^^,

0 Workshop
Mqnuql
MITSUBISHI
MOIORS

chossis
SUPPTEMENT

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3ClCloGiT'97

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v
Pub.No.PWUE9I
l9-F
v

MITSUBISHI General E
Fuel IE
3000GiT ServiceBrakes
Supplemental
System(SRS)
Restraint
E
E
WORKSHOPMANUAL
SUPPLEMENT
FOREWORD
,r , This WorkshopManualcontainsprocedures for
\/ r e m o v a l , d i s a s s e m bi lnys, p e c t i o n , a d j u s t m e n t ,
reassembla y n d i n s t a l l a t i o ne, t c . f o r s e r v i c e
mechanics.
Usethefollowing manualsin combination withthis
manualas required.
TECHNICAL
INFORMATION
MANUAL
PYUE92O1

WORKSHOP MANUAL
C H A S S I GR
S OU P PWUE9119
(Loose-leafedition)
PWUE9119-E
(Supplement)
E N G I NG
E ROUP PWEEN!trN
(Loose-leafedition)
WIR
EL EC T RIC A L IN G PHUE92O1
(Loose-leafedition)
PHUE92O1-D
v (Supplement)
PHUE92O1.E
(Supplement)
PARTSCATALOGUE 8608K4onAn
8608K454Atr
8608K406An
8608K407An

and productdescrip-
illustrations
All information,
tionscontainedin thismanualarecurrentas at the
timeof publication.We, however,reservethe right
to makechangesat anytimewithoutpriornoticeor
obligation.

v
o Mitsubishi Motors Corporation July 1996
WARNINGSREGARDING
OFSUPPLEMENTAL
RESTRAINT
SYSTEM
(sRs)EQUTPPED
VEHTCLES
WARNING!
(1) lmproperserviceor maintenanceoJany componentof the SRS,or any SRS-related component,
can leadto personaliniury or death_to_servicepersonnel(from inadvertentfiring of the iir Uagl
or to the driver(fromrenderingthe SRSinoperative).
(2) lt it is possiblethat the SRScomponentsare subjectedto heatover 93"C(200'F)in bakingor in
dryingafterpainting,removethe SRScomponents(air bag module,SRS-ECU) beforehand.
(3) Serviceor maintenanceoJ any SRS componentor SRS-related componentmust be performed
only at an authorizedMITSUBISHI dealer.
(4) MITSUBISHI dealerpersonnelmust thoroughlyreviewthis manual,and especiallyits GROUp
528 - SupplementalRestraintSystem(SRS),before beginningany serviceor maintenanceof
any componentof the SRSor any SRS-related component.

lJ-
 GENERAL- Vehicleldentification 00-1
v
GROUPOO
GENERAL
VEHICLEIDENTIFICATION
MODELS
Modelcode Enginemodel Transmissionmodel Fuelsupplysystem

i' Zl6AMJGFL6
Zl6AMJGFR6
6G72(2,972m/) W6MG1 MPI

NUMBER
CHASSIS
The chassisnumberis stampedon the toeboardinsidethe
enginecompartment.

A JMBMJ216A P Y 000001 A
TTT-tTTTT_t T
12 3 4 5 6 7I I 10
1 . Asia 7. Sort
2 . Japan A - Passenger
car
3. MITSUBISHI 8. Modelyear
A - For Europe,righthand drive P-1993
B - For Europe,left hand drive R-1994
4 . Body style s-1995
M - 2-doorhatchback T - 1996
5 . Transmissiontype v-1997
N - 5-speedmanualtransmission L Plant
J - 6-speedmanualtransmission Y - OheMotorVehicleWorks
6 . Developmentorder 10.Serialnumber
2 1 6 - 2 , 9 7 2m I ( F u l lt i m e4 W D )

v
00-2 GENERAL- MajorSpecifications

MAJORSPECIFICATIONS

ooFoo64

Dimensions
Items Zl6AMJGFL6 Zl6AMJGFR6
O v e r a llle n g t hm m ( i n . ) o 4,570(179.9) 4,570(179.9)
h m (in.)
O v e r a l l w i d tm @ 1 , 8 4 O( 7 2 . 4 \ 1 , 8 4 O( 7 2 . 4 )
Overallheight(unladen)mm (in.) @ 1 , 2 8 5( 5 0 . 6 ) 1 , 2 8 5( 5 0 . 6 )
mm (in.)
Wheelbase @ 2,470(97.2) 2 , 4 7 0( 9 7 . 2 )
mm (in.)
Track-front !9 1 , 5 6 0( 6 1 . 4 ) 1 , 5 6 0( 6 1 . 4 )
Track-rearmm (in.) @ 1 , 5 8 0( 6 2 . 2 ) 1 , 5 8 0( 6 2 . 2 )
Groundclearance(unladen)mm (in.) €) 1 4 0( 5 . 5 ) 1 4 0( 5 . 5 )
mm (in.)
Overhang-front @ 1 , 0 3 0( 4 0 . 6 ) 1 , 0 3 0( 4 0 . 6 )
mm (in.)
Overhang-rear o 1 , 0 7 0( 4 2 . 1 ) 1 , 0 7 0( 4 2 . 1 )
Angleof approachdegrees @ 11.0" 11.0'
Angleof departuredegrees o 17.6' 17.6'

Weight
Items Zl64MJGFL6 Z.I64MJGFR6
Kerbweightkg (lbs.) 1 , 7 3 0( 3 , 8 5 8 ) 1 , 7 3 0( 3 , 8 5 8 )
Grossvehicleweightkg (lbs.) 2,120(4,674) 2,120(4,674)
M a x .a x l ew e i g h tk g ( l b s . ) f ront 1 , 1 5 0( 2 , 5 3 5 ) 1 , 1 5 0( 2 , 5 3 5 )
rear 1,O20(2,249) 1,02O(2,249)

Seatingcapacity
Items Zl64MJGFL6 Z16AMJGFR6
Seatingcapacity 4 4

Engine
Items Z16AMJGFL6 Zl6AMJGFR6
Model 6G72 6G72
Totaldisplacementm I 2,972 2,972

Transmission
Items Z16AMJGFL6 Z16AMJGFR6
Model W6MG1 W6MG1
Type 6-soeedmanual 6-soeedmanual

LL)
 13-1
Y

T
FUEL
CONTENTS

GENERAL ......2 OF MPI

ON.VEHICLEINSPECTION
O u t l i no
efC h a n g e .............2 ........
coMPoNENTS .......3
P o w e rS u p p l ya n d l g n i t i o n . . . . . . . . . . . . . . . . 3. . . . .
Switch-lG
S PE C |F | C A T T ON S ............2 F u e lP u m p . . . . . . . . . . . . . . . . .5
.....
G e n e r aSl p e c i f i c a t i o n. .s. . . . . . . . . . . . . . .........2

v
13-2 FUEL - General/Specif
ications

GENERAL
OF CHANGE
OUTLINE
The maintenance servicepointsbelowhavebeenestablished
to correspondto the separation
of the engine
controlrelayandfuelpumpcontrolrelaywhichwerepreviously
integrated.

SPECIFICATIONS
SPECIFICATIONS
GENERAL
Items Specifications

Engine ldentification Vehicleswithout E2T61379<L.H.drivevehicles>

control modelNo. immobilizersystem
unit E2T61380<R.H.drivevehicles>

Vehicleswith immobilizer E2T61383<L.H.drivevehicles>

system
E2T61384<R.H.drivevehicles>
L

o
 FUEL - On-vehicleInspectionof MPIComponents 13-3
,ly oN-vEHtcLEtNSpECTtON
OF MptCOMPONENTS
POWERSUPPLYAND IGNITION
SWITCH.IG

Battery
rlrlrlrlrl lgnitionswitch[G]

Enginecontrol
unit YVV V
I

-j- -J-, L
l $ i l : ; l l G ; ; p i ;pl H A?
-\tr V
-ilri

?FU1943

Enginecontrolunit

9FU0l0l
13-4 FUEL - On-vehicleInspectionof MPIComponents

Measurethe ignitionswitch(lG) terminal

inputvoltage.
o Enginecontrolunitconnector:
Disconnected

lgnitionswitch Voltage(V) Repairthe

harness.
OFF 0-1
(lgnition
ON SV switch- oz)
or checkthe
ignition
switch

Measurethe power supplyvoltageof the

controlrelay.
o lgnitionswitch:OFF
o Controlrelayconnector:
Disconnected

Voltage(V) Repairthe
SV
harness.
-
(Battery
@ s)
-
(Battery
?FUt928 @ a)

or a short-circuit
Checkfor an open-circuit,
to earth,betweenthe enginecontrolunit and
the controlrelay.
o Enginecontrolunitconnector:
Disconnected
o Controlrelayconnector:
Disconnected Repairthe
harness.
(@ z -oa;
(@r -rz,
25)

Measurepowervoltageto the actuator.

o Controlrelayconnector:
Connected
. Enginecontrolunitconnector:
Connected

Engine Voltage(V)
Malfunction
Cranking 8V or higher
of control
Racing SV relayor
engine
?FU1930 controlunit

CONTROLRELAYINSPECTION
(1) Checkfor continuity
betweencontrolrelayterminals.
Battery TerminalNo.
voltage
1 2 3 4

Not supplied C ---c

Supplied C- --{

o- ----@

?FU1931 (2) Replacethe controlrelayif faulty.

 FUEL- On-vehicleInspectionof MPIGomponents 13-5
F U E LP U M P

)
-t

r) \\

<t
11-!

Fuelpump
relayNo.2

Fuelpump
relayNo.1or
controlrelay :

*/
1,3-6 FUEL- On-vehiclelnspectionof MPIComponents

lgnitionswitch|Gl I
@ Equipment
F u e lp u m p
side
connector @ Harnessside
Equipment relayNo.1 connector
connector
-g-
lml
il ltatl

Fuelpump
relayNo.2

@ Equipmentside
conneclor
,
Resistor
(forfuel pump)
O Fuelpump
checkterminal
-N/-
t@t
O Equipment
connector

Enginecontrolunit 8 or 22*

?FU203?

Enginecontrolunitconnector

9FU0l0l

NOTE
-: Vehicles system.
withimmobilizer
 FUEL - On-vehicleInspectionof MPIComponents 13-7
HARNESSINSPECTION

Checkthe fuel pump.

o Apply batteryvoltageto the checking
terminaland operatethe pump.

Checkthe earthcircuitof the fuel pump.

l-Y-l o Fuelpumpconnector:
l-X-l
L____\z_J
Disconnected

Repairthe
narness.
(@z-
Earth)

Check for continuitybetweenthe fuel pump

o and the checkingterminal.

F
I-\-----l
l;\---=:l o Connector:Disconnected
tol

I Repairthe
narness.
(@t-
O r)

Check for continuitybetweenthe checking

o terminaland the fuel pump relayNo.2,and
betweenthe resistor(for fuel pump).
o Fuel pump relay No.2 connector:
Disconnected

T
o Resistor(for fuel pump) connector:
Disconnected
Repairthe
r Fuelpumpconnector:
harness.
Disconnected (Ot-
@ z)
(Oz-
O z)

Checkfor an open-circuit,or a short-circuit

to earth,betweenthe fuel pump relay No.2
and the enginecontrolunlt.
o Fuel pump relay No.2 connector:
Disconnected
o Enginecontrolunitconnector:
Disconnected
Repairthe
i harness.
v (@ r -zr;
 FUEL - On-vehicleInspectionof MPIComponents

Checkfor continuitybetweenthe fuel pump

rJ
relayNo.2and the resistor(forfuel pump)'
o Fuelpump relayNo.2connector:
Disconnected
o Resistor(forfuel pump)connector:
Disconnected

Repairthe
narness.
(O+-
@ r)

Measurethe power supplyvoltageof the

f u e lp u m pr e l a yN o . 1 .
o Fuelpump relayNo.1connector:
Disconnected

lgnitionswitch Voltage(V) Repairthe

OFF
ON
0
SV
narness.
(lgnition
switch-
,
@ e +)or
checkthe
switch.
ignition
?FU1928

Checkfor an open-circuit, or a short-circuil

to earth betweenthe fuel pump relay No.1
and the enginecontrolunit.
o Controlrelayconnector:
Disconnected
o Enginecontrolunitconnector:
Disconnected
Repairthe
harness.
(@z-s
or zz)

Check for continuitybetweenthe control

relayNo.1and the controlrelayNo.2.
. ControlrelayNo.'l connector:
Disconnected
o Controlrelay No.2 connector:
Disconnected
Repairthe
narness.
(@t-
@ s)
(@r-
O s)
?FU2038

Checkfor an open-circuit,or a short-circuit

to earth,betweenthe fuel pump relayNo'2
tFt and the fuel pumP.
I-E-l
t ____v__J r Fuelpump relayNo.2connector:
Disconnected
o Fuelpumpconnector:
Disconnected
Repairthe
narness.
(@r-
O z)

t,
 FUEL- On-vehicleInspectionof MPIComponents 13-9
FUELPUMPRELAYNo.1INSPECTTON
( 1 ) C h e c kf o r c o n t i n u i t yb e t w e e nf u e l p u m p r e l a yN o . 1
terminals.
Battery TerminalNo.
voltage
1 2 3 4
Notsupplied a)
Supplied 1-)
?FU1931
e-- @

(2) Replacethe fuelpumprelayNo.1if fautty.

rtz
 35-1

SERVICEBRAKES
CONTENTS

SERVICE
ADJUSTM ENT
PROCED U R ES
.....,.20
ABSOperationCheck .....20
{' ValveRelayandMotorRelayCheck<ABS>........21

H Y D R A U L I CU N I T ..........21

G SENSOR ....................2

(L,)
35-2 SERVICEBRAKES - General/Service Tools
Specification/Special

GENERAL (

OF CHANGES
OUTLINE
. The hydraulicunit has been made more lightweightand compact.
. The ABS valve relayand the ABS motorrelayhave been separatedfrom the hydraulicunit.
o The G-sensorand the ABS-ECUhavebeenchanged.

SPECIFICATION
SERVICE
Items Standardvalue

Hydraulicunitsolenoidvalve internalresistanceo OUT 4.04- 4.54

IN 8.04- 9.04

ResistancebetweenspeedsensorterminalskO 1 . 4- 1 . 8

G-sensoroutputvoltage V Wheninstalled 2 . 4- 2 . 6
When removedwith arrow 3 . 4- 3 . 6
markfacinodown

SPECIALTOOLS
Tool Number Name Use
MB991529 ABS check For checkingof ABS (Diagnosiscode display
harness whenusingthe ABS warninglamp)

M8991638 ABS check Forcheckinoof ABS

narness

M8991348 Test harnessset For checkingof G-sensor

(L
 SERVICEBRAKES- ABS Troubteshooting 35-3
i. ABS TROUBLESHOOTTNG
STANDARD
FLOWOF DIAGNOSTIC
TROUBLESHOOTING

Verifycomplaint

I Reoccurs I c oes not reoccur

VY

"S""rb
F""d, a"d"
I l ( R e r etorP.35-4.) -t
No diagnosiscode
oiaonosis
cooeoisotaveol- iagnosiscode displayed No Diagnosis
code
or MUT-ll can't J I
communtcate Read (and write down) all displayed
diagnosiscodes and tfre service ciata
( f a u l td u r a t i o na n d h o w m a n v t i m e s
m e m o r i e sa r e e r a s e d' ) .A n d e r a s e
them.(Referto P.35-5.)
lnspectionchart for trouble symptoms
(Referto P.35-14.)

.----l-
t Read troublecodes
t
No Diagnosis
code

Diagnosiscode displayed

Inspectionchart for diaqnosiscodes Intermittentmalfunction

(Referto P.35-6.)

NOTESWITH REGARDTO DIAGNOSIS

The phenomenalistedin the followingtableare not abnormal.

Phenomenon Explanationof phenomenon

Systemchecksound
{t
ABS operationsound
ABS operation(Long
brakingdistance)
When startingtfr"
"n
theenginecompartment, but this is becausethe systemoperationcheckis deing
performed,and is not an abnormalitv.
1. sound of the motorinsidethe ABS hydraulicunitoperation(whine)
2. sound is generatedatongwith vibrationof the brakepedal.(scrapfng;
3. When ABS operates,.sound is generatedfrom the vehiclechassisoib to repeated
brakeapplicationand release.
(Thump:suspension;squeak;tyres)
For road surfacesrr"
for vehicleswith ABS can sometimesbe longerthanlhat for othervehicles.X.corJingty,
advisethe customerto drivesafelyon such ioads by loweringthe vehiclespeed
beingtoo overconfident. "nJ"not

Diagnosisdetectionconditioncan vary dependingon the diagnosiscode.

35-4 SERVICEBRAKES- ABSTroubleshooting
FUNCTION
DIAGNOSIS

W DIAGNOSISCODESCHECK
With thE MUT.II

4 Connectthe MUT-IIto the diagnosisconnector,then check

diagnosiscodes.
Caution
Turn the ignition switch off before connecting or discon-
necting the MUT-II.

Without the MUT-II

1. Use the specialtool to eadh diagnosisconnectorterminal
No.1.
NEE

2. Turn the ignitionswitchto ON and then take a readingof

the diagnosiscodes from the flashingof the ABS warning
When diagnosis code No.24is output lamp.

oN r secs.
OFF

Pausetime Tens Place Units

3 secs. signal division signal
2 secs.
14tO173

Whenno diagnosiscodeis output

 SERVICEBRAKES- ABS Troubteshooting 35-5
ERASING DIAGNOSIS CODES
with the MUT-rr
1. Connectthe M UT- IIto the diagnosisconn ec torthen
,
erasethe diagnosis
codes.
NOTE
Commands cannotbe receivedfromthe MUT-IIafterthe
memoryhas beenerased.To checkthe diagnosis codes,
stopthe engineandstartit again.The MUT-IIcanthenbe
usedagain.
2. Checkthe diagnosis codesto confirmthat the memory
hasbeenerased.
Withoutthe MUT-II
ffiG:-=\\ 1. Usethe specialtoolto earthdiagnosisconnectorterminal
U\\ED No.1.

2. Turnthe--ignition
switchto ON and turn the stop lamp
switchoff and on ten timesas shownin the illustratioh
below.Oncethis has beendone,all of the di agnos i s
codeswillbe erased.

ON
lgnitionswitch
OFF

ON
ABS warninglamp
OFF

ABS-ECU
memory
j within i within i within i i withini i
i 3 s e c . i 1 s e c . i 1 s e c .I ; t sec.i,
# _i Rtter1 second,
First Second Third T;rh* erasingis complete.
14CO120

&
35-6 SERVICEBRAKES- ABSTroubleshooting

CODES
CHARTFORDIAGNOSIS
INSPECTION
Inspectaccordingto the inspectionchartthat is appropriatefor the malfunctioncode.
Diagnosis Inspectionitem Diagnosiscontent Referencepage
code No.
11 Frontrightwheelspeedsensor Opencircuit 35-7

12 Frontleftwheelspeedsensor
13 Rearrightwheelspeedsensor
14 Rearleft wheelspeedsensor

15 Wheelspeedsensor outputsignal
Abnormal 35-8

16 Powersupplysystem 35-8

21 Frontrightwheelspeedsensor Shortcircuit 35-9

22 Frontleftwheelspeedsensor

23 Rear rightwheelspeedsensor

24 Rear leftwheelspeedsensor

26 G sensor Ooen-crrcuit. or
short-circuit 35-9
outputsigna.
abnormal
38 Stop lamp switchsystem 35-10

41 Frontrightsolenoidvalve lN 35-11

42 Frontleft solenoidvalve lN

43 Rear rightsolenoidvalve lN

44 Rear left solenoidvalve lN

45 FrontrightsolenoidvalveOUT

46 Frontleft solenoidvalveOUT

47 Rear rightsolenoidvalveOUT

48 Rear leftsolenoidvalveOUT

51 Valverelay 35-12

53 Motorrelay,motor 35-13

63 ABS-ECU Reolacethe ABS-

ECU.
 SERVICEBRAKES- ABSTroubteshooting 35-7
INSPECTION
PROCEDURE
FORDIAGNOSIS
CODES
9ode No.l1,12,13,14Wheelspeedsensoropencircuit Probablecause
The ABS-ECUdeterminesthat an open circuitoccursin more than one line of wheel a Malfunctionof wheelspeed sensor
speeosensors. a Malfunctionof wirinqharnessor connector
a Malfunctionof ABS-ECU

Measureat the ABS-ECUconnector. Check the followinq conn'ectors.

E-10 A-12,A-33,C-26,E--i3and E-15
. Disconnectthe connectorand mea-
sure from the harnessside.
. Resistancevalues between46 and
73, 69 and 70,71 and 72,24 and
Check the harnesswire betweeneach
O K : 1 . 4- 1 . 8k O w h e e l s p e e d s e n s o ra n d A B S - E C U .
and repairif necessary.

{, Wheel speed sensorinspection. Replacethe wheelspeed sensor.

v
35-8 SERVICEBRAKES- ABSTroubleshooting

CodeNo.15Wheelspeedsensor(Abnormaloutputsignal) Probablecause
A wheelspeed sensoroutputsan abnormalsignal(otherthan an open or short- . lmproperinstallationof wheel speedsensor
circuit). o Malfunctionof wheelspeed sensor
o Malfunctionof rotor
o Malfunctionof wheel bearing
. Malfunctionof wiringharnessor connector
. Malfunctionof ABS-ECU

W h e e l s p e e d s e n s o r i n s t a l l a t i o ni n -
soeclron.

Wheel speed sensoroutputvoltagein- Wheel speed sensorinspection. Replacethe wheel speed sensor.
spectron.

Replacethe rotor.

Check the harnesswire betweeneach

w h e e l s p e e d s e n s o ra n d A B S - E C U ,
and repairif necessary.

GodeNo.l6 Powersupplysystem Probablecause

The voltaqeof the ABS-ECUpowersupplydrops loweror riseshigherthan the . Malfunctionof wiringharnessor connector.
specifiedvalue. lf the voltagerelurnsto the specifiedvalue,this code is no longer . Malfunctionof ABS-ECU
output.

Caution
lf batteryvoltagedrops or rises during inspection,this code will be output as well. lf the voltage
returnsto standardvalue,this code is no longeroutput.
Beforecarryingout the followinginspection,checkthe batterylevel,and refill it if necessary.

Measureat the ABS-ECUconnector Check the following connectors.

E-10. C-25,C-59,C-66 and C-78
o Disconnectthe connectorand mea-
sure from the harnessside.
r Start the engine. Voltage between
83 - Body earth Checktroublesymptoms. Check the harnesswire betweenthe
OK: Systemvoltage and the ABS-ECU,and
ignition-switch
reparrrl necessary.

tI)
 SERVICEBRAKES- ABSTroubteshooting 35-9
CodeNo.21
,22,23,24Wheelspeedsensorshortcircuit Probablecause
These codes are outputat the followinqtimes: . Malfunctionof wheelspeed sensor
o When an open circuitcannotbe fou'nd,but more than one wheel speedsensor o Malfunctionof rotor
doesnot outputany signalduringdrivingat 8 km/hor higher. o Malfunctionof wheel bearino
. Wnen a chrppedor ptugged-uprotortooth,etc. is detected. o Malfunctionof wiringharnesi or connector
. When the sensoroutputdrops and anti-lockcontrolis continuouslvcarriedout . Malfunctionof ABS-ECU
due to a defectivesensoror a waroedrotor.

Measure at the ABS-ECU connectors Check the following connectors.

E - 10 . A - 1 2 ,A - 3 3 ,C - 2 6 ,E - 1 3a n d E - 1 5
. Disconnectthe connectorand mea-
sure from the harnessside.
. Resistancevalues between46 and
73, 69 and 70,71 and 72,74 and
Check the harnesswire betweeneach
O K : 1 . 4- 1 . 8k f ) w h e e l s p e e d s e n s o ra n d A B S - E C U ,
and repairif necessary.

Replacethe wheelspeed sensor.

Replacethe rotor.

CodeNo.26G-sensorsystem(open-,short-circuitedor Probablecause
signalabnormal)
Outputis providedin the followingcases. o G-sensordefective
. G-sensoroutputdrops below0.5V or risesabove 4.5V

,s, . G-sensorsystemharnessis brokenor shorted

. Harnessand connectordefective
o ABS-ECUdefective

Check G-sensor.(Referto P.35-22.) ReplaceG-sensor

Measureat ABS-ECUconnectorE-10. Check the following connector. D-27

o Disconnectconnectorsand make measure.
mentson harnessside.
. lgnitionswitch:ON
. VoltagebetweenNo.62and 45
OK: 2.3-2.7V
Checktroublesymptoms.

Check harnessbetweenG-sensorand ABS-

ECU, and repairif necessary.

Check the following connector. E-10

& ReplaceABS-ECU.

;
35-10 SERVICEBRAKES- ABSTroubleshooting

corle No-38 Stoo lamp switch system Probablecause

a Malfunctionof stop lamp switch
These codes are outputat the followingtimes: o Malfunctionof harnessor connector
a" WH;ih; iiop rampswiicrris not b5 turnedoff (whenthe stop lamp switchstavs a Malfunctionof ABS-ECU
on for 15 minLtesdr more althoughthe ABS is not operating)
. wd; inl Aa6-ECU Oetermines inat there is an opeh circuil'inharnessof the
stop lamp switchsystem.

D o e s t h e s t o P l a m P i l l u m i n a t ea n c l Stop lamp switch installation

switchoft normallY? inspection.

Stop lamp switchinspection Replacethe stop lamp switch

Check the harnessbetweendedicated

f u s e N o . 1 7a n d t h e A B S - E C U a
' nd
repairif necessary.

Measureat ABS-ECUconnectorE-10. Check the following connectors.

. D i s c o n n e c tt h e c o n n e c t o ra n d C-50,C-65 and C-79
measureat the harnessside.
. Stop lamp switchON.
o Voliage6etween36 - bodYearth
OK: Systemvoltage

Check the harnessbetweenstop lamp

switchand the ABS-ECU'and reparrll
necessary.

Check the following connector.

 SERVICEBRAKES- ABSTroubteshooting 35-11
Code No.41, 42, 43, 44, 45, 46, 47,48 Solenoid valve Probablecause
The ABS-ECUalwaysmonitorsthe solenoidvalve drivecircuit.lt determinesthat a Malfunctionof harnessor connector
there is an open or short-circuitin the solenoidcoil or in a harness:when no currenl a Malfunctionof hvdraulicunit
flows in the solenoideven thoughthe ABS-ECUturnson it, and vice versa. a Malfunctionof Ai3S-ECU

Solenoidvalve insDection
(Referto P.35-21.)

Measureat hydraulicunil connectorA- Check the following connectors.

78 and ABS-ECUconnectorsE-10. A-78.C-25.C-59and E-10
r D i s c o n n e c tt h e c o n n e c t o r a n d
measureat the harnessside.
. C o n t i n u i t yb e t w e e nt h e f o l l o w i n g
terminals
OK: Conlinuitv
HU side 1234
ABS-ECU 30
t t t l31 78 Check the harness betweenthe hv-
79
side draulicunit and ABS-ECU,and repdir
rs necessary.
HU side 5678
lttl
ABS-ECU 58 59 50 51
side

Replacethe ABS-ECU.
35-12 SERVICEBRAKES- ABSTroubleshooting

CodeNo.51ValverelaY Probablecause
o Malfunctionof valve relaY
lCommentl
i:[1!_AgS-ECUcontinuallymonitorsthe solenoiddrivecircuit.lf no currenlis being
. Malfunciionof wiringharnessor connector
o Malfunctionof ABS-ECU
sropf,eOto i iolenoid coil even thoughthe solenoidvalve relayis.on.or if.current o of hydraulicunit
cohiinuesto be suppliedto five or more solenoidcoils even thougn_tnesolenolo Malfunction
valve relayis off, the ABS-ECUjudgesthal there is a problemwltn tne Ats5 valve
relay.Thi6 diagnosiscode is then output.

Replacethe valve relaY.

Measureat valve relay connectorA- Check the harness between fusible

94. link No.7 and valve relay,and repair if
. Disconnectthe connectorand mea- necessary.
sure at the harnessside.
. Voltagebetween5 - bodYearth
OK: Systemvoltage

Measureat ABS-ECUconnectorE-10. Check the tollowing connectors.

o D i s c o n n e c tt h e c o n n e c t o r a n d A-94 and C-94 or C-96
measureat the harnessside.
. Resistancebetween82-47
OK:60-120O
Check the harness betweenvalve
r e l a y a n d A B S - E C U ,a n d r e P a i ri f
necessary.
Solenoidvalve insPection
(Referto P.35-21.)

Measureat hydraulicunit connectorA- Check the following connectors.

78 and ABS-ECUconnectorsE-10. A-78,C-25and E-10
. D i s c o n n e c tt h e c o n n e c t o ra n d
measureat the harnessside.
. C o n t i n u i t yb e t w e e nt h e f o l l o w i n g
terminals
OK: Continuity
HU SidE 1234

ABS.ECU 3|o 311 t|u ?1, Check the harness between the hY-
side draulicunit and ABS-ECU,and repair
It necessary.
HU side 5678

ABS-ECU 5|u 51, 5|o J,

side

Check the following connectors'

Measureat hydraulicunit connectorA- A-77 and A-94
77 and valveielay connectorA-94.
. Disconnectthe connectorand mea-
sureat the harnessside.
. C o n t i n u i t yb e t w e e nt h e f o l l o w i n g
Check the harness between the hY-
terminals draulicunit and valve relay,and repair
OK: Continuity if necessary.
HUside 11

Reolacethe ABS-ECU.
 SERVICEBRAKES- ABS Troubleshooting 35-13
CodeNo.53Motorrelay,motor Probablecause
These codes are outputat the followinqtimes: o Malfunctionof motor relav
when the motor rela! is on bul no sign-alis inputto the molor monitorline (motoris . Malfunctionof wiringharnessor connector
not operating,etc.) . Malfunctionof hvdraulicunit
When the motor relayis off but a signalis inputto the motormonitorline for 5 . Malfunctionof ABS-ECU
s.etondsor more (motorcontinuesoperating,etc.)
When the motor relavdoes not ooerite

Caution
Becauseforce'drivingof the motor by meansof the actuatortest will drain the battery,the engine
shouldbe startedand left to run for a while aftertestingis completed.
Yes
MUT-II actuator test Check the harnessesbetweenthe hv-
ls the sound of the motor operating draulicunrtand ABS-ECU,and repdir
head? rrnecessary.

relavinsnection
(Rerer
to
A?:-ffi"t

Measure at motor relav connectorA- C h e c k t h e h a r n e s sb e t w e e nf u s i b l e

77. link No.7and motorrelay,and repairif
. Disconnectthe connectorand mea- necessarv.
sureat the harnessside.
. Voltagebetween5 - body earth
OK: Systemvoltage

Measureat ABS-ECUconnectorE-10. Repair

. Disconnectthe connectorand mea-
sure at the harnessside
. Resistancebelween77-82
OK: 78-88O
C h e c k t h e h a r n e s sb e t w e e nm o t o r
relayand ABS-ECU,and repairif nec-
essary.
Measureat ABS-ECUconnectorE-10. Check the harness between the hv-
. Disconnectthe connectorand mea- draulicunit and ABS-ECU,and reodir
sureat the harnessside. i f n e c e s s a r y .M o t o r e a r t h . r e p a i r i f
. R e s i s t a n c eb e t w e e n 6 5 - b o d v necessary.
earth
O K : 0 .1 - 0 . 3 O

inspection
y.Blo_rrii"r",'"n (Referro Replacethe hvdraulicunit.

Repair

Replacethe ABS-ECU.
35-14 SERVICEBRAKES- ABSTroubleshooting

CHARTFORTROUBLESYMPTOMS
INSPECTION
of the troublesymptomsand checkaccordingto the inspectionprocedurechart.
Get an understanding
Troublesymptom Inspection Reference
proceoure page
No.
Communication withMUT-II with all systemsis not possible.
Communication 1 35-15
is not possible.
with ABS only is not possible.
Communication 2 JC- tO

When the ignitionkey is turnedto "ON" (enginestopped),the ABS warninglamp does 3 35-17
not illuminate.
Afterthe enginestarts,the lamp remainsilluminated. 4 35-17

FaultyABSoperation Unequalbrakingpoweron both sides 5 35-18

brakingpower
Insufficient
ABS operatesundernormalbrakingconditions
ABS operatesbeforevehiclestopsundernormalbrak-
ing conditions

Largebrakepedalvibration(Caution2.)

Caution
1. lf steeringmovementsare madewhen driving at high speed,or when driving on road surfaces
with low frictionalresistance,or when passingover bumps,the ABS may operateeven though
s u d d e n bra ki n gi s n o t b e i n g a pplied.Becauseof this, when getting infor m ati onfr om the
customer,checkif the problemoccurredwhiledriving undersuch conditionsas these.
2. DuringABS operation,the brake pedal may vibrateor may not be able to be depressed.Such
p h e n o me n a a red u e to i n te rmittentchangesin hydr aulicpr essur einsidethe br ak e l i ne to
preventthe wheelsfrom lockingand is not an abnormality.
 SERVICEBRAKES- ABSTroubleshooting 35-15
,(, rNspEcnoNpRocEDURE
FoRTRoUBLE
syMproMs
InspectionProcedure1

with MUT-IIis not possible.

Communication Probablecause
with all systemsis not possible.)
(Communication
The cause is probablya defectin the powersupplysystem(includingearth)for the o Malfunctionof the connector
diagnosisline. . Maliunctionof the harnesswire

Measureat the diagnosticconnector Check the following connectors.

A-11x.C-65.C-67and C-79
. Voltagebetween16 and earth
OK: Systemvoltage

Check the harnesswire betweenthe

power supply and diagnosisconnector
and repairif necessary.

Measureat the diagnosticconnector

. Continuitybetween4 and earth
o Continuitvbetween5 and earth
OK: Cohtinuitv
Check the harnesswire betweenthe
diagnosisconnectorand earth,and re-
parrrr necessary.
Reolacethe MUT-ll

ry
35-16 SERVICEBRAKES- ABSTroubleshooting
Inspectionprocedure2

with MUT-IIis not possible.

Communication Probablecause
with ABS only is not possible.)
(Communication
When communicationwith the MUT-ll is not possible,the cause is probablyan open . Blownfuse
circuitin the ABS-ECUpowercircuitor an opencircuitin the diagnosisoutputcircuit. o Malfunctionof wiringharnessor connector
o Malfunctionof ABS-ECU

Measureat diagnosisconnectorC-70 Check the following connectors.

and ABS-ECUconnectorE-10. C - 2 7 , C - 7 0a n d E - 1 0
. Disconnectthe connectorand mea-
sureat the harnessside.
. C o n t i n u i t yb e t w e e nt h e f o l l o w i n g
terminals Check the harness betweenthe ABS-
OK: Continuity ECU and diagnosisconnector,and re-
pair if necessary.
ABS-ECU 38 68
side
Diagnosisconnector 7 1
stoe

Measureat ABS-ECUconnectorE-10. Gheck the following connectors.

. Disconnectthe connectorand mea- C-25,C-66 and C-78
sureat the harnessside.
o lgnitionswitchON
. Voltagebetween83 body earth
OK: Systemvoltage Check the harnessbetweenfuse No.3
i n s i d e t h e j u n c t i o nb l o c k a n d A B S -
ECU, and repairif necessary.

Measureat ABS-ECUconnectorE-10.
o Disconnectthe connectorand mea-
sure at the harnessside.
. Continuitybetween55, 56 - body
earth
OK: Continuity
 SERVICEBRAKES- ABS Troubleshooting 35-17
InspectionProcedure3

Whenignitionkey is turnedto o'ON"(enginestopped), Probablecause

ABSwarninglampdoesnot illuminate.
lf the lampdoesnot illuminate,
the causemay be: an opencircuitin the lamppower o Blownfuse
supplycircuit,a_blownlamp bulb,an open cirbuitbetweenthe ABS warningla'mp . Burntout ABS warninglampbulb
and the ABS-ECU. o Malfunctionof wiringhirness or connector

Fuse inspection,Multi-purposefuse Refer to InspectionService Points for

a BlownFuse.

Measureat connectorD-16 Checkwhetherthe ABS warninglamp Replacethe ABS warninglampbulb

. Disconnectthe ionnector and mea- bulbis burntout.
sureat the maleoin.
o lgnitionswitch:ON
o Does the ABS warning lamp
i l l u m i n a t ew h e n t e r m i n a l7 i s Check the followinq connectors.
earthed? C-68.C-78. D-04ana D-45
OK: llluminates

C h e c k t h e h a r n e s s e sb e t w e e n t h e
A B S - E C U a n d c o n n e c t o rD - 1 6 .
Repair,if necessary.

InspectionProcedure4

Evenafterthe engineis started,the ABS warninglamp Probablecause

remainsilluminated.
The causeis probablya short-crrcuit
in the ABS warninglampillumination
circuit. a Malfunctionof combinationmeter
a Malfunctionof ABS-ECU
a Malfunctionof wiringharness

NOTE
Thistroublesymptomis limitedto caseswherecommunication
withthe MUT-IIis possible
(ABS-ECU
powersupplyis
normal)andthediagnosis codeis a normaldiagnosis
code.

Disconnect
connectorD-16and turnthe ignitionswitchto ON. Replacethe combinationmeter.
o Doesthe ABS warninglampremainilluminated?

. Disconnect ABS-ECUconnectorE-10.
. lgnitionswitch:ON
o Does the ABS warninglamp switchoff?

Check the harnessesbelweenthe combinationmeter and the

ABS-ECU.Repair.if necessarv.
35-18 SERVICEBRAKES- ABSTroubleshooting

InspectionProcedure5

Brakeoperationis abnormal. Probablecause

This variesdependingon the drivingconditionsand the road surfaceconditions,so a lmproperinstallationof wheel speed sensor
pioOfemCiagnbsisisAifficutt.Howeier, if a normaldiagnosiscode is displayed,carry a lncorrectsensorharnesscontact
out the followinginspection
a Foreignmaterialadheringto wheel speed sensor
a Malfuhctionof wheel speed sensor
a Malfunctionof rotor
a Malfunctionof wheelbearing
o Malfunctionof hydraulicunit
a Malfunctionof ABS-ECU

W h e e l s p e e d s e n s o r i n s t a l l a l i o ni n -
speclron

Replacethe wheelspeed sensor.

Rotorinspection.

Check the following connectors.

A - 1 2 ,A - 3 3 ,C - 2 6 ,E - 1 3a n d E - 1 5

Measureat ABS-ECUconnectorC-29.
. Disconnectthe connectorand mea-
sureat the harnessside
. Resistancevalue between terml-
nals 46-73,69-70,71-72and 74'75
O K : 1 . 4- 1 . 8k C )
(The sensorharnessand connector
i h o u l d b e m o v e d w h i l et h e s e i n -
spectionsare carriedout.)

Check the following connector.

E-10
 SERVICEBRAKES- ABS Troubteshooting 35-19
SERVICEDATAREFERENCE
TABLE
Thefollowing
itemscanbe readby the MUT-IIfromthe ABS-Ecuinputdata.
1. Whenthe systemis normal
ItemNo. Check ltem Checking
Requirements NormalValue
11 Front-right
wheelspeed Do a testrun Vehiclespeeds
sensor displayedon the
12 Front-leftwheelspeedsensor speedometer
and MUT-IIare
13 Rear-rightwheelspeed identical.
sensor
14 Rear-left
wheelspeedsensor
16 powersupplyvott-
ABS-ECU lgnition
switchpowersupplyvoltageandvalve Systemvoltage
age monitorvoltage
17 G-sensor
outputvoltage Vehicleis stationary. 2 . 4- 2 . 6 V
Perform
actualrunning. Displayedvalue
risesaboveor
drops below
2.5V.
3B Stop lamp switch Depressthe brakepedal. ON
Releasethe brakepedal. OFF

2. Whenthe ABS-ECUshut off ABS operation.

Whenthe diagnosis
systemstopstheABS-ECU,the MUT-IIdisplaydatawillbe unreliable.
ACTUATOR
TESTREFERENCE
TABLE
TheMUT-IIactivates thefollowing
actuators
for testing.
NOTE
1. lf the ABS-ECUrunsdown,actuatortestingcannotbe carriedout.
2' Actuatortestingis only possiblewhenthe vehicleis stationary.
lf the vehiclespeedduringactuator
testingexceeds10 km/h,forcedactuationwillcancels.

Activationpattern ACTUATOR
TESTSPECIFICATIONS
Hydraulic Start of forced
pressure -l actuation
increases I
No. Item
Sote- Hydraulic i
noid pressure
vatve l19r9s,.
i
i
01 Solenoidvalvefor front-right Solenoidvalvesand
Hydraulac
pressure i
!
wheelandmotor pump motorsin the
decreases i
tr hydraulicunit(simple
40-45 msi i 02 Solenoidvalvefor front-leftwheel inspectionmode)
ON and motor
Pump
motor
OFF 03 Solenoidvalvefor rear-right
wheelandmotor
o4 Solenoidvalvefor rear-leftwheel
and motor
35-20 SERVICEBRAKES- ServiceAdiustmentProcedures
PROCEDURES
ADJUSTMENT
SERVICE
CHECK
ABS OPERATION
WHEELSPEEDSENSOR OUTPUTVOLTAGE CHECK
1. Liftup thevehicleand releasethe parkingbrake.
2. Disconnect the ECU har nessconnectorand us e the
specialtool to measurefromthe harnesssideconnector'
3. iotate the wheelto be measuredat approximately 112-1
rotationpersecond,and check the voltage
output usinga
Main wiring harness M8991638 i4co13o
circuittesteror an oscilloscope.
Wheel Front left Front Rear left Rear right
speed right
sensor
Terminal 1 9 14 16 18
No.
20 15 17 46

Outputvoltage
Whenmeasuringwith a circuittester:
70 mV or more
Whenmeasuringwith an oscilloscope:
100mV P-Por more
4 . lf the outputvoltageis lowerthan the abovevalues,the
reasoncouldbe as follow:
o Faultywheelspeedsensor.
So replacethewheelsPeedsensor.

InspectingWaveFormsWith An Oscilloscope
Usethe followingmethodto observethe outputvoltagewave
formfromeachwheelsensorwithan oscilloscope .
o Startthe engine,and rotatethe frontwheelsby engaging
1st gear (vehicles with manualtransmission) or D range
( vehicleswith automatictr ansmission) . nthe r ear T ur
wheelsmanually so thattheyrotateat a constantspeed.
NOTE
1 . C h e c kt h e c o n n e c t i o no f t h e s e n s o rh a r n e s sa n d
connector beforeusingthe oscilloscope.
2. The waveform measurements can also be takenwhile
thevehicleis actuallymoving.
3. The outputvoltagewill be smallwhenthe wheelspeedis
low,and similarlyit will be largewhenthe wheelspeedis
high.
sERVlcEBRAKES- serviceAdjustment
procedure/Hydrautic
Unir 3S-21
VALVERELAYAND MOTORRELAYCHECK
<ABS>
Removethe splashshield(FR) and removethe relavs.

Batteryvoltage TerminalNo.
$)iu""JrJy
1 3 4 5
Continuityno voltage G- --{

Continuity
withvoltage c- --{

0- --€

HYDRAULIC
UNIT
INSPECTION
/lrel SOLENOID VALVECHECK
,EL- I
Measurethe resistance
betweenterminals.
€jFJ-Fffir Standardvalue:
lf.X.Xetl
Solenoidvalve Measurement Resistancebetween
terminals terminals.
FrontlN (rightside) 1- 11 8.04- 9.04O
FrontlN (leftside) -1 1- ||
11

RearlN (rightside) 3-11

RearlN (leftside) 2-11
FrontOUT (rightside) 5-11 4.O4- 4.54A
FrontOUT (leftside) 8-11
RearOUT (rightside) 7-11
RearOUT (leftside) 6-11

MOTOROPERATION CHECK
connectthe batteryand checkto be surethat the soundof
the hydraulic
unitmotoroperating
canbe heard.
Caution
The batterypower should not be appliedfor more than 1
second.
35-22 SERVICEBRAKES- HydraulicUniUG-Sensor
INSTALLATIONSERVICEPOINT
1. BRAKE PIPEINSTALLATION
Connectthe tube to the hydraulicunit as shown in the
illustration.
(1) Fromhydraulicunitto frontbrake(L.H.)
(2) Fromhydraulicunitto rearbrake(R.H.)
(3) Fromhydraulicunitto rearbrake(L.H.)
(4) Fromhydraulicunitto frontbrake(R.H.)
(5) From mastercylinderto hydraulicunit (frontL.H. line
and rear R.H.line)
(6) From mastercylinderto hydraulicunit (frontR.H. line
and rearL.H.line)

G-SENSOR
INSPECTION
1 . D i s c o n n etchte G - s e n s ocro n n e c t oarn dc o n n e ct th e
specialtool betweenthe terminalsof the disconnected
connector.
2. Turn the ignitionswitch to ON and take a readingof the
followingoutPutvoltage.
BetweenterminalsNo.2and No.3.
MB991348 Standard value: 2.4 - 2.6 V

With the specialtool still connected,securethe G-sensor

so that the labelsurfaceis facing straightdown, and then
take a readingof the followingoutputvoltage'
BetweenterminalsNo.2and No.3.
Standard value: 3.4 - 3.6 V
4 . lf the voltageis outsidethe standardvalue,afterchecking
to be sure that there is no abnormalityin the powersupply
and earthwires,replacethe G-sensor.
 528-1

SUPPLEMENTAL
RESTRAINT
SYSTEM(SRS)
0
CONTENTS

TROUBLESHOOTING .." ...4

StandardFlowof Diagnostic Troubleshooting '.......4
I n s p e c t i oCnh a r tf o r D i a g n o s t iCco d e s. . . . . . . " . . . . . . .5' . . '
InspectionprocedureClassifiedby
D i a g n o s iCs o d e . . . . . . . . . . . . . ' . .5.
Chartfor TroubleSymptoms.".-...'.'.'."12
lnspection
Procedure
lnspection for TroubleSymptoms'."'.'.12

A I R B A G M O D U L E A N D C L O C K S P R I N G . . . . . .1 4

o
52B'-2 SRS - SRSServicePrecautions

PRECAUTIONS
SRSSERVICE
1. In orderto avoidinjuryto yourselfor others
f r o m a c c i d e n tadl e p l o yme not f the air bag
duringservicing, readand carefully followall
the precautions and procedures described in
this manual.
2. Do not use any electrical testequipment on or
nearSRS components, except those specified
on P.52B-4.
3 . N e v e r A t t e m p t t o R e p a i rt h e F o l l o w i n g
Components:
. SRSairbagcontrolunit(SRS-ECU)
o ClockSpring
. AirBagModule
(Driver's sideor frontpassenger's side)

4. Do not attemptto repairthe wiring harnessconnectorsof

the SRS. lf any of the connectorsare diagnosedas faulty,
replacethe wiring harness.lf the wires are diagnosedas
connector
SRS-ECU faulty, replaceor repair the wiring harness accordingto
the followingtable.
 SRS - SRSServiceprecautions
528-3
Corrective
action

21 pins,yellow

Bodywiringharness- Clockspring- Air bag Corrector replaceeach

module(Drive/sside) wiringharness.Replace
clockspring.
Bodywiringharness---
Air bagmodule(Front Corrector replaceeach
passenger's
side) wrnngnarness.

Bodywiringharness- Diagnosis
connector Corrector replaceeach
wiringharness.

Bodywiringharness--.+Junctionblock(fuseNo.11) Corrector replaceeach

Bodywiringharness---rJunctionblock(fuseNo.1g) wiringharness.

Bodywiringharness
- SRSwarninglamp
1 6t o 1 9

Body wiring harness.-+Earth

Corrector replacebody
wiringharness.

5 . A f t e r d i s c o n n e c t i n gt h e b a t t e r y c a b l e , w a i t
Insulating
s e c o n d s o r m _ o r e ^ b e f o r pe r o c ; e d i n g * l t n - t6n0e
tape Battery fottowingwork. The.sRSsystdmis oeiiln-eoio'i"t"in
enoughvottageto deptoy ihe air bag foi JJrrortiirn"
even after the battery has been aisconneci"-ol'"o
serious injury_mayresult from unintended
deptoym ent if wor k is done on the SRC "ii'O"g
imm ediater yafter the batter y cabr es " V"
oi " "ion-
",
nected. "r "

6 . SRScomponents
shouldnot be subjected
to hear over93.C,so removethe SRS-ECU, air bag module
andclocksprino b*1" gryjp ql oa!1s thevehicreaflei[aintins
-finish
7 . wheneveryou servicirigtne snb, checkwarningiampoperation
functions properly. to makesurethat the system
8 . Makecertainthatthe ignitionswitchis oFF when
the MUT-IIis connected or disconnected.
9 . lf you haveanyquestions aboutthe SRS,pr""r" .oitaciyour tocaldistributor.
NOTE
S ER I O U S
I N J U R YC A N R E S U L TF R OMUNINTENDED
T H EPR O C E D U R E AIR BAGDEPLOYMENT, SO USE ONLY
ASN DE QU IP ME NT SPECIFIEDINTHISM ANUAL.
52B'-4 SRS - SpecialTool/TestEquipmenUTroubleshooting

SPECIALTOOL
Tool Number Name Use
M8991613 SRS check Checkingthe SRS electricalcircuitry
harness

TESTEQUIPMENT
Tool Name Use
Digitalmulti-meter Checkingthe SRS electricalcircuitry
for whichthe
Use a multi-meter
maximumtest currentis 2 mA or lessat
the minimumrangeof resistance
measurement

TROUBLESHOOTING
TROUBLESHOOTING
FLOWOF DIAGNOSTIC
STANDARD

Gathering information from customer Verifycomplaint

- I

I *"o".r,..
t
resnol reoccur

Check diagnosis co d" agnosis code

--T-
osrs
I D i a g n o s i sc o d e
i'*qrr**,'.*.il- J displayed
Recheck diagnosis code(s) then erase

-=t-
1n

{ No Diagnosis
cooe
Check trouble codes
(Refer to P.528-5.)

D i a g n o s i sc o d e
displayed

Inspection chart for trouble irn"-@'l lntermittent mallunction

|
syniptoms (Refer to P.52B-12.) | (nefer to P.528-5.)
 SRS - Troubleshooting 528-5
INSPECTION
CHARTFORDIAGNOSIS
CODES
Inspectaccordingto the inspectionchartthat is appropriatefor the malfunction
code.

AnalogG-sensorsystemin the SRS-ECU

SafingG-sensorsystemin the SRS-ECU

21,22,61,62 Driver'sside air bag modute(squib)system
2 4 , 2 5 , 6 4 ,6 5 Frontpassenger'sside air bag module(squib)system

SRS-ECUcapacitorsvsrem
Connectorlocksystem
SRS-ECU(deployedair bag) system
lG, (A) powercircuitsystem
lG, (B) powercircuitsystem
SRS warninglampdrivecircuit Lampdoesnot illuminate.
sysrem
Lampdoes not switchoff.
SRS warninglampdrivecircuitsystem
sRS-ECunon-volatite
memory(EEpRoM)andA/Dconverter
svstem
Driver'sside air bag modure(squibignitiondrivecircuit)system
Frontpassenger'sside air bag modure(squibignitiondrivecircuit)svstem

NOTE
,t,.'lff;J;,1ffii:t;:?n returns
to normal,
thediasnosis
codewiflbeautomaricaly
erased,
andthesRSwarning
(2) ff the vehicle has,a dischargedbatteryit will store the fault
codes 41 or 42. when these diagnosiscooes are
displayed,checkthe batterv.

INSPECTION
PROCEDURE
CLASSIFIED
BY DIAGNOSIS
CODE
Gode No.14Analog G-sensor system in the SRS-EC- Probable cause
Ine sH5-EL;Umonitorsthe outputof the analogG-sensorinsidethe sRS-Ecu. .
It outputsthis code when any of the followinqari Celecteo. Malfunction
of SRS-ECU
r Whenthe analogG-sens6ris not operatiio
. When the characteristics of the analogG_sensorare abnormal
. Whenthe outputfromthe analogG-s6nsoris abnormal

Replacethe SRS-ECU.
528-6 SRS - Troubleshooting

cocle No-l5 Safino G-sensor svstem in the SRS'ECU Probablecause

of the . of SRS-ECU
Malfunction
This code is outputif there is a short or open circuitbetweenthe terminals
safinqG-sensorinsidethe SRS-ECU.
in" tiornte ciuses for each diagnosiscode No are as follows'

CodeNo. TroublesymPtom
15 Shortcircuitin thesafingG-sensor
16

Replacelhe SRS-ECU.

CoO"No.21,22,61 or 62 Driver'ssideair bag module Probablecause

{errrrih\ svstem
the Inpul a Malfunctionof clocksPring
These diaqnosiscodes are outputif there is abnormalresistancebetween a Malfunctionof wiringharnessesor conneclors
terminals5f the drivefs sideair bag module (squlb)'
a Malfunctionof drivei'sside air bag module(squib)
in" irJrorc iiuses tor each diagnosiscode No are as follows' a Malfunctionof SRS-ECU

Code No. TroublesymPtom

21 o short in driver'sside air bag module(squib)or harnessshort

r Shortin clocksPring

22 a Ooen crrcurtin driver'sside air bag module(squib)or open harness

a Open circuitin clocksPring
a Malfunctionof connectorcontact

61 o Shortin driver'sside air bag module(squib)harnessleadingto the powersupply

62 o Shortin driver'sside air bag module(squib)harnessleadingto the earth

SRS checkharness MUT-llSelf-diagcode Check the following

(M8991613) o Disconneciclock sPring connectors:
connectorC-92. C-92 and D-51
o ConnectSRS check harness
connector(1).
. Erase diagnosis code
memory.
Are code No.21, 22,61 or 62
outout?

C h e c k t h e h a r n e s sw l r e
b e t w e e nt h e S R S - E C U
and clockspring.

Reolacethe driver'ssideair bag module.

528-8 SRS - Troubleshooting

CodeNo.35SRS-ECU(deployedair bag)system Probablecause

This diagnosiscode is outputafterthe air bag deploys.lf this code is outputbeto_re . of SRS-ECL
Malfunction
the air bag has deployed,the causeis probablya malfunclion insidethe SRS-ECU.

Reolacethe SRS-ECU.

CodeNo.41lG1(A) powercircuit system Probablecause

Thisdiagnosiscodeis outputif the voltagebetweenthe lGi (A)terminaland the o Malfunctionof wiringharnessesor connectors
earth is fowerthan the specifiedvalue for a continuousperiodof 5 secondsor more. . Malfunctionof SRS-ECU
However,if the vehicleconditionreturnsto normal,diagnosis codeNo.41willbe
automatically erased,and the SRS warninglampwillswitchoff.

SRS checkharness Measureat SRS check harness Check the following

(M8991613) connector(5). connectors:
. Disconnect SRS-ECU C 7 4 , C 7 a8 n dD 5 1
connectorD-51.
r ConnectSRS checkharness
connector(3).
r Continuitvbetweenterminals
(20)and i21)
OK: Continuity

Check the harness wire betweenlhe SRS-ECU and earth, and

repairil necessary.

Measureat SRS checkharnessconnector(5). Check the following

. Disconnect SRS-ECUconnectorD-51. connectors:
o ConnectSRS check harnessconnector(3). C-74andD-51
. Connectnegativebatterycable
o lonitionswitch:ON
o Vbltagebetweenterminal(14) and body earth
OK: 9Vormore

C h e c k t h e h a r n e s sw i r e b e t w e e nt h e S R S - E C Ua n d i q n i t i o n
switchlG1,and repairif necessary.
 SRS - Troubleshooting 528-9
CodeNo.42lG1(B) powercircuitsystem Probablecause
]frl; is outpu.tif the voltagebetweenthe lG1 (B) terminaland the
Qqagnosis.,code . Malfunctionof wiringharnessesor connectors
eann rs towertnan the specifiedvalue for a continuousperiodof 5 secondsor more.
However,rt the vehiclecondilio_n returnslo normal,diajnosis code No.42will be
automaticallyerased,and the SRS warninglampwillswitchoff.

SRS checkharness Measureat SRS checkharness Check the following

(M89e1613) connector(5). connectors:
o Disconnect SRS-ECU C-74,C-78and D-51
connectorD-51.
o ConnectSRS checkharness
connector(3).
. Continuitybetweenterminals
(20)and (21)
OK: Continuity

Check the harnesswire between the SRS-ECU and earlh, and

repairif necessary.

Measureat SRS checkharnessconnector(5).

' ' C h e c k _t h e f o l l o w i n g
. Disconnect SRS-ECUconnectorD-51. connectors:
. ConnectSRS checkharnessconnector(3). C-79and D-51
. Connectnegativebatterycable
. lgnitionswitch:ON
. betweenterminal(13) and body earth
Y91taS9
OK: 9Vormore

C h e c k t h e h a r n e s sw i r e b e t w e e nt h e S R S - E C Ua n d i g n i t i o n
switchlG1,and repairif necessary.

0,
52B-10 SRS - Troubleshooting

CodeNo.43SRSwarninglampdrive circuitsystem Probablecause rd

(Lampdoes not illu
for a continuousperiodol . Malfunctionoi wiringharnessesor connectors
This diaonosiscode is outputwhen an open circuito_ccurs o Blownbulb
i';il;il;hitil[e SnsEcu in monitoring rhe sBS warningrampand the lampis
. Malfunctionof SRS-ECL
OFF (transistor OFF). o Malfunctionof combinationmeter
ii,*duJi,iilhis code!is outputdue to an open circuit,if the vehicleconditionreturns
o.+Swill b'eautomaticallyerased,and the SRS
iJrioimli, this diagnosiscoOJf.rf
warninglamp will returnto normal.

Measureat SRS check harness Check the following

SRS checkharness
(MB991613) connector(5). connectors:
. Disconnect SRS-ECU C-74,C-78and D-51
connectorD-51.
o ConneclSRS check harness
connector(3).
o Continuitybetweenterminals
(20)and (21)
OK: Continuity

Check the harness wire betweenthe SRS-ECU and earth, and

repairif necessary.

,l

Measureat SRS check harnessconnector(5)'

. Disconnect SRS-ECUconnectorD-51.
o ConnectSRS checkharnessconnector(3)'
. lonitionswitch:ON
o Connectnegativebatterycable , Check the lollowing
. Connectterminal(15)to the bodyeann. connectors:
OK: LamP illuminates c - 1 3 , c - 6 8 , C - 7 8 ,D - 0 4
and D-05

the SRS-ECU
ReDlace

C h e c k t h e h a r n e s sw i r e
b e t w e e nt h e S R S - E C U
and ignitionswitch(lGr).

Replacethe combination
meter.
q
 SRS - Troubleshooting 528-11
|& CodeNo.43SRSwarninglampdrive circuitsystem Probablecause
llgtp does not switch off.)
This diagnosiscode is outputwhen a shortto earth occursin the harnessbetween . Malfunctionof wiringharnessesor conneclors
the.lampand the-SFS-ECUwhiteSRS-ECUis monitoringtn" SRS;a-r,;!l;;;" . Malfunction
andthe lamois ON. of SRS:ECU
o Malfunctionof combinationmeter

SRSwarninglamp inspection Check the lotlowing

. lgnitionswitch:ON
o D o e s l a m p s w i t c h o f f w h e n S R S - E C Uc o n n e c t o rD - 5 1 i s connectors:
C-l3, D-05and D51
drsconnected?

Fleplace
the SRS-ECU.

C h e c k t h e h a r n e s sw i r e
b e t w e e nt h e S R S - E C U
a n d c o m b i n a t i o nm e t e r ,
and repairif necessary.

o |mafuncrron
! i g o 1 9 9 1ot
ECUis monitoring
o the
si9.9odeisoutputWhenaShortoccursintffi
outputtransistor
theSRSwarning
insidethesRS-Ecuis ddtected
lampdriveciicLrrt.
whilethesRS_
cuit system Probablecause
. Maltunctionof wiringharnessesor connectors
o Malfunctionof SRS-ECU

--
|tn;t.;ti;-erszE-iT.j''..,|q|l|Pu||vcu||Uu|t5y>tEl||.ru

CodeNo.45.SRS-ECUnon-votatite
memory(EEPROM) Probablecause
and A/D convertersystem
Tfrisdiagno_sis_code
is outputif there is a malfunctionin the sRS-ECU non-volatile o Malfunction
memory(EEPROM)and A,/Dconverter. of SRS-ECL

i Replacethe SRS-ECU.
tl

GodeNo.51or 52 Driver'sside air bag module(squib Probablecause

ignitiondrivecircuit)system

o I nrsoragnosrs code is outputif a short(No.51)or an opencircuit(No.52)is detected

in the circuitfor the driver'3sear.

Replacethe SRS-ECU.
. Malfunction
of SRS-ECU

CodeNo.54or 55 Frontpassenger'sside air bag module Probablecause

(squibignitiondrive circuit)syslem
This diagnosiscode is outputif a short (No.sa)or an open circuit(No.55)is detected .
in the circuitfor the passenoer'sseat. Malfunction
of SRS-ECL

Replace
the SRS-ECU.

3
528-12 SRS - Troubleshooting

INSPECTION
CHARTFORTROUBLESYMPTOMS
Get an understanding
of the troublesymptomsand checkaccordingto the inspectionprocedurechar1.
Troublesymptom InspectionprocedureNo. Referencepage
Communication with Communication withallsvstemsis I
I 528-12
MUT-Ilis not oossible. not oossible.

is not possiblewith
Communication 2 52B-12
SRS only.
When the ignitionkey is turnedto "ON" (enginestopped),the Referto diagnosiscode 528-10
SRS warninglampdoesnot illuminate. No.43.
Afterthe ignitionswitchis turnedto ON, the SRS warninglamp Referto diagnosiscode 528-11
is stillon afterapproximately7 secondshave passed. No.43.

INSPECTION
PROCEDURE
FORTROUBLESYMPTOMS
Inspectionprocedure1
with MUT-IIis not possible.
Communication Probablecause t|rd
(Gommunication
with all systemsis not possible.)
The causeis probablya powersupplysystem(including
earthcircuit)of the a Malfunctionof connectors
diagnosisline. a Malfunctionof wiringharness

Referto GROUP35 - Troubleshootino

InspectionProcedure2

with MUT-IIis not possible.

Communication Probable cause
(Communication
is not possiblewith SRSonly.)
lf communication is not possiblewiththe SRS only,the causeis probablyan open a Malfunction
of wiringharnesses
or connectors
circuitin the diagnosisoutputcircuitof the SRS or in the powercircuit(including a Malfunction
of SRS-ECU
earthcircuit).

,&
I
 SRS - Troubleshooting 528-13
SRS checkharness Measureat SRS check harness C h e c k .t h e f o l l o w i n g
(M8991613) connector(5). connectors:
o Disconnect SRS-ECU C-74.C-78 and D-51
connectorD-51.
. ConnectSRS check harness
connector(3).
o Continuitybetweenterminals
(20)and (21)
OK: Continuitv

Check the harness wire betweenthe SRS-ECUand earth, and

repairis necessary.

Measureat SRS check harnessconnector(S).

' ' Check the followino
. Disconnect SRS-ECUconnectorD-51.
. ConnectSRS checkharnessconnector(3). connectors:
. Connectnegativebatterycable C-74,C-79and D-51
. lgnitionswitch:ON
.
Y-olt"Sgbetweenterminal(13) and body earth
OK: 9Vormore
. betweenterminat(14) and body earth
Yg.ltaSg
OK: 9Vormore

C h e c k t h e h a r n e s sw i r e b e t w e e nt h e S R S - E C Ua n d i g n i t i o n
switchlct, and repairif necessary.

Check the harnesswire betweenthe SRS-ECUand diagnosis

connector.
528-14 SRS - Air Bag Moduleand ClockSpring

AIR BAG MODULEANDCLOCK

SPRING
CLOCKSPRING
INSPECTION
lf, as resultof followingchecks,even one abnormalpoint is
discovered, replacethe clockspringwitha new one.
1. Check connectorsand protectivetube for damage,and
terminalsfor deformation.
2. Visuallycheckthe casefor damage
3. Check that there is continuitybetweenthe clock spring
c o n n e c t o rN
s o . 1 ,N o . 2 ,N o . 3a n d N o . 4 .
ConnectorNo. 1 2 .t 4
TerminalNo. I 2 3 4 J
I 2 1 2
Continuity G _C
between
terminals G -c
G _C
_C
G C
Paintedmark 4 . W h e n j o i n i n gS R S C h e c k h a r n e s sc o n n e c t o rN o . 2 a n d

'".@ clock springconnectorNo.6 align paintof the No.2 with

+
,""*0k) the arrow portionof the No.6.
5 . Check for continuitybetweenterminal25 and terminal26
Resistance(3 Q) of SRS CheckharnessconnectorNo.3.
SRS check
harness

ViewA
 l9-F
Pub.No.PWUE9I
ENGTISH
EUROPE

{)
MoToRs
A mrsuBrsHr coRPoRATroN
July'96 Printed in Japan