivalent to 2-1/2 teeth.
4. Tighten the timing belt tensioner to the specified torque.
5. Turn the crankshaft clockwise and align the timing mark.
Timing marks
Injection
pump
sprocket
Camshaft sprocket
Timing mark
Timing mark
Oil pump
sprocket
Crankshaft
sprocket
Move to the
bottom of the slot.
Timing mark
1/2 tooth
Timing mark
2-1/2 teeth
Timing mark
Timing mark
6. Using the index finger, press between the camshaft
sprocket and the injection pump sprocket, and check
whether or not the amount of flexion is within the standard
value range.
Standard value: 4 - 5 mm Injection
pump
sprocket
Camshaft
sprocket
ENGINE <4D6> - Timing Belt B 11C-30
TIMING BELT B 11200460113
(Engine oil)
48 Nm
19 Nm
108 - 127 Nm
1
2
3
4
5
Removal steps
1. Idler pulley
AA" "BA 2. Crankshaft sprocket
3. Flange
4. Timing belt tensioner
AB" "AA 5. Timing belt B
AA"CRANKSHAFT SPROCKET REMOVAL
Crankshaft
sprocket
MB991385
MB991367
AB"TIMING BELT B REMOVAL
Caution
If the timing belt B is to be re-used, use chalk to
mark (onits flat side) anarrowindicating the clockwise
direction.
"AATIMING BELT B INSTALLATION
1. Install the timing belt B by the following procedure.
(1) Ensure that crankshaft sprocket B timing mark and
the counterbalance shaft sprocket timing mark are
aligned.
(2) Fit timing belt B over crankshaft sprocket B and
the counterbalance shaft sprocket. Ensure that there
is no slack in the belt.
2. Adjust timing belt B by the following procedure,
(1) Temporarily fix the timing belt B tensioner such that
the centre of the tensioner pulley is to the left and
above the centre of the installation bolt, and
temporarily attach the tensioner pulley so that the
flange is toward the front of the engine.
(2) Holding the timing belt B tensioner up with your
finger in the direction of the arrow, place pressure
on the timing belt so that the tension side of the
belt is taut. Now tighten the bolt to fix the tensioner.
Caution
When tightening the bolt, ensure that the tensioner
pulley shaft does not rotate with the bolt. Allowing
it to rotate with the bolt can cause excessive
tension of the belt.
(3) Check to ensure that when centre of span on tension
side is depressed with index finger in direction of
arrow, tension of belt is up to specification.
Standard value: 5 - 7 mm
Belt tension side
Counter balance shaft sprocket
Timing mark
Crankshaft
sprocket B
Centre of
tensioner
pulley
Centre of
installation bolt
Shaft
Centre
of pulley
Centre of installation bolt
"BACRANKSHAFT SPROCKET INSTALLATION
1. Apply as little engine oil as possible to the seat and the
thread of the crankshaft bolt.
2. Secure the crankshaft sprocket in the same way as during
removal, and then tighten the bolt to the specified torque.
Tightening torque: 108 - 127 Nm
ENGINE <4D6> - Engine Assembly 11C-33
D Air Cleaner Assembly Removal
D Radiator Assembly Removal (Refer to GROUP14.)
D Front Exhaust Pipe Installation
D Radiator Assembly Installation
D Accelerator Cable Adjustment
D Air Cleaner Assembly Installation
1
2
3
4
5
6
7
8
9
10 11
12 13
14
15
16
17
Removal steps
2. Vacuum air temperature sensor con-
nector
3. Brake booster vacuum hose connec-
tion
5. Oil pressure switch connector
6. Engine oil level sensor connector
7. Glow plug connector
connector
unit connector
10. Pump revolution sensor connector
11. Timing control valve connector
12. Solenoid-type spill valve connector
13. Fuel cut solenoid valve connector
14. Injection rate correction resistor con-
nector
15. Injection timing correction resistor con-
nector
17. Fuel temperature sensor connector
18
19
20
21
22
23
24
25
26
27
28
29
29 - 34 Nm
98 Nm
12 Nm
57 Nm*
39 Nm
22 Nm
28
19. Drive belt (Power steering)
20. Drive belt (A/C)
21. Oil pump brace
AA" 22. Power steering oil pump and bracket
assembly
24. Engine oil cooler pipe connection
25. Fuel hose connection
26. Clamp bolt (Power steering hose and
pipe)
Caution
provisionally tightened, and then fully tightened
after placing the vehicle horizontally and loading
the full weight of the engine on the vehicle
body.
ASSEMBLY REMOVAL
NOTE
attached.
NOTE
<M/T>:
Refer to GROUP 22.
Caution
<A/T>:
Refer to GROUP 23.
tool.
mount bracket.
compartment.
<M/T>
Flywheel
Bolt
MZ203827
MB991453
Engine
mount
stopper
Engine side
Dynamic damper
Arrow
12-1
ENGINE
LUBRICATION
LUBRICANTS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Check 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Replacement 3 . . . . . . . . . . . . . . . . . . . . . .
Oil Filter Replacement 4 . . . . . . . . . . . . . . . . . . . . . . . .
Oil Level Warning System Check 5 . . . . . . . . . . . . . .
ENGINE OIL COOLER
<6A1> 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
<4D6> 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE LUBRICATION - General Information 12-2
The lubrication method is a fully force-fed, full-flow
filtration type. The oil pump for 6A1 engines is a
trochoid type which is directly mounted to the
crankshaft, and the one for 4G6 and 4D6 engines
is a gear type which is driven by the crankshaft
via the timing belt.
Furthermore, the oil level sensor is located in the
oil pan, and a system is equipped whereby an
indicator gives a warning when the oil level drops.
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil
will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentially
harmful contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example
by using enclosedsystems for handling usedengine
oil and by degreasing components, where
practicable, before handling them.
Other precautions:
D Avoid prolonged and repeated contact with oils,
particularly used engine oils.
D Wear protective clothing, including impervious
gloves where practicable.
D Avoid contaminating clothes, particularly
underpants, with oil.
D Do not put oily rags in pockets, the use of
overalls without pockets will avoid this.
D Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separate from
personal clothing.
D Where there is a risk of eye contact, eye
protection should be worn, for example,
chemical goggles or face shields; in addition
an eye wash facility should be provided.
D Obtain First Aid treatment immediately for open
cuts and wounds.
D Wash regularly with soap and water to ensure
all oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin
oils is advised.
D Do not use petrol, kerosine, diesel fuel, gas
oil, thinners or solvents for cleaning skin.
D Use barrier creams, applying them before each
work period, to help the removal of oil from
the skin after work.
D If skin disorders develop, obtain medical advice
without delay.
ENGINE LUBRICATION - Lubricants/Special Tools/On-vehicle Service 12-3
LUBRICANTS 12100040151
Items 4G6 6A1 4D6
Engine oil (API classification) SG or higher SG or higher CD or higher
Engine oil quantity L Oil filter 0.3 0.3 0.8
Oil cooler - 0.1 0.3
Total 4.3 4.3 5.1
MB991396 Oil filter wrench Removal and installation of engine oil filter
(When using the oil filter of MD135737)
<4G6>
MB991610 Oil filter wrench Removal and installation of engine oil filter
(When using the oil filter of MD136466)
<6A1>
ENGINE OIL CHECK
1. Pull out the level gauge slowly and check that the oil
level is in the illustrated range.
2. Check that the oil is not excessively dirty, that there is
no coolant or gasoline mixed in, and that it has sufficient
viscosity.
ENGINE OIL REPLACEMENT 12100100163
temperature of the coolant reaches 80_C to 90_C.
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
Caution
Use care as oil could be hot.
4. Install a new drain plug gasket so that it faces in the
direction shown in the illustration, and then tighten the
drain plug to the specified torque.
NOTE
Install the drain plug gasket so it faces in the direction
Drain plug gasket
Oil
pan
side
Drain plug
39 Nm
ENGINE LUBRICATION - On-vehicle Service 12-4
5. Refill with specified quantity of oil.
Specified Engine Oil (API classification):
<4G6, 6A1> SG or higher
<4D6> CD or higher
Total quantity (Includes volume inside oil filter and
oil cooler):
<4G6, 6A1> 4.3 L
<4D6> 5.1 L
6. Install the engine oil filler cap.
7. Check oil level.
OIL FILTER REPLACEMENT 12100110159
temperature of the coolant reaches 80_C to 90_C.
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
Caution
Use care as oil could be hot.
4. Use the respective tool in the following table to remove
the engine oil filter.
Caution
For vehicles with 6A1 engine, the oil which is still
inside the oil filter may overflow from the oil guide
groove and get onto the starter motor. To prevent
this, the oil inside the filter should be gradually
removed while removing the oil filter.
5. Clean the filter bracket side mounting surface.
6. Apply a small amount of engine oil to the O-ring of the
new oil filter.
7. Once the O-ring of the oil filter is touching the flange,
use the respective tool in the following table to tighten
to the specified torque.
8. Install the drain plug and refill engine oil. (Refer to Engine
Oil Replacement on P.12-3.)
9. Race the engine 2 - 3 times, and check to be sure that
no engine oil leaks from installation section of the oil
filter.
<Petrol-powered vehicles>
Barometric temperature
<Diesel-powered vehicles>
Barometric temperature
MB991396,
MB991610
or commer-
cially-avail-
able tool
O-ring
Number Engine Tool Tightening torque
MD135737 4G6 MB991396 or equivalent tool Approx. 1 turn (14 Nm)
MD136466 6A1 MB991610 or equivalent tool Approx. 3/4 turn (17 Nm)
MD336080 4D6 Commercially-available tool Approx. 1-1/8 turns (20 Nm)
OIL LEVEL WARNING SYSTEM CHECK 12100200047
1. Check that the proper amount of oil has been filled.
2. When the ignition switch is turned to ON (do not start
the engine), check that the oil level warning lamp
illuminates.
NOTE
If the oil level warning lamp does not illuminate, the cause
is probably a blown lamp, or a malfunction in the relay.
3. When the engine is started, check that the oil level warning
lamp turns off.
If the oil level warning lamp will not go out, disconnect
the connector of the oil level relay and measure the voltage
of the No.1 terminal on the harness side of the connector
while idling the engine in order to confirm that it is the
same as the battery voltage.
NOTE
(1) If the voltage at the connector is the same as the
battery voltage, the problem is probably a malfunction
of either the oil level relay or the oil level sensor.
(2) If the voltage at the connector is lower than the battery
voltage, the problemis probably amalfunction of either
the alternator or the wiring harness.
4. Disconnect the oil level sensor connector. Check that
the oil level warning lamp illuminates after approximately
40 seconds.
If the oil level warning lamp does not illuminate, replace
the oil level relay.
Engine oil level relay
Engine oil level sensor
connector (Harness side)
5. Check the continuity between the oil level sensor
terminals.
Engine oil temper-
ature
Oil level Continuity
At 50_C or lower Normal
(proper volume)
Continuity
Low (drained) Continuity
At 60_C or higher Normal
(proper volume)
Continuity
Low (drained) No continuity
6. If there is a defect, replace the oil level sensor.
connector (Equipment side)
Oil pan
9 Nm
ENGINE LUBRICATION - Engine Oil Cooler <6A1> 12-7
ENGINE OIL COOLER <6A1> 12100130155
Engine Coolant Draining and Supplying
64 - 69 Nm
2
3
4
1
5
2
Removal steps
1. Oil filter (Refer to P.12-4.)
3. Oil cooler bolt
"AA 4. Engine oil cooler
5. O-ring
"AAENGINE OIL COOLER INSTALLATION
Insert the engine oil cooler positioning tab into the cylinder
block rib, and tighten it with the oil cooler bolt.
INSPECTION 12100140110
D Check the water hoses for crack, damage, clogging or
deterioration.
D Check the oil cooler bolt for clogging or deformation.
ENGINE LUBRICATION - Engine Oil Cooler <4D6> 12-8
ENGINE OIL COOLER <4D6> 12100130162
D Engine Oil Draining and Supplying (Refer to P.12-3.)
D Front Bumper Removal and Installation
D Air Guide Panel Removal and Installation
12 Nm
5 Nm
29 - 34 Nm
39 - 44 Nm
5 Nm
5 Nm
39 - 44 Nm
39 - 44 Nm
1
2
3
4
5
6
7
1
Removal steps
1. Hose assembly and joint connec-
tion
2. Engine oil cooler
3. Joint
4. Return hose assembly
5. Feed hose assembly
"AA 6. Return tube assembly
7. Feed tube assembly
"AARETURN TUBE ASSEMBLY INSTALLATION
Insert the eye joint pin into the oil filter bracket hole and
install the return tube assembly.
Eye joint pin
ENGINE LUBRICATION - Engine Oil Cooler <4D6> 12-9
D Check for foreign material between oil cooler fins.
D Check the oil cooler fins for bend or damage.
D Check the oil cooler hoses for crack, damage, clogging
or deterioration.
D Check the eye bolts for clogging or deformation.
NOTES
MULTIPOINT FUEL INJECTION (MPI) 13A . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC CONTROL TYPE CARBURETTOR 13B . . . . . . . . . . . . . . . . . . .
CONVENTIONAL TYPE CARBURETTOR 13C . . . . . . . . . . . . . . . . . . . . . . . . . .
VARIABLE VENTURI TYPE CARBURETTOR 13D . . . . . . . . . . . . . . . . . . . . . . .
DIESEL FUEL 13E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SUPPLY 13F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTO-CRUISE CONTROL SYSTEM Refer to GROUP17 . . . . . . . . . . . . . . . . .
TRACTION CONTROL SYSTEM (TCL) 13H . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTE
THE GROUPS MARKED BY ARE NOT IN THIS MANUAL
13A-1
FUEL
13A-2
MULTIPOINT FUEL
INJECTION (MPI)
MULTIPOINT FUEL INJECTION <4G6>
GENERAL INFORMATION 4 . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 7 . . . . . . . . . . . . . .
SEALANT 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 8 . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 9 . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 81 . . . . . . . . . . . . . . . .
Throttle Body (Throttle Valve Area)
Cleaning 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Position Switch and Throttle Position
Sensor Adjustment 81 . . . . . . . . . . . . . . . . . . . . . . .
Fixed SAS Adjustment 83 . . . . . . . . . . . . . . . . . . . .
Basic Idle Speed Adjustment 83 . . . . . . . . . . . . . .
Fuel Pressure Test 85 . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Connector Disconnection (How to
Reduce the Fuel Pressure) 88 . . . . . . . . . . . . . . .
Fuel Pump Operation Check 88 . . . . . . . . . . . . . .
Component Location 89 . . . . . . . . . . . . . . . . . . . . . .
Control Relay and Fuel Pump Relay Continuity
Check 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Air Temperature Sensor Check 90 . . . . . .
Engine Coolant Temperature Sensor
Check 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor Check 91 . . . . . . . . . . . .
Idle Position Switch Check 91 . . . . . . . . . . . . . . . .
Oxygen Sensor Check 92 . . . . . . . . . . . . . . . . . . . .
Injector Check 93 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Speed Control (ISC) Servo (Stepper
Motor) Check 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purge Control Solenoid Valve Check 95 . . . . . . .
EGR Control Solenoid Valve Check 95 . . . . . . . .
INJECTOR 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE BODY 98 . . . . . . . . . . . . . . . . . . . . .
MULTIPOINT FUEL INJECTION <6A1>
GENERAL INFORMATION 102 . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 106 . . . . . . . . . . .
SEALANT 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 107 . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 108 . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 184 . . . . . . . . . . . . . . .
Throttle Body (Throttle Valve Area) Cleaning
184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Position Switch and Throttle Position
Sensor Adjustment <Vehicles without TCL>
184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor Adjustment
<Vehicles with TCL> 186 . . . . . . . . . . . . . . . . . . . .
Idle Position Switch and Accelerator Pedal
Position Sensor Adjustment
Fixed SAS Adjustment 187 . . . . . . . . . . . . . . . . . . .
Basic Idle Speed Adjustment 188 . . . . . . . . . . . . .
CONTINUED ON NEXT PAGE
13A-3
Fuel Pressure Test 189 . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Connector Disconnection (How to
Reduce the Fuel Pressure) 191 . . . . . . . . . . . . . .
Fuel Pump Operation Check 191 . . . . . . . . . . . . .
Component Location 192 . . . . . . . . . . . . . . . . . . . . .
Control Relay and Fuel Pump Relay Continuity
Check 193 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Air Temperature Sensor Check 193 . . . . .
Engine Coolant Temperature Sensor Check
193 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Position Sensor Check 194 . . . . . . . . . . .
Accelerator Pedal Position Sensor Check
Idle Position Switch Check
<Vehicles without TCL> 195 . . . . . . . . . . . . . . . . . .
Idle Position Switch Check
Oxygen Sensor Check 196 . . . . . . . . . . . . . . . . . . .
Injector Check 197 . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Speed Control (ISC) Servo (Stepper
Motor) Check 199 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purge Control Solenoid Valve Check 200 . . . . . .
EGR Control Solenoid Valve Check 200 . . . . . . .
Ventilation Control Solenoid Valve Check
Vacuum Control Solenoid Valve Check
Vacuum Tank Check
Vacuum Actuator Check
Throttle Valve Operation Check
Negative Pressure Check during Traction
Control Operation <Vehicles with TCL> 203 . . .
Power Steering Air Control Valve Operation
Check 203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INJECTOR 204 . . . . . . . . . . . . . . . . . . . . . . . . . . .
THROTTLE BODY 207 . . . . . . . . . . . . . . . . . . . .
MPI <4G6> - General Information 13A-4
MULTIPOINT FUEL INJECTION (MPI) <4G6> 13100010449
GENERAL INFORMATION
The Multipoint Fuel Injection System consists
of sensors which detect the engine conditions,
the engine-ECU which controls the system
based on signals from these sensors, and
actuators which operate under the control of
the engine-ECU. The engine-ECU carries out
activities such as fuel injection control, idle
speed control and ignition timing control. In
addition, the engine-ECU is equipped with
several diagnosis modes which simplify
troubleshooting when a problem develops.
FUEL INJECTION CONTROL
The injector drive times and injector timing are
controlled so that the optimum air/fuel mixture
is supplied to the engine to correspond to the
continually-changing engine operation condi-
tions.
A single injector is mounted at the intake port
of each cylinder. Fuel is sent under pressure
from the fuel tank by the fuel pump, with the
pressure being regulated by the fuel pressure
regulator. The fuel thus regulated is distributed
to each of the injectors.
Fuel injection is normally carried out once for
each cylinder for every two rotations of the
crankshaft. The firing order is 1-3-4-2. This is
called sequential fuel injection.
The engine-ECU provides a richer air/fuel
mixture by carrying out open-loop control
when the engine is cold or operating under
high load conditions in order to maintain engine
performance. In addition, when the engine is
warm or operating under normal conditions,
the engine-ECU controls the air/fuel mixture
by using the oxygen sensor signal to carry out
closed-loop control in order to obtain the
theoretical air/fuel mixture ratio that provides
the maximum cleaning performance from the
three way catalyst.
IDLE AIR CONTROL
The idle speed is kept at the optimum speed
by controlling the amount of air that bypasses
the throttle valve in accordance with changes
in idling conditions and engine load during
idling. The engine-ECU drives the idle speed
control (ISC) motor to keep the engine running
at the pre-set idle target speed in accordance
with the engine coolant temperature and air
conditioner load. In addition, when the air
conditioner switch is turned off and on while
the engine is idling, the ISC motor operates
to adjust the throttle valve bypass air amount
in accordance with the engine load conditions
in order to avoid fluctuations in the engine
speed.
IGNITION TIMING CONTROL
The power transistor located in the ignition
primary circuit turns ON and OFF to control
the primary current flow to the ignition coil. This
controls the ignition timing in order to provide
the optimum ignition timing with respect to the
engine operating conditions. The ignition timing
is determined by the engine-ECU from the
engine speed, intake air volume, engine coolant
temperature and atmospheric pressure.
SELF-DIAGNOSIS FUNCTION
D When an abnormality is detected in one
of the sensors or actuators related to
emission control, the engine warning lamp
(check engine lamp) illuminates as a
warning to the driver.
of the sensors or actuators, a diagnosis
code corresponding to the abnormality is
output.
D The RAM data inside the engine-ECU that
is related to the sensors and actuators can
be read by means of the MUT-II. In addition,
the actuators can be force-driven under
certain circumstances.
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control
Turns the fuel pumprelay ONso that current
is supplied to the fuel pumpwhile theengine
is cranking or running.
2. A/C Relay Control
Turns the compressor clutch of the A/C
ON and OFF.
3. Fan Relay Control
The revolutions of the radiator fan and
condenser fan are controlled in response
to the engine coolant temperature and
vehicle speed.
4. Purge Control Solenoid Valve Control
Refer to GROUP 17.
5. EGR Control Solenoid Valve Control
Refer to GROUP 17.
GENERAL SPECIFICATIONS
Items Specifications
Throttle body Throttle bore mm 54
Throttle position sensor Variable resistor type
Idle speed control servo Stepper motor type
(Stepper motor typeby-pass air control systemwiththeair
volume limiter)
Idle position switch Rotary contact type, within throttle position sensor
Engine-ECU Identification model No. E2T67673
Sensors Air flow sensor Karman vortex type
Barometric pressure sensor Semiconductor type
Intake air temperature sensor Thermistor type
Engine coolant temperature sensor Thermistor type
Oxygen sensor Zirconia type
Vehicle speed sensor Magnetic resistive element type
Inhibitor switch Contact switch type
Camshaft position sensor Hall element type
Crank angle sensor Hall element type
Detonation sensor Piezoelectric type
Power steering fluid pressure switch Contact switch type
Actuators Control relay type Contact switch type
Fuel pump relay type Contact switch type
Injector type and number Electromagnetic type, 4
Injector identification mark CDH275
EGR control solenoid valve Duty cycle type solenoid valve
Purge control solenoid valve ON/OFF type solenoid valve
Fuel pressure
regulator
Regulator pressure kPa 329
MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM
z1 Injector
z2 Purge control solenoid valve
z3 Idle speed control servo
z4 EGR control solenoid valve
D Fuel pump relay
D Control relay
D A/C power relay
D Engine warning lamp
D Diagnosis signal
D Ignition coil, power transistor
D Fan controller
D Alternator G terminal
D A/T-ECU
*1 Oxygen sensor (front)
*2 Air flow sensor
*3 Intake air temperature sensor
*4 Throttle position sensor
*5 Idle position switch
*6 Camshaft position sensor
*7 Crank angle sensor
*8 Barometric pressure sensor
*9 Engine coolant temperature sensor
*10 Detonation sensor
*11 Oxygen sensor (rear)
D Power supply voltage
D Vehicle speed sensor
D A/C switch 1, 2
D Inhibitor switch
D Power steering fluid pressure switch
D Ignition switch - ST
D Ignition switch - IG
D Alternator FR terminal
D A/T-ECU
Engine-ECU
z3
z1
z2
z4
*6 Camshaft position sensor
Idle speed
control servo
*3 Intake air
temperature
sensor
Air flow sensor (with
barometric pressure sensor)
Air cleaner
Fuel pressure
regulator
To fuel
tank
From fuel
pump
Throttle position sensor
(with idle position switch)
PCV valve
Injector
EGR valve
Engine coolant
temperature sensor
EGR
control
solenoid
valve
Purge control
solenoid valve
Canister
*10 Detonation sensor
*1 Oxygen sensor
Catalytic converter
Air
*4, *5
*8 *2
*9
MPI <4G6> - Service Specifications/Sealant 13A-7
Basic idle speed r/min 75050
Throttle position sensor adjusting voltage mV 400 - 1,000
Throttle position sensor resistance kW 3.5 - 6.5
Idle speed control servo coil resistance W 28 - 33 (at 20_C)
Intakeair temperaturesensor 20_C 2.3 - 3.0
resistance kW
80_C 0.30 - 0.42
Engine coolant temperature 20_C 2.1 - 2.7
sensor resistance kW
80_C 0.26 - 0.36
Oxygen sensor output voltage V 0.6 - 1.0
Fuel pressure kPa Vacuumhose disconnection 324 - 343 at kerb idle
Vacuum hose connection Approx. 265 at kerb idle
Injector coil resistance W 13 - 16 (at 20_C)
SEALANT 13100050199
Item Specified sealant Remark
Engine coolant temperature sensor
threaded portion
3M Nut Locking Part No. 4171 or equivalent Drying sealant
MPI <4G6> - Special Tools 13A-8
B
A
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
D Fuel gauge simple inspection
A: Connector pin contact pressure inspection
B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester connection
MB991502 MUT-II sub
assembly
D Reading diagnosis code
D MPI system inspection
MB991348 Test harness set D Measurement of voltage during trouble-
shooting
D Inspection using an analyzer
MB991709 Test harness
MB991519 Alternator harness
connector
Measurement of voltage during
troubleshooting
MD998463 Test harness
(6-pin, square)
D Inspection of idle speed control servo
(3-pin, triangle)
D Measurement of voltage during trouble-
shooting
MPI <4G6> - Special Tools/Troubleshooting 13A-9
MD998709 Adaptor hose Measurement of fuel pressure
MD998742 Hose adaptor
MD998706 Injector test set Checking the spray condition of injectors
MB991607 Injector test
harness
MD998741 Injector test
adaptor
MB991608 Clip
TROUBLESHOOTING 13100850256
DIAGNOSIS TROUBLESHOOTING FLOW
Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.
DIAGNOSIS FUNCTION 13100860358
ENGINE WARNING LAMP (CHECK ENGINE LAMP)
If an abnormality occurs in any of the following items related
to the Multipoint Fuel Injection (MPI) system, the engine
warning lamp will illuminate.
If the lamp remains illuminated or if the lamp illuminates while
the engine is running, check the diagnosis code output.
Engine warning lamp
(check engine lamp)
MPI <4G6> - Troubleshooting 13A-10
Engine warning lamp inspection items
Engine-ECU
Oxygen sensor
Air flow sensor
Intake air temperature sensor
Crank angle sensor
Camshaft position sensor
Barometric pressure sensor
Detonation sensor
Injector
Ignition coil, power transister
Immobilizer system
METHOD OF READING AND ERASING DIAGNOSIS
CODES
Service Points.
INSPECTION USING MUT-II DATA LIST AND
ACTUATOR TESTING
1. Carry out inspection by means of the data list and the
actuator test function.
If there is an abnormality, check and repair the chassis
harnesses and components.
2. After repairing, re-check using the MUT-II and check that
the abnormal input and output have returned to normal
as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II.
5. Start the engine again and carry out a road test to confirm
that the problem has disappeared.
FAIL-SAFE FUNCTION REFERENCE TABLE 13100910299
When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled
by means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning item Control contents during malfunction
Air flow sensor 1. Uses the throttle position sensor signal and engine speed signal (crank angle sensor
signal) to take reading of the basic injector drive time and basic ignition timing from
the pre-set mapping.
2. Fixes the ISC servo in the appointed position so idle control is not performed.
Intake air temperature
sensor
Controls as if the intake air temperature is 25_C.
Throttle position
sensor (TPS)
No increase in fuel injection amount during acceleration due to the throttle position sensor
signal.
Engine coolant
temperature sensor
Controls as if the engine coolant temperature is 80_C.
Camshaft position
sensor
Injects fuel to all cylinders simultaneously.
(However, after the ignition switch is turned to ON, the No. 1 cylinder top dead centre is not
detected at all.)
Barometric pressure
sensor
Controls as if the barometric pressure is 101 kPa.
Detonation sensor Switches the ignition timing fromignition timing for super petrol to ignition timing for standard
petrol.
Ignition coil, power
transistor
Cuts off the fuel supply to cylinders with an abnormal ignition.
Oxygen sensor Air/fuel ratio feedback control (closed loop control) is not performed.
Communication wire
with transmission
control unit <A/T>
Ignition timing is not retarded during transmission gear shifting (overall engine and
transmission control).
Alternator FR terminal Does not control the output of the alternator according to an electrical load. (works as a
normal alternator)
INSPECTION CHART FOR DIAGNOSIS CODES 13100870375
Code No. Diagnosis item Reference page
11 Oxygen sensor (front) system 13A-13
12 Air flow sensor system 13A-14
13 Intake air temperature sensor system 13A-14
14 Throttle position sensor system 13A-15
21 Engine coolant temperature sensor system 13A-16
22 Crank angle sensor system 13A-17
23 Camshaft position sensor 13A-18
24 Vehicle speed sensor system 13A-19
25 Barometric pressure sensor system 13A-20
31 Detonation sensor system 13A-21
41 Injector system 13A-21
44 Ignition coil system 13A-22
54 Immobilizer system 13A-23
59 Oxygen sensor (rear) system 13A-24
61 Communication wire with A/T-ECU system <A/T> 13A-25
64 Alternator FR terminal system 13A-25
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No. 11 Oxygen sensor (front) system Probable cause
Range of Check
D 3 minutes have passed after engine was started.
D Engine coolant temperature is approx. 80_C or more.
D Intake air temperature is 20- 50_C.
D Engine speed is approx. 2,000- 3,000 r/min
D Vehicle is moving at constant speed on a flat, level road surface
Set conditions
D The oxygen sensor (front) output voltage is around 0.6 V for 30 seconds (does
not cross 0.6 V for 30 seconds).
D When the range of check operations given above which accompany starting of
the engine are carried out four time in succession, a problem is detected after
each operation.
D Malfunction of the oxygen sensor (front)
D Improper connector contact, open circuit or
short-circuited harness wire
D Malfunction of the engine-ECU
Check the oxygen sensor (front). (Refer to P.13A-92.)
NG
Replace
OK
Measure at the oxygen sensor (front) connector C-46.
D Disconnect the connector, and measure at the
harness side.
1. Voltage between 3 and earth (Ignition switch: ON)
OK: System voltage
2. Continuity between 2 and earth
OK: Continuity
OK
1. NG
Check the harness wire between the
oxygen sensor (front) and the control
relay connector, and repair if necessary.
2. NG
Check the following connector:
C-40
NG
Repair
OK
NG
engine-ECU and the oxygen sensor
(front) connector.
NG
Repair
OK
Replace the engine-ECU.
Measure at the engine-ECU connector C-38.
harness side.
D Voltage between 60 and earth (Ignition switch: ON)
OK: System voltage
NG
C-46
NG
Repair
OK
Check the following connectors:
C-46, C-38
NG
Repair
OK
OK
NG
(front) connector, and repair if neces-
sary.
NG
Check the harness wire between the engine-ECU and
the oxygen sensor (front) connector.
NG
Repair
OK
Code No. 12 Air flow sensor system Probable cause
Range of Check
D Engine speed is 500 r/min or more.
Set conditions
D Sensor output frequency is 3 Hz or less for 4 seconds.
D Malfunction of the air flow sensor
short-circuited harness wire of the air flow sensor
Measure at the air flowsensor con-
nector B-12.
D Connect the connector. (Use
the test harness: MB991709)
1. Voltage between 3 and earth
(Engine: Idling)
OK: 2.2- 3.2 V
OK: 0- 1 V (Engine: idling)
6- 9 V (2,000 r/min)
OK
1. NG
Check the air flow sensor circuit.
(Refer to P.13A-59, INSPECTION
PROCEDURE 48.)
2. NG
Measure at the engine-ECU con-
nector C-34.
D Connect the connector.
D Voltage between 19 and earth
(Ignition switch: ON)
OK: 6- 9 V
OK
C-34
OK
NG
NG
B-12
NG
Repair
OK
NG
NG
Repair
Replace the air flow sensor.
Code No. 13 Intake air temperature sensor system Probable cause
Range of Check
D Ignition switch: ON
D Excluding 60 seconds after the ignition switch is turned to ON or immediately
after the engine starts.
Set conditions
D Sensor output voltage is 4.6 V or more (corresponding to an intake air temperature
of - 45_C or less) for 4 seconds.
or
D Sensor output voltage is 0.2V or less (corresponding to an intake air temperature
of 125_C or more) for 4 seconds.
D Malfunction of the intake air temperature sensor
short-circuited harness wire of the intake air
temperature sensor circuit
Check the intake air temperature
sensor. (Refer to P.13A-90.)
NG
Replace
OK
nector B-12.
D Disconnect the connector, and
measure at the harness side.
OK: 4.5- 4.9 V
D Continuity between 5 and earth
OK: Continuity
NG
C-40
NG
Repair
OK
NG
Check the harness wire between
the engine-ECU and the intake air
temperature sensor connector.
NG
Repair
OK
OK
B-12
NG
Repair
OK
NG
Code No. 14 Throttle position sensor system Probable cause
Range of Check
Set conditions
D When the idle position switch is ON, the sensor output voltage is 2 V or more
for 4 seconds.
or
D The sensor output voltage is 0.2 V or less for 4 seconds.
D Malfunction of the throttle position sensor or
maladjustment
short-circuited harness wire of the throttle position
sensor circuit
D Improper ON state of idle position switch
D Short circuit of the idle position switch signal line
MUT-II Data list
26 Idle position switch system
OK: With the throttle valve at the
idle position: ON
With the throttle valve slight-
ly open: OFF
NG
Check the idle position switch system.
PROCEDURE 28.)
OK
Check the throttle position sensor.
(Refer to P.13A-91.)
NG
Replace
OK
Measure at the throttle position sensor
connector B-07.
OK: 4.8- 5.2 V
OK: Continuity
NG
C-40
NG
Repair
OK
NG
engine-ECU and the throttle position
sensor connector.
NG
Repair
OK
OK
Check the throttle position sensor out-
put circuit. (Refer to P.13A-60, IN-
SPECTION PROCEDURE 49.)
Code No. 21 Engine coolant temperature sensor system Probable cause
Range of Check
Set conditions
D Sensor output voltage is 4.6 V or more (corresponding to an engine coolant
temperature of - 45_C or less) for 4 seconds.
or
D Sensor output voltage is 0.1 V or less (corresponding to an engine coolant
temperature of 140_C or more) for 4 seconds.
D Malfunction of the engine coolant temperature sensor
short-circuited harness wire of the engine coolant
Range of Check
D Engine speed is approx. 50 r/min or more
Set conditions
D The sensor output voltage increases from 1.6 V or less (corresponding to an
engine coolant temperature of 40_C or more) to 1.6 V or more (corresponding
to an engine coolant temperature of 40_C or less).
D After this, the sensor output voltage is 1.6 V or more for 5 minutes.
Check the engine coolant temperature
NG
Replace
OK
Measure at the engine coolant temper-
ature sensor connector B-33.
OK: 4.5- 4.9 V
OK: Continuity
NG
C-40
NG
Repair
OK
NG
engine-ECU and the engine coolant
NG
Repair
OK
B-33
OK
NG
NG
Repair
OK
Code No. 22 Crank angle sensor system Probable cause
Range of Check
D Engine is cranking.
Set conditions
D Sensor output voltage does not change for 4 seconds (no pulse signal input.)
D Malfunction of the crank angle sensor
short-circuited harness wire of the crank angle sensor
Measure at the crank angle sensor connector B-77.
D Connect the connector. (Use the test harness: MD998478.)
D Voltage between 2 and earth (Engine: cranking)
OK: 0.4- 4.0 V
D Voltage between 2 and earth (Engine: idling)
OK: 1.5- 2.5 V
NG
OK
D Disconnect the connector, and measure at the harness side.
OK: System voltage
OK: 4.8- 5.2 V
OK: Continuity
OK
Check the following con-
nector: B-77
NG
Repair
OK
NG
Replace the crank angle sensor.
1. NG
Check the harness wire between the crank angle sensor and the
control relay connector, and repair if necessary.
2. NG
nector: C-40
NG
Repair
OK
3. NG
NG
Check the harness wire
between the engine-ECUand
the crank angle sensor
connector.
NG
Repair
OK
earth, and repair if necessary.
Code No. 23 Camshaft position sensor system Probable cause
Range of Check
D Engine speed is approx. 50 r/min or more.
Set conditions
D Malfunction of the camshaft position sensor
short-circuited harness wire of the camshaft position
sensor circuit
Measure at the camshaft position sensor connector B-64.
D Connect the connector. (Use the test harness: MB991223 and
jumper wire.)
OK: 0.4- 3.0 V
OK: 1.5- 2.0 V
OK
NG
Measure at the camshaft position sensor connector B-64.
OK: System voltage
OK: 4.8- 5.2 V
OK: Continuity
1. NG
Check the harness wire between the camshaft position sensor
and the control relay connector, and repair if necessary.
2. NG
nector: C-40
NG
Repair
OK
NG
the camshaft position sensor
connector.
NG
Repair
OK
3. NG
Check the harness wire between the camshaft position sensor
and the earth, and repair if necessary.
OK
nector: B-64
NG
Repair
OK
NG
Replace the camshaft position sensor.
Code No. 24 Vehicles speed sensor system Probable cause
Range of check
D Idle position switch: OFF
D Engine speed is 3,000 r/min or more.
D Driving under high engine load conditions.
Set conditions
D Sensor output voltage does not change for 4 seconds (no pulse signal input).
D Malfunction of the vehicle speed sensor
short-circuited harness wire of the vehicle speed
sensor circuit
OK
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.)
2. NG
OK
3. NG
OK
NG
between the engine-ECU
and the vehicle speed
sensor connector.
NG
Repair
OK
OK
Check the following
connectors:
B-66 <M/T>, B-67 <A/T>,
C-40
NG
Repair
NG
sensor connector.
NG
Repair
OK
Check the following
connectors:
B-65 <M/T>, C-48, C-40
NG
Repair
NG
between the vehicle
speed sensor and ignition
switch connector.
NG
Repair
OK
OK
Measure at the vehicle speed sensor connector B-66 <M/T>,
B-67 <A/T>.
side.
OK: System voltage
OK: 4.8 - 5.2 V
OK: Continuity
1. NG
Check the following
connectors:
B-65 <M/T>, C-90, C-135,
C-131
NG
Repair
Check the vehicle speed sensor. (Refer to GROUP 54 - Combina-
tion Meters.)
NG
Replace
OK
Check the harness wire between the vehicle speed sensor and
the earth, and repair if necessary.
OK
Check the following
connector:
B-65 <M/T>
NG
Repair
Code No. 25 Barometric pressure sensor system Probable cause
Range of Check
D Battery voltage is 8 V or more.
Set conditions
D Sensor output voltage is 4.5 V or more (corresponding to a barometric pressure
of 114 kPa or more) for 4 seconds.
or
D Sensor output voltage is 0.2 V or less (corresponding to a barometric pressure
of 5.33 kPa or less) for 4 seconds.
D Malfunction of the barometric pressure sensor
short-circuited harness wire of the barometric pressure
sensor circuit
nector B-12.
OK: 3.7- 4.3 V (Altitude: 0 m)
3.2- 3.8 V (Altitude:
1,200 m)
NG
nector B-12.
OK: 4.8- 5.2 V
OK: Continuity
NG
C-40
NG
Repair
OK
NG
the engine-ECU and the baromet-
ric pressure sensor connector.
NG
Repair
OK
OK
B-12
NG
Repair
OK
NG
NG
Repair
OK
OK
nector C-40.
1,200 m)
NG
ric pressure sensor connector, and
repair if necessary.
C-40
OK
NG
NG
Repair
OK
MPI <4G6> - Troubleshooting MPI <4G6> - Troubleshooting 13A-21
Code No. 31 Detonation sensor system Probable cause
Range of Check
D Engine speed is approx. 5,000 r/min or more
Set conditions
The change in the detonation sensor output voltage (detonation sensor peak voltage
at each 1/2 revolution of the crankshaft) is less than 0.06 V for 200 times in succession.
D Malfunction of the detonation sensor
short-circuited harness wire of the detonation sensor
circuit
Measure at the detonation sensor con-
nector B-34.
D Disconnect the connector and
OK: Continuity
OK
B-34, C-40
NG
Repair
OK
NG
engine-ECU and the detonation sensor
connector.
OK
Replace the detonation sensor.
NG
NG
Repair
NG
detonation sensor and earth, and repair
if necessary.
Code No. 41 Injector system Probable cause
Range of Check
D Engine speed is approx. 50- 1,000 r/min
D The throttle position sensor output voltage is 1.15 V or less.
D Actuator test by MUT-II is not carried out.
Set conditions
D Surge voltage of injector coil is not detected for 4 seconds.
D Malfunction of the injector
short-circuited harness wire of the injector circuit
Check the injector. (Refer to P.13A-93.)
NG
Replace
OK
Measure at the injector connectors
B-02, B-03, B-05, B-36.
OK: System voltage
NG
B-02, B-03, B-05, B-36
NG
Repair
OK
NG
control relay and the injector connector,
and repair if necessary.
Check the injector control circuit.
(Refer to P.13A-60, INSPECTIONPRO-
CEDURE 50.)
OK
Code No. 44 Ignition coil system Probable cause
Range of Check
D Excluding deceleration driving and sudden acceleration or deceleration driving
Set conditions
D Misfire occurs in No.1 and No.4 cylinders or No.2 and No.3 cylinders more than
predeterminated times per 1,000 r/min.
D Malfunction of the ignition coil
short-circuited harness wire of the ignition primary
circuit
D Malfunction of the spark plug and spark plug cable
D Improper compression pressure
NG
Repair or replace
OK
OK
Measure at the ignition coil connectors
B-01, B-11
measure at the harness.
OK: System voltage
(Engine: Cranking)
OK: 0.5- 4.0 V
3. Continuity between the 2 and earth
OK: Continuity
1. NG
C-92, C-131
OK
NG
ignition coil and ignition switch connec-
tor, and repair if necessary.
2. NG
Check the following connector: C-34
NG
Repair
NG
engine-ECU and ignition coil connector.
OK
NG
Repair
3. NG
ignition coil connector and earth, and
B-01, B-11
NG
Repair
NG
Check the following items.
D Check the spark plugs, spark plug
cables.
D Check the compression pressure.
NG
Repair
OK
Replace the ignition coil.
NG
Code No.54 Immobilizer system Probable cause
Range of Check
Set Conditions
D Improper communication between the engine-ECU and immobilizer-ECU
D Radio interference of ID codes
D Incorrect ID code
D Malfunction of harness or connector
D Malfunction of immobilizer-ECU
D Malfunction of engine-ECU
NOTE
(1) If the ignition switches are close each other when starting the engine, radio interference may cause
this code to be displayed.
(2) This code may be displayed when registering the key ID code.
No
Is there another ignition key near the ignition key that is inserted
in the ignition switch?
Yes
Remove the extra ignition key.
NG
Is a diagnosis code output from the immobilizer-ECU?
Yes
Check the immobilizer system. (Refer to GROUP 54 - Ignition
Switch and Immobilizer System.)
No
C-38, C-81, C-68
NG
Repair
OK
NG
Check the harness wire between the engine-ECUand theimmobiliz-
er-ECU.
OK
Replace the immobilizer-ECU.
NG
NG
Repair
NG
Code No. 59 Oxygen sensor (rear) system Probable cause
Range of Check
D The throttle position sensor output voltage is 4.1 V or more.
D Open loop control in operation
D 20 seconds have passed after deceleration finished.
Set conditions
D The oxygen sensor (rear) output voltage is 0.1 V or less.
D The difference in the maximum and minimum values for the oxygen sensor (rear)
output voltage is 0.08 V or less.
D The oxygen sensor (rear) output voltage is 0.5 V or more.
D The above conditions continue for a continuous period of 5 seconds.
D Malfunction of the oxygen sensor (rear)
OK
NG
(rear) connector.
NG
Repair
OK
OK
C-85, C-40
NG
Repair
OK
NG
the oxygen sensor (rear) connector.
NG
Repair
OK
Replace the oxygen sensor (rear).
NG
3. NG
oxygen sensor (rear) and the earth, and
OK
Measure at the oxygen sensor (rear) connector C-85.
harness side.
OK: System voltage
OK: Continuity
OK: Continuity
1. NG
oxygen sensor (rear) and the control
2. NG
C-40
NG
Repair
Check the oxygen sensor (rear). (Refer to P.13A-93.)
NG
Replace
Code No. 61 Communication wire with A/T-ECU system
<A/T>
Probable cause
Range of Check
D 60 seconds or more have passed immediately after engine was started.
Set conditions
The voltage of the torque reduction request signal from the A/T-ECU is LOW for
1.5 seconds or more.
D Malfunction of the harness wire and the connector
D Malfunction of the A/T-ECU
C-34, C-38, C-30
NG
Repair
OK
NG
Check the harness wire between the engine-ECUand the A/T-ECU
connector.
NG
Repair
OK
NG
Replace the A/T-ECU.
Code No. 64 Alternator FR Terminal System Probable cause
Range of Check, Set Conditions
D The alternator FRterminal signal voltage remains high for approximately 20 seconds
while the engine is running.
D Open circuit in alternator FR terminal circuit
Measure at the alternator connector B-38.
(Engine: Idling)
(Radiator fan: Stopped)
(Headlamp: OFF ON)
OK: 1.8 - 2.4 1.0 - 1.6 V
OK
NG
OK: 4.8 - 5.2 V
NG
Check the following
connectors: B-31, C-36
NG
Repair
OK
NG
and the alternator con-
nector.
NG
Repair
OK
OK
Check the following connector: B-38
NG
Repair
OK
NG
Check the harness wire between the engine-ECUand the alternator
connector.
NG
Repair
OK
Replace the alternator.
INSPECTION CHART FOR TROUBLE SYMPTOMS 13100880354
Trouble symptom Inspection
procedure
No.
Reference page
Communication
II
Communication with all systems is not possible. 1 13A-28
with MUT-II is
impossible. Communication with engine-ECU only is not possible. 2 13A-29
Engine warning
lamp and
The engine warning lamp does not illuminate right after the
ignition switch is turned to the ON position.
3 13A-30
related parts
The engine warning lamp remains illuminating and never goes
out.
4 13A-30
Starting No initial combustion (starting impossible) 5 13A-31
Initial combustion but no complete combustion
(starting impossible)
6 13A-32
Long time to start (improper starting) 7 13A-33
Idling stability Unstable idling (Rough idling, hunting) 8 13A-34
(Improper idling)
Idling speed is high. (Improper idling speed) 9 13A-35
Idling speed is low. (Improper idling speed) 10 13A-36
Idling stability When the engine is cold, it stalls at idling. (Die out) 11 13A-37
(Engine stalls)
When the engine becomes hot, it stalls at idling. (Die out) 12 13A-38
The engine stalls when starting the car. (Pass out) 13 13A-39
The engine stalls when decelerating. 14 13A-39
Driving Hesitation, sag or stumble 15 13A-40
The feeling of impact or vibration when accelerating 16 13A-40
The feeling of impact or vibration when decelerating 17 13A-41
Poor acceleration 18 13A-41
Surge 19 13A-42
Knocking 20 13A-42
Dieseling 21 13A-42
Too high CO and HC concentration when idling 22 13A-43
Low alternator output voltage (approx. 12.3 V) 23 13A-44
Idling speed is improper when A/C is operating 24 13A-44
Fans (radiator fan, A/C condensor fan) are inoperative 25 13A-45
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)
Items Symptom
Starting Wont start The starter is used to crank the engine, but there is no combustion within the
cylinders, and the engine wont start.
Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Hard starting Engine starts after cranking a while.
Idling Hunting Engine speed doesnt remain constant; changes at idle.
stability
Rough idle Usually, a judgement can be based upon the movement of the tachometer
pointer, and the vibration transmitted to the steering wheel, shift lever, body, etc.
This is called rough idle.
Incorrect idle speed The engine doesnt idle at the usual correct speed.
Engine stall
(Die out)
The engine stalls when the foot is taken from the accelerator pedal, regardless
of whether the vehicles is moving or not.
Engine stall
(Pass out)
The engine stalls when the accelerator pedal is depressed or while it is being
used.
Driving Hesitation Sag Hesitation is the delay in response
of the vehicle speed (engine speed)
that occurs when the accelerator is
depressed in order to accelerate
from the speed at which the vehicle
is nowtraveling, or a temporary drop
in vehicle speed (engine speed)
during such acceleration.
Serious hesitation is called sag.
Vehicle
speed
Initial ac-
celerator
pedal de-
pression
Normal
Hesitation
Sag
Time
Poor acceleration Poor acceleration is inability to obtain an acceleration corresponding to the
degree of throttle opening, even though acceleration is smooth, or the inability
to reach maximum speed.
Stumble Engine speed increase is delayed
when the accelerator pedal is
initially depressed for accelera-
tion.
Normal
Initial ac-
celerator
pedal de-
pression
Idling Stumble
Time
Vehicle
speed
Items Symptom
Driving Shock The feeling of a comparatively large impact or vibration when the engine is
accelerated or decelerated.
Surge This is repeated surging ahead during constant speed travel or during variable
speed travel.
Knocking A sharp sound like a hammer striking the cylinder walls during driving and which
adversely affects driving.
Stopping Run on
(Dieseling)
The condition in which the engine continues to run after the ignition switch is
turned to OFF. Also called Dieseling.
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE 1
Communication with MUT-II is not possible.
(Communication with all systems is not possible.)
Probable cause
The cause is probably a defect in the power supply system (including earth) for the
diagnosis line.
D Malfunction of the connector
D Malfunction of the harness wire
Measure at the diagnostic connector
(16-pin) C-20.
OK: Battery voltage
NG
C-66, (C-63, C-132, C-141) <L.H.>,
(C-62, C-14) <R.H.>
NG
Repair
OK
NG
power supply and diagnostic connector
(16 pin), and repair if necessary.
OK
(16-pin) C-20.
OK: Continuity
NG
diagnostic connector (16-pin) and earth,
OK
Replace the MUT-II.
MUT-II communication with engine-ECU is impossible. Probable cause
One of the following causes may be suspected.
D No power supply to engine-ECU.
D Defective earth circuit of engine-ECU.
D Defective engine-ECU.
D Improper communication line between engine-ECU and MUT-II
D Malfunction of engine-ECU power supply circuit
D Open circuit between immobilizer-ECU and diagnosis
connector
D Open circuit between engine-ECU and immobilizer-
ECU
Yes
NG
Repair
OK
between engine-ECUand
earth.
NG
Repair
OK
Check the power supply and ignition switch-IG system. (Refer to
P.13A-45, INSPECTION PROCEDURE 26.)
OK
Check the harness wire between engine-ECU and immobilizer-
ECU.
NG
Check the harness wire between engine-ECU and diagnosis con-
nector.
NG
Repair
OK
C-20, C-66, C-68, C-83, C-81, C-38
NG
Repair
Is communication possible between the MUT-II and the immobilizer-
ECU?
No
Check the diagnosis line between the immobilizer-ECU and the
MUT-II, and repair if necessary. (Refer to GROUP 54 - Ignition
Key and Immobilizer.)
The engine warning lamp does not illuminate right after
the ignition switch is turned to the ON position.
Probable cause
Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp
to illuminate for five seconds immediately after the ignition switch is turned to ON.
If the engine warning lamp does not illuminate immediately after the ignition switch
is turned to ON, one of the malfunctions listed at right has probably occurred.
D Burnt-out bulb
D Defective warning lamp circuit
MUT-II Data list
16 engine-ECU power supply voltage (Refer to P.13A-62.)
NG
Check the engine-ECU power supply and earth circuit.
(Refer to P.13A-58, INSPECTION PROCEDURE 45.)
OK
D Earth the terminal No. 36.
OK: The engine warning lamp illuminates.
OK
Check the following
connector: C-36.
NG
Repair
OK
NG
NG
Check a burnt-out bulb.
NG
Replace
OK
Measure at the combination meter connector D-03.
OK: System voltage
NG
Check the engine warning lamp power supply circuit, and repair
if necessary.
OK
D-03, C-90, C-36
NG
Repair
OK
NG
Check the harness wire between combination meter and engine-
ECU, and repair if necessary.
The engine warning lamp remains illuminating and never
goes out.
Probable cause
In cases such as the above, the cause is probably that the engine-ECU is detecting
a problem in a sensor or actuator, or that one of the malfunctions listed at right has
occurred.
D Short-circuit between the engine warning lamp and
engine-ECU
MUT-II Self-Diag code
Are diagnosis codes displayed?
Yes
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
CODES
No
D Disconnect the engine-ECU connector
OK: No continuity
NG
ECU connector, and repair if necessary.
OK
No initial combustion (starting impossible) Probable cause
In cases such as the above, the cause is probably that a spark plug is defective,
or that the supply of fuel to the combustion chamber is defective.
In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel.
D Malfunction of the ignition system
D Malfunction of the fuel pump system
D Malfunction of the injectors
D Malfunction of the immobilizer system
D Foreign materials in fuel
Check battery voltage when cranking.
OK: 8 V or higher
NG
Check the battery. (Refer to GROUP 54 - Battery.)
OK
Is immobilizer-ECU diagnosis code displayed?
Yes
Check the immobilizer.
(Refer to GROUP 54 - Ignition Key and Immobilizer.)
No
MUT-II: Inspection of no initial combustion.
OK
Can any sound be heard from the injectors when cranking?
NG
Check the injector system. (Refer to P.13A-21, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
Ignition system: Inspection of no initial combustion.
OK
D Check the ignition coil, spark plugs, spark plug cables.
D Check if the injectors are clogged.
D Check if foreign materials (water, alcohol, etc.) got into fuel.
D Check the immobilizer system.
Probable cause
In such cases as the above, the cause is probably that the spark plugs are generating
sparks but the sparks are weak, or the initial mixture for starting is not appropriate.
D Malfunction of the injector system
D Poor compression
OK: 8 V or higher
NG
OK
MUT-II: Check if uncompleted combustion occurs.
OK
NG
Check the injector system, (Refer to P.13A-21, INSPECTION PRO-
OK
Is starting good if the engine is cranked with the accelerator pedal
slightly depressed?
Yes
Check ISC servo for op-
eration sound.
NG
Check the ISC servo sys-
tem. (Refer to P.13A-50,
INSPECTION PROCE-
DURE 34.)
OK
D Clean the throttle valve area. (Refer to P.13A-81.)
D Check and adjust the fixed SAS. (Refer to P.13A-83.)
No
Check the ignition timing when cranking.
OK: Approx. 5_BTDC
NG
Check that the crank angle sensor is installed properly.
OK
D Check fuel lines for clogging.
It takes too long time to start. (Incorrect starting) Probable cause
In cases such as the above, the cause is probably that the spark is weak and ignition
is difficult, the initial mixture for starting is not appropriate, or sufficient compression
pressure is not being obtained.
D Inappropriate gasoline use
D Poor compression
Check battery voltage when cranking
OK: 8 V or higher
NG
OK
MUT-II: Check if uncomplete combustion occurs.
OK
NG
OK
OK: Approx. 5_BTDC
NG
OK
Unstable idling (Rough idling, hunting) Probable cause
In cases as the above, the cause is probably that the ignition system, air/fuel mixture,
idle speed control (ISC) or compression pressure is defective.
Because the range of possible causes is broad, inspection is narrowed down to simple
items.
D Malfunction of air-fuel ratio control system
D Malfunction of the ISC system
D Malfunction of the purge control solenoid valve system
D Malfunction of the EGR solenoid valve system
D Poor compression
D Drawing air into exhaust system
Were the battery terminals disconnected?
Yes
After warming-up, let the engine run at idling for 10 minutes.
No
Yes
CODES.
No
Does idling speed fluctuate excessively?
Yes
Check if hunting occurs.
No
Check the ISC servo for operation sound. (Refer to P.13A-95.)
NG
Check the ISC servo system.
OK
Check the injector for operation sound.
NG
OK
MUT-II: Check if idling speed is unstable.
OK
Check the ignition timing.
(Refer to GROUP 11A - On-vehicle Service.)
NG
OK
D Check the purge control system.
D Check the EGR control system.
Idling speed is high. (Improper idling speed) Probable cause
In such cases as the above, the cause is probably that the intake air volume during
idling is too great.
D Malfunction of the ISC servo system
D Malfunction of the throttle body
OK
MUT-II Data list
26 Idle position switch (Refer to P.13A-63.)
NG
No
NG
OK
MUT-II Data list
21 Engine coolant temperature sensor (Refer to P.13A-62.)
NG
Check the engine coolant temperature sensor system.
(Refer toP.13A-16, INSPECTIONPROCEDUREFORDIAGNOSIS
CODE 21.)
OK
MUT-II Data list
28 A/C switch (Refer to P.13A-63.)
NG
Check the A/C switch and A/C relay system.
OK
Basic idle adjustment (Refer to P.13A-83.)
NG
Clean the throttle valve area. (Refer to P.13A-81.)
Check and adjust the fixed SAS. (Refer to P.13A-83.)
Yes
CODES.
Idling speed is low. (Improper idling speed) Probable cause
In cases such as the above, the cause is probably that the intake air volume during
idling is too small.
Yes
CODES.
No
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
CODE 21.)
OK
MUT-II Data list
29 Inhibitor switch (Refer to P.13A-63.)
NG
Check the ignition switch ST and inhibitor switch system <A/T>.
OK
NG
When the engine is cold, it stalls at idling. (Die out) Probable cause
Insuchcases as theabove, thecause isprobably that the air/fuel mixture is inappropriate
when the engine is cold, or that the intake air volume is insufficient.
Yes
No
Yes
CODES.
OK
Check the fuel pressure. (Refer to P.13A-85.)
OK
NG
OK
D Check the engine oil viscosity.
OK
MUT-II Data list
NG
OK
NG
Yes
NG
No
Is engine-idling stable after the warming-up?
No
Check if the unstable idling (Rough idling, hunting).
No
Does the engine stall right after the accelerator pedal is released?
Yes
Clean the throttle valve
area. (Refer to P.13A-81.)
Check and adjust the
fixed SAS.
OK
MUT-II Data list
NG
CODE 21.)
OK
MUT-II Actuator test
10 EGR control solenoid valve (Refer to P.13A-65.)
NG
Check the EGR control solenoid valve system. (Refer to P.13A-51,
INSPECTION PROCEDURE 36.)
When the engine is hot, it stalls at idling. (Die out) Probable cause
In such cases as the above, the cause is probably that ignition system, air/fuel mixture,
In addition, if the engine suddenly stalls, the cause may also be a defective connector
contact.
D Drawing air into intake system
D Improper connector contact
Yes
No
Yes
CODES.
No
NG
OK
NG
OK
Yes
area. (Refer to P.13A-81.)
fixed SAS.
No
Does the engine stall easily again?
No
While carrying out an intermittent malfunction simulation test (Refer
to GROUP 00 - Points to Note for Intermittent Malfunctions.), check
for sudden changes in the signals shown below.
D Crank angle sensor signal
D Air flow sensor signal
D Injector drive signal
D Primary and secondary
ignition signal
D Fuel pump drive signal
D Engine-ECUpower supply
voltage
Yes
MUT-II: Engine stalling inspection when the engine is warm and
idling. (Refer to P.13A-55, INSPECTION PROCEDURE 42.)
OK
NG
OK
The engine stalls when starting the car. (Pass out) Probable cause
In cases such as the above, the cause is probably misfiring due to a weak spark,
or an inappropriate air/fuel mixture when the accelerator pedal is depressed.
Yes
CODES.
OK
D Check if air was drawn into the intake system.
Broken intake manifold gasket
Broken or disconnected vacuum hose
Improper operation of the PCV valve
Broken air intake hose
No
NG
The engine stalls when decelerating. Probable cause
In cases such as the above, the cause is probably that theintake air volume is insufficient
due to a defective idle speed control (ISC) servo system.
No
MUT-II Data list
NG
OK
MUT-II Data list
14 Throttle position sensor (Refer to P.13A-62.)
NG
Check the throttle position sensor system. (Refer to P.13A-15, IN-
SPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
OK
MUT-II Data list
45 ISC servo position
D Is the idle speed control (ISC) servo position drops to 0- 2
steps when decelerating (engine r/min less than 1,000)?
Yes
Check the vehicle speed sensor system. (Refer to P.13A-19, IN-
OK
D Clean the throttle valve area.
D Check and adjust the fixed SAS.
No
MUT-II Data list
NG
No
NG
No
Yes
CODES.
Yes
Hesitation, sag or stumble Probable cause
In cases such as the above, the cause is probably that ignition system, air/fuel mixture
or compression pressure is defective.
D Malfunction of the fuel supply system
D Malfunction of the EGR control solenoid valve system
D Poor compression
Yes
CODES.
No
Check the injectors for operation sound.
NG
OK
NG
OK
MUT-II: Check if hesitation, sag, stumble or poor acceleration occur.
OK
OK
D Check the fuel filter or fuel line for clogging.
The feeling of impact or vibration when accelerating Probable cause
In cases such as the above, the cause is probably that there is an ignition leak
accompanying the increase in the spark plug demand voltage during acceleration.
Yes
CODES.
No
D Check for occurrence of ignition leak.
The feeling of impact or vibration when decelerating. Probable cause
Malfunction of the ISC system is suspected. D Malfunction of the ISC system
Yes
CODES.
No
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
OK
Poor acceleration Probable cause
Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc.
are suspected.
D Poor compression pressure
D Clogged exhaust system
Yes
CODES.
No
NG
OK
NG
OK
OK
OK
D Broken air intake hose
D Clogged air cleaner
Surge Probable cause
Defective ignition system, abnormal air-fuel ratio, etc. are suspected. D Malfunction of the ignition system
Yes
CODES.
No
NG
OK
NG
OK
MUT-II: Check if surge occurs.
(Refer to P.13-57, INSPECTION PROCEDURE 44.)
OK
OK
Knocking Probable cause
In cases as the above, the cause is probably that the detonation control is defective
or the heat value of the spark plug is inappropriate.
D Defective detonation sensor
D Inappropriate heat value of the spark plug
Yes
CODES.
No
Does knocking occur when driving with the sensor disconnected?
At this time, use the MUT-II to check if the timing is retarded
compared to when the detonation sensor connector is connected.
No
Check the detonation sensor system. (Refer to P.13A-21, INSPEC-
TION PROCEDURE FOR DIAGNOSIS CODE 31.)
Yes
D Spark plugs
Dieseling Probable cause
Fuel leakage from injectors is suspected. D Fuel leakage from injectors
Check the injectors for fuel leakage.
Too high CO and HC concentration when idling Probable cause
Abnormal air-fuel ratio is suspected. D Malfunction of the air-fuel ratio control system
D Deteriorated catalyst
No
NG
OK
MUT-II Data list
21 Engine coolant temperature sensor. (Refer to P.13A-62.)
NG
CODE 21.)
OK
MUT-II Data list
13 Intake air temperature sensor (Refer to P.13A-62.)
NG
Check the intake air temperaturesensor system. (Refer toP.13A-14,
INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
OK
MUT-II Data list
25 Barometric pressure sensor (Refer to P.13A-63.)
NG
Check the barometric pressure sensor system. (Refer to P.13A-20,
OK
MUT-II Data list
11 Oxygen sensor
OK: 600- 1,000 mV when racing suddenly (Refer to P.13A-61.)
NG
Check theoxygensensor system. (Refer to P.13A-13, INSPECTION
PROCEDURE FOR DIAGNOSIS CODE 11.)
OK
MUT-II Data list
11 Oxygen sensor
OK: Repeat 0- 400 mV and 600- 1,000 mV alternately when
idling. (Refer to P.13A-61.)
OK
NG
OK
NG
D Check the injectors for operation sound.
D Check the injectors for fuel leakage.
D Check the positive crankcase ventilation system.
Check the trouble symptom.
NG
Replace the catalytic converter.
Replace the oxygen sensor.
Yes
CODES.
OK
MUT-II Data list
59 Oxygen sensor (rear) (Refer to P.13A-65.)
D Transmission: 2nd gear <M/T>, L range <A/T>
D Driving with throttle widely open
OK: 600 - 1,000 mV
NG
Check the oxygen sensor (rear) system. (Refer to P.13A-24, IN-
Low alternator output voltage (approx. 12.3 V) Probable cause
The alternator may be defective, or malfunctions, which are listed in the right column,
may be suspected.
D Malfunction of charging system
D Short circuit in harness between alternator G terminal
and engine-ECU
Measure at the alternator connector
side. B-38
(Test harness: MB991519)
D Voltage between 1 (black clip) and
earth
Engine: at idle
Radiator fan: does not run
Headlamp: OFF ON
Brake lamp: OFF ON
Rear defogger switch:
OFF ON
OK: Voltages rises
by 0.2 - 3.5 V.
NG
Measure at the alternator connector.
B-38
D Disconnect the engine-ECU con-
nector.
OK: No continuity
NG
alternator and the engine-ECU connec-
OK
Check the alternator. (Refer to GROUP
16 - Charging System.)
OK
tor.
NG
Repair
OK
Idling speed is improper when A/C is operating Probable cause
If the engine-ECU detects that the air conditioner is on, it activates the idle
speed control (ISC) servo to control idle-up operation.
The A/C-ECU judges if the load caused by air conditioner operation is high or
low, and converts it to voltage signal (high or low voltage) and inputs the signal
to the engine-ECU.
Based on this voltage signal, the engine-ECU controls the idle-up speed (for
high or low load).
D Malfunction of the A/C control system
NG
Repair
NG
NG
Check the A/Csystem. (Refer to GROUP 55 - On-vehicle Service.)
OK
D Voltage between 24 and earth (Engine: at idle, outside air
temperature: 25_C or more)
OK: 0 - 3 V [When A/C is MAX. COOL condition (when
the load by A/C is high)]
System voltage [When A/C is MAX. HOT condition
(when the load by A/C is low)]
OK
C-34
Fans (radiator fan, A/C condenser fan) are inoperative Probable cause
The engine-ECU outputs a duty signal to the fan controller depending on the
engine coolant temperature, vehicle speed, and air conditioner switch condition.
Based on this signal, the fan controller controls the radiator fan and condenser
fan speeds (The more the average voltage at the terminal approaches 5 V, the
higher the fan speed become.)
D Malfunction of the fan motor relay
D Malfunction of the fan motor
D Malfunction of the fan controller
OK
Check the radiator fan
and condenser fan circuit.
(Refer to GROUP 14 -
Troubleshooting.)
NG
OK
OK
Check the following
connector:
C-34
NG
Repair
side.
OK: 4.8 - 5.2 V (Fan rotates at high speed.)
D Connect a jumper cable between 21 and earth (Ignition
switch: ON)
OK: Fan stops
NG
and the fan controller con-
nector.
NG
Repair
Power supply system and ignition switch-IG system Probable cause
When an ignition switch ON signal is input to the engine-ECU, the engine-ECU turns
the control relay ON. This causes battery voltage to be supplied to the engine-ECU,
injectors and air flow sensor.
D Malfunction of the ignition switch
D Malfunction of the control relay
D Disconnected engine-ECU earth wire
Check the control relay. (Refer to P.13A-90.)
NG
Replace
OK
Measure at the control relay connector C-31.
D Voltage between 3, 4 and earth
OK: System voltage
NG
Check the following
connector: B-30
NG
Repair
OK
NG
Check theharness wirebetweenbattery andcontrol relayconnector,
OK
Fuel pump system Probable cause
The engine-ECU turns the control relay ON when the engine is cranking or running,
and this supplies power to drive the fuel pump.
D Malfunction of the fuel pump relay
D Malfunction of the fuel pump
Check the fuel pump operation. (Refer to P.13A-88.)
NG
Check the fuel pump circuit.
OK
Check the fuel pump relay. (Refer to P.13A-90.)
NG
Replace
OK
Measure at the fuel pump relay connector C-32.
D MUT-II Actuator test: Fuel pump drive
OK: System voltage
NG
Check the fuel pump drive control circuit.
OK
Check the harness wire between fuel pump relay connector and
fuel pump drive terminal, and repair if necessary.
Idle position switch system Probable cause
The idle position switch inputs the condition of the accelerator pedal, i.e. whether
it is depressed or released (HIGH/LOW), to the engine-ECU.
The engine-ECU controls the idle speed control servo based on this input.
D Maladjustment of the accelerator pedal
D Maladjustment of the fixed SAS
D Maladjustment of the idle position switch and throttle
position sensor
Check the idle position switch. (Refer to P.13A-91.)
NG
Replace the throttle position sensor.
OK
Measure at the throttle position sensor connector B-07.
OK: 4 V or higher
OK: Continuity
NG
Check the following
connector: C-40
NG
Repair
OK
NG
Check the harness wire between engine-ECU and throttle position
sensor connector.
OK
NG
Repair
OK
Check the following
connector: B-07
NG
Repair
OK
NG
Ignition switch-ST system <M/T> Probable cause
The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine is
cranking.
The engine-ECU controls fuel injection, etc. during starting based on this input.
D Malfunction of ignition switch
1. Voltage between 71 and earth (Ignition switch: START)
OK: 8V or more
OK: Continuity
1. NG
Check the following
connector: C-92
NG
Repair
OK
NG
Check harness wire be-
tween the engine-ECU
and ignition switch con-
nector.
NG
Repair
OK
Check the ignition switch.
(Refer to GROUP 54 - Ignition Switch and Immobilizer system.)
2. NG
Check the harness wire between engine-ECU connector (terminal
No. 91) and earth, and repair if necessary.
OK
Check the following
connector: C-40
NG
Repair
OK
NG
Ignition switch-ST and inhibitor switch system <A/T> Probable cause
D The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine
is cranking.
D The inhibitor switch inputs the condition of the select lever, i.e. whether it is in
P or N range or in some other range, to the engine-ECU.
The engine-ECU controls the idle speed control (ISC) servo based on this input.
D Malfunction of inhibitor switch
D Malfunction of the engine-ECU.
Check the following
connector: B-72
OK
Measure at the inhibitor switch connector B-72.
OK: System voltage
OK: Continuity
D Ignition switch: START
D Disconnect engine-ECU connector.
OK: System voltage
1. NG
tween engine-ECU and
inhibitor switch connector.
NG
Repair
OK
2. NG
Check harness wire between inhibitor switch connector and starter
S terminal, and repair if necessary.
3. NG
Check the following
connector:
C-92
NG
Repair
OK
NG
NG
Repair Check harness wire be-
tween inhibitor switch and
ignition switch connector.
OK
OK
NG
Repair
OK
NG
NG
Repair
OK
NG
Replace Check the inhibitor switch.
Power steering fluid pressure switch system Probable cause
The presence or absence of power steering load is input to the engine-ECU.
D Malfunction of power steering fluid pressure switch
Check the power steering fluid pressure switch.
NG
Replace
OK
Measure at the power steering fluid pressure switch connector
B-76.
OK: System voltage
NG
Check the following
connector: C-36
NG
Repair
OK
NG
power steering fluid pres-
sure switch connector.
NG
Repair
OK
OK
Check the following
connector: B-76
NG
Repair
OK
NG
A/C switch and A/C relay system Probable cause
When an A/C ON signal is input to the engine-ECU, the engine-ECU carries out
control of the idle speed control (ISC) servo, and also operates the A/C compressor
magnetic clutch.
D Malfunction of A/C control system
D Malfunction of A/C switch
Check the A/C compressor relay.
NG
Replace
OK
Measure at the engine-ECU connectors C-34, C-36.
D Voltage between 8 and earth, and 45 and earth
OK: 0 - 3 V (A/C switch: OFF)
System voltage (A/C switch: ON)
D Short circuit between 8 and earth
(Ignition switch: ON, A/C switch: ON)
OK: A/C compressor clutch turns on.
NG
Check the A/C system. (Refer to GROUP 55 - Troubleshooting.)
OK
Check the following
connectors: C-34, C-36
NG
Replace
OK
NG
Ignition circuit system Probable cause
Theengine-ECUinterruptstheignitioncoil primarycurrent by turningthe power transistor
inside the engine-ECU ON and OFF.
D Malfunction of ignition switch.
Measure at the ignition coil connectors B-01, B-11.
D Disconnect the connector and measure at the harness side.
OK: System voltage
OK: Continuity
1. NG
Check the following
NG
Repair
OK
NG
between ignition coil and
NG
Repair
OK
(Refer to GROUP 54 - Ignition Switch and Immobilizer System.)
2. NG
Check the harness wire between power transistor unit connector
and earth, and repair if necessary.
OK
Check the following
connectors: B-01, B-11
NG
Repair
OK
NG
Check ignition coil and power transistor unit system. (Refer to
P.13A-22, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
44.)
Idle speed control (ISC) servo (Stepper motor) system Probable cause
The engine-ECU controls the intake air volume during idling by opening and closing
the servo valve located in the bypass air passage.
D Malfunction of ISC servo
Check the ISC servo
NG
Replace
OK
Measure at the ISC servo connector B-10.
D Voltage between 2 and earth, and 5 and earth (Ignition switch:
ON)
OK: System voltage
NG
Check the harness wire between control relay and ISC servo con-
nector, and repair if necessary.
OK
D Disconnect the connector, measure at the harness side.
D Voltage between each of 4, 5, 17, 18 and earth (Ignition switch:
ON)
OK: System voltage
NG
Check the following
connector: B-10
NG
Repair
OK
NG
Check harness wire between engine-ECUand ISCservoconnector,
OK
Check the following
connector: C-34
NG
Repair
OK
NG
Purge control solenoid valve system Probable cause
The purge control solenoid valve controls the purging of air from the canister located
inside the intake manifold.
D Malfunction of solenoid valve
short-circuited harness wire.
Check the purge control solenoid valve.
(Refer to GROUP 17 - Emission Control System.)
NG
Replace
OK
Measure at the purge control solenoid valve connector B-04.
OK: System voltage
NG
Check the harness wire between control relay and solenoid valve
connector, and repair if necessary.
OK
OK: System voltage
NG
Check the following
connector: B-04
NG
Repair
OK
NG
Check the harness wire between engine-ECU and solenoid valve
OK
Check the following
connector: C-34
NG
Repair
OK
NG
EGR control solenoid valve system Probable cause
The EGR control solenoid valve is controlled by the negative pressure resulting from
EGR operation leaking to port A of the throttle body.
Check the EGR control solenoid valve.
NG
Replace
OK
Measure at the EGR control solenoid valve connector B-06.
OK: System voltage
NG
OK
OK: System voltage
NG
Check the following
connector:
B-06
NG
Repair
OK
NG
OK
OK
NG
Check the following
connector: C-34
NG
Repair
MUT-II: Inspection of no initial combustion
MUT-II Data list
16 Power supply voltage (Refer to P.13A-62.)
NG
Check the power supply and ignition switch-IG system.
OK
Does the camshaft rotate at the engine cranking?
(When oil filler cap is removed.)
No
Check timing belt for breakage.
Yes
Yes
CODES.
No
MUT-II Data list
22 Crank angle sensor
OK: Cranking speed is displayed.
No
Check the crank angle sensor system.
CODE 22.)
OK
07 Fuel pump (Refer to P.13A-65.)
NG
Check the fuel pump system.
OK
MUT-II Data list
NG
CODE 21.)
Check ignition circuit system.
OK
OK: Approx. 5_BTDC
NG
Yes
Refer to P.13A-12, INSPECTIONCHARTFORDIAGNOSISCODE
No
NG
OK
MUT-II Data list
NG
(Refer to P.13A-16, INSPECTION PROCEDURES FOR DIAGNO-
SIS CODE 21.)
OK
MUT-II Data list
18 Ignition switch-ST (Refer to P.13A-62.)
NG
Check the ignition switch-ST system <M/T>.
Check the ignition switch-ST and inhibitor switch system <A/T>.
Clean the throttle body. (Refer to P.13A-81.)
NG
Inspect the intake of air into the air intake system
D Broken intake manifold gasket
D Broken vacuum hose
D Positive crankcase ventilation valve does not operate.
MUT-II Data list
NG
OK
MUT-II Data list
NG
Check the intake air temperaturesensor system. (Refer toP.13A-14,
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
CODE 21.)
OK
08 Purge control solenoid valve (Refer to P.13A-65.)
NG
Check the purge control solenoid valve system
OK
MUT-II Data list
11 Oxygen sensor
OK: 600- 1,000 mV during sudden racing
NG
Check the oxygen sensor (front) system. (Refer to P.13A-13, IN-
OK
MUT-II Data list
11 Oxygen sensor
OK: Changes between 0- 400 mV and 600- 1,000 mV during
idling
NG
Check the fuel pressure.
OK
1. Inspect the intake of
air into the air intake
system.
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
2. Check the injector for
clog.
OK
MUT-II Data list
27 Power steering fluid pressure switch (Refer to P.13A-63.)
NG
Check the power steering
fluid pressure switch sys-
INSPECTION PROCE-
DURE 31.)
OK
MUT-II Data list
NG
(Refer to P.13A-49. INSPECTION PROCEDURE 32.)
OK
MUT-II Data list
NG
Check the ignition switch-ST and inhibitor switch system. <A/T>
OK
MUT-II Data list
45 ISC Servo position (Refer to P.13A-64.)
NG
Adjust the basic idle speed. (Refer to P.13A-83.)
OK
NG
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
MUT-II: Engine stalling inspection when the engine is warmed up and idling.
MUT-II Data list
NG
OK
MUT-II Data list
NG
Check the intake air sensor system. (Refer to P.13A-14, INSPEC-
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
CODE 21.)
OK
MUT-II Data list
11 Oxygen sensor
OK: Changes between 600- 1,000 mV during sudden racing
NG
OK
MUT-II Data list
11 Oxygen sensor
idling
NG
OK
system
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
OK
MUT-II Data list
NG
INSPECTION PROCE-
DURE 31.)
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
45 ISC servo position (Refer to P.13A-64.)
NG
OK
NG
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
MUT-II: Check if hesitation, sug, stumble or poor acceleration occurs.
MUT-II Data list
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
(Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOS-
TIC CODE 21.)
OK
MUT-II Data list
NG
OK
NG
Check the EGR control solenoid valve system.
OK
MUT-II Data list
11 Oxygen sensor
NG
OK
MUT-II Data list
11 Oxygen sensor
idling
NG
OK
system
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
MUT-II Data list
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
CODE 21.)
OK
MUT-II Data list
NG
OK
NG
OK
MUT-II Data list
11 Oxygen sensor
NG
OK
MUT-II Data list
11 Oxygen sensor
idling
NG
OK
system
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
Measure the engine-ECU connectors, C-34, C-36, C-40.
D Disconnect the connector and measure at the harness side
OK: System voltage
OK: System voltage
3. Voltage between 12, 25 and earth (Ignition switch: ON)
OK: System voltage (when the terminal 38 is earthed)
4. Continuity between 13, 26 and earth
OK: Continuity
OK: System voltage
1. NG
Check the following
NG
Repair
OK
OK
NG
Repair
OK
2, 3. NG
4. NG
Check the harness wire between engine-ECU and earth, and repair
if necessary.
5. NG
OK
Check the following
connectors:
C-34, C-36, C-40
NG
Repair
OK
NG
C-47, C-83, C-66, (C-63, C-132,
C-141) <L.H.>, (C-62, C-14) <R.H.>
NG
Repair
OK
Check trouble symptom
NG
Check the harness wire between engine-ECU and battery, and
Check the harness wire between engine-ECU and control relay
Check fuel pump circuit.
Measure at the fuel pump connector E-16.
OK: Continuity
NG
E-11
NG
Repair
OK
NG
Check the harness wire between fuel pump and earth, and repair
if necessary.
OK
Check the following connectors: E-16, E-11, C-123, C-92, B-09
NG
Repair
OK
NG
Check the harness wire between terminal for fuel pump drive and
fuel pump connector.
NG
Repair
OK
Replace the fuel pump.
OK
NG
between fuel pump relay
nector.
NG
Repair
OK
Check the harness wire between engine-ECU and fuel pump relay
OK
NG
NG
Repair
OK
OK
OK: System voltage
NG
D Voltage between 3, 4 and earth (Ignition switch: ON)
OK: System voltage
NG
Check the following
NG
Repair
Check air flow sensor (AFS) control circuit.
2, 3. NG
Check the following
connector: C-40
NG
Repair
OK
NG
and air flow sensor con-
nector.
NG
Repair
OK
OK
NG
NG
Repair
OK
Measure at the air flow sensor connector B-12.
OK: System voltage
OK: 4.8- 5.2 V
OK: Continuity
1. NG
Check the harness wire between the air flow sensor and control
Check throttle position sensor (TPS) output circuit.
OK: 0.3- 1.0 V (Throttle valve at idle position)
4.5- 5.5 V (Throttle valve fully open)
OK
Check the following
connector: C-40
NG
Repair
OK
NG
NG
sensor connector, and repair if necessary.
Check injector control circuit
D Voltage between 1, 2, 14, 15 and earth (Ignition switch: ON)
OK: System voltage
NG
Check the following
connectors: B-02, B-03,
B-05, B-36
NG
Repair
OK
NG
Check the harness between engine-ECU and injector connector,
OK
OK
NG
NG
Repair
MPI <4G6> - Troubleshooting MPI <4G6> - Troubleshooting 13A-61
DATA LIST REFERENCE TABLE 13100890289
Caution
When shifting the select lever to D range, the brakes should be applied so that the vehicle does
not move forward.
NOTE
*1. In a new vehicle [driven approximately 500 kmor less], the air flowsensor output frequency is sometimes
10% higher than the standard frequency.
*2. The idle position switch normally turns off when the voltage of the throttle position sensor is 50 -
100 mV higher than the voltage at the idle position. If the throttle position switch turns back on
after the throttle position sensor voltage has risen by 100 mV and the throttle valve has opened,
the idle position switch and the throttle position sensor need to be adjusted.
*3. The injector drive time represents the time when the cranking speed is at 250 r/min or below when
the power supply voltage is 11 V.
*4. In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10%
longer than the standard time.
*5. In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes
30 steps greater than the standard value.
Item
No.
Inspection
item
Inspection contents Normal condition Inspection
procedure
No.
Reference
page
11 Oxygen
sensor
(front)
Engine:After having
warmed up
Air/fuel mixture is
When at 4,000 r/min,
engine is suddenly
decelerated
200 mV or less Code No.
11
13A-13
made leaner when de-
celerating, and is made
richer when racing.
When engine is
suddenly raced
600 - 1,000 mV
Engine:After having
warmed up
The oxygen sensor
signal is used to check
Engine is idling 400 mV or less
(Changes)
signal is used to check
the air/fuel mixture
ratio, and control
condition is also
checked by the ECU.
2,500 r/min
600 - 1,000 mV
12 Air flow
sensor*
1
D Engine coolant
temperature: 80 -
Engine is idling 17 - 43 Hz - -
sensor* temperature: 80 -
95_C
D Lamps, electric
2,500 r/min 70 - 110 Hz
cooling fan and all
accessories: OFF
D Transmission:
Neutral (A/T:
P range)
Engine is raced Frequency
increases in
response to
racing
13 Intake air
temperature
Ignition switch: ON or
with engine running
When intake air
temperature is - 20_C
- 20_C Code No.
13
13A-14
sensor
When intake air
temperature is 0_C
0_C
When intake air
temperature is 20_C
20_C
When intake air
temperature is 40_C
40_C
When intake air
temperature is 80_C
80_C
13A-62
Item
No.
Reference
page
Inspection
procedure
No.
Normal condition Inspection contents Inspection
item
14 Throttle Ignition switch: ON Set to idle position 300 - 1,000 mV Code No. 13A-15
position
sensor Gradually open Increases in
proportion to
throttle opening
angle
14
Open fully 4,500 - 5,500 mV
16 Power
supply
voltage
Ignition switch: ON System voltage Procedure
No. 26
13A-45
18 Cranking
signal
(ignition
Ignition switch: ON Engine: Stopped OFF Procedure
No. 29
<M/T>
13A-47
<M/T>
13A-48
(ignition
switch-ST)
Engine: Cranking ON
<M/T>
Procedure
No. 30
<A/T>
13A-48
<M/T>
21 Engine
coolant
temperature
Ignition switch: ON or
with engine running
When engine
coolant temperature
is - 20_C
- 20_C Code No.
21
13A-16
sensor
When engine
coolant temperature
is 0_C
0_C
When engine
coolant temperature
is 20_C
20_C
When engine
coolant temperature
is 40_C
40_C
When engine
coolant temperature
is 80_C
80_C
Item
No.
Reference
page
Inspection
procedure
No.
item
22 Crank angle
sensor
D Engine: Cranking
D Tachometer:
Connected
Compare the engine
speed readings on
the tachometer and
the MUT-II.
Accord Code No.
22
13A-17
D Engine: Idling
D Idle position
switch: ON
When engine
coolant temperature
is - 20_C
1,275 - 1,475 rpm
When engine
coolant temperature
is 0_C
1,225 - 1,425 rpm
When engine
coolant temperature
is 20_C
1,100 - 1,300 rpm
When engine
coolant temperature
is 40_C
950 - 1,150 rpm
When engine
coolant temperature
is 80_C
650 - 850 rpm
25 Barometric Ignition switch: ON At altitude of 0 m 101 kPa Code No. 13A-20
pressure
sensor At altitude of 600 m 95 kPa
25
At altitude of 1,200 m 88 kPa
26 Idle position
switch
Ignition switch: ON
Check by operating
Throttle valve:
Set to idle position
ON Procedure
No. 28
13A-46
accelerator pedal
repeatedly Throttle valve:
Slightly open
OFF*
2
27 Power
steering fluid
Engine: Idling Steering wheel
stationary
OFF Procedure
No. 31
13A-49
pressure
switch Steering wheel
turning
ON
28 A/C switch Engine: Idling
(when A/C switch is
A/C switch: OFF OFF Procedure
No. 32
13A-49
(when A/C switch is
ON, A/C compressor
should be operating.)
A/C switch: ON ON
No. 32
29 Inhibitor Ignition switch: ON P or N P or N Procedure 13A-48
switch
<A/T> D, 2, L or R D, 2, L or R
No. 30
Item
No.
Reference
page
Inspection
procedure
No.
item
41 Injectors *
3
Engine: Cranking When engine
coolant temperature
is 0_C (injection is
carried out for all
cylinders
simultaneously)
12 - 19 ms - -
When engine
coolant temperature
is 20_C
26 - 40 ms
When engine
coolant temperature
is 80_C
6.0 - 9.1 ms
Injectors*
4
D Engine coolant
temperature:
Engine is idling 1.6 - 2.8 ms
8095_C
D Lamps, electric
cooling fan and all
2,500 r/min 1.4 - 2.6 ms
accessories: OFF
D Transmission:
Neutral (A/T :
P range)
When engine is
suddenly raced
Increases
44 Ignitioncoils
and power
transistors
D Engine: After
having warmed up
D Timing lamp is set.
Engine is idling 2 - 18_BTDC - -
(The timing lamp
is set in order to
check actual
ignition timing.)
2,500 r/min 18 - 38_BTDC
45 ISC
(stepper)
motor
position *
5
D Engine coolant
temperature: 80 -
95_C
D Lamps, electric
A/C switch: OFF 2 - 25 STEP - -
position * D Lamps, electric
cooling fan and all
accessories: OFF
D Transmission:
Neutral (A/T :
P range)
A/C switch:
OFF ON
Increases by
10 - 70 steps
D Idle position
switch: ON
D Engine: Idling
D When A/C switch
is ON, A/C
compressor should
be operating
D A/C switch: OFF
D Select lever:
N range D
range
Increases by
5 - 50 steps
49 A/C relay Engine: After having
warmed up/Engine is
idling
A/C switch: OFF OFF (Compressor
clutch is not
operating)
Proce-
dure No.
32
13A-49
A/C switch: ON ON (Compressor
clutch is
operating)
Item
No.
Reference
page
Inspection
procedure
No.
item
59 Oxygen
sensor
(rear)
D Transmission:
2nd gear <M/T>,
L range <A/T>
D Drive with throttle
widely open
3,500 r/min 600 - 1,000 mV Code No.
59
13A-24
ACTUATOR TEST REFERENCE TABLE 13100900357
Item
No.
Inspection
item
Drive contents Inspection contents Normal condition Inspection
procedure
No.
Reference
page
01 Injectors Cut fuel to No.
1 injector
Engine:
After having warmed
Idling condition
becomes different
Code No.
41
13A-21
02 Cut fuel to No.
2 injector
up/Engine is idling
(Cut the fuel supply to each
injector in turn and check
(becomes unsta-
ble).
03 Cut fuel to No.
3 injector
cylinders which dont affect
idling.)
04 Cut fuel to No.
4 injector
07 Fuel pump Fuel pump
operates and
fuel is recircu-
lated.
D Engine:
Cranking
D Fuel
pump:
Forced
driving
Inspect
Pinch the
return hose
with fingers
to feel the
pulse of the
fuel being
recirculated.
Pulse is felt. Procedure
No. 27
13A-46
according
to both
the above
conditions.
Listen near
the fuel tank
for the
sound of
fuel pump
operation.
Sound of opera-
tion is heard.
08 Purge
control
solenoid
valve
Solenoid valve
turns from
OFF to ON.
Ignition switch: ON Sound of opera-
tion can be heard
when solenoid
valve is
driven.
Procedure
No. 35
13A-51
10 EGR
control
solenoid
valve
Solenoid valve
turns from
OFF to ON.
tion can be heard
when solenoid
valve is
driven.
Procedure
No. 36
13A-51
17 Basic igni-
tion timing
Set to ignition
timing adjust-
ment mode
Engine: Idling
Timing light is set
5_BTDC - -
21 Fan con-
troller
Drive the fan
motor
Ignition switch: ON Radiator fan and
condenser fan
operate at high
speed
Proce-
dure
No. 25
13A-45
CHECK AT THE ENGINE-ECU TERMINALS
13100920285
TERMINAL VOLTAGE CHECK CHART
1. Connect a needle-nosed wire probe (test harness:
MB991223 or paper clip) to a voltmeter probe.
2. Insert the needle-nosed wire probe into each of the
engine-ECU connector terminals from the wire side, and
measure the voltage while referring to the check chart.
NOTE
(1) Make the voltage measurement with the engine-ECU
connectors connected.
(2) You may find it convenient to pull out the engine-ECU
to make it easier to reach the connector terminals.
(3) The checks can be carried out off the order given
in the chart.
Caution
Short-circuiting the positive (+) probe between a
connector terminal and earth could damage the
vehicle wiring, the sensor, engine-ECU or all of them.
Be careful to prevent this!
3. If voltmeter shows any division fromstandard value, check
the corresponding sensor, actuator and related electrical
wiring, then repair or replace.
4. After repair or replacement, recheck with the voltmeter
to confirm that the repair has corrected the problem.
Needle-nosed wire probe
Engine-ECU Connector Terminal Arrangement
Terminal No. Check item Check condition (Engine condition) Normal condition
1 No. 1 injector While engine is idling after having From 11 - 14 V, momentarily
14 No. 2 injector
warmed up, suddenly depress the
accelerator pedal.
drops slightly
2 No. 3 injector
15 No. 4 injector
4 Stepper motor coil <A1> Engine: Soon after the warmed up System voltage 0 V
17 Stepper motor coil <A2>
engine is started (Changes repeatedly)
5 Stepper motor coil <B1>
6 EGR control solenoid Ignition switch: ON System Voltage
valve
While engine is idling, suddenly depress
the accelerator pedal.
From system voltage,
momentarily drops
8 A/C relay D Engine: Idle speed
D A/C switch: OFF ON
(A/C compressor is operating)
System voltage or
momentarily
6V or more 0 - 3V
9 Purge control solenoid Ignition switch: ON System voltage
valve
Running at 3,000r/min while engine is
warming up after having been started.
0 - 3V
10 Ignition coil - No. 1,
No. 4 (power transistor)
Engine r/min: 3,000 r/min 0.3 - 3.0V
23 Ignition coil - No. 2,
No. 3 (power transistor)
12 Power supply Ignition switch: ON System voltage
25
19 Air flow sensor reset Engine: Idle speed 0 - 1V
signal
Engine r/min: 3,000 r/min 6 - 9V
21 Fan controller Radiator fan and condenser fan are not
operating
0 - 0.3 V
Radiator fan and condenser fan are
operating
0.7 V or more
Terminal No. Normal condition Check condition (Engine condition) Check item
22 Fuel pump relay Ignition switch: ON System voltage
Engine: Idle speed 0 - 3V
24 A/C switch 2 D Engine: Idling
D Outside air
temperature:
25_C or more
When A/C is MAX.
COOL condition
(when the load by
A/C is high)
0 - 3 V
(When A/C is
MAX. HOT
condition (when
the load by A/C is
low)
System voltage
33 Alternator G terminal D Engine: Warm, idle
(radiator fan: OFF)
D Headlamp: OFF to ON
D Rear defogger switch: OFF to ON
D Brake lamp: ON
Voltage rises by 0.2 - 3.5 V.
41 Alternator FR terminal D Engine: Warm, idle
(radiator fan: OFF)
D Brake lamp: ON
Voltage drops by 0.2 - 3.5 V.
36 Engine warning lamp Ignition switch: OFF ON 0 - 3V 9 - 13V
(After several seconds have
elapsed)
37 Power steering fluid
pressure switch
Engine: Idling after
warming up
When steering
wheel is stationary
System voltage
When steering
wheel is turned
0 - 3V
38 Control relay Ignition switch: OFF System voltage
(Power supply)
Ignition switch: ON 0 - 3V
45 A/C switch 1 Engine: Idle speed Turn the A/C
switch OFF
0 - 3V
Turn the A/C
switch ON (A/C
compressor is
operating)
System voltage
58 Tachometer signal Engine r/min: 3,000 r/min 0.3 - 3.0V
60 Oxygen sensor heater Engine: Idling after warming up 0 - 3V
Engine r/min: 5,000r/min. System voltage
71 Ignition switch - ST Engine: Cranking 8V or more
72 Intake air temperature
sensor
Ignition switch:
ON
When intake air
temperature is
0_C
3.2 - 3.8V
When intake air
temperature is
20_C
2.3 - 2.9V
When intake air
temperature is
40_C
1.5 - 2.1V
When intake air
temperature is
80_C
0.4 - 1.0V
75 Oxygen sensor (rear) D Transmission: 2nd gear <M/T>,
L range <A/T>
D Engine r/min: 3,500 r/min or more
D Driving with the throttle valve
widely open
0.6 - 1.0 V
76 Oxygen sensor (front) Engine: Running at 2,500 r/min after
warmed up (Check using a digital type
voltmeter)
0 0.8V
(Changes repeatedly)
80 Backup power supply Ignition switch: OFF System voltage
81 Sensor impressed
voltage
Ignition switch: ON 4.5 - 5.5V
82 Ignition switch - IG Ignition switch: ON System voltage
83 Engine coolant
temperature sensor
Ignition switch:
ON
When engine
coolant tempera-
ture is 0_C
3.2 - 3.8V
When engine
coolant tempera-
ture is 20_C
2.3 - 2.9V
When engine
coolant tempera-
ture is 40_C
1.3 - 1.9V
When engine
coolant tempera-
ture is 80_C
0.3 - 0.9V
84 Throttle position
sensor
Ignition switch:
ON
Set throttle valve
to idle position
0.3 - 1.0V
Fully open throttle
valve
4.5 - 5.5V
85 Barometric pressure
sensor
Ignition switch:
ON
When altitude is
0m
3.7 - 4.3V
When altitude is
1,200m
3.2 - 3.8V
86 Vehicle speed sensor D Ignition switch: ON
D Move the vehicle slowly forward
0 5V
87 Idle position switch Ignition switch:
ON
Set throttle valve
to idle position
0 - 1V
Slightly open
throttle valve
4V or more
88 Camshaft position Engine: Cranking 0.4 - 3.0V
sensor
Engine: Idle speed 0.5 - 2.0V
89 Crank angle sensor Engine: Cranking 0.4 - 4.0V
90 Air flow sensor Engine: Idle speed 2.2 - 3.2V
Engine r/min: 2,500r/min
91 Inhibitor switch <A/T> Ignition switch:
ON
Set selector lever
to P or N
0 - 3V
Set selector lever
to Other than P or
N
8 - 14V
CHECK CHART FOR RESISTANCE AND CONTINUITY
BETWEEN TERMINALS
1. Turn the ignition switch to OFF.
2. Disconnect the engine-ECU connector.
3. Measure the resistance and check for continuity between
the terminals of the engine-ECU harness-side connector
while referring to the check chart.
NOTE
(1) When measuring resistance and checking continuity,
a harness for checking contact pin pressure should
be used instead of inserting a test probe.
(2) Checking need not be carried out in the order given
in the chart.
Caution
If the terminals that should be checked are mistaken,
or if connector terminals are not correctly shorted
to earth, damage may be caused to the vehicle wiring,
sensors, engine-ECU and/or ohmmeter.
4. If the ohmmeter shows any deviation from the standard
value, check the corresponding sensor, actuator and
related electrical wiring, and then repair or replace.
5. After repair or replacement, recheck with the ohmmeter
to confirm that the repair or replacement has corrected
the problem.
Engine-ECU Harness Side Connector Terminal Arrangement
Terminal No. Inspection item Normal condition (Check condition)
1 - 12 No. 1 injector 13 - 16 W (At 20_C)
14 - 12 No. 2 injector
4 - 12 Stepper motor coil (A1) 28 - 33 W (At 20_C)
17 - 12 Stepper motor coil (A2)
5 - 12 Stepper motor coil (B1)
6 - 12 EGR control solenoid valve 36 - 44 W (At 20_C)
9 - 12 Purge control solenoid valve 36 - 44 W (At 20_C)
13 - Body earth Engine-ECU earth Continuity (0W)
26 - Body earth Engine-ECU earth
60 - 12 Oxygen sensor heater 11 - 18 W (At 20_C)
72 - 92 Intake air temperature sensor 5.3 - 6.7 kW (When intake air temperature is 0_C)
2.3 - 3.0 kW (When intake air temperature is 20_C)
83 - 92 Engine coolant temperature sensor 5.1 - 6.5 kW (When coolant temperature is 0_C)
2.1 - 2.7 kW (When coolant temperature is 20_C)
87 - 92 Idle position switch Continuity (when throttle valve is at idle position)
No continuity (when throttle valve is slightly open)
91- Body earth Inhibitor switch <A/T> Continuity (when select lever is at P or N)
No continuity (when select lever is at D, 2, L or R)
INSPECTIONPROCEDUREUSINGANANALYZER
13100930219
AIR FLOW SENSOR (AFS)
Measurement Method
1. Disconnect the air flow sensor connector, and connect
the special tool (test harness: MB991709) in between.
(All terminals should be connected.)
2. Connect the analyzer special patterns pickup to air flow
sensor connector terminal 3.
Alternate Method (Test harness not available)
1. Connect the analyzer special patterns pickup to
engine-ECU terminal 90.
Standard Wave Pattern
Observation conditions
Function Special patterns
Pattern height Low
Pattern selector Display
Engine r/min Idle speed
Standard wave pattern
(V)
10
0
The time (cycle time) T is reduced when
the amount of intake air increases.
Times T1 and T2 are equal.
Time
T
T1 T2
Observation conditions (from conditions above engine speed is increased by racing.)
Time
(V)
10
0
T
Wave Pattern Observation Points
Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.
Analyzer
Special
patterns
pickup
Examples of Abnormal Wave Patterns
D Example 1
Cause of problem
Sensor interface malfunction
Wave pattern characteristics
Rectangular wave pattern is output even when the engine
is not started.
D Example 2
Cause of problem
Damaged rectifier or vortex generation column
Unstable wave pattern with non-uniform frequency.
However, when anignition leak occurs duringacceleration,
the wave pattern will be distorted temporarily, even if
the air flow sensor is normal.
CAMSHAFT POSITION SENSOR AND CRANK ANGLE
SENSOR
Measurement Method
1. Disconnect the camshaft position sensor connector and
connect the special tool (test harness: MB991223) and
jumper wire in between. (All terminals should be
connected.)
2. Connect the analyzer special patterns pickup to camshaft
position sensor terminal 2.
3. Disconnect the crank angle sensor connector and connect
the special tool (test harness: MD998478) in between.
4. Connect the analyzer special patterns pickup to crank
angle sensor terminal 2.
engine-ECU terminal 88. (When checking the camshaft
position sensor signal wave pattern.)
engine-ECU terminal 89. (When checking the crank angle
sensor signal wave pattern.)
Pattern height Low
Crank angle
sensor connector
connector
Analyzer
Special patterns
pick-up
Crank angle
sensor output
wave pattern
(V)
75_BTDC
2 engine revolutions
(1 camshaft revolution)
5_BTDC
The time (cycle time) T is
reduced when the engine
speed increases
0
Camshaft posi-
tion sensor out-
put wave pat-
tern
TDC: Top dead centre
131 49
No. 1 TDC No. 3 TDC No. 4 TDC No. 2 TDC
Time
0
56 34
Check that cycle time T becomes shorter when the engine speed increases.
D Example 1
Cause of problem
is not started.
D Example 2
Cause of problem
Loose timing belt
Abnormality in sensor disk
Wave pattern is displaced to the left or right.
INJECTOR
Measurement Method
1. Disconnect the injector connector, and then connect the
special tool (test harness: MB991348) in between.
(Both the power supply side and engine-ECU side should
be connected.)
2. Connect the analyzer special patterns pickup to terminal
2 of the injector connector.
engine-ECU terminal 1. (When checking the No. 1
cylinder.)
cylinder.)
cylinder.)
cylinder.)
Special
patterns
pickup
Analyzer
Pattern height Variable
Variable knob Adjust while viewing the wave pattern
(V)
Point A
Point B
Solenoid back electromotive force
(Approx. 710 V)
Injector drive time
Power voltage
Drive signal: ON Drive signal: OFF
Time
50
0
Point A: Height of solenoid back electromotive force
Contrast with standard wave pattern Probable cause
Solenoid coil back electromotive force is low or doesnt
appear at all.
Short in the injector solenoid
Point B: Injector drive time
D The injector drive time will be synchronized with the MUT-II
tester display.
D When the engine is suddenly raced, the drive time will
be greatly extended at first, but the drive time will soon
match the engine speed.
When idling
When racing
---
- -
STEPPER MOTOR
Measurement Method
1. Disconnect the stepper motor connector, and connect
2. Connect the analyzer special patterns pickup to the
stepper motor-side connector terminal 1 (red clip of special
tool), terminal 3 (blue clip), terminal 4 (black clip) and
terminal 6 (yellow clip) respectively.
engine-ECU terminal 4, connection terminal 5, connection
terminal 17, and connection terminal 18 respectively.
Pattern height High
Engine condition When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF
to ON (without starting the engine).
While the engine is idling, turn the A/C switch to ON.
Immediately after starting the warm engine
Stepper
motor
control
signal
wave
pattern
(V)
30
20
10
The wave pattern
appears for an
instant, but soon
disappears.
Point B
Coil reverse electromotive
force (Approx. 3 10V)
Point A
Induced electromotive force
from the motor turning
Time
Special
patterns
pickup
Analyzer
Check that the standard wave pattern appears when the stepper motor is operating.
Point A: Presence or absence of induced electromotive force fromthe motor turning. (Refer to the abnormal
wave pattern.)
Induced electromotive force does not appear or is extremely small. Motor is malfunctioning
Point B: Height of coil reverse electromotive force
Coil reverse electromotive force does not appear or is extremely small. Short in the coil
Examples of Abnormal Wave Pattern
D Example 1
Cause of problem
Motor is malfunctioning. (Motor is not operating.)
Induced electromotive force from the motor turning does
not appear.
D Example 2
Cause of problem
Open circuit in the line between the stepper motor and
the engine-ECU.
Current is not supplied to the motor coil on the open
circuit side. (Voltage does not drop to 0 V.)
Furthermore, the induced electromotive force waveform
at the normal side is slightly different from the normal
waveform.
Open
circuit
side
Normal
side
IGNITION COIL AND POWER TRANSISTOR
Power transistor control signal
Measurement Method
1. Disconnect the ignition coil connector, and connect the
special tool (test harness: MB991348) in between. (All
terminals should be connected.)
3 of each ignition coil connector in turn.
engine-ECU terminal 10 (No. 1 - No. 4), terminal 23
(No. 2 - No. 3) respectively.
Observation condition
Pattern height Low
Engine r/min Approx. 1,200 r/min
Crank angle
sensor output
wave pattern
Power transistor
control signal
wave pattern
(V)
75_BTDC
5_BTDC
T: Revolution time corresponding to a crank angle of 180_
Compression top dead center
q: Spark
advance
angle
Ignition period
OFF ON
Dwell section
T1: Time computed by the engine-ECU
Time
q T1
T
6
4
2
0
4
2
0
Special
patterns
pickup
Analyzer
Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave
pattern examples 1 and 2.)
Conditionof wavepatternbuild-upsectionandmaximumvoltage Probable cause
Rises from approx. 2V to approx. 4.5V at the top-right Normal
2V rectangular wave Open-circuit in ignition primary circuit
Rectangular wave at power voltage Power transistor malfunction
D Example 1
Wave pattern during engine cranking
Cause of problem
Open-circuit in ignition primary circuit
Top-right part of the build-up section cannot be seen,
and voltage value is approximately 2V too low.
D Example 2
Cause of problem
Malfunction in power transistor
Power voltage results when the power transistor is ON.
--- Normal wave pattern
2V
V
B
MPI <4G6> - On-vehicle Service 13A-81
THROTTLE BODY (THROTTLE VALVE AREA)
CLEANING
1. Start the engine and warm it up until the coolant is heated
to 80_C or higher and then stop the engine.
2. Remove the air intake hose from the throttle body.
3. Plug the bypass passage inlet of the throttle body.
Caution
Do not allow cleaning solvent to enter the bypass
passage.
4. Spray cleaning solvent into the valve through the throttle
body intake port and leave it for about 5 minutes.
5. Start the engine, race it several times and idle it for about
1 minute. If the idling speed becomes unstable (or if the
engine stalls) due to the bypass passage being plugged,
slightly open the throttle valve to keep the engine running.
6. If the throttle valve deposits are not removed, repeat
steps 4 and 5.
7. Unplug the bypass passage inlet.
8. Attach the air intake hose.
9. Use the MUT-II to erase the self-diagnosis code.
10. Adjust the basic idle speed. (Refer to P.13A-83.)
NOTE
If the engine hunts while idling after adjustment of the
basic idle speed, disconnect the () cable from the battery
for 10 seconds or more, and then reconnect it and run
the engine at idle for about 10 minutes.
IDLE POSITION SWITCH AND THROTTLE
POSITION SENSOR ADJUSTMENT 13100130268
Throttle position sensor (with
built-in idle position switch)
2. Insert a thickness gauge as follows:
<Vehicles without auto-cruise control system>
Insert a thickness gauge with a thickness of 0.45 mm
between the fixed SAS and the throttle lever.
<Vehicles with auto-cruise control system>
Insert a 1.4-mm thick thickness gauge up to approx. 3
mm between the levers shown in the figure.
NOTE
Do not insert the thickness gauge 3 mm or more. If doing
that, the throttle lever opening angle becomes larger than
the predetermined angle, causing maladjustment.
3. Turn the ignition switch to ON (but do not start the engine).
4. Loosen the throttle position sensor mounting bolt, and
then turn the throttle position sensor anti-clockwise as
far as it will go.
5. Check that the idle position switch is ON at this position.
6. Slowly turn the throttle position sensor clockwise and
find the point where the idle position switch turns off.
Securely tighten the throttle position sensor mounting
bolt at this point.
7. Check the throttle position sensor output voltage.
Standard value: 400 - 1,000 mV
the throttle position sensor and the related harness.
9. Remove the thickness gauge.
11. Disconnect the MUT-II.
Fixed
SAS
Thick-
ness
gauge
Fixed SAS
Throttle lever
Throttle lever
Thickness
gauge
Free
lever
FIXED SAS ADJUSTMENT 13100150301
NOTE
(1) The fixed SAS should not be moved unnecessarily;
it has been precisely adjusted by the manufacturer.
(2) If the adjustment is disturbed for any reason, readjust
as follows.
1. Loosen the tension of the accelerator cable sufficiently.
2. Back out the fixed SAS lock nut.
3. Turn the fixed SAS counterclockwise until it is sufficiently
backed out, and fully close the throttle valve.
4. Tighten the fixed SAS until the point where the throttle
lever is touched (i.e., the point at which the throttle valve
begins to open) is found.
From that point, tighten the fixed SAS 1-1/4 turn.
5. While holding the fixed SASso that it doesnt move, tighten
the lock nut securely.
6. Adjust the tension of the accelerator cable.
7. Adjust the basic idling speed.
8. Adjust the idle position switch and the throttle position
sensor (P.13A-81).
BASIC IDLE SPEED ADJUSTMENT 13100180348
NOTE
(1) The standard idling speed has been adjusted by the
speed adjusting screw (SAS) by the manufacturer,
and there should usually be no need for readjustment.
(2) If the adjustment has been changed by mistake, the
idle speed may become too high or the idle speed
may drop too low when loads from components such
as the A/C are placed on the engine. If this occurs,
(3) The adjustment, if made, should be made after first
confirming that the spark plugs, the injectors, the idle
speed control servo, the compression pressure, etc.,
are all normal.
1. Before inspection and adjustment, set the vehicle to the
2. Connect the MUT-II to the diagnosis connector (16-pin).
NOTE
When the MUT-II is connected, the diagnosis control
terminal should be earthed.
Fixed SAS
4. Select the item No.30 of the MUT-II Actuator test.
NOTE
This holds the ISC servo at the basic step to adjust the
basic idle speed.
5. Check the idle speed.
Standard value:
750 50 r/min
NOTE
(1) The engine speed may be 20 to 100 r/min lower
than indicated above for a new vehicle [driven
approximately 500 km or less], but no adjustment
is necessary.
(2) If the engine stalls or the engine speed is low even
though the vehicle has been driven approximately
500 km or more, it is probable that deposits are
adhered to the throttle valve, so clean it. (Refer to
P.13A-81.)
6. If not within the standard value range, turn the speed
adjusting screw (SAS) to make the necessary adjustment.
NOTE
If the idling speed is higher than the standard value range
even when the SAS is fully closed, check whether or
not there is any indication that the fixed SAS has been
moved. If there is an indication that it has been moved,
adjust the fixed SAS.
7. Press the MUT-II clear key, and release the ISC servo
from the Actuator test mode.
NOTE
Unless the ISC servo is released, the Actuator test mode
will continue 27 minutes.
8. Switch OFF the ignition switch.
10. Start the engine again and let it run at idle speed for
about 10 minutes; check that the idling condition is normal.
FUEL PRESSURE TEST 13100190303
1. Release residual pressure fromthe fuel pipeline toprevent
fuel gush out. (Refer to P.13A-88.)
2. Disconnect the fuel high pressure hose at the delivery
pipe side.
Caution
Cover the hose connectionwith rags to prevent splash
of fuel that couldbe causedby some residual pressure
in the fuel pipe line.
3. Remove the union joint and bolt from the special tool
(adapter hose MD998709) and instead attach the special
tool (hose adapter MD998742) to the adapter hose.
4. Install a fuel pressure gauge on the adapter hose that
was set up in step 3.
Use a suitable O-ring or gasket between the fuel pressure
gauge and the special tool so as to seal in order to prevent
fuel leakage at this time.
5. Install the special tool, which was set in place in steps
3 and 4 between the delivery pipe and the high pressure
hose.
6. Connect the No. 2 terminal of 3 pin connector (fuel pump
drive terminal) shown in the figure at left to the battery
(+) terminal using a jumper wire and drive the fuel pump.
Under fuel pressure, check the fuel pressure gauge and
special tool connections for leaks.
7. Disconnect the jumper wire from the fuel pump drive
terminal to stop the fuel pump.
9. Measure fuel pressure while the engine is running at
idle.
Standard value:
Approx. 265 kPa at kerb idle
Fuel high
pressure
hose
Delivery pipe
Fuel pressure
gauge
O-ring or
gasket
MD998709
MD998742
High
pressure
hose
Delivery pipe
Fuel pump
drive connector
10. Disconnect the vacuum hose from the fuel pressure
regulator and measure fuel pressure with the hose end
closed by a finger.
Standard value:
324 - 343 kPa at kerb idle
11. Check to see that fuel pressure at idle does not drop
even after the engine has been raced several times.
12. Racing the engine repeatedly, hold the fuel return hose
lightly with fingers to feel that fuel pressure is present
in the return hose.
NOTE
If the fuel flow rate is low, there will be no fuel pressure
in the return hose.
13. If any of fuel pressure measured in steps 9 to 12 is out
of specification, troubleshoot and repair according to the
table below.
Symptom Probable cause Remedy
D Fuel pressure too low Clogged fuel filter Replace fuel filter
D Fuel pressure drops after racing
D No fuel pressure in fuel return
hose
Fuel leaking toreturn sidedue topoor
fuel regulator valve seating or settled
spring
Replace fuel pressure regulator
Low fuel pump delivery pressure Replace fuel pump
Fuel pressure too high Binding valve in fuel pressure
regulator
Clogged fuel return hose or pipe Clean or replace hose or pipe
Same fuel pressure when vacuum
hose is connected and when
disconnected
Damaged vacuum hose or clogged
nipple
Replace vacuumhoseor cleannipple
14. Stop the engine and check change of fuel pressure gauge
reading. Normal if the reading does not drop within 2
minutes. If it does, observe the rate of drop and
troubleshoot and repair according to the table below.
Fuel pressure drops gradually after Leaky injector Replace injector
engine is stopped
Leaky fuel regulator valve seat Replace fuel pressure regulator
Fuel pressure drops sharply
immediately after engine is stopped
Check valve in fuel pumpis heldopen Replace fuel pump
15. Release residual pressure from the fuel pipe line. (Refer
to P.13A-88.)
16. Remove the fuel pressure gauge and special tool from
the delivery pipe.
Caution
17. Replace the O-ring at the end of the fuel high pressure
hose with a new one. Furthermore, apply engine oil to
the new O-ring before replacement.
18. Fit the fuel high pressure hose over the delivery pipe
and tighten the bolt to specified torque.
19. Check for fuel leaks.
(1) Apply the battery voltage to the fuel pump drive
terminal to drive the fuel pump.
(2) Under fuel pressure, check the fuel line for leaks.
FUEL PUMP CONNECTOR DISCONNECTION
(HOW TO REDUCE THE FUEL PRESSURE)
13100090252
When removing the fuel pipe, hose, etc., since fuel pressure
in the fuel pipe line is high, do the following operation so
as to release fuel pressure in the line and prevent fuel from
running out.
1. Raise the rear seat cushion.
2. Disconnect the floor wiringharness andfuel wiringharness
under the floor carpet.
3. After starting the engine and letting it run until it stops
naturally, turn the ignition switch to OFF.
4. Connect the fuel wiring harness and floor wiring harness.
5. Install the rear seat cushion.
FUEL PUMP OPERATION CHECK 13100200105
1. Check the operation of the fuel pump by using the MUT-II
to force-drive the fuel pump.
2. If the fuel pump will not operate, check by using the
following procedure, and if it is normal, check the drive
circuit.
(1) Turn the ignition switch to OFF.
(2) When the fuel pump drive connector (black) is
attached directly to the battery, check if the sound
of the fuel pump operation can be heard.
NOTE
As the fuel pump is an in-tank type, the fuel pump
sound is hard to hear, so remove the fuel filler cap
and check from the tank inlet.
(3) Check the fuel pressure by pinching the fuel hose
with the fingertips.
Fuel pump
drive connector
COMPONENT LOCATION 13100210368
Name Symbol Name Symbol
A/C relay G Engine warning lamp (check engine lamp) N
A/C switch R Fuel pump check terminal E
Air flow sensor (with intake air temperature F Idle speed control servo C
sensor and barometric pressure sensor)
Ignition coil J
Camshaft position sensor K Inhibitor switch <A/T> M
Control relay and fuel pump relay P Injectors J
Crank angle sensor I Oxygen sensor (front) S
Detonation sensor B Oxygen sensor (rear) T
Diagnosis connector O Power steering fluid pressure switch H
EGR control solenoid valve A Purge control solenoid valve A
Engine coolant temperature sensor L Throttle position sensor (with idle position
switch)
C
Engine-ECU Q Vehicle speed sensor D
T
CONTROL RELAY AND FUEL PUMP RELAY
CONTINUITY CHECK 13100990170
Battery voltage Terminal No.
1 2 3 4
Not supplied
Supplied
INTAKE AIR TEMPERATURE SENSOR CHECK
13100280239
1. Disconnect the air flow sensor connector.
2. Measure resistance between terminals 5 and 6.
Standard value:
2.3 - 3.0 kW (at 20_C)
0.30 - 0.42 kW (at 80_C)
3. Measure resistance while heating the sensor using a hair
drier.
Normal condition:
Temperature (_C) Resistance (kW)
Higher Smaller
4. If the value deviates from the standard value or the
resistance remains unchanged, replace the air flowsensor
assembly.
ENGINE COOLANT TEMPERATURE SENSOR
CHECK 13100310242
Caution
Be careful not to touch the connector (resin section) with
the tool when removing and installing.
1. Remove the engine coolant temperature sensor.
2. With temperature sensing portion of engine coolant
temperature sensor immersed in hot water, check
resistance.
Standard value:
2.1 - 2.7 kW (at 20_C)
0.26 - 0.36 kW (at 80_C)
3. If the resistance deviates from the standard value greatly,
replace the sensor.
Equipment side
connector
Fuel
pump
relay and
control
relay
Equipment side
connector
Air flow sensor
sensor
Engine coolant
temperature sensor
4. Apply sealant to threaded portion.
Specified sealant:
3M NUT Locking Part No.4171 or equivalent
5. Install the engine coolant temperature sensor and tighten
it to the specified torque.
THROTTLE POSITION SENSOR CHECK 13100320276
1. Disconnect the throttle position sensor connector.
2. Measure the resistance between the throttle position
sensor side connector terminal 1 and terminal 4.
Standard value: 3.5 - 6.5 kW
Normal condition:
Throttle valve slowly open
until fully open from the idle
position
Changes smoothly in
proportion to the opening
angle of the throttle valve
4. If the resistance is outside the standard value, or if it
doesnt change smoothly, replace the throttle position
sensor.
NOTE
For the throttle position sensor adjustment procedure,
refer to P.13A-81.
IDLE POSITION SWITCH CHECK 13100330262
2. Check the continuity between the throttle position sensor
connector side terminal 3 and terminal 4.
Normal condition:
Accelerator pedal Continuity
Depressed Non-conductive
Released Conductive (0 W)
3. If out of specification, replace the throttle position sensor.
NOTE
After replacement, the idle position switch and throttle
position sensor should be adjusted. (Refer to P.13A-81.)
Equipment side connector
Throttle position
sensor
TPS equipment
side connector
Throttle position
sensor
OXYGEN SENSOR CHECK 13100510161
<Oxygen sensor (front)>
1. Disconnect the oxygen sensor connector and connect
the special tool (test harness) to the connector on the
oxygen sensor side.
2. Make sure that there is continuity (11 - 18 W at 20_C)
between terminal 3 and terminal 4 on the oxygen sensor
connector.
3. If there is no continuity, replace the oxygen sensor.
4. Warmup the engine until engine coolant is 80_Cor higher.
5. Use the jumper wire to connect terminal 3 of the oxygen
sensor connector to the battery (+) terminal and terminal
4 to the battery ( - ) terminal.
Caution
Be very careful when connecting the jumper wire;
incorrect connection can damage the oxygen sensor.
6. Connect a digital voltage meter between terminal 1 and
terminal 2.
7. While repeatedly racing the engine, measure the oxygen
sensor output voltage.
Standard value:
Engine Oxygen sensor
output voltage
Remarks
When
racing the
engine
0.6 - 1.0 V If you make the air/fuel ratio
rich by racing the engine
repeatedly, a normal oxy-
gen sensor will output a
voltage of 0.6 - 1.0 V.
8. If the sensor is defective, replace the oxygen sensor.
NOTE
For removal and installation of the oxygen sensor, refer
to GROUP 15 - Exhaust Pipe and Main Muffler.
Equipment side
connector
Oxygen sensor
(front)
MB991223
MB991223
<Oxygen sensor (rear)>
the special tool (test harness set) to the connector on
the oxygen sensor side.
connector.
NOTE
(1) If the MUT-II does not display the standard value
although no abnormality is found by the above
mentioned continuity test and harness check, replace
the oxygen sensor (rear).
(2) For removal and installation of the oxygen sensor,
refer to GROUP 15 - Exhaust Pipe and Main Muffler.
INJECTOR CHECK 13100520287
Measurement of Resistance between Terminals
1. Remove the injector connector.
2. Measure the resistance between terminals.
Standard value: 13 - 16 W (at 20_C)
3. Install the injector connector.
Checking the Injection Condition
1. Following the steps below, bleed out the residual pressure
within the fuel pipe line to prevent flow of the fuel.
(Refer to P.13-88.)
2. Remove the injector.
Equipment side
connector
Oxygen
sensor
(rear)
MB991223
Injector
3. Arrange the special tool (injector test set), adaptor, fuel
pressure regulator and clips as shown in the illustration
below.
MB991607
High-pressure fuel hose
MD998741
MD998706
Return hose
Battery
Injector
Pressure regulator
(MD116395)
Clip (MB991608)
4. Apply battery voltage to the No. 2 terminal of 3 pin
connector (fuel pump drive connector) shown in the figure
at left and drive the fuel pump.
5. Activate the injector and check the atomized spray
condition of the fuel.
The condition can be considered satisfactory unless it
is extremely poor.
6. Stop the actuation of the injector, and check for leakage
from the injectors nozzle.
Standard value: 1 drop or less per minute
7. Activate the injector without activating the fuel pump; then,
when the spray emission of fuel from the injector stops,
disconnect the special tool and restore it to its original
condition.
Fuel pump
drive connector
Main hose
Battery
Injector
Return hose
IDLE SPEED CONTROL (ISC) SERVO
(STEPPER MOTOR) CHECK 13100540238
Checking the Operation Sound
1. Check that the engine coolant temperature is 20_C or
below.
NOTE
Disconnecting the engine coolant temperature sensor
connector and connecting the harness-side of the
connector to another engine coolant temperature sensor
that is at 20_C or below is also okay.
2. Check that the operation sound of the stepper motor
can be heard after the ignition is switched ON. (but without
starting the motor.)
3. If the operation sound cannot be heard, check the stepper
motors activation circuit.
If the circuit is normal, it is probable that there is a
malfunction of the stepper motor or of the engine control
unit.
Checking the Coil Resistance
1. Disconnect the idle speed control servo connector and
connect the special tool (test harness).
2. Measure the resistance between terminal 2 (white clip
of the special tool) and either terminal 1 (red clip) or
terminal 3 (blue clip) of the connector at the idle speed
control servo side.
3. Measure the resistance between terminal 5 (green clip
of the special tool) and either terminal 6 (yellow clip)
or terminal 4 (black clip) of the connector at the idle speed
control servo side.
PURGE CONTROL SOLENOID VALVE CHECK
13100560241
Refer to GROUP 17 - Emission Control System.
EGR CONTROL SOLENOID VALVE CHECK
13100570206
Idle speed
control servo
MPI <4G6> - Injector 13A-96
INJECTOR 13100710332
D Fuel Discharge Prevention (Refer to P.13A-88.)
O-ring
9 Nm
8
5, 7
11
12
O-ring
10 - 13 Nm
Engine oil
1
2
3
4
5
6
7
8
9
10
11
12
Removal steps
3. Purge control solenoid valve con-
nector
"AA 5. High-pressure fuel hose connection
"AA 7. Fuel pressure regulator
AA" 8. Delivery pipe
9. Insulator
10. Insulator
AA" "AA 11. Injector
12. Grommet
MPI <4G6> - Injector 13A-97
AA"DELIVERY PIPE/INJECTOR REMOVAL
Remove the delivery pipe (with the injectors attached to it).
Caution
Care must be taken, when removing the delivery pipe,
not to drop the injector.
"AAINJECTOR/FUEL PRESSURE REGULATOR/
HIGH-PRESSURE FUEL HOSE INSTALLATION
1. Apply a drop of new engine oil to the O-ring.
Caution
Be sure not to let engine oil in the delivery pipe.
2. While turning the injector, high-pressure fuel hose and
fuel pressure regulator to the right and left, install the
delivery pipe, while being careful not to damage the O-ring.
After installing, check that the hose turns smoothly.
3. If it does not turn smoothly, the O-ring may be trapped,
remove the fuel pressure regulator and then re-insert
it into the delivery pipe and check once again.
4. Tighten the high-pressure fuel hose tothe standardtorque,
and tighten the fuel pressure regulator to the specified
torque.
Tightening torque:
9 Nm (Fuel pressure regulator)
MPI <4G6> - Throttle Body 13A-98
THROTTLE BODY 13100770132
3
4
2
6
1
7
19 Nm
5
Removal steps
3. Idle speed control servo connector
6. Throttle body
"AA 7. Throttle body gasket
"AATHROTTLE BODY GASKET INSTALLATION
Place the gasket so that the projecting part is positioned
as shown in the illustration, and then install it between the
intake manifold and the throttle body.
Towards front
of vehicle
Up
DISASSEMBLY AND REASSEMBLY 13100970280
1
4
3
2
5
6
7
Disassembly steps
"AA 1. Throttle position sensor
2. Idle speed control body assembly
3. O-ring
4. Throttle body
5. Fixed SAS
6. Speed adjusting screw
7. O-ring
NOTE
1. The fixed SAS and the speed adjusting screw are
correctly adjusted at the factory and should not be
removed.
2. If the fixed SAS should happen to have been
removed, carry out fixed SAS adjustment.
(Refer to page 13A-83.)
3. If the speed adjusting screw should happen to have
been removed, carry out speed adjusting screw
adjustment. (Refer to 13A-83.)
1
5
4
3
6
7
8
2
Disassembly steps
"AA 1. Throttle position sensor
2. Lever assembly
3. Idle speed control body assembly
4. O-ring
5. Throttle body
6. Fixed SAS
8. O-ring
NOTE
removed.
CLEANING THROTTLE BODY PARTS
1. Clean all throttle body parts.
Do not use solvent to clean the following parts:
D Throttle position sensor
D Accelerator pedal position sensor
D Idle speed control body assembly
If these parts are immersed in solvent, their insulation
will deteriorate.
Wipe them with cloth only.
2. Check if the vacuum port or passage is clogged. Use
compressed air to clean the vacuum passage.
REASSEMBLY SERVICE POINT
"AATHROTTLE POSITION SENSOR (TPS)
INSTALLATION
1. Install the TPS so that it faces as shown in the illustration,
and then tighten it with the screw.
2. Connect a multimeter between terminal (1) (TPS power
supply) and terminal (2) (TPS output) of the TPS
connector, and check that the resistance increases
gradually as the throttle valve is opened slowly to the
fully-open position.
3. For vehicles without TCL, check the continuity between
terminal (3) (idle position switch) and terminal (4) (earth)
of the TPS connector when the throttle valve is fully closed
and fully open.
Normal condition:
Throttle valve condition Continuity
Fully closed Continuity
Fully open No continuity
If there is no continuity when the throttle valve is fully
closed, turn the TPS body anti-clockwise and then check
again.
4. If there is an abnormality, replace the TPS.
TPS output
TPS power
supply Earth
Idle position switch
MPI <6A1> - General Information 13A-102
MULTIPOINT FUEL INJECTION (MPI) <6A1> 13100010456
GENERAL INFORMATION
The Multipoint Fuel Injection System consists
of sensors which detect the engine conditions,
the engine-ECU which controls the system
based on signals from these sensors, and
actuators which operate under the control of
the engine-ECU. The engine-ECU carries out
activities such as fuel injection control, idle
speed control and ignition timing control. In
addition, the engine-ECU is equipped with
several diagnosis modes which simplify
troubleshooting when a problem develops.
FUEL INJECTION CONTROL
The injector drive times and injector timing are
controlled so that the optimum air/fuel mixture
is supplied to the engine to correspond to the
continually-changing engine operation condi-
tions.
A single injector is mounted at the intake port
of each cylinder. Fuel is sent under pressure
from the fuel tank by the fuel pump, with the
pressure being regulated by the fuel pressure
regulator. The fuel thus regulated is distributed
to each of the injectors.
Fuel injection is normally carried out once for
each cylinder for every two rotations of the
crankshaft. The firing order is 1-2-3-4-5-6. This
is called sequential fuel injection.
The engine-ECU provides a richer air/fuel
mixture by carrying out open-loop control
when the engine is cold or operating under
high load conditions in order to maintain engine
performance. In addition, when the engine is
warm or operating under normal conditions,
the engine-ECU controls the air/fuel mixture
by using the oxygen sensor signal to carry out
closed-loop control in order to obtain the
theoretical air/fuel mixture ratio that provides
the maximum cleaning performance from the
three way catalyst.
IDLE AIR CONTROL
The idle speed is kept at the optimum speed
by controlling the amount of air that bypasses
the throttle valve in accordance with changes
in idling conditions and engine load during
idling. The engine-ECU drives the idle speed
control (ISC) motor to keep the engine running
at the pre-set idle target speed in accordance
with the engine coolant temperature and air
conditioner load. In addition, when the air
conditioner switch is turned off and on while
the engine is idling, the ISC motor operates
to adjust the throttle valve bypass air amount
in accordance with the engine load conditions
in order to avoid fluctuations in the engine
speed.
IGNITION TIMING CONTROL
The power transistor located in the ignition
primary circuit turns ON and OFF to control
the primary current flow to the ignition coil. This
controls the ignition timing in order to provide
the optimum ignition timing with respect to the
engine operating conditions. The ignition timing
is determined by the engine-ECU from the
engine speed, intake air volume, engine coolant
temperature and atmospheric pressure.
of the sensors or actuators related to
emission control, the engine warning lamp
(check engine lamp) illuminates as a
warning to the driver.
of the sensors or actuators, a diagnosis
code corresponding to the abnormality is
output.
D The RAM data inside the engine-ECU that
is related to the sensors and actuators can
be read by means of the MUT-II. In addition,
the actuators can be force-driven under
certain circumstances.
1. Fuel Pump Control
Turn the fuel pump relay ON so that current
is supplied to the fuel pumpwhile theengine
is cranking or running.
Turn the compressor clutch of the A/C ON
and OFF.
3. Fan Relay Control
The revolutions of the radiator fan and
condenser fan are controlled in response
to the engine coolant temperature and
vehicle speed.
4. Traction Control
Engine output torque is reduced based on
signals from the TCL-ECU in response to
the conditions under which slipping of the
driven wheels and turning of the vehicle
occur.
Furthermore, reduction of output torque is
performed by closing the throttle valve and
retarding the ignition timing.
5. Purge Control Solenoid Valve Control
Refer to GROUP 17.
6. EGR Control Solenoid Valve Control
Refer to GROUP 17.
GENERAL SPECIFICATIONS
Throttle body Throttle bore mm 60
Throttle position sensor Variable resistor type
Accelerator pedal position sensor Variable resistor type
Idle speed control servo Stepper motor type
(Stepper motor typeby-pass air control systemwiththeair
volume limiter)
<Vehicles without TCL>
Rotary contact type, within throttle position sensor
Idle position switch <Vehicles with TCL> Rotary contact type, within accelerator pedal position
sensor
Engine-ECU Identification model No. E2T66876 <Vehicles without TCL>
E2T66877 <Vehicles with TCL>
Sensors Air flow sensor Karman vortex type
Barometric pressure sensor Semiconductor type
Intake air temperature sensor Thermistor type
Engine coolant temperature sensor Thermistor type
Oxygen sensor Zirconia type
Vehicle speed sensor Magnetic resistive element type
Inhibitor switch Contact switch type
Top dead centre sensor Hall element type
Crank angle sensor Hall element type
Detonation sensor Piezoelectric type
Power steering fluid pressure switch Contact switch type
Actuators Control relay type Contact switch type
Fuel pump relay type Contact switch type
Injector type and number Electromagnetic type, 6
Injector identification mark CDH210
EGR control solenoid valve Duty cycle type solenoid valve
Purge control solenoid valve ON/OFF type solenoid valve
Ventilation control solenoid valve Duty cycle type solenoid valve
Vacuum control solenoid valve Duty cycle type solenoid valve
Fuel pressure
regulator
Regulator pressure kPa 329
MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM
*7
z3
z2
z4
*4, *5
*1
*8
z1
*6
*10
Vacuum control solenoid
valve <TCL>
Idle speed
control servo
Air cleaner
To fuel
tank
Fuel pressure
regulator
From fuel
pump
PCV valve
Injector
EGR
valve
Engine
coolant
tempera-
ture sensor
EGR control
solenoid valve
Canister
Throttle
position
sensor (with
idle position
switch)
Oxygen
sensor
(front)
Oxygen
sensor
(rear)
Crank angle sensor
Catalytic converter
Distributor
Air
z6
*1 Oxygen sensor (front)
*2 Air flow sensor
*4 Throttle position sensor
*5 Idle position switch
*6 Top dead centre sensor
*9 Barometric pressure sensor
*10 Oxygen sensor (rear)
D A/C switch 1, 2
D Inhibitor switch
D Power steering fluid pressure switch
D Ignition switch - ST
D Ignition switch - IG
D Alternator FR terminal
D A/T-ECU
D TCL-ECU <TCL>
Engine-
ECU
z1 Injector
z2 Purge control solenoid valve
z3 Idle speed control servo
z4 EGR control solenoid valve
z5 Ventilation control solenoid valve
<TCL>
z6 Vacuum control solenoid valve <TCL>
D Fuel pump relay
D Control relay
D A/C power relay
D Diagnosis signal
D Ignition coil, power transistor
D Fan controller
D Alternator G terminal
D A/T-ECU
D TCL-ECU <TCL>
Vacuum
tank
Vacuum
actuator
<TCL>
Top dead centre sensor
*3
Ventiration control solenoid valve <TCL> z5
Air flowsensor (withbarometric
pressure sensor)
Purge control
solenoid valve
*9 *2
MPI <6A1> - Service Specifications/Sealant 13A-106
Basic idle speed r/min 65050
Throttle position sensor ad- Vehicles without TCL 400 - 1,000
justing voltage mV
Vehicles with TCL 580 - 690
Accelerator pedal position sensor adjusting voltage mV 400 - 1,000
Throttle position sensor resistance kW 3.5 - 6.5
Accelerator pedal position sensor resistance kW 3.5 - 6.5
Idle speed control servo coil resistance W 28 - 33 (at 20_C)
Intakeair temperaturesensor 20_C 2.3 - 3.0
resistance kW
80_C 0.30 - 0.42
Engine coolant temperature 20_C 2.1 - 2.7
sensor resistance kW
80_C 0.26 - 0.36
Oxygen sensor output voltage V 0.6 - 1.0
Fuel pressure kPa Vacuumhose disconnection 324 - 343 at kerb idle
Vacuum hose connection Approx. 265 at kerb idle
Injector coil resistance W 13 - 16 (at 20_C)
Ventilation control solenoid valve coil resistance W 36 - 44 (at 20_C)
Vacuum control solenoid valve coil resistance W 36 - 44 (at 20_C)
SEALANT 13100050205
threaded portion
MPI <6A1> - Special Tools 13A-107
A
B
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
D Fuel gauge simple inspection
MB991502 MUT-II sub
assembly
D Reading diagnosis code
D MPI system inspection
MB991348 Test harness set D Measurement of voltage during trouble-
shooting
MB991709 Test harness
MB991519 Alternator harness
connector
Measurement of voltage during
troubleshooting
(6-pin, square)
D Inspection of idle speed control servo
(3-pin, triangle)
D Measurement of voltage during trouble-
shooting
MPI <6A1> - Special Tools/Troubleshooting 13A-108
MD998709 Adaptor hose Measurement of fuel pressure
MD998742 Hose adaptor
MD998706 Injector test set Checking the spray condition of injectors
MB991607 Injector test
harness
MD998741 Injector test
adaptor
MB991608 Clip
Service Points.
If an abnormality occurs in any of the following items related
to the Multipoint Fuel Injection (MPI) system, the engine
warning lamp will illuminate.
Engine warning lamp
(check engine lamp)
MPI <6A1> - Troubleshooting 13A-109
Engine-ECU
Oxygen sensor
Air flow sensor
Crank angle sensor
Top dead centre sensor
Detonation sensor
Injector
Vacuum control solenoid valve <TCL>
Ventilation control solenoid valve <TCL>
Immobilizer system
CODES
Service Points.
ACTUATOR TESTING
FAIL-SAFE FUNCTION REFERENCE TABLE 13100910305
Air flow sensor 1. Uses the throttle position sensor signal and engine speed signal (crank angle sensor
signal) to take reading of the basic injector drive time and basic ignition timing from
the pre-set mapping.
2. Fixes the ISC servo in the appointed position so idle control is not performed.
sensor
Controls as if the intake air temperature is 25_C.
Throttle position
sensor (TPS)
No increase in fuel injection amount during acceleration due to the throttle position sensor
signal.
Engine coolant
temperature sensor
Controls as if the engine coolant temperature is 80_C.
Top dead centre sen-
sor
Injects fuel to all cylinders simultaneously.
(However, after the ignition switch is turned to ON, the No. 1 cylinder top dead centre is not
detected at all.)
Barometric pressure
sensor
Controls as if the barometric pressure is 101 kPa.
Detonation sensor Switches the ignition timing fromignition timing for super petrol to ignition timing for standard
petrol.
Oxygen sensor Air/fuel ratio feedback control (closed loop control) is not performed.
Communication wire
with transmission
control unit <A/T>
Ignition timing is not retarded during transmission gear shifting (overall engine and
transmission control).
Alternator FR terminal Does not control the output of the alternator according to an electrical load. (works as a
normal alternator)
NOTE
When a problem is detected in the vacuum control solenoid valve, ventilation control solenoid valve,
crank angle sensor or any of the above items, traction control is not performed <Vehicles with TCL>.
11 Oxygen sensor (front) system 13A-112
12 Air flow sensor system 13A-113
13 Intake air temperature sensor system 13A-113
14 Throttle position sensor system 13A-114
21 Engine coolant temperature sensor system 13A-115
22 Crank angle sensor system 13A-116
23 Top dead centre sensor 13A-117
24 Vehicle speed sensor system 13A-118
25 Barometric pressure sensor system 13A-119
31 Detonation sensor system 13A-120
41 Injector system 13A-120
54 Immobilizer system 13A-121
59 Oxygen sensor (rear) system 13A-122
61 Communication wire with A/T-ECU system <A/T> 13A-123
64 Alternator FR terminal system 13A-123
71 Vacuum control solenoid valve system <Vehicles with TCL> 13A-124
72 Ventilation control solenoid valve system <Vehicles with TCL> 13A-125
Code No. 11 Oxygen sensor (front) system Probable cause
Range of Check
D Intake air temperature is 20- 50_C.
D Engine speed is approx. 2,000- 3,000 r/min
D Vehicle is moving at constant speed on a flat, level road surface
Set conditions
D The oxygen sensor (front) output voltage is around 0.6 V for 30 seconds (does
not cross 0.6 V for 30 seconds).
D When the range of check operations given above which accompany starting of
the engine are carried out four time in succession, a problem is detected after
each operation.
D Malfunction of the oxygen sensor (front)
OK
NG
(front) connector.
NG
Repair
OK
OK
C-46, C-39
NG
Repair
OK
oxygen sensor (front) and the earth,
NG
the oxygen sensor (front) connector.
NG
Repair
OK
3. NG
OK
Measure at the oxygen sensor (front) connector C-46.
harness side.
OK: System voltage
OK: Continuity
OK: Continuity
1. NG
oxygen sensor (front) and the control
2. NG
C-39
NG
Repair
Check the oxygen sensor (front). (Refer to P.13A-196.)
NG
Replace
Code No. 12 Air flow sensor system Probable cause
Range of Check
D Engine speed is 500 r/min or more.
Set conditions
D Sensor output frequency is 3 Hz or less for 4 seconds.
D Malfunction of the air flow sensor
short-circuited harness wire of the air flow sensor
nector B-12.
(Engine: Idling)
OK: 2.2- 3.2 V
OK: 0- 1 V (Engine: idling)
6- 9 V (2,000 r/min)
OK
1. NG
Check the air flow sensor circuit.
(Refer to P.13A-159, INSPEC-
TION PROCEDURE 49.)
2. NG
nector C-33.
OK: 6- 9 V
OK
C-33
OK
NG
NG
B-12
NG
Repair
OK
NG
NG
Repair
Code No. 13 Intake air temperature sensor system Probable cause
Range of Check
Set conditions
D Sensor output voltage is 4.6 V or more (corresponding to an intake air temperature
of - 45_C or less) for 4 seconds.
or
D Sensor output voltage is 0.2V or less (corresponding to an intake air temperature
of 125_C or more) for 4 seconds.
short-circuited harness wire of the intake air
Check the intake air temperature
sensor.
NG
Replace
OK
nector B-12.
OK: 4.5- 4.9 V
OK: Continuity
NG
C-39
NG
Repair
OK
NG
the engine-ECU and the intake air
NG
Repair
OK
OK
B-12
NG
Repair
OK
NG
Code No. 14 Throttle position sensor system Probable cause
Range of Check
Set conditions
D When the idle position switch is ON, the sensor output voltage is 2 V or more
for 4 seconds.
or
D The sensor output voltage is 0.2 V or less for 4 seconds.
D Malfunction of the throttle position sensor or
maladjustment
short-circuited harness wire of the throttle position
sensor circuit
D Improper ON state of idle position switch
D Short circuit of the idle position switch signal line
MUT-II Data list
26 Idle position switch system
OK: With the throttle valve at the
idle position: ON
With the throttle valve slight-
ly open: OFF
NG
PROCEDURE 28.) <Vehicles without
TCL>
PROCEDURE 29.) <Vehicles with
TCL>
OK
Check the throttle position sensor.
NG
Replace
OK
Measure at the throttle position sensor
connector B-07.
OK: 4.8- 5.2 V
OK: Continuity
NG
C-39
NG
Repair
OK
NG
engine-ECU and the throttle position
sensor connector.
NG
Repair
OK
OK
Check the throttle position sensor out-
put circuit. (Refer to P.13A-160, IN-
Code No. 21 Engine coolant temperature sensor system Probable cause
Range of Check
Set conditions
D Sensor output voltage is 4.6 V or more (corresponding to an engine coolant
temperature of - 45_C or less) for 4 seconds.
or
D Sensor output voltage is 0.1 V or less (corresponding to an engine coolant
temperature of 140_C or more) for 4 seconds.
short-circuited harness wire of the engine coolant
Range of Check
Set conditions
D The sensor output voltage increases from 1.6 V or less (corresponding to an
engine coolant temperature of 40_C or more) to 1.6 V or more (corresponding
to an engine coolant temperature of 40_C or less).
D After this, the sensor output voltage is 1.6 V or more for 5 minutes.
Check the engine coolant temperature
NG
Replace
OK
Measure at the engine coolant temper-
ature sensor connector B-33.
OK: 4.5- 4.9 V
OK: Continuity
NG
C-39
NG
Repair
OK
NG
engine-ECU and the engine coolant
NG
Repair
OK
B-33
OK
NG
NG
Repair
OK
Range of Check
D Engine is cranking.
Set conditions
short-circuited harness wire of the crank angle sensor
D Connect the connector. (Use the test harness: MD998478.)
OK: 0.4- 4.0 V
OK: 1.5- 2.5 V
NG
OK
OK: System voltage
OK: 4.8- 5.2 V
OK: Continuity
OK
nector: B-77
NG
Repair
OK
NG
1. NG
2. NG
nector: C-39
NG
Repair
OK
3. NG
NG
the crank angle sensor
connector.
NG
Repair
OK
Code No.23 Top dead centre sensor system Probable cause
Range of Check
D Engine speed is approx. 50 r/min or more.
Set conditions
D Malfunction of the top dead centre sensor
short-circuited harness wire of the top dead centre
sensor circuit
Measure at the distributor connector B-42.
D Connect the connector. (Use the test harness: MB991348 and
jumper wire.)
OK: 0.4- 3.0 V
OK: 1.5- 2.0 V
OK
NG
OK: System voltage
OK: 4.8- 5.2 V
OK: Continuity
1. NG
Check the harness wire between the top dead centre sensor and
the control relay connector, and repair if necessary.
2. NG
nector: C-39
NG
Repair
OK
NG
the top dead centre sensor
connector.
NG
Repair
OK
3. NG
Check the harness wire between the top dead centre sensor and
OK
nector: B-42
NG
Repair
OK
NG
Replace the distributor
Code No. 24 Vehicles speed sensor system Probable cause
Range of check
D Engine speed is 3,000 r/min or more.
D Driving under high engine load conditions.
Set conditions
D Sensor output voltage does not change for 4 seconds (no pulse signal input).
short-circuited harness wire of the vehicle speed
sensor circuit
OK
2. NG
OK
3. NG
OK
NG
sensor connector.
NG
Repair
OK
OK
Check the following
connectors:
B-66 <M/T>, B-67 <A/T>
NG
Repair
NG
sensor connector.
NG
Repair
OK
Check the following
connectors:
B-65 <M/T>, C-48, C-39
NG
Repair
NG
between the vehicle
switch connector.
NG
Repair
OK
OK
Measure at the vehicle speed sensor connector B-66 <M/T>, B-67
<A/T>.
side.
OK: System voltage
OK: 4.8 - 5.2 V
OK: Continuity
1. NG
Check the following
connectors:
B-65 <M/T>, C-90, C-135,
C-131
NG
Repair
tion Meters.)
NG
Replace
NG
OK
Check the following
connector:
B-65 <M/T>
NG
Repair
Code No. 25 Barometric pressure sensor system Probable cause
Range of Check
Set conditions
D Sensor output voltage is 4.5 V or more (corresponding to a barometric pressure
of 114 kPa or more) for 4 seconds.
or
D Sensor output voltage is 0.2 V or less (corresponding to a barometric pressure
of 5.33 kPa or less) for 4 seconds.
D Malfunction of the barometric pressure sensor
short-circuited harness wire of the barometric pressure
sensor circuit
nector B-12.
1,200 m)
NG
nector B-12.
OK: 4.8- 5.2 V
OK: Continuity
NG
C-39
NG
Repair
OK
NG
NG
Repair
OK
OK
B-12
NG
Repair
OK
NG
NG
Repair
OK
OK
nector C-39.
1,200 m)
NG
ric pressure sensor connector, and
C-39
OK
NG
NG
Repair
OK
MPI <6A1> - Troubleshooting MPI <6A1> - Troubleshooting 13A-120
Code No. 31 Detonation sensor system Probable cause
Range of Check
D Engine speed is approx. 5,000 r/min or more
Set conditions
The change in the detonation sensor output voltage (detonation sensor peak voltage
at each 1/2 revolution of the crankshaft) is less than 0.06 V for 200 times in succession.
D Malfunction of the detonation sensor
short-circuited harness wire of the detonation sensor
circuit
Measure at the detonation sensor con-
nector B-34.
OK: Continuity
OK
B-34, C-39
NG
Repair
OK
NG
engine-ECU and the detonation sensor
connector.
OK
Replace the detonation sensor.
NG
NG
Repair
NG
detonation sensor and earth, and repair
if necessary.
Code No. 41 Injector system Probable cause
Range of Check
D The throttle position sensor output voltage is 1.15 V or less.
D Actuator test by MUT-II is not carried out.
Set conditions
D Surge voltage of injector coil is not detected for 4 seconds.
D Malfunction of the injector
short-circuited harness wire of the injector circuit
Check the injector. (Refer toP.13A-197.)
NG
Replace
OK
Measure at the injector connectors
B-02, B-03, B-05, B-36, B-40, B-44.
OK: System voltage
NG
B-02, B-03, B-05, B-36, B-40, B-44.
NG
Repair
OK
NG
engine-ECU and the injector connector,
Check the injector control circuit.
PROCEDURE 51.)
OK
Range of Check
Set Conditions
D Improper communication between the engine-ECU and immobilizer-ECU
D Incorrect ID code
NOTE
(1) If the ignition switches are close each other when starting the engine, radio interference may cause
this code to be displayed.
(2) This code may be displayed when registering the key ID code.
No
Yes
NG
Is a diagnosis code output from the immobilizer-ECU?
Yes
No
C-37, C-81, C-68
NG
Repair
OK
NG
er-ECU.
OK
NG
NG
Repair
NG
Code No. 59 Oxygen sensor (rear) system Probable cause
Range of Check
D The throttle position sensor output voltage is 4.1 V or more.
D Open loop control in operation
D 20 seconds have passed after deceleration finished.
Set conditions
D The oxygen sensor (rear) output voltage is 0.1 V or less.
D The difference in the maximum and minimum values for the oxygen sensor (rear)
output voltage is 0.08 V or less.
D The oxygen sensor (rear) output voltage is 0.5 V or more.
D The above conditions continue for a continuous period of 5 seconds.
D Malfunction of the oxygen sensor (rear)
OK
NG
(rear) connector.
NG
Repair
OK
OK
C-85, C-39
NG
Repair
OK
NG
the oxygen sensor (rear) connector.
NG
Repair
OK
Replace the oxygen sensor (rear).
NG
3. NG
oxygen sensor (rear) and the earth, and
OK
Measure at the oxygen sensor (rear) connector C-85.
harness side.
OK: System voltage
OK: Continuity
OK: Continuity
1. NG
oxygen sensor (rear) and the control
2. NG
C-39
NG
Repair
Check the oxygen sensor (rear). (Refer to P.13A-197.)
NG
Replace
Code No. 61 Communication wire with A/T-ECU system
<A/T>
Probable cause
Range of Check
D 60 seconds or more have passed immediately after engine was started.
Set conditions
The voltage of the torque reduction request signal from the A/T-ECU is LOW for
1.5 seconds or more.
D Malfunction of the harness wire and the connector
Check the following connectors.
(C-30, C-37) <Vehicles without TCL>,
(C-28, C-35) <Vehicles with TCL>
NG
Repair
OK
NG
Check the harness wire between the engine-ECUand the A/T-ECU
connector.
NG
Repair
OK
NG
Code No. 64 Alternator FR Terminal System Probable cause
D The alternator FRterminal signal voltage remains high for approximately 20 seconds
while the engine is running.
D Open circuit in alternator FR terminal circuit
(Engine: Idling)
(Radiator fan: Stopped)
(Headlamp: OFF ON)
OK: 1.8 - 2.4 1.0 - 1.6 V
OK
NG
OK: 4.8 - 5.2 V
NG
Check the following
connectors: B-31, C-37
NG
Repair
OK
NG
and the alternator con-
nector.
NG
Repair
OK
OK
NG
Repair
OK
NG
Check the harness wire between the engine-ECUand the alternator
connector.
NG
Repair
OK
Replace the alternator.
Code No. 71 Vacuum control solenoid valve system
<Vehicles with TCL>
Probable cause
Range of Check
D Excluding 60 seconds immediately after the engine starts.
D Forced actuation by means of MUT-II is not being carried out.
Set condition
Solenoid valve drive or non-drive instruction and energized condition of solenoid coil
are different.
D Malfunction of the vacuum control solenoid valve
short-circuited harness wire of the vacuum control
solenoid valve
Check the vacuum control solenoid valve.
NG
Replace
OK
Measure at the vacuum control solenoid valve con-
nector B-78.
D Disconnect the connector and measure at the
harness side.
OK: System voltage
NG
Check the harness wire between the vacuumcontrol
solenoid valve connector and the control relay con-
OK
harness side.
OK: System voltage
NG
B-78
NG
Repair
OK
NG
Check the harness wire between the engine-ECU
and the vacuum control solenoid valve connector,
OK
C-35
NG
Repair
OK
NG
Code No. 72 Ventilation control solenoid valve system
<Vehicles with TCL>
Probable cause
Range of Check
D Excluding 60 seconds immediately after the engine starts.
D Forced actuation by means of MUT-II is not being carried out.
Set condition
Solenoid valve drive or non-drive instruction and energized condition of solenoid coil
are different.
D Malfunction of the ventilation control solenoid valve
short-circuited harness wire of the ventilation control
solenoid valve
Replace
NG
OK
Measure at the ventilation control solenoid valve
connector B-79.
harness side.
OK: System voltage
NG
Check the harness wire between the control relay
and the ventilation control solenoid valve connector,
OK
harness side.
OK: System voltage
NG
Check the harness wire between the engine-ECU
and the ventilation control solenoid valve connector,
OK
C-35
NG
Repair
OK
NG
NG
B-79
NG
Repair
OK
Check the ventilation control solenoid valve.
procedure
No.
Reference page
Communication
II
Communication with all systems is not possible. 1 13A-128
with MUT-II is
impossible. Communication with engine-ECU only is not possible. 2 13A-129
Engine warning
lamp and
3 13A-130
related parts
The engine warning lamp remains illuminating and never goes
out.
4 13A-130
Starting No initial combustion (starting impossible) 5 13A-131
6 13A-132
Long time to start (improper starting) 7 13A-133
Idling stability Unstable idling (Rough idling, hunting) 8 13A-134
(Improper idling)
Idling speed is high. (Improper idling speed) 9 13A-135
Idling speed is low. (Improper idling speed) 10 13A-136
Idling stability When the engine is cold, it stalls at idling. (Die out) 11 13A-137
(Engine stalls)
When the engine becomes hot, it stalls at idling. (Die out) 12 13A-138
The engine stalls when starting the car. (Pass out) 13 13A-139
The engine stalls when decelerating. 14 13A-139
Driving Hesitation, sag or stumble 15 13A-140
The feeling of impact or vibration when accelerating 16 13A-140
The feeling of impact or vibration when decelerating 17 13A-141
Poor acceleration 18 13A-141
Surge 19 13A-142
Knocking 20 13A-142
Dieseling 21 13A-142
Too high CO and HC concentration when idling 22 13A-143
Low alternator output voltage (approx. 12.3 V) 23 13A-144
Idling speed is improper when A/C is operating 24 13A-144
Fans (radiator fan, A/C condensor fan) are inoperative 25 13A-145
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)
Items Symptom
Starting Wont start The starter is used to crank the engine, but there is no combustion within the
cylinders, and the engine wont start.
Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Hard starting Engine starts after cranking a while.
Idling Hunting Engine speed doesnt remain constant; changes at idle.
stability
Rough idle Usually, a judgement can be based upon the movement of the tachometer
pointer, and the vibration transmitted to the steering wheel, shift lever, body, etc.
This is called rough idle.
Incorrect idle speed The engine doesnt idle at the usual correct speed.
Engine stall
(Die out)
The engine stalls when the foot is taken from the accelerator pedal, regardless
of whether the vehicles is moving or not.
Engine stall
(Pass out)
The engine stalls when the accelerator pedal is depressed or while it is being
used.
Driving Hesitation Sag Hesitation is the delay in response
of the vehicle speed (engine speed)
that occurs when the accelerator is
depressed in order to accelerate
from the speed at which the vehicle
is nowtraveling, or a temporary drop
in vehicle speed (engine speed)
during such acceleration.
Serious hesitation is called sag.
Vehicle
speed
Initial ac-
celerator
pedal de-
pression
Normal
Hesitation
Sag
Time
Poor acceleration Poor acceleration is inability to obtain an acceleration corresponding to the
degree of throttle opening, even though acceleration is smooth, or the inability
to reach maximum speed.
Stumble Engine speed increase is delayed
when the accelerator pedal is
initially depressed for accelera-
tion.
Normal
Initial ac-
celerator
pedal de-
pression
Idling
Stumble
Time
Vehicle
speed
Items Symptom
Driving Shock The feeling of a comparatively large impact or vibration when the engine is
accelerated or decelerated.
Surge This is repeated surging ahead during constant speed travel or during variable
speed travel.
Knocking A sharp sound like a hammer striking the cylinder walls during driving and which
adversely affects driving.
Stopping Run on
(Dieseling)
The condition in which the engine continues to run after the ignition switch is
turned to OFF. Also called Dieseling.
Probable cause
diagnosis line.
(16-pin) C-20.
OK: Battery voltage
NG
C-66, (C-63, C-132, C-141) <L.H.>,
(C-62, C-14) <R.H.>
NG
Repair
OK
NG
power supply and diagnostic connector
(16 pin), and repair if necessary.
OK
(16-pin) C-20.
OK: Continuity
NG
diagnostic connector (16-pin) and earth,
OK
Replace the MUT-II.
MUT-II communication with engine-ECU is impossible. Probable cause
D No power supply to engine-ECU.
D Defective earth circuit of engine-ECU.
D Defective engine-ECU.
D Malfunction of engine-ECU power supply circuit
connector
ECU
Yes
NG
Repair
OK
earth.
NG
Repair
OK
Check the power supply and ignition switch-IG system. (Refer to
OK
Check the harness wire between engine-ECU and immobilizer-
ECU.
NG
Check the harness wire between engine-ECU and diagnosis con-
nector.
NG
Repair
OK
Check the following connectors: C-37, C-81, C-68
NG
Repair
Is communication possible between the MUT-II and the immobilizer-
ECU?
No
Key and Immobilizer.)
Probable cause
Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp
D Burnt-out bulb
MUT-II Data list
16 Engine-ECU power supply voltage (Refer to P.13A-163.)
NG
OK
D Earth the terminal No. 36.
OK
Check the following
connector: C-35.
NG
Repair
OK
NG
NG
Check a burnt-out bulb.
NG
Replace
OK
OK: System voltage
NG
Check the engine warning lamp power supply circuit, and repair
if necessary.
OK
D-03, C-90, C-35
NG
Repair
OK
NG
goes out.
Probable cause
In cases such as the above, the cause is probably that the engine-ECU is detecting
occurred.
engine-ECU
Yes
CODES
No
D Disconnect the engine-ECU connector
OK: No continuity
NG
ECU connector, and repair if necessary.
OK
No initial combustion (starting impossible) Probable cause
In cases such as the above, the cause is probably that a spark plug is defective,
or that the supply of fuel to the combustion chamber is defective.
In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel.
D Malfunction of the fuel pump system
D Malfunction of the injectors
OK: 8 V or higher
NG
OK
Is immobilizer-ECU diagnosis code displayed?
Yes
Check the immobilizer.
(Refer to GROUP 54 - Ignition Key and Immobilizer.)
No
MUT-II: Inspection of no initial combustion.
OK
NG
Check the injector system. (Refer to P.13A-120, INSPECTION
OK
OK
D Check the immobilizer system.
Probable cause
In such cases as the above, the cause is probably that the spark plugs are generating
sparks but the sparks are weak, or the initial mixture for starting is not appropriate.
D Poor compression
OK: 8 V or higher
NG
OK
MUT-II: Check if uncompleted combustion occurs.
OK
NG
Check the injector system, (Refer to P.13A-120, INSPECTION
OK
Is starting good if the engine is cranked with the accelerator pedal
slightly depressed?
Yes
Check ISC servo for op-
eration sound.
NG
Check the ISC servo sys-
INSPECTION PROCE-
DURE 35.)
OK
D Clean the throttle valve area. (Refer to P.13A-184.)
D Check and adjust the fixed SAS. (Refer to P.13A-187.)
No
OK: Approx. 5_BTDC
NG
OK
D Check fuel lines for clogging.
In takes too long time to start. (Incorrect starting) Probable cause
In cases such as the above, the cause is probably that the spark is weak and ignition
is difficult, the initial mixture for starting is not appropriate, or sufficient compression
pressure is not being obtained.
D Inappropriate gasoline use
D Poor compression
Check battery voltage when cranking
OK: 8 V or higher
NG
OK
OK
NG
OK
OK: Approx. 5_BTDC
NG
OK
Unstable idling (Rough idling, hunting) Probable cause
In cases as the above, the cause is probably that the ignition system, air/fuel mixture,
Because the range of possible causes is broad, inspection is narrowed down to simple
items.
D Malfunction of the purge control solenoid valve system
D Malfunction of the EGR solenoid valve system
D Poor compression
D Drawing air into exhaust system
Yes
No
Yes
CODES.
No
Does idling speed fluctuate excessively?
Yes
No
NG
OK
NG
OK
OK
(Refer to GROUP 11B - On-vehicle Service.)
NG
OK
D Check the operation of the power steering control valve.
Idling speed is high. (Improper idling speed) Probable cause
In such cases as the above, the cause is probably that the intake air volume during
idling is too great.
OK
MUT-II Data list
NG
<Vehicles with TCL>
No
NG
OK
MUT-II Data list
NG
(Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE 21.)
OK
MUT-II Data list
NG
OK
NG
Yes
CODES.
Idling speed is low. (Improper idling speed) Probable cause
In cases such as the above, the cause is probably that the intake air volume during
idling is too small.
Yes
CODES.
No
NG
OK
MUT-II Data list
NG
(Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles
without TCL>
with TCL>
OK
MUT-II Data list
NG
SIS CODE 21.)
OK
MUT-II Data list
NG
Check the ignition switch ST and inhibitor switch system <A/T>.
OK
NG
When the engine is cold, it stalls at idling. (Die out) Probable cause
Insuchcases as theabove, thecause isprobably that the air/fuel mixture is inappropriate
when the engine is cold, or that the intake air volume is insufficient.
Yes
No
Yes
CODES.
OK
OK
NG
OK
D Check the engine oil viscosity.
OK
MUT-II Data list
NG
without TCL>
with TCL>
OK
NG
Yes
NG
No
Is engine-idling stable after the warming-up?
No
Check if the unstable idling (Rough idling, hunting).
No
Yes
area.
fixed SAS.
OK
MUT-II Data list
NG
SIS CODE 21.)
OK
NG
When the engine is hot, it stalls at idling. (Die out) Probable cause
In such cases as the above, the cause is probably that ignition system, air/fuel mixture,
In addition, if the engine suddenly stalls, the cause may also be a defective connector
contact.
D Improper connector contact
Yes
No
Yes
CODES.
No
NG
OK
NG
OK
Yes
area.
fixed SAS.
No
Does the engine stall easily again?
No
While carrying out an intermittent malfunction simulation test (Refer
to GROUP 00 - Points to Note for Intermittent Malfunctions.), check
for sudden changes in the signals shown below.
D Crank angle sensor signal
D Air flow sensor signal
D Injector drive signal
D Primary and secondary
ignition signal
D Fuel pump drive signal
D Engine-ECUpower supply
voltage
Yes
MUT-II: Engine stalling inspection when the engine is warm and
idling. (Refer to P.13A-155, INSPECTION PROCEDURE 43.)
OK
NG
OK
The engine stalls when starting the car. (Pass out) Probable cause
In cases such as the above, the cause is probably misfiring due to a weak spark,
or an inappropriate air/fuel mixture when the accelerator pedal is depressed.
Yes
CODES.
OK
D Check if air was drawn into the intake system.
Broken intake manifold gasket
Broken or disconnected vacuum hose
Improper operation of the PCV valve
Broken air intake hose
No
NG
The engine stalls when decelerating. Probable cause
In cases such as the above, the cause is probably that theintake air volume is insufficient
due to a defective idle speed control (ISC) servo system.
OK
MUT-II Data list
NG
Check the throttle position sensor system. (Refer to P.13A-114,
OK
MUT-II Data list
45 ISC servo position
D Is the idle speed control (ISC) servo position drops to 0- 2
steps when decelerating (engine r/min less than 1,000)?
Yes
Check the vehicle speed sensor system. (Refer to P.13A-119, IN-
OK
D Clean the throttle valve area.
D Check and adjust the fixed SAS.
No
MUT-II Data list
NG
without TCL>
with TCL>
No
NG
No
Yes
CODES.
Yes
Hesitation, sag or stumble Probable cause
In cases such as the above, the cause is probably that ignition system, air/fuel mixture
or compression pressure is defective.
D Poor compression
Yes
CODES.
No
NG
OK
NG
OK
OK
OK
D Check the injector operating sound at the rear bank.
D Check the operation vacuum of the traction control (TCL).
D Check the operation of the throttle valve.
D Check the vacuum tank and vacuum actuator.
The feeling of impact or vibration when accelerating Probable cause
In cases such as the above, the cause is probably that there is an ignition leak
accompanying the increase in the spark plug demand voltage during acceleration.
Yes
CODES.
No
D Check for occurrence of ignition leak.
The feeling of impact or vibration when decelerating. Probable cause
Malfunction of the ISC system is suspected. D Malfunction of the ISC system
Yes
CODES.
No
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
without TCL>
with TCL>
OK
Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc.
are suspected.
D Poor compression pressure
D Clogged exhaust system
Yes
CODES.
No
NG
OK
NG
OK
OK
OK
D Check the injector operating sound at the rear bank.
D Check the operation vacuum of the traction control (TCL).
D Check the operation of the throttle valve.
D Check the vacuum tank and vacuum actuator.
D Clogged air cleaner
Surge Probable cause
Defective ignition system, abnormal air-fuel ratio, etc. are suspected. D Malfunction of the ignition system
Yes
CODES.
No
NG
OK
NG
OK
(Refer to P.13-157, INSPECTION PROCEDURE 45.)
OK
OK
D Check the injector operation sound at the rear bank.
Knocking Probable cause
In cases as the above, the cause is probably that the detonation control is defective
or the heat value of the spark plug is inappropriate.
D Defective detonation sensor
D Inappropriate heat value of the spark plug
Yes
CODES.
No
Does knocking occur when driving with the sensor disconnected?
At this time, use the MUT-II to check if the timing is retarded
compared to when the detonation sensor connector is connected.
No
Check the detonation sensor system. (Refer to P.13A-120, INSPEC-
Yes
D Spark plugs
Dieseling Probable cause
Fuel leakage from injectors is suspected. D Fuel leakage from injectors
Check the injectors for fuel leakage.
Too high CO and HC concentration when idling Probable cause
Abnormal air-fuel ratio is suspected. D Malfunction of the air-fuel ratio control system
D Deteriorated catalyst
No
NG
OK
MUT-II Data list
21 Engine coolant temperature sensor. (Refer to P.13A-163.)
NG
SIS CODE 21.)
OK
MUT-II Data list
NG
Check the intake air temperature sensor system. (Refer to
13.)
OK
MUT-II Data list
NG
OK
MUT-II Data list
11 Oxygen sensor (front)
OK: 600- 1,000 mV when racing suddenly (Refer to
P.13A-162.)
NG
OK
MUT-II Data list
OK: Repeat 0- 400 mV and 600- 1,000 mV alternately when
idling. (Refer to P.13A-162.)
OK
NG
OK
NG
D Check the injectors for operation sound.
D Check the injectors for fuel leakage.
D Check the positive crankcase ventilation system.
NG
Replace the catalytic converter.
Replace the oxygen sensor (front).
Yes
CODES.
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
Low alternator output voltage (approx. 12.3 V) Probable cause
The alternator may be defective, or malfunctions, which are listed in the right column,
may be suspected.
D Malfunction of charging system
D Short circuit in harness between alternator G terminal
and engine-ECU
Measure at the alternator connector
side. B-38
(Test harness: MB991519)
D Voltage between 1 (black clip) and
earth
Engine: at idle
Radiator fan: does not run
Headlamp: OFF ON
Brake lamp: OFF ON
Rear defogger switch:
OFF ON
OK: Voltage rises by 0.2 - 3.5 V.
NG
Measure at the alternator connector.
B-38
D Disconnect the engine-ECU con-
nector.
OK: No continuity
NG
OK
Check the alternator. (Refer to GROUP
16 - Charging System.)
OK
tor.
NG
Repair
OK
Idling speed is improper when A/C is operating Probable cause
If the engine-ECU detects that the air conditioner is on, it activates the idle
speed control (ISC) servo to control idle-up operation.
The A/C-ECU judges if the load caused by air conditioner operation is high or
low, and converts it to voltage signal (high or low voltage) and inputs the signal
to the engine-ECU.
Based on this voltage signal, the engine-ECU controls the idle-up speed (for
high or low load).
D Malfunction of the A/C control system
NG
Repair
NG
NG
OK
D Voltage between 57 and earth (Engine: at idle, outside air
temperature: 25_C or more)
OK: 0 - 3 V [When A/C is MAX. COOL condition (when
the load by A/C is high)]
System voltage [When A/C is MAX. HOT condition
(when the load by A/C is low)]
OK
C-37
Fans (radiator fan, A/C condenser fan) are inoperative Probable cause
The engine-ECU outputs a duty signal to the fan controller depending on the
engine coolant temperature, vehicle speed, and air conditioner switch condition.
Based on this signal, the fan controller controls the radiator fan and condenser
fan speeds (The more the average voltage at the terminal approaches 5 V, the
higher the fan speed become.)
D Malfunction of the fan motor relay
D Malfunction of the fan motor
D Malfunction of the fan controller
OK
Check the radiator fan
and condenser fan circuit.
(Refer to GROUP 14 -
Troubleshooting.)
NG
OK
OK
Check the following
connector:
C-33
NG
Repair
side.
D Connect a jumper cable between 21 and earth (Ignition
switch: ON)
OK: Fan stops
NG
and the fan controller con-
nector.
NG
Repair
Power supply system and ignition switch-IG system Probable cause
When an ignition switch ON signal is input to the engine-ECU, the engine-ECU turns
the control relay ON. This causes battery voltage to be supplied to the engine-ECU,
injectors and air flow sensor.
D Malfunction of the control relay
D Disconnected engine-ECU earth wire
Check the control relay. (Refer to P.13A-193.)
NG
Replace
OK
D Voltage between 3, 4 and earth
OK: System voltage
NG
Check the following
connector: B-30
NG
Repair
OK
NG
Check theharness wirebetweenbattery andcontrol relayconnector,
OK
Fuel pump system Probable cause
The engine-ECU turns the control relay ON when the engine is cranking or running,
and this supplies power to drive the fuel pump.
D Malfunction of the fuel pump relay
D Malfunction of the fuel pump
Check the fuel pump operation. (Refer to P.13A-191.)
NG
Check the fuel pump circuit.
OK
Check the fuel pump relay. (Refer to P.13A-193.)
NG
Replace
OK
D MUT-II Actuator test: Fuel pump drive
OK: System voltage
NG
OK
Check the harness wire between fuel pump relay connector and
fuel pump drive terminal, and repair if necessary.
Idle position switch system <Vehicles without TCL> Probable cause
D Maladjustment of the idle position switch and throttle
position sensor
NG
OK
Measure at the throttle position sensor connector B-07.
OK: 4 V or higher
OK: Continuity
NG
Check the following
connector: C-39
NG
Repair
OK
NG
sensor connector.
OK
NG
Repair
OK
Check the following
connector: B-07
NG
Repair
OK
NG
Idle position switch system <Vehicles with TCL> Probable cause
D Maladjustment of the idle position switch and
accelerator pedal position sensor
NG
Replace the accelerator pedal position sensor.
OK
Measure at the accelerator pedal position sensor connector B-41.
OK: 4 V or higher
OK: Continuity
NG
Check the following
connector: C-39
NG
Repair
OK
NG
Check the harness wire between engine-ECUand accelerator pedal
position sensor connector.
OK
NG
Repair
OK
Check the following
connector: B-41
NG
Repair
OK
NG
Ignition switch-ST system <M/T> Probable cause
The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine is
cranking.
OK: 8V or more
OK: Continuity
1. NG
Check the following
connector: C-92
NG
Repair
OK
NG
tween the engine-ECU
nector.
NG
Repair
OK
2. NG
Check the harness wire between engine-ECU connector (terminal
No. 91) and earth, and repair if necessary.
OK
Check the following
connector: C-39
NG
Repair
OK
NG
Ignition switch-ST and inhibitor switch system <A/T> Probable cause
D The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine
is cranking.
D The inhibitor switch inputs the condition of the select lever, i.e. whether it is in
P or N range or in some other range, to the engine-ECU.
D Malfunction of inhibitor switch
D Malfunction of the engine-ECU.
Check the following
connector: B-72
OK
Measure at the inhibitor switch connector B-72.
OK: System voltage
OK: Continuity
D Ignition switch: START
D Disconnect engine-ECU connector.
OK: System voltage
1. NG
NG
Repair
OK
2. NG
Check harness wire between inhibitor switch connector and starter
S terminal, and repair if necessary.
3. NG
Check the following
connector:
C-92
NG
Repair
OK
NG
NG
Repair Check harness wire be-
tween inhibitor switch and
OK
OK
NG
Repair
OK
NG
NG
Repair
OK
NG
Replace Check the inhibitor switch.
Power steering fluid pressure switch system Probable cause
The presence or absence of power steering load is input to the engine-ECU.
D Malfunction of power steering fluid pressure switch
Check the power steering fluid pressure switch.
NG
Replace
OK
Measure at the power steering fluid pressure switch connector
B-76.
OK: System voltage
NG
Check the following
connector: C-35
NG
Repair
OK
NG
power steering fluid pres-
sure switch connector.
NG
Repair
OK
OK
Check the following
connector: B-76
NG
Repair
OK
NG
A/C switch and A/C relay system Probable cause
When an A/C ON signal is input to the engine-ECU, the engine-ECU carries out
control of the idle speed control (ISC) servo, and also operates the A/C compressor
magnetic clutch.
D Malfunction of A/C control system
D Malfunction of A/C switch
NG
Replace
OK
Measure at the engine-ECU connectors C-33, C-35.
D Voltage between 8 and earth, and 45 and earth
NG
OK
Check the following
NG
Replace
OK
NG
Ignition circuit system Probable cause
Theengine-ECUinterruptstheignitioncoil primarycurrent by turningthe power transistor
inside the engine-ECU ON and OFF.
D Malfunction of ignition switch.
D Malfunction of power transistor
1. NG
Check the following
NG
Repair
OK
NG
between distributor and
NG
Repair
OK
2. NG
Check the harness wire between distributor connector and earth,
OK
Check ignition coil and power transistor unit circuit. (Refer to
OK: System voltage
OK: Continuity
Idle speed control (ISC) servo (Stepper motor) system Probable cause
The engine-ECU controls the intake air volume during idling by opening and closing
the servo valve located in the bypass air passage.
D Malfunction of ISC servo
Check the ISC servo
NG
Replace
OK
Measure at the ISC servo connector B-10.
D Voltage between 2 and earth, and 5 and earth (Ignition switch:
ON)
OK: System voltage
NG
Check the harness wire between control relay and ISC servo con-
OK
D Disconnect the connector, measure at the harness side.
D Voltage between each of 4, 5, 17, 18 and earth (Ignition switch:
ON)
OK: System voltage
NG
Check the following
connector: B-10
NG
Repair
OK
NG
Check harness wire between engine-ECUand ISCservoconnector,
OK
Check the following
connector: C-33
NG
Repair
OK
NG
Purge control solenoid valve system Probable cause
The purge control solenoid valve controls the purging of air from the canister located
inside the intake manifold.
Check the purge control solenoid valve.
NG
Replace
OK
Measure at the purge control solenoid valve connector B-04.
OK: System voltage
NG
OK
OK: System voltage
NG
Check the following
connector: B-04
NG
Repair
OK
NG
OK
Check the following
connector: C-33
NG
Repair
OK
NG
EGR control solenoid valve system Probable cause
The EGR control solenoid valve is controlled by the negative pressure resulting from
EGR operation leaking to port A of the throttle body.
Check the EGR control solenoid valve.
NG
Replace
OK
Measure at the EGR control solenoid valve connector B-06.
OK: System voltage
NG
OK
OK: System voltage
NG
Check the following
connector: B-06
NG
Repair
OK
NG
OK
OK
NG
Check the following
connector: C-33
NG
Repair
MUT-II: Inspection of no initial combustion
MUT-II Data list
16 Voltage of engine-ECU power source (Refer to P.13A-163.)
NG
Check the power supply and ignition switch-IG system.
OK
Does the camshaft rotate at the engine cranking?
(When oil filler cap is removed.)
No
Check timing belt for breakage.
Yes
Yes
CODES.
No
MUT-II Data list
22 Crank angle sensor
OK: Cranking speed is displayed.
No
Check the crank angle sensor system.
SIS CODE 22.)
OK
NG
OK
MUT-II Data list
NG
SIS CODE 21.)
Does the engine tachometer display the cranking speed?
D Set the tachometer of primary voltage detection type.
NG
Check the ignition circuit system
OK
OK: Approx. 5_BTDC
NG
Check the installation condition of crank angle sensor and timing
belt cover.
Yes
CODE
No
NG
OK
MUT-II Data list
NG
(Refer to P.13A-115, INSPECTIONPROCEDURES FORDIAGNO-
SIS CODE 21.)
OK
MUT-II Data list
18 Ignition switch-ST (Refer to P.13A-163.)
NG
Check the ignition switch-ST system <M/T>.
Check the ignition switch-ST and inhibitor switch system <A/T>.
Clean the throttle body. (Refer to P.13A-184.)
NG
Inspect the intake of air into the air intake system
D Broken intake manifold gasket
D Broken vacuum hose
D Positive crankcase ventilation valve does not operate.
MUT-II Data list
NG
without TCL>
with TCL>
OK
MUT-II Data list
NG
Check the intake air temperature sensor system. (Refer to
13.)
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
SIS CODE 21.)
OK
08 Purge control solenoid valve (Refer to P.13A-167.)
NG
Check the purge control solenoid valve system
OK
MUT-II Data list
OK: 600- 1,000 mV during sudden racing
NG
OK
MUT-II Data list
idling
NG
OK
system.
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
OK
MUT-II Data list
NG
INSPECTION PROCE-
DURE 32.)
OK
MUT-II Data list
NG
(Refer to P.13A-149. INSPECTION PROCEDURE 33.)
OK
MUT-II Data list
NG
OK
MUT-II Data list
45 ISC Servo position (Refer to P.13A-166.)
NG
OK
NG
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
MUT-II: Engine stalling inspection when the engine is warmed up and idling.
OK
MUT-II Data list
45 ISC servo position (Refer to P.13A-166.)
NG
OK
MUT-II Data list
34 Air flow sensor reset signal (Refer to P.13A-165.)
NG
Check the air flow sensor system. (Refer to P.13A-113, INSPEC-
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
INSPECTION PROCE-
DURE 32.)
OK
MUT-II Data list
idling
NG
OK
system
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
OK
MUT-II Data list
NG
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
OK
NG
OK
MUT-II Data list
NG
SIS CODE 21.)
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
MUT-II Data list
NG
without TCL>
with TCL>
MUT-II: Check if hesitation, sug, stumble or poor acceleration occurs.
OK
16 Ventilation control solenoid valve <Vehicles with TCL>
NG
Check the ventilation control solenoid valve system. (Refer to
72.)
OK
15 Vacuum control solenoid valve <Vehicles with TCL> (Refer
to P.13A-167.)
NG
Check the vacuum control solenoid valve system. (Refer to
71.)
OK
MUT-II Data list
idling
NG
OK
system
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
OK
MUT-II Data list
NG
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
OK
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
(Refer to P.13A-115, INSPECTIONPROCEDURE FORDIAGNOS-
TIC CODE 21.)
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
MUT-II Data list
NG
without TCL>
with TCL>
MUT-II Data list
NG
without TCL>
with TCL>
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
NG
SIS CODE 21.)
OK
MUT-II Data list
NG
OK
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
idling
NG
OK
system
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
Measure the engine-ECU connectors, C-33, C-35, C-39.
OK: System voltage
OK: System voltage
3. Voltage between 12, 25 and earth (Ignition switch: ON)
OK: System voltage (when the terminal 38 is earthed)
4. Continuity between 13, 26 and earth
OK: Continuity
OK: System voltage
1. NG
Check the following
NG
Repair
OK
OK
NG
Repair
OK
2, 3. NG
4. NG
Check the harness wire between engine-ECU and earth, and repair
if necessary.
5. NG
OK
Check the following
connectors:
C-33, C-35, C-39
NG
Repair
OK
NG
C-47, C-83, C-66, (C-63, C-132,
C-141) <L.H.>, (C-62, C-14) <R.H.>
NG
Repair
OK
NG
Check the harness wire between engine-ECU and battery, and
Check the harness wire between engine-ECU and control relay
Check fuel pump circuit.
Measure at the fuel pump connector E-16.
OK: Continuity
NG
E-11
NG
Repair
OK
NG
Check the harness wire between fuel pump and earth, and repair
if necessary.
OK
Check the following connectors: E-16, E-11, C-123, C-92, B-09
NG
Repair
OK
NG
Check the harness wire between terminal for fuel pump drive and
fuel pump connector.
NG
Repair
OK
Replace the fuel pump.
OK
NG
between fuel pump relay
nector.
NG
Repair
OK
Check the following
connector: C-32
NG
Repair
OK
NG
Check the harness wire between engine-ECU and fuel pump relay
OK
NG
NG
Repair
OK
OK
OK: System voltage
NG
OK: System voltage
NG
Check the following
NG
Repair
Check air flow sensor (AFS) control circuit.
2, 3. NG
Check the following
connector: C-39
NG
Repair
OK
NG
and air flow sensor con-
nector.
NG
Repair
OK
OK
NG
NG
Repair
OK
Measure at the air flow sensor connector B-12.
OK: System voltage
OK: 4.8- 5.2 V
OK: Continuity
1. NG
Check the harness wire between the air flow sensor and control
Check throttle position sensor (TPS) output circuit.
OK: 0.3- 1.0 V (Throttle valve at idle position)
4.5- 5.5 V (Throttle valve fully open)
OK
Check the following
connector: C-39
NG
Repair
OK
NG
NG
OK
NG
sensor connector, and repair if necessary.
NG
Repair
Check injector control circuit
D Voltage between 1, 2, 3, 14, 15, 16 and earth (Ignition switch:
ON)
OK: System voltage
NG
Check the following
connectors: B-02, B-03,
B-05, B-36, B-40, B-44
NG
Repair
OK
NG
Check the harness between engine-ECU and injector connector,
OK
OK
NG
NG
Repair
Check ignition coil and power transistor unit circuit.
Check the ignition coil. (Refer to GROUP 16 Ignition System.)
NG
Replace
OK
Check the power transistor unit.
(Refer to GROUP 16 Ignition System.)
NG
Replace
OK
OK: 2 - 7 V
OK: No continuity
1. NG
Check the following
connector: C-33
NG
Repair
OK
NG
and the distributor con-
nector.
NG
Repair
OK
2. NG
As short circuit occurs between distributor and combination meter
(tachometer), check the harness wire, and repair if necessary.
OK
Check the following connectors, and repair if necessary.
B-42
Caution
When shifting the select lever to D range, the brakes should be applied so that the vehicle does
not move forward.
NOTE
*1. In a new vehicle [driven approximately 500 kmor less], the air flowsensor output frequency is sometimes
10% higher than the standard frequency.
*2. The idle position switch normally turns off when the voltage of the throttle position sensor is 50 -
100 mV higher than the voltage at the idle position. If the throttle position switch turns back on
after the throttle position sensor voltage has risen by 100 mV and the throttle valve has opened,
the idle position switch and the throttle position sensor need to be adjusted.
*3. The injector drive time represents the time when the cranking speed is at 250 r/min or below when
the power supply voltage is 11 V.
*4. In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10%
longer than the standard time.
*5. In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes
30 steps greater than the standard value.
Item
No.
Inspection
item
Inspection contents Normal condition Inspection
procedure
No.
Reference
page
11 Oxygen
sensor
(front)
Engine:After having
warmed up
Air/fuel mixture is
made leaner when
When at 4,000 r/min,
engine is suddenly
decelerated
200 mV or less Code No.
11
13A-112
made leaner when
decelerating, and is
made richer when
racing.
When engine is
suddenly raced
600 - 1,000 mV
Engine:After having
warmed up
The oxygen sensor
signal is used to
Engine is idling 400 mV or less
(Changes)
600 - 1,000 mV
check the air/fuel
mixture
ratio, and control
condition is also
checked by the ECU.
2,500 r/min
12 Air flow
sensor*
1
D Engine coolant
temperature: 80
Engine is idling 14 - 40 Hz - -
- 95_C
D Lamps, electric
cooling fan and
2,500 r/min 42 - 82 Hz
cooling fan and
all accessories:
OFF
D Transmission:
Neutral (A/T:
P range)
Engine is raced Frequency
increases in
response to
racing
Item
No.
Reference
page
Inspection
procedure
No.
item
13 Intake air
tempera-
ture sensor
Ignition switch: ON
or with engine
running
When intake air
temperature is
- 20_C
- 20_C Code No.
13
13A-113
When intake air
temperature is 0_C
0_C
When intake air
temperature is 20_C
20_C
When intake air
temperature is 40_C
40_C
When intake air
temperature is 80_C
80_C
14 Throttle Ignition switch: ON Set to idle position 300 - 1,000 mV Code No. 13A-114
position
sensor Gradually open Increases in
proportion to
throttle opening
angle
14
Open fully 4,500 - 5,500 mV
16 Power
supply
voltage
Ignition switch: ON System voltage Procedure
No. 25
13A-145
18 Cranking
signal
(ignition
Ignition switch: ON Engine: Stopped OFF Procedure
No. 30
<M/T>
13A-147
<M/T>
13A-148
(ignition
switch-ST)
Engine: Cranking ON
<M/T>
Procedure
No. 31
<A/T>
13A-148
<M/T>
21 Engine
coolant
tempera-
Ignition switch: ON
or with engine
running
When engine
coolant temperature
is - 20_C
- 20_C Code No.
21
13A-115
ture sensor
When engine
coolant temperature
is 0_C
0_C
When engine
coolant temperature
is 20_C
20_C
When engine
coolant temperature
is 40_C
40_C
When engine
coolant temperature
is 80_C
80_C
Item
No.
Reference
page
Inspection
procedure
No.
item
22 Crank
angle sen-
sor
D Engine: Crank-
ing
D Tachometer:
Connected
Compare the engine
speed readings on
the tachometer and
the MUT-II.
Accord Code No.
22
13A-116
D Engine: Idling
D Idle position
switch: ON
When engine
coolant temperature
is - 20_C
1,300 - 1,500 rpm
When engine
coolant temperature
is 0_C
1,300 - 1,500 rpm
When engine
coolant temperature
is 20_C
1,300 - 1,500 rpm
When engine
coolant temperature
is 40_C
1,100 - 1,300 rpm
When engine
coolant temperature
is 80_C
550 - 750 rpm
25 Barometric Ignition switch: ON At altitude of 0 m 101 kPa Code No. 13A-119
pressure
25
At altitude of 1,200
m
88 kPa
At altitude of 1,800
m
81 kPa
26 Idle posi-
tion switch
Ignition switch: ON
Check by operating
accelerator pedal
repeatedly
Throttle valve:
Set to idle position
ON Procedure
No.28
<Vehicles
without
13A-146
<Vehicles
without
TCL>
Throttle valve:
Slightly open
OFF*
2
TCL>
Procedure
No.29
<Vehicles
with TCL>
13A-147
<Vehicles
with TCL>
27 Power
steering
Engine: Idling Steering wheel
stationary
OFF Procedure
No. 32
13A-149
fluid pres-
sure switch Steering wheel
turning
ON
(when A/C switch is
A/C switch: OFF OFF Procedure
No. 33
13A-149
(when A/C switch is
ON, A/C compressor
should be operating.)
A/C switch: ON ON
No. 33
29 Inhibitor Ignition switch: ON P or N P or N Procedure 13A-148
switch
<A/T> D, 2, L or R D, 2, L or R
No. 31
Item
No.
Reference
page
Inspection
procedure
No.
item
34 Air flow
sensor
Engine: After having
warmed up
Engine is idling ON Code
No.12
13A-113
sensor
reset sig-
nal
warmed up
2,000 r/min OFF
No.12
37 Volumetric
efficiency
D Engine coolant
temperature: 80
Engine is idling 15 - 35 % - -
- 95 _C
D Lights, power
cooling fan and
2,000 r/min 15 - 35 %
cooling fan and
all accessories:
OFF
D Transmission:
Neutral (A/T: P
range)
Engine is suddenly
raced
Volumetric effi-
ciency increases
in response to
racing
38 Crank
angle sen-
sor
D Engine: Cranking [reading is possible
at 2,000 r/min or less]
D Tachometer: Connected
Engine speeds
displayed on the
MUT-II and
tachometer are
identical.
- -
41
Injectors *
3
Engine: Cranking When engine
coolant temperature
is 0_C (injection is
carried out for all
cylinders
simultaneously)
23 - 80 ms - -
When engine
coolant temperature
is 20_C
12 - 40 ms
When engine
coolant temperature
is 80_C
2.0 - 8.0 ms
Injectors*
4
D Engine coolant
temperature:
8095_C
Engine is idling 2.6 - 3.8 ms
8095_C
D Lamps, electric
cooling fan and
all accessories:
2,500 r/min 1.8 - 3.0 ms
OFF
D Transmission:
Neutral (A/T :
P range)
When engine is
suddenly raced
Increases
44 Ignition
coils and
power
transistors
D Engine: After
having warmed
up
D Timing lamp is
Engine is idling 1 - 15_BTDC - -
set. (The timing
lamp is set in
order to check
actual ignition
timing.)
2,500 r/min 23 - 43_BTDC
Item
No.
Reference
page
Inspection
procedure
No.
item
45 ISC
(stepper)
motor
position *
5
D Engine coolant
temperature: 80
- 95_C
D Lamps, electric
A/C switch: OFF 2 - 25 STEP - -
cooling fan and
all accessories:
OFF
D Transmission:
Neutral (A/T :
P range)
A/C switch:
OFF ON
Increases by
10 - 70 steps
P range)
D Idle position
switch: ON
D Engine: Idling
D When A/C switch
is ON, A/C
compressor
should be
operating
D A/C switch:
OFF
D Select lever:
N range D
range
Increases by
5 - 50 steps
49 A/C relay Engine: After having
warmed up/Engine is
idling
A/C switch: OFF OFF (Compressor
clutch is not
operating)
Procedure
No. 33
13A-149
A/C switch: ON ON (Compressor
clutch is
operating)
59 Oxygen
sensor
(rear)
D Transmission:
2nd gear <M/T>,
L range <A/T>
D Drive with
throttle widely
open
3,500 r/min 600 - 1,000 mV Code No.
59
13A-122
Item
No.
Inspection
item
Drive contents Inspection contents Normal condition Inspection
procedure
No.
Reference
page
01 Injectors Cut fuel to No.
1 injector
Engine:
After having warmed up/
Idling condition
becomes different
Code No.
41
13A-120
02 Cut fuel to No.
2 injector
Engine is idling
(Cut the fuel supply to each
injector in turn and check
(becomes unsta-
ble).
03 Cut fuel to No.
3 injector
cylinders which dont affect
idling.)
04 Cut fuel to No.
4 injector
05 Cut fuel to No.
5 injector
06 Cut fuel to No.
6 injector
Item
No.
Reference
page
Inspection
procedure
No.
Normal condition Inspection contents Drive contents Inspection
item
07 Fuel pump Fuel pump
operates and
fuel is recircu-
lated.
D Engine:
Cranking
D Fuel
pump:
Forced
driving
Inspect
Pinch the
return hose
with fingers
to feel the
pulse of the
fuel being
recirculated.
Pulse is felt. Procedure
No. 27
13A-146
according
to both
the above
conditions.
Listen near
the fuel tank
for the
sound of
fuel pump
operation.
Sound of opera-
tion is heard.
08 Purge
control
solenoid
valve
Solenoid valve
turns from OFF
to ON.
tion can be heard
when solenoid
valve is
driven.
Procedure
No. 36
13A-151
10 EGR
control
solenoid
valve
Solenoid valve
turns from OFF
to ON.
tion can be heard
when solenoid
valve is
driven.
Procedure
No. 37
13A-152
15 Vacuum
control
solenoid
valve
<Vehicles
with TCL>
Solenoid valve
turns from OFF
to ON.
tion can be heard
when solenoid
valve is driven.
Code No.
71
13A-124
16 Ventilation
control
solenoid
valve
<Vehicles
with TCL>
Solenoid valve
turns from OFF
to ON.
tion can be heard
when solenoid
valve is driven.
Code No.
72
13A-125
17 Basic igni-
tion timing
Set to ignition
timing adjust-
ment mode
Engine: Idling
Timing light is set
5_BTDC - -
21 Fan con-
troller
Drive the fan
motor
D Ignition switch: ON Radiator fan and
condenser fan
rotate at high
speed
Procedure
No. 25
13A-145
13100920292
NOTE
1. Make the voltage measurement with the engine-ECU
2. You may find it convenient to pull out the engine-ECU
3. The checks can be carried out off the order given
in the chart.
Caution
1 No. 1 injector While engine is idling after having From 11 - 14 V, momentarily
14 No. 2 injector
warmed up, suddenly depress the
accelerator pedal.
drops slightly
2 No. 3 injector
15 No. 4 injector
3 No. 5 injector
16 No. 6 injector
4 Stepper motor coil <A1> Engine: Soon after the warmed up System voltage 0 V
17 Stepper motor coil <A2>
engine is started (Changes repeatedly)
6 EGR control solenoid Ignition switch: ON System Voltage
valve
While engine is idling, suddenly depress
From system voltage,
momentarily drops
8 A/C relay D Engine: Idle speed
System voltage or
momentarily
6V or more 0 - 3V
10 Power transistor unit Engine r/min: 3,000 r/min 0.3 - 3.0V
12 Power supply Ignition switch: ON System voltage
25
19 Air flow sensor reset Engine: Idle speed 0 - 1V
signal
Engine r/min: 3,000 r/min 6 - 9V
21 Fan controller When the radiator fan and condenser
fan are not operating
0 - 0.3 V
When the radiator fan and condenser
fan are operating
0.7 V or more
22 Fuel pump relay Ignition switch: ON System voltage
Engine: Idle speed 0 - 3V
24 Purge control solenoid Ignition switch: ON System voltage
valve
Running at 3,000 r/min while engine is
warming up after having been started.
0 - 3V
31 Ventilation control
solenoid valve <Vehicles
with TCL>
Ignition switch: ON System voltage
32 Vacuum control solenoid
valve <Vehicles with
TCL>
36 Engine warning lamp Ignition switch: OFF ON 0 - 3V 9 - 13V
(After several seconds have
elapsed)
37 Power steering fluid
pressure switch
Engine: Idling after
warming up
When steering
wheel is stationary
System voltage
When steering
wheel is turned
0 - 3V
38 Control relay Ignition switch: OFF System voltage
(Power supply)
Ignition switch: ON 0 - 3V
45 A/C switch 1 Engine: Idle speed Turn the A/C
switch OFF
0 - 3V
Turn the A/C
switch ON (A/C
compressor is
operating)
System voltage
54 Alternator G terminal D Engine: Warm, idle (radiator fan:
OFF)
D Brake lamp: ON
Voltage rises by 0.2 - 3.5 V.
55 Alternator FR terminal D Engine: Warm, idle (radiator fan:
OFF)
D Brake lamp: ON
Voltage drops by 0.2 - 3.5 V.
D Outside air
temperature:
25_C or more
When A/C is MAX.
COOL condition
(when the load by
A/C is high)
0 - 3 V
When A/C is MAX.
HOT condition
(When the load by
A/C is low)
System voltage
71 Ignition switch - ST Engine: Cranking 8V or more
72 Intake air temperature
sensor
Ignition switch:
ON
When intake air
temperature is
0_C
3.2 - 3.8V
When intake air
temperature is
20_C
2.3 - 2.9V
When intake air
temperature is
40_C
1.5 - 2.1V
When intake air
temperature is
80_C
0.4 - 1.0V
75 Oxygen sensor (rear) D Transmission: 2nd gear <M/T>,
L range <A/T>
D Engine r/min: 3,500 r/min or more
D Driving with the throttle valve widely
open
0.6 - 1.0 V
76 Oxygen sensor (front) Engine: Running at 2,500 r/min after
warmed up (Check using a digital type
voltmeter)
0 0.8V
80 Backup power supply Ignition switch: OFF System voltage
81 Sensor impressed
voltage
Ignition switch: ON 4.5 - 5.5V
82 Ignition switch - IG Ignition switch: ON System voltage
83 Engine coolant
temperature sensor
Ignition switch:
ON
When engine
coolant tempera-
ture is 0_C
3.2 - 3.8V
When engine
coolant tempera-
ture is 20_C
2.3 - 2.9V
When engine
coolant tempera-
ture is 40_C
1.3 - 1.9V
When engine
coolant tempera-
ture is 80_C
0.3 - 0.9V
84 Throttle position
sensor
Ignition switch:
ON
Set throttle valve
to idle position
0.3 - 1.0V
Fully open throttle
valve
4.5 - 5.5V
85 Barometric pressure
sensor
Ignition switch:
ON
When altitude is
0m
3.7 - 4.3V
When altitude is
1,200m
3.2 - 3.8V
86 Vehicle speed sensor D Ignition switch: ON
D Move the vehicle slowly forward
0 5V
87 Idle position switch Ignition switch:
ON
Set throttle valve
to idle position
0 - 1V
Slightly open
throttle valve
4V or more
88 Top dead centre sensor Engine: Cranking 0.4 - 3.0V
89 Crank angle sensor Engine: Cranking 0.4 - 4.0V
90 Air flow sensor Engine: Idle speed 2.2 - 3.2V
Engine r/min: 2,500r/min
91 Inhibitor switch <A/T> Ignition switch:
ON
Set selector lever
to P or N
0 - 3V
Set selector lever
to Other than P or
N
8 - 14V
BETWEEN TERMINALS
NOTE
1. When measuring resistance and checking continuity,
2. Checking need not be carried out in the order given
in the chart.
Caution
the problem.
Engine-ECU Harness Side Connector Terminal Arrangement
Terminal No. Inspection item Normal condition (Check condition)
1 - 12 No. 1 injector 13 - 16 W (At 20_C)
Terminal No. Normal condition (Check condition) Inspection item
4 - 12 Stepper motor coil (A1) 28 - 33 W (At 20_C)
17 - 12 Stepper motor coil (A2)
6 - 12 EGR control solenoid valve 36 - 44 W (At 20_C)
24 - 12 Purge control solenoid valve 36 - 44 W (At 20_C)
13 - Body
earth
Engine-ECU earth Continuity (0 W)
26 - Body
earth
Engine-ECU earth
31 - 12 Ventilation control solenoid valve
<Vehicles with TCL>
36 - 44 W (At 20 _C)
32 - 12 Vacuum control solenoid valve <Vehicles
with TCL>
36 - 44 W (At 20 _C)
72 - 92 Intake air temperature sensor 5.3 - 6.7 kW (When intake air temperature is 0_C)
0.30 - 0.42 kW (When intake air temperature is
80_C)
83 - 92 Engine coolant temperature sensor 5.1 - 6.5 kW (When coolant temperature is 0_C)
0.26 - 0.36 kW (When coolant temperature is
80_C)
87 - 92 Idle position switch Continuity (when throttle valve is at idle position)
No continuity (when throttle valve is slightly open)
91 - Body Inhibitor switch <A/T> Continuity (when select lever is at P or N)
earth
No continuity (when select lever is at D, 2, L or R)
INSPECTIONPROCEDUREUSINGANANALYZER
13100930226
AIR FLOW SENSOR (AFS)
Measurement Method
1. Disconnect the air flow sensor connector, and connect
the special tool (test harness: MB991709) in between.
(All terminals should be connected.)
2. Connect the analyzer special patterns pickup to air flow
sensor connector terminal 3.
Pattern height Low
(V)
10
0
The time (cycle time) T is reduced when
the amount of intake air increases.
Times T1 and T2 are equal.
Time
T
T1 T2
Observation conditions (from conditions above engine speed is increased by racing.)
Time
(V)
10
0
T
Analyzer
Special
patterns
pickup
D Example 1
Cause of problem
is not started.
D Example 2
Cause of problem
Damaged rectifier or vortex generation column
Unstable wave pattern with non-uniform frequency.
However, when anignition leak occurs duringacceleration,
the wave pattern will be distorted temporarily, even if
the air flow sensor is normal.
TOP DEAD CENTER SENSOR AND CRANK ANGLE
SENSOR
Measurement Method
1. Disconnect the distributor connector and connect the
special tool (test harness: MB991348) and jumper wire
in between. (All terminals should be connected.)
2. Connect the analyzer special patterns pickup to distributor
terminal 5 (top dead centre sensor).
angle sensor terminal 2.
engine-ECU terminal 88. (When checking the top dead
centre sensor signal wave pattern.)
engine-ECU terminal 89. (When checking the crank angle
sensor signal wave pattern.)
Pattern height Low
Distributor connector Analyzer
Special patterns
pick-up
Crank angle
sensor connector
TDC
sensor
output
wave
pattern
Crank
angle
sensor
output
wave
pattern
No.1 TDC No.2 TDC No.3 TDC No.4 TDC No.5 TDC No.6 TDC
35 85
75_BTDC
5_BTDC
The time (cycle time) T is reduced when the
amount of intake air increases.
2 engine revolutions (1 camshaft revolution)
Time
T
D Example 1
Cause of problem
is not started.
D Example 2
Cause of problem
Loose timing belt
INJECTOR
Measurement Method
Measurement at the front bank (No.2, No.4, or No.6 cylinder)
1. Disconnect the injector connector, and then connect the
special tool (test harness: MB991348) in between.
(Both the power supply side and engine-ECU side should
be connected.)
2 of the injector connector.
Measurement at the rear bank (No.1, No.3, or No.5 cylinder)
1. Disconnect the injector intermediate harness connector,
and connect the special tool (test harness: MD998464)
in between.
2. Connect the probe of the oscilloscope to the following
terminal: terminal 2 (the black clip of the special tool)
when observing at the No.1 cylinder; terminal 3 (the blue
clip) when observing at the No.3 cylinder; terminal 4 (the
white clip) when observing at the No.5 cylinder
cylinder.)
cylinder.)
cylinder.)
cylinder.)
cylinder.)
cylinder.)
Special
patterns
pickup
Analyzer
Analyzer
Special
patterns
pickup
(V)
Point A
Point B
Solenoid back electromotive force
(Approx. 710 V)
Injector drive time
Power voltage
Drive signal: ON Drive signal: OFF
Time
50
0
appear at all.
Point B: Injector drive time
D The injector drive time will be synchronized with the MUT-II
tester display.
D When the engine is suddenly raced, the drive time will
be greatly extended at first, but the drive time will soon
match the engine speed.
When idling
When racing
---
- -
STEPPER MOTOR
Measurement Method
1. Disconnect the stepper motor connector, and connect
2. Connect the analyzer special patterns pickup to the
stepper motor-side connector terminal 1 (red clip of special
tool), terminal 3 (blue clip), terminal 4 (black clip) and
terminal 6 (yellow clip) respectively.
engine-ECU terminal 4, connection terminal 5, connection
terminal 17, and connection terminal 18 respectively.
Pattern height High
Engine condition When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF
to ON (without starting the engine).
While the engine is idling, turn the A/C switch to ON.
Immediately after starting the warm engine
Stepper
motor
control
signal
wave
pattern
(V)
30
20
10
The wave pattern
appears for an
instant, but soon
disappears.
Point B
Coil reverse electromotive
force (Approx. 3 10V)
Point A
Induced electromotive force
from the motor turning
Time
Special
patterns
pickup
Analyzer
Check that the standard wave pattern appears when the stepper motor is operating.
Point A: Presence or absence of induced electromotive force fromthe motor turning. (Refer to the abnormal
wave pattern.)
Induced electromotive force does not appear or is extremely small. Motor is malfunctioning
Point B: Height of coil reverse electromotive force
Coil reverse electromotive force does not appear or is extremely small. Short in the coil
Examples of Abnormal Wave Pattern
D Example 1
Cause of problem
Motor is malfunctioning. (Motor is not operating.)
Induced electromotive force from the motor turning does
not appear.
D Example 2
Cause of problem
Open circuit in the line between the stepper motor and
the engine-ECU.
Current is not supplied to the motor coil on the open
circuit side. (Voltage does not drop to 0 V.)
Furthermore, the induced electromotive force waveform
at the normal side is slightly different from the normal
waveform.
Open
circuit
side
Normal
side
IGNITION COIL AND POWER TRANSISTOR
D Ignition coil primary signal
Refer to GROUP 16 - Ignition System.
D Power transistor control signal
Measurement Method
1. Disconnect the distributor connector, and connect the
terminals should be connected.)
2. Connect the analyzer special patterns pickup to distributor
connector terminal 3.
Observation condition
Pattern height Low
Engine r/min Approx. 1,200 r/min
OFF
Crank angle
sensor output
wave pattern
Power transistor
control signal
wave pattern
(V)
Compression
top dead centre
T: Revolution time corresponding
to a crank angle of 180_
Point
Wave build-up section
q: Spark advance angle
ON
Dwell section
Time
6
4
2
0
6
4
2
0
T
q
Analyzer
Special
patterns
pickup
Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern
examples 1 and 2.)
Conditionof wavepatternbuild-upsectionandmaximumvoltage Probable cause
Rises from approx. 2V to approx. 4.5V at the top-right Normal
2V rectangular wave Open-circuit in ignition primary circuit
Rectangular wave at power voltage Power transistor malfunction
D Example 1
Cause of problem
Open-circuit in ignition primary circuit
Top-right part of the build-up section cannot be seen,
and voltage value is approximately 2 V too low.
D Example 2
Cause of problem
Malfunction in power transistor
Power voltage results when the power transistor is ON.
2V
V
B
MPI <6A1> - On-vehicle Service 13A-184
THROTTLE BODY (THROTTLE VALVE AREA)
CLEANING
1. Start the engine and warm it up until the coolant is heated
to 80_C or higher and then stop the engine.
2. Remove the air intake hose from the throttle body.
3. Plug the bypass passage inlet of the throttle body.
Caution
Do not allow cleaning solvent to enter the bypass
passage.
4. Spray cleaning solvent into the valve through the throttle
body intake port and leave it for about 5 minutes.
5. Start the engine, race it several times and idle it for about
1 minute. If the idling speed becomes unstable (or if the
engine stalls) due to the bypass passage being plugged,
slightly open the throttle valve to keep the engine running.
6. If the throttle valve deposits are not removed, repeat
steps 4 and 5.
7. Unplug the bypass passage inlet.
8. Attach the air intake hose.
9. Use the MUT-II to erase the self-diagnosis code.
10. Adjust the basic idle speed. (Refer to P.13A-188.)
NOTE
If the engine hunts while idling after adjustment of the
basic idle speed, disconnect the () cable from the battery
for 10 seconds or more, and then reconnect it and run
the engine at idle for about 10 minutes.
IDLE POSITION SWITCH AND THROTTLE
POSITION SENSOR ADJUSTMENT (Vehicles
without TCL> 13100130275
(with built-inidle position switch)
2. Insert a thickness gauge as follows:
Insert a thickness gauge with a thickness of 0.65 mm
between the fixed SAS and the throttle lever.
Insert a 1.4-mm thick thickness gauge up to approx. 3
mm between the levers shown in the figure.
NOTE
Do not insert the thickness gauge 3 mm or more. If doing
that, the throttle lever opening angle becomes larger than
the predetermined angle, causing maladjustment.
4. Loosen the throttle position sensor mounting bolt, and
then turn the throttle position sensor clockwise as far
as it will go.
6. Slowly turn the throttle position sensor counterclockwise
and find the point where the idle position switch turns
off.
Securely tighten the throttle position sensor mounting
bolt at this point.
the throttle position sensor and the related harness.
When the MUT-II is not used, remove the special tool,
and connect the throttle position sensor.
Fixed SAS
Thickness
gauge
Fixed SAS
<Vehicles without auto-cruise control
system>
Throttle lever
Thickness
gauge
<Vehicles with auto-cruise control
system>
Throttle lever
Free lever
THROTTLE POSITION SENSOR ADJUSTMENT
<Vehicles with TCL> 13100110040
Standard value: 580 - 690 mV
4. If the voltage is outside the standard value, adjust by
loosening the throttle position sensor mounting bolts and
turning the throttle position sensor body. After adjusting,
tighten the bolts securely.
6. If a diagnosis code is output while adjusting the throttle
position sensor, use the MUT-II to erase the diagnosis
code.
IDLE POSITION SWITCH AND ACCELERATOR
PEDAL POSITION SENSOR ADJUSTMENT
2. Insert a thickness gauge with a thickness of 0.5 mm in
between the accelerator lever and throttle lever to a depth
of approximately 3 mm.
NOTE
If the thickness gauge is inserted more than 3 mm, the
accelerator lever opening angle will become greater than
the set opening angle, which will result in defective
adjustment.
Accelerator pedal
position sensor
(with built-in idle
position switch)
Accelerator lever
Thickness
gauge
Throttle lever
<Vehicles without auto-cruise control
system>
Thickness
gauge
<Vehicles with auto-cruise control
system>
Throttle lever
Throttle lever
4. Loosen the accelerator pedal position sensor mounting
bolt, and then turn the accelerator pedal position sensor
counterclockwise as far as it will go.
6. Slowly turn the accelerator pedal position sensor
clockwise and find the point where the idle position switch
turns off.
Securely tighten the accelerator pedal position sensor
mounting bolt at this point.
7. Select Traction Control System on the MUT-II.
8. Check the accelerator pedal position sensor output
voltage.
9. If the voltage is outside the standard value, check the
accelerator pedal position sensor and related harnesses.
FIXED SAS ADJUSTMENT 13100150318
NOTE
1. The fixed SAS should not be moved unnecessarily;
it has been precisely adjusted by the manufacturer.
2. If the adjustment is disturbed for any reason, readjust
as follows.
2. Back out the fixed SAS lock nut.
3. Turn the fixed SAS counterclockwise until it is sufficiently
backed out, and fully close the throttle valve.
4. Tighten the fixed SAS until the point where the throttle
lever is touched (i.e., the point at which the throttle valve
begins to open) is found.
From that point, tighten the fixed SAS 1 turn.
5. While holding the fixed SASso that it doesnt move, tighten
the lock nut securely.
7. Adjust the basic idling speed.
8. Adjust the idle position switch and throttle position sensor
<vehicles without TCL> (P.13A-184), throttle position
sensor <vehicles with TCL> (P.13A-186), idle position
switch and accelerator pedal position sensor <vehicles
with TCL> (P.13A-186).
Accelerator pedal
position sensor
(with built-in idle
position switch)
Fixed SAS
BASIC IDLE SPEED ADJUSTMENT 13100180355
NOTE
(1) The standard idling speed has been adjusted, by
the speed adjusting screw(SAS), by themanufacturer,
and there should usually be no need for readjustment.
(2) If the adjustment has been changed by mistake, the
idle speed may become too high or the idle speed
may drop too low when loads from components such
as the A/C are placed on the engine. If this occurs,
(3) The adjustment, if made, should be made after first
confirming that the spark plugs, the injectors, the idle
speed control servo, the compression pressure, etc.,
are all normal.
1. Before inspection and adjustment, set the vehicle to the
NOTE
When the MUT-II is connected, the diagnosis control
terminal should be earthed.
4. Select the item No.30 of the MUT-II Actuator test.
NOTE
This holds the ISC servo at the basic step to adjust the
basic idle speed.
5. Check the idle speed.
NOTE
(1) The engine speed may be 20 to 100 r/min lower
than indicated above for a new vehicle [driven
approximately 500 km or less], but no adjustment
is necessary.
(2) If the engine stalls or the engine speed is low even
though the vehicle has been driven approximately
500 km or more, it is probable that deposits are
adhered to the throttle valve, so clean it. (Refer to
P.13A-184.)
6. If not within the standard value range, turn the speed
adjusting screw (SAS) to make the necessary adjustment.
NOTE
If the idling speed is higher than the standard value range
even when the SAS is fully closed, check whether or
not there is any indication that the fixed SAS has been
moved. If there is an indication that it has been moved,
adjust the fixed SAS.
7. Press the MUT-II clear key, and release the ISC servo
from the Actuator test mode.
NOTE
Unless the ISC servo is released, the Actuator test mode
will continue 27 minutes.
8. Switch OFF the ignition switch.
10. Start the engine again and let it run at idle speed for
about 10 minutes; check that the idling condition is normal.
FUEL PRESSURE TEST 13100190310
1. Release residual pressure fromthe fuel pipeline toprevent
fuel gush out. (Refer to P.13A-191.)
2. Disconnect the fuel high pressure hose at the delivery
pipe side.
Caution
3. Remove the union joint and bolt from the special tool
(adapter hose MD998709) and instead attach the special
tool (hose adapter MD998742) to the adapter hose.
4. Install a fuel pressure gauge on the adapter hose that
was set up in step 3.
Use a suitable O-ring or gasket between the fuel pressure
gauge and the special tool so as to seal in order to prevent
fuel leakage at this time.
5. Install the special tool, which was set in place in steps
3 and 4 between the delivery pipe and the high pressure
hose.
6. Use a jumper wire to connect the terminal No.2 (fuel
pump drive terminal) of the 3-pin connector shown in
the illustration to the battery (+) terminal in order to activate
the fuel pump.
Under fuel pressure, check the fuel pressure gauge and
special tool connections for leaks.
7. Disconnect the jumper wire from the fuel pump drive
terminal to stop the fuel pump.
9. Measure fuel pressure while the engine is running at
idle.
Standard value:
Approx. 265 kPa at kerb idle
Fuel pressure
gauge
O-ring or
gasket
MD998709
MD998742
High pres-
sure hose
Delivery pipe
10. Disconnect the vacuum hose from the fuel pressure
regulator and measure fuel pressure with the hose end
closed by a finger.
Standard value:
324 - 343 kPa at kerb idle
11. Check to see that fuel pressure at idle does not drop
even after the engine has been raced several times.
12. Racing the engine repeatedly, hold the fuel return hose
lightly with fingers to feel that fuel pressure is present
in the return hose.
NOTE
If the fuel flow rate is low, there will be no fuel pressure
in the return hose.
13. If any of fuel pressure measured in steps 9 to 12 is out
of specification, troubleshoot and repair according to the
table below.
D Fuel pressure too low Clogged fuel filter Replace fuel filter
D Fuel pressure drops after racing
D No fuel pressure in fuel return
hose
Fuel leaking toreturn sidedue topoor
fuel regulator valve seating or settled
spring
Low fuel pump delivery pressure Replace fuel pump
Fuel pressure too high Binding valve in fuel pressure
regulator
Clogged fuel return hose or pipe Clean or replace hose or pipe
Same fuel pressure when vacuum
hose is connected and when
disconnected
Damaged vacuum hose or clogged
nipple
Replace vacuumhoseor cleannipple
14. Stop the engine and check change of fuel pressure gauge
reading. Normal if the reading does not drop within 2
minutes. If it does, observe the rate of drop and
troubleshoot and repair according to the table below.
Fuel pressure drops gradually after Leaky injector Replace injector
engine is stopped
Leaky fuel regulator valve seat Replace fuel pressure regulator
Fuel pressure drops sharply
immediately after engine is stopped
Check valve in fuel pumpis heldopen Replace fuel pump
15. Release residual pressure from the fuel pipe line. (Refer
to P.13A-191.)
16. Remove the fuel pressure gauge and special tool from
the delivery pipe.
Caution
17. Replace the O-ring at the end of the fuel high pressure
hose with a new one. Furthermore, apply engine oil to
the new O-ring before replacement.
18. Fit the fuel high pressure hose over the delivery pipe
and tighten the bolt to specified torque.
19. Check for fuel leaks.
(1) Apply the battery voltage to the fuel pump drive
terminal to drive the fuel pump.
(2) Under fuel pressure, check the fuel line for leaks.
FUEL PUMP CONNECTOR DISCONNECTION
(HOW TO REDUCE THE FUEL PRESSURE)
13100090269
Refer to P.13A-88.
FUEL PUMP OPERATION CHECK 13100200242
Refer to P.13A-88.
A/C relay H Fuel pump check terminal F
A/C switch R Idle speed control servo C
Accelerator pedal position sensor (with idle
position switch) <Vehicles with TCL>
C Inhibitor switch <A/T> M
Air flow sensor (with intake air temperature
sensor and barometric pressure sensor)
G Injectors J
Control relay and fuel pump relay P Oxygen sensor (front) S
Crank angle sensor A Oxygen sensor (rear) T
Detonation sensor
<Vehicles for Hong Kong and Singapore>
J Power steering fluid pressure switch I
Diagnosis connector O Purge control solenoid valve B
Distributor (with top dead centre sensor and
ignition coil)
L Throttle position sensor <Vehicles with TCL> C
EGR control solenoid valve B Throttle position sensor (with idle position
switch) <Vehicles without TCL>
C
Engine coolant temperature sensor K Vacuum control solenoid valve
<Vehicles with TCL>
D
Engine-ECU Q Vehicle speed sensor E
Engine warning lamp (check engine lamp) N Ventilation control solenoid valve
<Vehicles with TCL>
D
T
CONTROL RELAY AND FUEL PUMP RELAY
1 2 3 4
Not supplied
Supplied
13100280246
1. Disconnect the air flow sensor connector.
Standard value:
2.3 - 3.0 kW (at 20_C)
0.30 - 0.42 kW (at 80_C)
drier.
Normal condition:
Higher Smaller
resistance remains unchanged, replace the air flowsensor
assembly.
CHECK 13100310259
Caution
resistance.
Standard value:
2.1 - 2.7 kW (at 20_C)
0.26 - 0.36 kW (at 80_C)
replace the sensor.
Equipment side
connector
Fuel pump relay and control relay
Equipment side
connector
Air flow sensor (with
intake air tempera-
ture sensor)
Engine coolant
temperature sensor
Specified sealant:
3M Nut Locking Part No.4171 or equivalent
THROTTLE POSITION SENSOR CHECK 13100320283
Normal condition:
position
Changes smoothly in
doesnt change smoothly, replace the throttle position
sensor.
NOTE
For the throttle position sensor adjustment procedure,
refer to P.13A-184 <Vehicles without TCL>, P.13A-186
<Vehicles with TCL>.
ACCELERATOR PEDAL POSITION SENSOR
CHECK <Vehicles with TCL> 13100340012
1. Disconnect the accelerator pedal position sensor
connector.
2. Measure the resistance between the accelerator pedal
position sensor side connector terminal 1 and terminal
4.
2.
Normal condition:
position
Changes smoothly in
Throttleposition sensor
Equipment
side connector
Throttleposition sensor
<Vehicles with TCL>
Accelerator pedal
position sensor
Equipment
side connector
doesnt change smoothly, replace the accelerator pedal
position sensor.
NOTE
For the accelerator pedal position sensor adjustment
procedure, refer to P.13A-186.
IDLE POSITION SWITCH CHECK <Vehicles
without TCL> 13100330279
2. Check the continuity between the throttle position sensor
connector side terminal 1 and terminal 2.
Normal condition:
3. If out of specification, replace the throttle position sensor.
NOTE
After replacement, the idle position switch and throttle
position sensor should be adjusted. (Refer to P.13A-184.)
IDLE POSITION SWITCH CHECK
connector.
2. Check the continuity between the accelerator pedal
position sensor connector side terminal 3 and terminal
4.
Normal condition:
Depressed Non-conductive ( W)
3. If out of specification, replace the accelerator pedal
position sensor.
NOTE
After replacement, the idle position switch and accelerator
pedal position sensor should be adjusted. (Refer to
P.13A-186.)
Accelerator pedal
position sensor
Equipment side
connector
OXYGEN SENSOR CHECK 13100510178
<Oxygen sensor (front)>
the special tool (test harness) to the connector on the
oxygen sensor side.
connector.
4. Warmup the engine until engine coolant is 80_Cor higher.
5. Use the jumper wire to connect terminal 3 of the oxygen
sensor connector to the battery (+) terminal and terminal
4 to the battery ( - ) terminal.
Caution
Be very careful when connecting the jumper wire;
incorrect connection can damage the oxygen sensor.
6. Connect a digital voltage meter between terminal 1 and
terminal 2.
7. While repeatedly racing the engine, measure the oxygen
sensor output voltage.
Standard value:
Engine Oxygen sensor
output voltage
Remarks
When
racing the
engine
0.6 - 1.0 V If you make the air/fuel ratio
rich by racing the engine
repeatedly, a normal oxy-
gen sensor will output a
voltage of 0.6 - 1.0 V.
8. If the sensor is defective, replace the oxygen sensor.
NOTE
For removal and installation of the oxygen sensor, refer
to GROUP 15 - Exhaust Pipe and Main Muffler.
Equipment side
connector
Oxygen sensor
(front)
MB991223
MB991223
<Oxygen sensor (rear)>
the special tool (test harness set) to the connector on
the oxygen sensor side.
connector.
NOTE
(1) If the MUT-II does not display the standard value
although no abnormality is found by the above
mentioned continuity test and harness check, replace
the oxygen sensor (rear).
(2) For removal and installation of the oxygen sensor,
refer to GROUP 15 - Exhaust Pipe and Main Muffler.
INJECTOR CHECK 13100520294
Measurement of Resistance between Terminals
D Front bank side (No.2, No.4, No.6 cylinders)
1. Remove the injector connector.
D Rear bank side (No.1, No.3, No.5 cylinders)
1. Disconnect the injector intermediate harness connectors.
Injector Measurement probe
No.1 cylinder 1 - 2
No.3 cylinder 1 - 3
No.5 cylinder 1 - 4
Equipment side
connector
Oxygen sensor (rear)
MB991223
Intermediate harness
side connector
Injector intermediate
harness connector
Checking the Injection Condition
1. Following the steps below, bleed out the residual pressure
within the fuel pipe line to prevent flow of the fuel. (Refer
to P.13-191.)
2. Remove the injector.
3. Arrange the special tool (injector test set), adaptor, fuel
pressure regulator and clips as shown in the illustration
below.
MB991607
MD998741
MD998706
Return hose
Battery
Injector
Pressure regulator
(MD116395)
Clip (MB991608)
4. Apply battery voltage to terminal 2 (fuel pump drive
terminal) of the 3-pin connector shown in the illustration,
and activate the fuel pump
5. Activate the injector and check the atomized spray
condition of the fuel.
The condition can be considered satisfactory unless it
is extremely poor.
Main hose
Battery
Injector
Return hose
6. Stop the actuation of the injector, and check for leakage
from the injectors nozzle.
Standard value: 1 drop or less per minute
7. Activate the injector without activating the fuel pump; then,
when the spray emission of fuel from the injector stops,
disconnect the special tool and restore it to its original
condition.
IDLE SPEED CONTROL (ISC) SERVO
(STEPPER MOTOR) CHECK 13100540245
Checking the Operation Sound
1. Check that the engine coolant temperature is 20_C or
below.
NOTE
Disconnecting the engine coolant temperature sensor
connector and connecting the harness-side of the
connector to another engine coolant temperature sensor
that is at 20_C or below is also okay.
2. Check that the operation sound of the stepper motor
can be heard after the ignition is switched ON. (but without
starting the motor.)
3. If the operation sound cannot be heard, check the stepper
motors activation circuit.
If the circuit is normal, it is probable that there is a
malfunction of the stepper motor or of the engine control
unit.
Checking the Coil Resistance
1. Disconnect the idle speed control servo connector and
connect the special tool (test harness).
2. Measure the resistance between terminal 2 (white clip
of the special tool) and either terminal 1 (red clip) or
terminal 3 (blue clip) of the connector at the idle speed
control servo side.
3. Measure the resistance between terminal 5 (green clip
of the special tool) and either terminal 6 (yellow clip)
or terminal 4 (black clip) of the connector at the idle speed
control servo side.
Idle speed
control servo
Operation Check
1. Remove the throttle body.
2. Remove the stepper motor.
3. Connect the special tool (test harness) to the idle speed
control servo connector.
4. Connect the positive (+) terminal of a power supply
(approx. 6 V) to the white clip and the green clip.
5. With the idle speed control servo as shown in the
illustration, connect the negative ( - ) terminal of the power
supply to each clip as described in the following steps,
and check whether or not a vibrating feeling (a feeling
of very slight vibration of the stepper motor) is generated
as a result of the activation of the stepper motor.
(1) Connect the negative ( - ) terminal of the power supply
to the red and black clip.
to the blue and black clip.
to the blue and yellow clip.
to the red and yellow clip.
to the red and black clip.
(6) Repeat the tests in sequence from (5) to (1).
6. If, as a result of these tests, vibration is detected, the
stepper motor can be considered to be normal.
13100560241
13100570206
White
Green
MD998463
Idle
speed
control
servo
VENTILATION CONTROL SOLENOID VALVE
CHECK <Vehicles with TCL> 13100630041
NOTE
When disconnecting the vacuum hose, always make a mark
so that it can be reconnected at original position.
1. Disconnect the vacuum hose (green stripe) from the
solenoid valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to the nipple.
4. Check air-tightness by applying a vacuum with voltage
applied directly from the battery to the solenoid valve
and without applying voltage.
Normal condition:
Battery voltage Normal condition
Applied Vacuum maintained
Not applied Vacuum leaks
5. Measure the resistance between the terminals of the
solenoid valve.
VACUUM CONTROL SOLENOID VALVE CHECK
NOTE
1. Disconnect the vacuum hose (blue stripe, green stripe)
from the solenoid valve.
Ventilation control
solenoid valve
Vacuum control
solenoid valve
Battery
Ventilation control
solenoid valve
Vacuum control
solenoid valve
3. Connect a hand vacuum pump to the nipple to which
the blue-striped vacuum hose was connected.
4. Check air-tightness by applying a vacuum with voltage
applied directly from the battery to the solenoid valve
and without applying voltage.
Applied Vacuum leaks
Not applied Vacuum maintained
solenoid valve.
VACUUM TANK CHECK 13100810049
<Vehicles with TCL>
1. Connect a hand vacuum pump to vacuum tank A nipple,
apply 67 kPa of vacuum and check that the vacuum
is held.
2. Connect a hand vacuum pump to vacuum tank B nipple.
3. First, close A nipple with your finger and apply 67 kPa
of vacuum. Then, check that the vacuum leaks
immediately when you remove the finger blocking the
nipple.
VACUUM ACTUATOR CHECK 13100820042
<Vehicles with TCL>
1. Remove the vacuum hose (green stripe) from the vacuum
actuator and connect a hand vacuumpump to the vacuum
actuator.
2. With the accelerator pedal depressed, check that the
rod is pulled up and that vacuum is held when 27 kPa
of vacuum is applied.
THROTTLE VALVE OPERATION CHECK 13100830052
<Vehicles with TCL>
1. Check that the throttle valve opens and closes smoothly
(throttle lever moves) according to the opening and closing
of the accelerator lever.
2. If the throttle valve does not open and close smoothly,
there might be a deposit on the throttle valve, so clean
the throttle body. (Refer to P.13A-184.)
Battery
B
A
Vacuumactuator
Rod
Throttlevalve
Accelerator lever
Throttle lever
NEGATIVE PRESSURE CHECK DURING
TRACTION CONTROL OPERATION 13100840055
<Vehicles with TCL>
vacuum actuator, connect a hand vacuum pump between
the actuator nipple and the vacuum hose via a T-joint.
Set the hand vacuum pump near the drivers seat so
that the negative pressure check can be carried out at
the drivers seat.
2. Check the negative pressure during traction control
operation.
Inspection service points are the same as for the traction
control operation inspection.
(Refer to GROUP 13H or 23 - On-vehicle Service.)
Normal condition:
Vehicle condition Normal negative pressure
when accelerator pedal is
depressed
Vehicle is lifted up 20 kPa or more
Driving on a dry, sealed
road surface
No change
NOTE
The traction control system function will stop 20 seconds
after the accelerator pedal has been depressed, and
negative pressure will gradually drop.
POWER STEERING AIR CONTROL VALVE
OPERATION CHECK 13101180019
1. Disconnect the vacuum hose (connected to air intake
hose) from the power steering air control valve, and plug
the vacuum hose.
2. Connect a vacuumgauge to the power steering air control
valve nipple from which the vacuum hose has been
disconnected.
4. Check that the value of the vacuum gauge changes from
0 kPa (barometric pressure) to 60 kPa or more when
turning the steering wheel.
Green stripe
T-joint
Vacuumactuator
Power steering
air control valve
MPI <6A1> - Injector 13A-204
INJECTOR 13100710349
<Front bank>
9 Nm
14
13
8, 9
O-ring
O-ring
18 Nm
10
Engine oil
3 Nm
12 Nm
9 Nm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
4
Removal steps
1. Engine cover
5. Air pipe assembly mounting bolt
"AA 8. Fuel pressure regulator
"AA 9. Fuel pipe assembly
11. Insulator
12. Insulator
14. Grommets
<Rear bank>
Post-installation operation
17 - On-vehicle service.)
O-ring
18 Nm
Engine oil
3 Nm
12 Nm
9 Nm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15, 16
16
17
19
20
21
18 Nm
18 Nm
O-ring
17
15
18
21
20
4
Removal steps
1. Engine cover
4. Vacuum hose
connection
7. Connector bracket mounting bolt
9. Noise condenser mounting bolt
connector
12. Air intake plenum
13. Air intake plenum gasket
"AA 15. High pressure fuel hose connection
"AA 16. Fuel pipe assembly
18. Insulator
19. Insulator
21. Grommets
AA"DELIVERY PIPE/INJECTOR REMOVAL
Remove the delivery pipe (with the injectors attached to it).
Caution
"AAINJECTOR/FUEL PIPE ASSEMBLY/FUEL
PRESSURE REGULATOR/HIGH-PRESSURE FUEL
HOSE INSTALLATION
1. Apply a drop of new engine oil to the O-ring.
Caution
Be sure not to let engine oil in the delivery pipe.
2. While turning the injector, fuel pipe assembly,
high-pressure fuel hose and fuel pressure regulator to
the right and left, install the delivery pipe, while being
careful not to damage the O-ring.
3. If it does not turn smoothly, the O-ring may be trapped,
remove the fuel pressure regulator and then re-insert
4. Tighten the high-pressure fuel hose tothe standardtorque,
and tighten the fuel pressure regulator and fuel pipe
assembly to the specified torque.
Tightening torque:
9 Nm (Fuel pressure regulator)
MPI <6A1> - Throttle Body 13A-207
3
4
2
6
1
8
10 - 13 Nm
5
18 Nm
7
4
<Vehicles without traction control system>
Removal steps
6. Vacuum pipe assembly
7. Throttle body
10 - 13 Nm
18 Nm
1
2
3
4
5
6
7
8
9
10 - 13 Nm
<Vehicles with TCL and
auto-cruise control system>
<Vehicles with TCL>
4
3
6
7 2
8
9
Removal steps
connector
8. Throttle body
"AATHROTTLE BODY GASKET INSTALLATION
Place the gasket so that the projecting part is positioned
as shown in the illustration, and then install it between the
intake manifold and the throttle body.
Up
Towards front
of vehicle
<Vehicles without TCL and auto-cruise control system>
1
2
3
4
5
6
7
8
9
Disassembly steps
"BA 1. Throttle position sensor
2. Idle speed control servo (Stepper
motor)
3. O-ring
4. Fast idle air valve
5. O-ring
6. Throttle body
7. Fixed SAS
9. O-ring
NOTE
removed.
1
2
3
4
5
6
7
8
9
10
Disassembly steps
2. Idle speed control servo
(Stepper motor)
3. O-ring
5. O-ring
6. Lever assembly
7. Throttle body
8. Fixed SAS
10. O-ring
NOTE
removed.
<Vehicles with TCL>
1
2
3
4
5
6
7
8
9
10
11
12
11
Disassembly steps
1. Water hose
"AA 3. Accelerator pedal position sensor
4. Idle speed control servo (Stepper mo-
tor)
5. O-ring
7. O-ring
8. Throttle lever
9. Throttle body
10. Fixed SAS
12. O-ring
NOTE
removed.
removed, carry out fixed SAS adjustment. (Refer to
13A-187.)
<Vehicles with TCL and auto-cruise control system>
1
2
3
4
5
6
7
9
8
10
11
12
Disassembly steps
1. Water hose
"AA 3. Accelerator pedal position sensor
4. Idle speed control servo (Stepper mo-
tor)
5. O-ring
7. O-ring
8. Throttle lever
9. Throttle body
10. Fixed SAS
12. O-ring
NOTE
removed.
removed, carry out fixed SAS adjustment. (Refer to
13A-187.)
CLEANING THROTTLE BODY PARTS
1. Clean all throttle body parts.
Do not use solvent to clean the following parts:
D Throttle position sensor
D Idle speed control body assembly
If these parts are immersed in solvent, their insulation
will deteriorate.
Wipe them with cloth only.
2. Check if the vacuum port or passage is clogged. Use
compressed air to clean the vacuum passage.
REASSEMBLY SERVICE POINTS
"AAACCELERATOR PEDAL POSITION SENSOR (APS)
INSTALLATION
1. Install the APS so that it faces as shown in the illustration,
2. Connect a multimeter between terminal (3) (APS output)
and terminal (4) (APSpower supply) of the APSconnector,
and check that the resistance increases gradually as the
throttle valve is opened slowly to the fully-open position.
3. Check the continuity between terminal (2) (idle position
switch) and terminal (1) (earth) of the APS connector
when the throttle valve is fully closed and fully open.
Normal condition:
closed, turn the APS body clockwise and then check
again.
4. If there is an abnormality, replace the APS.
Accelerator pedal
position sensor
Earth APS power
supply
APS output
"BATHROTTLE POSITION SENSOR (TPS)
INSTALLATION
1. Install the TPS so that it faces as shown in the illustration,
2. Connect a multimeter between terminal (1) (TPS power
supply) and terminal (2) (TPS output) of the TPS
connector, and check that the resistance increases
gradually as the throttle valve is opened slowly to the
fully-open position.
3. For vehicles without TCL, check the continuity between
terminal (3) (idle position switch) and terminal (4) (earth)
of the TPS connector when the throttle valve is fully closed
and fully open.
Normal condition:
closed, turn the TPS body anti-clockwise and then check
again.
4. If there is an abnormality, replace the TPS.
TPS output
TPS power
supply Earth
(Vehicles without TCL only)
13E-1
DIESEL FUEL
SEALANT 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 5 . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 6 . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 53 . . . . . . . . . . . . . . . . . . .
Evacuation of Water from Fuel Filter 53 . . . . . . . . .
Evacuation of Air from Fuel Line 53 . . . . . . . . . . . . .
Fuel Filter Cartridge Replacement 53 . . . . . . . . . . . .
Accelerator Pedal Position Sensor and Idle
Position Switch 1 Adjustment 53 . . . . . . . . . . . . . . . .
Idle Position Switch 2 Adjustment 54 . . . . . . . . . . . .
Component Location 55 . . . . . . . . . . . . . . . . . . . . . . . . .
Control Relay and Solenoid-type Spill Valve Relay
Continuity Check 56 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Air Temperature Sensor Check 56 . . . . . . . .
Engine Coolant Temperature Sensor
Check 57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal Position Sensor Check 57 . . . . .
Idle Position Switch 1 Check 58 . . . . . . . . . . . . . . . . .
Idle Position Switch 2 Check 58 . . . . . . . . . . . . . . . . .
Solenoid-type Spill Valve Check 59 . . . . . . . . . . . . . .
Timing Control Solenoid Valve Check 59 . . . . . . . . .
Diesel Fuel Temperature Sensor Check 59 . . . . . . .
Pump Operation Sensor Check 60 . . . . . . . . . . . . . . .
Injection Timing Correction Resistor Check 60 . . . .
Injection Rate Correction Resistor Check 60 . . . . . .
Fuel Cut Solenoid Valve Check 60 . . . . . . . . . . . . . .
Throttle Solenoid Valve Check 60 . . . . . . . . . . . . . . .
Throttle Actuator Check 61 . . . . . . . . . . . . . . . . . . . . .
Injection Nozzle Check and Adjustment 61 . . . . . . .
INJECTION PUMP AND NOZZLE 63 . . . . . . . . .
THROTTLE BODY 68 . . . . . . . . . . . . . . . . . . . . . . . .
DIESEL FUEL - General Information 13E-2
The electronically-controlled fuel injection system consists of sensors which detect the condition of the
diesel engine, an engine-ECU which controls the systembased on signals fromthese sensors, and actuators
which operate according to control commands from the engine-ECU.
The engine-ECU carries out operations such as fuel injection rate control, fuel injection timing control
and idle up control. In addition, the engine-ECU is equipped with several self-diagnosis functions which
make troubleshooting easier in the event that a problem develops.
FUEL INJECTION RATE CONTROL
The fuel injection completion timing is controlled by means of a solenoid-type spill valve to ensure that
the optimum amount of fuel is supplied to the engine in accordance with gradual changes in the engine
running condition.
Before fuel injection starts, the solenoid-type spill valve is on (energized), so that the valve is closed.
As the plunger turns and rises, fuel is sent out under pressure, and when the fuel flow rate reaches
the target value for fuel injection, the solenoid-type spill valve turns off. When the solenoid-type spill
valve turns off, the fuel under high pressure inside the plunger is leaked out into the pump chamber
and fuel injection is completed.
FUEL INJECTION TIMING CONTROL
The position of the injection pump timer piston is controlled so that fuel injection is carried out at the
optimum timing in accordance with the engine running condition.
The timer piston position is determined by duty control of the timing control solenoid valve which is located
in the line between the high-pressure chamber and the low-pressure chamber of the timer piston.
The fuel injection timing is advanced by increasing the control duty of the timing control solenoid valve.
IDLE SPEED CONTROL
Controlling the fuel injection rate in accordance with the engine running condition maintains the idle speed
at the optimum condition.
D When an abnormality is detected in any of the sensors or actuators, the engine warning lamp illuminates
to warn the driver.
D When an abnormality is detected in any of the sensors or actuators, a diagnosis code number
corresponding to the problem which occurred is output.
D The RAM data relating to the sensors and actuators which is stored in the engine-ECU can be read
using the MUT-II. In addition, the actuators can be force-driven under certain conditions.
1. Power Supply Control
When the ignition switch is turned to ON, the relay turns on and power is supplied to components
such as the timing control solenoid valve.
2. Intake Air Throttle Control
When the engine is idling after having warmed up, the throttle valve is half opened to restrict the
amount of intake air in order to reduce vibration and noise.
Turns the compressor clutch of the A/C ON and OFF
4. Fan motor relay control
The radiator fan and condenser fan operating speeds are controlled in accordance with the engine
coolant temperature and the vehicle speed.
5. Glow Control
Refer to GROUP 16.
6. EGR Control
Refer to GROUP 17.
DIESEL FUEL - General Information 13E-3
DIESEL FUEL SYSTEM DIAGRAM
*5 Diesel fuel temperature
sensor
*1 Pump
operation
sensor
*1 Pump operation sensor
*4 Boost sensor
*5 Diesel fuel temperature sensor
D Idle position switch 1
D Idle position switch 2
D Ignition switch-IG
D Ignition switch-ST
D A/C switch
D Injection timing correction resistor
D Injection rate correction resistor
Engine-ECU z1 Solenoid-type spill valve
z2 Timing control solenoid valve
z3 EGR solenoid valve
z4 Throttle solenoid valve
D Control relay
D Solenoid-type spill valve relay
D Glow plug relay
D A/C power relay
D Fan motor relay
D Glow indicator lamp
D Diagnosis signal
z4 Throttle solenoid valve
z3 EGR solenoid valve
Vacuumpump
Alternator
Air cleaner
Throttle
actuator
*6 Intake air
temperature
sensor
Throttle valve
*4 Boost sensor
z1 Solenoid-type spill valve
Injection pump
EGR valve
Turbocharger
Waste gate actuator
Oxidation catalyst
z2 Timing control
solenoid valve
*3 Engine coolant
temperature
sensor
DIESEL FUEL - Service Specifications/Sealant 13E-4
Accelerator pedal position sensor adjusting voltage mV 530 - 570
Idle position switch 1 check voltage mV 875 - 925
Intake air temperature sensor resis- At 20 _C 2.3 - 3.0
tance kW
At 80 _C 0.30 - 0.42
Engine coolant temperature sensor At 20 _C 2.1 - 2.7
resistance kW
At 80 _C 0.26 - 0.36
Resistance between accelerator pedal position sensor
terminals (1) and (4) kW
3.5 - 6.5
Solenoid-type spill valve resistance W 1 - 2 (at 20 _C)
Timing control solenoid valve resistance W 8 - 12 (at 20 _C)
Diesel fuel temperature sensor resistance kW 2.2 - 2.7 (at 20 _C)
Pump operation sensor resistance W 215 - 245 (at 20 _C)
Injection timing correction resistor resistance kW 0.1 - 2.5 (at 20 _C)
Injection rate correction resistor resistance kW 0.1 - 2.5 (at 20 _C)
Fuel cut solenoid valve resistance W 8 - 10
Throttle solenoid valve resistance W 36 - 44 (at 20 _C)
SEALANT 13300050010
threaded portion
DIESEL FUEL - Special Tools 13E-5
MB991502 MUT-II sub assembly D Reading diagnosis code
D Checking the electronically-
controlled fuel injection
system
MB991348 Test harness set Inspection using an analyzer
(3 pin, triangle)
Inspection using an analyzer
MB990767 End yoke holder Fuel injection pump sprocket
holding
MD998719 Crankshaft pulley holder
pin
MD998388 Sprocket puller Fuel injection pump sprocket
removal
DIESEL FUEL - Troubleshooting 13E-6
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
If an abnormality occurs in any of the following items which
are related to the electronically-controlled fuel injection
system, the engine warning lamp will illuminate.
Accelerator pedal position sensor
Boost sensor
Diesel fuel temperature sensor
Pump operation sensor
Crank angle sensor
Idle position switch 1
Throttle solenoid valve system
Timing control solenoid valve system
Solenoid-type spill valve system
Immobilizer system
Engine-ECU
Engine warning lamp
CODES
Service Points.
ACTUATOR TESTING
FAIL-SAFE/BACKUP FUNCTION TABLE 13300390020
Accelerator pedal position sensor Carries out control as if the accelerator opening angle is at a specified angle
(0 %/approx. 10%) on the basis of idle position switch inputs (ON/OFF).
Boost sensor Carries out control as if theintakeair pressureis at a specifiedvalue (101kPa).
Diesel fuel temperature sensor Carries out control as if the fuel temperature is 50 _C.
Engine coolant temperature sensor Carries out control as if the engine coolant temperature is at a specified value
(80_C).
Intake air temperature sensor Carries out control as if the intake air temperature is at a specified value
(25_C).
Vehicle speed sensor Carries out control as if the vehicle is moving.
Pump operation sensor Controls the injection rate according to the speed reported by the crank angle
sensor.
Crank angle sensor D Reduces the fuel injection rate.
D Fixes the injection timing at a specified value.
Ignition switch-ST Carries out control as if ignition switch ST is OFF.
Timing control solenoid valve Reduces the fuel injection rate.
Solenoid-type spill valve Solenoid-type spill valve relay is turned off (engine stops).
Correction resistors (injection timing
and injection rate)
Carries out control as if the correction resistance are at specified values.
Caution
Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
11 Accelerator pedal position sensor system 13E-9
12 Boost sensor system 13E-10
13 Barometric pressure sensor system 13E-11
14 Diesel fuel temperature sensor system 13E-11
15 Engine coolant temperature sensor system 13E-12
16 Intake air temperature sensor system 13E-12
17 Vehicle speed sensor system 13E-13
18 Pump operation sensor system (open circuit) 13E-14
19 Pump operation sensor system (intermittent fault) 13E-14
21 Crank angle sensor system 13E-15
22 Ignition switch-ST signal system 13E-16
23 Idle position switch 1 system 13E-16
24 Idle position switch 2 system 13E-17
41 Throttle solenoid valve system 13E-18
43 Timing control solenoid valve system 13E-19
44 Solenoid-type spill valve system 13E-20
45 Injection timing correction resistor system 13E-21
46 Injection rare correction resistor system 13E-21
47 Immobilizer system 13E-22
Code No.11 Accelerator pedal position sensor system Probable cause
D Open or short circuit is detected in accelerator pedal position sensor circuit.
or
D Mechanical problem is detected in accelerator pedal position sensor.
D Malfunction of the accelerator pedal position sensor
D Open or short circuit in accelerator pedal position
sensor circuit or poor connector contact
Range of Check
D Idle position switch 1: ON
Set Conditions
D Accelerator pedal position sensor signal output is 1.2 V or higher
NG
Repair
NG
Repair
OK
Repair the engine-ECU.
NG
Repair
NG
OK
OK
B-41
NG
Check the harness wire between the engine-ECUand the accelera-
tor pedal position sensor connector.
OK
OK
connector.
OK: 4.5 - 5.5 V
OK: Continuity
NG
C-54
Check the accelerator pedal position sensor. (Refer to P.13E-57.)
NG
Replace
Code No.12 Boost sensor system Probable cause
D Open or short circuit is detected in boost sensor circuit for 1 second.
D Malfunction of the boost sensor
D Open or short circuit in boost sensor circuit or poor
connector contact
NG
Repair
OK
OK NG
Repair
NG
OK
NG
Repair
OK
NG
Repair
OK
NG
Repair
OK
Replace the boost sensor.
OK
NG
Repair
OK
NG
B-50, C-54
OK
Measure at the engine-ECU connector
C-54.
OK: 2.0 - 2.6 V (Altitude: 0 m)
1.7 - 2.3 V (Altitude: 1200 m)
NG
engine-ECU and the boost sensor con-
Check the vacuum hose between the
boost sensor and the intake manifold.
NG
nector.
B-50
nector.
Measure at the boost sensor connector
B-50.
(Use the test harness: MB991348)
OK: 2.0 - 2.6 V (Altitude: 0 m)
1.7 - 2.3 V (Altitude: 1200 m)
NG
Measure at the boost sensor connector
B-50.
measure at the harness side
connector.
OK: 4.8 - 5.2 V
OK: Continuity
NG
C-54
Code No.13 Barometric pressure sensor system Probable cause
D An abnormal signal being output from the barometric pressure sensor is detected
for 3 seconds.
NG
MUT-II Data list
03 Barometric pressure sensor
OK
INTERMITTENT MALFUNCTIONS
Code No.14 Diesel fuel temperature sensor system Probable cause
Range of Check
D Open or short circuit is detected in diesel fuel temperature sensor circuit for 4
seconds.
D Malfunction of the diesel fuel temperature sensor
D Open or short circuit in diesel fuel temperature sensor
circuit or poor connector contact
NG
Repair
NG
Repair
OK
NG
Repair
NG
OK
OK
B-62
NG
Check the harness wire between the engine-ECU and the diesel
fuel temperature sensor connector.
OK
OK
Measure at the diesel fuel temperature sensor connector B-62.
connector.
OK: 4.5 - 5.5 V
OK: Continuity
NG
C-54
Check the diesel fuel temperature sensor. (Refer to P.13E-59.)
NG
Replace the injection pump.
Code No.15 Engine coolant temperature sensor system Probable cause
D Open or short circuit is detected in engine coolant temperature sensor circuit for
1 second.
D Open or short circuit in engine coolant temperature
sensor circuit or poor connector contact
NG
Repair
NG
Repair
OK
NG
Repair
NG
OK
OK
B-33
NG
Check the harness wire between the engine-ECU and the engine
coolant temperature sensor connector.
OK
OK
Measure at the engine coolant temperature sensor connector B-33.
connector.
OK: 4.5 - 5.5 V
OK: Continuity
NG
C-54
Check the engine coolant temperature sensor. (Refer to P.13E-57.)
NG
Replace
Code No.16 Intake air temperature sensor system Probable cause
D Open or short circuit is detected in intake air temperature sensor circuit for 3
seconds.
D Open or short circuit in intake air temperature sensor
NG
Repair
NG
Repair
OK
NG
Repair
NG
OK
OK
B-45
NG
Check the harness wire between the engine-ECU and the intake
air temperature sensor connector.
OK
OK
Measure at the intake air temperature sensor connector B-45.
connector.
OK: 4.5 - 5.5 V
OK: Continuity
NG
C-54
Check the intake air temperature sensor. (Refer to P.13E-56.)
NG
Replace
Code No.17 Vehicle speed sensor system Probable cause
Range of Check
D Engine speed: 2,400 r/min or more
D Accelerator pedal opening amount: 50 % or more
D Engine coolant temperature: 60 _C or higher
Set Conditions
D Vehicle speed signal is 0 km/h for 10 seconds or more.
D Open or short circuit in vehicle speed sensor circuit
or poor connector contact
OK
2. NG
OK
3. NG
OK
NG
OK
NG
Repair
NG
Repair
NG
Repair
NG
Repair
NG
Repair
NG
Repair
NG
Repair
NG
Check the harness wire between the engine-ECU and the vehicle
speed sensor connector.
OK
OK
B-66, C-53
B-65
NG
Check the harness wire between the engine-ECU and the vehicle
speed sensor connector.
OK
B-65, C-56, C-53
NG
OK
OK
Measure at the vehicle speed sensor connector B-66.
side.
OK: System voltage
OK: 4.8 - 5.2 V
OK: Continuity
1. NG
B-65, C-90, C-135, C-131
tion Meters.)
NG
Replace
Code No.18 Pump operation sensor system (open circuit) Probable cause
Range of Check
D The injection pump operation speed computed from the crank angle sensor signal
is 80 r/min or more.
Set Conditions
D No injection pump operation signal (pump operation sensor signal) is not during
six successive crank angle sensor pulse signal inputs.
D Malfunction of the pump operation sensor
D Open or short circuit in pump operation sensor circuit
NG
Repair
NG
Check the harness wire between the engine-ECU and the pomp
operation sensor connector, and repair if necessary.
OK
OK
OK
D Voltage between 10 and 23 (AC range)
OK: 0.2 - 1.0 V (Engine: idling)
1.2 - 2.2 V (Engine: 2500 r/min)
NG
C-53, B-63
Check the pump operation sensor. (Refer to P.13E-60.)
NG
Code No.19 Pump operation sensor system (intermittent
fault)
Probable cause
Range of Check
D No open circuit in pump operation sensor
D Injection pump speed: 650 r/min or more
D Ignition switch-ST signal: OFF
Set Conditions
D Abnormal number of pump operation sensor signal pulses counted during two
full engine rotations.
D Pulse count abnormality occurs 10 times or more.
D Malfunction of the pump operation sensor
D Poor contact in pump operation sensor connector or
malfunction of circuit
D Malfunction of pump operation sensor circuit shielding
OK
NG
Check the harness wire between the engine-ECU and the pump
operation sensor connector.
NG
Repair
OK
C-53, B-63
NG
Repair
Code No.21 Crank angle sensor system Probable cause
Range of Check
Set Conditions
D No crank angle sensor signal pulses input during two full engine rotations.
D Open or short circuit in crank angle sensor circuit or
poor connector contact
2.NG
NG
Repair
NG
Repair
OK
3.NG
NG
Repair
NG
OK
OK
B-77 NG
Check the harness wire between the engine-ECU and the crank
angle sensor connector.
OK
C-53
NG
connector.
OK: System voltage
OK: 4.8 - 5.2 V
OK: Continuity
1.NG
D Connect the connector. (Use the test harness: MD998478)
OK: 0.4 - 4.0 V
OK: 2.5 - 4.5 V
OK
Code No.22 Ignition switch-ST signal system Probable cause
Range of Check
D Injection pump speed: 1,200 r/min or more
Set Conditions
D Ignition switch-ST signal (high) is input for 10 seconds or more.
D Malfunction of the starter relay
D Malfunction of starter relay-related circuit
NG
Repair
NG
Repair
OK
Replace the starter relay.
NG
Repair
NG
OK
OK
C-55
NG
Check the harness wire between the engine-ECU and the starter
relay connector.
OK
connector.
D Voltage between 51 and earth (Ignition switch: ST)
OK: 8 V or higher
NG
B-30, A-10
Code No.23 Idle position switch 1 system Probable cause
Range of Check
D Accelerator pedal position sensor signal output is 1.2 V or higher.
D Idle position switch 2: OFF
Set Conditions
D Idle position switch 1 on signal is input for 1 second or more.
D Malfunction of the idle position switch 1
D Open or short circuit in idle position switch 1 circuit
Range of Check
D Accelerator pedal position sensor signal output is 0.58 V or lower.
Set Conditions
D Idle position switch 1 off signal is input for 1 second or more.
NG
Repair
NG
Repair
OK
NG
Repair
NG
OK
NG
Check the harness wire between the engine-ECUand the accelera-
tor pedal position sensor connector.
OK
OK
B-41
OK
connector.
OK: 4 V or higher
OK: Continuity
NG
C-54
Check the idle position switch 1. (Refer to P.13E-58.)
NG
Replace the accelerator pedal position sensor.
Code No.24 Idle position switch 2 system Probable cause
Range of Check
D Accelerator pedal position sensor signal output is 1.2 V or higher.
D Idle position switch 1: OFF
Set Conditions
D Idle position switch 2 on signal is input for 1 second or more.
D Malfunction of the idle position switch 2
D Open or short circuit in idle position switch 2 circuit
Range of Check
D Accelerator pedal position sensor signal output is 0.48 V or lower.
Set Conditions
D Idle position switch 2 off signal is input for 1 second or more.
NG
Repair
NG
Repair
OK
NG
Repair
NG
OK
OK
B-47
NG
Check the harness wire between the engine-ECU and the idle
position switch 2 connector.
OK
OK
Measure at the idle position switch 2 connector B-47 <L.H. drive
vehicles>, B-48 <R.H. drive vehicles>.
connector.
OK: 4 V or higher
NG
C-53
Check the idle position switch 2. (Refer to P.13E-58.)
NG
Replace
Code No.41 Throttle solenoid valve system Probable cause
Range of Check
From the following condition, the ignition switch is turned to OFF.
D 2.2 seconds or more have passed since idle position switch turned on and ignition
switch-ST turned off
D Accelerator pedal opening amount: Approx. 0 %
D Vehicle speed: 0 km/h
D Injection pump speed: Between 700 r/min and 1,500 r/min
Set Conditions
D The difference between the boost sensor signal output before and after the engine
stops is 50 mmHg or less for 10 times in succession (ignition switch transition
to off counted as one time).
D Malfunction of the throttle solenoid valve
D Open or short circuit in throttle solenoid valve circuit
D Incorrect vacuum hose routing
D Malfunction of the throttle actuator
NG
Repair
NG
Check the harness wire between the engine-ECU and the throttle
solenoid valve connector, and repair if necessary.
NG
Repair
NG
Repair
OK
NG
Check the vacuum hose routing.
OK
Check the vacuum hose routing.
OK
C-53
OK
OK
connector.
OK: System voltage
NG
B-49
OK
Measure at the throttle solenoid valve connector B-49.
connector.
OK: System voltage
NG
Check the harness wire between the control relay and the throttle
solenoid valve connector, and repair if necessary.
OK
Check the throttle actuator. (Refer to P.13E-61.)
NG
Replace
Check the throttle solenoid valve. (Refer to P.13E-60.)
NG
Replace
Code No.43 Timing control solenoid valve system Probable cause
Range of Check
D Ignition switch-ST: OFF
D Engine speed: 400 r/min or more
D Engine coolant temperature: 60 _C or higher
Set Conditions
D Target advance value differs from actual advance value by 7_ or more for a
continuous period of 10 seconds or more.
D Malfunction of the timing control solenoid valve
D Open or short circuit in timing control solenoid valve
D Incorrect ignition timing adjustment
D Malfunction of the injection pomp
NG
Repair
NG
Check the harness wire between the engine-ECU and the timing
control solenoid valve connector, and repair if necessary.
NG
Repair
NG
OK
NG
11 Timing control solenoid valve
OK: Sound of operation can be heard.
OK
OK
C-53
OK
OK
connector.
OK: System voltage
NG
B-56
OK
Measure at the timing control solenoid valve connector B-56 <L.H.
drive vehicles>, B-57 <R.H. drive vehicles>.
connector
OK: System voltage
NG
Check the harness wire between the control relay and the timing
control solenoid valve connector, and repair if necessary.
Check the timing control solenoid valve. (Refer to P.13E-59.)
NG
Code No.44 Solenoid-type spill valve system Probable cause
Range of Check
D Ignition switch-ST: OFF
D Solenoid-type spill valve relay: ON
Set Conditions
D Solenoid-type spill valve does not turn off.
D Malfunction of the solenoid-type spill valve
D Open or short circuit in solenoid-type spill valve circuit
D Malfunction of the injection pump
D Injection pump speed is 5,400 r/min or more for a continuous period of 2 seconds
or more.
NG
Repair
NG
Check the harness wire between the engine-ECUand the solenoid-
type spill valve connector, and repair if necessary.
NG
Repair
NG
OK
NG
01 Solenoid-type spill valve
OK
OK
C-53
OK
OK
connector.
OK: System voltage
NG
B-61
OK
Measure at the solenoid-type spill valve connector B-61.
connector.
OK: System voltage
NG
Check the harness wire between the solenoid-type spill valve relay
and the solenoid-type spill valve connector, and repair if necessary.
Check the solenoid-type spill valve. (Refer to P.13E-59.)
NG
Code No.45 Injection timing correction resistor system Probable cause
D Open or short circuit is detected in injection timing correction resistor circuit.
D Malfunction of the injection timing correction resistor
D Open or short circuit in injection timing correction
resistor circuit of poor connector contact
NG
Repair
NG
Repair
OK
NG
Repair
NG
OK
OK
B-60
NG
Check the harness wire between the engine-ECU and the injection
timing correction resistor connector.
OK
OK
Measure at the injection timing correction resistor connector B-60.
connector.
OK: 4.5 - 5.5 V
OK: Continuity
NG
C-54
Check the injection timing correction resistor. (Refer to P.13E-60.)
NG
Code No.46 Injection rate correction resistor system Probable cause
D Open or short circuit is detected in injection rate correction resistor circuit.
D Malfunction of the injection rate correction resistor
D Open or short circuit in injection rate correction resistor
NG
Repair
NG
Repair
OK
NG
Repair
NG
OK
OK
B-58 <L.H. drive vehicles>, B-59 <R.H. drive vehicles>
NG
Check the harness wire between the engine-ECU and the injection
rate correction resistor connector.
OK
OK
Measure at the injection rate correction resistor connector B-58
<L.H. drive vehicles>, B-59 <R.H. drive vehicles>.
connector.
OK: 4.5 - 5.5 V
OK: Continuity
NG
C-54
Check the injection rate correction resistor. (Refer to P.13E-60.)
NG
Range of Check
Set Conditions
D Communication problem between the engine-ECU and the immobilizer-ECU.
NOTE
If the engine is started while several ignition keys are present nearly, signal mixing
may occur, which will cause this diagnosis code to be generated. This code may
also be generated when registering the key ID codes.
D Incorrect ID code
D Malfunction of the immobilizer-ECU
No
NG
NG
Repair
NG
NG
NG
er-ECU.
OK
OK
No
C-54, C-81, C-66
NG
Repair
Is a diagnosis code output from the immobilizer-ECU.
Yes
Yes
INSPECTION CHART FOR TROUBLE SYMPTOM 13300410023
Caution
Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
Trouble symptoms Inspection
procedure No.
Reference
page
Communication
II
MUT-II communication with all systems is impossible. 1 13E-24
with MUT-II is
impossible. MUT-II communication with engine-ECU only is impossible. 2 13E-24
Engine warning
lamp and related
3 13E-25
parts
goes out.
4 13E-25
Starting No initial combustion (Starting not possible) 5 13E-26
Poor startability when engine is cold (Poor starting) 6 13E-26
Poor startability when engine is cold or warm (Poor
starting)
7 13E-27
Idling stability
(Improper idling)
Idling speed is low when engine is cold (Improper idling
speed)
8 13E-27
Idling speed is high (Improper idling speed) 9 13E-28
Idling speed is low (Improper idling speed) 10 13E-28
Idling speed is unstable (Rough idling, hunting) 11 13E-29
Idling stability Engine stops soon after starting 12 13E-29
(Engine stalls)
Engine stops during idling 13 13E-30
Driving Engine output is too low 14 13E-30
Abnormal engine knocking occurs 15 13E-31
Abnormally black smoke 16 13E-31
Abnormally white smoke 17 13E-32
Hunting occurs while driving 18 13E-32
Idling speed is improper when A/C is operating 19 13E-33
Fans (radiator fan and A/C condenser fan) are imoperative 20 13E-33
Communication with MUT-II is impossible. (MUT-II
communication with all systems is impossible.)
Probable cause
diagnosis line.
OK
NG
power supply and the diagnosis connec-
diagnosis connector and the earth, and
OK
Replace the MUT-II.
OK
Measure at the diagnosis connector
C-20.
OK: Continuity
NG
C-20.
OK: System voltage
NG
C-66, C-63, (C-132, C-141) <L.H. drive
vehicles>, (C-62, C-14) <R.H. drive ve-
hicles>
NG
Repair
MUT-II communication with engine-ECU only is impossi-
ble.
Probable cause
D No power supply to engine-ECU
D Defective earth circuit of engine-ECU
D Defective engine-ECU
D Malfunction of the engine-ECU power supply circuit
connector
ECU
NG
Repair
OK
Check the engine-ECU power supply and earth circuit. (Refer to
P.13E-34, INSPECTION PROCEDURE 21.)
NG
Repair
OK
er-ECU.
OK
Check the harness wire between the engine-ECU and the earth
NG
Check the harness wire between the engine-ECUand the diagnosis
connector.
NG
Repair
OK
Yes
C-54, C-81, C-68, C-66, C-56 <R.H. drive vehicles>, C-83, C-20
NG
Repair
Is communication possible between the MUT-II and the immo-
bilizer-ECU.
No
Probable cause
Because there is a burn-out bulb, the engine-ECU causes the engine warning lamp
D Burn-out bulb
NG
Repair
NG
NG
Replace
NG
Repair
NG
Check the harness wire between the engine warning lamp and
the ignition switch connector, and repair if necessary.
NG
Repair
OK
NG
Check the harness wire between the combination meter and the
engine-ECU connector, and repair if necessary.
OK
D-03, C-90
OK
OK
connector.
OK: System voltage
NG
C-135, C-131
OK
NG
Check a burn-out bulb.
OK
connector.
D Earth the terminal No.57.
OK
C-55
MUT-II Data list
11 Battery voltage (Refer to 13E-39.)
NG
Check the engine-ECU power supply and earth circuit. (Refer to
P.13E-34, INSPECTION PROCEDURE 21.)
goes out.
Probable cause
In case such as the above, the cause is probably that the engine-ECU is detecting
occurred.
the engine-ECU
OK
No
connector.
OK: No continuity
NG
Check the harness wire between the combination meter and the
engine-ECU connector, and repair if necessary.
MUT-II Self-Diagnosis code
Are diagnosis codes output?
Yes
Refer to P.13E-8, INSPECTION CHART FOR DIAGNOSIS
CODES.
No initial combustion (Starting not possible) Probable cause
The cause is probably a malfunction of the control system, injection nozzles, injection
pump, glow system or power supply.
D Malfunction of the control system
D Malfunction of the injection nozzles
D Malfunction of the glow system
NG
Repair
OK
Check the following items:
D Glow plug, glow plug relay
D Battery
D Fuel cut solenoid valve
D Injection nozzle
D Injection pump
D Contamination (water, kerosene, etc.) in fuel
D Immobilizer system
Yes
CODES.
No
No
Carry out MUT-II Data list check and Actuator test.
(Refer to P.13E-38, 42.)
Is immobilizer-ECU diagnosis code output?
Yes
Poor startability when engine is cold (Poor starting) Probable cause
The cause is probably a malfunction of the control system, injection pump, fuel system,
air intake system or glow system.
D Malfunction of the fuel system
D Malfunction of the air intake system
NG
Repair
OK
D Injection nozzle, fuel filter
D Throttle body assembly
D Starter switch input signal
D Engine oil viscosity
D Injection pump
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Poor startability when engine is cold or warm
(Poor starting)
Probable cause
The cause is probably a malfunction of the control system, injection pump, fuel system
or air intake system.
NG
Repair
OK
D Injection pump
Yes
CODES.
No
(Refer to P.13E-38, 42.)
INSPECTION PROCEDURES 8
Idling speed is low when engine is cold
(Improper idling speed)
Probable cause
The cause is probably a malfunction of the control system, injection pump or fuel
system.
NG
Repair
OK
D Injection nozzle
D Injection pump
D Fuel filter
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Idling speed is high (Improper idling speed) Probable cause
The cause is probably a malfunction of the control system, injection nozzles or injection
pump.
D Malfunction of the injection nozzles
NG
Repair
OK
D Injection nozzle
D Injection pump
D Starter switch input signal
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Idling speed is low (Improper idling speed) Probable cause
system.
NG
Repair
OK
D Injection pump
D Injection nozzle
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Idling speed is unstable (Rough idling, hunting) Probable cause
air intake system or glow system.
D malfunction of the glow system
D Malfunction of the EGR system
NG
Repair
OK
D EGR system
D Injection nozzle
D Valve clearance
D Injection timing
D Air in fuel line
D Injection pump
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Engine stops soon after starting Probable cause
or air intake system.
NG
Repair
OK
D Injection pump
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Engine stops during idling Probable cause
The cause is probably a malfunction of the control system, injection pump, air intake
system or power supply system.
NG
Repair
OK
D Power supply system
D EGR system
D Injection pump
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Engine output is too low Probable cause
air intake system or EGR system.
NG
Repair
OK
D EGR system
D Turbocharger
D Injection timing
D Injection pump
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Abnormal engine knocking occurs Probable cause
system.
NG
Repair
OK
D Injection nozzle
D Injection timing
D Injection pump
Yes
CODES.
No
(Refer to P.13E-38, 42)
Abnormally black smoke Probable cause
air intake system or EGR system.
NG
Repair
OK
D Air cleaner
D Injection nozzle
D EGR system
D Turbocharger
D Injection pump
D Injection timing
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Abnormally white smoke Probable cause
air intake system, EGR system or glow system.
NG
Repair
OK
D Injection nozzle
D EGR system
D Turbocharger
D Injection pump
D Injection timing
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Hunting occurs while driving Probable cause
or EGR system.
NG
Repair
OK
D EGR system
D Injection pump
Yes
CODES.
No
(Refer to P.13E-38, 42.)
Idling speed is improper when A/C is operating
NG
Repair
NG
NG
OK
D Voltage between 39 and earth (Engine: Idling, Outside air
temperature: 25 _C or higher)
OK: 0 - 3 V [When A/C is MAX. COOL condition (when the
load by A/C is high)]
Systemvoltage[(When A/Cis MAX. HOT condition(When
the load by A/C is low)]
OK
C-54
Fans (radiator fan and A/C condenser fan) are imoperative
NG
Repair
OK
Check the radiator fan and the condenser fan circuit. (Refer to
GROUP 14 - Troubleshooting.)
NG
Repair
NG
OK
Check trouble symptoms.
OK
C-53
connector.
D Short circuit between 18 and earth (Ignition switch: ON)
OK: Fan stops.
NG
Check the harness wire between the engine-ECU and the fan con-
troller connector.
Check the engine-ECU power supply and earth circuit
NG
Repair
NG
Check the harness wire between the battery and control relay con-
NG
Repair
NG
Repair
OK
2,3 NG
Check the harness wire between the engine-ECU and control relay
4.NG
Check the harness wire between the engine-ECU and earth, and
5.NG
NG
Repair
NG
Check the harness wire between the battery and engine-ECU con-
NG
Repair
NG
OK
C-83, C-66, (C-63, C-132, C-141) <L.H. drive vehicles>, (C-62,
C-14) <R.H. drive vehicles>
OK
OK
C-53, C-55
NG
Check the harness wire betweenthe engine-ECUand ignitionswitch
connector.
OK
OK
Measure at the engine-ECU connector C-53, C-55.
connector.
OK: System voltage
OK: System voltage
OK: System voltage (When the terminal 59 is earthed)
4. Continuity between 1, 14, 26 and earth
OK: Continuity
OK: System voltage
1.NG
C-92, C-131
OK
OK
connector.
1. Voltage between 2, 3 and earth
OK: System voltage
NG
B-30
Check the control relay. (Refer to P.13E-56.)
NG
Replace
Check the solenoid-type spill valve relay circuit.
NG
Repair
NG
Check the harness wire between the solenoid-type spill valve relay
and engine-ECU connectors, and repair if necessary.
NG
Repair
NG
OK
OK
OK
C-55
OK
connector.
OK: System voltage (When the terminal 3 is earthed)
NG
C-52
OK
Measure at solenoid-type spill valve relay connector C-52.
connector.
OK: System voltage
NG
Check the harness wire between the control relay and solenoid-type
spill valve relay connectors, and repair if necessary.
Check the solenoid-type spill valve relay. (Refer to P.13E-56.)
NG
Replace
Check the fuel cut solenoid valve circuit.
NG
Repair
NG
Check the harness wire between the fuel cut solenoid valve and
solenoid-type spill valve relay connectors, and repair if necessary.
OK
Check the connector B-55, and repair if necessary.
OK
OK
Measure at the fuel cut solenoid valve connector B-55.
connector.
OK: System voltage
NG
C-52
Check the fuel cut solenoid valve. (Refer to P.13E-60.)
NG
Replace
Check the EGR solenoid valve circuit.
NG
Repair
NG
Check the harness wire betweenthe engine-ECUand EGRsolenoid
valve connector, and repair if necessary.
NG
Repair
NG
OK
OK
C-53
OK
OK
connector.
OK: System voltage
NG
B-06
OK
Measure at the EGR solenoid valve connector B-06.
connector.
OK: System voltage
NG
Check the harness wire between the control relay and EGRsolenoid
valve connector, and repair if necessary.
Check the EGR solenoid valve.
NG
Replace
DIESEL FUEL - Troubleshooting DIESEL FUEL - Troubleshooting 13E-37
Check the glow plug relay circuit
NG
Repair
NG
Repair
NG
Repair
OK
OK
Check the following connector, and repair if necessary.
B-52
OK
Check the glow control system.
(Refer to GROUP 16 - Glow System.)
NG
Check the harness wire between the engine-ECU and glow plug
relay connector.
OK
OK
Measure at the glow plug relay connector B-52.
connector.
D Voltage between 1 and earth (Ignition switch: ON)(Engine
coolant temperature: 40 _C or lower)
OK: System voltage (Between approx. 4 - 8 seconds)
NG
C-55
Check the glow plug relay. (Refer to GROUP 16 - Glow System.)
NG
Replace
Check the A/C switch and A/C relay circuit
NG
Repair
NG
OK
OK
C-55
OK
connector.
D Voltage between 52 and earth, and between 53 and earth
NG
OK
Check the A/C variable capacity relay.
NG
Replace
NG
Replace
Caution
Driving tests always need another personnel.
ItemNo. Inspection
item
Inspection contents Normal
condition
Inspection
procedure
No.
Reference
page
01 Intake air
temperature
Ignition switch: ON
or with engine
Intake air temperature is
- 20 _C
- 20 _C Code
No.16
13E-12
sensor running
0 _C
0 _C
20 _C
20 _C
40 _C
40 _C
80 _C
80 _C
02 Engine cool-
ant tempera-
Ignition switch: ON
or with engine
Engine coolant
temperature is - 20 _C
- 20 _C Code
No.15
13E-12
ture sensor running
Engine coolant
temperature is 0 _C
0 _C
Engine coolant
temperature is 20 _C
20 _C
Engine coolant
40 _C
Engine coolant
80 _C
03 Barometric Ignition switch: ON At altitude of 0 m 101 kPa Code 13E-11
pressure
No.13
04 Boost sen- D Engine coolant At altitude of 0 m 101 kPa Code 13E-10
sor temperature: 80
- 95 _C
D Lamps, electric
At altitude of 600 m 95 kPa
No.12
D Lamps, electric
cooling fan and
all accessories:
OFF
D Transmission:
Neutral
D Ignition switch:
ON
When the engine is
suddenly raced
Increases
ItemNo. Reference
page
Inspection
procedure
No.
Normal
condition
Inspection contents Inspection
item
05 Diesel fuel
temperature
Ignition switch: ON
or with engine
Fuel temperature is
- 20 _C
- 20 _C Code
No.14
13E-11
sensor running
Fuel temperature is 0 _C 0 _C
Fuel temperature is
20 _C
20 _C
Fuel temperature is
40 _C
40 _C
Fuel temperature is
80 _C
80 _C
06 Vehicle
speed sen-
sor
When vehicle is
moving
Compare the speeds
displayed on the
speedometer and the
MUT-II.
Identical Code
No.17
13E-13
07 Pump op-
eration sen-
sor (high
speed)
Engine: Idling Compare the engine
speeds displayed on the
tachometer and MUT-II.
The same
engine
speed is
displayed.
Code
No.18, 19
13E-14
08 Pump op-
eration sen-
sor (low
speed)
Engine: Idling Compare the engine
speeds displayed on the
tachometer and the
MUT-II.
The same
engine
speed is
displayed.
Code
No.18, 19
13E-14
09 Accelerator
pedal posi-
Ignition switch: ON Accelerator pedal is
released
480 - 570
mV
Code
No.11
13E-9
tion sensor
Accelerator pedal is fully
depressed
4000 -
4690 mV
10 Accelerator
pedal posi-
tion sensor
Ignition switch: ON Throttle lever: Idle
position
0 % Code
No.11
13E-9
tion sensor
(Accelerator
opening
angle)
Throttle lever: Fully open
position
100 %
11 Battery
voltage
Ignition switch: ON System
voltage
- -
12 Solenoid-
type spill
Engine: After
having warmed up
Engine: Idling 51.5 -
66.5 deg
Code
No.44
13E-20
valve
A/C switch OFF ON Advances
slightly
13 Timing con-
trol solenoid
valve duty
ratio
Engine: After
having warmed up
When engine is
suddenly decelerated
from 3,000 r/min.
Momen-
tarily in-
creases
slightly
Code
No.43
13E-19
ItemNo. Inspection
item
condition
Inspection
procedure
No.
Reference
page
14 EGR com- Engine: Idle 44.8 % Procedure 13E-36
mand value
Engine: After
having warmed up
When engine is
suddenly raced
0 %
No.24
15 Injection rate
correction
resistance
value
Ignition switch: ON 0.2 - 4.5
V
Code
No.46
13E-21
16 Injection
timing
correction
resistance
value
Ignition switch: ON 0.2 - 4.5
V
Code
No.45
13E-21
17 Fuel injec-
tion rate
Engine: After
having warmed up
Engine: Idling 3.5 - 12.5
m
3
/st
- -
command
value A/C switch: OFF ON Increases
slightly
18 Actual injec-
tion timing
Engine: After having warmed up The same
value as
the injec-
tion timing
command
value is
displayed.
Code
No.43
13E-19
19 Injection
timing com-
Engine: After
having warmed up
Engine: Idling 12.6 -
14.6 deg
- -
mand value
Engine: Racing to 3500
r/min or more
Advances
slightly
20 Radiator fan,
A/C con-
denser fan
Engine: Idling When radiator fan and
condenser fan are not
operating
0 % Procedure
No.26
13E-20
duty ratio
When radiator fan and
condenser fan are
operating
5 % or
more
(varies in
accor-
dance
with fan
operating
speed)
ItemNo. Inspection
item
condition
Inspection
procedure
No.
Reference
page
41 Idle position
switch 1
(Built into
released
ON Code
No.23
13E-16
(Built into
accelerator
pedal posi-
tion sensor)
Accelerator pedal is
slightly depressed
OFF
42 Idle position
switch 2
released
ON Code
No.24
13E-17
slightly depressed
OFF
(When the A/C
A/C switch: ON ON Procedure
No.26
13E-37
switch is on, the
A/C compressor
should be driven.)
A/C switch: OFF OFF
44 Ignition Ignition switch: ON Engine: Stopped OFF Code 13E-16
switch: ST
Engine: Cranking ON
No.22
45 Ignition
switch-IG
Ignition switch: ON ON - -
46 Control relay Ignition switch: ON ON Procedure
No.21
13E-34
47 A/C relay Engine: Idling after A/C switch: ON ON Procedure 13E-37
having warmed up
A/C switch: OFF OFF
No.26
49 Solenoid-
type spill
valve relay
Ignition switch: ON ON Code
No.44
13E-20
52 Glow plug
relay
MUT-II Actuator test: Glow plug relay (item
No.2) is driven
ON (for
approx. 6
seconds)
Procedure
No.25
13E-37
53 Throttle Engine: After Engine: Idling ON Code 13E-18
solenoid
valve
having warmed up
Gently racing OFF
No.41
55 Engine
warning
lamp
MUT-II Actuator test: Engine warning lamp
(item No.16) is driven
ON (For
approx. 6
seconds)
- -
56 Glow indica-
tor lamp
MUT-II Actuator test: Glow indicator lamp (item
No.15) is driven
ON (for
approx. 6
seconds)
- -
Item No. Inspection
item
Drive contents Inspection
contents
Normal
condition
Inspection
procedure No.
Reference
page
01 Solenoid-type
spill valve
relay
Turns relay
from OFF to
ON and from
ON to OFF
Ignition
switch: ON
Operation
sound can be
heard.
- -
02 Glow plug
relay
Turns relay
from OFF to
ON and from
ON to OFF.
Ignition
switch: ON
Battery volt-
age is applied
to glow plug
when glow
plug relay is
ON.
Procedure
No.25
13E-37
03 A/C compres-
sor relay
Turns relay
from OFF to
ON and from
ON to OFF.
D Ignition
switch: ON
D A/C
switch: ON
A/C compres-
sor clutch
operation
sound can be
heard.
Procedure
No.26
13E-37
08 Throttle sole-
noid valve
Turns throttle
solenoid valve
ON.
Engine: 1500
r/min
Throttle valve
opens half
way.
Code No.41 13E-18
09 Turns throttle
solenoid valve
OFF.
Engine: Idling Throttle valve
opens fully.
Code No.41 13E-18
11 Timing control
solenoid valve
Drives timing
control sole-
noid valve at
94 % duty.
Ignition
switch: ON
Operation
sound can be
heard.
Code No.43 13E-19
13 Solenoid-type
spill valve
Turns sole-
noid-type spill
valve from
OFF to ON
and from ON
to OFF.
Ignition
switch: ON
Operation
sound can be
heard.
Code No.44 13E-20
14 EGR solenoid
valve
Turns EGR
solenoid valve
OFF.
Engine: Idling EGR valve
closes.
Procedure
No.24
13E-36
15 Glow indicator
lamp
Turns glow
indicator lamp
ON and OFF.
Ignition
switch: ON
Glow indicator
lamp illumi-
nates and
switches OFF.
- -
16 Engine warn-
ing lamp
Turns engine
warning lamp
ON and OFF.
Ignition
switch: ON
Engine warn-
ing lamp
illuminates
and switches
OFF.
- -
Item No. Reference
page
Inspection
procedure No.
Normal
condition
Inspection
contents
Drive contents Inspection
item
17 Radiator fan,
A/C condens-
er fan
Drives radiator
fan and A/C
condenser fan
at 0 % duty
Ignition
switch: ON
Fans stop. Procedure
No.20
13E-33
18 Drives radiator
fan and A/C
condenser fan
at 50 % duty
Ignition
switch: ON
Fans operate
at medium
speed.
19 Drives radiator
fan and A/C
condenser fan
at 100 % duty
Ignition
switch: ON
Fans operate
at high speed.
13300450025
NOTE
(1) Make the voltage measurement with the engine-ECU
(2) You may find it convenient to pull out the engine-ECU
(3) The checks can be carried out off the order given
in the chart.
Caution
2 Timing control Ignition switch: ON 11 - 13 V
solenoid valve
Engine: Idling 3.5 - 7.5 V
Engine: 2,500 r/min 5 - 9 V
3 Solenoid-type spill Ignition switch: ON 11 - 13 V
valve
When engine is suddenly decelerated from 3000
r/min
0 12.5 V
(varies repeatedly)
and momentarily
increases
4 Throttle solenoid Ignition switch: ON 0 - 3 V
valve
Engine: Idling Engine coolant tempera-
ture is 40 _C or lower
12 - 15 V
Engine coolant tempera-
ture is 80 _C or higher
0 - 3 V
9 Crank angle sensor Engine: Cranking 0.4 - 4.0 V
Between
terminals 10
Pump operation
sensor
(AC range)
and 23
Engine: 2,500 r/min 1.2 - 2.2 V
(AC range)
16 EGR solenoid valve Ignition switch: OFF ON 11 - 13 V
When idling after having warmed up, engine is
suddenly raced.
Momentarily in-
creases
18 Fan controller When radiator fan and A/C condenser fan are not
operating
0 - 0.3 V
When radiator fan and A/C condenser fan are
operating
0.7 V or more
19 Idle position switch 2 Ignition switch: ON Accelerator pedal is
released
0 - 1 V
slightly depressed
4 V or higher
21 Vehicle speed
sensor
D Vehicle is moving forward slowly
0 5 V
(Varies repeatedly)
25 Ignition switch-IG Ignition switch: ON 11 - 13 V
D Outside air tem-
perature: 25 _C
When A/C is MAX. COOL
condition (When the load
by A/C is high)
0 - 3 V
or more
When A/C is MAX. HOT
condition (When the load
by A/C is low)
System voltage
33 Fuel injection rate
correction resistor
Ignition switch: ON 0.2 - 4.5 V
34 Diesel fuel tempera-
ture sensor
Ignition switch: ON (when cranking at cold engine) 0.5 - 3.4 V
35 Engine coolant
temperature sensor
Ignition switch: ON Engine coolant tempera-
ture is 0 _C
3.2 - 3.8 V
ture is 20 _C
2.3 - 2.9 V
ture is 40 _C
1.3 - 1.9 V
ture is 80 _C
0.3 - 0.9 V
36 Intake air tempera-
ture sensor
Ignition switch: ON Intake air temperature is 0
_C
3.2 - 3.8 V
20 _C
2.3 - 2.9 V
40 _C
1.5 - 2.1 V
80 _C
0.4 - 1.0 V
37 Boost sensor Ignition switch: ON Altitude is 0 m 2.0 - 2.6 V
Altitude is 1,200 m 1.7 - 2.3 V
38 Sensor applied
voltage
41 Fuel injection timing
correction resistor
43 Idle position switch 1 Ignition switch: ON Accelerator pedal is
released
0 - 1 V
depressed
4 V or higher
44 Accelerator pedal
position sensor
released
0.3 - 0.8 V
Accelerator pedal is fully
depressed
4.2 - 4.5 V
51 Ignition switch-ST Engine: Cranking 8 V or higher
52 A/C switch 1 Engine: Idling A/C switch is off 0 - 3 V
A/C switch is on (A/C
compressor is operating)
13 - 15 V
53 A/C relay D Engine: Idling
13 - 15 V or momen-
tarily 6 V or more
0 - 3 V
55 Glow indicator lamp D Ignition switch: OFF ON
D Engine coolant temperature is 40 _C or less
0 - 1 V; after approx.
1 second 11 - 13
V (at engine coolant
temperature of 20 _C)
57 Engine warning lamp Ignition switch: OFF ON 0 - 3 V (after
several seconds)
9 - 13 V
59 Control relay Ignition switch: OFF 11 - 13 V
Ignition switch: ON 0 - 3 V
60 Glow plug relay
(pre-heat time
control)
D Ignition switch: OFF ON
D Engine coolant temperature is 40 _C or less
(Pre-glow function check)
9 - 12 V; after
approx. 8 seconds
0 - 0.5 V (at engine
coolant temperature
of 20 _C)
61 Backup power
supply
Ignition switch: OFF 11 - 13 V
66 A/C variable
capacity relay
D Engine: Idling
D A/C switch: ON
ture is 5 _C or less
0 - 3 V
ture is 5 _C or more
13 - 15 V
71 Solenoid-type spill
valve
Ignition switch: ON OFF 0.39 V (after
approx. 3 seconds)
0 V
72 Power supply Ignition switch: ON 11 - 13 V
BETWEEN TERMINALS
NOTE
(1) When measuring resistance and checking continuity,
(2) Checking need not be carried out in the order given
in the chart.
Caution
the problem.
Terminal No. Check item Normal condition (Check condition)
2 - 72 Timing control valve 8 - 12 W (At 20 _C)
4 - 72 Throttle solenoid valve 36 - 44 W (At 20 _C)
10 - 23 Pump operation sensor 215 - 245 W (At 20 _C)
16 - 72 EGR solenoid valve 11 - 14 W (At 20 _C)
19 - Body earth Idle position switch 2 Continuity (When accelerator lever is at idle position)
No continuity (When accelerator lever is at slightly open)
Terminal No. Normal condition (Check condition) Check item
26 - Body earth Engine-ECU earth Continuity (0 W)
33 - 46 Injection rate correction resistor 0.1 - 2.5 kW (At 20 _C)
34 - 46 Diesel fuel temperature sensor 2.2 - 2.7 kW
35 - 46 Engine coolant temperature 5.1 - 6.5 kW (When engine coolant temperature is 0 _C)
sensor
2.1 - 2.7 kW (When engine coolant temperature is 20 _C)
36 - 46 Intake air temperature sensor 5.3 - 6.7 kW (When intake air temperature is 0 _C)
2.3 - 3.0 kW (When intake air temperature is 20 _C)
41 - 46 Injection timing correction
resistor
0.1 - 2.5 kW (At 20 _C)
43 - 46 Idle position switch 1 Continuity (When accelerator lever is at idle position)
No continuity (When accelerator lever is at slightly open)
INSPECTION PROCEDURE USING AN
ANALYZER 13300460028
CRANK ANGLE SENSOR
Measurement Method
angle sensor connector terminal (2) (black clip of special
tool).
Connect the analyzer special patterns pickup to engine-ECU
terminal 9.
Analyzer
Special
patterns
pickup
Standard Wave pattern
Pattern height Low
15 _BTDC
75 _ATDC
reduced when theengine
speed increase
No.1 TDC No.3 TDC No.4 TDC No.2 TDC
Time
(V)
0
D Example 1
Cause of problem
is not started.
D Example 2
Cause of problem
Loose timing belt
PUMP OPERATION SENSOR
Measurement Method
1. Disconnect the pump operation sensor connector and
connect the special tool (test harness: MB991348) in
between. (All terminals should be connected.)
2. Connect the analyzer special patterns pickup to pump
operation sensor connector terminal (1).
terminal 10.
Pattern height Low
Analyzer
Special
patterns
pickup
reduced when the engine
speed increases Time
Time
0
(V)
D Example
Cause of problem
Loose timing belt
Incorrect installation of injection pump or pump operation
sensor
SOLENOID-TYPE SPILL VALVE
Measurement Method
1. Disconnect the solenoid-type spill valve connector and
connect the special tool (test harness: MB991348) in
between. (Both the power supply side and theengine-ECU
side should be connected.)
solenoid-type spill valve connector terminal (2).
Analyzer
Special
patterns
pickup
terminal 3.
Point B
Point A
Solenoid back
electromotive
force
Time
0
(V)
10
T
appear at all.
Point B: Solenoid-type spill valve drive cycle
DIESEL FUEL - On-vehicle Service 13E-53
EVACUATION OF WATER FROM FUEL FILTER
Water is in the filter when fuel filter warning lamp lights.
Evacuate water by the following procedures.
1. Loosen the water level sensor.
2. Operate the hand pump to drain the water, and then
tighten the water level sensor to the specified torque.
EVACUATION OF AIR FROM FUEL LINE
13300130059
Bleed the air from the fuel line after refilling the fuel.
D When fuel is drained for service.
D When fuel filter is replaced.
D When main fuel line is removed.
1. Loosen fuel filter air plug.
2. Place rags around air plug hole. Operate hand pump
repeatedly until no bubbles come from plug hole. Tighten
air plug.
3. Repeat until hand pump operation becomes stiff.
FUEL FILTER CARTRIDGE REPLACEMENT
13300320036
Refer to GROUP 13F.
AND IDLE POSITION SWITCH 1 ADJUSTMENT
13300600017
2. Turn the ignition switch to ON. (but do not start the engine.)
voltage.
4. If the output voltage is outside the standard value range,
loosen the accelerator pedal position sensor mounting
bolt and turn the accelerator pedal position sensor body
to adjust. After adjusting, securely tighten the mounting
bolt.
5. Check the voltage at the point where idle position switch
1 turns from on to off.
6. If the voltage is outside the standard value range, replace
the accelerator pedal position sensor assembly.
Water level sensor
Hand pump
Air plug
Accelerator pedal
position sensor (with
built-in idle position
switch 1)
voltage when the accelerator pedal is fully depressed.
Standard value: 4,000 - 4,690 mV
NOTE
If the voltage is outside the standard value range, check
whether there are any marks which show that idle position
switch 2 has been moved. If such marks can be found,
adjust the idle position switch 2.
If no such marks can be found, re-adjust the output voltage
of the accelerator pedal position sensor.
IDLE POSITION SWITCH 2 ADJUSTMENT
13300610010
NOTE
(1) The idle position switch 2 should not be moved
unnecessarily; it has been precisely adjusted by the
manufacturer.
(2) If the adjustment is disturbed for any reason, re-adjust
as follows.
3. Turn the ignition switch to ON. (but do not start the engine.)
voltage when the accelerator pedal is fully depressed.
Standard value: 4,000 - 4,690 mV
5. If the output voltage is outside the standard value range,
loosen the accelerator pedal position sensor mounting
bolt and turn the accelerator pedal position sensor body
to adjust.
Standard value: 4,350 mV
6. Tighten securely the accelerator pedal position sensor
mounting bolt.
7. Back out the idle position switch 2 lock nut.
8. Adjust the idle position switch 2 so that the accelerator
pedal position sensor output voltage is within the standard
value range when the accelerator pedal is released.
9. While holding the idle position switch 2 so that it doesnt
move, tighten the lock nut securely.
A/C relay G Engine coolant temperature sensor I
A/C switch N Engine-ECU M
(with built-in idle position switch 1)
C Engine warning lamp (check engine lamp) J
Boost sensor D Glow indicator lamp J
Control relay L Glow plug relay F
Crank angle sensor A Idle position switch 2 C
Diagnosis connector K Intake air temperature sensor B
Diesel fuel temperature sensor H Pump operation sensor H
EGR solenoid valve D Throttle solenoid valve D
Solenoid-type spill valve H Timing control solenoid valve H
Solenoid-type spill valve relay L Vehicle speed sensor E
A B C D E F G
H I
J K L M N
CONTROL RELAY AND SOLENOID-TYPE
SPILL VALVE RELAY CONTINUITY CHECK
13300620013
1 2 3 4
Not supplied
Supplied
13300490027
1. Disconnect the intake air temperature sensor connector.
Standard value:
2.3 - 3.0 kW (at 20_C)
0.30 - 0.42 kW (at 80_C)
3. Remove the intake air temperature sensor.
drier.
Normal condition:
Higher Smaller
resistance remains unchanged, replace the intake air
temperature sensor.
6. Install the intake air temperature sensor and tighten it
Control
relay and
solenoid-
type spill
valve
relay
Intake air
temperature
sensor
CHECK 13300500027
Caution
resistance.
Standard value:
2.1 - 2.7 kW (at 20_C)
0.26 - 0.36 kW (at 80_C)
replace the sensor.
Specified sealant:
3M NUT Locking Part No.4171 or equivalent
CHECK 13300630016
connector.
4.
4.
Normal condition:
Depress the accelerator ped-
al slowly until fully depressed
position from the idle posi-
tion.
Changes smoothly in propor-
tion to the opening angle of
the throttle valve.
Engine coolant
temperaturesensor
Accelerator pedal
position sensor
doesnt change smoothly, replace the accelerator pedal
position sensor.
NOTE
For the accelerator pedal position sensor adjustment
procedure, refer to P.13E-53.
IDLE POSITION SWITCH 1 CHECK 13300640019
connector.
2. Check the continuity between the accelerator pedal
position sensor connector side terminal 3 and terminal
4.
Normal condition:
3. If out of specification, replace the idle position switch
1.
NOTE
After replacement, the accelerator pedal position sensor
should be adjusted. (Refer to P.13E-53.)
IDLE POSITION SWITCH 2 CHECK 13300650012
1. Disconnect the idle position switch 2 connector.
2. Check the continuity between the idle position switch
2 terminal and body earth.
Normal condition:
3. If out of specification, replace the idle position switch
2.
NOTE
After replacement, the accelerator pedal position sensor
should be adjusted. (Refer to P.13E-53.)
APS equipment side connector
Accelerator pedal
position sensor
Idleposition switch 2
SOLENOID-TYPE SPILL VALVE CHECK 13300660015
1. Disconnect the solenoid-type spill valve connector.
2. Measure the resistance between terminals 1 and 2.
3. Check that the sound of the solenoid valve operating
can be heard when battery voltage is applied momentarily
(for 2 - 3 seconds) between the solenoid-type spill valve
terminals.
Caution
Because the solenoid-type spill valve is
current-controlled, it should not be left for a long time
with the voltage applied.
TIMING CONTROL SOLENOID VALVE CHECK
13300560025
1. Disconnect the timing control solenoid valve connector.
3. Check that the sound of the solenoid valve operating
can be heard when battery voltage is applied between
the timing control solenoid valve terminals.
DIESEL FUEL TEMPERATURE SENSOR
CHECK 13300680011
1. Disconnect the diesel fuel temperature sensor connector.
Standard value: 2.2 - 2.7 kW (at 20_C)
Solenoid-type spill valve
Timing
control
sole-
noid
valve
Diesel fuel temperature sensor
PUMP OPERATION SENSOR CHECK 13300690014
1. Disconnect the pump operation sensor connector.
INJECTION TIMING CORRECTION RESISTOR
CHECK 13300700014
1. Disconnect the injection timing correction resistor
connector.
INJECTION RATE CORRECTION RESISTOR
CHECK 13300710017
1. Disconnect the injection rate correction resistor connector.
FUEL CUT SOLENOID VALVE CHECK 13300720010
1. When a sound scope is held against the fuel cut solenoid
valve and the ignition switch is turned to ON, check that
the sound of the valve operating can be heard.
2. Disconnect the fuel cut solenoid valve connector.
3. Measure the resistance between fuel cut solenoid valve
terminal and the injection pump body.
Standard value: 8 - 10 W
THROTTLE SOLENOID VALVE CHECK 13300730013
NOTE
1. Disconnect the vacuum hose (green stripe, yellow stripe)
Injection timing
correctionresistor
Injection rate
correction
resistor
Fuel cut
solenoid
valve
Throttle solenoid valve
3. Connect a hand vacuum pump to nipple B of the solenoid
valve.
4. Use jumper wires to connect the terminals of the solenoid
valve and the battery.
5. Check the air-tightness when negative pressure is applied
while the jumper wire is connected to the battery ( - )
terminal and while it is disconnected.
Normal condition:
Jumper wire Nipple A condition Normal condition
Connected Open Negative pressure
leaks
Closed Negative pressure
is maintained
Disconnected Open Negative pressure
leaks
solenoid valve.
THROTTLE ACTUATOR CHECK 13300740016
1. Remove the vacuum hose (red stripe) from the throttle
actuator and connect a hand vacuum pump to the throttle
actuator nipple.
2. Check that the actuator rod moves smoothly when
applying vacuum gradually.
Also, check that the vacuum is maintained when applying
53 kPa of vacuum.
INJECTION NOZZLE CHECK AND
Caution
Never touch the injection spray that is injected from the
nozzle.
FUEL INJECTION INITIAL PRESSURE CHECK
1. Install the injection nozzle to a nozzle tester.
2. Move the lever of the nozzle tester 2 - 3 times to inject
fuel and to bleed the air.
3. Gently press down the lever of the nozzle tester, and
take a reading of the indication value on the pressure
gauge at the point where the needle slowly rises and
then suddenly drops.
Standard value: 14,710 - 15,690 kPa
Battery
A
B
Throttle actuator
4. If the fuel injection initial pressure is outside the standard
value, disassemble the nozzle holder to clean it, and
then change the thickness of the shim to adjust the fuel
injection initial pressure.
NOTE
(1) For disassembly, reassembly and adjustment of the
nozzle holder, refer to P.13E-66.
(2) There are 10 shims for adjustment, with thicknesses
in the range of 0.10 - 0.80 mm.
(3) When the shim thickness is increased by 0.1 mm,
the fuel injection initial pressure increases by 2,350
kPa.
INJECTION SPRAY CONDITION CHECK 13300180023
1. Move the lever of the nozzle tester rapidly (4 - 6 times
per second) to eject the fuel continuously. Check to be
sure that the injection spray comes out evenly in a cone
shape (injection spray angle is 10_). The injection spray
patterns shown in the illustration at left are wrong.
A. Injection angle is too large
B. Bias
C. Intermittent fuel injection
2. Check to be sure that no fuel drips after injection is
completed.
3. If there are any drips, disassemble the nozzle, clean it
and re-inspect, or replace the nozzle.
NOZZLE FUEL-TIGHT CHECK 13300190026
1. Gently raise the lever of the nozzle tester until the pressure
inside the nozzle (value displayed on pressure gauge)
becomes 12,750 - 13,730 kPa, and after holding this
pressure for approximately 10 seconds, check to be sure
that there are no fuel leaks from the nozzle.
2. If there are any leaks, disassemble the nozzle, clean
it and re-inspect, or replace the nozzle.
A B C
DIESEL FUEL - Injection Pump and Nozzle 13E-63
INJECTION PUMP AND NOZZLE 13300210036
D Glow Plug Removal and Installation
(Refer to GROUP 11C.)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
49 - 59 Nm
78 - 88 Nm
9 Nm
29 Nm
12 - 15 Nm
35 Nm
9 Nm
9 Nm
29 Nm
29 Nm
19 Nm
24 Nm
19 Nm
Fuel injection pump removal steps
3. Fuel main hose connection
4. Control wiring harness connection
6. Flange
AB" 7. Fuel injection pump sprocket
AB" 8. Fuel injection pump
9. Key
10. Injection pump stay
11. Injection pump bracket stay
Fuel injection nozzle removal steps
AC" "CA 12. Nut
AC" "CA 13. Fuel return pipe
14. Fuel return pipe gasket
AD" "BA 15. Fuel injection nozzle and holder
assembly
"AA 16. Holder gasket
"AA 17. Nozzle gasket
AA"FUEL INJECTION PIPE REMOVAL
When loosening nuts at both ends of injection pipe, hold
the delivery holder (for pump side) an the injection nozzle
holder (for nozzle side) with wrench and loosen nut.
Caution
After disconnecting the injection pipe, be sure to use
a plug so that foreign material, etc. does not get into
the pump.
AB"FUEL INJECTION PUMP SPROCKET/
FUEL INJECTION PUMP REMOVAL
1. Use the special tool to hold the injection pump sprocket,
and then remove the injection pump sprocket fixing nut.
2. After removing the nut, install the special tool to the
injection pump sprocket.
3. Pull the injection pump sprocket off from the pump drive
shaft.
Caution
(1) When removing the sprocket, care must be taken
not to subject the pump drive shaft to an impact.
(2) After removal, thecrankshaft shouldnot beturned.
4. Remove the fuel injection pump.
AC"NUT/FUEL RETURN PIPE REMOVAL
1. While using a spanner or similar tool to hold the hexagonal
nut of the fuel return pipe, remove the nut.
Caution
If an attempt is made to loosen the nut without first
holding the fuel return pipe, the pipe may be broken
or otherwise damaged.
2. Disconnect the fuel return pipe.
AD"FUEL INJECTION NOZZLE AND HOLDER
ASSEMBLY REMOVAL
Using a deep socket wrench, remove the fuel injection nozzle
and holder assembly.
Caution
(1) Make a mark on the removed injection nozzle
assembly (the cylinder No.).
(2) Use a cap to prevent foreign material, etc. from
entering the injection nozzle hole.
Fuel injection pipe
Nut
Delivery
holder or
nozzle
holder
MB990767
MD998719
MD998388
Nut
Fuel return pipe
Deep socket
wrench
"AANOZZLE GASKET/HOLDER GASKET
INSTALLATION
Clean the cylinder heads injection nozzle hole, and insert
a new gasket.
"BAFUEL INJECTION NOZZLE AND HOLDER
ASSEMBLY INSTALLATION
Use a deep socket wrench in the same way as during removal
to tighten to the specified torque.
"CAFUEL RETURN PIPE/NUT INSTALLATION
While holding the hexagonal nut on the fuel return pipe with
a spanner in the same way as during removal, tighten the
nut to the specified torque.
Caution
If anattempt is made to tightenthe nut without first holding
the fuel return pipe, the pipe may be broken or otherwise
damaged.
"DAFUEL INJECTION PIPE INSTALLATION
When tightening the nuts at both ends of the fuel injection
pipe, hold the delivery holder (for pump side) an the injection
nozzle holder (for nozzle side) with wrench in the same way
as during removal, and then tighten the nuts to the specified
torque.
Holder gasket
Nozzle gasket
1
2
3
4
5
6
7
39 Nm
Disassembly steps
AA" "AA 1. Retaining nut
2. Nozzle tip
3. Distance piece
4. Retaining pin
5. Pressure spring
6. Shim
7. Nozzle holder body
DISASSEMBLY SERVICE POINT
AA"RETAINING NUT REMOVAL
1. Lightly clamp the retaining nut in a vise with soft jaws.
2. Hold the retaining nut with a box wrench, and loosen
the nozzle holder body using a deep socket.
"AARETAINING NUT INSTALLATION
1. Finger-tighten the nozzle holder body.
2. Lightly clamp the retaining nut in a vise with soft jaws.
3. While holding the retaining nut with a box wrench in the
same way as during removal, use a deep socket wrench
to tighten the nozzle holder body to the specified torque.
Deep socket
NOZZLE TIP
1. Check the nozzle tip for carbon deposits. Scape off carbon
deposits with a piece of wood and clean each part with
petrol. After cleaning, keep parts submerged in diesel
fuel. Take particular care to protect the nozzle tip needle
valve from damage.
2. While the nozzle tip is submerged in diesel fuel, check
that the needle valve slides smoothly.
If the needle valve does not slide smoothly, replace the
nozzle tip.
When replacing the nozzle tip, completely wash off the
anticorrosive oil from the new nozzle tip with clean diesel
fuel before using it.
3. Check plunger tip A for deformation and breakage. If
A is damaged or broken, replace it.
DISTANCE PIECE
Check the surface in contact with the nozzle holder body
by using minium.
PRESSURE SPRING
Check spring for weakness and breakage.
Plunger
Nozzle tip
A
DIESEL FUEL - Throttle Body 13E-68
1
2
3
4
5
6
7
18 Nm
6 Nm
Removal steps
1. Air hose connection
2. Intake air temperature sensor
connector
4. Air intake fitting
5. Intake fitting gasket
6. Throttle body assembly
7. Intake fitting gasket
13F-1
FUEL SUPPLY
SPECIAL TOOL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL FILTER 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SUPPLY - General Information/Special Tool 13F-2
D The steel fuel tank is located under the floor
of the rear seats to provide increased safety
and increase the amount of luggage
compartment space.
D The fuel tank has been equipped with a valve
assembly which incorporates a fuel cut-off valve
to prevent fuel from leaking out in the event
of a collision and a two-way valve for adjusting
the pressure inside the fuel tank.
D A plastic snap-fitting hose (high-pressure fuel
hose) has been adopted between the fuel pump
assembly and the fuel filter assembly in
petrol-powered vehicles in order to improve
ease of maintenance.
SPECIAL TOOL 13500060088
MB991610 Oil filter wrench Fuel filter cartridge replacement
FUEL SUPPLY - Fuel Tank 13F-3
FUEL TANK 13500190244
D Draining Fuel
D Reduce the Inner Pressure of Fuel Line and Hose
<Petrol-powered Vehicles>
D Refilling Fuel.
D Checking for Fuel Leaks
25 Nm
4
<Petrol-powered
vehicles>
<Diesel-powered
vehicles>
<Petrol-powered ve-
hicles>
<Diesel-powered
vehicles>
<Diesel-powered
vehicles>
3
2
13
8
14
11
12
10
9
1
17
15
6
5
5
16
7
Removal steps
1. Drain plug
2. Fuel filler cap
3. Fuel filler neck assembly
4. Packing
D Parking brake cable connection (Refer
to GROUP 36)
D Rear seat cushion (Refer to GROUP
52A)
5. Return hose
"AA 6. High-pressure fuel hose
7. Main hose
8. Vapour hose
9. Fuel tank assembly
10. Fuel wiring harness
11. Filler hose
12. Vapour hose
13. Vapour cap
14. Valve assembly
15. Fuel pump assembly
16. Fuel pipe assembly
17. Fuel gauge unit assembly
FUEL SUPPLY - Fuel tank 13F-4
"AAHIGH-PRESSURE FUEL HOSE INSTALLATION
Caution
After connecting the high-pressure fuel hose, pull it gently
in the direction of removal to check that the hose is firmly
connected.
VALVE CHECK
If the sound of the float valve moving (knocking sound) can
be heard when the valve assembly is gently shaken up and
down, then the valve is okay.
FUEL GAUGE UNIT CHECK
Refer to GROUP 54 - Combination Meter.
FUEL GAUGE UNIT REPLACEMENT 13500140065
1. Remove the rear seat cushion. (Refer to GROUP 52A.)
2. Remove the protector, and then disconnect the connector
from the fuel gauge unit.
3. Remove the mounting nut, andthen removethe fuel gauge
unit.
4. Install the new fuel gauge unit, align the projections on
the packing (indicated by arrows in the illustration) with
the holes in the fuel gauge unit, and then tighten the
mounting nut to the standard torque.
5. Connect the connector, and then install the protector.
6. Install the rear seat cushion. (Refer to GROUP 52A.)
FUEL SUPPLY - Fuel Filter 13F-5
FUEL FILTER 13500280101
D Reduce the Inner Pressure of Fuel Line and Hose
<Petrol-powered Vehicles>
D Checking for Fuel Leaks
3 Nm
<Petrol-powered vehicles>
8
12 - 14 Nm
3
3
6
5
2
7
9
4
4
1
Removal steps
AA" "BA 1. High-pressure fuel hose connection
2. Main pipe connection
"AA 3. Main hose connection
4. Fuel filter assembly
5. Water level sensor
6. Fuel filter cartridge
7. Breather screw
8. Fuel filter pump body
9. Fuel filter bracket
AA"HIGH-PRESSURE FUEL HOSE DISCONNECTION
Caution
As there will be some pressure remaining in the fuel
pipe line, cover it with a rag to prevent fuel from spraying
out.
"AAMAIN HOSE CONNECTION
Insert the main hose as far as the stepped section of the
pipe.
"BAHIGH-PRESSURE FUEL HOSE CONNECTION
Caution
After connecting the high-pressure fuel hose, pull it gently
in the direction of removal to check that the hose is firmly
connected.
WATER LEVEL SENSOR CHECK <DIESEL-POWERED
VEHICLES>
1. Connect the circuit tester to the water level sensor
connector.
2. The water level sensor is operating correctly if there is
continuity when the float is raised, and no continuity when
it is lowered.
FUEL FILTER CARTRIDGE REPLACEMENT
13500130147
<DIESEL-POWERED VEHICLES>
1. Remove the fuel tank cap to release the pressure inside
the fuel tank.
2. Disconnect the connector and the main hose, and then
remove the fuel filter assembly from the bracket.
3. Remove the water level sensor.
4. Use an oil filter wrench to remove the fuel filler cartridge
from the fuel filter pump body.
Caution
Cover the cartridge with a rag to prevent fuel from
spraying out.
5. Install a new filter, and bleed the air from fuel line. (Refer
to GROUP 13E - On-vehicle Service.)
6. Start the engine, and check that there are no fuel leakage.
FUEL FILTER ASSEMBLY REPLACEMENT
<PETROL-POWERED VEHICLES> 13500130130
1. Bleed the residual pressure from inside the fuel line.
2. Remove the parking brake cable clamp.
3. Disconnect the high-pressure fuel hose.
Caution
As there will be some pressure remaining in the fuel
pipe line, cover it with a rag to prevent fuel from
spraying out.
Float
MB991610
Main pipe
Fuel filter
assembly
High-pressure
fuel hose
36 Nm
4. Hold the fuel filter with a spanner and loosen the flare
nut. Then disconnect the main pipe connection.
5. Remove the fuel filter.
6. After installing the new fuel filter, tighten the main pipe
flare nut to the specified torque.
7. Connect the high-pressure fuel hose.
Caution
After connecting the high-pressure fuel hose, pull
it gently in the direction of removal to check that
the hose is firmly connected.
8. After installation, check that there are no fuel leaks.
(1) Apply battery voltage to the fuel pump drive terminal
to operate the fuel pump. (Refer to GROUP 13A -
(2) Check for leaks when fuel pressure is applied.
NOTES
13H-1
TRACTION
CONTROL SYSTEM
(TCL)
SERVICE SPECIFICATION 3 . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
System Check Using the TCL Indicator
Lamps 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TCL Operation Check 25 . . . . . . . . . . . . . . . . . . . . . . .
Stop Lamp Switch Check 27 . . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor Check 27 . . . . . . . . . . . . . . . . .
Vacuum Solenoid Valve Check 27 . . . . . . . . . . . . . . .
Ventilation Solenoid Valve Check 27 . . . . . . . . . . . . .
Vacuum Tank Check 27 . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Actuator Check 27 . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal Position Sensor (APS)
Check 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TCL SWITCH 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING WHEEL SENSOR* 29 . . . . . . . . . . . .
TCL-ECU 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING!
(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injuryor deathtoservice personnel (frominadvertent firingof the air bag) or tothedriver andpassenger (fromrendering
the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System(SRS) before beginning any service or maintenance of any component of the SRSor any SRS-related
component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensor and
interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or
maintenance) are indicated in the table of contents by an asterisk (*)
TCL - General Information 13H-2
For vehicles with 6A13 engine, the TCL system
(slip control and trace control) is available as an
option. This systemfacilitates starting, accelerating,
and cornering on slippery roads such as snowy
roads. In addition, this system improves driveability
while cornering on normal roads and contributes
to easier driving.
Ventilation
solenoid valve
Vacuum solenoid
valve
Steering wheel sensor
Engine-ECU
Vacuum actuator
TCL-ECU
ABS-ECU
Vacuum tank
Accelerator pedal
position sensor (APS)
A/T-ECU
Stop lamp switch
TCL switch Indicator
TCL - Service Specification/Special Tools/Troubleshooting 13H-3
SERVICE SPECIFICATION 13600030013
Item Standard value
Accelerator pedal position sensor resistance kW 3.5- 6.5
MB991502 MUT-II sub
assembly
For checking of TCL (Diagnosis code display
when using the MUT-II)
MB991529 Diagnosis code
check harness
For checking of TCL (Diagnosis code display
when using the TCL-OFF warning lamp)
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
NOTE
Before carrying out trouble diagnosis, check to be sure that all of the following items are normal.
D Is the standard steering wheel being used, and has it been correctly installed to the straight-ahead
position on the steering shaft?
D Are the size, specifications, air pressure, balance and wear conditions of the tyres and wheels normal?
D Is the wheel alignment normal?
D Have any other modifications been made to the engine or suspension which could conceivably have
an effect on the TCL system?
DIAGNOSTIC FUNCTION
METHOD OF READING THE DIAGNOSIS CODES
Use the MUT-II or the warning lamp to read the diagnosis codes.
(Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)
NOTE
Connect the MUT-II to the diagnosis connector (16 pin) under the instrument under cover.
METHOD OF ERASING THE DIAGNOSIS CODES
TCL - Troubleshooting 13H-4
11 APS circuit system 13H-5
12 APS or TPS circuit system 13H-6
13 TPS circuit system 13H-7
23 Stop lamp switch circuit system 13H-7
24 TCL switch circuit system 13H-8
26 Ignition switch (IG2) circuit system 13H-8
27 TCL-ECU power supply voltage circuit (engine control relay circuit) system 13H-9
31 Front right wheel speed sensor circuit system 13H-10
32 Front left wheel speed sensor circuit system 13H-10
33 Rear right wheel speed sensor circuit system 13H-10
34 Rear left wheel speed sensor circuit system 13H-10
35 Rear wheel speed sensor circuit system (1) 13H-11
36 Rear wheel speed sensor circuit system (2) 13H-11
41 Steering wheel sensor (ST-1) circuit system (open circuit) 13H-12
42 Steering wheel sensor (ST-2) circuit system (open circuit) 13H-12
43 Steering wheel sensor (ST-N) circuit system (open circuit) 13H-12
44 Steering wheel sensor circuit system (short circuit) 13H-13
45 Steering wheel sensor (ST-N) circuit system (short circuit) 13H-13
71 Engine-ECU communication circuit system 13H-14
72 Engine-ECU circuit system GROUP 13A -
73
Troubleshooting
74 A/T-ECU communication circuit system 13H-14
76 ABS circuit system 13H-15
INSPECTION PROCEDURES FOR DIAGNOSIS CODES
Code No. 11 APS circuit system Probable cause
This diagnosis code is output if the APS output voltage is less than 0.2 V due to
an open circuit or other malfunction in the APS circuit. The APS power supply and
earth are supplied from the engine-ECU, and the output signal is used by the A/T-ECU
and auto-cruise control-ECU as well as by the TCL-ECU.
D Malfunction of APS
D Malfunction of TCL-ECU
OK
OK
OK
NG
MUT-II Data list
11APSoutput Open andclose
the throttle lever.
OK: Changes smoothly be-
tween 300 mV - 5,500
mV
NG
Measure the voltage at APS
connector B-41.
D Disconnect the APS
connector and measure at
harness side.
D Measure at the harness
side.
D Between terminal (1) and
body earth
OK: 4.8- 5.2 V
NG
nectors:
B-41, C-39
NG
Repair
OK
NG
Check the harness between
the APS and the engine-ECU,
OK
Check the APS.
(Refer to P.13H-27.)
NG
Replace
OK
Measure the voltage at TCL-
ECU connector C-10.
D Disconnect the TCL-ECU
the harness side.
body earth
OK: 0.3 V or more
NG
nectors:
C-10, C-51, B-41
NG
Repair
OK
NG
the APS and the TCL-ECU,
OK
nector:
C-10
NG
Repair
OK
NG
Replace the TCL-ECU.
NG
Repair
Check the following
connectors:
C-10, B-41, C-39
NG
Repair
Code No. 12 APS or TPS circuit system Probable cause
This diagnosis code is output if the APS opening angle is 20_ or greater than the
TPS opening angle because of a short in the APS, an open circuit in the TPS or
sticking of the vacuum actuator. As this detection condition can be applicable during
throttle control, trouble diagnosis is invalid at this time.
D Malfunciton of APS
D Malfunction of TPS
D Malfunction of vacuum actuator
OK
Replace the TCL-ECU
NG
Repair
MUT-II Data list
13TPSoutput Open andclose
the throttle lever.
OK: Changes smoothly be-
tween 300 mV - 5,500
mV
OK
Check the APS.
OK
nectors:
C-10, C-51, B-41
NG
Repair
OK
NG
the APS and the TCL-ECU,
NG
Replace
NG
Vacuumactuator operation in-
spection (Refer to GROUP
13A - On-vehicle Service.)
NG
Replace
OK
Measure the voltage at TPS
connector B-07.
D Disconnect the TPS
the harness side.
body earth
OK: 4.8- 5.2 V
NG
nectors:
B-07, C-39
NG
Repair
OK
NG
the TPS and the engine-ECU,
NG
Repair
OK
OK
Check the TPS.
(Refer to GROUP 13A - On-
vehicle Service.)
NG
Replace
OK
Measure the voltage at en-
gine-ECU connector C-39.
D Connect the engine-ECU
connector.
body earth.
Move the accelerator lever
OK: 0.3- 1.0 V (Set to idle
position)
4.5- 5.5 V (Fully open)
NG
nectors:
B-07, C-39
NG
Repair
OK
NG
the TPS and the engine-ECU,
OK
nector:
C-39
NG
Repair
OK
NG
Code No.13 TPS circuit system Probable cause
This diagnosis code is output if the TPS opening angle is 20_ or greater than the
APS opening angle because of a short in the TPS or an open circuit in the APS.
If there is an open circuit in the APS, diagnosis code No. 11 is output at the same
time. Accordingly, if only diagnosis code No. 11 is output, the cause is probably an
abnormality in the TPS circuit system.
D Malfunction of APS
D Malfunction of TPS
Is TCL diagnosis code No. 11 output?
Yes
Code No. 11 APS circuit system
(Refer to P.13H-5.)
No
Check the TPS.
NG
Replace
OK
Measure the voltage at engine-ECU connector C-39.
D Connect the engine-ECU connector.
D Between terminals (84) and body earth
D Move the accelerator lever.
OK: 0.3- 1.0 V (Set to idle position)
4.5- 5.5 V (Fully open)
NG
B-07, C-39
NG
Repair
OK
NG
Check the harness between the TPS and the engine-ECU,
OK
C-39
OK
NG
NG
Repair
Code No. 23 Stop lamp switch circuit system Probable cause
This diagnosis code is output if the stop lamp switch remains ON for a continuous
period of 15 minutes or more, or for a continuous period of 1 minute or more when
driving at a speed of 10 km/h or more, because of a short circuit or defective adjustment
of the stop lamp switch. This diagnosis code No. may also occur while driving in
traffic jams or if the foot is resting on the brake pedal with driving.
D Malfunction of stop lamp switch
Measure the continuity at the stop lamp switch connector C-02.
D Disconnect the connector and measure at the switch side.
D Between terminals (1) - (2)
OK: Continuity when the brake pedal is depressed
No continuity when the brake pedal is released
OK
Check the following
connectors:
C-02, C-65, C-75, C-11
NG
Repair
OK
NG
Inspect the harness be-
tween stop lamp switch
and the TCL-ECU.
NG
Repair
OK
NG
Stop lamp switch installation check (Refer to GROUP 35A - On-ve-
hicle Service.)
OK
Replace the stop lamp switch.
NG
Stop lamp switch adjustment (Refer to GROUP 35A - On-vehicle
Service.)
Code No. 24 TCL switch circuit system Probable cause
This diagnosis code is output if signals are input simultaneously fromboth the TCL-OFF
and TCL-ON positions because of a short circuit in the TCL switch circuit.
D Malfunction of the TCL switch
Measure the continuity at TCL switch connector C-98.
D Disconnect the connector and measure at the switch side.
D Between terminals (2) - (3) and (3) - (6)
OK: No continuity
NG
Replace the TCL switch.
OK
C-98, C-75, C-11
NG
Repair
OK
NG
Inspect the harness between the TCL switch and the TCL-ECU.
NG
Repair
OK
Code No. 26 Ignition switch (IG2) circuit system Probable cause
This diagnosis code is output if the IG2 power supply is not distributed, even though
the engine speed is 450 r/min or more.
Measure the voltage at TCL-ECU connector C-11.
D Ignition switch : ON
D Disconnect theTCL-ECUconnector and measureat theharness
side.
D Between terminal (35) and body earth
OK: System voltage
OK
Check the following
connector:
C-11
NG
Repair
OK
NG
NG
C-131, C-134, C-66, C-75, C-11
NG
Repair
OK
NG
Check the harness between the ignition switch and the TCL-ECU,
Code No. 27 TCL-ECU power supply voltage circuit
(engine control relay circuit) system
Probable cause
This diagnosis code is output if the TCL-ECU power supply voltage (engine control
relay supply voltage) is lower than the specified value.
If the voltage returns to the specified value or greater, the diagnosis code is erased.
D Malfunction of control relay
Measure the voltage at TCL-ECU connector C-10.
D Engine: idling
D Disconnect the TCL-ECU connector and measure at the
harness side.
D Between terminal (25) and body earth
OK: 10 V or more
OK
C-10
OK
NG
NG
C-31, C-47, C-51, C-10
NG
Repair
OK
NG
Inspect the harness between the control relay and the TCL-ECU.
NG
Repair
OK
Engine control relay inspection (Refer to GROUP 13A - On-vehicle
Service.)
CodeNo. 31Front right wheel speedsensor circuit system Probable cause
Code No. 32 Front left wheel speed sensor circuit system
These diagnosis codes are output if a pulse (from the front wheels) indicates that
the difference between the front wheels and the rear wheels is 8km/h or more because
of an open or short circuit in a wheel speed sensor or a malfunction of sensor.
D Malfunction of front wheel speed sensor
D Malfunction of ABS-ECU
NOTE
When these diagnosis codes are output, erase the diagnosis code memory after carrying out repairs, and then
carry out a road test at 20 km/h or more and check to be sure that the diagnosis codes are not output again.
Is the ABS warning lamp illuminated, or is an ABS diagnosis code
output?
Yes
Carry out ABS troubleshooting (Refer to GROUP 35B - Trouble-
shooting.)
No
Measure at ABS-ECU connector A-04.
D Measure at the ECU side with the connector connected.
D Voltage between terminal (17) and body earth
OK: 4.8 - 5.2 V
NG
OK
A-04, C-10
NG
Repair
OK
NG
Check the harness connectors between the ABS-ECU and the
TCL-ECU, and repair if necessary.
Code No. 33 Rear right wheel speed sensor circuit system Probable cause
Code No. 34 Rear left wheel speed sensor circuit system
These diagnosis codes are output if a pulse (from the wheels on one side of rear)
indicates that the difference between the left wheel and the right wheel is 8km/h or
more because of an open or short circuit in a wheel speed sensor or a defective
sensor.
D Malfunction of rear wheel speed sensor
NOTE
When these diagnosis codes are output, erase the diagnosis code memory after carrying out repairs, and then
output?
Yes
shooting.)
No
Measure at ABS-ECU connector A-04.
D Ignition switch : ON
D Measure at the ECU side with the connector connected.
OK: 4.8- 5.2 V
NG
OK
A-04, C-10
NG
Repair
OK
NG
Code No. 35 Rear wheel speed sensor circuit system (1) Probable cause
Code No. 36 Rear wheel speed sensor circuit system (2)
Diagnosis code No. 35 is output if the pulse signal from a rear wheel sensor is
momentarily interrupted (0.02 sec.) because of a transient open circuit in a rear wheel
speed sensor.
Diagnosis code No. 36 is output if a rear wheel speed sensor abnormality is judged
when the turning speed of both rear wheels is 0 km/h for 20 seconds or more while
TCL is operating.
D Malfunction of rear wheel speed sensor
NOTE
(1) If the front wheels only are turning while the rear wheels are stationary (wheel slip), the TCL-OFF indicator
will start flashing after 20 seconds, and the system will be isolated.
(2) When these diagnosis codes are output, erase the diagnosis code memory after carrying out repairs, and then
Is a diagnosis code output from the ABS-ECU?
Yes
shooting.)
No
MUT-II Data list
33, 34 Wheel speed sensor
Accelerate from a stationary position.
OK: Vehicle speeds displayed on the speedometer and MUT-II
are identical.
OK
NG
A-04, C-10
OK
Repair
NG
NG
Code No. 41 Steering wheel sensor (ST-1) circuit system
(open circuit)
Probable cause
Code No. 42 Steering wheel sensor (ST-2) circuit system
(open circuit)
Code No. 43 Steering wheel sensor (ST-N) circuit system
(open circuit)
These diagnosis codes are output if there is an open circuit in the output wire of
the steering wheel sensor circuit.
D Malfunction of steering wheel sensor
Measure at TCL-ECU connector C-11.
D Connector connected
D Voltage between terminals (32), (40) and (41) and the body
earth
OK: Changes between approx. 3 V and approx. 0.5 V when
the steering wheel is turned
OK
Check the following
connectors:
C-11, C-75, C-106
NG
Repair
NG: Stays at
0V without
changing
OK
NG
NG: Changes between 4 V
or more and approx. 0.5 V
NG: Stays at 4 V or more
without changing
Measure at steering wheel sensor connector C-106.
D Continuity between terminal (3) and body earth
OK: Continuity
NG
Check the following
connectors:
C-106, C-62
NG
Repair
OK
NG
Check the harness between the steering wheel sensor and the
body earth, and repair if necessary.
OK
C-106, C-75, C-11
NG
Repair
OK
NG
Inspect the harness between the steering wheel sensor and the
TCL-ECU.
NG
Repair
OK
Replace the steering wheel sensor.
Code No. 44 Steering wheel sensor circuit system
(short circuit)
Probable cause
This diagnosis code is output when no steering angle signal is output because there
is a short-circuit in either steering wheel sensor ST-1 or steering wheel sensor ST-2
when the speed averages output by the left and right rear wheel speed sensors are
15 km/h or more.
NG
D Voltage between terminals (40) and (41) and the body earth
OK: Changes between approx. 3 V and approx. 0.5 V when
OK
Check the following
connector:
C-11
NG
Repair
OK
NG
TCL-ECU.
NG
Repair
OK
Measure at steering wheel sensor connector C-106.
OK: System voltage
NG
Check the following
connectors:
C-131, C-132, C-61,
C-106
NG
Repair
OK
NG
Check the harness between the steering wheel sensor and the
ignition switch, and repair if necessary.
OK
C-106
NG
Repair
OK
C-11, C-75, C-106
NG
Repair
OK
Code No. 45 Steering wheel sensor (ST-N) circuit system
(short circuit)
Probable cause
This diagnosis code is output if it is considered that there is an abnormality in the
steering wheel sensor (ST-N) circuit system when the straight-ahead position is
continuously detected even though the steering wheel is turned 20_ or more.
D Voltage between terminals (32) and the body earth
OK: Changes between approx. 3V and approx. 0.5 V when
OK
Check the following
connector:
C-11
NG
Repair
OK
NG
NG
TCL-ECU.
NG
Repair
OK
C-11, C-75, C-106
NG
Repair
OK
Code No. 71 Engine-ECU communication circuit system Probable cause
This diagnosis code is output if an error is detected in the communication contents
because of an open or short circuit in the serial communication circuit between the
TCL-ECU and the engine-ECU, a malfunction of ECU and a defective shielding of
the shield wire.
C-10, C-51, C-37
NG
Repair
OK
NG
Inspect the harness between the TCL-ECU and the engine-ECU.
NG
Repair
No
NG
OK
Is a diagnosis code output from the engine-ECU?
Yes
Carry out engine-ECU troubleshooting
(Refer to GROUP 13A - Troubleshooting.)
Code No. 74 A/T-ECU communication circuit system Probable cause
This diagnosis code is output if an error is detected in the communication contents
because of an open or short circuit in the serial communication circuit between the
TCL-ECU and the A/T-ECU, a malfunction of ECU and a defective shielding of the
shield wire.
D Malfunction of A/T-ECU
C- 10, C-51, C-49, C-29, C-30
NG
Repair
OK
NG
Inspect the harness between the TCL-ECU and the A/T-ECU.
NG
Repair
No
NG
OK
Is a diagnosis code output from the A/T-ECU?
Yes
Carry out A/T-ECU troubleshooting
(Refer to GROUP 23 - Troubleshooting.)
Code No. 76 ABS circuit system Probable cause
This diagnosis code is output if the ABS-ECU detects the system abnormality (when
ABS warning lamp illumination is controlled).
output?
Yes
Carry out ABS troubleshooting. (Refer to GROUP 35B - Trouble-
shooting.)
No
A-04, C-10
NG
Repair
OK
NG
Inspect the harness between the ABS-ECU and the TCL-ECU.
NG
Repair
OK
NG
Replace the ABS-ECU.
INSPECTION CHART FOR TROUBLE SYMPTOMS
procedure No.
Reference page
Communication
II
Communication with all systems is not possible. 1 13H-16
with the MUT-II
is not possible. Communication with TCL-ECU only is not possible. 2 13H-17
Malfunction of
TCL indicator
None of the TCL indicator lamps (TCL OFF, TCL) illuminate
when the ignition switch is ON.
3 13H-18
lamp display
One of the TCL indicator lamps does not illuminate when
the ignition switch is ON (Another lamp does illuminate).
4 13H-18
TCL OFF indicator lamp remains illuminated even after the
engine is started.
5 13H-19
TCL OFF indicator lamp flashes after the engine is started.
TCL remains illuminated even after the engine is started. 6 13H-19
TCL OFF indicator lamp does not illuminate even if the TCL
switch is continuously pressed to the OFF side while the
engine is idling.
7 13H-20
Malfunction of
TCL operation
TCL illuminates in the TCL operation range, but torque is
not reduced.
8 13H-20
Poor starting
Poor acceleration
Engine output is reduced in the TCL non-operation range
(TCL indicator lamp does not illuminate) and starting and
acceleration performance is poor.
INSPECTION PROCEDURES FOR EACH TROUBLE SYMPTOM
Inspection Procedure 1
Communication with the MUT-II is not possible.
Probable cause
The cause is probably a defective power supply system (including earth) for the
diagnosis line.
D Malfunction of connector
D Malfunction of harness
C-20.
Voltage between terminal (16) and body
earth
OK: System voltage
NG
C-141, C-132, C-63, C-66, C-20
<L.H. drive vehicles>
C-14, C-62, C-66, C-20
<R.H.drive vehicles>
NG
Repair
OK
NG
Check the harness between the fusible
link No. 2 and diagnosis connector, and
OK
C-20.
Continuity between terminal (4), (5) and
body earth
OK: Continuity
NG
C-20
NG
Repair
OK
NG
Check the harness between the diagno-
sis connector and the earth, and repair
if necessary.
OK
NG
Replace the MUT-II.
Communication with the MUT-II is not possible.
(Communication with TCL-ECU only is not possible.)
Probable cause
If the MUT-II cannot communicate with the TCL-ECU only, the cause is probably
an abnormality in the TCL diagnosis line or in the TCL-ECU power supply line or
earth line.
D Malfunction of engine control relay
Measure at diagnosis connector C-20
and TCL-ECU connector C-10.
D Continuity between the following
terminals
OK: Continuity
TCL-ECU side 1 14
| |
Diagnosis connector side 1 7
NG
C-20, C-66, C-83, C-49, C-51, C-10
NG
Repair
OK
NG
Check the harness between the TCL-
ECU and diagnosis connector, and re-
pair if necessary.
OK
D Engine: idling
D Voltage between 25 - body earth
OK: 10 V or more
NG
C-31, C-47, C-51, C-10
NG
Repair
OK
NG
Check the harness between the engine
control relay and TCL-ECU.
OK
Check the engine control relay.
(Refer to GROUP 13A - On-vehicle
Service.)
NG
Repair
OK
Measure at TCL-ECU connectors C-10
and C-11.
D Continuity between 13, 26 (C-10),
31 (C-11) - body earth
OK: Continuity
NG
Check the harness between the TCL-
ECU and the earth, and repair if neces-
sary.
OK
C-10, C-11
NG
Repair
OK
NG
None of the TCLindicator lamps (TCLOFF, TCL) illuminate
when the ignition switch is ON.
Probable cause
The main cause is an open circuit in the indicator circuit because of a burnt-out
indicator lamp bulb.
D Malfunction of indicator lamp bulb
Yes
Do other warning lamps illuminate when
the ignition switch is at ON position?
No
C-131, C-135, D-03
OK
NG
Check the harness between the com-
bination meter and the junction block,
NG
Repair
No
D-03, C-50, C-11
NG
Repair
OK
NG
Inspect the harness between the com-
bination meter and the TCL-ECU.
NG
Repair
OK
Check if a TCL indicator lamp bulb is
burnt out.
NG
Replace the lamp bulb.
OK
Is code No.27 output?
Yes
Code No.27 TCL-ECU power supply
voltage circuit system (Refer to
P.13H-9.)
One of the TCL indicator lamps does not illuminate when
the ignition switch is ON.
Probable cause
Because the TCL indicators utilise shared power supply circuits, if one of the indicator
lamps is illuminated, the power supply circuit can be judged to be normal.
D Open circuit in indicator lamp power supply circuit.
D Burnt-out indicator lamp bulb
Is the bulb of the non-illuminated indica-
tor lamp normal?
No
Replace the lamp bulb.
Yes
Measure at the TCL-ECU connector
C-11.
D Voltage between terminal (45) and
body earth
D Voltage between terminal (46) and
body earth
OK: System voltage
OK
NG
D-03, C-50, C-11
OK
NG
bination meter and the TCL-ECU, and
D TCL OFF indicator lamp remains illuminated even
after the engine is started.
D TCL OFF indicator lamp flashes after the engine is
started.
Probable cause
The TCL-OFF indicator is also used as a system warning indicator. If there is a system
abnormality, this indicator will illuminate or flash.
D Other system related to the TCL
Is the diagnosis code normal?
(Is communication with the MUT-II pos-
sible?)
No
To trouble symptom inspection proce-
dure 1
Yes
Does theTCL OFFindicator lampswitch
off when TCL-ECU connector C-11 is
disconnected?
Yes
No
D-03, C-50, C-11
OK
NG
NG
Repair
TCL indicator lamp remains illuminated even after the
engine is started.
Probable cause
The TCL indicator lamp only illuminates while the engine is running if the TCL is
operating.
D Malfunction of TCL indicator power supply circuit
Does the TCL indicator remain illumi-
nated when TCL-ECU connector C-11
is disconnected and the ignition switch
is turned to ON?
No
Yes
D-03, C-50, C-11
OK
NG
NG
Repair
TCL OFF indicator lamp does not illuminate even if the
TCL switch is continuously pressed to the OFF side while
the engine is idling.
Probable cause
If the indicator lamp does not illuminate when the switch is operated, there is a
malfunction in the switch, switch circuit or in the TCL-ECU.
D Malfunction of TCL switch
MUT-II Data list
D 25 TCL OFF switch
D Press the TCL switch continuously
to the OFF side while the engine
is idling.
OK: ON is displayed
OK
NG
C-11, C-75, C-98
NG
Repair
OK
NG
Inspect the harnesses between the
TCL-ECU and the TCL switch, and be-
tween the TCL switch and the body
earth.
OK
Repair
OK
TCL switch component inspection (Re-
fer to P.13H-28.)
D TCL illuminates in the TCL operation range, but
torque is not reduced.
D Engine output is reduced in the TCL non-operation
range (TCL indicator lamp does not illuminate) and
starting and acceleration performance is poor.
Probable cause
In cases such as the above, the electrical system is normal, and the cause is probably
an abnormality in the mechanical system (vacuum actuator).
D Malfunction of vacuum solenoid valve
D Malfunction of ventilation solenoid valve
D Malfunction of vacuum actuator
D Incorrect vacuum hose connector
D Malfunction of throttle link
D Malfunction of vacuum tank
D Blocked air cleaner element
As the cause is probably a malfunction of the vacuum actuator system, carry out inspection of the following items
in order.
D Vacuum solenoid valve operation inspection (Refer to GROUP 13A - On-vehicle Service.)
D Ventilation solenoid valve operation inspection (Refer to GROUP 13A - On-vehicle Service.)
D Disconnected or mis-connected vacuum hose inspection (Refer to GROUP 13A - On-vehicle Service.)
D Throttle link operation inspection (Refer to GROUP 13A - On-vehicle Service.)
D Vacuum tank inspection (Refer to GROUP 13A - On-vehicle Service.)
D Air cleaner element blockage inspection
DATA LIST REFERENCE TABLE
No. Check item Check condition Normal condition
11 APS Accelerator pedal position Fully closed 300- 1,000 mV
Engine stop
Selector lever position: P
Depressed Gradually rises from
the above value
Fully open 4,500- 5,500 mV
13 TPS Accelerator pedal position Fully closed 300- 1,000 mV
Engine stop
Depressed Gradually rises from
the above value
Fully open 4,500- 5,500 mV
15*
1
Inhibitor switch Ignition switch: ON Selector lever: P position P
Engine stop
Selector lever: R position R
Selector lever: N position N
Selector lever: D position D
Selector lever: 3 position 3
Selector lever: 2 position 2
Selector lever: L position L
16*
1
Shift position Shift lever position: D Driving at constant speed
of 10 km/h in 1 range
1st
Driving at constant speed
2nd
3rd
4th
21 Idle switch Accelerator pedal position Depressed OFF
Ignition switch: ON
Released ON
22 Ignition switch Ignition switch: ON ON
Ignition switch: OFF OFF
23 Stop lamp switch Brake pedal position Depressed ON
Ignition switch: ON
Released OFF
24 TCL ON switch TCL ON switch operation Pressed ON
Ignition switch : ON
Released OFF
25 TCL OFF switch TCL OFF switch operation Pressed ON
Ignition switch: ON
Released OFF
No. Check item Check condition Normal condition
27 ECU power supply
voltage
31 Front right wheel Engine running Vehicle stopped 0 km/h
speed sensor
Selector lever position: D
Driving at 40 km/h 40 km/h
32 Front left wheel Engine running Vehicle stopped 0 km/h
speed sensor
33 Rear right wheel Engine running Vehicle stopped 0 km/h
speed sensor
34 Rear left wheel Engine running Vehicle stopped 0 km/h
speed sensor
40 Engine speed Ignition switch: ON Engine: idling Engine speeds
displayed on the
MUT-II and tachome-
ter are identical.
44 Steering angle Steering wheel position Turned 90_ to the right R 88 deg or R 92 deg
Ignition switch: ON
Turned 90_ to the left L 88 deg or L 92 deg
45 Steering straight-
ahead point
Steering wheel position
Ignition switch: ON
Immediately after ignition
switch is ON
OFF
learning
Immediately after city
driving
ON
51 Slip control TCL switch: ON
Driving on low frictional
TCL indicator lamp
illuminated
ON
resistance road
TCL indicator lamp
switched off
OFF
52 Trace control TCL switch: ON
Driving on winding road
TCL indicator lamp
illuminated
ON
TCL indicator lamp
switched off
OFF
74 Steering wheel Steering wheel position Neutral position LOW
sensor (ST-N)
Engine idling
Steering wheel turned
90_ from neutral position
HIGH
75 Steering wheel
sensor (ST-1)
Ignition switch: ON
slowly to left
HIGH and LOW
display alternately
76 Steering wheel
sensor (ST-2)
Ignition switch: ON
slowly to right
HIGH and LOW
display alternately
81 Engine model Ignition switch: ON 6A13
82 Valve type Ignition switch: ON SOHC
83 Aspiration type Ignition switch: ON N/A
84 Engine classifica-
tion
Ignition switch: ON NORMAL
85 Destination Ignition switch: ON EUR*
2
NOTE
*1: A/T
*2: For Europe
CHECK AT ECU TERMINALS
Terminal
No.
Check item Measurement condition Normal condition
1 Diagnosis control When MUT-II is not connected Approx. 5 V
When MUT-II is connected 0 V
13 Earth Ignition switch: ON 0 V
14 Diagnosis data input When MUT-II is connected Serial communica-
tion with MUT-II
When MUT-II is not connected 1 V or less
15 A/T-ECU data communication Engine: Idling Other than 0 V
16
17 Engine-ECU data communication Engine: Idling Other than 0 V
18
19 APS output Ignition switch: ON
Accelerator pedal fully depressed
4.5 - 5.5 V
Ignition switch: ON
Accelerator pedal released
0.4 - 1.0 V
20 Wheel speed sensor input (rear left
wheel)
Engine: Idling, Vehicleslowly movingforward Flashes between 0
V and approx. 5 V
21 Wheel speed sensor input (front
right wheel)
V and approx. 5 V
22 Wheel speed sensor input (front
left wheel)
V and approx. 5 V
23 Wheel speed sensor input (rear
right wheel)
V and approx. 5 V
25 ECU power supply Ignition switch: ON Battery voltage
Terminal
No.
Normal condition Measurement condition Check item
32 Steering wheel sensor (ST-N) input Engine: Idling
Steering wheel in straight-ahead position
0.5 V or less
Engine: Idling
Steering wheel turned 90_ from
straight-ahead position
2.5 - 3.5 V
34 TCL ON switch Ignition switch: ON
TCL switch: Pressed to ON side
0 - 2 V
Ignition switch: ON
TCL switch: Released
Battery voltage
35 Ignition switch IG2 Ignition switch: ON Battery voltage
39 ECU back-up power supply Ignition switch: OFF Battery voltage
40 Steering wheel sensor (ST-1) input Ignition switch: ON
Steering wheel turned slowly
Flashes between 0
V and approx. 3 V
41 Steering wheel sensor (ST-2) input Ignition switch: ON
Steering wheel turned slowly.
Flashes between 0
V and approx. 3 V
42 TCL OFF switch Ignition switch: ON
TCL switch: Pressed to OFF side
0 - 2 V
Ignition switch: ON
TCL switch: Released
Battery voltage
43 Stop lamp switch input Ignition switch: ON
Brake pedal depressed
Battery voltage
Ignition switch: ON
Brake pedal released
0 - 2 V
44 ABS fail signal During ABS fail 0 - 2 V
When ABS is normal Battery voltage
45 TCL-OFF indicator Ignition switch: ON
Indicator: Extinguished
Battery voltage
Ignition switch: ON
Indicator: Illuminated
0 - 2 V
46 TCL indicator Ignition switch: ON
Indicator: Illuminated
0 - 2 V
Ignition switch: ON
Indicator: Extinguished
Battery voltage
TCL - On-Vehicle Service 13H-25
SYSTEM CHECK USING THE TCL INDICATOR
LAMPS
Press the TCL switch and check if each TCL indicator lamp
illuminates or switches off.
TCL switch mode Inspection conditions TCL OFF indicator (A) TCL indicator (B)
Switch does not Turn the ignition switch to the ON position. f f
operate
Start the engine.
TCL OFF mode Engine is idling. f -
TCL ON mode Drive the vehicle at 30 km/h for 2 minutes or
more.
No illumination -
NOTE
O: illuminated, X: extinguished, - : not relevant
Caution
If a different result is obtained when checking, refer to the Troubleshooting section for remedy.
TCL OPERATION CHECK 13600110038
<When using the MUT-II>
2. Move the selector lever to P range <A/T>, or move the
shift lever to the neutral position <M/T>.
4. Turn the TCL switch to ON.
5. Operate the MUT-II to start the actuator test (item No.
05) and fully depress the accelerator pedal at the same
time. Check that the engine speed is kept down to 3,000
r/min at this time.
Caution
The actuator test should only be carried out for 3
seconds.
Because the engine speed will increase once the
actuator test is stopped, the accelerator pedal should
be released quickly after it has been depressed.
NOTE
The TCL-ECU will output a request torque: 0 signal
to the engine-ECU for 3 seconds while the actuator test
is being carried out, and the TCL OFF indicator will
illuminate during this time.
A
B
TCL - On-vehicle Service 13H-26
<When not using the MUT-II>
1. Turn the TCL switch to ON.
2. Place the front wheels onto a speedometer tester or a
chassis dynamo and start the engine. (The front wheels
may also be jacked up.)
3. Move the shift lever to 1st position <M/T> or the selector
lever to D range <A/T>.
4. Check to be sure that the engine speed is restrained
when the accelerator pedal is depressed.
NOTE
If the following symptoms occur when the accelerator
pedal is depressed, refer to Troubleshooting.
(1) If the TCL indicator lamp does not illuminate.
(2) If the TCL indicator lamp illuminates but the engine
is not restrained.
Caution
(1) Inspectionshouldbe completedwithin20seconds
after the accelerator pedal was depressed. If it
takes longer than 20 seconds, the TCL system
function will stop and the engine speed will
gradually increase.
(2) Because the TCL OFF indicator will flash when
the TCL system operation is stopped, the
diagnosis codes should be erased if you notice
that the indicator is flashing. (Refer to P.13H-3.)
TCL - On-vehicle Service 13H-27
STOP LAMP SWITCH CHECK 13600120024
Refer to GROUP 35A - On-vehicle Service.
WHEEL SPEED SENSOR CHECK 13600130027
Refer to GROUP 35B - On-vehicle Service.
VACUUM SOLENOID VALVE CHECK 13600390012
VENTILATION SOLENOID VALVE CHECK
13600400012
VACUUM TANK CHECK 13600410015
VACUUM ACTUATOR CHECK 13600420018
(APS) CHECK 13600430028
1. Disconnect the APS connector.
2. Measure the resistance between terminals (1) and (4)
of the APS connector.
Standard value: 3.5- 6.5 kW
3. When the accelerator pedal is gradually depressed, check
that the resistance between terminals (1) and (2) of the
APS connector changes smoothly in proportion to the
pedal opening amount.
4. If the resistance is outside the standard value, or if the
resistance does not change smoothly, replace the APS.
Adjust the APS after it has been replaced.
APS
connector
Throttle body
APS
TCL - TCL Switch 13H-28
TCL SWITCH 13600160033
1
2
Removal steps
1. Switch bezel
2. TCL switch
TCL SWITCH CONTINUITY CHECK
Switch position Terminal No.
1 2 3 6 4 - 5
ON
Neutral
OFF
ON
Neutral
OFF
TCL - Steering Wheel Sensor 13H-29
STEERING WHEEL SENSOR 13600220014
CAUTION: SRS
Before removal of air bag module and clock spring, refer to GROUP 52B - Service Precautions and Air
Bag Module and Clock Spring.
1
Removal steps
D Steering wheel and column cover
(Refer to GROUP 37A - Steering
Wheel and Shaft.)
AA" 1. Steering wheel sensor
AA"STEERING WHEEL SENSOR REMOVAL
Caution
1. Do not adhere any dust or grease, etc. to the steering
wheel sensor, which has a photo coupler in it.
2. Do not bend the slit plate of the column switch nor
adhere any grease etc. to it.
STEERING WHEEL SENSOR CHECK
Refer to P.13H-22.
Slit plate
Steering
wheel sensor
TCL - TCL-ECU 13H-30
TCL-ECU 13600280036
Grove Box, Grove Box Frame, Side Cover and Corner Panel Removal and Installation (Refer to GROUP
52A - Instrument panel.)
5 Nm
5 Nm
5 Nm
3
2
4
1
Removal steps
1. Instrument panel lower passenger side
bracket
AA" 2. Upper bracket
3. TCL-ECU
4. Lower bracket
AA"UPPER BRACKET REMOVAL
Loosen the dash wiring harness mounting nut. Lower the
dash wiring harness to the position where the upper bracket
can be removed, and the remove the upper bracket.
TCL-ECU CHECK
Refer to P.13H-23.
Dash wiring
harness
14-1
ENGINE
COOLING
LUBRICANT 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANTS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Leak Checking 9 . . . . . . . . . . . . . . . .
Radiator Cap Opening Pressure
Check 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Replacement 10 . . . . . . . . . . . . . . . . .
Concentration Measurement 11 . . . . . . . . . . . . . . . . . .
Fan Controller Check 12 . . . . . . . . . . . . . . . . . . . . . . . .
Fan Control Relay Continuity Check 12 . . . . . . . . . .
THERMOSTAT 13 . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP
<4G6> 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
<6A1> 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
<4D6> 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER HOSE AND WATER PIPE 19 . . . . . . . .
RADIATOR 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLING -
General Information/
Service Specifications/Lubricant/Sealants
14-2
The cooling systemis designed to keep every part
of the engine at appropriate temperature in
whatever condition the engine may be operated.
Thecoolingmethodis of thewater-cooled, pressure
forced circulation type in which the water pump
pressurizes coolant and circulates it throughout the
engine. If the coolant temperature exceeds the
prescribed temperature, the thermostat opens to
circulate the coolant through the radiator as well
so that the heat absorbed by the coolant may be
radiated into the air.
The water pump is of the centrifugal type and is
driven by the timing belt or drive belt from the
crankshaft.
The radiator is the corrugated fin, down flow type
and is cooled by the electrical radiator fan.
The cooling fans are controlled by a fan controller
and the engine-ECU depending on driving
conditions.
Radiator Performance kJ /h 4G6 175,800
6A1 200,900
4D6 213,500
A/T oil cooler Performance kJ /h 4G6 5,700
6A1, 4D6 7,100
Radiator cap opening pressure kPa 74 - 103 64
Range of coolant antifreeze concentration of radiator % 30 - 60 -
Thermostat Valve opening temperature of thermostat _C 82 1.5 -
Full-opening temperature of thermostat _C 95 -
Valve lift (at 95_C) mm 8.5 or more -
LUBRICANT 14100040148
Items Quantity L
HIGH QUALITY ETHYLENE GLYCOL 4G6, 6A1 6
ANTIFREEZE COOLANT
4D6 8
Items Specified sealant Remarks
Cylinder block drain plug 3MNut Locking Part No. 4171 or equivalent Drying sealant
Water pump <6A1>,
Thermostat case assembly <4G6, 4D6>,
Water outlet fitting <4D6>
Mitsubishi Genuine Parts No. MD970389 or
equivalent
Semi-drying sealant
ENGINE COOLING - Special Tool/Troubleshooting 14-3
A
B
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: probe
Measurement of terminal voltage
Trouble symptoms Inspection procedure
No.
Reference page
Radiator fan and condenser fan do not operate. <Vehicles with A/C>
Radiator fan does not operate. <Vehicles without A/C>
1 14-3
Radiator fan and condenser fan do not change speed or stop.
<Vehicles with A/C>
Radiator fan does not change speed or stop. <Vehicles without A/C>
2 14-6
Radiator fan does not operate. <Vehicles with A/C> 3 14-8
Condenser fan does not operate. <Vehicles with A/C> 4 14-8
Radiator fan and condenser fan do not operate.
<Vehicles with A/C>
Radiator fan does not operate. <Vehicles without A/C>
Probable cause
The cause could be a malfunction of the fan controller power supply or earth circuit.
The cause could also be a malfunction of the fan controller or the engine-ECU.
D Malfunction of fusible link
D Malfunction of fan control relay
D Malfunction of fan controller
D Malfunction of wiring harness or connector
ENGINE COOLING - Troubleshooting 14-4
<Vehicles with A/C>
OK
1. NG
Check the harness wire between fan control relay and fusible link
(4), and repair if necessary.
2. NG
3. NG
Check the harness wire between fan control relay and body earth,
OK
NG
Repair
OK NG
Replace
Check the automatic compressor-ECU <manual air conditioner>
or A/C-ECU <automatic air conditioner>, and repair if necessary.
YES NO
Engine-ECU terminal voltage check (Refer to GROUP 13A - Trou-
bleshooting.)
Replace the radiator fan motor and fan controller assembly.
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
OK
Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3.
<Except 4D6>
D Pull out the terminal No.21 to disconnect it (Ignition switch: ON)
OK: The radiator fan motor and condenser fan motor operate.
<4D6>
bleshooting.)
OK
<Except 4D6>
D Voltage between 21 and body earth
(Engine: idling, A/C switch: ON)
OK: 0.7 V or more (When A/C compressor is operating)
<4D6>
(Engine: idling, A/C switch: ON)
NG
Check the harness wire between fan controller and engine-ECU.
OK
1. NG
Check the harness wire between fan controller and fan control
relay, and repair if necessary.
2. NG
Check the harness wire between fan controller and body earth,
Measure at the fan controller connector A-22.
D Disconnect the connector, and measure at the harness side
connector.
1. Voltage between 3 and body earth (Ignition switch: ON)
OK: Battery voltage
2. Continuity between 1 and body earth
OK: Continuity
Measure at the fan control relay connector B-20X.
D Remove the relay, and measure at the harness side connector.
1. Voltage between 4 and body earth
OK: Battery voltage
OK: Battery voltage
OK: Continuity
D Fusible links (4) and (7) check
D Fan control relay check (Refer to P.14-12.)
NG
Replace
<Vehicles without A/C>
OK
1. NG
2. NG
3. NG
Check the harness wire between fan control relay and body earth,
OK
1. NG
Check the harness wire between fan controller and fan control
2. NG
Check the harness wire between fan controller and body earth,
OK NG
Repair
bleshooting.)
YES NO
bleshooting.)
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
OK
<Except 4D6>
OK: The radiator fan motor operates.
<4D6>
OK
<Except 4D6>
D Voltage between 21 and body earth (Engine: idling)
OK: 0.7 V or more (When radiator fan is operating)
<4D6>
D Voltage between 18 and body earth (Engine: idling)
NG
Measure at the fan controller connector A-22.
connector.
OK: Battery voltage
OK: Continuity
Measure at the fan control relay connector B-20X.
D Remove the relay, and measure at the harness side connector.
1. Voltage between 4 and body earth
OK: Battery voltage
OK: Battery voltage
OK: Continuity
D Fusible links (4) and (7) check
D Fan control relay check (Refer to P.14-12.)
NG
Replace
Radiator fan and condenser fan do not change speed or
stop. <Vehicles with A/C>
Radiator fan does not change speed or stop.
Probable cause
Thefancontroller carries out step-freecontrol of the radiator fan motor and thecondenser
fan motor speeds using signals transmitted from the engine-ECU.
D Malfunction of fan control relay
<Vehicles with A/C>
OK
NG
Repair
OK
NG
Replace
Check the automatic compressor-ECU <manual air conditioner>
or A/C-ECU <automatic air conditioner>, and repair if necessary.
YES NO
bleshooting.)
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
OK
<Except 4D6>
D Connect the terminal No.21 to the body earth (Ignition switch: ON)
OK: The radiator fan motor and condenser fan motor stop.
<4D6>
OK: The radiator fan motor and condenser fan motor stop.
OK
Fan controller check (Refer to P.14-12.)
NG
bleshooting.)
OK
<Except 4D6>
(Engine: idling, engine coolant temperature: 80_C or less)
OK: 0 - 0.3 V (Engine: idling, A/C switch: ON)
<4D6>
OK: 0 - 0.3 V (Engine: idling, A/C switch: ON)
NG
OK
D Check the harness wire between fan control relay and fusible
link (7).
D Check the harness wire between fan control relay and body
earth.
D Check the harness wire between fan control relay and fan
controller.
NG
Repair
Fan control relay check (Refer to P.14-12.)
NG
Replace
OK NG
Repair
bleshooting.)
YES NO
bleshooting.)
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
OK
<Except 4D6>
OK: The radiator fan motor stops.
<4D6>
OK: The radiator fan motor stops.
OK
Fan controller check (Refer to P.14-12.)
NG
OK
<Except 4D6>
OK: 0 - 0.3 V (Engine: idling)
<4D6>
OK: 0 - 0.3 V (Engine: idling)
NG
OK
D Check the harness wire between fan control relay and fusible
link (7).
D Check the harness wire between fan control relay and body
earth.
D Check the harness wire between fan control relay and fan
controller.
NG
Repair
Fan control relay check (Refer to P.14-12.)
NG
Replace
Radiator fan does not operate. <Vehicles with A/C> Probable cause
The cause could be a malfunction of the radiator fan motor or an open circuit between
the fan controller and the radiator fan motor.
D Malfunction of radiator fan motor
D Open circuit between fan controller and radiator fan
motor
Condenser fan does not operate. <Vehicles with A/C> Probable cause
The cause could be a malfunction of the condenser fan motor or of the fan controller. D Malfunction of condenser fan motor
OK
Replace the radiator fan motor and fan
controller assembly.
OK
NG
Replace the condenser fan motor.
Condenser fan motor check (Refer to
GROUP 55.)
NG
Condenser fan motor connector
NG
Repair
ENGINE COOLING - On-vehicle Service 14-9
ENGINE COOLANT LEAK CHECKING
1. Confirm that the coolant level is up to the filler neck.
Install a radiator cap tester and apply 160 kPa pressure,
and then check for leakage from the radiator hose or
connections.
Caution
(1) Be sure to completely clean away any moisture
from the places checked.
(2) When the tester is taken out, be careful not to
spill any coolant from it.
(3) Be careful, wheninstallingandremovingthe tester
and when testing, not to deform the filler neck
of the radiator.
2. If there is leakage, repair or replace the appropriate part.
RADIATOR CAP OPENING PRESSURE CHECK
14100130159
1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge
stops moving.
Limit: 64 kPa
Standard value: 74 - 103 kPa
3. Replace the radiator cap if the reading does not remain
at or above the limit.
NOTE
Be sure that the cap is clean before testing, since rust
or other foreign material on the cap seal will cause an
improper indication.
Cap adapter
Adapter
Cap adapter
ENGINE COOLANT REPLACEMENT 14100120231
1. Drain the engine coolant by removing the drain plug and
then the radiator cap.
2. Remove the drain plug from the cylinder block to drain
the engine coolant.
Cylinder block drain plug
<4G6> <4D6>
<6A1> Front bank
<6A1> Rear bank
3. Remove the reserve tank to drain the engine coolant.
4. When the engine coolant has drained, pour in water from
the radiator cap to clean the engine coolant line.
5. Coat the thread of the cylinder block drain plug with the
specified sealant and tighten to the specified torque.
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent
6. Securely tighten the radiator drain plug.
7. Install the reserve tank.
39 Nm
<6A1> <4G6, 4D6>
44 Nm
8. Remove the air bleed bolt and replace the seal washer.
9. Fill the radiator until the engine coolant flows from the
air bleed bolt section, and then close the air bleed bolt.
10. Slowly pour the engine coolant into the mouth of the
radiator until the radiator is full, and pour also into the
reserve tank up to the FULL line.
Recommended antifreeze:
HIGH QUALITY ETHYLENE GLYCOL ANTIFREEZE
COOLANT
Quantity:
<4G6, 6A1> 6 L
<4D6> 8 L
NOTE
For Norway, the non-amine type of antifreeze should be
used.
11. Install the radiator cap securely.
12. Start the engine and warm the engine until the thermostat
opens. (Touch the radiator hose with your hand to check
that warm water is flowing.)
13. After the thermostat opens, race the engine several times,
and then stop the engine.
14. Cool down the engine, and then pour engine coolant
into the reserve tank until the level reaches the FULL
line. If the level is low, repeat the operation from step
11.
CONCENTRATION MEASUREMENT 14100110146
Measure the temperature and specific gravity of the engine
coolant to check the antifreeze concentration.
Standard value: 30 - 60 %(allowable concentration range)
RECOMMENDED ANTIFREEZE
Antifreeze Allowable concentration
HIGH QUALITY ETHYLENE
GLYCOL ANTIFREEZE COOLANT
30 - 60 %
Caution
If the concentration of the antifreeze is below 30 %, the
anti-corrosion property will be adversely affected. In
addition, if the concentration is above 60 %, both the
anti-freezing and engine cooling properties will decrease,
affecting the engine adversely. For these reasons, be
sure to maintain the concentration level within the
specified range.
Water outlet
fitting
Air bleed bolt
12- 15 Nm
Seal washer
<6A1>
FAN CONTROLLER CHECK 14100610011
1. Remove the fan controller mounting bolt, and then
disconnect the condenser fan motor connector.
2. Start the engine and run it at idle.
3. Turn the A/C switch to ON and maintain the coolant
temperature at 80_C or less.
4. When measuring the voltage between the fan
controller-side connector terminals, check that the value
changes repeatedly as indicated by (1) - (3) below.
(1) 0 V
(2) <4G6> 8.2 2.6 V
<Except 4G6> 6.8 2.6 V
(3) Battery voltage 2.6 V
5. If the voltage does not repeatedly change as indicated,
replace the radiator fan motor and the fan controller
assembly.
FAN CONTROL RELAY CONTINUITY CHECK
14100620014
1 2 3 4
When current is not
supplied
When current is
supplied
Fan controller
- +
Fan control relay
ENGINE COOLING - Thermostat 14-13
THERMOSTAT 14100240265
D Engine Coolant Draining and Supplying
(Refer to P.14-10.)
D Air Cleaner and Air Intake Hose Assembly Removal
and Installation
D Air Hose and Air Pipe Assembly Removal and
Installation <4D6> (Refer to P.14-21.)
17 - 20 Nm
<4G6>
<6A1>
<4D6>
13 Nm
12 - 15 Nm
12 - 15 Nm
13 Nm
1
2
3
4
5
6
7
4
4
7
6
3
3
6
7
Removal steps
1. Heater hose connection <4D6>
2. Water hose connection <4D6>
AA" "BA 3. Radiator lower hose connection
4. Control wiring harness mounting
bolt
5. Fuel pipe mounting bolt <4D6>
6. Water inlet fitting
"AA 7. Thermostat
ENGINE COOLING - Thermostat 14-14
AA"RADIATOR LOWER HOSE DISCONNECTION
"AATHERMOSTAT INSTALLATION
Install the thermostat so that the jiggle valve is facing straight
up.
Caution
Make absolutely sure that no oil is adhering to the rubber
ring of the thermostat. In addition, be careful not to fold
over or scratch the rubber ring when inserting. If the
rubber ring is damaged, replace the thermostat.
"BARADIATOR LOWER HOSE CONNECTION
inlet fitting.
THERMOSTAT CHECK
1. Immerse the thermostat in water, and heat the water while
stirring. Check the thermostat valve opening temperature.
Standard value:
Valve opening temperature: 821.5_C
2. Check that the amount of valve lift is at the standard
value when the water is at the full-opening temperature.
Standard value:
Full-opening temperature: 95_C
Amount of valve lift: 8.5 mm or more
NOTE
Measure the valve height when the thermostat is fully
closed, and use this measurement to calculate the valve
height when the thermostat is fully open.
Jiggle valve
Rubber ring
Valve lift
ENGINE COOLING - Water Pump <4G6> 14-15
WATER PUMP <4G6> 14100270363
(Refer to P.14-10.)
D Timing Belt Tensioner Pulley Removal and
Installation (Refer to GROUP 11.)
12 - 15 Nm
24 Nm
8 60 8 22
8 14
20 - 25 Nm
Bolt specifications
8 25
8 22
Screw diameter length mm
1
2
4
3
2
Removal steps
1. Alternator brace
2. Water pump
3. Water pump gasket
"AA 4. O-ring
"AAO-RING INSTALLATION
Insert the O-ring to the water inlet pipe assembly, and coat
the outer circumference of the O-ring with water or engine
coolant.
Caution
Do not allow engine oil or other greases to adhere to
the O-ring
Water pump
O-ring
Water inlet pipe assembly
ENGINE COOLING - Water Pump <6A1> 14-16
WATER PUMP <6A1> 14100270370
(Refer to P.14-10.)
D Power Steering Fluid Draining and Supplying
D Radiator Removal and Installation (Refer to P.14-24.)
D A/C Compressor Removal and Installation
D Engine Mount Bracket Removal and Installation(Refer
to GROUP 32.)
24 Nm
8 30
8 25
Bolt specifications
8 25
Screw diameter length mm
49 Nm
12 Nm
18 Nm
39 Nm
39 Nm
Sealant:
Mitsubishi Genuine Part No.
8 20
8 30
8 25
8 30
1
2
3
4
5
5
5
f3mm
Removal steps
1. Pressure tube connection
3. Power steering oil pump bracket
4. Engine support bracket
"AA 5. Water pump
ENGINE COOLING - Water Pump <6A1> 14-17
AA"POWER STEERING OIL PUMP ASSEMBLY
REMOVAL
Remove the power steering oil pump assembly with the hoses
still attached.
NOTE
Secure the removed oil pump with rope, etc. in a place where
it will not be in the way when removing and installing the
power steering oil pump bracket.
"AAWATER PUMP INSTALLATION
Squeeze out the sealant from the tube evenly and apply
it so that there is not too much sealant and no places without
sealant.
Specified Sealant:
Mitsubishi Genuine Part No. MD970389 or equivalent
ENGINE COOLING - Water Pump <4D6> 14-18
WATER PUMP <4D6> 14100270387
(Refer to P.14-10.)
D Timing Belt Idler Pulley Removal and Installation
12 - 15 Nm
24 Nm
8 20
8 22
Bolt specifications
8 65
8 22
Screwdiameter length mm
1
2
4
3
8 25
24 Nm
Removal steps
1. Alternator brace
2. Water pump
3. Water pump gasket
"AA 4. O-ring
Insert the O-ring to the water inlet pipe assembly, and coat
the outer circumference of the O-ring with water or engine
coolant.
Caution
the O-ring
Water pump
O-ring
Water inlet pipe assembly
ENGINE COOLING - Water Hose and Water Pipe 14-19
WATER HOSE AND WATER PIPE 14100330306
<4G6>
D Engine Coolant Draining and Suppling
(Refer to P.14-10.)
and Installation
24 Nm
12
7
8
13 Nm
6
1
5
2
11
3
4
10
9
13 Nm
7
Sealant:
Mitsubishi Genuine Part No.
f3mm
Removal steps
AA" "CA 1. Radiator lower hose connection
bolt
unit connector
5. Water hose
"BA 7. Thermostat case assembly
"AA 8. O-ring
10. Water hose
11. Water inlet pipe assembly
"AA 12. O-ring
<6A1>
(Refer to P.14-10.)
and Installation
D Distributor Removal and Installation
10 - 12 Nm
22 - 25 Nm
27 - 33 Nm
22 Nm
39 Nm
12 - 15 Nm
22 - 25 Nm
12 - 15 Nm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Removal steps
bolt
2. Spark plug cable clamp mounting
bolt
AA" "CA 3. Radiator upper hose connection
connector
unit connector
7. Water hose
8. Water hose
10. Heater pipe assembly
"AA 11. O-ring
12. Water hose
13. Thermostat case assembly
"AA 14. O-ring
"AA 16. O-ring
17. Water hose
18. Water pipe assembly
19. Water pipe joint
<4D6>
Pre-removal operation
D Engine Coolant Draining (Refer to P.14-10.)
D Engine Coolant Supplying (Refer to P.14-10.)
D Engine Oil Supplying and Checking (Refer to
D Air Cleaner and Air Intake hose Assembly
Installation
45 Nm
12 - 15 Nm
10 - 12 Nm
12 - 15 Nm
20 - 25 Nm
1
2
3
4
5
6
7
8
9
10
11
12
13
10 - 13 Nm
12 - 15 Nm
12 - 15 Nm
10 - 12 Nm
6 Nm
17 Nm
9 Nm
17 Nm
6 Nm
7
Removal steps
1. Air hose and air pipe assembly
AA" "CA 2. Radiator upper hose connection
5. Turbocharger heat protector
6. Oil return hose and pipe assembly
8. Air pipe bracket stay
9. Oil pipe assembly
10. Oil pipe assembly
11. Vacuum pump assembly
bolt
13. Fuel pipe mounting bolt
27 - 33 Nm
13 Nm
10 Nm
13 Nm
24 Nm
24 Nm
27 - 33 Nm
14
15
16
17
18
19
10 Nm
20
21
22
23
24
Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent
18
17
f3mm
f3mm
14. Water pipe assembly (A)
15. Water hose
"BA 17. Thermostat case assembly
"BA 18. Water outlet fitting
"AA 19. O-ring
21. Water hose
22. Water pipe assembly (B)
"AA 24. O-ring
HOSE DISCONNECTION
Insert the O-ring to the water inlet pipe assembly or the heater
pipe assembly and coat the outer circumference of the O-ring
with water or engine coolant.
Caution
the O-ring
"BAWATER OUTLET FITTING/THERMOSTAT CASE
ASSEMBLY INSTALLATION
Squeeze out the sealant from the tube evenly and apply
it so that there is not too much sealant and no places without
sealant.
Specified Sealant:
Mitsubishi Genuine Parts No. MD970389 or equivalent
"CARADIATOR LOWER HOSE/RADIATOR UPPER
HOSE CONNECTION
inlet fitting or water outlet fitting.
WATER PIPE AND HOSE CHECK
Check the water pipe and hose for cracks, damage, clog
and replace them if necessary.
Thermostat case assembly,
water pump or cylinder block
O-ring
Water inlet pipe assembly or
heater pipe assembly
ENGINE COOLING - Radiator 14-24
RADIATOR 14100150285
Pre-removal operation
D Engine Coolant Draining (Refer to P.14-10.)
D Engine Coolant Supplying (Refer to P.14-10.)
D A/TFluid Supplying and Checking (Refer toGROUP
D Air Cleaner and Air Intake Hose Assembly
Installation
12 Nm
12 Nm
12 Nm
5 Nm
5 Nm
5 Nm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
13
11
Radiator removal steps
1. Drain plug
2. Radiator cap
3. Overflow hose
4. Reserve tank
5. Reserve tank bracket
AA" "AA 6. Radiator upper hose
AA" "AA 7. Radiator lower hose
8. Clamp <6A1 - A/T>
AB" 9. Transmission fluid cooler hose con-
nection <A/T>
10. Engine oil cooler hose mounting
bolt <4D6>
11. Upper insulator
12. Radiator assembly
13. Lower insulator
14. Bolt <A/T>
AB" 15. Transmission fluid cooler hose and
pipe assembly <A/T>
16. Condenser fan motor assembly
<Vehicle with A/C>
17. Radiator fan motor assembly
Radiator fan motor and fan
controller assembly removal steps
AA" "AA 6. Radiator upper hose
8. Clamp <6A1 - A/T>
14. Bolt <A/T>
17. Radiator fan motor assembly
18. Fan
19. Radiator fan motor and fan control-
ler assembly
20. Shroud
ENGINE COOLING - Radiator 14-25
HOSE DISCONNECTION
AB"TRANSMISSION FLUID COOLER HOSE AND PIPE
ASSEMBLY REMOVAL
After disconnecting the hoses from the radiator and the
transmission, plug all of the pipes and hoses to prevent dirt
and other foreign objects from getting inside.
"AARADIATOR LOWERHOSE/RADIATOR UPPER HOSE
CONNECTION
inlet fitting.
NOTES
15-1
INTAKE AND
EXHAUST
SERVICE SPECIFICATION 2 . . . . . . . . . . . . . . . . . .
SPECIAL TOOL 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turbocharger Supercharging Check 3 . . . . . . . . . . . .
Waste Gate Actuator Check 3 . . . . . . . . . . . . . . . . . .
INTERCOOLER 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR INTAKE PLENUM 6 . . . . . . . . . . . . . . . . . . . . . .
INTAKE MANIFOLD 8 . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD 13 . . . . . . . . . . . . . . . . . . . .
TURBOCHARGER 16 . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE AND MAIN MUFFLER 22 . . . .
INTAKE AND EXHAUST -
Service Specifications/Special Tool
15-2
The intake manifold is made of an aluminiumalloy,
and the shape provides an increased intake inertia
effect and has a good volumetric efficiency.
The exhaust manifold is made of stainless steel.
The exhaust pipe is divided into three parts; the
front pipe, the centre pipe, and the main muffler.
Manifold distortion of the installation surface mm 0.15 or less 0.20
Waste gate actuator activation pressure kPa Approx. 75 -
Air temperature switch _C OFF ON 57 or more -
<Vehicles with intercooler
turbocharger>
ON OFF 45 or less -
MD998770 Oxygen sensor
wrench
Removal/Installation of oxygen sensor
INTAKE AND EXHAUST - On-vehicle Service 15-3
TURBOCHARGER SUPERCHARGING CHECK
<4D6>
Caution
Conduct the driving test in a location where driving at
full acceleration can be done with safety. Two persons
should be in the vehicle when the test is conducted; the
person in the passenger seat should read the indications
shown by the pressure meter.
1. Connect the pressure gauge to the hose between the
turbochager and the waste gate actuator.
2. Drive at full-throttle acceleration in second gear and then
measure the supercharging when the engine speed in
about 3,000 r/min.
3. When the indicated supercharging does not become
positive pressure, check the following items.
D Malfunction of the waste gate actuator.
D Leakage of supercharging pressure.
D Malfunction of the turbocharger.
4. When the indicated supercharging is 76 kPa or more,
supercharging control may be faulty, therefore check the
followings.
D Disconnection or cracks of the waste gate actuator
rubber hose.
D Malfunction of the waste gate actuator.
D Malfunction of the waste gate valve.
WASTE GATE ACTUATOR CHECK <4D6>
15100120054
1. Connect a manual pump (pressure-application type) to
nipple A.
2. While gradually applying pressure, check the pressure
that begins to activate (approx. 1 mm stroke) the waste
gate actuator rod.
Standard value: Approx. 75 kPa
Caution
In order to avoid damage to the diaphragm, do not
apply a pressure of 109 kPa or higher.
3. If there is a significant deviation from the standard value,
check the actuator or the waste gate valve: replace if
necessary.
INTAKE AND EXHAUST - Intercooler 15-4
INTERCOOLER 15100420055
Hose clamp tightening
torque
Pipe installation bolt
tightening torque
6 Nm
10 - 13 Nm
10 - 13 Nm
1
2
3
4
5
6
7
8
9
10
11
10 - 13 Nm
Air hose and air pipe removal
steps
"AA 1. Air hose E
"AA 2. Air hose B
"BA 3. Air hose F
"AA 4. Air hose A
5. Air pipe A
"AA 6. Air hose C
"AA 7. Air hose C
8. Air pipe B
9. Air pipe C
Intercooler assembly removal steps
"AA 6. Air hose C
"AA 7. Air hose C
10. Intercooler duct
11. Intercooler assembly
INTAKE AND EXHAUST - Intercooler 15-5
"AAAIR HOSE C/AIR HOSE A/AIR HOSE B/AIR
HOSE E INSTALLATION
Align the alignment mark (white paint) on each hose with
the protrusion on each pipe.
"BAAIR HOSE F INSTALLATION
Install the hose with its marking (white paint) upward.
INTAKE AND EXHAUST - Air Intake Plenum 15-6
AIR INTAKE PLENUM 15100270124
D Throttle Body Removal (Refer to GROUP 13A.)
D Throttle Body Installation (Refer to GROUP 13A.)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
3 Nm
18 Nm
19 Nm
10 - 12 Nm
9 Nm
14 Nm
9 Nm
4
18 Nm
15
Removal steps
1. Engine cover
2. Crankshaft position sensor connector
6. Brake booster vacuum hose connec-
tion
9. Noise condenser mounting bolt
10. EGR valve
11. Solenoid valve assembly
13. Air intake plenum
"AA 14. Air intake plenum gasket
15. Air intake plenum stay
INTAKE AND EXHAUST - Air Intake Plenum 15-7
"AAAIR INTAKE PLENUM GASKET INSTALLATION
Install with gasket protrusions in the position illustrated.
Front Protrusion
INTAKE AND EXHAUST - Intake Manifold 15-8
INTAKE MANIFOLD 15100300441
<4G6>
D Throttle Body Removal (Refer to GROUP 13A.)
D Throttle Body Installation (Refer to GROUP 13A.)
D Accelerator Cable Ajdustment
1
2
3
4
5
Removal steps
1. Accelerator cable
connection
connector
6
7
8
9
10
11
12
13
14
31 Nm
20 Nm
10 - 13 Nm
9 Nm
20 Nm
10 - 12 Nm
20 Nm
6. EGR valve
7. PCV hose
AA" 9. Delivery pipe, injector and pressure
regulator
11. Solenoid valve assembly
12. Intake manifold
13. Intake manifold gasket
14. Intake manifold stay
<6A1>
D Fuel Discharge Prevention
D Air Intake Plenum Removal (Refer to P.15-6.)
Post-Installation Operation
D Air Intake Plenum Installation (Refer to P.15-6.)
1
2
3
4
5
6
7
8
9
35 Nm
18 Nm
12 Nm
O-ring
Engine oil
3
18 Nm
5
Removal steps
"BA 3. Fuel high-pressure hose connection
AA" 5. Delivery pipe, injector and pressure
regulator
8. Intake manifold
"AA 9. Intake manifold gasket
<4D6>
(Refer to P.15-4.)
1
2
3
4
5
6
7
8
9
10
10 - 12 Nm
12 - 15 Nm
18 Nm
25 Nm
18 Nm
18 Nm
18 Nm
12 - 15 Nm
Removal steps
1. Air inlet fitting
3. Vacuum hose
4. Throttle body assembly
5. EGR valve and pipe assembly
7. Rear heat protector
8. Vacuum hose
9. Intake manifold
D Turbocharger (Refer to P.15-6.)
10. Intake and exhaust manifold gasket
AA"DELIVERY PIPE, INJECTOR AND PRESSURE
REGULATOR REMOVAL
Remove the delivery pipe (with the injectors and pressure
regulator attached to it).
Caution
"AAINTAKE MANIFOLD GASKET INSTALLATION
Install gasket with its protrusion in the position illustrated.
"BAHIGH-PRESSURE FUEL HOSE INSTALLATION
1. When connecting the high-pressure fuel hose to the
delivery pipe, apply a small amount of new engine oil
to the O-ring and then insert the high-pressure fuel hose,
being careful not to damage the O-ring.
Caution
Be careful not to let any engine oil get into the delivery
pipe.
2. While turning the high-pressure fuel hose to the left and
right, install it to the delivery pipe.
3. Check to be sure that the injector turns smoothly.
If it does not turn smoothly, the O-ring may be trapped,
remove the high-pressure fuel hose and then re-insert
Check the following points; replace the part if a problem is
found.
INTAKE MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum)
outlet port, and for obstruction of the water passage or
gas passage.
3. Using a straight edge and thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
Front
Protrusion
Protrusion
Delivery pipe
O-ring
INTAKE AND EXHAUST - Exhaust Manifold 15-13
EXHAUST MANIFOLD 15100330440
D Front Exhaust Pipe Removal and Installation
(Refer to P.15-22.)
29 Nm
2
49 Nm
1
3
49 Nm
12 - 15 Nm
<4G6>
Removal steps
1. Exhaust manifold cover
2. Exhaust manifold
3. Exhaust manifold gasket
<6A1>
12 - 15 Nm
49 Nm
44 Nm
1
2
3
4
12 - 15 Nm
2
34 Nm
49 Nm
12 - 15 Nm
1
3
4
Removal steps
1. Heat protector
2. Exhaust manifold stay
3. Exhaust manifold
4. Exhaust manifold gasket
<4D6>
14 Nm
29 Nm
4
2
1
3
29 Nm
Removal steps
1. Front heat protector
2. Engine hanger
3. Exhaust manifold
D Turbocharger (Refer to P.15-16.)
4. Intake and exhaust manifold gasket
EXHAUST MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Using a straight edge and thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
INTAKE AND EXHAUST - Turbocharger 15-16
TURBOCHARGER 15100450047
D Engine Oil Draining and Supplying
D Intake Manifold Removal and Installation (Refer to
P.15-8.)
D Front Exhaust Pipe and Front Heat Protector Removal
and Installation (Refer to P.15-15, 23.)
12 - 15 Nm
12 - 15 Nm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
10 Nm
18 Nm
10 - 12 Nm
27 - 33 Nm
59 Nm
12 - 15 Nm
6 Nm
17 Nm
12 - 15 Nm
25 Nm
59 Nm
59 Nm
27 - 33 Nm
10 Nm
9 Nm
Removal steps
1. Air hose A
2. EGR valve and pipe assembly
AA" 4. Oil pipe assembly A
AA" 5. Oil pipe assembly B
6. Water pipe assembly A
7. Water pipe assembly B
AA" 8. Oil return pipe
9. Rear heat protector
10. Exhaust fitting heat protector
11. Turbocharger assembly
12. Exhaust fitting assembly
13. Exhaust fitting gasket
"AA 14. Turbocharger
15. Turbocharger gasket
AA"OIL PIPE ASSEMBLY A/OIL PIPE ASSEMBLY
B/OIL RETURN PIPE REMOVAL
Caution
After disconnecting the oil pipe, take care that foreign
material does not enter the oil passage hole of the
turbocharger assembly.
"AATURBOCHARGER INSTALLATION
1. Clean the alignment surfaces shown in the illustration.
Caution
When cleaning, take care that no foreign material gets
into the engine coolant or oil passages hole.
2. Supply clean engine oil through the oil pipe installation
hole of the turbocharger.
TURBOCHARGER ASSEMBLY CHECK
D Visually check the turbine wheel and the compressor
wheel for cracking or other damage.
D Check whether the turbine wheel and the compressor
wheel can be easily turned by hand.
D Check for oil leakage from the turbocharger assembly.
D Check whether or not the waste gate valve remains open.
If any problemis found, replace the part after disassembly.
OIL PIPE ASSEMBLY AND OIL-RETURN PIPE CHECK
Check the oil pipe assembly and oil-return for clogging,
bending, or other damage. If there is clogging, clean it.
Compressor
wheel
DISASSEMBLY AND REASSEMBLY
1
2
3
4
5
6
7
8
9
10
Disassembly steps
1. Hose clip
2. Hose
3. Snap ring (E-ring)
"FA 4. Turbocharger waste gate actuator
"EA 5. Coupling
"DA 6. Turbine housing
AA" "CA 7. Snap ring
AB" "BA 8. Turbine wheel assembly
9. Compressor cover
"AA 10. O-ring
DISASSEMBLY SERVICE POINTS
AA"SNAP RING REMOVAL
Lay the unit with the compressor cover side facing down
and using snap ring pliers, remove the compressor cover
attaching snap ring.
Caution
When removing the snap ring, hold it with fingers to
prevent it from springing away.
Snap ring
AB"TURBINE WHEEL ASSEMBLY REMOVAL
Remove the turbine wheel assembly, striking the
circumference of the compressor cover with a plastic hammer.
The turbine wheel assembly may be a little hard to remove
due to an O-ring put on the outer circumference.
CLEANING
1. Use a clean cleaning oil commercially available. Do not
use corrosive cleaning oils as they could damage to some
parts.
2. Use a plastic scraper or hard brush to clean aluminum
parts.
Apply a light coat of engine oil to a new O-ring and fit in
the turbine wheel assembly groove.
Caution
When installing the O-ring, use care not to damage it.
A damaged O-ring causes oil leaks.
"BATURBINE WHEEL ASSEMBLY
1. Apply a light coat of engine oil to the periphery of the
O-ring.
2. Install the turbine wheel assembly to the compressor cover
while aligning the dowel pin with the hole.
Caution
Use care not to damage the blades of turbine wheel
and compressor wheel.
"CASNAP RING INSTALLATION
Lay the assembly with the compressor cover facing down
and fit the snap ring.
Caution
Fit the snap ring with its chamfered side facing up.
Turbine
wheel
assembly
O-ring
Dowel pin hole
Dowel pin
Compressor
cover
Turbine wheel
assembly
Chamfered
edge Snap ring
"DATURBINE HOUSING INSTALLATION
Install the turbine housing while aligning the dowel pin with
the hole.
Caution
Use care not to damage the blades of turbine wheel.
"EACOUPLING INSTALLATION
Install the coupling and tighten to the specified torque.
"FA TURBOCHARGER WASTE GATE ACTUATOR
OPERATION INSPECTION
Using a tester, apply pressure to the actuator and check
the pressure when the rod starts moving (moves approx.
1 mm).
Standard value: Approx. 75 kPa
Caution
Do not apply a pressure of more than 109 kPa to the
actuator.
Otherwise, diaphragm may be damaged.
Never attempt to adjust the turbocharger waste gate valve.
TURBINE HOUSING
1. Check the housing for traces of contact with the turbine
wheel, cracks due to overheating, pitching, deformation
and other damage. Replace with a new turbine housing
if cracked.
2. Operate the waste gate valve lever manually to check
that the gate can be operated and closed smoothly.
Dower pin
Dower pin hole
Coupling
Traces of contact
COMPRESSOR COVER
Check the compressor cover for traces of contact with the
compressor wheel and other damage.
TURBINE WHEEL ASSEMBLY
1. Check the turbine and compressor wheel blades for bend,
burr, damage, corrosion and traces of contact on the
back side and replace if defective.
2. Check the oil passage of the turbine wheel assembly
for deposit and clogging.
3. Check also the water passage for deposit and clogging.
4. Check the turbine wheel and compressor wheel for light
and smooth turning.
OIL PIPE/OIL RETURN PIPE
Correct or replace the oil pipe and oil return pipe if clogged,
collapsed, deformed or otherwise damaged.
Oil passage
Turbine wheel
Compressor
wheel
Water passage
INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler 15-22
EXHAUST PIPE AND MAIN MUFFLER 15100540355
<4G6>
Hanger installation
bolt tightening torque
1
2
3
4
5
6
8
9
10
11
12
13
14
15
16
17
18
34 Nm
49 - 59 Nm
44 Nm
34 Nm
49 Nm
13 Nm
49 Nm
49 - 59 Nm
7
10
13 Nm
34 Nm
13 Nm
13 Nm
3
3
3, 10, 17
Main muffler removal steps
1. Main muffler assembly
2. Gasket
3. Hanger
4. Tail hanger
5. Rear hanger
6. Rear floor heat protector panel
Center exhaust pipe removal steps
AA" "AA 7. Oxygen sensor
8. Center exhaust pipe
9. Gasket
10. Hanger
11. Center hanger
Catalytic converter removal steps
12. Catalytic converter
13. Gasket
Front exhaust pipe removal steps
15. Front exhaust pipe
16. Gasket
17. Hanger
18. Front exhaust pipe bracket
Hanger installation
bolt tightening torque
<6A1>
<4D6>
1
2
3
4
5
6
7
8
9
10
11
13
14
15
16
17
49 Nm
13 Nm
49 Nm
16
49 Nm
49 - 59 Nm
12
1
2
3
4
5
6
8
9
10
11
12
49 Nm
49 - 59 Nm
13 Nm
34 Nm
13 Nm
10
3
3
13 Nm
3, 10, 17
49 Nm
17
16
15
49 Nm
13
49 Nm
10
34 Nm
13 Nm
3
3
13 Nm
13 Nm
Main muffler removal steps
1. Main muffler assembly
2. Gasket
3. Hanger
4. Tail hanger
5. Rear hanger
6. Rear floor heat protector panel
Center exhaust pipe removal steps
8. Center exhaust pipe
9. Gasket
10. Hanger
11. Center hanger
Catalytic converter removal steps
13. Gasket
Front exhaust pipe removal steps
16. Gasket
17. Hanger
AA"OXYGEN SENSOR REMOVAL
"AAOXYGEN SENSOR INSTALLATION
MD998770
16-1
ENGINE
ELECTRICAL
CHARGING SYSTEM 3 . . . . . . . . . . . . . . . .
SPECIAL TOOLS 5 . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 6 . . . . . . . . . . . . . . . . . .
Alternator Output Line Voltage Drop Test 6 . . . .
Output Current Test 8 . . . . . . . . . . . . . . . . . . . . . . .
Regulated Voltage Test 10 . . . . . . . . . . . . . . . . . . .
Waveform Check Using An Analyzer 12 . . . . . . .
Alternator Relay Continuity Check 13 . . . . . . . . .
ALTERNATOR 14 . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING SYSTEM 23 . . . . . . . . . . . . . . . .
GENERAL INFORMATION 23 . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 23 . . . . . . . . . . . .
Starter Relay Continuity Check <4D6> 24 . . . . .
STARTER MOTOR 24 . . . . . . . . . . . . . . . . . . . . .
IGNITION SYSTEM <4G6, 6A1> 35 . . . . .
SPECIAL TOOLS 37 . . . . . . . . . . . . . . . . . . . . . .
Power Transistor Continuity Check <4G6>
38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil Check <6A1> 38 . . . . . . . . . . . . . . . .
Power Transistor Continuity Check <6A1> 39 . .
Resistive Cord Check 39 . . . . . . . . . . . . . . . . . . . . .
Spark Plug Check and Cleaning <4G6> 39 . . . .
Spark Plug Check <6A1> 40 . . . . . . . . . . . . . . . . .
Camshaft Position Sensor Check <4G6> 40 . . .
Top Dead Center Sensor Check <6A1> 40 . . . .
Crank Angle Center Sensor Check 40 . . . . . . . .
Detonation Sensor Check 41 . . . . . . . . . . . . . . . . .
Waveform Check Using An Analyzer 41 . . . . . . .
16-2
DISTRIBUTOR <6A1> 52 . . . . . . . . . . . . . . . . . .
IGNITION COIL <4G6> 54 . . . . . . . . . . . . . . . . .
CAMSHAFT POSITION SENSOR <4G6>
54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANK ANGLE SENSOR 55 . . . . . . . . . . . . . .
DETONATION SENSOR 56 . . . . . . . . . . . . . . . .
GLOW SYSTEM <4D6> 57 . . . . . . . . . . . . .
Self-regulating Glow System Check 58 . . . . . . . .
Check at the Engine-ECU Terminals 59 . . . . . . .
Glow Plug Relay Check 60 . . . . . . . . . . . . . . . . . .
Glow Plug Check 60 . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor Check
60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GLOW PLUG 61 . . . . . . . . . . . . . . . . . . . . . . . . . .
INJECTION SYSTEM <4D6> 62 . . . . . . . .
CRANK ANGLE SENSOR 62 . . . . . . . . . . . . . .
ENGINE ELECTRICAL - Charging System 16-3
CHARGING SYSTEM 16100010341
GENERAL INFORMATION
The charging system uses the alternator output
to keep the battery charged at a constant level
under various electrical loads.
OPERATION
Rotation of the excited field coil generates AC voltage in
the stator.
This alternating current is rectified through diodes to DC
voltage having a waveform shown in the illustration at left.
The average output voltage fluctuates slightly with the
alternator load condition.
When the ignition switch is turned on, current flows
in the field coil and initial excitation of the field
coil occurs.
When the stator coil begins to generate power after
the engine is started, the field coil is excited by
the output current of the stator coil.
The alternator output voltage rises as the field
current increases and it falls as the field current
decreases. When the battery voltage (alternator
S terminal voltage) reaches a regulated voltage
of approx. 14.4 V, the field current is cut off. When
the battery voltage drops below the regulated
voltage, the voltage regulator regulates the output
voltage to a constant level by controlling the field
current.
In addition, when the field current is constant, the
alternator output voltage rises as the engine speed
increases.
Voltage
Time
Approx. 14.4 V
SYSTEM DIAGRAM
<4G6, 6A1>
Stator coil
Field coil
Voltage
regulator
Engine-ECU
Charging
warning lamp
Ignition
switch
Battery
B
G
L
FR
S
+
-
<4D6>
Stator coil
Field coil
Voltage
regulator
Charging
warning lamp Ignition
switch
Battery
+
-
ALTERNATOR SPECIFICATIONS
Items 4G6 6A1 4D6
Type Battery voltage sensing Battery voltage sensing Battery voltage sensing
Rated output V/A 12/90 12/85 <M/T>, 12/100 <A/T> 12/100 <Except cold climate zone>,
12/120 <Cold climate zone>
Voltage regulator Electronic built-in type Electronic built-in type Electronic built-in type
Alternator output line voltage drop (at 30A) V - max. 0.3
Regulated voltage ambient - 20_C 14.2- 15.4 -
temp. at voltage regulator V
20_C 13.9- 14.9 -
60_C 13.4- 14.6 -
80_C 13.1- 14.5 -
Output current - 70% of normal output current
MB991519 Alternator test
harness
Checking the alternator (S terminal voltage)
<4G6, 6A1>
MB991450 Alternator test
harness
Checking the alternator (S terminal voltage)
<4D6>
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST
Alternator
Terminal B
Voltmeter
Ammeter
Battery
+ -
+ -
This test determines whether the wiring from the
alternator B terminal to the battery (+) terminal
(including the fusible line) is in a good condition
or not.
(1) Always be sure to check the following before
the test.
D Alternator installation
D Alternator drive belt tension
D Fusible link
D Abnormal noise from the alternator while
the engine is running
(2) Turn the ignition switch off.
(3) Disconnect the negative battery cable.
(4) Disconnect the alternator output wire from the
alternator B terminal and connect a DC test
ammeter with a range of 0- 100 A in series
between the B terminal and the disconnected
output wire. (Connect the (+) lead of the
ammeter to the B terminal, and then connect
the ( - ) lead of the ammeter to the disconnected
output wire.)
NOTE
An inductive-type ammeter which enables
measurements to be taken without
disconnecting the alternator output wire should
be recommended. Using this equipment will
lessen the possibility of a voltage drop caused
by a loose B terminal connection.
(5) Connect a digital-type voltmeter between the
alternator B terminal and the battery (+)
terminal. (Connect the (+) lead of the voltmeter
to the B terminal and the connect the ( - ) lead
of the voltmeter to the battery (+) cable.)
(6) Reconnect the negative battery cable.
(7) Connect a tachometer or the MUT-II.
(8) Leave the hood open.
(9) Start the engine.
(10)With the engine running at 2,500 r/min, turn
the headlamps and other lamps on and off
to adjust the alternator load so that the value
displayed on the ammeter is slightly above 30
A.
Adjust the engine speed by gradually
decreasing it until the value displayed on the
ammeter is 30 A. Take a reading of the value
displayed on the voltmeter at this time.
Limit: max. 0.3 V
NOTE
When the alternator output is high and the value
displayed on the ammeter does not decrease
until 30 A, set the value to 40 A. Read the
value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is max.
0.4 V.
(11)If the value displayed on the voltmeter is above
the limit value, there is probably a malfunction
in the alternator output wire, so check the wiring
between the alternator B terminal and the
battery (+) terminal (including fusible link).
If a terminal is not sufficiently tight or if the
harness has become discolored due to
overheating, repair and then test again.
(12)After the test, run the engine at idle.
(13)Turn off all lamps and the ignition switch.
(14)Remove the tachometer or the MUT-II.
(15)Disconnect the negative battery cable.
(16)Disconnect the ammeter and voltmeter.
(17)Connect the alternator output wire to the
alternator B terminal.
(18)Connect the negative battery cable.
OUTPUT CURRENT TEST 16100100314
<4G6, 6A1>
Charging warning lamp
Voltmeter
Ammeter
Ignition switch
Alternator relay
Load
Battery
Engine
-ECU
Alternator
FR
L
S
G
+ - + -
B
<4D6>
Charging warning
lamp
Voltmeter
Alternator
Ignition
switch
Alternator relay
Load
Battery
Ammeter
+ - + -
L
S
B
This test determines whether the alternator output
current is normal.
(1) Before the test, always be sure to check the
following.
D Battery
NOTE
The battery should be slightly discharged.
The load needed by a fully-charged battery
is insufficient for an accurate test.
D Fusible link
the engine is running.
(2) Turn the ignition switch off.
alternator B terminal. Connect a DC test
ammeter with a range of 0- 100 A in series
between the B terminal and the disconnected
output wire. (Connect the (+) lead of the
ammeter to the B terminal. Connect the ( - )
lead of the ammeter to the disconnected output
wire.)
Caution
Never use clips but tighten bolts and nuts
to connect the line. Otherwise loose
connections (e.g. using clips) will lead to
a serious accident because of high current.
NOTE
An inductive-type ammeter which enables
measurements to be taken without
disconnecting the alternator output wire should
be recommended.
(5) Connect a voltmeter with a range of 0- 20 V
between the alternator B terminal and the
earth. (Connect the (+) lead of the voltmeter
to the B terminal, and then connect the ( - )
lead of the voltmeter to the earth.)
(6) Connect the negative battery cable.
(8) Leave the hood open.
(9) Check that the reading on the voltmeter is equal
to the battery voltage.
NOTE
If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator B terminal and the battery (+)
terminal.
(10)Turn the light switch on to turn on headlamps
and then start the engine.
(11)Immediately after setting the headlamps to high
beam and turning the heater blower switch to
the high revolution position, increase the engine
speed to 2,500 r/min and read the maximum
current output value displayed on the ammeter.
Limit: 70% of normal current output
NOTE
D For the nominal current output, refer to the
Alternator Specifications.
D Because the current from the battery will
soon drop after the engine is started, the
above step should be carried out as quickly
as possible in order to obtain the maximum
current output value.
D The current output value will depend on
the electrical load and the temperature of
the alternator body.
D If the electrical load is small while testing,
the specified level of current may not be
output even though the alternator is normal.
In such cases, increase the electrical load
by leaving the headlamps turned on for
some time to discharge the battery or by
using the lighting systemin another vehicle,
and then test again.
D The specified level of current also may not
be output if the temperatureof thealternator
body or the ambient temperature is too
high. In such cases, cool the alternator and
then test again.
(12)The reading on the ammeter should be above
the limit value. If the reading is below the limit
value and the alternator output wire is normal,
remove the alternator from the engine and
check the alternator.
(13)Run the engine at idle after the test.
(14)Turn the ignition switch off.
REGULATED VOLTAGE TEST 16100110317
<4G6, 6A1>
Ignition
switch
Charging warning
lamp
Load
Alternator
Alternator relay
Yellow
Engine-
ECU
Battery
Voltmeter
Ammeter
+ -
+ -
FR
L
S
G
MB991519
<4D6>
Ignition
switch
Charging warning
lamp
MB991450
Load
Alternator
Alternator relay
Yellow
Battery
Voltmeter
Ammeter
+ -
+ -
L
S
B
This test determines whether the voltage regulator
is correctly controlling the alternator output voltage.
(1) Always be sure to check the following before
the test.
D Check that the battery installed in the
vehicle is fully charged.
D Fusible link
the engine is running
(2) Turn the ignition switch to the OFF position.
(4) Use the special tool (Alternator test harness:
MB991519, MB991450) to connect a digital
voltmeter between the alternator S terminal and
earth. (Connect the (+) lead of the voltmeter
to the S terminal, and then connect the (-)
lead of the voltmeter to a secure earth or to
the battery (-) terminal.)
(6) Connect a DC test ammeter with a range of
0- 100 A in series between the B terminal
and the disconnected output wire. (Connect
the (+) lead of the ammeter to the B terminal.
Connect the ( - ) lead of the ammeter to the
disconnected output wire.)
(7) Reconnect the negative battery cable.
(9) Turn the ignition switch to the ON position and
check that the reading on the voltmeter is equal
to the battery voltage.
NOTE
If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator S terminal and the battery (+)
terminal.
(10)Turn all lamps and accessories off.
(11)Start the engine.
(12)Increase the engine speed to 2,500 r/min.
(13)Read the value displayed onthe voltmeter when
the alternator output current alternator
becomes 10 A or less.
(14)If the voltage reading conforms to the value
in the voltage regulation, then the voltage
regulator is operating normally.
If the voltage is not within the standard value,
there is a malfunction of the voltage regulator
or of the alternator.
(15)After the test, lower the engine speed to the
idle speed.
(16)Turn the ignition switch off.
(21)Remove the special tool, and return the
connector to the original condition.
Voltage Regulation Table
Standard value:
Inspection terminal Voltage regulator ambient temperature _C Voltage V
Terminal S - 20 14.2- 15.4
20 13.9- 14.9
60 13.4- 14.6
80 13.1- 14.5
WAVEFORM CHECK USING AN ANALYZER
16100120211
MEASUREMENT METHOD
Connect the analyzer special patterns pick-up to the alternator
B terminal.
STANDARD WAVEFORM
Observation Conditions
FUNCTION SPECIAL PATTERNS
PATTERN HEIGHT VARIABLE
VARIABLE knob Adjust while viewing the wave-
form.
PATTERN SELECTOR RASTER
Engine speed Curb idle speed
Voltage at
alternator
Bterminal
0.4
0.2
0
- 0.2
- 0.4
Time
NOTE
The voltage waveformof the alternator Bterminal can undulate
as shown at left. This waveformis produced when the regulator
operates according to fluctuations in the alternator load
(current), and is normal for the alternator.
In addition, when the voltage waveform reaches an
excessively high value (approx. 2 V or higher at idle), it often
indicates an open circuit due to a brown fuse between
alternator B terminal and battery, but not a defective alternator.
Alternator
Special
patterns
pickup
Analyzer
B terminal
EXAMPLES OF ABNORMAL WAVEFORMS
NOTE
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob
on the analyzer.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
Abnormal waveforms Problem
cause
Abnormal waveforms Problem
cause
Example 1 D Open
diode
Example 4 D Short in
stator coil
Example 2 D Short in
diode
Example 5 D Open
supple-
mentary
diode
Example 3 D Broken
wire in
stator coil
At this time, the charging warning lamp
is illuminated.
ALTERNATOR RELAY CONTINUITY CHECK
16100190045
1. Remove the alternator relay from the relay box inside
the engine compartment.
2. Set the analogue-type circuit tester to the W range and
check that there is continuity when the (+) terminal of
the tester is connected to terminal 2 of the alternator
relay and the ( - ) terminal is connected to terminal 4.
3. Next, check that there is nocontinuity whenthe (+) terminal
is connected to terminal 4 and the ( - ) terminal is connected
to terminal 2.
4. If the continuity checks in steps 2 and 3 show a defect,
replace the alternator relay.
Alternator
relay
1
2
3
4
ALTERNATOR 16100140286
<4G6>
D Under Cover Removal (R.H. side)
D Engine Mount Bracket Removal
D Engine Mount Bracket Installation
D Under Cover Installation (R.H. side)
D Drive Belt Tension Adjustment
12 Nm
5
44 Nm
20 - 25 Nm
7
3
4
9 Nm
1
2
6
8
24 Nm
12 Nm
1
12 Nm
Removal steps
1. Oil pressure hose and tube assembly
clamp bolt
2. Oil return tube assembly clamp bolt
AA" 3. Drive belt (Power steering, A/C)
7. Alternator
8. Alternator brace
<6A1>
Solenoid Valve Assembly Removal
(Refer to GROUP 15 - Air Intake Plenum.)
D Solenoid Valve Assembly Installation
(Refer to GROUP 15 - Air Intake Plenum.)
12 Nm
5
44 Nm
22 Nm
18 Nm
6
2
24 Nm
4
3
1
Removal steps
clamp bolt
4. Air intake plenum stay
5. Alternator brace
6. Alternator
<4D6>
D Under Cover Removal (R.H. side)
D Engine Mount Bracket Removal
D Engine Mount Bracket Installation
D Under Cover Installation (R.H. side)
(Refer to GROUP 11C On-vehicle Service.)
12 - 15 Nm
5
44 Nm
24 Nm
29 Nm
6
3
4
9
11
2
7
8
10
1
1
24 Nm
12 Nm
9 Nm
Removal steps
clamp bolt
2. Oil level gauge guide assembly
mounting bolt
AB" 3. Drive belt (Power steering)
AC" 4. Drive belt (A/C)
8. Alternator
9. Alternator brace
10. Engine hanger
11. Alternator brace stay
AA"DRIVE BELT (POWER STEERING, A/C)
REMOVAL
1. Loosen nut A for holding the tension pulley.
2. Loosen bolt B for adjustment.
3. Remove the drive belt.
AB"DRIVE BELT (POWER STEERING) REMOVAL
Loosen the power steering oil pump fixing bolt, and then
remove the drive belt.
AC"DRIVE BELT (A/C) REMOVAL
1. Loosen tension pulley fixing nut A.
2. Loosen adjusting nut B, and then remove the drive belt.
A
B
Power steering
oil pump
A
B
1
2
7
6
5
3 4
14
13
12
11
10
9
8
Disassembly steps
AA" 1. Front bracket assembly
AB" 2. Alternator pulley
"BA 3. Rotor
4. Rear bearing
5. Bearing retainer
6. Front bearing
7. Front bracket
AC" 8. Stator
9. Plate
AC" "AA 10. Regulator assembly
11. Brush
12. Slinger
13. Rectifier
14. Rear bracket
AA"FRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdriver, etc., in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
The stator coil could be damaged so do not insert the
screwdriver too far.
AB"ALTERNATOR PULLEY REMOVAL
Face the pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care so that the rotor is not damaged.
AC"STATOR/REGULATOR ASSEMBLY REMOVAL
(1) When removing the stator, remove the stator lead wire
soldered onto the main diode of the rectifier.
(2) When removing the rectifier from the regulator assembly,
remove the soldered sections of the rectifier.
Caution
1. Use care tomake sure that the heat of thesoldering
iron is not transmitted to the diodes for a long
period.
2. Use care that no undue force is exerted to the
lead wires of the diodes.
Soldered
"AAREGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.
"BAROTOR INSTALLATION
After installing the rotor, remove the wire used to fix the brush.
ROTOR CHECK
1. Check the continuity between the rotor coil slip rings,
and replace the rotor if the resistance value is not at
the standard value.
Standard value: 3 - 5 W
2. Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.
Wire
Rear bracket
Brush
Wire
Wire
STATOR CHECK
1. Check the continuity between the coil leads, and if there
is continuity, replace the stator.
2. Check the continuity between the coil and core, and if
there is continuity, replace the stator.
RECTIFIER CHECK
1. Inspect the (+) heat sink by checking the continuity
between the (+) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
2. Inspect the ( - ) heat sink by checking the continuity
between the ( - ) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
3. Check the diode trio by connecting an ohmmeter to both
ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the rectifier.
BRUSH CHECK
1. Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Limit: 2 mm or less
2. The brush can be removed if the solder of the brush
lead wire is removed.
3. When installing a new brush, insert the brush into the
holder as shown in the illustration, and then solder the
lead wires.
Protrusion
length
Soldered
ENGINE ELECTRICAL - Starting System 16-23
STARTING SYSTEM 16200010290
GENERAL INFORMATION
If the ignition switch is turned to the START
position, current flows in the pull-in and holding
coils provided inside magnetic switch, attracting
the plunger. When the plunger is attracted, the
lever connected to the plunger is actuated to
engage the starter clutch.
On the other hand, attracting the plunger will turn
on the magnetic switch, allowing the B terminal
and M terminal to conduct. Thus, current flows to
engage the starter motor.
When the ignition switch is returned to the ON
position after starting the engine, the starter clutch
is disengaged from the ring gear.
An overrunning clutch is provided between the
pinion and the armature shaft, to prevent damage
to the starter.
SYSTEM DIAGRAM
Pull-in coil
Holding coil
Ignition
switch
Battery
Armature
Brush
Yoke
Plunger
Lever
Over-running
clutch
Pinion shaft
STARTER MOTOR SPECIFICATIONS
Items 4G6-M/T <Except
models for cold climate>
4G6-M/T <Models for cold
climate>, 4G6-A/T, 6A1
4D6 <Except mod-
els for cold climate>
4D6 <Models for
cold climate>
Type Direct drive Reduction drive with
planetary gear
Reduction drive with
planetary gear
Reduction drive
with planetary gear
Rated output kW/V 0.9/12 1.2/12 2.0/12 2.2/12
No. of pinion teeth 8 8 10 12
Items 4G6 <Models for cold climate>,
6A1
4G6 <Except models cold climate>,
4D6
Pinion gap mm 0.5- 2.0 0.5- 2.0
Commutator outer diameter Standard value 29.4 32.0
mm
Limit 28.4 31.0
Commutator runout mm Standard value 0.05 0.05
Limit 0.1 0.1
Commutator undercut mm Standard value 0.5 0.5
Limit 0.2 0.2
STARTER RELAY CONTINUITY CHECK <4D6>
1 3 4 5
Not supplied
Supplied
STARTER MOTOR 16200110242
INSPECTION
PINION GAP ADJUSTMENT
1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12V battery between S-terminal and
M-terminal.
3. Set switch to ON, and pinion will move out.
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
Starter
relay
S
Switch
Battery
Field coil wire
B
M
<4G6>
B
Switch
Battery
Field
coil wire
S
<6A1>
M
Switch
Battery
Field
coil wire
S
M
<4D6>
B
4. Check pinion to stopper clearance (pinion gap) with a
thickness gauge.
Pinion gap: 0.5- 2.0 mm
5. If pinion gap is out of specification, adjust by adding or
removing gaskets between magnetic switch and front
bracket.
MAGNETIC SWITCH PULL-IN TEST
switch.
2. Connect a 12V battery between S-terminal and
M-terminal.
Caution
3. If pinion moves out, then pull-in coil is good. If it doesnt,
replace magnetic switch.
Stopper
Pinion gap
Pinion
Field coil wire
S
M Battery
<4G6>
S
Battery
Field
coil wire
M
<6A1>
S
Battery
Field
coil wire
M
<4D6>
MAGNETIC SWITCH HOLD-IN TEST
switch.
2. Connect a 12V battery between S-terminal and body.
Caution
3. Manually pull out the pinion as far as the pinion stopper
position.
4. If pinion remains out, everything is in order. If pinion moves
in, hold-in circuit is open. Replace magnetic switch.
FREE RUNNING TEST
1. Place starter motor in a vise equipped with soft jaws
and connect a fully-charged 12-volt battery to starter motor
as follows:
2. Connect a test ammeter (100-ampere scale) and carbon
pile rheostat in series with battery positive post and starter
motor terminal.
3. Connect a voltmeter (15-volt scale) across starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect battery cable frombattery negative post to starter
motor body.
6. Adjust the rheostat until the battery voltage shown by
the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly
and freely.
Current: max. 60 Amps
Field coil wire
S
Battery
<4G6>
S
Battery
Field
coil wire
<6A1>
S
Battery
Field
coil wire
<4D6>
Carbon-pile rheostat
M
S
B
Starter
motor
Ammeter
Battery
Voltmeter
<4G6>
B
Carbon-pile rheostat <6A1>
S
Ammeter
Battery
Voltmeter
M
MAGNETIC SWITCH RETURN TEST
switch.
2. Connect a 12V battery between M-terminal and body.
Caution
3. Pull pinion out and release. If pinion quickly returns to
its original position, everything is in order. If it doesnt,
replace magnetic switch.
Caution
Be careful not to get your fingers caught when pulling
out the pinion.
B
Carbon-pile rheostat <4D6>
M
S
Ammeter
Battery
Voltmeter
Field coil wire
M
Battery
<4G6>
M
Battery
Field
coil wire
<6A1>
M
Battery
Field
coil wire
<4D6>
<DIRECT DRIVE TYPE>
2
1
18
13
4
3
14
15
16
17
12
10
11
9
8
6
5
7
Disassembly steps
1. Screw
AA" 2. Magnetic switch
3. Packing
4. Plate
5. Screw
6. Through bolt
7. Rear bracket
8. Rear bearing
9. Brush holder
10. Yoke assembly
11. Brush
12. Armature
13. Lever
14. Washer
AC" "AA 15. Snap ring
AC" "AA 16. Stop ring
17. Overrunning clutch
18. Front bracket
<PLANETARY GEAR REDUCTION DRIVE TYPE FOR PETROL ENGINE>
2
14
15
17
1
23
18
19
20
21
22
16
12
13
10
5
11
7
8
9
6
4
3
Disassembly steps
1. Screw
3. Starter cover
4. Screw
5. Through bolt
6. Rear bracket
7. Brush holder
8. Brush
9. Rear bearing
AB" 10. Armature
11. Yoke assembly
AB" 12. Ball
13. Packing A
14. Packing B
15. Plate
16. Planetary gear
17. Lever
21. Internal gear
22. Planetary gear holder
23. Front bracket
<PLANETARY GEAR REDUCTION DRIVE TYPE FOR DIESEL ENGINE>
2
12
13
16
23
1
17
18
19
20
21
22
15
14
11
4
3
5
8
6
10
7
9
Disassembly steps
1. Screw
3. Screw
4. Through bolt
5. Rear bracket
6. Brush holder
7. Yoke assembly
8. Brush
AB" 9. Armature
10. Bearing
11. Packing A
12. Packing A
13. Plate
AB" 14. Ball
15. Planetary gear
16. Lever
20. Internal gear
21. Washer
22. Planetary gear holder
23. Front bracket
AA"MAGNETIC SWITCH REMOVAL
Disconnect the field coil wire from terminal M of the
magnetic switch.
AB"ARMATURE AND BALL REMOVAL
When removing the armature, do not lose the ball placed
at the end as a bearing.
AC"SNAP RING/STOP RING REMOVAL
1. Using an appropriate wrench socket, push the stop ring
toward the overrunning clutch.
2. Remove the snap ring with snap ring pliers and then
remove the stop ring and overrunning clutch.
STARTER MOTOR PARTS CLEANING
1. Do not immerse the parts in cleaning solvent. Immersing
the yoke and field coil assembly and/or armature will
damage insulation. Wipe these parts with a cloth only.
2. Do not immerse the drive unit in cleaning solvent. The
overrunning clutch is pre-lubricated at the factory and
solvent will wash lubrication from clutch.
3. The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
Magnetic
switch
S terminal
M terminal
Field coil
wire
Stop ring
Socket
Pinion gear
Overrunning
clutch
Armature
Snap ring
Pinion gear
Overrunning
clutch
Snap ringpliers
Armature
"AASTOP RING/SNAP RING INSTALLATION
Using an appropriate tool, pull the stop ring over the snap
ring.
COMMUTATOR
1. Place the armature in a pair of V blocks and check
the runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm
2. Measure the commutator outer diameter.
Direct drive type and planetary gear reduction drive
type (for diesel engine)
Limit: 31.0 mm
Planetary gear reduction drive type (for petrol engine)
Limit: 28.4 mm
3. Check the undercut depth between segments.
Limit: 0.2 mm
FIELD COIL OPEN-CIRCUIT TEST - Except planetary
gear reduction drive type (for petrol engine)
Check the continuity between field brushes. If there is
continuity, the field coil is in order.
Stop ring
Overrunning
clutch
Stop ring
Snap ring
Undercut
Segment
Mica
Yoke
FIELD COIL GROUND TEST - Except planetary gear
reduction drive type (for petrol engine)
Check the continuity between field coil brush and yoke. If
there is no continuity, the field coil is free from earth.
BRUSH HOLDER
Check the continuity between brush holder plate and brush
holder.
If there is no continuity, the brush holder is in order.
OVERRUNING CLUTCH
1. Check that the pinion locks when it is turned
counterclockwise and moves smoothly when it is turned
clockwise.
2. Check the pinion for wear or damage.
BRUSH
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length.
Limit: Wear limit line
2. In case the contacting surface has been corrected or
the brush has been replaced, correct the contacting
surface by winding sandpaper around the commutator.
3. When removing a worn brush by breaking with pliers,
use care to prevent damage to the pigtail.
4. Polish the pigtail end for secure soldering.
5. Insert the pigtail into the hole of a new brush and solder.
Make sure that there is no excess solder on the brush
surface.
Field brush
Yoke
Brush holder
Free
Lock
Wear limit line
Pigtail
New brush
Soldered
(Make sure that
there is no
excess solder
on blush
surface)
Mark
ARMATURE COIL SHORT-CIRCUIT TEST
1. Place armature in a growler.
2. Holdathin steel blade parallel and just above whilerotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
Caution
Clean the armature surface thoroughly before
checking.
3. Check the insulation between each commutator segment
and armature coil core.
If there is no continuity, the insulation is in order.
ARMATURE COIL OPEN-CIRCUIT INSPECTION
Check the continuity between segments. If there is continuity,
the coil is in order.
Growler
ENGINE ELECTRICAL - Ignition System <4G6, 6A1> 16-35
IGNITION SYSTEM <4G6, 6A1> 16300010316
GENERAL INFORMATION
<4G6>
This system is equipped with two ignition coils (A
and B) with built-in power transistors for the No.
1 and No. 4 cylinders and the No. 2 and No. 3
cylinders respectively.
Interruption of the primary current flowing in the
primary side of ignition coil A generates a high
voltage in the secondary side of ignition coil A.
The high voltage thus generated is applied to the
spark plugs of No. 1 and No. 4 cylinders to generate
sparks. At the time that the sparks are generated
at both spark plugs, if one cylinder is at the
compression stroke, the other cylinder is at the
exhaust stroke, so that ignition of the compressed
air/fuel mixture occurs only for the cylinder which
is at the compression stroke.
In the same way, when the primary current flowing
in ignition coil B is interrupted, the high voltage
thus generated is applied to the spark plugs of
No. 2 and No. 3 cylinders.
The engine-ECU turns the two power transistors
inside the ignition coils alternately on and off. This
causes the primary currents in the ignition coils
to be alternately interrupted and allowed to flow
to fire the cylinders in the order 1- 3- 4- 2.
The engine-ECU determines which ignition coil
should be controlled by means of the signals from
the camshaft position sensor which is incorporated
in the camshaft and from the crank angle sensor
which is incorporated in the crankshaft. It also
detects the crankshaft position in order to provide
ignition at the most appropriate timing in response
to the engine operation conditions. It also detects
the crankshaft position in order to provide ignition
at the most appropriate timing in response to the
engine operation conditions.
When the engine is cold or operated at high
altitudes, the ignition timing is slightly advanced
to provide optimum performance.
Furthermore, if knocking occurs, the ignition timing
is gradually retarded until knocking ceases.
SYSTEM DIAGRAM
Engine coolant temperaturesensor
Crank angle sensor
Ignition switch- ST
Detonation sensor
Vehicle speed sensor
Inhibitor switch <A/T>
A/T-ECU
Engine-ECU
Ignition coil A
Ignition coil B
Ignition
switch
Spark plugs
Battery
To tachometer
Cylinder No.
Air flow sensor
3 2 1 4
<6A1>
Interruption of the primary current flowing in the
primary side of the ignition coil generates high
voltage in the secondary side of the ignition coil.
The high voltage thus generated is directed by
the distributor to the applicable spark plug. The
engine firing order is 1 - 2 - 3 - 4 - 5 - 6 cylinders.
On application of high voltage, the spark plug
generates a spark to ignite the compressed air
fuel mixture in the combustion chamber.
The engine-ECU makes and breaks the primary
current of the ignition coil to regulate the ignition
timing.
The engine-ECU detects the crankshaft position
by the crank angle sensor incorporated in the
distributor to provide ignition at the most appropriate
timing for the engine operating condition.
When the engine is cold or operated at a high
altitude, the ignition timing is slightly advanced to
provide optimum performance to the operating
condition.
Furthermore, if knocking occurs, the ignition timing
is gradually retarded until knocking ceases.
When the automatic transmission shifts gears, the
ignition timing is also retarded in order to reduce
output torque, thereby alleviating shifting shocks.
SYSTEM DIAGRAM
Ignition switch- ST
Inhibitor switch <A/T>
Engine-ECU
Spark
plug
A/T-ECU
Power
transistor
Distributor
Air flow sensor
Crank angle sensor
Detonation sensor
Top dead
centre sensor
DISTRIBUTOR SPECIFICATIONS
Items 6A1
Type Contact pointless
Advance mechanism Electronic
Firing order 1 - 2 - 3 - 4 - 5 - 6
IGNITION COIL SPECIFICATIONS
Items 4G6 6A1
Type Molded 2-coil Molded single-coil with a built-in distributor
SPARK PLUG SPECIFICATIONS
Items 4G6 6A1
NGK BKR6E-11 PFR6G-11
DENSO K20PR-U11 PK20PR11
IGNITION COIL
Items Standard value
Primary coil resistance W 6A1 0.5- 0.7
Secondary coil resistance kW 6A1 9- 13
SPARK PLUG
Spark plug gap mm 4G6, 6A1 1.0- 1.1
RESISTIVE CORD
Items Limit
Resistance kW 4G6, 6A1 max. 22
MB991348 Test harness set Inspection of ignition primary voltage (power
transistor connection)
MD998773 Detonation sensor
wrench
Detonation sensor removal and installation
POWER TRANSISTOR CONTINUITY CHECK
<4G6>
NOTE
1. An analogue-type circuit tester should be used.
2. Connect the negative ( - ) prove of the circuit tester
to terminal 1.
Caution
10 seconds) to prevent coil from burning and power
transistor from breakage.
Voltage: 1.5V Terminal No.
1 2 3
When current is
flowing
When current is
not flowing
Replace the power transistor if there is a malfunction.
IGNITION COIL CHECK <6A1> 16300120323
1. Measurement of the primary coil resistance
Measure the resistance between connector terminal 1
and 2 of the distributor.
Standard value: 0.5- 0.7 W
2. Measurement of secondary coil resistance
Measure the resistance between the high-voltage
terminals and connector terminals 1.
Standard value: 9- 13 kW
Ignition coil
High-voltage
terminal
POWER TRANSISTOR CONTINUITY CHECK
<6A1> 16300130241
NOTE
1. An analogue-type circuit tester should be used.
2. Connect the negative ( - ) prove of the circuit tester
to terminal 2.
Caution
10 seconds) to prevent coil from burning and power
transistor from breakage.
Voltage: 1.5V Terminal No.
2 3 4
When current is
flowing
When current is
not flowing
Replace the power transistor if there is a malfunction.
RESISTIVE CORD CHECK 16300140107
Measure the resistance of the all spark plug cables.
1. Check cap and coating for cracks.
2. Measure resistance.
Limit: Max. 22 kW
SPARK PLUG CHECK AND CLEANING
<4G6> 16300150315
1. Remove the spark plug cables.
Caution
When pulling off the spark plug cable from the plug
always hold the cable cap, not the cable.
2. Remove the spark plugs.
3. Check for burned out electrode or damaged insulator.
Check for even burning.
4. Remove carbon deposits with wire brush or plug cleaner.
Remove sand from plug screw with compressed air.
1.5V
Distributor connector
+ -
+ -
5. Use a plug gap gauge to check that the plug gap is
within the standard value range.
Standard value: 1.0- 1.1 mm
If the plug gap is not within the standard value range,
adjust by bending the earth electrode.
6. Clean the engine plug holes.
Caution
Be careful not to allow foreign matter in cylinders.
7. Install the spark plugs.
SPARK PLUG CHECK <6A1> 16300150322
1. Remove the air intake plenum.
2. Remove the spark plug cables.
Caution
When pulling off the spark plug cable from the plug
always hold the cable cap, not the cable.
3. Remove the spark plugs.
4. Check the plug gap and replace if the limit is exceeded.
Limit: 1.3 mm
Caution
1. Do not attempt to adjust the gap of the platinum
plug.
2. Always use a plug cleaner and finish cleaning
within 20 seconds. Do not use wire brushes.
Otherwise, the platinum tip may be damaged.
5. Clean the engine plug holes.
Caution
Be careful not to allow foreign matter in cylinders.
6. Install the spark plugs.
CAMSHAFT POSITION SENSOR CHECK <4G6>
16300260438
Refer to GROUP 13A - Troubleshooting.
TOP DEAD CENTER SENSOR CHECK <6A1>
16300380011
CRANK ANGLE SENSOR CHECK 16300260445
Plug gap gauge
Measurement direction
Platinum tips
DETONATION SENSOR CHECK 16300180086
Check the detonation sensor circuit if self-diagnosis code,
No. 31 is shown.
NOTE
For information concerning the self-diagnosis codes, refer
to GROUP 13A - Troubleshooting.
WAVEFORM CHECK USING AN ANALYZER
16300170427
Ignition Secondary Voltage Waveform Check
<4G6>
MEASUREMENT METHOD
1. Clamp the secondary pickup around the spark plug cable.
NOTE
(1) The peak ignition voltage will be reversed when the
spark cables No. 2 and No. 4, or No. 1 and No.
3 cylinders are clamped.
(2) Because of the two-cylinder simultaneous ignition
system, the waveforms for two cylinders in each group
appear during waveform observation (No. 1 cylinder
- No. 4 cylinder, No. 2 cylinder - No. 3 cylinder).
However, waveform observation is only applicable
for the cylinder with the spark plug cable clamped
by the secondary pickup.
(3) Identifying which cylinder waveform is displayed can
be difficult. For reference, remember that the
waveform of the cylinder attached to the secondary
pickup will be displayed as stable.
2. Clamp the spark plug cable with the trigger pickup.
NOTE
Clamp the trigger pickup to the same spark plug cable
clamped by the secondary pickup.
STANDARD WAVEFORM
Function Secondary
Pattern height High (or Low)
Pattern selector Raster
Engine revolutions Curb idle speed
kV
Secondary
ignition
voltage
waveform
Ignition voltage
(point D)
Dwell
section
Point C
Spark line (point A)
Wave damping
reduction section
(point B)
Time
Observation Condition (The only change from above condition is the pattern selector.)
Secondary
ignition
voltage
waveform
kV
No. 4 cylinder
No. 2 cylinder
ignition noise
No. 1 cylinder
No. 3 cylinder
ignition noise
Neutral section
0
2
Time
WAVEFORM OBSERVATION POINTS
Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal
waveform examples, 1, 2, 3 and 4).
Spark line Plug gap Condition of
electrode
Compression
force
Concentration of
air mixture
Ignition timing Spark plug
cable
Length Long Small Normal Low Rich Advanced Leak
Short Large Large wear High Lean Retarded High
resistance
Height High Large Large wear High Lean Retarded High
resistance
Low Small Normal Low Rich Advanced Leak
Slope Large Plug is fouled - - - -
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations Coil and condenser
Three or more Normal
Except above Abnormal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations Coil
5- 6 or higher Normal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition
voltage
Plug gap Condition of
electrode
Compression
force
Concentration of
air mixture
Ignition timing Spark plug cable
High Large Large wear High Lean Retarded High resistance
Abnormal waveform Wave characteristics Cause of problem
Example 1
01P0215
Spark line is high and short. Spark plug gap is too large.
Example 2 Spark line is low and long, and is
sloping.
Also, the second half of the spark line
is distorted. This could be a result of
misfiring.
Spark plug gap is too small.
sloping. However, there is almost no
spark line distortion.
Spark plug gap is fouled.
Example 4 Spark line is high and short.
Difficult to distinguish between this
and abnormal waveform example 1.
Spark plug cable is nearly falling off.
(Causing a dual ignition)
Example 5 No waves in wave damping section. Layer short in ignition coil
Ignition Secondary Voltage Waveform Check
<6A1>
MEASUREMENT METHOD
1. Clamp the spark plug cable of the No. 1 cylinder with
the secondary pickup and check the waveform.
2. Connect the secondary pickup to the other cylinders in
turn and check the waveforms for each cylinder.
STANDARD WAVEFORM
FUNCTION SECONDARY
PATTERN HEIGHT HIGH (or LOW)
Engine Speed Curb idle speed
Ignition
secondary
voltage
waveform
Dwell
section
(Point C)
Spark line
(Point A)
Vibration damping
section (Point B)
Time
kV
Ignition
voltage
(Point D)
Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal
waveform examples, 1, 2, 3 and 4).
electrode
Compression
force
Concentration of
air mixture
Ignition timing Spark plug
cable
resistance
resistance
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations Coil and condenser
Three or more Normal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations Coil
5- 6 or higher Normal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition
voltage
Plug gap Condition of
electrode
Compression
force
Concentration of
air mixture
Ignition timing Spark plug cable
High Large Large wear High Lean Retarded High resistance
Example 1
01P0215
Spark line is high and short. Spark plug gap is too large.
sloping.
misfiring.
Example 4 Spark line is high and short.
Difficult to distinguish between this
and abnormal waveform example 1.
Spark plug cable is nearly falling off.
Example 5 No waves in wave damping section. Layer short in ignition coil
Ignition Primary Voltage Waveform Check
<6A1>
MEASUREMENT METHOD
1. Disconnect the distributor connector and connect the
of the terminals should be connected.)
2. Connect the analyzer primary pickup to the distributor
connector terminal 2.
3. Connect the primary pickup earth terminal.
4. Clamp the spark plug cable with the trigger pickup.
NOTE
The waveformof the cylinder clamped to the trigger pickup
will appear at the left edge of the screen.
Analyzer
Primary
pickup
Earth
STANDARD WAVEFORM
FUNCTION SECONDARY
PATTERN HEIGHT HIGH (or LOW)
Engine Speed Curb idle speed
Ignition
primary
voltage
waveform
(V)
Zener voltage
(Point C)
(Approx. 4010V)
Dwell
section
Spark line
(Point A)
Vibration damping
section (Point B)
Time
100
0
(Only the pattern selector shown below changes from the previous conditions)
PATTERN SELECTOR DISPLAY
(V)
Ignition
primary
voltage
waveform
Centre
section
Time
100
0
Point A: The height, length and slope of the spark line (refer to abnormal waveform examples 1, 2,
3 and 4) show the following trends.
electrode
Compression
force
Concentration of
air mixture
Ignition timing High tension
cable
resistance
resistance
Point B: Number of vibration in reduction vibration section
(Refer to abnormal waveform example 5)
Number of vibrations Coil, condenser
3 or higher Normal
Point C: Height of Zener voltage
Height of Zener voltage Probable cause
High Problem in Zener diode
Low Abnormal resistance in
primary coil circuit
Example 1 Spark line is high and short. Spark plug gap is too large.
sloping.
misfiring.
Example 4 Spark line is high and short. Spark plug cable is nearly falling off.
Example 5 No waves in wave damping section Layer short in ignition coil
DISTRIBUTOR <6A1> 16300200188
Air Cleaner, Air Intake Hose Removal
D Air Cleaner, Air Intake Hose Installation
D Ignition timing Check and Adjustment
(Refer to GROUP 11B - On-vehicle service.)
25 Nm
22 - 25 Nm
1
5
10 - 12 Nm
2
3
4
25 Nm
6
5
6
Removal steps
1. Distributor connector
2. Spark plug cable connection
3. Water guard
"AA 4. Distributor
D Air intake plenum
5. Spark plug cable
6. Spark plug
"AADISTRIBUTOR INSTALLATION
1. Set the No. 1 cylinder to top dead compression centre.
2. Align the mating marks on the distributor housing and
coupling, and then install the distributor to the engine.
3. Check that the ignition timing is at the standard value.
(Refer to GROUP 11B - On-vehicle service.)
Mating
marks
4
5
2
1
3
Disassembly steps
1. Distributor cap
2. Packing
3. Rotor
4. O-ring
5. Distributor housing
Check the following points; repair or replace if a problem
is found.
CAP, ROTOR
1. There must be no cracking in the cap.
2. There must be no damage to the caps electrode or the
rotors electrode.
3. Clean away any dirt from the cap and rotor.
IGNITION COIL <4G6> 16300320174
10 Nm
25 Nm
1
2
1 2
3
10 Nm
Removal steps
1. Spark plug cable
2. Ignition coil assembly
3. Spark plug
CAMSHAFT POSITION SENSOR <4G6> 16300340026
9 Nm
CRANK ANGLE SENSOR 16300350036
D Timing Belt Removal and Installation <4G6>
(Refer to GROUP 11A.)
D Timing Belt Cover Removal and Installation <6A1>
(Refer to GROUP 11B.)
10 - 12 Nm
9 Nm
2
1
10 - 13 Nm
49 Nm
12 Nm
<4G6>
<6A1>
28 Nm
9 Nm
4
1
4
49 Nm
28 Nm
3
Removal steps
1. Pressure hose and tube assembly
connection
3. Power steering oil pump bracket
4. Crank angle sensor
AA"POWER STEERING OIL PUMP ASSEMBLY
REMOVAL
Remove the power steering oil pump assembly with the hoses
still attached.
NOTE
Secure the removed oil pump with rope, etc. in a place where
it will not be in the way when removing and installing the
power steering oil pump bracket.
DETONATION SENSOR 16300280144
Intake Manifold Removal and Installation <6A1>
20 - 25 Nm
1
<4G6> <6A1>
1
20 - 25 Nm
AA" "AA 1. Detonation sensor Caution
Do not subject the detonation sensor to any shocks.
AA"DETONATION SENSOR REMOVAL
"AADETONATION SENSOR INSTALLATION
<4G6>
<6A1>
MD998773
MD998773
ENGINE ELECTRICAL - Glow System <4D6> 16-57
GLOW SYSTEM <4D6> 16400010043
GENERAL INFORMATION
SELF-REGULATING GLOW SYSTEM
The self-regulating glow system reduces the time
required for starting at low temperatures to provide
a degree of starting and operation that is identical
to petrol-engine vehicles by preheating the glow
plugs at super-quick speed.
The engine-ECUcontrols both thetime duringwhich
current is supplied to the glowplugs after the ignition
switch is turned to the ON position and also the
glow indicator lamp illumination time in accordance
with the engine coolant temperature.
The resistances of the heating coils which are built
into the glow plugs increase as the glow plug
temperatures become higher. As a result of this,
the flow of current gradually decreases, thus
stabilizing the glow plug temperature at the
specified temperature.
Glow plug relay
Engine-ECU
Pre-heat indicator lamp
Engine coolant
temperature sensor
Glow plugs
Charge lamp
ON
ST
Ignition switch
Alternator
Starter motor
Battery
ENGINE ELECTRICAL - Glow System 16-58
Item Standard value
Resistance between glow plug plate and glow plug body
(parallel resistance for 4 glow plugs) (at 20 _C) W
0.10 - 0.15
Voltage between glow plug
plate and glow plug body V
Immediately after ignition
switch is turned to ON
(without starting the engine)
9 - 11 (Drops to 0 Vafter 4 - 8seconds havepassed)
While engine is cranking 6 or more
While engine is warming up 12 - 15 (Drops to 0 V when the engine coolant
temperature increases to 60 _C or more or if 30
seconds have passed since the engine was started)
Glow plug resistance (at 20 _C) W 0.6 - 1.0
SELF-REGULATING GLOW SYSTEM CHECK
1. Check that the battery voltage is 11 - 13 V.
2. Check that the engine coolant temperature is 40 _C or
less.
NOTE
If the engine coolant temperature is too high, disconnect
the engine coolant temperature sensor connector.
3. Measure the resistance between the glow plug plate and
the glow plug body (earth).
Standard value: 0.10 - 0.15 W (at 20 _C)
NOTE
The resistance value is the parallel resistance value for
the four glow plugs.
4. Connect a voltmeter between the glow plug plate and
the glow plug body (earth).
5. Measure the voltage immediately after the ignition switch
is turned to ON (without starting the engine).
Standard value:
9 - 11 V (Drops to 0 V after 4 - 8 seconds have
passed)
In addition, check to be sure that the glow indicator lamp
(red) illuminates immediately after the ignition switch is
turned to ON.
NOTE
The time during which the voltage appears (energizing
time) will depend on the engine coolant temperature.
(+)
(- )
6. Measure the voltage while the engine is cranking.
Standard value: 6 V or more
7. Start the engine and measure the voltage while the engine
is warming up.
However, if the engine coolant temperature rises above
60 _Cor when 180 seconds have passed since the engine
was started, the voltage will always return to 0 V. (Refer
to the Glow Plug Energization Timing Chart.)
Standard value: 12 - 15 V
<Reference>
Glow Plug Energization Timing Chart
Ignition
switch
START
ON
OFF
Glow
indicator
lamp
ON
OFF
Glow plug
relay
ON
OFF
Alternator
L terminal
H
L
T
1
: Glow indicator lamp
T
2
: Glow plug relay drive time after ignition switch is turned ON
T
3
: Glow plug relay drive time after engine starts (after glow)
NOTE
After glowtime T
3
becomes longer as the engine coolant temperature drops.
T
1
T
2
T
3
CHECK AT THE ENGINE-ECU TERMINALS 16400360025
Refer to GROUP 13E - Troubleshooting.
GLOW PLUG RELAY CHECK 16400330026
1. Check to be sure that there is continuity (approx. 3 W)
between glow plug relay terminal C and the terminal E.
2. Use jumper cables to connect terminal C of the glow
plug relay to the battery (+) terminal and the terminal
E to the battery ( - ) terminal
Caution
(1) Always be sure to disconnect the harnesses
connected to glow plug relay terminals B and G
before using the jumper cables.
(2) The terminals of the disconnectedharnesses must
not be shorted to earth.
(3) When connecting the jumper cables, be very
careful not to make a mistake in connecting the
terminals, as this will cause damage to the relay.
3. Check the continuity between glow plug relay terminals
B and G while disconnecting and connecting the jumper
cable at the battery (+) terminal
Jumper cable at battery (+)
terminal
Continuity between terminals
B - G
Connected Continuity (0.01 W or less)
Disconnected No continuity (infinite
resistance)
GLOW PLUG CHECK 16400340029
1. Remove the glow plug plate.
2. Measure the resistance between the glow plug terminals
and the body.
Standard value: 0.6 - 1.0 W (at 20 _C)
CHECK 16400350015
Refer to GROUP 13E - On-vehicle Service.
Glow plug relay
Gterminal
B terminal
(+)
(- )
GLOW PLUG 16400180058
18 Nm
1.8 Nm
1
2
3
Removal steps
1. Control wiring harness connection
2. Glow plug plate
AA" 3. Glow plug
AA"GLOW PLUG REMOVAL
Remove glow plug by hand after loosening with tool as its
ceramic part is fragile.
D Check for rust on glow plug plate.
D Check glow plug for damage.
Caution
Do not use a plug that has been dropped from a height
of 10 cm or more.
ENGINE ELECTRICAL - Injection System <4D6> 16-62
INJECTION SYSTEM <4D6> 16500010015
GENERAL INFORMATION
For the injection system, refer to GROUP 13E - General Information.
CRANK ANGLE SENSOR CHECK
CRANK ANGLE SENSOR 16500120015
Timing Belt Removal and Installation
(Refer to GROUP 11C.)
10 - 12 Nm
9 Nm
1
2
Removal steps
1. Harness support
2. Crank angle sensor
17-1
ENGINE AND
EMISSION
CONTROL
ENGINE CONTROL SYSTEM 3 . . . . . . . .
Accelerator Cable Check and Adjustment 3 . . . .
Accelerator Pedal Position Sensor Check 4 . . . .
ACCELERATOR CABLE AND PEDAL 5 . . . .
ACCELERATOR PEDAL POSITION
SENSOR 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTO-CRUISE CONTROL SYSTEM
8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL 8 . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING!
MITSUBISHI dealer.
component.
NOTE
The SRSincludes the following components: SRS-ECU, SRSwarning lamp, air bag module, clock spring, side impact sensors and
maintenance) are indicated in the table of contents by an asterisk (*).
17-2
Auto-cruise Control Main Switch Check 27 . . . .
Auto-cruise Control Switch Check 27 . . . . . . . . . .
Auto-cruise Control Component Check 28 . . . . .
AUTO-CRUISE CONTROL* 30 . . . . . . . . . . . . .
EMISSION CONTROL SYSTEM (MPI)
33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emission Control Device Reference Table
33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL 34 . . . . . . . . . . . . . . . . . . . . . . .
VACUUM HOSE 34 . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Hose Piping Diagram 34 . . . . . . . . . . . . .
Vacuum Circuit Diagram 35 . . . . . . . . . . . . . . . . . .
Vacuum Hose Check 36 . . . . . . . . . . . . . . . . . . . . .
Vacuum Hose Installation 36 . . . . . . . . . . . . . . . . .
CRANKCASE EMISSION CONTROL
SYSTEM 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 37 . . . . . . . . . . . . . . . . . . . . . .
System Diagram 37 . . . . . . . . . . . . . . . . . . . . . . . . .
Positive Crankcase Ventilation System
Check 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PCV Valve Check 38 . . . . . . . . . . . . . . . . . . . . . . . .
EVAPORATIVE EMISSION CONTROL
SYSTEM 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Diagram 39 . . . . . . . . . . . . . . . . . . . . . . . . .
Purge Control System Check 40 . . . . . . . . . . . . . .
Purge Port Vacuum Check 40 . . . . . . . . . . . . . . . .
Purge Control Solenoid Valve Check 41 . . . . . . .
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Diagram 42 . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Gas Recirculation (EGR) Control
system Check 43 . . . . . . . . . . . . . . . . . . . . . . . . . . .
EGR Valve Check 44 . . . . . . . . . . . . . . . . . . . . . . . .
EGR Port Vacuum Check <4G6> 44 . . . . . . . . . .
EGR Port Vacuum Check <6A1> 45 . . . . . . . . . .
EGR Control Solenoid Valve Check <4G6>
45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EGR Control Solenoid Valve Check <6A1>
46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CATALYTIC CONVERTER 47 . . . . . . . . . . . . . .
CANISTER 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMISSION CONTROL SYSTEM
<DIESEL> 49 . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATION 49 . . . . . . . . . . . . . . . .
EXHAUST GAS RECIRCULATION SYSTEM
(EGR) SYSTEM 49 . . . . . . . . . . . . . . . . . . . . . . . . . .
System Check 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EGR Solenoid Valve Check 50 . . . . . . . . . . . . . . . . . .
Accelerator Pedal Position Sensor Check 50 . . . . .
Pump Operation Sensor Check 50 . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor Check 50 . . .
Intake Air Temperature Sensor Check 51 . . . . . . . .
Barometric Pressure Sensor Check 51 . . . . . . . . . . .
A/C Switch Check 51 . . . . . . . . . . . . . . . . . . . . . . . . . .
Check at the Engine-ECU Terminals 51 . . . . . . . . . .
CATALYTIC CONVERTER 51 . . . . . . . . . . . . . . . . .
General Information 51 . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE AND EMISSION CONTROL - Engine Control System 17-3
ENGINE CONTROL SYSTEM 17100010102
GENERAL INFORMATION
A cable-type accelerator mechanism and a
suspended-type pedal have been adopted.
Accelerator pedal position sensor is used for
vehicles with 4D6 engine which is equipped with
the electronically-controlled fuel injection system.
Accelerator cable play mm 1- 2
Engine idle speed r/min 4G6 75050
6A1 65050
4D6 80030
ACCELERATOR CABLE CHECK AND
ADJUSTMENT
1. Turn A/C and lamps OFF.
Inspect and adjust at no load.
2. Warm engine until stabilized at idle.
3. Confirm idle speed is at prescribed value.
Standard value:
<4G6> 75050 r/min
<6A1> 65050 r/min
<4D6> 80030 r/min
4. Stop engine (ignition switch OFF).
5. Confirm there are no sharp bends in accelerator cable.
6. Check inner cable for correct slack.
Standard value: 1- 2 mm
7. If there is too much slack or no slack, adjust play by
the following procedures.
<Except 4D6>
(1) Loosen the adjusting bolt to release the cable.
(2) Move the plate until the inner cable play is at the
standard value, and then tighten the adjusting bolt.
(3) After adjusting, check that the throttle lever is touching
the stopper.
<4D6>
(1) Loosen the adjusting nut, and then move the lever
to throttle fully-closed position.
(2) Tighten the adjusting nut until the lever start to move,
turn back one turn, and then tighten the lock nut
CHECK 17100190011
Refer to GROUP 13E - On-vehicle Service.
<Except 4D6>
Adjusting bolts
Plate
<4D6>
Adjusting nut
Lever Lock nut
10 Nm
ACCELERATOR CABLE AND PEDAL 17100120256
Adjusting the Accelerator Cable (Refer to P.17-3.)
<4G6, 6A1>
10 Nm
<4D6>
<4G6, 4D6>
12 Nm
<A/T>
<M/T>
1
3
4
5
7
<6A1>
5
7
2
3
4
5
6
7 9
8
12
11
5
15
15
14
13
10
11
Removal steps
1. Adjusting bolt
2. Adjusting nut
3. Inner cable connection
6. Snap ring
7. Accelerator arm assembly
8. Spring
9. Pedal pad
10. Accelerator pedal bracket
11. Bushing
12. Stopper
13. Accelerator pedal stopper <M/T>
14. Wide open throttle switch <A/T>
15. Bracket
<4G6, 6A1>
12 Nm
<R.H. drive vehicles>
<4G6, 4D6>
10 Nm
<4D6>
<6A1>
2
3
4
5
6
7
8
9
10
11
12
13
14
5
7
5
7
11
3
1
5
4
Removal steps
1. Adjusting bolt
2. Adjusting nut
6. Snap ring
7. Accelerator arm assembly
8. Spring
9. Pedal pad
10. Accelerator pedal bracket
11. Bushing
12. Stopper
13. Accelerator pedal stopper <M/T>
14. Wide open throttle switch <A/T>
ACCELERATOR PEDAL POSITION SENSOR 17100180018
Adjusting the Accelerator Cable (Refer to P.17-3.)
10 Nm
10 - 13 Nm
10 Nm
10 - 13 Nm
1
2
4
3
5
6
1
2
5
10 - 13 Nm
3
4
10 - 13 Nm
6
10 - 13 Nm
Removal steps
1. Adjusting nut
3. Idle position switch connector
connector
assembly
bracket
ENGINE AND EMISSION CONTROL - Auto-cruise Control System 17-8
AUTO-CRUISE CONTROL SYSTEM 17200010143
GENERAL INFORMATION
By using the auto-cruise control, the driver can
drive at the speed he/she likes (in a range of
approximately 40- 200 km/h) without depressing
Stop lamp switch
Clutch switch
Vacuum
actuator
Auto-cruise
vacuum pump
assembly
Throttle
position
sensor
Accelerator pedal
position sensor
Inhibitor switch
Vehicle speed
sensor
Auto-cruise
control-ECU
Auto-cruise control
main switch
Auto-cruise control
main switch
Auto-cruise control switch
Auto-cruise control
indicator lamp
MB991502 MUT-II sub
assembly
D Reading diagnosis codes
D Auto-cruise control system check
STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
NOTE
Check that the vacuum hose is connected correctly and is not damaged, and then carry out the diagnosis.
METHOD OF READING THE DIAGNOSIS CODES
1. Connect the MUT-II to the diagnosis connector (16-pin)
under the instrument under cover. (Refer to GROUP 00
- How to Use Troubleshooting/Inspection Service Points.)
2. With the ignition switch in the ON position, turn the
auto-cruise control main switch to ON and take a reading
of the diagnosis codes.
METHOD OF ERASING THE DIAGNOSIS CODES
The diagnosis codes can erased by disconnecting the ( - )
cable from the battery for 10 seconds or more and then
re-connecting it, or by the following procedure.
1. Turn the ignition switch to ON.
2. After pushing the auto-cruise control switch in the direction
of arrow (B) in the illustration, press the cruise control
main switch to the ON position, and within 1 second after
doing this, push the cruise control switch back in the
direction of arrow (A).
3. After pushing the auto-cruise control switch once more
in the direction of arrow (A) in the illustration and keeping
it in this position, press the stop lamp switch to the ON
position for 5 seconds or more.
INPUT SWITCH CODE CHECK METHOD
1. Connect the MUT-II to the diagnosis connector (16-pin)
under the instrument under cover.
2. Turn the ignition switch to ON.
3. After pushing the auto-cruise control switch in the direction
of arrow (B) in the illustration, press the cruise control
main switch to the ON position, and within 1 second after
doing this, push the cruise control switch back in the
direction of arrow (A).
4. Operate each switch listed in the input check table and
take a reading of the input switch codes with the MUT-II.
Auto-cruise
control
main switch
Auto-cruise control
switch
Auto-cruise
control
main switch
(A)
(B)
Input Check Table
Code No. Input operation Operation judgement
21 SET switch ON Auto-cruise control-ECU judges that SET switch is ON
22 RESUME switch ON Auto-cruise control-ECU judges that RESUME switch is ON
23
Stop lamp switch
(ON when brake pedal depressed)
Auto-cruise control-ECU judges that stop lamp switch is ON
24
Auto-cruise control-ECU judges that vehicle speed is 40 km/h
or higher
25
Vehicle speed signal
Auto-cruise control-ECU judges that vehicle speed is lower
than 40 km/h
26
D Clutch switch <M/T>
(ON when clutch pedal depressed)
D Inhibitor switch <A/T>
(ON when select lever in N range)
Auto-cruise control-ECU judges that clutch switch <M/T> or
inhibitor switch <A/T> is ON
27 CANCEL switch ON Auto-cruise control-ECU judges that CANCEL switch is ON
28
Throttle position sensor (accelerator
pedal position sensor*) signal
Auto-cruise control-ECU judges that throttle position sensor
(accelerator pedal position sensor*) voltage is 1.5 V or more
29 Idle switch Auto-cruise control-ECU judges that idle switch is OFF
NOTE
* : Vehicles with TCL
11 Auto-cruise vacuum pump drive system 17-11
12 Vehicle speed signal system 17-11
14 Auto-cruise vacuum pump power supply system 17-12
15 Auto-cruise control switch 17-12
16 Auto-cruise control-ECU 17-12
17 Throttle position sensor system<Vehicles without TCL> or accelerator pedal position
sensor system <Vehicles with TCL>
17-13
Code No. 11 Auto-cruise vacuum pump drive system Probable cause
This diagnosis code is output if the release valve, control valve or motor drive signals
from the auto-cruise vacuum pump are not input to the auto-cruise control-ECU.
D Malfunction of the auto-cruise vacuum pump
D Malfunction of the harness
D Malfunction of the auto-cruise control-ECU
Check the auto-cruise vacuum pump. (Refer to P.17-29.)
NG
Replace
OK
C-74 <L.H.> or C-113 <R.H.>, A-02 and C-82
NG
Repair
OK
NG
Check the harness between the auto-cruise vacuum pump and
auto-cruise control-ECU.
NG
Repair
OK
Replace the auto-cruise control-ECU.
Code No. 12 Vehicle speed signal system Probable cause
This diagnosis code is output if the vehicle speed signals from the vehicle speed
sensor are not input to the auto-cruise control-ECU when the vehicle speed is 40
km/h or more.
NG
Is the speedometer operating normally?
No
Vehicle speed sensor circuit inspection
(Refer to GROUP 54 - Combination Meter.)
Yes
Disconnect the vehicle speed sensor connector B-66 <M/T> or
B-67 <A/T>.
Measure at auto-cruise control-ECU connector C-82.
D Voltage between terminal (11) and earth
OK: 4.5 V or more
OK
NG
Check the harness between the vehicle speed sensor and auto-
cruise control-ECU, and repair if necessary.
Repair
OK
NG
Code No. 14 Auto-cruise vacuum pump power supply
system
Probable cause
This diagnosis code is output when none of the drive signals from the release valve,
control valve and motor of the auto-cruise vacuum pump are input to the auto-cruise
control-ECU.
D Malfunction of the stop lamp switch
OK
Measure at the auto-cruise vacuum pump connector A-02.
D Ignition switch and main switch: ON
D Stop lamp switch: OFF (When brake pedal is not depressed.)
OK: System voltage
OK
Check the auto-cruise vacuum pump. (Refer to P.17-29.)
NG
Check the stop lamp switch (Refer to P.17-28.)
NG
Replace
NG
Replace
OK
C-74 <L.H.> or C-113 <R.H.>, A-02, C-02 and C-82
OK
C-74 <L.H.> or C-113 <R.H.>, A-02 and C-82
OK
NG
NG
Check the harness between the auto-cruise vacuum pump and
auto-cruise control-ECU.
NG
Repair
OK
NG
Repair
Code No. 15 Auto-cruise control switch Probable cause
This diagnosis code is output if the cruise control RESUME switch or SET switch
remains ON.
D Malfunction of the auto-cruise control switch
Replace the auto-cruise control switch.
Code No. 16 Auto-cruise control-ECU Probable cause
This diagnosis code is output if there is an abnormality in the CANCEL hold circuit
or the microprocessor monitor circuit in the auto-cruise control-ECU.
ENGINE AND EMISSION CONTROL - Auto-cruise Control System ENGINE AND EMISSION CONTROL - Auto-cruise Control System 17-13
Code No. 17 Throttle position sensor system <Vehicles
without TCL>or accelerator pedal positionsensor system
<Vehicles with TCL>
Probable cause
This diagnosis code is output if a voltage of 2.5 V or more when the idle switch
is ON or 0.2 V or less when the idle switch is OFF is output for a continuous period
of 4 seconds or more.
D Malfunction of the throttle position sensor <Vehicles
without TCL>
<Vehicles with TCL>
MUT-II SELF DIAG CODE
Is diagnosis code No.14 output from the engine-ECU? <Vehicles
without TCL>
Is diagnosis code No.11 output from the TCL-ECU? <Vehicles with
TCL>
Yes
D Throttle position sensor check <Vehicles without TCL> (Refer
to GROUP 13A - Troubleshooting.)
D Accelerator pedal position sensor check <Vehicles with TCL>
No
B-07 <Vehicles without TCL> or B-41 <Vehicles with TCL>, C-48,
C-49, C-83 and C-82
NG
Repair
OK
NG
D Check the harness between the throttle position sensor and
auto-cruise control-ECU <Vehicles without TCL>
D Check the harness between the accelerator pedal position
sensor and auto-cruise control-ECU <Vehicles with TCL>
NG
Repair
OK
procedure No.
Reference page
Communication with
II
Communication with all systems is not possible. 1 17-14
MUT-II is not possible.
Communication with auto-cruise control-ECU only is
not possible.
2 17-15
Input switch inspection using the MUT-II is not possible. (However, diagnosis
inspection is possible.)
3 17-16
Trouble symptom Reference page Inspection
procedure No.
Auto-cruise control is Even if brake pedal is depressed 4 17-17
not cancelled.
Even if clutch pedal is depressed <M/T> 5 17-18
Even if select lever is set to N range <A/T> 6 17-18
Even if CANCEL switch is set to ON 7 17-19
The diagnosis result displayed on the MUT-II is normal even though auto-cruise
control cannot be set.
8 17-19
Auto-cruise control cannot be set. 9 17-20
Hunting(repeatedaccelerationanddeceleration) occurs at theset vehiclespeed. 10 17-21
Even though auto-cruise control main switch is ON, switch indicator lamp does
not illuminate. (However, auto-cruise control is normal.)
11 17-21
Auto-cruise control main switch illumination lamp does not illuminate. 12 17-22
Auto-cruise control indicator lamp (CRUISE MAIN, CRUISE SET) inside
combination meter does not illuminate. (However, auto-cruise control is normal.)
13 17-22
Communication with MUT-II is not possible. (Communica-
tion with all system is not possible.)
Probable cause
The reason is probably a defect in the power supply system (including earth) for
the diagnosis line.
C-20.
OK: Battery voltage
OK
C-20.
OK: Continuity
OK
Replace the MUT-II.
NG
<L.H.> C-20, C-66, C-63, C-132, C-141
<R.H.> C-20, C-66, C-62, C-14
NG
power supply and diagnosis connector,
NG
C-20
NG
diagnosis connector and earth, and re-
pair if necessary.
NG
Repair
NG
Repair
OK
OK
Communication with MUT-II is not possible. (Communica-
tion with auto-cruise control-ECU only is not possible.)
Probable cause
The cause is probably a malfunction of auto-cruise control main switch circuit or a
malfunction of auto-cruise control-ECU earth circuit.
D Malfunction of the auto-cruise control main switch
Auto-cruise control main switch check (Refer to P.17-32.)
NG
Replace
OK
Measure at auto-cruise control main switch connector C-22.
D Voltage between the terminal (1) and earth
OK: System voltage
NG
Check the following connectors: C-22, C-134
NG
Repair
OK
OK
NG
Check the harness between the auto-cruise control main switch
and power supply, and repair if necessary.
OK
<L.H.> C-22, C-62, C-82
<R.H.> C-22, C-63, C-64, C-82
NG
Repair
OK
Check the harnesses between the auto-cruise control main switch
and earth or between the auto-cruise control main switch and auto-
cruise control-ECU.
NG
Repair
OK
D Continuity between terminal (9) and earth, terminal (13) and
earth.
OK: Continuity
OK
NG
Repair
NG
Check the harness between the auto-cruise control-ECU and earth,
OK
NG
Check the harness between the auto-cruise control-ECU and diag-
nosis connector
NG
Repair
OK
Input switch inspection using the MUT-II is not possible.
(However, diagnosis inspection is possible.)
Probable cause
The cause is probably a malfunction of auto-cruise control switch circuit system. D Malfunction of the auto-cruise control switch
D Malfunction of the clock spring
NG
Replace
OK
Clock spring check (Refer to GROUP 52B - Air Bag Modules
and Clock Spring.)
NG
Replace
OK
Measure at the clock spring connector C-107.
OK: System voltage
NG
C-107, C-61, C-134, C-63 <R.H.>
NG
Repair
OK
OK
OK
C-107, C-82
NG
Repair
NG
Check the harness between the clock spring and power supply,
NG
Check theharness betweentheclock springand auto-cruisecontrol-
Even if brake pedal is depressed, auto-cruise control is
not cancelled.
Probable cause
The cause is probably a malfunction of stop lamp switch or a malfunction of stop
lamp circuit.
NG
Replace
NG
Repair
NG
Repair
Does stop lamp illuminate?
Yes
NG
Repair
No
Stop lamp switch check
(Refer to P.17-28.)
OK
NG
Check the harness between the stop lamp switch and auto-cruise
control-ECU.
OK
OK
Measure at stop lamp switch connector C-02.
OK: System voltage
NG
OK
NG
Check the harness between the stop lamp switch and power supply,
OK
C-02, C-65, C-82
NG
Repair
OK
NG
Check the harness between the stop lamp switch and auto-cruise
control-ECU, and repair if necessary.
Even if clutch pedal is depressed, auto-cruise control is
not cancelled. <M/T>
Probable cause
The cause is probably a malfunction of clutch switch or clutch circuit. D Malfunction of the clutch switch
Clutch switch check (Refer to P.17-29.)
NG
Replace
OK
Measure at clutch switch connector C-01.
OK: 5 V
NG
NG
Repair
OK
OK
OK
<L.H.> C-01, C-62
<R.H.> C-01, C-63, C-64
NG
Repair
NG
Check the harness between the clutch switch and auto-cruise con-
trol-ECU, and repair if necessary.
NG
Check the harness between the clutch switch and earth.
OK
NG
Repair
Even if select lever is set to N range, auto-cruise control
is not cancelled. <A/T>
Probable cause
The cause is probably an open-circuit in the output signal circuit in N range. D Malfunction of the connector
Inhibitor switch check (N range) (Refer to P.17-29.)
NG
Replace
OK
C-48, C-83, C-82
OK
NG
Check the harness between the inhibitor switch and auto-cruise
control-ECU.
NG
Repair
OK
Even if auto-cruise control CANCEL switch is set to ON,
auto-cruise control is not cancelled.
Probable cause
The cause is probably an open-circuit in the circuit inside the CANCEL switch. D Malfunction of the auto-cruise control-ECU
Replace the auto-cruise control switch.
The diagnosis result displayed on the MUT-II is normal
even though auto-cruise control cannot be set.
Probable cause
Because of an open-circuit in the battery backup circuit system, the fail-safe function
prevents diagnosis codes frombeing memorised and displayed even though auto-cruise
control is cancelled.
NG
Repair
NG
Repair
OK: System voltage
NG
C-66 <L.H.> or C-62 <R.H.> and C-82
OK
OK
NG
Check the harness between the auto-cruise control-ECUand power
supply, and repair if necessary.
OK
NG
Auto-cruise control cannot be set. Probable cause
The cause is probably that the fail-safe function is cancelling auto-cruise control.
In this case, the MUT-II can be used to check the trouble symptoms in each system
by inspecting the diagnosis codes. The MUT-II can also be used to check if the
circuits of each input switch are normal or not by inspecting the input switch codes.
D Malfunction of the auto-cruise control switch
D Malfunction of the clock spring
D Malfunction of the harnesses or connectors
D Malfunction of the clutch switch <M/T>
Can the auto-cruise control communicate with the MUT-II?
No
Check for each trouble symptom. (Refer to inspection procedure
No. 2 on P.17-15.)
Yes
Is the diagnosis system diagnosis displayed on the MUT-II normal?
Yes
No. 8 on P.17-19.)
No
Are any of MUT-II diagnosis code Nos. 11, 12, 14, 15, 16 or 17
output?
Yes
Check for each diagnosis code.
(CODE No.11: Refer to P.17-11.)
No
Is input switch inspection possible with the MUT-II?
No
No. 3 on P.17-16.)
Yes
Are either of MUT-II diagnosis code Nos. 23 or 26 output?
Yes
D Stop lamp switch input circuit system [code No. 23] inspection
(Refer to inspection procedure No. 14 on P.17-24.)
D Clutch switch <M/T> or inhibitor switch <A/T> input circuit
system [code No. 26] inspection (Refer to inspection procedure
No. 15 on P.17-24.)
No
Hunting (repeated acceleration and deceleration) occurs
at the set vehicle speed.
Probable cause
The cause is probably a malfunction of vehicle speed sensor or incorrect vacuum
in the auto-cruise vacuum pump or vacuum actuator.
D Malfunction of the vacuum actuator
Vehicle speed sensor check
(Refer to GROUP 54 - Combination Meter.)
NG
Replace
OK
Auto-cruise vacuum pump check (Refer to P.17-29.)
NG
Replace
OK
Vacuum actuator check (Refer to P.17-29.)
NG
Replace
OK
Even though auto-cruise control main switch is ON,
switch indicator lamp does not illuminate. (However,
auto-cruise control is normal.)
Probable cause
Blown bulb in auto-cruise control main switch D Malfunction of the auto-cruise control main switch
Replace the auto-cruise control main switch.
Auto-cruise control main switch illumination lamp does
not illuminate.
Probable cause
The cause is probably a malfunction of auto-cruise control main switch or a malfunction
of harness or connector.
NG
Replace
OK
Measure at auto-cruise control main switch connector C-22.
D Lighting switch: TAIL
OK: System voltage
NG
<L.H.> C-22, C-64, C-67, C-116
<R.H.> C-22, C-61, C-62, C-14
NG
Repair
OK
OK
<L.H.> C-22, C-64, C-25
<R.H.> C-22, C-61, C-62, C-25
OK
NG
and rheostat, and repair if necessary.
NG
Repair
NG
Auto-cruise control indicator lamp (CRUISE MAIN,
CRUISE SET) inside combination meter does not
illuminate. (However, auto-cruise control is normal.)
Probable cause
The cause is probably a malfunction of bulb or a malfunction of connector or harness. D Malfunction of the bulb
<CRUISE MAIN indicator lamp>
CRUISE MAIN indicator lamp bulb check
NG
Replace
NG
Repair
OK
Combination meter check
NG
Repair
OK
D Ignition switch and main switch: ON
OK: System voltage
NG
D-01, C-26
OK
NG
Check the harness between the combination meter and auto-cruise
control main switch, and repair if necessary.
OK
C-135, C-131
OK
NG
Repair
NG
Check the harness between the combination meter and earth, and
<CRUISE SET indicator lamp>
CRUISE SET indicator lamp bulb check
NG
Replace
OK
Combination meter check
NG
Repair
OK
OK: System voltage
NG
D-03, C-135
NG
Repair
OK
NG
Check the harness between the combination meter and power
supply, and repair if necessary.
OK
OK: System voltage
NG
C-82, C-25
NG
Repair
OK
NG
Check the harness between the combination meter and auto-cruise
control-ECU, and repair if necessary.
OK
Replace the and auto-cruise control-ECU.
Stop lamp switch input circuit system inspection (Code No. 23)
OK
NG
Check the harness between fusible link No. 1 and auto-cruise con-
trol-ECU, and repair if necessary.
Stop lamp switch check (Refer to P.17-28.)
NG
Replace
NG
OK
Check the followingconnectors: C-82, C-65, C-02, C-134, C-142,
C-12 <R.H.>
Repair
Clutch switch <M/T> or inhibitor switch <A/T> input circuit system inspection (Code No. 26)
NG
OK
NG
Check the harness between auto-cruise control-ECU and earth,
Clutch switch check (Refer to P.17-29.)
NG
Replace
OK
<L.H.> C-82, C-01, C-62
<R.H.> C-82, C-01, C-63, C-64
Repair
<M/T>
NG
Inhibitor switch check (Refer to P.17-29.)
NG
Replace
OK
B-72, C-48, C-83, C-82
Repair
<A/T>
OK
NG
Check the harness between the auto-cruise control-ECUand inhibi-
tor switch, and repair if necessary.
CHECK AT THE ECU TERMINALS 17200270121
Terminal
No.
Check item Check conditions Normal condition
1 Throttle posi-
tion sensor
When accelerator pedal is fully depressed 4.5- 5.5V
(accelerator
pedal position
sensor*) input
When accelerator pedal is released 0.3- 1.0V
2 Idle switch
output
When accelerator pedal is de-
pressed
When idle switch is OFF 4.5- 5.5V
When accelerator pedal is not
depressed
When idle switch is ON 0V
3 ACC power
supply
When ignition switch is in ACC position System voltage
4 Stop lamp When brake pedal is depressed Whenstop lampswitch is ON System voltage
switch input
Whenbrakepedal is not depressed When stop lamp switch is
OFF
0V
5 Diagnosis
control input
When ignition switch is ON 4V or more
6 ECU backup
power supply
At any time System voltage
7 Auto-cruise When decelerating with the SET Release valve closed 0V
8
vacuum
pump release
switch while driving at constant
speed Control valve open/closed System voltage/0V
7
valve and
control valve
When cancelling constant speed Release valve open System voltage
8
input
driving with the CANCEL switch
Control valve open System voltage
9 Earth At any time Continuity
10 A/T control No OD-OFF request System voltage
output
OD-OFF request 0V
NOTE
*: Vehicles with TCL
Terminal
No.
Check item Check conditions Normal condition
11 Vehicle speed When vehicle is moved forwards When sensor is ON 0V
sensor input and backwards, sensor turns ON
and OFF repeatedly When sensor is OFF 4.5V or more
12 Auto-cruise
control switch
When input switch has not been
operated
When all switches are OFF 0V
input
When input switch is pushed down When SET switch is ON Approx. 3V
When input switch is pushed up WhenRESUMEswitchisON Approx. 6V
When input switchis pulledforward When CANCEL switch is ON System voltage
13 Earth At any time Continuity
14 Clutch switch When pedal is not depressed When clutch switch is OFF 5V
input <M/T>
When pedal is depressed When clutch switch is ON 0V
Inhibitor
switch input
When select lever is in a position
other than N range
When inhibitor switch is OFF 5V
<A/T>
When select lever is in N range When inhibitor switch is ON 0V
15 Pump power
supply
Main switch : ON
Stop lamp switch : OFF
System voltage
16 ECU power
supply
Main switch : ON
System voltage
17 Indicator lamp
input (inside
When driving at constant speed When indicator lamp is illumi-
nated
0V
combination
meter)
When constant-speed driving is
cancelled
When indicator lamp is
switched off
System voltage
18 Auto-cruise
vacuum pump
When driving at constant speed
using the SET switch
Motor stopped/running System voltage/0V
motor input
When accelerating with the RE-
SUME switch while driving at
constant speed
Motor stopped/running System voltage/0V
When decelerating with the SET
switch while driving at constant
speed
Motor stopped System voltage
When cancelling constant speed
driving with the CANCEL switch
Motor stopped System voltage
AUTO-CRUISE CONTROL MAIN SWITCH CHECK
1. Turn the ignition key to ON.
2. Check to be sure that the indicator lamp within the switch
illuminates when the main switch is switched ON.
AUTO-CRUISE CONTROL SWITCH CHECK
17200120143
AUTO-CRUISE CONTROL SETTING
1. Switch ON the main switch.
2. Drive at the desired speed within the range of
approximately 40- 200 km/h.
3. Push the auto-cruise control switch in the direction of
arrow (B).
4. Check to be sure that when the switch is released the
speed is the desired constant speed.
NOTE
If the vehicles speed decreases to approximately 15 km/h
belowthe set speed because of climbing a hill for example,
the auto-cruise control will be cancelled.
SPEED-INCREASE SETTING
1. Set to the desired speed.
arrow (A).
3. Check to be sure that acceleration continues while the
switch is hold, and that when it is released the constant
speed at the time when it was released becomes the
driving speed.
NOTE
Acceleration can be continued even if the vehicle speed
has passed the high-speed limit (approx. 200 km/h). But
the speed when the auto-cruise control switch is released
will be recorded as the high-speed limit.
Auto-cruise
control
main switch
Auto-cruise
control
main switch
(A)
(B)
(C)
SPEED-REDUCTION SETTING
1. Set to the desired speed.
arrow (B).
3. Check to be sure that deceleration continues while the
switch is pressed, and that when it is released the constant
speed at the time when it was released becomes the
driving speed.
NOTE
When the vehicle speed reaches the low limit
(approximately 40 km/h) during deceleration, the
auto-cruise control will be cancelled.
RETURN TO THE SET SPEED BEFORE CANCELLATION
AND AUTO-CRUISE CONTROL CANCELLATION
1. Set the auto-cruise speed control.
2. When any of the following operations are performed while
at constant speed during auto-cruise control, check if
normal driving is resumed and deceleration occurs.
a. The auto-cruise control switch is pushed in the
direction of arrow (C).
b. The brake pedal is depressed.
c. The clutch pedal is depressed. <M/T>
d. The selector lever is moved to the N range. <A/T>
3. When the auto-cruise control switch is pushed in the
direction of arrow (A) at a vehicle speed of 40 km/h or
higher, check if the vehicle speed returns to the speed
before auto-cruise control driving was cancelled, and
constant speed driving occurs.
4. When the main switch is turned to OFF while driving
at constant speed, check if normal driving is resumed
and deceleration occurs.
AUTO-CRUISE CONTROL COMPONENT CHECK
17200170223
STOP LAMP SWITCH
1. Disconnect the connector.
2. Check for continuity between the terminals of the switch.
Measurement conditions Terminal No.
1 2 3 4
When brake pedal is depressed.
(for stop lamp circuit)
When brake pedal is not depressed.
(for auto-cruise control circuit)
CLUTCH SWITCH
2. Check for continuity between the terminals of the switch.
Measurement conditions Terminal No.
1 2
When clutch pedal is depressed.
When clutch pedal is not depressed.
INHIBITOR SWITCH (N POSITION)
Refer to GROUP 23 - On-vehicle Service.
THROTTLE POSITION SENSOR
<Vehicles with TCL>
AUTO-CRUISE VACUUM PUMP
1. Disconnect the vacuumhose fromthe auto-cruise vacuum
pump and connect a vacuum gauge to the vacuumpump.
2. Disconnect the vacuum pump connector.
3. Check that the reading on the vacuum gauge matches
the values in the table belowwhen the battery is connected
to each connector terminal.
Terminal No.
Vacuum gauge
1 2 3 4
Valve condition
Vacuum gauge
kPa
Release valve closed
Control valve closed
53 or more
Release valve open
Control valve open
20 or less
VACUUM ACTUATOR
1. Disconnect the vacuum hose from the vacuum actuator,
and connect a hand vacuum pump to the actuator.
2. Check that the throttle lever operates when applying
vacuum, and the vacuum is kept.
Vacuum
gauge
Re-
lease
valve
Control
valve
1
2 3 4
Vacuum actuator
AUTO-CRUISE CONTROL 17200140224
1
2
3
4
5
6
6
Auto-cruise vacuum pump removal
steps
1. Vacuum hose
2. Auto-cruise vacuum pump and
pump bracket assembly
3. Auto-cruise vacuum pump
assembly
4. Pump bracket
5. Body pump bracket
Auto-cruise control main switch
removal steps
D Meter bezel assembly <L.H. drive
vehicles> (Refer to GROUP 52A.)
D Bezel switch <R.H. drive vehicles>
6. Auto-cruise control main switch
CAUTION: SRS
Before removal of air bag module, refer to
GROUP 52B - SRS Service Precautions and Air
Bag Modules and Clock Spring.
9 Nm
7
8
10
11
9
12
13
14
Auto-cruise control switch removal
steps
D Steering wheel (Refer to GROUP
37A.)
7. Auto-cruise control switch
Auto-cruise control-ECU removal
steps
D Radio and tape player (Refer to
GROUP 54.)
8. Auto-cruise control-ECU
Sensor removal
9. Throttle position sensor
<Vehicles with TCL>
11. Stop lamp switch
12. Clutch switch <M/T>
13. Vehicle speed sensor
14. Inhibitor switch <A/T>
AUTO-CRUISE CONTROL MAIN SWITCH CHECK
1. Connect the terminal 1 to the battery (+) side and connect
the terminal 4 to the battery ( - ) side, and then turn the
main switch to ON. Check that the voltage between the
terminal 5 and earth is battery voltage. Also, check that
the indicator lamp illuminates.
2. When the main switch is turned to OFF, check that the
voltage between the terminal 5 and earth becomes 0
V.
3. Check the continuity between terminals 2 and 7.
AUTO-CRUISE CONTROL SWITCH CHECK 17200120150
Measure the resistance between the terminals when each
of the SET, RESUME and CANCEL switches is pressed.
If the values measured at this time correspond to those in
the table below, then there is no problem.
Switch position Resistance between terminals
Switch OFF No continuity
CANCEL switch ON Approx. 0 W
RESUME switch ON Approx. 820 W
SET switch ON Approx. 2,700 W
VEHICLE SPEED SENSOR CHECK 17200300042
Refer to GROUP 54 - Combination Meters.
<L.H. drive vehicles> <R.H. drive vehicles>
OFF
ON
ON
N OFF N
ILL IND
1 2
4 7 5
OFF
SET
ON
OFF
CANCEL RESUME
ON OFF ON
1
2
ENGINE AND EMISSION CONTROL - Emission Control System <MPI> 17-33
EMISSION CONTROL SYSTEM <MPI> 17300010252
GENERAL INFORMATION
The emission control system consists of the following subsystems:
D Crankcase emission control system
D Exhaust emission control system
Items Name Specification
Crankcase emission
control system
Positive crankcase ventilation (PCV) valve Variable flow type
(Purpose: HC reduction)
Evaporative emission
control system
Canister
Purge control solenoid valve
Equipped
ON/OFF type solenoid valve
(Purpose: HC reduction)
Exhaust emission
control system
Air-fuel ratio control device- MPI system Oxygen sensor feedback type
(Purpose: CO, HC, NOx reduction)
Exhaust gas recirculation system
D EGR valve
D EGR control solenoid valve
Equipped
Single type
Duty cycle type solenoid valve
(Purpose: NOx reduction)
Catalytic converter Monolith type
(Purpose: CO, HC, NOx reduction)
EMISSION CONTROL DEVICE REFERENCE TABLE
Related parts Crankcase
emission
control
system
Evaporative
emission
control
system
Air/fuel
ratio
control
system
Catalytic
converter
Exhaust
gas
recircula-
tion system
Reference
page
PCV valve 17-38
Purge control solenoid valve 17-41
MPI system component GROUP13A
Catalytic converter 17-47
EGR valve 17-44
EGR control solenoid valve 17-45
Purge control solenoid valve coil resistance (at 20_C) W 36 - 44
EGR control solenoid valve coil resistance (at 20_C) W 36 - 44
MD998770 Oxygen sensor
wrench
Removal/Installation of oxygen sensor
VACUUM HOSE 17300090317
VACUUM HOSE PIPING DIAGRAM
<4G6>
OFF
OFF
EGR valve
Air cleaner
Fuel pressure
regulator
PCV valve
ON
ON
Canister
Purge control
solenoid valve
EGR control
solenoid valve
Oxygen sensor
(front)
Oxygen sensor (rear)
Three-way catalytic
converter
Air
<6A1>
Fuel
pressure
regulator
PCV
valve
EGR
valve
Air cleaner
EGR control
solenoid valve
OFF ON
OFF
ON
Canister
Purge control
solenoid valve
Oxygen sensor
(front)
Three-way catalytic
converter
Air
OFF ON
Vacuum
tank <TCL>
Oxygen sensor
(rear)
Vacuum cotrol
solenoid valve <TCL>
Ventilation control
VACUUM CIRCUIT DIAGRAM
<4G6>
To
combustion
chamber
Intake manifold Throttle body
From air
cleaner
Fuel
pressure
regulator
EGR control
solenoid valve
(ON: OPEN)
Vacuum hose colour
B: Black
G: Green
L: Light blue
R: Red
W: White
Purge control
solenoid valve
(ON: OPEN)
EGR valve
Canister
Y: Yellow
<6A1>
Intake manifold Throttle body
To
combustion
chamber
From air
cleaner
Fuel
pressure
regulator
EGR control
solenoid valve
(ON: CLOSE)
Canister
Purge control
solenoid
valve
(ON: OPEN)
EGR valve
Vacuum hose colour
B: Black
G: Green
L: Light blue
R: Red
Y: Yellow
Vacuum
tank <TCL>
Vacuum
actuator <TCL>
Vacuum control
(ON: OPEN)
Ventilation control
(ON: CLOSE)
VACUUM HOSE CHECK
1. Using the piping diagram as a guide, check to be sure
that the vacuum hoses are correctly connected.
2. Check the connection condition of the vacuum hoses,
(removed, loose, etc.) and check to be sure that there
are no bends or damage.
VACUUM HOSE INSTALLATION
1. When connecting the vacuum hoses, they should be
securely inserted onto the nipples.
2. Connect thehoses correctly, using thevacuumhosepiping
diagram as a guide.
ENGINE AND EMISSION CONTROL - Emission Control System <MPI>
<4G6>
PCV valve
<6A1>
PCV valve
17-37
CRANKCASE EMISSION CONTROL SYSTEM 17300500247
GENERAL INFORMATION
The crankcase emission control system prevents
blow-by gases from escaping inside the crankcase
into the atmosphere.
Fresh air is sent from the air cleaner into the
crankcase through the breather hose. The air
becomes mixed with the blow-by gases inside the
crankcase.
The blow-by gas inside the crankcase is drawn
into the intake manifold through the positive
crankcase ventilation (PCV) valve.
The PCV valve lifts the plunger according to the
intake manifold vacuum so as to regulate the flow
of blow-by gas properly. In other words, the blow-by
gas flow is regulated during low load engine
operation to maintain engine stability, while the flow
is increased during high load operation to improve
the ventilation performance.
SYSTEM DIAGRAM
Ventilation hose
Breather hose
PCV valve
NOTE
The illustration shows the system for 4G63 engine.
COMPONENT LOCATION
POSITIVE CRANKCASE VENTILATION SYSTEM
CHECK 17300110136
1. Remove the ventilation hose from the PCV valve.
2. Remove the PCV valve from the rocker cover.
3. Reinstall the PCV valve at the ventilation hose.
5. Place a finger at the opening of the PCV valve and check
that vacuum of the intake manifold is felt.
NOTE
At this moment, the plunger in the PCV valve moves
back and forth.
6. If vacuum is not felt, clean the PCV valve or replace
it.
PCV VALVE CHECK 17300120122
1. Insert a thin rod into the PCV valve from the side shown
in the illustration (rocker cover installation side), and move
the rod back and forth to check that the plunger moves.
2. If the plunger does not move, there is clogging in the
PCV valve. In this case, clean or replace the PCV valve.
PCV valve
PCV valve
<4G6>
<6A1>
17-39
EVAPORATIVE EMISSION CONTROL SYSTEM 17300510363
GENERAL INFORMATION
The evaporative emission control system prevents
fuel vapours generated in the fuel tank from
escaping into the atmosphere.
Fuel vapours from the fuel tank flow through the
fuel tank pressure control valve and vapour
pipe/hose to be stored temporarily in the canister.
When driving the vehicle, fuel vapours stored in
the canister flow through the purge solenoid and
purge port and go into the intake manifold to be
sent to the combustion chamber.
When the engine coolant temperature is low or
when the intake air quantity is small (when the
engine is at idle, for example), the engine control
unit turns the purge solenoid off to shut off the
fuel vapour flow to the intake manifold.
This does not only insure the driveability when the
engine is cold or running under low load but also
stabilize the emission level.
SYSTEM DIAGRAM
From fuel tank
Canister
Purge control
solenoid valve
OFF
ON
Air flow sensor
Barometric pressure
sensor
Control
relay
Throttle body
Engine-ECU
Engine coolant
temperature sensor
Intake air
temperature sensor
COMPONENT LOCATION
PURGE CONTROL SYSTEM CHECK 17300140357
1. Disconnect the vacuum hose (red stripe) from the throttle
body and connect it to a hand vacuum pump.
2. Plug the nipple fromwhich the vacuumhose was removed.
3. When the engine is cold or hot, apply a vacuum while
the engine is idling, and check the condition of the engine
and the vacuum.
When engine is cold
(Engine coolant temperature: 40_C or less)
Vacuum Engine condition Normal condition
53 kPa 3,000 r/min Vacuum is
maintained
When engine is hot
(Engine coolant temperature: 80_C or higher)
Vacuum Engine condition Normal condition
53 kPa At idle Vacuum is
maintained
3,000 r/min Vacuum will leak
for approximately
3 minutes after
the engine is
started. After 3
minutes have
passed, the
vacuum will be
maintained
momentarily, after
which it will again
leak.*
NOTE
*: The vacuum will leak continuously if the atmospheric
pressure is approximately 77 kPa or less, or the temperature
of the intake air is approximately 50_C or higher.
PURGE PORT VACUUM CHECK 17300150282
1. Disconnect the vacuum hose (red stripe) from the throttle
body purge vacuum nipple and connect a hand vacuum
pump to the nipple.
Plug
<4G6>
Red stripe
Red stripe
Plug
<6A1>
Purge port
vacuum nipple
<4G6>
2. Start the engine and check that, after raising the engine
speed by racing the engine, purge vacuum raises
according to engine speed.
NOTE
If there is a problem with the change in vacuum, the
throttle body purge port may be clogged and require
cleaning.
17300170127
NOTE
1. Disconnect the vacuum hose (black stripe, red stripe)
3. Connect a hand vacuumpump to nipple (A) of the solenoid
valve (refer to the illustration at left).
4. Check airtightness by applying a vacuum with voltage
applied directly from the battery to the purge control
solenoid valve and without applying voltage.
Applied Vacuum leaks
Not applied Vacuum maintained
solenoid valve.
Standard value: 36- 44 W (at 20_C)
Purge port
vacuum nipple
<6A1>
Vacuum
Engine speed (r/min)
Battery
B
A
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 17300520274
GENERAL INFORMATION
The exhaust gas recirculation (EGR) systemlowers
the nitrogen oxide (NOx) emission level. When the
air/fuel mixture combustion temperature is high,
a large quantity of nitrogen oxides (NOx) is
generated in the combustion chamber. Therefore,
this system recirculates part of emission gas from
the exhaust port of the cylinder head to the
combustion chamber through the intake manifold
to decrease the air/fuel mixture combustion
temperature, resulting in reduction of NOx.
The EGR flow rate is controlled by the EGR valve
so as not to decrease the driveability.
OPERATION
The EGR valve is being closed and does not
recirculate exhaust gases under one of the following
conditions. Otherwise, the EGR valve is opened
and recirculates exhaust gases.
D The engine coolant temperature is low.
D The engine is at idle.
D The throttle valve is widely opened.
SYSTEM DIAGRAM
ON
OFF
EGR
control
solenoid
valve Air flow sensor
Engine coolant
temperature sensor
Crank angle sensor
Control
relay
Engine-ECU
Battery
EGR valve
A
<4G6>
ON OFF
EGR
control
solenoid
valve
Air flow sensor
Engine coolant
temperature sensor
Crank angle sensor
Control
relay
Engine-ECU
Battery
EGR valve
<6A1>
EGR control solenoid valve
<4G6>
EGRcontrol solenoidvalve
<6A1>
A
EGR valve
<4G6>
B
EGR valve
<6A1>
17-43
COMPONENT LOCATION
EXHAUST GAS RECIRCULATION (EGR)
CONTROL SYSTEM CHECK 17300260282
1. Disconnect the vacuum hose (green stripe) from the EGR
valve, and then connect a hand vacuum pump via the
three-way terminal.
2. When the engine is hot or cold, check the condition of
vacuum by racing the engine.
When engine is cold
(Engine coolant temperature: 20_C or less)
Throttle valve Normal vacuum condition
Open quickly No vacuum will generate
(the same as barometric pressure.)
When engine is hot
(Engine coolant temperature: 80_C or higher)
Throttle valve Normal vacuum condition
Open quickly It will momentarily rise over 13 kPa
Three-way terminal
EGR valve
Green stripe
<4G6>
Three-way terminal
EGR valve
Green stripe
<6A1>
3. Disconnect the three-way terminal.
4. Connect the hand vacuum pump to the EGR valve.
5. Check whether the engine stalls or the idling is unstable
when a vacuum of 30 kPa or higher is applied during
idling.
EGR VALVE CHECK 17300280196
1. Remove the EGR valve and inspect for sticking, carbon
deposits, etc. If found, clean with a suitable solvent so
that the valve seats correctly.
2. Connect a hand vacuum pump to the EGR valve.
3. Apply 67 kPa of vacuum, and check that the vacuum
is maintained.
4. Apply a vacuum and check the passage of air by blowing
through one side of the EGR passage.
Vacuum Passage of air
3.3 kPa or less Air is not blown out
28 kPa or more Air is blown out
5. Replace the gasket, and tighten to the specified torque.
Specified torque: 22 Nm
EGR PORT VACUUM CHECK <4G6> 17300290199
1. Disconnect the vacuumhose(white stripe) fromthethrottle
body EGR vacuum nipple and connect a hand vacuum
pump to the nipple.
Plug
EGR valve
Green stripe
<4G6>
Plug
EGR valve
Green stripe
<6A1>
EGR vacuum
nipple
2. Start the engine and check that the vacuum remains
fairly constant after racing the engine.
NOTE
If vacuum changes, it is possible that the throttle body
EGR port may be clogged and require cleaning.
EGR PORT VACUUM CHECK <6A1> 17300290205
throttle body EGR vacuum nipple and connect a hand
vacuum pump to the nipple.
2. Start the engine and check to see that, after raising the
engine speed by racing the engine, EGR vacuum raises
proportionately with the rise in engine speed.
NOTE
If there is a problem with the change in vacuum, it is
possible that the throttle body EGR port may be clogged
and require cleaning.
<4G6> 17300310222
NOTE
1. Disconnect the vacuum hose (yellow stripe, white stripe,
green stripe) from the solenoid valve.
the white-striped vacuum hose was connected.
applied directly from the battery to the EGR control
Battery voltage B nipple condition Normal condition
Not applied Open Vacuummaintained
Applied Open Vacuum leaks
Closed Vacuummaintained
Vacuum
EGR port
vacuum nipple
Vacuum
A
B
C
Battery
solenoid valve.
<6A1> 17300310239
NOTE
1. Disconnect the vacuum hose (yellow stripe, green stripe)
the green-striped vacuum hose was connected.
applied directly from the battery to the EGR control
Not applied Vacuum leaks
Applied Vacuum maintained
solenoid valve.
Battery
CATALYTIC CONVERTER 17300530055
GENERAL INFORMATION
The three-way catalytic converter, together with
the closed loop air-fuel ratio control based on the
oxygen sensor signal, oxidizes carbon monoxides
(CO) and hydrocarbons (HC) and reduces nitrogen
oxides (NOx).
When the mixture is controlled at stoichiometric
air-fuel ratio, the three-way catalytic converter
provides the highest purification against the three
constituents, namely, CO, HC and NOx.
REMOVAL AND INSTALLATION 17300390233
Under Cover Removal and Installation
34 Nm
44 Nm
49 Nm
13 Nm
49 Nm
49 - 59 Nm
49 Nm
13 Nm
49 Nm
7 Nm
49 Nm
49 Nm
2
3
4
<4G6>
<6A1>
3
1
44 Nm
4
2
Removal steps
1. Heat protector
AA"OXYGEN SENSOR REMOVAL
"AAOXYGEN SENSOR INSTALLATION
CANISTER 17300420055
4
1
2
3
5
Removal steps
1. Vapor hose connection
2. Vent hose
3. Hose clamp
4. Canister
5. Canister bracket
MD998770
ENGINE AND EMISSION CONTROL - Emission Control System <Diesel> 17-49
EMISSION CONTROL SYSTEM <DIESEL> 17500010036
GENERAL INFORMATION
Item Name Specification
Exhaust emission control system Exhaust gas recirculation system
D EGR valve
D EGR solenoid valve
Equipped
Single type
Duty cycle type solenoid valve
SERVICE SPECIFICATION 17500030032
Item Specification
EGR solenoid valve coil resistance W 11 - 14 (at 20_C)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 17500010030
SYSTEM CHECK
Vacuum pump
EGR solenoid
valve
Engine-ECU
A/C switch
(built into engine-ECU)
EGR
valve
1. Start the engine and let it warmup until the engine coolant
temperature is 80_C or above.
2. Check that the diaphragm of the EGR valve moves
towards the EGR valve closing direction when the engine
is raced by suddenly depressing the accelerator pedal.
Diaphragm
EGR SOLENOID VALVE CHECK 17500290027
NOTE
1. Disconnect the vacuum hose (yellow stripes green stripe)
the yellow-striped vacuum hose was connected.
4. Check that the needle reading rises by 47 kPa or more
when negative pressure is applied.
NOTE
There is no problem if the needle reading rises by 47
kPa or more, even though there is a leak.
5. Apply a voltage of 6 V between the terminals, and check
that the pressure leaks at this time even when negative
pressure applied.
6. Measure the resistance between the terminals.
Standard value: 11 - 14W (at 20_C)
CHECK 17500340012
PUMP OPERATION SENSOR CHECK 17500350015
CHECK 17500150028
EGR solenoid
valve
17500360018
BAROMETRIC PRESSURE SENSOR CHECK
17500370011
A/C SWITCH CHECK 17500380014
17500300010
CATALYTIC CONVERTER 17500270021
GENERAL INFORMATION
A monolith-type oxidation catalytic converter is
located between the front exhaust pipe and the
center exhaust pipe. This catalytic converter
reduces the amounts of carbon monoxide (CO)
and hydrocarbons (HC) in the exhaust gas.
REMOVAL AND INSTALLATION 17500210030
Under Cover Removal and Installation
49 Nm
49 Nm
13 Nm
49 Nm
1
2
Removal steps
NOTES
21-1
CLUTCH
LUBRICANTS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pedal Inspection and Adjustment 2 . . . . . . .
Bleeding 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH CONTROL 5 . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Master Cylinder 7 . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH -
General Information/Service
Specifications/Lubricants/On-vehicle Service
21-2
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
Clutch pedal height mm 163 - 166
Clutch pedal clevis pin play mm 1 - 3
Clutch pedal free play mm 6 - 13
Distance between the clutch pedal and the toeboard
when the clutch is disengaged mm
80 or more
Items Specified lubricants Quantity
Clutch fluid Brake fluid DOT3 or DOT4 As required
Push rod assembly Rubber grease
Boot
Release cylinder push rod MITSUBISHI genuine grease
Part No. 0101011
CLUTCH PEDAL INSPECTION AND
ADJUSTMENT
1. Turn up the carpet, etc. under the clutch pedal.
2. Measure the clutch pedal height.
Standard value (A): 163 - 166 mm
3. If the height of the clutch pedal is outside the standard
value, loosen the lock nut and adjust the pedal height
to the standard value using the push rod, adjusting bolt
<vehicles without auto cruise control system>or clutch
switch <vehicles with auto cruise control system>.
Clutch pedal height
A
Lock nut
Adjusting bolt or
clutch switch
Lock nut
Push rod
13 Nm
13 Nm
CLUTCH - On-vehicle Service 21-3
4. Measure the clutch pedal play.
Standard value (B): 1 - 3 mm
5. If the clutch pedal play is not within the standard value,
loosen the lock nut and move the push rod to adjust.
Caution
Do not push in the master cylinder push rod at this
time.
6. After completing the adjustments, confirm that the clutch
pedal free play (measured at the face of the pedal pad)
and the distance between the clutch pedal (the face of
the pedal pad) and the toeboard when the clutch is
disengaged are within the standard value ranges.
Standard value (C): 6- 13 mm
Standard value (D): 80 mm or more
7. If the clutch pedal free play and the distance between
the clutch pedal and the toeboard when the clutch is
disengaged do not agree with the standard values, it
is probably the result of either air in the hydraulic system
or a faulty master cylinder or clutch. Bleed the air, or
disassemble and inspect the master cylinder or clutch.
8. Turn back the carpet, etc.
BLEEDING 21100140143
Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture of
the specified fluid and other fluid.
Clutch pedal clevis pin play
B
Clutch pedal free play
Distance between the clutch pedal and the
toeboard when the clutch is disengaged
C
D
CLUTCH - Clutch Pedal 21-4
CLUTCH PEDAL 21100160224
Post-installtion Operation
Clutch Pedal Adjustment (Refer to P.21-2)
19
2
3
4
5
6
7
8
9
10
11
12
13
14
13 Nm
29 Nm
15
17
1
12
18
13 Nm
20 21
12 Nm
22
16
Removal steps
1. Clevis pin assembly
2. Bushing
3. Nut
4. Bolt
5. Clevis pin <6A1>
6. Rod A <6A1>
7. Turnover spring <6A1>
8. Rod B <6A1>
9. Bushing <6A1>
10. Bolt
11. Clutch return spring
12. Clutch pedal bushing
13. Pipe
14. Stopper <R.H. drive vehicles>
15. Clutch pedal
16. Pedal pad
17. Stopper
18. Adjusting bolt <Vehicles without auto
cruise control system>
19. Lock nut <Vehicles without auto cruise
control system>
20. Clutch switch <Vehicles with auto
cruise control system>
21. Clip <Vehicles with auto cruise control
system>
22. Master cylinder member assembly
CLUTCH - Clutch Control 21-5
CLUTCH CONTROL 21100190216
REMOVAL AND INSTALLTION
Clutch Fluid Draining
D Clutch Fluid Supplying
D Clutch Line Bleeding (Refer to P.21-3)
D Clutch Pedal Adjustment (Refer to P.21-2)
Release
cylinder
push rod
Release
fork
7
6
8
4
4
8
5
10
8
2
1
3
9
10 - 12 Nm
13 Nm
Specified grease:
MITSUBISHI genuine
grease Part No. 0101011
15 Nm
8
<4G6>
19 Nm
<4D6, 6A1>
Clutch master cylinder removal
steps
2. Clutch pipe connection
3. Clutch master cylinder
Clutch release cylinder removal
steps
5. Clutch release cylinder
Clutch fluid line damper removal
steps <4D6, 6A1>
7. Clutch fluid line damper
Clutch line removal steps
8. Clutch pipe
9. Bracket
10. Clutch hose
Release
cylinder push
rod
Release
fork
1
2
3
4
5
8
9
10
8 4
7
10 - 12 Nm
13 Nm
8
Specified grease:
MITSUBISHI genuine
grease Part No. 0101011
15 Nm
8
<4G6>
6
19 Nm
<4D6, 6A1>
Clutch master cylinder removal
steps
3. Clutch master cylinder
Clutch release cylinder removal
steps
5. Clutch release cylinder
Clutch fluid line damper removal
steps <4D6, 6A1>
7. Clutch fluid line damper
Clutch line removal steps
8. Clutch pipe
9. Bracket
10. Clutch hose
CLUTCH MASTER CYLINDER
1
2
3
4
5
6
7
8
2
2
<4G6, 4D6> 3
4
4
1
2
3
Grease: Rubber grease
Clutch fluid:
Brake fluid DOT3 or DOT4 Piston repair kit
13 Nm
<6A1>
Dsassembly steps
1. Piston stopper ring
2. Piston assembly
"AA 3. Push rod assembly
4. Boot
5. Reservoir cap
6. Spring pin
7. Reservoir tank
8. Clutch master cylinder assembly
Caution
Do not disassemble piston assembly.
"AAPUSH ROD ASSEMBLY INSTALLATION
Set the length of the push rod assembly to the shown
dimension to make the adjustment of clutch pedal easier.
121 mm
NOTES
22-1
MANUAL
TRANSMISSION
LUBRICANT 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Check 3 . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Replacement 3 . . . . . . . . . . . . . . . .
TRANSMISSION CONTROL* 4 . . . . . . . . . . . . . . . .
TRANSMISSION ASSEMBLY 6 . . . . . . . . . . . . . . . .
WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICULES
WARNING!
injury or death to service personnel (from inadvertent firing of the air bag) or to driver and passenger (fromrendering
MITSUBISHI dealer.
component.
NOTE
MANUAL TRANSMISSION - Lubricant/Special Tools 22-2
LUBRICANT 22100040242
Item Specified lubricant Quantity L
Transmission oil Hypoid gear oil SAE 75W - 90 or 75W - 85W
conforming to API GL-4
2.2
MB990635 or
MB991113
Steering linkage
puller
Ball joint disconnection
GENERAL
SERVICE
TOOL
MZ203827
MANUAL TRANSMISSION - On-vehicle Service 22-3
TRANSMISSION OIL CHECK
(1) Remove the oil filler plug.
(2) Oil level should be at the lower portion of the filler plug
hole.
(3) Check that the transmission oil is not noticeably dirty,
and that it has a suitable viscosity.
(4) Tighten the filler plug to the specified torque.
TRANSMISSION OIL REPLACEMENT 22100100247
(1) Remove the drain plug to drain oil.
(2) Tighten the drain plug to the specified torque.
(3) Remove the filler plug and fill with specified oil till the
level comes to the lower portion of filler plug hole.
Transmission oil
Specified oil:
Hypoid gear oil SAE 75W - 90 or 75W - 85W
conforming to API GL-4
Quantity: 2.2 L
(4) Tighten the filler plug to the specified torque.
Transmission oil
Filler plug hole
Filler plug
Drain plug
32 Nm
MANUAL TRANSMISSION - Transmission Control 22-4
TRANSMISSION CONTROL 22100380238
D Air Cleaner Assembly Removal and Installation
D Battery and Battery Tray Removal and Installation
Caution: SRS
Be careful not to subject the SRS-ECU to any
shocks during removal and installation of the
shift cable and select cable assembly.
12 Nm
4
5
6
7
8
9
10
11
12
13
14
1
2
3
12 Nm
8
Shift cable and select cable
assembly removal steps
D Lower cover and side cover (Refer
to GROUP 52A - Instrument Panel.)
"BA 1. Shift knob
"BA 2. Spring washer
"BA 3. Nut
D Floor console box
4. Snap pin
5. Select cable connection
(Shift lever side)
6. Clip
7. Shift cable connection
(Shift lever side)
8. Snap pin
"AA 9. Select cable connection
(Transmission side)
"AA 10. Shift cable connection
(Transmission side)
"AA 11. Shift cable and select cable
assembly
Shift lever assembly removal steps
"BA 1. Shift knob
"BA 2. Spring washer
"BA 3. Nut
D Floor console box
4. Snap pin
(Shift lever side)
6. Clip
(Shift lever side)
12. Shift lever assembly
13. Distance piece
14. Bushing
"AASHIFT CABLE AND SELECT CABLE ASSEMBLY/
SHIFT CABLE CONNECTION/SELECT CABLE
CONNECTION
(1) Set the transmission side shift lever and the passenger
compartment side shift lever to the neutral position.
(2) For the transmission side, the white and yellow paint
marks on the shift and select cable ends should face
the snap pins.
(3) Move the shift lever to all positions and check that the
operation is smooth.
"BANUT/SPRING WASHER/SHIFT KNOB
INSTALLATION
(1) Screw in the nut all the way by hand, turn back half
a turn, and then insert the spring washer.
(2) Screw in the shift knob until it touches the spring washer,
and make one more turn. Then turn more to adjust the
shift pattern on the shift knob.
(3) If the above steps are impossible, you can turn back
the shift knob by one turn at most after screwing in all
the way to adjust the shift pattern.
Shift lever
Neutral position
SHIFT LEVER ASSEMBLY 22100400101
1
2
3
4
5
6
7
8
9
10
5 Nm
6 Nm
3
Disassembly steps
1. Bolt
2. Select lever
3. Bushing
4. Return spring
5. Collar
6. Cap
7. Spacer
8. Shift lever
9. Shift lever bushing
10. Lever bracket
MANUAL TRANSMISSION - Transmission Assembly 22-7
TRANSMISSION ASSEMBLY 22100270290
D Transmission Oil Draining (Refer to P.22-3.)
D Battery and Battery Tray Removal
D Battery and Battery Tray Installation
D Transmission Oil Supplying (Refer to P.22-3.)
D Check the Dust Cover for Cracks or Damage by
Pushing it with Finger.
D Shift Lever Operation Check
D Speedometer Operation Check
D Wheel Alignment Adjustment
88 Nm*
1
81 Nm
19 Nm
98 - 118 Nm*
1
44 Nm
11
67 - 78 Nm
24 - 33 Nm
81 Nm
98 - 118 Nm
88 Nm
103 Nm
19 Nm
30 Nm 30 Nm
9
10
8
15
5
1
2
15
4
10 - 12 Nm
3
6
7
<4G6>
5
<4D6, 6A1> 19 Nm
14
13
12
Removal steps
3. Backup lamp switch connector
4. Vehicle speed sensor connector
5. Clutch release cylinder connection
6. Clutch fluid line damper connection
7. Starter motor <6A1>
AA" 8. Tie rod end connection
9. Stabilizer link connection
10. Damper fork
11. No.2 stay
12. Lateral lower arm connection
AB" 13. No.3 stay
14. Compression lower arm connection
AC" 15. Drive shaft
Caution
*1: Indicates parts which should be temporarily
tightened, and then fully tightened with the
vehicle on the ground in the unladen condition.
16
57 Nm
57 Nm*
2
69 Nm
10Nm <Flange bolts>
9Nm <Washer assembled bolts>
18
19
17
19
20
21
93 Nm
49 Nm
25
24
49 Nm
30 Nm
69 - 78 Nm
10 - 12 Nm
22
25 Nm
23
44 Nm
7 Nm
81 Nm*
2
49 Nm
24
16. Starter motor <4G6, 4D6>
17. Transmission assembly upper part
coupling bolts
AD" 18. Transmission mount bracket
"AA 19. Transmission mount stopper
AE" D Engine and transmission assembly
supporting
20. Centermember assembly
21. Rear roll stopper
22. Bell housing cover <4G6, 4D6>
23. Cover <6A1>
AF" 24. Transmission assembly lower part
coupling bolts
AF" 25. Transmission assembly
Caution
Mounting locations marked by *2 should be
provisionally tightened, and thenfully tightenedafter
placing the vehicle horizontally and loading the full
weight of the engine on the vehicle body.
AA"TIE ROD END DISCONNECTION
Caution
1. Use the special tool to loosen the tie rod end mounting
nut. Only loosen the nut; do not remove it from the
ball joint.
2. Support the special tool with a cord, etc. not to let
it come off.
AB"NO.3 STAY REMOVAL
No.3 stay is tightened together with the crossmember.
Therefore, after removing No.3 stay, install the nut and bolt
to the crossmember provisionally.
AC"DRIVE SHAFT DISCONNECTION
(1) Insert a pry bar between the transmission case and the
drive shaft as shown to remove the drive shaft.
NOTE
Do not remove the hub and knuckle from the drive shaft.
Caution
Always use a pry bar, or the TJ will be damaged.
(2) Suspend the removed drive shaft with a wire so that
there are no sharp bends in any of the joints.
(3) Use a shop towel to cover the transmission case not
to let foreign material get into it.
AD"TRANSMISSION MOUNT BRACKET REMOVAL
Jack up the transmission assembly gently with a garage jack,
and then remove the transmission mount bracket.
Cord
Ball joint
MB990635 or
MB991113
Nut
No.3 stay Crossmember
Pry bar
Trans-
mission
side
AE"ENGINE AND TRANSMISSION ASSEMBLY
SUPPORTING
Set the special tool to the vehicle to support the engine and
transmission assembly.
AF" TRANSMISSION ASSEMBLY LOWER PART
COUPLING BOLTS/TRANSMISSION ASSEMBLY
REMOVAL
1. Support the transmission assembly with a transmission
jack.
2. Remove the transmission assembly lower part coupling
bolts, and lower the transmission assembly to remove.
Caution
Do not remove the flywheel mounting bolt shown in
the illustration. If this bolt is removed, the flywheel
will become out of balance and damaged.
"AATRANSMISSION MOUNT STOPPER INSTALLATION
Install the transmission mount stopper so that the arrow points
MZ203827
MB991453
Flywheel
Bolt
Transmission
mount
stopper
Transmission
mount
bracket
Engine side
Arrow
23-1
AUTOMATIC
TRANSMISSION
LUBRICANTS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Essential Service 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/T Control Component Location 51 . . . . . . . . . . . . .
A/T Control Component Check 52 . . . . . . . . . . . . . . .
Torque Converter Stall Test 54 . . . . . . . . . . . . . . . . . .
Hydraulic Pressure Test 56 . . . . . . . . . . . . . . . . . . . . .
Hydraulic Circuit 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Adjustment 62 . . . . . . . . . . . . . . . . . . . .
Selector Lever Operation Check 62 . . . . . . . . . . . . . .
TRANSMISSION CONTROL* 63 . . . . . . . . . . . . . .
TRANSMISSION ASSEMBLY 66 . . . . . . . . . . . . . .
WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICULES
WARNING!
injury or death to service personnel (from inadvertent firing of the air bag) or to driver and passenger (fromrendering
MITSUBISHI dealer.
component.
NOTE
AUTOMATIC TRANSMISSION -
Service Specifications/
Lubricants/Special Tools
23-2
Oil temperature sensor kW at 0_C 16.5 - 20.5
at 100_C 0.57 - 0.69
Resistance of damper clutch control solenoid valve coil (at 20_C) W 2.7 - 3.4
Resistance of Low-Reverse solenoid valve coil (at 20_C) W 2.7 - 3.4
Resistance of second solenoid valve coil (at 20_C) W 2.7 - 3.4
Resistance of underdrive solenoid valve coil (at 20_C) W 2.7 - 3.4
Resistance of overdrive solenoid valve coil (at 20_C) W 2.7 - 3.4
Stall speed r/min 2,100 - 2,600
Items Specified lubricant Quantity L
Transmission fluid DIA QUEEN ATF SPII or equivalent 7.8
MB991502 MUT-II sub
assembly
Checking of the diagnosis code
MD998330
(including
MD998331)
Oil pressuregauge
(2,942 kPa)
Measurement of oil pressure
MD998332 Adapter
MD998900 Adapter
AUTOMATIC TRANSMISSION - Special Tools 23-3
MB990635 or
MB991113
Steering linkage
puller
MB991610 Oil filter wrench Removal and installation of automatic trans-
mission oil filter
GENERAL
SERVICE
TOOL
MZ203827
assembly
Supporting the engine assembly during
AUTOMATIC TRANSMISSION - Troubleshooting 23-4
Gathering information from custom-
er.
Read the diagnosis code (GROUP 00
- How to Use Troubleshooting/In-
spection Service Points.)
Communication with
MUT-II not possible
Inspection procedure No. 1 in
Inspection Chart For Trouble
Symptoms (Refer to P.23-27.)
Diagnosis code
displayed
Erase the diagnosis code (GROUP
00 - How to Use Troubleshooting/In-
spection Service Points.)
No diagnosis code displayed
Carry out the essential service
(Refer to P.23-46.)
Road test (Refer to P.23-6.)
Abnormality exists (no diagnosis code)
No abnormality
Recheck diagnosis codes which
were read before the road test.
Abnormality exists
(diagnosis code
present)
Diagnosis
code displayed
No diagnosis
code displayed
To INSPECTION CHART FOR
DIAGNOSIS CODES
(Refer to P.23-14.)
To INSPECTION CHART FOR
TROUBLE SYMPTOMS
(Refer to P.23-26.)
Search for cause.
Found Not found
Repair
Confirmation test (road test)
NG
NG
INTERMITTENT MALFUNCTION
(GROUP 00 - Points to Note for
Intermittent Malfunctions.)
OK
Completed
OK
1. N range lamp
The N range lamp flashes at a frequency of approximately
1 Hz if there is an abnormality in any of the items in the
table below which are related to the A/T system. Check
the diagnosis code output if the N range lamp is flashing
at a frequency of approximately 1 Hz.
N range lamp flashing items
Crank angle sensor
Input shaft speed sensor
Output shaft speed sensor
Each solenoid valve
Out of phase at each shift point
Caution
If the N range lamp is flashing at a frequency of
approximately 2 Hz (faster than at 1 Hz), it means that
the automatic transmission fluid temperature is too high.
Stop the vehicle in a safe place and wait until the N range
lamp switches off.
2. Method of reading the diagnosis code
Use the MUT-II or the N range lamp to take a reading of
the diagnosis codes. (Refer to GROUP 00 - How to Use
Troubleshooting/Inspection Service Points.)
ROAD TEST 23100780271
Check by the following procedure.
No. State prior to test
and operation
Test and operation Judgement value Check item Diag-
nosis
code
No.
Inspection
procedure page
if there is an
abnormality
1 Ignition switch:
OFF
Ignition switch
(1) ON
Data list No. 54
Battery voltage [V]
Control relay 54 A/T Control
relay system
(23-25)
2 Ignition switch:
ON
Engine: Stopped
Selector lever
position: P
Selector lever
position
(1) P, (2) R,
(3) N, (4) D,
(5) 3, (6) 2, (7) L
Data list No. 61
(1) P, (2) R, (3)N,
(4) D, (5) 3, (6) 2,
(7) L
Inhibitor switch - Inhibitor switch
system (23-36)
position: P
Accelerator pedal
(1) Released
(2) Half depressed
(3) Depressed
Data list No. 11
(1) 400 - 1,000 mV
(2) Gradually rises
from (1)
(3) 4,500 - 5,000
mV
Throttle posi-
tion sensor
<Vehicles
without TCL>
Accelerator
pedal position
sensor
<Vehicles with
TCL>
11
12
14
Throttle
position sensor
system (23-15)
Accelerator
pedal position
sensor system
(23-15)
Data list No. 25
(1) OFF
(2) ON
Wide open
throttle switch
25 Wide open
throttle switch
system (23-17)
Brake pedal
(1) Depressed
(2) Released
Data list No. 26
(1) ON
(2) OFF
Stop lamp
switch
26 Stop lamp switch
system (23-18)
3 Ignition switch:
ST
Engine: Stopped
Starting test with
lever P or N range
Starting should be
possible
Starting
possible or
impossible
- Starting
impossible
(23-28)
4 Warming up Drive for 15
minutes or more so
that the automatic
fluid temperature
becomes 70 -
90_C.
Data list No. 15
Gradually rises to
70 - 90_C
Oil temperature
sensor
15 Oil temperature
sensor system
(23-15)
and operation
nosis
code
No.
Inspection
procedure page
if there is an
abnormality
5 Engine: Idling
Selector lever
position: N
Brake pedal
(Retest)
(1) Depressed
(2) Released
Data list No. 26
(1) ON
(2) OFF
Stop lamp
switch
26 Stop lamp switch
system (23-18)
A/C switch
(1) ON
(2) OFF
Data list No. 65
(1) ON
(2) OFF
Dual pressure
switch
- Dual pressure
switch system
(23-37)
Accelerator pedal
(1) Released
(2) Half depressed
Data list No. 64
(1) ON
(2) OFF
Idle position
switch
- Idle position
switch system
(23-37)
Data list No. 21
(1) 550 - 850 rpm
Gradually rises
from (1)
Crank angle
sensor
21 Crank angle
sensor system
(23-16)
Data list No. 57
(2) Data changes
Communication
with engine-
ECU
<Vehicles
without TCL>
Communication
with TCL-ECU
<Vehicles with
TCL>
51 Serial
communication
system (23-25)
Selector lever
position
(1) N D
Should be no
abnormal shifting
shocks
Malfunction
when starting
- Engine stalling
during shifting
(23-30)
(1) N D
(2) N R Time lag should be
within 2 seconds
- Shocks when
changing from N
to D and large
time lag (23-30)
- Shocks when
changing from N
to R and large
time lag (23-31)
- Shocks when
changing from N
to D,N to R and
large time lag
(23-32)
Driving
impossible
- Does not move
forward (23-28)
- Does not
reverse (23-29)
- Does not move
(forward or
reverse) (23-29)
and operation
nosis
code
No.
Inspection
procedure page
if there is an
abnormality
6 Selector lever
position: N
(Carry out on a
Selector lever
position and
vehicle speed
Data list No. 63
(2) 1st, (4) 3rd, (3)
2nd, (5) 4th
Shift condition - -
flat and straight
road.)
(1) Idling in
L range
(Vehicle
stopped)
(2) Driving at
Data list No. 31
(2) 0 %, (4) 100 %,
(3) 100 %, (5) 100
%
Low and reverse
solenoid valve
31 Low and reverse
solenoid valve
system (23-18)
constant speed
of
10 km/h in
L position
Data list No. 32
(2) 0 %, (4) 0 %,
(3) 0 %, (5) 100 %
Underdrive
solenoid valve
32 Underdrive
solenoid valve
system (23-18)
(3) Driving at
constant speed
of
30 km/h in
Data list No. 33
(2)100 %, (4) 100
%, (3) 0 %, (5) 0 %
Second
solenoid valve
33 Second solenoid
valve system
(23-18)
2 position
(4) Driving at
50 km/h in
3 position with
accelerator fully
Data list No. 34
(2) 100 %, (4) 0 %,
(3) 100 %, (5) 0 %
Overdrive
solenoid valve
34 Overdrive
solenoid valve
system (23-18)
closed
(5) Driving at
constant speed
of
Data list No. 29
(1) 0 km/h
(4) 50 km/h
Vehicle speed
sensor
- Vehicle speed
sensor system
(23-38)
50 km/h in
D position
(Each
condition
Data list No. 22
(4) 1,800 - 2,100
rpm
Input shaft
speed sensor
22 Input shaft speed
sensor system
(23-16)
should be
maintained for
10 seconds or
more.)
Data list No. 23
(4) 1,800 - 2,100
rpm
Output shaft
speed sensor
23 Output shaft
speed sensor
system (23-17)
7 Selector lever
position: 3
(Carry out on a
flat and straight
road.)
Selector lever
position and
vehicle speed
(1) Release the ac-
celerator pedal
Data list No. 36
(1) 0 %
(2) Approx. 70 - 90
%
Damper clutch
control solenoid
valve
36
52
Damper clutch
control solenoid
valve system
(23-19)
fully while driv-
ing at 50 km/h
in 3rd gear.
(2) Driving at
constant speed
of 50 km/h in
3rd gear.
Data list No. 52
(1) Approx.
100 - 300 rpm
(2) Approx.
0 - 10 rpm
and operation
nosis
code
No.
Inspection
procedure page
if there is an
abnormality
8 Use the MUT-II to
stop the INVECS-
II function.
Monitor data list
No. 11, 23, and 63
with the MUT-II.
For (1), (2) and (3),
the reading should
be the same as the
Malfunction
when shifting
- Shocks and
running up
(23-32)
Selector lever (1) Accelerate to specified output
Displaced - All points (23-33)
position: D
(Carry out on a flat
and straight road.)
4th gear at a
throttle
position
shaft speed and no
abnormal shocks
should occur.
shifting points
- Some points
(23-34)
and straight road.)
position
sensor output
of 1.5V
should occur.
For (4), (5) and (6),
downshifting
Does not shift - No diagnosis
code (23-34)
(accelerator
opening angle
of 30 %).
(2) Gently
should occur
immediately
after the shifting
operation is made.
22 Input shaft
speed sensor
system (23-16)
(2) Gently
decelerate to a
standstill.
(3) Accelerate to
operation is made.
23 Output shaft
speed sensor
system (23-17)
4th gear at a
throttle
position
sensor output
Does not shift
from 1 to 2 or 2
to 1
31 Low and reverse
solenoid valve
system (23-18)
of 2.5 V
(accelerator
opening angle
33 Second
solenoid valve
system (23-18)
of 50%).
(4) While driving at
60 km/h in 4th
gear, shift
41 1st gear ratio is
not specified
(23-20)
down to
3 range.
42 2nd gear ratio is
not specified
(23-21)
40 km/h in 3rd
gear, shift
down to
2 range.
Does not shift
from 2 to 3 or 3
to 2
33 Second
solenoid valve
system (23-18)
20 km/h in 2nd
gear, shift
down to
34 Overdrive
solenoid valve
system (23-18)
down to
L range. 42 2nd gear ratio is
not specified
(23-21)
43 3rd gear ratio is
not specified
(23-22)
Does not shift
from 3 to 4 or 4
to 3
32 Underdrive
solenoid valve
system (23-18)
33 Second
solenoid valve
system (23-18)
43 3rd gear ratio is
not specified
(23-22)
44 4th gear ratio is
not specified
(23-23)
and operation
nosis
code
No.
Inspection
procedure page
if there is an
abnormality
9 Selector lever
position: N
(Carry out on a
Monitor data list
No. 22
and No. 23 with the
II
The ratio between
data list No. 22 and
No. 23 should be
Does not shift 22 Input shaft
speed sensor
system (23-16)
(Carry out on a
flat and straight
road.)
MUT-II.
(1) Move selector
lever to
the same as the
gear ratio when
reversing.
23 Output shaft
speed sensor
system (23-17)
R range, drive
at constant
speed of
10 km/h.
46 Reverse gear
ratio is not
specified (23-24)
SHIFT PATTERN
<4G63 engine>
UPSHIFT PATTERN
Output shaft speed r/min
Thick line: Standard shift pattern
100
Throttle opening %
0 1,000 2,000 3,000 4,000
5,000
6,000 7,000
2 3
movement
range 3 4
movement
range
Vehicle speed km/h
0
50
0 50 100 150 200
1 2 2 3 3 4
DOWNSHIFT PATTERN
3 (L,2) 4
(L,2,3)
3
Thick line: Standard shift pattern Throttle opening %
2 3
movement
range
3 4
movement
range
100
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
Vehicle speed km/h
0
50
0 50 100
1 2 2 3 3 4
200 150
1 2 (L) 2
HOLD MODE PATTERN
Thick line: Standard shift pattern
Throttle opening %
100
0 2,000 4,000 6,000 8,000
Vehicle speed km/h
0
50
0 50 100
1 2
2 3 3 4
200 150
3 4
<6A13 engine>
UPSHIFT PATTERN
100
Vehicle speed km/h
0
50
0 50 100
1 2 2 3 3 4
200 150
2 3
movement
range
3 4
movement
range
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
DOWNSHIFT PATTERN
4
(L,2,3)
3
2 3
movement
range
3 4
movement
range
100
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
Vehicle speed km/h
0
50
0 50 100
1 2 2 3 3 4
200 150
1 2 (L) 2 3 (L,2)
HOLD MODE PATTERN
100
0 2,000 4,000 6,000 8,000
Vehicle speed km/h
0
50
0 50 100
3 4
2 3
1 2
200 150
3 4
INSPECTION CHART FOR DIAGNOSIS CODE 23100790243
Code Diagnosis item Reference page
11 Throttle position sensor system Short circuit 23-15
12
Accelerator pedal position sensor system
Open circuit 23-15
14
Accelerator pedal position sensor system
<Vehicles with TCL>
Sensor maladjustment 23-15
15 Oil temperature sensor system Open circuit 23-15
21 Crank angle sensor system Open circuit 23-16
22 Input shaft speed sensor system Short circuit/open circuit 23-16
23 Output shaft speed sensor system Short circuit/open circuit 23-17
25 Wide open throttle switch system Short circuit 23-17
26 Stop lamp switch system Short circuit/open circuit 23-18
31 Low and reverse solenoid valve system Short circuit/open circuit 23-18
32 Underdrive solenoid valve system Short circuit/open circuit 23-18
33 Second solenoid valve system Short circuit/open circuit 23-18
34 Overdrive solenoid valve system Short circuit/open circuit 23-18
36 Damper control clutch solenoid valve system Short circuit/open circuit 23-19
41 1st gear ratio does not meet the specification 23-20
42 2st gear ratio does not meet the specification 23-21
43 3rd gear ratio does not meet the specification 23-22
44 4th gear ratio does not meet the specification 23-23
46 Reverse gear ratio does not meet the specification 23-24
51 Abnormal communication with engine-ECU <Vehicles without TCL>
Abnormal communication with TCL-ECU <Vehicles with TCL>
23-25
52 Damper control clutch solenoid valve system Defective system 23-19
54 A/T Control relay system Short circuit to earth/
open circuit
23-25
56 N range lamp system Short circuit to earth 23-26
71 Malfunction of A/T-ECU 23-26
Code No. 11, 12, 14 Throttle position sensor system
<Vehicles without TCL>, accelerator pedal position
sensor <Vehicles with TCL>
Probable cause
If the TPS or APS output voltage is 4.8 V or higher when the engine is idling, the
output is judged to be too high and diagnosis code No. 11 is output. Code No. 11
is also output if there is a problem with the APS and an APS fail-safe signal is received
from the TCL-ECU. If the TPS or APS output voltage is 0.2 V or lower at times
other than when the engine is idling, the output is judged to be too low and diagnosis
code No. 12 is output. If the TPS or APS output voltage is 0.2 V or lower or if it
is 1.2 V or higher when the engine is idling, the TPS or APS adjustment is judged
to be incorrect and diagnosis code No. 14 is output.
D Malfunction of the throttle position sensor <Vehicles
without TCL>
<Vehicles with TCL>
Throttle position sensor check <Vehicles without TCL>
Accelerator pedal position sensor check<Vehicles with TCL>
(Refer to GROUP 13H - On-vehicle Service.)
NG
Replace
OK
B-07 <Vehicles without TCL>, B-41 <Vehicles with TCL>, C-29
NG
Repair
OK
Harness check
D Between throttle position sensor and A/T-ECU
D Between accelerator pedal position sensor and A/T-ECU
<Vehicles with TCL>
NG
Repair
OK
Check the trouble symptoms.
NG
Code No. 15 Oil temperature sensor system Probale cause
If the oil temperature sensor output voltage is 2.6 V or more even after driving for
10 minutes or more (if the oil temperature does not increase), it is judged that there
is an open circuit in the oil temperature sensor and diagnosis code No. 15 is output.
D Malfunction of the oil temperature sensor
Oil temperature sensor check (Refer to P.23-52.)
NG
Replace
OK
Check the follwing connectors: B-70, C-29
NG
Repair
OK
Harness check
D Between oil temperature sensor and A/T-ECU
NG
Repair
OK
NG
If no output pulse is detected from the crank angle sensor for 5 seconds or more
while driving at 25 km/h or more, it is judged that there is an open circuit in the
crank angle sensor and diagnosis code No. 21 is output.
Check the follwing connectors: B-77, C-29
NG
Repair
OK
Harness check
D Between crank angle sensor and A/T-ECU
NG
Repair
OK
Crank angle sensor system check
OK
NG
Code No. 22 Input shaft speed sensor system Probable cause
If no output pulse is detected from the input shaft speed sensor for 1 second or
more while driving in 3rd or 4th gear at a speed of 30 km/h or more, there is judged
to be an open circuit or short-circuit in the input shaft speed sensor and diagnosis
code No. 22 is output. If diagnosis code No. 22 is output four times, the transmission
is locked into 3rd gear (D range) or 2nd gear as a fail-safe measure, and the N
range lamp flashes at a frequency of 1 Hz.
D Malfunction of the input shaft speed sensor
D Malfunction of the underdrive clutch retainer
L: Refer to the Transmission Workshop Manual.
A/T overhaul K
D Replace the underdrive clutch
retainer.
NG
Eliminate the cause of the noise.
NG
OK
OK
Check the following harness:
D Between the input shaft speed
sensor and the ignition switch
D Between the input shaft speed
sensor and A/T-ECU
NG
Repair
NG
NG
OK
OK
Measure output waveform of the input
shaft speed sensor.
(using an oscilloscope)
D Engine: 2,000 r/min (approx. 50
km/h)
D Transmission: 3rd gear (Voltage)
OK: Conforms to the waveform
shown at page 23-45 (Inspec-
tion procedure using an oscil-
loscope). There is no noise
in the output waveform.
NG
Replace the input shaft speed sensor.
Measure at the input shaft speed sensor
connector B-71.
(1) Voltage between 3 and earth
OK: Battery voltage
OK approx. 5 V
(3) Continuity between 1 and earth
OK: Continuity
NG
B-71, C-29
NG
Repair
Code No. 23 Output shaft speed sensor system Probable cause
If the output from the output shaft speed sensor is continuously 50% lower than the
vehicle speed for 1 second or more while driving in 3rd or 4th gear at a speed of
30 km/h or more, there is judged to be an open circuit or short-circuit in the output
shaft speed sensor and diagnosis code No. 23 is output.
If diagnosis code No. 23 is output four times, the transmission is locked into 3rd
gear (D range) or 2nd gear as a fail-safe measure, and the N range lamp flashes
at a frequency of 1 Hz.
D Malfunction of the output shaft speed sensor
D Malfunction of the transfer drive gear or driven gear
A/T overhaul L
D Replace the transfer drive gear and
driven gear.
NG
NG
OK
OK
Check the following harness:
D Between the output shaft speed
sensor and the ignition switch
D Between the output shaft speed
sensor and A/T-ECU
NG
Repair
NG
NG
OK
OK
Measure output waveform of the output
shaft speed sensor.
D Engine: 2,000 r/min
(approx. 50 km/h)
D Transmission: 3rd gear
(Voltage)
OK: Conforms to the waveform
shown at page 23-45 (Inspec-
tion procedure using an oscil-
loscope). There is no noise
in the output waveform.
NG
Replace the output shaft speed sensor.
Measure at the output shaft speed sen-
sor connector B-68.
OK: Battery voltage
OK: approx. 5 V
(3) Continuity between 1 and earth
OK: Continuity
NG
B-68, C-29
NG
Repair
Code No. 25 Wide open throttle switch system Probable cause
If the wide open throttle switch is on for 1 second or more with the throttle valve
opening angle at 70% or less, it is judged that there is a short circuit in the wide
open throttle switch and diagnosis code No. 25 is output.
D Malfunction of the wide open throttle switch
Wide open throttle switch check (Refer to P.23-64).
NG
Replace
OK
NG
Repair
OK
Harness check
D Between the wide open throttle switch and the A/T-ECU.
NG
Repair
OK
NG
Code No. 26 Stop lamp switch system Probable cause
If the stop lamp switch is on for 5 minutes or more while driving, it is judged that
there is a short circuit in the stop lamp switch and diagnosis code No. 26 is output.
Stop lamp switch check (Refer to GROUP 35 - Brake Pedal.)
NG
Replace
OK
Check the following connectors: C-02, C-30, C-65, C-83
NG
Repair
OK
Harness check
D Between stop lamp switch and A/T-ECU
NG
Repair
OK
NG
Code No. 31 Low and reverse solenoid valve system Probable cause
Code No. 32 Underdrive solenoid valve system
Code No. 33 Second solenoid valve system
Code No. 34 Overdrive solenoid valve system
If the resistance value for a solenoid valve is too large or too small, it is judged
that there is a short-circuit or an open circuit in the solenoid valve and the respective
diagnosis code is output. The transmission is locked into 3rd gear as a fail-safemeasure,
and the N range lamp flashes at a frequency of 1 Hz.
Solenoid valve check (Refer to P.23-54.)
NG
Replace
OK
Check the following connectors: B-70, C-28, C-30, C-41
NG
Repair
OK
Harness check
D Between solenoid valve and A/T-ECU
NG
Repair
OK
Replace the solenoid valve.
NG
Code No. 36, 52 Damper clutch control solenoid valve
system
Probable cause
If the resistance value for the damper clutch control solenoid valve is too large or
too small, it is judged that there is a short-circuit or an open circuit in the damper
clutch control solenoid valve and diagnosis code No. 36 is output. If the drive duty
rate for the damper clutch control solenoid valve is 100 % for a continuous period
of 4 seconds or more, it is judged that there is an abnormality in the damper clutch
control system and diagnosis code No. 52 is output. When diagnosis code No. 36
is output, the transmission is locked into 3rd gear as a fail-safe measure, and the
N range lamp flashes at a frequency of 1 Hz.
D Malfunction of the damper clutch control solenoid valve
Damper clutch control solenoid valve check (Refer to P.23-54.)
NG
Replace
OK
Check the following connectors: B-70, C-28, C-41
NG
Repair
OK
Harness check
D Between damper clutch control solenoid valve and A/T-ECU
NG
Repair
OK
Replace the damper clutch control solenoid valve.
NG
Code No. 41 1st gear ratio does not meet the specification Probable cause
If the output from the output shaft speed sensor multiplied by the 1st gear ratio is
not the same as the output from the input shaft speed sensor after shifting to 1st
gear has been completed, diagnosis code No. 41 is output. If diagnosis code No.
41 is output four times, the transmission is locked into 3rd gear as a fail-safe measure,
D Malfunction of the low and reverse brake system
D Malfunction of the underdrive clutch system
D Noise generated
Is the diagnosis code No. 22 output?
Yes
Code No. 22 Input shaft speed sensor system check
(Refer to P.23-16.)
No
Yes
Code No. 23 Output shaft speed sensor system check
(Refer to P.23-17.)
No
Measure output waveformfrom the input shaft speed sensor. (using
an oscilloscope)
D Connect the connector B-71 and measure voltage between
31 and 43 at the A/T-ECU.
D Engine: 2,000 r/min (approx. 50 km/h)
D Selector lever position: 3
(Voltage)
OK: Awaveformsuchas theone shownon P.23-45(Inspection
Procedure Using an Oscilloscope) is output (flalshing
between 0 5V) and there is no noise appearing
in the waveform.
NG
NG
A/T overhaul L
D Replace the underdrive clutch retainer.
NG
OK
Measure output waveform from the output shaft speed sensor.
(Voltage)
in the waveform.
NG
NG
A/T overhaul L
D Replace the transfer drive gear and driven gear.
NG
OK
A/T overhaul L
D Underdrive clutch system check
(No. 42, No. 43, or no diagnosis code is output).
D Low and reverse brake system check
(No. 46 or no diagnosis code is output).
Code No. 42 2ndgear ratiodoes not meet the specification Probable cause
If the output from the output shaft speed sensor multiplied by the 2nd gear ratio
is not the same as the output from the input shaft speed sensor after shifting to
2nd gear has been completed, diagnosis code No. 42 is output. If diagnosis code
No. 42 is output four times, the transmission is locked into 3rd gear as a fail-safe
measure, and the N range lamp flashes at a frequency of 1 Hz.
D Malfunction of the second brake system
D Noise generated
Yes
(Refer to P.23-16.)
No
Yes
(Refer to P.23-17.)
No
an oscilloscope)
(Voltage)
in the waveform.
NG
NG
A/T overhaul L
NG
OK
(Voltage)
in the waveform.
NG
NG
A/T overhaul L
NG
OK
A/T overhaul L
D Second brake system check
Code No. 43 3rdgear ratio does not meet the specification Probable cause
If the output from the output shaft speed sensor multiplied by the 3rd gear ratio is
not the same as the output from the input shaft speed sensor after shifting to 3rd
D Malfunciton of the transfer drive gear or driven gear
D Malfunction of the overdrive clutch system
D Noise generated
Yes
(Refer to P.23-16.)
No
Yes
(Refer to P.23-17.)
No
an oscilloscope)
(Voltage)
in the waveform.
NG
NG
A/T overhaul L
NG
OK
(Voltage)
in the waveform.
NG
NG
A/T overhaul L
NG
OK
A/T overhaul L
D Overdrive clutch system check
Code No. 44 4th gear ratio does not meet the specification Probable cause
If the output from the output shaft speed sensor multiplied by the 4th gear ratio is
not the same as the output from the input shaft speed sensor after shifting to 4th
D Malfunction of the second brake system
D Malfunction of the overdrive clutch system
D Noise generated
Yes
(Refer to P.23-16.)
No
Yes
(Refer to P.23-17.)
No
an oscilloscope)
(Voltage)
Procedure Using an Oscilloscope) is output (flashing be-
tween 0 5V) and there is no noise appearing in
the waveform.
NG
NG
A/T overhaul L
NG
OK
(Voltage)
in the waveform.
NG
NG
A/T overhaul L
NG
OK
A/T overhaul L
D Second brake system check
D Overdrive clutch system check
Code No. 46 Reverse gear ratio does not meet the
specification
Probable cause
If the output from the output shaft speed sensor multiplied by the reverse gear ratio
is not the same as the output from the input shaft speed sensor after shifting to
reverse gear has been completed, diagnosis code No. 46 is output. If diagnosis code
No. 46 is output four times, the transmission is locked into 3rd gear as a fail-safe
measure, and the N range lamp flashes at a frequency of 1 Hz.
D Malfunciton of the transfer drive gear or driven gear
D Malfunction of the low and reverse brake system
D Malfunction of the reverse clutch system
D Noise generated
Yes
(Refer to P.23-16.)
No
Yes
(Refer to P.23-17.)
No
an oscilloscope)
(Voltage)
in the waveform.
NG
NG
A/T overhaul L
NG
OK
(Voltage)
in the waveform.
NG
NG
A/T overhaul L
NG
OK
A/T overhaul L
D Low and reverse brake system check
D Reverse clutch system check (No diagnosis code is output).
Code No. 51 Abnormal communication with engine-ECU
Abnormal communication with TCL-ECU
<Vehicles with TCL>
Probable cause
If normal communication is not possible for a continuous period of 1 second or more
when the ignition switch is at the ON position, the battery voltage is 10 V or more
and the engine speed is 450 r/min or more, diagnosis code No. 51 is output. Diagnosis
code No. 51 is also output if the data being received is abnormal for a continuous
period of 4 seconds under the same conditions.
D Malfunction of the engine-ECU<Vehicles without TCL>
D Malfunction of the TCL-ECU <Vehicles with TCL>
NG
NG
<Vehicles with TCL>
OK
OK
Harness check
D Between engine-ECU and A/T-ECU
D Between TCL-ECU and A/T-ECU
<Vehicles with TCL>
NG
Repair
D C-30, C-34, C-38
<4G6-vehicles without TCL>
D C-30, C-37
<6A1-vehicles without TCL>
D C-10, C-30, C-51
<Vehicles with TCL>
NG
Repair
Code No. 54 A/T control relay system Probable cause
If the A/T control relay voltage is less than 7 V after the ignition switch has been
turned ON, it is judged that there is an open circuit or a short-circuit in the A/T control
relay earth and diagnosis code No. 54 is output.
Then the transmission is locked into 3rd gear as a fail-safe measure, and the N
range lamp flashes at a frequency of 1 Hz.
D Malfunction of the A/T control relay
Check the A/T control relay. (Refer to P.23-53.)
NG
Replace
OK
Check the following connectors: B-30, C-28, C-30, C-41, C-45
NG
Repair
OK
Harness check
D Between control relay and body earth
D Between control relay and battery
D Between control relay and A/T-ECU
NG
Repair
OK
NG
Code No. 56 N range lamp system Probable cause
If the N range signal is off after an N range lamp illumination instruction (ON instruction)
has been given, it is judged that there is a short-circuit in the N range lamp earth
and diagnosis code No. 56 is output.
D Malfunction of the N range lamp bulb
Check the N range lamp bulb
(Refer to GROUP 52A - Instrument Panel.)
NG
Replace
OK
Check the following connectors: C-30, C-90, D-02
NG
Repair
OK
Harness check
D Between N range lamp bulb and A/T-ECU
NG
Repair
OK
NG
Code No. 71 Malfunction of A/T-ECU Probale cause
There is an abnormality in the A/T-ECU. The transmission is locked into 3rd gear
as a fail-safe measure.
procedure No.
Reference
page
Communication with MUT-II is not possible 1 23-27
Driving impossible Starting impossible 2 23-28
Does not move forward 3 23-28
Does not reverse 4 23-29
Does not move (forward or reverse) 5 23-29
Malfunction when starting Engine stalling when shifting 6 23-30
Shocks whenchangingfromNtoDandlargetimelag 7 23-30
Shocks whenchangingfromNtoRandlargetimelag 8 23-31
Shocks when changing fromNto D, Nto Rand large
time lag
9 23-32
Malfunction when shifting Shocks and running up 10 23-32
Trouble symptom Reference
page
Inspection
procedure No.
Displaced shifting points All points 11 23-33
Some points 12 23-34
Does not shift No diagnosis codes 13 23-34
Malfunction while driving Poor acceleration 14 23-35
Vibration 15 23-35
Inhibitor switch system 16 23-36
Mode control switch system 17 23-36
Idle position switch system 18 23-37
Dual pressure switch system 19 23-37
Vehicle speed sensor system 20 23-38
Auto-cruse-ECU signal system 21 23-38
Communication with MUT-II is not possible Probable cause
If communication with the MUT-II is not possible, the cause is probably a defective
diagnosis line or the A/T-ECU is not functioning.
D Malfunction of diagnosis line
Is communication with other systems
possible using the MUT-II?
No
Check the diagnosis line with MUT-II,
Yes
Check the continuity and voltage of the
A/T-ECU connector.
D Disconnect the connector C-28 and
check at harness side.
D Voltage between terminals No. 11,
24 and earth
OK: Battery voltage
D Voltage between C-28 terminals
Nos.12, 13, 25, 26, C-30 terminal
No. 72 and earth
OK: Continuity
NG
C-28, C-30, C-45, C-83, C-131, C-134
NG
Repair
OK
Harness check
D Between power supply and
A/T-ECU
D Between earth and A/T-ECU
NG
Repair
OK
NG
Repalce the A/T-ECU.
OK
C-20, C-28, C-30, C-49, C-66, C-83
NG
Repair
OK
Harness check
D Between diagnosis connector and
A/T-ECU
NG
Repair
OK
NG
Starting impossible Probable cause
Starting is not possible when the selector lever is in P or N range.In such cases,
the cause is probably a defective engine system, torque converter or oil pump.
D Malfunction of the engine system
D Malfunction of the torque converter
D Malfunction of the oil pump
Check the engine system.
D Control system, ignition system, fuel system, main engine
system
NG
Repair, replace
OK
Torque converter check
D Check for incorrect installation (inserted at an angle, etc.) and
for damaged splines.
NG
Repair if possible. If the splines are damaged and repairs are not
possible, replace the torque converter assembly.
OK
Repalce the oil pump assembly. L
(The oil pump cannot be disassembled.)
Does not move (forward) Probable cause
If the vehicle does not move forward when the selector lever is shifted from N to
D, 3, 2 or L range while the engine is idling, the cause is probably abnormal line
pressure or a malfunction of the underdrive clutch or valve body.
D Abnormal line pressure
D Malfunction of the underdrive solenoid valve
D Malfunction of the underdrive clutch
D Malfunction of the valve body
D No. 2 Underdrive solenoid valve
NG
Replace the solenoid valve. L
OK
Hydraulic pressure test (Refer to P.23-56.)
D Measure the hydraulic pressure for each element when in L
range.
Standard value: Refer to P.23-57.
NG
Valve body disassembly, cleaning and reassembly L
D Pay particular attention to loosening of bolts, and to damage
and slippage of O-rings, valves and valve bodies.
D If the damage cannot be repaired, replace the valve body
assembly.
OK
Underdrive clutch system check L
D Remove the transmission assembly, valve body cover and valve
body.
D Pistons should operate and pressure should be maintained
when air is blown through the underdrive clutch oil hole in the
transmission case.
OK
NG
Underdrive clutch check L
D Check for burning of the facing, defective piston seal rings
and interference at the retainer.
Does not reverse Probable cause
If the vehicle does not reverse when the selector lever is shifted from N to R range
while the engine is idling, the cause is probably abnormal pressure in the reverse
clutch or low and reverse brake or a malfunction of the reverse clutch, low and reverse
brake or valve body.
D Abnormal reverse clutch pressure
D Abnormal low and reverse brake pressure
D Malfunction of the low and reverse solenoid valve
D Malfunction of the reverse clutch
D Malfunction of the low and reverse brake
D No. 1 Low and reverse solenoid valve
NG
Replace the low and reverse solenoid valve. L
OK
Hydraulic pressure check (Refer to P.23-56.)
D Measure the reverse clutch pressure in R range.
NG
OK
D Measure the low and reverse brake pressure in R range.
NG
OK
Reverse clutch system and low and reverse brake system check
L
body.
when air is blown through the reverse clutch oil hole and the
low reverse brake oil hole in the transmission case.
OK
NG
Reverse clutch and low and reverse brake check L
assembly.
Does not move (forward or reverse) Probable cause
If the vehicle does not move forward or reverse when the selector lever is shifted
to any position while the engine is idling, the cause is probably abnormal line pressure,
or a malfunction of the power train, oil pump or valve body.
D Malfunction of power train
D Measure the hydraulic pressure for each element when moving
forward and back.
OK
Power train check L
D Disassemble the transmission, check the condition of the
planetary carrier, output shaft and differential, etc.
NG
Replace the oil pump assembly. L
NG
assembly.
Engine stalling when shifting Probable cause
If the engine stalls when the selector lever is shifted from N to D or R range while
the engine is idling, the cause is probably a malfunction of the engine system, damper
clutch solenoid valve, valve body or torque converter (damper clutch malfunction).
D Malfunction of the torque converter (Malfuction of the
damper clutch)
Engine system check
D Check the control system, ignition system, fuel system and
main system.
NG
Repair, replace
OK
Replace the damper clutch control solenoid valve.
assembly.
NG
Repalce the torque converter.
Shocks when changing from N to D and large time lag Probable cause
If abnormal shocks or a time lag of 2 seconds or more occur when the selector
lever is shifted from N to D range while the engine is idling, the cause is probably
abnormal underdrive clutch pressure or a malfunction of the underdrive clutch, valve
body or idle position switch.
D Abnormal underdrive clutch pressure
D Malfunction of the underdrive solenoid valve
D Malfunction of the underdrive clutch
D Malfunction of the idle position switch
NG
Replace the underdrive solenoid valve. L
OK
When does the shock occur?
When starting
Shocks sometimes occur
No Yes
MUT-II Data list
D No. 64 Idle position switch
OK: Turns from on to off when the accelerator pedal is slightly
depressed from the fully closed position.
OK NG
Idle position switch check
D INSPECTION PROCEDURE 18 - Idle position switch system
check (Refer to P.23-37.)
assembly.
When shifting
D Measure the underdrive clutch pressure when shifting from
N to D.
NG
OK
Underdrive clutch system check L
body.
when air is blown through the underdrive clutch oil hole in the
transmission case.
OK
NG
Underdrive clutch check L
Shocks when changing from N to R and large time lag Probable cause
If abnormal shocks or a time lag of 2 seconds or more occurs when the selector
lever is shifted from N to R range while the engine is idling, the cause is probably
abnormal reverse clutch pressure or low and reverse brake pressure, or a malfunction
of the reverse clutch, low and reverse brake, valve body or idle position switch.
D Abnormal reverse clutch pressure
D Abnormal low and reverse brake pressure
D Malfunction of the low and reverse solenoid valve
D Malfunction of the reverse clutch
D Malfunction of the low and reverse brake
D Malfunction of the idle position switch
NG
Replace the low and reverse solenoid valve. L
OK
When starting
Shocks sometimes occur
No Yes
MUT-II Data list
D No. 64 Idle position switch
OK: Turns from on to off when the accelerator pedal is slightly
depressed from the fully closed position.
OK NG
D INSPECTION PROCEDURE 18 - Idle position switch system
check (Refer to P.23-37.)
assembly.
When shifting
D Measure the reverse clutch pressure in R range.
NG
OK
D Measure the low and reverse brake pressure in R range.
NG
OK
Reverse clutch system and low reverse brake system check L
body.
when air is blown through the reverse clutch oil hole and low
and reverse brake oil hole in the transmission case.
OK
NG
Reverse clutch and low reverse brake check L
Shocks when changing from N to D, N to R and large time
lag
Probable cause
If abnormal shocks or a time lag of 2 seconds or more occur when the selector
lever is shifted from N to D range and from N to R range while the engine is idling,
the cause is probably abnormal line pressure or a malfunction of the oil pump or
valve body.
OK
When
starting
assembly.
D Measure the hydraulic pressure for each element when in D
range and R range.
NG
Adjust the line pressure. (Refer to P.23-62.)
NG
When shifting
Shocks and running up Probable cause
If shocks occur when driving due to upshifting or downshifting and the transmission
speed becomes higher than the engine speed, the cause is probably abnormal line
pressure or a malfunction of a solenoid valve, oil pump, valve body or of a brake
or clutch.
D Malfunction of each solenoid valve
D Malfunction of each brake or each clutch
D No. 3 Second solenoid valve
D No. 4 Overdrive solenoid valve
NG
Replace the solenoid valve.
OK
NG
NG
assembly.
OK
Clutch and brake check L
All points (Displaced shifting points) Probable cause
If all shift points are displaced while driving, the cause is probably a malfunction
of the output shaft speed sensor, TPS or of a solenoid valve.
D Malfunction of the throttle position sensor
D Malfunction of each solenoid valve
MUT-II Data list
D No. 23 Output shaft speed sensor
OK: Increases in proportion to vehicle speed.
NG
Code No. 23 - Output shaft speed sensor system(Refer to P.23-17.)
OK
MUT-II Data list
D No. 11 TPS/APS
OK: Increases in proportion to accelerator pedal opening angle
NG
Code No. 11, 12, 14 TPS/APS system check (Refer to P.23-15.)
OK
MUT-II Data list
D No. 31 Low and reverse solenoid valve duty %
D No. 32 Underdrive solenoid valve duty %
D No. 33 Second solenoid valve duty %
D No. 34 Overdrive solenoid valve duty %
OK: Refer to the table below.
NG
Replace the solenoid valve. L
NG
OK
NG
assembly.
No. 31 No. 32 No. 33 No. 34
Driving at constant speed in 1st gear 0 % 0 % 100 % 100 %
Driving at constant speed in 2nd gear 100 % 0 % 0 % 100 %
Driving at constant speed in 3rd gear 100 % 0 % 100 % 0 %
Driving at constant speed in 4th gear 100 % 100 % 0 % 0 %
Some points (Displaced shifting points) Probable cause
If some of the shift points are displaced while driving, the cause is probably a malfunction
of the valve body, or it is related to control and is not an abnormality.
INVECS-II CANCEL COMMAND
D Use the MUT-II to stop the
INVECS-II function.
Does standard shifting occur normally?
No
Does the problem occur only when the
automatictransmissionfluidtemperature
is - 29_C or lower or 125_C or higher?
No
Valve body disassembly, cleaning and
reassembly L
D Pay particular attention to loosening
of bolts, and to damage and slippage
of O-rings, valves and valve bodies.
D If the damage cannot be repaired,
replace the valve body assembly.
Yes
It is related to control and is not an ab-
normality.
Yes
No diagnosis codes (Does not shift) Probable cause
If shifting does not occur while driving and no diagnosis codes are output, the cause
is probably a malfunction of the inhibitor switch, or A/T-ECU.
D Malfunction of the inhibitor switch
Does the transmission remain in 3rd
gear with selector lever in position
D ?
No
MUT-II Data list
D No. 61 Inhibitor switch
OK: A/T-ECU input signal and se-
lector lever position should
match.
NG
Inhibitor switch check
D INSPECTION PROCEDURE 16 -
Inhibitor switch system check.
(Refer to P.23-36.)
OK
Yes
Is backup power being supplied to the
A/T-ECU?
No Yes
Is power being supplied to the
A/T-ECU?
Yes
No
Power supply circuit check
D Pay particular attention to open
circuits in the harnesses, poor
connector connections and open
circuits in fuses.
D If there is a blown fuse, investigate
why a short-circuit has occurred and
then replace the fuse.
OK
MUT-II Data list
D No. 62 Hold mode signal
OK: The signal should change
when the mode control switch
position is changed.
NG
Mode control switch check
D INSPECTION PROCEDURE 17 -
Mode control switch system check
(Refer to P.23-36.)
If acceleration is poor even if downshifting occurs while driving, the cause is probably
a malfunction of the engine system or of a brake or clutch.
D Malfunction of the brake or clutch
Engine system check
main system.
NG
Replace, repair
OK
Brake or clutch check L
Vibration Probable cause
If vibration occurs when driving at constant speed or when accelerating and deceleration
in top range, the cause is probably abnormal damper clutch pressure or a malfunction
of the engine system, damper clutch control solenoid valve, torque converter or valve
body.
D Abnormal damper clutch pressure
D Malfunction of the torque converter
D No. 6 Damper clutch control solenoid valve
NG
Replace the damper clutch control solenoid valve. L
OK
Does the problem occur even when the oil temperature sensor
connector is disconnected?
Yes
Engine system check
main system.
No
D Measure the damper clutch pressure.
NG
assembly.
OK
Replace the torque converter assembly.
Inhibitor switch system Probable cause
The cause is probably a malfunction of the inhibitor switch circuit, ignition switch
circuit or a defective A/T-ECU.
D Malfunction of the inhibitor switch
Inhibitor switchcheck (Refer toP.23-49.)
NG
Replace
OK
Check the voltage of the inhibitor switch
connector B-72.
D Voltage between terminal No. 8 and
earth
OK: Battery voltage
NG
C-49, C-83, C-131, C-134
NG
Repair
OK
Harness check
D Between inhibitor switch and
ignition switch
NG
Repair
OK
NG
Ignition switch check
(Refer to GROUP54 - Ignition Switch.)
OK
B-72, C-30, C-47, C-48
NG
Repair
OK
Harness check
D Between inhibitor switch and
A/T-ECU connector
NG
Repair
OK
NG
Mode control switch system Probable cause
The cause is probably a defective mode control switch circuit or a defective A/T-ECU. D Malfunction of the mode control switch
OK
Check the following the connector:
C-30
OK
NG
NG
Repair
NG
Repair
NG
Ignition switch check (Refer to GROUP
54 - Ignition Switch.)
OK
OK
Harness check
D Between mode control switch and
ignition switch
OK
Harness check.
D Between mode control switch and
A/T-ECU
OK
Check the voltage of the A/T-ECU con-
nector C-30.
D Disconnect theconnector andcheck
at the harness side.
D Select the HOLD mode.
D Voltage between terminal No. 70and
earth
OK: Battery voltage
NG
C-49, C-83, C-89, C-131, C-134
NG
Repair
Mode control switch check
NG
Replace
Idle position switch system Probable cause
The cause is probably a defective idle position switch circuit or a defective A/T-ECU. D Malfunction of the idle position switch
NG
OK
B-07 <Vehicles without TCL>, B-41 <Vehicles with TCL>, C-29
NG
Repair
OK
Harness check
D Between idle position switch and A/T-ECU
NG
Repair
OK
NG
Dual pressure switch system Probable cause
The cause is probably a defective dual pressure switch circuit or a defective A/T-ECU. D Malfunction of the dual pressure switch
D Malfunction of A/C system
Dual pressure switch check (Refer to
GROUP 55 - On-vehicle service.)
NG
Replace
OK
Check the voltage of the A/T-ECU con-
nector C-28.
check at the harness side.
D A/C switch: ON
D Voltage between terminal No. 10
and earth
OK: Battery voltage
OK
B-30, C-28
NG
Repair
OK
NG
NG
Check the A/C system. (Refer to
GROUP 55 - Troubleshooting.)
Repair
OK
NG
A/C system check (Refer to GROUP
55 - Troubleshooting.)
Vehicle speed sensor system Probable cause
The cause is probably a defective vehicle speed sensor circuit or a defective A/T-ECU. D Malfunction of the vehicle speed sensor
2. NG
3. NG
OK
Check the ignition switch. (Refer to GROUP 54 - Ignition switch.)
NG
OK
OK
OK
NG
sensor connector.
NG
Repair
Check the following
connectors:
C-30, C-48
NG
Repair
NG
between the vehicle
switch connector.
NG
Repair
OK
sensor connector.
NG
Repair
OK
OK
Check the following
connector:
B-67
NG
Repair
OK
Measure at the vehicle speed sensor connector B-67.
OK: Battery voltage
OK: 4.8 - 5.2 V
OK: Continuity
1. NG
Check the following
connectors:
C-90, C-131, C-135
NG
Repair
Check the vehicle speed sensor.
(Refer to GROUP 54 - Combination Meters.)
NG
Replace
Auto-cruise-ECU signal system Probable cause
The cause is probably a defective auto-cruise signal line circuit or a defective A/T-ECU. D Malfunction of connector
D Malfunction of the auto-cruise-ECU
Auto-cruise systemcheck (Refer to GROUP 17 - Troubleshooting.)
NG
Repair
OK
NG
Repair
OK
Harness check
D Between auto-cruise-ECU and A/T-ECU
OK
NG
Repair
ItemNo. Check item Check requirement Normal value
11 Throttle position sensor
Engine: Stopped
Selector lever
Accelerator pedal:
Released
400 - 1,000 mV
Accelerator pedal
position sensor
<Vehicles with TCL>
position: P
Accelerator pedal:
Halfly depressed
Gradually rises from the
above value
Accelerator pedal:
Depressed
4,500 - 5,000 mV
15 Oil temperature sensor Warming up Drive for 15 minutes or
more so that the
automatic transmission
fluid temperature
becomes 70 - 90 _C.
Gradually rises to
70 - 90 _C
21 Crank angle sensor Engine: Idling
Selector lever
Accelerator pedal:
Released
550 - 900 rpm
position: P
Accelerator pedal:
Halfly depressed
Gradually rises from the
above value
22 Input shaft speed
sensor
Selector lever
position: 3
of 50 km/h in 3rd gear
1,800 - 2,100 rpm
23 Output shaft speed
sensor
Selector lever
position: 3
1,800 - 2,100 rpm
25 Wide open throttle Accelerator pedal Released OFF
switch position
Depressed ON
26 Stop lamp switch Ignition switch: ON Brake pedal: Depressed ON
Engine: Stopped
Brake pedal: Released OFF
29 Vehicle speed sensor Selector lever
position: 3
Idling with 1st gear
(Vehicle stopped)
0 km/h
50 km/h
31 Low and reverse
solenoid valve duty %
Selector lever
position: L, 2, 3, D
10 km/h in 1st gear No. 31: 0 %, No. 32: 0
%, No. 33: 100 %,
No. 34: 100%
32 Underdrive solenoid
valve duty %
30 km/h in 2nd gear No. 31: 100 %, No. 32:
0 %, No. 33: 0 %,
No. 34: 100%
33 Second solenoid valve
duty %
50 km/h in 3rd gear No. 31: 100 %, No. 32:
0 %, No. 33: 100 %,
No. 34: 0%
34 Overdrive solenoid valve
duty %
70 km/h in 4th gear No. 31: 100 %, No. 32:
100 %, No. 33: 0 %,
No. 34: 0%
ItemNo. Normal value Check requirement Check item
36 Damper clutch control
solenoid valve duty %
Selector lever
position: 3
Driving at 50 km/h in
3rd gear with accelerator
released
0 %
Approx. 70 - 90 %
52 Amount of damper
clutch slippage
Selector lever
position: 3
Driving at 50 km/h in 3rd
gear with accelerator
fully closed
Approx. 100 - 300 rpm*
Approx. 0 - 10 rpm
54 Control relay output
voltage
Ignition switch : OFF Ignition switch:
ON OFF
Battery voltage (mV)
0 mV
57 Engine volumetric
efficiency
Selector lever
position: N
N range with accelerator
pedal released
depressed.
Data changes
61 Inhibitor switch Ignition switch: ON Selector lever position: P P
Engine: Stopped
Selector lever position: R R
Selector lever position: N N
Selector lever position: D D
Selector lever position: 3 3
Selector lever position: 2 2
Selector lever position: L L
62 HOLD mode signal Mode control switch HOLD ON
position
AUTO OFF
63 Shift position Selector lever posi-
tion: L, 2, 3, D
of 10 km/h in 1st gear
1st
of 30 km/h in 2nd gear
2nd
3rd
of 70 km/h in 4th gear
4th
64 Idle position switch Engine: Idling
Selector lever posi-
Accelerator pedal:
Released
ON
tion: N
Accelerator pedal:
Halfly depressed
OFF
65 Dual pressure switch Engine: Idling A/C switch: ON ON
Selector lever posi-
tion: N
A/C switch: OFF OFF
ItemNo. Normal value Check requirement Check item
66 Auto-cruse-ECU signal While auto-cruise Plain road OFF
operating
Sloping road ON
NOTE
*: The damper clutch is released when the accelerator is fully closed (Idle position switch: ON).
ACTUATOR TEST JUDGEMENT VALUE 23100820065
ItemNo. Check item Test content Check requirement Normal value
1 Low reverse solenoid valve Drive the solenoid Ignition switch: ON The operation sound should
2 Underdrive solenoid valve
valve specified by
the MUT-II at 50 %
Selector lever
position: P
be audible when the solenoid
valve is driven.
3 Second solenoid valve
duty for 5 seconds.
No other solenoid
Engine: 0 r/min
Vehicle speed:
4 Overdrive solenoid valve
valve should be
energised.
Vehicle speed:
0 km/h
6 Damper clutch control
solenoid valve
(Vehicle stopped)
Throttle
(Accelerator)
12 A/T control relay Control relay is OFF
for 3 seconds.
opening voltage:
Less than 0 V
Idle switch: ON
Data list No. 54
(1) During test: 0 mV
(2) Normal: Battery voltage
[mV]
INVECS-II CANCEL COMMAND 23100950023
Item No. Item Content Remarks
14 INVECS-II Stop the INVECS-II control and change gears
according to the standard shift pattern.
Usethis functionwhencarrying
out procedure 8 in the road
tests.
CHECK AT A/T-ECU TERMINALS 23100840207
Terminal
No.
Check item Check requirement Standard value
1 Underdrive solenoid valve Selector lever position: D (1st gear) Battery voltage
Selector lever position: P Approx.7 - 9 V
2 Solenoid valve power supply Ignition switch: OFF 0 V
Ignition switch: ON Battery voltage
3 Solenoid valve power supply Ignition switch: OFF 0 V
8 Auto-cruse control unit No OD-OFF request Battery voltage
OD-OFF request 0V
10 A/C compressor load signal A/C switch: OFF 0 V
A/C switch: ON Battery voltage
11 Power supply Ignition switch: OFF 0 V
12 Earth Always 0 V
13 Earth Always 0 V
14 Overdrive solenoid valve Selector lever position: D (3rd gear) Battery voltage
Selector lever position: P Approx. 7 - 9 V
15 Damper clutch control solenoid Selector lever position: L (1st gear) Battery voltage
valve
Selector lever position: 3 (50 km/h in 3rd gear) Other than
battery voltage
16 Second solenoid valve Selector lever position: 2 (2nd gear) Battery voltage
Selector lever position: P Approx. 7 - 9 V
21 Engine-ECU torque reduction
request signal
<Vehicles with TCL>
Ignition switch: ON (except during shifting) 4 - 5 V
Terminal
No.
Standard value Check requirement Check item
23 Diagnosis control - -
24 Power supply Ignition switch: OFF 0 V
25 Earth Always 0 V
26 Earth Always 0 V
31 Input shaft speed sensor Measure between terminal No. 31 and No. 43 by
an oscilloscope.
Engine: 2,000 r/min
Selector lever position: 3
Refer to P.23-45,
Oscilloscope
inspection
procedure.
32 Output shaft speed sensor Measure between terminal No. 32 and No. 43 by
an oscilloscope.
Engine: 2,000 r/min
Selector lever position: 3
Refer to P.23-45,
Oscilloscope
inspection
procedure.
33 Crank angle sensor Engine: Idling 2.0 - 2.4 V
36 Idle position switch Engine: Idling 0 V
Engine: Other than idling 5 V
38 Back up power suuply Ignition switch: OFF Battery voltage
43 Sensor earth Always 0 V
44 Oil temperature sensor ATF temperature: 25 _C 3.8 - 4.0 V
ATF temperature: 80 _C 2.3 - 2.5 V
45 Throttle position sensor (TPS)
Accelerator pedal: Released (Engine stopped) 0.5 - 1.0 V
(APS) <Vehicles with TCL>
Accelerator pedal: Depressed (Engine stopped) 4.5 - 5.0 V
53 Communication with engine-ECU
Communication with TCL-ECU
<Vehicles with TCL>
Engine: Idling
Other than 0 V
54 Communication with engine-ECU
Communication with TCL-ECU
<Vehicles with TCL>
Engine: Idling
Other than 0 V
55 Inhibitor switch P Selector lever position: P Battery voltage
Selector lever position: Other than above 0 V
56 Inhibitor switch N Selector lever position: N Battery voltage
57 Inhibitor switch 3 Selector lever position: 3 Battery voltage
Terminal
No.
Standard value Check requirement Check item
58 Inhibitor switch L Selector lever position: L Battery voltage
59 Stop lamp switch Brake pedal: Depressed Battery voltage
Brake pedal: Released 0 V
62 Low and reverse solenoid valve Selector lever position: D (1st gear) Battery voltage
Selector lever position: D (2nd gear) Approx. 7 - 9 V
63 Diagnosis output Normal (No diagnosis code output) 0 5 V flashing
65 Wide open throttle switch Accelerator pedal: Released 4.5 - 5.5 V
Accelerator pedal: Depressed Less than 0.4 V
66 Inhibitor switch R Selector lever position: R Battery voltage
67 Inhibitor switch D Selector lever position: D Battery voltage
68 Inhibitor switch 2 Selector lever position: 2 Battery voltage
69 Vehicle speed sensor When stopped 0 V
Move forward slowly 0 5 V flashing
70 Mode control switch Select HOLD mode Battery voltage
Select AUTO mode 0V
71 A/T control relay Ignition switch: OFF 0 V
OSCILLOSCOPE INSPECTION PROCEDURE 23100850064
Check item Check requirement Normal condition
(Waveformsample)
Crank angle sensor Selector lever position: N Idling (Vehicle stopped) Waveform A
Input shaft speed
sensor
Selector lever position: 3 Driving at constant speed of 50
km/h in 3rd gear
Waveform B
Output shaft
speed sensor
(Engine: 1,800 - 2,100 r/min)
Low reverse
solenoid valve
Ignition switch: ON
Force drive each solenoid valve
(Actuator test)
Waveform C
Underdrive solenoid
valve
Engine: 0 r/min
Vehicle speed: 0 km/h
(Vehicle stopped)
Second solenoid
valve
(Vehicle stopped)
Throttle (Accelerator) opening
angle: Less than 1 V
Overdrive solenoid
valve
Idle switch: ON
Damper clutch
control solenoid
valve
Waveform sample
Waveform A
(ms)
(V)
0
5
Waveform B
(ms)
(V)
0
5
Waveform C
(ms)
(V)
60
40
20
0
AUTOMATIC TRANSMISSION - On-vehicle Service 23-46
ESSENTIAL SERVICE
AUTOMATIC TRANSMISSION FLUID CHECK
1. Drive the vehicle until the fluid temperature rises to the
normal temperature (70- 80_C).
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the
torque converter and the hydraulic circuits with fluid, and
then move the selector lever to the N position.
4. After wiping off any dirt around the oil level gauge, remove
the oil level gauge and check the condition of the fluid.
NOTE
If the fluid smells as if it is burning, it means that the
fluid has been contaminated by the particles from the
bushes and friction materials, a transmission overhaul
and flushing the cooler line may be necessary.
5. Check that the fluid level is at the HOT mark on the
oil level gauge. If the fluid level is lower than this, pour
in more fluid until the level reaches the HOT mark.
Automatic transmission fluid:
Dia Queen ATF SP II or equivalent
NOTE
If the fluid level is low, the oil pump will draw in air along
with the fluid, which will cause bubbles to form inside
the hydraulic circuit. This will in turn cause the hydraulic
pressure to drop, which will result in late shifting and
slipping of the clutches and brakes.
If there is too much fluid, the gears can churn it up into
foam and cause the same conditions that can occur with
low fluid levels.
In either case, air bubbles can cause overheating and
oxidation of the fluid which can interfere with normal valve,
clutch, and brake operation. Foaming can also result in
fluid escaping from the transmission vent, in which case
it may be mistaken for a leak.
6. Securely insert the oil level gauge.
7. The fluid and oil filters should always be replaced in the
following conditions:
When troubleshooting the transmission
When overhauling the transmission
When the oil is noticeably dirty or deteriorates (driving
under the severe condition)
Furthermore, the oil filters are special filters which are
only to be used for the automatic transmission.
AUTOMATIC TRANSMISSION FLUID REPLACEMENT
23100100251
If you have a fluid changer, use this changer to replace the
fluid. If you do not have a fluid changer, replace the fluid
by the following procedure.
1. Disconnect the hose shown in the illustration which
connects the transmission and the oil cooler (inside the
radiator).
2. Start the engine and let the fluid drain out.
Running conditions: N range with engine idling
Caution
The engine should be stopped within one minute after
it is started. If the fluid has all drained out before
then, the engine should be stopped at that point.
Discharge volume: Approx. 3.5 L
3. Remove the drain plug fromthe bottomof the transmission
case to drain the fluid.
Discharge volume: Approx. 2.0 L
4. Replace the oil filters. (Refer to P.23-48.)
5. Install the drain plug via a new gasket, and tighten it
6. Pour the new fluid in through the oil filler tube.
Adding volume: Approx. 5.5 L
Caution
Stop pouring if the full volume of fluid cannot be
poured in.
7. Repeat the procedure in step 2.
NOTE
Drain the fluid from the cooler hose 7 L at least. Then
drain the fluid a little and check the fluid for dirt.
If it has been contaminated, repeat the steps 6 and 7.
8. Pour the new fluid in through the oil filler tube.
Adding volume: Approx. 3.5 L
9. Reconnect the hose which was disconnected in step 1
above, and firmly replace the oil level gauge.
10. Start the engine and run it at idle for 1 - 2 minutes.
11. Move the selector lever through all positions, and then
move it to the N position.
12. Check that the fluid level is at the COLD mark on the
oil level gauge. If the level is lower than this, pour in
more fluid.
13. Drive the vehicle until the fluid temperature rises to the
normal temperature (70 - 80_C), and then check the
fluid level again.
The fluid level must be at the HOT mark.
NOTE
The COLDlevel is for reference only; the HOT level should
be regarded as the standard level.
14. Firmly insert the oil level gauge into the oil filler tube.
OIL FILTER REPLACEMENT 23101050067
1. Use the special tool (MB991610) to remove the automatic
transmission oil filter.
2. Clean the filter bracket side mounting surface.
3. Apply a small amount of automatic transmission fluid to
the O-ring of the new oil filter.
4. Use the special tool (MB991610) to install the automatic
transmission oil filter.
NOTE
5. Check the quantity of the automatic transmission fluid.
(Refer to P.23-46.)
THROTTLE POSITION SENSOR ADJUSTMENT
<Vehicles without TCL> 23100190142
ADJUSTMENT <Vehicles with TCL> 23100250048
Apply ATF
to O-ring
INHIBITOR SWITCH CONTINUITY CHECK 23100140345
Items Terminal No.
1 2 3 4 5 6 7 8 9 10
P
R
N
D
3
2
L
INHIBITOR SWITCH AND CONTROL CABLE
1. Set the selector lever to the N position.
2. Loosen the control cable to manual control lever coupling
nut to free the cable and lever.
3. Set the manual control lever to the neutral position.
Inhibitor switch
P
R
N
D
L
2
3
Transmission
control cable
Adjusting nut
Manual
control
lever
4. Loosen the inhibitor switch body mounting bolts and the
turn the inhibitor switch body so the hole in the end of
the manual control lever and the hole (cross section A-A
in the figure on the left) in the flange of the inhibitor
switch body flange are aligned.
5. Tighten the inhibitor switch body mounting bolts to the
specified torque. Be careful at this time that the position
of the switch body is not changed.
6. Gently pull the transmission control cable in the direction
of the arrow, and then tighten the adjusting nut.
7. Check that the selector lever is in the N position.
8. Check that each range on the transmission side operates
and functions correctly for each position of the selector
lever.
10 - 12 Nm
Mounting bolts
Manual
control lever
Section A-A
Hole in end
Hole in
flange
Manual control
lever
Inhibitor
switch body
A
A
Adjusting nut
12 Nm
Manual control lever
A/T CONTROL COMPONENT LOCATION 23100860234
Accelerator position sensor (with idle position
switch) <Vehicles with TCL>
C Mode control switch L
A/T control relay M Oil temperature sensor G
A/T-ECU K Output shaft speed sensor E
Crank angle sensor B Shift indicator lamp I
Diagnosis connector O Solenoid valve G
Dual pressure switch A Stop lamp switch P
Engine ECU K TCL-ECU J
Inhibitor switch F Throttle position sensor (with idle position
switch) <Vehicles without TCL>
C
Input shaft speed sensor H Vehicle speed sensor D
Wide open throttle switch N
A
B
C D
E
F
G
H
I
J
K
L
M
N
O
P
A/T CONTROL COMPONENT CHECK 23100900011
CRANK ANGLE SENSOR CHECK
THROTTLE POSITION SENSOR CHECK
<Vehicles without TCL> 23100390030
ACCELERATOR PEDAL POSITION SENSOR CHECK
Refer to GROUP 13H - On-vehicle Service.
OIL TEMPERATURE SENSOR CHECK 23100450035
1. Remove the oil temperature sensor.
2. Measure the resistance between terminals No. 1 and
No. 2 of the oil temperature sensor connector.
Standard value:
Oil temperature (_C) Resistance (kW)
0 16.7- 20.5
100 0.57- 0.69
INHIBITOR SWITCH CHECK 23100140352
Refer to P.23A-49.
Refer to GROUP 35 - Brake Pedal.
VEHICLE SPEED SENSOR CHECK 23100460038
Oil temperature sensor
ATF
DUAL POSITION PRESSURE SWITCH CHECK
23100470031
IDLE POSITION SWITCH CHECK 23100410033
MODE CONTROL SWITCH CHECK 23100920048
Refer to P.23-65.
WIDE OPEN THROTTLE SWITCH CHECK 23100890080
Refer to P.23-64.
A/T CONTROL RELAY CHECK 23100930065
1. Remove the A/T control relay.
2. Use jumper wires to connect A/T control relay terminal
2 to the battery ( - ) terminal and terminal 4 to the battery
(+) terminal.
3. Check the continuity between terminal 1 and terminal
3 of the A/T control relay when the jumper wires are
connected to and disconnected from the battery.
Jumper wire Continuity between terminals No. 1
and No. 3
Connected Continuity
Disconnected No continuity
4. If there is a problem, replace the A/T control relay.
SOLENOID VALVE CHECK 23100940013
1. Remove the valve body cover.
2. Disconnect the connectors of each solenoid valve.
3. Measure the resistance between terminals 1 and 2 of
each solenoid valve.
Standard value:
Name Resistance
Damper clutch solenoid valve 2.7 - 3.4 W
Low and reverse solenoid valve
(at 20_C)
Second solenoid valve
Underdrive solenoid valve
Overdrive solenoid valve
4. If the resistance is outside the standard value, replace
the solenoid valve.
TORQUE CONVERTER STALL TEST 23100540206
This test measures the maximum engine speed when the
selector lever is at the Dor Rposition and the torque converter
stalls to test the operation of the torque converter, starter
motor and one-way clutch operation and the holding
performance of the clutches and brakes in the transmission.
Caution
Do not let anybody stand in front of or behind the vehicle
while this test is being carried out.
1. Check the automatic transmission fluid level and
temperature and the engine coolant temperature.
D Fluid level: At the HOT mark on the oil level gauge
D Fluid temperature: 80 - 100_C
D Engine coolant temperature: 80 - 100_C
Overdrive
solenoid
valve
Low and
reverse
solenoid
valve
Second
solenoid
valve
Damper
clutch
solenoid
valve
Underdrive
solenoid
valve
Reverse
clutch
Low-reverse
brake
Underdrive
clutch
Torque
converter
2. Check both rear wheels (left and right).
3. Pull the parking brake lever on, with the brake pedal
fully depressed.
5. Move the selector lever to the D position, fully depress
the accelerator pedal and take a reading of the maximum
engine speed at this time.
Caution
1. The throttle should not be left fully open for any
more than eight seconds.
2. If carrying out the stall test two or more times,
move the selector lever to the N position and run
the engine at 1,000 r/min to let the automatic
transmission fluid cool down before carrying out
subsequent tests.
Standard value
Stall speed: 2,100 - 2,600 r/min
6. Move the selector lever to the R position and carry out
the same test again.
Standard value
Stall speed: 2,100 - 2,600 r/min
TORQUE CONVERTER STALL TEST JUDGEMENT
RESULTS
a. Stall speed is too high in both D and R ranges
D Low line pressure
D Low & reverse brake slippage
b. Stall speed is too high in D range only
D Underdrive clutch slippage
c. Stall speed is too high in R range only
D Reverse clutch slippage
d. Stall speed too low in both D and R ranges
D Malfunction of torque converter
D Insufficient engine output
HYDRAULIC PRESSURE TEST 23100550216
1. Warm up the engine until the automatic transmission fluid
temperature is 80 - 100_C.
2. Jack up the vehicle so that the wheels are free to turn.
3. Connect the special tools (2,942 kPa oil pressure gauge
[MD998330] and joints [MD998332, MD998900]) to each
pressure discharge port.
4. Measure the hydraulic pressure at each port under the
conditions given in the standard hydraulic pressure table,
and check that the measured values are within the
standard value ranges.
5. If a value is outside the standard range, correct the
problem while referring to the hydraulic pressure test
diagnosis table.
STANDARD HYDRAULIC PRESSURE TEST
<4G63>
Measurement condition Standard hydraulic pressure kPa
Selector
lever
position
Shift posi-
tion
Engine
speed
(r/min)
Under-
drive
clutch
pressure
Reverse
clutch
pressure
Overdrive
clutch
pressure
Low and
reverse
brake
pressure
Second
brake
pressure
Torque
converter
pressure
P - 2,500 - - - 310 - 390 - 310 - 390
R Reverse 2,500 - 1,320 -
1,720
- 1,320 -
1,720
- 500 - 700
N - 2,500 - - - 310 - 390 - 310 - 390
D 1st gear 2,500 1,010 -
1,050
- - 1,010 -
1,050
- 500 - 700
2nd gear 2,500 1,010 -
1,050
- - - 1,010 -
1,050
500 - 700
3rd gear 2,500 590 - 690 - 590 - 690 - - 450 - 650
4th gear 2,500 - - 590 - 690 - 590 - 690 450 - 650
<6A13>
Measurement condition Standard hydraulic pressure kPa
Selector
lever
position
Shift posi-
tion
Engine
speed
(r/min)
Under-
drive
clutch
pressure
Reverse
clutch
pressure
Overdrive
clutch
pressure
Low and
reverse
brake
pressure
Second
brake
pressure
Torque
converter
pressure
P - 2,500 - - - 260 - 340 - 260 - 340
R Reverse 2,500 - 1,320 -
1,720
- 1,320 -
1,720
- 500 - 700
N - 2,500 - - - 260 - 340 - 260 - 340
D 1st gear 2,500 1,010 -
1,050
- - 1,010 -
1,050
- 500 - 700
2nd gear 2,500 1,010 -
1,050
- - - 1,010 -
1,050
500 - 700
3rd gear 2,500 780 - 880 - 780 - 880 - - 450 - 650
4th gear 2,500 - - 780 - 880 - 780 - 880 450 - 650
HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE
Trouble symptom Probable cause
All hydraulic pressures are high. Incorrect transmission control cable adjustment
Malfunction of the regulator valve
All hydraulic pressures are low. Incorrect transmission control cable adjustment
Malfunction of the oil pump
Clogged internal oil filter
Clogged external oil filter
Clogged oil cooler
Malfunction of the relief valve
Incorrect valve body installation
Hydraulic pressure is abnormal Malfunction of the regulator valve
in R range only.
Clogged orifice
Hydraulic pressure is abnormal Malfunction of the overdrive solenoid valve
in 3 or 4 range only.
Malfunction of the overdrive pressure control valve
Malfunction of the switch valve
Clogged orifice
Only underdrive hydraulic Malfunction of the oil seal K
pressure is abnormal.
Malfunction of the oil seal L
Malfunction of the oil seal M
Malfunction of the underdrive solenoid valve
Malfunction of the underdrive pressure control valve
Malfunction of check ball
Clogged orifice
Only reverse clutch hydraulic Malfunction of the oil seal A
Malfunction of the oil seal B
Malfunction of the oil seal C
Clogged orifice
Trouble symptom Probable cause
Only overdrive hydraulic Malfunction of the oil seal D
Malfunction of the oil seal E
Malfunction of the oil seal F
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Malfunction check ball
Clogged orifice
Only low and reverse hydraulic Malfunction of the oil seal I
Malfunction of the oil seal J
Malfunction of the low and reverse solenoid valve
Malfunction of the low and reverse pressure control valve
Malfunction of the switch valve
Malfunction of the fail safe valve A
Clogged orifice
Only second hydraulic pressure Malfunction of the oil seal G
is abnormal.
Malfunction of the oil seal H
Malfunction of the oil seal O
Malfunction of the second solenoid valve
Malfunction of the second pressure control valve
Malfunction of the fail safe valve B
Clogged orifice
Only torque converter pressure Malfunction of the oil cooler
is abnormal.
Malfunction of the oil seal N
Malfunction of the damper clutch control solenoid valve
Malfunction of the damper clutch control valve
Malfunction of the torque converter pressure control valve
Clogged orifice
Pressure applied to non Incorrect transmission control cable adjustment
operating element.
Malfunction of the manual valve
OIL SEAL LAYOUT
O
A
H
B
C
D
E
F G
I J K
L
M N
HYDRAULIC CIRCUIT 23100880070
PARKING AND NEUTRAL
1 2 3 4 5
6 7
8
9 10
11
12
13
14 15 16 17 18
19
20
21 22
23
24
25
26
27
28
29
30
32
31
6 6 6
RND
P3
2
L
1. Reverse clutch
2. Low-reverse brake
3. Second brake
4. Underdrive clutch
5. Overdrive clutch
6. Accumulator
7. Check ball
8. Damper clutch
9. Fail safe valve A
10. Fail safe valve B
11. Damper clutch control valve
12. Switch valve
13. Automatic transmission fluid cooler
14. Lubrication
15. Low-reverse pressure control valve
16. Second pressure control valve
17. Underdrive pressure control valve
18. Overdrive pressure control valve
19. Damper clutch control solenoid
valve
20. Low-reverse solenoid valve
21. Second solenoid valve
22. Underdrive solenoid valve
23. Overdrive solenoid valve
24. Torque converter pressure control
valve
25. Regulator valve
26. Manual valve
27. Oil filter
28. Oil pump
29. Oil strainer
30. Oil filter (Built in type)
31. Relief valve
32. Oil pan
LINE PRESSURE ADJUSTMENT 23100170122
1. Discharge the automatic transmission fluid, and then
remove the valve body cover.
2. Turn the adjusting screw shown in the illustration at left
to adjust the underdrive pressure to the standard value.
The pressure increases when the screw is turned to the
left.
NOTE
When adjusting the underdrive pressure, adjust to the
middle of the standard value range.
Standard value: 1,010 - 1,050 kPa
Change in pressure for each turn of the adjusting screw:
35 kPa
3. Install the valve body cover, and pour in the standard
volume of automatic transmission fluid.
4. Carry out a hydraulic pressure test. (Refer to P.23-56.)
Readjust the line pressure if necessary.
SELECTOR LEVER OPERATION CHECK
23100130090
1. Shift selector lever to each range and check that lever
moves smoothly and is controlled. Check that position
indicator is correct.
2. Check the selector lever can be moved to each position
(by button operation as shown in the illustration).
3. Start the engine and check if the vehicle moves forward
when the selector lever is moved from N or D, and moves
backward when moved to R.
4. When the shift lever malfunctions, adjust control cable
and selector lever sleeve. Check for worm shift lever
assembly sliding parts.
Adjusting
screw
Push button
Button not pressed
Button pressed
AUTOMATIC TRANSMISSION - Transmission Control 23-63
TRANSMISSION CONTROL 23100660247
D Lower Cover and Side Cover Removal and
Installation (Refer to GROUP 52A - Instrument
Panel.)
D Floor Console Box Removal and Installation
Caution: SRS
Be careful not to subject the SRS-ECU to any
shocks during removal and installation of the
transmission control cable and selector lever
assembly.
12 Nm
12 Nm
12 Nm
1
2
3
4
5
6
7
8
9
7
Transmission control cable removal
steps
1. Foot rest <R.H. drive vehicles>
2. Engine-ECU, A/T-ECU and A/T
control relay assembly
"AA 3. Nut
4. Adjuster
5. Transmission control cable connec-
tion
6. Transmission control cable assem-
bly
Selector lever assembly removal
steps
tion
7. Wiring harness connector
8. Selector lever assembly
A/T-ECU removal steps
1. Foot rest <R.H. drive vehicles>
2. Engine-ECU, A/T-ECU and A/T
control relay assembly
Wide open throttle switch removal
step
9. Wide open throttle switch
"AANUT INSTALLATION
1. Put the selector lever in the N position.
2. Loosen the adjusting nut, gently pull the transmission
control cable in the direction of the arrow and tighten
the nut.
WIDE OPEN THROTTLE SWITCH CHECK
1 2
OFF
ON
Manual control lever
Nut
OFF
ON
SELECTOR LEVER ASSEMBLY 23100680168
11
2 Nm
1
2
3
4
5
6
8
9
10
11
14
13
2 Nm
13 Nm
12
15
7
Disassembly steps
1. Push button
2. Spring
3. Bumper
4. Adjuster
5. Shift knob
6. Indicator panel assembly
7. Switch holder
8. A/T mode changeover switch
9. Bolt
10. Shift lever assembly
11. Bushing
12. Detent spring
13. Pipe
14. Position indicator lamp assembly
15. Bracket assembly
A/T MODE CHANGEOVER SWITCH CHECK
1 2 4 3 5
OFF
ON
AUTOMATIC TRANSMISSION - Transmission Assembly 23-66
TRANSMISSION ASSEMBLY 23100570274
D Carry out the essential service for the
troubleshooting (Refer to P.23-46.)
D Transmission Fluid Draining (Refer to P.23-47.)
D Battery and Battery Tray Removal
D Battery and Battery Tray Installation
D Transmission Fluid Supplying <Supplying should
be done before starting the engine>
(Refer to P.23-47.)
D Selector Lever Operation Check
D Speedometer Operation Check
D Wheel Alignment Adjustment
88 Nm*
1
98 - 118 Nm*
1
12 Nm
103 Nm
44 Nm
81 Nm
67 - 78 Nm
24 - 33 Nm
81 Nm
98 - 118 Nm
88 Nm
30 Nm
30 Nm
10 - 12 Nm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
17
Removal steps
tion
2. Transmission fluid cooler hoses
connection
3. Bolt
4. Input shaft speed sensor connector
5. Output shaft speed sensor
connector
6. Inhibitor switch connector
7. A/T control solenoid valve assem-
bly connector
8. Vehicle speed sensor connector
9. Starter motor <6A1>
AA" 10. Tie rod end connection
12. Damper fork
13. No. 2 stay
AB" 15. No. 3 stay
16. Compression lower arm connection
AC" 17. Drive shaft
Caution
*1: Indicates parts which should be temporarily
7 Nm
44 Nm
18
57 Nm
57 Nm*
2
69 Nm
10 Nm <Flange bolts>
9 Nm <Washer assembled bolts>
20
21
21
22
23
93 Nm
49 Nm
27
26
49 Nm
30 Nm
69 - 78 Nm
10 - 12 Nm
24
25 Nm
25
81 Nm*
2
49 Nm
26
19
45 - 52 Nm
18. Starter motor <4G6>
19. Transmission assembly upper part
coupling bolts
AD" 20. Transmission mount bracket
"BA 21. Transmission mount stopper
AE" D Engine and transmission assembly
supporting
22. Centermember assembly
24. Bell housing cover <4G6>
25. Cover <6A1>
AF" 26. Transmission assembly lower part
coupling bolts
AF" "AA 27. Transmission assembly
Caution
Mounting locations marked by *2 should be
AA"TIE ROD END DISCONNECTION
Caution
1. Use the special tool to loosen the tie rod end mounting
ball joint.
2. Support the special tool with a cord, etc. not to let
it come off.
AB"NO.3 STAY REMOVAL
AC"DRIVE SHAFT DISCONNECTION
1. Insert a pry bar between the transmission case and the
drive shaft as shown to remove the drive shaft.
NOTE
Do not remove the hub and knuckle from the drive shaft.
Caution
Always use a pry bar, or the TJ will be damaged.
2. Suspend the removed drive shaft with a wire so that
there are no sharp bends in any of the joints.
3. Use a shop towel to cover the transmission case not
to let foreign material get into it.
AD"TRANSMISSION MOUNT BRACKET REMOVAL
Jack up the transmission assembly gently with a garage jack,
and then remove the transmission mount bracket.
Cord
Ball joint
MB990635 or
MB991113
Nut
No.3 stay Crossmember
Pry bar
Trans-
mission
side
AE"ENGINE AND TRANSMISSION ASSEMBLY
SUPPORTING
Set the special tool to the vehicle to support the engine and
transmission assembly.
AF" TRANSMISSION ASSEMBLY LOWER PART
COUPLING BOLTS/TRANSMISSION ASSEMBLY
REMOVAL
1. Support the transmission assembly by using a
transmission jack.
2. Remove the drive plate bolts while turning the crank shaft.
3. Press in the torque converter to the transmission side
so that the torque converter does not remain on the engine
side.
4. Remove the transmission assembly lower bolts and lower
the transmission assembly.
"AATRANSMISSION ASSEMBLY INSTALLATION
After securely inserting the torque converter into the
transmission side so that the value shown in the illustration
becomes the reference value, install the transmission
assembly to the engine.
Reference value (A): Approx. 12.2 mm
"BATRANSMISSION MOUNT STOPPER
INSTALLATION
Install the transmission mount stopper so that the arrow points
MZ203827
MB991453
Drive plate bolts
A
Transmis-
sion mount
stopper
Engine side
Arrow
Transmission
mount bracket
NOTES
26-1
FRONT AXLE
LUBRICANTS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Bearing Axial Play Check 4 . . . . . . . . . . . . . .
Hub Bolt Replacement 4 . . . . . . . . . . . . . . . . . . . . . . . .
FRONT HUB ASSEMBLY 5 . . . . . . . . . . . . . . . . . . .
KNUCKLE 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT AXLE - General Information/Service Specifications/Lubricants 26-2
The front axle consists of a knuckle, front hub,
unit bearing and drive shaft. The unit bearing is
press-fitted to the front hub and bolted to the
knuckle. Also, the unit bearing utilizes a double
row angular contact ball bearing. The drive shaft
has a tripod joint (T.J.) on the transmission side
and a birfield joint (B.J.) or rzeppa joint (R.J.) on
the wheel side.
Knuckle
Dynamic damper
T.J.
Front hub
Drive shaft
B.J. (or R.J.)
Unit bearing
Wheel bearing axial play mm - 0.05
Wheel bearing rotation starting torque Nm - 1.0 or less
Setting of T.J. boot length mm 2000 - petrol-powered
vehicles
82 -
2000 - diesel-powered
vehicles, 2500
81 -
Opening dimension of the
special tool (MB991561) mm
When the B.J. (or R.J.) boot band (small)
is crimped
2.9 -
When the B.J. (or R.J.) boot band (large) is
crimped
3.2 -
Crimped width of the B.J. (or R.J.) boot band mm 2.4 - 2.8 -
Clearance between the B.J. (or R.J.) boot (large diameter side) and the
stepped phase of the B.J. (or R.J.) housing mm
0.1 - 1.5 -
Items Specified lubricant Quantity g
T.J. 2000 - petrol-powered vehicles Repair kit grease 120
2000 - diesel-powered vehicles, 2500 Repair kit grease 150
FRONT AXLE - Lubricants/Special Tools 26-3
Items Quantity g Specified lubricant
B.J. (or R.J.) 2000 Repair kit grease 120
2500 Repair kit grease 135
MB990767 End yoke holder Fixing of the hub
MB991618 Hub bolt remover Hub bolt removal
MB991406,
MB990635 or
MB991113
Steering linkage
puller
A
B
MB990241
A: MB990242
B: MB990244
Axle shaft puller
A: Puller shaft
B: Puller bar
D Front hub assembly removal
D Drive shaft removal
MB990998 Front hub remover
and installer
D Removal of or pressing-in the hub
D Provisional holding of the wheel bearing
MB990326 Preload socket Wheel bearing rotation starting torque
measurement
MB991461 Plug Preventing of entry of foreign objects into the
transmission case
MB991561 Boot band crimp-
ing tool
B.J. (or R.J.) boot band installation
FRONT AXLE - On-vehicle Service 26-4
WHEEL BEARING AXIAL PLAY CHECK
1. Remove the disc brake caliper and suspend it with a
wire.
2. Remove the brake disc from the front hub.
3. Attach a dial gauge as shown in the illustration, and then
measure the axial play while moving the hub in the axial
direction.
Limit: 0.05 mm
4. If axial play exceeds the limit, replace the front hub
assembly.
HUB BOLT REPLACEMENT 26100100085
1. Remove the caliper assembly and secure it with wire
so that it does not fall.
2. Remove the brake disc.
3. Use the special tools to remove the hub bolts.
4. Install the plain washer to the new hub bolt, and install
the bolt with a nut.
MB991618
MB990767
Plane
washer
MB990767
FRONT AXLE - Front Hub Assembly FRONT AXLE - Front Hub Assembly 26-5
FRONT HUB ASSEMBLY 26100170154
Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
1
2
3
4
5
6
196 - 255 Nm
100 Nm
28 Nm
88 Nm
Removal steps
1. Front wheel speed sensor
<Vehicles with ABS>
AA" 2. Caliper assembly
3. Brake disc
AB" "AA 4. Drive shaft nut
AC" 5. Upper arm ball joint and knuckle
connection
AD" 6. Front hub assembly
Caution
The front hub assembly should not be disassembled.
When removing the front hub assembly, the wheel
bearing inner race may be left at the spindle side.
In this case, always replace the front hub assembly,
otherwise the hub will damage the oil seal, causing
oil leaks or excessive play.
AA"CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, so that it
does not fall.
AB"DRIVE SHAFT NUT REMOVAL
Caution
Do not apply the vehicle weight to the wheel bearing
while loosening the drive shaft nut.
MB990767
FRONT AXLE - Front Hub Assembly 26-6
AC"UPPER ARM BALL JOINT AND KNUCKLE
DISCONNECTION
Caution
1. Use the special tool to loosen the nut only; do not
remove it from the ball joint.
2. Tie the special tool with a cord not to let it fall off.
AD"FRONT HUB ASSEMBLY REMOVAL
(1) Use the special tool to push out the drive shafts from
the hub.
(2) Shift the knuckle to the outside in order to maintain the
clearance between the front hub assembly mounting bolts
and the drive shaft.
Caution
1. Do not damage the ball joint boot.
2. Be careful not to damage the rotor.
"AADRIVE SHAFT NUT INSTALLATION
(1) Install the drive shaft washer in the specified direction.
(2) Using the special tool, tighten the drive shaft nut.
Caution
Before securely tightening the drive shaft nuts, make
sure there is no load on the wheel bearings.
(3) If the position of the split pin holes does not match, tighten
the nut up to 255 Nm in maximum.
(4) Install the split pin in the first matching holes and bend
it securely.
MB991406,
MB990635 or
MB991113
Ball joint
Cord
Nut
MB990767
MB990241
MB990767
196 - 255 Nm
Washer
FRONT AXLE - Front Hub Assembly 26-7
WHEEL BEARING ROTATION STARTING TORQUE
CHECK
(1) Install the special tool to the front hub assembly and
tighten the nut to the specified torque 196 - 255 Nm.
(2) Use the special tool to measure the wheel bearing starting
torque.
Limit: 1.0 Nm or less
(3) The wheel bearing starting torque should be within the
limit value range, and there should be no engagement
or feeling of roughness.
WHEEL BEARING AXIAL PLAY CHECK 26100110095
(1) Install the special tool to the front hub assembly and
tighten the nut to the specified torque 196 - 255 Nm.
(2) Measure the play in the hub axial direction.
Limit: 0.05 mm
(3) If the limit value of hub axial play cannot be obtained,
replace the front hub assembly.
MB990998
MB990326
196 - 255 Nm
MB990998
FRONT AXLE - Knuckle 26-8
KNUCKLE 26100240138
Front Hub Assembly Removal (Refer to P.26-5.)
D Front Hub Assembly Installation (Refer to P.26-5.)
59 - 71 Nm
88 Nm*
24 - 33 Nm 9 Nm
1
2
3
4
5
6
Removal steps
1. Dust shield
AA" 2. Tie rod end and knuckle connec-
tion
3. Damper fork and lateral lower arm
connection
AA" 4. Lateral lower arm and knuckle con-
nection
AA" 5. Compression lower arm and
knuckle connection
6. Knuckle
Caution
*: Indicates parts which should be temporarily
tightened, and then fully tightened with the vehicle
on the ground in the unladen condition.
AA"TIE ROD END AND KNUCKLE/LATERAL LOWER
ARM AND KNUCKLE/COMPRESSION LOWER
ARM AND KNUCKLE DISCONNECTION
Caution
MB991406,
MB990635 or
MB991113
Ball joint
Cord
Nut
FRONT AXLE - Drive Shaft 26-9
DRIVE SHAFT 26100350213
D Wheel Alignment Check and Adjustment (Refer to
GROUP 33A - On-vehicle Service.)
103 Nm
44 Nm
88 Nm*
98 - 118 Nm*
81 Nm
69 - 78 Nm
196 - 255 Nm
24 - 33 Nm
81 Nm
1
2
3
4
5
6
7
8
9
Removal steps
1. Front wheel speed sensor
<Vehicles with ABS>
AA" "AA 2. Drive shaft nut
AB" 3. Tie rod end and knuckle connec-
tion
4. Stabilizer link and damper fork
connection
5. Damper fork
6. No.2 stay
AC" 8. Compression lower arm connection
AD" 9. Drive shaft
Caution
1. *: Indicates parts which should be temporarily
2. For vehicles with ABS, be careful not to damage
the rotors installed to the B.J. (or R.J.) outer
race during removal and installation of the drive
shaft.
AA"DRIVE SHAFT NUT REMOVAL
Caution
while loosening the drive shaft nut.
AB"TIE ROD END AND KNUCKLE DISCONNECTION
Caution
AC"COMPRESSION LOWER ARM DISCONNECTION
To remove the compression lower armfrom the crossmember,
No.3 stay must not be removed as it is tightened together
with the crossmember.
AD"DRIVE SHAFT REMOVAL
(1) Use the special tools to push out the drive shafts from
the hub.
(2) While pulling out the lower side of the rotor toward you,
rotate it toward the rear side of the vehicle 90_ to remove
the drive shaft from the hub.
MB990767
MB991406,
MB990635 or
MB991113
Ball joint
Cord
Nut
Compression
lower arm
No.3 stay
Crossmember
MB990767
MB990241
(3) Insert a pry bar between the transmission case and the
drive shaft, and then pry the drive shaft from the
transmission.
Caution
1. Always use a lever as pulling out the drive shaft
from B.J. (or R.J.) assembly may damage the T.J.
assembly.
2. Do not insert the pry bar so deep as to damage
the oil seal.
(4) Use the special tool as a cover not to let foreign objects
get into the transmission case.
Caution
while loosening the drive shaft nut. If, however, the vehicle
weight must be applied to the bearing (because of moving
the vehicle), temporarily secure the wheel bearing by
using the special tool.
"AADRIVE SHAFT NUT INSTALLATION
(1) Be sure to install the drive shaft washer in the specified
direction.
(2) Using the special tool, tighten the drive shaft nut.
Caution
Before securely tightening the drive shaft nuts, make
sure there is no load on the wheel bearings.
(3) If the position of the split pin holes does not match, tighten
the nut up to 255 Nm in maximum.
(4) Install the split pin in the first matching holes and bend
it securely.
Drive shaft
Pry bar
Transmission
Oil seal
MB991460
MB990998
MB990767
196 - 255 Nm
Washer
T.J. repair kit T.J. boot repair kit B.J. (or R.J.) boot repair kit
3
4
5
6
7
1
2
3
4
5
7
4
5
6
7
1
2
4
8
11
12
13
1
2
10
9
8
2
1
5
Disassembly steps
"CA 1. T.J. boot band (large)
"CA 2. T.J. boot band (small)
AA" "BA 3. T.J. case
4. Circlip
5. Snap ring
AA" "BA 6. Spider assembly
AB" "AA 7. T.J. boot
"AA 8. Damper band
"AA 9. Dynamic damper
10. B.J. (or R.J.) assembly
11. B.J. (or R.J.) boot band (small)
12. B.J. (or R.J.) boot band (large)
13. B.J. (or R.J.) boot
Caution
1. Never disassemble the B.J. (or R.J.) assembly
except when replacing the B.J. (or R.J.) boot.
2. On vehicles with ABS, be sure not to damage
the rotor attached to the B.J. (or R.J.) outer race.
AA"T.J. CASE/SPIDER ASSEMBLY REMOVAL
(1) Wipe off grease from the spider assembly and the inside
of the T.J. case.
(2) Always clean the spider assembly when the grease
contains water or foreign material.
Caution
1. Do not disassemble the spider assembly.
2. Use care in handling so as not to damage the
drive shaft.
AB"T.J. BOOT REMOVAL
(1) Wipe off grease from the shaft spline.
(2) When reusing the T.J. boot, wrap plastic tape around
the shaft spline to avoid damaging the boot.
"AADYNAMIC DAMPER/DAMPER BAND/T.J. BOOT
INSTALLATION
(1) Straighten the B.J. (or R.J.) assembly, and secure the
dynamic damper with the damper band as shown in the
figure.
Caution
There should be no grease adhered to the rubber
part of the dynamic damper.
NOTE
The damper band and the T.J. boot band (small) are
the same parts.
(2) Wrap plastic tape around the shaft spline, and then install
the T.J. boot band (small) and T.J. boot.
"BASPIDER ASSEMBLY/T.J. CASE INSTALLATION
(1) Apply the specified grease furnished in the repair kit to
the spider assembly between the spider axle and the
roller.
Specified grease: Repair kit grease
Caution
1. The drive shaft joint uses special grease. Do not
mix old and new or different types of grease.
2. If the spider assembly has been cleaned, take
special care to apply the specified grease.
LH: 229 mm
RH: 278 mm
Bevelled
section
(2) Install the spider assembly to the shaft from the direction
of the spline bevelled section.
(3) After applying the specified grease to the T.J. case, insert
the drive shaft and apply grease one more time.
Amount to use:
<2000 - petrol-powered vehicles> 120 g
<2000 - diesel-powered vehicles, 2500> 150 g
NOTE
The grease in the repair kit should be divided in half
for use, respectively, at the joint and inside the boot.
Caution
The drive shaft joint uses special grease. Do not mix
old and new or different types of grease.
"CAT.J. BOOT BAND (SMALL)/T.J. BOOT BAND
(LARGE) INSTALLATION
Set the T.J. boot bands at the specified distance in order
to adjust the amount of air inside the T.J. boot, and then
tighten the T.J. boot bands securely.
Standard value (A):
<2000 - petrol-powered vehicles> 82 mm
<2000 - diesel-powered vehicles, 2500> 81 mm
D Check the drive shaft for damage, bending or corrosion.
D Check the drive shaft spline part for wear or damage.
D Check the spider assembly for roller rotation, wear or
corrosion.
D Check the groove inside T.J. case for wear or corrosion.
D Check the dynamic damper for damage or cracking.
D Check the boots for deterioration, damage or cracking.
B.J. (or R.J.) BOOT (RESIN BOOT)
REPLACEMENT 26100520089
(1) Remove the B.J. (or R.J.) boot bands (large and small).
NOTE
The B.J. (or R.J.) boot bands cannot be re-used.
(2) Remove the B.J. (or R.J.) boot.
(3) Wrap a plastic tape around the shaft spline, and assemble
the B.J. (or R.J.) boot band and B.J. (or R.J.) boot.
A
(4) Install the B.J. (or R.J.) boot with the part with the smallest
diameter in a position such that the shaft groove can
be seen.
(5) Turn the adjusting bolt on the special tool so that the
size of the opening (W) is at the standard value.
Standard value (W): 2.9 mm
<If it is larger than 2.9 mm>
Tighten the adjusting bolt.
<If it is smaller than 2.9 mm>
Loosen the adjusting bolt.
NOTE
(1) The value of W will change by approximately 0.7
mm for each turn of the adjusting bolt.
(2) The adjusting bolt should not be turned more than
once.
(6) Place the B.J. (or R.J.) boot band (small) against the
projection at the edge of the boot, and then secure it
so that there is a clearance left as shown by (A) in the
illustration.
(7) Use the special tool to crimp the B.J. (or R.J.) boot band
(small).
Caution
1. Secure the drive shaft in an upright position and
clamp the part of the B.J. (or R.J.) boot band to
be crimped securely in the jaws of the special
tool.
2. Crimp the B.J. (or R.J.) boot band until the special
tool touches the stopper.
MB991561
Stopper
Adjusting bolt
W
B.J. (or R.J.)
boot band
(small)
Projection
A
B.J. (or R.J.)
boot
MB991561
(8) Check that the crimping amount (B) of the B.J. (or R.J.)
boot band is at the standard value.
Standard value (B): 2.4 - 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step (5) according
to the following formula, and then repeat the
operation in step (7).
W = 5.5 mm - B
Example: If B = 2.9 mm, then W = 2.6 mm.
<If the crimping amount is smaller than 2.4 mm>
Remove the B.J. (or R.J.) boot band, readjust
the value of (W) in step (5) according to the
following formula, and then repeat the
operations in steps (6) and (7) using a new
B.J. (or R.J.) boot band.
W = 5.5 mm - B
Example: If B = 2.3 mm, then W = 3.2 mm.
(9) Check that the B.J. (or R.J.) boot band is not sticking
out past the place where it has been installed. If the
B.J. (or R.J.) boot band is sticking out, remove it and
then repeat the operations in steps (6) to (8) using a
new B.J. (or R.J.) boot band.
(10)Fill the inside of the B.J. (or R.J.) boot with the specified
amount of the specified grease.
Amount to use: <2000> 120 g, <2500> 135 g
Caution
The drive shaft joint uses special grease. Do not mix
old and new or different types of grease.
(11)Install the B.J. (or R.J.) boot band (large) so that there
is the clearance (C) between it and the B.J. (or R.J.)
housing is at the standard value.
Standard value (C): 0.1 - 1.5 mm
(12)Follow the same procedure as in step (5) to adjust the
size of the opening (W) on the special tool so that it
is at the standard value.
(13)Place the B.J. (or R.J.) boot band (large) against the
projection at the edge of the boot, and then secure it
so that there is a clearance left as shown by (D) in the
illustration.
(14)Use the special tool to crimp the B.J. (or R.J.) boot band
(large) in the same way as in step (7).
B
C
B.J. (or R.J.)
boot
Projection
B.J. (or R.J.)
boot band
(large)
D
(15)Check that the crimping amount (E) of the B.J. (or R.J.)
boot band is at the standard value.
Standard value (e): 2.4 - 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) instep (12) according
to the following formula, and then repeat the
operation in step (14).
W = 5.8 mm - E
Example: If E = 2.9 mm, then W = 2.9 mm.
<If the crimping amount is smaller than 2.4 mm>
Remove the B.J. (or R.J.) boot band, readjust
the value of (W) in step (12) according to the
following formula, and then repeat the
operations in steps (13) and (14) using a new
B.J. (or R.J.) boot band.
W = 5.8 mm - E
Example: If E = 2.3 mm, then W = 3.5 mm.
(16)Check that the B.J. (or R.J.) boot band is not sticking
out past the place where it has been installed.
If the B.J. (or R.J.) boot band is sticking out, remove
it and then repeat the operations in steps (13) to (15)
using a new B.J. (or R.J.) boot band.
E
NOTES
27-1
REAR AXLE
SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Bearing Axial Play Check 3 . . . . . . . . . . . . . .
Wheel Bearing Rotary-Sliding Resistance Check
3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hub Bolt Replacement 4 . . . . . . . . . . . . . . . . . . . . . . . .
REAR AXLE HUB 5 . . . . . . . . . . . . . . . . . . . . . . . . . .
KNUCKLE 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR AXLE -
General Information/Service Specifications/
Special Tools
27-2
The rear axle consists of a knuckle, rear hub, unit
bearing and axle shaft. The unit bearing is
press-fitted to the rear axle shaft and bolted to
theknuckle. Also, theunitbearingutilizes thesame
type of double row angular contact ball bearing
as does the front axle. A rotor for detecting the
vehicle speed is located on the rear axle shaft,
and a speed sensor is located on the knuckle.
Oil seal
Knuckle
Unit bearing
Cap
Oil seal
Rear axle shaft
Rotor
<Vehicles with ABS>
Items Limit
Wheel bearing axial play mm 0.05
Wheel bearing rotary-sliding resistance N 18 or less
MB990767 End yoke holder Fixing of the hub
MB991618 Hub bolt remover Removal of the hub bolt
MB991248 Inner shaft
remover
Rotor removal
REAR AXLE - Special Tools/On-vehicle Service 27-3
MB991406
MB990635 or
MB991113
Steering linkage
puller
WHEEL BEARING AXIAL PLAY CHECK
1. For vehicles with rear disc brake, remove the caliper
assembly, suspend the caliper assembly with a wire and
remove the brake disc.
2. For vehicles with rear drumbrake, remove the brake drum.
3. Check the bearings axial play.
Place a dial gauge against the hub surface; then move
the hub in the axial direction and check whether or not
there is axial play.
Limit: 0.05 mm
4. If the play exceeds the limit value, replace the rear hub
assembly.
WHEEL BEARING ROTARY-SLIDING
RESISTANCE CHECK 27100110153
3. After turning the hub a few times to seat the bearing,
wind a rope around the hub bolt and turn the hub by
pulling at a 90_ angle with a spring balance. Measure
to determine whether or not the rotary-sliding resistance
of the rear hub is at the limit value.
Limit: 18 N or less
4. If the rotary-sliding resistance exceeds the limit value,
replace the rear hub assembly.
REAR AXLE - On-vehicle Service 27-4
HUB BOLT REPLACEMENT 27100100112
3. Pull the hub bolt out using the special tool.
NOTE
For vehicles with drum brakes, the hub bolts should be
removed near the retainer spring installation position in
order to maintain enough clearance for removal.
4. Install the plain washer to the new hub bolt, and install
the bolt with a nut.
MB990767
MB991618
Plane
washer
MB990767
REAR AXLE - Rear Axle Hub 27-5
REAR AXLE HUB 27100200188
<Vehicles with drum brake>
<Vehicles with disc brake>
74 - 88 Nm
100 Nm
74 - 88 Nm
1
2
3
4
5
6
7
8
1
8 7
6
Removal steps
1. Rear wheel-speed sensor <Vehicles
with ABS> (Refer to GROUP 35B.)
AA" 2. Caliper assembly
3. Brake drum
4. Brake disc
5. Brake hose installation bracket
6. Rear hub assembly
AB" "AA 7. Rotor <Vehicles with ABS>
AC" 8. Backing plate
Caution
The rear hub unit bearing should not be dismantled.
When removing the rear hub assembly, the wheel
bearing inner race may be left at the spindle side.
In this case, always replace the rear hub assembly,
otherwise the hub will damage the oil seal, causing
oil leaks or excessive play.
REAR AXLE - Rear Axle Hub 27-6
AA"CALIPER ASSEMBLY REMOVAL
Remove the caliper assembly and suspend it.
AB"ROTOR REMOVAL
AC"BACKING PLATE REMOVAL
Remove the backing plate and suspend it.
"AAROTOR INSTALLATION
Socket
MB991248
Socket
REAR AXLE - Knuckle 27-7
KNUCKLE 27100300123
Rear Hub Assembly Removal (Refer to P.27-5.)
Pushing It with Finger.
D Rear Hub Assembly Installation (Refer to P.27-5.)
1
2
3
4
5
6
7
98 Nm
98 Nm*
98 Nm*
28 Nm
118 - 137 Nm*
Removal steps
1. Trailing arm connection
2. Lower arm connection
AA" 3. Toe control arm connection
4. Shock absorber connection
5. Upper arm connection
6. Hub cap
7. Knuckle
Caution
AA"TOE CONTROL ARM DISCONNECTION
Caution
MB990635,
MB991113 or
MB991406
Nut
Cord
Ball joint
NOTES
31-1
WHEEL AND TYRE
Tyre Inflation Pressure Check 6 . . . . . . . . . . . . . . . . .
Tyre Wear Check 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Runout Check 6 . . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL AND TYRE 6 . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL AND TYRE - General Information 31-2
Both steel type and aluminium type wheels have
been adopted. The type of wheel used depends
on the vehicle model.
A compact spare tyre has been adopted as the
spare tyre in some models.
Items EA2ASNJEQL6,
WLNJEQL6
EA2ASNHEQL6,
ASRHEQL6,
WLNHEQL6,
WLRHEQL6
EA5ASNGEQL6,
ASRGEQL6,
WLNGEQL6,
WLRGEQL6
Wheel Type Steel type
Aluminium type*
Steel type
Aluminium type*
Aluminium type
Size 14 5 1/2 JJ 14 5 1/2 JJ
15 6 JJ*
15 6 JJ
Amount of wheel offset
mm
46 46 46
Pitch circle diameter
(P.C.D.) mm
114.3 114.3 114.3
Tyre Size 195/65R14 89 V 195/65R14 89 V
195/60R15 88 V*
195/60R15 88 V
205/60R15 91 V*
Spare Type Steel type Steel type Steel type
wheel
Size 15 x 4.0T
14 x 5 1/2 JJ*
15 x 4.0T
14 x 5 1/2 JJ*
15 x 6 JJ*
15 x 4.0T
15 x 6 JJ*
mm
46 46 46
(P.C.D) mm
114.3 114.3 114.3
Spare
tyre
Size T125/70D15
(High pressure)
195/65R14 89V*
T125/70D15
(High pressure)
195/65R14 89V*
195/60R15 88V*
T125/70D15
(High pressure)
195/60R15 88V*
205/60R15 91 V*
NOTE
*: Optional items
WHEEL AND TYRE - General Information 31-3
Items EA6ASNHFQL6,
WLNHFQL6
EA2ASNJEQL6C,
WLNJEQL6C
EA2ASNHEQL6C,
ASRHEQL6C,
ASNHEQR6,
ASRHEQR6,
WLNHEQL6C,
WLRHEQL6C,
WLNHEQR6,
WLRHEQR6
Wheel Type Steel type
Aluminium type*
Steel type
Aluminium type*
Steel type
Aluminium type*
Size 14 5 1/2 JJ
15 6 JJ*
14 5 1/2 JJ 14 5 1/2 JJ
15 6 JJ*
mm
46 46 46
(P.C.D.) mm
114.3 114.3 114.3
Tyre Size 185/70R14 88H
195/60R15 88 V*
195/65R14 89 V 195/65R14 89 V
195/60R15 88 V*
Spare
wheel
Type Steel type Steel type
Aluminium type*
Steel type
Aluminium type*
Size 15 x 4.0T
14 x 5 1/2 JJ*
15 6 JJ*
14 5 1/2 JJ 14 5 1/2 JJ
15 6 JJ*
mm
46 46 46
(P.C.D.) mm
114.3 114.3 114.3
Spare
tyre
Size T125/70D15
(High pressure)
185/70R14 88H*
195/60R15 88 V*
195/65R14 89 V 195/65R14 89 V
195/60R15 88 V*
NOTE
*: Optional items
WHEEL AND TYRE - General Information/Service Specifications 31-4
Items EA5ASNGEQL6C,
ASRGEQL6C,
WLNGEQL6C,
WLRGEQL6C
EA6ASNHFQL6C,
ASNHFQR6,
WLNHFQL6C,
WLNHFQR6
EA5ASNGEQR6,
ASRGEQR6,
WLNGEQR6,
WLRGEQR6
Wheel Type Aluminium type Steel type
Aluminium type*
Aluminium type
Size 15 6 JJ 14 5 1/2 JJ
15 6 JJ*
15 6 JJ
mm
46 46 46
(P.C.D.) mm
114.3 114.3 114.3
Tyre Size 205/60R15 91 V 185/70R14 88 H
195/60R15 88 V*
195/60R15 88 V
205/60R15 91 V*
Spare
wheel
Type Steel type Steel type
Aluminium type*
Aluminium type
Size 15 6 JJ 14 5 1/2 JJ
15 6 JJ*
15 6 JJ
mm
46 46 46
(P.C.D.) mm
114.3 114.3 114.3
Spare
tyre
Size 205/60R15 91 V 185/70R14 88 H
195/60R15 88 V
195/60R15 88 V
205/60R15 91 V*
NOTE
*: Optional items
Items Limit
Tread depth of tyre mm 1.6
Wheel runout (Radial runout) mm Steel wheel 1.2 or less
Aluminium wheel 1.0 or less
Wheel runout (Lateral runout) mm Steel wheel 1.2 or less
Aluminium wheel 1.0 or less
WHEEL AND TYRE - Troubleshooting 31-5
Symptom Probable cause Remedy Reference page
Rapid wear at
shoulders
Under-inflation
or lack of rotation
Adjust the tyre
pressure.
31-6.
Rapid wear at
centre
Over-inflation or
lack of rotation
Cracked treads Under-inflation Adjust the tyre
pressure.
31-6.
Wear on one
side
Excessive cam-
ber
Inspect the cam-
ber.
Refer to GROUP
33A - On-ve-
hicle Service.
Feathered edge Incorrect toe-in Adjust the toe-in.
Bald spots Unbalanced
wheel
Adjust the imbal-
anced wheels.
-
Scalloped wear Lack of rotation of tyres or worn or
out-of-alignment suspension
Rotate the tyres
and check the
front suspension
alignment.
Refer to GROUP
33A - On-ve-
hicle Service.
WHEEL AND TYRE - On-vehicle Servic/Wheel and Tyre 31-6
TYRE INFLATION PRESSURE CHECK
NOTE
For information on tyre inflation pressure, refer to the label
attached at the drivers side to the centre pillar.
TYRE WEAR CHECK 31100100034
Measure the tread depth of tyres.
Limit: 1.6 mm
If the remaining tread depth is less than the limit, replace
the tyre.
NOTE
When the tread depth of tyres is reduced to 1.6 mm or less,
wear indicators will appear.
WHEEL RUNOUT CHECK 31100110037
Jack up the vehicle so that the wheels are clear of the floor.
While slowly turning the wheel, measure wheel runout with
a dial indicator.
Limit:
Item Steel wheel Aluminium wheel
Radial runout mm 1.2 1.0
Lateral runout mm 1.2 1.0
If wheel runout exceeds the limit, replace the wheel.
WHEEL AND TYRE 31100130071
Tighten the wheel nut to the specified torque.
Radial
Lateral
32-1
POWER PLANT
MOUNT
SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MOUNTING 4 . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION MOUNTING 5 . . . . . . . . . . . . . . . .
ENGINE ROLL STOPPER,
CENTERMEMBER 6 . . . . . . . . . . . . . . . . . . . . . . . . . .
CROSSMEMBER 7 . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER PLANT MOUNT - General Information/Service Specifications 32-2
The engine-transmission mount is of an inertial axis
supporting type whose excellent features have
already been proven in many Mitsubishi vehicles.
The inertial axis supporting type mount supports
the front upper part of the engine at the front and
the rear upper part of the transmission at the rear.
This arrangement effectively supresses the engine
vibration.
Dynamic damper
Engine mount
Crossmember
Centermember
Front
Front roll stopper
Transmission mount
Rear roll stopper
Dynamic damper
Engine mount
Transmission mount
Rear roll stopper
Front roll stopper
Centermember
Crossmember
Dynamic
damper
Crossmember Bushing (A) projection mm 9.0 1.0
Bushing (B) projection mm 4.0 1.0
Bushing (C) projection mm 4.0 0.5
POWER PLANT MOUNT - Special Tools 32-3
MB991453 Engine hanger To support the engine assembly during
mount
GENERAL
SERVICE
TOOL
MZ203827
Engine lifter
MB991045 Bushing remover
and installer
Driving out and press-fitting of crossmember
bushings A and B
MB990828 Bushing remover
and installer
Driving out and press-fitting of crossmember
bushing C
POWER PLANT MOUNT - Engine Mounting 32-4
ENGINE MOUNTING 32100110263
D Jack Up the Engine and Transmission Assembly Until
There is no Weight on the Engine Mount Bracket
Insulator.
D Reserve Tank Removal and Installation
(Refer to GROUP 14)
D Engine Cover Removal and Installation <6A1>
5 Nm
<6A1> 35 Nm
<4D6> 12 Nm
67 Nm
57 Nm
98 - 118 Nm*
1
2
3
4
5
6
Removal steps
1. Engine mount stay <6A1>
2. Power steering hose bracket
<4D6>
3. Engine mount insulator mounting
bolt
4. Engine mount bracket
"AA 5. Engine mount stopper
6. Dynamic damper
Caution
"AAENGINE MOUNT STOPPER INSTALLATION
Engine
mount
stopper
Engine side
Dynamic damper
Arrow
POWER PLANT MOUNT - Transmission Mounting 32-5
TRANSMISSION MOUNTING 32100140170
D Centermember Removal and Installation
D Transmission and Rear Roll Stopper Connecting Bolt
Removal and Installation (Refer to P.32-6.)
D Rear Roll Stopper Bracket Removal and Installation
(Refer to GROUP 22, 23 - Transmission Assembly)
81 Nm*
57 Nm
2
1
Removal steps
AA" 1. Transmission mount bracket
"AA 2. Transmission mount stopper
Caution
AA"TRANSMISSION MOUNT BRACKET REMOVAL
(1) Install the special tool to the vehicle body to support
the engine and transmission assembly.
(2) Remove the centermember and rear roll stopper bracket.
(3) Remove the bolt and nut of the transmission mount
bracket.
(4) After lowering the engine and transmission assembly,
remove the transmission mount bracket.
"AATRANSMISSION MOUNT STOPPER INSTALLATION
Clamp the transmission mount stopper so that the arrowpoints
MZ203827
MB991453
Engine side
Arrow
Transmission
mount bracket
Trans-
mission
mount
stopper
POWER PLANT MOUNT - Engine Roll Stopper, Centermember 32-6
ENGINE ROLL STOPPER, CENTERMEMBER 32100200144
1
2
3
4
5
6
7
8
9
10
11
44 Nm
57 Nm*
93 Nm
25 Nm
69 - 78 Nm
69 - 78 Nm
44 Nm*
44 Nm
2
2
Front roll stopper, centermember
removal steps
1. Transmission and front roll stopper
connecting bolt
2. Centermember mounting bolts
3. Stopper
4. Centermember
"AA 5. Front roll stopper
6. Collar
7. Bushing (lower)
8. Bushing (upper)
9. Dynamic damper <4G6, 4D6>
Rear roll stopper removal steps
10. Transmission and rear roll stopper
connecting bolt
Caution
"AAFRONT ROLL STOPPER INSTALLATION
Install so that the hole in the front roll stopper is facing towards
the front of the vehicle.
Hole
Front of vehicle
POWER PLANT MOUNT - Crossmember 32-7
CROSSMEMBER 32100320178
CAUTION: SRS
For vehicles with SRS, before removal of steering gear box, refer to GROUP 52B, centre front wheels and
remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative,
risking serious driver injury.
D Power Steering Fluid Draining (Refer to GROUP
37A - On-vehicle Service.)
D Centermember Removal (Refer to P.32-6.)
D Front Exhaust Pipe Removal (Refer to GROUP 15.)
D Stabilizer Bar Removal (Refer to GROUP 33A.)
D Rear Roll Stopper Removal (Refer to P.32-6.)
D Rear Roll Stopper Installation (Refer to P.32-6.)
D Stabilizer Bar Installation (Refer to GROUP 33A.)
15.)
D Centermember Installation (Refer to P.32-6.)
D Power SteeringFluid Supplying and Bleeding(Refer
to GROUP 37A - On-vehicle Service.)
D Steering Wheel Straight Ahead Position Checking
D Wheel Alignment Check and Adjustment (Refer to
GROUP 33A - On-vehicle Service.)
8
14
98 - 118 Nm*
81 Nm
69 - 78 Nm
88 Nm*
88 Nm
98 - 118 Nm
81 Nm
88 Nm
1
2
3
4
5
6
7
9
10
11
12
13
Removal steps
1. No. 2 stay
2. Lateral lower arm and damper fork
connection
3. Lateral lower arm and crossmem-
ber connection
AA" 4. No. 3 stay
5. Compression lower arm mounting
bolts
6. No. 1 stay
D Power steering gear box
7. Crossmember mounting nut
8. Lower plate
9. Crossmember
10. Stopper A
11. Stopper B
12. Bushing C
13. Bushing A
14. Bushing B
Caution
POWER PLANT MOUNT - Crossmember 32-8
AA"NO.3 STAY REMOVAL
Hold the crossmember with a transmission jack, and remove
No.3 stay.
CROSSMEMBER BUSHING REPLACEMENT
32100090062
CROSSMEMBER BUSHINGS A AND B
(1) Apply soapy water to the contact surface of the bushing
when press-fitted the bushing.
(2) The bushing should be press-fitted so that the inner pipe
projection is at the standard length.
Standard values
Bushing A: 9.0 1.0 mm
Bushing B: 4.0 1.0 mm
CROSSMEMBER BUSHING C
(1) Use the special tool to drive out and press-fit the
crossmember bushing C.
(2) The bushing should be press-fitted so that the inner pipe
projection is at the standard length.
Standard value (A): 4.0 0.5 mm
Crossmember
Transmission jack
Bolt
Base
Removal Press-fitting
Bolt
Washer
Base
Nut
Nut
Washer
MB991045
Bushing A
Inner pipe
Bushing B
Inner pipe
Removal Press-fitting
MB990828
Inner pipe
A
33A-1
FRONT
SUSPENSION
SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Alignment Check and Adjustment 4 . . . . . . .
Ball Joint Dust Cover Check 5 . . . . . . . . . . . . . . . . . .
UPPER ARM ASSEMBLY 6 . . . . . . . . . . . . . . . . . . .
SHOCK ABSORBER ASSEMBLY 9 . . . . . . . . . . .
COMPRESSION LOWER ARM AND LATERAL
LOWER ARM ASSEMBLIES 12 . . . . . . . . . . . . . .
STABILIZER BAR 15 . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION - General Information 33A-2
The front suspension is of a multi-link construction
with two lower arms which create the ideal virtual
kingpin axis for the suspension system. In addition,
by mounting the upper arm in a higher position
than the tyres, excellent steering stability and ride
comfort are obtained.
COIL SPRING
Items Sedan (2000 - petrol-powered
vehicles - M/T),
Wagon (2000 - petrol-powered
vehicles)
Sedan (except 2000 -
petrol-powered vehicles - M/T),
Wagon (except 2000 -
petrol-powered vehicles)
Wire diameter average diameter
free length mm
12 70 - 110 366 12 70 - 110 374
CONSTRUCTION DIAGRAM
Compression
lower arm
Shock absorber
Stabilizer bar
Upper arm
Knuckle
Lateral lower arm
Centermember
Crossmember
FRONT SUSPENSION - Service Specifications/Special Tools 33A-3
Toe-in At the centre of tyre tread mm 0 3
Toe-angle (per wheel) 0_00 09
Toe-out angle on turns
(inner wheel when outer wheel at 20_)
22_
Camber 0_00 30 (difference between right and left wheel:
less than 30)
Caster 4_20 1_30 (difference between right and left wheel:
less than 30)
Kingpin inclination 7_20 1_30
Upper arm ball joint rotation starting torque Nm 0.3 - 1.5
Compression lower armball joint rotation starting torque Nm 0.5 - 2.5
Lateral lower arm ball joint rotation starting torque Nm 1.5 or less
Stabilizer link ball joint turning torque Nm 0.5 - 1.5
Tools Number Name Use
MB991004 Wheel alignment
gauge attachment
Wheel alignment measurement
<Vehicles with aluminium type wheels>
A
B
A: MB991237
B: MB991238
A: Spring com-
pressor body
B: Arm set
Coil spring compression
MB991406,
MB990635 or
MB991113
Steering linkage
puller
MB990326 Preload socket Ball joint rotation starting torque and turning
torque measurement
MB990800 Ball joint remover
and installer
Ball joint dust cover installation
FRONT SUSPENSION - On-vehicle Service 33A-4
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
Measure the wheel alignment with the vehicle parked on a
level surface.
The front suspension, steering system, and wheels should
be serviced to normal condition prior to measurement of wheel
alignment.
TOE-IN
Standard value:
At the centre of tyre tread 03 mm
Toe angle (per wheel) 0_0009
(1) If the toe-in is not within the standard value, adjust the
toe-in by undoing the clips and turning the left and right
tie rod turnbuckles by the same amount (in opposite
directions).
NOTE
The toe will move out as the left turnbuckle is turned
toward the front of the vehicle and the right turnbuckle
is turned toward the rear of the vehicle.
(2) Use a turning radius gauge to check that the steering
angle is at the standard value. (Refer to GROUP 37A
TOE-OUT ANGLE ON TURNS
To check the steering linkage, especially after the vehicle
has been involved in an accident or if an accident is presumed,
it is advisable to check the toe-out angle on turns in addition
to the wheel alignment.
Conduct this test on the left turn as well as on the right turn.
Standard value:
22_ (inner wheel when outer wheel at 20_)
Clip
FRONT SUSPENSION - On-vehicle Service 33A-5
CAMBER, CASTER AND KINGPIN INCLINATION
Standard value:
Camber
0_00 30 (difference betweenright andleft wheel:
less than 30)
Caster
4_20 1_30 (difference between right and left
wheel: less than 30)
Kingpin inclination 7_20 1_30
NOTE
1. Camber and caster are preset at the factory and cannot
be adjusted.
2. If camber is not within the standard value, check and
replace bent or damaged parts.
3. For vehicles with aluminium type wheels, attach the
camber/caster/kingpin gauge to the drive shaft by using
the special tool. Tighten the special tool to the same
torque 196 - 255 Nm as the drive shaft nut.
Caution
Never subject the wheel bearings to the vehicle load
when the drive shaft nuts are loosened.
BALL JOINT DUST COVER CHECK 33200860021
(1) Check the dust cover for cracks or damage by pushing
it with finger.
(2) If the dust cover is cracked or damaged, replace the
upper arm assembly, compression lower arm assembly,
lateral lower arm assembly or stabilizer link.
NOTE
Cracks or damage of the dust cover may cause damage
of the ball joint.
MB991004
FRONT SUSPENSION - Upper Arm Assembly 33A-6
UPPER ARM ASSEMBLY 33200430079
D Wheel Alignment Check and Adjustment
(Refer to P.33A-4.)
1
2
3
4
86 Nm
57 Nm
28 Nm
57 Nm
4
Removal steps
AA" 1. Upper arm and knuckle connection
2. Upper arm mounting nut
"AA 3. Upper arm shaft assembly
4. Upper arm assembly
AA"UPPER ARM AND KNUCKLE DISCONNECTION
Caution
MB991406,
MB990635 or
MB991113
Ball joint
Cord
Nut
"AAUPPER ARM SHAFT ASSEMBLY INSTALLATION
Install the upper arm shaft assembly at the angle shown
NOTE
If the upper arm shaft is installed at the above-mentioned
angle, the reference dimension is determine as follows;
A: 300.1 mm
B: 234.3 mm
Ball joint case
V groove
A
B
A B
UPPER ARM BALL JOINT ROTATION STARTING
TORQUE CHECK
(1) After shaking the ball joint stud several times, install the
nut to the stud and use the special tool to measure the
rotation starting torque of the ball joint.
Standard value: 0.3 - 1.5 Nm
(2) When the measured value exceeds the standard value,
replace the upper arm assembly.
(3) When the measured value is lower than the standard
value, check that the ball joint turns smoothly without
excessive play. If so, it is possible to use that ball joint.
Upper armshaft
assembly
85_ 1_
Upper arm
MB990326
UPPER ARM BALL JOINT DUST COVER CHECK
33200870017
it with finger.
upper arm assembly.
NOTE
of the ball joint. When it is damaged during service work,
replace the dust cover.
UPPER ARM BALL JOINT DUST COVER
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
(1) Remove the dust cover.
(2) Apply multipurpose grease to the lip and inside of the
dust cover.
(3) Drive in the dust cover with special tool until it is fully
seated.
it with finger.
MB990800
Dust cover
Snap ring
FRONT SUSPENSION - Shock Absorber Assembly 33A-9
SHOCK ABSORBER ASSEMBLY 33200460078
(Refer to P.33A-4.)
44 Nm
103 Nm
88 Nm*
44 Nm
1
2
3
4
5
6
Removal steps
1. Stabilizer link
2. Shock absorber mounting nuts
3. Damper fork and lateral lower arm
connection
4. Damper fork and shock absorber
connection
"AA 5. Damper fork
6. Shock absorber assembly
Caution
"AADAMPER FORK INSTALLATION
The damper fork must face against the damper fork positioning
projection of the shock absorber assembly as shown in the
figure.
Damper fork mounting bolt
Damper fork positioning projection
Inside of
the body
7
1
2
3
4
5
6
23 Nm
8
9
10
11
12
Disassembly steps
AA" "CA 1. Self-locking nut
2. Washer
3. Upper bushing A
"BA 4. Upper bracket assembly
5. Upper spring pad
6. Collar
7. Upper bushing B
8. Cup assembly
9. Bump rubber
10. Dust cover
"AA 11. Coil spring
AA"SELF-LOCKING NUT REMOVAL
(1) Use the special tools to compress the coil spring.
Caution
1. Install the special tools evenly, and so that the
maximum length will be attained within the
installation range.
2. Do not use an impact wrench to tighten the special
tool bolt.
(2) While holding the piston rod, remove the self-locking nut.
Caution
Do not use an impact wrench.
MB991238
MB991237
"AACOIL SPRING INSTALLATION
(1) Install the special tool in the same manner as for removal,
and compress the coil spring to install to the shock
absorber.
Caution
Do not use an impact wrench to tighten the bolt of
the special tool.
(2) Align the upper side of the coil spring with the upper
spring pad stepped portion and the lower side with the
spring seat stepped portion, respectively.
"BAUPPER BRACKET ASSEMBLY INSTALLATION
The upper bracket assembly must face against the damper
fork positioning projection of the shock absorber as shown
in the figure.
"CASELF-LOCKING NUT INSTALLATION
(1) Temporarily tighten the self-locking nut.
(2) Remove the special tools (MB991237, MB991238), and
tighten the self-locking nut to the specified torque.
Caution
Spring seat
End of coil spring
Damper fork positioning projection
FRONT SUSPENSION -
Compression Lower Arm and
Lateral Lower Arm Assemblies
33A-12
COMPRESSION LOWER ARM AND LATERAL LOWER ARM
ASSEMBLIES 33200510100
(Refer to P.33A-4.)
59 - 71 Nm
LATERAL LOWER ARM
98 - 118 Nm*
81 Nm
69 - 78 Nm
88 Nm*
81 Nm
88 Nm
98 - 118 Nm
1
2
3
4, 10
5
6
7
8
9
10
4
Compression lower arm assembly
removal steps
AA" 1. No.3 stay
AB" 2. Compression lower arm and
knuckle connection
3. Compression lower arm mounting
bolts
4. Compression lower arm assembly
Lateral lower arm assembly
removal steps
5. No.2 stay
6. Lateral lower arm and damper fork
connection
AB" 7. Lateral lower arm and knuckle con-
nection
8. Lateral lower arm mounting bolt
9. Stopper
10. Lateral lower arm assembly
Caution
FRONT SUSPENSION -
33A-13
AB"COMPRESSION LOWER ARM AND
KNUCKLE/LATERAL LOWER ARM AND
KNUCKLE DISCONNECTION
Caution
LOWER ARM BALL JOINT ROTATION STARTING
TORQUE CHECK
rotation starting torque of the ball joint.
Compression lower arm ball joint
Lateral lower arm ball joint
Standard value: 1.5 Nm or less
replace the lower arm assembly.
LOWER ARM BALL JOINT DUST COVER CHECK
33200880010
it with finger.
lower arm assembly.
NOTE
No.3 stay
Crossmember
MB991406,
MB990635 or
MB991113
Nut
Cord
Ball joint
MB990326
FRONT SUSPENSION -
33A-14
LOWER ARM BALL JOINT DUST COVER
(1) Remove the dust cover.
(2) Applymultipurpose grease to the inside of the dust cover.
(3) Apply multipurpose grease to the shown portion on the
top of the lateral lower arm assembly dust cover.
Caution
Be careful not to let multipurpose grease touch the
ball joint threadandthe knucklejoint (taperedportion).
If it touches, wipe away it.
(4) Drive in the dust cover with special tool until it is fully
seated.
it with finger.
Tapered
portion
LATERAL LOWER ARM
Dust cover
MB990800
FRONT SUSPENSION - Stabilizer Bar 33A-15
STABILIZER BAR 33200540079
D Left Side of No.1 and No.2 Stays Disconnection
<L.H. Drive Vehicles> (Refer to GROUP 32 -
Crossmember.)
D Right Side of No.1 and No.2 Stays Disconnection
<R.H. Drive Vehicles> (Refer to GROUP 32 -
Crossmember.)
D Right Side of No.1 and No.2 Stays Connection
<R.H. Drive Vehicles> (Refer to GROUP 32 -
Crossmember.)
D Left Side of No.1 and No.2 Stays Connection
<L.H. Drive Vehicles> (Refer to GROUP 32 -
Crossmember.)
44 Nm
44 Nm
1
2
3
4
5
1
Removal steps
1. Stabilizer link mounting nut
2. Stabilizer link
"AA 3. Stabilizer bar bracket
"AA 4. Bushing
"AA 5. Stabilizer bar
"AASTABILIZER BAR/BUSHING/STABILIZER BAR
BRACKET INSTALLATION
Position the stabilizer bar so that left side identification mark
is at the shown position, and tighten the stabilizer bar bracket
mounting bolt.
Approx. 20 mm
Inside of
the body
FRONT SUSPENSION - Stabilizer Bar 33A-16
STABILIZER LINK BALL JOINT TURNING TORQUE
CHECK
turning torque of the ball joint.
replace the stabilizer link.
STABILIZER LINK BALL JOINT DUST COVER CHECK
33200890013
it with finger.
stabilizer link.
NOTE
STABILIZER LINK BALL JOINT DUST COVER
(1) Remove the clip ring and the dust cover.
(2) Apply multipurpose grease to the inside of the dust cover.
(3) Use plastic tape on the stabilizer link threads as shown
in the illustration, and then install the dust cover to the
stabilizer link.
(4) Secure the dust cover by the clip ring. When installing
the clip ring, align the ends at a 90_ angle from the axis
of the stabilizer link.
it with finger.
Clip ring
Approx.
90_
Clip ring ends (180_ on
opposite side also possible)
Plastic
tape
34-1
REAR
SUSPENSION
SPECIAL TOOLS 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Alignment Check and Adjustment 4 . . . . . . .
Ball Joint Dust Cover Check 4 . . . . . . . . . . . . . . . . . .
REAR SUSPENSION ASSEMBLY 5 . . . . . . . . . . .
UPPER ARM ASSEMBLY 7 . . . . . . . . . . . . . . . . . . .
TRAILING ARM ASSEMBLY 9 . . . . . . . . . . . . . . . .
LOWER ARM AND TOE CONTROL ARM
ASSEMBLIES 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHOCK ABSORBER ASSEMBLY 13 . . . . . . . . .
STABILIZER BAR 16 . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION - General Information 34-2
The rear suspension is a multi-link suspension,
which has been used for the previous models. The
layout of each arm and the rigidity balance of each
bushing have been rationalized to provide both
excellent steering stability and riding comfort.
COIL SPRING
Items Sedan Wagon
Wire diameter average diameter
free length mm
9 62 - 102 397,
9 94 - 102 330*
1
,
9 - 10 63 - 103 386*
2
9 - 10 63 - 103 405,
10 95 - 103 321*
1
,
10 - 11 64 - 104 383*
2
NOTE
*1: Self-leveling shock absorber
*2: Heavy-duty suspension
Shock absorber
Knuckle
Crossmember
Upper arm
Toe control arm
Lower arm
Trailing arm
REAR SUSPENSION - Service Specifications/Special Tools 34-3
Toe-in At the centre of tyre tread mm 3 3
Toe-angle (per wheel) 0_09 09
Camber - 1_00 30
Dimension for positioning upper arm bracket mm 37.2 2
Toe control arm ball joint turning torque Nm 1.0 - 2.6
Stabilizer link ball joint turning torque Nm 0.5 - 1.5
MB990635,
MB991113 or
MB991406
Steering linkage puller Ball joint and knuckle disconnec-
tion
MB990326 Preload socket Ball joint continuous rotating
check
MB990800 Ball joint remover and
installer
Ball joint dust cover installation
A
B
A: MB991237
B: MB991239
A: Spring compressor
body
B: Arm set
Coil spring compression
REAR SUSPENSION - On-vehicle Service 34-4
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
TOE-IN
Standard value:
At the centre of tyre tread 3 3 mm
Toe angle (per wheel) 0_09 09
Turn the toe control arm mounting bolts of the left and right
toe control arms by equal amounts to adjust.
LH: Clockwise viewed from the rear Toe-out
RH: Clockwise viewed from the rear Toe-in
Furthermore, toe adjustment can be mode at graduations
of approximately 2.5 mm
CAMBER
Standard value: - 1_00 30
NOTE
1. Camber is preset at the factory and can not be adjusted.
2. If camber is not within the standard value, check and
replace bent or damaged parts.
1. Check the dust cover for cracks or damage by pushing
it with finger.
2. If the dust cover is cracked or damaged, replace the
toe control arm assembly or stabilizer link.
NOTE
of the ball joint.
Crossmember
REAR SUSPENSION - Rear Suspension Assembly 34-5
REAR SUSPENSION ASSEMBLY 34100330113
D Brake Fluid Draining <Vehicles with drum brake>
D Rear Seat Removal <Sedan>
D Retractor Trim Removal <Wagon>
D Center Exhaust Pipe Removal
D Center Exhaust Pipe Installation
D Retractor Trim Installation <Wagon>
D Rear Seat Installation <Sedan>
D Parking Brake Lever Stroke Check
D Brake Line bleeding <Vehicles with drum brake>
(Refer to P.34-4.)
1
2
3
4
5
6
7
8
9
10
11
12
13
44 Nm
39 Nm
137 - 157 Nm*
15 Nm
100 Nm
88 Nm
Removal steps
1. Cap
AA" 3. Brake caliper assembly
4. Brake disc or brake dram
5. Shoe and lining assembly (Refer to
GROUP 36 - Parking Brake
Drum.)
6. Parking brake cable connection
7. Brake hose connection <Vehicles
with drum brake>
8. Upper arm mounting bolts
9. Grommet
10. Trailing arm mounting bolt
AB" 11. Crossmember mounting nuts
12. Rear wheel speed sensor connec-
tor connection <Vehicles with ABS>
13. Rear suspension assembly
Caution
vehicles on the ground in the unladen condition.
REAR SUSPENSION - Rear Suspension Assembly 34-6
AA"BRAKE CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, so that it
does not fall.
AB"CROSSMEMBER MOUNTING NUT REMOVAL
Hold the crossmember with a garage jack or transmission
jack to remove a crossmember mounting nut.
REAR SUSPENSION - Upper Arm Assembly 34-7
UPPER ARM ASSEMBLY 34100360082
Wheel Alignment Check and Adjustment
(Refer to P.34-4.)
39 Nm
98 Nm*
57 Nm
57 Nm
1
2
3
4
5
Removal steps
1. Upper arm and knuckle connecting
bolt
2. Upper arm assembly mounting
bolts
3. Upper arm assembly
"AA 4. Upper arm bracket
5. Upper arm
Caution
REAR SUSPENSION - Upper Arm Assembly 34-8
"AAUPPER ARM BRACKET INSTALLATION
Install the upper arm bracket that the dimension shown in
the illustration is at the standard value.
Standard value (A): 37.2 2 mm
NOTE
Refer to distances B and C shown in the illustration to check
the installation angle of the upper arm bracket.
B
C B C
B: 220.1 mm
C: 274.4 mm
Upper arm
Upper arm bracket
A
REAR SUSPENSION - Trailing Arm Assembly 34-9
TRAILING ARM ASSEMBLY 34100420162
Wheel Alignment Check and Adjustment
(Refer to P.34-4.)
137 - 157 Nm*
1
2
3
4
5
118 - 137 Nm*
Removal steps
1. Knuckle and trailing arm assembly
connecting bolt
2. Grommet
3. Trailing arm assembly mounting
bolt
4. Stopper
5. Trailing arm assembly
Caution
REAR SUSPENSION - Lower Arm and Toe Control Arm Assemblies 34-10
LOWER ARM AND TOE CONTROL ARM ASSEMBLIES 34100450086
Pushing it with Finger
(Refer to P.34-4.)
67 - 98 Nm*
98 Nm*
28 Nm
39 Nm
1
2
3
4
5
6
7
8
98 Nm*
8
2
Lower arm assembly removal steps
2. Wheel speed sensor mounting
bolts
3. Lower arm assembly and knuckle
connecting bolt
4. Lower arm assembly mounting bolt
5. Lower arm assembly
Toe control arm assembly removal
steps
AA" 6. Toe control arm and knuckle con-
nection
AB" 7. Toe control arm assembly mounting
bolt
8. Toe control arm assembly
Caution
AA"TOE CONTROL ARM AND KNUCKLE
DISCONNECTION
Caution
removal it from the ball joint.
AB"TOE CONTROL ARM ASSEMBLY MOUNTING
BOLT REMOVAL
Place mating marks on the crossmember and the plate before
removing the bolt.
TOE CONTROL ARM BALL JOINT TURNING TORQUE
CHECK
1. After shaking the ball joint stud several times, install the
2. When the measured value exceeds the standard value,
replace the toe control arm assembly.
3. When the measured value is lower than the standard
TOE CONTROL ARM BALL JOINT DUST
COVER CHECK 34101290014
it with finger.
toe control arm assembly.
NOTE
Cracks or damage of the dust cover may cause damaged
MB990635,
MB991113 or
MB991406
Nut
Cord
Ball joint
Plate
Mating marks
MB990326
MB990800
Dust cover
Snap ring
TOE CONTROL ARM BALL JOINT DUST
COVER REPLACEMENT 34101080062
1. Remove the dust cover.
2. Apply multipurpose grease to inside and lip of the dust
cover.
3. Using the special tool, press the dust cover until it contacts
the snap ring.
it with finger.
REAR SUSPENSION - Shock Absorber Assembly 34-13
SHOCK ABSORBER ASSEMBLY 34100510159
D Rear Seat Removal and Installation <Sedan>
D Retractor Trim Removal and Installation <Wagon>
44 Nm
98 Nm
1
2
3
4
Removal steps
1. Cap
3. Bolt
"AA 4. Shock absorber assembly
"AASHOCK ABSORBER ASSEMBLY INSTALLATION
Install the shock absorber so that the larger diameter side
of the lower bushing inner pipe faces toward the outside
of the vehicle.
Outside of
the body
Lower bushing
inner pipe
23 Nm
1
2
3
4
5
8
6
7
9
11
10
12
Disassembly steps
AA" "CA 1. Self-locking nut
2. Washer
3. Upper bushing A
"BA 4. Upper bracket assembly
5. Upper spring pad
6. Collar
7. Upper bushing B
8. Cup assembly
9. Bump rubber
10. Dust cover
"AA 11. Coil spring
AA"SELF-LOCKING NUT REMOVAL
1. Use the special tools to compress the coil spring.
Caution
(1) Install the special tools evenly, and so that the
maximum length will be attained within the
installation range.
(2) Do not use an impact wrench to tighten the special
tool bolt.
2. While holding the piston rod, remove the self-locking nut.
Caution
MB991239
MB991237
"AACOIL SPRING INSTALLATION
1. Install the special tool in the same manner as for removal,
and compress the coil spring to install the shock absorber.
Caution
Do not use an impact wrench to tighten the special
tool bolt.
2. Align the edge of the coil spring to the stepped part of
the shock absorber spring seat.
"BAUPPER BRACKET ASSEMBLY INSTALLATION
Install the upper bracket assembly so that the lower bushing
inner pipe of the shock absorber is at the shown position.
"CASELF-LOCKING NUT INSTALLATION
1. Temporarily tighten the self-locking nut.
2. Remove the special tools (MB991237, MB991239), and
tighten the self-locking nut to the specified torque.
Caution
Coil spring
edge
Spring seat
Lower bushing
inner pipe
REAR SUSPENSION - Stabilizer Bar 34-16
STABILIZER BAR 34100560109
Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
39 Nm
39 Nm
44 Nm
1
2
3
4
5
1
Removal steps
1. Stabilizer link mounting nuts
2. Stabilizer link
"AA 3. Stabilizer bar bracket
"AA 4. Bushing
"AA 5. Stabilizer bar
"AASTABILIZER BAR/BUSHING/STABILIZER BAR
BRACKET INSTALLATION
Position the stabilizer bar identification mark to the left side.
Adjust the identification mark position as shown in the figure,
and tighten the stabilizer bar bracket mounting bolt.
Approx. 20 mm
Outside of
the body
REAR SUSPENSION - Stabilizer Bar 34-17
STABILIZER LINK BALL JOINT TURNING TORQUE
CHECK
1. After shaking the ball joint stud several times, install the
2. When the measured value exceeds the standard value,
replace the stabilizer link.
3. When the measured value is lower than the standard
STABILIZER LINK BALL JOINT DUST COVER CHECK
34101300014
it with finger.
stabilizer link.
NOTE
STABILIZER LINK BALL JOINT DUST COVER
1. Remove the clip ring and the dust cover.
2. Apply multipurpose grease to the lip and inside of the
dust cover.
3. Use plastic tape on the stabilizer link threads as shown
in the illustration, and then install the dust cover to the
stabilizer link.
4. Secure the dust cover with the clip ring.
When installing the clip ring, align the ends at a 90_
angle from the axis of the stabilizer link.
it with finger.
MB990326
Clip ring
Plastic tape
Approx. 90_
Clip ring ends (180_ on
opposite side also possible)
NOTES
BASIC BRAKE SYSTEM 35A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ANTI-SKID BRAKING SYSTEM (ABS) <2WD> 35B . . . . . . . . . . . . . . . . . . . . . .
ANTI-SKID BRAKING SYSTEM (ABS) <4WD> 35C . . . . . . . . . . . . . . . . . . . . . .
NOTE
THE GROUPS MARKED BY ARE NOT IN THIS MANUAL
35A-1
SERVICE BRAKES
35A-2
BASIC BRAKE
SYSTEM
LUBRICANTS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANTS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 5 . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Check and Adjustment 6 . . . . . . . . . . .
Stop Lamp Switch Check 7 . . . . . . . . . . . . . . . . . . . . .
Brake Booster Operating Test 7 . . . . . . . . . . . . . . . . .
Check Valve Operation Check 8 . . . . . . . . . . . . . . . . .
Proportioning Valve Function Test 9 . . . . . . . . . . . . .
Brake Fluid Level Sensor Check 9 . . . . . . . . . . . . . .
Bleeding 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc Brake Pad Check and Replacement 10 . . . . .
Disc Brake Rotor Check 12 . . . . . . . . . . . . . . . . . . . . .
Brake Lining Thickness Check 14 . . . . . . . . . . . . . . .
Brake Drum Inside Diameter Check 14 . . . . . . . . . .
Brake Lining and Brake Drum Connection
Check 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PEDAL 15 . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER AND BRAKE
BOOSTER 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISC BRAKE 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR DRUM BRAKE 24 . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROPORTIONING VALVE 28 . . . . . . . . . . . . . . . . .
BASIC BRAKE SYSTEM - General Information 35A-3
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.
Master cylinder Type Tandem type (with level sensor)
I.D. mm 23.8
Brake booster Type Vacuum type, single
Effective dia. of power cylinder mm 230
Boosting ratio 6.0
Proportioning valve Type Dual type
Decompression ratio 0.25
Front brakes Type Floating caliper, 1-piston, ventilated disc
Disc effective dia. thickness mm 256 24
Wheel cylinder I.D. mm 60.3
Pad thickness mm 10.0
Clearance adjustment Automatic
Rear disc brakes Type Floating caliper, 1-piston, solid disc
Rear drum brakes Type Leading trailing
Drum I.D. mm 203
Lining thickness mm 4.4
Brake fluid DOT3 or DOT4
BASIC BRAKE SYSTEM -
ServiceSpecifications
35A-4
Brake booster
Master cylinder
Front brake
Proportioningvalve
Brake pedal
Rear brake
Brake pedal height mm 162.8 - 165.8 -
Brake pedal free play mm 3- 8 -
Brake pedal to floor board clearance mm 90 or more -
Proportioning valve Split point MPa Sedan 2.94 0.25 -
Wagon 3.43 0.25 -
Output fluid pressure Sedan 4.66 0.39 (9.81) -
(Input fluid pressure) MPa
Wagon 5.80 0.39 (9.81) -
Output fluid pressure difference between left
and right MPa
- 0.39
Brake booster push rod protruding length mm 9.65 - 9.90 -
Front disc brake Pad thickness mm 10.0 2.0
Disc thickness mm 24.0 22.4
Disc runout mm - 0.06
Dragforce(tangential forceof wheel mounting
bolts) N
69 or less -
BASIC BRAKE SYSTEM -
Service Specifications/Lubricants/
Sealants/Special Tools
35A-5
Rear disc brake Pad thickness mm 10.0 2.0
Disc thickness mm 10.0 8.4
Disc runout mm - 0.08
Drag force (tangential force of wheel mounting
bolts) N
69 or less -
Rear drum brake Lining thickness mm 4.4 1.0
Drum inside diameter mm 203 205
Items Specified Lubricant
Brake piston seal Repair kit grease (orange)
Slide pin boot and slide pin bush inner surfaces
Brake piston boot inner surfaces
Piston boot mounting grooves
Rear brake shoe and backing plate contact surfaces Brake grease SAE J310, NLGI No.1
Shoe assembly and auto adjuster assembly contact
surfaces
Shoe and lever assembly and auto adjuster assembly
contact surfaces
Thread part fitting 3M ATD Part No. 8661 or equivalent Semi-drying sealant
Vacuum switch
MB990964
MB990520
MB990619
Brake tool set D Pushing-in of the disc brake piston
D Installation of drum brake wheel cylinder
piston cup
and installer
Provisional holding of the wheel bearing
BASIC BRAKE SYSTEM - On-vehicle Service 35A-6
BRAKE PEDAL CHECK AND ADJUSTMENT
BRAKE PEDAL HEIGHT
1. Turn up the carpet, etc under the brake pedal.
2. Measure the brake pedal height as illustrated. If the brake
pedal height is not within the standard value, follow the
procedure below.
(1) Disconnect the stop lamp switch connector.
(2) Adjust the brake pedal height by turning the operating
rod with pliers (with the operating rod lock nut
loosened), until the correct brake pedal height is
obtained.
(3) Secure by tightening the lock nut of the operating
rod.
(4) Push the stop lamp switch in the direction of the
pedal stroke until it stops. (The switch will slide if
it is pushed firmly.)
(5) Lift up the pedal until the operating rod is fully
extended, and then slide the stop lamp switch back
to the required position. Adjust the position of the
switch by turning it until the distance shown in the
illustration is correct.
(6) Connect the connector of the stop lamp switch.
(7) Check that the stop lamp is not illuminated with the
brake pedal unpressed.
3. Return the carpet etc.
BRAKE PEDAL FREE PLAY
With the engine stopped, depress the brake pedal two or
three times. After eliminating the vacuum in the power brake
booster, press the pedal down by hand, and confirm that
the amount of movement before resistance is met (the free
play) is within the standard value range.
Operating
rod
Operating
rod lock nut
Stop lamp
switch
Pedal down
Pedal up
Lock nut
Lock nut
Outer case
0.5 - 1.0 mm
Standard value: 38 mm
If the free play exceeds the standard value, it is probably
due to excessive play between the retaining ring bolt and
brake pedal arm.
Check for excessive clearance and replace faulty parts as
required.
CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR
BOARD
1. Turn back the carpet etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 490 N of force, and measure the clearance
between the brake pedal and the floorboard.
Standard value: 90 mm or more
3. If the clearance is outside the standard value, check for
air trapped in the brake line, clearance between the lining
and the drum and dragging in the parking brake.
Adjust and replace defective parts as required.
4. Return the carpet etc.
Connect a circuit tester to the stop lamp switch, and check
whether or not there is continuity when the plunger of the
stop lamp switch is pushed in and when it is released. The
stop lamp switch is in good condition if there is no continuity
when the plunger is pushed in to a depth of within 4 mm
from the outer case edge surface, and if there is continuity
when it is released.
BRAKE BOOSTER OPERATING TEST 35100100117
For simple checking of the brake booster operation, carry
out the following tests:
1. Run the engine for one or two minutes, and then stop
it.
If the pedal depresses fully the first time but gradually
becomes higher when depressed succeeding times, the
booster is operating properly, if the pedal height remains
unchanged, the booster is defective.
No continuity
Continuity
4 mm
Good No good
2. With the engine stopped, step on the brake pedal several
times.
Then step on the brake pedal and start the engine.
If the pedal moves downward slightly, the booster is in
good condition. If there is no change, the booster is
defective.
3. With the engine running, step on the brake pedal and
then stop the engine.
Hold the pedal depressed for 30 seconds. If the pedal
height does not change, the booster is in good condition,
if the pedal rises, the booster is defective.
If the above three tests are okay, the booster performance
can be determined as good.
If one of the above three tests is not okay at last, the
check valve, vacuum hose, or booster will be defective.
CHECK VALVE OPERATION CHECK 35100900151
1. Remove the vacuum hose. (Refer to P.35A-16.)
Caution
The check valve should not be removed from the
vacuum hose.
2. Check the operation of the check valve by using a vacuum
pump.
Vacuum pump connection Accept/reject criteria
Connection at the brake
booster side (A)
A negative pressure (vacu-
um) is created and held.
Connection at the intake
manifold side (B)
A negative pressure (vacu-
um) is not created.
Caution
If the check valve is defective, replace it as an
assembly unit together with the vacuum hose.
When engine is
stopped
When engine is
started
Valve Spring
Booster
side
Intake
manifold
side
A B
PROPORTIONING VALVE FUNCTION TEST
35100110172
1. Connect two pressure gauges, one each to the input
side and output side of the proportioning valve, as shown.
2. Bleed the air in the brake line and the pressure gauge.
3. While gradually depressing the brake pedal, make the
following measurements and check to be sure that the
measured values are within the allowable range.
(1) Output pressure begins to drop relative to input
pressure (split point).
Standard value:
MPa
Sedan Wagon
2.94 0.25 3.43 0.25
(2) Check to be sure that the output fluid pressure is
at the standard value when the pedal depression
force is increased so that the input fluid pressure
is at the values shown in the table below.
Standard value:
MPa
Sedan Wagon
Output fluid pressure
(Input fluid pressure)
4.66 0.39
(9.81)
5.80 0.39
(9.81)
(3) Output pressure difference between left and right
brake lines.
Limit: 0.39 MPa
4. If the measured pressures are not within the permissible
ranges, replace the proportioning valve.
BRAKE FLUID LEVEL SENSOR CHECK
35100910123
The brake fluid level sensor is in good condition if there is
no continuity when the float surface is above MIN and if
there is continuity when the float surface is below MIN.
Pressure gauge
Proportioning valve
Split point
Output
pressure
Input pressure
Caution
Use the specified brake fluid. Avoid using a mixture of
the specified brake fluid and other fluid.
Specified brake fluid: DOT3 or DOT4
MASTER CYLINDER BLEEDING
The master cylinder used has no check valve, so if bleeding
is carried out by the following procedure, bleeding of air from
the brake pipeline will become easier. (When brake fluid is
not contained in the master cylinder.)
(1) Fill the reserve tank with brake fluid.
(2) Keep the brake pedal depressed.
(3) Have another person cover the master cylinder outlet
with a finger.
(4) With the outlet still closed, release the brake pedal.
(5) Repeat steps (2) - (4) three or four times to fill the inside
of the master cylinder with brake fluid.
BRAKE PIPE LINE BLEEDING
Bleed the air in the sequence shown in the figure.
DISC BRAKE PAD CHECK AND
NOTE
The left side outer brake pad has a wear indicator.
The wear indicator contacts the brake disc when the brake
pad thickness becomes 2 mm and emit a squealing sound
to warn the driver.
( ): R.H. drive vehicles
4 (2) 1 (3)
2 (4) 3 (1)
When new When worn
Pad
Wear indicator
Brake disc
1. Check brake pad thickness through caliper body check
port.
Limit: 2.0 mm
Caution
1. When the limit is exceeded, replace the pads at
both sides, and also the brake pads for the wheels
on the opposite side at the same time.
2. If there is a significant difference in the thickness
of the pads on the left and right sides, check the
sliding condition of the piston and guide pin.
2. Remove the guide pin. Lift caliper assembly and retain
with wires.
Caution
Do not wipe off the special grease that is on the guide
pin or allow it to contaminate the guide pin.
3. Remove the following parts from caliper support.
(1) Pad and wear indicator assembly <L.H.>, and pad
assembly <R.H.>
(2) Pad assembly
(3) Pad liner
(4) Outer shim
4. In order to measure the brake drag force after pad
installation, measure the rotary-sliding resistance of the
hub with the pads removed. (Refer to P.35A-19.)
5. Install the pads and the caliper assembly, and then check
the brake drag force. (Refer to P.35A-19.)
1
2
3
4
3
DISC BRAKE ROTOR CHECK 35100290012
Caution
When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within
the allowable service values in order to maintain normal brake operation.
Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.
Inspection items Remarks
Scratches, rust, saturated lining materials
and wear
D If the vehicle is not driven for a certain period, the sections of
the discs that are not in contact with lining will become rusty, causing
noise and shuddering.
D If grooves resulting from excessive disc wear and scratches are
not removed prior to installing a new pad assembly, there will
momentarily be inappropriate contact between the disc and the
lining (pad).
Run-out or drift Excessive run-out or drift of the discs will increase the pedal depression
resistance due to piston knock-back.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause pedal pulsation,
shuddering and surging.
Inset or warping (flatness) Overheating and improper handling while servicing will cause inset or
warping.
THICKNESS CHECK 35100240017
1. Using a micrometer, measure disc thickness at eight
positions, approximately 45_ apart and 10 mm in from
the outer edge of the disc.
Brake disc thickness
Standard value: 24.0 mm<Front>, 10.0 mm<Rear>
Limit: 22.4 mm <Front>, 8.4 mm <Rear>
Thickness variation (at least 8 positions)
The difference between any thickness measurements
should not be more than 0.015 mm.
2. If the disc is beyond the limits for thickness, remove it
and install a new one. If thickness variation exceeds the
specification, replace the brake disc or turn rotor with
on the car type brake lathe (MAD, DL-8700PF or
equivalent).
RUN-OUT CHECK 35100250010
1. Remove the caliper support; then raise the caliper
assembly upward and secure by using wire.
2. Inspect the disc surface for grooves, cracks and rust.
Clean the disc thoroughly and remove all rust.
3. Place a dial gauge approximately 5 mm from the outer
circumference of the brake disc, and measure the run-out
of the disc.
Limit:
0.06 mm or less <Front>
0.08 mm or less <Rear>
NOTE
Tighten the nuts in order to secure the disc to the hub.
RUN-OUT CORRECTION 35100180081
1. If the run-out of the brake disc is equivalent to or exceeds
the limit specification, change the phase of the disc and
hub, and then measure the run-out again.
(1) Before removing the brake disc, chalk both sides
of the wheel stud on the side at which run-out is
greatest.
(2) Remove the brake disc, and then place a dial gauge
as shown in the illustration; then move the hub in
the axial direction and measure the play.
Limit: 0.05 mm
If the play is equivalent to or exceeds the limit,
disassemble the hub knuckle and check each part.
(3) If the play does not exceed the limit specification,
install the brake disc at a position 180_ away from
the chalk mark, and then check the run-out of the
brake disc once again.
2. If the run-out cannot be corrected by changing the phase
of the brake disc, replace the disc or turn rotor with on
the car type brake lathe (MAD, DL-8700PF or
equivalent).
Chalk mark
BRAKE LINING THICKNESS CHECK 35100300166
1. Remove the brake drum.
2. Measure the wear of the brake lining at the place worn
the most.
Limit: 1.0 mm
Replace the shoe and lining assembly if brake lining
thickness is less than the limit or if it is not worn evenly.
For information concerning the procedures for installation
of the shoe and lining assembly, refer to P.35A-24.
Caution
1. Whenever the shoe and lining assembly is
replaced, replace both R.H. and L.H. assemblies
as a set to prevent car from pulling to one side
when braking.
2. If there is a significant difference in the thickness
of the shoe and lining assemblies on the left and
right sides, check the sliding condition of the
piston.
BRAKE DRUM INSIDE DIAMETER CHECK
35100320148
2. Measure the inside diameter of the brake drum at two
or more locations.
Limit: 205 mm
3. Replace brake drums, shoe and lining assembly when
wear exceeds the limit value or is badly imbalanced.
BRAKE LINING AND BRAKE DRUM
CONNECTION CHECK 35100310169
2. Remove the shoe and lining assembly.
3. Chalk inner surface of brake drum and rub with shoe
and lining assembly.
4. Replace shoe and lining assembly or brake drums if there
are any irregular contact area.
NOTE
Clean off chalk after check.
BASIC BRAKE SYSTEM - Brake Pedal 35A-15
BRAKE PEDAL 35100340243
Brake Pedal Adjustment (Refer to P.35A-6.)
11
5
2
1
9
8
4
7
9
10
3
6
29 Nm
14 Nm
12 Nm
13 Nm
8
Removal steps
1. Stop lamp switch connector
2. Stop lamp switch
3. Snap pin
4. Pin assembly
5. Brake pedal shaft bolt
6. Brake pedal
7. Brake pedal pad
8. Brake pedal return spring
9. Bushing
10. Pipe
11. Pedal support member
BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster 35A-16
MASTER CYLINDER AND BRAKE BOOSTER 35100370242
Brake Fluid Draining
D Brake Fluid Supplying
D Brake Line Bleeding (Refer to P.35A-10.)
D Brake Pedal Adjustment (Refer to P.35A-6.)
Sealant: 3M ATD Part No.8661 or equivalent
10
1
2
3
4
6
7
8
9
15 Nm
15 Nm
14 Nm
15 Nm
6
7
15 Nm
4
5
4
7
12
6
1
20 - 25 Nm
11
12
13
22 Nm
14
<L.H. drive vehicles - 4G6, 6A1> <L.H. drive vehicles - 4D6> <R.H. drive vehicles - 4G6, 6A1>
<R.H. drive vehicles - 4D6>
10 Nm
Removal steps
1. Brake pipe connection
2. Brake fluid level sensor connector
3. Master cylinder assembly
"BA D Push rod protruding length check and
adjustment
4. Vacuum hose <4D6>
5. Vacuum pipe <4D6>
"AA 6. Vacuum hose
(with built-in check valve)
7. Fitting
8. Snap pin
9. Pin assembly
10. Clevis
11. Vacuum switch connector <4D6>
12. Vacuum switch <4D6>
13. Brake booster
14. Sealer
"AAVACUUM HOSE CONNECTION
Insert securely and completely until the vacuum hose at the
engine side contacts the edge of the hexagonal part of the
fitting, and then secure by using the hose clip.
"BAPUSH ROD PROTRUDING LENGTH CHECK AND
ADJUSTMENT
1. Measure dimension A.
2. If the protruding length is not within the standard value
range, adjust by changing the push rod length by turning
the end of the push rod.
Measuring dimension A
Block gauge
A
MASTER CYLINDER 35100420145
10
11
12
1
2
3
4
5
6
7
8
9
Brake fluid: DOT3 or DOT4
11
10
9
12
11
10
Master cylinder kit
Disassembly steps
1. Reservoir cap assembly
2. Reservoir cap
3. Diaphragm
4. Brake fluid level indicator assembly
5. Float
6. Spring pin
7. Reservoir tank
8. Reservoir seal
9. Piston retainer
10. Primary piston assembly
11. Secondary piston assembly
12. Master cylinder body
BASIC BRAKE SYSTEM - Disc Brake 35A-19
DISC BRAKE 35100800017
29 Nm
90 - 110 Nm
1
2
3
4
55 - 65 Nm
<Front>
<Rear>
29 Nm
2
1
3
4
Removal steps
1. Brake hose connection
2. Gasket
"AA 3. Disc brake assembly
4. Brake disc
INSTALLATION SERVICE POIINT
"AADISC BRAKE ASSEMBLY INSTALLATION
1. In order to measure the brake drag torque after pad
installtion, measure the rotary-sliding resistance of the
hub by the following procedure with the pads removed.
<Front>
(1) Remove the drive shaft.
(Refer to GROUP 26 - Front Axle.)
MB990998
Bolt
Tighten the nut with
the bolt secured.
(2) Attach the special tool to the front hub assembly as
shown in the illustration, and tighten it to the specified
torque.
(3) Use a spring balance to measure the rotary-sliding
resistance of the hub in the forward direction.
<Rear>
Use a spring balance to measure the rotary-sliding
2. After installing the caliper support to the knuckle, install
the pad clips and the pads to the caliper support.
Caution
Do not let any oil, grease or other contamination get
onto the friction surfaces of the pads and brake discs.
3. Clean piston and insert into cylinder with special tool.
4. Be careful that the piston boot does not become caught
when lowering the caliper assembly, and tighten the guide
pin to the specified torque.
5. Start the engine and then depress the brake pedal 2- 3
times.
6. Stop engine.
7. Turn brake disc forward 10 times.
8. Use a spring balance to measure the rotation sliding
9. Calculate the drag force of the disc brake (difference
between of values measured in item 8 and item 1.)
Standard value: 69 N or less
10. If the drag force of the disc brake exceeds the standard
value, disassemble piston and clean piston. Check for
corrosion or worn piston seal, and check the sliding
condition of the lock pin and guide pin.
MB990520
10
11
12
13
14
1
2 3
4
5
6
7
8
9
74 Nm
8 Nm
74 Nm
Brake caliper kit Pad repair kit Seal and boots repair kit
14
5
2
3
5
1
10
5
9
8
7
6
4
14
13
12
11
14 14
13
12
14
11
9 3
5
5 7
6
Grease
Caliper assembly disassembly
steps
"AA 1. Guide pin
"AA 2. Lock pin
3. Bushing
4. Caliper support (pad, clip, shim)
5. Boot
6. Boot ring
AA" 7. Piston boot
AA" 8. Piston
AB" 9. Piston seal
10. Caliper body
Pad assembly disassembly steps
"AA 1. Guide pin
"AA 2. Lock pin
3. Bushing
4. Caliper support (pad, clip, shim)
11. Pad and wear indicator assembly
12. Pad assembly
13. Outer shim (coated with rubber)
14. Clip
LUBRICATION POINTS
Piston
seal
Grease: Repair kit grease
Caution
The piston seal inside the seal
and boot kit is coated with
special grease, so do not wipe
this grease off.
When disassembling the disc brakes, disassemble both sides
(left and right) as a set.
AA"PISTON BOOT/PISTON REMOVAL
Protect caliper body with cloth. Blow compressed air through
brake hose to remove piston boot and piston.
Caution
Blow compressed air gently.
AB"PISTON SEAL REMOVAL
1. Remove piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
2. Clean piston surface and inner cylinder with
trichloroethylene, alcohol or specified brake fluid.
"AALOCK PIN/GUIDE PIN INSTALLATION
Install the guide pin and lock pin as illustrated that each
head mark of the guide pin and the lock pin matches the
indication mark (G or L) located on the caliper body.
D Check cylinder for wear, damage or rust.
D Check piston surface for wear, damage or rust.
D Check caliper body or sleeve for wear.
D Check pad for damage or adhesion of grease, check
backing metal for damage.
Lock pin
Front
L
Guide pin
G
BASIC BRAKE SYSTEM - Rear Drum Brake 35A-24
REAR DRUM BRAKE 35100750145
D Loosening the Parking Brake Cable Adjusting Nut.
D Brake Fluid Draining
D Parking Brake Lever Stroke Adjustment
(Refer to GROUP 36 On-vehicle Service.)
74 - 88 Nm
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
15 Nm
Specified grease: Brake grease SAE J310, NLGI No.1
8 7
16
10
5
4
15
5
20
Removal steps
1. Brake drum
2. Lever return spring
3. Shoe-to-lever spring
4. Adjuster lever
5. Auto adjuster assembly
6. Retainer spring
7. Shoe hold-down cup
8. Shoe hold-down spring
9. Shoe-to-shoe spring
10. Shoe and lining assembly
11. Shoe and lever assembly
AA" "BA 12. Retainer
"AA 13. Wave washer
14. Parking lever
16. Shoe hold-down pin
18. Snap ring
20. Backing plate
AA"RETAINER REMOVAL
Use a flat-tipped screwdriver or the like to open up the retainer
joint, and remove retainer.
"AAWAVE WASHER INSTALLATION
Install the washer in the direction shown in the illustration.
"BARETAINER INSTALLATION
Use pliers or the like to install the retainer or the pin positively.
Pin of shoe assembly
Retainer
Washer
Shoe assembly
Pin
Parking lever
Pin of shoe assembly
Retainer
WHEEL CYLINDER 35100930082
Brake Fluid draining
1
2
3
4
5
6
7
15 Nm
10 Nm
8 Nm
Removal steps
1. Brake drum
6. Wheel cylinder
7. Bleeder screw
1
2
3
4
5
6
Grease: Repair kit grease Brake fluid: DOT3 or DOT4
Wheel cylinder repair kit
3
6
1
2
3
3 4
4
6
1
4
Grease
Disassembly steps
1. Boots
2. Piston assembly
"AA 3. Pistons
"AA 4. Piston cups
5. Spring
6. Wheel cylinder body
"AAPISTON CUP/PISTON REASSEMBLY
1. Use alcohol or specified brake fluid to clean the wheel
cylinder and the piston.
2. Apply the specified brake fluid to the piston cups and
the special tool.
3. Set the piston cup on the special tool with the lip of the
cup facing up, fit the cup onto the special tool, and then
slide it down the outside of the tool into the piston groove.
Caution
In order to keep the piston cup from becoming twisted
or slanted, slide the piston cup down the tool slowly
and carefully, without stopping.
MB990619
Piston
Have the lip facing
upwards.
BASIC BRAKE SYSTEM - Rear Drum Brake/Proportioning Valve 35A-28
Check the piston and wheel cylinder walls for rust or damage,
andif there isany abnormality, replace theentire wheel cylinder
assembly.
PROPORTIONING VALVE 35100570154
Flared brake line nuts
15 Nm
1
1
2
1
Removal steps
"AA 1. Brake pipe
2. Proportioning valve
"AABRAKE PIPE CONNECTION
Connect the pipes to the hydraulic unit as shown in the
illustration.
1. Proportioning valve Rear brake (L.H.)
2. Proportioning valve Rear brake (R.H.)
3. Proportioning valve Front brake (R.H.)
4. Proportioning valve Front brake (L.H.)
5. Proportioning valve Master cylinder (secondary)
6. Proportioning valve Master cylinder (primary)
1 2
3 4
5
6
35B-1
ANTI-SKID
BRAKING SYSTEM
(ABS) <2WD>
LUBRICANTS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 5 . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Check and Adjustment
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Stop Lamp Switch Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Booster Operating Test
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Valve Operation Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Proportioning Valve Function Test
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Fluid Level Sensor Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding Refer to GROUP 35A . . . . . . . . . . . . . . . . . .
Disc Brake Pad Check and Replacement
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc Brake Rotor Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining Thickness Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Drum Inside Diameter Check
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining and Brake Drum Connection
Check Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor Output Voltage
Check 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS Warning Lamp Relay Continuity
Check 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Unit Check 22 . . . . . . . . . . . . . . . . . . . . . . . .
Remedy for a Flat Battery 23 . . . . . . . . . . . . . . . . . . .
35B-2
BRAKE PEDAL Refer to GROUP 35A . . . . . . . .
MASTER CYLINDER AND BRAKE
BOOSTER 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISC BRAKE Refer to GROUP 35A . . . . . . . . . .
REAR DRUM BRAKE
Refer to GROUP 35A . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder Refer to GROUP 35A . . . . . . . . . . .
PROPORTIONING VALVE 25 . . . . . . . . . . . . . . . . .
HYDRAULIC UNIT 26 . . . . . . . . . . . . . . . . . . . . . . . .
WHEEL SPEED SENSOR 28 . . . . . . . . . . . . . . . . .
ABS <2WD> - General Information 35B-3
The ABS consists of components such as the wheel
speed sensors, stop lamp switch, hydraulic unit
assembly, ABS control unit (ABS-ECU) and the
ABS warning lamp. If a problem occurs in the
system, the malfunctioning components can be
identified and the trouble symptoms will be
memorized by the diagnosis function.
In addition, reading of diagnosis codes and service
data and actuator testing are possible by using
the MUT-II.
Master cylinder Type Tandem type (with level sensor)
I.D. mm 25.4
Brake booster Type Vacuum type, tandem
Effective dia. of power cylinder mm 180 + 205
Boosting ratio 6.5
Proportioning valve Type Dual type
Decompression ratio 0.25
Front brakes Type Floating caliper, 1-piston, ventilated disc
Rear drum brakes Type Leading trailing
Drum I.D. mm 203
Lining thickness mm 4.4
ABS type 4-sensor, 3-channel method
Speed sensor Magnet coil type on 4 wheels
Front ABS rotor teeth 43
Rear ABS rotor teeth 43
ABS <2WD> - General Information 35B-4
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
1. ABS relay
2. ABS warning lamp
3. Stop lamp switch
4. ABS rotor
5. Wheel-speed sensor
6. ABS-ECU
7. Diagnosis connector
8. Hydraulic unit
ABS <2WD> - Service Specifications/Lubricants/Special Tools 35B-5
Wheel speed sensor internal resistance kW 1.0 - 1.5
Clearance between the wheel speed sensor mounting
surface and the ABS toothed rotor mm
28.2 - 28.5
Wheel speed sensor insulation resistance kW 100 or more
Items Specified lubricant
MB991502 MUT-II sub
assembly
For checking of ABS (Diagnosis code display
when using the MUT-II)
check harness
For checking of ABS (Diagnosis code display
when using the ABS warning lamp)
ABS <2WD> - Troubleshooting 35B-6
NOTES WITH REGARD TO DIAGNOSIS
The phenomena listed in the following table are not abnormal.
Phenomenon Explanation of phenomenon
System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside
the engine compartment, but this is because the system operation check is being
performed, and is not an abnormality.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic unit operation. (whine)
2. Sound is the generated along with vibration of the brake pedal. (scraping)
3. When ABS operates, sound is generated from the vehicle chassis due to repeated
brake application and release.
(Thump: suspension; squeak: tyres)
ABS operation
(Long braking distance)
For road surfaces such as snow-covered roads and gravel roads, the braking distance for
vehicles with ABScan sometimes be longer than that for other vehicles. Accordingly, advise
the customer to drive safely on such roads by lowering the vehicle speed and not being too
overconfident.
Diagnosis detection condition can vary depending on the diagnosis code.
Make sure that checking requirements listed in the Comment are satisfied when checking the trouble
symptom again.
DIAGNOSIS CODES CHECK
Read a diagnosis code by the MUT-II or ABS warning lamp.
(Refer to GROUP00 - Howto Use Troubleshooting/Inspection
Service Points.)
ERASING DIAGNOSIS CODES
With the MUT-II
Service Points.
With the ABS Warning Lamp
1. Use the special tool to earth terminal (1) (diagnosis control terminal) of the diagnosis connector.
2. Stop the engine.
3. Turn on the stop lamp switch. (Depress the brake.)
4. After carrying out steps 1. to 3., turn the ignition switch to ON. Within 3 seconds after turning the
ignition switch to ON, turn off the stop lamp switch (release the brake). Then, turn the stop lamp
switch on and off a total of 10 times.
NOTE
If the ABS-ECU function has been stopped because of fail-safe operation, it will not be possible
to erase the diagnosis codes.
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
Within
1
second
Within
1
second
Within
1
second
Within
1
second
Within
1
second
Within
1
second
Within
1
second
Within
1
second
Within
1
second
Within
1
second
1 se-
cond
Ignition switch
ON
OFF
Stop lamp switch
ON
OFF
ABS warning lamp
ON
OFF
ABS-ECU memory
Within 3
seconds
Erasing of
ABS-ECU
diagnosis
codes
complete.
Inspect according to the inspection chart that is appropriate for the malfunction code.
Diagnosis
code No.
Inspection item Diagnosis content Reference page
11 Front right wheel speed sensor Open circuit 35B-9
12 Front left wheel speed sensor
13 Rear right wheel speed sensor
14 Rear left wheel speed sensor
15 Wheel speed sensor Abnormal output signal 35B-10
16 Power supply system 35B-10
21 Front right wheel speed sensor Short circuit 35B-9
22 Front left wheel speed sensor
23 Rear right wheel speed sensor
24 Rear left wheel speed sensor
33 Stop lamp switch system 35B-11
41 Front right solenoid valve 35B-26 (Replace
42 Front left solenoid valve
the hydraulic unit.)
43 Rear right solenoid valve
44 Rear left solenoid valve
51 Valve relay problem (stays on)
52 Valve relay problem (stays off)
53 Motor relay problem (stays off)
54 Motor relay problem (stays on)
55 Motor system (seized pump motor)
63 ABS-ECU
Code Nos.11, 12, 13 and 14 Wheel speed sensor
(open circuit or short circuit)
Probable cause
Code Nos.21, 22, 23 and 24 Wheel speed sensor
Code Nos 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit or
short-circuit in the (+) wire or (- ) wire in any one of the four wheel speed sensors.
D Malfunction of wheel speed sensor
D Malfunction of hydraulic unit
Code Nos.21, 22, 23 and 24 are output in the following cases.
D When there is no input fromany one of the four wheel speed sensors when travelling
at several km/h or more, even though open circuit can not be verified.
D When a chipped or blocked-up ABS rotor is detected and if the anti-lock system
operates continuously because a malfunctioning sensor or a warped ABS rotor
is causing sensor output to drop.
D Malfunction of ABS rotor
D Too much gap between the sensor and the rotor
D Malfunction of wheel bearing
NG
Replace
OK
NG
Check the harness wire, and repair if necessary.
D Between each wheel speed sensor and ABS-ECU
NG
Repair
OK
Wheel bearing check (Re-
fer to GROUP 26 and
GROUP 27 - On-vehicle
Service.)
NG
Repair
NG
Replace the hydraulic unit.
OK
Check the trouble symp-
tom.
Check the following connector: A-04
OK
ABS rotor check (Refer
to P.35B-29.)
NG
Replace
NG
Wheel speed sensor
check (Refer to
P.35B-29.)
NG
Replace
OK
Wheel speed sensor output voltage check (Refer to P.35B-19.)
OK
tom.
OK
A-09, C-115, C-75, A-39, C-74, E-14, E-13, E-11, C-123, E-12
A-09, A-41, A-39, C-115, C-75, E-14, E-13, E-11, C-121, E-12
OK
Measure at the ABS-ECU connector A-04.
connector.
D Resistances between 20 and 19, 2 and 1, 22 and 23, 6 and
5
OK: 1.0 - 1.5 kW
NG
Wheel speed sensor check (Refer to P.35B-29.)
Wheel speed sensor installation check
NG
Repair
Code No.15 Wheel speed sensor (abnormal output signal) Probable cause
This code is output when there is an abnormality in the output signal from any one
of the four wheel speed sensors while driving (except for an open circuit or short
circuit).
D The four vehicle tires are of different sizes
D Improper installation of wheel speed sensor
NG
NG
Repair
NG
Replace
NG
Replace
NG
D Between each wheel speed sensor and ABS-ECU
OK
Wheel bearing check (Refer to GROUP 26 and GROUP 27 -
OK
ABS rotor check (Refer to P.35B-29.)
OK
tom.
OK
OK
NG
NG
NG
Repair
YES
Are the sizes of all four tires identical?
NO
Equip the vehicle with tires of identical sizes.
Code No.16 ABS-ECU power supply system (abnormal
voltage drop or rise)
Probable cause
This code is output if the ABS-ECU power supply voltage drops below or rises above
the rated values.
Furthermore, if the voltage returns to normal, this code is no longer output.
D Malfunction of battery
Caution
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage
returns to standard value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
NG
Repair
NG
NG
Repair
NG
D Between ignition switch and ABS-ECU
OK
tom.
OK
Check the battery.
OK
tom.
OK
connector.
D Start the engine. Voltage between 4 and body earth
OK: Battery voltage
NG
A-04, C-75, C-66 <L.H. drive vehicles>, C-134, C-131
Code No.33 Stop lamp switch system(opencircuit or stop
lamp stays ON)
Probable cause
This code is output in the following cases.
D If the stop lamp switch is continuously on for 15 minutes or more even though
the ABS system is not operating.
D If there is an open circuit in the stop lamp switch input circuit harness.
D Malfunction of stop lamp switch
NG
Repair
OK NG
Repair
OK NG
Repair
NG
Replace
NG
Replace the hydraulic
unit.
NG
Check the harness wire,
D Between stop lamp
switch and ABS-ECU
NG
Repair
NG
D Between fusible link No.1 and ABS-ECU
tom.
NG
Check the following
connectors:
A-04, C-75, C-65
tom.
OK
Check the following
connector: A-04
YES
connector.
D Stop lamp switch: ON
OK: Battery voltage
OK
tom.
OK
C-12 <R.H. drive vehicles>, C-142, C-134, C-02, C-65, C-75, A-04
OK
Stop lamp switch check (Refer to GROUP 35A - Brake Pedal.)
Does the stop lamp turn on and off normally?
NO
Stop lamp switch installation check
ABS WARNING LAMP INSPECTION 35201200123
Check that the ABS warning lamp illuminates as
follows.
1. When the ignition key is turned to ON, the ABS warning
lamp illuminates for approximately 3 seconds and then
switches off.
2. When the ignition key is turned to START, the ABS
warning lamp remains illuminated.
3. When the ignition key is turned from START back to
ON, the ABS warning lamp illuminates for approximately
3 seconds and then switches off.
NOTE
The ABS warning lamp may remain on until the vehicle
reaches a speed of several km/h. This is limited to cases
where diagnosis code Nos.21 - 24 and 55 have been
recorded because of a previous problem occurring. In
this case, the ABS-ECU keeps the warning lamp
illuminated until the problem corresponding to that
diagnosis code can be detected.
4. If the illumination is other than the above, check the
diagnosis codes.
Not
illuminated
ABS
warning
lamp
ABS warning lamp
Illuminated
Approx. 3 s Approx. 3 s
Ignition
switch
START
ON
ACC,
LOCK
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Trouble symptoms Inspection procedure
No.
Reference page
Communication between the MUT-II and the whole system is not
possible.
1 35B-12
Communication between the MUT-II and the ABS-ECU is not possible. 2 35B-13
When the ignition key is turned to ON (engine stopped), the ABS
warning lamp does not illuminate.
3 35B-14
Even after the engine is started, the ABS warning lamp remains
illuminated.
4 35B-15
Faulty ABS operation 5 35B-16
Caution
1. If steering movements are made when driving at high speed, or when driving on road surfaces
with low frictional resistance, or when passing over bumps, the ABS may operate even though
sudden braking is not being applied. Because of this, whengetting informationfromthe customer,
check if the problem occurred while driving under such conditions as these.
2. During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormality.
Communicationbetweenthe MUT-II andthe whole system
is not possible.
Probable cause
The cause may be a malfunction of the power supply circuit or the earth circuit of
the diagnosis connector.
D Malfunction of diagnosis connector
NG
Repair
NG
Replace the MUT-II.
NG
Repair
NG
D Between diagnosis connector and earth
OK
tom. OK
Measure at the diagnosis connector C-20.
D Continuity between 4 and body earth, and between 5 and body
earth
OK: Continuity
NG
OK
NG
D Between power supply and diagnosis connector
OK
tom.
Measure at the diagnosis connector C-20.
OK: Battery voltage
NG
C-20, C-66, C-63, C-132, C-141
C-20, C-66, C-62, C-14
Communication between MUT-II and the ABS-ECU is not
possible.
Probable cause
The cause may be an open circuit in the ABS-ECU power supply circuit or an open
circuit in the diagnosis output circuit.
D Blown fuse
NG
Repair
NG
D Between ABS-ECU and diagnosis connector
OK
NG
Repair
NG
D Between ignition switch and ABS-ECU
OK
NG
Repair
NG
D Between ABS-ECU and earth
NG
Repair
NG
OK
tom.
OK
tom.
OK
connector.
D Continuity between 8 and body earth, between 11 and body
earth and between 24 and body earth
OK: Continuity
NG
OK
tom.
connector.
OK: Battery voltage
NG
A-04, C-75, C-66 <L.H. drive vehicles>, C-134, C-131
OK
tom.
Measure at the diagnosis connector C-20 and the ABS-ECU con-
nector A-04.
connector.
D Continuity between the following terminals
ABS-ECU side - Diagnosis connector side
14 - 1
7 - 7
OK: Continuity
NG
<PETROL-POWERED VEHICLES>
C-51, C-49, C-83, C-66, C-20
<DIESEL-POWERED VEHICLES>
C-51, C-56, C-83, C-66, C-20
When the ignition key is turned to ON (engine stopped),
the ABS warning lamp does not illuminate.
Probable cause
The cause may be an open circuit in the lamp power supply circuit, a blown lamp,
a malfunction of the ABS warning lamp relay or an open circuit between the ABS
warning lamp and the earth.
D Blown fuse
D Burn out ABS warning lamp bulb
D Malfunction of ABS warning lamp relay
OK
NG
Replace the ABS warning
lamp bulb.
NG
Repair
NG
Replace the combination meter.
NG
Replace the ABS warning
lamp relay.
NG
Repair
OK
NG
D Between ABS warning lamp and ABS warning lamp relay
D Between ABS warning lamp relay and earth
OK
tom.
OK
Disconnect the ABS warning lamp relay connector A-05X and ABS-
ECU connector A-04, and measure at the harness side connector
of ABS warning lamp relay.
OK: Battery voltage
NG
Check the following connector: A-05X
OK
tom.
OK
Check the following
connectors:
D-01, D-03, C-135, C-131
OK
ABS warning lamp relay check (Refer to P.35B-21.)
Measure at the connector C-50.
D Disconnect the connector, and measure at the combination
meter side connector.
D ABS warning lamp condition when terminal 2 <LHD> or terminal
7 <RHD> is earthed.
OK: Illuminates
NG
Check whether the ABS warning lamp bulb is burnt out.
Fuse check
Multi-purpose fuse No.13
NG
Refer to GROUP 00 - Inspection Service Points for Blown Fuse.
Even after the engine is started, the ABS warning lamp
remains illuminated.
Probable cause
The cause is probably a short-circuit in the ABS warning lamp illumination circuit. D Malfunction of combination meter
D Malfunction of ABS warning lamp relay
D Malfunction of wiring harness (short circuit)
NOTE
This trouble symptom is limited to cases where communication with the MUT-II is possible (ABS-ECU
power supply is normal) and the diagnosis code is a normal diagnosis code.
NG
Repair
OK
NG
D Between ABS warning lamp and ABS warning lamp relay
D Between ABS warning lamp relay and ABS-ECU
OK
tom.
OK
Disconnect the ABS warning lamp relay connector A-05X and ABS-
ECU connector A-04, and measure at the harness side connector
of ABS warning lamp relay.
OK: Battery voltage
NG
Check the following connectors: A-05X, A-04
NO
ABS warning lamp relay check (Refer to P.35B-21.)
NG
Replace the ABS warning lamp relay.
Does the ABS warning lamp stay illuminated when the connector
C-50 is disconnected and the ignition switch is turned to ON?
YES
Faulty ABS operation Probable cause
This varies depending on the driving conditions and the road surface conditions, so
problem diagnosis is difficult. However, if a normal diagnosis code is displayed, carry
out the following inspection.
D Improper installation of wheel speed sensor
D Foreign material adhering to wheel speed sensor
NG
OK
OK
NG
connector.
D Resistances between 20 and 19, 2 and 1, 22 and 23, 6 and
5
OK: 1.0 - 1.5 kW
(The sensor harness and connector should be moved while
these inspections are carried out.)
NG
Repair
OK
OK
A-09, C-115, C-75, A-39, C-74, E-14, E-13, E-11, C-123, E-12
A-09, A-41, A-39, C-115, C-75, E-14, E-13, E-11, C-121, E-12
NG
Repair
OK
Wheel bearing check (Refer to GROUP 26 and GROUP 27 -
NG
Repair
OK
ABS rotor check (Refer to P.35B-29.)
NG
Repair
NG
NG
Replace the wheel speed sensor.
OK
OK
Hydraulic unit check (Refer to P.35B-22.)
NG
Repair
The following items can be read by the MUT-II from the ABS-ECU input data.
1. When the system is normal
Item No. Check item Checking requirements Normal value
11 Front-right wheel speedsensor Perform a test run Vehicle speeds
12 Front-left wheel speed sensor
displayed on the
speedometer
II
13 Rear-right wheel speed sensor
and MUT-II are
identical.
14 Rear-left wheel speed sensor
16 ABS-ECU power supply
voltage
Ignition switch power supply voltage and valve
monitor voltage
9.2 - 17.5 V
33 Stop lamp switch Depress the brake pedal. ON
Release the brake pedal. OFF
2. When the ABS-ECU shut off ABS operation.
When the diagnosis system stops the ABS-ECU, the MUT-II display data will be unreliable.
The MUT-II activates the following actuators for testing.
NOTE
1. If the ABS-ECU runs down, actuator testing cannot be carried out.
2. Actuator testing is only possible when the vehicle is stationary. If the vehicle speed during actuator
testing exceeds 10 km/h, forced actuation will be canceled.
3. During the actuator test, the ABS warning lamp will illuminate and the anti-skid control will be cancelled.
ACTUATOR TEST SPECIFICATIONS
No. Item
01 Solenoid valve for front-left
wheel
Solenoid valves and pump
motors in the hydraulic unit
02 Solenoid valve for front-right
wheel
(simple inspection mode)
03 Solenoid valve for rear-left
wheel
04 Solenoid valve for rear-right
wheel
2s
1s
Activation pattern
Solenoid
valve
Pump
motor
ON
OFF
Start of
forced
action
End of forced
action
A
B
C
48 ms
8 ms
NOTE
A: Hydraulic pressure increase
B: Hydraulic pressure holds
C: Hydraulic pressure decrease
CHECK AT ABS-ECU 35201180229
1. Measure the voltage between each terminal and earth.
2. The terminal layout is shown in the illustration below.
Terminal No. Check item Checking requirements Normal condition
4 ABS-ECU power sup- Ignition switch: ON Battery voltage
ply
Ignition switch: START 0 V
7 MUT-II When the MUT-II is connected Serial communication
with MUT-II
When the MUT-II is not connected 1 V or less
9 Solenoid valve power
supply
Always Battery voltage
14 Diagnosis changeover When the MUT-II is connected 0 V
input
When the MUT-II is not connected Approx. 12 V
16 ABS valve transistor
output
Ignition switch: ON When the lamp is
switched off
2 V or less
When the lamp is
illuminated
Battery voltage
18 Stop lamp switch input Ignition switch: ON Stop lamp switch: ON Battery voltage
Stop lamp switch: OFF 1 V or less
25 Motor power supply Always Battery voltage
RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS
1. Turn the ignition switch off and disconnect the ABS-ECU connectors before checking resistance and
continuity.
2. Check them between the terminals indicated in the table below.
3. The terminal layouts are shown in the illustrations below.
Terminal No. Signal Normal condition
1 - 2 Wheel speed sensor (front left) 1.0 - 1.5 kW
5 - 6 Wheel speed sensor (rear left) 1.0 - 1.5 kW
19 - 20 Wheel speed sensor (front right) 1.0 - 1.5 kW
ABS <2WD> - Troubleshooting/On-vehicle Service 35B-19
Terminal No. Normal condition Signal
23 - 22 Wheel speed sensor (rear right) 1.0 - 1.5 kW
8 - Body earth Solenoid valve earth Continuity
24 - Body earth Motor earth
WHEEL SPEED SENSOR OUTPUT VOLTAGE
CHECK
1. Lift up the vehicle and release the parking brake.
2. Disconnect the ABS-ECU connector, and then use the
special tool (inspection harness for connector pin contact
pressure) to measure the output voltage at the
harness-side connector.
3. Rotate the wheel to be measured at approximately 1/2- 1
rotation per second, and check the output voltage using
a circuit tester or an oscilloscope.
Wheel
speed
sensor
Front left Front
right
Rear left Rear
right
Terminal 1 19 5 23
No.
2 20 6 22
Output voltage
When measuring with a circuit tester:
42 mV or more
When measuring with an oscilloscope:
120 mV p-p or more
4. If the output voltage is lower than the above values, the
reason could be as follow:
D Faulty wheel speed sensor.
So replace the wheel speed sensor.
ABS-ECU connector
(harness side)
ABS <2WD> - On-vehicle Service 35B-20
Inspecting Waveforms With An Oscilloscope
Use the following method to observe the output voltage
waveform from each wheel sensor with an oscilloscope.
D Start the engine, and rotate the front wheels by engaging
1st gear (vehicles with manual transmission) or D range
(vehicles with automatic transmission). Turn the rear
wheels manually so that they rotate at a constant speed.
NOTE
1. Check the connection of the sensor harness and
connector before using the oscilloscope.
2. The waveform measurements can also be taken while
the vehicle is actually moving.
3. The output voltage will be small when the wheel speed
is low, and similarly it will be large when the wheel speed
is high.
Points In Waveform Measurement
Symptom Probable causes Remedy
Too small or zero waveform
amplitude
Faulty wheel speed sensor Replace sensor
Waveform amplitude fluctuates
excessively (this is no problem if
the minimum amplitude is 100 mV
or more)
Axle hub eccentric or with large runout Replace hub
Noisy or disturbed waveform Open circuit in sensor Replace sensor
Open circuit in harness Correct harness
Incorrectly mounted wheel speed sensor Mount correctly
Rotor with missing or damaged teeth Replace rotor
Caution
Because the wheel speed sensor cables move together with the front and rear suspension, they
vibrate greatly when driving over poor road surfaces. As a result, the sensor harnesses should
also be shaken when monitoring of output waveforms of the wheel speed sensors in order to
simulate conditions such as driving over poor road surfaces.
When turning by hand
When idling (5- 6 km/h),
1st gear (manual trans-
mission) or Drange (auto-
matic transmission)
10.0 ms/DIV 1 V/DIV
ABS WARNING LAMP RELAY CONTINUITY
CHECK 35200930023
1 2 3 5
Power is not sup-
plied
Power is supplied
HYDRAULIC UNIT CHECK 35200170227
Caution
Turn the ignition switch off before connecting or disconnecting the MUT-II.
1. Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack-up points
or place the wheels which are checked on the rollers of the braking force tester.
Caution
1. The roller of the braking force tester and the tyre should be dry during testing.
2. When testing the front brakes, apply the parking brake, and when testing the rear brakes,
stop the front wheels by chocking them.
2. Release the parking brake, and feel the drag force (drag torque) on each road wheel.
When using the braking force tester, take a reading of the brake drag force.
3. Turn the ignition key to the OFF position and set the MUT-II.
4. After checking that the shift lever <M/T> or the selector lever <A/T> is in neutral, start the engine.
5. Use the MUT-II to force-drive the actuator.
NOTE
1. During the actuator test, the ABS warning lamp will illuminate and the anti-skid control will be
cancelled.
2. When the ABS has been interrupted by the fail-safe function, the MUT-II actuator testing cannot
be used.
6. Turn the wheel by hand and check the change in braking force when the brake pedal is depressed.
When using the braking force tester, depress the brake pedal until the braking force is at the following
values, and check that the braking force decreases when the actuator is force-driven.
Front wheel 785 - 981 N
Rear wheel 588 - 784 N
The result should be as shown in the following diagram.
Pedal operation
Depressed
Released
Solenoid valve
position
Increase in pressure
Steady pressure
Reduction in pressure (when not working)
Checking the
brake force
Lock
Drag force when the pedal is free
MUT-II actuator test
(Item No. 01, 02, 03, 04) start
1 seconds
2 seconds
3 seconds
7. If the result of inspection is abnormal, correct according to the Diagnosis Table (Refer to P.35B-23).
8. After inspection, disconnect the MUT-II immediately after turning the ignition switch to OFF.
Diagnosis Table
No. Operation Judgement
- Normal
Judgement
- Abnormal
Probable cause Remedy
01 (1) Depress brake pedal
to lock wheel.
(2) Using the MUT-II,
Brake force
released for 3
seconds after
Wheel does not
lock when brake
pedal is de-
Clogged brake
line other than
hydraulic unit
Check and clean
brake line
02
select the wheel to be
checked and force the
actuator to operate.
(3) Turn the selected
locking. pressed.
Clogged hydrau-
lic circuit in
hydraulic unit
Replace hydrau-
lic unit assembly
03
wheel manually to
check the change of
brake force.
Brake force is
not released
Incorrect hydrau-
lic unit brake
tube connection
Connect correct-
ly
04 Hydraulic unit
solenoid valve
not functioning
correctly
Replace hydrau-
lic unit assembly
REMEDY FOR A FLAT BATTERY 35200350188
When booster cables are used to start the engine when the
battery is completely flat and then the vehicle is immediately
driven without waiting for the battery to recharge itself to
some extent, the engine may misfire, and driving might not
be possible.
This happens because ABS consumes a great amount of
current for its self-check function; the remedy is to either
allow the battery to recharge sufficiently, or to remove the
fusible link for ABS circuit, thus disabling the anti-skid brake
system. The ABS warning lamp will illuminate when the fusible
link (for ABS) is removed.
After the battery has sufficiently recharged, install the fusible
link (for ABS) and restart the engine; then check to be sure
the ABS warning lamp is not illuminated.
Fusible link
ABS <2WD> - Master Cylinder and Brake Booster 35B-24
MASTER CYLINDER AND BRAKE BOOSTER 35200400142
Refer to GROUP 35A.
MASTER CYLINDER 35200450147
14
13 12
1
4
2
3
6
8
9
5
7
10
12
13
14
11
Master cylinder kit
12
13
11
10
9
Disassembly steps
1. Reservoir cap assembly
2. Reservoir cap
3. Diaphragm
4. Filter
5. Brake fluid level indicator assembly
6. Float
7. Spring pin
8. Reservoir tank
9. Reservoir seal
10. Pin
11. Piston retainer
12. Primary piston assembly
13. Secondary piston assembly
14. Master cylinder body
D Check the inner surface of master cylinder body for rust
or pitting.
D Check the primary and secondary pistons for rust, scoring,
wear, damage or wear.
D Check the diaphragm for cracks and wear.
ABS <2WD> - Proportioning Valve 35B-25
PROPORTIONING VALVE 35200570126
D Brake Line Bleeding (Refer to GROUP 35A -
Flared brake line nuts
1
2
15 Nm
1
Removal steps
"AA 1. Brake pipe
2. Proportioning valve
Connect the pipes to the hydraulic unit as shown in the
illustration.
1. Proportioning valve Rear brake (L.H.)
2. Proportioning valve Rear brake (R.H.)
3. Proportioning valve Hydraulic unit
4. Proportioning valve Hydraulic unit
1 2
3 4
ABS <2WD> - Hydraulic Unit 35B-26
HYDRAULIC UNIT 35200860261
D Brake Line Bleeding
D Brake Pedal Adjustment
15 Nm
2
2
3
1
4
2
1
3
4
9 Nm
22 Nm
22 Nm
9 Nm
Removal steps
AA" 1. Harness connector
"AA 2. Brake pipe connection
AB" 3. Hydraulic unit and ABS-ECU
4. Hydraulic unit bracket assembly
ABS <2WD> - Hydraulic Unit 35B-27
AA"HARNESS CONNECTOR REMOVAL
Raise the locking lever as shown in the illustration, and then
disconnect the harness connector.
AB"HYDRAULIC UNIT ASSEMBLY REMOVAL
Caution
1. The hydraulic unit assembly is heavy, and so care
should be taken when removing it.
2. The hydraulic unit assembly is not to be disassem-
bled; its nuts and bolts should absolutely not be loos-
ened.
3. The hydraulic unit assembly must not be dropped
or otherwise subjected to impact shocks.
4. The hydraulic unit assembly must not be turned
upside down or laid on its side.
Connect the pipes to the hydraulic unit assembly as shown
1. To the proportioning valve (RH)
2. To the proportioning valve (LH)
3. From the master cylinder (Primary)
4. From the master cylinder (Secondary)
5. To the front brake (RH)
6. To the front brake (LH)
Locking lever
3
4
6
1 5 2
ABS <2WD> - Wheel Speed Sensor 35B-28
WHEEL SPEED SENSOR 35200830279
Wheel Speed Sensor Output Voltage Check
<Front> <Rear>
1
2
4
3
Front speed sensor removal steps
D Splash Shield Removal (Refer to
GROUP 42 - Fender.)
AA" "AA 1. Front speed sensor
2. Front ABS rotor (Refer to GROUP
26 - Drive Shaft.)
Rear speed sensor removal steps
AA" "AA 3. Rear speed sensor
4. Rear ABS rotor (Refer to GROUP
27 - Rear Axle Hub.)
NOTE
The front rotor is integrated with the drive shaft and is not
disassembled.
AA"FRONT SPEED SENSOR/REAR SPEED SENSOR
REMOVAL
Caution
Be careful when handling the pole piece at the tip of
the speed sensor and the toothed edge of the rotor so
as not to damage them by striking against other parts.
"AAFRONT SPEED SENSOR/REAR SPEED SENSOR
INSTALLATION
The clearance between the wheel speed sensor and the ABS
rotors toothed surface is not adjustable, but measure the
distance between the sensor installation surface and the ABS
rotors toothed surface.
SPEED SENSOR
1. Check whether any metallic foreign material has adhered
to the pole piece at the speed sensor tip, and if so, remove
it.
Also check whether the pole piece is damaged, and if
so, replace it with a new one.
NOTE
The pole piece can become magnetized because of the
magnet but into the speed sensor, with the result that
metallic foreign material easily adheres to it. Moreover,
the pole piece may not be able to function to correctly
sense the wheel rotation speed if it is damaged.
2. Measure the resistance between the speed sensor
terminals.
If the internal resistance of the speed sensor is not within
the standard value, replace with a new speed sensor.
3. Check the speed sensor cable for breakage, damage
or disconnection; replace with a new one if a problem
is found.
NOTE
When checking for cable damage, remove the cable clamp
part from the body and then bend and pull the cable
near the clamp to check whether or not temporary
disconnection occurs.
Front Rear
ABS
rotors
toothed
surface
ABS
rotors
toothed
surface
Front Rear
SPEED SENSOR INSULATION INSPECTION
1. Remove all connections from the speed sensor, and then
measure the resistance between terminals 1 and 2 and
the body of the speed sensor.
Standard value: 100 kW or more
2. If the speed sensor insulation resistance is outside the
standard value range, replace with a new speed sensor.
ABS TOOTHED ROTOR
Check whether ABS rotor teeth are broken or deformed, and,
if so, replace the ABS rotor.
36-1
PARKING BRAKES
LUBRICANTS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever Stroke Check and
Adjustment 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Switch Check 4 . . . . . . . . . . . . . . . . . .
Lining Running-In 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE LEVER 5 . . . . . . . . . . . . . . . . . .
PARKING BRAKE CABLE
<DRUM BRAKE> 6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING BRAKE CABLE
<DRUM-IN-DISC BRAKE> 7 . . . . . . . . . . . . . . . . . . .
PARKING BRAKE DRUM 9 . . . . . . . . . . . . . . . . . . .
PARKING BRAKES -
Service Specifications/Lubricants
36-2
The parking brake is of a mechanical control type
acting on the rear wheels. A lever is used to apply
the parking brake. The operation method utilizes
a parking brake lever which is in an offset position
at the passengers side.
Parking brake lever
Parkingbrakecable
Parking brake
switch
Parking brake lever stroke 5 - 7notches*
1
, 3- 5notches*
2
-
Rear brake lining thickness mm 2.8 1.0
Rear druminside diameter mm 168.0 169.0
NOTE
*1:
Vehicles with drum brake
*
2:
Vehicles with drum-in-disc brake
Items Specified lubricant
Backing plate Multipurpose grease
Shoe and lining assembly
Adjuster
PARKING BRAKES - Special Tool/On-Vehicle Service 36-3
and installer
Fixing of the rear hub
PARKING BRAKE LEVER STROKE CHECK
AND ADJUSTMENT
1. Pull the parking brake lever with a force of approx. 196
N and count the number of notches.
Standard value:
5 - 7 notches <Vehicles with drum brake>
3 - 5 notches <Vehicles with drum in disc brake>
2. If the parking brake lever stroke is not the standard value,
adjust as described below.
Remove the floor console cup holder, loosen the adjusting
nut as far as the end of the cable rod to release the
cable, and then adjust by the following procedure:
<Vehicles with drum brake>
Depress the brake pedal repeatedly until the stroke no
longer changes.
NOTE
Depressing the brake pedal repeatedly will automatically
adjust the shoe clearance to the normal setting.
<Vehicles with drum-in-disc brake>
(1) Attach the special tool to the hub as shown in the
illustration.
(2) Remove the adjustment hole plug, and then use a
flat-tip ( - ) screwdriver to turn the adjuster in the
direction of the arrow (the direction which expands
the shoe) so that the disc will not rotate.
Return the adjuster five notches in the direction
opposite to the direction of the arrow.
Adjusting nut
Cable rod
Bolt
Hold the bolt in
place when
tightening
MB990998
Adjuster
PARKING BRAKES - On-Vehicle Service 36-4
(3) Turn the adjusting nut to adjust the parking brake
lever stroke to the standard value. After adjusting,
check that there is no space between the adjusting
nut and the parking brake lever.
Caution
If the parking brake lever stroke is below the standard
value and the braking is too firm, the rear brakes
may drag.
(4) After adjusting the parking brake lever stroke, jack
up the rear of the vehicle. Release the parking brake
and turn the rear wheels to check that the rear brakes
are not dragging.
PARKING BRAKE SWITCH CHECK 36100330124
1. Remove the floor console. (Refer to GROUP 52A.)
2. Check for continuity between the parking brake switch
terminal and the switch mounting bolt.
When parking brake lever is pulled Continuity
When parking brake lever is released No continuity
LINING RUNNING-IN 36100110087
Carry out running-in by the following procedure when replacing
the parking brake linings or the rear brake disc rotors, or
when brake performance is insufficient.
Caution
Carry out running-in in a place with good visibility, and
pay careful attention to safety.
1. Adjust the parking brake stroke to the specified value.
Standard value [Operation force: Approx. 196 N]
5 - 7 notches <Vehicles with drum brake>
3 - 5 notches <Vehicles with drum in disc brake>
2. Hook a spring balance onto the centre of the parking
brake lever grip and pull it with a force of 98 - 147 N
in a direction perpendicular to the handle.
3. Drive the vehicle at a constant speed of 35 - 50 km/h
for 100 metres.
4. Release the parking brake and let the brakes cool for
5 - 10 minutes.
5. Repeat the procedure in steps 2. to 4. 4 - 5 times.
Nut holder
Adjusting nut
Pin
Pull
Spring balance
Approx.
40 mm
PARKING BRAKES - Parking Brake Lever 36-5
PARKING BRAKE LEVER 36100130168
D Floor Console Removal (Refer to GROUP 52A.)
D Parking Brake Lever Stroke Check and Adjustment
(Refer to P.36-3.)
D Floor Console Installation (Refer to GROUP 52A.)
5
Ratchet plate
Section A - A Section B - B
Ratchet
pawl
A
B
B
A
4
1
2
3
3
1
5
Removal steps
1. Adjusting nut
2. Parking brake stay
3. Bushing
4. Parking brake switch
5. Parking brake lever
PARKING BRAKES - Parking Brake Cable <Drum brake> 36-6
PARKING BRAKE CABLE <DRUM BRAKE> 36100190197
D Floor Console and Rear Seat Removal
(Refer to P.36-3.)
D Floor Console and Rear Seat Installation
10
11
10
1
3
9
4
8
2
5
6
7
Removal steps
1. Rear brake drum
5. Retainer spring
10. Clip
11. Parking brake cable
PARKING BRAKES - Parking Brake Cable <Drum-in-disc brake> 36-7
PARKING BRAKE CABLE <DRUM-IN-DISC BRAKE> 36100190203
D Floor Console and Rear Seat Removal
(Refer to P.36-3.)
D Floor Console and Rear Seat Installation
12
13
12
90 - 110 Nm
1
2
3
6
7
4
5
8
9
10
11
Removal steps
AA" 1. Rear brake caliper assembly
2. Rear brake disc
"BA 3. Shoe-to-anchor spring
4. Adjusting screw spring
"AA 5. Adjuster
6. Strut
7. Strut return spring
AB" 8. Shoe hold-down cup
12. Clip
PARKING BRAKES - Parking Brake Cable <Drum-in-disc brake> 36-8
AA"REAR BRAKE CALIPER ASSEMBLY REMOVAL
Remove the rear brake caliper assembly and support it with
wire or similar.
AB"SHOE HOLD-DOWN CUP REMOVAL
Extend the shoe and lining assembly, and remove the shoe
hold-down cup.
"AAADJUSTER INSTALLATION
Install the adjuster so that the shoe adjusting bolt of left hand
wheel is attached towards the front of the vehicle, and the
shoe adjusting bolt of right hand wheel is towards the rear
of the vehicle.
"BASHOE-TO-ANCHOR SPRING INSTALLATION
Install the shoe-to-anchor springs in the order shown in the
illustration.
Caution
The load on the respective shoe-to-anchor springs is
different, so the spring in the figure has been painted.
NOTE
The figure shows the left wheel; for the right wheel, the position
is symmetrical.
Shoe
hold-down
cup
Shoe adjusting
bolt
Rear
(Painted) 1 2
PARKING BRAKES - Parking Brake Drum 36-9
PARKING BRAKE DRUM 36100250109
(Refer to P.36-3.)
74 - 88 Nm
90 - 110 Nm
1
Brake grease: Multipurpose grease
13
12
10
11 9 8
5 11 9
8
2
14
4
3
3
7 6
15
11
11
15
5
Removal steps
1. Rear brake caliper
(Refer to P.36-8)
2. Rear brake disc
3. Shoe-to-anchor spring
(Refer to P.36-8)
4. Adjusting screw spring
5. Adjuster (Refer to P.36-8)
6. Strut
7. Strut return spring
(Refer to P.36-8)
12. Clip
15. Backing plate
PARKING BRAKES - Parking Brake Drum 36-10
BRAKE LINING AND BRAKE DRUM CHECK
1. Measurethe thickness of thebrake liningat several places.
Limit: 1.0 mm
2. If the thickness of the brake lining has worn down to
the limit value or more, replace the shoe and lining
assemblies on both sides of the vehicle.
3. Measure the inside diameter of the brake disc in two
places or more.
Limit: 169.0 mm
4. If the inside of the brake disc has worn down to the
limit value or more, or if it is excessively worn on one
side, replace the brake disc.
37A-1
STEERING
LUBRICANTS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANT 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 4 . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Free Play Check 6 . . . . . . . . . . . . . .
Steering Angle Check 7 . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Ball Joint Starting Torque
Check 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stationary Steering Effort Check 8 . . . . . . . . . . . . . . .
Checking Steering Wheel Return to Centre 8 . . . . .
Drive Belt Tension Check 8 . . . . . . . . . . . . . . . . . . . . .
Fluid Level Check 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Replacement 9 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Pressure Test 11 . . . . . . . . . . . . . . . . . . . . .
Power Steering Oil Pressure Switch Check 12 . . . .
Ball Joint Dust Cover Check 12 . . . . . . . . . . . . . . . . .
STEERING WHEEL AND SHAFT* 13 . . . . . . . . .
POWER STEERING GEAR BOX* 16 . . . . . . . . .
POWER STEERING OIL PUMP 29 . . . . . . . . . . .
POWER STEERING HOSES 34 . . . . . . . . . . . . . .
WARNING!
MITSUBISHI dealer.
component.
NOTE
STEERING - General Information 37A-2
The steering wheel is 4-spoke type.
The steering wheel including the air bag is a3-spoke
type. The steering column is equipped with both
shock absorbing and tilt steering mechanisms.
The power steering is an integral rack and pinion
type that combines the steering gear and linkage
into one light-weight and compact assembly.
The steering system uses a vane oil pump with
a fluid flow control system, so that steering effort
varies with engine speed.
Steering gear and linkage Type Integral type
Gear type Rack and pinion
Oil pump Type Vane type
Displacement mL 9.6
Relief set pressure MPa 11.8
Oil reservoir
Oil pump
Steering gear and linkage
Steering wheel
Steering column assembly
Tilt lever
STEERING - Service Specifications/Lubricants/Sealant 37A-3
Steering wheel with engine stopped 10 or less -
free play mm
when hydraulic operation - 30
Steering angle Inner wheel 38_00 2_
<Except 6A1 - R.H. drive vehicles>
39_00 2_
<6A1 - R.H. drive vehicles>
-
Outer wheel 30_30 -
Tie rod end ball joint starting torque Nm 0.5 - 2.5 -
Stationary steering effort N (Fluctuation allowance) 30 or less
(5.9 or less)
-
Oil pump pressure Oil pump relief pressure 11.8 -
MPa
Pressure under no-load conditions 0.8 - 1.0 -
Steering gear retention hydraulic pressure 11.8 -
Oil pressure switch operating pressure MPa OFFON 1.8 - 2.4 -
ONOFF 0.8 - 2.4 -
Total pinion torque Nm (Change in torque: 0.4 Nm) 0.7 - 1.4 -
Tie rod joint swing resistance N(Tie rod joint swing torque Nm) 8 - 27 (1.5 - 4.9) -
Opening dimension of special tool (MB991561) mm 2.9 -
Band crimped width mm 2.4 - 2.8 -
Items Specified lubricant Quantity
Power steering fluid Automatic transmission fluid DEXRON or DEXRON II As required
Bellows Silicone grease As required
Pinion and valve assembly Repair kit grease As required
Rack assembly
Oil seal, pinion and valve assembly,
ball bearing, needle roller bearing,
special tool (MB991213)
Automatic transmission fluid DEXRON or DEXRON II As required
Flowcontrol valve, frictionsurfaceof
rotor, vanes, cam ring, pump cover,
O-ring
SEALANT 37200050136
End plug screw 3M ATD Part No. 8661 or equivalent Semi-drying sealant
Power steering rack support cover screw
Dust cover lip for tie rod end ball joint
STEERING - Special Tools 37A-4
MB990635,
MB991113 or
MB991406
Steering linkage
puller
Disconnection of tie rod end
MB990685 Torque wrench D Measurement of the ball joint starting
torque
D Measurement of the total pinion torque
MB991006 Preload socket Measurement of the total pinion torque
MB990326 Preload socket Measurement of the ball joint starting torque
MB990993 Power steering oil
pressure gauge
adapter (pump
side)
MB990994 Power steering oil
pressure gauge
adapter (hose
side)
MB990662 Oil pressure gauge
assembly
MB991204 Torque wrench
socket
D Adjustment of rack support
D Removal of rack support cover
MB990803 Steering wheel
puller
Disconnection of the steering wheel
STEERING - Special Tools 37A-5
MB991202 Oil seal and
bearing installer
Press fitting of rack housing bearing
MB991197 Bar (long type) To press in the oil seal for the rack
MB991199 Oil seal installer To press in the oil seal for the rack
MB991213 Rack installer Rack installation
MB990925 Bearing and oil
seal installer set
Installation of the oil seal and bearing
MB991120 Needle bearing
puller
Removal of rack housing needle bearing
MB991203 Oil seal and
bearing installer
To press in the valve housing oil seal and
bearing
MB991317 Seal ring installer Compression of the seal rings after
replacement of the pinion seal rings
MB990941 Torque tube
bearing installer
Installation of valve housing oil seal
STEERING - Special Tools/On-vehicle Service 37A-6
MB991561 Boot band crimp-
ing tool
Installation of bellows band
MB990776 Front axle base Installationof dust cover for tie rodend ball joint
STEERING WHEEL FREE PLAY CHECK
1. With engine running (hydraulic operation), set front wheels
straight ahead.
2. Measure the play on steering wheel circumference before
wheels start to move when slightly moving steering wheel
in both directions.
Limit: 30 mm
3. When play exceeds the limit, check for play on steering
shaft connection and steering linkage. Correct or replace.
4. If the free play still exceeds the limit value, set steering
wheel straight ahead with engine stopped. Load 5 N
towards steering wheel circumference and check play.
Standard value (steering wheel play with engine
stopped): 10 mm or less
If the play exceeds the standard value, remove steering
gear box and check total pinion torque.
STEERING - On-vehicle Service 37A-7
STEERING ANGLE CHECK 37200110179
1. Locate front wheels on turning radius gauge and measure
steering angle.
Standard value:
Inner wheel
38_00 2_ <Except 6A1-R.H. drive vehicles>
39_00 2_ <6A1-R.H. drive vehicles>
Outer wheel 30_30
2. When the angle is not within the standard value, the
toe is probably incorrect. Adjust toe (Refer to GROUP
33A - On-vehicle Service) and recheck steering angle.
TIE ROD END BALL JOINT STARTING TORQUE
CHECK 37200150140
1. Disconnect tie rod and knuckle with special tool.
Caution
1. Using the special tool, loosen the tie rod end
mounting nut. Only loosen the nut; do not remove
it from the ball joint.
2. Support the special tool witha cord, etc. toprevent
it from coming off.
2. Move ball joint stud several times and install nut on stud.
Measure ball joint starting torque with special tools.
3. When the starting torque exceeds the standard value,
replace tie rod end.
4. When the starting torque is under the standard value,
check ball joint for end play or ratcheting. If none of these,
the joint is still serviceable.
Cord
Ball joint
Nut
MB990635,
MB991113 or
MB991406
MB990685
MB990326
STATIONARY STEERING EFFORT CHECK
37200170160
1. With the vehicle stopped on a flat, paved surface, turn
the steering wheel to the straight ahead position.
2. Start the engine and set it to 1,000100 r/min.
Caution
After checking the engine r/min must return to the
standard idling r/min.
3. Attach a spring balance to the outer circumference of
the steering wheel and measure the steering force
required to turn the steering wheel fromthe straight ahead
position to the left and right (within a range of 1.5 turns).
Also check to be sure that there is no significant fluctuation
of the required steering force.
Standard value:
Steering effort: 30N or less
Fluctuation allowance: 5.9N or less
CHECKING STEERING WHEEL RETURN TO
CENTRE 37200180156
To make this test, conduct a road test and check as follows.
1. Make both gradual and sudden turns and check the
steering feeling to be sure that there is not difference
in the steeringforce requiredand thewheel returnbetween
left and right turns.
2. At a speed of 35 km/h, turn the steering wheel 90_ and
release the steering wheel after 1 or 2 seconds. If the
steering wheel then returns 70_ or more, the return can
be judged to be satisfactory.
NOTE
There will be a momentary feeling or heaviness when
the wheel is turned quickly, but this is not abnormal. (This
is because the oil pump discharge amount is especially
apt to be insufficient during idling.)
DRIVE BELT TENSION CHECK 37200190050
70_ 70_
FLUID LEVEL CHECK 37200200043
1. Park the vehicle on a flat, level surface, start the engine,
and then turn the steering wheel several times to raise
the temperature of the fluid to approximately 50- 60_C.
2. With the engine running, turn the wheel all the way to
the left and right several times.
3. Check the fluid in the oil reservoir for foaming or milkiness.
Check the difference of the fluid level when the engine
is stopped, and while it is running. If the change of the
fluid level is 5 mm or more, air bleeding should be done.
FLUID REPLACEMENT 37200210046
1. Raise the front wheels on a jack, and then support them
with rigid racks.
2. Disconnect the return hose connection.
3. Connect a vinyl hose to the return hose, and drain the
oil into a container.
4. Disconnect the high tension cable.
Caution
Be careful not to position the high-tension cable near
the delivery pipe.
5. While operating the starting motor intermittently, turn the
steering wheel all the way to the left and right several
times to drain all of the fluid.
6. Connect the return hoses securely, and then secure it
with the clip.
7. Fill the oil reservoir with the specified fluid up to the lower
position of the filter, and then bleed the air.
Specified fluid:
Automatic transmission fluid
DEXRON or DEXRON II
Fluid level change: Within 5 mm
Whileengine
running
Whileengine
stopped
Return hose Vinyl hose
1. Jack up the front wheels and support them by using a
rigid rack.
2. Manually turn the oil pump pulley a few times.
3. Turn the steering wheel all the way to the left and to
the right five or six times.
4. On vehicles with a petrol engine, disconnect the
high-tension cable. On vehicles with a diesel engine,
remove the fuel cut valve connector attached to the
injection pump.
Caution
Be careful not to position the high-tension cable near
the delivery pipe.
5. While operating the starting motor intermittently, turn the
steering wheel all the way to the left and right five or
six times (for 15 to 20 seconds).
Caution
1. During air bleeding, refill the fluid so that the level
never falls below the lower position of the filter.
2. If air bleeding is done while engine is running,
the air will be broken up and absorbed into the
fluid; be sure to do the bleeding only while
cranking.
6. On vehicles with a petrol engine, connect the high-tension
cable. On vehicles with a diesel engine, connect the fuel
cut valve connector attached to the injection pump. Start
the engine (idling).
7. Turn the steering wheel to the left and right until there
are no air bubbles in the oil reservoir.
8. Confirm that the fluid is not milky, and that the level is
up to the specified position on the level gauge.
9. Confirm that there is very little change in the fluid level
when the steering wheel is turned left and right.
10. Check whether or not the change in the fluid level is
within 5 mm when the engine is stopped and when it
is running.
11. If the change of the fluid level is 5 mm or more, the
air has not been completely bled from the system, and
thus must be bled completely.
Caution
1. If the fluid level rises suddenly after the engine
is stopped, the air has not been completely bled.
2. If air bleeding is not complete, there will be
abnormal noises from the pump and the
flow-control valve, and this condition could cause
a lessening of the life of the pump, etc.
Fluid level change: Within 5 mm
Whileengine
running
Whileengine
stopped
OIL PUMP PRESSURE TEST 37200230189
1. Disconnect the pressure hose from the oil pump, and
then connect the special tools.
2. Bleed the air, and then turn the steering wheel several
times while the vehicle is not moving so that the
temperature of the fluid rises to approximately 50- 60_C.
3. Start the engine and idle it at 1,000100 r/min.
4. Fully close the shut-off valve of the pressure gauge and
measure the oil pump relief pressure to confirm that it
is within the standard value range.
Standard value: 11.8 MPa
Caution
Pressure gauge shut off valve must not remain closed
for more than 10 seconds.
5. If it is not within the standard value, replace the oil pump.
6. Check whether or not the hydraulic pressure is the
standard value when no-load conditions are created by
fully opening the shut-off valve of the pressure gauge.
Standard value: 0.8 - 1.0 MPa
7. If it is not within the standard value, the probable cause
is a malfunction of the oil line or steering gear box, so
check these parts and repair as necessary.
8. Fully open the shut-off valve of the pressure gauge.
9. Turn the steering wheel all the way to the left or right;
then check whether or not the retention hydraulic pressure
is the standard value.
Standard value: 11.8 MPa
10. When not within the standard value, replace the power
steering gear box.
Remeasure fluid pressure.
11. Remove the special tools, and then tighten the pressure
hose to the specified torque.
12. Bleed the system.
Temperature
gauge
Pressure
gauge
(MB990662) Shut-off valve
Oil pump
relief
pressure
Adapter
(MB990993)
Oil
pump
Reservoir
Pressure
hose
Adapter
(MB990994)
POWER STEERING OIL PRESSURE SWITCH
CHECK 37200720150
1. Disconnect the pressure hose from the oil pump, and
then connect the special tools.
2. Bleed the air, and then turn the steering wheel several
times while the vehicle is not moving so that the
temperature of the fluid rises to approximately 50- 60_C.
3. The engine should be idling.
4. Disconnect the connection of the connector for the oil
pressure switch, and place an ohmmeter in position.
5. Gradually close the shut-off valve of the pressure gauge
and increase the hydraulic pressure, then check whether
or not the hydraulic pressure that activates the switch
is the standard value.
6. Gradually open the shut-off valve and reduce the hydraulic
pressure; then check whether or not the hydraulic pressure
that deactivates the switch is the standard value.
7. Remove the special tools, and then tighten the pressure
hose to the specified torque.
8. Bleed the system.
it with finger.
tie rod end.
NOTE
of the ball joint.
Temperature
gauge
Pressure
gauge
(MB990662)
Shut-off valve
Adapter
(MB990993)
Oil
pump
Reservoir
Adapter
(MB990994)
STEERING - Steering Wheel and Shaft 37A-13
STEERING WHEEL AND SHAFT 37200260218
CAUTION: SRS
For vehicles with SRS, before removal of air bag module, refer to GROUP 52B - Service Precautions and
Air Bag Module and Clock Spring.
Instrument Lower Panel Assembly Removal
D Instrument Lower Panel Assembly Installation
D Checking Steering Wheel Position with Wheels
Straight Ahead
5 Nm
12 Nm
18 Nm
Standard bolt
12 Nm 22 Nm
Earth bolt
41 Nm
25 Nm
4
5
1
2
3
7
6
Removal steps
1. Air bag module
(Refer to GROUP 52B - Air Bag
Module and Clock Spring.)
AA" 2. Steering wheel
3. Lower column cover
4. Upper column cover
"AA 5. Clock spring and column switch
(Refer to GROUP 52B - Air Bag
Module and Clock Spring.)
6. Steering shaft assembly
7. Steering cover assembly
Caution
One of the steering shaft assembly mounting bolts
must be the earth bolt. The earth bolt has a E
mark on its head.
AA"STEERING WHEEL REMOVAL
"AACLOCK SPRING AND COLUMN SWITCH/COLUMN
SWITCH INSTALLATION
Tighten the screws in an alphabetical order.
1
4
3
5
6
5
7
8
9
2
Disassembly steps
AA" "AA 1. Special bolt
"AA 2. Steering lock bracket
"AA 3. Steering lock cylinder
4. Snap ring
5. Stopper
6. Spacer
7. Steering shaft assembly
8. Snap ring
9. Steering column assembly
MB990803
A
B
C
AA"STEERING LOCK BRACKET/STEERING LOCK
CYLINDER REMOVAL
If it is necessary to remove the steering lock cylinder, use
a hacksaw to cut the special bolts at the steering lock bracket
side.
"AASTEERING LOCK CYLINDER/STEERING LOCK
BRACKET/SPECIAL BOLT INSTALLATION
1. When installing the steering lock cylinder and steering
lock bracket to the column tube, temporarily install the
steering lock in alignment with the column boss.
2. After checking that the lock works properly, tighten the
special bolts until the head twists off.
Caution
The steering lock bracket and bolts must be replaced
with new ones when the steering lock is installed.
Steering lock bracket
Steering lock cylinder
STEERING - Power Steering Gear Box 37A-16
POWER STEERING GEAR BOX 37200390207
CAUTION: SRS
For vehicles with SRS, before removal of steering gear box, refer to GROUP 52B, centre front wheels and
remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative,
risking serious driver injury.
D Power Steering Fluid Draining (Refer to P.37A-9.)
D Center Member Removal (Refer to GROUP 32.)
D Front Exhaust Pipe Removal (Refer to GROUP 15.)
D Stabilizer Bar Removal (Refer to GROUP 33A.)
D Stabilizer Bar Installation (Refer to GROUP 33A.)
D Front Exhaust Pipe Installation
D Center Member Installation (Refer to GROUP 32.)
D Power Steering Fluid Supplying (Refer to P.37A-9.)
D Power Steering Fluid Line Bleeding
D Checking Steering Wheel Position with Wheels
Straight Ahead
D Front Wheel Alignment Adjustment
69 - 78 Nm
24 - 33 Nm
8
4
81 Nm
18 Nm 15 Nm
69 Nm
9
7
3
2
6
5
1
Removal steps
1. Steering shaft assembly and gear
box connecting bolt
2. No.2 stay
AA" 3. No.3 stay
4. Split pin
AB" 5. Tie rod end and knuckle connection
6. Pressure tube connection
7. Return tube connection
8. Cylinder clamp
AC" 9. Gear box assembly
Hold the crossmember with a transmission jack, and remove
the No.3 stay.
AB"TIE ROD END DISCONNECTION
Caution
1. Using the special tool, loosen the tie rod endmounting
ball joint.
2. Support the special tool with a cord, etc. to prevent
it from coming off.
AC"GEAR BOX ASSEMBLY REMOVAL
Caution
Be careful not to damage the bellows and the tie rod
end dust cover when removing the gear box assembly.
D Check the rubber parts for cracks and breakage.
Crossmember
Transmission jack
Cord
Ball joint
Nut
MB990635 or
MB991113
GEAR BOX TOTAL PINION TORQUE
Using the special tools, rotate the pinion gear at the rate
of one rotation in approximately 4 to 6 seconds to check
the total pinion torque.
[Change in torque: 0.4 Nm]
Caution
When holding the steering gear box assembly in a vice,
secure its mounting positions. If it is secured in any other
places, the gear housing may become deformed or
damaged.
NOTE
When measuring, remove the bellows from the rack housing.
Measure the pinion torque through the whole stroke of the
rack.
If the measured value is not within the standard range, first
adjust the rack support cover, and then check the total pinion
starting torque again.
If the total pinion starting torque cannot be adjusted to within
the standard range by adjusting the rack support cover, check
the rack support cover, rack support spring, rack support
and replace any parts if necessary.
CHECK THE TIE ROD FOR SWING RESISTANCE
1. Give 10 hard swings to the tie rod.
2. Measure the tierod swingresistance witha springbalance.
Standard value: 8 - 27 N [1.5- 4.9 Nm]
3. If the measured value exceeds the standard value, replace
tie rod.
4. Even if the measured value is below the standard value,
the tie rod which swings smoothly without excessive play
may be used.
TIE ROD END BALL JOINT DUST COVER
CHECK
it with finger.
tie rod end. (Refer to P.37A-19.)
NOTE
MB991006
15 Nm - 30
Steering gear seal kit
Flare nut
1
4
5
6
7
8
9
10
11
12
13
16
17
18
20
23
24
25
28
31
32
34
2
19 21
22
33
15
26
27
30
29
22 Nm
25 Nm
59 Nm
49 - 54 Nm
59 Nm
22 Nm
13 Nm
1
2
6
9
33
27 15
30
29
2
9
6
26
17
2
19
21
3
14
Disassembly steps
1. Feed pipe
2. O-ring
"NA 3. Tie rod end locking nut
"NA 4. Tie rod end
5. Bellows clip
"MA 6. Bellows band
7. Bellows
"LA 8. Tie rod
"LA 9. Tab washer
"KA D Total pinion torque adjustment
"JA 10. Locking nut
AA" "JA 11. Rack support cover
12. Rack support spring
13. Rack support
"IA 14. End plug
15. Self-locking nut
16. Valve housing assembly
AB" "HA 17. Oil seal
AB" 18. Pinion and valve assembly
AC" "GA 19. Seal ring
AD" "FA 20. Ball bearing
AD" "FA 21. Oil seal
22. Valve housing
AE" "EA 23. Circlip
AF" 24. Rack stopper
AF" "DA 25. Rack bushing
AG" "DA 26. Oil seal
27. O-ring
AF" "CA 28. Rack
AC" 29. Seal ring
30. O-ring
AH" "BA 31. Ball bearing
AI" "BA 32. Needle roller bearing
AJ" "AA 33. Oil seal
34. Rack housing
Lubrication and Sealing Points
Fluid: Automatic transmission fluid
DEXRON or DEXRON II
Fluid:
DEXRON or DEXRON II
Fluid:
Automatic transmission
fluid DEXRON or
DEXRON II
Fluid:
DEXRON or DEXRON II
Sealant:
3M ATD Part No. 8661 or
equivalent
Sealant:
3M ATD Part No. 8661
or equivalent
Grease: Silicone grease
Fluid: Automatic transmission
fluid DEXRON or DEXRON II
AA"RACK SUPPORT COVER REMOVAL
Use the special tool to remove the rack support cover from
the gear box.
AB"OIL SEAL/PINION AND VALVE ASSEMBLY
REMOVAL
Using a plastic hammer, gently tap the pinion to remove it.
AC"SEAL RING REMOVAL
Cut the seal ring and remove it from the pinion and valve
assembly and the rack.
Caution
When cutting the seal ring, be careful not to damage
the pinion and valve assembly or the rack.
AD"BALL BEARING/OIL SEAL REMOVAL
Use a socket, remove the oil seal and the ball bearing from
the valve housing assembly simultaneously.
AE"CIRCLIP REMOVAL
1. Turn the rack stopper clockwise until the end of the circlip
comes out of the slot in the rack housing.
2. Turn the rack stopper anticlockwise to remove the circlip.
Caution
Note that if the rack stopper is first turned
anticlockwise, the circlip will get caught in the slot
in the housing and the rack stopper will not turn.
MB991204
Socket
Rack stopper
Circlip
AF" RACK STOPPER/RACK BUSHING/RACK
REMOVAL
Pull out the rack assembly gently, and remove the rack stopper
and rack bushing together.
AG"OIL SEAL REMOVAL
Partially bend the oil seal to remove from the rack bushing.
Caution
Do not damage the oil seal press fitting surface of the
rack bushing.
AH"BALL BEARING REMOVAL
Use a brass bar or the special tool to remove the ball bearing
from the gear housing.
AI" NEEDLE ROLLER BEARING REMOVAL
Use the special tool to remove the needle roller bearing from
the rack housing.
Caution
Do not open the special tool excessively to prevent
damaging housing interior.
AJ" OIL SEAL REMOVAL
Use a piece of pipe or similar tool to remove the oil seal
from the gear housing.
Caution
Be careful not to damage the inner surface of the rack
cylinder of the gear housing.
Rack bushing
Ball
bearing
MB990925 (MB990939)
or brass bar
MB991120
Needle roller
bearing
Gear housing
Pipe or similar tool
Oil seal
"AAOIL SEAL INSTALLATION
"BANEEDLE ROLLER BEARING/BALL BEARING
INSTALLATION
"CARACK INSTALLATION
1. Apply a coating of repair kit grease to the rack tooth
face.
Caution
Do not close the vent hole in the rack with grease.
2. Cover rack serrations with special tool.
3. Apply the specified fluid on the special tool.
Specified fluid:
DEXRON or DEXRON II
4. Match the oil seal centre with rack to prevent retainer
spring from slipping and slowly insert rack from power
cylinder side.
"DAOIL SEAL/RACK BUSHING INSTALLATION
1. Apply the specified fluid to the outer surface of the oil
seal. Press-fit the oil seal using the special tool until it
is flush with the bushing end face.
Specified fluid:
DEXRON or DEXRON II
MB991197
Gear housing
Oil seal
MB991199
Ball bearing
MB990925
(MB990938)
Needle
roller
bearing
MB990925
(MB990938)
MB991202
MB991202
Vent hole
Seal ring, O-ring
MB991213
Oil seal
MB990925
(MB990927)
Oil seal
O-ring
Rack
bushing
2. Apply the specified fluid to the oil seal inner surface and
the O-ring.
Specified fluid:
DEXRON or DEXRON II
3. Wrap the rack end with plastic tape, and push the rack
bushing onto the rack.
"EACIRCLIP INSTALLATION
Insert the circlip to the rack stopper hole through the cylinder
hole. Turn the rack stopper clockwise and insert the circlip
firmly.
Caution
Insert the circlip to the rack stopper hole while turning
the rack stopper clockwise.
"FA OIL SEAL/BALL BEARING INSTALLATION
1. Apply a coating of the specified fluid to the outside of
the oil seal. Using the special tools, press the oil seal
into the valve housing.
Specified fluid:
DEXRON or DEXRON II
2. Apply a coating of the specified fluid to the outside of
the ball bearing. Using the special tools, press the ball
bearing into the valve housing.
Specified fluid:
DEXRON or DEXRON II
"GASEAL RING INSTALLATION
1. Kneed the seal ring to soften it.
2. Apply the specified fluid to the seal ring, and install to
the rack groove.
Specified fluid:
DEXRON or DEXRON II
Rack bushing
Plastic tape
Rack
Circlip
Slot
Circlip
Slot
Oil seal
MB990938
MB991203
Ball bearing
MB990938
MB991203
Pinion gear
MB991317
Tapered side
3. Insert the tapered side of the special tool from the pinion
gear side, and compress the seal ring.
"HAOIL SEAL INSTALLATION
Use the special tool to press the oil seal into the valve housing.
The upper surface of the oil seal should project outwards
approx. 1 mm from the housing edge surface.
Caution
If the oil seal is flush with or lower than the housing
edge, it will cause oil leaks and require reassembly.
"IA END PLUG INSTALLATION
1. Apply the specified sealant to the threaded part of the
end plug.
Specified sealant:
3M ATD Part No.8661 or equivalent
2. Secure the threaded portion of the end plug at two places
by using a punch.
"JA RACK SUPPORT COVER/LOCKING NUT
INSTALLATION
1. Use the special tool to tighten the rack support cover
to 15 Nm.
2. Return the rack support cover 30_.
3. Use the special tool to hold the rack support cover and
tighten the locking nut to the specified torque.
"KATOTAL PINION TORQUE ADJUSTMENT
1. Using the special tool, rotate the pinion shaft at the rate
of one rotation in 4 to 6 seconds to check the total pinion
torque and the change in torque.
Standard value:
Total pinion torque: 0.7 - 1.4 Nm
Change in torque: 0.4 Nm or less
Approx. 1 mm
MB990941
End plug
Sealant
End plug
MB991204
MB991006
2. If the total pinion torque or the change in torque is outside
the standard value, return the rack support cover within
0 to 30_, and adjust again.
Caution
(1) When adjusting, set the standard value at its
highest value.
(2) Assure no ratcheting or catching when operating
the rack towards the shaft direction.
(3) Measure the total pinion torque through the whole
stroke of the rack.
NOTE
If the total pinion toque cannot be adjusted to the standard
value within the specified return angle, check the rack
support cover components and replace any parts if
necessary.
"LA TAB WASHER/TIE ROD INSTALLATION
After installing the tie rod to the rack, fold the tab washer
end (2 locations) to the tie rod notch.
"MABELLOWS BAND INSTALLATION
1. Turn the adjusting bolt of the special tool to adjust the
opening dimension (W) to the standard value.
<When more than 2.9 mm>
Screw in the adjusting bolt.
<When less than 2.9 mm>
Loosen the adjusting bolt.
NOTE
(1) The dimension (W) is adjusted by approx. 0.7 mm
per one turn.
(2) Do not turn the adjusting bolt more than one turn.
2. Use the special tool to crimp the bellows band.
Caution
(1) Hold the rack housing, and use the special tool
to crimp the bellows band securely.
(2) Crimp the bellows band until the special tool
touches the stopper.
MB991561
Stopper
Adjusting bolt
W
MB991561
3. Check that the crimped width (A) is within the standard
value.
<When more than 2.8 mm>
Readjust the dimension (W) of step (1) to the value
calculated by the following equation, and repeat
step (2).
W = 5.5 mm - A [Example: If (A) is 2.9 mm, (W)
is 2.6 mm.]
<When less than 2.4 mm>
Remove the bellows band, readjust the dimension
(W) of step (1) to the value calculated by the
following equation, and use a new bellows band
to repeat steps (2) to (3).
W = 5.5 mm - A [Example: If (A) is 2.3 mm, (W)
is 3.2 mm.]
"NATIE ROD END/TIE ROD END LOCKING NUT
INSTALLATION
Screw in the tie rod end to have its right and left length
as illustrated. Lock with lock nut.
RACK CHECK
D Check the rack tooth surfaces for damage or wear.
D Check the oil seal contact surfaces for uneven wear.
D Check the rack for bends.
PINION AND VALVE ASSEMBLY CHECK
D Check the pinion gear tooth surfaces for damage or wear.
D Check for worn or defective seal ring.
BEARING CHECK
D Check for roughness or abnormal noise during bearing
operation.
D Check the bearing for play.
D Check the needle roller bearing for roller slip-off.
A
Edge of bellows
assembly groove
Lock nut
104 mm
OTHER CHECK
D Check the cylinder inner surface of the rack housing for
damage.
D Check the boots for damage, cracking or deterioration.
D Check the rack support for uneven wear or dents.
D Check the rack bushing for uneven wear or damage.
TIE ROD END BALL JOINT DUST COVER
REPLACEMENT
1. Apply grease to the inside of the dust cover.
2. Apply the specified sealant to the mounting surface of
the dust cover.
Specified sealant: 3M ATD Part No.8661 or equivalent
3. Drive in the dust cover with special tool until it is fully
seated.
it with finger.
MB990776
STEERING - Power Steering Oil Pump 37A-29
POWER STEERING OIL PUMP 37200520262
D Condenser Fan Motor Assembly Removal
(Refer to GROUP 14.) <6A1>
D Condenser Fan Motor Assembly Installation
(Refer to GROUP 14.) <6A1>
D Drive Belt Tension Adjusting (Refer to GROUP 11
D Oil Pump Pressure Check (Refer to P.37A-11.)
12 Nm
10 - 12 Nm
7
<4G6>
<4D6>
28 Nm
49 Nm
12 Nm
49 Nm
18 Nm
28 Nm
1
2
5
8
6
22 Nm
18 Nm
39 Nm
9
3
8
4
1
6
3
4
5
10
Removal steps
1. Drive belt
2. Pressure switch connector
3. Suction hose
4. Pressure hose
5. O-ring
6. Bolt
7. Bolt
8. Oil pump
9. Oil pump brace
10. Oil pump bracket
5
4
8
10
3
1
7
9
2
6
5
18 Nm
39 Nm
36 Nm
12 Nm
39 Nm
<6A1>
Removal steps
1. Drive belt
2. Pressure switch connector
3. Suction hose
4. Air control valve
5. Pressure hose
6. O-ring
7. Bolt
8. Bolts
9. Oil pump
10. Oil pump bracket
D Check the drive belt for cracks.
D Check the pulley assembly for uneven rotation.
Oil pump seal kit Oil pump cartridge
kit
Fluid: Automatic transmission
fluid DEXRON or DEXRON II
1
20 Nm
7.9 Nm
29 Nm
2
3
4
5
6
7
8
9
10
11
13
14
15
16
18
20
21
22
23
24
25
9
7
3
4
5
2
24
13
21
20
19
17
12
59 Nm
9
Disassembly steps
1. Pump cover
2. O-ring
"EA 3. Vanes
4. Rotor
"DA 5. Cam ring
"CA 6. Side plate
"AA 7. O-ring
8. Connector
"AA 9. O-ring
10. Flow control valve
11. Flow control spring
12. Terminal assembly
"AA 13. O-ring
"BA 14. Spring
15. Plunger
16. Piston rod
17. Snap ring
18. Terminal
19. Washer
20. Insulator
"AA 21. O-ring
22. Plug
23. Suction connector
"AA 24. O-ring
25. Oil pump body and pulley assem-
bly
Caution
Do not disassemble the flow control valve.
"AAO-RINGS INSTALLATION
Apply the specified fluid on O-rings to install.
No. I.D. Width mm
1 11 1.9
2 13 1.9
3 17.8 2.4
4 13.5 1.5
5 3.8 1.9
6 16.8 2.4
7 17.8 2.4
8 13.0 1.9
"BASPRING INSTALLATION
Fit the spring to the oil pump body with the larger diameter
end at the terminal assembly side.
"CASIDE PLATE INSTALLATION
Install the side plate so that the screw hole in the oil pump
body and the knock pin holes in the side plate are all in
a straight line.
"DACAM RING INSTALLATION
Install the cam ring with the punch mark facing the side plate.
Connector Side plate
Terminal assembly
Suction connector
mounting portion of
oil pump body
1
2
3
4
6
5
8
7
Knock pin hole
(oval hole)
Screw hole
Knock pin
hole (round
hole)
Side plate
Screw hole
Punch mark
"EAVANE INSTALLATION
Install the vanes on the rotor, paying close attention to the
installation direction.
D Check the flow control valve for clogging.
D Check the pulley assembly for wear or damage.
D Check the groove of rotor and vanes for stepped wear.
D Check the contact surface of cam ring and vanes for
stepped wear.
D Check the vanes for damage.
Direct round edge to
the cam ring.
Rotor
Vane
Cam ring
STEERING - Power Steering Hoses 37A-34
POWER STEERING HOSES 37200570267
D Front Bumper Removal (Refer to GROUP 51.)
D Front Bumper Installation (Refer to GROUP 51.)
18 Nm
<4G6>
12 Nm
15 Nm
34 Nm
8
7
5
6
15 Nm
15 Nm
12 Nm
34 Nm
3
1
2
13
12 Nm
12 Nm
11
9
10
12 Nm
15 Nm
6
5
12 Nm
8
12 Nm
12
12 Nm
12 Nm
4
3
7
4
"AA 1. Pressure hose
2. O-ring
3. Pressure tube
4. O-ring
5. Return tube
6. O-ring
7. Return hose
8. Return tube
9. Return hose
10. Suction hose
11. Return hose
12. Oil reservoir
13. Cooler tube
18 Nm
<4D6>
12 Nm
15 Nm
34 Nm
5
7
7
5
8
8
12
11
9
10
13
2
6
6
3
3
4
34 Nm
12 Nm
12 Nm
12 Nm
12 Nm
15 Nm
4
12 Nm
1
12 Nm
15 Nm
15 Nm
12 Nm
2. O-ring
3. Pressure tube
4. O-ring
5. Return tube
6. O-ring
7. Return hose
8. Return tube
9. Return hose
10. Suction hose
11. Return hose
12. Oil reservoir
13. Cooler tube
18 Nm
<6A1>
12 Nm
15 Nm 34 Nm
15 Nm
15 Nm
15 Nm
12 Nm
12 Nm
36 Nm
12 Nm
3
1
14
10
12
11
13
9
8
6
12 Nm
9
12 Nm
2
5
4
7
7
6
8
12 Nm
12 Nm
34 Nm
4
5
12 Nm
1. Air control valve
3. O-ring
4. Pressure tube
5. O-ring
6. Return tube
7. O-ring
8. Return hose
9. Return tube
10. Return hose
11. Suction hose
12. Return hose
13. Oil reservoir
14. Cooler tube
"AAPRESSURE HOSE INSTALLATION
Align the marks on the pressure hose and pressure tube,
and install the pressure hose.
Mating mark
42-1
BODY
HOOD 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRUNK LID <Sedan> 4 . . . . . . . . . . . . . . . .
TRUNK LID 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FENDER 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANT 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FENDER 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL FILLER DOOR 7 . . . . . . . . . . . . . . . .
WINDOW GLASS 8 . . . . . . . . . . . . . . . . . . .
ADHESIVES 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 8 . . . . . . . . . . . . . . . . . . . . . . . .
WINDOW REPAIR 8 . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD 11 . . . . . . . . . . . . . . . . . . . . . . . . . . .
QUARTER WINDOW GLASS
<Wagon> 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAILGATE WINDOW GLASS
<Wagon> 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW GLASS <Sedan> 17 . . . . . .
DOOR 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALANT 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 19 . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 20 . . . . . . . . . . . . . . . . . .
Door Fit Adjustment 28 . . . . . . . . . . . . . . . . . . . . . .
Door Window Glass Adjustment 28 . . . . . . . . . . .
Adjustment and Replacement When
There is a Malfunction of the Power
Windows 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Window Safety Mechanism
Check 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Outside Handle Play Check 30 . . . . . . . . . .
Power Window Operation Current
Inspection 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker (Incorporated in the Power
Window Motor) Inspection 30 . . . . . . . . . . . . . . . . .
Door Inside Handle Play Check and
Adjustment 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR ASSEMBLY 31 . . . . . . . . . . . . . . . . . . . . .
DOOR TRIM AND WATERPROOF
FILM 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42-2
DOOR GLASS AND REGULATOR 36 . . . . . .
DOOR HANDLE AND LATCH 41 . . . . . . . . . .
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP 44 . . . . .
TAILGATE <Wagon> 45 . . . . . . . . . . . . . . .
SERVICE SPECIFICATION 45 . . . . . . . . . . . . .
SEALANT 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 45 . . . . . . . . . . . . . . . . . . . . . .
Tailgate Fit Adjustment 46 . . . . . . . . . . . . . . . . . . .
Tailgate Handle Play Check 46 . . . . . . . . . . . . . . .
TAILGATE ASSEMBLY 47 . . . . . . . . . . . . . . . . .
TAILGATE TRIM AND WATERPROOF
FILM 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAILGATE HANDLE AND LATCH 50 . . . . . . .
KEYLESS ENTRY SYSTEM 51 . . . . . . . . .
SPECIAL TOOL 51 . . . . . . . . . . . . . . . . . . . . . . .
How to Replace a Battery of the
Transmitter 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secret Code Registration Method 56 . . . . . . . . . .
KEYLESS ENTRY SYSTEM 57 . . . . . . . . . . . .
SUNROOF 57 . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATION 57 . . . . . . . . . . . . .
SPECIAL TOOL 57 . . . . . . . . . . . . . . . . . . . . . . .
Water Test 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sunroof Fit Adjustment 62 . . . . . . . . . . . . . . . . . . .
SUNROOF 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY - Hood 42-3
HOOD 42100160229
9 Nm
Adjustment of hood step and hood
striker linkage Adjustment of clearance and height
around hood
5, 6
1
2
3
4
5
6
7
8
9
10
11
12
5 Nm
22 Nm
12 Nm
1
9
12
9
1. Hood lock release handle
2. Hood weatherstrip
3. Front hood weatherstrip
4. Hood insulator
"AA 5. Bumper A
"AA 6. Bumper B
7. Hood support rod
Hood lock release cable removal
steps
D Splash shield <Drivers side>
(Refer to P.42-6.)
8. Hood lock release cable
Hood latch removal steps
D Radiator grille (Refer to GROUP 51.)
9. Hood latch
Hood and hood hinge removal
steps
10. Washer hose connection
11. Hood
12. Hood hinge
BODY - Hood/Trunk Lid <Sedan> 42-4
"AABUMPER B/BUMPER A INSTALLATION
Install the bumpers A and B as shown in the illustration.
TRUNK LID <Sedan> 42100220132
Adjustment of clearance around
trunk lid and trunk lid striker linkage
9 Nm
9 Nm
1
2
3
4
5
6
7
8
9
10
11
12
7
9
8
Trunk lid panel removal steps
"BA 1. Bumper A
"BA 2. Bumper B
D Licence plate lamp
3. Licence plate lamp garnish
4. Trunk lid lock cylinder
5. Trunk lid latch
D Spring cover (Refer to GROUP 52A
- Trims.)
6. Trunk lid hinge spring
7. Trunk lid panel
Trunk lid hinge removal steps
D Rear shelf trim (Refer to GROUP 52A
- Trims.)
7. Trunk lid panel assembly
8. Trunk lid hinge
Trunk lid latch removal
5. Trunk lid latch
Trunk lid striker removal steps
D Rear end trim (Refer to GROUP 52A
- Trims.)
9. Trunk lid striker
Trunk lid release handle and cable
removal steps
D Front seat (drivers side) (Refer to
GROUP 52A.)
D Rear seat (Refer to GROUP 52A.)
D Front scuff plate (drivers side)
D Rear scuff plate (drivers side)
D Trunk room side trim (drivers side)
5. Trunk lid latch
10. Trunk lid release handle
11. Trunk lid release cable
Trunk lid weatherstrip removal
"AA 12. Trunk lid weatherstrip removal
16.0 0.5 mm
Bumper A Bumper B
18.8 0.5 mm
BODY - Trunk Lid <Sedan>/Fender 42-5
"AATRUNK LID WEATHER STRIP INSTALLATION
Install the trunk lid weatherstrip so that the marking and the
joint are aligned with the body centre line.
"BABUMPER B/BUMPER A INSTALLATION
Install the bumpers A and B as shown in the illustration.
TRUNK LID LATCH CONTINUITY CHECK
Switch position Terminal No.1 Body earth
ON (Latch open)
OFF (Latch shut)
FENDER 42100050137
SEALANT
Splash shield 3M ATD Part No. 8625 or equivalent Ribbon sealer
Fender
14 mm
15 mm
Bumper A Bumper B
ON OFF
BODY - Fender 42-6
FENDER 42100190204
D Front Bumper Removal and Installation
D Front Turn-signal Lamp Removal and Installation
D Side Sill Cover Removal and Installation (Refer to
GROUP 51 - Aero Parts.)
2
3
1
Sealant:
3M ATD Part No. 8625 or equivalent
3
Sealant:
3M ATD Part No. 8625 or equivalent
1
Removal steps
1. Splash shield
"AA 2. Side turn signal lamp
3. Fender
"AASIDE TURN-SIGNAL LAMP INSTALLATION
Insert the hook into the fender panel, and then install the
side turn signal lamp.
Front of vehicle
Hook
Fender panel
BODY - Fuel Filler Door 42-7
FUEL FILLER DOOR 42100250254
D Front Seat (drivers side), Rear Seat Removal and
Installation (Refer to GROUP 52A.)
D Front Scuff Plate (drivers side), Rear Scuff Plate
(drivers side), Center Pillar Lower Trim (drivers side),
Trunk Side Trim (drivers side) <Sedan>, Quarter
Lower Trim (drivers side) <Wagon> Removal and
Installation (Refer to GROUP 52A.)
Fuel filler door height and clearance
adjustment
3
1
4
2
2
1
3
Removal steps
1. Fuel filler door pannel assembly
2. Fuel filler door hook assembly
3. Lid lock release handle
4. Fuel filler door lock release cable
BODY - Window Glass 42-8
WINDOW GLASS 42200050123
ADHESIVES
Items Specified adhesives
Windshield 3M ATD Part No. 8609 Super Fast Urethane Auto Glass
Quarter window glass
Sealants or equivalent
Tailgate window glass
Rear window glass
MB990480 Glass holder D Removal and installation of windshield
D Removal and installationof tailgatewindow
glass
D Removal and installation of rear window
glass
MB990449 Window moulding
remover
Removal of roof drip moulding
WINDOW REPAIR 42200560084
The following glass sections are installed by means of a liquid
urethane adhesive method.
D Windshield
D Quarter window glass
D Tailgate window glass
D Rear window glass
ITEMS NEEDED
Name Remarks
Adhesive 3MATDPart No. 8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
Spacers Available as service part
Anti-rust solvent
(or Tectyl 506T...Valvoline Oil Company)
For rust prevention
Isopropyl alcohol For grease removal from bonded surface
Steel piano wire Dia. length...0.6mm 1m For cutting adhesive
Adhesive gun For pressing-out adhesive
NOTE
The TEROSON 127.37V auto window sealer kit can also be used. If using the TEROSON 127.37V auto window
sealer kit, follow the instructions in the manual included with the kit.
HANDLING OF AUTO WINDOW SEALER
Keep the sealant in a cool place, not exposed to the direct
rays of the sun. Do not place any heavy article on the sealant
nor press it, otherwise it will become deformed. Avoid storing
the sealant for more than 6 months, because it will lose its
sealing effect.
BODY PINCH-WELD FLANGE SERVICING.
Before servicing the body pinch-weld flange, remove old
adhesive completely. If the flange requires painting, bake
it after painting is completed.
WORKING PROCESS
Window glass installation procedure
Body side
Cleaning of adhesion surface
Cut off the residual adhesive until the
thickness is less than 2 mm. Clean the
adhesion surface with isopropyl alcohol,
and let dry for 3 minutes or more.
Attaching of clip
Attach the clip to set the positions for
the glass to be installed.
Application of primer
Apply to the adhesion surface of the
body and let dry for 3 minutes or more.
Window glass side
Reusing the glass Replacing the glass
Competely cut off all of the residual
adhesive. Clean the adhesion surface
with isopropyl alcohol, and let dry for
3 minutes or more.
Clean off any dirt adhering to the adhe-
sion surface with isopropyl alcohol, and
let dry for 3 minutes or more.
Gluing of window spacer and glass stoppers
Glue the window spacer along the standard position on the glass outer circumference. Install
the glass stoppers to the specified positions.
Application of primer
Apply sufficient primer evenly to the adhesion surface so that there is no patchiness. After
application, let dry for 3 to 30 minutes.
Application of adhesive
Within 30 minutes after applying the primer, apply the adhesive evenly all the way around
the inside edge of the glass.
Installing the glass
After applying the adhesive, lightly press the glass evenly so that it adheres
completely.
Cleaning
After removing any adhesive that is sticking out or adhering to the body or
glass with a spatula, ect., clean off with isopropyl alcohol.
Checking for water leaks
Carry out a shower test to check that no water will leak through.
WINDSHIELD 42200100255
D Front Pillar Trim Removal and Installation
D Headlining Removal and Installation
(Entire
circumference)
Section A-A
Primer
Section B-B
Section C-C
mm
Primer
Primer
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
8
7
4
C
C
A
A
B
B
2
5
1
7.5
22
16
9
2
36
6
3
4
Removal steps
AA" 1. Roof drip moulding
D Front deck garnish
(Refer to GROUP 51 - Windshield
Wiper and Washer.)
AB" "AA 2. Windshield
"AA 3. Glass stopper
"AA 4. Window spacer
"AA 5. Windshield upper moulding
6. Drip moulding clip A
7. Drip moulding clip B
8. Drip moulding clip C
AA"ROOF DRIP MOULDING REMOVAL
Use the special tool to lever out the moulding.
Caution
If the moulding has become warped, it should not be
reused.
AB"WINDSHIELD REMOVAL
1. In order to protect the body (paint surface), apply cloth
tape to all body areas around the installed windshield.
2. Using a sharp-point drill, make hole in the windshield
adhesive.
3. Pass the piano wire from the inside of the vehicle through
the hole.
4. Pull the piano wire alternately from the inside and outside
along the windshield to cut the adhesive.
Caution
Do not let the piano wire touch the edge of the
windshield.
5. Make mating marks on the windshield and body.
6. Use the special tool to remove the windshield.
7. Use a knife to cut away the remaining adhesive so that
the thickness is within 2 mm around the entire
circumference of the body flange.
MB990449
MB990480
8. Finish the flange surfaces so that they are smooth.
Caution
(1) Be careful not to remove more adhesive than is
necessary.
(2) Be careful also not to damage the paintwork on
the body surface with the knife. If the paintwork
is damaged, repair the damaged area with repair
paint or anti-rust agent.
9. When reusing the windshield, remove the adhesive still
adhering to the windshield, and clean with isopropyl
alcohol.
10. Clean the body side in the same way.
Caution
Let the cleaned places stand for 3 minutes or more,
and carry out the next procedures after they have
dried. Also, do not touch any surface that has been
cleaned.
"AAWINDSHIELD UPPER MOULDING/WINDOW
SPACER/GLASS STOPPER/WINDSHIELD
INSTALLATION
1. When replacing the windshield, temporarily set the
windshield against the body, and place a mating mark
on the windshield and body.
2. Use isopropyl alcohol to degrease the inside and outside
of the windshield and the body flanges.
3. Soak a sponge in the primer, and apply evenly to the
windshield and the body in the specified places.
4. Apply the primer, and then let it dry for 3 to 30 minutes.
Caution
(1) The primer strengthens the adhesive, so be sure
to apply it evenly around the entire circumference.
However, a too thick application will weaken the
adhesive.
(2) Do not touch the coated surface.
5. Install the windshield upper moulding to the windshield.
6. Place the window spacer to the windshield so that it
inclines toward the windshield and its right and left
clearances are equal. Then install the spacer firmly so
that it is not adrift.
7. Install the glass stopper to the shown dimension.
8. Fill a sealant gun with adhesive. Then apply the adhesive
evenly around the windshield within 30 minutes after
applying the primer.
NOTE
Cut the tip of the sealant gun nozzle into a V shape
to simplify adhesive application.
9. After applying the adhesive, align the mating marks on
the windshield and the body, and thenpress thewindshield
gently to seat it.
10. Use a spatula or the like to remove any excessive
adhesive. Then clean the surface with isopropyl alcohol.
Install the roof drip moulding before the adhesive hardens.
11. Try not to move the vehicle until the adhesive sets. Wait
30 minutes or more, and then test for water leakage.
Caution
(1) Do not move the vehicle unless absolutely
necessary.
(2) When testing for water leakage, do not pinch the
end of the hose to spray the water.
20 mm
300 mm
Centre
Glass stopper
Section A - A
Glass stopper
300 mm
A
A
10 mm
15 mm
QUARTER WINDOW GLASS <Wagon> 42200250127
D Quarter Upper Trim, Retractor Trim and Belt Line Trim
Removal and Installation (Refer to GROUP 52A.)
9.5
5.5
5.5
22 7.5
5.5
A
B
3
2
B
A
C
C
D
D
Primer
Section C - C Section D - D
Primer
Primer
Primer
3
2
1
mm
5
5
Removal steps
AA" "AA 1. Quarter window glass
2. Packing
3. Clip
AA"QUARTER WINDOW GLASS REMOVAL
Remove the quarter window glass in the same manner as
for the windshield, except the clips (Refer to P.42-11.)
"AAQUARTER WINDOW GLASS INSTALLATION
Install the quarter window glass in the same manner as for
the windshield, except the clips (Refer to P.42-11.)
TAILGATE WINDOW GLASS 42200370144
D Side Tailgate Trim, Lower Tailgate Trim and Cover
Removal and Installation (Refer to P.42-49.)
D Rear Wiper Removal and Installation
Primer
Primer
Primer
Primer
A
B
1
3
B C D
D
3
2
mm
Section C - C Section D - D
81.5
56.5
A
C
5
15 5 15
5
5
Removal steps
1. Harness connector
AA" "AA 2. Tailgate window glass
3. Glass stopper
AA"TAILGATE WINDOW GLASS REMOVAL
Remove the tailgate window glass in the same manner as
for the windshield, except the glass stopper (Refer to P.42-11).
"AATAILGATE WINDOW GLASS INSTALLATION
Install the tailgate window glass in the same manner as for
the windshield, except the glass stopper (Refer to P.42-11).
REAR WINDOW GLASS <Sedan> 42200160123
D Rear Wiper Motor Removal and Installation
D High Mounted Stop Lamp Removal and Installation
D Rear Pillar Trim Removal and Installation
B
A
C
B
mm
A
C
6.7
8.5
Primer
Section C - C
Primer
Primer
Adhesive tape:
double-sided tape [6 mm width
and 0.125 mm thickness]
1
2
3
4
5
6
7
8
9
10
1
8
14
11
7
7
Removal steps
AA" 2. Roof drip moulding
AA" 3. Rear window lower moulding
4. Rear window moulding clip
AB" "AA 5. Rear window glass
"AA 6. Glass stopper
"AA 7. Window spacer
"AA 8. Rear window upper moulding
9. Clip grommet A
10. Rear drip moulding clip
AA"ROOF DRIP MOULDING/ REAR WINDOW LOWER
MOULDING REMOVAL
Caution
reused.
AB"REAR WINDOW GLASS REMOVAL
Remove the rear window glass by the same procedure as
for the windshield. (Refer to P.42-11.)
"AAREAR WINDOW UPPER MOULDING/WINDOW
SPACER/GLASS STOPPER/REAR WINDOW
GLASS INSTALLATION
Install the rear window glass in the same manner as for the
windshield (Refer to P.42-11).
MB990449
BODY - Door 42-19
DOOR 42300030137
SERVICE SPECIFICATIONS
Door outside handle play mm Front 3.7 or more
Rear 2.4 or more
Power window operating current A 5 1 (for 14- 15 V power supply at 25_C)
Door inside handle play mm 5.3 or more
SEALANT 42300050065
Waterproof film 3M ATD Part No. 8625 or equivalent Ribbon sealer
MB991502 MUT-II sub
assembly
ETACS-ECU input signal checking
MB990784 Ornament remover Removal of door trim
MB990900 or
MB991164
Door adjusting
wrench
Adjustment of door fit
BODY - Door 42-20
A
B
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: probe
DIAGNOSIS FUNCTION
INPUT SIGNAL INSPECTION POINTS
<VEHICLES WITH ETACS-ECU>
2. If buzzer of the MUT-II sounds once when door lock
actuator switch is operated (LOCK/UNLOCK), the
ETACS-ECU input signal for that switch circuit system
is normal.
MUT-II
BODY - Door 42-21
procedure
Reference
page
Power windows The power windows cannot be operated by any of the power
window switches.
1 42-22
Drivers side power window cannot be operated by the power
window main switch.
2 42-24
Passengers side and rear power windows cannot be operated by
the power window main switch. (However, they can be operated
by the power window sub-switches.)
3 42-25
When the glass is raised, it then lowers automatically. 4 42-25
The glass is not lowered when something is jammed in the
window.
5 42-25
When the glass is fully raised, it then lowers automatically. 6 42-26
Door locking None of the door lock functions operate. 7 42-26
mechanism
Noneof thedoors lock or unlock whenthe drivers side insidedoor
locking knob is operated (including by means of the door key).
8 42-27
Some doors do not lock or unlock. 9 42-27
BODY - Door 42-22
The power windows cannot be operated by any of the
power window switches. <Vehicles without ETACS>
Probable cause
The cause may be a malfunction of the power window relay and of the power window
relay drive circuit.
D Malfunction of power window relay
OK
NG
Check the harness wire betweenignition
switch (IG2) and power window relay,
between fusible link No. 3 and power
window relay, and repair if necessary.
NG
Check the harness wire between power
window relay and the earth, and repair
if necessary.
Repair
OK
NG
window main switch and power window
OK
NG
window main switch and earth, and re-
pair if necessary.
OK
Replace the power window switch.
OK
Measure at the power window main
switch connector F-19.
D Continuity between 9 and body earth
OK: Continuity
NG
C-120, F-19
NG
Repair
OK
OK: System voltage
NG
F-19, C-120, C-114, B-15X
NG
OK
Measure at the power windowrelay con-
nector B-15X.
OK: Continuity
NG
OK
Measure at the power windowrelay con-
nector B-15X.
OK: System voltage
NG
C-131, C-141
NG
Repair
Check power window relay continuity.
(Refer to P.42-40.)
NG
Replace
BODY - Door 42-23
The power windows cannot be operated by any of the
power window switches. <Vehicles with ETACS>
Probable cause
The cause may be a malfunction of the power window relay, power window relay
drive circuit and of the ETACS-ECU.
D Malfunction of power window relay
D Malfunction of ETACS-ECU
OK
NG
Check the harness wire between fusible
link No.3 and power window relay, and
OK
NG
window relay and ETACS-ECU, and re-
pair if necessary.
OK
Replace the ETACS-ECU.
OK
Measure at the ETACS-ECU connector
C-138.
OK: System voltage
NG
C-138, C-116, B-15X
NG
Repair
OK
D Ignition switch: ON and OFF
OK: System voltage (ON)
0 V (OFF)
NG
F-19, C-120, C-114, B-15X
NG
Repair
Check the power window relay continu-
ity. (Refer to P.42-40.)
NG
Replace
BODY - Door 42-24
Drivers side power window cannot be operated by the
power window main switch.
Probable cause
The cause may be a malfunction of power window main switch, power window
motor-ECU, or open circuit or short circuit in the communication line between power
window main switch and power window motor-ECU.
D Malfunction of power window main switch
D Malfunction of power window motor-ECU
OK
Replace the power windowmain switch.
OK
NG
window relay and power window motor-
ECU, and between power window mo-
tor-ECU and earth.
OK
NG
window relay and power window main
switch, between power window main
switch and earth, and repair if neces-
sary.
NG
Replace the power window motor-ECU.
OK
Replace the power windowmain switch.
OK
switch connector F-19 and the power
window motor-ECU connector F-21.
D Continuity between 2 (power
window main switch side) and 4
(power window motor-ECU side)
OK: Continuity
NG
window main switch and power window
motor-ECU, and repair if necessary.
OK
Measure at the power window motor-
ECU connector F-21.
0 V (OFF)
OK: Continuity
NG
F-21, C-120
NG
Repair
0 V (OFF)
OK: Continuity
NG
F-19, C-120, C-114, B-15X
NG
Repair
BODY - Door 42-25
Passengers side and rear power windows cannot be
operated by the power window main switch. (However,
they canbe operatedby the power windowsub-switches.)
Probable cause
The cause may be open circuit or short circuit in the communication line between
power window main switch, passengers side power window motor-ECU and rear
power window motor-ECU.
OK
NG
Check the harness wire between joint connector and power window
motor-ECU.
OK
Passengers side: <LHD> C-61, C-124 <RHD> C-65, C-120
Rear <LH>: <LHD> C-61, C-119, E-17 <RHD> C-65, C-119, E-17
Rear <RH>: <LHD> C-61, C-123, E-10 <RHD> C-65, C-123, E-10
NG
Repair
OK
Check the harness wire between power window main switch F-19
and joint connector (1 or 5).
NG
Repair
F-10, F-15, F-04 or F-21
NG
Repair
When the glass is raised, it then lowers automatically. Probable cause
If the sliding resistance is too large when the glass is being raised, it is judged that
something is jammed in the window, and the window is lowered by approximately
150 mm.
D Incorrect window glass adjustment
D Glass slider is incorrectly installed or warped
NO
NG
Replace the window regulator assembly.
Does the glass move in the opposite direction when the power
window drive current is above the following value? (Refer to
P.42-30.)
Drive current: 5 1 A
YES
Adjust the window glass. (Refer to P.42-28.)
The glass is not loweredwhensomethingis jammedinthe
window.
Probable cause
The cause may be a malfunction of the revolution detection sensor in the power
window motor-ECU.
D Malfunction of power window motor-ECU
BODY - Door 42-26
When the glass is fully raised, it then lowers
automatically.
Probable cause
When the window is within 15 mm of being fully closed, the limit switch turns off
to prevent the window from being lowered. However, the above problem can occur
if there is a malfunction of the limit switch in the power window motor-ECU.
D Malfunction of the power window motor-ECU
Limit switch operation position adjustment (Refer to P.42-40.)
NG
None of the door lock functions operate. Probable cause
The cause may be a malfunction of the ETACS-ECU power supply circuit system
or of the earth circuit system.
Measure at the junction block connector
C-142.
D Remove the ETACS-ECU and
measure at the junction block side.
OK: System voltage
NG
C-142, C-144
NG
Repair
OK
OK
C-142, C-144
NG
Repair
OK
NG
ETACS-ECU and body earth.
NG
Repair
OK
NG
link No.1 and junction block, and repair
if necessary.
BODY - Door 42-27
None of the doors lock or unlock when the drivers-side
inside door locking knob is operated (including by means
of the door key).
Probable cause
The cause may be a malfunction of the door lock actuator switch, the ETACS-ECU
or of a wiring harness or connector.
D Malfunction of front door lock actuator (drivers side)
MUT-II Pulse check
Front door lock actuator switch (drivers-
side) input signal
OK: The MUT-II buzzer sounds once
when the front door lock actuator
moves from the locked to the un-
locked position, or from the un-
locked to the locked position.
NG
Check the front door lock actuator (driv-
ers side). (Refer to P.42-42.)
NG
Replace
OK
F-17, C-120, C-138
NG
Repair
OK
OK
NG
front door lock actuator (drivers side)
and ETACS-ECU, between front door
lock actuator and the earth, and repair
if necessary.
Some doors do not lock or unlock. Probable cause
The cause may be a malfunction of the door lock actuator or tailgate lock actuator
or of a wiring harness or connector.
D Malfunction of door lock actuator
D Malfunction of tailgate lock actuator
Check the door lock actuator of the door that does not operate.
NG
Replace
OK
NG
Check the harness between the ETACS-ECU and the door lock
actuator of the door that does not operate, and repair if necessary.
OK
Repair
NG
<Front L.H.> F-17, C-120, C-138
<Front R.H.> F-08, C-124, C-138
<Rear L.H.> F-14, E-17, C-119, C-138
<Rear R.H.> F-12, E-10, C-123, C-138
<Tailgate> G-30, G-29, C-138
BODY - Door 42-28
DOOR FIT ADJUSTMENT
1. If the clearance between the door and the vehicle body
is uneven, affix protective tape to the fender around the
hinge and to the edge of the door. Then use the special
tool to loosen the door hinge mounting bolts on the body,
and adjust the clearance around the door so that it
becomes even.
2. If the door and the body are not flush with each other,
use the special tool to loosen the door hinge mounting
bolts. Then align the door.
Caution
Do not load more than 98 Nm on the special tool
(MB991164).
3. If the door opening and closing is heavy, adjust the
meshing of the striker and the door latch (in thelongitudinal
direction) by adding shims to the striker and by moving
the striker up and down or to the left and right.
DOOR WINDOW GLASS ADJUSTMENT 42300100227
Check that the door glass moves securely along the door
glass runchannel when the window glass is fully raised and
fully lowered. If the glass does not move correctly, adjust
by the following procedure.
1. Remove the door trim and the waterproof film.
(Refer to P.42-33.)
2. Loosen the mounting screw through the adjusting hole
with the door window glass fully closed, and lower the
door window glass slightly.
3. Close the door window glass fully again, and tighten the
door glass mounting screw securely through the adjusting
hole.
MB990900 or
MB991164
Striker
Shim
Front Rear
Adjusting
hole
Adjusting
hole
BODY - Door 42-29
ADJUSTMENT AND REPLACEMENT WHEN
THERE IS A MALFUNCTION OF THE POWER
WINDOWS 42900190062
If the window glass automatically starts moving downwards
at the wrong time while it is being raised, carry out the following
adjustment or replacement procedures.
1. Remove the door trim and waterproof film. (Refer to
P.42-33.)
2. Remove the window regulator assembly from the door
window glass, and then raise and lower the door window
glass by hand to check the operation force.
NOTE
Insert a cushion or similar object to prevent damage to
the glass if it should happen to fall down.
3. If the door window glass does not move up and down
smoothly, check or repair the following points.
D Check the installation condition of the runchannel.
D Repair the twisting in the door sash.
D Check the installation condition of the lower sash
or the center sash.
NOTE
The lower sash cannot normally be adjusted, but it may
be possible to adjust the sash span slightly within the
range allowed by manufacturing tolerances by pushing
the lower sash outwards while re-installing it.
4. If repair or adjustment is not possible, replace the door
assembly.
POWER WINDOW SAFETY MECHANISM
CHECK 42900100065
1. Place a wooden board with a thickness of approximately
10 mm as shown in the illustration, and then raise the
window glass.
2. Check that the window lowers by a distance of
approximately 150 mm when the window clamps the
wooden board. If this doesnt happen, refer to
Troubleshooting (P.42-25).
Runchannel
Door
sash
Lower sash
BODY - Door 42-30
DOOR OUTSIDE HANDLE PLAY CHECK 42300160126
1. Check that the door outside handle play is within the
standard value range.
Standard value (B):
Front door: 3.7 mm or more
Rear door: 2.4 mm or more
2. If the door outside handle play is not within the standard
value range, check the door outside handle or the door
latch assembly. Replace, if necessary.
POWER WINDOW OPERATION CURRENT
1. Remove the power window fuse and connect a circuit
analyser as shown in the illustration.
2. When the power window switch is pressed to the UP
position, a large amount of current flows at the time the
window starts to close and when it is fully closed, so
measure the operation current in the interval between
these two points.
Standard value:
5 1 A (for 14- 15 V power supply voltage at
25_C)
3. If the operation current is outside the standard value,
refer to Troubleshooting (P.42-25).
CIRCUIT BREAKER (INCORPORATED IN THE
POWER WINDOW MOTOR) INSPECTION42900170080
1. Press the power window switch to the UP position to
fully close the window glass, and keep pressing the switch
for a further 10 seconds.
2. Release the power window switch from the UP position
and immediately press it to the DOWN position. The
condition of the circuit breaker is good if the power window
glass starts to move downwards within 60 seconds.
DOOR INSIDE HANDLE PLAY CHECK AND
1. Check that the door inside handle play is within the
standard value range.
Standard value (A): 5.3 mm or more
2. If the door inside handle play is outside the standard
value range, remove the door trim. (Refer to P.42-33.)
3. Loosen the inside handle mounting screws, and then
move the inside handle back and forth to adjust the play.
Section A - A
A
A
B
A
BODY - Door 42-31
DOOR ASSEMBLY 42300220237
Door Adjustment (Refer to P.42-28.)
26 Nm
Front door
12 Nm
22 Nm
Rear door
22 Nm
22 Nm
4, 5
6
6
7
8
3
3
9
7
1
1
4
4
2
2
5
5
9
26 Nm
22 Nm
26 Nm
26 Nm
12 Nm
8
Door assembly removal steps
2. Spring pin
3. Door assembly
"AA 4. Door upper hinge
"AA 5. Door lower hinge
Striker removal steps
6. Striker
7. Striker shim
Door switch removal steps
8. Door switch cap
9. Door switch
BODY - Door 42-32
"AADOOR LOWER HINGE/DOOR UPPER HINGE
INSTALLATION
The door hinges differ according to where they are used,
so check the identification marks before installation.
Applicable location Identification
mark
Front left side door Upper hinge V
Lower hinge U
Front right side door Upper hinge U
Lower hinge V
Rear left side door Upper hinge M2
Lower hinge O2
Rear right side door Upper hinge N2
Lower hinge P2
DOOR SWITCH CONTINUITY CHECK
Switch Terminal No.
position
1 2
Open (ON)
Depressed
(OFF)
Front (upper, lower)
Rear (upper)
Rear (lower)
Identification mark
Identification mark
Stroke
ON OFF
1
2
BODY - Door 42-33
DOOR TRIM AND WATERPROOF FILM 42300430210
Front door
NOTE
: Resin clip position
Sealant:
3M ATD Part. No. 8625 or equivalent
1
2
3
4
5
6
7
8
9
10
11
12
12
Removal steps
1. Power window switch panel
2. Power window switch
3. Inside handle cover
4. Inner delta cover or tweeter cover
5. Door trim
6. Cover
7. Pull handle bracket A
8. Pull handle bracket B
9. Door inside handle
10. Speaker
11. Speaker cover
12. Waterproof film
BODY - Door 42-34
Rear door
NOTE
Sealant:
3MATDPart. No. 8625 or equivalent
1
2
3
4
5
6
7
8
9
10
11
12
13
14
14
Removal steps
AA" "AA 1. Clip
<Vehicles without power windows>
"AA 2. Regulator handle
"AA 3. Escutcheon
4. Power window switch panel
<Vehicles with power windows>
5. Power window switch
<Vehicles with power windows>
6. Pull handle box
7. Inside handle cover
8. Door trim
9. Pull handle bracket A
10. Pull handle bracket B
12. Speaker
13. Speaker cover
14. Waterproof film
BODY - Door 42-35
AA"CLIP REMOVAL
Remove the clip by using a rag, and then remove the regulator
handle.
"AAESCUTCHEON/REGULATOR HANDLE/CLIP
INSTALLATION
1. Install the escutcheon and the clip to the regulator handle.
2. Fully close the front door glass, and install the regulator
handle so that it faces as shown in the illustration.
30_
Horizontal line
Front of vehicle
BODY - Door 42-36
DOOR GLASS AND REGULATOR 42900130231
D Door Trim and Waterproof Film Removal
(Refer to P.42-33.)
D Door Beltline Inner Weatherstrip Removal
(Refer to P.42-44.)
D Door Window Glass Adjustment (Refer to P.42-28.)
D Door Beltline Inner Weatherstrip Installation
(Refer to P.42-44.)
D Door Trim and Waterproof Film Installation
(Refer to P.42-33.)
Front door Rear door
<Vehicles without
power windows>
<Vehicles with
power windows>
1
2
3
4
5
6
7
8
1
2
4
3
3
Front window regulator assembly
removal steps
"BA 1. Door window glass
2. Door window glass holder
"AA 3. Window regulator assembly
AA" "AA 4. Power window motor
Rear window regulator assembly
removal steps
D Window glass runchannel
(Refer to P.42-44.)
"BA 1. Door window glass
2. Door window glass holder
"AA 3. Window regulator assembly
AA" "AA 4. Power window motor
Stationary window glass removal
steps
D Window glass runchannel
(Refer to P.42-44.)
1. Door window glass
AB" 5. Door center sash
6. Stationary window glass and
weatherstrip assembly
7. Stationary window glass
8. Stationary window weatherstrip
BODY - Door 42-37
AA"POWER WINDOW MOTOR ASSEMBLY
Caution
Be careful when handling the power window motor
assembly, as the force of the spring may cause the wires
to pull out of the drum.
AB"DOOR CENTER SASH REMOVAL
1. Remove the door outer opening weatherstrip from the
door center sash only.
2. Remove the door center sash mounting screws, and then
remove the door center sash from the door panel.
"AAPOWER WINDOW MOTOR ASSEMBLY/WINDOW
REGULATOR ASSEMBLY
POWER WINDOW MOTOR ASSEMBLY AND WINDOW
REGULATOR ASSEMBLY INSTALLATION PROCEDURE
1. Align the power window motor drive shaft and the square
hole in the drum while using the guide and the opening
in the motor housing as a reference for the installation
position.
NOTE
(1) Align the square hole with the drive shaft by sliding
the glass bracket (glass mounting section) or by
turning the drumusing a ratchet wrench (with a socket
diameter of 12.7 mm).
(2) Support the drum and the guide with your hand while
turning the drum, otherwise the wires may pull out
of the drum.
(3) If the wires pull out of the drum, re-insert them by
following the drum and regulator wire installation
procedure.
2. Align the guide and the opening of the motor housing,
and slide the guide into the motor housing while holding
the guide and drum.
Door outer
opening
weatherstrip
Door center sash
Opening
Drive
shaft
Drum
Guide
Square hole
Rachet wrench
Glass
bracket
BODY - Door 42-38
3. Install the metal cover securely to the housing.
Caution
Make sure that the metal cover is installed securely
and does not move, in order to stop the drum from
vibrating. If the drum vibrates, the glass may not slide
up and down smoothly, or it may fall down.
4. Apply battery voltage to the power window motor, and
check that the glass bracket moves smoothly.
DRUM AND REGULATOR WIRE INSTALLATION
PROCEDURE
1. Place the drum, guide and regulator on a work bench
(1) Place the drum so that the square hole is facing
upward.
(2) Place the guide so that the slits are facing upward.
(3) Place the regulator so that the glass bracket is facing
downward. Position the glass bracket so that glass
is in the fully-open position.
2. Pass the springs over the wires, and then install the
lowering wire to the guide first, followed by the lifting
wire. (The lifting wire should be on top of the lowering
wire.)
Mounting
screw
Metal cover
Spring A
Lower-
ing wire
Square hole
Spring B
Drum
Guide
Lifting
wire
Slit
Lowering
wire
Spring
Slit
Lifting wire
Guide
BODY - Door 42-39
3. Use some narrow-gauge wire (approx. 0.5 mm diameter)
to compress the springs.
NOTE
Tie the narrow-gauge wires to the slits in the guide.
4. Insert the end of the lowering wire into the wire hole
at the bottomof the drum, and then wrap the wire securely
around the groove of the drum from the bottom so that
there is no slackness in the wire.
5. Install the lifting wire to the drum as follows:
(1) Insert the end of the lifting wire into the wire hole
at the top of the drum.
(2) Raise the front of the drum until the drum is vertical,
and then position the lifting wire in the groove of
the drum.
Narrow-
gauge wire
Lowering wire
Lifting wire
BODY - Door 42-40
(3) Return the drum to its original position while holding
the wires to make sure that they do not pull out.
6. After installing the power window motor assembly to the
window regulator assembly, cut and remove the wires
which are compressing the springs.
"BADOOR WINDOW GRASS INSTALLATION
1. Provisionally secure the door window glass to the window
regulator assembly.
2. After raising the door window glass as far as it will go,
fully secure the door windowglass to the windowregulator
assembly.
NOTE
Fully raising the door window glass will set the door limit
switch to the correct position.
POWER WINDOW RELAY CONTINUITY CHECK
System Terminal No.
voltage
1 3 4 5
Not applied
Applied
Power window relay
BODY - Door 42-41
DOOR HANDLE AND LATCH 42300460219
D Door Trim Removal (Refer to P.42-33.)
D Door Inside Handle Play Check (Refer to P.42-30.)
D Door Outside Handle Play Check (Refer toP.42-30.)
D Door Trim Installation (Refer to P.42-33.)
6 Nm
6 Nm
3 7
4
8
8
6
9
2
5
1
1
5
9
Front door handle and door latch
D Waterproof film (Refer to P.42-33.)
2. Door outside handle
3. Door lock key cylinder
4. Rear lower sash
5. Door latch assembly
Rear door handle and door latch
D Door center sash (Refer to P.42-36.)
5. Door latch assembly
6. Door lock actuator
7. Door outside handle
Door check removal steps
8. Spring pin
9. Door check
BODY - Door 42-42
INSPECTION
FRONT DOOR LOCK ACTUATOR CHECK 42300610102
L.H. drive vehicles
<Drivers side>
Rod position Terminal No. Rod operation
1 2 3 4 6
LOCK LOCK position
UNLOCK position
UNLOCK UNLOCK position
LOCK position
LOCK
UNLOCK
<Passengers side>
4 6
LOCK LOCK position
UNLOCK position
LOCK position
R.H. drive vehicles
<Drivers side>
1 2 3 4 6
LOCK LOCK position
UNLOCK position
LOCK position
LOCK
UNLOCK
<Passengers side>
4 6
LOCK LOCK position
UNLOCK position
LOCK position
<L.H.>
View A
Unlock
<R.H.>
View B Unlock
Lock
A
B
Lock
BODY - Door 42-43
REAR DOOR LOCK ACTUATOR CHECK 42300620082
<L.H.>
2 3
LOCK LOCK position
UNLOCK position
LOCK position
<R.H.>
2 3
LOCK LOCK position
UNLOCK position
LOCK position
DOOR LOCK KEY CYLINDER SWITCH CHECK 42300630122
1 2 3
LOCK
NEUTRAL (OFF)
UNLOCK
Unlock
<L.H.>
View A
<R.H.>
View B
Lock
Unlock
Lock
A
B
Unlock
21_
21_
Neutral
Lock
BODY - Door 42-44
WINDOW GLASS RUNCHANNEL AND DOOR OPENING
WEATHERSTRIP 42300310187
5
6
3
1
2
5
4
3
1
2
6
Door inner opening weatherstrip
removal steps
D Scuff plate (Refer to GROUP 52A.)
D Cowl side trim <Front door>
D Center pillar lower trim
1. Door inner opening weatherstrip
Door outer opening weatherstrip
removal
AA" "AA 2. Door outer opening weatherstrip
Door window glass runchannel
removal steps
3. Door window glass runchannel
4. Door window glass lower runchan-
nel <Rear door>
Door beltline inner weatherstrip
removal steps
D Door trim (Refer to P.42-33.)
5. Door beltline inner weatherstrip
Door beltline moulding removal
steps
D Door mirror (Refer to GROUP 51.)
6. Door beltline moulding
AA"DOOR OUTER OPENING WEATHERSTRIP
REMOVAL
Make a tool as shown in the illustration to remove the door
opening weatherstrip.
15 mm
4 mm
8 mm
Thickness
1mm
BODY - Door/Tailgate <Wagon> 42-45
"AADOOR OUTER OPENING WEATHERSTRIP
INSTALLATION
The clip colour identifies the left and right weatherstrips, so
be sure to use the colours so as to install correctly.
Item Identification colour
Front door Left White
Right Brown
Rear door Left Yellow
Right Blue
TAILGATE <Wagon> 42400030017
SERVICE SPECIFICATION
Item Standard value
Tailgate handle free play mm 1.5 - 5.5
SEALANT 42400050044
Waterproof film 3M ATD Part No.8625 or equivalent Ribbon sealer
MB990784 Ornament remover Removal of the tailgate trim
A
B
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: probe
BODY - Tailgate <Wagon> 42-46
Trouble symptom Reference page
Door lock mechanism does operate. 42-26.
TAILGATE FIT ADJUSTMENT
1. If the striker and the latch do not mesh properly, move
the striker forward or back or to the left or right to adjust.
2. If the clearance all the way around the tailgate is not
uniform when the tailgate is closed, adjust by moving
the tailgate hinges forward or back or to the left or right
until the clearance is uniform.
3. Check the contact between the upper tailgate damper
and the lower tailgate damper when the tailgate is closed.
If they do not contact properly, adjust by moving the upper
tailgate damper in the direction of the arrows.
TAILGATE HANDLE PLAY CHECK
1. Check that the tailgate handle play is within the standard
value range.
Standard value (B): 1.5 - 5.5 mm
2. If the play is outside the standard value range, open
the tailgate handle holder and adjust the contact condition
between the tailgate latch rod and the tailgate handle.
Upper tailgate dumper
Section A - A
Holder
Tailgate
handle
Rod
A
A
B
TAILGATE ASSEMBLY 42400110124
<Tailgate assembly>
D Tailgate fit adjustment (Refer to P.42-46.)
12 Nm
9 Nm
14 Nm
1
2
3
4
5
6
7
8
9
10
11
12
9
9
11
Adjustment of clearance around tailgate
Adjustment of tailgate step and tailgate
striker linkage
Tailgate assembly removal steps
D High-mounted stop lamp
1. Bumper
2. Washer hose
AA" 4. Tailgate gas spring
5. Tailgate side weatherstrip
6. Tailgate assembly
7. Upper tailgate dumper
8. Lower tailgate dumper
Tailgate striker removal steps
10. Rear end trim
11. Tailgate striker
Tailgate opening weatherstrip
removal steps
10. Rear end trim
"AA 12. Tailgate opening weatherstrip
Tailgate hinge removal steps
2. Washer hose
AA" 4. Tailgate gas spring
6. Tailgate assembly
D Headlining
9. Tailgate hinge
AA"TAILGATE GAS SPRING REMOVAL
Caution
1. Never try to disassemble the tailgate gas spring or
burn it.
2. Always bore a hole in the tailgate gas spring to release
the interior gas before the gas spring is discarded.
"AATAILGATE OPENING WEATHERSTRIP
INSTALLATION
Install the tailgate opening weatherstrip so that the marked
part is at the centre of the body.
TAILGATE TRIM AND WATERPROOF FILM 42400140048
NOTE
Sealant: 3M ATD Part No.8625 or equivalent
1
2
3
4
5
6
7
8
8
5
: Sheet metal clip position
Removal steps
1. Tailgate grip
2. Lower tailgate trim
3. Tailgate clip
4. Cover
5. Side tailgate trim
6. Rear roof rail trim
7. Tailgate trim bracket
8. Waterproof film
TAILGATE HANDLE AND LATCH 42400170054
D Tailgate Handle Free Play Check (Refer to P.42-46.)
1
2
3
4
5
6
9 Nm
1
6
Tail handle and lock key cylinder
removal steps
D Tailgate trim and waterproof film
(Refer to P.42-49.)
D Tailgate garnish
1. Tailgate handle
2. Cylinder lock retainer
3. Tailgate lock key cylinder
Tailgate latch removal steps
D Tailgate trim and waterproof film
(Refer to P.42-49.)
D Tailgate garnish
4. Tailgate lock actuator
5. Holder
6. Tailgate latch assembly
TAILGATE LOCK ACTUATOR CHECK
2 3
LOCK LOCK position UNLOCK
position
LOCK
UNLOCK
View A
A
BODY - Keyless Entry System 42-51
KEYLESS ENTRY SYSTEM 42800060032
SPECIAL TOOL
MB991502 MUT-II sub assembly Recording secret codes
Trouble symptom Inspection procedure No. Reference page
None of the doors can be locked or unlocked using the transmitter. 1 42-51
All of the doors can be locked and unlocked using the transmitter,
but the roomlamp does not flash or illuminate. (However, the room
lamp operates normally when the doors are opened and closed.)
2 42-53
Secret codes cannot be registered. 3 42-53
None of the doors can be locked or unlocked using the
transmitter.
Probable cause
The cause may be a malfunction of the transmitter, a malfunction of the receiver
or the lock and unlock signals are not being input to the ETACS-ECU.
D Malfunction of transmitter
D Malfunction of receiver
D Malfunction of key reminder switch
D Malfunction of door switch
NG
To next page
OK
Replace the transmitter battery. (Refer to P.42-55.)
Yes
Has the secret code been registered properly? *
NG
Re-register the secret code. (Refer to P.42-56.)
Can the doors be locked and unlocked by the drivers-side door
key cylinder and lock knob?
No
Check the centre door lock system.
NOTE
*: This should be done if a transmitter or receiver has been replaced, and if a secret code has not
been registered properly.
NG
Repair
NG
D Between receiver and earth
NG
Repair
OK
Replace the ETACS-
ECU.
NG
Repair
OK
Replace the transmitter.
NG
Replace the receiver.
NG
Check the harness wire.
D Between key reminder switch and receiver
D Between key reminder switch and ETACS-ECU
D Between key reminder switch and earth
NG
Repair
OK
OK
C-109, C-65, C-80
NG
Repair
OK
Key reminder switch continuity check (Refer to GROUP54 - Ignition
Switch.)
NG
Replace
NG
D Between ETACS-ECU and door switch
NG
Repair
OK
OK
E-19, E-08, G-16, G-09, G-32, G-28, C-65, C-143
NG
Repair
NG
D Between ETACS-ECU and receiver
OK
Door switch continuity check (Refer to P.42-32.)
NG
Replace
OK
OK
Measure at the receiver connector C-80.
D Disconnect the connector, and measure at harness side.
OK: Battery voltage
NG
Check the connectors:
C-80, C-138
OK
OK
OK: Continuity
NG
C-80, C-62
NG
Repair
NG
D Between ignition switch (ACC) and receiver
D Between fusible link No.2 and receiver
OK
OK: Battery voltage
NG
C-80, C-63, C-132, C-141, C-61, C-134, C-131
From previous page
All of the doors can be locked and unlocked using the
transmitter, but the room lamp does not flash or
illuminate. (However, the room lamp operates normally
when the doors are opened and closed.)
Probable cause
If the room lamp operates normally when the doors are opened and closed, the cause
of the problem may be a malfunction of the ETACS-ECU or a malfunction of the
drivers-side door lock actuator.
D Malfunction of drivers door lock actuator
D Malfunction of connector or wiring harness
OK
Drivers door lock actuator check (Refer to P.42-42.)
NG
Replace
Secret codes cannot be registered. Probable cause
The cause may be a malfunction of the diagnosis connector, a malfunction of the
power supply or earth circuit of the receiver, a malfunction of the ETACS-ECU or
a malfunction of the diagnosis output circuit.
D Malfunction of receiver
D Malfunction of MUT-II
D Malfunction of connector or wiring harness
NG
Repair
NG
D Between receiver and diagnosis connector
NG
Repair
NG
D Between fusible link No.2 and diagnosis connector
OK
NG
D Between diagnosis connector and earth
Yes
To next page
NG
Check the following
connector:
C-20
NG
Repair
OK
Measure at the diagnosis
connector C-14.
D Continuity between 4
and body earth
D Continuity between 5
and body earth
OK: Continuity
OK
Replace MUT-II.
OK
No
Measure at the diagnosis
connector C-20.
D Voltage between 16
and body earth
OK: Battery voltage
NG
C-20, C-66, C-63, C-132, C-141
OK
Can the MUT-II communicate with other systems?
OK
Measureat thediagnosis connector C-20 andthe receiver connector
C-80.
D Disconnect the connector, and measure at harness side.
D Continuity between following terminals:
OK: Continuity
7 <Receiver side> - 1 <Diagnosis connector side>
NG
C-20, C-66, C-80
NG
Repair
NG
D Between fusible link No.2 and receiver
D Between ignition switch and receiver
NG
Repair
NG
D Between receiver and earth
OK
Replace the receiver.
OK
OK
D Between 20 and body earth
OK: Continuity
NG
C-80, C-62
OK
OK: Battery voltage
NG
C-80, C-63, C-132, C-141, C-61, C-134, C-131
From previous page
INSPECTION OF RECEIVER TERMINAL VOLTAGE
Terminal Signal name Conditions Terminal voltage
2 Door switch Room lamp switch:
OFF or ON
One or more doors are
open (Door switch: ON)
0 V
All doors are closed
(Door switch: OFF)
5 V and pulse output*
Room lamp switch:
DOOR
One or more doors are
open (Door switch: ON)
0 V
All doors are closed
(Door switch: OFF)
Battery voltage
6 Door lock actuator LOCK 5 V and pulse output*
switch (drivers side)
UNLOCK 0 V
7 Diagnosis changeover When MUT-II is connected 0 V
input
When MUT-II is disconnected
(Ignition switch: ACC or OFF)
5 V and pulse output*
8 Key reminder switch OFF (When ignition key is inserted) 5 V and pulse output*
ON (When ignition key is removed) 0 V
9 Ignition switch Ignition switch: ACC or ON Battery voltage
Ignition switch: OFF 0 V
Terminal Signal name Conditions Terminal voltage
10 Receiver power supply At all times Battery voltage
11 Room lamp output All doors are closed
(Door switch: OFF)
Room lamp switch: OFF
or ON
0 V
Room lamp switch:
DOOR
Battery voltage
12 Door lock output When door lock control unit outputs signal, or
door lock switch: LOCK
0 V
Other than above Battery voltage
14 Door unlock output When door lock control unit outputs signal, or door
lock switch or door lock key cylinder: UNLOCK
0 V
Other than above Battery voltage
16 Driver identification
signal output (Vehicles
When keyless entry system is operating
(When transmitter switch is pressed)
5 V and pulse output
(fluctuation pulse)
with theft-alarm system)
When keyless entry system is not operating
(When transmitter switch is not pressed)
5 V and pulse output
(constant pulse)
20 Earth At all times 0 V
NOTE
Values marked with * should be measured using an oscilloscope. (The value will alternate between 0
V and 0.03 V if a circuit tester is used.)
HOW TO REPLACE A BATTERY OF THE
TRANSMITTER
1. Remove the set screw to remove the battery from the
transmitter.
2. Install a battery with its (+) side face-down.
Battery required for replacement:
Coin type battery CR2032
3. Insert the claw first, and with care not to displace the
O-ring, assemble the transmitter.
4. Check to see if the keyless entry system operates.
NOTE
(1) Do not let water or dust stick to the inside of the
transmitter when it is open. Also, do not touch the
precision electronic device.
(2) If the O-ring is displaced during the assembly of the
transmitter, water or dust penetrates in it causing
trouble.
Open
Battery
Claw
Screw
O-ring
SECRET CODE REGISTRATION METHOD 42800100109
Each individual secret code is registered inside
the transmitter, and so it is necessary to register
these codes with the EEPROM inside the receiver
in the following cases.
D When either the transmitter or receiver is
replaced;
D If a second transmitter is to be used;
D If it appears that a problemis occurring because
of faulty registration of a code.
A maximum of two different codes can be stored
in the memory area of the EEPROM (two different
transmitters can be used). When the code for the
first transmitter is registered, the previously-regis-
tered codes for two transmitters are cleared.
Therefore, if you are using two transmitters or are
adding a second transmitter, the codes for both
transmitters must be registered at the same time.
1. Check that the doors lock normally when the
key is used.
NOTE
This will connect terminal (1) of the diagnosis
connector to earth, and the system will be in
secret code registration standby mode.
Caution
AlwaysturntheignitionswitchtoOFFbefore
connecting and disconnecting the MUT-II.
3. Within 10 seconds after connecting the MUT-II,
turn the ignition switch to ACC ON for 1 second
and then to OFF for 1 second; repeat this
procedure three times.
NOTE
The doors will lock and unlock once at this
time and the system will switch to registration
mode.
4. Press the transmitter switch, and then press
it two times within 10 seconds of the first press.
This will register the code.
5. After registration is completed, the doors will
be automatically locked and unlocked once.
6. If you are using two transmitters or have added
a second transmitter, the same registration
procedure should be carried out for the second
transmitter, and it should be carried out within
one minute after registration of the code for
the first transmitter has been completed. After
the second registration is completed, the doors
will be automatically locked and unlocked once.
7. Registration mode will be cancelled under the
following conditions.
D When the secret codes for two transmitters
have been registered;
D When 1 minute has passed after
registration mode started;
D If the MUT-II is disconnected (the earth
connection is broken);
D If the ignition switch is turned to ON;
D If any of the doors are opened;
BODY - Keyless Entry System/Sunroof 42-57
KEYLESS ENTRY SYSTEM 42800130153
D Side Cover Removal and Installation (Refer to
GROUP 52A - Instrument Panel.)
Keyless entry receiver
ETACS-ECU
SUNROOF 42600030068
Roof lid glass operating current A 7 or less (at 20_C)
A
B
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
BODY - Sunroof 42-58
Trouble symptom Inspection procedure Reference page
Thesunroof does not operatewhenthe ignitionswitch is turned
to ON.
1 42-58
The motor does not reverse its direction when a load of 140 N
or more is applied while the sunroof is closing.
2 42-60
The timer does not operate for 30 seconds after the ignition
switch is turned to OFF.
3 42-60
Opening or closing of the sunroof is possible immediately after
turning the ignition switch to OFF, but the timer function does
not operate continuously for another 30 seconds if the drivers
side door is opened within 30 seconds.
4 42-60
The sunroof does not operate when the ignition switch is
turned to ON.
Probable cause
One of the following items may be defective.
D Sunroof switch
D Sunroof motor
D Sunroof-ECU
D Power supply circuit
D Earth circuit
D Malfunction of sunroof switch
D Malfunction of sunroof motor
D Malfunction of sunroof-ECU
OK
NG
Check the harness wire between igni-
tion switch (IG2) and sunroof-ECU, and
(2) NG
E-07, C-27, C-114
NG
Repair
OK
NG
Check the harness wire betweenfusible
link No. 3 and sunroof-ECU, and repair
if necessary.
NG
Check the harness wire between sunroof-ECU and
OK
Check sunroof switch continuity (Refer to P.42-66.)
NG
Repair
OK
Measure at the sunroof-ECU connector E-07.
OK: Continuity present when UP sunroof switch is on
OK: Continuity present when CLOSE/DOWN sunroof switch
is on
OK: Continuity present when OPEN sunroof switch is on
NG
E-07, E-04, C-133, C-131
NG
Repair
OK
NG
Check the harness wire between sun-
roof-ECU and sunroof switch, between
sunroof switch and the earth, and repair
if necessary.
OK
Check the sunroof motor. (Refer to P.42-66.)
Check limit switch continuity. (Refer to P.42-66.)
NG
Replace
OK
Measure at the sunroof motor connector E-03.
OK: Continuity
NG
E-03, C-133, C-131
NG
Repair
OK
NG
roof motor and the earth, and repair
if necessary.
OK
E-03, E-07
NG
Repair
OK
NG
roof-ECU and sunroof motor.
NG
Repair
OK
Replace the sunroof-ECU.
OK
(3) NG
E-07, C-133, C-131
NG
Repair
Measure at the sunroof-ECU connector E-07.
(1) Voltage between 6 and body earth
(2) Voltage between 7 and body earth
OK: System voltage
(3) Continuity between 17 and body earth
OK: Continuity
(1) NG
E-07, C-27, C-134, C-131
NG
Repair
The motor does not reverse its direction when a load of
140 N or more is applied while the sunroof is closing.
Probable cause
The sunroof-ECU monitors the load conditions from the amount of current flowing
to the motor. If more than the constant amount of current is flowing, the direction
of motor operation is reversed to prevent jamming.
If the motor does not reverse direction even when an excessive load is being applied,
the cause may be a malfunction of the sunroof-ECU.
The timer does not operate for 30 seconds after the
ignition switch is turned to OFF.
Probable cause
The sunroof-ECU has a timer function which operates for 30 seconds after the ignition
switch is turned to OFF. If the timer does not operate, the cause may be a malfunction
of the sunroof-ECU or of the wiring harness or connector.
Measure at the sunroof-ECU connector
E-07.
OK: System voltage
NG
C-27, C-114
NG
Repair
OK
OK
link No.3 and sunroof-ECU, and repair
if necessary.
NG
Opening or closing of the sunroof is possible immediately
after turning the ignition switch to OFF, but the timer
function does not operate continuously for another 30
seconds if the drivers side door is opened within 30
seconds.
Probable cause
The operation period for the sunroof timer is extended when an on signal is output
from the drivers-side door switch. Because of this, if the timer operation period is
not extended, the cause may be a malfunction of the door switch input circuit.
D Malfunction of the front door switch (drivers side)
Check front door switch (drivers side)
continuity. (Refer to P.42-32.)
NG
Replace
OK
E-19 or E-08, C-143, C-134, C-65, C-27,
E-07
NG
Repair
OK
NG
Check the harness wire between front
door switch (drivers side) and sunroof-
ECU.
NG
Repair
OK
TERMINAL VOLTAGE CHART
Terminal No. Check Item Check Condition Normal Condition
1 Sensor power supply Ignition switch: ON Battery voltage
2 Sensor 1 When motor is operating Battery voltage (pulse)
3 Sunroof switch (open Sunroof switch ON 0 V
input) (open position)
OFF Battery voltage
4 Sunroof switch (up input) Sunroof switch ON 0 V
(up position)
OFF Battery voltage
6 Timer operation power
supply
7 ECU power supply Always Battery voltage
8 Motor output While sunroof is closing or moving up Battery voltage
Other than the above 0 V
9 Sensor earth Always 0 V
10 Sensor 2 When motor is operating Battery voltage (pulse)
12 Sunroof switch (close or Sunroof switch (close ON 0 V
down) input position or down position)
OFF Battery voltage
14 Limit switch input From tilt up condition to fully-closed
condition
Battery voltage
From fully-closed condition to fully-open
condition
0 V
16 Door switch input Drivers door switch ON 0 V
OFF Battery voltage
17 Earth Always 0 V
18 Motor output While sunroof is opening or moving
down
Battery voltage
Other than the above 0 V
WATER TEST
Check if there are any leaks in the sunroof by the following
procedure.
1. Fully close the roof lid glass.
2. Adjust the water pressure so that water comes out of
the hose to a height of approximately 50 cm when the
hose is held vertically facing upwards.
3. Hold the end of the hose approximatery 30 cm above
the roof and let the water run onto the weatherstrip for
5 minutes or more.
4. While doing this, check if any water leaks through into
the passenger compartment fromaround the roof lid glass.
SUNROOF FIT ADJUSTMENT 42600100110
1. Fully close the roof lid glass.
2. Fully open the sunshade.
3. Loosen the roof lid glass assembly mounting screws (four
for sedans or six for wagons), and then slide the roof
lid glass assembly along the slot in the drive cable
assembly to adjust the height of the roof lid glass.
4. After adjustment, check to be sure that the sunroof
operates smoothly.
Hose
Apporox. 30cm
SUNROOF 42600120239
<Roof lid glass assembly, Sunroof assembly>
(1) Sunroof Water Test (Refer to P.42-62.)
(2) Sunroof Fit Adjustment (Refer to P.42-62.)
<Sedan>
1
2
3
4
6
7
8
9
10
11
13
7
1. Roof lid glass assembly
2. Roof wind deflector panel
Sunroof switch removal steps
3. Sunroof switch cover
4. Sunroof switch
Drain hose removal steps
D Splash shield (Front drain hose)
6. Headlining
AA" "BA 7. Drain hose
Sunroof-ECU removal steps
6. Headlining
8. Sunroof-ECU
Sunroof motor removal steps
6. Headlining
AB" "AA 9. Sunroof motor
Sunroof assembly removal steps
6. Headlining
7. Drain hose connection
10. Room lamp bracket
11. Sunroof switch bracket
13. Sunroof assembly
<Wagon>
1
3
4
5
6
7
8
9
10
11
12
13
NOTE
: indicates the sheet metal
clip position.
7
Sunroof switch removal steps
3. Sunroof switch cover
4. Sunroof switch
Drain hose removal steps
D Splash shield (Front drain hose)
6. Headlining
AA" "BA 7. Drain hose
Sunroof-ECU removal steps
6. Headlining
8. Sunroof-ECU
Sunroof motor removal steps
6. Headlining
AB" "AA 9. Sunroof motor
Sunroof assembly removal steps
6. Headlining
7. Drain hose connection
10. Room lamp bracket
11. Sunroof switch bracket
12. Set bracket
13. Sunroof assembly
AA"DRAIN HOSE REMOVAL
Tie a cord to the end of the drain hose, and wind tape around
the tie until it is smooth. Then pull the drain hose out from
the passenger compartment.
AB"SUNROOF MOTOR REMOVAL
Caution
Always close the roof lid glass fully before removing
the sunroof motor. If the fully-closed positions of the roof
lid glass and the sunroof motor are not the same, the
sunroof will not operate properly.
"AASUNROOF MOTOR INSTALLATION
If the fully-closed position of the sunroof motor is incorrect,
set the motor to the fully-closed position by the procedure
given below before installing the motor.
1. Connect a circuit analyser between terminals (5) and (6)
of the motor connector.
2. Operate the motor until the position is reached at which
continuity switches from on to off or from off to on, and
then install the motor.
"BADRAIN HOSE INSTALLATION
1. Tie the cord that was used during removal to the end
of the drain hose, and wind tape around it so that there
is no unevenness.
2. Pull the cord to pull through the drain hose
3. Make the protrusion from the drain hose grommet as
Drain hose
Cord
Cord
Drain hose
Grommet
20- 30 mm
ROOF LID GLASS OPERATION CURRENT CHECK
1. Remove the sunroof fuse and connect a circuit analyser
2. Press the sunroof switch to the ON position, and then
measure the operation current in the intervals between
the points when the sunroof starts to operate, when it
is fully open, when it is fully closed and when it is fully
tilted up.
Standard value: 7 A or less (at 20_C)
3. If the operation current is outside the standard value,
check the following points.
D Installation condition, warping or jamming of sunroof
assembly
D Sticking of drive cable
D Tilt of roof lid glass
SUNROOF MOTOR CHECK
Check the direction of rotation of the drive gear when the
battery is connected to the connector.
Battery connection terminal Drive gear rotation
1 4
direction
Right
Left
LIMIT SWITCH CONTINUITY CHECK
Remove the limit switch from the sunroof motor, and then
check the operation of the limit switch.
Switch Terminal No.
5 6
Limit switch ON
OFF
SUNROOF SWITCH CONTINUITY CHECK
3 4 5 6
Slide open
Off
Tilt up
Slide close, Tilt down
Left rotation
Drive gear
Right rotation
ON
OFF
<Sedan>
1
2
3
4
5
6
7
8
9
10
11
12
13
11
13
Disassembly steps
2. Weatherstrip
3. Sunroof motor
5. Guide block
6. Roof drip channel
7. Panel stopper
8. Sunshade assembly
9. Guide rail stopper
10. Rail sub assembly
11. Housing sub assembly
12. Side deflector
13. Drive cable assembly
<Wagon>
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
11
15
Disassembly steps
2. Weatherstrip
3. Sunroof motor
5. Roof drip channel
6. Panel stopper
7. Sunshade assembly
8. Guide rail stopper
9. Cable guide casing
10. Side deflector
11. Drive cable assembly
12. Seal
13. Seal
14. Clamp
15. Guide rail sub assembly
51-1
EXTERIOR
SEALANT AND ADHESIVE 2 . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 2 . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BUMPER 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BUMPER 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR GRILLE 7 . . . . . . . . . . . . . . . . . . . . . . . .
ROOF RAIL 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOULDINGS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AERO PARTS 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD WIPER AND WASHER 12 . . . . . .
REAR WIPER AND WASHER 15 . . . . . . . . . . . . .
HEADLAMP WASHER 18 . . . . . . . . . . . . . . . . . . . .
MARKS 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR MIRROR 22 . . . . . . . . . . . . . . . . . . . . . . . . . .
EXTERIOR - Service Specifications/Sealant and Adhesive/Special Tools 51-2
Windshield wiper blade installation position mm Drivers side 35 5
Passengers side 205
Rear wiper blade installation position mm 155
SEALANT AND ADHESIVE 51100050177
Items Specified sealant and adhesive
Side protect moulding to body panel Adhesive tape: double-sided tape <(10 mm width and 0.8 mm thickness>)
Side sill cover to body panel Adhesive tape: double-sided tape (5 mm width and 0.8 mm thickness)
MB990784 Ornament remover Removal of bumper mounting clips (front and
rear) and door mirror control switch
MB990449 Window moulding
remover
Removal of roof drip moulding, etc.
EXTERIOR - Front Bumper 51-3
FRONT BUMPER 51100140201
D Splash Shield Removal and Installation
(Refer to GROUP 42 - Fender.)
D Radiator Grile Removal and Installation
(Refer to P.51-7.)
1
2
4
3
5
3
Removal Steps
1. Fog lamp bezel
2. Fog lamp
AA" 3. Clip
4. Front bumper assembly
5. Front bumper reinforcement assembly
AA"CLIP REMOVAL
(1) Use the special tool to pull up the centre pin in the clip.
(2) Remove the clip.
MB990784
Pin
MB990784
Clip
EXTERIOR - Front Bumper 51-4
3
6
2
5
4
1
Disassembly steps
1. Dynamic damper assembly <except
vehicles with 6A1 engine>
2. Fog lamp hole cover
3. Licence plate bracket
AA" 4. Clip
5. Front bumper upper reinforcement
6. Front bumper face
AA"CLIP REMOVAL
MB990784
Pin
MB990784
Clip
EXTERIOR - Rear Bumper 51-5
REAR BUMPER 51100190220
D Trunk Rear Trim (side, centre), Side Tray Removal
and Installation <Sedan>
(Refer to GROUP 52A - Trims.)
D Quarter Lower Trim Removal and Installation
<Wagon> (Refer to GROUP 52A - Trims.)
D Lower Tailgate Damper Removal and Installation
<Wagon> (Refer to GROUP 42 - Tailgate.)
<Sedan>
Rear bumper assembly
<Wagon>
Rear bumper assembly
EXTERIOR - Rear Bumper 51-6
<Sedan>
1
2
<Wagon>
1
1
1
1
1
1
4
6
5
7
3
5
7
3
1
4
2
Disassembly steps
AA" 1. Clip
2. Side upper bracket
3. Rear bumper reinforcement
4. Side retainer
5. Rear bumper lower plate
6. Muffler cutter cover
7. Rear bumper face
AA"CLIP REMOVAL
MB990784
Pin
MB990784
Clip
EXTERIOR - Radiator Grille/Roof Rail 51-7
RADIATOR GRILLE 51100280026
RADIATOR GRILLE REMOVAL
Remove the radiator grille by pushing the tab of the radiator
grille clips in the direction of the arrows with a flat-tipped
screwdriver, while lightly pulling the radiator grille towards
you.
ROOF RAIL 51101660010
Roof rail
EXTERIOR - Mouldings 51-8
MOULDINGS 51100470157
2
<Sedan>
<Wagon>
1
6
3
6
4
5
1
2
6
AA" "AA 1. Roof drip moulding
2. Windshield upper moulding
(Refer to GROUP 42 - Windshield.)
3. Belt line moulding (Refer to
GROUP 42.)
4. Rear window moulding, upper (Refer
to GROUP 42 - Rear Window Glass.)
5. Rear window moulding, lower (Refer
to GROUP 42 - Rear Window Glass.)
AB" "BA 6. Side protect moulding
Adhesive tape: double-sided tape <A (10 mm width and 0.8 mm thickness) B, C (0.8 mm thickness)>
B
A
C
B
C
f 10
71 mm
40 mm 35 mm
f 10
73 mm
AA"ROOF DRIP MOULDING REMOVAL
Caution
reused.
AB"SIDE PROTECT MOULDING REMOVAL
1. Attach protection tape all the way along the edges of
the double-sided tape which is still adhering to the body.
MB990449
Protection tape
Double-sided tape
2. Use a resin spatula to scrape off the double-sided tape.
3. Peel off the protection tape.
4. Wipe the body surface and clean it with a rag moistened
with isopropyl alcohol.
"BASIDE PROTECT MOULDING INSTALLATION
Double-sided tape affixing to the side protect moulding
(when reusing)
1. Scrape off the double-sided tape with a resin spatula
or gasket scraper.
2. Wipe off the side protect moulding adhesion surface and
clean it with a shop towel moistened with isopropyl alcohol.
3. Affix the specified double sided tape to the side protect
moulding.
Specified adhesive tape:
Double-sided tape
A: 10 mm width and 0.8 mm thickness
B, C: 0.8 mm thickness
4. Remove strip paper from the pressure sensitive
double-sided tape.
NOTE
Affix double-sided tape to the end of strip paper for ease
of strip paper removal.
5. Install the side protect moulding.
NOTE
If it is hard to affix the double-sided tape in winter, heat
the application surfaces at both the vehicle body and
the side protect moulding.
Body 40- 60_C
Side protect moulding 20 - 30 _C
Apply pressure fully to the side protect moulding.
Double-sided tape
EXTERIOR - Mouldings/Aero Parts 51-11
"AAROOF DRIP MOULDING INSTALLATION
Install the clip to the roof drip moulding before installing the
moulding to the vehicle body.
AERO PARTS 51100500184
Adhesive tape: double-sided tape (5 mm
width and 0.8 mm thickness)
1
1
AA" "AA 1. Side sill cover
AA"SIDE SILL COVER REMOVAL
Remove the side sill cover in the same manner as for the
side protect moulding (Refer to P.51-8).
"AASIDE SILL COVER INSTALLATION
Install the side sill cover in the same manner as for the side
protect moulding (Refer to P.51-8).
EXTERIOR - Windshield Wiper and Washer 51-12
WINDSHIELD WIPER AND WASHER 51100760261
13 Nm
Section A - A
Clip
4
3
2
5
5 Nm
A
A
7
6
9 Nm
9
12
11
10 8
8
5
1
1. Column switch assembly
2. Washer hose
3. Washer nozzle assembly
Wiper motor and linkage removal
steps
"AA 4. Wiper arm and blade assembly
5. Front deck garnish
AA" 6. Wiper motor
7. Linkage
Washer tank removal steps
D Draining washer fluid
D Front bumper (Refer to P.51-3.)
8. Washer hose
9. Washer tank
10. Washer motor (front)
11. Washer motor (rear)
12. Washer motor <vehicles with
headlamp washer>
AA"WIPER MOTOR REMOVAL
Loosen the wiper motor assembly mounting bolts, and then
remove the wiper motor assembly. Disconnect the linkage
and the motor assembly, and then remove the linkage.
Caution
Because the installation angle of the crank arm and the
motor has been set, do not remove them unless it is
necessary to do so. If they must be removed, remove
them only after marking their mounting positions.
"AAWIPER ARM AND BLADE ASSEMBLY
INSTALLATION
Install the wiper blade in the specified position (standard value)
Standard value (A):
<Drivers side> 35 5 mm
<Passengers side> 20 5 mm
COLUMN SWITCH CHECK
Wiper and Washer Switch
6 7 8 9 10
Wiper switch OFF
INT
1 (LO)
2 (HI)
Washer switch ON
Wiper motor
Crank arm
Linkage
Front deck garnish end
A A
8 9 10 11 12
Wiper switch OFF
INT
1 (LO)
2 (HI)
Washer switch ON
Intermittent Wiper Relay (Intermittent Operation
Inspection)
1. Connect the column switch connector.
2. Turn the ignition switch to ACC.
3. Inspect the intermittent operation time when the wiper
switch is turned to INT.
Vehicles with variable intermittent control
FAST: Approx. 2 seconds
SLOW: Approx. 15 seconds
WIPER MOTOR CHECK 51101260104
Check the wiper motor after disconnecting the wiring harness
connector, and with the wiper motor remaining installed to
the body.
Wiper Motor at Low Speed and High Speed Operation
Connect a battery to the wiper motor as shownin theillustration
and inspect motor operation at low speed and high speed.
Wiper Motor at Stop Position Operation
1. Run the wiper motor at low speed, disconnect the battery,
and stop the motor.
2. Reconnect the battery as shown in the illustration, and
confirm that after the motor starts turning at low speed,
it stops at the automatic stop position.
WASHER MOTOR CHECK 51101270107
1. With the washer motor installed to the washer tank, fill
the washer tank with water.
2. Check that the water squirts out strongly when battery
voltage is applied to terminals (1) and (2).
Inspection while operating
Battery
Inspection while stopped
Low speed
Automatic stop
Battery
Low speed
High speed
EXTERIOR - Rear Wiper and Washer 51-15
REAR WIPER AND WASHER 51100850159
9.8 Nm
4
5
2
<Sedan>
7.4 Nm
7.4 Nm
<Wagon>
9.8 Nm
<Wagon>
8
3
1
9
12
8
11
2
6
8
1
11
10
7
12
Wiper motor assembly removal
steps
1. Cover
2. Wiper arm and blade assembly
3. Shield cap
4. Cover
5. Nozzle collar assembly
6. Packing and washer <Wagon>
7. Tailgate trim (Refer to group 42.)
8. Wiper motor and bracket assembly
9. Packing and washer <Sedan>
Rear washer hose removal steps
D Scuff plate, quarter trim, quarter upper
trim, beltline trim (Refer to GROUP
52A.)
D Front seat, rear seat (Refer to GROUP
52A.)
10. Washer nozzle
11. Washer hose
Rear intermittent wiper relay removal
7. Tailgate trim (Refer to GROUP 42.)
12. Rear intermittent wiper relay
NOTE
1. *: For washer tank (Refer to P.51-12.)
2. For removal and installation of the column switch
assembly (windshieldwiper andwasher switch), refer
to GROUP 37A - Steering Wheel and Shaft.}
"AAWIPER ARM AND BLADE ASSEMBLY
INSTALLATION
<Sedan>
Install the wiper armto the pivot shaft so that the wiper blades
stop position is the position (standard value) shown in the
illustration.
Standard value (A): 15 5 mm
<Wagon>
Install the wiper arm by aligning the blade with the marking
position.
WIPER MOTOR CHECK
Check the wiper motor after first disconnecting the wiring
harness connector, and with the wiper motor remaining
installed to the body.
Wiper Motor Operation
Connect a battery to the wiper motor as shownin theillustration
and inspect the motor operation.
Wiper Motor at Stop Position Operation
1. Run the wiper motor, disconnect the battery, and stop
the motor.
2. Reconnect the battery as shown in the illustration, and
confirm that after the motor starts turning, it stops at the
automatic stop position.
<Sedan>
Glass end line
<Wagon>
Marking position
Operation check
Battery
Stop position check
Battery
REAR INTERMITTENT WIPER RELAY CHECK
51101300066
1. Apply battery voltage to terminal 4, and earth the terminal
7.
2. Measure voltage according to the table below.
Measurement requirement Terminal number 2
Apply battery voltage to terminal 6. Battery voltage
Apply battery voltage to terminal 5. Battery voltage generates
every approx. eight seconds.
Apply battery voltage to terminal 8. Battery voltage generates
after approx. one second.
3. Check that there is continuity between terminals 1 and
2.
COLUMN SWITCH (WIPER AND WASHER)
CHECK 51100950057
2 3 4 10, 8*
Wiper switch INT
ON
Washer switch ON
NOTE
*: R.H. drive vehicles
WASHER MOTOR CHECK 51101310083
2. Check that washer fluid sprays strongly when battery
voltage is applied to terminal 2 and terminal 1 is earthed.
Rear intermittent
wiper relay
EXTERIOR - Headlamp Washer 51-18
HEADLAMP WASHER 51100970107
4.9 Nm
1
4.9 Nm
6
5
4
3
4
4
4
2
5
6
2
4
1. Headlamp washer relay
Nozzle, check valve and joint
removal steps
D Draining of washer fluid
D Front bumper (Refer to P.51-3.)
2. Check valve
3. Joint
4. Washer hose assembly
5. Collar
6. Nozzle
NOTE
1. For removal and installation of the column switch
assembly (built-in headlamp washer switch), refer to
GROUP 37A - Steering Wheel and Shaft.
2. For removal and installation of the washer tank, refer
to P.51-12.
HEADLAMP WASHER RELAY CHECK
1. Connect battery and test lamp to the relay as illustrated.
Headlamp
washer relay
STEP 1
Test lamp
EXTERIOR - Headlamp Washer 51-19
2. The relay is normal if the lamp lights for approximately
0.5 second upon connection of terminal (2) to battery
( - ).
COLUMN SWITCH (HEADLAMP WASHER SWITCH)
CHECK 51100980063
Check the continuity between terminal 2 of connector A and
terminal 1 of connector B with headlamp washer switch in
ON position.
CHECK VALVE CHECK 51101330058
Apply pressure to the inlet of the check valve to check its
opening pressure.
Opening pressure: 78 kPa
HEADLAMP WASHER MOTOR CHECK 51101340051
2. Connect battery (+) and ( - ) cables to terminals (1) and
(2) respectively to see that the washer motor runs and
water is injected.
STEP 2
Test lamp
Connector A
Connector B
EXTERIOR - Marks 51-20
MARKS 51101180110
<Sedan> <Wagon>
1
2
2
1
"AA 1. Mitsubishi mark
"AA 2. Grade mark
"AAINSTALLATION OF MARKS
1. APPLICATION POSITION
MITSUBISHI mark
<Sedan> <Wagon>
Trunk lid end line
Trunk lidpress line
Tailgate end line
35 mm
30 mm 7 mm
12 mm 7 mm
24 mm
26.6 mm
EXTERIOR - Marks 51-21
Grade mark
<Sedan>
GLS (also applicable to GLX and V6-24)
Trunk lid press line Trunk lid end line
Trunk lid press line Trunk lid end line
<Wagon>
GLS (also applicable to GLX and V6-24)
Tailgate end line Tailgate end line
35 mm
15 mm
28 mm 24 mm 26.9 mm
15 mm
35 mm
35 mm
35 mm
24 mm
21 mm
GLS TD
GLS TD
21 mm
2. INSTALLATION PROCEDURE
(1) Clean the mark installation surfaces on the body with
unleaded petrol.
(2) Peel off the backing paper from the reverse side of the
marks, and then attach the marks to the vehicle body
so that they fit properly into position.
Caution
When attaching the marks, the surrounding
temperature should be 20- 38_C and the air should
be completely free from dust.
If the surrounding temperature is lower than 20_C,
the marks and the places on the body where the marks
are to be attached should be heated to 20- 38_C.
EXTERIOR - Door Mirror 51-22
DOOR MIRROR 51100640121
1
3
6
5
7
5
6
3
2
7
2
4
1. Door mirror control switch
Door mirror removal steps
2. Door trim attaching screw
3. Delta cover inner
4. Boot
5. Door mirror
6. Delta cover base
AA" 7. Mirror
AA"MIRROR REMOVAL
Let the mirror face up, insert a flat-tipped screwdriver wound
with masking tape, and remove the mirror by releasing the
spring from the hook.
Spring
Hook
EXTERIOR - Door Mirror
Printed
heating
wire
51-23
REMOTE CONTROL MIRROR ASSEMBLY CHECK
1. Check to be sure that the mirror moves as described
in the table when each terminal is connected to the battery.
2. For printed heater, check the continuity between terminals
1 and 4.
Battery connection terminal Direction of operation
5 6 7 1 4
UP
DOWN
RIGHT
LEFT
DOOR MIRROR CONTROL SWITCH CONTINUITY CHECK
51101350061
2 3 4 6 7 8 9
Left side UP
DOWN
LEFT
RIGHT
Right side UP
DOWN
LEFT
RIGHT
SWITCH AND RELAY OF DOOR MIRROR
PRINTED HEATING WIRE CHECK 51101360019
The printed heating wire of the door mirror operates in
conjunction with the rear window defogger.
The switch and relay are used for the rear window defogger
also, so refer to GROUP 54 for inspection service points.
NOTES
INTERIOR 52A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 52B . . . . . . . . . . . . . . . . . . . . .
52A-1
INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
52A-2
INTERIOR
SPECIAL TOOL 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL* 3 . . . . . . . . . . . . . . . . . . . . . .
FLOOR CONSOLE 7 . . . . . . . . . . . . . . . . . . . . . . . . .
TRIMS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSIDE REAR VIEW MIRROR 11 . . . . . . . . . . . . . .
FRONT SEAT* 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SEAT 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SEAT BELT 19 . . . . . . . . . . . . . . . . . . . . . .
REAR SEAT BELT 20 . . . . . . . . . . . . . . . . . . . . . . .
WARNING!
MITSUBISHI dealer.
component.
NOTE
INTERIOR - Service Specifications/Special Tool/Instrument Panal 52A-3
Seatback heater resistance (between terminals) W Approx. 8
Seat cushion heater resistance (between terminals) W Between terminals 2 and 3 Approx. 8
Between terminals 1 and 2 0
MB990784 Ornament remover Removal of switch, trim, etc.
INSTRUMENT PANEL 52100170252
For installation of the instrument panel, the bolts and screws described below are used. They are indicated
by symbols in the illustration.
Name Symbol Size mm (D L) Colour Shape
Tapping screw A 512 -
B 514 -
C 516 -
D 425 Black
E 512 -
F 520 -
Washer-assembled screw G 516 -
H 520 -
Washer-assembled bolt I 616 -
J 620 -
D = Thread diameter
L = Effective thread length
INTERIOR - Instrument Panel 52A-4
CAUTION: SRS
For the passenger side air bag module
removal/installation, always observe the service
procedures of GROUP 52B - Air Bag Module and
Clock Spring.
1
C
NOTE
: metal clip position
<Manual air conditioner>
<Automatic air conditioner>
A
3
4
5
2
6
8
D
9
10
12
11
13
19
21
20
16
18
22
14
B
16
23
15
17
F
F
H
C
C
C
7
Removal steps
2. Switch bezel
3. TCL switch or auto-cruise control main
switch
4. TCL switch or plug
5. Headlamp leveling switch
6. Lower cover
7. Column cover
8. Meter bezel
9. Combination meter
10. Door mirror control switch
11. Fog lamp switch
12. Side air outlet assembly (L.H.)
AA" 13. Center air outlet assembly
14. Side air outlet assembly (R.H.)
15. Ashtray
D Floor console panel
(Refer to P.52A-7.)
16. Centre console panel
17. Sunglasses box
18. Radio and tape player
19. Heater control assembly (Refer to
GROUP 55 - Manual air conditioner.)
20. Rear window defogger switch
21. A/C switch
22. Inside/Outside air changeover
switch
23. Air conditioner control panel and ECU
assembly
12 Nm
12 Nm
Standard bolt Earth bolt
22 Nm
24
30
A
I
NOTE
29
29
25
I I
I
J
G
27
26
G
J
32
31
H
C
28
G
I
I
C
24. Centre display bezel
25. Clock
26. Glove box
D Under cover (Refer to GROUP 55 -
Ventilators.)
27. Side cover
28. Glove box frame
29. Steering mounting bolts
30. Front passengers side air bag
module (Refer to GROUP 52B.)
D Floor console box (Refer to P.52A-7.)
31. Corner panel
32. Instrument panel assembly
Caution
One of the steering shaft assembly mounting bolts
must be the earth bolt. The earth bolt has a E
mark on its head.
AA"CENTER AIR OUTLET ASSEMBLY REMOVAL
Refer to GROUP 54 - Hazard warning lamp switch.
3
E
E
1
2
8
9
7
6
I
I
5
I
I
I
I
I
4
I
I
I
Disassembly steps
D Heater ducts (Refer to GROUP 55.)
1. Photo sensor (Refer to GROUP 55.)
2. Defroster garnish
3. Instrument panel wiring harness
4. Instrument panel lower drivers side
bracket
5. Center reinforcement
6. Console bracket
7. Instrument panel lower passengers
side bracket
8. Passengers side air bag rear
bracket
9. Air bag reinforcement assembly
INTERIOR - Floor Console 52A-7
FLOOR CONSOLE 52100220193
3
NOTE
<Vehicles without
heated seat>
<Vehicles with
heated seat>
2
2
4
1
8
6
5
7
Removal steps
1. Floor console panel
2. Cup holder assembly
3. Heated seat switch
4. Floor console box
5. Floor console
6. Ashtray
7. Console bracket B
8. Console bracket A
INTERIOR - Trims 52A-8
TRIMS 52100110292
Clip
Clip
C
C
B
B
3
A
A
44 Nm
<Sedan>
NOTE
: resin clip position
For door trim, refer to GROUP 42.
Section A - A
Scuff plate
Clip
Section B - B
Front pillar
trim
Section C - C
Trim
Section D - D
Trim
C
C
1
5
2
9
8
7
6
4
D
D
C C
1. Front scuff plate
2. Rear scuff plate
3. Cowl side trim
4. Front pillar trim
5. Center pillar lower trim
6. Center pillar upper trim
7. Rear pillar trim
8. Rear shelf trim
9. Shelf front cover
<Sedan>
Section E - E
Rear end
trim cover
Clip
10
12
E
E
13
14
12
15
16
11
17
NOTE
10. Trunk side trim
11. Corner plate
12. Trunk rear side trim
13. Rear end trim cover
14. Trunk rear center trim
15. Side tray
16. Under tray
17. Trunk lid trim
Trim
Clip
For door trim, refer to GROUP 42.
Section I - I Section H - H
C
C
B
B
4
44 Nm
<Wagon>
Section A - A
Scuff plate
Clip
Section B - B
Front pillar
trim
Section C - C Section F - F
Trim
Clip
Section G - G
Trim
Clip
Trim, Lid
Clip
Clip
Trim
I
I
6
13
12
14
13
10
15
11
10
16
9
7
F
F
G
G
C
C
C
C
5
1
4
3
A
A
8
11
H
H
H
H
C
C
2
C
C
H
H
NOTE
1. Front scuff plate
2. Rear scuff plate
3. Cowl side trim
4. Front pillar trim
5. Center pillar lower trim
6. Center pillar upper trim
7. Quarter upper trim
8. Retractor trim
9. Belt line trim
10. Quarter lower trim
11. Maintenance lid
12. Rear end trim
13. Luggage under floor side trim
14. Luggage under floor centre box
15. Utility box lid
16. Shelf holder
INTERIOR - Inside Rear View Mirror/Front Seat 52A-11
INSIDE REAR VIEW MIRROR 52100270105
Remove by pushing in the direction of the arrow in the
illustration.
NOTE
1. The mirror spring fits firmly in the groove of the button
that is attached to the glass.
2. The mirror breaking load is within 450 N.
FRONT SEAT 52200130222
Caution: SRS
Before removal of the seat equipped with the side air bag module, refer to GROUP 52B - SRS Service
Precautions and Air Bag Module.
44 Nm
44 Nm
29 Nm
1
3
44 Nm
44 Nm
29 Nm
2
4
3
3
2
3
4
3
D Cup holder assembly <Vehicles with
heated seat> (Refer to P.52A-7.)
1. Heated seat switch
<vehicles with heated seat>
2. Headrestraint
Front seat assembly removal steps
D Harness connector
3. Seat anchor cover
4. Front seat assembly
NOTE
After provisionally tightening the seat assembly mounting
nuts and bolts in every installation location, fully tighten
them to the specified torque.
Spring
Button
INTERIOR - Front Seat 52A-12
HEATED SEAT SWITCH CONTINUITY CHECK
1 3 4 5 - 8 9 2 - 6
Drivers
seat
switch
HI
LO
Passen-
gers seat
switch
HI
LO
NOTE
To inspect the diode, match the polarity of the circuit tester with
the (+) (- ) polarities in the table.
SEATBACK HEATER CHECK
Measure the resistance between terminals.
Standard value: Approx. 8 W
SEAT CUSHION HEATER CHECK
Measure the resistance between terminals.
Standard value:
Between terminals 2 and 3: Approx. 8 W
Between terminals 1 and 2: 0 W
Caution
Do not disassemble the front seatback assembly
with built-in side air bag module.
44 Nm
13 Nm
<Normal seat>
Seat without height adjuster
Seat with height adjuster
21 Nm
13
17
16
18
12
9
10
11
44 Nm
44 Nm 14
5
1
2
21
8
20
14
6
7
3
4
2
1
5
14
44 Nm
20
13 Nm
21 Nm
7
14
6
21
8
15
14
19
Disassembly steps
1. Reclining adjuster knob
2. Slide adjuster knob
3. Clip
4. Height adjuster knob
5. Front seat side shield cover
6. Front seat hinge cover
7. Inner seat belt
8. Bolt
9. Front seat cushion assembly
10. Front seat cushion cover
11. Front seat cushion frame
AA" 12. Front seatback panel
13. Front seatback assembly
14. Cap
15. Lumbar support lever
16. Headrestraint guide
17. Front seatback cover
18. Front seatback frame
19. Seat heater harness
20. Seat adjuster assembly
21. Wire
44 Nm
<Power seat>
21 Nm
13
17
14
18
12
9
10
11
8 6
7
5
1
4
22
3
2
21 Nm
21 Nm
23
19 20
21
24
16
15
Disassembly steps
1. Front seat side shield cover
2. Front seat hinge cover
3. Inner seat belt
4. Bolt
5. Front seat cushion assembly
6. Front seat reclining adjuster lever
7. Front seat slide adjuster lever
8. Garnish
9. Power seat switch
10. Front seat cushion cover
11. Front seat cushion pad
12. Front seat cushion frame
AA" 13. Front seatback panel
14. Front seatback assembly
15. Cap
16. Lumbar support lever
18. Front seatback cover
19. Front seatback pad
20. Front seatback frame
21. Reclining adjuster lower cover
22. Seat heater harness
23. Power seat harness
24. Power seat adjuster assembly
AA"FRONT SEATBACK PANEL DISASSEMBLY
1. Using a screwdriver or similar tool, push inward the clip
of the front seatback panel lower portion to remove it.
2. Pull down the front seatback panel to remove it.
POWER SEAT SWITCH CONTINUITY CHECK
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Reclining switch Forward*
1
/
Backward*
2
Backward*
1
/
Forward*
2
Slide switch Forward*
1
/
Backward*
2
Backward*
1
/
Forward*
2
Front height switch*
1
/
Rear height switch*
2
Up
Down
Rear height switch*
1
/
Front height switch*
2
Up
Down
NOTE
*
1
: Power seat switch (R.H.)
*
2
: Power seat switch (L.H.)
Clip
Front seatback panel
Reclining switch
Slide and
height switch
POWER SEAT MOTOR OPERATION CHECK
Inspect the operation of each motor according to the following
procedures.
1. Disconnect the connector for each motor.
2. When the battery is connected directly to the motor
terminals, check if the motors run smoothly, and check
if each setting mechanism runs in the direction shown
in the table below for each motor.
3. If there is an abnormality, replace the power seat adjuster
assembly.
Name of Direction of Terminal No. Stop position
motor operation
1 2 3 4
Front/Rear Down Stop at
height
Up
operating
range limit.
Slide Backward
Forward
Reclining Backward
Forward
Rear height
motor connector
Slide
motor
connector
Reclining
motor
connector
Front height
motor connector
INTERIOR - Rear Seat 52A-17
REAR SEAT 52200180258
22 Nm
2
22 Nm
29 Nm
1
7
4
6
3
5
Removal steps
AA" "CA 1. Seat cushion
"BA 2. Seatback (R.H.)
"BA 3. Seatback (L.H.)
"AA 4. Side seatback (R.H.)
"AA 5. Side seatback (L.H.)
6. Headrestraint
7. Armrest
AA"SEAT CUSHION REMOVAL
While keeping the rear seat stopper pulled, lift up the seat
cushion to remove it.
"AASIDE SEATBACK (L.H.)/SIDE SEATBACK (R.H.)
INSTALLATION
Push the side seatback in the direction indicated in the
illustration; then securely attach the attachment wire to the
body side hook and install the side seatback.
Rear seat stopper
Side seatback
Hook
Attachment wire
INTERIOR - Rear Seat 52A-18
"BASEATBACK (L.H.)/SEATBACK (R.H.)
INSTALLATION
Put the seatback (R.H.) hinge bracket upon the seatback
(L.H.) hinge bracket.
"CASEAT CUSHION INSTALLATION
1. Pull the rear seat belt on top of the seat cushion.
2. Insert the seat cushion attachment wire securely below
the seatback.
3. Insert the seat cushion lock plate securely into the floor
holes.
10
11
7
8
5
4
3
1
2
7
8
9
4
5
3
10
11
6
9
Disassembly steps
1. Seat cushion cover
2. Seat cushion pad*
3. Seatback panel
5. Unlock knob
6. Armrest
7. Seatback cover
8. Seatback pad*
9. Seatback frame
10. Side seatback cover
11. Side seatback pad*
NOTE
*: Vehicles with front power seat
Seatback (R.H.)
hinge bracket
Seatback (L.H.)
hinge bracket
Rear seat belt
Lock plate
Attachment wire
INTERIOR - Front Seat Belt 52A-19
FRONT SEAT BELT 52300130225
44 Nm
1
44 Nm
44 Nm
2
3
4
Outer seat belt removal steps
1. Outer seat belt (seat belt with pre
tensioner) (Refer to GROUP 52B.)
2. Center pillar trim upper
3. Adjustable seat belt anchor
Inner seat belt removal steps
D Front seat assembly
D Front seat hinge cover
(Refer to P.52A-13, 14.)
4. Inner seat belt
INTERIOR - Rear Seat Belt 52A-20
REAR SEAT BELT 52300160194
2
44 Nm
1
3
2
44 Nm
44 Nm
Removal steps
D Rear seat (Refer to P.52A-17.)
1. Rear center seat belt assembly
2. Rear seat belt assembly (inner)
D Rear shelf trim <Sedan>
(Refer to P.52A-8.)
D Retractor trim <Wagon>
3. Rear seat belt assembly (outer)
52B-1
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
SRS SERVICE PRECAUTIONS 4 . . . . . . . . . . . . . .
SPECIAL TOOLS 7 . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST EQUIPMENT 8 . . . . . . . . . . . . . . . . . . . . . . . . .
SRS MAINTENANCE 21 . . . . . . . . . . . . . . . . . . . . .
POST-COLLISION DIAGNOSIS 25 . . . . . . . . . . . .
INDIVIDUAL COMPONENT SERVICE 28 . . . . . .
WARNING/CAUTION LABELS 29 . . . . . . . . . . . . .
SRS AIR BAG CONTROL UNIT
(SRS-ECU) 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BAG MODULES AND CLOCK
SPRING 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE IMPACT SENSOR 38 . . . . . . . . . . . . . . . . . .
SEAT BELT WITH PRE-TENSIONER 40 . . . . . .
AIR BAG MODULE AND SEAT BELT
PRE-TENSIONER DISPOSAL
PROCEDURES 42 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Undeployed Air Bag Module and Seat Belt
Pre-tensioner Disposal 42 . . . . . . . . . . . . . . . . . . . . . . .
Deployed Air Bag Module or Operated Seat Belt
Pre-tensioner Disposal Procedures 49 . . . . . . . . . . . .
CAUTION
D Carefully read and observe the information in the SERVICE PRECAUTIONS (P.52B-4.) prior to any service.
D For information concerning troubleshooting or maintenance, always observe the procedures in the Troubleshooting
(P.52B-8.) section.
D If any SRS components are removed or replaced in connection with any service procedures, be sure to follow the
procedures in the INDIVIDUAL COMPONENT SERVICE section (P.52B-28.) for the components involved.
D If you have any questions about the SRS, please contact your local distributor.
SRS - General Information 52B-2
To improve safety, the SRS and seat belts with
pre-tensioner are available as optional parts. These
systems enhance collision safety by restraining the
front passengers in case of an accident. The SRS
works with the pre-tensioner simultaneously when
a collision is detected.
The SRS consists of four air bag modules, SRS
air bag control unit (SRS-ECU), side impact
sensors, SRS warning lamp and clock spring. The
air bags are located in the centre of the steering
wheel, above the glove box, and built into the front
seat back assemblies. Each air bag has a folded
air bag and an inflator unit. The SRS-ECU under
the floor console monitors the system and has a
safing G sensor and an analog G sensor. The side
impact sensor inside the center pillar monitors any
shocks coming from the side of the vehicle. The
warning lamp on the instrument panel indicates
the operational status of the SRS. The clock spring
is installed in the steering column.
The SRS side air bag deploys if an impact received
at the side of the vehicle is stronger than a certain
set value, in order to protect the upper bodies of
front seat passengers in the event of a collision.
The seat belt pre-tensioner is built into the front
seat belt retractor. Only authorized service
personnel should do work on or around the SRS
components and seat belt with pre-tensioner. Those
service personnel should read this manual carefully
before starting any such work. Extreme care must
be used when servicing the SRS to avoid injury
to the service personnel (by inadvertent deployment
of the air bags or inadvertent operation of the seat
belt with pre-tensioner) or the driver (by rendering
the SRS or the seat belt with pre-tensioner
inoperative).
Diagnosis
connector
Side air bag module
Side impact sensor
Clock spring
Air bag module
(Front passengers side)
Air bag module
(Drivers side)
SRS-ECU
Seat belt with
pre-tensioner
SRS warning lamp
SRS - General Information 52B-3
SEAT BELT WITH PRE-TENSIONER
The seat belt with pre-tensioner has a pre-tensioner
operating mechanismand aG-sensor whichdetects
the force from an impact built into the seat belt
retractor.
The G-sensor is a mechanical-type sensor which
includes components such as aweight whichmoves
as a result of the impact from a collision, and a
spike which strikes a charge and causes it to
detonate.
Thus the pre-tensioner is equipped with a safety
mechanism to prevent mis-operation during
maintenance operations such as removal and
installation of the seat belt.
The safety mechanism operates automatically
when the retractor top mounting screw is removed
during removal of the seat belt.
When the retractor top mounting screw is removed,
the force of the spring plate causes the tab at the
lower edge of plate (A) to push in the pin of the
G-sensor, which prevents the weight inside the
G-sensor from moving.
At the same time, the retractor bracket and the
top of plate (A) become separated. A stopper is
inserted into the gap thus formed by the force from
a spring to prevent the tab from being removed
from the pin if an outside force is applied to plate
(A).
Stopper
Retractor bracket
Plate (A)
Spring
Spring plate
Tab
mechanismis disengaged)
mechanismis engaged)
Stopper
G-sensor structure
Charge
Spike
Pin (when safe-
ty mechanismis
engaged)
Sensor
weight
Tab
Pin
Tab
SRS - SRS Service Precautions 52B-4
SRS SERVICE PRECAUTIONS 52400030238
1. In order to avoid injury to yourself or others
from accidental deployment of the air bag and
accidental operation of the seat belt with
pre-tensioner during servicing, read and
carefully follow all the precautions and
procedures described in this manual.
2. Do not use any electrical test equipment on
or near SRS components, except those
specified on P.52B-7.
3. Never Attempt to Repair the Following
Components:
D SRS air bag control unit (SRS-ECU)
D Clock spring
D Front air bag module (Drivers side or front
passengers side)
D Seat belt with pre-tensioner
NOTE
If any of these components are diagnosed as
faulty, they should only be replaced, in
accordance with the INDIVIDUAL COM-
PONENTS SERVICE procedures in this
manual, starting at page 52B-28.
4. After disconnecting the battery cable, wait 60 seconds
or more before proceeding with the following work.
The SRS system is designed to retain enough voltage
to deploy the air bag for a short time even after the
battery has been disconnected, so serious injury may
result from unintended air bag deployment if work
is done on the SRS system immediately after the
battery cables are disconnected.
5. Do not attempt to repair the wiring harness connectors
of the SRS. If any of the connectors are diagnosed as
faulty, replace the wiring harness. If the wires are
diagnosed as faulty, replace or repair the wiring harness
according to the following table.
Insulating tape
Battery
SRS-ECU connector
SRS-ECU
Terminal No.
1 to 4 - -
5, 6 Dash wiring harness Clock spring Air bag module (Drivers
side)
Correct or replace the dash wiring
harness. Replacethe clock spring.
7, 8 Dash wiring harness Air bag module (Front passengers side) Correct or replace the dash wiring
9, 10 -
harness.
12 -
13 Dash wiring harness Junction block (fuse No.4)
15 Dash wiring harness Instrument panel wiring harness SRS
warning lamp
Correct or replace each wiring
harness.
16 to 19 - -
20, 21 Dash wiring harness Earth Correct or replace the dash wiring
harness.
SRS-ECU
Terminal No.
1, 2 - -
3 Dash wiring harness Earth Correct or replace thedash wiringharness.
4 Dash wiring harness Instrument panel wiring harness
SRS warning lamp
5, 6 Dash wiring harness Air bag module (Front
Passengers side)
Correct or replace thedash wiringharness.
7, 8 Dash wiring harness Clock spring Air bag module
(Drivers side)
Correct or replace thedash wiringharness.
Replace the clock spring.
9 Dash wiring harness Junction block (fuse No.4) Correct or replace thedash wiringharness.
10, 11 -
13 -
14, 15 Dash wiring harness Earth
17 to 20 -
21, 22 Dash wiring harness Side air bag module (L.H.)
23, 24 Dash wiring harness Side air bag module (R.H.)
SRS-ECU
Terminal No.
Corrective action Destination of harness
25 to 33 - -
impact sensor (L.H.)
37 to 39 -
impact sensor (R.H.)
6. Inspection of the SRS-ECU harness connector <vehicles with SRS side air bag> should be carried
out by the following procedure.
Insert the special tool (narrow probe in the harness set) into connector from harness side (rear side),
and connect the tester to this probe. If any to other than the special tool is used, it may cause
damage to the harness and other components. Furthermore, measurement should not be carried
out by touching the probe directly against the terminals from the front of the connector. The terminals
are plated to increase their conductivity, so that if they are touched directly by the probe, the plating
may break, which will cause drops in reliability.
MB991222
SRS-ECU harness connector
SRS-ECU harness connector (rear side)
7. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the
SRS-ECU, air bag module (drivers side and front passengers side), clock spring, side impact sensors,
front seat assemblies (side air bag module), and seat belts with pre-tensioner before drying or baking
the vehicle after painting.
8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to P.52B-19.)
9. Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected.
10. If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.
SRS - Special Tools 52B-7
MB991502 MUT-II sub
assembly
D Reading diagnosis codes
D Erasing diagnosis code
D Reading trouble period
D Reading erase times
MB991613 SRS check har-
ness
Checking the SRS electrical circuitry
A
B
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Check harness
B: LED harness
C: LED harness
adapter
D: Probe
Checking the continuity and measuring the
voltage at the SRS-ECU harness connector
<vehicles with SRS side air bag>
MB990803 Steering wheel
puller
Steering wheel removal
MB686560 SRS air bag
adapter harness A
D Deployment of air bag modules inside the
vehicle
D Deployment of air bag module (front
passengers side) and side air bag module
outside the vehicle
MR203491 or
MB628919
SRS air bag
adapter harness B
Deployment of air bag module (drivers side)
outside the vehicle
SRS - Test Equipment/Troubleshooting 52B-8
TEST EQUIPMENT 52400080035
Tool Name Use
Digital multi-meter Checking the SRS electrical circuitry
Use a multi-meter for which the
maximum test current is 2 mA or less
at the minimum range of resistance
measurement
Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check
diagnosis codes.
Inspect according to the inspection chart that is appropriate for the malfunction code.
Code No. Diagnosis Item Reference page
14 Analog G-sensor system in the SRS-ECU 52B-9
15, 16 Front impact safing G sensor system inside SRS-ECU 52B-9
17 Side impact safing G sensor system inside SRS-ECU 52B-10
21, 22, 61, 62 Drivers side air bag module (squib) system 52B-10
24, 25, 64, 65 Front passengers side air bag module (squib) system 52B-11
31, 32 SRS-ECU capacitor system 52B-11
34* Connector lock system 52B-12
35 SRS-ECU (deployed air bag) system 52B-12
41* IG
1
(A) power circuit system 52B-12
42* IG
1
(B) power circuit system 52B-13
43 SRS warning lamp drive circuit Lamp does not illuminate.* 52B-14
system
Lamp does not switch off. 52B-15
44* SRS warning lamp drive circuit system 52B-15
45 Internal circuit system of non-volatile memory (EEPROM) inside SRS-ECU 52B-15
SRS - Troubleshooting 52B-9
Code No. Reference page Diagnosis Item
51, 52 Drivers side air bag module (squib ignition drive circuit) system 52B-15
54, 55 Front passengers side air bag module (squib ignition drive circuit) system 52B-15
71, 72, 75, 76 Side air bag module (R.H) (squib) system 52B-16
73, 74 Side air bag module (R.H.) (squib) ignition drive circuit system 52B-16
79, 93 Side impact sensor (L.H.) communication system 52B-16
81, 82, 85, 86 Side air bag module (L.H.) (squib) system 52B-17
83, 84 Side air bag module (L.H.) (squib) ignition drive circuit system 52B-17
89, 96 Side impact sensor (R.H.) communication system 52B-17
91* Side impact sensor (L.H.) power supply circuit system 52B-18
92 Side impact sensor (L.H.) system 52B-18
94* Side impact sensor (R.H.) power supply circuit system 52B-18
95 Side impact sensor (R.H.) system 52B-18
NOTE
(1) *: If the vehicle condition returns to normal, the diagnosis code will be automatically erased, and the SRS warning
lamp will return to normal.
(2) If the vehicle has a discharged battery it will store the fault codes 41 or 42. When these diagnosis codes are
displayed, check the battery.
INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE
Code No.14 Analog G-sensor system in the SRS-ECU Probable cause
The SRS-ECU monitors the output of the analog G-sensor inside the SRS-ECU.
It outputs this code when any of the following are detected.
D When the analog G-sensor is not operating
D When the characteristics of the analog G-sensor are abnormal
D When the output from the analog G-sensor is abnormal
D Malfunction of SRS-ECU
Replace the SRS-ECU.
Code No.15 or 16 Front impact safing G sensor system
inside SRS-ECU
Probable cause
These diagnosis codes are output if there is a short or open circuit between the
terminals of the safing G-sensor inside the SRS-ECU.
The trouble causes for each diagnosis code No. are as follows.
Code No. Trouble cause
15 Short circuit in the safing G-sensor
16 Open circuit in the safing G-sensor
Code No.17 Side impact safing G sensor system inside
SRS-ECU
Probable cause
This code is output if the following are detected from the side impact safing G sensor
output.
D Safing G sensor is not operating
D Safing G sensor characteristics are abnormal
D Safing G sensor output is abnormal
Malfunction of SRS-ECU
Code No.21, 22, 61 or 62 Drivers side air bag module
(squib) system
Probable cause
These diagnosis codes are output if there is abnormal resistance between the input
terminals of the drivers side air bag module (squib).
D Malfunction of clock spring
D Partial disconnection due to incorrect clock spring
neutral position
D Malfunction of wiring harnesses or connectors
D Malfunction of drivers side air bag module (squib)
21 D Short in drivers side air bag module (squib) or harness short
D Short in clock spring
22 D Open circuit in drivers side air bag module (squib) or open harness
D Open circuit in clock spring
D Disconnected drivers side air bag module (squib) connector
D Partial disconnection due to incorrect clock spring neutral position
D Malfunction of connector contact
61 D Short in drivers side air bag module (squib) harness leading to the power supply
62 D Short in drivers side air bag module (squib) harness leading to the earth
YES
NO
MUT-II Self-diag code
D Disconnect clock spring
connector C-108, and
connect the harness side
connector to SRS check
harness connector 1.
D Erase diagnosis code
memory.
Are code Nos.21, 22, 61 or 62
output?
Check the clock spring (Refer to P.52B-37.)
NG
Replace
OK
<Vehicles with SRS side air bag> C-108, C-43
<Vehicles without SRS side air bag> C-108, C-44
OK
NG
Repair
NG
Check the harness wire between the clock spring and SRS-ECU.
OK
NG
Repair
C-110
OK
NG
Repair
NG
Replace the drivers side air bag module (squib).
SRScheck harness
(MB991613)
Dash wiring
harness
Clock spring
1
Code No.24, 25, 64 or 65 Front passengers side air bag
module (squib) system
Probable cause
These diagnosis codes are output if there is abnormal resistance between the input
terminals of the front passengers side air bag module (squib).
D Malfunction of front passengers side air bag module
(squib)
24 D Short in front passengers side air bag module (squib) or harness short
25 D Open circuit in front passengers side air bag module (squib) or open harness
64 D Short in front passengers side air bag module (squib) harness leading to the power
supply
65 D Short in front passengers side air bag module (squib) harness leading to the earth
D Disconnect front
passengers side air bag
module connector C-71,
and connect the harness
side connector to SRS
check harness connector
1.
memory.
output?
YES
OK
NO
Replace the front passengers side air bag module (squib).
<Vehicles without SRS side air bag> C-71, C-44
NG
Repair
NG
Check the harness wire between the front passengers side air
bag module (squib) and SRS-ECU.
OK
NG
Repair
SRS check harness
(MB991613)
Dash wiring
harness
1
Code No.31 or 32 SRS-ECU capacitor system Probable cause
These diagnosis codes are output if the voltage at the SRS-ECU capacitor terminals
is higher (No.31) or lower (No.32) than the specified value for 5 seconds or more.
However, if diagnosis code Nos.41 and 42 are being output due to a drop in battery
voltage, code No.32 will not be detected.
Code No.34 Connector lock system Probable cause
This diagnosis code is output if a poor connection of the SRS-ECUis detected. However,
if the vehicle condition returns to normal, diagnosis code No.34 will be automatically
erased, and the SRS warning lamp will switch off.
D Malfunction of connectors
<Vehicles without SRS side air bag> C-44
NG
Repair
OK
Code No.35 SRS-ECU (deployed air bag) system Probable cause
This diagnosis code is output after the air bag deploys. If this code is output before
the air bag has deployed, the cause is probably a malfunction inside the SRS-ECU.
Code No.41 IG
1
(A) power circuit system Probable cause
This diagnosis code is output if the voltage between the IG
1
(A) terminal and the
earth is lower than the specified value for a continuous period of 5 seconds or more.
However, if the vehicle condition returns to normal, diagnosis code No.41 will be
automatically erased, and the SRS warning lamp will switch off.
Measure at SRS-ECU connector C-43.
connector.
D Connect the battery (- ) terminal.
D Voltage between terminal 12 and body earth
OK: 9 V or more
NG
C-43, C-134
OK
NG
Repair
NG
Check the harness wire between the SRS-ECU and ignition switch
IG1, and repair if necessary.
OK
Measure at SRS check harness
connector 5.
D Disconnect SRS-ECU con-
nector C-44.
D Connect SRS check har-
ness connector 3 to
SRS-ECU connector.
D Connect the battery (- )
terminal.
D Voltage between terminal 14
and body earth
OK: 9 V or more
NG
SRS check harness
(MB991613)
C-44, C-134
OK
NG
Repair
NG
OK
5
3
Code No.42 IG
1
(B) power circuit system Probable cause
This diagnosis code is output if the voltage between the IG
1
(B) terminal and the
earth is lower than the specified value for a continuous period of 5 seconds or more.
connector.
OK: 9 V or more
NG
C-43, C-134
OK
NG
Repair
NG
OK
connector 5.
nector C-44.
ness connector 3 to
SRS-ECU connector.
terminal.
D Voltage between terminal 13
and body earth
OK: 9 V or more
NG
SRS check harness
(MB991613)
C-44, C-134
OK
NG
Repair
NG
OK
5
3
Code No.43 SRSwarning lamp drive circuit system(Lamp
does not illuminate.)
Probable cause
This diagnosis code is output when an open circuit occurs for a continuous period
of 5 seconds while the SRS-ECU in monitoring the SRS warning lamp and the lamp
is OFF (transistor OFF).
However, if this code is output due to an open circuit, if the vehicle condition returns
to normal, this diagnosis code No.43 will be automatically erased, and the SRS warning
lamp will return to normal.
D Blown bulb
D Malfunction of combination meter
OK
connector.
D Connect terminal 4 to the body earth.
OK: Lamp illuminates
NG
Blown bulb inspection
OK
NG
Repair
C-43, C-25, D-01, D-03
OK
connector 5.
nector C-44.
ness connector 3 to
SRS-ECU connector.
terminal.
D Connect terminal 15 to the
body earth.
OK: Lamp illuminates
NG
SRS check harness
(MB991613)
Blown bulb inspection
OK
Replace the combination
meter.
NG
Repair
C-44, C-25, D-01, D-03
OK
NG
Repair
NG
Check the harness wire between the SRS-ECU, combination meter
and ignition switch IG1.
OK
Replace the combination
meter.
NG
Repair
OK
NG
Repair
NG
Check the harness wire between the SRS-ECU, combination meter
and ignition switch IG1.
NG
Repair
OK
5
3
Code No.43 SRS warning lamp drive circuit system
(Lamp does not switch off.)
Probable cause
This diagnosis code is output when a short to earth occurs in the harness between
the lamp and the SRS-ECU while SRS-ECU is monitoring the SRS warning lamp
and the lamp is ON.
D Malfunction of combination meter
OK
SRS warning lamp inspection
D Does lamp switch off when
SRS-ECU connector C-43 <ve-
hicles with SRS side air bag> or
C-44 <vehicles without SRS side
air bag> is disconnected?
NO
<Vehicles with SRS side air bag> C-43,
C-25, D-01
C-44, C-25, D-01
NG
Repair
OK
NG
SRS-ECU and combination meter.
NG
Repair
YES
Code No.44 SRS warning lamp drive circuit system Probable cause
This diagnosis code is output when a short occurs in the lamp drive circuit or a
malfunction of the output transistor inside the SRS-ECUis detected while the SRS-ECU
is monitoring the SRS warning lamp drive circuit.
Check the SRS warning lamp drive circuit system.
OK
CodeNo.45 Internal circuit systemof non-volatilememory
(EEPROM) inside SRS-ECU
Probable cause
This diagnosis code is output if there is an internal problem with the non-volatile
memory (EEPROM) ,etc. inside the SRS-ECU.
Code No.51 or 52 Drivers side air bag module (squib
ignition drive circuit) system
Probable cause
This diagnosis code is output if a short (No.51) or an open circuit (No.52) is detected
in the circuit for the drivers seat.
Code No.54 or 55 Front passengers side air bag module
(squib ignition drive circuit) system
Probable cause
This diagnosis code is output if a short (No.54) or an open circuit (No.55) is detected
in the circuit for the passengers seat.
Code No.71, 72, 75 or 76 Side air bagmodule (R.H.) (squib)
system
Probable cause
These diagnosis codes are output if the resistance value between the side air bag
module (R.H.) (squib) input terminals of the SRS-ECU is abnormal. The problems
which cause these codes to be output are as follows.
D Malfunction of side air bag module (R.H.) (squib)
71 Short in side air bag module (R.H.) (squib) or harness short
72 D Open circuit in side air bag module (R.H.) (squib) or open harness
75 Short in side air bag module (R.H.) (squib) harness leading to the power supply
76 Short in side air bag module (R.H.) (squib) harness leading to the earth
OK
NO
Replace the seat back assembly of the front seat (R.H.).
D Disconnect side air bag
module (squib) connector
C-16, and connect the
harness side connector to
SRS check harness con-
nector 1.
memory.
output?
YES
SRS check harness
(MB991613)
C-16, C-42
NG
Repair
NG
Check the harness wire between the side air bag module (R.H.)
(squib) and SRS-ECU.
OK
NG
Repair
1
Code No.73 or 74 Side air bag module (R.H.) (squib)
ignition drive circuit system
Probable cause
These diagnosis codes are output if there is a short-circuit (code No.73) or an open
circuit (code No.74) in the squib ignition drive circuit.
Code No.79 or 93 Side impact sensor (L.H.)
communication system
Probable cause
These diagnosis codes are output if communication between the side impact sensor
(L.H.) and the SRS-ECU is not possible (code No.79) or abnormal (code No.93).
D Malfunction of side impact sensor (L.H.)
D Switch over the right side impact sensor (R.H.) and the side
impact sensor (L.H.).
D Erase diagnosis code memory.
Are code Nos.79 and 93 erased and code Nos.89 and 96 output?
NO
C-42, C-117, E-18
OK
NG
Repair
NG
Check the harness wire between the side impact sensor (L.H.)
and SRS-ECU.
OK
NG
Repair
YES
Replace the side impact sensor (L.H.).
Code No.81, 82, 85 or 86 Side air bag module (L.H.) (squib)
system
Probable cause
These diagnosis codes are output if the resistance value between the side air bag
module (L.H.) (squib) input terminals of the SRS-ECU is abnormal. The problems
which cause these codes to be output are as follows.
D Malfunction of side air bag module (L.H.) (squib)
81 Short in side air bag module (L.H.) (squib) or harness short
82 D Open circuit in side air bag module (L.H.) (squib) or open harness
85 Short in side air bag module (L.H.) (squib) harness leading to the power supply
86 Short in side air bag module (L.H.) (squib) harness leading to the earth
OK
NO
Replace the seat back assembly of the front seat (L.H.).
D Disconnect side air bag
module (L.H.) (squib) con-
nector C-21, and connect
the harness side connector
to SRS check harness
connector 1.
memory.
output?
YES
SRS check harness
(MB991613)
C-21, C-42
NG
Repair
NG
Check the harness wire between the side air bag module (L.H.)
(squib) and SRS-ECU.
OK
NG
Repair
1
Code No.83 or 84 Side air bag module (L.H.) (squib)
ignition drive circuit system
Probable cause
These diagnosis codes are output if there is a short-circuit (code No.83) or an open
circuit (code No.84) in the squib ignition drive circuit.
Code No.89 or 96 Side impact sensor (R.H.)
communication system
Probable cause
These diagnosis codes are output if communication between the side impact sensor
(R.H.) and the SRS-ECU is not possible (code No.89) or abnormal (code No.96).
D Malfunction of side impact sensor (R.H.)
D Switch over the side impact sensor (R.H.) and the side impact
sensor (L.H.).
D Erase diagnosis code memory.
Are code Nos.89 and 96 erased and code Nos.79 and 93 output?
NO
C-42, C-121, E-09
OK
NG
Repair
NG
and SRS-ECU.
OK
NG
Repair
YES
Replace the side impact sensor (R.H.).
Code No.91Side impact sensor (L.H.) power supplycircuit
system
Probable cause
This diagnosis code is output if the power supply voltage of the side impact sensor
(L.H.) drops below the rated value for a continuous period of 5 seconds or more.
However, code No.91 will be automatically cleared and the SRS warning lamp will
switch off if the condition returns to normal.
Measure at side impact sensor (L.H.) connector E-18.
connector.
OK: 9 V or more
Continuity between terminal 3 and body earth
NG
C-42, C-117, E-18
OK
NG
Repair
NG
and SRS-ECU.
OK
OK
NG
Repair
Code No.92 Side impact sensor (L.H.) system Probable cause
This diagnosis code is output if the following are detected from the analog G-sensor
output.
D Analog G-sensor is not operating.
D Analog G-sensor characteristics are abnormal.
D Analog G-sensor output is abnormal.
Code No.94 Side impact sensor (R.H.) power supply
circuit system
Probable cause
This diagnosis code is output if the power supply voltage of the side impact sensor
(R.H.) drops below the rated value for a continuous period of 5 seconds or more.
However, code No.94 will be automatically cleared and the SRS warning lamp will
switch off if the condition returns to normal.
Measure at side impact sensor (R.H.) connector E-09.
connector.
OK: 9 V or more
Continuity between terminal 3 and body earth
NG
C-42, C-121, E-09
OK
NG
Repair
NG
Check the harness wire between the side impact sensor (R.H.)
and SRS-ECU.
OK
OK
NG
Repair
Code No.95 Side impact sensor (R.H.) system Probable cause
This diagnosis code is output if the following are detected from the analog G-sensor
output.
D Analog G-sensor is not operating.
D Analog G-sensor characteristics are abnormal.
D Analog G-sensor output is abnormal.
SRS WARNING LAMP INSPECTION 52400430052
1. Check to be sure that the SRS warning lamp illuminates
when the ignition switch is in the ON position.
2. Check to be sure that it illuminates for approximately
7 seconds and then switches off.
3. If the above is not the cause, inspect the diagnosis codes.
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Communication with
MUT-II is not possible.
Communication with all systems is not
possible.
1 52B-19
Communication is not possible with
SRS only.
2 52B-20
When the ignition key is turned to ON(engine stopped), the SRS
warning lamp does not illuminate.
Refer to diagnosis code No.43. 52B-14
After the ignition switch is turned to ON, the SRS warning lamp
is still on after approximately 7 seconds have passed.
Refer to diagnosis code No.43,
44.
52B-15
Probable cause
The cause is probably a power supply system (including earth circuit) of the diagnosis
line.
D Malfunction of connectors
D Malfunction of wiring harness
(Communication is not possible with SRS only.)
Probable cause
If communication is not possible with the SRS only, the cause is probably an open
circuit in the diagnosis output circuit of the SRS or in the power circuit (including
earth circuit).
OK
C-44, C-20
NG
Repair
connector.
(1) Continuity between terminal 14 and body earth, and between
terminal 15 and body earth
OK: Continuity
(2) Voltage between terminal 9 andbody earth, and betweenterminal
12 and body earth
OK: 9 V or more
(1) NG
C-43
OK
NG
Repair
NG
Check the harness wire between the SRS-ECU and earth, and
C-43, C-134, C-131
(2) NG
OK
Check the following
connectors:
C-43, C-20
NG
Repair
OK
OK
NG
NG
Repair
NG
Check the harness wire between the SRS-ECU and diagnosis
connector.
OK
NG
Repair
(2), (3) NG
C-44, C-134, C-131
connector 5.
nector C-44.
ness connector 3 to
SRS-ECU connector.
(1) Continuity between terminal
20 and body earth, and
between terminal 21 and
body earth
OK: Continuity
(2) Voltage between terminal 13
and body earth
OK: 9 V or more
(3) Voltage between terminal 14
and body earth
OK: 9 V or more
(1) NG
NG
Check the harness wire between the SRS-ECU and earth, and
C-44
OK
NG
Repair
NG
OK
NG
Repair
OK
NG
Check the harness wire between the SRS-ECU and diagnosis
connector.
NG
Repair
OK
3
5
SRS check harness
(MB991613)
SRS - SRS Maintenance 52B-21
SRS MAINTENANCE 52400390176
The SRS must be inspected by an authorized dealer 10 years
after the date of vehicle registration.
SRS WARNING LAMP CHECK
Turn the ignition key to the ON position. Does the SRS
warning lamp illuminate for about 7 seconds, turn off and
then remain extinguished for at least 5 seconds? If yes, SRS
system is functioning properly. If no, consult page 52B-8.
SRS COMPONENT VISUAL CHECK
Turn the ignition key to the LOCK position, disconnect the
negative battery cable and tape the terminal.
Caution
Wait at least 60 seconds after disconnecting the battery
cable before doing any further work. (Refer to P.52B-4.)
SRS AIR BAG CONTROL UNIT (SRS-ECU)
1. Check SRS-ECU case and brackets for dents, cracks,
deformation or rust.
Caution
The SRS may not activate if the SRS-ECU is not
installed properly, which could result in serious injury
or death to the vehicles driver or front passenger.
2. Check connector for damage, and terminals for
deformation or rust.
Replace SRS-ECU if it fails visual check.
Battery (- ) cable
Insulating tape
Battery
SRS-ECU
AIR BAG MODULES, STEERING WHEEL AND CLOCK
SPRING
1. Remove the air bag modules, steering wheel and clock
spring. (Refer to P.52B-32, 33.)
Caution
The removed air bag modules should be stored in
a clean, dry place with the air bag deployment side
face up.
2. Check pad cover for dents, cracks or deformation.
3. Check connector for damage, terminals deformities, and
harness for binds.
4. Check air bag inflator case for dents, cracks or deformities.
5. Check harness and connectors for damage, and terminals
for deformation.
6. Check clock spring connectors and protective tube for
damage, and terminals for deformation.
7. Visually check the clock spring case for damage.
8. Align the mating marks of the clock spring and, after
turning the vehicles front wheels to straight-ahead
position, install the clock spring to the column switch.
Mating Mark Alignment
Turn the clock spring clockwise fully, and then turn back
it approx. 3 4/5 turns counterclockwise to align the mating
marks.
Caution
If the clock springs mating mark is not properly
aligned, the steering wheel may not be completely
rotational during a turn, or the flat cable within the
clock spring may be severed, obstructing normal
operation of the SRS and possibly leading to serious
injury to the vehicles driver or front passenger.
9. Install the steering column covers, steering wheel and
the air bag module.
10. Check steering wheel for noise, binds of difficult operation.
11. Check steering wheel for excessive free play.
REPLACE ANY VISUALLY INSPECTED PART IF IT
FAILS THAT INSPECTION. (Refer to P.52B-32, 33.)
Caution
The SRS may not activate if any of the above
components is not installed properly, which could
result in serious injury or death to the vehicles driver
or front passenger.
Connector
<Drivers side>
Connector
Inflator case
<Front passengers side>
Inflator case
Protective tube
Case
Matingmarks
Protective tube
FRONT SEAT BACK ASSEMBLY (SIDE AIR BAG
MODULE)
1. Check that there is no abnormality in the seat air bag
module deployment section.
2. Check that there is no connector damage, bent terminals
or clamping of the harness.
SIDE IMPACT SENSORS
1. Check that there is no bending or corrosion in the center
pillar.
2. Check that there is no denting, breakage, bending or
corrosion of the side impact sensor.
3. Check that there is no clamping of the harness, connector
damage or bent terminals.
NOTE
The illustration at left shows the side impact sensor (L.H.).
The position of the side impact sensor (R.H.) is
symmetrical to this.
Caution
The SRS may not activate if the side impact sensors
are not installed properly, which could result in
serious injury or death to the vehicles driver or front
passenger.
Air bag module
deployment
section
Front of
vehicle
Center
pillar
Side impact
sensor
DASH WIRING HARNESS/FLOOR WIRING HARNESS
Dash wiring harness
Floor wiring harness
Dash wiring harness
1. Check connector for poor connection.
2. Check harnesses for binds, connectors for damage, and
terminals for deformation.
REPLACE ANY CONNECTORS OR HARNESSES THAT
FAIL THE VISUAL INSPECTION. (Refer to P.52B-5.)
Caution
The SRS may not activate if SRS harnesses or
connectors are damaged or improperly connected,
which could result in serious injury or death to the
vehicles driver or front passenger.
POST-INSTALLATION INSPECTION
Reconnect the negative battery terminal. Turn the ignition
key to the ON position. Does the SRSwarning lampilluminate
for about 7 seconds, turn off and then remain extinguished
for at least 5 seconds? If yes, SRS system is functioning
properly. If no, consult page 52B-8.
SRS warning lamp
SRS - Post-collision Diagnosis 52B-25
POST-COLLISION DIAGNOSIS 52400110239
To inspect and service the SRS after a collision (whether
or not the air bags have deployed), perform the following
steps.
SRS-ECU MEMORY CHECK
Caution
Make certain that the ignition switch is OFF when
the MUT-II is connected or disconnected.
2. Read (and write down) all displayed diagnosis codes.
(Refer to P.52B-8.)
NOTE
If the battery power supply has been disconnected or
disrupted by the collision, the MUT-II cannot communicate
with the SRS-ECU. Inspect and, if necessary, repair the
dash wiring harness before proceeding further.
3. Read the data list (fault duration and how many times
memories are erased) using the MUT-II.
Data list
No Service Data Item Applicability
92 Number indicating how often the memory is cleared Maximum time to be stored: 250
93 How long a problem has lasted (How long it takes
from the occurrence of the problem till the firest
igniting signal)
Maximum time to be stored: 9999 minutes
(approximately 7 days)
94 How long a problem has lasted (How long it takes
from the first igniting signal till now)
4. Erase the diagnosis codes and after waiting 45 seconds
or more read (and write down) all displayed diagnosis
codes. (Refer to P.52B-8.)
REPAIR PROCEDURE
WHEN AIR BAGS (DRIVERS SIDE AND FRONT
PASSENGERS SIDE) DEPLOY OR SEAT BELT
PRE-TENSIONER OPERATES IN A COLLISION.
1. Replace the following parts with new ones.
D SRS-ECU (Refer to P.52B-30.)
D Drivers side air bag module (Refer to P.52B-32.)
D Front passengers side air bag module (Refer to
P.52B-33.)
D Seat belt with pre-tensioner (Refer to P.52B-40.)
D Instrument pad assembly (Refer to GROUP 52A -
Instrument Panel.)
2. Check the following parts and replace if there are any
malfunctions.
D Clock spring (Refer to P.52B-32.)
D Steering wheel, steering column and intermediate
joint
(1) Check wiring harness (built into steering wheel)
and connectors for damage, and terminals for
deformation.
(2) Install air bag module to check fit or alignment
with steering wheel.
(3) Check steering wheel for noise, binds or difficult
operation and excessive free play.
3. Check harnesses for binding, connectors for damage,
poor connections, and terminals for deformation.
WHEN SRS SIDE AIR BAG DEPLOYS OR SEAT BELT
PRE-TENSIONER OPERATES IN A COLLISION
1. Replace the following parts with new ones.
D SRS-ECU (Refer to P.52B-30.)
D Side impact sensor (Refer to P.52B-38.)
D Front seat back assembly (Refer to GROUP 52A -
Seat.)
D Seat belt with pre-tensioner (Refer to P.52B-40.)
2. Check harnesses for binding, connectors for damage,
poor connections, and terminals for deformation.
WHEN AIR BAG OR SEAT BELT PRE-TENSIONER DOES
NOT DEPLOY IN LOW-SPEED COLLISION.
Check the SRS components and seat belt with pre-tensioner.
If the SRS components and seat belt with pre-tensioner are
showing any visible damage such as dents, cracks, or
deformation, replace them with new ones. Concerning parts
removed for inspection, replacement with new parts and
cautionary points for working, refer to appropriate INDIVIDUAL
COMPONENT SERVICE, P. 52B-28.
SRS-ECU
1. Check SRS-ECU case and brackets for dents, cracks
or deformation.
2. Check connector for damage, and terminals for
deformation.
Air bag modules
2. Check connector for damage, terminals deformities, and
harness for binds.
3. Check air bag inflator case for dents, cracks or deformities.
4. Install air bag module to steering wheel to check fit or
alignment with the wheel.
Front seat back assembly (Side air bag module)
1. Check that there is no abnormality in the seat air bag
module deployment section.
2. Check that there is no connector damage, bent terminals
or clamping of the harness.
Clock spring
1. Check clock spring connectors and protective tube for
damage, and terminals for deformation.
2. Visually check the case for damage.
SRS-ECU
<Drivers side>
Connector
Inflator case
Connector
Inflator case
Air bag module
deployment
section
Case
Protective tube
Protective tube
SRS - Post-collision Diagnosis/Individual Component Service 52B-28
Steering wheel, steering column and intermediate joint
1. Check wiring harness (built into steering wheel) and
connectors for damage, and terminals for deformation.
2. Install air bag module to check fit or alignment with steering
wheel.
3. Check steering wheel for noise, binds or difficult operation
and excessive free play.
Side impact sensor
1. Check that there is no bending or corrosion in the center
pillar.
2. Check that there is no denting, breakage or bending of
the side impact sensor.
3. Check that there is no clamping of the harness, connector
damage or bent terminals.
NOTE
The illustration at left shows the side impact sensor(L.H.).
The position of the side impact sensor (R.H.) is
Harness connector (dash wiring harness and floor
wiring harness)
Check harnesses for binding, connectors for damage, poor
connection, and terminals for deformation. (Refer toP.52B-24.)
Seat belt with pre-tensioner
1. Check the seat belt for damage or deformation.
2. Check the pre-tensioner for cracks or deformation.
3. Check that the unit is installed correctly to the vehicle
body.
INDIVIDUAL COMPONENT SERVICE 52400290223
If the SRS components and seat belt with pre-tensioner are to be removed or replaced as a result of
maintenance, troubleshooting, etc., follow each procedure (P.52B-24 - P.52B-33).
Caution
1. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove
the SRS-ECU, air bag modules (drivers side and front passengers side), front seat assemblies
(side air bag module), clock spring, side impact sensors and seat belts with pre-tensioner
before drying or baking the vehicle after painting.
Recheck SRS system operability after re-installing them.
2. If the SRS components and seat belts with pre-tensioner are removed for the purpose of check,
sheet metal repair, painting, etc., they should be stored in a clean, dry place until they are
reinstalled.
Front of
vehicle
Side impact
sensor
Center pillar
SRS - Warning/Caution Labels 52B-29
WARNING/CAUTION LABELS 52400300070
A number of caution labels relating to the SRS
and seat belt with pre-tensioner are found in the
vehicle, as shown in the following illustration. Follow
label instructions when servicing SRS and seat
belt pre-tensioner. If labels are dirty or damaged,
replace them with new ones.
*
Steering wheel Air bag module (drivers side) Clock spring
Sun visor SRS-ECU Glove box
Air bag module
(front passengers side)
Steering gear box Seat belt pre-tensioner
Side air bag module
(drivers seat and front
passengers seat) Side impact sensor
Center pillar
NOTE
*: Vehicles with front passengers air bag
SRS - SRS-ECU 52B-30
SRS AIR BAG CONTROL UNIT (SRS-ECU) 52400210168
Caution
1. Disconnect the battery ( - ) terminal and wait
for 60 seconds or more before starting work.
Furthermore, the disconnected battery
terminal should be covered with tape to
insulate it. (Refer to P.52B-4.)
2. Never attempt to disassemble or repair the
SRS-ECU. If faulty, replace it.
3. Do not drop or subject the SRS-ECU to
impact or vibration.
If denting, cracking, deformation, or rust
are discovered in the SRS-ECU, replace it
with a new SRS-ECU. Discard the old one.
4. After deployment of an air bag, replace the
SRS-ECU with a new one.
5. Never use an ohmmeter on or near the
SRS-ECU, and use only the special test
equipment described on P.52B-7.
Turn the ignition key to the LOCK position.
1
2
4.9 Nm
Removal steps
"BA D Post-installation inspection
D Negative (- ) battery cable connection
D Lower cover, side cover (Refer to
1. Engine-ECU, A/T-ECU, and A/T
control relay
"AA 2. SRS-ECU
SRS - SRS-ECU 52B-31
"AASRS-ECU INSTALLATION
Caution
The SRS may not activate if SRS-ECU is not installed
properly, which could result in serious injury or death
to the vehicles driver or front passenger.
"BAPOST-INSTALLATION INSPECTION
1. Reconnect the negative battery terminal.
2. Turn the ignition key to the ON position.
3. Does the SRS warning lamp illuminate for about 7
seconds, and then remain extinguished for at least 5
seconds after turning OFF?
4. If yes, SRS system is functioning properly.
If no, consult page 52B-8.
D Check the SRS-ECU and brackets for dents, cracks or
deformation.
D Check connector for damage, and terminals for
deformation.
Caution
If a dent, crack, deformation or rust is discovered,
replace the SRS-ECU with a new one.
NOTE
For checking of the SRS-ECUother than described above,
refer to the section concerning troubleshooting. (Refer
to P.52B-8.)
SRS warning lamp
SRS - Air Bag Modules and Clock Spring 52B-32
AIR BAG MODULES AND CLOCK SPRING 52400240211
Caution
air bag modules or clock spring.
If faulty, replace it.
3. Do not drop the air bag modules or clock
spring or allow contact with water, grease
or oil.
Replace it if a dent, crack, deformation or
rust is detected.
4. The air bag modules should be stored on
a flat surface and placed so that the air bag
deployment surfaces are facing upward.
5. Do not expose the air bag modules to
temperatures over 93_C.
6. When the drivers-side and passengers-
side air bags have been deployed, the air
bag modules (drivers-side and passen-
gers-side) should be replaced with new
modules. When a side air bag has been
deployed, the front seat back assembly
(drivers seat or passengers seat) should
be replaced with a new assembly.
7. Wear gloves and safety glasses when
handling air bags that have already
deployed.
8. An undeployed air bag module should only
be disposed of in accordance with the
procedures (Refer to P.52B-42.)
<Side air bag module>
For removal and installation of the front seat back assembly with side air bag module, refer to GROUP
52A - Seat.
<Air bag module (drivers side), clock spring>
After setting the steering wheel and the front wheels
to the straight ahead position, remove the ignition key.
1
2
3
4
1
0.69 Nm
9 Nm
Air bag module removal steps
"DA D Post-installation inspection
1. Air bag module mounting screw
(Torx screw)
AA" 2. Air bag module
"AA D Pre-installation inspection
Clock spring removal steps
1. Air bag module mounting screw
(Torx screw)
AA" 2. Air bag module
AB" "CA 3. Steering wheel
D Lower cover, column cover (Refer to
AC" "BA 4. Clock spring
SRS - Air Bag Modules and Clock Spring SRS - Air Bag Modules and Clock Spring 52B-33
<Air bag module (front passengers side)>
1
2
1
Air bag module removal steps
D Glove box (Refer to GROUP 52A -
Instrument Panel.)
1. Bolt
AD" 2. Air bag module
AA"AIR BAG MODULE REMOVAL (DRIVERS SIDE)
When disconnecting the connector of the clock spring from
the air bag module, press the air bags lock towards the outer
side to spread it open. Use a flat-tipped screwdriver, as shown
in the figure at the left, to pry so as to remove the connector
gently.
Caution
1. When disconnect the air bag module-clock spring
connector, take care not to apply excessive force to
it.
2. The removed air bag module should be stored in a
clean, dry place with the pad cover face up.
Lock
Lock
Connector
Flat-tipped
screwdriver
AB"STEERING WHEEL REMOVAL
Caution
Do not hammer on the steering wheel. Doing so may
damage the collapsible column mechanism.
AC"CLOCK SPRING REMOVAL
Caution
The removed clock spring should be stored in a clean,
dry place.
AD"AIR BAG MODULE REMOVAL
(FRONT PASSENGERS SIDE)
Caution
The removed air bag module should be stored in a clean,
dry place with the air bag deployment side face up.
"AAPRE-INSTALLATION INSPECTION
1. When installing the new air bag modules and clock spring,
refer to INSPECTION, P.52B-36.
Caution
Dispose of air bag modules only according to the
specified procedure. (Refer to P.52B-42.)
2. Connect the battery ( - ) terminal.
Caution
Make certain that the ignition switch is OFF when
the MUT-II is connected or disconnected.
5. Conduct self-diagnosis using the MUT-II to ensure entire
SRS operates properly, except open circuit of air bag
modules.
6. Turn the ignition key to the LOCK position, disconnect
the negative battery cable and tape the terminal.
Caution
Wait at least 60 seconds after disconnecting the
battery cable before doing any further work.
(Refer to P.52B-4.)
MB990803
"BACLOCK SPRING INSTALLATION
Align the mating marks of the clock spring and, after turning
the front wheels to the straight-ahead position, install the
clock spring to the column switch.
Mating Mark Alignment
Turn the clock spring clockwise fully, and then turn back it
approx. 3 4/5 turns counterclockwise to align the matingmarks.
Caution
If the clocksprings matingmarks arenot properlyaligned,
the steeringwheel maynot becompletely rotational during
a turn, or the flat cable within the clock spring may be
severed, obstructing normal operation of the SRS and
possibly leading to serious injury to the vehicles driver.
"CASTEERING WHEEL INSTALLATION
1. Before installation the steering wheel, be sure to first
turn the vehicles front wheels to the straight-ahead
position and align the mating marks of the clock spring.
Caution
Be sure when installing the steering wheel, that the
harness of the clock spring does not become caught
or tangled.
2. After clamping, turn the steering wheel all the way in
both directions to confirm that steering is normal.
"DAPOST-INSTALLATION INSPECTION
seconds after turning OFF?
4. If yes, SRS system is functioning properly.
If no, consult page 52B-8.
Mating marks
SRS warning lamp
AIR BAG MODULE CHECK
If any improper part is found during the following inspection,
replace the air bag modules with a new one.
Dispose the old one according to the specified procedure.
Caution
Never attempt to measure the circuit resistance of the
air bag modules (squib) even if you are using the specified
tester. If the circuit resistance is measured with a tester,
accidental air bags deployment will result in serious
personal injury.
2. Check connectors for damage, terminals for deformation,
and harness for binds.
3. Check air bag inflator case for dents, cracks or
deformation.
4. Install the air bag module to steering wheel to check
fit or alignment with the wheel.
Caution
If dents, cracks, deformation, or rust are discovered in
the air bag module, replace it with a new one.
Dispose of the old one according to the specified
procedure. (Refer to P.52B-42.)
FRONT SEAT BACK ASSEMBLY WITH SIDE AIR BAG
MODULE CHECK
If any improper part is found during the following inspection,
replace the front seat back assembly with a new one.
Dispose the old one according to the specified procedure.
Caution
Never attempt to measure the circuit resistance of the
air bag module (squib) even if you are using the specified
tester. If the circuit resistance is measured with a tester,
accidental air bag deployment will result in serious
personal injury.
1. Check the air bag module deployment section for dents
or deformation.
2. Check connector for damage, terminals for deformation,
and harness for binds.
<Drivers side>
Connector
Inflator case
Connector
Inflator case
Air bag module
deployment
section
CLOCK SPRING CHECK
If, as result of following checks, even one abnormal point
is discovered, replace the clock spring with a new one.
1. Check connectors and protective tube for damage, and
terminals for deformation.
2. Visually check the case for damage.
3. Check continuity between the No.1 connector of the clock
spring and connectors No.3 and 4.
No.1 connector No.3 No.4 connector
Termi-
nal 1
Termi-
nal 2
Termi-
nal 3
connec-
tor Termi-
nal 1
Termi-
nal 2
To auto-
cruise
control
unit
To ACC
power
To horn
relay
To horn
switch
To auto-cruise
control switch
4. Align the paint mark of the SRS check harness connector
No.4 with the notch in clock spring connector No.2 to
connect the connectors Nos.2 and 4.
5. Check continuity between the terminals 22 and 23 of
the SRS check harness connector No.5.
Protective tube
Case
Protective tube
5
1
2
3
4
Paint
mark
SRS check
harness
(MB991613)
Clock spring
connector 2
View A
4
A
5
Notch
SRS - Side Impact Sensor 52B-38
SIDE IMPACT SENSOR 52400460013
Caution
side impact sensor. If faulty, replace it.
3. Do not drop or subject the side impact
sensor to impact or vibration.
If denting, cracking, deformation, or rust
are discovered in the side impact sensor,
replace it with a new side impact sensor.
Discard the old one.
4. After deployment of an air bag, replace the
side impact sensor with a new one.
Turn the ignition key to the LOCK position.
Front of vehicle
Center pillar
2
3
4
1
5 Nm
5 Nm
Removal steps
"CA D Post-installation inspection
D Center pillar lower trim (Refer to
GROUP 52A.)
D Seat belt with pre-tensioner (Refer to
P.52B-40.)
1. Water proof cover
2. Side impact sensor and bracket
3. Bracket
"BA 4. Side impact sensor
NOTE
The illustration above shows the side impact sensor
(L.H.). The position of the side impact sensor (R.H.) is
SRS - Side Impact Sensor 52B-39
Check the side impact sensor for dents, breakage and bending
and measure the resistance between the terminals, even
when installing a new side impact sensor.
"BASIDE IMPACT SENSOR INSTALLATION
Securely connect the connector.
Caution
If the side impact sensor is not installed securely and
correctly, the side air bag may not operate normally.
"CAPOST-INSTALLATION INSPECTION
seconds after turning the ignition key to OFF position?
4. If yes, SRS system is functioning properly. If no, consult
page 52B-8.
D Check the sideimpact sensor and bracket for dents, cracks
or deformation.
D Check connector for damage, and terminals for
deformation.
Caution
If a dent, crack, deformation or rust is discovered,
replace the side impact sensor with a new one.
NOTE
For checking of the side impact sensor other than
described above, refer to the section concerning
troubleshooting. (Refer to P.52B-8.)
D Check that there is no bending or corrosion in the center
pillar.
Center pillar
SRS warning lamp
SRS - Seat Belt with Pre-tensioner 52B-40
SEAT BELT WITH PRE-TENSIONER 52400410056
Caution
seat belt with pre-tensioner. If faulty, replace
it.
2. Be extremely careful when handling the seat
belt with pre-tensioner. Do not subject it
to shocks, drop it, bring it close to strong
magnets or allow contact with water, grease
or oil. Always replace it with a new part
if any dents, cracks or deformation is found.
3. Do not place anything on top of the seat
belt pre-tensioner.
4. Do not expose the seat belt with
pre-tensioner to temperatures over 90_C.
5. After operating the seat belt pre-tensioner,
replace the seat belt pre-tensioner with a
new part.
6. Gloves and protective goggles should be
worn when handling a pre-tensioner once
it has been used.
7. If disposing of a seat belt with pre-tensioner
which has not yet been used, its
pre-tensioner should be operated first
before disposal. (Refer to P.52B-42.)
Center Pillar Lower TrimRemoval and Installation(Refer
to GROUP 52A.)
2
1
3
4
44 Nm
44 Nm
Removal steps
AA" "BA 1. Retractor top mounting screw (for
engaging and disengaging safety
mechanism)
2. Sash guide cover
3. Sash guide
4. Seat belt with pre-tensioner
SRS - Seat Belt with Pre-tensioner 52B-41
AA"RETRACTOR TOP MOUNTING SCREW REMOVAL
(SAFETY MECHANISM ENGAGEMENT)
The safety mechanism which is equipped in the seat belt
pre-tensioner will engage automatically when the retractor
top mounting screw is removed.
Caution
All of the following operations should be carried out
while the safety mechanism is engaged to prevent
mis-operation of the seat belt pre-tensioner.
Furthermore, the safety mechanism should not be
disengaged while the seat belt pre-tensioner is
removed from the vehicle.
When installing a new seat belt with pre-tensioner refer to
INSPECTION, P.52B-42.
Caution
Disposal of the pre-tensioner must be carriedout as stated
in the procedure. (Refer to P.52B-42.)
"BA RETRACTOR TOP MOUNTING SCREW
INSTALLATION (SAFETY MECHANISM
DISENGAGEMENT)
1. Lift up the stopper and then bring the retractor bracket
and plate (A) together so that the stopper tab goes into
the hole in the retractor bracket.
2. Screw the retractor bracket and plate (A) together with
the retractor top mounting screw.
3. Check that the seat belt can be pulled out smoothly.
If it does not move smoothly, the safety mechanism may
not have been properly disengaged, so remove the
retractor top mounting screw and repeat the installation
procedure.
When safety mecha-
nism is engaged
Retractor
bracket
Plate(A)
Stopper
SRS-
Seat Belt with Pre-tensioner/Air Bag Module and
Seat Belt Pre-tensioner Disposal Procedures
52B-42
SEAT BELT WITH PRE-TENSIONER CHECK
If any part is found to be faulty during the inspection. It must
be replaced with a new one.
Dispose of the old one according to the specified procedure
described below.
D Check seat belt pre-tensioner for dents, cracks or
deformation.
AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL
PROCEDURES 52400120225
Before disposing of a vehicle which is equipped
with air bags or seat belts with pre-tensioner, or
when disposing of the air bags or seat belt
pre-tensioner themselves, the followingprocedures
must be used to deploy the air bags or operate
the seat belt pre-tensioners before disposal.
UNDEPLOYED AIR BAG MODULE AND SEAT
BELT PRE-TENSIONER DISPOSAL
Caution
1. If the vehicle is to be scrapped or otherwise disposed
of, deploy the air bags inside the vehicle, and operate
the seat belt pre-tensioners outside the vehicle. If
the vehicle will continue to be operated and only the
air bag modules and seat belt pre-tensioner are to
be disposed of, deploy the air bags and operate the
seat belt pre-tensioners outside the vehicle.
2. Since a large amount of smoke is produced when
the air bag are deployed or the seat belt pre-tensioner
is operated, avoid residential areas whenever
possible.
3. Since there is a loud noise when the air bags are
deployed and when the seat belt pre-tensioners are
operated, avoid residential areas whenever possible.
If anyone is nearby, give warning of the impending
noise.
4. Suitable ear protection should be worn by personnel
performing these procedures or by people in the
immediate area.
AIR BAG MODULE DEPLOYMENT
Deployment Inside The Vehicle
(when disposing of a vehicle)
1. Move the vehicle to an isolated spot.
2. Disconnectthenegative(-) andpositive(+) batterycables
fromthe battery terminals, and then remove the battery
from the vehicle.
Caution
battery cables before doing any further work.
(Refer to P.52B-4.)
SRS-
Air Bag Module and Seat Belt
Pre-tensioner Disposal Procedures
52B-43
3. To deploy the air bag module (drivers side):
(1) Remove the lower cover and the steering column
lower cover.
(2) Remove the connection between the clock spring
2-pin connector (red) and the dash wiring harness
connector.
NOTE
If the clock spring connector is disconnected from
the dash wiring harness, both electrodes of the clock
spring connector will be automatically shorted to
prevent unintended deployment of the air bag due
to static electricity, etc.
4. To deploy the air bag module (front passengers side):
(1) Remove the glove box.
(2) Remove the connection between the air bag module
(front passengers side) connector (red 2-pin) and
the dash wiring harness connector.
NOTE
If the air bag module connector is disconnected from
the dash wiring harness, both electrodes of the air bag
module connector will be automatically shorted to prevent
unintended deployment of the air bag due to static
electricity, etc.
5. To deploy the side air bag module:
Remove the connection between the side air bag module
connector (red 2-pin) and the dash wiring harness
connector.
Caution
The side air bag modules for both the drivers-side
and passengers-side should be deployed.
NOTE
If the side air bag module connector is disconnected from
the dash wiring harness, both electrodes of the side air
bag module connector will be automatically shorted to
prevent unintended deployment of the side air bag due
to static electricity, etc.
Clock spring 2-pin
connector (red)
Dash wiring harness connector (2-pin)
Dash wiring harness
connector
(2-pin)
Air bag module 2-pin
connector (red)
Side air bag
module 2-pin
connector (red)
Dash wiringharness
connector (2-pin)
SRS-
52B-44
6. Connect two wires, each six meters or longer, to the two
leads of SRS air bag adapter harness A and cover the
connections with insulation tape. The other ends of the
two wires should be connected to each other
(short-circuited), to prevent sudden unexpected
deployment of the air bag.
7. Connect the clock spring, air bag module (front
passengers side), or sideair bagmodule 2-pinconnector
(red) to SRS air bag adapter harness A and pass the
deployment wires out of the vehicles.
8. Fully close all door windows, close the doors and place
a cover over the vehicle to minimize the amount of noise.
Caution
If the glass is damaged, it may break, so the car must
be covered.
9. At a location as far away from the vehicle as possible,
disconnect the two connectedwires fromeach other, and
connect them to the two terminals of the battery (which
has been removed from the vehicle) to deploy the air
bag.
Caution
1. Before deploying the air bag in this manner, first
check to be sure that there is no one in or near
the vehicle. Wear safety glasses.
2. The inflator will be quite hot immediately following
the deployment, so wait at least 30 minutes to
allow it to cool before attempting to handle it.
Although not poisonous, do not inhale gas from
air bag deployment.
See Deployed Air Bag Module or Operated Seat
Belt Pre-tensioner Disposal Procedures
(P.52B-49.) for post-deployment handling instruc-
tions.
3. If the air bag module fails to deploy when the
procedures above are followed, do not go near
the module. Contact your local distributor.
10. After deployment, dispose of air bag module according
to the Deployed Air Bag Module or Operated Seat Belt
Pre-tensioner Disposal Procedures. (Refer to P.52B-49.)
SRS air bag
adapter
harness A
MB686560
Connection
6 mor
longer
Two wires
Insulation
tape
SRS air bag adapter
harness A
MB686560
2-pin connector (red)
Deployment wires
Cover
Wires 6 mor longer
SRS-
52B-45
Deployment Outside The Vehicle
Caution
1. This should be carried out in a wide, flat area at least
6 m away from obstacles and other people.
2. Do not perform deployment outside, if a strong wind
is blowing, and if there is even a slight breeze, the
air bag module should be placed and deployed
downwind from the battery.
1. Disconnect the negative ( - ) and positive (+) battery cables
from the battery terminals, and then remove the battery
from the vehicle.
Caution
battery cables before doing any further work. (Refer
to P.52B-4.)
2. Remove the air bag modules (drivers-side and front
passengers-side) (Refer to P.52B-32, 33.) and the front
seat back assemblies with built-in side air bag module
from the vehicle. (Refer to GROUP 52A - Front Seat.)
Caution
The air bag modules should be stored on flat surface
and placed so that the air bag deployment surfaces
are facing upward. Do not place anything on top of
them.
3. Connect two wires, each six meters or longer, to the two
leads of SRS air bag adapter harness B <air bag module
(drivers side)> or SRS air bag adapter harness A <air
bag module (front passengers side) and side air bag
module>, and cover the connections with insulation tape.
The other ends of the two wires should be connected
to each other (short-circuited), to prevent sudden
unexpected deployment of the air bag module.
Two wires
SRS air bag
adapter harness A
MB686560
SRS air bag
adapter harness B
MR203491 or
MB628919
<Air bag module
(drivers side)>
Connection
6 m
long or
more
Insulation tape
Two wires
Connection
Insulation tape
6 m
long or
more
<Air bag module (front
passengers side) and
side air bag module>
SRS-
52B-46
4. Set the air bag modules as follows:
<Air bag module (drivers side)>
(1) Take the SRS air bag adapter harness B that is
connected to the wires, pass it beneath the old tyre
wheel assembly, andconnect it to the air bagmodule.
(2) Pass the thick wire through the air bag module
mounting hole, and then secure the air bag module
to an old tyre with a wheel in it so that the pad on
the module is facing upwards.
Caution
Leave some space belowthe wheel for the adaptor
harness. If there is no space, the reaction when
the air bag deploys could damage the adaptor
harness.
(3) Place three old tyres with no wheels on top of the
tyre secured to the air bag module.
<Air bag module (front passengers side)>
(1) Connect the deployment wires to the SRS air bag
adaptor harness A, pass it beneath the tyre, and
wheel assembly, andconnect it to the air bagmodule.
(2) Pass thick wires into the hole of the air bag module
bracket, and secure them to the wheel of the old
tyre with wheel (4 locations) with the air bag
deployment surface facing upwards.
Caution
1. Leave some space below the wheel for the
deployment wires.
If there is no space, the reaction of the air
bag deployment could result in damage of
the adaptor harness.
2. While deployment takes place, do not have
the connector of the SRS air bag adaptor
harness A inserted between the tyres.
Air bag module
Wires
Tyres without wheels
Wires
Deployment wire
Air bag module
SRS-
52B-47
(3) Place four old tyres, without wheels, on top of the
tyre secured to the air bag module, and secure all
tyres with ropes (4 locations).
<Side air bag module>
(1) Place the seat back assembly so that the rear of
the assembly is lying on the ground.
(2) Connect SRS air bag adapter harness A (which is
connected to the deployment harness) to the side
air bag module connector.
5. At a location as far away from the air bag module as
possible, and from a shielded position, disconnect the
two connected wires fromeach other, and connect them
to the two terminals of the battery (which has been
removed from the vehicle) to deploy the air bag.
Caution
1. Before deployment, check carefully to be sure
that no one is nearby.
deployment, so wait at least 30 minutes to allow
it to cool before attempting to handle it. Although
the gas resulting from air bag deployment is not
poisonous, it should not be inhaled. Refer to the
Deployed Air Bag Module or Operated Seat Belt
Pre-tensioner Disposal Procedures (P.52B-49) for
post-deployment handling instructions.
3. If the air bag fails to deploy when the procedures
above are followed, do not go near the module.
Contact your local distributor.
6. After deployment, dispose of air bag module according
to the Deployed Air Bag Module or Operated Seat Belt
Pre-tensioner Disposal Procedures. (Refer to P.52B-49.)
SEAT BELT PRE-TENSIONER OPERATION
Operatetheseatbeltpre-tensioner bythefollowingprocedure
after it has been removed from the vehicle.
Caution
Operation of the seat belt pre-tensioner should be carried
out in a clear, open space at least 5 meters away from
people and other objects.
Tyres without wheels
Deployment wire
Seat back assembly
SRS air bag
adapter harness A
MB686560
SRS-
52B-48
1. Remove the seat belt with pre-tensioner. (Refer to
P.52B-40.)
Caution
The pre-tensioner safety mechanism should be
engaged to prevent accidental operation of the
pre-tensioner.
2. Tie a rope which is 6 meters or more in length to the
seat belt pre-tensioner so that the pre-tensioner is level
and the sensor side (the side with the white cover) is
at the bottom when the pre-tensioner is suspended.
3. Disengage the pre-tensioner safety mechanism by the
following procedure.
Caution
After disengaging the safety mechanism, the
pre-tensioner can operate even if it is dropped by
a distance of as little as 5 cm, so be extremely careful
when handling the pre-tensioner in this condition.
(1) Liftupthestopper andthenbringthe retractor bracket
and plate (A) together so that the stopper tab goes
into the hole in the retractor bracket. This will
disengage the safety mechanism.
(2) Use a bulldog clip to secure the retractor bracket
and plate (A) so that they do not become separated.
4. Place the pre-tensioner down gently onto a solid base
such as a concrete floor, and stack four tyres without
wheels around it. Then place one more tyre with the
wheel still attached on top, and pass the rope through
the hole in the middle of the wheel.
5. Tie the tyres together with rope so that they do not slip
apart.
6. Froma distance of 5 meters away, pull the rope to raise
the seat belt pre-tensioner off the ground by 20 cm or
more.
Sensor side
(white cover side)
6 mor more
Approx.
0.4 m
Retractor bracket
Plate (A)
Stopper
Old tyre with
wheel attached
Old
tyres
without
wheels
20 cm
or more
5 mor more
SRS-
52B-49
7. Release the rope so that the pre-tensioner drops down
and operates from the force of the impact.
Caution
1. Check that nobody is near the tyres before
operating the pre-tensioner.
2. The seat belt pre-tensioner will be hot after it has
operated, so leave it for 30 minutes or more to
wait for it to cool down before handling it further.
3. If the safety mechanism has not been properly
disengaged or if the cylinder is not at the bottom
when the pre-tensioner is dropped, the
pre-tensioner may not operate. In such cases,
repeat the procedure from the beginning, while
being careful to avoid applying shocks to the
pre-tensioner.
8. After the seat belt pre-tensioner has operated, dispose
of itaccordingtotheproper disposal procedures discribed
below.
DEPLOYED AIR BAG MODULE OR OPERATED
SEAT BELT PRE-TENSIONER DISPOSAL
PROCEDURES
After deployment or operation, the air bag module and the
seat belt pre-tensioner should be disposed of in the same
manner as anyotherscrapparts, adheringtolocal laws and/or
legislationthatmaybeinforceexcept thatthe followingpoints
should be carefully noted during disposal.
deployment, so wait at least 30 minutes to allow it cool
before attempting to handle it.
2. Do not put water or oil on the air bag after deployment
or on the seat belt pre-tensioner after operation.
3. There may be, adhered to the deployed air bag module
or theoperatedseatbeltpre-tensioner, material thatcould
irritate the eye and/or skin, so wear gloves and safety
glasses when handling a deployed air bag module or
a operated seat belt pre-tensioner. IF AFTER
FOLLOWING THESE PRECAUTIONS, ANY MATERIAL
DOES GET INTO THE EYES OR ON THE SKIN,
IMMEDIATELY RINSE THE AFFECTED AREA WITH A
LARGE AMOUNT OF CLEAN WATER.
IF ANY IRRITATION DEVELOPS, SEEK MEDICAL
ATTENTION.
4. Tightlyseal theair bagmoduleandseatbeltpre-tensioner
in a strong vinyl bag for disposal.
NOTE
Thesideairbagmoduledoes notcontainanytoxicsodium
azides, so that the seat back assembly with built-in side
air bag module can be disposed of in the same way
as a seat without a side air bag.
5. Be sure to always wash your hands after completing this
operation.
Strong
vinyl bag
Air bag module
and seat belt
pre-tensioner
NOTES
54-1
CHASSIS
ELECTRICAL
BATTERY 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATION 4 . . . . . . . . . . . . . . .
Fluid Level and Specific Gravity Check 4 . . . . .
Charging 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Testing Procedure 6 . . . . . . . . . . . . . . . . . .
IGNITION SWITCH, ETACS-ECU AND
IMMOBILIZER SYSTEM* 7 . . . . . . . . . . . . .
SPECIAL TOOL 7 . . . . . . . . . . . . . . . . . . . . . . . . .
IGNITION SWITCH, ETACS-ECU AND
IMMOBILIZER SYSTEM 17 . . . . . . . . . . . . . . . .
COMBINATION METERS 20 . . . . . . . . . . . .
SEALANT 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 21 . . . . . . . . . . . . . . . . . . . . . .
WARNING!
MITSUBISHI dealer.
component.
NOTE
54-2
Speedometer Check 24 . . . . . . . . . . . . . . . . . . . . . .
Tachometer Check 24 . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Simple Check 25 . . . . . . . . . . . . . . . .
Fuel Gauge Unit Check 25 . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Gauge Simple
Check 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Gauge Unit
Check 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMBINATION METERS 28 . . . . . . . . . . . . . . .
HEADLAMP AND FRONT
TURN-SIGNAL LAMP* 30 . . . . . . . . . . . . . .
SPECIAL TOOLS 30 . . . . . . . . . . . . . . . . . . . . . .
Headlamp Aiming 37 . . . . . . . . . . . . . . . . . . . . . . . .
Intensity Measurement 38 . . . . . . . . . . . . . . . . . . . .
Bulb Replacement 39 . . . . . . . . . . . . . . . . . . . . . . . .
HEADLAMP AND FRONT TURN-SIGNAL
LAMP 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIDE TURN-SIGNAL LAMP 44 . . . . . . . . .
SPECIAL TOOL 44 . . . . . . . . . . . . . . . . . . . . . . .
FRONT FOG LAMP 45 . . . . . . . . . . . . . . . .
SPECIAL TOOL 45 . . . . . . . . . . . . . . . . . . . . . . .
Front Fog Lamp Aiming 45 . . . . . . . . . . . . . . . . . .
Bulb Replacement 46 . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FOG LAMP 47 . . . . . . . . . . . . . . . . . . . .
REAR COMBINATION LAMP 48 . . . . . . . .
SPECIAL TOOL 48 . . . . . . . . . . . . . . . . . . . . . . .
REAR COMBINATION LAMP 49 . . . . . . . . . . .
HIGH MOUNTED STOP LAMP 51 . . . . . .
RHEOSTAT 52 . . . . . . . . . . . . . . . . . . . . . . . .
HAZARD WARNING LAMP
SWITCH 53 . . . . . . . . . . . . . . . . . . . . . . . . . . .
HORN 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIGARETTE LIGHTER 54 . . . . . . . . . . . . . .
CLOCK 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL 55 . . . . . . . . . . . . . . . . . . . . . . .
CLOCK 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54-3
RADIO AND TAPE PLAYER 56 . . . . . . . .
RADIO AND TAPE PLAYER 72 . . . . . . . . . . . .
SPEAKER 73 . . . . . . . . . . . . . . . . . . . . . . . . .
ANTENNA 74 . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW DEFOGGER 77 . . . . . . .
Printed-heater Line Check 77 . . . . . . . . . . . . . . . . .
Rear Window Defogger Relay Continuity Check
77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW DEFOGGER SWITCH
<VEHICLES WITH MANUAL A/C> 78 . . . . . .
THEFT-ALARM SYSTEM 79 . . . . . . . . . . . .
SPECIAL TOOLS 79 . . . . . . . . . . . . . . . . . . . . . .
TRACTION CONTROL (TCL)
Refer to GROUP 13 . . . . . . . . . . . . . . . . . . .
RADIATOR FAN MOTOR
Refer to GROUP 14 . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
Refer to GROUP 23 . . . . . . . . . . . . . . . . . . .
SERVICE BRAKES (ABS)
Refer to GROUP 35B . . . . . . . . . . . . . . . . .
DOOR GLASS AND REGULATOR
(POWER WINDOWS)
Refer to GROUP 42 . . . . . . . . . . . . . . . . . . .
DOOR HANDLE AND LATCH
(DOOR LOCKING)
Refer to GROUP 42 . . . . . . . . . . . . . . . . . . .
KEYLESS ENTRY SYSTEM
Refer to GROUP 42 . . . . . . . . . . . . . . . . . . .
SUNROOF Refer to GROUP 42 . . . . . . . .
WINDSHIELD WIPER AND WASHER
Refer to GROUP 51 . . . . . . . . . . . . . . . . . . .
REAR WIPER AND WASHER
Refer to GROUP 51 . . . . . . . . . . . . . . . . . . .
DOOR MIRROR (ELECTRONIC
CONTROLLED DOOR MIRROR)
Refer to GROUP 51 . . . . . . . . . . . . . . . . . . .
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) Refer to GROUP 52B . . . . . . . . . . .
HEATER Refer to GROUP 55 . . . . . . . . . .
AIR CONDITIONER
Refer to GROUP 55 . . . . . . . . . . . . . . . . . . .
CHASSIS ELECTRICAL - Battery 54-4
BATTERY 54100030028
Item Specification
Specific gravity of the battery fluid 1.220- 1.290 [20_C]
FLUID LEVEL AND SPECIFIC GRAVITY CHECK
1. Inspect whether or not the battery fluid is between the
UPPER LEVEL and LOWER LEVEL marks.
2. Use a hydrometer and thermometer to check the specific
gravity of the battery fluid.
Standard value: 1.220- 1.290 [20_C]
The specific gravity of the battery fluid varies with the
temperature, so use the following formula to calculate
the specific gravity for 20_C. Use the calculated value
to determine whether or not the specific gravity is
satisfactory.
D20=Dt+0.0007 (t - 20)
D20: Specific gravity of the battery fluid calculated
for 20_C.
Dt: Actually measured specific gravity
t: Actually measured temperature
Thermo
meter
Hydrometer
Good
CHARGING 54100110029
1. When charging a battery while still installed in the vehicle,
disconnect the battery cables to prevent damage to
electrical parts.
2. The current normally used for charging a battery should
be approximately 1/10th of the battery capacity.
3. When performing a quick-charging due to lack of time,
etc., the charging current should never exceed the battery
capacity as indicated in amperes.
4. Determining if charging is completed.
(1) If the specific gravity of the battery fluid reaches
1.250- 1.290 and remains constant for at least one
hour.
(2) If the voltage of each cell reaches 2.5- 2.8 V and
remains constant for at least one hour.
Caution
1. Be careful since the battery fluid level may rise
during charging.
2. Keep all sources of fire away while charging
because there is a danger of explosion.
3. Be careful not to do anything that could generate
sparks while charging.
4. When charging is completed, replace the battery
caps, pour clean water over the battery to remove
any sulfuric acid and dry.
BATTERY TESTING PROCEDURE 54100120176
TEST STEP
(1) Turn headlamps on for 15 seconds.
(2) Turn headlamps off for 2 minutes to allow battery voltage to
stabilize.
(3) Disconnect cables.
OK
Read open circuit voltage.
OK: Open circuit voltage is more than 12.4 V
(specific gravity: 1.240)
NG
Charge battery at 5 amps. (see LOAD TEST RATE CHART)
Retest OK
(1) Connect a load tester to the battery.
(2) Load the battery at the recommended discharge rate (seeLOAD
TEST RATE CHART) for 15 seconds.
(3) Read voltage after 15 seconds, then remove load.
(4) Compare the measured value with the minimum voltage (see
LOAD TEST CHART).
OK: Higher than minimum voltage
NG
Replace battery
OK
Normal
LOAD TEST RATE CHART
Battery type 75D26L 95D31L
Charging time when fully discharged
h [5-amp rated current charging]
11 14
Load test (Amps) 260 310
LOAD TEST CHART
Temperature _C 21 and
above
16 10 4 - 1 - 7 - 12 - 18
Minimum voltage V 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
CHASSIS ELECTRICAL -
Ignition Switch, ETACS-ECU
and Immobilizer System
54-7
IGNITION SWITCH, ETACS-ECU AND IMMOBILIZER
SYSTEM 54300060092
SPECIAL TOOL
MB991502 MUT-II sub
assembly
D Immobilizer system check
(Diagnosis display using the MUT-II)
D Registration of the ID code
D ETACS-ECU input signal checking
IGNITION SWITCH
DIAGNOSIS FUNCTION
INPUT SIGNAL INSPECTION POINTS <VEHICLES
WITH ETACS-ECU>
2. If buzzer of the MUT-II sounds once when a switch is
operated (ON/OFF), the ETACS-ECU input signal for that
switch circuit system is normal.
procedure No.
Reference page
Communication with MUT-II is not
possible.
Communication with all systems is not
possible.
1 54-8
Communication with the one-shot
pulse input signal only is not possible.
2 54-8
While key hole illumination lamp is illuminated, ignition key is turned to the ON
position but key hole illumination lamp does not switch off. (However, it switch
off after 10 seconds.)
3 54-8
Key hole illumination lamp remains illuminated. 4 54-9
Even if drivers side door is opened, key hole illumination lamp does not
illuminate.
5 54-9
MUT-II
54-8
CommunicationwithMUT-II is not possible. (Communica-
tion with all systems is not possible.)
Probable cause
diagnosis line.
D Malfunction of harness wire
tion with the one-shot pulse input signal only is not
possible.)
Probable cause
The cause is probably a defective one-shot pulse input signal circuit system of the
diagnosis line.
D Malfunction of ECU
sis connector and junction block.
OK
C-20, C-134 and C-144
NG
Repair
NG
Repair
OK
NG
Replace the ECU.
While key hole illumination lamp is illuminated, ignition
key is turned to the ON position but key hole illumination
lamp does not switch off. (However, it switch off after 10
seconds.)
Probable cause
The cause is probably a defective ignition switch input circuit or a defective ECU. D Malfunction of connector
NG
MUT-II Input Signal Inspection
Ignition switch input signal
when the ignition key is turned
to the ON or OFF position.
OK
Replace the ECU.
NG
Disconnect the junction block connector
C-131, andmeasureat the harnessside.
D Voltage between the terminal (6) and
earth
OK: System voltage
OK
C-144 and C-131
NG
Repair
NG
ignition switch (IG1) and junction block,
OK
Check trouble symptom. Replace the ECU.
54-9
Key hole illumination lamp remains illuminated. Probable cause
The cause is probably a harness short or a defective ECU. D Malfunction of harness wire
When the connector C-134 of the junction block (1) is disconnected,
does the lamp switch off?
NO
Check the harness wire between the key reminder switch and
junction block, and repair if necessary.
YES
Replace the ECU.
Even if drivers side door is opened, key hole illumination
lamp does not illuminate.
Probable cause
The cause is probably a defective key hole illumination lamp circuit systemor a defective
drivers side door switch input circuit system.
D Malfunction of drivers side door switch
D Malfunction of bulb
OK
Key hole illumination lamp inspection
NG
Replace
NG
key reminder switch and junction block,
OK
OK
C-109, C-134 and C-144
NG
Repair
MUT-II Input Signal Inspection
Drivers side door switch input signal
when the drivers side door switch
is ON.
NG
Drivers side door switch input circuit
system inspection (Refer to Inspection
Procedure 6 on P.54-10.)
OK
Disconnect the key reminder switch
connector C-109, and measure at the
harness side.
earth
OK: System voltage
NG
L.H. drive vehicles: C-66, C-63, C-132,
C-141
R.H. drive vehicles: C-62, C-14
NG
Repair
OK
NG
NG
key reminder switch and junction block,
Repair
OK
Replace the ECU.
54-10
Drivers side door switch input circuit system inspection
OK
NG
Replace the ECU.
Door switch inspection (Refer to
GROUP 42 - Door Assembly.)
NG
Replace
OK
Door switch earth inspection
NG
Repair
OK
Disconnect the door switch connector
E-09 <L.H. drive vehicles>, E-08 <R.H.
drive vehicles>, and measure at the har-
ness side.
earth
OK: System voltage
NG
C-144 and C-143
NG
Repair
OK
NG
door switch and junction block, and re-
pair if necessary.
IMMOBILIZER SYSTEM
Caution
The ID code should always be re-registered when replacing the immobilizer-ECU.
Refer to GROUP 00 - How To Use Troubleshooting/Inspection Service Points.
DIAGNOSIS FUNCTION
Caution
The diagnosis codes which result from disconnecting the battery cables cannot be erased.
Diagnosis codeNo. Inspection items Reference
page
11* Transponder communication system 54-11
12* ID code are not the same or are not registered 54-11
21 Communication system between immobilizer-ECU and engine-ECU 54-12
31 EEPROM abnormality inside immobilizer-ECU 54-12
32 Ignition switch IG signal circuit system 54-12
33* Starting prevention system activated due to incorrect operation. 54-13
NOTE
*: Diagnosis code No. 11, No. 12 and No.33 are not recorded.
54-11
Code No. 11 Transponder communication system Probable cause
The ID code of the transponder is not sent to the immobilizer-ECU immediately after
If the engine is started while several ignition keys are in the vicinity, then interference
between the different keys may occur, which will cause this code to be generated.
D Malfunction of the transponder
D Malfunction of the ignition key ring antenna
NG
OK
C-68, C-104
NG
Repair
OK
NG
Check the harness wire between immo-
bilizer-ECU and key ring antenna.
NG
Repair
OK
Does the engine start using the spare
ignition key which has had the ID code
registered?
OK
Replace the ignition key that does not
work.
Re-register the ID code.
(Refer to P.54-19.)
NG
Diagnosis codes check
Code No. 12 occurs
To INSPECTION PROCEDURE FOR
DIAGNOSIS CODE No. 12
(Refer to P.54-11.)
Code No. 11 occurs
Check the continuity of the ignition key
ring antenna. (Refer to P.54-18.)
NG
Replace
Are there any other ignition keys in the
vicinity of the ignition key being used
for starting?
Yes
Move other keys well away from the
key being used.
No
Code No. 12 IDcode are not the same or are not registered Probable cause
The ID code which is sent from the transponder is not the same as the ID code
which is registered in the immobilizer-ECU.
D The ID code in the ignition key being used has not
been properly registered.
(Refer to P.54-19.)
NG
54-12
Code No.21 Communication system between immobiliz-
er-ECU and engine-ECU
Probable cause
After the ignition switch is turned to the ON position, the confirmation code is not
receivedfromtheengine-ECUwithintheallowabletime, or an abnormal code is received.
Is diagnosis code No. 54 being gener-
ated by the engine-ECU?
NO
Check the engine-ECU power source
and the earth circuit.
(Refer to GROUP 13A - Troubleshoot-
ing.)
YES
C-68, C-81, C-38 <4G6>
C-37, <6A1>, C-54 <4D6>
NG
Repair
OK
NG
Check the harness wire between en-
gine-ECU and immobilizer-ECU.
NG
Repair
OK
NG
OK
NG
Code No. 31 EEPROM abnormality inside immobilizer-
ECU
Probable cause
No data has been written to the EEPROM inside the immobilizer-ECU. D Malfunction of the immobilizer-ECU
NG
Code No.32 Ignition switch IG signal circuit system Probable cause
The ignition switch signsl is not being input to the immobilizer-ECU. D Malfunction of harness or connector
Check the input of the ignition switch
IG signal.
Measure at the immobilizer-ECU con-
nector C-68.
(Ignition switch: ON position)
OK System voltage
NG
C-68, C-134, C-131
NG
Repair
OK
NG
NG
Check the fuse and the harness wire
between ignition switch (IG) and immo-
bilizer-ECU.
Repair
OK
Check trouble symptoms
NG
(Refer to 54-18.)
OK
54-13
Code No.33 Starting prevention system activated due to
incorrect operation
Probable cause
If the transponder ID code mismatches five times in succession, this code will be
output. This code can be canceled by turning the ignition switch ON, and then turning
it OFF after 16 minutes have passed.
Turn the ignition switch ON and then turn it OFF after 16 minutes
have passed.
Re-register the ID code. (Refer to P.54-19.)
NG
Replace the ignition key.
NG
Replace the immobilizer-ECU
Communication with MUT-II is impossible. 1 54-14
Diagnosis code No. 54 has been generated by the engine-ECU. 2 54-14
ID code cannot be registered using the MUT-II. 3 54-15
Engine does not start (Cranking but no initial combustion). 4 54-15
Malfunction of the immobilizer-ECU power source and earth circuit 5 54-16
54-14
Communication with MUT-II is impossible. Probable cause
The cause is probably that a malfunction of the diagnosis line or the immobilizer-ECU
is not functioning.
D Malfunction of the diagnosis line
D Malfunction of the immobilizer
Can the MUT-II communicate with the
engine-ECU?
NO
C-68, C-104
NG
Repair
YES
Disconnect the immobilizer-ECU con-
nector C-68 and check at the harness
side.
(Short-circuited harness wire between
terminal No. 13 and No. 14)
NG
Repair
OK
NG
Check the harness wire between immo-
bilizer-ECU and diagnosis connector.
NG
Repair
OK
Check the immobilizer-ECU power sup-
ply and earth circuit. (Refer to INSPEC-
TION PROCEDURE 5.)
OK
NG
OK
NG
Diagnosis code No. 54 has been generated by the
engine-ECU.
Probable cause
There is a problem with communication between the engine-ECU and the
immobilizer-ECU.
C-68, C-81, C-38 <4G6>,
C-37 <6A1>, C-54 <4D6>
NG
Repair
OK
NG
Check the harness wire between en-
gine-ECU and immobilizer-ECU.
NG
Repair
OK
Is diagnosis code No. 21 being gener-
ated by the immobilizer-ECU?
YES
NO
Check the immobilizer-ECU power sup-
ply and earth circuit. (Refer to INSPEC-
TION PROCEDURE 5.)
OK
NG
NG
NG
54-15
ID code cannot be registered using the MUT-II. Probable cause
The cause is probably that there is no ID code registered in the immobilizer-ECU,
or there is a malfunction of the immobilizer-ECU.
D Malfunction of the ignition key ring antenna
No ignition key can be registered.
NO
Replace the ignition key that cannot be
registered.
(Refer to P.54-19.)
YES
Is a normal diagnosis code output?
NO
To INSPECTION CHART FOR DIAG-
NOSIS CODE (Refer to P.54-10.)
YES
Check the immobilizer-ECU power
source and earth circuit. (Refer to IN-
OK
NG
Engine does not start (crankingbut noinitial combustion). Probable cause
If the fuel injectors are not operating, there might be a problem with the MPI system
in addition to a malfunction of the immobilizer system.
It is normal for this to occur if an attempt is made to start the engine using a key
that has not been properly registered.
D Malfunction of the MPI system
Check the systemvoltage during crank-
ing
OK: 8V or more
NG
Check the battery. (Refer to P 54-4.)
OK
Is the diagnosis code ouutput?
Yes
To INSPECTION CHART FOR DIAG-
NOSIS CODE (Refer to P.54-10.)
No
Check thefuel system(Refer toGROUP
13E - On-vehicle Service.)
NG
Repair
OK
Check thepower supplyand earthcircuit
of the immobilizer (Refer to INSPEC-
TION PROCEDURE 5)
OK
NG
Replace the immobilizer-EUC.
NG
Replace the Injection pump assembly.
NG
Repair
54-16
Malfunction of the immobilizer-ECU power supply and earth circuit
Measure at the immobilizer-ECU con-
nector.
1. Voltage between 1 and earth and
between 9 and earth <Petrol-pow-
ered vehicles>
OK: System voltage
2 Continuity between 8 and earth
OK: Continuity
3 Continuity between 16 and body
earth
OK: Continuity
1. NG
C-81, C-47
NG
Repair
OK
NG
Checktheharness wire betweenimmo-
bilizer-ECUandenginecontrol relayand
2, 3. NG
L.H. drive vehicles: C-62.
R.H. drive vehicles: C-63, C-64.
NG
Repair
OK
NG
Checktheharness wirebetweenimmo-
bilizer-ECU and body earth and repair
if necessary.
CHECK AT IMMOBILIZER-ECU
Terminal No. Signal Checking requirements Terminal voltage
1 Immobilizer-ECU power supply Ignition switch: ON Systemvoltage
2 Ignition switch-IG Ignition switch: OFF 0V
Ignition switch: ON Systemvoltage
8 Immobilizer-ECU earth Always 0V
9 Immobilizer-ECU power supply Ignition switch: ON Systemvoltage
16 Immobilizer-ECU earth Always 0V
CHASSIS ELECTICAL -
and Immobolizer System
54-17
IGNITION SWITCH, ETACS-ECU AND IMMOBILIZER SYSTEM 54300210220
Caution: SRS
Before removal of air bag module and clock
spring, refer to GROUP 52B - Service
Precautions and Air Bag Module and Clock
Spring.
5
6
9
7
12
11
10
8
2
1
3
4
ETACS-ECU removal steps
1. J unction block
2. ETACS-ECU
Immobilizer-ECU removal steps
4. Instrument under cover
(Refer to GROUP 52A - Instru-
ment Panel.)
5. Immobilizer-ECU
Ignition switch and ignition key
ring antenna removal steps
4. Instrument under cover
(Refer to GROUP 52A - Instru-
ment Panel.)
6. Steering wheel
7. Column cover, upper
8. Column cover, lower
9. Column switch (Refer to GROUP
37A - Steering Wheel and Shaft.)
10. Ignition key ring antenna
A A" 11. Steering lock cylinder
12. Ignition switch
CHASSIS ELECTICAL -
54-18
A A" STEERING LOCK CYLINDER REMOVAL
1. Insert the key in the steering lock cylinder and turn it
to the ACC position.
2. Using a cross-tip (+) screwdriver (small) or a similar tool,
push the lock pin of the steering lock cylinder inward
and then pull the steering lock cylinder toward you.
IGNITION SWITCH CONTINUITY CHECK
1. Remove the column cover lower and upper.
2. Disconnect the wiring connector fromthe ignition switch.
3. Operate the switch, and check the continuity between
the terminals.
Ignition key posi-
Terminal No.
Ignition key posi-
tion
1 2 3 4 5 6
LOCK
ACC
ON
START
IGNITION KEY RING ANTENNA CONTINUITY CHECK
Use a circuit tester to check the continuity between the
terminals.
Cross-tip (+)
screwdriver
CHASSIS ELECTICAL -
54-19
ID CODE REGISTRATION METHOD 54300810062
If using an ignition key that has just been newly purchased,
or if the immobilizer-ECU has been replaced, you will need
to register the ID codes for each ignition key being used
into the immobilizer-ECU. (A maximum of eight different ID
codes can be registered.)
Moreover, whenthe immobilizer-ECU has been replaced, you
will need to use the MUT-II to register the ID number that
the user specifies into the immobilizer-ECU. (Refer to the
MUT-II instructionmanual forinstructionsonusingtheMUT-II.)
Caution
If registering of the ID codes is carried out all
previously-registered codes will be erased. Accordingly,
you should have ready all of the ignition keys that have
already been registered.
Caution
Connection and disconnection of the MUT-II should
always be carried out with the ignition switch in the
OFF position.
2. Use the ignition key that is to be registered to turn the
ignition switch to the ON position.
3. Use the MUT-II to register the ID code. If you are
registering two or more codes, use the next key to be
registered to turn the ignition switch to the ON position
without disconnecting the MUT-II.
4. Disconnect the MUT-II. This completes the registration
operation.
MUT-II
CHASSIS ELECTRICAL - Combination Meters 54-20
COMBINATION METERS 54300030215
Speedometer indicationerror km/h(mph) 40 (20) 40- 48 (20- 25)
80 (40) 80- 92 (40- 47)
120 (60) 120- 136 (60- 69)
160 (80) 160- 180 (80- 91)
- (100) - (100- 114)
Tachometer indication error r/min 700 100
3,000 150
5,000 250
6,000 300
Fuel gauge unit resistance W Float point F 4 2
Float point E 112 7
Fuel gauge unit float height mm A (Float point F) 28.6
B (Float point E) 159.9
Fuel gauge resistance W Power supply and earth 111.5
Power supply and fuel gauge 98.2
Fuel gauge and earth 101.0
Engine coolant temperature gauge Power supply and earth 111.5
resistance W
Power supply and engine coolant
temperature gauge
53.6
Engine coolant temperature gauge
and earth
165.0
Engine coolant temperature gauge unit resistance (at 70_C) W 10413.5
SEALANT 54300050037
Items Specified sealant Remark
Engine coolant temperature gauge
unit threaded portion
3M Adhesive nut locking No. 4171 or
equivalent
Drying sealant
A
B
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Making voltage and resistance measurements
during troubleshooting
A: Connector pin contact pressure check
B: Power circuit check
C: Power circuit check
procedure
Reference
page
Speedometer does not work. 1 54-22
Tachometer does not work. 2 54-23
Speedometer does not work. Probable cause
The cause may be a defective vehicle speed sensor circuit system or a defective
speedometer. Vehicle speed sensor is also used by the engine-ECU and A/T-ECU.
D Malfunction of vehicle speed sensor
D Malfunction of speedometer
Disconnect the combination meter con-
nectors D-01, D-02 and D-03 and mea-
sure at the harness sides.
1. Measure the voltage between
terminal No.25 and body earth when
the vehicle is moved forwards and
backwards.
OK: 4.7 V or more
2. Voltage between the terminal No.4
and body earth
OK: System voltage (Ignition
switch: ON)
3. Continuity between the terminal
No.46 and body earth
OK: Continuity
1. NG
Vehicle speed sensor circuit system
inspection (Refer to Inspection
Procedure 3 on P.54-23.)
2. NG
D-03, C-135, C-131
NG
Repair
OK
NG
power supply and combination meter,
3. NG
C-25, D-01
NG
Repair
OK
Replace the speedometer.
OK
NG
body earth and combination meter, and
Tachometer does not work. Probable cause
The ignition signal may not be input from the engine, or there may be a malfunction
in the power supply or ground circuit.
D Malfunction of tachometer
Disconnect the combination meter con-
nector D-03 and measure at the harness
sides.
1. Measure the voltage between
terminal No.8 and body earth.
OK: 5 V
2. Continuity between the terminal
No.7 and body earth
OK: Continuity
3. Voltage between the terminal No.4
and body earth
OK: System voltage
1. NG
C-90, D-03
NG
Repair
OK
NG
distributor assembly <6A1> or engine-
ECU <4G6, 4D6> and combination me-
ter, and repair if necessary.
2. NG
C-45, C-90, D-03
NG
Repair
OK
NG
combination meter and the body earth,
OK
Replace the tachometer.
3. NG
C-131, C-135, D-03
NG
Repair
OK
NG
power supply and combination meter,
Vehicle speed sensor circuit system inspection
Vehicle speed sensor inspection (Refer to P.54-29.)
NG
Replace
OK
Disconnect the vehicle speed sensor connector B-67 <A/T> or
B-66 <M/T> and measure at the harness side.
1. Voltage between the terminal No.3 and body earth
OK: 4.5 V or more
2. Continuity between terminal No.2 and body earth
OK: Continuity
3. Voltage between the terminal No.1 and body earth
OK: System voltage (Ignition switch: ON)
1. NG
Check the following
connectors:
D-02, C-25, C-66, C-83,
B-67 <A/T>, B-66 <M/T>,
B-65 <M/T>
NG
Repair
NG
NG
combination meter, and repair if necessary.
3. NG
Check the following
connectors:
B-65<M/T>, C-90, C-135,
C-131
NG
Repair
2. NG
Check the following
connector:
B-65 <M/T>, B-67 <A/T>,
B-66 <M/T>
NG
Repair
OK
NG
Check theharnesswirebetween thevehicle speedsensor
OK
NG
body earth, and repair if necessary.
OK
Replace the speedometer.
SPEEDOMETER CHECK
1. Adjust tire pressure to the specified level.
(Refer to GROUP 31 Service Specifications.)
2. Set the vehicle onto a speedometer tester and use wheel
chocks to hold the rear wheels.
3. To prevent the front wheel from moving from side to side,
attach tension bars to the tie-down hook, and secure
both ends to anchor plates.
4. To prevent the vehicle from launching, attach a chain
or wire to the rear retraction hook, and make sure the
end of the chain or wire is secured firmly.
5. Check if the speedometer indicator range is within the
standard values.
Caution
Do not operate the clutch suddenly. Do not
increase/decrease speed rapidly while testing.
Standard values:
Standard indication km/h
(mph)
Allowable range km/h (mph)
40 (20) 40 - 48 (20 - 25)
80 (40) 80 - 92 (40 - 47)
120 (60) 120 - 136 (60 - 69)
160 (80) 160 - 180 (80 - 91)
- (100) - (100 - 114)
TACHOMETER CHECK 54300100176
1. Insert a paper clip in the engine speed detection connector
from the harness side, and attach an external high quality
tachometer.
NOTE
For tachometer check, use an external high quality
inductive tachometer.
2. Compare the readings of the vehicle tachometer and the
external tachometer at every engine speed, and check
if the variations are within the standard values.
Standard values:
700 r/min : 100 r/min
3,000 r/min : 150 r/min
5,000 r/min : 250 r/min
6,000 r/min : 300 r/min
Wheel chocks
Tension bar
Front
Anchor plate
Engine speed
detection connector
Tachometer
Paper clip
FUEL GAUGE SIMPLE CHECK 54300110179
NG
Replace the fuel gauge.
NG
Repair the harness.
When the ignition switch is turned to
ON, the test lamp illuminates.
OK
The needle of the fuel gauge moves.
OK
Replace the fuel gauge unit.
Use the special tool to connect a test
lamp (12 V - 3.4 W) to the harness
connector.
Remove the fuel gauge unit connector.
MB991219
Earth
Test lamp
(12 V - 3.4 W)
Fuel gauge
FUEL GAUGE UNIT CHECK 54300120240
Remove the fuel gauge unit from the fuel tank.
(Refer to GROUP 13F.)
FUEL GAUGE UNIT RESISTANCE
1. Check that resistance value between the fuel gauge
terminal and ground terminal is at standard value when
fuel gauge unit float is at point F (highest) and point
E (lowest).
Standard value:
Point F: 4 2 W
Point E: 112 7 W
2. Check that resistance value changes smoothly when float
moves slowly between point F (highest) and point E
(lowest).
Fuel gauge unit
Earth
FUEL GAUGE UNIT FLOAT HEIGHT
Move float and measure the height A at point F (highest)
and B at point E (lowest) with float arm touching stopper.
Standard value:
A: 28.6 mm
B: 159.9 mm
THERMISTOR
1. Connect fuel gauge unit (thermistor) to battery via test
lamp (12 V - 3.4 W). Immerse in water.
2. Condition is good if lamp goes off when the thermistor
is immersed in water and comes on when it is taken
out of water.
Caution
After finishing this test, wipe the unit dry and install
it in the fuel tank.
Point F
(highest)
Point E
(lowest) B
A
Thermistor
Earth
Thermistor
Illuminated
Not
illuminated
ENGINE COOLANT TEMPERATURE GAUGE SIMPLE CHECK 54300140215
When the ignition switch is turned to
ON, the test lamp illuminates.
OK
The needle of the engine coolant tem-
perature gauge moves.
NG
Replace the engine coolant
temperature gauge.
OK
Replace the engine coolant temperature
gauge unit.
NG
Repair the harness.
Connect a test lamp (12 V - 3.4 W)
between the harness side connector
and the earth.
Remove the engine coolant gauge unit
connector.
Earth
Test lamp
(12 V - 3.4 W)
Connector
Test lamp
(12 V - 3.4 W)
Test lamp
(12 V - 3.4 W)
Connector
Earth
MB991219
<4G6> <6A1>
<4D6>
Earth
ENGINE COOLANT TEMPERATURE GAUGE UNIT
CHECK 54300150041
1. Bleed the engine coolant.
(Refer to GROUP 00 Maintenance Service.)
2. Remove the engine coolant temperature gauge unit.
3. Immerse the unit in 70_Cwater to measure the resistance.
Standard value: 104 13.5 W
4. After checking, apply the specified adhesive around the
thread of engine coolant temperature gauge unit.
Specified sealant:
3M Adhesive Nut Locking No. 4171 or equivalent
5. Add engine coolant.
(Refer to GROUP 14 On-vehicle Service.)
COMBINATION METERS 54300290200
3
2
1
Vehicle speed sensor removal
steps
D Air cleaner assembly
1. Vehicle speed sensor
Combination meter removal steps
2. Meter bezel
3. Combination meter
11 Nm
CHASSIS ELECTRICAL - Combination Meters CHASSIS ELECTRICAL - Combination Meters 54-29
VEHICLE SPEED SENSOR CHECK
1. Remove the vehicle speed sensor and connect a 3 -
10 kW resistance as shown in the illustration.
2. Turn the shaft of the vehicle speed sensor and check
that there is voltage between terminals 2 - 3. (1 turn
= 4 pulses)
FUEL GAUGE RESISTANCE CHECK 54300300132
1. Remove the power supply tightening screw.
2. Use an ohmmeter to measure the resistance value
between the terminals.
Standard value:
Power supply - Earth: 111.5 W
Power supply - Fuel gauge: 98.2 W
Fuel gauge - Ground: 101.0 W
Caution
Wheninsertingthe testingprobe intothe power supply
terminal, be careful not to touch the printed board.
ENGINE COOLANT TEMPERATURE GAUGE
RESISTANCE CHECK
1. Remove the power supply tightening screw.
2. Use an ohmmeter to measure the resistance value
between the terminals.
Standard value:
Power supply - Earth: 111.5 W
Power supply - Engine coolant temperature
gauge: 53.6 W
Engine coolant temperature gauge - Earth:
165.0 W
Caution
Wheninsertingthe testingprobe intothe power supply
terminal, be careful not to touch the printed board.
Turn
Shaft
Ohmmeter
Resistance
3 - 10 kW
Power supply
Fuel gauge
Earth
Engine coolant
temperature
gauge
Earth
Power supply
CHASSIS ELECTRICAL - Headlamp and Front Turn-Signal Lamp 54-30
HEADLAMP AND FRONT TURN-SIGNAL LAMP 54200300199
Headlight airming for low Vertical direction 60 mm below horizontal (H) -
beam
Horizontal direction Position where the 15 sloping section
intersects the vertical line (V)
-
Headlamp aiming for high Vertical direction 22 mm below horizontal (H) -
beam
Horizontal direction Parallel to direction of vehicle travel -
Headlamp intensity cd - 30,000 or more
MB991502 MUT-II sub assen-
bly
A
B
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Making voltage and resistance
measurements during troubleshooting
A: Connector pin contact pressure check
B: Power circuit check
C: Power circuit check
The special tool (MB991223) should always be used to measure voltages and resistance when carrying
out troubleshooting.
DIAGNOSTIC FUNCTION
2. If a buzzer of the MUT-II sounds once when a switch
is operated (ON/OFF), the ETACS-ECU input signal for
that switch circuit system is normal.
Trouble symptoms Trouble symptoms Inspection
procedure
Reference
page
Communication with MUT-II is impossi-
ble. <Vehicles with ETACS-ECU>
Communication with all systems is
impossible.
1 54-32
Communication with one-shot pulse input
signal only is impossible.
2 54-32
The lighting monitor buzzer doesnt sound under the following conditions while tail
lamps or headlamps illuminate.
D When the ignition switch is turned to OFF and the drivers side door is open.
3 54-32
Headlamp leveling does not occur when the headlamp leveling switch is operated. 5 54-34
The headlamps do not illuminate when the vehicle is in the following condition and the
ignition switch is at the ON position. However, the headlamps illuminate when the
lighting switch is moved to the HEAD position.
<Vehicles with daytime running lamp system>
D Lighting switch: OFF
D Passing switch: OFF
6 54-35
The headlamps do not switch off when the vehicle is in the following condition and the
lighting switch is moved to the TAIL position.
<Vehicles with daytime running lamp system>
D Ignition switch: OFF
7 54-36
MUT-II
Communication with MUT-II is impossible. (Communica-
tion with all systems is impossible.)
Probable cause
The cause is probably a defective power supply system (including ground) for the
diagnosis line.
Refer to GROUP 13A - Troubleshoot-
ing.
Communication with the MUT-II is impossible. (Commu-
nication with the one-shot pulse input signal only is
impossible.)
Probable cause
The cause is probably a defective one-shot pulse input circuit system of the diagnosis
line.
diagnosis connector and junction block.
OK
C-20, C-134
NG
Repair
NG
Repair
OK
NG
The ignition switch is turned tothe OFF position andthe
drivers side door is opened while the tail lamps or
headlamps are operating, but the lighting monitor buzzer
does not sound.
Probable cause
The cause is probably a defective lighting switch input circuit system or a defective
drivers side door switch input circuit system.
D Malfunction of drivers side door switch
D Malfunction of BUZZER-ECU or ETACS-ECU
Drivers side door switch input circuit
system inspection
(Refer to Inspection Procedure 4.)
OK
C-20, C-134
NG
Repair
OK
NG
junction block and column switch.
OK
Replace the BUZZER-ECU or
ETACS-ECU.
NG
Repair
Drivers side door switch input circuit system inspection
Door switch inspection
(Refer to GROUP 42 Door Assembly.)
NG
Replace
OK
Door switch earth inspection
NG
Repair
OK
Disconnect the door switch connector
E-19 <L.H. drive vehicles>,
E-08 <R.H. drive vehicles>
and measure at the harness side.
D Voltage between the terminal No.
2 and body earth
OK: 5 V
NG
L.H. drive vehicles: E-19, C-144, C-145
R.H. drive vehicles: E-08, C-144, C-145
NG
Repair
OK
NG
door switch and junction block, and
OK
NG
Replace the BUZZER-ECU or
ETACS-ECU.
Inspection procedure 5
Headlamp leveling does not occur when the headlamp
leveling switch is operated.
Probable cause
The cause is probably a malfunction of the headlamp leveling switch circuit system
or a malfunction of the headlamp leveling unit circuit system.
If there is a blown fuse, there may also be a short-circuit in a harness.
D Malfunction of fuse
D Malfunction of the headlamp leveling switch
D Malfunction of the headlamp leveling unit
Headlamp leveling switch check
(Refer to P.54-42.)
NG
Replace
OK
Disconnect the headlamp leveling
switch connector C-94 and measure at
the harness side.
D Continuity between terminal No.3
- earth
OK: Continuity
NG
C-94, A-33
NG
Repair
OK
NG
Check the harness between the head-
lamp leveling switch and body earth.
Repair, if necessary.
1. NG
A-12, A-33, C-74, C-115
NG
Repair
OK
NG
lamp relay and the headlamp leveling
unit
OK
Disconnect the headlamp leveling unit
connectors A-12, A-33 and measure at
the harness side. Both the left and right
connectors of the headlamp leveling unit
should be checked.
1 Voltage between terminal No.1 -
earth
OK: System voltage
2 Continuity between terminal No.2 -
earth
OK: Continuity
2. NG
A-12, A-33
NG
Repair
OK
NG
Check the harness between the body
earth and the headlamp leveling unit.
OK
Disconnect the headlamp leveling unit
(LH), headlamp leveling unit (RH) and
headlamp leveling switch connectors
A-12, A-33, C-94 and measure at the
harness side.
D Continuity between terminal No. 3
of the headlamp leveling unit (both)
and terminal No. 4 of the headlamp
leveling switch.
OK: Continuity
NG
A-12, A-33, C-115, C-74, C-94
NG
Repair
OK
NG
lamp leveling switch and the headlamp
leveling unit (both).
OK
Malfunction of the headlamp leveling
unit.
Replace
The headlamps donot illuminate whenthe vehicle is inthe
followingconditionandthe ignitionswitchis movedtothe
ON position. However, they illuminate when the lighting
switch is moved to the HEAD position.
<Vehicles with daytime running lamp>
D Lighting switch: OFF
Probable cause
The cause is probably a malfunction of the daytime running lamp control unit (DRL-ECU)
circuit system. If there is a blown fuse, there may also be a short-circuit in a harness.
D Malfunction of the DRL-ECU
OK
Malfunction of the DRL-ECU. Replace
2. NG
A-37, C-14, C-116, B-18X
Headlamp relay check (Refer to
P.54-42.)
NG
Replace
OK
Disconnect the DRL-ECU connector
A-37 and measure at the harness side.
1. Voltage between terminal (No.1) and
earth
OK: System voltage
2. Voltage between terminal (No.9) and
earth
OK: System voltage
3. Continuity between terminal (No.2)
and earth
OK: Continuity
1. NG
A-37, C-14, C-63, C-132, C-131
NG
Repair
OK
NG
Check the harness between the DRL-
ECU and the ignition switch. Repair, if
necessary.
OK
NG
ECU and the headlamp relay. Repair,
if necessary.
3. NG
A-37, C-14
OK
NG
ECU and the body earth. Repair, if nec-
essary.
The headlamps donot switchoff whenthe vehicle is inthe
followingconditionandthe lightingswitchis movedtothe
TAIL position.
<Vehicles with daytime running lamp>
D Ignition switch: OFF
Probable cause
The cause is probably a malfunction of the daytime running lamp control unit (DRL-ECU)
circuit system. If there is a blown fuse, there may also be a short-circuit in a harness.
D Malfunction of the tail lamp relay
D Malfunction of the DRL-ECU
OK
NG
{{36#1}}
Lighting switch check
(Refer to P.54-41.)
NG
Replace
OK
Disconnect DRL-ECU connector A-37
and measure at the harness side.
D Continuity between terminal (2) -
earth
OK: Continuity
NG
A-37, C-14
NG
Repair
OK
NG
ECU and body earth.
OK
Malfunction of the DRL-ECU Replace
OK
Disconnect the DRL-ECU connector
A-37 and measure at the harness side.
D Continuity between terminal (5) -
earth
OK: System voltage
NG
A-37, C-14, C-116, B-14X
NG
Repair
OK
Tail lamp relay check (Refer to P.54-40.) Replace
HEADLAMP AIMING
<USING A BEAMSETTING EQUIPMENT>
1. The headlamps should be aimed with the proper
beamsetting equipment, and in accordance with the
equipment manufactures instructions.
NOTE
If there are any regulations pertinent to the aiming of
headlamps in the area where the vehicle is to be used,
adjust so as to meet those requirements.
2. Alternately turn the adjusting screwto adjust the headlamp
aiming. (Refer to P.54-38.)
3. With the engine running at 2,000 r/min. aimthe headlamp.
<USING A SCREEN>
1. Inflate the tyres to the specified pressures and there
should be no other load in the vehicles other than driver
or substituted weight of approximately 75 kg placed in
drivers position.
2. Set the distance between the screen and the centre marks
of the headlamps as shown in the illustration.
3. Check if the beam shining onto the screen is at the
standard value.
Standard value:
<For lower beam adjustment>
(Vertical direction)
60 mm below horizontal (H)
(Horizontal direction)
Position where the 15_ sloping section
intersects the vertical line (V)
Screen
5 m
Distance of
vertical direction
Lamp centre
15
High intensity zone
(V)
(H)
Standard value:
<For upper beam adjustment>
Parallel to direction of vehicle travel
Caution
1. When making the aiming adjustment, be sure to
mask those lamps which are not being adjusted.
2. When it is difficult, because of outside light, to
distinguish the light/dark dividing line, use a
curtain, screen or similar material to reduce the
effects of the outside light.
4. Alternately turn the adjusting screwto adjust the headlamp
aiming.
Caution
Be sure to adjust the aiming adjustment screw in
the tightening direction.
INTENSITY MEASUREMENT 54200100135
Using a photometer, and following its manufactures instruction
manual, measure the headlamp intensity and check to be
sure that the limit value is satisfied.
Limit: 30,000 cd or more
NOTE
1. When measuring the intensity, maintain an engine speed
of 2,000 r/min, with the battery in the charging condition.
2. There may be special local regulations pertaining to
headlamp intensity, be sure to make any adjustments
necessary to satisfy such regulations.
3. If an illuminometer is used to make the measurements,
convert its values to photometer values by using the
following formula.
I = Er
2
Where:
I = intensity (cd)
E = illumination (lux)
r = distance (m) from headlamps to illuminometer
(V)
Lamp centre
(H)
Centre of high
intensity zone High intensity
zone
Distance
of vertical
direction
Horizontal direction ad-
justment (Lower beam)
Horizontal direction
adjustment
(Upper beam)
Vertical direction
adjustment
(Upper beam)
BULB REPLACEMENT 54200130189
<Headlamp Bulb>
2. Remove the socket cover.
3. Unhook the spring which secures the bulb, and then
remove the bulb.
Caution
Do not touch the surface of the bulb with hands or
dirty gloves. If the surface does become dirty, clean
it with alcohol or thinner, and let it dry thoroughly
before installing.
<Position Lamp Bulb>
1. Disconnect the connector, and then remove the socket
cover of headlamp lower beam.
2. Pinch the spring and pull out the position lamp bulb.
<Turn-signal Lamp Bulb>
2. Turn the bulb socket counterclockwise together with the
bulb, and remove the bulb.
Caution
If the bulb socket is not securely installed, the lens
will moisten, or water will get inside the lamp unit,
so the bulb socket should be securely installed.
Socket cover
Spring
Spring
Spring
HEADLAMP AND FRONT TURN-SIGNAL LAMP 54200240141
CAUTION: SRS
spring, refer to GROUP 52B - Service
Spring.
6
4
1
2
3
5 Nm
5 Nm
5 Nm
5
1. Column switch <Lighting switch and
dimmer/passing switch>
Wheel and Shaft.)
Headlamp leveling switch removal
steps
2. Switch bezel
3. Headlamp leveling switch
Headlamp removal steps
AA" 4. Radiator grille
5. Front turn-signal lamp
6. Headlamp
CHASSIS ELECTRICAL - Headlamp and Front Turn-Signal Lamp
*
2
*
1
54-41
AA"RADIATOR GRILLE REMOVAL
Remove the radiator grille by pushing the tab of the radiator
grille clips in the direction of the arrows with a flat-tipped
screwdriver, while lightly pulling the radiator grille towards
you.
LIGHTING SWITCH, DIMMER/PASSING SWITCH AND
TURN-SIGNAL LAMP SWITCH CHECK
Switch position Connector A-
terminal No.
Connector B-
terminal No.
1 2 3 4 6 3 5 6 7 8 9
LIGHTING OFF
SWITCH
TAIL
HEAD
DIMMER/ LOWER
PASSING
UPPER
SWITCH
PASSING
TURN- RH
SIGNAL
OFF
LAMP
SWITCH LH
NOTE
1. *
1
indicates continuity when the dimmer switch is in the lower
position.
2. *
2
indicates continuity when the dimmer switch is in the upper
position.
Connector A
Connector B
HEADLAMP RELAY AND TAIL LAMP RELAY CHECK
1 3 4 5
Supplied
Not supplied
HEADLAMP LEVELING SWITCH CHECK
Check the resistance between the terminals when the
headlamp leveling switch is operated.
Standard value:
Resistance measure- Switch position
ment terminal No.
0 1 2 3 4
Between 3 and 4 W 1,235 1,114 977 862 747
Between 4 and 6 W 548 669 806 921 1,036
Between 3 and 6 W 1,003
Tail lamp relay
Headlamp relay
DAYTIME RUNNING LAMP RELAY CHECK
1 2 3 4
Supplied
Not supplied
Daytime running
lamp relay
CHASSIS ELECTRICAL - Side Turn-signal Lamp 54-44
SIDE TURN-SIGNAL LAMP 54200060105
SPECIAL TOOL
MB990784 Ornament remover Removal of side turn-signal lamp
REMOVAL SERVICE POINT 54200330091
AA"SIDE TURN-SIGNAL LAMP REMOVAL
Use a special tool to remove the lock from the fender panel,
and then remove the side turn-signal lamp.
"AASIDE TURN-SIGNAL LAMP INSTALLATION
1. Fit the lock into the fender panel.
2. Push the side turn-signal lamp into the fender, and secure
it with the hook.
MB990784
Fender panel
Hook
Fender panel
CHASSIS ELECTRICAL - Front Fog Lamp 54-45
FRONT FOG LAMP 54200030069
Front fog lamp aiming Vertical direction 100 mm below horizontal (H)
Horizontal direction Parallel to direction of vehicle travel
MB990784 Ornament remover Removal of switch garnish
FRONT FOG LAMP AIMING
1. Measure the centre of the fog lamps, as shown in the
illustration.
2. Set the distance between the screen and the centre of
the fog lamps as shown in the illustration.
3. Inflate the tyres to the specified pressures and there
should be no other load in the vehicles other than driver
or substituted weight of approximately 75 kg placed in
the drivers position.
4. With the engine running at 2,000 r/min, aim the fog lamp.
Parabola type
Unit: mm
Lamp
centre
Projector type
Lamp
centre
76
28
37
49
Screen
5 m
5 Check if the beam shining onto the screen is at the
standard value.
Standard value:
Parallel to direction of vehicle travel
NOTE
The horizontal direction is non-adjustable. If the deviation
of the light beam axis exceeds the standard value, check
to be sure that the mounting location or some other point
is not defective.
Caution
When making the aiming adjustment, be sure to mask
those lamps which are not being adjusted.
BULB REPLACEMENT 54200130196
1. Remove the fog lamp bezel.
2. Remove the fog lamp unit.
3. Undo the fog lamp rear cover.
4. Unhook the spring which secures the bulb and then
remove the bulb.
Caution
Do not touch the surface of the bulb with hands or
dirty gloves. If the surface does become dirty, clean
it with alcohol or thinner, and let it dry thoroughly
before installing.
Lamp centre
Distance of
vertical direction
Centre of high
intensity zone
High intensity zone
Parabola type
Adjusting
screw
Projector type
Adjusting screw
Fog lamp
rear cover
Fog lamp
rear cover
Spring
FRONT FOG LAMP 54200150161
3
3
4
1
2
4
5
5
Front fog lamp switch removal
steps
1. Side air outlet
2. Front fog lamp switch
Front fog lamp removal steps
3. Fog lamp bezel
4. Fog lamp
D Front bumper (Refer to GROUP 51.)
5. Fog lamp bracket
CHASSIS ELECTRICAL - Rear Combination Lamp 54-48
REAR COMBINATION LAMP 54200060471
SPECIAL TOOLS
MB991502 MUT-II sub
assembly
MB990784 Ornament remover Removal of side air outlet (L.H.)
REAR COMBINATION LAMP 54200450094
Caution: SRS
spring, refer to GROUP 52B - SRS Service
Spring.
<Sedan>
<Wagon>
2
3
1
5 Nm
5 Nm
5 6
4
7
8
9
5 Nm
9
1. Column switch <Lighting switch and
turn-signal lamp switch>
Wheel and Shaft.)
Rear fog lamp switch removal
steps
2. Side air outlet
3. Rear fog lamp switch
Rear combination lamp removal
steps <Sedan>
D Rear end side trim (L.H.)
D Side box (L.H.)
AA" 4. Rear combination lamp
Rear combination lamp removal
steps <Wagon>
5. Maintenance lid
6. Tailgate lamp lid
7. Rear combination lamp
D Tail gate waterproof film (Refer to
GROUP 42.)
8. Tailgate lamp
9. Packing
AA"REAR COMBINATION LAMP REMOVAL <SEDAN>
1. Turn up the trunk room rear side trim as shown in the
figure, and remove the mounting nut and disconnect the
connector.
2. Remove the rear combination lamp.
LIGHTING SWITCH AND TURN-SIGNAL LAMP SWITCH
CHECK
Refer to P.54-41.
TAIL LAMP RELAY CHECK <Vehicles with Daytime
Running Lamp System>
Refer to P.54-42.
Trunk
room rear
side trim
CHASSIS ELECTRICAL - High Mounted Stop Lamp 54-51
HIGH MOUNTED STOP LAMP 54200510204
<Sedan> <Wagon>
3
2
1 1
2
4
3
Removal steps <Sedan>
1. Socket assembly
2. Bulb
3. High mounted stop lamp
Removal steps <Wagon>
1. Cover
2. Lamp unit
3. Bulb
4. Socket assembly
CHASSIS ELECTRICAL - Rheostat 54-52
RHEOSTAT 54200600093
1
2
Removal steps
1. Meter bezel assembly
2. Rheostat
1. Connect the battery and the test bulb (40W) as shown
2. Operate the rheostat, and if the brightness changes
smoothly without switching off, then the rheostat function
is normal.
40W
CHASSIS ELECTRICAL - Hazard Warning Lamp Switch
ILL
ILL
54-53
HAZARD WARNING LAMP SWITCH 54200660121
1
2
Removal steps
D Center console panel (Refer to
GROUP 52A.)
D A/C-ECU or heater control panel
AA" 1. Center outlet assembly
2. Hazard warning lamp switch
AA"CENTER OUTLET ASSEMBLY REMOVAL
Press the tabs indicated in the illustration, and pull the center
outlet assembly to remove it.
Switch Terminal No.
position
1 2 3 4 5 6 7 9 - 10
OFF
ON
CHASSIS ELECTRICAL - Horn/Cigarette Lighter 54-54
HORN 54300800038
INSPECTION
1 3 4 5
Power is not supplied
Power is supplied
CIGARETTE LIGHTER 54300570083
INSPECTION
D Take out the plug, and check for a worn edge on the
element spot connection, and for shreds of tobacco or
other material on the element.
D Using a circuit tester, check the continuity of the element.
Horn relay
Theft-alarm
horn relay
Element
Spot
CHASSIS ELECTRICAL - Clock 54-55
CLOCK 54300060436
SPECIAL TOOL
MB990784 Ornament remover Removal of center display bezel
CLOCK 54300590072
1
2
Removal steps
AA" 1. Center display bezel
AA" 2. Clock
AA"CENTER DISPLAY BEZEL/CLOCK REMOVAL
Use the special tool (MB990784) to pry up the tabs indicated
in the illustration, and remove the center display bezel and
the clock.
CHASSIS ELECTRICAL - Radio and Tape Player 54-56
RADIO AND TAPE PLAYER 54400070227
TROUBLESHOOTING
QUICK-REFERENCE TROUBLESHOOTING CHART
Items Problem symptom Relevant chart
Noise Noise appears at certain places when travelling (AM). A- 1
Noise appears at certain places when travelling (FM). A- 2
Mixed with noise, only at night (AM). A- 3
Broadcasts can be heard but both AM and FM have a lot of noise. A- 4
There is more noise either on AM or on FM. A- 5
There is noise when starting the engine. A- 6
Some noise appears when there is vibration or shocks during
travelling.
A- 7
Noise sometimes appears on FM during travelling. A- 8
Ever-present noise. A- 9
Radio When switch is set to ON, no power is available. B- 1
No sound from one speaker. B- 2
There is noise but no reception for both AM and FM or no sound
from AM, or no sound from FM.
B- 3
Insufficient sensitivity. B- 4
Distortion on AM or on both AM and FM. B- 5
Distortion on FM only. B- 6
Too few automatic select stations. B- 7
Insufficient memory (preset stations are erased). B- 8
NOTE
Refer to problem symptoms of AM radio for MW radio.
Items Problem symptom Relevant chart
Tape player Cassette tape will not be inserted. C- 1
No sound. C- 2
No sound from one speaker. C- 3
Sound quality is poor, or sound is weak. C- 4
Cassette tape will not be ejected. C- 5
Uneven revolution. Tape speed is fast or slow. C- 6
Faulty auto reverse. C- 7
Tape gets caught in mechanism. C- 8
Motor antenna Motor antenna wont extend or retract. D- 1
Motor antenna extends and retracts but does not receive. D- 2
CHART
A. NOISE
A- 1 Noise appears at certain places when travelling (AM).
Is there a particular structure?
No
Do the following measures eliminate the
noise?
1. Change to a different station with
a strong signal to boost resistance
to interference.
2. Suppress high tones to reduce
noise.
3. Extend antenna completely.
Yes
OK
Yes
Find out the following information from
the user:
1. Place
2. Locality conditions (valley, moun-
tain, etc.)
3. Name and frequency of stations
affected by noise
No
If due to vehicle noise:
It may not be possible to prevent noise
if the signal is weak.
If there is more noise than other radios, find out the noise
conditions and the name and frequency of the receiving
stations from the user, and consult with the service centre.
If due to external noise:
In almost all cases, prevention on the
receiver side is impossible. Weak sig-
nals especially are susceptible to inter-
ference.
CHASSIS ELECTRICAL - Radio and Tape Player
FM Broadcast Good Reception Areas
10 kW
output FM
broadcast
For stereo:
20- 25 km
For monaural:
30- 40 km
For home stereos:
80- 90 km
FM Signal Characteristics and Signal Interference
Multipath interference
First fading
interference
54-58
A- 2 Noise appears at certain places when travelling (FM).
Do the following measures eliminate the noise?
D Change to a different station with a strong signal to boost
resistance to interference.
D Suppress high tones to reduce noise.
D Extend antenna completely.
Yes
OK
No
If there is more noise than other radios, find out the noise conditions
and the name and frequency of the receiving stations from the
user, and consult with the service centre.
NOTE
About FM waves:
FM waves have the same properties as light, and
can be deflected and blocked. Wave reception is
not possible in the shadow of obstructions such
as buildings or mountains.
1. The signal becomes weak as the distance from
the stations transmission antenna increases.
Although this may vary according to the signal
strength of the transmitting station and
intervening geographical formation or buildings,
the area of good reception is approx. 20- 25
km for stereo reception, and 30- 40 km for
monaural reception.
2. The signal becomes weak when an area of
shadow from the transmitting antenna (places
where thereare obstructions such as mountains
or buildings between the antenna and the car),
and noise will appear. <This is called first fading,
and gives a steady buzzing noise.>
3. If a direct signal hits the antenna at the same
time as a signal reflected by obstructions such
as mountains or buildings, interference of the
two signals will generate noise. During
travelling, noise will appear each time the
vehicles antenna passes through this kind of
obstructed area. The strength and interval of
the noise varies according to the signal strength
and the conditions of deflection. <This is called
multipath noise, and is a repetitious buzzing.>
4. Since FM stereo transmission and reception
has a weaker field than monaural, it is often
accompanied by a hissing noise.
A- 3 Mixed with noise, only at night (AM).
The following factors can be considered as possible
causes of noise appearing at night.
1. Factors due to signal conditions: Due to the
fact that long-distance signals are more easily
received at night, even stations that are
received without problem during the day may
experience interference in a general worsening
of reception conditions. The weaker a station
is the more susceptible it is to interference,
and a change to a different station or the
appearance of a beating sound* may occur.
Beat sound*: Two signals close in frequency
interfere with each other, creating a repetitious
high-pitched sound. This sound is generated
not only by sound signals but by electrical
waves as well.
2. Factors due to vehicle noise: Alternator noise
may be a cause.
Is the noise still obvious even with the
lamps OFF?
No
Yes
Do the following measures eliminate the
noise?
D Tune to a station witha strongsignal.
D Tune to a station with a strong signal
without completely extending the
antenna.
Yes
OK
No
Does the noise fade away when the
vehicle harness is moved away from
the radio chassis? (if the harness is not
in the proper position.)
Yes
OK
No
If there is more noise than other radios, consult a service
centre.
A-4 Broadcasts can be heard but both AM and FM have a lot of noise.
(1) (2)
Noise occurs when the engine is stopped.
Yes
Do the following measures eliminate the noise?
D Tune to a station with a strong signal.
D Extend the antenna completely.
D Adjust the sound quality to suppress high tones.
Yes
OK
No
Is the radio body earth mounted securely?
No
Securely tighten the nuts for the body
earth.
Yes
Is the antenna plug properly connected to the radio?
No
Correctly attach the antenna plug.
Yes
Is the antenna itself in good condition or is it properly
mounted?
No
Clean the antenna plug and earth wire
mounting area. Mount the antenna se-
curely.
Yes
If there is more noise than other radios, consult a service
centre.
Is the noise eliminated?
No
Yes
OK
Noise occurs when the engine in running.
Inspect the vehicles noise suppressor. (Refer to A-6.)
NOTE
About noise encountered during FM reception only.
Due to differences in FM and AM systems, FM
is not as susceptible as AM to interference from
engines, power lines, lightning, etc. On the other
hand, there are cases due to the characteristics
of FM waves of noise or distortion generated by
typical noise interference (first fading and
multipath). (Refer to A- 2.)
<Noise (hissing) occurs in weak signal areas such
as mountainous regions, but this is not due to a
problem with the radio.>
A- 5 There is more noise either on AM or on FM.
1. There is much noise only on AM.
Due to differences in AM and FM systems,
AM is more susceptible to noise interference.
Were conditions such as the following present when noise was
received?
D Lightning was flashing. A motorcycle was passing.
D A vehicle passed close by, but it appeared to be a vehicle
generating a particularly large amount of noise radiation.
D Passed beneath a power line. Passed under a bridge.
D Passed beneath a telephone line.
D Passed close by a signal generator.
D Passed close by some other source of electrical noise.
Yes
No
Continue to check for static; when static is detected, check for
the conditions listed above.
Yes
Noise prevention on the radio side is difficult. If the problem is
particularly worse than other radios, consult a service centre.
No
If the problem is particularly worse than other radios, consult a
service centre.
2. There is much noise only on FM.
Due to differences in FM and AM systems,
FM is not as susceptible as AM to interference
from engines, power lines, lightning, etc. On
the other hand, there are cases due to the
characteristics of FM waves of noise or
distortion generated by typical noise
interference (first fading and multipath). (Refer
to A- 2) <Noise (hissing) occurs in weak signal
areas such as mountainous regions, but this
is not due to a problem with the radio.>
A- 6 There is noise when starting the engine.
Noise type Sounds
are in parentheses ( ).
Conditions Cause Remedy
AM, FM: Ignition
noise (Popping,
snapping, cracking,
buzzing)
D Increasing the en-
gine speed caus-
ing the popping
sound to speed
up, and volume
decreases.
D Disappears when
the ignition switch
is turned to ACC.
D Mainly due to the
spark plugs.
D Due to the engine
noise.
D Check or replace the earth cable.
Earth cable
D Check or replace the noise capacitor.
Other electrical
components
- Noise may appear as
electrical compo-
nents become older.
Repair or replace electrical components.
Static electricity
(Cracking, crinkling)
D Disappears when
the vehicle is
completely
stopped.
D Severe when the
clutchis engaged.
Occurs when parts
or wiring move for
some reason and
contact metal parts
of the body.
Return parts or wiring to their proper
position.
D Various noises
are produced de-
pending on the
body part of the
vehicle.
Due to detachment
from the body of the
front hood, bumpers,
exhaust pipe and
muffler, suspension,
etc.
Tighten the mounting bolts securely.
Cases where the problem is not
eliminated by a single response to one
area are common, due to several body
parts being imperfectly earthed.
Caution
1. Connecting a high tension cable to the noise
filter may destroy the noise filter and should
never be done.
2. Check that there is no external noise. Since
failure caused by this may result in
misdiagnosis due to inability to identify the
noise source, this operation must be
performed.
3. Noise prevention should be performed by
suppressing strong sources of noise step
by step.
NOTE
1. Capacitor
The capacitor does not pass D.C. current, but
as the number of waves increases when it
passes A.C. current, impedance (resistance
against A.C.) decreases, and current flow is
facilitated. A noise suppressing condenser
which takes advantage of this property is
inserted between the power line for the noise
source and the earth. This suppresses noise
by earthing the noise component (A.C. or pulse
signal) to the body of the vehicle.
2. Coil
The coil passes D.C. current, but impedance
rises as the number of waves increases relative
to the A.C. current. A noise suppressing coil
which takes advantage of this property is
inserted into the power line for the noise source,
and works by preventing the noise component
from flowing or radiating out of the line.
A- 7 Some noise appears when there is vibration or shocks during travelling.
Are connectors properly connected?
No
Ensure proper connection.
Yes
Does noise appear when the radio switch is turned on while the
vehicle is stopped and the radio is struck while tuned away from
a station?
No
Static electricity noise:
Body static electric from the shock absorber rubber bushings used
to prevent vibration, tyres, etc. occurs because of separation from
the earth, causing a buzzing noise. Since no measures can be
taken on the radio side, other steps should be taken to discharge
the static electricity of the vehicle body.
Yes
Is the radio correctly earthed? (Is the mounting screw tightened
securely?)
No
Tighten the screw securely.
Yes
Is theantenna correctly earthed? (If noise appearswhen theantenna
is moved, this means the earth is not securely connected.)
No
If rust is present at the antenna earth screw, clean and tighten
the earth securely.
Yes
Repair or replace radio.
A- 8 Noise sometimes appears on FM during travelling.
Does the problem clear up when returned?
Yes
OK
No
Does the problem appear only in certain locations and only with
certain stations?
Yes
Due to electrical field conditions. (Multipath noise*, fading noise*).
Are connectors properly connected?
No
Check connector connections.
Yes
Does noise appear when the radio switch is turned on while the
vehicle is stopped and the radio is struck while tuned away from
a station?
No
Static electricity noise:
Body static electric from the shock absorber rubber bushings used
to prevent vibration, tyres, etc. occurs because of separation from
the earth, causing a buzzing noise. Since no measures can be
taken on the radio side, other steps should be taken to discharge
the static electricity of the vehicle body.
Yes
Is the radio body correctly earthed? (Is themounting screwtightened
securely?)
No
Tighten the screw securely.
Yes
Is theantenna correctly earthed? (If noise appearswhen theantenna
is moved, this means the earth is not securely connected.)
No
If rust is present at the antenna earth screw, clean and tighten
the earth securely.
Yes
No
* About multipath noise and fading noise
Because the frequency of FM waves is
extremely high, it is highly susceptible to effects
from geological formations and buildings.
These effects disrupt the broadcast signal and
obstruct reception in several ways.
D Multipath noise
This describes the echo that occurs when
the broadcast signal is reflected by a large
obstruction and enters the receiver with
a slight time delay relative to the direct
signal (repetitious buzzing).
D Fading noise
This is a buzzing noise that occurs when
the broadcast beam is disrupted by
obstructing objects and the signal strength
fluctuates intricately within a narrow range.
A- 9 Ever-present noise.
Noise is often created by the following factors, and
often the radio is OK when it is checked individually.
D Travelling conditions of the vehicle
D Terrain of area travelled through
D Surrounding buildings
D Signal conditions
D Time period
For this reason, if there are still problems with noise
even after the measures described in steps A- 1
to A- 8 have been taken, get information on the
factors listed above as well as determining whether
the problem occurs with AM or FM, the station
names, frequencies, etc., and contact a service
centre.
B. RADIO
B- 1 No power is supplied when the switch is set to ON.
Is dedicated fuse No. 6 blown or is the circuit open?
Yes
Replace fuse or repair harness.
No
Is the connector at the back of the radio connected properly?
No
Connect connector securely.
Yes
Disconnect and check the connector at the rear of the radio. Is
the ACC power (12 V) being supplied to the radio?
No
Repair harness.
Yes
B- 2 No sound from one speaker.
Check to see if there is any sound when
attached to another radio.
Yes
No
Remove the connector on the back of
theradioandcheck the speaker harness
for conductance.
Yes
It conducts electricity but is shorted out. Repair speaker harness.
No
Check the speaker for conductance.
Yes
Repair speaker harness and ensure
proper connection of relay connectors.
No
Repair or replace speaker.
B- 3 There is noise but no reception for both AM and FM or no sound from AM, or no sound from
FM.
OK
Is thecheck beingconducted under spe-
cial electrical field conditions?
Yes
Example: In an underground
garage or inside a building.
No
Does tuning solve the problem?
Is proper performance obtained when
the vehicle is moved?
Yes
OK
Yes
No
No
Reconnect
No
Are the antenna plug and radio unit properly connected?
Yes
Yes
Does the problemdisappear if connected to another radio?
No
Replace the antenna.
B- 4 Insufficient sensitivity.
No
Yes
Yes
Does the problem disappear when a different radio is con-
nected?
OK
Yes
garage or inside a building.
No
Does tuning solve the problem?
Yes
OK
Yes
No
No
Electrical field condition related*
(multipath noise or fading noise)
Yes
Is the problem limited to the reception of a specific radio
station from a specific position?
No
No
Is the antenna plug properly connected to the unit?
* For multipath noise and fading noise problems, refer to P. 54-63.
B- 5 Distortion on AM or on both AM and FM.
How much distortion is there?
Occasional
Distortion in the vicinity of the radio sta-
tion
Yes
Excessive antenna input
Constant
No
Are the speaker cords in contact with the cone paper?
Yes
Remove cords away from cone paper.
No
Remove the speakers and check for torn cone paper or foreign
objects.
Yes
Repair or replace speakers.
No
Check for deformation with speaker installed.
Yes
Install speaker securely.
No
B- 6 Distortion on FM only
Does thedistortionpersist whenthe radiois tunedto another station?
No
Due to weak electrical field of radio station
Yes
Does distortion increase or decrease when the vehicle is moved?
Yes
Due to multipath noise
No
B- 7 Too few automatic select stations.
OK
Yes
garage or inside a building
No
Is the antenna plug properly connected to the equipment?
No
No
Yes
Yes
Does the equipment work properly if the radio is changed?
No
Yes
B- 8 Insufficient memory (preset stations are erased).
Yes
No
Disconnect and check the connector at the rear of the radio.
Is the memory backup (battery) power being supplied?
No
Repair harness.
Yes
C. TAPE PLAYER
C- 1 Cassette tape will not be inserted.
Are there any foreign objects in the tape player?
Yes
Remove the object(s)*
1
No
*
1
Attempting to force a foreign object (e.g., a coin or clip, etc.) out
of the tape player may damage the mechanism. The player should
be taken to a service dealer for repair.
Does the tape player work if another tape is inserted?
Yes
Replace tape*
2
No
Repair or replace tape player.
*
2
Ensure that the tape label is not loose, that the tape itself is not
deformed and that the tape is tightly wound. Also, tape of C-120
or greater length often get caught in the mechanism and should
not be used.
C- 2 No sound (even after a tape has been inserted).
Yes
No
Is connector at rear of radio connected tightly?
No
Connect connector firmly.
Yes
Disconnect connector at rear of radio. Is ACCpower being supplied
to the radio?
Yes
No
Repair harness.
C- 3 No sound from one speaker.
Clean the tape player head and check
again.
Yes
OK
No
Replace the tape player and check again.
Yes
No
Remove the connector on the back of the radio and check
the speaker harness for conductance.
Yes
It conducts electricity but is
shorted out.
Repair harness.
No
Check the speaker for conductance.
Yes
Repair harness.
No
C- 4 Sound quality is poor, or sound is weak.
Does the player play properly when another tape* is inserted?
Yes
OK
No
*:
D Ensure that the tape label is not loose, that the tape
itself is not deformed and that the tape is tightly wound.
D Tapes of C-120 or greater length often get caught in
the mechanism and should not be used.
Does the player play properly when the tape player head is cleaned?
Yes
OK
No
Is proper operation obtained when the tape player is replaced?
Yes
No
C- 5 Cassette tape will not be ejected.
The problems covered here are all the result of
the use of a bad tape (deformed or not properly
tightened) or of a malfunction of the tape player
itself. Malfunctions involving the tape becoming
caught in the mechanism and ruining the case are
also possible, and attempting to force the tape out
of the player can cause damage to the mechanism.
The player should be taken to a service dealer
for repair.
C- 6 Uneven revolution. Tape speed is fast or slow.
Does the player play OK if the tape*
1
is changed?
Yes
OK
*
1
Ensure that the tape label is not loose, that the tape itself
is not deformed and that the tape is tightly wound. Also,
tape of C-120 or greater length often get caught in the
mechanism and should not be used.
No
No
Are there any foreign objects *
2
inside the tape player?
Yes
Remove foreign object(s).
*
2
Attempting to force a foreign object (e.g., a coin or clip,
etc.) out of the tape player may damage the mechanism.
The player should be taken to a service dealer for repair.
No
Is the head or capstan roller diry?
Yes
Clean.
Pinch roller Head Capstan roller
C- 7 Faulty auto reverse.
Does the player play OK if the tape* is changed?
Yes
OK
No
*:
D Ensure that the tape label is not loose, that the tape
itself is not deformed and that the tape is tightly wound.
D Tapes of C-120 or greater length often get caught in
the mechanism and should not be used.
Does the problem only occur while the vehicle is being driven?
No
Yes
Is the tape player properly installed to the vehicle?
No
Ensure tape player installation.
Yes
C- 8 Tape gets caught in mechanism*
1
.
*
1
When the tape is caught in the mechanism, the case may
not eject. When this occurs, do not try to force the tape
out as this may damage the tape player mechanism. Take
the cassette to a service dealer for repair.
Does the player play OK if the tape*
2
is changed?
Yes
Tape used is bad.
No
*
2
Ensure that the tape label is not loose, that the tape itself
is not deformed and that the tape is tightly wound. Also,
tapes of C-120 or greater length often get caught in the
mechanism and should not be used.
D. MOTOR ANTENNA
D-1 Motor antenna wont extend or retract.
Clean and polish the surface of the antenna rod.
Is the radio power switch ON?
No
Switch it ON.
Yes
Is voltage (approx. 12 V) emitted to the radios motor antenna terminal?
No
Repair or replace the radio.
No
Is the antenna relay OK?
No
Replace the antenna relay.
Yes
Is the motor OK?
No
Replace the motor.
Yes
Repair the harness.
Yes
Is the antenna bent?
Yes
Repair the bend, or replace the antenna
mast.
D-2 Motor antenna extends and retracts but does not receive.
Is the antenna itself OK?
No
Repair or replace it.
Yes
Is operation normal when a new antenna assembly is directly
installed to the radio?
No
Refer to B Radio trouble-
shooting.
Yes
Replace the feeder cable.
A
B
C
D
E
F
G
H
Ohmmeter measurement locations
Circuits from F to A, B, C, D and E
Circuit between G and H
Circuits from H to A, B, C, D and E
Result
Continuity
Continuity
No continuity
Fender
RADIO AND TAPE PLAYER 54400140126
Ashtray and Sunglasses Pocket Removal and
Installation
NOTE
: Metal clip position
1
2
3
4
5
4
Removal steps
1. Floor console panel
2. Centre console panel assembly
4. Radio bracket
5. Box
CHASSIS ELECTRICAL - Speaker 54-73
SPEAKER 54400260266
<Sedan, Wagon>
<Wagon>
<Sedan>
1
2
3
4 5
6
7
8
9
10
11
Speaker (front door) removal steps
1. Tweeter cover
<Vehicles with 6 speakers>
2. Tweeter
<Vehicles with 6 speakers>
3. Front door trim
4. Speaker
5. Speaker cover
Speaker (rear door) removal steps
6. Rear door trim
7. Speaker
8. Speaker cover
Speaker (rear shelf) removal steps
9. Speaker garnish
10. Speaker
11. Speaker bracket
CHASSIS ELECTRICAL - Antenna 54-74
ANTENNA 54400290180
<Sedan - Vehicles with motor antenna>
<Sedan - Vehicles with pole antenna>
1
2
3
4
5
3
4
6
Antenna feeder cable removal
steps
D Instrument panel
D Front pillar trim
D Centre pillar trim
D Rear pillar trim
D Headlining
2. Antenna feeder cable
Motor antenna or pole antenna
removal steps
D Trunk side trim (L.H.)
3. Ring nut
4. Base
5. Motor antenna
6. Pole antenna
<Wagon>
1
2
3
4
5
Antenna feeder cable removal
steps
D Instrument panel
D Front pillar trim
D Centre pillar trim
D Quarter upper trim
D Headlining
2. Antenna feeder cable
Antenna (rear roof) removal steps
3. Rod assembly
D Headlining
4. Cover
5. Packing
MOTOR ANTENNA ASSEMBLY CHECK
1. Connect the circuit as indicated by the solid lines in the
illustration.
2. Check that the motor antenna extends when the
connection indicated by the broken line is made.
3. Check that the motor antenna retracts fully when the
connection indicated by the broken line is removed.
ANTENNA POLE REPLACEMENT 54400090032
1. Remove the ring nut.
2. After turning the ignition switch to ACC or ON, turn the
radio switch to ON to raise the antenna pole, and remove
it, together with the rack cable.
3. Draw out the antenna pole to the maximum extension.
NOTE
If there is a bend in the motor end of the rack cable,
remove the bend.
4. Insert the rack cable into the motor assembly with the
rack cable teeth facing the luggage compartment side.
5. Turn the rack cable teeth towards the rear of the vehicle
(right 90_) so that the rack cable meshes with the motor
gear.
6. If the rack cable pulls out with no resistance when it
is lightly pulled, then the cable is not meshed with the
motor gear, so check that there are no bends in the end
of the rack cable, and then repeat steps 4 and 5 above.
7. Set the antenna pole vertically and turn the radio switch
OFF to wind up the rack cable. Insert the antenna to
the motor antenna side to align it with the wound-up
rack cable.
8. After tightening the ring nut, check the movement of the
antenna by turning the radio switch ON and OFF.
Antenna pole
Rack cable
Rack cable teeth
Luggage compartment side
Rack cable
Rack cable
teeth
Rear of the vehicle
CHASSIS ELECTRICAL - Rear Window Defogger 54-77
REAR WINDOW DEFOGGER 54300720488
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOM
Trouble symptom Reference page
Rear window defogger does not operate. <Vehicles with
automatic A/C>
Refer to GROUP 55.
PRINTED-HEATER LINE CHECK
1. Run engine at 2,000 r/min. Check heater element with
battery at full.
2. Turn ON rear window defogger switch. Measure heater
element voltage with circuit tester at rear window glass
centre A.
Condition is good if it indicates about 6V.
3. If 12 V is indicated at A, there is a break in the negative
terminals from A.
Move test bar slowly to negative terminal to detect where
voltage changes suddenly (0V).
4. If 0 V is indicated at A, there is a break in the positive
terminals from A. Detect where the voltage changes
suddenly (12 V) in the same method described above.
REAR WINDOW DEFOGGER RELAY
1 2 3 5
Power is supplied
Normal characteristic curve
Voltage
A(Centre point)
approx. 6 V
Positive
terminal
Printed
heater line
Negative
terminal
Abnormal characteristic curve
Voltage
Open-circuit
point
Positive
terminal
Printed
heater line
Negative
terminal
Junction block
Defogger relay
CHASSIS ELECTRICAL - Rear Window Defogger
ILL
ILL IND
54-78
REAR WINDOW DEFOGGER SWITCH
<VEHICLES WITH MANUAL A/C>
54300620115
Refer to GROUP 55 - Heater Control Assembly, A/C Switch
and Inside/Outside Air Changeover Switch.
DEFOGGER SWITCH CONTINUITY CHECK
1 3 2 4 5
OFF
ON
OFF
ON
CHASSIS ELECTRICAL - Theft-alarm System 54-79
THEFT-ALARM SYSTEM 54700060070
SPECIAL TOOLS
MB991502 MUT-II sub assen-
bly
A
B
C
D
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
Making voltage and resistance
measurements during troubleshooting
The special tool (MB991223) should always be used to measure voltages and resistance when carrying
out troubleshooting.
DIAGNOSTIC FUNCTION 54700130030
2. If a buzzer of the MUT-II sounds once when a switch
is operated (ON/OFF), the ETACS-ECU input signal for
that switch circuit system is normal.
MUT-II
procedure No.
Reference
page
Communication with MUT-II Communication with all system is not possible. 1 54-80
is not possible. <Vehicles
with ETACS-ECU> Communication with one-shot pulse input signal
only is not possible.
2 54-80
Arming/disarming
relationship
The system is not armed.
(The security indicator lamp does not illuminate,
and the alarm does not function.)
3 54-81
The arming procedures are followed, but the
security indicator lamp does not illuminate.
(There is an alarm, however, when an alarm
test is conducted after about 20 seconds have
passed.)
4 54-82
The alarm sounds in error when, the system is
armed, a door or the tailgate is unlocked by
using the key.
- 54-83
tion with all system is not possible.)
Probable cause
The cause is probably a defect in the power supply system (including earth) for
the diagnosis line.
Refer to GROUP13A - Troubleshooting
tion with one-shot pulse input signal only is not possible.)
Probable cause
The cause is probably a defective one-shot pulse input signal circuit system of
the diagnosis line.
diagnosis connector and junction block.
OK
C-20, C-134, C-144
NG
Repair
NG
Repair
OK
NG
The system is not armed. (The security indicator lamp does not illuminate, and the alarm does not
function.)
Check the dedicated fuse No.14.
NG
Replace the fuse.
OK
Check the fusible link No.2.
NG
Replace the fusible link.
OK
Disconnect the ETACS-ECU connector C-43 and measure at the
harness side connector.
OK: System voltage
NG
L.H. drive vehicles: C-144, C-141
R.H. drive vehicles: C-144, C-141, C-62, C-14
NG
Repair
OK
NG
Check the harness wire between the fusible link No.2 and ETACS-
ECU. Repair, if necessary.
OK
Measure at the harness side connector.
D Continuity between the terminal (1) and body earth
OK: Continuity
NG
C-131 and C-144
OK
OK
NG
Repair
NG
Check the harness wire between the ETACS-ECU and body earth.
The arming procedures are followed, but the security indicator lamp does not illuminate. (There is
an alarm, however, when an alarm test is conducted after about 20 seconds have passed.)
Remove the combination meter and check if the security indicator
lamp bulb is burnt out.
NG
Replace
OK
Disconnect the combination meter connector D-03, and measure
at the combination meter side.
D Continuity between terminals (10) and (11)
OK: Continuity
NG
OK
Measure at the harness side of the same connector.
OK: System voltage
NG
L.H. drive vehicles: D-03, C-135, C-144, C-141
R.H. drive vehicles: D-03, C-135, C-144, C-141, C-62, C-141
OK
NG
Check the harness wire between the combination meter and fusible
link (2). Repair, if necessary.
OK
Disconnect the ETACS-ECU connector C-139, and measure at
the harness side.
D Earth the terminal (49) and check if the security indicator
lamp illuminates.
OK: Illuminates
NG
C-139, C-25, D-03
OK
MEASUREMENT AT ECU TERMINALS
Terminal No. Item Check condition Normal value
1 Earth - -
2 ECU power supply At all times System voltage
7 Ignition switch (ACC) ON System voltage
OFF 0 V
11 Ignition switch (IG1) ON System voltage
OFF 0 V
13,19 Front door switch (L.H.) Door open 0 V
Door closed 5 V
17 Key reminder switch Ignition switch ON (Removed) 0 V
OFF (Inserted) 5 V
28 Keyless entry Receiver output signal ON 0 V
receiver-ECU
OFF 5 V
29 Theft-alarm horn relay ON 0 V
OFF System voltage
33 Front door lock actuator Lock 5 V
switch (R.H.)
Unlock 0 V
34 Lock 0 V
Unlock 5 V
35 Front door lock actuator Lock 5 V
switch (L.H.)
Unlock 0 V
36 Lock 0 V
Unlock 5 V
41 Rear door lock actuator Lock 5 V
switch (R.H.)
Unlock 0 V
42 Lock 0 V
Unlock 5 V
43 Trunk lid latch switch ON 0 V
<Sedan>
OFF 5 V
Terminal No. Normal value Check condition Item
44 Trunk lid lock key cylinder ON 0 V
switch <Sedan>
OFF 5 V
45 Tailgate lock actuator Lock 5 V
<Wagon>
Unlock 0 V
46 Lock 0 V
Unlock 5 V
47 Door lock key cylinder Unlock 0 V
switch
Neutral 5 V
48 Lock 0 V
Neutral 5 V
49 Combination meter ON 0 V
(Security indicator lamp)
OFF System voltage
50 Front door switch (R.H.) ON 0 V
OFF 5 V
51 Hood switch ON 0 V
OFF 5 V
55-1
HEATER,
AIR CONDITIONER
AND VENTILATION
MANUAL AIR CONDITIONER 3 . . . . . . . .
Safety Precautions 3 . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICANTS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 5 . . . . . . . . . . . . . . . . . . . . . . . .
Sight Glass Refrigerant Level Test 7 . . . . . . . . . .
Magnetic Clutch Test 7 . . . . . . . . . . . . . . . . . . . . . .
Receiver Drier Test 7 . . . . . . . . . . . . . . . . . . . . . . . .
Dual Pressure Switch Check 8 . . . . . . . . . . . . . . .
WARNING!
MITSUBISHI dealer.
component.
NOTE
55-2
Compressor Drive Belt Adjustment 8 . . . . . . . . . .
Charging 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance Test 14 . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Leak Repair 15 . . . . . . . . . . . . . . . . . . .
Compressor Noise 16 . . . . . . . . . . . . . . . . . . . . . . . .
Power Relay Check 16 . . . . . . . . . . . . . . . . . . . . . .
Idle-up Operation Check 18 . . . . . . . . . . . . . . . . . .
HEATER CONTROL ASSEMBLY, A/C
SWITCH AND INSIDE/OUTSIDE AIR
CHANGEOVER SWITCH 19 . . . . . . . . . . . . . . .
HEATER UNIT*, HEATER CORE AND
BLOWER UNIT 22 . . . . . . . . . . . . . . . . . . . . . . . .
RESISTOR, BLOWER FAN AND MOTOR
AND INSIDE/OUTSIDE AIR CHANGEOVER
MOTOR 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAPORATOR 25 . . . . . . . . . . . . . . . . . . . . . . . . .
AIR PURIFIER ASSEMBLY 27 . . . . . . . . . . . . .
COMPRESSOR AND TENSION PULLEY
27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REFRIGERANT LINE 28 . . . . . . . . . . . . . . . . . .
CONDENSER AND CONDENSER FAN
MOTOR 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VENTILATORS 33 . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC AIR CONDITIONER 35 . . . .
LUBRICANTS 36 . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 36 . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER CONTROL PANEL AND
ECU ASSEMBLY 57 . . . . . . . . . . . . . . . . . . . . . .
DAMPER MOTOR ASSEMBLY AND
POWER TRANSISTOR 58 . . . . . . . . . . . . . . . . .
COMPRESSOR AND TENSION PULLEY
61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PHOTO SENSOR 67 . . . . . . . . . . . . . . . . . . . . . .
OUTSIDE AIR TEMPERATURE SENSOR
68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEATER WATER TEMPERATURE
SENSOR* 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OTHER MAINTENANCE SERVICE POINTS
70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- General Information
HEATER, AIR CONDITIONER AND VEN-
TILATION <MANUAL AIR CONDITIONER>
55-3
MANUAL AIR CONDITIONER 55200010190
GENERAL INFORMATION
The heater system uses a two-way-flow full-air-mix
system that features high performance and low
operating noise, and includes an independent face
air blowing function. The A/C system is basically
the same as the conventional system, but a new
refrigerant systemhas been adopted as a response
to restrictions on the use of chlorofluorocarbons.
In addition, an air purifier which carries out fine
A/C control has been included.
Heater unit Type Two-way-flow full-air-mix system
Heater control assembly Dial type
Compressor Model Scroll type <MSC90>
Dual pressure switch High-pressure switch ON OFF: 2,942, OFF ON: 2,353
kPa
Low-pressure switch ON OFF: 196, OFF ON: 221
Refrigerant and quantity g R-134a (HFC-134a), Approx. 670- 710
SAFETY PRECAUTIONS
Because R-134a refrigerant is a hydrofluorocarbon
(HFC) which contains hydrogen atoms in place of
chlorine atoms, it will not cause damage to the
ozone layer.
Refrigerant R-134a is transparent and colourless
in both the liquid and vapour state. Since it has
a boiling point of - 29.8_C, at atmospheric pressure,
it will be a vapour at all normal temperatures and
pressures. The vapour is heavier than air,
non-flammable, and nonexplosive. The following
precautions must be observed when handling
R-134a.
Caution
Wear safety goggles when servicing the
refrigeration system.
R-134a evaporates so rapidly at normal
atmospheric pressures and temperatures that it
tends to freeze anything it contacts. For this reason,
extreme care must be taken to prevent any liquid
refrigerant from contacting the skin and especially
the eyes. Always wear safety goggles when
servicing the refrigeration part of the A/C system.
Keep a bottle of sterile mineral oil handy when
working on the refrigeration system. Should any
liquid refrigerant get into the eyes, use a few drops
of mineral oil to wash them out. R-134a is rapidly
absorbed by the oil. Next splash the eyes with
plenty of cold water. Call your doctor immediately
even though irritation has ceased after treatment.
Service Specifications/Lubricants
-
55-4
Caution
Do not heat R-134a above 40_C
In most instances, moderate heat is required to
bring the pressure of the refrigerant in its container
above the pressure of the system when charging
or adding refrigerant.
A bucket or large pan of hot water not over 40_C
is all the heat required for this purpose. Do not
heat the refrigerant container with a blow torch
or any other means that would raise temperature
and pressure above this temperature. Do not weld
or steam clean on or near the system components
or refrigerant lines.
Caution
Keep R-134a containers upright when charging
the system.
When metering R-134a into the refrigeration system
keep the supply tank or cans in an upright position.
If the refrigerant container is on its side or upside
down, liquid refrigerant will enter the system and
damage the compressor.
Caution
1. The leak detector for R-134a should be used
to check for refrigerant gas leaks.
2. Donot allowliquidrefrigerant totouchbright
metal.
Refrigerant will tarnish bright metal and chrome
surfaces, and in combination with moisture can
severely corrode all metal surfaces.
Idle speed r/min 4G6 750 50
6A1 650 50
4D6 800 30
Idle-up speed r/min When load by 4G6 750 50
A/C is low
6A1 650 50
4D6 850 50
When load by 4G6 850 50
A/C is high
6A1 900 50
4D6 850 50
Resistor (for blower motor) W LO: 2.30, ML: 1.10, MH: 0.40
Air gap (Magnetic clutch) mm 0.40 - 0.65
Each connection of refrigerant line SUN PAG 56 As required
Compressor refrigerant unit lubricant mL SUN PAG 56 120
- Special Tools/Troubleshooting
55-5
MB991367 Special spanner Removal and installation of armature mounting
nut of compressor
MB991386 Pin
TROUBLESHOOTING PROCEDURES
Trouble symptom Problem cause Remedy Reference
page
When the ignition
switch is ON,
A/C compressor relay is defective Replace the A/C compressor
relay
55-17
the A/C does not
operate.
Magnetic clutch is defective Replace the armature plate,
rotor or clutch coil
55-65
Refrigerant leak or overfilling of refrigerant Replenish the refrigerant, re-
pair the leak or takeout someof
the refrigerant
55-15
Dual pressure switch is defective Replace the dual pressure
switch
55-28, 29
A/C switch is defective Replace the A/C switch 55-19
Blower switch is defective Replace the blower switch 55-21
Refrigerant temperature switch is defective Replace the refrigerant temper-
ature switch
55-65
Automatic compressor-ECU is defective Replace the automatic com-
pressor-ECU
55-26
Engine-ECU is defective Replace the engine-ECU -
When the A/C is
operating, tem-
Refrigerant leak Replenish the refrigerant and
repair the leak
55-15
perature inside
the passenger
compartment
Dual pressure switch is defective Replace the dual pressure
switch
55-28, 29
compartment
doesnt decrease
(cool air is not
Refrigerant temperature switch is defective Replace the refrigerant temper-
ature switch
55-65
emitted).
Automatic compressor ECU is defective Replace the automatic com-
pressor-ECU
55-26
- Troubleshooting
55-6
Trouble symptom Reference
page
Remedy Problem cause
Blower fan and Blower relay is defective Replace the blower relay 55-16
motor doesnt
turn
Blower fan and motor is defective Replace the blower fan and
motor
55-23
Resistor (for blower motor) is defective Replace the resistor 55-23
Blower fan and
motor doesnt
Short circuit of theharness betweentheblower
fan and motor and the blower switch
Repair the harness -
stop turning.
Blower relay is defective Replace the blower relay 55-16
When the A/C is
operating con-
Condenser fan motor is defective Replace the condenser fan
motor
55-31
denser fan or ra-
diator fan does
Radiator fan motor is defective Replace the radiator fan motor -
diator fan does
not run
Fan control relay is defective Replace the fan control relay 55-17
INSPECTION AT THE AUTOMATIC COMPRESSOR-ECU TERMINAL 55201030041
Terminal
No.
Check item Checking requirements Normal condition
1 Input from A/C switch to ECU A/C switch: OFF 0 V
A/C switch: ON Battery voltage
2 Output from ECU to A/C compressor A/C compressor relay: OFF Battery voltage
relay
A/C compressor relay: ON 0 V
3 Output from ECU to engine-ECU Air thermo sensor detection tempera-
ture: 5_C or less
Battery voltage
Air thermo sensor detection tempera-
ture: 8_C or more
0 V
4 Earth Always 0V
- On-vehicle Service
55-7
SIGHT GLASS REFRIGERANT LEVEL TEST
The sight glass is a refrigerant level indicator. To check the
refrigerant level, clean the sight glass and start the vehicle
engine. Push the A/C button to operate the compressor, place
the blower switch to high and move the temperature control
lever to max cool. After operating for a few minutes in this
manner, check the sight glass.
1. If the sight glass is clear, the magnetic clutch is engaged,
the compressor discharge lineis warmand thecompressor
inlet line is cool; the system has a full charge.
2. If the sight glass is clear, the magnetic clutch is engaged
and there is no significant temperature difference between
compressor inlet and discharge lines; the system has
lost some refrigerant.
3. If the sight glass shows foam or bubbles, the system
could be low on charge. The system has to be recharged
with refrigerant.
MAGNETIC CLUTCH TEST 55200850174
1. Disconnect the connector (1-pin) to the magnetic clutch.
2. Connect battery (+) voltage directly to the connector for
the magnetic clutch.
3. If the magnetic clutch is normal, there will be click. If
the pulley and armature do not make contact (click),
there is a malfunction.
RECEIVER DRIER TEST 55200860115
Operate the unit and check the piping temperature by touching
the receiver drier outlet and inlet.
If there is a difference in the temperatures, the receiver drier
is restricted.
Replace the receiver drier.
Sight glass
Magnetic clutch
connector
55-8
DUAL PRESSURE SWITCH CHECK 55201040167
1. Remove the dual pressure switch connector and connect
the high/low pressure side terminals located on the
harness side as shown in the illustration.
2. Install a gauge manifold to the high-pressure side service
valve of the refrigerant line. (Refer to Performance Test.)
3. When the high/low pressure sides of the dual pressure
switch are at operation pressure (ON) and there is
continuity between the respective terminals, then the
condition is normal. If there is no continuity, replace the
switch.
Items Switch position
OFF ON ON OFF
Low-pressure
side kPa
221 196
High-pressure
side kPa
2,353 2,942
COMPRESSOR DRIVE BELT ADJUSTMENT
55200100101
High/Low
pressure side
LOW-PRESSURE
SIDE
HIGH-PRESSURE
SIDE
ON
OFF
ON
OFF
55-9
CHARGING 55200120176
1. With the handles turned back all the way (valve closed),
install the adaptor valve to the low-pressure side of the
gauge manifold.
2. Connect the charging hose (blue) to the adaptor valve.
3. Connect the quick joint (for low pressure) to the charging
hose (blue).
4. Connect the quick joint (for low pressure) to the low
pressure service valve.
NOTE
The low-pressure service valve should be connected to
the suction flexible hose.
Caution
(1) Use tools that are suited to R-134a.
(2) To install the quick joint, press section A firmly
against the service valve until a click is heard.
When connecting, run your hand along the hose
while pressing to ensure that there are no bends
in the hose.
5. Close the high and low-pressure valves of the gauge
manifold.
6. Install the vacuum pump adaptor to the vacuum pump.
7. Connect the vacuum pump plug to the vacuum pump
adaptor.
8. Connect the charging hose (yellow) to the R-134a
connection port of the vacuum pump adaptor.
9. Tighten the adaptor valve handle (valve open).
10. Open the low-pressure valve of the gauge manifold.
11. Turn the power switch of the vacuum pump to the ON
position.
NOTE
Even if the vacuum pump power switch is turned ON,
the vacuum pump will not operate because of the power
supply connection in step (7).
Low-pressure
valve
High-pressure
valve
Gauge manifold
Adapter
valve
Charging hose
(yellow)
Charging hose
(blue)
R-12
connection
port
Switch
R-134a
connection
port
Vacuum
pump
adaptor
Vacuum
pump
Power supply
plug
Switch
Quick
joint (for
low
pressure)
Low-pressure
service valve
Sleeve
A
55-10
12. Turn the vacuum pump adaptor switch to the R-134a
side to start the vacuum pump.
Caution
Do not operate the compressor for evacuation.
13. Evacuate to a vacuumreading of 100 kPa or higher (takes
approx. 10 minutes).
14. Turn the vacuum pump adaptor switch OFF and allow
to stand it for 5 minutes.
Caution
Do not operate the compressor in the vacuum
condition; damage may occur.
15. Carry out a leak test. (Good if the negative pressure
does not drop.)
Caution
If the negative pressure drops, increase the tightness
of the connections, and then repeat the evacuation
procedure from step (12).
16. With the handle turned back all the way (valve open),
install the charging valve to the service can.
17. Turn the handle of the adaptor valve back all the way
(valve closed), remove it from the gauge manifold and
install the service can.
18. Tighten the handle of the charging valve (valve closed)
to puncture the service can.
Low-pressure
service valve
Vacuum pump
Adaptor valve
Valve open
Valve close
Charging
valve
Service can
55-11
19. Turn the handle of the charging valve back (valve open)
and tighten the handle of the adaptor valve (valve open)
to charge the system with refrigerant.
Caution
If the service can is inverted, liquid refrigerant may
be drawn into the compressor damaging it by liquid
compression. Keep the service can upright to ensure
that refrigerant is charged in gas state.
20. If the refrigerant is not drawn in, turn the handle of the
adaptor valve back all the way (valve closed).
21. Check for gas leaks using a leak detector.
If a gas leak is detected, re-tighten the connections, and
then repeat the charging procedure from evacuation in
step (12).
Caution
The leak detector for R-134a should be used.
23. Operate the A/C and set to the lowest temperature (MAX.
COOL).
24. Fix the engine speed at 1,500 r/min.
25. Tighten the handle of the adaptor valve (valve open)
to charge the required volume of refrigerant.
Caution
be drawn into the compressor damaging it by liquid
that refrigerant is charged in gas state.
26. After charging with refrigerant, turn the handle of the
adaptor valve back all the way (valve closed).
27. Tighten the charging valve handle (valve closed).
Remove the quick joint (for low pressure) from the
low-pressure service valve.
NOTE
If the service can is not emptied completely, keep the
handles of the charging valve and adaptor valve closed
for the next charging.
Charging valve
Service can
(Refrigerant container)
Low-pressure
service valve
55-12
CORRECTING LOW REFRIGERANT LEVEL IN CASE
THE SERVICE CAN IS USED.
1. Install the charging valve with the handle turned all the
way back (valve open) to the service can.
2. Install the adaptor valve with the handle turned all the
way back (valve close) to the charging valve.
3. Connect the charging hose (blue) to the adaptor valve.
4. Connect the charging hose (blue) to the quick joint (for
low pressure).
5. Tighten the handle of the charging valve (valve close),
and pierce the service can.
6. Turn the handle of the adaptor valve to bleed the air.
7. Install the quick joint (for low pressure) to the low-pressure
service valve.
NOTE
9. Operate the air conditioner and set at the lowest
temperature (MAX. COOL).
10. Fix the engine speed at 1,500 r/min.
11. Tighten the handle of the adaptor valve (valve open),
and replenish refrigerant while checking the quantity
through the sight glass.
Caution
be draw into the compressor damaging it by liquid
that refrigerant is changed in gas state.
12. After replenishing is completed, turn the handle of the
adaptor valve all the way back (valve close), and remove
the quick joint.
NOTE
When there is remainder of refrigerant in the service can,
keep it for next use with the charge value and the valve
of the adaptor valve being closed.
Valve open
Valve close
Service can
(Refrigerant
container)
Charging valve
Adaptor valve
Charging hose (blue)
Quick joint (for low pressure)
Quick joint
(for lowpressure)
Low-pressure
service valve
Charging valve
Service can
(Refrigerant container)
Low-pressure
service valve
55-13
DISCHARGING SYSTEM
1. Run the engine at an engine speed of 1,200- 1,500 r/min
for approximately 5 minutes with the A/C operating to
return to the oil.
NOTE
Returning the oil will be more effective if it is done while
driving.
2. Stop the engine.
3. Connect the charging hose (blue) to the adaptor valve
with its handle turned back all the way (valve closed).
4. Connect the quick joint to the charging hose (blue).
5. Install the quick joint to the low-pressure service valve.
NOTE
Caution
To connect the quick joint, press section A firmly
When connecting, run your hand along the hose while
pressing to ensure that there are no bends in the
hose.
6. Place the adaptor valve inside the container and discharge
the refrigerant by opening the handle gradually so that
oil does not gush out.
NOTE
Any oil remaining in the container should be returned
to the A/C system.
REFILLING OF OIL IN THE A/C SYSTEM
Too little oil will provide inadequate compressor lubrication
and cause a compressor failure. Too much oil will increase
discharge air temperature.
When a compressor is installed at the factory, it contains
120 mL of refrigerant oil. While the A/C system is in operation,
the oil is carried through the entire system by the refrigerant.
Some of this oil will be trapped and retained in various parts
of the system.
When the following system components are changed, it is
necessary to add oil to the system to replace the oil being
removed with the component.
Compressor oil: SUN PAG 56
Quantity
Condenser: 15 mL
Evaporator: 60 mL
Suction hose: 10 mL
Receiver: 10 mL
Sleeve
Charging hose (blue)
Quick joint
Low-pressure
service valve
Oil
Adaptor valve
A
55-14
PERFORMANCE TEST 55200140189
1. The vehicles to be tested should be in a place that is
not in direct sunlight.
2. Close the high and low-pressure valve of the gauge
manifold.
3. Connect the charging hose (blue) to the low-pressure
valve and connect the charging hose (red) to the
high-pressure valve of the gauge manifold.
4. Install the quick joint (for low pressure) to the charging
hose (blue), and connect the quick joint (for high pressure)
to the charging hose (red).
5. Connect the quick joint (for low pressure) to the
low-pressure service valve and connect the quick joint
(for high pressure) to the high-pressure service valve.
NOTE
The high-pressure service valve is on liquid pipe B and
the low-pressure service valve is on the suction flexible
hose.
Caution
To connect the quick joint, press section A firmly
When connecting, run your hand along the hose while
pressing to ensure that there are no bends in the
hose.
7. Set the controls to the A/C as follows:
A/C switch: A/C - ON position
Mode selection: Face position
Temperature control: Max. cooling position
Air selection: Recirculation position
Blower switch: HI (Fast) position
8. Adjust engine speed to 1,000 r/min with A/C clutch
engaged.
9. Engine should be warmed up with doors and windows
closed.
10. Insert a thermometer in the left center A/C outlet and
operate the engine for 20 minutes.
11. Note the discharge air temperature.
NOTE
If the clutch cycles, take the reading before the clutch
disengages.
Low-pressure valve
High-pressure valve
Gauge manifold
Charging
hose (red)
Charging
hose (blue)
Adaptor
valve (for low
pressure)
Sleeve
Adaptor valve
(for high pressure)
Low-
pressure
service
valve
High-
pressure
service
valve
A
Thermometer
55-15
Performance Temperature Chart
Garage ambient temperature _C 20 25 35 40
Discharge air temperature _C 2.5- 4.5 2.5- 4.5 4.0- 6.5 6.5- 9.0
Compressor high pressure kPa 765- 960 765- 960 1,325- 1,420 1,570- 1,765
Compressor low pressure kPa 40- 135 40- 135 80- 175 155- 255
REFRIGERANT LEAK REPAIR 55200150045
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system. (See procedure.)
2. Charge the system with approximately one
pound of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
6. Replace receiver drier.
Caution
Replacement filter-drier units must be
sealed while in storage. The drier used in
these units will saturate water quickly upon
exposure to the atmosphere. When
installing a drier, have all tools and supplies
ready for quick reassembly to avoid keeping
the systemopen any longer than necessary.
7. Evacuate and charge system.
LOW CHARGE
If the systemhas not lost all of its refrigerant charge;
locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak
(because of an especially low charge) add
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the
procedure for correcting low refrigerant level.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are
produced in the system when it is operating.
Extreme care must be exercised to make sure that
all connections are pressure tight. Dirt and moisture
can enter the system when it is opened for repair
or replacement of lines or components. The
following precautions must be observed. The
system must be completely discharged before
opening any fitting of connection in the refrigeration
system. Open fittings with caution even after the
system has been discharged. If any pressure is
noticed as a fitting is loosened, allow trapped
pressure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use
the correct line for the installation you are servicing.
A good rule for the flexible hose lines is keep the
radius of all bends at least 10 times the diameter
of the hose.
Sharper bends will reduce the flow of refrigerant.
The flexible hose lines should be routed so that
they are at least 80 mm from the exhaust manifold.
It is good practice to inspect all flexible hose lines
at least once a year to make sure they are in good
condition and properly routed.
Unified plumbing connections with O-rings, these
O-rings are not reusable.
55-16
COMPRESSOR NOISE 55200870033
You must first know the conditions when the noise
occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or
any other special conditions.
Noises that develop during A/C operation can often
be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be
caused by loose bolts, nuts, mounting brackets,
or a loose clutch assembly. Verify accessory drive
belt tension (power steering or alternator).
Improper accessory drive belt tension can cause
a misleading noise when the compressor is
engaged and little or no noise when the compressor
is disengaged.
Drive belts are speed-sensitive. That is, at different
engine speeds, and depending upon belt tension,
belts can develop unusual noises that are often
mistaken for mechanical problems within the
compressor.
ADJUSTMENT
1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure),
restrict air flow through condenser. Install
manifold gauge set to make sure discharge
pressure doesnt exceed 2,070 kPa.
2. Tighten all compressor mounting bolts, clutch
mounting bolt, and compressor drive belt.
Check to assure clutch coil is tight (no rotation
or wobble).
3. Check refrigerant hoses for rubbing or
interference that can cause unusual noises.
4. Check refrigerant charge. (See Charging
System.)
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting
bolts and retorque. Repeat Step 1.
7. If noise continues, replace compressor and
repeat Step 1.
POWER RELAY CHECK 55200880210
BLOWER RELAY
1 3 2 5
Power is supplied
Blower relay
55-17
A/C COMPRESSOR RELAY
1 3 4 5
Power is supplied
FAN CONTROL RELAY
Refer to GROUP 14 - Radiator.
A/C compressor relay
55-18
IDLE-UP OPERATION CHECK 55200160208
1. Before inspection and adjustment, set vehicle in the
following condition:
D Engine coolant temperature: 80 - 90_C
D Lights, electric cooling fan and accessories: Set to
OFF
D Transmission: Neutral (N or P for vehicles with A/T)
D Steering wheel: Straightforward
2. Check whether or not the idle speed is the standard value.
Standard value:
<4G6> 750 50 r/min
<6A1> 650 50 r/min
<4D6> 800 30 r/min
3. When the A/C is running after turning the A/C switch
to ON, and the blower switch to the MH or HI position,
check to be sure that the idle speed is at the standard
value.
Standard value:
Engine Idle speed r/min
When load by A/C is
low
When load by A/C is
high
4G6 750 50 850 50
6A1 650 50 900 50
4D6 850 50 850 50
NOTE
(1) The engine-ECU determine whether the load by A/C
is low or high according to the output signal from
the automatic compressor-ECU <manual A/C> or the
A/C-ECU <automatic A/C>.
(2) There is no necessity to make an adjustment, because
the idle speed is automatically adjusted by the ISC
system. If, however, there occurs a deviation from
the standard value for some reason, check the ISC
system. (Refer to GROUP 13A - On-vehicle Service.)
Heater Control Assembly, A/C Switch and
Inside/Outside Air Changeover Switch
-
55-19
HEATER CONTROL ASSEMBLY, A/C SWITCH AND
INSIDE/OUTSIDE AIR CHANGEOVER SWITCH 55201240017
D Center Console Panel, Side Cover Removal and
Installation (Refer toGROUP52A - Instrument Panel.)
D Radio, Tape Player Removal and Installation (Refer
to GROUP 54.)
3
4
1
2
5
6
Removal steps
"BA 1. Air mix damper cable connection
"AA 2. Air outlet changeover damper cable
connection
3. Rear window defogger switch
4. A/C switch
5. Inside/outside air changeover
switch
6. Heater control assembly
"AA AIR OUTLET CHANGEOVER DAMPER CABLE
CONNECTION
1. Set the air outlet changeover control knob on the heater
control assembly to the DEF position.
2. Set the air outlet changeover damper lever of the heater
unit to the DEF position (turn clockwise the damper lever
until it stops), and then connect the to cable to the lever.
"BA AIR MIX DAMPER CABLE CONNECTION
1. Set the temperature control knob on the heater control
assembly to the MAX HOT position.
2. Set the air mix damper lever of the heater unit to the
MAX HOT position (turn clockwise the damper lever until
it stops), and then connect the cable to the lever.
Air outlet
changeover
damper lever
DEF position
Air mix
damper
lever
MAX HOT position
-
55-20
BLOWER SWITCH CONTINUITY CHECK
1 2 3 4 5 6 7 8
OFF
D (LO)
D (ML)
D (MH)
D(HI)
INSIDE/OUTSIDE AIR CHANGEOVER SWITCH
CONTINUITY CHECK
Switch Terminal No.
position
1 ILL 2 3 IND 4 5 6
RECIRC
FRESH
A/C SWITCH CONTINUITY CHECK
Switch Terminal No.
position
1 ILL 2 IND 4 5 7
OFF
ON
FRESH
position
RECIRC
position
OFF
position
ON position
-
55-21
HEATER CONTROL ASSEMBLY 55100130077
1
2
3
4
5
6
7
8
Disassembly steps
1. Knob assembly
2. Bulb harness
AA" 3. Air outlet changeover damper cable
AA" 4. Air mix damper cable
5. Heater control panel
6. Nut
7. Blower switch
8. Control base assembly
AA"AIR OUTLET CHANGEOVER DAMPER
CABLE/AIR MIX DAMPER CABLE REMOVAL
Insert a flat-tipped screwdriver into the control base clip from
inner side, and then remove the cable by lifting the claw
part of the clip.
Flat-tipped
screwdriver
Claw
part
- Heater Unit, Heater Core, and Blower Unit
55-22
HEATER UNIT, HEATER CORE, AND BLOWER UNIT 55201270016
D Under Cover Removal and Installation (Refer to
P.55-33.)
D Instrument Panel removal and Installation (Refer
to GROUP 52A.)
Caution: SRS
When removing and installing the heater unit
from vehicles equipped with SRS, do not let it
bump against the SRS-ECU or the components.
Vehicles with automatic A/C
1
2 3
4
5
6
2
Heater unit and heater core
removal steps
D Center reinforcement (Refer to
GROUP 52A - Instrument panel.)
D Center duct assembly and foot
distribution duct (Refer to P.55-33.)
D Draining and refilling engine coolant
(Refer to GROUP 14 - On-vehicle
service.)
2. Evaporator mounting bolt and nut
AA" 3. Heater unit
4. Heater core
Blower unit removal steps
2. Evaporator mounting bolt and nut
5. Clip
6. Blower unit
AA"HEATER UNIT REMOVAL
After sliding the cooling unit towards you slightly, remove
the heater unit.
Heater
unit
Resistor, Blower Fan and Motor, and
Inside/OutsideAir Changeover Damper Motor
-
55-23
RESISTOR, BLOWER FAN AND MOTOR, AND INSIDE/OUTSIDE
AIR CHANGEOVER DAMPER MOTOR 55100500014
Glove Box Removal and Installation (Refer to GROUP
52A - Instrument Panel.)
1
2
3
Resistor removal steps
D Under cover (Refer to P.55-33.)
1. Resistor
Blower fan and motor removal
steps
2. Blower fan and motor
Inside/outside air changeover
damper motor removal
3. Inside/outside air changeover
damper motor
BLOWER FAN AND MOTOR CHECK
When battery voltage is applied between the terminals, check
that the motor operates. Also, check that there is no abnormal
noise.
Resistor, Blower Fan and Motor, and
Inside/OutsideAir Changeover Damper Motor
-
55-24
RESISTOR CHECK
Use a circuit tester to measure the resistance between the
terminals as indicated below. Check that the measured value
is at the standard value.
Standard value:
Measurement terminal Standard value W
Between terminals 3 and 2 (LO) 2.30
Between terminals 3 and 4 (ML) 1.10
Between terminals 3 and 1 (MH) 0.40
INSIDE/OUTSIDE CHANGEOVER DAMPER MOTOR
CHECK
Battery connection
terminal
Lever operation
1 2
Moves to the outside air position
Moves to the inside air position
Caution
Cut off the battery voltage when the damper is in the
inside air position or outside air position.
- Evaporator
55-25
EVAPORATOR 55200360165
D Discharging and Charging of Refrigerant (Refer to
P.55-9.)
D Glove Box, Side Cover and Glove Box FrameRemoval
and Installation (Refer to GROUP 52A - Instrument
Panel.)
P.55-33.)
Piping connection
3
Compressor oil: SUNPAG56
3
2
1
4
5
6
Removal steps
AA" 1. Suction hose connection
AA" 2. Discharge pipe connection
3. O-ring
4. Drain hose
5. Plate
"AA 6. Evaporator
AA"SUCTION HOSE, DISCHARGE PIPE
DISCONNECTION
Plug the disconnected hose and the evaporator nipple not
to let foreign matter get into them.
Caution
Seal the hoses completely, otherwise the compressor
oil and receiver will absorb water vapour easily.
"AAEVAPORATOR INSTALLATION
When replacing the evaporator, refill it with a specified amount
of compressor oil and install it (to the vehicle).
Quantity: 60 mL
- Evaporator
55-26
6
7
7
1
3
2
6
5
4
7
8
Disassembly steps
AA" 1. Clip
2. Evaporator case (upper)
3. Automatic compressor-ECU
<Manual A/C>
4. Air thermo sensor <Automatic A/C>
5. Evaporator case (lower)
6. Expansion valve
7. O-ring
8. Evaporator
AA"CLIP REMOVAL
Remove the clips with a flat-tipped screwdriver covered with
a shop towel to prevent damage to case surfaces.
Clip
Evaporator/Air Purifier Assembly/
Compressor and Tension Pulley
-
55-27
AIR THERMO SENSOR
When the resistance value between the sensor terminals
is measured under two or more temperature conditions, the
resistance value should be close to the values shown in the
graph.
NOTE
The temperature conditions when testing should not exceed
the range of the characteristic curve in the graph.
AIR PURIFIER ASSEMBLY 55500100032
D Glove Box, Side Cover and Glove Box FrameRemoval
and Installation (Refer to GROUP 52A - Instrument
Panel.)
P.55-33.)
Air purifier assembly
COMPRESSOR AND TENSION PULLEY 55200410266
Refer to P.55-61.
Resistance kW
Temperature _C
20
15
10
0
5
- 10 0 40 20 30 10
- Refrigerant Line
55-28
REFRIGERANT LINE 55200640269
<L.H. DRIVE VEHICLES>
D Discharging and Changing of Refrigerant (Refer to
P.55-9.)
D Reserve Tank Removal and Installation (Refer to
GROUP 14 - Radiator.)
D Oil Reservoir Removal and Installation (Refer to
GROUP 37A - Power Steering Hoses.)
1
9
10
10
3
6
5
2
4
10
8
Piping connection
10
7
10
2
10
10
Removal steps
AA" 1. Suction pipe
2. Clamp and bracket
AA" 3. Suction flexible hose
AA" 4. Liquid pipe A
AA" 5. Liquid pipe B
6. Dual pressure switch
7. Receiver bracket assembly
AA" "AA 8. Receiver assembly
9. Discharge flexible hose
AA" 10. O-ring
- Refrigerant Line
55-29
<R.H. DRIVE VEHICLES>
D Discharging and Changing of Refrigerant (Refer to
P.55-9.)
D Canister Removal and Installation (Refer to GROUP
17.)
D Reserve Tank Removal and Installation (Refer to
GROUP 14 - Radiator.)
D Oil Reservoir Removal and Installation (Refer to
GROUP 37A - Power Steering Hoses.)
1
9
11
10
11
3
7
2
4
Piping connection
Compressor oil:
SUN PAG 56
5
11
11
6
11
11
11
8
Removal steps
1. Clamp
AA" 2. Suction pipe
3. Clamp and bracket
AA" 4. Suction flexible hose
AA" 5. Liquid pipe B
AA" 6. Liquid pipe A
7. Dual pressure switch
8. Receiver bracket assembly
AA" "AA 9. Receiver assembly
AA" 10. Discharge flexible hose
11. O-ring
- Refrigerant Line
55-30
AA"HOSE/PIPE/RECEIVER ASSEMBLY
DISCONNECTION
Plug the disconnected hose, the receiver, the evaporator and
the compressor nipple not to let foreign matter get into them.
Caution
"AASUCTION HOSE/RECEIVER ASSEMBLY
INSTALLATION
When replacing the suction hose or receiver assembly, refill
them with a specified amount of compressor oil, and then
install them.
Quantity:
Suction hose: 10 mL
Receiver assembly: 10 mL
- Condenser and Condenser Fan Motor
55-31
CONDENSER AND CONDENSER FAN MOTOR 55200670244
6
2
3
4
1
5
Piping connection
O-ring
Condenser fan motor removal
steps
1. Condenser fan motor and shroud
assembly
2. Condenser fan
3. Shroud
4. Condenser fan motor
Condenser removal steps
D Discharging and charging of
refrigerant (Refer to P.55-9.)
D Air cleaner
D Engine coolant draining and supplying
(Refer to GROUP 14 - On-vehicle
service.)
D Radiator (Refer to GROUP 14.)
AA" 5. Discharge flexible hose and liquid
pipe A connection
"AA 6. Condenser
AA"DISCHARGE FLEXIBLE HOSE AND LIQUID PIPE
A CONNECTION
Plug the disconnected pipe, hose and the condenser nipple
not to let foreign matter get into them.
Caution
- Condenser and Condenser Fan Motor
55-32
"AACONDENSER INSTALLATION
When replacing the condenser, refill it with a specified amount
of compressor oil and install it. (to the vehicle).
Quantity: 15 mL
CONDENSER FAN MOTOR CHECK
Check to be sure that the condenser fan motor operates
when battery voltage is applied to terminal 1 and terminal
2 earthed.
- Ventilators
55-33
VENTILATORS 55300160119
<Automatic A/C>
1
2
3
4
5
6
7
8
9
2
Under cover removal
1. Under cover
Defroster nozzle and distribution
duct removal steps
D Floor console assembly (Refer to
GROUP 52A.)
D Instrument panel (Refer to GROUP
52A.)
2. Side defroster duct
3. Defroster nozzle assembly
4. Distribution duct assembly
5. Defroster garnish and photo sensor
6. Center duct assembly
Rear heater duct and foot
distribution duct removal steps
D Front seat (Refer to GROUP 52A.)
D Floor console assembly (Refer to
GROUP 52A.)
D Instrument panel and center reinforce-
ment (Refer to GROUP 52A.)
7. Rear heater duct (R.H.)
8. Rear heater duct (L.H.)
9. Foot distribution duct
NOTE
For the center air outlet assembly and the side air outlet
assembly, refer to GROUP 52A - Instrument panel.
- Ventilators
55-34
<Sedan>
<Wagon>
10
Rear ventilation duct assembly
removal steps
D Rear bumper (Refer to GROUP 51.)
10. Rear ventilation duct assembly
NOTE
For the front deck garnish, refer toGROUP51 - Windshieldwiper
and washer.
Service Specifications
HEATER, AIR CONDITIONER AND VENTILA-
TION <AUTOMATIC AIR CONDITIONER>
-
55-35
AUTOMATIC AIR CONDITIONER 55400010080
GENERAL INFORMATION
The heater system uses a two-way-flow full-air-mix
system that features high performance and low
operating noise, and includes an independent
face-directed air flow function.
An air purifier which carries out fine A/C control
has been included.
The A/Csystemis basically the same as the manual
air conditioner in which a new refrigerant system
has been adopted. However, an A/C control panel
with a reduced number of buttons and more
compact arrangement of necessary functions owing
to more functions being assigned to each button
has been adopted.
Heater unit Type Two-way-flow full-air-mix system
Heater control assembly Push button type
Compressor Model Scroll type <MSC 90>
Dual pressure switch High-pressure switch ON OFF: 2,942, OFF ON: 2,353
kPa
Low-pressure switch ON OFF: 196, OFF ON: 221
Refrigerant and quantity g R-134a (HFC-134a), Approx. 670 - 710
Idle speed r/min 4G6 750 50
6A1 650 50
4D6 800 30
Idle-up speed r/min When load by A/C is low 4G6 750 50
6A1 650 50
4D6 850 50
When load by A/C is high 4G6 850 50
6A1 900 50
4D6 850 50
Air mix damper motor poten- MAX. HOT position Approx. 4.8
tiometer resistance kW
MAX. COOL position Approx. 0.2
Outlet air changeover damp- DEF position Approx. 4.8
er motor potentiometer resis-
tance kW FACE position Approx. 0.2
Air gap (Magnetic clutch) mm 0.40 - 0.65
Lubricants/Special Tools/
Troubleshooting
-
55-36
Each connection of refrigerant line SUN PAG 56 As required
Compressor refrigerant unit lubricant mL SUN PAG 56 120
MB991502 MUT-II
sub-assembly
Inspection of automatic air conditioner
check harness
Inspection of automatic air conditioner using a
voltmeter
NOTE
Other special tools are the same as for the manual A/C.
Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check
diagnosis codes.
- Troubleshootimg
55-37
Code No. Diagnosis item Reference
page
11 Inside air temperature sensor system (open circuit) 55-37
12 Inside air temperature sensor system (short circuit) 55-37
13 Outside air temperature sensor system (open circuit) 55-38
14 Outside air temperature sensor system (short circuit) 55-38
15 Heater water temperature sensor system (open circuit) 55-39
16 Heater water temperature sensor system (short circuit) 55-39
21 Air thermo sensor system (open circuit) 55-40
22 Air thermo sensor system (short circuit) 55-40
31 Potentiometer system of air mix damper motor assembly 55-41
32 Potentiometer system of air outlet changeover damper motor assembly 55-42
41 Drive system of air mix damper motor assembly 55-43
42 Drive system of air outlet changeover damper motor assembly 55-43
Code No.11 or 12 Inside air temperature sensor system Probable cause
This diagnosis code is output if the inside air temperature sensor inside the
A/C-ECU is defective.
D Malfunction of the A/C-ECU
Replace the A/C-ECU.
- Troubleshootimg
55-38
Code No.13 Outside air temperature sensor system(open
circuit)
Probable cause
This diagnosis code is output if there is a defective connector connection, or if
there is an open circuit in the harness.
D Malfunction of the outside air temperature sensor
Outside air temperature sensor check (Refer to P.55-68.)
NG
Replace
OK
Measure at the outside air temperature sensor connector A-21.
side connector.
OK: 5 V
NG
C-05, C-64 <L.H. drive vehicles>, C-116 <L.H. drive vehicles>,
C-99 <R.H. drive vehicles>
NG
Repair
OK
NG
Check the harness between the outside air temperature sensor
and the A/C-ECU.
NG
Repair
OK
OK
Measure at the A/C-ECU connector C-05.
OK: 2.3 - 2.9 V
NG
C-05, C-116 <L.H. drive vehicles>, C-99 <R.H. drive vehicles>
NG
Repair
OK
NG
and the A/C-ECU, and repair if necessary.
OK
NG
Repair
OK
NG
Code No.14 Outside air temperature sensor system(short
circuit)
Probable cause
This diagnosis code is output if there is a short circuit in the outside air
temperature sensor input circuit.
D Malfunction of the outside air temperature sensor
Outside air temperature sensor check (Refer to P.55-68.)
NG
Replace
OK
OK: 2.3 - 2.9 V
NG
OK
- Troubleshootimg
55-39
Code No.15 Heater water temperature sensor system
(open circuit)
Probable cause
D Malfunction of the heater water temperature sensor
Heater water temperature sensor check (Refer to P.55-70.)
NG
Replace
OK
Measure at the heater water temperature sensor connector C-70.
side connector.
OK: 5 V
NG
C-05, C-64 <L.H. drive vehicles>
NG
Repair
OK
NG
Check the harness between the heater water temperature sensor
and the A/C-ECU.
NG
Repair
OK
OK
OK: 2.3 - 2.9 V
NG
C-70
NG
Repair
OK
NG
OK
NG
Repair
OK
NG
Code No.16 Heater water temperature sensor system
(short circuit)
Probable cause
This diagnosis code is output if there is a short circuit in the heater water
temperature sensor input circuit.
D Malfunction of the heater water temperature sensor
Heater water temperature sensor check (Refer to P.55-70.)
NG
Replace
OK
OK: 2.3 - 2.9 V
NG
OK
- Troubleshootimg
55-40
Code No.21 Air thermo sensor system (open circuit) Probable cause
D Malfunction of the air thermo sensor
Air thermo sensor check (Refer to P.55-26.)
NG
Replace
OK
Measure at the air thermo sensor connector C-73.
side connector.
OK: 5 V
NG
NG
Repair
OK
NG
Check the harness betweenthe air thermo sensor and theA/C-ECU.
NG
Repair
OK
OK
OK: 2.3 - 2.9 V
NG
C-73
NG
Repair
OK
NG
Check the harness betweenthe air thermo sensor and theA/C-ECU,
OK
NG
Repair
OK
NG
Code No.22 Air thermo sensor system (short circuit) Probable cause
This diagnosis code is output if there is a short circuit in the air thermo sensor
input circuit.
D Malfunction of the air thermo sensor
Air thermo sensor check (Refer to P.55-26.)
NG
Replace
OK
OK: 2.3 - 2.9 V
NG
Check the harness betweenthe air thermo sensor and theA/C-ECU,
OK
- Troubleshootimg
55-41
Code No.31 Potentiometer system of air mix damper
motor assembly
Probable cause
This diagnosis code is output if there is an open or short circuit in the
potentiometer input circuit, or if there is an open circuit in the power circuit or
earth circuit.
D Malfunction of the air mix damper motor assembly
Air mix damper motor potentiometer check (Refer to P.55-59.)
NG
Replace
OK
Measure at the air mix damper motor potentiometer connector C-79.
side connector.
OK: 5 V
NG
NG
Repair
OK
NG
Check the harness between the air mix damper motor potentiometer
and the A/C-ECU.
NG
Repair
OK
OK
D Air mix damper position: MAX.HOT
OK: 4.7 - 5.0 V
NG
C-79
NG
Repair
OK
NG
Check the harness between the air mix damper motor potentiometer
OK
NG
Repair
OK
NG
- Troubleshootimg
55-42
Code No.32 Potentiometer system of air outlet change-
over damper motor assembly
Probable cause
This diagnosis code is output if there is an open or short circuit in the
potentiometer input circuit, or if there is an open circuit in the power circuit or
earth circuit.
D Malfunction of the air outlet changeover damper
motor assembly
Air outlet changeover damper motor potentiometer check (Refer
to P.55-60.)
NG
Replace
OK
Measure at the air outlet changeover damper motor potentiometer
connector C-17.
side connector.
OK: 5 V
NG
NG
Repair
OK
NG
Check the harness between the air outlet changeover damper motor
potentiometer and the A/C-ECU.
NG
Repair
OK
OK
D Air outlet changeover damper position: DEF
OK: 4.8 - 5.2 V
NG
C-17
NG
Repair
OK
NG
Check the harness between the air outlet changeover damper motor
potentiometer and the A/C-ECU, and repair if necessary.
OK
NG
Repair
OK
NG
- Troubleshootimg
55-43
Code No.41 Drive system of air mix damper motor
assembly
Probable cause
This diagnosis code is output if the motor drive circuit is defective. D Malfunction of the air mix damper motor assembly
Air mix damper motor check (Refer to P.55-59.)
NG
Replace
OK
C-07, C-79
NG
Repair
OK
NG
Check the harness between the air mix damper motor and the
A/C-ECU.
OK
NG
Repair
Code No.42 Drive systemof air outlet changeover damper
motor assembly
Probable cause
This diagnosis code is output if the motor drive circuit is defective. D Malfunction of the air outlet changeover damper
motor assembly
Air outlet changeover damper motor check (Refer to P.55-60.)
NG
Replace
OK
C-17, C-07
NG
Repair
OK
NG
Check the harness between the air outlet changeover damper
motor and the A/C-ECU.
OK
NG
Repair
- Troubleshootimg
55-44
Trouble symptom Inspection proce-
dure No.
Reference page
Communication with the MUT-II is not possible. 1 55-45
Air conditioner does not operate. 2 55-46
A/C graphic display on control panel is blank. 3 55-47
Temperature cannot be set. 4 55-47
A/C outlet air temperature does not increase. 5 55-47
A/C outlet air temperature does not decrease. 6 55-47
Blower does not operate. 7 55-48
Blower air amount cannot be changed. 8 55-49
Air outlet port cannot be changed. 9 55-49
Inside/outside air changeover is not possible. 10 55-50
Defroster function does not operate. 11 55-51
Rear defogger does not operate. 12 55-51
A/C-ECU power supply circuit check 13 55-52
A/C compressor control circuit check 14 55-53
Radiator fan does not operate. 15 Refer to GROUP
Condenser fan does not operate. 16
14 - Trouble-
shooting.
- Troubleshootimg
55-45
Communication with the MUT-II is not possible. Probable cause
If communication with all other systems is not possible, there is a high possibility
that there is a malfunction of the diagnosis line. If communication with only the
A/C is not possible, the cause is probably a malfunction of the diagnosis line or
of the A/C-ECU power supply system (earth).
D Malfunction of connector or harness
D Malfunction of A/C-ECU
Is communication between MUT-II and
other system is possible?
NO
Check the MUT-II diagnosis line, and
YES
C-20.
D Voltage between terminal (11)
and body earth
OK: Indication fluctuates be-
tween 0 V and 12 V.
OK
Measure at the A/C-ECU connector
C-05.
connector.
and body earth
OK: Battery voltage - 2 V
NG
C-05
OK
NG
Repair
NG
C-05.
and body earth
OK: Indication fluctuates be-
tween 0 V and 12 V.
NG
OK
C-05
NG
sis connector and the A/C-ECU, and
NG
Repair
OK
sis connector and the A/C-ECU.
NG
Repair
OK
NG
C-05, C-20
NG
Repair
OK
NG
C-07.
connector.
and body earth
OK: Battery voltage
NG
C-132, C-63 <L.H. drive vehicles>, C-61
NG
Repair
OK
NG
Check the harness between the junction
block and the A/C-ECU, and repair if
necessary.
OK
C-07.
connector.
D Continuity between terminales
(27), (35) and body earth
OK: Continuity
NG
NG
Repair
OK
NG
Check the harness between the
A/C-ECUand the body earth, and repair
if necessary.
OK
NG
- Troubleshootimg
55-46
Air conditioner does not operate. Probable cause
If the A/C does not operate when the A/C switch is on and the temperature
setting is at 17_C, the cause is probably insufficient refrigerant, or a malfunction
of the blower or of the magnet clutch power supply.
D Malfunction of blower
D Insufficient refrigerant
D Malfunction of magnetic clutch
D Malfunction of air thermo sensor
D Malfunction of A/C compressor relay
D Malfunction of refrigerant temperature switch
D Malfunction of dual pressure switch
Does the blower operate?
NO
Inspection procedure 7 (Refer to P.55-48.)
YES
A/C system refrigerant pressure check (Refer to P.55-14.)
NG
Refill the specified amount of refrigerant. (Refer to P.55-9.)
OK
MUT-II DIAGNOSIS CODE
Is any of the codes 11, 21 and 22 output?
YES
INSPECTION CHART FOR DIAGNOSIS CODES (Refer to
P.55-37.)
NO
D Magnetic clutch check (Refer to P.55-7.)
D A/C compressor relay check (Refer to P.55-17.)
D Refrigerant temperature switch check (Refer to P.55-65.)
D Dual pressure switch check (Refer to P.55-8.)
NG
Replace
OK
Measure at the A/C compressor relay connector B-28X.
side connector.
(1) Continuity between terminal (4) and body earth
OK: Continuity
(2) Voltage between terminal (5) and body earth
OK: Battery voltage
OK
(2) NG
B-28X
(1) NG
B-28X, B-30, B-75
NG
Repair
NG
Repair
OK
NG
Check the harness between the fusible link and the A/Ccompressor
OK
NG
Check the harness between the magnetic clutch and the A/C com-
pressor relay, and repair if necessary.
- Troubleshootimg
55-47
A/C graphic display on control panel is blank. Probable cause
The cause is probably a malfunction of the A/C-ECU power supply system
(earth).
Does the A/C operate?
NO
YES
Temperature cannot be set. Probable cause
The cause is probably a malfunction of the temperature setting signal input
system or output system.
A/C outlet air temperature does not increase. Probable cause
If the outlet air temperature does not increase when the temperature setting is
increased, the cause is probably a sensor malfunction or a problem with
operation of the air mix damper. The MUT-II can be used to check the diagnosis
codes in order to check the cause of the problem for each separate system.
D Malfunction of air mix damper motor potentiometer
D Malfunction of air mix damper motor
D Malfunction of air mix damper
D Malfunction of thermostat
Is any of the codes 11, 12, 31 and 41 output?
YES
P.55-37.)
NO
Thermostat check (Refer to GROUP 14 - On-vehicle Service.)
NG
Replace
OK
A/C outlet air temperature does not decrease. Probable cause
If the outlet air temperature does not decrease when the temperature setting is
decreased, the cause is probably a problem in A/C system operation due to a
sensor error, or a problem with operation of the air mix damper. The MUT-II can
be used to check the diagnosis codes in order to check the cause of the
problem for each separate system.
D Malfunction of outside air temperature sensor
D Malfunction of air mix damper motor potentiometer
D Malfunction of air mix damper motor
D Malfunction of air thermo sensor
D Malfunction of air mix damper
NO
YES
Is any of the codes 11, 12, 13, 14, 21, 22, 31 and 41 output?
YES
P.55-37.)
NO
- Troubleshootimg
55-48
Blower does not operate. Probable cause
If no air comes out of the blower even though the blower switch is on, the
cause is probably a malfunction of the blower motor relay circuit.
D Malfunction of blower motor relay
D Malfunction of blower motor
Can an operating sound be heard when the blower speed change-
over switch is operated?
NO
YES
D Blower relay check (Refer to P.55-16.)
D Blower motor check (Refer to P.55-23.)
NG
Replace
OK
Measure at the blower relay connector C-140.
side connector.
OK: Continuity
(2) Voltage between terminal (3) and body earth (Ignition
switch: ON)
OK: Battery voltage
(3) Voltage between terminal (2) and body earth
OK: Battery voltage
(1) NG
Check the harness between the blower relay and the body earth,
(2) NG
Check the harness between the blower relay and the ignition switch,
(3) NG
Check the harness between the blower relay and the fusible link
No.1, and repair if necessary.
OK
Measure at the blower motor connector C-09.
side connector.
D Voltage between terminal (1) and body earth (Ignition
switch: ON)
OK: Battery voltage
NG
C-131
NG
Repair
OK
NG
Check the harness between the blower relay and the blower motor,
OK
C-09
NG
Repair
OK
NG
Check the harness between the blower motor and the A/C-ECU,
- Troubleshootimg
55-49
Blower air amount cannot be changed. Probable cause
If the blower does not operate in any mode other than HI setting, the cause is
probably a malfunction of the power transistor system.
D Malfunction of power transistor
Measure at the power transistor connector C-77.
D Blower switch position: LO
OK: Continuity
switch: ON)
OK: Battery voltage - 2 V
switch: ON)
OK: Approx. 1.3 V
OK
C-77
NG
Repair
OK
(1) NG
Check the harness between the power transistor and the body
(2) NG
Check the harness between the power transistor and the blower
motor, and repair if necessary.
(3) NG
D Blower switch position: LO
switch: ON)
OK: Approx. 7 V
switch: ON)
OK: Approx. 1.3 V
NG
C-05
NG
Repair
OK
OK
Check the harness between the power transistor and the A/C-ECU.
NG
Repair
OK
Replace the power transistor.
NG
Replace the power transistor.
NG
Air outlet port cannot be changed. Probable cause
The cause is probably a malfunction of the air outlet port changeover signal
input system or output system. The MUT-II can be used to check the diagnosis
codes in order to check the cause of the problem for each separate system.
D Malfunction of air outlet changeover damper motor
potentiometer
D Malfunction of air outlet changeover damper motor
D Malfunction of air outlet changeover damper
Can an operating sound be heard when the air outlet port
changeover switch is operated?
NO
YES
Is either code 32 or code 42 output?
YES
P.55-37.)
NO
Air outlet changeover damper check
NG
Repair
OK
- Troubleshootimg
55-50
Inside/outside air changeover is not possible. Probable cause
If inside/outside air changeover is not possible even when the inside/outside air
changeover switch is on, the cause is probably a malfunction of the
inside/outside air changeover damper motor.
D Malfunction of inside/outside air changeover
damper motor
D Malfunction of inside/outside air changeover
damper
Can an operating sound be heard when the inside/outside air
changeover switch is operated?
NO
YES
Inside/outside air changeover damper motor check (Refer to
P.55-24.)
NG
Replace
OK
Measure at the inside/outsideair changeover damper motor connec-
tor C-78.
side connector.
D Outside air select button: ON
OK: 10 V
D Inside air select button: ON
OK: 10 V
NG
C-07
NG
Repair
OK
NG
Check the harness between the inside/outside air changeover
damper motor and the A/C-ECU, and repair if necessary.
NG
Repair
OK
OK
C-78
NG
Repair
OK
NG
Inside/outside air changeover damper check
NG
Repair
OK
- Troubleshootimg
55-51
Defroster function does not operate. Probable cause
If the defroster function does not operate when the defroster switch is turned on,
the cause is probably a malfunction of the A/C or of the air outlet port
changeover circuit.
D Malfunction of air conditioner drive system
D Malfunction of air outlet changeover damper drive
system
Can an operating sound be heard when the defroster switch is
operated?
NO
YES
NO
YES
Can the air outlet port be changed over?
NO
YES
Air outlet changeover damper (for defroster) check
NG
Repair
OK
Rear defogger does not operate. Probable cause
If the rear defogger does not operate when the rear defogger switch is turned
on (timer operates for 20 minutes), the cause is probably a malfunction of the
A/C-ECU power supply system (earth).
Can an operating sound be heard when the rear defogger switch
is operated?
NO
YES
- Troubleshootimg
55-52
A/C-ECU power supply circuit check
side connector.
OK: Battery voltage
NG
C-63, C-132, C-141 <L.H. drive vehicles>, C-62, C-14 <R.H. drive
vehicles>
NG
Repair
OK
NG
Check the harness between the A/C-ECU and the fusible link No.2,
OK
side connector.
switch: ON)
OK: Battery voltage
NG
C-63 <L.H. drive vehicles>, C-61 <R.H. drive vehicles>, C-132
NG
Repair
OK
NG
Check the harness between the A/C-ECU and the junction block,
OK
side connector.
OK: Continuity
OK: Continuity
NG
Check the harness between the A/C-ECU and the body earth,
OK
C-07
NG
Repair
OK
NG
- Troubleshootimg
55-53
A/C compressor control circuit check
D Blower switch and A/C switch: ON
D Setting temperature: 17_C
switch: ON)
OK: Battery voltage
NG
C-07
NG
Repair
OK
NG
OK
Measure at the A/C compressor relay connector B-28X.
D Blower switch and A/C switch: ON
side connector.
OK: Battery voltage
NG
C-116, C-67, C-14, C-64, C-07 <L.H. drive vehicles>
C-14, C-66, C-115, C-07 <L.H. drive vehicles>
NG
Repair
OK
NG
Check the harness between the A/C-ECU and the A/C compressor
OK
Measure at the engine-ECU connector C-55 <4D6>, C-34 <4G6>,
C-33 <6A1>.
side connector.
D Voltage between terminal (53) and body earth <4D6>
D Voltage between terminal (8) and body earth <4G6, 6A1>
OK: Battery voltage
NG
B-30, B-28X
NG
Repair
OK
NG
Check the harness between the A/C compressor relay and the
engine-ECU, and repair if necessary.
OK
- Troubleshootimg
55-54
Item No. Check item Check condition Normal condition
11 Inside air tempera-
ture sensor
Ignition switch: ON Inside air temperature and tem-
perature displayed on the MUT-II
are identical.
13 Outside air temper-
ature sensor
Ignition switch: ON Outside air temperature and
temperature displayed on the
MUT-II are identical.
15 Heater water tem-
perature sensor
Ignition switch: ON Heater core surface temperature
and temperature displayed on
the MUT-II are identical.
21 Air thermo sensor Ignition switch: ON Evaporator surface temperature
and temperature displayed on
the MUT-II are identical.
25 Photo sensor Ignition switch: ON Amount of incident light is
proportional to voltage displayed
on the MUT-II.
31 Air mix damper mo- Ignition switch: ON Damper position Opening degree (%)
tor potentiometer
MAX. HOT Approx. 100
MAX. COOL Approx. 0
32 Air outlet change- Ignition switch: ON Damper position Opening degree (%)
over damper motor
potentiometer FACE Approx. 0
FOOT Approx. 50
FOOT/DEF. Approx. 75
DEF. Approx. 100
CHECK AT THE A/C-ECU TERMINALS 55400540077
Terminal
No.
Check item Check condition Normal condition
1 Power MOS FET drain output When blower switch is at OFF System voltage
When blower switch is at LO Approx. 9 V
When blower switch is at HI Almost no voltage (0 V)
- Troubleshootimg
55-55
Terminal
No.
Normal condition Check condition Check item
2 Power MOS FET gate output When blower switch is at OFF 0 V
When blower switch is at LO Approx. 1.3 V
When blower switch is at HI Approx. 2.5 V
3 A/C-ECU backup power supply At all times System voltage
4 Heater water temperature sensor
input
When sensor section temperature is
25_C (4 kW)
2.3 - 2.9 V
5 Air mix damper motor potentiometer
input
When damper is moved to MAX. HOT
position
4.7 - 5.0 V
6 Air outlet changeover damper motor
potentiometer input
When damper is moved to DEF.
position
4.8 - 5.2 V
7 Outside air temperature sensor input When sensor section temperature is
25_C (4 kW)
2.3 - 2.9 V
8 Air thermo sensor input When sensor section temperature is
25_C (4 kW)
2.3 - 2.9 V
9 Photo sensor (- ) At luminous intensity of 100,000 lux or
more
- 0.1 - 0.2 V
At luminous intensity of 0 lux 0 V
10 Sensor power supply At all times 4.8 - 5.2 V
16 Rear defogger input When rear defogger switch is ON 1.5 V or less
When rear defogger switch is OFF System voltage
17 Diagnosis date output When ignition switch is ON 0 V System voltage
18 Diagnosis control input When ignition switch is ON Battery voltage - 2 V
19 Photo sensor (+) At all times 0 V
20 Air mix damper motor and air outlet
changeover damper motor potentiom-
eters
At all times 0 V
(+)
Set to FACE position (OFF after 40
seconds of output)
10 V
Set to DEF. position (OFF after 40
seconds of output)
0.5 V
22 Air mix damper motor (- ) Set the setting temperature to 17_C
and set to MAX. COOL position (OFF
after 40 seconds of output)
10 V
Set the setting temperature to 32_C
and set to MAX. HOT position (OFF
0.5 V
Troubleshooting/
On-vehicle Service
-
55-56
Terminal
No.
Normal condition Check condition Check item
23 Inside/outside air changeover damper
motor (- )
Set to inside air position (OFF after 40
seconds of output)
0.5 V
Set to outside air position (OFF after
40 seconds of output)
10 V
(- )
Set to FACE position (OFF after 40
seconds of output)
0.5 V
Set to DEF. position (OFF after 40
seconds of output)
10 V
25 Air mix damper motor (+) Set the setting temperature to 17_C
and set to MAX. COOL position (OFF
0.5 V
Set the setting temperature to 32_C
and set to MAX. HOT position (OFF
10 V
26 Inside/outside air changeover damper
motor (+)
Set to inside air position (OFF after 40
seconds of output)
10 V
Set to outside air position (OFF after
40 seconds of output)
0.5 V
27 Earth At all times Continuity
28 A/C-ECU power supply When ignition switch is ON System voltage
29 ILL earth (rheostat) At all times Continuity
30 ILL power supply When lighting switch is at ON System voltage
33 Engine-ECU output When air mix damper is at MAX.
COOL position
0 V
When air mix damper is at MAX. HOT
position
System voltage
34 A/C output When A/C is OFF 0 V
When A/C is ON System voltage
35 Earth At all times Continuity
The service procedures are the same as for the manual air conditioner. (Refer to P.55-7.)
Air Conditioner Control Panel and
ECU Assembly
-
55-57
AIR CONDITIONER CONTROL PANEL AND ECU ASSEMBLY 55400100084
D Floor Console Panel Removal and Installation
(Refer to GROUP 52A - Floor Console Box.)
1
3
2
Removal steps
1. Center console panel and air condi-
tioner control panel assembly
2. Center console panel
3. Air conditioner control panel and ECU
assembly
Damper Motor Assembly and
Power Transistor
-
55-58
DAMPER MOTOR ASSEMBLY AND POWER TRANSISTOR 55400580024
1
2
3
4
5
Inside/outside air changeover
damper motor assembly removal
steps
Instrument Panel.)
1. Inside/outside air changeover damper
motor assembly
Outlet air changeover damper
motor assembly removal steps
D Lower cover (Refer to GROUP 52A
- Instrument Panel.)
2. Outlet air changeover damper motor
assembly
Air mix damper motor assembly
removal steps
D Glove box, side cover, glove box
frame, radio, tape player (Refer to
3. Control relay bracket assembly
4. Air mix damper motor assembly
Power transistor removal steps
Instrument Panel.)
5. Power transistor
INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR
ASSEMBLY CHECK
For inspection service points, refer to P.55-24 for heater and
manual A/C.
Power Transistor
-
55-59
AIR MIX DAMPER MOTOR ASSEMBLY CHECK
Motor
Check that the lever moves when battery voltage is applied
across terminals 1 and 3 of the motor assembly connector.
Check also that the lever moves in the backward direction
when polarity is changed.
Caution
1. Cut off the voltage when the damper is in the MAX.
HOT or MAX. COOL position.
2. Cut off the voltage if the motor does not turn when
battery voltage is applied.
Potentiometer
Connect a circuit tester across terminals 2 and 5 of the motor
assembly connector and check that resistance gradually
changes as the damper is moved from MAX. HOT to MAX.
COOL position.
Standard value:
MAX. HOT position: Approx. 4.8 kW
MAX. COOL position: Approx. 0.2 kW
Lever
MOTOR
POTENTIOMETER
Power Transistor
-
55-60
AIR OUTLET CHANGEOVER DAMPER MOTOR
ASSEMBLY CHECK
Motor
Check that the lever moves when battery voltage is applied
across terminals 1 and 3 of the motor assembly connector.
Check also that the lever moves in the backward direction
when polarity is changed.
Caution
1. Cut off the voltage when the damper is in the DEF
or FACE position.
2. Cut off the voltage if the motor does not turn when
battery voltage is applied.
Potentiometer
Connect a circuit tester across terminals 5 and 6 of the motor
assembly connector and check that resistance gradually
changes as the damper is moved from DEF. to FACE position.
Standard value:
DEF. position: Approx. 4.8 kW
FACE position: Approx. 0.2 kW
Lever
MOTOR
POTENTIOMETER
- Compressor and Tension Pulley
55-61
COMPRESSOR AND TENSION PULLEY 55200410273
D Discharging of Refrigerant (Refer to P.55-13.)
D Charging of Refrigerant (Refer to P.55-9.)
<4G6>
<6A1>
6
3
1
1
2
6
3
4
25 Nm
Piping connection
49 Nm
O-ring
5
5
2
Removal steps
D Under cover
D Condenser fan motor (Refer to
P.55-31.)
D Drive belt (for alternator) <6A1>(Refer
to GROUP 11 - Crankshaft Pulley.)
AA" 1. Drive belt
2. Tension pulley
AB" 3. Hose connections
4. Power steering oil pressure switch
harness <6A1>
AC" "AA 5. Compressor
6. Compressor bracket
55-62
Piping connection
6
3
1
2
8
4
25 Nm
20 - 25 Nm
O-ring
39 Nm
7
5
<4D6>
Removal steps
D Under cover
D Condenser fan motor (Refer to
P.55-31.)
AA" 1. Drive belt (for compressor)
2. Tension pulley
3. Tension pulley bracket
AB" 4. Hose connections
AC" "AA 5. Compressor
6. Drive belt (for power steering oil pump)
7. Power steering oil pump
8. Compressor bracket
55-63
AA"DRIVE BELT REMOVAL
1. Loosen the nut A for holding.
2. Loosen the bolt B <4G6 and 6A1> or nut B <4D6>
for adjustment.
3. Remove the drive belt.
AB"HOSE DISCONNECTION
Plug the disconnected hose and the compressor nipple not
to let foreign matter get into them.
Caution
AC"COMPRESSOR REMOVAL
When doing this work, be careful not to spill the compressor
oil.
<4G6>
<6A1>
<4D6>
Bolt B
Nut A
Nut A
Bolt B
Nut A
Nut B
55-64
"AACOMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the amount of
oil according to the procedures described below, and then
install the compressor.
1. Measure the amount (X mL) of oil within the removed
compressor.
2. Drain (from the new compressor) the amount of oil
calculated according to the following formula, and then
install the new compressor.
New compressor oil amount
120 mL - X mL = Y mL
NOTE
(1) Y mL indicates the amount of oil in the refrigerant
line, the condenser, the evaporator etc.
(2) When replacing the following parts at the same times
as the compressor, subtract the rated oil amount of
the each part from Y mL and discharge from the
new compressor.
Quantity
Evaporator: 60 mL
Condenser: 15 mL
Suction hose: 10 mL
Receiver: 10 mL
55-65
REFRIGERANT TEMPERATURE SWITCH SIMPLE
CHECK
When the A/C is off, check that there is continuity between
the refrigerant temperature switch terminals. If no, replace
the refrigerant temperature switch.
COMPRESSOR MAGNETIC CLUTCH OPERATION
CHECK 55200850181
Connect the battery (+) terminal to the compressor side
terminal, and earth the battery ( - ) terminal to the body of
the compressor. The condition is normal if the sound of the
magnetic clutch (click) can be heard.
MAGNETIC CLUTCH AND REFRIGERANT TEMPERATURE SWITCH 55200460216
1
3
2
4
6
7
<4G6>
<6A1, 4D6>
8
9
10
3
4
6
7
8
9
5
5
Magnetic clutch disassembly steps
1. Bolt <4G6>
2. Pulley <4G6>
"EA D Air gap adjustment
AA" "DA 3. Nut
"CA 4. Armature plate
5. Shims
"BA 6. Snap ring
7. Rotor
8. Snap ring
"AA 9. Clutch coil
Refrigerant temperature switch
removal
10. Refrigerant temperature switch
Refrigerant
temperature
switch
55-66
AA"NUT REMOVAL
"AACLUTCH COIL INSTALLATION
When installing the clutch coil to the A/C compressor body,
install so that the pin hole of the A/C compressor body and
the clutch coil projection are aligned.
"BASNAP RING INSTALLATION
Install the snap ring so that the tapered surface is at the
outer side.
"CAARMATURE PLATE INSTALLATION
Align the mating mark of the crankshaft spline and the mating
mark of the armature plate, and then fit them together.
"DANUT INSTALLATION
Use the special tool to hold the magnet clutch, and tighten
the nut in the same manner as removal.
"EAAIR GAP ADJUSTMENT
Check whether or not the air gap of the clutch is within the
standard value.
NOTE
If there is a deviation of the air gap from the standard value,
make the necessary adjustment by adjusting the number of
shims.
MB991367
MB991386
Clutch coil
projection
Compressor
body pin hole
Snap ring Rotor Clutch coil
Tapered part
Armatureplate
Serration notch
Matching mark
Crankshaft
Thickness gauge
- Photo Sensor
55-67
PHOTO SENSOR 55400310067
1
Removal step
AA" 1. Photo sensor
AA"PHOTO SENSOR REMOVAL
Use a flat-tipped screwdriver (width: 3 mm or less) to remove
the photo sensor.
If the blower speed drops when the receiver section of the
photo sensor is covered with your hand, then the photo sensor
is normal. If the speed does not drop, replace the photo
sensor.
Flat-tipped
screwdriver
Photo sensor
- Outside Air Temperature Sensor
55-68
OUTSIDE AIR TEMPERATURE SENSOR 55400340042
D Front Bumper Removal and Installation (Refer to
GROUP 51.)
Outside air temperature sensor
graph.
NOTE
Resistance kW
Temperature _C
20
15
10
0
5
- 10 0 40 20 30 10
- Heater Water Temperature Sensor
55-69
HEATER WATER TEMPERATURE SENSOR 55400450080
D Lower Cover and Side Cover Removal and
Installation (Refer to GROUP 52A - Instrument
Panel.)
D Engine-ECU, A/T-ECU and A/T Control Relay
Removal and Installation (Refer to GROUP 52B
- SRS-ECU.)
Caution: SRS
When removing and installing the engine-ECU,
A/T-ECU, A/T control relay and clip from vehicles
equipped with SRS, do not let them bump against
the SRS-ECU.
1
2
Removal steps
AA" "AA 1. Heater water temperature sensor clip
AA" "AA 2. Heater water temperature sensor
AA"HEATER WATER TEMPERATURE SENSOR CLIP
AND HEATER WATER TEMPERATURE SENSOR
REMOVAL
Pull out the heater water temperature sensor clip which is
at the bottom of the heater unit, and then remove the heater
water temperature sensor from the heater unit.
"AAHEATER WATER TEMPERATURE SENSOR AND
HEATER WATER TEMPERATURE SENSOR CLIP
INSTALLATION
Insert the heater water temperature sensor into its mounting
hole at the bottomof the heater unit, and then fix it by inserting
the heater water temperature sensor clip.
Foot distribution
duct
Heater unit
Heater water
temperature
sensor clip
Heater Water Temperature Sensor/
Other Maintenance Service Points
-
55-70
graph.
NOTE
OTHER MAINTENANCE SERVICE POINTS 55400400078
The following maintenance service points are the same as for the manual A/C.
Items Reference page
GENERAL INFORMATIONS Safety Precautions 55-3
ON-VEHICLE SERVICE Sight Glass Refrigerant Level Test 55-7
Magnetic Clutch Test 55-7
Receiver Drier Test 55-7
Dual Pressure Switch Check 55-8
Compressor Drive Belt Adjustment 55-8
Charging 55-9
Performance Test 55-14
Refrigerant Leak Repair 55-15
Compressor Noise 55-16
Power Relay Check 55-16
Idle-up Operation Check 55-18
HEATER UNIT, HEATER CORE, AND BLOWER UNIT 55-22
BLOWER FAN AND MOTOR 55-23
EVAPORATOR 55-25
AIR PURIFIER ASSEMBLY 55-27
REFRIGERANT LINE 55-28
CONDENSER AND CONDENSER FAN MOTOR 55-31
VENTILATORS 55-33
RJST612005 - 1218
Resistance kW
Temperature _C
20
15
10
0
5
- 10 0 40 20 30 10

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