Mitsibushi Galant 8G Workshop Manual

00109000812
General . . . . . . . . . . . . . . . . . . . . . . . .
00
Engine . . . . . . . . . . . . . . . . . . . . . . . . .
11
Engine Lubrication . . . . . . . . . . . . .
12
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
Engine Cooling . . . . . . . . . . . . . . . . .
14
Intake and Exhaust
............
15
FOREWORD
Engine Electrical . . . . . . . . . . . . . . .
16
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.
Engine and Emission Control . . . .
17
Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
21
Manual Transmission . . . . . . . . . . .
22
TECHNICAL INFORMATION MANUAL

PYDE9604
WORKSHOP MANUAL
ENGINE GROUP
PWEEjjjj
(Looseleaf edition)
ELECTRICAL WIRING
PHDE9608
BODY REPAIR MANUAL
PBDE9609
PARTS CATALOGUE
Sedan
B608S107Aj
Wagon
B608T507Aj
Automatic Transmission . . . . . . . .
23
Front Axle . . . . . . . . . . . . . . . . . . . . . .
26
Rear Axle . . . . . . . . . . . . . . . . . . . . . .
27
Wheel and Tyre . . . . . . . . . . . . . . . . .
31
Power Plant Mount . . . . . . . . . . . . . .
32
Front Suspension . . . . . . . . . . . . . . .
33
Rear Suspension . . . . . . . . . . . . . . .
34
Service Brakes . . . . . . . . . . . . . . . . .
35
Parking Brakes . . . . . . . . . . . . . . . . .
36
Steering . . . . . . . . . . . . . . . . . . . . . . . .
37
Body . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
Exterior . . . . . . . . . . . . . . . . . . . . . . . .
51
WORKSHOP MANUAL
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.
Interior and Supplemental

Restraint System (SRS) . . . . . . . . .
Chassis Electrical . . . . . . . . . . . . . .
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . . .
E Mitsubishi Motors Corporation
Dec. 1996
52
54
55
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
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Scope of Maintenance, Repair and Servicing

Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine Model Number . . . . . . . . . . . . . . . . . . . . . . . 17
Indication of Tightening Torque . . . . . . . . . . . . . . . . 2
Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MAJOR SPECIFICATIONS . . . . . . . . . . . . . . . . 18
Explanation of Manual Contents . . . . . . . . . . . . . . . 4
PRECAUTIONS BEFORE SERVICE . . . . . . . 20
HOW TO USE
TROUBLESHOOTING/INSPECTION SERVICE
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

AND SEAT BELT WITH
PRE-TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . 24
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
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
00-2
GENERAL - How to Use This Manual
HOW TO USE THIS MANUAL
00100010302
SCOPE OF MAINTENANCE, REPAIR

AND SERVICING EXPLANATIONS
DEFINITION OF TERMS
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.
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.
ON-VEHICLE SERVICE
REFERENCE VALUE
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.
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).
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.
STANDARD VALUE
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.
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.
00-3
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.
00-4
EXPLANATION OF MANUAL CONTENTS
Indicates procedures to be performed

before the work in that section is started,
and procedures to be performed after
the work in that section is finished.
Component Diagram
A diagram of the component parts is
provided near the front of each section
in order to give a reader a better understanding of the installed condition of
component parts.
Indicates (by symbols) where lubrication is necessary.
Maintenance and Servicing Procedures

The numbers provided within the diagram indicate the sequence for maintenance and servicing 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
(such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.), these are arranged together as major maintenance and service points and explained in detail.
AA"
"AA
: Indicates that there are essential points for removal or disassembly.

: Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives

Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts or on the page following the component parts page, and explained.
: Grease
(multipurpose grease unless there is a
brand or type specified)
: Sealant or adhesive
: Brake fluid or automatic transmission fluid
: Engine oil, gear oil or air conditioner compressor oil
: Adhesive tape or butyl rubber tape
00-5

Indicates the
group title.
Indicates the
section title.
Indicates the
group number.
Indicates the
page number.
Denotes
able part.
non-reus-
Denotes tightening torque.

For bolts and nuts which do not
have a tightening torque listed,
refer to the Standard Partstightening-torque Table.
Repair kit or set parts
are shown. (Only very
frequently used parts
are shown.)
Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described.
indicates that there is

a continuity between the terminals.
indicates terminals to
which battery voltage is applied.
The title of the page (following

the page on which the diagram
of component parts is presented) indicating the locations of
lubrication and sealing procedures.
00-6
GENERAL - How to Use Troubleshooting/Inspection Service Points
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
Read the diagnosis code

Diagnosis code
displayed.
Refer to the INSPECTION

CHART FOR TROUBLE
SYMPTOMS
(Refer
to
applicable group.)
Diagnosis code
displayed.
No diagnosis
code
After taking note of the

malfunction code, erase
the
diagnosis
code
memory
Recheck trouble symptom.
Read the diagnosis codes.

Diagnosis code
displayed.
Refer to the INSPECTION CHART FOR DIAGNOSIS

CODES (Refer to applicable group.)
No diagnosis
code
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.
00-7
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
MUT-II
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.
00-8

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.
Diagnosis connector
NOTE
That is because the valve relay is off and the warning
lamp remains illuminated if there is a fault in the ABS
system.
MB991529
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
On
Off
1.5 secs.
Pause
time 3
secs.
0.5 sec.
Tens
signal
Place
division
2 secs.
When no diagnosis code is output*

0.5 sec.
Units
signal
0.5 sec. <MPI, A/T>

0.25 sec. <ABS>
On
Off
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.
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.
1.
CHECKING PROCEDURE 4
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
2.
Indicates inspection carried out using the

MUT-II.
Indicates the operation and inspection procedures.
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.
In the above cases, the ECS switch circuit is defective or the indicator
circuit is defective.
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.
Comments on the diagnosis code or trouble

symptom above.
OK
NG
4. Indicates voltage and resistance to be measured at a particular

NG connector.
(Refer to Connector Measurement Service Points.)
OK
The connector position can be located in the wiring diagram in the
OK
electrical wiring manual by means of this symbol.
Measure at switch connector A-44
Indicates operation and inspection procedures, inspection terminals
D Disconnect the connector, and measure at the harness
and inspection conditions.
side.
Indicates the OK judgement conditions.
D Voltage between terminal 6 - earth and terminal 8 ECU switch component inspection (Refer to P.3-44.)
earth
OK: Approx. 5V
OK
NG
Check the following connector. A-44
OK
5.

Replace the ECS-ECU.
6.
7.
Repair
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.
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.
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 ECU and check
if the trouble symptom disappears.
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.
00-10

CONNECTOR MEASUREMENT SERVICE POINTS
Turn the ignition switch to OFF when connecting disconnecting
the connectors, and turn the ignition switch to ON when
measuring if there are no instructions to be contrary.
Harness connector
Extra-thin probe
Test bar
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.
Connector
Inspection harness
for connector pin
contact pressure
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.

Connector disconnected or improperly
connected
00-11
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 Low connection pressure due to rusted terminals or foreign
matter lodged in terminals
Defective connector contact
Harness wire breakage

at terminal section
Low contact pressure
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.
MB991219
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)
00-12

INSPECTION SERVICE POINTS FOR A BLOWN
FUSE
0W
Battery
Fuse
Load
switch
Connector
inspection
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.)
Load
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.
00-13
GENERAL - Vehicle Identification
VEHICLE IDENTIFICATION
00100540085
VEHICLE INFORMATION CODE PLATE

LOCATION
Vehicle information code plate is riveted on the toeboard
inside the engine compartment.
1
2
3
4
5
CODE PLATE DESCRIPTION

The plate shows model code, engine model, transmission
model, and body colour code.
No.
Item
Contents
MODEL
EA2A
SNHEQL6
EA2A: Vehicle model

SNHEQL6: Model series
ENGINE
4G63
Engine model
EXT
B60B
Exterior code
TRANS
AXLE
F5M42
Transmission code
COLOR
INT OPT
B60 41H 03V
B60: Body colour code

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
EA2A
SNJEQL6
Engine model
Transmission model
Fuel supply system
4G63-SOHC (1,997 mL)
F5M42 (2WD-5M/T)
MPI
SNHEQL6
SRHEQL6
EA5A
SNGEQL6
F4A42 (2WD-4A/T)
6A13-SOHC (2,497 mL)
SRGEQL6
F5M42 (2WD-5M/T)
MPI
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)
00-14
Model code
EA5A
SNGEQL6C
Engine model
Transmission model
Fuel supply system
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
EA5A
SNGEQR6
F4A42 (2WD-4A/T)
6A13-SOHC (2,497 mL)
SRGEQR6
EA6A
SNHFQR6
F5M42 (2WD-5M/T)
MPI
F4A42 (2WD-4A/T)
4D68-SOHC (1,998 mL)
F5M42 (2WD-5M/T)
Electronically
pump
Engine model
Transmission model
Fuel supply system
4G63-SOHC (1,997 mL)
F5M42 (2WD-5M/T)
MPI
<WAGON>
Model code
EA2W
LNJEQL6
LNHEQL6
LRHEQL6
EA5W
LNGEQL6
F4A42 (2WD-4A/T)
6A13-SOHC (2,497 mL)
LRGEQL6
F5M42 (2WD-5M/T)
MPI
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
EA5W
LNGEQL6C
F4A42 (2WD-4A/T)
6A13-SOHC (2,497 mL)
LRGEQL6C
F5M42 (2WD-5M/T)
MPI
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
EA5W
LNGEQR6
F4A42 (2WD-4A/T)
6A13-SOHC (2,497 mL)
LRGEQR6
EA6W
LNHFQR6
F5M42 (2WD-5M/T)
MPI
F4A42 (2WD-4A/T)
4D68-SOHC (1,998 mL)
F5M42 (2WD-5M/T)
Electronically
pump
00-15

MODEL CODE
1 2 3 4 5 6 7 8 9 10
00100040257
No.
Items
Contents
Development
EA: MITSUBISHI GALANT
Engine type
2: 2,000 mL petrol engine

5: 2,500 mL petrol engine
6: 2,000 mL diesel engine
Sort
A: Passenger car
W: Wagon
Body style
S: 4-door sedan
L: 4-door station wagon
Transmission type
N: 5-speed manual
transmission
R: 4-speed automatic
transmission
Trim level
J: GLX
H: GLS
G: V6-24
Specification engine
feature
E: MPI-SOHC
F: Turbocharger with
intercooler
Exhaust system
specification
Q: With catalytic converter

None: Without catalytic
converter
Steering wheel location
L: Left hand
R: Right hand
10
Destination
6: For Europe
C: Central Europe
00-16

CHASSIS NUMBER
00100560104
The chassis number is stamped on the toeboard inside the

engine compartment.
10
11
No.
Items
Fixed figure
Asia
Distribution channel
Japan channel
Destination
For Europe, right hand drive
For Europe, left hand drive
4-door sedan
4-door station wagon
5-speed manual transmission
4-speed automatic transmission
Body style
Transmission type
Contents
Development order
EA
GALANT
Engine
4G63: 1,997 mL petrol engine
6A13: 2,498 mL petrol engine
4D68: 1,998 mL diesel engine
Sort
Passenger car
Model year
1997
10
Plant
Okazaki Motor Vehicle Works
11
Serial number
00-17

ENGINE MODEL NUMBER
<4G63>
1. The engine model number is stamped at the cylinder

block as shown in the following.
Front of vehicle
<6A13>
00100570107
Front of vehicle
<4D68>
Front of vehicle
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
00-18
GENERAL - Major Specifications
MAJOR SPECIFICATIONS
00100080143
<Sedan>
9
5
2
Vehicle
weight kg
EA2AS
NJEQL6,
NJEQL6C
Items
Vehicle
dimensions
mm
EA2AS
NHEQL6,
NHEQL6C,
NHEQR6
EA2AS
RHEQL6,
RHEQL6C,
RHEQR6
EA5AS
NGEQL6,
NGEQL6C,
NGEQR6
EA5AS
RGEQL6,
RGEQL6C,
RGEQR6
EA6AS
NHFQL6,
NHFQL6C,
NHFQR6
Overall length
1 4,630
4,630
4,630
4,630
4,630
4,630
Overall width
2 1,740
1,740
1,740
1,740
1,740
1,740
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 clearance (unladen)
9 150
150
150
150
150
150
1,280
1,290
1,310
1,300
Kerb weight
1,260
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
Engine
Model No.
4G63
6A13
4D68
Total displacement
mL
1,997
2,498
1,998
Transmission
Model No.
F5M42
F4A42
F5M42
F4A42
F5M42
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
Electronically controlled fuel

injection
00-19
GENERAL - Major Specifications

<Wagon>
Vehicle
weight kg
EA2WL
NJEQL6,
NJEQL6C
Items
Vehicle
dimensions
mm
EA2WL
NHEQL6,
NHEQL6C,
NHEQR6
EA2WL
RHEQL6,
RHEQL6C,
RHEQR6
EA5WL
NGEQL6,
NGEQL6C,
NGEQR6
EA5WL
RGEQL6,
RGEQL6C,
RGEQR6
EA6WL
NHFQL6,
NHFQL6C,
NHFQR6
Overall length
1 4,680
4,680
4,680
4,680
4,680
4,680
Overall width
2 1,740
1,740
1,740
1,740
1,740
1,740
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 clearance (unladen)
9 150
150
150
150
150
150
1,310
1,330
1,340
1,360
1,350
Kerb weight
1,310
Max. gross vehicle

weight
1,830
1,860
Max. axle weight

rating-front
920
950
Max. axle weight

rating-rear
910
910
900
1,850
Seating capacity
Engine
Model No.
4G63
6A13
4D68
Total displacement
mL
1,997
2,498
1,998
Transmission
Model No.
F5M42
F4A42
F5M42
F4A42
F5M42
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
Electronically controlled fuel

injection
00-20
GENERAL - Precautions Before Service
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.
00-21
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 connecting or disconnecting the 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 oxygen sensor with a protective cover when applying
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
Approx.
40 cm
If high-pressure car-washing equipment or steam car-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.
00-22

MUT-II
MUT-II
sub-assembly
Refer to the MUT-II INSTRUCTION MANUAL for instructions

on handling the MUT-II.
ROM pack
Connect the MUT-II to the diagnosis connector as shown

in the illustration.
MUT-II
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 from the skin, leading to dryness,
irritation and dermatitits. 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 enclosed systems
for handling used engine oil and by degreasing components,
where practicable, before handling them.
00-23
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.
00-24
GENERAL -
Supplemental Restraint System (SRS)

and Seatbelts with Pre-tensioner
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEATBELTS

00100590073
WITH PRE-TENSIONER
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).
Side impact sensor

Side air bag module
Clock spring
Air bag module

(Front passengers side)
Air bag module

(Drivers side)
Diagnosis
connector
SRS-ECU
Seat belt with
pre-tensioner
SRS warning lamp
GENERAL -

SEAT BELT WITH PRE-TENSIONER

The seat belt with pre-tensioner has a pre-tensioner
operating mechanism and a G-sensor which detects
the force from an impact built into the seat belt
retractor.
The G-sensor is a mechanical-type sensor which
includes components such as a weight which moves
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.
00-25
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).
Plate (A)
Plate (A) (when safety
mechanism is disengaged)
Spring
Stopper

mechanism is engaged)
Retractor bracket
Stopper
Spring plate
Tab
Tab
G-sensor structure
Charge
Spike
Pin
Pin (when safety mechanism is
engaged)
Sensor
weight
Tab
00-26
GENERAL -

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
Insulating tape
SRS-ECU connector
<Vehicles without SRS side air bag>
<Vehicles with SRS side air bag>
Battery
NOTE
If any of these components are diagnosed as
faulty, they should only be replaced, in
accordance with the INDIVIDUAL COMPONENTS 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.
GENERAL -

00-27

SRS-ECU
Terminal No.
Destination of harness
Corrective action
1 to 4
5, 6
Dash wiring harness Clock spring Air bag module (Drivers

side)
Correct or replace the dash wiring

harness. Replace the clock spring.
7, 8
Dash wiring harness Air bag module (Front passengers side)
9, 10

harness.
11
Dash wiring harness Diagnosis connector
12
13
Dash wiring harness Junction block (fuse No.4)
14
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 wring

harness.

SRS-ECU
Terminal No.
Corrective action
1, 2
Correct or replace the dash wiring harness
Dash wiring harness Instrument panel wiring harness

SRS warning lamp
Correct or replace each wiring harness.
5, 6
Dash wiring harness Air bag module (Front

Passengers side)
Correct or replace the dash wiring harness.
7, 8
Dash wiring harness Clock spring Air bag module

(Drivers side)

Replace the clock spring.
10, 11
12
13
14, 15
16
17 to 20
21, 22
Dash wiring harness Side air bag module (LH)
23, 24
Dash wiring harness Side air bag module (RH)
00-28
GENERAL -

SRS-ECU
Terminal No.
Corrective action
25 to 33
34, 35, 36
Dash wiring harness Floor wiring harness Side

impact sensor (LH)
Correct or replace each wiring harness
37 to 39
40, 41, 42

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 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 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 INJURY 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
SUPPORT LOCATIONS FOR LIFTING AND JACKING
00-29
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.
Caution
Never support the rear floor crossmember.
AXLE STANDS
Notch
Notch
Rubber
Rubber
00-30
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
Notch
SINGLE-POST LIFT
Notch
00-31
SUPPORT POSITIONS AND SUPPORT METHOD

FOR AN H-BAR LIFT
H-bar lift
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.
Chassis-support position
(side sill)
Attachment
Section A-A
Side sill
H-bar lift
Attachment
H-bar lift
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.
00-32

PREPARATION OF ATTACHMENTS
1. Prepare the blocks (wooden) and nails as shown in the
figure.
mm
Block (A)
1,800
90
95
Block (B)
15
Block (C)
40
15
20
40
60
40
40
20
140
100
40
Block (C)
100
Block (C)
Nail
140
Block (B)
Finished attachment
Movable according
to vehicle width
Item
Dimensions mm
Quantity
Block (A)
90 95 1,800
Block (B)
60 100 95
Block (C)
140 40 95
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.
00-33
GENERAL - Standard Part/Tightening-Torque Table
STANDARD PART/TIGHTENING-TORQUE TABLE

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.
00100110033
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
11A-1
ENGINE
CONTENTS
ENGINE <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A

ENGINE <6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B
ENGINE <4D6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11C
11109000276
11A-2
ENGINE <4G6>
CONTENTS
11109000603
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 15
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAMSHAFT AND CAMSHAFT OIL SEAL . . . 16
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6
CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 20
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
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 22

TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE <4G6> - General Information/Service Specifications
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
Number of valve
Intake
Exhaust
Intake
Valve timing
Exhaust
11A-3
Opening
BTDC 11_
Closing
ABDC 53_
Opening
BBDC 63_
Closing
ATDC 21_
Fuel system
Electronically controlled multipoint fuel injection
Rocker arm
Roller type
Auto-lash adjuster
Equipped
SERVICE SPECIFICATIONS
Items
11100030489
Standard value
Limit
When checked
294 - 490
When a used belt is installed
343 - 441
When a new belt is installed
490 - 686
When checked
7.7 - 12.3
8.4 - 10.6
5.9 - 7.7
When checked
392 - 588
441 - 539
637 - 833
When checked
11.7 - 15.3
12.5 - 14.3
8.8 - 11.0
Basic ignition timing
5_ BTDC2_
Ignition timing
Approx. 10_BTDC
Tension N
Alternator drive
belt
tension
Power steering
oil pump and
A/C compressor
drive belt
tension
Deflection
(Reference
value) mm
Tension N
Deflection
mm
11A-4
ENGINE <4G6> - Service Specifications/Sealants/Special Tools
Items
Standard value
Limit
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
MD970389 or equivalent
Semi-drying sealant
Flywheel bolt
3M Stud Locking 4170 or equivalent
PART
SPECIAL TOOLS
Tool
11100060457
Number
Name
Use
MB991502
MUT-II sub assembly
D
D
Checking the idle speed

Erasing diagnosis code
MB990767
End yoke holder
D
D
Holding the camshaft sprocket

Holding the crankshaft sprocket
Crankshaft pulley
holder pin
D
D

Holding the crankshaft sprocket
MD998719
MD998754
or
ENGINE <4G6> - Special Tools

Tool
11A-5
Number
Name
Use
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
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
11A-6
ENGINE <4G6> - On-vehicle Service
Alternator pulley
Water pump
pulley
ON-VEHICLE SERVICE
11100090432
DRIVE BELT TENSION CHECK AND

ADJUSTMENT
Crankshaft pulley
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:
Adjusting bolt
Items
When a used
belt is installed
When a new
belt is installed
Tension N
343 - 441
490 - 686
Lock bolt
Deflection (Reference 8.4 - 10.6

value) mm
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.
11A-7

<Vehicles without A/C>
Oil pump pulley
98 N
A
Crankshaft
pulley
Tensioner pulley
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
<Vehicles with A/C>

Oil pump pulley
98 N
Crankshaft
pulley
Tensioner
pulley
A
B
A/C
compressor
pulley
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.
11A-8

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.
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 from cracks inside the cylinder,
these materials will become heated and will gush
out from the spark plug hole, which is dangerous.
11A-10

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
Compression gauge
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

Vacuum gage
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

LASH ADJUSTER CHECK
11A-11
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.
11A-12

(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 new lash 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.)
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 arm moves 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 from inside
the lash adjusters.
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.
Good
High
pressure
chamber
Drive pattern for air bleeding

Gradually open the
Close the throttle
throttle valve.
valve.
Approx.
3,000 r/min.
Idle speed
15
seconds
15
seconds
Once
(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.
ENGINE <4G6> - Crankshaft Pulley
CRANKSHAFT PULLEY
11A-15
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
2
3
25 Nm
Removal steps
1. Drive belt (Power steering and
A/C)
2. Drive belt (Alternator)

3. Crankshaft pulley
11A-16
ENGINE <4G6> - Camshaft and Camshaft Oil Seal
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
10 Nm
1
2
(f 3 1 mm)
4
3.4 Nm
14 Nm
Sealant:
MITSUBISHI GENUINE PART
22 Nm
5
28 - 34 Nm
Lip section
11
5
10
6
12
88 Nm
Cam section and

journal section
12
8
7
Engine oil
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
11A-17
REMOVAL SERVICE POINTS

AA" CAMSHAFT SPROCKET REMOVAL
MB990767
MD998719 or
MD998754
MD998443
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.
11A-18

"BA CAMSHAFT 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.
MD998713
"CA CAMSHAFT 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.
11A-19
ENGINE <4G6> - Oil Pan
OIL PAN
11200280207

D Engine Oil Draining and Supplying (Refer to GROUP
12 - On-vehicle Service.)
D Oil Level Gauge Removal and Installation
Front Exhaust Pipe Removal and Installation (Refer

to GROUP 15.)
5
f 4 1 mm
Groove
Bolt
hole
3
Sealant:
MITSUBISHI GENUINE
PART
7 Nm
9 Nm
Removal steps
1. Drain plug
"AA 2. Drain plug gasket
3. Bell housing cover
MD998727
MD998727
2
1
AA"
9 Nm
4. Oil level sensor

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

Oil pan side
Drain plug
gasket
"AA DRAIN PLUG GASKET INSTALLATION

Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
11A-20
ENGINE <4G6> - Crankshaft Oil Seal
CRANKSHAFT OIL SEAL
11200310135

127 - 137 Nm
<M/T>
11
12
127 - 137 Nm
<A/T>
6
2
8
4
10
1
<M/T>
<A/T>
Crankshaft
(Engine oil:
bolt washer surface)
Crankshaft
(Engine oil:
bolt washer
surface)
12
Lip section
Lip section
10
Sealant: 3M Stud locking 4170 or equivalent
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
Engine oil
AA"
AB"
AB"
AB"
AB"
AB"
"BA
"BA
"BA
"BA
"BA
"AA
Crankshaft rear oil seal removal

steps
D Oil pan (Refer to P.11A-19.)
D Transmission assembly
D Clutch cover and disc <M/T>
6. Crankshaft bushing
7. Plate <M/T>
8. Adapter plate
9. Flywheel <M/T>
10. Drive plate <A/T>
11. Adapter plate <M/T>
12. Crankshaft rear oil seal
ENGINE <4G6> - Crankshaft Oil Seal
11A-21
<M/T>
AA" TRANSMISSION ASSEMBLY REMOVAL

<M/T>:
Refer to GROUP 22.
Flywheel
Bolt
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.
MD998781
Crankshaft
rear oil seal
MD990938

Crankshaft
"AA CRANKSHAFT 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.
MD998776
"BA DRIVE 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.
"CA CRANKSHAFT 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.
11A-22
ENGINE <4G6> - Cylinder Head Gasket
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 On-vehicle Service.)
D Accelerator Cable Adjustment (Refer to GROUP
Delivery pipe
O-ring
1
9
10
10
Engine oil
5
2
8
6
4
3
11
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
11A-23

10 Nm
15
14
<Cold engine>
78 Nm 0 Nm 20 Nm + 90_ + 90_
16
3.4 Nm
27
12
(Engine oil)
26
17
19
28
13
29
22
49 Nm
18
20
21
24
24 Nm
44 Nm
25
34 Nm
23
31 Nm
12.
13.
14.
15.
16.
17.
Radiator upper hose connection

PCV hose
Ignition coil connector
Ignition coil assembly
Breather hose
Engine coolant temperature sensor
connector
18. Engine coolant temperature gauge
unit connector
19. Camshaft position sensor
20. Water hose connection
AA"
21.
22.
23.
24.
25.
26.
D
AB" "BA 27.
28.
"AA 29.
Heater hose connection

Thermostat case assembly
Water hose connection
Power steering oil pump and
bracket assembly
Front exhaust pipe connection
Rocker cover
Timing belt (Refer to P.11A-26.)
Cylinder head bolt
Cylinder head assembly
Cylinder head gasket
11A-24

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.
Intake side
Front of engine
10
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.
Exhaust side

"AA CYLINDER 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.
Burred side
Head bolt
washer
Cylinder
head
Head bolt
(Engine
oil)
"BA CYLINDER 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.
11A-25

Intake side
10
4. Tighten the bolts by the following procedure.
Front of engine
Step
Operation
Remarks
Tighten to 78 Nm.
Carry out in the order

shown in the illustration.
Fully loosen.
Carry out in the reverse

order of that shown in the
illustration.
Tighten to 20 Nm.

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.
Exhaust side
Step 4
90_
Painted mark
Step 5
90_
Painted mark
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.
"CA HIGH-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.
11A-26
ENGINE <4G6> - Timing Belt
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.)
1
10 - 12 Nm
48 Nm
4
24 Nm
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

Timing mark (Top
of cylinder head)
Timing mark
Camshaft sprocket
Timing mark
Timing mark
Timing mark
Oil pump
sprocket
Crankshaft
sprocket
11A-27

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.
Centre bolt
Caution
If the timing belt is to be re-used, use chalk to mark
(on its flat side) an arrow indicating the clockwise
direction.

98N - 196N
Movement
Push rod
Auto tensioner
"AA AUTO 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.
11A-28

4. Once the holes are aligned, insert the set pin.
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 mark (Top

of cylinder head)
Timing mark
Camshaft sprocket
Timing mark
Timing mark
Timing mark
Oil pump
sprocket
Crankshaft
sprocket
Plug
"BA TIMING BELT INSTALLATION

1. Align the timing marks on the camshaft sprocket,
crankshaft sprocket and oil pump sprocket.
60 mm or
more
8 mm
Screwdriver
Counterbalance
shaft
Cylinder
block
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.
Fixing bolt
Belt tension side
Pin hole
Belt tension side
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.

50 Nm
MD998767
Tension
direction
11A-29
"CA TIMING 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
Auto tensioner
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.
11A-30
ENGINE <4G6> - Timing Belt B
TIMING BELT B
11200460106
5
1
19 Nm
3
2
108 - 127 Nm
Removal steps
1. Timing belt (Refer to P.11A-26.)
AA" "CA 2. Crankshaft sprocket
"BA 3. Flange
Crankshaft
sprocket
MD998719 or MD998754
4. Timing belt B tensioner

AB" "AA 5. Timing belt B

AA" CRANKSHAFT SPROCKET REMOVAL
MB990767
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).

Counterbalance shaft sprocket
Belt tension side
Timing marks
Timing
marks
Crankshaft
sprocket B
11A-31

"AA TIMING 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.
Centre of
tensioner
pulley
Centre of installation
bolt
(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.
Shaft
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
Centre of
tensioner
pulley
Centre of
installation
bolt
"BA FLANGE INSTALLATION

When installing, make sure the direction is correct. See figure.
Crankshaft
Crankshaft
sprocket B
Crankshaft
sprocket
Flange
11A-32
Crankshaft
sprocket

MD998719 or MD998754
MB990767
"CA CRANKSHAFT SPROCKET INSTALLATION

NOTE
Apply the minimum amount of engine oil to the bearing surface
and thread of the crankshaft bolt.
11A-33
ENGINE <4G6> - Engine Assembly
ENGINE ASSEMBLY
11200090015

D Engine Coolant Draining
D Thermostat Case Assembly Removal (Refer to
D Front Exhaust Pipe Removal (Refer to GROUP 15.)
D Hood Removal (Refer to GROUP 42.)
D Radiator Assembly Removal (Refer to GROUP 14.)
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
Delivery pipe
10
10
O-ring
7
5
Engine oil
8
2
12
6
4
3
11
Removal steps
3. Brake booster vacuum hose connection
6. Idle speed control connector
8. Purge control solenoid valve connector
"DA 10. High-pressure fuel hose connection
11A-34
20
15
26
23
22
49 Nm
21
19
16
17
18
14
13
57 Nm*
24
25
25
98 Nm
AA"
AB"

A/C)
15. Power steering oil pump and
bracket assembly
16. A/C compressor
17. Alternator connector
18. Oil pressure switch connector
19. Heater hose connection
unit connector
21. Engine coolant temperature sensor
connector
22.
23.
AC"
D
AD" "CA 24.
"BA 25.
AE" "AA 26.
Camshaft position sensor connector

Detonation sensor connector
Transmission assembly
Engine mount bracket
Engine mount stopper
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.
11A-35

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.
<M/T>
Flywheel
Bolt
MZ203827
MB991453
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.
11A-36

"AA ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, checking that the cables, hoses,
and harness connectors are not clamped.
Engine side
Dynamic damper
Arrow
"BA ENGINE MOUNT STOPPER INSTALLATION

Clamp the engine mount stopper so that the arrow points
in the direction as shown in the diagram.
Engine
mount
stopper
"CA ENGINE 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.
"DA HIGH-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.
11B-1
ENGINE <6A1>
CONTENTS
11109000610
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 30
11B-2
ENGINE <6A1> - General Information/Service Specifications
GENERAL INFORMATION
11100010452
Items
6A13
2,498
Bore Stroke mm
81.0 80.8
Compression ratio
9.5
Combustion chamber
Pentroof type
SOHC
Number of valve
Intake
12
Exhaust
12
Intake
Valve timing
Exhaust
Opening
BTDC 15_
Closing
ABDC 53_
Opening
BBDC 53_
Closing
ATDC 15_
Fuel system
Electronically controlled multipoint fuel injection
Rocker arm
Roller type
Auto-lash adjuster
Equipped
Items
11100030496
Standard value
Limit
When checked
294 - 490
343 - 441
490 - 686
When checked
9.0 - 13.0
10.0 - 12.0
6.8 - 8.0
When checked
490 - 686
539 - 637
784 - 980
When checked
11.0 - 15.0
12.0 - 14.0
8.0 - 12.0
5_ BTDC3_
Ignition timing
Approx. 7 BTDC
Tension N
Alternator drive
belt
tension
Power steering
oil pump and
A/C compressor
drive belt
tension
Deflection
(Reference
value) mm
Tension N
Deflection
(Reference
value) mm
ENGINE <6A1> - Service Specifications/Sealants/Special Tools

Items
Standard value
Limit
Idle speed r/min
650 100
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
96.4
Auto-tensioner push rod movement mm
Within 1
Timing belt tension torque Nm
Auto-tensioner rod protrusion amount mm
3.8 - 4.5
SEALANTS
11100050379
Items
Specified sealants
Oil pan
MITSUBISHI
GENUINE
Flywheel bolt or drive plate bolt
Remarks
PART
Semi-drying sealant
-
SPECIAL TOOLS
Tool
11B-3
11100060464
Number
Name
Use
MB991502
MUT-II sub
assembly
Engine idle speed check

MB990767
End yoke holder
D
D
MD998719
Crankshaft pulley
holder pin
MD998715
Crankshaft pulley
holder pin

Holding the crankshaft pulley
11B-4
Tool
ENGINE <6A1> - Special Tools

Number
Name
Use
MD998443
Auto-lash adjuster
holder
Supporting of auto-lash adjuster
MD998713
Camshaft oil seal

installer
Press-in of the camshaft oil seal
MD998776
Crankshaft rear oil

seal installer
MB990938
Handle
MD998767
Tension pulley
socket wrench
MD998717
Crankshaft front
oil seal installer
Press-in of the crankshaft front oil seal
MD998727
Oil pan remover
Removal of oil pan
MD998781
Flywheel stopper
Securing the flywheel <M/T> or drive plate

<A/T>
GENERAL
SERVICE
TOOL
MZ203827
Engine lifter

11B-5
ENGINE <6A1> - Special Tools/On-vehicle Service

Tool
Alternator pulley
Number
Name
Use
MB991453
Engine hanger
assembly

Tension pulley
ON-VEHICLE SERVICE
11100090425

ADJUSTMENT
Crankshaft pulley
Standard value:
Adjusting bolt
Fixing nut
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 10.0 - 12.0

value) mm
6.8 - 8.0
3. Tighten the fixing nut.

Caution
Turn the crankshaft one full rotation or more clockwise
before this check.
11B-6
ENGINE <6A1> - On-vehicle Service

Power steering
oil pump pulley
A/C compressor
pulley
Crankshaft
pulley
POWER STEERING OIL PUMP AND AIR CONDITIONER

ADJUSTMENT
11100130134
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.
11B-7
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.
IDLE SPEED CHECK
11100350059

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.
11B-8

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.
11100260482
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.
Crank angle
sensor connector
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 from cracks inside the cylinder,
out from the spark plug hole, which is dangerous.

Compression gauge
11B-9
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

Vacuum gauge
Fuel pressure regulator
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
11B-10

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.
11B-11
(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 new lash 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.)
11B-12
Timing belt side

<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 arm moves 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 from inside
the lash adjusters.
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.
Good
High
pressure
chamber
Drive pattern for air bleeding

Gradually open the
Close the throttle
throttle valve.
valve.
Approx.
3,000 r/min.
Idle speed
15
seconds
15
seconds
Once
(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.
11B-14
ENGINE <6A1> - Crankshaft Pulley
CRANKSHAFT PULLEY
11200160310

D Drive Belt Tension Adjustment (Refer to P.11B-5.)
(Engine oil)
3
1
4
177 - 186 Nm
2
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
MD998719
MB990767

"AA CRANKSHAFT BOLT INSTALLATION
When installing the crankshaft bolt, apply the minimum amount
of engine oil to the bearing surface and thread of the bolt.
11B-15
ENGINE <6A1> - Camshaft and Camshaft Oil Seal
11200220124

<Front bank>
D Engine Coolant Draining and Refilling (Refer to
GROUP 14 - On-vehicle Service.)
D Air Intake Hose Assembly Removal and Installation
D
D
Timing Belt Removal and Installation (Refer to

P.11B-26.)
Drive Belt Tension Adjustment (Refer to P.11B-5.)
Apply engine oil to all

sliding parts when
installing.
6
3
4
1
3.4 Nm
5
2
7
10
22 Nm
(Engine oil)
28 - 34 Nm
12
24 Nm
5
11
13
8
88 Nm
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

"BA 9. Camshaft oil seal
10. Engine hanger
11. Thrust case
12. Rocker arm and shaft assembly
AC"
"AA 13. Camshaft
11B-16
<Rear bank>
D Air Intake Plenum Removal and Installation
D Timing Belt Removal and Installation
(Refer to P.11B-26.)
D
D
Distributor Removal and Installation

Apply engine oil to all

sliding parts when
installing.
6
1
7
3.4 Nm
2
28 - 34 Nm
12
8
9
13
88 Nm
Removal steps
1. Breather hose connection
6. Spark plug cable
7. Rocker cover
AB" "CA
"BA
AC"
"AA
8.
9.
12.
13.
Camshaft sprocket
Camshaft oil seal
Rocker arm and shaft assembly
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.
11B-17
AB" CAMSHAFT SPROCKET REMOVAL

MB990767
MD998715
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.
MD998443
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
assembly.
<Front bank side>
<Rear bank side>
and shaft

"AA CAMSHAFT INSTALLATION
Set the camshaft dowel pins so that they are in the position
Approx.
35_
Approx.
35_
Dowel
pin
Dowel
pin
<Front bank side>
<Rear bank side>
MD998713 MD991559
MD998713
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.
"BA CAMSHAFT 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.
11B-18

"CA CAMSHAFT SPROCKET INSTALLATION
"DA RADIATOR 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.
11B-19
ENGINE <6A1> - Oil Pan
OIL PAN
11200280214

D Engine Oil Draining and Supplying (Refer to GROUP
D Oil Level Gauge Removal and Installation
D Front Exhaust Pipe Removal and Installation (Refer
to GROUP 15.)
D
D
Under Cover Removal and Installation

Starter Motor Removal and Installation
Groove
Bolt
hole
Sealant:
7 Nm
39 Nm
2
7 Nm
3
44 Nm
44 Nm
7 Nm
Removal steps
1. Drain plug
AA"
3. Lower oil pan
AA"
4. Cover
5. Upper oil pan
7 Nm
11B-20
MD998727
ENGINE <6A1> - Oil Pan

MD998727

AA" LOWER OIL PAN/UPPER OIL PAN REMOVAL
Caution
flange.

Oil pan side
Drain plug
gasket

11B-21
ENGINE <6A1> - Crankshaft Oil Seal
CRANKSHAFT OIL SEAL
11200310142

<M/T>
Crankshaft
(Engine oil:
bolt washer surface)
5
4
3
1
<A/T>
Crankshaft
(Engine oil:
bolt washer
surface)
10
7
Sealant: 3M Stud Locking

4170 or equivalent
<M/T>
11
Lip section
<A/T>
11
93 - 103 Nm
10
Lip section
7
Engine oil

steps
D Timing belt (Refer to P.11B-26.)
2. Crankshaft sensing blade
3. Crankshaft spacer
4. Key
AA"
AB"
AB"
AB"
AB"
AB"
"BA
"BA
"BA
"BA
"BA
"AA

steps
6. Plate <M/T>
7. Adapter plate
8. Flywheel <M/T>
11B-22

<M/T>

<M/T>:
Refer to GROUP 22.
Flywheel
Bolt
Caution
<A/T>:
Refer to GROUP 23.
AB" PLATE <M/T>/ADAPTER PLATE/FLYWHEEL
<M/T>/DRIVE PLATE <A/T> REMOVAL
MD998781
Crankshaft
rear oil seal
MD990938

Crankshaft

MD998776

PLATE/PLATE <M/T> INSTALLATION
plate bolts.
Crankshaft
MD998717
MD998717
Oil seal
11B-23

2. Tap the oil seal unit it is flush with the oil seal case.
11B-24
ENGINE <6A1> - Cylinder Head Gasket
11200400559

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 GROUP 15 - Air Intake Plenum.)
D Engine Cover Removal and Installation
D Timing Belt Removal and Installation (Refer to
P.11B-26.)
D
D
D
D
Fuel Discharge Prevention (Refer to GROUP 13A

Front Exhaust Pipe Removal and Installation (Refer
to GROUP 15.)
Thermostat Case Assembly Removal and Installation
(Refer to GROUP 14 - Water Hoses and Pipes.)
Water Inlet Pipe Removal and Installation (Refer to
GROUP 14 - Water Hoses and Pipes.)
6
3.4 Nm
3.4 Nm
(Engine oil)
20 Nm + 120_ + 120_
20 Nm + 120_ + 120_
10
(Engine oil)
11
10 - 12 Nm
11
35 Nm
Removal steps
5. Spark plug cable
6. Rocker cover
7.
8.
AA" "BA 9.
10.
"AA 11.
Idler pulley
Timing belt rear centre cover
Cylinder head bolt
Cylinder head assembly
Cylinder head gasket
ENGINE <6A1> - Cylinder Head Gasket

<Front bank side>
Exhaust side
<Rear bank side> Intake side
11B-25
Front of
engine
AA" CYLINDER HEAD BOLT REMOVAL

assembly.
Exhaust side
Identification mark

surface.
2. Install the gasket to the cylinder block with the identification
mark facing upwards.
Burred side
Head bolt
(Engine
oil)
Head bolt
washer
Limit (A): 96.4 mm

Cylinder
head
<Front bank side>

Exhaust side
<Rear bank side> Intake side
Exhaust side
Front of
engine
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).
11B-26
ENGINE <6A1> - Timing Belt
TIMING BELT
11200430480

D Under Cover Removal and Installation
D Crankshaft Pulley Removal and Installation
D Alternator Removal and Installation
3 Nm
1
44 Nm
9
12 Nm
10
3
7
10 - 12 Nm
6
4
24 Nm
10 - 12 Nm
35 Nm
24 Nm
22 Nm
11
2
14
13
10 - 12 Nm
12
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
11B-27

AA" TIMING BELT REMOVAL
1. Align each of the timing marks.
Tensioner
pulley
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.
Timing belt

98 N - 196 N
Movement
Push rod
Auto tensioner
"AA AUTO 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.
Set pin
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.
11B-28
Rocker cover

Rocker cover
Camshaft
sprocket
Camshaft
sprocket
Timing
marks
"BA TIMING 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.
Crankshaft
sprocket
Tension side A
Rear
bank
side
camshaft
sprocket
Tension side B
Tension side C
Tension side D
Pin holes
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.
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.

MD998767
Tension direction
Tensioner
pulley
48 Nm
11B-29
"CA TIMING 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.
A
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.
11B-30
ENGINE <6A1> - Engine Assembly
ENGINE ASSEMBLY
11200100558

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
18 Nm
3
17
5 6
18
9
10
23
19
24
11
16
20
21
22
9
12
O-ring
19
14
Engine oil
13
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
15
13. Power steering oil pressure switch

connector
14. Oil pressure harness connector
15. Thermo switch connector
16. Crank angle sensor connector
"DA 19. High-pressure fuel hose connection
20. Earth cable connection
21. Control harness connector
22. Front harness connector
connector
11B-31

30
12 Nm
28
27
27
12 Nm
27
39 Nm
25
26
34
29
35 Nm
31
67 Nm
32
33
57 Nm
33
98 - 118 Nm*
AA"
AB"
AC"

A/C)
27. Clamp bolt (Power steering hose
and pipe)
28. Power steering oil pump assembly
29. A/C compressor
AD" "CA 32. Engine mount bracket

"BA 33. Engine mount stopper
AE" "AA 34. 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.
11B-32

ASSEMBLY REMOVAL
NOTE
attached.
NOTE

<M/T>:
Refer to GROUP 22.
<M/T>
Flywheel
Bolt
MZ203827
MB991453
Caution
<A/T>:
Refer to GROUP 23.
tool.
mount bracket.
compartment.
11B-33

Engine side
Dynamic damper

Arrow
Engine
mount
stopper

"DA HIGH-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.
NOTES
11C-1
ENGINE <4D6>
CONTENTS
11109000627
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 33
11C-2
ENGINE <4D6> - General Information/Service Specifications
GENERAL INFORMATION
11100010476
Items
4D68
1,998
Bore Stroke mm
82.7 93.0
Compression ratio
22.4
Combustion chamber
Vortex chamber type
SOHC
Number of valve
Valve timing
Intake
Exhaust
Intake
Exhaust
Opening
BTDC 20_
Closing
ABDC 48_
Opening
BBDC 54_
Closing
ATDC 22_
Fuel system
Distribution type injection pump
Rocker arm
Roller type
Adjusting screw
Elephant foot type
11100030502
Items
Alternator
drive belt
tension
Tension N
Deflection
(Reference
value) mm
Standard value
Limit
When checked
343 - 490
392 - 490
490 - 588
Centre of belt
between alternator
pulley and water
pump pulley
When checked
8.0 - 10.0
When a used belt is

installed
8.0 - 9.4
When a new belt is

installed
7.0 - 8.0
When checked
7.9 - 9.9
When a used belt is

installed
7.9 - 9.2
When a new belt is

installed
6.8 - 7.9
Centre of belt
between crankshaft
pulley and alternator
pulley
11C-3
ENGINE <4D6> - Service Specifications/Sealants

Items
Standard value
Limit
When checked
294 - 490
343 - 441
490 - 686
When checked
12.6 - 16.3
13.4 - 15.3
10.0 - 12.6
When checked
392 - 588
441 - 539
637 - 833
When checked
9.2 - 12.0
9.8 - 11.2
7.0 - 8.6
Intake valve
0.35
Exhaust valve
0.45
Injection timing (Dial gauge display value mm)
1 0.03
(10_ATDC)
Idle speed r/min
800 30
Compression pressure kPa
3,500
Min. 2,560
Compression pressure difference of all cylinder

(at engine speed of 280 r/min) kPa
Max. 300
99.4
Timing belt deflection mm
4-5
Timing belt B deflection mm
5-7
Power
steering oil
pump drive
belt tension
Tension N
Deflection
mm
A/C compressor
drive belt
tension
Tension N
Deflection
mm
Valve clearance (at hot)

mm
SEALANTS
11100050362
Items
Specified sealants
Remarks
Oil pan

Semi-drying sealant
Semi-circular packing and rocker

cover seal, and cylinder head seal
Flywheel bolt or adapter plate bolt
11C-4
ENGINE <4D6> - Special Tools
SPECIAL TOOLS
Tool
11100060471
Number
Name
Use
MB991502
MUT-II sub
assembly
Idle speed check
MB998720
Prestroke
measuring adapter
Adjustment of the injection timing
MB990767
End yoke holder
MD998719
Crankshaft pulley
holder pin
MD998754
Crankshaft pulley
holder pin
MD998364
Camshaft oil seal

installer
Installing the camshaft oil seal
MD998727
Oil pan remover
Removal of oil pan
MD998776
Crankshaft rear oil

seal installer
MB990938
Handle
ENGINE <4D6> - Special Tools

Tool
11C-5
Number
Name
Use
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
Engine lifter

MB991453
Engine hanger assembly
11C-6
ENGINE <4D6> - On-vehicle Service
ON-VEHICLE SERVICE
11100090449

ADJUSTMENT
Alternator
pulley
Water pump
pulley

Standard value:
Tension N
B
Crankshaft
pulley
Adjusting bolt
Lock
bolt
343 - 490
Deflection (Reference
value) mm
Portion A
8.0 - 10.0
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
Portion A
8.0 - 9.4
7.0 - 8.0
Portion B
7.9 - 9.2
6.8 - 7.9
Pivot bolt
Deflection
(Reference
value) mm
4. Tighten the lock bolt.

5. Tighten the nut of the alternator pivot bolt.
6. Tighten the adjusting bolt.
Caution
11C-7

Power steering
oil pump pulley
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:
Water pump
pulley
Oil pump
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
11C-8

A
A/C compressor
pulley

ADJUSTMENT
11100100203
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:
Crankshaft
pulley
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

ADJUSTMENT
11100150130
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.
Camshaft
sprocket
Timing
marks
Timing marks
Crankshaft
pulley
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.
11C-9
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
Timing
belt
side
Standard value:
A
B
Adjusting
screw
Pad
Flat-tipped
screwdriver
Pad
Thickness
gauge
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.
Thickness gauge
Thickness
gauge
(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.
11C-10

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

ADJUSTMENT
11100180054
1. Remove all of the glow plugs.

Camshaft
sprocket
3. Align the timing marks of the camshaft sprocket and set

the No.1 cylinder to the top dead centre position.
Timing
marks
Timing marks
Crankshaft
pulley
4. Remove the timing check plug at the rear of the injection

pump.
Timing check plug
Dial gauge
MD998720
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.
Set to 0
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.
Approx.
30_
Timing mark
Set to 10_
ATDC
11C-11
1 0.03 mm
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.)
Bolts
Nuts
When the value is
1 0.03 mm or more
When the value

is 1 0.03 mm
or less
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.
11C-12

IDLE SPEED CHECK
11100350073
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.
11100260505
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.
Fuel cut solenoid
valve connector
4. Cover the glow plug hole with a shop towel etc., and
Caution
1. Keep away from the glow plug hole when cranking.
etc,. that has come from cracks inside the cylinder,
out from glow plug hole, which is dangerous.
Compression gauge
11C-13
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)
Adapter
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.
Timing marks
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.
11C-14

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).
Timing mark
1/2 the
width of
a tooth
Timing mark
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.
Timing mark
Width
of 2-1/2
teeth
1/2 the
width of
a tooth
Timing mark
Deflection
Camshaft
sprocket
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
Injection
pump
sprocket
11. Install the timing belt upper cover.

ENGINE <4D6> - Crankshaft Pulley
CRANKSHAFT PULLEY
11C-15
11200160327

D Drive Belt Tension Adjustment (Refer to P.11C-6.)
4
3
25 Nm
Removal steps
1. Drive belt (Power steering)
2. Drive belt (A/C)

11C-16
ENGINE <4D6> - Camshaft and Camshaft Oil Seal
11200190425

D Timing Belt Removal and Installation
(Refer to P.11C-26.)
D Air Pipe A Removal and Installation
D Vacuum Pump Removal and Installation
6 Nm
Lip section
19 - 21 Nm
27 - 31 Nm
27 - 31 Nm
19 - 21 Nm
7
Cam section
and journal
section
7
19 - 21 Nm
5
4
Engine oil
88 Nm
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
MB990767
AA" CAMSHAFT SPROCKET REMOVAL
MD998719 or
MD998754
Camshaft sproket
side
"AA CAMSHAFT 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.
Cap No.
"BA ROCKER 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.)
Indent
Bearing cap
Oil seal
Camshaft
"CA CAMSHAFT 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
MD998364
5.5 mm
"DA CAMSHAFT SPROCKET INSTALLATION

11C-18
ENGINE <4D6> - Oil Pan
OIL PAN
11200280221

D Front Exhaust Pipe Removal and Installation
D
D
Engine Oil Level Gauge Removal and Insertion

Engine Oil Draining and Refilling
(Refer to GROUP 12 - On-vehicle Service.)
BOLT IDENTIFICATION
f4 1 mm
Groove
Bolt
hole
B
B
A: 6 8 mm
B: 6 10 mm
Sealant:
29 - 34 Nm
9 Nm
4
3
2
7
39 Nm
Removal steps
1. Drain plug
3. Oil filter
4. Engine oil cooler pipe connection
Washer assembled bolt

9 Nm
Flange bolt
10 Nm
7 Nm
AA"
5. Bell housing cover

6. Oil level sensor
7. Oil pan
ENGINE <4D6> - Oil Pan

MD998727
MD998727
11C-19

AA" OIL PAN REMOVAL
Caution
flange.

Oil pan side
Drain plug
gasket

11C-20
ENGINE <4D6> - Crankshaft Oil Seal
CRANKSHAFT OIL SEAL
11200310159

<M/T>
9
127 - 137 Nm
10
6
11
7
<A/T>
5
4
127 - 137 Nm
2
1
6
8
10
(Engine oil)
108 - 127 Nm
Crankshaft
(Engine oil:
bolt washer
surface)
11
Lip section
Crankshaft
(Engine oil:
bolt washer
surface)
Lip section
Engine oil

steps
D Timing belt (Refer to P.11C-26.)
2. Flange
3. Crankshaft sprocket B
4. Key
Sealant: 3M Stud Locking 4170 or equivalent
AA"
AB"
AB"
AB"
AB"
"BA
"BA
"BA
"BA
"AA

steps
6. Adapter plate
7. Flywheel <M/T>
10. Crankshaft bushing
11C-21
<M/T>

<M/T>:
Refer to GROUP 22.
Flywheel
Bolt
Caution
<A/T>:
Refer to GROUP 23.
AB" ADAPTER PLATE/FLYWHEEL <M/T>/DRIVE
PLATE <A/T> REMOVAL
MD998781
Crankshaft
rear oil seal
MD990938

Crankshaft

MD998776

PLATE INSTALLATION
plate bolts.
11C-22

Crankshaft
MD998382
Oil seal
MD998383
Front
lower
case

2. Tap the oil seal unit it is flush with the oil seal case.
11C-23
ENGINE <4D6> - Cylinder Head Gasket
11200400566

D Engine Coolant Draining and Refilling
(Refer to GROUP 15 - Intercooler.)
D Vacuum Pump Removal and Installation
D
D
Timing Belt Removal and Installation

Thermostat Case Assembly Removal and Installation
(Refer to GROUP 14 - Water Hoses and Pipes.)
6 Nm
2
16
27 - 31 Nm
O-ring
27 - 31 Nm
19 - 21 Nm 27 - 31 Nm
Engine oil
7
12 - 15 Nm
13 Nm
16
9
18
6
10
88 Nm 0 Nm 39 Nm + 90_ + 90_
11
12
19
8
15
44 Nm
9 Nm
14
20
29 Nm
17
13
24 Nm
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
10 - 12 Nm

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
19. Cylinder head assembly
"AA 20. Cylinder head gasket
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.
Intake side
Front of engine
10
AB" CYLINDER HEAD BOLT REMOVAL

assembly.
Exhaust side

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
Identification mark
Identification holes
Burred side
Head bolt
washer
Cylinder
head
Head bolt
(Engine
oil)

Limit (A): 119.7 mm
11C-25
ENGINE <4D6> - Cylinder Head Gasket

Intake side
10
4. Tighten the bolts by the following procedure.
Front of engine
Step
Operation
Remarks
Tighten to 88 Nm.

Fully loosen.
Carry out in the reverse

order of that shown in the
illustration.
Tighten to 39 Nm.


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.
Exhaust side
Step 4
Step 5
90_
90_
Painted mark
Indent
Painted mark
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.
"CA ROCKER 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.)
Bearing cap
Fuel injection pipe

Nut
Nozzle holder
"DA FUEL 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.
11C-26
ENGINE <4D6> - Timing Belt
TIMING BELT
11200430497

10 - 12 Nm
7
9 Nm
10 - 12 Nm
1
19 Nm
25 Nm
10 - 12 Nm
4
10 - 12 Nm
2
5
9 Nm
23 Nm
AA"
10 - 12 Nm
Removal steps
1. Water pump pulley
2. A/C tension pulley assembly
3. Timing belt front upper cover
4. Timing belt front centre cover
5.
6.
"BA D
AB" "AA 7.
Timing belt front lower cover

Injection pump bracket stay
Timing belt
11C-27

AA" TIMING BELT FRONT UPPER COVER
INSTALLATION
Attach protective tape to the engine mount bracket, and then
remove the timing belt front upper cover.
Protective tape
Timing marks
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.
Thread diameter
length pitch (mm)
Move to the bottom

of the slot.
11C-28

Timing marks
Injection
pump
sprocket
Camshaft sprocket
Timing mark
Crankshaft
sprocket
"AA TIMING 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.
Timing mark
Oil pump
sprocket
Move to the
bottom of the slot.
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.
"BA TIMING 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.
1/2 tooth
Timing mark
Timing mark
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.
Timing mark
2-1/2 teeth
3. In addition, turn the crankshaft anti-clockwise by a distance

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 mark
11C-29
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.
Camshaft
sprocket
Injection
pump
sprocket
11C-30
ENGINE <4D6> - Timing Belt B
TIMING BELT B
11200460113


1
48 Nm
4
19 Nm
108 - 127 Nm
3
2
(Engine oil)
Removal steps
1. Idler pulley
AA" "BA 2. Crankshaft sprocket
3. Flange
Crankshaft
sprocket
4. Timing belt tensioner

AB" "AA 5. Timing belt B

MB991385
MB991367
AA" CRANKSHAFT SPROCKET REMOVAL
11C-31
AB" TIMING BELT B REMOVAL

Caution
If the timing belt B is to be re-used, use chalk to
mark (on its flat side) an arrow indicating the clockwise
direction.
Counter balance shaft sprocket

Belt tension side
Crankshaft
sprocket B
Timing mark
Centre of
tensioner
pulley

"AA TIMING 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.
Centre of
installation bolt
(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.
Shaft
Centre
of pulley
Centre of installation bolt
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.
11C-32

"BA CRANKSHAFT 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
11C-33
ENGINE <4D6> - Engine Assembly
ENGINE ASSEMBLY
11200100565

D Air Cleaner Assembly Removal
D Radiator Assembly Removal (Refer to GROUP 14.)
D Front Exhaust Pipe Installation
D Radiator Assembly Installation
D Accelerator Cable Adjustment
D Air Cleaner Assembly Installation
1
7
3
8
12
10
13
11
4
5
17
14
6
15
16
Removal steps
2. Vacuum air temperature sensor connector
5. Oil pressure switch connector
6. Engine oil level sensor connector
7. Glow plug connector
connector
unit connector
10.
11.
12.
13.
14.
Pump revolution sensor connector

Timing control valve connector
Solenoid-type spill valve connector
Fuel cut solenoid valve connector
Injection rate correction resistor connector
15. Injection timing correction resistor connector
17. Fuel temperature sensor connector
11C-34
18
25
19
29
22 Nm
21
20
39 Nm
29 - 34 Nm
22
23
24
12 Nm
26
57 Nm*
27
28
28
98 Nm
AA"
AB"
18.
19.
20.
21.
22.
23.
24.
25.
26.

Drive belt (Power steering)
Drive belt (A/C)
Oil pump brace
Power steering oil pump and bracket
assembly
A/C compressor
Engine oil cooler pipe connection
Fuel hose connection
Clamp bolt (Power steering hose and
pipe)
AC"
AD" "CA
"BA
AE" "AA
D
27.
28.
29.
Transmission assembly
Engine mount stopper
Engine assembly
Caution
provisionally tightened, and then fully tightened
after placing the vehicle horizontally and loading
the full weight of the engine on the vehicle
body.
11C-35

ASSEMBLY REMOVAL
NOTE
attached.
NOTE

<M/T>:
Refer to GROUP 22.
<M/T>
Flywheel
Bolt
MZ203827
MB991453
Caution
<A/T>:
Refer to GROUP 23.
tool.
mount bracket.
compartment.
11C-36

Engine side
Dynamic damper

Arrow
Engine
mount
stopper

12-1
ENGINE
LUBRICATION
CONTENTS
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12109000129
Engine Oil Replacement . . . . . . . . . . . . . . . . . . . . . . 3

Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil Level Warning System Check . . . . . . . . . . . . . . 5
ENGINE OIL COOLER
<6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
<4D6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
12-2
ENGINE LUBRICATION - General Information
GENERAL INFORMATION
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
12100010114
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 enclosed systems for handling used engine
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
D
D
D
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.
Obtain First Aid treatment immediately for open
cuts and wounds.
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.
Do not use petrol, kerosine, diesel fuel, gas
oil, thinners or solvents for cleaning skin.
Use barrier creams, applying them before each
work period, to help the removal of oil from
the skin after work.
If skin disorders develop, obtain medical advice
without delay.
ENGINE LUBRICATION - Lubricants/Special Tools/On-vehicle Service
LUBRICANTS
12-3
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
SPECIAL TOOLS
Tool
12100060119
Number
Name
Use
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>
ON-VEHICLE SERVICE
12100090095
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.
Drain plug
39 Nm
Drain plug gasket
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.
Oil
pan
side
NOTE
Install the drain plug gasket so it faces in the direction
12-4
ENGINE LUBRICATION - On-vehicle Service

5. Refill with specified quantity of oil.
<Petrol-powered vehicles>
Specified Engine Oil (API classification):

<4G6, 6A1> SG or higher
<4D6> CD or higher
Barometric temperature
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.
<Diesel-powered vehicles>
Barometric temperature
OIL FILTER REPLACEMENT

MB991396,
MB991610
or commercially-available tool
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.
O-ring
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.
12-5

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)
Engine oil level relay
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.
Engine oil level sensor

connector (Harness side)
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 problem is probably a malfunction 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.
12-6

connector (Equipment side)
5. Check the continuity between the oil level sensor

terminals.
Engine oil temperature
Oil level
Continuity
At 50_C or lower
Normal
(proper volume)
Continuity
Low (drained)
Continuity
Normal
(proper volume)
Continuity
Low (drained)
No continuity
At 60_C or higher
6. If there is a defect, replace the oil level sensor.
9 Nm

Oil pan
ENGINE LUBRICATION - Engine Oil Cooler <6A1>
ENGINE OIL COOLER <6A1>
12-7
12100130155

Engine Coolant Draining and Supplying
2
4
64 - 69 Nm
5
2
Removal steps
1. Oil filter (Refer to P.12-4.)
3. Oil cooler bolt
"AA
4. Engine oil cooler

5. O-ring

"AA ENGINE OIL COOLER INSTALLATION
Insert the engine oil cooler positioning tab into the cylinder
block rib, and tighten it with the oil cooler bolt.
INSPECTION
D
D
12100140110
Check the water hoses for crack, damage, clogging or

deterioration.
Check the oil cooler bolt for clogging or deformation.
12-8
ENGINE LUBRICATION - Engine Oil Cooler <4D6>
ENGINE OIL COOLER <4D6>
12100130162

D Engine Oil Draining and Supplying (Refer to P.12-3.)
D Front Bumper Removal and Installation
Air Guide Panel Removal and Installation
2
29 - 34 Nm
39 - 44 Nm
3
12 Nm
5 Nm
39 - 44 Nm
5 Nm
5 Nm
4
39 - 44 Nm
Removal steps
1. Hose assembly and joint connection
2. Engine oil cooler
3. Joint
"AA
4.
5.
6.
7.
Return hose assembly

Feed hose assembly
Return tube assembly
Feed tube assembly

Eye joint pin
"AA RETURN TUBE ASSEMBLY INSTALLATION

Insert the eye joint pin into the oil filter bracket hole and
install the return tube assembly.
ENGINE LUBRICATION - Engine Oil Cooler <4D6>

INSPECTION
D
D
D
D
12-9
12100140127
Check for foreign material between oil cooler fins.

Check the oil cooler fins for bend or damage.
Check the oil cooler hoses for crack, damage, clogging
or deterioration.
Check the eye bolts for clogging or deformation.
NOTES
13A-1
FUEL
CONTENTS
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 GROUP 17
TRACTION CONTROL SYSTEM (TCL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13H
NOTE
THE GROUPS MARKED BY
ARE NOT IN THIS MANUAL
13109000195
13A-2
MULTIPOINT FUEL
INJECTION (MPI)
CONTENTS
MULTIPOINT FUEL INJECTION <4G6>
13109000409
Idle Speed Control (ISC) Servo (Stepper

Motor) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
GENERAL INFORMATION . . . . . . . . . . . . . . . . 4
Purge Control Solenoid Valve Check . . . . . . . 95
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 7
EGR Control Solenoid Valve Check . . . . . . . . 95
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 9
INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . 98
MULTIPOINT FUEL INJECTION <6A1>
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 81
GENERAL INFORMATION . . . . . . . . . . . . . 102
Throttle Body (Throttle Valve Area)

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
SERVICE SPECIFICATIONS . . . . . . . . . . . 106
Idle Position Switch and Throttle Position

Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . 81
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fixed SAS Adjustment . . . . . . . . . . . . . . . . . . . . 83
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . 107
Basic Idle Speed Adjustment . . . . . . . . . . . . . . 83
TROUBLESHOOTING . . . . . . . . . . . . . . . . . 108
Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 85
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 184
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
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
Purge Control Solenoid Valve Check . . . . . . 200
Fuel Pump Connector Disconnection (How to

Reduce the Fuel Pressure) . . . . . . . . . . . . . . 191
EGR Control Solenoid Valve Check . . . . . . . 200
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
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
Idle Position Switch Check

INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . 196
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . 207
Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Idle Speed Control (ISC) Servo (Stepper
Motor) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
13A-4
MPI <4G6> - General Information
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
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 conditions.
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.
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.
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.
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 pump relay ON so that current
is supplied to the fuel pump while the engine
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
13A-5
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
Throttle body
Specifications
Throttle bore mm
54
Throttle position sensor
Variable resistor type
Idle speed control servo
Stepper motor type

(Stepper motor type by-pass air control system with the air
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
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
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
Actuators
Fuel pressure Regulator pressure kPa

regulator
329
13A-6
MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM

*1
*2
*3
*4
*5
*6
*7
*8
*9
*10
*11
Oxygen sensor (front)

Air flow sensor
Crank angle sensor
Detonation sensor
Oxygen sensor (rear)
D
D
D
D
D
D
D
D
D
Power supply voltage

A/C switch 1, 2
Inhibitor switch
Ignition switch - ST
Ignition switch - IG
Alternator FR terminal
A/T-ECU
Engine-ECU
z1
z2
z3
z4
Injector
D
D
D
D
D
D
D
D
D
Fuel pump relay

Control relay
A/C power relay
Engine warning lamp
Diagnosis signal
Ignition coil, power transistor
Fan controller
Alternator G terminal
A/T-ECU
z3 Idle speed
control servo
*3 Intake air
temperature
sensor
Air flow sensor (with
barometric pressure sensor)
Air cleaner
*6 Camshaft position sensor

*4, *5
Fuel pressure
regulator
To fuel
tank
PCV valve
Air
*8 *2
From fuel
pump
z1 Injector
EGR valve
*9 Engine coolant
z4
temperature sensor
*10 Detonation sensor
*1 Oxygen sensor
Catalytic converter
*7 Crank angle sensor
EGR
control
solenoid
valve

(with idle position switch)
Canister
z2
Purge control
solenoid valve
13A-7
MPI <4G6> - Service Specifications/Sealant
13100030339
Items
Specifications
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)

resistance kW
20_C
2.3 - 3.0
80_C
0.30 - 0.42
Engine coolant temperature

sensor resistance kW
20_C
2.1 - 2.7
80_C
0.26 - 0.36
Oxygen sensor output voltage V
0.6 - 1.0
Fuel pressure kPa
Vacuum hose 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

threaded portion
3M Nut Locking Part No. 4171 or equivalent
Drying sealant
13A-8
MPI <4G6> - Special Tools
SPECIAL TOOLS
Tool
A
13100060338
Number
Name
Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
D
A:
B:
C:
D:
Fuel gauge simple inspection

Connector pin contact pressure inspection
Power circuit inspection
Commercial tester connection
MB991502
MUT-II sub
assembly
D
D
Reading diagnosis code

MPI system inspection
MB991348
Test harness set
Measurement of voltage during troubleshooting

Inspection using an analyzer
MB991709
Test harness
MB991519
Alternator harness
connector
Measurement of voltage during

troubleshooting
MD998463
Test harness
(6-pin, square)
D
D
Inspection of idle speed control servo

MD998478
Test harness
(3-pin, triangle)

MPI <4G6> - Special Tools/Troubleshooting

Tool
Number
Name
Use
MD998709
Adaptor hose
Measurement of fuel pressure
MD998742
Hose adaptor
MD998706
Injector test set
MB991607
Injector test
harness
MD998741
Injector test
adaptor
MB991608
Clip
13A-9
Checking the spray condition of injectors
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)
13A-10
MPI <4G6> - Troubleshooting

Engine warning lamp inspection items
Engine-ECU
Oxygen sensor
Air flow sensor
Crank angle 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
13A-11
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.
2.
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.
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 from ignition timing for super petrol to ignition timing for standard
petrol.
Ignition coil,
transistor
Cuts off the fuel supply to cylinders with an abnormal ignition.
power
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).
Does not control the output of the alternator according to an electrical load. (works as a
normal alternator)
13A-12
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
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
13A-13

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
D
Check the oxygen sensor (front). (Refer to P.13A-92.)
NG
Malfunction of the oxygen sensor (front)

Improper connector contact, open circuit
short-circuited harness wire
Malfunction of the engine-ECU
Replace
OK
1. NG
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)
2. NG
OK: System voltage
2. Continuity between 2 and earth
OK: Continuity
Check the harness wire between the

oxygen sensor (front) and the control
relay connector, and repair if necessary.
Check the following connector:
C-40
NG
Repair
OK
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.

NG
harness side.
D Voltage between 60 and earth (Ignition switch: ON)
OK: System voltage
OK
Check the following connectors:
C-46, C-38
NG

C-46
OK
Repair
OK
Check the harness wire between the engine-ECU and

the oxygen sensor (front) connector.
OK
NG
(front) connector, and repair if necessary.

NG
NG
Repair
NG
Repair
or
13A-14
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
D
D
1. NG
Measure at the air flow sensor conCheck the air flow sensor circuit.
nector B-12.
(Refer to P.13A-59, INSPECTION
D Connect the connector. (Use
PROCEDURE 48.)
the test harness: MB991709)
1. Voltage between 3 and earth
NG
2. NG
(Engine: Idling)
Measure at the engine-ECU conOK: 2.2 - 3.2 V
nector C-34.
D Connect the connector.
OK: 0 - 1 V (Engine: idling)
D Voltage between 19 and earth
6 - 9 V (2,000 r/min)
(Ignition switch: ON)
OK: 6 - 9 V
OK
OK

C-34
NG
OK
Malfunction of the air flow sensor

Improper connector contact, open circuit or
short-circuited harness wire of the air flow sensor

B-12
NG
Repair
OK
NG
Repair
Replace the air flow sensor.

NG
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
D
Check the intake air temperature

sensor. (Refer to P.13A-90.)
OK
Measure at the air flow sensor connector 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
OK
B-12
NG
Replace
NG

C-40
NG
Repair
OK
NG
NG
Check the harness wire between

the engine-ECU and the intake air
temperature sensor connector.
Repair
OK
OK
Malfunction of the intake air temperature sensor

short-circuited harness wire of the intake air
temperature sensor circuit
NG
NG
Repair
13A-15

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.
MUT-II Data list

26 Idle position switch system
OK: With the throttle valve at the
idle position: ON
With the throttle valve slightly open: OFF
NG
D
D
D
D
Malfunction of the throttle position sensor or

maladjustment
short-circuited harness wire of the throttle position
sensor circuit
Improper ON state of idle position switch
Short circuit of the idle position switch signal line
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
OK
Check the throttle position sensor output circuit. (Refer to P.13A-60, INSPECTION PROCEDURE 49.)
NG

C-40
NG
Repair
OK
NG
engine-ECU and the throttle position
sensor connector.
OK
NG
Repair
13A-16
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
D
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 temperature sensor connector B-33.
OK: 4.5 - 4.9 V
OK: Continuity
NG

C-40
NG
engine-ECU and the engine coolant
OK
NG
Repair
Repair
OK
OK

B-33
NG
OK

NG
NG
Repair
13A-17

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
D
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
OK
Malfunction of the crank angle sensor

short-circuited harness wire of the crank angle sensor
NG
1. NG
D Disconnect the connector, and measure at the harness side.
2. NG
OK: System voltage
OK: 4.8 - 5.2 V
3. NG
OK: Continuity
OK
Check the following connector: B-77
NG
OK
NG
Replace the crank angle sensor.
Check the harness wire between the crank angle sensor and the
control relay connector, and repair if necessary.
Check the following connector: C-40
Repair
OK
NG
Repair
NG
Check the harness wire

between the engine-ECU and
the crank angle sensor
connector.
NG
Repair
OK
earth, and repair if necessary.
13A-18
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
D
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
Malfunction of the camshaft position sensor

short-circuited harness wire of the camshaft position
sensor circuit
NG
1. NG
Measure at the camshaft position sensor connector B-64.
2. NG
OK: System voltage
OK: 4.8 - 5.2 V
3. NG
OK: Continuity
OK
NG
OK
NG
Replace the camshaft position sensor.
Check the harness wire between the camshaft position sensor

and the control relay connector, and repair if necessary.
Repair
OK
NG
Repair
NG

the camshaft position sensor
connector.
NG
Repair
OK
Check the harness wire between the camshaft position sensor

and the earth, and repair if necessary.
13A-19

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
D
Check the vehicle speed sensor. (Refer to GROUP 54 - Combination Meters.)
NG
Malfunction of the vehicle speed sensor

short-circuited harness wire of the vehicle speed
sensor circuit
Replace
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
OK
Check the following
connectors:
B-66 <M/T>, B-67 <A/T>,
C-40
OK
NG
Repair

between the engine-ECU
and the vehicle speed
sensor connector.
OK
2. NG
Check the following

connectors:
B-65 <M/T>, C-90, C-135,
C-131
NG
Repair
OK
3. NG
NG
between the vehicle
speed sensor and ignition
switch connector.
OK
NG
Repair
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.)

NG
1. NG
NG
Repair
Check the following

connectors:
B-65 <M/T>, C-48, C-40
NG
Repair
OK
NG
sensor connector.
OK
NG
Repair

Check the following
connector:
B-65 <M/T>
NG
Repair
OK
OK
Check the harness wire between the vehicle speed sensor and
the earth, and repair if necessary.
13A-20
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
D

OK: 3.7 - 4.3 V (Altitude: 0 m)
3.2 - 3.8 V (Altitude:
1,200 m)
NG

OK: 4.8 - 5.2 V
OK: Continuity
NG

B-12

C-40
NG
the engine-ECU and the barometric pressure sensor connector.
NG
Repair
OK
NG
NG
the engine-ECU and the baromet- OK
ric pressure sensor connector.
NG

the engine-ECU and the barometric pressure sensor connector, and
repair if necessary.
OK
C-40
OK
NG
NG
Repair
Repair
OK

OK: 3.7 - 4.3 V (Altitude: 0 m)
1,200 m)
NG
OK
OK
OK
Malfunction of the barometric pressure sensor

short-circuited harness wire of the barometric pressure
sensor circuit
Repair
NG
Repair
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
D
Measure at the detonation sensor connector B-34.

D Disconnect the connector and
OK: Continuity
OK

B-34, C-40
Malfunction of the detonation sensor

short-circuited harness wire of the detonation sensor
circuit
NG
Repair
OK
NG
NG

engine-ECU and the detonation sensor
connector.

detonation sensor and earth, and repair
if necessary.
OK
Replace the detonation sensor.

NG
NG
Repair
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
D
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
OK
Check the injector control circuit.
(Refer to P.13A-60, INSPECTION PROCEDURE 50.)
NG
Malfunction of the injector

short-circuited harness wire of the injector circuit

B-02, B-03, B-05, B-36
OK
NG
NG
Repair

control relay and the injector connector,
and repair if necessary.
13A-22
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
D
1. NG
Measure at the ignition coil connectors
B-01, B-11
measure at the harness.
OK: System voltage
2. NG
(Engine: Cranking)
OK: 0.5 - 4.0 V
3. Continuity between the 2 and earth 3. NG
OK: Continuity
OK
D
D
D

C-92, C-131

ignition coil connector and earth, and
Repair

NG
OK
Replace the ignition coil.
NG
NG
Repair
Repair
NG

ignition coil and ignition switch connector, and repair if necessary.
OK
NG
Check the following items.

D Check the spark plugs, spark plug
cables.
D Check the compression pressure.

NG
Repair
NG
NG
OK
NG

engine-ECU and ignition coil connector.

B-01, B-11
Malfunction of the ignition coil

short-circuited harness wire of the ignition primary
circuit
Malfunction of the spark plug and spark plug cable
Improper compression pressure
Repair or replace
OK
13A-23

Code No.54 Immobilizer system
Probable cause
Range of Check
Set Conditions
D Improper communication between the engine-ECU and immobilizer-ECU
D
D
D
D
D
Radio interference of ID codes

Incorrect ID code
Malfunction of harness or connector
Malfunction of immobilizer-ECU
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.
Is there another ignition key near the ignition key that is inserted
in the ignition switch?
Yes
Remove the extra ignition key.

NG
No
Is a diagnosis code output from the immobilizer-ECU?
Yes
No
C-38, C-81, C-68
NG

Check the immobilizer system. (Refer to GROUP 54 - Ignition
Switch and Immobilizer System.)
Repair
OK
NG
Check the harness wire between the engine-ECU and the immobilizer-ECU.
NG
OK
Replace the immobilizer-ECU.

NG
Repair
NG
13A-24
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
D
Check the oxygen sensor (rear). (Refer to P.13A-93.)
NG
Malfunction of the oxygen sensor (rear)

Replace
OK
1. NG
Measure at the oxygen sensor (rear) connector C-85.
harness side.
2. NG
OK: System voltage
OK: Continuity
3. NG
OK: Continuity

oxygen sensor (rear) and the control
C-40
NG
(rear) connector.
OK

C-85, C-40
Repair
OK
NG
the oxygen sensor (rear) connector.
OK
Replace the oxygen sensor (rear).
NG
NG
Repair
OK
OK
NG
NG
Repair

oxygen sensor (rear) and the earth, and
NG
Repair
or
13A-25

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
D
D

C-34, C-38, C-30
NG
Malfunction of the harness wire and the connector

Malfunction of the A/T-ECU
Repair
OK
NG
Check the harness wire between the engine-ECU and the A/T-ECU
connector.
OK
NG
Repair
NG
Replace the A/T-ECU.
Code No. 64 Alternator FR Terminal System
Probable cause
Range of Check, Set Conditions

D The alternator FR terminal signal voltage remains high for approximately 20 seconds
while the engine is running.
D
D
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
Open circuit in alternator FR terminal circuit

NG
OK: 4.8 - 5.2 V
OK
NG
NG
NG
Repair
and the alternator connector.
NG
Replace the alternator.
Repair
OK
NG
OK
OK
Check the harness wire between the engine-ECU and the alternator
connector.
Check the following

connectors: B-31, C-36
NG
Repair
OK
NG
Repair
13A-26
INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom
13100880354
Inspection
procedure
No.
Reference page
Communication
with MUT-II
II is
impossible.
Communication with all systems is not possible.
13A-28
Communication with engine-ECU only is not possible.
13A-29
Engine warning
lamp and
related parts
The engine warning lamp does not illuminate right after the
ignition switch is turned to the ON position.
13A-30
The engine warning lamp remains illuminating and never goes

out.
13A-30
Starting
No initial combustion (starting impossible)
13A-31
Initial combustion but no complete combustion

(starting impossible)
13A-32
Long time to start (improper starting)
13A-33
Unstable idling (Rough idling, hunting)
13A-34
Idling speed is high. (Improper idling speed)
13A-35
Idling speed is low. (Improper idling speed)
10
13A-36
When the engine is cold, it stalls at idling. (Die out)
11
13A-37
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
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
Idling stability
(Improper idling)
Idling stability
(Engine stalls)
Driving
13A-27

PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)
Items
Starting
Idling
stability
Symptom
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.
Hunting
Engine speed doesnt remain constant; changes at idle.
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.
Driving
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.
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 now traveling, or a temporary drop
in vehicle speed (engine speed)
during such acceleration.
Serious hesitation is called sag.
Hesitation
Normal
Vehicle Initial acspeed celerator
pedal depression
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 acceleration.
Vehicle
speed
Normal
Initial accelerator
pedal depression
Idling
Stumble
Time
13A-28
Items
Driving
Stopping
Symptom
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.
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
D
Measure at the diagnostic connector

(16-pin) C-20.
OK: Battery voltage
NG
OK
OK

(16-pin) C-20.
OK: Continuity
OK
Replace the MUT-II.

C-66, (C-63, C-132, C-141) <L.H.>,
(C-62, C-14) <R.H.>
NG

diagnostic connector (16-pin) and earth,
Malfunction of the connector

Malfunction of the harness wire
NG
NG
Repair

power supply and diagnostic connector
(16 pin), and repair if necessary.
13A-29

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
D
D
D
Is communication possible between the MUT-II and the immobilizerECU?
No
Yes
C-20, C-66, C-68, C-83, C-81, C-38
NG
Malfunction of engine-ECU power supply circuit

Open circuit between immobilizer-ECU and diagnosis
connector
Open circuit between engine-ECU and immobilizerECU
Check the diagnosis line between the immobilizer-ECU and the

MUT-II, and repair if necessary. (Refer to GROUP 54 - Ignition
Key and Immobilizer.)
Repair
OK
NG
Check the harness wire between engine-ECU and diagnosis connector.
OK
Check the harness wire between engine-ECU and immobilizerECU.
NG
Repair
NG
OK
Repair

between engine-ECU and
earth.
NG
Repair
OK
Check the power supply and ignition switch-IG system. (Refer to
P.13A-45, INSPECTION PROCEDURE 26.)
13A-30
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
D
D
MUT-II Data list

16 engine-ECU power supply voltage (Refer to P.13A-62.)
OK
D Earth the terminal No. 36.
OK: The engine warning lamp illuminates.
NG
OK
Check the engine-ECU power supply and earth circuit.

Check the following

connector: C-36.
NG
Repair
OK
NG
Check a burnt-out bulb.
Burnt-out bulb
Defective warning lamp circuit
NG
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
OK
NG
NG
Repair
Check the harness wire between combination meter and engineECU, 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.
Yes
MUT-II Self-Diag code

Are diagnosis codes displayed?
No
D Disconnect the engine-ECU connector
OK: No continuity
OK
NG
Short-circuit between the engine warning lamp and

engine-ECU
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS

CODES
Check the harness wire between combination meter and engineECU connector, and repair if necessary.
13A-31
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
D
D
D
D
D
Check battery voltage when cranking.

OK: 8 V or higher
OK
Is immobilizer-ECU diagnosis code displayed?
NG
Yes
No
Malfunction of the ignition system

Malfunction of the fuel pump system
Malfunction of the injectors
Malfunction of the immobilizer system
Foreign materials in fuel
Check the battery. (Refer to GROUP 54 - Battery.)
Check the immobilizer.

(Refer to GROUP 54 - Ignition Key and Immobilizer.)
MUT-II: Inspection of no initial combustion.

OK
Can any sound be heard from the injectors when cranking?
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.
NG
Check the injector system. (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.)
13A-32
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
D
D
D
D

OK: 8 V or higher
NG

Malfunction of the injector system
Poor compression
OK
MUT-II: Check if uncompleted combustion occurs.
OK
NG
OK
Is starting good if the engine is cranked with the accelerator pedal
slightly depressed?
Yes
No
Check the injector system, (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.)
Check ISC servo for operation sound.
OK
D
D
Check the ignition timing when cranking.

OK: Approx. 5_BTDC
OK
D Check fuel lines for clogging.
NG
NG
Check the ISC servo system. (Refer to P.13A-50,

INSPECTION PROCEDURE 34.)
Clean the throttle valve area. (Refer to P.13A-81.)

Check and adjust the fixed SAS. (Refer to P.13A-83.)
Check that the crank angle sensor is installed properly.
13A-33
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
D
D
D
Check battery voltage when cranking

OK: 8 V or higher
NG

Inappropriate gasoline use
Poor compression
OK
MUT-II: Check if uncomplete combustion occurs.
OK
OK
OK: Approx. 5_BTDC
OK
NG
NG
13A-34
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
D
D
D
D
D
D
Were the battery terminals disconnected?

No
No
Does idling speed fluctuate excessively?
No
Check the ISC servo for operation sound. (Refer to P.13A-95.)
OK
Check the injector for operation sound.
Yes
Yes
Yes
NG
NG
OK

Malfunction of air-fuel ratio control system
Malfunction of the ISC system
Malfunction of the purge control solenoid valve system
Malfunction of the EGR solenoid valve system
Poor compression
Drawing air into exhaust system
After warming-up, let the engine run at idling for 10 minutes.

CODES.
Check if hunting occurs.
Check the ISC servo system.
MUT-II: Check if idling speed is unstable.

OK
Check the ignition timing.
(Refer to GROUP 11A - On-vehicle Service.)
OK
D Check the purge control system.
D Check the EGR control system.
NG
13A-35
Probable cause
In such cases as the above, the cause is probably that the intake air volume during
idling is too great.
D
D
Yes

No
OK
MUT-II Data list
26 Idle position switch (Refer to P.13A-63.)
OK
MUT-II Data list
21 Engine coolant temperature sensor (Refer to P.13A-62.)
NG
NG
NG
OK
MUT-II Data list
28 A/C switch (Refer to P.13A-63.)
NG
Malfunction of the ISC servo system

Malfunction of the throttle body

CODES.
Check the engine coolant temperature sensor system.

(Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 21.)
Check the A/C switch and A/C relay system.
OK
Basic idle adjustment (Refer to P.13A-83.)
NG

13A-36
Probable cause
In cases such as the above, the cause is probably that the intake air volume during
idling is too small.
D
D
Yes

No
OK
MUT-II Data list
OK
MUT-II Data list
NG
NG
NG
OK
MUT-II Data list
29 Inhibitor switch (Refer to P.13A-63.)
NG


CODES.

CODE 21.)
Check the ignition switch ST and inhibitor switch system <A/T>.
OK
NG

13A-37

Probable cause
In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate
when the engine is cold, or that the intake air volume is insufficient.
D
D
D
D

No
Yes
Yes
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
ISC servo system

throttle body
injector system
ignition system

CODES.
No
Does the engine stall right after the accelerator pedal is released?
Yes
No
Is engine-idling stable after the warming-up?
No
Yes
NG
OK
NG
OK
MUT-II Data list
OK
MUT-II Data list
OK
MUT-II Actuator test
10 EGR control solenoid valve (Refer to P.13A-65.)
NG
NG
NG
Clean the throttle valve

area. (Refer to P.13A-81.)
Check and adjust the

fixed SAS.
Check if the unstable idling (Rough idling, hunting).


CODE 21.)
Check the EGR control solenoid valve system. (Refer to P.13A-51,
OK
Check the fuel pressure. (Refer to P.13A-85.)
OK
OK
D Check the engine oil viscosity.
NG
13A-38
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
D
D
D
D

No
No
Yes
Yes
NG
OK
NG
OK
Yes
No
Does the engine stall easily again?
No
Yes
MUT-II: Engine stalling inspection when the engine is warm and
idling. (Refer to P.13A-55, INSPECTION PROCEDURE 42.)
OK

OK
NG

Drawing air into intake system
Improper connector contact

CODES.
area. (Refer to P.13A-81.)

fixed SAS.
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 Primary and secondary
D Air flow sensor signal
ignition signal
D Injector drive signal
D Fuel pump drive signal
D Engine-ECU power supply
voltage
13A-39
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.
D
D
Yes

No
NG


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
Probable cause
In cases such as the above, the cause is probably that the intake air volume is insufficient
due to a defective idle speed control (ISC) servo system.

No
No
MUT-II Data list
P.13A-69.)
OK
MUT-II Data list
14 Throttle position sensor (Refer to P.13A-62.)
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)?
No
OK
D Clean the throttle valve area.
D Check and adjust the fixed SAS.
Yes
Yes
NG
NG
Yes
NG

CODES.
(Refer to P.13A-46,
26.)
Check the throttle position sensor system. (Refer to P.13A-15, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
Check the vehicle speed sensor system. (Refer to P.13A-19, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 24.)

13A-40
Probable cause
In cases such as the above, the cause is probably that ignition system, air/fuel mixture
or compression pressure is defective.
D
D
D
D
D
Yes

No
Check the injectors for operation sound.
NG
OK
NG

Malfunction of the fuel supply system
Malfunction of the EGR control solenoid valve system
Poor compression

CODES.
OK
MUT-II: Check if hesitation, sag, stumble or poor acceleration occur.
OK
OK
D Check the fuel filter or fuel line for clogging.
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

No
D Check for occurrence of ignition leak.

CODES.
13A-41
The feeling of impact or vibration when decelerating.
Probable cause
Malfunction of the ISC system is suspected.
D
Yes

No
OK
MUT-II Data list
NG
NG

CODES.
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
D
D
D
D
Yes

No
NG
OK
OK
OK
OK
D Broken air intake hose
D Clogged air cleaner
NG

Poor compression pressure
Clogged exhaust system

CODES.
13A-42
Surge
Probable cause
Defective ignition system, abnormal air-fuel ratio, etc. are suspected.
D
D
D
Yes

No
NG
OK
NG


CODES.
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
D
Yes

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
Defective detonation sensor

Inappropriate heat value of the spark plug

CODES.
Check the detonation sensor system. (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 31.)
Yes
D Spark plugs
Dieseling
Probable cause
Fuel leakage from injectors is suspected.
Check the injectors for fuel leakage.
Fuel leakage from injectors
13A-43

Probable cause
Abnormal air-fuel ratio is suspected.
D
D
Yes

No
OK
MUT-II Data list
21 Engine coolant temperature sensor. (Refer to P.13A-62.)
NG
NG
OK
MUT-II Data list
13 Intake air temperature sensor (Refer to P.13A-62.)
NG
Malfunction of the air-fuel ratio control system

Deteriorated catalyst

CODES.

CODE 21.)
Check the intake air temperature sensor system. (Refer to P.13A-14,
INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
OK
MUT-II Data list
25 Barometric pressure sensor (Refer to P.13A-63.)
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
NG
Check the barometric pressure sensor system. (Refer to P.13A-20,

Check the oxygen sensor (rear) system. (Refer to P.13A-24, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)
OK
MUT-II Data list
11 Oxygen sensor
OK: 600 - 1,000 mV when racing suddenly (Refer to P.13A-61.)
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.)
NG
OK
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.
NG
OK
Check the oxygen sensor system. (Refer to P.13A-13, INSPECTION

PROCEDURE FOR DIAGNOSIS CODE 11.)
Replace the oxygen sensor.

NG
13A-44
Probable cause
The alternator may be defective, or malfunctions, which are listed in the right column,
may be suspected.
D
D
D
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 connector.
OK: No continuity
OK
alternator and the engine-ECU connector.
NG
NG

alternator and the engine-ECU connector, and repair if necessary.
Repair
OK
OK
Check the alternator. (Refer to GROUP
16 - Charging System.)
Malfunction of charging system

Short circuit in harness between alternator G terminal
and engine-ECU
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
D

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)]
NG
Check the A/C system. (Refer to GROUP 55 - On-vehicle Service.)
OK
Malfunction of the A/C control system


C-34
OK
NG
Repair

NG
13A-45

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
D
D
D

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
OK
Check the following
connector:
C-34
OK
NG
NG
Malfunction of the fan motor relay

Malfunction of the fan motor
Malfunction of the fan controller

and the fan controller connector.
NG
Repair
OK
Check the radiator fan
and condenser fan circuit.
(Refer to GROUP 14 Troubleshooting.)
Repair

NG
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
D
D
D
D
Check the control relay. (Refer to P.13A-90.)
NG
Malfunction of the ignition switch

Malfunction of the control relay
Improper connector contact, open
Disconnected engine-ECU earth wire
circuit
or
Replace
OK
Measure at the control relay connector C-31.
D Voltage between 3, 4 and earth
OK: System voltage
OK
NG
Check the following

connector: B-30
NG
Repair
OK
NG
Check the harness wire between battery and control relay connector,
13A-46
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
D
D
D
Check the fuel pump operation. (Refer to P.13A-88.)
NG
OK
Check the fuel pump relay. (Refer to P.13A-90.)
OK
Measure at the fuel pump relay connector C-32.
D MUT-II Actuator test: Fuel pump drive
OK: System voltage
NG
NG
Malfunction of the fuel pump relay

Malfunction of the fuel pump
circuit
or
Check the fuel pump circuit.

Replace
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
D
D
D
D
Check the idle position switch. (Refer to P.13A-91.)
NG
Maladjustment of the accelerator pedal

Maladjustment of the fixed SAS
Maladjustment of the idle position switch and throttle
position sensor
Replace the throttle position sensor.
OK
Measure at the throttle position sensor connector B-07.
OK: 4 V or higher
OK: Continuity
OK
Check the following
connector: B-07
OK
NG
NG
Repair
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
13A-47

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
D
1. NG
2. NG
1. Voltage between 71 and earth (Ignition switch: START)
OK: 8V or more
OK: Continuity
OK
Check the following
connector: C-40
OK
NG
NG
Repair
Malfunction of ignition switch

Improper connector contact,
Check the following

connector: C-92
NG
open
circuit
or
Repair
OK
NG
Check harness wire between the engine-ECU
and ignition switch connector.
NG
Repair
OK
Check the ignition switch.
(Refer to GROUP 54 - Ignition Switch and Immobilizer system.)

Check the harness wire between engine-ECU connector (terminal
No. 91) and earth, and repair if necessary.
13A-48
Ignition switch-ST and inhibitor switch system <A/T>
Probable cause
D
D
D
The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine
is cranking.
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.
Check the inhibitor switch.

OK
NG
1. NG
Measure at the inhibitor switch connector B-72.
2. NG
OK: System voltage
OK: Continuity
D Ignition switch: START
D Disconnect engine-ECU connector.
3. NG
OK: System voltage
OK
Check the following
connector: B-72
NG
Repair
OK
Check harness wire between engine-ECU and

inhibitor switch connector.
OK
open
circuit
or
Replace

NG
Repair
OK
Check harness wire between inhibitor switch connector and starter
S terminal, and repair if necessary.
Check the
connector:
C-92
following
NG
Repair
OK

NG

Malfunction of inhibitor switch
Malfunction of the engine-ECU.
NG

Repair
NG
Check harness wire between inhibitor switch and
ignition switch connector.
NG
Repair
OK
13A-49

Power steering fluid pressure switch system
Probable cause
The presence or absence of power steering load is input to the engine-ECU.

D
D
D
Check the power steering fluid pressure switch.

NG
Malfunction of power steering fluid pressure switch

Replace
OK
Measure at the power steering fluid pressure switch connector
B-76.
OK: System voltage
OK
Check the following
connector: B-76
NG
Check the following

connector: C-36
Repair
OK
NG
NG
NG
Repair

power steering fluid pressure switch connector.
OK
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
D
D
D
Check the A/C compressor relay.

NG
Malfunction of A/C control system

Malfunction of A/C switch
circuit
or
Replace
OK
NG
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)
OK
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.
Check the A/C system. (Refer to GROUP 55 - Troubleshooting.)
Check the following

connectors: C-34, C-36
OK
NG
NG
Replace
13A-50
Ignition circuit system
Probable cause
The engine-ECU interrupts the ignition coil primary current by turning the power transistor
inside the engine-ECU ON and OFF.
D
D
D
1. NG
Measure at the ignition coil connectors B-01, B-11.
D Disconnect the connector and measure at the harness side.
2. NG
OK: System voltage
OK: Continuity
Malfunction of ignition switch.

Check the following

NG
open
circuit
or
Repair
OK
NG
OK

between ignition coil and
NG
Repair
OK
Check the following

connectors: B-01, B-11
NG

(Refer to GROUP 54 - Ignition Switch and Immobilizer System.)
Repair
Check the harness wire between power transistor unit connector
and earth, and repair if necessary.
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
D
D
Check the ISC servo

NG
Malfunction of ISC servo

open
circuit
or
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 connector, 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
OK
Check the following
connector: C-34
OK
NG
NG
Check the following

connector: B-10
NG
Repair
OK
NG
Repair
Check harness wire between engine-ECU and ISC servo connector,

NG
13A-51

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
D
D
Check the purge control solenoid valve.

(Refer to GROUP 17 - Emission Control System.)
OK
Measure at the purge control solenoid valve connector B-04.
OK: System voltage
NG
NG
Malfunction of solenoid valve

short-circuited harness wire.
open
circuit
or
Replace
Check the harness wire between control relay and solenoid valve
connector, and repair if necessary.
OK
OK: System voltage
OK
Check the following
connector: C-34
NG
NG
Check the following

connector: B-04
NG
Repair
OK
NG
Repair
Check the harness wire between engine-ECU and solenoid valve

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.
D
D
D
Check the EGR control solenoid valve.

OK
Measure at the EGR control solenoid valve connector B-06.
OK: System voltage
NG
NG

open
circuit
or
Replace
OK
OK: System voltage
OK
Check the following
connector: C-34
OK
NG
NG
Repair
NG
Check the
connector:
B-06
following
NG
Repair
OK
NG
13A-52
MUT-II: Inspection of no initial combustion
MUT-II Data list
16 Power supply voltage (Refer to P.13A-62.)
OK
Does the camshaft rotate at the engine cranking?
(When oil filler cap is removed.)
Yes
No
MUT-II Data list
22 Crank angle sensor
OK: Cranking speed is displayed.
OK
07 Fuel pump (Refer to P.13A-65.)
OK
MUT-II Data list
NG
No
Yes
No
NG
NG
Check the power supply and ignition switch-IG system.

Check timing belt for breakage.

CODES.
Check the crank angle sensor system.
CODE 22.)
Check the fuel pump system.

CODE 21.)
Check ignition circuit system.
OK

OK: Approx. 5_BTDC
NG
13A-53
Yes

No
OK
MUT-II Data list
NG
NG
OK
MUT-II Data list
18 Ignition switch-ST (Refer to P.13A-62.)
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.
NG
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODE

(Refer to P.13A-16, INSPECTION PROCEDURES FOR DIAGNOSIS CODE 21.)
Check
(Refer
Check
(Refer
the ignition switch-ST system <M/T>.

to P.13A-47, INSPECTION PROCEDURE 29.)
the ignition switch-ST and inhibitor switch system <A/T>.
13A-54
MUT-II Data list
NG

OK
MUT-II Data list
NG
Check the intake air temperature sensor system. (Refer to P.13A-14,

OK
MUT-II Data list
NG

OK
MUT-II Data list
NG
OK
08 Purge control solenoid valve (Refer to P.13A-65.)
OK
OK
MUT-II Data list
OK: 600 - 1,000 mV
OK
MUT-II Data list
11 Oxygen sensor
OK: 600 - 1,000 mV during sudden racing
NG
NG
NG
NG

CODE 21.)
Check the purge control solenoid valve system

Check the oxygen sensor (front) system. (Refer to P.13A-13, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 11.)
OK
MUT-II Data list
11 Oxygen sensor
OK: Changes between 0 - 400 mV and 600 - 1,000 mV during
idling
OK
MUT-II Data list
27 Power steering fluid pressure switch (Refer to P.13A-63.)
NG
NG
OK
MUT-II Data list

OK
MUT-II Data list
OK
MUT-II Data list
45 ISC Servo position (Refer to P.13A-64.)
NG
NG
NG
Check the fuel pressure.

Check the power steering

fluid pressure switch system. (Refer to P.13A-49,
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.

(Refer to P.13A-49. INSPECTION PROCEDURE 32.)
Check the ignition switch-ST and inhibitor switch system. <A/T>
Adjust the basic idle speed. (Refer to P.13A-83.)
13A-55

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, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
OK
MUT-II Data list
NG

OK
MUT-II Data list
OK
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
NG
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
OK
MUT-II Data list
NG
NG
OK
MUT-II Data list

OK
MUT-II Data list
OK
MUT-II Data list
45 ISC servo position (Refer to P.13A-64.)
NG
NG
NG


OK

system
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.

13A-56
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
OK
MUT-II Data list
NG

(Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSTIC CODE 21.)
OK
OK
MUT-II Data list
OK: 600 - 1,000 mV
OK
MUT-II Data list
11 Oxygen sensor
NG
NG
NG
Check the EGR control solenoid valve system.

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.
13A-57

MUT-II Data list
NG

OK
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
OK
MUT-II Data list
OK: 600 - 1,000 mV
OK
MUT-II Data list
11 Oxygen sensor
NG
NG
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.
13A-58
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
2, 3. NG
5. NG
NG
Repair
OK
OK
4. NG

NG
Repair
OK
OK
Check the following
connectors:
C-34, C-36, C-40
Check the following


NG
Repair
Check the harness wire between engine-ECU and control relay
OK
Check the harness wire between engine-ECU and earth, and repair
if necessary.
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 fuel pump circuit.
Measure at the fuel pump connector E-16.

OK: Continuity
NG

E-11
NG
Repair
OK
OK
NG
Check the following connectors: E-16, E-11, C-123, C-92, B-09
NG
OK
Check the harness wire between fuel pump and earth, and repair
if necessary.
Repair
NG
Check the harness wire between terminal for fuel pump drive and
fuel pump connector.
OK
Replace the fuel pump.
NG
Repair
13A-59

D Voltage between 3, 4 and earth (Ignition switch: ON)
OK: System voltage
NG
NG
Repair
OK
OK
OK: System voltage
NG
OK
OK
Check the following

NG
NG
between fuel pump relay
OK
NG
Repair

Repair
Check the harness wire between engine-ECU and fuel pump relay

NG
Check air flow sensor (AFS) control circuit.
1. NG
OK: System voltage
2, 3. NG
OK: 4.8 - 5.2 V
OK: Continuity
OK
NG
NG
Repair
OK
NG
NG
Repair
Check the following

connector: C-40

OK
Check the harness wire between the air flow sensor and control

and air flow sensor connector.
OK
NG
Repair
13A-60
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
OK

NG
Check the harness between engine-ECU and injector connector,

OK
NG
NG
Repair
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 km or less], the air flow sensor 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
11
Oxygen
sensor
(front)
Engine:After having
warmed up
Air/fuel mixture is
made leaner when decelerating, and is made
richer when racing.
Engine:After having
warmed up
The oxygen sensor
signal is used to check
the air/fuel mixture
ratio, and control
condition is also
checked by the ECU.
12
Air flow
sensor*1
D
D
D
13
Intake air
temperature
sensor
Normal condition
Inspection
procedure
No.
Reference
page
When at 4,000 r/min,

engine is suddenly
decelerated
200 mV or less
Code No.
11
13A-13
When engine is
suddenly raced
600 - 1,000 mV
Engine is idling
400 mV or less
Code No.
13
13A-14
(Changes)
2,500 r/min
Engine coolant
Engine is idling
temperature: 80 95_C
2,500 r/min
Lamps,
electric
cooling fan and all
accessories: OFF Engine is raced
Transmission:
Neutral (A/T:
P range)
Ignition switch: ON or
with engine running
600 - 1,000 mV
17 - 43 Hz
70 - 110 Hz
Frequency
increases in
response to
racing
When intake air

temperature is - 20_C
- 20_C
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.
Inspection
item
Inspection contents
14
Throttle
position
sensor
Ignition switch: ON
16
Power
supply
voltage
Ignition switch: ON
18
Cranking
signal
(ignition
switch-ST)
Ignition switch: ON
Engine
coolant
temperature
sensor
Ignition switch: ON or
with engine running
21
Normal condition
Inspection
procedure
No.
Reference
page
Set to idle position
300 - 1,000 mV
13A-15
Gradually open
Increases in
proportion to
throttle opening
angle
Code No.
14
Open fully
4,500 - 5,500 mV
System voltage
Procedure
No. 26
13A-45
Engine: Stopped
OFF
Engine: Cranking
ON
Procedure
No. 29
<M/T>
Procedure
No. 30
<A/T>
13A-47
<M/T>
13A-48
<M/T>
When engine
coolant temperature
is - 20_C
- 20_C
Code No.
21
13A-16
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
13A-63

Item
No.
Inspection
item
Inspection contents
22
Crank angle
sensor
D
D
Engine: Cranking
Tachometer:
Connected
D
D
Engine: Idling
Idle position
switch: ON
25
26
27
28
29
Normal condition
Inspection
procedure
No.
Reference
page
Compare the engine

speed readings on
the tachometer and
the MUT-II.
Accord
Code No.
22
13A-17
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
At altitude of 0 m
101 kPa
13A-20
At altitude of 600 m
95 kPa
Code No.
25
At altitude of 1,200 m
88 kPa
81 kPa
Throttle valve:
ON
Procedure
No. 28
13A-46
Throttle valve:
Slightly open
OFF*2
Power
Engine: Idling
steering fluid
pressure
switch
Steering wheel
stationary
OFF
Procedure
No. 31
13A-49
Steering wheel
turning
ON
A/C switch
Engine: Idling
(when A/C switch is
ON, A/C compressor
should be operating.)
A/C switch: OFF
OFF
Procedure
No. 32
13A-49
A/C switch: ON
ON
Ignition switch: ON
P or N
P or N
13A-48
D, 2, L or R
D, 2, L or R
Procedure
No. 30
Barometric
pressure
sensor
Idle position
switch
Inhibitor
switch
<A/T>
Ignition switch: ON
Ignition switch: ON
Check by operating
accelerator pedal
repeatedly
13A-64
Item
No.
Inspection
item
Inspection contents
41
Injectors *3
Engine: Cranking
Injectors*4
D
D
D
44
45
Ignition coils
and power
transistors
ISC
(stepper)
motor
position *5
D
D
D
D
D
D
D
D
49
A/C relay
Engine coolant
temperature:
8095_C
Lamps,
electric
cooling fan and all
accessories: OFF
Transmission:
Neutral (A/T :
P range)
Normal condition
Inspection
procedure
No.
Reference
page
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
Engine is idling
1.6 - 2.8 ms
2,500 r/min
1.4 - 2.6 ms
When engine is
suddenly raced
Increases
Procedure No.
32
13A-49
Engine: After
Engine is idling
having warmed up
Timing lamp is set.
(The timing lamp
is set in order to 2,500 r/min
check actual
ignition timing.)
2 - 18_BTDC
Engine coolant
temperature: 80 95_C
Lamps,
electric
cooling fan and all
accessories: OFF
Transmission:
Neutral (A/T :
P range)
Idle position
switch: ON
Engine: Idling
When A/C switch
is ON, A/C
compressor should
be operating
A/C switch: OFF
2 - 25 STEP
A/C switch:
OFF ON
Increases by
10 - 70 steps
D
D
Increases by
5 - 50 steps
Engine: After having

warmed up/Engine is
idling
A/C switch: OFF

Select lever:
N range D
range
18 - 38_BTDC
A/C switch: OFF
OFF (Compressor
clutch is not
operating)
A/C switch: ON
ON (Compressor
clutch is
operating)
13A-65

Item
No.
59
Inspection
item
Inspection contents
Oxygen
sensor
(rear)
D
D
Transmission:
2nd gear <M/T>,
L range <A/T>
Drive with throttle
widely open
3,500 r/min
Normal condition
Inspection
procedure
No.
Reference
page
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
up/Engine is idling
(Cut the fuel supply to each
injector in turn and check
cylinders which dont affect
idling.)
Idling condition
becomes different
(becomes unstable).
Code No.
41
13A-21
Pinch the
return hose
with fingers
to feel the
pulse of the
fuel being
recirculated.
Pulse is felt.
Procedure
No. 27
13A-46
Listen near
the fuel tank
for the
sound of
fuel pump
operation.
Sound of operation is heard.
02
Cut fuel to No.

2 injector
03
Cut fuel to No.

3 injector
04
Cut fuel to No.

4 injector
07
08
Fuel pump
Fuel pump
operates and
fuel is recirculated.
Purge
control
solenoid
valve
Solenoid valve
EGR
control
solenoid
valve
Solenoid valve
17
21
Fan controller
10
Engine:
Cranking
Fuel
pump:
Forced
driving
Inspect
according
to both
the above
conditions.
Ignition switch: ON
Sound of operation can be heard

when solenoid
valve is
driven.
Procedure
No. 35
13A-51
Ignition switch: ON

when solenoid
valve is
driven.
Procedure
No. 36
13A-51
Set to ignition
timing adjustment mode
Engine: Idling
Timing light is set
5_BTDC
Drive the fan

motor
Ignition switch: ON
Radiator fan and

condenser fan
operate at high
speed
Procedure
No. 25
13A-45
turns from
OFF to ON.
turns from
OFF to ON.
13A-66
Needle-nosed wire probe

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 from standard 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.
13A-67

Engine-ECU Connector Terminal Arrangement
Terminal No. Check item
Check condition (Engine condition)
Normal condition
No. 1 injector
14
No. 2 injector
While engine is idling after having

warmed up, suddenly depress the
accelerator pedal.
From 11 - 14 V, momentarily
drops slightly
No. 3 injector
15
No. 4 injector
Stepper motor coil <A1>
17
Engine: Soon after the warmed up

engine is started
System voltage 0 V
(Changes repeatedly)
Stepper motor coil <B1>
18
EGR control solenoid

valve
Ignition switch: ON
System Voltage
While engine is idling, suddenly depress

the accelerator pedal.
From system voltage,

momentarily drops
A/C relay
D
D
System voltage or
momentarily
6V or more 0 - 3V
Purge control solenoid

valve
Ignition switch: ON
System voltage
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
Air flow sensor reset

signal
Engine: Idle speed
0 - 1V
6 - 9V
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
Engine: Idle speed

A/C switch: OFF ON
(A/C compressor is operating)
25
19
21
13A-68
Normal condition
22
Ignition switch: ON
System voltage
Engine: Idle speed
0 - 3V
24
33
Fuel pump relay
A/C switch 2
D
D
D
D
D
D
41
D
D
D
D
Engine: Idling
Outside air
temperature:
25_C or more
When A/C is MAX.

COOL condition
(when the load by
A/C is high)
0 - 3V
(When A/C is
MAX. HOT
condition (when
the load by A/C is
low)
System voltage
Engine: Warm, idle

(radiator fan: OFF)
Headlamp: OFF to ON
Rear defogger switch: OFF to ON
Brake lamp: ON
Voltage rises by 0.2 - 3.5 V.
Engine: Warm, idle

(radiator fan: OFF)
Headlamp: OFF to ON
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
45
Control relay
(Power supply)
Ignition switch: OFF
System voltage
Ignition switch: ON
0 - 3V
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
0.3 - 3.0V
60
Oxygen sensor heater
Engine: Idling after warming up
0 - 3V
Engine r/min: 5,000r/min.
System voltage
Engine: Cranking
8V or more
71
13A-69

Normal condition
72
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

sensor
D
D
D
Transmission: 2nd gear <M/T>,

L range <A/T>
Engine r/min: 3,500 r/min or more
Driving with the throttle valve
widely open
0.6 - 1.0 V
76
Engine: Running at 2,500 r/min after

warmed up (Check using a digital type
voltmeter)
0 0.8V
80
Backup power supply
System voltage
81
Sensor impressed
voltage
Ignition switch: ON
4.5 - 5.5V
82
Ignition switch: ON
System voltage
83
Engine coolant
temperature sensor
Ignition switch:
ON
84
85
86
Throttle position
sensor
Barometric pressure
sensor
Ignition switch:
ON
Ignition switch:
ON
D
D
When engine
coolant temperature is 0_C
3.2 - 3.8V
When engine
2.3 - 2.9V
When engine
1.3 - 1.9V
When engine
0.3 - 0.9V
Set throttle valve

to idle position
0.3 - 1.0V
Fully open throttle

valve
4.5 - 5.5V
When altitude is
0m
3.7 - 4.3V
When altitude is
1,200m
3.2 - 3.8V
Ignition switch: ON
Move the vehicle slowly forward
0 5V
13A-70
Normal condition
87
Ignition switch:
ON
Set throttle valve

to idle position
0 - 1V
Slightly open
throttle valve
4V or more
88
89
90
Camshaft position
sensor
Engine: Cranking
0.4 - 3.0V
Engine: Idle speed
0.5 - 2.0V
Crank angle sensor
Engine: Cranking
0.4 - 4.0V
Engine: Idle speed
1.5 - 2.5V
Engine: Idle speed
2.2 - 3.2V
Air flow sensor
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.
13A-71
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
2 - 12
No. 3 injector
15 - 12
No. 4 injector
4 - 12
Stepper motor coil (A1)
17 - 12
5 - 12
Stepper motor coil (B1)
18 - 12
6 - 12
36 - 44 W (At 20_C)
9 - 12
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
5.3 - 6.7 kW (When intake air temperature is 0_C)
28 - 33 W (At 20_C)

83 - 92
5.1 - 6.5 kW (When coolant temperature is 0_C)

87 - 92
Continuity (when throttle valve is at idle position)

No continuity (when throttle valve is slightly open)
91 - Body earth
Continuity (when select lever is at P or N)

No continuity (when select lever is at D, 2, L or R)
13A-72

INSPECTION PROCEDURE USING AN ANALYZER
Analyzer
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.
Special
patterns
pickup
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
T1
The time (cycle time) T is reduced when

the amount of intake air increases.
T
T2
Times T1 and T2 are equal.
Time
Observation conditions (from conditions above engine speed is increased by racing.)

(V)
10
Time
Wave Pattern Observation Points

Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.
13A-73
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 an ignition leak occurs during acceleration,
the wave pattern will be distorted temporarily, even if
the air flow sensor is normal.
Camshaft
connector
position
sensor
Special patterns
pick-up
Crank angle
sensor connector
Analyzer
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.)

Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine r/min
Idle speed
13A-74

2 engine revolutions
(1 camshaft revolution)
(V)
75_BTDC
The time (cycle time) T is

reduced when the engine
speed increases
5_BTDC
Crank angle
sensor output
wave pattern
0
131
49
56 34
Camshaft position sensor output wave pattern
Time
0
No. 1 TDC
No. 3 TDC
No. 4 TDC
No. 2 TDC
TDC: Top dead centre

Check that cycle time T becomes shorter when the engine speed increases.

D Example 1
Cause of problem
is not started.
Example 2
Cause of problem
Loose timing belt
Abnormality in sensor disk
Wave pattern is displaced to the left or right.

Analyzer
13A-75
INJECTOR
Measurement Method
Special
patterns
pickup
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.

1. Connect the analyzer
cylinder.)
cylinder.)
cylinder.)
cylinder.)
special patterns pickup to

(When checking the No. 1
13A-76

Function
Special patterns
Pattern height
Variable
Variable knob
Adjust while viewing the wave pattern
Pattern selector
Display
Engine r/min
Idle speed

(V)
Point A
50
Solenoid back electromotive force
(Approx. 710 V)
Point B
Injector drive time
Power voltage
0
Drive signal: ON
Drive signal: OFF
Time

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
D
--- When idling

- - When racing
The injector drive time will be synchronized with the MUT-II

tester display.
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.
13A-77
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.
Analyzer
Special
patterns
pickup

engine-ECU terminal 4, connection terminal 5, connection
terminal 17, and connection terminal 18 respectively.
Function
Special patterns
Pattern height
High
Pattern selector
Display
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
(V)
30
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
20
Stepper
motor
control
signal
wave
pattern
10
Time
13A-78

Check that the standard wave pattern appears when the stepper motor is operating.
Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal
wave pattern.)
Probable cause
Induced electromotive force does not appear or is extremely small.
Motor is malfunctioning
Point B: Height of coil reverse electromotive force

Probable cause
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.
Open
circuit
side
Example 2
Cause of problem
Open circuit in the line between the stepper motor and
the engine-ECU.
Normal
side
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.
13A-79
IGNITION COIL AND POWER TRANSISTOR

Power transistor control signal
Analyzer
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.
Special
patterns
pickup

engine-ECU terminal 10 (No. 1 - No. 4), terminal 23
(No. 2 - No. 3) respectively.

Observation condition
Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine r/min
Approx. 1,200 r/min

(V)
6
T
75_BTDC
T: Revolution time corresponding to a crank angle of 180_

5_BTDC Compression top dead center
4
Crank angle
sensor output
wave pattern
2
0
4
Power transistor
control signal
2
wave pattern
0
T1
Ignition period
q: Spark
advance
angle
OFF
ON
Dwell section
T1: Time computed by the engine-ECU
Time
13A-80

Point:
Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave
pattern examples 1 and 2.)
Condition of wave pattern build-up section and maximum voltage
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
--- Normal wave pattern

D Example 1
Wave pattern during engine cranking
Cause of problem
2V

Top-right part of the build-up section cannot be seen,
and voltage value is approximately 2V too low.

VB
Example 2
Cause of problem
Malfunction in power transistor
Power voltage results when the power transistor is ON.
MPI <4G6> - On-vehicle Service
ON-VEHICLE SERVICE
13A-81
13100100306
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.
Throttle position sensor (with

built-in idle position switch)
IDLE POSITION SWITCH AND THROTTLE

13100130268
POSITION SENSOR ADJUSTMENT
13A-82
<Vehicles without auto-cruise control system>

Throttle lever

Insert a thickness gauge with a thickness of 0.45 mm
between the fixed SAS and the throttle lever.
Thickness
gauge
Fixed
SAS
2. Insert a thickness gauge as follows:
Fixed SAS
<Vehicles with auto-cruise control system>

Throttle lever
Free
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.
Thickness
gauge
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 ADJUSTMENT
13A-83
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.
Fixed SAS
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 SAS so 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.
13A-84

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
Delivery pipe
Fuel high
pressure
hose
13A-85
13100190303
1. Release residual pressure from the fuel pipe line to prevent

fuel gush out. (Refer to P.13A-88.)
2. Disconnect the fuel high pressure hose at the delivery
pipe side.
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.
High
pressure
hose
Fuel pressure
gauge
O-ring or
gasket
MD998709
MD998742
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.
Delivery pipe
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.
Fuel pump
drive connector
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
13A-86

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
D
D
Clogged fuel filter
Replace fuel filter
Fuel leaking to return side due to poor

fuel regulator valve seating or settled
spring
Replace fuel pressure regulator
Low fuel pump delivery pressure
Replace fuel pump
Binding valve in fuel pressure

regulator
Clogged fuel return hose or pipe
Clean or replace hose or pipe
Damaged vacuum hose or clogged

nipple
Replace vacuum hose or clean nipple
Fuel pressure too low

Fuel pressure drops after racing
No fuel pressure in fuel return
hose
Fuel pressure too high
Same fuel pressure when vacuum

hose is connected and when
disconnected
13A-87
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.
Symptom
Probable cause
Remedy
Fuel pressure drops gradually after

engine is stopped
Leaky injector
Replace injector
Leaky fuel regulator valve seat
Fuel pressure drops sharply

immediately after engine is stopped
Check valve in fuel pump is held open
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.
13A-88

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 wiring harness and fuel wiring harness
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
Fuel pump
drive connector
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.

COMPONENT LOCATION
13A-89
13100210368
Name
Symbol
Name
Symbol
A/C relay
Engine warning lamp (check engine lamp)
A/C switch
Fuel pump check terminal
Air flow sensor (with intake air temperature

sensor and barometric pressure sensor)
Ignition coil
Control relay and fuel pump relay
Injectors
Crank angle sensor
Detonation sensor
Diagnosis connector
Throttle position sensor (with idle position

switch)
Engine-ECU
13A-90

CONTROL RELAY AND FUEL PUMP RELAY
13100990170
CONTINUITY CHECK
Equipment side
connector
Battery voltage
Terminal No.
1
Fuel
pump
relay and
control
relay
Equipment side
connector
Not supplied
Supplied
INTAKE AIR TEMPERATURE SENSOR CHECK

Air flow sensor
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)

sensor
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 flow sensor
assembly.
ENGINE COOLANT TEMPERATURE SENSOR

13100310242
CHECK
Engine coolant
temperature sensor
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.
13A-91

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.
Equipment side connector
Throttle position
sensor
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.
Throttle position
sensor
TPS equipment
side connector
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.)
13A-92
Equipment side
connector
Oxygen sensor
(front)
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. Warm up the engine until engine coolant is 80_C or higher.
MB991223
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.
MB991223
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 oxygen 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
(rear)
13A-93
<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.
MB991223
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.
Injector
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.
13A-94

3. Arrange the special tool (injector test set), adaptor, fuel
pressure regulator and clips as shown in the illustration
below.
High-pressure fuel hose
MD998741
Return hose
MB991607
Pressure regulator
(MD116395)
Injector
Battery
MD998706
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.
Fuel pump
drive connector
Main hose
Return hose
5. Activate the injector and check the atomized spray

condition of the fuel.
The condition can be considered satisfactory unless it
is extremely poor.
Injector
Battery
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 servo
13A-95
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
13A-96
MPI <4G6> - Injector
INJECTOR
13100710332

D Fuel Discharge Prevention (Refer to P.13A-88.)
11
12
10
5, 7
8
3
O-ring
9 Nm
11
10 - 13 Nm
12
Engine oil
Removal steps
3. Purge control solenoid valve connector
"AA 5. High-pressure fuel hose connection
"AA 7.
8.
9.
10.
AA" "AA 11.
12.
AA"
Fuel pressure regulator

Delivery pipe
Insulator
Insulator
Injector
Grommet
O-ring
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.

"AA INJECTOR/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 to the standard torque,
and tighten the fuel pressure regulator to the specified
torque.
Tightening torque:
9 Nm (Fuel pressure regulator)
13A-98
MPI <4G6> - Throttle Body
THROTTLE BODY
13100770132

19 Nm
3
6
Removal steps
3. Idle speed control servo connector
Up

6. Throttle body
"AA 7. Throttle body gasket

"AA THROTTLE 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

DISASSEMBLY AND REASSEMBLY
13A-99
13100970280
6
1
7
5
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.)
13A-100
7
8
6
1
2
5
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.
13A-101

REASSEMBLY SERVICE POINT
"AA THROTTLE 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.
TPS output
TPS power
supply
Earth
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.
13A-102
MPI <6A1> - General Information
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
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 conditions.
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.
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.
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.
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 pump while the engine
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.
13A-103
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
Items
Throttle body
Specifications
Throttle bore mm
60
Accelerator pedal position sensor
Stepper motor type

(Stepper motor type by-pass air control system with the air
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
Semiconductor type
Thermistor type
Thermistor type
Oxygen sensor
Zirconia type
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
Contact switch type
13A-104
Items
Actuators
Specifications
Control relay type
Contact switch type
Fuel pump relay type
Contact switch type
Injector type and number
Electromagnetic type, 6
Injector identification mark
CDH210
Ventilation control solenoid valve
Vacuum control solenoid valve
Fuel pressure Regulator pressure kPa

regulator
329
13A-105

MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM
*1
*2
*3
*4
*5
*6
*7
*8
*9
*10

Air flow sensor
Crank angle sensor
EngineECU
D
D
D
D
D
D
D
D
D
D

A/C switch 1, 2
Inhibitor switch
A/T-ECU
TCL-ECU <TCL>
z1
z2
z3
z4
z5
Injector
<TCL>
z6 Vacuum control solenoid valve <TCL>
D
D
D
D
D
D
D
D
D
D
Fuel pump relay

Control relay
A/C power relay
Engine warning lamp
Diagnosis signal
Ignition coil, power transistor
Fan controller
A/T-ECU
TCL-ECU <TCL>
z6 Vacuum control solenoid

valve <TCL>
z5 Ventiration control solenoid valve <TCL>
Vacuum
tank
*3 Intake air temperature sensor

Air flow sensor (with barometric
z3 Idle speed
pressure sensor)
control servo
Vacuum
actuator
<TCL>
Fuel pressure
regulator
PCV valve
To fuel
tank
*8 Engine
coolant
temperature sensor
Air cleaner
*4, *5
Air
EGR
valve
Throttle
position
sensor (with
idle position
switch)
z1 Injector
z4
From fuel
pump
EGR control
solenoid valve
*9
*2
Canister
z2 Purge control
solenoid valve
*1 Oxygen
sensor
(front)
*10 Oxygen
sensor
(rear)
Distributor
Catalytic converter
*6 Top dead centre sensor
13A-106
MPI <6A1> - Service Specifications/Sealant
13100030346
Items
Specifications
Basic idle speed r/min
65050
Throttle position sensor adjusting voltage mV
Vehicles without TCL
400 - 1,000
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)

resistance kW
20_C
2.3 - 3.0
80_C
0.30 - 0.42

sensor resistance kW
20_C
2.1 - 2.7
80_C
0.26 - 0.36
Oxygen sensor output voltage V
0.6 - 1.0
Fuel pressure kPa
Vacuum hose disconnection
324 - 343 at kerb idle
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
Item
Specified sealant
Remark

threaded portion
Drying sealant
MPI <6A1> - Special Tools
SPECIAL TOOLS
Tool
A
13A-107
13100060345
Number
Name
Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe
D
A:
B:
C:
D:
Fuel gauge simple inspection

Connector pin contact pressure inspection
Commercial tester connection
MB991502
MUT-II sub
assembly
D
D

MPI system inspection
MB991348
Test harness set

MB991709
Test harness
MB991519
Alternator harness
connector
Measurement of voltage during

troubleshooting
MD998463
Test harness
(6-pin, square)
D
D
Inspection of idle speed control servo

MD998478
Test harness
(3-pin, triangle)

13A-108
Tool
MPI <6A1> - Special Tools/Troubleshooting

Number
Name
Use
MD998709
Adaptor hose
Measurement of fuel pressure
MD998742
Hose adaptor
MD998706
Injector test set
MB991607
Injector test
harness
MD998741
Injector test
adaptor
MB991608
Clip
Checking the spray condition of injectors
TROUBLESHOOTING
13100850256

Service Points.
DIAGNOSIS FUNCTION
13100860365

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
Detonation sensor
Injector
Vacuum control solenoid valve <TCL>
Ventilation control solenoid valve <TCL>
Immobilizer system

CODES
Service Points.
ACTUATOR TESTING
13A-110
FAIL-SAFE FUNCTION REFERENCE TABLE
13100910305
Malfunctioning item
Air flow sensor
1.
2.
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.
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.
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 from ignition 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).
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>.
13A-111
13100870382
Code No.
Diagnosis item
Reference page
11
Oxygen sensor (front) system
13A-112
12
Air flow sensor system
13A-113
13
13A-113
14
13A-114
21
13A-115
22
13A-116
23
13A-117
24
13A-118
25
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
13A-112

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
D
Check the oxygen sensor (front). (Refer to P.13A-196.)
NG
Malfunction of the oxygen sensor (front)

Replace
OK
1. NG
Measure at the oxygen sensor (front) connector C-46.
harness side.
2. NG
OK: System voltage
OK: Continuity
3. NG
OK: Continuity
OK
NG
C-46, C-39

oxygen sensor (front) and the control
C-39
Repair
NG
(front) connector.
OK

the oxygen sensor (front) connector.
NG

Repair
OK
Repair
OK
OK
NG
NG

oxygen sensor (front) and the earth,
NG
Repair
or
13A-113

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
D
D
1. NG
Measure at the air flow sensor conCheck the air flow sensor circuit.
nector B-12.
(Refer to P.13A-159, INSPECD Connect the connector. (Use
TION PROCEDURE 49.)
NG
2. NG
(Engine: Idling)
Measure at the engine-ECU conOK: 2.2 - 3.2 V
nector C-33.
OK: 0 - 1 V (Engine: idling)
6 - 9 V (2,000 r/min)
OK: 6 - 9 V
OK
OK

C-33
NG
OK
Malfunction of the air flow sensor

short-circuited harness wire of the air flow sensor

B-12
NG
Repair
OK
NG
Repair

NG
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.
D
D
Check the intake air temperature

sensor.
OK
OK: 4.5 - 4.9 V
OK: Continuity
OK
B-12
NG
Replace
NG

C-39
NG
Repair
OK
NG
NG

the engine-ECU and the intake air
Repair
OK
OK

short-circuited harness wire of the intake air
NG
NG
Repair
13A-114
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.
MUT-II Data list

26 Idle position switch system
OK: With the throttle valve at the
idle position: ON
With the throttle valve slightly open: OFF
NG
OK
Check the throttle position sensor.
NG
D
D
D
D
Malfunction of the throttle position sensor or

maladjustment
short-circuited harness wire of the throttle position
sensor circuit
Improper ON state of idle position switch
Short circuit of the idle position switch signal line

PROCEDURE 28.) <Vehicles without
TCL>
PROCEDURE 29.) <Vehicles with
TCL>
Replace
OK
Measure at the throttle position sensor
connector B-07.
OK: 4.8 - 5.2 V
OK: Continuity
OK
Check the throttle position sensor output circuit. (Refer to P.13A-160, INSPECTION PROCEDURE 50.)
NG

C-39
NG
Repair
OK
NG
engine-ECU and the throttle position
sensor connector.
OK
NG
Repair
13A-115

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
D
D

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
OK: 4.5 - 4.9 V
OK: Continuity
NG

C-39
NG
engine-ECU and the engine coolant
OK
NG
Repair
Repair
OK
OK

B-33
NG
OK

NG
NG
Repair
13A-116
Probable cause
Range of Check
D Engine is cranking.
Set conditions
D
D

D Connect the connector. (Use the test harness: MD998478.)
OK: 0.4 - 4.0 V
OK: 1.5 - 2.5 V
OK

short-circuited harness wire of the crank angle sensor
NG
1. NG
2. NG
OK: System voltage
OK: 4.8 - 5.2 V
3. NG
OK: Continuity
OK
NG
OK
NG
Repair
OK
NG
Repair
NG

the crank angle sensor
connector.
NG
Repair
OK
13A-117

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
D
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
Malfunction of the top dead centre sensor

short-circuited harness wire of the top dead centre
sensor circuit
NG
1. NG
2. NG
OK: System voltage
OK: 4.8 - 5.2 V
3. NG
OK: Continuity
OK
OK
NG
Replace the distributor
NG
Check the harness wire between the top dead centre sensor and
the control relay connector, and repair if necessary.
Repair
OK
NG
Repair
NG

the top dead centre sensor
connector.
NG
Repair
OK
Check the harness wire between the top dead centre sensor and
13A-118
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).
D
D
NG

short-circuited harness wire of the vehicle speed
sensor circuit
Replace
OK
1. NG
Measure at the vehicle speed sensor connector B-66 <M/T>, B-67
<A/T>.
side.
2. NG
OK: System voltage
3. NG
OK: 4.8 - 5.2 V
OK: Continuity
OK
Check the following
connectors:
B-66 <M/T>, B-67 <A/T>
OK
NG
Repair

sensor connector.
OK
NG
Repair

NG
between the vehicle
switch connector.
OK
NG
Repair

NG
Check the following

connectors:
B-65 <M/T>, C-90, C-135,
C-131
OK
NG
Repair
Check the following

connectors:
B-65 <M/T>, C-48, C-39
NG
Repair
OK
NG
sensor connector.
OK
NG
Repair

Check the following
connector:
B-65 <M/T>
NG
Repair
OK
NG
13A-119

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
D

OK: 3.7 - 4.3 V (Altitude: 0 m)
1,200 m)
NG

OK: 4.8 - 5.2 V
OK: Continuity
NG

B-12

C-39
NG
the engine-ECU and the barometric pressure sensor connector.
NG
Repair
OK
NG
NG
the engine-ECU and the baromet- OK
ric pressure sensor connector.
NG

the engine-ECU and the barometric pressure sensor connector, and
OK
C-39
OK
NG
NG
Repair
Repair
OK

OK: 3.7 - 4.3 V (Altitude: 0 m)
1,200 m)
NG
OK
OK
OK
Malfunction of the barometric pressure sensor

short-circuited harness wire of the barometric pressure
sensor circuit
Repair
NG
Repair
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
D
Measure at the detonation sensor connector B-34.

OK: Continuity
OK

B-34, C-39
Malfunction of the detonation sensor

short-circuited harness wire of the detonation sensor
circuit
NG
Repair
OK
NG
NG

engine-ECU and the detonation sensor
connector.

detonation sensor and earth, and repair
if necessary.
OK
Replace the detonation sensor.

NG
NG
Repair
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
D
Check the injector. (Refer to P.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
OK
Check the injector control circuit.
PROCEDURE 51.)
NG
Malfunction of the injector

short-circuited harness wire of the injector circuit

B-02, B-03, B-05, B-36, B-40, B-44.
OK
NG
NG
Repair

engine-ECU and the injector connector,
13A-121

Probable cause
Range of Check
Set Conditions
D Improper communication between the engine-ECU and immobilizer-ECU
D
D
D
D
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.
Yes

NG
No
Is a diagnosis code output from the immobilizer-ECU?
Yes
No
C-37, C-81, C-68
NG

Repair
OK
NG
NG
OK

NG
Repair
NG
13A-122
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
D
Check the oxygen sensor (rear). (Refer to P.13A-197.)
NG
Malfunction of the oxygen sensor (rear)

Replace
OK
1. NG
Measure at the oxygen sensor (rear) connector C-85.
harness side.
2. NG
OK: System voltage
OK: Continuity
3. NG
OK: Continuity

oxygen sensor (rear) and the control
C-39
NG
(rear) connector.
OK

C-85, C-39
Repair
OK
NG
the oxygen sensor (rear) connector.
OK
Replace the oxygen sensor (rear).
NG
NG
Repair
OK
OK
NG
NG
Repair

oxygen sensor (rear) and the earth, and
NG
Repair
or
13A-123

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
D
D
Check the following connectors.

(C-30, C-37) <Vehicles without TCL>,
(C-28, C-35) <Vehicles with TCL>
NG
Malfunction of the harness wire and the connector

Repair
OK
NG
Check the harness wire between the engine-ECU and the A/T-ECU
connector.
OK
NG
Repair
NG
Code No. 64 Alternator FR Terminal System
Probable cause

D The alternator FR terminal signal voltage remains high for approximately 20 seconds
while the engine is running.
D
D

(Engine: Idling)
(Radiator fan: Stopped)
(Headlamp: OFF ON)
OK: 1.8 - 2.4 1.0 - 1.6 V
OK
Open circuit in alternator FR terminal circuit

NG
OK: 4.8 - 5.2 V
OK
NG
NG
NG
Repair
and the alternator connector.
NG
Replace the alternator.
Repair
OK
NG
OK
OK
Check the harness wire between the engine-ECU and the alternator
connector.
Check the following

connectors: B-31, C-37
NG
Repair
OK
NG
Repair
13A-124
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
D
Check the vacuum control solenoid valve.

OK
Measure at the vacuum control solenoid valve connector B-78.
D Disconnect the connector and measure at the
harness side.
OK: System voltage
NG
Malfunction of the vacuum control solenoid valve

short-circuited harness wire of the vacuum control
solenoid valve
Replace
NG
Check the harness wire between the vacuum control

solenoid valve connector and the control relay connector, and repair if necessary.
OK
harness side.
OK: System voltage
NG

B-78
OK
NG
OK
C-35
NG
Repair
Check the harness wire between the engine-ECU

and the vacuum control solenoid valve connector,
OK
NG
NG
Repair
13A-125

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
D
Check the ventilation control solenoid valve.

OK
Measure at the ventilation control solenoid valve
connector B-79.
harness side.
OK: System voltage
NG
Malfunction of the ventilation control solenoid valve

short-circuited harness wire of the ventilation control
solenoid valve
Replace
NG
Check the harness wire between the control relay

and the ventilation control solenoid valve connector,
OK
harness side.
OK: System voltage
NG

B-79
OK
NG
OK
C-35
NG
Repair
Check the harness wire between the engine-ECU

and the ventilation control solenoid valve connector,
OK
NG
NG
Repair
13A-126

Trouble symptom
13100880361
Inspection
procedure
No.
Reference page
Communication
with MUT-II
II is
impossible.
13A-128
Communication with engine-ECU only is not possible.
13A-129
Engine warning
lamp and
related parts
13A-130
The engine warning lamp remains illuminating and never goes

out.
13A-130
Starting
13A-131

13A-132
Long time to start (improper starting)
13A-133
13A-134
13A-135
10
13A-136
11
13A-137
When the engine becomes hot, it stalls at idling. (Die out)
12
13A-138
13
13A-139
14
13A-139
15
13A-140
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
22
13A-143
23
13A-144
24
13A-144
Fans (radiator fan, A/C condensor fan) are inoperative
25
13A-145
Idling stability
(Improper idling)
Idling stability
(Engine stalls)
Driving
13A-127

PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)
Items
Starting
Idling
stability
Symptom
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.
Hunting
Engine speed doesnt remain constant; changes at idle.
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.
Driving
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.
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 now traveling, or a temporary drop
in vehicle speed (engine speed)
during such acceleration.
Serious hesitation is called sag.
Hesitation
Normal
Vehicle Initial acspeed celerator
pedal depression
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 acceleration.
Vehicle
speed
Normal
Initial accelerator
pedal depression
Idling
Stumble
Time
13A-128
Items
Driving
Stopping
Symptom
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.
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.
D
D

(16-pin) C-20.
OK: Battery voltage
NG
OK
OK

(16-pin) C-20.
OK: Continuity
OK
Replace the MUT-II.

C-66, (C-63, C-132, C-141) <L.H.>,
(C-62, C-14) <R.H.>
NG

diagnostic connector (16-pin) and earth,

NG
NG
Repair

power supply and diagnostic connector
(16 pin), and repair if necessary.
13A-129

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
D
D
D
Is communication possible between the MUT-II and the immobilizerECU?
No
Yes
Check the following connectors: C-37, C-81, C-68
NG
Malfunction of engine-ECU power supply circuit

connector

Key and Immobilizer.)
Repair
OK
NG
Check the harness wire between engine-ECU and diagnosis connector.
OK
Check the harness wire between engine-ECU and immobilizerECU.
NG
Repair
NG
OK
Repair

earth.
NG
Repair
OK
Check the power supply and ignition switch-IG system. (Refer to
13A-130
Probable cause
Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp
D
D
D
MUT-II Data list

16 Engine-ECU power supply voltage (Refer to P.13A-163.)
OK
D Earth the terminal No. 36.
NG
OK

Check the following

connector: C-35.
NG
Repair
OK
NG
Check a burnt-out bulb.
Burnt-out bulb
NG
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
OK
NG
NG
Repair
Check the harness wire between combination meter and engineECU, and repair if necessary.
goes out.
Probable cause
In cases such as the above, the cause is probably that the engine-ECU is detecting
occurred.
Yes

No
D Disconnect the engine-ECU connector
OK: No continuity
OK
NG

engine-ECU

CODES
Check the harness wire between combination meter and engineECU connector, and repair if necessary.
13A-131
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
D
D
D
D
D

OK: 8 V or higher
OK
Is immobilizer-ECU diagnosis code displayed?
NG
Yes
No

Malfunction of the fuel pump system
Malfunction of the injectors
Malfunction of the immobilizer system
Check the immobilizer.

(Refer to GROUP 54 - Ignition Key and Immobilizer.)
MUT-II: Inspection of no initial combustion.

OK
OK
OK
D Check the immobilizer system.
NG
Check the injector system. (Refer to P.13A-120, INSPECTION

13A-132
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
D
D
D
D

OK: 8 V or higher
NG

Poor compression
OK
MUT-II: Check if uncompleted combustion occurs.
OK
NG
OK
Is starting good if the engine is cranked with the accelerator pedal
slightly depressed?
Yes
No
Check the injector system, (Refer to P.13A-120, INSPECTION

Check ISC servo for operation sound.
OK
D
D

OK: Approx. 5_BTDC
OK
D Check fuel lines for clogging.
NG
NG
Check the ISC servo system. (Refer to P.13A-151,


13A-133
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
D
D
D
Check battery voltage when cranking

OK: 8 V or higher
NG

Inappropriate gasoline use
Poor compression
OK
OK
OK
OK: Approx. 5_BTDC
OK
NG
NG

13A-134
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
D
D
D
D
D
D

No
No
Does idling speed fluctuate excessively?
No
OK
Yes
Yes
Yes
NG
NG
OK

Malfunction of the purge control solenoid valve system
Malfunction of the EGR solenoid valve system
Poor compression
Drawing air into exhaust system

CODES.

OK
(Refer to GROUP 11B - On-vehicle Service.)
OK
D Check the operation of the power steering control valve.
NG
13A-135
Probable cause
In such cases as the above, the cause is probably that the intake air volume during
idling is too great.
D
D
Yes

No
OK
MUT-II Data list
NG
NG
OK
MUT-II Data list

NG
OK
MUT-II Data list
NG


CODES.
<Vehicles with TCL>

(Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)
OK
NG

13A-136
Probable cause
In cases such as the above, the cause is probably that the intake air volume during
idling is too small.
D
D
Yes

No
OK
MUT-II Data list
NG
NG
OK
MUT-II Data list

NG
OK
MUT-II Data list
NG


CODES.
(Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles
without TCL>
with TCL>

Check the ignition switch ST and inhibitor switch system <A/T>.
OK
NG

13A-137

Probable cause
In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate
when the engine is cold, or that the intake air volume is insufficient.
D
D
D
D

No
Yes
Yes
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
ISC servo system

throttle body
injector system
ignition system

CODES.
No
Yes
No
Is engine-idling stable after the warming-up?
No
Yes
NG
OK
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list

OK
NG
NG

area.

fixed SAS.
Check if the unstable idling (Rough idling, hunting).

without TCL>
with TCL>

OK
OK
OK
D Check the engine oil viscosity.
NG
13A-138
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
D
D
D
D

No
No
Yes
Yes
NG
OK
NG
OK
Yes
No
Does the engine stall easily again?
No
Yes
MUT-II: Engine stalling inspection when the engine is warm and
idling. (Refer to P.13A-155, INSPECTION PROCEDURE 43.)
OK

OK
NG

Improper connector contact

CODES.
area.

fixed SAS.
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 Primary and secondary
D Air flow sensor signal
ignition signal
D Injector drive signal
D Fuel pump drive signal
D Engine-ECU power supply
voltage
13A-139
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.
D
D
Yes

No
NG


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
Probable cause
In cases such as the above, the cause is probably that the intake air volume is insufficient
due to a defective idle speed control (ISC) servo system.

No
No
MUT-II Data list
Yes
Yes
NG
OK
MUT-II Data list

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)?
No
OK
D Clean the throttle valve area.
D Check and adjust the fixed SAS.
NG
Yes
NG

CODES.
without TCL>
with TCL>
Check the throttle position sensor system. (Refer to P.13A-114,
Check the vehicle speed sensor system. (Refer to P.13A-119, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)

13A-140
Probable cause
In cases such as the above, the cause is probably that ignition system, air/fuel mixture
or compression pressure is defective.
D
D
D
D
D
Yes

No
NG
OK
NG

Poor compression

CODES.
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.
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

No
D Check for occurrence of ignition leak.

CODES.
13A-141
The feeling of impact or vibration when decelerating.
Probable cause
Malfunction of the ISC system is suspected.
D
Yes

No
OK
MUT-II Data list
NG
NG

CODES.
OK
MUT-II Data list
NG
OK

without TCL>
with TCL>
Poor acceleration
Probable cause
Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc.
are suspected.
D
D
D
D
D
Yes

No
NG
OK
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
NG

Poor compression pressure
Clogged exhaust system

CODES.
13A-142
Surge
Probable cause
Defective ignition system, abnormal air-fuel ratio, etc. are suspected.
D
D
D
Yes

No
NG
OK
NG


CODES.
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
D
Yes

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
Defective detonation sensor

Inappropriate heat value of the spark plug

CODES.
Check the detonation sensor system. (Refer to P.13A-120, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 31.)
Yes
D Spark plugs
Dieseling
Probable cause
Fuel leakage from injectors is suspected.
Check the injectors for fuel leakage.
Fuel leakage from injectors
13A-143

Probable cause
Abnormal air-fuel ratio is suspected.
D
D
Yes

No
OK
MUT-II Data list
21 Engine coolant temperature sensor. (Refer to P.13A-163.)
NG
NG
OK
MUT-II Data list
NG
OK
MUT-II Data list
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
NG
Malfunction of the air-fuel ratio control system

Deteriorated catalyst

CODES.

Check the intake air temperature sensor system. (Refer to
13.)
OK
MUT-II Data list
11 Oxygen sensor (front)
OK: 600 - 1,000 mV when racing suddenly (Refer to
P.13A-162.)
OK
MUT-II Data list
OK: Repeat 0 - 400 mV and 600 - 1,000 mV alternately when
idling. (Refer to P.13A-162.)
NG
OK
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.
NG
OK
Replace the oxygen sensor (front).

NG
13A-144
Probable cause
The alternator may be defective, or malfunctions, which are listed in the right column,
may be suspected.
D
D
D
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
OK
Measure at the alternator connector.

B-38
D Disconnect the engine-ECU connector.
OK: No continuity
OK
alternator and the engine-ECU connector.
Malfunction of charging system

Short circuit in harness between alternator G terminal
and engine-ECU
NG
NG

alternator and the engine-ECU connector, and repair if necessary.
Repair
OK
Check the alternator. (Refer to GROUP

16 - Charging System.)
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
D

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)]
NG
OK
Malfunction of the A/C control system


C-37
OK
NG
Repair

NG
13A-145

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
D
D
D

side.
D Connect a jumper cable between 21 and earth (Ignition
switch: ON)
OK: Fan stops
OK
Check the following
connector:
C-33
OK
NG
NG
Malfunction of the fan motor relay

Malfunction of the fan motor
Malfunction of the fan controller

and the fan controller connector.
NG
Repair
OK
Check the radiator fan
and condenser fan circuit.
(Refer to GROUP 14 Troubleshooting.)
Repair

NG
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
D
D
D
D
Check the control relay. (Refer to P.13A-193.)
NG

Malfunction of the control relay
Disconnected engine-ECU earth wire
circuit
or
Replace
OK
D Voltage between 3, 4 and earth
OK: System voltage
OK
NG
Check the following

connector: B-30
NG
Repair
OK
NG
Check the harness wire between battery and control relay connector,
13A-146
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
D
D
D
Check the fuel pump operation. (Refer to P.13A-191.)
NG
OK
Check the fuel pump relay. (Refer to P.13A-193.)
OK
D MUT-II Actuator test: Fuel pump drive
OK: System voltage
NG
NG
Malfunction of the fuel pump relay

Malfunction of the fuel pump
circuit
or
Check the fuel pump circuit.

Replace

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
D
D
D
D
NG

Maladjustment of the idle position switch and throttle
position sensor
OK
Measure at the throttle position sensor connector B-07.
OK: 4 V or higher
OK: Continuity
OK
Check the following
connector: B-07
OK
NG
NG
Repair
NG
Check the following

connector: C-39
NG
Repair
OK
NG
sensor connector.
OK
NG
Repair
13A-147

Idle position switch system <Vehicles with TCL>
Probable cause
D
D
D
D
D
NG

Maladjustment of the idle position switch and
accelerator pedal position sensor
Replace the accelerator pedal position sensor.
OK
Measure at the accelerator pedal position sensor connector B-41.
OK: 4 V or higher
OK: Continuity
OK
Check the following
connector: B-41
NG
NG
Repair
Check the following

connector: C-39
NG
Repair
OK
NG
Check the harness wire between engine-ECU and accelerator pedal
position sensor connector.
OK
OK
NG
Repair
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.
D
D
1. NG
2. NG
OK: 8V or more
OK: Continuity
OK
Check the following
connector: C-39
OK
NG
NG
Repair

Check the following

connector: C-92
NG
open
circuit
or
Repair
OK
NG
Check harness wire between the engine-ECU
NG
Repair
OK

Check the harness wire between engine-ECU connector (terminal
No. 91) and earth, and repair if necessary.
13A-148
Ignition switch-ST and inhibitor switch system <A/T>
Probable cause
D
D
D
The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine
is cranking.
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.
Check the inhibitor switch.

OK
NG
1. NG
Measure at the inhibitor switch connector B-72.
2. NG
OK: System voltage
OK: Continuity
D Ignition switch: START
D Disconnect engine-ECU connector.
3. NG
OK: System voltage
OK
Check the following
connector: B-72
NG
Repair
OK

OK
open
circuit
or
Replace

NG
Repair
OK
Check harness wire between inhibitor switch connector and starter
S terminal, and repair if necessary.
Check the
connector:
C-92
following
NG
Repair
OK

NG

Malfunction of inhibitor switch
Malfunction of the engine-ECU.
NG

Repair
NG
Check harness wire between inhibitor switch and
NG
Repair
OK
13A-149

Power steering fluid pressure switch system
Probable cause
The presence or absence of power steering load is input to the engine-ECU.

D
D
D
Check the power steering fluid pressure switch.

NG
Malfunction of power steering fluid pressure switch

Replace
OK
Measure at the power steering fluid pressure switch connector
B-76.
OK: System voltage
OK
Check the following
connector: B-76
NG
Check the following

connector: C-35
Repair
OK
NG
NG
NG
Repair

power steering fluid pressure switch connector.
OK
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
D
D
D

NG
Malfunction of A/C control system

Malfunction of A/C switch
circuit
or
Replace
OK
NG
Measure at the engine-ECU connectors C-33, C-35.
D Voltage between 8 and earth, and 45 and earth
OK
Check the following

OK
NG
NG
Replace
13A-150
Ignition circuit system
Probable cause
The engine-ECU interrupts the ignition coil primary current by turning the power transistor
inside the engine-ECU ON and OFF.
D
D
D
D
1. NG
2. NG
OK: System voltage
OK: Continuity
OK
Check ignition coil and power transistor unit circuit. (Refer to
Malfunction of ignition switch.

Malfunction of power transistor
Check the following

NG
open
circuit
or
Repair
OK
NG
between distributor and
NG
Repair
OK
Check the harness wire between distributor connector and earth,
13A-151

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
D
D
Check the ISC servo

NG
Malfunction of ISC servo

open
circuit
or
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 connector, 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
OK
Check the following
connector: C-33
NG
NG
Check the following

connector: B-10
NG
Repair
OK
NG
Repair
OK
Check harness wire between engine-ECU and ISC servo connector,

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
D
D
Check the purge control solenoid valve.

OK
Measure at the purge control solenoid valve connector B-04.
OK: System voltage
NG
NG

open
circuit
or
Replace
OK
OK: System voltage
OK
Check the following
connector: C-33
OK
NG
NG
NG
Check the following

connector: B-04
NG
Repair
OK
Repair
NG
13A-152
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.
D
D
D
Check the EGR control solenoid valve.

OK
Measure at the EGR control solenoid valve connector B-06.
OK: System voltage
NG
NG

open
circuit
or
Replace
OK
OK: System voltage
OK
Check the following
connector: C-33
NG
NG
Check the following

connector: B-06
NG
Repair
OK
Repair
NG
OK


NG
MUT-II: Inspection of no initial combustion
MUT-II Data list
16 Voltage of engine-ECU power source (Refer to P.13A-163.)
OK
Does the camshaft rotate at the engine cranking?
(When oil filler cap is removed.)
Yes
No
MUT-II Data list
22 Crank angle sensor
OK: Cranking speed is displayed.
OK
OK
MUT-II Data list
NG
No
Yes
No
NG
NG
Check the power supply and ignition switch-IG system.

Check timing belt for breakage.

CODES.
Check the crank angle sensor system.
13A-153
Does the engine tachometer display the cranking speed?
D Set the tachometer of primary voltage detection type.
OK
OK: Approx. 5_BTDC
NG
NG
Check the ignition circuit system

Check the installation condition of crank angle sensor and timing
belt cover.
Yes

No
OK
MUT-II Data list
NG
NG
OK
MUT-II Data list
18 Ignition switch-ST (Refer to P.13A-163.)
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.
NG

CODE
(Refer to P.13A-115, INSPECTION PROCEDURES FOR DIAGNOSIS CODE 21.)
Check
(Refer
Check
(Refer
the ignition switch-ST system <M/T>.

the ignition switch-ST and inhibitor switch system <A/T>.
13A-154
MUT-II Data list
NG
OK
MUT-II Data list

NG
OK
MUT-II Data list
NG

without TCL>
with TCL>
Check the intake air temperature sensor system. (Refer to
13.)
OK
MUT-II Data list
NG
OK
08 Purge control solenoid valve (Refer to P.13A-167.)
OK
OK
MUT-II Data list
OK: 600 - 1,000 mV
OK
MUT-II Data list
OK: 600 - 1,000 mV during sudden racing
NG
NG
NG
NG

Check the purge control solenoid valve system

OK
MUT-II Data list
idling
OK
MUT-II Data list
NG
NG
OK
MUT-II Data list

OK
MUT-II Data list
OK
MUT-II Data list
45 ISC Servo position (Refer to P.13A-166.)
NG
NG
NG


OK

system.
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.

(Refer to P.13A-149. INSPECTION PROCEDURE 33.)
13A-155

MUT-II: Engine stalling inspection when the engine is warmed up and idling.
MUT-II Data list
NG
OK
MUT-II Data list

NG

without TCL>
with TCL>
OK
MUT-II Data list
NG

OK
MUT-II Data list
OK
OK
MUT-II Data list
OK: 600 - 1,000 mV
NG
NG
NG

OK
MUT-II Data list
NG
OK
MUT-II Data list
idling
OK
MUT-II Data list
NG
NG
OK
MUT-II Data list

OK
MUT-II Data list
OK
MUT-II Data list
34 Air flow sensor reset signal (Refer to P.13A-165.)
OK
MUT-II Data list
45 ISC servo position (Refer to P.13A-166.)
NG
NG
NG
NG


OK

system
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.

Check the air flow sensor system. (Refer to P.13A-113, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 12.)
13A-156
MUT-II: Check if hesitation, sug, stumble or poor acceleration occurs.
MUT-II Data list
NG
OK
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

(Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSTIC CODE 21.)
OK
OK
MUT-II Data list
OK: 600 - 1,000 mV
OK
MUT-II Data list
NG
NG
NG

OK
MUT-II Data list
idling
NG
OK

15 Vacuum control solenoid valve <Vehicles with TCL> (Refer
to P.13A-167.)
OK
16 Ventilation control solenoid valve <Vehicles with TCL>
NG
NG

OK

system
D Broken intake
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
Check the vacuum control solenoid valve system. (Refer to

71.)
Check the ventilation control solenoid valve system. (Refer to
72.)
13A-157

MUT-II Data list
NG
OK
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

OK
OK
MUT-II Data list
OK: 600 - 1,000 mV
OK
MUT-II Data list
NG
NG
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.
13A-158
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
2, 3. NG
5. NG
NG
Repair
OK
OK
4. NG

NG
Repair
OK
OK
Check the following
connectors:
C-33, C-35, C-39
Check the following


NG
Repair
Check the harness wire between engine-ECU and control relay
OK
Check the harness wire between engine-ECU and earth, and repair
if necessary.
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 fuel pump circuit.
Measure at the fuel pump connector E-16.

OK: Continuity
NG

E-11
NG
Repair
OK
OK
NG
Check the following connectors: E-16, E-11, C-123, C-92, B-09
NG
OK
Check the harness wire between fuel pump and earth, and repair
if necessary.
Repair
NG
Check the harness wire between terminal for fuel pump drive and
fuel pump connector.
OK
Replace the fuel pump.
NG
Repair
13A-159

OK: System voltage
NG
NG
Repair
OK
OK
OK: System voltage
NG
OK
OK
Check the following

NG
NG
between fuel pump relay
OK
NG
Repair

Repair
Check the following
connector: C-32

NG
NG
Repair
OK

NG
Check the harness wire between engine-ECU and fuel pump relay
Check air flow sensor (AFS) control circuit.
1. NG
OK: System voltage
2, 3. NG
OK: 4.8 - 5.2 V
OK: Continuity
OK
NG
NG
Repair
OK
NG
NG
Repair
Check the following

connector: C-39

OK
Check the harness wire between the air flow sensor and control

and air flow sensor connector.
OK
NG
Repair
13A-160
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
NG
Repair
OK
NG
sensor connector, and repair if necessary.
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
OK
NG
Check the harness between engine-ECU and injector connector,

OK
NG
NG
Repair
13A-161

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
1. NG
OK: 2 - 7 V
2. NG
OK: No continuity
OK
Check the following connectors, and repair if necessary.
B-42
Check the following

connector: C-33
NG
Repair
OK
NG
and the distributor connector.
NG
Repair
OK
As short circuit occurs between distributor and combination meter
(tachometer), check the harness wire, and repair if necessary.
13A-162
13100890296
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 km or less], the air flow sensor 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
11
Oxygen
sensor
(front)
Engine:After having
warmed up
Air/fuel mixture is
made leaner when
decelerating, and is
made richer when
racing.
12
Air flow
sensor*1
Normal condition
Inspection
procedure
No.
Reference
page
When at 4,000 r/min,

engine is suddenly
decelerated
200 mV or less
Code No.
11
13A-112
When engine is
suddenly raced
600 - 1,000 mV
Engine:After having
warmed up
The oxygen sensor
signal is used to
check the air/fuel
mixture
ratio, and control
condition is also
checked by the ECU.
Engine is idling
400 mV or less
(Changes)
600 - 1,000 mV
Engine is idling
14 - 40 Hz
2,500 r/min
42 - 82 Hz
Engine is raced
Frequency
increases in
response to
racing
Engine coolant
temperature: 80
- 95_C
Lamps, electric
cooling fan and
all accessories:
OFF
Transmission:
Neutral (A/T:
P range)
2,500 r/min
13A-163

Item
No.
Inspection
item
Inspection contents
13
Intake air
temperature sensor
Ignition switch: ON
or with engine
running
14
Throttle
position
sensor
Ignition switch: ON
16
Power
supply
voltage
Ignition switch: ON
18
Cranking
signal
(ignition
switch-ST)
Ignition switch: ON
Engine
coolant
temperature sensor
Ignition switch: ON
or with engine
running
21
Normal condition
Inspection
procedure
No.
Reference
page
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
300 - 1,000 mV
13A-114
Gradually open
Increases in
proportion to
throttle opening
angle
Code No.
14
Open fully
4,500 - 5,500 mV
System voltage
Procedure
No. 25
13A-145
Engine: Stopped
OFF
Engine: Cranking
ON
Procedure
No. 30
<M/T>
Procedure
No. 31
<A/T>
13A-147
<M/T>
13A-148
<M/T>
When engine
coolant temperature
is - 20_C
- 20_C
Code No.
21
13A-115
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
13A-164
Item
No.
Inspection
item
Inspection contents
22
Crank
angle sensor
D
D
D
D
25
26
27
28
29
Barometric
pressure
sensor
Normal condition
Inspection
procedure
No.
Reference
page
Code No.
22
13A-116
Code No.
25
13A-119
Procedure
No.28
<Vehicles
without
TCL>
Procedure
No.29
<Vehicles
with TCL>
13A-146
<Vehicles
without
TCL>
13A-147
<Vehicles
with TCL>
Procedure
No. 32
13A-149
Procedure
No. 33
13A-149
Procedure
No. 31
13A-148
Engine: Cranking
Tachometer:
Connected
Compare the engine

speed readings on
the tachometer and
the MUT-II.
Accord
Engine: Idling
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
At altitude of 0 m
101 kPa
95 kPa
At altitude of 1,200
m
88 kPa
At altitude of 1,800
m
81 kPa
Throttle valve:
ON
Throttle valve:
Slightly open
OFF*2
Steering wheel
stationary
OFF
Steering wheel
turning
ON
Ignition switch: ON
Ignition switch: ON
Check by operating
accelerator pedal
repeatedly
Power
steering
fluid pressure switch
Engine: Idling
A/C switch
Engine: Idling
(when A/C switch is
ON, A/C compressor
should be operating.)
A/C switch: OFF
OFF
A/C switch: ON
ON
Ignition switch: ON
P or N
P or N
D, 2, L or R
D, 2, L or R
Inhibitor
switch
<A/T>
13A-165

Item
No.
Inspection
item
Inspection contents
34
Air flow
sensor
reset signal

warmed up
Volumetric
efficiency
37
38
41
Inspection
procedure
No.
Reference
page
Engine is idling
ON
Code
No.12
13A-113
2,000 r/min
OFF
Engine is idling
15 - 35 %
2,000 r/min
15 - 35 %
Engine is suddenly
raced
Volumetric efficiency increases

in response to
racing
Engine: Cranking [reading is possible

at 2,000 r/min or less]
Tachometer: Connected
Engine speeds
displayed on the
MUT-II and
tachometer are
identical.
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
Engine coolant
temperature:
8095_C
Lamps, electric
cooling fan and
all accessories:
OFF
Transmission:
Neutral (A/T :
P range)
Engine is idling
2.6 - 3.8 ms
2,500 r/min
1.8 - 3.0 ms
When engine is
suddenly raced
Increases
Engine: After
having warmed
up
Timing lamp is
set. (The timing
lamp is set in
order to check
actual ignition
timing.)
Engine is idling
1 - 15_BTDC
2,500 r/min
23 - 43_BTDC
Engine coolant
temperature: 80
- 95 _C
Lights, power
cooling fan and
all accessories:
OFF
Transmission:
Neutral (A/T: P
range)
Crank
angle sensor
Injectors *3
Engine: Cranking
Injectors*4
D
D
44
Normal condition
Ignition
coils and
power
transistors
D
D
13A-166
Item
No.
Inspection
item
Inspection contents
45
ISC
(stepper)
motor
position *5
D
D
D
D
D
D
49
59
A/C relay
Oxygen
sensor
(rear)
Engine coolant
temperature: 80
- 95_C
Lamps, electric
cooling fan and
all accessories:
OFF
Transmission:
Neutral (A/T :
P range)
Idle position
switch: ON
Engine: Idling
When A/C switch
is ON, A/C
compressor
should be
operating

warmed up/Engine is
idling
D
D
Transmission:
2nd gear <M/T>,
L range <A/T>
Drive with
throttle widely
open
Normal condition
Inspection
procedure
No.
Reference
page
A/C switch: OFF
2 - 25 STEP
A/C switch:
OFF ON
Increases by
10 - 70 steps
Increases by
5 - 50 steps
Procedure
No. 33
13A-149
Code No.
59
13A-122
A/C switch:
OFF
Select lever:
N range D
range
A/C switch: OFF
OFF (Compressor
clutch is not
operating)
A/C switch: ON
ON (Compressor
clutch is
operating)
3,500 r/min
600 - 1,000 mV
13100900364
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/
Engine is idling
(Cut the fuel supply to each
injector in turn and check
cylinders which dont affect
idling.)
Idling condition
becomes different
(becomes unstable).
Code No.
41
13A-120
02
Cut fuel to No.

2 injector
03
Cut fuel to No.

3 injector
04
Cut fuel to No.

4 injector
05
Cut fuel to No.

5 injector
06
Cut fuel to No.

6 injector
13A-167

Item
No.
Inspection
item
Drive contents
Inspection contents
Normal condition
Inspection
procedure
No.
Reference
page
07
Fuel pump
Fuel pump
operates and
fuel is recirculated.
Pinch the
return hose
with fingers
to feel the
pulse of the
fuel being
recirculated.
Pulse is felt.
Procedure
No. 27
13A-146
Listen near
the fuel tank
for the
sound of
fuel pump
operation.
Sound of operation is heard.
Engine:
Cranking
Fuel
pump:
Forced
driving
Inspect
according
to both
the above
conditions.
08
Purge
control
solenoid
valve
Solenoid valve
turns from OFF
to ON.
Ignition switch: ON

when solenoid
valve is
driven.
Procedure
No. 36
13A-151
10
EGR
control
solenoid
valve
Solenoid valve
turns from OFF
to ON.
Ignition switch: ON

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.
Ignition switch: ON

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.
Ignition switch: ON

when solenoid
valve is driven.
Code No.
72
13A-125
17
Set to ignition
timing adjustment mode
Engine: Idling
Timing light is set
5_BTDC
21
Fan controller
Drive the fan

motor
Radiator fan and

condenser fan
rotate at high
speed
Procedure
No. 25
13A-145
Ignition switch: ON
13A-168

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
13A-169

Normal condition
No. 1 injector
14
No. 2 injector
While engine is idling after having

warmed up, suddenly depress the
accelerator pedal.
From 11 - 14 V, momentarily
drops slightly
No. 3 injector
15
No. 4 injector
No. 5 injector
16
No. 6 injector
17
Engine: Soon after the warmed up

engine is started
System voltage 0 V
18
EGR control solenoid

valve
Ignition switch: ON
System Voltage
While engine is idling, suddenly depress

From system voltage,

momentarily drops
A/C relay
D
D
System voltage or
momentarily
6V or more 0 - 3V
10
Power transistor unit
0.3 - 3.0V
12
Power supply
Ignition switch: ON
System voltage
Air flow sensor reset

signal
Engine: Idle speed
0 - 1V
6 - 9V
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
Ignition switch: ON
System voltage
Engine: Idle speed
0 - 3V
Engine: Idle speed

A/C switch: OFF ON
25
19
21
22
Fuel pump relay
13A-170
Normal condition
24
Purge control solenoid

valve
Ignition switch: ON
System voltage
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>
Ignition switch: ON
System voltage
36
Engine warning lamp
0 - 3V 9 - 13V
(After several seconds have
elapsed)
37

pressure switch

warming up
When steering
wheel is stationary
System voltage
When steering
wheel is turned
0 - 3V
38
45
54
Control relay
(Power supply)
System voltage
Ignition switch: ON
0 - 3V
A/C switch 1
Engine: Idle speed
D
D
D
D
55
D
D
D
D
57
71
A/C switch 2
D
D
Turn the A/C

switch OFF
0 - 3V
Turn the A/C

switch ON (A/C
compressor is
operating)
System voltage
Engine: Warm, idle (radiator fan:

OFF)
Headlamp: OFF to ON
Brake lamp: ON
Voltage rises by 0.2 - 3.5 V.
Engine: Warm, idle (radiator fan:

OFF)
Headlamp: OFF to ON
Brake lamp: ON
Voltage drops by 0.2 - 3.5 V.
Engine: Idling
Outside
air
temperature:
25_C or more
When A/C is MAX.

COOL condition
(when the load by
A/C is high)
0 - 3V
When A/C is MAX.

HOT condition
(When the load by
A/C is low)
System voltage
Engine: Cranking
8V or more
13A-171

Normal condition
72
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

sensor
D
D
D
Transmission: 2nd gear <M/T>,

L range <A/T>
Engine r/min: 3,500 r/min or more
Driving with the throttle valve widely
open
0.6 - 1.0 V
76
Engine: Running at 2,500 r/min after

warmed up (Check using a digital type
voltmeter)
0 0.8V
80
Backup power supply
System voltage
81
Sensor impressed
voltage
Ignition switch: ON
4.5 - 5.5V
82
Ignition switch: ON
System voltage
83
Engine coolant
temperature sensor
Ignition switch:
ON
84
85
86
Throttle position
sensor
Barometric pressure
sensor
Ignition switch:
ON
Ignition switch:
ON
D
D
When engine
3.2 - 3.8V
When engine
2.3 - 2.9V
When engine
1.3 - 1.9V
When engine
0.3 - 0.9V
Set throttle valve

to idle position
0.3 - 1.0V
Fully open throttle

valve
4.5 - 5.5V
When altitude is
0m
3.7 - 4.3V
When altitude is
1,200m
3.2 - 3.8V
Ignition switch: ON
Move the vehicle slowly forward
0 5V
13A-172
Normal condition
87
Ignition switch:
ON
Set throttle valve

to idle position
0 - 1V
Slightly open
throttle valve
4V or more
88
89
90
Crank angle sensor
Air flow sensor
Engine: Cranking
0.4 - 3.0V
Engine: Idle speed
0.5 - 2.0V
Engine: Cranking
0.4 - 4.0V
Engine: Idle speed
1.5 - 2.5V
Engine: Idle speed
2.2 - 3.2V
Engine r/min: 2,500r/min

91
Ignition switch:
ON
Set selector lever

to P or N
0 - 3V
Set selector lever

to Other than P or
N
8 - 14V
13A-173

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
1 - 12
No. 1 injector
13 - 16 W (At 20_C)
14 - 12
No. 2 injector
2 - 12
No. 3 injector
15 - 12
No. 4 injector
3 - 12
No. 5 injector
16 - 12
No. 6 injector
13A-174
Terminal No.
Inspection item
4 - 12
28 - 33 W (At 20_C)
17 - 12
5 - 12
18 - 12
6 - 12
36 - 44 W (At 20_C)
24 - 12
36 - 44 W (At 20_C)
13 - Body
earth
Engine-ECU earth
Continuity (0 W)
26 - Body
earth
Engine-ECU earth
31 - 12

<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

0.30 - 0.42 kW (When intake air temperature is
80_C)
83 - 92

0.26 - 0.36 kW (When coolant temperature is
80_C)
87 - 92
Continuity (when throttle valve is at idle position)

No continuity (when throttle valve is slightly open)
91 - Body
earth
Continuity (when select lever is at P or N)

No continuity (when select lever is at D, 2, L or R)
13A-175
INSPECTION PROCEDURE USING AN ANALYZER
Analyzer
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.
Special
patterns
pickup

Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine r/min
Idle speed

(V)
10
T1
The time (cycle time) T is reduced when

the amount of intake air increases.
T
T2
Times T1 and T2 are equal.
Time
Observation conditions (from conditions above engine speed is increased by racing.)

(V)
10
Time

13A-176

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 an ignition leak occurs during acceleration,
the wave pattern will be distorted temporarily, even if
the air flow sensor is normal.
Distributor connector
Crank angle
sensor connector
Special patterns
pick-up
Analyzer
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.)

Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine r/min
Idle speed
13A-177

2 engine revolutions (1 camshaft revolution)

75_BTDC
Crank
angle
sensor
output
wave
pattern
The time (cycle time) T is reduced when the

amount of intake air increases.
5_BTDC
35
85
TDC
sensor
output
wave
pattern
Time
No.1 TDC
No.2 TDC
No.3 TDC
No.4 TDC
No.5 TDC
No.6 TDC


D Example 1
Cause of problem
is not started.
Example 2
Cause of problem
Loose timing belt
13A-178

Analyzer
Special
patterns
pickup
Analyzer
Special
patterns
pickup
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

engine-ECU terminal 1. (When checking the No. 1
cylinder.)
cylinder.)
cylinder.)
cylinder.)
cylinder.)
cylinder.)
13A-179

Function
Special patterns
Pattern height
Variable
Variable knob
Pattern selector
Display
Engine r/min
Idle speed

(V)
Point A
50
Solenoid back electromotive force
(Approx. 710 V)
Point B
Injector drive time
Power voltage
0
Drive signal: ON
Drive signal: OFF
Time

Probable cause

appear at all.
Point B: Injector drive time
D
D
--- When idling

- - When racing
The injector drive time will be synchronized with the MUT-II

tester display.
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.
13A-180

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.
Analyzer
Special
patterns
pickup

engine-ECU terminal 4, connection terminal 5, connection
terminal 17, and connection terminal 18 respectively.
Function
Special patterns
Pattern height
High
Pattern selector
Display
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
(V)
30
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
20
Stepper
motor
control
signal
wave
pattern
10
Time
13A-181

Check that the standard wave pattern appears when the stepper motor is operating.
Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal
wave pattern.)
Probable cause
Induced electromotive force does not appear or is extremely small.
Motor is malfunctioning
Point B: Height of coil reverse electromotive force

Probable cause
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.
Open
circuit
side
Example 2
Cause of problem
Open circuit in the line between the stepper motor and
the engine-ECU.
Normal
side
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.
13A-182

Analyzer
IGNITION COIL AND POWER TRANSISTOR

D Ignition coil primary signal
Refer to GROUP 16 - Ignition System.
D Power transistor control signal
Measurement Method
Special
patterns
pickup
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
Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine r/min
Approx. 1,200 r/min
(V)
Crank angle
sensor output
wave pattern
T: Revolution time corresponding

to a crank angle of 180_
T
Compression
top dead centre
4
2
0
Power transistor
6
control signal
wave pattern
Point
Wave build-up section
q: Spark advance angle
4
2
OFF
ON
Dwell section
Time
13A-183

Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern
examples 1 and 2.)
Condition of wave pattern build-up section and maximum voltage
Probable cause
Rises from approx. 2V to approx. 4.5V at the top-right
Normal
2V rectangular wave
Rectangular wave at power voltage
Power transistor malfunction

D Example 1
Cause of problem
2V

Top-right part of the build-up section cannot be seen,
and voltage value is approximately 2 V too low.

VB
Example 2
Cause of problem
Malfunction in power transistor
Power voltage results when the power transistor is ON.
13A-184
MPI <6A1> - On-vehicle Service
ON-VEHICLE SERVICE
13100100313
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
13100130275
without TCL>

(with built-in idle position switch)

<Vehicles without auto-cruise control
system> Throttle lever
Fixed SAS
13A-185
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.
Thickness
gauge
Fixed SAS
<Vehicles with auto-cruise control

system>
Throttle lever
Thickness
gauge

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.
Free lever
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.
13A-186

THROTTLE POSITION SENSOR ADJUSTMENT
13100110040
<Vehicles with TCL>
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
13100140049
<Vehicles with TCL>
Accelerator pedal
position sensor
(with built-in idle
position switch)
<Vehicles without auto-cruise control

system>
Accelerator lever
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.
Thickness
gauge
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.
Throttle lever
<Vehicles with auto-cruise control

system>
Throttle lever
Throttle lever
Thickness
gauge

Accelerator pedal
position sensor
(with built-in idle
position switch)
13A-187
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
Fixed SAS
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.
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 turn.
5. While holding the fixed SAS so 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).
13A-188

BASIC IDLE SPEED ADJUSTMENT
13100180355
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
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.
13A-189
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 from the fuel pipe line to prevent

fuel gush out. (Refer to P.13A-191.)
2. Disconnect the fuel high pressure hose at the delivery
pipe side.
Caution
High pressure hose
Fuel pressure
gauge
O-ring or
gasket
MD998709
MD998742
Delivery pipe
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
13A-190

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
D
D
Clogged fuel filter
Replace fuel filter
Fuel leaking to return side due to poor

fuel regulator valve seating or settled
spring
Low fuel pump delivery pressure
Replace fuel pump
Binding valve in fuel pressure

regulator
Clogged fuel return hose or pipe
Clean or replace hose or pipe
Damaged vacuum hose or clogged

nipple
Replace vacuum hose or clean nipple
Fuel pressure too low

Fuel pressure drops after racing
No fuel pressure in fuel return
hose
Fuel pressure too high
Same fuel pressure when vacuum

hose is connected and when
disconnected
13A-191
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.
Symptom
Probable cause
Remedy
Fuel pressure drops gradually after

engine is stopped
Leaky injector
Replace injector
Leaky fuel regulator valve seat
Fuel pressure drops sharply

immediately after engine is stopped
Check valve in fuel pump is held open
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

Refer to P.13A-88.
13100200242
13A-192
COMPONENT LOCATION
13100210375
Name
Symbol
Name
Symbol
A/C relay
Fuel pump check terminal
A/C switch
Accelerator pedal position sensor (with idle
position switch) <Vehicles with TCL>
R
C

C
M
Air flow sensor (with intake air temperature

sensor and barometric pressure sensor)
Injectors
Control relay and fuel pump relay
Crank angle sensor
Detonation sensor
<Vehicles for Hong Kong and Singapore>
Diagnosis connector
Distributor (with top dead centre sensor and

ignition coil)
Throttle position sensor <Vehicles with TCL>

switch) <Vehicles without TCL>
Vacuum control solenoid valve

<Vehicles with TCL>
Engine-ECU

<Vehicles with TCL>
13A-193
CONTROL RELAY AND FUEL PUMP RELAY

13100990187
CONTINUITY CHECK
Battery voltage
Equipment side
connector
Terminal No.
1
Not supplied
Supplied
Fuel pump relay and control relay
Air flow sensor (with

intake air temperature sensor)
Equipment side
connector

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:
Temperature (_C)
Resistance (kW)
Higher
Smaller

resistance remains unchanged, replace the air flow sensor
assembly.

13100310259
CHECK
Caution
Engine coolant
temperature sensor

resistance.
Standard value:
2.1 - 2.7 kW (at 20_C)
0.26 - 0.36 kW (at 80_C)
replace the sensor.
13A-194

Specified sealant:
3M Nut Locking Part No.4171 or equivalent

13100320283


Normal condition:
position
<Vehicles with TCL>

Equipment
side connector
Equipment
side connector
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
ACCELERATOR PEDAL POSITION SENSOR

13100340012
CHECK <Vehicles with TCL>
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
13A-195

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

13100330279
without TCL>
2. Check the continuity between the throttle position sensor
connector side terminal 1 and terminal 2.
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-184.)
Equipment side
connector
Accelerator pedal
position sensor

<Vehicles with TCL>
13100330286

connector.
2. Check the continuity between the accelerator pedal
position sensor connector side terminal 3 and terminal
4.
Normal condition:
Accelerator pedal
Continuity
Depressed
Non-conductive ( W)
Released
Conductive (0 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.)
13A-196

OXYGEN SENSOR CHECK
Oxygen sensor
(front)
Equipment side
connector
13100510178
<Oxygen sensor (front)>

the special tool (test harness) to the connector on the
oxygen sensor side.
connector.

4. Warm up the engine until engine coolant is 80_C or higher.
MB991223
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.
MB991223
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 oxygen 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.
13A-197

Equipment side
connector
<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.
MB991223
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.
Intermediate harness
side connector
Injector intermediate
harness connector

Injector
Measurement probe
No.1 cylinder
1- 2
No.3 cylinder
1- 3
No.5 cylinder
1- 4
13A-198

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.
MD998741
Return hose
MB991607
Pressure regulator
(MD116395)
Injector
Battery
MD998706
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
Main hose
Return hose
Injector
Battery
5. Activate the injector and check the atomized spray

condition of the fuel.
The condition can be considered satisfactory unless it
is extremely poor.
13A-199
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.
Idle speed
control servo
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.
13A-200

Operation Check
1. Remove the throttle body.
2. Remove the stepper motor.
White
Green
MD998463
Idle
speed
control
servo
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
13A-201
Ventilation control
solenoid valve
Vacuum control
solenoid valve
VENTILATION CONTROL SOLENOID VALVE

13100630041
CHECK <Vehicles with TCL>
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
Battery voltage
Normal condition
Applied
Vacuum maintained
Not applied
Vacuum leaks
5. Measure the resistance between the terminals of the

solenoid valve.
Ventilation control
solenoid valve
Vacuum control
solenoid valve
VACUUM CONTROL SOLENOID VALVE CHECK

13100620048
<Vehicles with TCL>
NOTE
1. Disconnect the vacuum hose (blue stripe, green stripe)
from the solenoid valve.
13A-202

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.
Battery
Battery voltage
Normal condition
Applied
Vacuum leaks
Not applied
Vacuum maintained

solenoid valve.
VACUUM TANK CHECK
<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.
A
B
Vacuum actuator
Rod
VACUUM ACTUATOR CHECK
Throttle valve
13100820042
<Vehicles with TCL>

1. Remove the vacuum hose (green stripe) from the vacuum
actuator and connect a hand vacuum pump 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
Accelerator lever
Throttle lever
13100810049
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.)
13A-203

Vacuum actuator
T-joint
Green stripe
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
POWER STEERING AIR CONTROL VALVE

13101180019
OPERATION CHECK
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 vacuum gauge 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.
13A-204
MPI <6A1> - Injector
INJECTOR
13100710349

<Front bank>
18 Nm
8, 9
10
4
O-ring
13
4
3 Nm
14
Engine oil
9 Nm
6
8
12 Nm
10
7
11
14
13
9
12
Removal steps
1. Engine cover
5. Air pipe assembly mounting bolt
9 Nm
"AA 8. Fuel pressure regulator

"AA 9. Fuel pipe assembly
AA"
10. Delivery pipe
11. Insulator
12. Insulator
AA" "AA 13. Injector
14. Grommets
O-ring
13A-205

<Rear bank>
Post-installation operation
17 - On-vehicle service.)
18 Nm
4
8
3 Nm
4
9
1
2
12
18 Nm
7
12 Nm
13
11
10
16
17
15 18
18 Nm
21
20
14
20
9 Nm
19
15, 16
21
O-ring
17
O-ring
Engine oil
Removal steps
1. Engine cover
4. Vacuum hose
connection
7. Connector bracket mounting bolt
9. Noise condenser mounting bolt
connector
12.
13.
14.
"AA 15.
"AA 16.
AA"
17.
18.
19.
AA" "AA 20.
21.
Air intake plenum

Air intake plenum gasket
Injector connector
High pressure fuel hose connection
Fuel pipe assembly
Delivery pipe
Insulator
Insulator
Injector
Grommets
13A-206

AA" DELIVERY PIPE/INJECTOR REMOVAL
Remove the delivery pipe (with the injectors attached to it).
Caution

"AA INJECTOR/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 to the standard torque,
and tighten the fuel pressure regulator and fuel pipe
assembly to the specified torque.
Tightening torque:
9 Nm (Fuel pressure regulator)
13A-207
MPI <6A1> - Throttle Body
THROTTLE BODY
13100770293

<Vehicles without traction control system>
10 - 13 Nm
4
8
4
3
18 Nm
Removal steps
5.
6.
7.
"AA 8.

Vacuum pipe assembly
Throttle body
Throttle body gasket
13A-208
<Vehicles with TCL and

<Vehicles with TCL>
auto-cruise control system>
10 - 13 Nm
2
8
4
10 - 13 Nm
3
3
2
5
9
4
8
18 Nm
Removal steps
connector
Up
5.
6.
7.
8.
"AA 9.

Throttle body
Throttle body gasket

"AA THROTTLE 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

13A-209
13100970297
<Vehicles without TCL and auto-cruise control system>
7
8
9
1
5
4
2
3
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.
13A-210
10
7
5
2
3
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.
13A-211

<Vehicles with TCL>
3
11
12
11
10
9
7
4
5
6
Disassembly steps
1. Water hose
"AA 3. Accelerator pedal position sensor
4. Idle speed control servo (Stepper motor)
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.)
13A-212
<Vehicles with TCL and auto-cruise control system>

3
11
12
10
9
7
4
5
6
Disassembly steps
1. Water hose
"AA 3. Accelerator pedal position sensor
4. Idle speed control servo (Stepper motor)
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.)
13A-213

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.
Accelerator pedal
position sensor
REASSEMBLY SERVICE POINTS

"AA ACCELERATOR 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) (APS power supply) of the APS connector,
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:
APS power
supply
Earth
APS output
Continuity
Fully closed
Continuity
Fully open
No continuity

closed, turn the APS body clockwise and then check
again.
4. If there is an abnormality, replace the APS.
13A-214

"BA THROTTLE 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.
TPS output
TPS power
supply
Normal condition:
Earth

(Vehicles without TCL only)
Continuity
Fully closed
Continuity
Fully open
No continuity

closed, turn the TPS body anti-clockwise and then check
again.
4. If there is an abnormality, replace the TPS.
13E-1
DIESEL FUEL
CONTENTS
13309000047
Engine Coolant Temperature Sensor

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Accelerator Pedal Position Sensor Check . . . . . 57
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6
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
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 53
Pump Operation Sensor Check . . . . . . . . . . . . . . . 60
Evacuation of Water from Fuel Filter . . . . . . . . . 53
Injection Timing Correction Resistor Check . . . . 60
Evacuation of Air from Fuel Line . . . . . . . . . . . . . 53
Injection Rate Correction Resistor Check . . . . . . 60
Fuel Filter Cartridge Replacement . . . . . . . . . . . . 53
Fuel Cut Solenoid Valve Check . . . . . . . . . . . . . . 60
Accelerator Pedal Position Sensor and Idle

Position Switch 1 Adjustment . . . . . . . . . . . . . . . . 53
Throttle Solenoid Valve Check . . . . . . . . . . . . . . . 60
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
Throttle Actuator Check . . . . . . . . . . . . . . . . . . . . . 61

Injection Nozzle Check and Adjustment . . . . . . . 61
INJECTION PUMP AND NOZZLE . . . . . . . . . 63

THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 68
13E-2
DIESEL FUEL - General Information
GENERAL INFORMATION
13300010063
The electronically-controlled fuel injection system consists of sensors which detect the condition of the
diesel engine, an engine-ECU which controls the system based on signals from these 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.
13E-3
DIESEL FUEL - General Information

DIESEL FUEL SYSTEM DIAGRAM
*1
*2
*3
*4
*5
*6
Pump operation sensor

Crank angle sensor
Boost sensor
Diesel fuel temperature sensor
D
D
D
D
D
D
D
D
D
D

Idle position switch 1
Ignition switch-IG
Ignition switch-ST
A/C switch
Injection timing correction resistor
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
D
D
D
D
D
D
D
Control relay
Solenoid-type spill valve relay
Glow plug relay
A/C power relay
Fan motor relay
Engine warning lamp
Glow indicator lamp
Diagnosis signal
z4 Throttle solenoid valve

z3 EGR solenoid valve
Vacuum pump
Alternator
Air cleaner
Throttle
actuator
z1 Solenoid-type spill valve

*4 Boost sensor
*6 Intake air
temperature
sensor
Throttle valve
EGR valve
Turbocharger
Waste gate actuator

Oxidation catalyst
*5 Diesel fuel temperature

sensor
*1 Pump
operation
sensor
Injection pump
z2 Timing control
solenoid valve
*3 Engine coolant
temperature
sensor
13E-4
DIESEL FUEL - Service Specifications/Sealant
13300030069
Items
Specifications
Accelerator pedal position sensor adjusting voltage mV
530 - 570
Idle position switch 1 check voltage mV
875 - 925
Intake air temperature sensor resistance kW
At 20 _C
2.3 - 3.0
At 80 _C
0.30 - 0.42

resistance kW
At 20 _C
2.1 - 2.7
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
Item
Specified sealant
Remark

threaded portion
Drying sealant
13E-5
DIESEL FUEL - Special Tools
SPECIAL TOOLS
Tool
13300060068
Number
Name
Use
MB991502
MUT-II sub assembly
D
D
MB991348
Test harness set
MD998478
Test harness
(3 pin, triangle)
MB990767
End yoke holder
Fuel injection pump sprocket

holding
MD998719
Crankshaft pulley holder

pin
MD998388
Sprocket puller

Checking the electronicallycontrolled
fuel injection
system
Fuel injection pump sprocket

removal
13E-6
DIESEL FUEL - Troubleshooting
TROUBLESHOOTING
13300370024

Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
DIAGNOSIS FUNCTION
13300380027

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.
Engine warning lamp

Boost sensor
Crank angle sensor
Throttle solenoid valve system
Timing control solenoid valve system
Solenoid-type spill valve system
Immobilizer system
Engine-ECU
13E-7

CODES
Service Points.
ACTUATOR TESTING
FAIL-SAFE/BACKUP FUNCTION TABLE
13300390020
Malfunctioning item
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 the intake air pressure is at a specified value (101 kPa).
Carries out control as if the fuel temperature is 50 _C.
Carries out control as if the engine coolant temperature is at a specified value

(80_C).
Carries out control as if the intake air temperature is at a specified value

(25_C).
Carries out control as if the vehicle is moving.
Controls the injection rate according to the speed reported by the crank angle
sensor.
Crank angle sensor
D
D
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.
Reduces the fuel injection rate.

Fixes the injection timing at a specified value.
13E-8
13300400044
Caution
Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
Code No.
Diagnosis item
Reference page
11
Accelerator pedal position sensor system
13E-9
12
Boost sensor system
13E-10
13
13E-11
14
Diesel fuel temperature sensor system
13E-11
15
13E-12
16
13E-12
17
13E-13
18
Pump operation sensor system (open circuit)
13E-14
19
Pump operation sensor system (intermittent fault)
13E-14
21
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
13E-9

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
D
D
Malfunction of the accelerator pedal position sensor

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
Check the accelerator pedal position sensor. (Refer to P.13E-57.)

OK
connector.
OK: 4.5 - 5.5 V
OK: Continuity
OK
NG
Replace

C-54
OK
Repair
NG
Check the harness wire between the engine-ECU and the accelerator pedal position sensor connector.
OK
NG
Repair
NG
NG
NG

B-41
OK
NG
Repair
Repair the engine-ECU.
13E-10
Code No.12 Boost sensor system
Probable cause

D Open or short circuit is detected in boost sensor circuit for 1 second.
D
D
D
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
OK
Measure at the boost sensor connector

B-50.
measure at the harness side
connector.
OK: 4.8 - 5.2 V
OK: Continuity
Malfunction of the boost sensor

Open or short circuit in boost sensor circuit or poor
connector contact
NG

C-54
OK
NG
Repair

NG
engine-ECU and the boost sensor connector.
OK
OK
B-50
OK
NG
Repair
NG
Repair
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 connector, and repair if necessary.
OK
NG
Repair
OK
NG
Repair

B-50, C-54
Replace the boost sensor.
NG
Repair

engine-ECU and the boost sensor connector.
Check the vacuum hose between the

boost sensor and the intake manifold.
OK
OK
NG
NG

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.
OK
MUT-II Data list

03 Barometric pressure sensor
13E-11
INTERMITTENT MALFUNCTIONS
NG
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
D
Check the diesel fuel temperature sensor. (Refer to P.13E-59.)

OK
Measure at the diesel fuel temperature sensor connector B-62.
connector.
OK: 4.5 - 5.5 V
OK: Continuity
OK
NG
Replace the injection pump.

C-54
OK
Repair
NG
Check the harness wire between the engine-ECU and the diesel
fuel temperature sensor connector.
OK
Repair
NG
NG
NG

B-62
OK
NG
Malfunction of the diesel fuel temperature sensor

Open or short circuit in diesel fuel temperature sensor
circuit or poor connector contact
NG
Repair
13E-12
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
D
Check the engine coolant temperature sensor. (Refer to P.13E-57.)

OK
connector.
OK: 4.5 - 5.5 V
OK: Continuity
NG
NG

Open or short circuit in engine coolant temperature
sensor circuit or poor connector contact
Replace

C-54
OK
NG
Repair
OK
NG

B-33
OK
Check the harness wire between the engine-ECU and the engine
coolant temperature sensor connector.
NG
OK
Repair
NG
Repair
NG
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
D
Check the intake air temperature sensor. (Refer to P.13E-56.)

OK
Measure at the intake air temperature sensor connector B-45.
connector.
OK: 4.5 - 5.5 V
OK: Continuity
OK
NG
Replace

C-54
OK
Repair
NG
Check the harness wire between the engine-ECU and the intake
air temperature sensor connector.
OK
Repair
NG
NG
NG

B-45
OK
NG

Open or short circuit in intake air temperature sensor
NG
Repair

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
D
NG
13E-13

Open or short circuit in vehicle speed sensor circuit
or poor connector contact
Replace
OK
Measure at the vehicle speed sensor connector B-66.
side.
OK: System voltage
OK: 4.8 - 5.2 V
OK: Continuity
OK
2. NG

B-65, C-90, C-135, C-131
OK
NG
Repair
3. NG

NG
OK
NG

B-66, C-53
OK
1. NG
NG
Repair
Repair

NG
Check the harness wire between the engine-ECU and the vehicle
speed sensor connector.
OK
NG
Repair

B-65, C-56, C-53
OK
NG
Repair

NG
Check the harness wire between the engine-ECU and the vehicle
speed sensor connector.
OK
NG
Repair
B-65
OK
NG
Repair

NG
13E-14
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
D
Check the pump operation sensor. (Refer to P.13E-60.)

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
NG
Malfunction of the pump operation sensor

Open or short circuit in pump operation sensor circuit

C-53, B-63
OK
NG
Repair
OK
NG
Check the harness wire between the engine-ECU and the pomp
operation sensor connector, and repair if necessary.
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
D

C-53, B-63
NG
Repair
OK
NG
Check the harness wire between the engine-ECU and the pump
operation sensor connector.
OK
NG
Repair
D
D
Malfunction of the pump operation sensor

Poor contact in pump operation sensor connector or
malfunction of circuit
Malfunction of pump operation sensor circuit shielding

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
D

D Connect the connector. (Use the test harness: MD998478)
OK: 0.4 - 4.0 V
OK: 2.5 - 4.5 V
OK
13E-15

Open or short circuit in crank angle sensor circuit or
poor connector contact
NG
1.NG
connector.
2.NG
OK: System voltage
OK: 4.8 - 5.2 V
3.NG
OK: Continuity
C-53
OK
Repair
OK

B-77
OK
NG
NG
NG
Repair
Check the harness wire between the engine-ECU and the crank
angle sensor connector.
OK
NG
Repair
NG
13E-16
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
D
D

connector.
D Voltage between 51 and earth (Ignition switch: ST)
OK: 8 V or higher
NG
Malfunction of the starter relay

Malfunction of starter relay-related circuit

B-30, A-10
OK
NG
Repair
OK

C-55
OK
NG
NG
Check the harness wire between the engine-ECU and the starter
relay connector.
Repair
OK
NG
Repair
NG
Replace the starter relay.
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
D
D
Malfunction of the idle position switch 1

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.
Check the idle position switch 1. (Refer to P.13E-58.)

OK
connector.
OK: 4 V or higher
OK: Continuity
OK
NG
Replace the accelerator pedal position sensor.

C-54
OK
Repair
NG
Check the harness wire between the engine-ECU and the accelerator pedal position sensor connector.
OK
Repair
NG
NG
NG

B-41
OK
NG
NG
Repair

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
D
D
13E-17
Malfunction of the idle position switch 2

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.
Check the idle position switch 2. (Refer to P.13E-58.)

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
OK
NG
Replace

C-53
OK
Repair
NG
NG
Repair
Check the harness wire between the engine-ECU and the idle
position switch 2 connector.
OK
NG
Repair

NG
NG

B-47
OK
NG
13E-18
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
D
Check the throttle solenoid valve. (Refer to P.13E-60.)
NG
D
D
Malfunction of the throttle solenoid valve

Open or short circuit in throttle solenoid valve circuit
Incorrect vacuum hose routing
Malfunction of the throttle actuator
Replace
OK
NG
Check the throttle actuator. (Refer to P.13E-61.)

OK
Measure at the throttle solenoid valve connector B-49.
connector.
OK: System voltage
OK
connector.
OK: System voltage
NG
NG
Replace
Check the harness wire between the control relay and the throttle
solenoid valve connector, and repair if necessary.

B-49
OK
NG
Repair
OK

C-53
OK
NG
NG
Repair
Check the vacuum hose routing.

NG
Check the vacuum hose routing.
OK
NG
Repair
Check the harness wire between the engine-ECU and the throttle
solenoid valve connector, and repair if necessary.

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
D
Check the timing control solenoid valve. (Refer to P.13E-59.)

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
OK
connector.
OK: System voltage
NG
NG
NG
D
D
D
13E-19
Malfunction of the timing control solenoid valve

Open or short circuit in timing control solenoid valve
Incorrect ignition timing adjustment
Malfunction of the injection pomp

Check the harness wire between the control relay and the timing
control solenoid valve connector, and repair if necessary.

B-56
OK
NG
Repair
OK

C-53
OK
NG
NG
Check the harness wire between the engine-ECU and the timing
control solenoid valve connector, and repair if necessary.
Repair
NG
11 Timing control solenoid valve
OK: Sound of operation can be heard.
OK
NG
13E-20
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
D
D
D
Malfunction of the solenoid-type spill valve

Open or short circuit in solenoid-type spill valve circuit
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.
Check the solenoid-type spill valve. (Refer to P.13E-59.)

OK
Measure at the solenoid-type spill valve connector B-61.
connector.
OK: System voltage
OK
connector.
OK: System voltage
NG
NG
NG

Check the harness wire between the solenoid-type spill valve relay
and the solenoid-type spill valve connector, and repair if necessary.

B-61
OK
NG
Repair
OK

C-53
OK
NG
NG
Check the harness wire between the engine-ECU and the solenoidtype spill valve connector, and repair if necessary.
Repair
NG
01 Solenoid-type spill valve
OK
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
D
D
Check the injection timing correction resistor. (Refer to P.13E-60.)

OK
Measure at the injection timing correction resistor connector B-60.
connector.
OK: 4.5 - 5.5 V
OK: Continuity
NG
NG
13E-21
Malfunction of the injection timing correction resistor

Open or short circuit in injection timing correction
resistor circuit of poor connector contact

C-54
OK
NG
Repair
OK
NG

B-60
OK
Check the harness wire between the engine-ECU and the injection
timing correction resistor connector.
NG
OK
NG
Repair
Repair
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
D
D
Check the injection rate correction resistor. (Refer to P.13E-60.)

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
OK
B-58 <L.H. drive vehicles>, B-59 <R.H. drive vehicles>
OK
NG
NG
NG
Malfunction of the injection rate correction resistor

Open or short circuit in injection rate correction resistor

C-54
OK
Repair
NG
Check the harness wire between the engine-ECU and the injection
rate correction resistor connector.
OK
Repair
NG
NG
NG
Repair
13E-22
Probable cause
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
D
D
D
D
Yes
No
Is a diagnosis code output from the immobilizer-ECU.

No
C-54, C-81, C-66

NG
Yes
NG

Incorrect ID code
Malfunction of the immobilizer-ECU

Repair
OK
NG
NG
OK

NG
Repair
NG
13E-23

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
with MUT-II
II is
impossible.
MUT-II communication with all systems is impossible.
13E-24
MUT-II communication with engine-ECU only is impossible.
13E-24
Engine warning
lamp and related
parts
13E-25

goes out.
13E-25
Starting
No initial combustion (Starting not possible)
13E-26
Poor startability when engine is cold (Poor starting)
13E-26
Poor startability when engine is cold or warm (Poor

starting)
13E-27
Idling speed is low when engine is cold (Improper idling

speed)
13E-27
Idling speed is high (Improper idling speed)
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 stalls)
Engine stops soon after starting
12
13E-29
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
19
13E-33
Fans (radiator fan and A/C condenser fan) are imoperative
20
13E-33
Idling stability
(Improper idling)
13E-24

Communication with MUT-II is impossible. (MUT-II
communication with all systems is impossible.)
Probable cause
diagnosis line.
D
D
Measure at the diagnosis connector

C-20.
OK: System voltage
OK
NG

C-66, C-63, (C-132, C-141) <L.H. drive
vehicles>, (C-62, C-14) <R.H. drive vehicles>
OK
NG
NG
NG

C-20.
OK: Continuity

Repair

power supply and the diagnosis connector, and repair if necessary.

diagnosis connector and the earth, and
OK
Replace the MUT-II.
MUT-II communication with engine-ECU only is impossible.
Probable cause

D No power supply to engine-ECU
D Defective earth circuit of engine-ECU
D Defective engine-ECU
D
D
D
D
Is communication possible between the MUT-II and the immobilizer-ECU.
No
Yes
C-54, C-81, C-68, C-66, C-56 <R.H. drive vehicles>, C-83, C-20
NG
Malfunction of the engine-ECU power supply circuit

connector

Repair
OK
NG
Check the harness wire between the engine-ECU and the diagnosis
connector.
OK
NG
NG
OK
Repair
Check the harness wire between the engine-ECU and the earth
OK
NG
Repair
Repair
Check the engine-ECU power supply and earth circuit. (Refer to
P.13E-34, INSPECTION PROCEDURE 21.)
13E-25
Probable cause
Because there is a burn-out bulb, the engine-ECU causes the engine warning lamp
D
D
D
NG
MUT-II Data list

11 Battery voltage (Refer to 13E-39.)
OK
connector.
D Earth the terminal No.57.
OK
Burn-out bulb
Check the engine-ECU power supply and earth circuit. (Refer to

P.13E-34, INSPECTION PROCEDURE 21.)

C-55
OK
NG
Repair
NG
Check a burn-out bulb.

OK
NG
NG
Replace
connector.
OK: System voltage
NG

C-135, C-131
OK
NG
Repair
OK

D-03, C-90
OK
NG
NG
Check the harness wire between the engine warning lamp and
the ignition switch connector, and repair if necessary.
Repair
NG
Check the harness wire between the combination meter and the
engine-ECU connector, and repair if necessary.
goes out.
Probable cause
In case such as the above, the cause is probably that the engine-ECU is detecting
occurred.
Yes
MUT-II Self-Diagnosis code

Are diagnosis codes output?
No
connector.
OK: No continuity
OK
NG

the engine-ECU
Refer to P.13E-8, INSPECTION CHART FOR DIAGNOSIS

CODES.
Check the harness wire between the combination meter and the
engine-ECU connector, and repair if necessary.
13E-26
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
D
D
D
D
D
Is immobilizer-ECU diagnosis code output?

No
Yes
No
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
of
the
the
the
the
the
the
control system
injection nozzles
injection pump
glow system
immobilizer system
engine-ECU

Carry out MUT-II Data list check and Actuator test.
(Refer to P.13E-38, 42.)
Yes
OK
NG

CODES.
Repair
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
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
D
D
D
D
D
No

Yes
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
of
the
the
the
the
the
the
control system
injection pump
fuel system
air intake system
glow system
engine-ECU

(Refer to P.13E-38, 42.)
OK

CODES.
NG
Repair

D Injection nozzle, fuel filter
D Throttle body assembly
D Starter switch input signal
D Engine oil viscosity
D Injection pump
13E-27

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.
D
D
D
D
D
No

Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
the
the
the
the
the
control system
injection pump
fuel system
air intake system
engine-ECU

(Refer to P.13E-38, 42.)
Yes
OK
NG

CODES.
Repair
D Injection pump
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.
D
D
D
D
No

Yes
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
control system
injection pump
fuel system
engine-ECU

(Refer to P.13E-38, 42.)
OK

CODES.
NG
Repair

D Injection nozzle
D Injection pump
D Fuel filter
13E-28
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
D
D
D
No

Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
control system
injection nozzles
injection pump
engine-ECU

(Refer to P.13E-38, 42.)
Yes
OK
NG

CODES.
Repair
D Injection nozzle
D Injection pump
D Starter switch input signal
Idling speed is low (Improper idling speed)
Probable cause
system.
D
D
D
D
No

Yes
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
control system
injection pump
fuel system
engine-ECU

(Refer to P.13E-38, 42.)
OK

CODES.
NG
Repair

D Injection pump
D Injection nozzle
13E-29

Idling speed is unstable (Rough idling, hunting)
Probable cause
air intake system or glow system.
D
D
D
D
D
D
D
No

Malfunction
Malfunction
Malfunction
Malfunction
malfunction
Malfunction
Malfunction
of
of
of
of
of
of
of
the
the
the
the
the
the
the
control system
injection pump
fuel system
air intake system
glow system
EGR system
engine-ECU

(Refer to P.13E-38, 42.)
Yes
OK
NG

CODES.
Repair
D EGR system
D Injection nozzle
D Valve clearance
D Injection timing
D Air in fuel line
D Injection pump
Engine stops soon after starting
Probable cause
or air intake system.
D
D
D
D
D
No

Yes
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
the
the
the
the
the
control system
injection pump
fuel system
air intake system
engine-ECU

(Refer to P.13E-38, 42.)
OK

CODES.
NG
Repair

D Injection pump
13E-30
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.
D
D
D
D
D
No

Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
the
the
the
the
the
control system
injection pump
EGR system
air intake system
engine-ECU

(Refer to P.13E-38, 42.)
Yes
OK
NG

CODES.
Repair
D Power supply system
D EGR system
D Injection pump
Engine output is too low
Probable cause
air intake system or EGR system.
D
D
D
D
D
D
No

Yes
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
of
the
the
the
the
the
the
control system
injection pump
fuel system
air intake system
EGR system
engine-ECU

(Refer to P.13E-38, 42.)
OK

CODES.
NG
Repair

D EGR system
D Turbocharger
D Injection timing
D Injection pump
13E-31

Abnormal engine knocking occurs
Probable cause
system.
D
D
D
D
No

Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
control system
injection pump
fuel system
engine-ECU

(Refer to P.13E-38, 42)
Yes
OK
NG

CODES.
Repair
D Injection nozzle
D Injection timing
D Injection pump
Abnormally black smoke
Probable cause
air intake system or EGR system.
D
D
D
D
D
D
No

Yes
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
of
the
the
the
the
the
the
control system
injection pump
fuel system
air intake system
EGR system
engine-ECU

(Refer to P.13E-38, 42.)
OK

CODES.
NG
Repair

D Air cleaner
D Injection nozzle
D EGR system
D Turbocharger
D Injection pump
D Injection timing
13E-32
Abnormally white smoke
Probable cause
air intake system, EGR system or glow system.
D
D
D
D
D
D
D
No

Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
of
of
the
the
the
the
the
the
the
control system
injection pump
fuel system
air intake system
EGR system
glow system
engine-ECU

(Refer to P.13E-38, 42.)
Yes
OK
NG

CODES.
Repair
D Injection nozzle
D EGR system
D Turbocharger
D Injection pump
D Injection timing
Hunting occurs while driving
Probable cause
or EGR system.
D
D
D
D
D
No

Yes
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
the
the
the
the
the
control system
injection pump
fuel system
EGR system
engine-ECU

(Refer to P.13E-38, 42.)
OK

CODES.
NG
Repair

D EGR system
D Injection pump
13E-33

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)]
System voltage [(When A/C is MAX. HOT condition (When
the load by A/C is low)]
OK

C-54
OK
NG
Repair

NG
NG
Fans (radiator fan and A/C condenser fan) are imoperative

connector.
D Short circuit between 18 and earth (Ignition switch: ON)
OK: Fan stops.
OK
C-53
OK
NG
Repair
Check trouble symptoms.

NG
NG
Check the harness wire between the engine-ECU and the fan controller connector.
OK
NG
Repair
Check the radiator fan and the condenser fan circuit. (Refer to
GROUP 14 - Troubleshooting.)
13E-34
Check the engine-ECU power supply and earth circuit
NG
Check the control relay. (Refer to P.13E-56.)

OK
connector.
1. Voltage between 2, 3 and earth
OK: System voltage
NG
Replace

B-30
OK
NG
Repair
OK
NG
Check the harness wire between the battery and control relay connector, and repair if necessary.
1.NG
Measure at the engine-ECU connector C-53, C-55.
connector.
2,3 NG
OK: System voltage
4.NG
OK: System voltage
OK: System voltage (When the terminal 59 is earthed)
4. Continuity between 1, 14, 26 and earth
5.NG
OK: Continuity
OK: System voltage
OK

C-92, C-131
OK
NG
Repair

NG
Check the harness wire between the engine-ECU and ignition switch
connector.
OK
NG
Repair

C-53, C-55
OK
NG
Repair

NG

Check the harness wire between the engine-ECU and control relay
Check the harness wire between the engine-ECU and earth, and

C-83, C-66, (C-63, C-132, C-141) <L.H. drive vehicles>, (C-62,
C-14) <R.H. drive vehicles>
OK
NG
Repair

NG
Check the harness wire between the battery and engine-ECU connector, and repair if necessary.
13E-35
Check the solenoid-type spill valve relay circuit.
Check the solenoid-type spill valve relay. (Refer to P.13E-56.)

OK
Measure at solenoid-type spill valve relay connector C-52.
connector.
OK: System voltage
OK
connector.
OK: System voltage (When the terminal 3 is earthed)
NG
NG
NG
Replace
Check the harness wire between the control relay and solenoid-type
spill valve relay connectors, and repair if necessary.

C-52
OK
NG
Repair
OK

C-55
OK
NG
NG
Repair

NG
Check the harness wire between the solenoid-type spill valve relay
and engine-ECU connectors, and repair if necessary.
13E-36
Check the fuel cut solenoid valve circuit.
Check the fuel cut solenoid valve. (Refer to P.13E-60.)

OK
Measure at the fuel cut solenoid valve connector B-55.
connector.
OK: System voltage
NG
NG
Replace

C-52
OK
NG
Repair
OK
Check the connector B-55, and repair if necessary.
NG
Check the harness wire between the fuel cut solenoid valve and
solenoid-type spill valve relay connectors, and repair if necessary.
Check the EGR solenoid valve circuit.
NG
Check the EGR solenoid valve.

OK
Measure at the EGR solenoid valve connector B-06.
connector.
OK: System voltage
OK
connector.
OK: System voltage
NG
NG
Replace
Check the harness wire between the control relay and EGR solenoid
valve connector, and repair if necessary.

B-06
OK
NG
Repair
OK

C-53
OK
NG
NG
Check the harness wire between the engine-ECU and EGR solenoid
valve connector, and repair if necessary.
Repair
NG
13E-37
Check the glow plug relay circuit
Check the glow plug relay. (Refer to GROUP 16 - Glow System.)

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
NG
Replace

C-55
OK
NG
Repair
OK

NG
Check the following connector, and repair if necessary.

B-52
Check the harness wire between the engine-ECU and glow plug
relay connector.
OK
NG
Repair
Check the glow control system.

(Refer to GROUP 16 - Glow System.)
OK
NG
Repair
Check the A/C switch and A/C relay circuit

NG
Replace
OK
Check the A/C variable capacity relay.
NG
Replace
OK
NG
connector.
D Voltage between 52 and earth, and between 53 and earth
OK

C-55
OK
NG
Repair

NG
13E-38
13300420026
Caution
Driving tests always need another personnel.
Item No.
Inspection
item
Inspection contents
01
Intake air
temperature
sensor
Ignition switch: ON
or with engine
running
02
03
04
Barometric
pressure
sensor
Boost sensor
Ignition switch: ON
or with engine
running
Ignition switch: ON
D
D
D
D
Engine coolant
temperature: 80
- 95 _C
Lamps, electric
cooling fan and
all accessories:
OFF
Transmission:
Neutral
Ignition switch:
ON
Normal
condition
Inspection
procedure
No.
Reference
page
Intake air temperature is

- 20 _C
- 20 _C
Code
No.16
13E-12

0 _C
0 _C

20 _C
20 _C

40 _C
40 _C

80 _C
80 _C
Engine coolant
temperature is - 20 _C
- 20 _C
Code
No.15
13E-12
Engine coolant
temperature is 0 _C
0 _C
Engine coolant
temperature is 20 _C
20 _C
Engine coolant
40 _C
Engine coolant
80 _C
At altitude of 0 m
101 kPa
13E-11
95 kPa
Code
No.13
88 kPa
81 kPa
At altitude of 0 m
101 kPa
Code
No.12
13E-10
95 kPa
88 kPa
81 kPa
When the engine is

suddenly raced
Increases
13E-39

Item No.
Inspection
item
Inspection contents
05
Diesel fuel
temperature
sensor
Ignition switch: ON
or with engine
running
Normal
condition
Inspection
procedure
No.
Reference
page
Fuel temperature is
- 20 _C
- 20 _C
Code
No.14
13E-11
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 sensor
When vehicle is
moving
Compare the speeds

displayed on the
speedometer and the
MUT-II.
Identical
Code
No.17
13E-13
07
Pump operation sensor (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 operation sensor (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 position sensor
Ignition switch: ON
Accelerator pedal is
released
480 - 570
mV
Code
No.11
13E-9
Accelerator pedal is fully

depressed
4000 4690 mV
Accelerator
pedal position sensor
(Accelerator
opening
angle)
Ignition switch: ON
Throttle lever: Idle

position
0%
Code
No.11
13E-9
Throttle lever: Fully open

position
100 %
11
Battery
voltage
Ignition switch: ON
System
voltage
12
Solenoidtype spill
valve
Engine: After
having warmed up
Engine: Idling
51.5 66.5 deg
Code
No.44
13E-20
A/C switch OFF ON
Advances
slightly
Timing control solenoid

valve duty
ratio
Engine: After
having warmed up
When engine is
suddenly decelerated
from 3,000 r/min.
Momentarily increases
slightly
Code
No.43
13E-19
10
13
13E-40
Item No.
Inspection
item
Inspection contents
Normal
condition
Inspection
procedure
No.
Reference
page
14
EGR command value
Engine: Idle
44.8 %
Procedure
No.24
13E-36
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 injection rate

command
value
Engine: After
having warmed up
Engine: Idling
3.5 - 12.5
m3/st
A/C switch: OFF ON
Increases
slightly
18
Actual injection timing
Engine: After having warmed up
The same
value as
the injection timing
command
value is
displayed.
Code
No.43
13E-19
19
Injection
timing command value
Engine: After
having warmed up
Engine: Idling
12.6 14.6 deg
Engine: Racing to 3500

r/min or more
Advances
slightly
Radiator fan,
A/C condenser fan
duty ratio
Engine: Idling
When radiator fan and

condenser fan are not
operating
0%
Procedure
No.26
13E-20
When radiator fan and

condenser fan are
operating
5 % or
more
(varies in
accordance
with fan
operating
speed)
20
Engine: After
having warmed up
When engine is
suddenly raced
0%
13E-41

Item No.
Inspection
item
Inspection contents
Normal
condition
Inspection
procedure
No.
Reference
page
41
Idle position
switch 1
(Built into
accelerator
pedal position sensor)
Ignition switch: ON
released
ON
Code
No.23
13E-16
slightly depressed
OFF
Idle position
switch 2
Ignition switch: ON
released
ON
Code
No.24
13E-17
slightly depressed
OFF
Engine: Idling
(When the A/C
switch is on, the
A/C compressor
should be driven.)
A/C switch: ON
ON
Procedure
No.26
13E-37
A/C switch: OFF
OFF
Ignition
switch: ST
Ignition switch: ON
Engine: Stopped
OFF
13E-16
Engine: Cranking
ON
Code
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

having warmed up
A/C switch: ON
ON
13E-37
A/C switch: OFF
OFF
Procedure
No.26
42
43
44
A/C switch
49
Solenoidtype 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
solenoid
valve
Engine: After
having warmed up
Engine: Idling
ON
13E-18
Gently racing
OFF
Code
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 indicator lamp
MUT-II Actuator test: Glow indicator lamp (item

No.15) is driven
ON (for
approx. 6
seconds)
13E-42
13300440022
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 voltage is applied

to glow plug
when glow
plug relay is
ON.
Procedure
No.25
13E-37
03
A/C compressor relay
Turns relay
from OFF to
ON and from
ON to OFF.
A/C compressor clutch

operation
sound can be
heard.
Procedure
No.26
13E-37
Throttle solenoid valve
Turns throttle
solenoid valve
ON.
Engine: 1500
r/min
Throttle valve
opens half
way.
Code No.41
13E-18
Turns throttle
solenoid valve
OFF.
Engine: Idling
Throttle valve
opens fully.
Code No.41
13E-18
08
09
Ignition
switch: ON
A/C
switch: ON
11
Timing control
solenoid valve
Drives timing
control solenoid valve at
94 % duty.
Ignition
switch: ON
Operation
sound can be
heard.
Code No.43
13E-19
13
Solenoid-type
spill valve
Turns solenoid-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 illuminates and
switches OFF.
16
Engine warning lamp
Turns engine
warning lamp
ON and OFF.
Ignition
switch: ON
Engine warning lamp

illuminates
and switches
OFF.
13E-43

Item No.
Inspection
item
Drive contents
Inspection
contents
Normal
condition
Inspection
procedure No.
Reference
page
17
Radiator fan,
A/C condenser 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
13E-44
Terminal No.
Check item
Normal condition
Timing control
solenoid valve
Ignition switch: ON
11 - 13 V
Engine: Idling
3.5 - 7.5 V
Engine: 2,500 r/min
5 - 9V
Solenoid-type spill
valve
Ignition switch: ON
11 - 13 V
When engine is suddenly decelerated from 3000

r/min
0 12.5 V
(varies repeatedly)
and momentarily
increases
Throttle solenoid
valve
Ignition switch: ON
0 - 3V
Crank angle sensor
Between
terminals 10
and 23
Pump operation
sensor
16
EGR solenoid valve
18
19
Fan controller
Engine: Idling
Engine coolant temperature is 40 _C or lower
12 - 15 V
Engine coolant temperature is 80 _C or higher
0 - 3V
Engine: Cranking
0.4 - 4.0 V
Engine: Idling
2.5 - 4.5 V
Engine: Idling
0.2 - 1.0 V
(AC range)
Engine: 2,500 r/min
1.2 - 2.2 V
(AC range)
11 - 13 V
When idling after having warmed up, engine is

suddenly raced.
Momentarily increases
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
Ignition switch: ON
released
0 - 1V
slightly depressed
4 V or higher
13E-45

Terminal No.
Check item
Normal condition
21
Vehicle speed
sensor
D
D
05V
(Varies repeatedly)
25
Ignition switch-IG
Ignition switch: ON
11 - 13 V
31
A/C switch 2
D
D
0 - 3V
Ignition switch: ON
Vehicle is moving forward slowly
Engine: Idling
When A/C is MAX. COOL
Outside air tem- condition (When the load
perature: 25 _C by A/C is high)
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
Ignition switch: ON (when cranking at cold engine)
0.5 - 3.4 V
35
Engine coolant
temperature sensor
Ignition switch: ON
Engine coolant temperature is 0 _C
3.2 - 3.8 V
2.3 - 2.9 V
1.3 - 1.9 V
0.3 - 0.9 V
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
Altitude is 0 m
2.0 - 2.6 V
Altitude is 1,200 m
1.7 - 2.3 V
36
37
Boost sensor
Ignition switch: ON
Ignition switch: ON
38
Sensor applied
voltage
Ignition switch: ON
4.5 - 5.5 V
41
Fuel injection timing

correction resistor
Ignition switch: ON
0.2 - 4.5 V
43
Ignition switch: ON
released
0 - 1V
depressed
4 V or higher
13E-46
Terminal No.
Check item
Normal condition
44
Accelerator pedal
position sensor
Ignition switch: ON
released
0.3 - 0.8 V
Accelerator pedal is fully

depressed
4.2 - 4.5 V
51
Ignition switch-ST
Engine: Cranking
52
A/C switch 1
Engine: Idling
8 V or higher
A/C switch is off
0 - 3V
A/C switch is on (A/C

compressor is operating)
13 - 15 V
53
A/C relay
D
D
Engine: Idling
A/C switch: OFF ON
55
Glow indicator lamp
D
D

0 - 1 V; after approx.
Engine coolant temperature is 40 _C or less 1 second 11 - 13
V (at engine coolant
temperature of 20 _C)
57
Engine warning lamp
0 - 3 V (after
several seconds)
9 - 13 V
59
Control relay
11 - 13 V
Ignition switch: ON
0 - 3V
60
Glow plug relay

(pre-heat time
control)
D
D
61
Backup power
supply
66
A/C variable
capacity relay
D
D
13 - 15 V or momentarily 6 V or more
0 - 3V

9 - 12 V; after
Engine coolant temperature is 40 _C or less approx. 8 seconds
(Pre-glow function check)
0 - 0.5 V (at engine
coolant temperature
of 20 _C)
Engine: Idling
A/C switch: ON
11 - 13 V
Engine coolant temperature is 5 _C or less
0 - 3V
Engine coolant temperature is 5 _C or more
13 - 15 V
71
Solenoid-type spill
valve
Ignition switch: ON OFF
0.39 V (after
approx. 3 seconds)
0V
72
Power supply
Ignition switch: ON
11 - 13 V
13E-47

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
2 - 72
Timing control valve
8 - 12 W (At 20 _C)
4 - 72
36 - 44 W (At 20 _C)
10 - 23
215 - 245 W (At 20 _C)
16 - 72
EGR solenoid valve
11 - 14 W (At 20 _C)
19 - Body earth
Continuity (When accelerator lever is at idle position)

No continuity (When accelerator lever is at slightly open)
13E-48
Terminal No.
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
2.2 - 2.7 kW
35 - 46

sensor
5.1 - 6.5 kW (When engine coolant temperature is 0 _C)

36 - 46
5.3 - 6.7 kW (When intake air temperature is 0 _C)

41 - 46
Injection timing correction

resistor
0.1 - 2.5 kW (At 20 _C)
43 - 46
Continuity (When accelerator lever is at idle position)

No continuity (When accelerator lever is at slightly open)
Analyzer
Special
patterns
pickup
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.
13E-49

Standard Wave pattern
Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine r/min
Idle speed
speed increase
(V) 15 _BTDC
75 _ATDC
Time
0
No.1 TDC
No.3 TDC
No.4 TDC
No.2 TDC

13E-50

D Example 1
Cause of problem
is not started.
Example 2
Cause of problem
Loose timing belt
Analyzer
Special
patterns
pickup
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.

Function
Special patterns
Pattern height
Low
Pattern selector
Display
Engine r/min
Idle speed
13E-51

speed increases Time
(V)
Time


D Example
Cause of problem
Loose timing belt
Incorrect installation of injection pump or pump operation
sensor
Analyzer
Special
patterns
pickup
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 the engine-ECU
side should be connected.)
solenoid-type spill valve connector terminal (2).
13E-52

terminal 3.

Function
Special patterns
Pattern height
Variable
Variable knob
Pattern selector
Display
Engine r/min
Idle speed
(V)
Point B
Point A
10
Solenoid back
electromotive
force
Time

Probable cause

appear at all.
Point B: Solenoid-type spill valve drive cycle

DIESEL FUEL - On-vehicle Service
13E-53
ON-VEHICLE SERVICE
13300120056
EVACUATION OF WATER FROM FUEL FILTER
Water level sensor
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
Hand pump
Air plug
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
Accelerator pedal
position sensor (with
built-in idle position
switch 1)

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.
13E-54

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.
1.
2.
3.
4.
Loosen the tension of the accelerator cable sufficiently.

Connect the MUT-II to the diagnosis connector.
Turn the ignition switch to ON. (but do not start the engine.)
Check the accelerator pedal position sensor output
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.
13E-55

COMPONENT LOCATION
13300470021
Name
Symbol
Name
Symbol
A/C relay
A/C switch
Engine-ECU

(with built-in idle position switch 1)
Boost sensor
Glow indicator lamp
Control relay
Glow plug relay
Crank angle sensor
Diagnosis connector
EGR solenoid valve
Timing control solenoid valve
Solenoid-type spill valve relay
13E-56

CONTROL RELAY AND SOLENOID-TYPE
SPILL VALVE RELAY CONTINUITY CHECK
13300620013
Control
relay and
solenoidtype spill
valve
relay
Battery voltage
Terminal No.
1
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.
Intake air
temperature
sensor

drier.
Normal condition:
Temperature (_C)
Resistance (kW)
Higher
Smaller

resistance remains unchanged, replace the intake air
temperature sensor.
6. Install the intake air temperature sensor and tighten it
13E-57
Engine coolant
temperature sensor

13300500027
CHECK
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

Accelerator pedal
position sensor

13300630016
CHECK
connector.
4.
4.
Normal condition:
Depress the accelerator pedal slowly until fully depressed
position from the idle position.
Changes smoothly in proportion to the opening angle of

the throttle valve.
13E-58

doesnt change smoothly, replace the accelerator pedal
position sensor.
NOTE
For the accelerator pedal position sensor adjustment
procedure, refer to P.13E-53.
APS equipment side connector

Accelerator pedal
position sensor
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:
Accelerator pedal
Continuity
Depressed
Non-conductive
Released
Conductive (0 W)
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:
Accelerator pedal
Continuity
Depressed
Non-conductive
Released
Conductive (0 W)
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.)
13E-59
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
Timing
control
solenoid
valve
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)
13E-60

PUMP OPERATION SENSOR CHECK
13300690014
1. Disconnect the pump operation sensor connector.

INJECTION TIMING CORRECTION RESISTOR

13300700014
CHECK
Injection timing
correction resistor
1. Disconnect the injection timing correction resistor

connector.
Injection rate
correction
resistor
INJECTION RATE CORRECTION RESISTOR

13300710017
CHECK
1. Disconnect the injection rate correction resistor connector.
FUEL CUT SOLENOID VALVE CHECK

Fuel cut
solenoid
valve
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)
13E-61
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.
B
A
Normal condition:
Battery
Jumper wire
Nipple A condition
Normal condition
Connected
Open
Negative pressure
leaks
Closed
Negative pressure
is maintained
Open
Negative pressure
leaks
Disconnected

solenoid valve.
Throttle actuator
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

ADJUSTMENT
13300170020
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
13E-62

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.
13300180023
INJECTION SPRAY CONDITION CHECK
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.
13300190026
NOZZLE FUEL-TIGHT CHECK
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.
13E-63
DIESEL FUEL - Injection Pump and Nozzle
INJECTION PUMP AND NOZZLE
13300210036

D Glow Plug Removal and Installation

(Refer to GROUP 11C.)
29 Nm
9 Nm
9 Nm
49 - 59 Nm
29 Nm
12
15
2
17
29 Nm
14
16
13
78 - 88 Nm
8
4
6
9
9 Nm
24 Nm
19 Nm
10
11
12 - 15 Nm
19 Nm
Fuel injection pump removal steps

3. Fuel main hose connection
4. Control wiring harness connection
AA" "DA 5. Fuel injection pipe
6. Flange
AB"
7. Fuel injection pump sprocket
AB"
8. Fuel injection pump
9. Key
10. Injection pump stay
11. Injection pump bracket stay
35 Nm
AA" "DA
AC" "CA
AC" "CA
AD" "BA
"AA
"AA
Fuel injection nozzle removal steps

5. Fuel injection pipe
12. Nut
13. Fuel return pipe
14. Fuel return pipe gasket
15. Fuel injection nozzle and holder
assembly
16. Holder gasket
17. Nozzle gasket
13E-64

Fuel injection pipe
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.
Nut
Delivery
holder or
nozzle
holder
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.
MB990767
MD998719
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.
MD998388
Caution
(1) When removing the sprocket, care must be taken
not to subject the pump drive shaft to an impact.
(2) After removal, the crankshaft should not be turned.
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.
Nut
Fuel return pipe
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.
Deep socket
wrench
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.
13E-65

Holder gasket
Nozzle gasket
"AA NOZZLE GASKET/HOLDER GASKET

INSTALLATION
Clean the cylinder heads injection nozzle hole, and insert
a new gasket.
"BA FUEL INJECTION NOZZLE AND HOLDER

ASSEMBLY INSTALLATION
Use a deep socket wrench in the same way as during removal
to tighten to the specified torque.
"CA FUEL 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 an attempt is made to tighten the nut without first holding
the fuel return pipe, the pipe may be broken or otherwise
damaged.
"DA FUEL 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.
13E-66
13300350035
2
6
5
Disassembly steps
AA" "AA 1. Retaining nut
2. Nozzle tip
3. Distance piece
4. Retaining pin
39 Nm
5. Pressure spring
6. Shim
7. Nozzle holder body
DISASSEMBLY SERVICE POINT

Deep socket
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.

"AA RETAINING 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.

INSPECTION
Plunger
Nozzle tip
13E-67
13300360038
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.
13E-68
DIESEL FUEL - Throttle Body
THROTTLE BODY
13300760012
1
18 Nm
6 Nm
2
5
3
6
Removal steps
1. Air hose connection
2. Intake air temperature sensor
connector
4.
5.
6.
7.
Air intake fitting

Intake fitting gasket
Throttle body assembly
Intake fitting gasket
13F-1
FUEL SUPPLY
CONTENTS
13509000197
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
13F-2
FUEL SUPPLY - General Information/Special Tool
GENERAL INFORMATION
D
13500010120
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.
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.
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
Tool
13500060088
Number
Name
Use
MB991610
Oil filter wrench
Fuel filter cartridge replacement

13F-3
FUEL SUPPLY - Fuel Tank
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
4
<Petrol-powered
vehicles>
<Diesel-powered
vehicles>
7
6
16
<Petrol-powered ve<Diesel-powered
hicles>
vehicles>
13
15
8
14
11
17
12
10
9
25 Nm
1 <Diesel-powered
vehicles>
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.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Vapour hose
Fuel tank assembly
Fuel wiring harness
Filler hose
Vapour hose
Vapour cap
Valve assembly
Fuel pump assembly
Fuel pipe assembly
Fuel gauge unit assembly
13F-4
FUEL SUPPLY - Fuel tank

"AA HIGH-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.
INSPECTION
13500300104
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, and then remove the 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.)
13F-5
FUEL SUPPLY - Fuel Filter
FUEL FILTER
13500280101

D Reduce the Inner Pressure of Fuel Line and Hose
<Petrol-powered Vehicles>
D Checking for Fuel Leaks
<Petrol-powered vehicles>
8
7
4
3
12 - 14 Nm
5
3 Nm
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.
7.
8.
9.
Fuel filter cartridge

Breather screw
Fuel filter pump body
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.

"AA MAIN HOSE CONNECTION
Insert the main hose as far as the stepped section of the
pipe.
13F-6

"BA HIGH-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.
INSPECTION
Float
13500290043
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

MB991610
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

13500130130
<PETROL-POWERED VEHICLES>
Fuel filter
assembly
Main pipe
36 Nm
High-pressure
fuel hose
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.
13F-7
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 On-vehicle Service.)
(2) Check for leaks when fuel pressure is applied.
NOTES
13H-1
TRACTION
CONTROL SYSTEM
(TCL)
CONTENTS
SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
13609000039
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
System Check Using the TCL Indicator

Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TCL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TCL Operation Check . . . . . . . . . . . . . . . . . . . . . . . 25
STEERING WHEEL SENSOR* . . . . . . . . . . . . 29
Stop Lamp Switch Check . . . . . . . . . . . . . . . . . . . . 27
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
injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering
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 SRS or 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 (*)
13H-2
TCL - General Information
GENERAL INFORMATION
13600010031
For vehicles with 6A13 engine, the TCL system

(slip control and trace control) is available as an
option. This system facilitates 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
SERVICE SPECIFICATION
13600030013
Item
Standard value
Accelerator pedal position sensor resistance kW
3.5 - 6.5
SPECIAL TOOLS
Tool
13H-3
13600060029
Number
Name
Use
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)
TROUBLESHOOTING
13600070039
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
13H-4
TCL - Troubleshooting
13600330014
Code No.
Diagnosis item
Reference page
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 Troubleshooting
74
A/T-ECU communication circuit system
13H-14
76
ABS circuit system
13H-15
73
13H-5
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
D
D
D
MUT-II Data list

11 APS output Open and close
the throttle lever.
OK: Changes smoothly between 300 mV - 5,500
mV
NG
OK
Check the following

connectors:
C-10, B-41, C-39
OK
NG
Replace the TCL-ECU.
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
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
APS
TCL-ECU
engine-ECU
harness or connector

B-41, C-39
NG
Repair
OK
NG
Check the harness between
the APS and the engine-ECU,
NG
Repair
OK
Repair
OK
Check the APS.
(Refer to P.13H-27.)
OK
Measure the voltage at TCLECU connector C-10.
D Disconnect the TCL-ECU
the harness side.
body earth
OK: 0.3 V or more
NG

NG
OK
NG

C-10, C-51, B-41
OK
NG
the APS and the TCL-ECU,
OK

C-10
Replace
NG
Repair
NG
Repair
13H-6
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
D
D
D
D
D
MUT-II Data list

13 TPS output Open and close
the throttle lever.
OK: Changes smoothly between 300 mV - 5,500
mV
OK
Check the APS.

OK
NG
NG

the APS and the TCL-ECU,
Replace
OK
NG
Repair
OK
NG
Replace the TCL-ECU

B-07, C-39
OK
NG
NG
Replace
Repair

the TPS and the engine-ECU,
OK
Measure the voltage at engine-ECU connector C-39.

D Connect the engine-ECU NG
connector.
body earth.
Move the accelerator lever
OK: 0.3 - 1.0 V (Set to idle
position)
4.5 - 5.5 V (Fully open)

C-39
Repair
OK
OK
NG
NG
Measure the voltage at TPS

connector B-07.
D Disconnect
the
TPS NG
the harness side.
body earth
OK: 4.8 - 5.2 V
Check the TPS.

(Refer to GROUP 13A - Onvehicle Service.)
APS
TPS
TCL-ECU
engine-ECU
vacuum actuator

C-10, C-51, B-41
OK
OK
of
of
of
of
of
of
OK
Replace
NG
Vacuum actuator operation inspection (Refer to GROUP
13A - On-vehicle Service.)
Malfunciton
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
NG
NG

B-07, C-39
OK
Repair
NG
NG
Repair

the TPS and the engine-ECU,
NG
Repair
13H-7
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
D
D
D

Is TCL diagnosis code No. 11 output?
Yes
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
APS
TPS
engine-ECU
Code No. 11 APS circuit system

(Refer to P.13H-5.)
No
Check the TPS.
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
Replace
NG
NG

B-07, C-39
OK
NG
OK
Check the harness between the TPS and the engine-ECU,


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
D
D
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
Malfunction of stop lamp switch

Malfunction of TCL-ECU
Check the following

connectors:
C-02, C-65, C-75, C-11
NG
OK
NG
NG
Inspect the harness between stop lamp switch
and the TCL-ECU.
NG
OK
Stop lamp switch installation check (Refer to GROUP 35A - On-vehicle Service.)
NG
Stop lamp switch adjustment (Refer to GROUP 35A - On-vehicle
Service.)
Repair
OK
Replace the stop lamp switch.
Repair
Repair
13H-8
Code No. 24 TCL switch circuit system
Probable cause
This diagnosis code is output if signals are input simultaneously from both the TCL-OFF
and TCL-ON positions because of a short circuit in the TCL switch circuit.
D
D
D
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
Malfunction of the TCL switch

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.
D
D
Measure the voltage at TCL-ECU connector C-11.

D Ignition switch : ON
D Disconnect the TCL-ECU connector and measure at the harness
side.
D Between terminal (35) and body earth
OK: System voltage
OK

Check the
connector:
C-11
following

NG
OK
NG
Check the harness between the ignition switch and the TCL-ECU,
Repair
OK
NG

C-131, C-134, C-66, C-75, C-11
NG
NG
Repair
13H-9
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
D
D
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
Malfunction of control relay


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.
OK
Engine control relay inspection (Refer to GROUP 13A - On-vehicle
Service.)
NG
Repair
13H-10
Code No. 31 Front right wheel speed sensor 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
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
front wheel speed sensor

TCL-ECU
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?
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
Yes
NG
Carry out ABS troubleshooting (Refer to GROUP 35B - Troubleshooting.)

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
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
rear wheel speed sensor

TCL-ECU
ABS-ECU
NOTE
When these diagnosis codes are output, erase the diagnosis code memory after carrying out repairs, and then
output?
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
Yes
NG

OK
A-04, C-10
OK
NG
NG
Repair

13H-11
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
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
rear wheel speed sensor

ABS-ECU
TCL-ECU
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?
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.
Yes
OK

NG
A-04, C-10
NG
OK
NG
Repair

13H-12
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
D
D

Malfunction of steering wheel sensor
NG
OK
Check the following
Measure at TCL-ECU connector C-11.
connectors:
C-11, C-75, C-106
D Connector connected
D Voltage between terminals (32), (40) and (41) and the body NG: Stays at
OK
earth
0V without
OK: Changes between approx. 3 V and approx. 0.5 V when changing
the steering wheel is turned
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
Repair
NG

NG
Check the
connectors:
C-106, C-62
following
NG
Repair
OK
OK

NG
Check the harness between the steering wheel sensor and the
body earth, and repair if necessary.

C-106, C-75, C-11
NG
Repair
OK
NG
Inspect the harness between the steering wheel sensor and the
TCL-ECU.
OK
Replace the steering wheel sensor.
NG
Repair
13H-13
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.
D
D
D

D Voltage between terminals (40) and (41) and the body earth
OK: Changes between approx. 3 V and approx. 0.5 V when
OK
following
NG
Repair

NG
NG
Repair
OK
TCL-ECU.
Check the
connector:
C-11
OK
NG
C-11, C-75, C-106

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
OK

NG

C-106
NG
Check the harness between the steering wheel sensor and the
ignition switch, and repair if necessary.
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
D
D

D Voltage between terminals (32) and the body earth
OK: Changes between approx. 3V and approx. 0.5 V when
OK

Check the
connector:
C-11
following
NG
Repair
OK
NG
NG
C-11, C-75, C-106
NG
Repair
OK
TCL-ECU.
OK
NG
Repair
13H-14
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.
D
D
D

C-10, C-51, C-37
NG

Repair
OK
NG
Inspect the harness between the TCL-ECU and the engine-ECU.
OK
Is a diagnosis code output from the engine-ECU?
NG
Yes
No
Repair
Carry out engine-ECU troubleshooting

(Refer to GROUP 13A - Troubleshooting.)

NG
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
D
D

C- 10, C-51, C-49, C-29, C-30
NG

Malfunction of A/T-ECU
Repair
OK
NG
Inspect the harness between the TCL-ECU and the A/T-ECU.
OK
Is a diagnosis code output from the A/T-ECU?
NG
Yes
No
Repair
Carry out A/T-ECU troubleshooting

(Refer to GROUP 23 - Troubleshooting.)

NG
13H-15
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).
D
D
D

output?
Yes

Malfunction of ABS-ECU
Carry out ABS troubleshooting. (Refer to GROUP 35B - Troubleshooting.)
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.

Trouble symptom
Inspection
procedure No.
Reference page
Communication
II
with the MUT-II
is not possible.
13H-16
Communication with TCL-ECU only is not possible.
13H-17
Malfunction of
TCL indicator
lamp display
None of the TCL indicator lamps (TCL OFF, TCL) illuminate

when the ignition switch is ON.
13H-18
One of the TCL indicator lamps does not illuminate when

the ignition switch is ON (Another lamp does illuminate).
13H-18
TCL OFF indicator lamp remains illuminated even after the

engine is started.
13H-19
TCL remains illuminated even after the engine is started.
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.
13H-20
Malfunction of
TCL operation
TCL illuminates in the TCL operation range, but torque is

not reduced.
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.
TCL OFF indicator lamp flashes after the engine is started.
13H-16
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
D

C-20.
Voltage between terminal (16) and body
earth
OK: System voltage
NG
OK

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>
OK

C-20.
Continuity between terminal (4), (5) and
body earth
OK: Continuity
NG

C-20
OK
OK
NG
Replace the MUT-II.
Malfunction of connector
Malfunction of harness
NG
NG
NG
NG
Repair
Check the harness between the fusible

link No. 2 and diagnosis connector, and
Repair
Check the harness between the diagnosis connector and the earth, and repair
if necessary.
13H-17
(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
D
D
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
OK
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
NG
Repair

C-10, C-11
OK
NG
NG
Repair
Check the harness between the TCLECU and diagnosis connector, and repair if necessary.
Repair

Check the harness between the engine
control relay and TCL-ECU.
OK
NG
OK
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

Malfunction of engine control relay
NG
NG
NG
Check the harness between the TCLECU and the earth, and repair if necessary.
Repair
OK
Check the engine control relay.

(Refer to GROUP 13A - On-vehicle
Service.)
13H-18
None of the TCL indicator lamps (TCL OFF, 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
D
D
Do other warning lamps illuminate when

the ignition switch is at ON position?
No

C-131, C-135, D-03
Yes

Malfunction of indicator lamp bulb
OK
NG
NG
Check the harness between the combination meter and the junction block,
Repair
Is code No.27 output?
No
D-03, C-50, C-11
Yes
NG
Code No.27 TCL-ECU power supply

voltage circuit system (Refer to
P.13H-9.)
Repair
OK
NG
Inspect the harness between the combination meter and the TCL-ECU.
OK
Check if a TCL indicator lamp bulb is
burnt out.
NG
NG
Repair
Replace the lamp bulb.
OK
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
D
Is the bulb of the non-illuminated indicator lamp normal?

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
NG
D-03, C-50, C-11
No
OK
OK
Open circuit in indicator lamp power supply circuit.

Burnt-out indicator lamp bulb
Replace the lamp bulb.
NG
Check the harness between the combination meter and the TCL-ECU, and
13H-19
D
D
TCL OFF indicator lamp remains illuminated even

after the engine is started.
TCL OFF indicator lamp flashes after the engine is
started.
The TCL-OFF indicator is also used as a system warning indicator. If there is a system
abnormality, this indicator will illuminate or flash.
Is the diagnosis code normal?

(Is communication with the MUT-II possible?)
Yes
Does the TCL OFF indicator lamp switch
off when TCL-ECU connector C-11 is
disconnected?
No
D-03, C-50, C-11
No
Yes
OK
Probable cause
D
D
Other system related to the TCL

To trouble symptom inspection procedure 1

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
D
D
Does the TCL indicator remain illuminated when TCL-ECU connector C-11
is disconnected and the ignition switch
is turned to ON?
Yes
D-03, C-50, C-11
NG
Repair
No
OK
Malfunction of TCL indicator power supply circuit

NG
13H-20
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
D
D
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

Malfunction of TCL switch
NG
C-11, C-75, C-98
NG
Repair
OK
NG
Inspect the harnesses between the

TCL-ECU and the TCL switch, and between the TCL switch and the body
earth.
OK
Repair
OK
TCL switch component inspection (Refer to P.13H-28.)
D
D
TCL illuminates in the TCL operation range, but

torque is not reduced.
Engine output is reduced in the TCL non-operation
range (TCL indicator lamp does not illuminate) and
starting and acceleration performance is poor.
In cases such as the above, the electrical system is normal, and the cause is probably
an abnormality in the mechanical system (vacuum actuator).
Probable cause
D
D
D
D
D
D
D
Malfunction of vacuum solenoid valve

Malfunction of ventilation solenoid valve
Malfunction of vacuum actuator
Incorrect vacuum hose connector
Malfunction of throttle link
Malfunction of vacuum tank
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
13H-21
No.
Check item
Check condition
11
APS
Accelerator pedal position

Engine stop
Selector lever position: P
13
15*1
16*1
21
22
23
24
25
TPS
Inhibitor switch
Shift position
Idle switch
Ignition switch
Stop lamp switch
TCL ON switch
TCL OFF switch

Engine stop
Ignition switch: ON
Engine stop
Shift lever position: D

Ignition switch: ON
Normal condition
Fully closed
300 - 1,000 mV
Depressed
Gradually rises from

the above value
Fully open
4,500 - 5,500 mV
Fully closed
300 - 1,000 mV
Depressed
Gradually rises from

the above value
Fully open
4,500 - 5,500 mV
Selector lever: P position
Selector lever: R position
Selector lever: N position
Selector lever: D position
Selector lever: 3 position
Selector lever: 2 position
Selector lever: L position
Driving at constant speed

of 10 km/h in 1 range
1st

2nd

3rd

4th
Depressed
OFF
Released
ON
Ignition switch: ON
ON
OFF
Brake pedal position

Ignition switch: ON
Depressed
ON
Released
OFF
TCL ON switch operation

Ignition switch : ON
Pressed
ON
Released
OFF
TCL OFF switch operation

Ignition switch: ON
Pressed
ON
Released
OFF
13H-22
No.
Check item
Check condition
Normal condition
27
ECU power supply

voltage
Ignition switch: ON
System voltage
31
Front right wheel

speed sensor
Engine running
Selector lever position: D
Vehicle stopped
0 km/h
Driving at 40 km/h
40 km/h
Front left wheel

speed sensor
Engine running
Vehicle stopped
0 km/h
Driving at 40 km/h
40 km/h
Rear right wheel

speed sensor
Engine running
Vehicle stopped
0 km/h
Driving at 40 km/h
40 km/h
Rear left wheel

speed sensor
Engine running
Vehicle stopped
0 km/h
Driving at 40 km/h
40 km/h
40
Engine speed
Ignition switch: ON
Engine: idling
Engine speeds
displayed on the
MUT-II and tachometer are identical.
44
Steering angle
Steering wheel position

Ignition switch: ON
Turned 90_ to the right
R 88 deg or R 92 deg
Turned 90_ to the left
L 88 deg or L 92 deg
Steering straightahead point

learning

Ignition switch: ON
Immediately after ignition

switch is ON
OFF
Immediately after city

driving
ON
Slip control
TCL switch: ON
Driving on low frictional
resistance road
TCL indicator lamp

illuminated
ON
TCL indicator lamp

switched off
OFF
TCL switch: ON
Driving on winding road
TCL indicator lamp

illuminated
ON
TCL indicator lamp

switched off
OFF
32
33
34
45
51
52
Trace control
Steering wheel
sensor (ST-N)

Engine idling
Neutral position
LOW
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 classification
Ignition switch: ON
NORMAL
85
Destination
Ignition switch: ON
EUR*2
74
NOTE
*1: A/T
*2: For Europe
13H-23
CHECK AT ECU TERMINALS
Terminal
No.
Check item
Measurement condition
Normal condition
Diagnosis control
When MUT-II is not connected
Approx. 5 V
When MUT-II is connected
0V
13
Earth
Ignition switch: ON
0V
14
Diagnosis data input
Serial communication with MUT-II
When MUT-II is not connected
1 V or less
A/T-ECU data communication
Engine: Idling
Other than 0 V
Engine-ECU data communication
Engine: Idling
Other than 0 V
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
15
16
17
18
19
20
Wheel speed sensor input (rear left

wheel)
Engine: Idling, Vehicle slowly moving forward
Flashes between 0
V and approx. 5 V
21
Wheel speed sensor input (front

right wheel)
Flashes between 0
V and approx. 5 V
22
Wheel speed sensor input (front

left wheel)
Flashes between 0
V and approx. 5 V
23
Wheel speed sensor input (rear

right wheel)
Flashes between 0
V and approx. 5 V
25
ECU power supply
Ignition switch: ON
Battery voltage
26
Earth
Ignition switch: ON
0V
31
Earth
Ignition switch: ON
0V
13H-24
Terminal
No.
Check item
Normal condition
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
Ignition switch: ON
TCL switch: Pressed to ON side
0 - 2V
Ignition switch: ON
TCL switch: Released
Battery voltage
34
TCL ON switch
35
Ignition switch IG2
Ignition switch: ON
Battery voltage
39
ECU back-up power supply
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 - 2V
Ignition switch: ON
TCL switch: Released
Battery voltage
Ignition switch: ON
Brake pedal depressed
Battery voltage
Ignition switch: ON
Brake pedal released
0 - 2V
During ABS fail
0 - 2V
When ABS is normal
Battery voltage
Ignition switch: ON
Indicator: Extinguished
Battery voltage
Ignition switch: ON
Indicator: Illuminated
0 - 2V
Ignition switch: ON
Indicator: Illuminated
0 - 2V
Ignition switch: ON
Indicator: Extinguished
Battery voltage
43
44
45
46
Stop lamp switch input
ABS fail signal
TCL-OFF indicator
TCL indicator
13H-25
TCL - On-Vehicle Service
ON-VEHICLE SERVICE
13600090035
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

operate
Turn the ignition switch to the ON position.
Start the engine.
TCL OFF mode
Engine is idling.
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.
13H-26
TCL - On-vehicle Service

<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) Inspection should be completed within 20 seconds
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

STOP LAMP SWITCH CHECK
13H-27
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
connector
APS

13600430028
(APS) CHECK
1. Disconnect the APS connector.
2. Measure the resistance between terminals (1) and (4)
of the APS connector.
Throttle body
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.
13H-28
TCL - TCL Switch
TCL SWITCH
13600160033
1
Removal steps
1. Switch bezel
2. TCL switch
INSPECTION
13600170036
TCL SWITCH CONTINUITY CHECK

ON
Neutral
OFF
Switch position
Terminal No.
1
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.
AA"
Removal steps
D Steering wheel and column cover
(Refer to GROUP 37A - Steering
Wheel and Shaft.)
1. Steering wheel sensor
Slit plate
AA" STEERING WHEEL SENSOR REMOVAL
Steering
wheel sensor
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.
INSPECTION
STEERING WHEEL SENSOR CHECK
Refer to P.13H-22.
13600230017
13H-30
TCL - TCL-ECU
TCL-ECU
13600280036

Grove Box, Grove Box Frame, Side Cover and Corner Panel Removal and Installation (Refer to GROUP
52A - Instrument panel.)
5 Nm
3
2
5 Nm
5 Nm
AA"
Removal steps
1. Instrument panel lower passenger side
bracket
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.
Dash wiring
harness
INSPECTION
TCL-ECU CHECK
Refer to P.13H-23.
13600290015
14-1
ENGINE
COOLING
CONTENTS
14109000208
Engine Coolant Replacement . . . . . . . . . . . . . . . . . 10

Concentration Measurement . . . . . . . . . . . . . . . . . . 11
Fan Controller Check . . . . . . . . . . . . . . . . . . . . . . . . 12
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fan Control Relay Continuity Check . . . . . . . . . . 12
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WATER PUMP
Engine Coolant Leak Checking . . . . . . . . . . . . . . . . 9
Radiator Cap Opening Pressure
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
<6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
<4D6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
WATER HOSE AND WATER PIPE . . . . . . . . 19
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
14-2
ENGINE COOLING -
General Information/
Service Specifications/Lubricant/Sealants
GENERAL INFORMATION
14100010217
The cooling system is designed to keep every part

of the engine at appropriate temperature in
whatever condition the engine may be operated.
The cooling method is of the water-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.
Items
Specifications
Radiator
Performance kJ/h
A/T oil cooler
Performance kJ/h
4G6
175,800
6A1
200,900
4D6
213,500
4G6
5,700
6A1, 4D6
7,100
14100030091
Items
Standard value
Limit
Radiator cap opening pressure kPa
74 - 103
64
Range of coolant antifreeze concentration of radiator %
30 - 60
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
Thermostat
LUBRICANT
14100040148
Items
HIGH QUALITY ETHYLENE GLYCOL
ANTIFREEZE COOLANT
Quantity L
4G6, 6A1
4D6
SEALANTS
14100050172
Items
Specified sealant
Remarks
Cylinder block drain plug
Drying sealant
Water pump <6A1>,

Thermostat case assembly <4G6, 4D6>,
Water outlet fitting <4D6>
Mitsubishi Genuine Parts No. MD970389 or

equivalent
Semi-drying sealant
14-3
ENGINE COOLING - Special Tool/Troubleshooting
SPECIAL TOOL
Tool
A
14100060038
Number
Name
Use
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

A: Connector pin contact pressure inspection
B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester connection
TROUBLESHOOTING
14100560019

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>
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>
14-6
Radiator fan does not operate. <Vehicles with A/C>
14-8
Condenser fan does not operate. <Vehicles with A/C>
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
D
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
fusible link
fan control relay
fan controller
engine-ECU
wiring harness or connector
14-4
ENGINE COOLING - Troubleshooting
<Vehicles with A/C>

D
D
Fusible links (4) and (7) check

Fan control relay check (Refer to P.14-12.)
NG
Replace
OK
1. NG
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
2. NG
OK: Battery voltage
2. Voltage between 3 and body earth (Ignition switch: ON)
OK: Battery voltage
3. NG
3. Continuity between 1 and body earth
OK: Continuity
OK
1. NG
Measure at the fan controller connector A-22.
D Disconnect the connector, and measure at the harness side
connector.
2. NG
OK: Battery voltage
OK: Continuity
OK
Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3.
<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)
OK
NG
Check the harness wire between fan control relay and fusible link
(4), and repair if necessary.
Check the harness wire between fan control relay and body earth,
Check the harness wire between fan controller and fan control
relay, and repair if necessary.
Check the harness wire between fan controller and body earth,
Check the harness wire between fan controller and engine-ECU.

OK
NG
Repair
Engine-ECU terminal voltage check (Refer to GROUP 13A - Troubleshooting.)

NG
OK
Replace
Check the automatic compressor-ECU <manual air conditioner>
or A/C-ECU <automatic air conditioner>, and repair if necessary.

<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>
YES
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
NO
Replace the radiator fan motor and fan controller assembly.
14-5

D
D
Fusible links (4) and (7) check

NG
Replace
OK
1. NG
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
2. NG
OK: Battery voltage
OK: Battery voltage
3. NG
OK: Continuity
OK
1. NG
Measure at the fan controller connector A-22.
connector.
2. NG
OK: Battery voltage
OK: Continuity
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
Check the harness wire between fan control relay and body earth,
Check the harness wire between fan controller and fan control
Check the harness wire between fan controller and body earth,

OK
NG
Repair
OK
<Except 4D6>
OK: The radiator fan motor operates.
<4D6>
YES
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
NO
14-6
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
The fan controller carries out step-free control of the radiator fan motor and the condenser
fan motor speeds using signals transmitted from the engine-ECU.
D
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
fan control relay

fan controller
engine-ECU
<Vehicles with A/C>

NG
Replace
OK
D
D
D
Check the harness wire between fan control relay and fusible
link (7).
Check the harness wire between fan control relay and body
earth.
Check the harness wire between fan control relay and fan
controller.
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
NG

NG
OK
Repair

NG
OK
Replace
Check the automatic compressor-ECU <manual air conditioner>

or A/C-ECU <automatic air conditioner>, and repair if necessary.
OK
Fan controller check (Refer to P.14-12.)

OK
Repair
NG

<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.
YES
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
NO
14-7

NG
Replace
OK
D
D
D
Check the harness wire between fan control relay and fusible
link (7).
Check the harness wire between fan control relay and body
earth.
Check the harness wire between fan control relay and fan
controller.
OK

<Except 4D6>
OK: 0 - 0.3 V (Engine: idling)
<4D6>
OK: 0 - 0.3 V (Engine: idling)
OK
Fan controller check (Refer to P.14-12.)
NG
NG
Repair

OK
NG
Repair
NG
OK
<Except 4D6>
OK: The radiator fan motor stops.
<4D6>
OK: The radiator fan motor stops.
YES
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
NO
14-8
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
D
Malfunction of radiator fan motor

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
D
D
Condenser fan motor check (Refer to

GROUP 55.)
OK
Replace the radiator fan motor and fan
controller assembly.
NG
Condenser fan motor connector

OK
Malfunction of condenser fan motor

Malfunction of fan controller
Malfunction of wiring harness or connector
NG
NG
Repair
Replace the condenser fan motor.
ENGINE COOLING - On-vehicle Service
ON-VEHICLE SERVICE
Cap adapter
Adapter
14-9
14100100136
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, when installing and removing the 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
Cap adapter
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.
14-10

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.
<6A1>
<4G6, 4D6>
5. Coat the thread of the cylinder block drain plug with the
specified sealant and tighten to the specified torque.
Specified sealant:
6. Securely tighten the radiator drain plug.
7. Install the reserve tank.
39 Nm
44 Nm
14-11

<6A1>
Water outlet
fitting
Air bleed bolt

12 - 15 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.
Seal washer
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.
14-12

FAN CONTROLLER CHECK
Fan controller
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
Fan control relay
Battery voltage
Terminal No.
1
When current is not

supplied
When current
supplied
is
14-13
ENGINE COOLING - Thermostat
THERMOSTAT
14100240265

D Engine Coolant Draining and Supplying
(Refer to P.14-10.)
D Air Cleaner and Air Intake Hose Assembly Removal
and Installation
<4G6>
Air Hose and Air Pipe Assembly Removal and

Installation <4D6> (Refer to P.14-21.)
4
13 Nm
6
7
3
<6A1>
4
17 - 20 Nm
6
7
3
<4D6>
12 - 15 Nm
13 Nm
12 - 15 Nm
6
1
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
14-14
ENGINE COOLING - Thermostat

AA" RADIATOR LOWER HOSE DISCONNECTION

Jiggle valve
"AA THERMOSTAT 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.
Rubber ring
"BA RADIATOR LOWER HOSE CONNECTION

inlet fitting.
INSPECTION
14100250275
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
Valve lift
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.
14-15
ENGINE COOLING - Water Pump <4G6>
WATER PUMP <4G6>
14100270363

(Refer to P.14-10.)
D Timing Belt Tensioner Pulley Removal
Installation (Refer to GROUP 11.)
and
Bolt specifications
8 60
8 22
1
8 14
8 25
3
20 - 25 Nm
2
24 Nm
2
8 22
Screw diameter length mm
12 - 15 Nm
Removal steps
1. Alternator brace
2. Water pump
3. Water pump gasket
"AA 4. O-ring

Water pump
O-ring
Water inlet pipe assembly
"AA O-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
14-16
ENGINE COOLING - Water Pump <6A1>
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
D

Engine Mount Bracket Removal and Installation (Refer
to GROUP 32.)
Bolt specifications
8 30
8 25
8 25
8 20
39 Nm
24 Nm
4
5
8 30
8 30
49 Nm
f3mm
5
3
12 Nm
8 25
39 Nm
18 Nm
Sealant:
Mitsubishi Genuine Part
AA"
Removal steps
1. Pressure tube connection
3. Power steering oil pump bracket
4. Engine support bracket

"AA 5. Water pump
No.
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.

"AA WATER 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
14-18
ENGINE COOLING - Water Pump <4D6>
WATER PUMP <4D6>
14100270387

(Refer to P.14-10.)
D Timing Belt Idler Pulley Removal and Installation
4
24 Nm
Bolt specifications
8 25
8 22
3
8 65
24 Nm
8 20
12 - 15 Nm
8 22
Removal steps
1. Alternator brace
2. Water pump
3. Water pump gasket
"AA 4. O-ring
Water pump
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
ENGINE COOLING - Water Hose and Water Pipe
WATER HOSE AND WATER PIPE
14-19
14100330306

<4G6>
D Engine Coolant Draining and Suppling
(Refer to P.14-10.)
and Installation
4
2
24 Nm
13 Nm
5
7
10
1
13 Nm
7
12
11
9
f3mm
Sealant:
Mitsubishi Genuine Part No.
Removal steps
AA" "CA 1. Radiator lower hose connection
bolt
3. Water inlet fitting
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
14-20
<6A1>
(Refer to P.14-10.)
and Installation
Distributor Removal and Installation

10 - 12 Nm
22 - 25 Nm
8
1
7
6
13
10
11
4
12 - 15 Nm
16
14
22 - 25 Nm
15
12
12 - 15 Nm
22 Nm
19
39 Nm
17
18
27 - 33 Nm
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
9.
10.
"AA 11.
12.
13.
"AA 14.
15.
"AA 16.
17.
18.
19.

Heater pipe assembly
O-ring
Water hose
O-ring
O-ring
Water hose
Water pipe assembly
Water pipe joint
14-21

<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
17 Nm
11
9
7
10
1
17 Nm
20 - 25 Nm
45 Nm
6 Nm
2
6 Nm
10 - 12 Nm
9 Nm
10 - 13 Nm
12 - 15 Nm
5
4
12 - 15 Nm
12
12 - 15 Nm
10 - 12 Nm
13
12 - 15 Nm
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.
9.
10.
11.
12.
Air pipe bracket stay

Oil pipe assembly
Oil pipe assembly
Vacuum pump assembly
Control wiring harness mounting
bolt
13. Fuel pipe mounting bolt
14-22
24 Nm
10 Nm
18
14
17
27 - 33 Nm
15
16
23
27 - 33 Nm
24
24 Nm
19
13 Nm
13 Nm
22
21
20
10 Nm
17
18
f3mm
f3mm
Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent

14.
15.
16.
"BA 17.
"BA 18.
"AA 19.
Water pipe assembly (A)

Water hose
Water inlet fitting
Water outlet fitting
O-ring
20.
21.
22.
23.
"AA 24.

Water hose
Water pipe assembly (B)
O-ring
14-23

HOSE DISCONNECTION
Thermostat case assembly,

water pump or cylinder block
O-ring
Water inlet pipe assembly or

heater pipe assembly

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
"BA WATER 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
"CA RADIATOR LOWER HOSE/RADIATOR UPPER

HOSE CONNECTION
inlet fitting or water outlet fitting.
INSPECTION
14100340118
WATER PIPE AND HOSE CHECK

Check the water pipe and hose for cracks, damage, clog
and replace them if necessary.
14-24
ENGINE COOLING - Radiator
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/T Fluid Supplying and Checking (Refer to GROUP
D Air Cleaner and Air Intake Hose Assembly
Installation
12 Nm
12 Nm
11
17
18
20
11
19
12
12 Nm
1
5 Nm
9
5
8
16
10
14
5 Nm
15
5 Nm
13
13
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 connection <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 controller 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.

"AA RADIATOR LOWER HOSE/RADIATOR UPPER HOSE
CONNECTION
inlet fitting.
NOTES
15-1
INTAKE AND
EXHAUST
CONTENTS
15109000250
AIR INTAKE PLENUM . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 2
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 13
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . 16
Turbocharger Supercharging Check . . . . . . . . . . . . 3

Waste Gate Actuator Check . . . . . . . . . . . . . . . . . . 3
INTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EXHAUST PIPE AND MAIN MUFFLER . . . . 22
15-2
INTAKE AND EXHAUST -
Service Specifications/Special Tool
GENERAL INFORMATION
15100010061
The intake manifold is made of an aluminium alloy,

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.
15100030197
Items
Standard value
Limit
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

<Vehicles with intercooler
turbocharger>
OFF ON
57 or more
ON OFF
45 or less
SPECIAL TOOL
Tool
15100060066
Number
Name
Use
MD998770
Oxygen sensor
wrench
Removal/Installation of oxygen sensor
INTAKE AND EXHAUST - On-vehicle Service
15-3
ON-VEHICLE SERVICE
15100100072
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.
15-4
INTAKE AND EXHAUST - Intercooler
INTERCOOLER
15100420055
Hose clamp tightening

torque
Pipe installation bolt

tightening torque
10 - 13 Nm
6 Nm
1
2
10 - 13 Nm
10 - 13 Nm
6
11
10
"AA
"AA
"BA
"AA
"AA
"AA
Air hose and air pipe removal

steps
1. Air hose E
2. Air hose B
3. Air hose F
4. Air hose A
5. Air pipe A
6. Air hose C
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

"AA AIR 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.
"BA AIR HOSE F INSTALLATION
Install the hose with its marking (white paint) upward.
15-6
INTAKE AND EXHAUST - Air Intake Plenum
AIR INTAKE PLENUM
15100270124

D Throttle Body Removal (Refer to GROUP 13A.)
D Throttle Body Installation (Refer to GROUP 13A.)
3 Nm
14 Nm
9
4
2
18 Nm
12
10 - 12 Nm
13
15
14
11
9 Nm
10
19 Nm
9 Nm
18 Nm
15
Removal steps
1. Engine cover
2. Crankshaft position sensor connector
8.
9.
10.
11.
12.
13.
"AA 14.
15.
Connector bracket mounting bolt

Noise condenser mounting bolt
EGR valve
Solenoid valve assembly
Air intake plenum
Air intake plenum gasket
Air intake plenum stay
INTAKE AND EXHAUST - Air Intake Plenum
15-7

Protrusion
Front
"AA AIR INTAKE PLENUM GASKET INSTALLATION

Install with gasket protrusions in the position illustrated.
15-8
INTAKE AND EXHAUST - Intake Manifold
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
4
5
2
Removal steps
1. Accelerator cable
connection
connector
15-9

10 - 13 Nm
10
9
10 - 12 Nm
8
7
9 Nm
20 Nm
20 Nm
11
6
13
14
12
20 Nm
31 Nm
AA"
6.
7.
8.
9.
EGR valve
PCV hose
Fuel return hose connection
Delivery pipe, injector and pressure
regulator
10.
11.
12.
13.
14.

Solenoid valve assembly
Intake manifold
Intake manifold gasket
Intake manifold stay
15-10
<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.)
2
3
5
12 Nm
O-ring
Engine oil
4
35 Nm
18 Nm
7
1
8
9
18 Nm
Removal steps
"BA 3. Fuel high-pressure hose connection
AA"
5. Delivery pipe, injector and pressure
regulator
6.
7.
8.
"AA 9.
PCV hose connection

Intake manifold
Intake manifold gasket
15-11
<4D6>
(Refer to P.15-4.)
10 - 12 Nm
18 Nm
12 - 15 Nm
25 Nm
3
4
18 Nm
9
18 Nm
18 Nm
10
12 - 15 Nm
Removal steps
1. Air inlet fitting
3. Vacuum hose
4. Throttle body assembly
5. EGR valve and pipe assembly
7.
8.
9.
D
10.
Rear heat protector

Vacuum hose
Intake manifold
Turbocharger (Refer to P.15-6.)
Intake and exhaust manifold gasket
15-12

AA" DELIVERY PIPE, INJECTOR AND PRESSURE
REGULATOR REMOVAL
Remove the delivery pipe (with the injectors and pressure
regulator attached to it).
Caution
Front
Protrusion

"AA INTAKE MANIFOLD GASKET INSTALLATION
Install gasket with its protrusion in the position illustrated.
Protrusion
Delivery pipe
O-ring
"BA HIGH-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
INSPECTION
15100310161
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
INTAKE AND EXHAUST - Exhaust Manifold
EXHAUST MANIFOLD
15-13
15100330440

D Front Exhaust Pipe Removal and Installation
(Refer to P.15-22.)
<4G6>
3
29 Nm
49 Nm
12 - 15 Nm
49 Nm
Removal steps
1. Exhaust manifold cover
2. Exhaust manifold
3. Exhaust manifold gasket
15-14
<6A1>
12 - 15 Nm
12 - 15 Nm
1
3
49 Nm
12 - 15 Nm
49 Nm
2
34 Nm
2
44 Nm
Removal steps
1. Heat protector
2. Exhaust manifold stay
3. Exhaust manifold
4. Exhaust manifold gasket
15-15
<4D6>
29 Nm
14 Nm
29 Nm
2
3
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
INSPECTION
15100340061
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
15-16
INTAKE AND EXHAUST - Turbocharger
TURBOCHARGER
15100450047

D Engine Oil Draining and Supplying
D Intake Manifold Removal and Installation (Refer to
P.15-8.)
Front Exhaust Pipe and Front Heat Protector Removal

and Installation (Refer to P.15-15, 23.)
25 Nm
17 Nm
18 Nm
10 - 12 Nm
12 - 15 Nm
10 Nm
5
6 Nm
3
27 - 33 Nm
14
11
13
12 - 15 Nm
12
12 - 15 Nm
59 Nm
10 Nm
15
59 Nm
12 - 15 Nm
27 - 33 Nm
59 Nm
9 Nm
10
AA"
AA"
AA"
Removal steps
1. Air hose A
2. EGR valve and pipe assembly
4. Oil pipe assembly A
5. Oil pipe assembly B
6. Water pipe assembly A
7. Water pipe assembly B
8. Oil return pipe
9.
10.
11.
12.
13.
"AA 14.
15.
Rear heat protector

Exhaust fitting heat protector
Turbocharger assembly
Exhaust fitting assembly
Exhaust fitting gasket
Turbocharger
Turbocharger gasket
15-17

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.

"AA TURBOCHARGER 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.
INSPECTION
Compressor
wheel
15100460057
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 problem is 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.
15-18

2
9
10
1
8
7
5
6
3
Disassembly steps
1. Hose clip
2. Hose
3. Snap ring (E-ring)
"FA 4. Turbocharger waste gate actuator
"EA 5. Coupling
"DA 6.
AA" "CA 7.
AB" "BA 8.
9.
"AA 10.
Turbine housing
Snap ring
Turbine wheel assembly
Compressor cover
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.
Snap ring
Caution
When removing the snap ring, hold it with fingers to
prevent it from springing away.
15-19
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.
Turbine
wheel
assembly
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.
O-ring
Dowel pin hole

Dowel pin
Caution
When installing the O-ring, use care not to damage it.
A damaged O-ring causes oil leaks.
"BA TURBINE 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.
Snap ring
Chamfered
edge
"CA SNAP 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
Compressor
cover
15-20

"DA TURBINE HOUSING INSTALLATION
Install the turbine housing while aligning the dowel pin with
the hole.
Dower pin
Caution
Use care not to damage the blades of turbine wheel.
Dower pin hole
"EA COUPLING INSTALLATION

Install the coupling and tighten to the specified torque.
Coupling
"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.
Traces of contact
INSPECTION
15100610025
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.

Oil passage
Turbine wheel
Compressor
wheel
Water passage
15-21
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.
15-22
INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler
EXHAUST PIPE AND MAIN MUFFLER
15100540355

<4G6>
Hanger installation
bolt tightening torque
3, 10, 17
6
13 Nm
13 Nm
4
13 Nm
34 Nm
49 Nm
49 - 59 Nm
34 Nm
16
11
49 Nm
49 - 59 Nm
18
13
13 Nm
14
1
3
2
34 Nm
12
15
44 Nm
10
8
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
15-23

Hanger installation
bolt tightening torque
3, 10, 17
13 Nm
13 Nm
16
49 Nm
49 Nm
11
<6A1>
16
34 Nm
13 Nm
49 - 59 Nm
13 Nm
49 - 59 Nm
14
3
12
49 Nm
2
10
10
49 Nm
13
15
6
17
13 Nm
3
13 Nm
<4D6>
11
16
34 Nm
49 Nm
13 Nm
49 Nm
13
15
1
3
2
8
12
49 Nm
10
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
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
15-24

AA" OXYGEN SENSOR REMOVAL

"AA OXYGEN SENSOR INSTALLATION
MD998770
16-1
ENGINE
ELECTRICAL
CONTENTS
16109000233
CHARGING SYSTEM . . . . . . . . . . . . . . . . 3
IGNITION SYSTEM <4G6, 6A1> . . . . . 35
GENERAL INFORMATION . . . . . . . . . . . . . . 35
SERVICE SPECIFICATIONS . . . . . . . . . . . . 37
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 37
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 6
Alternator Output Line Voltage Drop Test . . . . 6
Power Transistor Continuity Check <4G6>

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Output Current Test . . . . . . . . . . . . . . . . . . . . . . . 8

Regulated Voltage Test . . . . . . . . . . . . . . . . . . . 10
Waveform Check Using An Analyzer . . . . . . . 12
Alternator Relay Continuity Check . . . . . . . . . 13
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . 14
STARTING SYSTEM . . . . . . . . . . . . . . . . 23
Starter Relay Continuity Check <4D6> . . . . . 24
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . 24
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
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
DETONATION SENSOR . . . . . . . . . . . . . . . . 56
GLOW SYSTEM <4D6> . . . . . . . . . . . . . 57
INJECTION SYSTEM <4D6> . . . . . . . . 62

CRANK ANGLE SENSOR . . . . . . . . . . . . . . 62
ENGINE ELECTRICAL - Charging System
CHARGING SYSTEM
16-3
16100010341
GENERAL INFORMATION
The charging system uses the alternator output
to keep the battery charged at a constant level
under various electrical loads.
Voltage
OPERATION
Approx. 14.4 V
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.
Time
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.
16-4
SYSTEM DIAGRAM
<4G6, 6A1>
B
Stator coil
Engine-ECU
Field coil
Voltage
regulator
G
S
L
FR
+
Charging
warning lamp
Ignition
switch
Battery
<4D6>
Stator coil
Charging
warning lamp
Ignition
switch
Field coil
Voltage
regulator
+
Battery
16-5
ALTERNATOR SPECIFICATIONS
Items
4G6
6A1
4D6
Type
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
16100030231
Items
Standard value
Limit
Alternator output line voltage drop (at 30A) V
max. 0.3
Regulated voltage ambient

temp. at voltage regulator V
- 20_C
14.2 - 15.4
20_C
13.9 - 14.9
60_C
13.4 - 14.6
80_C
13.1 - 14.5
70% of normal output current
Output current
SPECIAL TOOLS
Tool
16100060117
Number
Name
Use
MB991519
Alternator test
harness
Checking the alternator (S terminal voltage)

<4G6, 6A1>
MB991450
Alternator test
harness
Checking the alternator (S terminal voltage)

<4D6>
16-6
ON-VEHICLE SERVICE
16100090314
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST
+
Alternator
Terminal B
Ammeter
Voltmeter
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
Battery
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.
16-7
(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.
16-8
OUTPUT CURRENT TEST
16100100314
<4G6, 6A1>
Load
Voltmeter
Ammeter
Charging warning lamp
Ignition switch
Alternator relay
FR
L
S
G
Battery
Alternator
Engine
-ECU
<4D6>
Load
Alternator
Charging warning
lamp
Ignition
switch
L
Alternator relay
Voltmeter
Ammeter
Battery

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.
16-9
(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 system in another vehicle,
and then test again.
D The specified level of current also may not
be output if the temperature of the alternator
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.
16-10
REGULATED VOLTAGE TEST
16100110317
<4G6, 6A1>
Ignition
switch
Load
Charging warning
lamp
MB991519
Alternator
FR
L
Alternator relay
S
G
Yellow
EngineECU
Ammeter
Voltmeter
Battery
<4D6>
Ignition
switch
Charging warning
lamp
Load
Alternator
MB991450
L
Alternator relay
B
Ammeter
Voltmeter
Battery
+
-
Yellow

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.
16-11
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 on the 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
16-12

Special
patterns
pickup
Alternator
Analyzer
WAVEFORM CHECK USING AN ANALYZER

16100120211
MEASUREMENT METHOD
Connect the analyzer special patterns pick-up to the alternator
B terminal.
B terminal
STANDARD WAVEFORM
Observation Conditions
FUNCTION
SPECIAL PATTERNS
PATTERN HEIGHT
VARIABLE
VARIABLE knob
Adjust while viewing the waveform.
PATTERN SELECTOR
RASTER
Engine speed
Curb idle speed
0.4
0.2
Voltage at
alternator
B terminal
0
- 0.2
- 0.4
Time
NOTE
The voltage waveform of the alternator B terminal can undulate
as shown at left. This waveform is 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.
16-13

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
Open
diode
Example 4
Short in
stator coil
Example 2
Short in
diode
Example 5
Open
supplementary
diode
Example 3
Broken
wire in
stator coil
At this time, the charging warning lamp

is illuminated.
ALTERNATOR RELAY CONTINUITY CHECK

Alternator
relay
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 no continuity when the (+) 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.
16-14
ALTERNATOR
16100140286

<4G6>
D Under Cover Removal (R.H. side)
D Engine Mount Bracket Removal
12 Nm
D Engine Mount Bracket Installation
D Under Cover Installation (R.H. side)
D Drive Belt Tension Adjustment
1
2
12 Nm
12 Nm
1
6
9 Nm
20 - 25 Nm
4
8
24 Nm
44 Nm
AA"
Removal steps
1. Oil pressure hose and tube assembly
clamp bolt
2. Oil return tube assembly clamp bolt
3. Drive belt (Power steering, A/C)
5.
6.
7.
8.
Water pump pulley

Alternator connector
Alternator
Alternator brace
16-15
<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
4
5
18 Nm
22 Nm
6
44 Nm
24 Nm
Removal steps
clamp bolt
4. Air intake plenum stay

5. Alternator brace
6. Alternator
16-16
<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
1
24 Nm
12 Nm
1
29 Nm
11
10
44 Nm
8
9
24 Nm
9 Nm
AB"
AC"
Removal steps
clamp bolt
2. Oil level gauge guide assembly
mounting bolt
3. Drive belt (Power steering)
4. Drive belt (A/C)
6.
7.
8.
9.
10.
11.
Water pump pulley

Alternator connector
Alternator
Alternator brace
Engine hanger
Alternator brace stay
16-17

B
A
Power steering
oil pump
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.
16-18
16100160213
12
14
9
13
8
11
10
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.
9.
AC" "AA 10.
11.
12.
13.
14.
Stator
Plate
Regulator assembly
Brush
Slinger
Rectifier
Rear bracket
16-19

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.
Soldered
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 to make sure that the heat of the soldering
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.
16-20

Wire
"AA REGULATOR 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.
Rear bracket
Brush
Wire
Wire
"BA ROTOR INSTALLATION

After installing the rotor, remove the wire used to fix the brush.
INSPECTION
16100170216
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.
16-21
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.
16-22

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
Protrusion
length
Soldered
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.
16-23
ENGINE ELECTRICAL - Starting System
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 Plunger

Lever
Over-running
clutch
Pinion shaft
Ignition
switch
Armature
Battery
Brush
Yoke
STARTER MOTOR SPECIFICATIONS

Items
4G6-M/T <Except
4G6-M/T <Models for cold
models for cold climate> climate>, 4G6-A/T, 6A1
4D6 <Except models for cold climate>
Type
Direct drive
Reduction drive with

planetary gear
Reduction drive with Reduction drive

planetary gear
with planetary gear
Rated output kW/V
0.9/12
1.2/12
2.0/12
2.2/12
No. of pinion teeth
10
12
4D6 <Models for

cold climate>
16200030173
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

mm
Limit
29.4
32.0
28.4
31.0
Commutator runout mm
Standard value
0.05
0.05
Limit
0.1
0.1
Standard value
0.5
0.5
Limit
0.2
0.2
Commutator undercut mm
16-24
ON-VEHICLE SERVICE
16200140074
STARTER RELAY CONTINUITY CHECK <4D6>

Battery voltage
Terminal No.
1
Starter
relay
Not supplied
Supplied
Switch
<4G6>
STARTER MOTOR
16200110242
INSPECTION
S
Battery
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.
Field coil wire
<6A1>
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
Switch
B
Battery
S
M
<4D6>
Field
coil wire
Switch
B
Battery
S
M
Field
coil wire
16-25
4. Check pinion to stopper clearance (pinion gap) with a

thickness gauge.
Pinion gap: 0.5 - 2.0 mm
Stopper
Pinion gap
Pinion
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.
<4G6>
S
Battery
Caution
Field coil wire
3. If pinion moves out, then pull-in coil is good. If it doesnt,

replace magnetic switch.
<6A1>
Battery
S
M
Field
coil wire
<4D6>
Battery
S
M
Field
coil wire
16-26

MAGNETIC SWITCH HOLD-IN TEST
switch.
2. Connect a 12V battery between S-terminal and body.
<4G6>
S
Battery
Caution
Field coil wire
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.
<6A1>
Battery
Field
coil wire
<4D6>
Battery
Field
coil wire
Carbon-pile rheostat
<4G6>
S
M
Ammeter
Starter
motor
<6A1>
B
Battery
Voltmeter
Ammeter
Battery
M
Voltmeter
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 from battery 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
16-27
<4D6>
B
Ammeter
S
M
Battery
Voltmeter
MAGNETIC SWITCH RETURN TEST

switch.
2. Connect a 12V battery between M-terminal and body.
<4G6>
Battery
Caution
Field coil wire
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.
<6A1>
Battery
M
Field
coil wire
<4D6>
Battery
M
Field
coil wire
16-28
16200120269
<DIRECT DRIVE TYPE>

2
13
6
4
16
12
18
14
15
17
10
11
AA"
Disassembly steps
1. Screw
2. Magnetic switch
3. Packing
4. Plate
5. Screw
6. Through bolt
7. Rear bracket
8. Rear bearing
9.
10.
11.
12.
13.
14.
AC" "AA 15.
AC" "AA 16.
17.
18.
Brush holder
Yoke assembly
Brush
Armature
Lever
Washer
Snap ring
Stop ring
Overrunning clutch
Front bracket
16-29

<PLANETARY GEAR REDUCTION DRIVE TYPE FOR PETROL ENGINE>
2
13
23
14
17
10
15
12
16
20
22
18
11
21
8
19
4
7
6
9
AA"
AB"
AB"
Disassembly steps
1. Screw
2. Magnetic switch
3. Starter cover
4. Screw
5. Through bolt
6. Rear bracket
7. Brush holder
8. Brush
9. Rear bearing
10. Armature
11. Yoke assembly
12. Ball
13.
14.
15.
16.
17.
AC" "AA 18.
AC" "AA 19.
20.
21.
22.
23.
Packing A
Packing B
Plate
Planetary gear
Lever
Snap ring
Stop ring
Overrunning clutch
Internal gear
Planetary gear holder
Front bracket
16-30
<PLANETARY GEAR REDUCTION DRIVE TYPE FOR DIESEL ENGINE>

2
11
13
12
15
16
14
21
23
1
22
17
20
7
5
19
18
8
10
AA"
AB"
Disassembly steps
1. Screw
2. Magnetic switch
3. Screw
4. Through bolt
5. Rear bracket
6. Brush holder
7. Yoke assembly
8. Brush
9. Armature
10. Bearing
11. Packing A
12. Packing A
13.
14.
15.
16.
AC" "AA 17.
AC" "AA 18.
19.
20.
21.
22.
23.
AB"
Plate
Ball
Planetary gear
Lever
Snap ring
Stop ring
Overrunning clutch
Internal gear
Washer
Planetary gear holder
Front bracket

Magnetic
switch
S terminal
M terminal
16-31

AA" MAGNETIC SWITCH REMOVAL
Disconnect the field coil wire from terminal M of the
magnetic switch.
Field coil
wire
AB" ARMATURE AND BALL REMOVAL

When removing the armature, do not lose the ball placed
at the end as a bearing.
Socket
Stop ring
Armature
Pinion gear
Overrunning
clutch
Snap ring
Pinion gear
AC" SNAP RING/STOP RING REMOVAL

1. Using an appropriate wrench socket, push the stop ring
toward the overrunning clutch.
Snap ring pliers
2. Remove the snap ring with snap ring pliers and then
remove the stop ring and overrunning clutch.
Overrunning
clutch
Armature
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.
16-32

"AA STOP RING/SNAP RING INSTALLATION
Using an appropriate tool, pull the stop ring over the snap
ring.
Stop ring
Stop ring
Overrunning
clutch
Snap ring
INSPECTION
16200130255
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.

Undercut
Segment
Mica

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.
Yoke
16-33
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.
Field brush
Yoke
BRUSH HOLDER
Check the continuity between brush holder plate and brush
holder.
If there is no continuity, the brush holder is in order.
Brush holder
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.
Free
Lock
BRUSH
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length.
Wear limit line
New brush
Pigtail
Soldered
(Make sure that
there is no
excess solder
on blush
surface)
Mark
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.
16-34

Growler
ARMATURE COIL SHORT-CIRCUIT TEST

1. Place armature in a growler.
2. Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
Caution
Clean the
checking.
armature
surface
thoroughly before
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.
ENGINE ELECTRICAL - Ignition System <4G6, 6A1>
IGNITION SYSTEM <4G6, 6A1>
16-35
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
Air flow sensor
Ignition coil A

Engine-ECU
Ignition coil B
Ignition
switch
Crank angle sensor

Detonation sensor
Battery
Spark plugs
A/T-ECU
Cylinder No.
To tachometer
16-36
<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
Air flow sensor

Engine-ECU
Top dead
centre sensor
Spark
plug
Crank angle sensor

Detonation sensor
A/T-ECU
Power
transistor
Distributor
16-37
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
16300030282
IGNITION COIL
Items
Standard value
Primary coil resistance W
6A1
0.5 - 0.7
Secondary coil resistance kW
6A1
9 - 13
SPARK PLUG
Items
Standard value
Spark plug gap mm
4G6, 6A1
1.0 - 1.1
RESISTIVE CORD
Items
Limit
Resistance kW
4G6, 6A1
max. 22
SPECIAL TOOLS
Tool
16300060250
Number
Name
Use
MB991348
Test harness set
Inspection of ignition primary voltage (power

transistor connection)
16-38
Tool
Number
Name
Use
MD998773
Detonation sensor
wrench
Detonation sensor removal and installation
ON-VEHICLE SERVICE
16300130234
POWER TRANSISTOR CONTINUITY CHECK

<4G6>
Ignition coil
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
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
High-voltage
terminal
2. Measurement of secondary coil resistance

Measure the resistance between the high-voltage
terminals and connector terminals 1.
Standard value: 9 - 13 kW
16-39
POWER TRANSISTOR CONTINUITY CHECK

16300130241
<6A1>
+
-
1.5V
Distributor connector
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
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.
16-40

Plug gap gauge
5. Use a plug gap gauge to check that the plug gap is

within the standard value range.
Measurement direction
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
Platinum tips
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
16-41
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.
16-42
STANDARD WAVEFORM
Function
Secondary
Pattern height
High (or Low)
Pattern selector
Raster
Engine revolutions
Curb idle speed

Spark line (point A)
kV
Ignition voltage
(point D)
Wave damping
reduction section
(point B)
Dwell
section
Secondary
ignition
voltage
waveform
Point C
Time
Observation Condition (The only change from above condition is the pattern selector.)
Pattern selector
Display
kV
No. 4 cylinder
No. 2 cylinder
ignition noise
Secondary
ignition
voltage
waveform
No. 1 cylinder
No. 3 cylinder
ignition noise
Time
0
2
Neutral section
16-43
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
High
Large
Large wear
High
Lean
Retarded
High
resistance
Low
Small
Normal
Low
Rich
Advanced
Leak
Large
Plug is fouled
Height
Slope
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)
Coil
5 - 6 or higher
Normal
Except above
Abnormal
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
Low
Small
Normal
Low
Rich
Advanced
Leak
16-44

Abnormal waveform
Wave characteristics
Cause of problem
Example 1
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.
Example 3

sloping. However, there is almost no
spark line distortion.
Spark plug gap is fouled.
Example 4

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
01P0215
16-45
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)
PATTERN SELECTOR
RASTER
Engine Speed
Curb idle speed

Spark line
(Point A)
kV
Ignition
voltage
(Point D)
Vibration damping
section (Point B)
Ignition
secondary
voltage
waveform
Dwell
section
(Point C)
Time
16-46

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
High
Large
Large wear
High
Lean
Retarded
High
resistance
Low
Small
Normal
Low
Rich
Advanced
Leak
Large
Plug is fouled
Height
Slope
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
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)
Coil
5 - 6 or higher
Normal
Except above
Abnormal
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
Low
Small
Normal
Low
Rich
Advanced
Leak
16-47

Abnormal waveform
Cause of problem
Example 1
Example 2

sloping.
misfiring.
Example 3

Example 4

Difficult to distinguish between this
and abnormal waveform example 1.

Example 5
No waves in wave damping section.
01P0215
16-48

Ignition Primary Voltage Waveform Check
<6A1>
MEASUREMENT METHOD
1. Disconnect the distributor connector and connect the
of the terminals should be connected.)
Analyzer
Primary
pickup
Earth
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 waveform of the cylinder clamped to the trigger pickup
will appear at the left edge of the screen.
16-49

STANDARD WAVEFORM
FUNCTION
SECONDARY
PATTERN HEIGHT
HIGH (or LOW)
PATTERN SELECTOR
RASTER
Engine Speed
Curb idle speed
(V)
Zener voltage
(Point C)
100
(Approx. 4010V)
Spark line
(Point A)
Vibration damping
section (Point B)
Dwell
section
Ignition
primary
voltage
0
waveform
Time
(Only the pattern selector shown below changes from the previous conditions)
PATTERN SELECTOR DISPLAY
(V)
100
Centre
section
Ignition
primary
voltage
waveform
Time
16-50

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.
Spark line
Plug gap
Condition of
electrode
Compression
force
Concentration of
air mixture
Ignition timing
High tension
cable
Length
Long
Small
Normal
Low
Rich
Advanced
Leak
Short
Large
Large wear
High
Lean
Retarded
High
resistance
High
Large
Large wear
High
Lean
Retarded
High
resistance
Low
Small
Normal
Low
Rich
Advanced
Leak
Large
Plug is fouled
Height
Slope
Point B: Number of vibration in reduction vibration section

(Refer to abnormal waveform example 5)
Coil, condenser
3 or higher
Normal
Except above
Abnormal
Point C: Height of Zener voltage

Height of Zener voltage
Probable cause
High
Problem in Zener diode
Low
Abnormal resistance in
primary coil circuit
16-51

Abnormal waveform
Cause of problem
Example 1
Example 2

sloping.
misfiring.
Example 3

Example 4

Example 5
No waves in wave damping section
16-52
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.)
22 - 25 Nm
3
5
4
10 - 12 Nm
25 Nm
6
25 Nm
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

"AA DISTRIBUTOR 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
16-53

16300220207
Disassembly steps
1. Distributor cap
2. Packing
3. Rotor
4. O-ring
5. Distributor housing
INSPECTION
16300230125
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.
16-54
IGNITION COIL <4G6>
16300320174

10 Nm
10 Nm
1
2
3
25 Nm
Removal steps
1. Spark plug cable
2. Ignition coil assembly
3. Spark plug
CAMSHAFT POSITION SENSOR <4G6>
16300340026
9 Nm
CRANK ANGLE SENSOR
16-55
16300350036

D Timing Belt Removal and Installation <4G6>
(Refer to GROUP 11A.)
D Timing Belt Cover Removal and Installation <6A1>
(Refer to GROUP 11B.)
<4G6>
<6A1>
1
10 - 13 Nm
12 Nm
1
10 - 12 Nm
28 Nm
28 Nm
9 Nm
4
49 Nm
4
49 Nm
AA"
Removal steps
1. Pressure hose and tube assembly
connection
9 Nm
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.
16-56
DETONATION SENSOR
16300280144

Intake Manifold Removal and Installation <6A1>
<4G6>
<6A1>
20 - 25 Nm
20 - 25 Nm
AA" "AA 1. Detonation sensor
Caution
Do not subject the detonation sensor to any shocks.
<4G6>
AA" DETONATION SENSOR REMOVAL

MD998773

"AA DETONATION SENSOR INSTALLATION
<6A1>
MD998773
16-57
ENGINE ELECTRICAL - Glow System <4D6>
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-ECU controls both the time during which
current is supplied to the glow plugs 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
Charge lamp
Glow plugs
ON
ST
Ignition switch
Alternator
Starter motor
Battery
16-58
ENGINE ELECTRICAL - Glow System
16400030056
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 V after 4 - 8 seconds have passed)
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
ON-VEHICLE SERVICE
16400100047
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.
16-59
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 _C or 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
START
Ignition
switch
ON
Glow
indicator
lamp
ON
Glow plug
relay
ON
Alternator
L terminal
OFF
T1
OFF
T2
T3
OFF
T1: Glow indicator lamp

T2: Glow plug relay drive time after ignition switch is turned ON
T3: Glow plug relay drive time after engine starts (after glow)
NOTE
After glow time T3 becomes longer as the engine coolant temperature drops.

Refer to GROUP 13E - Troubleshooting.
16400360025
16-60

GLOW PLUG RELAY CHECK
Glow plug relay
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
G terminal
B 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 disconnected harnesses 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)
(- )

16400350015
CHECK
Refer to GROUP 13E - On-vehicle Service.
GLOW PLUG
16-61
16400180058

1.8 Nm
1
2
3
18 Nm
AA"
Removal steps
1. Control wiring harness connection
2. Glow plug plate
3. Glow plug

AA" GLOW PLUG REMOVAL
Remove glow plug by hand after loosening with tool as its
ceramic part is fragile.
INSPECTION
D
D
16400190044
Check for rust on glow plug plate.

Check glow plug for damage.
Caution
Do not use a plug that has been dropped from a height
of 10 cm or more.
16-62
ENGINE ELECTRICAL - Injection System <4D6>
INJECTION SYSTEM <4D6>
16500010015
GENERAL INFORMATION
For the injection system, refer to GROUP 13E - General Information.
ON-VEHICLE SERVICE
16500130018

CRANK ANGLE SENSOR

(Refer to GROUP 11C.)
10 - 12 Nm
9 Nm
2
1
Removal steps
1. Harness support
2. Crank angle sensor
16500120015
17-1
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL SYSTEM . . . . . . . . 3
17109000193
ACCELERATOR PEDAL POSITION

SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AUTO-CRUISE CONTROL SYSTEM

..................................... 8
Accelerator Cable Check and Adjustment . . . . 3

Accelerator Pedal Position Sensor Check . . . . 4
ACCELERATOR CABLE AND PEDAL . . . . 5
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 8

WARNING!
MITSUBISHI dealer.
component.
NOTE
The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors and
maintenance) are indicated in the table of contents by an asterisk (*).
17-2
EXHAUST GAS RECIRCULATION (EGR)

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
General Information . . . . . . . . . . . . . . . . . . . . . . 42
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
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
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 37
EXHAUST GAS RECIRCULATION SYSTEM

(EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 49
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Positive Crankcase Ventilation System

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
EGR Solenoid Valve Check . . . . . . . . . . . . . . . . . . 50
PCV Valve Check . . . . . . . . . . . . . . . . . . . . . . . . 38
Accelerator Pedal Position Sensor Check . . . . . 50

Pump Operation Sensor Check . . . . . . . . . . . . . . . 50
EVAPORATIVE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Engine Coolant Temperature Sensor Check . . . 50
Barometric Pressure Sensor Check . . . . . . . . . . . 51
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 39
A/C Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Check at the Engine-ECU Terminals . . . . . . . . . . 51
Purge Control System Check . . . . . . . . . . . . . . 40

Purge Port Vacuum Check . . . . . . . . . . . . . . . . 40
Purge Control Solenoid Valve Check . . . . . . . 41
Intake Air Temperature Sensor Check . . . . . . . . 51
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . 51
General Information . . . . . . . . . . . . . . . . . . . . . . . . . 51
ENGINE AND EMISSION CONTROL - Engine Control System
ENGINE CONTROL SYSTEM
17-3
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.
17100030139
Items
Standard value
Accelerator cable play mm
1-2
Engine idle speed r/min
4G6
75050
6A1
65050
4D6
80030
ON-VEHICLE SERVICE
17100090243
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.
17-4

7. If there is too much slack or no slack, adjust play by
the following procedures.
<Except 4D6>
Adjusting bolts
<4D6>
Plate
Adjusting nut
Lever
Lock nut
<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
10 Nm

17100190011
CHECK
Refer to GROUP 13E - On-vehicle Service.
17-5
ACCELERATOR CABLE AND PEDAL
17100120256

Adjusting the Accelerator Cable (Refer to P.17-3.)
<4G6, 6A1>
1
5
<4D6>
2
5
4
3
10 Nm
<4G6, 4D6>
10
11
8
<6A1>
11
5
6
12
14
12 Nm
13
<A/T>
15
Removal steps
1. Adjusting bolt
2. Adjusting nut
3. Inner cable connection
6. Snap ring
7. Accelerator arm assembly
8. Spring
<M/T>
15
9.
10.
11.
12.
13.
14.
15.
Pedal pad
Accelerator pedal bracket
Bushing
Stopper
Accelerator pedal stopper <M/T>
Wide open throttle switch <A/T>
Bracket
17-6
<R.H. drive vehicles>
1
5
<4G6, 6A1>
3
5
<4D6>
2
3
4
12 Nm
10 Nm
10
<4G6, 4D6>
5
6
8
11
7
11
<6A1>
12
14
13
Removal steps
1. Adjusting bolt
2. Adjusting nut
6. Snap ring
7. Accelerator arm assembly
8.
9.
10.
11.
12.
13.
14.
Spring
Pedal pad
Accelerator pedal bracket
Bushing
Stopper
Accelerator pedal stopper <M/T>
Wide open throttle switch <A/T>
17-7
17100180018

Adjusting the Accelerator Cable (Refer to P.17-3.)

10 - 13 Nm
4
5
6
2

1
10 Nm
1
10 Nm
3
10 - 13 Nm
10 - 13 Nm
10 - 13 Nm
4
5
6
10 - 13 Nm
Removal steps
1. Adjusting nut
3. Idle position switch connector
connector

assembly
bracket
17-8
ENGINE AND EMISSION CONTROL - Auto-cruise Control System
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

Auto-cruise control
main switch
Stop lamp switch

Clutch switch
Vacuum
actuator
Accelerator pedal
position sensor
Auto-cruise
vacuum pump
assembly
Auto-cruise control
main switch
Auto-cruise control switch
Throttle
position
sensor
Inhibitor switch
Vehicle speed
sensor
Auto-cruise
control-ECU
Auto-cruise control
indicator lamp
SPECIAL TOOL
Tool
17200060179
Number
Name
Use
MB991502
MUT-II sub
assembly
D
D
Reading diagnosis codes

Auto-cruise control system check
TROUBLESHOOTING
17-9
17200200236
STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

NOTE
Check that the vacuum hose is connected correctly and is not damaged, and then carry out the diagnosis.
DIAGNOSIS FUNCTION
Auto-cruise
control
main switch
Auto-cruise
control
main switch
(A)
Auto-cruise control
switch
(B)
17200210161
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.
17-10
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
Vehicle speed signal
25
D
26
Clutch switch <M/T>

(ON when clutch pedal depressed)
(ON when select lever in N range)
Auto-cruise control-ECU judges that vehicle speed is 40 km/h

or higher
Auto-cruise control-ECU judges that vehicle speed is lower
than 40 km/h
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
17200220249
Code No.
Diagnosis item
Reference page
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
17-11

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
D
D
D
Check the auto-cruise vacuum pump. (Refer to P.17-29.)
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
auto-cruise vacuum pump

connector
harness
auto-cruise control-ECU
Replace
OK
C-74 <L.H.> or C-113 <R.H.>, A-02 and C-82
OK
NG
NG
Repair
Check the harness between the auto-cruise vacuum pump and

auto-cruise control-ECU.
OK
NG
Repair
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.
D
D
D
D
Is the speedometer operating normally?
No
Yes
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
vehicle speed sensor

connector
harness
Vehicle speed sensor circuit inspection

(Refer to GROUP 54 - Combination Meter.)
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
NG
Check the harness between the vehicle speed sensor and autocruise control-ECU, and repair if necessary.
OK

OK
NG
Repair

NG
17-12
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
D
D
D
D
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
NG
OK
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
the
the
the
the
the
stop lamp switch

connector
harness
Check the auto-cruise vacuum pump. (Refer to P.17-29.)

OK
Replace
C-74 <L.H.> or C-113 <R.H.>, A-02 and C-82
OK
Check the stop lamp switch (Refer to P.17-28.)

OK
NG
Replace
NG
NG
Repair

NG

C-74 <L.H.> or C-113 <R.H.>, A-02, C-02 and C-82
OK
NG
Check the harness between the auto-cruise vacuum pump and
auto-cruise control-ECU.
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.
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.
Malfunction of the auto-cruise control-ECU
17-13

Code No. 17 Throttle position sensor system <Vehicles
without TCL> or accelerator pedal position sensor 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
D
D
D
D
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
D
Malfunction of the throttle position sensor <Vehicles

without TCL>
<Vehicles with TCL>
Malfunction of the harness
Throttle position sensor check <Vehicles without TCL> (Refer

to GROUP 13A - Troubleshooting.)
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
OK
NG
NG
Repair
D
D
Check the harness between the throttle position sensor and

auto-cruise control-ECU <Vehicles without TCL>
Check the harness between the accelerator pedal position
sensor and auto-cruise control-ECU <Vehicles with TCL>
OK
NG
Repair

Trouble symptom
17200230228
Inspection
procedure No.
Reference page
17-14
Communication with auto-cruise control-ECU only is

not possible.
17-15
Input switch inspection using the MUT-II is not possible. (However, diagnosis
inspection is possible.)
17-16
Communication with
II is not possible.
MUT-II
17-14
Trouble symptom
Inspection
procedure No.
Reference page
Even if brake pedal is depressed
17-17
Even if clutch pedal is depressed <M/T>
17-18
Even if select lever is set to N range <A/T>
17-18
Even if CANCEL switch is set to ON
17-19
The diagnosis result displayed on the MUT-II is normal even though auto-cruise
control cannot be set.
17-19
Auto-cruise control cannot be set.
17-20
Hunting (repeated acceleration and deceleration) occurs at the set vehicle speed.
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
Auto-cruise control is
not cancelled.

Communication with MUT-II is not possible. (Communication 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.
D
D

C-20.
OK: Battery voltage
NG
OK
OK

C-20.
OK: Continuity
OK
Replace the MUT-II.

<L.H.> C-20, C-66, C-63, C-132, C-141
<R.H.> C-20, C-66, C-62, C-14
NG

C-20

NG
NG
NG
Repair

power supply and diagnosis connector,
Repair
OK
NG

diagnosis connector and earth, and repair if necessary.
17-15
Communication with MUT-II is not possible. (Communication 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
D
D
D
Auto-cruise control main switch check (Refer to P.17-32.)

OK
Measure at auto-cruise control main switch connector C-22.
D Voltage between the terminal (1) and earth
OK: System voltage
NG
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
auto-cruise control main switch

connector
harness
Replace
Check the following connectors: C-22, C-134
OK
NG
Repair
OK
NG
Check the harness between the auto-cruise control main switch
and power supply, and repair if necessary.

<L.H.> C-22, C-62, C-82
<R.H.> C-22, C-63, C-64, C-82
NG
Repair
OK
OK
Check the harnesses between the auto-cruise control main switch
and earth or between the auto-cruise control main switch and autocruise control-ECU.
OK
D Continuity between terminal (9) and earth, terminal (13) and
earth.
OK: Continuity
NG
Check the harness between the auto-cruise control-ECU and earth,
NG
OK
Repair

OK
NG
Repair

NG
Check the harness between the auto-cruise control-ECU and diagnosis connector
OK
NG
Repair
17-16
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
D
D
D
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
auto-cruise control switch

clock spring
connector
harness
Replace
OK
Clock spring check (Refer to GROUP 52B - Air Bag Modules
and Clock Spring.)
OK
Measure at the clock spring connector C-107.
OK: System voltage
NG
NG
OK
NG
Check the harness between the clock spring and auto-cruise controlECU, and repair if necessary.

C-107, C-61, C-134, C-63 <R.H.>
OK
NG
Repair
OK

C-107, C-82
Replace

NG
NG
Repair
Check the harness between the clock spring and power supply,
17-17

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.
D
D
D
D
Yes
Does stop lamp illuminate?
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
stop lamp switch

connector
harness

OK
No
Stop lamp switch check
(Refer to P.17-28.)
NG
Repair
OK
NG
NG
Replace
Check the harness between the stop lamp switch and auto-cruise
control-ECU.
OK
NG
Repair

Measure at stop lamp switch connector C-02.
OK: System voltage
NG

OK
NG
Repair
OK

NG
Check the harness between the stop lamp switch and power supply,

C-02, C-65, C-82
OK
NG
NG
Repair
Check the harness between the stop lamp switch and auto-cruise
control-ECU, and repair if necessary.
17-18
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
D
D
D
Clutch switch check (Refer to P.17-29.)

OK
Measure at clutch switch connector C-01.
OK: 5 V
NG
NG
clutch switch
connector
harness
Replace

NG

NG
NG
Repair
Check the harness between the clutch switch and auto-cruise control-ECU, and repair if necessary.

Check the harness between the clutch switch and earth.
the
the
the
the
Repair
OK
NG
of
of
of
of
OK
OK
<L.H.> C-01, C-62
<R.H.> C-01, C-63, C-64
Malfunction
Malfunction
Malfunction
Malfunction
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
D
D
Inhibitor switch check (N range) (Refer to P.17-29.)

OK
C-48, C-83, C-82
NG
OK

Replace
NG
Check the harness between the inhibitor switch and auto-cruise
control-ECU.
OK
NG
Repair
17-19

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.
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 from being memorised and displayed even though auto-cruise
control is cancelled.
D
D
D

OK: System voltage
NG


C-66 <L.H.> or C-62 <R.H.> and C-82
OK
OK
Repair

OK

NG
Repair

NG
NG
NG
Check the harness between the auto-cruise control-ECU and power
supply, and repair if necessary.
17-20
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
D
D
D
D
D
Can the auto-cruise control communicate with the MUT-II?
No
Yes
Is the diagnosis system diagnosis displayed on the MUT-II normal?
Yes
No
Are any of MUT-II diagnosis code Nos. 11, 12, 14, 15, 16 or 17
output?
Yes
No
Is input switch inspection possible with the MUT-II?
No
Yes
Are either of MUT-II diagnosis code Nos. 23 or 26 output?
No
Yes
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
of
the
the
the
the
the
the
auto-cruise control main switch

auto-cruise control switch
clock spring
harnesses or connectors
clutch switch <M/T>
Check for each trouble symptom. (Refer to inspection procedure

No. 2 on P.17-15.)
No. 8 on P.17-19.)
Check for each diagnosis code.
(CODE No.11: Refer to P.17-11.)
No. 3 on P.17-16.)
D
D
Stop lamp switch input circuit system [code No. 23] inspection
(Refer to inspection procedure No. 14 on P.17-24.)
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.)
17-21
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
D
D
D
Vehicle speed sensor check

(Refer to GROUP 54 - Combination Meter.)
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
vehicle speed sensor

vacuum actuator
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
Replace the auto-cruise control main switch.
Malfunction of the auto-cruise control main switch
17-22
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.
D
D
D

OK
Measure at auto-cruise control main switch connector C-22.
D Lighting switch: TAIL
OK: System voltage
NG
NG
Malfunction of the auto-cruise control main switch

Replace

<L.H.> C-22, C-64, C-67, C-116
<R.H.> C-22, C-61, C-62, C-14
OK
Repair
OK

<L.H.> C-22, C-64, C-25
<R.H.> C-22, C-61, C-62, C-25
OK
NG
NG
NG
Repair
NG

and rheostat, and repair if necessary.
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
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the
the
the
the
bulb
harness
connector
<CRUISE MAIN indicator lamp>

NG
CRUISE MAIN indicator lamp bulb check
Replace
OK
NG
Combination meter check

OK
D Ignition switch and main switch: ON
OK: System voltage
OK

D-01, C-26
OK
NG
Repair

C-135, C-131
OK
NG
Repair
NG
NG
Repair

NG
Check the harness between the combination meter and earth, and
Check the harness between the combination meter and auto-cruise

control main switch, and repair if necessary.
17-23
<CRUISE SET indicator lamp>

CRUISE SET indicator lamp bulb check
NG
Replace
OK
NG
Combination meter check

OK
OK: System voltage
NG
Repair

D-03, C-135
OK
NG
Repair
OK

NG
Check the harness between the combination meter and power
supply, and repair if necessary.

OK: System voltage
OK
Replace the and auto-cruise control-ECU.
NG

C-82, C-25
OK
NG
Repair

NG
Check the harness between the combination meter and auto-cruise
control-ECU, and repair if necessary.
17-24
Stop lamp switch input circuit system inspection (Code No. 23)
Stop lamp switch check (Refer to P.17-28.)
OK
Check the following connectors: C-82, C-65, C-02, C-134, C-142,
C-12 <R.H.>
OK
NG
NG
NG
Replace
Repair
Check the harness between fusible link No. 1 and auto-cruise control-ECU, and repair if necessary.
Clutch switch <M/T> or inhibitor switch <A/T> input circuit system inspection (Code No. 26)
<M/T>
Clutch switch check (Refer to P.17-29.)
OK
<L.H.> C-82, C-01, C-62
<R.H.> C-82, C-01, C-63, C-64
OK
NG
NG
NG
Replace
Repair
Check the harness between auto-cruise control-ECU and earth,

<A/T>
Inhibitor switch check (Refer to P.17-29.)
OK
B-72, C-48, C-83, C-82
OK
NG
NG
NG
Replace
Repair
Check the harness between the auto-cruise control-ECU and inhibitor switch, and repair if necessary.
17-25

CHECK AT THE ECU TERMINALS
17200270121
Terminal
No.
Check item
Check conditions
Normal condition

(accelerator
pedal position
sensor*) input
When accelerator pedal is fully depressed
4.5 - 5.5V
When accelerator pedal is released
0.3 - 1.0V
Idle switch
output
When accelerator pedal is depressed
When idle switch is OFF
4.5 - 5.5V
When accelerator pedal is not

depressed
When idle switch is ON
0V
ACC power
supply
When ignition switch is in ACC position
System voltage
Stop lamp
switch input
When brake pedal is depressed
When stop lamp switch is ON
System voltage
When brake pedal is not depressed
When stop lamp switch is

OFF
0V
Diagnosis
control input
When ignition switch is ON
4V or more
ECU backup
power supply
At any time
System voltage
Auto-cruise
vacuum
pump release
valve and
control valve
input
When decelerating with the SET

switch while driving at constant
speed
Release valve closed
0V
Control valve open/closed
System voltage/0V
When cancelling constant speed

driving with the CANCEL switch
Release valve open
System voltage
Control valve open
System voltage
Earth
At any time
Continuity
10
A/T control
output
No OD-OFF request
System voltage
OD-OFF request
0V
8
7
8
NOTE
*: Vehicles with TCL
17-26
Terminal
No.
Check item
Check conditions
11
Vehicle speed
sensor input
When vehicle is moved forwards

and backwards, sensor turns ON
and OFF repeatedly
When sensor is ON
0V
When sensor is OFF
4.5V or more
Auto-cruise
control switch
input
When input switch has not been

operated
When all switches are OFF
0V
When input switch is pushed down
When SET switch is ON
Approx. 3V
When input switch is pushed up
When RESUME switch is ON
Approx. 6V
When input switch is pulled forward
When CANCEL switch is ON
System voltage
12
Normal condition
13
Earth
At any time
14
Clutch switch
input <M/T>
When pedal is not depressed
When clutch switch is OFF
5V
When pedal is depressed
When clutch switch is ON
0V
Inhibitor
switch input
<A/T>
When select lever is in a position

other than N range
When inhibitor switch is OFF
5V
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
combination
meter)
When driving at constant speed
When indicator lamp is illuminated
0V
When constant-speed driving is

cancelled
When indicator
switched off
System voltage
Auto-cruise
vacuum pump
motor input
When driving at constant speed

using the SET switch
Motor stopped/running
System voltage/0V
When accelerating with the RESUME 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
18
Continuity
lamp
is
ON-VEHICLE SERVICE
17-27
17200110133
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
main switch
Auto-cruise
control
main switch
AUTO-CRUISE CONTROL SWITCH CHECK

(A)
17200120143
(C)
(B)
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
below the 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.
17-28

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
When brake pedal is depressed.

(for stop lamp circuit)
When brake pedal is not depressed.
(for auto-cruise control circuit)
17-29
CLUTCH SWITCH
2. Check for continuity between the terminals of the switch.
Measurement conditions
Terminal No.
1
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 vacuum hose from the auto-cruise vacuum
pump and connect a vacuum gauge to the vacuum pump.
2. Disconnect the vacuum pump connector.
3. Check that the reading on the vacuum gauge matches
the values in the table below when the battery is connected
to each connector terminal.
Vacuum
gauge
Terminal No.
1
1
Release
valve
2
Vacuum gauge
kPa
Release valve closed

Control valve closed
53 or more
Release valve open

Control valve open
Control
valve
3
Valve condition
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 actuator
17-30
AUTO-CRUISE CONTROL
17200140224
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
17-31
CAUTION: SRS
Before removal of air bag module, refer to
GROUP 52B - SRS Service Precautions and Air
Bag Modules and Clock Spring.
9 Nm
10
11
8
12
14
13
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>
17-32
<L.H. drive vehicles> <R.H. drive vehicles>
INSPECTION
17200110140
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.
OFF
ON
ON
OFF N
N
ILL
IND
17200120150
AUTO-CRUISE CONTROL SWITCH CHECK
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.
2
OFF
ON
OFF
1
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

Refer to GROUP 54 - Combination Meters.
SET
ON
RESUME CANCEL
OFF
Switch position
ON
17200300042
ENGINE AND EMISSION CONTROL -
17-33
Emission Control System <MPI>
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
Equipped
(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
(Purpose: NOx reduction)
Catalytic converter
Monolith type
(Purpose: CO, HC, NOx reduction)
EMISSION CONTROL DEVICE REFERENCE TABLE

Related parts
PCV valve
Crankcase
emission
control
system
Evaporative
emission
control
system
Catalytic
converter
Exhaust
gas
recirculation system
Reference
page
17-38
MPI system component
Catalytic converter
Air/fuel
ratio
control
system
17-41
GROUP 13A
17-47
EGR valve
17-44
17-45
17-34
17300030265
Items
Standard value
Purge control solenoid valve coil resistance (at 20_C) W
36 - 44
EGR control solenoid valve coil resistance (at 20_C) W
36 - 44
SPECIAL TOOL
Tool
17300060073
Number
Name
MD998770
Oxygen
wrench
Use
sensor
Removal/Installation of oxygen sensor
VACUUM HOSE
17300090317
VACUUM HOSE PIPING DIAGRAM

<4G6>
Air cleaner
Fuel pressure
regulator
PCV valve
EGR valve
OFF
OFF
ON
EGR control
solenoid valve
Oxygen sensor
(front)
Three-way catalytic
converter
Canister
ON
Purge control
solenoid valve
Air
<6A1>
Vacuum cotrol
solenoid valve <TCL>
OFF
ON
ON
Vacuum
tank <TCL>
OFF
Ventilation control
Air cleaner
PCV
valve
EGR
valve
Fuel
pressure
regulator
EGR control
solenoid valve
OFF
ON
Canister
Purge control
solenoid valve
Oxygen sensor Oxygen sensor
(front)
(rear)
Three-way catalytic
converter
VACUUM CIRCUIT DIAGRAM

<4G6>
Intake manifold
Throttle body
To
combustion
chamber
Fuel
pressure
regulator
Vacuum hose colour

B: Black
G: Green
L: Light blue
R: Red
W: White
Y: Yellow
From air
cleaner
EGR control
solenoid valve
(ON: OPEN)
EGR valve
Purge control
solenoid valve
(ON: OPEN)
Canister
Air
17-35
17-36
<6A1>
Intake manifold
Throttle body
To
combustion
chamber
From air
cleaner
Fuel
pressure
regulator
Purge control
solenoid
valve
(ON: OPEN)
EGR control
solenoid valve
(ON: CLOSE)
Vacuum
tank <TCL>
EGR valve
Canister
Ventilation control
(ON: CLOSE)
Vacuum control
(ON: OPEN)
Vacuum hose colour
B: Black
G: Green
L: Light blue
R: Red
Y: Yellow
Vacuum
actuator <TCL>
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 the hoses correctly, using the vacuum hose piping
diagram as a guide.
CRANKCASE EMISSION CONTROL SYSTEM
17-37
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
PCV valve
Breather hose
NOTE
The illustration shows the system for 4G63 engine.
COMPONENT LOCATION
PCV valve
<4G6>
PCV valve
<6A1>
17-38
POSITIVE CRANKCASE VENTILATION SYSTEM

17300110136
CHECK
1.
2.
3.
4.
PCV valve
Remove the ventilation hose from the PCV valve.

Remove the PCV valve from the rocker cover.
Reinstall the PCV valve at the ventilation hose.
Start the engine and run at idle.
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

PCV valve
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.
EVAPORATIVE EMISSION CONTROL SYSTEM
17-39
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
Engine-ECU
Throttle body
From fuel tank
Canister
Air flow sensor

Engine coolant
temperature sensor
Intake air
temperature sensor
OFF
ON
Purge control
solenoid valve
Control
relay
Barometric pressure
sensor
COMPONENT LOCATION
<4G6>
<6A1>
17-40
PURGE CONTROL SYSTEM CHECK
<4G6>
Red stripe
17300140357
1. Disconnect the vacuum hose (red stripe) from the throttle

body and connect it to a hand vacuum pump.
2. Plug the nipple from which the vacuum hose 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)
Plug
<6A1>
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)
Red stripe
Plug
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
<4G6>
Purge port
vacuum nipple
17300150282
1. Disconnect the vacuum hose (red stripe) from the throttle

body purge vacuum nipple and connect a hand vacuum
pump to the nipple.
17-41
<6A1>
Purge port
vacuum nipple
2. Start the engine and check that, after raising the engine
speed by racing the engine, purge vacuum raises
according to engine speed.
Vacuum
NOTE
If there is a problem with the change in vacuum, the
throttle body purge port may be clogged and require
cleaning.
Engine speed (r/min)
17300170127
Battery
NOTE
1. Disconnect the vacuum hose (black stripe, red stripe)
3. Connect a hand vacuum pump 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.
Battery voltage
Normal condition
Applied
Vacuum leaks
Not applied
Vacuum maintained

solenoid valve.
17-42
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
17300520274
GENERAL INFORMATION
The exhaust gas recirculation (EGR) system lowers
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
D
D
The engine coolant temperature is low.

The engine is at idle.
The throttle valve is widely opened.
SYSTEM DIAGRAM
<4G6>
EGR
control
solenoid
valve
Air flow sensor

Engine coolant
temperature sensor
OFF
Crank angle sensor
EGR valve ON
Control
relay
Engine-ECU
Battery
<6A1>
EGR valve
EGR
control
solenoid
valve
OFF
ON
Air flow sensor

Engine coolant
temperature sensor
Crank angle sensor
Control
relay
Battery
Engine-ECU
17-43
COMPONENT LOCATION
<4G6>
<6A1>
A
EGR valve
B
EGR valve
<4G6>
<6A1>
EXHAUST GAS RECIRCULATION (EGR)

CONTROL SYSTEM CHECK
<4G6>
Green stripe
Three-way terminal
EGR valve
<6A1>
Green stripe
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)
Three-way terminal
EGR valve
Throttle valve
Normal vacuum condition
Open quickly
It will momentarily rise over 13 kPa
17-44
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.
<4G6>
Green stripe
Plug
EGR valve
<6A1>
Green stripe
Plug
EGR valve
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>

EGR vacuum
nipple
17300290199
1. Disconnect the vacuum hose (white stripe) from the throttle

body EGR vacuum nipple and connect a hand vacuum
pump to the nipple.
17-45
2. Start the engine and check that the vacuum remains

fairly constant after racing the engine.
Vacuum
NOTE
If vacuum changes, it is possible that the throttle body
EGR port may be clogged and require cleaning.
EGR PORT VACUUM CHECK <6A1>

EGR port
vacuum nipple
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.
Vacuum
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.

17300310222
<4G6>
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
C
Battery
Battery voltage
B nipple condition
Normal condition
Not applied
Open
Vacuum maintained
Applied
Open
Vacuum leaks
Closed
Vacuum maintained
17-46

solenoid valve.

17300310239
<6A1>
Battery
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
Battery voltage
Normal condition
Not applied
Vacuum leaks
Applied
Vacuum maintained

solenoid valve.
CATALYTIC CONVERTER
17-47
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.
17300390233

<4G6>
49 - 59 Nm
49 Nm
34 Nm
44 Nm
4
3
49 Nm
<6A1>
49 Nm
13 Nm
49 Nm
44 Nm
49 Nm
2
4
3
49 Nm
1
13 Nm
Removal steps
1. Heat protector
7 Nm

17-48

AA" OXYGEN SENSOR REMOVAL

"AA OXYGEN SENSOR INSTALLATION
MD998770
CANISTER
17300420055
4
3
Removal steps
1. Vapor hose connection
2. Vent hose
3. Hose clamp
4. Canister
5. Canister bracket
Emission Control System <Diesel>
EMISSION CONTROL SYSTEM <DIESEL>
17-49
17500010036
GENERAL INFORMATION
Item
Name
Specification
Exhaust emission control system
Exhaust gas recirculation system

D EGR valve
D EGR solenoid valve
Equipped
Single type
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
A/C switch
EGR
valve
Engine-ECU

(built into engine-ECU)
1. Start the engine and let it warm up 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
17-50 ENGINE AND EMISSION CONTROL EGR solenoid

valve
Emission Control System <Diesel>
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)

17500340012
CHECK
PUMP OPERATION SENSOR CHECK
17500350015

17500150028
CHECK
ENGINE AND EMISSION CONTROL - Emission Control System <Diesel>
17-51

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.
17500210030

49 Nm
49 Nm
49 Nm
2
1
13 Nm
Removal steps
NOTES
21-1
CLUTCH
CONTENTS
21109000190
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 5
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clutch Pedal Inspection and Adjustment . . . . . . . 2
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 7
21-2
General Information/Service
Specifications/Lubricants/On-vehicle Service
CLUTCH -
GENERAL INFORMATION
21100010093
The clutch is a dry single-disc, diaphragm type;

hydraulic pressure is used for the clutch control.
21100030150
Items
Standard value
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
LUBRICANTS
21100040078
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
ON-VEHICLE SERVICE
Clutch pedal height
21100090158
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
Adjusting bolt or
clutch switch
Lock nut
Lock nut
13 Nm
13 Nm
Push rod
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 - On-vehicle Service
21-3
4. Measure the clutch pedal play.
Clutch pedal clevis pin 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.
Clutch pedal free play
Distance between the clutch pedal and the

toeboard when the clutch is disengaged
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.
21-4
CLUTCH - Clutch Pedal
CLUTCH PEDAL
21100160224

Post-installtion Operation
Clutch Pedal Adjustment (Refer to P.21-2)
13 Nm
10
22
3
4
29 Nm
12 Nm
21
20
5
19
18
13
13 Nm
12
11
7
12
1
2
17
15
16
14
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.
15.
16.
17.
18.
19.
20.
21.
22.
Stopper <R.H. drive vehicles>

Clutch pedal
Pedal pad
Stopper
Adjusting bolt <Vehicles without auto
cruise control system>
Lock nut <Vehicles without auto cruise
control system>
Clutch switch <Vehicles with auto
cruise control system>
Clip <Vehicles with auto cruise control
system>
Master cylinder member assembly
21-5
CLUTCH - Clutch Control
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)

<4G6>
8
10
<4D6, 6A1>
8
6
5
9
10 - 12 Nm
19 Nm
3
13 Nm
Release
cylinder
push rod
Release
fork
15 Nm
Clutch master cylinder removal

steps
2. Clutch pipe connection
3. Clutch master cylinder
Clutch release cylinder removal
steps
5. Clutch release cylinder
Specified grease:
MITSUBISHI genuine
grease Part No. 0101011
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
21-6
13 Nm
3
<4G6>
2
4
8
10
<4D6, 6A1>
8
6
9
10 - 12 Nm
19 Nm
Release
cylinder push
rod
Release
fork
15 Nm
Clutch master cylinder removal

steps
3. Clutch master cylinder
Clutch release cylinder removal
steps
5. Clutch release cylinder
Specified grease:
MITSUBISHI genuine
grease Part No. 0101011
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
21-7

21100210172
CLUTCH MASTER CYLINDER

5
3 <4G6, 4D6>
7
6
13 Nm
8
1
3 <6A1>
3
Piston repair kit
Dsassembly steps
1. Piston stopper ring
2. Piston assembly
"AA 3. Push rod assembly
4. Boot
5. Reservoir cap
6. Spring pin
Clutch fluid:
Brake fluid DOT3 or DOT4
Grease: Rubber grease
7. Reservoir tank
8. Clutch master cylinder assembly
Caution
Do not disassemble piston assembly.

"AA PUSH 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
CONTENTS
22109000319
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Transmission Oil Replacement . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TRANSMISSION CONTROL* . . . . . . . . . . . . . . . . 4
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . 6
Transmission Oil Check . . . . . . . . . . . . . . . . . . . . . . . 3
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 (from rendering
MITSUBISHI dealer.
component.
NOTE
22-2
MANUAL TRANSMISSION - Lubricant/Special Tools
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
SPECIAL TOOLS
Tool
22100060187
Number
Name
Use
MB990635 or
MB991113
Steering linkage
puller
Ball joint disconnection
GENERAL
SERVICE
TOOL
MZ203827
Engine lifter

MB991453
Engine hanger
MANUAL TRANSMISSION - On-vehicle Service
ON-VEHICLE SERVICE
22-3
22100090124
TRANSMISSION OIL CHECK

Transmission oil
Filler plug hole
(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

Filler plug
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
32 Nm
Drain plug
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.
22-4
MANUAL TRANSMISSION - Transmission Control
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.
8
12 Nm
1
8
5
10
11
2
3
12 Nm
12
14
13
"BA
"BA
"BA
"AA
"AA
"AA
Shift cable and select cable

assembly removal steps
D Lower cover and side cover (Refer
to GROUP 52A - Instrument Panel.)
1. Shift knob
2. Spring washer
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
(Transmission side)
(Transmission side)
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
22-5

Shift lever
"AA SHIFT 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.
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.
"BA NUT/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.
22-6
SHIFT LEVER ASSEMBLY

22100400101
5 Nm
9
6
6 Nm
7
3
3
1
4
5
Disassembly steps
1. Bolt
2. Select lever
3. Bushing
4. Return spring
5. Collar
10
6.
7.
8.
9.
10.
Cap
Spacer
Shift lever
Shift lever bushing
Lever bracket
22-7
MANUAL TRANSMISSION - Transmission Assembly
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
5 <4G6>
19 Nm
5 <4D6, 6A1>
19 Nm
1
103 Nm
19 Nm
44 Nm
9
88
Nm*1
98 - 118 Nm*1
10
8
15
15
10 - 12 Nm
81 Nm
12
30 Nm
11
30 Nm
24 - 33 Nm
81 Nm
67 - 78 Nm
14
13
88 Nm
98 - 118 Nm
AA"
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>
8. Tie rod end connection
9. Stabilizer link connection
10. Damper fork
AB"
AC"
11.
12.
13.
14.
15.
No.2 stay
Lateral lower arm connection
No.3 stay
Compression lower arm connection
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.
22-8
57 Nm
16
18
81 Nm*2
49 Nm
19
17
25
19
30 Nm
24
10 - 12 Nm
24 49 Nm
22
25 Nm
49 Nm
57 Nm*2
23
44 Nm
7 Nm
20
10Nm <Flange bolts>

9Nm <Washer assembled bolts>
21
69 Nm
93 Nm
69 - 78 Nm
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>
AF"
AF"
23. Cover <6A1>

24. Transmission assembly lower part
coupling bolts
25. Transmission assembly
Caution
Mounting locations marked by *2 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.
22-9
Cord
AA" TIE ROD END DISCONNECTION
Ball joint
MB990635 or
MB991113
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.
Nut
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.
No.3 stay
Crossmember
Transmission
side
Pry bar
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.
22-10

MZ203827
AE" ENGINE AND TRANSMISSION ASSEMBLY

SUPPORTING
Set the special tool to the vehicle to support the engine and
transmission assembly.
MB991453
Flywheel
Bolt
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.
Engine side
"AA TRANSMISSION MOUNT STOPPER INSTALLATION

Install the transmission mount stopper so that the arrow points
Arrow
Transmission
mount
bracket
Transmission
mount
stopper
23-1
AUTOMATIC
TRANSMISSION
CONTENTS
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Essential Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
A/T Control Component Location . . . . . . . . . . . . . 51
23109000347
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 (from rendering
MITSUBISHI dealer.
component.
NOTE
23-2
AUTOMATIC TRANSMISSION -
Service Specifications/
Lubricants/Special Tools
23100030222
Items
Standard value
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
LUBRICANTS
23100040034
Items
Specified lubricant
Quantity L
Transmission fluid
DIA QUEEN ATF SPII or equivalent
7.8
SPECIAL TOOLS
Tool
23100060214
Number
Name
Use
MB991502
MUT-II sub
assembly
Checking of the diagnosis code
MD998330
(including
MD998331)
Oil pressure gauge

(2,942 kPa)
Measurement of oil pressure
MD998332
Adapter
MD998900
Adapter
AUTOMATIC TRANSMISSION - Special Tools

Tool
23-3
Number
Name
Use
MB990635 or
MB991113
Steering linkage
puller
MB991610
Oil filter wrench
Removal and installation of automatic transmission oil filter
GENERAL
SERVICE
TOOL
MZ203827
Engine lifter

MB991453
Engine hanger
assembly

23-4
AUTOMATIC TRANSMISSION - Troubleshooting
TROUBLESHOOTING
23100760275

Gathering information from customer.
Read the diagnosis code (GROUP 00

- How to Use Troubleshooting/Inspection Service Points.)
Communication with
MUT-II not possible
Inspection procedure No. 1 in

Inspection
Chart
For
Trouble
Symptoms (Refer to P.23-27.)
No diagnosis code displayed
Diagnosis code
displayed
Erase the diagnosis code (GROUP
00 - How to Use Troubleshooting/Inspection Service Points.)
Carry out the essential service

(Refer to P.23-46.)
Abnormality exists (no diagnosis code)
Road test (Refer to P.23-6.)

Abnormality exists
(diagnosis code
present)
No abnormality
Recheck diagnosis codes which
were read before the road test.
Diagnosis
code displayed
To INSPECTION CHART
DIAGNOSIS CODES
(Refer to P.23-14.)
FOR
To INSPECTION CHART
TROUBLE SYMPTOMS
(Refer to P.23-26.)
No diagnosis
code displayed
FOR
Search for cause.

Found
Repair
NG
Confirmation test (road test)
OK
NG
Not found
INTERMITTENT MALFUNCTION
(GROUP 00 - Points to Note for
Intermittent Malfunctions.)
OK
Completed

DIAGNOSIS FUNCTION
1. N range lamp
The N range lamp flashes at a frequency
1 Hz if there is an abnormality in any of
table below which are related to the A/T
the diagnosis code output if the N range
at a frequency of approximately 1 Hz.
23-5
23100770186
of approximately
the items in the
system. Check
lamp is flashing
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.)
23-6
ROAD TEST
23100780271
Check by the following procedure.

No.
State prior to test

and operation
Test and operation
Judgement value
Check item
Diagnosis
code
No.
Inspection
procedure page
if there is an
abnormality
Ignition switch:
OFF
Ignition switch
(1) ON
Data list No. 54

Battery voltage [V]
Control relay
54
A/T Control
relay system
(23-25)
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)

<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)
Data list No. 11

Accelerator pedal
(1) 400 - 1,000 mV
(1) Released
(2) Half depressed (2) Gradually rises
from (1)
(3) Depressed
(3) 4,500 - 5,000
mV
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)
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)
23-7

No.
State prior to test

and operation
Test and operation
Judgement value
Check item
Diagnosis
code
No.
Inspection
procedure page
if there is an
abnormality
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)
Idle position
switch
Idle position
switch system
(23-37)
Data list No. 21

Crank angle
(1) 550 - 850 rpm sensor
Gradually rises
from (1)
21
Crank angle
sensor system
(23-16)
Data list No. 57

(2) Data changes
Communication
with engineECU
<Vehicles
without TCL>
Communication
with TCL-ECU
<Vehicles with
TCL>
51
Serial
communication
system (23-25)
Should be no
abnormal shifting
shocks
Time lag should be
Malfunction
when starting
Engine stalling
during shifting
(23-30)
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)
Does not move

forward (23-28)
Does not
reverse (23-29)
Does not move

(forward or
reverse) (23-29)
Data list No. 64

Accelerator pedal
(1) ON
(1) Released
(2) Half depressed (2) OFF
Selector lever
position
(1) N D
(2) N R
within 2 seconds
Driving
impossible
23-8
No.
State prior to test

and operation
Test and operation
Judgement value
Check item
Diagnosis
code
No.
Inspection
procedure page
if there is an
abnormality
Selector lever
position: N
(Carry out on a
flat and straight
road.)
Selector lever
position and
vehicle speed
(1) Idling in
L range
(Vehicle
stopped)
(2) Driving at
constant speed
of
10 km/h in
L position
(3) Driving at
constant speed
of
30 km/h in
2 position
(4) Driving at
50 km/h in
3 position with
accelerator fully
closed
(5) Driving at
constant speed
of
50 km/h in
D position
(Each
condition
should be
maintained for
10 seconds or
more.)
Data list No. 63

(2) 1st, (4) 3rd, (3)
2nd, (5) 4th
Shift condition
Data list No. 31

(2) 0 %, (4) 100 %,
(3) 100 %, (5) 100
%
Low and reverse 31

solenoid valve
Low and reverse

solenoid valve
system (23-18)
Data list No. 32

(2) 0 %, (4) 0 %,
(3) 0 %, (5) 100 %
Underdrive
solenoid valve
32
Underdrive
solenoid valve
system (23-18)
Data list No. 33

(2)100 %, (4) 100
%, (3) 0 %, (5) 0 %
Second
solenoid valve
33
Second solenoid
valve system
(23-18)
Data list No. 34

(2) 100 %, (4) 0 %,
Overdrive
solenoid valve
34
Overdrive
solenoid valve
system (23-18)
Vehicle speed
sensor
Vehicle speed
sensor system
(23-38)
Data list No. 22

Input shaft
(4) 1,800 - 2,100 speed sensor
rpm
22
Input shaft speed

sensor system
(23-16)
Data list No. 23

Output shaft
(4) 1,800 - 2,100 speed sensor
rpm
23
Output shaft
speed sensor
system (23-17)
Selector lever
position and
vehicle speed
(1) Release the accelerator pedal
fully while driving at 50 km/h
in 3rd gear.
(2) Driving
at
constant speed
of 50 km/h in
3rd gear.
Data list No. 36

Damper clutch
control solenoid
(1) 0 %
(2) Approx. 70 - 90 valve
%
36
52
Damper clutch
control solenoid
valve system
(23-19)
Selector lever
position: 3
(Carry out on a
flat and straight
road.)
(3) 100 %, (5) 0 %

Data list No. 29
(1) 0 km/h
(4) 50 km/h
Data list No. 52

(1) Approx.
100 - 300 rpm
(2) Approx.
0 - 10 rpm
23-9

No.
State prior to test

and operation
Test and operation
Judgement value
Check item
Diagnosis
code
No.
Inspection
procedure page
if there is an
abnormality
Use the MUT-II to

stop the INVECSII function.
Selector lever
position: D
(Carry out on a flat
and straight road.)
Monitor data list

No. 11, 23, and 63
with the MUT-II.
(1) Accelerate to
4th gear at a
throttle
position
sensor output
of 1.5V
(accelerator
opening angle
of 30 %).
(2) Gently
decelerate to a
standstill.
(3) Accelerate to
4th gear at a
throttle
position
sensor output
of 2.5 V
(accelerator
opening angle
of 50%).
(4) While driving at
60 km/h in 4th
gear,
shift
down to
3 range.
40 km/h in 3rd
gear,
shift
down to
2 range.
20 km/h in 2nd
gear,
shift
down to
L range.
For (1), (2) and (3),

the reading should
be the same as the
specified output
shaft speed and no
abnormal shocks
should occur.
For (4), (5) and (6),
downshifting
should occur
immediately
after the shifting
operation is made.
Malfunction
when shifting
Shocks and
running up
(23-32)
Displaced
shifting points
All points (23-33)
Some points
(23-34)
Does not shift
No diagnosis
code (23-34)
22
Input shaft
speed sensor
system (23-16)
23
Output shaft
speed sensor
system (23-17)
31
Low and reverse

solenoid valve
system (23-18)
33
Second
solenoid valve
system (23-18)
41
1st gear ratio is

not specified
(23-20)
42
2nd gear ratio is

not specified
(23-21)
33
Second
solenoid valve
system (23-18)
34
Overdrive
solenoid valve
system (23-18)
42
2nd gear ratio is

not specified
(23-21)
43
3rd gear ratio is

not specified
(23-22)
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)
Does not shift

from 1 to 2 or 2
to 1
Does not shift

from 2 to 3 or 3
to 2
Does not shift

from 3 to 4 or 4
to 3
23-10
No.
State prior to test

and operation
Test and operation
Judgement value
Check item
Diagnosis
code
No.
Inspection
procedure page
if there is an
abnormality
Selector lever
position: N
(Carry out on a
flat and straight
road.)
Monitor data list

No. 22
and No. 23 with the
MUT-II.
II
(1) Move selector
lever to
R range, drive
at constant
speed of
10 km/h.
The ratio between

data list No. 22 and
No. 23 should be
the same as the
gear ratio when
reversing.
Does not shift
22
Input shaft
speed sensor
system (23-16)
23
Output shaft
speed sensor
system (23-17)
46
Reverse gear
ratio is not
specified (23-24)
SHIFT PATTERN
<4G63 engine>
UPSHIFT PATTERN
Throttle opening %
Thick line: Standard shift pattern
100
1
50
23
movement
range
1,000
2,000
34
movement
range
3,000
4,000
5,000
6,000
7,000
Output shaft speed r/min

0
50
100
Vehicle speed km/h
150
200
23-11

DOWNSHIFT PATTERN
Throttle opening %
100
1,000
2,000
3 (L,2)
4
(L,2,3)
34
movement
range
23
movement
range
2 (L)
50
50
3,000
4,000
5,000
100
6,000
7,000
150
200
Vehicle speed km/h
HOLD MODE PATTERN
Throttle opening %
100
50
1
2,000
50
4,000
100
Vehicle speed km/h
6,000
150
8,000
200
23-12
<6A13 engine>
UPSHIFT PATTERN
Throttle opening %
100

1
50
23
movement
range
1,000
2,000
50
34
movement
range
3,000
4,000
5,000
100
Vehicle speed km/h
150
6,000
7,000
200
DOWNSHIFT PATTERN
Throttle opening %
100

1
2 (L)
3 (L,2)
4
(L,2,3)
50
23
movement
range
34
movement
range
1,000
2,000
50
3,000
4,000
100
Vehicle speed km/h
5,000
150
6,000
7,000
200
23-13

HOLD MODE PATTERN
Throttle opening %
100
50
1
2,000
50
4,000
100
Vehicle speed km/h
6,000
150
8,000
200
23-14
INSPECTION CHART FOR DIAGNOSIS CODE
23100790243
Code
Diagnosis item
11
Short circuit
23-15
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
Open circuit
23-16
22
Input shaft speed sensor system
Short circuit/open circuit
23-16
23
Output shaft speed sensor system
23-17
25
Wide open throttle switch system
Short circuit
23-17
26
Stop lamp switch system
23-18
31
Low and reverse solenoid valve system
23-18
32
Underdrive solenoid valve system
23-18
33
Second solenoid valve system
23-18
34
Overdrive solenoid valve system
23-18
36
Damper control clutch solenoid valve system
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
12
Reference page
23-26
23-15

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.
Throttle position sensor check <Vehicles without TCL>

Accelerator pedal position sensor check<Vehicles with TCL>
(Refer to GROUP 13H - On-vehicle Service.)
NG
D
D
D
Malfunction of the throttle position sensor <Vehicles

without TCL>
<Vehicles with TCL>
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>
OK
Check the trouble symptoms.
NG
NG
Repair
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
D
D
Oil temperature sensor check (Refer to P.23-52.)
NG
Malfunction of the oil temperature sensor

Replace
OK
Check the follwing connectors: B-70, C-29
NG
Repair
OK
Harness check
D Between oil temperature sensor and A/T-ECU
OK
NG
NG
Repair
23-16
Probable cause
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.
D
D
D
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
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the input shaft speed sensor

the underdrive clutch retainer
connector
A/T-ECU
L: Refer to the Transmission Workshop Manual.

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
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
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 (Inspection procedure using an oscilloscope). There is no noise
in the output waveform.
OK

B-71, C-29
NG
NG
NG
NG
Repair
Repair
Replace the input shaft speed sensor.
NG
A/T overhaul K
D Replace the
retainer.
underdrive
clutch

NG
NG
Eliminate the cause of the noise.
23-17

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
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the output shaft speed sensor

the transfer drive gear or driven gear
connector
the A/T-ECU

Measure at the output shaft speed sensor connector B-68.
OK: Battery voltage
OK: approx. 5 V
(3) Continuity between 1 and earth
OK: Continuity
NG
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
OK
OK
NG
NG
Repair
Repair
Replace the output shaft speed sensor.

NG
A/T overhaul L
D Replace the transfer drive gear and
driven gear.
NG
NG
NG
NG
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 (Inspection procedure using an oscilloscope). There is no noise
in the output waveform.

B-68, C-29
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
D
D
Wide open throttle switch check (Refer to P.23-64).
NG
Malfunction of the wide open throttle switch

Replace
OK
NG
Repair
OK
Harness check
D Between the wide open throttle switch and the A/T-ECU.
OK
NG
NG
Repair
23-18
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.
D
D
D
Stop lamp switch check (Refer to GROUP 35 - Brake Pedal.)
NG
Malfunction of the stop lamp switch

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
OK
NG
NG
Repair
Probable cause
Code No. 31 Low and reverse solenoid valve system

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-safe measure,
and the N range lamp flashes at a frequency of 1 Hz.
Solenoid valve check (Refer to P.23-54.)
NG
D
D
D

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
D
D
Damper clutch control solenoid valve check (Refer to P.23-54.)
NG
Malfunction of the damper clutch control solenoid valve

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
23-19
23-20
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
D
D
D
D
D
D
Malfunction of the
Malfunction of the
Malfunction of the
Malfunction of the
Malfunction of the
Malfunction of the
Noise generated
input shaft speed sensor

output shaft speed sensor
underdrive clutch retainer
transfer drive gear or driven gear
low and reverse brake system
underdrive clutch system

Is the diagnosis code No. 22 output?
No
No
Measure output waveform from 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: A waveform such as the one shown on P.23-45 (Inspection
Procedure Using an Oscilloscope) is output (flalshing
between 0 5V) and there is no noise appearing
in the waveform.
Yes
Yes
NG
Code No. 22 Input shaft speed sensor system check

(Refer to P.23-16.)
Code No. 23 Output shaft speed sensor system check
(Refer to P.23-17.)

NG
A/T overhaul L
D Replace the underdrive clutch retainer.
OK
NG
Measure output waveform from the output shaft speed sensor.
(Voltage)
in the waveform.
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).
NG

NG
A/T overhaul L
D Replace the transfer drive gear and driven gear.
NG

Code No. 42 2nd gear ratio does 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
D
D
D
D
D
D
Malfunction of the
Malfunction of the
Malfunction of the
Malfunction of the
Malfunction of the
Malfunction of the
Noise generated
23-21

second brake system

No
No
an oscilloscope)
(Voltage)
in the waveform.
Yes
Yes
NG

(Refer to P.23-16.)
(Refer to P.23-17.)

NG
A/T overhaul L
OK
NG
(Voltage)
in the waveform.
OK
A/T overhaul L
D Second brake system check
NG

NG
A/T overhaul L
NG
23-22
Code No. 43 3rd gear 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
D
D
D
D
D
D
Malfunction of the
Malfunction of the
Malfunction of the
Malfunciton of the
Malfunction of the
Malfunction of the
Noise generated

overdrive clutch system

No
No
an oscilloscope)
(Voltage)
in the waveform.
Yes
Yes
NG

(Refer to P.23-16.)
(Refer to P.23-17.)

NG
A/T overhaul L
OK
NG
(Voltage)
in the waveform.
OK
A/T overhaul L
D Overdrive clutch system check
NG

NG
A/T overhaul L
NG

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
D
D
D
D
D
D
Malfunction of the
Malfunction of the
Malfunction of the
Malfunction of the
Malfunction of the
Malfunction of the
Noise generated
23-23

second brake system
overdrive clutch system

No
No
an oscilloscope)
(Voltage)
Procedure Using an Oscilloscope) is output (flashing between 0 5V) and there is no noise appearing in
the waveform.
Yes
Yes
NG

(Refer to P.23-16.)
(Refer to P.23-17.)

NG
A/T overhaul L
OK
NG
(Voltage)
in the waveform.
OK
A/T overhaul L
D Second brake system check
D Overdrive clutch system check
NG

NG
A/T overhaul L
NG
23-24
Code No. 46 Reverse gear ratio

specification
does not meet the
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.
Probable cause
D
D
D
D
D
D
D
Malfunction of the
Malfunction of the
Malfunction of the
Malfunciton of the
Malfunction of the
Malfunction of the
Noise generated

low and reverse brake system
reverse clutch system

No
No
an oscilloscope)
(Voltage)
in the waveform.
Yes
Yes
NG

(Refer to P.23-16.)
(Refer to P.23-17.)

NG
A/T overhaul L
OK
NG
(Voltage)
in the waveform.
OK
A/T overhaul L
D Low and reverse brake system check
D Reverse clutch system check (No diagnosis code is output).
NG

NG
A/T overhaul L
NG

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
D
D
D

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>
OK
Harness check
D Between engine-ECU and A/T-ECU
D Between TCL-ECU and A/T-ECU
<Vehicles with TCL>
NG
NG
Malfunction of the engine-ECU <Vehicles without TCL>
Malfunction of the TCL-ECU <Vehicles with TCL>
Repair
Repair
OK
NG
<Vehicles with TCL>
NG
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
D
D
Check the A/T control relay. (Refer to P.23-53.)
NG
Malfunction of the A/T control relay

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
OK
NG
NG
23-25
Repair
23-26
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
D
D
Check the N range lamp bulb

(Refer to GROUP 52A - Instrument Panel.)
NG
Malfunction of the N range lamp bulb

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
OK
NG
NG
Repair
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.
23100800267
Trouble symptom
Inspection
procedure No.
Reference
page
Communication with MUT-II is not possible
23-27
Driving impossible
Starting impossible
23-28
Does not move forward
23-28
Does not reverse
23-29
Does not move (forward or reverse)
23-29
Engine stalling when shifting
23-30
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
Shocks and running up
10
23-32
Malfunction when starting
Malfunction when shifting
23-27

Trouble symptom
Inspection
procedure No.
Reference
page
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
18
23-37
Dual pressure switch system
19
23-37
20
23-38
Auto-cruse-ECU signal system
21
23-38
Displaced shifting points

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
D
D
Is communication with other systems

possible using the 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
OK
No
Harness check
D Between diagnosis connector and
A/T-ECU
OK
Check the diagnosis line with MUT-II,

NG

C-28, C-30, C-45, C-83, C-131, C-134
OK
Harness check
power
supply
and
D Between
A/T-ECU
D Between earth and A/T-ECU
OK
NG

C-20, C-28, C-30, C-49, C-66, C-83
OK
Malfunction of diagnosis line

NG
NG
NG
Repair
Repalce the A/T-ECU.
Repair
NG
NG
Repair
Repair
23-28
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
D
D
Malfunction of the engine system

Malfunction of the torque converter
Malfunction of the oil pump

Check the engine system.
D Control system, ignition system, fuel system, main engine
system
OK
Torque converter check
D Check for incorrect installation (inserted at an angle, etc.) and
for damaged splines.
NG
NG
Repair, replace
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
D
D
D
Abnormal line
Malfunction of
Malfunction of
Malfunction of
pressure
the underdrive solenoid valve
the underdrive clutch
the valve body

D No. 2 Underdrive solenoid valve
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
NG
OK
OK
Underdrive clutch system check L
D Remove the transmission assembly, valve body cover and valve
body.
NG
D Pistons should operate and pressure should be maintained
when air is blown through the underdrive clutch oil hole in the
transmission case.
Replace the solenoid valve. L
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.
Underdrive clutch check L

D Check for burning of the facing, defective piston seal rings
and interference at the retainer.
23-29
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
D
D
D
D
D
Abnormal reverse clutch pressure

Abnormal low and reverse brake pressure
Malfunction of the low and reverse solenoid valve
Malfunction of the reverse clutch
Malfunction of the low and reverse brake
Malfunction of the valve body

D No. 1 Low and reverse solenoid valve
OK
Hydraulic pressure check (Refer to P.23-56.)
D Measure the reverse clutch pressure in R range.
OK
D Measure the low and reverse brake pressure in R range.
NG
Replace the low and reverse solenoid valve. L
NG
NG
OK
Reverse clutch system and low and reverse brake system check OK
L
body.
D Pistons should operate and pressure should be maintained NG
when air is blown through the reverse clutch oil hole and the
low reverse brake oil hole in the transmission case.

assembly.
Reverse clutch and low and reverse brake check L

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
D
D
D
Abnormal line
Malfunction of
Malfunction of
Malfunction of
pressure
power train
the oil pump
the valve body

D Measure the hydraulic pressure for each element when moving
forward and back.
NG
Replace the oil pump assembly. L
OK
NG
Power train check L

D Disassemble the transmission, check the condition of the
planetary carrier, output shaft and differential, etc.

assembly.
23-30
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
D
D
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
D
D
D
D
Abnormal underdrive clutch pressure

Malfunction of the underdrive solenoid valve
Malfunction of the underdrive clutch
Malfunction of the idle position switch

OK
NG
Replace the underdrive solenoid valve. L
When starting
Shocks sometimes occur
When does the shock occur?
No
When shifting
D Measure the underdrive clutch pressure when shifting from
N to D.
NG
Underdrive clutch system check L

body.
when air is blown through the underdrive clutch oil hole in the
transmission case.
NG
Underdrive clutch check L
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
OK
OK
Yes
NG
Idle position switch check

D INSPECTION PROCEDURE 18 - Idle position switch system
check (Refer to P.23-37.)

assembly.
23-31
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
D
D
D
D
D
D
Abnormal reverse clutch pressure

Abnormal low and reverse brake pressure
Malfunction of the reverse clutch
Malfunction of the low and reverse brake

OK
NG
Replace the low and reverse solenoid valve. L
When starting
Shocks sometimes occur
No
When shifting
D Measure the reverse clutch pressure in R range.
NG
OK

D Measure the low and reverse brake pressure in R range.
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.
NG
Reverse clutch and low reverse brake check L
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
OK
Yes
NG

D INSPECTION PROCEDURE 18 - Idle position switch system
check (Refer to P.23-37.)
assembly.
23-32
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.
D
D
D
Abnormal line pressure


D Measure the hydraulic pressure for each element when in D
range and R range.
OK
NG
Adjust the line pressure. (Refer to P.23-62.)

NG
When
starting
When shifting

assembly.
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
D
D
D
D
Abnormal line
Malfunction of
Malfunction of
Malfunction of
Malfunction of
pressure
each solenoid valve
the oil pump
the valve body
each brake or each clutch

D No. 3 Second solenoid valve
D No. 4 Overdrive solenoid valve
OK
OK
Clutch and brake check L
NG
NG
Replace the solenoid valve.

NG
assembly.
23-33

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
D
D
D
D
D
Malfunction of
Malfunction of
Malfunction of
Abnormal line
Malfunction of
Malfunction of
the output shaft speed sensor

the throttle position sensor
each solenoid valve
pressure
the valve body
the A/T-ECU

MUT-II Data list
D No. 23 Output shaft speed sensor
OK: Increases in proportion to vehicle speed.
OK
MUT-II Data list
D No. 11 TPS/APS
OK: Increases in proportion to accelerator pedal opening angle
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.
OK
NG
Code No. 23 - Output shaft speed sensor system (Refer to P.23-17.)
NG
Code No. 11, 12, 14 TPS/APS system check (Refer to P.23-15.)
NG
Replace the solenoid valve. L

NG
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%
23-34
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
Yes
Does the problem occur only when the

automatictransmissionfluidtemperature
is - 29_C or lower or 125_C or higher?
No
Yes
It is related to control and is not an abnormality.
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.
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
D
Does the transmission remain in 3rd

gear with selector lever in position
D ?
No
Yes
Is backup power being supplied to the
A/T-ECU?
No
OK
Yes
Is power being supplied to the

A/T-ECU?
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.
MUT-II Data list

D No. 61 Inhibitor switch
OK: A/T-ECU input signal and selector lever position should
match.
Yes
MUT-II Data list

D No. 62 Hold mode signal
OK: The signal should change
when the mode control switch
position is changed.
OK
Malfunction of the inhibitor switch

NG
NG
Inhibitor switch check

D INSPECTION PROCEDURE 16 Inhibitor switch system check.
(Refer to P.23-36.)
Mode control switch check

D INSPECTION PROCEDURE 17 Mode control switch system check
(Refer to P.23-36.)
23-35
Poor acceleration
Probable cause
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
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
D
D
D
D
Abnormal damper clutch pressure

Malfunction of the torque converter

D No. 6 Damper clutch control solenoid valve
OK
Does the problem occur even when the oil temperature sensor
connector is disconnected?
NG
Yes
No
D Measure the damper clutch pressure.
OK
Replace the torque converter assembly.
NG
Replace the damper clutch control solenoid valve. L
Engine system check

main system.
assembly.
23-36
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
D
D
D
Inhibitor switch check (Refer to P.23-49.)

OK
Check the voltage of the inhibitor switch
connector B-72.
D Voltage between terminal No. 8 and
earth
OK: Battery voltage
OK
B-72, C-30, C-47, C-48
OK
Harness check
D Between inhibitor
A/T-ECU connector
NG
the inhibitor switch

the ignition switch
connector
the A/T-ECU

C-49, C-83, C-131, C-134
OK
Harness check
D Between inhibitor switch and
ignition switch
NG
NG
NG
Repair
Repair
OK
Repair

NG
and
OK
of
of
of
of
Replace
NG
NG
switch
Malfunction
Malfunction
Malfunction
Malfunction
Repair
NG
Ignition switch check

(Refer to GROUP54 - Ignition Switch.)
Mode control switch system
Probable cause
The cause is probably a defective mode control switch circuit or a defective A/T-ECU.
D
D
D
Mode control switch check

OK
Check the voltage of the A/T-ECU connector C-30.
D Disconnect the connector and check
at the harness side.
D Select the HOLD mode.
D Voltage between terminal No. 70 and
earth
OK: Battery voltage
NG
NG
Malfunction of the mode control switch

Replace

C-49, C-83, C-89, C-131, C-134
OK
Harness check.
D Between mode control switch and
A/T-ECU
Harness check
D Between mode control switch and
ignition switch
OK
NG
Check the following the connector:

C-30
NG
Repair
Repair
OK
OK
OK
NG
Ignition switch check (Refer to GROUP

54 - Ignition Switch.)
NG
NG
Repair
23-37

Probable cause
The cause is probably a defective idle position switch circuit or a defective A/T-ECU.
D
D
D
NG


OK
B-07 <Vehicles without TCL>, B-41 <Vehicles with TCL>, C-29
NG
Repair
OK
NG
Harness check
D Between idle position switch and A/T-ECU
OK
NG
Repair
Dual pressure switch system
Probable cause
The cause is probably a defective dual pressure switch circuit or a defective A/T-ECU.
D
D
D
D
Dual pressure switch check (Refer to

GROUP 55 - On-vehicle service.)
OK
Check the voltage of the A/T-ECU connector C-28.
check at the harness side.
D A/C switch: ON
D Voltage between terminal No. 10
and earth
OK: Battery voltage
NG
A/C system check (Refer to GROUP
55 - Troubleshooting.)
NG
OK
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the dual pressure switch

connector
A/C system
the A/T-ECU
Replace

B-30, C-28
NG
Repair
OK
NG
Check the A/C system. (Refer to
GROUP 55 - Troubleshooting.)
OK
NG
Repair
23-38
Probable cause
The cause is probably a defective vehicle speed sensor circuit or a defective A/T-ECU.
D
D
D
Check the vehicle speed sensor.

(Refer to GROUP 54 - Combination Meters.)
NG

Replace
OK
1. NG
Measure at the vehicle speed sensor connector B-67.
2. NG
OK: Battery voltage
3. NG
OK: 4.8 - 5.2 V
OK: Continuity
OK
Check the
connector:
B-67
following
NG
Repair
Repair

NG
NG
Repair
Check the ignition switch. (Refer to GROUP 54 - Ignition switch.)

sensor connector.
OK
NG
OK

between the vehicle
switch connector.
OK
OK
NG
Check the following

connectors:
C-90, C-131, C-135
NG
Check the
connectors:
C-30, C-48
Repair
following
NG
Repair
OK
NG

sensor connector.
OK
NG
Repair

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
D
D
Auto-cruise system check (Refer to GROUP 17 - Troubleshooting.)
NG
Malfunction of the auto-cruise-ECU
Repair
OK
OK
Harness check
D Between auto-cruise-ECU and A/T-ECU
NG
Repair
NG
OK
Repair
23-39

Item No. Check item
Check requirement
11
Engine: Stopped
Selector lever
position: P

Accelerator pedal
position sensor
<Vehicles with TCL>
23100810208
Normal value
Accelerator pedal:
Released
400 - 1,000 mV
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
position: P
Accelerator pedal:
Released
550 - 900 rpm
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

switch
Accelerator pedal
position
Released
OFF
Depressed
ON
Stop lamp switch
Ignition switch: ON
Engine: Stopped
Brake pedal: Depressed
ON
Brake pedal: Released
OFF
Selector lever
position: 3
Idling with 1st gear

(Vehicle stopped)
0 km/h

50 km/h
10 km/h in 1st gear
No. 31: 0 %, No. 32: 0

%, No. 33: 100 %,
No. 34: 100%
26
29
31
Low and reverse

solenoid valve duty %
Selector lever
position: L, 2, 3, D
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%
23-40
Item No. Check item
Check requirement
36
Selector lever
position: 3
52
Damper clutch control

solenoid valve duty %
Amount of damper
clutch slippage
Selector lever
position: 3
Normal value
Driving at 50 km/h in
3rd gear with accelerator
released
0%

Approx. 70 - 90 %
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
Engine: Stopped
Selector lever position: R
Selector lever position: N
Selector lever position: 3
Selector lever position: L
Mode control switch

position
HOLD
ON
AUTO
OFF
Selector lever position: 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
Engine: Idling
Accelerator pedal:
Released
ON
Accelerator pedal:
Halfly depressed
OFF
Engine: Idling
A/C switch: ON
ON
A/C switch: OFF
OFF
62
63
64
65
HOLD mode signal
Shift position
Dual pressure switch
23-41

Item No. Check item
Check requirement
66
While auto-cruise
operating
Auto-cruse-ECU signal
Normal value
Plain road
OFF
Sloping road
ON
NOTE
*: The damper clutch is released when the accelerator is fully closed (Idle position switch: ON).
ACTUATOR TEST JUDGEMENT VALUE
23100820065
Item No.
Check item
Test content
Check requirement
Normal value
Low reverse solenoid valve
Underdrive solenoid valve

Damper clutch control

solenoid valve
12
A/T control relay
Ignition switch: ON
Selector lever
position: P
Engine: 0 r/min
Vehicle speed:
0 km/h
(Vehicle stopped)
Throttle
(Accelerator)
opening voltage:
Less than 0 V
Idle switch: ON
The operation sound should

be audible when the solenoid
valve is driven.
Drive the solenoid

valve specified by
the MUT-II at 50 %
duty for 5 seconds.
No other solenoid
valve should be
energised.
Control relay is OFF

for 3 seconds.
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.
Use this function when carrying

out procedure 8 in the road
tests.
23-42
CHECK AT A/T-ECU TERMINALS
23100840207
Terminal
No.
Check item
Check requirement
Standard value
Selector lever position: D (1st gear)
Battery voltage
Approx.7 - 9 V
0V
Ignition switch: ON
Battery voltage
0V
Ignition switch: ON
Battery voltage
No OD-OFF request
Battery voltage
OD-OFF request
0V
A/C switch: OFF
0V
A/C switch: ON
Battery voltage
0V
Ignition switch: ON
Battery voltage
10
11
Solenoid valve power supply
Solenoid valve power supply
Auto-cruse control unit
A/C compressor load signal
Power supply
12
Earth
Always
0V
13
Earth
Always
0V
14
Selector lever position: D (3rd gear)
Battery voltage
Approx. 7 - 9 V
Damper clutch control solenoid

valve
Selector lever position: L (1st gear)
Battery voltage
Selector lever position: 3 (50 km/h in 3rd gear)
Other than
battery voltage
Selector lever position: 2 (2nd gear)
Battery voltage
Approx. 7 - 9 V
Ignition switch: ON (except during shifting)
4 - 5V
15
16
21
Engine-ECU torque reduction

request signal
<Vehicles with TCL>
23-43

Terminal
No.
Check item
Check requirement
Standard value
23
Diagnosis control
24
Power supply
0V
Ignition switch: ON
Battery voltage
25
Earth
Always
0V
26
Earth
Always
0V
31
Measure between terminal No. 31 and No. 43 by

an oscilloscope.
Engine: 2,000 r/min
Refer to P.23-45,
Oscilloscope
inspection
procedure.
32
Measure between terminal No. 32 and No. 43 by

an oscilloscope.
Engine: 2,000 r/min
Refer to P.23-45,
Oscilloscope
inspection
procedure.
33
Crank angle sensor
Engine: Idling
2.0 - 2.4 V
36
Engine: Idling
0V
Engine: Other than idling
5V
38
Back up power suuply
Battery voltage
43
Sensor earth
Always
0V
44
ATF temperature: 25 _C
3.8 - 4.0 V
ATF temperature: 80 _C
2.3 - 2.5 V
Throttle position sensor (TPS)

(APS) <Vehicles with TCL>
Accelerator pedal: Released (Engine stopped)
0.5 - 1.0 V
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
Battery voltage
Selector lever position: Other than above
0V
Battery voltage
0V
Battery voltage
0V
45
56
57
Inhibitor switch N
Inhibitor switch 3
23-44
Terminal
No.
Check item
Check requirement
Standard value
58
Inhibitor switch L
Selector lever position: L
Battery voltage
0V
Brake pedal: Depressed
Battery voltage
Brake pedal: Released
0V
Selector lever position: D (1st gear)
Battery voltage
Selector lever position: D (2nd gear)
Approx. 7 - 9 V
59
62
Stop lamp switch
Low and reverse solenoid valve
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
Selector lever position: R
Battery voltage
0V
Battery voltage
0V
Battery voltage
0V
When stopped
0V
Move forward slowly
0 5 V flashing
Select HOLD mode
Battery voltage
Select AUTO mode
0V
0V
Ignition switch: ON
Battery voltage
Ignition switch: ON
0V
66
67
68
69
70
71
72
Inhibitor switch R
Inhibitor switch D
Inhibitor switch 2
Mode control switch
A/T control relay
Earth

OSCILLOSCOPE INSPECTION PROCEDURE
23-45
23100850064
Check item
Check requirement
Crank angle sensor
Idling (Vehicle stopped)
Waveform A
Input shaft speed

sensor
Driving at constant speed of 50

km/h in 3rd gear
(Engine: 1,800 - 2,100 r/min)
Waveform B
Ignition switch: ON
Engine: 0 r/min
Vehicle speed: 0 km/h
(Vehicle stopped)
Throttle (Accelerator) opening
angle: Less than 1 V
Idle switch: ON
Force drive each solenoid valve

(Actuator test)
Waveform C
Output shaft
speed sensor
Normal condition
(Waveform sample)

Low reverse
solenoid valve
Underdrive solenoid
valve
Second solenoid
valve
Overdrive solenoid
valve
Damper clutch
control solenoid
valve
Waveform sample
Waveform A
Waveform B
(V)
Waveform C
(V)
60
(V)
5
40
20
0
0
(ms)
(ms)
(ms)
23-46
AUTOMATIC TRANSMISSION - On-vehicle Service
ON-VEHICLE SERVICE
23100090237
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.
23-47
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 from the bottom of 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
23-48

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 COLD level is for reference only; the HOT level should
be regarded as the standard level.
Apply ATF
to O-ring
14. Firmly insert the oil level gauge into the oil filler tube.
23101050067
OIL FILTER REPLACEMENT
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
23100190142

ADJUSTMENT <Vehicles with TCL>
23100250048
23-49

INHIBITOR SWITCH CONTINUITY CHECK
Items
23100140345
Terminal No.
1
10
P
R
N
D
Inhibitor switch
3
2
L
P
R
N
D
3
2
L
Transmission
control cable
Manual
control
lever
Adjusting nut
INHIBITOR SWITCH AND CONTROL CABLE

23100150096
ADJUSTMENT
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.
23-50

10 - 12 Nm
Mounting bolts
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.
A
Manual
control lever
Section A-A
Hole in end
Hole in
flange
Manual control
lever
Inhibitor
switch body
12 Nm
Adjusting nut
Manual control lever
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.
23-51

A/T CONTROL COMPONENT LOCATION
23100860234
Name
Symbol
Name
Symbol
Accelerator position sensor (with idle position

switch) <Vehicles with TCL>
Mode control switch
A/T control relay
A/T-ECU
Crank angle sensor
Shift indicator lamp
Diagnosis connector
Solenoid valve
Stop lamp switch
Engine ECU
TCL-ECU
Inhibitor switch

switch) <Vehicles without TCL>
Wide open throttle switch
B
E
A
F
G
H
P
O
K
N
M
23-52

A/T CONTROL COMPONENT CHECK
23100900011

23100390030
ACCELERATOR PEDAL POSITION SENSOR CHECK

23100420029
<Vehicles with TCL>
Refer to GROUP 13H - On-vehicle Service.
OIL TEMPERATURE SENSOR CHECK

1. Remove the oil temperature sensor.
23100450035
2. Measure the resistance between terminals No. 1 and

No. 2 of the oil temperature sensor connector.
Standard value:
ATF
Oil temperature (_C)
Resistance (kW)
16.7- 20.5
100
0.57- 0.69
INHIBITOR SWITCH CHECK

Refer to P.23A-49.
23100140352

Refer to GROUP 35 - Brake Pedal.
23100910014

23100460038
23-53
DUAL POSITION PRESSURE SWITCH CHECK

23100470031

23100410033
MODE CONTROL SWITCH CHECK

Refer to P.23-65.
23100920048
WIDE OPEN THROTTLE SWITCH CHECK

Refer to P.23-64.
23100890080
A/T CONTROL RELAY CHECK

1. Remove the A/T control relay.
23100930065
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.
23-54
Overdrive
solenoid
valve

Underdrive
solenoid
valve
23100940013
SOLENOID VALVE CHECK
1. Remove the valve body cover.
2. Disconnect the connectors of each solenoid valve.
Second
solenoid
valve
Low and
reverse
solenoid
valve
Damper
clutch
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
(at 20_C)
Low and reverse solenoid valve

4. If the resistance is outside the standard value, replace

the solenoid valve.
TORQUE CONVERTER STALL TEST

Reverse
clutch
Torque
converter
Low-reverse Underdrive
brake
clutch
23100540206
This test measures the maximum engine speed when the

selector lever is at the D or R position 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
23-55
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
23-56

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.
23-57
STANDARD HYDRAULIC PRESSURE TEST

<4G63>
Standard hydraulic pressure kPa
Selector
lever
position
Shift position
Engine
speed
(r/min)
Underdrive
clutch
pressure
Reverse
clutch
pressure
Overdrive
clutch
pressure
Low and
reverse
brake
pressure
Second
brake
pressure
Torque
converter
pressure
2,500
310 - 390
310 - 390
Reverse
2,500
1,320 1,720
1,320 1,720
500 - 700
2,500
310 - 390
310 - 390
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>
Standard hydraulic pressure kPa
Selector
lever
position
Shift position
Engine
speed
(r/min)
Underdrive
clutch
pressure
Reverse
clutch
pressure
Overdrive
clutch
pressure
Low and
reverse
brake
pressure
Second
brake
pressure
Torque
converter
pressure
2,500
260 - 340
260 - 340
Reverse
2,500
1,320 1,720
1,320 1,720
500 - 700
2,500
260 - 340
260 - 340
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
23-58
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.

Clogged internal oil filter
Clogged external oil filter
Clogged oil cooler
Malfunction of the relief valve
Incorrect valve body installation
Hydraulic pressure is abnormal

in R range only.

Clogged orifice
Hydraulic pressure is abnormal

in 3 or 4 range only.
Malfunction of the overdrive solenoid valve

Malfunction of the overdrive pressure control valve
Malfunction of the switch valve
Clogged orifice
Only underdrive hydraulic

pressure is abnormal.
Malfunction of the oil seal K

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 pressure control valve
Malfunction of the switch valve
Malfunction of the fail safe valve A
Clogged orifice
Only second hydraulic pressure

is abnormal.
Malfunction of the oil seal G

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

is abnormal.
Malfunction of the oil cooler

Malfunction of the oil seal N
Malfunction of the damper clutch control valve
Malfunction of the torque converter pressure control valve
Clogged orifice
Pressure applied to non

operating element.

Malfunction of the manual valve
23-59
23-60
OIL SEAL LAYOUT
F G
D
C
B
A
23-61

HYDRAULIC CIRCUIT
23100880070
PARKING AND NEUTRAL
5
6
10
11
12
13
14
15
19
17
21
16
20
24
18
22
23
25
26
R ND
P3
2
L
27
29
28
30
31
32
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Reverse clutch
Low-reverse brake
Second brake
Underdrive clutch
Overdrive clutch
Accumulator
Check ball
Damper clutch
Fail safe valve A
Fail safe valve B
Damper clutch control valve
Switch valve
Automatic transmission fluid cooler
Lubrication
Low-reverse pressure control valve
Second pressure control valve
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
23-62

LINE PRESSURE ADJUSTMENT
Adjusting
screw
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
Push button
Button not pressed

Button pressed
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.
23-63
AUTOMATIC TRANSMISSION - Transmission Control
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.
9
1
12 Nm
3
4
8
12 Nm
12 Nm
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 connection
6. Transmission control cable assembly
Selector lever assembly removal

steps
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
23-64

Nut
Manual control lever
"AA NUT 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.
INSPECTION
23100890097
WIDE OPEN THROTTLE SWITCH CHECK

OFF
ON
Switch position
Terminal No.
1
OFF
ON
23-65

SELECTOR LEVER ASSEMBLY
23100680168
1
2
3
4
6
2 Nm
10
2 Nm
7
12
14
11
11
15
13 Nm
13
9
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.
10.
11.
12.
13.
14.
15.
Bolt
Shift lever assembly
Bushing
Detent spring
Pipe
Position indicator lamp assembly
Bracket assembly
INSPECTION
23100670059
A/T MODE CHANGEOVER SWITCH CHECK

Switch position
Terminal No.
1
OFF
ON
23-66
AUTOMATIC TRANSMISSION - Transmission Assembly
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
12 Nm
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
103 Nm
11
44 Nm
5
17
88 Nm*1
12
98 - 118 Nm*1
10
17
10 - 12 Nm
81 Nm
14
13
30 Nm
30 Nm
24 - 33 Nm
67 - 78 Nm
81 Nm
16
98 - 118 Nm
Removal steps
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 assembly connector
8. Vehicle speed sensor connector
9. Starter motor <6A1>
15
88 Nm
AA"
AB"
10.
11.
12.
13.
14.
15.
16.
17.
Tie rod end connection

Stabilizer link connection
Damper fork
No. 2 stay
Lateral lower arm connection
No. 3 stay
Compression lower arm connection
Drive shaft
AC"
Caution
*1: Indicates parts which should be temporarily
23-67
57 Nm
20
18
49 Nm
10 - 12 Nm
30 Nm
81 Nm*2
26
21
19
21
45 - 52 Nm
27
26
24
49 Nm
25 Nm
49 Nm
57 Nm*2
25
44 Nm
7 Nm
10 Nm <Flange bolts>
9 Nm <Washer assembled bolts>
23
22
69 Nm
93 Nm
69 - 78 Nm
18. Starter motor <4G6>

19. Transmission assembly upper part
coupling bolts
AD"
"BA 21. Transmission mount stopper
AE"
D Engine and transmission assembly
supporting
22. Centermember assembly
24. Bell housing cover <4G6>
25. Cover <6A1>

26. Transmission assembly lower part
coupling bolts
AF" "AA 27. Transmission assembly
AF"
Caution
Mounting locations marked by *2 should be
23-68

Cord
AA" TIE ROD END DISCONNECTION
Ball joint
MB990635 or
MB991113
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.
Nut
AB" NO.3 STAY REMOVAL

No.3 stay
Crossmember
Transmission
side
Pry bar
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.

MZ203827
23-69
AE" ENGINE AND TRANSMISSION ASSEMBLY

SUPPORTING
Set the special tool to the vehicle to support the engine and
transmission assembly.
MB991453
Drive plate bolts
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.

"AA TRANSMISSION 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
"BA TRANSMISSION MOUNT STOPPER

INSTALLATION
Install the transmission mount stopper so that the arrow points
Engine side
Arrow
Transmission
mount bracket
Transmission mount
stopper
NOTES
26-1
FRONT AXLE
CONTENTS
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
26109000157
Wheel Bearing Axial Play Check . . . . . . . . . . . . . . 4
Hub Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . 5

KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
26-2
FRONT AXLE - General Information/Service Specifications/Lubricants
GENERAL INFORMATION
26100010173
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
Knuckle
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.
Dynamic damper
Front hub
T.J.
Drive shaft
B.J. (or R.J.)

Unit bearing
26100030179
Items
Standard value
Limit
Wheel bearing axial play mm
0.05
Wheel bearing rotation starting torque Nm
1.0 or less
2000 - petrol-powered
vehicles
82
2000 - diesel-powered
vehicles, 2500
81
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
Setting of T.J. boot length mm
Opening dimension of the

special tool (MB991561) mm
LUBRICANTS
26100040202
Items
T.J.
Specified lubricant
Quantity g
2000 - petrol-powered vehicles
Repair kit grease
120
2000 - diesel-powered vehicles, 2500
Repair kit grease
150
26-3
FRONT AXLE - Lubricants/Special Tools

Items
B.J. (or R.J.)
Specified lubricant
Quantity g
2000
Repair kit grease
120
2500
Repair kit grease
135
SPECIAL TOOLS
Tool
26100060185
Number
Name
Use
MB990767
End yoke holder
Fixing of the hub
MB991618
Hub bolt remover
Hub bolt removal
MB991406,
MB990635 or
MB991113
Steering linkage
puller
MB990241
A: MB990242
B: MB990244
Axle shaft puller

A: Puller shaft
B: Puller bar
D
D
Front hub assembly removal

Drive shaft removal
MB990998
Front hub remover

and installer
D
D
Removal of or pressing-in the hub

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 crimping tool
B.J. (or R.J.) boot band installation
26-4
FRONT AXLE - On-vehicle Service
ON-VEHICLE SERVICE
26100110088
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

MB991618
MB990767
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.
MB990767
Plane
washer
26-5
FRONT AXLE - Front Hub Assembly
FRONT HUB ASSEMBLY
26100170154

Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
28 Nm
88 Nm
100 Nm
196 - 255 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
MB990767
Caution
Do not apply the vehicle weight to the wheel bearing
while loosening the drive shaft nut.
26-6

AC" UPPER ARM BALL JOINT AND KNUCKLE
DISCONNECTION
MB991406,
MB990635 or
MB991113
Ball joint
Cord
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.
Nut
AD" FRONT HUB ASSEMBLY REMOVAL

(1) Use the special tool to push out the drive shafts from
the hub.
MB990767
MB990241
(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.
Washer

"AA DRIVE 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.
196 - 255 Nm
MB990767
(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.

INSPECTION
MB990998
MB990326
196 - 255 Nm
26-7
26100180119
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.
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
MB990998
(3) If the limit value of hub axial play cannot be obtained,

replace the front hub assembly.
26-8
FRONT AXLE - Knuckle
KNUCKLE
26100240138

Front Hub Assembly Removal (Refer to P.26-5.)
D Front Hub Assembly Installation (Refer to P.26-5.)
2
59 - 71 Nm
6
3
88 Nm*
5
24 - 33 Nm
9 Nm
1
4
Removal steps
1. Dust shield
2. Tie rod end and knuckle connection
3. Damper fork and lateral lower arm
connection
4. Lateral lower arm and knuckle connection
5. Compression lower arm and
knuckle connection
AA"
AA"
AA"
6. Knuckle
Caution
*: Indicates parts which should be temporarily
tightened, and then fully tightened with the vehicle
on the ground in the unladen condition.

MB991406,
MB990635 or
MB991113
AA" TIE ROD END AND KNUCKLE/LATERAL LOWER

ARM AND KNUCKLE/COMPRESSION LOWER
ARM AND KNUCKLE DISCONNECTION
Ball joint
Cord
Nut
Caution
26-9
FRONT AXLE - Drive Shaft
DRIVE SHAFT
26100350213

D Wheel Alignment Check and Adjustment (Refer to
GROUP 33A - On-vehicle Service.)
103 Nm
44 Nm
88 Nm*
3
98 - 118 Nm*
81 Nm
7
9
6
69 - 78 Nm
8
24 - 33 Nm
196 - 255 Nm
81 Nm
Removal steps
1. Front wheel speed sensor
<Vehicles with ABS>
AA" "AA 2. Drive shaft nut
AB"
3. Tie rod end and knuckle connection
4. Stabilizer link and damper fork
connection
5. Damper fork
6. No.2 stay
7. Lateral lower arm connection
AC"
AD"
8. Compression lower arm connection

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.
26-10

AA" DRIVE SHAFT NUT REMOVAL
Caution
while loosening the drive shaft nut.
MB990767
AB" TIE ROD END AND KNUCKLE DISCONNECTION

MB991406,
MB990635 or
MB991113
Ball joint
Cord
Caution
Nut
AC" COMPRESSION LOWER ARM DISCONNECTION

To remove the compression lower arm from the crossmember,
No.3 stay must not be removed as it is tightened together
with the crossmember.
Compression
lower arm
No.3 stay
Crossmember
AD" DRIVE SHAFT REMOVAL

(1) Use the special tools to push out the drive shafts from
the hub.
MB990767
MB990241
(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.
26-11
(3) Insert a pry bar between the transmission case and the
drive shaft, and then pry the drive shaft from the
transmission.
Oil seal
Drive shaft
Transmission
Pry bar
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.
MB991460
MB990998
Washer
196 - 255 Nm
MB990767
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.

"AA DRIVE 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.
26-12
26100370233
3
5
6
7
1
2
9
8
10
4 3
4 5
5 6
7 1
T.J. repair kit
4 5
1
T.J. boot repair kit
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
8 11
12
13
B.J. (or R.J.) boot repair kit
10.
11.
12.
13.
B.J.
B.J.
B.J.
B.J.
(or
(or
(or
(or
R.J.)
R.J.)
R.J.)
R.J.)
assembly
boot band (small)
boot band (large)
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.
26-13

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.

LH: 229 mm
RH: 278 mm
"AA DYNAMIC 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.
Bevelled
section
"BA SPIDER 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.
26-14

(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.
"CA T.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
INSPECTION
D
D
D
D
D
D
26100380120
Check the drive shaft for damage, bending or corrosion.

Check the drive shaft spline part for wear or damage.
Check the spider assembly for roller rotation, wear or
corrosion.
Check the groove inside T.J. case for wear or corrosion.
Check the dynamic damper for damage or cracking.
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.
26-15
(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.
MB991561
Stopper
(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.
W
Adjusting bolt
B.J. (or R.J.)

boot
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.
B.J. (or R.J.)

boot band
(small)
Projection
(7) Use the special tool to crimp the B.J. (or R.J.) boot band
(small).
MB991561
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.
26-16

(8) Check that the crimping amount (B) of the B.J. (or R.J.)
boot band is at the standard value.
B
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.
B.J. (or R.J.)

boot
Projection
B.J. (or R.J.)
boot band
(large)
D
(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).
26-17
(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) in step (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.
E
<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.
NOTES
27-1
REAR AXLE
CONTENTS
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
27109000161
Wheel Bearing Axial Play Check . . . . . . . . . . . . . . 3
Wheel Bearing Rotary-Sliding Resistance Check
............................................. 3
Hub Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . 5

KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
27-2
General Information/Service Specifications/

Special Tools
REAR AXLE -
GENERAL INFORMATION
27100010156
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
the knuckle. Also, the unit bearing utilizes the same
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
Rear axle shaft

Cap
Rotor
<Vehicles with ABS>
Oil seal
Unit bearing
27100030183
Items
Limit
Wheel bearing axial play mm
0.05
Wheel bearing rotary-sliding resistance N
18 or less
SPECIAL TOOLS
Tool
27100060175
Number
Name
Use
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

Tool
Number
Name
Use
MB991406
MB990635 or
MB991113
Steering linkage
puller
ON-VEHICLE SERVICE
27-3
27100090136

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 drum brake, 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.
27-4
REAR AXLE - On-vehicle Service

HUB BOLT REPLACEMENT
MB991618
MB990767
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
Plane
washer
27-5
REAR AXLE - Rear Axle Hub
REAR AXLE HUB
27100200188

<Vehicles with drum brake>
5
74 - 88 Nm
3
8
7
6
<Vehicles with disc brake>

74 - 88 Nm
1
100 Nm
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.
27-6
REAR AXLE - Rear Axle Hub

Socket
MB991248
Socket
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.

"AA ROTOR INSTALLATION
27-7
REAR AXLE - Knuckle
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.)
5
98 Nm*
7
98 Nm
28 Nm
4
6
118 - 137 Nm*
98 Nm*
Removal steps
1. Trailing arm connection
2. Lower arm connection
3. Toe control arm connection
4. Shock absorber connection
5. Upper arm connection
6. Hub cap
AA"
7. Knuckle
Caution
MB990635,
MB991113 or
MB991406
AA" TOE CONTROL ARM DISCONNECTION
Nut
Cord
Ball joint
Caution
NOTES
31-1
WHEEL AND TYRE

CONTENTS
31109000120
Tyre Inflation Pressure Check . . . . . . . . . . . . . . . . . 6
Tyre Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wheel Runout Check . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL AND TYRE . . . . . . . . . . . . . . . . . . . . . . . . 6
31-2
WHEEL AND TYRE - General Information
GENERAL INFORMATION
Both steel type and aluminium type wheels have
been adopted. The type of wheel used depends
on the vehicle model.
Items
31100010221
A compact spare tyre has been adopted as the

spare tyre in some models.
EA2ASNJEQL6,
WLNJEQL6
EA2ASNHEQL6,
ASRHEQL6,
WLNHEQL6,
WLRHEQL6
EA5ASNGEQL6,
ASRGEQL6,
WLNGEQL6,
WLRGEQL6
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
wheel
Type
Steel type
Steel type
Steel type
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
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*
Wheel
Spare
tyre
NOTE
*: Optional items
31-3
WHEEL AND TYRE - General Information

Items
EA6ASNHFQL6,
WLNHFQL6
EA2ASNJEQL6C,
WLNJEQL6C
EA2ASNHEQL6C,
ASRHEQL6C,
ASNHEQR6,
ASRHEQR6,
WLNHEQL6C,
WLRHEQL6C,
WLNHEQR6,
WLRHEQR6
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
Size
T125/70D15
(High pressure)
185/70R14 88H*
195/60R15 88 V*
195/65R14 89 V
195/65R14 89 V
195/60R15 88 V*
Wheel
Spare
tyre
NOTE
*: Optional items
31-4
WHEEL AND TYRE - General Information/Service Specifications
Items
EA5ASNGEQL6C,
ASRGEQL6C,
WLNGEQL6C,
WLRGEQL6C
EA6ASNHFQL6C,
ASNHFQR6,
WLNHFQL6C,
WLNHFQR6
EA5ASNGEQR6,
ASRGEQR6,
WLNGEQR6,
WLRGEQR6
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
Size
205/60R15 91 V
185/70R14 88 H
195/60R15 88 V
195/60R15 88 V
205/60R15 91 V*
Wheel
Spare
tyre
NOTE
*: Optional items
31100030135
Items
Limit
Tread depth of tyre mm
1.6
Wheel runout (Radial runout) mm
Wheel runout (Lateral runout) mm
Steel wheel
1.2 or less
Aluminium wheel
1.0 or less
Steel wheel
1.2 or less
Aluminium wheel
1.0 or less
31-5
WHEEL AND TYRE - Troubleshooting
TROUBLESHOOTING
31100070083
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
side
Excessive camber
Inspect the camber.
Refer to GROUP
33A - On-vehicle Service.
Feathered edge
Incorrect toe-in
Adjust the toe-in.
Bald spots
Unbalanced
wheel
Adjust the imbalanced 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-vehicle Service.
on
one
31-6
WHEEL AND TYRE - On-vehicle Servic/Wheel and Tyre
ON-VEHICLE SERVICE
31100090089
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

Radial
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:
Lateral
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

Tighten the wheel nut to the specified torque.
31100130071
32-1
POWER PLANT
MOUNT
CONTENTS
32109000165
TRANSMISSION MOUNTING . . . . . . . . . . . . . . . . 5
ENGINE ROLL STOPPER,

CENTERMEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . 4
32-2
POWER PLANT MOUNT - General Information/Service Specifications
GENERAL INFORMATION
32100010150
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
Dynamic damper
Transmission mount
Engine mount
Rear roll stopper
Centermember
Front
Front roll stopper

Front roll stopper
Transmission mount
Rear roll stopper
Crossmember
Centermember
Items
Crossmember
Dynamic
damper
32100030095
Standard value
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
SPECIAL TOOLS
Tool
32-3
32100060148
Number
Name
Use
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
32-4
POWER PLANT MOUNT - Engine Mounting
ENGINE MOUNTING
32100110263

D Jack Up the Engine and Transmission Assembly Until
There is no Weight on the Engine Mount Bracket
Insulator.
Reserve Tank Removal and Installation

(Refer to GROUP 14)
Engine Cover Removal and Installation <6A1>
<6A1> 35 Nm
<4D6> 12 Nm
1
5 Nm
2
67 Nm
6
4
57 Nm
98 - 118 Nm*
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
Engine side
Dynamic damper
Arrow
Engine
mount
stopper
Caution

"AA ENGINE MOUNT STOPPER INSTALLATION
POWER PLANT MOUNT - Transmission Mounting
TRANSMISSION MOUNTING
32-5
32100140170

D Centermember Removal and Installation
D
D
Transmission and Rear Roll Stopper Connecting Bolt

Removal and Installation (Refer to P.32-6.)
Rear Roll Stopper Bracket Removal and Installation
(Refer to GROUP 22, 23 - Transmission Assembly)
81 Nm*
57 Nm
2
1
Removal steps
AA"
"AA 2. Transmission mount stopper
MZ203827

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.
MB991453
Engine side
"AA TRANSMISSION MOUNT STOPPER INSTALLATION

Clamp the transmission mount stopper so that the arrow points
Arrow
Transmission
mount bracket
Caution
Transmission
mount
stopper
32-6
POWER PLANT MOUNT - Engine Roll Stopper, Centermember
ENGINE ROLL STOPPER, CENTERMEMBER
32100200144

44 Nm
44 Nm*
11
10
44 Nm
57 Nm*
2
69 - 78 Nm
7
25 Nm
3
2
69 - 78 Nm
93 Nm
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

Hole
Front of vehicle
"AA FRONT ROLL STOPPER INSTALLATION

Install so that the hole in the front roll stopper is facing towards
the front of the vehicle.
32-7
POWER PLANT MOUNT - Crossmember
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 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 Steering Fluid 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.)
11
10
98 - 118 Nm*
14
8
88 Nm
13
12
3
81 Nm
81 Nm
2
69 - 78 Nm
88 Nm*
4
98 - 118 Nm
88 Nm
AA"
Removal steps
1. No. 2 stay
2. Lateral lower arm and damper fork
connection
3. Lateral lower arm and crossmember connection
4. No. 3 stay
5. Compression lower arm mounting
bolts
6. No. 1 stay
D Power steering gear box
7. Crossmember mounting nut
8.
9.
10.
11.
12.
13.
14.
Lower plate
Crossmember
Stopper A
Stopper B
Bushing C
Bushing A
Bushing B
Caution
32-8
POWER PLANT MOUNT - Crossmember

AA" NO.3 STAY REMOVAL
Hold the crossmember with a transmission jack, and remove
No.3 stay.
Transmission jack
Crossmember
Removal
Bolt
Washer
Base
Nut
Press-fitting
CROSSMEMBER BUSHING REPLACEMENT

32100090062
Nut
CROSSMEMBER BUSHINGS A AND B

(1) Apply soapy water to the contact surface of the bushing
when press-fitted the bushing.
Base
Washer
Bolt
MB991045
Bushing A
Inner pipe
Removal
(2) The bushing should be press-fitted so that the inner pipe

projection is at the standard length.
Bushing B
Inner pipe
Standard values
Bushing A: 9.0 1.0 mm
Bushing B: 4.0 1.0 mm
Press-fitting
CROSSMEMBER BUSHING C
(1) Use the special tool to drive out and press-fit the
crossmember bushing C.
MB990828
(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
A
Inner pipe
33A-1
FRONT
SUSPENSION
CONTENTS
33209000158
UPPER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . 6
SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPRESSION LOWER ARM AND LATERAL

LOWER ARM ASSEMBLIES . . . . . . . . . . . . . . 12
Wheel Alignment Check and Adjustment . . . . . . . 4
Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . . 5
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 15
33A-2
FRONT SUSPENSION - General Information
GENERAL INFORMATION
33200010181
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
Shock absorber
Upper arm
Crossmember
Stabilizer bar
Knuckle
Compression
lower arm
Centermember
Lateral lower arm
FRONT SUSPENSION - Service Specifications/Special Tools
33A-3
33200030125
Items
Standard value
Toe-in
At the centre of tyre tread mm
03
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 arm ball 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
SPECIAL TOOLS
Tools
33200060117
Number
Name
Use
MB991004
Wheel alignment
gauge attachment
Wheel alignment measurement

<Vehicles with aluminium type wheels>
A: MB991237
A:
Spring
com- Coil spring compression
pressor body
B:
Arm set
B: MB991238
A
B
MB991406,
MB990635
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
or
33A-4
FRONT SUSPENSION - On-vehicle Service
ON-VEHICLE SERVICE
33100090175
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
Clip
(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_)
FRONT SUSPENSION - On-vehicle Service
33A-5
CAMBER, CASTER AND KINGPIN INCLINATION

MB991004
Standard value:
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
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.
33A-6
FRONT SUSPENSION - Upper Arm Assembly
UPPER ARM ASSEMBLY
33200430079

D Wheel Alignment Check and Adjustment
(Refer to P.33A-4.)
2
86 Nm
57 Nm
57 Nm
28 Nm
Removal steps
1. Upper arm and knuckle connection
2. Upper arm mounting nut
AA"
"AA 3. Upper arm shaft assembly

4. Upper arm assembly

MB991406,
MB990635 or
MB991113
AA" UPPER ARM AND KNUCKLE DISCONNECTION
Ball joint
Cord
Nut
Caution
33A-7

Upper arm shaft

assembly
"AA UPPER ARM SHAFT ASSEMBLY INSTALLATION

Install the upper arm shaft assembly at the angle shown
85_ 1_
Upper arm
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
INSPECTION
MB990326
33200440072
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.
33A-8

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

33200770065
REPLACEMENT
MB990800
Dust cover
Snap ring
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.
FRONT SUSPENSION - Shock Absorber Assembly
SHOCK ABSORBER ASSEMBLY
33A-9
33200460078

(Refer to P.33A-4.)
2
44 Nm
1
44 Nm
4
103 Nm
88 Nm*
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
Damper fork positioning projection
Inside of
the body
Damper fork mounting bolt
"AA 5. Damper fork

6. Shock absorber assembly
Caution

"AA DAMPER FORK INSTALLATION
The damper fork must face against the damper fork positioning
projection of the shock absorber assembly as shown in the
figure.
33A-10
33200480050
23 Nm
1
2
3
10
4
5
11
12
7
8
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.
8.
9.
10.
"AA 11.
12.
Upper bushing B
Cup assembly
Bump rubber
Dust cover
Coil spring
Shock absorber assembly

MB991237
MB991238
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.
33A-11

"AA COIL 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.
Spring seat
End of coil spring
Damper fork positioning projection
"BA UPPER BRACKET ASSEMBLY INSTALLATION

The upper bracket assembly must face against the damper
fork positioning projection of the shock absorber as shown
in the figure.
"CA SELF-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
33A-12
FRONT SUSPENSION -
Compression Lower Arm and

Lateral Lower Arm Assemblies
COMPRESSION LOWER ARM AND LATERAL LOWER ARM

ASSEMBLIES
33200510100

(Refer to P.33A-4.)
8
4
98 - 118 Nm*
6
88 Nm*
81 Nm
59 - 71 Nm
81 Nm
5
9
1
69 - 78 Nm
10
LATERAL LOWER ARM
88 Nm
98 - 118 Nm
4, 10
AA"
AB"
Compression lower arm assembly

removal steps
1. No.3 stay
2. Compression lower arm and
knuckle connection
3. Compression lower arm mounting
bolts
4. Compression lower arm assembly
AB"
Lateral lower arm assembly

removal steps
5. No.2 stay
6. Lateral lower arm and damper fork
connection
7. Lateral lower arm and knuckle connection
8. Lateral lower arm mounting bolt
9. Stopper
10. Lateral lower arm assembly
Caution
FRONT SUSPENSION -

33A-13

No.3 stay
Nut
Crossmember
AB" COMPRESSION LOWER ARM AND

KNUCKLE/LATERAL LOWER ARM AND
KNUCKLE DISCONNECTION
MB991406,
MB990635 or
MB991113
Cord
Caution
Ball joint
INSPECTION
MB990326
33200520066
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
33A-14
FRONT SUSPENSION LATERAL LOWER ARM

Tapered
portion

LOWER ARM BALL JOINT DUST COVER

33200780051
REPLACEMENT
(1) Remove the dust cover.
(2) Apply multipurpose 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 thread and the knuckle joint (tapered portion).
If it touches, wipe away it.
MB990800
Dust cover
(4) Drive in the dust cover with special tool until it is fully
seated.
it with finger.
FRONT SUSPENSION - Stabilizer Bar
STABILIZER BAR
33A-15
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.)
5
1
44 Nm
44 Nm
Removal steps
1. Stabilizer link mounting nut
2. Stabilizer link
"AA 3. Stabilizer bar bracket
Approx. 20 mm
Inside of
the body
"AA 4. Bushing
"AA 5. Stabilizer bar

"AA STABILIZER 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.
33A-16
FRONT SUSPENSION - Stabilizer Bar

INSPECTION
33200550072
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

33200790078
REPLACEMENT
(1) Remove the clip ring and the dust cover.
(2) Apply multipurpose grease to the inside of the dust cover.
Clip ring
Plastic
tape
Approx.
90_
Clip ring ends (180_ on
opposite side also possible)
(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.
34-1
REAR
SUSPENSION
CONTENTS
34109000145
UPPER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . 7
TRAILING ARM ASSEMBLY . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LOWER ARM AND TOE CONTROL ARM

ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wheel Alignment Check and Adjustment . . . . . . . 4
SHOCK ABSORBER ASSEMBLY . . . . . . . . . 13
Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . . 4
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 16
REAR SUSPENSION ASSEMBLY . . . . . . . . . . . 5
34-2
REAR SUSPENSION - General Information
GENERAL INFORMATION
34100010192
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
Upper arm
Knuckle
Crossmember
Toe control arm
Lower arm
Trailing arm
34-3
REAR SUSPENSION - Service Specifications/Special Tools
34100030174
Items
Specifications
Toe-in
At the centre of tyre tread mm
33
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
SPECIAL TOOLS
Tool
A
B
34100060159
Number
Name
Use
MB990635,
MB991113 or
MB991406
Steering linkage puller
Ball joint and knuckle disconnection
MB990326
Preload socket
Ball joint continuous rotating

check
MB990800
Ball joint remover and

installer
Ball joint dust cover installation
A: MB991237
B: MB991239
A:
Coil spring compression
B:
Spring compressor
body
Arm set
34-4
REAR SUSPENSION - On-vehicle Service
ON-VEHICLE SERVICE
Crossmember
33100100106
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.
34101280011
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.
34-5
REAR SUSPENSION - Rear Suspension Assembly
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
44 Nm
8
39 Nm
12
13
11
88 Nm
137 - 157 Nm*
100 Nm
7
15 Nm
AA"
10
9
4
6
Removal steps
1. Cap
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
AB"
9.
10.
11.
12.
Grommet
Trailing arm mounting bolt
Crossmember mounting nuts
Rear wheel speed sensor connector connection <Vehicles with ABS>
13. Rear suspension assembly
Caution
vehicles on the ground in the unladen condition.
34-6
REAR SUSPENSION - Rear Suspension Assembly

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.
34-7
REAR SUSPENSION - Upper Arm Assembly
UPPER ARM ASSEMBLY
34100360082

Wheel Alignment Check and Adjustment
(Refer to P.34-4.)
39 Nm
2
3
98 Nm*
1
4
57 Nm
57 Nm
Removal
1. Upper
bolt
2. Upper
bolts
3. Upper
"AA 4. Upper
steps
arm and knuckle connecting
arm assembly mounting
arm assembly
arm bracket
5. Upper arm
Caution
34-8
REAR SUSPENSION - Upper Arm Assembly

Upper arm
"AA UPPER 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.
Upper arm bracket
B: 220.1 mm
C: 274.4 mm
REAR SUSPENSION - Trailing Arm Assembly
TRAILING ARM ASSEMBLY
34-9
34100420162

Wheel Alignment Check and Adjustment
(Refer to P.34-4.)
137 - 157 Nm*
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
34-10 REAR SUSPENSION -
Lower Arm and Toe Control Arm Assemblies
LOWER ARM AND TOE CONTROL ARM ASSEMBLIES
34100450086

Pushing it with Finger
(Refer to P.34-4.)
67 - 98 Nm*
4
8
98 Nm*
6
28 Nm
2
5
98 Nm*
39 Nm
Lower arm assembly removal steps

1. Stabilizer link connection
2. Wheel speed sensor mounting
bolts
3. Lower arm assembly and knuckle
connecting bolt
4. Lower arm assembly mounting bolt
5. Lower arm assembly
AA"
AB"
Toe control arm assembly removal

steps
6. Toe control arm and knuckle connection
7. Toe control arm assembly mounting
bolt
8. Toe control arm assembly
Caution
REAR SUSPENSION - Lower Arm and Toe Control Arm Assemblies
Nut
34-11
MB990635,
MB991113 or
MB991406
AA" TOE CONTROL ARM AND KNUCKLE

DISCONNECTION
Cord
Caution
removal it from the ball joint.
Ball joint
AB" TOE CONTROL ARM ASSEMBLY MOUNTING

BOLT REMOVAL
Place mating marks on the crossmember and the plate before
removing the bolt.
Plate
Mating marks
INSPECTION
MB990326
34100460096
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

34101290014
COVER CHECK
MB990800
Dust cover
Snap ring

it with finger.
toe control arm assembly.
NOTE
Cracks or damage of the dust cover may cause damaged
34-12 REAR SUSPENSION -
Lower Arm and Toe Control Arm Assemblies
TOE CONTROL ARM BALL JOINT DUST

34101080062
COVER REPLACEMENT
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
SHOCK ABSORBER ASSEMBLY
34-13
34100510159

D Rear Seat Removal and Installation <Sedan>
D Retractor Trim Removal and Installation <Wagon>
1
2
44 Nm
3
98 Nm
Removal steps
1. Cap
3. Bolt
"AA 4. Shock absorber assembly

Outside of
the body
Lower bushing
inner pipe
"AA SHOCK 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.
34-14
34100530117
23 Nm
1
2
3
8
11
10
5
6
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.
8.
9.
10.
"AA 11.
12.
Upper bushing B
Cup assembly
Bump rubber
Dust cover
Coil spring
Shock absorber assembly

MB991237
MB991239
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
34-15

"AA COIL 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.
Coil spring
edge
Spring seat
2. Align the edge of the coil spring to the stepped part of

the shock absorber spring seat.
"BA UPPER BRACKET ASSEMBLY INSTALLATION
Install the upper bracket assembly so that the lower bushing
inner pipe of the shock absorber is at the shown position.
Lower bushing
inner pipe
"CA SELF-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
34-16
REAR SUSPENSION - Stabilizer Bar
STABILIZER BAR
34100560109

Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
44 Nm
1
39 Nm
39 Nm
Removal steps
1. Stabilizer link mounting nuts
2. Stabilizer link
"AA 3. Stabilizer bar bracket
Approx. 20 mm
Outside of
the body
"AA 4. Bushing
"AA 5. Stabilizer bar

"AA STABILIZER 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.
REAR SUSPENSION - Stabilizer Bar

INSPECTION
34-17
34100570119
STABILIZER LINK BALL JOINT TURNING TORQUE

CHECK
1. After shaking the ball joint stud several times, install the
MB990326

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

34101090089
REPLACEMENT
1. Remove the clip ring and the dust cover.
2. Apply multipurpose grease to the lip and inside of the
dust cover.
Clip ring
Plastic tape
Approx. 90_
Clip ring ends (180_ on
opposite side also possible)
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.
NOTES
35A-1
SERVICE BRAKES
CONTENTS
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
35109000159
35A-2
BASIC BRAKE
SYSTEM
CONTENTS
35109000302
Disc Brake Pad Check and Replacement . . . . . 10

Disc Brake Rotor Check . . . . . . . . . . . . . . . . . . . . . 12
Brake Lining Thickness Check . . . . . . . . . . . . . . . 14
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Drum Inside Diameter Check . . . . . . . . . . 14
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake Lining and Brake Drum Connection

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MASTER CYLINDER AND BRAKE

BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Brake Pedal Check and Adjustment . . . . . . . . . . . 6

Stop Lamp Switch Check . . . . . . . . . . . . . . . . . . . . . 7
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Brake Booster Operating Test . . . . . . . . . . . . . . . . . 7
DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Check Valve Operation Check . . . . . . . . . . . . . . . . . 8

Proportioning Valve Function Test . . . . . . . . . . . . . 9
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . 24
Brake Fluid Level Sensor Check . . . . . . . . . . . . . . 9
Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . 28
BASIC BRAKE SYSTEM - General Information
GENERAL INFORMATION
35A-3
35100010182
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.
Items
Master cylinder
Brake booster
Proportioning valve
Front brakes
Rear disc brakes
Rear drum brakes
Brake fluid
Specifications
Type
Tandem type (with level sensor)
I.D. mm
23.8
Type
Vacuum type, single
Effective dia. of power cylinder mm
230
Boosting ratio
6.0
Type
Dual type
Decompression ratio
0.25
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
Type
Floating caliper, 1-piston, solid disc
262 24
34.9
Pad thickness mm
10.0
Automatic
Type
Leading trailing
Drum I.D. mm
203
20.6
Lining thickness mm
4.4
Automatic
DOT3 or DOT4
35A-4
BASIC BRAKE SYSTEM -
Service Specifications
Brake booster
Master cylinder
Rear brake
Brake pedal
Proportioning valve
Front brake
35100030201
Items
Standard value
Limit
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
Sedan
2.94 0.25
Wagon
3.43 0.25
Sedan
4.66 0.39 (9.81)
Wagon
5.80 0.39 (9.81)
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
Drag force (tangential force of wheel mounting

bolts) N
69 or less
Proportioning valve
Split point MPa
Output fluid pressure

(Input fluid pressure) MPa
Output fluid pressure difference between left

and right MPa
BASIC BRAKE SYSTEM -
Service Specifications/Lubricants/
Sealants/Special Tools
Items
Rear disc brake
Rear drum brake
35A-5
Standard value
Limit
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
Lining thickness mm
4.4
1.0
Drum inside diameter mm
203
205
LUBRICANTS
35100040082
Items
Specified Lubricant
Brake fluid
DOT3 or DOT4
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
SEALANTS
35100050153
Items
Specified sealant
Remarks
Thread part fitting
3M ATD Part No. 8661 or equivalent
Semi-drying sealant
Vacuum switch
SPECIAL TOOLS
Tool
35100060071
Number
Name
Use
MB990964
MB990520
MB990619
Brake tool set
D
D
MB990998
Front hub remover

and installer
Provisional holding of the wheel bearing
Pushing-in of the disc brake piston

Installation of drum brake wheel cylinder
piston cup
35A-6
BASIC BRAKE SYSTEM - On-vehicle Service
ON-VEHICLE SERVICE
35100090186
BRAKE PEDAL CHECK AND ADJUSTMENT

Operating
rod
Stop lamp
switch
Operating
rod lock nut
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.
Pedal down
Pedal up
Lock nut
Lock nut
Outer case
0.5 - 1.0 mm
(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.
35A-7
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.
No continuity
Continuity
35100890120
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.
4 mm
Good
No good
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.
35A-8
When engine is
stopped
When engine is
started
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.
Valve
A
Booster
side
2. Check the operation of the check valve by using a vacuum

pump.
Spring
B
Intake
manifold
side
Vacuum pump connection
Accept/reject criteria
Connection at the brake

booster side (A)
A negative pressure (vacuum) is created and held.
Connection at the intake

manifold side (B)
A negative pressure (vacuum) is not created.
Caution
If the check valve is defective, replace it as an
assembly unit together with the vacuum hose.
35A-9

Pressure gauge
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.
Proportioning valve
(1) Output pressure begins to drop relative to input

pressure (split point).
Split point
Output
pressure
Standard value:
MPa
Sedan
Wagon
2.94 0.25
3.43 0.25
Input pressure
(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:
Output fluid pressure

(Input fluid pressure)
MPa
Sedan
Wagon
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.
35A-10

BLEEDING
35100140089
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.
4 (2)
1 (3)
2 (4)
3 (1)
BRAKE PIPE LINE BLEEDING

Bleed the air in the sequence shown in the figure.
( ): R.H. drive vehicles
When new
When worn
35100230014
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.
Pad
Wear indicator
DISC BRAKE PAD CHECK AND

REPLACEMENT
Brake disc
35A-11
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
3
2
1
3
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.)
35A-12
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
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.
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.
35100240017
THICKNESS CHECK
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).
35A-13
35100250010
RUN-OUT CHECK
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.
35100180081
RUN-OUT CORRECTION
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.
Chalk mark
(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).
35A-14

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.)
14 Nm
5
11
12 Nm
13 Nm
29 Nm
9
8
8
4
10
3
6
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.
8.
9.
10.
11.
Brake pedal pad

Brake pedal return spring
Bushing
Pipe
Pedal support member
35A-16
BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster
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.)
11
12
20 - 25 Nm
14
9
15 Nm
22 Nm
10
14 Nm
10 Nm
1 15 Nm
<L.H. drive vehicles - 4G6, 6A1>
13
<L.H. drive vehicles - 4D6>
<R.H. drive vehicles - 4G6, 6A1>
6
7 15 Nm
6
7
15 Nm
<R.H. drive vehicles - 4D6>
4
7
12
5
Sealant: 3M ATD Part No.8661 or equivalent

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.
8.
9.
10.
11.
12.
13.
14.
35A-17
Fitting
Snap pin
Pin assembly
Clevis
Vacuum switch connector <4D6>
Vacuum switch <4D6>
Brake booster
Sealer

"AA VACUUM 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.
"BA PUSH ROD PROTRUDING LENGTH CHECK AND

ADJUSTMENT
1. Measure dimension A.
A
Measuring dimension A
Block gauge
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.
35A-18
MASTER CYLINDER
35100420145
1
9
3
10
5
11
9
Master cylinder kit
4
12
8
10
11
11
12
Disassembly steps
1. Reservoir cap assembly
2. Reservoir cap
3. Diaphragm
4. Brake fluid level indicator assembly
5. Float
6. Spring pin
10
Brake fluid: DOT3 or DOT4
7.
8.
9.
10.
11.
12.
Reservoir tank
Reservoir seal
Piston retainer
Primary piston assembly
Secondary piston assembly
Master cylinder body
BASIC BRAKE SYSTEM - Disc Brake
DISC BRAKE
35A-19
35100800017

<Front>
4
90 - 110 Nm
29 Nm
2
3
<Rear>
29 Nm
2
55 - 65 Nm
Removal steps
1. Brake hose connection
2. Gasket
INSTALLATION SERVICE POIINT
MB990998
"AA DISC 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.
Bolt
Tighten the nut with

the bolt secured.
"AA 3. Disc brake assembly

4. Brake disc
<Front>
(1) Remove the drive shaft.
(Refer to GROUP 26 - Front Axle.)
35A-20

(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.
MB990520
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.
35A-21

35100820013
14
2
12
3
11
13
74 Nm
14
8 Nm
1
74 Nm
10
9
5
8
7
6
14
5
9
6
7
14
9
13
4
Grease
13
10 5
12
11
Brake caliper kit
5
14
Pad repair kit
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
11
12
14
Seal and boots repair kit
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
35A-22
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.
35A-23
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.
Lock pin
L
Front
"AA LOCK 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.
Guide pin
G
INSPECTION
D
D
D
D
35100630081
Check cylinder for wear, damage or rust.

Check piston surface for wear, damage or rust.
Check caliper body or sleeve for wear.
Check pad for damage or adhesion of grease, check
backing metal for damage.
35A-24
BASIC BRAKE SYSTEM - Rear Drum Brake
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.)
15 Nm
17
74 - 88 Nm
16
11
12
3 13 14
15
5
20
16
4
19
9
18
10
5
10
20
15
Specified grease: Brake grease SAE J310, NLGI No.1

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
15. Shoe and lining assembly
16. Shoe hold-down pin
18. Snap ring
19. Rear hub assembly
20. Backing plate
35A-25
Pin of shoe assembly
AA" RETAINER REMOVAL

Use a flat-tipped screwdriver or the like to open up the retainer
joint, and remove retainer.
Retainer

Washer
Shoe assembly
"AA WAVE WASHER INSTALLATION

Install the washer in the direction shown in the illustration.
Pin
Parking lever
Pin of shoe assembly
Retainer
"BA RETAINER INSTALLATION

Use pliers or the like to install the retainer or the pin positively.
35A-26
WHEEL CYLINDER
35100930082
Brake Fluid draining
3
15 Nm
10 Nm
8 Nm
7
5
6
1
Removal steps
1. Brake drum

6. Wheel cylinder
7. Bleeder screw
35A-27

35100770097
6
3
4
3
2
6
Grease
Wheel cylinder repair kit

Disassembly steps
1. Boots
2. Piston assembly
"AA 3. Pistons
"AA 4. Piston cups

5. Spring
6. Wheel cylinder body

"AA PISTON 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.
MB990619

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.
Piston
Have the lip facing

upwards.
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.
35A-28 BASIC BRAKE SYSTEM -
Rear Drum Brake/Proportioning Valve
INSPECTION
35100780038
Check the piston and wheel cylinder walls for rust or damage,
and if there is any abnormality, replace the entire wheel cylinder
assembly.
PROPORTIONING VALVE
35100570154

Flared brake line nuts
2
1
1
15 Nm
Removal steps
"AA 1. Brake pipe
2. Proportioning valve

1
"AA BRAKE 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)
35B-1
ANTI-SKID
BRAKING SYSTEM
(ABS) <2WD>
CONTENTS
35209000206
Bleeding . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Disc Brake Pad Check and Replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disc Brake Rotor Check

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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
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
Wheel Speed Sensor Output Voltage

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ABS Warning Lamp Relay Continuity
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hydraulic Unit Check . . . . . . . . . . . . . . . . . . . . . . . . 22
Remedy for a Flat Battery . . . . . . . . . . . . . . . . . . . 23
Proportioning Valve Function Test

. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Brake Fluid Level Sensor Check
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
35B-2
BRAKE PEDAL . . . . . . . . Refer to GROUP 35A
Wheel Cylinder . . . . . . . . . . . Refer to GROUP 35A
MASTER CYLINDER AND BRAKE

BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . 25
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
HYDRAULIC UNIT . . . . . . . . . . . . . . . . . . . . . . . . 26
DISC BRAKE . . . . . . . . . . Refer to GROUP 35A
WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . 28
REAR DRUM BRAKE

. . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
ABS <2WD> - General Information
GENERAL INFORMATION
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
35200010222
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.
Items
Master cylinder
Brake booster
Proportioning valve
Front brakes
Rear drum brakes
35B-3
Specifications
Type
Tandem type (with level sensor)
I.D. mm
25.4
Type
Vacuum type, tandem
Effective dia. of power cylinder mm
180 + 205
Boosting ratio
6.5
Type
Dual type
Decompression ratio
0.25
Type
Floating caliper, 1-piston, ventilated disc
256 24
60.3
Pad thickness mm
10.0
Automatic
Type
Leading trailing
Drum I.D. mm
203
20.6
Lining thickness mm
4.4
Automatic
Brake fluid
DOT3 or DOT4
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
35B-4
ABS <2WD> - General Information
2
7
6
8
1
3
5

3
2
7
5
6
1.
2.
3.
4.
ABS
ABS
Stop
ABS
relay
warning lamp
lamp switch
rotor
5.
6.
7.
8.
Wheel-speed sensor
ABS-ECU
Diagnosis connector
Hydraulic unit
ABS <2WD> - Service Specifications/Lubricants/Special Tools
35200030242
Items
Standard value
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
LUBRICANTS
35200040054
Items
Specified lubricant
Brake fluid
DOT3 or DOT4
SPECIAL TOOLS
Tool
35B-5
35200060210
Number
Name
Use
MB991502
MUT-II sub
assembly
For checking of ABS (Diagnosis code display

when using the MUT-II)
MB991529
Diagnosis code
check harness
For checking of ABS (Diagnosis code display

when using the ABS warning lamp)
35B-6
ABS <2WD> - Troubleshooting
TROUBLESHOOTING
35201110129

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.
2.
3.
ABS operation
(Long braking distance)
For road surfaces such as snow-covered roads and gravel roads, the braking distance for
vehicles with ABS can 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.
Sound of the motor inside the ABS hydraulic unit operation. (whine)
Sound is the generated along with vibration of the brake pedal. (scraping)
When ABS operates, sound is generated from the vehicle chassis due to repeated
brake application and release.
(Thump: suspension; squeak: tyres)
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 FUNCTION
35201120221
DIAGNOSIS CODES CHECK

Read a diagnosis code by the MUT-II or ABS warning lamp.
(Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.)
ERASING DIAGNOSIS CODES

With the MUT-II
Service Points.
35B-7
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.
Ignition switch
Stop lamp switch
ABS warning lamp
ABS-ECU memory
ON
OFF
ON
OFF
ON
OFF
Within 3
seconds
Within Within Within Within Within Within Within Within Within Within
1
1
1
1
1
1
1
1
1
1
second second second second second second second second second second
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
1 second
Erasing of
ABS-ECU
diagnosis
codes
complete.
35B-8
35201130323
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
21
Front right wheel speed sensor
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
42
Front left solenoid valve
35B-26 (Replace
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
35B-10
Short circuit
35B-9
35B-9

Probable cause
Code Nos.11, 12, 13 and 14 Wheel speed sensor

(open circuit or short circuit)
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
D
D
Malfunction of wheel speed sensor

Malfunction of hydraulic unit
Code Nos.21, 22, 23 and 24 are output in the following cases.

D When there is no input from any 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
D
D
D
D
D

Malfunction of ABS rotor
Too much gap between the sensor and the rotor
Malfunction of wheel bearing
NG
Wheel speed sensor installation check

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.)
OK
ABS rotor check (Refer
to P.35B-29.)
OK
Wheel bearing check (Refer to GROUP 26 and
GROUP 27 - On-vehicle
Service.)
Check the following connector: A-04

OK
NG
Replace the hydraulic unit.
NG
Repair
NG
NG
Replace

A-09, C-115, C-75, A-39, C-74, E-14, E-13, E-11, C-123, E-12
NG
A-09, A-41, A-39, C-115, C-75, E-14,
E-13,
Repair E-11, C-121, E-12
Wheel speed sensor output voltage check (Refer to P.35B-19.)

NG
Wheel speed sensor check (Refer to P.35B-29.)

OK
OK
OK
Repair
Replace
OK

NG
NG
Replace
Check the harness wire, and repair if necessary.

D Between each wheel speed sensor and ABS-ECU
35B-10
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
D
D
D
D
D
D
NO
Are the sizes of all four tires identical?
The four vehicle tires are of different sizes

Improper installation of wheel speed sensor
Equip the vehicle with tires of identical sizes.
YES
NG
NG

OK
NG
Repair
OK
OK
NG

OK
Replace
NG
ABS rotor check (Refer to P.35B-29.)
Repair
OK
NG
NG
Replace
Wheel bearing check (Refer to GROUP 26 and GROUP 27 On-vehicle Service.)

NG
D Between each wheel speed sensor and ABS-ECU
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
D
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.
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
OK
Repair
OK
OK
NG
NG
Repair
NG
OK
Check the battery.
NG
D Between ignition switch and ABS-ECU
35B-11

Code No.33 Stop lamp switch system (open circuit 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
D
D
NO
Does the stop lamp turn on and off normally?

YES
OK
NG
Check the following

connectors:
A-04, C-75, C-65
OK
NG
Repair
Repair
NG
the
hydraulic

NG
NG
Repair
Stop lamp switch check (Refer to GROUP 35A - Brake Pedal.)

OK
NG
Replace
NG
Check the following

connector: A-04
Replace
unit.
Stop lamp switch installation check

OK

connector.
D Stop lamp switch: ON
OK: Battery voltage
OK
Malfunction of stop lamp switch


C-12 <R.H. drive vehicles>, C-142, C-134, C-02, C-65, C-75, A-04
OK
NG
Repair
NG
D Between fusible link No.1 and ABS-ECU
Check the harness wire,

D Between stop lamp
switch and ABS-ECU
ABS WARNING LAMP INSPECTION
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.
ABS warning lamp

Approx. 3 s
Illuminated
ABS
warning Not
lamp
illuminated
START
Ignition
ON
switch
ACC,
LOCK
35201200123
Approx. 3 s
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.
35B-12
35201140289
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Trouble symptoms
No.
Reference page
Communication between the MUT-II and the whole system is not

possible.
35B-12
Communication between the MUT-II and the ABS-ECU is not possible.
35B-13
When the ignition key is turned to ON (engine stopped), the ABS

warning lamp does not illuminate.
35B-14
Even after the engine is started, the ABS warning lamp remains
illuminated.
35B-15
Faulty ABS operation
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, when getting information from the 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.

Communication between the MUT-II and the 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
D
Measure at the diagnosis connector C-20.

OK: Battery voltage
NG
OK
Malfunction of diagnosis connector


C-20, C-66, C-63, C-132, C-141
C-20, C-66, C-62, C-14
OK
NG
Repair
NG
D Between power supply and diagnosis connector
Measure at the diagnosis connector C-20.
D Continuity between 4 and body earth, and between 5 and body
earth
OK: Continuity
OK

OK
NG
Repair
NG

NG
Replace the MUT-II.
NG

D Between diagnosis connector and earth
35B-13

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
D
D
Measure at the diagnosis connector C-20 and the ABS-ECU connector A-04.
connector.
D Continuity between the following terminals
ABS-ECU side - Diagnosis connector side
14 - 1
7 - 7
OK: Continuity
NG
Blown fuse

<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
OK
OK
NG
Repair
NG
D Between ABS-ECU and diagnosis connector

connector.
OK: Battery voltage
NG

A-04, C-75, C-66 <L.H. drive vehicles>, C-134, C-131
OK
NG
NG
OK
Repair

D Between ignition switch and ABS-ECU
connector.
D Continuity between 8 and body earth, between 11 and body
earth and between 24 and body earth
OK: Continuity
OK

NG

OK
NG
NG
Repair

D Between ABS-ECU and earth

OK
NG
NG
Repair
35B-14
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
D
D
D
D
NG
Fuse check
Multi-purpose fuse No.13
OK
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
warning lamp bulb

ABS warning lamp relay
hydraulic unit
Refer to GROUP 00 - Inspection Service Points for Blown Fuse.
Check whether the ABS warning lamp bulb is burnt out.

NG
OK
Replace the ABS warning

lamp bulb.
OK
Check the following

connectors:
D-01, D-03, C-135, C-131
ABS warning lamp relay check (Refer to P.35B-21.)
NG
Repair
OK
NG
OK
Blown fuse
Burn out ABS
Malfunction of
Malfunction of
Malfunction of
Replace the ABS warning

lamp relay.
NG
Replace the combination meter.
Disconnect the ABS warning lamp relay connector A-05X and ABSECU connector A-04, and measure at the harness side connector
of ABS warning lamp relay.
OK: Battery voltage
OK
NG
Check the following connector: A-05X

OK
NG
Repair
NG
D Between ABS warning lamp and ABS warning lamp relay
D Between ABS warning lamp relay and earth
35B-15

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
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
combination meter
ABS warning lamp relay
wiring harness (short circuit)
hydraulic unit
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.
Does the ABS warning lamp stay illuminated when the connector
C-50 is disconnected and the ignition switch is turned to ON?
NO
ABS warning lamp relay check (Refer to P.35B-21.)
OK
Disconnect the ABS warning lamp relay connector A-05X and ABSECU connector A-04, and measure at the harness side connector
of ABS warning lamp relay.
OK: Battery voltage
OK
YES
NG
NG
Replace the ABS warning lamp relay.

Check the following connectors: A-05X, A-04
OK
NG
Repair
NG
D Between ABS warning lamp and ABS warning lamp relay
D Between ABS warning lamp relay and ABS-ECU
35B-16
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
D
D
D
D
D
D

OK
NG
NG
OK
NG
Repair
Hydraulic unit check (Refer to P.35B-22.)
Replace the wheel speed sensor.
OK
ABS rotor check (Refer to P.35B-29.)
NG
Repair
OK
Wheel bearing check (Refer to GROUP 26 and GROUP 27 On-vehicle Service.)
NG
Repair
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
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.)
OK
OK
NG
NG
Improper installation of wheel speed sensor

Foreign material adhering to wheel speed sensor
Repair
35B-17

35201150206
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 speed sensor
Perform a test run
12
Front-left wheel speed sensor
13
Rear-right wheel speed sensor
Vehicle speeds
displayed on the
speedometer
II are
and MUT-II
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.
35201160025
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

Activation pattern
Solenoid
B
valve
C
48 ms
Pump
motor
NOTE
Start of
forced
action
1s
End of forced
action
2s
ON
OFF
A: Hydraulic pressure increase

B: Hydraulic pressure holds
C: Hydraulic pressure decrease
8 ms
No.
Item
01
Solenoid valve for front-left

wheel
02
Solenoid valve for front-right

wheel
03
Solenoid valve for rear-left

wheel
04
Solenoid valve for rear-right

wheel
Solenoid valves and pump

motors in the hydraulic unit
(simple inspection mode)
35B-18
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
Normal condition
ABS-ECU power supply
Ignition switch: ON
Battery voltage
Ignition switch: START
0V
MUT-II
When the MUT-II is connected
Serial communication
with MUT-II
When the MUT-II is not connected
1 V or less
Solenoid valve power

supply
Always
Battery voltage
14
Diagnosis changeover
input
When the MUT-II is connected
0V
When the MUT-II is not connected
Approx. 12 V
ABS valve transistor

output
Ignition switch: ON
16
18
25
Stop lamp switch input
Motor power supply
Ignition switch: ON
Always
When the lamp

switched off
is
2 V or less
When the
illuminated
is
Battery voltage
lamp
Stop lamp switch: ON
Battery voltage
Stop lamp switch: OFF
1 V or less
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
35B-19
ABS <2WD> - Troubleshooting/On-vehicle Service

Terminal No.
Signal
Normal condition
23 - 22
Wheel speed sensor (rear right)
1.0 - 1.5 kW
8 - Body earth
Solenoid valve earth
Continuity
24 - Body earth
Motor earth
ABS-ECU connector
(harness side)
ON-VEHICLE SERVICE
35200160224
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
No.
19
23
20
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.
35B-20
ABS <2WD> - On-vehicle Service

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.
When turning by hand
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.
When idling (5 - 6 km/h),

1st gear (manual transmission) or D range (automatic transmission)
10.0 ms/DIV 1 V/DIV
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.
35B-21

ABS WARNING LAMP RELAY CONTINUITY

35200930023
CHECK
Battery voltage
Terminal No.
1
Power is not supplied

Power is supplied
35B-22
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.

Depressed
Pedal operation
Released
Solenoid valve
position
Increase in pressure
Steady pressure
Reduction in pressure (when not working)
Checking the
brake force
MUT-II actuator test

(Item No. 01, 02, 03, 04) start
2 seconds
1 seconds
Lock
Drag force when the pedal is free
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.
35B-23
Diagnosis Table
No.
Operation
Judgement
- Normal
Judgement
- Abnormal
Probable cause
Remedy
01
(1) Depress brake pedal

to lock wheel.
(2) Using the MUT-II,
select the wheel to be
checked and force the
actuator to operate.
(3) Turn the selected
wheel manually to
check the change of
brake force.
Brake force
released for 3
seconds after
locking.
Wheel does not

lock when brake
pedal is depressed.
Clogged brake
line other than
hydraulic unit
Check and clean

brake line
Clogged hydraulic circuit in

hydraulic unit
Replace hydraulic unit assembly
Brake force is
not released
Incorrect hydraulic unit brake

tube connection
Connect correctly
Hydraulic unit
solenoid valve
not functioning
correctly
Replace hydraulic unit assembly
02
03
04
REMEDY FOR A FLAT BATTERY

Fusible link
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.
35B-24
ABS <2WD> - Master Cylinder and Brake Booster
MASTER CYLINDER AND BRAKE BOOSTER
35200400142

Refer to GROUP 35A.
MASTER CYLINDER
35200450147
9
2
1
11
10
12
13
5
Master cylinder kit
14
6
9
11
12
7
13
10
13
12
14
Disassembly steps
1. Reservoir cap assembly
2. Reservoir cap
3. Diaphragm
4. Filter
5. Brake fluid level indicator assembly
6. Float
7. Spring pin
INSPECTION
D
D
D
8.
9.
10.
11.
12.
13.
14.
Reservoir tank
Reservoir seal
Pin
Piston retainer
Primary piston assembly
Secondary piston assembly
Master cylinder body
35200460027
Check the inner surface of master cylinder body for rust

or pitting.
Check the primary and secondary pistons for rust, scoring,
wear, damage or wear.
Check the diaphragm for cracks and wear.
ABS <2WD> - Proportioning Valve
PROPORTIONING VALVE
35B-25
35200570126

D Brake Line Bleeding (Refer to GROUP 35A On-vehicle Service.)
Flared brake line nuts
15 Nm
Removal steps
"AA 1. Brake pipe
2. Proportioning valve

1

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
35B-26
ABS <2WD> - Hydraulic Unit
HYDRAULIC UNIT
35200860261

D Brake Line Bleeding
D Brake Pedal Adjustment
15 Nm
2
2
3
3
9 Nm
9 Nm
22 Nm
22 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

Locking lever
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 disassembled; its nuts and bolts should absolutely not be loosened.
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.
6
5
4

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)
35B-28
ABS <2WD> - Wheel Speed Sensor
WHEEL SPEED SENSOR
35200830279

Wheel Speed Sensor Output Voltage Check
<Front>
<Rear>
4
2
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.

Front
Front
Rear
ABS
rotors
toothed
surface
Rear
35B-29
ABS
rotors
toothed
surface
"AA FRONT 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.
INSPECTION
35200840227
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.
35B-30

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
CONTENTS
36109000187
Lining Running-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . 5
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PARKING BRAKE CABLE

<DRUM BRAKE> . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking Brake Lever Stroke Check and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking Brake Switch Check . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE CABLE

<DRUM-IN-DISC BRAKE> . . . . . . . . . . . . . . . . . . . 7
PARKING BRAKE DRUM . . . . . . . . . . . . . . . . . . . 9
36-2
PARKING BRAKES -
Service Specifications/Lubricants
GENERAL INFORMATION
36100010158
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
Parking brake cable
Parking brake
switch
36100030147
Items
Standard value
Limit
Parking brake lever stroke
5 - 7 notches*1, 3 - 5 notches*2
Rear brake lining thickness mm
2.8
1.0
Rear drum inside diameter mm
168.0
169.0
NOTE
*1: Vehicles with drum brake
*2: Vehicles with drum-in-disc brake
LUBRICANTS
36100040126
Items
Specified lubricant
Backing plate
Multipurpose grease
Shoe and lining assembly

Adjuster
PARKING BRAKES - Special Tool/On-Vehicle Service
SPECIAL TOOL
Tool
36-3
36100060047
Number
Name
Use
MB990998
Front hub remover

and installer
Fixing of the rear hub
ON-VEHICLE SERVICE
Adjusting nut
36100090145
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>
Cable rod
MB990998
Bolt
Hold the bolt in

place when
tightening
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.
Adjuster
(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.
36-4
PARKING BRAKES - On-Vehicle Service

Adjusting nut
Nut holder Pin
(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.
Continuity
When parking brake lever is released
No continuity
LINING RUNNING-IN
Pull
Spring balance
Approx.
40 mm
When parking brake lever is pulled
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.
36-5
PARKING BRAKES - Parking Brake Lever
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.)
3
4
1
2
Ratchet plate
Section A - A
Section B - B
Ratchet
pawl
Removal steps
1. Adjusting nut
2. Parking brake stay
3. Bushing
4. Parking brake switch

5. Parking brake lever
36-6
PARKING BRAKES - Parking Brake Cable <Drum brake>
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
10
11
2
5
7
6
Removal steps
1. Rear brake drum
5. Retainer spring
7.
8.
9.
10.
11.
Shoe hold-down spring

Shoe hold-down pin
Clip
Parking brake cable
36-7
PARKING BRAKES - Parking Brake Cable <Drum-in-disc brake>
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
90 - 110 Nm
12
2
13
11
10
3
6
7
4
5
9
AA"
Removal steps
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.
9.
10.
11.
12.
13.
Shoe hold-down cup

Shoe hold-down pin
Clip
Parking brake cable
36-8
PARKING BRAKES - Parking Brake Cable <Drum-in-disc brake>

AA" REAR BRAKE CALIPER ASSEMBLY REMOVAL
Remove the rear brake caliper assembly and support it with
wire or similar.
Shoe
hold-down
cup
AB" SHOE HOLD-DOWN CUP REMOVAL

Extend the shoe and lining assembly, and remove the shoe
hold-down cup.

"AA ADJUSTER 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.
Shoe adjusting
bolt
"BA SHOE-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.
Rear
1
2 (Painted)
NOTE
The figure shows the left wheel; for the right wheel, the position
is symmetrical.
36-9
PARKING BRAKES - Parking Brake Drum
PARKING BRAKE DRUM
36100250109

(Refer to P.36-3.)
74 - 88 Nm
14
90 - 110 Nm
15
3
13
10
12
11
9 8
11 9 8
11
15
11
Brake grease: Multipurpose grease
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)
9.
10.
11.
12.
13.
14.

Shoe hold-down pin
Clip
Parking brake cable
Rear hub assembly
15. Backing plate
36-10
PARKING BRAKES - Parking Brake Drum

INSPECTION
36100260096
BRAKE LINING AND BRAKE DRUM CHECK

1. Measure the thickness of the brake lining at 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
CONTENTS
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
37209000217
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
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . 12
STEERING WHEEL AND SHAFT* . . . . . . . . . 13
Steering Wheel Free Play Check . . . . . . . . . . . . . . 6
POWER STEERING GEAR BOX* . . . . . . . . . 16
Steering Angle Check . . . . . . . . . . . . . . . . . . . . . . . . 7

Tie Rod End Ball Joint Starting Torque
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER STEERING OIL PUMP . . . . . . . . . . . 29
Stationary Steering Effort Check . . . . . . . . . . . . . . . 8
POWER STEERING HOSES . . . . . . . . . . . . . . 34
Checking Steering Wheel Return to Centre . . . . . 8

WARNING!
MITSUBISHI dealer.
component.
NOTE
37A-2
STEERING - General Information
GENERAL INFORMATION
The steering wheel is 4-spoke type.
The steering wheel including the air bag is a 3-spoke
type. The steering column is equipped with both
shock absorbing and tilt steering mechanisms.
The power steering is an integral rack and pinion
37200010172
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.
Items
Specifications
Steering gear and linkage
Oil pump
Type
Integral type
Gear type
Rack and pinion
Type
Vane type
Displacement mL
9.6
Relief set pressure MPa
11.8
Steering wheel
Oil reservoir
Steering column assembly
Oil pump
Tilt lever
Steering gear and linkage
37A-3
STEERING - Service Specifications/Lubricants/Sealant
37200030192
Items
Standard value
Limit
Steering wheel
free play mm
with engine stopped
10 or less
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

MPa
Oil pump relief pressure
11.8
Pressure under no-load conditions
0.8 - 1.0
Steering gear retention hydraulic pressure
11.8
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
Oil pressure switch operating pressure MPa
LUBRICANTS
37200040140
Items
Specified lubricant
Quantity
Automatic transmission fluid DEXRON or DEXRON II
As required
Bellows
Silicone grease
As required
Pinion and valve assembly
Repair kit grease
As required
Automatic transmission fluid DEXRON or DEXRON II
As required
Rack assembly
Oil seal, pinion and valve assembly,
ball bearing, needle roller bearing,
special tool (MB991213)
Flow control valve, friction surface of
rotor, vanes, cam ring, pump cover,
O-ring
SEALANT
37200050136
Items
Specified sealant
Remarks
End plug screw
Semi-drying sealant
Power steering rack support cover screw

Dust cover lip for tie rod end ball joint
37A-4
STEERING - Special Tools
SPECIAL TOOLS
Tool
37200060177
Number
Name
Use
MB990635,
MB991113 or
MB991406
Steering linkage
puller
Disconnection of tie rod end
MB990685
Torque wrench
D
D
Measurement of the ball joint starting

torque
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
D
MB990803
Steering wheel
puller
Disconnection of the steering wheel
Adjustment of rack support

Removal of rack support cover
STEERING - Special Tools

Tool
37A-5
Number
Name
Use
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
37A-6
Tool
STEERING - Special Tools/On-vehicle Service

Number
Name
Use
MB991561
Boot band crimping tool
Installation of bellows band
MB990776
Front axle base
Installation of dust cover for tie rod end ball joint
ON-VEHICLE SERVICE
37200100138
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

STEERING ANGLE CHECK
37A-7
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

37200150140
CHECK
Cord
1. Disconnect tie rod and knuckle with special tool.
Ball joint
MB990635,
MB991113 or
MB991406
Nut
MB990685
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 with a cord, etc. to prevent
it from coming off.
2. Move ball joint stud several times and install nut on stud.
Measure ball joint starting torque with special tools.
MB990326

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.
37A-8

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 from the 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

37200180156
CENTRE
70_
70_
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 steering force required and the wheel return between
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

Fluid level change: Within 5 mm
While engine
running
While engine
stopped
FLUID LEVEL CHECK
Vinyl hose
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
Return hose
37A-9
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
37A-10

BLEEDING
37200220155
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.
Fluid level change: Within 5 mm
While engine
running
While engine
stopped
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.

Pressure
gauge
(MB990662) Shut-off valve
Temperature
gauge
Oil pump
relief
pressure
Adapter
(MB990993)
OIL PUMP PRESSURE TEST
37A-11
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
Oil
pump
Reservoir
Pressure
hose
Adapter
(MB990994)
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.
37A-12
Adapter
(MB990993) Pressure
gauge
(MB990662)
Temperature
gauge
Shut-off valve
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.
Oil
pump
Reservoir
POWER STEERING OIL PRESSURE SWITCH

37200720150
CHECK
Adapter
(MB990994)

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.
37200860012

it with finger.
tie rod end.
NOTE
of the ball joint.
37A-13
STEERING - Steering Wheel and Shaft
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
41 Nm
25 Nm
2
6
Standard bolt
Earth bolt
12 Nm
22 Nm
12 Nm
3
18 Nm
5 Nm
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.
37A-14

MB990803
AA" STEERING WHEEL REMOVAL
"AA CLOCK SPRING AND COLUMN SWITCH/COLUMN

SWITCH INSTALLATION
Tighten the screws in an alphabetical order.
A
B
37200280153
1
2
4
5
9
8
7
Disassembly steps
AA" "AA 1. Special bolt
"AA 2. Steering lock bracket
"AA 3. Steering lock cylinder
4. Snap ring
5. Stopper
6.
7.
8.
9.
Spacer
Steering shaft assembly
Snap ring
Steering column assembly

Steering lock bracket
37A-15

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.
Steering lock cylinder

"AA STEERING 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.
37A-16
STEERING - Power Steering Gear Box
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 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
18 Nm
15 Nm
8
5
2
81 Nm
24 - 33 Nm
69 Nm
69 - 78 Nm
AA"
Removal steps
1. Steering shaft assembly and gear
box connecting bolt
2. No.2 stay
3. No.3 stay
4. Split pin
AB"
AC"
5.
6.
7.
8.
9.
Tie rod end and knuckle connection

Pressure tube connection
Return tube connection
Cylinder clamp
Gear box assembly
37A-17

Hold the crossmember with a transmission jack, and remove
the No.3 stay.
Transmission jack
Crossmember
Cord
Ball joint
MB990635 or
MB991113
AB" TIE ROD END DISCONNECTION

Caution
1. Using the special tool, loosen the tie rod end mounting
ball joint.
2. Support the special tool with a cord, etc. to prevent
it from coming off.
Nut
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.
INSPECTION
D
37200400139
Check the rubber parts for cracks and breakage.
37A-18

MB991006
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 tie rod swing resistance with a spring balance.
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
37A-19

37200410132
Steering gear seal kit

22 Nm
21
26 17
19 2
22
21
20
19
34
16
2
29
30
15
27 33
9
18
17
32
33
31
25 Nm
Flare nut
15
4
14
49 - 54 Nm
59 Nm
13
12 11
59 Nm
10
13 Nm
15 Nm - 30
8
9
5
26
7
25
28
22 Nm
23
24
27
30
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
29
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
37A-20
Lubrication and Sealing Points
Fluid:
Automatic transmission
fluid DEXRON or
DEXRON II
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
Fluid: Automatic transmission fluid

DEXRON or DEXRON II
37A-21

MB991204
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.
Socket
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.
Rack stopper
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.
37A-22

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.
Rack bushing
MB990925 (MB990939)
or brass bar
AH" BALL BEARING REMOVAL

Use a brass bar or the special tool to remove the ball bearing
from the gear housing.
Ball
bearing
MB991120
Needle roller
bearing
Gear housing
Pipe or similar tool
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.
Oil seal
37A-23

Gear housing
MB991199
MB991197
"AA OIL SEAL INSTALLATION
Oil seal
MB990925
(MB990938)
Needle
roller
bearing
MB990925
(MB990938)
"BA NEEDLE ROLLER BEARING/BALL BEARING

INSTALLATION
MB991202
MB991202
Ball bearing
"CA RACK INSTALLATION

1. Apply a coating of repair kit grease to the rack tooth
face.
Vent hole
Caution
Do not close the vent hole in the rack with grease.
Seal ring, O-ring
2. Cover rack serrations with special tool.

3. Apply the specified fluid on the special tool.
Oil seal
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.
MB991213
MB990925
(MB990927)
Oil seal
O-ring
Rack
bushing
"DA OIL 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
37A-24

2. Apply the specified fluid to the oil seal inner surface and
the O-ring.
Rack
Specified fluid:
DEXRON or DEXRON II
3. Wrap the rack end with plastic tape, and push the rack
bushing onto the rack.
Plastic tape
Rack bushing
"EA CIRCLIP INSTALLATION

Insert the circlip to the rack stopper hole through the cylinder
hole. Turn the rack stopper clockwise and insert the circlip
firmly.
Circlip
Circlip
Caution
Insert the circlip to the rack stopper hole while turning
the rack stopper clockwise.
Slot
Slot
MB990938
MB991203
Oil seal
MB990938
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
MB991203
Ball bearing
MB991317
Pinion gear
"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.
Tapered side
"GA SEAL 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
37A-25
3. Insert the tapered side of the special tool from the pinion
gear side, and compress the seal ring.
MB990941
Caution
If the oil seal is flush with or lower than the housing
edge, it will cause oil leaks and require reassembly.
Approx. 1 mm
End plug
End plug
"HA OIL 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.
"IA END PLUG INSTALLATION

1. Apply the specified sealant to the threaded part of the
end plug.
Specified sealant:
2. Secure the threaded portion of the end plug at two places
by using a punch.
Sealant
"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.
MB991204
MB991006
"KA TOTAL 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
37A-26

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.
MB991561
Stopper
W
Adjusting bolt
MB991561
"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.
37A-27
3. Check that the crimped width (A) is within the standard

value.
A

<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.]
Edge of bellows
assembly groove
Lock nut
"NA TIE 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.
104 mm
INSPECTION
37200440131
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.
37A-28

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
MB990776

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.
37A-29
STEERING - Power Steering Oil Pump
POWER STEERING OIL PUMP
37200520262

D Condenser Fan Motor Assembly Removal
(Refer to GROUP 14.) <6A1>
<4G6>
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
12 Nm
49 Nm
10
28 Nm
7
5
10 - 12 Nm
18 Nm
49 Nm
28 Nm
<4D6>
22 Nm
3
9
1
18 Nm
Removal steps
1. Drive belt
2. Pressure switch connector
3. Suction hose
4. Pressure hose
5. O-ring
6.
7.
8.
9.
10.
Bolt
Bolt
Oil pump
Oil pump brace
Oil pump bracket
39 Nm
37A-30
<6A1>
36 Nm
5
4
10
3
39 Nm
9
8
18 Nm
12 Nm
39 Nm
Removal steps
1. Drive belt
2. Pressure switch connector
3. Suction hose
4. Air control valve
5. Pressure hose
6.
7.
8.
9.
10.
INSPECTION
D
D
O-ring
Bolt
Bolts
Oil pump
Oil pump bracket
37200530036
Check the drive belt for cracks.

Check the pulley assembly for uneven rotation.
37A-31

24
37200540220
5
3
13
4
21
Oil pump seal kit
Oil pump cartridge

kit
Fluid: Automatic transmission

fluid DEXRON or DEXRON II
20 Nm
7.9 Nm
23
3
6
7
24
25
11
10
9
59 Nm
8
9
16
15
14
13
18 20
21 22
29 Nm
12
"EA
"DA
"CA
"AA
"AA
"AA
"BA
Disassembly steps
1. Pump cover
2. O-ring
3. Vanes
4. Rotor
5. Cam ring
6. Side plate
7. O-ring
8. Connector
9. O-ring
10. Flow control valve
11. Flow control spring
12. Terminal assembly
13. O-ring
14. Spring
15. Plunger
20
19 17
16.
17.
18.
19.
20.
"AA 21.
22.
23.
"AA 24.
25.
Piston rod
Snap ring
Terminal
Washer
Insulator
O-ring
Plug
Suction connector
O-ring
Oil pump body and pulley assembly
Caution
Do not disassemble the flow control valve.
37A-32
Connector
Side plate
"AA O-RINGS INSTALLATION

Apply the specified fluid on O-rings to install.
1
2
3
6
4
Suction connector
mounting portion of
oil pump body
Terminal assembly
8
5
No.
I.D. Width mm
11 1.9
13 1.9
17.8 2.4
13.5 1.5
3.8 1.9
16.8 2.4
17.8 2.4
13.0 1.9
"BA SPRING INSTALLATION

Fit the spring to the oil pump body with the larger diameter
end at the terminal assembly side.
"CA SIDE 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.
Screw hole
Knock pin
hole (round
hole)
Knock pin hole

(oval hole)
Screw hole
Side plate
"DA CAM RING INSTALLATION

Install the cam ring with the punch mark facing the side plate.
Punch mark
Direct round edge to

the cam ring.
Rotor
Vane
37A-33
"EA VANE INSTALLATION

Install the vanes on the rotor, paying close attention to the
installation direction.
Cam ring
INSPECTION
D
D
D
D
D
37200550087
Check the flow control valve for clogging.

Check the pulley assembly for wear or damage.
Check the groove of rotor and vanes for stepped wear.
Check the contact surface of cam ring and vanes for
stepped wear.
Check the vanes for damage.
37A-34
STEERING - Power Steering Hoses
POWER STEERING HOSES
37200570267

D Front Bumper Removal (Refer to GROUP 51.)
D Front Bumper Installation (Refer to GROUP 51.)
<4G6>
12 Nm
12
7
11
12 Nm
10
7
5
13
12 Nm
15 Nm
15 Nm
12 Nm
6
12 Nm
12 Nm
12 Nm
1
12 Nm
18 Nm
34 Nm
3
12 Nm
4
15 Nm
34 Nm
15 Nm
"AA 1.
2.
3.
4.
5.
6.
7.
Pressure hose
O-ring
Pressure tube
O-ring
Return tube
O-ring
Return hose
8.
9.
10.
11.
12.
13.
Return tube
Return hose
Suction hose
Return hose
Oil reservoir
Cooler tube
37A-35

<4D6>
12 Nm
12
11
12 Nm
10
9
7
5

12 Nm
13
15 Nm
5
15 Nm
12 Nm
6
12 Nm
12 Nm

12 Nm
34 Nm
2
12 Nm
4
18 Nm
15 Nm 34 Nm
"AA 1.
2.
3.
4.
5.
6.
7.
Pressure hose
O-ring
Pressure tube
O-ring
Return tube
O-ring
Return hose
8.
9.
10.
11.
12.
13.
15 Nm
Return tube
Return hose
Suction hose
Return hose
Oil reservoir
Cooler tube
37A-36

12 Nm
<6A1>
13
12
12 Nm
11
10

12 Nm
15 Nm
14
12 Nm
15 Nm
12 Nm
12 Nm
36 Nm
12 Nm
12 Nm
34 Nm
3
4
12 Nm
18 Nm
5
15 Nm 34 Nm
15 Nm
1.
"AA 2.
3.
4.
5.
6.
7.
Air control valve

Pressure hose
O-ring
Pressure tube
O-ring
Return tube
O-ring
8.
9.
10.
11.
12.
13.
14.
Return hose
Return tube
Return hose
Suction hose
Return hose
Oil reservoir
Cooler tube

"AA PRESSURE HOSE INSTALLATION
Align the marks on the pressure hose and pressure tube,
and install the pressure hose.
Mating mark
42-1
BODY
CONTENTS
42109000201
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRUNK LID <Sedan> . . . . . . . . . . . . . . . . 4
TRUNK LID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 19
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 20
Door Fit Adjustment . . . . . . . . . . . . . . . . . . . . . . 28
QUARTER WINDOW GLASS

<Wagon> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Door Window Glass Adjustment . . . . . . . . . . .

Adjustment and Replacement When
There is a Malfunction of the Power
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Window Safety Mechanism
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Outside Handle Play Check . . . . . . . . . .
Power Window Operation Current
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker (Incorporated in the Power
Window Motor) Inspection . . . . . . . . . . . . . . . . .
TAILGATE WINDOW GLASS

<Wagon> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Door Inside Handle Play Check and

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REAR WINDOW GLASS <Sedan> . . . . . . 17
DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 31
FUEL FILLER DOOR . . . . . . . . . . . . . . . . 7

WINDOW GLASS . . . . . . . . . . . . . . . . . . . 8
ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 8
WINDOW REPAIR . . . . . . . . . . . . . . . . . . . . . . . 8
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
28
29
29
30
30
30
DOOR TRIM AND WATERPROOF

FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
42-2
DOOR GLASS AND REGULATOR . . . . . . 36
KEYLESS ENTRY SYSTEM . . . . . . . . . 51
DOOR HANDLE AND LATCH . . . . . . . . . . 41
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 51
WINDOW GLASS RUNCHANNEL AND

DOOR OPENING WEATHERSTRIP . . . . . 44
TAILGATE <Wagon> . . . . . . . . . . . . . . . 45
SERVICE SPECIFICATION . . . . . . . . . . . . . 45
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 45
How to Replace a Battery of the
Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Secret Code Registration Method . . . . . . . . . . 56
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . 57
SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . 57
SERVICE SPECIFICATION . . . . . . . . . . . . . 57
Tailgate Fit Adjustment . . . . . . . . . . . . . . . . . . . 46
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 57
Tailgate Handle Play Check . . . . . . . . . . . . . . . 46
TAILGATE ASSEMBLY . . . . . . . . . . . . . . . . . 47
TAILGATE TRIM AND WATERPROOF

FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Water Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Sunroof Fit Adjustment . . . . . . . . . . . . . . . . . . . 62
TAILGATE HANDLE AND LATCH . . . . . . . 50
SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
42-3
BODY - Hood
HOOD
42100160229

3
11
10
6
5
12 Nm
5 Nm
12
22 Nm
1
9 Nm
9
7
12
5, 6
9
Adjustment of hood step and hood
striker linkage
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.)
Adjustment of clearance and height

around hood
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
42-4
BODY - Hood/Trunk Lid <Sedan>
Bumper A
16.0 0.5 mm
Bumper B
"AA BUMPER B/BUMPER A INSTALLATION

Install the bumpers A and B as shown in the illustration.
18.8 0.5 mm
TRUNK LID <Sedan>
42100220132
10
9 Nm
11
12
8
5
9 Nm
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
Adjustment of clearance around

trunk lid and trunk lid striker linkage
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
42-5
BODY - Trunk Lid <Sedan>/Fender

"AA TRUNK LID WEATHER STRIP INSTALLATION

Install the trunk lid weatherstrip so that the marking and the
joint are aligned with the body centre line.
Bumper A
"BA BUMPER B/BUMPER A INSTALLATION

Install the bumpers A and B as shown in the illustration.
Bumper B
15 mm
14 mm
ON OFF
INSPECTION
42100410034
TRUNK LID LATCH CONTINUITY CHECK

Switch position
Terminal No.1
Body earth
ON (Latch open)
OFF (Latch shut)
FENDER
42100050137
SEALANT
Item
Specified sealant
Remark
Splash shield
Ribbon sealer
Fender
42-6
BODY - Fender
FENDER
42100190204

D Front Bumper Removal and Installation
D Front Turn-signal Lamp Removal and Installation
Side Sill Cover Removal and Installation (Refer to

GROUP 51 - Aero Parts.)
2
3
Sealant:
Sealant:
Removal steps
1. Splash shield
"AA 2. Side turn signal lamp
3. Fender

Hook
Front of vehicle
Fender panel
"AA SIDE TURN-SIGNAL LAMP INSTALLATION

Insert the hook into the fender panel, and then install the
side turn signal lamp.
42-7
BODY - Fuel Filler Door
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.)
1
3
2
3
1
2
Fuel filler door height and clearance

adjustment
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
42-8
BODY - Window Glass
WINDOW GLASS
42200050123
ADHESIVES
Items
Specified adhesives
Windshield
3M ATD Part No. 8609 Super Fast Urethane Auto Glass

Sealants or equivalent
Quarter window glass

Tailgate window glass
Rear window glass
SPECIAL TOOLS
Tool
42200060126
Number
Name
Use
MB990480
Glass holder
D
D
D
MB990449
Window moulding
remover
Removal and installation of windshield

Removal and installation of tailgate window
glass
Removal and installation of rear window
glass
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
BODY - Window Glass
42-9
ITEMS NEEDED
Name
Remarks
Adhesive
3M ATD Part 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.
42-10
BODY - Window Glass
WORKING PROCESS
Window glass installation procedure
Body side
Window glass side
Reusing the glass
Replacing the glass
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.

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 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.
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 to the adhesion surface of the
body and let dry for 3 minutes or more.
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.
42-11
BODY - Window Glass
WINDSHIELD
42200100255

D Front Pillar Trim Removal and Installation
Section A-A
Headlining Removal and Installation
mm
Section B-B
A
36
A
C
22
Primer
16
Primer
2 (Entire
circumference)
Section C-C
B
B
Primer
7.5
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
5
2
6
7
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
42-12
BODY - Window Glass

AA" ROOF DRIP MOULDING REMOVAL
Use the special tool to lever out the moulding.
MB990449
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.
MB990480
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.
BODY - Window Glass
42-13
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.

"AA WINDSHIELD 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.
42-14
BODY - Window Glass

7. Install the glass stopper to the shown dimension.
Centre
A
300 mm
300 mm
A
Glass stopper
Section A - A
20 mm
Glass stopper
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.
10 mm
15 mm
9. After applying the adhesive, align the mating marks on

the windshield and the body, and then press the windshield
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.
42-15
BODY - Window Glass
QUARTER WINDOW GLASS <Wagon>
42200250127

D Quarter Upper Trim, Retractor Trim and Belt Line Trim
Removal and Installation (Refer to GROUP 52A.)
Section A - A
Section B - B
mm
Primer
5.5
5
B
22
A
A
Section C - C
5
7.5
Section D - D
Primer
Primer
5.5
9.5
5.5
Primer
3
3
2
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.)

"AA QUARTER WINDOW GLASS INSTALLATION
Install the quarter window glass in the same manner as for
the windshield, except the clips (Refer to P.42-11.)
42-16
BODY - Window Glass
TAILGATE WINDOW GLASS
42200370144

D Side Tailgate Trim, Lower Tailgate Trim and Cover
Removal and Installation (Refer to P.42-49.)
Rear Wiper Removal and Installation

Section A - A
mm
Section B - B
Primer
A
Primer
5
15
5 15
Section C - C
B
B
Section D - D
Primer
Primer
81.5
56.5
3
2
3
Removal steps
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).

"AA TAILGATE 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).
42-17
BODY - Window Glass
REAR WINDOW GLASS <Sedan>
42200160123

D Rear Wiper Motor Removal and Installation
D High Mounted Stop Lamp Removal and Installation
D
D
Rear Pillar Trim Removal and Installation

Section A - A
8.5
Primer
14
B
mm
Section B - B 6.7
A
B
Section C - C
Primer
7
11
C
7
C
Primer
8
5
7
2
1
10
Adhesive tape:
double-sided tape [6 mm width
and 0.125 mm thickness]
4
9
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
42-18
BODY - Window Glass

MB990449
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.)

"AA REAR 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).
42-19
BODY - Door
DOOR
42300030137
Items
Standard value
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
Item
Specified sealant
Remark
Waterproof film
Ribbon sealer
SPECIAL TOOLS
Tool
42300060105
Number
Name
Use
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
42-20
Tool
A
BODY - Door
Number
Name
Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: probe

TROUBLESHOOTING
42300070160
DIAGNOSIS FUNCTION
MUT-II
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.
42-21
BODY - Door
Trouble symptom
Power windows
Door locking
mechanism
42300700021
Inspection
procedure
Reference
page
The power windows cannot be operated by any of the power

window switches.
42-22
Drivers side power window cannot be operated by the power

window main switch.
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.)
42-25
When the glass is raised, it then lowers automatically.
42-25
The glass is not lowered when something is jammed in the

window.
42-25
When the glass is fully raised, it then lowers automatically.
42-26
None of the door lock functions operate.
42-26
None of the doors lock or unlock when the drivers side inside door
locking knob is operated (including by means of the door key).
42-27
Some doors do not lock or unlock.
42-27
42-22
BODY - Door

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
D
Check power window relay continuity.

(Refer to P.42-40.)
OK
Measure at the power window relay connector B-15X.
OK: System voltage
NG
NG
Malfunction of power window relay

Replace

C-131, C-141
OK
NG
NG
OK
Measure at the power window relay connector B-15X.
D Continuity between 3 and body earth
OK: Continuity
NG
NG
Repair
Check the harness wire between ignition

switch (IG2) and power window relay,
between fusible link No. 3 and power
window relay, and repair if necessary.
Check the harness wire between power
window relay and the earth, and repair
if necessary.
OK
Measure at the power window main
switch connector F-19.
OK: System voltage
NG

F-19, C-120, C-114, B-15X
OK
OK
OK: Continuity
OK
Replace the power window switch.
NG

C-120, F-19
OK
NG
NG
NG
NG
Repair

window main switch and power window
Repair

window main switch and earth, and repair if necessary.
42-23
BODY - Door
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
D
D
Check the power window relay continuity. (Refer to P.42-40.)

OK
D Ignition switch: ON and OFF
OK: System voltage (ON)
0 V (OFF)
OK
Measure at the ETACS-ECU connector
C-138.
OK: System voltage
OK
Replace the ETACS-ECU.
NG
NG
Replace

F-19, C-120, C-114, B-15X
OK
NG
Malfunction of power window relay

Malfunction of ETACS-ECU

C-138, C-116, B-15X
OK
NG
NG
NG
NG
Repair
Check the harness wire between fusible

link No.3 and power window relay, and
Repair

window relay and ETACS-ECU, and repair if necessary.
42-24
BODY - Door
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
D
D

0 V (OFF)
OK: Continuity
OK
Measure at the power window motorECU connector F-21.
0 V (OFF)
OK: Continuity
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

F-19, C-120, C-114, B-15X
OK
Malfunction of power window main switch

Malfunction of power window motor-ECU
NG
NG
OK
Replace the power window main switch.
NG

F-21, C-120
OK
NG
NG
NG
Repair

window relay and power window main
switch, between power window main
switch and earth, and repair if necessary.
Repair

window relay and power window motorECU, and between power window motor-ECU and earth.

window main switch and power window
motor-ECU, and repair if necessary.
OK
Replace the power window main switch.
NG
Replace the power window motor-ECU.
42-25
BODY - Door
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.)
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.

F-10, F-15, F-04 or F-21
NG
Repair
OK
Check the harness wire between power window main switch F-19
and joint connector (1 or 5).
NG
Repair
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
OK
NG
NG
Repair
Check the harness wire between joint connector and power window
motor-ECU.
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
D
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
NO
YES
Incorrect window glass adjustment

Glass slider is incorrectly installed or warped
Adjust the window glass. (Refer to P.42-28.)

NG
Replace the window regulator assembly.
The glass is not lowered when something is jammed in the
window.
Probable cause
The cause may be a malfunction of the revolution detection sensor in the power
window motor-ECU.
Malfunction of power window motor-ECU
42-26
BODY - Door
When the glass
automatically.
is
fully
raised,
it
then lowers
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.
Probable cause
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.
D
D
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
OK
NG
NG
OK
C-142, C-144
OK
NG
NG
Repair

link No.1 and junction block, and repair
if necessary.
Repair

ETACS-ECU and body earth.
OK
NG
Repair
42-27
BODY - Door
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
D
D
MUT-II Pulse check

Front door lock actuator switch (driversside) input signal
OK: The MUT-II buzzer sounds once
when the front door lock actuator
moves from the locked to the unlocked position, or from the unlocked to the locked position.
NG
OK
Check the front door lock actuator (drivers side). (Refer to P.42-42.)
OK
Malfunction of front door lock actuator (drivers side)

NG
NG

F-17, C-120, C-138
OK
NG
Replace
Repair

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
D
D
Check the door lock actuator of the door that does not operate.
OK
<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
OK
NG
NG
NG
Malfunction of door lock actuator

Malfunction of tailgate lock actuator
Replace
Repair
Check the harness between the ETACS-ECU and the door lock
actuator of the door that does not operate, and repair if necessary.
42-28
BODY - Door
ON-VEHICLE SERVICE
MB990900 or
MB991164
42300090128
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).
Striker
Front
Adjusting
hole
Rear
Adjusting
hole
Shim
3. If the door opening and closing is heavy, adjust the

meshing of the striker and the door latch (in the longitudinal
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.
BODY - Door
Runchannel
Door
sash
Lower sash
42-29
ADJUSTMENT AND REPLACEMENT WHEN

THERE IS A MALFUNCTION OF THE POWER
42900190062
WINDOWS
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

42900100065
CHECK
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).
42-30
BODY - Door
Section A - A
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
A
B
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

42900110051
INSPECTION
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) INSPECTION 42900170080
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

42300150208
ADJUSTMENT
1. Check that the door inside handle play is within the
standard value range.
Standard value (A): 5.3 mm or more
A
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.
42-31
BODY - Door
DOOR ASSEMBLY
42300220237

Door Adjustment (Refer to P.42-28.)
4, 5
Front door
22 Nm
26 Nm
6 7
12 Nm
26 Nm
22 Nm
Rear door
26 Nm
12 Nm
6
22 Nm
26 Nm
22 Nm
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
42-32
BODY - Door
Front (upper, lower)

Rear (upper)
Identification mark
Rear (lower)

"AA DOOR LOWER HINGE/DOOR UPPER HINGE
INSTALLATION
The door hinges differ according to where they are used,
so check the identification marks before installation.
Identification mark
Applicable location
Front left side door
Front right side door
Rear left side door
Rear right side door
Identification
mark
Upper hinge
Lower hinge
Upper hinge
Lower hinge
Upper hinge
M2
Lower hinge
O2
Upper hinge
N2
Lower hinge
P2
INSPECTION
42300600093
DOOR SWITCH CONTINUITY CHECK

2
1
ON OFF
Stroke
Switch
position
Open (ON)
Depressed
(OFF)
Terminal No.
1
BODY - Door
42-33
DOOR TRIM AND WATERPROOF FILM
42300430210

Front door
7
2
5
8
3
12
11
10
12
NOTE
: Resin clip position
Sealant:
3M ATD Part. No. 8625 or equivalent
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.
8.
9.
10.
11.
12.
Pull handle bracket A

Pull handle bracket B
Door inside handle
Speaker
Speaker cover
Waterproof film
42-34
BODY - Door
Rear door
11
9
4
14
10
1
7
8
13
12
NOTE
14
Sealant:
3M ATD Part. No. 8625 or equivalent
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.
7.
8.
9.
10.
11.
12.
13.
14.
Pull handle box

Inside handle cover
Door trim
Pull handle bracket A
Pull handle bracket B
Door inside handle
Speaker
Speaker cover
Waterproof film
BODY - Door
42-35

AA" CLIP REMOVAL
Remove the clip by using a rag, and then remove the regulator
handle.

Horizontal line
30_
Front of vehicle
"AA ESCUTCHEON/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.
42-36
BODY - Door
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
5
6
7
1
2
2
4
3
3
4
<Vehicles without
power windows>
3
<Vehicles with
power windows>
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
AB"
Stationary window glass removal

steps
D Window glass runchannel
(Refer to P.42-44.)
1. Door window glass
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.
Door outer
opening
weatherstrip
Door center sash
Opening
Drum
Drive
shaft
Guide
Square hole
Rachet wrench
Glass
bracket
"AA POWER 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 drum using 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.
42-38
BODY - Door
3. Install the metal cover securely to the housing.
Mounting
screw
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.
Metal cover
4. Apply battery voltage to the power window motor, and

check that the glass bracket moves smoothly.
Guide
Spring A
Drum
Lifting
wire
Square hole
Spring B
Slit
Lowering wire
Lowering
wire
Spring
Slit
Lifting wire
Guide
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.)
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.
Narrowgauge wire
Lowering wire
Lifting wire
4. Insert the end of the lowering wire into the wire hole
at the bottom of 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.
42-40
BODY - Door
(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.
"BA DOOR 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 window glass to the window regulator
assembly.
NOTE
Fully raising the door window glass will set the door limit
switch to the correct position.
INSPECTION
42900180106
POWER WINDOW RELAY CONTINUITY CHECK

System
voltage
Not applied
Applied
Power window relay
Terminal No.
1
42-41
BODY - Door
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 to P.42-30.)
D Door Trim Installation (Refer to P.42-33.)
Front door
Rear door
6 Nm
5
6 Nm
1
8
8
5
9
9
4
Front door handle and door latch

1. Door inside handle
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
42-42
BODY - Door
<L.H.>
INSPECTION
View A
Lock
Unlock
FRONT DOOR LOCK ACTUATOR CHECK

L.H. drive vehicles
<Drivers side>
Rod position
Terminal No.
1
A
<R.H.>
View B
Unlock
Lock
42300610102
Rod operation
4
LOCK
LOCK position
UNLOCK position
UNLOCK
UNLOCK position
LOCK position
LOCK
UNLOCK
<Passengers side>
Rod position
Terminal No.
4
Rod operation
6
LOCK
LOCK position
UNLOCK position
UNLOCK
UNLOCK position
LOCK position
R.H. drive vehicles

<Drivers side>
Rod position
Terminal No.
1
Rod operation
4
LOCK
LOCK position
UNLOCK position
UNLOCK
UNLOCK position
LOCK position
LOCK
UNLOCK
<Passengers side>
Rod position
Terminal No.
4
Rod operation
6
LOCK
LOCK position
UNLOCK position
UNLOCK
UNLOCK position
LOCK position
42-43
BODY - Door
REAR DOOR LOCK ACTUATOR CHECK
<L.H.>
<L.H.>
View A
Rod position
Terminal No.
2
Lock
Unlock
A
42300620082
Rod operation
3
LOCK
LOCK position
UNLOCK position
UNLOCK
UNLOCK position
LOCK position
<R.H.>
<R.H.>
View B
Rod position
Terminal No.
2
Rod operation
3
LOCK
LOCK position
UNLOCK position
UNLOCK
UNLOCK position
LOCK position
Lock
Unlock
B
DOOR LOCK KEY CYLINDER SWITCH CHECK

Switch position
Terminal No.
1
LOCK
NEUTRAL (OFF)
UNLOCK
Neutral
21_
Unlock
21_
Lock
42300630122
42-44
BODY - Door
WINDOW GLASS RUNCHANNEL AND DOOR OPENING

WEATHERSTRIP
42300310187

Front door
Rear door
6
6
5
3
2
5
2
1
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 runchannel <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

15 mm
4 mm
8 mm
Thickness
1mm
AA" DOOR OUTER OPENING WEATHERSTRIP

REMOVAL
Make a tool as shown in the illustration to remove the door
opening weatherstrip.
42-45
BODY - Door/Tailgate <Wagon>

"AA DOOR 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
Rear door
Left
White
Right
Brown
Left
Yellow
Right
Blue
TAILGATE <Wagon>
42400030017
Item
Standard value
Tailgate handle free play mm
1.5 - 5.5
SEALANT
42400050044
Item
Specified sealant
Remark
Waterproof film
Ribbon sealer
SPECIAL TOOLS
Tool
42400060030
Number
Name
Use
MB990784
Ornament remover
Removal of the tailgate trim
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: probe

42-46
BODY - Tailgate <Wagon>
TROUBLESHOOTING
42400070088

Trouble symptom
Reference page
Door lock mechanism does operate.
42-26.
ON-VEHICLE SERVICE
42400090039
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.
Upper tailgate dumper
TAILGATE HANDLE PLAY CHECK
Section A - A
Holder
Tailgate
handle
1. Check that the tailgate handle play is within the standard

value range.
Standard value (B): 1.5 - 5.5 mm
Rod
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.
42-47
TAILGATE ASSEMBLY
42400110124

<Tailgate assembly>
D Tailgate fit adjustment (Refer to P.42-46.)
7
1
9
5
Adjustment of clearance around tailgate
12 Nm
3
9
11
9 Nm
Adjustment of tailgate step and tailgate

striker linkage
12
14 Nm
10
11
8
AA"
Tailgate assembly removal steps

D High-mounted stop lamp
1. Bumper
2. Washer hose
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
42-48

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.

"AA TAILGATE OPENING WEATHERSTRIP
INSTALLATION
Install the tailgate opening weatherstrip so that the marked
part is at the centre of the body.
42-49
TAILGATE TRIM AND WATERPROOF FILM
42400140048
5
4
5
3
2
NOTE
: Sheet metal clip position
Sealant: 3M ATD Part No.8625 or equivalent
Removal steps
1. Tailgate grip
2. Lower tailgate trim
3. Tailgate clip
4. Cover
5.
6.
7.
8.
Side tailgate trim

Rear roof rail trim
Tailgate trim bracket
Waterproof film
42-50
TAILGATE HANDLE AND LATCH
42400170054

D Tailgate Handle Free Play Check (Refer to P.42-46.)
3
1
2
4
5
6
6
9 Nm
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
INSPECTION
42400180033
TAILGATE LOCK ACTUATOR CHECK

Rod position
Terminal No.
2
View A
UNLOCK
LOCK
Rod operation
LOCK
LOCK position UNLOCK

position
UNLOCK
UNLOCK position
42-51
BODY - Keyless Entry System
KEYLESS ENTRY SYSTEM
42800060032
SPECIAL TOOL
Tool
Number
Name
Use
MB991502
MUT-II sub assembly
Recording secret codes
TROUBLESHOOTING
42800180035

Trouble symptom
Inspection procedure No.
Reference page
None of the doors can be locked or unlocked using the transmitter.
42-51
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.)
42-53
Secret codes cannot be registered.
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
D
D
D
D
D
Can the doors be locked and unlocked by the drivers-side door

key cylinder and lock knob?
Yes
Has the secret code been registered properly? *
No
NG
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
of
transmitter
receiver
ETACS-ECU
key reminder switch
door switch
Check the centre door lock system.
Re-register the secret code. (Refer to P.42-56.)
OK
Replace the transmitter battery. (Refer to P.42-55.)
NG
To next page
NOTE
*: This should be done if a transmitter or receiver has been replaced, and if a secret code has not
been registered properly.
42-52
From previous page

Measure at the receiver connector C-80.
OK: Battery voltage
NG

C-80, C-63, C-132, C-141, C-61, C-134, C-131
OK
OK
NG
Repair
NG
D Between ignition switch (ACC) and receiver
D Between fusible link No.2 and receiver

OK: Continuity
NG

C-80, C-62
OK
OK
NG
Repair
NG
D Between receiver and earth
D Disconnect the connector, and measure at harness side.
OK: Battery voltage
NG
Check the connectors:

C-80, C-138
OK
Check the harness wire.
D Between ETACS-ECU and receiver
OK
Replace
ECU.
NG
the
ETACS-
Replace
OK
E-19, E-08, G-16, G-09, G-32, G-28, C-65, C-143
NG
Repair
OK
NG
D Between ETACS-ECU and door switch
NG
Repair
OK
Key reminder switch continuity check (Refer to GROUP 54 - Ignition
Switch.)
NG
Replace
OK
C-109, C-65, C-80
NG
Repair
OK
NG
D Between key reminder switch and receiver
D Between key reminder switch and ETACS-ECU
D Between key reminder switch and earth
OK
Replace the transmitter.
Repair
NG
OK
Door switch continuity check (Refer to P.42-32.)
NG
NG
NG
Repair
Replace the receiver.
NG
Repair
42-53

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
D
D
NG
Drivers door lock actuator check (Refer to P.42-42.)
Malfunction of drivers door lock actuator
Malfunction of connector or wiring harness
Replace
OK
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
D
D
D
Measure at the diagnosis connector C-20 and the 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
of
of
of
of
receiver
MUT-II
connector or wiring harness
ETACS-ECU

C-20, C-66, C-80
OK
NG
Repair
NG
OK

D Between receiver and diagnosis connector
Can the MUT-II communicate with other systems?

Yes
Malfunction
Malfunction
Malfunction
Malfunction
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
OK
NG
Repair
NG
D Between fusible link No.2 and diagnosis connector
Measure at the diagnosis

connector C-14.
D Continuity between 4
and body earth
D Continuity between 5
and body earth
OK: Continuity
NG
Check the
connector:
C-20
following
OK
To next page
OK
NG
NG
Replace MUT-II.
Repair

D Between diagnosis connector and earth
42-54
From previous page

OK: Battery voltage
NG

C-80, C-63, C-132, C-141, C-61, C-134, C-131
OK
NG
OK
Repair
NG
D Between fusible link No.2 and receiver
D Between ignition switch and receiver

D Between 20 and body earth
OK: Continuity
OK
NG

C-80, C-62
OK
NG
Repair
NG
Replace the receiver.

D Between receiver and earth
INSPECTION OF RECEIVER TERMINAL VOLTAGE
Terminal
Signal name
Conditions
Door switch
Room lamp switch:

OFF or ON
Room lamp switch:

DOOR
Terminal voltage
One or more doors are
open (Door switch: ON)
0V
All doors are closed

(Door switch: OFF)
5 V and pulse output*
One or more doors are

open (Door switch: ON)
0V

(Door switch: OFF)
Battery voltage
Door lock actuator

switch (drivers side)
LOCK
UNLOCK
0V
Diagnosis changeover
input
0V
When MUT-II is disconnected

(Ignition switch: ACC or OFF)
Key reminder switch
OFF (When ignition key is inserted)
ON (When ignition key is removed)
0V
Ignition switch: ACC or ON
Battery voltage
0V
Ignition switch
42-55

Terminal
Signal name
Conditions
Terminal voltage
10
Receiver power supply
At all times
Battery voltage
11
Room lamp output

(Door switch: OFF)
12
Door lock output
14
20
0V
Room
DOOR
Battery voltage
lamp
switch:
When door lock control unit outputs signal, or

door lock switch: LOCK
0V
Other than above
Battery voltage
When door lock control unit outputs signal, or door

lock switch or door lock key cylinder: UNLOCK
0V
Other than above
Battery voltage
Driver identification
signal output (Vehicles
with theft-alarm system)
When keyless entry system is operating

(When transmitter switch is pressed)
5 V and pulse output

(fluctuation pulse)
When keyless entry system is not operating

(When transmitter switch is not pressed)
5 V and pulse output

(constant pulse)
Earth
At all times
0V
Door unlock output
16
Room lamp switch: OFF

or ON
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.)
Battery
Open
Claw
ON-VEHICLE SERVICE
42800090079
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.
Screw
O-ring
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.
42-56
SECRET CODE REGISTRATION METHOD

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 problem is 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-registered 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
Always turn the ignition switch to OFF before
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.
42800100109
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
42800130153

D Side Cover Removal and Installation (Refer to
GROUP 52A - Instrument Panel.)
ETACS-ECU
Keyless entry receiver
SUNROOF
42600030068
Items
Standard value
Roof lid glass operating current A
7 or less (at 20_C)
SPECIAL TOOL
Tool
A
42600060043
Number
Name
Use
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness
adapter
D: Probe

42-58
BODY - Sunroof
TROUBLESHOOTING
42600200070

Trouble symptom
Reference page
The sunroof does not operate when the ignition switch is turned
to ON.
42-58
The motor does not reverse its direction when a load of 140 N
or more is applied while the sunroof is closing.
42-60
The timer does not operate for 30 seconds after the ignition
switch is turned to OFF.
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.
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
D
D
D
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
sunroof switch
sunroof motor
sunroof-ECU
42-59
BODY - Sunroof
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
OK
(3) NG
(1) NG

E-07, C-27, C-134, C-131
NG
Check the harness wire between ignition switch (IG2) and sunroof-ECU, and
E-07, C-27, C-114
NG
OK
NG
Repair
OK
Repair
NG

NG

link No. 3 and sunroof-ECU, and repair
if necessary.
Check the harness wire between sunroof-ECU and

Check sunroof switch continuity (Refer to P.42-66.)
Repair
OK
(2) NG

E-07, C-133, C-131
NG
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
NG
Repair
OK
NG
Check the harness wire between sunroof-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.)

E-07, E-04, C-133, C-131
NG
Replace
OK
Measure at the sunroof motor connector E-03.
OK: Continuity
NG

E-03, C-133, C-131
NG
Repair
OK
OK
NG
Check the harness wire between sunroof motor and the earth, and repair
if necessary.
E-03, E-07
NG
Repair
OK
NG
Check the harness wire between sunroof-ECU and sunroof motor.

OK
Replace the sunroof-ECU.
NG
Repair
42-60
BODY - Sunroof
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.
Malfunction of 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.
D
D
Measure at the sunroof-ECU connector

E-07.
OK: System voltage
NG

C-27, C-114
NG
Repair
OK
NG
OK

link No.3 and sunroof-ECU, and repair
if necessary.
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
D
D
Check front door switch (drivers side)

continuity. (Refer to P.42-32.)
OK
E-19 or E-08, C-143, C-134, C-65, C-27,
E-07
NG
NG
Replace
Repair
OK
NG
Malfunction of the front door switch (drivers side)

Check the harness wire between front

door switch (drivers side) and sunroofECU.
OK
NG
Repair
42-61
BODY - Sunroof
TERMINAL VOLTAGE CHART
Terminal No.
Check Item
Check Condition
Normal Condition
Sensor power supply
Ignition switch: ON
Battery voltage
Sensor 1
When motor is operating
Battery voltage (pulse)
Sunroof switch (open

input)
Sunroof switch
(open position)
ON
0V
OFF
Battery voltage
Sunroof switch (up input)
Sunroof switch
(up position)
ON
0V
OFF
Battery voltage
Timer operation power

supply
Ignition switch: ON
Battery voltage
ECU power supply
Always
Battery voltage
Motor output
While sunroof is closing or moving up
Battery voltage
Other than the above
0V
Sensor earth
Always
0V
10
Sensor 2
When motor is operating
Battery voltage (pulse)
12
Sunroof switch (close or

down) input
Sunroof switch (close

position or down position)
Limit switch input
From tilt up condition to fully-closed

condition
Battery voltage
From fully-closed condition to fully-open

condition
0V
Drivers door switch
ON
0V
OFF
Battery voltage
14
16
Door switch input
ON
0V
OFF
Battery voltage
17
Earth
Always
0V
18
Motor output
While sunroof is opening or moving

down
Battery voltage
Other than the above
0V
42-62
BODY - Sunroof
ON-VEHICLE SERVICE
Hose
42600090127
WATER TEST
Apporox. 30cm
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 from around 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.
42-63
BODY - Sunroof
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
7
13
7
10
6
9
11
3
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
42-64
BODY - Sunroof
<Wagon>
5
1
13
8
12
10
11
7
6
9
NOTE
: indicates the sheet metal
clip position.

Sunroof switch removal steps
3. Sunroof switch cover
4. Sunroof switch
Drain hose removal steps
D Splash shield (Front drain hose)
5. Rear roof rail trim
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
BODY - Sunroof
Drain hose
Cord
42-65

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.

"AA SUNROOF 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.
Cord
"BA DRAIN 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
Drain hose
Grommet
20 - 30 mm
3. Make the protrusion from the drain hose grommet as

42-66
BODY - Sunroof
INSPECTION
42600130119
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
Drive gear
Left rotation
Right rotation
SUNROOF MOTOR CHECK

Check the direction of rotation of the drive gear when the
battery is connected to the connector.
Battery connection terminal
1
Drive gear rotation

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
ON
OFF
Terminal No.
5
Limit switch
ON
OFF
SUNROOF SWITCH CONTINUITY CHECK

Switch position
Terminal No.
3
Slide open
Off
Tilt up
Slide close, Tilt down
42-67
BODY - Sunroof
42600140105
<Sedan>
13
11
1
2
6
5
9
4
10
12
3
11
13
Disassembly steps
2. Weatherstrip
3. Sunroof motor
5. Guide block
6. Roof drip channel
7. Panel stopper
8.
9.
10.
11.
12.
13.
Sunshade assembly
Guide rail stopper
Rail sub assembly
Housing sub assembly
Side deflector
Drive cable assembly
42-68
BODY - Sunroof
<Wagon>
11
15
5
1
4
10
12
14
11
9
15
13
Disassembly steps
2. Weatherstrip
3. Sunroof motor
5. Roof drip channel
6. Panel stopper
7. Sunshade assembly
8. Guide rail stopper
9.
10.
11.
12.
13.
14.
15.
Cable guide casing

Side deflector
Drive cable assembly
Seal
Seal
Clamp
Guide rail sub assembly
51-1
EXTERIOR
CONTENTS
51109000210
MOULDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SEALANT AND ADHESIVE . . . . . . . . . . . . . . . . . 2
AERO PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
WINDSHIELD WIPER AND WASHER . . . . . . 12
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR WIPER AND WASHER . . . . . . . . . . . . . 15
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
HEADLAMP WASHER . . . . . . . . . . . . . . . . . . . . 18
RADIATOR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . 7
MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ROOF RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . 22
51-2
EXTERIOR - Service Specifications/Sealant and Adhesive/Special Tools
51100030195
Items
Standard value
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)
SPECIAL TOOLS
Tool
51100060071
Number
Name
Use
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.
51-3
EXTERIOR - Front Bumper
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.)
3
3
AA"
Removal Steps
1. Fog lamp bezel
2. Fog lamp
3. Clip
4. Front bumper assembly
5. Front bumper reinforcement assembly
MB990784
MB990784
Pin
Clip
AA" CLIP REMOVAL

(1) Use the special tool to pull up the centre pin in the clip.
(2) Remove the clip.
51-4
EXTERIOR - Front Bumper
51100160238
1
4
5
3
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
MB990784
MB990784
Pin
Clip
AA" CLIP REMOVAL

EXTERIOR - Rear Bumper
REAR BUMPER
51-5
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
51-6
EXTERIOR - Rear Bumper
51100210186
<Sedan>
1
1
1
<Wagon>
3
1
7
2
1
5
6
AA"
Disassembly steps
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
MB990784
MB990784
Pin
Clip
AA" CLIP REMOVAL

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

D Headlining Removal and Installation
Roof rail
51-8
EXTERIOR - Mouldings
MOULDINGS
51100470157

<Sedan>
1
4
2
5
<Wagon>
1
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
51-9
73 mm
71 mm
35 mm
40 mm
f 10
f 10
Adhesive tape: double-sided tape <A (10 mm width and 0.8 mm thickness) B, C (0.8 mm thickness)>

AA" ROOF DRIP MOULDING REMOVAL
Caution
reused.
MB990449
Protection tape
Double-sided tape
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.
51-10
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.

"BA SIDE 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

double-sided tape.
from the
pressure sensitive
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.
51-11
EXTERIOR - Mouldings/Aero Parts
"AA ROOF 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)
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).

"AA SIDE SILL COVER INSTALLATION
Install the side sill cover in the same manner as for the side
protect moulding (Refer to P.51-8).
51-12
EXTERIOR - Windshield Wiper and Washer
WINDSHIELD WIPER AND WASHER
51100760261

3
2
13 Nm
9 Nm
A
5 Nm
6
9
11
7
8
12
10
Section A - A
1
Clip
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>
51-13

Linkage
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.
Crank arm
Wiper motor
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.
"AA WIPER 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
Front deck garnish end
INSPECTION
51101450044
COLUMN SWITCH CHECK

Wiper and Washer Switch
Terminal No.
Switch position
6
Wiper switch
OFF
INT
1 (LO)
2 (HI)
Washer switch
ON
10
51-14

Terminal No.
Switch position
8
Wiper switch
10
11
12
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
51101260104
WIPER MOTOR CHECK
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 shown in the illustration
and inspect motor operation at low speed and high speed.
Wiper Motor at Stop Position Operation
Inspection while operating
Battery
Low speed High speed
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.
Inspection while stopped
Battery
Low speed Automatic stop
51101270107
WASHER MOTOR CHECK
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).
51-15
EXTERIOR - Rear Wiper and Washer
REAR WIPER AND WASHER
51100850159

<Sedan>
1
2
7.4 Nm
3
9.8 Nm
5
9
11
12
8
7.4 Nm
<Wagon>
4
10
11
9.8 Nm
6
8
<Wagon>
7
8
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 (windshield wiper and washer switch), refer
to GROUP 37A - Steering Wheel and Shaft.}
51-16

<Sedan>
"AA WIPER ARM AND BLADE ASSEMBLY

INSTALLATION
<Sedan>
Install the wiper arm to the pivot shaft so that the wiper blades
stop position is the position (standard value) shown in the
illustration.
Glass end line
<Wagon>
Standard value (A): 15 5 mm

<Wagon>
Install the wiper arm by aligning the blade with the marking
position.
Marking position
INSPECTION
51101290080
WIPER MOTOR CHECK

Check the wiper motor after first disconnecting the wiring
harness connector, and with the wiper motor remaining
installed to the body.
Operation check
Battery
Stop position check
Battery
Wiper Motor Operation

Connect a battery to the wiper motor as shown in the illustration
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.
51-17
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
Rear intermittent
wiper relay
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)

51100950057
CHECK
Terminal No.
Switch position
2
Wiper switch
10, 8*
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.
51-18
EXTERIOR - Headlamp Washer
HEADLAMP WASHER
51100970107

3
1
4
4
4
2
2
4
4.9 Nm
4.9 Nm
6
6
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.
INSPECTION
51101320055
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

STEP 2
Connector A
Test lamp
Connector B
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)

51100980063
CHECK
Check the continuity between terminal 2 of connector A and
terminal 1 of connector B with headlamp washer switch in
ON position.
51101330058
CHECK VALVE CHECK
Apply pressure to the inlet of the check valve to check its
opening pressure.
Opening pressure: 78 kPa
51101340051
HEADLAMP WASHER MOTOR CHECK
2. Connect battery (+) and ( - ) cables to terminals (1) and
(2) respectively to see that the washer motor runs and
water is injected.
51-20
EXTERIOR - Marks
MARKS
51101180110

<Sedan>
<Wagon>
2
2
1
"AA 1. Mitsubishi mark

"AA 2. Grade mark

"AA INSTALLATION OF MARKS
1.
APPLICATION POSITION
MITSUBISHI mark
<Sedan>
<Wagon>
30 mm
12 mm 7 mm
24 mm
Trunk lid end line
7 mm
26.6 mm
Trunk lid press line
35 mm
Tailgate end line
51-21
EXTERIOR - Marks
Grade mark
<Sedan>
GLS TD
GLS (also applicable to GLX and V6-24)
15 mm
28 mm
24 mm
21 mm
24 mm
26.9 mm
Trunk lid end line
21 mm
Trunk lid end line
<Wagon>
GLS TD
GLS (also applicable to GLX and V6-24)
35 mm
35 mm
35 mm
35 mm
Tailgate end line
15 mm
Tailgate end line
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.
51-22
EXTERIOR - Door Mirror
DOOR MIRROR
51100640121

5
6
3
1
7
AA"
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
7. Mirror
Spring

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.
Hook
51-23
EXTERIOR - Door Mirror

INSPECTION
51100650100
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
5
Direction of operation
4
UP
DOWN
Printed
heating
wire
RIGHT
LEFT
DOOR MIRROR CONTROL SWITCH CONTINUITY CHECK

51101350061
Switch position
Terminal No.
2
Left side
UP
DOWN
LEFT
RIGHT
Right side UP
DOWN
LEFT
RIGHT
SWITCH AND RELAY OF DOOR MIRROR

51101360019
PRINTED HEATING WIRE CHECK
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
52A-1
INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . . . . . . . . . . 52B
52109000187
52A-2
INTERIOR
CONTENTS
52109000385
INSIDE REAR VIEW MIRROR . . . . . . . . . . . . . . 11
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT SEAT* . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTRUMENT PANEL* . . . . . . . . . . . . . . . . . . . . . . 3
REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT SEAT BELT . . . . . . . . . . . . . . . . . . . . . . 19
TRIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REAR SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . 20

WARNING!
MITSUBISHI dealer.
component.
NOTE
INTERIOR - Service Specifications/Special Tool/Instrument Panal
52100030055
Items
Standard value
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
SPECIAL TOOL
Tool
52A-3
52100060191
Number
Name
Use
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
Tapping screw
512
514
516
425
Black
512
520
516
520
616
620
Washer-assembled screw
Washer-assembled bolt
D = Thread diameter
L = Effective thread length
Shape
52A-4
INTERIOR - Instrument Panel
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.
12
10
C
9
8
11
C
16
7
13
19
21 20
14
D
2
22
F F
23
17
3
<Manual air conditioner>
<Automatic air conditioner>
15
C
H
18
B
16
NOTE
: metal clip position
AA"
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.)
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
52A-5
24
30
25
32
29
29
12 Nm
I
I
Standard bolt
Earth bolt
12 Nm
22 Nm
31
G
C
27
26
28
G
J
H
NOTE
24.
25.
26.
D
27.
28.
29.
30.
Centre display bezel

Clock
Glove box
Under cover (Refer to GROUP 55 Ventilators.)
Side cover
Glove box frame
Steering mounting bolts
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.
52A-6
52100190210
1
2
E
E
I
4
7
I
I
I
I
I
I
5
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
I
8
9
6. Console bracket
7. Instrument panel lower passengers
side bracket
8. Passengers side air bag rear
bracket
9. Air bag reinforcement assembly
52A-7
INTERIOR - Floor Console
FLOOR CONSOLE
52100220193

<Vehicles without
heated seat>
<Vehicles with
heated seat>
3
2
6
8
7
NOTE
Removal steps
1. Floor console panel
2. Cup holder assembly
3. Heated seat switch
4. Floor console box
5.
6.
7.
8.
Floor console
Ashtray
Console bracket B
Console bracket A
52A-8
INTERIOR - Trims
TRIMS
52100110292

<Sedan>
C
C
D
C
B
D
C
44 Nm
5
2
1
A
A
8
NOTE
: resin clip position
For door trim, refer to GROUP 42.
Section A - A
Section B - B
Scuff plate
Front pillar
trim
Section C - C
Trim
Clip
Section D - D
Clip
Trim
Clip
1.
2.
3.
4.
5.
Front scuff plate

Rear scuff plate
Cowl side trim
Front pillar trim
Center pillar lower trim
6.
7.
8.
9.
Center pillar upper trim

Rear pillar trim
Rear shelf trim
Shelf front cover
52A-9
INTERIOR - Trims
<Sedan>
17
12
10
13
E E
14
12
11
15
16
NOTE
Section E - E
Rear end
trim cover
Clip
10.
11.
12.
13.
Trunk side trim

Corner plate
Trunk rear side trim
Rear end trim cover
14.
15.
16.
17.
Trunk rear center trim

Side tray
Under tray
Trunk lid trim
52A-10
INTERIOR - Trims
<Wagon>
7
6
4
C
C
B
16
4
44 Nm
8
2
C
H
H
10
H
H
11
I
13
12
11
3
15
14
13
NOTE
For door trim, refer to GROUP 42.
Section A - A
Section B - B
Scuff plate
Front pillar
trim
H
H
Section C - C
Trim
Section F - F
10
Section G - G
Trim
Trim
Clip
Clip
Clip
Clip
Section H - H
Section I - I
Clip
Trim, Lid
Clip
1.
2.
3.
4.
5.
6.
7.
8.
Trim
Front scuff plate

Rear scuff plate
Cowl side trim
Front pillar trim
Center pillar lower trim
Center pillar upper trim
Quarter upper trim
Retractor trim
9.
10.
11.
12.
13.
14.
15.
16.
Belt line trim

Quarter lower trim
Maintenance lid
Rear end trim
Luggage under floor side trim
Luggage under floor centre box
Utility box lid
Shelf holder
INTERIOR - Inside Rear View Mirror/Front Seat
52A-11
INSIDE REAR VIEW MIRROR
Button
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.
Spring
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.
2
44 Nm
4
3
44 Nm
4
44 Nm
3
29 Nm
44 Nm
3
29 Nm
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.
52A-12
INTERIOR - Front Seat

INSPECTION
52200390033
HEATED SEAT SWITCH CONTINUITY CHECK

Switch position
Terminal No.
1
Drivers
seat
switch
HI
LO
Passengers 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
52A-13

52200150297
Caution
Do not disassemble the front seatback assembly
with built-in side air bag module.
<Normal seat>
13
17
16
18
Seat with height adjuster
12
10
14 44 Nm
15
14
11
20
14 13 Nm
6
19
44 Nm
8
21 Nm
21
Seat without height adjuster
2
14 44 Nm
20
13 Nm
14
44 Nm
8
21
7
21 Nm
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.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Front seatback panel

Front seatback assembly
Cap
Lumbar support lever
Headrestraint guide
Front seatback cover
Front seatback frame
Seat heater harness
Seat adjuster assembly
Wire
52A-14
<Power seat>
14
18
17
19
20
13
8
9
7
16
15
10
5
11
12
22
21 Nm
21
1
21 Nm
3
44 Nm
4
21 Nm
23
24
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.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

Front seatback assembly
Cap
Lumbar support lever
Headrestraint guide
Front seatback cover
Front seatback pad
Front seatback frame
Reclining adjuster lower cover
Seat heater harness
Power seat harness
Power seat adjuster assembly
52A-15

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.
Clip
INSPECTION
Reclining switch
52200160122
POWER SEAT SWITCH CONTINUITY CHECK
Slide and
height switch
Switch position
Terminal No.
1
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.)
10
11
12
13
14
52A-16
Rear height
motor connector
Reclining
motor
connector
Slide
motor
connector
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
motor
Direction of
operation
Front/Rear
height
Down
Slide
Backward
Up
Forward
Front height
motor connector
Reclining
Backward
Forward
Terminal No.
1
Stop position
4
Stop at
operating
range limit.
52A-17
INTERIOR - Rear Seat
REAR SEAT
52200180258

2
4
3
22 Nm
5
7
AA" "CA
"BA
"BA
"AA
"AA
29 Nm
22 Nm
Removal steps
1. Seat cushion
2. Seatback (R.H.)
3. Seatback (L.H.)
4. Side seatback (R.H.)
5. Side seatback (L.H.)
6. Headrestraint
7. Armrest
Rear seat stopper
AA" SEAT CUSHION REMOVAL

While keeping the rear seat stopper pulled, lift up the seat
cushion to remove it.
Side seatback
"AA SIDE 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.
Hook
Attachment wire
52A-18
INTERIOR - Rear Seat

"BA SEATBACK (L.H.)/SEATBACK (R.H.)
INSTALLATION
Put the seatback (R.H.) hinge bracket upon the seatback
(L.H.) hinge bracket.
Seatback (R.H.)
hinge bracket
Seatback (L.H.)
hinge bracket
"CA SEAT 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.
Attachment wire
Lock plate
Rear seat belt

5
8 9
11
52200200077
4
3
10
4
7
9
3
10
11
Disassembly steps
1. Seat cushion cover
2. Seat cushion pad*
3. Seatback panel
4. Headrestraint guide
5. Unlock knob
6. Armrest
7. Seatback cover
8.
9.
10.
11.
Seatback pad*
Seatback frame
Side seatback cover
Side seatback pad*
NOTE
*: Vehicles with front power seat
52A-19
INTERIOR - Front Seat Belt
FRONT SEAT BELT
52300130225

3
2
44 Nm
44 Nm
44 Nm
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
52A-20
INTERIOR - Rear Seat Belt
REAR SEAT BELT
52300160194

44 Nm
44 Nm
44 Nm
2
2
1
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)
CONTENTS
52409000193
SRS AIR BAG CONTROL UNIT

(SRS-ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SRS SERVICE PRECAUTIONS . . . . . . . . . . . . . . 4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AIR BAG MODULES AND CLOCK

SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 8
SIDE IMPACT SENSOR . . . . . . . . . . . . . . . . . . 38
SEAT BELT WITH PRE-TENSIONER . . . . . . 40
SRS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 21
POST-COLLISION DIAGNOSIS . . . . . . . . . . . . 25
AIR BAG MODULE AND SEAT BELT

PRE-TENSIONER DISPOSAL
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INDIVIDUAL COMPONENT SERVICE . . . . . . 28
Undeployed Air Bag Module and Seat Belt

Pre-tensioner Disposal . . . . . . . . . . . . . . . . . . . . . . . 42
WARNING/CAUTION LABELS . . . . . . . . . . . . . 29
Deployed Air Bag Module or Operated Seat Belt

Pre-tensioner Disposal Procedures . . . . . . . . . . . . 49
CAUTION
D
D
D
D
Carefully read and observe the information in the SERVICE PRECAUTIONS (P.52B-4.) prior to any service.
For information concerning troubleshooting or maintenance, always observe the procedures in the Troubleshooting
(P.52B-8.) section.
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.
If you have any questions about the SRS, please contact your local distributor.
52B-2
SRS - General Information
GENERAL INFORMATION
52400010232
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).
Side impact sensor

Side air bag module
Clock spring
Air bag module

(Front passengers side)
Air bag module

(Drivers side)
Diagnosis
connector
SRS-ECU
Seat belt with
pre-tensioner
SRS warning lamp
52B-3
SRS - General Information

The seat belt with pre-tensioner has a pre-tensioner
operating mechanism and a G-sensor which detects
the force from an impact built into the seat belt
retractor.
The G-sensor is a mechanical-type sensor which
includes components such as a weight which moves
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).
Plate (A)
mechanism is disengaged)
Spring
Stopper

mechanism is engaged)
Retractor bracket
Stopper
Spring plate
Tab
Tab
G-sensor structure
Charge
Spike
Pin
Pin (when safety mechanism is
engaged)
Sensor
weight
Tab
52B-4
SRS - SRS Service Precautions
SRS SERVICE PRECAUTIONS

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
Insulating tape
SRS-ECU connector
Battery
52400030238
NOTE
If any of these components are diagnosed as
faulty, they should only be replaced, in
accordance with the INDIVIDUAL COMPONENTS 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.
52B-5

SRS-ECU
Terminal No.
Corrective action
1 to 4
5, 6
Dash wiring harness Clock spring Air bag module (Drivers

side)

harness. Replace the clock spring.
7, 8
Dash wiring harness Air bag module (Front passengers side)
9, 10

harness.
11
12
13
14
15
Dash wiring harness Instrument panel wiring harness SRS

warning lamp
Correct or replace each wiring

harness.
16 to 19
20, 21

harness.

SRS-ECU
Terminal No.
Corrective action
1, 2
Dash wiring harness Instrument panel wiring harness

SRS warning lamp
5, 6
Dash wiring harness Air bag module (Front

Passengers side)
7, 8
Dash wiring harness Clock spring Air bag module

(Drivers side)

Replace the clock spring.
10, 11
12
13
14, 15
16
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.)
52B-6
SRS-ECU
Terminal No.
Corrective action
25 to 33
34, 35, 36

impact sensor (L.H.)
37 to 39
40, 41, 42

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.
52B-7
SRS - Special Tools
SPECIAL TOOLS
Tool
52400070209
Number
Name
Use
MB991502
MUT-II sub
assembly
D
D
D
D
MB991613
SRS check harness
Checking the SRS electrical circuitry
MB991223
A: MB991219
B: MB991220
C: MB991221
D: MB991222
Harness set
Checking the continuity and measuring the
A: Check harness voltage at the SRS-ECU harness connector
<vehicles with SRS side air bag>
B: LED harness
C: LED harness
adapter
D: Probe
MB990803
Steering wheel
puller
Steering wheel removal
MB686560
SRS air bag

adapter harness A
SRS air bag

adapter harness B
Deployment of air bag module (drivers side)

outside the vehicle
Reading diagnosis codes

Reading trouble period
Reading erase times
MR203491 or
MB628919
Deployment of air bag modules inside the

vehicle
Deployment of air bag module (front
passengers side) and side air bag module
outside the vehicle
52B-8
SRS - Test Equipment/Troubleshooting
TEST EQUIPMENT
Tool
52400080035
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
TROUBLESHOOTING
52400310097

DIAGNOSIS FUNCTION
52400320083

Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check
diagnosis codes.
52400330222
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*
IG1 (A) power circuit system
52B-12
42*
IG1 (B) power circuit system
52B-13
43
SRS warning lamp drive circuit

system
Lamp does not illuminate.*
52B-14
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
52B-9
SRS - Troubleshooting
Code No.
Diagnosis Item
Reference page
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
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
52B-10
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
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
D
D
D
D
Malfunction of clock spring

Partial disconnection due to incorrect clock spring
neutral position
Malfunction of wiring harnesses or connectors
Malfunction of drivers side air bag module (squib)
Code No.
Trouble cause
21
D
D
Short in drivers side air bag module (squib) or harness short

Short in clock spring
22
D
D
D
D
D
Open circuit in drivers side air bag module (squib) or open harness
Open circuit in clock spring
Disconnected drivers side air bag module (squib) connector
Partial disconnection due to incorrect clock spring neutral position
Malfunction of connector contact
61
Short in drivers side air bag module (squib) harness leading to the power supply
62
Short in drivers side air bag module (squib) harness leading to the earth
Check the clock spring (Refer to P.52B-37.)

OK
SRS check harness

(MB991613)
Dash wiring
harness
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?
NG
YES

<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
NO
Clock spring
Replace
NG
Repair

C-110
OK
NG
Repair
NG
Replace the drivers side air bag module (squib).
52B-11
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
D
D

Malfunction of front passengers side air bag module
(squib)
Code No.
Trouble cause
24
Short in front passengers side air bag module (squib) or harness short
25
D
D
Open circuit in front passengers side air bag module (squib) or open harness
64
Short in front passengers side air bag module (squib) harness leading to the power
supply
65
Short in front passengers side air bag module (squib) harness leading to the earth
SRS check harness

(MB991613)

D Disconnect front
passengers side air bag
module connector C-71,
and connect the harness
side connector to SRS
check harness connector
1.
D Erase
diagnosis
code
memory.
output?
YES

<Vehicles without SRS side air bag> C-71, C-44
OK
Repair
NG
Check the harness wire between the front passengers side air
bag module (squib) and SRS-ECU.
OK
Dash wiring
harness
NO
Replace the front passengers side air bag module (squib).
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.
NG
NG
Repair
52B-12
Code No.34 Connector lock system
Probable cause
This diagnosis code is output if a poor connection of the SRS-ECU is 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
D

<Vehicles without SRS side air bag> C-44
NG
Malfunction of connectors
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 IG1 (A) power circuit system
Probable cause
This diagnosis code is output if the voltage between the IG1 (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.
D
D

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
OK
Check the harness wire between the SRS-ECU and ignition switch
IG1, and repair if necessary.

SRS check harness
(MB991613)
Measure at SRS check harness

connector 5.
D Disconnect SRS-ECU connector C-44.
D Connect SRS check harness connector 3 to
SRS-ECU connector.
D Connect the battery (- )
terminal.
D Voltage between terminal 14
and body earth
OK: 9 V or more
OK
NG

C-44, C-134
OK
NG
Repair
NG
52B-13
Code No.42 IG1 (B) power circuit system
Probable cause
This diagnosis code is output if the voltage between the IG1 (B) terminal and the
earth is lower than the specified value for a continuous period of 5 seconds or more.
D
D


connector.
OK: 9 V or more
NG

C-43, C-134
OK
NG
Repair
NG
OK

SRS check harness
(MB991613)

connector 5.
SRS-ECU connector.
terminal.
D Voltage between terminal 13
and body earth
OK: 9 V or more
OK
NG

C-44, C-134
OK
NG
Repair
NG
52B-14
Code No.43 SRS warning 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
D
D
D

Blown bulb
Malfunction of combination meter

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
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

SRS check harness
(MB991613)

connector 5.
SRS-ECU connector.
terminal.
D Connect terminal 15 to the
body earth.
OK: Lamp illuminates
NG
Blown bulb inspection

OK
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
OK
NG
Replace the combination

meter.
NG
Repair
52B-15
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
D
D
SRS warning lamp inspection

D Does lamp switch off when
SRS-ECU connector C-43 <vehicles with SRS side air bag> or
C-44 <vehicles without SRS side
air bag> is disconnected?
NO
YES

<Vehicles with SRS side air bag> C-43,
C-25, D-01
C-44, C-25, D-01
OK

Malfunction of combination meter
NG
NG
Repair

SRS-ECU and combination meter.
OK
NG
Repair
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-ECU is detected while the SRS-ECU
is monitoring the SRS warning lamp drive circuit.
D
D
Check the SRS warning lamp drive circuit system.

OK

Code No.45 Internal circuit system of non-volatile memory

(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.
52B-16
Code No.71, 72, 75 or 76 Side air bag module (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
D
D

Malfunction of side air bag module (R.H.) (squib)
Code No.
Trouble cause
71
Short in side air bag module (R.H.) (squib) or harness short
72
D
D
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
SRS check harness
(MB991613)
Open circuit in side air bag module (R.H.) (squib) or open harness

D Disconnect side air bag
module (squib) connector
C-16, and connect the
harness side connector to
SRS check harness connector 1.
D Erase
diagnosis
code
memory.
output?
NO
YES

C-16, C-42
OK
NG
Repair
NG
Check the harness wire between the side air bag module (R.H.)
(squib) and SRS-ECU.
OK
Replace the seat back assembly of the front seat (R.H.).
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.
NG
Repair
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
D
D

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?
YES
Replace the side impact sensor (L.H.).
NO

Malfunction of side impact sensor (L.H.)

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
52B-17
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
D
D

Malfunction of side air bag module (L.H.) (squib)
Code No.
Trouble cause
81
Short in side air bag module (L.H.) (squib) or harness short
82
D
D
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
SRS check harness
(MB991613)
Open circuit in side air bag module (L.H.) (squib) or open harness

D Disconnect side air bag
module (L.H.) (squib) connector C-21, and connect
the harness side connector
to SRS check harness
connector 1.
D Erase
diagnosis
code
memory.
output?
NO
YES

C-21, C-42
OK
NG
Repair
NG
Check the harness wire between the side air bag module (L.H.)
(squib) and SRS-ECU.
OK
Replace the seat back assembly of the front seat (L.H.).
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.
NG
Repair
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
D
D

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?
YES
Replace the side impact sensor (R.H.).
NO

Malfunction of side impact sensor (R.H.)

C-42, C-121, E-09
OK
NG
Repair
NG
and SRS-ECU.
OK
NG
Repair
52B-18
Code No.91 Side impact sensor (L.H.) power supply circuit

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.
D
D
D
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
OK
and SRS-ECU.
OK
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.
NG
Repair
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.
D
D
D
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
Repair
Check the harness wire between the side impact sensor (R.H.)
and SRS-ECU.
OK
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.
NG
NG
OK

NG
Repair
52B-19
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.
52400340201
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Trouble symptom
Reference page
Communication with all systems is not

possible.
52B-19
Communication is not possible with

SRS only.
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
Communication with
MUT-II is not possible.

Probable cause
The cause is probably a power supply system (including earth circuit) of the diagnosis
line.
D
D
Malfunction of connectors
Malfunction of wiring harness
52B-20
(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).
D
D


(1) NG
connector.
(1) Continuity between terminal 14 and body earth, and between
(2) NG
terminal 15 and body earth
OK: Continuity
(2) Voltage between terminal 9 and body earth, and between terminal
12 and body earth
OK: 9 V or more
OK
Check the
connectors:
C-43, C-20
following
NG
Repair

C-43
OK
NG
Repair
NG
Check the harness wire between the SRS-ECU and earth, and
C-43, C-134, C-131
OK
OK
NG
Repair
NG
NG
Check the harness wire between the SRS-ECU and diagnosis

connector.
OK
NG
Repair

SRS check harness
(MB991613)
(1) NG
connector 5.
C-44
D Disconnect SRS-ECU conOK
NG
nector C-44.
D Connect SRS check harCheck trouble symptoms.
Repair
ness connector 3 to
SRS-ECU connector.
NG
(1) Continuity between terminal
Check the harness wire between the SRS-ECU and earth, and
20 and body earth, and
between terminal 21 and
body earth
(2), (3) NG
OK: Continuity
C-44, C-134, C-131
(2) Voltage between terminal 13
and body earth
OK
NG
OK: 9 V or more
(3) Voltage between terminal 14
Repair
and body earth
NG
OK: 9 V or more
OK
C-44, C-20
NG
Repair
OK
NG
Check the harness wire between the SRS-ECU and diagnosis
connector.
OK
NG
Repair
SRS - SRS Maintenance
SRS MAINTENANCE
52B-21
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.
Insulating tape
SRS COMPONENT VISUAL CHECK

Battery
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.)
Battery (- ) cable
SRS-ECU
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
deformation or rust.
Replace SRS-ECU if it fails visual check.
for
52B-22
<Drivers side>
Connector
Inflator case
<Front passengers side>
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.
Connector
Inflator case
Protective tube
Case
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
Protective tube
Mating marks
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.
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.
Air bag module

deployment
section
Center
pillar
52B-23
Side impact
sensor
Front of
vehicle
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.
52B-24
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 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 warning lamp
SRS - Post-collision Diagnosis
POST-COLLISION DIAGNOSIS
52B-25
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.)
52B-26

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
<Drivers side>
Connector
52B-27
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.
Inflator case
Connector
Inflator case
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.
Air bag module

deployment
section
Protective tube
Protective tube
Case
Clock spring
1. Check clock spring connectors and protective tube for
damage, and terminals for deformation.
2. Visually check the case for damage.
52B-28
SRS - Post-collision Diagnosis/Individual Component Service

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.
Center pillar
Side impact
sensor
Front of
vehicle
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 to P.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.
52B-29
SRS - Warning/Caution Labels
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
Steering wheel
Sun visor
label instructions when servicing SRS and seat

belt pre-tensioner. If labels are dirty or damaged,
replace them with new ones.
Air bag module (drivers side)
SRS-ECU
Clock spring
Glove box
Air bag module

(front passengers side)
Steering gear box
Side air bag module

(drivers seat and front
passengers seat)
Side impact sensor
Center pillar
NOTE
*: Vehicles with front passengers air bag
Seat belt pre-tensioner
52B-30
SRS - SRS-ECU
SRS AIR BAG CONTROL UNIT (SRS-ECU)

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.
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
52400210168
"AA 2. SRS-ECU
SRS - SRS-ECU
52B-31

"AA SRS-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.
"BA POST-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.
SRS warning lamp
INSPECTION
D
D
52400220147
Check the SRS-ECU and brackets for dents, cracks or

deformation.
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-ECU other than described above,
refer to the section concerning troubleshooting. (Refer
to P.52B-8.)
52B-32
SRS - Air Bag Modules and Clock Spring
AIR BAG MODULES AND CLOCK SPRING

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.
52400240211
5. Do not expose the air bag modules to

temperatures over 93_C.
6. When the drivers-side and passengersside air bags have been deployed, the air
bag modules (drivers-side and passengers-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.
3
2
0.69 Nm
1
1
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
52B-33
<Air bag module (front passengers side)>
Air bag module removal steps

D Glove box (Refer to GROUP 52A Instrument Panel.)
AD"
1. Bolt
2. Air bag module
Lock
Connector
Flat-tipped
screwdriver
Lock
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.
52B-34
MB990803

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.

"AA PRE-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.)

Mating marks
52B-35
"BA CLOCK 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 mating marks.
Caution
If the clock springs mating marks are 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.
"CA STEERING 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.
"DA POST-INSTALLATION INSPECTION
seconds after turning OFF?
4. If yes, SRS system is functioning properly.
If no, consult page 52B-8.
SRS warning lamp
52B-36
<Drivers side>

Connector
INSPECTION
52400250238
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.
Connector

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.
Inflator case
Inflator case
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.)
Air bag module

deployment
section
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.
52B-37
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.
Protective tube
Case
Protective tube
3. Check continuity between the No.1 connector of the clock

spring and connectors No.3 and 4.
No.1 connector
5
2
Terminal 1
Terminal 2
Terminal 3
To autocruise
control
unit
To ACC
power
To horn
relay
No.3
connector
No.4 connector
To horn
switch
To auto-cruise
control switch
Terminal 1
Terminal 2
1
4
Paint
mark
Notch
SRS check
harness
(MB991613)
5
View A
Clock spring
connector 2
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.
52B-38
SRS - Side Impact Sensor
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.
5 Nm
Center pillar
Front of vehicle
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.
Center pillar
"BA SIDE 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.
"CA POST-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.
SRS warning lamp
INSPECTION
D
D
52400470016
Check the side impact sensor and bracket for dents, cracks
or deformation.
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.)
Check that there is no bending or corrosion in the center
pillar.
52B-40
SRS - Seat Belt with Pre-tensioner

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.
52400410056
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 Trim Removal and Installation (Refer
to GROUP 52A.)
3
44 Nm
2
4
1
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

When safety mechanism is engaged
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 carried out as stated
in the procedure. (Refer to P.52B-42.)
"BA RETRACTOR TOP MOUNTING SCREW

Retractor
bracket
Plate (A)
Stopper
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.
52B-42
SRS -
Seat Belt with Pre-tensioner/Air Bag Module and

Seat Belt Pre-tensioner Disposal Procedures
INSPECTION
52400420059
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

52400120225
PROCEDURES
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 following procedures

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. 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.)
SRS Dash wiring harness connector (2-pin)
Clock spring 2-pin

connector (red)
Dash wiring harness

connector
(2-pin)
Air bag module 2-pin

connector (red)
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.
Dash wiring harness

connector (2-pin)
Caution
The side air bag modules for both the drivers-side
and passengers-side should be deployed.
Side air bag

module 2-pin
connector (red)
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.
52B-44
SRS Connection
Insulation
SRS air bag tape
adapter
harness A
MB686560
6 m or
longer

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.
Two wires
SRS air bag adapter

harness A
MB686560
7. Connect the clock spring, air bag module (front

passengers side), or side air bag module 2-pin connector
(red) to SRS air bag adapter harness A and pass the
deployment wires out of the vehicles.
2-pin connector (red)

Deployment wires
Cover
Wires 6 m or longer
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 connected wires from each 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 instructions.
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 -

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.
<Air bag module

(drivers side)>
Two wires
SRS air bag
adapter harness B
MR203491 or
MB628919
Connection
6m
long or
more
Insulation tape
<Air bag module (front
passengers side) and
side air bag module>
Two wires
SRS air bag
adapter harness A
MB686560
Insulation tape
Connection
6m
long or
more
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.
52B-46
SRS Air bag module

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, and connect it to the air bag module.
(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.
Wires
Caution
Leave some space below the wheel for the adaptor
harness. If there is no space, the reaction when
the air bag deploys could damage the adaptor
harness.
Tyres without wheels
(3) Place three old tyres with no wheels on top of the

tyre secured to the air bag module.
Wires
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, and connect it to the air bag module.
(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.
Deployment wire
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.
SRS -
Tyres without wheels

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).
Deployment wire
Seat back assembly
<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.
SRS air bag

adapter harness A
MB686560
5. At a location as far away from the air bag module as

possible, and from a shielded position, disconnect the
two connected wires from each 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
Operate the seat belt pre-tensioner by the following procedure
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.
52B-48
SRS 6 m or more
Approx.
0.4 m

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.
Sensor side
(white cover side)
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.
Retractor bracket
Plate (A)
Stopper
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.
Old tyre with

wheel attached
Old
tyres
without
wheels
5 m or more
20 cm
or more
(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. 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.
6. From a distance of 5 meters away, pull the rope to raise

the seat belt pre-tensioner off the ground by 20 cm or
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 it according to the proper 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 any other scrap parts, adhering to local laws and/or
legislation that may be in force except that the following points
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 the operated seat belt pre-tensioner, material that could
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.
Strong
vinyl bag
4. Tightly seal the air bag module and seat belt pre-tensioner
in a strong vinyl bag for disposal.
Air bag module
and seat belt
pre-tensioner
NOTE
The side air bag module does not contain any toxic sodium
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.
NOTES
54-1
CHASSIS
ELECTRICAL
CONTENTS
54109000211
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMBINATION METERS . . . . . . . . . . . . 20
SERVICE SPECIFICATION . . . . . . . . . . . . . . . 4
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fluid Level and Specific Gravity Check . . . . . 4

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 21
Battery Testing Procedure . . . . . . . . . . . . . . . . . . 6
IGNITION SWITCH, ETACS-ECU AND

IMMOBILIZER SYSTEM* . . . . . . . . . . . . . 7
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 7
IGNITION SWITCH, ETACS-ECU AND
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . 17

WARNING!
MITSUBISHI dealer.
component.
NOTE
54-2
Speedometer Check . . . . . . . . . . . . . . . . . . . . . . 24
FRONT FOG LAMP . . . . . . . . . . . . . . . . 45
Tachometer Check . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel Gauge Simple Check . . . . . . . . . . . . . . . . 25
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 45
Fuel Gauge Unit Check . . . . . . . . . . . . . . . . . . . 25

Engine Coolant Temperature Gauge Simple
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine Coolant Temperature Gauge Unit

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . 46
Front Fog Lamp Aiming . . . . . . . . . . . . . . . . . . 45
FRONT FOG LAMP . . . . . . . . . . . . . . . . . . . . 47

COMBINATION METERS . . . . . . . . . . . . . . . 28
HEADLAMP AND FRONT

TURN-SIGNAL LAMP* . . . . . . . . . . . . . . 30
REAR COMBINATION LAMP . . . . . . . . 48

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 48
REAR COMBINATION LAMP . . . . . . . . . . . 49
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 30
HIGH MOUNTED STOP LAMP . . . . . . 51
RHEOSTAT . . . . . . . . . . . . . . . . . . . . . . . . 52
HAZARD WARNING LAMP

SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Headlamp Aiming . . . . . . . . . . . . . . . . . . . . . . . . 37
Intensity Measurement . . . . . . . . . . . . . . . . . . . . 38
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . 39
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
HEADLAMP AND FRONT TURN-SIGNAL

LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CIGARETTE LIGHTER . . . . . . . . . . . . . . 54
CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SIDE TURN-SIGNAL LAMP . . . . . . . . . 44

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 55
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 44
CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
54-3
RADIO AND TAPE PLAYER . . . . . . . . 56
SERVICE BRAKES (ABS)

. . . . . . . . . . . . . . . . . Refer to GROUP 35B
RADIO AND TAPE PLAYER . . . . . . . . . . . . 72
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . 73
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . 74
REAR WINDOW DEFOGGER . . . . . . . 77
DOOR GLASS AND REGULATOR

(POWER WINDOWS)
. . . . . . . . . . . . . . . . . . . Refer to GROUP 42
DOOR HANDLE AND LATCH
(DOOR LOCKING)
. . . . . . . . . . . . . . . . . . . Refer to GROUP 42
. . . . . . . . . . . . . . . . . . . Refer to GROUP 42
Printed-heater Line Check . . . . . . . . . . . . . . . . . 77
Rear Window Defogger Relay Continuity Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
REAR WINDOW DEFOGGER SWITCH

<VEHICLES WITH MANUAL A/C> . . . . . . 78
SUNROOF . . . . . . . . Refer to GROUP 42

WINDSHIELD WIPER AND WASHER
. . . . . . . . . . . . . . . . . . . Refer to GROUP 51
REAR WIPER AND WASHER
. . . . . . . . . . . . . . . . . . . Refer to GROUP 51
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
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
54-4
CHASSIS ELECTRICAL - Battery
BATTERY
54100030028
Item
Specification
Specific gravity of the battery fluid
1.220 - 1.290 [20_C]
ON-VEHICLE SERVICE
54100090026
FLUID LEVEL AND SPECIFIC GRAVITY CHECK

Thermo
meter
Good
Hydrometer
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

CHARGING
54-5
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.
54-6
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
NG
Read open circuit voltage.

OK: Open circuit voltage is more than 12.4 V
(specific gravity: 1.240)
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 (see LOAD
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
-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
Tool
Number
Name
Use
MB991502
MUT-II sub
assembly
D
D
D
Immobilizer system check

(Diagnosis display using the MUT-II)
Registration of the ID code
TROUBLESHOOTING
54300070477
IGNITION SWITCH
DIAGNOSIS FUNCTION
MUT-II
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.

Trouble symptom
Inspection
procedure No.
Reference page
Communication with all systems is not

possible.
54-8
Communication with the one-shot

pulse input signal only is not possible.
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.)
54-8
Key hole illumination lamp remains illuminated.
54-9
Even if drivers side door is opened, key hole illumination lamp does not
illuminate.
54-9
Communication with MUT-II is not

possible.
54-8


Communication with MUT-II is not possible. (Communication with all systems is not possible.)
Probable cause
diagnosis line.
D
D
Malfunction of harness wire
Communication with MUT-II is not possible. (Communication 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
D
D
Check the harness between the diagnosis connector and junction block.
OK

C-20, C-134 and C-144
NG
OK
NG
NG
Repair
Malfunction of ECU
Repair
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
D
D
MUT-II Input Signal Inspection

Ignition switch input signal
OK: The MUT-II buzzer sounds once OK
when the ignition key is turned
to the ON or OFF position.
Replace the ECU.
NG
Disconnect the junction block connector
C-131, and measure at the harness side.
D Voltage between the terminal (6) and
earth
OK: System voltage
NG
ignition switch (IG1) and junction block,
OK
Malfunction of ECU

C-144 and C-131
OK
NG
NG
Repair
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
D
When the connector C-134 of the junction block (1) is disconnected,

does the lamp switch off?
NO

Malfunction of ECU
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 system or a defective
drivers side door switch input circuit system.
D
D
D
D
D
MUT-II Input Signal Inspection

Drivers side door switch input signal
OK: The MUT-II buzzer sounds once
NG
when the drivers side door switch
is ON.
OK
Key hole illumination lamp inspection
NG
OK
C-109, C-134 and C-144
NG
of
of
of
of
of
drivers side door switch

bulb
connector
harness wire
ECU
Drivers side door switch input circuit

system inspection (Refer to Inspection
Procedure 6 on P.54-10.)
Replace
OK
Disconnect the key reminder switch
connector C-109, and measure at the
harness side.
earth
OK: System voltage
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction

L.H. drive vehicles: C-66, C-63, C-132,
C-141
R.H. drive vehicles: C-62, C-14
NG
Repair
OK
NG
Repair
NG
OK
NG
key reminder switch and junction block,

key reminder switch and junction block,
OK
Replace the ECU.
NG
Repair
54-10

Drivers side door switch input circuit system inspection
Door switch inspection (Refer
GROUP 42 - Door Assembly.)
to
OK
Door switch earth inspection
NG
NG
Replace
Repair
OK
Disconnect the door switch connector
E-09 <L.H. drive vehicles>, E-08 <R.H.
drive vehicles>, and measure at the harness side.
earth
OK: System voltage
OK
NG
OK
NG

C-144 and C-143
NG
NG
Repair

door switch and junction block, and repair if necessary.
Replace the ECU.
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.
54300710065
Diagnosis code No.
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
D
D
D
D
Are there any other ignition keys in the

vicinity of the ignition key being used
for starting?
Yes
No

Malfunction of the transponder
Malfunction of the ignition key ring antenna
Move other keys well away from the

key being used.
NG
Does the engine start using the spare

ignition key which has had the ID code
registered?
NG
Diagnosis codes check
OK
Code No. 12 occurs

To INSPECTION PROCEDURE FOR
DIAGNOSIS CODE No. 12
(Refer to P.54-11.)
Code No. 11 occurs

NG
Check the continuity of the ignition key
ring antenna. (Refer to P.54-18.)
OK
C-68, C-104
NG
Replace
Repair
OK
Re-register the ID code.

(Refer to P.54-19.)
Replace the ignition key that does not

work.
NG
Check the harness wire between immobilizer-ECU and key ring antenna.
NG
Repair
OK
Code No. 12 ID code 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.

(Refer to P.54-19.)
The ID code in the ignition key being used has not

been properly registered.
NG
54-12

Code No.21 Communication system between immobilizer-ECU and engine-ECU
Probable cause
After the ignition switch is turned to the ON position, the confirmation code is not
received from the engine-ECU within the allowable time, or an abnormal code is received.
D
D
D
Is diagnosis code No. 54 being generated by the engine-ECU?
NO
YES

C-68, C-81, C-38 <4G6>
C-37, <6A1>, C-54 <4D6>
NG
Check the engine-ECU power source

and the earth circuit.
Repair
OK
NG

Check the harness wire between engine-ECU and immobilizer-ECU.
NG
Repair
OK
NG
OK
NG
Code No. 31 EEPROM abnormality inside immobilizerECU
Probable cause
No data has been written to the EEPROM inside 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
D
D
Check the input of the ignition switch

IG signal.
Measure at the immobilizer-ECU connector C-68.
(Ignition switch: ON position)
OK System voltage
OK
NG

C-68, C-134, C-131

NG
Repair
OK
NG
Check the fuse and the harness wire
between ignition switch (IG) and immobilizer-ECU.
OK
Check trouble symptoms
NG
NG
Repair

(Refer to 54-18.)

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.
D
D
54-13

Malfunction of the transponder
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

Trouble symptom
Reference page
Communication with MUT-II is impossible.
54-14
Diagnosis code No. 54 has been generated by the engine-ECU.
54-14
ID code cannot be registered using the MUT-II.
54-15
Engine does not start (Cranking but no initial combustion).
54-15
Malfunction of the immobilizer-ECU power source and earth circuit
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
D
D
Can the MUT-II communicate with the

engine-ECU?
NO

C-68, C-104
YES
Malfunction of the diagnosis line

Malfunction of the immobilizer
NG
Repair
OK
Disconnect the immobilizer-ECU connector C-68 and check at the harness

side.
(Short-circuited harness wire between
terminal No. 13 and No. 14)
NG
Repair
NG
Check the harness wire between immobilizer-ECU and diagnosis connector.
NG
Repair
OK
OK
Check the immobilizer-ECU power supply and earth circuit. (Refer to INSPECTION PROCEDURE 5.)

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.
D
D
D

C-68, C-81, C-38 <4G6>,
C-37 <6A1>, C-54 <4D6>
NG

Repair
OK
NG
Check the harness wire between engine-ECU and immobilizer-ECU.
OK
Is diagnosis code No. 21 being generated by the immobilizer-ECU?
NO
Check the immobilizer-ECU power supply and earth circuit. (Refer to INSPECTION PROCEDURE 5.)
NG
Repair
YES
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
D
D
D
No ignition key can be registered.
NO
YES
Is a normal diagnosis code output?
NO
YES
Check the immobilizer-ECU power
source and earth circuit. (Refer to INSPECTION PROCEDURE 5.)
OK
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
the transponder
the ignition key ring antenna
the immobilizer-ECU

(Refer to P.54-19.)
Replace the ignition key that cannot be

registered.
To INSPECTION CHART FOR DIAGNOSIS CODE (Refer to P.54-10.)
NG
Engine does not start (cranking but no initial 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
D
Check the system voltage during cranking

OK: 8V or more
OK
Is the diagnosis code ouutput?
No
Check the fuel system (Refer to GROUP
13E - On-vehicle Service.)
OK
Check the power supply and earth circuit
of the immobilizer (Refer to INSPECTION PROCEDURE 5)
NG
NG
Yes
NG
OK
Malfunction of the MPI system

Check the battery. (Refer to P 54-4.)
To INSPECTION CHART FOR DIAGNOSIS CODE (Refer to P.54-10.)

Repair

NG
Replace the immobilizer-EUC.
Repair
NG
Replace the Injection pump assembly.
54-16

Malfunction of the immobilizer-ECU power supply and earth circuit
1. NG
Measure at the immobilizer-ECU connector.
1. Voltage between 1 and earth and
between 9 and earth <Petrol-powered vehicles>
OK: System voltage
2 Continuity between 8 and earth
OK: Continuity
2, 3. NG
3 Continuity between 16 and body
earth
OK: Continuity

C-81, C-47
OK

L.H. drive vehicles: C-62.
R.H. drive vehicles: C-63, C-64.
OK
NG
NG
NG
Repair
Check the harness wire between immobilizer-ECU and engine control relay and
Repair

NG
Check the harness wire between immobilizer-ECU and body earth and repair
if necessary.
CHECK AT IMMOBILIZER-ECU
Terminal No.
Signal
Terminal voltage
Immobilizer-ECU power supply
Ignition switch: ON
System voltage
Ignition switch-IG
0V
Ignition switch: ON
System voltage
Immobilizer-ECU earth
Always
0V
Immobilizer-ECU power supply
Ignition switch: ON
System voltage
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.
6
9
10
12
11
1
8
3
2
ETACS-ECU removal steps

1. Junction block
2. ETACS-ECU
Immobilizer-ECU removal steps
4. Instrument under cover
5. Immobilizer-ECU
AA"
Ignition switch and ignition key

ring antenna removal steps
4. Instrument under cover
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
11. Steering lock cylinder
12. Ignition switch
54-18
CHASSIS ELECTICAL -

Cross-tip (+)
screwdriver
AA" 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.
INSPECTION
54300220032
IGNITION SWITCH CONTINUITY CHECK

1. Remove the column cover lower and upper.
2. Disconnect the wiring connector from the ignition switch.
3. Operate the switch, and check the continuity between
the terminals.
Ignition key position
Terminal No.
1
LOCK
ACC
ON
START
IGNITION KEY RING ANTENNA CONTINUITY CHECK

Use a circuit tester to check the continuity between the
terminals.
CHASSIS ELECTICAL -

ID CODE REGISTRATION METHOD
54-19
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, when the 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 instruction manual for instructions on using the MUT-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.
MUT-II
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.
54-20
CHASSIS ELECTRICAL - Combination Meters
COMBINATION METERS
54300030215
Items
Standard value
Speedometer indication error km/h(mph)
Tachometer indication error r/min
Fuel gauge unit resistance W
Fuel gauge unit float height mm
Fuel gauge resistance W
Engine coolant temperature gauge

resistance W
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)
700
100
3,000
150
5,000
250
6,000
300
Float point F
42
Float point E
112 7
A (Float point F)
28.6
B (Float point E)
159.9
Power supply and earth
111.5
Power supply and fuel gauge
98.2
Fuel gauge and earth
101.0
Power supply and earth
111.5
Power supply and engine coolant

temperature gauge
53.6

and earth
165.0
Engine coolant temperature gauge unit resistance (at 70_C) W
10413.5
SEALANT
54300050037
Items
Specified sealant
Remark

unit threaded portion
3M Adhesive nut locking No. 4171 or

equivalent
Drying sealant
SPECIAL TOOLS
Tool
C
D
54-21
54300060429
Number
Name
Use
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
54-22
TROUBLESHOOTING
5430070471

Trouble symptom
Inspection
procedure
Reference
page
Speedometer does not work.
54-22
Tachometer does not work.
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
D
D
1. NG
Disconnect the combination meter connectors D-01, D-02 and D-03 and measure at the harness sides.
1. Measure the voltage between
terminal No.25 and body earth when
the vehicle is moved forwards and 2. NG
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
OK
Vehicle speed sensor circuit system

inspection
(Refer
to
Inspection
Procedure 3 on P.54-23.)

D-03, C-135, C-131
OK
NG
NG
Repair

power supply and combination meter,
3. NG

C-25, D-01
OK
Replace the speedometer.
Malfunction of vehicle speed sensor

Malfunction of speedometer
NG
NG
Repair

body earth and combination meter, and
54-23

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
D
1. NG
Disconnect the combination meter connector 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
2. NG
OK: System voltage
OK

C-90, D-03
OK

C-45, C-90, D-03
OK
NG
NG

C-131, C-135, D-03
OK
Replace the tachometer.
NG
NG
3. NG
Malfunction of tachometer
NG
NG
Repair

distributor assembly <6A1> or engineECU <4G6, 4D6> and combination meter, and repair if necessary.
Repair

combination meter and the body earth,
Repair

power supply and combination meter,
Vehicle speed sensor circuit system inspection
NG
Vehicle speed sensor inspection (Refer to P.54-29.)
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)
OK
3. NG
Check the following
connectors:
B-65<M/T>, C-90, C-135,
C-131
NG
1. NG
2. NG
Repair
OK
NG
Check the harness wire between the vehicle speed sensor
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.
Check the following

connector:
B-65 <M/T>, B-67 <A/T>,
B-66 <M/T>
NG
Repair
OK
NG
Replace the speedometer.
body earth, and repair if necessary.
54-24
ON-VEHICLE SERVICE
54300090176
SPEEDOMETER CHECK
Wheel chocks
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.
Tension bar
Front
Anchor plate
Caution
Do not operate the clutch suddenly. Do not
increase/decrease speed rapidly while testing.
Standard values:
Standard
(mph)
Engine speed
detection connector
Tachometer
Paper clip
indication
km/h
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

FUEL GAUGE SIMPLE CHECK
54-25
54300110179
Remove the fuel gauge unit connector.

Use the special tool to connect a test
lamp (12 V - 3.4 W) to the harness
connector.
Fuel gauge
Test lamp
(12 V - 3.4 W)
When the ignition switch is turned to

ON, the test lamp illuminates.
OK
NG
Earth
MB991219
The needle of the fuel gauge moves.
OK
Replace the fuel gauge unit.
NG
Replace the fuel gauge.
Repair the harness.
FUEL GAUGE UNIT CHECK
54300120240
Remove the fuel gauge unit from the fuel tank.

(Refer to GROUP 13F.)
Fuel gauge unit

Earth
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).
54-26

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.
A
Point F
(highest)
Thermistor
Point E
B (lowest)
Earth
Thermistor
Illuminated
Not
illuminated
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.
54-27

ENGINE COOLANT TEMPERATURE GAUGE SIMPLE CHECK
54300140215
Remove the engine coolant gauge unit

connector.
Connect a test lamp (12 V - 3.4 W)

between the harness side connector
and the earth.
<4G6>
Test lamp
(12 V - 3.4 W)
<6A1>
Earth
Earth
Test lamp
(12 V - 3.4 W)
Connector
Connector
<4D6>
Test lamp
(12 V - 3.4 W)
MB991219
Earth
When the ignition switch is turned to

ON, the test lamp illuminates.
NG
Repair the harness.
OK
The needle of the engine coolant temperature gauge moves.

OK
Replace the engine coolant temperature
gauge unit.
NG
Replace the engine coolant

temperature gauge.
54-28

ENGINE COOLANT TEMPERATURE GAUGE UNIT
54300150041
CHECK
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_C water 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.)
11 Nm
COMBINATION METERS
54300290200
Vehicle speed sensor removal

steps
D Air cleaner assembly
1. Vehicle speed sensor
2
Combination meter removal steps
2. Meter bezel
3. Combination meter

Turn
INSPECTION
Shaft
Resistance
3 - 10 kW
54-29
5430060135

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)
Ohmmeter
Power supply
Fuel gauge
Earth
54300300132
FUEL 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 - Fuel gauge: 98.2 W
Fuel gauge - Ground: 101.0 W
Caution
When inserting the testing probe into the power supply
terminal, be careful not to touch the printed board.
Engine coolant
temperature
gauge
Earth
Power supply
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
When inserting the testing probe into the power supply
terminal, be careful not to touch the printed board.
54-30
CHASSIS ELECTRICAL - Headlamp and Front Turn-Signal Lamp
HEADLAMP AND FRONT TURN-SIGNAL LAMP
54200300199
Items
Standard value
Limit
Headlight airming for low

beam
Vertical direction
60 mm below horizontal (H)
Horizontal direction
Position where the 15 sloping section

intersects the vertical line (V)
Headlamp aiming for high

beam
Vertical direction
Parallel to direction of vehicle travel
30,000 or more
Headlamp intensity cd
SPECIAL TOOLS
Tool
54200060457
Number
Name
Use
MB991502
MUT-II sub assenbly
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
TROUBLESHOOTING
54-31
54200900063
The special tool (MB991223) should always be used to measure voltages and resistance when carrying
out troubleshooting.
DIAGNOSTIC FUNCTION
MUT-II

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
Communication with MUT-II is impossible. <Vehicles with ETACS-ECU>
Communication with all systems

impossible.
54200910103
Inspection
procedure
Reference
page
is
54-32
Communication with one-shot pulse input

signal only is impossible.
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.
54-32
Headlamp leveling does not occur when the headlamp leveling switch is operated.
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
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
54-36
54-32

Communication with MUT-II is impossible. (Communication with all systems is impossible.)
Probable cause
The cause is probably a defective power supply system (including ground) for the
diagnosis line.
D
D
Communication with the MUT-II is impossible. (Communication 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.
D
D
D

diagnosis connector and junction block.
OK

C-20, C-134
NG
OK
NG
NG
Repair
Repair
The ignition switch is turned to the OFF position and the
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
D
D
Malfunction of drivers side door switch

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
OK
NG
NG
Repair

junction block and column switch.
NG
Repair
OK
Replace the BUZZER-ECU or

ETACS-ECU.
54-33
Drivers side door switch input circuit system inspection
Door switch inspection
(Refer to GROUP 42 Door Assembly.)
OK
Door switch earth inspection
NG
NG
Replace
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
OK
NG
Replace the BUZZER-ECU or
ETACS-ECU.
NG

L.H. drive vehicles: E-19, C-144, C-145
R.H. drive vehicles: E-08, C-144, C-145
OK
NG
NG
Repair

door switch and junction block, and
54-34
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
D
D
D
D
Headlamp leveling switch check

(Refer to P.54-42.)
NG
NG

C-94, A-33
OK
NG
NG
OK
1.
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
2.
OK: Continuity
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-74, C-115
OK
NG

A-12, A-33
OK
OK
NG

A-12, A-33, C-115, C-74, C-94
OK
OK
Malfunction of the headlamp leveling
unit.
of
of
of
of
of
fuse
the headlamp leveling switch
connector
harness
the headlamp leveling unit
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
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Replace
NG
NG
NG
NG
NG
NG
Repair
Check the harness between the headlamp leveling switch and body earth.
Repair, if necessary.
Repair
Check the harness between the headlamp relay and the headlamp leveling
unit
Repair
Check the harness between the body

earth and the headlamp leveling unit.
Repair
Check the harness between the headlamp leveling switch and the headlamp
leveling unit (both).
54-35
The headlamps do not illuminate when the vehicle is in the
following condition and the ignition switch is moved to the
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
D
D
D
Headlamp
P.54-42.)
relay
check
(Refer
to
NG
OK
3. NG
of
of
of
of
fuse
connector
harness
the DRL-ECU
Replace
OK
1. NG
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
2. NG
OK: System voltage
3. Continuity between terminal (No.2)
and earth
OK: Continuity
Malfunction
Malfunction
Malfunction
Malfunction

A-37, C-14, C-63, C-132, C-131
OK
NG
NG
Repair
Check the harness between the DRLECU and the ignition switch. Repair, if
necessary.

A-37, C-14, C-116, B-18X
OK
NG
Check the harness between the DRLECU and the headlamp relay. Repair,
if necessary.

A-37, C-14
OK
Malfunction of the DRL-ECU.
Replace
NG
Check the harness between the DRLECU and the body earth. Repair, if necessary.
54-36
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>
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
D
D
D
D
Lighting switch check

(Refer to P.54-41.)
NG
NG

A-37, C-14
OK
NG
NG
OK
Tail lamp relay check (Refer to P.54-40.)
NG

A-37, C-14, C-116, B-14X
OK
OK
Malfunction of the DRL-ECU
fuse
connector
harness
the tail lamp relay
the DRL-ECU
Repair
Check the harness between the DRLECU and body earth.

Replace
OK
Disconnect the DRL-ECU connector
A-37 and measure at the harness side.
D Continuity between terminal (5) earth
OK: System voltage
of
of
of
of
of
Replace
OK
Disconnect DRL-ECU connector A-37
and measure at the harness side.
D Continuity between terminal (2) earth
OK: Continuity
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Replace
NG
NG
Repair
{{36#1}}
ON-VEHICLE SERVICE
54-37
54200090173
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 screw to adjust the headlamp
aiming. (Refer to P.54-38.)
3. With the engine running at 2,000 r/min. aim the 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.
Screen
5m
3. Check if the beam shining onto the screen is at the

standard value.
(V)
Distance of
vertical direction
(H)
Lamp centre
15
High intensity zone
Standard value:
<For lower beam adjustment>
(Vertical direction)
(Horizontal direction)
Position where the 15_ sloping section
intersects the vertical line (V)
54-38

Standard value:
<For upper beam adjustment>
(V)
Lamp centre
(H)
Centre of high
intensity zone
Distance
High intensity of vertical
zone
direction
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 screw to adjust the headlamp

aiming.
Horizontal direction adjustment (Lower beam)
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.
adjustment
(Upper beam)
Vertical direction
adjustment
(Upper beam)
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 = Er2 Where:
I = intensity (cd)
E = illumination (lux)
r = distance (m) from headlamps to illuminometer

BULB REPLACEMENT
54-39
54200130189
<Headlamp Bulb>
2. Remove the socket cover.
Socket cover
Spring
Spring
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.
Spring
<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.
54-40
HEADLAMP AND FRONT TURN-SIGNAL LAMP
54200240141

CAUTION: SRS
spring, refer to GROUP 52B - Service
Spring.
5 Nm
5 Nm
5
6
5 Nm
1. Column switch <Lighting switch and

dimmer/passing switch>
Wheel and Shaft.)
Headlamp leveling switch removal
steps
2. Switch bezel
3. Headlamp leveling switch
AA"
Headlamp removal steps

4. Radiator grille
5. Front turn-signal lamp
6. Headlamp
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.
Connector A
INSPECTION
54200250045
LIGHTING SWITCH, DIMMER/PASSING SWITCH AND

TURN-SIGNAL LAMP SWITCH CHECK
Switch position
Connector Aterminal No.

1
LIGHTING
SWITCH
Connector Bterminal No.

6
OFF
TAIL
HEAD
DIMMER/
PASSING
SWITCH
LOWER
UPPER
PASSING
Connector B
TURNSIGNAL
LAMP
SWITCH
*1
*2
RH
OFF
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.
54-42

HEADLAMP RELAY AND TAIL LAMP RELAY CHECK
Headlamp relay
Terminal No.
Battery voltage
Supplied
Not supplied
Tail lamp relay
HEADLAMP LEVELING SWITCH CHECK

Check the resistance between the terminals when the
headlamp leveling switch is operated.
Standard value:
Resistance measurement terminal No.
Switch position
0
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
54-43
DAYTIME RUNNING LAMP RELAY CHECK

Battery voltage
Terminal No.
1
Daytime running
lamp relay
Supplied
Not supplied
54-44
CHASSIS ELECTRICAL - Side Turn-signal Lamp
SIDE TURN-SIGNAL LAMP
54200060105
SPECIAL TOOL
Tool
Number
Name
Use
MB990784
Ornament remover
Removal of side turn-signal lamp
MB990784
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.
Fender panel

Hook
Fender panel
"AA SIDE 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.
CHASSIS ELECTRICAL - Front Fog Lamp
FRONT FOG LAMP
54-45
54200030069
Items
Standard value
Front fog lamp aiming
Vertical direction
SPECIAL TOOL
Tool
54200060464
Number
Name
Use
MB990784
Ornament remover
Removal of switch garnish
Unit: mm
Parabola type
76
Lamp
centre
ON-VEHICLE SERVICE
54200110138
FRONT FOG LAMP AIMING

1. Measure the centre of the fog lamps, as shown in the
illustration.
28
Projector type
37
Lamp
centre
49
Screen
5m
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.
54-46

5
Lamp centre
Distance of
vertical direction
Check if the beam shining onto the screen is at the

standard value.
Standard value:
High intensity zone
Centre of high
intensity zone
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.
Parabola type
Adjusting
screw
Caution
When making the aiming adjustment, be sure to mask
those lamps which are not being adjusted.
Projector type
Adjusting screw
BULB REPLACEMENT
54200130196
1. Remove the fog lamp bezel.

2. Remove the fog lamp unit.
Fog lamp
rear cover
3. Undo the fog lamp rear cover.

4. Unhook the spring which secures the bulb and then
remove the bulb.
Fog lamp
rear cover
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.
Spring
FRONT FOG LAMP
54-47
54200150161
5
4
5
4
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
54-48
CHASSIS ELECTRICAL - Rear Combination Lamp
REAR COMBINATION LAMP
54200060471
SPECIAL TOOLS
Tool
Number
Name
Use
MB991502
MUT-II sub
assembly
MB990784
Ornament remover
Removal of side air outlet (L.H.)
54-49
REAR COMBINATION LAMP
54200450094

Caution: SRS
spring, refer to GROUP 52B - SRS Service
Spring.
3
2
1
<Sedan>
5 Nm
4
<Wagon>
6
5 Nm
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>
AA"
D Rear end side trim (L.H.)

D Side box (L.H.)
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
54-50

Trunk
room rear
side trim
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.
INSPECTION
54200460035
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.
CHASSIS ELECTRICAL - High Mounted Stop Lamp
HIGH MOUNTED STOP LAMP
54200510204

<Sedan>
<Wagon>
2
1
3
2
Removal steps <Sedan>

1. Socket assembly
2. Bulb
3. High mounted stop lamp
54-51
Removal steps <Wagon>

1. Cover
2. Lamp unit
3. Bulb
4. Socket assembly
54-52
CHASSIS ELECTRICAL - Rheostat
RHEOSTAT
54200600093
2
Removal steps
1. Meter bezel assembly
2. Rheostat
40W
INSPECTION
54200610034
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.
54-53
CHASSIS ELECTRICAL - Hazard Warning Lamp Switch
HAZARD WARNING LAMP SWITCH
54200660121
AA"
Removal steps
D Center console panel (Refer to
GROUP 52A.)
D A/C-ECU or heater control panel
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.
INSPECTION
Switch
position
54200670155
Terminal No.
1
OFF
ILL
ON
ILL
10
54-54
CHASSIS ELECTRICAL - Horn/Cigarette Lighter
HORN
Horn relay
Theft-alarm
horn relay
54300800038
INSPECTION
Switch position
Terminal No.
1

Power is supplied
CIGARETTE LIGHTER
Element
Spot
54300570083
INSPECTION
D
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.
Using a circuit tester, check the continuity of the element.
CHASSIS ELECTRICAL - Clock
CLOCK
54-55
54300060436
SPECIAL TOOL
Tool
Number
Name
Use
MB990784
Ornament remover
Removal of center display bezel
CLOCK
54300590072

1
2
AA"
AA"
Removal steps
1. Center display bezel
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.
54-56
CHASSIS ELECTRICAL - Radio and Tape Player
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
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
Radio
NOTE
Refer to problem symptoms of AM radio for MW radio.
54-57

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 wont extend or retract.
D- 1
Motor antenna extends and retracts but does not receive.
D- 2
Motor antenna
CHART
A. NOISE
A - 1 Noise appears at certain places when travelling (AM).
No
Is there a particular structure?

Yes
Find out the following information from
the user:
1. Place
2. Locality conditions (valley, mountain, etc.)
3. Name and frequency of stations
affected by noise
Do the following measures eliminate the

noise?
Yes
OK
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.
No
If due to vehicle noise:
If due to external noise:
It may not be possible to prevent noise

if the signal is weak.
In almost all cases, prevention on the

receiver side is impossible. Weak signals especially are susceptible to interference.
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.
54-58
A - 2 Noise appears at certain places when travelling (FM).

Do the following measures eliminate the noise?
D
D
D
Yes
OK
Change to a different station with a strong signal to boost

resistance to interference.
Suppress high tones to reduce noise.
Extend antenna completely.
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 there are 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.>
FM Broadcast Good Reception Areas
10 kW
output FM
broadcast
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.
FM Signal Characteristics and Signal Interference
Multipath interference
For stereo:
20 - 25 km
For monaural:
30 - 40 km
For home stereos:
80 - 90 km
First fading
interference
54-59

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,
Is the noise still obvious even with the
lamps OFF?
Yes
Do the following measures eliminate the
noise?
D
D
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.
No
Yes
OK
Tune to a station with a strong signal.

Tune to a station with a strong signal
without completely extending the
antenna.
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.)
No
If there is more noise than other radios, consult a service

centre.
Yes
OK
54-60
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.
Noise occurs when the engine in running.
Yes
Do the following measures eliminate the noise?
D
D
D
Inspect the vehicles noise suppressor. (Refer to A-6.)
Tune to a station with a strong signal.

Extend the antenna completely.
Adjust the sound quality to suppress high tones.
No
Yes
No
Is the radio body earth mounted securely?

Yes
Is the antenna plug properly connected to the radio?
Yes
Is the antenna itself in good condition or is it properly
mounted?
No
No
Yes
OK
Securely tighten the nuts for the body

earth.
Correctly attach the antenna plug.
Clean the antenna plug and earth wire

mounting area. Mount the antenna securely.
Is the noise eliminated?
Yes
OK
No
If there is more noise than other radios, consult a service
centre.
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.>
54-61
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
D
D
D
D
D
Yes
Lightning was flashing. A motorcycle was passing.
A vehicle passed close by, but it appeared to be a vehicle
generating a particularly large amount of noise radiation.
Passed beneath a power line. Passed under a bridge.
Passed beneath a telephone line.
Passed close by a signal generator.
Passed close by some other source of electrical noise.
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.>
54-62
A - 6 There is noise when starting the engine.

Noise type Sounds
are in parentheses ( ).
Conditions
AM, FM: Ignition

noise (Popping,
snapping, cracking,
buzzing)
Cause
Increasing the en- D

gine speed causing the popping D
sound to speed
up, and volume
decreases.
Disappears when
the ignition switch
is turned to ACC.
Remedy
Mainly due to the D

spark plugs.
Due to the engine
noise.
Earth cable
D
Other electrical
components
Static electricity
(Cracking, crinkling)
D
D
Check or replace the earth cable.
Check or replace the noise capacitor.
Noise may appear as

electrical components become older.
Repair or replace electrical components.
Disappears when
the vehicle is
completely
stopped.
Severe when the
clutch is 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.
Various
noises
are produced depending 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.
54-63
A - 7 Some noise appears when there is vibration or shocks during travelling.

Are connectors properly connected?
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
No
Yes
Is the radio correctly earthed? (Is the mounting screw tightened

securely?)
Yes
Is the antenna correctly earthed? (If noise appears when the antenna
is moved, this means the earth is not securely connected.)
No
No
Ensure proper connection.

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.
Tighten the screw securely.
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?
No
Does the problem appear only in certain locations and only with
certain stations?
No
Are connectors properly connected?
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?
Yes
Yes
No
No
Yes
Is the radio body correctly earthed? (Is the mounting screw tightened
securely?)
Yes
Is the antenna correctly earthed? (If noise appears when the antenna
is moved, this means the earth is not securely connected.)
No
No
OK
Due to electrical field conditions. (Multipath noise*, fading noise*).
Check connector connections.

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.
Tighten the screw securely.
If rust is present at the antenna earth screw, clean and tighten

the earth securely.
Yes
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).
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.
54-64
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?
No
Is the connector at the back of the radio connected properly?
Yes
Disconnect and check the connector at the rear of the radio. Is
the ACC power (12 V) being supplied to the radio?
Yes
No
No
Replace fuse or repair harness.

Connect connector securely.
Repair harness.
Yes
B - 2 No sound from one speaker.

Check to see if there is any sound when
attached to another radio.
No
Remove the connector on the back of
the radio and check the speaker harness
for conductance.
No
Check the speaker for conductance.
No
Repair or replace speaker.
Yes
Yes
Yes
It conducts electricity but is shorted out.
Repair speaker harness and ensure

proper connection of relay connectors.
Repair speaker harness.
54-65
B - 3 There is noise but no reception for both AM and FM or no sound from AM, or no sound from
FM.
Is the check being conducted under special electrical field conditions?
No
Yes
Example: In an underground
garage or inside a building.
Is proper performance obtained when

the vehicle is moved?
Yes
OK
No
Yes
Does tuning solve the problem?
OK
No
Are the antenna plug and radio unit properly connected?
No
Reconnect
Yes
Does the problem disappear if connected to another radio?
Yes
No
Replace the antenna.
B - 4 Insufficient sensitivity.
No
Yes
garage or inside a building.

Yes
OK
No
Does tuning solve the problem?
Yes
OK
No
Is the problem limited to the reception of a specific radio
station from a specific position?
Yes
Electrical field condition related*

(multipath noise or fading noise)
No
Is the antenna plug properly connected to the unit?
No
Yes
Does the problem disappear when a different radio is connected?
Yes
No
For multipath noise and fading noise problems, refer to P. 54-63.
54-66
B - 5 Distortion on AM or on both AM and FM.

Occasional
How much distortion is there?

Constant
Distortion in the vicinity of the radio station

No
Are the speaker cords in contact with the cone paper?

No
Remove the speakers and check for torn cone paper or foreign
objects.
No
Yes
Excessive antenna input
Remove cords away from cone paper.
Yes
Repair or replace speakers.
Yes
Check for deformation with speaker installed.
Yes
Install speaker securely.
No
B - 6 Distortion on FM only
Does the distortion persist when the radio is tuned to another station?
Yes
Does distortion increase or decrease when the vehicle is moved?
No
Due to weak electrical field of radio station
Yes
Due to multipath noise
No
B - 7 Too few automatic select stations.

No
Yes
garage or inside a building

Yes
OK
No
Is the antenna plug properly connected to the equipment?
No
Yes
Does the equipment work properly if the radio is changed?
No
Yes
54-67
B - 8 Insufficient memory (preset stations are erased).

No
Disconnect and check the connector at the rear of the radio.
Is the memory backup (battery) power being supplied?
Yes
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
No
Does the tape player work if another tape is inserted?
Remove the object(s)*1

*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.
Yes
No
Replace tape*2
*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.
Repair or replace tape player.
C - 2 No sound (even after a tape has been inserted).

No
Is connector at rear of radio connected tightly?
Yes
Disconnect connector at rear of radio. Is ACC power being supplied
to the radio?
No
Repair harness.
Yes
No
Yes

Connect connector firmly.
54-68
C - 3 No sound from one speaker.

Clean the tape player head and check
again.
Yes
No
Replace the tape player and check again.
No
Remove the connector on the back of the radio and check
the speaker harness for conductance.
No
Check the speaker for conductance.
OK
Yes
Yes
Yes

It conducts electricity but is
shorted out.
Repair harness.
Repair harness.
No
C - 4 Sound quality is poor, or sound is weak.

Does the player play properly when another tape* is inserted?
No
Yes
OK
*:
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?
No
Is proper operation obtained when the tape player is replaced?
Yes
Yes
OK
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.
54-69
C - 6 Uneven revolution. Tape speed is fast or slow.

Yes
Does the player play OK if the tape*1 is changed?

No
*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.
Yes
Are there any foreign objects *2 inside the tape player?

No
OK
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.
Yes
Is the head or capstan roller diry?
Pinch roller
Head
Clean.
Capstan roller
No
C - 7 Faulty auto reverse.

Does the player play OK if the tape* is changed?
No
Yes
OK
*:
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?
Yes
Is the tape player properly installed to the vehicle?
Yes
No
No

Ensure tape player installation.
54-70
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?
Yes
Is voltage (approx. 12 V) emitted to the radios motor antenna terminal?
Yes
Is the antenna bent?
No
Is the antenna relay OK?
Yes
Is the motor OK?
Yes
Repair the harness.
No
No
Yes
No
No
Switch it ON.
Repair or replace the radio.
Repair the bend, or replace the antenna
mast.
Replace the antenna relay.
Replace the motor.

D-2 Motor antenna extends and retracts but does not receive.
Is the antenna itself OK?
A
B
Ohmmeter measurement locations
Result
Circuits from F to A, B, C, D and E
Continuity
Circuit between G and H
Continuity
Circuits from H to A, B, C, D and E
No continuity
No
Fender
H
Yes
Is operation normal when a new antenna assembly is directly
installed to the radio?
Yes
Replace the feeder cable.
No
Refer to B Radio troubleshooting.
Repair or replace it.
54-71
54-72
RADIO AND TAPE PLAYER
54400140126

Ashtray and Sunglasses Pocket Removal and
Installation
4
2
3
4
NOTE
: Metal clip position
Removal steps
1. Floor console panel
2. Centre console panel assembly
4. Radio bracket
5. Box
54-73
CHASSIS ELECTRICAL - Speaker
SPEAKER
54400260266

<Sedan, Wagon>
1
2
5
<Sedan>
<Wagon>
9
3
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
54-74
CHASSIS ELECTRICAL - Antenna
ANTENNA
54400290180

<Sedan - Vehicles with motor antenna>
2
3
4
<Sedan - Vehicles with pole antenna>
3
4
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
54-75
<Wagon>
3
4
5
2
1
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
54-76

INSPECTION
54400360072
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.
Antenna pole
Rack cable
Rack cable teeth

Luggage compartment side
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.
Rack cable
Rack cable
teeth
Rear of the vehicle
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.
54-77
CHASSIS ELECTRICAL - Rear Window Defogger
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.
Normal characteristic curve
A (Centre point)
approx. 6 V
Printed
heater line
Negative
terminal
Abnormal characteristic curve

Voltage
Open-circuit
point
Positive
terminal
54300180033
PRINTED-HEATER LINE CHECK
Voltage
Positive
terminal
ON-VEHICLE SERVICE
Printed
heater line
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.
Negative
terminal
REAR WINDOW DEFOGGER RELAY

CONTINUITY CHECK
54300680168
Defogger relay
Battery voltage
Terminal No.
1

Power is supplied
Junction block
54-78
CHASSIS ELECTRICAL - Rear Window Defogger
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.
OFF
INSPECTION
54300670097
DEFOGGER SWITCH CONTINUITY CHECK

ON
Switch position
Terminal No.
1
OFF
ILL
ON
ILL
IND
CHASSIS ELECTRICAL - Theft-alarm System
THEFT-ALARM SYSTEM
54-79
54700060070
SPECIAL TOOLS
Tool
Number
Name
Use
MB991502
MUT-II sub assenbly
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
TROUBLESHOOTING
5420070066
The special tool (MB991223) should always be used to measure voltages and resistance when carrying
out troubleshooting.
DIAGNOSTIC FUNCTION
MUT-II
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.
54-80
54700150074
Trouble symptom
Inspection
procedure No.
Reference
page
Communication with MUT-II

is not possible. <Vehicles
with ETACS-ECU>
Communication with all system is not possible.
54-80
Communication with one-shot pulse input signal

only is not possible.
54-80
Arming/disarming
relationship
The system is not armed.

(The security indicator lamp does not illuminate,
and the alarm does not function.)
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.)
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

Communication with MUT-II is not possible. (Communication 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.
D
D
Refer to GROUP 13A - Troubleshooting
Communication with MUT-II is not possible. (Communication 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.
D
D
D

diagnosis connector and junction block.
NG
Repair
OK

C-20, C-134, C-144
OK
Malfunction of ECU
NG
NG
Repair
54-81

The system is not armed. (The security indicator lamp does not illuminate, and the alarm does not
function.)
Check the dedicated fuse No.14.
OK
Check the fusible link No.2.
OK
Disconnect the ETACS-ECU connector C-43 and measure at the
harness side connector.
OK: System voltage
NG
NG
NG
Replace the fuse.

Replace the fusible link.

L.H. drive vehicles: C-144, C-141
R.H. drive vehicles: C-144, C-141, C-62, C-14
OK
OK
NG
Repair

NG
Check the harness wire between the fusible link No.2 and ETACSECU. Repair, if necessary.
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.
54-82
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.
OK
Disconnect the combination meter connector D-03, and measure
at the combination meter side.
D Continuity between terminals (10) and (11)
OK: Continuity
OK
Measure at the harness side of the same connector.
OK: System voltage
NG
NG
NG
Replace

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
OK
NG
Check the harness wire between the combination meter and fusible
link (2). Repair, if necessary.
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
OK
NG

C-139, C-25, D-03
54-83

MEASUREMENT AT ECU TERMINALS
Terminal No.
Item
Check condition
Normal value
Earth
ECU power supply
At all times
System voltage
Ignition switch (ACC)
ON
System voltage
OFF
0V
ON
System voltage
OFF
0V
Door open
0V
Door closed
5V
11
13,19
17
28
29
33
Ignition switch (IG1)
Front door switch (L.H.)
Key reminder switch
OFF (Inserted)
5V
ON
0V
OFF
5V
Theft-alarm horn relay
ON
0V
OFF
System voltage
Lock
5V
Unlock
0V
Lock
0V
Unlock
5V
Lock
5V
Unlock
0V
Lock
0V
Unlock
5V
Lock
5V
Unlock
0V
Lock
0V
Unlock
5V
ON
0V
OFF
5V
Front door lock actuator

switch (R.H.)
Front door lock actuator

switch (L.H.)
Rear door lock actuator

switch (R.H.)
42
43
0V
Receiver output signal
36
41
ON (Removed)
Keyless entry
receiver-ECU
34
35
Ignition switch
Trunk lid latch switch

<Sedan>
54-84
Terminal No.
Item
Check condition
Normal value
44
Trunk lid lock key cylinder

switch <Sedan>
ON
0V
OFF
5V
Tailgate lock
<Wagon>
Lock
5V
Unlock
0V
Lock
0V
Unlock
5V
Unlock
0V
Neutral
5V
Lock
0V
Neutral
5V
Combination meter
(Security indicator lamp)
ON
0V
OFF
System voltage
Front door switch (R.H.)
ON
0V
OFF
5V
ON
0V
OFF
5V
45
actuator
46
47
Door lock key cylinder

switch
48
49
50
51
Hood switch
55-1
HEATER,
AIR CONDITIONER
AND VENTILATION
CONTENTS
55109000119
MANUAL AIR CONDITIONER . . . . . . . . 3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . 3
Sight Glass Refrigerant Level Test . . . . . . . . . . 7
Magnetic Clutch Test . . . . . . . . . . . . . . . . . . . . . . 7

Receiver Drier Test . . . . . . . . . . . . . . . . . . . . . . . . 7
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dual Pressure Switch Check . . . . . . . . . . . . . . . 8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 5

WARNING!
MITSUBISHI dealer.
component.
NOTE
55-2
Compressor Drive Belt Adjustment . . . . . . . . . . 8
AUTOMATIC AIR CONDITIONER . . . . 35
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Performance Test . . . . . . . . . . . . . . . . . . . . . . . . 14
Refrigerant Leak Repair . . . . . . . . . . . . . . . . . . . 15
Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Relay Check . . . . . . . . . . . . . . . . . . . . . . 16
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . 36
Idle-up Operation Check . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 36
HEATER CONTROL ASSEMBLY, A/C

SWITCH AND INSIDE/OUTSIDE AIR
CHANGEOVER SWITCH . . . . . . . . . . . . . . . 19
HEATER UNIT*, HEATER CORE AND
BLOWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 22
AIR CONDITIONER CONTROL PANEL AND
ECU ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 57
RESISTOR, BLOWER FAN AND MOTOR

AND INSIDE/OUTSIDE AIR CHANGEOVER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DAMPER MOTOR ASSEMBLY AND

POWER TRANSISTOR . . . . . . . . . . . . . . . . . 58
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . 25
COMPRESSOR AND TENSION PULLEY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AIR PURIFIER ASSEMBLY . . . . . . . . . . . . . 27
PHOTO SENSOR . . . . . . . . . . . . . . . . . . . . . . 67

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
OUTSIDE AIR TEMPERATURE SENSOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
REFRIGERANT LINE . . . . . . . . . . . . . . . . . . 28
CONDENSER AND CONDENSER FAN
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
VENTILATORS . . . . . . . . . . . . . . . . . . . . . . . . 33
HEATER WATER TEMPERATURE

SENSOR* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
OTHER MAINTENANCE SERVICE POINTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - General Information
MANUAL AIR CONDITIONER
55-3
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
Items
Heater unit
refrigerant system has 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.
Specifications
Type
Two-way-flow full-air-mix system
Heater control assembly
Dial type
Compressor
Model
Scroll type <MSC90>

kPa
High-pressure switch
ON OFF: 2,942, OFF ON: 2,353
Low-pressure switch
ON OFF: 196, OFF ON: 221
Refrigerant and quantity g
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.
R-134a (HFC-134a), Approx. 670 - 710
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.
55-4
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER>
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.
Service Specifications/Lubricants
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. Do not allow liquid refrigerant to touch bright
metal.
Refrigerant will tarnish bright metal and chrome
surfaces, and in combination with moisture can
severely corrode all metal surfaces.
Caution
Keep R-134a containers upright when charging
the system.
Items
Standard value
Idle speed r/min
Idle-up speed r/min
55200030219
When load by
A/C is low
When load by
A/C is high
4G6
750 50
6A1
650 50
4D6
800 30
4G6
750 50
6A1
650 50
4D6
850 50
4G6
850 50
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
LUBRICANTS
55200040199
Items
Quantity
Each connection of refrigerant line
SUN PAG 56
As required
Compressor refrigerant unit lubricant mL
SUN PAG 56
120
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Special Tools/Troubleshooting
55-5
SPECIAL TOOLS
Tool
55200060133
Number
Name
Use
MB991367
Special spanner
Removal and installation of armature mounting

nut of compressor
MB991386
Pin
TROUBLESHOOTING
55200070242
TROUBLESHOOTING PROCEDURES
Trouble symptom
Problem cause
Remedy
Reference
page
When the ignition

switch is ON,
the A/C does not
operate.
A/C compressor relay is defective
Replace the A/C compressor

relay
55-17
Magnetic clutch is defective
Replace the armature plate,

rotor or clutch coil
55-65
Refrigerant leak or overfilling of refrigerant
Replenish the refrigerant, repair the leak or take out some of

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 temperature switch
55-65
Automatic compressor-ECU is defective
Replace the automatic compressor-ECU
55-26
Engine-ECU is defective
Replace the engine-ECU
Refrigerant leak
Replenish the refrigerant and

repair the leak
55-15
Dual pressure switch is defective
Replace the dual pressure

switch
55-28, 29
Refrigerant temperature switch is defective
Replace the refrigerant temperature switch
55-65
Automatic compressor ECU is defective
Replace the automatic compressor-ECU
55-26
When the A/C is

operating, temperature inside
the
passenger
compartment
doesnt decrease
(cool air is not
emitted).
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Troubleshooting
55-6
Trouble symptom
Problem cause
Remedy
Reference
page
Blower fan and

motor
doesnt
turn
Blower relay is defective
Replace the blower relay
55-16
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
55-21
Short circuit of the harness between the blower

fan and motor and the blower switch
Repair the harness
55-21
Blower relay is defective
Replace the blower relay
55-16
Condenser fan motor is defective
Replace the condenser fan

motor
55-31
Radiator fan motor is defective
Replace the radiator fan motor
Fan control relay is defective
Replace the fan control relay
55-17
Blower fan and

motor
doesnt
stop turning.
When the A/C is

operating
condenser fan or radiator fan does
not run
INSPECTION AT THE AUTOMATIC COMPRESSOR-ECU TERMINAL
55201030041
Terminal
No.
Check item
Normal condition
Input from A/C switch to ECU
A/C switch: OFF
0V
A/C switch: ON
Battery voltage
Output from ECU to A/C compressor

relay
A/C compressor relay: OFF
Battery voltage
A/C compressor relay: ON
0V
Output from ECU to engine-ECU
Air thermo sensor detection temperature: 5_C or less
Battery voltage
Air thermo sensor detection temperature: 8_C or more
0V
Always
0V
Earth
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - On-vehicle Service
ON-VEHICLE SERVICE
55-7
55200840133
SIGHT GLASS REFRIGERANT LEVEL TEST
Sight glass
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 line is warm and the compressor
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.
Magnetic clutch
connector
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.
55-8
High/Low
pressure side
LOW-PRESSURE
SIDE
HIGH-PRESSURE
SIDE
ON
ON
OFF
OFF
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
CHARGING
High-pressure
valve
Low-pressure
valve
Gauge manifold
Charging hose
(yellow)
Adapter
valve
Charging hose
(blue)
Switch
R-12
connection
port
Vacuum
pump
Quick
joint (for adaptor
low
pressure)
Vacuum
pump
R-134a
connection
port
Power supply
plug
Switch
Low-pressure
service valve
A
Sleeve
55-9
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).
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 vacuum reading 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.)
Low-pressure
service valve
Caution
If the negative pressure drops, increase the tightness
of the connections, and then repeat the evacuation
procedure from step (12).
Vacuum pump
Valve open
Valve close
Charging
valve
Adaptor valve
Service can
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.
Charging valve
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).
Service can
(Refrigerant container)
Low-pressure
service valve
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.
55-12
Valve open
Charging valve
Valve close
Adaptor valve
Charging hose (blue)

Service can
(Refrigerant
container)
Quick joint (for low pressure)
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.
Quick joint
(for low pressure)
NOTE
Low-pressure
service valve
Charging valve

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.
Service can
(Refrigerant container)
12. After replenishing is completed, turn the handle of the

adaptor valve all the way back (valve close), and remove
the quick joint.
Low-pressure
service valve
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.
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.
A
Sleeve
Charging hose (blue)
Quick joint
Low-pressure
service valve
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.
Adaptor valve
NOTE
Any oil remaining in the container should be returned
to the A/C system.
Oil
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
55-14
PERFORMANCE TEST
Low-pressure valve
High-pressure valve
Gauge manifold
Charging
hose (red)
Charging
hose (blue)
A
Adaptor
valve (for low
pressure)
Sleeve
Adaptor valve
(for high pressure)
Lowpressure
service
valve
Highpressure
service
valve
Thermometer
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.
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 system open any longer than necessary.
7. Evacuate and charge system.
LOW CHARGE
If the system has 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
Battery voltage
Blower relay
Terminal No.
1

Power is supplied
55-17
A/C COMPRESSOR RELAY

A/C compressor relay
Battery voltage
Terminal No.
1

Power is supplied
FAN CONTROL RELAY

Refer to GROUP 14 - Radiator.
55-18
IDLE-UP OPERATION CHECK
55200160208
1. Before inspection and adjustment, set vehicle in the

following condition:
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
HEATER CONTROL ASSEMBLY, A/C SWITCH AND

INSIDE/OUTSIDE AIR CHANGEOVER SWITCH
55-19
55201240017

D Center Console Panel, Side Cover Removal and
Installation (Refer to GROUP 52A - Instrument Panel.)
Radio, Tape Player Removal and Installation (Refer

to GROUP 54.)
6
3
4
5
2
1
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.
Air outlet
changeover
damper lever
DEF position
"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 mix
damper
lever
MAX HOT position
55-20

INSPECTION
55201250010
BLOWER SWITCH CONTINUITY CHECK

Terminal No.
Switch position
OFF
D (LO)
D (ML)
(MH)
D (HI)
FRESH
position
RECIRC
position
INSIDE/OUTSIDE AIR CHANGEOVER SWITCH

CONTINUITY CHECK
Switch
position
Terminal No.
1
ILL
IND
RECIRC
FRESH
OFF
position
A/C SWITCH CONTINUITY CHECK

Switch
position
ON position
OFF
ON
Terminal No.
1
ILL
IND

HEATER CONTROL ASSEMBLY
55-21
55100130077
4
3
AA"
AA"
Disassembly steps
1. Knob assembly
2. Bulb harness
3. Air outlet changeover damper cable
4. Air mix damper cable
5.
6.
7.
8.
Heater control panel

Nut
Blower switch
Control base assembly

Flat-tipped
screwdriver
Claw
part
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.
55-22
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Heater Unit, Heater Core, and Blower Unit
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.
1
Vehicles with automatic A/C
2
5
2
6
4
AA"
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
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/Outside Air Changeover Damper Motor
55-23
RESISTOR, BLOWER FAN AND MOTOR, AND INSIDE/OUTSIDE

55100500014
AIR CHANGEOVER DAMPER MOTOR
Glove Box Removal and Installation (Refer to GROUP
52A - Instrument Panel.)
Resistor removal steps

D Under cover (Refer to P.55-33.)
1. Resistor
Blower fan and motor removal
steps
2. Blower fan and motor
INSPECTION
Inside/outside air changeover

damper motor removal
3. Inside/outside air changeover
damper motor
55100510017
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.
55-24
Resistor, Blower Fan and Motor, and

Inside/Outside Air Changeover Damper Motor
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
1
Lever operation
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.
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Evaporator
55-25
EVAPORATOR
55200360165

D Discharging and Charging of Refrigerant (Refer to
P.55-9.)
D Glove Box, Side Cover and Glove Box Frame Removal
and Installation (Refer to GROUP 52A - Instrument
Panel.)
Under Cover Removal and Installation (Refer to

P.55-33.)
Piping connection
3
4
AA"
AA"
Removal steps
1. Suction hose connection
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.

"AA EVAPORATOR INSTALLATION
When replacing the evaporator, refill it with a specified amount
of compressor oil and install it (to the vehicle).
Quantity: 60 mL
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Evaporator
55-26
55200380154
3
2
7
6
1
8
7
6
5
Disassembly steps
1. Clip
2. Evaporator case (upper)
3. Automatic compressor-ECU
<Manual A/C>
4. Air thermo sensor <Automatic A/C>
AA"
5.
6.
7.
8.
Evaporator case (lower)

Expansion valve
O-ring
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
INSPECTION
Resistance kW
20
55200390058
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.
15
10
5
0
- 10
55-27
0 10 20 30 40
Temperature _C
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 Frame Removal
and Installation (Refer to GROUP 52A - Instrument
Panel.)
Under Cover Removal and Installation (Refer to

P.55-33.)
Air purifier assembly

Refer to P.55-61.
55200410266
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - 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.)
Oil Reservoir Removal and Installation (Refer to

GROUP 37A - Power Steering Hoses.)
1
Piping connection
2
10
10
10
2
10
10
10
8
AA"
AA"
AA"
AA"
Removal steps
1. Suction pipe
2. Clamp and bracket
3. Suction flexible hose
4. Liquid pipe A
5. Liquid pipe B
6.
7.
AA" "AA 8.
9.
AA"
10.

Receiver bracket assembly
Receiver assembly
Discharge flexible hose
O-ring
10
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
D
Reserve Tank Removal and Installation (Refer to

GROUP 14 - Radiator.)
Oil Reservoir Removal and Installation (Refer to
GROUP 37A - Power Steering Hoses.)
Piping connection
1
5
11
11
Compressor oil:
SUN PAG 56
11
11
3
6
11
4
11
11
9
10
8
AA"
AA"
AA"
AA"
Removal steps
1. Clamp
2. Suction pipe
3. Clamp and bracket
4. Suction flexible hose
5. Liquid pipe B
6. Liquid pipe A
7.
8.
AA" "AA 9.
AA"
10.
11.

Receiver bracket assembly
Receiver assembly
Discharge flexible hose
O-ring
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

"AA SUCTION 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
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Condenser and Condenser Fan Motor
CONDENSER AND CONDENSER FAN MOTOR
55-31
55200670244
Piping connection
O-ring
6
2
4
1
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
55-32
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Condenser and Condenser Fan Motor

"AA CONDENSER INSTALLATION
When replacing the condenser, refill it with a specified amount
of compressor oil and install it. (to the vehicle).
Quantity: 15 mL
INSPECTION
55200680148
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.
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Ventilators
55-33
VENTILATORS
55300160119

<Automatic A/C>
5
3
2
2
4
6
9
1
7
8
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 reinforcement (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.
55-34
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Ventilators
<Wagon>
<Sedan>
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 to GROUP 51 - Windshield wiper
and washer.
HEATER, AIR CONDITIONER AND VENTILATION <AUTOMATIC AIR CONDITIONER>
Service Specifications
AUTOMATIC AIR CONDITIONER
55-35
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.
Items
Heater unit
The A/C system is 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.
Specifications
Type
Two-way-flow full-air-mix system
Heater control assembly
Push button type
Compressor
Model
Scroll type <MSC 90>

kPa
High-pressure switch
ON OFF: 2,942, OFF ON: 2,353
Low-pressure switch
ON OFF: 196, OFF ON: 221
Refrigerant and quantity g
R-134a (HFC-134a), Approx. 670 - 710
55400030086
Items
Standard value
Idle speed r/min
Idle-up speed r/min
When load by A/C is low
When load by A/C is high
4G6
750 50
6A1
650 50
4D6
800 30
4G6
750 50
6A1
650 50
4D6
850 50
4G6
850 50
6A1
900 50
4D6
850 50
Air mix damper motor potentiometer resistance kW
MAX. HOT position
Approx. 4.8
MAX. COOL position
Approx. 0.2
Outlet air changeover damper motor potentiometer resistance kW
DEF position
Approx. 4.8
FACE position
Approx. 0.2
Air gap (Magnetic clutch) mm
0.40 - 0.65
55-36
Lubricants/Special Tools/
Troubleshooting
LUBRICANTS
55400040072
Items
Quantity
Each connection of refrigerant line
SUN PAG 56
As required
Compressor refrigerant unit lubricant mL
SUN PAG 56
120
SPECIAL TOOLS
Tool
55400060061
Number
Name
Use
MB991502
MUT-II
sub-assembly
Inspection of automatic air conditioner
MB991529
Diagnosis code
check harness
Inspection of automatic air conditioner using a

voltmeter
NOTE
Other special tools are the same as for the manual A/C.
TROUBLESHOOTING
55400470055

DIAGNOSIS FUNCTION
55400480072

Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check
diagnosis codes.
HEATER, AIR CONDITIONER AND VENTILA- Troubleshootimg

TION <AUTOMATIC AIR CONDITIONER>
55-37
55400490051
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.
Replace the A/C-ECU.
Malfunction of the A/C-ECU
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
D
D
D
Outside air temperature sensor check (Refer to P.55-68.)

OK
Measure at the outside air temperature sensor connector A-21.
side connector.
OK: 5 V
NG
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
connector
harness
the outside air temperature sensor
the A/C-ECU
Replace

C-05, C-64 <L.H. drive vehicles>, C-116 <L.H. drive vehicles>,
C-99 <R.H. drive vehicles>
OK
NG
Repair
OK

NG
Check the harness between the outside air temperature sensor
and the A/C-ECU.
OK
NG
Repair

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>
OK
NG
Repair
OK
NG

and the A/C-ECU, and repair if necessary.

OK
NG
NG
Repair
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
D
D
D
Outside air temperature sensor check (Refer to P.55-68.)

OK
OK: 2.3 - 2.9 V
OK
NG
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
harness
connector
the outside air temperature sensor
the A/C-ECU
Replace

Code No.15 Heater water temperature sensor system

(open circuit)
Probable cause

D
D
D
D
Heater water temperature sensor check (Refer to P.55-70.)

OK
Measure at the heater water temperature sensor connector C-70.
side connector.
OK: 5 V
NG
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
55-39
connector
harness
the heater water temperature sensor
the A/C-ECU
Replace

C-05, C-64 <L.H. drive vehicles>
OK
NG
Repair
OK

NG
Check the harness between the heater water temperature sensor
and the A/C-ECU.
OK
NG
Repair

OK: 2.3 - 2.9 V
NG

C-70
OK
OK
NG
Repair

NG

OK
NG
NG
Repair
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
D
D
D
Heater water temperature sensor check (Refer to P.55-70.)

OK
OK: 2.3 - 2.9 V
OK
NG
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
harness
connector
the heater water temperature sensor
the A/C-ECU
Replace
55-40

Code No.21 Air thermo sensor system (open circuit)
Probable cause

D
D
D
D
Air thermo sensor check (Refer to P.55-26.)

OK
Measure at the air thermo sensor connector C-73.
side connector.
OK: 5 V
NG
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
connector
harness
the air thermo sensor
the A/C-ECU
Replace

OK
NG
Repair
OK

NG
Check the harness between the air thermo sensor and the A/C-ECU.
OK
NG
Repair

OK: 2.3 - 2.9 V
NG

C-73
OK
OK
NG
Repair

NG
Check the harness between the air thermo sensor and the A/C-ECU,
OK
NG
NG
Repair
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
D
D
D
Air thermo sensor check (Refer to P.55-26.)

OK
OK: 2.3 - 2.9 V
OK
NG
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
harness
connector
the air thermo sensor
the A/C-ECU
Replace
Check the harness between the air thermo sensor and the A/C-ECU,

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
D
D
D
Air mix damper motor potentiometer check (Refer to P.55-59.)

OK
Measure at the air mix damper motor potentiometer connector C-79.
side connector.
OK: 5 V
NG
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
55-41
the air mix damper motor assembly

connector
harness
the A/C-ECU
Replace

OK
NG
Repair
OK

NG
Check the harness between the air mix damper motor potentiometer
and the A/C-ECU.
OK
NG
Repair

D Air mix damper position: MAX.HOT
OK: 4.7 - 5.0 V
NG

C-79
OK
NG
Repair
OK

NG
Check the harness between the air mix damper motor potentiometer

OK
NG
NG
Repair
55-42

Code No.32 Potentiometer system of air outlet changeover 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.
Air outlet changeover damper motor potentiometer check (Refer

to P.55-60.)
OK
Measure at the air outlet changeover damper motor potentiometer
connector C-17.
side connector.
OK: 5 V
NG
NG
D
D
D
Malfunction of the air outlet changeover damper

motor assembly
Replace

OK
NG
Repair
OK
NG
Check the harness between the air outlet changeover damper motor
potentiometer and the A/C-ECU.
OK
NG
Repair

D Air outlet changeover damper position: DEF
OK: 4.8 - 5.2 V
NG

C-17
OK
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
NG
Repair

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
D
D
D
Air mix damper motor check (Refer to P.55-59.)
NG
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
55-43
the air mix damper motor assembly

connector
harness
the A/C-ECU
Replace
OK
C-07, C-79
OK
NG
NG
Repair
Check the harness between the air mix damper motor and the
A/C-ECU.
OK
NG
Repair
Code No.42 Drive system of air outlet changeover damper

motor assembly
Probable cause
This diagnosis code is output if the motor drive circuit is defective.
D
D
D
D
Air outlet changeover damper motor check (Refer to P.55-60.)
NG
Malfunction of the air outlet changeover damper

motor assembly
Replace
OK
C-17, C-07
OK
NG
NG
Repair
Check the harness between the air outlet changeover damper

motor and the A/C-ECU.
OK
NG
Repair
55-44

55400500068
Trouble symptom
Reference page
55-45
Air conditioner does not operate.
55-46
A/C graphic display on control panel is blank.
55-47
Temperature cannot be set.
55-47
A/C outlet air temperature does not increase.
55-47
A/C outlet air temperature does not decrease.
55-47
Blower does not operate.
55-48
Blower air amount cannot be changed.
55-49
Air outlet port cannot be changed.
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
Condenser fan does not operate.
16
Refer to GROUP
14 - Troubleshooting.

55-45

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
D
Is communication between MUT-II and

other system is possible?
YES
C-20.
D Voltage between terminal (11)
and body earth
OK: Indication fluctuates between 0 V and 12 V.
NO
OK
NG
Measure at the A/C-ECU connector

C-05.
and body earth
OK: Indication fluctuates between 0 V and 12 V.
NG
Malfunction of connector or harness

Malfunction of A/C-ECU
Check the MUT-II diagnosis line, and

C-05.
connector.
and body earth
OK: Battery voltage - 2 V
NG

C-05
OK
Repair
NG
OK
Check the harness between the diagnosis connector and the A/C-ECU, and

C-05
OK
NG
NG
Repair
OK
NG
Check the harness between the diagnosis connector and the A/C-ECU.
NG
C-05, C-20
NG
NG
Repair
Repair
OK
NG
C-07.
connector.
and body earth
OK: Battery voltage
NG

C-132, C-63 <L.H. drive vehicles>, C-61
OK
OK
C-07.
connector.
D Continuity between terminales
(27), (35) and body earth
OK: Continuity
OK
NG

OK
NG
NG
NG
NG
Repair
Check the harness between the junction

block and the A/C-ECU, and repair if
necessary.
Repair
Check the harness between the

A/C-ECU and the body earth, and repair
if necessary.
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
D
D
D
D
D
D
D
D
D
NO
Does the blower operate?

YES
A/C system refrigerant pressure check (Refer to P.55-14.)
OK
MUT-II DIAGNOSIS CODE
Is any of the codes 11, 21 and 22 output?
NG
YES
Malfunction of blower
Insufficient refrigerant
Malfunction of magnetic clutch
Malfunction of air thermo sensor
Malfunction of A/C compressor relay
Malfunction of refrigerant temperature switch
Malfunction of dual pressure switch
Inspection procedure 7 (Refer to P.55-48.)

Refill the specified amount of refrigerant. (Refer to P.55-9.)
INSPECTION CHART FOR DIAGNOSIS CODES (Refer to
P.55-37.)
NO
D
D
D
D
Magnetic clutch check (Refer to P.55-7.)

A/C compressor relay check (Refer to P.55-17.)
Refrigerant temperature switch check (Refer to P.55-65.)
Dual pressure switch check (Refer to P.55-8.)
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
NG
OK
(2) NG
Replace

B-28X
OK
(1) NG
B-28X, B-30, B-75
OK
NG
NG
Repair
Repair
NG

NG
Check the harness between the magnetic clutch and the A/C compressor relay, and repair if necessary.
Check the harness between the fusible link and the A/C compressor

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).
D
D
NO
Does the A/C operate?

YES
Temperature cannot be set.
Probable cause
The cause is probably a malfunction of the temperature setting signal input

system or output system.
D
D

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
D
D
D
D
D

Is any of the codes 11, 12, 31 and 41 output?
YES
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
of
air mix damper motor potentiometer

air mix damper motor
air mix damper
connector or harness
thermostat
A/C-ECU

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
D
D
D
D
D
D
NO
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
of
of
of
outside air temperature sensor

air mix damper motor potentiometer
air mix damper motor
air thermo sensor
air mix damper
A/C-ECU
YES
Is any of the codes 11, 12, 13, 14, 21, 22, 31 and 41 output?
NO
YES

P.55-37.)
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
D
D
D
Can an operating sound be heard when the blower speed changeover switch is operated?
NO
Malfunction
Malfunction
Malfunction
Malfunction
of
of
of
of
blower motor relay

blower motor
A/C-ECU
YES
D
D
Blower relay check (Refer to P.55-16.)

Blower motor check (Refer to P.55-23.)
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
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
(1) NG
(2) NG
(3) NG
NG
Replace
Check the harness between the blower relay and the body earth,
Check the harness between the blower relay and the ignition switch,
Check the harness between the blower relay and the fusible link
No.1, and repair if necessary.

C-131
OK
NG
Repair
OK
NG
Check the harness between the blower relay and the blower motor,

C-09
OK
NG
NG
Repair
Check the harness between the blower motor and the A/C-ECU,

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
D
D
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
NG
Repair

NG
Replace the power transistor.
(2) NG
(3) NG
NG
Check the harness between the power transistor and the body
Check the harness between the power transistor and the blower
motor, and repair if necessary.

C-05
OK
NG
Repair

NG
OK
Check the harness between the power transistor and the A/C-ECU.

C-77
OK
(1) NG

D Blower switch position: LO
switch: ON)
OK: Approx. 7 V
switch: ON)
OK: Approx. 1.3 V
Malfunction of power transistor

NG

Repair
OK
Replace the power transistor.
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.
Can an operating sound be heard when the air outlet port

changeover switch is operated?
YES
Is either code 32 or code 42 output?
NO
YES
OK
NG
air outlet changeover damper motor

air outlet changeover damper motor
air outlet changeover damper
A/C-ECU

P.55-37.)
NO
Air outlet changeover damper check
D
D
D
D
Malfunction of
potentiometer
Malfunction of
Malfunction of
Malfunction of
Malfunction of
Repair
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
D
D
D
Can an operating sound be heard when the inside/outside air

changeover switch is operated?
NO
Malfunction of
damper motor
Malfunction of
damper
Malfunction of
Malfunction of
inside/outside air changeover

inside/outside air changeover
A/C-ECU
YES
Inside/outside air changeover damper motor check (Refer to
P.55-24.)
OK
Measure at the inside/outside air changeover damper motor connector C-78.
side connector.
D Outside air select button: ON
OK: 10 V
D Inside air select button: ON
OK: 10 V
NG
NG

C-07
OK

NG
NG
Check the harness between the inside/outside air changeover

damper motor and the A/C-ECU, and repair if necessary.
Repair

NG
OK
OK
NG
Repair
OK
Inside/outside air changeover damper check
NG
Repair
OK
C-78
Replace
NG
Repair

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
D
Can an operating sound be heard when the defroster switch is

operated?
YES
YES
Can the air outlet port be changed over?
NO
NO
NO
D
D
Malfunction
Malfunction
system
Malfunction
Malfunction
of air conditioner drive system

of air outlet changeover damper drive
of connector or harness
of A/C-ECU

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).
D
D
Can an operating sound be heard when the rear defogger switch

is operated?
YES
NO

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>
OK
NG
Repair
OK
NG
Check the harness between the A/C-ECU and the fusible link No.2,
side connector.
switch: ON)
OK: Battery voltage
NG

C-63 <L.H. drive vehicles>, C-61 <R.H. drive vehicles>, C-132
OK
NG
Repair
OK
NG
Check the harness between the A/C-ECU and the junction block,

side connector.
OK: Continuity
OK: Continuity
NG
Check the harness between the A/C-ECU and the body earth,
OK
C-07
OK
NG
NG
Repair

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
OK
NG
Repair
OK
NG
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>
OK
NG
Repair
OK

NG
Check the harness between the A/C-ECU and the A/C compressor
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
OK
NG

B-30, B-28X
OK
NG
Repair

NG
Check the harness between the A/C compressor relay and the
engine-ECU, and repair if necessary.
55-54

55400510078
Item No.
Check item
Check condition
Normal condition
11
Inside air temperature sensor
Ignition switch: ON
Inside air temperature and temperature displayed on the MUT-II

are identical.
13
Outside air temperature sensor
Ignition switch: ON
Outside air temperature and

temperature displayed on the
MUT-II are identical.
15
Heater water temperature 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 motor potentiometer
Ignition switch: ON
32
Air outlet changeover damper motor

potentiometer
Ignition switch: ON
Damper position
Opening degree (%)
MAX. HOT
Approx. 100
MAX. COOL
Approx. 0
Damper position
Opening degree (%)
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
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)

55-55
Terminal
No.
Check item
Check condition
Normal condition
Power MOS FET gate output
When blower switch is at OFF
0V
When blower switch is at LO
Approx. 1.3 V
When blower switch is at HI
Approx. 2.5 V
A/C-ECU backup power supply
At all times
System voltage
Heater water temperature sensor

input
When sensor section temperature is

25_C (4 kW)
2.3 - 2.9 V
Air mix damper motor potentiometer

input
When damper is moved to MAX. HOT

position
4.7 - 5.0 V

potentiometer input
When damper is moved to DEF.

position
4.8 - 5.2 V
Outside air temperature sensor input

25_C (4 kW)
2.3 - 2.9 V
Air thermo sensor input

25_C (4 kW)
2.3 - 2.9 V
Photo sensor (- )
At luminous intensity of 100,000 lux or

more
- 0.1 - 0.2 V
At luminous intensity of 0 lux
0V
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
0 V System voltage
18
Diagnosis control input
Battery voltage - 2 V
19
Photo sensor (+)
At all times
0V
20
Air mix damper motor and air outlet

changeover damper motor potentiometers
At all times
0V
21

(+)
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
Set the setting temperature to 17_C

and set to MAX. COOL position (OFF
after 40 seconds of output)
10 V

and set to MAX. HOT position (OFF
0.5 V
22
Air mix damper motor (- )
55-56
Troubleshooting/
On-vehicle Service
Terminal
No.
Check item
Check condition
Normal condition
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

and set to MAX. COOL position (OFF
0.5 V

and set to MAX. HOT position (OFF
10 V
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
24
25
26

(- )
Air mix damper motor (+)
Inside/outside air changeover damper

motor (+)
27
Earth
At all times
Continuity
28
A/C-ECU power supply
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
0V
When air mix damper is at MAX. HOT

position
System voltage
When A/C is OFF
0V
When A/C is ON
System voltage
At all times
Continuity
34
35
A/C output
Earth
ON-VEHICLE SERVICE
The service procedures are the same as for the manual air conditioner. (Refer to P.55-7.)
55400080029
Air Conditioner Control Panel and

ECU Assembly
AIR CONDITIONER CONTROL PANEL AND ECU ASSEMBLY

D Floor Console Panel Removal and Installation
(Refer to GROUP 52A - Floor Console Box.)
1
2
3
Removal steps
1. Center console panel and air conditioner control panel assembly
2. Center console panel
3. Air conditioner control panel and ECU
assembly
55-57
55400100084
55-58
Damper Motor Assembly and

Power Transistor
DAMPER MOTOR ASSEMBLY AND POWER TRANSISTOR
55400580024
Inside/outside air changeover

damper motor assembly removal
steps
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
INSPECTION
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
5. Power transistor
55400590027
INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR

ASSEMBLY CHECK
For inspection service points, refer to P.55-24 for heater and
manual A/C.
Lever
MOTOR

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
POTENTIOMETER
55-60
Lever
MOTOR

Power Transistor
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
POTENTIOMETER
HEATER, AIR CONDITIONER AND VENTILA- Compressor and Tension Pulley

55-61
55200410273

D Discharging of Refrigerant (Refer to P.55-13.)
D Charging of Refrigerant (Refer to P.55-9.)
<4G6>
Piping connection
2
O-ring
25 Nm
5
6
<6A1>
5
3
2
49 Nm
4
1
AA"
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.)
1. Drive belt
2. Tension pulley
3. Hose connections
4. Power steering oil pressure switch
harness <6A1>
AC" "AA 5. Compressor
6. Compressor bracket
AB"

55-62
<4D6>
39 Nm
Piping connection
O-ring
8
3
5
25 Nm
20 - 25 Nm
4
1
AA"
Removal steps
D Under cover
D Condenser fan motor (Refer
P.55-31.)
1. Drive belt (for compressor)
2. Tension pulley
3. Tension pulley bracket
to
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
<4G6>
Bolt B
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.
Nut A
<6A1>
Nut A
Bolt B
<4D6>
Nut A
Nut B
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.
55-64


"AA COMPRESSOR 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

INSPECTION
55-65
55200930083
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.
Refrigerant
temperature
switch
COMPRESSOR MAGNETIC CLUTCH OPERATION

55200850181
CHECK
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
9
8
7
1
<4G6>
10
5
3
9
8
<6A1, 4D6>
6
3
"EA
AA" "DA
"CA
"BA
Magnetic clutch disassembly steps

1. Bolt <4G6>
2. Pulley <4G6>
D Air gap adjustment
3. Nut
4. Armature plate
5. Shims
6. Snap ring
7. Rotor
8. Snap ring
"AA 9. Clutch coil
Refrigerant temperature switch
removal
10. Refrigerant temperature switch

55-66

MB991386
AA" NUT REMOVAL
MB991367
Clutch coil
projection

"AA CLUTCH 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.
Compressor
body pin hole
Snap ring
Rotor
Clutch coil
"BA SNAP RING INSTALLATION

Install the snap ring so that the tapered surface is at the
outer side.
Tapered part
Armature plate
Serration notch
"CA ARMATURE PLATE INSTALLATION

Align the mating mark of the crankshaft spline and the mating
mark of the armature plate, and then fit them together.
"DA NUT INSTALLATION
Use the special tool to hold the magnet clutch, and tighten
the nut in the same manner as removal.
Matching mark
Crankshaft
Thickness gauge
"EA AIR 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.
- Photo Sensor
PHOTO SENSOR
55-67
55400310067

1
AA"
Removal step
1. Photo sensor

AA" PHOTO SENSOR REMOVAL
Use a flat-tipped screwdriver (width: 3 mm or less) to remove
the photo sensor.
Flat-tipped
screwdriver
Photo sensor
INSPECTION
55400320046
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.
HEATER, AIR CONDITIONER AND VENTILA- 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
INSPECTION

graph.
Resistance kW
20
15
10
5
0
- 10
55400350021
0 10 20 30 40
Temperature _C
NOTE
HEATER, AIR CONDITIONER AND VENTILA- Heater Water Temperature Sensor

HEATER WATER TEMPERATURE SENSOR
55-69
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.
Removal steps
AA" "AA 1. Heater water temperature sensor clip
AA" "AA 2. Heater water temperature sensor

Foot distribution
duct
Heater unit
Heater water
temperature
sensor clip
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.

"AA HEATER WATER TEMPERATURE SENSOR AND
HEATER WATER TEMPERATURE SENSOR CLIP
INSTALLATION
Insert the heater water temperature sensor into its mounting
hole at the bottom of the heater unit, and then fix it by inserting
the heater water temperature sensor clip.
55-70
Heater Water Temperature Sensor/

Other Maintenance Service Points
INSPECTION

graph.
Resistance kW
20
15
10
5
0
- 10
55400460021
NOTE
0 10 20 30 40
Temperature _C
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

Mitsibushi Galant 8G Workshop Manual

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Mitsibushi Galant 8G Workshop Manual

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00109000812

Intake and Exhaust

This Workshop Manual contains procedures for

Engine and Emission Control . . . .

TECHNICAL INFORMATION MANUAL

Wheel and Tyre . . . . . . . . . . . . . . . . .

Power Plant Mount . . . . . . . . . . . . . .

Interior and Supplemental

E Mitsubishi Motors Corporation

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . 2

Scope of Maintenance, Repair and Servicing

Engine Model Number . . . . . . . . . . . . . . . . . . . . . . . 17

Indication of Tightening Torque . . . . . . . . . . . . . . . . 2

Explanation of Manual Contents . . . . . . . . . . . . . . . 4

PRECAUTIONS BEFORE SERVICE . . . . . . . 20

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SUPPORT LOCATIONS FOR LIFTING AND

GENERAL - How to Use This Manual

HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR

This manual provides explanations, etc. concerning

Indicates the value used as the standard for judging

On-vehicle Service is procedures for performing

Indicates the adjustment value prior to starting the

INDICATION OF TIGHTENING TORQUE

GENERAL - How to Use This Manual

GENERAL - How to Use This Manual

EXPLANATION OF MANUAL CONTENTS

Indicates procedures to be performed

Maintenance and Servicing Procedures

Classifications of Major Maintenance/Service Points

: Indicates that there are essential points for removal or disassembly.

Symbols for Lubrication, Sealants and Adhesives

GENERAL - How to Use This Manual

Denotes tightening torque.

indicates that there is

The title of the page (following

GENERAL - How to Use Troubleshooting/Inspection Service Points

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

Check trouble symptom.

Does not reoccur.

Read the diagnosis code

Read the diagnosis code

Refer to the INSPECTION

After taking note of the

Recheck trouble symptom.

Read the diagnosis codes.

Refer to the INSPECTION CHART FOR DIAGNOSIS

INTERMITTENT MALFUNCTIONS (Refer to P.00-12.)

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

GENERAL - How to Use Troubleshooting/Inspection Service Points

4. INSPECTION CHART FOR DIAGNOSIS CODES

METHOD OF READING DIAGNOSIS CODES

GENERAL - How to Use Troubleshooting/Inspection Service Points

3. Turn off the ignition switch.

Warning lamp name

Engine warning lamp

Neutral position indicator lamp

ABS warning lamp

TCL-OFF indicator lamp

Indication of diagnosis code by warning lamp

When no diagnosis code is output*

0.5 sec. <MPI, A/T>

GENERAL - How to Use Troubleshooting/Inspection Service Points