Mitsibushi Galant Workshop Manual PDF

00109000812
General . . . . . . . . . . . . . . . . . . . . . . . . 00
Engine . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Lubrication . . . . . . . . . . . . . 12
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WORKSHOP MANUAL Engine Cooling . . . . . . . . . . . . . . . . . 14
Intake and Exhaust ............ 15
FOREWORD Engine Electrical . . . . . . . . . . . . . . . 16
This Workshop Manual contains procedures for Engine and Emission Control . . . . 17
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and Clutch . . . . . . . . . . . . . . . . . . . . . . . . . 21
installation. Use the following manuals in
combination with this manual as required. Manual Transmission . . . . . . . . . . . 22
TECHNICAL INFORMATION MANUAL Automatic Transmission . . . . . . . . 23
PYDE9604
WORKSHOP MANUAL Front Axle . . . . . . . . . . . . . . . . . . . . . . 26
ENGINE GROUP PWEEjjjj
(Looseleaf edition) Rear Axle . . . . . . . . . . . . . . . . . . . . . . 27
ELECTRICAL WIRING PHDE9608
BODY REPAIR MANUAL PBDE9609 Wheel and Tyre . . . . . . . . . . . . . . . . . 31
PARTS CATALOGUE
Sedan B608S107Aj Power Plant Mount . . . . . . . . . . . . . . 32
Wagon B608T507Aj
Front Suspension . . . . . . . . . . . . . . . 33
Rear Suspension . . . . . . . . . . . . . . . 34
All information, illustrations and product
descriptions contained in this manual are current Service Brakes . . . . . . . . . . . . . . . . . 35
as at the time of publication. We, however, reserve
the right to make changes at any time without prior Parking Brakes . . . . . . . . . . . . . . . . . 36
notice or obligation.
Steering . . . . . . . . . . . . . . . . . . . . . . . . 37
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Exterior . . . . . . . . . . . . . . . . . . . . . . . . 51
Interior and Supplemental
Restraint System (SRS) . . . . . . . . . 52
Chassis Electrical . . . . . . . . . . . . . . 54
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . . . 55
E Mitsubishi Motors Corporation Dec. 1996

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 (driver’s side and front passenger’s 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 Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Engine Model Number . . . . . . . . . . . . . . . . . . . . . . . 17
Indication of Tightening Torque . . . . . . . . . . . . . . . . 2
Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MAJOR SPECIFICATIONS . . . . . . . . . . . . . . . . 18
Explanation of Manual Contents . . . . . . . . . . . . . . . 4 PRECAUTIONS BEFORE SERVICE . . . . . . . 20
HOW TO USE SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
TROUBLESHOOTING/INSPECTION SERVICE AND SEAT BELT WITH
POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PRE-TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . 24
Troubleshooting Contents . . . . . . . . . . . . . . . . . . . . . 6
Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SUPPORT LOCATIONS FOR LIFTING AND
JACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to Use the Inspection Procedures . . . . . . . . 9
Support Positions for a Garage Jack and Axle
Connector Measurement Service Points . . . . . . . 10 Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Connector Inspection . . . . . . . . . . . . . . . . . . . . . . . . 11 Support Positions for a Single-Post Lift or
Inspection Service Points for a Blown Fuse . . . 12 Double-Post Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Points to Note for Intermittent Malfunctions . . . . 12 Support Positions and Support Method for an
H-Bar Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . 13
STANDARD PART/TIGHTENING-TORQUE
Vehicle Information Code Plate . . . . . . . . . . . . . . . 13
TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
00-2 GENERAL - How to Use This Manual
HOW TO USE THIS MANUAL 00100010302
SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS

AND SERVICING EXPLANATIONS STANDARD VALUE
This manual provides explanations, etc. concerning Indicates the value used as the standard for judging
procedures for the inspection, maintenance, repair the quality of a part or assembly on inspection
and servicing of the subject model. Note, however, or the value to which the part or assembly is
that for engine and transmission-related component corrected and adjusted. It is given by tolerance.
parts, this manual covers only on-vehicle
inspections, adjustments, and the removal and LIMIT
installation procedures for major components.
For detailed information concerning the inspection, Shows the standard for judging the quality of a
checking, adjustment, disassembly and reassembly part or assembly on inspection and means the
of the engine, transmission and major components maximum or minimum value within which the part
after they have been removed from the vehicle, or assembly must be kept functionally or in strength.
please refer to separate manuals covering the It is a value established outside the range of
engine and the transmission. standard value.
ON-VEHICLE SERVICE REFERENCE VALUE

“On-vehicle Service” is procedures for performing Indicates the adjustment value prior to starting the
inspections and adjustments of particularly work (presented in order to facilitate assembly and
important locations with regard to the construction adjustment procedures, and so they can be
and for maintenance and servicing, but other completed in a shorter time).
inspection (for looseness, play, cracking, damage,
etc.) must also be performed. CAUTION
Indicates the presentation of information particularly
INSPECTION vital to the worker during the performance of
Under this title are presented inspection and maintenance and servicing procedures in order to
checking procedures to be performed by using avoid the possibility of injury to the worker, or
special tools and measuring instruments and by damage to component parts, or a reduction of
feeling, but, for actual maintenance and servicing component or vehicle function or performance, etc.
procedures, visual inspections should always be
performed as well. 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.
GENERAL - How to Use This Manual 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 GENERAL - How to Use This Manual
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 under-
standing of the installed condition of
component parts.
Indicates (by symbols) where lubrica-

tion is necessary.
Maintenance and Servicing Procedures

The numbers provided within the diagram indi- D Installation steps:
cate the sequence for maintenance and servic- Specified in case installation is impossible
ing procedures. in reverse order of removal steps. Omitted
D Removal steps: if installation is possible in reverse order of
The part designation number corresponds removal steps.
to the number in the illustration to indicate D Reassembly steps:
removal steps. Specified in case reassembly is impossible
D Disassembly steps: in reverse order of disassembly steps.
The part designation number corresponds Omitted if reassemby is possible in reverse
to the number in the illustration to indicate order of disassembly steps.
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 stan-
dard values, information regarding the use of special tools, etc.), these are ar-
ranged together as major maintenance and service points and explained in detail.
AA" : Indicates that there are essential points for removal or disassembly.
"AA : Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for lubrica- : Grease

tion and for application of sealants and adhe- (multipurpose grease unless there is a
sives is provided, by using symbols, in the dia- brand or type specified)
gram of component parts or on the page follow-
ing the component parts page, and explained. : Sealant or adhesive
: Brake fluid or automatic transmission fluid
: Engine oil, gear oil or air conditioner com-

pressor oil
: Adhesive tape or butyl rubber tape

GENERAL - How to Use This Manual 00-5
Indicates the Indicates the Indicates the Indicates the

group title. section title. group num- page number.
ber.
Denotes non-reus-
able part.
Denotes tightening torque.

For bolts and nuts which do not
have a tightening torque listed,
refer to the “Standard Parts-
tightening-torque Table”.
Repair kit or set parts

are shown. (Only very
frequently used parts
are shown.)
Operating procedures, cau-

tions, etc. on removal, installa-
tion, disassembly and reas-
sembly are described.
indicates that there is

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

the page on which the diagram
of component parts is pres-
ented) indicating the locations of
lubrication and sealing proce-
dures.
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 Read the diagnosis code
No diagnosis code
or communication Diagnosis code Diagnosis code No diagnosis
with MUT-II not displayed. displayed. code
possible
Refer to the INSPECTION After taking note of the

CHART FOR TROUBLE malfunction code, erase
SYMPTOMS (Refer to the diagnosis code
applicable group.) memory
Recheck trouble symptom.
Read the diagnosis codes.

Diagnosis code No diagnosis
displayed. code
Refer to the INSPECTION CHART FOR DIAGNOSIS INTERMITTENT MALFUNCTIONS (Refer to P.00-12.)
CODES (Refer to applicable group.)
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.
GENERAL - How to Use Troubleshooting/Inspection Service Points 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
METHOD OF READING DIAGNOSIS CODES
WHEN USING THE MUT-II
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.
WHEN USING THE WARNING LAMP

1. Use the special tool to earth No.1 terminal (diagnosis
Diagnosis connector control terminal) of the diagnosis connector.
2. To check ABS system, remove the valve relay.
NOTE
That is because the valve relay is off and the warning
MB991529
lamp remains illuminated if there is a fault in the ABS
system.
3. Turn off the ignition switch.
4. Read out a diagnosis code by observing how the warning
lamp flashes.
Applicable systems
System name Warning lamp name
MPI Engine warning lamp
A/T Neutral position indicator lamp
ABS ABS warning lamp
TCL TCL-OFF indicator lamp
Indication of diagnosis code by warning lamp

When the diagnosis code No.24 is output When no diagnosis code is output*
0.5 sec.
0.5 sec. <MPI, A/T>
1.5 secs. 0.5 sec. 0.25 sec. <ABS>
On
Off On
Pause Tens Place Units Off
time 3 signal division signal
secs. 2 secs.
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.
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. Comments on the diagnosis code or trouble

symptom above.
CHECKING PROCEDURE 4
D Indicator does not turn on or off even if control Probable cause

mode switch is pressed. 2. Indicates inspection carried out using the
D Indicator switch should not be illuminated is MUT-II.
illuminated. Indicates the operation and inspection proce-
dures.
In the above cases, the ECS switch circuit is defective or the indicator Indicates the OK judgement conditions.
circuit is defective.
3. Detailed inspection procedures (methods)

such as component inspection and circuit
inspection are listed on a separate page, and
OK are given here for reference.
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.
NG
4. Indicates voltage and resistance to be measured at a particular
ECU switch component inspection (Refer to P.3-44.) NG connector.
(Refer to Connector Measurement Service Points.)
OK The connector position can be located in the wiring diagram in the
Measure at switch connector A-44
OK electrical wiring manual by means of this symbol.
D Disconnect the connector, and measure at the harness Indicates operation and inspection procedures, inspection terminals
side. and inspection conditions.
D Voltage between terminal 6 - earth and terminal 8 - Indicates the OK judgement conditions.
earth
OK: Approx. 5V
OK
Check the following connector. A-44
NG
Repair
OK
5. Inspect the contact condition at each connector terminal.
Check trouble symptom. (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
Replace the ECS-ECU.
After carrying out connector inspection, always be sure to
reconnect the connector as it was before.
6. Confirm that there are trouble symptoms. If trouble symptoms have

disappeared, the connector may have been inserted incorrectly and the
trouble symptom may have disappeared during inspection.
If it seems that trouble symptoms still remain, proceed to the next page of
instructions.
7. If trouble symptoms still remain up to this stage, there is a possibility that there is an
open or short circuit in the harness between the connectors, so check the harness.
Alternatively, the cause may be a defective ECU, so try replacing the 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.
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 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

Extra-thin probe
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.
Test bar
Connector
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
Inspection harness should be used. the test bar should never be forcibly inserted,
for connector pin
contact pressure 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 CONNECTOR INSPECTION
connected
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.
CONNECTOR ENGAGEMENT INSPECTION

Use the special tool (connector pin connection pressure
MB991219
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)
INSPECTION SERVICE POINTS FOR A BLOWN

FUSE
Remove the fuse and measure the resistance between the
load side of the fuse and the earth. Set the switches of all
0W 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.
Battery 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.
Fuse The main causes of a short circuit are the following.
D Harness being clamped by the vehicle body
Connector
D Damage to the outer casing of the harness due to wear
Load inspection or heat
switch 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.
GENERAL - Vehicle Identification 00-13
VEHICLE IDENTIFICATION 00100540085
VEHICLE INFORMATION CODE PLATE

LOCATION
Vehicle information code plate is riveted on the toeboard
inside the engine compartment.
CODE PLATE DESCRIPTION

The plate shows model code, engine model, transmission
model, and body colour code.
1
2 No. Item Contents
3
4 1 MODEL EA2A EA2A: Vehicle model
5 SNHEQL6
SNHEQL6: Model series
2 ENGINE 4G63 Engine model
3 EXT B60B Exterior code
4 TRANS F5M42 Transmission code

AXLE
5 COLOR B60 41H 03V B60: Body colour code

INT OPT
41H: Interior code
03V: Equipment code
For monotone colour vehicles, the body colour code shall

be indicated. For two-tone or three-way two-tone colour
vehicles, each colour code only shall be indicated in series.
MODELS 00100030223
<SEDAN>
Model code Engine model Transmission model Fuel supply system
EA2A SNJEQL6 4G63-SOHC (1,997 mL) F5M42 (2WD-5M/T) MPI
SNHEQL6
SRHEQL6 F4A42 (2WD-4A/T)
EA5A SNGEQL6 6A13-SOHC (2,497 mL) F5M42 (2WD-5M/T) MPI
SRGEQL6 F4A42 (2WD-4A/T)
EA6A SNHFQL6 4D68-SOHC (1,998 mL) F5M42 (2WD-5M/T) Electronically

controlled injection
pump
EA2A SNJEQL6C 4G63-SOHC (1,997 mL) F5M42 (2WD-5M/T) MPI
SNHEQL6C
SRHEQL6C F4A42 (2WD-4A/T)

00-14 GENERAL - Vehicle Identification
EA5A SNGEQL6C 6A13-SOHC (2,497 mL) F5M42 (2WD-5M/T) MPI
SRGEQL6C F4A42 (2WD-4A/T)
EA6A SNHFQL6C 4D68-SOHC (1,998 mL) F5M42 (2WD-5M/T) Electronically

pump
EA2A SNHEQR6 4G63-SOHC (1,997 mL) F5M42 (2WD-5M/T) MPI
SRHEQR6 F4A42 (2WD-4A/T)
EA5A SNGEQR6 6A13-SOHC (2,497 mL) F5M42 (2WD-5M/T) MPI
SRGEQR6 F4A42 (2WD-4A/T)
EA6A SNHFQR6 4D68-SOHC (1,998 mL) F5M42 (2WD-5M/T) Electronically

pump
<WAGON>
EA2W LNJEQL6 4G63-SOHC (1,997 mL) F5M42 (2WD-5M/T) MPI
LNHEQL6
LRHEQL6 F4A42 (2WD-4A/T)
EA5W LNGEQL6 6A13-SOHC (2,497 mL) F5M42 (2WD-5M/T) MPI
LRGEQL6 F4A42 (2WD-4A/T)
EA6W LNHFQL6 4D68-SOHC (1,998 mL) F5M42 (2WD-5M/T) Electronically

pump
EA2W LNJEQL6C 4G63-SOHC (1,997 mL) F5M42 (2WD-5M/T) MPI
LNHEQL6C
LRHEQL6C F4A42 (2WD-4A/T)
EA5W LNGEQL6C 6A13-SOHC (2,497 mL) F5M42 (2WD-5M/T) MPI
LRGEQL6C F4A42 (2WD-4A/T)
EA6W LNHFQL6C 4D68-SOHC (1,998 mL) F5M42 (2WD-5M/T) Electronically

pump
EA2W LNHEQR6 4G63-SOHC (1,997 mL) F5M42 (2WD-5M/T) MPI
LRHEQR6 F4A42 (2WD-4A/T)
EA5W LNGEQR6 6A13-SOHC (2,497 mL) F5M42 (2WD-5M/T) MPI
LRGEQR6 F4A42 (2WD-4A/T)
EA6W LNHFQR6 4D68-SOHC (1,998 mL) F5M42 (2WD-5M/T) Electronically

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

5: 2,500 mL petrol engine
6: 2,000 mL diesel engine
3 Sort A: Passenger car

W: Wagon
4 Body style S: 4-door sedan

L: 4-door station wagon
5 Transmission type N: 5-speed manual

transmission
R: 4-speed automatic
transmission
6 Trim level J: GLX

H: GLS
G: V6-24
7 Specification engine E: MPI-SOHC

feature F: Turbocharger with
intercooler
8 Exhaust system Q: With catalytic converter

specification None: Without catalytic
converter
9 Steering wheel location L: Left hand

R: Right hand
10 Destination 6: For Europe

C: Central Europe
00-16 GENERAL - Vehicle Identification
CHASSIS NUMBER 00100560104
The chassis number is stamped on the toeboard inside the

engine compartment.
1 2 3 4 5 6 7 8 9 10 11
No. Items Contents
1 Fixed figure J Asia
2 Distribution channel M Japan channel
3 Destination A For Europe, right hand drive
B For Europe, left hand drive
4 Body style S 4-door sedan
L 4-door station wagon
5 Transmission type N 5-speed manual transmission
R 4-speed automatic transmission
6 Development order EA GALANT
7 Engine 2 4G63: 1,997 mL petrol engine
5 6A13: 2,498 mL petrol engine
6 4D68: 1,998 mL diesel engine
8 Sort A Passenger car
9 Model year V 1997
10 Plant Z Okazaki Motor Vehicle Works
11 Serial number - -
ENGINE MODEL NUMBER 00100570107
<4G63>
1. The engine model number is stamped at the cylinder
block as shown in the following.
Engine model Engine displacement mL
4G63 1,997
6A13 2,498
4D68 1,998
Front of vehicle 2. The engine serial number is stamped near the engine
model number.
Front of vehicle Engine serial number AA0201 to YY9999
<6A13>
<4D68>
Front of vehicle
00-18 GENERAL - Major Specifications
MAJOR SPECIFICATIONS 00100080143
<Sedan>
9
5 7 4 8 6
2 1
Items EA2AS EA2AS EA2AS EA5AS EA5AS EA6AS

NJEQL6, NHEQL6, RHEQL6, NGEQL6, RGEQL6, NHFQL6,
NJEQL6C NHEQL6C, RHEQL6C, NGEQL6C, RGEQL6C, NHFQL6C,
NHEQR6 RHEQR6 NGEQR6 RGEQR6 NHFQR6
Vehicle Overall length 1 4,630 4,630 4,630 4,630 4,630 4,630
dimensions
Overall width 2 1,740 1,740 1,740 1,740 1,740 1,740
mm
Overall height 3 1,415 1,415 1,415 1,415 1,415 1,415
(unladen)
Wheelbase 4 2,635 2,635 2,635 2,635 2,635 2,635
Track-front 5 1,510 1,510 1,510 1,510 1,510 1,510
Track-rear 6 1,505 1,505 1,505 1,505 1,505 1,505
Overhang-front 7 930 930 930 930 930 930
Overhang-rear 8 1,065 1,065 1,065 1,065 1,065 1,065
Ground clear- 9 150 150 150 150 150 150
ance (unladen)
Vehicle Kerb weight 1,260 1,280 1,290 1,310 1,300
weight kg
Max. gross vehicle 1,775 1,805 1,795
weight
Max. axle weight 925 955 955
rating-front
rating-rear
Seating capacity 5
Engine Model No. 4G63 6A13 4D68
Total displacement 1,997 2,498 1,998
mL
Transmis- Model No. F5M42 F4A42 F5M42 F4A42 F5M42
sion
Type 5-speed manual 4-speed 5-speed 4-speed 5-speed
automatic manual automatic manual
Fuel system Fuel supply Electronically controlled multi-point injection Electroni-
system cally con-
trolled fuel
injection
GENERAL - Major Specifications 00-19
<Wagon>
9
5 7 4 8 6
2 1
Items EA2WL EA2WL EA2WL EA5WL EA5WL EA6WL

NJEQL6, NHEQL6, RHEQL6, NGEQL6, RGEQL6, NHFQL6,
NJEQL6C NHEQL6C, RHEQL6C, NGEQL6C, RGEQL6C, NHFQL6C,
NHEQR6 RHEQR6 NGEQR6 RGEQR6 NHFQR6
Vehicle Overall length 1 4,680 4,680 4,680 4,680 4,680 4,680
dimensions
Overall width 2 1,740 1,740 1,740 1,740 1,740 1,740
mm
Overall height 3 1,495 1,495 1,495 1,495 1,495 1,495
(unladen)
Wheelbase 4 2,635 2,635 2,635 2,635 2,635 2,635
Track-front 5 1,510 1,510 1,510 1,510 1,510 1,510
Track-rear 6 1,505 1,505 1,505 1,505 1,505 1,505
Overhang-front 7 930 930 930 930 930 930
Overhang-rear 8 1,115 1,115 1,115 1,115 1,115 1,115
Ground clear- 9 150 150 150 150 150 150
ance (unladen)
Vehicle Kerb weight 1,310 1,310 1,330 1,340 1,360 1,350
weight kg
Max. gross vehicle 1,830 1,860 1,850
weight
Max. axle weight 920 950
rating-front
rating-rear
Seating capacity 5
Engine Model No. 4G63 6A13 4D68
Total displacement 1,997 2,498 1,998
mL
Transmis- Model No. F5M42 F4A42 F5M42 F4A42 F5M42
sion
Type 5-speed manual 4-speed 5-speed 4-speed 5-speed
automatic manual automatic manual
Fuel system Fuel supply Electronically controlled multi-point injection Electroni-
system cally con-
trolled 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 (driver’s side and front passenger’s 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.
GENERAL - Precautions Before Service 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
If high-pressure car-washing equipment or steam car-washing
Approx. equipment is used to wash the vehicle, be sure to note the
40 cm 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 GENERAL - Precautions Before Service
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.
Caution
MUT-II
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 MMC’s 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.
GENERAL - Precautions Before Service 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.
Supplemental Restraint System (SRS)
00-24 GENERAL - and Seatbelts with Pre-tensioner
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEATBELTS

WITH PRE-TENSIONER 00100590073
To improve safety, the SRS and seat belts with operational status of the SRS. The clock spring
pre-tensioner are available as optional parts. These is installed in the steering column.
systems enhance collision safety by restraining the The SRS side air bag deploys if an impact received
front passengers in case of an accident. The SRS at the side of the vehicle is stronger than a certain
works with the pre-tensioner simultaneously when set value, in order to protect the upper bodies of
a collision is detected. front seat passengers in the event of a collision.
The SRS consists of four air bag modules, SRS The seat belt pre-tensioner is built into the front
air bag control unit (SRS-ECU), side impact sensor, seat belt retractor. Only authorized service
SRS warning lamp and clock spring. The air bags personnel should do work on or around the SRS
are located in the centre of the steering wheel, components and seat belt with pre-tensioner. Those
above the glove box, and built into the front seat service personnel should read this manual carefully
back assemblies. Each air bag has a folded air before starting any such work. Extreme care must
bag and an inflator unit. The SRS-ECU under the be used when servicing the SRS to avoid injury
floor console monitors the system and has a safing to the service personnel (by inadvertent deployment
G sensor and an analog G sensor. The side impact of the air bags or inadvertent operation of the seat
sensor inside the center pillar monitors any shocks belt with pre-tensioner) or the driver (by rendering
coming from the side of the vehicle. The warning the SRS or the seat belt with pre-tensioner
lamp on the instrument panel indicates the inoperative).
Side impact sensor
Side air bag module
Clock spring
Air bag module
(Front passenger’s side)
Air bag module
(Driver’s side)
Diagnosis
connector
SRS-ECU
Seat belt with

pre-tensioner
SRS warning lamp
GENERAL - and Seatbelts with Pre-tensioner 00-25
SEAT BELT WITH PRE-TENSIONER
The seat belt with pre-tensioner has a pre-tensioner The safety mechanism operates automatically
operating mechanism and a G-sensor which detects when the retractor top mounting screw is removed
the force from an impact built into the seat belt during removal of the seat belt.
retractor. When the retractor top mounting screw is removed,
The G-sensor is a mechanical-type sensor which the force of the spring plate causes the tab at the
includes components such as a weight which moves lower edge of plate (A) to push in the pin of the
as a result of the impact from a collision, and a G-sensor, which prevents the weight inside the
spike which strikes a charge and causes it to G-sensor from moving.
detonate. At the same time, the retractor bracket and the
Thus the pre-tensioner is equipped with a safety top of plate (A) become separated. A stopper is
mechanism to prevent mis-operation during inserted into the gap thus formed by the force from
maintenance operations such as removal and a spring to prevent the tab from being removed
installation of the seat belt. from the pin if an outside force is applied to plate
(A).
Plate (A)
Plate (A) (when safety
Spring mechanism is disengaged)
Stopper
Retractor bracket Plate (A) (when safety
mechanism is engaged)
Stopper
Spring plate
Tab
Tab
G-sensor structure
Charge Spike
Tab
Pin
Pin (when safe-

ty mechanism is
engaged) Sensor
weight
SRS SERVICE PRECAUTIONS 00100600073
1. In order to avoid injury to yourself or others NOTE

from accidental deployment of the air bag and If any of these components are diagnosed as
accidental operation of the seat belt with faulty, they should only be replaced, in
pre-tensioner during servicing, read and accordance with the INDIVIDUAL COM-
carefully follow all the precautions and PONENTS SERVICE procedures in this
procedures described in this manual. manual, starting at page GROUP 52B.
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 (Driver’s side or front
passenger’s side)
D Seat belt with Pre-tensioner
4. After disconnecting the battery cable, wait 60 seconds

Insulating tape Battery 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.
SRS-ECU connector 5. Do not attempt to repair the wiring harness connectors

<Vehicles without SRS side air bag> 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.
<Vehicles with SRS side air bag>
GENERAL - and Seatbelts with Pre-tensioner 00-27
<Vehicles without SRS side air bag>
SRS-ECU Destination of harness Corrective action
Terminal No.
1 to 4 - -
5, 6 Dash wiring harness ® Clock spring ® Air bag module (Driver’s Correct or replace the dash wiring
side) harness. Replace the clock spring.
7, 8 Dash wiring harness ® Air bag module (Front passenger’s side) Correct or replace the dash wiring
harness.
9, 10 -
11 Dash wiring harness ® Diagnosis connector
12 -
13 Dash wiring harness ® Junction block (fuse No.4)
15 Dash wiring harness ® Instrument panel wiring harness ® SRS Correct or replace each wiring
warning lamp harness.
16 to 19 - -
20, 21 Dash wiring harness ® Earth Correct or replace the dash wring
harness.

Terminal No.
1, 2 - -
3 Dash wiring harness ® Earth Correct or replace the dash wiring harness
4 Dash wiring harness ® Instrument panel wiring harness Correct or replace each wiring harness.
® SRS warning lamp
5, 6 Dash wiring harness ® Air bag module (Front Correct or replace the dash wiring harness.
Passenger’s side)
7, 8 Dash wiring harness ® Clock spring ® Air bag module Correct or replace the dash wiring harness.
(Driver’s side) Replace the clock spring.
9 Dash wiring harness ® Junction block (fuse No.4) Correct or replace the dash wiring harness.
10, 11 -
13 -
14, 15 Dash wiring harness ® Earth
17 to 20 -
21, 22 Dash wiring harness ® Side air bag module (LH)
23, 24 Dash wiring harness ® Side air bag module (RH)


Terminal No.
25 to 33 - Correct or replace the dash wiring harness.
34, 35, 36 Dash wiring harness ® Floor wiring harness ® Side Correct or replace each wiring harness
impact sensor (LH)
37 to 39 -
40, 41, 42 Dash wiring harness ® Floor wiring harness ® Side

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.
SRS-ECU harness connector
MB991222
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 (driver’s side and front passenger’s 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 00-29
SUPPORT LOCATIONS FOR LIFTING AND JACKING 00100070065
Caution
Do not support the vehicles at locations other than specified supporting points. If do so, this
will cause damage, etc.
SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS

GARAGE JACK
Caution
Never support any point other than the specified one, or it will be deformed.
Caution
Never support the rear floor crossmember.
AXLE STANDS
Notch
Notch
Rubber
Rubber
00-30 GENERAL - Support Locations for Lifting and Jacking
SUPPORT POSITIONS FOR A Caution

SINGLE-POST LIFT OR DOUBLE-POST When service procedures require removing rear
LIFT 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 Notch
SINGLE-POST LIFT
GENERAL - Support Locations for Lifting and Jacking 00-31
H-bar lift SUPPORT POSITIONS AND SUPPORT METHOD

FOR AN 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.
Chassis-sup- 1. Place the vehicle on the H-bar lift (same direction).

port position 2. Place attachments on the H-bar lift at the designated
(side sill) Attachment chassis-support positions. When making the attachments,
refer to the section concerning making them.
Section A-A Caution
Side sill 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.
H-bar lift
H-bar lift 3. Raise the H-bar lift to the height at which the vehicle
Attachment
is slightly raised and check to be sure that the vehicle
is correctly and sufficiently secured; then raise the vehicle.
A
00-32 GENERAL - Support Locations for Lifting and Jacking
PREPARATION OF “ATTACHMENTS”
Block (A) mm
1. Prepare the blocks (wooden) and nails as shown in the
1,800 figure.
Item Dimensions mm Quantity
90 Block (A) 90 ´ 95 ´ 1,800 2
Block (B) 60 ´ 100 ´ 95 4
95
Block (C) 140 ´ 40 ´ 95 8
Block (B) Block (C) Nail 70 or more 32
15 Caution
15
40 20 40 The wood selected for the blocks must be hard.
40 20
40 2. For the (B) blocks and (C) blocks, use a saw and chisel
60 140
or similar tool to make grooves of the dimensions shown
in the figure.
3. Make four “ATTACHMENTS” such as shown in the figure
100 40 nailing (B) and (C) blocks so that each (B) blocks is
sandwiches between (C) blocks.
Block (C)
100
Block (C)
140 Nail
Block (B)
Finished attachment
Movable according
to vehicle width
GENERAL - Standard Part/Tightening-Torque Table 00-33
STANDARD PART/TIGHTENING-TORQUE TABLE 00100110033
Each torque value in the table is a standard value The values in the table are not applicable:
for tightening under the following conditions. (1) If toothed washers are inserted.
(1) Bolts, nuts and washers are all made of steel (2) If plastic parts are fastened.
and plated with zinc. (3) If bolts are tightened to plastic or die-cast
(2) The threads and bearing surface of bolts and inserted nuts.
nuts are all in dry condition. (4) If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque

Thread size Torque Nm
Bolt nominal Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
diameter (mm)
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 Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
diameter (mm)
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
ENGINE <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A
ENGINE <6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B
ENGINE <4D6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11C

11A-2
ENGINE <4G6>
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
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 22
Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . 7
Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Compression Pressure Check . . . . . . . . . . . . . . . . . 9
Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . 10 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE <4G6> - General Information/Service Specifications 11A-3
GENERAL INFORMATION 11100010469
Items 4G63
Total displacement mL 1,997
Bore ´ Stroke mm 85.0 ´88.0
Compression ratio 10.0
Combustion chamber Pentroof type
Camshaft arrangement SOHC
Intake 8
Number of valve
Exhaust 8
Opening BTDC 11_

Intake
Closing ABDC 53_
Valve timing
Opening BBDC 63_
Exhaust
Closing ATDC 21_
Fuel system Electronically controlled multipoint fuel injection
Rocker arm Roller type
Auto-lash adjuster Equipped
SERVICE SPECIFICATIONS 11100030489
Items Standard value Limit
When checked 294 - 490 -
Tension N When a used belt is installed 343 - 441 -
Alternator drive When a new belt is installed 490 - 686 -

belt
tension When checked 7.7 - 12.3 -
Deflection
(Reference When a used belt is installed 8.4 - 10.6 -
value) mm
When a new belt is installed 5.9 - 7.7 -

Power steering
oil pump and When a new belt is installed 637 - 833 -
A/C compressor
drive belt When checked 11.7 - 15.3 -
tension Deflection When a used belt is installed 12.5 - 14.3 -
mm
Basic ignition timing 5_ BTDC±2_ -
Ignition timing Approx. 10_BTDC -

11A-4 ENGINE <4G6> - Service Specifications/Sealants/Special Tools
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 3M ATD Part No.8660 or equivalent -

Semi-circular packing
Oil pan MITSUBISHI GENUINE PART Semi-drying sealant

Thermostat case MD970389 or equivalent
Flywheel bolt 3M Stud Locking 4170 or equivalent -
SPECIAL TOOLS 11100060457
Tool Number Name Use

MB991502 MUT-II sub assem- D Checking the idle speed
bly D Erasing diagnosis code
MB990767 End yoke holder D Holding the camshaft sprocket

D Holding the crankshaft sprocket
MD998719 or Crankshaft pulley D Holding the camshaft sprocket

MD998754 holder pin D Holding the crankshaft sprocket
ENGINE <4G6> - Special Tools 11A-5

MD998713 Camshaft oil seal Press-in of the camshaft oil seal
installer
MD998443 Auto-lash adjuster Supporting of auto-lash adjuster

holder
MD998727 Oil pan remover Removal of oil pan
MD998781 Flywheel stopper Securing the flywheel
MD998776 Crankshaft rear oil Press-in of the crankshaft rear oil seal
seal installer
MB990938 Handle Press-in of the crankshaft rear oil seal
MD998767 Tension pulley Timing belt tension adjustment

socket wrench
GENERAL Engine lifter Supporting the engine assembly during

SERVICE removal and installation of the transmission
TOOL
MZ203827
MB991453 Engine hanger

assembly
11A-6 ENGINE <4G6> - On-vehicle Service
Alternator pulley Water pump ON-VEHICLE SERVICE 11100090432

pulley
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
ALTERNATOR DRIVE BELT TENSION CHECK
Use a belt tension gauge to check that the belt tension is
at the standard value at a point half-way between the two
pulleys as shown in the illustration. In addition, press this
section with a force of 98 N and check that the amount of
Crankshaft pulley 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 When a new
Lock bolt belt is installed belt is installed
Tension N 343 - 441 490 - 686
Deflection (Reference 8.4 - 10.6 5.9 - 7.7
value) mm
4. Tighten the nut of the alternator pivot bolt.
Tightening torque: 44 Nm
5. Tighten the lock bolt.
6. Tighten the adjusting bolt.
ENGINE <4G6> - On-vehicle Service 11A-7
<Vehicles without A/C> POWER STEERING OIL PUMP AND AIR CONDITIONER
Oil pump pulley COMPRESSOR DRIVE BELT TENSION CHECK AND
ADJUSTMENT 11100130127
98 N
1. Use a belt tension gauge to check that the belt tension
A
B is at the standard value at a point half-way between the
Crankshaft two pulleys (indicated by an arrow in the illustration).
pulley In addition, press this section with a force of 98 N and
Tensioner pulley check that the amount of belt deflection is at the standard
value.
Standard value:
Items When When a When a new
<Vehicles with A/C> checked used belt is belt is
Oil pump pulley installed installed
98 N
Tensioner
Tension N 392 - 588 441 - 539 637 - 833
pulley Deflection 11.7 - 15.3 12.5 - 14.3 8.8 - 11.0
Crankshaft A B (Reference
pulley value) mm
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.
7. Check that basic ignition timing is within the standard

value.
Standard value: 5_ BTDC±2_
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.
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.
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.
Compression gauge Standard value (at engine speed of 250 - 400 r/min):
1,400 kPa
Limit (at engine speed of 250 - 400 r/min):
Min. 1,060 kPa
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: Max. 100 kPa
9. If there is a cylinder with compression or a compression
difference that is outside the limit, pour a small amount
of engine oil through the spark plug hole, and repeat
the operations in steps 7 and 8.
(1) If the compression increases after oil is added, the
cause of the malfunction is a worn or damaged piston
ring and/or cylinder inner surface.
(2) If the compression does not rise after oil is added,
the cause is a burnt or defective valve seat, or pressure
is leaking from the gasket.
10. Connect the crank angle sensor connector.
11. Install the spark plugs and spark plug cables.
12. Use the MUT-II to erase the diagnosis codes.
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.
MANIFOLD VACUUM CHECK 11100270409

Vacuum gage 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 11100290344
If an abnormal noise (knocking) that seems to be coming

from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
1. Start the engine.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused y
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied (for example,
by shifting from N ® D).
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or has disappeared,
the cause of the noise was probably that oil sludge had
caused the lash adjusters to become stuck. If this
happens, carry out the following check. If the noise level
does not change, go to step 5.
(1) Let the engine cool down sufficiently.
(2) Turn the crankshaft two full revolutions.
(3) Carry out lash adjuster simple check. (Refer to

P.11A-13.)
D If any of the rocker arms can be pushed down
easily during the lash adjuster simple check,
replace the corresponding lash adjusters.
D If the lash adjuster simple check has been carried
out but all lash adjusters are normal (if none of
the rocker arms could be pushed down easily),
check for some other cause of the problem.
NOTE
You can check whether the lash adjusters are normal
or not by carrying out a leak-down test. (Refer to
the Engine Workshop Manual.)
Caution
Make sure that the air has been fully bled before
installation of a new lash adjuster. (Refer to the
Engine Workshop Manual.)
5. Bleed the air from the lash adjusters. (Refer to P.11A-13.)
6. If the noise does not disappear even after the air has
been bled from the lash adjusters, carry out the following
check.
Carry out lash adjuster simple check. (Refer to P.11A-13.)
D If one of the rocker arms can be pushed down easily
during the lash adjuster simple check, replace the
corresponding lash adjuster.
D If two or more of the rocker arms can be pushed
down easily during the lash adjuster simple check,
the cause may be that the oil passage to the cylinder
head is blocked.
Check for blockages in the oil passage, and clear
the blockages if any are found. If there are no
blockages, replace the lash adjusters.
out but all lash adjusters are normal (if none of the
rocker arms could be pushed down easily), check
for some other cause of the problem.
NOTE
or not by carrying out a leak-down test. (Refer to the
Caution
installation of a 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.)
<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.
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
Good amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
High
pressure chamber will be compressed when the valve
pressure is open and the lash adjuster will over-compress,
chamber 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.
Drive pattern for air bleeding 2. Run the engine at idle for 1 - 3 minutes to let it warm
Gradually open the
up.
Close the throttle
throttle valve. valve. 3. With no load on the engine, repeat the drive pattern shown
Approx. in the illustration at left and check if the abnormal noise
3,000 r/min. disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
Idle speed level after 30 repetitions or more, the problem is probably
15 15 not due to air inside the lash adjusters.)
seconds seconds
4. After the noise has disappeared, repeat the drive pattern
Once 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 11A-15
CRANKSHAFT PULLEY 11200160303
REMOVAL AND INSTALLATION

Pre-removal Operation Post-installation Operation
D Under Cover Removal D Drive Belt Tension Adjustment (Refer to P.11A-6.)
D Under Cover Installation
25 Nm
Removal steps
1. Drive belt (Power steering and 2. Drive belt (Alternator)
A/C) 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 5
2
(f 3 ± 1 mm)
4
14 Nm 3.4 Nm
Sealant:
MITSUBISHI GENUINE PART
MD970389 or equivalent
3
22 Nm
5 8
28 - 34 Nm Lip section
9
11
5
6 10
12 Cam section and

88 Nm journal section
12
8
7
Engine oil
Removal steps
1. Control harness connection "BA 8. Camshaft oil seal
2. Spark plug cable 9. Spark plug guide oil seal
3. PCV hose connection AB" "AA 10. Rocker arm and shaft assembly
4. Rocker cover (intake side)
5. Camshaft position sensor support AB" "AA 11. Rocker arm and shaft assembly
6. Camshaft position sensing cylinder (exhaust side)
AA" "CA 7. Camshaft sprocket 12. Camshaft
ENGINE <4G6> - Camshaft and Camshaft Oil Seal 11A-17
REMOVAL SERVICE POINTS
MB990767 AA" CAMSHAFT SPROCKET REMOVAL
MD998719 or
MD998754
AB" ROCKER ARM AND SHAFT ASSEMBLY

MD998443 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 ENGINE <4G6> - Camshaft and Camshaft Oil Seal
"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.
ENGINE <4G6> - Oil Pan 11A-19
OIL PAN 11200280207

D Engine Oil Draining and Supplying (Refer to GROUP D Front Exhaust Pipe Removal and Installation (Refer
12 - On-vehicle Service.) to GROUP 15.)
D Oil Level Gauge Removal and Installation
f 4 ± 1 mm
Bolt
Groove hole 5
3
Sealant:
MITSUBISHI GENUINE PART 4
7 Nm
2
9 Nm 1 9 Nm
Removal steps
1. Drain plug 4. Oil level sensor
"AA 2. Drain plug gasket AA" 5. Oil pan
3. Bell housing cover
MD998727 MD998727 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

"AA DRAIN PLUG GASKET INSTALLATION
Oil pan side
Install the drain plug gasket in the direction so that it faces
as shown in the illustration.
Drain plug
gasket
11A-20 ENGINE <4G6> - Crankshaft Oil Seal
CRANKSHAFT OIL SEAL 11200310135

<M/T>
127 - 137 Nm 7
8 9
11
12
127 - 137 Nm
<A/T>
6
2
8 4
10
1
<M/T> <A/T>
5 3
Crankshaft Crankshaft
(Engine oil:
bolt washer 12 5
(Engine oil: surface)
bolt wash-
er surface)
9 Lip section Lip section
10
Sealant: 3M Stud locking 4170 or equivalent Engine oil
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
D Timing belt (Refer to P.11A-26.) D Oil pan (Refer to P.11A-19.)
D Crank angle sensor AA" D Transmission assembly
(Refer to GROUP 16.) D Clutch cover and disc <M/T>
1. Crankshaft sprocket 6. Crankshaft bushing
2. Flange AB" "BA 7. Plate <M/T>
3. Crankshaft sprocket B AB" "BA 8. Adapter plate
4. Key AB" "BA 9. Flywheel <M/T>
"CA 5. Crankshaft front oil seal AB" "BA 10. Drive plate <A/T>
AB" "BA 11. Adapter plate <M/T>
"AA 12. Crankshaft rear oil seal
ENGINE <4G6> - Crankshaft Oil Seal 11A-21
<M/T>
AA" TRANSMISSION ASSEMBLY REMOVAL
<M/T>:
Refer to GROUP 22.
Flywheel
Caution
Do not remove the flywheel mounting bolt shown by the
Bolt 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 Crankshaft
"AA CRANKSHAFT REAR OIL SEAL INSTALLATION
MD990938 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 D Thermostat Case Assembly Installation (Refer to
- On-vehicle Service.) GROUP 14 - Water Hose and Water Pipe.)
D Engine Oil Draining (Refer to GROUP 12 - D Engine Oil Supplying (Refer to GROUP 12 -
On-vehicle Service.) On-vehicle Service.)
D Thermostat Case Assembly Removal (Refer to D Accelerator Cable Adjustment (Refer to GROUP
GROUP 14 - Water Hose and Water Pipe.) 17 - On-vehicle Service.)
Delivery pipe O-ring
9
10
10
Engine oil
7
5
2
8
6
3
11
Removal steps
1. Accelerator cable connection 7. Injector connector
2. Vacuum hose connection 8. Purge control solenoid valve
3. Brake booster vacuum hose connector
connection 9. EGR solenoid valve connector
4. Vacuum hose connection "CA 10. High-pressure fuel hose connection
5. Throttle position sensor connector 11. Fuel return hose connection
6. Idle speed control connector
ENGINE <4G6> - Cylinder Head Gasket 11A-23
10 Nm
15
<Cold engine> 14
78 Nm ® 0 Nm ® 20 Nm ® + 90_ ® + 90_
16
3.4 Nm
27
(Engine oil)
12
26
17
19
28 13
22 29
49 Nm
18
20
21
24
24 Nm
44 Nm
25
34 Nm
23
31 Nm
12. Radiator upper hose connection 21. Heater hose connection

13. PCV hose 22. Thermostat case assembly
14. Ignition coil connector 23. Water hose connection
15. Ignition coil assembly AA" 24. Power steering oil pump and
16. Breather hose bracket assembly
17. Engine coolant temperature sensor 25. Front exhaust pipe connection
connector 26. Rocker cover
18. Engine coolant temperature gauge D Timing belt (Refer to P.11A-26.)
unit connector AB" "BA 27. Cylinder head bolt
19. Camshaft position sensor 28. Cylinder head assembly
20. Water hose connection "AA 29. Cylinder head gasket
11A-24 ENGINE <4G6> - Cylinder Head Gasket

AA" POWER STEERING OIL PUMP AND BRACKET
ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly
from the engine with the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
cylinder head assembly, and tie it with a cord.
Intake side
AB" CYLINDER HEAD BOLT REMOVAL
Front of engine
Loosen the bolts in 2 or 3 steps in order of the numbers
shown in the illustration, and remove the cylinder head
assembly.
3 5 10 8 2
Caution
Because the plug guides cannot be replaced by
1 7 9 6 4 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.
"BA CYLINDER HEAD BOLT INSTALLATION

Head bolt
Burred side 1. When installing the cylinder head bolts, the length below
the head of the bolts should be within the limit.
Head bolt (Engine If it is outside the limit, replace the bolts.
washer oil)
A Limit (A): 99.4 mm
Cylinder 2. The head bolt washer should be installed with the burred
head 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.
ENGINE <4G6> - Cylinder Head Gasket 11A-25
Intake side
4. Tighten the bolts by the following procedure.
Front of engine
Step Operation Remarks
1 Tighten to 78 Nm. Carry out in the order
8 6 1 3 9 shown in the illustration.
2 Fully loosen. Carry out in the reverse
order of that shown in the
10 4 2 5 7 illustration.
Exhaust side shown in the illustration.
4 Tighten 90_ of a turn. In the order shown in the
illustration. Mark the head
Step 4 Step 5 of the cylinder head bolt
and cylinder head by paint.
90_ 90_
illustration. Check that the
painted mark of the head
bolt is lined up with that of
the cylinder head.
Painted mark 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 48 Nm
5
10 - 12 Nm
24 Nm
9 Nm
2
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
ENGINE <4G6> - Timing Belt 11A-27
Timing mark (Top Timing mark REMOVAL SERVICE POINT
of cylinder head) Camshaft sprocket
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.
Timing mark
Timing mark Caution
Timing mark Oil pump The crankshaft should always be turned only
sprocket clockwise.
Crankshaft
sprocket
2. Loosen the tension pulley centre bolt.

3. Move the tension pulley to the water pump side, and
then remove the timing belt.
Caution
Centre bolt 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
"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
B Movement
movement of the push rod.
A
Standard value: Within 1 mm
Push rod A: Length when it is free (not pressed)
Auto tensioner B: Length when it is pressed
A - B: Movement
2. If it is out of the standard value, replace the auto tensioner.
A B
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 ENGINE <4G6> - Timing Belt
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 Timing mark "BA TIMING BELT INSTALLATION

of cylinder head) Camshaft sprocket
1. Align the timing marks on the camshaft sprocket,
crankshaft sprocket and oil pump sprocket.
Timing mark
Timing mark
Timing mark Oil pump
sprocket
Crankshaft
sprocket
2. After aligning the timing mark on the oil pump sprocket,

60 mm or remove the cylinder block plug and insert a Phillips
more 8 mm
Plug 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
Screwdriver the counterbalance shaft, turn the sprocket once, realign
the timing mark and check that the screwdriver goes in
Counter-
balance 60 mm or more. The screwdriver should not be taken
shaft Cylinder out until the timing belt is installed.
block
3. Install the belt to the crankshaft sprocket, oil pump

sprocket and camshaft sprocket in that order, so that
there is no slackness in the belt tension.
Caution
Fixing bolt If the timing belt is re-used, install so that the arrow
Belt tension side
marked on it at time of removal is pointing in the
Pin hole 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 tension side belt, and then provisionally tighten the fixing bolt.
5. Adjust the timing belt tension.
ENGINE <4G6> - Timing Belt 11A-29
"CA TIMING BELT TENSION ADJUSTMENT
50 Nm
1. After turning the crankshaft 1/4 of a revolution in the
anticlockwise direction, turn it in the clockwise direction
Tension until the timing marks are aligned.
MD998767 direction 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
A it for 15 minutes, measure the amount of protrusion of
the auto tensioner.
Standard value (A): 3.8 - 4.5 mm
4. If the amount of protrusion is outside the standard value,
repeat the operation in steps (1) to (3).
Auto tensioner 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
4
3
2
108 - 127 Nm
Removal steps
1. Timing belt (Refer to P.11A-26.) 4. Timing belt B tensioner
AA" "CA 2. Crankshaft sprocket AB" "AA 5. Timing belt B
"BA 3. Flange
Crankshaft REMOVAL SERVICE POINTS

sprocket MD998719 or MD998754
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).
ENGINE <4G6> - Timing Belt B 11A-31
Counterbalance shaft sprocket INSTALLATION SERVICE POINTS
Belt tension side "AA TIMING BELT B INSTALLATION, ADJUSTMENT
1. Install timing belt “B” by the following procedure.
Timing marks (1) Ensure that crankshaft sprocket “B” timing mark and
Timing
marks the counterbalance shaft sprocket timing mark are
aligned.
(2) Fit timing belt “B” over crankshaft sprocket “B” and
Crankshaft the counterbalance shaft sprocket. Ensure that there
sprocket B 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
Centre of the centre of the tensioner pulley is to the left and
tensioner above the centre of the installation bolt, and
pulley 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
Shaft belt is taut. Now tighten the bolt to fix the tensioner.
Caution
When tightening the bolt, ensure that the tensioner
pulley shaft does not rotate with the bolt. Allowing
it to rotate with the bolt can cause excessive
tension on the belt.
3. To ensure that the tension is correct, depress the belt

A (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
Crankshaft sprocket “B”
sprocket
Flange
11A-32 ENGINE <4G6> - Timing Belt B
Crankshaft "CA CRANKSHAFT SPROCKET INSTALLATION

sprocket MD998719 or MD998754
NOTE
Apply the minimum amount of engine oil to the bearing surface
and thread of the crankshaft bolt.
MB990767
ENGINE <4G6> - Engine Assembly 11A-33
ENGINE ASSEMBLY 11200090015

D Fuel Discharge Prevention (Refer to GROUP 13A D Thermostat Case Assembly Installation (Refer to
- On-vehicle Service.) GROUP 14 - Water Hose and Water Pipe.)
D Engine Coolant Draining D Engine Coolant Supplying
D Thermostat Case Assembly Removal (Refer to D Accelerator Cable Adjustment (Refer to GROUP
GROUP 14 - Water Hose and Water Pipe.) 17 - On-vehicle Service.)
D Front Exhaust Pipe Removal (Refer to GROUP 15.) D Front Exhaust Pipe Installation (Refer to GROUP
D Hood Removal (Refer to GROUP 42.) 15.)
D Under Cover Removal D Hood Installation (Refer to GROUP 42.)
D Radiator Assembly Removal (Refer to GROUP 14.) D Under Cover Installation
D Air Cleaner Removal D Radiator Assembly Installation (Refer to GROUP
14.)
D Air Cleaner Installation
1 Delivery pipe O-ring
10
10 9
5 Engine oil
8
2
12
6
11
Removal steps
1. Accelerator cable connection 7. Injector connector
2. Vacuum hose connection 8. Purge control solenoid valve con-
3. Brake booster vacuum hose connector
nection 9. EGR solenoid valve connector
4. Vacuum hose connection "DA 10. High-pressure fuel hose connection
5. Throttle position sensor connector 11. Fuel return hose connection
6. Idle speed control connector 12. PCV hose connection
11A-34 ENGINE <4G6> - Engine Assembly
23 26 15
20
22
49 Nm
21
19 17 16
18
14
13
57 Nm*
24
25
25
98 Nm
13. Drive belt (Alternator) 22. Camshaft position sensor connector

14. Drive belt (Power steering and 23. Detonation sensor connector
A/C) AC" D Transmission assembly
AA" 15. Power steering oil pump and AD" "CA 24. Engine mount bracket
bracket assembly "BA 25. Engine mount stopper
AB" 16. A/C compressor AE" "AA 26. Engine assembly
17. Alternator connector
18. Oil pressure switch connector Caution
19. Heater hose connection Mounting locations marked by * should be provisionally
20. Engine coolant temperature gauge tightened, and then fully tightened after placing the vehicle
unit connector horizontally and loading the full weight of the engine on
the vehicle body.
21. Engine coolant temperature sensor
connector
ENGINE <4G6> - Engine Assembly 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>
<M/T>:
Refer to GROUP 22.
Caution
Flywheel Do not remove the flywheel mounting bolt shown by the
arrow. If this bolt Is removed, the flywheel will become
Bolt
<A/T>:
Refer to GROUP 23.
MZ203827 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
MB991453 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 ENGINE <4G6> - Engine Assembly

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

Dynamic damper Clamp the engine mount stopper so that the arrow points
in the direction as shown in the diagram.
Arrow
Engine
mount
stopper
Engine mount bracket
"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>
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 14
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 CAMSHAFT AND CAMSHAFT OIL SEAL . . . 15
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 21
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 5 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 24

TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . 6
Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 30
Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Compression Pressure Check . . . . . . . . . . . . . . . . . 8
Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . . 9
Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 10
11B-2 ENGINE <6A1> - General Information/Service Specifications
Items 6A13
Bore ´ Stroke mm 81.0 ´ 80.8
Combustion chamber Pentroof type
Intake 12
Number of valve
Exhaust 12
Opening BTDC 15_

Intake
Closing ABDC 53_
Valve timing
Opening BBDC 53_
Exhaust
Closing ATDC 15_
Fuel system Electronically controlled multipoint fuel injection
Auto-lash adjuster Equipped
Alternator drive When a new belt is installed 490 - 686 -

belt
tension When checked 9.0 - 13.0 -
Deflection
value) mm

Power steering
oil pump and When a new belt is installed 784 - 980 -
A/C compressor
drive belt When checked 11.0 - 15.0 -
tension Deflection
value) mm
Basic ignition timing 5_ BTDC±3_ -
Ignition timing Approx. 7° BTDC -

ENGINE <6A1> - Service Specifications/Sealants/Special Tools 11B-3
CO contents % 0.2 or less -
HC contents ppm 100 or less -
Compression pressure (250 - 400 r/min) kPa 1177 Min. 875
Compression pressure difference of all cylinder kPa - Max. 98
Intake manifold vacuum kPa - Min. 60
Auto-tensioner push rod movement mm Within 1 -
Timing belt tension torque Nm 3 -
Auto-tensioner rod protrusion amount mm 3.8 - 4.5 -

Flywheel bolt or drive plate bolt 3M Stud Locking 4170 or equivalent -

MB991502 MUT-II sub Engine idle speed check
assembly Erasing diagnosis code
MB990767 End yoke holder D Holding the camshaft sprocket

D Holding the crankshaft pulley
MD998719 Crankshaft pulley

holder pin

holder pin
11B-4 ENGINE <6A1> - Special Tools

MD998443 Auto-lash adjuster Supporting of auto-lash adjuster
holder
MD998713 Camshaft oil seal Press-in of the camshaft oil seal

installer
seal installer
MB990938 Handle Press-in of the crankshaft rear oil seal
MD998767 Tension pulley Timing belt tension adjustment

socket wrench
MD998717 Crankshaft front Press-in of the crankshaft front oil seal

oil seal installer
MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate

<A/T>

TOOL
MZ203827
ENGINE <6A1> - Special Tools/On-vehicle Service 11B-5

MB991453 Engine hanger Supporting the engine assembly during
assembly removal and installation of the transmission
Alternator pulley
Tension pulley
ON-VEHICLE SERVICE 11100090425

ADJUSTMENT
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
Crankshaft pulley 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 9.0 - 13.0

Adjusting bolt 1. Loosen the tension pulley fixing nut.
2. Use the adjusting bolt to adjust the belt tension or
deflection to the standard value.
Fixing nut Standard value:
Items When a used When a new
belt is installed belt is installed
Tension N 343 - 441 490 - 686
Deflection (Reference 10.0 - 12.0 6.8 - 8.0
value) mm
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
POWER STEERING OIL PUMP AND AIR CONDITIONER
oil pump pulley COMPRESSOR DRIVE BELT TENSION CHECK AND
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).
A In addition, press this section with a force of 98 N and
A/C compressor check that the amount of belt deflection is at the standard
Crankshaft pulley
value.
pulley
B Standard value:
checked used belt is belt is
installed installed
Tension N 490 - 686 539 - 637 784 - 980
Deflection 11.0 - 15.0 12.0 - 14.0 8.0 - 12.0
(Reference
value) mm
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.
ENGINE <6A1> - On-vehicle Service 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.

condition.
3. Check the basic ignition timing. Adjust if necessary.
4. Run the engine at idle for 2 minutes.
5. Check the idle speed. Select item No. 22 and take a
reading of the idle speed.
Curb idle speed: 650 ± 100 r/min
NOTE
The idle speed is controlled automatically by the idle speed
control (ISC) system.
6. If the idle speed is outside the standard value, check
the MPI components by referring to GROUP 13A -
Troubleshooting.
IDLE MIXTURE CHECK 1110020401

condition.
3. Check that the basic ignition timing is within the standard
value.
4. Run the engine at 2,500 r/min for 2 minutes.
5. Set the CO, HC tester.

6. Check the CO contents and the HC contents at idle.
Standard value
CO contents: 0.2% or less
HC contents: 100 ppm or less
the following items:
D Diagnosis output
D Closed-loop control (When the closed-loop control
is normal, the output signal of the oxygen sensor
changes between 0 - 400 mV and 600 - 1,000 mV
at idle.)
D Fuel pressure
D Injector
D Ignition coil, spark plug cable, spark plug
D Leak in the EGR system and in the EGR valve
NOTE
Replace the three way catalyst when the CO and HC
contents are not within the standard value, even though
the result of the inspection is normal on all items.
1. Before inspection, check that the engine oil, starter and

battery are normal. In addition, set the vehicle to the
2. Disconnect the spark plug cables.
3. Remove all of the spark plugs.
Crank angle 4. Disconnect the crank angle sensor connector.

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
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 6. Set compression gauge to one of the spark plug holes.
7. Crank the engine with the throttle valve fully open and
measure the compression pressure.
Standard value (at engine speed of 250 - 400 r/min):
1,177 kPa
Limit (at engine speed of 250 - 400 r/min):
Min. 875 kPa
8. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: Max. 98 kPa
of engine oil through the spark plug hole, and repeat
the operations in steps 7 and 8.
10. Connect the crank angle sensor connector.
11. Install the spark plugs and spark plug cables.
12. Use the MUT-II to erase the diagnosis codes.
NOTE
This will erase the diagnosis code resulting from the crank
angle sensor connector being disconnected.
MANIFOLD VACUUM CHECK 11100270393

Vacuum gauge 1. Start the engine and allow it to warm up until the
Fuel pressure regulator 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
LASH ADJUSTER CHECK 11100290337
If an abnormal noise (knocking) that seems to be coming

from the lash adjuster is heard after starting the engine and
does not stop, carry out the following check.
NOTE
(1) The abnormal noise which is caused by a problem
with the lash adjusters is generated after the engine
is started, and will vary according to the engine speed.
However, this noise is not related to the actual engine
load.
Because of this, if the noise does not occur
immediately after the engine is started, if it does not
change in accordance with the engine speed, or if
it changes in accordance with the engine load, the
source of the noise is not the lash adjusters.
(2) If there is a problem with the lash adjusters, the noise
will almost never disappear, even if the engine has
been run at idle to let it warm up.
The only case where the noise might disappear is
if the oil in the engine has not been looked after
properly and oil sludge has caused the lash adjusters
to stick.
2. Check that the noise occurs immediately after the engine
is started, and that the noise changes in accordance
with changes in the engine speed.
If the noise does not occur immediately after the engine
is started, or if it does not change in accordance with
the engine speed, the problem is not being caused y
the lash adjusters, so check for some other cause of
the problem. Moreover, if the noise does not change in
accordance with the engine speed, the cause of the
problem is probably not with the engine. (In these cases,
the lash adjusters are normal.)
3. While the engine is idling, check that the noise level does
not change when the engine load is varied (for example,
by shifting from N ® D).
If the noise level changes, the cause of the noise is
probably parts striking because of worn crankshaft
bearings or connecting rod bearings. (In such cases, the
lash adjusters are normal.)
4. After the engine has warmed up, run it at idle and check
if any noise can be heard.
If the noise has become smaller or has disappeared,
the cause of the noise was probably that oil sludge had
caused the lash adjusters to become stuck. If this
happens, carry out the following check. If the noise level
does not change, go to step 5.
(1) Let the engine cool down sufficiently.
(2) Turn the crankshaft two full revolutions.
(3) Carry out lash adjuster simple check. (Refer to
P.11B-12.)
D If any of the rocker arms can be pushed down
easily during the lash adjuster simple check,
replace the corresponding lash adjusters.
out but all lash adjusters are normal (if none of
the rocker arms could be pushed down easily),
check for some other cause of the problem.
NOTE
or not by carrying out a leak-down test. (Refer to
the Engine Workshop Manual.)
Caution
installation of a new lash adjuster. (Refer to the
5. Bleed the air from the lash adjusters. (Refer to P.11B-12.)
6. If the noise does not disappear even after the air has
been bled from the lash adjusters, carry out the following
check.
Carry out lash adjuster simple check. (Refer to P.11B-12.)
D If one of the rocker arms can be pushed down easily
during the lash adjuster simple check, replace the
corresponding lash adjuster.
D If two or more of the rocker arms can be pushed
down easily during the lash adjuster simple check,
the cause may be that the oil passage to the cylinder
head is blocked.
Check for blockages in the oil passage, and clear
the blockages if any are found. If there are no
blockages, replace the lash adjusters.
out but all lash adjusters are normal (if none of the
rocker arms could be pushed down easily), check
for some other cause of the problem.
NOTE
or not by carrying out a leak-down test. (Refer to the
Caution
installation of a 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.)
<LASH ADJUSTER SIMPLE CHECK>

1. Stop the engine.
Timing belt side
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.
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
Good amount of air may get mixed into the oil.
(3) If the oil is degenerated, air and oil will not separate
easily in oil, and the amount of air mixed into the
oil will increase.
(4) If the air which has been mixed in with the oil due
to any of the above reasons gets into the high pressure
chamber of the lash adjuster, the air inside the high
High
pressure chamber will be compressed when the valve
pressure is open and the lash adjuster will over-compress,
chamber 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.
Drive pattern for air bleeding 2. Run the engine at idle for 1 - 3 minutes to let it warm
Gradually open the
up.
Close the throttle
throttle valve. valve. 3. With no load on the engine, repeat the drive pattern shown
Approx. in the illustration at left and check if the abnormal noise
3,000 r/min. disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
Idle speed level after 30 repetitions or more, the problem is probably
15 15 not due to air inside the lash adjusters.)
seconds seconds
4. After the noise has disappeared, repeat the drive pattern
Once 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

D Under Cover Removal D Drive Belt Tension Adjustment (Refer to P.11B-5.)
(Engine oil)
1
4 5
177 - 186 Nm
2
Removal steps
1. Drive belt (Power steering oil AA" "AA 3. Crankshaft bolt
pump, or A/C compressor and 4. Washer
power steering oil pump) 5. Crankshaft pulley
2. Drive belt (Alternator)
REMOVAL SERVICE POINT

AA" CRANKSHAFT BOLT REMOVAL
MB990767
MD998719

"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.
ENGINE <6A1> - Camshaft and Camshaft Oil Seal 11B-15

<Front bank>

D Engine Coolant Draining and Refilling (Refer to D Timing Belt Removal and Installation (Refer to
GROUP 14 - On-vehicle Service.) P.11B-26.)
D Air Intake Hose Assembly Removal and Installation D Drive Belt Tension Adjustment (Refer to P.11B-5.)
Apply engine oil to all

sliding parts when
installing.
6
3
4
3.4 Nm 1
5
2
7 10
22 Nm
(Engine oil)
28 - 34 Nm
12
24 Nm
5
11
9 13
8
88 Nm
Removal steps
AA" "DA 1. Radiator upper hose connection AB" "CA 8. Camshaft sprocket
AA" "DA 2. Radiator lower hose connection "BA 9. Camshaft oil seal
3. Blow-by hose connection 10. Engine hanger
4. PCV hose connection 11. Thrust case
5. Vacuum hose connection AC" 12. Rocker arm and shaft assembly
6. Spark plug cable "AA 13. Camshaft
7. Rocker cover
11B-16 ENGINE <6A1> - Camshaft and Camshaft Oil Seal
<Rear bank>

D Air Intake Plenum Removal and Installation D Distributor Removal and Installation
(Refer to GROUP 15.) (Refer to GROUP 16.)
D Timing Belt Removal and Installation D Drive Belt Tension Adjustment (Refer to P.11B-5.)
(Refer to P.11B-26.)
Apply engine oil to all

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

AA" RADIATOR UPPER HOSE/RADIATOR LOWER
HOSE DISCONNECTION
After making mating marks on the radiator hose and the hose
clamp, disconnect the radiator hose.
ENGINE <6A1> - Camshaft and Camshaft Oil Seal 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 and shaft
assembly.
<Front bank side> <Rear bank side> INSTALLATION SERVICE POINTS

"AA CAMSHAFT INSTALLATION
Set the camshaft dowel pins so that they are in the position
shown in the illustration.
Approx. Approx. Caution
35_ 35_
Do not mistake the camshafts for the front bank and the
Dowel Dowel
pin pin
rear bank. The camshaft for the rear bank has a slit with
a width of approximately 4 mm on its rear end.
<Front bank side> <Rear bank side> "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 MD991559 MD998713

11B-18 ENGINE <6A1> - Camshaft and Camshaft Oil Seal
"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.
ENGINE <6A1> - Oil Pan 11B-19
OIL PAN 11200280214

D Engine Oil Draining and Supplying (Refer to GROUP D Under Cover Removal and Installation
12 - On-vehicle Service.) D Starter Motor Removal and Installation
D Oil Level Gauge Removal and Installation
D Front Exhaust Pipe Removal and Installation (Refer
to GROUP 15.)
Bolt
Groove hole
3 5
Sealant:
7 Nm
39 Nm
4 7 Nm
2
7 Nm
3 44 Nm
44 Nm
7 Nm
Removal steps
1. Drain plug 4. Cover
"AA 2. Drain plug gasket AA" 5. Upper oil pan
AA" 3. Lower oil pan
11B-20 ENGINE <6A1> - Oil Pan

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

Oil pan side
Drain plug
gasket
ENGINE <6A1> - Crankshaft Oil Seal 11B-21
<M/T>
Crankshaft
(Engine oil:
bolt wash-
er surface)
5
4 8
3
2
1
<A/T>
Crankshaft
(Engine oil:
bolt washer
surface)
10
9
8
7
6 Sealant: 3M Stud Locking
4170 or equivalent
<M/T>
5
11 Lip section
<A/T>
11
93 - 103 Nm
10
Lip section
7
Engine oil
steps steps
D Timing belt (Refer to P.11B-26.) AA" D Transmission assembly
D Crank angle sensor D Clutch cover and disc <M/T>
(Refer to GROUP 16.) AB" "BA 6. Plate <M/T>
1. Crankshaft sprocket AB" "BA 7. Adapter plate
2. Crankshaft sensing blade AB" "BA 8. Flywheel <M/T>
3. Crankshaft spacer AB" "BA 9. Adapter plate <M/T>
4. Key AB" "BA 10. Drive plate <A/T>
"CA 5. Crankshaft front oil seal "AA 11. Crankshaft rear oil seal
11B-22 ENGINE <6A1> - Crankshaft Oil Seal
<M/T> REMOVAL SERVICE POINTS

<M/T>:
Refer to GROUP 22.
Flywheel
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 "AA CRANKSHAFT REAR OIL SEAL INSTALLATION
Crankshaft
MD998776

PLATE/PLATE <M/T> INSTALLATION
plate bolts.
ENGINE <6A1> - Crankshaft Oil Seal 11B-23
"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION
Crankshaft 1. Apply a small amount of engine oil to the entire
MD998717 circumference of the oil seal lip.
2. Tap the oil seal unit it is flush with the oil seal case.
MD998717
Oil seal
11B-24 ENGINE <6A1> - Cylinder Head Gasket

D Engine Coolant Draining and Refilling (Refer to D Fuel Discharge Prevention (Refer to GROUP 13A
GROUP 14 - On-vehicle Service.) - On-vehicle Service.)
D Air Intake Hose Assembly Removal and Installation D Front Exhaust Pipe Removal and Installation (Refer
D Radiator Assembly Removal and Installation (Refer to GROUP 15.)
to GROUP 14 - Radiator.) D Thermostat Case Assembly Removal and Installation
D Air Intake Plenum and Intake Manifold Removal and (Refer to GROUP 14 - Water Hoses and Pipes.)
Installation (Refer to GROUP 15 - Air Intake Plenum.) D Water Inlet Pipe Removal and Installation (Refer to
D Engine Cover Removal and Installation GROUP 14 - Water Hoses and Pipes.)
D Drive Belt Tension Adjustment (Refer to P.11B-5.)
D Timing Belt Removal and Installation (Refer to
P.11B-26.)
5
5
3
2
6 1
3.4 Nm
2 4
3.4 Nm
(Engine oil)
20 Nm ® + 120_ ® + 120_
10
9
20 Nm ® + 120_ ® + 120_ 9
(Engine oil)
4
11
10 - 12 Nm
11
7
35 Nm 8
Removal steps
1. PCV hose connection 7. Idler pulley
2. Blow-by hose connection 8. Timing belt rear centre cover
3. Breather hose connection AA" "BA 9. Cylinder head bolt
4. Vacuum hose connection 10. Cylinder head assembly
5. Spark plug cable "AA 11. Cylinder head gasket
6. Rocker cover
ENGINE <6A1> - Cylinder Head Gasket 11B-25
<Front bank side> Exhaust side REMOVAL SERVICE POINT
AA" CYLINDER HEAD BOLT REMOVAL
Front of assembly.
<Rear bank side> Intake side engine
Exhaust side
Identification mark INSTALLATION SERVICE POINTS

surface.
2. Install the gasket to the cylinder block with the identification
mark facing upwards.

Head bolt
washer oil)
head
side caused by tapping out facing upwards.
<Front bank side> Exhaust side 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
Front of 120_ in the same sequence.
<Rear bank side> Intake side engine (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.
Exhaust side
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

D Under Cover Removal and Installation D Drive Belt Tension Adjustment (Refer to P.11B-5.)
D Crankshaft Pulley Removal and Installation
D Alternator Removal and Installation
(Refer to GROUP 16.)
3 Nm
44 Nm
9
12 Nm
10
3
7 8 10 - 12 Nm
4
10 - 12 Nm
24 Nm
35 Nm
5
24 Nm
22 Nm
11
2 14
10 - 12 Nm 13
12
Removal steps
1. Engine cover 9. Timing belt cover (front, upper
2. Engine mount stay right)
3. Power steering hose clamp bolt 10. Timing belt cover (front, upper left)
4. Crank angle sensor mounting bolt 11. Timing belt cover (front, lower)
5. Oil level gauge assembly 12. Flange
6. Engine hanger "CA D Timing belt tension adjustment
7. Tension pulley bracket assembly AA" "BA 13. Timing belt
8. Tensioner bracket "AA 14. Auto tensioner
ENGINE <6A1> - Timing Belt 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
Timing belt (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.

98 N - 196 N "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
A B Movement
movement of the push rod.
Standard value: Within 1 mm
Push rod A: Length when it is free (not pressed)
Auto tensioner B: Length when it is pressed
A - B: Movement
2. If it is out of the standard value, replace the auto tensioner.
A B
3. Use a press or vice to gently compress the auto tensioner
push rod until pin hole A of the push rod and pin hole
B of the tensioner cylinder are aligned.
Caution
If the compression speed is too fast, the rod may
become damaged, so be sure to carry out this
operation slowly.
4. Once the holes are aligned, insert the set pin.

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 ENGINE <6A1> - Timing Belt
Rocker cover Rocker cover "BA TIMING BELT INSTALLATION

1. Check that the timing marks of the both camshaft
sprockets and the crankshaft sprocket are aligned.
NOTE
Camshaft In this condition, the No.1 cylinder will be in the
sprocket
compression top dead centre position.
Camshaft Timing
sprocket marks
Crank-
shaft
sprocket
Tension side A Tension side B 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
Rear Tension side C installing the timing belt.
bank
side NOTE
camshaft
Tension side D If reusing the old timing belt, install it so that the arrow
sprocket 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
Pin holes 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.
ENGINE <6A1> - Timing Belt 11B-29
"CA TIMING BELT TENSION ADJUSTMENT
MD998767
1. After turning the crankshaft 1/4 of a revolution in the
Tension direction 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
Tensioner timing belt.
pulley
48 Nm Standard value: 3 Nm <Timing belt tension torque>
Caution
When tightening the fixing bolt, make sure that the
tensioner pulley does not turn with the bolt.
3. Turn the crankshaft two revolutions in the clockwise

direction, and after leaving it for 5 minutes or more, check
if the set pin of the auto tensioner can be removed and
inserted easily.
NOTE
If the set pin cannot be inserted easily, the auto tensioner
A 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

D Fuel Discharge Prevention (Refer to GROUP 13A D Front Exhaust Pipe Installation (Refer to GROUP
- On-vehicle Service.) 15.)
D Under Cover Removal D Radiator Installation (Refer to GROUP 14.)
D Hood Removal (Refer to GROUP 42.) D Air Cleaner Installation
D Air Cleaner Removal D Hood Installation (Refer to GROUP 42.)
D Radiator Removal (Refer to GROUP 14.) D Under Cover Installation
D Front Exhaust Pipe Removal (Refer to GROUP 15.) D Drive Belt Tension Adjustment (Refer to P.11B-5.)
D Engine Cover Removal D Accelerator Cable Adjustment (Refer to GROUP
D Battery Removal 17 - On-vehicle Service.)
D Engine Coolant Draining D Engine Cover Installation
D Battery Installation
D Engine Coolant Supplying
1
18 Nm 5 6 7
4 8 18
3
9
17 2
10
23
19
24
11 20
16 21
22
9
O-ring 12
19
14
15
Engine oil 13
Removal steps
1. Accelerator cable connection 13. Power steering oil pressure switch
2. Capacitor connector connector
3. Vacuum hose connection 14. Oil pressure harness connector
4. TPS connector 15. Thermo switch connector
5. Accelerator pedal position sensor 16. Crank angle sensor connector
connector <TCL> 17. Brake booster vacuum hose con-
6. ISC connector nection
7. Control harness connector 18. Fuel return hose connection
8. Distributor connector "DA 19. High-pressure fuel hose connection
9. Vacuum hose connection 20. Earth cable connection
10. Engine coolant temperature sensor 21. Control harness connector
connector 22. Front harness connector
11. Engine coolant temperature gauge 23. Purge control solenoid valve
unit connector connector
12. Injector connector 24. EGR solenoid valve connector
ENGINE <6A1> - Engine Assembly 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*
25. Drive belt (Alternator) AD" "CA 32. Engine mount bracket
26. Drive belt (Power steering and "BA 33. Engine mount stopper
A/C) AE" "AA 34. Engine assembly
27. Clamp bolt (Power steering hose
and pipe) Caution
AA" 28. Power steering oil pump assembly Mounting locations marked by * should be
AB" 29. A/C compressor provisionally tightened, and then fully tightened
30. Heater hose connection after placing the vehicle horizontally and loading
AC" D Transmission assembly the full weight of the engine on the vehicle
31. Engine mount stay body.
11B-32 ENGINE <6A1> - Engine Assembly

ASSEMBLY REMOVAL
NOTE

attached.
NOTE
<M/T> AC" TRANSMISSION ASSEMBLY REMOVAL

<M/T>:
Refer to GROUP 22.
Caution
Bolt <A/T>:
Refer to GROUP 23.

tool.
mount bracket.

compartment.
ENGINE <6A1> - Engine Assembly 11B-33
"BA ENGINE MOUNT STOPPER INSTALLATION

Engine side
Clamp the engine mount stopper so that the arrow points
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>
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 15
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 CAMSHAFT AND CAMSHAFT OIL SEAL . . . 16
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 20
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 23

TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Valve Clearance Check and Adjustment . . . . . . . . 8
Injection Timing Check and Adjustment . . . . . . . . 10 TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 33
Compression Pressure Check . . . . . . . . . . . . . . . . 12
Timing Belt Tension Adjustment . . . . . . . . . . . . . . . 13
11C-2 ENGINE <4D6> - General Information/Service Specifications
Items 4D68
Bore ´ Stroke mm 82.7 ´ 93.0
Combustion chamber Vortex chamber type
Number of valve Intake 4
Exhaust 4
Valve timing Intake Opening BTDC 20_
Closing ABDC 48_
Exhaust Opening BBDC 54_
Closing ATDC 22_
Fuel system Distribution type injection pump
Adjusting screw Elephant foot type
Alternator Tension N When checked 343 - 490 -

drive belt
tension When a used belt is installed 392 - 490 -
When a new belt is installed 490 - 588 -
Deflection Centre of belt When checked 8.0 - 10.0 -

(Reference between alternator
value) mm pulley and water When a used belt is 8.0 - 9.4 -
pump pulley installed
When a new belt is 7.0 - 8.0 -

installed
Centre of belt When checked 7.9 - 9.9 -

between crankshaft
pulley and alternator When a used belt is 7.9 - 9.2 -
pulley installed
When a new belt is 6.8 - 7.9 -

installed
ENGINE <4D6> - Service Specifications/Sealants 11C-3
Power Tension N When checked 294 - 490 -

steering oil
pump drive When a used belt is installed 343 - 441 -
belt tension
Deflection When checked 12.6 - 16.3 -

mm
When a used belt is installed 13.4 - 15.3 -
A/C com- Tension N When checked 392 - 588 -

pressor
drive belt When a used belt is installed 441 - 539 -
tension
Deflection When checked 9.2 - 12.0 -

mm
When a used belt is installed 9.8 - 11.2 -
Valve clearance (at hot) Intake valve 0.35 -

mm
Exhaust valve 0.45 -
Injection timing (Dial gauge display value mm) 1 ± 0.03 -

(10_ATDC)
Compression pressure kPa 3,500 Min. 2,560
Compression pressure difference of all cylinder - Max. 300

(at engine speed of 280 r/min) kPa
Timing belt deflection mm 4-5 -
Timing belt B deflection mm 5-7 -

Semi-circular packing and rocker 3M ATD Part No.8660 or equivalent

cover seal, and cylinder head seal
Flywheel bolt or adapter plate bolt 3M Stud Locking 4170 or equivalent -

11C-4 ENGINE <4D6> - Special Tools

MB991502 MUT-II sub Idle speed check
assembly
MB998720 Prestroke Adjustment of the injection timing

measuring adapter
MB990767 End yoke holder Holding the camshaft sprocket

holder pin

holder pin
MD998364 Camshaft oil seal Installing the camshaft oil seal

installer
seal installer
MB990938 Handle
ENGINE <4D6> - Special Tools 11C-5

MD998382 Crankshaft front oil Installing the crankshaft front oil seal
seal installer
MD998383 Crankshaft front oil

seal guide
MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate

<A/T>

TOOL
MZ203827
MB991453 Engine hanger as-

sembly
11C-6 ENGINE <4D6> - On-vehicle Service

ADJUSTMENT
A Water pump Use a belt tension gauge to check that the belt tension is
Alternator pulley at the standard value at a point half-way between the two
pulley 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 343 - 490
B Deflection (Reference Portion A 8.0 - 10.0
Crankshaft value) mm
Portion B 7.9 - 9.9
pulley

Adjusting bolt 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.
Lock
bolt Standard value:
Items When a When a new
used belt is belt is
Pivot bolt installed installed
Tension N 392 - 490 490 - 588
Deflection Portion A 8.0 - 9.4 7.0 - 8.0
(Reference
value) mm Portion B 7.9 - 9.2 6.8 - 7.9
4. Tighten the lock bolt.

5. Tighten the nut of the alternator pivot bolt.
6. Tighten the adjusting bolt.
Caution
ENGINE <4D6> - On-vehicle Service 11C-7
POWER STEERING OIL PUMP DRIVE BELT TENSION
Power steering CHECK AND ADJUSTMENT 11100110183
oil pump pulley
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 checked used belt is belt is
pulley installed installed
Tension N 294 - 490 343 - 441 490 - 686
Deflection 12.6 - 16.3 13.4 - 15.3 10.0 - 12.6
(Reference
value) mm
2. If the tension is outside the standard value, adjust by

A Oil pump (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
B 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
A/C compressor COMPRESSOR DRIVE BELT TENSION CHECK AND

A
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 checked used belt is belt is
pulley installed installed
B
Tension N 392 - 588 441 - 539 637 - 833
Deflection 9.2 - 12.0 9.8 - 11.2 7.0 - 8.6
(Reference
value) mm
2. If the tension is outside the standard value, adjust by
(2) Adjust the belt tension using adjusting bolt B.
(4) Check the belt frequency, tension or deflection, and
Caution
VALVE CLEARANCE CHECK AND

1. Start the engine and allow it to warm up until the engine

coolant temperature reaches 80 to 95 _C.
2. Remove the timing belt upper cover.
4. Remove the glow plug plate and all of the glow plugs.
Camshaft Timing 5. Turn the crankshaft clockwise to align the crankshaft pulley
sprocket marks timing mark and to set the No.1 cylinder or No.4 cylinder
Timing marks 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.
Crankshaft
pulley
6. Measure the valve clearance in the places indicated by
arrows in the illustration.
Arrow A: When the No.1 cylinder is at compression top
dead centre
Arrow B: When the No.4 cylinder is at compression top
dead centre
Timing
belt Standard value:
side
A When warm When cold (NOTE)
B
Intake 0.35 mm 0.25 mm
Exhaust 0.45 mm 0.35 mm
NOTE
Adjusting (1) When inserting the thickness gauge, press the pad
screw from the opposite side using a flat-tipped screwdriver
or similar tool to make a gap for the thickness gauge
Pad to be inserted.
Thickness gauge
Flat-tipped
screwdriver
(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.
Thickness
Pad gauge
7. If the clearance is outside the standard value, loosen

the lock nut and turn the adjusting screw while using
Thickness a thickness gauge to adjust the clearance.
gauge
8. Tighten the lock nut while holding the adjusting screw

with a screwdriver so that it doesn’t turn.
9. Turn the crankshaft one full revolution to align the
crankshaft pulley timing mark.
10. Adjust the remaining valves by the same procedure as
in steps 7. - 9. above.
11. Install the glow plugs and the glow plug plate.
12. Install the rocker cover.
13. Install the timing belt upper cover.
INJECTION TIMING CHECK AND

1. Remove all of the glow plugs.

Camshaft Timing 3. Align the timing marks of the camshaft sprocket and set
sprocket marks the No.1 cylinder to the top dead centre position.
Timing marks
Crankshaft
pulley
4. Remove the timing check plug at the rear of the injection

pump.
Timing check plug
Dial gauge 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.
MD998720
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.
Set to 0
9. Check that the needle doesn’t move even if the crankshaft
is turned slightly (2 - 3_) in both clockwise and
anti-clockwise direction.
Approx.
30_
NOTE
If the needle moves, the notch is not positioned properly,
so once again move the No.1 cylinder approximately 30_
Timing mark before compression top dead centre.
10. Turn the crankshaft clockwise to align the No.1 cylinder

to 10_ ATDC.
Set to 10_ 11. Check that the value indicated on the dial gauge is at
ATDC
1 ± 0.03 mm the standard value.
Standard value: 1 ± 0.03 mm
12. If the value is outside the standard value, adjust the

injection timing by the following procedure.
(1) Loosen the injection pipe union nuts (4 places) on
the injection pump. (Do not remove the union nuts.)
Caution
When loosening the nuts, hold the delivery valve
Bolts
holders with a spanner so that they don’t turn
at the same time.
(2) Loosen the upper mounting nuts and the lower
Nuts mounting bolts of the injection pump. (Do not remove
the nut and bolt.)
When the value is (3) Tilt the injection pump to the left or right and adjust
1 ± 0.03 mm or more 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.
When the value
is 1 ± 0.03 mm (7) Tighten the injection pump union nuts securely.
or less
Caution
When tightening the nuts, hold the delivery valve
holders with a spanner so that they don’t 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.
NOTE
Check that the injection timing is normal, and then perform
this check.
condition.
3. Start the engine and check that the idle speed is at the
standard value.
4. If the idle speed is not at the standard value, refer to
GROUP 13E - Troubleshooting.
1. Before inspection, check that the engine oil, starter motor

and battery are normal. In addition, set the vehicle to
the pre-inspection condition.
3. Disconnect the fuel cut solenoid valve connector.

NOTE
Doing this will prevent carrying out fuel injection.
4. Cover the glow plug hole with a shop towel etc., and
Fuel cut solenoid after the engine has been cranked, check that no foreign
valve connector
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.
5. Set compression gauge to one of the glow plug holes.
6. Crank the engine and measure the compression pressure.
Compression gauge
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.
10. Install the glow plugs and the glow plug plate.
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.
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).
1/2 the
width of
a tooth
Timing mark 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.
Width
of 2-1/2
Timing mark teeth
1/2 the
width of
a tooth
Timing mark
8. Securely tighten the timing belt tensioner mounting bolt.

9. Turn the crankshaft clockwise to align the timing mark.
Deflection
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.
Camshaft
sprocket Standard value: 4.0 - 5.0 mm
Injection 11. Install the timing belt upper cover.
pump 12. Install the glow plugs and the glow plug plate.
sprocket
ENGINE <4D6> - Crankshaft Pulley 11C-15

D Under Cover Removal D Drive Belt Tension Adjustment (Refer to P.11C-6.)
4
3
25 Nm
Removal steps
1. Drive belt (Power steering) 3. Drive belt (Alternator)
2. Drive belt (A/C) 4. Crankshaft pulley
11C-16 ENGINE <4D6> - Camshaft and Camshaft Oil Seal

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 1
5
3
19 - 21 Nm
27 - 31 Nm 27 - 31 Nm
8 7
19 - 21 Nm
7 6
Cam section 7
and journal 19 - 21 Nm
section 5
4
8
Engine oil
88 Nm
Removal steps
1. Breather hose connection "CA 5. Camshaft oil seal
2. Control harness "BA 6. Rocker arm and shaft assembly
3. Rocker cover "AA 7. Camshaft bearing cap
AA" "DA 4. Camshaft sprocket 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,
Cap No. no numbers are embossed on bearing caps 1 and 5.
"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
"CA CAMSHAFT OIL SEAL INSTALLATION
Camshaft 1. Apply a small amount of engine oil to the entire
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 as shown in the illustration.
5.5 mm
"DA CAMSHAFT SPROCKET INSTALLATION

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

D Under Cover Removal and Installation D Engine Oil Level Gauge Removal and Insertion
D Front Exhaust Pipe Removal and Installation D Engine Oil Draining and Refilling
(Refer to GROUP 15.) (Refer to GROUP 12 - On-vehicle Service.)
BOLT IDENTIFICATION
7 B 7
A
B
f4 ± 1 mm
Groove Bolt B
hole
B
B
A: 6 ´ 8 mm
Sealant: B: 6 ´ 10 mm
29 - 34 Nm 9 Nm
6 5
4
2
7 Washer assembled bolt
9 Nm
Flange bolt
39 Nm 10 Nm
1 7 Nm
Removal steps
1. Drain plug 5. Bell housing cover
"AA 2. Drain plug gasket 6. Oil level sensor
3. Oil filter AA" 7. Oil pan
4. Engine oil cooler pipe connection
ENGINE <4D6> - Oil Pan 11C-19
AA" OIL PAN REMOVAL
Caution
flange.

Oil pan side
Drain plug
gasket
11C-20 ENGINE <4D6> - Crankshaft Oil Seal

<M/T>
9
127 - 137 Nm
10
6
11
7
5 <A/T>
4
3
127 - 137 Nm
2
1
6
10 8
(Engine oil)
108 - 127 Nm
Crankshaft
Crankshaft
11 5 (Engine oil:
bolt washer (Engine oil:
surface) bolt washer
surface)
Lip section Lip section

9
Engine oil Sealant: 3M Stud Locking 4170 or equivalent
steps steps
D Timing belt (Refer to P.11C-26.) AA" D Transmission assembly
D Crank angle sensor D Clutch cover and disc <M/T>
(Refer to GROUP 16.) AB" "BA 6. Adapter plate
1. Crankshaft sprocket AB" "BA 7. Flywheel <M/T>
2. Flange AB" "BA 8. Drive plate <A/T>
3. Crankshaft sprocket B AB" "BA 9. Adapter plate <M/T>
4. Key 10. Crankshaft bushing
"CA 5. Crankshaft front oil seal "AA 11. Crankshaft rear oil seal
ENGINE <4D6> - Crankshaft Oil Seal 11C-21
<M/T> REMOVAL SERVICE POINT
<M/T>:
Refer to GROUP 22.
Flywheel
Caution
<A/T>:
Refer to GROUP 23.
AB" ADAPTER PLATE/FLYWHEEL <M/T>/DRIVE
PLATE <A/T> REMOVAL
MD998781

Crankshaft
rear oil seal "AA CRANKSHAFT REAR OIL SEAL INSTALLATION
Crankshaft
MD998776

PLATE INSTALLATION
plate bolts.
11C-22 ENGINE <4D6> - Crankshaft Oil Seal
Oil seal "CA CRANKSHAFT FRONT OIL SEAL INSTALLATION

Crankshaft Front
lower 1. Apply a small amount of engine oil to the entire
case circumference of the oil seal lip.
2. Tap the oil seal unit it is flush with the oil seal case.
MD998382 MD998383
ENGINE <4D6> - Cylinder Head Gasket 11C-23

D Engine Coolant Draining and Refilling D Timing Belt Removal and Installation
(Refer to GROUP 14 - On-vehicle Service.) (Refer to P.11C-26.)
D Air Pipe A Removal and Installation D Thermostat Case Assembly Removal and Installation
(Refer to GROUP 15 - Intercooler.) (Refer to GROUP 14 - Water Hoses and Pipes.)
D Vacuum Pump Removal and Installation
6 Nm
3 1
2
16
27 - 31 Nm
O-ring
27 - 31 Nm
19 - 21 Nm 27 - 31 Nm
Engine oil 7
12 - 15 Nm 13 Nm
5
16
9
18
10 6
88 Nm ® 0 Nm ® 39 Nm ® + 90_ ® + 90_
12 11
19
8
15
4
9 Nm
14
20 29 Nm
44 Nm
17
13
24 Nm 10 - 12 Nm
Removal steps
1. Breather hose connection 12. Brake booster vacuum hose
2. Control harness connection
3. Rocker cover 13. Timing belt rear centre cover
AA" "DA 4. Fuel injection pipe 14. Front exhaust pipe connection
5. Camshaft bearing cap 15. Oil return pipe connection
6. Glow plug plate 16. Oil level gauge guide assembly
"CA 7. Rocker arm and shaft assembly 17. Alternator brace
8. Fuel return hose connection AB" "BA 18. Cylinder head bolt
9. Water temperature sensor connector 19. Cylinder head assembly
10. Vacuum air temperature sensor "AA 20. Cylinder head gasket
connector
11. Engine coolant temperature gauge
unit connector
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
AB" CYLINDER HEAD BOLT REMOVAL
Front of engine
assembly.
3 5 10 8 2
1 7 9 6 4
Exhaust side

surface.
Identification mark 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 holes

Head bolt
washer oil)
head side caused by tapping out facing upwards.
ENGINE <4D6> - Cylinder Head Gasket 11C-25
Intake side
4. Tighten the bolts by the following procedure.
Front of engine
Step Operation Remarks
8 6 1 3 9 shown in the illustration.
2 Fully loosen. Carry out in the reverse
order of that shown in the
10 4 2 5 7 illustration.
Exhaust side shown in the illustration.
illustration. Mark the head
Step 4 Step 5 of the cylinder head bolt
and cylinder head by paint.
90_ 90_
illustration. Check that the
painted mark of the head
bolt is lined up with that of
the cylinder head.
Painted mark 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.)
Indent
Bearing cap
Fuel injection pipe "DA FUEL INJECTION PIPE INSTALLATION

When tightening the nuts at both ends of the fuel injection
Nut pipe, hold the delivery holder (for pump side) and the fuel
injection nozzle assembly (for nozzle side) with a wrench,
Nozzle holder
and tighten the nuts to the specified torque.
11C-26 ENGINE <4D6> - Timing Belt

D Crankshaft Pulley Removal and Installation
(Refer to P.11C-15.)
10 - 12 Nm 3
7
9 Nm
10 - 12 Nm
1
19 Nm
25 Nm
10 - 12 Nm
4
10 - 12 Nm 6
2
9 Nm
10 - 12 Nm
23 Nm
Removal steps
1. Water pump pulley 5. Timing belt front lower cover
2. A/C tension pulley assembly 6. Injection pump bracket stay
AA" 3. Timing belt front upper cover "BA D Timing belt tension adjustment
4. Timing belt front centre cover AB" "AA 7. Timing belt
ENGINE <4D6> - 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
AB" TIMING BELT REMOVAL

Timing marks
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 doesn’t 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 ENGINE <4D6> - Timing Belt
Timing marks INSTALLATION SERVICE POINTS

Injection
"AA TIMING BELT INSTALLATION
pump 1. Ensure that the timing marks of the camshaft sprocket,
sprocket the injection pump sprocket, the crankshaft sprocket, and
Camshaft sprocket the oil pump sprocket are all aligned.
Timing mark Timing mark
Oil pump
sprocket
Crankshaft
sprocket
Move to the 2. Move the timing belt tensioner downward and loosely
bottom of the slot. tighten the bolt so that the tensioner doesn’t 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.
3. In addition, turn the crankshaft anti-clockwise by a distance

equivalent to 2-1/2 teeth.
Timing mark 4. Tighten the timing belt tensioner to the specified torque.
2-1/2 teeth
5. Turn the crankshaft clockwise and align the timing mark.
Timing mark
ENGINE <4D6> - Timing Belt 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 Injection Standard value: 4 - 5 mm
sprocket pump
sprocket
11C-30 ENGINE <4D6> - Timing Belt B
TIMING BELT B 11200460113

D Crankshaft Pulley Removal and Installation D Timing Belt Removal and Installation
(Refer to P.11C-15.) (Refer to P.11C-26.)
1
48 Nm
4
19 Nm
108 - 127 Nm 5
3
2
(Engine oil)
Removal steps
1. Idler pulley 4. Timing belt tensioner
AA" "BA 2. Crankshaft sprocket AB" "AA 5. Timing belt B
3. Flange
Crankshaft REMOVAL SERVICE POINTS

sprocket MB991385 AA" CRANKSHAFT SPROCKET REMOVAL
MB991367
ENGINE <4D6> - Timing Belt B 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 INSTALLATION SERVICE POINTS

Belt tension side "AA TIMING BELT B INSTALLATION
Crankshaft 1. Install the timing belt “B” by the following procedure.
sprocket B
(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
Timing mark
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
Centre of
the centre of the tensioner pulley is to the left and
tensioner above the centre of the installation bolt, and
pulley 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.
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
Shaft
tension of the belt.
(3) Check to ensure that when centre of span on tension

side is depressed with index finger in direction of
Centre arrow, tension of belt is up to specification.
of pulley
Centre of installation bolt

11C-32 ENGINE <4D6> - Timing Belt B
"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
ENGINE <4D6> - Engine Assembly 11C-33

D Hood Removal (Refer to GROUP 42.) D Front Exhaust Pipe Installation
D Air Cleaner Assembly Removal (Refer to GROUP 15.)
D Engine Coolant Draining D Under Cover Installation
D Radiator Assembly Removal (Refer to GROUP 14.) D Radiator Assembly Installation
D Under Cover Removal (Refer to GROUP 14.)
D Front Exhaust Pipe Removal (Refer to GROUP 15.) D Engine Coolant Supplying
D Accelerator Cable Adjustment
(Refer to GROUP 17 - On-vehicle Service.)
D Air Cleaner Assembly Installation
D Hood Installation (Refer to GROUP 42.)
1
2
7
3
12 13
10 11
17
5 9
14
6
15
16
Removal steps
1. Vacuum hose connection 10. Pump revolution sensor connector
2. Vacuum air temperature sensor con- 11. Timing control valve connector
nector 12. Solenoid-type spill valve connector
3. Brake booster vacuum hose connec- 13. Fuel cut solenoid valve connector
tion 14. Injection rate correction resistor con-
4. Alternator connector nector
5. Oil pressure switch connector 15. Injection timing correction resistor con-
6. Engine oil level sensor connector nector
7. Glow plug connector 16. Crank angle sensor connector
8. Engine coolant temperature sensor 17. Fuel temperature sensor connector
connector
9. Engine coolant temperature gauge
unit connector
11C-34 ENGINE <4D6> - Engine Assembly
18
25
29
19 22 Nm
21
20
39 Nm
29 - 34 Nm 22
24 23
12 Nm
26
57 Nm*
27
28
28
98 Nm
18. Heater hose connection AC" D Transmission assembly

19. Drive belt (Power steering) AD" "CA 27. Engine mount bracket
20. Drive belt (A/C) "BA 28. Engine mount stopper
21. Oil pump brace AE" "AA 29. Engine assembly
AA" 22. Power steering oil pump and bracket
assembly Caution
AB" 23. A/C compressor Mounting locations marked by * should be
24. Engine oil cooler pipe connection provisionally tightened, and then fully tightened
25. Fuel hose connection after placing the vehicle horizontally and loading
26. Clamp bolt (Power steering hose and the full weight of the engine on the vehicle
pipe) body.
ENGINE <4D6> - Engine Assembly 11C-35
ASSEMBLY REMOVAL
NOTE

attached.
NOTE
<M/T> AC" TRANSMISSION ASSEMBLY REMOVAL

<M/T>:
Refer to GROUP 22.
Caution
Bolt
<A/T>:
Refer to GROUP 23.

tool.
mount bracket.

compartment.
11C-36 ENGINE <4D6> - Engine Assembly

Engine side
"BA ENGINE MOUNT STOPPER INSTALLATION
Dynamic damper
Arrow
Engine
mount
stopper

12-1
ENGINE
LUBRICATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Engine Oil Replacement . . . . . . . . . . . . . . . . . . . . . . 3

Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil Level Warning System Check . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE OIL COOLER
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3 <6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 <4D6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
12-2 ENGINE LUBRICATION - General Information
The lubrication method is a fully force-fed, full-flow via the timing belt.
filtration type. The oil pump for 6A1 engines is a Furthermore, the oil level sensor is located in the
trochoid type which is directly mounted to the oil pan, and a system is equipped whereby an
crankshaft, and the one for 4G6 and 4D6 engines indicator gives a warning when the oil level drops.
is a gear type which is driven by the crankshaft
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil harmful contaminants which may cause skin cancer.
will result in the removal of natural fats from the Adequate means of skin protection and washing
skin, leading to dryness, irritation and dermatitis. facilities must be provided.
In addition, used engine oil contains potentially
Recommended Precautions
The most effective precaution is to adapt working D Where there is a risk of eye contact, eye
practices which prevent, as far as practicable, the protection should be worn, for example,
risk of skin contact with mineral oils, for example chemical goggles or face shields; in addition
by using enclosed systems for handling used engine an eye wash facility should be provided.
oil and by degreasing components, where D Obtain First Aid treatment immediately for open
practicable, before handling them. cuts and wounds.
Other precautions: D Wash regularly with soap and water to ensure
D Avoid prolonged and repeated contact with oils, all oil is removed, especially before meals (skin
particularly used engine oils. cleansers and nail brushes will help). After
D Wear protective clothing, including impervious cleaning, the application of preparations
gloves where practicable. containing lanolin to replace the natural skin
D Avoid contaminating clothes, particularly oils is advised.
underpants, with oil. D Do not use petrol, kerosine, diesel fuel, gas
D Do not put oily rags in pockets, the use of oil, thinners or solvents for cleaning skin.
overalls without pockets will avoid this. D Use barrier creams, applying them before each
D Do not wear heavily soiled clothing and work period, to help the removal of oil from
oil-impregnated foot-wear. Overalls must be the skin after work.
cleaned regularly and kept separate from D If skin disorders develop, obtain medical advice
personal clothing. without delay.
ENGINE LUBRICATION - Lubricants/Special Tools/On-vehicle Service 12-3
LUBRICANTS 12100040151
Items 4G6 6A1 4D6
Engine oil (API classification) SG or higher SG or higher CD or higher
Engine oil quantity L Oil filter 0.3 0.3 0.8
Oil cooler - 0.1 0.3
Total 4.3 4.3 5.1

MB991396 Oil filter wrench Removal and installation of engine oil filter
(When using the oil filter of MD135737)
<4G6>
MB991610 Oil filter wrench Removal and installation of engine oil filter
(When using the oil filter of MD136466)
<6A1>
ENGINE OIL CHECK

1. Pull out the level gauge slowly and check that the oil
level is in the illustrated range.
2. Check that the oil is not excessively dirty, that there is
no coolant or gasoline mixed in, and that it has sufficient
viscosity.
ENGINE OIL REPLACEMENT 12100100163
1. Start the engine and allow it to warm up until the

temperature of the coolant reaches 80_C to 90_C.
2. Remove the engine oil filler cap.
3. Remove the drain plug to drain oil.
Caution
Use care as oil could be hot.
4. Install a new drain plug gasket so that it faces in the

direction shown in the illustration, and then tighten the
Drain plug gasket drain plug to the specified torque.
NOTE
Oil Install the drain plug gasket so it faces in the direction
pan
side shown in the illustration.
39 Nm
Drain plug
12-4 ENGINE LUBRICATION - On-vehicle Service
<Petrol-powered vehicles> 5. Refill with specified quantity of oil.

Barometric temperature Specified Engine Oil (API classification):
<4G6, 6A1> SG or higher
<4D6> CD or higher
Total quantity (Includes volume inside oil filter and
oil cooler):
<4G6, 6A1> 4.3 L
<4D6> 5.1 L
6. Install the engine oil filler cap.
7. Check oil level.
<Diesel-powered vehicles>
Barometric temperature
OIL FILTER REPLACEMENT 12100110159
MB991396, 1. Start the engine and allow it to warm up until the

MB991610 temperature of the coolant reaches 80_C to 90_C.
or commer- 2. Remove the engine oil filler cap.
cially-avail- 3. Remove the drain plug to drain oil.
able tool
Caution
Use care as oil could be hot.
4. Use the respective tool in the following table to remove
the engine oil filter.
Caution
For vehicles with 6A1 engine, the oil which is still
inside the oil filter may overflow from the oil guide
groove and get onto the starter motor. To prevent
this, the oil inside the filter should be gradually
removed while removing the oil filter.
5. Clean the filter bracket side mounting surface.
6. Apply a small amount of engine oil to the O-ring of the

new oil filter.
7. Once the O-ring of the oil filter is touching the flange,
use the respective tool in the following table to tighten
to the specified torque.
8. Install the drain plug and refill engine oil. (Refer to Engine
Oil Replacement on P.12-3.)
9. Race the engine 2 - 3 times, and check to be sure that
O-ring no engine oil leaks from installation section of the oil
filter.
ENGINE LUBRICATION - On-vehicle Service 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)
OIL LEVEL WARNING SYSTEM CHECK 12100200047

Engine oil level relay
1. Check that the proper amount of oil has been filled.
2. When the ignition switch is turned to ON (do not start
the engine), check that the oil level warning lamp
illuminates.
NOTE
If the oil level warning lamp does not illuminate, the cause
is probably a blown lamp, or a malfunction in the relay.
3. When the engine is started, check that the oil level warning
Engine oil level sensor
connector (Harness side) 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 ENGINE LUBRICATION - On-vehicle Service
5. Check the continuity between the oil level sensor

Engine oil level sensor terminals.
connector (Equipment side)
Engine oil temper- Oil level Continuity
ature
At 50_C or lower Normal Continuity

(proper volume)
Low (drained) Continuity
At 60_C or higher Normal Continuity

(proper volume)
Low (drained) No continuity
6. If there is a defect, replace the oil level sensor.
9 Nm
Engine oil level sensor
Oil pan
ENGINE LUBRICATION - Engine Oil Cooler <6A1> 12-7
ENGINE OIL COOLER <6A1> 12100130155

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

"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 12100140110
D Check the water hoses for crack, damage, clogging or

deterioration.
D 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 Air Guide Panel Removal and Installation
D Front Bumper Removal and Installation
2
29 - 34 Nm
39 - 44 Nm
3 1
12 Nm
1 5 Nm
39 - 44 Nm
5 Nm
5 Nm
5
7
4
39 - 44 Nm 6
Removal steps
1. Hose assembly and joint connec- 4. Return hose assembly
tion 5. Feed hose assembly
2. Engine oil cooler "AA 6. Return tube assembly
3. Joint 7. 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> 12-9
D Check for foreign material between oil cooler fins.

D Check the oil cooler fins for bend or damage.
D Check the oil cooler hoses for crack, damage, clogging
or deterioration.
D Check the eye bolts for clogging or deformation.
NOTES
13A-1
FUEL
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
13A-2
MULTIPOINT FUEL
INJECTION (MPI)
MULTIPOINT FUEL INJECTION <4G6> Idle Speed Control (ISC) Servo (Stepper
Motor) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
GENERAL INFORMATION . . . . . . . . . . . . . . . . 4 Purge Control Solenoid Valve Check . . . . . . . 95
EGR Control Solenoid Valve Check . . . . . . . . 95
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 7
INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . 98
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 9 MULTIPOINT FUEL INJECTION <6A1>
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 81 GENERAL INFORMATION . . . . . . . . . . . . . 102
Throttle Body (Throttle Valve Area) SERVICE SPECIFICATIONS . . . . . . . . . . . 106
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Idle Position Switch and Throttle Position SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . 81
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . 107
Fixed SAS Adjustment . . . . . . . . . . . . . . . . . . . . 83
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 Throttle Body (Throttle Valve Area) Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Fuel Pump Operation Check . . . . . . . . . . . . . . 88
Idle Position Switch and Throttle Position
Component Location . . . . . . . . . . . . . . . . . . . . . . 89 Sensor Adjustment <Vehicles without TCL>
Control Relay and Fuel Pump Relay Continuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Throttle Position Sensor Adjustment
Intake Air Temperature Sensor Check . . . . . . 90 <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 186
Engine Coolant Temperature Sensor Idle Position Switch and Accelerator Pedal
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Position Sensor Adjustment
<Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 186
Throttle Position Sensor Check . . . . . . . . . . . . 91
Fixed SAS Adjustment . . . . . . . . . . . . . . . . . . . 187
Idle Position Switch Check . . . . . . . . . . . . . . . . 91
Basic Idle Speed Adjustment . . . . . . . . . . . . . 188
Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . . 92
CONTINUED ON NEXT PAGE
Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
13A-3
Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . 189 Purge Control Solenoid Valve Check . . . . . . 200
Fuel Pump Connector Disconnection (How to EGR Control Solenoid Valve Check . . . . . . . 200
Reduce the Fuel Pressure) . . . . . . . . . . . . . . 191 Ventilation Control Solenoid Valve Check
Fuel Pump Operation Check . . . . . . . . . . . . . 191 <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 201
Component Location . . . . . . . . . . . . . . . . . . . . . 192 Vacuum Control Solenoid Valve Check
Control Relay and Fuel Pump Relay Continuity
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Vacuum Tank Check
Intake Air Temperature Sensor Check . . . . . 193
Vacuum Actuator Check
Engine Coolant Temperature Sensor Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Throttle Valve Operation Check
Throttle Position Sensor Check . . . . . . . . . . . 194
Accelerator Pedal Position Sensor Check
Negative Pressure Check during Traction
Control Operation <Vehicles with TCL> . . . 203
Idle Position Switch Check
Power Steering Air Control Valve Operation
<Vehicles without TCL> . . . . . . . . . . . . . . . . . . 195
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Idle Position Switch Check
<Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 195 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 activities such as fuel injection control, idle
of sensors which detect the engine conditions, speed control and ignition timing control. In
the engine-ECU which controls the system addition, the engine-ECU is equipped with
based on signals from these sensors, and several diagnosis modes which simplify
actuators which operate under the control of troubleshooting when a problem develops.
the engine-ECU. The engine-ECU carries out
FUEL INJECTION CONTROL

The injector drive times and injector timing are The engine-ECU provides a richer air/fuel
controlled so that the optimum air/fuel mixture mixture by carrying out “open-loop” control
is supplied to the engine to correspond to the when the engine is cold or operating under
continually-changing engine operation condi- high load conditions in order to maintain engine
tions. performance. In addition, when the engine is
A single injector is mounted at the intake port warm or operating under normal conditions,
of each cylinder. Fuel is sent under pressure the engine-ECU controls the air/fuel mixture
from the fuel tank by the fuel pump, with the by using the oxygen sensor signal to carry out
pressure being regulated by the fuel pressure “closed-loop” control in order to obtain the
regulator. The fuel thus regulated is distributed theoretical air/fuel mixture ratio that provides
to each of the injectors. the maximum cleaning performance from the
Fuel injection is normally carried out once for three way catalyst.
each cylinder for every two rotations of the
crankshaft. The firing order is 1-3-4-2. This is
called sequential fuel injection.
IDLE AIR CONTROL

The idle speed is kept at the optimum speed conditioner load. In addition, when the air
by controlling the amount of air that bypasses conditioner switch is turned off and on while
the throttle valve in accordance with changes the engine is idling, the ISC motor operates
in idling conditions and engine load during to adjust the throttle valve bypass air amount
idling. The engine-ECU drives the idle speed in accordance with the engine load conditions
control (ISC) motor to keep the engine running in order to avoid fluctuations in the engine
at the pre-set idle target speed in accordance speed.
with the engine coolant temperature and air
IGNITION TIMING CONTROL

The power transistor located in the ignition engine operating conditions. The ignition timing
primary circuit turns ON and OFF to control is determined by the engine-ECU from the
the primary current flow to the ignition coil. This engine speed, intake air volume, engine coolant
controls the ignition timing in order to provide temperature and atmospheric pressure.
the optimum ignition timing with respect to the
SELF-DIAGNOSIS FUNCTION
D When an abnormality is detected in one code corresponding to the abnormality is
of the sensors or actuators related to output.
emission control, the engine warning lamp D The RAM data inside the engine-ECU that
(check engine lamp) illuminates as a is related to the sensors and actuators can
warning to the driver. be read by means of the MUT-II. In addition,
D When an abnormality is detected in one the actuators can be force-driven under
of the sensors or actuators, a diagnosis certain circumstances.
MPI <4G6> - General Information 13A-5
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control condenser fan are controlled in response
Turns the fuel pump relay ON so that current to the engine coolant temperature and
is supplied to the fuel pump while the engine vehicle speed.
is cranking or running. 4. Purge Control Solenoid Valve Control
2. A/C Relay Control Refer to GROUP 17.
Turns the compressor clutch of the A/C 5. EGR Control Solenoid Valve Control
ON and OFF. Refer to GROUP 17.
3. Fan Relay Control
The revolutions of the radiator fan and
GENERAL SPECIFICATIONS
Items Specifications
Throttle body Throttle bore mm 54
Throttle position sensor Variable resistor type
Idle speed control servo Stepper motor type

(Stepper motor 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
Engine coolant temperature sensor Thermistor type
Oxygen sensor Zirconia type
Vehicle speed sensor Magnetic resistive element type
Inhibitor switch Contact switch type
Camshaft position sensor Hall element type
Crank angle sensor Hall element type
Detonation sensor Piezoelectric type
Power steering fluid pressure switch Contact switch type
Actuators Control relay type Contact switch type
Fuel pump relay type Contact switch type
Injector type and number Electromagnetic type, 4
Injector identification mark CDH275
EGR control solenoid valve Duty cycle type solenoid valve
Purge control solenoid valve ON/OFF type solenoid valve
Fuel pressure Regulator pressure kPa 329

regulator
13A-6 MPI <4G6> - General Information
MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM

*1 Oxygen sensor (front) Engine-ECU z1 Injector
*2 Air flow sensor z2 Purge control solenoid valve
*3 Intake air temperature sensor z3 Idle speed control servo
*4 Throttle position sensor z4 EGR control solenoid valve
*5 Idle position switch
*6 Camshaft position sensor D Fuel pump relay
*7 Crank angle sensor D Control relay
*8 Barometric pressure sensor D A/C power relay
*9 Engine coolant temperature sensor D Engine warning lamp
*10 Detonation sensor D Diagnosis signal
*11 Oxygen sensor (rear) D Ignition coil, power transistor
D Fan controller
D Power supply voltage D Alternator G terminal
D Vehicle speed sensor D A/T-ECU
D A/C switch 1, 2
D Inhibitor switch
D Power steering fluid pressure switch
D Ignition switch - ST
D Ignition switch - IG
D Alternator FR terminal
D A/T-ECU
*3 Intake air
temperature
sensor
z3 Idle speed Air flow sensor (with
control servo barometric pressure sensor)
*6 Camshaft position sensor Air cleaner

Air
*4, *5
Fuel pressure
regulator
*8 *2
From fuel
To fuel pump EGR Throttle position sensor
tank control (with idle position switch)
solenoid
EGR valve valve
PCV valve z1 Injector Canister
*9 Engine coolant z4 z2
temperature sensor
Purge control
solenoid valve
*10 Detonation sensor
*1 Oxygen sensor
Catalytic converter
*7 Crank angle sensor
MPI <4G6> - Service Specifications/Sealant 13A-7
Basic idle speed r/min 750±50
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)
Intake air temperature sensor 20_C 2.3 - 3.0

resistance kW
80_C 0.30 - 0.42
Engine coolant temperature 20_C 2.1 - 2.7

sensor resistance kW
80_C 0.26 - 0.36
Oxygen sensor output voltage V 0.6 - 1.0
Fuel pressure kPa 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
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent Drying sealant
threaded portion
13A-8 MPI <4G6> - Special Tools
A MB991223 Harness set D Fuel gauge simple inspection

A: MB991219 A: Test harness A: Connector pin contact pressure inspection
B: MB991220 B: LED harness B: Power circuit inspection
C: Power circuit inspection
C: MB991221 C: LED harness D: Commercial tester connection
D: MB991222 adapter
D: Probe
B
MB991502 MUT-II sub D Reading diagnosis code

assembly D MPI system inspection
MB991348 Test harness set D Measurement of voltage during trouble-

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

connector troubleshooting
MD998463 Test harness D Inspection of idle speed control servo

(6-pin, square) D Inspection using an analyzer
MD998478 Test harness D Measurement of voltage during trouble-

(3-pin, triangle) shooting
MPI <4G6> - Special Tools/Troubleshooting 13A-9

MD998709 Adaptor hose Measurement of fuel pressure
MD998742 Hose adaptor
MD998706 Injector test set Checking the spray condition of injectors
MB991607 Injector test

harness
MD998741 Injector test

adaptor
MB991608 Clip
TROUBLESHOOTING 13100850256
DIAGNOSIS TROUBLESHOOTING FLOW

Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.
DIAGNOSIS FUNCTION 13100860358
ENGINE WARNING LAMP (CHECK ENGINE LAMP)

If an abnormality occurs in any of the following items related
to the Multipoint Fuel Injection (MPI) system, the engine
warning lamp will illuminate.
If the lamp remains illuminated or if the lamp illuminates while
the engine is running, check the diagnosis code output.
Engine warning lamp

(check engine lamp)
13A-10 MPI <4G6> - Troubleshooting
Engine warning lamp inspection items

Engine-ECU
Oxygen sensor
Air flow sensor
Intake air temperature sensor
Throttle position sensor
Engine coolant temperature sensor
Crank angle sensor
Camshaft position sensor
Barometric pressure sensor
Detonation sensor
Injector
Ignition coil, power transister
Immobilizer system
METHOD OF READING AND ERASING DIAGNOSIS

CODES
Service Points.
INSPECTION USING MUT-II DATA LIST AND
ACTUATOR TESTING
1. Carry out inspection by means of the data list and the
actuator test function.
If there is an abnormality, check and repair the chassis
harnesses and components.
2. After repairing, re-check using the MUT-II and check that
the abnormal input and output have returned to normal
as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II.
5. Start the engine again and carry out a road test to confirm
that the problem has disappeared.
MPI <4G6> - Troubleshooting 13A-11
FAIL-SAFE FUNCTION REFERENCE TABLE 13100910299
When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled
by means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning item Control contents during malfunction
Air flow sensor 1. Uses the throttle position sensor signal and engine speed signal (crank angle sensor
signal) to take reading of the basic injector drive time and basic ignition timing from
the pre-set mapping.
2. Fixes the ISC servo in the appointed position so idle control is not performed.
Intake air temperature Controls as if the intake air temperature is 25_C.

sensor
Throttle position No increase in fuel injection amount during acceleration due to the throttle position sensor
sensor (TPS) signal.
Engine coolant Controls as if the engine coolant temperature is 80_C.

temperature sensor
Camshaft position Injects fuel to all cylinders simultaneously.

sensor (However, after the ignition switch is turned to ON, the No. 1 cylinder top dead centre is not
detected at all.)
Barometric pressure Controls as if the barometric pressure is 101 kPa.

sensor
Detonation sensor Switches the ignition timing from ignition timing for super petrol to ignition timing for standard
petrol.
Ignition coil, power Cuts off the fuel supply to cylinders with an abnormal ignition.
transistor
Oxygen sensor Air/fuel ratio feedback control (closed loop control) is not performed.
Communication wire Ignition timing is not retarded during transmission gear shifting (overall engine and
with transmission transmission control).
control unit <A/T>
Alternator FR terminal Does not control the output of the alternator according to an electrical load. (works as a
normal alternator)
INSPECTION CHART FOR DIAGNOSIS CODES 13100870375
Code No. Diagnosis item Reference page
11 Oxygen sensor (front) system 13A-13
12 Air flow sensor system 13A-14
13 Intake air temperature sensor system 13A-14
14 Throttle position sensor system 13A-15
21 Engine coolant temperature sensor system 13A-16
22 Crank angle sensor system 13A-17
23 Camshaft position sensor 13A-18
24 Vehicle speed sensor system 13A-19
25 Barometric pressure sensor system 13A-20
31 Detonation sensor system 13A-21
41 Injector system 13A-21
44 Ignition coil system 13A-22
54 Immobilizer system 13A-23
59 Oxygen sensor (rear) system 13A-24
61 Communication wire with A/T-ECU system <A/T> 13A-25
64 Alternator FR terminal system 13A-25

INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No. 11 Oxygen sensor (front) system Probable cause
Range of Check D Malfunction of the oxygen sensor (front)
D 3 minutes have passed after engine was started. D Improper connector contact, open circuit or
D Engine coolant temperature is approx. 80_C or more. short-circuited harness wire
D Intake air temperature is 20 - 50_C. D Malfunction of the engine-ECU
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.
NG
Check the oxygen sensor (front). (Refer to P.13A-92.) Replace
OK
1. NG
Measure at the oxygen sensor (front) connector C-46. Check the harness wire between the
D Disconnect the connector, and measure at the oxygen sensor (front) and the control
harness side. relay connector, and repair if necessary.
1. Voltage between 3 and earth (Ignition switch: ON)
2. NG NG
OK: System voltage Check the following connector: Repair
2. Continuity between 2 and earth C-40
OK: Continuity
OK
OK
NG
NG
Check the harness wire between the Repair
engine-ECU and the oxygen sensor
(front) connector.
OK
Replace the engine-ECU.

Measure at the engine-ECU connector C-38.
D Disconnect the connector, and measure at the
NG NG
harness side. Check the following connector: Repair
D Voltage between 60 and earth (Ignition switch: ON) C-46
OK: System voltage
OK
OK
NG Check trouble symptom.
Check the following connectors: Repair
C-46, C-38 NG
OK Check the harness wire between the
Check trouble symptom. (front) connector, and repair if neces-
NG sary.
NG
Check the harness wire between the engine-ECU and Repair
the oxygen sensor (front) connector.
OK

Code No. 12 Air flow sensor system Probable cause

Range of Check D Malfunction of the air flow sensor
D Engine speed is 500 r/min or more. D Improper connector contact, open circuit or
Set conditions short-circuited harness wire of the air flow sensor
D Sensor output frequency is 3 Hz or less for 4 seconds. D Malfunction of the engine-ECU
1. NG
Measure at the air flow sensor con- Check 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
2. NG NG NG
(Engine: Idling) Measure at the engine-ECU con- Check the following connector: Repair
OK: 2.2 - 3.2 V nector C-34. B-12
2. Voltage between 7 and earth D Connect the connector.
OK: 0 - 1 V (Engine: idling) OK
D Voltage between 19 and earth
6 - 9 V (2,000 r/min) (Ignition switch: ON)
OK OK: 6 - 9 V
NG
OK
NG
Check the following connector: Repair
C-34
Replace the air flow sensor.
OK

NG
Code No. 13 Intake air temperature sensor system Probable cause

Range of Check D Malfunction of the intake air temperature sensor
D Ignition switch: ON D Improper connector contact, open circuit or
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the intake air
after the engine starts. temperature sensor circuit
Set conditions D Malfunction of the engine-ECU
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.
NG
Check the intake air temperature Replace
sensor. (Refer to P.13A-90.)
OK
NG NG
Measure at the air flow sensor con- Check the following connector: Repair
nector B-12. C-40
D Disconnect the connector, and OK
measure at the harness side.
D Voltage between 6 and earth Check trouble symptom.
(Ignition switch: ON)
OK: 4.5 - 4.9 V NG
D Continuity between 5 and earth NG
OK: Continuity Check the harness wire between Repair
the engine-ECU and the intake air
OK temperature sensor connector.
NG
Check the following connector: Repair OK
B-12
OK
NG
Check trouble symptom. Replace the engine-ECU.
Code No. 14 Throttle position sensor system Probable cause
Range of Check D Malfunction of the throttle position sensor or
D Ignition switch: ON maladjustment
D Excluding 60 seconds after the ignition switch is turned to ON or immediately D Improper connector contact, open circuit or
after the engine starts. short-circuited harness wire of the throttle position
Set conditions sensor circuit
D When the idle position switch is ON, the sensor output voltage is 2 V or more D Improper “ON” state of idle position switch
for 4 seconds. D Short circuit of the idle position switch signal line
or D Malfunction of the engine-ECU
D The sensor output voltage is 0.2 V or less for 4 seconds.
NG
MUT-II Data list Check the idle position switch system.
26 Idle position switch system (Refer to P.13A-46, INSPECTION
OK: With the throttle valve at the PROCEDURE 28.)
idle position: ON
With the throttle valve slight-
ly open: OFF
OK
NG
Check the throttle position sensor. Replace
(Refer to P.13A-91.)
OK
NG NG
Measure at the throttle position sensor Check the following connector: Repair
connector B-07. C-40
D Disconnect the connector, and
OK
OK: 4.8 - 5.2 V NG
OK: Continuity Check the harness wire between the Repair
engine-ECU and the throttle position
OK sensor connector.
Check the throttle position sensor out- OK
put circuit. (Refer to P.13A-60, IN-
SPECTION PROCEDURE 49.) Replace the engine-ECU.
Code No. 21 Engine coolant temperature sensor system Probable cause

Range of Check D Malfunction of the engine coolant temperature sensor
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the engine coolant
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.
Range of Check
D Ignition switch: ON
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.
NG
Check the engine coolant temperature Replace
OK
NG NG
Measure at the engine coolant temper- Check the following connector: Repair
ature sensor connector B-33. C-40
OK: 4.5 - 4.9 V NG
engine-ECU and the engine coolant
OK
OK
Check the following connector: Check trouble symptom.
B-33
NG
NG
Repair
Code No. 22 Crank angle sensor system Probable cause
Range of Check D Malfunction of the crank angle sensor
D Engine is cranking. D Improper connector contact, open circuit or
Set conditions short-circuited harness wire of the crank angle sensor
D Sensor output voltage does not change for 4 seconds (no pulse signal input.) D Malfunction of the engine-ECU
OK
Measure at the crank angle sensor connector B-77. Replace the engine-ECU.
D Connect the connector. (Use the test harness: MD998478.)
D Voltage between 2 and earth (Engine: cranking)
OK: 0.4 - 4.0 V
D Voltage between 2 and earth (Engine: idling)
OK: 1.5 - 2.5 V
NG
1. NG
Measure at the crank angle sensor connector B-77. Check the harness wire between the crank angle sensor and the
D Disconnect the connector, and measure at the harness side. control relay connector, and repair if necessary.
2. NG NG
OK: System voltage Check the following con- Repair
2. Voltage between 2 and earth (Ignition switch: ON) nector: C-40
OK: 4.8 - 5.2 V
3. Continuity between 1 and earth 3. NG OK
OK: Continuity
OK
NG NG
Check the following con- Repair NG
nector: B-77 Check the harness wire Repair
between the engine-ECU and
OK the crank angle sensor
connector.
OK
NG
Replace the crank angle sensor.
Check the harness wire between the crank angle sensor and the
earth, and repair if necessary.
Code No. 23 Camshaft position sensor system Probable cause

Range of Check D Malfunction of the camshaft position sensor
D Engine speed is approx. 50 r/min or more. short-circuited harness wire of the camshaft position
OK
Measure at the camshaft position sensor connector B-64. Replace the engine-ECU.
D Connect the connector. (Use the test harness: MB991223 and
jumper wire.)
OK: 0.4 - 3.0 V
OK: 1.5 - 2.0 V
NG
1. NG
Measure at the camshaft position sensor connector B-64. Check the harness wire between the camshaft position sensor
D Disconnect the connector, and measure at the harness side. and the control relay connector, and repair if necessary.
2. NG NG
OK: 4.8 - 5.2 V
OK: Continuity
OK
NG NG
OK the camshaft position sensor
connector.
OK
NG
Replace the camshaft position sensor.
Check the harness wire between the camshaft position sensor

and the earth, and repair if necessary.
Code No. 24 Vehicles speed sensor system Probable cause
Range of check D Malfunction of the vehicle speed sensor
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the vehicle speed
after the engine starts. sensor circuit
D Idle position switch: OFF D Malfunction of the engine-ECU
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).
NG
Check the vehicle speed sensor. (Refer to GROUP 54 - Combina- Replace
tion Meters.)
OK
1. NG NG
Measure at the vehicle speed sensor connector B-66 <M/T>, Check the following Repair
B-67 <A/T>. connectors:
D Disconnect the connector, and measure at the harness B-65 <M/T>, C-90, C-135,
side. 2. NG C-131
1. Voltage between 1 and earth (Ignition switch: ON) OK
OK: System voltage
2. Voltage between 3 and earth (Ignition switch: ON) Check trouble symptom.
OK: 4.8 - 5.2 V
3. Continuity between 2 and earth 3. NG NG
OK: Continuity NG
OK Check the harness wire Repair
NG between the vehicle
Check the following Repair speed sensor and ignition
connectors: switch connector.
B-66 <M/T>, B-67 <A/T>,
C-40 OK
OK Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.)
Check trouble symptom. NG
Check the following Repair
NG
connectors:
NG B-65 <M/T>, C-48, C-40
Check the harness wire Repair
between the engine-ECU OK
and the vehicle speed
sensor connector. Check trouble symptom.
OK NG
NG
Replace the engine-ECU. Check the harness wire Repair
between the engine-ECU
sensor connector.
OK
NG
connector:
B-65 <M/T>
OK

OK
Check the harness wire between the vehicle speed sensor and
the earth, and repair if necessary.
Code No. 25 Barometric pressure sensor system Probable cause

Range of Check D Malfunction of the barometric pressure sensor
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the barometric pressure
D Battery voltage is 8 V or more. D Malfunction of the engine-ECU
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.
NG NG NG
Measure at the air flow sensor con- Measure at the air flow sensor con- Check the following connector: Repair
nector B-12. nector B-12. C-40
D Connect the connector. (Use D Disconnect the connector, and
OK
the test harness: MB991709) measure at the harness side.
D Voltage between 2 and earth D Voltage between 1 and earth Check trouble symptom.
(Ignition switch: ON) (Ignition switch: ON)
OK: 3.7 - 4.3 V (Altitude: 0 m) OK: 4.8 - 5.2 V NG
3.2 - 3.8 V (Altitude: D Continuity between 5 and earth NG
1,200 m) OK: Continuity Check the harness wire between Repair
the engine-ECU and the baromet-
OK OK ric pressure sensor connector.
NG OK
B-12
OK

NG
NG
Check the harness wire between Repair
the engine-ECU and the baromet- OK
ric pressure sensor connector. Replace the air flow sensor.
NG
Measure at the engine-ECU con- Check the harness wire between
nector C-40. the engine-ECU and the baromet-
D Connect the connector. ric pressure sensor connector, and
D Voltage between 85 and earth repair if necessary.
OK: 3.7 - 4.3 V (Altitude: 0 m)
3.2 - 3.8 V (Altitude:
1,200 m)
OK
NG
C-40
OK

NG

Code No. 31 Detonation sensor system Probable cause
Range of Check D Malfunction of the detonation sensor
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the detonation sensor
after the engine starts. circuit
D Engine speed is approx. 5,000 r/min or more D Malfunction of the engine-ECU
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.
OK NG
Measure at the detonation sensor con- Check the following connectors: Repair
nector B-34. B-34, C-40
D Disconnect the connector and
OK
D Continuity between 2 and earth
OK: Continuity
NG
NG
OK
Check the harness wire between the Replace the detonation sensor.
Check the harness wire between the engine-ECU and the detonation sensor
detonation sensor and earth, and repair connector.
if necessary.
NG
Repair
Code No. 41 Injector system Probable cause

Range of Check D Malfunction of the injector
D Engine speed is approx. 50 - 1,000 r/min D Improper connector contact, open circuit or
D The throttle position sensor output voltage is 1.15 V or less. short-circuited harness wire of the injector circuit
D Actuator test by MUT-II is not carried out. D Malfunction of the engine-ECU
Set conditions
D Surge voltage of injector coil is not detected for 4 seconds.
NG
Check the injector. (Refer to P.13A-93.) Replace
OK
NG NG
Measure at the injector connectors Check the following connectors: Repair
B-02, B-03, B-05, B-36. B-02, B-03, B-05, B-36
OK
D Voltage between 1 and earth NG
Check trouble symptom. Check the harness wire between the
control relay and the injector connector,
OK: System voltage
and repair if necessary.
OK
Check the injector control circuit.

(Refer to P.13A-60, INSPECTION PRO-
CEDURE 50.)
Code No. 44 Ignition coil system Probable cause

Range of Check D Malfunction of the ignition coil
D Excluding deceleration driving and sudden acceleration or deceleration driving short-circuited harness wire of the ignition primary
Set conditions circuit
D Misfire occurs in No.1 and No.4 cylinders or No.2 and No.3 cylinders more than D Malfunction of the spark plug and spark plug cable
predeterminated times per 1,000 r/min. D Improper compression pressure
D Malfunction of the engine-ECU
1. NG OK
Measure at the ignition coil connectors Check the following connectors: Check trouble symptom.
B-01, B-11 C-92, C-131
NG
NG
measure at the harness. Check the harness wire between the
1. Voltage between 1 and earth Repair ignition coil and ignition switch connec-
(Ignition switch: ON) tor, and repair if necessary.
OK: System voltage
2. NG NG
(Engine: Cranking) Check the following connector: C-34 Repair
OK: 0.5 - 4.0 V
3. Continuity between the 2 and earth 3. NG OK
OK: Continuity
OK
NG
OK
Check the harness wire between the Replace the engine-ECU.
engine-ECU and ignition coil connector.
NG
Repair
Check the harness wire between the

ignition coil connector and earth, and
repair if necessary.
NG
B-01, B-11

NG
NG
Check the following items. Repair or replace
D Check the spark plugs, spark plug
cables.
D Check the compression pressure.
OK
Replace the ignition coil.

NG

Code No.54 Immobilizer system Probable cause
Range of Check D Radio interference of ID codes
D Ignition switch: ON D Incorrect ID code
Set Conditions D Malfunction of harness or connector
D Improper communication between the engine-ECU and immobilizer-ECU D Malfunction of immobilizer-ECU
D Malfunction of engine-ECU
NOTE
(1) If the ignition switches are close each other when starting the engine, radio interference may cause
this code to be displayed.
(2) This code may be displayed when registering the key ID code.
Yes
Is there another ignition key near the ignition key that is inserted Remove the extra ignition key.
in the ignition switch?
NG
No
Yes
Is a diagnosis code output from the immobilizer-ECU? Check the immobilizer system. (Refer to GROUP 54 - Ignition
Switch and Immobilizer System.)
No
NG
C-38, C-81, C-68
OK

NG
OK
Check the harness wire between the engine-ECU and the immobiliz- Replace the immobilizer-ECU.
er-ECU. NG
NG
Repair NG

Code No. 59 Oxygen sensor (rear) system Probable cause

Range of Check D Malfunction of the oxygen sensor (rear)
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.
NG
Check the oxygen sensor (rear). (Refer to P.13A-93.) Replace
OK
1. NG
Measure at the oxygen sensor (rear) connector C-85. Check the harness wire between the
D Disconnect the connector, and measure at the oxygen sensor (rear) and the control
2. NG NG
OK: Continuity
OK: Continuity
OK
NG
NG
(rear) connector.
OK

oxygen sensor (rear) and the earth, and
NG repair if necessary.
C-85, C-40
OK

NG
NG
the oxygen sensor (rear) connector.
OK
Replace the oxygen sensor (rear).

NG

Code No. 61 Communication wire with A/T-ECU system Probable cause
<A/T>
Range of Check D Malfunction of the harness wire and the connector
D 60 seconds or more have passed immediately after engine was started. D Malfunction of the engine-ECU
D Engine speed is approx. 50 r/min or more D Malfunction of the A/T-ECU
Set conditions
The voltage of the torque reduction request signal from the A/T-ECU is LOW for
1.5 seconds or more.
NG
C-34, C-38, C-30
OK

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

Range of Check, Set Conditions D Open circuit in alternator FR terminal circuit
D The alternator FR terminal signal voltage remains high for approximately 20 seconds D Malfunction of the engine-ECU
while the engine is running.
OK
Measure at the alternator connector B-38. Replace the engine-ECU.
D Connect the connector.
(Engine: Idling)
(Radiator fan: Stopped)
(Headlamp: OFF ® ON)
OK: 1.8 - 2.4 ® 1.0 - 1.6 V
NG
NG NG
Measure at the alternator connector B-38. Check the following Repair
D Disconnect the connector, and measure at the harness side. connectors: B-31, C-36
(Ignition switch: ON) OK
OK: 4.8 - 5.2 V
OK NG
NG
Check the following connector: B-38 Repair
OK NG
Check trouble symptom. between the engine-ECU
NG and the alternator con-
nector.
NG OK
Check the harness wire between the engine-ECU and the alternator Repair
connector.
OK Replace the engine-ECU.
Replace the alternator.

INSPECTION CHART FOR TROUBLE SYMPTOMS 13100880354
Trouble symptom Inspection Reference page

procedure
No.
Communication Communication with all systems is not possible. 1 13A-28

with MUT-II
II is
impossible. Communication with engine-ECU only is not possible. 2 13A-29
Engine warning The engine warning lamp does not illuminate right after the 3 13A-30
lamp and ignition switch is turned to the ON position.
related parts
The engine warning lamp remains illuminating and never goes 4 13A-30
out.
Starting No initial combustion (starting impossible) 5 13A-31
Initial combustion but no complete combustion 6 13A-32

(starting impossible)
Long time to start (improper starting) 7 13A-33
Idling stability Unstable idling (Rough idling, hunting) 8 13A-34

(Improper idling)
Idling speed is high. (Improper idling speed) 9 13A-35
Idling speed is low. (Improper idling speed) 10 13A-36
Idling stability When the engine is cold, it stalls at idling. (Die out) 11 13A-37
(Engine stalls)
When the engine becomes hot, it stalls at idling. (Die out) 12 13A-38
The engine stalls when starting the car. (Pass out) 13 13A-39
The engine stalls when decelerating. 14 13A-39
Driving Hesitation, sag or stumble 15 13A-40
The feeling of impact or vibration when accelerating 16 13A-40
The feeling of impact or vibration when decelerating 17 13A-41
Poor acceleration 18 13A-41
Surge 19 13A-42
Knocking 20 13A-42
Dieseling 21 13A-42
Too high CO and HC concentration when idling 22 13A-43
Low alternator output voltage (approx. 12.3 V) 23 13A-44
Idling speed is improper when A/C is operating 24 13A-44
Fans (radiator fan, A/C condensor fan) are inoperative 25 13A-45

PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)
Items Symptom
Starting Won’t start The starter is used to crank the engine, but there is no combustion within the
cylinders, and the engine won’t start.
Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Hard starting Engine starts after cranking a while.
Idling Hunting Engine speed doesn’t remain constant; changes at idle.

stability
Rough idle Usually, a judgement can be based upon the movement of the tachometer
pointer, and the vibration transmitted to the steering wheel, shift lever, body, etc.
This is called rough idle.
Incorrect idle speed The engine doesn’t idle at the usual correct speed.
Engine stall The engine stalls when the foot is taken from the accelerator pedal, regardless
(Die out) of whether the vehicles is moving or not.
Engine stall The engine stalls when the accelerator pedal is depressed or while it is being
(Pass out) used.
Driving Hesitation Sag “Hesitation” is the delay in response

Hesitation
of the vehicle speed (engine speed) Normal
that occurs when the accelerator is
depressed in order to accelerate Vehicle Initial ac-
from the speed at which the vehicle speed celerator
pedal de-
is now traveling, or a temporary drop pression
in vehicle speed (engine speed) Sag
during such acceleration.
Serious hesitation is called “sag”.
Time
Poor acceleration Poor acceleration is inability to obtain an acceleration corresponding to the

degree of throttle opening, even though acceleration is smooth, or the inability
to reach maximum speed.
Stumble Engine speed increase is delayed

when the accelerator pedal is
initially depressed for accelera-
tion. Vehicle
speed Normal
Initial ac-
celerator
pedal de-
pression
Idling Stumble
Time
Items Symptom
Driving Shock The feeling of a comparatively large impact or vibration when the engine is
accelerated or decelerated.
Surge This is repeated surging ahead during constant speed travel or during variable
speed travel.
Knocking A sharp sound like a hammer striking the cylinder walls during driving and which
adversely affects driving.
Stopping Run on The condition in which the engine continues to run after the ignition switch is
(“Dieseling”) turned to OFF. Also called “Dieseling”.
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1
Communication with MUT-II is not possible. Probable cause
(Communication with all systems is not possible.)
The cause is probably a defect in the power supply system (including earth) for the D Malfunction of the connector
diagnosis line. D Malfunction of the harness wire
NG NG
Measure at the diagnostic connector Check the following connectors: Repair
(16-pin) C-20. C-66, (C-63, C-132, C-141) <L.H.>,
D Voltage between 16 and earth (C-62, C-14) <R.H.>
OK: Battery voltage
OK
OK NG
power supply and diagnostic connector
(16 pin), and repair if necessary.
NG
Measure at the diagnostic connector Check the harness wire between the
(16-pin) C-20. diagnostic connector (16-pin) and earth,
D Continuity between 4 and earth and repair if necessary.
OK: Continuity
OK
Replace the MUT-II.

MUT-II communication with engine-ECU is impossible. Probable cause
One of the following causes may be suspected. D Malfunction of engine-ECU power supply circuit
D No power supply to engine-ECU. D Malfunction of engine-ECU
D Defective earth circuit of engine-ECU. D Malfunction of immobilizer-ECU
D Defective engine-ECU. D Open circuit between immobilizer-ECU and diagnosis
D Improper communication line between engine-ECU and MUT-II connector
D Open circuit between engine-ECU and immobilizer-
ECU
No
Is communication possible between the MUT-II and the immobilizer- Check the diagnosis line between the immobilizer-ECU and the
ECU? MUT-II, and repair if necessary. (Refer to GROUP 54 - Ignition
Key and Immobilizer.)
Yes
NG
C-20, C-66, C-68, C-83, C-81, C-38
OK

NG
NG
Check the harness wire between engine-ECU and diagnosis con- Repair
nector.
OK
OK NG
Check the harness wire between engine-ECU and immobilizer- Check the harness wire Repair
ECU. between engine-ECU and
earth.
NG
OK
Repair
Check the power supply and ignition switch-IG system. (Refer to
P.13A-45, INSPECTION PROCEDURE 26.)
The engine warning lamp does not illuminate right after Probable cause
the ignition switch is turned to the ON position.
Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp D Burnt-out bulb
to illuminate for five seconds immediately after the ignition switch is turned to ON. D Defective warning lamp circuit
If the engine warning lamp does not illuminate immediately after the ignition switch D Malfunction of the engine-ECU
is turned to ON, one of the malfunctions listed at right has probably occurred.
NG
MUT-II Data list Check the engine-ECU power supply and earth circuit.
16 engine-ECU power supply voltage (Refer to P.13A-62.) (Refer to P.13A-58, INSPECTION PROCEDURE 45.)
OK
OK NG
Measure at the engine-ECU connector C-36. Check the following Repair
D Disconnect the connector, and measure at the harness side. connector: C-36.
D Earth the terminal No. 36.
OK
OK: The engine warning lamp illuminates.
NG
NG
Check a burnt-out bulb. Replace Replace the engine-ECU.
OK
NG
Measure at the combination meter connector D-03. Check the engine warning lamp power supply circuit, and repair
D Disconnect the connector, and measure at the harness side. if necessary.
D Voltage between 4 and earth (Ignition switch: ON)
OK: System voltage
OK
NG
D-03, C-90, C-36
OK
NG
Check trouble symptom. Check the harness wire between combination meter and engine-
ECU, and repair if necessary.
The engine warning lamp remains illuminating and never Probable cause
goes out.
In cases such as the above, the cause is probably that the engine-ECU is detecting D Short-circuit between the engine warning lamp and
a problem in a sensor or actuator, or that one of the malfunctions listed at right has engine-ECU
occurred. D Malfunction of the engine-ECU
Yes
MUT-II Self-Diag code Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES
No
NG
Measure at the combination meter connector D-03. Check the harness wire between combination meter and engine-
D Disconnect the connector, and measure at the harness side. ECU connector, and repair if necessary.
D Disconnect the engine-ECU connector
OK: No continuity
OK

No initial combustion (starting impossible) Probable cause
In cases such as the above, the cause is probably that a spark plug is defective, D Malfunction of the ignition system
or that the supply of fuel to the combustion chamber is defective. D Malfunction of the fuel pump system
In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel. D Malfunction of the injectors
D Malfunction of the immobilizer system
D Foreign materials in fuel
NG
Check battery voltage when cranking. Check the battery. (Refer to GROUP 54 - Battery.)
OK: 8 V or higher
OK
Yes
Is immobilizer-ECU diagnosis code displayed? Check the immobilizer.
(Refer to GROUP 54 - Ignition Key and Immobilizer.)
No
MUT-II: Inspection of no initial combustion.

(Refer to P.13A-52, INSPECTION PROCEDURE 37.)
OK
NG
Can any sound be heard from the injectors when cranking? Check the injector system. (Refer to P.13A-21, INSPECTION PRO-
CEDURE FOR DIAGNOSIS CODE 41.)
OK
Ignition system: Inspection of no initial combustion.

OK
Check the following items.

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.
Initial combustion but no complete combustion Probable cause
In such cases as the above, the cause is probably that the spark plugs are generating D Malfunction of the ignition system
sparks but the sparks are weak, or the initial mixture for starting is not appropriate. D Malfunction of the injector system
D Poor compression
NG
OK: 8 V or higher
OK
MUT-II: Check if uncompleted combustion occurs.

OK
NG
Can any sound be heard from the injectors when cranking? Check the injector system, (Refer to P.13A-21, INSPECTION PRO-
OK
Yes NG
Is starting good if the engine is cranked with the accelerator pedal Check ISC servo for op- Check the ISC servo sys-
slightly depressed? eration sound. tem. (Refer to P.13A-50,
(Refer to P.13A-95.) INSPECTION PROCE-
No DURE 34.)
OK
D Clean the throttle valve area. (Refer to P.13A-81.)

D Check and adjust the fixed SAS. (Refer to P.13A-83.)
NG
Check the ignition timing when cranking. Check that the crank angle sensor is installed properly.
OK: Approx. 5_BTDC
OK

D Check fuel lines for clogging.
It takes too long time to start. (Incorrect starting) Probable cause
In cases such as the above, the cause is probably that the spark is weak and ignition D Malfunction of the ignition system
is difficult, the initial mixture for starting is not appropriate, or sufficient compression D Malfunction of the injector system
pressure is not being obtained. D Inappropriate gasoline use
D Poor compression
NG
Check battery voltage when cranking Check the battery. (Refer to GROUP 54 - Battery.)
OK: 8 V or higher
OK
MUT-II: Check if uncomplete combustion occurs.

OK
NG
Can any sound be heard from the injectors when cranking? Check the injector system. (Refer to P.13A-21, INSPECTION PRO-
OK
NG
OK: Approx. 5_BTDC
OK

Unstable idling (Rough idling, hunting) Probable cause
In cases as the above, the cause is probably that the ignition system, air/fuel mixture, D Malfunction of the ignition system
idle speed control (ISC) or compression pressure is defective. D Malfunction of air-fuel ratio control system
Because the range of possible causes is broad, inspection is narrowed down to simple D Malfunction of the ISC system
items. D Malfunction of the purge control solenoid valve system
D Malfunction of the EGR solenoid valve system
D Poor compression
D Drawing air into exhaust system
Yes
Were the battery terminals disconnected? After warming-up, let the engine run at idling for 10 minutes.
No
Yes
Are diagnosis codes displayed? CODES.
No
Yes
Does idling speed fluctuate excessively? Check if hunting occurs.
No
NG
Check the ISC servo for operation sound. (Refer to P.13A-95.) Check the ISC servo system.
OK
NG
Check the injector for operation sound. Check the injector system. (Refer to P.13A-21, INSPECTION PRO-
OK
MUT-II: Check if idling speed is unstable.

OK
NG
Check the ignition timing. Check that the crank angle sensor is installed properly.
(Refer to GROUP 11A - On-vehicle Service.)
OK

D Check the purge control system.
D Check the EGR control system.
Idling speed is high. (Improper idling speed) Probable cause
In such cases as the above, the cause is probably that the intake air volume during D Malfunction of the ISC servo system
idling is too great. D Malfunction of the throttle body
Yes
No
NG
OK
NG
26 Idle position switch (Refer to P.13A-63.) (Refer to P.13A-46, INSPECTION PROCEDURE 28.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13A-62.) (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 21.)
OK
NG
MUT-II Data list Check the A/C switch and A/C relay system.
28 A/C switch (Refer to P.13A-63.) (Refer to P.13A-49, INSPECTION PROCEDURE 32.)
OK
Basic idle adjustment (Refer to P.13A-83.)
NG
Check trouble symptom. Clean the throttle valve area. (Refer to P.13A-81.)
Check and adjust the fixed SAS. (Refer to P.13A-83.)

Idling speed is low. (Improper idling speed) Probable cause
In cases such as the above, the cause is probably that the intake air volume during D Malfunction of the ISC servo system
idling is too small. D Malfunction of the throttle body
Yes
No
NG
OK
NG
OK
NG
CODE 21.)
OK
NG
MUT-II Data list Check the ignition switch ST and inhibitor switch system <A/T>.
29 Inhibitor switch (Refer to P.13A-63.) (Refer to P.13A-48, INSPECTION PROCEDURE 30.)
OK
NG

When the engine is cold, it stalls at idling. (Die out) Probable cause
In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate D Malfunction of the ISC servo system
when the engine is cold, or that the intake air volume is insufficient. D Malfunction of the throttle body
D Malfunction of the injector system
D Malfunction of the ignition system
Yes
No
Yes
No
Yes
Does the engine stall right after the accelerator pedal is released? Clean the throttle valve Check and adjust the
area. (Refer to P.13A-81.) fixed SAS.
No
No
Is engine-idling stable after the warming-up? Check if the unstable idling (Rough idling, hunting).
Yes
NG
OK
NG
OK
NG
OK
NG
CODE 21.)
OK
NG
MUT-II Actuator test Check the EGR control solenoid valve system. (Refer to P.13A-51,
10 EGR control solenoid valve (Refer to P.13A-65.) INSPECTION PROCEDURE 36.)
OK
Check the fuel pressure. (Refer to P.13A-85.)

OK
NG
OK

D Check the engine oil viscosity.
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, D Malfunction of the ignition system
In addition, if the engine suddenly stalls, the cause may also be a defective connector D Malfunction of the ISC system
contact. D Drawing air into intake system
D Improper connector contact
Yes
No
Yes
No
NG
OK
NG
OK
Yes
area. (Refer to P.13A-81.) fixed SAS.
No
No
Does the engine stall easily again? While carrying out an intermittent malfunction simulation test (Refer
to GROUP 00 - Points to Note for Intermittent Malfunctions.), check
Yes for sudden changes in the signals shown below.
D Crank angle sensor signal D Primary and secondary
MUT-II: Engine stalling inspection when the engine is warm and D Air flow sensor signal ignition signal
idling. (Refer to P.13A-55, INSPECTION PROCEDURE 42.) D Injector drive signal D Fuel pump drive signal
OK D Engine-ECU power supply
voltage
NG
OK

The engine stalls when starting the car. (Pass out) Probable cause
In cases such as the above, the cause is probably misfiring due to a weak spark, D Drawing air into intake system
or an inappropriate air/fuel mixture when the accelerator pedal is depressed. D Malfunction of the ignition system
Yes
No
NG
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
The engine stalls when decelerating. Probable cause
In cases such as the above, the cause is probably that the intake air volume is insufficient D Malfunction of the ISC system
due to a defective idle speed control (ISC) servo system.
Yes
No
Yes
No
NG
26 Idle position switch (Refer to P.13A-63.)
P.13A-69.) (Refer to P.13A-46,
26.)
OK
NG
MUT-II Data list Check the throttle position sensor system. (Refer to P.13A-15, IN-
14 Throttle position sensor (Refer to P.13A-62.) SPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
OK
Yes
MUT-II Data list Check the vehicle speed sensor system. (Refer to P.13A-19, IN-
45 ISC servo position SPECTION PROCEDURE FOR DIAGNOSIS CODE 24.)
D Is the idle speed control (ISC) servo position drops to 0 - 2
steps when decelerating (engine r/min less than 1,000)?
No
NG
OK

D Clean the throttle valve area.
D Check and adjust the fixed SAS.
Hesitation, sag or stumble Probable cause
In cases such as the above, the cause is probably that ignition system, air/fuel mixture D Malfunction of the ignition system
or compression pressure is defective. D Malfunction of air-fuel ratio control system
D Malfunction of the fuel supply system
D Malfunction of the EGR control solenoid valve system
D Poor compression
Yes
No
NG
Check the injectors for operation sound. Check the injector system. (Refer to P.13A-21, INSPECTION PRO-
OK
NG
OK
MUT-II: Check if hesitation, sag, stumble or poor acceleration occur.

OK

OK

D Check the fuel filter or fuel line for clogging.
The feeling of impact or vibration when accelerating Probable cause
In cases such as the above, the cause is probably that there is an ignition leak D Malfunction of the ignition system
accompanying the increase in the spark plug demand voltage during acceleration.
Yes
No

D Check for occurrence of ignition leak.
The feeling of impact or vibration when decelerating. Probable cause
Malfunction of the ISC system is suspected. D Malfunction of the ISC system
Yes
No
NG
OK
NG
OK
NG
OK
Clean the throttle valve area. (Refer to P.13A-81.)
Poor acceleration Probable cause
Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc. D Malfunction of the ignition system
are suspected. D Malfunction of air-fuel ratio control system
D Poor compression pressure
D Clogged exhaust system
Yes
No
NG
OK
NG
OK

OK

OK

D Broken air intake hose
D Clogged air cleaner
Surge Probable cause
Defective ignition system, abnormal air-fuel ratio, etc. are suspected. D Malfunction of the ignition system
D Malfunction of air-fuel ratio control system
Yes
No
NG
OK
NG
OK
MUT-II: Check if surge occurs.

(Refer to P.13-57, INSPECTION PROCEDURE 44.)
OK

OK

Knocking Probable cause
In cases as the above, the cause is probably that the detonation control is defective D Defective detonation sensor
or the heat value of the spark plug is inappropriate. D Inappropriate heat value of the spark plug
Yes
No
No
Does knocking occur when driving with the sensor disconnected? Check the detonation sensor system. (Refer to P.13A-21, INSPEC-
At this time, use the MUT-II to check if the timing is retarded TION PROCEDURE FOR DIAGNOSIS CODE 31.)
compared to when the detonation sensor connector is connected.
Yes

D Spark plugs
Dieseling Probable cause
Fuel leakage from injectors is suspected. D Fuel leakage from injectors
Check the injectors for fuel leakage.

Too high CO and HC concentration when idling Probable cause
Abnormal air-fuel ratio is suspected. D Malfunction of the air-fuel ratio control system
D Deteriorated catalyst
Yes
No
NG
OK
NG
21 Engine coolant temperature sensor. (Refer to P.13A-62.) (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS
CODE 21.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to P.13A-14,
13 Intake air temperature sensor (Refer to P.13A-62.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13A-20,
25 Barometric pressure sensor (Refer to P.13A-63.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13A-24, IN-
59 Oxygen sensor (rear) (Refer to P.13A-65.) SPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)
D Transmission: 2nd gear <M/T>, L range <A/T>
D Driving with throttle widely open
OK: 600 - 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor system. (Refer to P.13A-13, INSPECTION
11 Oxygen sensor PROCEDURE FOR DIAGNOSIS CODE 11.)
OK: 600 - 1,000 mV when racing suddenly (Refer to P.13A-61.)
OK
OK
MUT-II Data list Replace the oxygen sensor.
11 Oxygen sensor
OK: Repeat 0 - 400 mV and 600 - 1,000 mV alternately when
idling. (Refer to P.13A-61.) Check trouble symptom.
NG 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.

Low alternator output voltage (approx. 12.3 V) Probable cause
The alternator may be defective, or malfunctions, which are listed in the right column, D Malfunction of charging system
may be suspected. D Short circuit in harness between alternator G terminal
and engine-ECU
NG NG
Measure at the alternator connector Measure at the alternator connector. Check the harness wire between the
side. B-38 B-38 alternator and the engine-ECU connec-
D Connect the connector. D Disconnect the connector, and tor, and repair if necessary.
(Test harness: MB991519) measure at the harness side.
D Voltage between 1 (black clip) and D Disconnect the engine-ECU con-
earth nector.
Engine: at idle D Continuity between 1 and earth
Radiator fan: does not run OK: No continuity
Headlamp: OFF ® ON
OK
Brake lamp: OFF ® ON
Rear defogger switch: NG
OFF ® ON
alternator and the engine-ECU connec-
OK: Voltages rises tor.
by 0.2 - 3.5 V.
OK
OK
Check the alternator. (Refer to GROUP
16 - Charging System.)
Idling speed is improper when A/C is operating Probable cause
If the engine-ECU detects that the air conditioner is on, it activates the idle D Malfunction of the A/C control system
speed control (ISC) servo to control idle-up operation. D Improper connector contact, open circuit or
The A/C-ECU judges if the load caused by air conditioner operation is high or short-circuited harness wire
low, and converts it to voltage signal (high or low voltage) and inputs the signal D Malfunction of the engine-ECU
to the engine-ECU.
Based on this voltage signal, the engine-ECU controls the idle-up speed (for
high or low load).
OK
Measure at the engine-ECU connector C-34. Check the following connector:
D Connect the connector. C-34
D Voltage between 24 and earth (Engine: at idle, outside air
OK NG
temperature: 25_C or more)
OK: 0 - 3 V [When A/C is MAX. COOL condition (when Repair
the load by A/C is high)]
System voltage [When A/C is MAX. HOT condition
(when the load by A/C is low)] Check trouble symptom.
NG NG
Check the A/C system. (Refer to GROUP 55 - On-vehicle Service.) Replace the engine-ECU.
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 D Malfunction of the fan motor relay
engine coolant temperature, vehicle speed, and air conditioner switch condition. D Malfunction of the fan motor
Based on this signal, the fan controller controls the radiator fan and condenser D Malfunction of the fan controller
fan speeds (The more the average voltage at the terminal approaches 5 V, the D Improper connector contact, open circuit or
higher the fan speed become.) short-circuited harness wire
NG NG
Measure at the engine-ECU connector C-34. Check the harness wire Repair
D Disconnect the connector, and measure at the harness between the engine-ECU
side. and the fan controller con-
D Voltage between 21 and earth (Ignition switch: ON) nector.
OK: 4.8 - 5.2 V (Fan rotates at high speed.) OK
D Connect a jumper cable between 21 and earth (Ignition
switch: ON) Check the radiator fan
OK: Fan stops and condenser fan circuit.
OK (Refer to GROUP 14 -
NG Troubleshooting.)
connector:
C-34
OK

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 D Malfunction of the ignition switch
the control relay ON. This causes battery voltage to be supplied to the engine-ECU, D Malfunction of the control relay
injectors and air flow sensor. D Improper connector contact, open circuit or
short-circuited harness wire
D Disconnected engine-ECU earth wire
NG
Check the control relay. (Refer to P.13A-90.) Replace
OK
NG NG
Measure at the control relay connector C-31. Check the following Repair
D Disconnect the connector, and measure at the harness side. connector: B-30
D Voltage between 3, 4 and earth
OK
OK: System voltage
OK Check trouble symptom.
NG
Check the engine-ECU power supply and earth circuit.
(Refer to P.13A-58, INSPECTION PROCEDURE 45.) Check the harness wire between battery and control relay connector,
Fuel pump system Probable cause
The engine-ECU turns the control relay ON when the engine is cranking or running, D Malfunction of the fuel pump relay
and this supplies power to drive the fuel pump. D Malfunction of the fuel pump
D Improper connector contact, open circuit or
NG
Check the fuel pump operation. (Refer to P.13A-88.) Check the fuel pump circuit.
OK (Refer to P.13A-58, INSPECTION PROCEDURE 46.)
NG
Check the fuel pump relay. (Refer to P.13A-90.) Replace
OK
NG
Measure at the fuel pump relay connector C-32. Check the fuel pump drive control circuit.
D Connect the connector. (Refer to P.13A-59, INSPECTION PROCEDURE 47.)
D MUT-II Actuator test: Fuel pump drive
OK: System voltage
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 D Maladjustment of the accelerator pedal
it is depressed or released (HIGH/LOW), to the engine-ECU. D Maladjustment of the fixed SAS
The engine-ECU controls the idle speed control servo based on this input. D Maladjustment of the idle position switch and throttle
position sensor
NG
Check the idle position switch. (Refer to P.13A-91.) Replace the throttle position sensor.
OK
NG NG
Measure at the throttle position sensor connector B-07. Check the following Repair
D Disconnect the connector, and measure at the harness side. connector: C-40
OK
OK: 4 V or higher
D Continuity between 4 and earth Check trouble symptom.
OK: Continuity
NG
OK
NG Check the harness wire between engine-ECU and throttle position
sensor connector.
connector: B-07
OK NG
OK
Replace the engine-ECU. 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 D Malfunction of ignition switch
cranking. D Improper connector contact, open circuit or
The engine-ECU controls fuel injection, etc. during starting based on this input. short-circuited harness wire
1. NG NG
1. Voltage between 71 and earth (Ignition switch: START) 2. NG
OK
OK: 8V or more
2. Continuity between 91 and earth Check trouble symptom.
OK: Continuity
NG
OK NG
NG Check harness wire be- Repair
Check the following Repair tween the engine-ECU
connector: C-40 and ignition switch con-
OK nector.
OK
NG 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.
Ignition switch-ST and inhibitor switch system <A/T> Probable cause
D The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine D Malfunction of ignition switch
is cranking. D Malfunction of inhibitor switch
The engine-ECU controls fuel injection, etc. during starting based on this input. D Improper connector contact, open circuit or
D The inhibitor switch inputs the condition of the select lever, i.e. whether it is in short-circuited harness wire
P or N range or in some other range, to the engine-ECU. D Malfunction of the engine-ECU.
The engine-ECU controls the idle speed control (ISC) servo based on this input.
NG
Check the inhibitor switch. Replace
OK
1. NG NG
Measure at the inhibitor switch connector B-72. Check harness wire be- Repair
D Disconnect the connector, and measure at the harness side. tween engine-ECU and
1. Voltage between 10 and earth (Ignition switch: ON) inhibitor switch connector.
OK: System voltage 2. NG
OK
2. Continuity between 9 and earth
OK: Continuity Replace the engine-ECU.
D Ignition switch: START
D Disconnect engine-ECU connector.
OK: System voltage 3. NG Check harness wire between inhibitor switch connector and starter
S terminal, and repair if necessary.
OK
NG
Check the following Repair NG
connector: B-72 Check the following Repair
connector:
OK C-92
Check trouble symptom. OK
NG
Check harness wire be- Repair NG
tween engine-ECU and NG
inhibitor switch connector. Check harness wire be- Repair
tween inhibitor switch and
OK ignition switch connector.
Replace the engine-ECU. OK
Check the ignition switch.

Power steering fluid pressure switch system Probable cause
The presence or absence of power steering load is input to the engine-ECU. D Malfunction of power steering fluid pressure switch
The engine-ECU controls the idle speed control (ISC) servo based on this input. D Improper connector contact, open circuit or
NG
Check the power steering fluid pressure switch. Replace
OK
NG NG
Measure at the power steering fluid pressure switch connector Check the following Repair
B-76. connector: C-36
D Disconnect the connector, and measure at the harness side.
OK
OK: System voltage Check trouble symptom.
OK NG
NG NG
Check the following Repair Check harness wire be- Repair
connector: B-76 tween engine-ECU and
OK power steering fluid pres-
sure switch connector.
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 D Malfunction of A/C control system
control of the idle speed control (ISC) servo, and also operates the A/C compressor D Malfunction of A/C switch
magnetic clutch. D Improper connector contact, open circuit or
NG
Check the A/C compressor relay. Replace
OK
NG
Measure at the engine-ECU connectors C-34, C-36. Check the A/C system. (Refer to GROUP 55 - Troubleshooting.)
D Voltage between 8 and earth, and 45 and earth
OK: 0 - 3 V (A/C switch: OFF) OK NG
System voltage (A/C switch: ON) Check the following Replace
D Short circuit between 8 and earth connectors: C-34, C-36
(Ignition switch: ON, A/C switch: ON) OK
OK: A/C compressor clutch turns on.
NG

Ignition circuit system Probable cause
The engine-ECU interrupts the ignition coil primary current by turning the power transistor D Malfunction of ignition switch.
inside the engine-ECU ON and OFF. D Improper connector contact, open circuit or
1. NG NG
Measure at the ignition coil connectors B-01, B-11. Check the following Repair
D Disconnect the connector and measure at the harness side. connectors: C-92, C-131
OK: Continuity
NG
OK NG
between ignition coil and
ignition switch connector.
OK

(Refer to GROUP 54 - Ignition Switch and Immobilizer System.)
NG
connectors: B-01, B-11
Check the harness wire between power transistor unit connector
OK
and earth, and repair if necessary.
NG
Check trouble symptom. 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 D Malfunction of ISC servo
the servo valve located in the bypass air passage. D Improper connector contact, open circuit or
NG
Check the ISC servo Replace
OK
NG
Measure at the ISC servo connector B-10. Check the harness wire between control relay and ISC servo con-
D Disconnect the connector and measure at the harness side. nector, and repair if necessary.
D Voltage between 2 and earth, and 5 and earth (Ignition switch:
ON)
OK: System voltage
OK
NG NG
D Disconnect the connector, measure at the harness side. connector: B-10
D Voltage between each of 4, 5, 17, 18 and earth (Ignition switch:
OK
ON)
OK NG
NG
Check the following Repair Check harness wire between engine-ECU and ISC servo connector,
connector: C-34 and repair if necessary.
OK
NG
Purge control solenoid valve system Probable cause
The purge control solenoid valve controls the purging of air from the canister located D Malfunction of solenoid valve
inside the intake manifold. D Improper connector contact, open circuit or
short-circuited harness wire.
NG
Check the purge control solenoid valve. Replace
(Refer to GROUP 17 - Emission Control System.)
OK
NG
Measure at the purge control solenoid valve connector B-04. Check the harness wire between control relay and solenoid valve
D Disconnect the connector and measure at the harness side. connector, and repair if necessary.
OK: System voltage
OK
NG NG
D Disconnect the connector and measure at the harness side. connector: B-04
OK
OK: System voltage
NG
connector: C-34
Check the harness wire between engine-ECU and solenoid valve
OK connector, and repair if necessary.

NG
EGR control solenoid valve system Probable cause
The EGR control solenoid valve is controlled by the negative pressure resulting from D Malfunction of solenoid valve
EGR operation leaking to port “A” of the throttle body. D Improper connector contact, open circuit or
NG
Check the EGR control solenoid valve. Replace
OK
NG
Measure at the EGR control solenoid valve connector B-06. Check the harness wire between control relay and solenoid valve
OK: System voltage
OK
NG NG
D Disconnect the connector and measure at the harness side. connector:
D Voltage between 6 and earth (Ignition switch: ON) B-06
OK: System voltage
OK
OK
connector: C-34 NG
OK Check the harness wire between engine-ECU and solenoid valve

connector, and repair if necessary.
NG

MUT-II: Inspection of no initial combustion
NG
MUT-II Data list Check the power supply and ignition switch-IG system.
16 Power supply voltage (Refer to P.13A-62.) (Refer to P.13A-45, INSPECTION PROCEDURE 26.)
OK
No
Does the camshaft rotate at the engine cranking? Check timing belt for breakage.
(When oil filler cap is removed.)
Yes
Yes
No
No
MUT-II Data list Check the crank angle sensor system.
22 Crank angle sensor (Refer to P.13A-17, INSPECTION PROCEDURE FOR DIAGNOSIS
OK: Cranking speed is displayed. CODE 22.)
OK
NG
MUT-II Actuator test Check the fuel pump system.
07 Fuel pump (Refer to P.13A-65.) (Refer to P.13A-46, INSPECTION PROCEDURE 27.)
OK
NG
CODE 21.)
Check ignition circuit system.

OK
NG
OK: Approx. 5_BTDC
Yes
MUT-II Self-Diag code Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODE
Are diagnosis codes displayed?
No
NG
OK
NG
21 Engine coolant temperature sensor (Refer to P.13A-62.) (Refer to P.13A-16, INSPECTION PROCEDURES FOR DIAGNO-
SIS CODE 21.)
OK
NG
MUT-II Data list Check the ignition switch-ST system <M/T>.
18 Ignition switch-ST (Refer to P.13A-62.) (Refer to P.13A-47, INSPECTION PROCEDURE 29.)
Check the ignition switch-ST and inhibitor switch system <A/T>.
Check if hunting occurs.
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
OK
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to P.13A-14,
13 Intake air temperature sensor (Refer to P.13A-62.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
OK
NG
OK
NG
CODE 21.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve system
08 Purge control solenoid valve (Refer to P.13A-65.) (Refer to P.13A-51, INSPECTION PROCEDURE 35.)
OK
NG
OK
NG
OK: 600 - 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13A-13, IN-
11 Oxygen sensor SPECTION PROCEDURE FOR DIAGNOSIS CODE 11.)
OK: 600 - 1,000 mV during sudden racing
OK
NG OK
MUT-II Data list Check the fuel pressure. 1. Inspect the intake of
11 Oxygen sensor (Refer to P.13A-85.) air into the air intake
OK: Changes between 0 - 400 mV and 600 - 1,000 mV during system.
idling D Broken intake
manifold gasket
OK
D Broken vacuum
NG hose
MUT-II Data list Check the power steering
27 Power steering fluid pressure switch (Refer to P.13A-63.) fluid pressure switch sys- D PCV valve does
tem. (Refer to P.13A-49, not operate.
OK D Broken air intake
INSPECTION PROCE-
DURE 31.) hose
2. Check the injector for
clog.
NG
28 A/C switch (Refer to P.13A-63.) (Refer to P.13A-49. INSPECTION PROCEDURE 32.)
OK
NG
MUT-II Data list Check the ignition switch-ST and inhibitor switch system. <A/T>
OK
NG
MUT-II Data list Adjust the basic idle speed. (Refer to P.13A-83.)
45 ISC Servo position (Refer to P.13A-64.)
MUT-II: Engine stalling inspection when the engine is warmed up and idling.
NG
OK
NG
MUT-II Data list Check the intake air sensor system. (Refer to P.13A-14, INSPEC-
13 Intake air temperature sensor (Refer to P.13A-62.) TION PROCEDURE FOR DIAGNOSIS CODE 13.)
OK
NG
OK
NG
CODE 21.)
OK
NG
OK
NG
OK: 600 - 1,000 mV
OK
NG
OK: Changes between 600 - 1,000 mV during sudden racing
OK
NG OK
OK: Changes between 0 - 400 mV and 600 - 1,000 mV during system
OK manifold gasket
NG D Broken vacuum
MUT-II Data list Check the power steering hose
INSPECTION PROCE-
DURE 31.) hose
clog.
NG
OK
NG
OK
NG
45 ISC servo position (Refer to P.13A-64.)
MUT-II: Check if hesitation, sug, stumble or poor acceleration occurs.
NG
OK
NG
OK
NG
OK
NG
21 Engine coolant temperature sensor (Refer to P.13A-62.) (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOS-
TIC CODE 21.)
OK
NG
OK
NG
MUT-II Actuator test Check the EGR control solenoid valve system.
10 EGR control solenoid valve (Refer to P.13A-65.) (Refer to P.13A-51, INSPECTION PROCEDURE 36.)
OK
NG
OK: 600 - 1,000 mV
OK
NG
OK
NG OK
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
NG
OK
NG
OK
NG
OK
NG
CODE 21.)
OK
NG
OK
NG
OK
NG
OK: 600 - 1,000 mV
OK
NG
OK
NG OK
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
1. NG NG
Measure the engine-ECU connectors, C-34, C-36, C-40. Check the following Repair
D Disconnect the connector and measure at the harness side connectors: C-92, C-131
OK: System voltage 2, 3. NG
2. Voltage between 38 and earth Check trouble symptom.
OK: System voltage
3. Voltage between 12, 25 and earth (Ignition switch: ON) OK
4. NG NG
OK: System voltage (when the terminal 38 is earthed)
4. Continuity between 13, 26 and earth Check the harness wire Repair
OK: Continuity between engine-ECU and
5. NG ignition switch connector.
OK: System voltage OK
OK
NG
connectors:
C-34, C-36, C-40 Check the harness wire between engine-ECU and control relay
OK

Check the harness wire between engine-ECU and earth, and repair
NG if necessary.
NG
C-47, C-83, C-66, (C-63, C-132,
C-141) <L.H.>, (C-62, C-14) <R.H.>
OK
Check trouble symptom

NG
Check the harness wire between engine-ECU and battery, and

Check fuel pump circuit.
NG NG
Measure at the fuel pump connector E-16. Check the following connector: Repair
D Disconnect the connector and measure at the harness side. E-11
OK
OK: Continuity
OK Check trouble symptom
NG
NG
Check the following connectors: E-16, E-11, C-123, C-92, B-09 Check the harness wire between fuel pump and earth, and repair
if necessary.
OK
Check trouble symptom. Repair

NG
NG
Check the harness wire between terminal for fuel pump drive and Repair
fuel pump connector.
OK
Replace the fuel pump.

Check the fuel pump drive control circuit.
NG NG
Measure at the fuel pump relay connector C-32. Check the following Repair
D Voltage between 3, 4 and earth (Ignition switch: ON) OK
OK: System voltage
NG NG
Measure at the engine-ECU connector C-34. NG
D Disconnect the connector and measure at the harness side. Check the harness wire Repair
D Voltage between 22 and earth (Ignition switch: ON) between fuel pump relay
OK: System voltage and ignition switch con-
OK nector.
OK
Check the following connector: C-34
OK NG
Repair
Check trouble symptom. Check the harness wire between engine-ECU and fuel pump relay
NG
Check air flow sensor (AFS) control circuit.
1. NG
Measure at the air flow sensor connector B-12. Check the harness wire between the air flow sensor and control
D Disconnect the connector and measure at the harness side. relay connector, and repair if necessary.
OK: System voltage
2. Voltage between 3 and earth (Ignition switch: ON) 2, 3. NG NG
OK: 4.8 - 5.2 V connector: C-40
OK: Continuity OK
Check the following connector: B-12 NG
NG
OK NG Check the harness wire Repair
Repair and air flow sensor con-
nector.
NG
Check throttle position sensor (TPS) output circuit.
OK NG
D Connect the connector. connector: C-40
D Voltage between 84 and earth (Ignition switch: ON) OK
OK: 0.3 - 1.0 V (Throttle valve at idle position)
4.5 - 5.5 V (Throttle valve fully open) Check trouble symptom.
NG NG
Check the harness wire between engine-ECU and throttle position Replace the engine-ECU.
sensor connector, and repair if necessary.
Check injector control circuit
NG NG
D Disconnect the connector and measure at the harness side. connectors: B-02, B-03,
D Voltage between 1, 2, 14, 15 and earth (Ignition switch: ON) B-05, B-36
OK
NG
Check the harness between engine-ECU and injector connector,

NG
Check the following connector: C-34 Repair
OK

NG

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 Inspection Inspection contents Normal condition Inspection Reference

No. item procedure page
No.
11 Oxygen Engine:After having When at 4,000 r/min, 200 mV or less Code No. 13A-13
sensor warmed up engine is suddenly 11
(front) Air/fuel mixture is decelerated
made leaner when de-
celerating, and is made When engine is 600 - 1,000 mV
richer when racing. suddenly raced
Engine:After having Engine is idling 400 mV or less

warmed up
The oxygen sensor (Changes)
signal is used to check
the air/fuel mixture 2,500 r/min 600 - 1,000 mV
ratio, and control
condition is also
checked by the ECU.
12 Air flow D Engine coolant Engine is idling 17 - 43 Hz - -
sensor*1 temperature: 80 -
95_C 2,500 r/min 70 - 110 Hz
D Lamps, electric
cooling fan and all
accessories: OFF Engine is raced Frequency
D Transmission: increases in
Neutral (A/T: response to
P range) racing
13 Intake air Ignition switch: ON or When intake air - 20_C Code No. 13A-14
temperature with engine running temperature is - 20_C 13
sensor
When intake air 0_C
temperature is 0_C
When intake air 20_C

temperature is 20_C

temperature is 40_C

temperature is 80_C
13A-62

No.
14 Throttle Ignition switch: ON Set to idle position 300 - 1,000 mV Code No. 13A-15
position 14
sensor Gradually open Increases in
proportion to
throttle opening
angle
Open fully 4,500 - 5,500 mV
16 Power Ignition switch: ON System voltage Procedure 13A-45

supply No. 26
voltage
18 Cranking Ignition switch: ON Engine: Stopped OFF Procedure 13A-47

signal No. 29 <M/T>
(ignition <M/T> 13A-48
switch-ST) Procedure <M/T>
Engine: Cranking ON
No. 30
<A/T>
21 Engine Ignition switch: ON or When engine - 20_C Code No. 13A-16

coolant with engine running coolant temperature 21
temperature is - 20_C
sensor
When engine 0_C
coolant temperature
is 0_C
When engine 20_C

coolant temperature
is 20_C
When engine 40_C

coolant temperature
is 40_C
When engine 80_C

coolant temperature
is 80_C

No.
22 Crank angle D Engine: Cranking Compare the engine Accord Code No. 13A-17
sensor D Tachometer: speed readings on 22
Connected the tachometer and
the MUT-II.
D Engine: Idling When engine 1,275 - 1,475 rpm

D Idle position coolant temperature
switch: ON is - 20_C
When engine 1,225 - 1,425 rpm

coolant temperature
is 0_C

coolant temperature
is 20_C
When engine 950 - 1,150 rpm

coolant temperature
is 40_C
When engine 650 - 850 rpm

coolant temperature
is 80_C
25 Barometric Ignition switch: ON At altitude of 0 m 101 kPa Code No. 13A-20

pressure 25
sensor At altitude of 600 m 95 kPa
At altitude of 1,200 m 88 kPa
26 Idle position Ignition switch: ON Throttle valve: ON Procedure 13A-46

switch Check by operating Set to idle position No. 28
accelerator pedal
repeatedly Throttle valve: OFF*2
Slightly open
27 Power Engine: Idling Steering wheel OFF Procedure 13A-49

steering fluid stationary No. 31
pressure
switch Steering wheel ON
turning
28 A/C switch Engine: Idling A/C switch: OFF OFF Procedure 13A-49
(when A/C switch is No. 32
ON, A/C compressor
A/C switch: ON ON
should be operating.)
29 Inhibitor Ignition switch: ON P or N P or N Procedure 13A-48

switch No. 30
<A/T> D, 2, L or R D, 2, L or R

No.
41 Injectors *3 Engine: Cranking When engine 12 - 19 ms - -

coolant temperature
is 0_C (injection is
carried out for all
cylinders
simultaneously)
When engine 26 - 40 ms
coolant temperature
is 20_C
When engine 6.0 - 9.1 ms

coolant temperature
is 80_C
Injectors*4 D Engine coolant Engine is idling 1.6 - 2.8 ms

temperature:
80–95_C
D Lamps, electric 2,500 r/min 1.4 - 2.6 ms
cooling fan and all
accessories: OFF
D Transmission: When engine is Increases
Neutral (A/T : suddenly raced
P range)
44 Ignition coils D Engine: After Engine is idling 2 - 18_BTDC - -

and power having warmed up
transistors D Timing lamp is set.
(The timing lamp
is set in order to 2,500 r/min 18 - 38_BTDC
check actual
ignition timing.)
45 ISC D Engine coolant A/C switch: OFF 2 - 25 STEP - -

(stepper) temperature: 80 -
motor 95_C
position *5 D Lamps, electric
cooling fan and all A/C switch: Increases by
accessories: OFF OFF ® ON 10 - 70 steps
D Transmission:
Neutral (A/T :
P range)
D Idle position
switch: ON D A/C switch: OFF Increases by
D Engine: Idling D Select lever: 5 - 50 steps
D When A/C switch N range ® D
is ON, A/C range
compressor should
be operating
49 A/C relay Engine: After having A/C switch: OFF OFF (Compressor Proce- 13A-49
warmed up/Engine is clutch is not dure No.
idling operating) 32
A/C switch: ON ON (Compressor

clutch is
operating)

No.
59 Oxygen D Transmission: 3,500 r/min 600 - 1,000 mV Code No. 13A-24

sensor 2nd gear <M/T>, 59
(rear) L range <A/T>
D Drive with throttle
widely open
ACTUATOR TEST REFERENCE TABLE 13100900357
Item Inspection Drive contents Inspection contents Normal condition Inspection Reference
No.
01 Injectors Cut fuel to No. Engine: Idling condition Code No. 13A-21
1 injector After having warmed becomes different 41
up/Engine is idling (becomes unsta-
02 Cut fuel to No. (Cut the fuel supply to each ble).
2 injector injector in turn and check
cylinders which don’t affect
03 Cut fuel to No. idling.)
3 injector
04 Cut fuel to No.

4 injector
07 Fuel pump Fuel pump D Engine: Pinch the Pulse is felt. Procedure 13A-46
operates and Cranking return hose No. 27
fuel is recircu- D Fuel with fingers
lated. pump: to feel the
Forced pulse of the
driving fuel being
Inspect recirculated.
according
to both Listen near Sound of opera-
the above the fuel tank tion is heard.
conditions. for the
sound of
fuel pump
operation.
08 Purge Solenoid valve Ignition switch: ON Sound of opera- Procedure 13A-51

control tion can be heard No. 35
solenoid turns from when solenoid
valve OFF to ON. valve is
driven.
10 EGR Solenoid valve Ignition switch: ON Sound of opera- Procedure 13A-51

control tion can be heard No. 36
solenoid turns from when solenoid
valve OFF to ON. valve is
driven.
17 Basic igni- Set to ignition Engine: Idling 5_BTDC - -

tion timing timing adjust- Timing light is set
ment mode
21 Fan con- Drive the fan Ignition switch: ON Radiator fan and Proce- 13A-45
troller motor condenser fan dure
operate at high No. 25
speed
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.
Engine-ECU Connector Terminal Arrangement
Terminal No. Check item Check condition (Engine condition) Normal condition
1 No. 1 injector While engine is idling after having From 11 - 14 V, momentarily

warmed up, suddenly depress the drops slightly
14 No. 2 injector accelerator pedal.
2 No. 3 injector
15 No. 4 injector
4 Stepper motor coil <A1> Engine: Soon after the warmed up System voltage « 0 V
engine is started (Changes repeatedly)
17 Stepper motor coil <A2>
5 Stepper motor coil <B1>
6 EGR control solenoid Ignition switch: ON System Voltage

valve
While engine is idling, suddenly depress From system voltage,
the accelerator pedal. momentarily drops
8 A/C relay D Engine: Idle speed System voltage or

D A/C switch: OFF ® ON momentarily
(A/C compressor is operating) 6V or more ® 0 - 3V
9 Purge control solenoid Ignition switch: ON System voltage

valve
Running at 3,000r/min while engine is 0 - 3V
warming up after having been started.
10 Ignition coil - No. 1, Engine r/min: 3,000 r/min 0.3 - 3.0V

No. 4 (power transistor)
23 Ignition coil - No. 2,

No. 3 (power transistor)
12 Power supply Ignition switch: ON System voltage
25
19 Air flow sensor reset Engine: Idle speed 0 - 1V

signal
Engine r/min: 3,000 r/min 6 - 9V
21 Fan controller Radiator fan and condenser fan are not 0 - 0.3 V
operating
Radiator fan and condenser fan are 0.7 V or more

operating
22 Fuel pump relay Ignition switch: ON System voltage
Engine: Idle speed 0 - 3V
24 A/C switch 2 D Engine: Idling When A/C is MAX. 0 - 3V

D Outside air COOL condition
temperature: (when the load by
25_C or more A/C is high)
(When A/C is System voltage

MAX. HOT
condition (when
the load by A/C is
low)
33 Alternator G terminal D Engine: Warm, idle Voltage rises by 0.2 - 3.5 V.

(radiator fan: OFF)
D Headlamp: OFF to ON
D Rear defogger switch: OFF to ON
D Brake lamp: ON
41 Alternator FR terminal D Engine: Warm, idle Voltage drops by 0.2 - 3.5 V.

(radiator fan: OFF)
D Brake lamp: ON
36 Engine warning lamp Ignition switch: OFF ® ON 0 - 3V ® 9 - 13V

(After several seconds have
elapsed)
37 Power steering fluid Engine: Idling after When steering System voltage
pressure switch warming up wheel is stationary
When steering 0 - 3V
wheel is turned
38 Control relay Ignition switch: OFF System voltage

(Power supply)
Ignition switch: ON 0 - 3V
45 A/C switch 1 Engine: Idle speed Turn the A/C 0 - 3V

switch OFF
Turn the A/C System voltage

switch ON (A/C
compressor is
operating)
58 Tachometer signal Engine r/min: 3,000 r/min 0.3 - 3.0V
60 Oxygen sensor heater Engine: Idling after warming up 0 - 3V
Engine r/min: 5,000r/min. System voltage
71 Ignition switch - ST Engine: Cranking 8V or more

72 Intake air temperature Ignition switch: When intake air 3.2 - 3.8V
sensor ON temperature is
0_C
When intake air 2.3 - 2.9V

temperature is
20_C

temperature is
40_C

temperature is
80_C
75 Oxygen sensor (rear) D Transmission: 2nd gear <M/T>, 0.6 - 1.0 V

L range <A/T>
D Engine r/min: 3,500 r/min or more
D Driving with the throttle valve
widely open
76 Oxygen sensor (front) Engine: Running at 2,500 r/min after 0 « 0.8V

warmed up (Check using a digital type (Changes repeatedly)
voltmeter)
80 Backup power supply Ignition switch: OFF System voltage
81 Sensor impressed Ignition switch: ON 4.5 - 5.5V

voltage
82 Ignition switch - IG Ignition switch: ON System voltage
83 Engine coolant Ignition switch: When engine 3.2 - 3.8V

temperature sensor ON coolant tempera-
ture is 0_C
When engine 2.3 - 2.9V

coolant tempera-
ture is 20_C

coolant tempera-
ture is 40_C

coolant tempera-
ture is 80_C
84 Throttle position Ignition switch: Set throttle valve 0.3 - 1.0V

sensor ON to idle position
Fully open throttle 4.5 - 5.5V

valve
85 Barometric pressure Ignition switch: When altitude is 3.7 - 4.3V

sensor ON 0m
When altitude is 3.2 - 3.8V

1,200m
86 Vehicle speed sensor D Ignition switch: ON 0 « 5V

D Move the vehicle slowly forward (Changes repeatedly)
87 Idle position switch Ignition switch: Set throttle valve 0 - 1V

ON to idle position
Slightly open 4V or more

throttle valve
88 Camshaft position Engine: Cranking 0.4 - 3.0V

sensor
Engine: Idle speed 0.5 - 2.0V
89 Crank angle sensor Engine: Cranking 0.4 - 4.0V
90 Air flow sensor Engine: Idle speed 2.2 - 3.2V
Engine r/min: 2,500r/min
91 Inhibitor switch <A/T> Ignition switch: Set selector lever 0 - 3V

ON to P or N
Set selector lever 8 - 14V

to Other than P or
N
CHECK CHART FOR RESISTANCE AND CONTINUITY

BETWEEN TERMINALS
1. Turn the ignition switch to OFF.
2. Disconnect the engine-ECU connector.
3. Measure the resistance and check for continuity between
the terminals of the engine-ECU harness-side connector
while referring to the check chart.
NOTE
(1) When measuring resistance and checking continuity,
a harness for checking contact pin pressure should
be used instead of inserting a test probe.
(2) Checking need not be carried out in the order given
in the chart.
Caution
If the terminals that should be checked are mistaken,
or if connector terminals are not correctly shorted
to earth, damage may be caused to the vehicle wiring,
sensors, engine-ECU and/or ohmmeter.
4. If the ohmmeter shows any deviation from the standard
value, check the corresponding sensor, actuator and
related electrical wiring, and then repair or replace.
5. After repair or replacement, recheck with the ohmmeter
to confirm that the repair or replacement has corrected
the problem.
Engine-ECU Harness Side Connector Terminal Arrangement
Terminal No. Inspection item Normal condition (Check condition)
1 - 12 No. 1 injector 13 - 16 W (At 20_C)
14 - 12 No. 2 injector
4 - 12 Stepper motor coil (A1) 28 - 33 W (At 20_C)
17 - 12 Stepper motor coil (A2)
5 - 12 Stepper motor coil (B1)
6 - 12 EGR control solenoid valve 36 - 44 W (At 20_C)
9 - 12 Purge control solenoid valve 36 - 44 W (At 20_C)
13 - Body earth Engine-ECU earth Continuity (0W)
26 - Body earth Engine-ECU earth
60 - 12 Oxygen sensor heater 11 - 18 W (At 20_C)
72 - 92 Intake air temperature sensor 5.3 - 6.7 kW (When intake air temperature is 0_C)
2.3 - 3.0 kW (When intake air temperature is 20_C)
83 - 92 Engine coolant temperature sensor 5.1 - 6.5 kW (When coolant temperature is 0_C)
2.1 - 2.7 kW (When coolant temperature is 20_C)
87 - 92 Idle position switch Continuity (when throttle valve is at idle position)
No continuity (when throttle valve is slightly open)
91 - Body earth Inhibitor switch <A/T> Continuity (when select lever is at P or N)
No continuity (when select lever is at D, 2, L or R)

Analyzer INSPECTION PROCEDURE USING AN ANALYZER

13100930219
AIR FLOW SENSOR (AFS)

Special
patterns Measurement Method
pickup 1. Disconnect the air flow sensor connector, and connect
the special tool (test harness: MB991709) in between.
(All terminals should be connected.)
2. Connect the analyzer special patterns pickup to air flow
sensor connector terminal 3.
Alternate Method (Test harness not available)
1. Connect the analyzer special patterns pickup to
engine-ECU terminal 90.
Standard Wave Pattern
Observation conditions
Function Special patterns

Pattern height Low
Pattern selector Display
Engine r/min Idle speed
Standard wave pattern
(V) The time (cycle time) T is reduced when
10 T the amount of intake air increases.
T1 T2 Times T1 and T2 are equal.
Time
0
Observation conditions (from conditions above engine speed is increased by racing.)
(V)
10
T
Time
0
Wave Pattern Observation Points

Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.
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.

Analyzer
CAMSHAFT POSITION SENSOR AND CRANK ANGLE
connector SENSOR
Special patterns
pick-up 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
Crank angle position sensor terminal 2.
sensor connector 3. Disconnect the crank angle sensor connector and connect
the special tool (test harness: MD998478) in between.
4. Connect the analyzer special patterns pickup to crank
angle sensor terminal 2.
engine-ECU terminal 88. (When checking the camshaft
position sensor signal wave pattern.)
engine-ECU terminal 89. (When checking the crank angle
sensor signal wave pattern.)
Pattern height Low

2 engine revolutions
(1 camshaft revolution) The time (cycle time) T is
(V)
reduced when the engine
75_BTDC speed increases
5_BTDC
Crank angle
sensor output
wave pattern
0
131° 49° 56° 34°
Camshaft posi-
tion sensor out-
put wave pat-
tern
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.
D Example 2
Cause of problem
Loose timing belt
Abnormality in sensor disk
Wave pattern is displaced to the left or right.
Analyzer INJECTOR
Measurement Method
1. Disconnect the injector connector, and then connect the
special tool (test harness: MB991348) in between.
(Both the power supply side and engine-ECU side should
be connected.)
Special
patterns 2. Connect the analyzer special patterns pickup to terminal
pickup 2 of the injector connector.

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

Pattern height Variable
Variable knob Adjust while viewing the wave pattern
(V)
Point A
50
Solenoid back electromotive force

(Approx. 7´10 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 doesn’t Short in the injector solenoid
appear at all.
Point B: Injector drive time
D The injector drive time will be synchronized with the MUT-II

tester display.
D When the engine is suddenly raced, the drive time will
be greatly extended at first, but the drive time will soon
match the engine speed.
--- When idling

- - When racing
STEPPER MOTOR
Analyzer
Measurement Method
1. Disconnect the stepper motor connector, and connect
Special 2. Connect the analyzer special patterns pickup to the
patterns
pickup stepper motor-side connector terminal 1 (red clip of special
tool), terminal 3 (blue clip), terminal 4 (black clip) and
terminal 6 (yellow clip) respectively.

engine-ECU terminal 4, connection terminal 5, connection
terminal 17, and connection terminal 18 respectively.
Pattern height High
Engine condition When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF
to ON (without starting the engine).
While the engine is idling, turn the A/C switch to ON.
Immediately after starting the warm engine
(V)
The wave pattern
appears for an Point B Point A
instant, but soon Coil reverse electromotive Induced electromotive force
30 disappears. force (Approx. 3 ´ 10V) from the motor turning
20
10
Stepper
motor
control
signal
wave
pattern
Time

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.)
Induced electromotive force does not appear or is extremely small. Motor is malfunctioning
Point B: Height of coil reverse electromotive force
Coil reverse electromotive force does not appear or is extremely small. Short in the coil
Examples of Abnormal Wave Pattern

D Example 1
Cause of problem
Motor is malfunctioning. (Motor is not operating.)
Induced electromotive force from the motor turning does
not appear.
D Example 2
Open
circuit Cause of problem
side
Open circuit in the line between the stepper motor and
the engine-ECU.
Current is not supplied to the motor coil on the open
circuit side. (Voltage does not drop to 0 V.)
Normal Furthermore, the induced electromotive force waveform
side at the normal side is slightly different from the normal
waveform.
Analyzer IGNITION COIL AND POWER TRANSISTOR
Power transistor control signal
Measurement Method
1. Disconnect the ignition coil connector, and connect the
special tool (test harness: MB991348) in between. (All
terminals should be connected.)
Special 2. Connect the analyzer special patterns pickup to terminal
patterns 3 of each ignition coil connector in turn.
pickup
engine-ECU terminal 10 (No. 1 - No. 4), terminal 23
(No. 2 - No. 3) respectively.
Observation condition
Pattern height Low
Engine r/min Approx. 1,200 r/min
(V)
T
T: Revolution time corresponding to a crank angle of 180_
6 5_BTDC Compression top dead center
75_BTDC
4
Crank angle
sensor output 2
wave pattern
Ignition period
4
T1 q q: Spark
Power transistor advance
control signal 2 angle
wave pattern
0
OFF ON
Dwell section
Time
T1: Time computed by the engine-ECU

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
Open-circuit in ignition primary circuit
Top-right part of the build-up section cannot be seen,
and voltage value is approximately 2V too low.
D Example 2
VB
Cause of problem
Malfunction in power transistor
Power voltage results when the power transistor is ON.
MPI <4G6> - On-vehicle Service 13A-81
THROTTLE BODY (THROTTLE VALVE AREA)

CLEANING
1. Start the engine and warm it up until the coolant is heated
to 80_C or higher and then stop the engine.
2. Remove the air intake hose from the throttle body.
3. Plug the bypass passage inlet of the throttle body.

Caution
Do not allow cleaning solvent to enter the bypass
passage.
4. Spray cleaning solvent into the valve through the throttle
body intake port and leave it for about 5 minutes.
5. Start the engine, race it several times and idle it for about
1 minute. If the idling speed becomes unstable (or if the
engine stalls) due to the bypass passage being plugged,
slightly open the throttle valve to keep the engine running.
6. If the throttle valve deposits are not removed, repeat
steps 4 and 5.
7. Unplug the bypass passage inlet.
8. Attach the air intake hose.
9. Use the MUT-II to erase the self-diagnosis code.
10. Adjust the basic idle speed. (Refer to P.13A-83.)
NOTE
If the engine hunts while idling after adjustment of the
basic idle speed, disconnect the (–) cable from the battery
for 10 seconds or more, and then reconnect it and run
the engine at idle for about 10 minutes.
Throttle position sensor (with

IDLE POSITION SWITCH AND THROTTLE
built-in idle position switch) POSITION SENSOR ADJUSTMENT 13100130268

13A-82 MPI <4G6> - On-vehicle Service
<Vehicles without auto-cruise control system> 2. Insert a thickness gauge as follows:

Throttle lever
<Vehicles without auto-cruise control system>
Insert a thickness gauge with a thickness of 0.45 mm
Thick-
ness between the fixed SAS and the throttle lever.
Fixed gauge
SAS
Fixed SAS
<Vehicles with auto-cruise control system> <Vehicles with auto-cruise control system>
Insert a 1.4-mm thick thickness gauge up to approx. 3
Throttle lever 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 Thickness 3. Turn the ignition switch to ON (but do not start the engine).
gauge
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 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 doesn’t 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.
4. Select the item No.30 of the MUT-II Actuator test.

NOTE
This holds the ISC servo at the basic step to adjust the
basic idle speed.
5. Check the idle speed.
Standard value:
750 ± 50 r/min
NOTE
(1) The engine speed may be 20 to 100 r/min lower
than indicated above for a new vehicle [driven
approximately 500 km or less], but no adjustment
is necessary.
(2) If the engine stalls or the engine speed is low even
though the vehicle has been driven approximately
500 km or more, it is probable that deposits are
adhered to the throttle valve, so clean it. (Refer to
P.13A-81.)
6. If not within the standard value range, turn the speed

adjusting screw (SAS) to make the necessary adjustment.
NOTE
If the idling speed is higher than the standard value range
even when the SAS is fully closed, check whether or
not there is any indication that the fixed SAS has been
moved. If there is an indication that it has been moved,
adjust the fixed SAS.
7. Press the MUT-II clear key, and release the ISC servo
from the Actuator test mode.
NOTE
Unless the ISC servo is released, the Actuator test mode
will continue 27 minutes.
8. Switch OFF the ignition switch.
10. Start the engine again and let it run at idle speed for
about 10 minutes; check that the idling condition is normal.
FUEL PRESSURE TEST 13100190303
Fuel high 1. Release residual pressure from the fuel pipe line to prevent
Delivery pipe pressure fuel gush out. (Refer to P.13A-88.)
hose
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.
3. Remove the union joint and bolt from the special tool
High Fuel pressure (adapter hose MD998709) and instead attach the special
pressure gauge tool (hose adapter MD998742) to the adapter hose.
hose O-ring or 4. Install a fuel pressure gauge on the adapter hose that
gasket was set up in step 3.
MD998709 Use a suitable O-ring or gasket between the fuel pressure
MD998742 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
10. Disconnect the vacuum hose from the fuel pressure

regulator and measure fuel pressure with the hose end
closed by a finger.
Standard value:
324 - 343 kPa at kerb idle
11. Check to see that fuel pressure at idle does not drop
even after the engine has been raced several times.
12. Racing the engine repeatedly, hold the fuel return hose
lightly with fingers to feel that fuel pressure is present
in the return hose.
NOTE
If the fuel flow rate is low, there will be no fuel pressure
in the return hose.
13. If any of fuel pressure measured in steps 9 to 12 is out
of specification, troubleshoot and repair according to the
table below.
Symptom Probable cause Remedy
D Fuel pressure too low Clogged fuel filter Replace fuel filter
D Fuel pressure drops after racing
D No fuel pressure in fuel return Fuel leaking to return side due to poor Replace fuel pressure regulator
hose fuel regulator valve seating or settled
spring
Low fuel pump delivery pressure Replace fuel pump
Fuel pressure too high Binding valve in fuel pressure Replace fuel pressure regulator
regulator
Clogged fuel return hose or pipe Clean or replace hose or pipe
Same fuel pressure when vacuum Damaged vacuum hose or clogged Replace vacuum hose or clean nipple
hose is connected and when nipple
disconnected
14. Stop the engine and check change of fuel pressure gauge
reading. Normal if the reading does not drop within 2
minutes. If it does, observe the rate of drop and
troubleshoot and repair according to the table below.
Fuel pressure drops gradually after Leaky injector Replace injector

engine is stopped
Leaky fuel regulator valve seat Replace fuel pressure regulator
Fuel pressure drops sharply Check valve in fuel pump is held open Replace fuel pump
immediately after engine is stopped
15. Release residual pressure from the fuel pipe line. (Refer
to P.13A-88.)
16. Remove the fuel pressure gauge and special tool from
the delivery pipe.
Caution
17. Replace the O-ring at the end of the fuel high pressure
hose with a new one. Furthermore, apply engine oil to
the new O-ring before replacement.
18. Fit the fuel high pressure hose over the delivery pipe
and tighten the bolt to specified torque.
19. Check for fuel leaks.
(1) Apply the battery voltage to the fuel pump drive
terminal to drive the fuel pump.
(2) Under fuel pressure, check the fuel line for leaks.
FUEL PUMP CONNECTOR DISCONNECTION

(HOW TO REDUCE THE FUEL PRESSURE)
13100090252
When removing the fuel pipe, hose, etc., since fuel pressure
in the fuel pipe line is high, do the following operation so
as to release fuel pressure in the line and prevent fuel from
running out.
1. Raise the rear seat cushion.
2. Disconnect the floor 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 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
Fuel pump attached directly to the battery, check if the sound
drive connector
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 13100210368
Name Symbol Name Symbol
A/C relay G Engine warning lamp (check engine lamp) N
A/C switch R Fuel pump check terminal E
Air flow sensor (with intake air temperature F Idle speed control servo C
sensor and barometric pressure sensor)
Ignition coil J
Camshaft position sensor K Inhibitor switch <A/T> M
Control relay and fuel pump relay P Injectors J
Crank angle sensor I Oxygen sensor (front) S
Detonation sensor B Oxygen sensor (rear) T
Diagnosis connector O Power steering fluid pressure switch H
EGR control solenoid valve A Purge control solenoid valve A
Engine coolant temperature sensor L Throttle position sensor (with idle position C
switch)
Engine-ECU Q Vehicle speed sensor D
T
Equipment side CONTROL RELAY AND FUEL PUMP RELAY

connector CONTINUITY CHECK 13100990170
Battery voltage Terminal No.

1 2 3 4
Fuel Not supplied
pump
relay and Supplied
control
relay
Equipment side INTAKE AIR TEMPERATURE SENSOR CHECK

connector 13100280239
Air flow sensor
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)
Intake air temperature 3. Measure resistance while heating the sensor using a hair
sensor 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

CHECK 13100310242
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.
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 CHECK 13100320276

Throttle position
sensor 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 Changes smoothly in
until fully open from the idle proportion to the opening
position angle of the throttle valve
4. If the resistance is outside the standard value, or if it
doesn’t change smoothly, replace the throttle position
sensor.
NOTE
For the throttle position sensor adjustment procedure,
refer to P.13A-81.
IDLE POSITION SWITCH CHECK 13100330262

Throttle position
sensor 1. Disconnect the throttle position sensor connector.
2. Check the continuity between the throttle position sensor
TPS equipment connector side terminal 3 and terminal 4.
side connector
Normal condition:
Accelerator pedal Continuity
Depressed Non-conductive
Released Conductive (0 W)
3. If out of specification, replace the throttle position sensor.
NOTE
After replacement, the idle position switch and throttle
position sensor should be adjusted. (Refer to P.13A-81.)
Equipment side
Oxygen sensor
OXYGEN SENSOR CHECK 13100510161
connector
(front) <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.
6. Connect a digital voltage meter between terminal 1 and
terminal 2.
MB991223 7. While repeatedly racing the engine, measure the oxygen
sensor output voltage.
Standard value:
Engine Oxygen sensor Remarks
output voltage
When 0.6 - 1.0 V If you make the air/fuel ratio
racing the rich by racing the engine
engine repeatedly, a normal oxy-
gen sensor will output a
voltage of 0.6 - 1.0 V.
8. If the sensor is defective, replace the oxygen sensor.
NOTE
For removal and installation of the oxygen sensor, refer
to GROUP 15 - Exhaust Pipe and Main Muffler.
Equipment side
<Oxygen sensor (rear)>
connector 1. Disconnect the oxygen sensor connector and connect
the special tool (test harness set) to the connector on
Oxygen the oxygen sensor side.
sensor
(rear) 2. Make sure that there is continuity (11 - 18 W at 20_C)
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.
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
MD998706
Clip (MB991608)
Battery
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 5. Activate the injector and check the atomized spray
Return hose
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 injector’s 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 IDLE SPEED CONTROL (ISC) SERVO

control 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
motor’s 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

Pre-removal Operation
D Fuel Discharge Prevention (Refer to P.13A-88.)
5 8
11
12
10 5, 7
6 9
4 8
O-ring
3
7 2
9 Nm
10 - 13 Nm 11
12 O-ring
Engine oil
1
Removal steps
1. PCV hose connection "AA 7. Fuel pressure regulator
2. Injector connector AA" 8. Delivery pipe
3. Purge control solenoid valve con- 9. Insulator
nector 10. Insulator
4. EGR solenoid valve connector AA" "AA 11. Injector
"AA 5. High-pressure fuel hose connection 12. Grommet
6. Fuel return hose connection
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

D Engine Coolant Draining D Air Cleaner Installation
(Refer to GROUP 14 - On-vehicle Service.) D Engine Coolant Supplying
D Air Cleaner Removal (Refer to GROUP 14 - On-vehicle Service.)
2
4
19 Nm
7 1
Removal steps
1. Accelerator cable connection 5. Water hose connection
2. Throttle position sensor connector 6. Throttle body
3. Idle speed control servo connector "AA 7. Throttle body gasket
4. Vacuum hose connection
Up INSTALLATION SERVICE POINT

"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
MPI <4G6> - Throttle Body 13A-99
DISASSEMBLY AND REASSEMBLY 13100970280
6
1
7
5
Disassembly steps
"AA 1. Throttle position sensor NOTE
2. Idle speed control body assembly 1. The fixed SAS and the speed adjusting screw are
3. O-ring correctly adjusted at the factory and should not be
4. Throttle body removed.
5. Fixed SAS 2. If the fixed SAS should happen to have been
6. Speed adjusting screw removed, carry out fixed SAS adjustment.
7. O-ring (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 MPI <4G6> - Throttle Body
<Vehicles with auto-cruise control system>
7
8
6
1
2
5
Disassembly steps
"AA 1. Throttle position sensor NOTE
2. Lever assembly 1. The fixed SAS and the speed adjusting screw are
3. Idle speed control body assembly correctly adjusted at the factory and should not be
4. O-ring removed.
5. Throttle body 2. If the fixed SAS should happen to have been
6. Fixed SAS removed, carry out fixed SAS adjustment.
7. Speed adjusting screw (Refer to page 13A-83.)
8. O-ring 3. If the speed adjusting screw should happen to have
been removed, carry out speed adjusting screw
adjustment. (Refer to 13A-83.)
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.
MPI <4G6> - Throttle Body 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)
TPS output of the TPS connector when the throttle valve is fully closed
and fully open.
TPS power
supply Earth Normal condition:
Throttle valve condition Continuity
Fully closed Continuity
Fully open No continuity
Idle position switch
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 activities such as fuel injection control, idle
of sensors which detect the engine conditions, speed control and ignition timing control. In
the engine-ECU which controls the system addition, the engine-ECU is equipped with
based on signals from these sensors, and several diagnosis modes which simplify
actuators which operate under the control of troubleshooting when a problem develops.
the engine-ECU. The engine-ECU carries out
FUEL INJECTION CONTROL

The injector drive times and injector timing are The engine-ECU provides a richer air/fuel
controlled so that the optimum air/fuel mixture mixture by carrying out “open-loop” control
is supplied to the engine to correspond to the when the engine is cold or operating under
continually-changing engine operation condi- high load conditions in order to maintain engine
tions. performance. In addition, when the engine is
A single injector is mounted at the intake port warm or operating under normal conditions,
of each cylinder. Fuel is sent under pressure the engine-ECU controls the air/fuel mixture
from the fuel tank by the fuel pump, with the by using the oxygen sensor signal to carry out
pressure being regulated by the fuel pressure “closed-loop” control in order to obtain the
regulator. The fuel thus regulated is distributed theoretical air/fuel mixture ratio that provides
to each of the injectors. the maximum cleaning performance from the
Fuel injection is normally carried out once for three way catalyst.
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.
IDLE AIR CONTROL

The idle speed is kept at the optimum speed conditioner load. In addition, when the air
by controlling the amount of air that bypasses conditioner switch is turned off and on while
the throttle valve in accordance with changes the engine is idling, the ISC motor operates
in idling conditions and engine load during to adjust the throttle valve bypass air amount
idling. The engine-ECU drives the idle speed in accordance with the engine load conditions
control (ISC) motor to keep the engine running in order to avoid fluctuations in the engine
at the pre-set idle target speed in accordance speed.
with the engine coolant temperature and air
IGNITION TIMING CONTROL

The power transistor located in the ignition engine operating conditions. The ignition timing
primary circuit turns ON and OFF to control is determined by the engine-ECU from the
the primary current flow to the ignition coil. This engine speed, intake air volume, engine coolant
controls the ignition timing in order to provide temperature and atmospheric pressure.
the optimum ignition timing with respect to the
D When an abnormality is detected in one code corresponding to the abnormality is
of the sensors or actuators related to output.
emission control, the engine warning lamp D The RAM data inside the engine-ECU that
(check engine lamp) illuminates as a is related to the sensors and actuators can
warning to the driver. be read by means of the MUT-II. In addition,
D When an abnormality is detected in one the actuators can be force-driven under
of the sensors or actuators, a diagnosis certain circumstances.
MPI <6A1> - General Information 13A-103
1. Fuel Pump Control 4. Traction Control
Turn the fuel pump relay ON so that current Engine output torque is reduced based on
is supplied to the fuel pump while the engine signals from the TCL-ECU in response to
is cranking or running. the conditions under which slipping of the
2. A/C Relay Control driven wheels and turning of the vehicle
Turn the compressor clutch of the A/C ON occur.
and OFF. Furthermore, reduction of output torque is
3. Fan Relay Control performed by closing the throttle valve and
The revolutions of the radiator fan and retarding the ignition timing.
condenser fan are controlled in response 5. Purge Control Solenoid Valve Control
to the engine coolant temperature and Refer to GROUP 17.
vehicle speed. 6. EGR Control Solenoid Valve Control
Refer to GROUP 17.
GENERAL SPECIFICATIONS
Throttle body Throttle bore mm 60
Throttle position sensor Variable resistor type
Accelerator pedal position sensor Variable resistor type
Idle speed control servo Stepper motor type

(Stepper motor type by-pass air control system with the air
volume limiter)
Idle position switch Rotary contact type, within throttle position sensor
<Vehicles without TCL>
Idle position switch <Vehicles with TCL> Rotary contact type, within accelerator pedal position
sensor
Engine-ECU Identification model No. E2T66876 <Vehicles without TCL>

E2T66877 <Vehicles with TCL>
Sensors Air flow sensor Karman vortex type
Barometric pressure sensor Semiconductor type
Intake air temperature sensor Thermistor type
Engine coolant temperature sensor Thermistor type
Oxygen sensor Zirconia type
Vehicle speed sensor Magnetic resistive element type
Inhibitor switch Contact switch type
Top dead centre sensor Hall element type
Crank angle sensor Hall element type
Detonation sensor Piezoelectric type
Power steering fluid pressure switch Contact switch type

13A-104 MPI <6A1> - General Information
Actuators Control relay type Contact switch type
Fuel pump relay type Contact switch type
Injector type and number Electromagnetic type, 6
Injector identification mark CDH210
EGR control solenoid valve Duty cycle type solenoid valve
Purge control solenoid valve ON/OFF type solenoid valve
Ventilation control solenoid valve Duty cycle type solenoid valve
Vacuum control solenoid valve Duty cycle type solenoid valve
Fuel pressure Regulator pressure kPa 329

regulator
MPI <6A1> - General Information 13A-105
MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM
*1 Oxygen sensor (front) Engine- z1 Injector
*2 Air flow sensor ECU z2 Purge control solenoid valve
*3 Intake air temperature sensor z3 Idle speed control servo
*4 Throttle position sensor z4 EGR control solenoid valve
*5 Idle position switch z5 Ventilation control solenoid valve
*6 Top dead centre sensor <TCL>
*7 Crank angle sensor z6 Vacuum control solenoid valve <TCL>
*8 Engine coolant temperature sensor
*9 Barometric pressure sensor D Fuel pump relay
*10 Oxygen sensor (rear) D Control relay
D A/C power relay
D Power supply voltage D Engine warning lamp
D Vehicle speed sensor D Diagnosis signal
D A/C switch 1, 2 D Ignition coil, power transistor
D Inhibitor switch D Fan controller
D Power steering fluid pressure switch D Alternator G terminal
D Ignition switch - ST D A/T-ECU
D Ignition switch - IG D TCL-ECU <TCL>
D Alternator FR terminal
D A/T-ECU
D TCL-ECU <TCL>
z6 Vacuum control solenoid

valve <TCL>
z5 Ventiration control solenoid valve <TCL>
Vacuum
tank *3 Intake air temperature sensor
z3 Idle speed Air flow sensor (with barometric
Vacuum control servo pressure sensor)
actuator
<TCL> Air cleaner
Fuel pressure *4, *5

regulator Air
PCV valve
EGR
valve Throttle
position
*9 *2
z1 Injector z4 sensor (with
From fuel idle position
To fuel switch)
tank pump
EGR control
Canister
solenoid valve
*8 Engine
coolant z2 Purge control
tempera- solenoid valve
ture sensor
*10 Oxygen *6 Top dead centre sensor
sensor
*1 Oxygen (rear)
sensor
(front)
Distributor
Catalytic converter
13A-106 MPI <6A1> - Service Specifications/Sealant
Basic idle speed r/min 650±50
Throttle position sensor ad- Vehicles without TCL 400 - 1,000

justing voltage mV
Vehicles with TCL 580 - 690
Accelerator pedal position sensor adjusting voltage mV 400 - 1,000
Throttle position sensor resistance kW 3.5 - 6.5
Accelerator pedal position sensor resistance kW 3.5 - 6.5
Idle speed control servo coil resistance W 28 - 33 (at 20_C)
Intake air temperature sensor 20_C 2.3 - 3.0

resistance kW
80_C 0.30 - 0.42
Engine coolant temperature 20_C 2.1 - 2.7

sensor resistance kW
80_C 0.26 - 0.36
Oxygen sensor output voltage V 0.6 - 1.0
Fuel pressure kPa 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)
Ventilation control solenoid valve coil resistance W 36 - 44 (at 20_C)
Vacuum control solenoid valve coil resistance W 36 - 44 (at 20_C)
SEALANT 13100050205
threaded portion
MPI <6A1> - Special Tools 13A-107

MB991223 Harness set D Fuel gauge simple inspection
A
C: Power circuit inspection
C: MB991221 C: LED harness D: Commercial tester connection
D: MB991222 adapter
D: Probe
B
MB991502 MUT-II sub D Reading diagnosis code

assembly D MPI system inspection
MB991348 Test harness set D Measurement of voltage during trouble-

shooting
MB991709 Test harness
MB991519 Alternator harness Measurement of voltage during

connector troubleshooting
MD998463 Test harness D Inspection of idle speed control servo

(6-pin, square) D Inspection using an analyzer
MD998478 Test harness D Measurement of voltage during trouble-

(3-pin, triangle) shooting
13A-108 MPI <6A1> - Special Tools/Troubleshooting

MD998709 Adaptor hose Measurement of fuel pressure
MD998742 Hose adaptor
MD998706 Injector test set Checking the spray condition of injectors
MB991607 Injector test

harness
MD998741 Injector test

adaptor
MB991608 Clip

Service Points.

If an abnormality occurs in any of the following items related
to the Multipoint Fuel Injection (MPI) system, the engine
warning lamp will illuminate.
Engine warning lamp

(check engine lamp)
MPI <6A1> - Troubleshooting 13A-109
Engine-ECU
Oxygen sensor
Air flow sensor
Crank angle sensor
Top dead centre sensor
Detonation sensor
Injector
Vacuum control solenoid valve <TCL>
Ventilation control solenoid valve <TCL>
Immobilizer system

CODES
Service Points.
ACTUATOR TESTING
13A-110 MPI <6A1> - Troubleshooting
FAIL-SAFE FUNCTION REFERENCE TABLE 13100910305
Air flow sensor 1. Uses the throttle position sensor signal and engine speed signal (crank angle sensor
signal) to take reading of the basic injector drive time and basic ignition timing from
the pre-set mapping.
2. Fixes the ISC servo in the appointed position so idle control is not performed.
Intake air temperature Controls as if the intake air temperature is 25_C.

sensor
Throttle position No increase in fuel injection amount during acceleration due to the throttle position sensor
sensor (TPS) signal.
Engine coolant Controls as if the engine coolant temperature is 80_C.

temperature sensor
Top dead centre sen- Injects fuel to all cylinders simultaneously.

sor (However, after the ignition switch is turned to ON, the No. 1 cylinder top dead centre is not
detected at all.)
Barometric pressure Controls as if the barometric pressure is 101 kPa.

sensor
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 Ignition timing is not retarded during transmission gear shifting (overall engine and
with transmission transmission control).
control unit <A/T>
Alternator FR terminal Does not control the output of the alternator according to an electrical load. (works as a
normal alternator)
NOTE
When a problem is detected in the vacuum control solenoid valve, ventilation control solenoid valve,
crank angle sensor or any of the above items, traction control is not performed <Vehicles with TCL>.
11 Oxygen sensor (front) system 13A-112
12 Air flow sensor system 13A-113
13 Intake air temperature sensor system 13A-113
14 Throttle position sensor system 13A-114
21 Engine coolant temperature sensor system 13A-115
22 Crank angle sensor system 13A-116
23 Top dead centre sensor 13A-117
24 Vehicle speed sensor system 13A-118
25 Barometric pressure sensor system 13A-119
31 Detonation sensor system 13A-120
41 Injector system 13A-120
54 Immobilizer system 13A-121
59 Oxygen sensor (rear) system 13A-122
61 Communication wire with A/T-ECU system <A/T> 13A-123
64 Alternator FR terminal system 13A-123
71 Vacuum control solenoid valve system <Vehicles with TCL> 13A-124
72 Ventilation control solenoid valve system <Vehicles with TCL> 13A-125


Code No. 11 Oxygen sensor (front) system Probable cause
Range of Check D Malfunction of the oxygen sensor (front)
D Intake air temperature is 20 - 50_C. D Malfunction of the engine-ECU
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.
NG
Check the oxygen sensor (front). (Refer to P.13A-196.) Replace
OK
1. NG
Measure at the oxygen sensor (front) connector C-46. Check the harness wire between the
D Disconnect the connector, and measure at the oxygen sensor (front) and the control
2. NG NG
OK: Continuity
3. Continuity between 4 and earth OK
3. NG
OK: Continuity
OK
NG NG
Check the following connectors: Repair NG
C-46, C-39 Check the harness wire between the Repair
OK
(front) connector.
NG
NG
the oxygen sensor (front) connector.
OK
Replace the engine-ECU. oxygen sensor (front) and the earth,
Code No. 12 Air flow sensor system Probable cause
Range of Check D Malfunction of the air flow sensor
D Engine speed is 500 r/min or more. D Improper connector contact, open circuit or
Set conditions short-circuited harness wire of the air flow sensor
D Sensor output frequency is 3 Hz or less for 4 seconds. D Malfunction of the engine-ECU
1. NG
Measure at the air flow sensor con- Check the air flow sensor circuit.
nector B-12. (Refer to P.13A-159, INSPEC-
D Connect the connector. (Use TION PROCEDURE 49.)
the test harness: MB991709)
2. NG NG NG
(Engine: Idling) Measure at the engine-ECU con- Check the following connector: Repair
OK: 2.2 - 3.2 V nector C-33. B-12
2. Voltage between 7 and earth D Connect the connector.
OK: 0 - 1 V (Engine: idling) OK
6 - 9 V (2,000 r/min) (Ignition switch: ON)
OK OK: 6 - 9 V
NG
OK
NG
C-33
OK

NG
Code No. 13 Intake air temperature sensor system Probable cause

Range of Check D Malfunction of the intake air temperature sensor
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the intake air
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.
NG
Check the intake air temperature Replace
sensor.
OK
NG NG
Measure at the air flow sensor con- Check the following connector: Repair
nector B-12. C-39
OK: 4.5 - 4.9 V NG
OK: Continuity Check the harness wire between Repair
the engine-ECU and the intake air
NG
Check the following connector: Repair OK
B-12
OK
NG
Code No. 14 Throttle position sensor system Probable cause

Range of Check D Malfunction of the throttle position sensor or
D Ignition switch: ON maladjustment
D Excluding 60 seconds after the ignition switch is turned to ON or immediately D Improper connector contact, open circuit or
after the engine starts. short-circuited harness wire of the throttle position
D When the idle position switch is ON, the sensor output voltage is 2 V or more D Improper “ON” state of idle position switch
for 4 seconds. D Short circuit of the idle position switch signal line
or D Malfunction of the engine-ECU
D The sensor output voltage is 0.2 V or less for 4 seconds.
NG
26 Idle position switch system (Refer to P.13A-146, INSPECTION
OK: With the throttle valve at the PROCEDURE 28.) <Vehicles without
idle position: ON TCL>
With the throttle valve slight- (Refer to P.13A-147, INSPECTION
ly open: OFF PROCEDURE 29.) <Vehicles with
TCL>
OK
NG
Check the throttle position sensor. Replace
OK
NG NG
Measure at the throttle position sensor Check the following connector: Repair
connector B-07. C-39
OK
OK: 4.8 - 5.2 V NG
engine-ECU and the throttle position
OK sensor connector.
Check the throttle position sensor out- OK
put circuit. (Refer to P.13A-160, IN-
SPECTION PROCEDURE 50.) Replace the engine-ECU.
Code No. 21 Engine coolant temperature sensor system Probable cause
Range of Check D Malfunction of the engine coolant temperature sensor
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the engine coolant
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.
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.
NG
Check the engine coolant temperature Replace
OK
NG NG
Measure at the engine coolant temper- Check the following connector: Repair
ature sensor connector B-33. C-39
OK: 4.5 - 4.9 V NG
engine-ECU and the engine coolant
OK
OK
B-33
NG
NG
Repair

D Engine is cranking. D Improper connector contact, open circuit or
Set conditions short-circuited harness wire of the crank angle sensor
OK
D Connect the connector. (Use the test harness: MD998478.)
OK: 0.4 - 4.0 V
OK: 1.5 - 2.5 V
NG
1. NG
D Disconnect the connector, and measure at the harness side. control relay connector, and repair if necessary.
2. NG NG
OK: 4.8 - 5.2 V
OK: Continuity
OK
NG NG
OK the crank angle sensor
connector.
OK
NG
Replace the crank angle sensor.
Code No.23 Top dead centre sensor system Probable cause
Range of Check D Malfunction of the top dead centre sensor
D Engine speed is approx. 50 r/min or more. short-circuited harness wire of the top dead centre
OK
Measure at the distributor connector B-42. Replace the engine-ECU.
D Connect the connector. (Use the test harness: MB991348 and
jumper wire.)
OK: 0.4 - 3.0 V
OK: 1.5 - 2.0 V
NG
1. NG
Measure at the distributor connector B-42. Check the harness wire between the top dead centre sensor and
D Disconnect the connector, and measure at the harness side. the control relay connector, and repair if necessary.
2. NG NG
OK: 4.8 - 5.2 V
OK: Continuity
OK
NG NG
OK the top dead centre sensor
connector.
OK
NG
Replace the distributor
Check the harness wire between the top dead centre sensor and
Code No. 24 Vehicles speed sensor system Probable cause

Range of check D Malfunction of the vehicle speed sensor
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the vehicle speed
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).
NG
tion Meters.)
OK
1. NG NG
Measure at the vehicle speed sensor connector B-66 <M/T>, B-67 Check the following Repair
<A/T>. connectors:
D Disconnect the connector, and measure at the harness B-65 <M/T>, C-90, C-135,
side. 2. NG C-131 OK
OK: 4.8 - 5.2 V 3. NG NG
3. Continuity between 2 and earth NG
OK: Continuity Check the harness wire Repair
OK between the vehicle
NG speed sensor and ignition
Check the following Repair switch connector.
connectors:
B-66 <M/T>, B-67 <A/T> OK
OK Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.)
Check trouble symptom. NG
NG
connectors:
NG B-65 <M/T>, C-48, C-39
between the engine-ECU OK
sensor connector. Check trouble symptom.
OK NG
NG
Replace the engine-ECU. Check the harness wire Repair
sensor connector.
OK
NG
connector:
B-65 <M/T>
OK

NG
Code No. 25 Barometric pressure sensor system Probable cause
Range of Check D Malfunction of the barometric pressure sensor
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the barometric pressure
D Battery voltage is 8 V or more. D Malfunction of the engine-ECU
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.
NG NG NG
Measure at the air flow sensor con- Measure at the air flow sensor con- Check the following connector: Repair
nector B-12. nector B-12. C-39
D Connect the connector. (Use D Disconnect the connector, and
OK
the test harness: MB991709) measure at the harness side.
D Voltage between 2 and earth D Voltage between 1 and earth Check trouble symptom.
(Ignition switch: ON) (Ignition switch: ON)
OK: 3.7 - 4.3 V (Altitude: 0 m) OK: 4.8 - 5.2 V NG
3.2 - 3.8 V (Altitude: D Continuity between 5 and earth NG
1,200 m) OK: Continuity Check the harness wire between Repair
the engine-ECU and the baromet-
OK OK ric pressure sensor connector.
NG OK
B-12
OK

NG
NG
Check the harness wire between Repair
the engine-ECU and the baromet- OK
ric pressure sensor connector. Replace the air flow sensor.
NG
Measure at the engine-ECU con- Check the harness wire between
nector C-39. the engine-ECU and the baromet-
D Connect the connector. ric pressure sensor connector, and
D Voltage between 85 and earth repair if necessary.
OK: 3.7 - 4.3 V (Altitude: 0 m)
3.2 - 3.8 V (Altitude:
1,200 m)
OK
NG
C-39
OK

NG

Code No. 31 Detonation sensor system Probable cause

Range of Check D Malfunction of the detonation sensor
D Excluding 60 seconds after the ignition switch is turned to ON or immediately short-circuited harness wire of the detonation sensor
after the engine starts. circuit
D Engine speed is approx. 5,000 r/min or more D Malfunction of the engine-ECU
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.
OK NG
Measure at the detonation sensor con- Check the following connectors: Repair
nector B-34. B-34, C-39
OK
OK: Continuity
NG
NG
OK
Check the harness wire between the Replace the detonation sensor.
Check the harness wire between the engine-ECU and the detonation sensor
detonation sensor and earth, and repair connector.
if necessary.
NG
Repair
Code No. 41 Injector system Probable cause

Range of Check D Malfunction of the injector
D The throttle position sensor output voltage is 1.15 V or less. short-circuited harness wire of the injector circuit
D Actuator test by MUT-II is not carried out. D Malfunction of the engine-ECU
Set conditions
D Surge voltage of injector coil is not detected for 4 seconds.
NG
Check the injector. (Refer to P.13A-197.) Replace
OK
NG NG
Measure at the injector connectors Check the following connectors: Repair
B-02, B-03, B-05, B-36, B-40, B-44. B-02, B-03, B-05, B-36, B-40, B-44.
OK
D Voltage between 1 and earth NG
engine-ECU and the injector connector,
OK: System voltage
OK
Check the injector control circuit.

(Refer to P.13A-159, INSPECTION
PROCEDURE 51.)
D Improper communication between the engine-ECU and immobilizer-ECU D Malfunction of immobilizer-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.
Yes
NG
No
Yes
Is a diagnosis code output from the immobilizer-ECU? Check the immobilizer system. (Refer to GROUP 54 - Ignition
No
NG
C-37, C-81, C-68
OK

NG
OK
er-ECU. NG
NG
Repair NG

Code No. 59 Oxygen sensor (rear) system Probable cause

Range of Check D Malfunction of the oxygen sensor (rear)
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.
NG
Check the oxygen sensor (rear). (Refer to P.13A-197.) Replace
OK
1. NG
Measure at the oxygen sensor (rear) connector C-85. Check the harness wire between the
D Disconnect the connector, and measure at the oxygen sensor (rear) and the control
2. NG NG
OK: Continuity
OK: Continuity
OK
NG
NG
(rear) connector.
OK

oxygen sensor (rear) and the earth, and
NG repair if necessary.
C-85, C-39
OK

NG
NG
the oxygen sensor (rear) connector.
OK
Replace the oxygen sensor (rear).

NG

Code No. 61 Communication wire with A/T-ECU system Probable cause
<A/T>
Range of Check D Malfunction of the harness wire and the connector
D 60 seconds or more have passed immediately after engine was started. D Malfunction of the engine-ECU
D Engine speed is approx. 50 r/min or more D Malfunction of the A/T-ECU
Set conditions
The voltage of the torque reduction request signal from the A/T-ECU is LOW for
1.5 seconds or more.
NG
Check the following connectors. Repair
(C-30, C-37) <Vehicles without TCL>,
(C-28, C-35) <Vehicles with TCL>
OK

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

Range of Check, Set Conditions D Open circuit in alternator FR terminal circuit
D The alternator FR terminal signal voltage remains high for approximately 20 seconds D Malfunction of the engine-ECU
while the engine is running.
OK
Measure at the alternator connector B-38. Replace the engine-ECU.
(Engine: Idling)
(Radiator fan: Stopped)
(Headlamp: OFF ® ON)
OK: 1.8 - 2.4 ® 1.0 - 1.6 V
NG
NG NG
Measure at the alternator connector B-38. Check the following Repair
D Disconnect the connector, and measure at the harness side. connectors: B-31, C-37
(Ignition switch: ON) OK
OK: 4.8 - 5.2 V
OK NG
NG
OK NG
Check trouble symptom. between the engine-ECU
NG and the alternator con-
nector.
NG OK
Check the harness wire between the engine-ECU and the alternator Repair
connector.
OK Replace the engine-ECU.
Replace the alternator.

Code No. 71 Vacuum control solenoid valve system Probable cause

<Vehicles with TCL>
Range of Check D Malfunction of the vacuum control solenoid valve
D Excluding 60 seconds immediately after the engine starts. short-circuited harness wire of the vacuum control
D Battery voltage is 10 V or more. solenoid valve
D Forced actuation by means of MUT-II is not being carried out. D Malfunction of the engine-ECU
Set condition
Solenoid valve drive or non-drive instruction and energized condition of solenoid coil
are different.
NG
Check the vacuum control solenoid valve. Replace
OK
NG
Measure at the vacuum control solenoid valve con- Check the harness wire between the vacuum control
nector B-78. solenoid valve connector and the control relay con-
D Disconnect the connector and measure at the nector, and repair if necessary.
harness side.
OK: System voltage
OK
NG NG
Measure at the engine-ECU connector C-35. Check the following connector: Repair
D Disconnect the connector and measure at the B-78
harness side.
OK
OK: System voltage
NG
OK
NG Check the harness wire between the engine-ECU
Check the following connector: Repair and the vacuum control solenoid valve connector,
C-35 and repair if necessary.
OK
NG
Code No. 72 Ventilation control solenoid valve system Probable cause
<Vehicles with TCL>
Range of Check D Malfunction of the ventilation control solenoid valve
D Excluding 60 seconds immediately after the engine starts. short-circuited harness wire of the ventilation control
D Battery voltage is 10 V or more. solenoid valve
D Forced actuation by means of MUT-II is not being carried out. D Malfunction of the engine-ECU
Set condition
Solenoid valve drive or non-drive instruction and energized condition of solenoid coil
are different.
NG
Check the ventilation control solenoid valve. Replace
OK
NG
Measure at the ventilation control solenoid valve Check the harness wire between the control relay
connector B-79. and the ventilation control solenoid valve connector,
D Disconnect the connector and measure at the and repair if necessary.
harness side.
OK: System voltage
OK
NG NG
Measure at the engine-ECU connector C-35. Check the following connector: Repair
D Disconnect the connector and measure at the B-79
harness side.
OK
OK: System voltage
NG
OK
NG Check the harness wire between the engine-ECU
Check the following connector: Repair and the ventilation control solenoid valve connector,
C-35 and repair if necessary.
OK
NG

procedure
No.
Communication Communication with all systems is not possible. 1 13A-128

with MUT-II
II is
impossible. Communication with engine-ECU only is not possible. 2 13A-129
Engine warning The engine warning lamp does not illuminate right after the 3 13A-130
lamp and ignition switch is turned to the ON position.
related parts
The engine warning lamp remains illuminating and never goes 4 13A-130
out.
Starting No initial combustion (starting impossible) 5 13A-131
Initial combustion but no complete combustion 6 13A-132

Long time to start (improper starting) 7 13A-133
Idling stability Unstable idling (Rough idling, hunting) 8 13A-134

(Improper idling)
Idling speed is high. (Improper idling speed) 9 13A-135
Idling speed is low. (Improper idling speed) 10 13A-136
Idling stability When the engine is cold, it stalls at idling. (Die out) 11 13A-137
(Engine stalls)
When the engine becomes hot, it stalls at idling. (Die out) 12 13A-138
The engine stalls when starting the car. (Pass out) 13 13A-139
The engine stalls when decelerating. 14 13A-139
Driving Hesitation, sag or stumble 15 13A-140
The feeling of impact or vibration when accelerating 16 13A-140
The feeling of impact or vibration when decelerating 17 13A-141
Poor acceleration 18 13A-141
Surge 19 13A-142
Knocking 20 13A-142
Dieseling 21 13A-142
Too high CO and HC concentration when idling 22 13A-143
Low alternator output voltage (approx. 12.3 V) 23 13A-144
Idling speed is improper when A/C is operating 24 13A-144
Fans (radiator fan, A/C condensor fan) are inoperative 25 13A-145

PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)
Items Symptom
Starting Won’t start The starter is used to crank the engine, but there is no combustion within the
cylinders, and the engine won’t start.
Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Hard starting Engine starts after cranking a while.
Idling Hunting Engine speed doesn’t remain constant; changes at idle.

stability
Rough idle Usually, a judgement can be based upon the movement of the tachometer
pointer, and the vibration transmitted to the steering wheel, shift lever, body, etc.
This is called rough idle.
Incorrect idle speed The engine doesn’t idle at the usual correct speed.
Engine stall The engine stalls when the foot is taken from the accelerator pedal, regardless
(Die out) of whether the vehicles is moving or not.
Engine stall The engine stalls when the accelerator pedal is depressed or while it is being
(Pass out) used.
Driving Hesitation Sag “Hesitation” is the delay in response

Hesitation
of the vehicle speed (engine speed) Normal
that occurs when the accelerator is
depressed in order to accelerate Vehicle Initial ac-
from the speed at which the vehicle speed celerator
pedal de-
is now traveling, or a temporary drop pression
in vehicle speed (engine speed) Sag
during such acceleration.
Serious hesitation is called “sag”.
Time
Poor acceleration Poor acceleration is inability to obtain an acceleration corresponding to the

degree of throttle opening, even though acceleration is smooth, or the inability
to reach maximum speed.
Stumble Engine speed increase is delayed

when the accelerator pedal is
initially depressed for accelera-
tion. Normal
Vehicle
speed Initial ac-
celerator
pedal de-
pression
Idling Stumble
Time
Items Symptom
Driving Shock The feeling of a comparatively large impact or vibration when the engine is
accelerated or decelerated.
Surge This is repeated surging ahead during constant speed travel or during variable
speed travel.
Knocking A sharp sound like a hammer striking the cylinder walls during driving and which
adversely affects driving.
Stopping Run on The condition in which the engine continues to run after the ignition switch is
(“Dieseling”) turned to OFF. Also called “Dieseling”.

NG NG
Measure at the diagnostic connector Check the following connectors: Repair
(16-pin) C-20. C-66, (C-63, C-132, C-141) <L.H.>,
D Voltage between 16 and earth (C-62, C-14) <R.H.>
OK: Battery voltage
OK
OK NG
power supply and diagnostic connector
(16 pin), and repair if necessary.
NG
Measure at the diagnostic connector Check the harness wire between the
(16-pin) C-20. diagnostic connector (16-pin) and earth,
D Continuity between 4 and earth and repair if necessary.
OK: Continuity
OK
Replace the MUT-II.

MUT-II communication with engine-ECU is impossible. Probable cause
One of the following causes may be suspected. D Malfunction of engine-ECU power supply circuit
D No power supply to engine-ECU. D Malfunction of engine-ECU
D Defective earth circuit of engine-ECU. D Malfunction of immobilizer-ECU
D Defective engine-ECU. D Open circuit between immobilizer-ECU and diagnosis
ECU
No
Is communication possible between the MUT-II and the immobilizer- Check the diagnosis line between the immobilizer-ECU and the
ECU? MUT-II, and repair if necessary. (Refer to GROUP 54 - Ignition
Key and Immobilizer.)
Yes
NG
Check the following connectors: C-37, C-81, C-68 Repair
OK

NG
NG
Check the harness wire between engine-ECU and diagnosis con- Repair
nector.
OK
OK NG
Check the harness wire between engine-ECU and immobilizer- Check the harness wire Repair
ECU. between engine-ECU and
earth.
NG
OK
Repair
Check the power supply and ignition switch-IG system. (Refer to
Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp D Burnt-out bulb
NG
MUT-II Data list Check the engine-ECU power supply and earth circuit.
16 Engine-ECU power supply voltage (Refer to P.13A-163.) (Refer to P.13A-158, INSPECTION PROCEDURE 46.)
OK
OK NG
D Disconnect the connector, and measure at the harness side. connector: C-35.
D Earth the terminal No. 36.
OK
OK: The engine warning lamp illuminates.
NG
NG
Check a burnt-out bulb. Replace Replace the engine-ECU.
OK
NG
Measure at the combination meter connector D-03. Check the engine warning lamp power supply circuit, and repair
D Disconnect the connector, and measure at the harness side. if necessary.
OK: System voltage
OK
NG
D-03, C-90, C-35
OK
NG
Check trouble symptom. Check the harness wire between combination meter and engine-
goes out.
In cases such as the above, the cause is probably that the engine-ECU is detecting D Short-circuit between the engine warning lamp and
a problem in a sensor or actuator, or that one of the malfunctions listed at right has engine-ECU
Yes
Are diagnosis codes displayed? CODES
No
NG
Measure at the combination meter connector D-03. Check the harness wire between combination meter and engine-
D Disconnect the connector, and measure at the harness side. ECU connector, and repair if necessary.
D Disconnect the engine-ECU connector
OK: No continuity
OK

No initial combustion (starting impossible) Probable cause
In cases such as the above, the cause is probably that a spark plug is defective, D Malfunction of the ignition system
or that the supply of fuel to the combustion chamber is defective. D Malfunction of the fuel pump system
In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel. D Malfunction of the injectors
NG
OK: 8 V or higher
OK
Yes
Is immobilizer-ECU diagnosis code displayed? Check the immobilizer.
(Refer to GROUP 54 - Ignition Key and Immobilizer.)
No
MUT-II: Inspection of no initial combustion.

OK
NG
Can any sound be heard from the injectors when cranking? Check the injector system. (Refer to P.13A-120, INSPECTION
PROCEDURE FOR DIAGNOSIS CODE 41.)
OK

OK

D Check the immobilizer system.
Initial combustion but no complete combustion Probable cause
In such cases as the above, the cause is probably that the spark plugs are generating D Malfunction of the ignition system
sparks but the sparks are weak, or the initial mixture for starting is not appropriate. D Malfunction of the injector system
D Poor compression
NG
OK: 8 V or higher
OK
MUT-II: Check if uncompleted combustion occurs.

OK
NG
Can any sound be heard from the injectors when cranking? Check the injector system, (Refer to P.13A-120, INSPECTION
OK
Yes NG
Is starting good if the engine is cranked with the accelerator pedal Check ISC servo for op- Check the ISC servo sys-
slightly depressed? eration sound. tem. (Refer to P.13A-151,
(Refer to P.13A-199.) INSPECTION PROCE-
No DURE 35.)
OK
D Clean the throttle valve area. (Refer to P.13A-184.)

D Check and adjust the fixed SAS. (Refer to P.13A-187.)
NG
OK: Approx. 5_BTDC
OK

D Check fuel lines for clogging.
In takes too long time to start. (Incorrect starting) Probable cause
In cases such as the above, the cause is probably that the spark is weak and ignition D Malfunction of the ignition system
is difficult, the initial mixture for starting is not appropriate, or sufficient compression D Malfunction of the injector system
pressure is not being obtained. D Inappropriate gasoline use
D Poor compression
NG
Check battery voltage when cranking Check the battery. (Refer to GROUP 54 - Battery.)
OK: 8 V or higher
OK

OK
NG
Can any sound be heard from the injectors when cranking? Check the injector system. (Refer to P.13A-120, INSPECTION
OK
NG
OK: Approx. 5_BTDC
OK

Unstable idling (Rough idling, hunting) Probable cause
In cases as the above, the cause is probably that the ignition system, air/fuel mixture, D Malfunction of the ignition system
Because the range of possible causes is broad, inspection is narrowed down to simple D Malfunction of the ISC system
items. D Malfunction of the purge control solenoid valve system
D Malfunction of the EGR solenoid valve system
D Poor compression
D Drawing air into exhaust system
Yes
No
Yes
No
Yes
Does idling speed fluctuate excessively? Check if hunting occurs.
No
NG
OK
NG
Check the injector for operation sound. Check the injector system. (Refer to P.13A-120, INSPECTION
OK

OK
NG
(Refer to GROUP 11B - On-vehicle Service.)
OK

D Check the operation of the power steering control valve.
Idling speed is high. (Improper idling speed) Probable cause
In such cases as the above, the cause is probably that the intake air volume during D Malfunction of the ISC servo system
idling is too great. D Malfunction of the throttle body
Yes
No
NG
OK
NG
<Vehicles with TCL>
NG
21 Engine coolant temperature sensor (Refer to P.13A-163.) (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE 21.)
OK
NG
OK
NG

Idling speed is low. (Improper idling speed) Probable cause
In cases such as the above, the cause is probably that the intake air volume during D Malfunction of the ISC servo system
idling is too small. D Malfunction of the throttle body
Yes
No
NG
OK
NG
26 Idle position switch (Refer to P.13A-164.) (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles
without TCL>
OK (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles
with TCL>
NG
SIS CODE 21.)
OK
NG
MUT-II Data list Check the ignition switch ST and inhibitor switch system <A/T>.
OK
NG

When the engine is cold, it stalls at idling. (Die out) Probable cause
In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate D Malfunction of the ISC servo system
when the engine is cold, or that the intake air volume is insufficient. D Malfunction of the throttle body
D Malfunction of the injector system
D Malfunction of the ignition system
Yes
No
Yes
No
Yes
area. fixed SAS.
No
(Refer to P.13A-184.) (Refer to P.13A-187.)
No
Is engine-idling stable after the warming-up? Check if the unstable idling (Rough idling, hunting).
Yes
NG
OK
NG
OK
NG
without TCL>
with TCL>
NG
SIS CODE 21.)
OK
NG
OK

OK
NG
OK

D Check the engine oil viscosity.
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, D Malfunction of the ignition system
In addition, if the engine suddenly stalls, the cause may also be a defective connector D Malfunction of the ISC system
contact. D Drawing air into intake system
D Improper connector contact
Yes
No
Yes
No
NG
OK
NG
OK
Yes
area. fixed SAS.
No
(Refer to P.13A-184.) (Refer to P.13A-187.)
No
Does the engine stall easily again? While carrying out an intermittent malfunction simulation test (Refer
to GROUP 00 - Points to Note for Intermittent Malfunctions.), check
Yes for sudden changes in the signals shown below.
D Crank angle sensor signal D Primary and secondary
MUT-II: Engine stalling inspection when the engine is warm and D Air flow sensor signal ignition signal
idling. (Refer to P.13A-155, INSPECTION PROCEDURE 43.) D Injector drive signal D Fuel pump drive signal
OK D Engine-ECU power supply
voltage
NG
OK

The engine stalls when starting the car. (Pass out) Probable cause
In cases such as the above, the cause is probably misfiring due to a weak spark, D Drawing air into intake system
or an inappropriate air/fuel mixture when the accelerator pedal is depressed. D Malfunction of the ignition system
Yes
No
NG
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
The engine stalls when decelerating. Probable cause
In cases such as the above, the cause is probably that the intake air volume is insufficient D Malfunction of the ISC system
due to a defective idle speed control (ISC) servo system.
Yes
No
Yes
No
NG
without TCL>
with TCL>
NG
MUT-II Data list Check the throttle position sensor system. (Refer to P.13A-114,
14 Throttle position sensor (Refer to P.13A-163.) INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
OK
Yes
MUT-II Data list Check the vehicle speed sensor system. (Refer to P.13A-119, IN-
45 ISC servo position SPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)
D Is the idle speed control (ISC) servo position drops to 0 - 2
steps when decelerating (engine r/min less than 1,000)?
No
NG
OK

D Clean the throttle valve area.
D Check and adjust the fixed SAS.
Hesitation, sag or stumble Probable cause
In cases such as the above, the cause is probably that ignition system, air/fuel mixture D Malfunction of the ignition system
or compression pressure is defective. D Malfunction of air-fuel ratio control system
D Poor compression
Yes
No
NG
Check the injectors for operation sound. Check the injector system. (Refer to P.13A-120, INSPECTION
OK
NG
OK

OK

OK

D Check the injector operating sound at the rear bank.
D Check the operation vacuum of the traction control (TCL).
D Check the operation of the throttle valve.
D Check the vacuum tank and vacuum actuator.
The feeling of impact or vibration when accelerating Probable cause
In cases such as the above, the cause is probably that there is an ignition leak D Malfunction of the ignition system
accompanying the increase in the spark plug demand voltage during acceleration.
Yes
No

D Check for occurrence of ignition leak.
The feeling of impact or vibration when decelerating. Probable cause
Malfunction of the ISC system is suspected. D Malfunction of the ISC system
Yes
No
NG
OK
NG
OK
NG
without TCL>
with TCL>
Clean the throttle valve area. (Refer to P.13A-184.)
Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc. D Malfunction of the ignition system
are suspected. D Malfunction of air-fuel ratio control system
D Poor compression pressure
D Clogged exhaust system
Yes
No
NG
OK
NG
OK

OK

OK

D Check the injector operating sound at the rear bank.
D Check the operation vacuum of the traction control (TCL).
D Check the operation of the throttle valve.
D Check the vacuum tank and vacuum actuator.
D Clogged air cleaner
Surge Probable cause
Defective ignition system, abnormal air-fuel ratio, etc. are suspected. D Malfunction of the ignition system
D Malfunction of air-fuel ratio control system
Yes
No
NG
OK
NG
OK

(Refer to P.13-157, INSPECTION PROCEDURE 45.)
OK

OK

D Check the injector operation sound at the rear bank.
Knocking Probable cause
In cases as the above, the cause is probably that the detonation control is defective D Defective detonation sensor
or the heat value of the spark plug is inappropriate. D Inappropriate heat value of the spark plug
Yes
No
No
Does knocking occur when driving with the sensor disconnected? Check the detonation sensor system. (Refer to P.13A-120, INSPEC-
At this time, use the MUT-II to check if the timing is retarded TION PROCEDURE FOR DIAGNOSIS CODE 31.)
compared to when the detonation sensor connector is connected.
Yes

D Spark plugs
Dieseling Probable cause
Fuel leakage from injectors is suspected. D Fuel leakage from injectors
Check the injectors for fuel leakage.

Too high CO and HC concentration when idling Probable cause
Abnormal air-fuel ratio is suspected. D Malfunction of the air-fuel ratio control system
D Deteriorated catalyst
Yes
No
NG
OK
NG
21 Engine coolant temperature sensor. (Refer to P.13A-163.) (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNO-
SIS CODE 21.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to
13 Intake air temperature sensor (Refer to P.13A-163.) P.13A-113, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
13.)
OK
NG
OK
NG
OK: 600 - 1,000 mV
OK
NG
11 Oxygen sensor (front) SPECTION PROCEDURE FOR DIAGNOSIS CODE 11.)
OK: 600 - 1,000 mV when racing suddenly (Refer to
P.13A-162.)
OK
OK
MUT-II Data list Replace the oxygen sensor (front).
11 Oxygen sensor (front)
OK: Repeat 0 - 400 mV and 600 - 1,000 mV alternately when
idling. (Refer to P.13A-162.) Check trouble symptom.
NG 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.

Low alternator output voltage (approx. 12.3 V) Probable cause
The alternator may be defective, or malfunctions, which are listed in the right column, D Malfunction of charging system
may be suspected. D Short circuit in harness between alternator G terminal
and engine-ECU
NG NG
Measure at the alternator connector Measure at the alternator connector. Check the harness wire between the
side. B-38 B-38 alternator and the engine-ECU connec-
D Connect the connector. D Disconnect the connector, and tor, and repair if necessary.
(Test harness: MB991519) measure at the harness side.
D Voltage between 1 (black clip) and D Disconnect the engine-ECU con-
earth nector.
Engine: at idle D Continuity between 1 and earth
Radiator fan: does not run OK: No continuity
Headlamp: OFF ® ON
OK
Brake lamp: OFF ® ON
Rear defogger switch: NG
OFF ® ON
alternator and the engine-ECU connec-
OK: Voltage rises by 0.2 - 3.5 V. tor.
OK OK
Check the alternator. (Refer to GROUP Replace the engine-ECU.
16 - Charging System.)
Idling speed is improper when A/C is operating Probable cause
If the engine-ECU detects that the air conditioner is on, it activates the idle D Malfunction of the A/C control system
speed control (ISC) servo to control idle-up operation. D Improper connector contact, open circuit or
The A/C-ECU judges if the load caused by air conditioner operation is high or short-circuited harness wire
low, and converts it to voltage signal (high or low voltage) and inputs the signal D Malfunction of the engine-ECU
to the engine-ECU.
Based on this voltage signal, the engine-ECU controls the idle-up speed (for
high or low load).
OK
D Voltage between 57 and earth (Engine: at idle, outside air
OK NG
temperature: 25_C or more)
OK: 0 - 3 V [When A/C is MAX. COOL condition (when Repair
the load by A/C is high)]
System voltage [When A/C is MAX. HOT condition
(when the load by A/C is low)] Check trouble symptom.
NG NG
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 D Malfunction of the fan motor relay
engine coolant temperature, vehicle speed, and air conditioner switch condition. D Malfunction of the fan motor
Based on this signal, the fan controller controls the radiator fan and condenser D Malfunction of the fan controller
fan speeds (The more the average voltage at the terminal approaches 5 V, the D Improper connector contact, open circuit or
higher the fan speed become.) short-circuited harness wire
NG NG
Measure at the engine-ECU connector C-33. Check the harness wire Repair
D Disconnect the connector, and measure at the harness between the engine-ECU
side. and the fan controller con-
D Voltage between 21 and earth (Ignition switch: ON) nector.
OK: 4.8 - 5.2 V (Fan rotates at high speed.) OK
D Connect a jumper cable between 21 and earth (Ignition
switch: ON) Check the radiator fan
OK: Fan stops and condenser fan circuit.
OK (Refer to GROUP 14 -
NG Troubleshooting.)
connector:
C-33
OK

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 D Malfunction of the ignition switch
the control relay ON. This causes battery voltage to be supplied to the engine-ECU, D Malfunction of the control relay
injectors and air flow sensor. D Improper connector contact, open circuit or
D Disconnected engine-ECU earth wire
NG
Check the control relay. (Refer to P.13A-193.) Replace
OK
NG NG
Measure at the control relay connector C-31. Check the following Repair
D Disconnect the connector, and measure at the harness side. connector: B-30
D Voltage between 3, 4 and earth
OK
OK: System voltage
NG
(Refer to P.13A-158, INSPECTION PROCEDURE 46.) Check the harness wire between battery and control relay connector,
Fuel pump system Probable cause
The engine-ECU turns the control relay ON when the engine is cranking or running, D Malfunction of the fuel pump relay
and this supplies power to drive the fuel pump. D Malfunction of the fuel pump
NG
Check the fuel pump operation. (Refer to P.13A-191.) Check the fuel pump circuit.
NG
Check the fuel pump relay. (Refer to P.13A-193.) Replace
OK
NG
Measure at the fuel pump relay connector C-32. Check the fuel pump drive control circuit.
D Connect the connector. (Refer to P.13A-159, INSPECTION PROCEDURE 48.)
D MUT-II Actuator test: Fuel pump drive
OK: System voltage
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
The engine-ECU controls the idle speed control servo based on this input. D Maladjustment of the idle position switch and throttle
position sensor
NG
Check the idle position switch. (Refer to P.13A-195.) Replace the throttle position sensor.
OK
NG NG
Measure at the throttle position sensor connector B-07. Check the following Repair
OK
OK: 4 V or higher
OK: Continuity
NG
OK
NG Check the harness wire between engine-ECU and throttle position
sensor connector.
connector: B-07
OK NG
OK
NG

Idle position switch system <Vehicles with TCL> Probable cause
The engine-ECU controls the idle speed control servo based on this input. D Maladjustment of the idle position switch and
accelerator pedal position sensor
NG
Check the idle position switch. (Refer to P.13A-195.) Replace the accelerator pedal position sensor.
OK
NG NG
Measure at the accelerator pedal position sensor connector B-41. Check the following Repair
OK
OK: 4 V or higher
OK: Continuity
NG
OK
NG Check the harness wire between engine-ECU and accelerator pedal
position sensor connector.
connector: B-41
OK NG
OK
NG
Ignition switch-ST system <M/T> Probable cause
The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine is D Malfunction of ignition switch
cranking. D Improper connector contact, open circuit or
The engine-ECU controls fuel injection, etc. during starting based on this input. short-circuited harness wire
1. NG NG
1. Voltage between 71 and earth (Ignition switch: START) 2. NG
OK
OK: 8V or more
OK: Continuity
NG
OK NG
NG Check harness wire be- Repair
Check the following Repair tween the engine-ECU
connector: C-39 and ignition switch con-
OK nector.
OK
NG Check the ignition switch.
Check the harness wire between engine-ECU connector (terminal

No. 91) and earth, and repair if necessary.
Ignition switch-ST and inhibitor switch system <A/T> Probable cause
D The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine D Malfunction of ignition switch
is cranking. D Malfunction of inhibitor switch
The engine-ECU controls fuel injection, etc. during starting based on this input. D Improper connector contact, open circuit or
D The inhibitor switch inputs the condition of the select lever, i.e. whether it is in short-circuited harness wire
P or N range or in some other range, to the engine-ECU. D Malfunction of the engine-ECU.
The engine-ECU controls the idle speed control (ISC) servo based on this input.
NG
Check the inhibitor switch. Replace
OK
1. NG NG
Measure at the inhibitor switch connector B-72. Check harness wire be- Repair
D Disconnect the connector, and measure at the harness side. tween engine-ECU and
1. Voltage between 10 and earth (Ignition switch: ON) inhibitor switch connector.
OK
OK: Continuity Replace the engine-ECU.
D Ignition switch: START
D Disconnect engine-ECU connector.
OK: System voltage 3. NG Check harness wire between inhibitor switch connector and starter
S terminal, and repair if necessary.
OK
NG
connector: B-72 Check the following Repair
connector:
OK C-92
NG
Check harness wire be- Repair NG
tween engine-ECU and NG
inhibitor switch connector. Check harness wire be- Repair
tween inhibitor switch and
OK ignition switch connector.
Replace the engine-ECU. OK

Power steering fluid pressure switch system Probable cause
The presence or absence of power steering load is input to the engine-ECU. D Malfunction of power steering fluid pressure switch
The engine-ECU controls the idle speed control (ISC) servo based on this input. D Improper connector contact, open circuit or
NG
Check the power steering fluid pressure switch. Replace
OK
NG NG
Measure at the power steering fluid pressure switch connector Check the following Repair
B-76. connector: C-35
OK
OK NG
NG NG
Check the following Repair Check harness wire be- Repair
connector: B-76 tween engine-ECU and
OK power steering fluid pres-
sure switch connector.
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 D Malfunction of A/C control system
control of the idle speed control (ISC) servo, and also operates the A/C compressor D Malfunction of A/C switch
magnetic clutch. D Improper connector contact, open circuit or
NG
OK
NG
Measure at the engine-ECU connectors C-33, C-35. Check the A/C system. (Refer to GROUP 55 - Troubleshooting.)
D Voltage between 8 and earth, and 45 and earth
OK: 0 - 3 V (A/C switch: OFF) OK NG
System voltage (A/C switch: ON) Check the following Replace
D Short circuit between 8 and earth connectors: C-33, C-35
(Ignition switch: ON, A/C switch: ON) OK
OK: A/C compressor clutch turns on.
NG

Ignition circuit system Probable cause
The engine-ECU interrupts the ignition coil primary current by turning the power transistor D Malfunction of ignition switch.
inside the engine-ECU ON and OFF. D Malfunction of power transistor
1. NG NG
Measure at the distributor connector B-42. Check the following Repair
OK: Continuity
NG
OK NG
Check ignition coil and power transistor unit circuit. (Refer to between distributor and
P.13A-161, INSPECTION PROCEDURE 52.) ignition switch connector.
OK

Check the harness wire between distributor connector and earth,

Idle speed control (ISC) servo (Stepper motor) system Probable cause
The engine-ECU controls the intake air volume during idling by opening and closing D Malfunction of ISC servo
the servo valve located in the bypass air passage. D Improper connector contact, open circuit or
NG
Check the ISC servo Replace
OK
NG
Measure at the ISC servo connector B-10. Check the harness wire between control relay and ISC servo con-
D Disconnect the connector and measure at the harness side. nector, and repair if necessary.
D Voltage between 2 and earth, and 5 and earth (Ignition switch:
ON)
OK: System voltage
OK
NG NG
D Disconnect the connector, measure at the harness side. connector: B-10
D Voltage between each of 4, 5, 17, 18 and earth (Ignition switch:
OK
ON)
OK NG
NG
Check the following Repair Check harness wire between engine-ECU and ISC servo connector,
connector: C-33 and repair if necessary.
OK
NG
Purge control solenoid valve system Probable cause
The purge control solenoid valve controls the purging of air from the canister located D Malfunction of solenoid valve
inside the intake manifold. D Improper connector contact, open circuit or
NG
Check the purge control solenoid valve. Replace
OK
NG
Measure at the purge control solenoid valve connector B-04. Check the harness wire between control relay and solenoid valve
OK: System voltage
OK
NG NG
OK
OK: System voltage
NG
connector: C-33
Check the harness wire between engine-ECU and solenoid valve
OK connector, and repair if necessary.

NG

EGR control solenoid valve system Probable cause
The EGR control solenoid valve is controlled by the negative pressure resulting from D Malfunction of solenoid valve
EGR operation leaking to port “A” of the throttle body. D Improper connector contact, open circuit or
NG
Check the EGR control solenoid valve. Replace
OK
NG
Measure at the EGR control solenoid valve connector B-06. Check the harness wire between control relay and solenoid valve
OK: System voltage
OK
NG NG
OK: System voltage
OK
OK
connector: C-33 NG
OK Check the harness wire between engine-ECU and solenoid valve

NG
MUT-II: Inspection of no initial combustion
NG
MUT-II Data list Check the power supply and ignition switch-IG system.
16 Voltage of engine-ECU power source (Refer to P.13A-163.) (Refer to P.13A-145, INSPECTION PROCEDURE 26.)
OK
No
Does the camshaft rotate at the engine cranking? Check timing belt for breakage.
(When oil filler cap is removed.)
Yes
Yes
No
No
MUT-II Data list Check the crank angle sensor system.
22 Crank angle sensor (Refer to P.13A-116, INSPECTION PROCEDURE FOR DIAGNO-
OK: Cranking speed is displayed. SIS CODE 22.)
OK
NG
OK
NG
SIS CODE 21.)
NG
Does the engine tachometer display the cranking speed? Check the ignition circuit system
D Set the tachometer of primary voltage detection type. (Refer to P.13A-150, INSPECTION PROCEDURE 34.)
OK
NG
Check the ignition timing when cranking. Check the installation condition of crank angle sensor and timing
OK: Approx. 5_BTDC belt cover.
Yes
Are diagnosis codes displayed? CODE
No
NG
OK
NG
21 Engine coolant temperature sensor (Refer to P.13A-163.) (Refer to P.13A-115, INSPECTION PROCEDURES FOR DIAGNO-
SIS CODE 21.)
OK
NG
MUT-II Data list Check the ignition switch-ST system <M/T>.
18 Ignition switch-ST (Refer to P.13A-163.) (Refer to P.13A-147, INSPECTION PROCEDURE 30.)
Check the ignition switch-ST and inhibitor switch system <A/T>.
Check if hunting occurs.
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
without TCL>
OK
(Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles
with TCL>
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to
13 Intake air temperature sensor (Refer to P.13A-163.) P.13A-113, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
13.)
OK
NG
OK
NG
SIS CODE 21.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve system
08 Purge control solenoid valve (Refer to P.13A-167.) (Refer to P.13A-151, INSPECTION PROCEDURE 36.)
OK
NG
OK
NG
OK: 600 - 1,000 mV
OK
NG
OK: 600 - 1,000 mV during sudden racing
OK
NG OK
11 Oxygen sensor (front) (Refer to P.13A-189.) air into the air intake
OK: Changes between 0 - 400 mV and 600 - 1,000 mV during system.
manifold gasket
OK
D Broken vacuum
NG hose
MUT-II Data list Check the power steering
INSPECTION PROCE-
DURE 32.) hose
clog.
NG
28 A/C switch (Refer to P.13A-164.) (Refer to P.13A-149. INSPECTION PROCEDURE 33.)
OK
NG
OK
NG
45 ISC Servo position (Refer to P.13A-166.)
MUT-II: Engine stalling inspection when the engine is warmed up and idling.
NG
OK without TCL>
with TCL>
NG
OK
NG
OK
NG
SIS CODE 21.)
OK
NG
OK
NG
OK: 600 - 1,000 mV
OK
NG
OK
NG OK
OK manifold gasket
NG D Broken vacuum
MUT-II Data list Check the power steering hose
INSPECTION PROCE-
DURE 32.) hose
clog.
NG
OK
NG
OK
NG
MUT-II Data list Check the air flow sensor system. (Refer to P.13A-113, INSPEC-
34 Air flow sensor reset signal (Refer to P.13A-165.) TION PROCEDURE FOR DIAGNOSIS CODE 12.)
OK
NG
45 ISC servo position (Refer to P.13A-166.)
MUT-II: Check if hesitation, sug, stumble or poor acceleration occurs.
NG
without TCL>
with TCL>
NG
OK
NG
OK
NG
21 Engine coolant temperature sensor (Refer to P.13A-163.) (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOS-
TIC CODE 21.)
OK
NG
OK
NG
OK
NG
OK: 600 - 1,000 mV
OK
NG
OK
NG OK
manifold gasket
OK
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
NG
MUT-II Actuator test Check the vacuum control solenoid valve system. (Refer to
15 Vacuum control solenoid valve <Vehicles with TCL> (Refer P.13A-124, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
to P.13A-167.) 71.)
OK
NG
MUT-II Actuator test Check the ventilation control solenoid valve system. (Refer to
16 Ventilation control solenoid valve <Vehicles with TCL> P.13A-125, INSPECTION PROCEDURE FOR DIAGNOSIS CODE
(Refer to P.13A-167.) 72.)
NG
without TCL>
OK
with TCL>
NG
OK
NG
OK
NG
SIS CODE 21.)
OK
NG
OK
NG
OK
NG
OK: 600 - 1,000 mV
OK
NG
OK
NG OK
manifold gasket
D Broken vacuum
hose
D PCV valve does
not operate.
D Broken air intake
hose
clog.
1. NG NG
Measure the engine-ECU connectors, C-33, C-35, C-39. Check the following Repair
D Disconnect the connector and measure at the harness side connectors: C-92, C-131
OK: System voltage 2, 3. NG
2. Voltage between 38 and earth Check trouble symptom.
OK: System voltage
3. Voltage between 12, 25 and earth (Ignition switch: ON) OK
4. NG NG
OK: System voltage (when the terminal 38 is earthed)
4. Continuity between 13, 26 and earth Check the harness wire Repair
OK: Continuity between engine-ECU and
5. NG ignition switch connector.
OK
NG
connectors:
C-33, C-35, C-39 Check the harness wire between engine-ECU and control relay
OK

Check the harness wire between engine-ECU and earth, and repair
NG if necessary.
NG
C-47, C-83, C-66, (C-63, C-132,
C-141) <L.H.>, (C-62, C-14) <R.H.>
OK
Check trouble symptom

NG
Check the harness wire between engine-ECU and battery, and

Check fuel pump circuit.
NG NG
Measure at the fuel pump connector E-16. Check the following connectors: Repair
D Disconnect the connector and measure at the harness side. E-11
OK
OK: Continuity
OK Check trouble symptom
NG
NG
Check the following connectors: E-16, E-11, C-123, C-92, B-09 Check the harness wire between fuel pump and earth, and repair
if necessary.
OK

NG
NG
Check the harness wire between terminal for fuel pump drive and Repair
fuel pump connector.
OK
Replace the fuel pump.

Check the fuel pump drive control circuit.
NG NG
Measure at the fuel pump relay connector C-32. Check the following Repair
D Voltage between 3, 4 and earth (Ignition switch: ON) OK
OK: System voltage
NG NG
Measure at the engine-ECU connector C-33. NG
D Disconnect the connector and measure at the harness side. Check the harness wire Repair
D Voltage between 22 and earth (Ignition switch: ON) between fuel pump relay
OK: System voltage and ignition switch con-
OK nector.
OK
Check the following connector: C-33
OK NG
Repair
NG
Check trouble symptom. Check the following Repair
connector: C-32
NG
OK
NG
Check the harness wire between engine-ECU and fuel pump relay
Check air flow sensor (AFS) control circuit.
1. NG
Measure at the air flow sensor connector B-12. Check the harness wire between the air flow sensor and control
D Disconnect the connector and measure at the harness side. relay connector, and repair if necessary.
OK: System voltage
2. Voltage between 3 and earth (Ignition switch: ON) 2, 3. NG NG
OK: 4.8 - 5.2 V connector: C-39
OK: Continuity OK
Check the following connector: B-12 NG
NG
OK NG Check the harness wire Repair
Repair and air flow sensor con-
nector.
NG
Check throttle position sensor (TPS) output circuit.
OK NG
D Connect the connector. connector: C-39
D Voltage between 84 and earth (Ignition switch: ON) OK
OK: 0.3 - 1.0 V (Throttle valve at idle position)
4.5 - 5.5 V (Throttle valve fully open) Check trouble symptom.
NG NG

NG
OK

NG
Check the harness wire between engine-ECU and throttle position

sensor connector, and repair if necessary.
Check injector control circuit
NG NG
D Disconnect the connector and measure at the harness side. connectors: B-02, B-03,
D Voltage between 1, 2, 3, 14, 15, 16 and earth (Ignition switch: B-05, B-36, B-40, B-44
ON) OK
OK: System voltage
NG
Check the harness between engine-ECU and injector connector,

NG
OK

NG

Check ignition coil and power transistor unit circuit.
NG
Check the ignition coil. (Refer to GROUP 16 – Ignition System.) Replace
OK
NG
Check the power transistor unit. Replace
(Refer to GROUP 16 – Ignition System.)
OK
1. NG NG
Measure at the distributor connector B-42. Check the following Repair
D Disconnect the connector and measure at the harness side. connector: C-33
1. Voltage between 3 and earth (Ignition switch: START)
OK
OK: 2 - 7 V 2. NG
OK: No continuity
NG
OK
NG
Check the following connectors, and repair if necessary. between the engine-ECU
B-42 and the distributor con-
nector.
OK
As short circuit occurs between distributor and combination meter

(tachometer), check the harness wire, and repair if necessary.
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.

No.
11 Oxygen Engine:After having When at 4,000 r/min, 200 mV or less Code No. 13A-112
sensor warmed up engine is suddenly 11
(front) Air/fuel mixture is decelerated
made leaner when
decelerating, and is When engine is 600 - 1,000 mV
made richer when suddenly raced
racing.
Engine:After having Engine is idling 400 mV or less

warmed up (Changes)
The oxygen sensor 600 - 1,000 mV
signal is used to
check the air/fuel
mixture 2,500 r/min
ratio, and control
condition is also
checked by the ECU.
12 Air flow D Engine coolant Engine is idling 14 - 40 Hz - -

sensor*1 temperature: 80
- 95_C
D Lamps, electric 2,500 r/min 42 - 82 Hz
cooling fan and
all accessories: Engine is raced Frequency
OFF increases in
D Transmission: response to
Neutral (A/T: racing
P range)

No.
13 Intake air Ignition switch: ON When intake air - 20_C Code No. 13A-113
tempera- or with engine temperature is 13
ture sensor running - 20_C
When intake air 0_C

temperature is 0_C

temperature is 20_C

temperature is 40_C

temperature is 80_C
14 Throttle Ignition switch: ON Set to idle position 300 - 1,000 mV Code No. 13A-114
position 14
sensor Gradually open Increases in
proportion to
throttle opening
angle
Open fully 4,500 - 5,500 mV
16 Power Ignition switch: ON System voltage Procedure 13A-145

supply No. 25
voltage
18 Cranking Ignition switch: ON Engine: Stopped OFF Procedure 13A-147

signal No. 30 <M/T>
(ignition <M/T> 13A-148
switch-ST) Procedure <M/T>
Engine: Cranking ON
No. 31
<A/T>
21 Engine Ignition switch: ON When engine - 20_C Code No. 13A-115

coolant or with engine coolant temperature 21
tempera- running is - 20_C
ture sensor
When engine 0_C
coolant temperature
is 0_C
When engine 20_C

coolant temperature
is 20_C
When engine 40_C

coolant temperature
is 40_C
When engine 80_C

coolant temperature
is 80_C

No.
22 Crank D Engine: Crank- Compare the engine Accord Code No. 13A-116
angle sen- ing speed readings on 22
sor D Tachometer: the tachometer and
Connected the MUT-II.
D Engine: Idling When engine 1,300 - 1,500 rpm

D Idle position coolant temperature
switch: ON is - 20_C

coolant temperature
is 0_C

coolant temperature
is 20_C

coolant temperature
is 40_C
When engine 550 - 750 rpm

coolant temperature
is 80_C
25 Barometric Ignition switch: ON At altitude of 0 m 101 kPa Code No. 13A-119

pressure 25
At altitude of 1,200 88 kPa

m
At altitude of 1,800 81 kPa

m
26 Idle posi- Ignition switch: ON Throttle valve: ON Procedure 13A-146

tion switch Check by operating Set to idle position No.28 <Vehicles
accelerator pedal <Vehicles without
repeatedly without TCL>
TCL> 13A-147
Throttle valve: OFF*2 Procedure <Vehicles
Slightly open No.29 with TCL>
<Vehicles
with TCL>
27 Power Engine: Idling Steering wheel OFF Procedure 13A-149

steering stationary No. 32
fluid pres-
sure switch Steering wheel ON
turning
28 A/C switch Engine: Idling A/C switch: OFF OFF Procedure 13A-149
(when A/C switch is No. 33
ON, A/C compressor
A/C switch: ON ON
should be operating.)
29 Inhibitor Ignition switch: ON P or N P or N Procedure 13A-148

switch No. 31
<A/T> D, 2, L or R D, 2, L or R

No.
34 Air flow Engine: After having Engine is idling ON Code 13A-113

sensor warmed up No.12
reset sig-
2,000 r/min OFF
nal
37 Volumetric D Engine coolant Engine is idling 15 - 35 % - -

efficiency temperature: 80
- 95 _C
D Lights, power 2,000 r/min 15 - 35 %
cooling fan and
all accessories: Engine is suddenly Volumetric effi-
OFF raced ciency increases
D Transmission: in response to
Neutral (A/T: P racing
range)
38 Crank D Engine: Cranking [reading is possible Engine speeds - -

angle sen- at 2,000 r/min or less] displayed on the
sor D Tachometer: Connected MUT-II and
tachometer are
identical.
41 Injectors *3 Engine: Cranking When engine 23 - 80 ms - -

coolant temperature
is 0_C (injection is
carried out for all
cylinders
simultaneously)
When engine 12 - 40 ms
coolant temperature
is 20_C
When engine 2.0 - 8.0 ms

coolant temperature
is 80_C
Injectors*4 D Engine coolant Engine is idling 2.6 - 3.8 ms

temperature:
80–95_C
D Lamps, electric 2,500 r/min 1.8 - 3.0 ms
cooling fan and
all accessories:
OFF
D Transmission: When engine is Increases
Neutral (A/T : suddenly raced
P range)
44 Ignition D Engine: After Engine is idling 1 - 15_BTDC - -

coils and having warmed
power up
transistors D Timing lamp is
set. (The timing
lamp is set in 2,500 r/min 23 - 43_BTDC
order to check
actual ignition
timing.)

No.
45 ISC D Engine coolant A/C switch: OFF 2 - 25 STEP - -

(stepper) temperature: 80
motor - 95_C
position *5 D Lamps, electric
cooling fan and
all accessories: A/C switch: Increases by
OFF OFF ® ON 10 - 70 steps
D Transmission:
Neutral (A/T :
P range)
D Idle position D A/C switch: Increases by
switch: ON OFF 5 - 50 steps
D Engine: Idling D Select lever:
D When A/C switch N range ® D
is ON, A/C range
compressor
should be
operating
49 A/C relay Engine: After having A/C switch: OFF OFF (Compressor Procedure 13A-149
warmed up/Engine is clutch is not No. 33
idling operating)
A/C switch: ON ON (Compressor

clutch is
operating)
59 Oxygen D Transmission: 3,500 r/min 600 - 1,000 mV Code No. 13A-122

sensor 2nd gear <M/T>, 59
(rear) L range <A/T>
D Drive with
throttle widely
open
No.
01 Injectors Cut fuel to No. Engine: Idling condition Code No. 13A-120
1 injector After having warmed up/ becomes different 41
Engine is idling (becomes unsta-
02 Cut fuel to No. (Cut the fuel supply to each ble).
2 injector injector in turn and check
cylinders which don’t affect
03 Cut fuel to No. idling.)
3 injector
04 Cut fuel to No.

4 injector
05 Cut fuel to No.

5 injector
06 Cut fuel to No.

6 injector
No.
07 Fuel pump Fuel pump D Engine: Pinch the Pulse is felt. Procedure 13A-146
operates and Cranking return hose No. 27
fuel is recircu- D Fuel with fingers
lated. pump: to feel the
Forced pulse of the
driving fuel being
Inspect recirculated.
according
to both Listen near Sound of opera-
the above the fuel tank tion is heard.
conditions. for the
sound of
fuel pump
operation.
08 Purge Solenoid valve Ignition switch: ON Sound of opera- Procedure 13A-151

control turns from OFF tion can be heard No. 36
solenoid to ON. when solenoid
valve valve is
driven.
10 EGR Solenoid valve Ignition switch: ON Sound of opera- Procedure 13A-152

control turns from OFF tion can be heard No. 37
valve valve is
driven.
15 Vacuum Solenoid valve Ignition switch: ON Sound of opera- Code No. 13A-124
control turns from OFF tion can be heard 71
valve valve is driven.
<Vehicles
with TCL>
16 Ventilation Solenoid valve Ignition switch: ON Sound of opera- Code No. 13A-125
control turns from OFF tion can be heard 72
valve valve is driven.
<Vehicles
with TCL>
17 Basic igni- Set to ignition Engine: Idling 5_BTDC - -

tion timing timing adjust- Timing light is set
ment mode
21 Fan con- Drive the fan D Ignition switch: ON Radiator fan and Procedure 13A-145
troller motor condenser fan No. 25
rotate at high
speed

13100920292

NOTE
1. Make the voltage measurement with the engine-ECU
2. You may find it convenient to pull out the engine-ECU
3. The checks can be carried out off the order given
in the chart.
Caution
1 No. 1 injector While engine is idling after having From 11 - 14 V, momentarily

warmed up, suddenly depress the drops slightly
14 No. 2 injector accelerator pedal.
2 No. 3 injector
15 No. 4 injector
3 No. 5 injector
16 No. 6 injector
4 Stepper motor coil <A1> Engine: Soon after the warmed up System voltage « 0 V
engine is started (Changes repeatedly)
17 Stepper motor coil <A2>
6 EGR control solenoid Ignition switch: ON System Voltage

valve
While engine is idling, suddenly depress From system voltage,
the accelerator pedal. momentarily drops
8 A/C relay D Engine: Idle speed System voltage or

D A/C switch: OFF ® ON momentarily
(A/C compressor is operating) 6V or more ® 0 - 3V
10 Power transistor unit Engine r/min: 3,000 r/min 0.3 - 3.0V
12 Power supply Ignition switch: ON System voltage
25
19 Air flow sensor reset Engine: Idle speed 0 - 1V

signal
Engine r/min: 3,000 r/min 6 - 9V
21 Fan controller When the radiator fan and condenser 0 - 0.3 V

fan are not operating
When the radiator fan and condenser 0.7 V or more

fan are operating
22 Fuel pump relay Ignition switch: ON System voltage
Engine: Idle speed 0 - 3V

24 Purge control solenoid Ignition switch: ON System voltage

valve
Running at 3,000 r/min while engine is 0 - 3V
warming up after having been started.
31 Ventilation control Ignition switch: ON System voltage

solenoid valve <Vehicles
with TCL>
32 Vacuum control solenoid Ignition switch: ON System voltage

valve <Vehicles with
TCL>
36 Engine warning lamp Ignition switch: OFF ® ON 0 - 3V ® 9 - 13V

(After several seconds have
elapsed)
37 Power steering fluid Engine: Idling after When steering System voltage
pressure switch warming up wheel is stationary
When steering 0 - 3V
wheel is turned
38 Control relay Ignition switch: OFF System voltage

(Power supply)
45 A/C switch 1 Engine: Idle speed Turn the A/C 0 - 3V

switch OFF
Turn the A/C System voltage

switch ON (A/C
compressor is
operating)
54 Alternator G terminal D Engine: Warm, idle (radiator fan: Voltage rises by 0.2 - 3.5 V.
OFF)
D Brake lamp: ON
55 Alternator FR terminal D Engine: Warm, idle (radiator fan: Voltage drops by 0.2 - 3.5 V.
OFF)
D Brake lamp: ON
57 A/C switch 2 D Engine: Idling When A/C is MAX. 0 - 3V

D Outside air COOL condition
temperature: (when the load by
25_C or more A/C is high)
When A/C is MAX. System voltage

HOT condition
(When the load by
A/C is low)
71 Ignition switch - ST Engine: Cranking 8V or more

72 Intake air temperature Ignition switch: When intake air 3.2 - 3.8V
sensor ON temperature is
0_C

temperature is
20_C

temperature is
40_C

temperature is
80_C
75 Oxygen sensor (rear) D Transmission: 2nd gear <M/T>, 0.6 - 1.0 V

L range <A/T>
D Engine r/min: 3,500 r/min or more
D Driving with the throttle valve widely
open
76 Oxygen sensor (front) Engine: Running at 2,500 r/min after 0 « 0.8V

warmed up (Check using a digital type (Changes repeatedly)
voltmeter)
80 Backup power supply Ignition switch: OFF System voltage
81 Sensor impressed Ignition switch: ON 4.5 - 5.5V

voltage
82 Ignition switch - IG Ignition switch: ON System voltage
83 Engine coolant Ignition switch: When engine 3.2 - 3.8V

temperature sensor ON coolant tempera-
ture is 0_C

coolant tempera-
ture is 20_C

coolant tempera-
ture is 40_C

coolant tempera-
ture is 80_C
84 Throttle position Ignition switch: Set throttle valve 0.3 - 1.0V

sensor ON to idle position
Fully open throttle 4.5 - 5.5V

valve
85 Barometric pressure Ignition switch: When altitude is 3.7 - 4.3V

sensor ON 0m
When altitude is 3.2 - 3.8V

1,200m
86 Vehicle speed sensor D Ignition switch: ON 0 « 5V

D Move the vehicle slowly forward (Changes repeatedly)
87 Idle position switch Ignition switch: Set throttle valve 0 - 1V

ON to idle position
Slightly open 4V or more

throttle valve
88 Top dead centre sensor Engine: Cranking 0.4 - 3.0V
89 Crank angle sensor Engine: Cranking 0.4 - 4.0V
90 Air flow sensor Engine: Idle speed 2.2 - 3.2V
Engine r/min: 2,500r/min
91 Inhibitor switch <A/T> Ignition switch: Set selector lever 0 - 3V

ON to P or N
Set selector lever 8 - 14V

to Other than P or
N
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
1 - 12 No. 1 injector 13 - 16 W (At 20_C)
4 - 12 Stepper motor coil (A1) 28 - 33 W (At 20_C)
17 - 12 Stepper motor coil (A2)
6 - 12 EGR control solenoid valve 36 - 44 W (At 20_C)
24 - 12 Purge control solenoid valve 36 - 44 W (At 20_C)
13 - Body Engine-ECU earth Continuity (0 W)

earth
26 - Body Engine-ECU earth

earth
31 - 12 Ventilation control solenoid valve 36 - 44 W (At 20 _C)

<Vehicles with TCL>
32 - 12 Vacuum control solenoid valve <Vehicles 36 - 44 W (At 20 _C)

with TCL>
72 - 92 Intake air temperature sensor 5.3 - 6.7 kW (When intake air temperature is 0_C)
0.30 - 0.42 kW (When intake air temperature is

80_C)
83 - 92 Engine coolant temperature sensor 5.1 - 6.5 kW (When coolant temperature is 0_C)
0.26 - 0.36 kW (When coolant temperature is

80_C)
87 - 92 Idle position switch Continuity (when throttle valve is at idle position)
No continuity (when throttle valve is slightly open)
91 - Body Inhibitor switch <A/T> Continuity (when select lever is at P or N)

earth
No continuity (when select lever is at D, 2, L or R)
Analyzer INSPECTION PROCEDURE USING AN ANALYZER
13100930226
AIR FLOW SENSOR (AFS)

Special
patterns Measurement Method
pickup 1. Disconnect the air flow sensor connector, and connect
the special tool (test harness: MB991709) in between.
(All terminals should be connected.)
2. Connect the analyzer special patterns pickup to air flow
sensor connector terminal 3.

Pattern height Low
(V)
The time (cycle time) T is reduced when
10 T the amount of intake air increases.
T1 T2 Times T1 and T2 are equal.
Time
0
Observation conditions (from conditions above engine speed is increased by racing.)
(V)
10
T
Time
0


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 Analyzer TOP DEAD CENTER SENSOR AND CRANK ANGLE
SENSOR
Measurement Method
1. Disconnect the distributor connector and connect the
Crank angle special tool (test harness: MB991348) and jumper wire
sensor connector in between. (All terminals should be connected.)
2. Connect the analyzer special patterns pickup to distributor
terminal 5 (top dead centre sensor).
Special patterns
3. Disconnect the crank angle sensor connector and connect
pick-up the special tool (test harness: MD998478) in between.
angle sensor terminal 2.
engine-ECU terminal 88. (When checking the top dead
centre sensor signal wave pattern.)
engine-ECU terminal 89. (When checking the crank angle
sensor signal wave pattern.)
Pattern height Low

2 engine revolutions (1 camshaft revolution)
The time (cycle time) T is reduced when the

Crank 75_BTDC T amount of intake air increases.
angle
sensor 5_BTDC
output
wave
pattern
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.
D Example 2
Cause of problem
Loose timing belt
Analyzer 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
Special be connected.)
patterns 2. Connect the analyzer special patterns pickup to terminal
pickup
2 of the injector connector.
Measurement at the rear bank (No.1, No.3, or No.5 cylinder)

Analyzer 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
Special terminal: terminal 2 (the black clip of the special tool)
patterns when observing at the No.1 cylinder; terminal 3 (the blue
pickup
clip) when observing at the No.3 cylinder; terminal 4 (the
white clip) when observing at the No.5 cylinder

cylinder.)
cylinder.)
cylinder.)
cylinder.)
cylinder.)
cylinder.)
(V)
Point A
50
Solenoid back electromotive force

(Approx. 7´10 V)
Point B
Injector drive time
Power voltage
0 Drive signal: ON Drive signal: OFF

Time

appear at all.
Point B: Injector drive time
D The injector drive time will be synchronized with the MUT-II

tester display.
D When the engine is suddenly raced, the drive time will
be greatly extended at first, but the drive time will soon
match the engine speed.
--- When idling

- - When racing
STEPPER MOTOR
Analyzer
Measurement Method
1. Disconnect the stepper motor connector, and connect
Special 2. Connect the analyzer special patterns pickup to the
patterns
pickup stepper motor-side connector terminal 1 (red clip of special
tool), terminal 3 (blue clip), terminal 4 (black clip) and
terminal 6 (yellow clip) respectively.

engine-ECU terminal 4, connection terminal 5, connection
terminal 17, and connection terminal 18 respectively.
Pattern height High
Engine condition When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF
to ON (without starting the engine).
While the engine is idling, turn the A/C switch to ON.
Immediately after starting the warm engine
(V)
The wave pattern
appears for an Point B Point A
instant, but soon Coil reverse electromotive Induced electromotive force
30 disappears. force (Approx. 3 ´ 10V) from the motor turning
20
10
Stepper
motor
control
signal
wave
pattern
Time
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.)
Induced electromotive force does not appear or is extremely small. Motor is malfunctioning
Point B: Height of coil reverse electromotive force
Coil reverse electromotive force does not appear or is extremely small. Short in the coil
Examples of Abnormal Wave Pattern

D Example 1
Cause of problem
Motor is malfunctioning. (Motor is not operating.)
Induced electromotive force from the motor turning does
not appear.
D Example 2
Open
circuit Cause of problem
side
Open circuit in the line between the stepper motor and
the engine-ECU.
Current is not supplied to the motor coil on the open
circuit side. (Voltage does not drop to 0 V.)
Normal Furthermore, the induced electromotive force waveform
side at the normal side is slightly different from the normal
waveform.
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 1. Disconnect the distributor connector, and connect the
pickup special tool (test harness: MB991348) in between. (All
terminals should be connected.)
2. Connect the analyzer special patterns pickup to distributor
connector terminal 3.
Observation condition
Pattern height Low
Engine r/min Approx. 1,200 r/min
(V) T: Revolution time corresponding

T
to a crank angle of 180_
Crank angle Compression

sensor output 6 top dead centre
wave pattern
4
Power transistor Point

6 Wave build-up section q
control signal
wave pattern q: Spark advance angle
4
2
0
OFF ON
Dwell section
Time
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

D Example 1
Cause of problem
2V
Open-circuit in ignition primary circuit
Top-right part of the build-up section cannot be seen,
and voltage value is approximately 2 V too low.
D Example 2
VB
Cause of problem
Malfunction in power transistor
Power voltage results when the power transistor is ON.
13A-184 MPI <6A1> - On-vehicle Service
THROTTLE BODY (THROTTLE VALVE AREA)

CLEANING
1. Start the engine and warm it up until the coolant is heated
to 80_C or higher and then stop the engine.
2. Remove the air intake hose from the throttle body.
3. Plug the bypass passage inlet of the throttle body.

Caution
Do not allow cleaning solvent to enter the bypass
passage.
4. Spray cleaning solvent into the valve through the throttle
body intake port and leave it for about 5 minutes.
5. Start the engine, race it several times and idle it for about
1 minute. If the idling speed becomes unstable (or if the
engine stalls) due to the bypass passage being plugged,
slightly open the throttle valve to keep the engine running.
6. If the throttle valve deposits are not removed, repeat
steps 4 and 5.
7. Unplug the bypass passage inlet.
8. Attach the air intake hose.
9. Use the MUT-II to erase the self-diagnosis code.
10. Adjust the basic idle speed. (Refer to P.13A-188.)
NOTE
If the engine hunts while idling after adjustment of the
basic idle speed, disconnect the (–) cable from the battery
for 10 seconds or more, and then reconnect it and run
the engine at idle for about 10 minutes.
IDLE POSITION SWITCH AND THROTTLE

POSITION SENSOR ADJUSTMENT (Vehicles
without TCL> 13100130275

(with built-in idle position switch)
MPI <6A1> - On-vehicle Service 13A-185
<Vehicles without auto-cruise control 2. Insert a thickness gauge as follows:
system> Throttle lever
Fixed SAS
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 <Vehicles with auto-cruise control system>

system> Insert a 1.4-mm thick thickness gauge up to approx. 3
Throttle lever 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 Free lever 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 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 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.
THROTTLE POSITION SENSOR ADJUSTMENT

<Vehicles with TCL> 13100110040

2. Turn the ignition switch to ON (but do not start the engine).
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.
Accelerator pedal IDLE POSITION SWITCH AND ACCELERATOR

position sensor PEDAL POSITION SENSOR ADJUSTMENT
(with built-in idle
position switch) <Vehicles with TCL> 13100140049
<Vehicles without auto-cruise control 2. Insert a thickness gauge with a thickness of 0.5 mm in
system> between the accelerator lever and throttle lever to a depth
Accelerator lever of approximately 3 mm.
NOTE
If the thickness gauge is inserted more than 3 mm, the
accelerator lever opening angle will become greater than
the set opening angle, which will result in defective
Thickness
gauge adjustment.
Throttle lever 3. Turn the ignition switch to ON (but do not start the engine).
<Vehicles with auto-cruise control

system>
Throttle lever
Throttle lever
Thickness
gauge
4. Loosen the accelerator pedal position sensor mounting
Accelerator pedal bolt, and then turn the accelerator pedal position sensor
position sensor
(with built-in idle counterclockwise as far as it will go.
position switch) 5. Check that the idle position switch is ON at this position.
6. Slowly turn the accelerator pedal position sensor
clockwise and find the point where the idle position switch
turns off.
Securely tighten the accelerator pedal position sensor
mounting bolt at this point.
7. Select “Traction Control System” on the MUT-II.

8. Check the accelerator pedal position sensor output
voltage.
9. If the voltage is outside the standard value, check the
accelerator pedal position sensor and related harnesses.
FIXED SAS ADJUSTMENT 13100150318
NOTE
1. The fixed SAS should not be moved unnecessarily;
it has been precisely adjusted by the manufacturer.
2. If the adjustment is disturbed for any reason, readjust
as follows.
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 turn.
5. While holding the fixed SAS so that it doesn’t 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).
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.
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
3. Remove the union joint and bolt from the special tool
Fuel pressure (adapter hose MD998709) and instead attach the special
High pres- gauge tool (hose adapter MD998742) to the adapter hose.
sure hose O-ring or 4. Install a fuel pressure gauge on the adapter hose that
gasket
was set up in step 3.
MD998709 Use a suitable O-ring or gasket between the fuel pressure
MD998742 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
Delivery pipe
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
10. Disconnect the vacuum hose from the fuel pressure

regulator and measure fuel pressure with the hose end
closed by a finger.
Standard value:
324 - 343 kPa at kerb idle
11. Check to see that fuel pressure at idle does not drop
even after the engine has been raced several times.
12. Racing the engine repeatedly, hold the fuel return hose
lightly with fingers to feel that fuel pressure is present
in the return hose.
NOTE
If the fuel flow rate is low, there will be no fuel pressure
in the return hose.
13. If any of fuel pressure measured in steps 9 to 12 is out
of specification, troubleshoot and repair according to the
table below.
D Fuel pressure too low Clogged fuel filter Replace fuel filter
D Fuel pressure drops after racing
D No fuel pressure in fuel return Fuel leaking to return side due to poor Replace fuel pressure regulator
hose fuel regulator valve seating or settled
spring
Low fuel pump delivery pressure Replace fuel pump
Fuel pressure too high Binding valve in fuel pressure Replace fuel pressure regulator
regulator
Clogged fuel return hose or pipe Clean or replace hose or pipe
Same fuel pressure when vacuum Damaged vacuum hose or clogged Replace vacuum hose or clean nipple
hose is connected and when nipple
disconnected
14. Stop the engine and check change of fuel pressure gauge
reading. Normal if the reading does not drop within 2
minutes. If it does, observe the rate of drop and
troubleshoot and repair according to the table below.
Fuel pressure drops gradually after Leaky injector Replace injector

engine is stopped
Leaky fuel regulator valve seat Replace fuel pressure regulator
Fuel pressure drops sharply Check valve in fuel pump is held open Replace fuel pump
immediately after engine is stopped
15. Release residual pressure from the fuel pipe line. (Refer
to P.13A-191.)
16. Remove the fuel pressure gauge and special tool from
the delivery pipe.
Caution
17. Replace the O-ring at the end of the fuel high pressure
hose with a new one. Furthermore, apply engine oil to
the new O-ring before replacement.
18. Fit the fuel high pressure hose over the delivery pipe
and tighten the bolt to specified torque.
19. Check for fuel leaks.
(1) Apply the battery voltage to the fuel pump drive
terminal to drive the fuel pump.
(2) Under fuel pressure, check the fuel line for leaks.
FUEL PUMP CONNECTOR DISCONNECTION

(HOW TO REDUCE THE FUEL PRESSURE)
13100090269
Refer to P.13A-88.
FUEL PUMP OPERATION CHECK 13100200242
Refer to P.13A-88.

A/C relay H Fuel pump check terminal F
A/C switch R Idle speed control servo C
Accelerator pedal position sensor (with idle C Inhibitor switch <A/T> M
position switch) <Vehicles with TCL>
Air flow sensor (with intake air temperature G Injectors J
sensor and barometric pressure sensor)
Control relay and fuel pump relay P Oxygen sensor (front) S
Crank angle sensor A Oxygen sensor (rear) T
Detonation sensor J Power steering fluid pressure switch I
<Vehicles for Hong Kong and Singapore>
Diagnosis connector O Purge control solenoid valve B
Distributor (with top dead centre sensor and L Throttle position sensor <Vehicles with TCL> C
ignition coil)
EGR control solenoid valve B Throttle position sensor (with idle position C
switch) <Vehicles without TCL>
Engine coolant temperature sensor K Vacuum control solenoid valve D
<Vehicles with TCL>
Engine-ECU Q Vehicle speed sensor E
Engine warning lamp (check engine lamp) N Ventilation control solenoid valve D
<Vehicles with TCL>
T
CONTROL RELAY AND FUEL PUMP RELAY
CONTINUITY CHECK 13100990187

Equipment side
connector 1 2 3 4
Not supplied
Supplied
Fuel pump relay and control relay
Air flow sensor (with INTAKE AIR TEMPERATURE SENSOR CHECK

intake air tempera- 13100280246
ture sensor)
1. Disconnect the air flow sensor connector.
Equipment side
connector
Standard value:
2.3 - 3.0 kW (at 20_C)
0.30 - 0.42 kW (at 80_C)
Intake air temperature sensor 3. Measure resistance while heating the sensor using a hair
drier.
Normal condition:
Higher Smaller
resistance remains unchanged, replace the air flow sensor
assembly.

CHECK 13100310259
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.

Specified sealant:
3M Nut Locking Part No.4171 or equivalent
<Vehicles without TCL> THROTTLE POSITION SENSOR CHECK 13100320283

Equipment side connector 1. Disconnect the throttle position sensor connector.
Throttle position sensor sensor side connector terminal 3 and terminal 4.
Normal condition:
<Vehicles with TCL> position angle of the throttle valve
Throttle position sensor 4. If the resistance is outside the standard value, or if it
doesn’t change smoothly, replace the throttle position
Equipment sensor.
side connector
NOTE
For the throttle position sensor adjustment procedure,
refer to P.13A-184 <Vehicles without TCL>, P.13A-186
<Vehicles with TCL>.
ACCELERATOR PEDAL POSITION SENSOR

CHECK <Vehicles with TCL> 13100340012
Accelerator pedal
position sensor 1. Disconnect the accelerator pedal position sensor
Equipment connector.
side connector
2. Measure the resistance between the accelerator pedal
position sensor side connector terminal 1 and terminal
4.
2.
Normal condition:
position angle of the throttle valve
doesn’t 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

Equipment side connector
without TCL> 13100330279
1. Disconnect the throttle position sensor connector.

2. Check the continuity between the throttle position sensor
connector side terminal 1 and terminal 2.
Normal condition:
Throttle position sensor Accelerator pedal Continuity
3. If out of specification, replace the throttle position sensor.
NOTE
After replacement, the idle position switch and throttle
position sensor should be adjusted. (Refer to P.13A-184.)
IDLE POSITION SWITCH CHECK

Accelerator pedal
position sensor 1. Disconnect the accelerator pedal position sensor
Equipment side connector.
connector 2. Check the continuity between the accelerator pedal
position sensor connector side terminal 3 and terminal
4.
Normal condition:

Depressed Non-conductive (¥ W)
3. If out of specification, replace the accelerator pedal
position sensor.
NOTE
After replacement, the idle position switch and accelerator
pedal position sensor should be adjusted. (Refer to
P.13A-186.)
OXYGEN SENSOR CHECK 13100510178
Oxygen sensor <Oxygen sensor (front)>

(front)
1. Disconnect the oxygen sensor connector and connect
Equipment side the special tool (test harness) to the connector on the
connector
oxygen sensor side.
2. Make sure that there is continuity (11 - 18 W at 20_C)
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.
6. Connect a digital voltage meter between terminal 1 and
terminal 2.
MB991223 7. While repeatedly racing the engine, measure the oxygen
sensor output voltage.
Standard value:
Engine Oxygen sensor Remarks
output voltage
When 0.6 - 1.0 V If you make the air/fuel ratio
racing the rich by racing the engine
engine repeatedly, a normal oxy-
gen sensor will output a
voltage of 0.6 - 1.0 V.
8. If the sensor is defective, replace the oxygen sensor.
NOTE
For removal and installation of the oxygen sensor, refer
to GROUP 15 - Exhaust Pipe and Main Muffler.
<Oxygen sensor (rear)>
Oxygen sensor (rear) 1. Disconnect the oxygen sensor connector and connect
the special tool (test harness set) to the connector on
the oxygen sensor side.
Equipment side
connector 2. Make sure that there is continuity (11 - 18 W at 20_C)
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.
Intermediate harness
D Rear bank side (No.1, No.3, No.5 cylinders)
side connector 1. Disconnect the injector intermediate harness connectors.
Injector intermediate Standard value: 13 - 16 W (at 20_C)
harness connector
Injector Measurement probe
No.1 cylinder 1- 2
No.3 cylinder 1- 3
No.5 cylinder 1- 4
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.
High-pressure fuel hose MD998741
Return hose
MB991607
Pressure regulator
(MD116395)
Injector
MD998706
Clip (MB991608)
Battery
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 5. Activate the injector and check the atomized spray
Return hose
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 injector’s nozzle.
Standard value: 1 drop or less per minute
7. Activate the injector without activating the fuel pump; then,
when the spray emission of fuel from the injector stops,
disconnect the special tool and restore it to its original
condition.
IDLE SPEED CONTROL (ISC) SERVO

(STEPPER MOTOR) CHECK 13100540245
Checking the Operation Sound

1. Check that the engine coolant temperature is 20_C or
below.
NOTE
Disconnecting the engine coolant temperature sensor
Idle speed
connector and connecting the harness-side of the
control servo 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
motor’s 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.
Operation Check
1. Remove the throttle body.
2. Remove the stepper motor.
3. Connect the special tool (test harness) to the idle speed

control servo connector.
4. Connect the positive (+) terminal of a power supply
(approx. 6 V) to the white clip and the green clip.
5. With the idle speed control servo as shown in the
Idle illustration, connect the negative ( - ) terminal of the power
Green speed supply to each clip as described in the following steps,
White
control and check whether or not a vibrating feeling (a feeling
servo
of very slight vibration of the stepper motor) is generated
as a result of the activation of the stepper motor.
MD998463
(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

VENTILATION CONTROL SOLENOID VALVE
Vacuum control CHECK <Vehicles with TCL> 13100630041
Ventilation control solenoid valve
solenoid valve
NOTE
When disconnecting the vacuum hose, always make a mark
so that it can be reconnected at original position.
1. Disconnect the vacuum hose (green stripe) from the
solenoid valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to the nipple.

4. Check air-tightness by applying a vacuum with voltage
applied directly from the battery to the solenoid valve
and without applying voltage.
Normal condition:
Battery voltage Normal condition
Applied Vacuum maintained
Battery Not applied Vacuum leaks
5. Measure the resistance between the terminals of the

solenoid valve.
VACUUM CONTROL SOLENOID VALVE CHECK

Vacuum control <Vehicles with TCL> 13100620048
Ventilation control solenoid valve
solenoid valve
NOTE
1. Disconnect the vacuum hose (blue stripe, green stripe)
from the solenoid valve.
3. Connect a hand vacuum pump to the nipple to which

the blue-striped vacuum hose was connected.
4. Check air-tightness by applying a vacuum with voltage
applied directly from the battery to the solenoid valve
and without applying voltage.
Applied Vacuum leaks

Battery
Not applied Vacuum maintained

solenoid valve.
VACUUM TANK CHECK 13100810049
<Vehicles with TCL>

1. Connect a hand vacuum pump to vacuum tank A nipple,
apply 67 kPa of vacuum and check that the vacuum
A is held.
2. Connect a hand vacuum pump to vacuum tank B nipple.
B 3. First, close A nipple with your finger and apply 67 kPa
of vacuum. Then, check that the vacuum leaks
immediately when you remove the finger blocking the
nipple.
Vacuum actuator VACUUM ACTUATOR CHECK 13100820042
<Vehicles with TCL>

1. Remove the vacuum hose (green stripe) from the vacuum
actuator and connect a hand vacuum pump to the vacuum
Rod 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.
Accelerator lever
THROTTLE VALVE OPERATION CHECK 13100830052
<Vehicles with TCL>

1. Check that the throttle valve opens and closes smoothly
(throttle lever moves) according to the opening and closing
of the accelerator lever.
2. If the throttle valve does not open and close smoothly,
there might be a deposit on the throttle valve, so clean
the throttle body. (Refer to P.13A-184.)
Throttle valve
Throttle lever
NEGATIVE PRESSURE CHECK DURING
Vacuum actuator TRACTION CONTROL OPERATION 13100840055
<Vehicles with TCL>

T-joint 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 driver’s seat so
Green stripe that the negative pressure check can be carried out at
the driver’s 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 No change
road surface
NOTE
The traction control system function will stop 20 seconds
after the accelerator pedal has been depressed, and
negative pressure will gradually drop.
POWER STEERING AIR CONTROL VALVE

OPERATION CHECK 13101180019
Power steering
air control valve 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>
D Fuel Discharge Prevention (Refer to P.13A-88.)
18 Nm
5 8, 9
10 O-ring
4 4 13
3 Nm
O-ring
1 14
2
9 Nm Engine oil
6
8
12 Nm
10
11
7
14 9
13
12 9 Nm
Removal steps
1. Engine cover "AA 8. Fuel pressure regulator
2. Crank angle sensor connector "AA 9. Fuel pipe assembly
3. Injector connector AA" 10. Delivery pipe
4. Vacuum hose connection 11. Insulator
5. Air pipe assembly mounting bolt 12. Insulator
6. Vacuum hose connection AA" "AA 13. Injector
7. Fuel return hose connection 14. Grommets
MPI <6A1> - Injector 13A-205
<Rear bank>
Pre-removal Operation Post-installation operation
D Fuel Discharge Prevention (Refer to P.13A-88.) D Air Cleaner Installation
D Air Cleaner Removal D Accelerator Cable Adjustment (Refer to GROUP
17 - On-vehicle service.)
18 Nm
4 5
8
4 3 Nm
3 1
2
12
18 Nm
6
7
12 Nm
13
16
17
10 15 18
11
18 Nm
21
20 9 Nm
14
19
20 15, 16
O-ring 17
21 O-ring
Engine oil
Removal steps
1. Engine cover 12. Air intake plenum
2. Crank angle sensor connector 13. Air intake plenum gasket
3. Injector connector 14. Injector connector
4. Vacuum hose "AA 15. High pressure fuel hose connection
5. Air pipe assembly mounting bolt "AA 16. Fuel pipe assembly
6. Brake booster vacuum hose AA" 17. Delivery pipe
connection 18. Insulator
7. Connector bracket mounting bolt 19. Insulator
8. Connector bracket mounting bolt AA" "AA 20. Injector
9. Noise condenser mounting bolt 21. Grommets
10. EGR solenoid valve connector
11. Purge control solenoid valve
connector
13A-206 MPI <6A1> - Injector

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)
MPI <6A1> - Throttle Body 13A-207

D Engine Coolant Draining D Air Cleaner Installation
(Refer to GROUP 14 - On-vehicle Service.) D Engine Coolant Supplying
D Air Cleaner Removal (Refer to GROUP 14 - On-vehicle Service.)
<Vehicles without traction control system>
10 - 13 Nm 6 2 7 1
4
8
4
18 Nm
Removal steps
1. Accelerator cable connection 5. Water hose connection
2. Throttle position sensor connector 6. Vacuum pipe assembly
3. Idle speed control servo connector 7. Throttle body
4. Vacuum hose connection "AA 8. Throttle body gasket
13A-208 MPI <6A1> - Throttle Body
<Vehicles with TCL and <Vehicles with TCL>

auto-cruise control system>
10 - 13 Nm
7 2
8
4
10 - 13 Nm 9 1
7
3
3
2
9
6
4
8
18 Nm
Removal steps
1. Accelerator cable connection 5. Vacuum hose connection
2. Throttle position sensor connector 6. Water hose connection
3. Idle speed control servo connector 7. Vacuum pipe assembly
4. Accelerator pedal position sensor 8. Throttle body
connector "AA 9. Throttle body gasket
Up INSTALLATION SERVICE POINT

"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
<Vehicles without TCL and auto-cruise control system>
7
6
8
9
4
2
3
Disassembly steps
"BA 1. Throttle position sensor NOTE
2. Idle speed control servo (Stepper 1. The fixed SAS and the speed adjusting screw are
motor) correctly adjusted at the factory and should not be
3. O-ring removed.
4. Fast idle air valve 2. If the fixed SAS should happen to have been
5. O-ring removed, carry out fixed SAS adjustment.
6. Throttle body (Refer to page 13A-187.)
7. Fixed SAS 3. If the speed adjusting screw should happen to have
8. Speed adjusting screw been removed, carry out speed adjusting screw
9. O-ring adjustment. (Refer to 13A-188.)
<Vehicles with auto-cruise control system>
6 8
9
10
1
7
5 2
3
4
Disassembly steps
"BA 1. Throttle position sensor NOTE
2. Idle speed control servo 1. The fixed SAS and the speed adjusting screw are
(Stepper motor) correctly adjusted at the factory and should not be
3. O-ring removed.
4. Fast idle air valve 2. If the fixed SAS should happen to have been
5. O-ring removed, carry out fixed SAS adjustment.
6. Lever assembly (Refer to page 13A-187.)
7. Throttle body 3. If the speed adjusting screw should happen to have
8. Fixed SAS been removed, carry out speed adjusting screw
9. Speed adjusting screw adjustment. (Refer to 13A-188.)
10. O-ring
<Vehicles with TCL>
11
8
11 12
10
1 7
Disassembly steps NOTE

1. Water hose 1. The fixed SAS and the speed adjusting screw are
"BA 2. Throttle position sensor correctly adjusted at the factory and should not be
"AA 3. Accelerator pedal position sensor removed.
4. Idle speed control servo (Stepper mo- 2. If the fixed SAS should happen to have been
tor) removed, carry out fixed SAS adjustment. (Refer to
5. O-ring 13A-187.)
6. Fast idle air valve 3. If the speed adjusting screw should happen to have
7. O-ring been removed, carry out speed adjusting screw
8. Throttle lever adjustment. (Refer to 13A-188.)
9. Throttle body
10. Fixed SAS
11. Speed adjusting screw
12. O-ring
<Vehicles with TCL and auto-cruise control system>
3
11
12
10
7
1
Disassembly steps NOTE

1. Water hose 1. The fixed SAS and the speed adjusting screw are
"BA 2. Throttle position sensor correctly adjusted at the factory and should not be
"AA 3. Accelerator pedal position sensor removed.
4. Idle speed control servo (Stepper mo- 2. If the fixed SAS should happen to have been
tor) removed, carry out fixed SAS adjustment. (Refer to
5. O-ring 13A-187.)
6. Fast idle air valve 3. If the speed adjusting screw should happen to have
7. O-ring been removed, carry out speed adjusting screw
8. Throttle lever adjustment. (Refer to 13A-188.)
9. Throttle body
10. Fixed SAS
11. Speed adjusting screw
12. O-ring
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 REASSEMBLY SERVICE POINTS
position sensor
"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:
Earth APS power Throttle valve condition Continuity
supply
APS output If there is no continuity when the throttle valve is fully

closed, turn the APS body clockwise and then check
again.
4. If there is an abnormality, replace the APS.
"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
Throttle position sensor 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
TPS output and fully open.
TPS power Normal condition:
supply Earth
Throttle valve condition Continuity
Idle position switch If there is no continuity when the throttle valve is fully
(Vehicles without TCL only)
closed, turn the TPS body anti-clockwise and then check
again.
4. If there is an abnormality, replace the TPS.
13E-1
DIESEL FUEL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Engine Coolant Temperature Sensor

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4 Accelerator Pedal Position Sensor Check . . . . . 57
Idle Position Switch 1 Check . . . . . . . . . . . . . . . . . 58
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Idle Position Switch 2 Check . . . . . . . . . . . . . . . . . 58
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Solenoid-type Spill Valve Check . . . . . . . . . . . . . . 59
Timing Control Solenoid Valve Check . . . . . . . . . 59
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6
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 Throttle Solenoid Valve Check . . . . . . . . . . . . . . . 60
Position Switch 1 Adjustment . . . . . . . . . . . . . . . . 53
Throttle Actuator Check . . . . . . . . . . . . . . . . . . . . . 61
Idle Position Switch 2 Adjustment . . . . . . . . . . . . 54
Injection Nozzle Check and Adjustment . . . . . . . 61
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . 55
Control Relay and Solenoid-type Spill Valve Relay INJECTION PUMP AND NOZZLE . . . . . . . . . 63
Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Intake Air Temperature Sensor Check . . . . . . . . 56
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 68
13E-2 DIESEL FUEL - General Information
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.
3. A/C Relay Control
Turns the compressor clutch of the A/C ON and OFF
4. Fan motor relay control
The radiator fan and condenser fan operating speeds are controlled in accordance with the engine
coolant temperature and the vehicle speed.
5. Glow Control
Refer to GROUP 16.
6. EGR Control
Refer to GROUP 17.
DIESEL FUEL - General Information 13E-3
DIESEL FUEL SYSTEM DIAGRAM
*1 Pump operation sensor Engine-ECU z1 Solenoid-type spill valve
*2 Crank angle sensor z2 Timing control solenoid valve
*3 Engine coolant temperature sensor z3 EGR solenoid valve
*4 Boost sensor z4 Throttle solenoid valve
*5 Diesel fuel temperature sensor
*6 Intake air temperature sensor D Control relay
D Solenoid-type spill valve relay
D Accelerator pedal position sensor D Glow plug relay
D Idle position switch 1 D A/C power relay
D Idle position switch 2 D Fan motor relay
D Power supply voltage D Engine warning lamp
D Ignition switch-IG D Glow indicator lamp
D Ignition switch-ST D Diagnosis signal
D Vehicle speed sensor
D A/C switch
D Injection timing correction resistor
D Injection rate correction resistor
z4 Throttle solenoid valve

z3 EGR solenoid valve
Vacuum pump Alternator
Air cleaner
Throttle
actuator z1 Solenoid-type spill valve
*4 Boost sensor *5 Diesel fuel temperature
sensor
*1 Pump
operation
*6 Intake air Throttle valve sensor
temperature
sensor EGR valve
Turbocharger Injection pump
z2 Timing control
Waste gate actuator solenoid valve
Oxidation catalyst *3 Engine coolant

temperature
sensor
13E-4 DIESEL FUEL - Service Specifications/Sealant
Accelerator pedal position sensor adjusting voltage mV 530 - 570
Idle position switch 1 check voltage mV 875 - 925
Intake air temperature sensor resis- At 20 _C 2.3 - 3.0

tance kW
At 80 _C 0.30 - 0.42
Engine coolant temperature sensor At 20 _C 2.1 - 2.7

resistance kW
At 80 _C 0.26 - 0.36
Resistance between accelerator pedal position sensor 3.5 - 6.5

terminals (1) and (4) kW
Solenoid-type spill valve resistance W 1 - 2 (at 20 _C)
Timing control solenoid valve resistance W 8 - 12 (at 20 _C)
Diesel fuel temperature sensor resistance kW 2.2 - 2.7 (at 20 _C)
Pump operation sensor resistance W 215 - 245 (at 20 _C)
Injection timing correction resistor resistance kW 0.1 - 2.5 (at 20 _C)
Injection rate correction resistor resistance kW 0.1 - 2.5 (at 20 _C)
Fuel cut solenoid valve resistance W 8 - 10
Throttle solenoid valve resistance W 36 - 44 (at 20 _C)
SEALANT 13300050010
threaded portion
DIESEL FUEL - Special Tools 13E-5

MB991502 MUT-II sub assembly D Reading diagnosis code
D Checking the electronically-
controlled fuel injection
system
MB991348 Test harness set Inspection using an analyzer
MD998478 Test harness Inspection using an analyzer

(3 pin, triangle)
MB990767 End yoke holder Fuel injection pump sprocket

holding
MD998719 Crankshaft pulley holder

pin
MD998388 Sprocket puller Fuel injection pump sprocket

removal
13E-6 DIESEL FUEL - Troubleshooting

Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.

If an abnormality occurs in any of the following items which
are related to the electronically-controlled fuel injection
system, the engine warning lamp will illuminate.
Engine warning lamp
Accelerator pedal position sensor
Boost sensor
Diesel fuel temperature sensor
Pump operation sensor
Crank angle sensor
Idle position switch 1
Throttle solenoid valve system
Timing control solenoid valve system
Solenoid-type spill valve system
Immobilizer system
Engine-ECU
DIESEL FUEL - Troubleshooting 13E-7
CODES
Service Points.
ACTUATOR TESTING
FAIL-SAFE/BACKUP FUNCTION TABLE 13300390020
Accelerator pedal position sensor Carries out control as if the accelerator opening angle is at a specified angle
(0 %/approx. 10%) on the basis of idle position switch inputs (ON/OFF).
Boost sensor Carries out control as if the intake air pressure is at a specified value (101 kPa).
Diesel fuel temperature sensor Carries out control as if the fuel temperature is 50 _C.
Engine coolant temperature sensor Carries out control as if the engine coolant temperature is at a specified value
(80_C).
Intake air temperature sensor Carries out control as if the intake air temperature is at a specified value
(25_C).
Vehicle speed sensor Carries out control as if the vehicle is moving.
Pump operation sensor Controls the injection rate according to the speed reported by the crank angle
sensor.
Crank angle sensor D Reduces the fuel injection rate.

D Fixes the injection timing at a specified value.
Ignition switch-ST Carries out control as if ignition switch ST is OFF.
Timing control solenoid valve Reduces the fuel injection rate.
Solenoid-type spill valve Solenoid-type spill valve relay is turned off (engine stops).
Correction resistors (injection timing Carries out control as if the correction resistance are at specified values.
and injection rate)
Caution
Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
11 Accelerator pedal position sensor system 13E-9
12 Boost sensor system 13E-10
13 Barometric pressure sensor system 13E-11
14 Diesel fuel temperature sensor system 13E-11
15 Engine coolant temperature sensor system 13E-12
16 Intake air temperature sensor system 13E-12
17 Vehicle speed sensor system 13E-13
18 Pump operation sensor system (open circuit) 13E-14
19 Pump operation sensor system (intermittent fault) 13E-14
21 Crank angle sensor system 13E-15
22 Ignition switch-ST signal system 13E-16
23 Idle position switch 1 system 13E-16
24 Idle position switch 2 system 13E-17
41 Throttle solenoid valve system 13E-18
43 Timing control solenoid valve system 13E-19
44 Solenoid-type spill valve system 13E-20
45 Injection timing correction resistor system 13E-21
46 Injection rare correction resistor system 13E-21
47 Immobilizer system 13E-22

Code No.11 Accelerator pedal position sensor system Probable cause
Range of Check, Set Conditions D Malfunction of the accelerator pedal position sensor
D Open or short circuit is detected in accelerator pedal position sensor circuit. D Open or short circuit in accelerator pedal position
or sensor circuit or poor connector contact
D Mechanical problem is detected in accelerator pedal position sensor. D Malfunction of the engine-ECU
Range of Check
D Idle position switch 1: ON
Set Conditions
D Accelerator pedal position sensor signal output is 1.2 V or higher
NG
Check the accelerator pedal position sensor. (Refer to P.13E-57.) Replace
OK
NG
Measure at the accelerator pedal position sensor connector B-41. Check the following connector:
D Disconnect the connector and measure at the harness side C-54
connector. OK NG
OK: 4.5 - 5.5 V Repair
OK: Continuity
OK
NG
Check the following connector:
B-41 Check the harness wire between the engine-ECU and the accelera-
tor pedal position sensor connector.
OK NG
OK NG
Repair
Repair
Repair the engine-ECU.
NG

Code No.12 Boost sensor system Probable cause

Range of Check, Set Conditions D Malfunction of the boost sensor
D Open or short circuit is detected in boost sensor circuit for 1 second. D Open or short circuit in boost sensor circuit or poor
connector contact
NG NG
Measure at the boost sensor connector Measure at the boost sensor connector Check the following connector:
B-50. B-50. C-54
D Connect the connector. D Disconnect the connector and
OK NG
(Use the test harness: MB991348) measure at the harness side
D Voltage between 1 and earth connector. Repair
(Ignition switch: ON) D Voltage between 3 and earth
OK: 2.0 - 2.6 V (Altitude: 0 m) (Ignition switch: ON)
1.7 - 2.3 V (Altitude: 1200 m) OK: 4.8 - 5.2 V Check trouble symptom.
OK D Continuity between 2 and earth NG
OK: Continuity
OK Check the harness wire between the
engine-ECU and the boost sensor con-
nector.
OK NG
B-50 Repair
OK NG
Repair
NG
engine-ECU and the boost sensor con-
nector.
NG
Measure at the engine-ECU connector Check the harness wire between the OK NG
C-54. engine-ECU and the boost sensor con-
D Connect the connector. nector, and repair if necessary. Repair
(Ignition switch: ON) Check the vacuum hose between the
OK: 2.0 - 2.6 V (Altitude: 0 m) boost sensor and the intake manifold.
1.7 - 2.3 V (Altitude: 1200 m)
OK NG
OK
Repair
Check the following connectors:
B-50, C-54
Replace the boost sensor.
OK NG
Repair
NG
Code No.13 Barometric pressure sensor system Probable cause
Range of Check, Set Conditions D Malfunction of the engine-ECU
D An abnormal signal being output from the barometric pressure sensor is detected
for 3 seconds.
OK
MUT-II Data list INTERMITTENT MALFUNCTIONS
03 Barometric pressure sensor
NG
Code No.14 Diesel fuel temperature sensor system Probable cause

Range of Check D Malfunction of the diesel fuel temperature sensor
D Open or short circuit is detected in diesel fuel temperature sensor circuit for 4 D Open or short circuit in diesel fuel temperature sensor
seconds. circuit or poor connector contact
NG
Check the diesel fuel temperature sensor. (Refer to P.13E-59.) Replace the injection pump.
OK
NG
Measure at the diesel fuel temperature sensor connector B-62. Check the following connector:
connector. OK NG
OK: Continuity
OK
NG
B-62 Check the harness wire between the engine-ECU and the diesel
fuel temperature sensor connector.
OK NG
OK NG
Repair
Repair

NG

Code No.15 Engine coolant temperature sensor system Probable cause

Range of Check, Set Conditions D Malfunction of the engine coolant temperature sensor
D Open or short circuit is detected in engine coolant temperature sensor circuit for D Open or short circuit in engine coolant temperature
1 second. sensor circuit or poor connector contact
NG
Check the engine coolant temperature sensor. (Refer to P.13E-57.) Replace
OK
NG
Measure at the engine coolant temperature sensor connector B-33. Check the following connector:
connector. OK NG
OK: Continuity
OK
NG
B-33 Check the harness wire between the engine-ECU and the engine
coolant temperature sensor connector.
OK NG
OK NG
Repair
Repair
NG
Code No.16 Intake air temperature sensor system Probable cause

Range of Check, Set Conditions D Malfunction of the intake air temperature sensor
D Open or short circuit is detected in intake air temperature sensor circuit for 3 D Open or short circuit in intake air temperature sensor
seconds. circuit or poor connector contact
NG
Check the intake air temperature sensor. (Refer to P.13E-56.) Replace
OK
NG
Measure at the intake air temperature sensor connector B-45. Check the following connector:
connector. OK NG
OK: Continuity
OK
NG
B-45 Check the harness wire between the engine-ECU and the intake
air temperature sensor connector.
OK NG
OK NG
Repair
Repair

NG

Code No.17 Vehicle speed sensor system Probable cause
Range of Check D Malfunction of the vehicle speed sensor
D Engine speed: 2,400 r/min or more D Open or short circuit in vehicle speed sensor circuit
D Accelerator pedal opening amount: 50 % or more or poor connector contact
D Engine coolant temperature: 60 _C or higher D Malfunction of the engine-ECU
Set Conditions
D Vehicle speed signal is 0 km/h for 10 seconds or more.
NG
tion Meters.)
OK
1. NG
Measure at the vehicle speed sensor connector B-66. Check the following connectors:
D Disconnect the connector, and measure at the harness B-65, C-90, C-135, C-131
side. OK
2. NG NG
OK: System voltage
Repair
OK: 4.8 - 5.2 V
3. Continuity between 2 and earth 3. NG Check trouble symptom.
OK: Continuity NG
OK
Check the following connectors: ignition switch connector.
B-66, C-53 OK NG
OK NG
Repair
Repair
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.)
NG Check the following connectors:
B-65, C-56, C-53
Check the harness wire between the engine-ECU and the vehicle
speed sensor connector. OK NG
OK NG
Repair
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
Code No.18 Pump operation sensor system (open circuit) Probable cause
Range of Check D Malfunction of the pump operation sensor
D The injection pump operation speed computed from the crank angle sensor signal D Open or short circuit in pump operation sensor circuit
is 80 r/min or more. or poor connector contact
Set Conditions D Malfunction of the engine-ECU
D No injection pump operation signal (pump operation sensor signal) is not during
six successive crank angle sensor pulse signal inputs.
NG
Check the pump operation sensor. (Refer to P.13E-60.) Replace the injection pump.
OK
NG
Measure at the engine-ECU connector C-53. Check the following connectors:
D Connect the connector. C-53, B-63
D Voltage between 10 and 23 (AC range) OK NG
OK: 0.2 - 1.0 V (Engine: idling)
1.2 - 2.2 V (Engine: 2500 r/min) 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 Probable cause

fault)
Range of Check D Malfunction of the pump operation sensor
D No open circuit in pump operation sensor D Poor contact in pump operation sensor connector or
D Injection pump speed: 650 r/min or more malfunction of circuit
D Ignition switch-ST signal: OFF D Malfunction of pump operation sensor circuit shielding
D Abnormal number of pump operation sensor signal pulses counted during two
full engine rotations.
D Pulse count abnormality occurs 10 times or more.
NG
C-53, B-63
OK

NG
NG
Check the harness wire between the engine-ECU and the pump Repair
operation sensor connector.
OK

Code No.21 Crank angle sensor system Probable cause
D Injection pump speed: 500 r/min or more D Open or short circuit in crank angle sensor circuit or
Set Conditions poor connector contact
D No crank angle sensor signal pulses input during two full engine rotations. D Malfunction of the engine-ECU
OK
D Connect the connector. (Use the test harness: MD998478)
OK: 0.4 - 4.0 V
OK: 2.5 - 4.5 V
NG
1.NG
D Disconnect the connector and measure at the harness side control relay connector, and repair if necessary.
connector.
1. Voltage between 3 and earth (Ignition switch: ON) 2.NG
OK: System voltage Check the following connector:
2. Voltage between 2 and earth (Ignition switch: ON) C-53
OK: 4.8 - 5.2 V
3.NG OK NG
OK: Continuity
Repair
OK

B-77 NG
OK NG Check the harness wire between the engine-ECU and the crank
angle sensor connector.
Repair
OK NG
NG
Replace the crank angle sensor. Replace the engine-ECU.
Code No.22 Ignition switch-ST signal system Probable cause

Range of Check D Malfunction of the starter relay
D Ignition switch: ON D Malfunction of starter relay-related circuit
D Injection pump speed: 1,200 r/min or more D Malfunction of the engine-ECU
Set Conditions
D Ignition switch-ST signal (high) is input for 10 seconds or more.
NG
Measure at the engine-ECU connector C-55. Check the following connectors:
D Disconnect the connector and measure at the harness side B-30, A-10
connector. OK NG
D Voltage between 51 and earth (Ignition switch: ST)
OK: 8 V or higher Repair
OK
C-55 NG
OK NG Check the harness wire between the engine-ECU and the starter
relay connector.
Repair
OK NG
NG
Replace the starter relay.
Code No.23 Idle position switch 1 system Probable cause

Range of Check D Malfunction of the idle position switch 1
D Accelerator pedal position sensor signal output is 1.2 V or higher. D Open or short circuit in idle position switch 1 circuit
D Idle position switch 2: OFF or poor connector contact
D Idle position switch 1 on signal is input for 1 second or more.
Range of Check
D Accelerator pedal position sensor signal output is 0.58 V or lower.
Set Conditions
D Idle position switch 1 off signal is input for 1 second or more.
NG
Check the idle position switch 1. (Refer to P.13E-58.) Replace the accelerator pedal position sensor.
OK
NG
Measure at the accelerator pedal position sensor connector B-41. Check the following connector:
connector. OK NG
OK: 4 V or higher Repair
OK: Continuity
OK
NG
B-41 Check the harness wire between the engine-ECU and the accelera-
tor pedal position sensor connector.
OK NG
OK NG
Repair
Repair
NG

Code No.24 Idle position switch 2 system Probable cause
Range of Check D Malfunction of the idle position switch 2
D Accelerator pedal position sensor signal output is 1.2 V or higher. D Open or short circuit in idle position switch 2 circuit
D Idle position switch 1: OFF or poor connector contact
D Idle position switch 2 on signal is input for 1 second or more.
Range of Check
D Accelerator pedal position sensor signal output is 0.48 V or lower.
Set Conditions
D Idle position switch 2 off signal is input for 1 second or more.
NG
Check the idle position switch 2. (Refer to P.13E-58.) Replace
OK
NG
Measure at the idle position switch 2 connector B-47 <L.H. drive Check the following connector:
vehicles>, B-48 <R.H. drive vehicles>. C-53
D Disconnect the connector and measure at the harness side OK NG
connector.
D Voltage between 1 and earth (Ignition switch: ON) Repair
OK: 4 V or higher
Check the following connector: NG
B-47
Check the harness wire between the engine-ECU and the idle
OK NG position switch 2 connector.
Repair OK NG
Repair
NG Replace the engine-ECU.
Code No.41 Throttle solenoid valve system Probable cause

Range of Check D Malfunction of the throttle solenoid valve
From the following condition, the ignition switch is turned to OFF. D Open or short circuit in throttle solenoid valve circuit
D 2.2 seconds or more have passed since idle position switch turned on and ignition or poor connector contact
switch-ST turned off D Incorrect vacuum hose routing
D Accelerator pedal opening amount: Approx. 0 % D Malfunction of the throttle actuator
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).
NG
Check the throttle solenoid valve. (Refer to P.13E-60.) Replace
OK
NG
Check the throttle actuator. (Refer to P.13E-61.) Replace
OK
NG
Measure at the throttle solenoid valve connector B-49. Check the harness wire between the control relay and the throttle
D Disconnect the connector and measure at the harness side solenoid valve connector, and repair if necessary.
connector.
OK: System voltage
OK
NG
D Disconnect the connector and measure at the harness side B-49
connector. OK NG
OK: System voltage Repair
OK
C-53 NG
OK NG Check the harness wire between the engine-ECU and the throttle
solenoid valve connector, and repair if necessary.
Repair
Check the vacuum hose routing.

NG
Check the vacuum hose routing.

OK NG
Repair

Code No.43 Timing control solenoid valve system Probable cause
Range of Check D Malfunction of the timing control solenoid valve
D Ignition switch-ST: OFF D Open or short circuit in timing control solenoid valve
D Engine speed: 400 r/min or more circuit or poor connector contact
D Engine coolant temperature: 60 _C or higher D Incorrect ignition timing adjustment
Set Conditions D Malfunction of the injection pomp
D Target advance value differs from actual advance value by 7_ or more for a D Malfunction of the engine-ECU
continuous period of 10 seconds or more.
NG
Check the timing control solenoid valve. (Refer to P.13E-59.) Replace the injection pump.
OK
NG
Measure at the timing control solenoid valve connector B-56 <L.H. Check the harness wire between the control relay and the timing
drive vehicles>, B-57 <R.H. drive vehicles>. control solenoid valve connector, and repair if necessary.
D Disconnect the connector and measure at the harness side
connector
OK: System voltage
OK
NG
connector. OK NG
OK
C-53 NG
OK NG Check the harness wire between the engine-ECU and the timing
control solenoid valve connector, and repair if necessary.
Repair

NG
NG
MUT-II Actuator test Replace the injection pump.
11 Timing control solenoid valve
OK: Sound of operation can be heard.
OK

Code No.44 Solenoid-type spill valve system Probable cause

Range of Check D Malfunction of the solenoid-type spill valve
D Ignition switch-ST: OFF D Open or short circuit in solenoid-type spill valve circuit
D Injection pump speed: 750 r/min or more or poor connector contact
D Solenoid-type spill valve relay: ON D Malfunction of the injection pump
D Solenoid-type spill valve does not turn off.
Range of Check, Set Conditions
D Injection pump speed is 5,400 r/min or more for a continuous period of 2 seconds
or more.
NG
Check the solenoid-type spill valve. (Refer to P.13E-59.) Replace the injection pump.
OK
NG
Measure at the solenoid-type spill valve connector B-61. Check the harness wire between the solenoid-type spill valve relay
D Disconnect the connector and measure at the harness side and the solenoid-type spill valve connector, and repair if necessary.
connector.
OK: System voltage
OK
NG
connector. OK NG
OK
C-53 NG
OK NG Check the harness wire between the engine-ECU and the solenoid-
type spill valve connector, and repair if necessary.
Repair

NG
NG
MUT-II Actuator test Replace the injection pump.
01 Solenoid-type spill valve
OK

Code No.45 Injection timing correction resistor system Probable cause
Range of Check, Set Conditions D Malfunction of the injection timing correction resistor
D Open or short circuit is detected in injection timing correction resistor circuit. D Open or short circuit in injection timing correction
resistor circuit of poor connector contact
NG
Check the injection timing correction resistor. (Refer to P.13E-60.) Replace the injection pump.
OK
NG
Measure at the injection timing correction resistor connector B-60. Check the following connector:
connector. OK NG
OK: Continuity
OK
NG
B-60 Check the harness wire between the engine-ECU and the injection
timing correction resistor connector.
OK NG
OK NG
Repair
Repair
NG
Code No.46 Injection rate correction resistor system Probable cause

Range of Check, Set Conditions D Malfunction of the injection rate correction resistor
D Open or short circuit is detected in injection rate correction resistor circuit. D Open or short circuit in injection rate correction resistor
circuit or poor connector contact
NG
Check the injection rate correction resistor. (Refer to P.13E-60.) Replace the injection pump.
OK
NG
Measure at the injection rate correction resistor connector B-58 Check the following connector:
<L.H. drive vehicles>, B-59 <R.H. drive vehicles>. C-54
D Disconnect the connector and measure at the harness side OK NG
connector.
D Voltage between 1 and earth (Ignition switch: ON) Repair
OK: 4.5 - 5.5 V
OK: Continuity Check trouble symptom.
OK
NG
B-58 <L.H. drive vehicles>, B-59 <R.H. drive vehicles> Check the harness wire between the engine-ECU and the injection
rate correction resistor connector.
OK NG
OK NG
Repair
Repair
NG


D Communication problem between the engine-ECU and the immobilizer-ECU. D Malfunction of the immobilizer-ECU
NOTE D Malfunction of the engine-ECU
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.
Yes
No
NG
Yes
Is a diagnosis code output from the immobilizer-ECU. Check the immobilizer system. (Refer to GROUP 54 - Ignition
No Switch and Immobilizer System.)
NG
C-54, C-81, C-66
OK

NG
OK
er-ECU. NG
NG
Repair NG

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 Reference
procedure No. page
Communication MUT-II communication with all systems is impossible. 1 13E-24

with MUT-II
II is
impossible. MUT-II communication with engine-ECU only is impossible. 2 13E-24
Engine warning The engine warning lamp does not illuminate right after the 3 13E-25
lamp and related ignition switch is turned to the ON position.
parts
The engine warning lamp remains illuminating and never 4 13E-25
goes out.
Starting No initial combustion (Starting not possible) 5 13E-26
Poor startability when engine is cold (Poor starting) 6 13E-26
Poor startability when engine is cold or warm (Poor 7 13E-27

starting)
Idling stability Idling speed is low when engine is cold (Improper idling 8 13E-27
(Improper idling) speed)
Idling speed is high (Improper idling speed) 9 13E-28
Idling speed is low (Improper idling speed) 10 13E-28
Idling speed is unstable (Rough idling, hunting) 11 13E-29
Idling stability Engine stops soon after starting 12 13E-29

(Engine stalls)
Engine stops during idling 13 13E-30
Driving Engine output is too low 14 13E-30
Abnormal engine knocking occurs 15 13E-31
Abnormally black smoke 16 13E-31
Abnormally white smoke 17 13E-32
Hunting occurs while driving 18 13E-32
Idling speed is improper when A/C is operating 19 13E-33
Fans (radiator fan and A/C condenser fan) are imoperative 20 13E-33

Communication with MUT-II is impossible. (MUT-II Probable cause
communication with all systems is impossible.)
NG NG
Measure at the diagnosis connector Check the following connectors: Repair
C-20. C-66, C-63, (C-132, C-141) <L.H. drive
D Voltage between 16 and earth vehicles>, (C-62, C-14) <R.H. drive ve-
OK: System voltage hicles>
OK OK
NG
power supply and the diagnosis connec-
tor, and repair if necessary.
NG
Measure at the diagnosis connector Check the harness wire between the
C-20. diagnosis connector and the earth, and
D Continuity between 4 and earth repair if necessary.
OK: Continuity
OK
Replace the MUT-II.
MUT-II communication with engine-ECU only is impossi- Probable cause
ble.
One of the following causes may be suspected. D Malfunction of the engine-ECU power supply circuit
D No power supply to engine-ECU D Malfunction of the engine-ECU
D Defective earth circuit of engine-ECU D Malfunction of the immobilizer-ECU
D Defective engine-ECU D Open circuit between immobilizer-ECU and diagnosis
ECU
No
Is communication possible between the MUT-II and the immo- Check the diagnosis line between the immobilizer-ECU and the
bilizer-ECU. MUT-II, and repair if necessary. (Refer to GROUP 54 - Ignition
Yes Switch and Immobilizer System.)
NG
C-54, C-81, C-68, C-66, C-56 <R.H. drive vehicles>, C-83, C-20
OK

NG
NG
Check the harness wire between the engine-ECU and the diagnosis Repair
connector.
OK
OK
Check the harness wire between the engine-ECU and the immobiliz- Check the harness wire between the engine-ECU and the earth
er-ECU. OK NG
NG
Repair
Repair
Check the engine-ECU power supply and earth circuit. (Refer to
P.13E-34, INSPECTION PROCEDURE 21.)
Because there is a burn-out bulb, the engine-ECU causes the engine warning lamp D Burn-out bulb
NG
MUT-II Data list Check the engine-ECU power supply and earth circuit. (Refer to
11 Battery voltage (Refer to 13E-39.) P.13E-34, INSPECTION PROCEDURE 21.)
OK
OK
connector. OK NG
D Earth the terminal No.57.
OK: The engine warning lamp illuminates. Repair
NG
Check a burn-out bulb.
NG
OK NG
Replace
NG
Measure at the combination meter connector D-03. Check the following connectors:
D Disconnect the connector and measure at the harness side C-135, C-131
connector. OK NG
OK
D-03, C-90 NG
OK NG Check the harness wire between the engine warning lamp and
the ignition switch connector, and repair if necessary.
Repair
NG
Check trouble symptom. Check the harness wire between the combination meter and the
engine-ECU connector, and repair if necessary.
goes out.
In case such as the above, the cause is probably that the engine-ECU is detecting D Short-circuit between the engine warning lamp and
a problem in a sensor or actuator, or that one of the malfunctions listed at right has the engine-ECU
Yes
MUT-II Self-Diagnosis code Refer to P.13E-8, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes output? CODES.
No
NG
Measure at the combination meter connector D-03. Check the harness wire between the combination meter and the
D Disconnect the connector and measure at the harness side engine-ECU connector, and repair if necessary.
connector.
OK: No continuity
OK

No initial combustion (Starting not possible) Probable cause
The cause is probably a malfunction of the control system, injection nozzles, injection D Malfunction of the control system
pump, glow system or power supply. D Malfunction of the injection nozzles
D Malfunction of the injection pump
D Malfunction of the glow system
Yes
Is immobilizer-ECU diagnosis code output? Check the immobilizer system. (Refer to GROUP 54 - Ignition
No
No
MUT-II Self-Diagnosis code Carry out MUT-II Data list check and Actuator test.
Are diagnosis codes output? (Refer to P.13E-38, 42.)
Yes OK NG
Refer to P.13E-8, INSPECTION CHART FOR DIAGNOSIS Repair

CODES.
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, D Malfunction of the control system
air intake system or glow system. D Malfunction of the injection pump
D Malfunction of the fuel system
D Malfunction of the air intake system
No
Yes OK NG

CODES.
D Injection nozzle, fuel filter
D Throttle body assembly
D Starter switch input signal
D Engine oil viscosity
D Injection pump
Poor startability when engine is cold or warm Probable cause
(Poor starting)
The cause is probably a malfunction of the control system, injection pump, fuel system D Malfunction of the control system
or air intake system. D Malfunction of the injection pump
No
Yes OK NG

CODES.
D Injection pump
INSPECTION PROCEDURES 8
Idling speed is low when engine is cold Probable cause
(Improper idling speed)
The cause is probably a malfunction of the control system, injection pump or fuel D Malfunction of the control system
system. D Malfunction of the injection pump
No
Yes OK NG

CODES.
D Injection nozzle
D Injection pump
D Fuel filter
Idling speed is high (Improper idling speed) Probable cause
The cause is probably a malfunction of the control system, injection nozzles or injection D Malfunction of the control system
pump. D Malfunction of the injection nozzles
D Malfunction of the injection pump
No
Yes OK NG

CODES.
D Injection nozzle
D Injection pump
D Starter switch input signal
Idling speed is low (Improper idling speed) Probable cause
No
Yes OK NG

CODES.
D Injection pump
D Injection nozzle
Idling speed is unstable (Rough idling, hunting) Probable cause
air intake system or glow system. D Malfunction of the injection pump
D malfunction of the glow system
D Malfunction of the EGR system
No
Yes OK NG

CODES.
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 Malfunction of the injection pump
No
Yes OK NG

CODES.
D Injection pump
Engine stops during idling Probable cause
The cause is probably a malfunction of the control system, injection pump, air intake D Malfunction of the control system
system or power supply system. D Malfunction of the injection pump
No
Yes OK NG

CODES.
D Power supply system
D EGR system
D Injection pump
Engine output is too low Probable cause
air intake system or EGR system. D Malfunction of the injection pump
No
Yes OK NG

CODES.
D EGR system
D Turbocharger
D Injection timing
D Injection pump
Abnormal engine knocking occurs Probable cause
No
Are diagnosis codes output? (Refer to P.13E-38, 42)
Yes OK NG

CODES.
D Injection nozzle
D Injection timing
D Injection pump
Abnormally black smoke Probable cause
air intake system or EGR system. D Malfunction of the injection pump
No
Yes OK NG

CODES.
D Air cleaner
D Injection nozzle
D EGR system
D Turbocharger
D Injection pump
D Injection timing
Abnormally white smoke Probable cause
air intake system, EGR system or glow system. D Malfunction of the injection pump
No
Yes OK NG

CODES.
D Injection nozzle
D EGR system
D Turbocharger
D Injection pump
D Injection timing
Hunting occurs while driving Probable cause
or EGR system. D Malfunction of the injection pump
No
Yes OK NG

CODES.
D EGR system
D Injection pump
Idling speed is improper when A/C is operating
OK
D Voltage between 39 and earth (Engine: Idling, Outside air OK NG
temperature: 25 _C or higher)
OK: 0 - 3 V [When A/C is MAX. COOL condition (when the Repair
load by A/C is high)]
System voltage [(When A/C is MAX. HOT condition (When
the load by A/C is low)] Check trouble symptom.
NG NG
Fans (radiator fan and A/C condenser fan) are imoperative
NG
Measure at the engine-ECU connector C-53. Check the harness wire between the engine-ECU and the fan con-
D Disconnect the connector and measure at the harness side troller connector.
connector. OK NG
OK: 4.8 - 5.2 V (Fan rotates at high speed.) Repair
D Short circuit between 18 and earth (Ignition switch: ON)
OK: Fan stops.
Check the radiator fan and the condenser fan circuit. (Refer to
OK
GROUP 14 - Troubleshooting.)
C-53
OK NG
Repair
Check trouble symptoms.

NG

Check the engine-ECU power supply and earth circuit
NG
Check the control relay. (Refer to P.13E-56.) Replace
OK
NG
Measure at the control relay connector C-31. Check the following connector:
connector. OK NG
1. Voltage between 2, 3 and earth
OK
NG
Check the harness wire between the battery and control relay con-
nector, and repair if necessary.
1.NG
Measure at the engine-ECU connector C-53, C-55. Check the following connector:
D Disconnect the connector and measure at the harness side C-92, C-131
connector. OK NG
2,3 NG
OK: System voltage 4.NG
3. Voltage between 72 and earth Check trouble symptoms.
OK: System voltage (When the terminal 59 is earthed) NG
4. Continuity between 1, 14, 26 and earth
OK: Continuity 5.NG Check the harness wire between the engine-ECU and ignition switch
5. Voltage between 61 and earth connector.
OK: System voltage
OK NG
OK
Repair
C-53, C-55
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.)
OK NG
Repair
Check the harness wire between the engine-ECU and control relay
NG
Check the harness wire between the engine-ECU and earth, and
Replace the engine-ECU. repair if necessary.

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 con-
nector, and repair if necessary.
Check the solenoid-type spill valve relay circuit.
NG
Check the solenoid-type spill valve relay. (Refer to P.13E-56.) Replace
OK
NG
Measure at solenoid-type spill valve relay connector C-52. Check the harness wire between the control relay and solenoid-type
D Disconnect the connector and measure at the harness side spill valve relay connectors, and repair if necessary.
connector.
D Voltage between 2, 3 and earth (Ignition switch: ON)
OK: System voltage
OK
NG
connector. OK NG
OK: System voltage (When the terminal 3 is earthed) Repair
OK
C-55 NG
OK NG Check the harness wire between the solenoid-type spill valve relay
and engine-ECU connectors, and repair if necessary.
Repair

NG

Check the fuel cut solenoid valve circuit.
NG
Check the fuel cut solenoid valve. (Refer to P.13E-60.) Replace
OK
NG
Measure at the fuel cut solenoid valve connector B-55. Check the following connector:
connector. OK NG
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. Replace
OK
NG
Measure at the EGR solenoid valve connector B-06. Check the harness wire between the control relay and EGR solenoid
D Disconnect the connector and measure at the harness side valve connector, and repair if necessary.
connector.
OK: System voltage
OK
NG
connector. OK NG
OK
C-53 NG
OK NG Check the harness wire between the engine-ECU and EGR solenoid
valve connector, and repair if necessary.
Repair
NG
Check trouble symptoms. Replace the engine-ECU.
Check the glow plug relay circuit
NG
Check the glow plug relay. (Refer to GROUP 16 - Glow System.) Replace
OK
NG
Measure at the glow plug relay connector B-52. Check the following connector:
connector. OK NG
D Voltage between 1 and earth (Ignition switch: ON)(Engine
coolant temperature: 40 _C or lower) Repair
OK: System voltage (Between approx. 4 - 8 seconds)
OK Check trouble symptoms.
Check the following connector, and repair if necessary. NG
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
OK
NG
Check the A/C variable capacity relay. Replace
OK
NG
Measure at the engine-ECU connector C-55. Check the A/C system. (Refer to GROUP 55 - Troubleshooting.)
D Disconnect the connector and measure at the harness side
connector.
D Voltage between 52 and earth, and between 53 and earth
OK: 0 - 3 V (A/C switch: OFF) OK
System voltage (A/C switch: ON) Check the following connector:
D Short circuit between 53 and earth C-55
(Ignition switch: ON, A/C switch: ON)
OK: A/C compressor clutch turns on. OK NG
Repair

NG

Caution
Driving tests always need another personnel.
Item No. Inspection Inspection contents Normal Inspection Reference
item condition procedure page
No.
01 Intake air Ignition switch: ON Intake air temperature is - 20 _C Code 13E-12

temperature or with engine - 20 _C No.16
sensor running
Intake air temperature is 0 _C
0 _C

20 _C

40 _C

80 _C
02 Engine cool- Ignition switch: ON Engine coolant - 20 _C Code 13E-12

ant tempera- or with engine temperature is - 20 _C No.15
ture sensor running
Engine coolant 0 _C
temperature is 0 _C
Engine coolant 20 _C
temperature is 20 _C
03 Barometric Ignition switch: ON At altitude of 0 m 101 kPa Code 13E-11

pressure No.13
04 Boost sen- D Engine coolant At altitude of 0 m 101 kPa Code 13E-10

sor temperature: 80 No.12
- 95 _C At altitude of 600 m 95 kPa
D Lamps, electric
cooling fan and At altitude of 1,200 m 88 kPa
all accessories:
OFF
D Transmission: At altitude of 1,800 m 81 kPa
Neutral
D Ignition switch: When the engine is Increases
ON suddenly raced

No.
05 Diesel fuel Ignition switch: ON Fuel temperature is - 20 _C Code 13E-11

temperature or with engine - 20 _C No.14
sensor running
Fuel temperature is 0 _C 0 _C
Fuel temperature is 20 _C
20 _C
40 _C
80 _C
06 Vehicle When vehicle is Compare the speeds Identical Code 13E-13

speed sen- moving displayed on the No.17
sor speedometer and the
MUT-II.
07 Pump op- Engine: Idling Compare the engine The same Code 13E-14
eration sen- speeds displayed on the engine No.18, 19
sor (high tachometer and MUT-II. speed is
speed) displayed.
08 Pump op- Engine: Idling Compare the engine The same Code 13E-14
eration sen- speeds displayed on the engine No.18, 19
sor (low tachometer and the speed is
speed) MUT-II. displayed.
09 Accelerator Ignition switch: ON Accelerator pedal is 480 - 570 Code 13E-9

pedal posi- released mV No.11
tion sensor
Accelerator pedal is fully 4000 -
depressed 4690 mV
10 Accelerator Ignition switch: ON Throttle lever: Idle 0% Code 13E-9

pedal posi- position No.11
tion sensor
(Accelerator
Throttle lever: Fully open 100 %
opening position
angle)
11 Battery Ignition switch: ON System - -

voltage voltage
12 Solenoid- Engine: After Engine: Idling 51.5 - Code 13E-20

type spill having warmed up 66.5 deg No.44
valve
A/C switch OFF ® ON Advances
slightly
13 Timing con- Engine: After When engine is Momen- Code 13E-19

trol solenoid having warmed up suddenly decelerated tarily in- No.43
valve duty from 3,000 r/min. creases
ratio slightly

No.
14 EGR com- Engine: Idle 44.8 % Procedure 13E-36

mand value No.24
Engine: After When engine is 0%
having warmed up suddenly raced
15 Injection rate Ignition switch: ON 0.2 - 4.5 Code 13E-21

correction V No.46
resistance
value
16 Injection Ignition switch: ON 0.2 - 4.5 Code 13E-21

timing V No.45
correction
resistance
value
17 Fuel injec- Engine: After Engine: Idling 3.5 - 12.5 - -

tion rate having warmed up m3/st
command
value A/C switch: OFF ® ON Increases
slightly
18 Actual injec- Engine: After having warmed up The same Code 13E-19
tion timing value as No.43
the injec-
tion timing
command
value is
displayed.
19 Injection Engine: After Engine: Idling 12.6 - - -

timing com- having warmed up 14.6 deg
mand value
Engine: Racing to 3500 Advances
r/min or more slightly
20 Radiator fan, Engine: Idling When radiator fan and 0% Procedure 13E-20
A/C con- condenser fan are not No.26
denser fan operating
duty ratio
When radiator fan and 5 % or
condenser fan are more
operating (varies in
accor-
dance
with fan
operating
speed)

No.
41 Idle position Ignition switch: ON Accelerator pedal is ON Code 13E-16

switch 1 released No.23
(Built into
accelerator
Accelerator pedal is OFF
pedal posi- slightly depressed
tion sensor)
42 Idle position Ignition switch: ON Accelerator pedal is ON Code 13E-17

switch 2 released No.24
Accelerator pedal is OFF

slightly depressed
43 A/C switch Engine: Idling A/C switch: ON ON Procedure 13E-37

(When the A/C No.26
switch is on, the
A/C compressor A/C switch: OFF OFF
should be driven.)
44 Ignition Ignition switch: ON Engine: Stopped OFF Code 13E-16
switch: ST No.22
Engine: Cranking ON
45 Ignition Ignition switch: ON ON - -

switch-IG
46 Control relay Ignition switch: ON ON Procedure 13E-34

No.21
47 A/C relay Engine: Idling after A/C switch: ON ON Procedure 13E-37

having warmed up No.26
A/C switch: OFF OFF
49 Solenoid- Ignition switch: ON ON Code 13E-20

type spill No.44
valve relay
52 Glow plug MUT-II Actuator test: Glow plug relay (item ON (for Procedure 13E-37
relay No.2) is driven approx. 6 No.25
seconds)
53 Throttle Engine: After Engine: Idling ON Code 13E-18

solenoid having warmed up No.41
valve Gently racing OFF
55 Engine MUT-II Actuator test: Engine warning lamp ON (For - -

warning (item No.16) is driven approx. 6
lamp seconds)
56 Glow indica- MUT-II Actuator test: Glow indicator lamp (item ON (for - -
tor lamp No.15) is driven approx. 6
seconds)
Item No. Inspection Drive contents Inspection Normal Inspection Reference

item contents condition procedure No. page
01 Solenoid-type Turns relay Ignition Operation - -

spill valve from OFF to switch: ON sound can be
relay ON and from heard.
ON to OFF
02 Glow plug Turns relay Ignition Battery volt- Procedure 13E-37

relay from OFF to switch: ON age is applied No.25
ON and from to glow plug
ON to OFF. when glow
plug relay is
ON.
03 A/C compres- Turns relay D Ignition A/C compres- Procedure 13E-37

sor relay from OFF to switch: ON sor clutch No.26
ON and from D A/C operation
ON to OFF. switch: ON sound can be
heard.
08 Throttle sole- Turns throttle Engine: 1500 Throttle valve Code No.41 13E-18
noid valve solenoid valve r/min opens half
ON. way.
09 Turns throttle Engine: Idling Throttle valve Code No.41 13E-18

solenoid valve opens fully.
OFF.
11 Timing control Drives timing Ignition Operation Code No.43 13E-19

solenoid valve control sole- switch: ON sound can be
noid valve at heard.
94 % duty.
13 Solenoid-type Turns sole- Ignition Operation Code No.44 13E-20

spill valve noid-type spill switch: ON sound can be
valve from heard.
OFF to ON
and from ON
to OFF.
14 EGR solenoid Turns EGR Engine: Idling EGR valve Procedure 13E-36
valve solenoid valve closes. No.24
OFF.
15 Glow indicator Turns glow Ignition Glow indicator - -

lamp indicator lamp switch: ON lamp illumi-
ON and OFF. nates and
switches OFF.
16 Engine warn- Turns engine Ignition Engine warn- - -

ing lamp warning lamp switch: ON ing lamp
ON and OFF. illuminates
and switches
OFF.
Item No. Inspection Drive contents Inspection Normal Inspection Reference

item contents condition procedure No. page
17 Radiator fan, Drives radiator Ignition Fans stop. Procedure 13E-33

A/C condens- fan and A/C switch: ON No.20
er fan condenser fan
at 0 % duty
18 Drives radiator Ignition Fans operate

fan and A/C switch: ON at medium
condenser fan speed.
at 50 % duty
19 Drives radiator Ignition Fans operate

fan and A/C switch: ON at high speed.
condenser fan
at 100 % duty

13300450025

NOTE
(1) Make the voltage measurement with the engine-ECU
(2) You may find it convenient to pull out the engine-ECU
(3) The checks can be carried out off the order given
in the chart.
Caution
2 Timing control Ignition switch: ON 11 - 13 V

solenoid valve
Engine: Idling 3.5 - 7.5 V
Engine: 2,500 r/min 5 - 9V
3 Solenoid-type spill Ignition switch: ON 11 - 13 V

valve
When engine is suddenly decelerated from 3000 0 « 12.5 V
r/min (varies repeatedly)
and momentarily
increases
4 Throttle solenoid Ignition switch: ON 0 - 3V

valve
Engine: Idling Engine coolant tempera- 12 - 15 V
ture is 40 _C or lower
Engine coolant tempera- 0 - 3V

ture is 80 _C or higher
9 Crank angle sensor Engine: Cranking 0.4 - 4.0 V
Between Pump operation Engine: Idling 0.2 - 1.0 V

terminals 10 sensor (AC range)
and 23
Engine: 2,500 r/min 1.2 - 2.2 V
(AC range)
16 EGR solenoid valve Ignition switch: OFF ® ON 11 - 13 V
When idling after having warmed up, engine is Momentarily in-

suddenly raced. creases
18 Fan controller When radiator fan and A/C condenser fan are not 0 - 0.3 V
operating
When radiator fan and A/C condenser fan are 0.7 V or more
operating
19 Idle position switch 2 Ignition switch: ON Accelerator pedal is 0 - 1V

released
Accelerator pedal is 4 V or higher

slightly depressed
21 Vehicle speed D Ignition switch: ON 0«5V

sensor D Vehicle is moving forward slowly (Varies repeatedly)
25 Ignition switch-IG Ignition switch: ON 11 - 13 V
31 A/C switch 2 D Engine: Idling When A/C is MAX. COOL 0 - 3V

D Outside air tem- condition (When the load
perature: 25 _C by A/C is high)
or more
When A/C is MAX. HOT System voltage
condition (When the load
by A/C is low)
33 Fuel injection rate Ignition switch: ON 0.2 - 4.5 V

correction resistor
34 Diesel fuel tempera- Ignition switch: ON (when cranking at cold engine) 0.5 - 3.4 V
ture sensor
35 Engine coolant Ignition switch: ON Engine coolant tempera- 3.2 - 3.8 V

temperature sensor ture is 0 _C
Engine coolant tempera- 2.3 - 2.9 V

ture is 20 _C

ture is 40 _C

ture is 80 _C
36 Intake air tempera- Ignition switch: ON Intake air temperature is 0 3.2 - 3.8 V
ture sensor _C
Intake air temperature is 2.3 - 2.9 V

20 _C

40 _C

80 _C
37 Boost sensor Ignition switch: ON Altitude is 0 m 2.0 - 2.6 V
Altitude is 1,200 m 1.7 - 2.3 V
38 Sensor applied Ignition switch: ON 4.5 - 5.5 V

voltage
41 Fuel injection timing Ignition switch: ON 0.2 - 4.5 V

correction resistor
43 Idle position switch 1 Ignition switch: ON Accelerator pedal is 0 - 1V

released
Accelerator pedal is 4 V or higher

depressed
44 Accelerator pedal Ignition switch: ON Accelerator pedal is 0.3 - 0.8 V

position sensor released
Accelerator pedal is fully 4.2 - 4.5 V

depressed
51 Ignition switch-ST Engine: Cranking 8 V or higher
52 A/C switch 1 Engine: Idling A/C switch is off 0 - 3V
A/C switch is on (A/C 13 - 15 V

compressor is operating)
53 A/C relay D Engine: Idling 13 - 15 V or momen-

D A/C switch: OFF ® ON tarily 6 V or more ®
(A/C compressor is operating) 0 - 3V
55 Glow indicator lamp D Ignition switch: OFF ® ON 0 - 1 V; after approx.

D Engine coolant temperature is 40 _C or less 1 second ® 11 - 13
V (at engine coolant
temperature of 20 _C)
57 Engine warning lamp Ignition switch: OFF ® ON 0 - 3 V ® (after

several seconds)
9 - 13 V
59 Control relay Ignition switch: OFF 11 - 13 V
60 Glow plug relay D Ignition switch: OFF ® ON 9 - 12 V; after

(pre-heat time D Engine coolant temperature is 40 _C or less approx. 8 seconds ®
control) (Pre-glow function check) 0 - 0.5 V (at engine
coolant temperature
of 20 _C)
61 Backup power Ignition switch: OFF 11 - 13 V

supply
66 A/C variable D Engine: Idling Engine coolant tempera- 0 - 3V

capacity relay D A/C switch: ON ture is 5 _C or less
Engine coolant tempera- 13 - 15 V

ture is 5 _C or more
71 Solenoid-type spill Ignition switch: ON ® OFF 0.39 V ® (after

valve approx. 3 seconds)
0V
72 Power supply Ignition switch: ON 11 - 13 V

BETWEEN TERMINALS
NOTE
(1) When measuring resistance and checking continuity,
(2) Checking need not be carried out in the order given
in the chart.
Caution
the problem.
Terminal No. Check item Normal condition (Check condition)
2 - 72 Timing control valve 8 - 12 W (At 20 _C)
4 - 72 Throttle solenoid valve 36 - 44 W (At 20 _C)
10 - 23 Pump operation sensor 215 - 245 W (At 20 _C)
16 - 72 EGR solenoid valve 11 - 14 W (At 20 _C)
19 - Body earth Idle position switch 2 Continuity (When accelerator lever is at idle position)
No continuity (When accelerator lever is at slightly open)

Terminal No. Check item Normal condition (Check condition)
26 - Body earth Engine-ECU earth Continuity (0 W)
33 - 46 Injection rate correction resistor 0.1 - 2.5 kW (At 20 _C)
34 - 46 Diesel fuel temperature sensor 2.2 - 2.7 kW
35 - 46 Engine coolant temperature 5.1 - 6.5 kW (When engine coolant temperature is 0 _C)
sensor
2.1 - 2.7 kW (When engine coolant temperature is 20 _C)
36 - 46 Intake air temperature sensor 5.3 - 6.7 kW (When intake air temperature is 0 _C)
2.3 - 3.0 kW (When intake air temperature is 20 _C)
41 - 46 Injection timing correction 0.1 - 2.5 kW (At 20 _C)

resistor
43 - 46 Idle position switch 1 Continuity (When accelerator lever is at idle position)
No continuity (When accelerator lever is at slightly open)
Analyzer INSPECTION PROCEDURE USING AN

ANALYZER 13300460028
CRANK ANGLE SENSOR

Measurement Method
1. Disconnect the crank angle sensor connector and connect
Special angle sensor connector terminal (2) (black clip of special
patterns
pickup
tool).
Connect the analyzer special patterns pickup to engine-ECU
terminal 9.
Standard Wave pattern
Pattern height Low
(1 camshaft revolution)
(V) 15 _BTDC The time (cycle time) T is
reduced when the engine
75 _ATDC speed increase
Time
0
No.1 TDC No.3 TDC No.4 TDC No.2 TDC


D Example 1
Cause of problem
is not started.
D Example 2
Cause of problem
Loose timing belt
Analyzer 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
Special operation sensor connector terminal (1).
patterns
pickup Alternate Method (Test harness not available)
terminal 10.
Pattern height Low

(1 camshaft revolution)
The time (cycle time) T is
(V) reduced when the engine
speed increases Time
Time
0


D Example
Cause of problem
Loose timing belt
Incorrect installation of injection pump or pump operation
sensor
Analyzer 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.)
Special
patterns 2. Connect the analyzer special patterns pickup to
pickup solenoid-type spill valve connector terminal (2).

terminal 3.

(V) T Point B
Point A
10
Solenoid back
electromotive
force
Time
0

appear at all.
Point B: Solenoid-type spill valve drive cycle

DIESEL FUEL - On-vehicle Service 13E-53
EVACUATION OF WATER FROM FUEL FILTER

Water is in the filter when fuel filter warning lamp lights.
Evacuate water by the following procedures.
1. Loosen the water level sensor.
2. Operate the hand pump to drain the water, and then
Water level sensor tighten the water level sensor to the specified torque.
EVACUATION OF AIR FROM FUEL LINE

13300130059
Hand pump 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
Air plug
repeatedly until no bubbles come from plug hole. Tighten
air plug.
3. Repeat until hand pump operation becomes stiff.
FUEL FILTER CARTRIDGE REPLACEMENT
13300320036
Refer to GROUP 13F.

AND IDLE POSITION SWITCH 1 ADJUSTMENT
13300600017

2. Turn the ignition switch to ON. (but do not start the engine.)
Accelerator pedal voltage.
position sensor (with
built-in idle position Standard value: 530 - 570 mV
switch 1)
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 DIESEL FUEL - On-vehicle Service

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. Loosen the tension of the accelerator cable sufficiently.
3. Turn the ignition switch to ON. (but do not start the engine.)
voltage when the accelerator pedal is fully depressed.
Standard value: 4,000 - 4,690 mV
5. If the output voltage is outside the standard value range,
loosen the accelerator pedal position sensor mounting
bolt and turn the accelerator pedal position sensor body
to adjust.
Standard value: 4,350 mV
6. Tighten securely the accelerator pedal position sensor
mounting bolt.
7. Back out the idle position switch 2 lock nut.
8. Adjust the idle position switch 2 so that the accelerator
pedal position sensor output voltage is within the standard
value range when the accelerator pedal is released.
Standard value: 530 - 570 mV
9. While holding the idle position switch 2 so that it doesn’t
move, tighten the lock nut securely.

A/C relay G Engine coolant temperature sensor I
A/C switch N Engine-ECU M
Accelerator pedal position sensor C Engine warning lamp (check engine lamp) J
(with built-in idle position switch 1)
Boost sensor D Glow indicator lamp J
Control relay L Glow plug relay F
Crank angle sensor A Idle position switch 2 C
Diagnosis connector K Intake air temperature sensor B
Diesel fuel temperature sensor H Pump operation sensor H
EGR solenoid valve D Throttle solenoid valve D
Solenoid-type spill valve H Timing control solenoid valve H
Solenoid-type spill valve relay L Vehicle speed sensor E
A B C D E F G J K L M N
H I
Equipment side connector CONTROL RELAY AND SOLENOID-TYPE

SPILL VALVE RELAY CONTINUITY CHECK
13300620013
Control
relay and
solenoid- 1 2 3 4
type spill
valve Not supplied
relay
Supplied
INTAKE AIR TEMPERATURE SENSOR CHECK

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.
4. Measure resistance while heating the sensor using a hair

Intake air drier.
temperature
sensor Normal condition:
Higher Smaller

resistance remains unchanged, replace the intake air
temperature sensor.
6. Install the intake air temperature sensor and tighten it
CHECK 13300500027
Engine coolant
temperature sensor 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
Equipment side connector ACCELERATOR PEDAL POSITION SENSOR

Accelerator pedal CHECK 13300630016
position sensor
1. Disconnect the accelerator pedal position sensor
connector.
4.
4.
Normal condition:
Depress the accelerator ped- Changes smoothly in propor-

al slowly until fully depressed tion to the opening angle of
position from the idle posi- the throttle valve.
tion.

doesn’t 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 IDLE POSITION SWITCH 1 CHECK 13300640019
Accelerator pedal 1. Disconnect the accelerator pedal position sensor

position sensor connector.
2. Check the continuity between the accelerator pedal
position sensor connector side terminal 3 and terminal
4.
Normal condition:
3. If out of specification, replace the idle position switch

1.
NOTE
After replacement, the accelerator pedal position sensor
should be adjusted. (Refer to P.13E-53.)
IDLE POSITION SWITCH 2 CHECK 13300650012
1. Disconnect the idle position switch 2 connector.

Idle position switch 2 2. Check the continuity between the idle position switch
2 terminal and body earth.
Normal condition:
3. If out of specification, replace the idle position switch

2.
NOTE
After replacement, the accelerator pedal position sensor
Idle position switch 2 should be adjusted. (Refer to P.13E-53.)
SOLENOID-TYPE SPILL VALVE CHECK 13300660015
Solenoid-type spill valve 1. Disconnect the solenoid-type spill valve connector.
2. Measure the resistance between terminals 1 and 2.
3. Check that the sound of the solenoid valve operating

can be heard when battery voltage is applied momentarily
(for 2 - 3 seconds) between the solenoid-type spill valve
terminals.
Caution
Because the solenoid-type spill valve is
current-controlled, it should not be left for a long time
with the voltage applied.
TIMING CONTROL SOLENOID VALVE CHECK

13300560025
1. Disconnect the timing control solenoid valve connector.

Timing
control Standard value: 8 - 12 W (at 20_C)
sole-
noid
valve
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

Diesel fuel temperature sensor CHECK 13300680011
1. Disconnect the diesel fuel temperature sensor connector.

Standard value: 2.2 - 2.7 kW (at 20_C)
PUMP OPERATION SENSOR CHECK 13300690014

1. Disconnect the pump operation sensor connector.
INJECTION TIMING CORRECTION RESISTOR

Injection timing CHECK 13300700014
correction resistor
1. Disconnect the injection timing correction resistor
connector.
Injection rate INJECTION RATE CORRECTION RESISTOR

correction CHECK 13300710017
resistor
1. Disconnect the injection rate correction resistor connector.
FUEL CUT SOLENOID VALVE CHECK 13300720010
Fuel cut
1. When a sound scope is held against the fuel cut solenoid
solenoid valve and the ignition switch is turned to ON, check that
valve 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
Throttle solenoid valve NOTE

1. Disconnect the vacuum hose (green stripe, yellow stripe)
B 3. Connect a hand vacuum pump to nipple B of the solenoid
valve.
A 4. Use jumper wires to connect the terminals of the solenoid
valve and the battery.
5. Check the air-tightness when negative pressure is applied
while the jumper wire is connected to the battery ( - )
terminal and while it is disconnected.
Normal condition:
Battery Jumper wire Nipple A condition Normal condition
Connected Open Negative pressure

leaks
Closed Negative pressure

is maintained
Disconnected Open Negative pressure

leaks

solenoid valve.
THROTTLE ACTUATOR CHECK 13300740016

Throttle actuator
1. Remove the vacuum hose (red stripe) from the throttle
actuator and connect a hand vacuum pump to the throttle
actuator nipple.
2. Check that the actuator rod moves smoothly when
applying vacuum gradually.
Also, check that the vacuum is maintained when applying
53 kPa of vacuum.
INJECTION NOZZLE CHECK AND

Caution
Never touch the injection spray that is injected from the
nozzle.
FUEL INJECTION INITIAL PRESSURE CHECK
1. Install the injection nozzle to a nozzle tester.
2. Move the lever of the nozzle tester 2 - 3 times to inject
fuel and to bleed the air.
3. Gently press down the lever of the nozzle tester, and
take a reading of the indication value on the pressure
gauge at the point where the needle slowly rises and
then suddenly drops.
Standard value: 14,710 - 15,690 kPa
4. If the fuel injection initial pressure is outside the standard

value, disassemble the nozzle holder to clean it, and
then change the thickness of the shim to adjust the fuel
injection initial pressure.
NOTE
(1) For disassembly, reassembly and adjustment of the
nozzle holder, refer to P.13E-66.
(2) There are 10 shims for adjustment, with thicknesses
in the range of 0.10 - 0.80 mm.
(3) When the shim thickness is increased by 0.1 mm,
the fuel injection initial pressure increases by 2,350
kPa.
INJECTION SPRAY CONDITION CHECK 13300180023

A B C
1. Move the lever of the nozzle tester rapidly (4 - 6 times
per second) to eject the fuel continuously. Check to be
sure that the injection spray comes out evenly in a cone
shape (injection spray angle is 10_). The injection spray
patterns shown in the illustration at left are wrong.
A. Injection angle is too large
B. Bias
C. Intermittent fuel injection
2. Check to be sure that no fuel drips after injection is

completed.
3. If there are any drips, disassemble the nozzle, clean it
and re-inspect, or replace the nozzle.
NOZZLE FUEL-TIGHT CHECK 13300190026
1. Gently raise the lever of the nozzle tester until the pressure
inside the nozzle (value displayed on pressure gauge)
becomes 12,750 - 13,730 kPa, and after holding this
pressure for approximately 10 seconds, check to be sure
that there are no fuel leaks from the nozzle.
2. If there are any leaks, disassemble the nozzle, clean
it and re-inspect, or replace the nozzle.
DIESEL FUEL - Injection Pump and Nozzle 13E-63
INJECTION PUMP AND NOZZLE 13300210036

D Glow Plug Removal and Installation D Timing Belt Removal and Installation
(Refer to GROUP 16.) (Refer to GROUP 11C.)
29 Nm
9 Nm 9 Nm
5
49 - 59 Nm 29 Nm 12
15
2 29 Nm
17 14 3
16
78 - 88 Nm
13
1
7
8
6 4
9 Nm
9
24 Nm
19 Nm
10
11
12 - 15 Nm
19 Nm 35 Nm
Fuel injection pump removal steps Fuel injection nozzle removal steps
1. Fuel return hose connection 1. Fuel return hose connection
2. Fuel return hose connection AA" "DA 5. Fuel injection pipe
3. Fuel main hose connection AC" "CA 12. Nut
4. Control wiring harness connection AC" "CA 13. Fuel return pipe
AA" "DA 5. Fuel injection pipe 14. Fuel return pipe gasket
6. Flange AD" "BA 15. Fuel injection nozzle and holder
AB" 7. Fuel injection pump sprocket assembly
AB" 8. Fuel injection pump "AA 16. Holder gasket
9. Key "AA 17. Nozzle gasket
10. Injection pump stay
11. Injection pump bracket stay
13E-64 DIESEL FUEL - Injection Pump and Nozzle
Fuel injection pipe

AA" FUEL INJECTION PIPE REMOVAL
Nut
When loosening nuts at both ends of injection pipe, hold
Delivery the delivery holder (for pump side) an the injection nozzle
holder or holder (for nozzle side) with wrench and loosen nut.
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/

MB990767 FUEL INJECTION PUMP REMOVAL
1. Use the special tool to hold the injection pump sprocket,
and then remove the injection pump sprocket fixing nut.
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.
Caution
Nut If an attempt is made to loosen the nut without first
Fuel return pipe
holding the fuel return pipe, the pipe may be broken
or otherwise damaged.
2. Disconnect the fuel return pipe.
AD" FUEL INJECTION NOZZLE AND HOLDER

Deep socket ASSEMBLY REMOVAL
wrench 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.
"AA NOZZLE GASKET/HOLDER GASKET
INSTALLATION
Holder gasket
Clean the cylinder head’s injection nozzle hole, and insert
Nozzle gasket 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 DIESEL FUEL - Injection Pump and Nozzle
7
3
2
6
5 39 Nm
1
4
Disassembly steps
AA" "AA 1. Retaining nut 5. Pressure spring
2. Nozzle tip 6. Shim
3. Distance piece 7. Nozzle holder body
4. Retaining pin
DISASSEMBLY SERVICE POINT

AA" RETAINING NUT REMOVAL
Deep socket
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.
NOZZLE TIP
1. Check the nozzle tip for carbon deposits. Scape off carbon
Plunger 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
Nozzle tip valve from damage.
2. While the nozzle tip is submerged in diesel fuel, check
that the needle valve slides smoothly.
A 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
1
18 Nm
6 Nm
2
5
3
6
Removal steps
1. Air hose connection 4. Air intake fitting
2. Intake air temperature sensor 5. Intake fitting gasket
connector 6. Throttle body assembly
3. Vacuum hose connection 7. Intake fitting gasket
13F-1
FUEL SUPPLY
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

13F-2 FUEL SUPPLY - General Information/Special Tool
D The steel fuel tank is located under the floor D A plastic snap-fitting hose (high-pressure fuel
of the rear seats to provide increased safety hose) has been adopted between the fuel pump
and increase the amount of luggage assembly and the fuel filter assembly in
compartment space. petrol-powered vehicles in order to improve
D The fuel tank has been equipped with a valve ease of maintenance.
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.
SPECIAL TOOL 13500060088

MB991610 Oil filter wrench Fuel filter cartridge replacement
FUEL SUPPLY - Fuel Tank 13F-3
FUEL TANK 13500190244

D Draining Fuel D Refilling Fuel.
D Reduce the Inner Pressure of Fuel Line and Hose D Checking for Fuel Leaks
<Petrol-powered Vehicles>
4
<Petrol-powered <Diesel-powered
vehicles> vehicles>
5 2
5 3
7
6 <Petrol-powered ve-
<Diesel-powered
16 hicles> vehicles>
13
15
8
14
11
17
12
10
9
25 Nm
1 <Diesel-powered
vehicles>
Removal steps
1. Drain plug 8. Vapour hose
2. Fuel filler cap 9. Fuel tank assembly
3. Fuel filler neck assembly 10. Fuel wiring harness
4. Packing 11. Filler hose
D Parking brake cable connection (Refer 12. Vapour hose
to GROUP 36) 13. Vapour cap
D Rear seat cushion (Refer to GROUP 14. Valve assembly
52A) 15. Fuel pump assembly
5. Return hose 16. Fuel pipe assembly
"AA 6. High-pressure fuel hose 17. Fuel gauge unit assembly
7. Main hose
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.
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.)
FUEL SUPPLY - Fuel Filter 13F-5
FUEL FILTER 13500280101

D Reduce the Inner Pressure of Fuel Line and Hose D Checking for Fuel Leaks
<Petrol-powered Vehicles>
<Petrol-powered vehicles>
8
7 2
3 1
4
3 9
6 4
12 - 14 Nm
5
3 Nm
Removal steps
AA" "BA 1. High-pressure fuel hose connection 6. Fuel filter cartridge
2. Main pipe connection 7. Breather screw
"AA 3. Main hose connection 8. Fuel filter pump body
4. Fuel filter assembly 9. Fuel filter bracket
5. Water level sensor

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 FUEL SUPPLY - Fuel Filter
"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.
Float INSPECTION 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

13500130147
MB991610
<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

Fuel filter
assembly <PETROL-POWERED VEHICLES> 13500130130
1. Bleed the residual pressure from inside the fuel line.

Main pipe
2. Remove the parking brake cable clamp.
3. Disconnect the high-pressure fuel hose.
High-pressure
Caution
fuel hose As there will be some pressure remaining in the fuel
36 Nm pipe line, cover it with a rag to prevent fuel from
spraying out.
FUEL SUPPLY - Fuel Filter 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)
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Wheel Speed Sensor Check . . . . . . . . . . . . . . . . . 27

Vacuum Solenoid Valve Check . . . . . . . . . . . . . . . 27
SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 3
Ventilation Solenoid Valve Check . . . . . . . . . . . . . 27
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Vacuum Tank Check . . . . . . . . . . . . . . . . . . . . . . . . 27
Vacuum Actuator Check . . . . . . . . . . . . . . . . . . . . . 27
Accelerator Pedal Position Sensor (APS)
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 25
System Check Using the TCL Indicator TCL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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
For vehicles with 6A13 engine, the TCL system roads. In addition, this system improves driveability
(slip control and trace control) is available as an while cornering on normal roads and contributes
option. This system facilitates starting, accelerating, to easier driving.
and cornering on slippery roads such as snowy
Ventilation
solenoid valve
Vacuum solenoid
valve
Steering wheel sensor
Engine-ECU
Vacuum actuator
TCL-ECU
ABS-ECU
Vacuum tank
Accelerator pedal
position sensor (APS)
A/T-ECU
Stop lamp switch
TCL switch Indicator

TCL - Service Specification/Special Tools/Troubleshooting 13H-3
SERVICE SPECIFICATION 13600030013
Item Standard value
Accelerator pedal position sensor resistance kW 3.5 - 6.5

MB991502 MUT-II sub For checking of TCL (Diagnosis code display
assembly when using the MUT-II)
MB991529 Diagnosis code For checking of TCL (Diagnosis code display

check harness when using the TCL-OFF warning lamp)
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

NOTE
Before carrying out trouble diagnosis, check to be sure that all of the following items are normal.
D Is the standard steering wheel being used, and has it been correctly installed to the straight-ahead
position on the steering shaft?
D Are the size, specifications, air pressure, balance and wear conditions of the tyres and wheels normal?
D Is the wheel alignment normal?
D Have any other modifications been made to the engine or suspension which could conceivably have
an effect on the TCL system?
DIAGNOSTIC FUNCTION
METHOD OF READING THE DIAGNOSIS CODES
Use the MUT-II or the warning lamp to read the diagnosis codes.
(Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)
NOTE
Connect the MUT-II to the diagnosis connector (16 pin) under the instrument under cover.
METHOD OF ERASING THE DIAGNOSIS CODES

13H-4 TCL - Troubleshooting
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
73
74 A/T-ECU communication circuit system 13H-14
76 ABS circuit system 13H-15

TCL - Troubleshooting 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 D Malfunction of APS
an open circuit or other malfunction in the APS circuit. The APS power supply and D Malfunction of TCL-ECU
earth are supplied from the engine-ECU, and the output signal is used by the A/T-ECU D Malfunction of engine-ECU
and auto-cruise control-ECU as well as by the TCL-ECU. D Malfunction of harness or connector
NG NG NG
MUT-II Data list Measure the voltage at APS Check the following con- Repair
11 APS output Open and close connector B-41. nectors:
the throttle lever. D Ignition switch: ON B-41, C-39
OK: Changes smoothly be- D Disconnect the APS
OK
tween 300 mV - 5,500 connector and measure at
mV harness side. Check trouble symptom.
D Measure at the harness
OK side. NG
D Between terminal (1) and
body earth Check the harness between NG
the APS and the engine-ECU, Repair
OK: 4.8 - 5.2 V
NG
Check the following Repair OK
connectors: OK
C-10, B-41, C-39
NG
OK Check the APS. Replace
(Refer to P.13H-27.)
NG NG NG
Measure the voltage at TCL- Check the following con- Repair
ECU connector C-10. nectors:
Replace the TCL-ECU. D Ignition switch: ON C-10, C-51, B-41
D Disconnect the TCL-ECU OK
connector and measure at
the harness side. Check trouble symptom.
D Between terminal (19) and
body earth NG
OK: 0.3 V or more
Check the harness between
OK the APS and the TCL-ECU,
NG
Check the following con- Repair
nector:
C-10
OK

NG
Replace the TCL-ECU.

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 D Malfunciton of APS
TPS opening angle because of a short in the APS, an open circuit in the TPS or D Malfunction of TPS
sticking of the vacuum actuator. As this detection condition can be applicable during D Malfunction of TCL-ECU
throttle control, trouble diagnosis is invalid at this time. D Malfunction of engine-ECU
D Malfunction of harness or connector
D Malfunction of vacuum actuator
OK OK NG
MUT-II Data list Check the APS. Check the following con- Repair
13 TPS output Open and close (Refer to P.13H-27.) nectors:
the throttle lever. C-10, C-51, B-41
NG
OK: Changes smoothly be-
OK
tween 300 mV - 5,500 Replace
mV Check trouble symptom.
NG
NG
NG Check the harness between NG
Vacuum actuator operation in- Replace Repair
the APS and the TCL-ECU,
spection (Refer to GROUP
13A - On-vehicle Service.)
OK OK
Measure the voltage at TPS Replace the TCL-ECU

connector B-07.
D Disconnect the TPS NG NG
connector and measure at Check the following con- Repair
the harness side. nectors:
D Between terminal (4) and B-07, C-39
body earth OK
OK: 4.8 - 5.2 V NG NG
Check trouble symptom. Check the harness between Repair
OK the TPS and the engine-ECU,
NG and repair if necessary.
Check the TPS. Replace
(Refer to GROUP 13A - On- OK
vehicle Service.)
OK
Measure the voltage at en-

gine-ECU connector C-39.
D Connect the engine-ECU NG NG
connector. Check the following con- Repair
D Between terminal (84) and nectors:
body earth. B-07, C-39
Move the accelerator lever OK
OK: 0.3 - 1.0 V (Set to idle NG
position) Check trouble symptom. Check the harness between
4.5 - 5.5 V (Fully open) the TPS and the engine-ECU,
OK
NG
Check the following con- Repair
nector:
C-39
OK
NG
Code No.13 TPS circuit system Probable cause
This diagnosis code is output if the TPS opening angle is 20_ or greater than the D Malfunction of APS
APS opening angle because of a short in the TPS or an open circuit in the APS. D Malfunction of TPS
If there is an open circuit in the APS, diagnosis code No. 11 is output at the same D Malfunction of harness or connector
time. Accordingly, if only diagnosis code No. 11 is output, the cause is probably an D Malfunction of engine-ECU
abnormality in the TPS circuit system.
Yes
MUT-II Self-Diag code Code No. 11 APS circuit system
Is TCL diagnosis code No. 11 output? (Refer to P.13H-5.)
No
NG
Check the TPS. Replace
OK
NG NG
Measure the voltage at engine-ECU connector C-39. Check the following connectors: Repair
D Ignition switch: ON B-07, C-39
D Connect the engine-ECU connector.
OK
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
OK
Check the harness between the TPS and the engine-ECU,
OK
C-39
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 D Malfunction of stop lamp switch
period of 15 minutes or more, or for a continuous period of 1 minute or more when D Malfunction of harness or connector
driving at a speed of 10 km/h or more, because of a short circuit or defective adjustment D Malfunction of TCL-ECU
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.
OK NG
Measure the continuity at the stop lamp switch connector C-02. Check the following Repair
D Disconnect the connector and measure at the switch side. connectors:
D Between terminals (1) - (2) C-02, C-65, C-75, C-11
OK: Continuity when the brake pedal is depressed OK
No continuity when the brake pedal is released
NG
NG
NG
Inspect the harness be- Repair
tween stop lamp switch
and the TCL-ECU.
OK
OK
Stop lamp switch installation check (Refer to GROUP 35A - On-ve- Replace the stop lamp switch.
hicle Service.)
NG
Stop lamp switch adjustment (Refer to GROUP 35A - On-vehicle

Service.)
Code No. 24 TCL switch circuit system Probable cause

This diagnosis code is output if signals are input simultaneously from both the TCL-OFF D Malfunction of the TCL switch
and TCL-ON positions because of a short circuit in the TCL switch circuit. D Malfunction of harness or connector
D Malfunction of TCL-ECU
NG
Measure the continuity at TCL switch connector C-98. Replace the TCL switch.
D Disconnect the connector and measure at the switch side.
D Between terminals (2) - (3) and (3) - (6)
OK: No continuity
OK
NG
C-98, C-75, C-11
OK

NG
NG
Inspect the harness between the TCL switch and the TCL-ECU. 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 D Malfunction of harness or connector
the engine speed is 450 r/min or more. D Malfunction of TCL-ECU
OK NG
Measure the voltage at TCL-ECU connector C-11. Check the following Repair
D Ignition switch : ON connector:
D Disconnect the TCL-ECU connector and measure at the harness C-11
side. OK
D Between terminal (35) and body earth
NG NG

NG
C-131, C-134, C-66, C-75, C-11
OK

NG
Check the harness between the ignition switch and the TCL-ECU,
Code No. 27 TCL-ECU power supply voltage circuit Probable cause
(engine control relay circuit) system
This diagnosis code is output if the TCL-ECU power supply voltage (engine control D Malfunction of control relay
relay supply voltage) is lower than the specified value. D Malfunction of harness or connector
If the voltage returns to the specified value or greater, the diagnosis code is erased. D Malfunction of TCL-ECU
OK
Measure the voltage at TCL-ECU connector C-10. Check the following connector:
D Engine: idling C-10
D Disconnect the TCL-ECU connector and measure at the OK
harness side.
D Between terminal (25) and body earth Check trouble symptom.
OK: 10 V or more
NG
NG
NG
C-31, C-47, C-51, C-10
OK

NG
NG
Inspect the harness between the control relay and the TCL-ECU. Repair
OK
Engine control relay inspection (Refer to GROUP 13A - On-vehicle

Service.)
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 D Malfunction of front wheel speed sensor
the difference between the front wheels and the rear wheels is 8km/h or more because D Malfunction of harness or connector
of an open or short circuit in a wheel speed sensor or a malfunction of sensor. D Malfunction of TCL-ECU
D Malfunction of ABS-ECU
NOTE
When these diagnosis codes are output, erase the diagnosis code memory after carrying out repairs, and then
carry out a road test at 20 km/h or more and check to be sure that the diagnosis codes are not output again.
Yes
Is the ABS warning lamp illuminated, or is an ABS diagnosis code Carry out ABS troubleshooting (Refer to GROUP 35B - Trouble-
output? shooting.)
No
NG
Measure at ABS-ECU connector A-04. Replace the TCL-ECU.
D Measure at the ECU side with the connector connected.
D Voltage between terminal (17) and body earth
OK: 4.8 - 5.2 V
OK
NG
A-04, C-10
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) D Malfunction of rear wheel speed sensor
indicates that the difference between the left wheel and the right wheel is 8km/h or D Malfunction of harness or connector
more because of an open or short circuit in a wheel speed sensor or a defective D Malfunction of TCL-ECU
sensor. D Malfunction of ABS-ECU
NOTE
When these diagnosis codes are output, erase the diagnosis code memory after carrying out repairs, and then
Yes
Is the ABS warning lamp illuminated, or is an ABS diagnosis code Carry out ABS troubleshooting (Refer to GROUP 35B - Trouble-
output? shooting.)
No
NG
Measure at ABS-ECU connector A-04. Replace the TCL-ECU.
D Ignition switch : ON
D Measure at the ECU side with the connector connected.
OK: 4.8 - 5.2 V
OK
NG
A-04, C-10
OK
NG
Check trouble symptom. Check the harness connectors between the ABS-ECU and the
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 D Malfunction of rear wheel speed sensor
momentarily interrupted (0.02 sec.) because of a transient open circuit in a rear wheel D Malfunction of harness or connector
speed sensor. D Malfunction of ABS-ECU
Diagnosis code No. 36 is output if a rear wheel speed sensor abnormality is judged D Malfunction of TCL-ECU
when the turning speed of both rear wheels is 0 km/h for 20 seconds or more while
TCL is operating.
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
Yes
Is a diagnosis code output from the ABS-ECU? Carry out ABS troubleshooting (Refer to GROUP 35B - Trouble-
No shooting.)
OK
MUT-II Data list Replace the TCL-ECU.
33, 34 Wheel speed sensor
Accelerate from a stationary position.
OK: Vehicle speeds displayed on the speedometer and MUT-II
are identical.
NG
OK
A-04, C-10
NG
NG
Check trouble symptom. Check the harness connectors between the ABS-ECU and the
Code No. 41 Steering wheel sensor (ST-1) circuit system Probable cause
(open circuit)
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 D Malfunction of harness or connector
the steering wheel sensor circuit. D Malfunction of steering wheel sensor
OK NG
Measure at TCL-ECU connector C-11. Check the following Repair
D Ignition switch: ON connectors:
D Connector connected C-11, C-75, C-106
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 Check trouble symptom.
the steering wheel is turned
NG
NG: Changes between 4 V NG: Stays at 4 V or more
or more and approx. 0.5 V without changing Replace the TCL-ECU.
NG NG
Measure at steering wheel sensor connector C-106. Check the following Repair
D Disconnect the connector and measure at the harness side. connectors:
D Continuity between terminal (3) and body earth C-106, C-62
OK: Continuity
OK
OK
NG
Check the harness between the steering wheel sensor and the
body earth, and repair if necessary.
NG
C-106, C-75, C-11
OK

NG
NG
Inspect the harness between the steering wheel sensor and the Repair
TCL-ECU.
OK
Replace the steering wheel sensor.

Code No. 44 Steering wheel sensor circuit system Probable cause
(short circuit)
This diagnosis code is output when no steering angle signal is output because there D Malfunction of harness or connector
is a short-circuit in either steering wheel sensor ST-1 or steering wheel sensor ST-2 D Malfunction of steering wheel sensor
when the speed averages output by the left and right rear wheel speed sensors are D Malfunction of TCL-ECU
15 km/h or more.
OK NG
D Ignition switch: ON connector:
D Connector connected C-11
D Voltage between terminals (40) and (41) and the body earth
OK: Changes between approx. 3 V and approx. 0.5 V when OK
NG NG
NG
C-11, C-75, C-106
OK Replace the TCL-ECU.
NG
TCL-ECU.
OK
NG NG
Measure at steering wheel sensor connector C-106. Check the following Repair
D Ignition switch: ON connectors:
D Disconnect the connector and measure at the harness side. C-131, C-132, C-61,
D Continuity between terminal (2) and body earth C-106
OK: System voltage
OK
OK
NG
Check the harness between the steering wheel sensor and the
ignition switch, and repair if necessary.
NG
C-106
OK
Code No. 45 Steering wheel sensor (ST-N) circuit system Probable cause
(short circuit)
This diagnosis code is output if it is considered that there is an abnormality in the D Malfunction of steering wheel sensor
steering wheel sensor (ST-N) circuit system when the straight-ahead position is D Malfunction of harness or connector
continuously detected even though the steering wheel is turned 20_ or more. D Malfunction of TCL-ECU
OK NG
D Connector connected connector:
D Voltage between terminals (32) and the body earth C-11
OK: Changes between approx. 3V and approx. 0.5 V when OK
NG

NG
C-11, C-75, C-106
OK
NG
TCL-ECU.
OK

Code No. 71 Engine-ECU communication circuit system Probable cause

This diagnosis code is output if an error is detected in the communication contents D Malfunction of harness or connector
because of an open or short circuit in the serial communication circuit between the D Malfunction of TCL-ECU
TCL-ECU and the engine-ECU, a malfunction of ECU and a defective shielding of D Malfunction of engine-ECU
the shield wire.
NG
C-10, C-51, C-37
OK

NG
NG
Inspect the harness between the TCL-ECU and the engine-ECU. Repair
OK
Yes
Is a diagnosis code output from the engine-ECU? Carry out engine-ECU troubleshooting
(Refer to GROUP 13A - Troubleshooting.)
No
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 D Malfunction of harness or connector
because of an open or short circuit in the serial communication circuit between the D Malfunction of TCL-ECU
TCL-ECU and the A/T-ECU, a malfunction of ECU and a defective shielding of the D Malfunction of A/T-ECU
shield wire.
NG
C- 10, C-51, C-49, C-29, C-30
OK

NG
NG
Inspect the harness between the TCL-ECU and the A/T-ECU. Repair
OK
Yes
Is a diagnosis code output from the A/T-ECU? Carry out A/T-ECU troubleshooting
(Refer to GROUP 23 - Troubleshooting.)
No
NG
Check trouble symptom. Replace the A/T-ECU.
Code No. 76 ABS circuit system Probable cause
This diagnosis code is output if the ABS-ECU detects the system abnormality (when D Malfunction of harness or connector
ABS warning lamp illumination is controlled). D Malfunction of TCL-ECU
D Malfunction of ABS-ECU
Yes
Is the ABS warning lamp illuminated, or is an ABS diagnosis code Carry out ABS troubleshooting. (Refer to GROUP 35B - Trouble-
output? shooting.)
No
NG
A-04, C-10
OK

NG
NG
Inspect the harness between the ABS-ECU and the TCL-ECU. Repair
OK
NG
Check trouble symptom. Replace the ABS-ECU.
INSPECTION CHART FOR TROUBLE SYMPTOMS

procedure No.
Communication Communication with all systems is not possible. 1 13H-16

with the MUT-IIII
is not possible. Communication with TCL-ECU only is not possible. 2 13H-17
Malfunction of None of the TCL indicator lamps (TCL OFF, TCL) illuminate 3 13H-18
TCL indicator when the ignition switch is ON.
lamp display
One of the TCL indicator lamps does not illuminate when 4 13H-18
the ignition switch is ON (Another lamp does illuminate).
TCL OFF indicator lamp remains illuminated even after the 5 13H-19
engine is started.
TCL OFF indicator lamp flashes after the engine is started.
TCL remains illuminated even after the engine is started. 6 13H-19
TCL OFF indicator lamp does not illuminate even if the TCL 7 13H-20
switch is continuously pressed to the OFF side while the
engine is idling.
Malfunction of TCL illuminates in the TCL operation range, but torque is 8 13H-20
TCL operation not reduced.
Poor starting Engine output is reduced in the TCL non-operation range

Poor acceleration (TCL indicator lamp does not illuminate) and starting and
acceleration performance is poor.
INSPECTION PROCEDURES FOR EACH TROUBLE SYMPTOM

Inspection Procedure 1
Communication with the MUT-II is not possible. Probable cause
The cause is probably a defective power supply system (including earth) for the D Malfunction of connector
diagnosis line. D Malfunction of harness
NG NG
C-20. C-141, C-132, C-63, C-66, C-20
Voltage between terminal (16) and body <L.H. drive vehicles>
earth C-14, C-62, C-66, C-20
OK: System voltage <R.H.drive vehicles>
OK OK
NG
Check trouble symptom. Check the harness between the fusible
link No. 2 and diagnosis connector, and
NG NG
Measure at the diagnosis connector Check the following connector: Repair
C-20. C-20
Continuity between terminal (4), (5) and OK
body earth
OK: Continuity NG
Check trouble symptom. Check the harness between the diagno-
OK sis connector and the earth, and repair
if necessary.
NG
Check trouble symptom. Replace the MUT-II.
(Communication with TCL-ECU only is not possible.)
If the MUT-II cannot communicate with the TCL-ECU only, the cause is probably D Malfunction of harness or connector
an abnormality in the TCL diagnosis line or in the TCL-ECU power supply line or D Malfunction of engine control relay
earth line. D Malfunction of TCL-ECU
NG NG
Measure at diagnosis connector C-20 Check the following connectors: Repair
and TCL-ECU connector C-10. C-20, C-66, C-83, C-49, C-51, C-10
OK
D Continuity between the following NG
Check trouble symptoms. Check the harness between the TCL-
terminals
ECU and diagnosis connector, and re-
OK: Continuity
pair if necessary.
TCL-ECU side 1 14
| |
Diagnosis connector side 1 7
OK
NG NG
Measure at TCL-ECU connector C-10. Check the following connectors: Repair
D Disconnect the connector and C-31, C-47, C-51, C-10
OK
D Engine: idling
D Voltage between 25 - body earth
OK: 10 V or more
NG
OK
OK
Check the harness between the engine Check the engine control relay.
control relay and TCL-ECU. (Refer to GROUP 13A - On-vehicle
NG Service.)
Repair
NG
Measure at TCL-ECU connectors C-10 Check the harness between the TCL-
and C-11. ECU and the earth, and repair if neces-
D Disconnect the connector and sary.
D Continuity between 13, 26 (C-10),
31 (C-11) - body earth
OK: Continuity
OK
NG
C-10, C-11
OK
NG
Check trouble symptoms. Replace the TCL-ECU.
None of the TCL indicator lamps (TCL OFF, TCL) illuminate Probable cause
when the ignition switch is ON.
The main cause is an open circuit in the indicator circuit because of a burnt-out D Malfunction of harness or connector
indicator lamp bulb. D Malfunction of TCL-ECU
D Malfunction of indicator lamp bulb
No OK
Do other warning lamps illuminate when Check the following connectors: Check trouble symptom.
the ignition switch is at ON position? C-131, C-135, D-03 NG
Yes NG
Check the harness between the com-
Repair bination meter and the junction block,
Yes and repair if necessary.
MUT-II Self-Diag code Code No.27 TCL-ECU power supply
Is code No.27 output? voltage circuit system (Refer to
P.13H-9.)
No
NG
D-03, C-50, C-11
OK

NG
NG
Inspect the harness between the com- Repair
bination meter and the TCL-ECU.
OK
NG
Check if a TCL indicator lamp bulb is Replace the lamp bulb.
burnt out.
OK
One of the TCL indicator lamps does not illuminate when Probable cause
the ignition switch is ON.
Because the TCL indicators utilise shared power supply circuits, if one of the indicator D Open circuit in indicator lamp power supply circuit.
lamps is illuminated, the power supply circuit can be judged to be normal. D Burnt-out indicator lamp bulb
No
Is the bulb of the non-illuminated indica- Replace the lamp bulb.
tor lamp normal?
Yes
OK
Measure at the TCL-ECU connector Replace the TCL-ECU.
C-11.
D Voltage between terminal (45) and
body earth
D Voltage between terminal (46) and
body earth
OK: System voltage
NG
OK NG
Check the following connectors: Check trouble symptom Check the harness between the com-
D-03, C-50, C-11 bination meter and the TCL-ECU, and
D TCL OFF indicator lamp remains illuminated even Probable cause
after the engine is started.
D 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 D Other system related to the TCL
abnormality, this indicator will illuminate or flash. D Malfunction of harness or connector
No
Is the diagnosis code normal? To trouble symptom inspection proce-
(Is communication with the MUT-II pos- dure 1
sible?) (Refer to P.13H-16.)
Yes
Yes
Does the TCL OFF indicator lamp switch Replace the TCL-ECU.
off when TCL-ECU connector C-11 is
disconnected?
No
OK NG
Check the following connectors: Check trouble symptom. Check the harness between the com-
NG
Repair
TCL indicator lamp remains illuminated even after the Probable cause
engine is started.
The TCL indicator lamp only illuminates while the engine is running if the TCL is D Malfunction of TCL indicator power supply circuit
operating. D Malfunction of TCL-ECU
No
Does the TCL indicator remain illumi- Replace the TCL-ECU.
nated when TCL-ECU connector C-11
is disconnected and the ignition switch
is turned to ON?
Yes
OK NG
Check the following connectors: Check trouble symptom. Check the harness between the com-
NG
Repair
TCL OFF indicator lamp does not illuminate even if the Probable cause
TCL switch is continuously pressed to the OFF side while
the engine is idling.
If the indicator lamp does not illuminate when the switch is operated, there is a D Malfunction of harness or connector
malfunction in the switch, switch circuit or in the TCL-ECU. D Malfunction of TCL switch
OK
MUT-II Data list Replace the TCL-ECU.
D 25 TCL OFF switch
D Press the TCL switch continuously
to the OFF side while the engine
is idling.
OK: ON is displayed
NG
NG
C-11, C-75, C-98
OK
NG OK
Check trouble symptom Inspect the harnesses between the Repair
TCL-ECU and the TCL switch, and be-
tween the TCL switch and the body
earth.
OK
TCL switch component inspection (Re-

fer to P.13H-28.)
D TCL illuminates in the TCL operation range, but Probable cause
torque is not reduced.
D Engine output is reduced in the TCL non-operation
range (TCL indicator lamp does not illuminate) and
starting and acceleration performance is poor.
In cases such as the above, the electrical system is normal, and the cause is probably D Malfunction of vacuum solenoid valve
an abnormality in the mechanical system (vacuum actuator). D Malfunction of ventilation solenoid valve
D Malfunction of vacuum actuator
D Incorrect vacuum hose connector
D Malfunction of throttle link
D Malfunction of vacuum tank
D Blocked air cleaner element
As the cause is probably a malfunction of the vacuum actuator system, carry out inspection of the following items
in order.
D Vacuum solenoid valve operation inspection (Refer to GROUP 13A - On-vehicle Service.)
D Ventilation solenoid valve operation inspection (Refer to GROUP 13A - On-vehicle Service.)
D Disconnected or mis-connected vacuum hose inspection (Refer to GROUP 13A - On-vehicle Service.)
D Throttle link operation inspection (Refer to GROUP 13A - On-vehicle Service.)
D Vacuum tank inspection (Refer to GROUP 13A - On-vehicle Service.)
D Air cleaner element blockage inspection
DATA LIST REFERENCE TABLE
No. Check item Check condition Normal condition
11 APS Accelerator pedal position Fully closed 300 - 1,000 mV
Engine stop
Depressed Gradually rises from
Selector lever position: P the above value
Fully open 4,500 - 5,500 mV
13 TPS Accelerator pedal position Fully closed 300 - 1,000 mV
Engine stop
Depressed Gradually rises from
Selector lever position: P the above value
Fully open 4,500 - 5,500 mV
15*1 Inhibitor switch Ignition switch: ON Selector lever: P position P
Engine stop
Selector lever: R position R
Selector lever: N position N
Selector lever: D position D
Selector lever: 3 position 3
Selector lever: 2 position 2
Selector lever: L position L
16*1 Shift position Shift lever position: D Driving at constant speed 1st
of 10 km/h in 1 range
Driving at constant speed 2nd
Driving at constant speed 3rd
Driving at constant speed 4th
21 Idle switch Accelerator pedal position Depressed OFF
Ignition switch: ON
Released ON
22 Ignition switch Ignition switch: ON ON
Ignition switch: OFF OFF
23 Stop lamp switch Brake pedal position Depressed ON
Ignition switch: ON
Released OFF
24 TCL ON switch TCL ON switch operation Pressed ON
Ignition switch : ON
Released OFF
25 TCL OFF switch TCL OFF switch operation Pressed ON
Ignition switch: ON
Released OFF
No. Check item Check condition Normal condition

27 ECU power supply Ignition switch: ON System voltage
voltage
31 Front right wheel Engine running Vehicle stopped 0 km/h
speed sensor Selector lever position: D
Driving at 40 km/h 40 km/h
32 Front left wheel Engine running Vehicle stopped 0 km/h
33 Rear right wheel Engine running Vehicle stopped 0 km/h
34 Rear left wheel Engine running Vehicle stopped 0 km/h
40 Engine speed Ignition switch: ON Engine: idling Engine speeds
displayed on the
MUT-II and tachome-
ter are identical.
44 Steering angle Steering wheel position Turned 90_ to the right R 88 deg or R 92 deg
Ignition switch: ON
Turned 90_ to the left L 88 deg or L 92 deg
45 Steering straight- Steering wheel position Immediately after ignition OFF
ahead point Ignition switch: ON switch is ON
learning
Immediately after city ON
driving
51 Slip control TCL switch: ON TCL indicator lamp ON
Driving on low frictional illuminated
resistance road
TCL indicator lamp OFF
switched off
52 Trace control TCL switch: ON TCL indicator lamp ON
Driving on winding road illuminated
TCL indicator lamp OFF
switched off
74 Steering wheel Steering wheel position Neutral position LOW
sensor (ST-N) Engine idling
Steering wheel turned HIGH
90_ from neutral position
75 Steering wheel Steering wheel position Steering wheel turned HIGH and LOW
sensor (ST-1) Ignition switch: ON slowly to left display alternately
76 Steering wheel Steering wheel position Steering wheel turned HIGH and LOW
sensor (ST-2) Ignition switch: ON slowly to right display alternately
81 Engine model Ignition switch: ON 6A13

82 Valve type Ignition switch: ON SOHC
83 Aspiration type Ignition switch: ON N/A
84 Engine classifica- Ignition switch: ON NORMAL
tion
85 Destination Ignition switch: ON EUR*2
NOTE
*1: A/T
*2: For Europe
CHECK AT ECU TERMINALS
Terminal Check item Measurement condition Normal condition

No.
1 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 When MUT-II is connected Serial communica-

tion with MUT-II
When MUT-II is not connected 1 V or less
15 A/T-ECU data communication Engine: Idling Other than 0 V
16
17 Engine-ECU data communication Engine: Idling Other than 0 V
18
19 APS output Ignition switch: ON 4.5 - 5.5 V

Accelerator pedal fully depressed
Ignition switch: ON 0.4 - 1.0 V

Accelerator pedal released
20 Wheel speed sensor input (rear left Engine: Idling, Vehicle slowly moving forward Flashes between 0
wheel) V and approx. 5 V
21 Wheel speed sensor input (front Engine: Idling, Vehicle slowly moving forward Flashes between 0
right wheel) V and approx. 5 V
22 Wheel speed sensor input (front Engine: Idling, Vehicle slowly moving forward Flashes between 0
left wheel) V and approx. 5 V
23 Wheel speed sensor input (rear Engine: Idling, Vehicle slowly moving forward Flashes between 0
right wheel) V and approx. 5 V
25 ECU power supply Ignition switch: ON Battery voltage

Terminal Check item Measurement condition Normal condition

No.
32 Steering wheel sensor (ST-N) input Engine: Idling 0.5 V or less

Steering wheel in straight-ahead position

Steering wheel turned 90_ from
straight-ahead position
34 TCL ON switch Ignition switch: ON 0 - 2V

TCL switch: Pressed to ON side
Ignition switch: ON Battery voltage

TCL switch: Released
35 Ignition switch IG2 Ignition switch: ON Battery voltage
39 ECU back-up power supply Ignition switch: OFF Battery voltage
40 Steering wheel sensor (ST-1) input Ignition switch: ON Flashes between 0

Steering wheel turned slowly V and approx. 3 V
41 Steering wheel sensor (ST-2) input Ignition switch: ON Flashes between 0

Steering wheel turned slowly. V and approx. 3 V
42 TCL OFF switch Ignition switch: ON 0 - 2V

TCL switch: Pressed to OFF side

TCL switch: Released
43 Stop lamp switch input Ignition switch: ON Battery voltage

Brake pedal depressed
Brake pedal released
44 ABS fail signal During ABS fail 0 - 2V
When ABS is normal Battery voltage
45 TCL-OFF indicator Ignition switch: ON Battery voltage

Indicator: Extinguished
Indicator: Illuminated
46 TCL indicator Ignition switch: ON 0 - 2V

Indicator: Illuminated

Indicator: Extinguished
TCL - On-Vehicle Service 13H-25
SYSTEM CHECK USING THE TCL INDICATOR

LAMPS
Press the TCL switch and check if each TCL indicator lamp
illuminates or switches off.
A B
TCL switch mode Inspection conditions TCL OFF indicator (A) TCL indicator (B)
Switch does not Turn the ignition switch to the ON position. f f

operate
Start the engine. ´ ´
TCL OFF mode Engine is idling. f -
TCL ON mode Drive the vehicle at 30 km/h for 2 minutes or No illumination -

more.
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 13H-27
STOP LAMP SWITCH CHECK 13600120024
Refer to GROUP 35A - On-vehicle Service.
WHEEL SPEED SENSOR CHECK 13600130027
Refer to GROUP 35B - On-vehicle Service.
VACUUM SOLENOID VALVE CHECK 13600390012
VENTILATION SOLENOID VALVE CHECK

13600400012
VACUUM TANK CHECK 13600410015
VACUUM ACTUATOR CHECK 13600420018
APS ACCELERATOR PEDAL POSITION SENSOR

connector APS
(APS) CHECK 13600430028
1. Disconnect the APS connector.

2. Measure the resistance between terminals (1) and (4)
of the APS connector.
3. When the accelerator pedal is gradually depressed, check
that the resistance between terminals (1) and (2) of the
Throttle body 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
Removal steps
1. Switch bezel
2. TCL switch
TCL SWITCH CONTINUITY CHECK

ON
Switch position Terminal No.
Neutral
1 2 3 6 4 - 5
OFF ON
Neutral
OFF
TCL - Steering Wheel Sensor 13H-29
STEERING WHEEL SENSOR 13600220014

CAUTION: SRS
Before removal of air bag module and clock spring, refer to GROUP 52B - Service Precautions and Air
Bag Module and Clock Spring.
Removal steps
D Steering wheel and column cover
(Refer to GROUP 37A - Steering
Wheel and Shaft.)
AA" 1. Steering wheel sensor
Slit plate REMOVAL SERVICE POINT

AA" STEERING WHEEL SENSOR REMOVAL
Caution
1. Do not adhere any dust or grease, etc. to the steering
wheel sensor, which has a photo coupler in it.
Steering 2. Do not bend the slit plate of the column switch nor
wheel sensor adhere any grease etc. to it.
STEERING WHEEL SENSOR CHECK

Refer to P.13H-22.
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
1
Removal steps
1. Instrument panel lower passenger side
bracket
AA" 2. Upper bracket
3. TCL-ECU
4. Lower bracket

AA" UPPER BRACKET REMOVAL
Loosen the dash wiring harness mounting nut. Lower the
dash wiring harness to the position where the upper bracket
can be removed, and the remove the upper bracket.
Dash wiring
harness
TCL-ECU CHECK
Refer to P.13H-23.
14-1
ENGINE
COOLING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Engine Coolant Replacement . . . . . . . . . . . . . . . . . 10

Concentration Measurement . . . . . . . . . . . . . . . . . . 11
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2
Fan Controller Check . . . . . . . . . . . . . . . . . . . . . . . . 12
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fan Control Relay Continuity Check . . . . . . . . . . 12
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WATER PUMP

<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
<6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9 <4D6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine Coolant Leak Checking . . . . . . . . . . . . . . . . 9
WATER HOSE AND WATER PIPE . . . . . . . . 19
Radiator Cap Opening Pressure
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
General Information/
14-2 ENGINE COOLING - Service Specifications/Lubricant/Sealants
The cooling system is designed to keep every part The water pump is of the centrifugal type and is
of the engine at appropriate temperature in driven by the timing belt or drive belt from the
whatever condition the engine may be operated. crankshaft.
The cooling method is of the water-cooled, pressure The radiator is the corrugated fin, down flow type
forced circulation type in which the water pump and is cooled by the electrical radiator fan.
pressurizes coolant and circulates it throughout the The cooling fans are controlled by a fan controller
engine. If the coolant temperature exceeds the and the engine-ECU depending on driving
prescribed temperature, the thermostat opens to conditions.
circulate the coolant through the radiator as well
so that the heat absorbed by the coolant may be
radiated into the air.
Radiator Performance kJ/h 4G6 175,800
6A1 200,900
4D6 213,500
A/T oil cooler Performance kJ/h 4G6 5,700
6A1, 4D6 7,100
Radiator cap opening pressure kPa 74 - 103 64
Range of coolant antifreeze concentration of radiator % 30 - 60 -
Thermostat Valve opening temperature of thermostat _C 82 ± 1.5 -
Full-opening temperature of thermostat _C 95 -
Valve lift (at 95_C) mm 8.5 or more -
LUBRICANT 14100040148
Items Quantity L
HIGH QUALITY ETHYLENE GLYCOL 4G6, 6A1 6

ANTIFREEZE COOLANT
4D6 8
Items Specified sealant Remarks
Cylinder block drain plug 3M Nut Locking Part No. 4171 or equivalent Drying sealant
Water pump <6A1>, Mitsubishi Genuine Parts No. MD970389 or Semi-drying sealant
Thermostat case assembly <4G6, 4D6>, equivalent
Water outlet fitting <4D6>
ENGINE COOLING - Special Tool/Troubleshooting 14-3

MB991223 Harness set Measurement of terminal voltage
A
C: MB991221 C: LED harness C: Power circuit inspection
D: MB991222 adapter D: Commercial tester connection
D: probe
B

Trouble symptoms Inspection procedure Reference page
No.
Radiator fan and condenser fan do not operate. <Vehicles with A/C> 1 14-3
Radiator fan does not operate. <Vehicles without A/C>
Radiator fan and condenser fan do not change speed or stop. 2 14-6
<Vehicles with A/C>
Radiator fan does not change speed or stop. <Vehicles without A/C>
Radiator fan does not operate. <Vehicles with A/C> 3 14-8
Condenser fan does not operate. <Vehicles with A/C> 4 14-8

Radiator fan and condenser fan do not operate. Probable cause
<Vehicles with A/C>
Radiator fan does not operate. <Vehicles without A/C>
The cause could be a malfunction of the fan controller power supply or earth circuit. D Malfunction of fusible link
The cause could also be a malfunction of the fan controller or the engine-ECU. D Malfunction of fan control relay
D Malfunction of fan controller
D Malfunction of wiring harness or connector
14-4 ENGINE COOLING - Troubleshooting
<Vehicles with A/C>

NG
D Fusible links (4) and (7) check Replace
D Fan control relay check (Refer to P.14-12.)
OK
1. NG
Measure at the fan control relay connector B-20X. Check the harness wire between fan control relay and fusible link
D Remove the relay, and measure at the harness side connector. (4), and repair if necessary.
1. Voltage between 4 and body earth 2. NG
OK: Battery voltage Check the harness wire between fan control relay and fusible link
2. Voltage between 3 and body earth (Ignition switch: ON) (7), and repair if necessary.
OK: Battery voltage
3. Continuity between 1 and body earth 3. NG
Check the harness wire between fan control relay and body earth,
OK: Continuity and repair if necessary.
OK
1. NG
Measure at the fan controller connector A-22. Check the harness wire between fan controller and fan control
D Disconnect the connector, and measure at the harness side relay, and repair if necessary.
connector. 2. NG
1. Voltage between 3 and body earth (Ignition switch: ON) Check the harness wire between fan controller and body earth,
OK: Battery voltage and repair if necessary.
2. Continuity between 1 and body earth
OK: Continuity
OK
NG
Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3. Check the harness wire between fan controller and engine-ECU.
D Connect the connector. OK NG
<Except 4D6>
D Voltage between 21 and body earth Repair
(Engine: idling, A/C switch: ON)
OK: 0.7 V or more (When A/C compressor is operating)
<4D6>
Engine-ECU terminal voltage check (Refer to GROUP 13A - Trou-
D Voltage between 18 and body earth
bleshooting.)
(Engine: idling, A/C switch: ON)
OK: 0.7 V or more (When A/C compressor is operating) OK NG
OK
Replace
Check the automatic compressor-ECU <manual air conditioner>

or A/C-ECU <automatic air conditioner>, and repair if necessary.
Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3.

<Except 4D6>
D Pull out the terminal No.21 to disconnect it (Ignition switch: ON)
OK: The radiator fan motor and condenser fan motor operate.
<4D6>
YES NO
Engine-ECU terminal voltage check (Refer to GROUP 13A - Trou- Replace the radiator fan motor and fan controller assembly.
bleshooting.)
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
ENGINE COOLING - Troubleshooting 14-5
<Vehicles without A/C>
NG
D Fusible links (4) and (7) check Replace
D Fan control relay check (Refer to P.14-12.)
OK
1. NG
Measure at the fan control relay connector B-20X. Check the harness wire between fan control relay and fusible link
D Remove the relay, and measure at the harness side connector. (4), and repair if necessary.
1. Voltage between 4 and body earth 2. NG
OK: Battery voltage Check the harness wire between fan control relay and fusible link
2. Voltage between 3 and body earth (Ignition switch: ON) (7), and repair if necessary.
OK: Battery voltage
3. Continuity between 1 and body earth 3. NG
Check the harness wire between fan control relay and body earth,
OK
1. NG
Measure at the fan controller connector A-22. Check the harness wire between fan controller and fan control
D Disconnect the connector, and measure at the harness side relay, and repair if necessary.
connector. 2. NG
1. Voltage between 3 and body earth (Ignition switch: ON) Check the harness wire between fan controller and body earth,
OK: Battery voltage and repair if necessary.
2. Continuity between 1 and body earth
OK: Continuity
OK
NG
<Except 4D6>
D Voltage between 21 and body earth (Engine: idling) Repair
OK: 0.7 V or more (When radiator fan is operating)
<4D6>
D Voltage between 18 and body earth (Engine: idling) Engine-ECU terminal voltage check (Refer to GROUP 13A - Trou-
OK: 0.7 V or more (When radiator fan is operating) bleshooting.)
OK

<Except 4D6>
OK: The radiator fan motor operates.
<4D6>
YES NO
bleshooting.)
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
Radiator fan and condenser fan do not change speed or Probable cause
stop. <Vehicles with A/C>
Radiator fan does not change speed or stop.
The fan controller carries out step-free control of the radiator fan motor and the condenser D Malfunction of fan control relay
fan motor speeds using signals transmitted from the engine-ECU. D Malfunction of fan controller
<Vehicles with A/C>

NG
Fan control relay check (Refer to P.14-12.) Replace
OK
NG
D Check the harness wire between fan control relay and fusible Repair
link (7).
D Check the harness wire between fan control relay and body
earth.
D Check the harness wire between fan control relay and fan
controller.
OK
NG
D Connect the connector. NG
<Except 4D6>
OK Repair
(Engine: idling, engine coolant temperature: 80_C or less)
OK: 0 - 0.3 V (Engine: idling, A/C switch: ON)
Engine-ECU terminal voltage check (Refer to GROUP 13A - Trou-
bleshooting.)
<4D6>
D Voltage between 18 and body earth NG
OK: 0 - 0.3 V (Engine: idling, A/C switch: ON) OK Replace
OK Check the automatic compressor-ECU <manual air conditioner>
or A/C-ECU <automatic air conditioner>, and repair if necessary.
NG
Fan controller check (Refer to P.14-12.) Replace the radiator fan motor and fan controller assembly.
OK

<Except 4D6>
D Connect the terminal No.21 to the body earth (Ignition switch: ON)
OK: The radiator fan motor and condenser fan motor stop.
<4D6>
OK: The radiator fan motor and condenser fan motor stop.
YES NO
bleshooting.)
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
ENGINE COOLING - Troubleshooting 14-7
NG
Fan control relay check (Refer to P.14-12.) Replace
OK
NG
D Check the harness wire between fan control relay and fusible Repair
link (7).
D Check the harness wire between fan control relay and body
earth.
D Check the harness wire between fan control relay and fan
controller.
OK
NG
<Except 4D6>
D Voltage between 21 and body earth Repair
OK: 0 - 0.3 V (Engine: idling)
OK: 0.7 V or more (When radiator fan is operating) Engine-ECU terminal voltage check (Refer to GROUP 13A - Trou-
<4D6> bleshooting.)
OK: 0 - 0.3 V (Engine: idling)
OK: 0.7 V or more (When radiator fan is operating)
OK
NG
Fan controller check (Refer to P.14-12.) Replace the radiator fan motor and fan controller assembly.
OK

<Except 4D6>
OK: The radiator fan motor stops.
<4D6>
OK: The radiator fan motor stops.
YES NO
bleshooting.)
NOTE
*1: 4G6
*2: 6A1
*3: 4D6
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 D Malfunction of radiator fan motor
the fan controller and the radiator fan motor. D Open circuit between fan controller and radiator fan
motor
Replace the radiator fan motor and fan controller assembly.
Condenser fan does not operate. <Vehicles with A/C> Probable cause
The cause could be a malfunction of the condenser fan motor or of the fan controller. D Malfunction of condenser fan motor
D Malfunction of fan controller
NG NG
Condenser fan motor check (Refer to Condenser fan motor connector Repair
GROUP 55.) OK
OK NG
Check the trouble symptom. Replace the condenser fan motor.
Replace the radiator fan motor and fan
controller assembly.
ENGINE COOLING - On-vehicle Service 14-9
Cap adapter
ENGINE COOLANT LEAK CHECKING
1. Confirm that the coolant level is up to the filler neck.
Adapter 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
1. Use a cap adapter to attach the cap to the tester.

Cap adapter 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 COOLING - On-vehicle Service
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:
3M Nut Locking Part No. 4171 or equivalent
6. Securely tighten the radiator drain plug.
7. Install the reserve tank.
39 Nm 44 Nm
ENGINE COOLING - On-vehicle Service 14-11
8. Remove the air bleed bolt and replace the seal washer.
<6A1> Air bleed bolt
9. Fill the radiator until the engine coolant flows from the
Water outlet 12 - 15 Nm air bleed bolt section, and then close the air bleed bolt.
fitting
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 30 - 60 %
GLYCOL ANTIFREEZE COOLANT
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 ENGINE COOLING - On-vehicle Service
FAN CONTROLLER CHECK 14100610011
Fan controller 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
1 2 3 4
When current is not

supplied
When current is
supplied
ENGINE COOLING - Thermostat 14-13
THERMOSTAT 14100240265

D Engine Coolant Draining and Supplying D Air Hose and Air Pipe Assembly Removal and
(Refer to P.14-10.) Installation <4D6> (Refer to P.14-21.)
D Air Cleaner and Air Intake Hose Assembly Removal
and Installation
<4G6>
4
6 13 Nm
3
<6A1>
4
17 - 20 Nm
7
3
<4D6>
12 - 15 Nm
2 5
13 Nm
7 4
12 - 15 Nm
6
1
3
Removal steps
1. Heater hose connection <4D6> 5. Fuel pipe mounting bolt <4D6>
2. Water hose connection <4D6> 6. Water inlet fitting
AA" "BA 3. Radiator lower hose connection "AA 7. Thermostat
4. Control wiring harness mounting
bolt
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
Rubber ring over or scratch the rubber ring when inserting. If the
rubber ring is damaged, replace the thermostat.
"BA RADIATOR LOWER HOSE CONNECTION

inlet fitting.
THERMOSTAT CHECK
1. Immerse the thermostat in water, and heat the water while
stirring. Check the thermostat valve opening temperature.
Standard value:
Valve opening temperature: 82±1.5_C
2. Check that the amount of valve lift is at the standard

value when the water is at the full-opening temperature.
Standard value:
Full-opening temperature: 95_C
Amount of valve lift: 8.5 mm or more
NOTE
Valve lift 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.
ENGINE COOLING - Water Pump <4G6> 14-15
WATER PUMP <4G6> 14100270363

D Engine Coolant Draining and Supplying
(Refer to P.14-10.)
D Timing Belt Tensioner Pulley Removal and
Installation (Refer to GROUP 11.)
4 Bolt specifications
8 ´ 60 8 ´ 22
8 ´ 14
8 ´ 25
2
3
20 - 25 Nm 8 ´ 22
2 Screw diameter ´ length mm
24 Nm 12 - 15 Nm
Removal steps
1. Alternator brace
2. Water pump
3. Water pump gasket
"AA 4. O-ring

Water pump "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
O-ring coolant.
Caution
Do not allow engine oil or other greases to adhere to
Water inlet pipe assembly the O-ring
14-16 ENGINE COOLING - Water Pump <6A1>
WATER PUMP <6A1> 14100270370

D Engine Coolant Draining and Supplying D Timing Belt Removal and Installation
(Refer to P.14-10.) (Refer to GROUP 11.)
D Power Steering Fluid Draining and Supplying D Engine Mount Bracket Removal and Installation (Refer
(Refer to GROUP 37A - On-vehicle Service.) to GROUP 32.)
D Radiator Removal and Installation (Refer to P.14-24.)
D A/C Compressor Removal and Installation
Bolt specifications
8 ´ 30
8 ´ 25
5
8 ´ 25
8 ´ 20
39 Nm
24 Nm
4
5
8 ´ 30 8 ´ 25
8 ´ 30
49 Nm Screw diameter ´ length mm
f3mm
1 2
5
3
12 Nm 39 Nm
18 Nm
Sealant:
Mitsubishi Genuine Part No.
Removal steps
1. Pressure tube connection 4. Engine support bracket
AA" 2. Power steering oil pump assembly "AA 5. Water pump
3. Power steering oil pump bracket
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

D Engine Coolant Draining and Supplying
(Refer to P.14-10.)
D Timing Belt Idler Pulley Removal and Installation
24 Nm
Bolt specifications
8 ´ 25 8 ´ 22
1
2 3
24 Nm 8 ´ 65
12 - 15 Nm 8 ´ 20
8 ´ 22
Screw diameter ´ length mm
Removal steps
1. Alternator brace
2. Water pump
3. Water pump gasket
"AA 4. O-ring

Water pump
"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
O-ring coolant.
Caution
Water inlet pipe assembly the O-ring
ENGINE COOLING - Water Hose and Water Pipe 14-19
WATER HOSE AND WATER PIPE 14100330306

<4G6>
D Engine Coolant Draining and Suppling
(Refer to P.14-10.)
and Installation
4
2 24 Nm
3
13 Nm 5
7
1 10
13 Nm 6
8 7
12
11
9
f3mm
Sealant:
Mitsubishi Genuine Part No.
Removal steps
AA" "CA 1. Radiator lower hose connection 6. Heater hose connection
2. Control wiring harness mounting "BA 7. Thermostat case assembly
bolt "AA 8. O-ring
3. Water inlet fitting 9. Heater hose connection
4. Engine coolant temperature gauge 10. Water hose
unit connector 11. Water inlet pipe assembly
5. Water hose "AA 12. O-ring
14-20 ENGINE COOLING - Water Hose and Water Pipe
<6A1>
D Engine Coolant Draining and Supplying D Distributor Removal and Installation
(Refer to P.14-10.) (Refer to GROUP 16.)
and Installation
10 - 12 Nm
22 - 25 Nm 2
9
8
1 5
7
6
10 13
3
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
1. Control wiring harness mounting 9. Heater hose connection
bolt 10. Heater pipe assembly
2. Spark plug cable clamp mounting "AA 11. O-ring
bolt 12. Water hose
AA" "CA 3. Radiator upper hose connection 13. Thermostat case assembly
AA" "CA 4. Radiator lower hose connection "AA 14. O-ring
5. Engine coolant temperature sensor 15. Water inlet pipe assembly
connector "AA 16. O-ring
6. Engine coolant temperature gauge 17. Water hose
unit connector 18. Water pipe assembly
7. Water hose 19. Water pipe joint
8. Water hose
<4D6>
Pre-removal operation Post-installation Operation
D Engine Coolant Draining (Refer to P.14-10.) D Engine Coolant Supplying (Refer to P.14-10.)
D Air Cleaner and Air Intake Hose Assembly Removal D Engine Oil Supplying and Checking (Refer to
GROUP 11 - On-vehicle Service.)
D Air Cleaner and Air Intake hose Assembly
Installation
8 11 17 Nm
7 9
10
20 - 25 Nm 17 Nm
1
7
45 Nm
6 Nm
10 - 12 Nm
2 6 9 Nm
6 Nm
10 - 13 Nm
12 - 15 Nm
5 12 - 15 Nm
4
10 - 12 Nm
12 - 15 Nm
12
13
12 - 15 Nm
Removal steps
1. Air hose and air pipe assembly 8. Air pipe bracket stay
AA" "CA 2. Radiator upper hose connection 9. Oil pipe assembly
AA" "CA 3. Radiator lower hose connection 10. Oil pipe assembly
4. Heater hose connection 11. Vacuum pump assembly
5. Turbocharger heat protector 12. Control wiring harness mounting
6. Oil return hose and pipe assembly bolt
7. Vacuum hose connection 13. Fuel pipe mounting bolt
14-22 ENGINE COOLING - Water Hose and Water Pipe
24 Nm
10 Nm 14
18
17
27 - 33 Nm
16 15
23
27 - 33 Nm
24
24 Nm
13 Nm 19 13 Nm
22
21
10 Nm
20
18 17
f3mm
f3mm
Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent
14. Water pipe assembly (A) 20. Heater hose connection

15. Water hose 21. Water hose
16. Water inlet fitting 22. Water pipe assembly (B)
"BA 17. Thermostat case assembly 23. Water inlet pipe assembly
"BA 18. Water outlet fitting "AA 24. O-ring
"AA 19. O-ring
HOSE DISCONNECTION
Thermostat case assembly, INSTALLATION SERVICE POINTS

water pump or cylinder block
Insert the O-ring to the water inlet pipe assembly or the heater
pipe assembly and coat the outer circumference of the O-ring
O-ring with water or engine coolant.
Caution
Water inlet pipe assembly or the O-ring
heater pipe assembly
"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.
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 Post-installation Operation
D Engine Coolant Draining (Refer to P.14-10.) D Engine Coolant Supplying (Refer to P.14-10.)
D Air Cleaner and Air Intake Hose Assembly Removal D A/T Fluid Supplying and Checking (Refer to GROUP
23 - On-vehicle Service.)
D Air Cleaner and Air Intake Hose Assembly
Installation
12 Nm
12 Nm 11 17
18
2
3 20
11 19
12 6
4
12 Nm
1
5 Nm
9
5
16
8
10
14
5 Nm
15
5 Nm
7 13
13
Radiator removal steps

1. Drain plug AB" 15. Transmission fluid cooler hose and
2. Radiator cap pipe assembly <A/T>
3. Overflow hose 16. Condenser fan motor assembly
4. Reserve tank <Vehicle with A/C>
5. Reserve tank bracket 17. Radiator fan motor assembly
AA" "AA 6. Radiator upper hose Radiator fan motor and fan
AA" "AA 7. Radiator lower hose controller assembly removal steps
8. Clamp <6A1 - A/T>
AB" 9. Transmission fluid cooler hose con- AA" "AA 6. Radiator upper hose
nection <A/T> 8. Clamp <6A1 - A/T>
10. Engine oil cooler hose mounting 14. Bolt <A/T>
bolt <4D6> 17. Radiator fan motor assembly
11. Upper insulator 18. Fan
12. Radiator assembly 19. Radiator fan motor and fan control-
13. Lower insulator ler assembly
14. Bolt <A/T> 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
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 AIR INTAKE PLENUM . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 2 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 13
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . 16

Turbocharger Supercharging Check . . . . . . . . . . . . 3
EXHAUST PIPE AND MAIN MUFFLER . . . . 22
Waste Gate Actuator Check . . . . . . . . . . . . . . . . . . 3
INTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
15-2 INTAKE AND EXHAUST - Service Specifications/Special Tool
The intake manifold is made of an aluminium alloy, The exhaust manifold is made of stainless steel.
and the shape provides an increased intake inertia The exhaust pipe is divided into three parts; the
effect and has a good volumetric efficiency. front pipe, the centre pipe, and the main muffler.
Manifold distortion of the installation surface mm 0.15 or less 0.20
Waste gate actuator activation pressure kPa Approx. 75 -
Air temperature switch _C OFF ® ON 57 or more -

<Vehicles with intercooler
turbocharger> ON ® OFF 45 or less -

MD998770 Oxygen sensor Removal/Installation of oxygen sensor
wrench
INTAKE AND EXHAUST - On-vehicle Service 15-3
TURBOCHARGER SUPERCHARGING CHECK

<4D6>
Caution
Conduct the driving test in a location where driving at
full acceleration can be done with safety. Two persons
should be in the vehicle when the test is conducted; the
person in the passenger seat should read the indications
shown by the pressure meter.
1. Connect the pressure gauge to the hose between the

turbochager and the waste gate actuator.
2. Drive at full-throttle acceleration in second gear and then
measure the supercharging when the engine speed in
about 3,000 r/min.
3. When the indicated supercharging does not become
positive pressure, check the following items.
D Malfunction of the waste gate actuator.
D Leakage of supercharging pressure.
D Malfunction of the turbocharger.
4. When the indicated supercharging is 76 kPa or more,
supercharging control may be faulty, therefore check the
followings.
D Disconnection or cracks of the waste gate actuator
rubber hose.
D Malfunction of the waste gate actuator.
D Malfunction of the waste gate valve.
WASTE GATE ACTUATOR CHECK <4D6>

15100120054
1. Connect a manual pump (pressure-application type) to

nipple A.
2. While gradually applying pressure, check the pressure
that begins to activate (approx. 1 mm stroke) the waste
gate actuator rod.
Standard value: Approx. 75 kPa
Caution
In order to avoid damage to the diaphragm, do not
apply a pressure of 109 kPa or higher.
3. If there is a significant deviation from the standard value,
check the actuator or the waste gate valve: replace if
necessary.
15-4 INTAKE AND EXHAUST - Intercooler
INTERCOOLER 15100420055
Hose clamp tightening Pipe installation bolt 3

torque tightening torque
10 - 13 Nm 5
6 Nm 4
8 9 10 - 13 Nm
10 - 13 Nm
6
11
10
Air hose and air pipe removal Intercooler assembly removal steps
steps "AA 6. Air hose C
"AA 1. Air hose E "AA 7. Air hose C
"AA 2. Air hose B 10. Intercooler duct
"BA 3. Air hose F 11. Intercooler assembly
"AA 4. Air hose A
5. Air pipe A
"AA 6. Air hose C
"AA 7. Air hose C
8. Air pipe B
9. Air pipe C
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

(Refer to GROUP 14 - On-vehicle Service.) (Refer to GROUP 14 - On-vehicle Service.)
D Air Cleaner Removal D Throttle Body Installation (Refer to GROUP 13A.)
D Throttle Body Removal (Refer to GROUP 13A.) D Air Cleaner Installation
3 Nm
4 14 Nm
8 5
1
9
4
6
3
2
18 Nm
12 7
10 - 12 Nm
13
14
15 11 9 Nm
10 19 Nm
9 Nm
18 Nm
15
Removal steps
1. Engine cover 8. Connector bracket mounting bolt
2. Crankshaft position sensor connector 9. Noise condenser mounting bolt
3. Injector connector 10. EGR valve
4. Vacuum hose connection 11. Solenoid valve assembly
5. Air pipe assembly mounting bolt 12. Vacuum pipe assembly
6. Brake booster vacuum hose connec- 13. Air intake plenum
tion "AA 14. Air intake plenum gasket
7. Connector bracket mounting bolt 15. Air intake plenum stay
INTAKE AND EXHAUST - Air Intake Plenum 15-7
"AA AIR INTAKE PLENUM GASKET INSTALLATION
Protrusion Front Install with gasket protrusions in the position illustrated.
15-8 INTAKE AND EXHAUST - Intake Manifold
INTAKE MANIFOLD 15100300441

<4G6>
D Engine Coolant Draining D Throttle Body Installation (Refer to GROUP 13A.)
(Refer to GROUP 14 - On-vehicle Service.) D Air Cleaner Installation
D Air Cleaner Removal D Engine Coolant Supplying
D Throttle Body Removal (Refer to GROUP 13A.) (Refer to GROUP 14 - On-vehicle Service.)
D Accelerator Cable Ajdustment
5
2
Removal steps
1. Accelerator cable
2. Brake booster vacuum hose
connection
3. Injector connector
4. EGR solenoid valve connector
5. Purge control solenoid valve
connector
INTAKE AND EXHAUST - Intake Manifold 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
6. EGR valve 10. Vacuum pipe assembly

7. PCV hose 11. Solenoid valve assembly
8. Fuel return hose connection 12. Intake manifold
AA" 9. Delivery pipe, injector and pressure 13. Intake manifold gasket
regulator 14. Intake manifold stay
<6A1>
Pre-removal Operation Post-Installation Operation
D Fuel Discharge Prevention D Air Intake Plenum Installation (Refer to P.15-6.)
(Refer to GROUP 13A - On-vehicle Service.) D Air Cleaner Installation
(Refer to GROUP 14 - On-vehicle Service.) (Refer to GROUP 14 - On-vehicle Service.)
D Air Cleaner Removal D Accelerator Cable Adjustment
D Air Intake Plenum Removal (Refer to P.15-6.) (Refer to GROUP 17 - On-vehicle Service.)
2
3
5
12 Nm
5 O-ring 3
Engine oil
4
35 Nm
18 Nm 6
7
8 1
18 Nm
Removal steps
1. Engine mount stay 6. PCV hose connection
2. Fuel return hose connection 7. Vacuum hose connection
"BA 3. Fuel high-pressure hose connection 8. Intake manifold
4. Injector connector "AA 9. Intake manifold gasket
AA" 5. Delivery pipe, injector and pressure
regulator
INTAKE AND EXHAUST - Intake Manifold 15-11
<4D6>
D Air Pipe A Removal and Installation
(Refer to P.15-4.)
10 - 12 Nm
18 Nm
1
12 - 15 Nm
25 Nm
4
6
8
5
18 Nm
18 Nm
18 Nm
10
7
12 - 15 Nm
Removal steps
1. Air inlet fitting 7. Rear heat protector
2. Brake booster vacuum hose 8. Vacuum hose
3. Vacuum hose 9. Intake manifold
4. Throttle body assembly D Turbocharger (Refer to P.15-6.)
5. EGR valve and pipe assembly 10. Intake and exhaust manifold gasket
6. Turbocharger heat protector

AA" DELIVERY PIPE, INJECTOR AND PRESSURE
REGULATOR REMOVAL
Remove the delivery pipe (with the injectors and pressure
regulator attached to it).
Caution
Protrusion
Front
"AA INTAKE MANIFOLD GASKET INSTALLATION
Install gasket with its protrusion in the position illustrated.
Protrusion
"BA HIGH-PRESSURE FUEL HOSE INSTALLATION

1. When connecting the high-pressure fuel hose to the
Delivery pipe
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
O-ring pipe.
High-pressure fuel hose 2. While turning the high-pressure fuel hose to the left and
right, install it to the delivery pipe.
3. Check to be sure that the injector turns smoothly.
If it does not turn smoothly, the O-ring may be trapped,
remove the high-pressure fuel hose and then re-insert
Check the following points; replace the part if a problem is

found.
INTAKE MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Check for obstruction of the negative pressure (vacuum)
outlet port, and for obstruction of the water passage or
gas passage.
3. Using a straight edge and thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
INTAKE AND EXHAUST - Exhaust Manifold 15-13
EXHAUST MANIFOLD 15100330440

D Front Exhaust Pipe Removal and Installation
(Refer to P.15-22.)
<4G6>
29 Nm
49 Nm
12 - 15 Nm
2
49 Nm
Removal steps
1. Exhaust manifold cover
2. Exhaust manifold
3. Exhaust manifold gasket
15-14 INTAKE AND EXHAUST - Exhaust Manifold
<6A1>
12 - 15 Nm
12 - 15 Nm 4 1
3
49 Nm
4
12 - 15 Nm
49 Nm 2
3
34 Nm
2
44 Nm
Removal steps
1. Heat protector
2. Exhaust manifold stay
3. Exhaust manifold
4. Exhaust manifold gasket
INTAKE AND EXHAUST - Exhaust Manifold 15-15
<4D6>
29 Nm
14 Nm
4
29 Nm 1
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
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 Coolant Draining and Supplying D Front Exhaust Pipe and Front Heat Protector Removal
D Engine Oil Draining and Supplying and Installation (Refer to P.15-15, 23.)
D Intake Manifold Removal and Installation (Refer to
P.15-8.)
25 Nm
17 Nm
18 Nm
2
10 - 12 Nm
12 - 15 Nm 4
10 Nm
6
5
6 Nm
1 9
3
27 - 33 Nm
14
11
13 12 - 15 Nm
12 - 15 Nm 12 7
59 Nm
10 Nm
15
59 Nm
12 - 15 Nm
8 27 - 33 Nm
59 Nm
9 Nm
10
Removal steps
1. Air hose A 9. Rear heat protector
2. EGR valve and pipe assembly 10. Exhaust fitting heat protector
3. Turbocharger heat protector 11. Turbocharger assembly
AA" 4. Oil pipe assembly A 12. Exhaust fitting assembly
AA" 5. Oil pipe assembly B 13. Exhaust fitting gasket
6. Water pipe assembly A "AA 14. Turbocharger
7. Water pipe assembly B 15. Turbocharger gasket
AA" 8. Oil return pipe
INTAKE AND EXHAUST - Turbocharger 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.
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.
Compressor D Check whether or not the waste gate valve remains open.
wheel 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.
DISASSEMBLY AND REASSEMBLY

2
9
10
8 1
7
5
6
Disassembly steps
1. Hose clip "DA 6. Turbine housing
2. Hose AA" "CA 7. Snap ring
3. Snap ring (E-ring) AB" "BA 8. Turbine wheel assembly
"FA 4. Turbocharger waste gate actuator 9. Compressor cover
"EA 5. Coupling "AA 10. O-ring
DISASSEMBLY SERVICE POINTS

AA" SNAP RING REMOVAL
Lay the unit with the compressor cover side facing down
and using snap ring pliers, remove the compressor cover
attaching snap ring.
Caution
When removing the snap ring, hold it with fingers to
Snap ring
prevent it from springing away.
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.
REASSEMBLY SERVICE POINTS

Apply a light coat of engine oil to a new O-ring and fit in
the turbine wheel assembly groove.
Caution
O-ring When installing the O-ring, use care not to damage it.
A damaged O-ring causes oil leaks.
Dowel pin hole

"BA TURBINE WHEEL ASSEMBLY
1. Apply a light coat of engine oil to the periphery of the
Dowel pin
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.
Chamfered "CA SNAP RING INSTALLATION

Snap ring edge
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
"DA TURBINE HOUSING INSTALLATION

Install the turbine housing while aligning the dowel pin with
the hole.
Caution
Dower pin 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.
COMPRESSOR COVER
Oil passage
Check the compressor cover for traces of contact with the
Turbine wheel 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.
Water passage 2. Check the oil passage of the turbine wheel assembly
Compressor for deposit and clogging.
wheel
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

D Under Cover Removal and Installation
<4G6>
Hanger installation
bolt tightening torque
3, 10, 17
6 13 Nm
13 Nm
4
13 Nm 5
34 Nm 3 3
49 Nm 49 - 59 Nm 11
7
34 Nm
49 - 59 Nm 49 Nm
16 18 13 13 Nm
14 1
3
2
8 10
9 10
34 Nm 12
15
44 Nm 17
Main muffler removal steps Catalytic converter removal steps

1. Main muffler assembly 12. Catalytic converter
2. Gasket 13. Gasket
3. Hanger
4. Tail hanger Front exhaust pipe removal steps
5. Rear hanger
6. Rear floor heat protector panel AA" "AA 14. Oxygen sensor
15. Front exhaust pipe
16. Gasket
Center exhaust pipe removal steps 17. Hanger
AA" "AA 7. Oxygen sensor 18. Front exhaust pipe bracket
8. Center exhaust pipe
9. Gasket
10. Hanger
11. Center hanger
INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler 15-23
Hanger installation
bolt tightening torque
6
3, 10, 17
13 Nm
3
13 Nm 34 Nm 13 Nm
5 4
11 3
<6A1> 49 - 59 Nm
16 49 Nm 7 13 Nm
16
49 Nm 49 - 59 Nm
14 1
3
8
49 Nm 2
9
12 10
10
49 Nm
13
15 6
17
13 Nm
3
13 Nm
3
<4D6> 5 4
11
34 Nm
16 49 Nm
13 Nm
49 Nm
13
15
1
3
2
8 10
10
9
49 Nm 12
17
Main muffler removal steps Catalytic converter removal steps

1. Main muffler assembly 12. Catalytic converter
2. Gasket 13. Gasket
3. Hanger
4. Tail hanger Front exhaust pipe removal steps
5. Rear hanger
6. Rear floor heat protector panel AA" "AA 14. Oxygen sensor
16. Gasket
Center exhaust pipe removal steps 17. Hanger
AA" "AA 7. Oxygen sensor
8. Center exhaust pipe
9. Gasket
10. Hanger
11. Center hanger
15-24 INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler

AA" OXYGEN SENSOR REMOVAL

"AA OXYGEN SENSOR INSTALLATION
MD998770
16-1
ENGINE
ELECTRICAL
CHARGING SYSTEM . . . . . . . . . . . . . . . . 3 IGNITION SYSTEM <4G6, 6A1> . . . . . 35

GENERAL INFORMATION . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . 35
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 5 SERVICE SPECIFICATIONS . . . . . . . . . . . . 37
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 37
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 6 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 38

Alternator Output Line Voltage Drop Test . . . . 6 Power Transistor Continuity Check <4G6>
Output Current Test . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Regulated Voltage Test . . . . . . . . . . . . . . . . . . . 10 Ignition Coil Check <6A1> . . . . . . . . . . . . . . . . 38

Power Transistor Continuity Check <6A1> . . 39
Waveform Check Using An Analyzer . . . . . . . 12
Resistive Cord Check . . . . . . . . . . . . . . . . . . . . . 39
Alternator Relay Continuity Check . . . . . . . . . 13
Spark Plug Check and Cleaning <4G6> . . . . 39
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . 14 Spark Plug Check <6A1> . . . . . . . . . . . . . . . . . 40
Camshaft Position Sensor Check <4G6> . . . 40
STARTING SYSTEM . . . . . . . . . . . . . . . . 23
Top Dead Center Sensor Check <6A1> . . . . 40
GENERAL INFORMATION . . . . . . . . . . . . . . 23 Crank Angle Center Sensor Check . . . . . . . . 40
Detonation Sensor Check . . . . . . . . . . . . . . . . . 41
SERVICE SPECIFICATIONS . . . . . . . . . . . . 23
Waveform Check Using An Analyzer . . . . . . . 41
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 24
Starter Relay Continuity Check <4D6> . . . . . 24
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . 24
16-2
DISTRIBUTOR <6A1> . . . . . . . . . . . . . . . . . . 52 Self-regulating Glow System Check . . . . . . . . 58

Check at the Engine-ECU Terminals . . . . . . . 59
IGNITION COIL <4G6> . . . . . . . . . . . . . . . . . 54
Glow Plug Relay Check . . . . . . . . . . . . . . . . . . 60
CAMSHAFT POSITION SENSOR <4G6> Glow Plug Check . . . . . . . . . . . . . . . . . . . . . . . . 60
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Engine Coolant Temperature Sensor Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
CRANK ANGLE SENSOR . . . . . . . . . . . . . . 55
GLOW PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DETONATION SENSOR . . . . . . . . . . . . . . . . 56
INJECTION SYSTEM <4D6> . . . . . . . . 62
GLOW SYSTEM <4D6> . . . . . . . . . . . . . 57
GENERAL INFORMATION . . . . . . . . . . . . . . 62
GENERAL INFORMATION . . . . . . . . . . . . . . 57
CRANK ANGLE SENSOR . . . . . . . . . . . . . . 62
ENGINE ELECTRICAL - Charging System 16-3
CHARGING SYSTEM 16100010341
GENERAL INFORMATION
The charging system uses the alternator output
to keep the battery charged at a constant level
under various electrical loads.
Voltage OPERATION
Rotation of the excited field coil generates AC voltage in
the stator.
This alternating current is rectified through diodes to DC
voltage having a waveform shown in the illustration at left.
Approx. 14.4 V The average output voltage fluctuates slightly with the
alternator load condition.
Time
When the ignition switch is turned on, current flows of approx. 14.4 V, the field current is cut off. When
in the field coil and initial excitation of the field the battery voltage drops below the regulated
coil occurs. voltage, the voltage regulator regulates the output
When the stator coil begins to generate power after voltage to a constant level by controlling the field
the engine is started, the field coil is excited by current.
the output current of the stator coil. In addition, when the field current is constant, the
The alternator output voltage rises as the field alternator output voltage rises as the engine speed
current increases and it falls as the field current increases.
decreases. When the battery voltage (alternator
S terminal voltage) reaches a regulated voltage
16-4 ENGINE ELECTRICAL - Charging System
SYSTEM DIAGRAM
<4G6, 6A1>
Stator coil
Engine-ECU
Field coil G
S
L
+
Voltage
regulator FR
Ignition
Charging switch Battery
warning lamp
-
<4D6>
Stator coil
Charging
warning lamp Ignition
switch
Field coil
Voltage +
regulator
Battery
-
ALTERNATOR SPECIFICATIONS
Items 4G6 6A1 4D6
Type Battery voltage sensing Battery voltage sensing Battery voltage sensing
Rated output V/A 12/90 12/85 <M/T>, 12/100 <A/T> 12/100 <Except cold climate zone>,
12/120 <Cold climate zone>
Voltage regulator Electronic built-in type Electronic built-in type Electronic built-in type
Alternator output line voltage drop (at 30A) V - max. 0.3
Regulated voltage ambient - 20_C 14.2 - 15.4 -

temp. at voltage regulator V
20_C 13.9 - 14.9 -
60_C 13.4 - 14.6 -
80_C 13.1 - 14.5 -
Output current - 70% of normal output current

MB991519 Alternator test Checking the alternator (S terminal voltage)
harness <4G6, 6A1>
MB991450 Alternator test Checking the alternator (S terminal voltage)

harness <4D6>
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST
+ -
Alternator Ammeter
Voltmeter
Battery
Terminal B + -
This test determines whether the wiring from the output wire. (Connect the (+) lead of the
alternator “B” terminal to the battery (+) terminal ammeter to the “B” terminal, and then connect
(including the fusible line) is in a good condition the ( - ) lead of the ammeter to the disconnected
or not. output wire.)
(1) Always be sure to check the following before NOTE
the test. An inductive-type ammeter which enables
D Alternator installation measurements to be taken without
D Alternator drive belt tension disconnecting the alternator output wire should
D Fusible link be recommended. Using this equipment will
D Abnormal noise from the alternator while lessen the possibility of a voltage drop caused
the engine is running by a loose “B” terminal connection.
(2) Turn the ignition switch off.
(3) Disconnect the negative battery cable. (5) Connect a digital-type voltmeter between the
(4) Disconnect the alternator output wire from the alternator “B” terminal and the battery (+)
alternator “B” terminal and connect a DC test terminal. (Connect the (+) lead of the voltmeter
ammeter with a range of 0 - 100 A in series to the “B” terminal and the connect the ( - ) lead
between the “B” terminal and the disconnected of the voltmeter to the battery (+) cable.)
(6) Reconnect the negative battery cable. (11)If the value displayed on the voltmeter is above
(7) Connect a tachometer or the MUT-II. the limit value, there is probably a malfunction
(8) Leave the hood open. in the alternator output wire, so check the wiring
(9) Start the engine. between the alternator “B” terminal and the
(10)With the engine running at 2,500 r/min, turn battery (+) terminal (including fusible link).
the headlamps and other lamps on and off If a terminal is not sufficiently tight or if the
to adjust the alternator load so that the value harness has become discolored due to
displayed on the ammeter is slightly above 30 overheating, repair and then test again.
A. (12)After the test, run the engine at idle.
Adjust the engine speed by gradually (13)Turn off all lamps and the ignition switch.
decreasing it until the value displayed on the (14)Remove the tachometer or the MUT-II.
ammeter is 30 A. Take a reading of the value (15)Disconnect the negative battery cable.
displayed on the voltmeter at this time. (16)Disconnect the ammeter and voltmeter.
Limit: max. 0.3 V (17)Connect the alternator output wire to the
alternator “B” terminal.
NOTE (18)Connect the negative battery cable.
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.
OUTPUT CURRENT TEST 16100100314
<4G6, 6A1>
Load
Voltmeter
Ammeter
Charging warning lamp
Ignition switch
Alternator relay
- + + -
B
FR
L
S
G
Battery
Alternator
Engine
-ECU
<4D6>
Load
Charging warning Alternator
lamp
Ignition
switch L
B
Alternator relay
S
Voltmeter
Ammeter
Battery
- + + -
This test determines whether the alternator output (10)Turn the light switch on to turn on headlamps
current is normal. and then start the engine.
(1) Before the test, always be sure to check the (11)Immediately after setting the headlamps to high
following. beam and turning the heater blower switch to
D Alternator installation the high revolution position, increase the engine
D Battery speed to 2,500 r/min and read the maximum
NOTE current output value displayed on the ammeter.
The battery should be slightly discharged. Limit: 70% of normal current output
The load needed by a fully-charged battery NOTE
is insufficient for an accurate test. D For the nominal current output, refer to the
D Alternator drive belt tension Alternator Specifications.
D Fusible link D Because the current from the battery will
D Abnormal noise from the alternator while soon drop after the engine is started, the
the engine is running. above step should be carried out as quickly
(2) Turn the ignition switch off. as possible in order to obtain the maximum
(3) Disconnect the negative battery cable. current output value.
(4) Disconnect the alternator output wire from the D The current output value will depend on
alternator “B” terminal. Connect a DC test the electrical load and the temperature of
ammeter with a range of 0 - 100 A in series the alternator body.
between the “B” terminal and the disconnected D If the electrical load is small while testing,
output wire. (Connect the (+) lead of the the specified level of current may not be
ammeter to the “B” terminal. Connect the ( - ) output even though the alternator is normal.
lead of the ammeter to the disconnected output In such cases, increase the electrical load
wire.) by leaving the headlamps turned on for
Caution some time to discharge the battery or by
Never use clips but tighten bolts and nuts using the lighting system in another vehicle,
to connect the line. Otherwise loose and then test again.
connections (e.g. using clips) will lead to D The specified level of current also may not
a serious accident because of high current. be output if the temperature of the alternator
NOTE body or the ambient temperature is too
An inductive-type ammeter which enables high. In such cases, cool the alternator and
measurements to be taken without then test again.
disconnecting the alternator output wire should (12)The reading on the ammeter should be above
be recommended. the limit value. If the reading is below the limit
value and the alternator output wire is normal,
(5) Connect a voltmeter with a range of 0 - 20 V remove the alternator from the engine and
between the alternator “B” terminal and the check the alternator.
earth. (Connect the (+) lead of the voltmeter (13)Run the engine at idle after the test.
to the “B” terminal, and then connect the ( - ) (14)Turn the ignition switch off.
lead of the voltmeter to the earth.) (15)Remove the tachometer or the MUT-II.
(6) Connect the negative battery cable. (16)Disconnect the negative battery cable.
(7) Connect a tachometer or the MUT-II. (17)Disconnect the ammeter and voltmeter.
(8) Leave the hood open. (18)Connect the alternator output wire to the
(9) Check that the reading on the voltmeter is equal alternator “B” terminal.
to the battery voltage. (19)Connect the negative battery cable.
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.
REGULATED VOLTAGE TEST 16100110317
<4G6, 6A1>
Load
Charging warning
Ignition lamp
switch MB991519
Alternator
FR
Alternator relay L
S
G
Yellow
Engine-
ECU Ammeter
Voltmeter
Battery
- +
+ -
<4D6>
Load
Ignition Charging warning
switch Alternator
lamp MB991450
L
Alternator relay
S B
Ammeter
Voltmeter
Battery + -
- + Yellow
This test determines whether the voltage regulator NOTE
is correctly controlling the alternator output voltage. If the voltage is 0 V, the cause is probably
(1) Always be sure to check the following before an open circuit in the wire or fusible link between
the test. the alternator “S” terminal and the battery (+)
D Alternator installation terminal.
D Check that the battery installed in the (10)Turn all lamps and accessories off.
vehicle is fully charged. (11)Start the engine.
D Alternator drive belt tension (12)Increase the engine speed to 2,500 r/min.
D Fusible link (13)Read the value displayed on the voltmeter when
D Abnormal noise from the alternator while the alternator output current alternator
the engine is running becomes 10 A or less.
(2) Turn the ignition switch to the OFF position. (14)If the voltage reading conforms to the value
(3) Disconnect the negative battery cable. in the voltage regulation, then the voltage
(4) Use the special tool (Alternator test harness: regulator is operating normally.
MB991519, MB991450) to connect a digital If the voltage is not within the standard value,
voltmeter between the alternator S terminal and there is a malfunction of the voltage regulator
earth. (Connect the (+) lead of the voltmeter or of the alternator.
to the ”S” terminal, and then connect the (-) (15)After the test, lower the engine speed to the
lead of the voltmeter to a secure earth or to idle speed.
the battery (-) terminal.) (16)Turn the ignition switch off.
(5) Disconnect the alternator output wire from the (17)Remove the tachometer or the MUT-II.
alternator “B” terminal. (18)Disconnect the negative battery cable.
(6) Connect a DC test ammeter with a range of (19)Disconnect the ammeter and voltmeter.
0 - 100 A in series between the “B” terminal (20)Connect the alternator output wire to the
and the disconnected output wire. (Connect alternator “B” terminal.
the (+) lead of the ammeter to the “B” terminal. (21)Remove the special tool, and return the
Connect the ( - ) lead of the ammeter to the connector to the original condition.
disconnected output wire.) (22)Connect the negative battery cable.
(7) Reconnect the negative battery cable.
(8) Connect a tachometer or the MUT-II.
(9) Turn the ignition switch to the ON position and
check that the reading on the voltmeter is equal
to the battery voltage.
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
Special
Analyzer
WAVEFORM CHECK USING AN ANALYZER
patterns
Alternator pickup
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 wave-

form.
PATTERN SELECTOR RASTER
Engine speed Curb idle speed
0.4
0.2
Voltage at
alternator 0
B terminal
- 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.
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 Abnormal waveforms Problem
cause cause
Example 1 D Open Example 4 D Short in
diode stator coil
Example 2 D Short in Example 5 D Open

diode supple-
mentary
diode
Example 3 D Broken
wire in
stator coil
At this time, the charging warning lamp

is illuminated.
ALTERNATOR RELAY CONTINUITY CHECK

16100190045
Alternator
relay 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.
1 2
3 4
ALTERNATOR 16100140286

<4G6>
D Under Cover Removal (R.H. side) D Engine Mount Bracket Installation
D Engine Mount Bracket Removal (Refer to GROUP 32.)
(Refer to GROUP 32.) D Under Cover Installation (R.H. side)
D Drive Belt Tension Adjustment
12 Nm
1
2
12 Nm
12 Nm
1
6
9 Nm
20 - 25 Nm
4
8
24 Nm 44 Nm
7
5
Removal steps
1. Oil pressure hose and tube assembly 5. Water pump pulley
clamp bolt 6. Alternator connector
2. Oil return tube assembly clamp bolt 7. Alternator
AA" 3. Drive belt (Power steering, A/C) 8. Alternator brace
<6A1>
Solenoid Valve Assembly Removal D Solenoid Valve Assembly Installation
(Refer to GROUP 15 - Air Intake Plenum.) (Refer to GROUP 15 - Air Intake Plenum.)
12 Nm
1
3
4
5
18 Nm
22 Nm
44 Nm
24 Nm
Removal steps
1. Oil pressure hose and tube assembly 4. Air intake plenum stay
clamp bolt 5. Alternator brace
2. Drive belt (Alternator) 6. Alternator
3. Alternator connector
<4D6>
D Under Cover Removal (R.H. side) D Engine Mount Bracket Installation
D Engine Mount Bracket Removal (Refer to GROUP 32.)
(Refer to GROUP 32.) D Under Cover Installation (R.H. side)
(Refer to GROUP 11C On-vehicle Service.)
12 - 15 Nm
1
2 24 Nm
7 12 Nm
1
29 Nm
11
10
44 Nm
8
24 Nm 9
5 9 Nm
Removal steps
1. Oil pressure hose and tube assembly 6. Water pump pulley
clamp bolt 7. Alternator connector
2. Oil level gauge guide assembly 8. Alternator
mounting bolt 9. Alternator brace
AB" 3. Drive belt (Power steering) 10. Engine hanger
AC" 4. Drive belt (A/C) 11. Alternator brace stay
AA" DRIVE BELT (POWER STEERING, A/C)
REMOVAL
B 1. Loosen nut “A” for holding the tension pulley.
2. Loosen bolt “B” for adjustment.
3. Remove the drive belt.
A
AB" DRIVE BELT (POWER STEERING) REMOVAL

Power steering Loosen the power steering oil pump fixing bolt, and then
oil pump
remove the drive belt.
AC" DRIVE BELT (A/C) REMOVAL

1. Loosen tension pulley fixing nut “A”.
A 2. Loosen adjusting nut “B”, and then remove the drive belt.
B
1 3 4
12 14
2
9
13
8
11
10
Disassembly steps
AA" 1. Front bracket assembly AC" 8. Stator
AB" 2. Alternator pulley 9. Plate
"BA 3. Rotor AC" "AA 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Slinger
6. Front bearing 13. Rectifier
7. Front bracket 14. Rear bracket
AA" FRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdriver, etc., in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
The stator coil could be damaged so do not insert the
screwdriver too far.
AB" ALTERNATOR PULLEY REMOVAL

Face the pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care so that the rotor is not damaged.
AC" STATOR/REGULATOR ASSEMBLY REMOVAL

Soldered
(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.

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
"BA ROTOR INSTALLATION

Wire
After installing the rotor, remove the wire used to fix the brush.
ROTOR CHECK
1. Check the continuity between the rotor coil slip rings,
and replace the rotor if the resistance value is not at
the standard value.
Standard value: 3 - 5 W
2. Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.
STATOR CHECK
1. Check the continuity between the coil leads, and if there
is continuity, replace the stator.
2. Check the continuity between the coil and core, and if

there is continuity, replace the stator.
RECTIFIER CHECK
1. Inspect the (+) heat sink by checking the continuity
between the (+) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
2. Inspect the ( - ) heat sink by checking the continuity

between the ( - ) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.
3. Check the diode trio by connecting an ohmmeter to both

ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the rectifier.
BRUSH CHECK
1. Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Protrusion Limit: 2 mm or less
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.
ENGINE ELECTRICAL - Starting System 16-23
STARTING SYSTEM 16200010290
GENERAL INFORMATION
If the ignition switch is turned to the ”START” and M terminal to conduct. Thus, current flows to
position, current flows in the pull-in and holding engage the starter motor.
coils provided inside magnetic switch, attracting When the ignition switch is returned to the “ON”
the plunger. When the plunger is attracted, the position after starting the engine, the starter clutch
lever connected to the plunger is actuated to is disengaged from the ring gear.
engage the starter clutch. An overrunning clutch is provided between the
On the other hand, attracting the plunger will turn pinion and the armature shaft, to prevent damage
on the magnetic switch, allowing the B terminal to the starter.
SYSTEM DIAGRAM
Holding coil Plunger
Pull-in coil 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 4D6 <Except mod- 4D6 <Models for
models for cold climate> climate>, 4G6-A/T, 6A1 els for cold climate> cold climate>
Type Direct drive Reduction drive with Reduction drive with Reduction drive
planetary gear 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 8 8 10 12
Items 4G6 <Models for cold climate>, 4G6 <Except models cold climate>,
6A1 4D6
Pinion gap mm 0.5 - 2.0 0.5 - 2.0
Commutator outer diameter Standard value 29.4 32.0
mm
Limit 28.4 31.0
Commutator runout mm Standard value 0.05 0.05
Limit 0.1 0.1
Commutator undercut mm Standard value 0.5 0.5
Limit 0.2 0.2
16-24 ENGINE ELECTRICAL - Starting System
STARTER RELAY CONTINUITY CHECK <4D6>

Starter 1 3 4 5
relay Not supplied
Supplied
<4G6> Switch STARTER MOTOR 16200110242
INSPECTION
S PINION GAP ADJUSTMENT
Battery M
B 1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12V battery between S-terminal and
Field coil wire M-terminal.
3. Set switch to “ON”, and pinion will move out.
Caution
This test must be performed quickly (in less than
<6A1> Switch 10 seconds) to prevent coil from burning.
B
Battery S
M
Field
coil wire
<4D6> Switch
B
Battery
S
M
Field
coil wire
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.
<4G6> MAGNETIC SWITCH PULL-IN TEST

1. Disconnect field coil wire from M-terminal of magnetic
S
switch.
2. Connect a 12V battery between S-terminal and
Battery M M-terminal.
Caution
Field coil wire
10 seconds) to prevent coil from burning.
3. If pinion moves out, then pull-in coil is good. If it doesn’t,
replace magnetic switch.
<6A1>
Battery
S
M
Field
coil wire
<4D6>
Battery
S
M
Field
coil wire
<4G6> MAGNETIC SWITCH HOLD-IN TEST

switch.
S 2. Connect a 12V battery between S-terminal and body.
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
S
Field
coil wire
<4D6>
Battery
S
Field
coil wire
<4G6> Carbon-pile rheostat FREE RUNNING TEST

S 1. Place starter motor in a vise equipped with soft jaws
Ammeter and connect a fully-charged 12-volt battery to starter motor
M B as follows:
2. Connect a test ammeter (100-ampere scale) and carbon
Battery pile rheostat in series with battery positive post and starter
Starter motor terminal.
motor Voltmeter 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
<6A1> Carbon-pile rheostat the voltmeter is 11 V.
B 7. Confirm that the maximum amperage is within the
S
Ammeter specifications and that the starter motor turns smoothly
and freely.
M Battery Current: max. 60 Amps
Voltmeter
<4D6> Carbon-pile rheostat
B
Ammeter
S
M Battery
Voltmeter
<4G6> MAGNETIC SWITCH RETURN TEST

switch.
2. Connect a 12V battery between M-terminal and body.
Battery M Caution
Field coil wire
3. Pull pinion out and release. If pinion quickly returns to
its original position, everything is in order. If it doesn’t,
replace magnetic switch.
Caution
<6A1>
Be careful not to get your fingers caught when pulling
out the pinion.
Battery
M
Field
coil wire
<4D6>
Battery
M
Field
coil wire
<DIRECT DRIVE TYPE>
7
1 3 5
13
8
16 9
12
18
14 17
15
10
11
Disassembly steps
1. Screw 9. Brush holder
AA" 2. Magnetic switch 10. Yoke assembly
3. Packing 11. Brush
4. Plate 12. Armature
5. Screw 13. Lever
6. Through bolt 14. Washer
7. Rear bracket AC" "AA 15. Snap ring
8. Rear bearing AC" "AA 16. Stop ring
17. Overrunning clutch
18. Front bracket
<PLANETARY GEAR REDUCTION DRIVE TYPE FOR PETROL ENGINE>
2
13
23
14
17
1 10
15
12 5
16
20
22
18
11
21
8
19
4 3
7
6
9
Disassembly steps
1. Screw 13. Packing A
AA" 2. Magnetic switch 14. Packing B
3. Starter cover 15. Plate
4. Screw 16. Planetary gear
5. Through bolt 17. Lever
7. Brush holder AC" "AA 19. Stop ring
8. Brush 20. Overrunning clutch
9. Rear bearing 21. Internal gear
AB" 10. Armature 22. Planetary gear holder
11. Yoke assembly 23. Front bracket
AB" 12. Ball
<PLANETARY GEAR REDUCTION DRIVE TYPE FOR DIESEL ENGINE>

2
11
13
12
15
16
4
14
21
23
22 3
6
17
1
20 7
18 19 5
9
8
10
Disassembly steps
1. Screw 13. Plate
AA" 2. Magnetic switch AB" 14. Ball
3. Screw 15. Planetary gear
4. Through bolt 16. Lever
6. Brush holder AC" "AA 18. Stop ring
7. Yoke assembly 19. Overrunning clutch
8. Brush 20. Internal gear
AB" 9. Armature 21. Washer
10. Bearing 22. Planetary gear holder
11. Packing A 23. Front bracket
12. Packing A
S terminal DISASSEMBLY SERVICE POINTS

Magnetic
switch AA" MAGNETIC SWITCH REMOVAL
M terminal 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
AC" SNAP RING/STOP RING REMOVAL
1. Using an appropriate wrench socket, push the stop ring
toward the overrunning clutch.
Stop ring
Pinion gear
Overrunning
clutch
Armature
2. Remove the snap ring with snap ring pliers and then
Snap ring remove the stop ring and overrunning clutch.
Snap ring pliers
Pinion gear
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.

"AA STOP RING/SNAP RING INSTALLATION
Using an appropriate tool, pull the stop ring over the snap
ring.
Stop ring
Overrunning
Stop ring clutch
Snap ring
COMMUTATOR
1. Place the armature in a pair of “V” blocks and check
the runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm
2. Measure the commutator outer diameter.

Direct drive type and planetary gear reduction drive
type (for diesel engine)
Limit: 31.0 mm
Planetary gear reduction drive type (for petrol engine)
Limit: 28.4 mm
3. Check the undercut depth between segments.

Undercut Standard value: 0.5 mm
Segment Limit: 0.2 mm
Mica
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
FIELD COIL GROUND TEST - Except planetary gear
reduction drive type (for petrol engine)
Field brush
Check the continuity between field coil brush and yoke. If
there is no continuity, the field coil is free from earth.
Yoke
BRUSH HOLDER
Check the continuity between brush holder plate and brush
Brush holder holder.
If there is no continuity, the brush holder is in order.
OVERRUNING CLUTCH
1. Check that the pinion locks when it is turned
counterclockwise and moves smoothly when it is turned
clockwise.
2. Check the pinion for wear or damage.
Free
Lock
BRUSH
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length.
Limit: Wear limit line
2. In case the contacting surface has been corrected or
Wear limit line 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,

New brush use care to prevent damage to the pigtail.
Pigtail Soldered 4. Polish the pigtail end for secure soldering.
(Make sure that
there is no
5. Insert the pigtail into the hole of a new brush and solder.
excess solder Make sure that there is no excess solder on the brush
on blush surface.
surface)
Mark
ARMATURE COIL SHORT-CIRCUIT TEST

Growler
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 armature surface thoroughly before
checking.
3. Check the insulation between each commutator segment

and armature coil core.
If there is no continuity, the insulation is in order.
ARMATURE COIL OPEN-CIRCUIT INSPECTION

Check the continuity between segments. If there is continuity,
the coil is in order.
ENGINE ELECTRICAL - Ignition System <4G6, 6A1> 16-35
IGNITION SYSTEM <4G6, 6A1> 16300010316
GENERAL INFORMATION
<4G6>
This system is equipped with two ignition coils (A inside the ignition coils alternately on and off. This
and B) with built-in power transistors for the No. causes the primary currents in the ignition coils
1 and No. 4 cylinders and the No. 2 and No. 3 to be alternately interrupted and allowed to flow
cylinders respectively. to fire the cylinders in the order 1 - 3 - 4 - 2.
Interruption of the primary current flowing in the The engine-ECU determines which ignition coil
primary side of ignition coil A generates a high should be controlled by means of the signals from
voltage in the secondary side of ignition coil A. the camshaft position sensor which is incorporated
The high voltage thus generated is applied to the in the camshaft and from the crank angle sensor
spark plugs of No. 1 and No. 4 cylinders to generate which is incorporated in the crankshaft. It also
sparks. At the time that the sparks are generated detects the crankshaft position in order to provide
at both spark plugs, if one cylinder is at the ignition at the most appropriate timing in response
compression stroke, the other cylinder is at the to the engine operation conditions. It also detects
exhaust stroke, so that ignition of the compressed the crankshaft position in order to provide ignition
air/fuel mixture occurs only for the cylinder which at the most appropriate timing in response to the
is at the compression stroke. engine operation conditions.
In the same way, when the primary current flowing When the engine is cold or operated at high
in ignition coil B is interrupted, the high voltage altitudes, the ignition timing is slightly advanced
thus generated is applied to the spark plugs of to provide optimum performance.
No. 2 and No. 3 cylinders. Furthermore, if knocking occurs, the ignition timing
The engine-ECU turns the two power transistors is gradually retarded until knocking ceases.
SYSTEM DIAGRAM
Air flow sensor
Ignition coil A

Camshaft position sensor Engine-ECU Ignition coil B
Ignition
Crank angle sensor switch
Ignition switch - ST
Detonation sensor
Vehicle speed sensor
Inhibitor switch <A/T> Battery
Spark plugs
A/T-ECU Cylinder No. 3 2 1 4
To tachometer
16-36 ENGINE ELECTRICAL - Ignition System <4G6, 6A1>
<6A1>
Interruption of the primary current flowing in the by the crank angle sensor incorporated in the
primary side of the ignition coil generates high distributor to provide ignition at the most appropriate
voltage in the secondary side of the ignition coil. timing for the engine operating condition.
The high voltage thus generated is directed by When the engine is cold or operated at a high
the distributor to the applicable spark plug. The altitude, the ignition timing is slightly advanced to
engine firing order is 1 - 2 - 3 - 4 - 5 - 6 cylinders. provide optimum performance to the operating
On application of high voltage, the spark plug condition.
generates a spark to ignite the compressed air Furthermore, if knocking occurs, the ignition timing
fuel mixture in the combustion chamber. is gradually retarded until knocking ceases.
The engine-ECU makes and breaks the primary When the automatic transmission shifts gears, the
current of the ignition coil to regulate the ignition ignition timing is also retarded in order to reduce
timing. output torque, thereby alleviating shifting shocks.
The engine-ECU detects the crankshaft position
SYSTEM DIAGRAM
Air flow sensor

Engine coolant temperature sensor Top dead
centre sensor
Idle position switch Engine-ECU
Crank angle sensor Spark
plug
Power
Detonation sensor transistor
Ignition switch - ST
Inhibitor switch <A/T>
Distributor
A/T-ECU
DISTRIBUTOR SPECIFICATIONS
Items 6A1
Type Contact pointless
Advance mechanism Electronic
Firing order 1- 2- 3- 4- 5- 6
IGNITION COIL SPECIFICATIONS

Items 4G6 6A1
Type Molded 2-coil Molded single-coil with a built-in distributor
SPARK PLUG SPECIFICATIONS

Items 4G6 6A1
NGK BKR6E-11 PFR6G-11
DENSO K20PR-U11 PK20PR11
IGNITION COIL
Items Standard value
Primary coil resistance W 6A1 0.5 - 0.7
Secondary coil resistance kW 6A1 9 - 13
SPARK PLUG
Spark plug gap mm 4G6, 6A1 1.0 - 1.1
RESISTIVE CORD
Items Limit
Resistance kW 4G6, 6A1 max. 22

MB991348 Test harness set Inspection of ignition primary voltage (power
transistor connection)

MD998773 Detonation sensor Detonation sensor removal and installation
wrench
POWER TRANSISTOR CONTINUITY CHECK

<4G6>
NOTE
1. An analogue-type circuit tester should be used.
2. Connect the negative ( - ) prove of the circuit tester
to terminal 1.
Ignition coil
Caution
10 seconds) to prevent coil from burning and power
transistor from breakage.
Voltage: 1.5V Terminal No.
1 2 3
When current is
flowing
When current is
not flowing
Replace the power transistor if there is a malfunction.
IGNITION COIL CHECK <6A1> 16300120323
1. Measurement of the primary coil resistance

Measure the resistance between connector terminal 1
and 2 of the distributor.
Standard value: 0.5 - 0.7 W
2. Measurement of secondary coil resistance
High-voltage
terminal Measure the resistance between the high-voltage
terminals and connector terminals 1.
Standard value: 9 - 13 kW
POWER TRANSISTOR CONTINUITY CHECK
<6A1> 16300130241
+ -
1.5V NOTE
1. An analogue-type circuit tester should be used.
- + 2. Connect the negative ( - ) prove of the circuit tester
to terminal 2.
Caution
Distributor connector 10 seconds) to prevent coil from burning and power
transistor from breakage.
Voltage: 1.5V Terminal No.
2 3 4
When current is
flowing
When current is
not flowing
Replace the power transistor if there is a malfunction.
RESISTIVE CORD CHECK 16300140107
Measure the resistance of the all spark plug cables.

1. Check cap and coating for cracks.
2. Measure resistance.
Limit: Max. 22 kW
SPARK PLUG CHECK AND CLEANING

<4G6> 16300150315
1. Remove the spark plug cables.

Caution
When pulling off the spark plug cable from the plug
always hold the cable cap, not the cable.
2. Remove the spark plugs.
3. Check for burned out electrode or damaged insulator.
Check for even burning.
4. Remove carbon deposits with wire brush or plug cleaner.
Remove sand from plug screw with compressed air.
5. Use a plug gap gauge to check that the plug gap is

Plug gap gauge within the standard value range.
Standard value: 1.0 - 1.1 mm
If the plug gap is not within the standard value range,
Measurement direction
adjust by bending the earth electrode.
6. Clean the engine plug holes.
Caution
Be careful not to allow foreign matter in cylinders.
7. Install the spark plugs.
SPARK PLUG CHECK <6A1> 16300150322
1. Remove the air intake plenum.

2. Remove the spark plug cables.
Caution
When pulling off the spark plug cable from the plug
always hold the cable cap, not the cable.
3. Remove the spark plugs.
4. Check the plug gap and replace if the limit is exceeded.

Limit: 1.3 mm
Caution
1. Do not attempt to adjust the gap of the platinum
plug.
2. Always use a plug cleaner and finish cleaning
Platinum tips 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

DETONATION SENSOR CHECK 16300180086
Check the detonation sensor circuit if self-diagnosis code,

No. 31 is shown.
NOTE
For information concerning the self-diagnosis codes, refer
to GROUP 13A - Troubleshooting.
WAVEFORM CHECK USING AN ANALYZER

16300170427
Ignition Secondary Voltage Waveform Check
<4G6>
MEASUREMENT METHOD
1. Clamp the secondary pickup around the spark plug cable.
NOTE
(1) The peak ignition voltage will be reversed when the
spark cables No. 2 and No. 4, or No. 1 and No.
3 cylinders are clamped.
(2) Because of the two-cylinder simultaneous ignition
system, the waveforms for two cylinders in each group
appear during waveform observation (No. 1 cylinder
- No. 4 cylinder, No. 2 cylinder - No. 3 cylinder).
However, waveform observation is only applicable
for the cylinder with the spark plug cable clamped
by the secondary pickup.
(3) Identifying which cylinder waveform is displayed can
be difficult. For reference, remember that the
waveform of the cylinder attached to the secondary
pickup will be displayed as stable.
2. Clamp the spark plug cable with the trigger pickup.
NOTE
Clamp the trigger pickup to the same spark plug cable
clamped by the secondary pickup.
STANDARD WAVEFORM
Function Secondary
Pattern height High (or Low)
Pattern selector Raster
Engine revolutions Curb idle speed
kV Spark line (point A)
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.)
kV
No. 4 cylinder No. 1 cylinder No. 3 cylinder

No. 2 cylinder ignition noise
ignition noise
Secondary
ignition Time
voltage
waveform 0
Neutral section
2
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 Compression Concentration of Ignition timing Spark plug
electrode force air mixture cable
Length Long Small Normal Low Rich Advanced Leak
Short Large Large wear High Lean Retarded High

resistance
Height High Large Large wear High Lean Retarded High

resistance
Low Small Normal Low Rich Advanced Leak
Slope Large Plug is fouled - - - -
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations Coil and condenser
Three or more Normal
Except above Abnormal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations Coil
5 - 6 or higher Normal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition Plug gap Condition of Compression Concentration of Ignition timing Spark plug cable
voltage electrode force air mixture
High Large Large wear High Lean Retarded High resistance

Abnormal waveform Wave characteristics Cause of problem
Example 1 Spark line is high and short. Spark plug gap is too large.
01P0215
Example 2 Spark line is low and long, and is Spark plug gap is too small.
sloping.
Also, the second half of the spark line
is distorted. This could be a result of
misfiring.
Example 3 Spark line is low and long, and is Spark plug gap is fouled.
sloping. However, there is almost no
spark line distortion.
Example 4 Spark line is high and short. Spark plug cable is nearly falling off.
Difficult to distinguish between this (Causing a dual ignition)
and abnormal waveform example 1.
Example 5 No waves in wave damping section. Layer short in ignition coil

Ignition Secondary Voltage Waveform Check
<6A1>
MEASUREMENT METHOD
1. Clamp the spark plug cable of the No. 1 cylinder with
the secondary pickup and check the waveform.
2. Connect the secondary pickup to the other cylinders in
turn and check the waveforms for each cylinder.
STANDARD WAVEFORM
FUNCTION SECONDARY
PATTERN HEIGHT HIGH (or LOW)
Engine Speed Curb idle speed
Spark line
kV (Point A)
Ignition
voltage
(Point D)
Vibration damping
section (Point B)
Dwell
section
Ignition
secondary
voltage
waveform
(Point C)
Time

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 Compression Concentration of Ignition timing Spark plug

resistance

resistance
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations Coil and condenser
Three or more Normal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations Coil
5 - 6 or higher Normal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition Plug gap Condition of Compression Concentration of Ignition timing Spark plug cable
voltage electrode force air mixture
High Large Large wear High Lean Retarded High resistance

01P0215
sloping.
misfiring.
Difficult to distinguish between this (Causing a dual ignition)
and abnormal waveform example 1.
Example 5 No waves in wave damping section. Layer short in ignition coil

Ignition Primary Voltage Waveform Check

<6A1>
MEASUREMENT METHOD
1. Disconnect the distributor connector and connect the
special tool (test harness: MB991348) in between. (All
of the terminals should be connected.)
Analyzer 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
Primary will appear at the left edge of the screen.
pickup
Earth
STANDARD WAVEFORM
FUNCTION SECONDARY
PATTERN HEIGHT HIGH (or LOW)
Engine Speed Curb idle speed
(V)
Zener voltage
(Point C)
Spark line
100 (Approx. 40´10V) (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 0
waveform
Time

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 Compression Concentration of Ignition timing High tension

resistance

resistance
Point B: Number of vibration in reduction vibration section

(Refer to abnormal waveform example 5)
Number of vibrations Coil, condenser
3 or higher Normal
Point C: Height of Zener voltage
Height of Zener voltage Probable cause
High Problem in Zener diode
Low Abnormal resistance in

primary coil circuit
sloping.
misfiring.
(Causing a dual ignition)
Example 5 No waves in wave damping section Layer short in ignition coil

DISTRIBUTOR <6A1> 16300200188

Air Cleaner, Air Intake Hose Removal D Air Cleaner, Air Intake Hose Installation
D Ignition timing Check and Adjustment
(Refer to GROUP 11B - On-vehicle service.)
2
22 - 25 Nm
3
5
4
10 - 12 Nm
6
1
25 Nm
5
25 Nm
Removal steps
1. Distributor connector D Air intake plenum
2. Spark plug cable connection (Refer to GROUP 15.)
3. Water guard 5. Spark plug cable
"AA 4. Distributor 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
3
4
Disassembly steps
1. Distributor cap
2. Packing
3. Rotor
4. O-ring
5. Distributor housing
Check the following points; repair or replace if a problem

is found.
CAP, ROTOR
1. There must be no cracking in the cap.
2. There must be no damage to the cap’s electrode or the
rotor’s electrode.
3. Clean away any dirt from the cap and rotor.
IGNITION COIL <4G6> 16300320174
10 Nm
10 Nm
3 2 1
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 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
12 Nm 10 - 13 Nm
10 - 12 Nm
28 Nm
28 Nm
9 Nm
2
4
49 Nm
4
3
49 Nm 9 Nm
Removal steps
1. Pressure hose and tube assembly 3. Power steering oil pump bracket
connection 4. Crank angle sensor
AA" 2. Power steering oil pump assembly

AA" POWER STEERING OIL PUMP ASSEMBLY
REMOVAL
Remove the power steering oil pump assembly with the hoses
still attached.
NOTE
Secure the removed oil pump with rope, etc. in a place where
it will not be in the way when removing and installing the
power steering oil pump bracket.
DETONATION SENSOR 16300280144

Intake Manifold Removal and Installation <6A1>
<4G6> <6A1>
20 - 25 Nm
1 1
20 - 25 Nm
AA" "AA 1. Detonation sensor Caution

Do not subject the detonation sensor to any shocks.
<4G6> REMOVAL SERVICE POINT

AA" DETONATION SENSOR REMOVAL
MD998773 INSTALLATION SERVICE POINT

"AA DETONATION SENSOR INSTALLATION
<6A1>
MD998773
ENGINE ELECTRICAL - Glow System <4D6> 16-57
GLOW SYSTEM <4D6> 16400010043
GENERAL INFORMATION
SELF-REGULATING GLOW SYSTEM
The self-regulating glow system reduces the time The resistances of the heating coils which are built
required for starting at low temperatures to provide into the glow plugs increase as the glow plug
a degree of starting and operation that is identical temperatures become higher. As a result of this,
to petrol-engine vehicles by preheating the glow the flow of current gradually decreases, thus
plugs at super-quick speed. stabilizing the glow plug temperature at the
The engine-ECU controls both the time during which specified temperature.
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.
Glow plug relay
Engine-ECU
Pre-heat indicator lamp
Engine coolant Charge lamp

temperature sensor
Glow plugs ON
ST
Ignition switch
Starter motor
Alternator
Battery
16-58 ENGINE ELECTRICAL - Glow System
Item Standard value
Resistance between glow plug plate and glow plug body 0.10 - 0.15
(parallel resistance for 4 glow plugs) (at 20 _C) W
Voltage between glow plug Immediately after ignition 9 - 11 (Drops to 0 V after 4 - 8 seconds have passed)
plate and glow plug body V switch is turned to ON
(without starting the engine)
While engine is cranking 6 or more
While engine is warming up 12 - 15 (Drops to 0 V when the engine coolant

temperature increases to 60 _C or more or if 30
seconds have passed since the engine was started)
Glow plug resistance (at 20 _C) W 0.6 - 1.0
SELF-REGULATING GLOW SYSTEM CHECK

1. Check that the battery voltage is 11 - 13 V.
2. Check that the engine coolant temperature is 40 _C or
less.
NOTE
If the engine coolant temperature is too high, disconnect
the engine coolant temperature sensor connector.
3. Measure the resistance between the glow plug plate and

(+) the glow plug body (earth).
Standard value: 0.10 - 0.15 W (at 20 _C)
NOTE
The resistance value is the parallel resistance value for
the four glow plugs.
4. Connect a voltmeter between the glow plug plate and
(- ) the glow plug body (earth).
5. Measure the voltage immediately after the ignition switch
is turned to ON (without starting the engine).
Standard value:
9 - 11 V (Drops to 0 V after 4 - 8 seconds have
passed)
In addition, check to be sure that the glow indicator lamp
(red) illuminates immediately after the ignition switch is
turned to ON.
NOTE
The time during which the voltage appears (energizing
time) will depend on the engine coolant temperature.
6. Measure the voltage while the engine is cranking.
Standard value: 6 V or more
7. Start the engine and measure the voltage while the engine
is warming up.
However, if the engine coolant temperature rises above
60 _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 ON
switch OFF
T1
Glow ON
indicator
lamp OFF
T2 T3
Glow plug ON
relay OFF
Alternator H
L terminal L
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.
CHECK AT THE ENGINE-ECU TERMINALS 16400360025
Refer to GROUP 13E - Troubleshooting.

16-60 ENGINE ELECTRICAL - Glow System <4D6>
Glow plug relay GLOW PLUG RELAY CHECK 16400330026
1. Check to be sure that there is continuity (approx. 3 W)

between glow plug relay terminal C and the terminal E.
2. Use jumper cables to connect terminal C of the glow
plug relay to the battery (+) terminal and the terminal
E to the battery ( - ) terminal
G terminal
Caution
B terminal (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 (+) Continuity between terminals

terminal B- G
Connected Continuity (0.01 W or less)
Disconnected No continuity (infinite

resistance)
GLOW PLUG CHECK 16400340029
1. Remove the glow plug plate.

(+)
2. Measure the resistance between the glow plug terminals
and the body.
Standard value: 0.6 - 1.0 W (at 20 _C)
(- )

CHECK 16400350015
Refer to GROUP 13E - On-vehicle Service.

GLOW PLUG 16400180058
1.8 Nm
18 Nm
Removal steps
1. Control wiring harness connection
2. Glow plug plate
AA" 3. Glow plug

AA" GLOW PLUG REMOVAL
Remove glow plug by hand after loosening with tool as its
ceramic part is fragile.
D Check for rust on glow plug plate.

D Check glow plug for damage.
Caution
Do not use a plug that has been dropped from a height
of 10 cm or more.
16-62 ENGINE ELECTRICAL - Injection System <4D6>
INJECTION SYSTEM <4D6> 16500010015
GENERAL INFORMATION
For the injection system, refer to GROUP 13E - General Information.
CRANK ANGLE SENSOR CHECK

CRANK ANGLE SENSOR 16500120015

Timing Belt Removal and Installation
(Refer to GROUP 11C.)
10 - 12 Nm
9 Nm
2
1
Removal steps
1. Harness support
2. Crank angle sensor
17-1
ENGINE AND
EMISSION
CONTROL
ENGINE CONTROL SYSTEM . . . . . . . . 3 ACCELERATOR PEDAL POSITION

SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3
AUTO-CRUISE CONTROL SYSTEM
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 3 ..................................... 8
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . 8
Accelerator Cable Check and Adjustment . . . . 3
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 8
Accelerator Pedal Position Sensor Check . . . . 4
ACCELERATOR CABLE AND PEDAL . . . . 5

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
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 9 EXHAUST GAS RECIRCULATION (EGR)

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 27 General Information . . . . . . . . . . . . . . . . . . . . . . 42
Auto-cruise Control Main Switch Check . . . . 27 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Auto-cruise Control Switch Check . . . . . . . . . . 27 System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 42
Auto-cruise Control Component Check . . . . . 28 Component Location . . . . . . . . . . . . . . . . . . . . . . 43
AUTO-CRUISE CONTROL* . . . . . . . . . . . . . 30 Exhaust Gas Recirculation (EGR) Control

system Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
EMISSION CONTROL SYSTEM (MPI) EGR Valve Check . . . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 EGR Port Vacuum Check <4G6> . . . . . . . . . . 44
EGR Port Vacuum Check <6A1> . . . . . . . . . . 45
GENERAL INFORMATION . . . . . . . . . . . . . . 33 EGR Control Solenoid Valve Check <4G6>
Emission Control Device Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 EGR Control Solenoid Valve Check <6A1>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CATALYTIC CONVERTER . . . . . . . . . . . . . . 47
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 34
General Information . . . . . . . . . . . . . . . . . . . . . . 47
VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . 34
CANISTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Vacuum Hose Piping Diagram . . . . . . . . . . . . . 34
Vacuum Circuit Diagram . . . . . . . . . . . . . . . . . . 35 EMISSION CONTROL SYSTEM
Vacuum Hose Check . . . . . . . . . . . . . . . . . . . . . 36 <DIESEL> . . . . . . . . . . . . . . . . . . . . . . . . . 49
Vacuum Hose Installation . . . . . . . . . . . . . . . . . 36
GENERAL INFORMATION . . . . . . . . . . . . . . . . 49
CRANKCASE EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 SERVICE SPECIFICATION . . . . . . . . . . . . . . . . 49
General Information . . . . . . . . . . . . . . . . . . . . . . 37 EXHAUST GAS RECIRCULATION SYSTEM
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 37 (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Component Location . . . . . . . . . . . . . . . . . . . . . . 37 System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Positive Crankcase Ventilation System EGR Solenoid Valve Check . . . . . . . . . . . . . . . . . . 50
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Accelerator Pedal Position Sensor Check . . . . . 50
PCV Valve Check . . . . . . . . . . . . . . . . . . . . . . . . 38
Pump Operation Sensor Check . . . . . . . . . . . . . . . 50
EVAPORATIVE EMISSION CONTROL Engine Coolant Temperature Sensor Check . . . 50
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Intake Air Temperature Sensor Check . . . . . . . . 51
General Information . . . . . . . . . . . . . . . . . . . . . . 39 Barometric Pressure Sensor Check . . . . . . . . . . . 51
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 39 A/C Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Component Location . . . . . . . . . . . . . . . . . . . . . . 39 Check at the Engine-ECU Terminals . . . . . . . . . . 51
Purge Control System Check . . . . . . . . . . . . . . 40
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . 51
Purge Port Vacuum Check . . . . . . . . . . . . . . . . 40
General Information . . . . . . . . . . . . . . . . . . . . . . . . . 51
Purge Control Solenoid Valve Check . . . . . . . 41
ENGINE AND EMISSION CONTROL - Engine Control System 17-3
ENGINE CONTROL SYSTEM 17100010102
GENERAL INFORMATION
A cable-type accelerator mechanism and a Accelerator pedal position sensor is used for
suspended-type pedal have been adopted. vehicles with 4D6 engine which is equipped with
the electronically-controlled fuel injection system.
Accelerator cable play mm 1-2
Engine idle speed r/min 4G6 750±50
6A1 650±50
4D6 800±30
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> 750±50 r/min
<6A1> 650±50 r/min
<4D6> 800±30 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 ENGINE AND EMISSION CONTROL - Engine Control System
<Except 4D6>
7. If there is too much slack or no slack, adjust play by
the following procedures.
<Except 4D6>
(1) Loosen the adjusting bolt to release the cable.
(2) Move the plate until the inner cable play is at the
Adjusting bolts standard value, and then tighten the adjusting bolt.
(3) After adjusting, check that the throttle lever is touching
the stopper.
<4D6>
Plate (1) Loosen the adjusting nut, and then move the lever
<4D6> 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
Adjusting nut
Lever Lock nut 10 Nm

CHECK 17100190011
Refer to GROUP 13E - On-vehicle Service.

ACCELERATOR CABLE AND PEDAL 17100120256

Post-installation Operation
Adjusting the Accelerator Cable (Refer to P.17-3.)
<L.H. drive vehicles>

<4G6, 6A1>
1
5 3
<4D6>
2
5
4
10 Nm 3
<4G6, 4D6>
5
4
7 10
11 11
8
<6A1>
5
6
12
7 14 12 Nm
13
<A/T> 15 <M/T> 15 7 9
Removal steps
1. Adjusting bolt 9. Pedal pad
2. Adjusting nut 10. Accelerator pedal bracket
3. Inner cable connection 11. Bushing
4. Inner cable connection 12. Stopper
5. Accelerator cable 13. Accelerator pedal stopper <M/T>
6. Snap ring 14. Wide open throttle switch <A/T>
7. Accelerator arm assembly 15. Bracket
8. Spring
17-6 ENGINE AND EMISSION CONTROL - Engine Control System
<R.H. drive vehicles> 1

5
<4G6, 6A1>
3 4
<4D6>
3
4
12 Nm
10 Nm
10
<4G6, 4D6>
5
6 7 9
8
7 11
11 12
<6A1>
5
14 13
Removal steps
1. Adjusting bolt 8. Spring
2. Adjusting nut 9. Pedal pad
3. Inner cable connection 10. Accelerator pedal bracket
4. Inner cable connection 11. Bushing
5. Accelerator cable 12. Stopper
6. Snap ring 13. Accelerator pedal stopper <M/T>
7. Accelerator arm assembly 14. Wide open throttle switch <A/T>
ACCELERATOR PEDAL POSITION SENSOR 17100180018

Adjusting the Accelerator Cable (Refer to P.17-3.)

10 - 13 Nm
4
2 3
<R.H. drive vehicles>
1
10 Nm
1
10 Nm
3
10 - 13 Nm
10 - 13 Nm
2 10 - 13 Nm
4
5
10 - 13 Nm
Removal steps
1. Adjusting nut 5. Accelerator pedal position sensor
2. Inner cable connection assembly
3. Idle position switch connector 6. Accelerator pedal position sensor
4. Accelerator pedal position sensor bracket
connector
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 approximately 40 - 200 km/h) without depressing
drive at the speed he/she likes (in a range of the accelerator pedal.
Auto-cruise control
Stop lamp switch main switch
Clutch switch
Vacuum
actuator
Accelerator pedal
position sensor
Auto-cruise
vacuum pump Auto-cruise control
assembly main switch
Throttle Auto-cruise control switch

position
sensor
Inhibitor switch
Vehicle speed
sensor Auto-cruise
control-ECU
Auto-cruise control
indicator lamp

MB991502 MUT-II sub D Reading diagnosis codes
assembly D Auto-cruise control system check
ENGINE AND EMISSION CONTROL - Auto-cruise Control System 17-9
STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

NOTE
Check that the vacuum hose is connected correctly and is not damaged, and then carry out the diagnosis.

METHOD OF READING THE DIAGNOSIS CODES

1. Connect the MUT-II to the diagnosis connector (16-pin)
under the instrument under cover. (Refer to GROUP 00
- How to Use Troubleshooting/Inspection Service Points.)
2. With the ignition switch in the ON position, turn the
Auto-cruise auto-cruise control main switch to ON and take a reading
control of the diagnosis codes.
main switch
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.
Auto-cruise 2. After pushing the auto-cruise control switch in the direction
control
main switch 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.
(A)
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
Auto-cruise control of arrow (B) in the illustration, press the cruise control
switch (B)
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.
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
Stop lamp switch

23 Auto-cruise control-ECU judges that stop lamp switch is ON
(ON when brake pedal depressed)
Auto-cruise control-ECU judges that vehicle speed is 40 km/h

24
or higher
Vehicle speed signal
Auto-cruise control-ECU judges that vehicle speed is lower
25
than 40 km/h
D Clutch switch <M/T>

(ON when clutch pedal depressed) Auto-cruise control-ECU judges that clutch switch <M/T> or
26
D Inhibitor switch <A/T> inhibitor switch <A/T> is ON
(ON when select lever in N range)
27 CANCEL switch ON Auto-cruise control-ECU judges that CANCEL switch is ON
Throttle position sensor (accelerator Auto-cruise control-ECU judges that throttle position sensor
28
pedal position sensor*) signal (accelerator pedal position sensor*) voltage is 1.5 V or more
29 Idle switch Auto-cruise control-ECU judges that idle switch is OFF
NOTE
* : Vehicles with TCL
11 Auto-cruise vacuum pump drive system 17-11
12 Vehicle speed signal system 17-11
14 Auto-cruise vacuum pump power supply system 17-12
15 Auto-cruise control switch 17-12
16 Auto-cruise control-ECU 17-12
17 Throttle position sensor system <Vehicles without TCL> or accelerator pedal position 17-13
sensor system <Vehicles with TCL>
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 D Malfunction of the auto-cruise vacuum pump
from the auto-cruise vacuum pump are not input to the auto-cruise control-ECU. D Malfunction of the connector
D Malfunction of the harness
D Malfunction of the auto-cruise control-ECU
NG
Check the auto-cruise vacuum pump. (Refer to P.17-29.) Replace
OK
NG
C-74 <L.H.> or C-113 <R.H.>, A-02 and C-82
OK
NG
Check trouble symptom. 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 D Malfunction of the vehicle speed sensor
sensor are not input to the auto-cruise control-ECU when the vehicle speed is 40 D Malfunction of the connector
km/h or more. D Malfunction of the harness
No
Is the speedometer operating normally? Vehicle speed sensor circuit inspection
(Refer to GROUP 54 - Combination Meter.)
Yes
Disconnect the vehicle speed sensor connector B-66 <M/T> or

B-67 <A/T>.
OK
Measure at auto-cruise control-ECU connector C-82. Check the following connector: C-82
D Disconnect the connector and measure at the harness side.
OK NG
D Voltage between terminal (11) and earth Repair
OK: 4.5 V or more
NG
Check the harness between the vehicle speed sensor and auto-
cruise control-ECU, and repair if necessary.
Code No. 14 Auto-cruise vacuum pump power supply Probable cause

system
This diagnosis code is output when none of the drive signals from the release valve, D Malfunction of the stop lamp switch
control valve and motor of the auto-cruise vacuum pump are input to the auto-cruise D Malfunction of the connector
control-ECU. D Malfunction of the harness
D Malfunction of the auto-cruise vacuum pump
OK
Measure at the auto-cruise vacuum pump connector A-02. Check the auto-cruise vacuum pump. (Refer to P.17-29.)
D Disconnect the connector and measure at the harness side.
OK NG
D Ignition switch and main switch: ON
D Stop lamp switch: OFF (When brake pedal is not depressed.) Replace
D Voltage between terminal (1) and earth
OK: System voltage
NG C-74 <L.H.> or C-113 <R.H.>, A-02 and C-82
Check the stop lamp switch (Refer to P.17-28.) OK NG
OK NG Repair
Replace
Check the following connectors: 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 D Malfunction of the auto-cruise control switch
remains ON.
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 D Malfunction of the auto-cruise control-ECU
or the microprocessor monitor circuit in the auto-cruise control-ECU.

Code No. 17 Throttle position sensor system <Vehicles Probable cause
without TCL> or accelerator pedal position sensor system
<Vehicles with TCL>
This diagnosis code is output if a voltage of 2.5 V or more when the idle switch D Malfunction of the throttle position sensor <Vehicles
is ON or 0.2 V or less when the idle switch is OFF is output for a continuous period without TCL>
of 4 seconds or more. D Malfunction of the accelerator pedal position sensor
<Vehicles with TCL>
D Malfunction of the connector
Yes
MUT-II SELF DIAG CODE D Throttle position sensor check <Vehicles without TCL> (Refer
Is diagnosis code No.14 output from the engine-ECU? <Vehicles to GROUP 13A - Troubleshooting.)
without TCL> D Accelerator pedal position sensor check <Vehicles with TCL>
Is diagnosis code No.11 output from the TCL-ECU? <Vehicles with (Refer to GROUP 13A - Troubleshooting.)
TCL>
No
NG
B-07 <Vehicles without TCL> or B-41 <Vehicles with TCL>, C-48,
C-49, C-83 and C-82
OK
NG
Check trouble symptom. D Check the harness between the throttle position sensor and
auto-cruise control-ECU <Vehicles without TCL>
D Check the harness between the accelerator pedal position
sensor and auto-cruise control-ECU <Vehicles with TCL>
OK NG
Repair

procedure No.
Communication with Communication with all systems is not possible. 1 17-14

MUT-II
II is not possible.
Communication with auto-cruise control-ECU only is 2 17-15
not possible.
Input switch inspection using the MUT-II is not possible. (However, diagnosis 3 17-16
inspection is possible.)

procedure No.
Auto-cruise control is Even if brake pedal is depressed 4 17-17

not cancelled.
Even if clutch pedal is depressed <M/T> 5 17-18
Even if select lever is set to N range <A/T> 6 17-18
Even if CANCEL switch is set to ON 7 17-19
The diagnosis result displayed on the MUT-II is normal even though auto-cruise 8 17-19
control cannot be set.
Auto-cruise control cannot be set. 9 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 11 17-21
not illuminate. (However, auto-cruise control is normal.)
Auto-cruise control main switch illumination lamp does not illuminate. 12 17-22
Auto-cruise control indicator lamp (CRUISE MAIN, CRUISE SET) inside 13 17-22
combination meter does not illuminate. (However, auto-cruise control is normal.)

Communication with MUT-II is not possible. (Communica- Probable cause
tion with all system is not possible.)
The reason is probably a defect in the power supply system (including earth) for D Malfunction of the connector
the diagnosis line. D Malfunction of the harness
NG NG
C-20. <L.H.> C-20, C-66, C-63, C-132, C-141
D Voltage between 16 and earth <R.H.> C-20, C-66, C-62, C-14
OK: Battery voltage OK
OK NG
power supply and diagnosis connector,
NG NG
Measure at the diagnosis connector Check the following connector: Repair
C-20. C-20
OK
OK: Continuity NG
OK diagnosis connector and earth, and re-
pair if necessary.
Replace the MUT-II.
tion with auto-cruise control-ECU only is not possible.)
The cause is probably a malfunction of auto-cruise control main switch circuit or a D Malfunction of the auto-cruise control main switch
malfunction of auto-cruise control-ECU earth circuit. D Malfunction of the connector
NG
Auto-cruise control main switch check (Refer to P.17-32.) Replace
OK
NG
Measure at auto-cruise control main switch connector C-22. Check the following connectors: C-22, C-134
D Disconnect the connector and measure at the harness side. OK NG
D Voltage between the terminal (1) and earth Repair
OK: System voltage
NG
Check the harness between the auto-cruise control main switch

and power supply, and repair if necessary.
NG
<L.H.> C-22, C-62, C-82
<R.H.> C-22, C-63, C-64, C-82
OK

OK
NG
Check the harnesses between the auto-cruise control main switch Repair
and earth or between the auto-cruise control main switch and auto-
cruise control-ECU.
OK
OK
Measure at auto-cruise control-ECU connector C-82. Check the following connectors: C-82, C-20
D Disconnect the connector and measure at the harness side. NG
OK
D Continuity between terminal (9) and earth, terminal (13) and
earth. Repair
OK: Continuity
NG
Check the harness between the auto-cruise control-ECU and earth,
and repair if necessary. Check the harness between the auto-cruise control-ECU and diag-
nosis connector
OK NG
Repair

Input switch inspection using the MUT-II is not possible. Probable cause
(However, diagnosis inspection is possible.)
The cause is probably a malfunction of auto-cruise control switch circuit system. D Malfunction of the auto-cruise control switch
D Malfunction of the clock spring
NG
OK
NG
Clock spring check (Refer to GROUP 52B - Air Bag Modules Replace
and Clock Spring.)
OK
NG
Measure at the clock spring connector C-107. Check the following connectors:
D Disconnect the connector and measure at the harness side. C-107, C-61, C-134, C-63 <R.H.>
OK NG
D Voltage between the terminal (2) and earth
OK
NG
NG
C-107, C-82
OK Check the harness between the clock spring and power supply,
NG
Check the harness between the clock spring and auto-cruise control-
Even if brake pedal is depressed, auto-cruise control is Probable cause
not cancelled.
The cause is probably a malfunction of stop lamp switch or a malfunction of stop D Malfunction of the stop lamp switch
lamp circuit. D Malfunction of the connector
Yes
Does stop lamp illuminate? Check the following connectors: C-65, C-82
No OK NG
Stop lamp switch check Repair

(Refer to P.17-28.)
OK NG
NG
Replace
Check the harness between the stop lamp switch and auto-cruise
control-ECU.
OK NG
Repair
NG
Measure at stop lamp switch connector C-02. Check the following connectors: C-02, C-134
D Disconnect the connector and measure at the harness side. NG
OK
OK
NG
Check the harness between the stop lamp switch and power supply,
NG
C-02, C-65, C-82
OK
NG
Check trouble symptom. Check the harness between the stop lamp switch and auto-cruise
control-ECU, and repair if necessary.
Even if clutch pedal is depressed, auto-cruise control is Probable cause
not cancelled. <M/T>
The cause is probably a malfunction of clutch switch or clutch circuit. D Malfunction of the clutch switch
NG
Clutch switch check (Refer to P.17-29.) Replace
OK
NG
Measure at clutch switch connector C-01. Check the following connectors: C-01, C-82
D Disconnect the connector and measure at the harness side. OK NG
D Voltage between terminal (1) and earth Repair
OK: 5 V
NG
NG
<L.H.> C-01, C-62
<R.H.> C-01, C-63, C-64
OK Check the harness between the clutch switch and auto-cruise con-
trol-ECU, and repair if necessary.
NG
OK
Check the harness between the clutch switch and earth. Replace the auto-cruise control-ECU.
NG
Repair
Even if select lever is set to N range, auto-cruise control Probable cause
is not cancelled. <A/T>
The cause is probably an open-circuit in the output signal circuit in N range. D Malfunction of the connector
NG
Inhibitor switch check (N range) (Refer to P.17-29.) Replace
OK
OK
Check the following connectors: Check trouble symptom.
C-48, C-83, C-82 NG
Check the harness between the inhibitor switch and auto-cruise

control-ECU.
OK NG
Repair

Even if auto-cruise control CANCEL switch is set to ON, Probable cause
auto-cruise control is not cancelled.
The cause is probably an open-circuit in the circuit inside the CANCEL switch. D Malfunction of the auto-cruise control-ECU
Replace the auto-cruise control switch.
The diagnosis result displayed on the MUT-II is normal Probable cause
even though auto-cruise control cannot be set.
Because of an open-circuit in the battery backup circuit system, the fail-safe function D Malfunction of the connector
prevents diagnosis codes from being memorised and displayed even though auto-cruise D Malfunction of the harness
control is cancelled. D Malfunction of the auto-cruise control-ECU
NG
Measure at auto-cruise control-ECU connector C-82. Check the following connectors:
D Disconnect the connector and measure at the harness side. C-66 <L.H.> or C-62 <R.H.> and C-82
OK NG
OK: System voltage
OK Repair
Check the following connector: C-82 Check trouble symptom.

OK NG NG
Repair Check the harness between the auto-cruise control-ECU and power
supply, and repair if necessary.
NG

Auto-cruise control cannot be set. Probable cause
The cause is probably that the fail-safe function is cancelling auto-cruise control. D Malfunction of the auto-cruise control main switch
In this case, the MUT-II can be used to check the trouble symptoms in each system D Malfunction of the auto-cruise control switch
by inspecting the diagnosis codes. The MUT-II can also be used to check if the D Malfunction of the clock spring
circuits of each input switch are normal or not by inspecting the input switch codes. D Malfunction of the harnesses or connectors
D Malfunction of the clutch switch <M/T>
No
Can the auto-cruise control communicate with the MUT-II? Check for each trouble symptom. (Refer to inspection procedure
Yes No. 2 on P.17-15.)
Yes
Is the diagnosis system diagnosis displayed on the MUT-II normal? Check for each trouble symptom. (Refer to inspection procedure
No. 8 on P.17-19.)
No
Yes
Are any of MUT-II diagnosis code Nos. 11, 12, 14, 15, 16 or 17 Check for each diagnosis code.
output? (CODE No.11: Refer to P.17-11.)
(CODE No.12: Refer to P.17-11.)
No (CODE No.14: Refer to P.17-12.)
No
Is input switch inspection possible with the MUT-II? Check for each trouble symptom. (Refer to inspection procedure
No. 3 on P.17-16.)
Yes
Yes
Are either of MUT-II diagnosis code Nos. 23 or 26 output? D Stop lamp switch input circuit system [code No. 23] inspection
(Refer to inspection procedure No. 14 on P.17-24.)
No D Clutch switch <M/T> or inhibitor switch <A/T> input circuit
system [code No. 26] inspection (Refer to inspection procedure
Replace the auto-cruise control-ECU. No. 15 on P.17-24.)
Hunting (repeated acceleration and deceleration) occurs Probable cause
at the set vehicle speed.
The cause is probably a malfunction of vehicle speed sensor or incorrect vacuum D Malfunction of the vehicle speed sensor
in the auto-cruise vacuum pump or vacuum actuator. D Malfunction of the auto-cruise vacuum pump
D Malfunction of the vacuum actuator
NG
Vehicle speed sensor check Replace
(Refer to GROUP 54 - Combination Meter.)
OK
NG
Auto-cruise vacuum pump check (Refer to P.17-29.) Replace
OK
NG
Vacuum actuator check (Refer to P.17-29.) Replace
OK
Even though auto-cruise control main switch is ON, Probable cause
switch indicator lamp does not illuminate. (However,
auto-cruise control is normal.)
Blown bulb in auto-cruise control main switch D Malfunction of the auto-cruise control main switch
Replace the auto-cruise control main switch.

Auto-cruise control main switch illumination lamp does Probable cause
not illuminate.
The cause is probably a malfunction of auto-cruise control main switch or a malfunction D Malfunction of the auto-cruise control main switch
of harness or connector. D Malfunction of the connector
NG
OK
NG
Measure at auto-cruise control main switch connector C-22. Check the following connectors:
D Disconnect the connector and measure at the harness side. <L.H.> C-22, C-64, C-67, C-116
D Lighting switch: TAIL <R.H.> C-22, C-61, C-62, C-14
D Voltage between terminal (2) and earth OK NG
OK: System voltage
OK Repair
Check the following connectors: Check trouble symptom.

<L.H.> C-22, C-64, C-25 NG
<R.H.> C-22, C-61, C-62, C-25
OK NG Check the harness between the auto-cruise control main switch
Repair
NG
Check trouble symptom. Check the harness between the auto-cruise control main switch
and rheostat, and repair if necessary.
Auto-cruise control indicator lamp (CRUISE MAIN, Probable cause
CRUISE SET) inside combination meter does not
illuminate. (However, auto-cruise control is normal.)
The cause is probably a malfunction of bulb or a malfunction of connector or harness. D Malfunction of the bulb
<CRUISE MAIN indicator lamp>

NG
CRUISE MAIN indicator lamp bulb check Replace
OK
NG
Combination meter check Repair
OK
NG
D Disconnect the connector and measure at the harness side. D-01, C-26
D Ignition switch and main switch: ON OK NG
OK
Check the following connectors: NG
C-135, C-131
OK NG Check the harness between the combination meter and auto-cruise
control main switch, and repair if necessary.
Repair

NG
Check the harness between the combination meter and earth, and
<CRUISE SET indicator lamp>
NG
CRUISE SET indicator lamp bulb check Replace
OK
NG
Combination meter check Repair
OK
NG
D Disconnect the connector and measure at the harness side. D-03, C-135
D Ignition switch: ON OK NG
OK
NG
Check the harness between the combination meter and power

supply, and repair if necessary.
NG
Measure at auto-cruise control-ECU connector C-82. Check the following connectors:
D Disconnect the connector and measure at the harness side. C-82, C-25
OK NG
OK
Replace the and auto-cruise control-ECU. NG
Check the harness between the combination meter and auto-cruise

control-ECU, and repair if necessary.
Stop lamp switch input circuit system inspection (Code No. 23)
NG
Stop lamp switch check (Refer to P.17-28.) Replace
OK
NG
Check the following connectors: C-82, C-65, C-02, C-134, C-142, Repair
C-12 <R.H.>
OK
NG
Check trouble symptom. Check the harness between fusible link No. 1 and auto-cruise con-
trol-ECU, and repair if necessary.
Clutch switch <M/T> or inhibitor switch <A/T> input circuit system inspection (Code No. 26)
<M/T>
NG
Clutch switch check (Refer to P.17-29.) Replace
OK
NG
<L.H.> C-82, C-01, C-62
<R.H.> C-82, C-01, C-63, C-64
OK
NG
Check trouble symptom. Check the harness between auto-cruise control-ECU and earth,
<A/T>
NG
Inhibitor switch check (Refer to P.17-29.) Replace
OK
NG
B-72, C-48, C-83, C-82
OK
NG
Check trouble symptom. Check the harness between the auto-cruise control-ECU and inhibi-
tor switch, and repair if necessary.
CHECK AT THE ECU TERMINALS 17200270121
Terminal Check item Check conditions Normal condition

No.
1 Throttle posi- When accelerator pedal is fully depressed 4.5 - 5.5V
tion sensor
(accelerator
pedal position When accelerator pedal is released 0.3 - 1.0V
sensor*) input
2 Idle switch When accelerator pedal is de- When idle switch is OFF 4.5 - 5.5V
output pressed
When accelerator pedal is not When idle switch is ON 0V
depressed
3 ACC power When ignition switch is in ACC position System voltage
supply
4 Stop lamp When brake pedal is depressed When stop lamp switch is ON System voltage
switch input
When brake pedal is not depressed When stop lamp switch is 0V
OFF
5 Diagnosis When ignition switch is ON 4V or more
control input
6 ECU backup At any time System voltage
power supply
7 Auto-cruise When decelerating with the SET Release valve closed 0V
vacuum switch while driving at constant
8 pump release speed Control valve open/closed System voltage/0V
valve and
7 control valve When cancelling constant speed Release valve open System voltage
input driving with the CANCEL switch
8 Control valve open System voltage
9 Earth At any time Continuity
10 A/T control No OD-OFF request System voltage
output
OD-OFF request 0V
NOTE
*: Vehicles with TCL
Terminal Check item Check conditions Normal condition

No.
11 Vehicle speed When vehicle is moved forwards When sensor is ON 0V
sensor input and backwards, sensor turns ON
and OFF repeatedly When sensor is OFF 4.5V or more
12 Auto-cruise When input switch has not been When all switches are OFF 0V
control switch operated
input
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
13 Earth At any time Continuity
14 Clutch switch When pedal is not depressed When clutch switch is OFF 5V
input <M/T>
When pedal is depressed When clutch switch is ON 0V
Inhibitor When select lever is in a position When inhibitor switch is OFF 5V
switch input other than N range
<A/T>
When select lever is in N range When inhibitor switch is ON 0V
15 Pump power Ignition switch : ON System voltage
supply Main switch : ON
Stop lamp switch : OFF
16 ECU power Ignition switch : ON System voltage

supply Main switch : ON
17 Indicator lamp When driving at constant speed When indicator lamp is illumi- 0V
input (inside nated
combination
meter) When constant-speed driving is When indicator lamp is System voltage
cancelled switched off
18 Auto-cruise When driving at constant speed Motor stopped/running System voltage/0V
vacuum pump using the SET switch
motor input
When accelerating with the RE- Motor stopped/running System voltage/0V
SUME switch while driving at
constant speed
When decelerating with the SET Motor stopped System voltage

switch while driving at constant
speed
When cancelling constant speed Motor stopped System voltage

driving with the CANCEL switch
<L.H. drive vehicles> ON-VEHICLE SERVICE 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
AUTO-CRUISE CONTROL SETTING

1. Switch ON the main switch.
(C) 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).
(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.
SPEED-REDUCTION SETTING
1. Set to the desired speed.
arrow (B).
3. Check to be sure that deceleration continues while the
switch is pressed, and that when it is released the constant
speed at the time when it was released becomes the
driving speed.
NOTE
When the vehicle speed reaches the low limit
(approximately 40 km/h) during deceleration, the
auto-cruise control will be cancelled.
RETURN TO THE SET SPEED BEFORE CANCELLATION
AND AUTO-CRUISE CONTROL CANCELLATION
1. Set the auto-cruise speed control.
2. When any of the following operations are performed while
at constant speed during auto-cruise control, check if
normal driving is resumed and deceleration occurs.
a. The auto-cruise control switch is pushed in the
direction of arrow (C).
b. The brake pedal is depressed.
c. The clutch pedal is depressed. <M/T>
d. The selector lever is moved to the “N” range. <A/T>
3. When the auto-cruise control switch is pushed in the
direction of arrow (A) at a vehicle speed of 40 km/h or
higher, check if the vehicle speed returns to the speed
before auto-cruise control driving was cancelled, and
constant speed driving occurs.
4. When the main switch is turned to OFF while driving
at constant speed, check if normal driving is resumed
and deceleration occurs.
AUTO-CRUISE CONTROL COMPONENT CHECK

17200170223
STOP LAMP SWITCH

1. Disconnect the connector.
2. Check for continuity between the terminals of the switch.
Measurement conditions Terminal No.
1 2 3 4
When brake pedal is depressed.
(for stop lamp circuit)
When brake pedal is not depressed.
(for auto-cruise control circuit)
CLUTCH SWITCH
2. Check for continuity between the terminals of the switch.
Measurement conditions Terminal No.
1 2
When clutch pedal is depressed.
When clutch pedal is not depressed.
INHIBITOR SWITCH (“N” POSITION)

Refer to GROUP 23 - On-vehicle Service.
THROTTLE POSITION SENSOR


<Vehicles with TCL>
AUTO-CRUISE VACUUM PUMP

1. Disconnect the vacuum hose from the auto-cruise vacuum
pump and connect a vacuum gauge to the vacuum pump.
Vacuum
gauge 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.
Terminal No. Vacuum gauge
Valve condition
1 2 3 4 kPa
Release valve closed
53 or more
Control valve closed
1
Release valve open
20 or less
Control valve open
Re-
Control
lease
valve
valve
2 3 4
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
AUTO-CRUISE CONTROL 17200140224
2
4 6
Auto-cruise vacuum pump removal Auto-cruise control main switch

steps removal steps
1. Vacuum hose D Meter bezel assembly <L.H. drive
2. Auto-cruise vacuum pump and vehicles> (Refer to GROUP 52A.)
pump bracket assembly D Bezel switch <R.H. drive vehicles>
3. Auto-cruise vacuum pump (Refer to GROUP 52A.)
assembly 6. Auto-cruise control main switch
4. Pump bracket
5. Body pump bracket
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 8
11
12
13
14
Auto-cruise control switch removal Sensor removal

steps 9. Throttle position sensor
D Steering wheel (Refer to GROUP 10. Accelerator pedal position sensor
37A.) <Vehicles with TCL>
7. Auto-cruise control switch 11. Stop lamp switch
Auto-cruise control-ECU removal 12. Clutch switch <M/T>
steps 13. Vehicle speed sensor
14. Inhibitor switch <A/T>
D Radio and tape player (Refer to
GROUP 54.)
8. Auto-cruise control-ECU
<L.H. drive vehicles> <R.H. drive vehicles>

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.
2 1
OFF ON
ON
N OFF N
ILL IND
7 5 4
AUTO-CRUISE CONTROL SWITCH CHECK 17200120150
Measure the resistance between the terminals when each

of the SET, RESUME and CANCEL switches is pressed.
If the values measured at this time correspond to those in
the table below, then there is no problem.
Switch position Resistance between terminals
Switch OFF No continuity
CANCEL switch ON Approx. 0 W
RESUME switch ON Approx. 820 W
SET switch ON Approx. 2,700 W
2
VEHICLE SPEED SENSOR CHECK 17200300042
SET
OFF ON Refer to GROUP 54 - Combination Meters.
RESUME CANCEL
OFF ON OFF ON
1
ENGINE AND EMISSION CONTROL - Emission Control System <MPI> 17-33
EMISSION CONTROL SYSTEM <MPI> 17300010252
GENERAL INFORMATION
The emission control system consists of the following subsystems:
D Crankcase emission control system
D Exhaust emission control system
Items Name Specification
Crankcase emission Positive crankcase ventilation (PCV) valve Variable flow type
control system (Purpose: HC reduction)
Evaporative emission Canister Equipped

control system Purge control solenoid valve ON/OFF type solenoid valve
(Purpose: HC reduction)
Exhaust emission Air-fuel ratio control device- MPI system Oxygen sensor feedback type
control system (Purpose: CO, HC, NOx reduction)
Exhaust gas recirculation system Equipped

D EGR valve Single type
D EGR control solenoid valve Duty cycle type solenoid valve
(Purpose: NOx reduction)
Catalytic converter Monolith type

(Purpose: CO, HC, NOx reduction)
EMISSION CONTROL DEVICE REFERENCE TABLE

Related parts Crankcase Evaporative Air/fuel Catalytic Exhaust Reference
emission emission ratio converter gas page
control control control recircula-
system system system tion system
PCV valve ´ 17-38
Purge control solenoid valve ´ 17-41
MPI system component ´ ´ GROUP 13A
Catalytic converter ´ 17-47
EGR valve ´ 17-44
EGR control solenoid valve ´ 17-45

17-34 ENGINE AND EMISSION CONTROL - Emission Control System <MPI>
Purge control solenoid valve coil resistance (at 20_C) W 36 - 44
EGR control solenoid valve coil resistance (at 20_C) W 36 - 44

MD998770 Oxygen sensor Removal/Installation of oxygen sensor
wrench
VACUUM HOSE 17300090317
VACUUM HOSE PIPING DIAGRAM

<4G6>
Air cleaner
Air
Fuel pressure
regulator
PCV valve
EGR valve OFF
OFF
ON
Canister
ON
EGR control Purge control
solenoid valve solenoid valve
Oxygen sensor
(front) Oxygen sensor (rear)
Three-way catalytic
converter
<6A1>
Vacuum cotrol
solenoid valve <TCL>
OFF ON
Vacuum ON
tank <TCL> Ventilation control
OFF
Air cleaner
Air
PCV
valve
EGR
valve
Fuel
pressure EGR control
regulator 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 From air
chamber cleaner
Fuel EGR control

pressure solenoid valve
regulator (ON: OPEN)
Vacuum hose colour EGR valve

B: Black Canister
G: Green Purge control
L: Light blue solenoid valve
R: Red (ON: OPEN)
W: White
Y: Yellow
<6A1>
Intake manifold Throttle body
To
combustion
chamber From air
cleaner
Fuel
pressure Purge control EGR control
regulator solenoid solenoid valve
valve (ON: CLOSE)
(ON: OPEN)
Vacuum
tank <TCL>
EGR valve
Canister
Ventilation control
(ON: CLOSE)
Vacuum control
(ON: OPEN)
Vacuum hose colour Vacuum
B: Black actuator <TCL>
G: Green
L: Light blue
R: Red
Y: Yellow
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 17300500247
GENERAL INFORMATION
The crankcase emission control system prevents The PCV valve lifts the plunger according to the
blow-by gases from escaping inside the crankcase intake manifold vacuum so as to regulate the flow
into the atmosphere. of blow-by gas properly. In other words, the blow-by
Fresh air is sent from the air cleaner into the gas flow is regulated during low load engine
crankcase through the breather hose. The air operation to maintain engine stability, while the flow
becomes mixed with the blow-by gases inside the is increased during high load operation to improve
crankcase. the ventilation performance.
The blow-by gas inside the crankcase is drawn
into the intake manifold through the positive
crankcase ventilation (PCV) valve.
SYSTEM DIAGRAM
Ventilation hose
PCV valve Breather hose
NOTE
The illustration shows the system for 4G63 engine.
COMPONENT LOCATION
PCV valve PCV valve
<4G6> <6A1>
POSITIVE CRANKCASE VENTILATION SYSTEM

CHECK 17300110136
1. Remove the ventilation hose from the PCV valve.

2. Remove the PCV valve from the rocker cover.
3. Reinstall the PCV valve at the ventilation hose.
5. Place a finger at the opening of the PCV valve and check

PCV valve that vacuum of the intake manifold is felt.
NOTE
At this moment, the plunger in the PCV valve moves
back and forth.
6. If vacuum is not felt, clean the PCV valve or replace
it.
PCV VALVE CHECK 17300120122
1. Insert a thin rod into the PCV valve from the side shown
PCV valve 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 17300510363
GENERAL INFORMATION
The evaporative emission control system prevents sent to the combustion chamber.
fuel vapours generated in the fuel tank from When the engine coolant temperature is low or
escaping into the atmosphere. when the intake air quantity is small (when the
Fuel vapours from the fuel tank flow through the engine is at idle, for example), the engine control
fuel tank pressure control valve and vapour unit turns the purge solenoid off to shut off the
pipe/hose to be stored temporarily in the canister. fuel vapour flow to the intake manifold.
When driving the vehicle, fuel vapours stored in This does not only insure the driveability when the
the canister flow through the purge solenoid and engine is cold or running under low load but also
purge port and go into the intake manifold to be stabilize the emission level.
SYSTEM DIAGRAM
Engine-ECU
Throttle body
From fuel tank Air flow sensor

OFF
Engine coolant
Canister temperature sensor
ON Intake air
Purge control temperature sensor
solenoid valve
Control Barometric pressure
relay sensor
COMPONENT LOCATION
Purge control solenoid valve Purge control solenoid valve
<4G6> <6A1>
<4G6> PURGE CONTROL SYSTEM CHECK 17300140357
1. Disconnect the vacuum hose (red stripe) from the throttle

Red stripe Plug 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)
Vacuum Engine condition Normal condition
53 kPa 3,000 r/min Vacuum is
<6A1> maintained
When engine is hot
Red stripe
(Engine coolant temperature: 80_C or higher)
Vacuum Engine condition Normal condition
53 kPa At idle Vacuum is
maintained
Plug 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.
<4G6> PURGE PORT VACUUM CHECK 17300150282

Purge port 1. Disconnect the vacuum hose (red stripe) from the throttle
vacuum nipple
body purge vacuum nipple and connect a hand vacuum
pump to the nipple.
<6A1>
Purge port
vacuum nipple
Vacuum 2. Start the engine and check that, after raising the engine
speed by racing the engine, purge vacuum raises
according to engine speed.
NOTE
If there is a problem with the change in vacuum, the
throttle body purge port may be clogged and require
cleaning.
Engine speed (r/min)

A
17300170127
NOTE
B
1. Disconnect the vacuum hose (black stripe, red stripe)
Battery 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.
Applied Vacuum leaks
Not applied Vacuum maintained
solenoid valve.
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 17300520274
GENERAL INFORMATION
The exhaust gas recirculation (EGR) system lowers the exhaust port of the cylinder head to the
the nitrogen oxide (NOx) emission level. When the combustion chamber through the intake manifold
air/fuel mixture combustion temperature is high, to decrease the air/fuel mixture combustion
a large quantity of nitrogen oxides (NOx) is temperature, resulting in reduction of NOx.
generated in the combustion chamber. Therefore, The EGR flow rate is controlled by the EGR valve
this system recirculates part of emission gas from so as not to decrease the driveability.
OPERATION
The EGR valve is being closed and does not D The engine coolant temperature is low.
recirculate exhaust gases under one of the following D The engine is at idle.
conditions. Otherwise, the EGR valve is opened D The throttle valve is widely opened.
and recirculates exhaust gases.
SYSTEM DIAGRAM
<4G6> A
EGR
control
solenoid
valve Air flow sensor
Engine coolant
OFF temperature sensor
EGR valve ON Crank angle sensor

Control
relay
Engine-ECU
Battery
<6A1>
EGR valve
OFF ON
EGR
control Air flow sensor
solenoid
valve Engine coolant
temperature sensor
Crank angle sensor

Control
relay
Engine-ECU
Battery
COMPONENT LOCATION
EGR control solenoid valve EGR control solenoid valve
<4G6> <6A1>
A
EGR valve B
EGR valve
<4G6> <6A1>
<4G6> EXHAUST GAS RECIRCULATION (EGR)

CONTROL SYSTEM CHECK 17300260282
Green stripe
1. Disconnect the vacuum hose (green stripe) from the EGR
valve, and then connect a hand vacuum pump via the
three-way terminal.
Three-way terminal
2. When the engine is hot or cold, check the condition of
vacuum by racing the engine.
When engine is cold
EGR valve (Engine coolant temperature: 20_C or less)
Throttle valve Normal vacuum condition
<6A1> Open quickly No vacuum will generate

Green stripe (the same as barometric pressure.)
When engine is hot

(Engine coolant temperature: 80_C or higher)
Throttle valve Normal vacuum condition
Three-way terminal
Open quickly It will momentarily rise over 13 kPa
EGR valve
<4G6>
3. Disconnect the three-way terminal.
4. Connect the hand vacuum pump to the EGR valve.
Green stripe Plug 5. Check whether the engine stalls or the idling is unstable
when a vacuum of 30 kPa or higher is applied during
idling.
EGR valve
<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> 17300290199
1. Disconnect the vacuum hose (white stripe) from the throttle

EGR vacuum
nipple
body EGR vacuum nipple and connect a hand vacuum
pump to the nipple.
Vacuum 2. Start the engine and check that the vacuum remains
fairly constant after racing the engine.
NOTE
If vacuum changes, it is possible that the throttle body
EGR port may be clogged and require cleaning.
EGR PORT VACUUM CHECK <6A1> 17300290205

EGR port throttle body EGR vacuum nipple and connect a hand
vacuum nipple vacuum pump to the nipple.
Vacuum 2. Start the engine and check to see that, after raising the
engine speed by racing the engine, EGR vacuum raises
proportionately with the rise in engine speed.
NOTE
If there is a problem with the change in vacuum, it is
possible that the throttle body EGR port may be clogged
and require cleaning.

<4G6> 17300310222
NOTE
1. Disconnect the vacuum hose (yellow stripe, white stripe,
green stripe) from the solenoid valve.

A
the white-striped vacuum hose was connected.
B
applied directly from the battery to the EGR control
Battery voltage B nipple condition Normal condition
C
Not applied Open Vacuum maintained
Battery Applied Open Vacuum leaks
Closed Vacuum maintained

solenoid valve.

<6A1> 17300310239
NOTE
1. Disconnect the vacuum hose (yellow stripe, green stripe)
Battery 3. Connect a hand vacuum pump to the nipple to which
the green-striped vacuum hose was connected.
applied directly from the battery to the EGR control
Not applied Vacuum leaks
Applied Vacuum maintained

solenoid valve.
CATALYTIC CONVERTER 17300530055
GENERAL INFORMATION
The three-way catalytic converter, together with When the mixture is controlled at stoichiometric
the closed loop air-fuel ratio control based on the air-fuel ratio, the three-way catalytic converter
oxygen sensor signal, oxidizes carbon monoxides provides the highest purification against the three
(CO) and hydrocarbons (HC) and reduces nitrogen constituents, namely, CO, HC and NOx.
oxides (NOx).
REMOVAL AND INSTALLATION 17300390233

Under Cover Removal and Installation
<4G6>
49 Nm
2
49 - 59 Nm
34 Nm
44 Nm
4
49 Nm
3
<6A1>
49 Nm
13 Nm 49 Nm
44 Nm
49 Nm
3
49 Nm
1
13 Nm
7 Nm
Removal steps
1. Heat protector 3. Front exhaust pipe
AA" "AA 2. Oxygen sensor 4. Catalytic converter

AA" OXYGEN SENSOR REMOVAL

"AA OXYGEN SENSOR INSTALLATION
MD998770
CANISTER 17300420055
1 2
4
3
Removal steps
1. Vapor hose connection 4. Canister
2. Vent hose 5. Canister bracket
3. Hose clamp
ENGINE AND EMISSION CONTROL - Emission Control System <Diesel> 17-49
EMISSION CONTROL SYSTEM <DIESEL> 17500010036
GENERAL INFORMATION
Item Name Specification
Exhaust emission control system Exhaust gas recirculation system Equipped

D EGR valve Single type
D EGR solenoid valve Duty cycle type solenoid valve
SERVICE SPECIFICATION 17500030032
Item Specification
EGR solenoid valve coil resistance W 11 - 14 (at 20_C)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 17500010030
SYSTEM CHECK
Vacuum pump
EGR solenoid
valve
Accelerator pedal position sensor
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 - Emission Control System <Diesel>
EGR SOLENOID VALVE CHECK 17500290027

EGR solenoid
valve NOTE
1. Disconnect the vacuum hose (yellow stripes green stripe)
the yellow-striped vacuum hose was connected.
4. Check that the needle reading rises by 47 kPa or more

when negative pressure is applied.
NOTE
There is no problem if the needle reading rises by 47
kPa or more, even though there is a leak.
5. Apply a voltage of 6 V between the terminals, and check
that the pressure leaks at this time even when negative
pressure applied.
6. Measure the resistance between the terminals.

Standard value: 11 - 14W (at 20_C)

CHECK 17500340012

PUMP OPERATION SENSOR CHECK 17500350015

CHECK 17500150028

ENGINE AND EMISSION CONTROL - Emission Control System <Diesel> 17-51
INTAKE AIR TEMPERATURE SENSOR CHECK
17500360018

BAROMETRIC PRESSURE SENSOR CHECK
17500370011

A/C SWITCH CHECK 17500380014

CHECK AT THE ENGINE-ECU TERMINALS
17500300010
CATALYTIC CONVERTER 17500270021
GENERAL INFORMATION
A monolith-type oxidation catalytic converter is reduces the amounts of carbon monoxide (CO)
located between the front exhaust pipe and the and hydrocarbons (HC) in the exhaust gas.
center exhaust pipe. This catalytic converter
REMOVAL AND INSTALLATION 17500210030

Under Cover Removal and Installation
49 Nm
49 Nm
49 Nm
2
1
13 Nm
Removal steps
2. Catalytic converter
NOTES
21-1
CLUTCH
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 5

Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 7
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2
Clutch Pedal Inspection and Adjustment . . . . . . . 2
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Information/Service
21-2 CLUTCH - Specifications/Lubricants/On-vehicle Service
The clutch is a dry single-disc, diaphragm type;

hydraulic pressure is used for the clutch control.

Clutch pedal height mm 163 - 166
Clutch pedal clevis pin play mm 1- 3
Clutch pedal free play mm 6 - 13
Distance between the clutch pedal and the toeboard 80 or more
when the clutch is disengaged mm
Items Specified lubricants Quantity

Clutch fluid Brake fluid DOT3 or DOT4 As required
Push rod assembly Rubber grease
Boot
Release cylinder push rod MITSUBISHI genuine grease
Part No. 0101011
Clutch pedal height ON-VEHICLE SERVICE 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
A
Lock nut Adjusting bolt or 3. If the height of the clutch pedal is outside the standard
clutch switch 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>.
Lock nut
13 Nm
13 Nm
Push rod
CLUTCH - On-vehicle Service 21-3
Clutch pedal clevis pin play 4. Measure the clutch pedal play.
Standard value (B): 1 - 3 mm
5. If the clutch pedal play is not within the standard value,
loosen the lock nut and move the push rod to adjust.
Caution
Do not push in the master cylinder push rod at this
time.
B
Clutch pedal free play 6. After completing the adjustments, confirm that the clutch
pedal free play (measured at the face of the pedal pad)
and the distance between the clutch pedal (the face of
the pedal pad) and the toeboard when the clutch is
disengaged are within the standard value ranges.
Standard value (C): 6 - 13 mm
C 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
Distance between the clutch pedal and the disassemble and inspect the master cylinder or clutch.
toeboard when the clutch is disengaged
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
29 Nm 4 12 Nm
21 20
6 5
19
13 18
13 Nm
11 12
7
12
1
2
17
9 15
8
16
14
Removal steps
1. Clevis pin assembly 14. Stopper <R.H. drive vehicles>
2. Bushing 15. Clutch pedal
3. Nut 16. Pedal pad
4. Bolt 17. Stopper
5. Clevis pin <6A1> 18. Adjusting bolt <Vehicles without auto
6. Rod A <6A1> cruise control system>
7. Turnover spring <6A1> 19. Lock nut <Vehicles without auto cruise
8. Rod B <6A1> control system>
9. Bushing <6A1> 20. Clutch switch <Vehicles with auto
10. Bolt cruise control system>
11. Clutch return spring 21. Clip <Vehicles with auto cruise control
12. Clutch pedal bushing system>
13. Pipe 22. Master cylinder member assembly
CLUTCH - Clutch Control 21-5
CLUTCH CONTROL 21100190216
REMOVAL AND INSTALLTION

Clutch Fluid Draining D Clutch Fluid Supplying
D Clutch Line Bleeding (Refer to P.21-3)
D Clutch Pedal Adjustment (Refer to P.21-2)
<4G6>
4 8 2
10 8
<4D6, 6A1>
4 8
6
1
5
9
10 - 12 Nm
3
19 Nm 13 Nm
7
Release Release
cylinder fork
push rod
15 Nm
8 Specified grease:
MITSUBISHI genuine
grease Part No. 0101011
Clutch master cylinder removal Clutch fluid line damper removal

steps steps <4D6, 6A1>
1. Clevis pin assembly 6. Clutch pipe connection
2. Clutch pipe connection 7. Clutch fluid line damper
3. Clutch master cylinder
Clutch line removal steps
Clutch release cylinder removal 8. Clutch pipe
steps 9. Bracket
4. Clutch pipe connection 10. Clutch hose
5. Clutch release cylinder
21-6 CLUTCH - Clutch Control
13 Nm
1
<4G6>
2
4
8
10
8
<4D6, 6A1>
4 8
6
5
9
10 - 12 Nm
19 Nm
7
Release Release
cylinder push fork
rod
15 Nm
8 Specified grease:
MITSUBISHI genuine
grease Part No. 0101011
Clutch master cylinder removal Clutch fluid line damper removal

steps steps <4D6, 6A1>
1. Clevis pin assembly 6. Clutch pipe connection
2. Clutch pipe connection 7. Clutch fluid line damper
3. Clutch master cylinder
Clutch line removal steps
Clutch release cylinder removal 8. Clutch pipe
steps 9. Bracket
4. Clutch pipe connection 10. Clutch hose
5. Clutch release cylinder
CLUTCH - Clutch Control 21-7
CLUTCH MASTER CYLINDER

3 <4G6, 4D6>
5 4
7
6 2 13 Nm
8 3 <6A1>
1 4
2 2
1 4
2
3
Clutch fluid:
Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease
Dsassembly steps
1. Piston stopper ring 7. Reservoir tank
2. Piston assembly 8. Clutch master cylinder assembly
"AA 3. Push rod assembly
4. Boot Caution
5. Reservoir cap Do not disassemble piston assembly.
6. Spring pin

"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
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Transmission Oil Replacement . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TRANSMISSION CONTROL* . . . . . . . . . . . . . . . . 4
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3 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 2.2
conforming to API GL-4

MB990635 or Steering linkage Ball joint disconnection
MB991113 puller

TOOL
MZ203827
MB991453 Engine hanger

MANUAL TRANSMISSION - On-vehicle Service 22-3
TRANSMISSION OIL CHECK

Filler plug hole
Transmission oil (1) Remove the oil filler plug.
(2) Oil level should be at the lower portion of the filler plug
hole.
(3) Check that the transmission oil is not noticeably dirty,
and that it has a suitable viscosity.
(4) Tighten the filler plug to the specified torque.
TRANSMISSION OIL REPLACEMENT 22100100247
Filler plug (1) Remove the drain plug to drain oil.

(2) Tighten the drain plug to the specified torque.
(3) Remove the filler plug and fill with specified oil till the
level comes to the lower portion of filler plug hole.
Transmission oil
Specified oil:
32 Nm Drain plug 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

Pre-removal and Post-installation Operation Caution: SRS
D Air Cleaner Assembly Removal and Installation Be careful not to subject the SRS-ECU to any
D Battery and Battery Tray Removal and Installation shocks during removal and installation of the
shift cable and select cable assembly.
8
12 Nm
9 1
8 6
10 5 2
11 3
12 Nm
4
7
12
14
13
Shift cable and select cable Shift lever assembly removal steps
assembly removal steps "BA 1. Shift knob
D Lower cover and side cover (Refer "BA 2. Spring washer
to GROUP 52A - Instrument Panel.) "BA 3. Nut
"BA 1. Shift knob D Floor console box
"BA 2. Spring washer (Refer to GROUP 52A.)
"BA 3. Nut 4. Snap pin
D Floor console box 5. Select cable connection
(Refer to GROUP 52A.) (Shift lever side)
4. Snap pin 6. Clip
5. Select cable connection 7. Shift cable connection
(Shift lever side) (Shift lever side)
6. Clip 12. Shift lever assembly
7. Shift cable connection 13. Distance piece
(Shift lever side) 14. Bushing
8. Snap pin
"AA 9. Select cable connection
(Transmission side)
"AA 10. Shift cable connection
(Transmission side)
"AA 11. Shift cable and select cable
assembly
MANUAL TRANSMISSION - Transmission Control 22-5
"AA SHIFT CABLE AND SELECT CABLE ASSEMBLY/
Shift lever 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 MANUAL TRANSMISSION - Transmission Control
SHIFT LEVER ASSEMBLY 22100400101
5 Nm
6
6 Nm
7
3
1 4 10
2
5
Disassembly steps
1. Bolt 6. Cap
2. Select lever 7. Spacer
3. Bushing 8. Shift lever
4. Return spring 9. Shift lever bushing
5. Collar 10. Lever bracket
MANUAL TRANSMISSION - Transmission Assembly 22-7
TRANSMISSION ASSEMBLY 22100270290

D Transmission Oil Draining (Refer to P.22-3.) D Air Cleaner Assembly Installation
D Under Cover Removal D Battery and Battery Tray Installation
D Battery and Battery Tray Removal D Under Cover Installation
D Air Cleaner Assembly Removal 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
19 Nm 5 <4G6>
5 <4D6, 6A1> 19 Nm
1
103 Nm
19 Nm
44 Nm
9 3
6 2
88 Nm*1 4
10
98 - 118 Nm*1 8 15
15
10 - 12 Nm
81 Nm
12
30 Nm 30 Nm
11
24 - 33 Nm 7
81 Nm
67 - 78 Nm
14
13
88 Nm
98 - 118 Nm
Removal steps
1. Select cable connection 11. No.2 stay
2. Shift cable connection 12. Lateral lower arm connection
3. Backup lamp switch connector AB" 13. No.3 stay
4. Vehicle speed sensor connector 14. Compression lower arm connection
5. Clutch release cylinder connection AC" 15. Drive shaft
6. Clutch fluid line damper connection
7. Starter motor <6A1> Caution
AA" 8. Tie rod end connection *1: Indicates parts which should be temporarily
9. Stabilizer link connection tightened, and then fully tightened with the
10. Damper fork vehicle on the ground in the unladen condition.
22-8 MANUAL TRANSMISSION - Transmission Assembly
57 Nm
16
18
81 Nm*2
49 Nm 30 Nm
19 24 10 - 12 Nm
25
19
17
24 49 Nm
22 25 Nm
49 Nm
57 Nm*2
23
44 Nm
7 Nm
10Nm <Flange bolts>
20 9Nm <Washer assembled bolts>
21
69 Nm
93 Nm
69 - 78 Nm
16. Starter motor <4G6, 4D6> 23. Cover <6A1>

17. Transmission assembly upper part AF" 24. Transmission assembly lower part
coupling bolts coupling bolts
AD" 18. Transmission mount bracket AF" 25. Transmission assembly
"AA 19. Transmission mount stopper
AE" D Engine and transmission assembly Caution
supporting Mounting locations marked by *2 should be
20. Centermember assembly provisionally tightened, and then fully tightened after
21. Rear roll stopper placing the vehicle horizontally and loading the full
22. Bell housing cover <4G6, 4D6> weight of the engine on the vehicle body.
MANUAL TRANSMISSION - Transmission Assembly 22-9
Cord
AA" TIE ROD END DISCONNECTION
Ball joint
Caution
1. Use the special tool to loosen the tie rod end mounting
MB990635 or
MB991113 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
AC" DRIVE SHAFT DISCONNECTION

(1) Insert a pry bar between the transmission case and the
Trans- drive shaft as shown to remove the drive shaft.
mission
side NOTE
Do not remove the hub and knuckle from the drive shaft.
Caution
Pry bar 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 MANUAL TRANSMISSION - Transmission Assembly
MZ203827 AE" ENGINE AND TRANSMISSION ASSEMBLY

SUPPORTING
Set the special tool to the vehicle to support the engine and
transmission assembly.
MB991453
AF" TRANSMISSION ASSEMBLY LOWER PART

COUPLING BOLTS/TRANSMISSION ASSEMBLY
REMOVAL
1. Support the transmission assembly with a transmission
Flywheel jack.
Bolt 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 INSTALLATION SERVICE POINTS
"AA TRANSMISSION MOUNT STOPPER INSTALLATION
Arrow Install the transmission mount stopper so that the arrow points
Transmission
Transmission mount
mount stopper
bracket
23-1
AUTOMATIC
TRANSMISSION
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 A/T Control Component Check . . . . . . . . . . . . . . . 52

Torque Converter Stall Test . . . . . . . . . . . . . . . . . . 54
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . . 56
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Line Pressure Adjustment . . . . . . . . . . . . . . . . . . . . 62
Selector Lever Operation Check . . . . . . . . . . . . . . 62
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 46
TRANSMISSION CONTROL* . . . . . . . . . . . . . . 63
Essential Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
A/T Control Component Location . . . . . . . . . . . . . 51 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
Service Specifications/
23-2 AUTOMATIC TRANSMISSION - Lubricants/Special Tools
Oil temperature sensor kW at 0_C 16.5 - 20.5
at 100_C 0.57 - 0.69
Resistance of damper clutch control solenoid valve coil (at 20_C) W 2.7 - 3.4
Resistance of Low-Reverse solenoid valve coil (at 20_C) W 2.7 - 3.4
Resistance of second solenoid valve coil (at 20_C) W 2.7 - 3.4
Resistance of underdrive solenoid valve coil (at 20_C) W 2.7 - 3.4
Resistance of overdrive solenoid valve coil (at 20_C) W 2.7 - 3.4
Stall speed r/min 2,100 - 2,600
Items Specified lubricant Quantity L
Transmission fluid DIA QUEEN ATF SPII or equivalent 7.8

MB991502 MUT-II sub Checking of the diagnosis code
assembly
MD998330 Oil pressure gauge Measurement of oil pressure

(including (2,942 kPa)
MD998331)
MD998332 Adapter
MD998900 Adapter
AUTOMATIC TRANSMISSION - Special Tools 23-3

MB990635 or Steering linkage Ball joint disconnection
MB991113 puller
MB991610 Oil filter wrench Removal and installation of automatic trans-

mission oil filter

TOOL
MZ203827
MB991453 Engine hanger Supporting the engine assembly during

assembly removal and installation of the transmission
23-4 AUTOMATIC TRANSMISSION - Troubleshooting

Gathering information from custom-
er.

Communication with
MUT-II not possible
Read the diagnosis code (GROUP 00 Inspection procedure No. 1 in
- How to Use Troubleshooting/In- Inspection Chart For Trouble
spection Service Points.) Symptoms (Refer to P.23-27.)
Diagnosis code No diagnosis code displayed
displayed
Erase the diagnosis code (GROUP
00 - How to Use Troubleshooting/In-
spection 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 No abnormality

(diagnosis code
Recheck diagnosis codes which
present)
were read before the road test.
Diagnosis No diagnosis
code displayed code displayed
To INSPECTION CHART FOR To INSPECTION CHART FOR

DIAGNOSIS CODES TROUBLE SYMPTOMS
(Refer to P.23-14.) (Refer to P.23-26.)
Search for cause.

Found Not found
NG
Repair INTERMITTENT MALFUNCTION
(GROUP 00 - Points to Note for
Intermittent Malfunctions.)
OK
NG OK
Confirmation test (road test) Completed
AUTOMATIC TRANSMISSION - Troubleshooting 23-5
1. N range lamp
The N range lamp flashes at a frequency of approximately
1 Hz if there is an abnormality in any of the items in the
table below which are related to the A/T system. Check
the diagnosis code output if the N range lamp is flashing
at a frequency of approximately 1 Hz.
N range lamp flashing items
Crank angle sensor
Input shaft speed sensor
Output shaft speed sensor
Each solenoid valve
Out of phase at each shift point
Caution
If the N range lamp is flashing at a frequency of
approximately 2 Hz (faster than at 1 Hz), it means that
the automatic transmission fluid temperature is too high.
Stop the vehicle in a safe place and wait until the N range
lamp switches off.
2. Method of reading the diagnosis code
Use the MUT-II or the N range lamp to take a reading of
the diagnosis codes. (Refer to GROUP 00 - How to Use
Troubleshooting/Inspection Service Points.)
ROAD TEST 23100780271
Check by the following procedure.

No. State prior to test Test and operation Judgement value Check item Diag- Inspection
and operation nosis procedure page
code if there is an
No. abnormality
1 Ignition switch: Ignition switch Data list No. 54 Control relay 54 A/T Control
OFF (1) ON Battery voltage [V] relay system
(23-25)
2 Ignition switch: Selector lever Data list No. 61 Inhibitor switch - Inhibitor switch
ON position (1) P, (2) R, (3)N, system (23-36)
Engine: Stopped (1) P, (2) R, (4) D, (5) 3, (6) 2,
Selector lever (3) N, (4) D, (7) L
position: P (5) 3, (6) 2, (7) L
Accelerator pedal Data list No. 11 Throttle posi- 11 Throttle
(1) Released (1) 400 - 1,000 mV tion sensor 12 position sensor
(2) Half depressed (2) Gradually rises <Vehicles 14 system (23-15)
(3) Depressed from (1) without TCL> Accelerator
(3) 4,500 - 5,000 Accelerator pedal position
mV pedal position sensor system
sensor (23-15)
<Vehicles with
TCL>
Data list No. 25 Wide open 25 Wide open
(1) OFF throttle switch throttle switch
(2) ON system (23-17)
Brake pedal Data list No. 26 Stop lamp 26 Stop lamp switch
(1) Depressed (1) ON switch system (23-18)
(2) Released (2) OFF
3 Ignition switch: Starting test with Starting should be Starting - Starting
ST lever P or N range possible possible or impossible
Engine: Stopped impossible (23-28)
4 Warming up Drive for 15 Data list No. 15 Oil temperature 15 Oil temperature
minutes or more so Gradually rises to sensor sensor system
that the automatic 70 - 90_C (23-15)
fluid temperature
becomes 70 -
90_C.
code if there is an
No. abnormality
5 Engine: Idling Brake pedal Data list No. 26 Stop lamp 26 Stop lamp switch
Selector lever (Retest) (1) ON switch system (23-18)
position: N (1) Depressed (2) OFF
(2) Released
A/C switch Data list No. 65 Dual pressure - Dual pressure
(1) ON (1) ON switch switch system
(2) OFF (2) OFF (23-37)
Accelerator pedal Data list No. 64 Idle position - Idle position
(1) Released (1) ON switch switch system
(2) Half depressed (2) OFF (23-37)
Data list No. 21 Crank angle 21 Crank angle
(1) 550 - 850 rpm sensor sensor system
Gradually rises (23-16)
from (1)
Data list No. 57 Communication 51 Serial
(2) Data changes with engine- communication
ECU system (23-25)
<Vehicles
without TCL>
Communication
with TCL-ECU
<Vehicles with
TCL>
Selector lever Should be no Malfunction - Engine stalling
position abnormal shifting when starting during shifting
(1) N ® D shocks (23-30)
(2) N ® R Time lag should be - Shocks when
changing from N
within 2 seconds to D and large
time lag (23-30)
- Shocks when
changing from N
to R and large
time lag (23-31)
- Shocks when
changing from N
to D,N to R and
large time lag
(23-32)
Driving - Does not move
impossible forward (23-28)
- Does not
reverse (23-29)
- Does not move
(forward or
reverse) (23-29)
code if there is an
No. abnormality
6 Selector lever Selector lever Data list No. 63 Shift condition - -
position: N position and (2) 1st, (4) 3rd, (3)
(Carry out on a vehicle speed 2nd, (5) 4th
flat and straight (1) Idling in
road.) L range Data list No. 31 Low and reverse 31 Low and reverse
(Vehicle (2) 0 %, (4) 100 %, solenoid valve solenoid valve
stopped) (3) 100 %, (5) 100 system (23-18)
(2) Driving at %
constant speed
of Data list No. 32 Underdrive 32 Underdrive
10 km/h in (2) 0 %, (4) 0 %, solenoid valve solenoid valve
L position (3) 0 %, (5) 100 % system (23-18)
(3) Driving at
constant speed Data list No. 33 Second 33 Second solenoid
of (2)100 %, (4) 100 solenoid valve valve system
30 km/h in %, (3) 0 %, (5) 0 % (23-18)
2 position
(4) Driving at Data list No. 34 Overdrive 34 Overdrive
50 km/h in (2) 100 %, (4) 0 %, solenoid valve solenoid valve
3 position with system (23-18)
accelerator fully (3) 100 %, (5) 0 %
closed
(5) Driving at Data list No. 29 Vehicle speed - Vehicle speed
constant speed (1) 0 km/h sensor sensor system
of (4) 50 km/h (23-38)
50 km/h in
D position Data list No. 22 Input shaft 22 Input shaft speed
(Each (4) 1,800 - 2,100 speed sensor sensor system
condition rpm (23-16)
should be
maintained for Data list No. 23 Output shaft 23 Output shaft
10 seconds or (4) 1,800 - 2,100 speed sensor speed sensor
more.) rpm system (23-17)
7 Selector lever Selector lever Data list No. 36 Damper clutch 36 Damper clutch
position: 3 position and (1) 0 % control solenoid 52 control solenoid
(Carry out on a vehicle speed (2) Approx. 70 - 90 valve valve system
flat and straight (1) Release the ac- % (23-19)
road.) celerator pedal
fully while driv-
ing at 50 km/h Data list No. 52
in 3rd gear. (1) Approx.
(2) Driving at 100 - 300 rpm
constant speed (2) Approx.
of 50 km/h in 0 - 10 rpm
3rd gear.
code if there is an
No. abnormality
8 Use the MUT-II to Monitor data list For (1), (2) and (3), Malfunction - Shocks and
stop the INVECS- No. 11, 23, and 63 the reading should when shifting running up
II function. with the MUT-II. be the same as the (23-32)
Selector lever (1) Accelerate to specified output Displaced - All points (23-33)
position: D 4th gear at a shaft speed and no shifting points
(Carry out on a flat throttle abnormal shocks - Some points
and straight road.) position should occur. (23-34)
sensor output For (4), (5) and (6), Does not shift - No diagnosis
of 1.5V downshifting code (23-34)
(accelerator should occur
opening angle immediately 22 Input shaft
of 30 %). after the shifting speed sensor
(2) Gently operation is made. system (23-16)
decelerate to a 23 Output shaft
standstill. speed sensor
(3) Accelerate to system (23-17)
4th gear at a
throttle Does not shift 31 Low and reverse
position from 1 to 2 or 2 solenoid valve
sensor output to 1 system (23-18)
of 2.5 V 33 Second
(accelerator solenoid valve
opening angle system (23-18)
of 50%).
(4) While driving at 41 1st gear ratio is
60 km/h in 4th not specified
gear, shift (23-20)
down to
42 2nd gear ratio is
3 range.
not specified
(5) While driving at
(23-21)
40 km/h in 3rd
gear, shift Does not shift 33 Second
down to from 2 to 3 or 3 solenoid valve
2 range. to 2 system (23-18)
(6) While driving at
20 km/h in 2nd 34 Overdrive
gear, shift solenoid valve
system (23-18)
down to
L range. 42 2nd gear ratio is
not specified
(23-21)
43 3rd gear ratio is
not specified
(23-22)
Does not shift 32 Underdrive
from 3 to 4 or 4 solenoid valve
to 3 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)
code if there is an
No. abnormality
9 Selector lever Monitor data list The ratio between Does not shift 22 Input shaft
position: N No. 22 data list No. 22 and speed sensor
(Carry out on a and No. 23 with the No. 23 should be system (23-16)
flat and straight MUT-II.
II the same as the
23 Output shaft
road.) (1) Move selector gear ratio when
speed sensor
lever to reversing.
system (23-17)
R range, drive
at constant 46 Reverse gear
speed of ratio is not
10 km/h. specified (23-24)
SHIFT PATTERN
<4G63 engine>
UPSHIFT PATTERN
Throttle opening % Thick line: Standard shift pattern

100
1 2 2 3 3 4
50
2®3
movement
range 3®4
movement
range
0
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
Output shaft speed r/min
0 50 100 150 200

Vehicle speed km/h
DOWNSHIFT PATTERN

100
1 2 2 3 3 4
1 2 (L) 2 3 (L,2) 3 4
(L,2,3)
50
3¬4
movement
2¬3 range
movement
range
0
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
0 50 100 150 200

Vehicle speed km/h
HOLD MODE PATTERN

100 2 3 3 4
3 4
50
1 2
0
0 2,000 4,000 6,000 8,000
0 50 100 150 200

Vehicle speed km/h
<6A13 engine>
UPSHIFT PATTERN

100
1 2 2 3 3 4
50
2®3
movement
range
3®4
movement
range
0
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
0 50 100 150 200

Vehicle speed km/h
DOWNSHIFT PATTERN

100
1 2 2 3 3 4
1 2 (L) 2 3 (L,2) 3 4
(L,2,3)
50
2¬3
movement 3¬4
range movement
range
0
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
0 50 100 150 200

Vehicle speed km/h
HOLD MODE PATTERN

100
2 3 3 4
3 4
50
1 2
0
0 2,000 4,000 6,000 8,000
0 50 100 150 200

Vehicle speed km/h
INSPECTION CHART FOR DIAGNOSIS CODE 23100790243
Code Diagnosis item Reference page
11 Throttle position sensor system Short circuit 23-15

12 Accelerator pedal position sensor system Open circuit 23-15
14 <Vehicles with TCL> Sensor maladjustment 23-15
15 Oil temperature sensor system Open circuit 23-15
21 Crank angle sensor system Open circuit 23-16
22 Input shaft speed sensor system Short circuit/open circuit 23-16
23 Output shaft speed sensor system Short circuit/open circuit 23-17
25 Wide open throttle switch system Short circuit 23-17
26 Stop lamp switch system Short circuit/open circuit 23-18
31 Low and reverse solenoid valve system Short circuit/open circuit 23-18
32 Underdrive solenoid valve system Short circuit/open circuit 23-18
33 Second solenoid valve system Short circuit/open circuit 23-18
34 Overdrive solenoid valve system Short circuit/open circuit 23-18
36 Damper control clutch solenoid valve system Short circuit/open circuit 23-19
41 1st gear ratio does not meet the specification 23-20
42 2st gear ratio does not meet the specification 23-21
43 3rd gear ratio does not meet the specification 23-22
44 4th gear ratio does not meet the specification 23-23
46 Reverse gear ratio does not meet the specification 23-24
51 Abnormal communication with engine-ECU <Vehicles without TCL> 23-25

Abnormal communication with TCL-ECU <Vehicles with TCL>
52 Damper control clutch solenoid valve system Defective system 23-19
54 A/T Control relay system Short circuit to earth/ 23-25

open circuit
56 N range lamp system Short circuit to earth 23-26
71 Malfunction of A/T-ECU 23-26

Code No. 11, 12, 14 Throttle position sensor system Probable cause
<Vehicles without TCL>, accelerator pedal position
sensor <Vehicles with TCL>
If the TPS or APS output voltage is 4.8 V or higher when the engine is idling, the D Malfunction of the throttle position sensor <Vehicles
output is judged to be too high and diagnosis code No. 11 is output. Code No. 11 without TCL>
is also output if there is a problem with the APS and an APS fail-safe signal is received D Malfunction of the accelerator pedal position sensor
from the TCL-ECU. If the TPS or APS output voltage is 0.2 V or lower at times <Vehicles with TCL>
other than when the engine is idling, the output is judged to be too low and diagnosis D Malfunction of connector
code No. 12 is output. If the TPS or APS output voltage is 0.2 V or lower or if it D Malfunction of the A/T-ECU
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.
NG
Throttle position sensor check <Vehicles without TCL> Replace
Accelerator pedal position sensor check<Vehicles with TCL>
(Refer to GROUP 13H - On-vehicle Service.)
OK
NG
B-07 <Vehicles without TCL>, B-41 <Vehicles with TCL>, C-29
OK
NG
Harness check Repair
D Between throttle position sensor and A/T-ECU
D Between accelerator pedal position sensor and A/T-ECU
<Vehicles with TCL>
OK
NG
Check the trouble symptoms. Replace the A/T-ECU.
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 D Malfunction of the oil temperature sensor
10 minutes or more (if the oil temperature does not increase), it is judged that there D Malfunction of connector
is an open circuit in the oil temperature sensor and diagnosis code No. 15 is output. D Malfunction of the A/T-ECU
NG
Oil temperature sensor check (Refer to P.23-52.) Replace
OK
NG
Check the follwing connectors: B-70, C-29 Repair
OK
NG
D Between oil temperature sensor and A/T-ECU
OK
NG

If no output pulse is detected from the crank angle sensor for 5 seconds or more D Malfunction of the crank angle sensor
while driving at 25 km/h or more, it is judged that there is an open circuit in the D Malfunction of connector
crank angle sensor and diagnosis code No. 21 is output. D Malfunction of the A/T-ECU
NG
Check the follwing connectors: B-77, C-29 Repair
OK
NG
D Between crank angle sensor and A/T-ECU
OK
Crank angle sensor system check

(Refer to GROUP 13A - Troubleshooting.)
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 D Malfunction of the input shaft speed sensor
more while driving in 3rd or 4th gear at a speed of 30 km/h or more, there is judged D Malfunction of the underdrive clutch retainer
to be an open circuit or short-circuit in the input shaft speed sensor and diagnosis D Malfunction of connector
code No. 22 is output. If diagnosis code No. 22 is output four times, the transmission D Malfunction of A/T-ECU
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.
L: Refer to the Transmission Workshop Manual.

NG NG
Measure at the input shaft speed sensor Check the following connectors: Repair
connector B-71. B-71, C-29
D Disconnect the connector and OK
measure at the harness side. NG
(1) Voltage between 3 and earth Check the following harness: Repair
(Ignition switch: ON) D Between the input shaft speed
OK: Battery voltage sensor and the ignition switch
(2) Voltage between 2 and earth D Between the input shaft speed
(Ignition switch: ON) sensor and A/T-ECU
OK approx. 5 V
(3) Continuity between 1 and earth OK
OK: Continuity NG
OK
NG
Measure output waveform of the input Replace the input shaft speed sensor.
shaft speed sensor.
(using an oscilloscope)
D Engine: 2,000 r/min (approx. 50 NG
Check the trouble symptoms. A/T overhaul K
km/h) D Replace the underdrive clutch
D Transmission: 3rd gear (Voltage) retainer.
OK: Conforms to the waveform
shown at page 23-45 (Inspec-
tion procedure using an oscil-
loscope). There is no noise Check the trouble symptoms.
in the output waveform. NG
OK
NG Eliminate the cause of the noise.
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 D Malfunction of the output shaft speed sensor
vehicle speed for 1 second or more while driving in 3rd or 4th gear at a speed of D Malfunction of the transfer drive gear or driven gear
30 km/h or more, there is judged to be an open circuit or short-circuit in the output D Malfunction of connector
shaft speed sensor and diagnosis code No. 23 is output. D Malfunction of the A/T-ECU
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.

NG NG
Measure at the output shaft speed sen- Check the following connectors: Repair
sor connector B-68. B-68, C-29
(1) Voltage between 3 and earth Check the following harness: Repair
(Ignition switch: ON) D Between the output shaft speed
OK: Battery voltage sensor and the ignition switch
(2) Voltage between 2 and earth D Between the output shaft speed
(Ignition switch: ON) sensor and A/T-ECU
OK: approx. 5 V
(3) Continuity between 1 and earth OK
OK: Continuity NG
OK
NG
Measure output waveform of the output Replace the output shaft speed sensor.
shaft speed sensor.
NG
D Engine: 2,000 r/min Check the trouble symptoms. A/T overhaul L
(approx. 50 km/h) D Replace the transfer drive gear and
D Transmission: 3rd gear driven gear.
(Voltage)
OK: Conforms to the waveform
shown at page 23-45 (Inspec-
tion procedure using an oscil- Check the trouble symptoms.
loscope). There is no noise NG
in the output waveform.
OK Eliminate the cause of the noise.
NG
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 D Malfunction of the wide open throttle switch
opening angle at 70% or less, it is judged that there is a short circuit in the wide D Malfunction of connector
open throttle switch and diagnosis code No. 25 is output. D Malfunction of A/T-ECU
NG
Wide open throttle switch check (Refer to P.23-64). Replace
OK
NG
OK
NG
D Between the wide open throttle switch and the A/T-ECU.
OK
NG
Code No. 26 Stop lamp switch system Probable cause

If the stop lamp switch is on for 5 minutes or more while driving, it is judged that D Malfunction of the stop lamp switch
there is a short circuit in the stop lamp switch and diagnosis code No. 26 is output. D Malfunction of connector
D Malfunction of the A/T-ECU
NG
Stop lamp switch check (Refer to GROUP 35 - Brake Pedal.) Replace
OK
NG
Check the following connectors: C-02, C-30, C-65, C-83 Repair
OK
NG
D Between stop lamp switch and A/T-ECU
OK
NG
Code No. 31 Low and reverse solenoid valve system Probable cause
Code No. 32 Underdrive solenoid valve system
Code No. 33 Second solenoid valve system
Code No. 34 Overdrive solenoid valve system
If the resistance value for a solenoid valve is too large or too small, it is judged D Malfunction of solenoid valve
that there is a short-circuit or an open circuit in the solenoid valve and the respective D Malfunction of connector
diagnosis code is output. The transmission is locked into 3rd gear as a fail-safe measure, D Malfunction of the A/T-ECU
and the N range lamp flashes at a frequency of 1 Hz.
NG
Solenoid valve check (Refer to P.23-54.) Replace
OK
NG
Check the following connectors: B-70, C-28, C-30, C-41 Repair
OK
NG
D Between solenoid valve and A/T-ECU
OK
Replace the solenoid valve.
NG
Code No. 36, 52 Damper clutch control solenoid valve Probable cause
system
If the resistance value for the damper clutch control solenoid valve is too large or D Malfunction of the damper clutch control solenoid valve
too small, it is judged that there is a short-circuit or an open circuit in the damper D Malfunction of connector
clutch control solenoid valve and diagnosis code No. 36 is output. If the drive duty D Malfunction of the A/T-ECU
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.
NG
Damper clutch control solenoid valve check (Refer to P.23-54.) Replace
OK
NG
Check the following connectors: B-70, C-28, C-41 Repair
OK
NG
D Between damper clutch control solenoid valve and A/T-ECU
OK
Replace the damper clutch control solenoid valve.
NG
Code No. 41 1st gear ratio does not meet the specification Probable cause
If the output from the output shaft speed sensor multiplied by the 1st gear ratio is D Malfunction of the input shaft speed sensor
not the same as the output from the input shaft speed sensor after shifting to 1st D Malfunction of the output shaft speed sensor
gear has been completed, diagnosis code No. 41 is output. If diagnosis code No. D Malfunction of the underdrive clutch retainer
41 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, D Malfunction of the transfer drive gear or driven gear
and the N range lamp flashes at a frequency of 1 Hz. D Malfunction of the low and reverse brake system
D Malfunction of the underdrive clutch system
D Noise generated

Yes
MUT-II Self-Diag code Code No. 22 Input shaft speed sensor system check
Is the diagnosis code No. 22 output? (Refer to P.23-16.)
No
Yes
MUT-II Self-Diag code Code No. 23 Output shaft speed sensor system check
No
NG
Measure output waveform from the input shaft speed sensor. (using Replace the input shaft speed sensor.
an oscilloscope)
D Connect the connector B-71 and measure voltage between
31 and 43 at the A/T-ECU. Check the trouble symptoms.
D Engine: 2,000 r/min (approx. 50 km/h)
D Selector lever position: 3 NG
(Voltage)
OK: A waveform such as the one shown on P.23-45 (Inspection A/T overhaul L
Procedure Using an Oscilloscope) is output (flalshing D Replace the underdrive clutch retainer.
between 0 ¬® 5V) and there is no noise appearing
in the waveform.
OK Check the trouble symptoms.
NG
Eliminate the cause of the noise.
NG
Measure output waveform from the output shaft speed sensor. Replace the output shaft speed sensor.
(Voltage)
Procedure Using an Oscilloscope) is output (flalshing D Replace the transfer drive gear and driven gear.
in the waveform.
NG
A/T overhaul L
D Underdrive clutch system check Eliminate the cause of the noise.
(No. 42, No. 43, or no diagnosis code is output).
D Low and reverse brake system check
(No. 46 or no diagnosis code is output).
Code No. 42 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 D Malfunction of the input shaft speed sensor
is not the same as the output from the input shaft speed sensor after shifting to D Malfunction of the output shaft speed sensor
2nd gear has been completed, diagnosis code No. 42 is output. If diagnosis code D Malfunction of the underdrive clutch retainer
No. 42 is output four times, the transmission is locked into 3rd gear as a fail-safe D Malfunction of the transfer drive gear or driven gear
measure, and the N range lamp flashes at a frequency of 1 Hz. D Malfunction of the second brake system
D Malfunction of the underdrive clutch system
D Noise generated

Yes
No
Yes
No
NG
an oscilloscope)
(Voltage)
in the waveform.
NG
NG
(Voltage)
in the waveform.
NG
A/T overhaul L
D Second brake system check
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 D Malfunction of the input shaft speed sensor
not the same as the output from the input shaft speed sensor after shifting to 3rd D Malfunction of the output shaft speed sensor
43 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, D Malfunciton of the transfer drive gear or driven gear
and the N range lamp flashes at a frequency of 1 Hz. D Malfunction of the underdrive clutch system
D Malfunction of the overdrive clutch system
D Noise generated

Yes
No
Yes
No
NG
an oscilloscope)
(Voltage)
in the waveform.
NG
NG
(Voltage)
in the waveform.
NG
A/T overhaul L
D Overdrive clutch system check
Code No. 44 4th gear ratio does not meet the specification Probable cause
If the output from the output shaft speed sensor multiplied by the 4th gear ratio is D Malfunction of the input shaft speed sensor
not the same as the output from the input shaft speed sensor after shifting to 4th D Malfunction of the output shaft speed sensor
44 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, D Malfunction of the transfer drive gear or driven gear
and the N range lamp flashes at a frequency of 1 Hz. D Malfunction of the second brake system
D Malfunction of the overdrive clutch system
D Noise generated

Yes
No
Yes
No
NG
an oscilloscope)
(Voltage)
Procedure Using an Oscilloscope) is output (flashing be- D Replace the underdrive clutch retainer.
tween 0 ¬® 5V) and there is no noise appearing in
the waveform.
NG
NG
(Voltage)
in the waveform.
NG
A/T overhaul L
D Second brake system check Eliminate the cause of the noise.
D Overdrive clutch system check
Code No. 46 Reverse gear ratio does not meet the Probable cause
specification
If the output from the output shaft speed sensor multiplied by the reverse gear ratio D Malfunction of the input shaft speed sensor
is not the same as the output from the input shaft speed sensor after shifting to D Malfunction of the output shaft speed sensor
reverse gear has been completed, diagnosis code No. 46 is output. If diagnosis code D Malfunction of the underdrive clutch retainer
No. 46 is output four times, the transmission is locked into 3rd gear as a fail-safe D Malfunciton of the transfer drive gear or driven gear
measure, and the N range lamp flashes at a frequency of 1 Hz. D Malfunction of the low and reverse brake system
D Malfunction of the reverse clutch system
D Noise generated

Yes
No
Yes
No
NG
an oscilloscope)
(Voltage)
in the waveform.
NG
NG
(Voltage)
in the waveform.
NG
A/T overhaul L
D Low and reverse brake system check Eliminate the cause of the noise.
D Reverse clutch system check (No diagnosis code is output).
Code No. 51 Abnormal communication with engine-ECU Probable cause
Abnormal communication with TCL-ECU
<Vehicles with TCL>
If normal communication is not possible for a continuous period of 1 second or more D Malfunction of connector
when the ignition switch is at the ON position, the battery voltage is 10 V or more D Malfunction of the engine-ECU <Vehicles without TCL>
and the engine speed is 450 r/min or more, diagnosis code No. 51 is output. Diagnosis D Malfunction of the TCL-ECU <Vehicles with TCL>
code No. 51 is also output if the data being received is abnormal for a continuous D Malfunction of the A/T-ECU
period of 4 seconds under the same conditions.
NG
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
NG
D Between engine-ECU and A/T-ECU
D Between TCL-ECU and A/T-ECU
<Vehicles with TCL>
OK
Check the trouble symptoms.

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 D Malfunction of the A/T control relay
turned ON, it is judged that there is an open circuit or a short-circuit in the A/T control D Malfunction of connector
relay earth and diagnosis code No. 54 is output. D Malfunction of the A/T-ECU
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.
NG
Check the A/T control relay. (Refer to P.23-53.) Replace
OK
NG
Check the following connectors: B-30, C-28, C-30, C-41, C-45 Repair
OK
NG
D Between control relay and body earth
D Between control relay and battery
D Between control relay and A/T-ECU
OK
NG
Code No. 56 N range lamp system Probable cause

If the N range signal is off after an N range lamp illumination instruction (ON instruction) D Malfunction of the N range lamp bulb
has been given, it is judged that there is a short-circuit in the N range lamp earth D Malfunction of connector
and diagnosis code No. 56 is output. D Malfunction of the A/T-ECU
NG
Check the N range lamp bulb Replace
(Refer to GROUP 52A - Instrument Panel.)
OK
NG
Check the following connectors: C-30, C-90, D-02 Repair
OK
NG
D Between N range lamp bulb and A/T-ECU
OK
NG
Code No. 71 Malfunction of A/T-ECU Probale cause

There is an abnormality in the A/T-ECU. The transmission is locked into 3rd gear D Malfunction of the A/T-ECU
as a fail-safe measure.
Trouble symptom Inspection Reference

procedure No. page
Communication with MUT-II is not possible 1 23-27
Driving impossible Starting impossible 2 23-28
Does not move forward 3 23-28
Does not reverse 4 23-29
Does not move (forward or reverse) 5 23-29
Malfunction when starting Engine stalling when shifting 6 23-30
Shocks when changing from N to D and large time lag 7 23-30
Shocks when changing from N to R and large time lag 8 23-31
Shocks when changing from N to D, N to R and large 9 23-32

time lag
Malfunction when shifting Shocks and running up 10 23-32


procedure No. page
Displaced shifting points All points 11 23-33
Some points 12 23-34
Does not shift No diagnosis codes 13 23-34
Malfunction while driving Poor acceleration 14 23-35
Vibration 15 23-35
Inhibitor switch system 16 23-36
Mode control switch system 17 23-36
Idle position switch system 18 23-37
Dual pressure switch system 19 23-37
Vehicle speed sensor system 20 23-38
Auto-cruse-ECU signal system 21 23-38

Communication with MUT-II is not possible Probable cause
If communication with the MUT-II is not possible, the cause is probably a defective D Malfunction of diagnosis line
diagnosis line or the A/T-ECU is not functioning. D Malfunction of connector
No
Is communication with other systems Check the diagnosis line with MUT-II,
possible using the MUT-II? and repair if necessary.
Yes
NG NG
Check the continuity and voltage of the Check the following connectors: Repair
A/T-ECU connector. C-28, C-30, C-45, C-83, C-131, C-134
D Disconnect the connector C-28 and OK
check at harness side. NG
D Voltage between terminals No. 11, Harness check Repair
24 and earth D Between power supply and
OK: Battery voltage A/T-ECU
D Voltage between C-28 terminals D Between earth and A/T-ECU
Nos.12, 13, 25, 26, C-30 terminal
No. 72 and earth OK
OK: Continuity
OK
NG NG
C-20, C-28, C-30, C-49, C-66, C-83 Repalce the A/T-ECU.
OK
NG
D Between diagnosis connector and
A/T-ECU
OK
NG
Starting impossible Probable cause
Starting is not possible when the selector lever is in P or N range.In such cases, D Malfunction of the engine system
the cause is probably a defective engine system, torque converter or oil pump. D Malfunction of the torque converter
D Malfunction of the oil pump

NG
Check the engine system. Repair, replace
D Control system, ignition system, fuel system, main engine
system
OK
NG
Torque converter check Repair if possible. If the splines are damaged and repairs are not
D Check for incorrect installation (inserted at an angle, etc.) and possible, replace the torque converter assembly.
for damaged splines.
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 Abnormal line pressure
D, 3, 2 or L range while the engine is idling, the cause is probably abnormal line D Malfunction of the underdrive solenoid valve
pressure or a malfunction of the underdrive clutch or valve body. D Malfunction of the underdrive clutch
D Malfunction of the valve body

NG
MUT-II Actuator test Replace the solenoid valve. L
D No. 2 Underdrive solenoid valve
OK
NG
Hydraulic pressure test (Refer to P.23-56.) Valve body disassembly, cleaning and reassembly L
D Measure the hydraulic pressure for each element when in L D Pay particular attention to loosening of bolts, and to damage
range. and slippage of O-rings, valves and valve bodies.
Standard value: Refer to P.23-57. D If the damage cannot be repaired, replace the valve body
assembly.
OK
Underdrive clutch system check L OK

D Remove the transmission assembly, valve body cover and valve
body. NG
D Pistons should operate and pressure should be maintained Underdrive clutch check L
when air is blown through the underdrive clutch oil hole in the D Check for burning of the facing, defective piston seal rings
transmission case. and interference at the retainer.
Does not reverse Probable cause
If the vehicle does not reverse when the selector lever is shifted from N to R range D Abnormal reverse clutch pressure
while the engine is idling, the cause is probably abnormal pressure in the reverse D Abnormal low and reverse brake pressure
clutch or low and reverse brake or a malfunction of the reverse clutch, low and reverse D Malfunction of the low and reverse solenoid valve
brake or valve body. D Malfunction of the reverse clutch
D Malfunction of the low and reverse brake

NG
MUT-II Actuator test Replace the low and reverse solenoid valve. L
D No. 1 Low and reverse solenoid valve
OK
NG
Hydraulic pressure check (Refer to P.23-56.)
D Measure the reverse clutch pressure in R range.
Standard value: Refer to P.23-57.
OK
NG
Hydraulic pressure check (Refer to P.23-56.) Valve body disassembly, cleaning and reassembly L
D Measure the low and reverse brake pressure in R range. D Pay particular attention to loosening of bolts, and to damage
Standard value: Refer to P.23-57. and slippage of O-rings, valves and valve bodies.
D If the damage cannot be repaired, replace the valve body
OK
assembly.
Reverse clutch system and low and reverse brake system check OK
L
D Remove the transmission assembly, valve body cover and valve
body.
D Pistons should operate and pressure should be maintained NG Reverse clutch and low and reverse brake check L
when air is blown through the reverse clutch oil hole and the D Check for burning of the facing, defective piston seal rings
low reverse brake oil hole in the transmission case. and interference at the retainer.
Does not move (forward or reverse) Probable cause
If the vehicle does not move forward or reverse when the selector lever is shifted D Abnormal line pressure
to any position while the engine is idling, the cause is probably abnormal line pressure, D Malfunction of power train
or a malfunction of the power train, oil pump or valve body. D Malfunction of the oil pump

OK
Hydraulic pressure check (Refer to P.23-56.) Power train check L
D Measure the hydraulic pressure for each element when moving D Disassemble the transmission, check the condition of the
forward and back. planetary carrier, output shaft and differential, etc.
NG
NG
Replace the oil pump assembly. L Valve body disassembly, cleaning and reassembly L
(The oil pump cannot be disassembled.) D Pay particular attention to loosening of bolts, and to damage
and slippage of O-rings, valves and valve bodies.
assembly.
Engine stalling when shifting Probable cause
If the engine stalls when the selector lever is shifted from N to D or R range while D Malfunction of the engine system
the engine is idling, the cause is probably a malfunction of the engine system, damper D Malfunction of the damper clutch control solenoid valve
clutch solenoid valve, valve body or torque converter (damper clutch malfunction). D Malfunction of the valve body
D Malfunction of the torque converter (Malfuction of the
damper clutch)

NG
Engine system check Repair, replace
D Check the control system, ignition system, fuel system and
main system.
OK
Replace the damper clutch control solenoid valve.
NG
Valve body disassembly, cleaning and reassembly L Repalce the torque converter.
D Pay particular attention to loosening of bolts, and to damage
assembly.
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 D Abnormal underdrive clutch pressure
lever is shifted from N to D range while the engine is idling, the cause is probably D Malfunction of the underdrive solenoid valve
abnormal underdrive clutch pressure or a malfunction of the underdrive clutch, valve D Malfunction of the underdrive clutch
body or idle position switch. D Malfunction of the valve body
D Malfunction of the idle position switch

NG
MUT-II Actuator test Replace the underdrive solenoid valve. L
OK When starting
When does the shock occur? Shocks sometimes occur
When shifting No Yes
NG
Hydraulic pressure test (Refer to P.23-56.) MUT-II Data list
D Measure the underdrive clutch pressure when shifting from D No. 64 Idle position switch
N to D. OK: Turns from on to off when the accelerator pedal is slightly
Standard value: Refer to P.23-57. depressed from the fully closed position.
OK OK NG
OK
Underdrive clutch system check L Idle position switch check
D Remove the transmission assembly, valve body cover and valve D INSPECTION PROCEDURE 18 - Idle position switch system
body. check (Refer to P.23-37.)
D Pistons should operate and pressure should be maintained
when air is blown through the underdrive clutch oil hole in the
transmission case. Valve body disassembly, cleaning and reassembly L
NG D Pay particular attention to loosening of bolts, and to damage
Underdrive clutch check L D If the damage cannot be repaired, replace the valve body
D Check for burning of the facing, defective piston seal rings assembly.
and interference at the retainer.
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 D Abnormal reverse clutch pressure
lever is shifted from N to R range while the engine is idling, the cause is probably D Abnormal low and reverse brake pressure
abnormal reverse clutch pressure or low and reverse brake pressure, or a malfunction D Malfunction of the low and reverse solenoid valve
of the reverse clutch, low and reverse brake, valve body or idle position switch. D Malfunction of the reverse clutch
D Malfunction of the low and reverse brake
D Malfunction of the idle position switch

NG
MUT-II Actuator test Replace the low and reverse solenoid valve. L
OK When starting
When does the shock occur? Shocks sometimes occur
When shifting No Yes
NG
Hydraulic pressure test (Refer to P.23-56.) MUT-II Data list
D Measure the reverse clutch pressure in R range. D No. 64 Idle position switch
Standard value: Refer to P.23-57. OK: Turns from on to off when the accelerator pedal is slightly
depressed from the fully closed position.
OK
OK NG
NG Idle position switch check

Hydraulic pressure test (Refer to P.23-56.) D INSPECTION PROCEDURE 18 - Idle position switch system
D Measure the low and reverse brake pressure in R range. check (Refer to P.23-37.)
OK
Valve body disassembly, cleaning and reassembly L
OK
Reverse clutch system and low reverse brake system check L D Pay particular attention to loosening of bolts, and to damage
D Remove the transmission assembly, valve body cover and valve and slippage of O-rings, valves and valve bodies.
body. D If the damage cannot be repaired, replace the valve body
D Pistons should operate and pressure should be maintained assembly.
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

D Check for burning of the facing, defective piston seal rings
Shocks when changing from N to D, N to R and large time Probable cause
lag
If abnormal shocks or a time lag of 2 seconds or more occur when the selector D Abnormal line pressure
lever is shifted from N to D range and from N to R range while the engine is idling, D Malfunction of the oil pump
the cause is probably abnormal line pressure or a malfunction of the oil pump or D Malfunction of the valve body
valve body.

NG
Hydraulic pressure test (Refer to P.23-56.) Adjust the line pressure. (Refer to P.23-62.)
D Measure the hydraulic pressure for each element when in D
NG
range and R range.
OK When
When does the shock occur? starting Valve body disassembly, cleaning and reassembly L
When shifting and slippage of O-rings, valves and valve bodies.
Replace the oil pump assembly. L assembly.
Shocks and running up Probable cause
If shocks occur when driving due to upshifting or downshifting and the transmission D Abnormal line pressure
speed becomes higher than the engine speed, the cause is probably abnormal line D Malfunction of each solenoid valve
pressure or a malfunction of a solenoid valve, oil pump, valve body or of a brake D Malfunction of the oil pump
or clutch. D Malfunction of the valve body
D Malfunction of each brake or each clutch

NG
MUT-II Actuator test Replace the solenoid valve.
D No. 3 Second solenoid valve
D No. 4 Overdrive solenoid valve
OK
NG
Adjust the line pressure. (Refer to P.23-62.) Replace the oil pump assembly. L
OK
NG
Clutch and brake check L
D Check for burning of the facing, defective piston seal rings Valve body disassembly, cleaning and reassembly L
and interference at the retainer. D Pay particular attention to loosening of bolts, and to damage
assembly.
All points (Displaced shifting points) Probable cause
If all shift points are displaced while driving, the cause is probably a malfunction D Malfunction of the output shaft speed sensor
of the output shaft speed sensor, TPS or of a solenoid valve. D Malfunction of the throttle position sensor
D Malfunction of each solenoid valve
D Abnormal line pressure

NG
MUT-II Data list Code No. 23 - Output shaft speed sensor system (Refer to P.23-17.)
D No. 23 Output shaft speed sensor
OK: Increases in proportion to vehicle speed.
OK
NG
MUT-II Data list Code No. 11, 12, 14 TPS/APS system check (Refer to P.23-15.)
D No. 11 TPS/APS
OK: Increases in proportion to accelerator pedal opening angle
OK
NG
MUT-II Data list Replace the solenoid valve. L
D No. 31 Low and reverse solenoid valve duty % NG
D No. 32 Underdrive solenoid valve duty %
D No. 33 Second solenoid valve duty % Repalce the A/T-ECU.
D No. 34 Overdrive solenoid valve duty %
OK: Refer to the table below.
OK
NG
Adjust the line pressure. (Refer to P.23-62.) Valve body disassembly, cleaning and reassembly L
assembly.
No. 31 No. 32 No. 33 No. 34
Driving at constant speed in 1st gear 0% 0% 100 % 100 %
Driving at constant speed in 2nd gear 100 % 0% 0% 100 %
Driving at constant speed in 3rd gear 100 % 0% 100 % 0%
Driving at constant speed in 4th gear 100 % 100 % 0% 0%

Some points (Displaced shifting points) Probable cause
If some of the shift points are displaced while driving, the cause is probably a malfunction D Malfunction of the valve body
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.
No No
Does standard shifting occur normally? Does the problem occur only when the Valve body disassembly, cleaning and
automatictransmissionfluidtemperature reassembly L
Yes
is - 29_C or lower or 125_C or higher? D Pay particular attention to loosening
of bolts, and to damage and slippage
Yes
of O-rings, valves and valve bodies.
It is related to control and is not an ab- D If the damage cannot be repaired,
replace the valve body assembly.
normality.
No diagnosis codes (Does not shift) Probable cause
If shifting does not occur while driving and no diagnosis codes are output, the cause D Malfunction of the inhibitor switch
is probably a malfunction of the inhibitor switch, or A/T-ECU. D Malfunction of the A/T-ECU
No NG
Does the transmission remain in 3rd MUT-II Data list Inhibitor switch check
gear with selector lever in position D No. 61 Inhibitor switch D INSPECTION PROCEDURE 16 -
D ? OK: A/T-ECU input signal and se- Inhibitor switch system check.
lector lever position should (Refer to P.23-36.)
Yes
match.
Is backup power being supplied to the OK
A/T-ECU? NG
No Yes MUT-II Data list Mode control switch check
D No. 62 Hold mode signal D INSPECTION PROCEDURE 17 -
Yes
Is power being supplied to the OK: The signal should change Mode control switch system check
A/T-ECU? when the mode control switch (Refer to P.23-36.)
position is changed.
No
OK
Power supply circuit check
D Pay particular attention to open Replace the A/T-ECU.
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.
If acceleration is poor even if downshifting occurs while driving, the cause is probably D Malfunction of the engine system
a malfunction of the engine system or of a brake or clutch. D Malfunction of the brake or clutch

NG
Engine system check Replace, repair
D Check the control system, ignition system, fuel system and
main system.
OK
Brake or clutch check L

D Check for burning of the facing, defective piston seal rings
Vibration Probable cause
If vibration occurs when driving at constant speed or when accelerating and deceleration D Abnormal damper clutch pressure
in top range, the cause is probably abnormal damper clutch pressure or a malfunction D Malfunction of the engine system
of the engine system, damper clutch control solenoid valve, torque converter or valve D Malfunction of the damper clutch control solenoid valve
body. D Malfunction of the torque converter

NG
MUT-II Actuator test Replace the damper clutch control solenoid valve. L
D No. 6 Damper clutch control solenoid valve
OK
Yes
Does the problem occur even when the oil temperature sensor Engine system check
connector is disconnected? D Check the control system, ignition system, fuel system and
main system.
No
NG
Hydraulic pressure test (Refer to P.23-56.) Valve body disassembly, cleaning and reassembly L
D Measure the damper clutch pressure. D Pay particular attention to loosening of bolts, and to damage
Standard value: Refer to P.23-57. and slippage of O-rings, valves and valve bodies.
OK assembly.
Replace the torque converter assembly.
Inhibitor switch system Probable cause
The cause is probably a malfunction of the inhibitor switch circuit, ignition switch D Malfunction of the inhibitor switch
circuit or a defective A/T-ECU. D Malfunction of the ignition switch
D Malfunction of connector
NG
Inhibitor switch check (Refer to P.23-49.) Replace
OK
NG NG
Check the voltage of the inhibitor switch Check the following connectors: Repair
connector B-72. C-49, C-83, C-131, C-134
D Voltage between terminal No. 8 and Harness check Repair
earth D Between inhibitor switch and
OK: Battery voltage ignition switch
OK OK
NG
Check the following connectors: Repair Check the trouble symptoms.
B-72, C-30, C-47, C-48
NG
OK
NG Ignition switch check
Harness check Repair (Refer to GROUP54 - Ignition Switch.)
D Between inhibitor switch and
A/T-ECU connector
OK
NG
Check the trouble symptoms. Repalce the A/T-ECU.
Mode control switch system Probable cause
The cause is probably a defective mode control switch circuit or a defective A/T-ECU. D Malfunction of the mode control switch
NG
Mode control switch check Replace
OK
NG NG
Check the voltage of the A/T-ECU con- Check the following connectors: Repair
nector C-30. C-49, C-83, C-89, C-131, C-134
D Disconnect the connector and check OK
at the harness side.
NG
D Ignition switch: ON Harness check. Repair
D Select the HOLD mode. D Between mode control switch and
D Voltage between terminal No. 70 and A/T-ECU
earth
OK NG
D Between mode control switch and
ignition switch
OK

NG
Check the following the connector: Ignition switch check (Refer to GROUP
C-30 54 - Ignition Switch.)
OK
NG
Idle position switch system Probable cause
The cause is probably a defective idle position switch circuit or a defective A/T-ECU. D Malfunction of the idle position switch
NG
Idle position switch check Replace the throttle position sensor.
OK
NG
B-07 <Vehicles without TCL>, B-41 <Vehicles with TCL>, C-29
OK
NG
D Between idle position switch and A/T-ECU
OK
NG
Dual pressure switch system Probable cause
The cause is probably a defective dual pressure switch circuit or a defective A/T-ECU. D Malfunction of the dual pressure switch
D Malfunction of A/C system
NG
Dual pressure switch check (Refer to Replace
GROUP 55 - On-vehicle service.)
OK
OK NG
Check the voltage of the A/T-ECU con- Check the following connectors: Repair
nector C-28. B-30, C-28
check at the harness side.
D Ignition switch: ON Check the trouble symptoms.
D A/C switch: ON
D Voltage between terminal No. 10 NG
and earth NG
OK: Battery voltage Check the A/C system. (Refer to Repair
GROUP 55 - Troubleshooting.)
NG
OK
A/C system check (Refer to GROUP
55 - Troubleshooting.) Replace the A/T-ECU.
Vehicle speed sensor system Probable cause
The cause is probably a defective vehicle speed sensor circuit or a defective A/T-ECU. D Malfunction of the vehicle speed sensor
NG
Check the vehicle speed sensor. Replace
(Refer to GROUP 54 - Combination Meters.)
OK
1. NG NG
Measure at the vehicle speed sensor connector B-67. Check the following Repair
D Disconnect the connector, and measure at the harness side. connectors:
1. Voltage between 1 and earth (Ignition switch: ON) 2. NG C-90, C-131, C-135
OK: 4.8 - 5.2 V 3. NG
OK: Continuity NG
NG
OK Check the harness wire Repair
NG between the vehicle
Check the following Repair speed sensor and ignition
connector: switch connector.
B-67
OK
OK
Check the ignition switch. (Refer to GROUP 54 - Ignition switch.)
NG
NG
NG Check the following Repair
connectors:
between the engine-ECU C-30, C-48
sensor connector. OK
Replace the engine-ECU. NG
NG
sensor connector.
OK
Auto-cruise-ECU signal system Probable cause
The cause is probably a defective auto-cruise signal line circuit or a defective A/T-ECU. D Malfunction of connector
D Malfunction of the auto-cruise-ECU
NG
Auto-cruise system check (Refer to GROUP 17 - Troubleshooting.) Repair
OK
NG
OK
OK
Harness check Replace the A/T-ECU.
D Between auto-cruise-ECU and A/T-ECU
NG
Repair
Item No. Check item Check requirement Normal value
11 Throttle position sensor Engine: Stopped Accelerator pedal: 400 - 1,000 mV

<Vehicles without TCL> Selector lever Released
Accelerator pedal position: P
position sensor Accelerator pedal: Gradually rises from the
<Vehicles with TCL> Halfly depressed above value
Accelerator pedal: 4,500 - 5,000 mV

Depressed
15 Oil temperature sensor Warming up Drive for 15 minutes or Gradually rises to

more so that the 70 - 90 _C
automatic transmission
fluid temperature
becomes 70 - 90 _C.
21 Crank angle sensor Engine: Idling Accelerator pedal: 550 - 900 rpm
Selector lever Released
position: P
Accelerator pedal: Gradually rises from the
Halfly depressed above value
22 Input shaft speed Selector lever Driving at constant speed 1,800 - 2,100 rpm
sensor position: 3 of 50 km/h in 3rd gear
23 Output shaft speed Selector lever Driving at constant speed 1,800 - 2,100 rpm
sensor position: 3 of 50 km/h in 3rd gear
25 Wide open throttle Accelerator pedal Released OFF

switch position
Depressed ON
26 Stop lamp switch Ignition switch: ON Brake pedal: Depressed ON

Engine: Stopped
Brake pedal: Released OFF
29 Vehicle speed sensor Selector lever Idling with 1st gear 0 km/h
position: 3 (Vehicle stopped)
Driving at constant speed 50 km/h

of 50 km/h in 3rd gear
31 Low and reverse Selector lever 10 km/h in 1st gear No. 31: 0 %, No. 32: 0
solenoid valve duty % position: L, 2, 3, D %, No. 33: 100 %,
No. 34: 100%
32 Underdrive solenoid 30 km/h in 2nd gear No. 31: 100 %, No. 32:
valve duty % 0 %, No. 33: 0 %,
No. 34: 100%
33 Second solenoid valve 50 km/h in 3rd gear No. 31: 100 %, No. 32:
duty % 0 %, No. 33: 100 %,
No. 34: 0%
34 Overdrive solenoid valve 70 km/h in 4th gear No. 31: 100 %, No. 32:
duty % 100 %, No. 33: 0 %,
No. 34: 0%
36 Damper clutch control Selector lever Driving at 50 km/h in 0%

solenoid valve duty % position: 3 3rd gear with accelerator
released
Driving at constant speed Approx. 70 - 90 %

52 Amount of damper Selector lever Driving at 50 km/h in 3rd Approx. 100 - 300 rpm*
clutch slippage position: 3 gear with accelerator
fully closed
Driving at constant speed Approx. 0 - 10 rpm

54 Control relay output Ignition switch : OFF Ignition switch: Battery voltage (mV) ®
voltage ON ® OFF 0 mV
57 Engine volumetric Selector lever N range with accelerator Data changes

efficiency position: N pedal released ®
depressed.
61 Inhibitor switch Ignition switch: ON Selector lever position: P P

Engine: Stopped
Selector lever position: R R
Selector lever position: N N
Selector lever position: D D
Selector lever position: 3 3
Selector lever position: 2 2
Selector lever position: L L
62 HOLD mode signal Mode control switch HOLD ON

position
AUTO OFF
63 Shift position Selector lever posi- Driving at constant speed 1st

tion: L, 2, 3, D of 10 km/h in 1st gear
Driving at constant speed 2nd

of 30 km/h in 2nd gear
Driving at constant speed 3rd

Driving at constant speed 4th

of 70 km/h in 4th gear
64 Idle position switch Engine: Idling Accelerator pedal: ON

Selector lever posi- Released
tion: N
Accelerator pedal: OFF
Halfly depressed
65 Dual pressure switch Engine: Idling A/C switch: ON ON

Selector lever posi-
tion: N A/C switch: OFF OFF
66 Auto-cruse-ECU signal While auto-cruise Plain road OFF

operating
Sloping road ON
NOTE
*: The damper clutch is released when the accelerator is fully closed (Idle position switch: ON).
ACTUATOR TEST JUDGEMENT VALUE 23100820065
Item No. Check item Test content Check requirement Normal value
1 Low reverse solenoid valve Drive the solenoid Ignition switch: ON The operation sound should
valve specified by Selector lever be audible when the solenoid
2 Underdrive solenoid valve the MUT-II at 50 % position: P valve is driven.
duty for 5 seconds. Engine: 0 r/min
3 Second solenoid valve No other solenoid
Vehicle speed:
valve should be
4 Overdrive solenoid valve energised. 0 km/h
(Vehicle stopped)
6 Damper clutch control Throttle
solenoid valve (Accelerator)
opening voltage:
12 A/T control relay Control relay is OFF Less than 0 V Data list No. 54
for 3 seconds. Idle switch: ON (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 Use this function when carrying
according to the standard shift pattern. out procedure 8 in the road
tests.
CHECK AT A/T-ECU TERMINALS 23100840207
Terminal Check item Check requirement Standard value

No.
1 Underdrive solenoid valve Selector lever position: D (1st gear) Battery voltage
Selector lever position: P Approx.7 - 9 V
2 Solenoid valve power supply Ignition switch: OFF 0V
3 Solenoid valve power supply Ignition switch: OFF 0V
8 Auto-cruse control unit No OD-OFF request Battery voltage
OD-OFF request 0V
10 A/C compressor load signal A/C switch: OFF 0V
A/C switch: ON Battery voltage
11 Power supply Ignition switch: OFF 0V
12 Earth Always 0V
13 Earth Always 0V
14 Overdrive solenoid valve Selector lever position: D (3rd gear) Battery voltage
Selector lever position: P Approx. 7 - 9 V
15 Damper clutch control solenoid Selector lever position: L (1st gear) Battery voltage
valve
Selector lever position: 3 (50 km/h in 3rd gear) Other than
battery voltage
16 Second solenoid valve Selector lever position: 2 (2nd gear) Battery voltage
Selector lever position: P Approx. 7 - 9 V
21 Engine-ECU torque reduction Ignition switch: ON (except during shifting) 4 - 5V

request signal
<Vehicles with TCL>

No.
23 Diagnosis control - -
24 Power supply Ignition switch: OFF 0V
25 Earth Always 0V
26 Earth Always 0V
31 Input shaft speed sensor Measure between terminal No. 31 and No. 43 by Refer to P.23-45,
an oscilloscope. Oscilloscope
Engine: 2,000 r/min inspection
Selector lever position: 3 procedure.
32 Output shaft speed sensor Measure between terminal No. 32 and No. 43 by Refer to P.23-45,
an oscilloscope. Oscilloscope
Engine: 2,000 r/min inspection
Selector lever position: 3 procedure.
33 Crank angle sensor Engine: Idling 2.0 - 2.4 V
36 Idle position switch Engine: Idling 0V
Engine: Other than idling 5V
38 Back up power suuply Ignition switch: OFF Battery voltage
43 Sensor earth Always 0V
44 Oil temperature sensor ATF temperature: 25 _C 3.8 - 4.0 V
ATF temperature: 80 _C 2.3 - 2.5 V
45 Throttle position sensor (TPS) Accelerator pedal: Released (Engine stopped) 0.5 - 1.0 V
Accelerator pedal position sensor Accelerator pedal: Depressed (Engine stopped) 4.5 - 5.0 V
(APS) <Vehicles with TCL>
53 Communication with engine-ECU Engine: Idling Other than 0 V

<Vehicles without TCL> Selector lever position: D
Communication with TCL-ECU
<Vehicles with TCL>
54 Communication with engine-ECU Engine: Idling Other than 0 V

<Vehicles without TCL> Selector lever position: D
Communication with TCL-ECU
<Vehicles with TCL>
55 Inhibitor switch P Selector lever position: P Battery voltage
Selector lever position: Other than above 0V
56 Inhibitor switch N Selector lever position: N Battery voltage
57 Inhibitor switch 3 Selector lever position: 3 Battery voltage


No.
58 Inhibitor switch L Selector lever position: L Battery voltage
59 Stop lamp switch Brake pedal: Depressed Battery voltage
Brake pedal: Released 0V
62 Low and reverse solenoid valve Selector lever position: D (1st gear) Battery voltage
Selector lever position: D (2nd gear) Approx. 7 - 9 V
63 Diagnosis output Normal (No diagnosis code output) 0 ® 5 V flashing
65 Wide open throttle switch Accelerator pedal: Released 4.5 - 5.5 V
Accelerator pedal: Depressed Less than 0.4 V
66 Inhibitor switch R Selector lever position: R Battery voltage
67 Inhibitor switch D Selector lever position: D Battery voltage
68 Inhibitor switch 2 Selector lever position: 2 Battery voltage
69 Vehicle speed sensor When stopped 0V
Move forward slowly 0 ® 5 V flashing
70 Mode control switch Select HOLD mode Battery voltage
Select AUTO mode 0V
71 A/T control relay Ignition switch: OFF 0V

OSCILLOSCOPE INSPECTION PROCEDURE 23100850064
Check item Check requirement Normal condition

(Waveform sample)
Crank angle sensor Selector lever position: N Idling (Vehicle stopped) Waveform A
Input shaft speed Selector lever position: 3 Driving at constant speed of 50 Waveform B
sensor km/h in 3rd gear
(Engine: 1,800 - 2,100 r/min)
Output shaft
speed sensor
Low reverse Ignition switch: ON Force drive each solenoid valve Waveform C
solenoid valve Selector lever position: P (Actuator test)
Engine: 0 r/min
Underdrive solenoid
valve Vehicle speed: 0 km/h
(Vehicle stopped)
Second solenoid Throttle (Accelerator) opening
valve angle: Less than 1 V
Idle switch: ON
Overdrive solenoid
valve
Damper clutch
control solenoid
valve
Waveform sample
Waveform A Waveform B Waveform C
(V)
(V) (V)
60
5 5
40
20
0 0
0
(ms) (ms)
(ms)
23-46 AUTOMATIC TRANSMISSION - On-vehicle Service
ESSENTIAL SERVICE
AUTOMATIC TRANSMISSION FLUID CHECK
1. Drive the vehicle until the fluid temperature rises to the
normal temperature (70 - 80_C).
2. Park the vehicle on a level surface.
3. Move the selector lever through all positions to fill the
torque converter and the hydraulic circuits with fluid, and
then move the selector lever to the N position.
4. After wiping off any dirt around the oil level gauge, remove
the oil level gauge and check the condition of the fluid.
NOTE
If the fluid smells as if it is burning, it means that the
fluid has been contaminated by the particles from the
bushes and friction materials, a transmission overhaul
and flushing the cooler line may be necessary.
5. Check that the fluid level is at the HOT mark on the
oil level gauge. If the fluid level is lower than this, pour
in more fluid until the level reaches the HOT mark.
Automatic transmission fluid:
Dia Queen ATF SP II or equivalent
NOTE
If the fluid level is low, the oil pump will draw in air along
with the fluid, which will cause bubbles to form inside
the hydraulic circuit. This will in turn cause the hydraulic
pressure to drop, which will result in late shifting and
slipping of the clutches and brakes.
If there is too much fluid, the gears can churn it up into
foam and cause the same conditions that can occur with
low fluid levels.
In either case, air bubbles can cause overheating and
oxidation of the fluid which can interfere with normal valve,
clutch, and brake operation. Foaming can also result in
fluid escaping from the transmission vent, in which case
it may be mistaken for a leak.
6. Securely insert the oil level gauge.
7. The fluid and oil filters should always be replaced in the
following conditions:
When troubleshooting the transmission
When overhauling the transmission
When the oil is noticeably dirty or deteriorates (driving
under the severe condition)
Furthermore, the oil filters are special filters which are
only to be used for the automatic transmission.
AUTOMATIC TRANSMISSION - On-vehicle Service 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
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.
14. Firmly insert the oil level gauge into the oil filler tube.
OIL FILTER REPLACEMENT 23101050067
1. Use the special tool (MB991610) to remove the automatic

Apply ATF transmission oil filter.
to O-ring 2. Clean the filter bracket side mounting surface.
3. Apply a small amount of automatic transmission fluid to
the O-ring of the new oil filter.
4. Use the special tool (MB991610) to install the automatic
transmission oil filter.
NOTE
5. Check the quantity of the automatic transmission fluid.
(Refer to P.23-46.)
THROTTLE POSITION SENSOR ADJUSTMENT

<Vehicles without TCL> 23100190142

ADJUSTMENT <Vehicles with TCL> 23100250048

INHIBITOR SWITCH CONTINUITY CHECK 23100140345
Items Terminal No.

1 2 3 4 5 6 7 8 9 10
P
R
N
D
Inhibitor switch
3
2
L
P
R
N
D
3
2
L
INHIBITOR SWITCH AND CONTROL CABLE

Adjusting nut
Transmission 1. Set the selector lever to the “N” position.
control cable 2. Loosen the control cable to manual control lever coupling
Manual nut to free the cable and lever.
control
lever 3. Set the manual control lever to the neutral position.
10 - 12 Nm
4. Loosen the inhibitor switch body mounting bolts and the
turn the inhibitor switch body so the hole in the end of
Mounting bolts 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
A of the switch body is not changed.
A
Manual
control lever
Section A-A
Hole in end
Manual control
Hole in lever
flange
Inhibitor
switch body
6. Gently pull the transmission control cable in the direction

12 Nm 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
Adjusting nut and functions correctly for each position of the selector
lever.
Manual control lever

A/T CONTROL COMPONENT LOCATION 23100860234

Accelerator position sensor (with idle position C Mode control switch L
switch) <Vehicles with TCL>
A/T control relay M Oil temperature sensor G
A/T-ECU K Output shaft speed sensor E
Crank angle sensor B Shift indicator lamp I
Diagnosis connector O Solenoid valve G
Dual pressure switch A Stop lamp switch P
Engine ECU K TCL-ECU J
Inhibitor switch F Throttle position sensor (with idle position C
switch) <Vehicles without TCL>
Input shaft speed sensor H Vehicle speed sensor D
Wide open throttle switch N
C D
B
E
A
F
H
I
O K J
N
M L
A/T CONTROL COMPONENT CHECK 23100900011
CRANK ANGLE SENSOR CHECK

THROTTLE POSITION SENSOR CHECK

<Vehicles without TCL> 23100390030
ACCELERATOR PEDAL POSITION SENSOR CHECK

Refer to GROUP 13H - On-vehicle Service.
OIL TEMPERATURE SENSOR CHECK 23100450035
1. Remove the oil temperature sensor.
Oil temperature sensor
2. Measure the resistance between terminals No. 1 and

No. 2 of the oil temperature sensor connector.
Standard value:
Oil temperature (_C) Resistance (kW)
0 16.7- 20.5
ATF 100 0.57- 0.69
INHIBITOR SWITCH CHECK 23100140352
Refer to P.23A-49.
Refer to GROUP 35 - Brake Pedal.
VEHICLE SPEED SENSOR CHECK 23100460038

DUAL POSITION PRESSURE SWITCH CHECK
23100470031
IDLE POSITION SWITCH CHECK 23100410033
MODE CONTROL SWITCH CHECK 23100920048
Refer to P.23-65.
WIDE OPEN THROTTLE SWITCH CHECK 23100890080
Refer to P.23-64.
A/T CONTROL RELAY CHECK 23100930065
1. Remove the A/T control relay.
2. Use jumper wires to connect A/T control relay terminal

2 to the battery ( - ) terminal and terminal 4 to the battery
(+) terminal.
3. Check the continuity between terminal 1 and terminal
3 of the A/T control relay when the jumper wires are
connected to and disconnected from the battery.
Jumper wire Continuity between terminals No. 1
and No. 3
Connected Continuity
Disconnected No continuity
4. If there is a problem, replace the A/T control relay.
Overdrive Underdrive SOLENOID VALVE CHECK 23100940013

solenoid solenoid 1. Remove the valve body cover.
valve valve
2. Disconnect the connectors of each solenoid valve.
Second
solenoid
valve
Low and Damper
reverse clutch
solenoid solenoid
valve 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
Second solenoid valve
Underdrive solenoid valve
Overdrive solenoid valve
4. If the resistance is outside the standard value, replace
the solenoid valve.
TORQUE CONVERTER STALL TEST 23100540206

Torque
converter This test measures the maximum engine speed when the
Reverse
Low-reverse Underdrive
selector lever is at the D or R position and the torque converter
clutch stalls to test the operation of the torque converter, starter
brake clutch
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
2. Check both rear wheels (left and right).
3. Pull the parking brake lever on, with the brake pedal
fully depressed.
5. Move the selector lever to the D position, fully depress
the accelerator pedal and take a reading of the maximum
engine speed at this time.
Caution
1. The throttle should not be left fully open for any
more than eight seconds.
2. If carrying out the stall test two or more times,
move the selector lever to the N position and run
the engine at 1,000 r/min to let the automatic
transmission fluid cool down before carrying out
subsequent tests.
Standard value
Stall speed: 2,100 - 2,600 r/min
6. Move the selector lever to the R position and carry out
the same test again.
Standard value
Stall speed: 2,100 - 2,600 r/min
TORQUE CONVERTER STALL TEST JUDGEMENT
RESULTS
a. Stall speed is too high in both D and R ranges
D Low line pressure
D Low & reverse brake slippage
b. Stall speed is too high in D range only
D Underdrive clutch slippage
c. Stall speed is too high in R range only
D Reverse clutch slippage
d. Stall speed too low in both D and R ranges
D Malfunction of torque converter
D Insufficient engine output
HYDRAULIC PRESSURE TEST 23100550216
1. Warm up the engine until the automatic transmission fluid

temperature is 80 - 100_C.
2. Jack up the vehicle so that the wheels are free to turn.
3. Connect the special tools (2,942 kPa oil pressure gauge
[MD998330] and joints [MD998332, MD998900]) to each
pressure discharge port.
4. Measure the hydraulic pressure at each port under the
conditions given in the standard hydraulic pressure table,
and check that the measured values are within the
standard value ranges.
5. If a value is outside the standard range, correct the
problem while referring to the hydraulic pressure test
diagnosis table.
STANDARD HYDRAULIC PRESSURE TEST
<4G63>
Measurement condition Standard hydraulic pressure kPa
Selector Shift posi- Engine Under- Reverse Overdrive Low and Second Torque
lever tion speed drive clutch clutch reverse brake converter
position (r/min) clutch pressure pressure brake pressure pressure
pressure pressure
P - 2,500 - - - 310 - 390 - 310 - 390
R Reverse 2,500 - 1,320 - - 1,320 - - 500 - 700

1,720 1,720
N - 2,500 - - - 310 - 390 - 310 - 390
D 1st gear 2,500 1,010 - - - 1,010 - - 500 - 700

1,050 1,050
2nd gear 2,500 1,010 - - - - 1,010 - 500 - 700

1,050 1,050
3rd gear 2,500 590 - 690 - 590 - 690 - - 450 - 650
4th gear 2,500 - - 590 - 690 - 590 - 690 450 - 650
<6A13>
Measurement condition Standard hydraulic pressure kPa
Selector Shift posi- Engine Under- Reverse Overdrive Low and Second Torque
lever tion speed drive clutch clutch reverse brake converter
position (r/min) clutch pressure pressure brake pressure pressure
pressure pressure
P - 2,500 - - - 260 - 340 - 260 - 340
R Reverse 2,500 - 1,320 - - 1,320 - - 500 - 700

1,720 1,720
N - 2,500 - - - 260 - 340 - 260 - 340
D 1st gear 2,500 1,010 - - - 1,010 - - 500 - 700

1,050 1,050
2nd gear 2,500 1,010 - - - - 1,010 - 500 - 700

1,050 1,050
3rd gear 2,500 780 - 880 - 780 - 880 - - 450 - 650
4th gear 2,500 - - 780 - 880 - 780 - 880 450 - 650

HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

Trouble symptom Probable cause
All hydraulic pressures are high. Incorrect transmission control cable adjustment
Malfunction of the regulator valve
All hydraulic pressures are low. Incorrect transmission control cable adjustment
Malfunction of the oil pump
Clogged internal oil filter
Clogged external oil filter
Clogged oil cooler
Malfunction of the relief valve
Incorrect valve body installation
Hydraulic pressure is abnormal Malfunction of the regulator valve
in “R” range only.
Clogged orifice
Hydraulic pressure is abnormal Malfunction of the overdrive solenoid valve
in “3” or “4” range only.
Malfunction of the overdrive pressure control valve
Malfunction of the switch valve
Clogged orifice
Only underdrive hydraulic Malfunction of the oil seal K
pressure is abnormal.
Malfunction of the oil seal L
Malfunction of the oil seal M
Malfunction of the underdrive solenoid valve
Malfunction of the underdrive pressure control valve
Malfunction of check ball
Clogged orifice
Only reverse clutch hydraulic Malfunction of the oil seal A
Malfunction of the oil seal B
Malfunction of the oil seal C
Clogged orifice
Trouble symptom Probable cause

Only overdrive hydraulic Malfunction of the oil seal D
Malfunction of the oil seal E
Malfunction of the oil seal F
Malfunction of the overdrive solenoid valve
Malfunction of the overdrive pressure control valve
Malfunction check ball
Clogged orifice
Only low and reverse hydraulic Malfunction of the oil seal I
Malfunction of the oil seal J
Malfunction of the low and reverse solenoid valve
Malfunction of the low and reverse pressure control valve
Malfunction of the switch valve
Malfunction of the fail safe valve A
Clogged orifice
Only second hydraulic pressure Malfunction of the oil seal G
is abnormal.
Malfunction of the oil seal H
Malfunction of the oil seal O
Malfunction of the second solenoid valve
Malfunction of the second pressure control valve
Malfunction of the fail safe valve B
Clogged orifice
Only torque converter pressure Malfunction of the oil cooler
is abnormal.
Malfunction of the oil seal N
Malfunction of the damper clutch control solenoid valve
Malfunction of the damper clutch control valve
Malfunction of the torque converter pressure control valve
Clogged orifice
Pressure applied to non Incorrect transmission control cable adjustment
operating element.
Malfunction of the manual valve
OIL SEAL LAYOUT
H I J K L M N
E F G
O
HYDRAULIC CIRCUIT 23100880070
PARKING AND NEUTRAL
1 2 3 4 5
6 6 6 6 7
8
9 10
11
12
13
14 15 16 17 18
20 21 22 23
19
24
25
26
R ND
27 P3
2
L
28 29
30 31
32
1. Reverse clutch 18. Overdrive pressure control valve

2. Low-reverse brake 19. Damper clutch control solenoid
3. Second brake valve
4. Underdrive clutch 20. Low-reverse solenoid valve
5. Overdrive clutch 21. Second solenoid valve
6. Accumulator 22. Underdrive solenoid valve
7. Check ball 23. Overdrive solenoid valve
8. Damper clutch 24. Torque converter pressure control
9. Fail safe valve A valve
10. Fail safe valve B 25. Regulator valve
11. Damper clutch control valve 26. Manual valve
12. Switch valve 27. Oil filter
13. Automatic transmission fluid cooler 28. Oil pump
14. Lubrication 29. Oil strainer
15. Low-reverse pressure control valve 30. Oil filter (Built in type)
16. Second pressure control valve 31. Relief valve
17. Underdrive pressure control valve 32. Oil pan
LINE PRESSURE ADJUSTMENT 23100170122
1. Discharge the automatic transmission fluid, and then

remove the valve body cover.
2. Turn the adjusting screw shown in the illustration at left
to adjust the underdrive pressure to the standard value.
The pressure increases when the screw is turned to the
Adjusting
left.
screw 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 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.
Button not pressed
Button pressed
AUTOMATIC TRANSMISSION - Transmission Control 23-63
TRANSMISSION CONTROL 23100660247

D Air Cleaner Assembly Removal and Installation Be careful not to subject the SRS-ECU to any
D Battery and Battery Tray Removal and Installation shocks during removal and installation of the
D Lower Cover and Side Cover Removal and transmission control cable and selector lever
Installation (Refer to GROUP 52A - Instrument assembly.
Panel.)
D Floor Console Box Removal and Installation
9
1
12 Nm
3
4 6 8
12 Nm
5 7
12 Nm
Transmission control cable removal Selector lever assembly removal

steps steps
1. Foot rest <R.H. drive vehicles> 5. Transmission control cable connec-
2. Engine-ECU, A/T-ECU and A/T tion
control relay assembly 7. Wiring harness connector
"AA 3. Nut 8. Selector lever assembly
4. Adjuster A/T-ECU removal steps
5. Transmission control cable connec-
tion 1. Foot rest <R.H. drive vehicles>
6. Transmission control cable assem- 2. Engine-ECU, A/T-ECU and A/T
bly control relay assembly
Wide open throttle switch removal
step
9. Wide open throttle switch
23-64 AUTOMATIC TRANSMISSION - Transmission Control

"AA NUT INSTALLATION
Nut 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
Manual control lever the nut.
WIDE OPEN THROTTLE SWITCH CHECK

OFF
ON Switch position Terminal No.
1 2
OFF
ON
AUTOMATIC TRANSMISSION - Transmission Control 23-65
SELECTOR LEVER ASSEMBLY 23100680168
1
2
3
4
6
2 Nm
8 10 2 Nm
7
12
11
14 11
15
13 Nm
13
Disassembly steps
1. Push button 9. Bolt
2. Spring 10. Shift lever assembly
3. Bumper 11. Bushing
4. Adjuster 12. Detent spring
5. Shift knob 13. Pipe
6. Indicator panel assembly 14. Position indicator lamp assembly
7. Switch holder 15. Bracket assembly
8. A/T mode changeover switch
A/T MODE CHANGEOVER SWITCH CHECK
1 2 4 3 5
OFF
ON
23-66 AUTOMATIC TRANSMISSION - Transmission Assembly
TRANSMISSION ASSEMBLY 23100570274

D Carry out the essential service for the D Air Cleaner Assembly Installation
troubleshooting (Refer to P.23-46.) D Battery and Battery Tray Installation
D Transmission Fluid Draining (Refer to P.23-47.) D Under Cover Installation
D Under Cover Removal D Transmission Fluid Supplying <Supplying should
D Battery and Battery Tray Removal be done before starting the engine>
D Air Cleaner Assembly Removal (Refer to P.23-47.)
D Selector Lever Operation Check
D Speedometer Operation Check
D Wheel Alignment Adjustment
6 4
3
12 Nm 2
103 Nm 8
11
44 Nm
7 5
17
88 Nm*1
12 1
98 - 118 Nm*1 10
17
10 - 12 Nm
81 Nm
13 14 30 Nm
24 - 33 Nm 30 Nm 9
67 - 78 Nm
81 Nm
16 15
88 Nm
98 - 118 Nm
Removal steps
1. Transmission control cable connec- AA" 10. Tie rod end connection
tion 11. Stabilizer link connection
2. Transmission fluid cooler hoses 12. Damper fork
connection 13. No. 2 stay
3. Bolt 14. Lateral lower arm connection
4. Input shaft speed sensor connector AB" 15. No. 3 stay
5. Output shaft speed sensor 16. Compression lower arm connection
connector AC" 17. Drive shaft
6. Inhibitor switch connector Caution
7. A/T control solenoid valve assem- *1: Indicates parts which should be temporarily
bly connector tightened, and then fully tightened with the
8. Vehicle speed sensor connector vehicle on the ground in the unladen condition.
9. Starter motor <6A1>
AUTOMATIC TRANSMISSION - Transmission Assembly 23-67
57 Nm
20 10 - 12 Nm
49 Nm 18
81 Nm*2 30 Nm
21 26
27 45 - 52 Nm
21
19
26 25 Nm
49 Nm 24
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> 25. Cover <6A1>

19. Transmission assembly upper part AF" 26. Transmission assembly lower part
coupling bolts coupling bolts
AD" 20. Transmission mount bracket AF" "AA 27. Transmission assembly
"BA 21. Transmission mount stopper
AE" D Engine and transmission assembly Caution
supporting Mounting locations marked by *2 should be
22. Centermember assembly provisionally tightened, and then fully tightened after
23. Rear roll stopper placing the vehicle horizontally and loading the full
24. Bell housing cover <4G6> weight of the engine on the vehicle body.
23-68 AUTOMATIC TRANSMISSION - Transmission Assembly
Cord
AA" TIE ROD END DISCONNECTION
Ball joint
Caution
1. Use the special tool to loosen the tie rod end mounting
MB990635 or
MB991113 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 Crossmember
AC" DRIVE SHAFT DISCONNECTION

1. Insert a pry bar between the transmission case and the
Trans- drive shaft as shown to remove the drive shaft.
mission
side NOTE
Do not remove the hub and knuckle from the drive shaft.
Caution
Pry bar 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.
AUTOMATIC TRANSMISSION - Transmission Assembly 23-69
MZ203827 AE" ENGINE AND TRANSMISSION ASSEMBLY
SUPPORTING
Set the special tool to the vehicle to support the engine and
transmission assembly.
MB991453
AF" TRANSMISSION ASSEMBLY LOWER PART

COUPLING BOLTS/TRANSMISSION ASSEMBLY
REMOVAL
Drive plate bolts 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
A 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

Engine side
INSTALLATION
Install the transmission mount stopper so that the arrow points
Arrow as shown in the illustration.
Transmis-
sion mount
Transmission stopper
mount bracket
NOTES
26-1
FRONT AXLE
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4

Wheel Bearing Axial Play Check . . . . . . . . . . . . . . 4
Hub Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRONT HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . 5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
26-2 FRONT AXLE - General Information/Service Specifications/Lubricants
The front axle consists of a knuckle, front hub, row angular contact ball bearing. The drive shaft
unit bearing and drive shaft. The unit bearing is has a tripod joint (T.J.) on the transmission side
press-fitted to the front hub and bolted to the and a birfield joint (B.J.) or rzeppa joint (R.J.) on
knuckle. Also, the unit bearing utilizes a double the wheel side.
Knuckle
Dynamic damper
Front hub T.J.
Drive shaft
B.J. (or R.J.)
Unit bearing
Wheel bearing axial play mm - 0.05
Wheel bearing rotation starting torque Nm - 1.0 or less
Setting of T.J. boot length mm 2000 - petrol-powered 82 -

vehicles
2000 - diesel-powered 81 -
vehicles, 2500
Opening dimension of the When the B.J. (or R.J.) boot band (small) 2.9 -
special tool (MB991561) mm is crimped
When the B.J. (or R.J.) boot band (large) is 3.2 -

crimped
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 0.1 - 1.5 -
stepped phase of the B.J. (or R.J.) housing mm
Items Specified lubricant Quantity g
T.J. 2000 - petrol-powered vehicles Repair kit grease 120
2000 - diesel-powered vehicles, 2500 Repair kit grease 150

FRONT AXLE - Lubricants/Special Tools 26-3
Items Specified lubricant Quantity g
B.J. (or R.J.) 2000 Repair kit grease 120
2500 Repair kit grease 135

MB990767 End yoke holder Fixing of the hub
MB991618 Hub bolt remover Hub bolt removal
MB991406, Steering linkage Ball joint disconnection

MB990635 or puller
MB991113
MB990241 Axle shaft puller D Front hub assembly removal

A: MB990242 A: Puller shaft D Drive shaft removal
B B: MB990244 B: Puller bar
MB990998 Front hub remover D Removal of or pressing-in the hub

and installer D Provisional holding of the wheel bearing
MB990326 Preload socket Wheel bearing rotation starting torque

measurement
MB991461 Plug Preventing of entry of foreign objects into the

transmission case
MB991561 Boot band crimp- B.J. (or R.J.) boot band installation
ing tool
26-4 FRONT AXLE - On-vehicle Service
WHEEL BEARING AXIAL PLAY CHECK

1. Remove the disc brake caliper and suspend it with a
wire.
2. Remove the brake disc from the front hub.
3. Attach a dial gauge as shown in the illustration, and then
measure the axial play while moving the hub in the axial
direction.
Limit: 0.05 mm
4. If axial play exceeds the limit, replace the front hub
assembly.
HUB BOLT REPLACEMENT 26100100085
MB990767 1. Remove the caliper assembly and secure it with wire

MB991618 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
FRONT AXLE - Front Hub Assembly 26-5
FRONT HUB ASSEMBLY 26100170154

Check the Dust Cover for Cracks or Damage by Pushing
it with Finger.
28 Nm
88 Nm
100 Nm 6
3
196 - 255 Nm
Removal steps
1. Front wheel speed sensor
<Vehicles with ABS> Caution
(Refer to GROUP 35B.) The front hub assembly should not be disassembled.
AA" 2. Caliper assembly When removing the front hub assembly, the wheel
3. Brake disc bearing inner race may be left at the spindle side.
AB" "AA 4. Drive shaft nut In this case, always replace the front hub assembly,
AC" 5. Upper arm ball joint and knuckle otherwise the hub will damage the oil seal, causing
connection oil leaks or excessive play.
AD" 6. Front hub assembly

AA" CALIPER ASSEMBLY REMOVAL
Secure the removed caliper assembly with wire, so that it
does not fall.
AB" DRIVE SHAFT NUT REMOVAL
Caution
MB990767
Do not apply the vehicle weight to the wheel bearing
while loosening the drive shaft nut.
26-6 FRONT AXLE - Front Hub Assembly
AC" UPPER ARM BALL JOINT AND KNUCKLE

MB991406, DISCONNECTION
MB990635 or
MB991113 Caution
1. Use the special tool to loosen the nut only; do not
Ball joint
remove it from the ball joint.
Cord
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 INSTALLATION SERVICE POINT

"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
(3) If the position of the split pin holes does not match, tighten
MB990767
the nut up to 255 Nm in maximum.
(4) Install the split pin in the first matching holes and bend
it securely.
FRONT AXLE - Front Hub Assembly 26-7
MB990998 WHEEL BEARING ROTATION STARTING TORQUE

MB990326
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
196 - 255 Nm
torque.
Limit: 1.0 Nm or less
(3) The wheel bearing starting torque should be within the
limit value range, and there should be no engagement
or feeling of roughness.
WHEEL BEARING AXIAL PLAY CHECK 26100110095
(1) Install the special tool to the front hub assembly and
tighten the nut to the specified torque 196 - 255 Nm.
(2) Measure the play in the hub axial direction.
Limit: 0.05 mm
(3) If the limit value of hub axial play cannot be obtained,
MB990998 replace the front hub assembly.
26-8 FRONT AXLE - Knuckle
KNUCKLE 26100240138

Front Hub Assembly Removal (Refer to P.26-5.) D Check the Dust Cover for Cracks or Damage by
D Front Hub Assembly Installation (Refer to P.26-5.)
2
59 - 71 Nm
6
3
88 Nm*
24 - 33 Nm 9 Nm
1
4
Removal steps
1. Dust shield 6. Knuckle
AA" 2. Tie rod end and knuckle connec-
tion Caution
3. Damper fork and lateral lower arm *: Indicates parts which should be temporarily
connection tightened, and then fully tightened with the vehicle
AA" 4. Lateral lower arm and knuckle con- on the ground in the unladen condition.
nection
AA" 5. Compression lower arm and
knuckle connection

MB991406, AA" TIE ROD END AND KNUCKLE/LATERAL LOWER
MB990635 or
MB991113 ARM AND KNUCKLE/COMPRESSION LOWER
ARM AND KNUCKLE DISCONNECTION
Ball joint
Cord Caution
Nut
FRONT AXLE - Drive Shaft 26-9
DRIVE SHAFT 26100350213

D Wheel Alignment Check and Adjustment (Refer to
GROUP 33A - On-vehicle Service.)
103 Nm
4
44 Nm
5
88 Nm*
3
98 - 118 Nm*
81 Nm
7
9
6
1
2 8
69 - 78 Nm
24 - 33 Nm
196 - 255 Nm
81 Nm
Removal steps
1. Front wheel speed sensor AC" 8. Compression lower arm connection
<Vehicles with ABS> AD" 9. Drive shaft
(Refer to GROUP 35B.)
AA" "AA 2. Drive shaft nut Caution
AB" 3. Tie rod end and knuckle connec- 1. *: Indicates parts which should be temporarily
tion tightened, and then fully tightened with the
4. Stabilizer link and damper fork vehicle on the ground in the unladen condition.
connection 2. For vehicles with ABS, be careful not to damage
5. Damper fork the rotors installed to the B.J. (or R.J.) outer
6. No.2 stay race during removal and installation of the drive
7. Lateral lower arm connection shaft.
26-10 FRONT AXLE - Drive Shaft

AA" DRIVE SHAFT NUT REMOVAL
Caution
while loosening the drive shaft nut.
MB990767
AB" TIE ROD END AND KNUCKLE DISCONNECTION

MB991406,
MB990635 or Caution
MB991113 1. Use the special tool to loosen the nut only; do not
Ball joint
Cord
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
MB990767 the hub.
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.
(3) Insert a pry bar between the transmission case and the
drive shaft, and then pry the drive shaft from the
transmission.
Oil seal
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.
Drive shaft 2. Do not insert the pry bar so deep as to damage
Pry bar Transmission the oil seal.
(4) Use the special tool as a cover not to let foreign objects
get into the transmission case.
MB991460
Caution
while loosening the drive shaft nut. If, however, the vehicle
MB990998
weight must be applied to the bearing (because of moving
the vehicle), temporarily secure the wheel bearing by
using the special tool.
Washer INSTALLATION SERVICE POINT

"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
196 - 255 Nm sure there is no load on the wheel bearings.
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.
4
3
5 6
7
1
2
9
8
10
4 3 4 5 7 4 5 1
5 6 1 2
7 1 2 8 11
2 12 13
T.J. repair kit T.J. boot repair kit B.J. (or R.J.) boot repair kit
Disassembly steps
"CA 1. T.J. boot band (large) 10. B.J. (or R.J.) assembly
"CA 2. T.J. boot band (small) 11. B.J. (or R.J.) boot band (small)
AA" "BA 3. T.J. case 12. B.J. (or R.J.) boot band (large)
4. Circlip 13. B.J. (or R.J.) boot
5. Snap ring Caution
AA" "BA 6. Spider assembly 1. Never disassemble the B.J. (or R.J.) assembly
AB" "AA 7. T.J. boot except when replacing the B.J. (or R.J.) boot.
"AA 8. Damper band 2. On vehicles with ABS, be sure not to damage
"AA 9. Dynamic damper the rotor attached to the B.J. (or R.J.) outer race.
AA" T.J. CASE/SPIDER ASSEMBLY REMOVAL
(1) Wipe off grease from the spider assembly and the inside
of the T.J. case.
(2) Always clean the spider assembly when the grease
contains water or foreign material.
Caution
1. Do not disassemble the spider assembly.
2. Use care in handling so as not to damage the
drive shaft.
AB" T.J. BOOT REMOVAL
(1) Wipe off grease from the shaft spline.
(2) When reusing the T.J. boot, wrap plastic tape around
the shaft spline to avoid damaging the boot.

LH: 229 mm "AA DYNAMIC DAMPER/DAMPER BAND/T.J. BOOT
RH: 278 mm
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.
"BA SPIDER ASSEMBLY/T.J. CASE INSTALLATION

Bevelled
section (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.
(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
A
D Check the drive shaft for damage, bending or corrosion.

D Check the drive shaft spline part for wear or damage.
D Check the spider assembly for roller rotation, wear or
corrosion.
D Check the groove inside T.J. case for wear or corrosion.
D Check the dynamic damper for damage or cracking.
D Check the boots for deterioration, damage or cracking.
B.J. (or R.J.) BOOT (RESIN BOOT)

REPLACEMENT 26100520089
(1) Remove the B.J. (or R.J.) boot bands (large and small).
NOTE
The B.J. (or R.J.) boot bands cannot be re-used.
(2) Remove the B.J. (or R.J.) boot.
(3) Wrap a plastic tape around the shaft spline, and assemble
the B.J. (or R.J.) boot band and B.J. (or R.J.) boot.
(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 (5) Turn the adjusting bolt on the special tool so that the
Stopper 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.
W <If it is smaller than 2.9 mm>
Loosen the adjusting bolt.
Adjusting bolt NOTE
(1) The value of W will change by approximately 0.7
mm for each turn of the adjusting bolt.
(2) The adjusting bolt should not be turned more than
once.
(6) Place the B.J. (or R.J.) boot band (small) against the
B.J. (or R.J.) projection at the edge of the boot, and then secure it
boot A 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).
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
MB991561 tool touches the stopper.
(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.)
C 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.
Standard value (W): 3.2 mm
(13)Place the B.J. (or R.J.) boot band (large) against the
B.J. (or R.J.) Projection projection at the edge of the boot, and then secure it
boot so that there is a clearance left as shown by (D) in the
B.J. (or R.J.)
boot band illustration.
(large) (14)Use the special tool to crimp the B.J. (or R.J.) boot band
(large) in the same way as in step (7).
D
(15)Check that the crimping amount (E) of the B.J. (or R.J.)
boot band is at the standard value.
Standard value (e): 2.4 - 2.8 mm
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) 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

Wheel Bearing Axial Play Check . . . . . . . . . . . . . . 3
Wheel Bearing Rotary-Sliding Resistance Check
............................................. 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hub Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . 5
KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Information/Service Specifications/
27-2 REAR AXLE - Special Tools
The rear axle consists of a knuckle, rear hub, unit type of double row angular contact ball bearing
bearing and axle shaft. The unit bearing is as does the front axle. A rotor for detecting the
press-fitted to the rear axle shaft and bolted to vehicle speed is located on the rear axle shaft,
the knuckle. Also, the unit bearing utilizes the same and a speed sensor is located on the knuckle.
Oil seal Knuckle
Rear axle shaft
Cap
Oil seal Rotor

<Vehicles with ABS>
Unit bearing
Items Limit
Wheel bearing axial play mm 0.05
Wheel bearing rotary-sliding resistance N 18 or less

MB990767 End yoke holder Fixing of the hub
MB991618 Hub bolt remover Removal of the hub bolt
MB991248 Inner shaft Rotor removal

remover
REAR AXLE - Special Tools/On-vehicle Service 27-3

MB991406 Steering linkage Ball joint disconnection
MB990635 or puller
MB991113
WHEEL BEARING AXIAL PLAY CHECK

1. For vehicles with rear disc brake, remove the caliper
assembly, suspend the caliper assembly with a wire and
remove the brake disc.
2. For vehicles with rear drum brake, remove the brake drum.
3. Check the bearing’s 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
1. For vehicles with rear disc brake, remove the caliper

assembly, suspend the caliper assembly with a wire and
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 27100100112
MB990767 1. For vehicles with rear disc brake, remove the caliper
MB991618 assembly, suspend the caliper assembly with a wire and
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
REAR AXLE - Rear Axle Hub 27-5
REAR AXLE HUB 27100200188

<Vehicles with drum brake>
5
74 - 88 Nm
1
8 7
<Vehicles with disc brake>
74 - 88 Nm
1
100 Nm
2
4
8 7
Removal steps Caution

1. Rear wheel-speed sensor <Vehicles The rear hub unit bearing should not be dismantled.
with ABS> (Refer to GROUP 35B.) When removing the rear hub assembly, the wheel
AA" 2. Caliper assembly bearing inner race may be left at the spindle side.
3. Brake drum In this case, always replace the rear hub assembly,
4. Brake disc otherwise the hub will damage the oil seal, causing
5. Brake hose installation bracket oil leaks or excessive play.
6. Rear hub assembly
AB" "AA 7. Rotor <Vehicles with ABS>
AC" 8. Backing plate
27-6 REAR AXLE - Rear Axle Hub

AA" CALIPER ASSEMBLY REMOVAL
Socket
Remove the caliper assembly and suspend it.
MB991248
AB" ROTOR REMOVAL
AC" BACKING PLATE REMOVAL
Remove the backing plate and suspend it.
Socket
"AA ROTOR INSTALLATION
REAR AXLE - Knuckle 27-7
KNUCKLE 27100300123

Rear Hub Assembly Removal (Refer to P.27-5.) D Check the Dust Cover for Cracks or Damage by
Pushing It with Finger.
D Rear Hub Assembly Installation (Refer to P.27-5.)
5
98 Nm*
7
98 Nm
28 Nm
6
118 - 137 Nm*
98 Nm* 2
Removal steps
1. Trailing arm connection 7. Knuckle
2. Lower arm connection
AA" 3. Toe control arm connection Caution
4. Shock absorber connection *: Indicates parts which should be temporarily
5. Upper arm connection tightened, and then fully tightened with the
6. Hub cap vehicle on the ground in the unladen condition.
MB990635, REMOVAL SERVICE POINT

MB991113 or
MB991406 AA" TOE CONTROL ARM DISCONNECTION
Nut Caution
Cord remove it from the ball joint.
Ball joint
NOTES
31-1
WHEEL AND TYRE


Tyre Inflation Pressure Check . . . . . . . . . . . . . . . . . 6
Tyre Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5 Wheel Runout Check . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL AND TYRE . . . . . . . . . . . . . . . . . . . . . . . . 6

31-2 WHEEL AND TYRE - General Information
Both steel type and aluminium type wheels have A compact spare tyre has been adopted as the
been adopted. The type of wheel used depends spare tyre in some models.
on the vehicle model.
Items EA2ASNJEQL6, EA2ASNHEQL6, EA5ASNGEQL6,

WLNJEQL6 ASRHEQL6, ASRGEQL6,
WLNHEQL6, WLNGEQL6,
WLRHEQL6 WLRGEQL6
Wheel Type Steel type Steel type Aluminium 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 46 46 46

mm
Pitch circle diameter 114.3 114.3 114.3

(P.C.D.) mm
Tyre Size 195/65R14 89 V 195/65R14 89 V 195/60R15 88 V

195/60R15 88 V* 205/60R15 91 V*
Spare Type Steel type Steel type Steel type

wheel
Size 15 x 4.0T 15 x 4.0T 15 x 4.0T
14 x 5 1/2 JJ* 14 x 5 1/2 JJ* 15 x 6 JJ*
15 x 6 JJ*

mm

(P.C.D) mm
Spare Size T125/70D15 T125/70D15 T125/70D15

tyre (High pressure) (High pressure) (High pressure)
195/65R14 89V* 195/65R14 89V* 195/60R15 88V*
195/60R15 88V* 205/60R15 91 V*
NOTE
*: Optional items
WHEEL AND TYRE - General Information 31-3
Items EA6ASNHFQL6, EA2ASNJEQL6C, EA2ASNHEQL6C,

WLNHFQL6 WLNJEQL6C ASRHEQL6C,
ASNHEQR6,
ASRHEQR6,
WLNHEQL6C,
WLRHEQL6C,
WLNHEQR6,
WLRHEQR6
Wheel Type Steel type Steel type Steel type

Aluminium type* Aluminium type* Aluminium type*
Size 14 ¢ 5 1/2 JJ 14 ¢ 5 1/2 JJ 14 ¢ 5 1/2 JJ

15 ¢ 6 JJ* 15 ¢ 6 JJ*

mm

(P.C.D.) mm
Tyre Size 185/70R14 88H 195/65R14 89 V 195/65R14 89 V

195/60R15 88 V* 195/60R15 88 V*
Spare Type Steel type Steel type Steel type

wheel Aluminium type* Aluminium type*
Size 15 x 4.0T 14 ¢ 5 1/2 JJ 14 ¢ 5 1/2 JJ

14 x 5 1/2 JJ* 15 ¢ 6 JJ*
15 ¢ 6 JJ*

mm

(P.C.D.) mm
Spare Size T125/70D15 195/65R14 89 V 195/65R14 89 V

tyre (High pressure) 195/60R15 88 V*
185/70R14 88H*
195/60R15 88 V*
NOTE
*: Optional items
31-4 WHEEL AND TYRE - General Information/Service Specifications
Items EA5ASNGEQL6C, EA6ASNHFQL6C, EA5ASNGEQR6,

ASRGEQL6C, ASNHFQR6, ASRGEQR6,
WLNGEQL6C, WLNHFQL6C, WLNGEQR6,
WLRGEQL6C WLNHFQR6 WLRGEQR6
Wheel Type Aluminium type Steel type Aluminium type

Aluminium type*
Size 15 ¢ 6 JJ 14 ¢ 5 1/2 JJ 15 ¢ 6 JJ
15 ¢ 6 JJ*

mm

(P.C.D.) mm
Tyre Size 205/60R15 91 V 185/70R14 88 H 195/60R15 88 V

195/60R15 88 V* 205/60R15 91 V*
Spare Type Steel type Steel type Aluminium type

wheel Aluminium type*
Size 15 ¢ 6 JJ 14 ¢ 5 1/2 JJ 15 ¢ 6 JJ
15 ¢ 6 JJ*

mm

(P.C.D.) mm
Spare Size 205/60R15 91 V 185/70R14 88 H 195/60R15 88 V

tyre 195/60R15 88 V 205/60R15 91 V*
NOTE
*: Optional items
Items Limit
Tread depth of tyre mm 1.6
Wheel runout (Radial runout) mm Steel wheel 1.2 or less
Aluminium wheel 1.0 or less
Wheel runout (Lateral runout) mm Steel wheel 1.2 or less
Aluminium wheel 1.0 or less

WHEEL AND TYRE - Troubleshooting 31-5
Symptom Probable cause Remedy Reference page
Rapid wear at Under-inflation Adjust the tyre 31-6.

shoulders or lack of rotation pressure.
Rapid wear at Over-inflation or

centre lack of rotation
Cracked treads Under-inflation Adjust the tyre 31-6.

pressure.
Wear on one Excessive cam- Inspect the cam- Refer to GROUP

side ber ber. 33A - On-ve-
hicle Service.
Feathered edge Incorrect toe-in Adjust the toe-in.
Bald spots Unbalanced Adjust the imbal- -

wheel anced wheels.
Scalloped wear Lack of rotation of tyres or worn or Rotate the tyres Refer to GROUP
out-of-alignment suspension and check the 33A - On-ve-
front suspension hicle Service.
alignment.
31-6 WHEEL AND TYRE - On-vehicle Servic/Wheel and Tyre
TYRE INFLATION PRESSURE CHECK

NOTE
For information on tyre inflation pressure, refer to the label
attached at the driver’s side to the centre pillar.
TYRE WEAR CHECK 31100100034
Measure the tread depth of tyres.

Limit: 1.6 mm
If the remaining tread depth is less than the limit, replace
the tyre.
NOTE
When the tread depth of tyres is reduced to 1.6 mm or less,
wear indicators will appear.
WHEEL RUNOUT CHECK 31100110037
Jack up the vehicle so that the wheels are clear of the floor.
While slowly turning the wheel, measure wheel runout with
Radial a dial indicator.
Limit:
Item Steel wheel Aluminium wheel
Radial runout mm 1.2 1.0
Lateral Lateral runout mm 1.2 1.0
If wheel runout exceeds the limit, replace the wheel.
WHEEL AND TYRE 31100130071

Tighten the wheel nut to the specified torque.
32-1
POWER PLANT
MOUNT
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 TRANSMISSION MOUNTING . . . . . . . . . . . . . . . . 5
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 ENGINE ROLL STOPPER,

CENTERMEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . 4
32-2 POWER PLANT MOUNT - General Information/Service Specifications
The engine-transmission mount is of an inertial axis the front upper part of the engine at the front and
supporting type whose excellent features have the rear upper part of the transmission at the rear.
already been proven in many Mitsubishi vehicles. This arrangement effectively supresses the engine
The inertial axis supporting type mount supports vibration.
Dynamic damper
Dynamic damper
Engine mount Transmission mount
Crossmember
Engine mount
Rear roll stopper

Centermember
Front
Front roll stopper
Front roll stopper Crossmember Dynamic

Transmission mount Centermember damper
Rear roll stopper
Crossmember Bushing (A) projection mm 9.0 ± 1.0
Bushing (B) projection mm 4.0 ± 1.0
Bushing (C) projection mm 4.0 ± 0.5

POWER PLANT MOUNT - Special Tools 32-3

MB991453 Engine hanger To support the engine assembly during
removal and installation of the transmission
mount
GENERAL Engine lifter

SERVICE
TOOL
MZ203827
MB991045 Bushing remover Driving out and press-fitting of crossmember

and installer bushings A and B
MB990828 Bushing remover Driving out and press-fitting of crossmember

and installer bushing C
32-4 POWER PLANT MOUNT - Engine Mounting
ENGINE MOUNTING 32100110263

D Jack Up the Engine and Transmission Assembly Until D Reserve Tank Removal and Installation
There is no Weight on the Engine Mount Bracket (Refer to GROUP 14)
Insulator. D Engine Cover Removal and Installation <6A1>
<6A1> 35 Nm
<4D6> 12 Nm
1
5 Nm 2
67 Nm
6
4 57 Nm
5
98 - 118 Nm*
Removal steps
1. Engine mount stay <6A1> Caution
2. Power steering hose bracket Mounting locations marked by * should be
<4D6> provisionally tightened, and then fully tightened after
3. Engine mount insulator mounting placing the vehicle horizontally and loading the full
bolt weight of the engine on the vehicle body.
4. Engine mount bracket
"AA 5. Engine mount stopper
6. Dynamic damper
Engine side
Dynamic damper
"AA ENGINE MOUNT STOPPER INSTALLATION
Arrow in the direction as shown in the diagram.
Engine
mount
stopper

POWER PLANT MOUNT - Transmission Mounting 32-5
TRANSMISSION MOUNTING 32100140170

D Air Cleaner Assembly Removal and Installation D Transmission and Rear Roll Stopper Connecting Bolt
(Refer to GROUP 14.) Removal and Installation (Refer to P.32-6.)
D Battery and Battery Tray Removal and Installation D Rear Roll Stopper Bracket Removal and Installation
D Centermember Removal and Installation (Refer to GROUP 22, 23 - Transmission Assembly)
81 Nm*
57 Nm
Removal steps
AA" 1. Transmission mount bracket Caution
"AA 2. Transmission mount stopper 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.
MZ203827 REMOVAL SERVICE POINT

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
MB991453 bracket.
(4) After lowering the engine and transmission assembly,
remove the transmission mount bracket.
Engine side
"AA TRANSMISSION MOUNT STOPPER INSTALLATION
Clamp the transmission mount stopper so that the arrow points
Arrow
Trans-
mission
mount
Transmission
stopper
mount bracket
32-6 POWER PLANT MOUNT - Engine Roll Stopper, Centermember
ENGINE ROLL STOPPER, CENTERMEMBER 32100200144

44 Nm
44 Nm*
11
10
44 Nm
57 Nm*
1
5
8
2
7 69 - 78 Nm
4 25 Nm
6
3 2
69 - 78 Nm
2
93 Nm
Front roll stopper, centermember Rear roll stopper removal steps

removal steps 10. Transmission and rear roll stopper
1. Transmission and front roll stopper connecting bolt
connecting bolt 11. Rear roll stopper
2. Centermember mounting bolts Caution
3. Stopper Mounting locations marked by * should be
4. Centermember provisionally tightened, and then fully tightened after
"AA 5. Front roll stopper placing the vehicle horizontally and loading the full
6. Collar weight of the engine on the vehicle body.
7. Bushing (lower)
8. Bushing (upper)
9. Dynamic damper <4G6, 4D6>

"AA FRONT ROLL STOPPER INSTALLATION
Hole Install so that the hole in the front roll stopper is facing towards
the front of the vehicle.
Front of vehicle
POWER PLANT MOUNT - Crossmember 32-7
CROSSMEMBER 32100320178

CAUTION: SRS
For vehicles with SRS, before removal of steering gear box, refer to GROUP 52B, centre front wheels and
remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative,
risking serious driver injury.

D Power Steering Fluid Draining (Refer to GROUP D Rear Roll Stopper Installation (Refer to P.32-6.)
37A - On-vehicle Service.) D Stabilizer Bar Installation (Refer to GROUP 33A.)
D Centermember Removal (Refer to P.32-6.) D Front Exhaust Pipe Installation (Refer to GROUP
D Front Exhaust Pipe Removal (Refer to GROUP 15.) 15.)
D Stabilizer Bar Removal (Refer to GROUP 33A.) D Centermember Installation (Refer to P.32-6.)
D Rear Roll Stopper Removal (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.)
9 11
10
98 - 118 Nm*
6 14
8
88 Nm
7 13 12
3
81 Nm 81 Nm
1 5
2
69 - 78 Nm
88 Nm*
4
88 Nm 98 - 118 Nm
Removal steps
1. No. 2 stay 8. Lower plate
2. Lateral lower arm and damper fork 9. Crossmember
connection 10. Stopper A
3. Lateral lower arm and crossmem- 11. Stopper B
ber connection 12. Bushing C
AA" 4. No. 3 stay 13. Bushing A
5. Compression lower arm mounting 14. Bushing B
bolts Caution
6. No. 1 stay *: Indicates parts which should be temporarily
D Power steering gear box tightened, and then fully tightened with the
(Refer to GROUP 37A.) vehicle on the ground in the unladen condition.
7. Crossmember mounting nut
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 Press-fitting CROSSMEMBER BUSHING REPLACEMENT

Bolt 32100090062
Washer
Nut CROSSMEMBER BUSHINGS A AND B
Base (1) Apply soapy water to the contact surface of the bushing
Base when press-fitted the bushing.
Nut Washer
Bolt
MB991045
(2) The bushing should be press-fitted so that the inner pipe

Bushing A Bushing B
projection is at the standard length.
Inner pipe Inner pipe Standard values
Bushing A: 9.0 ± 1.0 mm
Bushing B: 4.0 ± 1.0 mm
Removal 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
Inner pipe
33A-1
FRONT
SUSPENSION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 UPPER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . 6
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 COMPRESSION LOWER ARM AND LATERAL

LOWER ARM ASSEMBLIES . . . . . . . . . . . . . . 12
Wheel Alignment Check and Adjustment . . . . . . . 4 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 15
Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . . 5
33A-2 FRONT SUSPENSION - General Information
The front suspension is of a multi-link construction by mounting the upper arm in a higher position
with two lower arms which create the ideal virtual than the tyres, excellent steering stability and ride
kingpin axis for the suspension system. In addition, comfort are obtained.
COIL SPRING
Items Sedan (2000 - petrol-powered Sedan (except 2000 -
vehicles - M/T), petrol-powered vehicles - M/T),
Wagon (2000 - petrol-powered Wagon (except 2000 -
vehicles) petrol-powered vehicles)
Wire diameter ´ average diameter ´ 12 ´ 70 - 110 ´ 366 12 ´ 70 - 110 ´ 374

free length mm
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
Toe-in At the centre of tyre tread mm 0±3
Toe-angle (per wheel) 0_00’ ± 09’
Toe-out angle on turns 22_

(inner wheel when outer wheel at 20_)
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
Tools Number Name Use

MB991004 Wheel alignment Wheel alignment measurement
gauge attachment <Vehicles with aluminium type wheels>
A: MB991237 A: Spring com- Coil spring compression

pressor body
A B: MB991238
B: Arm set
B
MB991406, Steering linkage Ball joint disconnection

MB990635 or puller
MB991113
MB990326 Preload socket Ball joint rotation starting torque and turning
torque measurement
MB990800 Ball joint remover Ball joint dust cover installation

and installer
33A-4 FRONT SUSPENSION - On-vehicle Service
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 0±3 mm
Toe angle (per wheel) 0_00’±09’
(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
Clip
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
- On-vehicle Service.)
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.)
86 Nm
4
57 Nm
57 Nm
28 Nm
1
Removal steps
AA" 1. Upper arm and knuckle connection "AA 3. Upper arm shaft assembly
2. Upper arm mounting nut 4. Upper arm assembly

MB991406, AA" UPPER ARM AND KNUCKLE DISCONNECTION
MB990635 or
MB991113
Caution
Ball joint 1. Use the special tool to loosen the nut only; do not
Cord remove it from the ball joint.
Nut
FRONT SUSPENSION - Upper Arm Assembly 33A-7
Upper arm shaft
assembly "AA UPPER ARM SHAFT ASSEMBLY INSTALLATION
Install the upper arm shaft assembly at the angle shown
NOTE
If the upper arm shaft is installed at the above-mentioned
angle, the reference dimension is determine as follows;
85_ ± 1_
Upper arm
A: 300.1 mm
B: 234.3 mm
A B
Ball joint case A B
V groove
MB990326 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 FRONT SUSPENSION - Upper Arm Assembly
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

MB990800
Only when the dust cover is damaged accidentally during

service work, replace the dust cover as follows:
Dust cover Snap ring (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 33A-9
SHOCK ABSORBER ASSEMBLY 33200460078

(Refer to P.33A-4.)
44 Nm
44 Nm
4
103 Nm
5 3
88 Nm*
Removal steps
1. Stabilizer link "AA 5. Damper fork
2. Shock absorber mounting nuts 6. Shock absorber assembly
3. Damper fork and lateral lower arm Caution
connection *: Indicates parts which should be temporarily
4. Damper fork and shock absorber tightened, and then fully tightened with the
connection vehicle on the ground in the unladen condition.
Damper fork positioning projection INSTALLATION SERVICE POINT

"AA DAMPER FORK INSTALLATION
The damper fork must face against the damper fork positioning
Inside of projection of the shock absorber assembly as shown in the
the body
figure.
Damper fork mounting bolt

33A-10 FRONT SUSPENSION - Shock Absorber Assembly
23 Nm
9
1
2
10 3
4
5
11
6
12
7
Disassembly steps
AA" "CA 1. Self-locking nut 7. Upper bushing B
2. Washer 8. Cup assembly
3. Upper bushing A 9. Bump rubber
"BA 4. Upper bracket assembly 10. Dust cover
5. Upper spring pad "AA 11. Coil spring
6. Collar 12. Shock absorber assembly

MB991237 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.
MB991238 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.
FRONT SUSPENSION - Shock Absorber Assembly 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
Compression Lower Arm and
33A-12 FRONT SUSPENSION - 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 3
7
2
81 Nm
9
69 - 78 Nm 1
10
LATERAL LOWER ARM
88 Nm
98 - 118 Nm
4, 10
Compression lower arm assembly Lateral lower arm assembly

removal steps removal steps
AA" 1. No.3 stay 5. No.2 stay
AB" 2. Compression lower arm and 6. Lateral lower arm and damper fork
knuckle connection connection
3. Compression lower arm mounting AB" 7. Lateral lower arm and knuckle con-
bolts nection
4. Compression lower arm assembly 8. Lateral lower arm mounting bolt
9. Stopper
10. Lateral lower arm assembly
Caution
*: Indicates parts which should be temporarily
tightened, and then fully tightened with the
vehicle on the ground in the unladen condition.
FRONT SUSPENSION - Lateral Lower Arm Assemblies 33A-13
Crossmember
No.3 stay
AB" COMPRESSION LOWER ARM AND

MB991406,
MB990635 or KNUCKLE/LATERAL LOWER ARM AND
MB991113 KNUCKLE DISCONNECTION
Nut
Caution
Cord 1. Use the special tool to loosen the nut only; do not
Ball joint
LOWER ARM BALL JOINT ROTATION STARTING

MB990326 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 Assemblies
LATERAL LOWER ARM LOWER ARM BALL JOINT DUST COVER

Tapered REPLACEMENT 33200780051
portion
(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 (4) Drive in the dust cover with special tool until it is fully
seated.
Dust cover (5) Check the dust cover for cracks or damage by pushing
it with finger.
FRONT SUSPENSION - Stabilizer Bar 33A-15
STABILIZER BAR 33200540079

D Left Side of No.1 and No.2 Stays Disconnection D Check the Dust Cover for Cracks or Damage by
<L.H. Drive Vehicles> (Refer to GROUP 32 - Pushing it with Finger.
Crossmember.) D Right Side of No.1 and No.2 Stays Connection
D Right Side of No.1 and No.2 Stays Disconnection <R.H. Drive Vehicles> (Refer to GROUP 32 -
<R.H. Drive Vehicles> (Refer to GROUP 32 - Crossmember.)
Crossmember.) D Left Side of No.1 and No.2 Stays Connection
<L.H. Drive Vehicles> (Refer to GROUP 32 -
Crossmember.)
3
4
44 Nm 1
1 44 Nm
Removal steps
1. Stabilizer link mounting nut "AA 4. Bushing
2. Stabilizer link "AA 5. Stabilizer bar
"AA 3. Stabilizer bar bracket
Approx. 20 mm INSTALLATION SERVICE POINT

"AA STABILIZER BAR/BUSHING/STABILIZER BAR
BRACKET INSTALLATION
Inside of Position the stabilizer bar so that left side identification mark
the body is at the shown position, and tighten the stabilizer bar bracket
mounting bolt.
33A-16 FRONT SUSPENSION - Stabilizer Bar
STABILIZER LINK BALL JOINT TURNING TORQUE

CHECK
turning torque of the ball joint.
replace the stabilizer link.
STABILIZER LINK BALL JOINT DUST COVER CHECK

33200890013

it with finger.
stabilizer link.
NOTE
STABILIZER LINK BALL JOINT DUST COVER


(1) Remove the clip ring and the dust cover.
(2) Apply multipurpose grease to the inside of the dust cover.
Clip ring
(3) Use plastic tape on the stabilizer link threads as shown

Plastic in the illustration, and then install the dust cover to the
tape
stabilizer link.
(4) Secure the dust cover by the clip ring. When installing
Approx. the clip ring, align the ends at a 90_ angle from the axis
90_ of the stabilizer link.
Clip ring ends (180_ on
opposite side also possible) it with finger.
34-1
REAR
SUSPENSION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 UPPER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . 7
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 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
The rear suspension is a multi-link suspension, bushing have been rationalized to provide both
which has been used for the previous models. The excellent steering stability and riding comfort.
layout of each arm and the rigidity balance of each
COIL SPRING
Items Sedan Wagon
Wire diameter ´ average diameter ´ 9 ¢ 62 - 102 ¢ 397, 9 - 10 ¢ 63 - 103 ¢ 405,

free length mm 9 ¢ 94 - 102 ¢ 330*1, 10 ¢ 95 - 103 ¢ 321*1,
9 - 10 ¢ 63 - 103 ¢ 386*2 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
REAR SUSPENSION - Service Specifications/Special Tools 34-3
Toe-in At the centre of tyre tread mm 3±3
Toe-angle (per wheel) 0_09’ ± 09’
Camber - 1_00’ ± 30’
Dimension for positioning upper arm bracket mm 37.2 ± 2
Toe control arm ball joint turning torque Nm 1.0 - 2.6
Stabilizer link ball joint turning torque Nm 0.5 - 1.5

MB990635, Steering linkage puller Ball joint and knuckle disconnec-
MB991113 or tion
MB991406
MB990326 Preload socket Ball joint continuous rotating

check
MB990800 Ball joint remover and Ball joint dust cover installation
installer
A A: MB991237 A: Spring compressor Coil spring compression

B: MB991239 body
B: Arm set
B
34-4 REAR SUSPENSION - On-vehicle Service
WHEEL ALIGNMENT CHECK AND

Crossmember ADJUSTMENT
TOE-IN
Standard value:
At the centre of tyre tread 3 ± 3 mm
Toe angle (per wheel) 0_09’± 09’
Turn the toe control arm mounting bolts of the left and right
toe control arms by equal amounts to adjust.
LH: Clockwise viewed from the rear ® Toe-out
RH: Clockwise viewed from the rear ® Toe-in
Furthermore, toe adjustment can be mode at graduations
of approximately 2.5 mm
CAMBER
Standard value: - 1_00’ ± 30’
NOTE
1. Camber is preset at the factory and can not be adjusted.
2. If camber is not within the standard value, check and
replace bent or damaged parts.
1. Check the dust cover for cracks or damage by pushing

it with finger.
2. If the dust cover is cracked or damaged, replace the
toe control arm assembly or stabilizer link.
NOTE
of the ball joint.
REAR SUSPENSION - Rear Suspension Assembly 34-5
REAR SUSPENSION ASSEMBLY 34100330113

D Brake Fluid Draining <Vehicles with drum brake> D Center Exhaust Pipe Installation
D Rear Seat Removal <Sedan> (Refer to GROUP 15.)
(Refer to GROUP 52A.) D Retractor Trim Installation <Wagon>
D Retractor Trim Removal <Wagon> (Refer to GROUP 52A.)
(Refer to GROUP 52A.) D Rear Seat Installation <Sedan>
D Center Exhaust Pipe Removal (Refer to GROUP 52A.)
(Refer to GROUP 15.) D Parking Brake Lever Stroke Check
D Brake Line bleeding <Vehicles with drum brake>
(Refer to P.34-4.)
1
2
44 Nm
39 Nm
12
13
11
88 Nm
137 - 157 Nm*
100 Nm 5
7 10 4
9
15 Nm 6 3
Removal steps
1. Cap 9. Grommet
2. Shock absorber mounting nuts 10. Trailing arm mounting bolt
AA" 3. Brake caliper assembly AB" 11. Crossmember mounting nuts
4. Brake disc or brake dram 12. Rear wheel speed sensor connec-
5. Shoe and lining assembly (Refer to tor connection <Vehicles with ABS>
GROUP 36 - Parking Brake 13. Rear suspension assembly
Drum.)
6. Parking brake cable connection Caution
(Refer to GROUP 36.) *: Indicates parts which should be temporarily
7. Brake hose connection <Vehicles tightened, and then fully tightened with the
with drum brake> vehicles on the ground in the unladen condition.
8. Upper arm mounting bolts
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.
REAR SUSPENSION - Upper Arm Assembly 34-7
UPPER ARM ASSEMBLY 34100360082

Wheel Alignment Check and Adjustment
(Refer to P.34-4.)
39 Nm
98 Nm*
4 57 Nm
57 Nm
5
Removal steps
1. Upper arm and knuckle connecting 5. Upper arm
bolt
2. Upper arm assembly mounting Caution
bolts *: Indicates parts which should be temporarily
3. Upper arm assembly tightened, and then fully tightened with the
"AA 4. Upper arm bracket vehicles on the ground in the unladen condition.
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.
A
Standard value (A): 37.2 ± 2 mm
NOTE
Upper arm bracket Refer to distances B and C shown in the illustration to check
the installation angle of the upper arm bracket.
B: 220.1 mm
C: 274.4 mm
B
C B C
REAR SUSPENSION - Trailing Arm Assembly 34-9
TRAILING ARM ASSEMBLY 34100420162

Wheel Alignment Check and Adjustment
(Refer to P.34-4.)
137 - 157 Nm*
118 - 137 Nm*
4 5
3
2
1
Removal steps
1. Knuckle and trailing arm assembly 5. Trailing arm assembly
connecting bolt
2. Grommet Caution
3. Trailing arm assembly mounting *: Indicates parts which should be temporarily
bolt tightened, and then fully tightened with the
4. Stopper vehicles on the ground in the unladen condition.
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 6
98 Nm*
28 Nm
7
1 2
2
5 3
98 Nm*
39 Nm
Lower arm assembly removal steps Toe control arm assembly removal
1. Stabilizer link connection steps
2. Wheel speed sensor mounting AA" 6. Toe control arm and knuckle con-
bolts nection
3. Lower arm assembly and knuckle AB" 7. Toe control arm assembly mounting
connecting bolt bolt
4. Lower arm assembly mounting bolt 8. Toe control arm assembly
5. Lower arm assembly Caution
*: Indicates parts which should be temporarily
tightened, and then fully tightened with the
vehicles on the ground in the unladen condition.
REAR SUSPENSION - Lower Arm and Toe Control Arm Assemblies 34-11
MB990635, REMOVAL SERVICE POINTS
MB991113 or
MB991406
AA" TOE CONTROL ARM AND KNUCKLE
Nut DISCONNECTION
Caution
Cord
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
TOE CONTROL ARM BALL JOINT TURNING TORQUE

MB990326
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

MB990800 COVER CHECK 34101290014

Dust cover it with finger.
Snap ring 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

COVER REPLACEMENT 34101080062

1. Remove the dust cover.
2. Apply multipurpose grease to inside and lip of the dust
cover.
3. Using the special tool, press the dust cover until it contacts
the snap ring.
it with finger.
REAR SUSPENSION - Shock Absorber Assembly 34-13
SHOCK ABSORBER ASSEMBLY 34100510159

D Rear Seat Removal and Installation <Sedan>
D Retractor Trim Removal and Installation <Wagon>
44 Nm
98 Nm
Removal steps
1. Cap
2. Shock absorber mounting nuts
3. Bolt
"AA 4. Shock absorber assembly

"AA SHOCK ABSORBER ASSEMBLY INSTALLATION
Outside of
the body Install the shock absorber so that the larger diameter side
of the lower bushing inner pipe faces toward the outside
Lower bushing of the vehicle.
inner pipe
34-14 REAR SUSPENSION - Shock Absorber Assembly
23 Nm
1
2
8 3
9 4
11
10 5
6
12 7
Disassembly steps
AA" "CA 1. Self-locking nut 7. Upper bushing B
2. Washer 8. Cup assembly
3. Upper bushing A 9. Bump rubber
"BA 4. Upper bracket assembly 10. Dust cover
5. Upper spring pad "AA 11. Coil spring
6. Collar 12. Shock absorber assembly

MB991237 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
MB991239 tool bolt.
2. While holding the piston rod, remove the self-locking nut.

Caution
REAR SUSPENSION - Shock Absorber Assembly 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 Spring seat 2. Align the edge of the coil spring to the stepped part of
edge 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
3
5 4
39 Nm
39 Nm 1
Removal steps
1. Stabilizer link mounting nuts "AA 4. Bushing
2. Stabilizer link "AA 5. Stabilizer bar
"AA 3. Stabilizer bar bracket

Approx. 20 mm
"AA STABILIZER BAR/BUSHING/STABILIZER BAR
BRACKET INSTALLATION
Position the stabilizer bar identification mark to the left side.
Outside of
the body Adjust the identification mark position as shown in the figure,
and tighten the stabilizer bar bracket mounting bolt.
REAR SUSPENSION - Stabilizer Bar 34-17
MB990326
STABILIZER LINK BALL JOINT TURNING TORQUE
CHECK
1. After shaking the ball joint stud several times, install the
2. When the measured value exceeds the standard value,
replace the stabilizer link.
3. When the measured value is lower than the standard
STABILIZER LINK BALL JOINT DUST COVER CHECK

34101300014

it with finger.
stabilizer link.
NOTE
STABILIZER LINK BALL JOINT DUST COVER


1. Remove the clip ring and the dust cover.
2. Apply multipurpose grease to the lip and inside of the
dust cover.
Clip ring
3. Use plastic tape on the stabilizer link threads as shown

in the illustration, and then install the dust cover to the
Plastic tape
stabilizer link.
4. Secure the dust cover with the clip ring.
Approx. 90_ When installing the clip ring, align the ends at a 90_
angle from the axis of the stabilizer link.
Clip ring ends (180_ on
opposite side also possible) it with finger.
NOTES
35A-1
SERVICE BRAKES
BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A
ANTI-SKID BRAKING SYSTEM (ABS) <2WD> . . . . . . . . . . . . . . . . . . . . . . 35B
ANTI-SKID BRAKING SYSTEM (ABS) <4WD> . . . . . . . . . . . . . . . . . . . . . . 35C
NOTE
THE GROUPS MARKED BY ARE NOT IN THIS MANUAL
35A-2
BASIC BRAKE
SYSTEM
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 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
Brake Lining and Brake Drum Connection
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6 MASTER CYLINDER AND BRAKE

Brake Pedal Check and Adjustment . . . . . . . . . . . 6 BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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 35A-3
The brake system offers high dependability and durability along with improved braking performance and
brake sensitivity.
Master cylinder Type Tandem type (with level sensor)
I.D. mm 23.8
Brake booster Type Vacuum type, single
Effective dia. of power cylinder mm 230
Boosting ratio 6.0
Proportioning valve Type Dual type
Decompression ratio 0.25
Front brakes Type Floating caliper, 1-piston, ventilated disc
Disc effective dia. ´ thickness mm 256 ´ 24
Wheel cylinder I.D. mm 60.3
Pad thickness mm 10.0
Clearance adjustment Automatic
Rear disc brakes Type Floating caliper, 1-piston, solid disc
Disc effective dia. ´ thickness mm 262 ´ 24
Rear drum brakes Type Leading trailing
Drum I.D. mm 203
Lining thickness mm 4.4
Brake fluid DOT3 or DOT4

35A-4 BASIC BRAKE SYSTEM - Service Specifications
Brake booster
Master cylinder
Rear brake
Proportioning valve Brake pedal
Front brake
Brake pedal height mm 162.8 - 165.8 -
Brake pedal free play mm 3-8 -
Brake pedal to floor board clearance mm 90 or more -
Proportioning valve Split point MPa Sedan 2.94 ± 0.25 -
Wagon 3.43 ± 0.25 -
Output fluid pressure Sedan 4.66 ± 0.39 (9.81) -

(Input fluid pressure) MPa
Wagon 5.80 ± 0.39 (9.81) -
Output fluid pressure difference between left - 0.39

and right MPa
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 69 or less -

bolts) N
Service Specifications/Lubricants/
BASIC BRAKE SYSTEM - Sealants/Special Tools 35A-5
Rear disc brake Pad thickness mm 10.0 2.0
Disc thickness mm 10.0 8.4
Disc runout mm - 0.08
Drag force (tangential force of wheel mounting 69 or less -

bolts) N
Rear drum brake Lining thickness mm 4.4 1.0
Drum inside diameter mm 203 205
Items Specified Lubricant
Brake piston seal Repair kit grease (orange)
Slide pin boot and slide pin bush inner surfaces
Brake piston boot inner surfaces
Piston boot mounting grooves
Rear brake shoe and backing plate contact surfaces Brake grease SAE J310, NLGI No.1
Shoe assembly and auto adjuster assembly contact

surfaces
Shoe and lever assembly and auto adjuster assembly

contact surfaces
Thread part fitting 3M ATD Part No. 8661 or equivalent Semi-drying sealant
Vacuum switch

MB990964 Brake tool set D Pushing-in of the disc brake piston
MB990520 D Installation of drum brake wheel cylinder
MB990619 piston cup
MB990998 Front hub remover Provisional holding of the wheel bearing

and installer
35A-6 BASIC BRAKE SYSTEM - On-vehicle Service
BRAKE PEDAL CHECK AND ADJUSTMENT

Operating Stop lamp BRAKE PEDAL HEIGHT
rod switch 1. Turn up the carpet, etc under the brake pedal.
Operating 2. Measure the brake pedal height as illustrated. If the brake
rod lock nut pedal height is not within the standard value, follow the
procedure below.
(1) Disconnect the stop lamp switch connector.

Pedal down (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 up
Lock nut
(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
Lock nut
Outer case
to the required position. Adjust the position of the
switch by turning it until the distance shown in the
0.5 - 1.0 mm 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.
BASIC BRAKE SYSTEM - On-vehicle Service 35A-7
Standard value: 3–8 mm
If the free play exceeds the standard value, it is probably
due to excessive play between the retaining ring bolt and
brake pedal arm.
Check for excessive clearance and replace faulty parts as
required.
CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR

BOARD
1. Turn back the carpet etc. under the brake pedal.
2. Start the engine, depress the brake pedal with
approximately 490 N of force, and measure the clearance
between the brake pedal and the floorboard.
Standard value: 90 mm or more
3. If the clearance is outside the standard value, check for
air trapped in the brake line, clearance between the lining
and the drum and dragging in the parking brake.
Adjust and replace defective parts as required.
4. Return the carpet etc.
Connect a circuit tester to the stop lamp switch, and check

whether or not there is continuity when the plunger of the
stop lamp switch is pushed in and when it is released. The
stop lamp switch is in good condition if there is no continuity
No continuity 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.
2. With the engine stopped, step on the brake pedal several

When engine is When engine is
stopped started 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 Spring 2. Check the operation of the check valve by using a vacuum
pump.
A B
Intake Vacuum pump connection Accept/reject criteria
Booster manifold
side side Connection at the brake A negative pressure (vacu-
booster side (A) um) is created and held.
Connection at the intake A negative pressure (vacu-
manifold side (B) um) is not created.
Caution
If the check valve is defective, replace it as an
assembly unit together with the vacuum hose.
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 Standard value:
MPa
Output Sedan Wagon
pressure
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:
MPa
Sedan Wagon
Output fluid pressure 4.66 ± 0.39 5.80 ± 0.39
(Input fluid pressure) (9.81) (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”.
Caution
Use the specified brake fluid. Avoid using a mixture of
the specified brake fluid and other fluid.
Specified brake fluid: DOT3 or DOT4
MASTER CYLINDER BLEEDING

The master cylinder used has no check valve, so if bleeding
is carried out by the following procedure, bleeding of air from
the brake pipeline will become easier. (When brake fluid is
not contained in the master cylinder.)
(1) Fill the reserve tank with brake fluid.
(2) Keep the brake pedal depressed.
(3) Have another person cover the master cylinder outlet
with a finger.
(4) With the outlet still closed, release the brake pedal.
(5) Repeat steps (2) - (4) three or four times to fill the inside
of the master cylinder with brake fluid.
BRAKE PIPE LINE BLEEDING

4 (2) Bleed the air in the sequence shown in the figure.
1 (3)
2 (4) 3 (1)
( ): R.H. drive vehicles
When new When worn

DISC BRAKE PAD CHECK AND
Pad 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.
Wear indicator Brake disc
1. Check brake pad thickness through caliper body check
port.
Standard value: 10 mm
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 3. Remove the following parts from caliper support.

(1) Pad and wear indicator assembly <L.H.>, and pad
2 assembly <R.H.>
(2) Pad assembly
(3) Pad liner
(4) Outer shim
4
1
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.)
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 D If the vehicle is not driven for a certain period, the sections of
and wear the discs that are not in contact with lining will become rusty, causing
noise and shuddering.
D If grooves resulting from excessive disc wear and scratches are
not removed prior to installing a new pad assembly, there will
momentarily be inappropriate contact between the disc and the
lining (pad).
Run-out or drift Excessive run-out or drift of the discs will increase the pedal depression
resistance due to piston knock-back.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause pedal pulsation,
shuddering and surging.
Inset or warping (flatness) Overheating and improper handling while servicing will cause inset or
warping.
THICKNESS CHECK 35100240017
1. Using a micrometer, measure disc thickness at eight

positions, approximately 45_ apart and 10 mm in from
the outer edge of the disc.
Brake disc thickness
Standard value: 24.0 mm <Front>, 10.0 mm <Rear>
Limit: 22.4 mm <Front>, 8.4 mm <Rear>
Thickness variation (at least 8 positions)
The difference between any thickness measurements
should not be more than 0.015 mm.
2. If the disc is beyond the limits for thickness, remove it
and install a new one. If thickness variation exceeds the
specification, replace the brake disc or turn rotor with
on the car type brake lathe (“MAD, DL-8700PF” or
equivalent).
RUN-OUT CHECK 35100250010
1. Remove the caliper support; then raise the caliper

assembly upward and secure by using wire.
2. Inspect the disc surface for grooves, cracks and rust.
Clean the disc thoroughly and remove all rust.
3. Place a dial gauge approximately 5 mm from the outer

circumference of the brake disc, and measure the run-out
of the disc.
Limit:
0.06 mm or less <Front>
0.08 mm or less <Rear>
NOTE
Tighten the nuts in order to secure the disc to the hub.
RUN-OUT CORRECTION 35100180081
1. If the run-out of the brake disc is equivalent to or exceeds

the limit specification, change the phase of the disc and
hub, and then measure the run-out again.
(1) Before removing the brake disc, chalk both sides
of the wheel stud on the side at which run-out is
greatest.
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).
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.
Standard value: 203 mm
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
2 1
9
8 8
10
9
3
6 7
Removal steps
1. Stop lamp switch connector 7. Brake pedal pad
2. Stop lamp switch 8. Brake pedal return spring
3. Snap pin 9. Bushing
4. Pin assembly 10. Pipe
5. Brake pedal shaft bolt 11. Pedal support member
6. Brake pedal
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.)
6
11
3 12
2 20 - 25 Nm
14
9
15 Nm
22 Nm 10 14 Nm
8
10 Nm
1 15 Nm 13
<L.H. drive vehicles - 4G6, 6A1> <L.H. drive vehicles - 4D6> <R.H. drive vehicles - 4G6, 6A1>
6
7 15 Nm 6
4 7
15 Nm
<R.H. drive vehicles - 4D6>

4
4
7
12
Sealant: 3M ATD Part No.8661 or equivalent

5
BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster 35A-17
Removal steps
1. Brake pipe connection 7. Fitting
2. Brake fluid level sensor connector 8. Snap pin
3. Master cylinder assembly 9. Pin assembly
"BA D Push rod protruding length check and 10. Clevis
adjustment 11. Vacuum switch connector <4D6>
4. Vacuum hose <4D6> 12. Vacuum switch <4D6>
5. Vacuum pipe <4D6> 13. Brake booster
"AA 6. Vacuum hose 14. Sealer
(with built-in check valve)

"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.
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 BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster
MASTER CYLINDER 35100420145
2
1
3 9
10
5 11
7 Master cylinder kit
4
12
8
10
11 10
6 11
12 Brake fluid: DOT3 or DOT4
Disassembly steps
1. Reservoir cap assembly 7. Reservoir tank
2. Reservoir cap 8. Reservoir seal
3. Diaphragm 9. Piston retainer
4. Brake fluid level indicator assembly 10. Primary piston assembly
5. Float 11. Secondary piston assembly
6. Spring pin 12. Master cylinder body
BASIC BRAKE SYSTEM - Disc Brake 35A-19
DISC BRAKE 35100800017

<Front>
4
90 - 110 Nm
29 Nm
1
3
<Rear>
1 3
29 Nm
4
2
55 - 65 Nm
Removal steps
1. Brake hose connection "AA 3. Disc brake assembly
2. Gasket 4. Brake disc
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 <Front>
(1) Remove the drive shaft.
Tighten the nut with
the bolt secured. (Refer to GROUP 26 - Front Axle.)
35A-20 BASIC BRAKE SYSTEM - Disc Brake
(2) Attach the special tool to the front hub assembly as

shown in the illustration, and tighten it to the specified
torque.
(3) Use a spring balance to measure the rotary-sliding

resistance of the hub in the forward direction.
<Rear>
Use a spring balance to measure the rotary-sliding
2. After installing the caliper support to the knuckle, install

the pad clips and the pads to the caliper support.
Caution
Do not let any oil, grease or other contamination get
onto the friction surfaces of the pads and brake discs.
3. Clean piston and insert into cylinder with special tool.

4. Be careful that the piston boot does not become caught
when lowering the caliper assembly, and tighten the guide
pin to the specified torque.
5. Start the engine and then depress the brake pedal 2 - 3
times.
MB990520
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.
14
2 3 12
11 13
5
74 Nm
14
8 Nm
74 Nm
10
9 4
5 8
7
6
3 5 14 14
13 9 3 5
2 9 6 4
8 Grease
7
1 13
10 5
12 5 7 6
11 11 12
14 14
Brake caliper kit Pad repair kit Seal and boots repair kit
Caliper assembly disassembly Pad assembly disassembly steps

steps "AA 1. Guide pin
"AA 1. Guide pin "AA 2. Lock pin
"AA 2. Lock pin 3. Bushing
3. Bushing 4. Caliper support (pad, clip, shim)
4. Caliper support (pad, clip, shim) 11. Pad and wear indicator assembly
5. Boot 12. Pad assembly
6. Boot ring 13. Outer shim (coated with rubber)
AA" 7. Piston boot 14. Clip
AA" 8. Piston
AB" 9. Piston seal
10. Caliper body
35A-22 BASIC BRAKE SYSTEM - Disc Brake
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.
Brake fluid: DOT3 or DOT4
Grease: Repair kit grease Grease: Repair kit grease

When disassembling the disc brakes, disassemble both sides
(left and right) as a set.
AA" PISTON BOOT/PISTON REMOVAL
Protect caliper body with cloth. Blow compressed air through
brake hose to remove piston boot and piston.
Caution
Blow compressed air gently.
AB" PISTON SEAL REMOVAL

1. Remove piston seal with finger tip.
Caution
Do not use a flat-tipped screwdriver or other tool to
prevent damage to inner cylinder.
2. Clean piston surface and inner cylinder with
trichloroethylene, alcohol or specified brake fluid.

Lock pin
"AA LOCK PIN/GUIDE PIN INSTALLATION
“L”
Install the guide pin and lock pin as illustrated that each
head mark of the guide pin and the lock pin matches the
Front indication mark (“G” or “L”) located on the caliper body.
Guide pin
“G”
D Check cylinder for wear, damage or rust.

D Check piston surface for wear, damage or rust.
D Check caliper body or sleeve for wear.
D Check pad for damage or adhesion of grease, check
backing metal for damage.
35A-24 BASIC BRAKE SYSTEM - Rear Drum Brake
REAR DRUM BRAKE 35100750145

D Loosening the Parking Brake Cable Adjusting Nut. D Brake Line Bleeding (Refer to P.35A-10.)
D Brake Fluid Draining D Parking Brake Lever Stroke Adjustment
(Refer to GROUP 36 – On-vehicle Service.)
15 Nm
17
74 - 88 Nm
16
20 11
12
16 3 13 14
5 15
4
19
9
1
10
18 8 6 8 7
7 2
5
10 4 5 20
15
Specified grease: Brake grease SAE J310, NLGI No.1
Removal steps
1. Brake drum 11. Shoe and lever assembly
2. Lever return spring AA" "BA 12. Retainer
3. Shoe-to-lever spring "AA 13. Wave washer
4. Adjuster lever 14. Parking lever
5. Auto adjuster assembly 15. Shoe and lining assembly
6. Retainer spring 16. Shoe hold-down pin
7. Shoe hold-down cup 17. Brake pipe connection
8. Shoe hold-down spring 18. Snap ring
9. Shoe-to-shoe spring 19. Rear hub assembly
10. Shoe and lining assembly 20. Backing plate
BASIC BRAKE SYSTEM - Rear Drum Brake 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

"AA WAVE WASHER INSTALLATION
Washer Shoe assembly
Install the washer in the direction shown in the illustration.
Pin
Parking lever
"BA RETAINER INSTALLATION

Pin of shoe assembly
Use pliers or the like to install the retainer or the pin positively.
Retainer
35A-26 BASIC BRAKE SYSTEM - Rear Drum Brake
WHEEL CYLINDER 35100930082

Brake Fluid draining D Brake Fluid Supplying
3
10 Nm 2
15 Nm 4
8 Nm
7
5 6
1
Removal steps
1. Brake drum 5. Brake pipe connection
2. Shoe-to-lever spring 6. Wheel cylinder
3. Shoe-to-shoe spring 7. Bleeder screw
4. Auto adjuster assembly
BASIC BRAKE SYSTEM - Rear Drum Brake 35A-27
6
3 6
4
3
Grease: Repair kit grease Brake fluid: DOT3 or DOT4
1
2
5 4 3
6
3 4 1 4
Grease
2
Wheel cylinder repair kit
Disassembly steps
1. Boots "AA 4. Piston cups
2. Piston assembly 5. Spring
"AA 3. Pistons 6. Wheel cylinder body

"AA PISTON CUP/PISTON REASSEMBLY
MB990619
1. Use alcohol or specified brake fluid to clean the wheel
cylinder and the piston.
2. Apply the specified brake fluid to the piston cups and
the special tool.
3. Set the piston cup on the special tool with the lip of the
cup facing up, fit the cup onto the special tool, and then
slide it down the outside of the tool into the piston groove.
Caution
In order to keep the piston cup from becoming twisted
or slanted, slide the piston cup down the tool slowly
and carefully, without stopping.
Piston
Have the lip facing

upwards.
35A-28 BASIC BRAKE SYSTEM - Rear Drum Brake/Proportioning Valve
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
15 Nm 1
Removal steps
"AA 1. Brake pipe
2. Proportioning valve

"AA BRAKE PIPE CONNECTION
1 2 Connect the pipes to the hydraulic unit as shown in the
illustration.
1. Proportioning valve – Rear brake (L.H.)
3 4 2. Proportioning valve – Rear brake (R.H.)
3. Proportioning valve – Front brake (R.H.)
4. Proportioning valve – Front brake (L.H.)
5 6 5. Proportioning valve – Master cylinder (secondary)
6. Proportioning valve – Master cylinder (primary)
35B-1
ANTI-SKID
BRAKING SYSTEM
(ABS) <2WD>
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 Bleeding . . . . . . . . . . . . . . . . . . Refer to GROUP 35A

Disc Brake Pad Check and Replacement
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 5 . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Disc Brake Rotor Check
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake Lining Thickness Check
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6 Brake Drum Inside Diameter Check
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 19 Brake Lining and Brake Drum Connection
Brake Pedal Check and Adjustment Check . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Wheel Speed Sensor Output Voltage
Stop Lamp Switch Check Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A ABS Warning Lamp Relay Continuity
Brake Booster Operating Test Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Hydraulic Unit Check . . . . . . . . . . . . . . . . . . . . . . . . 22
Check Valve Operation Check Remedy for a Flat Battery . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Proportioning Valve Function Test
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
Brake Fluid Level Sensor Check CONTINUED ON NEXT PAGE
. . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
35B-2
BRAKE PEDAL . . . . . . . . Refer to GROUP 35A Wheel Cylinder . . . . . . . . . . . Refer to GROUP 35A
MASTER CYLINDER AND BRAKE PROPORTIONING VALVE . . . . . . . . . . . . . . . . . 25

BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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 35B-3
The ABS consists of components such as the wheel identified and the trouble symptoms will be
speed sensors, stop lamp switch, hydraulic unit memorized by the diagnosis function.
assembly, ABS control unit (ABS-ECU) and the In addition, reading of diagnosis codes and service
ABS warning lamp. If a problem occurs in the data and actuator testing are possible by using
system, the malfunctioning components can be the MUT-II.
Master cylinder Type Tandem type (with level sensor)
I.D. mm 25.4
Brake booster Type Vacuum type, tandem
Effective dia. of power cylinder mm 180 + 205
Boosting ratio 6.5
Proportioning valve Type Dual type
Decompression ratio 0.25
Front brakes Type Floating caliper, 1-piston, ventilated disc
Disc effective dia. ´ thickness mm 256 ¢ 24
Rear drum brakes Type Leading trailing
Drum I.D. mm 203
Lining thickness mm 4.4
ABS type 4-sensor, 3-channel method
Speed sensor Magnet coil type on 4 wheels
Front ABS rotor teeth 43
Rear ABS rotor teeth 43

35B-4 ABS <2WD> - General Information
2
7
6
8
1
3
4 5
3
2
7
1
4 5
8
6
1. ABS relay 5. Wheel-speed sensor

2. ABS warning lamp 6. ABS-ECU
3. Stop lamp switch 7. Diagnosis connector
4. ABS rotor 8. Hydraulic unit
ABS <2WD> - Service Specifications/Lubricants/Special Tools 35B-5
Wheel speed sensor internal resistance kW 1.0 - 1.5
Clearance between the wheel speed sensor mounting 28.2 - 28.5

surface and the ABS toothed rotor mm
Wheel speed sensor insulation resistance kW 100 or more
Items Specified lubricant

MB991502 MUT-II sub For checking of ABS (Diagnosis code display
assembly when using the MUT-II)
MB991529 Diagnosis code For checking of ABS (Diagnosis code display

check harness when using the ABS warning lamp)
35B-6 ABS <2WD> - Troubleshooting

NOTES WITH REGARD TO DIAGNOSIS
The phenomena listed in the following table are not abnormal.
Phenomenon Explanation of phenomenon
System check sound When starting the engine, a thudding sound can sometimes be heard coming from inside
the engine compartment, but this is because the system operation check is being
performed, and is not an abnormality.
ABS operation sound 1. Sound of the motor inside the ABS hydraulic unit operation. (whine)
2. Sound is the generated along with vibration of the brake pedal. (scraping)
3. When ABS operates, sound is generated from the vehicle chassis due to repeated
brake application and release.
(Thump: suspension; squeak: tyres)
ABS operation For road surfaces such as snow-covered roads and gravel roads, the braking distance for
(Long braking distance) 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.
Diagnosis detection condition can vary depending on the diagnosis code.

Make sure that checking requirements listed in the “Comment” are satisfied when checking the trouble
symptom again.
DIAGNOSIS CODES CHECK

Read a diagnosis code by the MUT-II or ABS warning lamp.
(Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.)
ERASING DIAGNOSIS CODES

With the MUT-II
Service Points.
ABS <2WD> - Troubleshooting 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.
ON
Ignition switch
OFF
ON
Stop lamp switch
OFF
ON
ABS warning lamp
OFF
ABS-ECU memory
Within 3 Within Within Within Within Within Within Within Within Within Within
1 1 1 1 1 1 1 1 1 1
1 se-
seconds second second second second second second second second second second cond
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th Erasing of
ABS-ECU
diagnosis
codes
complete.
Inspect according to the inspection chart that is appropriate for the malfunction code.
Diagnosis Inspection item Diagnosis content Reference page

code No.
11 Front right wheel speed sensor Open circuit 35B-9
12 Front left wheel speed sensor
13 Rear right wheel speed sensor
14 Rear left wheel speed sensor
15 Wheel speed sensor Abnormal output signal 35B-10
16 Power supply system 35B-10
21 Front right wheel speed sensor Short circuit 35B-9
22 Front left wheel speed sensor
23 Rear right wheel speed sensor
24 Rear left wheel speed sensor
33 Stop lamp switch system 35B-11
41 Front right solenoid valve 35B-26 (Replace

the hydraulic unit.)
42 Front left solenoid valve
43 Rear right solenoid valve
44 Rear left solenoid valve
51 Valve relay problem (stays on)
52 Valve relay problem (stays off)
53 Motor relay problem (stays off)
54 Motor relay problem (stays on)
55 Motor system (seized pump motor)
63 ABS-ECU
Code Nos.11, 12, 13 and 14 Wheel speed sensor Probable cause
(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 D Malfunction of wheel speed sensor
short-circuit in the (+) wire or (- ) wire in any one of the four wheel speed sensors. D Malfunction of wiring harness or connector
D Malfunction of hydraulic unit
Code Nos.21, 22, 23 and 24 are output in the following cases. D Malfunction of wheel speed sensor
D When there is no input from any one of the four wheel speed sensors when travelling D Malfunction of wiring harness or connector
at several km/h or more, even though open circuit can not be verified. D Malfunction of ABS rotor
D When a chipped or blocked-up ABS rotor is detected and if the anti-lock system D Too much gap between the sensor and the rotor
operates continuously because a malfunctioning sensor or a warped ABS rotor D Malfunction of hydraulic unit
is causing sensor output to drop. D Malfunction of wheel bearing
NG
Wheel speed sensor installation check Repair
OK
NG
Measure at the ABS-ECU connector A-04. Wheel speed sensor check (Refer to P.35B-29.)
D Disconnect the connector, and measure at the harness side OK NG
connector.
D Resistances between 20 and 19, 2 and 1, 22 and 23, 6 and Replace
5
OK: 1.0 - 1.5 kW
OK <L.H. drive vehicles>
A-09, C-115, C-75, A-39, C-74, E-14, E-13, E-11, C-123, E-12
Wheel speed sensor output voltage check (Refer to P.35B-19.) NG
OK NG A-09, A-41, A-39, C-115, C-75, E-14,
Repair E-11, C-121, E-12
E-13,
NG OK
Wheel speed sensor Replace
check (Refer to Check the trouble symp-
P.35B-29.) tom.
OK NG
NG
ABS rotor check (Refer Replace Check the harness wire, and repair if necessary.
to P.35B-29.) D Between each wheel speed sensor and ABS-ECU
OK
Wheel bearing check (Re-

fer to GROUP 26 and
GROUP 27 - On-vehicle
Service.)
Check the following connector: A-04

OK NG
Check the trouble symp- Repair

tom.
NG
Replace the hydraulic unit.

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 D The four vehicle tires are of different sizes
of the four wheel speed sensors while driving (except for an open circuit or short D Improper installation of wheel speed sensor
circuit). D Malfunction of wheel speed sensor
D Malfunction of ABS rotor
D Malfunction of wheel bearing
NO
Are the sizes of all four tires identical? Equip the vehicle with tires of identical sizes.
YES

NG
NG
OK
NG
Wheel speed sensor output voltage check (Refer to P.35B-19.) Wheel speed sensor check (Refer to P.35B-29.)
OK OK NG
Check the following connector: A-04 Replace

OK NG
ABS rotor check (Refer to P.35B-29.)
Check the trouble symp- Repair OK NG
tom.
NG Replace
Wheel bearing check (Refer to GROUP 26 and GROUP 27 -
NG
Check the harness wire, and repair if necessary.

D Between each wheel speed sensor and ABS-ECU
Code No.16 ABS-ECU power supply system (abnormal Probable cause

voltage drop or rise)
This code is output if the ABS-ECU power supply voltage drops below or rises above D Malfunction of battery
the rated values. D Malfunction of wiring harness or connector
Furthermore, if the voltage returns to normal, this code is no longer output. D Malfunction of hydraulic unit
Caution
If battery voltage drops or rises during inspection, this code will be output as well. If the voltage
returns to standard value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
NG
Measure at the ABS-ECU connector A-04. Check the following connectors:
D Disconnect the connector, and measure at the harness side A-04, C-75, C-66 <L.H. drive vehicles>, C-134, C-131
connector.
OK NG
D Start the engine. Voltage between 4 and body earth
OK: Battery voltage Repair
OK
OK
Check the trouble symp- Check the battery.
tom.
OK NG NG
Check the trouble symp- Repair Check the harness wire, and repair if necessary.
tom. D Between ignition switch and ABS-ECU
NG

Code No.33 Stop lamp switch system (open circuit or stop Probable cause
lamp stays ON)
This code is output in the following cases. D Malfunction of stop lamp switch
D If the stop lamp switch is continuously on for 15 minutes or more even though D Malfunction of wiring harness or connector
the ABS system is not operating. D Malfunction of hydraulic unit
D If there is an open circuit in the stop lamp switch input circuit harness.
NO
Does the stop lamp turn on and off normally? Stop lamp switch installation check
YES OK NG
Measure at the ABS-ECU connector A-04. Repair

D Disconnect the connector, and measure at the harness side
connector. Stop lamp switch check (Refer to GROUP 35A - Brake Pedal.)
D Stop lamp switch: ON
D Voltage between 18 and body earth OK NG
OK: Battery voltage
Replace
OK NG
Check the following Check the following Check the following connectors:
connector: A-04 connectors: C-12 <R.H. drive vehicles>, C-142, C-134, C-02, C-65, C-75, A-04
A-04, C-75, C-65 OK NG
OK NG
OK NG
Repair tom.
Repair
Check the trouble symp- NG
tom. Check the trouble symp-
tom. Check the harness wire, and repair if necessary.
NG D Between fusible link No.1 and ABS-ECU
NG
Replace the hydraulic
unit. Check the harness wire,
D Between stop lamp
switch and ABS-ECU
ABS WARNING LAMP INSPECTION 35201200123
Check that the ABS warning lamp illuminates as

follows.
1. When the ignition key is turned to “ON”, the ABS warning
lamp illuminates for approximately 3 seconds and then
switches off.
2. When the ignition key is turned to “START”, the ABS
warning lamp remains illuminated.
3. When the ignition key is turned from “START” back to
“ON”, the ABS warning lamp illuminates for approximately
ABS warning lamp 3 seconds and then switches off.
NOTE
Approx. 3 s Approx. 3 s The ABS warning lamp may remain on until the vehicle
reaches a speed of several km/h. This is limited to cases
ABS Illuminated where diagnosis code Nos.21 - 24 and 55 have been
warning Not
lamp recorded because of a previous problem occurring. In
illuminated
START this case, the ABS-ECU keeps the warning lamp
Ignition ON illuminated until the problem corresponding to that
switch ACC, diagnosis code can be detected.
LOCK
4. If the illumination is other than the above, check the
diagnosis codes.
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Trouble symptoms Inspection procedure Reference page
No.
Communication between the MUT-II and the whole system is not 1 35B-12
possible.
Communication between the MUT-II and the ABS-ECU is not possible. 2 35B-13
When the ignition key is turned to “ON” (engine stopped), the ABS 3 35B-14
warning lamp does not illuminate.
Even after the engine is started, the ABS warning lamp remains 4 35B-15
illuminated.
Faulty ABS operation 5 35B-16
Caution
1. If steering movements are made when driving at high speed, or when driving on road surfaces
with low frictional resistance, or when passing over bumps, the ABS may operate even though
sudden braking is not being applied. Because of this, 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 Probable cause
is not possible.
The cause may be a malfunction of the power supply circuit or the earth circuit of D Malfunction of diagnosis connector
the diagnosis connector. D Malfunction of wiring harness or connector
NG
Measure at the diagnosis connector C-20. Check the following connectors:
D Voltage between 16 and body earth <L.H. drive vehicles>
OK: Battery voltage C-20, C-66, C-63, C-132, C-141
OK
C-20, C-66, C-62, C-14
OK NG

tom.
NG

D Between power supply and diagnosis connector
NG
Measure at the diagnosis connector C-20. Check the following connector: C-20
D Continuity between 4 and body earth, and between 5 and body
OK NG
earth
OK: Continuity Check the trouble symp- Repair
OK tom.
NG
NG Check the harness wire, and repair if necessary.
D Between diagnosis connector and earth
Replace the MUT-II.
Communication between MUT-II and the ABS-ECU is not Probable cause
possible.
The cause may be an open circuit in the ABS-ECU power supply circuit or an open D Blown fuse
circuit in the diagnosis output circuit. D Malfunction of wiring harness or connector
NG
Measure at the diagnosis connector C-20 and the ABS-ECU con- Check the following connectors:
nector A-04. <PETROL-POWERED VEHICLES>
D Disconnect the connector, and measure at the harness side C-51, C-49, C-83, C-66, C-20
connector. <DIESEL-POWERED VEHICLES>
D Continuity between the following terminals C-51, C-56, C-83, C-66, C-20
ABS-ECU side - Diagnosis connector side
OK NG
14 - 1
7 - 7 Check the trouble symp- Repair
OK: Continuity tom.
OK NG

D Between ABS-ECU and diagnosis connector
NG
Measure at the ABS-ECU connector A-04. Check the following connectors:
D Disconnect the connector, and measure at the harness side A-04, C-75, C-66 <L.H. drive vehicles>, C-134, C-131
connector. OK NG
D Voltage between 4 and body earth Check the trouble symp- Repair
OK: Battery voltage tom.
OK NG

D Between ignition switch and ABS-ECU
NG
Measure at the ABS-ECU connector A-04. Check the following connector: A-04
D Disconnect the connector, and measure at the harness side OK
connector. NG
D Continuity between 8 and body earth, between 11 and body Check the trouble symp- Repair
earth and between 24 and body earth tom.
OK: Continuity
NG
OK
Check the following connector: A-04 D Between ABS-ECU and earth
OK NG
tom.
NG

When the ignition key is turned to “ON” (engine stopped), Probable cause
the ABS warning lamp does not illuminate.
The cause may be an open circuit in the lamp power supply circuit, a blown lamp, D Blown fuse
a malfunction of the ABS warning lamp relay or an open circuit between the ABS D Burn out ABS warning lamp bulb
warning lamp and the earth. D Malfunction of ABS warning lamp relay
NG
Fuse check Refer to GROUP 00 - Inspection Service Points for Blown Fuse.
Multi-purpose fuse No.13
OK
NG
Measure at the connector C-50. Check whether the ABS warning lamp bulb is burnt out.
D Disconnect the connector, and measure at the combination NG
OK
meter side connector.
D Ignition switch: ON Replace the ABS warning
D ABS warning lamp condition when terminal 2 <LHD> or terminal lamp bulb.
7 <RHD> is earthed.
OK: Illuminates NG
OK Check the following Repair
connectors:
ABS warning lamp relay check (Refer to P.35B-21.) D-01, D-03, C-135, C-131
OK NG OK
Replace the ABS warning Check the trouble symp-

lamp relay. tom.
NG
Replace the combination meter.
NG
Disconnect the ABS warning lamp relay connector A-05X and ABS- Check the following connector: A-05X
ECU connector A-04, and measure at the harness side connector OK NG
of ABS warning lamp relay.
D Ignition switch: ON Check the trouble symp- Repair
D Voltage between 5 and body earth tom.
OK: Battery voltage
NG
OK
Replace the hydraulic unit. D Between ABS warning lamp and ABS warning lamp relay
D Between ABS warning lamp relay and earth
Even after the engine is started, the ABS warning lamp Probable cause
remains illuminated.
The cause is probably a short-circuit in the ABS warning lamp illumination circuit. D Malfunction of combination meter
D Malfunction of ABS warning lamp relay
D Malfunction of wiring harness (short circuit)
NOTE
This trouble symptom is limited to cases where communication with the MUT-II is possible (ABS-ECU
power supply is normal) and the diagnosis code is a normal diagnosis code.
YES
Does the ABS warning lamp stay illuminated when the connector Replace the combination meter.
C-50 is disconnected and the ignition switch is turned to ON?
NO
NG
ABS warning lamp relay check (Refer to P.35B-21.) Replace the ABS warning lamp relay.
OK
NG
Disconnect the ABS warning lamp relay connector A-05X and ABS- Check the following connectors: A-05X, A-04
ECU connector A-04, and measure at the harness side connector OK NG
of ABS warning lamp relay.
D Ignition switch: ON Check the trouble symp- Repair
D Voltage between 2 and body earth tom.
OK: Battery voltage
NG
OK
Replace the hydraulic unit. D Between ABS warning lamp and ABS warning lamp relay
D Between ABS warning lamp relay and ABS-ECU
Faulty ABS operation Probable cause
This varies depending on the driving conditions and the road surface conditions, so D Improper installation of wheel speed sensor
problem diagnosis is difficult. However, if a normal diagnosis code is displayed, carry D Malfunction of wiring harness or connector
out the following inspection. D Malfunction of wheel speed sensor
D Malfunction of ABS rotor
D Foreign material adhering to wheel speed sensor
D Malfunction of wheel bearing
NG
OK
OK
Wheel speed sensor output voltage check (Refer to P.35B-19.) Hydraulic unit check (Refer to P.35B-22.)
NG
NG
Wheel speed sensor check (Refer to P.35B-29.) Replace the wheel speed sensor.
OK
NG
ABS rotor check (Refer to P.35B-29.) Repair
OK
NG
Wheel bearing check (Refer to GROUP 26 and GROUP 27 - Repair
OK
NG
A-09, C-115, C-75, A-39, C-74, E-14, E-13, E-11, C-123, E-12
A-09, A-41, A-39, C-115, C-75, E-14, E-13, E-11, C-121, E-12
OK

NG
NG
Measure at the ABS-ECU connector A-04. Repair
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

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 Vehicle speeds

displayed on the
12 Front-left wheel speed sensor speedometer
and MUT-II II are
13 Rear-right wheel speed sensor identical.
14 Rear-left wheel speed sensor
16 ABS-ECU power supply Ignition switch power supply voltage and valve 9.2 - 17.5 V
voltage monitor voltage
33 Stop lamp switch Depress the brake pedal. ON
Release the brake pedal. OFF
2. When the ABS-ECU shut off ABS operation.

When the diagnosis system stops the ABS-ECU, the MUT-II display data will be unreliable.
The MUT-II activates the following actuators for testing.

NOTE
1. If the ABS-ECU runs down, actuator testing cannot be carried out.
2. Actuator testing is only possible when the vehicle is stationary. If the vehicle speed during actuator
testing exceeds 10 km/h, forced actuation will be canceled.
3. During the actuator test, the ABS warning lamp will illuminate and the anti-skid control will be cancelled.
ACTUATOR TEST SPECIFICATIONS

Activation pattern
No. Item
End of forced
Start of action
forced 01 Solenoid valve for front-left Solenoid valves and pump
A action wheel motors in the hydraulic unit
Solenoid (simple inspection mode)
valve B 1s 02 Solenoid valve for front-right
C 2s wheel
48 ms 8 ms
03 Solenoid valve for rear-left
Pump ON wheel
motor OFF 04 Solenoid valve for rear-right
wheel
NOTE
A: Hydraulic pressure increase
B: Hydraulic pressure holds
C: Hydraulic pressure decrease
CHECK AT ABS-ECU 35201180229

1. Measure the voltage between each terminal and earth.
2. The terminal layout is shown in the illustration below.
Terminal No. Check item Checking requirements Normal condition
4 ABS-ECU power sup- Ignition switch: ON Battery voltage

ply
Ignition switch: START 0V
7 MUT-II When the MUT-II is connected Serial communication

with MUT-II
When the MUT-II is not connected 1 V or less
9 Solenoid valve power Always Battery voltage

supply
14 Diagnosis changeover When the MUT-II is connected 0V

input
When the MUT-II is not connected Approx. 12 V
16 ABS valve transistor Ignition switch: ON When the lamp is 2 V or less

output switched off
When the lamp is Battery voltage

illuminated
18 Stop lamp switch input Ignition switch: ON Stop lamp switch: ON Battery voltage
Stop lamp switch: OFF 1 V or less
25 Motor power supply Always Battery voltage
RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS

1. Turn the ignition switch off and disconnect the ABS-ECU connectors before checking resistance and
continuity.
2. Check them between the terminals indicated in the table below.
3. The terminal layouts are shown in the illustrations below.
Terminal No. Signal Normal condition
1- 2 Wheel speed sensor (front left) 1.0 - 1.5 kW
5- 6 Wheel speed sensor (rear left) 1.0 - 1.5 kW
19 - 20 Wheel speed sensor (front right) 1.0 - 1.5 kW

ABS <2WD> - Troubleshooting/On-vehicle Service 35B-19
Terminal No. 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 ON-VEHICLE SERVICE 35200160224

(harness side)
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 Front left Front Rear left Rear
speed right right
sensor
Terminal 1 19 5 23
No.
2 20 6 22
Output voltage
When measuring with a circuit tester:
42 mV or more
When measuring with an oscilloscope:
120 mV p-p or more
4. If the output voltage is lower than the above values, the
reason could be as follow:
D Faulty wheel speed sensor.
So replace the wheel speed sensor.
35B-20 ABS <2WD> - On-vehicle Service
Inspecting Waveforms With An Oscilloscope

Use the following method to observe the output voltage
When turning by hand waveform from each wheel sensor with an oscilloscope.
D Start the engine, and rotate the front wheels by engaging
1st gear (vehicles with manual transmission) or D range
(vehicles with automatic transmission). Turn the rear
wheels manually so that they rotate at a constant speed.
NOTE
1. Check the connection of the sensor harness and
When idling (5 - 6 km/h), connector before using the oscilloscope.
1st gear (manual trans- 2. The waveform measurements can also be taken while
mission) or D range (auto-
matic transmission) 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.
10.0 ms/DIV 1 V/DIV
Points In Waveform Measurement

Symptom Probable causes Remedy
Too small or zero waveform Faulty wheel speed sensor Replace sensor
amplitude
Waveform amplitude fluctuates Axle hub eccentric or with large runout Replace hub
excessively (this is no problem if
the minimum amplitude is 100 mV
or more)
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.
ABS <2WD> - On-vehicle Service 35B-21
<L.H. drive vehicles> ABS WARNING LAMP RELAY CONTINUITY
CHECK 35200930023
1 2 3 5
Power is not sup-

plied
Power is supplied
35B-22 ABS <2WD> - On-vehicle Service
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 MUT-II actuator test
(Item No. 01, 02, 03, 04) start
Increase in pressure
Solenoid valve 2 seconds
position
Steady pressure
1 seconds
Reduction in pressure (when not working)
Lock
Checking the
brake force
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.
ABS <2WD> - On-vehicle Service 35B-23
Diagnosis Table
No. Operation Judgement Judgement Probable cause Remedy
- Normal - Abnormal
01 (1) Depress brake pedal Brake force Wheel does not Clogged brake Check and clean
to lock wheel. released for 3 lock when brake line other than brake line
(2) Using the MUT-II, seconds after pedal is de- hydraulic unit
select the wheel to be locking. pressed.
02 checked and force the Clogged hydrau- Replace hydrau-
actuator to operate. lic circuit in lic unit assembly
(3) Turn the selected hydraulic unit
wheel manually to
03 check the change of Brake force is Incorrect hydrau- Connect correct-
brake force. not released lic unit brake ly
tube connection
04 Hydraulic unit Replace hydrau-

solenoid valve lic unit assembly
not functioning
correctly
REMEDY FOR A FLAT BATTERY 35200350188
When booster cables are used to start the engine when the
battery is completely flat and then the vehicle is immediately
Fusible link 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
3 12
4 13
5
Master cylinder kit
8
14
6
9
11
12
7
10 13
13 12
Brake fluid: DOT3 or DOT4

14
Disassembly steps
1. Reservoir cap assembly 8. Reservoir tank
2. Reservoir cap 9. Reservoir seal
3. Diaphragm 10. Pin
4. Filter 11. Piston retainer
5. Brake fluid level indicator assembly 12. Primary piston assembly
6. Float 13. Secondary piston assembly
7. Spring pin 14. Master cylinder body
D Check the inner surface of master cylinder body for rust

or pitting.
D Check the primary and secondary pistons for rust, scoring,
wear, damage or wear.
D Check the diaphragm for cracks and wear.
ABS <2WD> - Proportioning Valve 35B-25
PROPORTIONING VALVE 35200570126

D Brake Line Bleeding (Refer to GROUP 35A -
Flared brake line nuts

2
15 Nm
Removal steps
"AA 1. Brake pipe
2. Proportioning valve

1 2 Connect the pipes to the hydraulic unit as shown in the
illustration.
1. Proportioning valve – Rear brake (L.H.)
3 4 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
2 15 Nm
2
2
1
3
3
1
9 Nm
9 Nm 4
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 disassem-
bled; its nuts and bolts should absolutely not be loos-
ened.
3. The hydraulic unit assembly must not be dropped
or otherwise subjected to impact shocks.
4. The hydraulic unit assembly must not be turned
upside down or laid on its side.
6
2 1 5 INSTALLATION SERVICE POINT
4 Connect the pipes to the hydraulic unit assembly as shown
1. To the proportioning valve (RH)
3 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>
Front speed sensor removal steps

D Splash Shield Removal (Refer to NOTE
GROUP 42 - Fender.) The front rotor is integrated with the drive shaft and is not
AA" "AA 1. Front speed sensor disassembled.
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.)

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.
ABS <2WD> - Wheel Speed Sensor 35B-29
Front Rear INSTALLATION SERVICE POINT
"AA FRONT SPEED SENSOR/REAR SPEED SENSOR
INSTALLATION
The clearance between the wheel speed sensor and the ABS
rotor’s toothed surface is not adjustable, but measure the
ABS distance between the sensor installation surface and the ABS
rotor’s
ABS toothed rotor’s toothed surface.
rotor’s surface
toothed
surface
Front Rear 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 ABS <2WD> - Wheel Speed Sensor
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
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Lining Running-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . 5
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PARKING BRAKE CABLE

<DRUM BRAKE> . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PARKING BRAKE CABLE
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3 <DRUM-IN-DISC BRAKE> . . . . . . . . . . . . . . . . . . . 7
Parking Brake Lever Stroke Check and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PARKING BRAKE DRUM . . . . . . . . . . . . . . . . . . . 9
Parking Brake Switch Check . . . . . . . . . . . . . . . . . . 4
36-2 PARKING BRAKES - Service Specifications/Lubricants
The parking brake is of a mechanical control type a parking brake lever which is in an offset position
acting on the rear wheels. A lever is used to apply at the passenger’s side.
the parking brake. The operation method utilizes
Parking brake lever
Parking brake cable
Parking brake
switch

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
Items Specified lubricant

Backing plate Multipurpose grease
Shoe and lining assembly
Adjuster
PARKING BRAKES - Special Tool/On-Vehicle Service 36-3

MB990998 Front hub remover Fixing of the rear hub
and installer
Adjusting nut ON-VEHICLE SERVICE 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>
Cable rod 3 - 5 notches <Vehicles with drum in disc brake>
2. If the parking brake lever stroke is not the standard value,

MB990998 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:
Bolt <Vehicles with drum brake>
Depress the brake pedal repeatedly until the stroke no
longer changes.
Hold the bolt in
place when NOTE
tightening Depressing the brake pedal repeatedly will automatically
adjust the shoe clearance to the normal setting.
<Vehicles with drum-in-disc brake>
(1) Attach the special tool to the hub as shown in the
illustration.
(2) Remove the adjustment hole plug, and then use a

Adjuster 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 (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 holder Pin nut and the parking brake lever.
Caution
If the parking brake lever stroke is below the standard
value and the braking is too firm, the rear brakes
may drag.
(4) After adjusting the parking brake lever stroke, jack
up the rear of the vehicle. Release the parking brake
and turn the rear wheels to check that the rear brakes
are not dragging.
PARKING BRAKE SWITCH CHECK 36100330124
1. Remove the floor console. (Refer to GROUP 52A.)

2. Check for continuity between the parking brake switch
terminal and the switch mounting bolt.
When parking brake lever is pulled Continuity
When parking brake lever is released No continuity
Pull LINING RUNNING-IN 36100110087
Carry out running-in by the following procedure when replacing

the parking brake linings or the rear brake disc rotors, or
Spring balance when brake performance is insufficient.
Caution
Carry out running-in in a place with good visibility, and
pay careful attention to safety.
Approx.
40 mm 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.
PARKING BRAKES - Parking Brake Lever 36-5
PARKING BRAKE LEVER 36100130168

D Floor Console Removal (Refer to GROUP 52A.) D Parking Brake Lever Stroke Check and Adjustment
(Refer to P.36-3.)
D Floor Console Installation (Refer to GROUP 52A.)
3 1
5
4 1
A Ratchet plate
Section A - A Section B - B
A B
5
Ratchet
pawl
B
Removal steps
1. Adjusting nut 4. Parking brake switch
2. Parking brake stay 5. Parking brake lever
3. Bushing
36-6 PARKING BRAKES - Parking Brake Cable <Drum brake>
PARKING BRAKE CABLE <DRUM BRAKE> 36100190197

D Floor Console and Rear Seat Removal D Parking Brake Lever Stroke Check and Adjustment
(Refer to GROUP 52A.) (Refer to P.36-3.)
D Floor Console and Rear Seat Installation
10
10 1
11
4
9
8 3
7
6
Removal steps
1. Rear brake drum 7. Shoe hold-down spring
2. Shoe-to-lever spring 8. Shoe hold-down pin
3. Auto adjuster assembly 9. Shoe and lining assembly
4. Shoe-to-shoe spring 10. Clip
5. Retainer spring 11. Parking brake cable
6. Shoe hold-down cup
PARKING BRAKES - Parking Brake Cable <Drum-in-disc brake> 36-7
PARKING BRAKE CABLE <DRUM-IN-DISC BRAKE> 36100190203

D Floor Console and Rear Seat Removal D Parking Brake Lever Stroke Check and Adjustment
(Refer to GROUP 52A.) (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
8
Removal steps
AA" 1. Rear brake caliper assembly AB" 8. Shoe hold-down cup
2. Rear brake disc 9. Shoe hold-down spring
"BA 3. Shoe-to-anchor spring 10. Shoe hold-down pin
4. Adjusting screw spring 11. Shoe and lining assembly
"AA 5. Adjuster 12. Clip
6. Strut 13. Parking brake cable
7. Strut return spring
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 AB" SHOE HOLD-DOWN CUP REMOVAL

hold-down
cup 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.
NOTE
Rear
The figure shows the left wheel; for the right wheel, the position
1 2 (Painted) is symmetrical.
PARKING BRAKES - Parking Brake Drum 36-9
PARKING BRAKE DRUM 36100250109

D Parking Brake Lever Stroke Check and Adjustment
(Refer to P.36-3.)
74 - 88 Nm
14
2
90 - 110 Nm
1 15
3 3
7 6
13 10
12
11 9 8 4
5 11 9 8
15 11
11
Brake grease: Multipurpose grease
Removal steps
1. Rear brake caliper 9. Shoe hold-down spring
(Refer to P.36-8) 10. Shoe hold-down pin
2. Rear brake disc 11. Shoe and lining assembly
3. Shoe-to-anchor spring 12. Clip
(Refer to P.36-8) 13. Parking brake cable
4. Adjusting screw spring 14. Rear hub assembly
5. Adjuster (Refer to P.36-8) (Refer to GROUP 27.)
6. Strut 15. Backing plate
7. Strut return spring
8. Shoe hold-down cup
(Refer to P.36-8)
36-10 PARKING BRAKES - Parking Brake Drum
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
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 Drive Belt Tension Check . . . . . . . . . . . . . . . . . . . . . 8

Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fluid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Oil Pump Pressure Test . . . . . . . . . . . . . . . . . . . . . 11
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power Steering Oil Pressure Switch Check . . . . 12
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . 12
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6 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 POWER STEERING OIL PUMP . . . . . . . . . . . 29
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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
The steering wheel is 4-spoke type. type that combines the steering gear and linkage
The steering wheel including the air bag is a 3-spoke into one light-weight and compact assembly.
type. The steering column is equipped with both The steering system uses a vane oil pump with
shock absorbing and tilt steering mechanisms. a fluid flow control system, so that steering effort
The power steering is an integral rack and pinion varies with engine speed.
Steering gear and linkage Type Integral type
Gear type Rack and pinion
Oil pump Type Vane type
Displacement mL 9.6
Relief set pressure MPa 11.8
Steering wheel
Oil reservoir
Steering column assembly
Oil pump
Tilt lever
Steering gear and linkage

STEERING - Service Specifications/Lubricants/Sealant 37A-3

Steering wheel with engine stopped 10 or less -
free play mm
when hydraulic operation - 30
Steering angle Inner wheel 38_00’ ± 2_ -
<Except 6A1 - R.H. drive vehicles>
39_00’ ± 2_
<6A1 - R.H. drive vehicles>
Outer wheel 30_30’ -
Tie rod end ball joint starting torque Nm 0.5 - 2.5 -
Stationary steering effort N (Fluctuation allowance) 30 or less -
(5.9 or less)
Oil pump pressure Oil pump relief pressure 11.8 -
MPa
Pressure under no-load conditions 0.8 - 1.0 -
Steering gear retention hydraulic pressure 11.8 -
Oil pressure switch operating pressure MPa OFF®ON 1.8 - 2.4 -
ON®OFF 0.8 - 2.4 -
Total pinion torque Nm (Change in torque: 0.4 Nm) 0.7 - 1.4 -
Tie rod joint swing resistance N (Tie rod joint swing torque Nm) 8 - 27 (1.5 - 4.9) -
Opening dimension of special tool (MB991561) mm 2.9 -
Band crimped width mm 2.4 - 2.8 -
Items Specified lubricant Quantity

Power steering fluid Automatic transmission fluid DEXRON or DEXRON II As required
Bellows Silicone grease As required
Pinion and valve assembly Repair kit grease As required
Rack assembly
Oil seal, pinion and valve assembly, Automatic transmission fluid DEXRON or DEXRON II As required
ball bearing, needle roller bearing,
special tool (MB991213)
Flow control valve, friction surface of
rotor, vanes, cam ring, pump cover,
O-ring
SEALANT 37200050136

End plug screw 3M ATD Part No. 8661 or equivalent Semi-drying sealant
Power steering rack support cover screw
Dust cover lip for tie rod end ball joint
37A-4 STEERING - Special Tools

MB990635, Steering linkage Disconnection of tie rod end
MB991113 or puller
MB991406
MB990685 Torque wrench D Measurement of the ball joint starting

torque
D Measurement of the total pinion torque
MB991006 Preload socket Measurement of the total pinion torque
MB990326 Preload socket Measurement of the ball joint starting torque
MB990993 Power steering oil Measurement of oil pressure

pressure gauge
adapter (pump
side)
MB990994 Power steering oil Measurement of oil pressure

pressure gauge
adapter (hose
side)
MB990662 Oil pressure gauge Measurement of oil pressure

assembly
MB991204 Torque wrench D Adjustment of rack support

socket D Removal of rack support cover
MB990803 Steering wheel Disconnection of the steering wheel

puller
STEERING - Special Tools 37A-5

MB991202 Oil seal and Press fitting of rack housing bearing
bearing installer
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 Installation of the oil seal and bearing
seal installer set
MB991120 Needle bearing Removal of rack housing needle bearing

puller
MB991203 Oil seal and To press in the valve housing oil seal and
bearing installer bearing
MB991317 Seal ring installer Compression of the seal rings after

replacement of the pinion seal rings
MB990941 Torque tube Installation of valve housing oil seal

bearing installer
37A-6 STEERING - Special Tools/On-vehicle Service

MB991561 Boot band crimp- Installation of bellows band
ing tool
MB990776 Front axle base Installation of dust cover for tie rod end ball joint
STEERING WHEEL FREE PLAY CHECK

1. With engine running (hydraulic operation), set front wheels
straight ahead.
2. Measure the play on steering wheel circumference before

wheels start to move when slightly moving steering wheel
in both directions.
Limit: 30 mm
3. When play exceeds the limit, check for play on steering
shaft connection and steering linkage. Correct or replace.
4. If the free play still exceeds the limit value, set steering
wheel straight ahead with engine stopped. Load 5 N
towards steering wheel circumference and check play.
Standard value (steering wheel play with engine
stopped): 10 mm or less
If the play exceeds the standard value, remove steering
gear box and check total pinion torque.
STEERING - On-vehicle Service 37A-7
STEERING ANGLE CHECK 37200110179
1. Locate front wheels on turning radius gauge and measure

steering angle.
Standard value:
Inner wheel
38_00’ ± 2_ <Except 6A1-R.H. drive vehicles>
39_00’ ± 2_ <6A1-R.H. drive vehicles>
Outer wheel 30_30’
2. When the angle is not within the standard value, the
toe is probably incorrect. Adjust toe (Refer to GROUP
33A - On-vehicle Service) and recheck steering angle.
Cord
TIE ROD END BALL JOINT STARTING TORQUE
CHECK 37200150140
Ball joint 1. Disconnect tie rod and knuckle with special tool.
Caution
1. Using the special tool, loosen the tie rod end
MB990635, mounting nut. Only loosen the nut; do not remove
MB991113 or
MB991406 it from the ball joint.
2. Support the special tool with a cord, etc. to prevent
it from coming off.
Nut
2. Move ball joint stud several times and install nut on stud.
Measure ball joint starting torque with special tools.
MB990685
MB990326 Standard value: 0.5 - 2.5 Nm
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 STEERING - On-vehicle Service
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 1,000±100 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

CENTRE 37200180156
To make this test, conduct a road test and check as follows.

70_ 70_ 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

FLUID LEVEL CHECK 37200200043
1. Park the vehicle on a flat, level surface, start the engine,

and then turn the steering wheel several times to raise
the temperature of the fluid to approximately 50 - 60_C.
2. With the engine running, turn the wheel all the way to
the left and right several times.
3. Check the fluid in the oil reservoir for foaming or milkiness.
Check the difference of the fluid level when the engine
While engine While engine is stopped, and while it is running. If the change of the
running stopped fluid level is 5 mm or more, air bleeding should be done.
FLUID REPLACEMENT 37200210046
1. Raise the front wheels on a jack, and then support them

with rigid racks.
2. Disconnect the return hose connection.
3. Connect a vinyl hose to the return hose, and drain the
Return hose
oil into a container.
Vinyl hose
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
1. Jack up the front wheels and support them by using a

rigid rack.
2. Manually turn the oil pump pulley a few times.
3. Turn the steering wheel all the way to the left and to
the right five or six times.
4. On vehicles with a petrol engine, disconnect the
high-tension cable. On vehicles with a diesel engine,
remove the fuel cut valve connector attached to the
injection pump.
Caution
Be careful not to position the high-tension cable near
the delivery pipe.
5. While operating the starting motor intermittently, turn the
steering wheel all the way to the left and right five or
six times (for 15 to 20 seconds).
Caution
1. During air bleeding, refill the fluid so that the level
never falls below the lower position of the filter.
2. If air bleeding is done while engine is running,
the air will be broken up and absorbed into the
fluid; be sure to do the bleeding only while
cranking.
6. On vehicles with a petrol engine, connect the high-tension

cable. On vehicles with a diesel engine, connect the fuel
cut valve connector attached to the injection pump. Start
the engine (idling).
7. Turn the steering wheel to the left and right until there
are no air bubbles in the oil reservoir.
8. Confirm that the fluid is not milky, and that the level is
up to the specified position on the level gauge.
9. Confirm that there is very little change in the fluid level
when the steering wheel is turned left and right.
10. Check whether or not the change in the fluid level is

Fluid level change: Within 5 mm 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
While engine While engine is stopped, the air has not been completely bled.
running stopped 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.
OIL PUMP PRESSURE TEST 37200230189
Pressure
gauge 1. Disconnect the pressure hose from the oil pump, and
(MB990662) Shut-off valve then connect the special tools.
Temperature 2. Bleed the air, and then turn the steering wheel several
gauge Oil pump
relief times while the vehicle is not moving so that the
pressure temperature of the fluid rises to approximately 50 - 60_C.
3. Start the engine and idle it at 1,000±100 r/min.
Adapter 4. Fully close the shut-off valve of the pressure gauge and
(MB990993) measure the oil pump relief pressure to confirm that it
is within the standard value range.
Standard value: 11.8 MPa
Oil Caution
pump
Pressure gauge shut off valve must not remain closed
Pressure for more than 10 seconds.
Reservoir hose
5. If it is not within the standard value, replace the oil pump.
Adapter 6. Check whether or not the hydraulic pressure is the
(MB990994) 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.
POWER STEERING OIL PRESSURE SWITCH

Adapter Shut-off valve CHECK 37200720150
(MB990993) Pressure
gauge 1. Disconnect the pressure hose from the oil pump, and
Temperature (MB990662) then connect the special tools.
gauge 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
Oil or not the hydraulic pressure that activates the switch
pump
is the standard value.
Reservoir 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.

it with finger.
tie rod end.
NOTE
of the ball joint.
STEERING - Steering Wheel and Shaft 37A-13
STEERING WHEEL AND SHAFT 37200260218

CAUTION: SRS
For vehicles with SRS, before removal of air bag module, refer to GROUP 52B - Service Precautions and
Air Bag Module and Clock Spring.

Instrument Lower Panel Assembly Removal D Instrument Lower Panel Assembly Installation
(Refer to GROUP 52A - Instrument Panel.) (Refer to GROUP 52A - Instrument Panel.)
D Checking Steering Wheel Position with Wheels
Straight Ahead
41 Nm
25 Nm
5
4 1
2
6
Standard bolt Earth bolt
12 Nm
7
3
12 Nm 22 Nm
18 Nm
5 Nm
Removal steps
1. Air bag module 6. Steering shaft assembly
(Refer to GROUP 52B - Air Bag 7. Steering cover assembly
Module and Clock Spring.)
AA" 2. Steering wheel Caution
3. Lower column cover One of the steering shaft assembly mounting bolts
4. Upper column cover must be the earth bolt. The earth bolt has a “E”
"AA 5. Clock spring and column switch mark on its head.
(Refer to GROUP 52B - Air Bag
Module and Clock Spring.)
37A-14 STEERING - Steering Wheel and Shaft

MB990803 AA" STEERING WHEEL REMOVAL
C INSTALLATION SERVICE POINT

"AA CLOCK SPRING AND COLUMN SWITCH/COLUMN
SWITCH INSTALLATION
Tighten the screws in an alphabetical order.
A
B
1
2
4
5
9 6
5
3
8
7
Disassembly steps
AA" "AA 1. Special bolt 6. Spacer
"AA 2. Steering lock bracket 7. Steering shaft assembly
"AA 3. Steering lock cylinder 8. Snap ring
4. Snap ring 9. Steering column assembly
5. Stopper
STEERING - Steering Wheel and Shaft 37A-15
Steering lock bracket
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 Check the Dust Cover for Cracks or Damage by
D Center Member Removal (Refer to GROUP 32.) Pushing it with Finger.
D Front Exhaust Pipe Removal (Refer to GROUP 15.) D Stabilizer Bar Installation (Refer to GROUP 33A.)
D Stabilizer Bar Removal (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
1
6
15 Nm 18 Nm
7
3 9
8
5
2
81 Nm
24 - 33 Nm
69 Nm
4
69 - 78 Nm
Removal steps
1. Steering shaft assembly and gear AB" 5. Tie rod end and knuckle connection
box connecting bolt 6. Pressure tube connection
2. No.2 stay 7. Return tube connection
AA" 3. No.3 stay 8. Cylinder clamp
4. Split pin AC" 9. Gear box assembly
STEERING - Power Steering Gear Box 37A-17
Hold the crossmember with a transmission jack, and remove
the No.3 stay.
Transmission jack
Crossmember
AB" TIE ROD END DISCONNECTION

Cord
Caution
Ball joint
1. Using the special tool, loosen the tie rod end mounting
nut. Only loosen the nut; do not remove it from the
ball joint.
MB990635 or
MB991113 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.
D Check the rubber parts for cracks and breakage.

GEAR BOX TOTAL PINION TORQUE

MB991006 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
Steering gear seal kit

2 22 Nm
2 21
26 17
22 19 2
1
9
6 2
19 21 29
20 30 15 27 33
16 9
34 6
18
33 17
32 Flare nut
25 Nm 31
15
14
4 59 Nm 59 Nm
49 - 54 Nm 13
12 11 10 1
3
15 Nm® - 30° 13 Nm
8
9
5 26
7 25
6 28
22 Nm 23
24
27
30
29
Disassembly steps
1. Feed pipe AB" 18. Pinion and valve assembly
2. O-ring AC" "GA 19. Seal ring
"NA 3. Tie rod end locking nut AD" "FA 20. Ball bearing
"NA 4. Tie rod end AD" "FA 21. Oil seal
5. Bellows clip 22. Valve housing
"MA 6. Bellows band AE" "EA 23. Circlip
7. Bellows AF" 24. Rack stopper
"LA 8. Tie rod AF" "DA 25. Rack bushing
"LA 9. Tab washer AG" "DA 26. Oil seal
"KA D Total pinion torque adjustment 27. O-ring
"JA 10. Locking nut AF" "CA 28. Rack
AA" "JA 11. Rack support cover AC" 29. Seal ring
12. Rack support spring 30. O-ring
13. Rack support AH" "BA 31. Ball bearing
"IA 14. End plug AI" "BA 32. Needle roller bearing
15. Self-locking nut AJ" "AA 33. Oil seal
16. Valve housing assembly 34. Rack housing
AB" "HA 17. Oil seal
Lubrication and Sealing Points
Fluid: Fluid:
Automatic transmission Automatic transmission fluid
fluid DEXRON or DEXRON or DEXRON II
DEXRON II
Fluid:
DEXRON or DEXRON II
Sealant:
3M ATD Part No. 8661 or
equivalent
Grease: Repair kit grease
Sealant:
3M ATD Part No. 8661
or equivalent
Fluid: Automatic transmission Fluid: Automatic transmission fluid

fluid DEXRON or DEXRON II DEXRON or DEXRON II
Grease: Silicone grease Grease: Repair kit grease
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
Rack stopper AE" CIRCLIP REMOVAL

1. Turn the rack stopper clockwise until the end of the circlip
comes out of the slot in the rack housing.
2. Turn the rack stopper anticlockwise to remove the circlip.
Caution
Note that if the rack stopper is first turned
Circlip anticlockwise, the circlip will get caught in the slot
in the housing and the rack stopper will not turn.
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
Rack bushing Do not damage the oil seal press fitting surface of the
rack bushing.
AH" BALL BEARING REMOVAL

MB990925 (MB990939)
or brass bar Use a brass bar or the special tool to remove the ball bearing
from the gear housing.
Ball
bearing
AI" NEEDLE ROLLER BEARING REMOVAL

MB991120 Use the special tool to remove the needle roller bearing from
the rack housing.
Caution
Do not open the special tool excessively to prevent
Needle roller damaging housing interior.
bearing
Gear housing AJ" OIL SEAL REMOVAL

Pipe or similar tool 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
MB991199
Gear housing MB991197 "AA OIL SEAL INSTALLATION
Oil seal
Needle "BA NEEDLE ROLLER BEARING/BALL BEARING

MB990925 roller MB990925
(MB990938)
INSTALLATION
(MB990938) bearing
MB991202
MB991202
Ball bearing
"CA RACK INSTALLATION

Vent hole
1. Apply a coating of repair kit grease to the rack tooth
face.
Caution
Do not close the vent hole in the rack with grease.
Seal ring, O-ring
2. Cover rack serrations with special tool.

Oil seal 3. Apply the specified fluid on the special tool.
Specified fluid:
DEXRON or DEXRON II
4. Match the oil seal centre with rack to prevent retainer
spring from slipping and slowly insert rack from power
MB991213 cylinder side.
"DA OIL SEAL/RACK BUSHING INSTALLATION

1. Apply the specified fluid to the outer surface of the oil
MB990925 seal. Press-fit the oil seal using the special tool until it
(MB990927)
is flush with the bushing end face.
Oil seal
Specified fluid:
O-ring
Rack DEXRON or DEXRON II
bushing
2. Apply the specified fluid to the oil seal inner surface and
Rack the O-ring.
Specified fluid:
DEXRON or DEXRON II
3. Wrap the rack end with plastic tape, and push the rack
Plastic tape bushing onto the rack.
Rack bushing
"EA CIRCLIP INSTALLATION

Circlip
Circlip Insert the circlip to the rack stopper hole through the cylinder
hole. Turn the rack stopper clockwise and insert the circlip
firmly.
Caution
Insert the circlip to the rack stopper hole while turning
the rack stopper clockwise.
Slot Slot
"FA OIL SEAL/BALL BEARING INSTALLATION

1. Apply a coating of the specified fluid to the outside of
MB990938
the oil seal. Using the special tools, press the oil seal
into the valve housing.
Specified fluid:
DEXRON or DEXRON II
Oil seal MB991203
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.
MB990938
Specified fluid:
DEXRON or DEXRON II
MB991203
Ball bearing
"GA SEAL RING INSTALLATION

MB991317
Tapered side 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
Pinion gear
3. Insert the tapered side of the special tool from the pinion
gear side, and compress the seal ring.
"HA OIL SEAL INSTALLATION

Use the special tool to press the oil seal into the valve housing.
MB990941 The upper surface of the oil seal should project outwards
approx. 1 mm from the housing edge surface.
Caution
If the oil seal is flush with or lower than the housing
edge, it will cause oil leaks and require reassembly.
Approx. 1 mm
"IA END PLUG INSTALLATION

End plug End plug 1. Apply the specified sealant to the threaded part of the
end plug.
Specified sealant:
3M ATD Part No.8661 or equivalent
2. Secure the threaded portion of the end plug at two places
by using a punch.
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
"KA TOTAL PINION TORQUE ADJUSTMENT

MB991006 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
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 "MABELLOWS BAND INSTALLATION

Stopper 1. Turn the adjusting bolt of the special tool to adjust the
opening dimension (W) to the standard value.
W Standard value (W): 2.9 mm
<When more than 2.9 mm>
Screw in the adjusting bolt.
<When less than 2.9 mm>
Adjusting bolt
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.
MB991561
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.
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.]
"NA TIE ROD END/TIE ROD END LOCKING NUT

Edge of bellows Lock nut INSTALLATION
assembly groove
Screw in the tie rod end to have its right and left length
as illustrated. Lock with lock nut.
104 mm
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.
OTHER CHECK
D Check the cylinder inner surface of the rack housing for
damage.
D Check the boots for damage, cracking or deterioration.
D Check the rack support for uneven wear or dents.
D Check the rack bushing for uneven wear or damage.
TIE ROD END BALL JOINT DUST COVER

REPLACEMENT
1. Apply grease to the inside of the dust cover.
MB990776 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.
STEERING - Power Steering Oil Pump 37A-29
POWER STEERING OIL PUMP 37200520262

D Power Steering Fluid Draining (Refer to P.37A-9.) D Condenser Fan Motor Assembly Installation
D Condenser Fan Motor Assembly Removal (Refer to GROUP 14.) <6A1>
(Refer to GROUP 14.) <6A1> D Power Steering Fluid Supplying (Refer to P.37A-9.)
D Drive Belt Tension Adjusting (Refer to GROUP 11
- On-vehicle Service.)
D Oil Pump Pressure Check (Refer to P.37A-11.)
<4G6> 12 Nm
12 Nm
49 Nm 3
10 8
28 Nm
7
5
10 - 12 Nm
6 4
18 Nm
49 Nm
28 Nm
2
1
<4D6>
3 22 Nm
9
8
39 Nm
6
5 4
1
18 Nm
Removal steps
1. Drive belt 6. Bolt
2. Pressure switch connector 7. Bolt
3. Suction hose 8. Oil pump
4. Pressure hose 9. Oil pump brace
5. O-ring 10. Oil pump bracket
37A-30 STEERING - Power Steering Oil Pump
<6A1>
36 Nm
5
4
10
3
39 Nm
9
18 Nm
8 6
5
12 Nm
39 Nm
7
2
1
Removal steps
1. Drive belt 6. O-ring
2. Pressure switch connector 7. Bolt
3. Suction hose 8. Bolts
4. Air control valve 9. Oil pump
5. Pressure hose 10. Oil pump bracket
D Check the drive belt for cracks.

D Check the pulley assembly for uneven rotation.
24
7 2
5
3
9
13
21 4
Oil pump seal kit Oil pump cartridge Fluid: Automatic transmission
kit fluid DEXRON or DEXRON II
1
20 Nm
7.9 Nm 2
5
23 4
3
6
7
24
25
11
10 9
59 Nm
8
9
16
15
14
13
18 20
21 22
29 Nm
20
19 17
12
Disassembly steps
1. Pump cover 16. Piston rod
2. O-ring 17. Snap ring
"EA 3. Vanes 18. Terminal
4. Rotor 19. Washer
"DA 5. Cam ring 20. Insulator
"CA 6. Side plate "AA 21. O-ring
"AA 7. O-ring 22. Plug
8. Connector 23. Suction connector
"AA 9. O-ring "AA 24. O-ring
10. Flow control valve 25. Oil pump body and pulley assem-
11. Flow control spring bly
12. Terminal assembly
"AA 13. O-ring Caution
"BA 14. Spring Do not disassemble the flow control valve.
15. Plunger
37A-32 STEERING - Power Steering Oil Pump
Connector Side plate

"AA O-RINGS INSTALLATION
1
Apply the specified fluid on O-rings to install.
2
No. I.D. ´ Width mm
3 1 11 ´ 1.9
6
4 2 13 ´ 1.9
Suction connector 3 17.8 ´ 2.4
mounting portion of
oil pump body 4 13.5 ´ 1.5
5 3.8 ´ 1.9
Terminal assembly
8 6 16.8 ´ 2.4
5
7 17.8 ´ 2.4
8 13.0 ´ 1.9
7
"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
Knock pin (oval hole)
hole (round
hole) Screw hole
Side plate
"DA CAM RING INSTALLATION

Install the cam ring with the punch mark facing the side plate.
Punch mark
"EA VANE INSTALLATION
Direct round edge to Install the vanes on the rotor, paying close attention to the
the cam ring. installation direction.
Cam ring
Rotor Vane
D Check the flow control valve for clogging.

D Check the pulley assembly for wear or damage.
D Check the groove of rotor and vanes for “stepped” wear.
D Check the contact surface of cam ring and vanes for
“stepped” wear.
D Check the vanes for damage.
37A-34 STEERING - Power Steering Hoses
POWER STEERING HOSES 37200570267

D Power Steering Fluid Draining (Refer to P.37A-9.) D Front Bumper Installation (Refer to GROUP 51.)
D Front Bumper Removal (Refer to GROUP 51.) D Power Steering Fluid Supplying (Refer to P.37A-9.)
<4G6> <L.H. drive vehicles>

12 Nm
8
12
7
11
12 Nm
9 10 7
5
8 15 Nm
6
12 Nm 5
13 15 Nm
12 Nm 6
12 Nm
12 Nm
12 Nm
1
2
18 Nm 12 Nm
34 Nm
3
12 Nm
4
15 Nm
34 Nm
3 15 Nm 4
"AA 1. Pressure hose 8. Return tube

2. O-ring 9. Return hose
3. Pressure tube 10. Suction hose
5. Return tube 12. Oil reservoir
6. O-ring 13. Cooler tube
7. Return hose
STEERING - Power Steering Hoses 37A-35
<4D6>
12 Nm
12 8
11 7
12 Nm
10
9 7

15 Nm 6
8
13 12 Nm 5
15 Nm
12 Nm
6
12 Nm
12 Nm 1
12 Nm
34 Nm
3
2
12 Nm
4
18 Nm 15 Nm 34 Nm
3 15 Nm 4

7. Return hose
37A-36 STEERING - Power Steering Hoses

12 Nm
<6A1>
13
9
12 8
12 Nm
11
10
8
9 15 Nm 7
12 Nm
14 6 15 Nm
12 Nm
7
12 Nm
12 Nm 1
36 Nm
12 Nm
2 12 Nm
34 Nm
3
4
12 Nm
18 Nm
5
15 Nm 34 Nm 4 15 Nm
5
1. Air control valve 8. Return hose


"AA PRESSURE HOSE INSTALLATION
Align the marks on the pressure hose and pressure tube,
and install the pressure hose.
Mating mark
42-1
BODY
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TRUNK LID <Sedan> . . . . . . . . . . . . . . . . 4 SERVICE SPECIFICATIONS . . . . . . . . . . . . 19
TRUNK LID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 19
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 20
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 28
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Door Fit Adjustment . . . . . . . . . . . . . . . . . . . . . . 28
FUEL FILLER DOOR . . . . . . . . . . . . . . . . 7 Door Window Glass Adjustment . . . . . . . . . . . 28
Adjustment and Replacement When
WINDOW GLASS . . . . . . . . . . . . . . . . . . . 8 There is a Malfunction of the Power
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Power Window Safety Mechanism
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 8 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
WINDOW REPAIR . . . . . . . . . . . . . . . . . . . . . . . 8 Door Outside Handle Play Check . . . . . . . . . . 30
Power Window Operation Current
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
QUARTER WINDOW GLASS Circuit Breaker (Incorporated in the Power
<Wagon> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Window Motor) Inspection . . . . . . . . . . . . . . . . . 30
TAILGATE WINDOW GLASS Door Inside Handle Play Check and
<Wagon> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
REAR WINDOW GLASS <Sedan> . . . . . . 17 DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 31
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 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 51
DOOR OPENING WEATHERSTRIP . . . . . 44
TAILGATE <Wagon> . . . . . . . . . . . . . . . 45 How to Replace a Battery of the
Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
SERVICE SPECIFICATION . . . . . . . . . . . . . 45
Secret Code Registration Method . . . . . . . . . . 56
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . 57
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 45
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 46 SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . 57
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 46 SERVICE SPECIFICATION . . . . . . . . . . . . . 57
Tailgate Fit Adjustment . . . . . . . . . . . . . . . . . . . 46 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 57
Tailgate Handle Play Check . . . . . . . . . . . . . . . 46 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 58
TAILGATE ASSEMBLY . . . . . . . . . . . . . . . . . 47 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 62
TAILGATE TRIM AND WATERPROOF Water Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Sunroof Fit Adjustment . . . . . . . . . . . . . . . . . . . 62
TAILGATE HANDLE AND LATCH . . . . . . . 50 SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
BODY - Hood 42-3
HOOD 42100160229
3 1
4 11
10
6
5
12 Nm
5 Nm 2 12
22 Nm 9
1
8
9 Nm 9
7
12 5, 6
9
Adjustment of hood step and hood
striker linkage Adjustment of clearance and height
around hood
1. Hood lock release handle 8. Hood lock release cable

2. Hood weatherstrip Hood latch removal steps
3. Front hood weatherstrip
4. Hood insulator D Radiator grille (Refer to GROUP 51.)
"AA 5. Bumper A 9. Hood latch
"AA 6. Bumper B Hood and hood hinge removal
7. Hood support rod steps
Hood lock release cable removal 10. Washer hose connection
steps 11. Hood
D Splash shield <Driver’s side> 12. Hood hinge
(Refer to P.42-6.)
42-4 BODY - Hood/Trunk Lid <Sedan>
Bumper A Bumper B INSTALLATION SERVICE POINT

"AA BUMPER B/BUMPER A INSTALLATION
16.0 ± 0.5 mm 18.8 ± 0.5 mm Install the bumpers A and B as shown in the illustration.
TRUNK LID <Sedan> 42100220132
7
10 6 7
4
9 Nm 9
3
11 12 8
8
5 Adjustment of clearance around
trunk lid and trunk lid striker linkage
2 9
1 9 Nm
Trunk lid panel removal steps Trunk lid striker removal steps
"BA 1. Bumper A D Rear end trim (Refer to GROUP 52A
"BA 2. Bumper B - Trims.)
D Licence plate lamp 9. Trunk lid striker
3. Licence plate lamp garnish
4. Trunk lid lock cylinder Trunk lid release handle and cable
5. Trunk lid latch removal steps
D Spring cover (Refer to GROUP 52A
- Trims.) D Front seat (driver’s side) (Refer to
6. Trunk lid hinge spring GROUP 52A.)
7. Trunk lid panel D Rear seat (Refer to GROUP 52A.)
D Front scuff plate (driver’s side)
Trunk lid hinge removal steps (Refer to GROUP 52A.)
D Rear shelf trim (Refer to GROUP 52A D Rear scuff plate (driver’s side)
- Trims.) (Refer to GROUP 52A.)
7. Trunk lid panel assembly D Trunk room side trim (driver’s side)
8. Trunk lid hinge (Refer to GROUP 52A.)
5. Trunk lid latch
Trunk lid latch removal 10. Trunk lid release handle
5. Trunk lid latch 11. Trunk lid release cable
Trunk lid weatherstrip removal

"AA 12. Trunk lid weatherstrip removal
BODY - Trunk Lid <Sedan>/Fender 42-5
"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 Bumper B "BA BUMPER B/BUMPER A INSTALLATION

Install the bumpers A and B as shown in the illustration.
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
Splash shield 3M ATD Part No. 8625 or equivalent Ribbon sealer
Fender
42-6 BODY - Fender
FENDER 42100190204

D Front Bumper Removal and Installation D Side Sill Cover Removal and Installation (Refer to
(Refer to GROUP 51.) GROUP 51 - Aero Parts.)
D Front Turn-signal Lamp Removal and Installation
2
3
Sealant:
3M ATD Part No. 8625 or equivalent
1
1
Sealant:
3M ATD Part No. 8625 or equivalent
Removal steps
1. Splash shield 3. Fender
"AA 2. Side turn signal lamp

"AA SIDE TURN-SIGNAL LAMP INSTALLATION
Hook Insert the hook into the fender panel, and then install the
side turn signal lamp.
Front of vehicle Fender panel

BODY - Fuel Filler Door 42-7
FUEL FILLER DOOR 42100250254

D Front Seat (driver’s side), Rear Seat Removal and Trunk Side Trim (driver’s side) <Sedan>, Quarter
Installation (Refer to GROUP 52A.) Lower Trim (driver’s side) <Wagon> Removal and
D Front Scuff Plate (driver’s side), Rear Scuff Plate Installation (Refer to GROUP 52A.)
(driver’s side), Center Pillar Lower Trim (driver’s side),

4
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

MB990480 Glass holder D Removal and installation of windshield
D Removal and installation of tailgate window
glass
D Removal and installation of rear window
glass
MB990449 Window moulding Removal of roof drip moulding

remover
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 For rust prevention

(or Tectyl 506T...Valvoline Oil Company)
Isopropyl alcohol For grease removal from bonded surface
Steel piano wire Dia. ´ length...0.6mm ´ 1m For cutting adhesive
Adhesive gun For pressing-out adhesive
NOTE
The TEROSON 127.37V auto window sealer kit can also be used. If using the TEROSON 127.37V auto window
sealer kit, follow the instructions in the manual included with the kit.
HANDLING OF AUTO WINDOW SEALER

Keep the sealant in a cool place, not exposed to the direct
rays of the sun. Do not place any heavy article on the sealant
nor press it, otherwise it will become deformed. Avoid storing
the sealant for more than 6 months, because it will lose its
sealing effect.
BODY PINCH-WELD FLANGE SERVICING.

Before servicing the body pinch-weld flange, remove old
adhesive completely. If the flange requires painting, bake
it after painting is completed.
WORKING PROCESS
Window glass installation procedure
Body side Window glass side
Reusing the glass Replacing the glass
Cleaning of adhesion surface Cleaning of adhesion surface Cleaning of adhesion surface

Cut off the residual adhesive until the Competely cut off all of the residual Clean off any dirt adhering to the adhe-
thickness is less than 2 mm. Clean the adhesive. Clean the adhesion surface sion surface with isopropyl alcohol, and
adhesion surface with isopropyl alcohol, with isopropyl alcohol, and let dry for let dry for 3 minutes or more.
and let dry for 3 minutes or more. 3 minutes or more.
Attaching of clip Gluing of window spacer and glass stoppers

Attach the clip to set the positions for Glue the window spacer along the standard position on the glass outer circumference. Install
the glass to be installed. the glass stoppers to the specified positions.
Application of primer
Application of primer Apply sufficient primer evenly to the adhesion surface so that there is no patchiness. After
Apply to the adhesion surface of the application, let dry for 3 to 30 minutes.
body and let dry for 3 minutes or more.
Application of adhesive
Within 30 minutes after applying the primer, apply the adhesive evenly all the way around
the inside edge of the glass.
Installing the glass

After applying the adhesive, lightly press the glass evenly so that it adheres
completely.
Cleaning
After removing any adhesive that is sticking out or adhering to the body or
glass with a spatula, ect., clean off with isopropyl alcohol.
Checking for water leaks

Carry out a shower test to check that no water will leak through.
WINDSHIELD 42200100255

D Front Pillar Trim Removal and Installation D Headlining Removal and Installation
Section A-A 9 Section B-B mm
36
A Primer
C 22
C Primer
2 (Entire
16 circumference)
Section C-C 4
B
B
Primer
7.5
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
2
3
8
4
Removal steps
AA" 1. Roof drip moulding "AA 4. Window spacer
D Front deck garnish "AA 5. Windshield upper moulding
(Refer to GROUP 51 - Windshield 6. Drip moulding clip A
Wiper and Washer.) 7. Drip moulding clip B
AB" "AA 2. Windshield 8. Drip moulding clip C
"AA 3. Glass stopper

MB990449 AA" ROOF DRIP MOULDING REMOVAL
Use the special tool to lever out the moulding.
Caution
If the moulding has become warped, it should not be
reused.
AB" WINDSHIELD REMOVAL

1. In order to protect the body (paint surface), apply cloth
tape to all body areas around the installed windshield.
2. Using a sharp-point drill, make hole in the windshield
adhesive.
3. Pass the piano wire from the inside of the vehicle through
the hole.
4. Pull the piano wire alternately from the inside and outside
along the windshield to cut the adhesive.
Caution
Do not let the piano wire touch the edge of the
windshield.
5. Make mating marks on the windshield and body.
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.
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.
7. Install the glass stopper to the shown dimension.

Centre
A
300 mm 300 mm
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.
QUARTER WINDOW GLASS <Wagon> 42200250127

D Quarter Upper Trim, Retractor Trim and Belt Line Trim D Headlining Removal and Installation
Removal and Installation (Refer to GROUP 52A.)
mm
Section A - A Section B - B
Primer
5.5
B
5
B 22 7.5
Primer
A
D
C Section C - C Section D - D Primer
A C 5
D 5.5
9.5
Primer
5.5
3
2
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.)
TAILGATE WINDOW GLASS 42200370144

D Side Tailgate Trim, Lower Tailgate Trim and Cover D Rear Wiper Removal and Installation
Removal and Installation (Refer to P.42-49.) (Refer to GROUP 51.)
Section A - A Section B - B mm
Primer
A Primer
5
15 5 15
A
Section C - C Section D - D
B
B C D Primer Primer
C D
81.5
5 56.5
5
Removal steps
1. Harness connector
AA" "AA 2. Tailgate window glass
3. Glass stopper

AA" TAILGATE WINDOW GLASS REMOVAL
Remove the tailgate window glass in the same manner as
for the windshield, except the glass stopper (Refer to P.42-11).
"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).
REAR WINDOW GLASS <Sedan> 42200160123

D Rear Wiper Motor Removal and Installation D Rear Pillar Trim Removal and Installation
(Refer to GROUP 51.) (Refer to GROUP 52A.)
D High Mounted Stop Lamp Removal and Installation D Headlining Removal and Installation
Section A - A Section B - B 6.7 mm
8.5
A
14 Primer
A
B Section C - C
B
Primer
7
C 11
7
C
Primer
6
8
1 8
5
7
2
1
3 Adhesive tape:
double-sided tape [6 mm width
and 0.125 mm thickness]
10
4
9
Removal steps
1. Harness connector "AA 6. Glass stopper
AA" 2. Roof drip moulding "AA 7. Window spacer
AA" 3. Rear window lower moulding "AA 8. Rear window upper moulding
4. Rear window moulding clip 9. Clip grommet A
AB" "AA 5. Rear window glass 10. Rear drip moulding clip

AA" ROOF DRIP MOULDING/ REAR WINDOW LOWER
MB990449 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).
BODY - Door 42-19
DOOR 42300030137
SERVICE SPECIFICATIONS
Door outside handle play mm Front 3.7 or more
Rear 2.4 or more
Power window operating current A 5 ± 1 (for 14 - 15 V power supply at 25_C)
Door inside handle play mm 5.3 or more
SEALANT 42300050065
Waterproof film 3M ATD Part No. 8625 or equivalent Ribbon sealer

MB991502 MUT-II sub ETACS-ECU input signal checking
assembly
MB990784 Ornament remover Removal of door trim
MB990900 or Door adjusting Adjustment of door fit

MB991164 wrench
42-20 BODY - Door

A A: MB991219 A: Test harness A: Connector pin contact pressure inspection
D: probe
DIAGNOSIS FUNCTION
INPUT SIGNAL INSPECTION POINTS
MUT-II <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.
BODY - Door 42-21

procedure page
Power windows The power windows cannot be operated by any of the power 1 42-22
window switches.
Driver’s side power window cannot be operated by the power 2 42-24

window main switch.
Passenger’s side and rear power windows cannot be operated by 3 42-25

the power window main switch. (However, they can be operated
by the power window sub-switches.)
When the glass is raised, it then lowers automatically. 4 42-25
The glass is not lowered when something is jammed in the 5 42-25

window.
When the glass is fully raised, it then lowers automatically. 6 42-26
Door locking None of the door lock functions operate. 7 42-26

mechanism
None of the doors lock or unlock when the driver’s side inside door 8 42-27
locking knob is operated (including by means of the door key).
Some doors do not lock or unlock. 9 42-27

42-22 BODY - Door

The power windows cannot be operated by any of the Probable cause
power window switches. <Vehicles without ETACS>
The cause may be a malfunction of the power window relay and of the power window D Malfunction of power window relay
relay drive circuit. D Malfunction of wiring harness or connector
NG
Check power window relay continuity. Replace
(Refer to P.42-40.)
OK
NG NG
Measure at the power window relay con- Check the following connectors: Repair
nector B-15X. C-131, C-141
OK
Check trouble symptoms. Check the harness wire between ignition
D Voltage between 5 and body earth switch (IG2) and power window relay,
OK: System voltage between fusible link No. 3 and power
OK window relay, and repair if necessary.
NG NG
Measure at the power window relay con- Check trouble symptoms. Check the harness wire between power
nector B-15X. window relay and the earth, and repair
D Disconnect the connector and if necessary.
D Continuity between 3 and body earth
OK: Continuity
OK
NG NG
Measure at the power window main Check the following connectors: Repair
switch connector F-19. F-19, C-120, C-114, B-15X
OK
Check trouble symptoms. Check the harness wire between power
OK: System voltage
window main switch and power window
OK relay, and repair if necessary.
NG NG
switch connector F-19. C-120, F-19
D Continuity between 9 and body earth NG
Check trouble symptoms. Check the harness wire between power
OK: Continuity window main switch and earth, and re-
OK pair if necessary.
Replace the power window switch.

BODY - Door 42-23
The power windows cannot be operated by any of the Probable cause
power window switches. <Vehicles with ETACS>
The cause may be a malfunction of the power window relay, power window relay D Malfunction of power window relay
drive circuit and of the ETACS-ECU. D Malfunction of ETACS-ECU
NG
Check the power window relay continu- Replace
ity. (Refer to P.42-40.)
OK
NG NG
NG
D Ignition switch: ON and OFF Check trouble symptoms. Check the harness wire between fusible
D Voltage between 6 and body earth link No.3 and power window relay, and
OK: System voltage (ON) repair if necessary.
0 V (OFF)
OK
NG NG
Measure at the ETACS-ECU connector Check the following connectors: Repair
C-138. C-138, C-116, B-15X
NG
D Voltage between 26 and body earth Check trouble symptoms. Check the harness wire between power
OK: System voltage window relay and ETACS-ECU, and re-
OK pair if necessary.
Replace the ETACS-ECU.

42-24 BODY - Door
Driver’s side power window cannot be operated by the Probable cause
power window main switch.
The cause may be a malfunction of power window main switch, power window D Malfunction of power window main switch
motor-ECU, or open circuit or short circuit in the communication line between power D Malfunction of power window motor-ECU
window main switch and power window motor-ECU. D Malfunction of wiring harness or connector
NG NG
NG
D Ignition switch: ON and OFF Check trouble symptoms. Check the harness wire between power
D Voltage between 6 and body earth window relay and power window main
OK: System voltage (ON) OK switch, between power window main
0 V (OFF) switch and earth, and repair if neces-
D Continuity between 9 and body earth Replace the power window main switch.
sary.
OK: Continuity
OK
NG NG
Measure at the power window motor- Check the following connectors: Repair
ECU connector F-21. F-21, C-120
NG
D Ignition switch: ON and OFF Check trouble symptoms. Check the harness wire between power
D Voltage between 2 and body earth window relay and power window motor-
OK: System voltage (ON) ECU, and between power window mo-
0 V (OFF) tor-ECU and earth.
OK: Continuity
OK
NG
Measure at the power window main Check the harness wire between power
switch connector F-19 and the power window main switch and power window
window motor-ECU connector F-21. motor-ECU, and repair if necessary.
D Continuity between 2 (power
window main switch side) and 4
(power window motor-ECU side)
OK: Continuity
OK
NG
Replace the power window main switch. Check trouble symptoms. Replace the power window motor-ECU.
BODY - Door 42-25
Passenger’s side and rear power windows cannot be Probable cause
operated by the power window main switch. (However,
they can be operated by the power window sub-switches.)
The cause may be open circuit or short circuit in the communication line between D Malfunction of wiring harness or connector
power window main switch, passenger’s side power window motor-ECU and rear
power window motor-ECU.
NG
F-10, F-15, F-04 or F-21
OK
NG
Check the harness wire between power window main switch F-19 Repair
and joint connector (1 or 5).
OK
NG
Passenger’s 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
Check trouble symptoms. 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 D Incorrect window glass adjustment
something is jammed in the window, and the window is lowered by approximately D Glass slider is incorrectly installed or warped
150 mm.
YES
Does the glass move in the opposite direction when the power Adjust the window glass. (Refer to P.42-28.)
window drive current is above the following value? (Refer to
P.42-30.)
Drive current: 5 ± 1 A Check trouble symptoms.
NO NG
Replace the power window motor-ECU. Replace the window regulator assembly.
The glass is not lowered when something is jammed in the Probable cause
window.
The cause may be a malfunction of the revolution detection sensor in the power D Malfunction of power window motor-ECU
window motor-ECU.
Replace the power window motor-ECU.

42-26 BODY - Door
When the glass is fully raised, it then lowers Probable cause
automatically.
When the window is within 15 mm of being fully closed, the limit switch turns off D Malfunction of the power window motor-ECU
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.
Limit switch operation position adjustment (Refer to P.42-40.)

NG
Replace the power window motor-ECU.
None of the door lock functions operate. Probable cause
The cause may be a malfunction of the ETACS-ECU power supply circuit system D Malfunction of ETACS-ECU
or of the earth circuit system. D Malfunction of wiring harness or connector
NG NG
Measure at the junction block connector Check the following connectors: Repair
C-142. C-142, C-144
D Remove the ETACS-ECU and
OK
measure at the junction block side.
Check trouble symptoms. Check the harness wire between fusible
OK: System voltage link No.1 and junction block, and repair
OK if necessary.
NG
C-142, C-144
OK
NG NG
Check trouble symptoms. Check the harness wire between Repair
ETACS-ECU and body earth.
OK

BODY - Door 42-27
None of the doors lock or unlock when the driver’s-side Probable cause
inside door locking knob is operated (including by means
of the door key).
The cause may be a malfunction of the door lock actuator switch, the ETACS-ECU D Malfunction of front door lock actuator (driver’s side)
or of a wiring harness or connector. D Malfunction of ETACS-ECU
NG NG
MUT-II Pulse check Check the front door lock actuator (driv- Replace
Front door lock actuator switch (driver’s- er’s side). (Refer to P.42-42.)
side) input signal OK
OK: The MUT-II buzzer sounds once NG
when the front door lock actuator Check the following connectors: Repair
moves from the locked to the un- F-17, C-120, C-138
locked position, or from the un-
locked to the locked position. OK
NG
OK Check trouble symptoms. Check the harness wire between the
front door lock actuator (driver’s side)
Replace the ETACS-ECU. 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 D Malfunction of door lock actuator
or of a wiring harness or connector. D Malfunction of tailgate lock actuator
NG
Check the door lock actuator of the door that does not operate. Replace
OK
NG
<Front L.H.> F-17, C-120, C-138
<Front R.H.> F-08, C-124, C-138
<Rear L.H.> F-14, E-17, C-119, C-138
<Rear R.H.> F-12, E-10, C-123, C-138
<Tailgate> G-30, G-29, C-138
OK
NG
Check trouble symptoms. 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
DOOR FIT ADJUSTMENT

MB990900 or
MB991164 1. If the clearance between the door and the vehicle body
is uneven, affix protective tape to the fender around the
hinge and to the edge of the door. Then use the special
tool to loosen the door hinge mounting bolts on the body,
and adjust the clearance around the door so that it
becomes even.
2. If the door and the body are not flush with each other,
use the special tool to loosen the door hinge mounting
bolts. Then align the door.
Caution
Do not load more than 98 Nm on the special tool
(MB991164).
3. If the door opening and closing is heavy, adjust the

meshing of the striker and the door latch (in the longitudinal
Striker Shim direction) by adding shims to the striker and by moving
the striker up and down or to the left and right.
Front Rear 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.
Adjusting Adjusting 1. Remove the door trim and the waterproof film.
hole hole (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 42-29
ADJUSTMENT AND REPLACEMENT WHEN
Runchannel THERE IS A MALFUNCTION OF THE POWER
Door
sash WINDOWS 42900190062
If the window glass automatically starts moving downwards

at the wrong time while it is being raised, carry out the following
adjustment or replacement procedures.
Lower sash
1. Remove the door trim and waterproof film. (Refer to
P.42-33.)
2. Remove the window regulator assembly from the door
window glass, and then raise and lower the door window
glass by hand to check the operation force.
NOTE
Insert a cushion or similar object to prevent damage to
the glass if it should happen to fall down.
3. If the door window glass does not move up and down
smoothly, check or repair the following points.
D Check the installation condition of the runchannel.
D Repair the twisting in the door sash.
D Check the installation condition of the lower sash
or the center sash.
NOTE
The lower sash cannot normally be adjusted, but it may
be possible to adjust the sash span slightly within the
range allowed by manufacturing tolerances by pushing
the lower sash outwards while re-installing it.
4. If repair or adjustment is not possible, replace the door
assembly.
POWER WINDOW SAFETY MECHANISM

CHECK 42900100065
1. Place a wooden board with a thickness of approximately

10 mm as shown in the illustration, and then raise the
window glass.
2. Check that the window lowers by a distance of
approximately 150 mm when the window clamps the
wooden board. If this doesn’t 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

A standard value range.
Standard value (B):
Front door: 3.7 mm or more
Rear door: 2.4 mm or more
2. If the door outside handle play is not within the standard
A
value range, check the door outside handle or the door
B latch assembly. Replace, if necessary.
POWER WINDOW OPERATION CURRENT

1. Remove the power window fuse and connect a circuit

analyser as shown in the illustration.
2. When the power window switch is pressed to the UP
position, a large amount of current flows at the time the
window starts to close and when it is fully closed, so
measure the operation current in the interval between
these two points.
Standard value:
5 ± 1 A (for 14 - 15 V power supply voltage at
25_C)
3. If the operation current is outside the standard value,
refer to “Troubleshooting” (P.42-25).
CIRCUIT BREAKER (INCORPORATED IN THE

POWER WINDOW MOTOR) 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

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.
BODY - Door 42-31
DOOR ASSEMBLY 42300220237

Door Adjustment (Refer to P.42-28.)
Front door 4, 5
22 Nm
26 Nm
2 6 7
12 Nm
4 8
9
26 Nm
5 1 3
22 Nm
Rear door
26 Nm
12 Nm
6
22 Nm 2 7
26 Nm 4 8
9
5 1 3
22 Nm
Door assembly removal steps Striker removal steps

1. Harness connector 6. Striker
2. Spring pin 7. Striker shim
3. Door assembly
"AA 4. Door upper hinge Door switch removal steps
"AA 5. Door lower hinge
8. Door switch cap
9. Door switch
42-32 BODY - Door
Front (upper, lower) Rear (lower) INSTALLATION SERVICE POINT

Rear (upper)
"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.
Applicable location Identification
Identification mark Identification mark mark
Front left side door Upper hinge V
Lower hinge U
Front right side door Upper hinge U
Lower hinge V
Rear left side door Upper hinge M2
Lower hinge O2
Rear right side door Upper hinge N2
Lower hinge P2
DOOR SWITCH CONTINUITY CHECK

2
Switch Terminal No.
1 position
1 2
Open (ON)
ON OFF
Stroke Depressed
(OFF)
BODY - Door 42-33
DOOR TRIM AND WATERPROOF FILM 42300430210
Front door
4 9 1
3
12
11
10
12 NOTE
: Resin clip position
Sealant:
3M ATD Part. No. 8625 or equivalent
Removal steps
1. Power window switch panel 7. Pull handle bracket A
2. Power window switch 8. Pull handle bracket B
3. Inside handle cover 9. Door inside handle
4. Inner delta cover or tweeter cover 10. Speaker
5. Door trim 11. Speaker cover
6. Cover 12. Waterproof film
42-34 BODY - Door
Rear door
11 9
4 6
14
10
1
7
8
13 3
2
12
5
NOTE
14
Sealant:
3M ATD Part. No. 8625 or equivalent
Removal steps
AA" "AA 1. Clip 6. Pull handle box
<Vehicles without power windows> 7. Inside handle cover
"AA 2. Regulator handle 8. Door trim
<Vehicles without power windows> 9. Pull handle bracket A
"AA 3. Escutcheon 10. Pull handle bracket B
<Vehicles without power windows> 11. Door inside handle
4. Power window switch panel 12. Speaker
<Vehicles with power windows> 13. Speaker cover
5. Power window switch 14. Waterproof film
<Vehicles with power windows>
BODY - Door 42-35
AA" CLIP REMOVAL
Remove the clip by using a rag, and then remove the regulator
handle.

Horizontal line "AA ESCUTCHEON/REGULATOR HANDLE/CLIP
INSTALLATION
1. Install the escutcheon and the clip to the regulator handle.
30_ 2. Fully close the front door glass, and install the regulator
handle so that it faces as shown in the illustration.
Front of vehicle
42-36 BODY - Door
DOOR GLASS AND REGULATOR 42900130231

D Door Trim and Waterproof Film Removal D Door Window Glass Adjustment (Refer to P.42-28.)
(Refer to P.42-33.) D Door Beltline Inner Weatherstrip Installation
D Door Beltline Inner Weatherstrip Removal (Refer to P.42-44.)
(Refer to P.42-44.) D Door Trim and Waterproof Film Installation
(Refer to P.42-33.)
Front door Rear door
5 6
1 7
8
2
2
3
4
3 <Vehicles without
power windows>
3
<Vehicles with
power windows>
Front window regulator assembly Stationary window glass removal

removal steps steps
"BA 1. Door window glass D Window glass runchannel
2. Door window glass holder (Refer to P.42-44.)
"AA 3. Window regulator assembly 1. Door window glass
AA" "AA 4. Power window motor AB" 5. Door center sash
6. Stationary window glass and
Rear window regulator assembly weatherstrip assembly
removal steps 7. Stationary window glass
8. Stationary window weatherstrip
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
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
"AA POWER WINDOW MOTOR ASSEMBLY/WINDOW
REGULATOR ASSEMBLY
POWER WINDOW MOTOR ASSEMBLY AND WINDOW
Drum REGULATOR ASSEMBLY INSTALLATION PROCEDURE
Drive 1. Align the power window motor drive shaft and the square
shaft Guide hole in the drum while using the guide and the opening
in the motor housing as a reference for the installation
Square hole
position.
Rachet wrench
NOTE
(1) Align the square hole with the drive shaft by sliding
the glass bracket (glass mounting section) or by
Glass turning the drum using a ratchet wrench (with a socket
bracket 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 Caution
screw 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.
DRUM AND REGULATOR WIRE INSTALLATION

PROCEDURE
Guide
Spring A 1. Place the drum, guide and regulator on a work bench
Drum as shown in the illustration.
(1) Place the drum so that the square hole is facing
Lifting
Square hole wire upward.
(2) Place the guide so that the slits are facing upward.
Spring B
(3) Place the regulator so that the glass bracket is facing
Slit downward. Position the glass bracket so that glass
Lower- is in the fully-open position.
ing wire
2. Pass the springs over the wires, and then install the
lowering wire to the guide first, followed by the lifting
Lowering wire. (The lifting wire should be on top of the lowering
wire Spring wire.)
Slit
Lifting wire
Guide
BODY - Door 42-39
3. Use some narrow-gauge wire (approx. 0.5 mm diameter)
to compress the springs.
NOTE
Narrow- Tie the narrow-gauge wires to the slits in the guide.
gauge 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
Lowering wire 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:

Lifting wire (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.
POWER WINDOW RELAY CONTINUITY CHECK
System Terminal No.

voltage
1 3 4 5
Not applied
Applied
Power window relay
BODY - Door 42-41
DOOR HANDLE AND LATCH 42300460219

D Door Trim Removal (Refer to P.42-33.) D Door Inside Handle Play Check (Refer to P.42-30.)
D Door Outside Handle Play Check (Refer to P.42-30.)
D Door Trim Installation (Refer to P.42-33.)
3 7 6 Nm
1 5
6 Nm
1
5
6
9
9
Front door handle and door latch Door check removal steps
assembly removal steps 1. Door inside handle
1. Door inside handle D Waterproof film (Refer to P.42-33.)
D Waterproof film (Refer to P.42-33.) 8. Spring pin
2. Door outside handle 9. Door check
3. Door lock key cylinder
4. Rear lower sash
5. Door latch assembly
Rear door handle and door latch

assembly removal steps
1. Door inside handle
D Waterproof film (Refer to P.42-33.)
D Door center sash (Refer to P.42-36.)
5. Door latch assembly
6. Door lock actuator
7. Door outside handle
42-42 BODY - Door
<L.H.>
INSPECTION
FRONT DOOR LOCK ACTUATOR CHECK 42300610102
Lock L.H. drive vehicles
View A Unlock
<Driver’s side>
Rod position Terminal No. Rod operation
1 2 3 4 6
LOCK LOCK position ®
UNLOCK position
A
UNLOCK UNLOCK position ®
<R.H.>
LOCK position
LOCK
View B Unlock Lock
UNLOCK
<Passenger’s side>
4 6
B UNLOCK position
LOCK position
R.H. drive vehicles
<Driver’s side>
1 2 3 4 6
UNLOCK position
LOCK position
LOCK
UNLOCK
<Passenger’s side>
4 6
UNLOCK position
LOCK position
BODY - Door 42-43
<L.H.> REAR DOOR LOCK ACTUATOR CHECK 42300620082
View A <L.H.>

2 3
Lock LOCK LOCK position ®
UNLOCK position
Unlock
A
LOCK position
<R.H.> <R.H.>
View B
2 3
Lock UNLOCK position
Unlock UNLOCK UNLOCK position ®

LOCK position
DOOR LOCK KEY CYLINDER SWITCH CHECK 42300630122
1 2 3
LOCK
NEUTRAL (OFF)
Neutral UNLOCK
21_ 21_
Unlock
Lock
42-44 BODY - Door
WINDOW GLASS RUNCHANNEL AND DOOR OPENING

WEATHERSTRIP 42300310187

6
6
5
3
3
2 2
5 1
1
Door inner opening weatherstrip Door window glass runchannel

removal steps removal steps
D Scuff plate (Refer to GROUP 52A.) 3. Door window glass runchannel
D Cowl side trim <Front door> 4. Door window glass lower runchan-
(Refer to GROUP 52A.) nel <Rear door>
D Center pillar lower trim Door beltline inner weatherstrip
1. Door inner opening weatherstrip removal steps
D Door trim (Refer to P.42-33.)
5. Door beltline inner weatherstrip
Door outer opening weatherstrip
removal
Door beltline moulding removal
AA" "AA 2. Door outer opening weatherstrip
steps
D Door mirror (Refer to GROUP 51.)
6. Door beltline moulding

15 mm
AA" DOOR OUTER OPENING WEATHERSTRIP
4 mm REMOVAL
Make a tool as shown in the illustration to remove the door
8 mm opening weatherstrip.
Thickness
1mm
BODY - Door/Tailgate <Wagon> 42-45
"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 Left White
Right Brown
Rear door Left Yellow
Right Blue
TAILGATE <Wagon> 42400030017
SERVICE SPECIFICATION
Item Standard value
Tailgate handle free play mm 1.5 - 5.5
SEALANT 42400050044
Waterproof film 3M ATD Part No.8625 or equivalent Ribbon sealer

MB990784 Ornament remover Removal of the tailgate trim

D: probe
B
D
42-46 BODY - Tailgate <Wagon>

Trouble symptom Reference page
Door lock mechanism does operate. 42-26.
TAILGATE FIT ADJUSTMENT

1. If the striker and the latch do not mesh properly, move
the striker forward or back or to the left or right to adjust.
2. If the clearance all the way around the tailgate is not

uniform when the tailgate is closed, adjust by moving
the tailgate hinges forward or back or to the left or right
until the clearance is uniform.
3. Check the contact between the upper tailgate damper

and the lower tailgate damper when the tailgate is closed.
If they do not contact properly, adjust by moving the upper
tailgate damper in the direction of the arrows.
Upper tailgate dumper
A
Section A - A TAILGATE HANDLE PLAY CHECK
Tailgate
handle
1. Check that the tailgate handle play is within the standard
Holder value range.
Standard value (B): 1.5 - 5.5 mm
2. If the play is outside the standard value range, open
the tailgate handle holder and adjust the contact condition
A Rod between the tailgate latch rod and the tailgate handle.
B
BODY - Tailgate <Wagon> 42-47
TAILGATE ASSEMBLY 42400110124

<Tailgate assembly>
D Tailgate fit adjustment (Refer to P.42-46.)
7 6
9
5
12 Nm Adjustment of clearance around tailgate

3
9
11
2 4
9 Nm
Adjustment of tailgate step and tailgate

striker linkage
14 Nm 12
10
11
8 9
Tailgate assembly removal steps Tailgate opening weatherstrip

D High-mounted stop lamp removal steps
(Refer to GROUP 54.) 10. Rear end trim
1. Bumper "AA 12. Tailgate opening weatherstrip
2. Washer hose Tailgate hinge removal steps
3. Harness connector
AA" 4. Tailgate gas spring 2. Washer hose
5. Tailgate side weatherstrip 3. Harness connector
6. Tailgate assembly AA" 4. Tailgate gas spring
7. Upper tailgate dumper 6. Tailgate assembly
8. Lower tailgate dumper D Headlining
9. Tailgate hinge
Tailgate striker removal steps
10. Rear end trim
11. Tailgate striker

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.
BODY - Tailgate <Wagon> 42-49
TAILGATE TRIM AND WATERPROOF FILM 42400140048
6
5
4
5
3
2
7
8
1
NOTE 8
: Sheet metal clip position
Sealant: 3M ATD Part No.8625 or equivalent
Removal steps
1. Tailgate grip 5. Side tailgate trim
2. Lower tailgate trim 6. Rear roof rail trim
3. Tailgate clip 7. Tailgate trim bracket
4. Cover 8. Waterproof film
TAILGATE HANDLE AND LATCH 42400170054

D Tailgate Handle Free Play Check (Refer to P.42-46.)
3 1
1
2
6
6
9 Nm
Tail handle and lock key cylinder Tailgate latch removal steps
removal steps D Tailgate trim and waterproof film
D Tailgate trim and waterproof film (Refer to P.42-49.)
(Refer to P.42-49.) D Tailgate garnish
D Tailgate garnish 4. Tailgate lock actuator
1. Tailgate handle 5. Holder
2. Cylinder lock retainer 6. Tailgate latch assembly
3. Tailgate lock key cylinder
TAILGATE LOCK ACTUATOR CHECK

A
2 3
View A
LOCK LOCK LOCK position ® UNLOCK
UNLOCK position
UNLOCK UNLOCK position

BODY - Keyless Entry System 42-51
KEYLESS ENTRY SYSTEM 42800060032
SPECIAL TOOL
MB991502 MUT-II sub assembly Recording secret codes

Trouble symptom Inspection procedure No. Reference page
None of the doors can be locked or unlocked using the transmitter. 1 42-51
All of the doors can be locked and unlocked using the transmitter, 2 42-53
but the room lamp does not flash or illuminate. (However, the room
lamp operates normally when the doors are opened and closed.)
Secret codes cannot be registered. 3 42-53

None of the doors can be locked or unlocked using the Probable cause
transmitter.
The cause may be a malfunction of the transmitter, a malfunction of the receiver D Malfunction of transmitter
or the lock and unlock signals are not being input to the ETACS-ECU. D Malfunction of receiver
D Malfunction of ETACS-ECU
D Malfunction of key reminder switch
D Malfunction of door switch
No
Can the doors be locked and unlocked by the driver’s-side door Check the centre door lock system.
key cylinder and lock knob?
Yes
NG
Has the secret code been registered properly? * 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 BODY - Keyless Entry System
From previous page
NG
Measure at the receiver connector C-80. Check the following connectors:
D Disconnect the connector, and measure at the harness side. C-80, C-63, C-132, C-141, C-61, C-134, C-131
OK: Battery voltage Check trouble symptoms. Repair
OK NG

D Between ignition switch (ACC) and receiver
D Between fusible link No.2 and receiver
NG
D Disconnect the connector, and measure at the harness side. C-80, C-62
D Continuity between 20 and body earth OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG

D Between receiver and earth
NG
Measure at the receiver connector C-80. Check the connectors:
D Disconnect the connector, and measure at harness side. C-80, C-138
D Voltage between 16 and body earth Check trouble symptoms. Repair
OK: Battery voltage
NG
OK
Check the harness wire.
D Between ETACS-ECU and receiver
OK NG
Replace the ETACS- Repair

ECU.
NG
Door switch continuity check (Refer to P.42-32.) Replace
OK
NG
E-19, E-08, G-16, G-09, G-32, G-28, C-65, C-143
OK

NG
NG
Check the harness wire. Repair
D Between ETACS-ECU and door switch
OK
NG
Key reminder switch continuity check (Refer to GROUP 54 - Ignition Replace
Switch.)
OK
NG
C-109, C-65, C-80
OK

NG
NG
Check the harness wire. Repair
D Between key reminder switch and receiver
D Between key reminder switch and ETACS-ECU
D Between key reminder switch and earth
OK
NG
Replace the transmitter. Replace the receiver.
All of the doors can be locked and unlocked using the Probable cause
transmitter, but the room lamp does not flash or
illuminate. (However, the room lamp operates normally
when the doors are opened and closed.)
If the room lamp operates normally when the doors are opened and closed, the cause D Malfunction of ETACS-ECU
of the problem may be a malfunction of the ETACS-ECU or a malfunction of the D Malfunction of driver’s door lock actuator
driver’s-side door lock actuator. D Malfunction of connector or wiring harness
NG
Driver’s door lock actuator check (Refer to P.42-42.) Replace
OK
Secret codes cannot be registered. Probable cause
The cause may be a malfunction of the diagnosis connector, a malfunction of the D Malfunction of receiver
power supply or earth circuit of the receiver, a malfunction of the ETACS-ECU or D Malfunction of MUT-II
a malfunction of the diagnosis output circuit. D Malfunction of connector or wiring harness
NG
Measure at the diagnosis connector C-20 and the receiver connector Check the following connectors:
C-80. C-20, C-66, C-80
D Disconnect the connector, and measure at harness side. OK NG
D Continuity between following terminals:
OK: Continuity Check trouble symptoms. Repair
7 <Receiver side> - 1 <Diagnosis connector side>
NG
OK
Can the MUT-II communicate with other systems? D Between receiver and diagnosis connector
Yes No
NG
Measure at the diagnosis Check the following connectors:
connector C-20. C-20, C-66, C-63, C-132, C-141
D Voltage between 16 OK NG
and body earth
OK NG

D Between fusible link No.2 and diagnosis connector
OK
Measure at the diagnosis Replace MUT-II.
connector C-14.
D Continuity between 4
and body earth
D Continuity between 5
and body earth
OK: Continuity
NG
NG
connector:
C-20
OK
NG
Check trouble symptoms. Check the harness wire, and repair if necessary.
D Between diagnosis connector and earth
To next page
From previous page
NG
D Disconnect the connector, and measure at the harness side. C-80, C-63, C-132, C-141, C-61, C-134, C-131
OK NG

D Between fusible link No.2 and receiver
D Between ignition switch and receiver
NG
D Disconnect the connector, and measure at the harness side. C-80, C-62
D Between 20 and body earth OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Replace the receiver.
D Between receiver and earth
INSPECTION OF RECEIVER TERMINAL VOLTAGE
Terminal Signal name Conditions Terminal voltage
2 Door switch Room lamp switch: One or more doors are 0V

OFF or ON open (Door switch: ON)
All doors are closed 5 V and pulse output*

(Door switch: OFF)
Room lamp switch: One or more doors are 0V

DOOR open (Door switch: ON)
All doors are closed Battery voltage

(Door switch: OFF)
6 Door lock actuator LOCK 5 V and pulse output*

switch (driver’s side)
UNLOCK 0V
7 Diagnosis changeover When MUT-II is connected 0V

input
When MUT-II is disconnected 5 V and pulse output*
(Ignition switch: ACC or OFF)
8 Key reminder switch OFF (When ignition key is inserted) 5 V and pulse output*
ON (When ignition key is removed) 0V
9 Ignition switch Ignition switch: ACC or ON Battery voltage
Ignition switch: OFF 0V

Terminal Signal name Conditions Terminal voltage
10 Receiver power supply At all times Battery voltage
11 Room lamp output All doors are closed Room lamp switch: OFF 0V
(Door switch: OFF) or ON
Room lamp switch: Battery voltage

DOOR
12 Door lock output When door lock control unit outputs signal, or 0V
door lock switch: LOCK
Other than above Battery voltage
14 Door unlock output When door lock control unit outputs signal, or door 0V
lock switch or door lock key cylinder: UNLOCK
Other than above Battery voltage
16 Driver identification When keyless entry system is operating 5 V and pulse output
signal output (Vehicles (When transmitter switch is pressed) (fluctuation pulse)
with theft-alarm system)
When keyless entry system is not operating 5 V and pulse output
(When transmitter switch is not pressed) (constant pulse)
20 Earth At all times 0V
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 ON-VEHICLE SERVICE 42800090079
Open HOW TO REPLACE A BATTERY OF THE

Claw
TRANSMITTER
1. Remove the set screw to remove the battery from the
transmitter.
2. Install a battery with its (+) side face-down.
Battery required for replacement:
Screw
Coin type battery CR2032
O-ring
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.
SECRET CODE REGISTRATION METHOD 42800100109
Each individual secret code is registered inside NOTE

the transmitter, and so it is necessary to register The doors will lock and unlock once at this
these codes with the EEPROM inside the receiver time and the system will switch to registration
in the following cases. mode.
D When either the transmitter or receiver is 4. Press the transmitter switch, and then press
replaced; it two times within 10 seconds of the first press.
D If a second transmitter is to be used; This will register the code.
D If it appears that a problem is occurring because 5. After registration is completed, the doors will
of faulty registration of a code. be automatically locked and unlocked once.
A maximum of two different codes can be stored 6. If you are using two transmitters or have added
in the memory area of the EEPROM (two different a second transmitter, the same registration
transmitters can be used). When the code for the procedure should be carried out for the second
first transmitter is registered, the previously-regis- transmitter, and it should be carried out within
tered codes for two transmitters are cleared. one minute after registration of the code for
Therefore, if you are using two transmitters or are the first transmitter has been completed. After
adding a second transmitter, the codes for both the second registration is completed, the doors
transmitters must be registered at the same time. will be automatically locked and unlocked once.
1. Check that the doors lock normally when the 7. Registration mode will be cancelled under the
key is used. following conditions.
2. Connect the MUT-II to the diagnosis connector. D When the secret codes for two transmitters
NOTE have been registered;
This will connect terminal (1) of the diagnosis D When 1 minute has passed after
connector to earth, and the system will be in registration mode started;
secret code registration standby mode. D If the MUT-II is disconnected (the earth
Caution connection is broken);
Always turn the ignition switch to OFF before D If the ignition switch is turned to ON;
connecting and disconnecting the MUT-II. D If any of the doors are opened;
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.
BODY - Keyless Entry System/Sunroof 42-57
KEYLESS ENTRY SYSTEM 42800130153

D Side Cover Removal and Installation (Refer to
GROUP 52A - Instrument Panel.)
ETACS-ECU
Keyless entry receiver
SUNROOF 42600030068
Roof lid glass operating current A 7 or less (at 20_C)

D: Probe
B
D
42-58 BODY - Sunroof

Trouble symptom Inspection procedure Reference page
The sunroof does not operate when the ignition switch is turned 1 42-58
to ON.
The motor does not reverse its direction when a load of 140 N 2 42-60
or more is applied while the sunroof is closing.
The timer does not operate for 30 seconds after the ignition 3 42-60
switch is turned to OFF.
Opening or closing of the sunroof is possible immediately after 4 42-60

turning the ignition switch to OFF, but the timer function does
not operate continuously for another 30 seconds if the driver’s
side door is opened within 30 seconds.

The sunroof does not operate when the ignition switch is Probable cause
turned to ON.
One of the following items may be defective. D Malfunction of sunroof switch
D Sunroof switch D Malfunction of sunroof motor
D Sunroof motor D Malfunction of sunroof-ECU
D Sunroof-ECU D Malfunction of wiring harness or connector
D Power supply circuit
D Earth circuit
BODY - Sunroof 42-59
(1) NG NG
Measure at the sunroof-ECU connector E-07. Check the following connectors: Repair
D Disconnect the connector and measure at the harness side. E-07, C-27, C-134, C-131
D Ignition switch: ON OK
(1) Voltage between 6 and body earth
(2) Voltage between 7 and body earth Check trouble symptoms.
OK: System voltage
(3) Continuity between 17 and body earth NG
OK: Continuity
Check the harness wire between igni-
OK (3) NG (2) NG tion switch (IG2) and sunroof-ECU, and
NG
E-07, C-27, C-114
OK
NG
E-07, C-133, C-131
Check trouble symptoms. NG
NG Check the harness wire between fusible

link No. 3 and sunroof-ECU, and repair
Check the harness wire between sunroof-ECU and if necessary.
NG
Check sunroof switch continuity (Refer to P.42-66.) Repair
OK
NG NG
Measure at the sunroof-ECU connector E-07. Check the following connectors: Repair
D Disconnect the connector and measure at the harness side. E-07, E-04, C-133, C-131
OK
OK: Continuity present when UP sunroof switch is on
D Continuity between 12 and body earth Check trouble symptoms.
OK: Continuity present when CLOSE/DOWN sunroof switch
is on NG
OK: Continuity present when OPEN sunroof switch is on Check the harness wire between sun-
roof-ECU and sunroof switch, between
OK sunroof switch and the earth, and repair
if necessary.
NG
Check the sunroof motor. (Refer to P.42-66.) Replace
Check limit switch continuity. (Refer to P.42-66.)
OK
NG NG
Measure at the sunroof motor connector E-03. Check the following connectors: Repair
D Disconnect the connector and measure at the harness side. E-03, C-133, C-131
OK
OK: Continuity
NG
Check the harness wire between sun-

roof motor and the earth, and repair
if necessary.
NG
E-03, E-07
OK
NG NG
Check trouble symptoms. Check the harness wire between sun- Repair
roof-ECU and sunroof motor.
OK
Replace the sunroof-ECU.

The motor does not reverse its direction when a load of Probable cause
140 N or more is applied while the sunroof is closing.
The sunroof-ECU monitors the load conditions from the amount of current flowing D Malfunction of sunroof-ECU
to the motor. If more than the constant amount of current is flowing, the direction
of motor operation is reversed to prevent jamming.
If the motor does not reverse direction even when an excessive load is being applied,
the cause may be a malfunction of the sunroof-ECU.
The timer does not operate for 30 seconds after the Probable cause
ignition switch is turned to OFF.
The sunroof-ECU has a timer function which operates for 30 seconds after the ignition D Malfunction of sunroof-ECU
switch is turned to OFF. If the timer does not operate, the cause may be a malfunction D Malfunction of wiring harness or connector
of the sunroof-ECU or of the wiring harness or connector.
NG NG
Measure at the sunroof-ECU connector Check the following connectors: Repair
E-07. C-27, C-114
OK
Check trouble symptoms. Check the harness wire between fusible
OK: System voltage link No.3 and sunroof-ECU, and repair
OK if necessary.
Opening or closing of the sunroof is possible immediately Probable cause
after turning the ignition switch to OFF, but the timer
function does not operate continuously for another 30
seconds if the driver’s side door is opened within 30
seconds.
The operation period for the sunroof timer is extended when an on signal is output D Malfunction of the front door switch (driver’s side)
from the driver’s-side door switch. Because of this, if the timer operation period is D Malfunction of sunroof-ECU
not extended, the cause may be a malfunction of the door switch input circuit. D Malfunction of wiring harness or connector
NG
Check front door switch (driver’s side) Replace
continuity. (Refer to P.42-32.)
OK
NG
E-19 or E-08, C-143, C-134, C-65, C-27,
E-07
OK
NG NG
Check trouble symptoms. Check the harness wire between front Repair
door switch (driver’s side) and sunroof-
ECU.
OK

TERMINAL VOLTAGE CHART
Terminal No. Check Item Check Condition Normal Condition
1 Sensor power supply Ignition switch: ON Battery voltage
2 Sensor 1 When motor is operating Battery voltage (pulse)
3 Sunroof switch (open Sunroof switch ON 0V

input) (open position)
OFF Battery voltage
4 Sunroof switch (up input) Sunroof switch ON 0V

(up position)
OFF Battery voltage
6 Timer operation power Ignition switch: ON Battery voltage

supply
7 ECU power supply Always Battery voltage
8 Motor output While sunroof is closing or moving up Battery voltage
Other than the above 0V
9 Sensor earth Always 0V
10 Sensor 2 When motor is operating Battery voltage (pulse)
12 Sunroof switch (close or Sunroof switch (close ON 0V

down) input position or down position)
OFF Battery voltage
14 Limit switch input From tilt up condition to fully-closed Battery voltage

condition
From fully-closed condition to fully-open 0V

condition
16 Door switch input Driver’s door switch ON 0V
OFF Battery voltage
17 Earth Always 0V
18 Motor output While sunroof is opening or moving Battery voltage

down
Other than the above 0V

Hose
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.
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>
7
13
7
10
9 6
11
3 4
1. Roof lid glass assembly Sunroof-ECU removal steps

2. Roof wind deflector panel 6. Headlining
Sunroof switch removal steps 8. Sunroof-ECU
3. Sunroof switch cover Sunroof motor removal steps
4. Sunroof switch 6. Headlining
Drain hose removal steps AB" "AA 9. Sunroof motor
D Splash shield (Front drain hose) Sunroof assembly removal steps
6. Headlining 6. Headlining
AA" "BA 7. Drain hose 7. Drain hose connection
10. Room lamp bracket
11. Sunroof switch bracket
13. Sunroof assembly
<Wagon>
5
1
7
13
12
10
11
7
6 NOTE
: indicates the sheet metal
clip position.
9
3
4
1. Roof lid glass assembly Sunroof-ECU removal steps

Sunroof switch removal steps 5. Rear roof rail trim
3. Sunroof switch cover 6. Headlining
4. Sunroof switch 8. Sunroof-ECU
Drain hose removal steps Sunroof motor removal steps
D Splash shield (Front drain hose) 5. Rear roof rail trim
5. Rear roof rail trim 6. Headlining
6. Headlining AB" "AA 9. Sunroof motor
AA" "BA 7. Drain hose Sunroof assembly removal steps
5. Rear roof rail trim
6. Headlining
7. Drain hose connection
10. Room lamp bracket
11. Sunroof switch bracket
12. Set bracket
13. Sunroof assembly
Drain hose REMOVAL SERVICE POINTS
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
Cord 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
3. Make the protrusion from the drain hose grommet as

shown in the illustration.
Grommet
20 - 30 mm
ROOF LID GLASS OPERATION CURRENT CHECK

1. Remove the sunroof fuse and connect a circuit analyser
2. Press the sunroof switch to the ON position, and then
measure the operation current in the intervals between
the points when the sunroof starts to operate, when it
is fully open, when it is fully closed and when it is fully
tilted up.
Standard value: 7 A or less (at 20_C)
3. If the operation current is outside the standard value,
check the following points.
D Installation condition, warping or jamming of sunroof
assembly
D Sticking of drive cable
D Tilt of roof lid glass
Drive gear SUNROOF MOTOR CHECK

Left rotation Right rotation Check the direction of rotation of the drive gear when the
battery is connected to the connector.
Battery connection terminal Drive gear rotation
direction
1 4
Right
Left
LIMIT SWITCH CONTINUITY CHECK

Remove the limit switch from the sunroof motor, and then
check the operation of the limit switch.
Switch Terminal No.
5 6
ON
OFF Limit switch ON
OFF
SUNROOF SWITCH CONTINUITY CHECK

3 4 5 6
Slide open
Off
Tilt up
Slide close, Tilt down
<Sedan>
13
11
2
6
5 7
9
4
10
12
11
3
13
Disassembly steps
1. Roof lid glass assembly 8. Sunshade assembly
2. Weatherstrip 9. Guide rail stopper
3. Sunroof motor 10. Rail sub assembly
4. Roof wind deflector panel 11. Housing sub assembly
5. Guide block 12. Side deflector
6. Roof drip channel 13. Drive cable assembly
7. Panel stopper
<Wagon>
11
15
5
1
2 6
7 8
4
10
12
14
11
9
13
15
Disassembly steps
1. Roof lid glass assembly 9. Cable guide casing
2. Weatherstrip 10. Side deflector
3. Sunroof motor 11. Drive cable assembly
4. Roof wind deflector panel 12. Seal
5. Roof drip channel 13. Seal
6. Panel stopper 14. Clamp
7. Sunshade assembly 15. Guide rail sub assembly
8. Guide rail stopper
51-1
EXTERIOR
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 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
Windshield wiper blade installation position mm Driver’s side 35 ±5
Passenger’s side 20±5
Rear wiper blade installation position mm 15±5
SEALANT AND ADHESIVE 51100050177
Items Specified sealant and adhesive
Side protect moulding to body panel Adhesive tape: double-sided tape <(10 mm width and 0.8 mm thickness>)
Side sill cover to body panel Adhesive tape: double-sided tape (5 mm width and 0.8 mm thickness)

MB990784 Ornament remover Removal of bumper mounting clips (front and
rear) and door mirror control switch
MB990449 Window moulding Removal of roof drip moulding, etc.

remover
EXTERIOR - Front Bumper 51-3
FRONT BUMPER 51100140201

D Splash Shield Removal and Installation
(Refer to GROUP 42 - Fender.)
D Radiator Grile Removal and Installation
(Refer to P.51-7.)
3
1
Removal Steps
1. Fog lamp bezel
2. Fog lamp
AA" 3. Clip
4. Front bumper assembly
5. Front bumper reinforcement assembly
MB990784
AA" CLIP REMOVAL
MB990784
(1) Use the special tool to pull up the centre pin in the clip.
(2) Remove the clip.
Pin Clip
51-4 EXTERIOR - Front Bumper
5
3 6
Disassembly steps
1. Dynamic damper assembly <except AA" 4. Clip
vehicles with 6A1 engine> 5. Front bumper upper reinforcement
2. Fog lamp hole cover 6. Front bumper face
3. Licence plate bracket
MB990784
AA" CLIP REMOVAL
MB990784
Pin Clip
EXTERIOR - Rear Bumper 51-5
REAR BUMPER 51100190220

D Trunk Rear Trim (side, centre), Side Tray Removal
and Installation <Sedan>
(Refer to GROUP 52A - Trims.)
D Quarter Lower Trim Removal and Installation
<Wagon> (Refer to GROUP 52A - Trims.)
D Lower Tailgate Damper Removal and Installation
<Wagon> (Refer to GROUP 42 - Tailgate.)
<Sedan>
Rear bumper assembly
<Wagon>
Rear bumper assembly

51-6 EXTERIOR - Rear Bumper
<Sedan>
1 3
2 7
1
1
1
4
<Wagon> 1
3
1
7
2
1
6
1
4
Disassembly steps
AA" 1. Clip 5. Rear bumper lower plate
2. Side upper bracket 6. Muffler cutter cover
3. Rear bumper reinforcement 7. Rear bumper face
4. Side retainer
MB990784
AA" CLIP REMOVAL
MB990784
Pin Clip
EXTERIOR - Radiator Grille/Roof Rail 51-7
RADIATOR GRILLE 51100280026

RADIATOR GRILLE REMOVAL
Remove the radiator grille by pushing the tab of the radiator
grille clips in the direction of the arrows with a flat-tipped
screwdriver, while lightly pulling the radiator grille towards
you.
ROOF RAIL 51101660010

D Headlining Removal and Installation
Roof rail
51-8 EXTERIOR - Mouldings
MOULDINGS 51100470157

<Sedan>
1
4
2
5
3 6
6
<Wagon>
1
AA" "AA 1. Roof drip moulding 4. Rear window moulding, upper (Refer
2. Windshield upper moulding to GROUP 42 - Rear Window Glass.)
(Refer to GROUP 42 - Windshield.) 5. Rear window moulding, lower (Refer
3. Belt line moulding (Refer to to GROUP 42 - Rear Window Glass.)
GROUP 42.) AB" "BA 6. Side protect moulding
EXTERIOR - Mouldings 51-9
B A C
73 mm 71 mm
35 mm 40 mm
B f 10 f 10 C
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
AB" SIDE PROTECT MOULDING REMOVAL

Protection tape 1. Attach protection tape all the way along the edges of
the double-sided tape which is still adhering to the body.
Double-sided tape
51-10 EXTERIOR - Mouldings
2. Use a resin spatula to scrape off the double-sided tape.

3. Peel off the protection tape.
Double-sided 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 from the pressure sensitive

double-sided tape.
NOTE
Affix double-sided tape to the end of strip paper for ease
of strip paper removal.
5. Install the side protect moulding.
NOTE
If it is hard to affix the double-sided tape in winter, heat
the application surfaces at both the vehicle body and
the side protect moulding.
Body 40 - 60_C
Side protect moulding 20 - 30 _C
Apply pressure fully to the side protect moulding.
EXTERIOR - Mouldings/Aero Parts 51-11
"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)
1
AA" "AA 1. Side sill cover

AA" SIDE SILL COVER REMOVAL
Remove the side sill cover in the same manner as for the
side protect moulding (Refer to P.51-8).

"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
4
2
13 Nm
5
9 Nm
A
5 Nm
6
9
11
7
12
8
8 10
Section A - A
Clip
1. Column switch assembly Washer tank removal steps

(Refer to GROUP 37A.) D Draining washer fluid
2. Washer hose D Front bumper (Refer to P.51-3.)
3. Washer nozzle assembly 8. Washer hose
Wiper motor and linkage removal 9. Washer tank
steps 10. Washer motor (front)
"AA 4. Wiper arm and blade assembly 11. Washer motor (rear)
5. Front deck garnish 12. Washer motor <vehicles with
AA" 6. Wiper motor headlamp washer>
7. Linkage
EXTERIOR - Windshield Wiper and Washer 51-13
Linkage REMOVAL SERVICE POINT
AA" WIPER MOTOR REMOVAL
Loosen the wiper motor assembly mounting bolts, and then
remove the wiper motor assembly. Disconnect the linkage
and the motor assembly, and then remove the linkage.
Caution
Crank arm
Because the installation angle of the crank arm and the
motor has been set, do not remove them unless it is
Wiper motor 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)
A A
Standard value (A):
<Driver’s side> 35 ± 5 mm
<Passenger’s side> 20 ± 5 mm
Front deck garnish end
COLUMN SWITCH CHECK

Wiper and Washer Switch
6 7 8 9 10
Wiper switch OFF
INT
1 (LO)
2 (HI)
Washer switch ON

51-14 EXTERIOR - Windshield Wiper and Washer

8 9 10 11 12
Wiper switch OFF
INT
1 (LO)
2 (HI)
Washer switch ON
Intermittent Wiper Relay (Intermittent Operation

Inspection)
1. Connect the column switch connector.
2. Turn the ignition switch to ACC.
3. Inspect the intermittent operation time when the wiper
switch is turned to INT.
Vehicles with variable intermittent control
FAST: Approx. 2 seconds
SLOW: Approx. 15 seconds
WIPER MOTOR CHECK 51101260104
Check the wiper motor after disconnecting the wiring harness

connector, and with the wiper motor remaining installed to
the body.
Wiper Motor at Low Speed and High Speed Operation
Connect a battery to the wiper motor as shown in the illustration
and inspect motor operation at low speed and high speed.
Wiper Motor at Stop Position Operation
1. Run the wiper motor at low speed, disconnect the battery,
Inspection while operating and stop the motor.
2. Reconnect the battery as shown in the illustration, and
confirm that after the motor starts turning at low speed,
Battery it stops at the automatic stop position.
Low speed High speed
Inspection while stopped
Battery
Low speed Automatic stop
WASHER MOTOR CHECK 51101270107
1. With the washer motor installed to the washer tank, fill

the washer tank with water.
2. Check that the water squirts out strongly when battery
voltage is applied to terminals (1) and (2).
EXTERIOR - Rear Wiper and Washer 51-15
REAR WIPER AND WASHER 51100850159

<Sedan> 1
2 7.4 Nm
3
9.8 Nm
5
11 9
12
8
1 2
7.4 Nm
4
<Wagon> 10
11
9.8 Nm
6
8
<Wagon>
7
8
12
Wiper motor assembly removal Rear washer hose removal steps

steps D Scuff plate, quarter trim, quarter upper
1. Cover trim, beltline trim (Refer to GROUP
2. Wiper arm and blade assembly 52A.)
3. Shield cap D Front seat, rear seat (Refer to GROUP
4. Cover 52A.)
5. Nozzle collar assembly 10. Washer nozzle
6. Packing and washer <Wagon> 11. Washer hose
7. Tailgate trim (Refer to group 42.) Rear intermittent wiper relay removal
8. Wiper motor and bracket assembly
9. Packing and washer <Sedan> 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 EXTERIOR - Rear Wiper and Washer
<Sedan> INSTALLATION SERVICE POINT

"AA WIPER ARM AND BLADE ASSEMBLY
INSTALLATION
<Sedan>
Install the wiper arm to the pivot shaft so that the wiper blade’s
stop position is the position (standard value) shown in the
illustration.
Standard value (A): 15 ± 5 mm
Glass end line
<Wagon>
Install the wiper arm by aligning the blade with the marking
<Wagon>
position.
Marking position
WIPER MOTOR CHECK

Check the wiper motor after first disconnecting the wiring
harness connector, and with the wiper motor remaining
installed to the body.
Wiper Motor Operation
Connect a battery to the wiper motor as shown in the illustration
Operation check and inspect the motor operation.
Wiper Motor at Stop Position Operation
1. Run the wiper motor, disconnect the battery, and stop
Battery
the motor.
2. Reconnect the battery as shown in the illustration, and
confirm that after the motor starts turning, it stops at the
Stop position check automatic stop position.
Battery
EXTERIOR - Rear Wiper and Washer 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 Terminal number 2
Apply battery voltage to terminal 6. Battery voltage
Rear intermittent
wiper relay Apply battery voltage to terminal 5. Battery voltage generates
every approx. eight seconds.
Apply battery voltage to terminal 8. Battery voltage generates
after approx. one second.
3. Check that there is continuity between terminals 1 and
2.
COLUMN SWITCH (WIPER AND WASHER)

CHECK 51100950057

2 3 4 10, 8*
Wiper switch INT
ON
Washer switch ON
NOTE
*: R.H. drive vehicles
WASHER MOTOR CHECK 51101310083

2. Check that washer fluid sprays strongly when battery
voltage is applied to terminal 2 and terminal 1 is earthed.
51-18 EXTERIOR - Headlamp Washer
HEADLAMP WASHER 51100970107
3
1
4
4
4
2
4
2
4
4.9 Nm
5
6 4.9 Nm
5
6
1. Headlamp washer relay NOTE

Nozzle, check valve and joint 1. For removal and installation of the column switch
removal steps assembly (built-in headlamp washer switch), refer to
GROUP 37A - Steering Wheel and Shaft.
D Draining of washer fluid 2. For removal and installation of the washer tank, refer
D Front bumper (Refer to P.51-3.) to P.51-12.
2. Check valve
3. Joint
4. Washer hose assembly
5. Collar
6. Nozzle
Headlamp HEADLAMP WASHER RELAY CHECK

washer relay
1. Connect battery and test lamp to the relay as illustrated.
STEP 1 Test lamp

EXTERIOR - Headlamp Washer 51-19
STEP 2 Test lamp 2. The relay is normal if the lamp lights for approximately
0.5 second upon connection of terminal (2) to battery
( - ).
Connector B COLUMN SWITCH (HEADLAMP WASHER SWITCH)

Connector A CHECK 51100980063
Check the continuity between terminal 2 of connector A and

terminal 1 of connector B with headlamp washer switch in
ON position.
CHECK VALVE CHECK 51101330058
Apply pressure to the inlet of the check valve to check its

opening pressure.
Opening pressure: 78 kPa
HEADLAMP WASHER MOTOR CHECK 51101340051

2. Connect battery (+) and ( - ) cables to terminals (1) and
(2) respectively to see that the washer motor runs and
water is injected.
51-20 EXTERIOR - Marks
MARKS 51101180110

<Sedan> <Wagon>
1 1
"AA 1. “Mitsubishi” mark

"AA 2. Grade mark

"AA INSTALLATION OF MARKS
1. APPLICATION POSITION
“MITSUBISHI” mark
<Sedan> <Wagon>
30 mm 7 mm
12 mm 7 mm
24 mm
26.6 mm 35 mm
Trunk lid end line Tailgate end line

Trunk lid press line
EXTERIOR - Marks 51-21
Grade mark
<Sedan>
GLS (also applicable to GLX and V6-24) GLS TD
15 mm
21 mm 21 mm
28 mm 24 mm 26.9 mm 24 mm
Trunk lid press line Trunk lid end line Trunk lid press line Trunk lid end line
<Wagon>
GLS (also applicable to GLX and V6-24) GLS TD
35 mm 35 mm
35 mm 35 mm
15 mm
Tailgate end line 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
1
7
2 5
7
4
1. Door mirror control switch

Door mirror removal steps
2. Door trim attaching screw
3. Delta cover inner
4. Boot
5. Door mirror
6. Delta cover base
AA" 7. Mirror
Spring REMOVAL SERVICE POINT

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
EXTERIOR - Door Mirror 51-23
REMOTE CONTROL MIRROR ASSEMBLY CHECK

1. Check to be sure that the mirror moves as described
in the table when each terminal is connected to the battery.
2. For printed heater, check the continuity between terminals
1 and 4.
Battery connection terminal Direction of operation
5 6 7 1 4
UP
DOWN
Printed RIGHT
heating
wire LEFT
DOOR MIRROR CONTROL SWITCH CONTINUITY CHECK

51101350061

2 3 4 6 7 8 9
Left side UP
DOWN
LEFT
RIGHT
Right side UP
DOWN
LEFT
RIGHT
SWITCH AND RELAY OF DOOR MIRROR

PRINTED HEATING WIRE CHECK 51101360019
The printed heating wire of the door mirror operates in

conjunction with the rear window defogger.
The switch and relay are used for the rear window defogger
also, so refer to GROUP 54 for inspection service points.
NOTES
52A-1
INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . . . . . . . . . . 52B

52A-2
INTERIOR
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 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 52A-3
Seatback heater resistance (between terminals) W Approx. 8
Seat cushion heater resistance (between terminals) W Between terminals 2 and 3 Approx. 8
Between terminals 1 and 2 0

MB990784 Ornament remover Removal of switch, trim, etc.
INSTRUMENT PANEL 52100170252

For installation of the instrument panel, the bolts and screws described below are used. They are indicated
by symbols in the illustration.
Name Symbol Size mm (D ´ L) Colour Shape
Tapping screw A 5¢12 -
B 5¢14 -
C 5¢16 -
D 4¢25 Black
E 5¢12 -
F 5¢20 -
Washer-assembled screw G 5¢16 -
H 5¢20 -
Washer-assembled bolt I 6¢16 -
J 6¢20 -
D = Thread diameter
L = Effective thread length
52A-4 INTERIOR - Instrument Panel
CAUTION: SRS
For the passenger side air bag module procedures of GROUP 52B - Air Bag Module and
removal/installation, always observe the service Clock Spring.
12
10
C
9
8
11
C
16 13
19
7 21 20
14
D
<Manual air conditioner>
6 C
2 22
F F
23
17 18
<Automatic air conditioner>
3 5 C 15
4
H
B
A 16
1
NOTE
: metal clip position
Removal steps
1. Hood lock release handle 15. Ashtray
2. Switch bezel D Floor console panel
3. TCL switch or auto-cruise control main (Refer to P.52A-7.)
switch 16. Centre console panel
4. TCL switch or plug 17. Sunglasses box
5. Headlamp leveling switch 18. Radio and tape player
6. Lower cover 19. Heater control assembly (Refer to
7. Column cover GROUP 55 - Manual air conditioner.)
8. Meter bezel 20. Rear window defogger switch
9. Combination meter 21. A/C switch
10. Door mirror control switch 22. Inside/Outside air changeover
11. Fog lamp switch switch
12. Side air outlet assembly (L.H.) 23. Air conditioner control panel and ECU
AA" 13. Center air outlet assembly assembly
14. Side air outlet assembly (R.H.)
INTERIOR - Instrument Panel 52A-5
24
30
I 25
A
I I
32
29
I 29
12 Nm
J
I Standard bolt Earth bolt
I
G 31
G
12 Nm 22 Nm
27 C
C
26 28
G
J
H
NOTE
24. Centre display bezel D Floor console box (Refer to P.52A-7.)

25. Clock 31. Corner panel
26. Glove box 32. Instrument panel assembly
D Under cover (Refer to GROUP 55 -
Ventilators.) Caution
27. Side cover One of the steering shaft assembly mounting bolts
28. Glove box frame must be the earth bolt. The earth bolt has a “E”
29. Steering mounting bolts mark on its head.
30. Front passenger’s side air bag
module (Refer to GROUP 52B.)

AA" CENTER AIR OUTLET ASSEMBLY REMOVAL
Refer to GROUP 54 - Hazard warning lamp switch.
52A-6 INTERIOR - Instrument Panel
3 1
2
E
E
I
4
7
I
I I I
I
I
I I
I
5
8
6 9
Disassembly steps
D Heater ducts (Refer to GROUP 55.) 6. Console bracket
1. Photo sensor (Refer to GROUP 55.) 7. Instrument panel lower passenger’s
2. Defroster garnish side bracket
3. Instrument panel wiring harness 8. Passenger’s side air bag rear
4. Instrument panel lower driver’s side bracket
bracket 9. Air bag reinforcement assembly
5. Center reinforcement
INTERIOR - Floor Console 52A-7
FLOOR CONSOLE 52100220193

<Vehicles without <Vehicles with
heated seat> heated seat>
2 2
5 8
7
NOTE
Removal steps
1. Floor console panel 5. Floor console
2. Cup holder assembly 6. Ashtray
3. Heated seat switch 7. Console bracket B
4. Floor console box 8. Console bracket A
52A-8 INTERIOR - Trims
TRIMS 52100110292

<Sedan> 7
6 C
C
4
D
C
C D
B
B
C C
44 Nm
5
2
1 A
A
8
3
NOTE
: resin clip position
For door trim, refer to GROUP 42.
Section A - A Section B - B Section C - C Section D - D
Scuff plate
Trim Clip
Front pillar Clip
trim
Trim
Clip
1. Front scuff plate 6. Center pillar upper trim

2. Rear scuff plate 7. Rear pillar trim
3. Cowl side trim 8. Rear shelf trim
4. Front pillar trim 9. Shelf front cover
5. Center pillar lower trim
INTERIOR - Trims 52A-9
<Sedan>
17
12
10
13
E E
14
12
11
15
16
NOTE
: metal clip position Section E - E
: resin clip position Rear end
trim cover
Clip
10. Trunk side trim 14. Trunk rear center trim

11. Corner plate 15. Side tray
12. Trunk rear side trim 16. Under tray
13. Rear end trim cover 17. Trunk lid trim
52A-10 INTERIOR - Trims
<Wagon>
6 7
F
4 C F
C 16 9
C G
C C
B G
B 4 C
44 Nm 8 C
5 C
2 11
10 H
1 A 13 C 12
H H I
I
A H C
11
3
15
14
NOTE 13
H
: resin clip position H 10
For door trim, refer to GROUP 42.
Section A - A Section B - B Section C - C Section F - F Section G - G

Trim
Scuff plate Trim
Front pillar Trim
trim Clip
Clip
Clip
Clip
Section H - H Section I - I
Clip
Trim, Lid
Clip
Trim
1. Front scuff plate 9. Belt line trim

2. Rear scuff plate 10. Quarter lower trim
3. Cowl side trim 11. Maintenance lid
4. Front pillar trim 12. Rear end trim
5. Center pillar lower trim 13. Luggage under floor side trim
6. Center pillar upper trim 14. Luggage under floor centre box
7. Quarter upper trim 15. Utility box lid
8. Retractor trim 16. Shelf holder
INTERIOR - Inside Rear View Mirror/Front Seat 52A-11
INSIDE REAR VIEW MIRROR 52100270105
Button
Remove by pushing in the direction of the arrow in the
illustration.
NOTE
Spring 1. The mirror spring fits firmly in the groove of the button
that is attached to the glass.
2. The mirror breaking load is within 450 N.
FRONT SEAT 52200130222

Caution: SRS
Before removal of the seat equipped with the side air bag module, refer to GROUP 52B - SRS Service
Precautions and Air Bag Module.
3 2
44 Nm
4 3 1
3
44 Nm
4
44 Nm
3
29 Nm 44 Nm
3
29 Nm
D Cup holder assembly <Vehicles with NOTE

heated seat> (Refer to P.52A-7.) After provisionally tightening the seat assembly mounting
1. Heated seat switch nuts and bolts in every installation location, fully tighten
<vehicles with heated seat> them to the specified torque.
2. Headrestraint
Front seat assembly removal steps

D Harness connector
3. Seat anchor cover
4. Front seat assembly
52A-12 INTERIOR - Front Seat
HEATED SEAT SWITCH CONTINUITY CHECK

1 3 4 5 - 8 9 2 - 6
Driver’s HI
seat
switch
LO
Passen- HI
ger’s seat
switch
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
INTERIOR - Front Seat 52A-13
Caution
Do not disassemble the front seatback assembly
with built-in side air bag module.
<Normal seat>
13
17
16
18
12
Seat with height adjuster 10
14 44 Nm 9 15
5 11 14
1
4 2 20
14 13 Nm
19
6
3 44 Nm
8 7
21 Nm
21
Seat without height adjuster
14 44 Nm
1 5
2
20
13 Nm 14
6
44 Nm
8
7
21 Nm
21
Disassembly steps
1. Reclining adjuster knob AA" 12. Front seatback panel
2. Slide adjuster knob 13. Front seatback assembly
3. Clip 14. Cap
4. Height adjuster knob 15. Lumbar support lever
5. Front seat side shield cover 16. Headrestraint guide
6. Front seat hinge cover 17. Front seatback cover
7. Inner seat belt 18. Front seatback frame
8. Bolt 19. Seat heater harness
9. Front seat cushion assembly 20. Seat adjuster assembly
10. Front seat cushion cover 21. Wire
11. Front seat cushion frame
<Power seat>
14
18 17 19 20
13
6 8
9
7
16
10 15
5 11
12
22
21 Nm
21
1
21 Nm
3
44 Nm
4
2
21 Nm 23
24
Disassembly steps
1. Front seat side shield cover AA" 13. Front seatback panel
2. Front seat hinge cover 14. Front seatback assembly
3. Inner seat belt 15. Cap
4. Bolt 16. Lumbar support lever
5. Front seat cushion assembly 17. Headrestraint guide
6. Front seat reclining adjuster lever 18. Front seatback cover
7. Front seat slide adjuster lever 19. Front seatback pad
8. Garnish 20. Front seatback frame
9. Power seat switch 21. Reclining adjuster lower cover
10. Front seat cushion cover 22. Seat heater harness
11. Front seat cushion pad 23. Power seat harness
12. Front seat cushion frame 24. Power seat adjuster assembly
INTERIOR - Front Seat 52A-15
Clip 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.
Front seatback panel
Reclining switch INSPECTION 52200160122
POWER SEAT SWITCH CONTINUITY CHECK
Slide and
height switch
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Reclining switch Forward*1/

Backward*2
Backward*1/
Forward*2
Slide switch Forward*1/

Backward*2
Backward*1/
Forward*2
Front height switch*1/ Up

Rear height switch*2
Down
Rear height switch*1/ Up

Front height switch*2
Down
NOTE
*1: Power seat switch (R.H.)
*2: Power seat switch (L.H.)
POWER SEAT MOTOR OPERATION CHECK

Rear height Inspect the operation of each motor according to the following
motor connector procedures.
Slide
motor 1. Disconnect the connector for each motor.
connector 2. When the battery is connected directly to the motor
terminals, check if the motors run smoothly, and check
if each setting mechanism runs in the direction shown
in the table below for each motor.
3. If there is an abnormality, replace the power seat adjuster
assembly.
Name of Direction of Terminal No. Stop position

motor operation
1 2 3 4
Front/Rear Down Stop at

height operating
Up range limit.
Reclining
motor Slide Backward
connector
Front height Forward
motor connector
Reclining Backward
Forward
INTERIOR - Rear Seat 52A-17
REAR SEAT 52200180258

6
2
3
22 Nm
7 29 Nm
1
22 Nm
Removal steps
AA" "CA 1. Seat cushion
"BA 2. Seatback (R.H.)
"BA 3. Seatback (L.H.)
"AA 4. Side seatback (R.H.)
"AA 5. Side seatback (L.H.)
6. Headrestraint
7. Armrest
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
Hook body side hook and install the side seatback.
Attachment wire
52A-18 INTERIOR - Rear Seat
Seatback (R.H.) "BA SEATBACK (L.H.)/SEATBACK (R.H.)

hinge bracket INSTALLATION
Put the seatback (R.H.) hinge bracket upon the seatback
(L.H.) hinge bracket.
Seatback (L.H.)
hinge bracket
Attachment wire "CA SEAT CUSHION INSTALLATION

Lock plate 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.
Rear seat belt
5 4
7 8 9
11 3
4 5
10 9
7 8
3
6 10
11
Disassembly steps
1. Seat cushion cover 8. Seatback pad*
2. Seat cushion pad* 9. Seatback frame
3. Seatback panel 10. Side seatback cover
4. Headrestraint guide 11. Side seatback pad*
5. Unlock knob
6. Armrest NOTE
7. Seatback cover *: Vehicles with front power seat
INTERIOR - Front Seat Belt 52A-19
FRONT SEAT BELT 52300130225
44 Nm
44 Nm
44 Nm
Outer seat belt removal steps Inner seat belt removal steps
1. Outer seat belt (seat belt with pre D Front seat assembly
tensioner) (Refer to GROUP 52B.) (Refer to P.52A-11.)
2. Center pillar trim upper D Front seat hinge cover
3. Adjustable seat belt anchor (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
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)
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SRS AIR BAG CONTROL UNIT

(SRS-ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SRS SERVICE PRECAUTIONS . . . . . . . . . . . . . . 4
AIR BAG MODULES AND CLOCK
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 8 SIDE IMPACT SENSOR . . . . . . . . . . . . . . . . . . 38
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 8 SEAT BELT WITH PRE-TENSIONER . . . . . . 40
SRS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 21 AIR BAG MODULE AND SEAT BELT

PRE-TENSIONER DISPOSAL
POST-COLLISION DIAGNOSIS . . . . . . . . . . . . 25 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Undeployed Air Bag Module and Seat Belt
INDIVIDUAL COMPONENT SERVICE . . . . . . 28 Pre-tensioner Disposal . . . . . . . . . . . . . . . . . . . . . . . 42
Deployed Air Bag Module or Operated Seat Belt
WARNING/CAUTION LABELS . . . . . . . . . . . . . 29 Pre-tensioner Disposal Procedures . . . . . . . . . . . . 49
CAUTION
D Carefully read and observe the information in the SERVICE PRECAUTIONS (P.52B-4.) prior to any service.
D For information concerning troubleshooting or maintenance, always observe the procedures in the Troubleshooting
(P.52B-8.) section.
D If any SRS components are removed or replaced in connection with any service procedures, be sure to follow the
procedures in the INDIVIDUAL COMPONENT SERVICE section (P.52B-28.) for the components involved.
D If you have any questions about the SRS, please contact your local distributor.
52B-2 SRS - General Information
To improve safety, the SRS and seat belts with the operational status of the SRS. The clock spring
pre-tensioner are available as optional parts. These is installed in the steering column.
systems enhance collision safety by restraining the The SRS side air bag deploys if an impact received
front passengers in case of an accident. The SRS at the side of the vehicle is stronger than a certain
works with the pre-tensioner simultaneously when set value, in order to protect the upper bodies of
a collision is detected. front seat passengers in the event of a collision.
The SRS consists of four air bag modules, SRS The seat belt pre-tensioner is built into the front
air bag control unit (SRS-ECU), side impact seat belt retractor. Only authorized service
sensors, SRS warning lamp and clock spring. The personnel should do work on or around the SRS
air bags are located in the centre of the steering components and seat belt with pre-tensioner. Those
wheel, above the glove box, and built into the front service personnel should read this manual carefully
seat back assemblies. Each air bag has a folded before starting any such work. Extreme care must
air bag and an inflator unit. The SRS-ECU under be used when servicing the SRS to avoid injury
the floor console monitors the system and has a to the service personnel (by inadvertent deployment
safing G sensor and an analog G sensor. The side of the air bags or inadvertent operation of the seat
impact sensor inside the center pillar monitors any belt with pre-tensioner) or the driver (by rendering
shocks coming from the side of the vehicle. The the SRS or the seat belt with pre-tensioner
warning lamp on the instrument panel indicates inoperative).
Side impact sensor
Side air bag module
Clock spring
Air bag module
(Front passenger’s side)
Air bag module

(Driver’s side)
Diagnosis
connector
SRS-ECU
Seat belt with

pre-tensioner
SRS warning lamp
SRS - General Information 52B-3
SEAT BELT WITH PRE-TENSIONER
The seat belt with pre-tensioner has a pre-tensioner The safety mechanism operates automatically
operating mechanism and a G-sensor which detects when the retractor top mounting screw is removed
the force from an impact built into the seat belt during removal of the seat belt.
retractor. When the retractor top mounting screw is removed,
The G-sensor is a mechanical-type sensor which the force of the spring plate causes the tab at the
includes components such as a weight which moves lower edge of plate (A) to push in the pin of the
as a result of the impact from a collision, and a G-sensor, which prevents the weight inside the
spike which strikes a charge and causes it to G-sensor from moving.
detonate. At the same time, the retractor bracket and the
Thus the pre-tensioner is equipped with a safety top of plate (A) become separated. A stopper is
mechanism to prevent mis-operation during inserted into the gap thus formed by the force from
maintenance operations such as removal and a spring to prevent the tab from being removed
installation of the seat belt. from the pin if an outside force is applied to plate
(A).
Plate (A)
Plate (A) (when safety
Spring mechanism is disengaged)
Stopper
Retractor bracket Plate (A) (when safety
mechanism is engaged)
Stopper
Spring plate
Tab
Tab
G-sensor structure
Charge Spike
Tab
Pin
Pin (when safe-

ty mechanism is
engaged) Sensor
weight
52B-4 SRS - SRS Service Precautions
SRS SERVICE PRECAUTIONS 52400030238
1. In order to avoid injury to yourself or others NOTE

from accidental deployment of the air bag and If any of these components are diagnosed as
accidental operation of the seat belt with faulty, they should only be replaced, in
pre-tensioner during servicing, read and accordance with the INDIVIDUAL COM-
carefully follow all the precautions and PONENTS SERVICE procedures in this
procedures described in this manual. manual, starting at page 52B-28.
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 (Driver’s side or front
passenger’s side)
D Seat belt with pre-tensioner
4. After disconnecting the battery cable, wait 60 seconds

Insulating tape Battery 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.
SRS-ECU connector 5. Do not attempt to repair the wiring harness connectors

<Vehicles without SRS side air bag> 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.
SRS - SRS Service Precautions 52B-5
Terminal No.
1 to 4 - -
5, 6 Dash wiring harness ® Clock spring ® Air bag module (Driver’s Correct or replace the dash wiring
side) harness. Replace the clock spring.
7, 8 Dash wiring harness ® Air bag module (Front passenger’s side) Correct or replace the dash wiring
harness.
9, 10 -
12 -
15 Dash wiring harness ® Instrument panel wiring harness ® SRS Correct or replace each wiring
warning lamp harness.
16 to 19 - -
20, 21 Dash wiring harness ® Earth Correct or replace the dash wiring
harness.

Terminal No.
1, 2 - -
3 Dash wiring harness ® Earth Correct or replace the dash wiring harness.
4 Dash wiring harness ® Instrument panel wiring harness Correct or replace each wiring harness.
® SRS warning lamp
5, 6 Dash wiring harness ® Air bag module (Front Correct or replace the dash wiring harness.
Passenger’s side)
7, 8 Dash wiring harness ® Clock spring ® Air bag module Correct or replace the dash wiring harness.
(Driver’s side) Replace the clock spring.
9 Dash wiring harness ® Junction block (fuse No.4) Correct or replace the dash wiring harness.
10, 11 -
13 -
14, 15 Dash wiring harness ® Earth
17 to 20 -
21, 22 Dash wiring harness ® Side air bag module (L.H.)
23, 24 Dash wiring harness ® Side air bag module (R.H.)

52B-6 SRS - SRS Service Precautions

Terminal No.
25 to 33 - -
34, 35, 36 Dash wiring harness ® Floor wiring harness ® Side Correct or replace each wiring harness.
impact sensor (L.H.)
37 to 39 -
40, 41, 42 Dash wiring harness ® Floor wiring harness ® Side

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.
SRS-ECU harness connector
MB991222
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 (driver’s side and front passenger’s side), clock spring, side impact sensors,
front seat assemblies (side air bag module), and seat belts with pre-tensioner before drying or baking
the vehicle after painting.
8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system
functions properly. (Refer to P.52B-19.)
9. Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected.
10. If you have any questions about the SRS, please contact your local distributor.
NOTE
SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY
THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.
SRS - Special Tools 52B-7

MB991502 MUT-II sub D Reading diagnosis codes
assembly D Erasing diagnosis code
D Reading trouble period
D Reading erase times
MB991613 SRS check har- Checking the SRS electrical circuitry

ness
MB991223 Harness set Checking the continuity and measuring the

A
A: MB991219 A: Check harness voltage at the SRS-ECU harness connector
B: MB991220 B: LED harness <vehicles with SRS side air bag>
C: MB991221 C: LED harness
D: MB991222 adapter
D: Probe
B
MB990803 Steering wheel Steering wheel removal

puller
MB686560 SRS air bag D Deployment of air bag modules inside the
adapter harness A vehicle
D Deployment of air bag module (front
passenger’s side) and side air bag module
outside the vehicle
MR203491 or SRS air bag Deployment of air bag module (driver’s side)
MB628919 adapter harness B outside the vehicle
52B-8 SRS - Test Equipment/Troubleshooting
TEST EQUIPMENT 52400080035
Tool Name Use

Digital multi-meter Checking the SRS electrical circuitry
Use a multi-meter for which the
maximum test current is 2 mA or less
at the minimum range of resistance
measurement


Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check
diagnosis codes.
Inspect according to the inspection chart that is appropriate for the malfunction code.
Code No. Diagnosis Item Reference page
14 Analog G-sensor system in the SRS-ECU 52B-9

15, 16 Front impact safing G sensor system inside SRS-ECU 52B-9
17 Side impact safing G sensor system inside SRS-ECU 52B-10

21, 22, 61, 62 Driver’s side air bag module (squib) system 52B-10
24, 25, 64, 65 Front passenger’s 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 Lamp does not illuminate.* 52B-14
system
Lamp does not switch off. 52B-15
44* SRS warning lamp drive circuit system 52B-15
45 Internal circuit system of non-volatile memory (EEPROM) inside SRS-ECU 52B-15
SRS - Troubleshooting 52B-9
Code No. Diagnosis Item Reference page
51, 52 Driver’s side air bag module (squib ignition drive circuit) system 52B-15
54, 55 Front passenger’s 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. D Malfunction of 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
Replace the SRS-ECU.
Code No.15 or 16 Front impact safing G sensor system Probable cause

inside SRS-ECU
These diagnosis codes are output if there is a short or open circuit between the D Malfunction of SRS-ECU
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 SRS - Troubleshooting
Code No.17 Side impact safing G sensor system inside Probable cause
SRS-ECU
This code is output if the following are detected from the side impact safing G sensor Malfunction of SRS-ECU
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 Driver’s side air bag module Probable cause
(squib) system
These diagnosis codes are output if there is abnormal resistance between the input D Malfunction of clock spring
terminals of the driver’s side air bag module (squib). D Partial disconnection due to incorrect clock spring
The trouble causes for each diagnosis code No. are as follows. neutral position
D Malfunction of wiring harnesses or connectors
D Malfunction of driver’s side air bag module (squib)
D Malfunction of SRS-ECU
21 D Short in driver’s side air bag module (squib) or harness short

D Short in clock spring
22 D Open circuit in driver’s side air bag module (squib) or open harness
D Open circuit in clock spring
D Disconnected driver’s side air bag module (squib) connector
D Partial disconnection due to incorrect clock spring neutral position
D Malfunction of connector contact
61 D Short in driver’s side air bag module (squib) harness leading to the power supply
62 D Short in driver’s side air bag module (squib) harness leading to the earth
NG
Check the clock spring (Refer to P.52B-37.) Replace
OK
YES
SRS check harness MUT-II Self-diag code Check the following connectors:
(MB991613) D Disconnect clock spring <Vehicles with SRS side air bag> C-108, C-43
connector C-108, and <Vehicles without SRS side air bag> C-108, C-44
connect the harness side OK NG
connector to SRS check
harness connector 1. Check trouble symptoms.
1 D Erase diagnosis code
Repair
memory. NG
Are code Nos.21, 22, 61 or 62
output? Check the harness wire between the clock spring and SRS-ECU.
Dash wiring OK NG
harness
Replace the SRS-ECU. Repair
NO
C-110
Clock spring OK NG
Check trouble symptoms. Repair

NG
Replace the driver’s side air bag module (squib).

Code No.24, 25, 64 or 65 Front passenger’s side air bag Probable cause
module (squib) system
These diagnosis codes are output if there is abnormal resistance between the input D Malfunction of wiring harnesses or connectors
terminals of the front passenger’s side air bag module (squib). D Malfunction of front passenger’s side air bag module
The trouble causes for each diagnosis code No. are as follows. (squib)

24 D Short in front passenger’s side air bag module (squib) or harness short
25 D Open circuit in front passenger’s side air bag module (squib) or open harness
64 D Short in front passenger’s side air bag module (squib) harness leading to the power
supply
65 D Short in front passenger’s side air bag module (squib) harness leading to the earth
YES
(MB991613) D Disconnect front <Vehicles with SRS side air bag> C-71, C-43
passenger’s side air bag <Vehicles without SRS side air bag> C-71, C-44
module connector C-71, OK NG
and connect the harness
1 side connector to SRS Check trouble symptoms. Repair
check harness connector
1. NG
D Erase diagnosis code
memory. Check the harness wire between the front passenger’s side air
Are code Nos.24, 25, 64 or 65 bag module (squib) and SRS-ECU.
output? OK NG
Dash wiring
harness
NO
Replace the front passenger’s 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 D Malfunction of SRS-ECU
is higher (No.31) or lower (No.32) than the specified value for 5 seconds or more.
However, if diagnosis code Nos.41 and 42 are being output due to a drop in battery
voltage, code No.32 will not be detected.

Code No.34 Connector lock system Probable cause

This diagnosis code is output if a poor connection of the SRS-ECU is detected. However, D Malfunction of connectors
if the vehicle condition returns to normal, diagnosis code No.34 will be automatically D Malfunction of SRS-ECU
erased, and the SRS warning lamp will switch off.
NG
<Vehicles with SRS side air bag> C-42, C-43
<Vehicles without SRS side air bag> C-44
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 D Malfunction of SRS-ECU
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 D Malfunction of wiring harnesses or connectors
earth is lower than the specified value for a continuous period of 5 seconds or more. D Malfunction of SRS-ECU
However, if the vehicle condition returns to normal, diagnosis code No.41 will be
automatically erased, and the SRS warning lamp will switch off.

NG
Measure at SRS-ECU connector C-43. Check the following connectors:
D Disconnect the connector, and measure at the harness side C-43, C-134
connector.
OK NG
D Connect the battery (- ) terminal.
D Ignition switch: ON Check trouble symptoms. Repair
D Voltage between terminal 12 and body earth
OK: 9 V or more NG
OK Check the harness wire between the SRS-ECU and ignition switch
IG1, and repair if necessary.

NG
SRS check harness Measure at SRS check harness Check the following connectors:
(MB991613) connector 5. C-44, C-134
D Disconnect SRS-ECU con- OK NG
3 nector C-44.
D Connect SRS check har- Check trouble symptoms. Repair
ness connector 3 to
SRS-ECU connector. NG
D Connect the battery (- )
terminal. Check the harness wire between the SRS-ECU and ignition switch
5 IG1, and repair if necessary.
D Voltage between terminal 14
and body earth
OK: 9 V or more
OK

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 D Malfunction of wiring harnesses or connectors
earth is lower than the specified value for a continuous period of 5 seconds or more. D Malfunction of SRS-ECU

NG
Measure at SRS-ECU connector C-43. Check the following connectors:
D Disconnect the connector, and measure at the harness side C-43, C-134
connector.
OK NG
OK: 9 V or more NG
OK Check the harness wire between the SRS-ECU and ignition switch

NG Check the following connectors:
SRS check harness Measure at SRS check harness
C-44, C-134
(MB991613) connector 5.
D Disconnect SRS-ECU con- OK NG
3 nector C-44.
D Connect SRS check har- Check trouble symptoms. Repair
ness connector 3 to NG
SRS-ECU connector.
D Connect the battery (- ) Check the harness wire between the SRS-ECU and ignition switch
5 terminal. IG1, and repair if necessary.
D Voltage between terminal 13
and body earth
OK: 9 V or more
OK

Code No.43 SRS warning lamp drive circuit system (Lamp Probable cause
does not illuminate.)
This diagnosis code is output when an open circuit occurs for a continuous period D Malfunction of wiring harnesses or connectors
of 5 seconds while the SRS-ECU in monitoring the SRS warning lamp and the lamp D Blown bulb
is OFF (transistor OFF). D Malfunction of SRS-ECU
However, if this code is output due to an open circuit, if the vehicle condition returns D Malfunction of combination meter
to normal, this diagnosis code No.43 will be automatically erased, and the SRS warning
lamp will return to normal.

NG
Measure at SRS-ECU connector C-43. Blown bulb inspection
OK NG
connector.
Repair
D Connect terminal 4 to the body earth. Check the following connectors:
OK: Lamp illuminates C-43, C-25, D-01, D-03
OK OK NG
Replace the SRS-ECU. Check trouble symptoms. Repair
NG
Check the harness wire between the SRS-ECU, combination meter

and ignition switch IG1.
OK NG
Replace the combination Repair

meter.

NG Blown bulb inspection
SRS check harness Measure at SRS check harness
(MB991613) connector 5. OK NG
3 D Disconnect SRS-ECU con-
nector C-44. Repair
D Connect SRS check har-
ness connector 3 to Check the following connectors:
SRS-ECU connector. C-44, C-25, D-01, D-03
D Connect the battery (- ) OK NG
5 terminal.
D Connect terminal 15 to the
body earth. NG
OK: Lamp illuminates
Check the harness wire between the SRS-ECU, combination meter
and ignition switch IG1.
OK NG
Replace the combination Repair

meter.
OK

Code No.43 SRS warning lamp drive circuit system Probable cause
(Lamp does not switch off.)
This diagnosis code is output when a short to earth occurs in the harness between D Malfunction of wiring harnesses or connectors
the lamp and the SRS-ECU while SRS-ECU is monitoring the SRS warning lamp D Malfunction of SRS-ECU
and the lamp is ON. D Malfunction of combination meter
NO NG
SRS warning lamp inspection Check the following connectors: Repair
D Connect the battery (- ) terminal. <Vehicles with SRS side air bag> C-43,
D Ignition switch: ON C-25, D-01
D Does lamp switch off when <Vehicles without SRS side air bag>
SRS-ECU connector C-43 <ve- C-44, C-25, D-01
hicles with SRS side air bag> or OK
C-44 <vehicles without SRS side
air bag> is disconnected? NG
Check trouble symptoms. Check the harness wire between the
YES SRS-ECU and combination meter.
OK NG
Repair
Replace the combination meter.
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 D Malfunction of wiring harnesses or connectors
malfunction of the output transistor inside the SRS-ECU is detected while the SRS-ECU D Malfunction of SRS-ECU
is monitoring the SRS warning lamp drive circuit.
OK
Check the SRS warning lamp drive circuit system. Replace the SRS-ECU.
Code No.45 Internal circuit system of non-volatile memory Probable cause

(EEPROM) inside SRS-ECU
This diagnosis code is output if there is an internal problem with the non-volatile D Malfunction of SRS-ECU
memory (EEPROM) ,etc. inside the SRS-ECU.
Code No.51 or 52 Driver’s side air bag module (squib Probable cause
ignition drive circuit) system
This diagnosis code is output if a short (No.51) or an open circuit (No.52) is detected D Malfunction of SRS-ECU
in the circuit for the driver’s seat.
Code No.54 or 55 Front passenger’s side air bag module Probable cause
(squib ignition drive circuit) system
This diagnosis code is output if a short (No.54) or an open circuit (No.55) is detected D Malfunction of SRS-ECU
in the circuit for the passenger’s seat.

Code No.71, 72, 75 or 76 Side air bag module (R.H.) (squib) Probable cause
system
These diagnosis codes are output if the resistance value between the side air bag D Malfunction of wiring harnesses or connectors
module (R.H.) (squib) input terminals of the SRS-ECU is abnormal. The problems D Malfunction of side air bag module (R.H.) (squib)
which cause these codes to be output are as follows. D Malfunction of SRS-ECU
71 Short in side air bag module (R.H.) (squib) or harness short
72 D Open circuit in side air bag module (R.H.) (squib) or open harness
75 Short in side air bag module (R.H.) (squib) harness leading to the power supply
76 Short in side air bag module (R.H.) (squib) harness leading to the earth
YES
(MB991613) D Disconnect side air bag C-16, C-42
module (squib) connector OK NG
C-16, and connect the
harness side connector to Check trouble symptoms. Repair
SRS check harness con-
1 nector 1. NG
memory. Check the harness wire between the side air bag module (R.H.)
Are code Nos.71, 72, 75 or 76 (squib) and SRS-ECU.
output? OK NG
NO
Replace the seat back assembly of the front seat (R.H.).
Code No.73 or 74 Side air bag module (R.H.) (squib) Probable cause
ignition drive circuit system
These diagnosis codes are output if there is a short-circuit (code No.73) or an open Malfunction of SRS-ECU
circuit (code No.74) in the squib ignition drive circuit.
Code No.79 or 93 Side impact sensor (L.H.) Probable cause

communication system
These diagnosis codes are output if communication between the side impact sensor D Malfunction of wiring harnesses or connectors
(L.H.) and the SRS-ECU is not possible (code No.79) or abnormal (code No.93). D Malfunction of side impact sensor (L.H.)
NO
MUT-II Self-diag code Check the following connectors:
D Switch over the right side impact sensor (R.H.) and the side C-42, C-117, E-18
impact sensor (L.H.).
OK NG
D Erase diagnosis code memory.
Are code Nos.79 and 93 erased and code Nos.89 and 96 output? Check trouble symptoms. Repair
YES NG
Replace the side impact sensor (L.H.). Check the harness wire between the side impact sensor (L.H.)
and SRS-ECU.
OK NG

Code No.81, 82, 85 or 86 Side air bag module (L.H.) (squib) Probable cause
system
These diagnosis codes are output if the resistance value between the side air bag D Malfunction of wiring harnesses or connectors
module (L.H.) (squib) input terminals of the SRS-ECU is abnormal. The problems D Malfunction of side air bag module (L.H.) (squib)
which cause these codes to be output are as follows. D Malfunction of SRS-ECU
81 Short in side air bag module (L.H.) (squib) or harness short
82 D Open circuit in side air bag module (L.H.) (squib) or open harness
85 Short in side air bag module (L.H.) (squib) harness leading to the power supply
86 Short in side air bag module (L.H.) (squib) harness leading to the earth
YES
(MB991613) D Disconnect side air bag C-21, C-42
module (L.H.) (squib) con- OK NG
nector C-21, and connect
the harness side connector Check trouble symptoms. Repair
to SRS check harness
1 connector 1. NG
memory. Check the harness wire between the side air bag module (L.H.)
Are code Nos.81, 82, 85 or 86 (squib) and SRS-ECU.
output? OK NG
NO
Replace the seat back assembly of the front seat (L.H.).
Code No.83 or 84 Side air bag module (L.H.) (squib) Probable cause
ignition drive circuit system
These diagnosis codes are output if there is a short-circuit (code No.83) or an open Malfunction of SRS-ECU
circuit (code No.84) in the squib ignition drive circuit.
Code No.89 or 96 Side impact sensor (R.H.) Probable cause

communication system
These diagnosis codes are output if communication between the side impact sensor D Malfunction of wiring harnesses or connectors
(R.H.) and the SRS-ECU is not possible (code No.89) or abnormal (code No.96). D Malfunction of side impact sensor (R.H.)
NO
MUT-II Self-diag code Check the following connectors:
D Switch over the side impact sensor (R.H.) and the side impact C-42, C-121, E-09
sensor (L.H.).
OK NG
D Erase diagnosis code memory.
Are code Nos.89 and 96 erased and code Nos.79 and 93 output? Check trouble symptoms. Repair
YES NG
Replace the side impact sensor (R.H.). Check the harness wire between the side impact sensor (L.H.)
and SRS-ECU.
OK NG

Code No.91 Side impact sensor (L.H.) power supply circuit Probable cause
system
This diagnosis code is output if the power supply voltage of the side impact sensor D Malfunction of wiring harnesses or connectors
(L.H.) drops below the rated value for a continuous period of 5 seconds or more. D Malfunction of side impact sensor (L.H.)
However, code No.91 will be automatically cleared and the SRS warning lamp will D Malfunction of SRS-ECU
switch off if the condition returns to normal.
NG
Measure at side impact sensor (L.H.) connector E-18. Check the following connectors:
D Disconnect the connector, and measure at the harness side C-42, C-117, E-18
connector.
OK NG
OK: 9 V or more Check trouble symptoms. Repair
Continuity between terminal 3 and body earth
NG
OK
Check the harness wire between the side impact sensor (L.H.)
Replace the side impact sensor (L.H.). and SRS-ECU.
OK NG
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 D Malfunction of side impact sensor (L.H.)
output.
D Analog G-sensor is not operating.
D Analog G-sensor characteristics are abnormal.
D Analog G-sensor output is abnormal.
Replace the side impact sensor (L.H.).
Code No.94 Side impact sensor (R.H.) power supply Probable cause
circuit system
This diagnosis code is output if the power supply voltage of the side impact sensor D Malfunction of wiring harnesses or connectors
(R.H.) drops below the rated value for a continuous period of 5 seconds or more. D Malfunction of side impact sensor (R.H.)
However, code No.94 will be automatically cleared and the SRS warning lamp will D Malfunction of SRS-ECU
switch off if the condition returns to normal.
NG
Measure at side impact sensor (R.H.) connector E-09. Check the following connectors:
D Disconnect the connector, and measure at the harness side C-42, C-121, E-09
connector.
OK NG
OK: 9 V or more Check trouble symptoms. Repair
Continuity between terminal 3 and body earth
NG
OK
Check the harness wire between the side impact sensor (R.H.)
Replace the side impact sensor (R.H.). and SRS-ECU.
OK NG
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 D Malfunction of side impact sensor (R.H.)
output.
D Analog G-sensor is not operating.
D Analog G-sensor characteristics are abnormal.
D Analog G-sensor output is abnormal.
Replace the side impact sensor (R.H.).

SRS WARNING LAMP INSPECTION 52400430052
1. Check to be sure that the SRS warning lamp illuminates

when the ignition switch is in the ON position.
2. Check to be sure that it illuminates for approximately
7 seconds and then switches off.
3. If the above is not the cause, inspect the diagnosis codes.
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Communication with Communication with all systems is not 1 52B-19

MUT-II is not possible. possible.
Communication is not possible with 2 52B-20

SRS only.
When the ignition key is turned to ON (engine stopped), the SRS Refer to diagnosis code No.43. 52B-14
warning lamp does not illuminate.
After the ignition switch is turned to ON, the SRS warning lamp Refer to diagnosis code No.43, 52B-15
is still on after approximately 7 seconds have passed. 44.

The cause is probably a power supply system (including earth circuit) of the diagnosis D Malfunction of connectors
line. D Malfunction of wiring harness

(Communication is not possible with SRS only.)
If communication is not possible with the SRS only, the cause is probably an open D Malfunction of wiring harnesses or connectors
circuit in the diagnosis output circuit of the SRS or in the power circuit (including D Malfunction of SRS-ECU
earth circuit).
(1) NG
Measure at SRS-ECU connector C-43. Check the following connector:
D Disconnect the connector, and measure at the harness side C-43
connector.
OK NG
(1) Continuity between terminal 14 and body earth, and between
terminal 15 and body earth (2) NG
OK: Continuity
(2) Voltage between terminal 9 and body earth, and between terminal NG
12 and body earth
OK: 9 V or more Check the harness wire between the SRS-ECU and earth, and
OK
NG
Check the following Repair Check the following connectors:
connectors: C-43, C-134, C-131
C-43, C-20
OK NG
OK
NG
NG
Check the harness wire between the SRS-ECU and ignition switch
Check the harness wire between the SRS-ECU and diagnosis
connector.
OK NG

(1) NG
SRS check harness Measure at SRS check harness Check the following connector:
(MB991613) connector 5. C-44
3 D Disconnect SRS-ECU con-
nector C-44. OK NG
D Connect SRS check har-
ness connector 3 to
SRS-ECU connector. NG
(1) Continuity between terminal
5 20 and body earth, and Check the harness wire between the SRS-ECU and earth, and
between terminal 21 and repair if necessary.
body earth (2), (3) NG
OK: Continuity Check the following connectors:
(2) Voltage between terminal 13 C-44, C-134, C-131
and body earth OK NG
OK: 9 V or more
(3) Voltage between terminal 14 Check trouble symptoms. Repair
and body earth
OK: 9 V or more NG
Check the harness wire between the SRS-ECU and ignition switch
OK
NG
C-44, C-20
OK

NG
NG
Check the harness wire between the SRS-ECU and diagnosis Repair
connector.
OK

SRS - SRS Maintenance 52B-21
SRS MAINTENANCE 52400390176
The SRS must be inspected by an authorized dealer 10 years

after the date of vehicle registration.
SRS WARNING LAMP CHECK

Turn the ignition key to the “ON” position. Does the SRS
warning lamp illuminate for about 7 seconds, turn off and
then remain extinguished for at least 5 seconds? If yes, SRS
system is functioning properly. If no, consult page 52B-8.
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 AIR BAG CONTROL UNIT (SRS-ECU)

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 vehicle’s driver or front passenger.
2. Check connector for damage, and terminals for
deformation or rust.
Replace SRS-ECU if it fails visual check.
52B-22 SRS - SRS Maintenance
<Driver’s side> AIR BAG MODULES, STEERING WHEEL AND CLOCK

Connector
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.
Inflator case
2. Check pad cover for dents, cracks or deformation.
<Front passenger’s side> 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
6. Check clock spring connectors and protective tube for
Case 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 vehicle’s front wheels to straight-ahead
position, install the clock spring to the column switch.
Mating Mark Alignment
Protective tube Turn the clock spring clockwise fully, and then turn back
it approx. 3 4/5 turns counterclockwise to align the mating
Mating marks marks.
Caution
If the clock spring’s 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 vehicle’s 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 vehicle’s driver
or front passenger.
SRS - SRS Maintenance 52B-23
FRONT SEAT BACK ASSEMBLY (SIDE AIR BAG
MODULE)
1. Check that there is no abnormality in the seat air bag
Air bag module
deployment module deployment section.
section 2. Check that there is no connector damage, bent terminals
or clamping of the harness.
SIDE IMPACT SENSORS

Center Side impact 1. Check that there is no bending or corrosion in the center
pillar sensor 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
Front of damage or bent terminals.
vehicle
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 vehicle’s driver or front
passenger.
52B-24 SRS - SRS Maintenance
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
vehicle’s 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 52B-25
POST-COLLISION DIAGNOSIS 52400110239
To inspect and service the SRS after a collision (whether

or not the air bags have deployed), perform the following
steps.
SRS-ECU MEMORY CHECK

Caution
Make certain that the ignition switch is OFF when
the MUT-II is connected or disconnected.
2. Read (and write down) all displayed diagnosis codes.
(Refer to P.52B-8.)
NOTE
If the battery power supply has been disconnected or
disrupted by the collision, the MUT-II cannot communicate
with the SRS-ECU. Inspect and, if necessary, repair the
dash wiring harness before proceeding further.
3. Read the data list (fault duration and how many times
memories are erased) using the MUT-II.
Data list
No Service Data Item Applicability
92 Number indicating how often the memory is cleared Maximum time to be stored: 250
93 How long a problem has lasted (How long it takes Maximum time to be stored: 9999 minutes
from the occurrence of the problem till the firest (approximately 7 days)
igniting signal)
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 SRS - Post-collision Diagnosis
REPAIR PROCEDURE
WHEN AIR BAGS (DRIVER’S SIDE AND FRONT
PASSENGER’S 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 Driver’s side air bag module (Refer to P.52B-32.)
D Front passenger’s 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 - Post-collision Diagnosis 52B-27
SRS-ECU
SRS-ECU
1. Check SRS-ECU case and brackets for dents, cracks
or deformation.
2. Check connector for damage, and terminals for
deformation.
<Driver’s side> Air bag modules

Connector
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
<Front passenger’s side>
Connector
Inflator case
Front seat back assembly (Side air bag module)

1. Check that there is no abnormality in the seat air bag
Air bag module module deployment section.
deployment 2. Check that there is no connector damage, bent terminals
section or clamping of the harness.
Clock spring
Protective tube
Case 1. Check clock spring connectors and protective tube for
damage, and terminals for deformation.
2. Visually check the case for damage.
Protective tube
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.
Side impact sensor

Center pillar Side impact 1. Check that there is no bending or corrosion in the center
sensor pillar.
2. Check that there is no denting, breakage or bending of
the side impact sensor.
Front of 3. Check that there is no clamping of the harness, connector
vehicle 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.
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 (driver’s side and front passenger’s 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.
SRS - Warning/Caution Labels 52B-29
WARNING/CAUTION LABELS 52400300070
A number of caution labels relating to the SRS label instructions when servicing SRS and seat
and seat belt with pre-tensioner are found in the belt pre-tensioner. If labels are dirty or damaged,
vehicle, as shown in the following illustration. Follow replace them with new ones.
Steering wheel Air bag module (driver’s side) Clock spring
Sun visor SRS-ECU Glove box
Air bag module Steering gear box Seat belt pre-tensioner

(front passenger’s side)
Side air bag module

(driver’s seat and front
passenger’s seat) Side impact sensor
Center pillar
NOTE
*: Vehicles with front passenger’s air bag
52B-30 SRS - SRS-ECU
SRS AIR BAG CONTROL UNIT (SRS-ECU) 52400210168
Caution 3. Do not drop or subject the SRS-ECU to

1. Disconnect the battery ( - ) terminal and wait impact or vibration.
for 60 seconds or more before starting work. If denting, cracking, deformation, or rust
Furthermore, the disconnected battery are discovered in the SRS-ECU, replace it
terminal should be covered with tape to with a new SRS-ECU. Discard the old one.
insulate it. (Refer to P.52B-4.) 4. After deployment of an air bag, replace the
2. Never attempt to disassemble or repair the SRS-ECU with a new one.
SRS-ECU. If faulty, replace it. 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 "AA 2. SRS-ECU
D Negative (- ) battery cable connection
D Lower cover, side cover (Refer to
1. Engine-ECU, A/T-ECU, and A/T
control relay
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 vehicle’s 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
D Check the SRS-ECU and brackets for dents, cracks or

deformation.
D Check connector for damage, and terminals for
deformation.
Caution
If a dent, crack, deformation or rust is discovered,
replace the SRS-ECU with a new one.
NOTE
For checking of the SRS-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 52400240211
Caution 5. Do not expose the air bag modules to

1. Disconnect the battery ( - ) terminal and wait temperatures over 93_C.
for 60 seconds or more before starting work. 6. When the driver’s-side and passenger’s-
Furthermore, the disconnected battery side air bags have been deployed, the air
terminal should be covered with tape to bag modules (driver’s-side and passen-
insulate it. (Refer to P.52B-4.) ger’s-side) should be replaced with new
2. Never attempt to disassemble or repair the modules. When a side air bag has been
air bag modules or clock spring. deployed, the front seat back assembly
If faulty, replace it. (driver’s seat or passenger’s seat) should
3. Do not drop the air bag modules or clock be replaced with a new assembly.
spring or allow contact with water, grease 7. Wear gloves and safety glasses when
or oil. handling air bags that have already
Replace it if a dent, crack, deformation or deployed.
rust is detected. 8. An undeployed air bag module should only
4. The air bag modules should be stored on be disposed of in accordance with the
a flat surface and placed so that the air bag procedures (Refer to P.52B-42.)
deployment surfaces are facing upward.

<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 (driver’s side), clock spring>
After setting the steering wheel and the front wheels
to the straight ahead position, remove the ignition key.
2
0.69 Nm 4
1
9 Nm
Air bag module removal steps Clock spring removal steps

"DA D Post-installation inspection "DA D Post-installation inspection
D Negative (- ) battery cable connection D Negative (- ) battery cable connection
1. Air bag module mounting screw 1. Air bag module mounting screw
(Torx screw) (Torx screw)
AA" 2. Air bag module AA" 2. Air bag module
"AA D Pre-installation inspection AB" "CA 3. Steering wheel
D Lower cover, column cover (Refer to
AC" "BA 4. Clock spring
"AA D Pre-installation inspection
SRS - Air Bag Modules and Clock Spring 52B-33
<Air bag module (front passenger‘s side)>
1
2
1
Air bag module removal steps

"DA D Post-installation inspection 1. Bolt
D Negative (- ) battery cable connection AD" 2. Air bag module
D Glove box (Refer to GROUP 52A - "AA D Pre-installation inspection
Instrument Panel.)

AA" AIR BAG MODULE REMOVAL (DRIVER’S SIDE)
When disconnecting the connector of the clock spring from
Lock the air bag module, press the air bag’s lock towards the outer
side to spread it open. Use a flat-tipped screwdriver, as shown
Connector in the figure at the left, to pry so as to remove the connector
Flat-tipped gently.
screwdriver
Caution
Lock 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.
AB" STEERING WHEEL REMOVAL

MB990803 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 PASSENGER’S 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.)
"BA CLOCK SPRING INSTALLATION
Mating marks 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 spring’s 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 vehicle’s driver.
"CA STEERING WHEEL INSTALLATION

1. Before installation the steering wheel, be sure to first
turn the vehicle’s 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

3. Does the “SRS” warning lamp illuminate for about 7
seconds after turning OFF?
4. If yes, SRS system is functioning properly.
If no, consult page 52B-8.
SRS warning lamp

<Driver’s 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
Inflator case
Never attempt to measure the circuit resistance of the
<Front passenger’s side>
air bag modules (squib) even if you are using the specified
tester. If the circuit resistance is measured with a tester,
accidental air bags deployment will result in serious
personal injury.
2. Check connectors for damage, terminals for deformation,
and harness for binds.
Connector 3. Check air bag inflator case for dents, cracks or
deformation.
Inflator case 4. Install the air bag module to steering wheel to check
fit or alignment with the wheel.
Caution
If dents, cracks, deformation, or rust are discovered in
the air bag module, replace it with a new one.
Dispose of the old one according to the specified
procedure. (Refer to P.52B-42.)
FRONT SEAT BACK ASSEMBLY WITH SIDE AIR BAG

MODULE CHECK
Air bag module If any improper part is found during the following inspection,
deployment replace the front seat back assembly with a new one.
section 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.
CLOCK SPRING CHECK
Protective tube
Case 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
3. Check continuity between the No.1 connector of the clock

spring and connectors No.3 and 4.
No.1 connector No.3 No.4 connector

connec-
Termi- Termi- Termi- tor Termi- Termi-
5 nal 1 nal 2 nal 3 nal 1 nal 2
2
To auto- To ACC To horn To horn To auto-cruise

1 cruise power relay switch control switch
control
unit
4
Notch
4. Align the paint mark of the SRS check harness connector
Paint No.4 with the notch in clock spring connector No.2 to
mark connect the connectors Nos.2 and 4.
5. Check continuity between the terminals 22 and 23 of
the SRS check harness connector No.5.
SRS check
harness
(MB991613)
A Clock spring
5 connector 2
View A
52B-38 SRS - Side Impact Sensor
SIDE IMPACT SENSOR 52400460013
Caution 3. Do not drop or subject the side impact

1. Disconnect the battery ( - ) terminal and wait sensor to impact or vibration.
for 60 seconds or more before starting work. If denting, cracking, deformation, or rust
Furthermore, the disconnected battery are discovered in the side impact sensor,
terminal should be covered with tape to replace it with a new side impact sensor.
insulate it. (Refer to P.52B-4.) Discard the old one.
2. Never attempt to disassemble or repair the 4. After deployment of an air bag, replace the
side impact sensor. If faulty, replace it. side impact sensor with a new one.
Turn the ignition key to the “LOCK” position.
5 Nm
Center pillar
3
2
4 Front of vehicle
5 Nm
Removal steps
"CA D Post-installation inspection 3. Bracket
D Negative (- ) battery cable connection "BA 4. Side impact sensor
D Center pillar lower trim (Refer to "AA D Pre-installation inspection
GROUP 52A.)
D Seat belt with pre-tensioner (Refer to NOTE
P.52B-40.) The illustration above shows the side impact sensor
1. Water proof cover (L.H.). The position of the side impact sensor (R.H.) is
2. Side impact sensor and bracket symmetrical to this.
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.
"BA SIDE IMPACT SENSOR INSTALLATION

Center pillar 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

3. Does the SRS warning lamp illuminate for about 7
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
D Check the side impact sensor and bracket for dents, cracks
or deformation.
D Check connector for damage, and terminals for
deformation.
Caution
If a dent, crack, deformation or rust is discovered,
replace the side impact sensor with a new one.
NOTE
For checking of the side impact sensor other than
described above, refer to the section concerning
troubleshooting. (Refer to P.52B-8.)
D Check that there is no bending or corrosion in the center
pillar.
52B-40 SRS - Seat Belt with Pre-tensioner
SEAT BELT WITH PRE-TENSIONER 52400410056
Caution 4. Do not expose the seat belt with

1. Never attempt to disassemble or repair the pre-tensioner to temperatures over 90_C.
seat belt with pre-tensioner. If faulty, replace 5. After operating the seat belt pre-tensioner,
it. replace the seat belt pre-tensioner with a
2. Be extremely careful when handling the seat new part.
belt with pre-tensioner. Do not subject it 6. Gloves and protective goggles should be
to shocks, drop it, bring it close to strong worn when handling a pre-tensioner once
magnets or allow contact with water, grease it has been used.
or oil. Always replace it with a new part 7. If disposing of a seat belt with pre-tensioner
if any dents, cracks or deformation is found. which has not yet been used, its
3. Do not place anything on top of the seat pre-tensioner should be operated first
belt pre-tensioner. before disposal. (Refer to P.52B-42.)

Center Pillar Lower Trim Removal and Installation (Refer
to GROUP 52A.)
3
44 Nm
2
4
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
"AA D Pre-installation inspection
SRS - Seat Belt with Pre-tensioner 52B-41
When safety mecha- REMOVAL SERVICE POINT
nism is engaged
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

INSTALLATION (SAFETY MECHANISM
Retractor DISENGAGEMENT)
bracket
Plate (A)
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.
Stopper 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.
Seat Belt with Pre-tensioner/Air Bag Module and
52B-42 SRS - Seat Belt Pre-tensioner Disposal Procedures
SEAT BELT WITH PRE-TENSIONER CHECK

If any part is found to be faulty during the inspection. It must
be replaced with a new one.
Dispose of the old one according to the specified procedure
described below.
D Check seat belt pre-tensioner for dents, cracks or
deformation.
AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL

PROCEDURES 52400120225
Before disposing of a vehicle which is equipped pre-tensioner themselves, the following procedures
with air bags or seat belts with pre-tensioner, or must be used to deploy the air bags or operate
when disposing of the air bags or seat belt 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.)
Air Bag Module and Seat Belt
SRS - Pre-tensioner Disposal Procedures 52B-43
Dash wiring harness connector (2-pin) 3. To deploy the air bag module (driver’s 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.
Clock spring 2-pin NOTE
connector (red) 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 passenger’s side):

Dash wiring harness (1) Remove the glove box.
connector (2) Remove the connection between the air bag module
(2-pin) (front passenger’s 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
Air bag module 2-pin
module connector will be automatically shorted to prevent
connector (red) 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 Caution
connector (2-pin) The side air bag modules for both the driver’s-side
and passenger’s-side should be deployed.
Side air bag NOTE
module 2-pin If the side air bag module connector is disconnected from
connector (red)
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 - Pre-tensioner Disposal Procedures
6. Connect two wires, each six meters or longer, to the two

Connection leads of SRS air bag adapter harness A and cover the
Insulation connections with insulation tape. The other ends of the
SRS air bag tape two wires should be connected to each other
adapter (short-circuited), to prevent sudden unexpected
harness A 6 m or
longer deployment of the air bag.
MB686560
Two wires
7. Connect the clock spring, air bag module (front

SRS air bag adapter passenger’s side), or side air bag module 2-pin connector
harness A
MB686560 (red) to SRS air bag adapter harness A and pass the
deployment wires out of the vehicles.
2-pin connector (red)
Deployment wires
8. Fully close all door windows, close the doors and place
Cover 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,
Wires 6 m or longer 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 instruc-
tions.
3. If the air bag module fails to deploy when the
procedures above are followed, do not go near
the module. Contact your local distributor.
10. After deployment, dispose of air bag module according
to the Deployed Air Bag Module or Operated Seat Belt
Pre-tensioner Disposal Procedures. (Refer to P.52B-49.)
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 (driver’s-side and front
passenger’s-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 3. Connect two wires, each six meters or longer, to the two
(driver’s side)> Connection leads of SRS air bag adapter harness B <air bag module
Two wires (driver’s side)> or SRS air bag adapter harness A <air
SRS air bag bag module (front passenger’s side) and side air bag
adapter harness B module>, and cover the connections with insulation tape.
MR203491 or
6m
The other ends of the two wires should be connected
MB628919 to each other (short-circuited), to prevent sudden
long or
more unexpected deployment of the air bag module.
Insulation tape
<Air bag module (front
passenger’s side) and
side air bag module> Connection
Two wires
SRS air bag
adapter harness A 6m
MB686560 long or
more
Insulation tape
4. Set the air bag modules as follows:

Air bag module
<Air bag module (driver’s 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
Wires mounting hole, and then secure the air bag module
to an old tyre with a wheel in it so that the pad on
the module is facing upwards.
Caution
Leave some space below the wheel for the adaptor
harness. If there is no space, the reaction when
the air bag deploys could damage the adaptor
harness.
(3) Place three old tyres with no wheels on top of the

Tyres without wheels tyre secured to the air bag module.
Wires
Air bag module <Air bag module (front passenger’s 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.
(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).
Tyres without wheels
Deployment wire
<Side air bag module>

Seat back assembly
(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.
6 m or more 1. Remove the seat belt with pre-tensioner. (Refer to

P.52B-40.)
Caution
The pre-tensioner safety mechanism should be
Approx. engaged to prevent accidental operation of the
0.4 m 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
Sensor side and the sensor side (the side with the white cover) is
(white cover side) at the bottom when the pre-tensioner is suspended.
3. Disengage the pre-tensioner safety mechanism by the
following procedure.
Caution
After disengaging the safety mechanism, the
pre-tensioner can operate even if it is dropped by
a distance of as little as 5 cm, so be extremely careful
when handling the pre-tensioner in this condition.
(1) Lift up the stopper and then bring the retractor bracket
Retractor bracket and plate (A) together so that the stopper tab goes
into the hole in the retractor bracket. This will
Plate (A)
disengage the safety mechanism.
(2) Use a bulldog clip to secure the retractor bracket
Stopper and plate (A) so that they do not become separated.
Old tyre with

4. Place the pre-tensioner down gently onto a solid base
wheel attached 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.
Old
tyres 5. Tie the tyres together with rope so that they do not slip
without apart.
wheels
6. From a distance of 5 meters away, pull the rope to raise

5 m or more
the seat belt pre-tensioner off the ground by 20 cm or
more.
20 cm
or more
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.
4. Tightly seal the air bag module and seat belt pre-tensioner
Strong in a strong vinyl bag for disposal.
vinyl bag Air bag module
and seat belt
NOTE
pre-tensioner 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
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 COMBINATION METERS . . . . . . . . . . . . 20

SERVICE SPECIFICATION . . . . . . . . . . . . . . . 4 SERVICE SPECIFICATIONS . . . . . . . . . . . . 20
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 4 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fluid Level and Specific Gravity Check . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 21
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery Testing Procedure . . . . . . . . . . . . . . . . . . 6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 22
IGNITION SWITCH, ETACS-ECU AND CONTINUED ON NEXT PAGE

IMMOBILIZER SYSTEM* . . . . . . . . . . . . . 7
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 7
IGNITION SWITCH, ETACS-ECU AND
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . 17

WARNING!
MITSUBISHI dealer.
component.
NOTE
54-2
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 24 FRONT FOG LAMP . . . . . . . . . . . . . . . . 45

Speedometer Check . . . . . . . . . . . . . . . . . . . . . . 24
Tachometer Check . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel Gauge Simple Check . . . . . . . . . . . . . . . . 25 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 45
Fuel Gauge Unit Check . . . . . . . . . . . . . . . . . . . 25
Engine Coolant Temperature Gauge Simple ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 45
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Front Fog Lamp Aiming . . . . . . . . . . . . . . . . . . 45
Engine Coolant Temperature Gauge Unit Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . 46
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FRONT FOG LAMP . . . . . . . . . . . . . . . . . . . . 47
COMBINATION METERS . . . . . . . . . . . . . . . 28
REAR COMBINATION LAMP . . . . . . . . 48
HEADLAMP AND FRONT
TURN-SIGNAL LAMP* . . . . . . . . . . . . . . 30 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 48
SERVICE SPECIFICATIONS . . . . . . . . . . . . 30 REAR COMBINATION LAMP . . . . . . . . . . . 49
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 30 HIGH MOUNTED STOP LAMP . . . . . . 51

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 31 RHEOSTAT . . . . . . . . . . . . . . . . . . . . . . . . 52
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 37 HAZARD WARNING LAMP
Headlamp Aiming . . . . . . . . . . . . . . . . . . . . . . . . 37 SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Intensity Measurement . . . . . . . . . . . . . . . . . . . . 38
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . 39 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
HEADLAMP AND FRONT TURN-SIGNAL CIGARETTE LIGHTER . . . . . . . . . . . . . . 54

LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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
DOOR GLASS AND REGULATOR
RADIO AND TAPE PLAYER . . . . . . . . . . . . 72 (POWER WINDOWS)
. . . . . . . . . . . . . . . . . . . Refer to GROUP 42
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . 73
DOOR HANDLE AND LATCH
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . 74
(DOOR LOCKING)
REAR WINDOW DEFOGGER . . . . . . . 77 . . . . . . . . . . . . . . . . . . . Refer to GROUP 42
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 77 KEYLESS ENTRY SYSTEM

. . . . . . . . . . . . . . . . . . . Refer to GROUP 42
Printed-heater Line Check . . . . . . . . . . . . . . . . . 77 SUNROOF . . . . . . . . Refer to GROUP 42
Rear Window Defogger Relay Continuity Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
WINDSHIELD WIPER AND WASHER
. . . . . . . . . . . . . . . . . . . Refer to GROUP 51
REAR WINDOW DEFOGGER SWITCH
<VEHICLES WITH MANUAL A/C> . . . . . . 78 REAR WIPER AND WASHER
. . . . . . . . . . . . . . . . . . . Refer to GROUP 51
THEFT-ALARM SYSTEM . . . . . . . . . . . . 79
DOOR MIRROR (ELECTRONIC
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 79 CONTROLLED DOOR MIRROR)
. . . . . . . . . . . . . . . . . . . Refer to GROUP 51
SUPPLEMENTAL RESTRAINT SYSTEM
TRACTION CONTROL (TCL) (SRS) . . . . . . . . . . . Refer to GROUP 52B
. . . . . . . . . . . . . . . . . . . Refer to GROUP 13
HEATER . . . . . . . . . . Refer to GROUP 55
RADIATOR FAN MOTOR
. . . . . . . . . . . . . . . . . . . Refer to GROUP 14 AIR CONDITIONER
. . . . . . . . . . . . . . . . . . . Refer to GROUP 55
AUTOMATIC TRANSMISSION
. . . . . . . . . . . . . . . . . . . Refer to GROUP 23
54-4 CHASSIS ELECTRICAL - Battery
BATTERY 54100030028
Item Specification
Specific gravity of the battery fluid 1.220 - 1.290 [20_C]
FLUID LEVEL AND SPECIFIC GRAVITY CHECK

Good 1. Inspect whether or not the battery fluid is between the
Thermo
meter UPPER LEVEL and LOWER LEVEL marks.
Hydrometer 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
CHASSIS ELECTRICAL - Battery 54-5
CHARGING 54100110029
1. When charging a battery while still installed in the vehicle,

disconnect the battery cables to prevent damage to
electrical parts.
2. The current normally used for charging a battery should
be approximately 1/10th of the battery capacity.
3. When performing a quick-charging due to lack of time,
etc., the charging current should never exceed the battery
capacity as indicated in amperes.
4. Determining if charging is completed.
(1) If the specific gravity of the battery fluid reaches
1.250 - 1.290 and remains constant for at least one
hour.
(2) If the voltage of each cell reaches 2.5 - 2.8 V and
remains constant for at least one hour.
Caution
1. Be careful since the battery fluid level may rise
during charging.
2. Keep all sources of fire away while charging
because there is a danger of explosion.
3. Be careful not to do anything that could generate
sparks while charging.
4. When charging is completed, replace the battery
caps, pour clean water over the battery to remove
any sulfuric acid and dry.
54-6 CHASSIS ELECTRICAL - Battery
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. Charge battery at 5 amps. (see LOAD TEST RATE CHART)
OK: Open circuit voltage is more than 12.4 V
(specific gravity: 1.240)
OK Retest
NG
(1) Connect a load tester to the battery. Replace 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
OK
Normal
LOAD TEST RATE CHART

Battery type 75D26L 95D31L
Charging time when fully discharged 11 14

h [5-amp rated current charging]
Load test (Amps) 260 310
LOAD TEST CHART

Temperature _C 21 and 16 10 4 -1 -7 - 12 - 18
above
Minimum voltage V 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
Ignition Switch, ETACS-ECU
CHASSIS ELECTRICAL - and Immobilizer System 54-7
IGNITION SWITCH, ETACS-ECU AND IMMOBILIZER

SYSTEM 54300060092
SPECIAL TOOL
MB991502 MUT-II sub D Immobilizer system check
assembly (Diagnosis display using the MUT-II)
D Registration of the ID code
D ETACS-ECU input signal checking
IGNITION SWITCH
MUT-II DIAGNOSIS FUNCTION
INPUT SIGNAL INSPECTION POINTS <VEHICLES
WITH ETACS-ECU>
2. If buzzer of the MUT-II sounds once when a switch is
operated (ON/OFF), the ETACS-ECU input signal for that
switch circuit system is normal.

procedure No.
Communication with MUT-II is not Communication with all systems is not 1 54-8
possible. possible.
Communication with the one-shot 2 54-8

pulse input signal only is not possible.
While key hole illumination lamp is illuminated, ignition key is turned to the ON 3 54-8
position but key hole illumination lamp does not switch off. (However, it switch
off after 10 seconds.)
Key hole illumination lamp remains illuminated. 4 54-9
Even if driver’s side door is opened, key hole illumination lamp does not 5 54-9
illuminate.
54-8 CHASSIS ELECTRICAL - and Immobilizer System

tion with all systems is not possible.)
The cause is probably a defect in the power supply system (including earth) for the D Malfunction of connector
diagnosis line. D Malfunction of harness wire
tion with the one-shot pulse input signal only is not
possible.)
The cause is probably a defective one-shot pulse input signal circuit system of the D Malfunction of connector
D Malfunction of ECU
OK NG
Check the harness between the diagno- Check the following connectors: Repair
sis connector and junction block. C-20, C-134 and C-144
NG OK
NG
Repair Check trouble symptom. Replace the ECU.
While key hole illumination lamp is illuminated, ignition Probable cause
key is turned to the ON position but key hole illumination
lamp does not switch off. (However, it switch off after 10
seconds.)
The cause is probably a defective ignition switch input circuit or a defective ECU. D Malfunction of connector
D Malfunction of harness wire
MUT-II Input Signal Inspection

Ignition switch input signal
OK: The MUT-II buzzer sounds once OK
Replace the ECU.
when the ignition key is turned
to the ON or OFF position.
NG
OK NG
Disconnect the junction block connector Check the following connectors: Repair
C-131, and measure at the harness side. C-144 and C-131
D Voltage between the terminal (6) and
OK
earth
OK: System voltage NG
Check trouble symptom. Replace the ECU.
NG

ignition switch (IG1) and junction block,
Key hole illumination lamp remains illuminated. Probable cause
The cause is probably a harness short or a defective ECU. D Malfunction of harness wire
NO
When the connector C-134 of the junction block (1) is disconnected, Check the harness wire between the key reminder switch and
does the lamp switch off? junction block, and repair if necessary.
YES
Replace the ECU.
Even if driver’s side door is opened, key hole illumination Probable cause
lamp does not illuminate.
The cause is probably a defective key hole illumination lamp circuit system or a defective D Malfunction of driver’s side door switch
driver’s side door switch input circuit system. D Malfunction of bulb
D Malfunction of harness wire
MUT-II Input Signal Inspection

Driver’s side door switch input signal
OK: The MUT-II buzzer sounds once Driver’s side door switch input circuit
NG system inspection (Refer to Inspection
when the driver’s side door switch
is ON. Procedure 6 on P.54-10.)
OK
NG
Key hole illumination lamp inspection Replace
OK
NG NG
Disconnect the key reminder switch Check the following connectors: Repair
connector C-109, and measure at the L.H. drive vehicles: C-66, C-63, C-132,
harness side. C-141
D Voltage between the terminal (2) and R.H. drive vehicles: C-62, C-14
earth
OK
OK: System voltage
NG NG
C-109, C-134 and C-144
OK

NG
NG
Check the harness wire between the key reminder switch and junction block,
key reminder switch and junction block, and repair if necessary.
and repair if necessary. OK
Replace the ECU.

Driver’s side door switch input circuit system inspection
NG
Door switch inspection (Refer to Replace
GROUP 42 - Door Assembly.)
OK
NG
Door switch earth inspection Repair
OK
NG NG
Disconnect the door switch connector Check the following connectors: Repair
E-09 <L.H. drive vehicles>, E-08 <R.H. C-144 and C-143
drive vehicles>, and measure at the har- OK
ness side.
D Voltage between the terminal (2) and NG
earth door switch and junction block, and re-
OK: System voltage pair if necessary.
OK
NG
Check trouble symptom. 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.
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.
Code No. 11 Transponder communication system Probable cause
The ID code of the transponder is not sent to the immobilizer-ECU immediately after D Radio interference of ID codes
the ignition switch is turned to the ON position. D Malfunction of the transponder
If the engine is started while several ignition keys are in the vicinity, then interference D Malfunction of the ignition key ring antenna
between the different keys may occur, which will cause this code to be generated. D Malfunction of harness or connector
D Malfunction of the immobilizer-ECU
Yes
Are there any other ignition keys in the Move other keys well away from the
vicinity of the ignition key being used key being used.
for starting?
No
NG
OK
Does the engine start using the spare Replace the ignition key that does not Re-register the ID code.
ignition key which has had the ID code work. (Refer to P.54-19.)
registered?
NG
Code No. 12 occurs
Diagnosis codes check 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 Replace
ring antenna. (Refer to P.54-18.)
OK
NG
C-68, C-104
OK
NG NG
Check trouble symptoms. Check the harness wire between immo- Repair
bilizer-ECU and key ring antenna.
OK
Replace the immobilizer-ECU.
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 D The ID code in the ignition key being used has not
which is registered in the immobilizer-ECU. been properly registered.
NG
Re-register the ID code. Check trouble symptoms. Replace the immobilizer-ECU.
(Refer to P.54-19.)
Code No.21 Communication system between immobiliz- Probable cause

er-ECU and engine-ECU
After the ignition switch is turned to the ON position, the confirmation code is not D Malfunction of harness or connector
received from the engine-ECU within the allowable time, or an abnormal code is received. D Malfunction of the engine-ECU
NO
Is diagnosis code No. 54 being gener- Check the engine-ECU power source
ated by the engine-ECU? and the earth circuit.
YES (Refer to GROUP 13A - Troubleshoot-
ing.)
NG
C-68, C-81, C-38 <4G6>
C-37, <6A1>, C-54 <4D6>
OK
NG NG
Check trouble symptoms. Check the harness wire between en- Repair
gine-ECU and immobilizer-ECU.
OK

NG

OK
NG
Code No. 31 EEPROM abnormality inside immobilizer- Probable cause

ECU
No data has been written to the EEPROM inside the immobilizer-ECU. D Malfunction of the immobilizer-ECU
NG
Check trouble symptoms. Replace the immobilizer-ECU.
Code No.32 Ignition switch IG signal circuit system Probable cause

The ignition switch signsl is not being input to the immobilizer-ECU. D Malfunction of harness or connector
D Malfunction of the ignition switch
NG NG
Check the input of the ignition switch Check the following connectors: Repair
IG signal. C-68, C-134, C-131
Measure at the immobilizer-ECU con-
OK
nector C-68.
D Disconnect the connector, and Check trouble symptoms.
(Ignition switch: ON position) NG
OK System voltage Check the fuse and the harness wire Repair
between ignition switch (IG) and immo-
OK bilizer-ECU.
Replace the immobilizer-ECU. OK
NG
Check trouble symptoms Check the ignition switch.
(Refer to 54-18.)
Code No.33 Starting prevention system activated due to Probable cause
incorrect operation
If the transponder ID code mismatches five times in succession, this code will be D Malfunction of the immobilizer-ECU
output. This code can be canceled by turning the ignition switch ON, and then turning D Malfunction of the transponder
it OFF after 16 minutes have passed.
Turn the ignition switch ON and then turn it OFF after 16 minutes
have passed.
Re-register the ID code. (Refer to P.54-19.)

NG
Replace the ignition key.
NG
Check trouble symptoms. Replace the immobilizer-ECU
Communication with MUT-II is impossible. 1 54-14
Diagnosis code No. 54 has been generated by the engine-ECU. 2 54-14
ID code cannot be registered using the MUT-II. 3 54-15
Engine does not start (Cranking but no initial combustion). 4 54-15
Malfunction of the immobilizer-ECU power source and earth circuit 5 54-16


Communication with MUT-II is impossible. Probable cause
The cause is probably that a malfunction of the diagnosis line or the immobilizer-ECU D Malfunction of the diagnosis line
is not functioning. D Malfunction of harness or connector
D Malfunction of the immobilizer
NO NG
Can the MUT-II communicate with the Check the following connectors: Repair
engine-ECU? C-68, C-104
YES OK

NG NG
Disconnect the immobilizer-ECU con- Repair
nector C-68 and check at the harness NG
side. Check the harness wire between immo- Repair
(Short-circuited harness wire between bilizer-ECU and diagnosis connector.
terminal No. 13 and No. 14) OK
OK
Check the immobilizer-ECU power sup-
Check trouble symptoms. ply and earth circuit. (Refer to INSPEC-
TION PROCEDURE 5.)
NG
OK
Replace the immobilizer-ECU. NG
Check trouble symptoms. Replace the immobilizer-ECU.
Diagnosis code No. 54 has been generated by the Probable cause
engine-ECU.
There is a problem with communication between the engine-ECU and the D Malfunction of harness or connector
immobilizer-ECU. D Malfunction of the immobilizer-ECU
NG
C-68, C-81, C-38 <4G6>,
C-37 <6A1>, C-54 <4D6>
OK

NG
NG
Check the harness wire between en- Repair
gine-ECU and immobilizer-ECU.
OK
YES
Is diagnosis code No. 21 being gener-
ated by the immobilizer-ECU?
NO
OK
Check the immobilizer-ECU power sup- Check trouble symptoms.
ply and earth circuit. (Refer to INSPEC- NG
TION PROCEDURE 5.)
NG
NG
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, D Malfunction of the transponder
or there is a malfunction of the immobilizer-ECU. D Malfunction of the ignition key ring antenna
NO
No ignition key can be registered. Replace the ignition key that cannot be Re-register the ID code.
registered. (Refer to P.54-19.)
YES
NO
Is a normal diagnosis code output? To INSPECTION CHART FOR DIAG-
NOSIS CODE (Refer to P.54-10.)
YES
OK NG
Check the immobilizer-ECU power Check trouble symptoms. Replace the immobilizer-ECU.
source and earth circuit. (Refer to IN-
SPECTION PROCEDURE 5.)
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 D Malfunction of the MPI system
in addition to a malfunction of the immobilizer system. D Malfunction of the immobilizer-ECU
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.
NG
Check the system voltage during crank- Check the battery. (Refer to P 54-4.)
ing
OK: 8V or more
OK
Yes
Is the diagnosis code ouutput? To INSPECTION CHART FOR DIAG-
No NOSIS CODE (Refer to P.54-10.)
NG
Check the fuel system (Refer to GROUP Repair
13E - On-vehicle Service.)
OK
OK
Check the power supply and earth circuit Check trouble symptoms.
of the immobilizer (Refer to INSPEC- NG
TION PROCEDURE 5)
NG Replace the immobilizer-EUC.
Repair
NG
Check trouble symptoms. Replace the Injection pump assembly.
Malfunction of the immobilizer-ECU power supply and earth circuit
1. NG NG
Measure at the immobilizer-ECU con- Check the following connectors: Repair
nector. C-81, C-47
OK
1. Voltage between 1 and earth and NG
Check trouble symptoms. Check the harness wire between immo-
between 9 and earth <Petrol-pow-
bilizer-ECU and engine control relay and
ered vehicles>
OK: System voltage
2 Continuity between 8 and earth
OK: Continuity 2, 3. NG NG
3 Continuity between 16 and body Check the following connectors: Repair
earth L.H. drive vehicles: C-62.
OK: Continuity R.H. drive vehicles: C-63, C-64.
OK

NG
Check the harness wire between immo-

bilizer-ECU and body earth and repair
if necessary.
CHECK AT IMMOBILIZER-ECU
Terminal No. Signal Checking requirements Terminal voltage
1 Immobilizer-ECU power supply Ignition switch: ON System voltage
2 Ignition switch-IG Ignition switch: OFF 0V
Ignition switch: ON System voltage
8 Immobilizer-ECU earth Always 0V
9 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 7
9
10
12
11
1
8
3 5
4
2
ETACS-ECU removal steps Ignition switch and ignition key

1. Junction block ring antenna removal steps
2. ETACS-ECU 3. Hood lock release handle
Immobilizer-ECU removal steps 4. Instrument under cover
(Refer to GROUP 52A - Instru-
3. Hood lock release handle ment Panel.)
4. Instrument under cover 6. Steering wheel
(Refer to GROUP 52A - Instru- (Refer to GROUP 37A.)
ment Panel.) 7. Column cover, upper
5. Immobilizer-ECU 8. Column cover, lower
9. Column switch (Refer to GROUP
37A - Steering Wheel and Shaft.)
10. Ignition key ring antenna
AA" 11. Steering lock cylinder
12. Ignition switch
54-18 CHASSIS ELECTICAL - and Immobolizer System

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.
Cross-tip (+)
screwdriver
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 posi- Terminal No.

tion 1 2 3 4 5 6
LOCK
ACC
ON
START
IGNITION KEY RING ANTENNA CONTINUITY CHECK

Use a circuit tester to check the continuity between the
terminals.
CHASSIS ELECTICAL - and Immobolizer System 54-19
ID CODE REGISTRATION METHOD 54300810062
If using an ignition key that has just been newly purchased,

or if the immobilizer-ECU has been replaced, you will need
to register the ID codes for each ignition key being used
into the immobilizer-ECU. (A maximum of eight different ID
codes can be registered.)
Moreover, 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.

Caution
Connection and disconnection of the MUT-II should
always be carried out with the ignition switch in the
MUT-II
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
Speedometer indication error km/h(mph) 40 (20) 40 - 48 (20 - 25)
80 (40) 80 - 92 (40 - 47)
120 (60) 120 - 136 (60 - 69)
160 (80) 160 - 180 (80 - 91)
- (100) - (100 - 114)
Tachometer indication error r/min 700 ±100
3,000 ±150
5,000 ±250
6,000 ±300
Fuel gauge unit resistance W Float point F 4±2
Float point E 112 ± 7
Fuel gauge unit float height mm A (Float point F) 28.6
B (Float point E) 159.9
Fuel gauge resistance W Power supply and earth 111.5
Power supply and fuel gauge 98.2
Fuel gauge and earth 101.0
Engine coolant temperature gauge Power supply and earth 111.5

resistance W
Power supply and engine coolant 53.6
temperature gauge
Engine coolant temperature gauge 165.0

and earth
Engine coolant temperature gauge unit resistance (at 70_C) W 104±13.5
SEALANT 54300050037
Items Specified sealant Remark
Engine coolant temperature gauge 3M Adhesive nut locking No. 4171 or Drying sealant
unit threaded portion equivalent
CHASSIS ELECTRICAL - Combination Meters 54-21

A MB991223 Harness set Making voltage and resistance measurements
A: MB991219 A: Test harness during troubleshooting
B: MB991220 B: LED harness A: Connector pin contact pressure check
C: MB991221 C: LED harness B: Power circuit check
D: MB991222 adapter C: Power circuit check
B D: Probe D: Commercial tester connection
D

procedure page
Speedometer does not work. 1 54-22
Tachometer does not work. 2 54-23

Speedometer does not work. Probable cause
The cause may be a defective vehicle speed sensor circuit system or a defective D Malfunction of vehicle speed sensor
speedometer. Vehicle speed sensor is also used by the engine-ECU and A/T-ECU. D Malfunction of speedometer
1. NG
Disconnect the combination meter con- Vehicle speed sensor circuit system
nectors D-01, D-02 and D-03 and mea- inspection (Refer to Inspection
sure at the harness sides. Procedure 3 on P.54-23.)
1. Measure the voltage between
terminal No.25 and body earth when
the vehicle is moved forwards and 2. NG NG
backwards. Check the following connectors: Repair
OK: 4.7 V or more D-03, C-135, C-131
2. Voltage between the terminal No.4 OK
and body earth NG
OK: System voltage (Ignition Check trouble symptom. Check the harness wire between the
switch: ON) power supply and combination meter,
3. Continuity between the terminal and repair if necessary.
No.46 and body earth
OK: Continuity
OK 3. NG
NG
C-25, D-01
OK
NG
body earth and combination meter, and
Replace the speedometer. repair if necessary.
Tachometer does not work. Probable cause
The ignition signal may not be input from the engine, or there may be a malfunction D Malfunction of tachometer
in the power supply or ground circuit. D Malfunction of harness or connector
1. NG NG
Disconnect the combination meter con- Check the following connectors: Repair
nector D-03 and measure at the harness C-90, D-03
sides.
OK
1. Measure the voltage between
terminal No.8 and body earth. NG
OK: 5 V
distributor assembly <6A1> or engine-
2. Continuity between the terminal
ECU <4G6, 4D6> and combination me-
No.7 and body earth
ter, and repair if necessary.
OK: Continuity
3. Voltage between the terminal No.4
and body earth 2. NG NG
OK: System voltage Check the following connectors: Repair
C-45, C-90, D-03
OK 3. NG OK
NG
combination meter and the body earth,
NG
C-131, C-135, D-03
OK
Replace the tachometer. NG
power supply and combination meter,
Vehicle speed sensor circuit system inspection
NG
Vehicle speed sensor inspection (Refer to P.54-29.) Replace
OK
1. NG NG
Disconnect the vehicle speed sensor connector B-67 <A/T> or Check the following Repair
B-66 <M/T> and measure at the harness side. connectors:
1. Voltage between the terminal No.3 and body earth D-02, C-25, C-66, C-83,
OK: 4.5 V or more B-67 <A/T>, B-66 <M/T>,
2. Continuity between terminal No.2 and body earth B-65 <M/T>
OK: Continuity
NG
3. Voltage between the terminal No.1 and body earth
OK: System voltage (Ignition switch: ON) Check trouble symptom.
3. NG
2. NG NG
OK NG
connectors: combination meter, and repair if necessary.
B-65<M/T>, C-90, C-135,
C-131
OK NG
connector:
B-65 <M/T>, B-67 <A/T>,
NG B-66 <M/T>
Check the harness wire between the vehicle speed sensor OK

NG
body earth, and repair if necessary.
Replace the speedometer.
SPEEDOMETER CHECK
1. Adjust tire pressure to the specified level.
(Refer to GROUP 31 – Service Specifications.)
2. Set the vehicle onto a speedometer tester and use wheel
Wheel chocks
chocks to hold the rear wheels.
Tension bar 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
Front
or wire to the rear retraction hook, and make sure the
end of the chain or wire is secured firmly.
Anchor plate 5. Check if the speedometer indicator range is within the
standard values.
Caution
Do not operate the clutch suddenly. Do not
increase/decrease speed rapidly while testing.
Standard values:
Standard indication km/h Allowable range km/h (mph)
(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)
Engine speed TACHOMETER CHECK 54300100176

detection connector
1. Insert a paper clip in the engine speed detection connector
Tachometer from the harness side, and attach an external high quality
tachometer.
NOTE
For tachometer check, use an external high quality
Paper clip
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 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 Earth

(12 V - 3.4 W) MB991219
OK OK
When the ignition switch is turned to The needle of the fuel gauge moves. Replace the fuel gauge unit.
ON, the test lamp illuminates.
NG
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 RESISTANCE
1. Check that resistance value between the fuel gauge
terminal and ground terminal is at standard value when
Fuel gauge unit fuel gauge unit float is at point F (highest) and point
E (lowest).
Earth Standard value:
Point F: 4 ± 2 W
Point E: 112 ± 7 W
2. Check that resistance value changes smoothly when float
moves slowly between point F (highest) and point E
(lowest).
FUEL GAUGE UNIT FLOAT HEIGHT

Move float and measure the height A at point F (highest)
A and B at point E (lowest) with float arm touching stopper.
Standard value:
Point F Point E A: 28.6 mm
(highest) B (lowest) B: 159.9 mm
Thermistor Earth THERMISTOR

Thermistor
1. Connect fuel gauge unit (thermistor) to battery via test
lamp (12 V - 3.4 W). Immerse in water.
Illuminated 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.
Not
illuminated Caution
After finishing this test, wipe the unit dry and install
it in the fuel tank.
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> Earth <6A1> Test lamp

(12 V - 3.4 W)
Earth
Test lamp
(12 V - 3.4 W)
Connector
Connector
<4D6>
Test lamp MB991219
(12 V - 3.4 W)
Earth
OK NG
When the ignition switch is turned to The needle of the engine coolant tem- Replace the engine coolant
“ON”, the test lamp illuminates. perature gauge moves. temperature gauge.
NG OK
Repair the harness. Replace the engine coolant temperature

gauge unit.
ENGINE COOLANT TEMPERATURE GAUGE UNIT

CHECK 54300150041
1. Bleed the engine coolant.

(Refer to GROUP 00 – Maintenance Service.)
2. Remove the engine coolant temperature gauge unit.
3. Immerse the unit in 70_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
3
2
Vehicle speed sensor removal Combination meter removal steps

steps 2. Meter bezel
D Air cleaner assembly 3. Combination meter
1. Vehicle speed sensor
Turn Shaft
VEHICLE SPEED SENSOR CHECK

1. Remove the vehicle speed sensor and connect a 3 -
10 kW resistance as shown in the illustration.
2. Turn the shaft of the vehicle speed sensor and check
Resistance that there is voltage between terminals 2 - 3. (1 turn
3 - 10 kW
= 4 pulses)
Ohmmeter
FUEL GAUGE RESISTANCE CHECK 54300300132
1. Remove the power supply tightening screw.

Power supply
2. Use an ohmmeter to measure the resistance value
Fuel gauge between the terminals.
Standard value:
Power supply - Earth: 111.5 W
Power supply - Fuel gauge: 98.2 W
Earth
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

RESISTANCE CHECK
Engine coolant
temperature 1. Remove the power supply tightening screw.
gauge 2. Use an ohmmeter to measure the resistance value
between the terminals.
Standard value:
Power supply - Earth: 111.5 W
Earth Power supply 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
Headlight airming for low Vertical direction 60 mm below horizontal (H) -

beam
Horizontal direction Position where the 15° sloping section -
intersects the vertical line (V)
Headlamp aiming for high Vertical direction 22 mm below horizontal (H) -

beam
Horizontal direction Parallel to direction of vehicle travel -
Headlamp intensity cd - 30,000 or more

MB991502 MUT-II sub assen- ETACS-ECU input signal checking
bly
MB991223 Harness set Making voltage and resistance

A A: MB991219 A: Test harness measurements during troubleshooting
B: MB991220 B: LED harness A: Connector pin contact pressure check
C: MB991221 C: LED harness B: Power circuit check
D: MB991222 adapter C: Power circuit check
D: Probe D: Commercial tester connection
D
CHASSIS ELECTRICAL - Headlamp and Front Turn-Signal Lamp 54-31
The special tool (MB991223) should always be used to measure voltages and resistance when carrying
out troubleshooting.
DIAGNOSTIC FUNCTION
<VEHICLES WITH ETACS-ECU>
MUT-II 1. Connect the MUT-II to the diagnosis connector.
2. If a buzzer of the MUT-II sounds once when a switch
is operated (ON/OFF), the ETACS-ECU input signal for
that switch circuit system is normal.
Trouble symptoms Trouble symptoms Inspection Reference

procedure page
Communication with MUT-II is impossi- Communication with all systems is 1 54-32

ble. <Vehicles with ETACS-ECU> impossible.
Communication with one-shot pulse input 2 54-32

signal only is impossible.
The lighting monitor buzzer doesn’t sound under the following conditions while tail 3 54-32
lamps or headlamps illuminate.
D When the ignition switch is turned to OFF and the driver’s side door is open.
Headlamp leveling does not occur when the headlamp leveling switch is operated. 5 54-34
The headlamps do not illuminate when the vehicle is in the following condition and the 6 54-35
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
The headlamps do not switch off when the vehicle is in the following condition and the 7 54-36
lighting switch is moved to the TAIL position.
<Vehicles with daytime running lamp system>
D Ignition switch: OFF

Communication with MUT-II is impossible. (Communica- Probable cause
tion with all systems is impossible.)
The cause is probably a defective power supply system (including ground) for the D Malfunction of connector
Refer to GROUP 13A - Troubleshoot-

ing.
Communication with the MUT-II is impossible. (Commu- Probable cause
nication with the one-shot pulse input signal only is
impossible.)
The cause is probably a defective one-shot pulse input circuit system of the diagnosis D Malfunction of connector
line. D Malfunction of harness wire
OK NG
Check the harness wire between the Check the following connectors: Repair
diagnosis connector and junction block. C-20, C-134
NG OK
NG
Repair Check trouble symptom. Replace the ETACS-ECU.
The ignition switch is turned to the “OFF” position and the Probable cause
driver’s side door is opened while the tail lamps or
headlamps are operating, but the lighting monitor buzzer
does not sound.
The cause is probably a defective lighting switch input circuit system or a defective D Malfunction of driver’s side door switch
driver’s side door switch input circuit system. D Malfunction of harness or connector
D Malfunction of BUZZER-ECU or ETACS-ECU
Driver’s side door switch input circuit

system inspection
(Refer to Inspection Procedure 4.)
OK
NG
C-20, C-134
OK
NG OK
Check trouble symptom. Check the harness wire between the Replace the BUZZER-ECU or
junction block and column switch. ETACS-ECU.
NG
Repair
Driver’s side door switch input circuit system inspection
NG
Door switch inspection Replace
(Refer to GROUP 42 – Door Assembly.)
OK
NG
Door switch earth inspection Repair
OK
NG NG
Disconnect the door switch connector Check the following connectors: Repair
E-19 <L.H. drive vehicles>, L.H. drive vehicles: E-19, C-144, C-145
E-08 <R.H. drive vehicles> R.H. drive vehicles: E-08, C-144, C-145
and measure at the harness side.
OK
D Voltage between the terminal No.
2 and body earth NG
OK: 5 V door switch and junction block, and
OK repair if necessary.

NG
Replace the BUZZER-ECU or

ETACS-ECU.
Inspection procedure 5
Headlamp leveling does not occur when the headlamp Probable cause
leveling switch is operated.
The cause is probably a malfunction of the headlamp leveling switch circuit system D Malfunction of fuse
or a malfunction of the headlamp leveling unit circuit system. D Malfunction of the headlamp leveling switch
If there is a blown fuse, there may also be a short-circuit in a harness. D Malfunction of connector
D Malfunction of harness
D Malfunction of the headlamp leveling unit
NG
Headlamp leveling switch check Replace
(Refer to P.54-42.)
OK
NG NG
Disconnect the headlamp leveling Check the following connectors: Repair
switch connector C-94 and measure at C-94, A-33
the harness side. OK
D Continuity between terminal No.3
- earth NG
Check trouble symptoms. Check the harness between the head-
OK: Continuity lamp leveling switch and body earth.
Repair, if necessary.
OK
1. NG NG
Disconnect the headlamp leveling unit Check the following connectors: Repair
connectors A-12, A-33 and measure at A-12, A-33, C-74, C-115
the harness side. Both the left and right
connectors of the headlamp leveling unit OK
should be checked. NG
1 Voltage between terminal No.1 - Check trouble symptoms. Check the harness between the head-
earth lamp relay and the headlamp leveling
OK: System voltage unit
2 Continuity between terminal No.2 - Repair, if necessary.
earth
OK: Continuity 2. NG NG
A-12, A-33
OK
OK NG
Check trouble symptoms. Check the harness between the body
earth and the headlamp leveling unit.
NG NG
Disconnect the headlamp leveling unit Check the following connectors: Repair
(LH), headlamp leveling unit (RH) and A-12, A-33, C-115, C-74, C-94
headlamp leveling switch connectors OK
A-12, A-33, C-94 and measure at the
harness side. NG
Check trouble symptoms. Check the harness between the head-
D Continuity between terminal No. 3 lamp leveling switch and the headlamp
of the headlamp leveling unit (both) leveling unit (both).
and terminal No. 4 of the headlamp Repair, if necessary.
leveling switch.
OK: Continuity
OK
Malfunction of the headlamp leveling Replace

unit.
The headlamps do not illuminate when the vehicle is in the Probable cause
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
The cause is probably a malfunction of the daytime running lamp control unit (DRL-ECU) D Malfunction of fuse
circuit system. If there is a blown fuse, there may also be a short-circuit in a harness. D Malfunction of connector
D Malfunction of the DRL-ECU
NG
Headlamp relay check (Refer to Replace
P.54-42.)
OK
1. NG NG
Disconnect the DRL-ECU connector Check the following connectors: Repair
A-37 and measure at the harness side. A-37, C-14, C-63, C-132, C-131
OK
1. Voltage between terminal (No.1) and
earth NG
Check trouble symptoms. Check the harness between the DRL-
OK: System voltage ECU and the ignition switch. Repair, if
2. Voltage between terminal (No.9) and necessary.
earth
3. Continuity between terminal (No.2) Check the following connectors:
and earth A-37, C-14, C-116, B-18X
OK: Continuity OK
OK 3. NG NG
ECU and the headlamp relay. Repair,
if necessary.

A-37, C-14
OK
NG
ECU and the body earth. Repair, if nec-
essary.
Malfunction of the DRL-ECU. Replace

The headlamps do not switch off when the vehicle is in the Probable cause
following condition and the lighting switch is moved to the
TAIL position.
<Vehicles with daytime running lamp>
D Ignition switch: OFF
The cause is probably a malfunction of the daytime running lamp control unit (DRL-ECU) D Malfunction of fuse
circuit system. If there is a blown fuse, there may also be a short-circuit in a harness. D Malfunction of connector
D Malfunction of the tail lamp relay
D Malfunction of the DRL-ECU
NG
Lighting switch check Replace
(Refer to P.54-41.)
OK
NG NG
Disconnect DRL-ECU connector A-37 Check the following connectors: Repair
and measure at the harness side. A-37, C-14
D Continuity between terminal (2) -
OK
earth
OK: Continuity NG
ECU and body earth.
OK Repair, if necessary.
Tail lamp relay check (Refer to P.54-40.) Replace
OK
NG NG
Disconnect the DRL-ECU connector Check the following connectors: Repair
A-37 and measure at the harness side. A-37, C-14, C-116, B-14X
D Continuity between terminal (5) -
OK
earth
Check trouble symptoms. {{36#1}}
OK
Malfunction of the DRL-ECU Replace

HEADLAMP AIMING
<USING A BEAMSETTING EQUIPMENT>
1. The headlamps should be aimed with the proper
beamsetting equipment, and in accordance with the
equipment manufacture’s 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
driver’s position.
2. Set the distance between the screen and the centre marks
of the headlamps as shown in the illustration.
Screen
5m
(V) 3. Check if the beam shining onto the screen is at the

standard value.
Distance of Standard value:
vertical direction Lamp centre
<For lower beam adjustment>
(H) (Vertical direction)
15 60 mm below horizontal (H)
(Horizontal direction)
High intensity zone Position where the 15_ sloping section
intersects the vertical line (V)
Standard value:
<For upper beam adjustment>
(V)
Lamp centre (Vertical direction)
22 mm below horizontal (H)
(H)
Parallel to direction of vehicle travel
Centre of high Distance Caution
intensity zone High intensity of vertical
zone direction 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.
Caution
Horizontal direction ad-
justment (Lower beam) Be sure to adjust the aiming adjustment screw in
the tightening direction.
INTENSITY MEASUREMENT 54200100135
Using a photometer, and following its manufacture’s instruction

Horizontal direction manual, measure the headlamp intensity and check to be
adjustment sure that the limit value is satisfied.
(Upper beam)
Vertical direction
Limit: 30,000 cd or more
adjustment NOTE
(Upper beam)
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 54200130189
<Headlamp Bulb>
2. Remove the socket cover.
Socket cover
Spring 3. Unhook the spring which secures the bulb, and then
Spring 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.
HEADLAMP AND FRONT TURN-SIGNAL LAMP 54200240141

CAUTION: SRS
spring, refer to GROUP 52B - Service
Spring.
5 Nm
5 Nm
4 5
6
5 Nm
1 3
1. Column switch <Lighting switch and Headlamp removal steps

dimmer/passing switch> AA" 4. Radiator grille
(Refer to GROUP 37A - Steering 5. Front turn-signal lamp
Wheel and Shaft.) 6. Headlamp
Headlamp leveling switch removal

steps
2. Switch bezel
3. Headlamp leveling switch
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 A- Connector B-

terminal No. terminal No.
1 2 3 4 6 3 5 6 7 8 9
LIGHTING OFF
SWITCH
TAIL
HEAD
DIMMER/ LOWER
PASSING
UPPER
SWITCH
PASSING *1
*2
TURN- RH
Connector B SIGNAL
OFF
LAMP
SWITCH LH
NOTE
1. *1 indicates continuity when the dimmer switch is in the lower
position.
2. *2 indicates continuity when the dimmer switch is in the upper
position.
HEADLAMP RELAY AND TAIL LAMP RELAY CHECK

Headlamp relay
1 3 4 5
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 measure- Switch position
ment terminal No.
0 1 2 3 4
Between 3 and 4 W 1,235 1,114 977 862 747
Between 4 and 6 W 548 669 806 921 1,036
Between 3 and 6 W 1,003
DAYTIME RUNNING LAMP RELAY CHECK

1 2 3 4
Daytime running Supplied
lamp relay
Not supplied
54-44 CHASSIS ELECTRICAL - Side Turn-signal Lamp
SIDE TURN-SIGNAL LAMP 54200060105
SPECIAL TOOL
MB990784 Ornament remover Removal of side turn-signal lamp
REMOVAL SERVICE POINT 54200330091

MB990784
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 "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.
Fender panel
CHASSIS ELECTRICAL - Front Fog Lamp 54-45
FRONT FOG LAMP 54200030069
Front fog lamp aiming Vertical direction 100 mm below horizontal (H)
Horizontal direction Parallel to direction of vehicle travel

MB990784 Ornament remover Removal of switch garnish
Parabola type Unit: mm ON-VEHICLE SERVICE 54200110138
Lamp FRONT FOG LAMP AIMING

centre 1. Measure the centre of the fog lamps, as shown in the
76
illustration.
28
Projector type
37
Lamp
centre
49
2. Set the distance between the screen and the centre of

Screen
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 driver’s position.
4. With the engine running at 2,000 r/min, aim the fog lamp.
5m
54-46 CHASSIS ELECTRICAL - Front Fog Lamp
5 Check if the beam shining onto the screen is at the

Lamp centre
standard value.
Distance of
vertical direction Standard value:
(Vertical direction)
100 mm below horizontal (H)
Parallel to direction of vehicle travel
High intensity zone
Centre of high
intensity zone
Parabola type NOTE

The horizontal direction is non-adjustable. If the deviation
Adjusting of the light beam axis exceeds the standard value, check
screw to be sure that the mounting location or some other point
is not defective.
Caution
When making the aiming adjustment, be sure to mask
those lamps which are not being adjusted.
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
CHASSIS ELECTRICAL - Front Fog Lamp 54-47
FRONT FOG LAMP 54200150161
5
4
5
4
Front fog lamp switch removal Front fog lamp removal steps
steps 3. Fog lamp bezel
1. Side air outlet 4. Fog lamp
2. Front fog lamp switch D Front bumper (Refer to GROUP 51.)
5. Fog lamp bracket
54-48 CHASSIS ELECTRICAL - Rear Combination Lamp
REAR COMBINATION LAMP 54200060471
SPECIAL TOOLS
MB991502 MUT-II sub ETACS-ECU input signal checking
assembly
MB990784 Ornament remover Removal of side air outlet (L.H.)

CHASSIS ELECTRICAL - Rear Combination Lamp 54-49
REAR COMBINATION LAMP 54200450094

Caution: SRS
spring, refer to GROUP 52B - SRS Service
Spring.
3
2
<Sedan>
5 Nm
4
<Wagon>
5 6
5 Nm
9
5 Nm
7 8
1. Column switch <Lighting switch and D Rear end side trim (L.H.)
turn-signal lamp switch> D Side box (L.H.)
(Refer to GROUP 37A - Steering AA" 4. Rear combination lamp
Wheel and Shaft.) Rear combination lamp removal
steps <Wagon>
Rear fog lamp switch removal 5. Maintenance lid
steps 6. Tailgate lamp lid
2. Side air outlet 7. Rear combination lamp
3. Rear fog lamp switch D Tail gate waterproof film (Refer to
GROUP 42.)
8. Tailgate lamp
Rear combination lamp removal 9. Packing
steps <Sedan>
54-50 CHASSIS ELECTRICAL - Rear Combination Lamp

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.
Trunk 2. Remove the rear combination lamp.
room rear
side trim
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 54-51
HIGH MOUNTED STOP LAMP 54200510204

<Sedan> 3 <Wagon>
2
1 1
4
3
Removal steps <Sedan> Removal steps <Wagon>

1. Socket assembly 1. Cover
2. Bulb 2. Lamp unit
3. High mounted stop lamp 3. Bulb
4. Socket assembly
54-52 CHASSIS ELECTRICAL - Rheostat
RHEOSTAT 54200600093
2
Removal steps
1. Meter bezel assembly
2. Rheostat
40W
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.
CHASSIS ELECTRICAL - Hazard Warning Lamp Switch 54-53
HAZARD WARNING LAMP SWITCH 54200660121
Removal steps
D Center console panel (Refer to
GROUP 52A.)
D A/C-ECU or heater control panel
AA" 1. Center outlet assembly
2. Hazard warning lamp switch

AA" CENTER OUTLET ASSEMBLY REMOVAL
Press the tabs indicated in the illustration, and pull the center
outlet assembly to remove it.
Switch Terminal No.

position
1 2 3 4 5 6 7 9 - 10
OFF ILL
ON ILL
54-54 CHASSIS ELECTRICAL - Horn/Cigarette Lighter
HORN 54300800038
Theft-alarm
Horn relay horn relay INSPECTION
1 3 4 5
Power is not supplied
Power is supplied
CIGARETTE LIGHTER 54300570083
Element
Spot INSPECTION
D Take out the plug, and check for a worn edge on the
element spot connection, and for shreds of tobacco or
other material on the element.
D Using a circuit tester, check the continuity of the element.
CHASSIS ELECTRICAL - Clock 54-55
CLOCK 54300060436
SPECIAL TOOL
MB990784 Ornament remover Removal of center display bezel
CLOCK 54300590072

1
2
Removal steps
AA" 1. Center display bezel
AA" 2. Clock

AA" CENTER DISPLAY BEZEL/CLOCK REMOVAL
Use the special tool (MB990784) to pry up the tabs indicated
in the illustration, and remove the center display bezel and
the clock.
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 A- 7

travelling.
Noise sometimes appears on FM during travelling. A- 8
Ever-present noise. A- 9
Radio When switch is set to ON, no power is available. B- 1
No sound from one speaker. B- 2
There is noise but no reception for both AM and FM or no sound B- 3

from AM, or no sound from FM.
Insufficient sensitivity. B- 4
Distortion on AM or on both AM and FM. B- 5
Distortion on FM only. B- 6
Too few automatic select stations. B- 7
Insufficient memory (preset stations are erased). B- 8
NOTE
Refer to problem symptoms of AM radio for MW radio.
CHASSIS ELECTRICAL - Radio and Tape Player 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 Motor antenna won’t extend or retract. D- 1
Motor antenna extends and retracts but does not receive. D- 2
CHART
A. NOISE
A - 1 Noise appears at certain places when travelling (AM).
No Yes
Is there a particular structure? Do the following measures eliminate the OK
noise?
Yes
1. Change to a different station with
a strong signal to boost resistance
Find out the following information from to interference.
2. Suppress high tones to reduce
the user:
noise.
1. Place 3. Extend antenna completely.
2. Locality conditions (valley, moun-
tain, etc.) No
3. Name and frequency of stations
affected by noise
If due to vehicle noise: If due to external noise:

It may not be possible to prevent noise In almost all cases, prevention on the
if the signal is weak. receiver side is impossible. Weak sig-
nals especially are susceptible to inter-
ference.
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.
A - 2 Noise appears at certain places when travelling (FM).
Yes
Do the following measures eliminate the noise? OK
D Change to a different station with a strong signal to boost
resistance to interference.
D Suppress high tones to reduce noise.
D Extend antenna completely.
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 3. If a direct signal hits the antenna at the same

About FM waves: time as a signal reflected by obstructions such
FM waves have the same properties as light, and as mountains or buildings, interference of the
can be deflected and blocked. Wave reception is two signals will generate noise. During
not possible in the shadow of obstructions such travelling, noise will appear each time the
as buildings or mountains. vehicle’s antenna passes through this kind of
1. The signal becomes weak as the distance from obstructed area. The strength and interval of
the station’s transmission antenna increases. the noise varies according to the signal strength
Although this may vary according to the signal and the conditions of deflection. <This is called
strength of the transmitting station and multipath noise, and is a repetitious buzzing.>
intervening geographical formation or buildings, 4. Since FM stereo transmission and reception
the area of good reception is approx. 20 - 25 has a weaker field than monaural, it is often
km for stereo reception, and 30 - 40 km for accompanied by a hissing noise.
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 FM Signal Characteristics and Signal Interference
First fading
interference
For stereo: Multipath interference
10 kW 20 - 25 km
output FM
broadcast For monaural:
30 - 40 km
For home stereos:
80 - 90 km
A - 3 Mixed with noise, only at night (AM).
The following factors can be considered as possible and a change to a different station or the
causes of noise appearing at night. appearance of a beating sound* may occur.
1. Factors due to signal conditions: Due to the Beat sound*: Two signals close in frequency
fact that long-distance signals are more easily interfere with each other, creating a repetitious
received at night, even stations that are high-pitched sound. This sound is generated
received without problem during the day may not only by sound signals but by electrical
experience interference in a general worsening waves as well.
of reception conditions. The weaker a station 2. Factors due to vehicle noise: Alternator noise
is the more susceptible it is to interference, may be a cause.
No
Is the noise still obvious even with the
lamps OFF?
Yes
Yes
Do the following measures eliminate the OK
noise?
D Tune to a station with a strong signal.
D Tune to a station with a strong signal
without completely extending the
antenna.
No
Yes
Does the noise fade away when the OK
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.
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? Inspect the vehicle’s noise suppressor. (Refer to A-6.)
D Tune to a station with a strong signal. Yes
D Extend the antenna completely. OK
D Adjust the sound quality to suppress high tones.
No
No
Is the radio body earth mounted securely? Securely tighten the nuts for the body
earth.
Yes
No
Is the antenna plug properly connected to the radio? Correctly attach the antenna plug.
Yes
No
Is the antenna itself in good condition or is it properly Clean the antenna plug and earth wire
mounted? mounting area. Mount the antenna se-
curely.
Yes
Yes
Is the noise eliminated? OK
No
If there is more noise than other radios, consult a service

centre.
NOTE of FM waves of noise or distortion generated by

About noise encountered during FM reception only. typical noise interference (first fading and
Due to differences in FM and AM systems, FM multipath). (Refer to A - 2.)
is not as susceptible as AM to interference from <Noise (hissing) occurs in weak signal areas such
engines, power lines, lightning, etc. On the other as mountainous regions, but this is not due to a
hand, there are cases due to the characteristics problem with the radio.>
A - 5 There is more noise either on AM or on FM.
1. There is much noise only on AM.

Due to differences in AM and FM systems,
AM is more susceptible to noise interference.
Were conditions such as the following present when noise was

received?
D Lightning was flashing. A motorcycle was passing. Yes
D A vehicle passed close by, but it appeared to be a vehicle
generating a particularly large amount of noise radiation.
D Passed beneath a power line. Passed under a bridge.
D Passed beneath a telephone line.
D Passed close by a signal generator.
D Passed close by some other source of electrical noise.
No
Yes
Continue to check for static; when static is detected, check for Noise prevention on the radio side is difficult. If the problem is
the conditions listed above. 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. distortion generated by typical noise

Due to differences in FM and AM systems, interference (first fading and multipath). (Refer
FM is not as susceptible as AM to interference to A - 2) <Noise (hissing) occurs in weak signal
from engines, power lines, lightning, etc. On areas such as mountainous regions, but this
the other hand, there are cases due to the is not due to a problem with the radio.>
characteristics of FM waves of noise or
A - 6 There is noise when starting the engine.
Noise type Sounds Conditions Cause Remedy

are in parentheses ( ).
AM, FM: Ignition D Increasing the en- D Mainly due to the D Check or replace the earth cable.
noise (Popping, gine speed caus- spark plugs.
snapping, cracking, ing the popping D Due to the engine
buzzing) sound to speed noise.
up, and volume Earth cable
decreases.
D Disappears when
the ignition switch
is turned to ACC.
D Check or replace the noise capacitor.
Other electrical - Noise may appear as Repair or replace electrical components.

components electrical compo-
nents become older.
Static electricity D Disappears when Occurs when parts Return parts or wiring to their proper
(Cracking, crinkling) the vehicle is or wiring move for position.
completely some reason and
stopped. contact metal parts
D Severe when the of the body.
clutch is engaged.
D Various noises Due to detachment Tighten the mounting bolts securely.

are produced de- from the body of the Cases where the problem is not
pending on the front hood, bumpers, eliminated by a single response to one
body part of the exhaust pipe and area are common, due to several body
vehicle. muffler, suspension, parts being imperfectly earthed.
etc.
Caution passes A.C. current, impedance (resistance

1. Connecting a high tension cable to the noise against A.C.) decreases, and current flow is
filter may destroy the noise filter and should facilitated. A noise suppressing condenser
never be done. which takes advantage of this property is
2. Check that there is no external noise. Since inserted between the power line for the noise
failure caused by this may result in source and the earth. This suppresses noise
misdiagnosis due to inability to identify the by earthing the noise component (A.C. or pulse
noise source, this operation must be signal) to the body of the vehicle.
performed. 2. Coil
3. Noise prevention should be performed by The coil passes D.C. current, but impedance
suppressing strong sources of noise step rises as the number of waves increases relative
by step. to the A.C. current. A noise suppressing coil
NOTE which takes advantage of this property is
1. Capacitor inserted into the power line for the noise source,
The capacitor does not pass D.C. current, but and works by preventing the noise component
as the number of waves increases when it from flowing or radiating out of the line.
A - 7 Some noise appears when there is vibration or shocks during travelling.
No
Are connectors properly connected? Ensure proper connection.
Yes
No
Does noise appear when the radio switch is turned on while the Static electricity noise:
vehicle is stopped and the radio is struck while tuned away from Body static electric from the shock absorber rubber bushings used
a station? to prevent vibration, tyres, etc. occurs because of separation from
the earth, causing a buzzing noise. Since no measures can be
Yes taken on the radio side, other steps should be taken to discharge
the static electricity of the vehicle body.
No
Is the radio correctly earthed? (Is the mounting screw tightened Tighten the screw securely.
securely?)
Yes
No
Is the antenna correctly earthed? (If noise appears when the antenna If rust is present at the antenna earth screw, clean and tighten
is moved, this means the earth is not securely connected.) the earth securely.
Yes
Repair or replace radio.
A - 8 Noise sometimes appears on FM during travelling.
Yes
Does the problem clear up when returned? OK
No
Yes
Does the problem appear only in certain locations and only with Due to electrical field conditions. (Multipath noise*, fading noise*).
certain stations?
No
No
Are connectors properly connected? Check connector connections.
Yes
No
Does noise appear when the radio switch is turned on while the Static electricity noise:
vehicle is stopped and the radio is struck while tuned away from Body static electric from the shock absorber rubber bushings used
a station? to prevent vibration, tyres, etc. occurs because of separation from
the earth, causing a buzzing noise. Since no measures can be
Yes taken on the radio side, other steps should be taken to discharge
the static electricity of the vehicle body.
No
Is the radio body correctly earthed? (Is the mounting screw tightened Tighten the screw securely.
securely?)
Yes
No
Is the antenna correctly earthed? (If noise appears when the antenna If rust is present at the antenna earth screw, clean and tighten
is moved, this means the earth is not securely connected.) the earth securely.
Yes
* About multipath noise and fading noise obstruction and enters the receiver with
Because the frequency of FM waves is a slight time delay relative to the direct
extremely high, it is highly susceptible to effects signal (repetitious buzzing).
from geological formations and buildings. D Fading noise
These effects disrupt the broadcast signal and This is a buzzing noise that occurs when
obstruct reception in several ways. the broadcast beam is disrupted by
D Multipath noise obstructing objects and the signal strength
This describes the echo that occurs when fluctuates intricately within a narrow range.
the broadcast signal is reflected by a large
A - 9 Ever-present noise.
Noise is often created by the following factors, and For this reason, if there are still problems with noise
often the radio is OK when it is checked individually. even after the measures described in steps A - 1
D Travelling conditions of the vehicle to A - 8 have been taken, get information on the
D Terrain of area travelled through factors listed above as well as determining whether
D Surrounding buildings the problem occurs with AM or FM, the station
D Signal conditions names, frequencies, etc., and contact a service
D Time period centre.
B. RADIO
B - 1 No power is supplied when the switch is set to ON.
Yes
Is dedicated fuse No. 6 blown or is the circuit open? Replace fuse or repair harness.
No
No
Is the connector at the back of the radio connected properly? Connect connector securely.
Yes
No
Disconnect and check the connector at the rear of the radio. Is Repair harness.
the ACC power (12 V) being supplied to the radio?
Yes
B - 2 No sound from one speaker.
Yes
Check to see if there is any sound when Repair or replace radio.
attached to another radio.
No
Yes
Remove the connector on the back of It conducts electricity but is shorted out. Repair speaker harness.
the radio and check the speaker harness
for conductance.
No
Yes
Check the speaker for conductance. Repair speaker harness and ensure
proper connection of relay connectors.
No
Repair or replace speaker.

B - 3 There is noise but no reception for both AM and FM or no sound from AM, or no sound from
FM.
Yes
Is the check being conducted under spe-
cial electrical field conditions?
No Example: In an underground
garage or inside a building.
Yes
Is proper performance obtained when OK
the vehicle is moved?
No
Yes
Does tuning solve the problem? OK
No
No
Are the antenna plug and radio unit properly connected? Reconnect
Yes
Yes
Does the problem disappear if connected to another radio? Repair or replace radio.
No
Replace the antenna.
B - 4 Insufficient sensitivity.
Yes
garage or inside a building.
Yes
No
Yes
Does tuning solve the problem? OK
No
Yes
Is the problem limited to the reception of a specific radio Electrical field condition related*
station from a specific position? (multipath noise or fading noise)
No
No
Is the antenna plug properly connected to the unit? Ensure proper connection.
Yes
Yes
Does the problem disappear when a different radio is con- Repair or replace radio.
nected?
No
* For multipath noise and fading noise problems, refer to P. 54-63.

B - 5 Distortion on AM or on both AM and FM.
Occasional Yes
How much distortion is there? Distortion in the vicinity of the radio sta- Excessive antenna input
tion
Constant
No
Yes
Are the speaker cords in contact with the cone paper? Remove cords away from cone paper.
No
Yes
Remove the speakers and check for torn cone paper or foreign Repair or replace speakers.
objects.
No
Yes
Check for deformation with speaker installed. Install speaker securely.
No
B - 6 Distortion on FM only
No
Does the distortion persist when the radio is tuned to another station? Due to weak electrical field of radio station
Yes
Yes
Does distortion increase or decrease when the vehicle is moved? Due to multipath noise
No
B - 7 Too few automatic select stations.
Yes
garage or inside a building
Yes
No
No
Is the antenna plug properly connected to the equipment? Ensure proper connection.
Yes
Yes
Does the equipment work properly if the radio is changed? Repair or replace radio.
No

B - 8 Insufficient memory (preset stations are erased).
Yes
No
No
Disconnect and check the connector at the rear of the radio. Repair harness.
Is the memory backup (battery) power being supplied?
Yes
C. TAPE PLAYER
C - 1 Cassette tape will not be inserted.
Yes
Are there any foreign objects in the tape player? Remove the object(s)*1
No
*1
Attempting to force a foreign object (e.g., a coin or clip, etc.) out
of the tape player may damage the mechanism. The player should
be taken to a service dealer for repair.
Yes
Does the tape player work if another tape is inserted? Replace tape*2
No
*2
Repair or replace tape player. Ensure that the tape label is not loose, that the tape itself is not
deformed and that the tape is tightly wound. Also, tape of C-120
or greater length often get caught in the mechanism and should
not be used.
C - 2 No sound (even after a tape has been inserted).
Yes
No
No
Is connector at rear of radio connected tightly? Connect connector firmly.
Yes
Yes
Disconnect connector at rear of radio. Is ACC power being supplied Repair or replace tape player.
to the radio?
No
Repair harness.
C - 3 No sound from one speaker.
Yes
Clean the tape player head and check OK
again.
No
Yes
Replace the tape player and check again. Repair or replace tape player.
No
Yes
Remove the connector on the back of the radio and check It conducts electricity but is Repair harness.
the speaker harness for conductance. shorted out.
No
Yes
Check the speaker for conductance. Repair harness.
No
C - 4 Sound quality is poor, or sound is weak.
Yes
Does the player play properly when another tape* is inserted? OK
No
*:
D Ensure that the tape label is not loose, that the tape
itself is not deformed and that the tape is tightly wound.
D Tapes of C-120 or greater length often get caught in
the mechanism and should not be used.
Yes
Does the player play properly when the tape player head is cleaned? OK
No
Yes
Is proper operation obtained when the tape player is replaced? Repair or replace tape player.
No
C - 5 Cassette tape will not be ejected.
The problems covered here are all the result of also possible, and attempting to force the tape out
the use of a bad tape (deformed or not properly of the player can cause damage to the mechanism.
tightened) or of a malfunction of the tape player The player should be taken to a service dealer
itself. Malfunctions involving the tape becoming for repair.
caught in the mechanism and ruining the case are
C - 6 Uneven revolution. Tape speed is fast or slow.
Yes
Does the player play OK if the tape*1 is changed? OK
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? Remove foreign object(s).
No
*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? Clean.
Pinch roller Head Capstan roller
No
Repair or replace tape player.
C - 7 Faulty auto reverse.
Yes
Does the player play OK if the tape* is changed? OK
No
*:
D Ensure that the tape label is not loose, that the tape
itself is not deformed and that the tape is tightly wound.
D Tapes of C-120 or greater length often get caught in
the mechanism and should not be used.
No
Does the problem only occur while the vehicle is being driven? Repair or replace tape player.
Yes
No
Is the tape player properly installed to the vehicle? Ensure tape player installation.
Yes
C - 8 Tape gets caught in mechanism*1.
*1
When the tape is caught in the mechanism, the case may
not eject. When this occurs, do not try to force the tape
out as this may damage the tape player mechanism. Take
the cassette to a service dealer for repair.
Yes
Does the player play OK if the tape*2 is changed? 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 won’t extend or retract.
Clean and polish the surface of the antenna rod.

No
Is the radio power switch ON? Switch it ON.
Yes
No
Is voltage (approx. 12 V) emitted to the radio’s motor antenna terminal? Repair or replace the radio.
Yes
Yes
Is the antenna bent? Repair the bend, or replace the antenna
mast.
No
No
Is the antenna relay OK? Replace the antenna relay.
Yes
No
Is the motor OK? Replace the motor.
Yes
Repair the harness.

D-2 Motor antenna extends and retracts but does not receive.
Is the antenna itself OK?

A
B D
E Ohmmeter measurement locations Result

C
Circuits from F to A, B, C, D and E Continuity
Circuit between G and H Continuity
G Circuits from H to A, B, C, D and E No continuity

No
F Repair or replace it.
Fender
H
Yes
No
Is operation normal when a new antenna assembly is directly Refer to B ”Radio trouble-
installed to the radio? shooting”.
Yes
Replace the feeder cable.

RADIO AND TAPE PLAYER 54400140126

Ashtray and Sunglasses Pocket Removal and
Installation
4
2
3
NOTE 1
: Metal clip position
Removal steps
1. Floor console panel
2. Centre console panel assembly
3. Radio and tape player
4. Radio bracket
5. Box
CHASSIS ELECTRICAL - Speaker 54-73
SPEAKER 54400260266

<Sedan, Wagon>
1
2
4 5
<Sedan>
<Wagon>
9
3 8
7
10
11
Speaker (front door) removal steps Speaker (rear door) removal steps
1. Tweeter cover 6. Rear door trim
<Vehicles with 6 speakers> (Refer to GROUP 42.)
2. Tweeter 7. Speaker
<Vehicles with 6 speakers> 8. Speaker cover
3. Front door trim
(Refer to GROUP 42.) Speaker (rear shelf) removal steps
4. Speaker
5. Speaker cover 9. Speaker garnish
10. Speaker
11. Speaker bracket
54-74 CHASSIS ELECTRICAL - Antenna
ANTENNA 54400290180

<Sedan - Vehicles with motor antenna>
2
1
<Sedan - Vehicles with pole antenna>
Antenna feeder cable removal Motor antenna or pole antenna

steps removal steps
1. Radio and tape player D Trunk side trim (L.H.)
D Instrument panel (Refer to GROUP 52A.)
(Refer to GROUP 52A.) 3. Ring nut
D Front pillar trim 4. Base
(Refer to GROUP 52A.) 5. Motor antenna
D Centre pillar trim 6. Pole antenna
D Rear pillar trim
D Headlining
2. Antenna feeder cable
CHASSIS ELECTRICAL - Antenna 54-75
<Wagon>
3
4
Antenna feeder cable removal Antenna (rear roof) removal steps

steps 3. Rod assembly
1. Radio and tape player D Headlining
D Instrument panel 4. Cover
D Front pillar trim 5. Packing
D Centre pillar trim
D Quarter upper trim
D Headlining
2. Antenna feeder cable
54-76 CHASSIS ELECTRICAL - Antenna
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
Antenna pole it, together with the rack cable.
Rack cable
3. Draw out the antenna pole to the maximum extension.

Rack cable teeth
NOTE
Luggage compartment side
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
5. Turn the rack cable teeth towards the rear of the vehicle
Rack cable (right 90_) so that the rack cable meshes with the motor
teeth 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
Rear of the vehicle rack cable.
8. After tightening the ring nut, check the movement of the
antenna by turning the radio switch ON and OFF.
CHASSIS ELECTRICAL - Rear Window Defogger 54-77
REAR WINDOW DEFOGGER 54300720488
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOM
Trouble symptom Reference page
Rear window defogger does not operate. <Vehicles with Refer to GROUP 55.
automatic A/C>
Normal characteristic curve

Voltage PRINTED-HEATER LINE CHECK

1. Run engine at 2,000 r/min. Check heater element with
A (Centre point) battery at full.
approx. 6 V 2. Turn ON rear window defogger switch. Measure heater
element voltage with circuit tester at rear window glass
centre A.
Positive Printed Negative Condition is good if it indicates about 6V.
terminal heater line terminal 3. If 12 V is indicated at A, there is a break in the negative
terminals from A.
Abnormal characteristic curve Move test bar slowly to negative terminal to detect where
Voltage voltage changes suddenly (0V).
4. If 0 V is indicated at A, there is a break in the positive
Open-circuit
point terminals from A. Detect where the voltage changes
suddenly (12 V) in the same method described above.
Positive Printed Negative

terminal heater line terminal
REAR WINDOW DEFOGGER RELAY

CONTINUITY CHECK 54300680168
Defogger relay
1 2 3 5
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
1 3 2 4 5
OFF ILL
ON ILL IND
CHASSIS ELECTRICAL - Theft-alarm System 54-79
THEFT-ALARM SYSTEM 54700060070
SPECIAL TOOLS
MB991502 MUT-II sub assen- ETACS-ECU input signal checking
bly
MB991223 Harness set Making voltage and resistance

A A: MB991219 A: Test harness measurements during troubleshooting
B: MB991220 B: LED harness A: Connector pin contact pressure inspection
C: MB991221 C: LED harness B: Power circuit inspection
D: MB991222 adapter C: Power circuit inspection
D: Probe D: Commercial tester connection
B
The special tool (MB991223) should always be used to measure voltages and resistance when carrying
out troubleshooting.
DIAGNOSTIC FUNCTION 54700130030

<VEHICLES WITH ETACS-ECU>
MUT-II 1. Connect the MUT-II to the diagnosis connector.
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 CHASSIS ELECTRICAL - Theft-alarm System

procedure No. page
Communication with MUT-II Communication with all system is not possible. 1 54-80
is not possible. <Vehicles
with ETACS-ECU> Communication with one-shot pulse input signal 2 54-80
only is not possible.
Arming/disarming The system is not armed. 3 54-81

relationship (The security indicator lamp does not illuminate,
and the alarm does not function.)
The arming procedures are followed, but the 4 54-82

security indicator lamp does not illuminate.
(There is an alarm, however, when an alarm
test is conducted after about 20 seconds have
passed.)
The alarm sounds in error when, the system is - 54-83

armed, a door or the tailgate is unlocked by
using the key.

tion with all system is not possible.)
The cause is probably a defect in the power supply system (including earth) for D Malfunction of connector
the diagnosis line. D Malfunction of harness wire
Refer to GROUP 13A - Troubleshooting
tion with one-shot pulse input signal only is not possible.)
The cause is probably a defective one-shot pulse input signal circuit system of D Malfunction of connector
the diagnosis line. D Malfunction of harness wire
OK NG
Check the harness wire between the Check the following connectors: Repair
diagnosis connector and junction block. C-20, C-134, C-144
NG OK
NG
Repair Check trouble symptom. Replace the ETACS-ECU.
The system is not armed. (The security indicator lamp does not illuminate, and the alarm does not
function.)
NG
Check the dedicated fuse No.14. Replace the fuse.
OK
NG
Check the fusible link No.2. Replace the fusible link.
OK
NG
Disconnect the ETACS-ECU connector C-43 and measure at the Check the following connectors:
harness side connector. L.H. drive vehicles: C-144, C-141
D Voltage between the terminal (2) and earth R.H. drive vehicles: C-144, C-141, C-62, C-14
OK
OK Repair

NG
Check the harness wire between the fusible link No.2 and ETACS-
ECU. Repair, if necessary.
NG
Measure at the harness side connector. Check the following connectors:
D Continuity between the terminal (1) and body earth C-131 and C-144
OK: Continuity NG
OK
OK
Repair

NG
Check the harness wire between the ETACS-ECU and body earth.
The arming procedures are followed, but the security indicator lamp does not illuminate. (There is
an alarm, however, when an alarm test is conducted after about 20 seconds have passed.)
NG
Remove the combination meter and check if the security indicator Replace
lamp bulb is burnt out.
OK
NG
Disconnect the combination meter connector D-03, and measure Replace the combination meter.
at the combination meter side.
D Continuity between terminals (10) and (11)
OK: Continuity
OK
NG
Measure at the harness side of the same connector. Check the following connectors:
D Voltage between the terminal (11) and earth L.H. drive vehicles: D-03, C-135, C-144, C-141
OK: System voltage 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.
NG
Disconnect the ETACS-ECU connector C-139, and measure at Check the following connectors:
the harness side. C-139, C-25, D-03
D Earth the terminal (49) and check if the security indicator
lamp illuminates.
OK: Illuminates
OK

MEASUREMENT AT ECU TERMINALS
Terminal No. Item Check condition Normal value
1 Earth - -
2 ECU power supply At all times System voltage
7 Ignition switch (ACC) ON System voltage
OFF 0V
11 Ignition switch (IG1) ON System voltage
OFF 0V
13,19 Front door switch (L.H.) Door open 0V
Door closed 5V
17 Key reminder switch Ignition switch ON (Removed) 0V
OFF (Inserted) 5V
28 Keyless entry Receiver output signal ON 0V

receiver-ECU
OFF 5V
29 Theft-alarm horn relay ON 0V
OFF System voltage
33 Front door lock actuator Lock 5V

switch (R.H.)
Unlock 0V
34 Lock 0V
Unlock 5V
35 Front door lock actuator Lock 5V

switch (L.H.)
Unlock 0V
36 Lock 0V
Unlock 5V
41 Rear door lock actuator Lock 5V

switch (R.H.)
Unlock 0V
42 Lock 0V
Unlock 5V
43 Trunk lid latch switch ON 0V

<Sedan>
OFF 5V
Terminal No. Item Check condition Normal value
44 Trunk lid lock key cylinder ON 0V

switch <Sedan>
OFF 5V
45 Tailgate lock actuator Lock 5V

<Wagon>
Unlock 0V
46 Lock 0V
Unlock 5V
47 Door lock key cylinder Unlock 0V

switch
Neutral 5V
48 Lock 0V
Neutral 5V
49 Combination meter ON 0V
(Security indicator lamp)
OFF System voltage
50 Front door switch (R.H.) ON 0V
OFF 5V
51 Hood switch ON 0V
OFF 5V
55-1
HEATER,
AIR CONDITIONER
AND VENTILATION
MANUAL AIR CONDITIONER . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 7

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . 3 Sight Glass Refrigerant Level Test . . . . . . . . . . 7
Magnetic Clutch Test . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 4
Receiver Drier Test . . . . . . . . . . . . . . . . . . . . . . . . 7
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dual Pressure Switch Check . . . . . . . . . . . . . . . 8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 5 CONTINUED ON NEXT PAGE

WARNING!
MITSUBISHI dealer.
component.
NOTE
55-2
Compressor Drive Belt Adjustment . . . . . . . . . . 8 AUTOMATIC AIR CONDITIONER . . . . 35

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Performance Test . . . . . . . . . . . . . . . . . . . . . . . . 14 GENERAL INFORMATION . . . . . . . . . . . . . . 35
Refrigerant Leak Repair . . . . . . . . . . . . . . . . . . . 15 SERVICE SPECIFICATIONS . . . . . . . . . . . . 35
Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Relay Check . . . . . . . . . . . . . . . . . . . . . . 16 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . 36
Idle-up Operation Check . . . . . . . . . . . . . . . . . . 18 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 36
HEATER CONTROL ASSEMBLY, A/C TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 36
SWITCH AND INSIDE/OUTSIDE AIR
CHANGEOVER SWITCH . . . . . . . . . . . . . . . 19
HEATER UNIT*, HEATER CORE AND
AIR CONDITIONER CONTROL PANEL AND
BLOWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 22
ECU ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 57
RESISTOR, BLOWER FAN AND MOTOR DAMPER MOTOR ASSEMBLY AND
AND INSIDE/OUTSIDE AIR CHANGEOVER POWER TRANSISTOR . . . . . . . . . . . . . . . . . 58
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COMPRESSOR AND TENSION PULLEY
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AIR PURIFIER ASSEMBLY . . . . . . . . . . . . . 27 PHOTO SENSOR . . . . . . . . . . . . . . . . . . . . . . 67
COMPRESSOR AND TENSION PULLEY OUTSIDE AIR TEMPERATURE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
REFRIGERANT LINE . . . . . . . . . . . . . . . . . . 28
HEATER WATER TEMPERATURE
SENSOR* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
CONDENSER AND CONDENSER FAN
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 OTHER MAINTENANCE SERVICE POINTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
VENTILATORS . . . . . . . . . . . . . . . . . . . . . . . . 33
HEATER, AIR CONDITIONER AND VEN-
TILATION <MANUAL AIR CONDITIONER> - General Information 55-3
MANUAL AIR CONDITIONER 55200010190
GENERAL INFORMATION
The heater system uses a two-way-flow full-air-mix refrigerant system has been adopted as a response
system that features high performance and low to restrictions on the use of chlorofluorocarbons.
operating noise, and includes an independent face In addition, an air purifier which carries out fine
air blowing function. The A/C system is basically A/C control has been included.
the same as the conventional system, but a new
Heater unit Type Two-way-flow full-air-mix system
Heater control assembly Dial type
Compressor Model Scroll type <MSC90>
Dual pressure switch High-pressure switch ON ® OFF: 2,942, OFF ® ON: 2,353
kPa
Low-pressure switch ON ® OFF: 196, OFF ® ON: 221
Refrigerant and quantity g R-134a (HFC-134a), Approx. 670 - 710
SAFETY PRECAUTIONS
Because R-134a refrigerant is a hydrofluorocarbon Caution
(HFC) which contains hydrogen atoms in place of Wear safety goggles when servicing the
chlorine atoms, it will not cause damage to the refrigeration system.
ozone layer. R-134a evaporates so rapidly at normal
Refrigerant R-134a is transparent and colourless atmospheric pressures and temperatures that it
in both the liquid and vapour state. Since it has tends to freeze anything it contacts. For this reason,
a boiling point of - 29.8_C, at atmospheric pressure, extreme care must be taken to prevent any liquid
it will be a vapour at all normal temperatures and refrigerant from contacting the skin and especially
pressures. The vapour is heavier than air, the eyes. Always wear safety goggles when
non-flammable, and nonexplosive. The following servicing the refrigeration part of the A/C system.
precautions must be observed when handling Keep a bottle of sterile mineral oil handy when
R-134a. 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.
HEATER, AIR CONDITIONER AND VEN- General Information/
55-4 TILATION <MANUAL AIR CONDITIONER> - Service Specifications/Lubricants
Caution When metering R-134a into the refrigeration system

Do not heat R-134a above 40_C keep the supply tank or cans in an upright position.
In most instances, moderate heat is required to If the refrigerant container is on its side or upside
bring the pressure of the refrigerant in its container down, liquid refrigerant will enter the system and
above the pressure of the system when charging damage the compressor.
or adding refrigerant. Caution
A bucket or large pan of hot water not over 40_C 1. The leak detector for R-134a should be used
is all the heat required for this purpose. Do not to check for refrigerant gas leaks.
heat the refrigerant container with a blow torch 2. Do not allow liquid refrigerant to touch bright
or any other means that would raise temperature metal.
and pressure above this temperature. Do not weld Refrigerant will tarnish bright metal and chrome
or steam clean on or near the system components surfaces, and in combination with moisture can
or refrigerant lines. severely corrode all metal surfaces.
Caution
Keep R-134a containers upright when charging
the system.
Idle speed r/min 4G6 750 ± 50
6A1 650 ± 50
4D6 800 ± 30
Idle-up speed r/min When load by 4G6 750 ± 50

A/C is low
6A1 650 ± 50
4D6 850 ± 50
When load by 4G6 850 ± 50

A/C is high
6A1 900 ± 50
4D6 850 ± 50
Resistor (for blower motor) W LO: 2.30, ML: 1.10, MH: 0.40
Air gap (Magnetic clutch) mm 0.40 - 0.65
Each connection of refrigerant line SUN PAG 56 As required
Compressor refrigerant unit lubricant mL SUN PAG 56 120

TILATION <MANUAL AIR CONDITIONER> - Special Tools/Troubleshooting 55-5

MB991367 Special spanner Removal and installation of armature mounting
nut of compressor
MB991386 Pin
TROUBLESHOOTING PROCEDURES
Trouble symptom Problem cause Remedy Reference
page
When the ignition A/C compressor relay is defective Replace the A/C compressor 55-17
switch is “ON”, relay
the A/C does not
operate. Magnetic clutch is defective Replace the armature plate, 55-65
rotor or clutch coil
Refrigerant leak or overfilling of refrigerant Replenish the refrigerant, re- 55-15
pair the leak or take out some of
the refrigerant
Dual pressure switch is defective Replace the dual pressure 55-28, 29
switch
A/C switch is defective Replace the A/C switch 55-19
Blower switch is defective Replace the blower switch 55-21
Refrigerant temperature switch is defective Replace the refrigerant temper- 55-65
ature switch
Automatic compressor-ECU is defective Replace the automatic com- 55-26
pressor-ECU
Engine-ECU is defective Replace the engine-ECU -
When the A/C is Refrigerant leak Replenish the refrigerant and 55-15
operating, tem- repair the leak
perature inside
the passenger Dual pressure switch is defective Replace the dual pressure 55-28, 29
compartment switch
doesn’t decrease Refrigerant temperature switch is defective Replace the refrigerant temper- 55-65
(cool air is not ature switch
emitted).
Automatic compressor ECU is defective Replace the automatic com- 55-26
pressor-ECU
55-6 TILATION <MANUAL AIR CONDITIONER> - Troubleshooting
Trouble symptom Problem cause Remedy Reference

page
Blower fan and Blower relay is defective Replace the blower relay 55-16
motor doesn’t
turn Blower fan and motor is defective Replace the blower fan and 55-23
motor
Resistor (for blower motor) is defective Replace the resistor 55-23
Blower fan and Short circuit of the harness between the blower Repair the harness -
motor doesn’t fan and motor and the blower switch
stop turning.
Blower relay is defective Replace the blower relay 55-16
When the A/C is Condenser fan motor is defective Replace the condenser fan 55-31
operating con- motor
denser fan or ra-
diator fan does Radiator fan motor is defective Replace the radiator fan motor -
not run Fan control relay is defective Replace the fan control relay 55-17
INSPECTION AT THE AUTOMATIC COMPRESSOR-ECU TERMINAL 55201030041
Terminal Check item Checking requirements Normal condition

No.
1 Input from A/C switch to ECU A/C switch: OFF 0V
A/C switch: ON Battery voltage
2 Output from ECU to A/C compressor A/C compressor relay: OFF Battery voltage
relay
A/C compressor relay: ON 0V
3 Output from ECU to engine-ECU Air thermo sensor detection tempera- Battery voltage
ture: 5_C or less
Air thermo sensor detection tempera- 0V

ture: 8_C or more
4 Earth Always 0V
TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service 55-7
SIGHT GLASS REFRIGERANT LEVEL TEST

The sight glass is a refrigerant level indicator. To check the
refrigerant level, clean the sight glass and start the vehicle
engine. Push the A/C button to operate the compressor, place
the blower switch to high and move the temperature control
lever to max cool. After operating for a few minutes in this
manner, check the sight glass.
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 TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service
High/Low
DUAL PRESSURE SWITCH CHECK 55201040167
pressure side 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.
LOW-PRESSURE HIGH-PRESSURE Items Switch position
SIDE SIDE
OFF ® ON ON ® OFF
ON ON Low-pressure 221 196
side kPa
OFF OFF
High-pressure 2,353 2,942
side kPa
COMPRESSOR DRIVE BELT ADJUSTMENT

55200100101

CHARGING 55200120176
1. With the handles turned back all the way (valve closed),
High-pressure
install the adaptor valve to the low-pressure side of the
Low-pressure valve gauge manifold.
valve 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.
Gauge manifold
NOTE
Charging hose The low-pressure service valve should be connected to
Adapter (yellow)
valve the suction flexible hose.
Charging hose Caution
(blue)
Switch R-134a
(1) Use tools that are suited to R-134a.
R-12 (2) To install the quick joint, press section “A” firmly
connection connection
port port against the service valve until a click is heard.
When connecting, run your hand along the hose
Vacuum
Quick pump while pressing to ensure that there are no bends
joint (for adaptor in the hose.
low Vacuum
pressure) pump 5. Close the high and low-pressure valves of the gauge
Power supply
plug
manifold.
6. Install the vacuum pump adaptor to the vacuum pump.
Switch
7. Connect the vacuum pump plug to the vacuum pump
Low-pressure adaptor.
service valve 8. Connect the charging hose (yellow) to the R-134a
A connection port of the vacuum pump adaptor.
9. Tighten the adaptor valve handle (valve open).
Sleeve
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).
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.)
Caution
If the negative pressure drops, increase the tightness
of the connections, and then repeat the evacuation
procedure from step (12).
Low-pressure
service valve Vacuum pump
16. With the handle turned back all the way (valve open),
Valve open
install the charging valve to the service can.
17. Turn the handle of the adaptor valve back all the way
Valve close (valve closed), remove it from the gauge manifold and
install the service can.
Charging 18. Tighten the handle of the charging valve (valve closed)
valve to puncture the service can.
Adaptor valve
Service can
19. Turn the handle of the charging valve back (valve open)
Charging valve 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).
Service can
(Refrigerant container) 21. Check for gas leaks using a leak detector.
If a gas leak is detected, re-tighten the connections, and
then repeat the charging procedure from evacuation in
step (12).
Caution
Low-pressure The leak detector for R-134a should be used.
service valve
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
compression. Keep the service can upright to ensure
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.
Valve open CORRECTING LOW REFRIGERANT LEVEL IN CASE

Charging valve
THE SERVICE CAN IS USED.
Valve close 1. Install the charging valve with the handle turned all the
Adaptor valve 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.
Charging hose (blue) 3. Connect the charging hose (blue) to the adaptor valve.
Service can 4. Connect the charging hose (blue) to the quick joint (for
(Refrigerant low pressure).
container)
Quick joint (for low pressure) 5. Tighten the handle of the charging valve (valve close),
and pierce the service can.
6. Turn the handle of the adaptor valve to bleed the air.
7. Install the quick joint (for low pressure) to the low-pressure

service valve.
NOTE
Quick joint
(for low pressure) The low-pressure service valve should be connected to
the suction flexible hose.
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
Service can compression. Keep the service can upright to ensure
(Refrigerant container) that refrigerant is changed in gas state.
12. After replenishing is completed, turn the handle of the
adaptor valve all the way back (valve close), and remove
the quick joint.
Low-pressure NOTE
service valve 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.
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 NOTE
Returning the oil will be more effective if it is done while
driving.
Sleeve 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.
Charging hose (blue)
NOTE
The low-pressure service valve should be connected to
Quick joint the suction flexible hose.
Caution
To connect 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
Low-pressure pressing to ensure that there are no bends in the
service valve hose.
6. Place the adaptor valve inside the container and discharge
the refrigerant by opening the handle gradually so that
oil does not gush out.
NOTE
Any oil remaining in the container should be returned
Adaptor valve 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
PERFORMANCE TEST 55200140189

Low-pressure valve High-pressure valve 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
Gauge manifold high-pressure valve of the gauge manifold.
Charging 4. Install the quick joint (for low pressure) to the charging
hose (red) hose (blue), and connect the quick joint (for high pressure)
Charging to the charging hose (red).
hose (blue) 5. Connect the quick joint (for low pressure) to the
A low-pressure service valve and connect the quick joint
Adaptor (for high pressure) to the high-pressure service valve.
valve (for low Sleeve
pressure) NOTE
Adaptor valve The high-pressure service valve is on liquid pipe B and
(for high pressure)
the low-pressure service valve is on the suction flexible
Low- High- hose.
pressure pressure
service service
valve valve Caution
To connect 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
Thermometer
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.
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 HANDLING TUBING AND FITTINGS

LOST CHARGE Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the
If the system has lost all charge due to a leak:
capacity of the entire system. High pressures are
1. Evacuate the system. (See procedure.)
produced in the system when it is operating.
2. Charge the system with approximately one
Extreme care must be exercised to make sure that
pound of refrigerant.
all connections are pressure tight. Dirt and moisture
3. Check for leaks.
can enter the system when it is opened for repair
4. Discharge the system.
or replacement of lines or components. The
5. Repair leaks.
following precautions must be observed. The
6. Replace receiver drier.
system must be completely discharged before
Caution opening any fitting of connection in the refrigeration
Replacement filter-drier units must be system. Open fittings with caution even after the
sealed while in storage. The drier used in system has been discharged. If any pressure is
these units will saturate water quickly upon noticed as a fitting is loosened, allow trapped
exposure to the atmosphere. When pressure to bleed off very slowly.
installing a drier, have all tools and supplies Never attempt to rebend formed lines to fit. Use
ready for quick reassembly to avoid keeping the correct line for the installation you are servicing.
the system open any longer than necessary. A good rule for the flexible hose lines is keep the
7. Evacuate and charge system. radius of all bends at least 10 times the diameter
of the hose.
LOW CHARGE Sharper bends will reduce the flow of refrigerant.
If the system has not lost all of its refrigerant charge; The flexible hose lines should be routed so that
locate and repair all leaks. If it is necessary to they are at least 80 mm from the exhaust manifold.
increase the system pressure to find the leak It is good practice to inspect all flexible hose lines
(because of an especially low charge) add at least once a year to make sure they are in good
refrigerant. If it is possible to repair the leak without condition and properly routed.
discharging the refrigerant system, use the Unified plumbing connections with O-rings, these
procedure for correcting low refrigerant level. O-rings are not reusable.
COMPRESSOR NOISE 55200870033 ADJUSTMENT

You must first know the conditions when the noise 1. Select a quiet area for testing. Duplicate
occurs. These conditions are: weather, vehicle conditions as much as possible. Switch
speed, in gear or neutral, engine temperature or compressor on and off several times to clearly
any other special conditions. identify compressor noise. To duplicate high
Noises that develop during A/C operation can often ambient conditions (high head pressure),
be misleading. For example: what sounds like a restrict air flow through condenser. Install
failed front bearing or connecting rod, may be manifold gauge set to make sure discharge
caused by loose bolts, nuts, mounting brackets, pressure doesn’t exceed 2,070 kPa.
or a loose clutch assembly. Verify accessory drive 2. Tighten all compressor mounting bolts, clutch
belt tension (power steering or alternator). mounting bolt, and compressor drive belt.
Improper accessory drive belt tension can cause Check to assure clutch coil is tight (no rotation
a misleading noise when the compressor is or wobble).
engaged and little or no noise when the compressor 3. Check refrigerant hoses for rubbing or
is disengaged. interference that can cause unusual noises.
Drive belts are speed-sensitive. That is, at different 4. Check refrigerant charge. (See “Charging
engine speeds, and depending upon belt tension, System”.)
belts can develop unusual noises that are often 5. Recheck compressor noise as in Step 1.
mistaken for mechanical problems within the 6. If noise still exists, loosen compressor mounting
compressor. bolts and retorque. Repeat Step 1.
7. If noise continues, replace compressor and
repeat Step 1.
POWER RELAY CHECK 55200880210
BLOWER RELAY
Blower relay 1 3 2 5
Power is supplied
A/C COMPRESSOR RELAY

A/C compressor relay
1 3 4 5
Power is supplied
FAN CONTROL RELAY

Refer to GROUP 14 - Radiator.
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 When load by A/C is
low 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, AIR CONDITIONER AND VEN- Heater Control Assembly, A/C Switch and
TILATION <MANUAL AIR CONDITIONER> - Inside/Outside Air Changeover Switch 55-19
HEATER CONTROL ASSEMBLY, A/C SWITCH AND
INSIDE/OUTSIDE AIR CHANGEOVER SWITCH 55201240017

D Center Console Panel, Side Cover Removal and D Radio, Tape Player Removal and Installation (Refer
Installation (Refer to GROUP 52A - Instrument Panel.) to GROUP 54.)
6
3
4
2
1
Removal steps
"BA 1. Air mix damper cable connection 4. A/C switch
"AA 2. Air outlet changeover damper cable 5. Inside/outside air changeover
connection switch
3. Rear window defogger switch 6. Heater control assembly

"AA AIR OUTLET CHANGEOVER DAMPER CABLE
CONNECTION
Air outlet 1. Set the air outlet changeover control knob on the heater
changeover control assembly to the DEF position.
damper lever 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.
DEF position
"BA AIR MIX DAMPER CABLE CONNECTION

1. Set the temperature control knob on the heater control
assembly to the MAX HOT position.
Air mix 2. Set the air mix damper lever of the heater unit to the
damper MAX HOT position (turn clockwise the damper lever until
lever
it stops), and then connect the cable to the lever.
MAX HOT position

55-20 TILATION <MANUAL AIR CONDITIONER> - Inside/Outside Air Changeover Switch
BLOWER SWITCH CONTINUITY CHECK

1 2 3 4 5 6 7 8
OFF
D (LO)
D (ML)
D (MH)
D (HI)
FRESH INSIDE/OUTSIDE AIR CHANGEOVER SWITCH

position CONTINUITY CHECK
Switch Terminal No.

RECIRC position
position 1 ILL 2 3 IND 4 5 6
RECIRC
FRESH
OFF A/C SWITCH CONTINUITY CHECK

position
Switch Terminal No.
position
1 ILL 2 IND 4 5 7
ON position OFF
ON
TILATION <MANUAL AIR CONDITIONER> - Inside/Outside Air Changeover Switch 55-21
HEATER CONTROL ASSEMBLY 55100130077
8
2
7
5 6
1
4
3
Disassembly steps
1. Knob assembly 5. Heater control panel
2. Bulb harness 6. Nut
AA" 3. Air outlet changeover damper cable 7. Blower switch
AA" 4. Air mix damper cable 8. Control base assembly

AA" AIR OUTLET CHANGEOVER DAMPER
CABLE/AIR MIX DAMPER CABLE REMOVAL
Flat-tipped
screwdriver 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.
Claw
part
55-22 TILATION <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 When removing and installing the heater unit
P.55-33.) from vehicles equipped with SRS, do not let it
D Instrument Panel removal and Installation (Refer bump against the SRS-ECU or the components.
to GROUP 52A.)
Vehicles with automatic A/C
2
5
3 2
6
4
Heater unit and heater core Blower unit removal steps

removal steps 2. Evaporator mounting bolt and nut
D Center reinforcement (Refer to 5. Clip
GROUP 52A - Instrument panel.) 6. Blower unit
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.)
1. Heater hose connection
2. Evaporator mounting bolt and nut
AA" 3. Heater unit
4. Heater core

AA" HEATER UNIT REMOVAL
After sliding the cooling unit towards you slightly, remove
the heater unit.
Heater
unit
HEATER, AIR CONDITIONER AND VEN- Resistor, Blower Fan and Motor, and
TILATION <MANUAL AIR CONDITIONER> - Inside/Outside Air Changeover Damper Motor 55-23
RESISTOR, BLOWER FAN AND MOTOR, AND INSIDE/OUTSIDE
AIR CHANGEOVER DAMPER MOTOR 55100500014

Glove Box Removal and Installation (Refer to GROUP
52A - Instrument Panel.)
3 2
1
Resistor removal steps Inside/outside air changeover

D Under cover (Refer to P.55-33.) damper motor removal
1. Resistor 3. Inside/outside air changeover
damper motor
Blower fan and motor removal
steps
D Under cover (Refer to P.55-33.)
2. Blower fan and motor
BLOWER FAN AND MOTOR CHECK

When battery voltage is applied between the terminals, check
that the motor operates. Also, check that there is no abnormal
noise.
HEATER, AIR CONDITIONER AND VEN- Resistor, Blower Fan and Motor, and
55-24 TILATION <MANUAL AIR CONDITIONER> - 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 Lever operation

terminal
1 2
Moves to the outside air position
Moves to the inside air position
Caution
Cut off the battery voltage when the damper is in the
inside air position or outside air position.
TILATION <MANUAL AIR CONDITIONER> - Evaporator 55-25
EVAPORATOR 55200360165

D Discharging and Charging of Refrigerant (Refer to D Under Cover Removal and Installation (Refer to
P.55-9.) P.55-33.)
D Glove Box, Side Cover and Glove Box Frame Removal
and Installation (Refer to GROUP 52A - Instrument
Panel.)
Piping connection 1
2
3
3
4
5
6
Removal steps
AA" 1. Suction hose connection 4. Drain hose
AA" 2. Discharge pipe connection 5. Plate
3. O-ring "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
55-26 TILATION <MANUAL AIR CONDITIONER> - Evaporator
3
2
7
6
1
8
7 4

7
Disassembly steps
AA" 1. Clip 5. Evaporator case (lower)
2. Evaporator case (upper) 6. Expansion valve
3. Automatic compressor-ECU 7. O-ring
<Manual A/C> 8. Evaporator
4. Air thermo sensor <Automatic A/C>

AA" CLIP REMOVAL
Remove the clips with a flat-tipped screwdriver covered with
a shop towel to prevent damage to case surfaces.
Clip
HEATER, AIR CONDITIONER AND VEN- Evaporator/Air Purifier Assembly/
TILATION <MANUAL AIR CONDITIONER> - Compressor and Tension Pulley 55-27
Resistance kW AIR THERMO SENSOR

20
When the resistance value between the sensor terminals
15
is measured under two or more temperature conditions, the
10 resistance value should be close to the values shown in the
5 graph.
0
- 10 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 D Under Cover Removal and Installation (Refer to
and Installation (Refer to GROUP 52A - Instrument P.55-33.)
Panel.)
Air purifier assembly
COMPRESSOR AND TENSION PULLEY 55200410266
Refer to P.55-61.
55-28 TILATION <MANUAL AIR CONDITIONER> - Refrigerant Line
REFRIGERANT LINE 55200640269

<L.H. DRIVE VEHICLES>
D Discharging and Changing of Refrigerant (Refer to D Oil Reservoir Removal and Installation (Refer to
P.55-9.) GROUP 37A - Power Steering Hoses.)
D Reserve Tank Removal and Installation (Refer to
GROUP 14 - Radiator.)
1
Piping connection
4 2
10
10
10
10 2
10
6 3
5
10
10
8
9
7
Removal steps
AA" 1. Suction pipe 6. Dual pressure switch
2. Clamp and bracket 7. Receiver bracket assembly
AA" 3. Suction flexible hose AA" "AA 8. Receiver assembly
AA" 4. Liquid pipe A 9. Discharge flexible hose
AA" 5. Liquid pipe B AA" 10. O-ring
TILATION <MANUAL AIR CONDITIONER> - Refrigerant Line 55-29
<R.H. DRIVE VEHICLES>
D Discharging and Changing of Refrigerant (Refer to D Reserve Tank Removal and Installation (Refer to
P.55-9.) GROUP 14 - Radiator.)
D Canister Removal and Installation (Refer to GROUP D Oil Reservoir Removal and Installation (Refer to
17.) GROUP 37A - Power Steering Hoses.)
Piping connection
1
5
11 2
11
Compressor oil: 11
SUN PAG 56 11 3
7 6
11
4
11
11
9
10
8
Removal steps
1. Clamp 7. Dual pressure switch
AA" 2. Suction pipe 8. Receiver bracket assembly
3. Clamp and bracket AA" "AA 9. Receiver assembly
AA" 4. Suction flexible hose AA" 10. Discharge flexible hose
AA" 5. Liquid pipe B 11. O-ring
AA" 6. Liquid pipe A
55-30 TILATION <MANUAL AIR CONDITIONER> - Refrigerant Line

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
TILATION <MANUAL AIR CONDITIONER> - Condenser and Condenser Fan Motor 55-31
CONDENSER AND CONDENSER FAN MOTOR 55200670244
Piping connection
O-ring
2
4
1 3
Condenser fan motor removal Condenser removal steps

steps D Discharging and charging of
1. Condenser fan motor and shroud refrigerant (Refer to P.55-9.)
assembly D Air cleaner
2. Condenser fan D Engine coolant draining and supplying
3. Shroud (Refer to GROUP 14 - On-vehicle
4. Condenser fan motor 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 TILATION <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
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.
TILATION <MANUAL AIR CONDITIONER> - Ventilators 55-33
VENTILATORS 55300160119
<Automatic A/C>
3
2
7
8
Under cover removal Rear heater duct and foot

1. Under cover distribution duct removal steps
D Front seat (Refer to GROUP 52A.)
Defroster nozzle and distribution D Floor console assembly (Refer to
duct removal steps GROUP 52A.)
D Floor console assembly (Refer to D Instrument panel and center reinforce-
GROUP 52A.) ment (Refer to GROUP 52A.)
D Instrument panel (Refer to GROUP 7. Rear heater duct (R.H.)
52A.) 8. Rear heater duct (L.H.)
2. Side defroster duct 9. Foot distribution duct
3. Defroster nozzle assembly
NOTE
4. Distribution duct assembly For the center air outlet assembly and the side air outlet
5. Defroster garnish and photo sensor assembly, refer to GROUP 52A - Instrument panel.
6. Center duct assembly
55-34 TILATION <MANUAL AIR CONDITIONER> - Ventilators
<Wagon>
<Sedan>
10
Rear ventilation duct assembly

removal steps
D Rear bumper (Refer to GROUP 51.) NOTE
10. Rear ventilation duct assembly For the front deck garnish, refer to GROUP 51 - Windshield wiper
and washer.
HEATER, AIR CONDITIONER AND VENTILA- General Information/
TION <AUTOMATIC AIR CONDITIONER> - Service Specifications 55-35
AUTOMATIC AIR CONDITIONER 55400010080
GENERAL INFORMATION
The heater system uses a two-way-flow full-air-mix The A/C system is basically the same as the manual
system that features high performance and low air conditioner in which a new refrigerant system
operating noise, and includes an independent has been adopted. However, an A/C control panel
face-directed air flow function. with a reduced number of buttons and more
An air purifier which carries out fine A/C control compact arrangement of necessary functions owing
has been included. to more functions being assigned to each button
has been adopted.
Heater unit Type Two-way-flow full-air-mix system
Heater control assembly Push button type
Compressor Model Scroll type <MSC 90>
Dual pressure switch High-pressure switch ON ® OFF: 2,942, OFF ® ON: 2,353
kPa
Low-pressure switch ON ® OFF: 196, OFF ® ON: 221
Refrigerant and quantity g R-134a (HFC-134a), Approx. 670 - 710

Idle speed r/min 4G6 750 ± 50
6A1 650 ± 50
4D6 800 ± 30
Idle-up speed r/min When load by A/C is low 4G6 750 ± 50
6A1 650 ± 50
4D6 850 ± 50
When load by A/C is high 4G6 850 ± 50
6A1 900 ± 50
4D6 850 ± 50
Air mix damper motor poten- MAX. HOT position Approx. 4.8
tiometer resistance kW
MAX. COOL position Approx. 0.2
Outlet air changeover damp- DEF position Approx. 4.8
er motor potentiometer resis-
tance kW FACE position Approx. 0.2
Air gap (Magnetic clutch) mm 0.40 - 0.65

HEATER, AIR CONDITIONER AND VENTILA- Lubricants/Special Tools/
55-36 TION <AUTOMATIC AIR CONDITIONER> - Troubleshooting
Each connection of refrigerant line SUN PAG 56 As required
Compressor refrigerant unit lubricant mL SUN PAG 56 120

MB991502 MUT-II Inspection of automatic air conditioner
sub-assembly
MB991529 Diagnosis code Inspection of automatic air conditioner using a

check harness voltmeter
NOTE
Other special tools are the same as for the manual A/C.


Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check
diagnosis codes.
HEATER, AIR CONDITIONER AND VENTILA-
TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg 55-37
Code No. Diagnosis item Reference

page
11 Inside air temperature sensor system (open circuit) 55-37
12 Inside air temperature sensor system (short circuit) 55-37
13 Outside air temperature sensor system (open circuit) 55-38
14 Outside air temperature sensor system (short circuit) 55-38
15 Heater water temperature sensor system (open circuit) 55-39
16 Heater water temperature sensor system (short circuit) 55-39
21 Air thermo sensor system (open circuit) 55-40
22 Air thermo sensor system (short circuit) 55-40
31 Potentiometer system of air mix damper motor assembly 55-41
32 Potentiometer system of air outlet changeover damper motor assembly 55-42
41 Drive system of air mix damper motor assembly 55-43
42 Drive system of air outlet changeover damper motor assembly 55-43

Code No.11 or 12 Inside air temperature sensor system Probable cause
This diagnosis code is output if the inside air temperature sensor inside the D Malfunction of the A/C-ECU
A/C-ECU is defective.
Replace the A/C-ECU.

55-38 TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg
Code No.13 Outside air temperature sensor system (open Probable cause
circuit)
This diagnosis code is output if there is a defective connector connection, or if D Malfunction of connector
there is an open circuit in the harness. D Malfunction of harness
D Malfunction of the outside air temperature sensor
D Malfunction of the A/C-ECU
NG
Outside air temperature sensor check (Refer to P.55-68.) Replace
OK
NG
Measure at the outside air temperature sensor connector A-21. Check the following connectors:
D Disconnect the connector, and measure at the harness C-05, C-64 <L.H. drive vehicles>, C-116 <L.H. drive vehicles>,
side connector. C-99 <R.H. drive vehicles>
D Voltage between terminal (1) and body earth OK NG
OK: 5 V
Repair
OK
NG
Check the harness between the outside air temperature sensor

and the A/C-ECU.
OK NG
Repair
NG
Measure at the A/C-ECU connector C-05. Check the following connectors:
D Connect the connector. C-05, C-116 <L.H. drive vehicles>, C-99 <R.H. drive vehicles>
D Voltage between terminal (7) and body earth NG
OK
OK: 2.3 - 2.9 V
OK Repair

NG
Check the harness between the outside air temperature sensor

and the A/C-ECU, and repair if necessary.
NG
OK
NG
Check the trouble symptom. Replace the A/C-ECU.
Code No.14 Outside air temperature sensor system (short Probable cause
circuit)
This diagnosis code is output if there is a short circuit in the outside air D Malfunction of harness
temperature sensor input circuit. D Malfunction of connector
D Malfunction of the outside air temperature sensor
NG
Outside air temperature sensor check (Refer to P.55-68.) Replace
OK
NG
Measure at the A/C-ECU connector C-05. Check the harness between the outside air temperature sensor
D Connect the connector. and the A/C-ECU, and repair if necessary.
OK: 2.3 - 2.9 V
OK

Code No.15 Heater water temperature sensor system Probable cause
(open circuit)
D Malfunction of the heater water temperature sensor
NG
Heater water temperature sensor check (Refer to P.55-70.) Replace
OK
NG
Measure at the heater water temperature sensor connector C-70. Check the following connectors:
D Disconnect the connector, and measure at the harness C-05, C-64 <L.H. drive vehicles>
side connector. OK NG
OK: 5 V Repair
OK
NG
Check the harness between the heater water temperature sensor

and the A/C-ECU.
OK NG
Repair
NG
Measure at the A/C-ECU connector C-05. Check the following connector:
OK: 2.3 - 2.9 V
OK Repair
NG
Check the harness between the heater water temperature sensor

NG
OK
NG
Code No.16 Heater water temperature sensor system Probable cause

(short circuit)
This diagnosis code is output if there is a short circuit in the heater water D Malfunction of harness
temperature sensor input circuit. D Malfunction of connector
D Malfunction of the heater water temperature sensor
NG
Heater water temperature sensor check (Refer to P.55-70.) Replace
OK
NG
Measure at the A/C-ECU connector C-05. Check the harness between the heater water temperature sensor
D Connect the connector. and the A/C-ECU, and repair if necessary.
OK: 2.3 - 2.9 V
OK

Code No.21 Air thermo sensor system (open circuit) Probable cause
D Malfunction of the air thermo sensor
NG
Air thermo sensor check (Refer to P.55-26.) Replace
OK
NG
Measure at the air thermo sensor connector C-73. Check the following connectors:
OK: 5 V Repair
OK
NG
Check the harness between the air thermo sensor and the A/C-ECU.
OK NG
Repair
NG
OK: 2.3 - 2.9 V
OK Repair

NG
Check the harness between the air thermo sensor and the A/C-ECU,
NG
OK
NG
Code No.22 Air thermo sensor system (short circuit) Probable cause
This diagnosis code is output if there is a short circuit in the air thermo sensor D Malfunction of harness
input circuit. D Malfunction of connector
D Malfunction of the air thermo sensor
NG
Air thermo sensor check (Refer to P.55-26.) Replace
OK
NG
Measure at the A/C-ECU connector C-05. Check the harness between the air thermo sensor and the A/C-ECU,
D Connect the connector. and repair if necessary.
OK: 2.3 - 2.9 V
OK

Code No.31 Potentiometer system of air mix damper Probable cause
motor assembly
This diagnosis code is output if there is an open or short circuit in the D Malfunction of the air mix damper motor assembly
potentiometer input circuit, or if there is an open circuit in the power circuit or D Malfunction of connector
earth circuit. D Malfunction of harness
NG
Air mix damper motor potentiometer check (Refer to P.55-59.) Replace
OK
NG
Measure at the air mix damper motor potentiometer connector C-79. Check the following connectors:
OK: 5 V Repair
OK
NG
Check the harness between the air mix damper motor potentiometer
and the A/C-ECU.
OK NG
Repair
NG
D Air mix damper position: MAX.HOT OK NG
OK Check the trouble symptom.
NG
Check the harness between the air mix damper motor potentiometer
NG
OK
NG
Code No.32 Potentiometer system of air outlet change- Probable cause

over damper motor assembly
This diagnosis code is output if there is an open or short circuit in the D Malfunction of the air outlet changeover damper
potentiometer input circuit, or if there is an open circuit in the power circuit or motor assembly
earth circuit. D Malfunction of connector
NG
Air outlet changeover damper motor potentiometer check (Refer Replace
to P.55-60.)
OK
NG
Measure at the air outlet changeover damper motor potentiometer Check the following connectors:
connector C-17. C-05, C-64 <L.H. drive vehicles>
D Disconnect the connector, and measure at the harness OK NG
side connector.
D Voltage between terminal (2) and body earth Repair
OK: 5 V
NG
Check the harness between the air outlet changeover damper motor
potentiometer and the A/C-ECU.
OK NG
Repair
NG
D Air outlet changeover damper position: DEF OK NG
OK
NG
Check the harness between the air outlet changeover damper motor
potentiometer and the A/C-ECU, and repair if necessary.
NG
OK
NG
Code No.41 Drive system of air mix damper motor Probable cause
assembly
This diagnosis code is output if the motor drive circuit is defective. D Malfunction of the air mix damper motor assembly
NG
Air mix damper motor check (Refer to P.55-59.) Replace
OK
NG
C-07, C-79
OK
NG
Check the trouble symptom. 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 Probable cause
motor assembly
This diagnosis code is output if the motor drive circuit is defective. D Malfunction of the air outlet changeover damper
motor assembly
NG
Air outlet changeover damper motor check (Refer to P.55-60.) Replace
OK
NG
C-17, C-07
OK
NG
Check the trouble symptom. Check the harness between the air outlet changeover damper
motor and the A/C-ECU.
OK NG
Repair

Trouble symptom Inspection proce- Reference page

dure No.
Communication with the MUT-II is not possible. 1 55-45
Air conditioner does not operate. 2 55-46
A/C graphic display on control panel is blank. 3 55-47
Temperature cannot be set. 4 55-47
A/C outlet air temperature does not increase. 5 55-47
A/C outlet air temperature does not decrease. 6 55-47
Blower does not operate. 7 55-48
Blower air amount cannot be changed. 8 55-49
Air outlet port cannot be changed. 9 55-49
Inside/outside air changeover is not possible. 10 55-50
Defroster function does not operate. 11 55-51
Rear defogger does not operate. 12 55-51
A/C-ECU power supply circuit check 13 55-52
A/C compressor control circuit check 14 55-53
Radiator fan does not operate. 15 Refer to GROUP

14 - Trouble-
Condenser fan does not operate. 16 shooting.
If communication with all other systems is not possible, there is a high possibility D Malfunction of connector or harness
that there is a malfunction of the diagnosis line. If communication with only the D Malfunction of A/C-ECU
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).
NO
Is communication between MUT-II and Check the MUT-II diagnosis line, and
other system is possible? repair if necessary.
YES
OK NG
Measure at the diagnosis connector Measure at the A/C-ECU connector Check the following connector:
C-20. C-05. C-05
D Voltage between terminal (11) D Disconnect the connector, and
OK NG
and body earth measure at the harness side
OK: Indication fluctuates be- connector. Repair
tween 0 V and 12 V. D Voltage between terminal (18)
and body earth Check the trouble symptom.
NG OK: Battery voltage - 2 V
NG
OK
NG Check the harness between the diagno-
Measure at the A/C-ECU connector Check the following connector: sis connector and the A/C-ECU, and
C-05. C-05 repair if necessary.
D Voltage between terminal (17)
and body earth Repair
OK: Indication fluctuates be-
tween 0 V and 12 V. Check the trouble symptom.
OK NG
NG
Check the harness between the diagno- Repair
sis connector and the A/C-ECU.
NG
NG
C-05, C-20
OK

NG
NG NG
Measure at the A/C-ECU connector Check the following connectors: Repair
C-07. C-132, C-63 <L.H. drive vehicles>, C-61
D Disconnect the connector, and <R.H. drive vehicles>
measure at the harness side OK
connector.
NG
D Voltage between terminal (28) Check the trouble symptom. Check the harness between the junction
and body earth block and the A/C-ECU, and repair if
OK: Battery voltage necessary.
OK
NG NG
Measure at the A/C-ECU connector Check the following connectors: Repair
C-07. C-07, C-62 <L.H. drive vehicles>
OK
measure at the harness side
connector. NG
Check the trouble symptom. Check the harness between the
D Continuity between terminales A/C-ECU and the body earth, and repair
(27), (35) and body earth if necessary.
OK: Continuity
OK

Air conditioner does not operate. Probable cause
If the A/C does not operate when the A/C switch is on and the temperature D Malfunction of blower
setting is at 17_C, the cause is probably insufficient refrigerant, or a malfunction D Insufficient refrigerant
of the blower or of the magnet clutch power supply. D Malfunction of magnetic clutch
D Malfunction of air thermo sensor
D Malfunction of A/C compressor relay
D Malfunction of refrigerant temperature switch
D Malfunction of dual pressure switch
D Malfunction of connector or harness
D Malfunction of A/C-ECU
NO
Does the blower operate? Inspection procedure 7 (Refer to P.55-48.)
YES
NG
A/C system refrigerant pressure check (Refer to P.55-14.) Refill the specified amount of refrigerant. (Refer to P.55-9.)
OK
YES
MUT-II DIAGNOSIS CODE INSPECTION CHART FOR DIAGNOSIS CODES (Refer to
Is any of the codes 11, 21 and 22 output? P.55-37.)
NO
NG
D Magnetic clutch check (Refer to P.55-7.) Replace
D A/C compressor relay check (Refer to P.55-17.)
D Refrigerant temperature switch check (Refer to P.55-65.)
D Dual pressure switch check (Refer to P.55-8.)
OK
OK
Measure at the A/C compressor relay connector B-28X. Inspection procedure 14 (Refer to P.55-53.)
D Disconnect the connector, and measure at the harness
side connector.
(1) Continuity between terminal (4) and body earth
OK: Continuity (2) NG
(2) Voltage between terminal (5) and body earth B-28X
OK: Battery voltage
OK NG
(1) NG
NG Repair
B-28X, B-30, B-75
Check the trouble symptom. NG
NG Check the harness between the fusible link and the A/C compressor
relay, and repair if necessary.
Check the harness between the magnetic clutch and the A/C com-
pressor relay, and repair if necessary.
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 D Malfunction of connector or harness
(earth). D Malfunction of A/C-ECU
NO
Does the A/C operate? Inspection procedure 13 (Refer to P.55-52.)
YES
Temperature cannot be set. Probable cause
The cause is probably a malfunction of the temperature setting signal input D Malfunction of connector or harness
system or output system. D Malfunction of A/C-ECU
Inspection procedure 13 (Refer to P.55-52.)
A/C outlet air temperature does not increase. Probable cause
If the outlet air temperature does not increase when the temperature setting is D Malfunction of air mix damper motor potentiometer
increased, the cause is probably a sensor malfunction or a problem with D Malfunction of air mix damper motor
operation of the air mix damper. The MUT-II can be used to check the diagnosis D Malfunction of air mix damper
codes in order to check the cause of the problem for each separate system. D Malfunction of connector or harness
D Malfunction of thermostat
YES
Is any of the codes 11, 12, 31 and 41 output? P.55-37.)
NO
NG
Thermostat check (Refer to GROUP 14 - On-vehicle Service.) 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 D Malfunction of outside air temperature sensor
decreased, the cause is probably a problem in A/C system operation due to a D Malfunction of air mix damper motor potentiometer
sensor error, or a problem with operation of the air mix damper. The MUT-II can D Malfunction of air mix damper motor
be used to check the diagnosis codes in order to check the cause of the D Malfunction of air thermo sensor
problem for each separate system. D Malfunction of connector or harness
D Malfunction of air mix damper
NO
YES
YES
Is any of the codes 11, 12, 13, 14, 21, 22, 31 and 41 output? P.55-37.)
NO

Blower does not operate. Probable cause
If no air comes out of the blower even though the blower switch is on, the D Malfunction of blower motor relay
cause is probably a malfunction of the blower motor relay circuit. D Malfunction of blower motor
NO
Can an operating sound be heard when the blower speed change- Inspection procedure 13 (Refer to P.55-52.)
over switch is operated?
YES
NG
D Blower relay check (Refer to P.55-16.) Replace
D Blower motor check (Refer to P.55-23.)
OK
(1) NG
Measure at the blower relay connector C-140. Check the harness between the blower relay and the body earth,
D Disconnect the connector, and measure at the harness and repair if necessary.
side connector. (2) NG
(1) Continuity between terminal (1) and body earth Check the harness between the blower relay and the ignition switch,
(2) Voltage between terminal (3) and body earth (Ignition
switch: ON) (3) NG
Check the harness between the blower relay and the fusible link
OK: Battery voltage
No.1, and repair if necessary.
(3) Voltage between terminal (2) and body earth
OK: Battery voltage
OK
NG
Measure at the blower motor connector C-09. Check the following connector:
D Disconnect the connector, and measure at the harness C-131
D Voltage between terminal (1) and body earth (Ignition
switch: ON) Repair
OK: Battery voltage
OK
NG
Check the harness between the blower relay and the blower motor,
NG
C-09
OK
NG
Check the trouble symptom. Check the harness between the blower motor and the A/C-ECU,
Blower air amount cannot be changed. Probable cause
If the blower does not operate in any mode other than HI setting, the cause is D Malfunction of power transistor
probably a malfunction of the power transistor system. D Malfunction of connector or harness
OK
Measure at the power transistor connector C-77. Check the following connector:
D Blower switch position: LO C-77
OK NG
(1) Continuity between terminal (1) and body earth
OK: Continuity Repair
switch: ON) Check the trouble symptom.
OK: Battery voltage - 2 V
(3) Voltage between terminal (4) and body earth (Ignition NG
switch: ON)
OK: Approx. 1.3 V Replace the power transistor.
(1) NG
Check the harness between the power transistor and the body
(2) NG
Check the harness between the power transistor and the blower
motor, and repair if necessary.
(3) NG
NG
D Blower switch position: LO C-05
switch: ON) Repair
OK: Approx. 7 V
(2) Voltage between terminal (2) and body earth (Ignition Check the trouble symptom.
switch: ON)
OK: Approx. 1.3 V NG
OK Replace the A/C-ECU.

NG
Check the harness between the power transistor and the A/C-ECU. 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 D Malfunction of air outlet changeover damper motor
input system or output system. The MUT-II can be used to check the diagnosis potentiometer
codes in order to check the cause of the problem for each separate system. D Malfunction of air outlet changeover damper motor
D Malfunction of air outlet changeover damper
NO
Can an operating sound be heard when the air outlet port Inspection procedure 13 (Refer to P.55-52.)
changeover switch is operated?
YES
YES
Is either code 32 or code 42 output? P.55-37.)
NO
NG
Air outlet changeover damper check Repair
OK

Inside/outside air changeover is not possible. Probable cause
If inside/outside air changeover is not possible even when the inside/outside air D Malfunction of inside/outside air changeover
changeover switch is on, the cause is probably a malfunction of the damper motor
inside/outside air changeover damper motor. D Malfunction of inside/outside air changeover
damper
NO
Can an operating sound be heard when the inside/outside air Inspection procedure 13 (Refer to P.55-52.)
changeover switch is operated?
YES
NG
Inside/outside air changeover damper motor check (Refer to Replace
P.55-24.)
OK
NG
Measure at the inside/outside air changeover damper motor connec- Check the following connector:
tor C-78. C-07
side connector.
D Outside air select button: ON Repair
OK: 10 V Check the trouble symptom.
D Inside air select button: ON
D Voltage between terminal (2) and body earth NG
OK: 10 V
Check the harness between the inside/outside air changeover
OK damper motor and the A/C-ECU, and repair if necessary.
NG OK
Check the following connector: Repair NG
C-78
Repair
OK
NG
NG
Inside/outside air changeover damper check Repair
OK

Defroster function does not operate. Probable cause
If the defroster function does not operate when the defroster switch is turned on, D Malfunction of air conditioner drive system
the cause is probably a malfunction of the A/C or of the air outlet port D Malfunction of air outlet changeover damper drive
changeover circuit. system
NO
Can an operating sound be heard when the defroster switch is Inspection procedure 13 (Refer to P.55-52.)
operated?
YES
NO
YES
NO
Can the air outlet port be changed over? Inspection procedure 9 (Refer to P.55-49.)
YES
NG
Air outlet changeover damper (for defroster) check Repair
OK
Rear defogger does not operate. Probable cause
If the rear defogger does not operate when the rear defogger switch is turned D Malfunction of connector or harness
on (timer operates for 20 minutes), the cause is probably a malfunction of the D Malfunction of A/C-ECU
A/C-ECU power supply system (earth).
NO
Can an operating sound be heard when the rear defogger switch Inspection procedure 13 (Refer to P.55-52.)
is operated?
YES

A/C-ECU power supply circuit check
NG
D Disconnect the connector, and measure at the harness C-63, C-132, C-141 <L.H. drive vehicles>, C-62, C-14 <R.H. drive
side connector. vehicles>
OK NG
OK: Battery voltage
OK Repair

NG
Check the harness between the A/C-ECU and the fusible link No.2,
NG
D Disconnect the connector, and measure at the harness C-63 <L.H. drive vehicles>, C-61 <R.H. drive vehicles>, C-132
D Voltage between terminal (28) and body earth (Ignition
switch: ON) Repair
OK: Battery voltage
OK
NG
Check the harness between the A/C-ECU and the junction block,
NG
Measure at the A/C-ECU connector C-07. Check the harness between the A/C-ECU and the body earth,
D Disconnect the connector, and measure at the harness and repair if necessary.
side connector.
D Continuity between terminal (27) and body earth
OK: Continuity
D Continuity between terminal (35) and body earth
OK: Continuity
OK
NG
C-07
OK
NG
A/C compressor control circuit check
NG
D Blower switch and A/C switch: ON C-07
D Setting temperature: 17_C
OK NG
D Voltage between terminal (34) and body earth (Ignition Repair
switch: ON)
OK: Battery voltage Check the trouble symptom.
OK NG
NG
Measure at the A/C compressor relay connector B-28X. Check the following connectors:
D Blower switch and A/C switch: ON C-116, C-67, C-14, C-64, C-07 <L.H. drive vehicles>
D Disconnect the connector, and measure at the harness C-14, C-66, C-115, C-07 <L.H. drive vehicles>
OK: Battery voltage Repair
OK
NG
Check the harness between the A/C-ECU and the A/C compressor
relay, and repair if necessary.
NG
Measure at the engine-ECU connector C-55 <4D6>, C-34 <4G6>, Check the following connectors:
C-33 <6A1>. B-30, B-28X
side connector.
D Voltage between terminal (53) and body earth <4D6> Repair
D Voltage between terminal (8) and body earth <4G6, 6A1>
OK: Battery voltage Check the trouble symptom.
OK NG
Replace the engine-ECU. Check the harness between the A/C compressor relay and the
engine-ECU, and repair if necessary.
Item No. Check item Check condition Normal condition
11 Inside air tempera- Ignition switch: ON Inside air temperature and tem-
ture sensor perature displayed on the MUT-II
are identical.
13 Outside air temper- Ignition switch: ON Outside air temperature and

ature sensor temperature displayed on the
MUT-II are identical.
15 Heater water tem- Ignition switch: ON Heater core surface temperature

perature sensor and temperature displayed on
the MUT-II are identical.
21 Air thermo sensor Ignition switch: ON Evaporator surface temperature

and temperature displayed on
the MUT-II are identical.
25 Photo sensor Ignition switch: ON Amount of incident light is

proportional to voltage displayed
on the MUT-II.
31 Air mix damper mo- Ignition switch: ON Damper position Opening degree (%)
tor potentiometer
MAX. HOT Approx. 100
MAX. COOL Approx. 0
32 Air outlet change- Ignition switch: ON Damper position Opening degree (%)
over damper motor
potentiometer FACE Approx. 0
FOOT Approx. 50
FOOT/DEF. Approx. 75
DEF. Approx. 100
CHECK AT THE A/C-ECU TERMINALS 55400540077
Terminal Check item Check condition Normal condition

No.
1 Power MOS FET drain output When blower switch is at OFF System voltage
When blower switch is at LO Approx. 9 V
When blower switch is at HI Almost no voltage (0 V)


No.
2 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
3 A/C-ECU backup power supply At all times System voltage
4 Heater water temperature sensor When sensor section temperature is 2.3 - 2.9 V
input 25_C (4 kW)
5 Air mix damper motor potentiometer When damper is moved to MAX. HOT 4.7 - 5.0 V
input position
6 Air outlet changeover damper motor When damper is moved to DEF. 4.8 - 5.2 V
potentiometer input position
7 Outside air temperature sensor input When sensor section temperature is 2.3 - 2.9 V
25_C (4 kW)
8 Air thermo sensor input When sensor section temperature is 2.3 - 2.9 V
25_C (4 kW)
9 Photo sensor (- ) At luminous intensity of 100,000 lux or - 0.1 - 0.2 V

more
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 When ignition switch is ON 0 V « System voltage
18 Diagnosis control input When ignition switch is ON Battery voltage - 2 V
19 Photo sensor (+) At all times 0V
20 Air mix damper motor and air outlet At all times 0V

changeover damper motor potentiom-
eters
21 Air outlet changeover damper motor Set to FACE position (OFF after 40 10 V
(+) seconds of output)
Set to DEF. position (OFF after 40 0.5 V

seconds of output)
22 Air mix damper motor (- ) Set the setting temperature to 17_C 10 V

and set to MAX. COOL position (OFF
after 40 seconds of output)
Set the setting temperature to 32_C 0.5 V

and set to MAX. HOT position (OFF
HEATER, AIR CONDITIONER AND VENTILA- Troubleshooting/
55-56 TION <AUTOMATIC AIR CONDITIONER> - On-vehicle Service

No.
23 Inside/outside air changeover damper Set to inside air position (OFF after 40 0.5 V
motor (- ) seconds of output)
Set to outside air position (OFF after 10 V

40 seconds of output)
24 Air outlet changeover damper motor Set to FACE position (OFF after 40 0.5 V
(- ) seconds of output)
Set to DEF. position (OFF after 40 10 V

seconds of output)
25 Air mix damper motor (+) Set the setting temperature to 17_C 0.5 V
and set to MAX. COOL position (OFF
Set the setting temperature to 32_C 10 V

and set to MAX. HOT position (OFF
26 Inside/outside air changeover damper Set to inside air position (OFF after 40 10 V
motor (+) seconds of output)
Set to outside air position (OFF after 0.5 V

40 seconds of output)
27 Earth At all times Continuity
28 A/C-ECU power supply When ignition switch is ON System voltage
29 ILL earth (rheostat) At all times Continuity
30 ILL power supply When lighting switch is at ON System voltage
33 Engine-ECU output When air mix damper is at MAX. 0V

COOL position
When air mix damper is at MAX. HOT System voltage

position
34 A/C output When A/C is OFF 0V
When A/C is ON System voltage
35 Earth At all times Continuity
The service procedures are the same as for the manual air conditioner. (Refer to P.55-7.)
HEATER, AIR CONDITIONER AND VENTILA- Air Conditioner Control Panel and
TION <AUTOMATIC AIR CONDITIONER> - ECU Assembly 55-57
AIR CONDITIONER CONTROL PANEL AND ECU ASSEMBLY 55400100084

D Floor Console Panel Removal and Installation
(Refer to GROUP 52A - Floor Console Box.)
1
2
3
Removal steps
1. Center console panel and air condi-
tioner control panel assembly
2. Center console panel
3. Air conditioner control panel and ECU
assembly
HEATER, AIR CONDITIONER AND VENTILA- Damper Motor Assembly and
55-58 TION <AUTOMATIC AIR CONDITIONER> - Power Transistor
DAMPER MOTOR ASSEMBLY AND POWER TRANSISTOR 55400580024
4 5
Inside/outside air changeover Air mix damper motor assembly

damper motor assembly removal removal steps
steps D Glove box, side cover, glove box
D Glove box (Refer to GROUP 52A - frame, radio, tape player (Refer to
Instrument Panel.) GROUP 52A - Instrument Panel.)
1. Inside/outside air changeover damper D Under cover (Refer to P.55-33.)
motor assembly 3. Control relay bracket assembly
4. Air mix damper motor assembly
Outlet air changeover damper
motor assembly removal steps Power transistor removal steps
D Lower cover (Refer to GROUP 52A D Glove box (Refer to GROUP 52A -
- Instrument Panel.) Instrument Panel.)
2. Outlet air changeover damper motor D Under cover (Refer to P.55-33.)
assembly 5. Power transistor
INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR

ASSEMBLY CHECK
For inspection service points, refer to P.55-24 for heater and
manual A/C.
TION <AUTOMATIC AIR CONDITIONER> - Power Transistor 55-59
AIR MIX DAMPER MOTOR ASSEMBLY CHECK
Lever
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
MOTOR 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 TION <AUTOMATIC AIR CONDITIONER> - Power Transistor
AIR OUTLET CHANGEOVER DAMPER MOTOR

Lever 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.
MOTOR 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
TION <AUTOMATIC AIR CONDITIONER> - Compressor and Tension Pulley 55-61
COMPRESSOR AND TENSION PULLEY 55200410273

D Discharging of Refrigerant (Refer to P.55-13.) D Drive Belt Tension Adjustment
D Charging of Refrigerant (Refer to P.55-9.)
Piping connection <4G6>
O-ring

25 Nm
5
<6A1> 6
5
6
3
2
49 Nm 3 1
4
1
Removal steps
D Under cover 2. Tension pulley
D Condenser fan motor (Refer to AB" 3. Hose connections
P.55-31.) 4. Power steering oil pressure switch
D Drive belt (for alternator) <6A1> (Refer harness <6A1>
to GROUP 11 - Crankshaft Pulley.) AC" "AA 5. Compressor
AA" 1. Drive belt 6. Compressor bracket
55-62 TION <AUTOMATIC AIR CONDITIONER> - Compressor and Tension Pulley
<4D6>
39 Nm Piping connection
7
O-ring
6 Compressor oil: SUN PAG 56
3
5
25 Nm
2 20 - 25 Nm 4
Removal steps
D Under cover AB" 4. Hose connections
D Condenser fan motor (Refer to AC" "AA 5. Compressor
P.55-31.) 6. Drive belt (for power steering oil pump)
AA" 1. Drive belt (for compressor) 7. Power steering oil pump
2. Tension pulley 8. Compressor bracket
3. Tension pulley bracket
<4G6>
AA" DRIVE BELT REMOVAL
1. Loosen the nut “A” for holding.
Bolt “B” 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.

"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
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
Refrigerant the refrigerant temperature switch.
temperature
switch
COMPRESSOR MAGNETIC CLUTCH OPERATION

CHECK 55200850181
Connect the battery (+) terminal to the compressor side

terminal, and earth the battery ( - ) terminal to the body of
the compressor. The condition is normal if the sound of the
magnetic clutch (click) can be heard.
MAGNETIC CLUTCH AND REFRIGERANT TEMPERATURE SWITCH 55200460216
9 5
8
7
6
1 4 10
<4G6>
2
3
9
<6A1, 4D6> 8
7
6
3 4
Magnetic clutch disassembly steps

1. Bolt <4G6> 7. Rotor
2. Pulley <4G6> 8. Snap ring
"EA D Air gap adjustment "AA 9. Clutch coil
AA" "DA 3. Nut
"CA 4. Armature plate Refrigerant temperature switch
5. Shims removal
"BA 6. Snap ring 10. Refrigerant temperature switch

MB991386 AA" NUT REMOVAL
MB991367
Clutch coil REASSEMBLY SERVICE POINTS

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 "CA ARMATURE PLATE INSTALLATION

Serration notch 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.
Crankshaft
Matching mark
"EA AIR GAP ADJUSTMENT

Thickness gauge
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.
TION <AUTOMATIC AIR CONDITIONER> - Photo Sensor 55-67
PHOTO SENSOR 55400310067
Removal step
AA" 1. Photo sensor

AA" PHOTO SENSOR REMOVAL
Use a flat-tipped screwdriver (width: 3 mm or less) to remove
the photo sensor.
Flat-tipped
screwdriver
Photo sensor
If the blower speed drops when the receiver section of the

photo sensor is covered with your hand, then the photo sensor
is normal. If the speed does not drop, replace the photo
sensor.
55-68 TION <AUTOMATIC AIR CONDITIONER> - Outside Air Temperature Sensor
OUTSIDE AIR TEMPERATURE SENSOR 55400340042

D Front Bumper Removal and Installation (Refer to
GROUP 51.)
Outside air temperature sensor
Resistance kW When the resistance value between the sensor terminals

20 is measured under two or more temperature conditions, the
10 graph.
5 NOTE
0 The temperature conditions when testing should not exceed
- 10 0 10 20 30 40 the range of the characteristic curve in the graph.
Temperature _C
TION <AUTOMATIC AIR CONDITIONER> - Heater Water Temperature Sensor 55-69
HEATER WATER TEMPERATURE SENSOR 55400450080

D Lower Cover and Side Cover Removal and When removing and installing the engine-ECU,
Installation (Refer to GROUP 52A - Instrument A/T-ECU, A/T control relay and clip from vehicles
Panel.) equipped with SRS, do not let them bump against
D Engine-ECU, A/T-ECU and A/T Control Relay the SRS-ECU.
Removal and Installation (Refer to GROUP 52B
- SRS-ECU.)
2
1
Removal steps
AA" "AA 1. Heater water temperature sensor clip
AA" "AA 2. Heater water temperature sensor

Foot distribution AA" HEATER WATER TEMPERATURE SENSOR CLIP
duct AND HEATER WATER TEMPERATURE SENSOR
REMOVAL
Heater unit
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.
Heater water
temperature
sensor clip

"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.
HEATER, AIR CONDITIONER AND VENTILA- Heater Water Temperature Sensor/
55-70 TION <AUTOMATIC AIR CONDITIONER> - Other Maintenance Service Points
Resistance kW When the resistance value between the sensor terminals

20 is measured under two or more temperature conditions, the
10 graph.
5 NOTE
0 The temperature conditions when testing should not exceed
- 10 0 10 20 30 40 the range of the characteristic curve in the graph.
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 Workshop Manual PDF

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00109000812

E Mitsubishi Motors Corporation Dec. 1996

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . 2 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

HOW TO USE THIS MANUAL 00100010302

SCOPE OF MAINTENANCE, REPAIR DEFINITION OF TERMS

ON-VEHICLE SERVICE REFERENCE VALUE

EXPLANATION OF MANUAL CONTENTS

Indicates procedures to be performed

Indicates (by symbols) where lubrica-

Maintenance and Servicing Procedures

Classifications of Major Maintenance/Service Points

Symbols for Lubrication, Sealants and Adhesives

Information concerning the locations for lubrica- : Grease

: Brake fluid or automatic transmission fluid

: Engine oil, gear oil or air conditioner com-

: Adhesive tape or butyl rubber tape

Indicates the Indicates the Indicates the Indicates the

Denotes tightening torque.

Repair kit or set parts

Operating procedures, cau-

indicates that there is

The title of the page (following

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

Check trouble symptom.

Reoccurs 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.

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS

6. INSPECTION CHART FOR TROUBLE SYMPTOMS

7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM

8. SERVICE DATA REFERENCE TABLE

9. CHECK AT ECU TERMINALS

10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE

WHEN USING THE WARNING LAMP

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

1. Comments on the diagnosis code or trouble

D Indicator does not turn on or off even if control Probable cause

3. Detailed inspection procedures (methods)

6. Confirm that there are trouble symptoms. If trouble symptoms have

CONNECTOR MEASUREMENT SERVICE POINTS

Harness connector IF INSPECTING WITH THE CONNECTOR CONNECTED

Ordinary (non-waterproof) Connectors

IF INSPECTING WITH THE CONNECTOR DISCONNECTED

<When Inspecting a Male Pin>

Defective connector contact

Harness wire breakage

Low contact pressure

CONNECTOR PIN INSPECTION

CONNECTOR ENGAGEMENT INSPECTION

INSPECTION SERVICE POINTS FOR A BLOWN

POINTS TO NOTE FOR INTERMITTENT

VEHICLE INFORMATION CODE PLATE

CODE PLATE DESCRIPTION

2 ENGINE 4G63 Engine model

3 EXT B60B Exterior code

4 TRANS F5M42 Transmission code