2003-2006 Mitsubishi Outlander Service Manual

2003 - 2006 GROUP INDEX
General . . . . . . . . . . . . . . . . . . . . . . . . 00
OUTLANDER Engine. . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Lubrication . . . . . . . . . . . . . . 12
WORKSHOP MANUAL Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Cooling . . . . . . . . . . . . . . . . . 14
FOREWORD
Intake and Exhaust . . . . . . . . . . . . . . 15
This Workshop manual contains procedures for Engine Electrical . . . . . . . . . . . . . . . . 16
service mechanics, including removal, disassembly,
inspection, adjustment, reassembly and installation.
Engine and Emission Control . . . . . 17
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . 21
Manual Transmission . . . . . . . . . . . . 22
Automatic Transmission. . . . . . . . . . 23
Propeller Shaft . . . . . . . . . . . . . . . . . . 25
Front Axle. . . . . . . . . . . . . . . . . . . . . . 26
Rear Axle . . . . . . . . . . . . . . . . . . . . . . 27
Wheel and Tyre . . . . . . . . . . . . . . . . . 31
Power Plant Mount . . . . . . . . . . . . . . 32
Front Suspension . . . . . . . . . . . . . . . 33
Rear Suspension . . . . . . . . . . . . . . . . 34
Service Brakes. . . . . . . . . . . . . . . . . . 35
Parking Brakes . . . . . . . . . . . . . . . . . 36
All information, illustrations and product descriptions
Power Steering . . . . . . . . . . . . . . . . . 37
contained in this manual are current as at the time of Body . . . . . . . . . . . . . . . . . . . . . . . . . . 42
publication. We, however, reserve the right to make
changes at any time without prior notice or obligation. Exterior . . . . . . . . . . . . . . . . . . . . . . . . 51
Interior and Supplemental
Restraint System (SRS)
.......... 52
Chassis Electrical . . . . . . . . . . . . . . . 54
Heater, Air Conditioner and
Ventilation
....... 55
Component Locations. . . . . . . . . . . . 70
Configration Diagrams . . . . . . . . . . . 80
©Mitsubishi Motors
Circuit Diagrams . . . . . . . . . . . . . . . . 90
Body Repair Manual . . . . . . . . . . . . . . .
WARNINGS REGARDING SERVICING OF SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
(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) The SRS components and seat belt with pretensioner should not be subjected to heat, so
remove the SRS-ECU, driver’s and front passenger’s air bag modules, clock spring, side air bag
modules, and seat belt -pre-tensioner before drying or baking the vehicle after painting.
• SRS-ECU, air bag module and clock spring 93°C or more
• Seat belt with pre-tensioner: 90°C or more
(3) Service or maintenance of any SRS component 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 or any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
00-1
GROUP 00
GENERAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

00-1
GROUP 00
GENERAL
CONTENTS
HOW TO USE THIS MANUAL. . . . . . 00-2 SUPPLEMENTAL RESTRAINT

SYSTEM (SRS) . . . . . . . . . . . . . . . . . . 00-26
HOW TO USE TROUBLESHOOTING/
INSPECTION SERVICE POINTS. . . . 00-6 SRS SERVICE PRECAUTIONS . . . . . 00-27
VEHICLE IDENTIFICATION . . . . . . . 00-16 SUPPORT LOCATIONS FOR

LIFTING AND JACKING. . . . . . . . . . . 00-30
GENERAL DATA AND
SPECIFICATIONS . . . . . . . . . . . . . . . 00-20 STANDARD PART/
TIGHTENING-TORQUE TABLE. . . . . 00-32
PRECAUTIONS BEFORE
SERVICE . . . . . . . . . . . . . . . . . . . . . . 00-21
00-2 GENERAL
HOW TO USE THIS MANUAL

M1001000101470
SCOPE OF MAINTENANCE, REPAIR AND REFERENCE VALUE

SERVICING EXPLANATIONS Indicates the adjustment value prior to starting the
This manual provides explanations, etc. concerning work (presented in order to facilitate assembly and
procedures for the inspection, maintenance, repair adjustment procedures, and so they can be com-
and servicing of the subject model. Note, however, pleted in a shorter time).
that for engine and transmission-related component
parts, this manual covers only on-vehicle inspec- DANGER, WARNING, AND CAUTION
tions, adjustments, and the removal and installation DANGER, WARNING, and CAUTION call special
procedures for major components. For detailed infor- attention to a necessary action or to an action that
mation concerning the inspection, checking, adjust- must be avoided. The differences among DANGER,
ment, disassembly and reassembly of the engine, WARNING, and CAUTION are as follows:
transmission and major components after they have • If a DANGER is not followed, the result is severe
been removed from the vehicle, please refer to sepa- bodily harm or even death.
rate manuals covering the engine and the transmis- • If a WARNING is not followed, the result could be
sion. bodily injury.
• If a CAUTION is not followed, the result could be
ON-VEHICLE SERVICE
damage to the vehicle, vehicle components or
"On-vehicle Service" is procedures for performing service equipment.
inspections and adjustments of particularly important
locations with regard to the construction and for INDICATION OF TIGHTENING TORQUE
maintenance and servicing, but other inspection (for
Tightening torques (units: N⋅m) are set to take into
looseness, play, cracking, damage, etc.) must also
account the central value and the allowable toler-
be performed.
ance. The central value is the target value, and the
INSPECTION allowable tolerance provides the checking range for
tightening torques. If bolts and nuts are not provided
Under this title are presented inspection and check-
with tightening torques, refer to P.00-32.
ing procedures to be performed by using special
tools and measuring instruments and by feeling, but,
for actual maintenance and servicing procedures,
MODEL INDICATIONS
visual inspections should always be performed as The following abbreviations are used in this manual
well. for identification of model types.
MPI:Indicates the multipoint injection.
DEFINITION OF TERMS MIVEC:Indicates the mitsubishi innovative valve tim-
ing and lift electronic control system.
STANDARD VALUE SOHC:Indicates an engine with the single overhead
Indicates the value used as the standard for judging camshaft.
the quality of a part or assembly on inspection or the DOHC:Indicates an engine with the double overhead
value to which the part or assembly is corrected and camshaft.
adjusted. It is given by tolerance. 2000: Indicates models equipped with the 1,997 mL
<4G63> petrol engine.
LIMIT 2400:Indicates models equipped with the 2,378 mL
Shows the standard for judging the quality of a part <4G69> petrol engine.
or assembly on inspection and means the maximum M/T: Indicates the manual transmission.
or minimum value within which the part or assembly A/T: Indicates the automatic transmission.
must be kept functionally or in strength. It is a value A/C: Indicates the air conditioner.
established outside the range of standard value.
GENERAL
00-3
NOTES
00-4 GENERAL
EXPLANATION OF MANUAL CONTENTS
Indicates the
Denotes tightening torque. section title.
For bolts and nuts which do
not have a tightening torque
listed, refer to the "Standard Indicates the Indicates the
Parts tightening-torque Table" group title. group number.
Indicates the page number.
Indicates procedures to be performed be-

fore 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 pro-
vided near the front of each section in order
to give the reader a better understanding of
the installed condition of component parts.
Mark N denotes nonreusable part.
Repair kit or parts sets are shown.

(Only very frequently used parts are shown.)
Maintenance and servicing procedures

The numbers provided within the diagram indicate the Installation steps :
sequence for maintenance and servicing procedures. Specified in case installation is impossible in
Removal steps : reverse order of removal steps. Omitted if
The part designation number corresponds to installation is possible in reverse order of re-
the number in the illustration to indicate remov- moval steps.
al steps. Reassembly steps :
Disassembly steps : Specified in case installation is impossible in
The part designation number corresponds to reverse order of removal steps. Omitted if
the number in the illustration to indicate disas- reassembly is possible in reverse order of dis-
sembly steps. assembly steps.
AC311238 AB
GENERAL
00-5
Classifications of major maintenance / service points

When there are major points relative to maintenance and servicing procedures (such as essential maintenance
and service points, maintenance and service standard values, information regarding the use of special tools, etc.).
These are arranged together as major maintenance and service points and explained in detail.
<<A>> : Indicates that there are essential points for removal or disassembly.
>>A<< : Indicates that there are essential points for installation or reassembly.
Operating procedures,
cautions, etc. on removal,
installation, disassembly and
reassembly are described
The title of the page

(following the page on which
the diagram of component
parts is presented) indicating
the locations of lubrication and
sealing procedures.
Indicates (by symbols) where

lubrication is necessary.
Symbols for lubrication, sealants and adhesives

Symbols are used to show the locations for lubrication Grease
and for application of sealants and adhesives. (Multi-purpose grease unless there is a
These symbols are included in the diagram of compo- brand or type specified)
nent parts or on the page following the component Sealant or adhesive
parts page. The symbols do not always have accomp- Brake fluid or automatic transmission fluid
anying text to support that symbol.
Engine oil, gear oil or air conditioning com-
pressor oil
Adhesive tape or butyl rubber tape
AC509265AB
00-6 GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

POINTS
M1001000201314
CONTENTS OF TROUBLESHOOTING
Troubleshooting of electronic control systems for which the M.U.T.-II/III can be used follows the basic outline
described below. Even in systems for which the M.U.T.-II/III cannot be used, some of these systems still fol-
low this outline.
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic 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.

Diagnosis code Diagnosis code
displayed. displayed.
After taking note of the

malfunction code, erase the
diagnosis code memory. No diagnosis
No diagnosis code
or communication code.
with MUT-II/III not
possible Recheck trouble symptom.
Read the diagnosis codes.

No diagnosis
Diagnosis code code.
displayed.
Refer to the INSPECTION CHART Refer to the INSPECTION CHART INTERMITTENT MALFUNCTIONS
FOR TROUBLE SYMPTOMS FOR DIAGNOSIS CODES
(Refer to applicable group.) (Refer to applicable group.)
AC300864AC
2. SYSTEM OPERATION AND SYMPTOM 4. DIAGNOSIS CODE CHART

VERIFICATION TESTS Diagnostic trouble codes and diagnostic items are
If verification of the symptom(s) is difficult, proce- shown.
dures for checking operation and verifying symptoms
are shown. 5. DIAGNOSIS CODE PROCEDURES
Indicates the inspection procedures corresponding to
3. DIAGNOSIS FUNCTION each diagnosis code (Refer to How to read inspec-
Details which are different from those in the "Diagno- tion procedure P.00-10).
sis function " section are described.
GENERAL
00-7
6. TROUBLE SYMPTOM CHART <Using the M.U.T.-III>
If there are trouble symptoms even though the <Using the MUT-III>
M.U.T.-II/III does not find any diagnosis codes,
Inspection procedures for each trouble symptom will
be found by means of this chart.
16-PIN
7. SYMPTOM PROCEDURES
Indicates the inspection procedures corresponding to
each symptoms classified in the Symptom Chart
(Refer to How to read inspection procedure P.00-10).
8. SERVICE DATA REFERENCE TABLE MB991911

Inspection items and normal judgment values have
been provided in this chart as reference information. MB991824
9. CHECK AT ECU TERMINALS

Terminal numbers for the ECU connectors, inspec-
tion items, and judgment values have been provided
in this chart as reference information.
10. INSPECTION PROCEDURE BY USING

MB991827 AC308915 AC
AN OSCILLOSCOPE
Connect the M.U.T.-III to the 16-pin diagnosis con-
When there are inspection procedures using an nector, and read the diagnosis code.
oscilloscope, these are described here.
NOTE: For details on how to use the M.U.T.-III, refer
DIAGNOSIS FUNCTION to the "M.U.T.-III operation manual."
1. Ensure that the ignition switch is at the
HOW TO READ DIAGNOSIS CODE "LOCK" (OFF).
CAUTION 2. Start up the personal computer.
Before connecting or disconnecting the 3. Connect M.U.T.-III USB cable MB991827 to
M.U.T.-II/III, turn the ignition switch to the "LOCK" special tool Vehicle Communication Interface
(OFF) position. (V.C.I.) MB991824 and the personal compu-
<Using the M.U.T.-II> ter.
4. Connect M.U.T.-III main harness B MB991911
<Using the M.U.T.-II>
to the V.C.I.
Steering shaft 5. Connect M.U.T.-III main harness B to the
diagnosis connector.
6. Turn the V.C.I. power switch to the "ON" posi-
tion.
M.U.T.-II
NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green
colour.
AC300830AG 7. Start the M.U.T.-III system on the PC and turn
Connect the M.U.T.-II to the diagnosis connector, the ignition switch to the "ON" position.
and read the diagnosis code. 8. Read the diagnosis code.
9. Disconnecting the M.U.T.-III is the reverse of
the connecting sequence, making sure that
the ignition switch is at the "LOCK" (OFF).
00-8 GENERAL
NOTE: The ABS warning lamp may flash when the ERASING DIAGNOSIS CODE (BY USING
ignition switch is turned ON with the M.U.T.-II/III con- NO M.U.T.-II/III)
nected. This is because the diagnosis display func-
tion of the ABS warning lamp is activated by CAUTION
grounding the diagnosis connector terminal No.1, Some diagnosis codes can not be erased accord-
and is not detrimental in any way. ing to the procedure below. If you attempt to
erase a diagnosis code, refer to an applicable
GROUP.
ERASING DIAGNOSIS CODE (BY USING
1. Turn the ignition switch to the "LOCK" (OFF)
THE M.U.T.-II/III) position.
CAUTION 2. Disconnect the negative battery cable, wait for at
Before connecting or disconnecting the least 10 minutes, and then reconnect it.
M.U.T.-II/III, turn the ignition switch to the "LOCK" 3. Start the engine and let it run at idle for 10
(OFF) position. minutes.
Steering shaft
M.U.T.-II
AC300830AG
<Using the MUT-III>
16-PIN
MB991911
MB991824
MB991827 AC308915 AC
Connect the M.U.T.-II/III to the diagnosis connector,

and erase the diagnosis code. The procedure is the
same as "HOW TO READ DIAGNOSIS CODE ".
GENERAL
00-9
INPUT SIGNAL CHECK (WHEN USING INPUT SIGNAL CHECK (WHEN USING A
THE M.U.T.-II/III) <SWS> VOLTMETER) <SWS>
CAUTION
Before connecting or disconnecting the Steering shaft
M.U.T.-II/III, turn the ignition switch to the "LOCK"
MB991529
(OFF) position.
Steering shaft
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
AC502909AB
M.U.T.-II 1. Use the special tool diagnosis code check

harness (MB991529) to connect the ETACS
terminal (terminal 9) and the earth terminals
AC300830AG (terminals 4 and 5) of the diagnosis connector to
<Using the MUT-III>
the voltmeter.
2. If the needle of the voltmeter flickers once when
each switch is operated (ON/OFF), the input
signal for that switch circuit system is normal.
16-PIN
MB991911
MB991824
MB991827 AC308915 AC
1. Connect the M.U.T.-II/III to the diagnosis

connector, and erase the diagnosis code.
2. If the M.U.T.-II/III buzzer sounds once when each
switch is operated (ON/OFF), the input signal for
that switch circuit system is normal.
00-10 GENERAL
HOW TO USE THE INSPECTION PROCE-

DURES
The causes of many of the problems occurring in
electric circuitry are generally the connectors, com-
ponents, the ECU, the wiring harnesses between
connectors, in that order. These inspection proce-
dures follow this order. They first try to discover a
problem with a connector or a defective component.
Relevant circuit(s) of the component which

the Code No. indicates are described.
Grey
AC301964AC
GENERAL
00-11
Start of diagnosis Describes

Explains about the basic
procedure inspection
operation of the components.
procedure.
Explains about
technical details.
Describes the
conditions for that
diagnosis code being
set.
Describes possible
causes(s) for that
diagnosis code.
AC301965AB
HARNESS CHECK MEASURES TO TAKE AFTER

Check for an open or short circuit in the harness REPLACING THE ECU
between the terminals which were faulty according to If the trouble symptoms have not disappeared even
the connector measurements. Carry out this inspec- after replacing the ECU, repeat the inspection proce-
tion while referring to the Electrical Wiring Manual. dure from the beginning.
Here, "Check the wiring harness between the power
supply and terminal xx" also includes checking for CONNECTOR MEASUREMENT SERVICE
blown fuse. For inspection service points when there
POINTS
is a blown fuse, refer to "Inspection Service Points
for a Blown Fuse ." Turn the ignition switch to the "LOCK" (OFF) position
when connecting and disconnecting the connectors.
Turn the ignition switch to "ON" when measuring,
unless there are instructions to the contrary.
00-12 GENERAL
IF INSPECTING WITH THE CONNECTOR IF INSPECTING WITH THE CONNECTOR

CONNECTED DISCONNECTED
<Waterproof Connectors> <When Inspecting a Female Pin>
MD998459
MB991219
AC300881AB ACX00865AB
Be sure to use special tool harness connector Use the special tool inspection harness (MB991219)
(MD998459). Never insert a test probe from the har- (inspection harness for connector pin contact pres-
ness side, as this will reduce the waterproof perform- sure in the harness set for inspection). The inspec-
ance and result in corrosion. tion harness for connector pin contact pressure
should be used. the test bar should never be forcibly
inserted, as it may cause a defective contact.
<Ordinary (non-waterproof) Connectors>
<When Inspecting a Male Pin>

CAUTION
MB992006
AC105598AH
Inspect by inserting a test probe from the harness

side. If the connector is too small to insert a test
probe (e.g. control unit connector), do not insert it AC300890
forcibly. Use special tool extra fine probe At this time, be careful not to short the connector
(MB992006). pins with the test bars. To do so may damage the
circuits inside the ECU.Touch the pin directly
with the test bar.
GENERAL
00-13
CONNECTOR INSPECTION SERVICE CONNECTOR PIN INSPECTION
POINTS
VISUAL INSPECTION
•
Connector disconnected or
improperly connected
AC300898
If the connector pin stopper is damaged, the terminal

connections (male and female pins) will not be per-
fect even if the connector body is connected, and the
Stretched or broken wires pins may pull out of the reverse side of the connec-
tor. Therefore, gently pull the harnesses one by one
to make sure that no pins pull out of the connector.
CONNECTOR ENGAGEMENT
INSPECTION
MB991219
Harness wire breakage

at terminal section
Low contact
pressure
Good
Bad
AC300899AB
Use the special tool inspection harness (MB991219)

(connector pin connection pressure inspection har-
ness of the inspection harness set) to inspect the
AC300896AB
engagement of the male pins and females pins. (Pin
drawing force: 1 N or more)
Connector is disconnected or improperly connected
• Connector pins are pulled out
• Due to harness tension at terminal section
• Low contact pressure between male and female
terminals
• Low connection pressure due to rusted terminals
or foreign matter lodged in terminals
00-14 GENERAL
INSPECTION SERVICE POINTS FOR A Remove the blown fuse and measure the resistance
BLOWN FUSE between the load side of the blown fuse and the
earth. Close the switches of all circuits which are
connected to this fuse. If the resistance is almost 0 Ω
at this time, there is a short somewhere between
these switches and the load. If the resistance is not 0
Ω, there is no short at the present time, but a
Battery momentary short has probably caused the fuse to
blow.
The main causes of a short circuit are the following.
• Harness being clamped by the vehicle body
• Damage to the outer casing of the harness due to
Fuse wear or heat
• Water getting into the connector or circuitry
• Human error (mistakenly shorting a circuit, etc.)
Short-circuit
Load occurrence
switch section
Load
AC300900AB
GENERAL
00-15
HOW TO COPE WITH INTERMITTENT Intermittent malfunctions often occur under certain
MALFUNCTIONS conditions, and if these conditions can be ascer-
tained, determining the cause becomes simple. In
NOTE: If determining the cause is difficult, the flight order to ascertain the conditions under which an
recorder function of the M.U.T.-II/III can also be intermittent malfunction occurs, first ask the cus-
used. tomer for details about the driving conditions,
weather conditions, frequency of occurrence and
trouble symptoms, and then try to recreate the trou-
ble symptoms. Next, ascertain whether the reason
why the trouble symptom occurred under these con-
ditions 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 gen-
erates diagnosis codes or trouble symptoms).
• Gently shake the connector up, down and to the
left and right.
• Gently shake the wiring harness up, down and to
the left and right.
• Gently rock each sensor and relay, etc. by hand.
• Gently shake the wiring harness at suspensions
and other moving parts.
AC300901
00-16 GENERAL
VEHICLE IDENTIFICATION
M1001000401954
VEHICLE IDENTIFICATION CODE PLATE The plate shows model code, engine model, trans-
mission model and body colour code.
1
No. Item Content
1 MODEL CU2WXNMM CU2W:
3 L6 Vehicle model
2
XNMML6:
Model series
2 ENGINE 4G63 Engine model
3 EXT W83A Exterior code
5 4 6 7
4 TRANS AXLE F5M42 F5M42:Trans
mission
model
5 COLOUR W83 W83: Body
colour code
6 INT 62A 62A: Interior
code
7 OPT ZP3 ZP3:
Equipment
code
AC605763AF
For monotone colour vehicles, the body colour code
The vehicle information code plate is riveted to the shall be indicated.
back of the hood.
MODELS
Model code Engine model Price class Transmission Fuel supply
model system
CU2W XNMML6 4G63-DOHC (1,997 Invite F5M42 MPI
mL) <2WD, 5M/T>
XNMMZL6 W5M42
XNHMZL6 Intense <4WD, 5M/T>
XNXFZL6 4G63-DOHC with Turbo W5M51
intercooler, <4WD, 5M/T>
turbocharger (1,997
mL)
CU5W XNHYZL6 4G69-SOHC MIVEC Intense W5M42
(2,378 mL) <4WD,5M/T>
XRHYZL6 W4A4B
<4WD, 4A/T with
sport mode>
GENERAL
00-17
MODEL CODE No. Item Content
5 Transmission N: 5-speed manual
type transmission
R: 4-speed automatic
CU 2 W X N M M Z L 6
transmission
6 Trim level M: INVITE
H: INTENSE
1 2 3 4 5 6 7 8 9 10 X: TURBO
7 Specification F: Turbochager
engine feature M: DOHC
AC301363 AB
Y: MIVEC, SOHC
No. Item Content 8 Special feature None: 2WD
1 Development CU: MITSUBISHI Z: 4WD
OUTLANDER 9 Steering wheel L: Left hand
2 Engine type 2: 1,997 mL petrol engine location
5: 2,378 mL petrol engine 10 Destination 6: For Europe
3 Sort W: Wagon
4 Body style X: 5-door hatchback
00-18 GENERAL
CHASSIS NUMBER
AC300903AB
The chassis number is stamped on the toeboard

inside the engine compartment.
AC606531AB
No. Item Content
1 Fixed figure J Asia

2 Distribution channel M Japan channel
3 Destination B For Europe, left hand drive
4 Body style X 5-door hatchback
5 Transmission type N 5-speed manual transmission
R 4-speed automatic transmission
6 Development order CU OUTLANDER
7 Engine 2 1,997 mL petrol engine
5 2,378 mL petrol engine
8 Soft W Station wagon
9 Model year 7 2007
10 Plant U Mizushima
11 Serial number − −
GENERAL
00-19
ENGINE MODEL STAMPING The engine model is stamped on the cylinder block.
This engine model numbers are shown as follows.
<4G63>
Engine model Engine displacement
4G63 1,997 mL
4G69 2,378 mL
The engine serial number is stamped near the
engine model number.
Front of the
vehicle
AC300905AD
<4G69>
Front of the vehicle

AC309481AB
00-20 GENERAL
GENERAL DATA AND SPECIFICATIONS
GENERAL DATA AND SPECIFICATIONS

M1001000901603
7
9
1
3 4 5
2 6
AC300072AB
Items CU2W CU5W

XNMML6 XNMMZL6 XNHMZL6 XNXFZL6 XNHYZL6 XRHYZL6
Vehicle Front track 1 1,495 1,510
dimensions Overall width 2 1,750 1,780
mm
Front overhang 3 945
Wheel base 4 2,625
Rear overhang 5 975
Overall length 6 4,545
Ground clearance (unladen) 7 195 170 195
Overall height (unladen) 8 1,620/1,670*
Rear track 9 1,505 1,520
Vehicle Kerb weight 1,440 1,540 1,550 1,595 1,555 1,575
weight kg Max. gross vehicle weight 1,970 2,070
Max. axle weight rating-front 1,050 1,070
Max. axle weight rating-rear 1,065 1,075
Max. trailer weight With brake 1,500
Without 570
brake
Max. trailer-nose weight 75
Seating capacity 5
Engine Model code 4G63 4G69
Total displacement mL 1,997 2,378
Transmissi Model code F5M42 W5M42 W5M51 W5M42 W4A4B
on Type 5-speed manual 5-speed 4-speed
manual automat
ic
Fuel Fuel supply system MPI
system
NOTE: *: Vehicles with roof rails
GENERAL
PRECAUTIONS BEFORE SERVICE
00-21
M1001000501274
SUPPLEMENTAL RESTRAINT SYSTEM 8. Be sure to deploy the air bag before dispos-
(SRS) ing of the air bag module or disposing of a
vehicle equipped with an air bag (Refer to
CAUTION GROUP 52B − Air Bag Module Disposal Pro-
Items to review when servicing SRS: cedures).
1. Be sure to read GROUP 52B − Supplemental Observe the following when carrying out opera-
Restraint System (SRS). For safe operation, tions on places where SRS components are
please follow the directions and heed all installed, including operations not directly
warnings. related to the SRS air bag.
2. Wait at least 60 seconds after disconnecting 1. When removing or installing parts, do not
the battery cable before doing any further allow any impact or shock to the SRS compo-
work. The SRS system is designed to retain nents.
enough voltage to deploy the air bag even
2. If heat damage may occur during paint work,
after the battery has been disconnected. Seri-
remove the SRS-ECU, the air bag module,
ous injury may result from unintended air bag
clock spring, the front impact sensor, the side
deployment if work is done on the SRS sys-
impact sensor, and the seat belt pre-ten-
tem immediately after the battery cable is dis-
sioner.
connected.
• SRS-ECU, air bag module, clock spring,
3. Warning labels must be heeded when servic-
front impact sensor, the side impact sen-
ing or handling SRS components. Warning
sor: 93 °C or more
labels can be found in the following locations.
• Seat belt pre-tensioner: 90 °C or more
• Front impact sensor
• Sun visor
• SRS-ECU
• Steering wheel
• Clock spring
• Air bag module (Driver's or front passen-
ger's)
• Side air bag module (Driver's side or front
passenger's side)
• Side impact sensor
• Seat belt pre-tensioner
• Instrument panel
4. Always use the designated special tools and
test equipment.
5. Store components removed from the SRS in a
clean and dry place. The air bag module
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-ECU, air bag module
and clock spring).
7. Whenever you finish servicing the SRS, check
the SRS warning lamp operation to make sure
that the system functions properly.
00-22 GENERAL
INITIALIZATION PROCEDURE FOR Learning Procedure

LEARNING VALUE IN MPI ENGINE 1. Start the engine and carry out the warm-up for the
Initialization Procedure engine coolant temperature to reach 80°C or
more.
1. After the ignition switch is in "LOCK" (OFF)
2. When the engine coolant temperature is 80°C or
position, connect M.U.T.-II/III with the diagnosis
more, the warm-up is not needed if the ignition
connector.
switch is in "ON" position once.
2. Select the item on the screen of the initialization
3. Place the ignition switch in "LOCK" (OFF) position
for learning, and perform the initialization.
and stop the engine.
Service Item 4. After 10 seconds or more, start the engine again.
At replacing engine All ranges 5. For 10 minutes, carry out the idling under the
assembly *1,*2 condition shown below and then confirm the
Misfire-related engine has the normal idling.
− *3
• Transmission: Neutral (A/T: "P" range)
At replacing injector and Learning value for • Operation in ignition-related, fan and attach-
at cleaning *2 air/fuel ratio ments: Not to be operated
At replacing throttle body Idle speed • Engine coolant temperature: 80°C or more
and at cleaning *2 control-related NOTE: When the engine stalls during the idling,
check the dirtiness (on the throttle valve) of the
At replacing detonation Learning value for throttle body and then perform the service from
sensor knocking Procedure 1 again.
NOTE: *1: Initialize A/T-related learning value.
NOTE: *2: After initializing the learning value, the SERVICING ELECTRICAL SYSTEM
idling learning in MPI engine is required (Refer to CAUTION
LEARNING PROCEDURE FOR IDLING IN MPI Before connecting or disconnecting the negative
ENGINE). (−) cable, be sure to turn off the ignition switch
NOTE: *3: The datum items on M.U.T.-II/III display and the lighting switch (If this is not done, there
are shown, but do not use them. is the possibility of semiconductor parts being
damaged).
LEARNING PROCEDURE FOR IDLING IN
MPI ENGINE
Purpose
When the engine-ECU <M/T> or the
engine-A/T-ECU <A/T> is replaced, or when the
learning value is initialized, the idling is not stabilized
because the learning value in MPI engine is not com-
pleted. In this case, carry out the learning method for
the idling through the following procedures.
AC300693
Before replacing a component related to the electri-

cal system and before undertaking any repair proce-
dures involving the electrical system, be sure to first
disconnect the negative (−) cable from the battery in
order to avoid damage caused by short-circuiting.
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.
GENERAL
00-23
PRE-INSPECTION CONDITION VEHICLE WASHING
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine inspec-
tion can be carried out. If you see the words "Set the
vehicle to the pre-inspection condition". In this man- Approximately 40 cm
ual, it means to set the vehicle to the following condi-
tion.
• Engine coolant temperature 80 to 90°C
• Lamps, electric cooling fan and all accessories:
OFF
• M/T: Neutral
AC300832AB
• A/T: P range
If high-pressure car-washing equipment or steam
car-washing equipment is used to wash the vehicle,
be sure to note the following information in order to
avoid damage to plastic components, etc.
• Spray nozzle distance: Approx. 40 cm or more
• Spray pressure: 3,900 kPa or less
• Spray temperature: 82°C or less
• Time of concentrated spray to one point: within
30 sec.
00-24 GENERAL
M.U.T.-II/III
MUT-II Sub-assembly
Rom pack
AC300834AB
M.U.T.-III sub assembly
Vehicle communication interface (V.C.I.) M.U.T.-III USB cable M.U.T.-III main harness A
Do not used
MB991824 MB991827 MB991910
M.U.T.-III main harness B M.U.T.-III measurement adapter M.U.T.-III trigger harness
MB991911 MB991825 MB991826
AC502279AE
Refer to the "M.U.T.-II REFERENCE MANUAL",

"M.U.T.-II OPERATING INSTRUCTIONS" or
"M.U.T.-III OPERATION MANUAL" for instructions on
handling the M.U.T.-II/III.
GENERAL
00-25
CAUTION ENGINE OILS
<Using the M.U.T.-II> Health Warning
Prolonged and repeated contact with mineral oil will
Steering shaft
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
tion, used engine oil contains potentially harmful con-
taminants which may cause skin cancer. Adequate
M.U.T.-II means of skin protection and washing facilities must
be provided.
AC300830AG Recommended Precautions

The most effective precaution is to adapt working
<Using the MUT-III> 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,
16-PIN
before handling them.
Other precautions:
• Avoid prolonged and repeated contact with oils,
particularly used engine oils.
• Wear protective clothing, including impervious
gloves where practicable.
MB991911
• Avoid contaminating clothes, particularly under-
pants, with oil.
MB991824 • Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
• Do not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separately from per-
sonal clothing.
• Where there is a risk of eye contact, eye protec-
MB991827 AC308915 AC tion should be worn, for example, chemical gog-
Turn the ignition switch to the "LOCK" (OFF) gles or face shields; in addition an eye wash
position before connecting or disconnecting the facility should be provided.
M.U.T.-II/III. • Obtain first aid treatment immediately for open
Connect the M.U.T.-II/III to the diagnosis connector cuts and wounds.
as shown in the illustration. • Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
IN ORDER TO PREVENT VEHICLES cleansers and nail brushes will help). After clean-
ing, the application of preparations containing
FROM FIRE lanolin to replace the natural skin oils is advised.
"Improper installation of electrical or fuel related parts • Do not use petrol, kerosine, diesel fuel, gas oil,
could cause a fire. In order to retain the high quality thinners or solvents for cleaning skin.
and safety of the vehicle, it is important that any • Use barrier creams, applying them before each
accessories that may be fitted or modifica- work period, to help the removal of oil from the
tions/repairs that may be carried out which involve skin after work.
the electrical or fuel systems, MUST be carried out in • If skin disorders develop, obtain medical advice
accordance with MMC's information/Instructions". without delay.
00-26 GENERAL
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

M1001009800387
The Supplemental Restraint System (SRS) and seat system and has a front air bag safing G-sensor, front
belt with pre-tensioner is designed to supplement the air bag analog G-sensor and a side air bag safing
driver's and front passenger's seat belts to help G-sensor. The front impact sensor is assembled out-
reduce the risk or severity of injury to the driver and side the headlamp support panel to monitor impact in
front passenger by activating and deploying both case of front impact. The side impact sensors inside
front air bags in certain frontal collisions. the centre pillars monitor the shock incurred by the
The SRS consist of four air bag modules, SRS air sides of the vehicle. The warning lamp on the instru-
bag control unit (SRS-ECU), two front impact sen- ment panel indicates the operational status of the
sors, two side impact sensors, SRS warning lamp, SRS. The clock spring is installed in the steering col-
clock spring and seat belt pre-tensioner. Front air umn. The seat belt pre-tensioner is built into the
bags are located in the centre of the steering wheel driver's and passenger's front seat belt retractor.
and above the glove box. Side air bag are located Only authorized service personnel should do work on
inside the front seatback assemblies. Each air bag is or around the SRS components. Those service per-
made up of a folded air bag and an inflator unit. The sonnel should read this manual carefully before start-
SRS-ECU under the front floor console monitors the ing any such work.
SRS warning lamp
Seat belt with pre-tensioner
Driver's air bag

module Passenger's (front)
air bag module
Side air bag module
Side impact sensor
Clock spring
SRS-ECU
Side impact sensor
Side air bag module
Front impact sensor

AC301343 AB
GENERAL
SRS SERVICE PRECAUTIONS
00-27
M1001006000434
DANGER CAUTION
In order to avoid injury to yourself or others
from accidental deployment of the air bag
SRS-ECU connector
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION
Do not use any electrical test equipment on or
near SRS components, except those specified on
P.52B-9.
AC300634 AB
CAUTION
Never Attempt to Repair the Following Compo- Do not attempt to repair the wiring harness con-
nents: nectors of the SRS. If a defective wiring harness
is found, repair or replace it by referring to the
1. SRS air bag control unit (SRS-ECU)
table below.
2. Front impact sensor
3. Clock spring
4. Driver's and front passenger's air bag mod-
ules
5. Side air bag module
6. Side impact sensor
7. Seat belt with pre-tensioner
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE pro-
cedures in this manual, starting at page P.52B-130.
SRS-ECU terminal No. Destination of harness Remedy
1, 2 Instrument panel wiring harness → Correct or replace each wiring
Front wiring harness (RH) → Front harness.
impact sensor (RH)
3, 4 Instrument panel wiring harness → Correct or replace each wiring
Front wiring harness (LH) → Front harness.
impact sensor (LH)
7 Instrument panel wiring harness→ Correct or replace the instrument
Earth panel wiring harness.
8 Instrument panel wiring harness → Correct or replace the instrument
SRS warning lamp panel wiring harness.
9, 10 Instrument panel wiring harness → Correct or replace the instrument
Air bag module (Front passenger's panel wiring harness.
side)
11, 12 Instrument panel wiring harness → Correct or replace instrument panel
Clock spring → Air bag module wiring harness. Replace the clock
(Driver's side) spring.
Junction block (fuse No.3) panel wiring harness.
Junction block (fuse No.2) panel wiring harness.
00-28 GENERAL
SRS-ECU terminal No. Destination of harness Remedy

Diagnosis connector panel wiring harness.
21, 22 Floor wiring harness (LH) → Side air Correct or replace the floor wiring
bag module (LH) harness.
23, 24 Floor wiring harness (RH) → Side air Correct or replace the floor wiring
bag module (RH) harness.
27, 28 Floor wiring harness (RH) → Seat Connect or replace the floor wiring
belt pre-tensioner (Front harness.
passenger's side)
29, 30 Floor wiring harness (RH) → Floor Connect or replace the floor wiring
wiring harness (LH) → Seat belt harness.
pre-tensioner (driver's side)
34, 36 Floor wiring harness (RH) → Floor Connect or replace the floor wiring
wiring harness (LH) → Side impact harness.
sensor (LH)
40, 42 Floor wiring harness (RH) → Side Connect or replace the floor wiring
impact sensor (RH) harness.
DANGER retain enough voltage to deploy the air bag

for a short time even after the battery has
Insulating tape been disconnected, so serious injury may
Battery result from unintended air bag deployment if
work is done on the SRS system immediately
after the battery cables are disconnected.
CAUTION
The SRS components and seat belt with pre-ten-
sioner should not be subjected to heat, so
Battery cable
remove the SRS-ECU, driver’s and front passen-
AC300580AB ger’s air bag modules, clock spring, side air bag
After disconnecting the battery cable, wait 60 modules, and seat belt pre-tensioner before dry-
seconds or more before proceeding with the ing or baking the vehicle after painting.
following work. In addition, insulate the neg- • SRS-ECU, air bag modules, clock spring,
ative battery terminal with a tape. The con- impact sensors: 93°C or more
denser inside the SRS-ECU is designed to • Seat belt with pre-tensioner: 90°C or more
GENERAL
00-29
CAUTION
Whenever you finish servicing the SRS, always
erase the diagnosis code and check warning
lamp operation to make sure that the system
functions properly.
CAUTION
SRS-Harness connector
SRS-ECU harness connector

(rear side)
AC300673AB
If checks are carried out by using the SRS-ECU

harness connector, observe the following proce-
dures: Insert the special tool (extra fine probe)
MB992006 into connector from harness side (rear
side), and connect the tester to this probe. If any
tool than special tool is used, damage to the har-
ness and other components will result. Never
insert the probe directly to 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.
00-30 GENERAL
SUPPORT LOCATIONS FOR LIFTING AND JACKING

M1001000700491
SUPPORT POSITIONS FOR A GARAGE JACK, AXLE STANDS, SINGLE-POST LIFT OR

DOUBLE-POST LIFT AND PLATE TYPE LIFT
CAUTION
Do not support the vehicles at locations other than specified supporting points. Doing so will cause
damage, etc.
GARAGE JACK
CAUTION
Never support any point other than the specified one, or that point will be deformed.
<2WD> Rear suspension crossmember <4WD> Rear differential
AC300835
GENERAL
00-31
AXLE STANDS AND A SINGLE-POST LIFT OR DOUBLE-POST LIFT
CAUTION
• If rubber attachments with grooves that are too thick are used at the front support positions, the
front fender may become bent, so be sure to use rubber attachments with groove thicknesses of
18 mm or less.
• If attachments which are not high enough are used, they may damage areas such as the side step.
Be sure to use attachments which are high enough, or remove the side step if not using attach-
ments.
AXLE STANDS
Notch Notch
Rubber
Rubber
SINGLE-POST LIFT
OR DOUBLE-POST LIFT
Notch Notch
AC300836AB
00-32 GENERAL
STANDARD PART/TIGHTENING-TORQUE TABLE
PLATE TYPE LIFT

CAUTION
To avoid damaging the side sill garnish, put a wooden block between the side sill and a lift.
Support the side sill flange with a lift.
STANDARD PART/TIGHTENING-TORQUE TABLE

M1001001100920
Each torque value in the table is a standard value for 1. If toothed washers are inserted.
tightening under the following conditions. 2. If plastic parts are fastened.
1. Bolts, nuts and washers are all made of steel and 3. If bolts are tightened to plastic or die-cast
plated with zinc. inserted nuts.
2. The threads and bearing surface of bolts and 4. If self-tapping screws or self-locking nuts are
nuts are all in dry condition. used.
The values in the table are not applicable:
STANDARD BOLT AND NUT TIGHTENING TORQUE
Thread size Torque N⋅m
Bolt nominal Pitch mm Head mark "4" Head mark "7" Head mark "8"
diameter mm
M5 0.8 2.5 ± 0.5 5.0± 1.0 6.0 ± 1.0
M6 1.0 5.0 ± 1.0 8.5 ± 1.5 10 ± 2
M8 1.25 11 ± 2 20 ± 4 24 ± 4
M10 1.25 23 ± 4 42 ± 8 53 ± 7
M12 1.25 42 ± 8 80 ± 10 93 ± 12
M14 1.5 70 ± 10 130 ± 20 150 ± 20
M16 1.5 105 ± 15 195 ± 25 230 ± 30
M18 1.5 150 ± 20 290 ± 40 335 ± 45
M20 1.5 210 ± 30 400 ± 60 465 ± 65
M22 1.5 290 ± 40 540 ± 80 630 ± 90
M24 1.5 375 ± 55 705 ± 105 820 ± 120
FLANGE BOLT AND NUT TIGHTENING TORQUE
Thread size Torque N⋅m
Bolt nominal Pitch mm Head mark "4" Head mark "7" Head mark "8"
diameter mm
M6 1.0 5.0 ± 1.0 10 ± 2 12 ± 2
M8 1.25 13 ± 2 24 ± 4 28 ± 5
M10 1.25 26 ± 5 50 ± 5 58 ± 7
M10 1.5 25 ± 4 46 ± 8 55 ± 5
M12 1.25 47 ± 9 93 ± 12 105 ± 15
M12 1.75 43 ± 8 83 ± 12 98 ± 12
NOTE: .
• Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
• Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the greater the
bolt strength.
00E-1
GROUP 00E
GENERAL
<ELECTRICAL>
CONTENTS
HOW TO READ WIRING HOW TO READ CIRCUIT DIAGRAMS . . . . 00E-4

DIAGRAMS . . . . . . . . . . . . . . . . . . . . 00E-2 MARKINGS FOR CONNECTOR AND
COMPOSITION AND CONTENTS OF EARTHING . . . . . . . . . . . . . . . . . . . . . . . . . 00E-6
WIRING DIAGRAMS. . . . . . . . . . . . . . . . . . 00E-2 WIRE COLOUR CODE . . . . . . . . . . . . . . . . 00E-9
HOW TO READ CONFIGURATION ABBREVIATION SYMBOLS . . . . . . . . . . . . 00E-10
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 00E-3
00E-2 GENERAL <ELECTRICAL>
HOW TO READ WIRING DIAGRAMS

COMPOSITION AND CONTENTS OF
WIRING DIAGRAMS
M1001012800097
In each section, all specifications are listed, including optional specifications. Accordingly, some specifica-
tions may not be applicable for individual vehicles.
Section Basic contents

Component Locations are shown for each point of relays, ECUs, sensors, solenoid valves,
locations inspection connectors, fusible links, fuses, etc. In the part’s lists, parts are listed in
alphabetical order.
Configuration Connector locations and harness wiring configurations on actual vehicles are
diagrams illustrated.
Circuit diagrams Circuits from power source to earth are shown completely, classified according to
system. There is a main division into power source circuits and circuits classified by
system.
• Junction block
The entire circuit for the junction block is described, because only the part of the
junction block needed is normally shown in each circuit diagram.
• Joint connectors
The internal circuits for all joint connectors are described, because only the part
needed is shown in each circuit diagram.
• Power source circuits
Circuits from the battery to fusible link, fuse, ignition switch, etc. are shown.
• Circuits classified by system
For each system, the circuits are shown from fuse to earth, excluding the power
source sections.
GENERAL <ELECTRICAL>
00E-3
HOW TO READ CONFIGURATION
DIAGRAMS
M1001006400186
The wiring harness diagrams clearly show the connector locations and harness routings at each site on
actual vehicles.
Denotes connector No.

The same connector No. is used throughout the circuit diagrams to facilitate connector location search.
The first alphabetical symbol indicates the location site of the connector and a number that follows is the unique number.
Numbers are usually assigned to part in clockwise order on the diagram.
Example: A-19
Number specific to connector (serial number)
Connector location site symbol

A: Engine compartment
B: Engine and transmission
C: Dash panel
D: Floor and roof
E: Door
F: Tailgate
A-19
Denotes earth point.
Same earth number is used throughout circuit
diagrams to facilitate search of earth point.
Refer to GROUP 70 COMPONENT LOCATIONS
- EARTH MOUNTING LOCATIONS 1
for details of earth points.
Front
wiring
harness
(RH)
Denotes harness name.
A-18
Denotes a section covered by a

corrugated tube. A-17
The mark shows the

standard mounting position
of wiring harness.
Denotes the colour of the tube A-16

(If not specified, it is black).
R: Red
Y: Yellow Y
The number of connector pins and the connector colour

(except milk white)* are shown for ease of retrieval. A-15
Example: (2-B)
Connector colour
(milk white if no colour is indicated) A-15 (2) Fog lamp (RH)
A-16 (2-GR) Horn (LO)
Number of connector pins A-17 (2-B) Headlamp (RH)
A-18 (2-B) Windshield washer motor
*: Typical connector colours A-19 (2-GR) Dual pressure switch
B: Black BR: Brown
Y: Yellow V: Violet
L: Blue O: Orange
G: Green GR: Grey Indicates the device to which the
R: Red None: Milk white connector is connected.
AC208446 AO
HOW TO READ CIRCUIT DIAGRAMS

M1001006500183
The circuit of each system from the fuse (or fusible link) to earth is shown. The power source is shown at the
top and the earth at the bottom to facilitate understanding of how the current flows. The circuit diagrams show
the state when switches are not operated.
Indicates power source. Indicates connector number.

The same number as used in the
wiring harness diagram.
Connector and connector numbers
Indicates that terminal is conne- are shown at the lower part of the
cted via a plate in the relay box. page.
Connector numbers not enclosed
by frame indicate the device incor-
porated into wiring harness.
Each circuit diagram consists of

block(s).
FUSIBLE FUSIBLE
LINK 1 LINK 2
Indicates harness junction point
numbers for another system.
The number corresponds to the RELAY
BOX
junction point number indicated
on another circuit diagram.
DIODE
Indicates the circuit name to be

connected. The arrow indicates HEATER
the current flow direction. STARTING

SYSTEM
MOTOR
ECU
Indicates the power supply in
the control unit. If no voltage is
displayed, this indicates battery
positive voltage.
RELAY
An "X" at the end of a connector

number indicates that the conn-
ector is connected to a central- SWITCH
ized junction that is shown in the
section "Centralized Junction."
RESISTOR
Indicates that the diagram contin- SENSOR

ues at which belongs to the
block in the same circuit.
Indicates the connector symbol.

Connectors in the circuit diagram
are indicated in numerical order.
Indicates the operating conditions Indicates shield wire. One-directional arrow indicates
of the engine coolant switch, etc. that current flows upwards.
AC502478 AB
00E-5
Indicates input/output Indicates a wiring connector which is inside

to/from control unit the equipment and which is not shown in
(current flow direction). the wiring harness configuration diagram.
Input Output Input/ Example C-15-2 Indicates a connector
output
which is inside the
equipment, numbered Indicates that the diagram comes
in order starting from 1. from which belongs to the
block in the same circuit.
Indicates the connector number shown in
the wiring harness configuration diagram.
Indicates that these connectors

IGNITION are the same intermediate
SWITCH (IG1) RESISTOR connectors.
SOLENOID
VALVE
ASSEMBLY
Indicates terminal number.
SOLENOID SOLENOID
VALVE 1 VALVE 2
In case two or more connectors
are connected to the same de-
vice, the same connector are
shown by a broken line.
Bi-directional arrow indicates

that current flows in both
directions due to control by an
ECU.
Indicates harness junction where

wire diameter or colour changes.
SENSOR
MOTOR Indicates intersections at
which the lead wires are
not connected.
Indicates intersections at
which the lead wires are
connected.
Indicates representative vehicle

body earth point. (Same number
as that of earth point in
EARTHING LOCATION).
Indicates that the terminal is a

spare one if the device (sensor
in this case) is not provided.
AC209124 AC
MARKINGS FOR CONNECTOR AND

EARTHING
M1001007900162
IGNITION FUSIBLE
SWITCH (IG1) LINK 1
SOLENOID
VALVE 5
1
8 ECU
4
SENSOR
MOTOR
INSPECTION
CONNECTOR
AC208460 AB
7
2
00E-7
Item No. Connector/Earthing Symbol Contents
Connector 1 Male terminal The male and female terminals
and terminal Male connector are indicated as shown. The
marking connector with male terminal(s)
is called as male connector and
indicated by two connector
ACX01252AD
contour lines, while the
Male connector
connector with female
terminal(s) is called as female
connector and indicated by
Male terminal single connector contour line.
ACX01253 AI
ACX01251AE
Female terminal
Female connector
ACX01255AD
Female connector
Female terminal
ACX01256 AH
ACX01254 AD
Connector 2 Device The symbol indicates the

symbol connector is viewed as shown.
marking At a device connection, the
connector symbol on the device
side is shown. For an
ACX01253 intermediate connector, the
ACX01257AD male connector symbol is
shown. For spare connectors
Intermediate connector
and check connectors, no
device is connected, and so the
harness-side connector symbol
is shown for these connectors.
However, a diagnosis connector
ACX01258AD is exceptional.
Spare connector, check connector
ACX01256
ACX01816 AD
Item No. Connector/Earthing Symbol Contents

Connector 3 Direct connection type Connection between a device
connection and the harness is either by
marking direct insertion in the device
(direct connection type) or by
connection with a harness
connector furnished on the
ACX01261
ACX01260 AD device side (harness
connection type). The two types
4 Harness connection type are indicated as illustrated.
ACX01263
ACX01262 AD
5 Intermediate connector
ACX01265
ACX01264AD
Earth 6 Body earth Earthing is either by body earth,

marking device earth or control unit
interior earth. These are
indicated as illustrated.
AC208448AB ACX01274
7 Device earth
AC208449AB ACX01276
8 Earth in control unit
ACX01278
AC208450AB
00E-9
WIRE COLOUR CODE
M1001008000195
Wire colours are identified by the following colour
codes.
Code Wire colour Code Wire colour Code Wire colour Code Wire colour
B Black L Blue PU Purple V Violet
BR Brown LG Light green R Red W White
G Green O Orange SB Sky blue Y Yellow
GR Grey P Pink SI Silver − −
No. Meaning
Example: <F> 1.25 G B 1 <F>: Flexible wire
1 2 3 4 <T>: Twisted wire
2 Wire size (mm2)*
3 Basic colour (colour of the cable
coating)
4 Marking colour
ACX01279 AE NOTE:
If a cable has two colours, the first of the two colour *: No code indicates 0.5 mm2. Cable colour code in
code characters indicates the basic colour (colour of parentheses indicates 0.3 mm2.
the cable coating) and the second indicates the
marking colour.
ABBREVIATION SYMBOLS
M1001008100170
The abbreviation symbols used in wiring diagrams are defined below.
1. FOR SYSTEM NAME
Abbreviation Meaning Abbreviation Meaning
symbol symbol
A/T Automatic transmission LHD L.H. drive vehicles
ABS Anti-skid braking system M/T Manual transmission
INVECS Intelligent and innovative vehicles MPI Multi-point injection
electronic control system
J/B Junction block RHD R.H. drive vehicles
J/C Joint connector SRS Supplemental restraint system
2. FOR COMBINATION METER

symbol symbol
A/T TEMP A/T temperature warning lamp FUEL Low fuel warning lamp
ABS Anti-skid braking system warning LCD Liquid crystal display
lamp
BEAM High beam indicator lamp OIL Oil pressure warning lamp
BRAKE Brake warning lamp P, R, N, D Selector lever position indicator
lamp
CHECK Check engine warning lamp REAR FOG Rear fog lamp indicator lamp
ENGINE
CHG Charging warning lamp SPEED Speedometer
CRUISE Auto-cruise control indicator lamp SRS Supplemental restraint system
warning lamp
DOOR Door-ajar warning lamp T/GA Engine coolant temperature gauge
F/GA Fuel gauge TACHO Tachometer
FRONT FOG Front fog lamp indicator lamp TURN (LH) Turn-signal indicator lamp, hazard
warning indicator lamp
TURN (RH)
00E-11
3. FOR SWITCHES AND RELAYS
Name of switches Abbreviation Operation
and relays symbol
Auto-cruise control MAIN Auto-cruise control system works.
switch RES Set the vehicle speed
SET
CAN Cancel the driving at a constant speed
Blower switch LO Blower operates at low speed
ML Blower operates at medium low speed
MH Blower operates at medium high speed
HI Blower operates at high speed
Door lock actuator, LOCK Door lock
door lock key cylinder UNLOCK Door unlock
switch
Front room lamp, rear DOOR Room lamp ON when a door is open
room lamp
Headlamp levelling 1 Lower the low-beam in one step
switch 2 Lower the low-beam in two steps
3 Lower the low-beam in three steps
4 Lower the low-beam in four steps
Heated seat switch LO Normal heating
HI Rapid heating
Ignition switch LOCK When turned to the LOCK position, no circuits will start
ACC When turned to the ACC (ACCESSORY) or ON position, the
power circuit will start
IG2 When at the ST (START) position, the power circuit will not start
functioning
IG1 Even when at the ST (START) position, the power circuit will start
ST Only when turned to the ST (START) position, the power circuit
will start
Inhibitor switch P Selector lever is at the P (PARKING) position
R Shift lever is at the R (REVERSE) position
N Shift lever is at the N (NEUTRAL) position
D Shift lever is at the D (DRIVE) position
Others ON Switched ON
OFF Switched OFF
Power window switch UP Window closes
DOWN Window opens
AUTO UP Window easily closes with one action
AUTO DOWN Window easily opens with one action
LOCK Prevents all switches other than the main switch from operating
the power windows
UNLOCK Every switch can open or close the respective window
Name of switches Abbreviation Operation

and relays symbol
Remote controlled LH LH mirror operates
mirror switch RH RH mirror operates
Shift switch assembly AUTO MODE Shift changes occur automatically in D (DRIVE) position
SPORTS Manual shift changes between 1st and 4th (4A/T) or 5th (5A/T)
MODE are possible
UP Upshifting occurs one gear at a time
DOWN Downshifting occurs one gear at a time
Sunroof switch OPEN Sunroof slides to open
UP Sunroof tilts up
CLOSE/DOWN Sunroof tilts down or slides to close
Switch and relay OFF Switched OFF
ON Switched ON
Turn-signal switch LH LH turn-signal lamps ON
RH RH turn-signal lamps ON
Windshield intermittent SLOW Lengthen pause time for intermittent operation
wiper interval adjusting FAST Shorten pause time for intermittent operation
knob
Windshield wiper MIST Wiper operates once
switch INT Wiper operates intermittently
LO Wiper operates at low speed
HI Wiper operates at high speed
4. FOR OTHERS
symbol symbol
2WD Front wheel-drive vehicle GND Earth
4WD 4 wheel-drive vehicle HI High
A/C Air conditioner IC Integrated circuit
CPU Central processing unit ILL Illumination lamp
DRL Daytime running lamp LH Left hand
ECU Electronic control unit LO Low
EGR Exhaust gas recirculation RH Right hand
ETACS Electronic time and alarm control
system
11-1
GROUP 11
ENGINE
CONTENTS
ENGINE MECHANICAL <4G63-Non-Turbo> . . . . . . . . . . . . . . 11A
ENGINE OVERHAUL <4G63-Non-Turbo> . . . . . . . . . . . . . . . . 11B
ENGINE MECHANICAL <4G63-Turbo>. . . . . . . . . . . . . . . . . . . 11C
ENGINE OVERHAUL <4G63-Turbo>. . . . . . . . . . . . . . . . . . . . . 11D
ENGINE MECHANICAL <4G69> . . . . . . . . . . . . . . . . . . . . . . . . 11E
ENGINE OVERHAUL <4G69> . . . . . . . . . . . . . . . . . . . . . . . . . . 11F

11A-1
GROUP 11A
ENGINE
MECHANICAL
<4G63-Non-Turbo>
CONTENTS
SERVICE SPECIFICATIONS. . . . . . . 11A-2 CAMSHAFT AND VALVE STEM

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-19
SEALANTS . . . . . . . . . . . . . . . . . . . . 11A-2 REMOVAL AND INSTALLATION . . . . . . . . 11A-19
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11A-3 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11A-27

REMOVAL AND INSTALLATION <2WD>. . 11A-27
ON-VEHICLE SERVICE. . . . . . . . . . . 11A-7 REMOVAL AND INSTALLATION <4WD>. . 11A-30
DRIVE BELT TENSION CHECK. . . . . . . . . 11A-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-32
AUTO-TENSIONER CHECK . . . . . . . . . . . 11A-7
IGNITION TIMING CHECK . . . . . . . . . . . . . 11A-11 CRANKSHAFT OIL SEAL . . . . . . . . . 11A-33
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A-12 REMOVAL AND INSTALLATION . . . . . . . . 11A-33
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11A-13
COMPRESSION PRESSURE CHECK. . . . 11A-13 CYLINDER HEAD GASKET . . . . . . . . 11A-36
MANIFOLD VACUUM CHECK . . . . . . . . . . 11A-14 REMOVAL AND INSTALLATION . . . . . . . . 11A-36
LASH ADJUSTER CHECK . . . . . . . . . . . . . 11A-15
TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-40
CRANKSHAFT PULLEY . . . . . . . . . . 11A-17 REMOVAL AND INSTALLATION . . . . . . . . 11A-40
REMOVAL AND INSTALLATION . . . . . . . . 11A-17 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11A-49
ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-50

REMOVAL AND INSTALLATION . . . . . . . . 11A-50
11A-2 ENGINE MECHANICAL <4G63-Non-Turbo>
SERVICE SPECIFICATIONS
M1112000300858
Item Standard value Limit

Drive belt tension Vibration frequency Hz 142 − 174 −
(Reference)
Tension N (Reference) 390 − 586 −
Basic ignition timing 5° BTDC ± 3° −
Ignition timing Approximately −
10° BTDC
Idle speed r/min 750 ± 100 −
CO contents % 0.5 or less −
HC contents ppm 100 or less −
Compression pressure kPa-r/min 1,370 − 250 930 − 250
Compression pressure difference of all cylinders kPa − Maximum 98
Intake manifold vacuum kPa − Minimum 60
Cylinder head bolt nominal length mm − 99.4
Balancer timing belt tension (When adjusted) Deflection mm 5−7 −
Balancer timing belt tension (When replaced) Deflection mm 5−7 −
Balancer timing belt tension (When checked) Deflection mm 5 − 10 −
Timing belt tensioner adjuster rod protrusion amount mm 3.8 − 4.5 −
Timing belt tensioner adjuster rod movement mm Within 1 −
SEALANTS
M1112000500238
Item Specified Sealant Remark

Cylinder head MITSUBISHI GENUINE PART MD970389 or Semi-drying
Camshaft position sensor support equivalent sealant
Rocker cover
Camshaft end seal 3M ATD Part No.8660 or equivalent
Rocker cover gasket MITSUBISHI GENUINE PART MD970389 or
Engine oil pan <2WD> equivalent
Engine upper oil pan <4WD>
Engine lower oil pan <4WD>
ENGINE MECHANICAL <4G63-Non-Turbo>
SPECIAL TOOLS
11A-3
SPECIAL TOOLS
M1112000601294
Tool Number Name Use
A
MB992080 Belt tension meter set Drive belt tension check
A: MB992081 A: Belt tension meter
B: MB992082 B: Microphone assembly
B
B992080
MB991502 M.U.T.-II sub assembly • Drive belt tension check

• Checking the ignition timing
• Checking the idle speed
B991502
MB991955 M.U.T.-III sub assembly CAUTION

A A: MB991824 A: Vehicle communication If you connect M.U.T.-III main
B: MB991827 interface (V.C.I.) harness A to a vehicle without
C: MB991910 B: M.U.T.-III USB cable CAN communication system
D: MB991911 C: M.U.T.-III main harness A to use the M.U.T.-III, a pulse
MB991824
E: MB991825 (Vehicles with CAN signal may interfere with the
B F: MB991826 communication system) simulated vehicle speed lines,
D: M.U.T.-III main harness B thus causing the M.U.T.-III
(Vehicles without CAN inoperative. Therefore, use
communication system) the M.U.T.-III main harness B
MB991827 E: M.U.T.-III adapter harness (MB991911) instead.
C
F: M.U.T.-III trigger harness Drive belt tension check
DO NOT USE
MB991910
MB991911
MB991825
MB991826
MB991955
SPECIAL TOOLS

MB991668 Belt tension meter set Drive belt tension check (used
together with M.U.T.-II or
M.U.T.-III)
B991668
MD998772 Valve spring compressor Compressing valve spring
MD998772
MD998737 Valve stem seal installer Valve stem seal installation
MD998713 Camshaft oil seal installer Camshaft oil seal installation
D998713
MD998727 Oil pan FIPG cutter Oil pan removal <2WD>
D998727
MD998781 Flywheel stopper Supporting the flywheel
D998781
MB990938 Installer bar Crankshaft rear oil seal

installation
MD998776 Crankshaft rear oil seal

installer
D998776
SPECIAL TOOLS
11A-5
MD998285 Crankshaft front oil seal Crankshaft front oil seal
guide installation
D998285
MD998375 Crankshaft front oil seal

installer
MB991654 Cylinder head bolt wrench Removal and installation of

(12) cylinder head bolt
B991654
MD998738 Adjusting bolt Supporting the timing belt

tensioner arm and timing belt
tensioner adjuster
D998738
MB991367 Special spanner Holding the crankshaft camshaft

drive sprocket
B991367
MB991385 Pin
B991385
MD998767 Tensioner wrench Valve timing belt tension

adjustment
D998767
SPECIAL TOOLS

MB991454 Engine hanger balancer When the engine hanger is
used: Supporting the engine
assembly during removal and
installation of the transmission
B991454
assembly
NOTE: Special tool MB991454
MB991527 Hanger is a part of engine hanger
attachment set MB991453.
B991527
MB991895 Engine hanger
Z203830

Slide bracket (HI) A: MB991929 A: Joint (50) × 2
B: MB991930 B: Joint (90) × 2
E C: MB991931 C: Joint (140) × 2
D: MB991932 D: Foot (standard) × 4
F E: MB991933 E: Foot (short) × 2
A F: MB991934 F: Chain and hook assembly
D
B
C
B991928
ON-VEHICLE SERVICE
11A-7
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK 4. If there are any problems in the procedure 1 or 3,
M1111003100537 replace the auto-tensioner.(Refer to P.11A-40).
CAUTION 5. Install the drive belt.(Refer to P.11A-17).
Check the drive belt tension after turning the
crankshaft clockwise one turn or more. FUNCTION CHECK
The auto-tensioner can be checked whether it is in
good condition by checking its tension.
Indicator mark
When the vibration frequency is
measured (Belt tension meter set is
used): Recommendation
A
1. Check the drive belt tension (Refer to P.11A-7).
2. Measure the drive belt tension vibration frequency
by the following procedures:
AC301702AB
Belt tension meter set (MB992080)
1. Make sure that the indicator mark is within the
area marked with A in the illustration. MB992081
2. If the mark is out of the area, replace the drive

belt. (Refer to P.11A-17).
NOTE: The drive belt tension check is not neces-
sary as auto-tensioner is adopted.
MB992082
AUTO-TENSIONER CHECK
M1111003000886 AC507219AB
OPERATION CHECK (1) Connect special tool microphone assembly

1. Turn OFF the engine from the idle state then (MB992082) to special tool belt tension meter
check to see that the drive belt is not protruding (MB992081) of special tool belt tension meter
from the pulley width of the auto-tensioner. set (MB992080).
2. Remove the drive belt.(Refer to P.11A-17). (2) Press the "POWER" button to turn on the
power supply.
(3) Press the numeral key of "1" and check that
"No. 1" appears on the upper left of the
display.
NOTE: This operation is to temporarily set the
preset data such as the belt specifications,
because if the measurement is taken without
input of the belt specifications, conversion to
tension value (N) cannot be made, resulting in
AC301703
judgement of error.
(4) Press "Hz" button twice to change the display
3. Securely insert the spindle handle or ratchet to the frequency display (Hz).
handle with a 12.7 mm insertion angle into the jig
hole of the auto tensioner. Turn the auto-tensioner
to the left and right to check and see that there is
no threading.
ON-VEHICLE SERVICE
CAUTION (8) Press and hold the "POWER" button to turn off
• The temperature of the surface of the belt the power supply.
should be as close to normal temperature as 3. If not within the standard value, replace the
possible. auto-tensioner (Refer to P.11A-40).
• Do not allow any contaminants such as water
or oil to get onto the microphone. When the vibration frequency is
• If strong gusts of wind blow against the measured (M.U.T.-II is used):
microphone or if there are any loud sources Recommendation
of noise nearby, the values measured by the 1. Check the drive belt tension. (Refer to P.11A-7).
microphone may not correspond to actual
values.
• If the microphone is touching the belt while
the measurement is being made, the values CAUTION
measured by the microphone may not corre-
spond to actual values.
• Do not take the measurement while the vehi-
cle's engine is running. 16-pin
Power steering
10 – 15 mm
oil pump pulley
MB992080 15˚
Water pump 15˚

pulley
Gentry tap with MUT-II

your finger
AC102806AE
(5) Hold special tool MB992080 to the middle of

the belt between the pulleys (at the place
indicated by arrow) where it does not contact MB991668
the belt (approximately 10 − 15 mm away from
the rear surface of the belt) so that it is AC211862 AB
perpendicular to the belt (within an angle of ±
To prevent damage to M.U.T.-II, always turn the
15°).
ignition switch to the "LOCK" (OFF) position
(6) Press the "MEASURE" button. before connecting or disconnecting M.U.T.-II.
(7) Gently tap the middle of the belt between the (1) Connect special tool belt tension meter set
pulleys (the place indicated by the arrow) with (MB991668) to the M.U.T.-II.
your finger as shown in the illustration, and
(2) Connect the M.U.T.-II to the diagnosis
check that the vibration frequency of the belt is
connector.
within the standard value.
(3) Turn the ignition switch to "ON" position, and
Standard value: 142 − 174 Hz select "BELT TENSION" on the menu screen.
NOTE: To take the measurement repeatedly,
fillip the belt again.
ON-VEHICLE SERVICE
11A-9
CAUTION When the vibration frequency is
• The temperature of the surface of the belt measured (V.C.I. is used):
should be as close to normal temperature as Recommendation
possible.
1. Check the drive belt tension. (Refer to P.11A-7).
or oil to get onto the microphone.
• If strong gusts of wind blow against the
microphone or if there are any loud sources CAUTION
of noise nearby, the values measured by the
values.
• If the microphone is touching the belt while 16-pin
the measurement is being made, the values
cle's engine is running.
Power steering
10 – 20 mm
oil pump pulley
MB991668 15˚
MB991824
Water pump 15˚
pulley
MB991668
Gentry tap with
your finger
MB991911
AC102806AB
AC211863AB
(4) Hold special tool belt tension meter set
To prevent damage to special tool V.C.I.
(MB991668) to the middle of the drive belt
(MB991824), always turn the ignition switch to
between the pulleys (at the place indicated by
the "LOCK" (OFF) position before connecting or
arrow), approximately 10 − 20 mm away from
disconnecting special tool V.C.I. (MB991824).
the rear surface of the belt so that it is
(1) Connect special tool belt tension meter set
(MB991668) to special tool V.C.I. (MB991824).
15 degree).
(2) Connect special tool M.U.T.-III main harness B
(5) Gently tap the middle of the belt between the
pulleys (the place indicated by the arrow) with
your finger as shown in the illustration, and (3) Connect special tool M.U.T.-III main harness B
measure that the vibration frequency of the (MB991911) to the diagnosis connector.
belt is within the standard value. (4) Turn the ignition switch to "ON" position, and
select "Belt Tension" on the menu screen.
Standard value: 142 − 174 Hz
3. If not within the standard value, replace the
auto-tensioner. (Refer to P.11A-40).
ON-VEHICLE SERVICE
CAUTION When the tension is measured

• The temperature of the surface of the belt 1. Check the drive belt tension. (Refer to P.11A-7).
should be as close to normal temperature as
possible. Belt tension gauge Power steering
oil pump pulley
Water pump
• If strong gusts of wind blow against the pulley
microphone or if there are any loud sources
values.
• If the microphone is touching the belt while AC102807AB
measured by the microphone may not corre- 2. Use a belt tension gauge in the middle of the belt
spond to actual values. between the pulleys (at the place indicated by the
• Do not take the measurement while the vehi- arrow) to measure that the belt tension is within
cle's engine is running. the standard value.
Power steering Standard value: 390 − 586 N
10 – 20 mm
oil pump pulley
MB991668 15˚
auto-tensioner. (Refer to P.11A-40).
Water pump 15˚
pulley
Gentry tap with

your finger
AC102806AB

15 degree).
measure that the vibration frequency of the
belt is within the standard value.
alternator drive belt auto tensioner. (Refer to
P.11A-40).
ON-VEHICLE SERVICE
11A-11
IGNITION TIMING CHECK 3. Connect a timing light.
M1111001700920
4. Start the engine and let it run at idle.
5. Use the M.U.T.-II/III to measure engine idle speed
and check that it is within the standard value.
Standard value: 750 ± 100 r/min
6. Select No. 17 of the M.U.T.-II/III Actuator test.
7. Check that basic ignition timing is within the
standard value.
16 PIN Standard value: 5° BTDC ± 3°
MB991502
AK303691AF
8. If the basic ignition timing is outside the standard
value, inspect the MPI system.
(Refer to P.13A-15, GROUP 13A −
Troubleshooting − Inspection chart for diagnosis
code.)
16-PIN CAUTION
If the test is not cancelled, a forced driving will
continue for 27 minutes. Driving under this con-
dition may damage the engine.
9. Press the M.U.T.-II/III clear key (Select a forced
driving cancel mode) to release the Actuator test.
MB991911 10.Check that ignition timing is at the standard value.
Standard value:
MB991824 approximately 10° BTDC
NOTE: .
• The ignition timing may fluctuate within ± 7°
BTDC. This is normal.
• In higher altitude, the ignition timing is more
advanced than the standard value by approxi-
mately 5°.
MB991827 AK303690AB
11.Remove the timing light.
1. Before inspection, set the vehicle to the 12.Turn off the ignition switch to the "LOCK" (OFF)
pre-inspection condition. position and then remove the M.U.T.-II/III.
position and then connect the M.U.T.-II/III to the
ON-VEHICLE SERVICE
IDLE SPEED CHECK 1. Before inspection, set the vehicle to the

M1111003500847 pre-inspection condition.
3. Connect a timing light.
5. Check that ignition timing is at the standard value.
Standard value:
16 PIN
AK303691AF
6. Check the idle speed.
NOTE: .
• The idle speed is controlled automatically by
the idle speed control system.
16-PIN
• When using the M.U.T.-II/III, select item No. 22
and take a reading of the idle speed.
7. If the idle speed is outside the standard value,
inspect the MPI system.
(Refer to P.13A-15, GROUP 13A −
MB991911
code.)
MB991824 8. Turn the ignition switch to the "LOCK" (OFF)
position and then remove the M.U.T.-II/III.
MB991827 AK303690AB
ON-VEHICLE SERVICE
11A-13
IDLE MIXTURE CHECK 9. If there is a deviation from the standard value,
M1111002100619 check the following items:
• Diagnosis output
• Fuel pressure
• Injector
• Ignition coil, spark plug cable, spark plug
• EGR control system
• Evaporative emission control system
• Compression pressure
16 PIN NOTE: Replace the three way catalyst when the
MB991502
CO and HC contents are not within the standard
AK303691AF
value, even though the result of the inspection is
normal on all items.
10.Turn the ignition switch to the "LOCK" (OFF)
16-PIN COMPRESSION PRESSURE CHECK

M1111002600960
Crank angle
sensor
connector
MB991911
MB991824
AK201364AC
1. Before inspection, set the vehicle to the

pre-inspection condition.
2. Disconnect the spark plug cables.
MB991827 AK303690AB
3. Remove all of the spark plugs.
1. Before inspection, set the vehicle to the 4. Disconnect the crank angle sensor connector.
pre-inspection condition. NOTE: Doing this will prevent the engine-ECU
2. Turn the ignition switch to the "LOCK" (OFF) from carrying out ignition and fuel injection.
position and then connect the M.U.T.-II/III to the CAUTION
diagnosis connector. • Keep away from the spark plug hole when
3. Connect a timing light. cranking.
4. Start the engine and let it run at idle. • If compression is measured with water, oil,
5. Check that ignition timing is at the standard value. fuel, etc., that has come from cracks inside
Standard value: the cylinder, these materials will become
approximately 10° BTDC heated and will gush out from the spark plug
hole, which is dangerous.
6. Run the engine at 2,500 r/min for 2 minutes.
5. Cover the spark plug hole with a shop towel etc.,
7. Set the CO, HC tester. and after the engine has been cranked, check that
8. Check the CO contents and the HC contents at no foreign material is adhering to the shop towel.
idle. 6. Set compression gauge to one of the spark plug
Standard value holes.
CO contents: 0.5% or less
HC contents: 100 ppm or less
ON-VEHICLE SERVICE
7. Crank the engine with the throttle valve fully open MANIFOLD VACUUM CHECK
and measure the compression pressure. M1111002700796
Standard value (at engine speed of 250

r/min):
1,370 kPa
Limit (at engine speed of 250 r/min):
Minimum 930 kPa
8. Measure the compression pressure for all the
cylinders, and check that the pressure differences 16 PIN
of the cylinders are below the limit. MB991502
Limit: Maximum 98 kPa AK303691AF
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 from (6) to (8). 16-PIN
(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 dose not rise after oil is
added, the cause is a burnt or defective valve MB991911
seat, or pressure is leaking from the gasket.
10.Connect the crank angle sensor connector. MB991824
11.Install the spark plugs and spark plug cables.

12.Use the M.U.T.-II/III to erase the diagnosis codes.
NOTE: This will erase the diagnosis code result-
ing from the crank angle sensor connector being
disconnected.
MB991827 AK303690AB

Vacuum
gauge
Fuel pressure
regulator
AK201369AB
3. Attach a three-way joint to the vacuum hose

between the fuel pressure regulator and the air
intake plenum, and connect a vacuum gauge.
ON-VEHICLE SERVICE
11A-15
4. Start the engine and check that idle speed is 1. Start the engine.
within the standard valve. 2. Check that the noise occurs immediately after the
Standard value: 750 ± 100 r/min engine is started, and that the noise changes in
5. Check the intake manifold vacuum. accordance with changes in the engine speed.
Limit: Minimum 60 kPa If the noise dose not occur immediately after the
engine is started, or if it dose not change in
6. Turn off the ignition switch. accordance with the engine speed, the problem is
7. Remove the vacuum gauge and the three-way not being caused by the lash adjusters, so check
joint, and then connect the vacuum hose. for some other cause of the problem. Moreover, if
8. Turn the ignition switch to the "LOCK" (OFF) the noise dose not change in accordance with the
position and then remove the M.U.T.-II/III. engine speed, the cause of the problem is
probably not with the engine (In these cases, the
LASH ADJUSTER CHECK lash adjusters are normal).
M1111002900767
If an abnormal noise (knocking) that seems to be 3. While the engine is idling, check that the noise
coming from the lash adjuster is heard after starting level does not change when the engine load is
the engine and dose not stop, carry out the following varied.
check. If the noise level changes, the cause of the noise
NOTE: . is probably parts striking because of worn
• If the vehicle is parked on a slope fir a long period crankshaft bearings or connecting rod bearings
of time, the amount of oil inside the lash adjuster (In such cases, the lash adjusters are normal).
will decrease, and air may get into the high pres- 4. After the engine has warmed up, run it at idle and
sure chamber when starting the engine. check if any noise can be heard.
• After parking the vehicle for long periods, the oil If the noise has become smaller or disappeared,
drains out of the oil passage, and it takes time for oil sludge could make the lash adjusters stick.
the oil to be supplied to the lash adjuster, so air Clean the lash adjusters (Refer to GROUP 11B −
can get into the high-pressure chamber. Rocker Arms and Camshaft − Inspection
• If either of the above situations occur, the abnor-
P.11B-33). If not improved, go to step 5.
mal noise can be eliminated by bleeding the air
from inside the lash adjusters. 5. Bleed air from the lash adjusters (Refer to
• The abnormal noise which is caused by a prob- P.11A-16).
lem with the lash adjusters is generated after the 6. If the noise has not disappeared even after the air
engine is started, and will vary according to the bleeding, clean the lash adjusters (Refer to
engine speed. However, this noise is not related GROUP 11B − Rocker Arms and Camshaft −
to the actual engine load. Inspection P.11B-33).
Because of this, if the noise dose not occur immedi-
ately after the engine is started, if it dose 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.
• 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.
ON-VEHICLE SERVICE
<LASH ADJUSTER AIR BLEEDING> Drive pattern for air breeding

Gradually open
the throttle valve Close the throttle valve
Approximately
3,000 r/min
Good
Idle speed 15 s 15 s
Max
Once
AKX00330AE
Min.
AKX00328 AE
2. Run the engine at idle for 1 − 3 minutes to let it
1. Check the engine oil and replenish or replace the warm up.
oil if necessary. 3. With no load on the engine, repeat the drive
pattern shown in the illustration above and check
NOTE: .
if the abnormal noise disappears (The noise
• If there is an only small amount of oil, air will
should normally disappear after 10 − 30
be drawn in through the oil screen and will get
repetitions, but if there is no change in the noise
into the oil passage.
level after 30 repetitions or more, the problem is
• If the amount of oil is greater than normal, then
probably not due to air inside the lash adjusters).
the oil will being mixed by the crankshaft and a
large amount of air may get mixed into the oil. 4. After the noise has disappeared, repeat the drive
• If the oil is degenerated, air and oil will not pattern shown in the illustration above a further 5
separate easily in oil, and the amount of air times.
mixed into the oil will increase. 5. Run the engine at idle for 1 − 3 minutes and check
that the noise has disappeared.
High-pressure chamber
AK100001AC
• If the air which has been mixed in with the oil

due to any of the above reasons gets into the
high pressure chamber of the lash adjuster,
the air inside the high pressure chamber will
be compressed when the valve is open and
the lash adjuster will over-compress, resulting
in abnormal noise when the valve close. 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.
CRANKSHAFT PULLEY
11A-17
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001600528
Pre-removal Operation Post-installation Operation

• Under Cover Removal (Refer to GROUP 51, Under Cover • Drive Belt Tension Check (Refer to P.11A-7).
P.51-31). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
25 ± 4 N·m
AC300537AB
Removal steps
<<A>> 1. Drive belt
2. Crank shaft damper pulley
CRANKSHAFT PULLEY
REMOVAL SERVICE POINT 2. Rotate the auto-tensioner anti-clockwise and align

<<A>> DRIVE BELT REMOVAL hole A with hole B.
The following operations will be needed due to the CAUTION
introduction of the serpentine drive system with the To reuse the drive belt, draw an arrow indicating
drive belt auto-tensioner. the rotating direction (clockwise) on the back of
AC301703
the belt using chalk, etc.
Auto-tensioner
Auto-tensioner
Hole B
Hole A L-shaped
AC301704AB hexagon
wrench AC301705AB
1. Securely insert the spindle handle or ratchet
handle with a 12.7 mm insertion angle into the jig 3. Insert an L-shaped hexagon wrench, etc. into the
hole of the auto-tensioner. hole to fix and then remove the drive belt.
CAMSHAFT AND VALVE STEM SEAL
11A-19
M1112006600329
CAUTION
*Remove and assemble the marked parts in each cylinder unit.
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Valve Timing Belt Installation (Refer to P.11A-40).
Service − Engine Coolant Replacement P.14-17). • Battery and Battery Tray Installation
• Air Cleaner and Air Cleaner Bracket Removal (Refer to • Air Cleaner and Air Cleaner Bracket installation (Refer to
GROUP 15, Air Cleaner P.15-6). GROUP 15, Air Cleaner P.15-6).
• Battery and Battery Tray Removal • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Valve Timing Belt Removal (Refer to P.11A-40). Service − Engine Coolant Replacement P.14-17).
• Drive Belt Tension Check (Refer to P.11A-7).
11 ± 1 N·m
11 ± 1 N·m
3.0 ± 0.5 N·m 2 4
6
3.5 ± 0.5 N·m
5
8
9.0 ± 2.0 N·m
1
8.8 ± 1.0 N·m 11 ± 1 N·m
9
N 11 12
11 ± 1 N·m
N 10
3 7
AC300538 AB
Removal steps Removal steps (Continued)

1. Accelerator cable connection • Spark plug cables and ignition coils
2. Rocker cover centre cover (Refer to GROUP 16, Ignition Coil
3. Crank angle sensor connector P.16-45).
4. Control wiring harness connection 5. Rocker cover PCV hose
6. Rocker cover breather hose
7. Control wiring harness connection
>>N<< 8. Rocker cover
Removal steps (Continued)

>>M<< 9. Camshaft end seal
10. Spark plug hole gaskets
>>L<< 11. Rocker cover gasket
<<A>> >>K<< 12. Radiator upper hose connection
20
22
24 Apply engine oil to all
25 moving parts before
20 ± 1 N·m 23 installation.
21
19 26
N 18
17
89 ± 9 N·m 11 ± 1 N·m
30 13
25 ± 4 N·m 29 22 ± 4 N·m
15
31* 16
27 10 ± 2 N·m
32* 28
33*
N 34* 14 N
36* 14 ± 1 N·m
31*
32*
33*
35* N
36*
AC308919 AB

13. Camshaft position sensor support >>F<< 24. Camshaft bearing caps, No.4
cover >>E<< 25. Inlet camshaft
14. Camshaft position sensor support >>E<< 26. Exhaust camshaft
cover gasket 27. Rocker arms
>>J<< 15. Camshaft position sensing cylinder >>D<< 28. Rocker arm lash adjusters
>>I<< 16. Camshaft position sensor support 29. Oil delivery body
<> >>H<< 17. Camshaft sprockets 30. Spark plugs
>>G<< 18. Camshaft oil seals <<C>> >>C<< 31. Valve spring retainer locks
>>F<< 19. Camshaft bearing caps, front 32. Valve spring retainers
>>F<< 20. Camshaft bearing caps, rear >>B<< 33. Valve springs
>>F<< 21. Camshaft bearing caps, No.2 >>A<< 34. Inlet valve stem seals
>>F<< 22. Camshaft bearing caps, No.5 >>A<< 35. Exhaust valve stem seals
>>F<< 23. Camshaft bearing caps, No.3 36. Valve spring seats
11A-21
LUBRICATION AND SEALING POINTS
<The bottom view of the rocker cover>
10 mm 10 mm
Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent

Rocker
<View A> cover
Cylinder
10 mm A head
10 mm 10 mm Sealant: 3M ATD Part No.8660

or equivalent
A
Sealant: A
MITSUBISHI GENUINE
PART MD970389 or
equivalent
φ 3 mm
(Lip section) Sealant: MITSUBISHI GENUINE

PART MD970389 or equivalent
Engine oil AC300541
<Top view of cylinder head>

REMOVAL SERVICE POINTS <<C>> VALVE SPRING RETAINER LOCKS

<<A>> RADIATOR UPPER HOSE DISCON- REMOVAL
NECTION CAUTION
When removing valve spring retainer locks, leave
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the cylin-
der if the piston is not properly in the TDC posi-
tion.
Mating marks
MD998772
AC200641AC
Make mating marks on the radiator hose and the

hose clamp. Disconnect the radiator hose.
<> CAMSHAFT SPROCKETS AC201799 AB

REMOVAL Use special tool valve spring compressor
(MD998772) to compress the valve spring, remove
the valve spring retainer locks.
INSTALLATION SERVICE POINTS

>>A<< EXHAUST VALVE STEM
SEALS/INLET VALVE STEM SEALS
INSTALLATION
AC201457AB Grey Grey green
1. Hold the hexagon part of the camshaft with a

wrench.
2. Loosen the camshaft sprocket mounting bolts and
remove the camshaft sprocket.
Inlet side Exhaust side

AC201542AB
1. Check the valve stem seal colour to identify the

inlet side or exhaust side.
2. Apply a small amount of engine oil to the valve
stem seals.
11A-23
CAUTION >>D<< ROCKER ARM LASH ADJUSTERS
• Valve stem seals cannot be reused. INSTALLATION
• The special tool valve stem seal installer CAUTION
(MD998737) must be used to install the valve If the rocker arm lash adjuster is reused, always
stem seal. Improper installation could result clean and check it before installation. (Refer to
in oil leaking past the valve guide. GROUP 11B, Rocker Arms and Camshaft −
Inspection P.11B-33).
MD998737
>>E<< EXHAUST CAMSHAFT/INLET
Valve
CAMSHAFT INSTALLATION
Valve stem 1. Remove sealant remained on the cylinder head.
seal
2. Apply engine oil to the cam and the journal of the
Valve guide camshaft.
CAUTION
AC308920AB
3. Use special tool to fill a new valve stem seal in the Engine front
valve guide using the valve stem area as a guide.
>>B<< VALVE SPRINGS INSTALLATION Slit
Rocker arm side

Exhaust camshaft
AC201458AB
Do not install wrong camshaft at the side of inlet

or exhaust. The exhaust camshaft has a slit at the
Identification
colour
rear surface.
3. Install the camshaft to the cylinder head.
AC201453AB
Install the valve springs with its identification colour >>F<< CAMSHAFT BEARING CAPS, NO.
painted end facing the locker arm. 4/CAMSHAFT BEARING CAPS, NO.
3/CAMSHAFT BEARING CAPS, NO.
>>C<< VALVE SPRING RETAINER LOCKS 5/CAMSHAFT BEARING CAPS, NO.
INSTALLATION 2/CAMSHAFT BEARING CAPS,
REAR/CAMSHAFT BEARING CAPS,
FRONT INSTALLATION
MD998772
Approximately 3˚
Dowel pin
AC201799 AB
Use special tool valve spring compressor Inlet side Exhaust side
(MD998772) to compress the valve spring in the
AC201459AB
same manner as removal.
1. Set the dowel pin of the camshaft to the position
as shown in the illustration.
Bearing Front
Engine front cap No. Engine front marking
E4
Identification of
inlet side and
exhaust side
AC201460AB AC201462AB
2. Since the shape of camshaft bearing caps No.2 − 4. Position the camshaft bearing caps, rear in the
5 is identical, check the identification marks so direction as shown in the illustration for
that the bearing cap No., inlet side, or exhaust installation.
side cannot be mistaken to install to the direction 5. Check the identification marks on the camshaft
as shown in the illustration. bearing caps, front so that inlet side and exhaust
Identification mark (engraved on the front side cannot be mistaken in the same way as that
and bearing caps No.2 − 5) of bearing caps No.2 − 5.
I: Inlet side CAUTION
E: Exhaust side Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the
Engine front
adhesion surface during that time.
6. Tighten the bearing cap mounting bolts increasing
the pressure in 2 to 3 times and finally tighten to
the specified torque.
Tightening torque: 20 ± 1 N⋅m
7. Ensure that the rocker arms are installed properly.
NOTE: Remove an excess of sealant completely.
AC201461AB
>>G<< CAMSHAFT OIL SEALS

3. Apply sealant to the positions (6 areas) of the
upper side of the cylinder head as shown in the INSTALLATION
illustration.
Specified sealant: MITSUBISHI GENUINE
NOTE: Install the camshaft bearing caps, rear and
camshaft bearing caps, front within 15 minutes
after applying liquid gasket.
MD998713 AC102323AB
1. Apply engine oil to the entire inner diameter of the

oil seal lip.
2. Use special tool camshaft oil seal installer
(MD998713) to press-fit the oil seals.
11A-25
>>H<< CAMSHAFT SPROCKETS >>J<< CAMSHAFT POSITION SENSING
INSTALLATION CYLINDER INSTALLATION
Approximately 45˚
Dowel pin
Vane (small)
Vane (large)
AC201457AB AC201464AB
1. Hold the hexagon part of the camshaft with a 1. Set the dowel pin of the exhaust camshaft to the
wrench in the same manner as removal. position (No.1 cylinder at compression TDC) as
2. Tighten the camshaft sprocket mounting bolts to shown in the illustration.
the specified torque. NOTE: Use the force of the exhaust valve spring
Tightening torque: 89 ± 9 N⋅m to rotate anti-clockwise.
2. Install the vane (small) of the camshaft position
sensing cylinder at an angle of approximately 45
>>I<< CAMSHAFT POSITION SENSOR degrees to the position of the dowel pin of the
SUPPORT INSTALLATION exhaust camshaft.
1. Remove sealant from the camshaft position 3. Tighten the camshaft position sensing cylinder
sensor support and cylinder head surfaces. mounting bolts to the specified torque.
>>K<< RADIATOR UPPER HOSE

CONNECTION
Projection
φ 3 mm AC201463AB
2. Apply the sealant to the camshaft position sensor

support flange in a continuous bead as shown in
Water outlet fitting Mating marks
the illustration.
Specified sealant: MITSUBISHI GENUINE AC200642 AE
NOTE: . Install the camshaft position sensor sup- 1. Insert each hose as far as the projection of the
port within 15 minutes after applying liquid gasket. water outlet fitting.
3. Install the camshaft position sensor support to the 2. Align the mating marks on the radiator hose and
cylinder head. hose clamp, and then connect the radiator hose.
CAUTION
Then wait at least one hour. Never start the
4. Tighten the camshaft position sensor support
mounting bolts to the specified torque.
>>L<< ROCKER COVER GASKET Apply sealant to the positions of the camshaft end
INSTALLATION seal as shown in the illustration and install to the cyl-
inder head.
1. Remove sealant remained on the rocker cover.
Specified sealant: 3M ATD Part No.8660 or
equivalent
NOTE: Install the camshaft end seal within 15 min-
utes after applying liquid gasket.
>>N<< ROCKER COVER INSTALLATION

Engine front
AC201465AB

lower side of the rocker cover as shown in the
illustration.
PART MD970389 or equivalent AC201469AB
NOTE: Install the rocker cover gasket within 15
minutes after applying liquid gasket. 1. Apply sealant to the positions of the rocker cover
gasket (6 areas) as shown in the illustration.
3. Install the rocker cover gasket to the rocker cover.
>>M<< CAMSHAFT END SEAL
NOTE: Install the rocker cover within 15 minutes
INSTALLATION
2. Install the rocker cover to the cylinder head.
CAUTION
3. Tighten the rocker cover mounting bolts to the
specified torque.
Tightening torque: 3.5 ± 0.5 N⋅m
10 mm
10 mm
Cylinder head
AC201468 AB
OIL PAN
11A-27
OIL PAN
REMOVAL AND INSTALLATION <2WD>
M1112002800752

• Under Cover Removal (Refer to GROUP 51, Under Cover • Front Exhaust Pipe Installation (Refer to GROUP 15,
P.51-31). Exhaust Pipe and Main Muffler P.15-25).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Service − Engine Oil Replacement P.12-4). Service − Engine Oil Replacement P.12-4).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Under Cover Installation (Refer to GROUP 51, Under
Exhaust Pipe and Main Muffler P.15-25). Cover P.51-31).
N 4 35 ± 6 N·m
39 ± 5 N·m 3
9.0 ± 3.0 N·m 2
26 ± 5 N·m
9.0 ± 1.0 N·m
9.0 ± 3.0 N·m AC300542 AB

1. Exhaust manifold bracket >>B<< 4. Engine oil pan drain plug gasket
2. Flywheel housing front lower cover <<A>> >>A<< 5. Engine oil pan
3. Engine oil pan drain plug
OIL PAN
REMOVAL SERVICE POINT INSTALLATION SERVICE POINTS

<<A>> ENGINE OIL PAN REMOVAL >>A<< ENGINE OIL PAN INSTALLATION
1. Remove the engine oil pan mounting bolts. 1. Remove sealant from the engine oil pan and
CAUTION cylinder block surfaces.
φ 4 mm
Groove portion Bolt hole portion
AC301325 AB AC102133AB
MD998727 MD998727 2. Apply a bead of the sealant to the cylinder block

mating surface of the engine oil pan as shown.
NOTE: Install the engine oil pan within 15 minutes
after applying sealant.
3. Assemble the engine oil pan to the cylinder block.
CAUTION
AC102324 AB Then wait at least one hour. Never start the
engine or let engine oil or coolant touch the seal-
Do not use special tool oil pan FIPG cutter ant surface during that time.
(MD998727) in area A of the engine oil pan. Using
the special tool in area A may cause deformation
of the front case because the front case is made
of aluminum.
2. Tap the special tool into the range (B) between the
cylinder block and the engine oil pan, and then
slide the tool sideways.
NOTE: If any sounding parts interfere with the
removal, there is no need to use the special tool. M6 × 8 mm
3. Remove the engine oil pan. AC102698 AB
4. Tighten the engine oil pan mounting bolts to the

specified torque. Be careful when installing, as the
oil pan mounting bolts (indicated in the illustration)
have different lengths from the other bolts.
OIL PAN
11A-29
>>B<< ENGINE OIL PAN DRAIN PLUG
GASKET INSTALLATION
Engine
oil pan
side
AC102325 AE
Replace the gasket with a new gasket. Install the

new gasket in the direction shown in the illustration.
OIL PAN
REMOVAL AND INSTALLATION <4WD>

M1112002800600

• Under Cover Removal (Refer to GROUP 51, Under Cover • Centre Member Installation (Refer to GROUP 32, Engine
P.51-31). Roll Stopper and Centre Member P.32-11).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Front Exhaust Pipe Installation (Refer to GROUP 15,
Service − Engine Oil Replacement P.12-4). Exhaust Pipe and Main Muffler P.15-25).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Exhaust Pipe and Main Muffler P.15-25). Service − Engine Oil Replacement P.12-4).
• Centre Member Removal (Refer to GROUP 32, Engine • Under Cover Installation (Refer to GROUP 51, Under
Roll Stopper and Centre Member P.32-11). Cover P.51-31).
9.0 ± 3.0 N·m
N 4 2
3 9.0 ± 3.0 N·m
39 ± 5 N·m
44 ± 10 N·m
1 9.0 ± 1.0 N·m
22 ± 4 N·m
5
9.0 ± 3.0 N·m 9.0 ± 3.0 N·m

AC300543 AB

>>D<< 1. Transmission housing front lower <<A>> >>B<< 5. Engine lower oil pan
cover stay <> >>A<< 6. Engine upper oil pan
2. Flywheel housing front lower cover
3. Engine oil pan drain plug
>>C<< 4. Engine oil pan drain plug gasket
OIL PAN
11A-31
REMOVAL SERVICE POINTS INSTALLATION SERVICE POINTS
<<A>> ENGINE LOWER OIL PAN >>A<< ENGINE UPPER OIL PAN INSTAL-
REMOVAL LATION
1. Remove the engine lower oil pan mounting bolts. 1. Remove sealant from the engine upper oil pan
CAUTION and cylinder block surfaces.
Do not use special tool oil pan FIPG cutter
(MD998727). The engine upper oil pan is made of
aluminium and this tool will damage it.
φ 4 mm
Groove Bolt hole
portion portion AC102242AB
2. Apply a bead of the sealant to the mating surface

Engine lower oil pan of the engine upper oil pan as shown.
AC102931AB
2. Apply a piece of wood to the lower oil pan and PART MD970389 or equivalent
strike it with a hammer to remove the engine NOTE: Install the engine upper oil pan within 15
lower oil pan. minutes after applying sealant.
3. Assemble the engine upper oil pan to the cylinder
<> ENGINE UPPER OIL PAN block.
REMOVAL CAUTION
1. Remove the engine upper oil pan mounting bolts. Then wait at least one hour. Never start the
CAUTION engine or let engine oil or coolant touch the seal-
(MD998727). The engine upper oil pan is made of B B
aluminium and this tool will damage it. B B
B
A
A B B
B B
AC102946AB
B B
2. Screw in the bolt into bolt hole A in the location B

shown. Then lift the upper oil pan and remove it. B
B
A A
AC102929AB
4. Insert the bolts to the engine upper oil pan as

shown, and tighten them to the specified torque.
OIL PAN
Name Symbol Quantity Size mm 4. Insert the bolts to the engine lower oil pan as
(D × L) shown, and tighten them to the specified torque in
the order shown.
Flange bolt A 2 M6 × 16
Name Symbol Quantity Size mm
B 16 M6 × 18
(D × L)
NOTE: D: Nominal diameter, L: Nominal length Flange bolt A 1 M6 × 75
B 11 M6 × 10
NOTE: D: Nominal diameter, L: Nominal length
>>B<< ENGINE LOWER OIL PAN
INSTALLATION
1. Remove sealant from the engine lower oil pan and
engine upper oil pan. >>C<< ENGINE OIL PAN DRAIN PLUG
GASKET INSTALLATION
Engine lower
oil pan side
φ 4 mm
Groove Bolt hole
AC102325 AF
of the engine lower oil pan as shown. Replace the gasket with a new one. Install the new
gasket in the direction shown in the illustration.
>>D<< TRANSMISSION HOUSING FRONT
NOTE: Install the engine lower oil pan within 15
minutes after applying sealant. LOWER COVER STAY INSTALLATION
Install the transmission housing front lower cover
3. Assemble the engine lower oil pan to the engine
stay in the following order.
upper oil pan.
1. Tighten the engine side four mounting bolts to the
CAUTION specified torque.
ant surface during that time. 2. Tighten the transmission side two mounting bolts
to the specified torque.
B-1 B-11
B-10 Tightening torque: 44 ± 10 N⋅m
B-4 INSPECTION
B-7 M1112002900210
• Check the oil pan for cracks.
B-5
B-6 • Check the oil pan sealant-coated surface for
B-8 A-3 damage and deformation.
B-9 B-12 B-2

AC102930AB
CRANKSHAFT OIL SEAL
11A-33
CRANKSHAFT OIL SEAL
M1112003101049
132 ± 5 N·m
4
5
7 6
8
9 N
3 9
N 3
2 (Lip section) (Lip section)
1 Engine oil
AC300544AB
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
• Valve timing belt, balancer timing <<A>> • Transmission assembly
belt (Refer to P.11A-40). • Clutch cover and clutch disc (Refer
>>D<< 1. Crankshaft balancer shaft drive to GROUP 21B, Clutch P.21B-3).
sprocket <> >>B<< 4. Flywheel bolts
2. Crankshaft key 5. Flywheel adapter plate
>>C<< 3. Crankshaft front oil seal 6. Flywheel assembly
7. Flywheel adapter plate
8. Crankshaft bush
>>A<< 9. Crankshaft rear oil seal
CRANKSHAFT OIL SEAL

<<A>> TRANSMISSION ASSEMBLY >>A<< CRANKSHAFT REAR OIL SEAL
REMOVAL INSTALLATION
CAUTION
Oil seal
AC300897
MB990938
Engine front (Engine oil)

Flywheel
assembly
Flywheel
bolt MD998776 Crankshaft
AC102328 AB
AC308604 AB
1. Apply a small amount of engine oil to the entire
Do not remove the flywheel bolt. If this bolt is inner diameter of the oil seal lip.
removed, the flywheel assembly will become out 2. Use the following special tools to press-fit the oil
of balance and damaged. seal.
Refer to GROUP 22A, Transmission Assembly • Installer bar (MB990938)
P.22A-14. • Crankshaft rear oil seal installer (MD998776)
<> FLYWHEEL BOLTS REMOVAL >>B<< FLYWHEEL BOLTS INSTALLATION
MD998781 MD998781
AC211914AC AC211914AC
1. Use special tool flywheel stopper (MD998781) to 1. Use special tool flywheel stopper (MD998781) to
secure the flywheel. secure the flywheel in the same manner as
2. Remove the flywheel bolts. removal.
2. Tighten the flywheel bolts to the specified torque.
CRANKSHAFT OIL SEAL
11A-35
>>C<< CRANKSHAFT FRONT OIL SEAL >>D<< CRANKSHAFT BALANCER SHAFT
INSTALLATION DRIVE SPROCKET INSTALLATION
Crankshaft MD998375
: Clean
: Clean and degrease
(Engine oil)
Crankshaft
MD998285 Oil seal

(Oil applied to the
circumference) AC102329AC

inner diameter of the oil seal lip.
2. Apply a small amount of engine oil to the outer
diameter of special tool crankshaft front oil seal
guide (MD998285) and install it to the crankshaft. Front case
Crankshaft
3. Use special tool crankshaft front oil seal installer balancershaft
(MD998375) to press-fit the oil seal. drive sprocket
Engine front
AC211222 AB
1. Clean or degrease the front case, the crankshaft

and the crankshaft balancer shaft drive sprocket
as shown.
NOTE: Also clean the degreased surfaces.
2. Install the crankshaft balancer shaft drive sprocket
in the direction shown in the illustration.
CYLINDER HEAD GASKET

M1112004000655

• Fuel Line Pressure Reduction [Refer to GROUP 13A, • Valve Timing Belt Installation (Refer to P.11A-40).
On-vehicle Service − Fuel Pump Connector Disconnection • Rocker Cover Centre Cover Installation (Refer to
(How to Reduce Pressurized Fuel Lines) P.13A-318.] P.11A-19).
• Under Cover Removal (Refer to GROUP 51, Under Cover • Battery Installation
P.51-31). • Air Cleaner and Air Cleaner Bracket installation (Refer to
• Engine Oil Draining (Refer to GROUP 12, On-vehicle GROUP 15, Air Cleaner P.15-6).
Service − Engine Oil Replacement P.12-4). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service − Engine Coolant Replacement P.14-17).
Service − Engine Coolant Replacement P.14-17). • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
• Air Cleaner and Air Cleaner Bracket Removal (Refer to Service − Engine Oil Replacement P.12-4).
GROUP 15, Air Cleaner P.15-6). • Accelerator Cable Adjustment (Refer to GROUP 17,
• Battery Removal On-vehicle Service − Accelerator Cable Check and Adjust-
• Rocker Cover Centre Cover Removal (Refer to ment P.17-6).
P.11A-19). • Drive Belt Tension Check (Refer to P.11A-7).
• Valve Timing Belt Removal (Refer to P.11A-40). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
• Fuel Leak Check
9
5.0 ± 1.0 N·m 10
16
7 12
5 6
17
14
8
5.0 ± 1.0 N·m 15
4
13 11
9.0 ± 2.0 N·m
18 3
20
13 ± 1 N·m 2
1
(Engine oil) N 19
AC300545 AB
11A-37
1. A/C compressor connector 12. Oxygen sensor connector
2. Power steering fluid pressure 13. Engine coolant temperature sensor
switch connector connector
3. Crank angle sensor connector 14. Engine coolant temperature gauge
4. Ignition coil connectors unit connector
5. Detonation sensor connector 15. Capacitor connector
6. Purge control solenoid valve 16. Accelerator cable connection
connector 17. Brake booster vacuum hose
7. EGR control solenoid valve connection
connector 18. Engine oil level gauge and guide
8. Injector connectors assembly
9. Throttle position sensor connector 19. O-ring
10. Idle speed control servo connector 20. Canister vacuum hose connection
11. Camshaft position sensor
connector
24
25
26
<Cold engine> 5.0 ± 1.0 N·m
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
27 N (Engine oil)
28
(Engine oil)
22 29
11 ± 1 N·m
21
30 N
31 ± 3 N·m
23
AC300546 AB

21. Detonation sensor connection • Exhaust manifold (Refer to GROUP
22. Battery wiring harness connection 15, Exhaust Manifold P.15-18).
23. Inlet manifold stay
Removal steps (Continued) Removal steps (Continued)

• Water outlet fitting and thermostat >>C<< 26. Fuel high-pressure hose
case assembly (Refer to GROUP connection
14, Water Hose and Water Pipe >>C<< 27. O-ring
P.14-28). <<A>> >>B<< 28. Cylinder head bolts
• Rocker cover (Refer to P.11A-19). 29. Cylinder head assembly
24. Heater water hose connection >>A<< 30. Cylinder head gasket
25. Fuel return line hose connection

<<A>> CYLINDER HEAD BOLTS >>A<< CYLINDER HEAD GASKET
CAUTION
Do not allow any foreign materials to get into the
coolant passages, oil passages and cylinder.
1. Remove the gasket from the cylinder head and
cylinder block.
MB991654
Engine front Identification

mark "63"
3 5 10 8 2 Exhaust side
AC107217AC
1 7 9 6 4
2. Assemble to the cylinder block so the cylinder
head gasket identification mark "63" is at the top
surface and on the exhaust side.
AC201623AB
>>B<< CYLINDER HEAD BOLTS
Using special tool cylinder head bolt wrench
(MB991654), loosen the cylinder head bolts in two or INSTALLATION
three steps in the order of the numbers shown in the
illustration. (Engine oil)
NOTE: If the cylinder head bolts cannot be pulled out
due to the washer being trapped in the valve spring,
raise the bolt slightly, then remove it while holding it
by using a magnet.
AC102537AB
1. Check that the nominal length of each cylinder

head bolt meets the limit. If it exceeds the limit,
replace the bolt with a new one.
Limit (A): 99.4 mm
11A-39
2. Apply a small amount of engine oil to the thread of (4) Apply a paint mark to the heads of the cylinder
the bolts and to the washers. head bolts and cylinder head, then tighten 90
degree angle as shown.
CAUTION
The bolt is not tightened sufficiently if the bolt is
tightened less than 90 degree angle.
(5) Tighten the bolt an additional 90 degree angle
MB991654 as shown. Then check to see that the paint
mark on the head of the cylinder head bolts
and the paint mark on the cylinder head are
aligned.
(6) If tightening the bolt 90 degree angle results in
moving the paint mark on the bolt past the
Engine front
paint mark on the cylinder head, remove the
bolt and start over from step 1.
8 6 1 3 9
>>C<< O-RING/FUEL HIGH-PRESSURE
10 4 2 5 7
HOSE INSTALLATION
CAUTION
Do not let any engine oil get into the delivery
pipe.
AC201625 AB
1. Apply a small amount of new engine oil to the
3. Use special tool cylinder head bolt wrench O-ring.
(MB991654) to tighten the cylinder head bolts as 2. Turning the fuel high-pressure hose to the right
follows: and left, install it to the delivery pipe, while being
(1) Tighten the cylinder head bolts to 78 ± 2 N⋅m careful not to damage the O-ring. After installing,
in the order shown. check that the hose turns smoothly.
(2) Loosen the bolts fully in the reverse order of 3. If the hose does not turn smoothly, the O-ring is
that shown. probably being clamped. Disconnect the fuel
(3) Tighten the cylinder head bolts to 20 ± 2 N⋅m high-pressure hose and check the O-ring for
in the order shown. damage. After this, re-insert it to the delivery pipe
and check that the hose turns smoothly.
Step (4) Step (5)
4. Tighten the fuel high-pressure hose mounting
90˚ 90˚ bolts to the specified torque.
Paint marking Paint marking
AC102331AB
TIMING BELT
TIMING BELT
M1112004300816

• Under Cover Removal (Refer to GROUP 51, Under Cover • Crankshaft Shaft Damper Pulley Installation (Refer to
P.51-31). P.11A-17).
• Crankshaft Shaft Damper Pulley Removal (Refer to • Drive Belt Tension Check (Refer to P.11A-7).
P.11A-17). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
9
8
2 7 48 ± 5 N·m
11 ± 1 N·m
21 ± 4 N·m
3
8.8 ± 1.0 N·m 23 ± 3 N·m 10
1
5
44 ± 10 N·m
4
79 ± 5 N·m
22 ± 4 N·m 6
11 ± 1 N·m
9.0 ± 1.0 N·m
AC308921AB

1. Control wiring harness connection >>G<< • Valve timing belt tension
2. Timing belt upper cover adjustment
3. Water pump pulley <<A>> >>F<< 7. Valve timing belt
4. Idler pulley >>E<< 8. Timing belt tensioner pulley
5. Auto-tensioner 9. Timing belt tensioner arm
6. Timing belt lower cover >>D<< 10. Timing belt tensioner adjuster
• Engine mounting insulator (Refer to
GROUP 32, Engine Mount P.32-6).
TIMING BELT
11A-41
11 22 ± 4 N·m
15
35 ± 6 N·m
20
19 22 ± 4 N·m
12
19 ± 3 N·m
13
(Engine oil)
49 ± 9 N·m
14 49 ± 9 N·m
16
18
17 8.8 ± 1.0 N·m
167 N·m
AC300548 AD

11. Power steering fluid pressure <<C>> >>C<< 17. Crankshaft camshaft drive sprocket
switch connector >>C<< 18. Crankshaft angle sensing blade
<> 12. Power steering oil pump assembly >>B<< • Balancer timing belt tension
13. A/C compressor connector adjustment
14. Power steering oil pump bracket >>A<< 19. Balancer timing belt tensioner
15. Timing belt idler pulley <<D>> >>A<< 20. Balancer timing belt
16. Crank angle sensor
TIMING BELT
REMOVAL SERVICE POINTS

<<A>> VALVE TIMING BELT REMOVAL
A
CAUTION B
Never turn the crankshaft anti-clockwise.
Timing mark
AC102775AB
4. Gradually screw in the special tool. Then align the

timing belt tensioner adjuster rod set hole A with
the timing belt tensioner adjustor cylinder set hole
AC102487 B.
1. Turn the crankshaft clockwise, align each timing Timing belt

tensioner pulley
mark to set No.1 cylinder to TDC of its mounting bolt
compression stroke.
Wire or pin
MD998738
AC107185AC
5. Insert a wire or pin in the set hole.

Timing belt
under cover CAUTION
AC102492AB To reuse the valve timing belt, draw an arrow
2. Remove the timing belt under cover rubber plug indicating the rotating direction (clockwise) on
and then set the special tool adjusting bolt the back of the belt using chalk.
(MD998738). 6. After removal of adjusting bolt special tool, loosen
the timing belt tensioner pulley mounting bolt and
CAUTION
remove the valve timing belt.
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
screwed in all at once, the timing belt tensioner <> POWER STEERING OIL PUMP
adjuster rod will not easily retract and the special ASSEMBLY REMOVAL
tool may bend. With the hose installed, remove the power steering
oil pump assembly from the bracket.
Timing belt
NOTE: Secure the removed power steering oil pump
tensioner arm
assembly with cord or rope at a position where they
will not interfere with the removal of the balancer tim-
ing belt.
MD998738
AC107289 AB
3. Screw in the special tool until it comes in contact

with the timing belt tensioner arm.
TIMING BELT
11A-43
<<C>> CRANKSHAFT CAMSHAFT DRIVE INSTALLATION SERVICE POINTS
SPROCKET REMOVAL >>A<< BALANCER TIMING BELT/BAL-
ANCER TIMING BELT TENSIONER
Crankshaft
camshaft MB991385 INSTALLATION
drive
Balancershaft sprocket
sprocket
Belt tension side
Timing mark
MB991367 Timing mark
AC102332AB
Crankshaft
1. Use the following special tools to support the balancershaft
crankshaft camshaft drive sprocket. drive sprocket AC102689AB
• Special spanner (MB991367)

1. Ensure that the crankshaft balancershaft drive
• Pin (MB991385)
sprocket timing marks and balancershaft sprocket
2. Loosen the crankshaft pulley centre bolt and timing marks are aligned.
remove the crankshaft camshaft drive sprocket.
2. Install the balancer timing belt on the crankshaft
balancershaft drive sprocket and balancershaft
<<D>> BALANCER TIMING BELT sprocket. There should be no slack on the tension
REMOVAL side.
CAUTION
Centre of the
To reuse the balancer timing belt, draw an arrow mounting bolt
indicating the rotating direction (clockwise) on
the back of the belt using chalk.
Centre of
the pulley
AC102690 AB
3. Assemble and temporarily fix the centre of the

pulley of the balancer timing belt tensioner so that
it is at the top left from the centre of the mounting
bolt, and the pulley flange is at the front-side of
the engine.
4. Adjust the balancer timing belt tension.
TIMING BELT
>>B<< BALANCER TIMING BELT 3. Apply a pressure of approximately 100N at the

TENSION ADJUSTMENT centre (arrow area) between the sprocket as
shown, then inspect whether the belt deflection is
CAUTION within the standard value.
When tightening the mounting bolt, ensure that
Standard value:
the tensioner does not rotate with the bolt. Allow-
At adjustment: 5 − 7 mm
ing it to rotate with the bolt can cause excessive
At replacement: 5 − 7 mm
tension of the belt.
4. If not within the standard value, adjust the belt
tension again.
>>C<< CRANKSHAFT ANGLE SENSING

BLADE/CRANKSHAFT CAMSHAFT
DRIVE SPROCKET INSTALLATION
: Clean
AC102691 : Clean and degrease
: Apply engine oil
1. With your fingers, lift the balancer timing belt
tensioner in the direction of the arrow. Apply Crankshaft pulley
pressure of 3.0 ± 0.4 N⋅m to the balancer timing centre bolt
belt. Tighten the assembling bolt to the specified Crankshaft camshaft
torque. Then, fix the balancer timing belt drive sprocket
tensioner.
Crankshaft
Timing mark
Timing mark
Crankshaft
pulley washer Crankshaft angle
Crankshaft sensing blade
balancershaft Engine front
AC211535AC
drive sprocket AC102689AC
1. Clean or degrease the crankshaft, the crankshaft

2. Turn the crankshaft clockwise two turns to set
angle sensing blade, the crankshaft camshaft
No.1 cylinder to TDC of its compression stroke
drive sprocket and crankshaft pulley washer as
and check that the sprocket timing marks are
shown.
aligned.
2. Install the crankshaft angle sensing blade and
Approximately 100 N crankshaft camshaft drive sprocket in the direction
shown.
3. Place the larger chamfer side of the crank shaft
pulley washer in the direction shown and then
Deflection assemble on the crankshaft pulley centre bolt.
4. Apply some engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
AC102693AB
TIMING BELT
11A-45
Crankshaft Wire or pin

camshaft MB991385
drive
sprocket
MB991367
AC102332AB AC102335AC
5. Use the following special tool as during removal to (2) Insert a wire or pin into the aligned set hole.
support the crankshaft camshaft drive sprocket. NOTE: When replacing the timing belt ten-
• Special spanner (MB991367) sioner adjuster with new parts, the timing belt
• Pin (MB991385) tensioner adjuster is set with a pin.
6. Tighten the crankshaft pulley centre bolts to the 2. Assemble the timing belt tensioner adjuster to the
specified torque. engine, then tighten the assembling bolt to the
Tightening torque: 167 N⋅m specified torque. Do not remove the wire or pin
until the tension of the valve timing belt is
adjusted.
>>D<< TIMING BELT TENSIONER Tightening torque: 23 ± 3 N⋅m
ADJUSTER INSTALLATION
1. Install according to the following procedures when >>E<< TIMING BELT TENSIONER
the timing belt tensioner adjuster rod is fully PULLEY INSTALLATION
extended.
CAUTION
If the compression is too fast, the procedure may
damage the rod.
B
A
Timing belt tensioner

pulley hole
AC102336AB
Temporarily tighten the timing belt tensioner pulley

as shown.
AC102334AB
(1) Slowly compress the timing belt tensioner

adjuster rod using a press or vice, then align
the set hole A of the rod with set hole B of the
timing belt tensioner adjuster cylinder.
TIMING BELT
>>F<< VALVE TIMING BELT

INSTALLATION Inlet side Exhaust side
camshaft sprocket camshaft sprocket
Timing mark
Timing belt Timing belt

Camshaft sprocket tensioner idler pulley
pulley
Crankshaft
camshaft Crankshaft Engine
drive sprocket Engine oil camshaft oil pump
pump sprocket drive sprocket
sprocket
AC102488 AC
Timing mark
(1) Pass the valve timing belt around the
Timing mark AC102486 AC crankshaft camshaft drive sprocket, the engine
oil pump sprocket and the timing belt idler
1. Align the timing marks on the camshaft sprocket, pulley in that order.
crankshaft camshaft drive sprocket and engine oil
pump sprocket.
Bolt
Balancershaft Paper clip
Plug
Cylinder AC201801AB
block
AC102337AE (2) Pass the valve timing belt around the
exhaust-side camshaft sprocket, and hold the
2. Adjust the timing mark of the engine oil pump valve timing belt with paper clip.
sprocket. Unplug the cylinder block plug. Insert a Timing mark
bolt (M6 sectional width 10 mm, minor diameter
45 mm) from the plug hole and then check. If the Timing mark
bolt comes in contact with the balancer shaft turn
the sprocket one rotation. Re-adjust the timing
mark and then check to see that the bolt fits. Do
not remove the bolt until the valve timing belt is
assembled.
3. Install the valve timing belt as follows:
AC201802AB
(3) Use two wrenches to align the timing mark on

the rocker cover with that on the camshaft
sprocket. Pass the valve timing belt around
the inlet-side camshaft sprocket.
TIMING BELT
11A-47
7. Tighten the cylinder block plug to the specified
torque.
8. Adjust the valve timing belt tension.
>>G<< VALVE TIMING BELT TENSION

Paper clip
ADJUSTMENT
AC201803AB
MD998738
(4) Hold the valve timing belt with paper clips.
(5) Pass the valve timing belt around the timing
belt tensioner pulley.
CAUTION
Incorporate the valve timing belt. Then apply
reverse rotation (anti-clockwise rotation) pres- Timing belt
under cover
sure to the cam shaft sprocket. Re-check to see
AC102492AB
that each timing mark is aligned while the ten-
sion side of the belt is tight. 1. Set special tool adjusting bolt (MD998738) when
(6) Remove the two paper clips. removing the valve timing belt.
CAUTION
Always screw in special tool by hand, since use
of a spanner or other tools may damage the wire
or pin inserted in the timing belt tensioner
adjuster.
2. Gradually screw in special tool until the wire or pin
MD998767
inserted in the timing belt tensioner adjuster lightly
moves.
3. Turn the crankshaft 1/4 turn anti-clockwise.
AC102694 AB
4. Turn the crankshaft in the clockwise direction until
4. Turn the timing belt tensioner in the direction you align each timing mark to set No.1 cylinder to
shown using special tool tensioner wrench TDC of its compression stroke.
(MD998767) to apply tension to the valve timing 5. Loosen the timing belt tensioner pulley mounting
belt. Then pre-tighten the timing belt tensioner bolt.
pulley.
CAUTION
5. Check that the timing marks are aligned. When tightening the mounting bolt, ensure that
Bolt the timing belt tensioner pulley does not rotate
Balancershaft with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.
Plug
Cylinder
block
AC102337AE MD998767
6. Remove the bolt inserted in Step 2 above, then

assemble the cylinder block plug.
AC102695AB
TIMING BELT
6. With special tool tensioner wrench (MD998767)

and torque wrench, apply tension torque 3.5
N⋅m, and tighten the timing belt tensioner pulley
mounting bolt to the specified torque. A
Timing belt
tensioner
Wire or pin adjuster
AC102338AB
If the projection of timing belt tensioner adjuster

rod is within the standard value, appropriate
tension is applied.
Standard value (A): 3.8 − 4.5 mm
AC102776AD
11.If wire or pin cannot be easily pulled out, repeat
7. Remove wire or pin inserted to timing belt Step 1 through Step 9 to reach proper valve timing
tensioner. belt tension.
CAUTION
Always check the tightening torque of the crank
MD998738 shaft pulley centre bolt when turning the crack
shaft pulley centre bolt anti-clockwise.
Re-tighten if it is loose.
Timing mark
Timing belt
under cover
AC102492AB
8. Remove the special tool adjusting bolt

(MD998738), and install the rubber plug to the
timing belt under cover.
9. Rotate the crankshaft clockwise two turns, and Camshaft
sprocket
leave it for about 15 minutes.
Crankshaft
Wire or pin camshaft Engine
drive sprocket oil pump
sprocket
Timing mark
Timing mark AC201411AB

AC102776AD
10.Insert wire or pin removed in Step 7 again, and 12.Check again that the timing marks on sprockets
ensure that it can be pulled out easily. When wire are aligned.
or pin can be easily removed, appropriate tension
is applied on timing belt. In this case, remove wire
or pin.
TIMING BELT
11A-49
INSPECTION BALANCER TIMING BELT TENSION
M1112004400352
CHECK
TIMING BELT TENSIONER ADJUSTER
Check the balancer timing belt tension as follows:
CHECK
1. Check for oil leak from seal, and replace it if leak
is detected. Approximately 100 N
2. Check for wear or damage at the top of the rod.
Replace it, if required.
98 – 196 N Movement Deflection
A B
AC102693AB
1. Apply a pressure of approximately 100 N at the

Timing belt centre (arrow area) between the sprocket as
Rod
tensioner
adjuster
shown then inspect whether the deflection is
AC102339AB
Standard value: 5 − 10 mm
3. Hold the timing belt tensioner adjuster by hand, 2. If not within the standard value, adjust the belt
and press the top end of the rod onto the metal tension. (Refer to P.11A-40).
(e.g. cylinder block) under a pressure of 98 − 196
N to measure the movement of the rod.
Standard value: Within 1 mm
A: Length when it is free (not pressed)
B: Length when it is pressed
A − B: Movement
4. If the measured value is out of the standard value,
replace the timing belt tensioner adjuster.
ENGINE ASSEMBLY
ENGINE ASSEMBLY
M1112001002179
CAUTION
• When the engine assembly replacement is performed, use the M.U.T.-II/III to initialise the learning
value (Refer to GROUP 00, Precautions Before Service − Initialisation Procedure for Learning
Value in MPI Engine P.00-21).
• *: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
• Fuel Line Pressure Reduction [Refer to GROUP 13A, • Starter Assembly Installation (Refer to GROUP 16, Starter
On-vehicle Service − Fuel Pump Connector Disconnection Motor Assembly P.16-25).
(How to Reduce Pressurized Fuel Lines) P.13A-318.] • Front Exhaust Pipe Installation (Refer to GROUP 15,
• Hood Removal (Refer to GROUP 42, Hood P.42-4). Exhaust Pipe and Main Muffler P.15-25).
• Under Cover Removal (Refer to GROUP 51, Under Cover • Radiator Assembly Installation (Refer to GROUP 14,
P.51-31). Radiator P.14-35).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Battery and Battery Tray Installation
Service − Engine Oil Replacement P.12-4). • Rocker Cover Centre Cover Installation (Refer to
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle P.11A-19).
Service − Engine Coolant Replacement P.14-17). • Air Cleaner and Air Cleaner Bracket installation (Refer to
• Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner P.15-6).
GROUP 15, Air Cleaner P.15-6). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Battery and Battery Tray Removal Service − Engine Coolant Replacement P.14-17).
• Rocker Cover Centre Cover Removal (Refer to • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
P.11A-19). Service − Engine Oil Replacement P.12-4).
• Radiator Assembly Removal (Refer to GROUP 14, Radia- • Accelerator Cable Adjustment (Refer to GROUP 17,
tor P.14-35). On-vehicle Service − Accelerator Cable Check and Adjust-
• Front Exhaust Pipe Removal (Refer to GROUP 15, ment P.17-6).
Exhaust Pipe and Main Muffler P.15-25). • Drive Belt Tension Check (Refer to P.11A-7).
• Starter Assembly Removal (Refer to GROUP 16, Starter • Under Cover Installation (Refer to GROUP 51, Under
Motor Assembly P.16-25). Cover P.51-31).
• Hood Installation (Refer to GROUP 42, Hood P.42-4).
• Fuel Leak Check
ENGINE ASSEMBLY
11A-51
9
5.0 ± 1.0 N·m
10
17
7 12
5 6
14
5.0 ± 1.0 N·m 8

15
4 9.0 ± 2.0 N·m 11
13
3
2
1 9.0 ± 2.0 N·m
18
5.0 ± 1.0 N·m
16
9.0 ± 2.0 N·m

5.0 ± 1.0 N·m
AC300549 AB

1. A/C compressor connector 10. Idle speed control servo connector
2. Power steering fluid pressure 11. Camshaft position sensor
switch connector connector
3. Crank angle sensor connector 12. Oxygen sensor connector
4. Ignition coil connectors 13. Engine coolant temperature sensor
5. Detonation sensor connector connector
6. Purge control solenoid valve 14. Engine coolant temperature gauge
connector unit connector
7. EGR control solenoid valve 15. Capacitor connector
connector 16. Battery wiring harness connection
8. Injector connectors 17. Accelerator cable connection
9. Throttle position sensor connector <<A>> 18. Drive belt
ENGINE ASSEMBLY
23
24
25
19
5.0 ± 1.0 N·m
26 N (Engine oil)
12 ± 2 N·m
20
44 ± 10 N·m*
22 ± 4 N·m
27 N
22
45 ± 5 N·m* 22 ± 4 N·m
29
28
21
AC300550 AB

19. Brake booster vacuum hose >>E<< 25. Fuel high-pressure hose
connection connection
20. Canister vacuum hose connection >>E<< 26. O-ring
<> 21. A/C compressor and clutch <<C>> >>D<< • Transmission assembly
assembly >>C<< 27. Self-locking nuts
<> 22. Power steering oil pump assembly <<D>> >>B<< 28. Engine mounting insulator
23. Heater water hoses connection <<E>> >>A<< 29. Engine assembly
ENGINE ASSEMBLY
11A-53
REMOVAL SERVICE POINTS <> A/C COMPRESSOR AND CLUTCH
<<A>> DRIVE BELT REMOVAL ASSEMBLY/POWER STEERING OIL
The following operations will be needed due to the PUMP ASSEMBLY REMOVAL
introduction of the serpentine drive system with the With the hose installed, remove the A/C compressor
drive belt auto-tensioner. and clutch assembly, and power steering oil pump
AC301703 assembly from the bracket.
Auto-tensioner
NOTE: Secure the removed A/C compressor and
clutch assembly, and power steering oil pump
will not interfere with the removal of the engine
assembly.
Hole B
<<C>> TRANSMISSION ASSEMBLY

Hole A
REMOVAL
AC301704AB

hole of the auto-tensioner.
2. Rotate the auto-tensioner anti-clockwise and align
hole A with hole B.
CAUTION
To reuse the drive belt, draw an arrow indicating
the rotating direction (clockwise) on the back of
the belt using chalk, etc. AC300950AB
1. Pre-tighten the 2 bolts on the car to assemble the

Auto-tensioner radiator support upper insulator to set the special
tools engine hanger MB991895 or engine hanger
MB991928.
CAUTION
AC300897
L-shaped
hexagon
wrench AC301705AB Engine front
3. Insert an L-shaped hexagon wrench, etc. into the Flywheel

assembly
hole to fix and then remove the drive belt.
Flywheel
bolt
AC308604 AB
Do not remove the flywheel bolt. If this bolt is

removed, the flywheel assembly will become out
of balance and damaged.
2. Remove the transmission assembly (Refer to
GROUP 22A, Transmission Assembly P.22A-14).
ENGINE ASSEMBLY
<<D>> ENGINE MOUNTING INSULATOR 4. Place a garage jack against the engine oil pan
REMOVAL with a piece of wood in between so that the weight
of the engine assembly is no longer being applied
1. Support the engine with a garage jack.
to the engine mounting insulator.
2. Remove the following special tool.
5. Loosen the engine mounting insulator mounting
MB991895 nuts and bolt, and remove the engine mounting
insulator.
MB991527
<<E>> ENGINE ASSEMBLY REMOVAL

After checking that all cables, hoses and wiring har-
ness connectors and so on are disconnected from
the engine, lift the chain block slowly to remove the
engine assembly upward from the engine compart-
MB991454
ment.
AC107631AB
(1) <Special tool engine hanger (MB991895) is INSTALLATION SERVICE POINTS

used>
>>A<< ENGINE ASSEMBLY INSTALLA-
Remove special tool MB991895.
TION
MB991928
MB991454
MB991527
MB991527
MB991454
AC211405AB
AC107632 AB
(2) <Special tool engine hanger (MB991928) is
used> Install the engine assembly, being careful not to
pinch the cables, hoses or wiring harness connec-
tors.
MB991454
MB991527
AC107632 AB
3. Hold the engine assembly with a chain block, etc.

ENGINE ASSEMBLY
11A-55
>>B<< ENGINE MOUNTING INSULATOR >>C<< SELF-LOCKING NUTS
INSTALLATION INSTALLATION
1. Place a garage jack against the engine oil pan CAUTION
with a piece of wood in between, and install the Do not tighten the self-locking nuts while the
engine mounting insulator while adjusting the engine is hot.
position of the engine. Tighten the self-locking nuts to the specified torque
2. Support the engine assembly with a garage jack. while the engine is cold.
3. Remove the chain block. Tightening torque: 45 ± 5 N⋅m
4. Use the following special tool as during removal to
support the engine. >>D<< TRANSMISSION ASSEMBLY
MB991895 INSTALLATION
MB991527 1. Install the transmission assembly (Refer to
MB991454
AC107631AB

used>
Set special tool MB991895. (Refer to AC300950AB
GROUP 22A, Transmission Assembly
P.22A-14). 2. Remove from the car the 2 bolts, to assemble the
radiator support upper insulator.
MB991928
MB991527
MB991454
AC211405AB

used>
Set special tool MB991928 (Refer to
P.22A-14).
ENGINE ASSEMBLY
>>E<< O-RING/FUEL HIGH-PRESSURE 3. If the hose does not turn smoothly, the O-ring is
HOSE INSTALLATION probably being clamped. Disconnect the fuel
high-pressure hose and check the O-ring for
CAUTION damage. After this, re-insert it to the delivery pipe
Do not let any engine oil get into the delivery and check that the hose turns smoothly.
pipe.
1. Apply a small amount of new engine oil to the bolts to the specified torque.
O-ring. Tightening torque: 5.0 ± 1.0 N⋅m
2. Turning the fuel high-pressure hose to the right
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
GROUP 11B
ENGINE OVERHAUL
<4G63-Non-Turbo>
CONTENTS
GENERAL INFORMATION . . . . . . . . 11B-2 EXHAUST MANIFOLD . . . . . . . . . . . . 11B-28

REMOVAL AND INSTALLATION . . . . . . . . 11B-28
GENERAL SPECIFICATIONS . . . . . . 11B-2
WATER PUMP AND
SERVICE SPECIFICATIONS. . . . . . . 11B-3 WATER HOSE . . . . . . . . . . . . . . . . . . 11B-29
REWORK DIMENSIONS . . . . . . . . . . 11B-4
ROCKER ARMS AND CAMSHAFT . . 11B-31
TORQUE SPECIFICATIONS . . . . . . . 11B-5 REMOVAL AND INSTALLATION . . . . . . . . 11B-31
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-33
SEALANTS . . . . . . . . . . . . . . . . . . . . 11B-7
CYLINDER HEAD AND VALVES. . . . 11B-36
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11B-9 REMOVAL AND INSTALLATION . . . . . . . . 11B-36
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-39
ALTERNATOR AND IGNITION
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11B-12 OIL PAN AND OIL PUMP. . . . . . . . . . 11B-42
REMOVAL AND INSTALLATION . . . . . . . . 11B-12 REMOVAL AND INSTALLATION . . . . . . . . 11B-42
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-51
TIMING BELT. . . . . . . . . . . . . . . . . . . 11B-13
REMOVAL AND INSTALLATION . . . . . . . . 11B-13 PISTON AND CONNECTING ROD . . 11B-52
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11B-23 REMOVAL AND INSTALLATION . . . . . . . . 11B-52
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-58
FUEL AND EMISSION PARTS . . . . . 11B-25
REMOVAL AND INSTALLATION . . . . . . . . 11B-25 CRANKSHAFT AND
CYLINDER BLOCK . . . . . . . . . . . . . . 11B-59
INLET MANIFOLD . . . . . . . . . . . . . . . 11B-27 REMOVAL AND INSTALLATION . . . . . . . . 11B-59
REMOVAL AND INSTALLATION . . . . . . . . 11B-27 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11B-63
11B-2 ENGINE OVERHAUL <4G63-Non-Turbo>
GENERAL INFORMATION
GENERAL INFORMATION
M1113000100233
VEHICLE AND ENGINE MODELS

Vehicle name Vehicle Engine model Displacement Specification
model mL
Outlander CU2W 4G63-7 1,997 Double overhead camshaft, 16-valve
GENERAL SPECIFICATIONS
M1113000200780
Item Specification
Bore × stroke mm 85 × 88
Displacement mL 1,997
Combustion chamber Pentroof type
Number of cylinders 4
Valve mechanism Type Double overhead camshaft
Number of intake valves 8
Number of exhaust 8
valves
Lash adjusters Hydraulic
Rocker arms Roller cam followers
Compresssion ratio 10.0
Fuel injection system Electronically controlled multi-point injection (MPI)
system
Ignition system Electronically controlled two-coil system
Generator Alternator (with built-in IC regulator)
Starter motor Gear reduction drive type
ENGINE OVERHAUL <4G63-Non-Turbo>
11B-3
M1113000300798

TIMING BELT
Auto-tensioner rod extension length 3.8 − 4.5 −
(with timing belt installed) mm
Auto-tensioner rod extension length (when free) mm 12.0 −
Auto-tensioner rod retraction length Less than 1 −
(when pressed with force of 98 to 196 N) mm
ROCKER ARMS AND CAMSHAFT
Cam height mm Intake 35.79 35.29
Exhaust 35.49 34.99
CYLINDER HEAD AND VALVES
Cylinder head gasket surface warp mm Less than 0.05 0.2
Cylinder head gasket surface grinding limit − 0.2
(including cylinder block grinding amount) mm
Cylinder head overall height mm 131.9 − 132.1 −
Valve margin mm Intake valves 1.0 0.5
Exhaust valves 1.5 1.0
Valve stem diameter mm 6.6 −
Valve face angle 45.5° −
Valve stem-to-guide clearance mm Intake valves 0.02 − 0.05 0.10
Exhaust valves 0.05 − 0.09 0.15
Valve height mm Intake valves 109.5 109.0
Valve stem projection mm Intake valves 49.20 49.70
Valve spring free height mm 48.3 47.3
Valve spring load/height N/mm 294/40 −
Valve spring squareness 1.5° or less 4°
Valve face-to-seat contact width mm 0.9 − 1.3 −
Valve guide inside diameter mm 6.6 −
Valve guide press-in height mm 19.2 − 19.8 −
OIL PAN AND OIL PUMP
Oil pump gear side clearance mm Drive gear 0.08 − 0.14 −
Driven gear 0.06 − 0.12 −
PISTON AND CONNECTING ROD
Piston outside diameter mm 85.0 −
REWORK DIMENSIONS

Piston ring side clearance in ring No. 1 0.02 − 0.06 0.1
groove mm No. 2 0.02 − 0.06 0.1
Piston ring end gap mm No. 1 0.20 − 0.30 0.8
No. 2 0.30 − 0.45 0.8
Oil ring 0.10 − 0.40 1.0
Piston pin outside diameter mm 22.0 −
Piston pin press-in load (at ambient temperature) N 7,350 − 17,100 −
Oil clearance at crankshaft pins mm 0.02 − 0.04 0.1
Connecting rod big end thrust clearance mm 0.10 − 0.25 0.4
CRANKSHAFT AND CYLINDER BLOCK
Crankshaft end play mm 0.05 − 0.25 0.4
Crankshaft journal diameter mm 57.0 −
Crankshaft pin diameter mm 45.0 −
Oil clearance at crankshaft journals No. 1,2,4,5 journal 0.02 − 0.03 0.1
mm No. 3 journal 0.03 − 0.04 0.1
Cylinder block gasket surface warp mm 0.05 0.1
Cylinder block gasket surface grinding limit − 0.2
(including cylinder head grinding amount) mm
Cylinder block overall height mm 284 −
Cylinder bore diameter mm 85 −
Taper of cylinder mm 0.01 or less −
Cylinder-to-piston clearance mm 0.02 − 0.04 −
Crankshaft bearing cap bolt nominal length mm − 71.1
REWORK DIMENSIONS
M1113024300402
Item Standard value

Diameter of oversize valve seat ring hole in cylinder head Intake 0.03 oversize 35.30 − 35.33
mm 0.06 oversize 35.60 − 35.63
Exhaust 0.03 oversize 33.30 − 33.33
0.06 oversize 33.60 − 33.63
Diameter of oversize valve guide hole in cylinder head mm 0.05 oversize 12.05 − 12.07
0.25 oversize 12.25 − 12.27
0.50 oversize 12.50 − 12.52
TORQUE SPECIFICATIONS
11B-5
M1113023401982
Item N⋅m
ALTERNATOR AND IGNITION SYSTEM
Oil level gauge guide bolt 13 ± 1
Idler pulley bolt 79 ± 5
Auto-tensioner assembly bolts (M8) 22 ± 4
Auto-tensioner assembly bolt (M10) 44 ± 10
Water pump pulley bolts 8.8 ± 1.0
Alternator brace bolt (flange bolt) 23 ± 3
Alternator brace bolts (washer assembled bolt) 22 ± 4
Alternator nut 44 ± 10
Crankshaft pulley bolts 25 ± 4
Center cover bolts 3.0 ± 0.5
Ignition coil bolts 10 ± 2
Spark plugs 25 ± 5
TIMING BELT
Timing belt cover bolts (flange bolts) 11 ± 1
Timing belt cover bolts (washer-assembled bolts) 9.0 ± 1.0
Power steering pump bracket bolts 49 ± 9
Tensioner pulley bolt 48 ± 5
Tensioner arm bolt 21 ± 4
Auto-tensioner bolts 23 ± 3
Crankshaft angle sensor bolts 8.8 ± 1.0
Oil pump sprocket nut 54 ± 5
Crankshaft bolt 167
Tensioner B bolt 19 ± 3
Counterbalance shaft sprocket bolt 45 ± 3
Rocker cover bolts 3.5 ± 0.5
Engine support bracket bolts 49 ± 5
Camshaft sprocket bolt 88 ± 10
FUEL AND EMISSION PARTS
Vacuum hose and pipe clamp bolt 11 ± 1
Throttle body bolts 19 ± 3
EGR valve bolts 20 ± 2
Fuel pressure regulator bolts 9.0 ± 2.0
Delivery pipe and injector assembly bolts 11 ± 1
Solenoid valve assembly bolts 9.0 ± 1.0
INLET MANIFOLD
Inlet manifold stay bolts 31 ± 3
Item N⋅m
Inlet manifold bolts (M8) 20 ± 2
Inlet manifold bolts and nuts (M10) 36 ± 6
Engine hanger bolt 19 ± 3
EXHAUST MANIFOLD
Oxygen sensor 44 ± 5
Exhaust manifold cover bolts 14 ± 1
Exhaust manifold bracket bolt (Cylinder block side) 35 ± 6
Exhaust manifold bracket bolt (Exhaust manifold side) 44 ± 5
Exhaust manifold nuts (M8) 29 ± 3
WATER PUMP AND WATER HOSE
Engine coolant temperature sensor 29 ± 10
Engine coolant temperature gauge unit 10.8 ± 1.0
Water inlet fitting bolts 13 ± 2
Water outlet fitting bolts 13 ± 2
Thermostat housing bolts 23 ± 4
Water inlet pipe bolts 13 ± 2
Water pump bolts 14 ± 1
Knock sensor 23 ± 2
Camshaft position sensor bolts 8.8 ± 1.0
Cover bolts 10 ± 2
Camshaft position sensing cylinder bolt 22 ± 4
Camshaft position sensor support bolts 14 ± 1
Bearing cap bolts 20 ± 1
Oil delivery body bolts 11 ± 1
Cylinder head bolts 78 ± 2 → 0 → 20 ± 2 → +90° → +90°
Drain plug 39 ± 5
Transmission stay bolts 22 ± 4
Oil pan upper section bolts 9.0 ± 3.0
Oil pan lower section bolts 9.0 ± 3.0
Oil screen bolts 19 ± 3
Oil pressure switch 19 ± 3
Relief plug 44 ± 5
Oil filter bracket bolts 19 ± 3
Plug cap 23 ± 3
Flange bolts 36 ± 3
Oil pump case bolts 23 ± 3
SEALANTS
11B-7
Item N⋅m
Oil pump cover bolts 17 ± 1
Oil pump cover screws 10 ± 2
Connecting rod cap nuts 20 ± 2 → +90° to 94°
Flywheel bolts 132 ± 5
Rear plate bolts 11 ± 1
Bell housing cover bolts 9.0 ± 1.0
Rear oil seal case bolts 11 ± 1
Beam bearing cap bolts 25 ± 2 → +90° to 100°
SEALANTS
M1113000500714
Item Specified sealant

Engine support bracket bolts Mitsubishi Genuine Part No.MD970389
or equivalent
Semicircular packing 3M ATD No.8660 or equivalent
Rocker cover Mitsubishi Genuine Part No. MD970389
or equivalent
Engine coolant temperature sensor 3M Nut Locking Part No.4171 or
equivalent
Engine coolant temperature e gauge unit 3M ATD No.8660 or equivalent
Water outlet fitting* Mitsubishi Genuine Part No. MD970389
Thermostat housing* or equivalent
Cylinder head (camshaft bearing cap fitting section) 3M ATD No.8660 or equivalent
Camshaft position sensor support* Mitsubishi Genuine Part No. MD970389
or equivalent
Oil pressure switch 3M ATD No.8660 or equivalent
Oil pan* Mitsubishi Genuine Part No. MD970389
Rear oil seal case* or equivalent
NOTE: *: Part to be sealed with a form-in-place gas-

ket (FIPG)
11B-8 SEALANTS
FORM-IN-PLACE GASKET (FIPG)

This engine has several areas where the CLEANING FIPG APPLICATION
form-in-place gasket (FIPG) is used for sealing. To SURFACE
ensure that the FIPG fully serves its purpose, it is
Thoroughly remove all substances deposited on the
necessary to observe some precautions when apply-
FIPG application surface, using a gasket scraper or
ing it.
wire brush. Make sure that the FIPG application sur-
Bead size, continuity and location are of paramount
face is flat and smooth. Also make sure that the sur-
importance. Too thin a bead could cause leaks. Too
face is free from oils, greases and foreign
thick a bead, on the other hand, could be squeezed
substances. Do not fail to remove old FIPG that may
out of location, causing blocking or narrowing of fluid
remain in the fastener fitting holes.
passages. To prevent leaks or blocking of passages,
therefore, it is absolutely necessary to apply the APPLICATION OF FIPG
FIPG evenly without a break, while observing the
Applied FIPG bead should be of the specified size
correct bead size.
and free of any break. FIPG can be wiped away
FIPG hardens as it reacts with the moisture in the
unless it has completely hardened. Install the mating
atmospheric air, and it is usually used for sealing
parts in position while the FIPG is still wet (in less
metallic flange areas.
than 15 minutes after application). Do not allow FIPG
REMOVAL OF FIPG SEALED PARTS to spread beyond the sealing areas during installa-
tion. Avoid operating the engine or letting oils or
Parts sealed with a FIPG can be easily removed
water come in contact with the sealed area before a
without need for the use of a special method. In
time sufficient for FIPG to harden (approximately one
some cases, however, the FIPG in joints may have to
hour) has passed. FIPG application method may
be broken by tapping parts with a mallet or similar
vary from location to location. Follow the instruction
tool. You can also tap a flat, thin gasket scraper into
for each particular case described later in this man-
the joint to break the FIPG, taking extreme care not
ual.
to damage the mating surfaces.The oil pan remover
(MD998727) is available as a special tool for remov-
ing the oil pan. The tool, however, must not be used
with an aluminium oil pan as it could damage the
mating surfaces.
SPECIAL TOOLS
11B-9
SPECIAL TOOLS
M1113000601770

MB991883 Flywheel stopper Retention of flywheel
MB991883
MD998778 Crankshaft sprocket Removal of crankshaft sprocket

puller and crankshaft sprocket B
MD998785 Sprocket stopper Retention of counterbalancer

shaft sprocket
MD998767 Tension pulley socket Manipulation of tensioner pulley

wrench during adjustment of timing belt
tension
D998767
MD998738 Set screw Retention of tentioner arm and

auto-tensioner during timing belt
installation
D998738
MD998713 Camshaft oil seal Installation of camshaft oil seal

installer
D998713
MD998442 Air bleed wire Air bleeding of lash adjuster
MB991654 Cylinder head bolt Removal and installation of

wrench cylinder head bolts
B991654
SPECIAL TOOLS

MD998772 Valve spring Compression of valve spring
compressor

compressor
MD998737 Valve stem seal Installation of valve stem seal

installer
MD998012 Oil pressure switch Removal and installation of oil

socket wrench pressure switch <to cylinder
block>
MD998162 Plug wrench Removal and installation of front

case plug cap
(Use with MD998783.)
MD998783 Plug wrench retainer Removal and installation of front

case plug cap
MD998371 Silent shaft bearing Removal of counterbalancer shaft

puller front bearing

puller front and rear bearings
SPECIAL TOOLS
11B-11
MB991603 Silent shaft bearing Guide and stopper for removal
installer stopper and press-fitting of
counterbalancer shaft rear
bearing
MD998705 Silent shaft bearing Press-fitting of counterbalancer

installer shaft front and rear bearings
MD998375 Crankshaft front oil Installation of crankshaft front oil

seal installer seal
MD998285 Crankshaft front oil Guide for installation of

seal guide crankshaft front oil seal
D998285
MD998780 Piston pin setting tool Removal and press-fitting of

piston pin
MD998776 Crankshaft rear oil Installation of crankshaft rear oil

seal installer seal
D998776
MB990938 Handle Installation of crankshaft rear oil

seal

M1113001000712
12 3.0 ± 0.5 N·m
N2
1
10 ± 2 N·m
13
14
13 ± 1 N·m 15
25 ± 5 N·m
3
10
44 ± 10 N·m
N4
9
22 ± 4 N·m
44 ± 10 N·m
23 ± 3 N·m
8.8 ± 1.0 N·m
25 ± 4 N·m
11
79 ± 5 N·m
6N
22 ± 4 N·m 5 AK400839AB

1. Oil level gauge 9. Alternator brace
2. O-ring 10. Alternator
3. Oil level gauge guide 11. Crankshaft pulley
4. O-ring 12. Center cover
5. Idler pulley 13. Spark plug cable
6. Cap 14. Ignition coil
7. Auto-tensioner assembly 15. Spark plug
8. Water pump pulley
TIMING BELT
11B-13
TIMING BELT
M1113001900878
3.5 ± 0.5 N·m

24
21 28
11 ± 1 N·m 1 22 25
20
5 6
48 ± 5 N·m
N 23
21 ± 4 N·m 26 N
12 7
11 ± 1 N·m 23 ± 3 N·m
27 N
32
11 ± 1 N·m
11 ± 1 N·m
11 33
167 N·m 29
2 49 ± 5 N·m
9.0 ± 1.0 N·m
4 45 ± 3 N·m
31 16 17
19 ± 3 N·m
14 3
30 34 9
88 ± 10 N·m 19
18 8.8 ± 1.0 N·m 49 ± 9 N·m
15
13
8 10
35 ± 6 N·m AK400840 AB
54 ± 5 N·m

1. Timing belt front upper cover <<D>> >>I<< 12. Crankshaft sprocket
2. Timing belt front lower cover >>I<< 13. Crankshaft sensing blade
3. Power steering pump bracket 14. Tensioner B
<<A>> >>M<< 4. Timing belt <<E>> >>H<< 15. Timing belt B
>>L<< 5. Tensioner pulley <<F>> >>G<< 16. Counterbalancer shaft sprocket
6. Tensioner arm >>F<< 17. Spacer
>>K<< 7. Auto-tensioner <<G>> >>E<< 18. Crankshaft sprocket B
8. Idler pulley 19. Crankshaft key
9. Crankshaft angle sensor 20. Breather hose
<> >>J<< 10. Oil pump sprocket 21. PCV hose
<<C>> >>I<< 11. Crankshaft bolt 22. PCV valve
TIMING BELT

23. PCV valve gasket >>B<< 29. Engine support bracket
24. Oil filler cap <<H>> >>A<< 30. Camshaft sprocket bolt
>>D<< 25. Rocker cover 31. Camshaft sprocket
>>D<< 26. Rocker cover gasket A 32. Timing belt rear cover, right
27. Rocker cover gasket B 33. Timing belt rear upper cover, left
>>C<< 28. Semicircular packing 34 Timing belt rear lower cover, left

<<A>> TIMING BELT REMOVAL <> OIL PUMP SPROCKET REMOVAL
Crosspoint
screwdriver
AK202825 AB
AK202756AB
1. If the timing belt is to be reused, make an arrow 1. Remove the plug on the left side of cylinder block.
mark with something like chalk on the back of the 2. Insert a crosspoint screwdriver (shank diameter 8
belt indicating the direction of rotation so it may be mm) to prevent the counterbalancer shaft from
reinstalled in the same direction. rotating.
3. Remove the flange bolt.
Timing mark
4. Remove the oil pump sprocket.
<<C>> CRANKSHAFT BOLT REMOVAL
AK202757 AB
CAUTION
Never remove the timing belt with any piston at MD998781
the top dead center (TDC). If a piston is at TDC,
the exhaust valves of the cylinder are pushed by AK202738 AB
the exhaust cams, compressing the valve
springs. If the belt is removed under this condi- 1. Hold the drive plate with the special tool Fly wheel
tion, the sprocket will be turned in the reverse stopper (MD998781).
direction by the force of the springs, incurring 2. Remove the crankshaft bolt.
risk of injury.
2. Set the timing mark of the exhaust camshaft
sprocket to a point about one tooth before the
TDC of the No.1 cylinder piston on compression
stroke.
3. Loosen the lock nut of the tensioner pulley, then
remove the timing belt.
TIMING BELT
11B-15
<<D>> CRANKSHAFT SPROCKET <<F>> COUNTERBALANCER SHAFT
REMOVAL SPROCKET REMOVAL
MD998778
MD998785
AK202741 AB AK202739AB
Use the special tool Crankshaft sprocket puller 1. Use the special tool Sprocket stopper
(MD998778) if the sprocket is stuck and hard to (MD998785) to prevent the counterbalancer shaft
remove. sprocket from rotating.
2. Remove the counterbalancer shaft mounting bolt.
<<E>> TIMING BELT B REMOVAL
<<G>> CRANKSHAFT SPROCKET B
REMOVAL
MD998778
AK202758AB
If the timing belt is to be reused, make an arrow mark

with something like chalk on the back of the timing AK202740AB
belt indicating the direction of rotation so it may be
reinstalled in the same direction. Use the special tool Crankshaft sprocket puller
(MD998778) if the sprocket is stuck and hard to
remove.
<<H>> CAMSHAFT SPROCKET BOLT

REMOVAL
AK305990AC
Remove the camshaft sprocket bolt while preventing

the camshaft from rotation using a wrench fitted on
the hexagonal portion of the camshaft.
TIMING BELT
INSTALLATION SERVICE POINTS >>C<< SEMICIRCULAR PACKING

>>A<< CAMSHAFT SPROCKET BOLT INSTALLATION
INSTALLATION 1. Remove thoroughly the old sealant and FIPG
remaining on the semicircular packing, cylinder
head, and rocker cover.
AK305990AC
AK202860AB
2. Apply sealant to the surface indicated in the

drawing of the semicircular packing.
Specified sealant:
3M ATD No.8660 or equivalent
3. Install the semicircular packing on the cylinder
head.
AK202859 10 mm
Tighten the camshaft sprocket bolt to 88 ± 10 N⋅m
while preventing the camshaft from rotation using a
wrench fitted on the hexagonal portion of the cam-
shaft.
>>B<< ENGINE SUPPORT BRACKET Semicircular

10 mm
INSTALLATION packing
Cylinder head AK202861 AB
4. Apply sealant to the area indicated in the drawing

of the semicircular packing and cylinder head.
Specified sealant:
AK202743AB
1. Remove thoroughly the old sealant remaining on

the indicated bolt and in its hole.
2. Coat the bolt with sealant, then install and tighten
it.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or
equivalent
TIMING BELT
11B-17
>>D<< ROCKER COVER/ROCKER >>E<< CRANKSHAFT SPROCKET B
COVER GASKET A INSTALLATION INSTALLATION
Timing belt side
Sprocket "B"
Crankshaft
Degrease
AK400841 AB Front case AK101651AC
1. Apply beads of FIPG on the surfaces of the rocker Clean and then degrease the crankshaft sprocket B
cover indicated in the drawing. and the sprocket fitting surface of the crankshaft.
Specified sealant: NOTE: Degreasing is necessary to prevent lack of
Mitsubishi Genuine Part No.MD970389 or frictional coefficient between the mating surfaces.
equivalent
2. Install the rocker cover gasket A on the rocker >>F<< SPACER INSTALLATION
cover before the FIPG hardens.
Spacer
Timing belt side Oil
seal
Counter-
balancer
Chamfer shaft
AK202820 AB
AK400842 AB
CAUTION
3. Apply beads of FIPG to the surfaces of the rocker If the spacer is opposite in direction to that
cover indicated in the drawing. shown in the drawing when installed, it will dam-
age the oil seal lip.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or 1. Smear slightly oil on the outer surface of the
equivalent spacer that comes into contact with the oil seal.
4. Install the rocker cover on the cylinder head 2. Install the spacer with the chamfered end toward
before the FIPG hardens. the oil seal.
TIMING BELT
>>G<< COUNTERBALANCER SHAFT Tension section of belt

Tensioner "B"
SPROCKET INSTALLATION Timing
belt "B"
MD998785
Tensioner "B"
centre
Mounting bolt centre AK305992 AC
3. Make sure that the tensioner B center is

AK202739AB positioned as shown in the drawing relative to the
mounting bolt center.
1. Use the special tool Sprocket stopper
(MD998785) as shown in the drawing to prevent
the counterbalancer shaft sprocket from rotating.
2. Tighten the sprocket mounting bolt to 45 ± 3 N⋅m.
>>H<< TIMING BELT B INSTALLATION
Timing
marks AK304436AB
4. Lift the tensioner B with fingers to move it in the

Timing direction of the arrow until the tension section of
marks the timing belt becomes taut. While keeping the
tensioner B in this position, tighten its bolt.
AK305991 AC NOTE: When the bolt is tightened, prevent the
tensioner B shaft from turning. If the shaft turns,
1. Align the timing marks on the crankshaft sprocket the belt will be overtightened.
B and counterbalancer shaft sprocket with the
5. Make sure that the timing marks on the oil pump
corresponding timing marks on the oil pump case.
case and those of the sprockets are all aligned
2. Install the timing belt B on the crankshaft sprocket with each other.
B and counterbalancer shaft sprocket. There
should be no slack in the tension section of the 5 – 7 mm
belt.
AK305993 AC
6. Push a central point of the timing belt B tension

section lightly with an index to see if it deflects 5 −
7 mm.
TIMING BELT
11B-19
>>I<< CRANKSHAFT >>J<< OIL PUMP SPROCKET
BOLT/CRANKSHAFT INSTALLATION
SPROCKET/CRANKSHAFT SENSING
BLADE INSTALLATION
Crankshaft sensing blade

Crankshaft bolt Crankshaft
Clean
Crosspoint screwdriver
AK202732 AB
Washer
Chamfer Degrease
Crankshaft sprocket 1. Prevent the counterbalancer shaft from rotating in
AK202838 AB the same method as in the removal procedure.
1. Clean and then degrease the crankshaft sprocket, 2. Install the oil pump sprocket.
sprocket fitting surface of the crankshaft, and 3. Install the oil pump sprocket.
crankshaft sensing blade. Install the crankshaft 4. Tighten the flange nut to 54 ± 5 N⋅m.
sprocket and crankshaft sensing blade on the
crankshaft.
2. Clean the bolt hole in the crankshaft, and then
washer.
3. Apply a necessary minimum amount of oil to the
threads and seating surface of the crankshaft bolt.
MD998781
AK202738 AB
4. Hold the drive plate using the special tool Fly

wheel stopper (MD998781).
5. Tighten the crankshaft bolt to a torque of 167 N⋅m.
TIMING BELT
>>K<< AUTO-TENSIONER INSTALLATION >>L<< TENSIONER PULLEY

INSTALLATION
A
B
Tensioner
AK202768 AB pulley holes
AK202759AB
1. If the auto-tensioner rod remains in its fully
extended position, reset it to the retracted position Install the tensioner pulley with its holes aligned as
as follows: shown in the drawing.
(1) Clamp the auto-tensioner in a vise at right
angles to the jaws. >>M<< TIMING BELT INSTALLATION
(2) Push in the rod little by little with the vise until
the set hole A in the rod is aligned with the set Timing marks
hole B in the cylinder.
(3) Insert a piece of wire (1.4 mm diameter) into
the set holes.
(4) Remove the auto-tensioner from the vise.
AK202903 AB
1. Bring the timing mark on the exhaust camshaft

sprocket to a point one sprocket tooth away from
the timing mark on the rocker cover in the
counterclockwise direction.
AK202767
NOTE: If the timing marks were aligned, the
exhaust camshaft would be turned counterclock-
2. Install the auto-tensioner in position. Leave the wise by one sprocket tooth and stay there by the
wire installed until the auto-tensioner is force of the valve springs.
completely installed.
Timing marks
AK202904 AB
2. Align the timing mark on the intake camshaft

sprocket with that on the rocker cover.
NOTE: The intake camshaft will be turned slightly
clockwise from where the timing marks are
aligned by the force of the valve springs and stay
there.
TIMING BELT
11B-21
AK202760 AK202771
3. Bring the timing mark on the crankshaft sprocket 5. Install the timing belt on the exhaust camshaft
to a point one sprocket tooth away from the sprocket, and hold it in place with a paper clip at
mating timing mark in the counterclockwise the point indicated in the drawing.
direction like in the operation with the exhaust
camshaft sprocket.
Plug Crosspoint
AK202772
screwdriver
AK202752 AB
6. Turn the intake camshaft sprocket
counterclockwise to bring the timing mark on it
4. Align the timing mark on the oil pump sprocket one sprocket tooth away from the mating timing
with that on the cylinder block. mark in the counterclockwise direction. Then
(1) Remove the plug from the cylinder block. install the timing belt on the sprocket and hold it in
(2) Insert a crosspoint screwdriver with a shank place with a paper clip.
diameter of 8 mm through the plug hole. If it NOTE: The timing marks will be aligned when the
can be inserted 60 mm or more, the sprocket belt is installed since the intake camshaft is turned
is in the correct phase. If the insertion depth is slightly clockwise by the force of the valve
up to 20 − 25 mm, the screwdriver is blocked springs.
by the counterbalancer shaft. Then turn the oil
Timing marks
pump sprocket one turn and realign the timing
marks. Then check that the screwdriver can
be inserted 60 mm or more. Keep the
screwdriver inserted until installation of timing
belt is finished.
Timing marks
AK305994 AC
7. Turn the exhaust camshaft sprocket clockwise to

align the timing marks, and make sure that the
intake camshaft sprocket timing marks are also
aligned.
AK202761 AB
(3) Turn the oil pump sprocket counterclockwise

by one sprocket tooth.
TIMING BELT
MD998767
Oil pump
Crankshaft sprocket
sprocket
AK202762AB AK202764 AB
8. Install the timing belt on the idler pulley, oil pump 12.Turn the tensioner pulley counterclockwise using
sprocket, and crankshaft sprocket, in this order. the special tool Tension pulley socket wrench
NOTE: There should be no slack in the installed (MD998767) to give tension to the belt and hold
portion of the belt. the tensioner in position by temporarily tightening
the tensioner lock bolt.
NOTE: Take up the slack in the belt portion
between the intake and exhaust camshaft sprock-
ets.
13.Turn the crankshaft clockwise to make the timing
Camshaft mark align with the No.1 cylinder top dead center
sprocket mark.
Tensioner
pulley
AK202773 AB MD998738
9. Install the timing belt on the tensioner pulley.

NOTE: Turning slightly the intake camshaft
sprocket counterclockwise will facilitate installa-
tion of the belt on the tensioner pulley.
Crankshaft
sprocket AK202774 AB
14.Install the special tool Set screw (MD998738) and

turn down the tool until the wire (inserted in the
auto-tensioner when it was installed) can be
moved freely.
15.Loosen the tensioner pulley lock bolt.
AK202763AB
10.Turn slightly the crankshaft sprocket clockwise to

take up the slack in the idler pulley portion of the
timing belt.
11.Check that each of the timing marks on the
crankshaft, oil pump, and exhaust camshaft
sprockets is one sprocket tooth away from its
mating timing mark in the counterclockwise MD998767 AK202775 AB
direction.
TIMING BELT
11B-23
CAUTION INSPECTION
M1113002000362
Prevent the timing belt from slipping as it
becomes loose following rotation of the intake TIMING BELT
and exhaust camshafts. Check closely the entire timing belt.
Replace it if any of the following conditions is found.
16.Turn the torque wrench attached to the special
tool Tension pulley socket wrench (MD998767)
counterclockwise until the slack in the timing belt
is taken up.
17.Turn the torque wrench clockwise from the
position of step 16. until the torque wrench
reading becomes 3.5 N⋅m, then tighten the
tensioner pulley lock bolt.
18.Remove the special tool Set screw (MD998738)
that was installed in step 14.
AK202794
19.Turn the crankshaft clockwise two turns, then let it
alone for approx. 15 minutes. 1. Hardened back side rubber
Back side surface is glossy, lacking in elasticity,
and so hard that no impression is left when
pressed with fingernail.
Extension Cracks Cracks
amount
Peeling of canvas
Cracks in sides
AK202829 AB
20.Check that the wire (inserted in the auto-tensioner

when it was installed) can be moved freely. If the
Cracks in tooth roots
wire can be pulled freely, the belt tensioner is AK202793 AB
adjusted properly. Remove the wire. At that time, 2. Cracks in back rubber surface
check that the auto-tensioner rod extends by the
specified amount. 3. Cracks in canvas
4. Cracks in tooth roots
Standard value: 3.8 − 4.5 mm
5. Cracks in belt sides
CAUTION
Be sure to check the tightening torque of the Rounded edge
crankshaft bolt anytime the crankshaft has been
turned counterclockwise. If the torque lower than
specification, tighten the bolt to the specified
torque.
21.If the wire cannot be pulled out freely, perform the
steps 14. through 18. again to make the belt
tension proper.
Abnormal wear
(Fluffy strand)
AK202795 AB
6. Abnormally worn belt sides;

NOTE: belt sides are normal if they have
“knife-cut” surfaces.
TIMING BELT
AUTO-TENSIONER
Canvas lost and
rubber exposed
12 mm
Missing
Tooth
AK202796 AB
AK202765 AB
7. Badly worn teeth
Initial stage: Canvas is worn (canvas fiber is fluffy; 1. Check the auto-tensioner for leaks from the
teeth look whitish due to worn-out rubber; canvas sealed sections.
texture is unclear)
Replace it if leaky.
Second stage: Canvas is lost and rubber is exposed
(tooth width narrows down) 2. Check the rod end for wear and other damage.
8. Missing tooth Replace the auto-tensioner if the rod is badly
worn or damaged.
3. Measure the extension length of the rod.
If it is not within the standard value range, replace
the auto-tensioner.
Standard value: 12 mm
98 to 196 N
Movement
AK202766 AB
4. Press the rod with a force of 98 to 196 N and

measure the amount of retraction. If the
measurement exceeds the standard value,
replace the auto-tensioner.
Standard value: 1 mm maximum
11B-25
M1113002200719
7
9 8 11 ± 1 N·m
9.0 ± 1.0 N·m
18
9.0 ± 2.0 N·m 10 N 17

2
11 ± 1 N·m 19 ± 3 N·m
15 N 3
14
16
13 N
5
11
12
4
20 ± 2 N·m
6
11 ± 1 N·m
11 ± 1 N·m
AK400843AB

1. Vacuum hose and pipe 10. O-ring
2. Vacuum pipe 11. Delivery pipe and injector
3. Throttle body assembly 12. Insulator
>>C<< 4. Throttle body gasket 13. Insulator
5. EGR valve >>A<< 14. Injector
6. EGR gasket 15. O-ring
7. Vacuum hose 16. Grommet
8. Fuel hose 17. Delivery pipe
>>B<< 9. Fuel pressure regulator 18. Solenoid valve assembly
INSTALLATION SERVICE POINTS >>B<< FUEL PRESSURE REGULATOR

>>A<< INJECTOR INSTALLATION INSTALLATION
1. Apply a thin coat of engine oil to a new O-ring. 1. Apply a thin coat of engine oil to a new O-ring.
CAUTION CAUTION
Prevent engine oil from getting into the delivery Prevent engine oil from getting into the delivery
pipe. pipe.
2. Insert the injector into the delivery pipe while 2. Insert the fuel pressure regulator into the delivery
turning it in both directions carefully not to pipe while turning it in both directions carefully not
damage the O-ring. to damage the O-ring.
3. Check that the injector turns smoothly. If it does 3. Check that the fuel pressure regulator turns
not, the O-ring may be jamming, so remove the smoothly. If it does not, the O-ring may be
injector and check the O-ring for damage. If the jamming, so remove the fuel pressure regulator
O-ring is intact, insert the injector into the delivery and check the O-ring for damage. If the O-ring is
pipe and check it for smooth rotation again. intact, insert it into the delivery pipe and check it
for smooth rotation again.
>>C<< THROTTLE BODY GASKET

INSTALLATION
Tab
AK305995AC
Install the throttle body gasket with its tab located as

shown in the drawing.
INLET MANIFOLD
11B-27
INLET MANIFOLD
M1113026100192
36 ± 6 N·m
19 ± 3 N·m
2 4
3
36 ± 6 N·m
20 ± 2 N·m
31 ± 3 N·m
AK400844 AB
Removal steps INSTALLATION SERVICE POINTS

>>A<< 1. Inlet manifold stay
>>A<< INLET MANIFOLD STAY INSTAL-
2. Inlet manifold
3. Inlet manifold gasket LATION
4. Engine hanger
Inlet manifold
stay
AK400845 AB
Tighten the bolts to the specified torque 31 ± 3 N⋅m

on both ends after making sure that the stay is in
close contact with the bosses on the inlet manifold
and cylinder block.
EXHAUST MANIFOLD
EXHAUST MANIFOLD
M1113004900736
14 ± 1 N·m
44 ± 5 N·m
29 ± 3 N·m
1
14 ± 1 N·m
2
6
4
5
49 ± 5 N·m
3 35 ± 6 N·m
44 ± 5 N·m
AK400846 AB

1. Oxygen sensor 4. Engine hanger
2. Exhaust manifold cover 5. Exhaust manifold
3. Exhaust manifold bracket 6. Exhaust manifold gasket
11B-29
M1113017900383
13 ± 2 N·m
7
9 13 ± 2 N·m
13 ± 2 N·m
6
1
23 ± 4 N·m
2
11 5
10 4
8
10.8 ± 1.0 N·m
29 ± 10 N·m
14
23 ± 2 N·m
13
12
14 ± 1 N·m
AK400847AB
Removal sequence INSTALLATION SERVICE POINTS

1. Water hose
>>A<< O-RING/WATER INLET PIPE
2. Water hose
>>E<< 3. Engine coolant temperature sensor INSTALLATION
>>D<< 4. Engine coolant temperature gauge CAUTION
unit • Never allow any oil or grease to touch the
5. Water inlet fitting
O-rings.
6. Thermostat
>>C<< 7. Water outlet fitting • Clamp the water inlet pipe only after installa-
>>B<< 8. Thermostat housing tion of the thermostat case.
>>A<< 9. O-ring Replace the O-rings at both ends of the water inlet
>>A<< 10. Water inlet pipe pipe with new ones. Insert the O-rings into the water
>>A<< 11. O-ring pump and thermostat housing after wetting their
12. Water pump peripheries with water.
13. Water pump gasket
14. Knock sensor
>>B<< THERMOSTAT HOUSING >>D<< ENGINE COOLANT

INSTALLATION TEMPERATURE GAUGE UNIT
INSTALLATION
AK305999AC
1. Remove all old FIPG remaining on the thermostat AK300711 AB
housing and cylinder head. 1. Remove all old sealant remaining on the threaded
2. Apply a 2.7 ± 0.3 mm diameter bead of FIPG on hole in the engine coolant temperature gauge unit
the indicated surface of the thermostat housing. and the thermostat housing.
Specified sealant: NOTE: A new engine coolant temperature gauge
Mitsubishi Genuine Part No.MD970389 or unit is coated with sealant. It does not require
equivalent coating with sealant before installation.
2. Apply sealant to the indicated threads of the
>>C<< WATER OUTLET FITTING engine coolant temperature gauge unit.
INSTALLATION Specified sealant:
3M Nut Locking Part No.4171 or equivalent
>>E<< ENGINE COOLANT

TEMPERATURE SENSOR INSTALLATION
AK202755AB
1. Remove all old FIPG remaining on the water

outlet fitting and thermostat housing.
2. Apply a 2.7 ± 0.3 mm diameter bead of FIPG to
the indicated surface of the water outlet fitting. AK300712 AB
Specified sealant: CAUTION

Mitsubishi Genuine Part No.MD970389 or When using a tool, avoid letting it touch the con-
equivalent nector portion which is made of plastic.
1. Remove all old sealant remaining on the threads
of the engine coolant temperature sensor and in
the threaded hole in the thermostat housing.
2. Apply sealant to the engine coolant temperature
sensor's threads indicated in the drawing.
Specified sealant:
3M ATD Part No.8660 or equivalent
11B-31
M1113005400864
10 ± 2 N·m
3
8
4
11
6
14
9
13
20 ± 1 N·m
12 14 ± 1 N·m
2
10 1
22 ± 4 N·m
15 5
8.8 ± 1.0 N·m
11 ± 1 N·m
18
N7
16
17
Apply engine oil to

all moving parts
before installation.
AK202894 AB

1. Camshaft position sensor >>C<<10. Bearing cap, front
2. O-ring >>C<<11. Bearing cap No.5
3. Cover >>C<<12. Bearing cap No.2
4. Gasket >>C<<13. Bearing cap No.3
>>F<< 5. Camshaft position sensing cylinder >>C<<14. Bearing cap No.4
>>E<< 6. Camshaft position sensor support >>B<<15. Camshaft
>>D<< 7. Camshaft oil seal 16. Rocker arm
>>C<< 8. Bearing cap, rear right <<A>> >>A<< 17. Lash adjuster
>>C<< 9. Bearing cap, rear left 18. Oil delivery body
SERVICE POINTS FOR REMOVAL >>C<< BEARING CAP INSTALLATION

<<A>> LASH ADJUSTER REMOVAL Dowel pin
CAUTION
When reusing a lash adjuster, it must be washed
and inspected before installation. (Refer to
P.11B-33, the instruction under LASH ADJUSTER
in the INSPECTION section.)

>>A<< LASH ADJUSTER INSTALLATION AK203979 AC
CAUTION 1. Set each camshaft with its dowel pin at the top.
When reusing a lash adjuster, it must be washed
and inspected before installation. (Refer to
P.11B-33, the instruction under LASH ADJUSTER
Install the lash adjuster into the rocker arm, being
Cap number
careful not to spill the diesel fuel it contains.
Intake/exhaust
identification
>>B<< CAMSHAFT INSTALLATION letter
Timing belt side

AK202870 AB
Slit 2. The bearing caps No. 2 to 5 are identical in shape

for both intake and exhaust camshafts. Check the
identification mark on each cap before installation.
Identification mark (stamped on front and
Nos. 2 − 5 bearing caps)
I: intake camshaft
Exhaust camshaft E: exhaust camshaft
AK202869 AB
3. Remove completely sealant remaining on the
CAUTION bearing caps and cylinder head.
• Do not confuse the intake camshaft with the
exhaust camshaft.
• The exhaust camshaft has a 4 mm wide slit at
the rear end.
AK202871AB
4. Apply sealant to the surfaces indicated in the

drawing.
Specified sealant:
5. Install each bearing cap and tighten its bolts in two
or three passes.
6. Finally tighten the bolts to 20 ± 1 N⋅m.
7. Check that the rocker arms are correctly installed.
NOTE: Wipe off any squeezed out sealant completely.
11B-33
>>D<< CAMSHAFT OIL SEAL >>F<< CAMSHAFT POSITION SENSING
INSTALLATION CYLINDER INSTALLATION
MD998713 Smaller vane
Camshaft
posittion sensor
AK202872 AB
AK306001AC
Use the special tool Camshaft oil seal installer
1. Turn the exhaust camshaft to the No.1 cylinder
(MD998713) to drive each oil seal into position in the
top dead center position.
cylinder head.
NOTE: The camshaft will slightly turn counter-
clockwise by the force of the exhaust valve spring.
>>E<< CAMSHAFT POSITION SENSOR
2. Install the camshaft position sensing cylinder with
SUPPORT INSTALLATION the smaller vane located as shown in the drawing.
INSPECTION
M1113005500504
CAMSHAFT
AK202754AB
1. Remove completely the FIPG remaining on the

camshaft position sensor support and cylinder
head.
AK202797AB
2. Apply a 3 ± 1 mm diameter bead of FIPG to the
indicated surface of the camshaft position sensor Measure the cam height (nose-to-heel diameter).
support. If any cam is worn beyond the limit, replace the cam-
Specified sealant: shaft.
Mitsubishi Genuine Part No.MD970389 or Standard value: 34.91 mm
equivalent Limit: 34.41 mm
LASH ADJUSTERS CAUTION

CAUTION The steel ball spring of the lash adjuster is
• The lash adjuster is a precision-engineered extremely weak. The lash adjuster's functionality
component. Do not allow dust or other for- may be badly affected if the special tool is
eign matter to enter it. inserted too strongly.
• Do not disassemble lash adjusters. 3. While gently pushing the internal steel ball using
• Use only non-contaminated diesel fuel to the special tool Air bleed wire (MD998442), move
clean the lash adjuster. the plunger in and out 5 − 10 times to eliminate
stiffness in the plunger and expel contaminated
oil.
For rough For finish For diesel
cleaning cleaning fuel filling NOTE: The plunger must be free from jamming
and any other abnormalities. If a defect is found in
plunger operation, replace the lash adjuster.
A B C
AK202836 AB
1. Prepare three containers and approximately five

liters of diesel fuel. Pour into each container the MD998442
diesel fuel in an amount enough for a lash
adjuster placed in the container in its upright Diesel fuel
position to completely submerge. AK202840 AC
CAUTION
The hole in the side of the lash adjuster must be
directed toward the inside of container A. Never
direct it against any person.
4. Take the lash adjuster out of the container, then
move the plunger by pushing the steel ball gently
to discharge the diesel fuel from the pressure
chamber.
AK202837
2. Place the lash adjuster in container A and wash

its outside surface.
NOTE: Use a nylon brush if there are
hard-to-remove deposits.
Diesel fuel
MD998442
AK202839 AB
Diesel fuel
MD998442
AK202839 AB
11B-35
CAUTION CAUTION
The steel ball spring of the lash adjuster is Do not use container C for cleaning. If cleaning is
extremely weak. The lash adjuster's functionality performed in container C, foreign matter could
may be badly affected if the special tool is enter the pressure chamber when the chamber is
inserted too strongly. filled with diesel fuel.
5. Soak the lash adjuster in the diesel fuel in 7. Soak the lash adjuster in the diesel fuel in
container B. Move the plunger in and out 5 − 10 container C. Gently push the internal steel ball
times by gently pushing the internal steel ball using the special tool Air bleed wire (MD998442).
using the special tool Air bleed wire (MD998442)
until the plunger moves smoothly to wash the lash
adjuster’s pressure chamber.
MD998442 Diesel fuel
AK202842 AB
MD998442
8. Place the lash adjuster upright with the plunger at
Diesel fuel
AK202840 AC
the top. Push the plunger firmly until it makes a
full stroke, then return the plunger slowly and
CAUTION release the hold of the steel ball to allow the
The hole in the side of the lash adjuster must be pressure chamber to be filled with diesel fuel.
directed toward the inside of container B. Never
chamber.
AK202843
9. Take the lash adjuster out of the container, place it

upright with the plunger at the top, and push the
Diesel fuel
plunger firmly. The plunger must not move at all.
MD998442
NOTE: If the lash adjuster contracts, perform the
AK202841 AB
operations 7. through 9. again. Replace the lash
adjuster if it still contracts even after the pressure
chamber has completely been filled with diesel
fuel (air has been bled).
10.Keep the serviced lash adjusters in their upright
positions to prevent diesel fuel from spilling out.
Protect them from dust or other foreign matter.
Install the lash adjusters onto the engine as soon
as possible.

M1113006900798
78 ± 2 N·m → 0 N·m →
20 ± 2 N·m → +90˚ → +90˚
1
2
8
9
4 10
5 20 14
6 15
12 17
13
16
19
18 11
Apply engine oil to

all moving parts
AK306002AC

<<A>> >>D<< 1. Cylinder head bolt 7. Intake valve
2. Cylinder head assembly <> >>C<< 8. Retainer lock
3. Cylinder head gasket 9. Valve spring retainer
<> >>C<< 4. Retainer lock >>B<< 10. Valve spring
5. Valve spring retainer 11. Exhaust valve
>>B<< 6. Valve spring >>A<< 12. Valve stem seal
13. Valve spring seat
11B-37
>>A<< 14. Valve stem seal 18. Intake valve seat
15. Valve spring seat 19. Exhaust valve seat
16. Intake valve guide 20. Cylinder head
17. Exhaust valve guide

<<A>> CYLINDER HEAD BOLT REMOVAL >>A<< VALVE STEM SEAL INSTALLA-
TION
MB991654
MD998737
AK202723 AB
Use the special tool Cylinder head bolt wrench AK202874 AB
(MB991654) to loosen the cylinder head bolts.

CAUTION
The special tool must always be used when
<> RETAINER LOCK REMOVAL installing the valve stem seal. Improper installa-
tion could result in oil leaks past the valve guide.
MD998735
1. Install the valve spring seat.
2. Install the valve.
3. Apply a thin coat of engine oil to a new valve stem
seal.
4. Use the special tool Valve stem seal installer
(MD998737) to install the stem seal on the valve
guide. Use the stem of the valve to guide the stem
AK202873 AB
seal.
Intake valve stem seal Exhaust valve stem seal

MD998772 Colour: Gray Colour: Grayish green
AK304538AB
AK202742 AB
NOTE: Do not confuse the stem seals for intake
Compress the valve spring using the special tool
valves with those for exhaust valves.
Valve spring compressor (MD998735 or MD998772),
then remove the retainer lock.
NOTE: . Store removed valves, springs and other
parts, after putting to each of them a tag that identi-
fies its cylinder No. or installation location.
>>B<< VALVE SPRING INSTALLATION >>D<< CYLINDER HEAD BOLT

INSTALLATION
Spring
retainer
Painted
end
Stem
seal
Spring Nominal length

seat
AK202551AB
Install each valve spring with the painted end toward AK202750 AB
the rocker arm.

1. When reusing a cylinder head bolt, check that its
nominal length (shank length) is not greater than
>>C<< RETAINER LOCK INSTALLATION the limit. If the limit is exceeded, replace the bolt.
MD998735
Limit: 99.4 mm
2. Apply engine oil to the threads and washer of the
bolt.
MB991654
AK202873 AB
MD998772
AK202723 AB
Timing belt side
AK202742 AB 8 6 1 3 9

Valve spring compressor (MD998735 or MD998772), 10 4 2 5 7
then install the retainer lock.
AK306004AC
3. Tighten the bolts to 78 ± 2 N⋅m in the indicated

sequence.
NOTE: Use the special tool Cylinder head bolt
wrench (MB991654) to tighten the bolts.
4. Loosen all the bolts completely.
5. Tighten the bolts again to a torque of 20 ± 2 N⋅m
in the indicated sequence.
11B-39
CAUTION
The thickness of the metal that can be removed
by grinding from both the cylinder head and the
90˚ mating cylinder block is limited to 0.2 mm in
total.
3. Check the cylinder head gasket surface for warp
using a straightedge and thickness gauge.
90˚
Paint marks If the surface is warped beyond the limit, grind the
AK202720 AB
surface for rectification.
Gasket surface warp
CAUTION Standard value: Less than 0.05 mm
• If the tightening angle is smaller than 90°, Limit: 0.2 mm
proper fastening performance could not be Grinding limit: 0.2 mm
assured. Be sure to respect that angle. Cylinder head height (standard value for new
• If the bolt is tightened to an angle greater than part): 131.9 − 132.1 mm
the specified angle, loosen the bolt com-
pletely and then retighten it beginning with
the first step.
VALVES
1. Check the valve face for correct contact with the
6. Make paint marks on each bolt’s head and on the
seat. Reface the valve if the contact is partial or
cylinder head.
one sided.
7. Turn the bolts 90° in the tightening direction and in
the indicated sequence.
8. Give another 90° turn in the tightening direction to
each bolt, making sure that the paint mark on the
bolt head and that on the cylinder head are on the Contact
(Should be at
same line. centre of face)
Margin
INSPECTION
M1113007000691
CYLINDER HEAD
AK202729 AB
1. Before cleaning the cylinder head, check it for
traces of water and gas leakage and for cracks 2. Measure the margin.
and any other damage.
Replace the valve if its margin is smaller than the
2. Thoroughly remove oils, scale, sealants, carbon
limit.
and other contamination. Clean the oil passages,
then check using compressed air that they are not Standard values:
blocked. Intake 1.0 mm
Exhaust 1.5 mm
Limits:
Intake 0.5 mm
Exhaust 1.0 mm
AK202724
Total length
AK202876 AB
3. Measure the total length of the valve. VALVE GUIDE

Replace the valve if the length is less than the
limit.
Standard values:
Intake 109.50 mm
Exhaust 109.70 mm valve
guide
Limits:
Intake 109.00 mm
Exhaust 109.20 mm
Stem diameter
Guide inside diameter AK202709 AB
VALVE SPRINGS Measure the valve guide inside diameter and valve
stem diameter to calculate the clearance between
Out of square the valve guide and valve stem.
If the limit is exceeded, replace the valve guide or
valve, or both.
Standard values:
Free height
Intake 0.02 − 0.05 mm
Exhaust 0.05 − 0.09 mm
Limits:
Intake 0.10 mm
AK202706 AB
Exhaust 0.15 mm
1. Measure the free height of the spring.
Replace the spring if its height is smaller than the VALVE SEATS
limit.
Valve stem
Standard value: 48.3 mm end
Limit: 47.3 mm
Valve stem
2. Measure the squareness of the spring. projection
Replace the spring if it is out of square beyond the

limit. Spring
seating
Standard value: 1.5° or less surface
Limit: 4°
AK202814 AB
With the valve installed in position and its face

pressed against the valve seat, measure the valve
stem projection (distance between the the valve
stem end and spring seating surface). If the meas-
urement exceeds the limit, replace the valve seat.
Standard values:
Intake 49.20 mm
Exhaust 48.40 mm
Limits:
Intake 49.70 mm
Exhaust 48.90 mm
11B-41
VALVE SEAT RECONDITIONING Intake valve seat hole diameters:
1. Before reconditioning the valve seat, check the 0.3 oversize: 35.30 − 35.33 mm
clearance between the valve guide and valve 0.6 oversize: 35.60 − 35.63 mm
stem and, if necessary, replace the valve guide. Exhaust valve seat hole diameters:
0.3 oversize: 33.30 − 33.33 mm
0.9 – 1.3mm 0.9 – 1.3 mm 0.6 oversize: 33.60 − 33.63 mm
65˚
3. Before fitting the valve seat, cool it in liquid
65˚
nitrogen to prevent damage to its hole in the
cylinder head due to interference.
4. Resurface the valve seat. See the VALVE SEAT
15˚ 25˚ RECONDITIONING section.
44˚
VALVE GUIDE REPLACEMENT
AK202850 AB
1. Force out the valve guide toward the cylinder
2. Resurface the valve seat to the indicated width block using a press.
and angles. CAUTION
3. After resurfacing, lap the valve and valve seat Do not use a replacement valve guide of the
using lapping compound. same size as the removed one.
2. Machine the valve guide hole in the cylinder head
VALVE SEAT REPLACEMENT to the size matched to the selected oversize valve
guide.
0.5 – 1 mm Valve guide hole diameters
0.05 oversize: 12.05 − 12.07 mm
0.25 oversize: 12.25 − 12.27 mm
0.50 oversize: 12.50 − 12.52 mm
Cut
0.5 – 1 mm
AK202707 AB
1. Cut inside of the valve seat to be replaced until its

wall becomes thin enough for removal, then
remove the valve seat. 19.2 – 19.8 mm
AK400848 AB
3. Press-fit the valve guide until it remains protruded

above the cylinder head by the amount indicated
Valve seat
height in the drawing.
NOTE: Press the valve guide from above the cyl-
inder head.
Oversize hole diameter NOTE: The valve guides for the intake valves are
different in length from those for the exhaust
AK202708 AB
valves (45.5 mm for intake valves; 50.5 mm for
2. Rebore the valve seat hole in the cylinder head to exhaust valves)
a diameter matched to the diameter of the 4. After installing the valve guide, insert a new valve
selected oversize valve seat. in it to check for smooth movement.

M1113008100668
19 ± 3 N·m 32
31
10
Apply engine oil to 28 30
all moving parts
21
23 ± 3 N·m
10 ± 2 N·m
29
20 22
23 ± 3 N·m
23 24 8 9
16 7
19 ± 3 N·m 19 ± 3 N·m
15 26
17 ± 1 N·m
25
19 27
14 4
17 18 23 ± 3 N·m
13
36 ± 3 N·m 9.0 ± 3.0 N·m
11 23 ± 3 N·m
39 ± 5 N·m
1
12 2
3
44 ± 5 N·m
5
6
9.0 ± 3.0 N·m 22 ± 4 N·m
9.0 ± 3.0 N·m
39 ± 5 N·m
2
1
9.0 ± 3.0 N·m
AK400849 AB
9.0 ± 3.0 N·m
1. Drain plug 11. Relief plug
>>O<< 2. Drain plug gasket 12.Gasket
>>N<< 3. Oil filter 13.Relief spring
4. Transmission stay <4WD> 14.Relief plunger
<<A>> >>M<< 5. Oil pan <2WD> 15.Oil filter bracket
<> >>L<< 6. Oil pan lower section <4WD> 16.Gasket
<<C>> >>L<< 7. Oil pan upper section <4WD> <<D>> >>J<< 17.Plug
8. Oil screen 18.O-ring
9. Gasket <<E>> >>I<< 19.Flange bolt
>>K<< 10.Oil pressure switch >>H<< 20.Front case
11B-43
21.Gasket 28.Counterbalancer shaft, right
22.Oil pump cover 29.Counterbalancer shaft, left
>>G<< 23.Oil pump driven gear <<F>> >>C<< 30.Counterbalancer shaft front bearing
>>G<< 24.Oil pump drive gear <<G>> >>B<< 31.Counterbalancer shaft rear bearing,
>>F<< 25.Crankshaft front oil seal right
>>E<< 26.Counterbalancer shaft oil seal <<G>> >>A<< 32.Counterbalancer shaft rear bearing,
>>D<< 27.Oil pump oil seal left
REMOVAL SERVICE POINTS <<C>> OIL PAN UPPER SECTION

<<A>> OIL PAN REMOVAL <2WD> REMOVAL <4WD>
MD998727 A
A
AK202574 AB AK304400 AB
Screw bolts into the bolt holes A shown in the draw-

1. Remove the oil pan bolts.
ing (holes at both ends) to remove the oil pan.
2. Insert the special tool Oil pen remover
(MD998727) into the joint between the cylinder CAUTION
block and oil pan by tapping the tool with a Do not use a scraper or the special tool to
hammer. remove the oil pan.
3. Remove the oil pan by tapping an edge of the
special tool with a hammer to move it sideways. <<D>> PLUG REMOVAL
<> OIL PAN LOWER SECTION MD998162

REMOVAL <4WD>
Remove the oil pan by tapping it through a piece of
wood applied to a side with a plastic hammer.
CAUTION
Do not use a scraper or the special tool to
remove the oil pan. MD998783
AK202585 AB
Fit the teeth of the special tools in notches of the plug

as shown in the drawing and support the tool with the
special tool to loosen the plug.
• Plug wrench (MD998162)
• Plug wrench retainer (MD998783)
<<E>> FLANGE BOLT REMOVAL <<G>> COUNTERBALANCER SHAFT

REAR BEARING REMOVAL
Plug
Crosspoint
screwdriver
AK202586 AB
MD998372
AK300175AD
1. Remove the plug on the left side of the cylinder
block. Insert a cross point screwdriver (shank 1. Use the special tool Silent shaft bearing puller
diameter 8 mm) into the plug hole more than 60 (MD998372) to remove the counterbalancer shaft
mm to prevent the left counterbalancer shaft from rear bearings from the cylinder block.
rotating.
MB991603
MD998372
AK202634 AB
AK202642
2. When removing the rear bearing of the left
2. Loosen and remove the flange bolt. counterbalancer shaft, install the special tool
Silent shaft bearing installer stopper (MB991603)
<<F>> COUNTERBALANCER SHAFT on the front of the cylinder block and use a special
FRONT BEARING REMOVAL tool Silent shaft bearing puller (MD998372) to pull
out the bearing.
CAUTION
Front
bearing
MD998371
AK202633 AB
Remove the front bearing first. Otherwise, the

special tool cannot be used.
Use the special tool Silent shaft bearing puller
(MD998371) to remove the counterbalancer shaft
front bearing from the cylinder block.
11B-45
>>A<< LEFT COUNTERBALANCER Ratchet ball
Oil hole
SHAFT REAR BEARING INSTALLATION
MB991603
Rear bearing right
AK300621AD
2. Align the ratchet ball of the special tool with the oil
MD998705 hole in the rear bearing to install the bearing of the
AK300177 AF special tool.
3. Apply engine oil to the bearing outer surface and
bearing hole in the cylinder block.
MB991603
MD998705
MD998705
Rear bearing
AK300619AG
MD998705(Guide pin)
1. Install special tool Silent shaft bearing installer AK300179 AG
stopper (MB991603) to the cylinder block.
2. Apply engine oil to the rear bearing outer surface
and bearing hole in the cylinder block. MD998705
3. Using special tool Silent shaft bearing installer

(MD998705), install the rear bearing.
NOTE: The left rear bearing has no oil holes.
>>B<< RIGHT COUNTERBALANCER

AK300622AG

(MD998705), install the rear bearing. Make sure
that the oil hole of the bearing is aligned with the
oil hole of the cylinder block.
MD998705(Guide pin)
AK300178 AD
1. Install the guide pin of the Silent shaft bearing

installer (MD998705) in the threaded hole of the
cylinder block as shown.
>>C<< COUNTERBALANCE SHAFT 4. Apply engine oil to the front bearing outer surface
FRONT BEARING INSTALLATION and bearing hole in the cylinder.
MD998705
MD998705
Rear bearing
installing portion MD998705(Guide pin)
AK300179 AG
AK300623AF
1. Remove the rear bearing installing portion from

the special tool Silent shaft bearing installer
(MD998705).
AK300624

MD998705(Guide pin)
AK300178 AD that the oil hole of the bearing is aligned with the
>>D<< OIL PUMP OIL SEAL
INSTALLATION
Ratchet ball Oil hole

Socket
Oil seal wrench
Front case
Front bearing right
AK304592AB
AK202639 AB
3. Align the ratchet ball of the special tool with the oil Use an appropriate socket wrench to install the oil
hole in the rear bearing to install the bearing of the pump oil seal.
special tool.
11B-47
>>E<< COUNTERBALANCER SHAFT OIL >>H<< FRONT CASE INSTALLATION
SEAL INSTALLATION
Counterbalancer
shaft, left
Socket wrench
Front case Counterbalancer

Oil seal shaft, right
MD998285
AK202577 AB
AK202646 AB
1. Install the special tool crankshaft front oil seal
Use an appropriate socket wrench to install the coun- guide (MD998285) on the front end of crankshaft
terbalancer shaft oil seal. and apply a thin coat of engine oil to the outer
surface of the special tool. Be sure to use the
>>F<< CRANKSHAFT OIL SEAL special tool when the front case is fitted with an oil
INSTALLATION seal.
2. Install the front case on the cylinder block with a
new front case gasket in between and temporarily
tighten all the flange bolts except those that are
used for tightening the filter bracket.
MD998375
3. Install the oil filter bracket on the front case with
Oil seal
the oil filter bracket gasket in between and
temporarily tighten the washer-assembled bolts.
Front case
AK202645 AB
Use the special tool Crankshaft front oil seal installer

(MD998375) to install the crankshaft oil seal.
>>G<< OIL PUMP DRIVEN GEAR/OIL MD998285

PUMP DRIVE GEAR INSTALLATION
AK202656 AB
4. Tighten all the bolts to the specified torques.

Alignment
marks
AK202660 AB
Apply engine oil generously to the gears and line up

the alignment marks.
>>I<< FLANGE BOLT INSTALLATION >>K<< OIL PRESSURE SWITCH

INSTALLATION
Crosspoint
screwdriver
AK202641 AB
AK202625AB
1. Insert a correspond screwdriver (shank diameter
8 mm) into the hole in the left side of the cylinder CAUTION
block to prevent the counterbalancer shaft from Be careful not to block the oil passage with seal-
rotating. ant.
1. Apply sealant to the threaded portion.
Specified Sealant:
AK202642
2. Tighten the flange bolts.

A
>>J<< PLUG INSTALLATION AK501228AD
1. Install a new O-ring on the front case.

MD998054 or MD998012
MD998162
MD998783 AK204037AE
AK202585 AB
2. Measure the dimension "A" shown in the
2. Use the special tools to tighten the plug to the illustration, and select the appropriate special tool
specified torque. Oil pressure switch socket wrench (MD998054 or
• Plug wrench (MD998162) MD998012) in the table shown below. Tight the
• Plug wrench retainer (MD998783) engine oil pressure switch to the specified toque.
Dimension "A" Special tool No.
26 mm MD998054
27 mm MD998012
11B-49
>>L<< OIL PAN UPPER SECTION / OIL CAUTION
PAN LOWER SECTION INSTALLATION Do not apply FIPG over remaining old FIPG.
<4WD> Doing so could result in oil leakage.
CAUTION 4. Thoroughly remove old FIPG from the gasket
Do not apply FIPG over remaining old FIPG. surfaces of the oil pan upper and lower sections.
Doing so could result in oil leakage.
Timing belt side
1. Clean the gasket surfaces of the cylinder block
and oil pan. Bolt hole
area
Bolt hole
Timing belt side area
Grooved area AK304403 AB
CAUTION
Grooved Too much FIPG will squeeze out, blocking cool-
area
AK304401 AB ant or oil passages, while too thin a bead could
result in leakage.
CAUTION
Too much FIPG will squeeze out, blocking cool- 5. Apply a 4 mm diameter bead of FIPG to the flange
ant or oil passages, while too thin a bead could surface all around the oil pan.
result in leakage. Specified sealant:
2. Apply a 4 mm diameter bead of FIPG to the flange
equivalent
surface all around the oil pan.
NOTE: In the grooved areas on the oil pan flange,
Specified sealant:
apply FIPG bead along the center of the groove.
equivalent Timing belt side
8
apply FIPG bead along the center of the groove. 9
5 4 1
12 11
M6 × 16 3
2 6
7 10
AK304404 AB
6. Install the oil pan lower section by tightening the

bolts in the indicated sequence.
AK304402 AB
3. Install the shorter bolts in the locations indicated

in the drawing.
>>M<< OIL PAN INSTALLATION <2WD> >>N<< OIL FILTER INSTALLATION

CAUTION
Do not apply FIPG over remaining old FIPG. Bracket side
1. Thoroughly remove old FIPG from the gasket
surfaces of the cylinder block and oil pan.
Engine oil
Timing belt side
Bolt hole
area AK202556 AB
1. Clean the installation surface of the filter bracket.

2. Apply engine oil to the o-ring of the oil filter.
Grooved
3. Install the oil filter to the bracket and tighten it to
area the specified torque.
AK400850 AB
CAUTION 4. If no torque wrench can be used for tightening,
Too much FIPG will squeeze out, blocking cool- use the following procedure:
ant or oil passages, while too thin a bead could (1) Screw in the oil filter until its o-ring contacts
result in leakage. the oil filter bracket.
2. Apply a 4 mm diameter bead of FIPG to the flange (2) Tighten the oil filter 3/4 turn.
Specified sealant:
equivalent
NOTE: . In the grooved areas on the oil pan
flange, apply FIPG bead along the center of the
groove.
Timing belt side
M6 × 8
AK400851 AB

in the drawing.
11B-51
>>O<< DRAIN PLUG GASKET INSPECTION
M1113008200212
INSTALLATION
COUNTERBALANCE SHAFTS
1. Check that the oil holes are not blocked.
Drain plug
Clean if necessary.
Oil pan
Gasket Oil pan

side
AK202835AB
2. Check the journals for seizure, damage and

defective contact with bearings.
If any of these faults is found, replace the
counterbalance shaft, bearings and/or oil pump
case assembly.
AK202603AB OIL PUMP

CAUTION
Installing the gasket with the wrong side facing
the oil pan will result in oil leakage.
Replace the drain plug gasket with a new one. Install
it with the side indicated in the drawing toward the oil
pan.
AK202831
1. Install the drive and driven gears in the oil pump

case.
2. Measure the gear side clearance using a straight
edge and thickness gauge.
Standard values:
Drive gear 0.08 − 0.14 mm
Driven gear 0.06 − 0.12 mm

M1113008400874
6
7
8
10
9 4
12
11
Apply engine oil to

all moving parts
2
20 ± 2 N·m → +90º to 94º
1
AK306012 AC

>>G<< 1. Connecting rod cap nut >>C<< 7. Piston ring No. 2
<<A>> >>F<< 2. Connecting rod cap >>B<< 8. Oil ring
>>E<< 3. Connecting rod bearing <<C>> >>A<< 9. Piston pin
<> >>D<< 4. Piston and connecting rod assembly 10. Piston
5. Connecting rod bearing 11. Connecting rod
>>C<< 6. Piston ring No. 1 12. Bolt
11B-53
REMOVAL SERVICE POINTS <<C>> PISTON PIN REMOVAL
<<A>> CONNECTING ROD CAP
Guide A: 18.9 mm
REMOVAL
Push rod Guide B
Cylinder Guide A: 17.9 mm

number
Guide C
Guide A: 20.9 mm
AK202812 AB
Base
Mark the cylinder number on the side of the connect-
ing rod big end as a guide for reassembly.
Guide A: 21.9 mm
<> PISTON AND CONNECTING ROD
ASSEMBLY REMOVAL
MB992010
AK202783 AB
The special tool Piston pin setting tool (MD998780),
consists of the elements shown in the drawing.
Push rod
Crank pin
AK402310 AC
1. Not to damage the crank pin, attach a special tool Front mark
Bolt guide (MB992010), to the connecting rod Front
mark
bolt.
2. Remove the piston and connecting rod assembly
from the cylinder block.
Guide C
Base
AK202781 AB
1. Insert the tool element, Push rod, into the piston

from the front mark side, then attach the element,
Guide C, to the push rod.
2. Place the piston and connecting rod assembly on
the element, Base, with the front mark facing up.
3. Use a press to remove the piston pin.
NOTE: . Keep the disassembled pistons, piston
pins and connecting rods cylinder by cylinder.

>>A<< PISTON PIN INSTALLATION L
Timing belt side Crankshaft

bore size mark
No.4
No.3 Guide B Guide A
No.2 AK301480 AD
No.1
6. Insert the tool element, Guide B, into the tool
AK305985 AC element, Guide A, with having 3 mm of the
clearance "L" between the tool element, Guide A
1. When replacing a piston, check the cylinder bore and B.
size mark stamped at the indicated location on the
cylinder block and select an appropriate
replacement piston using the following table.
Push rod
Cylinder bore size mark Piston size mark
I A Piston pin
II No mark
III C Front mark
Front
NOTE: The piston size mark is located on the pis- mark
ton top surface.
pin and attach the element, Guide A, to the push Guide A
rod end.
3. Assemble the connecting rod with the piston with Base
their front marks facing in the same direction.
4. Apply engine oil to the outside surface of the
piston pin. Guide B
5. Insert the assembly of piston pin, Push rod, and
Guide A (put together in step 4.) into the piston
holes from the front mark side.
AK202782 AB
7. Place the piston and connecting rod assembly

onto the element, Piston setting base, with the
front marks facing up.
8. Install the piston pin using a press. If the required
press force is less than the standard value,
replace the piston and piston pin assembly or the
connecting rod, or both.
Standard value: 7,350 − 17,100 N
11B-55
>>B<< OIL RING INSTALLATION >>C<< PISTON RING NO. 2/PISTON RING
NO. 1 INSTALLATION
Upper Lower
side side
rail rail
end gap end gap
Piston ring
expander
Spacer end gap AK202879 AB
AK202786 AB
1. Fit the oil ring spacer into the piston ring groove.
Install the upper side rail, then the lower side rail. Identification mark
NOTE: Locate the side rail and spacer end gaps Size marks
as shown in the drawing.
NOTE: New spacers and side rails are an identi-
fied by color marks as follows: No. 1
Size Color mark
No. 2
Standard Non mark
0.50 mm oversize Blue
AK202807 AB
1.00 mm oversize Yellow
Using a piston ring expander, install the piston rings
CAUTION with their identification marks facing up (toward the
Use of ring expander to expand the side rail end piston crown).
gap can break the side rail, unlike other piston Identification marks:
rings. No. 1 ring: 1R
No. 2 ring: 2R
Side rail end
NOTE: Each of the available piston rings has a size
mark as follows:
Size Size mark
Standard No. 1 ring No mark
(blue paint on periphery)
No. 2 ring No mark
(green paint on periphery)
AK202785 AB 0.50 mm oversize 50
2. To install each side rail, first fit one end of the rail 1.00 mm oversize 100
into the piston groove, then press the remaining
portion progressively into position by finger as
3. Make sure that the installed side rails move
smoothly in either direction.
>>D<< PISTON AND CONNECTING ROD CAUTION

ASSEMBLY INSTALLATION • Do not strike the assembly with a large force.
1. Apply engine oil generously to the piston's outside Doing so could break the piston rings.
surface, piston rings, and oil ring. • When striking the assembly into cylinder, do
not allow it to interfere with the oil jet.
Side rail
No. 1
5. Use a piston ring band to hold the piston rings
compressed when inserting the piston and
connecting rod assembly into the cylinder.
>>E<< CONNECTING ROD BEARING

INSTALLATION
Side rail 1. When replacing the connecting rod bearing,
No. 2
select a bearing of the size appropriate for the
AK202730 AB
crankshaft pin diameter in accordance with the
2. Align the end gaps of the piston rings and oil ring crankshaft pin and connecting rod bearing
(side rails and spacer) as shown in the drawing. matching table shown below.
3. Insert the piston and connecting rod assembly Locations of crankshaft pin diameter
marks
from the top of cylinder with the front mark on the
crown toward the camshaft sprocket.
Bolt
No. 2
No. 1 No. 3
MB992010
No. 4 AK304412 AB
2. Crankshaft pin diameter marks are stamped in the

Connecting rod indicated locations.
AK402300AC
4. Not to damage the crank pin, attach a special tool

Bolt guide (MB992010), to the connecting rod
bolt.
AK202719AB
3. Connecting rod bearing identification mark is

stamped in the indicated location on each
bearing.
AK202798 Crankshaft pin Connecting rod
bearing
Identification Diameter mm Identification
mark mark
I 44.995 − 45.000 1
II 44.985 − 44.995 2
III 44.980 − 44.985 3
11B-57
<Bearing selection example> >>G<< CONNECTING ROD CAP NUT
If the crankshaft pin diameter mark is “I,” select a INSTALLATION
bearing marked “1.” 1. The connecting rod cap bolts and nuts are
If the crankshaft pin diameter mark is illegible, tightened using the torque-to-yield method. For
measure the pin diameter and select a bearing this reason, each bolt to be reused must be
with the mark corresponding to the measurement. checked for elongation before installation.
4. Install the upper and lower halves of the selected Whether or not the bolt has been elongated can
bearing on the connecting rod big end and cap, be determined by running a nut with fingers
respectively. through all the threads of the bolt. If the nut does
not turn smoothly over all the threads, the bolt has
>>F<< CONNECTING ROD CAP been elongated and must be replaced.
INSTALLATION 2. Apply engine oil to the threads and bearing
surface of each nut before installation.
3. Finger-tighten the nuts on the bolts, then tighten
the nuts alternately and repeatedly to install the
cap properly.
Cylinder
number 4. Tighten the nuts to a torque of 20 ± 2 N⋅m.
Paint marks
90˚ to 94˚
Bearing Paint marks

locating
notches
AK202813 AB
1. Install the bearing cap on the connecting rod while

aligning the marks made during disassembly. If Nut Bolt
the connecting rod is new and has no alignment
mark, assemble it with the cap such that the both AK202721 AB
bearing locating notches are on the same side as
shown in the drawing. 5. Make a paint mark on the head of each nut.
CAUTION
• If the tightening angle is less than 90°, ade-
quate tightness could not be assured.
• If the tightening angle exceeds 94°, loosen the
nut completely and then perform the tighten-
ing procedure again beginning with the first
step.
6. Make a paint mark on the bolt at a point 90° to 94°
away from the paint mark made on the nut in the
AK202821
tightening direction.
2. Make sure that the thrust clearance of the 7. Turn the nut 90° to 94° to bring the mark on the
connecting rod big end is proper. nut into alignment with that on the bolt.
Limit: 0.4 mm
INSPECTION CRANKSHAFT PIN OIL CLEARANCE

M1113008500365
(PLASTIGAGE METHOD)
PISTON RING
1. Wipe off oil from the crankshaft pin and
connecting rod bearing.
2. Cut a piece of plastigage whose length is
equivalent to the width of the bearing and place it
on the crankshaft pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten
the nuts to the specified torque 20 ± 2 N⋅m + 90°
to 94°.
4. Remove the nuts, then remove the connecting rod
AK202787
cap carefully.
1. Measure the clearance between each piston ring

and its groove. If the limit is exceeded, replace the
ring or piston, or both.
Standard values:
No. 1 ring: 0.02 − 0.06 mm
No. 2 ring: 0.02 − 0.06 mm
Limits: 0.1 mm
Force ring down AK202848

with piston
5. Measure the largest width of the crushed
plastigage using the ruler printed on the bag of the
plastigage.
Limit: 0.1 mm
Piston ring End gap AK202788 AB
2. Install a piston ring or oil ring side rail into the

cylinder bore and force it down with the head of a
piston until the ring is at right angles to the
cylinder wall. Measure the end gap with a
thickness gauge.
NOTE: . If the end gap is excessive, replace the
piston ring.
Standard values:
No. 1 ring: 0.20 − 0.30 mm
No. 2 ring: 0.30 − 0.45 mm
Oil ring: 0.10 − 0.40 mm
Limits:
No. 1 ring: 0.8 mm
No. 2 ring: 0.8 mm
Oil ring: 1.0 mm
11B-59
M1113008700886
CAUTION
On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown in
the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Removing
the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in damage.
3 2
Apply engine oil to
all moving parts 11 ± 1 N·m 1
6 132 ± 5 N·m
9
8 4 A
16 5
9.0 ± 1.0 N·m

11 ± 1 N·m 7
15
14
13
12
11
25 ± 2 N·m → +90º to 100º

10
AK400852AB

1. Flywheel bolt >>D<< 9. Oil seal
2. Adapter plate >>C<< 10. Bearing cap bolt
3. Flywheel >>C<< 11. Beam bearing cap
4. Adapter plate >>B<< 12. Crankshaft bearing, lower
5. Crankshaft bushing 13. Crankshaft
6. Rear plate >>B<< 14. Crankshaft bearing, upper
7. Bell housing cover >>A<< 15. Thrust bearing
>>E<< 8. Oil seal case 16. Cylinder block
INSTALLATION SERVICE POINTS <Bearing selection example>

>>A<< THRUST BEARING INSTALLATION If the crankshaft journal diameter mark is “0” and
the cylinder block bearing bore mark is “1,” then
select a bearing with a “2” mark as the No. 1, 2, 4
or 5 bearing and a bearing with a “1” mark as the
No. 3 bearing.
If the crankshaft journal diameter mark is illegible,
measure the journal diameter and select a
bearing with the mark corresponding to the
Groove
measurement.
AK202769 AB Timing belt side
Install the two thrust bearings in the No. 3 bearing Diameter identification marks of
bore in the cylinder block. Each thrust bearing must bearing bores in cylinder block
be installed with the grooved end toward the crank-
No. 4
shaft web. No. 3
No. 1 No. 2 No. 5
NOTE: Applying engine oil to the bearings will help
facilitate holding them in position.
>>B<< CRANKSHAFT BEARING

INSTALLATION
Cylinder
Location of crankshaft journal bore size
diameter marks mark
No. 2
No. 1 No. 3
AK304518AB
No. 4 No. 5 AK304413 AB
2. The diameter identification marks of the bearing
1. Location of crankshaft journal diameter marks bores in the cylinder block are stamped in the
location shown in the drawing.
Crankshaft journal diameter Cylinder block Crankshaft bearing marking
Identification mark Journal diameter bearing bore No. 1, 2, 4 and 5 No. 3 bearing
measurement mm marking bearing
0 56.994 − 57.000 0 1 0
1 2 1
2 3 2
1 56.988 − 56.994 0 2 1
1 3 2
2 4 3
2 56.982 − 56.988 0 3 2
1 4 3
2 5 4
11B-61
Crankshaft bearing size mark location

>>C<< BEAM BEARING CAP/BEARING
size mark CAP BOLT INSTALLATION
1. Install the beam bearing cap on the cylinder block
with the arrow pointing to the timing belt.
Size mark
AK202753 AB
3. The size mark of each crankshaft bearing is

indicated by ink in the location shown in the Nominal length
drawing.
AK202805 AB
2. Measure the nominal length of each bearing cap

Groove bolt before installation. If the measurement
exceeds the limit, replace the bolt.
Limit: 71.1 mm
3. Apply engine oil to the threads and bearing
surface of the bolt.
Upper bearing half
Lower bearing half

AK202770 AB
8 4 1 5 9
4. Install bearing halves with oil grooves in the
cylinder block bearing bores.
5. Install bearing halves with no oil grooves in the
7 3 2 6 10
beam bearing cap.
Arrow AK202737 AB

sequence.
5. Make a paint mark on the head of the bolt.
6. Make a paint mark on the bearing cap at a point
90 to 100° away from the paint mark made on the
bolt head in the tightening direction.
Paint mark Paint mark
90˚ to 100˚
AK202722 AB
CAUTION >>D<< REAR OIL SEAL INSTALLATION

quate tightness could not be assured.
• If the tightening angle exceeds 100°, loosen MB990938
the bolt completely and then perform the
tightening again beginning with the first step.
MD998776
7. Turn clockwise the bolts 90° to 100° in the
indicated tightening sequence to bring the mark
on each bolt head into alignment with that on the
bearing cap.
AK202827 AB
Use the special tools to press-fit the rear oil seal in

the rear oil seal case.
• Handle (MB990938)
• Crankshaft rear oil seal installer (MD998776)
>>E<< REAR OIL SEAL CASE

INSTALLATION
1. Remove completely old FIPG remaining on the
AK202823
rear oil seal case and cylinder block.
8. After installing the beam bearing cap, measure
the end play of the crankshaft. If the end play
exceeds the limit, replace the crankshaft bearings.
Limit: 0.4 mm
AK202824AB
2. Apply a bead of FIPG to the surface of the rear oil

seal case as shown in the drawing.
Specified sealant:
equivalent
3. Install the oil seal into the cylinder block after
applying an appropriate amount of engine oil to
the entire circumference of its lip portion.
4. Install the rear oil seal case by tightening its bolts
to 11 ± 1 N⋅m.
11B-63
INSPECTION CYLINDER BLOCK
M1113008800656
1. Visually check the cylinder block for scratches,
CRANKSHAFT OIL CLEARANCE rust, and any other corrosion. Also check it for
(PLASTIGAGE METHOD) cracks using a flaw detecting penetrant.
This plastigage method is recommended as a sim- If any defect is evident, replace the cylinder block.
plest way of measuring the crankshaft oil clearance.
Measure the crankshaft oil clearance using a plasti-
gage as follows:
1. Wipe off oil from the crankshaft journal surface
and the crankshaft bearing inner surface.
2. Install the crankshaft.
Plastigage
AK401851
2. Use a straightedge and thickness gauge to check

the cylinder block top surface for warp.
Make sure that the surface is free from remaining
gasket material and other foreign matter.
AK202826 AB
Standard value: 0.05 mm
3. Cut a piece of plastigage whose length is Limit: 0.1 mm
equivalent to the width of the bearing and place it 3. Check cylinder walls for scratches and seizure.
on the crankshaft journal in parallel with its axis.
If defects are evident, rebore to oversize or
4. Install the crankshaft bearing cap carefully and
replace the cylinder block.
tighten the bolts to the specified torque of 25 ± 2
N⋅m + 90° to 100°.
5. Remove the bolts, then remove the crankshaft
bearing cap carefully.
12 mm
Center
Bottom
AK202731 AB
4. Use a cylinder gauge to measure the cylinder

Plastigage bore diameter and taper.
AK202822 AB
If the cylinder is worn badly, rebore it to an
6. Measure the largest width of the crushed oversize and replace the piston and piston rings
plastigage using the ruler printed on the bag of the with ones matched with the new bore size.
plastigage. Standard value: 85.0 mm
Standard value: Taper: 0.01 mm
No.1,2,4,5 journal: 0.02 − 0.03 mm
No.3 journal: 0.03 − 0.04 mm
Limit: 0.1 mm
BORING CYLINDERS 3. Based on the piston diameter measurement,

1. Select an oversize of the pistons to be used calculate the boring finish dimension.
based on the largest of the cylinder bores. • Boring finish dimension = [Piston diameter] +
[0.02 − 0.04 mm (clearance between piston and
cylinder)] − [0.02 mm (honing margin)]
CAUTION
To prevent deformation of cylinder block that
would result from the heat generated by boring,
bore the cylinders in the following sequence: No.
2 → No. 4 → No. 1 → No. 3.
4. Bore all the cylinders to the calculated boring
11.65 mm
Piston diameter finish dimension.
AK400853 AB 5. Hone the bored cylinders to the final finish
dimension (piston diameter + clearance between
2. Oversize pistons are available in two oversizes:
piston and cylinder).
0.50 mm and 1.00 mm. Bore each cylinder to a
size that provides the standard clearance when 6. Check the clearance between the piston and
combined with the selected piston. The reference cylinder.
position for piston diameter measurement is as Standard value: 0.02 − 0.04 mm
11C-1
GROUP 11C
ENGINE
MECHANICAL
<4G63-Turbo>
CONTENTS
SERVICE SPECIFICATIONS. . . . . . . 11C-2 CAMSHAFT AND VALVE STEM

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11C-17
SEALANTS . . . . . . . . . . . . . . . . . . . . 11C-2 REMOVAL AND INSTALLATION . . . . . . . . 11C-17
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11C-3 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11C-25

REMOVAL AND INSTALLATION . . . . . . . . 11C-25
ON-VEHICLE SERVICE. . . . . . . . . . . 11C-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11C-27
DRIVE BELT TENSION CHECK. . . . . . . . . 11C-7
AUTO-TENSIONER CHECK . . . . . . . . . . . 11C-7 CRANKSHAFT OIL SEAL . . . . . . . . . 11C-28
IGNITION TIMING CHECK . . . . . . . . . . . . . 11C-11 REMOVAL AND INSTALLATION . . . . . . . . 11C-28
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11C-12
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11C-12 CYLINDER HEAD GASKET . . . . . . . . 11C-30
COMPRESSION PRESSURE CHECK. . . . 11C-13 REMOVAL AND INSTALLATION . . . . . . . . 11C-30
MANIFOLD VACUUM CHECK . . . . . . . . . . 11C-14
LASH ADJUSTER CHECK . . . . . . . . . . . . . 11C-14 TIMING BELT . . . . . . . . . . . . . . . . . . . 11C-34
CRANKSHAFT PULLEY . . . . . . . . . . 11C-16 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11C-42
ENGINE ASSEMBLY . . . . . . . . . . . . . 11C-43
11C-2 ENGINE MECHANICAL <4G63-Turbo>
M1112000300869

Drive belt tension Vibration frequency Hz 142 − 174 −
(Reference)
Ignition timing Approximately 5° −
BTDC
Idle speed r/min 750 ± 100 −
Compression pressure kPa-r/min 1,270 − 250 880 − 250
SEALANTS
M1112000500410
Item Specified Sealant Remark

Cylinder head MITSUBISHI GENUINE PART MD970389 or Semi-drying
Camshaft position sensor support equivalent sealant
Rocker cover
Camshaft end seal 3M ATD Part No. 8660 or equivalent
Rocker cover gasket MITSUBISHI GENUINE PART MD970389 or
Engine upper oil pan equivalent
Engine lower oil pan
ENGINE MECHANICAL <4G63-Turbo>
SPECIAL TOOLS
11C-3
SPECIAL TOOLS
M1112000601302
A
B
B992080

B991502

MB991824
C
F: M.U.T.-III trigger harness Drive belt tension check
DO NOT USE
MB991910
MB991911
MB991825
MB991826
MB991955
SPECIAL TOOLS

M.U.T.-III)
B991668
MD998772
MD998737 Valve stem seal installer Valve stem seal installation
D998713
MD998781 Flywheel stopper Supporting the flywheel
D998781

installation

installer
D998776
SPECIAL TOOLS
11C-5
guide installation
D998285

installer

B991654

tensioner adjuster
D998738

drive sprocket
B991367
MB991385 Pin
B991385

adjustment
D998767
SPECIAL TOOLS

B991454
assembly
B991527
Z203830

B: MB991930 B: Joint (90) × 2
E C: MB991931 C: Joint (140) × 2
D
B
C
B991928
ON-VEHICLE SERVICE
11C-7
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK 4. If there are any problems in the procedure 1 or 3,
M1111003100805 replace the auto-tensioner.(Refer to P.11C-34).
CAUTION 5. Install the drive belt.(Refer to P.11C-16).
crankshaft clockwise one turn or more. FUNCTION CHECK
good condition by checking its tension.
Indicator mark
A
1. Check the drive belt tension (Refer to P.11C-7).
AC301702AB
Belt tension meter set (MB992080)
area marked with A in the illustration. MB992081
2. If the mark is out of the area, replace the drive

belt. (Refer to P.11C-16).
sary as auto-tensioner is adopted.
MB992082
AUTO-TENSIONER CHECK
M1111003000897 AC507219AB
OPERATION CHECK (1) Connect special tool microphone assembly

1. Turn OFF the engine from the idle state then (MB992082) to special tool belt tension meter
check to see that the drive belt is not protruding (MB992081) of special tool belt tension meter
from the pulley width of the auto-tensioner. set (MB992080).
2. Remove the drive belt.(Refer to P.11C-16). (2) Press the "POWER" button to turn on the
power supply.
(3) Press the numeral key of "1" and check that
"No. 1" appears on the upper left of the
display.
AC301703
judgement of error.
3. Securely insert the spindle handle or ratchet to the frequency display (Hz).
no threading.
ON-VEHICLE SERVICE
CAUTION (8) Press and hold the "POWER" button to turn off
• The temperature of the surface of the belt the power supply.
should be as close to normal temperature as 3. If not within the standard value, replace the
possible. auto-tensioner (Refer to P.11C-34).
or oil to get onto the microphone. When the vibration frequency is
• If strong gusts of wind blow against the measured (M.U.T.-II is used):
microphone or if there are any loud sources Recommendation
of noise nearby, the values measured by the 1. Check the drive belt tension. (Refer to P.11C-7).
values.
the measurement is being made, the values CAUTION
cle's engine is running. 16-pin
Power steering
10 – 15 mm
oil pump pulley
MB992080 15˚
Water pump 15˚

pulley
Gentry tap with MUT-II

your finger
AC102806AE
(5) Hold special tool MB992080 to the middle of

indicated by arrow) where it does not contact MB991668
the rear surface of the belt) so that it is AC211862 AB
15°).
(6) Press the "MEASURE" button. before connecting or disconnecting M.U.T.-II.
(7) Gently tap the middle of the belt between the (1) Connect special tool belt tension meter set
pulleys (the place indicated by the arrow) with (MB991668) to the M.U.T.-II.
connector.
Standard value: 142 − 174 Hz select "BELT TENSION" on the menu screen.
NOTE: To take the measurement repeatedly,
fillip the belt again.
ON-VEHICLE SERVICE
11C-9
CAUTION When the vibration frequency is
• The temperature of the surface of the belt measured (V.C.I. is used):
should be as close to normal temperature as Recommendation
possible.
1. Check the drive belt tension. (Refer to P.11C-7).
• If strong gusts of wind blow against the
microphone or if there are any loud sources CAUTION
values.
• If the microphone is touching the belt while 16-pin
Power steering
10 – 20 mm
oil pump pulley
MB991668 15˚
MB991824
Water pump 15˚
pulley
MB991668
Gentry tap with
your finger
MB991911
AC102806AB
AC211863AB
disconnecting special tool V.C.I. (MB991824).
15 degree).
your finger as shown in the illustration, and (3) Connect special tool M.U.T.-III main harness B
measure that the vibration frequency of the (MB991911) to the diagnosis connector.
belt is within the standard value. (4) Turn the ignition switch to "ON" position, and
select "Belt Tension" on the menu screen.
auto-tensioner. (Refer to P.11C-34).
ON-VEHICLE SERVICE
CAUTION (6) Gently tap the middle of the belt between the
• The temperature of the surface of the belt pulleys (the place indicated by the arrow) with
should be as close to normal temperature as your finger as shown in the illustration, and
possible. measure that the vibration frequency of the
• Do not allow any contaminants such as water belt is within the standard value.
or oil to get onto the microphone. Standard value: 142 − 174 Hz
• If strong gusts of wind blow against the 3. If not within the standard value, replace the
microphone or if there are any loud sources alternator drive belt auto tensioner. (Refer to
of noise nearby, the values measured by the P.11C-34).
values. When the tension is measured
• If the microphone is touching the belt while 1. Check the drive belt tension. (Refer to P.11C-7).
measured by the microphone may not corre- Belt tension gauge Power steering
oil pump pulley
Water pump
pulley
Power steering
10 – 20 mm
oil pump pulley
MB991668 15˚
Water pump 15˚

pulley
AC102807AB
Gentry tap with

2. Use a belt tension gauge in the middle of the belt
your finger between the pulleys (at the place indicated by the
arrow) to measure that the belt tension is within
AC102806AB the standard value.
(5) Hold special tool belt tension meter set Standard value: 390 − 586 N
(MB991668) to the middle of the drive belt 3. If not within the standard value, replace the
between the pulleys (at the place indicated by auto-tensioner. (Refer to P.11C-34).
15 degree).
ON-VEHICLE SERVICE
11C-11
IGNITION TIMING CHECK 3. Connect a timing light.
M1111001700986
and check that it is within the standard value.
standard value.
16 PIN Standard value: 5° BTDC ± 3°
MB991502
AK303691AF
8. If the basic ignition timing is outside the standard
value, inspect the MPI system.
(Refer to P.13B-20, GROUP 13B −
code.)
16-PIN CAUTION
driving cancel mode) to release the Actuator test.
MB991911 10.Check that ignition timing is at the standard value.
Standard value:
NOTE: .
• In higher altitude, the ignition timing is more
mately 5°.
MB991827 AK303690AB
1. Before inspection, set the vehicle to the 12.Turn off the ignition switch to the "LOCK" (OFF)
pre-inspection condition. position and then remove the M.U.T.-II/III.
ON-VEHICLE SERVICE
IDLE SPEED CHECK (Refer to P.13B-20, GROUP 13B −

M1111003500900 Troubleshooting − Inspection chart for diagnosis
code.)
IDLE MIXTURE CHECK

M1111002100675
16 PIN
MB991502
AK303691AF
16 PIN
MB991502
16-PIN
AK303691AF
MB991911 16-PIN
MB991824
MB991911
MB991824
MB991827 AK303690AB

diagnosis connector. MB991827 AK303690AB
Standard value: position and then connect the M.U.T.-II/III to the
approximately 5° BTDC diagnosis connector.
6. Check the idle speed. 3. Connect a timing light.
Standard value: 750 ± 100 r/min 4. Start the engine and let it run at idle.
NOTE: . 5. Check that ignition timing is at the standard value.
• The idle speed is controlled automatically by Standard value:
the idle speed control system. approximately 5° BTDC
and take a reading of the idle speed. 6. Run the engine at 2,500 r/min for 2 minutes.
7. If the idle speed is outside the standard value, 7. Set the CO, HC tester.
inspect the MPI system.
ON-VEHICLE SERVICE
11C-13
8. Check the CO contents and the HC contents at CAUTION
idle. • Keep away from the spark plug hole when
Standard value cranking.
CO contents: 0.5% or less • If compression is measured with water, oil,
HC contents: 100 ppm or less fuel, etc., that has come from cracks inside
9. If there is a deviation from the standard value, the cylinder, these materials will become
check the following items: heated and will gush out from the spark plug
• Diagnosis output hole, which is dangerous.
• Fuel pressure 5. Cover the spark plug hole with a shop towel etc.,
• Injector and after the engine has been cranked, check that
• Ignition coil, spark plug cable, spark plug no foreign material is adhering to the shop towel.
• EGR control system 6. Set compression gauge to one of the spark plug
• Evaporative emission control system holes.
• Compression pressure 7. Crank the engine with the throttle valve fully open
NOTE: Replace the three way catalyst when the and measure the compression pressure.
CO and HC contents are not within the standard Standard value (at engine speed of 250
value, even though the result of the inspection is r/min):
normal on all items. 1,270 kPa
Minimum 880 kPa
COMPRESSION PRESSURE CHECK 8. Measure the compression pressure for all the
M1111002601026 cylinders, and check that the pressure differences
of the cylinders are below the limit.
Limit: Maximum 98 kPa
Crank angle 9. If there is a cylinder with compression or a
sensor compression difference that is outside the limit,
connector
spark plug hole, and repeat the operations in
steps from (6) to (8).
(1) If the compression increases after oil is added,
the cause of the malfunction is a worn or
AK201364AC
1. Before inspection, set the vehicle to the surface.
pre-inspection condition. (2) If the compression dose not rise after oil is
2. Disconnect the spark plug cables. added, the cause is a burnt or defective valve
3. Remove all of the spark plugs. seat, or pressure is leaking from the gasket.
4. Disconnect the crank angle sensor connector. 10.Connect the crank angle sensor connector.
NOTE: Doing this will prevent the engine-ECU 11.Install the spark plugs and spark plug cables.
from carrying out ignition and fuel injection. 12.Use the M.U.T.-II/III to erase the diagnosis codes.
NOTE: This will erase the diagnosis code result-
disconnected.
ON-VEHICLE SERVICE
MANIFOLD VACUUM CHECK 4. Start the engine and check that idle speed is
M1111002700804 within the standard valve.
5. Check the intake manifold vacuum.
Limit: Minimum 60 kPa
6. Turn off the ignition switch.
7. Remove the vacuum gauge and the three-way
joint, and then connect the vacuum hose.
16 PIN
MB991502 8. Turn the ignition switch to the "LOCK" (OFF)
AK303691AF
LASH ADJUSTER CHECK

M1111002900778
If an abnormal noise (knocking) that seems to be
coming from the lash adjuster is heard after starting
the engine and dose not stop, carry out the following
16-PIN
check.
NOTE: .
• If the vehicle is parked on a slope fir a long period
of time, the amount of oil inside the lash adjuster
will decrease, and air may get into the high pres-
sure chamber when starting the engine.
MB991911
• After parking the vehicle for long periods, the oil
drains out of the oil passage, and it takes time for
MB991824
the oil to be supplied to the lash adjuster, so air
can get into the high-pressure chamber.
• If either of the above situations occur, the abnor-
mal noise can be eliminated by bleeding the air
from inside the lash adjusters.
• The abnormal noise which is caused by a prob-
lem with the lash adjusters is generated after the
MB991827 AK303690AB
engine is started, and will vary according to the
1. Before inspection, set the vehicle to the engine speed. However, this noise is not related
pre-inspection condition. to the actual engine load.
Because of this, if the noise dose not occur immedi-
ately after the engine is started, if it dose not
change in accordance with the engine speed, or if
it changes in accordance with the engine load,
Fuel pressure control Vacuum gauge the source of the noise is not the lash adjusters.
solenoid valve • 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.
AK200362AC
2. Check that the noise occurs immediately after the
3. Attach a three-way joint to the vacuum hose engine is started, and that the noise changes in
between the fuel pressure control solenoid valve accordance with changes in the engine speed.
and the air intake plenum, and connect a vacuum
gauge.
ON-VEHICLE SERVICE
11C-15
If the noise dose not occur immediately after the • If the oil is degenerated, air and oil will not
engine is started, or if it dose not change in separate easily in oil, and the amount of air
accordance with the engine speed, the problem is mixed into the oil will increase.
not being caused by the lash adjusters, so check
for some other cause of the problem. Moreover, if
the noise dose 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. High-pressure chamber
If the noise level changes, the cause of the noise AK100001AC
is probably parts striking because of worn • If the air which has been mixed in with the oil
crankshaft bearings or connecting rod bearings due to any of the above reasons gets into the
(In such cases, the lash adjusters are normal). high pressure chamber of the lash adjuster,
4. After the engine has warmed up, run it at idle and the air inside the high pressure chamber will
check if any noise can be heard. be compressed when the valve is open and
the lash adjuster will over-compress, resulting
If the noise has become smaller or disappeared,
in abnormal noise when the valve close. This
oil sludge could make the lash adjusters stick.
is the same effect as if the valve clearance is
Clean the lash adjusters (Refer to GROUP 11D −
adjusted to be too large by mistake. If the air
Rocker Arms and Camshaft − Inspection
inside the lash adjusters is then released, the
P.11D-35). If not improved, go to step 5.
operation of the lash adjusters will return to
5. Bleed air from the lash adjusters (Refer to normal.
P.11C-15).
Drive pattern for air breeding
6. If the noise has not disappeared even after the air
Gradually open
bleeding, clean the lash adjusters (Refer to the throttle valve Close the throttle valve
GROUP 11D − Rocker Arms and Camshaft − Approximately
Inspection P.11D-35). 3,000 r/min
<LASH ADJUSTER AIR BLEEDING>
Idle speed 15 s 15 s
Once
AKX00330AE
Good
2. Run the engine at idle for 1 − 3 minutes to let it
Max
warm up.
3. With no load on the engine, repeat the drive
pattern shown in the illustration above and check
Min.
if the abnormal noise disappears (The noise
AKX00328 AE
should normally disappear after 10 − 30
1. Check the engine oil and replenish or replace the repetitions, but if there is no change in the noise
oil if necessary. level after 30 repetitions or more, the problem is
NOTE: . probably not due to air inside the lash adjusters).
• If there is an only small amount of oil, air will 4. After the noise has disappeared, repeat the drive
be drawn in through the oil screen and will get pattern shown in the illustration above a further 5
into the oil passage. times.
• If the amount of oil is greater than normal, then 5. Run the engine at idle for 1 − 3 minutes and check
the oil will being mixed by the crankshaft and a that the noise has disappeared.
large amount of air may get mixed into the oil.
CRANKSHAFT PULLEY
CRANKSHAFT PULLEY
M1112001600670

• Under Cover Removal (Refer to GROUP 51, Under Cover • Drive Belt Tension Check (Refer to P.11C-7).
Cover P.51-31).
2
1
25 ± 4 N·m
AC401176AB
Removal steps 1. Securely insert the spindle handle or ratchet

<<A>> 1. Drive belt handle with a 12.7 mm insertion angle into the jig
2. Crank shaft damper pulley hole of the auto-tensioner.
REMOVAL SERVICE POINT
hole A with hole B.
<<A>> DRIVE BELT REMOVAL
CAUTION
The following operations will be needed due to the To reuse the drive belt, draw an arrow indicating
introduction of the serpentine drive system with the the rotating direction (clockwise) on the back of
drive belt auto-tensioner. the belt using chalk, etc.
AC301703
Auto-tensioner
Auto-tensioner
Hole B
Hole A L-shaped
hexagon
AC301704AB wrench AC301705AB
3. Insert an L-shaped hexagon wrench, etc. into the

11C-17
M1112006600482
CAUTION
*Remove and assemble the marked parts in each cylinder unit.
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Valve Timing Belt Installation (Refer to P.11C-34).
Service − Engine Coolant Replacement P.14-17). • Battery Installation
• Intercooler Removal (Refer to GROUP 15, Intercooler • Accelerator Cable Installation (Refer to GROUP 17,
P.15-9). Accelerator Cable and Pedal P.17-7).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-7). P.15-7).
• Accelerator Cable Removal (Refer to GROUP 17, Accel- • Intercooler Installation (Refer to GROUP 15, Intercooler
erator Cable and Pedal P.17-7). P.15-9).
• Battery Removal • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Valve Timing Belt Removal (Refer to P.11C-34). Service − Engine Coolant Replacement P.14-17).
• Accelerator Cable Adjustment (Refer to GROUP 17,
On-vehicle Service − Accelerator Cable Check and
Adjustment P.17-6).
• Drive Belt Tension Check (Refer to P.11C-7).
11 ± 1 N·m
11 ± 1 N·m 9
3.0 ± 0.5 N·m 1 4 11 ± 1 N·m
3.5 ± 0.5 N·m

6
11 ± 1 N·m
3.5 ± 0.5 N·m
8 10
7
10.5 ± 0.5 N·m

11
3 N 13 14
11 ± 1 N·m
12 N
4
2
AC401177AB

1. Rocker cover centre cover 7. Rocker cover breather hose
• Spark plug cables and ignition coils 8. Rocker cover PCV hose
(Refer to GROUP 16, Ignition Coil 9. Vacuum hose and pipe assembly
P.16-46.) >>N<< 10. Rocker cover
2. Oxygen sensor (front) connector >>M<< 11. Camshaft end seal
3. Crank angle sensor connector 12. Spark plug hole gaskets
4. Control wiring harness connection >>L<< 13. Rocker cover gasket
5. Camshaft position sensor <<A>> >>K<< 14. Radiator upper hose connection
connector
6. Capacitor connector
22
24
Apply engine oil to all
26 27 moving parts before
20 ± 1 N·m 25 installation.
23
21 28
N 20
19
11 ± 1 N·m
89 ± 9 N·m
32 15
25 ± 4 N·m 31 22 ± 4 N·m
17
33* 18
34* 29 10 ± 2 N·m
35* 30
N 36* 16 N
38* 14 ± 1 N·m
33*
34*
35*
37* N
38*
AC401570 AB

15. Camshaft position sensor support >>F<< 26. Camshaft bearing caps, No.4
cover >>E<< 27. Inlet camshaft
16. Camshaft position sensor support >>E<< 28. Exhaust camshaft
cover gasket 29. Rocker arms
>>J<< 17. Camshaft position sensing cylinder >>D<< 30. Rocker arm lash adjusters
>>I<< 18. Camshaft position sensor support 31. Oil delivery body
<> >>H<< 19. Camshaft sprockets 32. Spark plugs
>>G<< 20. Camshaft oil seals <<C>> >>C<< 33. Valve spring retainer locks
>>F<< 21. Camshaft bearing caps, front 34. Valve spring retainers
>>F<< 22. Camshaft bearing caps, rear >>B<< 35. Valve springs
>>F<< 23. Camshaft bearing caps, No.2 >>A<< 36. Inlet valve stem seals
>>F<< 24. Camshaft bearing caps, No.5 >>A<< 37. Exhaust valve stem seals
>>F<< 25. Camshaft bearing caps, No.3 38. Valve spring seats
11C-19
LUBRICATION AND SEALING POINTS
<The bottom view of the rocker cover>
10 mm 10 mm

Rocker
<View A> cover
Cylinder
10 mm A head
10 mm 10 mm Sealant: 3M ATD Part No.8660

or equivalent
A
Sealant: A
MITSUBISHI GENUINE
PART MD970389 or
equivalent
φ 3 mm
(Lip section) Sealant: MITSUBISHI GENUINE

Engine oil AC211726
<Top view of cylinder head>

REMOVAL SERVICE POINTS <<C>> VALVE SPRING RETAINER LOCKS

<<A>> RADIATOR UPPER HOSE DISCON- REMOVAL
NECTION CAUTION
When removing valve spring retainer locks, leave
Centre) position. The valve may fall into the cylin-
der if the piston is not properly in the TDC posi-
tion.
Mating marks
MD998772
AC200641AC

<> CAMSHAFT SPROCKETS AC201799 AB

REMOVAL Use special tool valve spring compressor
(MD998772) to compress the valve spring, remove
the valve spring retainer locks.

>>A<< EXHAUST VALVE STEM
SEALS/INLET VALVE STEM SEALS
INSTALLATION
AC201457AB Grey Grey green

wrench.
2. Loosen the camshaft sprocket mounting bolts and
remove the camshaft sprocket.

AC201542AB
1. Check the valve stem seal colour to identify the

inlet side or exhaust side.
stem seals.
11C-21
CAUTION >>D<< ROCKER ARM LASH ADJUSTERS
• Valve stem seals cannot be reused. INSTALLATION
• The special tool valve stem seal installer CAUTION
(MD998737) must be used to install the valve If the rocker arm lash adjuster is reused, always
stem seal. Improper installation could result clean and check it before installation. (Refer to
in oil leaking past the valve guide. GROUP 11D, Rocker Arms and Camshaft −
Inspection P.11D-35).
MD998737
>>E<< EXHAUST CAMSHAFT/INLET
Valve
CAMSHAFT INSTALLATION
Valve stem 1. Remove sealant remained on the cylinder head.
seal
2. Apply engine oil to the cam and the journal of the
Valve guide camshaft.
CAUTION
AC308920AB
3. Use special tool to fill a new valve stem seal in the Engine front
valve guide using the valve stem area as a guide.
>>B<< VALVE SPRINGS INSTALLATION Slit
Rocker arm side

Exhaust camshaft
AC201458AB
Do not install wrong camshaft at the side of inlet

or exhaust. The exhaust camshaft has a slit at the
Identification
colour
rear surface.
3. Install the camshaft to the cylinder head.
AC201453AB
Install the valve springs with its identification colour >>F<< CAMSHAFT BEARING CAPS, NO.
painted end facing the locker arm. 4/CAMSHAFT BEARING CAPS, NO.
3/CAMSHAFT BEARING CAPS, NO.
>>C<< VALVE SPRING RETAINER LOCKS 5/CAMSHAFT BEARING CAPS, NO.
INSTALLATION 2/CAMSHAFT BEARING CAPS,
REAR/CAMSHAFT BEARING CAPS,
FRONT INSTALLATION
MD998772
Approximately 3˚
Dowel pin
AC201799 AB
Use special tool valve spring compressor Inlet side Exhaust side
(MD998772) to compress the valve spring in the
AC201459AB
same manner as removal.
1. Set the dowel pin of the camshaft to the position
as shown in the illustration.
5. Check the identification marks on the camshaft

bearing caps, front so that inlet side and exhaust
side cannot be mistaken in the same way as that
Bearing of bearing caps No.2 − 5.
Engine front cap No.
CAUTION
E4
Identification of Then wait at least one hour. Never start the
inlet side and engine or let engine oil or coolant touch the
exhaust side adhesion surface during that time.
6. Tighten the bearing cap mounting bolts increasing
AC201460AB
the pressure in 2 to 3 times and finally tighten to
2. Since the shape of camshaft bearing caps No.2 − the specified torque.
5 is identical, check the identification marks so Tightening torque: 20 ± 1 N⋅m
that the bearing cap No., inlet side, or exhaust 7. Ensure that the rocker arms are installed properly.
side cannot be mistaken to install to the direction
as shown in the illustration. NOTE: Remove an excess of sealant completely.
Identification mark (engraved on the front
and bearing caps No.2 − 5) >>G<< CAMSHAFT OIL SEALS
I: Inlet side INSTALLATION
E: Exhaust side
Engine front
MD998713 AC102323AB
AC201461AB 1. Apply engine oil to the entire inner diameter of the

oil seal lip.
upper side of the cylinder head as shown in the 2. Use special tool camshaft oil seal installer
illustration. (MD998713) to press-fit the oil seals.
PART MD970389 or equivalent >>H<< CAMSHAFT SPROCKETS
NOTE: Install the camshaft bearing caps, rear and INSTALLATION
camshaft bearing caps, front within 15 minutes
Front
Engine front marking
AC201457AB

AC201462AB
wrench in the same manner as removal.
4. Position the camshaft bearing caps, rear in the 2. Tighten the camshaft sprocket mounting bolts to
direction as shown in the illustration for the specified torque.
installation. Tightening torque: 89 ± 9 N⋅m
11C-23
>>I<< CAMSHAFT POSITION SENSOR 2. Install the vane (small) of the camshaft position
SUPPORT INSTALLATION sensing cylinder at an angle of approximately 45
degrees to the position of the dowel pin of the
1. Remove sealant from the camshaft position
exhaust camshaft.
sensor support and cylinder head surfaces.
3. Tighten the camshaft position sensing cylinder
>>K<< RADIATOR UPPER HOSE

CONNECTION
Projection
φ 3 mm AC201463AB
2. Apply the sealant to the camshaft position sensor

support flange in a continuous bead as shown in
the illustration.
Specified sealant: MITSUBISHI GENUINE Water outlet fitting Mating marks
AC200642 AE
NOTE: Install the camshaft position sensor sup-
port within 15 minutes after applying liquid gasket. 1. Insert each hose as far as the projection of the
3. Install the camshaft position sensor support to the water outlet fitting.
cylinder head. 2. Align the mating marks on the radiator hose and
CAUTION hose clamp, and then connect the radiator hose.
engine or let engine oil or coolant touch the >>L<< ROCKER COVER GASKET
adhesion surface during that time. INSTALLATION
4. Tighten the camshaft position sensor support 1. Remove sealant remained on the rocker cover.
>>J<< CAMSHAFT POSITION SENSING

CYLINDER INSTALLATION
Approximately 45˚
Dowel pin
Vane (small)
AC201465AB

lower side of the rocker cover as shown in the
illustration.
Vane (large) Specified sealant: MITSUBISHI GENUINE
AC201464AB PART MD970389 or equivalent
1. Set the dowel pin of the exhaust camshaft to the NOTE: Install the rocker cover gasket within 15
position (No.1 cylinder at compression TDC) as minutes after applying liquid gasket.
shown in the illustration. 3. Install the rocker cover gasket to the rocker cover.
NOTE: Use the force of the exhaust valve spring
to rotate anti-clockwise.
>>M<< CAMSHAFT END SEAL >>N<< ROCKER COVER INSTALLATION

INSTALLATION
Engine front
AC201469AB
1. Apply sealant to the positions of the rocker cover

gasket (6 areas) as shown in the illustration.
10 mm Specified sealant: MITSUBISHI GENUINE
10 mm NOTE: Install the rocker cover within 15 minutes
2. Install the rocker cover to the cylinder head.
CAUTION
Cylinder head Then wait at least one hour. Never start the
AC201468 AB engine or let engine oil or coolant touch the
Apply sealant to the positions of the camshaft end
seal as shown in the illustration and install to the cyl- 3. Tighten the rocker cover mounting bolts to the
inder head. specified torque.
Specified sealant: 3M ATD Part No.8660 or Tightening torque: 3.5 ± 0.5 N⋅m
equivalent
NOTE: . Install the camshaft end seal within 15 min-
utes after applying liquid gasket.
OIL PAN
11C-25
OIL PAN
M1112002800989

• Under Cover Removal (Refer to GROUP 51, Under Cover • Starter Assembly Installation (Refer to GROUP 16, Starter
P.51-31). Motor Assembly P.16-26).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Centre Member Installation (Refer to GROUP 32, Engine
Service − Engine Oil Replacement P.12-4). Roll Stopper and Centre Member P.32-11).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-27). Exhaust Pipe and Main Muffler P.15-27).
• Centre Member Removal (Refer to GROUP 32, Engine • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Roll Stopper and Centre Member P.32-11). Service − Engine Oil Replacement P.12-4).
• Starter Assembly Removal (Refer to GROUP 16, Starter • Under Cover Installation (Refer to GROUP 51, Under
Motor Assembly P.16-26). Cover P.51-31).
N1 6N
48 ± 7 N·m
2
N 7
11 9.0 ± 1.0 N·m
5
N 1
12 ± 2 N·m 14 ± 1 N·m
48 ± 7 N·m
44 ± 10 N·m
N9
9.0 ± 3.0 N·m
9.0 ± 1.0 N·m
10
3
39 ± 5 N·m 8 9.0 ± 3.0 N·m
9.0 ± 3.0 N·m
22 ± 4 N·m
AC401138 AB

1. Engine oil cooler tube gaskets 7. Oil return tube gasket
2. Engine oil cooler hose and bracket 8. Engine oil pan drain plug
assembly >>C<< 9. Engine oil pan drain plug gasket
>>D<< 3. Transmission housing front lower <<A>> >>B<< 10. Engine lower oil pan
cover stay <> >>A<< 11. Engine upper oil pan
4. Flywheel housing front lower cover
5. Oil return tube
6. Oil return tube gasket
OIL PAN

REMOVAL LATION
φ 4 mm
AC401140AB

AC102931AB
REMOVAL CAUTION
Do not use special tool oil pan FIPGcutter ant surface during that time.
A B
A
B B
B B
B B
AC401139 AB

B
B
A A
AC401141AB

OIL PAN
11C-27
the order shown.
B 16 M6 × 18
(D × L)
B 11 M6 × 10
INSTALLATION
GASKET INSTALLATION
Engine lower
oil pan side
φ 4 mm
AC401142AB
AC102325 AF
Replace the gasket with a new one. Install the new
of the engine lower oil pan as shown.
minutes after applying sealant.
LOWER COVER STAY INSTALLATION
upper oil pan.
B-10
B-1 B-11 Tightening torque: 44 ± 10 N⋅m
B-4
B-7 INSPECTION
M1112002900210
B-5 B-6
• Check the oil pan sealant-coated surface for
A-3
B-8 damage and deformation.
B-9 B-12 B-2

AC401143AB
CRANKSHAFT OIL SEAL
CRANKSHAFT OIL SEAL

M1112003101050
132 ± 5 N·m
6 N 5
N 3
6
3
(Lip section) (Lip section)
Engine oil
AC401178 AB
Crankshaft front oil seal removal REMOVAL SERVICE POINT

steps
<<A>> FLYWHEEL BOLTS REMOVAL
• Valve timing belt, balancer timing
belt (Refer to P.11C-34).
>>D<< 1. Crankshaft balancer shaft drive
sprocket
2. Crankshaft key
>>C<< 3. Crankshaft front oil seal
Crankshaft front oil seal removal
steps
• Transfer assembly (Refer to
GROUP 22A, Transfer Assembly
MD998781
P.22A-12).
AC211171AB
• Clutch cover and clutch disc (Refer
to GROUP 21C, Clutch P.21C-3).
1. Use special tool flywheel stopper (MD998781) to
<<A>> >>B<< 4. Flywheel bolts
5. Flywheel assembly
secure the flywheel.
>>A<< 6. Crankshaft rear oil seal 2. Remove the flywheel mounting bolts.
CRANKSHAFT OIL SEAL
11C-29
INSTALLATION SERVICE POINTS >>C<< CRANKSHAFT FRONT OIL SEAL
>>A<< CRANKSHAFT REAR OIL SEAL INSTALLATION
INSTALLATION Crankshaft MD998375
Oil seal
(Engine oil)
MB990938
(Engine oil)
MD998285 Oil seal
(Oil applied to the
MD998776 Crankshaft
AC102328 AB 1. Apply a small amount of engine oil to the entire
1. Apply a small amount of engine oil to the entire inner diameter of the oil seal lip.
inner diameter of the oil seal lip. 2. Apply a small amount of engine oil to the outer
2. Use the following special tools to press-fit the oil diameter of special tool crankshaft front oil seal
seal. guide (MD998285) and install it to the crankshaft.
• Installer bar (MB990938) 3. Use special tool crankshaft front oil seal installer
• Crankshaft rear oil seal installer (MD998776) (MD998375) to press-fit the oil seal.
>>B<< FLYWHEEL BOLTS INSTALLATION >>D<< CRANKSHAFT BALANCER SHAFT

DRIVE SPROCKET INSTALLATION
: Clean
Crankshaft
MD998781
AC211171AB
1. Use special tool flywheel stopper (MD998781) to

secure the flywheel in the same manner as
removal.
2. Tighten the flywheel mounting bolts to the
specified torque.
Front case
Crankshaft
balancershaft
drive sprocket
Engine front
AC211222 AB

as shown.

M1112004001205

• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Valve Timing Belt Installation (Refer to P.11C-34).
On-vehicle Service − Fuel Pump Connector Disconnec- • Rocker Cover Center Cover Installation (Refer to
tion (How to Reduce Pressurized Fuel Lines) P.13B-393]. P.11C-17).
• Under Cover Removal (Refer to GROUP 51, Under Cover • Battery Installation
P.51-31). • Accelerator Cable Installation (Refer to GROUP 17,
• Engine Oil Draining (Refer to GROUP 12, On-vehicle Accelerator Cable and Pedal P.17-7).
Service − Engine Oil Replacement P.12-4). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle P.15-7).
Service − Engine Coolant Replacement P.14-17). • Intercooler Installation (Refer to GROUP 15, Intercooler
• Intercooler Removal (Refer to GROUP 15, Intercooler P.15-9).
P.15-9). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner Service − Engine Coolant Replacement P.14-17).
P.15-7). • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
• Accelerator Cable Removal (Refer to GROUP 17, Accel- Service − Engine Oil Replacement P.12-4).
erator Cable and Pedal P.17-7). • Accelerator Cable Adjustment (Refer to GROUP 17,
• Battery Removal On-vehicle Service − Accelerator Cable Check and
• Rocker Cover Center Cover Removal (Refer to Adjustment P.17-6).
P.11C-17). • Drive Belt Tension Check (Refer to P.11C-7).
• Valve Timing Belt Removal (Refer to P.11C-34). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
• Fuel Leak Check
9.0 ± 2.0 N·m

1
2
9.0 ± 2.0 N·m 8
6
7
3
6
13 ± 1 N·m
(Engine oil) N 5
AC401179 AB
11C-31
1. Control wiring harness connection 4. Engine oil level gauge and guide
2. Earth cable connection assembly
3. Brake booster vacuum hose 5 O-ring
connection 6. Canister vacuum hose connection
11
12
5.0 ± 1.0 N·m
<Cold engine>
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚ 13
14 N (Engine oil)
15
(Engine oil)
16
9
8
11 ± 1 N·m
17 N
31 ± 3 N·m
10
7
22 ± 4 N·m
AC401180 AB

7. Alternator brace bolt • Rocker cover (Refer to P.11C-17).
8. Detonation sensor connection 11. Heater water hose connection
9. Battery wiring harness connection 12. Fuel return line hose connection
10. Inlet manifold stay >>C<< 13. Fuel high-pressure hose
• Water outlet fitting and thermostat connection
case assembly (Refer to GROUP >>C<< 14. O-ring
14, Water Hose and Water Pipe <<A>> >>B<< 15. Cylinder head bolts
P.14-30). 16. Cylinder head assembly
• Turbocharger assembly (Refer to >>A<< 17. Cylinder head gasket
GROUP 15, Exhaust Manifold and
Turbocharger P.15-22).

<<A>> CYLINDER HEAD BOLTS >>A<< CYLINDER HEAD GASKET
CAUTION
Do not allow any foreign materials to get into the
1. Remove the gasket from the cylinder head and
cylinder block.
MB991654
Engine front Identification

mark "63"
3 5 10 8 2 Exhaust side
AC107217AC
1 7 9 6 4
2. Assemble to the cylinder block so the cylinder
head gasket identification mark "63" is at the top
surface and on the exhaust side.
AC201623AB
>>B<< CYLINDER HEAD BOLTS
Using special tool cylinder head bolt wrench
(MB991654), loosen the cylinder head bolts in two or INSTALLATION
three steps in the order of the numbers shown in the
illustration. (Engine oil)
NOTE: If the cylinder head bolts cannot be pulled out
due to the washer being trapped in the valve spring,
raise the bolt slightly, then remove it while holding it
by using a magnet.
AC102537AB

head bolt meets the limit. If it exceeds the limit,
replace the bolt with a new one.
Limit (A): 99.4 mm
2. Apply a small amount of engine oil to the thread of
the bolts and to the washers.
11C-33
(4) Apply a paint mark to the heads of the cylinder
head bolts and cylinder head, then tighten 90
degree angle as shown.
CAUTION
The bolt is not tightened sufficiently if the bolt is
MB991654 tightened less than 90 degree angle.
(5) Tighten the bolt an additional 90 degree angle
as shown. Then check to see that the paint
mark on the head of the cylinder head bolts
and the paint mark on the cylinder head are
aligned.
Engine front
(6) If tightening the bolt 90 degree angle results in
moving the paint mark on the bolt past the
8 6 1 3 9 paint mark on the cylinder head, remove the
bolt and start over from step 1.
10 4 2 5 7
>>C<< O-RING/FUEL HIGH-PRESSURE
HOSE INSTALLATION
CAUTION
AC201625 AB
Do not let any engine oil get into the delivery
3. Use special tool cylinder head bolt wrench pipe.
(MB991654) to tighten the cylinder head bolts as 1. Apply a small amount of new engine oil to the
follows: O-ring.
(1) Tighten the cylinder head bolts to 78 ± 2 N⋅m 2. Turning the fuel high-pressure hose to the right
in the order shown. and left, install it to the delivery pipe, while being
(2) Loosen the bolts fully in the reverse order of careful not to damage the O-ring. After installing,
that shown. check that the hose turns smoothly.
(3) Tighten the cylinder head bolts to 20 ± 2 N⋅m 3. If the hose does not turn smoothly, the O-ring is
in the order shown. probably being clamped. Disconnect the fuel
high-pressure hose and check the O-ring for
Step (4) Step (5)
damage. After this, re-insert it to the delivery pipe
90˚ 90˚ and check that the hose turns smoothly.
bolts to the specified torque.
AC102331AB
TIMING BELT
TIMING BELT
M1112004301002

• Under Cover Removal (Refer to GROUP 51, Under Cover • Accelerator Cable Installation (Refer to GROUP 17,
P.51-31.) Accelerator Cable and Pedal P.17-7).
• Crankshaft Shaft Damper Pulley Removal (Refer to • Starter Assembly Installation (Refer to GROUP 16, Starter
P.11C-16.) Motor Assembly P.16-26.)
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Front Exhaust Pipe Installation (Refer to GROUP 15,
Exhaust Pipe and Main Muffler P.15-27.) Exhaust Pipe and Main Muffler P.15-27.)
• Starter Assembly Removal (Refer to GROUP 16, Starter • Crankshaft Shaft Damper Pulley Installation (Refer to
Motor Assembly P.16-26.) P.11C-16.)
• Accelerator Cable Removal (Refer to GROUP 17, Accel- • Drive Belt Tension Check (Refer to P.11C-7.)
erator Cable and Pedal P.17-7). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31.)
On-vehicle Service − Accelerator Cable Check and
Adjustment P.17-6).
9
8
2 7 48 ± 5 N·m
11 ± 1 N·m
21 ± 4 N·m
3
8.8 ± 1.0 N·m
23 ± 3 N·m 10
1
5
44 ± 10 N·m
79 ± 5 N·m
4
22 ± 4 N·m 6 AC401181 AB
11 ± 1 N·m
9.0 ± 1.0 N·m
1. Control wiring harness connection • Engine mounting insulator (Refer to
2. Timing belt upper cover GROUP 32, Engine Mount P.32-7).
3. Water pump pulley >>G<< • Valve timing belt tension
4. Idler pulley adjustment
5. Auto-tensioner <<A>> >>F<< 7. Valve timing belt
6. Timing belt lower cover >>E<< 8. Timing belt tensioner pulley
TIMING BELT
11C-35
9. Timing belt tensioner arm
>>D<< 10. Timing belt tensioner adjuster
11 22 ± 4 N·m
15
35 ± 6 N·m
20
19 22 ± 4 N·m
12
19 ± 3 N·m
13
(Engine oil)
49 ± 9 N·m
14 49 ± 9 N·m
16
18
17 8.8 ± 1.0 N·m
167 N·m
AC401182 AB
Removal steps REMOVAL SERVICE POINTS

11. Power steering fluid pressure
<<A>> VALVE TIMING BELT REMOVAL
switch connector
<> 12. Power steering oil pump assembly CAUTION
13. A/C compressor connector Never turn the crankshaft anti-clockwise.
14. Power steering oil pump bracket
Timing mark
15. Timing belt idler pulley
16. Crank angle sensor
<<C>> >>C<< 17. Crankshaft camshaft drive sprocket
>>C<< 18. Crankshaft angle sensing blade
>>B<< • Balancer timing belt tension
adjustment
>>A<< 19. Balancer timing belt tensioner
<<D>> >>A<< 20. Balancer timing belt
AC102487
1. Turn the crankshaft clockwise, align each timing

mark to set No.1 cylinder to TDC of its
compression stroke.
TIMING BELT
Timing belt
tensioner pulley
MD998738 mounting bolt
Wire or pin
Timing belt
under cover
AC102492AB AC107185AC
2. Remove the timing belt under cover rubber plug 5. Insert a wire or pin in the set hole.
and then set the special tool adjusting bolt
CAUTION
(MD998738).
To reuse the valve timing belt, draw an arrow
CAUTION indicating the rotating direction (clockwise) on
The special tool can be gradually installed at a the back of the belt using chalk.
rate of a 30 degree turn per second. If it is 6. After removal of adjusting bolt special tool, loosen
screwed in all at once, the timing belt tensioner the timing belt tensioner pulley mounting bolt and
adjuster rod will not easily retract and the special remove the valve timing belt.
tool may bend.
Timing belt
<> POWER STEERING OIL PUMP
tensioner arm ASSEMBLY REMOVAL
With the hose installed, remove the power steering
oil pump assembly from the bracket.
MD998738
NOTE: Secure the removed power steering oil pump
will not interfere with the removal of the balancer tim-
ing belt.
AC107289 AB
<<C>> CRANKSHAFT CAMSHAFT DRIVE
with the timing belt tensioner arm. SPROCKET REMOVAL
Crankshaft
camshaft MB991385
A drive
B sprocket
MB991367
AC102332AB
AC102775AB
4. Gradually screw in the special tool. Then align the 1. Use the following special tools to support the
timing belt tensioner adjuster rod set hole A with crankshaft camshaft drive sprocket.
the timing belt tensioner adjustor cylinder set hole • Special spanner (MB991367)
B. • Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
remove the crankshaft camshaft drive sprocket.
TIMING BELT
11C-37
<<D>> BALANCER TIMING BELT >>B<< BALANCER TIMING BELT
REMOVAL TENSION ADJUSTMENT
CAUTION CAUTION
To reuse the balancer timing belt, draw an arrow When tightening the mounting bolt, ensure that
indicating the rotating direction (clockwise) on the tensioner does not rotate with the bolt. Allow-
the back of the belt using chalk. ing it to rotate with the bolt can cause excessive
tension of the belt.
>>A<< BALANCER TIMING BELT/BAL-
ANCER TIMING BELT TENSIONER
INSTALLATION
Belt tension side
Timing mark
Timing mark AC102691
1. With your fingers, lift the balancer timing belt

tensioner in the direction of the arrow. Apply
Crankshaft
balancershaft
pressure of 3.0 ± 0.4 N⋅m to the balancer timing
drive sprocket AC102689AB belt. Tighten the assembling bolt to the specified
torque. Then, fix the balancer timing belt
1. Ensure that the crankshaft balancershaft drive tensioner.
sprocket timing marks and balancershaft sprocket Tightening torque: 19 ± 3 N⋅m
timing marks are aligned.
2. Install the balancer timing belt on the crankshaft
balancershaft drive sprocket and balancershaft
sprocket. There should be no slack on the tension
side. Timing mark
Timing mark
Centre of the
mounting bolt
Crankshaft
balancershaft
drive sprocket AC102689AC
2. Turn the crankshaft clockwise two turns to set

No.1 cylinder to TDC of its compression stroke
Centre of
the pulley
and check that the sprocket timing marks are
AC102690 AB aligned.

pulley of the balancer timing belt tensioner so that Approximately 100 N
it is at the top left from the centre of the mounting
bolt, and the pulley flange is at the front-side of
the engine.
4. Adjust the balancer timing belt tension. Deflection
AC102693AB
TIMING BELT
3. Apply a pressure of approximately 100N at the 4. Apply some engine oil to the crankshaft pulley
centre (arrow area) between the sprocket as centre bolt bearing surface and screw.
shown, then inspect whether the belt deflection is
within the standard value. Crankshaft
camshaft MB991385
Standard value: drive
At adjustment: 5 − 7 mm sprocket
At replacement: 5 − 7 mm
tension again. MB991367
>>C<< CRANKSHAFT ANGLE SENSING

BLADE/CRANKSHAFT CAMSHAFT AC102332AB
DRIVE SPROCKET INSTALLATION 5. Use the following special tool as during removal to
support the crankshaft camshaft drive sprocket.
: Clean • Pin (MB991385)
: Apply engine oil 6. Tighten the crankshaft pulley centre bolts to the
specified torque.
Crankshaft pulley Tightening torque: 167 N⋅m
centre bolt
Crankshaft camshaft >>D<< TIMING BELT TENSIONER
drive sprocket
Crankshaft 1. Install according to the following procedures when
the timing belt tensioner adjuster rod is fully
extended.
CAUTION
If the compression is too fast, the procedure may
damage the rod.
B
Crankshaft A
pulley washer Crankshaft angle
sensing blade
Engine front
AC211535AC
1. Clean or degrease the crankshaft, the crankshaft

angle sensing blade, the crankshaft camshaft
drive sprocket and crankshaft pulley washer as
shown.
AC102334AB
(1) Slowly compress the timing belt tensioner
2. Install the crankshaft angle sensing blade and
adjuster rod using a press or vice, then align
crankshaft camshaft drive sprocket in the direction
the set hole A of the rod with set hole B of the
shown.
timing belt tensioner adjuster cylinder.
3. Place the larger chamfer side of the crank shaft
pulley washer in the direction shown and then
assemble on the crankshaft pulley centre bolt.
TIMING BELT
11C-39
Wire or pin
INSTALLATION
Timing mark
AC102335AC
(2) Insert a wire or pin into the aligned set hole.

Camshaft sprocket
NOTE: When replacing the timing belt ten-
sioner adjuster with new parts, the timing belt
tensioner adjuster is set with a pin.
2. Assemble the timing belt tensioner adjuster to the Crankshaft
engine, then tighten the assembling bolt to the camshaft
specified torque. Do not remove the wire or pin drive sprocket Engine oil
pump sprocket
until the tension of the valve timing belt is
adjusted.
Timing mark
>>E<< TIMING BELT TENSIONER Timing mark AC102486 AC
PULLEY INSTALLATION
1. Align the timing marks on the camshaft sprocket,
crankshaft camshaft drive sprocket and engine oil
pump sprocket.
Bolt
Balancershaft

pulley hole
AC102336AB Plug
Cylinder
Temporarily tighten the timing belt tensioner pulley block
as shown. AC201800 AB
2. Adjust the timing mark of the engine oil pump

sprocket. Unplug the cylinder block plug. Insert a
bolt (M6 sectional width 10 mm, minor diameter
45 mm) from the plug hole and then check. If the
bolt comes in contact with the balancer shaft turn
the sprocket one rotation. Re-adjust the timing
mark and then check to see that the bolt fits. Do
not remove the bolt until the valve timing belt is
assembled.
3. Install the valve timing belt as follows:
TIMING BELT

camshaft sprocket camshaft sprocket
Paper clip
AC201803AB
Timing belt Timing belt (4) Hold the valve timing belt with paper clips.
idler pulley
tensioner (5) Pass the valve timing belt around the timing
pulley
belt tensioner pulley.
CAUTION
Incorporate the valve timing belt. Then apply
Crankshaft Engine reverse rotation (anti-clockwise rotation) pres-
camshaft oil pump sure to the cam shaft sprocket. Re-check to see
drive sprocket
sprocket
that each timing mark is aligned while the ten-
sion side of the belt is tight.
AC102488 AC (6) Remove the two paper clips.
(1) Pass the valve timing belt around the
crankshaft camshaft drive sprocket, the engine
oil pump sprocket and the timing belt idler
pulley in that order.
MD998767
Paper clip
AC102694 AB
4. Turn the timing belt tensioner in the direction

shown using special tool tensioner wrench
(MD998767) to apply tension to the valve timing
AC201801AB
belt. Then pre-tighten the timing belt tensioner
(2) Pass the valve timing belt around the pulley.
exhaust-side camshaft sprocket, and hold the 5. Check that the timing marks are aligned.
valve timing belt with paper clip.
Bolt
Timing mark
Balancershaft
Timing mark
Plug
Cylinder
block
AC201800 AB
AC201802AB
(3) Use two wrenches to align the timing mark on assemble the cylinder block plug.
the rocker cover with that on the camshaft
sprocket. Pass the valve timing belt around
the inlet-side camshaft sprocket.
TIMING BELT
11C-41
7. Tighten the cylinder block plug to the specified 6. With special tool tensioner wrench (MD998767)
torque. and torque wrench, apply tension torque 3.5 N⋅m,
Tightening torque: 30 ± 3 N⋅m and tighten the timing belt tensioner pulley
mounting bolt to the specified torque.
8. Adjust the valve timing belt tension.
>>G<< VALVE TIMING BELT TENSION
ADJUSTMENT
Wire or pin
MD998738
AC102776AD
Timing belt
under cover 7. Remove wire or pin inserted to timing belt
AC102492AB tensioner.
1. Set special tool adjusting bolt (MD998738) when

removing the valve timing belt. MD998738
CAUTION
Always screw in special tool by hand, since use
of a spanner or other tools may damage the wire
or pin inserted in the timing belt tensioner
adjuster.
Timing belt
2. Gradually screw in special tool until the wire or pin under cover
inserted in the timing belt tensioner adjuster lightly AC102492AB
moves.
8. Remove the special tool adjusting bolt
3. Turn the crankshaft 1/4 turn anti-clockwise.
(MD998738), and install the rubber plug to the
4. Turn the crankshaft in the clockwise direction until timing belt under cover.
you align each timing mark to set No.1 cylinder to
9. Rotate the crankshaft clockwise two turns, and
TDC of its compression stroke.
leave it for about 15 minutes.
5. Loosen the timing belt tensioner pulley mounting
bolt.
CAUTION
When tightening the mounting bolt, ensure that Wire or pin
the timing belt tensioner pulley does not rotate
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt.
AC102776AD
10.Insert wire or pin removed in Step 7 again, and

ensure that it can be pulled out easily. When wire
MD998767 or pin can be easily removed, appropriate tension
is applied on timing belt. In this case, remove wire
or pin.
AC102695AB
TIMING BELT
INSPECTION
M1112004400352

A CHECK
is detected.
Timing belt 2. Check for wear or damage at the top of the rod.
tensioner Replace it, if required.
adjuster
AC102338AB
98 – 196 N Movement
If the projection of timing belt tensioner adjuster

rod is within the standard value, appropriate A B
tension is applied.
Timing belt
11.If wire or pin cannot be easily pulled out, repeat Rod
tensioner
Step 1 through Step 9 to reach proper valve timing adjuster
belt tension.
AC102339AB
CAUTION
Always check the tightening torque of the crank 3. Hold the timing belt tensioner adjuster by hand,
shaft pulley centre bolt when turning the crack and press the top end of the rod onto the metal
shaft pulley centre bolt anti-clockwise. (e.g. cylinder block) under a pressure of 98 − 196
Re-tighten if it is loose. N to measure the movement of the rod.
Timing mark
A − B: Movement
BALANCER TIMING BELT TENSION

Camshaft CHECK
sprocket Check the balancer timing belt tension as follows:
Crankshaft Approximately 100 N

camshaft Engine
drive sprocket oil pump
sprocket
Deflection
Timing mark
Timing mark AC201411AB AC102693AB
12.Check again that the timing marks on sprockets 1. Apply a pressure of approximately 100 N at the
are aligned. centre (arrow area) between the sprocket as
shown then inspect whether the deflection is
tension. (Refer to P.11C-34).
ENGINE ASSEMBLY
11C-43
ENGINE ASSEMBLY
M1112001002180
CAUTION
• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Starter Assembly Installation (Refer to GROUP 16, Starter
On-vehicle Service − Fuel Pump Connector Disconnec- Motor Assembly P.16-26.)
tion (How to Reduce Pressurized Fuel Lines) P.13B-393.] • Front Exhaust Pipe Installation (Refer to GROUP 15,
• Hood Removal (Refer to GROUP 42, Hood P.42-4.) Exhaust Pipe and Main Muffler P.15-27.)
• Under Cover Removal (Refer to GROUP 51, Under Cover • Radiator Assembly Installation (Refer to GROUP 14,
P.51-31.) Radiator P.14-35.)
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Battery and Battery Tray Installation
Service − Engine Oil Replacement P.12-4.) • Accelerator Cable Installation (Refer to GROUP 17,
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle Accelerator Cable and Pedal P.17-7).
Service − Engine Coolant Replacement P.14-17.) • Air Cleaner and Air Cleaner Bracket installation (Refer to
• Intercooler Removal (Refer to GROUP 15, Intercooler GROUP 15, Air Cleaner P.15-7).
P.15-9.) • Intercooler Installation (Refer to GROUP 15, Intercooler
• Air Cleaner and Air Cleaner Bracket Removal (Refer to P.15-9.)
GROUP 15, Air Cleaner P.15-7). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Accelerator Cable Removal (Refer to GROUP 17, Accel- Service − Engine Coolant Replacement P.14-17.)
erator Cable and Pedal P.17-7). • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
• Battery Removal Service − Engine Oil Replacement P.12-4.)
• Battery and Battery Tray Removal • Accelerator Cable Adjustment (Refer to GROUP 17,
• Radiator Assembly Removal (Refer to GROUP 14, Radia- On-vehicle Service − Accelerator Cable Check and
tor P.14-35.) Adjustment P.17-6.)
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Drive Belt Tension Check (Refer to P.11C-7.)
Exhaust Pipe and Main Muffler P.15-27.) • Under Cover Installation (Refer to GROUP 51, Under
• Starter Assembly Removal (Refer to GROUP 16, Starter Cover P.51-31.)
Motor Assembly P.16-26.) • Hood Installation (Refer to GROUP 42, Hood P.42-4.)
• Fuel Leak Check
ENGINE ASSEMBLY
9.0 ± 2.0 N·m

1
9.0 ± 2.0 N·m 2
5.0 ± 1.0 N·m 9.0 ± 2.0 N·m

4
5.0 ± 1.0 N·m
N 5 5N
6 9.0 ± 2.0 N·m
48 ± 7 N·m 3
12 ± 2 N·m
N 5
48 ± 7 N·m AC401183 AB

1. Control wiring harness connection 5. Engine oil cooler tube gaskets
2. Earth cable connection 6. Engine oil cooler hose and bracket
3. Battery wiring harness connection assembly
<<A>> 4. Drive belt
ENGINE ASSEMBLY
11C-45
11 12 5.0 ± 1.0 N·m
13
14 N (Engine oil)
8
N 15 70 ± 4 N·m* 12 ± 2 N·m
44 ± 10 N·m*
44 ± 10 N·m*
22 ± 4 N·m
16
10
22 ± 4 N·m
17
AC401184 AB

7. Brake booster vacuum hose >>D<< 13. Fuel high-pressure hose
8. Canister vacuum hose connection >>D<< 14. O-ring
<> 9. A/C compressor and clutch <<C>> >>C<< • Transmission assembly
assembly 15. Self-locking nuts
<> 10. Power steering oil pump assembly <<D>> >>B<< 16. Engine mounting insulator
11. Heater water hoses connection <<E>> >>A<< 17. Engine assembly
ENGINE ASSEMBLY
REMOVAL SERVICE POINTS <> A/C COMPRESSOR AND CLUTCH

<<A>> DRIVE BELT REMOVAL ASSEMBLY/POWER STEERING OIL
The following operations will be needed due to the PUMP ASSEMBLY REMOVAL
introduction of the serpentine drive system with the With the hose installed, remove the A/C compressor
drive belt auto-tensioner. and clutch assembly, and power steering oil pump
AC301703 assembly from the bracket.
Auto-tensioner
NOTE: Secure the removed A/C compressor and
clutch assembly, and power steering oil pump
will not interfere with the removal of the engine
assembly.
Hole B
<<C>> TRANSMISSION ASSEMBLY

Hole A
REMOVAL
AC301704AB

hole of the auto-tensioner.
hole A with hole B.
CAUTION
To reuse the drive belt, draw an arrow indicating
the belt using chalk, etc. AC300950AB

Auto-tensioner radiator support upper insulator to set the special
tools engine hanger MB991895 or engine hanger
MB991928.
2. Remove the transmission assembly (Refer to
L-shaped
hexagon
wrench AC301705AB

ENGINE ASSEMBLY
11C-47
<<D>> ENGINE MOUNTING INSULATOR 4. Place a garage jack against the engine oil pan
REMOVAL with a piece of wood in between so that the weight
of the engine assembly is no longer being applied
1. Support the engine with a garage jack.
2. Remove the following special tool.
5. Loosen the engine mounting insulator mounting
MB991895 nuts and bolt, and remove the engine mounting
insulator.
MB991527
<<E>> ENGINE ASSEMBLY REMOVAL

the engine, lift the chain block slowly to remove the
engine assembly upward from the engine compart-
MB991454
ment.
AC107631AB
(1) <Special tool engine hanger (MB991895) is INSTALLATION SERVICE POINTS

used>
TION
MB991928
MB991454
MB991527
MB991527
MB991454
AC211405AB
AC107632 AB
used> Install the engine assembly, being careful not to
tors.
MB991454
MB991527
AC107632 AB
3. Hold the engine assembly with a chain block, etc.

ENGINE ASSEMBLY
>>B<< ENGINE MOUNTING INSULATOR >>C<< TRANSMISSION ASSEMBLY

1. Place a garage jack against the engine oil pan 1. Install the transmission assembly (Refer to
with a piece of wood in between, and install the GROUP 22A, Transmission Assembly P.22A-14).
engine mounting insulator while adjusting the
position of the engine.
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
support the engine.
MB991895
MB991527
AC300950AB
2. Remove from the car the 2 bolts, to assemble the

radiator support upper insulator.
>>D<< O-RING/FUEL HIGH-PRESSURE

MB991454
AC107631AB
HOSE INSTALLATION
(1) <Special tool engine hanger (MB991895) is CAUTION
used> Do not let any engine oil get into the delivery
pipe.
Set special tool MB991895. (Refer to
GROUP 22A, Transmission Assembly 1. Apply a small amount of new engine oil to the
P.22A-14). O-ring.
2. Turning the fuel high-pressure hose to the right
MB991928 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.
3. If the hose does not turn smoothly, the O-ring is
probably being clamped. Disconnect the fuel
MB991527 high-pressure hose and check the O-ring for
damage. After this, re-insert it to the delivery pipe
and check that the hose turns smoothly.
MB991454
AC211405AB 4. Tighten the fuel high-pressure hose mounting
bolts to the specified torque.
used> Tightening torque: 5.0 ± 1.0 N⋅m
Set special tool MB991928 (Refer to
P.22A-14).
11D-1
GROUP 11D
ENGINE OVERHAUL
<4G63-Turbo>
CONTENTS
GENERAL INFORMATION . . . . . . . . 11D-2 EXHAUST MANIFOLD . . . . . . . . . . . . 11D-29

REMOVAL AND INSTALLATION . . . . . . . . 11D-29
GENERAL SPECIFICATIONS . . . . . . 11D-2
WATER PUMP AND
SERVICE SPECIFICATIONS. . . . . . . 11D-3 WATER HOSE . . . . . . . . . . . . . . . . . . 11D-31
REWORK DIMENSIONS . . . . . . . . . . 11D-5
ROCKER ARMS AND CAMSHAFT . . 11D-33
TORQUE SPECIFICATIONS . . . . . . . 11D-5 REMOVAL AND INSTALLATION . . . . . . . . 11D-33
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-35
SEALANTS . . . . . . . . . . . . . . . . . . . . 11D-8
CYLINDER HEAD AND VALVES. . . . 11D-38
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11D-9 REMOVAL AND INSTALLATION . . . . . . . . 11D-38
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-41
ALTERNATOR AND IGNITION
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11D-12 OIL PAN AND OIL PUMP. . . . . . . . . . 11D-44
REMOVAL AND INSTALLATION . . . . . . . . 11D-12 REMOVAL AND INSTALLATION . . . . . . . . 11D-44
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-52
SOLENOID AND VACUUM HOSE . . 11D-13
REMOVAL AND INSTALLATION . . . . . . . . 11D-13 PISTON AND CONNECTING ROD . . 11D-53
TIMING BELT. . . . . . . . . . . . . . . . . . . 11D-14 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-59
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11D-24 CRANKSHAFT AND
CYLINDER BLOCK . . . . . . . . . . . . . . 11D-60
FUEL AND EMISSION PARTS . . . . . 11D-26 REMOVAL AND INSTALLATION . . . . . . . . 11D-60
REMOVAL AND INSTALLATION . . . . . . . . 11D-26 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11D-64
INLET MANIFOLD . . . . . . . . . . . . . . . 11D-28

11D-2 ENGINE OVERHAUL <4G63-Turbo>
GENERAL INFORMATION
GENERAL INFORMATION
M1113000100523

model mL
OUTLANDER CU2W 4G63-7 1,997 Double overhead camshaft, 16-valve
M1113000200779
Item Specification
Bore × stroke mm 85 × 88
Displacement mL 1,997
Combustion chamber Pentroof type
Valve mechanism Type Double overhead camshaft
Number of intake valves 8
Number of exhaust 8
valves
Lash adjusters Hydraulic
Rocker arms Roller cam followers
Compresssion ratio 9.0
Fuel injection system Electronically controlled multi-point injection (MPI)
system
Ignition system Electronically controlled two-coil system
Generator Alternator (with built-in IC regulator)
Starter motor Gear reduction drive type
ENGINE OVERHAUL <4G63-Turbo>
11D-3
M1113000300776

TIMING BELT
Auto-tensioner rod extension length 3.8 − 4.5 −
(with timing belt installed) mm
Auto-tensioner rod extension length (when free) mm 12.0 −
Auto-tensioner rod retraction length Less than 1 −
(when pressed with force of 98 to 196 N) mm
Cam height mm Intake 35.79 35.29
Exhaust 35.49 34.99
Cylinder head gasket surface warp mm Less than 0.05 0.2
Cylinder head gasket surface grinding limit − 0.2
(including cylinder block grinding amount) mm
Cylinder head overall height mm 131.9 − 132.1 −
Valve margin mm Intake valves 1.0 0.5
Valve stem diameter mm 6.6 −
Valve face angle 43.5° − 44° −
Valve stem-to-guide clearance mm Intake valves 0.02 − 0.05 0.10
Exhaust valves 0.05 − 0.09 0.15
Valve height mm Intake valves 109.5 109.0
Valve stem projection mm Intake valves 49.2 49.7
Valve spring free height mm 48.3 47.3
Valve spring load/height N/mm 294/40 −
Valve spring squareness 1.5° or less 4°
Valve face-to-seat contact width mm 0.9 − 1.3 −
Valve guide press-in height mm 19.2 − 19.8 −

Oil pump gear side clearance mm Drive gear 0.08 − 0.14 −
Oil cooler by-pass valve mm Dimension (Normal 34.5 −
temperature)
By-pass hole closing 40.0 −
temperature 97 to
103°C
Oil pressure at curb idle speed kPa 78 or more −
[oil temperature is 75 to 90°]
Piston outside diameter mm 85.0 −
Piston ring side clearance in ring No. 1 0.03 − 0.07 0.1
groove mm No. 2 0.02 − 0.06 0.1
No. 2 0.30 − 0.45 0.8
Oil ring 0.10 − 0.40 1.0
Piston pin press-in load (at ambient temperature) N 7,350 − 17,100 −
Oil clearance at crankshaft pins mm 0.02 − 0.04 0.1
Connecting rod big end thrust clearance mm 0.10 − 0.25 0.4
Crankshaft journal diameter mm 57.0 −
Crankshaft pin diameter mm 45.0 −
Oil clearance at crankshaft journals No. 1,2,4,5 journal 0.02 − 0.03 0.1
mm No. 3 journal 0.03 − 0.04 0.1
Cylinder block gasket surface warp mm 0.05 0.1
Cylinder block gasket surface grinding limit − 0.2
(including cylinder head grinding amount) mm
Cylinder bore diameter mm 85 −
Taper of cylinder mm 0.01 or less −
Cylinder-to-piston clearance mm 0.02 − 0.04 −
Crankshaft bearing cap bolt nominal length mm − 71.1
REWORK DIMENSIONS
11D-5
REWORK DIMENSIONS
M1113024300394
Item Standard value

mm 0.6 oversize 35.60 − 35.63
0.6 oversize 33.60 − 33.63
0.25 oversize 12.25 − 12.27
0.50 oversize 12.50 − 12.52
M1113023402048
Item N⋅m
Water pump pulley bolts 8.8 ± 1.0
Alternator brace bolt (flange bolt) 23 ± 3
Alternator brace bolts (washer assembled bolt) 22 ± 4
Alternator nuts 44 ± 10
Crankshaft pulley bolts 25 ± 4
Center cover bolts 3.0 ± 0.5
Ignition coil bolts 10 ± 2
Spark plugs 25 ± 5
SOLENOID AND VACUUM HOSE
Vacuum pipe and hose assembly bolts 11 ± 1
EGR valve bolts 20 ± 2
Solenoid valve assembly nut 36 ± 6
Solenoid valve assembly bolts(M6) 9.0 ± 1.0
Solenoid valve assembly bolts(M8) 23 ± 4
TIMING BELT
Timing belt cover bolts (flange bolt) 11 ± 1
Timing belt cover bolt (washer-assembled bolt) 9.0 ± 1.0
Power steering pump bracket bolts 49 ± 9
Item N⋅m
Auto-tensioner bolts 23 ± 3
Crankshaft angle sensor bolts 8.8 ± 1.0
Crankshaft bolt 167
Tensioner "B" bolt 19 ± 3
Rocker cover bolts 3.5 ± 0.5
Engine support bracket bolts 49 ± 5
Camshaft sprocket bolts 88 ± 10
Throttle body bolts 19 ± 3
Fuel pressure regulator bolts 9.0 ± 2.0
Delivery pipe and injector assembly bolts 11 ± 1
INLET MANIFOLD
Inlet manifold stay bolts 31 ± 3
Inlet manifold bolts (M8) 20 ± 2
Inlet manifold bolts and nuts (M10) 36 ± 6
Detonation sensor 23 ± 2
EXHAUST MANIFOLD
Turbocharger heat protector bolts 23 ± 3
Exhaust fitting bracket bolts 36 ± 5
Exhaust fitting bolts 59 ± 5
Air outlet fitting bolts 19 ± 1
Oil return pipe bolts 14 ± 1
Exhaust manifold heat protector bolts 23 ± 3
Turbocharger assembly and pipe assembly bolts, nuts 59 ± 5
Oil pipe bolt (flange bolt) 11 ± 1
Oil pipe bolt (eye bolt M10) 17 ± 2
Water pipe bolt (eye bolt M12) 28 ± 5
Water pipe bolt (flange bolt) 10 ± 1
Engine coolant temperature gauge unit 10.8 ± 1.0
Water outlet fitting bolts 13 ± 2
Water inlet fitting bolts 13 ± 2
11D-7
Item N⋅m
Thermostat housing bolts 23 ± 4
Water inlet pipe bolt (M8) 13 ± 2
Water pump bolts 14 ± 1
Camshaft position sensor bolt 11 ± 1
Cover bolts 10 ± 2
Camshaft position sensor support bolts 14 ± 1
Bearing cap bolts 20 ± 1
Oil delivery body bolts 11 ± 1
Cylinder head bolts 78 ± 2 → 0 → 20 ± 2 → +90° → +90°
Drain plug 39 ± 5
Transmission stay bolts 22 ± 4
Oil pan bolts 9.0 ± 3.0
Oil screen bolts 19 ± 3
Oil cooler by-pass valve 54 ± 5
Relief plug 44 ± 5
Oil filter bracket bolts 19 ± 3
Plug cap 23 ± 3
Flange bolt 36 ± 3
Oil pump case bolts 23 ± 3
Oil pump cover bolts 17 ± 1
Oil pump cover screw 10 ± 2
Connecting rod cap nuts 20 ± 2 → +90° to 94°
Flywheel bolts 132 ± 5
Rear plate bolt 11 ± 1
Bell housing cover bolts 9.0 ± 1.0
Rear oil seal case bolts 11 ± 1
Beam bearing cap bolts 25 ± 2 → +90° to 100°
ENGINE OVERHAUL 4G63-Turbo!
11D-8 SEALANTS
SEALANTS
M1113000500703

Engine support bracket bolts Mitsubishi Genuine Part No.MD970389 or equivalent
Semicircular packing 3M ATD No.8660 or equivalent
Rocker cover Mitsubishi Genuine Part No. MD970389 or equivalent
Engine coolant temperature e gauge unit 3M Nut Locking Part No.4171 or equivalent
Engine coolant temperature sensor 3M ATD No.8660 or equivalent
Water outlet fitting* Mitsubishi Genuine Part No. MD970389 or equivalent
Thermostat housing*
Cylinder head (camshaft bearing cap fitting 3M ATD No.8660 or equivalent
section)
Camshaft position sensor support* Mitsubishi Genuine Part No. MD970389 or equivalent
Oil pan* Mitsubishi Genuine Part No. MD970389 or equivalent
Rear oil seal case*
NOTE: *: Part to be sealed with a form-in-place gas-
ket (FIPG)
ing it.
correct bead size.
ual.
to damage the mating surfaces.The oil pan cutter
with an aluminium oil pan as it could damage the
mating surfaces.
SPECIAL TOOLS
11D-9
SPECIAL TOOLS
M1113000601189

MD998781 Flywheel stopper Retention of flywheel
D998781

puller and crankshaft sprocket B
MD998785 Sprocket stopper Retention of counterbalancer

shaft sprocket
MD998767 Tension pulley socket Manipulation of tensioner pulley

wrench during adjustment of timing belt
tension
D998767
MD998738 Set screw Retention of tensioner arm and

auto-tensioner during timing belt
installation
D998738

installer
D998713
MD998442 Air bleed wire Air bleeding of lash adjuster

wrench cylinder head bolts
B991654
SPECIAL TOOLS

compressor

compressor
MD998737 Valve stem seal Installation of valve stem seal

installer

block>
MD998162 Plug wrench Removal and installation of front

case plug cap
MD998783 Plug wrench retainer Removal and installation of front

case plug cap

puller front bearing

puller front and rear bearings
SPECIAL TOOLS
11D-11
MB991603 Silent shaft bearing Guide and stopper for removal
installer stopper and press-fitting of
counterbalancer shaft rear
bearing
MD998705 Silent shaft bearing Press-fitting of counterbalancer

installer shaft front and rear bearings
MD998375 Crankshaft front oil Installation of crankshaft front oil

seal installer seal
MD998285 Crankshaft front oil Guide for installation of

seal guide crankshaft front oil seal
D998285
MD998780 Piston pin setting tool Removal and press-fitting of

piston pin
MD998776 Crankshaft rear oil Installation of crankshaft rear oil

seal installer seal
D998776

seal

M1113001000701
12 3.0 ± 0.5 N·m
1
2
10 ± 2 N·m
13
14
13 ± 1 N·m 15
25 ± 5 N·m
3
10
44 ± 10 N·m
9
22 ± 4 N·m
8
7
44 ± 10 N·m
23 ± 3 N·m
8.8 ± 1.0 N·m
25 ± 4 N·m
11
79 ± 5 N·m
6
24 ± 4 N·m 5 AK305988 AC

1. Oil level gauge 9. Alternator brace
2. O-ring 10. Alternator
3. Oil level gauge guide 11. Crankshaft pulley
4. O-ring 12. Center cover
5. Idler pulley 13. Spark plug cable
6. Cap 14. Ignition coil
7. Auto-tensioner assembly 15. Spark plug
8. Water pump pulley
11D-13
M1113025300074
20 ± 2 N·m
4
19 ± 3 N·m
5 8 23 ± 4 N·m
9.0 ± 1.0 N·m
36 ± 6 N·m
11 ± 1 N·m
7
3 6 11 ± 1 N·m
11 ± 1 N·m
AK400296AB

1. Vacuum pipe and hose assembly 5. EGR valve gasket
2. Vacuum pipe and hose assembly 6. Solenoid valve
3. Vacuum pipe and hose assembly 7. Solenoid valve
4. EGR valve 8. Engine hanger
TIMING BELT
TIMING BELT
M1113001900867
3.5 ± 0.5 N·m

24
21 28
11 ± 1 N·m 1 22 25
20
5 6
48 ± 5 N·m
23
21 ± 4 N·m 26
12 7
11 ± 1 N·m 23 ± 3 N·m
27
32
11 ± 1 N·m
11 ± 1 N·m 33
11
167 N·m 29
2 49 ± 5 N·m
9.0 ± 1.0 N·m
4 45 ± 3 N·m
31 16 17
19 ± 3 N·m
3
14
30 34 9
88 ± 10 N·m 19
49 ± 9 N·m
18 8.8 ± 1.0 N·m
15
13
8 10
35 ± 6 N·m AK305989AB
54 ± 5 N·m

1. Timing belt front upper cover <<D>> >>I<< 12. Crankshaft sprocket
2. Timing belt front lower cover >>I<< 13. Crankshaft sensing blade
3. Power steering pump bracket 14. Tensioner "B"
<<A>> >>M<< 4. Timing belt <<E>> >>H<< 15. Timing belt "B"
>>L<< 5. Tensioner pulley <<F>> >>G<< 16. Counterbalancer shaft sprocket
6. Tensioner arm >>F<< 17. Spacer
>>K<< 7. Auto-tensioner <<G>> >>E<< 18. Crankshaft sprocket "B"
9. Crankshaft angle sensor 20. Breather hose
<> >>J<< 10. Oil pump sprocket 21. PCV hose
<<C>> >>I<< 11. Crankshaft bolt 22. PCV valve
TIMING BELT
11D-15
23. PCV valve gasket >>B<< 29. Engine support bracket
24. Oil filler cap <<H>> >>A<< 30. Camshaft sprocket bolt
>>D<< 25. Rocker cover 31. Camshaft sprocket
>>D<< 26. Rocker cover gasket "A" 32. Timing belt rear cover, right
27. Rocker cover gasket "B" 33. Timing belt rear upper cover, left
>>C<< 28. Semicircular packing 34 Timing belt rear lower cover, left

<<A>> TIMING BELT REMOVAL <> OIL PUMP SPROCKET REMOVAL
1. Remove the plug on the left side of cylinder block.
Crosspoint
screwdriver
AK202756AB
AK202825 AD
1. If the timing belt is to be reused, make an arrow
mark with something like chalk on the back of the 2. Insert a crosspoint screwdriver (shank diameter 8
belt indicating the direction of rotation so it may be mm) to prevent the counterbalancer shaft from
reinstalled in the same direction. rotating.
3. Remove the flange bolt.
Timing marks 4. Remove the oil pump sprocket.
<<C>> CRANKSHAFT BOLT REMOVAL
AK304440AB
CAUTION
Never remove the timing belt with any piston at MD998781
the top dead center (TDC). If a piston is at TDC,
the exhaust valves of the cylinder are pushed by AK202738 AC
the exhaust cams, compressing the valve
springs. If the belt is removed under this condi- 1. Hold the drive plate with the special tool Fly wheel
tion, the sprocket will be turned in the reverse stopper (MD998781).
direction by the force of the springs, incurring 2. Remove the crankshaft bolt.
risk of injury.
2. Set the timing mark of the exhaust camshaft
sprocket to a point about one tooth before the
TDC of the No.1 cylinder piston on compression
stroke.
3. Loosen the lock nut of the tensioner pulley, then
remove the timing belt.
TIMING BELT
<<D>> CRANKSHAFT SPROCKET <<F>> COUNTERBALANCER SHAFT

REMOVAL SPROCKET REMOVAL
MD998778
MD998785
AK304176AB AK300138 AD
Use the special tool Crankshaft sprocket puller 1. Use the special tool Sprocket stopper
(MD998778) if the sprocket is stuck and hard to (MD998785) to prevent the counterbalancer shaft
remove. sprocket from rotating.
2. Remove the counterbalancer shaft mounting bolt.
<<E>> TIMING BELT "B" REMOVAL
<<G>> CRANKSHAFT SPROCKET "B"
REMOVAL
AK300137
CAUTION
Water or oil on the belt shortens its life drasti- MD998778 AK300139AD
cally, so the removed timing belt, sprocket, and
Use the special tool Crankshaft sprocket puller
tensioner must be free from oil and water. These
(MD998778) if the sprocket is stuck and hard to
parts should not be washed or immersed in sol-
remove.
vent. Replace parts if contaminated. If there is oil
or water on each part, check the front case oil
seals, camshaft oil seal and water pump for <<H>> CAMSHAFT SPROCKET BOLT
leaks. REMOVAL
1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner "B" bolt, and then remove
the timing belt "B."
AK305990AC
Remove the camshaft sprocket bolt while preventing

the camshaft from rotation using a wrench fitted on
the hexagonal portion of the camshaft.
TIMING BELT
11D-17
INSTALLATION SERVICE POINTS >>C<< SEMICIRCULAR PACKING
>>A<< CAMSHAFT SPROCKET BOLT INSTALLATION
INSTALLATION 1. Remove thoroughly the old sealant and FIPG
remaining on the semicircular packing, cylinder
head, and rocker cover.
AK305990AC
AK202860AB
2. Apply sealant to the surface indicated in the

drawing of the semicircular packing.
Specified sealant:
3. Install the semicircular packing on the cylinder
head.
AK304435
10 mm
Tighten the camshaft sprocket bolt to 88 ± 10 N⋅m
while preventing the camshaft from rotation using a
wrench fitted on the hexagonal portion of the cam-
shaft.
10 mm
>>B<< ENGINE SUPPORT BRACKET
INSTALLATION Semicircular
packing Cylinder head AK304411AB
4. Apply sealant to the area indicated in the drawing

of the semicircular packing and cylinder head.
Specified sealant:
AK202743AB
1. Remove thoroughly the old sealant remaining on

it.
Specified sealant:
equivalent
TIMING BELT
>>D<< ROCKER COVER/ROCKER >>E<< CRANKSHAFT SPROCKET "B"

COVER GASKET "A" INSTALLATION INSTALLATION
Timing belt side
Sprocket "B"
Crankshaft
Degrease
AK304203AB Front case AK301828AD
1. Apply beads of FIPG on the surfaces of the rocker Clean and then degrease the crankshaft sprocket "B"
cover indicated in the drawing. and the sprocket fitting surface of the crankshaft.
Specified sealant: NOTE: Degreasing is necessary to prevent lack of
Mitsubishi Genuine Part No.MD970389 or frictional coefficient between the mating surfaces.
equivalent
2. Install the rocker cover gasket "A" on the rocker
>>F<< SPACER INSTALLATION
cover before the FIPG hardens. Counter
Oil seal balance
Timing belt side shaft
Spacer
Chamfered
AK301298AD
AK304204AB
CAUTION
3. Apply beads of FIPG to the surfaces of the rocker If the spacer is opposite in direction to that
cover indicated in the drawing. shown in the drawing when installed, it will dam-
age the oil seal lip.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or 1. Smear slightly oil on the outer surface of the
equivalent spacer that comes into contact with the oil seal.
2. Install the spacer with the chamfered end toward
4. Install the rocker cover on the cylinder head
the oil seal.
before the FIPG hardens.
TIMING BELT
11D-19
>>G<< COUNTERBALANCER SHAFT 3. Make sure that the tensioner "B" center is
SPROCKET INSTALLATION positioned as shown in the drawing relative to the
mounting bolt center.
MD998785
AK300138 AD
AK304436AB
1. Use the special tool Sprocket stopper
(MD998785) as shown in the drawing to prevent 4. Lift the tensioner "B" with fingers to move it in the
the counterbalancer shaft sprocket from rotating. direction of the arrow until the tension section of
the timing belt becomes taut. While keeping the
2. Tighten the sprocket mounting bolt to 45 ± 3 N⋅m.
tensioner "B" in this position, tighten its bolt.
NOTE: When the bolt is tightened, prevent the
>>H<< TIMING BELT "B" INSTALLATION
tensioner "B" shaft from turning. If the shaft turns,
the belt will be overtightened.
5. Make sure that the timing marks on the oil pump
Timing case and those of the sprockets are all aligned
marks
with each other.
5 – 7 mm
Timing
marks
AK305991 AC
1. Align the timing marks on the crankshaft sprocket

"B" and counterbalancer shaft sprocket with the
corresponding timing marks on the oil pump case.
2. Install the timing belt "B" on the crankshaft AK305993 AC
sprocket "B" and counterbalancer shaft sprocket.

6. Push a central point of the timing belt "B" tension
There should be no slack in the tension section of
section lightly with an index to see if it deflects 5 −
the belt.
7 mm.
Tensioner "B" Tension section of belt
Timing
belt "B"
Tensioner "B"
centre
Mounting bolt centre AK305992 AC
TIMING BELT
>>I<< CRANKSHAFT >>J<< OIL PUMP SPROCKET

BOLT/CRANKSHAFT INSTALLATION
SPROCKET/CRANKSHAFT SENSING
BLADE INSTALLATION
Crankshaft Sensing blade

bolt
Sprocket Crankshaft
Clean
AK300172
Washer
Degrease 1. Prevent the counterbalancer shaft from rotating in
Big chamfered side
AK301075AD the same method as in the removal procedure.
2. Install the oil pump sprocket.
1. Clean and then degrease the crankshaft sprocket,
sprocket fitting surface of the crankshaft, and 3. Apply a thin coat of engine oil to the seating
crankshaft sensing blade. Install the crankshaft surface of the nut.
sprocket and crankshaft sensing blade on the 4. Tighten the flange nut to 54 ± 5 N⋅m.
crankshaft.
2. Clean the bolt hole in the crankshaft, and then >>K<< AUTO-TENSIONER INSTALLATION
washer.
3. Apply a necessary minimum amount of oil to the
threads and seating surface of the crankshaft bolt. A
B
AK301074AD
MD998781 1. If the auto-tensioner rod remains in its fully

extended position, reset it to the retracted position
AK202738 AC
as follows:
4. Hold the drive plate using the special tool Fly (1) Clamp the auto-tensioner in a vise at right
wheel stopper (MD998781). angles to the jaws.
5. Tighten the crankshaft bolt to a torque of 167 N⋅m. (2) Push in the rod little by little with the vise until
the set hole A in the rod is aligned with the set
hole "B" in the cylinder.
(3) Insert a piece of wire (1.4 mm diameter) into
the set holes.
(4) Remove the auto-tensioner from the vise.
TIMING BELT
11D-21
NOTE: If the timing marks were aligned, the
exhaust camshaft would be turned counterclock-
wise by one sprocket tooth and stay there by the
force of the valve springs.
Timing marks
AK300154
2. Install the auto-tensioner in position. Leave the

wire installed until the auto-tensioner is
completely installed. AK304441AB
>>L<< TENSIONER PULLEY 2. Align the timing mark on the intake camshaft
INSTALLATION sprocket with that on the rocker cover.
NOTE: The intake camshaft will be turned slightly
clockwise from where the timing marks are
aligned by the force of the valve springs and stay
there.
Tensioner
pulley hole AK300147 AE
Install the tensioner pulley with its holes aligned as

Timing marks
AK304563AB
>>M<< TIMING BELT INSTALLATION
3. Bring the timing mark on the crankshaft sprocket
to a point one sprocket tooth away from the
Timing marks
mating timing mark in the counterclockwise
direction like in the operation with the exhaust
camshaft sprocket.
60 mm or more
AK304440AB
1. Bring the timing mark on the exhaust camshaft

sprocket to a point one sprocket tooth away from
Counter
the timing mark on the rocker cover in the balance
counterclockwise direction. shaft AK301077 AD
4. Align the timing mark on the oil pump sprocket

with that on the cylinder block.
(1) Remove the plug from the cylinder block.
TIMING BELT
(2) Insert a crosspoint screwdriver with a shank 6. Turn the intake camshaft sprocket
diameter of 8 mm through the plug hole. If it counterclockwise to bring the timing mark on it
can be inserted 60 mm or more, the sprocket one sprocket tooth away from the mating timing
is in the correct phase. If the insertion depth is mark in the counterclockwise direction. Then
up to 20 − 25 mm, the screwdriver is blocked install the timing belt on the sprocket and hold it in
by the counterbalancer shaft. Then turn the oil place with a paper clip.
pump sprocket one turn and realign the timing NOTE: The timing marks will be aligned when the
marks. Then check that the screwdriver can belt is installed since the intake camshaft is turned
be inserted 60 mm or more. Keep the slightly clockwise by the force of the valve
screwdriver inserted until installation of timing springs.
belt is finished.
Timing marks
Timing marks
AK305994 AC
AK202761 AD
7. Turn the exhaust camshaft sprocket clockwise to
(3) Turn the oil pump sprocket counterclockwise
align the timing marks, and make sure that the
by one sprocket tooth.
intake camshaft sprocket timing marks are also
aligned.
Crankshaft
sprocket
AK202771
Oil pump
sprocket
5. Install the timing belt on the exhaust camshaft AK202762AE
sprocket, and hold it in place with a paper clip at

8. Install the timing belt on the idler pulley, oil pump
the point indicated in the drawing.
sprocket, and crankshaft sprocket, in this order.
NOTE: There should be no slack in the installed
portion of the belt.
Camshaft
AK202772
sprocket
Tensioner
pulley
AK202773 AD
9. Install the timing belt on the tensioner pulley.

TIMING BELT
11D-23
NOTE: Turning slightly the intake camshaft
sprocket counterclockwise will facilitate installa-
tion of the belt on the tensioner pulley. MD998738
Crankshaft
sprocket
AK202774 AD
14.Install the special tool Set screw (MD998738) and

AK202763AB
turn down the tool until the wire (inserted in the
auto-tensioner when it was installed) can be
10.Turn slightly the crankshaft sprocket clockwise to moved freely.
take up the slack in the idler pulley portion of the 15.Loosen the tensioner pulley lock bolt.
timing belt.
11.Check that each of the timing marks on the
crankshaft, oil pump, and exhaust camshaft
sprockets is one sprocket tooth away from its
mating timing mark in the counterclockwise
direction.
MD998767
MD998767 AK202775 AD
CAUTION
Prevent the timing belt from slipping as it
becomes loose following rotation of the intake
and exhaust camshafts.
AK202764 AD 16.Turn the torque wrench attached to the special
tool Tension pulley socket wrench (MD998767)
12.Turn the tensioner pulley counterclockwise using counterclockwise until the slack in the timing belt
the special tool Tension pulley socket wrench is taken up.
(MD998767) to give tension to the belt and hold 17.Turn the torque wrench clockwise from the
the tensioner in position by temporarily tightening position of step 16 until the torque wrench reading
the tensioner lock bolt. becomes 3.5 N⋅m, then tighten the tensioner
NOTE: Take up the slack in the belt portion pulley lock bolt.
between the intake and exhaust camshaft sprock- 18.Remove the special tool Set screw (MD998738)
ets. that was installed in step 14.
13.Turn the crankshaft clockwise to make the timing 19.Turn the crankshaft clockwise two turns, then let it
mark align with the No.1 cylinder top dead center alone for approx. 15 minutes.
mark.
TIMING BELT
Cracks Cracks
Extension
amount Peeling of canvas
Cracks in sides
AK202829 AB Cracks in tooth roots AK202793 AB
20.Check that the wire (inserted in the auto-tensioner 2. Cracks in back rubber surface.
when it was installed) can be moved freely. If the 3. Cracks in canvas.
wire can be pulled freely, the belt tensioner is 4. Cracks in tooth roots.
adjusted properly. Remove the wire. At that time,
5. Cracks in belt sides.
check that the auto-tensioner rod extends by the
specified amount. Rounded edge
CAUTION
Be sure to check the tightening torque of the
crankshaft bolt anytime the crankshaft has been
turned counterclockwise. If the torque lower than
specification, tighten the bolt to the specified
torque. Abnormal wear
21.If the wire cannot be pulled out freely, perform the (Fluffy strand)
AK202795 AB
steps 14 through 18 again to make the belt
tension proper. 6. Abnormally worn belt sides;
NOTE: belt sides are normal if they have
INSPECTION “knife-cut” surfaces.
M1113002000685
TIMING BELT
Check closely the entire timing belt. Canvas lost and
rubber exposed
Replace it if any of the following conditions is found.
Missing
Tooth
AK202796 AB
7. Badly worn teeth.

Initial stage: Canvas is worn (canvas fiber is fluffy;
AK202794 teeth look whitish due to worn-out rubber; canvas
texture is unclear)
1. Hardened back side rubber. Second stage: Canvas is lost and rubber is exposed
Back side surface is glossy, lacking in elasticity, (tooth width narrows down)
and so hard that no impression is left when 8. Missing tooth.
pressed with fingernail.
TIMING BELT
11D-25
AUTO-TENSIONER 3. Measure the extension length of the rod.
If it is not within the standard value range, replace
the auto-tensioner.
12 mm Standard value: 12 mm
98 to 196 N
Movement
AK301307AD
1. Check the auto-tensioner for leaks from the

sealed sections.
Replace it if leaky. AK301308AE
2. Check the rod end for wear and other damage. 4. Press the rod with a force of 98 to 196 N and
Replace the auto-tensioner if the rod is badly measure the amount of retraction. If the
worn or damaged. measurement exceeds the standard value,
replace the auto-tensioner.
Standard value: 1 mm maximum

M1113002200708
9.0 ± 2.0 N·m

4
11 ± 1 N·m
3 19 ± 3 N·m
11 1
2
9
10
8 7
5
6
AK400297 AB

1. Throttle body 7. O-ring
>>C<< 2. Throttle body gasket >>A<< 8. Injector
>>B<< 3. Fuel pressure regulator 9. O-ring
4. O-ring 10. Grommet
5. Injector and delivery pipe 11. Delivery pipe
6. Insulator
11D-27
INSTALLATION SERVICE POINTS >>B<< FUEL PRESSURE REGULATOR
>>A<< INJECTOR INSTALLATION INSTALLATION
1. Apply a thin coat of engine oil to a new O-ring. 1. Apply a thin coat of engine oil to a new O-ring.
CAUTION CAUTION
Prevent engine oil from getting into the delivery Prevent engine oil from getting into the delivery
pipe. pipe.
2. Insert the injector into the delivery pipe while 2. Insert the fuel pressure regulator into the delivery
turning it in both directions carefully not to pipe while turning it in both directions carefully not
damage the O-ring. to damage the O-ring.
3. Check that the injector turns smoothly. If it does 3. Check that the fuel pressure regulator turns
not, the O-ring may be jamming, so remove the smoothly. If it does not, the O-ring may be
injector and check the O-ring for damage. If the jamming, so remove the fuel pressure regulator
O-ring is intact, insert the injector into the delivery and check the O-ring for damage. If the O-ring is
pipe and check it for smooth rotation again. intact, insert it into the delivery pipe and check it
for smooth rotation again.

INSTALLATION
Tab
AK305995AC
Install the throttle body gasket with its tab located as

INLET MANIFOLD
INLET MANIFOLD
M1113026100062
36 ± 6 N·m
36 ± 6 N·m 3
20 ± 2 N·m
23 ± 2 N·m 1
31 ± 3 N·m
AK400302 AB
Removal steps INSTALLATION SERVICE POINTS

>>A<< 1. Inlet manifold stay
>>A<< INLET MANIFOLD STAY INSTAL-
2. Alternator brace stay
3. Inlet manifold LATION
4. Inlet manifold gasket
5. Detonatoin sensor
Inlet manifold
stay
AK400845 AB
Tighten the bolts to the specified torque 31 ± 3 N⋅m

on both ends after making sure that the stay is in
close contact with the bosses on the inlet manifold
and cylinder block.
EXHAUST MANIFOLD
11D-29
EXHAUST MANIFOLD
M1113004900725
19 ± 3 N·m 12
1 23 ± 3 N·m
21 59 ± 5 N·m
17 ± 2 N·m
33 ± 6 N·m
17 ± 2 N·m
11 ± 1 N·m
19 ± 1 N·m
16
14
20 7
55 ± 10 N·m 15
8
28 ± 5 N·m 10 ± 1 N·m
10 ± 1 N·m 18
13
17
28 ± 5 N·m
5
59 ± 5 N·m
19
23 ± 3 N·m
6
3
44 ± 5 N·m 10
2
4 36 ± 5 N·m 9 23 ± 3 N·m
11
14 ± 1 N·m
AK400396 AC

1. Engine hanger 12. Exhaust manifold heat protector
2. Oxygen sensor 13. Turbocharge assembly and pipe
3. Turbocharge heat protector assembly
4. Exhaust fitting bracket 14. Turbocharge gasket
5. Exhaust fitting 15. Ring
6. Exhaust fitting gasket 16. Oil pipe
7. Air outlet fitting 17. Water pipe "B"
>>C<< 8. Air outlet fitting gasket 18. Water pipe "A"
9. Oil return pipe 19. Turbocharge assembly
10. Oil return pipe gasket >>A<< 20. Exhaust manifold
>>B<< 11. Oil return pipe gasket 21. Exhaust manifold gasket
EXHAUST MANIFOLD
INSTALLATION SERVICE POINT >>B<< OIL RETURN PIPE GASKET

>>A<< EXHAUST MANIFOLD INSTALLA- INSTALLATION
TION
1. Hand tighten all the exhaust manifold mounting
nuts.
Tab
2. Tighten the M8 nuts to 29 ± 3 N⋅m in the indicated
sequence.
3. Tighten the M10 nuts to 49 ± 5 N⋅m in the
indicated sequence.
4. Tighten the M8 nuts again to 29 ± 3 N⋅m in the
indicated sequence. AK305998AC
Install the oil return pipe gasket with its tab located
NOTE: The gasket on the turbocharger end of the
3 4 5 6
pipe does not require special alignment for installa-
tion.
1 7 9 8 2
>>C<< AIR OUTLET FITTING GASKET
INSTALLATION
AK305997 AC
Tab
5. Finally tighten the M10 nuts and the M8 nuts to
the specified torque, both in the indicated
sequence.
Tightening torque:
33 ± 6 N⋅m <M8>
55 ± 10 N⋅m <M10>
AK400303AB
Install the air outlet fitting gasket with its tab located
11D-31
M1113017900372
13 ± 2 N·m
9
11 13 ± 2 N·m
13 ± 2 N·m
8
1
23 ± 4 N·m
13 7
2
12 6
4 10
10.8 ± 1.0 N·m
5
3
29 ± 10 N·m
15
14
14 ± 1 N·m
AK304981AC
Removal sequence INSTALLATION SERVICE POINTS

1. Water hose
>>A<< O-RING/WATER INLET PIPE
2. Water hose
3. Water hose INSTALLATION
4. Water hose CAUTION
>>E<< 5. Engine coolant temperature sensor • Never allow any oil or grease to touch the
>>D<< 6. Engine coolant temperature gauge
O-rings.
unit
7. Water inlet fitting • Clamp the water inlet pipe only after installa-
8. Thermostat tion of the thermostat case.
>>C<< 9. Water outlet fitting Replace the O-rings at both ends of the water inlet
>>B<< 10. Thermostat housing pipe with new ones. Insert the O-rings into the water
>>A<< 11. O-ring pump and thermostat housing after wetting their
>>A<< 12. Water inlet pipe peripheries with water.
>>A<< 13. O-ring
14. Water pump
>>B<< THERMOSTAT HOUSING >>D<< ENGINE COOLANT

INSTALLATION TEMPERATURE GAUGE UNIT
INSTALLATION
AK305999AC
1. Remove all old FIPG remaining on the thermostat AK300711 AB
housing and cylinder head. 1. Remove all old sealant remaining on the threaded
2. Apply a 2.7 ± 0.3 mm diameter bead of FIPG on hole in the engine coolant temperature gauge unit
the indicated surface of the thermostat housing. and the thermostat housing.
Specified sealant: NOTE: A new engine coolant temperature gauge
Mitsubishi Genuine Part No.MD970389 or unit is coated with sealant. It does not require
equivalent coating with sealant before installation.
2. Apply sealant to the indicated threads of the
>>C<< WATER OUTLET FITTING engine coolant temperature gauge unit.
INSTALLATION Specified sealant:
>>E<< ENGINE COOLANT

TEMPERATURE SENSOR INSTALLATION
AK202755AB
1. Remove all old FIPG remaining on the water

outlet fitting and thermostat housing.
2. Apply a 2.7 ± 0.3 mm diameter bead of FIPG to
the indicated surface of the water outlet fitting. AK300712 AB
Specified sealant: CAUTION

Mitsubishi Genuine Part No.MD970389 or When using a tool, avoid letting it touch the con-
equivalent nector portion which is made of plastic.
1. Remove all old sealant remaining on the threads
of the engine coolant temperature sensor and in
the threaded hole in the thermostat housing.
2. Apply sealant to the engine coolant temperature
sensor's threads indicated in the drawing.
Specified sealant:
11D-33
M1113005400853
8 3 10 ± 2 N·m
11
14 4
9
13 6
20 ± 1 N·m
12 14 ± 1 N·m
2
10 1
22 ± 4 N·m
15 5
11 ± 1 N·m
11 ± 1 N·m
18
7
16
17
Apply engine oil to

all moving parts
AK306000AC

1. Camshaft position sensor 16. Rocker arm
2. O-ring <<A>> >>A<< 17. Lash adjuster
3. Cover 18. Oil delivery body
4. Gasket
>>F<< 5. Camshaft position sensing cylinder SERVICE POINTS FOR REMOVAL
>>E<< 6. Camshaft position sensor support
<<A>> LASH ADJUSTER REMOVAL
>>D<< 7. Camshaft oil seal
>>C<< 8. Bearing cap, rear right CAUTION
>>C<< 9. Bearing cap, rear left When reusing a lash adjuster, it must be washed
>>C<< 10. Bearing cap, front and inspected before installation. (Refer to
>>C<< 11. Bearing cap No.5 P.11D-35, the instruction under LASH ADJUSTER
>>C<< 12. Bearing cap No.2
>>B<< 15. Camshaft
INSTALLATION SERVICE POINTS 2. The bearing caps No. 2 to 5 are identical in shape
>>A<< LASH ADJUSTER INSTALLATION for both intake and exhaust camshafts. Check the
identification mark on each cap before installation.
CAUTION Identification mark (stamped on front and
When reusing a lash adjuster, it must be washed Nos. 2 − 5 bearing caps)
and inspected before installation. (Refer to I: intake camshaft
P.11D-35, the instruction under LASH ADJUSTER E: exhaust camshaft
Install the lash adjuster into the rocker arm, being 3. Remove completely sealant remaining on the
careful not to spill the diesel fuel it contains. bearing caps and cylinder head.
>>B<< CAMSHAFT INSTALLATION

Timing belt side
Slit
AK202871AB
Exhaust camshaft 4. Apply sealant to the surfaces indicated in the

AK202869 AD drawing.
Specified sealant:
CAUTION
• Do not confuse the intake camshaft with the
exhaust camshaft. 5. Install each bearing cap and tighten its bolts in two
• The exhaust camshaft has a 4 mm wide slit at or three passes.
the rear end. 6. Finally tighten the bolts to 20 ± 1 N⋅m.
7. Check that the rocker arms are correctly installed.
>>C<< BEARING CAP INSTALLATION NOTE: Wipe off any squeezed out sealant com-
pletely.
Dowel pin
>>D<< CAMSHAFT OIL SEAL

INSTALLATION
MD998713
AK203979 AC
1. Set each camshaft with its dowel pin at the top.
AK304515AB
Use the special tool Camshaft oil seal installer

Cap number (MD998713) to drive each oil seal into position in the
Intake/exhaust cylinder head.
identification
letter
AK202870 AB
11D-35
>>E<< CAMSHAFT POSITION SENSOR INSPECTION
M1113005500708
SUPPORT INSTALLATION
CAMSHAFT
AK202754AB
AK202797AB
1. Remove completely the FIPG remaining on the
Measure the cam height (nose-to-heel diameter).
camshaft position sensor support and cylinder
If any cam is worn beyond the limit, replace the cam-
head.
shaft.
Standard value:
indicated surface of the camshaft position sensor
Intake: 35.79 mm
support.
Exhaust: 35.49 mm
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or Limit:
equivalent Intake: 35.29 mm
Exhaust: 34.99 mm
>>F<< CAMSHAFT POSITION SENSING

CYLINDER INSTALLATION LASH ADJUSTERS
CAUTION
Smaller vane
• The lash adjuster is a precision-engineered
component. Do not allow dust or other for-
eign matter to enter it.
• Do not disassemble lash adjusters.
• Use only non-contaminated diesel fuel to
clean the lash adjuster.
Camshaft
posittion sensor
For rough For finish For diesel
cleaning cleaning fuel filling
AK306001AC
1. Turn the exhaust camshaft to the No.1 cylinder

top dead center position.
NOTE: The camshaft will slightly turn counter-
clockwise by the force of the exhaust valve spring.
A B C
2. Install the camshaft position sensing cylinder with
the smaller vane located as shown in the drawing. AK202836 AB
1. Prepare three containers and approximately five

liters of diesel fuel. Pour into each container the
diesel fuel in an amount enough for a lash
adjuster placed in the container in its upright
position to completely submerge.
CAUTION
directed toward the inside of container A. Never
Diesel fuel chamber.
AK300587AB
2. Place the lash adjuster in container A and wash

its outside surface.
NOTE: Use a nylon brush if there are
hard-to-remove deposits.
Diesel fuel
MD998442
AK202839 AB
CAUTION
The steel ball spring of the lash adjuster is
extremely weak. The lash adjuster's functionality
Diesel fuel may be badly affected if the special tool is
MD998442 inserted too strongly.
AK202839 AB
5. Soak the lash adjuster in the diesel fuel in
CAUTION container B. Move the plunger in and out 5 − 10
The steel ball spring of the lash adjuster is times by gently pushing the internal steel ball
extremely weak. The lash adjuster's functionality using the special tool Air bleed wire (MD998442)
may be badly affected if the special tool is until the plunger moves smoothly to wash the lash
inserted too strongly. adjuster’s pressure chamber.
3. While gently pushing the internal steel ball using

the special tool Air bleed wire (MD998442), move
the plunger in and out 5 − 10 times to eliminate
stiffness in the plunger and expel contaminated
oil.
NOTE: The plunger must be free from jamming
and any other abnormalities. If a defect is found in MD998442
plunger operation, replace the lash adjuster.
Diesel fuel
AK202840 AC
CAUTION
directed toward the inside of container B. Never
MD998442
Diesel fuel
AK202840 AC chamber.
11D-37
Diesel fuel
MD998442
AK202841 AB AK202843
CAUTION 9. Take the lash adjuster out of the container, place it

Do not use container C for cleaning. If cleaning is upright with the plunger at the top, and push the
performed in container C, foreign matter could plunger firmly. The plunger must not move at all.
enter the pressure chamber when the chamber is NOTE: If the lash adjuster contracts, perform the
filled with diesel fuel. operations 7 through 9 again. Replace the lash
7. Soak the lash adjuster in the diesel fuel in adjuster if it still contracts even after the pressure
container C. Gently push the internal steel ball chamber has completely been filled with diesel
using the special tool Air bleed wire (MD998442). fuel (air has been bled).
10.Keep the serviced lash adjusters in their upright
positions to prevent diesel fuel from spilling out.
Protect them from dust or other foreign matter.
Install the lash adjusters onto the engine as soon
as possible.
MD998442 Diesel fuel
AK202842 AB
8. Place the lash adjuster upright with the plunger at

the top. Push the plunger firmly until it makes a
full stroke, then return the plunger slowly and
release the hold of the steel ball to allow the
pressure chamber to be filled with diesel fuel.

M1113006900787
78 ± 2 N·m → 0 N·m →
20 ± 2 N·m → +90˚ → +90˚
1
2
8
9
4 10
5 20 14
6 15
12 17
13
16
19
18 11
Apply engine oil to

all moving parts
AK306002AC

<<A>> >>D<< 1. Cylinder head bolt 7. Intake valve
2. Cylinder head assembly <> >>C<< 8. Retainer lock
3. Cylinder head gasket 9. Valve spring retainer
<> >>C<< 4. Retainer lock >>B<< 10. Valve spring
5. Valve spring retainer 11. Exhaust valve
>>B<< 6. Valve spring <<C>> >>A<< 12. Valve stem seal
13. Valve spring seat
11D-39
<<C>> >>A<< 14. Valve stem seal 18. Intake valve seat
15. Valve spring seat 19. Exhaust valve seat
16. Intake valve guide 20. Cylinder head
17. Exhaust valve guide

<<A>> CYLINDER HEAD BOLT REMOVAL <<C>> VALVE STEM SEAL REMOVAL
MB991654
AK202723 AE AK304633
Use the special tool Cylinder head bolt wrench Do not reuse removed valve stem seal.
(MB991654) to loosen the cylinder head bolts.
<> RETAINER LOCK REMOVAL INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEAL INSTALLA-
MD998735 TION
CAUTION
The special tool must always be used when
installing the valve stem seal. Improper installa-
tion could result in oil leaks past the valve guide.
1. Install the valve spring seat.
2. Install the valve.
AK306003 AC 3. Apply a thin coat of engine oil to a new valve stem
seal.
MD998772
MD998737
AK202742 AD
AK304485 AC
Valve spring compressor (MD998735 or MD998772), 4. Use the special tool Valve stem seal installer
then remove the retainer lock. (MD998737) to install the stem seal on the valve
NOTE: Store removed valves, springs and other guide. Use the stem of the valve to guide the stem
parts, after putting to each of them a tag that identi- seal.
fies its cylinder No. or installation location.

Intake valve stem seal Exhaust valve stem seal Valve spring compressor (MD998735 or MD998772),
Colour: Gray Colour: Grayish green
then install the retainer lock.
>>D<< CYLINDER HEAD BOLT

INSTALLATION
AK304538AB
NOTE: Do not confuse the stem seals for intake

valves with those for exhaust valves. Shank length
>>B<< VALVE SPRING INSTALLATION

AK300591AB
1. When reusing a cylinder head bolt, check that its

Painted end
nominal length (shank length) is not greater than
the limit. If the limit is exceeded, replace the bolt.
Limit: 99.4 mm
2. Apply engine oil to the threads and washer of the
bolt.
AK300717AB
Install the valve spring whose small diameter is

shown from the rocker arm side.
MB991654
>>C<< RETAINER LOCK INSTALLATION
MD998735
AK202723 AE
Timing belt side
AK306003 AC
8 6 1 3 9
MD998772
10 4 2 5 7
AK306004AC

sequence.
NOTE: Use the special tool Cylinder head bolt
wrench (MB991654) to tighten the bolts.
AK202742 AD 4. Loosen all the bolts completely.
5. Tighten the bolts again to a torque of 20 ± 2 N⋅m
in the indicated sequence.
11D-41
CAUTION
The thickness of the metal that can be removed
by grinding from both the cylinder head and the
90˚ mating cylinder block is limited to 0.2 mm in
total.
3. Check the cylinder head gasket surface for warp
using a straightedge and thickness gauge.
90˚
Paint marks If the surface is warped beyond the limit, grind the
AK202720 AB
surface for rectification.
Gasket surface warp
CAUTION Standard value: Less than 0.05 mm
• If the tightening angle is smaller than 90°, Limit: 0.2 mm
proper fastening performance could not be Grinding limit: 0.2 mm
assured. Be sure to respect that angle. Cylinder head height (standard value for new
• If the bolt is tightened to an angle greater than part): 131.9 − 132.1 mm
the specified angle, loosen the bolt com-
pletely and then retighten it beginning with
the first step.
VALVES
1. Check the valve face for correct contact with the
6. Make paint marks on each bolt’s head and on the
seat. Reface the valve if the contact is partial or
cylinder head.
one sided.
7. Turn the bolts 90° in the tightening direction and in
the indicated sequence.
8. Give another 90° turn in the tightening direction to
each bolt, making sure that the paint mark on the Contact
(Should be at
bolt head and that on the cylinder head are on the centre of face)
same line. Margin
INSPECTION
M1113007000680
CYLINDER HEAD
1. Before cleaning the cylinder head, check it for AK300593AB
traces of water and gas leakage and for cracks 2. Measure the margin.
and any other damage.
Replace the valve if its margin is smaller than the
2. Thoroughly remove oils, scale, sealants, carbon
limit.
and other contamination. Clean the oil passages,
then check using compressed air that they are not Standard values:
blocked. Intake 1.0 mm
Exhaust 1.5 mm
Limits:
Intake 0.5 mm
Exhaust 1.0 mm
AK202724
Total length
AK202876 AB
3. Measure the total length of the valve. Standard values:

Intake 0.02 − 0.05 mm
Replace the valve if the length is less than the
Exhaust 0.05 − 0.09 mm
limit.
Standard values: Limits:
Intake 109.5 mm Intake 0.10 mm
Exhaust 109.7 mm Exhaust 0.15 mm
Limits:
Intake 109.0 mm VALVE SEATS
Exhaust 109.2 mm Valve stem
end
VALVE SPRINGS Valve stem

projection
Out of square
Spring
seating
surface
Free height AK202814 AB
With the valve installed in position and its face

pressed against the valve seat, measure the valve
AK300594 AB
stem projection (distance between the valve stem
end and spring seating surface). If the measurement
1. Measure the free height of the spring. exceeds the limit, replace the valve seat.
Replace the spring if its height is smaller than the Standard values:
limit. Intake 49.2 mm
Exhaust 48.4 mm
Limit: 47.3 mm Limits:
2. Measure the squareness of the spring. Intake 49.7 mm
Exhaust 48.9 mm
Replace the spring if it is out of square beyond the
limit. VALVE SEAT RECONDITIONING
Standard value: 1.5° or smaller 1. Before reconditioning the valve seat, check the
Limit: 4° clearance between the valve guide and valve
stem and, if necessary, replace the valve guide.
VALVE GUIDE
0.9 – 1.3 mm 0.9 – 1.3 mm

44˚
65˚ 44˚
65˚
Valve 10˚
guide 10˚
AK304983 AC
Stem diameter
Guide inside diameter AK300168 AE
2. Resurface the valve seat to the indicated width
Measure the valve guide inside diameter and valve and angles.
stem diameter to calculate the clearance between 3. After resurfacing, lap the valve and valve seat
the valve guide and valve stem. using lapping compound.
If the limit is exceeded, replace the valve guide or
valve, or both.
11D-43
VALVE SEAT REPLACEMENT VALVE GUIDE REPLACEMENT
1. Force out the valve guide toward the cylinder
0.5 – 1 mm block using a press.
CAUTION
Do not use a replacement valve guide of the
same size as the removed one.
Cut
2. Machine the valve guide hole in the cylinder head
to the size matched to the selected oversize valve
0.5 – 1 mm guide.
Valve guide hole diameters
AK300719AB
0.05 oversize: 12.05 − 12.07 mm
1. Cut inside of the valve seat to be replaced until its 0.25 oversize: 12.25 − 12.27 mm
wall becomes thin enough for removal, then 0.50 oversize: 12.50 − 12.52 mm
remove the valve seat.
Valve seat
height
19.2 – 19.8 mm
Oversize hole diameter AK400848 AB
AK300720AB
3. Press-fit the valve guide until it remains protruded
2. Rebore the valve seat hole in the cylinder head to above the cylinder head by the amount indicated
a diameter matched to the diameter of the in the drawing.
selected oversize valve seat. Standard value: 19.2 − 19.8 mm
Intake valve seat hole diameters: NOTE: Press the valve guide from above the cyl-
0.3 oversize: 35.30 − 35.33 mm inder head.
0.6 oversize: 35.60 − 35.63 mm NOTE: The valve guides for the intake valves are
Exhaust valve seat hole diameters: different in length from those for the exhaust
0.3 oversize: 33.30 − 33.33 mm valves (45.5 mm for intake valves; 50.5 mm for
0.6 oversize: 33.60 − 33.63 mm exhaust valves)
3. Before fitting the valve seat, cool it in liquid 4. After installing the valve guide, insert a new valve
nitrogen to prevent damage to its hole in the in it to check for smooth movement.
cylinder head due to interference.
4. Resurface the valve seat. See the VALVE SEAT
RECONDITIONING section.

M1113008100884
19 ± 3 N·m 32
31
10
Apply engine oil to 28 30
all moving parts
21
23 ± 3 N·m
10 ± 2 N·m
29
20 22
54 ± 5 N·m
23 ± 3 N·m 23 24 7 8
9 6
16 19 ± 3 N·m
26
19 ± 3 N·m 17 ± 1 N·m
25
19 27
14 4
15 17 18 23 ± 3 N·m
13
36 ± 3 N·m 9.0 ± 3.0 N·m
11 23 ± 3 N·m
39 ± 5 N·m
1
12 2
3
44 ± 5 N·m 5
9.0 ± 3.0 N·m 22 ± 4 N·m
9.0 ± 3.0 N·m
AK400304 AB

1. Drain plug 18.O-ring
>>N<< 2. Drain plug gasket <<D>> >>I<< 19.Flange bolt
>>M<< 3. Oil filter >>H<< 20.Front case
4. Transmission stay 21.Gasket
<<A>> >>L<< 5. Oil pan lower 22.Oil pump cover
<> >>L<< 6. Oil pan upper >>G<< 23.Oil pump driven gear
7. Oil screen >>G<< 24.Oil pump drive gear
8. Gasket >>F<< 25.Crankshaft front oil seal
9. Oil cooler by-pass valve >>E<< 26.Counterbalancer shaft oil seal
10.Oil pressure switch >>D<< 27.Oil pump oil seal
>>K<< 11. Relief plug 28.Counterbalancer shaft, right
12.Gasket 29.Counterbalancer shaft, left
13.Relief spring <<E>> >>C<< 30.Counterbalancer shaft front bearing
14.Relief plunger <<F>> >>B<< 31.Counterbalancer shaft rear bearing,
15.Oil filter bracket right
16.Gasket <<F>> >>A<< 32.Counterbalancer shaft rear bearing,
<<C>> >>J<< 17.Plug left
11D-45
REMOVAL SERVICE POINTS <<D>> FLANGE BOLT REMOVAL
<<A>> OIL PAN LOWER REMOVAL

CAUTION
remove the oil pan.
Remove the oil pan by tapping it through a piece of
wood applied to a side with a plastic hammer.
Plug Crosspoint
<> OIL PAN UPPER REMOVAL screwdriver
AK202752 AD
A 1. Remove the plug on the left side of the cylinder

block. Insert a cross point screwdriver (shank
diameter 8 mm) into the plug hole more than 60
mm to prevent the left counterbalancer shaft from
rotating.
A
AK304400 AB
CAUTION
remove the oil pan.
Screw bolts into the bolt holes A shown in the draw-
ing (holes at both ends) to remove the oil pan. AK300173
<<C>> PLUG REMOVAL 2. Loosen and remove the flange bolt.
<<E>> COUNTERBALANCER SHAFT

MD998162
FRONT BEARING REMOVAL
MD998783 AK300171 AD
Fit the teeth of the special tools in notches of the plug

as shown in the drawing and support the tool with the MD998371
special tool to loosen the plug. AK300174 AD
• Plug wrench retainer (MD998783) CAUTION
Remove the front bearing first. Otherwise, the
special tool cannot be used.
Use the special tool Silent shaft bearing puller
front bearing from the cylinder block.
<<F>> COUNTERBALANCER SHAFT INSTALLATION SERVICE POINTS

REAR BEARING REMOVAL >>A<< LEFT COUNTERBALANCER
MB991603
MD998372
AK300175AD
MD998705
1. Use the special tool Silent shaft bearing puller AK300177 AF

rear bearings from the cylinder block.
MB991603
MD998705
MB991603
Rear bearing
AK300619AG
MD998372
AK300176 AD 1. Install special tool Silent shaft bearing installer
2. When removing the rear bearing of the left 2. Apply engine oil to the rear bearing outer surface
counterbalancer shaft, install the special tool and bearing hole in the cylinder block.
on the front of the cylinder block and use a special
tool Silent shaft bearing puller (MD998372) to pull
out the bearing. NOTE: The left rear bearing has no oil holes.

MD998705(Guide pin)
AK300178 AD

11D-47
>>C<< COUNTERBALANCE SHAFT
Ratchet ball
FRONT BEARING INSTALLATION
Oil hole
MD998705
Rear bearing right
AK300621AD
Rear bearing
installing portion
hole in the rear bearing to install the bearing of the AK300623AF
special tool. 1. Remove the rear bearing installing portion from

3. Apply engine oil to the bearing outer surface and the special tool Silent shaft bearing installer
bearing hole in the cylinder block. (MD998705).
MD998705
MD998705(Guide pin) MD998705(Guide pin)

AK300179 AG AK300178 AD

MD998705 installer (MD998705) in the threaded hole of the
AK300622AG

Front bearing right
that the oil hole of the bearing is aligned with the AK304592AB
hole in the rear bearing to install the bearing of the
special tool.
4. Apply engine oil to the front bearing outer surface
and bearing hole in the cylinder.
>>E<< COUNTERBALANCER SHAFT OIL

MD998705 SEAL INSTALLATION
Socket wrench
Oil seal Front case

MD998705(Guide pin)
AK300179 AG
AK304593AB
Use an appropriate socket wrench to install the coun-

terbalancer shaft oil seal.
>>F<< CRANKSHAFT OIL SEAL

INSTALLATION
MD998375
AK300624

Oil seal
Front case
>>D<< OIL PUMP OIL SEAL

INSTALLATION AK304595AB
Use the special tool Crankshaft front oil seal installer

Socket wrench
(MD998375) to install the crankshaft oil seal.
Oil seal
>>G<< OIL PUMP DRIVEN GEAR / OIL
Front case
AK304594AB
Use an appropriate socket wrench to install the oil

pump oil seal.
Alignment
mark
AK300180 AD
Apply engine oil generously to the gears and line up

the alignment marks.
11D-49
>>H<< FRONT CASE INSTALLATION >>I<< FLANGE BOLT INSTALLATION
MD998285
AK300181AD AK300172
1. Install the special tool crankshaft front oil seal 1. Insert a correspond screwdriver (shank diameter
guide (MD998258) on the front end of crankshaft 8 mm) into the hole in the left side of the cylinder
and apply a thin coat of engine oil to the outer block to prevent the counterbalancer shaft from
surface of the special tool. Be sure to use the rotating.
special tool when the front case is fitted with an oil
seal.
2. Install the front case on the cylinder block with a
new front case gasket in between and temporarily
tighten all the flange bolts except those that are
used for tightening the filter bracket.
3. Install the oil filter bracket on the front case with
the oil filter bracket gasket in between and
temporarily tighten the washer-assembled bolts.
AK300183
2. Tighten the flange bolts.
>>J<< PLUG INSTALLATION

1. Install a new O-ring on the front case.
MD998162
MD998285
AK300182 AD
4. Tighten all the bolts to the specified torques.
MD998783
AK300184 AD
2. Use the special tools to tighten the plug to the

specified torque.
>>K<< OIL PRESSURE SWITCH >>L<< OIL PAN UPPER / OIL PAN LOWER
CAUTION CAUTION
Do not apply FIPG over remaining old FIPG.
and oil pan.
CAUTION
Bolt hole
Timing belt side area
AK300715 AB
Be careful not to block the oil passage with seal-

ant.
Grooved
Specified Sealant: area
3M ATD Part No.8660 or equivalent AK304401 AB
Too much FIPG will squeeze out, blocking cool-

ant or oil passages, while too thin a bead could
MD998012 result in leakage.
2. Apply a 4 mm diameter bead of FIPG to the flange
Specified sealant:
equivalent
AK204037AF apply FIPG bead along the center of the groove.
2. Tighten the oil pressure switch together with the
cylinder block by the specified torque using of the
special tool Oil pressure switch wrench M6 × 16
MD998012.
AK304402 AB

in the drawing.
CAUTION
Do not apply FIPG over remaining old FIPG.
4. Thoroughly remove old FIPG from the gasket
surfaces of the oil pan upper and lower sections.
11D-51
CAUTION >>M<< OIL FILTER INSTALLATION
Timing belt side
Bolt hole
area
Grooved area AK304403 AB AK301069AD
Too much FIPG will squeeze out, blocking cool- 1. Clean the installation surface of the filter bracket.
result in leakage.
3. Install the oil filter to the bracket and tighten it to
5. Apply a 4 mm diameter bead of FIPG to the flange the specified torque.
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or 4. If no torque wrench can be used for tightening,
equivalent use the following procedure:
(1) Screw in the oil filter until its o-ring contacts
NOTE: . In the grooved areas on the oil pan
the oil filter bracket.
flange, apply FIPG bead along the center of the
groove. (2) Tighten the oil filter 3/4 turn.
Timing belt side
9 8
5 4 1
12 11
3
2 6
7 10
AK304404 AB

bolts in the indicated sequence.
>>N<< DRAIN PLUG GASKET OIL PUMP

INSTALLATION
Drain plug
AK202831
Oil pan 1. Install the drive and driven gears in the oil pump
Gasket case.
Oil pan
side 2. Measure the gear side clearance using a straight
edge and thickness gauge.
Standard values:
OIL COOLER BY-PASS VALVE

AK300601AB
L
CAUTION
Installing the gasket with the wrong side facing
the oil pan will result in oil leakage.
Replace the drain plug gasket with a new one. Install
it with the side indicated in the drawing toward the oil
pan.
INSPECTION Valve AK000032 AC

M1113008200386
COUNTERBALANCE SHAFTS 1. Make sure that valve moves smoothly.

1. Check that the oil holes are not blocked. 2. Ensure that the dimension L measures the
Clean if necessary. standard value under normal temperature and
humidity.
3. The dimension must be the standard value when
measured after the valve has been dipped in 97 to
103°C oil.
AK202835AB
2. Check the journals for seizure, damage and

defective contact with bearings.
If any of these faults is found, replace the
counterbalance shaft, bearings and/or oil pump
case assembly.
11D-53
M1113008400863
6
7
8
10
4
9
12
11
Apply engine oil to

all moving parts
2
20 ± 2 N·m → +90º to 94º
1
AK306012 AC

>>G<< 1. Connecting rod cap nut >>C<< 7. Piston ring No. 2
<<A>> >>F<< 2. Connecting rod cap >>B<< 8. Oil ring
>>E<< 3. Connecting rod bearing <<C>> >>A<< 9. Piston pin
<> >>D<< 4. Piston and connecting rod assembly 10. Piston
5. Connecting rod bearing 11. Connecting rod
>>C<< 6. Piston ring No. 1 12. Bolt

<<A>> CONNECTING ROD CAP Guide A: 18.9 mm
REMOVAL Guide B
Push rod
Cylinder
number
Guide A: 17.9 mm
Guide C
Guide A: 20.9 mm
AK300189 AD
Base
Mark the cylinder number on the side of the connect-
ing rod big end as a guide for reassembly.
Guide A: 21.9 mm
<> PISTON AND CONNECTING ROD
ASSEMBLY REMOVAL
MB992010
AK301431AD

P
Crank pin Push rod
AK402310 AC
Front mark
1. Not to damage the crank pin, attach a special tool Front mark
bolt. P
from the cylinder block. Guide C
Base
AK301478AC

11D-55
NOTE: Keep the disassembled pistons, piston L
pins and connecting rods cylinder by cylinder.

>>A<< PISTON PIN INSTALLATION
Timing belt side Crankshaft
bore size mark Guide B Guide A
AK301480 AD
6. Insert the tool element, Guide B, into the tool

No.4 element, Guide A, with having 2.75 mm of the
No.3 clearance "L" between the tool element, Guide A
No.2 and B.
No.1
AK305985 AC
Push rod
1. When replacing a piston, check the cylinder bore P
Front mark
replacement piston using the following table.
Front mark
I A P
II No mark
Guide A
III C
NOTE: The piston size mark is located on the pis-
ton top surface. Base

Guide B
pin and attach the element, Guide A, to the push
rod end.
3. Assemble the connecting rod with the piston with
their front marks facing in the same direction.
AK305971AC
piston pin.
5. Insert the assembly of piston pin, Push rod, and 7. Place the piston and connecting rod assembly
Guide A (put together in step 4.) into the piston onto the element, Piston setting base, with the
holes from the front mark side. front marks facing up.
8. Install the piston pin using a press. If the required
press force is less than the standard value,
replace the piston and piston pin assembly or the
connecting rod, or both.
Standard value: 7,350 − 17,100 N
>>B<< OIL RING INSTALLATION >>C<< PISTON RING NO. 2/PISTON RING
NO. 1 INSTALLATION
Upper Lower
side side
rail rail
end gap end gap
Piston ring
expander
Spacer end gap AK202879 AB
AK202786 AC
1. Fit the oil ring spacer into the piston ring groove.
Install the upper side rail, then the lower side rail. Identification mark
NOTE: Locate the side rail and spacer end gaps Size marks
NOTE: New spacers and side rails are an identi-
fied by color marks as follows: No. 1
Size Color mark
No. 2
Standard No mark
0.50 mm oversize Red
AK202807 AB
1.00 mm oversize Yellow
Using a piston ring expander, install the piston rings
CAUTION with their identification marks facing up (toward the
Use of ring expander to expand the side rail end piston crown).
gap can break the side rail, unlike other piston Identification marks:
rings. No.1 ring: 1R
Side rail end No.2 ring: 2R
NOTE: Each of the available piston rings has a size
mark as follows:
Size Size mark
Standard No. 1 ring No mark (white paint on
periphery)
No. 2 ring No mark
0.50 mm oversize 50
AK202785 AB
1.00 mm oversize 100
2. To install each side rail, first fit one end of the rail
portion progressively into position by finger as
3. Make sure that the installed side rails move
smoothly in either direction.
11D-57
>>D<< PISTON AND CONNECTING ROD >>E<< CONNECTING ROD BEARING
ASSEMBLY INSTALLATION INSTALLATION
1. Apply engine oil generously to the piston's outside 1. When replacing the connecting rod bearing,
surface, piston rings, and oil ring. select a bearing of the size appropriate for the
Side rail
crankshaft pin diameter in accordance with the
crankshaft pin and connecting rod bearing
No. 1
matching table shown below.
Locations of crankshaft pin diameter
marks
No. 2 Side rail

No. 2
AK202730 AB
No. 1 No. 3
2. Align the end gaps of the piston rings and oil ring
(side rails and spacer) as shown in the drawing. No. 4 AK304412 AB
3. Insert the piston and connecting rod assembly
2. Crankshaft pin diameter marks are stamped in the
from the top of cylinder with the front mark on the
indicated locations.
crown toward the camshaft sprocket.
Connecting bearing
Identification
mark position
AK304598AB
AK202798
CAUTION 3. Connecting rod bearing identification mark is

• Do not strike the assembly with a large force. stamped in the indicated location on each
Doing so could break the piston rings. bearing.
• When striking the assembly into cylinder, do Crankshaft pin Connecting rod
not allow it to interfere with the oil jet. bearing
4. Use a piston ring band to hold the piston rings Identification Diameter mm Identification
compressed when inserting the piston and mark mark
connecting rod assembly into the cylinder. I 44.995 − 45.000 0
II 44.985 − 44.995 1
III 44.980 − 44.985 2
<Bearing selection example>
If the crankshaft pin diameter mark is “I,” select a
bearing marked “1.”
If the crankshaft pin diameter mark is illegible,
measure the pin diameter and select a bearing
with the mark corresponding to the measurement.
4. Install the upper and lower halves of the selected
bearing on the connecting rod big end and cap,
respectively.
>>F<< CONNECTING ROD CAP >>G<< CONNECTING ROD CAP NUT

1. The connecting rod cap bolts and nuts are
Cylinder tightened using the torque-to-yield method. For
number this reason, each bolt to be reused must be
checked for elongation before installation.
Whether or not the bolt has been elongated can
be determined by running a nut with fingers
through all the threads of the bolt. If the nut does
not turn smoothly over all the threads, the bolt has
Notches been elongated and must be replaced.
AK300193 AD 2. Apply engine oil to the threads and bearing
surface of each nut before installation.
1. Install the bearing cap on the connecting rod while
aligning the marks made during disassembly. If 3. Finger-tighten the nuts on the bolts, then tighten
the connecting rod is new and has no alignment the nuts alternately and repeatedly to install the
mark, assemble it with the cap such that the both cap properly.
bearing locating notches are on the same side as 4. Tighten the nuts to a torque of 20 ± 2 N⋅m.
Paint marks
90˚ to 94˚
Paint marks
Nut Bolt
AK300612AC
AK202821
5. Make a paint mark on the head of each nut.
2. Make sure that the thrust clearance of the CAUTION
connecting rod big end is proper. • If the tightening angle is less than 90°, ade-
Standard value: 0.10 − 0.25 mm quate tightness could not be assured.
Limit: 0.4 mm • If the tightening angle exceeds 94°, loosen the
nut completely and then perform the tighten-
ing procedure again beginning with the first
step.
6. Make a paint mark on the bolt at a point 90° to 94°
away from the paint mark made on the nut in the
tightening direction.
7. Turn the nut 90° to 94° to bring the mark on the
nut into alignment with that on the bolt.
11D-59
INSPECTION CRANKSHAFT PIN OIL CLEARANCE
M1113008500688
(PLASTIGAGE METHOD)
PISTON RING
1. Wipe off oil from the crankshaft pin and
connecting rod bearing.
2. Cut a piece of plastigage whose length is
equivalent to the width of the bearing and place it
on the crankshaft pin in parallel with its axis.
3. Install the connecting rod cap carefully and tighten
the nuts to the specified torque 20 ± 2 N⋅m + 90°
to 94°.
4. Remove the nuts, then remove the connecting rod
AK202787
cap carefully.
1. Measure the clearance between each piston ring

and its groove. If the limit is exceeded, replace the
ring or piston, or both.
Standard values:
No. 1 ring: 0.03 − 0.07 mm
No. 2 ring: 0.02 − 0.06 mm
Limits: 0.1 mm
AK202848
Push in by
piston
5. Measure the largest width of the crushed
plastigage using the ruler printed on the bag of the
plastigage.
Limit: 0.1 mm
Piston ring Piston ring gap

AK301481AD
2. Install a piston ring or oil ring side rail into the

cylinder bore and force it down with the head of a
piston until the ring is at right angles to the
cylinder wall. Measure the end gap with a
thickness gauge.
NOTE: . If the end gap is excessive, replace the
piston ring.
Standard values:
No. 1 ring: 0.20 − 0.30 mm
No. 2 ring: 0.30 − 0.45 mm
Oil ring: 0.10 − 0.40 mm
Limits:
No. 1 ring: 0.8 mm
No. 2 ring: 0.8 mm
Oil ring: 1.0 mm

M1113008700875
11 ± 1 N·m
3
1
6
14 132 ± 5 N·m
4
5 9.0 ± 1.0 N·m
11 ± 1 N·m
12 11
13
10
8 Apply engine oil to

all moving parts
25 ± 2 N·m → +90˚ to 100˚

7
AK400305AB

1. Flywheel bolt >>D<< 8. Beam bearing cap
2. Flywheel >>C<< 9. Crankshaft bearing, lower
3. Rear plate 10. Crankshaft
4. Bell housing cover >>C<< 11. Crankshaft bearing, upper
>>F<< 5. Oil seal case >>B<< 12. Thrust bearing
>>E<< 6. Oil seal <<A>> >>A<< 13. Oil jet
>>D<< 7. Bearing cap bolt 14. Cylinder block
11D-61
<<A>> OIL JET REMOVAL >>C<< CRANKSHAFT BEARING
INSTALLATION
Location of crankshaft journal
diameter marks
No. 2
No. 1 No. 3
AK304984
No. 4 No. 5 AK304413 AB
CAUTION
Be extremely careful not to give damage to the 1. Location of crankshaft journal diameter marks
cylinder wall.
Use a suitably long metal rod to drive out the oil jet.
<Bearing selection example>
INSTALLATION SERVICE POINTS If the crankshaft journal diameter mark is “0” and
the cylinder block bearing bore mark is “1,” then
>>A<< OIL JET INSTALLATION
select a bearing with a “2” mark as the No. 1, 2, 4
or 5 bearing and a bearing with a “1” mark as the
No. 3 bearing.
If the crankshaft journal diameter mark is illegible,
measure the journal diameter and select a
bearing with the mark corresponding to the
measurement.
Timing belt side
AK304985 Diameter identification marks of

bearing bores in cylinder block
Using a 4.5 mm diameter pin punch, drive the oil jet
from the crankshaft journal bearing bore side of the No. 4
No. 3
cylinder block until it bottoms. No. 5
No. 1 No. 2
>>B<< THRUST BEARING INSTALLATION
Cylinder
bore size
mark
Groove
AK304599AB
Install the two thrust bearings in the No. 3 bearing AK304518AB

bore in the cylinder block. Each thrust bearing must
be installed with the grooved end toward the crank- 2. The diameter identification marks of the bearing
shaft web. bores in the cylinder block are stamped in the
NOTE: Applying engine oil to the bearings will help location shown in the drawing.
facilitate holding them in position.
Crankshaft journal diameter Cylinder Crankshaft >>D<< BEAM BEARING CAP/BEARING

block bearing CAP BOLT INSTALLATION
bearing bore
1. Install the beam bearing cap on the cylinder block
Identification Journal Identification Identification
mark diameter mark mark
with the arrow pointing to the timing belt.
measurement
mm
0 56.994 − 0 0
57.000 1 1
2 2
1 56.988 − 0 1
Shank length
56.994 1 2
2 3
AK301471AD
2 56.982 − 0 2
56.988 1 3 2. Measure the shank length of each bearing cap
bolt before installation. If the measurement
2 4 exceeds the limit, replace the bolt.
Crankshaft bearing identification mark location Limit: 71.1 mm
3. Apply engine oil to the threads and bearing
surface of the bolt.
8 4 1 5 9
Identification mark
AK304464AC
7 3 2 6 10
3. The size mark of each crankshaft bearing is
indicated by ink in the location shown in the
drawing. Arrow AK400306AB

sequence.
Groove 5. Make a paint mark on the head of the bolt.
6. Make a paint mark on the bearing cap at a point
90 to 100° away from the paint mark made on the
bolt head in the tightening direction.
For upper

For lower
AK301466AD
4. Install bearing halves with oil grooves in the

cylinder block bearing bores.
5. Install bearing halves with no oil grooves in the 90˚
beam bearing cap.
AK300200 AD
11D-63
CAUTION >>E<< REAR OIL SEAL INSTALLATION
quate tightness could not be assured. MB990938
• If the tightening angle exceeds 100°, loosen
the bolt completely and then perform the
MD998776
tightening again beginning with the first step.
7. Turn clockwise the bolts 90° to 100° in the
indicated tightening sequence to bring the mark
on each bolt head into alignment with that on the
bearing cap.
AK300202 AD
Use the special tools to press-fit the rear oil seal in

the rear oil seal case.
• Handle (MB990938)
>>F<< REAR OIL SEAL CASE

INSTALLATION
1. Remove completely old FIPG remaining on the
AK300201
rear oil seal case and cylinder block.
8. After installing the beam bearing cap, measure
the end play of the crankshaft. If the end play
exceeds the limit, replace the crankshaft bearings.
Limit: 0.4 mm
AK300576AD

Specified sealant:
INSPECTION CYLINDER BLOCK

M1113008800645
1. Visually check the cylinder block for scratches,
CRANKSHAFT OIL CLEARANCE rust, and any other corrosion. Also check it for
(PLASTIGAGE METHOD) cracks using a flaw detecting penetrant.
This plastigage method is recommended as a sim- If any defect is evident, replace the cylinder block.
plest way of measuring the crankshaft oil clearance.
Measure the crankshaft oil clearance using a plasti-
gage as follows:
1. Wipe off oil from the crankshaft journal surface
and the crankshaft bearing inner surface.
Plastigage
AK403250
2. Use a straightedge and thickness gauge to check

the cylinder block top surface for warp.
Make sure that the surface is free from remaining
gasket material and other foreign matter.
AK300203AE
3. Cut a piece of plastigage whose length is Limit: 0.1 mm
equivalent to the width of the bearing and place it 3. If the distortion is excessive, correct within the
on the crankshaft journal in parallel with its axis. allowable limit or replace.
4. Install the crankshaft bearing cap carefully and Grinding limit: 0.2 mm
tighten the bolts to the specified torque of 25 ± 2 *Includes/combined with cylinder head
N⋅m + 90° to 100°. grinding
5. Remove the bolts, then remove the crankshaft Cylinder block height (when new): 284 mm
bearing cap carefully. 4. Check cylinder walls for scratches and seizure.
Plastigage
If defects are evident, rebore to oversize or
replace the cylinder block.
A
B
12mm
AK300204 AE
Center
6. Measure the largest width of the crushed Bottom
plastigage using the ruler printed on the bag of the AK300206 AD
plastigage.
5. Use a cylinder gauge to measure the cylinder
Standard value:
bore diameter and taper.
No.1,2,4,5 journal: 0.02 − 0.03 mm
No.3 journal: 0.03 − 0.04 mm If the cylinder is worn badly, rebore it to an
Limit: 0.1 mm oversize and replace the piston and piston rings
with ones matched with the new bore size.
Taper: 0.01 mm
11D-65
BORING CYLINDERS 3. Based on the piston diameter measurement,
1. Select an oversize of the pistons to be used calculate the boring finish dimension.
based on the largest of the cylinder bores. • Boring finish dimension = [Piston diameter] +
[0.02 − 0.04 mm (clearance between piston and
cylinder)] − [0.02 mm (honing margin)]
CAUTION
To prevent deformation of cylinder block that
would result from the heat generated by boring,
bore the cylinders in the following sequence: No.
2 → No. 4 → No. 1 → No. 3.
Piston outside 4. Bore all the cylinders to the calculated boring
Thrust
diameter direction finish dimension.
AK300577AC
AD 5. Hone the bored cylinders to the final finish
dimension (piston diameter + clearance between
2. Oversize pistons are available in two oversizes: piston and cylinder).
0.50 mm and 1.00 mm. Bore each cylinder to a
size that provides the standard clearance when 6. Check the clearance between the piston and
combined with the selected piston. The reference cylinder.
position for piston diameter measurement is as Standard value: 0.02 − 0.04 mm
11E-1
GROUP 11E
ENGINE
MECHANICAL
<4G69>
CONTENTS
SERVICE SPECIFICATIONS. . . . . . . 11E-2 CAMSHAFT AND VALVE STEM

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 11E-18
SEALANTS . . . . . . . . . . . . . . . . . . . . 11E-2 REMOVAL AND INSTALLATION . . . . . . . . 11E-18
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11E-3 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . 11E-23

REMOVAL AND INSTALLATION . . . . . . . . 11E-23
ON-VEHICLE SERVICE. . . . . . . . . . . 11E-7 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11E-25
DRIVE BELT TENSION CHECK. . . . . . . . . 11E-7
AUTO-TENSIONER CHECK . . . . . . . . . . . 11E-7 CRANKSHAFT OIL SEAL . . . . . . . . . 11E-26
VALVE CLEARANCE CHECK AND REMOVAL AND INSTALLATION . . . . . . . . 11E-26
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 11E-10
ROCKER ARM PISTON OPERATION CYLINDER HEAD GASKET . . . . . . . . 11E-30
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11E-11
IGNITION TIMING CHECK . . . . . . . . . . . . . 11E-12
IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11E-13 TIMING BELT . . . . . . . . . . . . . . . . . . . 11E-36
IDLE MIXTURE CHECK . . . . . . . . . . . . . . . 11E-14 REMOVAL AND INSTALLATION . . . . . . . . 11E-36
COMPRESSION PRESSURE CHECK. . . . 11E-15 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11E-45
MANIFOLD VACUUM CHECK . . . . . . . . . . 11E-15
ENGINE ASSEMBLY . . . . . . . . . . . . . 11E-46
CRANKSHAFT PULLEY . . . . . . . . . . 11E-17 REMOVAL AND INSTALLATION . . . . . . . . 11E-46
11E-2 ENGINE MECHANICAL <4G69>
M1112000300278

Drive belt tension Vibration frequency Hz A/C compressor type: 113 − 145 −
(Reference) MSC90CA
A/C compressor type: 120 − 154 −
MSC105CA
Valve clearance (at hot) mm Intake valve 0.20 −
Exhaust valve 0.30 −
Ignition timing Approximately −
10° BTDC
Idle speed r/min M/T 680 ± 100 −
A/T 750 ± 100 −
Compression pressure kPa-r/min 1,560 − 200 1,130 − 200
SEALANTS
M1112000500294
Item Specified sealant Remark

Camshaft position sensor support MITSUBISHI GENUINE PART MD970389 or Semi-drying
Engine upper oil pan equivalent sealant
Engine lower oil pan
Taper plug LOCTITE203MP Anaerobic
sealant
ENGINE MECHANICAL <4G69>
SPECIAL TOOLS
11E-3
SPECIAL TOOLS
M1112000601313
A
B
B992080

B991502

MB991824
C
F: M.U.T.-III trigger harness • Drive belt tension check
DO NOT USE
MB991910
MB991911
MB991825
MB991826
MB991955
SPECIAL TOOLS

M.U.T.-III)
B991668
MB990767 Front hub and flange yoke Holding the camshaft sprocket
holder
B990767
MD998719 Pin
D998719
MD998772
MB991999 Valve stem seal installer Valve stem seal installation
D998713
MD998781 Flywheel stopper • Supporting the flywheel

assembly <M/T>
• Supporting the A/T drive plate
<A/T>
D998781
SPECIAL TOOLS
11E-5
installation

installer
D998776

guide installation
D998285

installer

tensioner adjuster
D998738

B991654

drive sprocket
B991367
MB991385 Pin
B991385
SPECIAL TOOLS

adjustment
D998767

B991454
assembly
B991527
Z203830

B: MB991930 B: Joint (90) × 2
E C: MB991931 C: Joint (140) × 2
D
B
C
B991928
ON-VEHICLE SERVICE
11E-7
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK FUNCTION CHECK
M1111003100548
CAUTION good condition by checking its tension.
crankshaft clockwise one turn or more.
Indicator mark 1. Check the drive belt tension (Refer to P.11E-7).
A Belt tension meter set (MB992080)
MB992081
AC301702AB

area marked with A in the illustration.
2. If the mark is out of the area, replace the drive MB992082
belt. (Refer to P.11E-17).
AC507219AB
sary as auto-tensioner is adopted. (1) Connect special tool microphone assembly
(MB992082) to special tool belt tension meter
AUTO-TENSIONER CHECK (MB992081) of special tool belt tension meter
M1111003000905 set (MB992080).
OPERATION CHECK (2) Press the "POWER" button to turn on the
1. Turn OFF the engine from the idle state then power supply.
check to see that the drive belt is not protruding (3) Press the numeral key of "1" and check that
from the pulley width of the auto-tensioner. "No. 1" appears on the upper left of the
2. Remove the drive belt.(Refer to P.11E-17). display.
judgement of error.
to the frequency display (Hz).
AC301703

no threading.
4. If there are any problems in the procedure 1 or 3,
replace the auto-tensioner.(Refer to P.11E-36).
5. Install the drive belt.(Refer to P.11E-17).
ON-VEHICLE SERVICE
CAUTION Standard value:

• The temperature of the surface of the belt <A/C compressor type: MSC90CA> 113 − 145
should be as close to normal temperature as Hz
possible. <A/C compressor type: MSC105CA> 120 − 154
• Do not allow any contaminants such as water Hz
or oil to get onto the microphone. NOTE: To take the measurement repeatedly,
• If strong gusts of wind blow against the fillip the belt again.
microphone or if there are any loud sources (8) Press and hold the "POWER" button to turn off
of noise nearby, the values measured by the the power supply.
microphone may not correspond to actual 3. If not within the standard value, replace the
values. auto-tensioner (Refer to P.11E-36).
the measurement is being made, the values When the vibration frequency is
measured by the microphone may not corre- measured (M.U.T.-II is used):
spond to actual values. Recommendation
• Do not take the measurement while the vehi- 1. Check the drive belt tension. (Refer to P.11E-7).
CAUTION
Water MB992080
pump
pulley
15 10 15 mm
15 16-pin
Gently tap
with your
finger
MUT-II
Alternator
pulley
AC301266AE MB991668
(5) Hold special tool MB992080 to the middle of AC211862 AB

indicated by arrow) where it does not contact
before connecting or disconnecting M.U.T.-II.
the rear surface of the belt) so that it is
(MB991668) to the M.U.T.-II.
15°).
(6) Press the "MEASURE" button.
connector.
select "BELT TENSION" on the menu screen.
ON-VEHICLE SERVICE
11E-9
or oil to get onto the microphone. 3. If not within the standard value, replace the
• If strong gusts of wind blow against the auto-tensioner. (Refer to P.11E-36).
microphone or if there are any loud sources
of noise nearby, the values measured by the When the vibration frequency is
microphone may not correspond to actual measured (V.C.I. is used):
values. Recommendation
• If the microphone is touching the belt while 1. Check the drive belt tension. (Refer to P.11E-7).
• Do not take the measurement while the vehi- CAUTION
16-pin
Water MB991668
pump
pulley
15˚ 10 – 20 mm
15˚
Gentry tap MB991824

with your
finger
MB991668
Alternator MB991911
pulley
AC211863AB

AC301266AB
(4) Hold special tool belt tension meter set disconnecting special tool V.C.I. (MB991824).
15 degree). (3) Connect special tool M.U.T.-III main harness B
(MB991911) to the diagnosis connector.
pulleys (the place indicated by the arrow) with (4) Turn the ignition switch to "ON" position, and
your finger as shown in the illustration, and select "Belt Tension" on the menu screen.
measure that the vibration frequency of the
belt is within the standard value.
ON-VEHICLE SERVICE

or oil to get onto the microphone. 3. If not within the standard value, replace the
• If strong gusts of wind blow against the alternator drive belt auto tensioner. (Refer to
microphone or if there are any loud sources P.11E-36).
microphone may not correspond to actual When the tension is measured
values. 1. Check the drive belt tension. (Refer to P.11E-7).
Belt tension
spond to actual values. Water pump
gauge
• Do not take the measurement while the vehi- pulley
Water MB991668
pump
pulley
15˚ 10 – 20 mm
15˚
Alternator
pulley
Gentry tap
with your
finger
AC301267AB
Alternator
2. Use a belt tension gauge in the middle of the belt
pulley
between the pulleys (at the place indicated by the
arrow) to measure that the belt tension is within
the standard value.
AC301266AB Standard value: 340 − 555 N
(5) Hold special tool belt tension meter set 3. If not within the standard value, replace the
(MB991668) to the middle of the drive belt auto-tensioner. (Refer to P.11E-36).
VALVE CLEARANCE CHECK AND
the rear surface of the belt so that it is ADJUSTMENT
M1111001500131
1. Start the engine and allow it to warm up until the
15 degree).
engine coolant temperature reaches 80 − 95°C.
position.
measure that the vibration frequency of the 3. Remove all ignition coils.
belt is within the standard value. 4. Remove all spark plugs from the cylinder head for
easy inspection.
5. Remove the rocker cover.
ON-VEHICLE SERVICE
11E-11
6. Turn the crankshaft clockwise until the notch on 14.Install the spark plugs and tighten to the specified
the pulley is lined up with the "T" mark on the torque.
timing indicator. Tightening torque: 25 ± 4 N⋅m
7. Move the rocker arms on the No.1 and No.4 15.Install the ignition coils.
cylinders up and down by hand to determine
which cylinder has its piston at the top dead ROCKER ARM PISTON OPERATION
center on the compression stroke. If both intake
CHECK
and exhaust valve rocker arms have a valve lash, M1111051000023
the piston in the cylinder corresponding to these
rocker arms is at the top dead center on the Taper plug
compression stroke.
Oil control valve
Intake valve side
Ignition coils
Rocker cover AK304505AB
No. 1 No. 2 No. 3 No. 4 1. Remove all of the ignition coils.

Exhaust valve side
AK303689 AB 2. Remove the rocker cover.
3. Remove the oil control valve.
8. Valve clearance inspection and adjustment can be
4. Remove the taper plug.
performed on rocker arms indicated by white
arrow mark when the No.1 cylinder piston is at the 5. Turn the crankshaft clockwise until the notch on
top dead centre on the compression stroke, and the crankshaft pulley is lined up with "T" mark on
on rocker arms indicated by black arrow mark the lower cover of timing belt.
when the No.4 cylinder piston is at the top dead 6. Move the rocker arms on the No.1 and No.4
centre on the compression stroke. cylinders up and down by hand to determine
9. Measure the valve clearance. which cylinder has its piston at the top dead
centre on the compression stroke.
If the valve clearance is not as specified, loosen
the rocker arm lock nut and adjust the clearance NOTE:
Intake valve side
using a thickness gauge while turning the
adjusting screw.
Standard value (hot engine):
Intake valve: 0.20 mm
Exhaust valve: 0.30 mm
10.While holding the adjusting screw with a
screwdriver to prevent it from turning, tighten the No. 1 No. 2 No. 3 No. 4
lock nut to the specified torque. Exhaust valve side
Tightening torque: 9 ± 1 N⋅m AK303689 AC
11.Turn the crankshaft through 360° to line up the The rocker arm piston operation check can be per-
notch on the crankshaft pulley with the "T" mark formed on rocker arms indicated by white arrow mark
on the timing indicator. when the No.1 cylinder piston is at the top dead cen-
tre on the compression stroke, and on rocker arms
12.Repeat steps (9) and (10) on other valves for
indicated by black arrow mark when the No.4 cylin-
clearance adjustment.
der piston is at the top dead centre on the compres-
13.Install the rocker cover. sion stroke.
ON-VEHICLE SERVICE
IGNITION TIMING CHECK

Rocker arm M1111001700997
Rocker arm
piston
Oil passage
Blow
compression
air AK302684AC 16 PIN
MB991502
7. While shutting up the oil passage hole at the AK303691AF
depth of the oil control valve's installation hole by
finger not to leak air, blow compression air into the
taper plug's installation hole by air blowgun. At
this time, confirm that the rocker arm piston can
operate.
16-PIN
NOTE: To fully confirm the check, prevent the com-
pression air from leaking as much as possible by
installing the O-ring to the end of air blowgun.
8. Turn the crankshaft clockwise until the notch on
the crankshaft pulley is lined up with "T" mark on
the lower cover of timing belt. MB991911
9. Confirm the rest of the rocker arm pistons under
the procedure 7. MB991824
10.When the rocker arm piston does not operate,
replace the rocker arm assy.
11.Apply sealant to threaded portion.
Specified sealant: LOCTITE203MP
CAUTION
Do not start the engine within one hour after the MB991827 AK303690AB
engine taper plug has been installed.
12.Install the taper plug and tighten to the specified 1. Before inspection, set the vehicle to the
torque. pre-inspection condition.
Tightening torque: 10 ± 2 N⋅m 2. Turn the ignition switch to the "LOCK" (OFF)
13.Install the oil control valve. (Refer to Camshaft diagnosis connector.
and Valve Stem Seal − Removal and Installation
P.11E-18.)
14.Install all of the ignition coils.
15.Install the rocker cover. and check that it is within the standard value.
Standard value
: 680 ± 100 r/min <M/T>
: 750 ± 100 r/min <A/T>
standard value.
Standard value: 5° BTDC ± 3°
ON-VEHICLE SERVICE
11E-13
8. If the basic ignition timing is outside the standard IDLE SPEED CHECK
value, inspect the MPI system (Refer to P.13C-21, M1111003500911
GROUP 13C − Troubleshooting − Inspection chart

for diagnosis code).
CAUTION
driving cancel mode) to release the Actuator test. 16 PIN
MB991502
10.Check that ignition timing is at the standard value. AK303691AF
Standard value: approximately 10° BTDC
NOTE: .
• In higher altitude, the ignition timing is more 16-PIN
mately 5°.
MB991911
MB991824
MB991827 AK303690AB

Standard value
: 680 ± 100 r/min <M/T>
: 750 ± 100 r/min <A/T>
NOTE: .
• The idle speed is controlled automatically by
the idle speed control system.
and take a reading of the idle speed.
ON-VEHICLE SERVICE
7. If the idle speed is outside the standard value, 3. Connect a timing light.
inspect the MPI system (Refer to P.13C-21, 4. Start the engine and let it run at idle.
GROUP 13C − Troubleshooting − Inspection chart 5. Check that ignition timing is at the standard value.
for diagnosis code).
position and then remove the M.U.T.-II/III. 6. Run the engine at 2,500 r/min for 2 minutes.
7. Set the CO, HC tester.
IDLE MIXTURE CHECK 8. Check the CO contents and the HC contents at
M1111002100426
idle.
Standard value
CO contents: 0.5 % or less
HC contents: 100 ppm or less
9. If there is a deviation from the standard value,
check the following items:
• Diagnosis output
• Fuel pressure
16 PIN
MB991502 • Injector
AK303691AF • Ignition coil, spark plug
• EGR control system
• Evaporative emission control system
• Compression pressure
NOTE: Replace the three way catalyst when the
16-PIN CO and HC contents are not within the standard
value, even though the result of the inspection is
normal on all items.
MB991911
MB991824
MB991827 AK303690AB

ON-VEHICLE SERVICE
11E-15
COMPRESSION PRESSURE CHECK (1) If the compression increases after oil is added,
M1111002600636 the cause of the malfunction is a worn or
surface.
(2) If the compression dose not rise after oil is
added, the cause is a burnt or defective valve
Crank angle
sensor seat, or pressure is leaking from the gasket.
connector 9. Connect the crank angle sensor connector.
10.Install the spark plugs and tighten to the specified
torque.
AK303421AB Tightening torque: 25 ± 4 N⋅m
11.Install the ignition coils.
pre-inspection condition. 12.Use the M.U.T.-II/III to erase the diagnosis codes.
2. Remove all of the ignition coils and spark plugs. NOTE: This will erase the diagnosis code result-
3. Disconnect the crank angle sensor connector.
disconnected.
NOTE: Doing this will prevent the
engine-ECU<M/T> or engine-A/T-ECU<A/T> from MANIFOLD VACUUM CHECK
carrying out ignition and fuel injection. M1111002700569
CAUTION
• Keep away from the spark plug hole when
cranking.
• 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. 16 PIN
MB991502
4. Cover the spark plug hole with a shop towel etc.,
AK303691AF
and after the engine has been cranked, check that
no foreign material is adhering to the shop towel.
5. Set compression gauge to one of the spark plug
holes.
6. Crank the engine with the throttle valve fully open
16-PIN
and measure the compression pressure.
Standard value (at engine speed of 200
r/min):
1,560 kPa
Minimum 1130 kPa MB991911
7. Measure the compression pressure for all the
cylinders, and check that the pressure differences MB991824
of the cylinders are below the limit.
Limit: Maximum 98 kPa
8. If there is a cylinder with compression or a
compression difference that is outside the limit,
spark plug hole, and repeat the operations in MB991827 AK303690AB
steps from (5) to (7).
ON-VEHICLE SERVICE
2. Turn the ignition switch to the "LOCK" (OFF) 4. Plug the PCV valve.
position and then connect the M.U.T.-II/III to the 5. Start the engine and check that idle speed is
diagnosis connector. within the standard valve.
Ventilation hose Standard value
: 680 ± 100 r/min <M/T>
: 750 ± 100 r/min <A/T>
6. Check the intake manifold vacuum.
Plug Limit: Minimum 60 kPa
PCV valve
7. Turn off the ignition switch.
Vacuum gauge
8. Remove the vacuum gauge and then connect the
ventilation hose.
AK303422 AB 9. Turn the ignition switch to the "LOCK" (OFF)
3. Disconnect the ventilation hose from the PCV position and then remove the M.U.T.-II/III.
valve, and connect a vacuum gauge to the
ventilation hose.
CRANKSHAFT PULLEY
11E-17
CRANKSHAFT PULLEY
M1112001600539

• Under Cover Removal (Refer to GROUP 51, Under Cover • Drive Belt Tension Check (Refer to P.11E-7).
Cover P.51-31).
1
2
25 ± 4 N·m
AC308973AB
Removal steps 1. Securely insert the spindle handle or ratchet

<<A>> 1. Drive belt handle with a 12.7 mm insertion angle into the jig
2. Crank shaft damper pulley hole of the auto-tensioner.
hole A with hole B.
<<A>> DRIVE BELT REMOVAL
CAUTION
The following operations will be needed due to the To reuse the drive belt, draw an arrow indicating
introduction of the serpentine drive system with the the rotating direction (clockwise) on the back of
drive belt auto-tensioner. the belt using chalk, etc.
AC301703
Auto-tensioner
Auto-tensioner
Hole B
Hole A L-shaped
hexagon
AC301704AB wrench AC301705AB


M1112006600501
CAUTION
* Remove and assemble the marked parts in each cylinder unit.
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Timing Belt Upper Cover Installation (Refer to P.11E-36).
P.15-8). • Ignition Coils Installation (Refer to GROUP 16, Ignition
• Ignition Coils Removal (Refer to GROUP 16, Ignition Sys- System − Ignition Coil P.16-47).
tem − Ignition Coil P.16-47). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Timing Belt Upper Cover Removal (Refer to P.11E-36). P.15-8).
• Drive Belt Tension Check (Refer to P.11E-7).
• Valve Clearance Check and Adjustment (Refer to
P.11E-10).
3.5 ± 0.5 N·m

1
7
N8
4 11 ± 1 N·m
9.0 ± 2.0 N·m 24 ± 3 N·m

N 9
5
6N (Engine oil)
44 ± 5 N·m
10
AC308974 AB
Camshaft removal steps Camshaft removal steps

1. Rocker cover PCV hose connection 7. Rocker cover assembly
2. Rocker cover breather hose 8. Rocker cover gasket
connection 9. Spark plug guide oil seals
3. Control wiring harness connection 10. Accumulator assembly
4. Engine hanger • Valve timing belt (Refer to
>>J<< 5. Oil control valve P.11E-36).
>>J<< 6. O-ring
11E-19
Apply engine oil to all 31 ± 3 N·m

moving parts before 11 11 ± 1 N·m
installation. 13 ± 1 N·m
18
12
19
47 ± 7 N·m 21
22
16 14 ± 1 N·m
25 ± 4 N·m
22 ± 4 N·m
23 13
24* 17
25* 20
26*
N 28*
29* 24*
25*
27*
28* N
89 ± 9 N·m
29*
15 N
14 AC308975AB
Camshaft removal steps Valve stem seal removal steps

11. Connector bracket 1. Rocker cover PCV hose connection
>>I<< 12. Camshaft position sensor support 2. Rocker cover breather hose
13. Camshaft position sensing cylinder connection
<<A>> >>H<< 14. Camshaft sprocket 3. Control wiring harness connection
>>G<< 15. Camshaft oil seal 4. Engine hanger
>>F<< 16. Exhaust rocker arm shaft caps 7. Rocker cover assembly
<> >>F<< 17. Exhaust rocker arm and shaft 8. Rocker cover gasket
assembly 9. Spark plug guide oil seals
>>E<< 18. Inlet rocker arm shaft caps >>F<< 16. Exhaust rocker arm shaft caps
<> >>E<< 19. Inlet rocker arm and shaft assembly <> >>F<< 17. Exhaust rocker arm and shaft
>>D<< 20. Camshaft assembly
• Water inlet fitting and thermostat >>E<< 18. Inlet rocker arm shaft caps
case assembly (Refer to GROUP <> >>E<< 19. Inlet rocker arm and shaft assembly
14, Water Hose and Water Pipe 23. Spark plugs
P.14-32). <<C>> >>C<< 24. Valve spring retainer locks
21. Cylinder head plug 25. Valve spring retainers
22. Oil control valve filter >>B<< 26. Inlet valve springs
>>B<< 27. Exhaust valve springs
>>A<< 28. Valve stem seals
29. Valve spring seats

<<A>> CAMSHAFT SPROCKET >>A<< VALVE STEM SEALS INSTALLA-
REMOVAL TION
stem seals.
MB990767
CAUTION
• Do not re-use the valve stem seal.
• Special tool valve stem seal installer
(MB991999) must be used to install the valve
MD998719
stem seal. Improper installation could result
in oil leaking past the valve guide.
AC102532AB
MB991999
1. Use the following special tools to hold the
Valve
camshaft sprocket.
• Front hub and flange yoke holder (MB990767) Valve stem
• Pin (MD998719) seal
2. Loosen the camshaft sprocket mounting bolt and
remove the camshaft sprocket. Valve guide
<> EXHAUST ROCKER ARM AND

AC308654AC
SHAFT ASSEMBLY/INLET ROCKER ARM 2. Use the special tool to fill a new valve stem seal in
AND SHAFT ASSEMBLY REMOVAL the valve guide using the valve stem area as a
guide.
CAUTION
Never disassemble the exhaust rocker arm and
shaft assembly, and inlet rocker arm and shaft
>>B<< EXHAUST VALVE SPRINGS/INLET
assembly. VALVE SPRINGS INSTALLATION
Rocker arm side
<<C>> VALVE SPRING RETAINER LOCKS
REMOVAL
CAUTION
When removing valve spring retainer locks, leave Identification
colour
Inlet side:
Centre) position. The valve may fall into the cylin- Light blue
der if the piston is not properly in the TDC posi- Exhaust side:
tion. Orange AC107415AC
Install the valve springs with its identification colour

painted end facing the locker arm.
MD998772
AC301867AB
Use special tool valve spring compressor

(MD998772) to compress the valve spring and then
remove the valve spring retainer lock.
11E-21
>>C<< VALVE SPRING RETAINER LOCKS >>F<< EXHAUST ROCKER ARM AND
INSTALLATION SHAFT ASSEMBLY/EXHAUST ROCKER
ARM SHAFT CAPS INSTALLATION
Engine front
MD998772
AC301867AB Notch
Use special tool valve spring compressor AC301870AB
(MD998772) to compress the valve spring and then
install the valve spring retainer lock in the same man- 1. Install the exhaust rocker shaft so that its notch is
ner as removal. positioned as shown.
2. Install the exhaust rocker arm shaft caps.
>>D<< CAMSHAFT INSTALLATION 3. Tighten the exhaust rocker shaft mounting bolts to
Dowel pin Tightening torque: 13 ± 1 N⋅m
>>G<< CAMSHAFT OIL SEAL

INSTALLATION
Camshaft oil seal
AC301868AB
Set the dowel pin of the camshaft in the position

shown in the figure. (Engine oil)
>>E<< INLET ROCKER ARM AND SHAFT

ASSEMBLY/INLET ROCKER ARM SHAFT MD998713 AC102323AC
CAPS INSTALLATION 1. Apply engine oil to the entire inner diameter of the
Engine front oil seal lip.
φ 5.5 mm
2. Use special tool camshaft oil seal installer
(MD998713) to press-fit the oil seal as shown.
AC301869AB
1. Place the inlet rocker shaft so that its 5.5 mm hole

faces toward the cylinder head.
2. Install the inlet rocker arm shaft caps.
3. Tighten the inlet rocker shaft mounting bolts to the
specified torque.
>>H<< CAMSHAFT SPROCKET NOTE: Install the camshaft position sensor sup-
INSTALLATION port within 15 minutes after applying the sealant.
3. Install the camshaft position sensor support to the
cylinder head.
MB990767 CAUTION
Wait at least one hour. Never start the engine or
let engine oil or coolant touch the adhesion sur-
face during that time.
MD998719 4. Tighten the camshaft position sensor support
AC102532AB
1. Use the following special tool as during removal to >>J<< O-RING/OIL CONTROL VALVE
hold the camshaft sprocket. INSTALLATION
• Front hub and flange yoke holder (MB990767)
• Pin (MD998719) CAUTION
2. Tighten the camshaft sprocket mounting bolt to • Never re-use the O-ring.
•

Tape
>>I<< CAMSHAFT POSITION SENSOR
1. Remove sealant from the camshaft position
sensor support and cylinder head surfaces.
AK303651AD
φ 3 mm Before installing O-ring, wind the tape with the

soft adhesion (sealing tape) around the oil
passages cut-out area of engine oil control
valve to prevent the damage. If the O-ring is
damaged, it can be the cause of oil leak.
1. Apply a small amount of engine oil to the O-ring
and then install it to the oil control valve.
AC301268AB
2. Assemble the oil control valve to the cylinder
2. Apply the sealant to the camshaft position sensor head.
support flange in a continuous bead as shown in 3. Tighten the oil control valve mounting bolt to the
the illustration. specified torque.
Specified sealant: MITSUBISHI GENUINE Tightening torque: 11 ± 1 N⋅m
OIL PAN
11E-23
OIL PAN
M1112002800763

• Under Cover Removal (Refer to GROUP 51, Under Cover • Centre Member Installation (Refer to GROUP 32, Engine
P.51-31). Roll Stopper and Centre Member P.32-13).
• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Front Exhaust Pipe Installation (Refer to GROUP 15,
Service − Engine Oil Replacement P.12-4). Exhaust Pipe and Main Muffler P.15-25).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Exhaust Pipe and Main Muffler P.15-25). Service − Engine Oil Replacement P.12-4).
• Centre Member Removal (Refer to GROUP 32, Engine • Under Cover Installation (Refer to GROUP 51, Under
Roll Stopper and Centre Member P.32-13). Cover P.51-31).
N 1
48 ± 7 N·m
2
8
N 1
12 ± 2 N·m
48 ± 7 N·m
9.0 ± 3.0 N·m

4
N 6
9.0 ± 3.0 N·m
9.0 ± 1.0 N·m
3
44 ± 10 N·m
39 ± 5 N·m 5
7 22 ± 4 N·m
9.0 ± 3.0 N·m 9.0 ± 3.0 N·m AC308976 AB

1. Engine oil cooler tube gaskets 4. Flywheel housing front lower cover
<M/T> <M/T> or torque converter housing
2. Engine oil cooler hose and bracket front lower cover <A/T>
assembly <M/T> 5. Engine oil pan drain plug
>>D<< 3. Transmission housing front lower >>C<< 6. Engine oil pan drain plug gasket
cover stay <<A>> >>B<< 7. Engine lower oil pan
<> >>A<< 8. Engine upper oil pan
OIL PAN

REMOVAL LATION
φ 4 mm
Groove Bolt hole

AC102931AB
REMOVAL CAUTION
B
A
A B B
B B
AC102946AB
B B

B
A A
AC102929AB

OIL PAN
11E-25
the order shown.
B 16 M6 × 18
(D × L)
B 11 M6 × 10
INSTALLATION
GASKET INSTALLATION
Engine lower
oil pan side
φ 4 mm
Groove Bolt hole
AC102325 AF
of the engine lower oil pan as shown. Replace the gasket with a new one. Install the new
minutes after applying sealant. LOWER COVER STAY INSTALLATION
upper oil pan.
B-1 B-11
B-10 Tightening torque: 44 ± 10 N⋅m
B-4 INSPECTION
B-7 M1112002900254
B-5
B-6 • Check the oil pan sealant-coated surface for
B-8 A-3 damage and deformation.
B-9 B-12 B-2

AC102930AB
CRANKSHAFT OIL SEAL
CRANKSHAFT OIL SEAL

M1112003101061
<M/T>
6 4 132 ± 5 N·m
7
9N
3 9
3N Engine oil
1
AC308977 AB
steps steps
• Valve timing belt, balancer timing <<A>> • Transmission assembly
belt (Refer to P.11E-36). • Clutch cover and clutch disc (Refer
>>D<< 1. Crankshaft balancer shaft drive to GROUP 21B, Clutch P.21B-3).
sprocket <> >>B<< 4. Flywheel bolts
2. Crankshaft key 5. Flywheel adapter plate
>>C<< 3. Crankshaft front oil seal 6. Flywheel assembly
7. Flywheel adapter plate
8. Crankshaft bush
CRANKSHAFT OIL SEAL
11E-27
<A/T>
4 132 ± 5 N·m
6
N 8
5
7
3 8
3N Engine oil
1
AC308978AB
steps steps
• Valve timing belt, balancer timing • Transmission assembly (Refer to
belt (Refer to P.11E-36). GROUP 23A, Transmission
>>D<< 1. Crankshaft balancer shaft drive Assembly P.23A-147).
sprocket <> >>B<< 4. A/T drive plate bolts
2. Crankshaft key 5. A/T drive plate adapter plate
>>C<< 3. Crankshaft front oil seal 6. A/T drive plate
7. Crankshaft bush
CRANKSHAFT OIL SEAL

<<A>> TRANSMISSION ASSEMBLY >>A<< CRANKSHAFT REAR OIL SEAL
CAUTION
Oil seal
AC300897
MB990938
Engine front (Engine oil)

Flywheel
assembly
Flywheel
bolt MD998776 Crankshaft
AC102328 AB
AC308604 AB
Do not remove the flywheel bolt. If this bolt is inner diameter of the oil seal lip.
removed, the flywheel assembly will become out 2. Use the following special tools to press-fit the oil
of balance and damaged. seal.
Refer to GROUP 22A, Transmission Assembly • Installer bar (MB990938)
P.22A-14. • Crankshaft rear oil seal installer (MD998776)
<> FLYWHEEL BOLTS/A/T DRIVE >>B<< FLYWHEEL BOLTS/A/T DRIVE

PLATE BOLTS REMOVAL PLATE BOLTS INSTALLATION
MD998781
MD998781
AC301854AB AC301855AB
1. Use special tool flywheel stopper (MD998781) to 1. Use special tool flywheel stopper (MD998781) to
secure the flywheel assembly or A/T drive plate. secure the flywheel assembly or A/T drive plate in
2. Remove the flywheel bolts or A/T drive plate bolts. the same manner as removal.
2. Tighten the flywheel bolts or A/T drive plate bolts
CRANKSHAFT OIL SEAL
11E-29
>>C<< CRANKSHAFT FRONT OIL SEAL >>D<< CRANKSHAFT BALANCER SHAFT
INSTALLATION DRIVE SPROCKET INSTALLATION
Crankshaft MD998375 : Clean
Crankshaft
(Engine oil) balancershaft
drive sprocket
MD998285 Oil seal

(Oil applied to the
1. Apply a small amount of engine oil to the outer

diameter of special tool crankshaft front oil seal
guide (MD998285) and install it to the crankshaft.
inner diameter of the oil seal lip. Crankshaft
3. Use special tool crankshaft front oil seal installer
(MD998375) to press-fit the oil seal. Front case
Engine front
AC301346AB

as shown.

M1112004001272

• Fuel Line Pressure Reduction [Refer to GROUP 13C, • Accelerator Cable Installation (Refer to GROUP 17,
On-vehicle Service − Fuel Pump Connector Disconnec- Accelerator Cable and Pedal P.17-7).
tion (How to Reduce Pressurized Fuel Lines) P.13C-428]. • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle P.15-8).
Service − Engine Coolant Replacement P.14-17). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner Service − Engine Coolant Replacement P.14-17).
P.15-8). • Accelerator Cable Adjustment (Refer to GROUP 17,
• Accelerator Cable Removal (Refer to GROUP 17, Accel- On-vehicle Service − Accelerator Cable Check and
erator Cable and Pedal P.17-7). Adjustment P.17-6).
• Fuel Leak Check
5
4
5.0 ± 1.0 N·m
6 2
9.0 ± 2.0 N·m
13 ± 1 N·m
1
14 ± 3 N·m
(Engine oil) N 7
AC308979AB

1. Control wiring harness connection 5. Brake booster vacuum hose
2. Battery wiring harness connection connection
3. Radiator lower hose clamp 6. Engine oil level gauge and guide
4. Canister vacuum hose connection assembly
7. O-ring
11E-31
13
14 (Engine oil)
<Cold engine>
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚
15 12
(Engine oil)
9 16
8
11 ± 1 N·m
11 17 N
31 ± 3 N·m
10
31 ± 3 N·m
89 ± 9 N·m AC308980AB

8. Detonation sensor connection • Water inlet fitting and thermostat
9. Battery wiring harness connection case assembly (Refer to GROUP
10. Inlet manifold stay 14, Water Hose and Water Pipe
• Exhaust manifold (Refer to GROUP P.14-32).
15, Exhaust Manifold P.15-20). <<C>> >>C<< 14. Fuel high-pressure hose
• Timing belt upper cover (Refer to connection
P.11E-36). • Rocker cover assembly (Refer to
<<A>> >>E<< 11. Camshaft sprocket P.11E-18).
<> >>D<< 12. Radiator upper hose connection <<D>> >>B<< 15. Cylinder head bolts
13. Water hose connection 16. Cylinder head assembly
>>A<< 17. Cylinder head gasket
REMOVAL SERVICE POINTS AC107621
<<A>> CAMSHAFT SPROCKET Wiring band

REMOVAL
CAUTION
Never turn the crankshaft anti-clockwise.
AC301451AC
Timing mark 4. Secure the camshaft sprocket and valve timing

belt with wiring bands and so on to prevent
slippage between the camshaft sprocket and
valve timing belt.
AC301450AB
1. Turn the crankshaft clockwise, align the timing

MB990767
marks on the camshaft sprocket to set No.1
cylinder to TDC of its compression stroke.
MD998719
MD998738
AC100302 AB
5. Use the following special tools to hold the

camshaft sprocket.
Timing belt
under cover
• Pin (MD998719)
AC301452AB
CAUTION
2. Remove the timing belt under cover rubber plug Do not rotate the crankshaft after camshaft
and then set special tool adjusting bolt sprocket removal.
(MD998738).
6. Remove the camshaft sprocket with the valve
timing belt and place it on the timing belt lower
Timing belt cover.
tensioner arm
<> RADIATOR UPPER HOSE
MD998738
DISCONNECTION
AC301373AB

with the timing belt tensioner arm.
Mating marks
AC200641AB
Make mating marks on the radiator upper hose and

the hose clamp. Disconnect the radiator upper hose.
11E-33
<<C>> FUEL HIGH-PRESSURE HOSE <<D>> CYLINDER HEAD BOLTS
DISCONNECTION REMOVAL
MB991654
Stopper
AC304581AB
1. Remove the fuel high-pressure hose stopper. Engine front
3 5 10 8 2
1 7 9 6 4
AC301454AB
Retainer
AC304582AB Use special tool cylinder head bolt wrench
(MB991654) to loosen the cylinder head bolts in two
2. Remove the fuel high-pressure hose in the or three steps in the order of the numbers shown in
direction shown in the figure while the retainer is the illustration. If the cylinder head bolts cannot be
pulled up. pulled out due to the washer being trapped in the
NOTE: If the retainer is released, install it after valve spring, raise the bolt slightly, then remove it
removing the fuel high-pressure hose. while holding it by using a magnet.

>>A<< CYLINDER HEAD GASKET
INSTALLATION
CAUTION
Do not allow any foreign materials get into the
1. Degrease the cylinder head gasket mounting
surface.
Identification
mark "381"
Exhaust side
AC302180AB
2. Assemble to the cylinder block so the cylinder 3. Use special tool cylinder head bolt wrench
head gasket identification mark of "381" is at the (MB991654) to tighten the cylinder head bolts in
top surface and on the exhaust side. the following procedures.
(1) Tighten the bolts to 78 ± 2 N⋅m in the order
>>B<< CYLINDER HEAD BOLTS shown.
INSTALLATION (2) Loosen the bolts fully in the reverse sequence
to that shown.
(Engine oil)
(3) Tighten the bolts to 20 ± 2 N⋅m in the order
shown.
Step (4) Step (5)
90˚ 90˚
AC102537AC

head bolt meets the limit. If it exceeds the limit, AC102331AB
replace the bolts with a new one.
(4) Apply a paint mark to the heads of the cylinder
Limit (A): 99.4 mm head bolts and cylinder head, then tighten 90
2. Apply a small amount of engine oil to the thread of degree angle as shown.
the bolts and to the washers. CAUTION
• The bolt is not tightening sufficiently if the
tightening angle is less than a 90 degree
angle.
• If the tightening angle exceeds the standard
specification, remove the bolt and start over
MB991654 from step 1.
(5) Tighten in a 90 degree angle as shown in the
instructions of the figure, then check to see
that the paint mark on the head of the cylinder
head bolts and the paint mark on the cylinder
head is on a linear line.
Engine front
8 6 1 3 9
10 4 2 5 7
AC301456AB
11E-35
>>C<< FUEL HIGH-PRESSURE HOSE >>D<< RADIATOR UPPER HOSE
CONNECTION CONNECTION
CAUTION
Fuel Projection
high-pressure
3 mm
hose
Water outlet fitting

Mating marks
Fuel line pipe
(Engine oil applied) AC200642 AB
AC301864AB
1. Insert radiator upper hose until it contacts the
projection on the water outlet fitting.
2. Align the mating marks on the radiator upper hose
and hose clamp, and then secure the radiator
upper hose.
>>E<< CAMSHAFT SPROCKET

INSTALLATION
Stopper
AC304583AB
MB990767
After connecting the fuel high-pressure hose,
slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
MD998719
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.
AC100302 AB

hold the camshaft sprocket.
• Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
TIMING BELT
TIMING BELT
M1112004301024

• Under Cover Removal (Refer to GROUP 51, Under Cover • Crankshaft Shaft Damper Pulley Installation (Refer to
P.51-31). P.11E-17).
• Crankshaft Shaft Damper Pulley Removal (Refer to • Drive Belt Tension Check (Refer to P.11E-7).
P.11E-17). • Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
2
14 ± 3 N·m
11 ± 1 N·m
1 3
5
4
14 ± 1 N·m 12
11
48 ± 5 N·m
14 ± 1 N·m
6
9
8.8 ± 1.0 N·m 11 ± 1 N·m
21 ± 4 N·m
8
13
44 ± 10 N·m
23 ± 3 N·m
22 ± 4 N·m
10
7
79 ± 5 N·m
11 ± 1 N·m
9.0 ± 1.0 N·m
AC308981AB

1. Control wiring harness connection 5. Timing belt upper cover
2. Battery wiring harness connection 6. Water pump pulley
3. Connector bracket 7. Idler pulley
• Engine mounting insulator (Refer to 8. Auto-tensioner
GROUP 32, Engine Mount P.32-7) 9. Timing belt lower cover
<M/T>. >>G<< • Valve timing belt tension
• Engine mounting insulator (Refer to adjustment (Installation only)
GROUP 32, Engine Mount P.32-6) <<A>> >>F<< 10. Valve timing belt
<A/T>. >>E<< 11. Timing belt tensioner pulley
4. Harness bracket
TIMING BELT
11E-37
12. Timing belt tensioner arm
>>D<< 13. Timing belt tensioner adjuster
14
35 ± 6 N·m
22
21
19 ± 3 N·m
18
(Engine oil)
20 16
15
19
167 N·m 17 8.5 ± 0.5 N·m
AC308982 AB

14. Timing belt Idler pulley >>C<< 20. Crankshaft angle sensing blade
15. Timing belt lower cover bracket >>B<< • Balancer timing belt tension
16. Crank angle sensor adjustment (Installation only)
<> >>C<< 17. Crankshaft pulley centre bolt >>A<< 21. Balancer timing belt tensioner
<> >>C<< 18. Crankshaft pulley washer <<C>> >>A<< 22. Balancer timing belt
<> >>C<< 19. Crankshaft camshaft drive sprocket
TIMING BELT

<<A>> VALVE TIMING BELT REMOVAL Timing belt
tensioner arm
CAUTION
Never turn the crankshaft anti-clockwise. MD998738
Timing mark
AC301373AB
3. Screw in the special tool with hands until it

contacts the timing belt tensioner arm.
Camshaft CAUTION
sprocket
The special tool can be gradually installed at a
rate of a 30 degree turn per second. If it is
Timing mark screwed in all at once, the timing belt tensioner
adjuster rod will not easily retract and the special
tool may bend.
Timing mark A
Engine oil pump B
Crankshaft sprocket
camshaft
drive sprocket AC301866AB
1. Turn the crankshaft clockwise, align each timing

mark to set No.1 cylinder to TDC of its
compression stroke. AC301856 AB
4. Gradually screw in the special tool and then align

MD998738 the timing belt tensioner adjuster rod set hole A
with the timing belt tensioner adjuster cylinder set
hole B.
pulley mounting bolt
Wire or pin
Timing belt
under cover
AC301452AB
2. Remove the timing belt under cover rubber plug

and then set special tool adjusting bolt
(MD998738).
AC302414AB
5. Insert a wire or pin in the set hole aligned.

CAUTION
To reuse the valve timing belt, draw an arrow
indicating the rotating direction (clockwise) on
the back of the belt using chalk, etc.
6. After removal of the special tool, loosen the timing
belt tensioner pulley mounting bolts and remove
the valve timing belt.
TIMING BELT
11E-39
<> CRANKSHAFT PULLEY CENTRE INSTALLATION SERVICE POINTS
BOLT/CRANKSHAFT PULLEY >>A<< BALANCER TIMING BELT/BAL-
WASHER/CRANKSHAFT CAMSHAFT ANCER TIMING BELT TENSIONER
DRIVE SPROCKET REMOVAL INSTALLATION
Crankshaft
camshaft MB991385
drive Balancershaft
sprocket sprocket
Belt tension
side
MB991367
Timing
AC102332AB mark
Timing
1. Use the following special tools to hold the mark
crankshaft camshaft drive sprocket.
• Pin (MB991385)
2. Loosen the crankshaft pulley centre bolt and
remove the crankshaft pulley washer and
crankshaft camshaft drive sprocket. Crankshaft
balancershaft
<<C>> BALANCER TIMING BELT drive sprocket
REMOVAL AC301402AB
CAUTION 1. Ensure that the crankshaft balancer shaft drive

To reuse the balancer timing belt, draw an arrow sprocket timing marks and balancer shaft
indicating the rotating direction on the back of sprocket timing marks are aligned.
the belt using chalk, etc. 2. Install the balancer timing belt on the crankshaft
balancer shaft drive sprocket and balancer shaft
sprocket. There should be no slack on the tension
side.
Centre of the
mounting bolt
Centre of
the pulley
AC301403AB

pulley of the balancer timing belt tensioner so that
it is at the top left from the centre of the
assembling bolt, and the pulley flange is at the
front-side of the engine.
4. Adjust the balancer timing belt tension.
TIMING BELT
>>B<< BALANCER TIMING BELT

TENSION ADJUSTMENT
Approximately 100 N
CAUTION
When tightening the mounting bolts, ensure that
the tensioner does not rotate with the bolts.
Allowing it to rotate with the bolts can cause Deflection
excessive tension of the belt.
AC301405AB

centre (arrow area) between the sprocket as
shown in the figure, then inspect whether the belt
deflection is within the standard value.
Standard value:
<When adjusting> 5 − 7 mm
AC301404 <When replacing> 5 − 7 mm
1. Lift with your fingers the balancer timing belt 4. If not within the standard value, adjust the belt
tensioner in the direction of the arrow. Apply a tension again.
tensile torque of 3.0 ± 0.4 N⋅m to the balancer
timing belt so the belt is tense without any >>C<< CRANKSHAFT ANGLE SENSING
looseness. Tighten the assembling bolt to the BLADE/CRANKSHAFT CAMSHAFT
specified torque in this state. Then, fix the DRIVE SPROCKET/CRANKSHAFT
balancer timing belt tensioner. PULLEY WASHER/CRANKSHAFT
Tightening torque: 19 ± 3 N⋅m PULLEY CENTRE BOLT INSTALLATION
: Clean
Balancershaft : Apply engine oil
sprocket
Crankshaft pulley
centre bolt
Crankshaft angle
sensing blade
Timing Crankshaft
mark pulley washer
Timing
mark
Crankshaft
balancershaft Crankshaft camshaft Crankshaft
drive sprocket drive sprocket
Engine front
AC301402AC AC301347AB
2. Turn the crankshaft clockwise two turns to set 1. Clean or degrease the crankshaft, the crankshaft
No.1 cylinder to TDC of its compression stroke angle sensing blade, the crankshaft camshaft
and check that sprocket timing marks are aligned. drive sprocket and crankshaft pulley washer as
shown.
TIMING BELT
11E-41
2. Install the crankshaft angle sensing blade and (1) Slowly compress the timing belt tensioner
crankshaft camshaft drive sprocket in the direction adjuster rod using a press or vice, then align
shown. the set hole A of the rod with set hole B of the
3. Place the larger chamfer side of the crankshaft timing belt tensioner adjuster cylinder.
pulley washer in the direction shown in the Figure
and then assemble on the crankshaft pulley Wire or pin
centre bolt.
4. Apply a small of engine oil to the crankshaft pulley
centre bolt bearing surface and screw.
Crankshaft
camshaft MB991385
drive
sprocket
AC302025AB
(2) Insert a wire or pin in the set hole aligned.

MB991367 NOTE: When replacing the timing belt ten-
sioner adjuster with new parts, the timing belt
tensioner adjuster is set with a pin.
AC102332AB
2. Install the timing belt tensioner adjuster to the
5. Use the following special tool as during removal to engine and then tighten the mounting bolt to the
hold the crankshaft camshaft drive sprocket. specified torque. Do not remove the wire or pin
• Special spanner (MB991367) until the tension of the valve timing belt is
• Pin (MB991385) adjusted.
6. Tighten the crankshaft pulley centre bolt to the Tightening torque: 23 ± 3 N⋅m
specified torque.
>>E<< TIMING BELT TENSIONER
Tightening torque: 167 N⋅m
PULLEY INSTALLATION
>>D<< TIMING BELT TENSIONER
1. Set according to the following procedures when
the timing belt tensioner adjuster rod is fully
extended.
CAUTION
If the compression is too fast the procedure may Timing belt tensioner
damage the rod. Make a point to slowly and thor- pulley hole
oughly compress. AC102336AB
Temporarily tighten the timing belt tensioner pulley

A B
as shown.
AC302024 AB
TIMING BELT

INSTALLATION Camshaft
sprocket
Timing mark
Timing belt
tensioner Belt tension
pulley side
Camshaft
sprocket
Timing belt
Idler pulley
Timing mark
Engine oil pump

Timing mark Crankshaft sprocket
camshaft
Engine oil pump drive sprocket AC301372AC
Crankshaft sprocket
camshaft
3. Incorporate the valve timing belt in the following
drive sprocket AC301374AB manner so that the tensile force of the belt is not
lax.
1. Align the timing marks on the camshaft sprocket,
crankshaft camshaft drive sprocket and engine oil (1) Place the valve timing belt on the timing belt
pump sprocket. tensioner pulley and crankshaft camshaft
driver sprocket and then support it with your
Bolt left hand so it does not slide.
Balancershaft
(2) Place the valve timing belt on the engine oil
pump sprocket while pulling it with the right
hand.
(3) Place the valve timing belt on the timing belt
idler pulley.
CAUTION
Plug Incorporate the valve timing belt. Then apply
Cylinder block
AC301871AB
reverse rotation (anti-clockwise rotation) pres-
sure to the camshaft sprocket. Re-check to see
2. Adjust the timing mark of the engine oil pump that each timing mark is aligned while the ten-
sprocket. Unplug the cylinder block plug. Insert a sion side of the belt is right.
bolt (M6, section width 10 mm, nominal length 45 (4) Place the valve timing belt on the camshaft
mm) from the plug hole. If the bolt comes in sprocket.
contact with the balancer shaft, turn the engine oil
sprocket one rotation. Re-adjust the timing mark
and then check to see that the bolt fits. Do not MD998767
remove the bolt until the valve timing belt is
assembled.
AC301858 AB
TIMING BELT
11E-43
4. Turn the timing belt tensioner pulley in the >>G<< VALVE TIMING BELT TENSION
direction shown in the figure using special tool ADJUSTMENT
tensioner wrench (MD998767) to apply tension to
the valve timing belt. Then temporarily tighten and
fix the timing belt tensioner pulley mounting bolt. MD998738
Timing mark
Timing belt
under cover
AC301452AB
Camshaft 1. Set special tool adjusting bolt (MD998738) used

sprocket when removing the valve timing belt.
CAUTION
Timing mark Always screw in the special tool in with your
hands, since use of a spanner or other tools may
damage the wire or pin inserted in the timing belt
tensioner adjuster.
Timing mark 2. Gradually screw in the special tool to a position in
Engine oil pump which the wire or pin inserted in the timing belt
Crankshaft sprocket tensioner adjuster lightly moves.
camshaft 3. Turn the crankshaft 1/4 of a revolution in the
drive sprocket AC301372AB anti-clockwise direction.
5. Check that the timing marks are aligned.
Bolt Timing mark
Balancershaft
Camshaft
sprocket
Plug
Cylinder block
AC301871AB
Timing mark
assemble the cylinder block plug.
7. Tighten the cylinder block plug to the specified
torque. Timing mark
Tightening torque: 30 ± 3 N⋅m Engine oil pump
8. Adjust the valve timing belt tension. Crankshaft sprocket
camshaft
drive sprocket AC301372AB
4. Turn the crankshaft in the clockwise direction,

align each timing mark to set No.1 cylinder to TDC
of its compression stroke.
5. Loosen the timing belt tensioner pulley mounting
bolt.
TIMING BELT
CAUTION 9. Rotate crankshaft clockwise two turns, and leave

When tightening the mounting bolt, ensure that it for about 15 minutes.
the timing belt tensioner pulley does not rotate
with the bolt. Allowing it to rotate with the bolt
can cause deficient tension of the belt. Wire or pin
MD998767
AC301857AB
10.Insert wire or pin removed in Step 7 again, and

ensure that it can be pulled out with a light load.
AC301859 AB
When wire or pin can be lightly removed,
6. With special tool tensioner wrench (MD998767) appropriate tension is applied on timing belt. In
and torque wrench, apply tension torque 3.5 N⋅m this case, remove wire or pin.
to the valve timing belt, and tighten the timing belt
tensioner pulley mounting bolt to the specified
torque.
Tightening torque: 48 ± 5 N⋅m A
Rod
Wire or pin
AC301375AB
Also the projection of timing belt tensioner

adjuster rod (A) is within the standard value,
appropriate tension is applied.
AC301857AB
7. Remove wire or pin inserted to timing belt 11.If wire or pin cannot be easily pulled out, repeat
tensioner adjuster. Step 1 through Step 9 to reach proper valve timing
belt tension.
MD998738
Timing belt
under cover
AC301452AB
8. Remove special tool adjusting bolt (MD998738),

and install the rubber plug to the timing belt under
cover.
TIMING BELT
11E-45
CAUTION 98 – 196 N
Always check the tightening torque of the crank-
shaft pulley centre bolt when turning the crank- Movement
A B
shaft pulley centre bolt anti-clockwise.
Re-tighten if it is loose.
Rod
Timing mark
AC301376AB
3. Hold the timing belt tensioner adjuster by hand,

and press top end of the rod onto the metal (e.g.
cylinder block) under a pressure of 98 − 196 N to
Camshaft
sprocket measure the movement of the rod.
Timing mark
A − B: Movement
Timing mark
Engine oil pump BALANCER TIMING BELT TENSION

Crankshaft sprocket
camshaft
CHECK
drive sprocket Check the balancer timing belt tension in the follow-
AC301866AB
ing procedures.
12.Check again that the timing marks on sprockets
are aligned.
Approximately 100 N
INSPECTION
M1112004400460

CHECK Deflection

is detected.
2. Check for wear or damage at the top of the rod. AC301405AB
Replace it, if required.

centre (arrow area) between the sprocket as
shown in the figure, then inspect whether the
flexure is within the standard value.
tension. (Refer to P.11E-36).
ENGINE ASSEMBLY
ENGINE ASSEMBLY
M1112001002191
<M/T>
CAUTION
• Fuel Line Pressure Reduction [Refer to GROUP 13C, • Radiator Assembly Installation (Refer to GROUP 14,
On-vehicle Service − Fuel Pump Connector Disconnec- Radiator P.14-35).
tion (How to Reduce Pressurized Fuel Lines) P.13C-428]. • Accelerator Cable Installation (Refer to GROUP 17,
Service − Engine Oil Replacement P.12-4). • Battery and Battery Tray Installation
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
Service − Engine Coolant Replacement P.14-17). P.15-8).
• Transmission Oil Draining (Refer to GROUP 22A, • Hood Installation (Refer to GROUP 42, Hood P.42-4).
On-vehicle Service − Transmission Oil Replacement • Transfer Oil Refilling (Refer to GROUP 22A, On-vehicle
P.22A-8). Service − Transfer Oil Replacement P.22A-8).
• Transfer Oil Draining (Refer to GROUP 22A, On-vehicle • Transmission Oil Refilling (Refer to GROUP 22A,
Service − Transfer Oil Replacement P.22A-8). On-vehicle Service − Transmission Oil Replacement
• Hood Removal (Refer to GROUP 42, Hood P.42-4). P.22A-8).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
P.15-8). Service − Engine Coolant Replacement P.14-17).
• Battery and Battery Tray Removal • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
tor P.14-35). Adjustment P.17-6).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Fuel Leak Check
Exhaust Pipe and Main Muffler P.15-25). • Drive Belt Tension Check (Refer to P.11E-7).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service − Front Wheel Alignment
Check and Adjustment P.33-5).
ENGINE ASSEMBLY
11E-47
9.0 ± 2.0 N·m
4 1
3
9.0 ± 2.0 N·m
5.0 ± 1.0 N·m
N 6 6N
48 ± 7 N·m 9.0 ± 2.0 N·m
7
5.0 ± 1.0 N·m
N 6 12 ± 2 N·m
48 ± 7 N·m
AC308983 AB

1. Control wiring harness connection <<A>> 5. Drive belt
2. Battery wiring harness connection 6. Engine oil cooler tube gaskets
3. Canister vacuum hose connection 7. Engine oil cooler hose and bracket
4. Brake booster vacuum hose assembly
connection
ENGINE ASSEMBLY
10 11
(Engine oil)
15
24 ± 4 N·m
8 44 ± 10 N·m
N 13 70 ± 4 N·m*
44 ± 10 N·m*
22 ± 4 N·m
44 ± 10 N·m*
12 9
14
AC308984 AB

<> 8. Power steering oil pump and <<E>> >>D<< • Transmission assembly
bracket assembly 12. Earth cable connection
<<C>> 9. A/C compressor and clutch 13. Self-locking nuts
assembly <<F>> >>B<< 14. Engine mounting insulator
10. Heater water hoses connection <<G>> >>A<< 15. Engine assembly
<<D>> >>E<< 11. Fuel high-pressure hose
connection
ENGINE ASSEMBLY
11E-49
<A/T>
CAUTION
• Fuel Line Pressure Reduction [Refer to GROUP 13C, • Radiator Assembly Installation (Refer to GROUP 14,
On-vehicle Service − Fuel Pump Connector Disconnec- Radiator P.14-35).
tion (How to Reduce Pressurized Fuel Lines) P.13C-428]. • Accelerator Cable Installation (Refer to GROUP 17,
Service − Engine Oil Replacement P.12-4). • Battery and Battery Tray Installation
• Transmission Fluid Draining (Refer to GROUP 23A, • Hood Installation (Refer to GROUP 42, Hood P.42-4).
On-vehicle Service − Automatic Transmission Fluid • Transfer Oil Refilling (Refer to GROUP 23A, On-vehicle
Change P.23A-124). Service − Transfer Oil Replacement P.23A-128).
• Transfer Oil Draining (Refer to GROUP 23A, On-vehicle • Transmission Fluid Refilling (Refer to GROUP 23A,
Service − Transfer Oil Replacement P.23A-128). On-vehicle Service − Automatic Transmission Fluid
• Hood Removal (Refer to GROUP 42, Hood P.42-4). Change P.23A-124).
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
P.15-8). Service − Engine Coolant Replacement P.14-17).
• Battery and Battery Tray Removal • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
tor P.14-35). Adjustment P.17-6).
• Front Exhaust Pipe Removal (Refer to GROUP 15, • Fuel Leak Check
Exhaust Pipe and Main Muffler P.15-25). • Drive Belt Tension Check (Refer to P.11E-7).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-31).
• Front Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service − Front Wheel Alignment
Check and Adjustment P.33-5).
ENGINE ASSEMBLY
9.0 ± 2.0 N·m
4 1
3
9.0 ± 2.0 N·m
5.0 ± 1.0 N·m
9.0 ± 2.0 N·m
5.0 ± 1.0 N·m

AC308985AB

1. Control wiring harness connection 4. Brake booster vacuum hose
2. Battery wiring harness connection connection
3. Canister vacuum hose connection <<A>> 5. Drive belt
ENGINE ASSEMBLY
11E-51
8 9
(Engine oil)
13
24 ± 4 N·m
6 44 ± 10 N·m
44 ± 10 N·m*
N 11 45 ± 5 N·m*
22 ± 4 N·m
44 ± 10 N·m*
10
12
7 AC308986AB

<> 6. Power steering oil pump and <<E>> >>D<< • Transmission assembly
bracket assembly 10. Earth cable connection
<<C>> 7. A/C compressor and clutch >>C<< 11. Self-locking nuts
assembly <<F>> >>B<< 12. Engine mounting insulator
8. Heater water hoses connection <<G>> >>A<< 13. Engine assembly
<<D>> >>E<< 9. Fuel high-pressure hose
connection
ENGINE ASSEMBLY
REMOVAL SERVICE POINTS <<C>> A/C COMPRESSOR AND CLUTCH

<<A>> DRIVE BELT REMOVAL ASSEMBLY REMOVAL
The following operations will be needed due to the With the hose installed, remove the A/C compressor
introduction of the serpentine drive system with the and clutch assembly from the bracket.
drive belt auto-tensioner. NOTE: After removing the A/C compressor and
AC301703 clutch assembly, secure it with a cord in the location
Auto-tensioner
where the removal and installation of the engine
assembly cannot be hindered.
<<D>> FUEL HIGH-PRESSURE HOSE

Hole B REMOVAL
Hole A
AC301704AB

hole of the auto-tensioner. Stopper
hole A with hole B.
AC304581AB
CAUTION
To reuse the drive belt, draw an arrow indicating 1. Remove the fuel high-pressure hose stopper.
the belt using chalk, etc.
Auto-tensioner
L-shaped Retainer
hexagon AC304582AB
wrench AC301705AB
2. Remove the fuel high-pressure hose in the
3. Insert an L-shaped hexagon wrench, etc. into the direction shown in the figure while the retainer is
hole to fix and then remove the drive belt. pulled up.
NOTE: If the retainer is released, install it after
<> POWER STEERING OIL PUMP removing the fuel high-pressure hose.
AND BRACKET ASSEMBLY REMOVAL
With the hose installed, remove the power steering
oil pump and bracket assembly from the engine
assembly.
NOTE: After removing the power steering oil pump
and bracket assembly, secure it with a cord in the
location where the removal and installation of the
engine assembly cannot be hindered.
ENGINE ASSEMBLY
11E-53
<<E>> TRANSMISSION ASSEMBLY (1) <Special tool engine hanger (MB991895) is
REMOVAL used>
MB991928
MB991527
AC300950AB MB991454
AC211405AB
radiator support upper insulator to set special tool
used>
engine hanger MB991895 or engine hanger
MB991928. Remove special tool MB991928.
CAUTION
MB991454
AC300897
MB991527
Engine front
Flywheel
assembly
Flywheel
bolt AC107632 AB
AC308604 AB 3. Hold the engine assembly with a chain block, etc.

M/T: Do not remove the flywheel bolt. If this bolt 4. Place a garage jack against the engine oil pan
is removed, the flywheel assembly will become with a piece of wood in between so that the weight
out of balance and damaged. of the engine assembly is no longer being applied
2. Remove the transmission assembly (M/T: Refer to
GROUP 22A, Transmission Assembly P.22A-14, 5. Loosen the engine mounting insulator mounting
A/T: Refer to GROUP 23A, Transmission nuts and bolts, and remove the engine mounting
Assembly P.23A-147). insulator.
<<F>> ENGINE MOUNTING INSULATOR <<G>> ENGINE ASSEMBLY REMOVAL

REMOVAL
1. Support the engine with a garage jack. the engine, lift the chain block slowly to remove the
2. Remove the following special tool. engine assembly upward from the engine compart-
MB991895 ment.
MB991527
MB991454
AC107631AB
ENGINE ASSEMBLY

MB991928
TION
MB991454
MB991527
MB991527
MB991454
AC211405AB

used>
AC107632 AB
Set special tool MB991928. (M/T: Refer to
Install the engine assembly, being careful not to
P.22A-14, A/T: Refer to GROUP 23A,
Transmission Assembly P.23A-147).
tors.
>>C<< SELF-LOCKING NUTS

>>B<< ENGINE MOUNTING INSULATOR
INSTALLATION
INSTALLATION
1. Place a garage jack against the engine oil pan CAUTION
with a piece of wood in between, and install the Do not tighten the self-locking nuts while the
engine mounting insulator while adjusting the engine is hot.
position of the engine. Tighten the self-locking nuts to the specified torque
while the engine is cold.
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
support the engine. >>D<< TRANSMISSION ASSEMBLY
MB991895 INSTALLATION
1. Install the transmission assembly. (M/T: Refer to
MB991527 GROUP 22A, Transmission Assembly P.22A-14,
A/T: Refer to GROUP 23A, Transmission
Assembly P.23A-147).
MB991454
AC107631AB

used>
Set special tool MB991895. (M/T: Refer to
P.22A-14, A/T: Refer to GROUP 23A, AC300950AB
Transmission Assembly P.23A-147). 2. Remove from the car the two bolts, to assemble
the radiator support upper insulator.
ENGINE ASSEMBLY
11E-55
>>E<< FUEL HIGH-PRESSURE HOSE
INSTALLATION
CAUTION
Fuel
high-pressure
3 mm
hose
Fuel line pipe

(Engine oil applied)
AC301864AB
Stopper
AC304583AB
After connecting the fuel high-pressure hose,

slightly pull it to ensure that it is installed
securely. Also confirm that there is a play
approximately 3 mm. Then install the stopper
securely.
Apply a small amount of engine oil to the fuel line
pipe and then install the fuel high-pressure hose.
11F-1
GROUP 11F
ENGINE OVERHAUL
<4G69>
CONTENTS
GENERAL INFORMATION . . . . . . . . 11F-2 INLET MANIFOLD AND

WATER PUMP . . . . . . . . . . . . . . . . . . 11F-30
GENERAL SPECIFICATIONS . . . . . . 11F-2 REMOVAL AND INSTALLATION . . . . . . . . 11F-30
SERVICE SPECIFICATIONS. . . . . . . 11F-3 ROCKER ARMS AND CAMSHAFT . . 11F-34

REMOVAL AND INSTALLATION . . . . . . . . 11F-34
REWORK DIMENSIONS . . . . . . . . . . 11F-5 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11F-36
TORQUE SPECIFICATIONS . . . . . . . 11F-5 CYLINDER HEAD AND VALVES. . . . 11F-37

SEALANTS . . . . . . . . . . . . . . . . . . . . 11F-8 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11F-40
SPECIAL TOOLS. . . . . . . . . . . . . . . . 11F-9 OIL PAN AND OIL PUMP. . . . . . . . . . 11F-43

ALTERNATOR AND IGNITION INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11F-51
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 11F-13
REMOVAL AND INSTALLATION . . . . . . . . 11F-13 PISTON AND CONNECTING ROD . . 11F-53
EXHAUST MANIFOLD. . . . . . . . . . . . 11F-16 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11F-58
CRANKSHAFT AND
TIMING BELT. . . . . . . . . . . . . . . . . . . 11F-18 CYLINDER BLOCK . . . . . . . . . . . . . . 11F-60
REMOVAL AND INSTALLATION . . . . . . . . 11F-18 REMOVAL AND INSTALLATION . . . . . . . . 11F-60
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 11F-26 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 11F-64
FUEL AND EMISSION PARTS . . . . . 11F-28

11F-2 ENGINE OVERHAUL <4G69>
GENERAL INFORMATION
GENERAL INFORMATION
M1113000100534

model mL
Outlander CU5W 4G69-2 2,378 Single overhead camshaft, 16-valve
M1113000200791
Item Specification
Type In-line OHV, SOHC
Combustion chamber Pent roof type
Total displacement cm3 2,378
Cylinder bore mm 87
Piston stroke mm 100
Compression ratio 9.5
Valve timing Intake valve Opens (BTDC) 10° <Low speed cam A>
12° <Low speed cam B>
24° <High speed cam>
Closes (ABDC) 42° <Low speed cam A>
44° <Low speed cam B>
68° <High speed cam>
Exhaust valve Opens (BBDC) 58°
Closes (ATDC) 18°
Lubrication system Pressure feed, full-flow filtration
Oil pump type Involute gear type
ENGINE OVERHAUL <4G69>
11F-3
M1113000300806

Timing belt
Auto tensioner rod length mm 3.8 − 4.5 −
Auto-tensioner rod projection length mm 12 −
Auto-tensioner rod pushed-in amount [When pushed with a 1.0 or less −
force of 98 − 196 N] mm
Valve clearance mm Intake 0.11 −
Exhaust 0.20 −
Rocker arms and camshaft
Camshaft cam height mm Intake Low speed 33.84 Minimum 33.34
cam A
Low speed 37.35 Minimum 36.85
cam B
High speed 37.21 Minimum 36.71
cam
Exhaust 37.86 Minimum 37.36
Camshaft journal outside diameter mm 45 −
Cylinder head and valves
Cylinder head flatness of gasket surface mm Less than 0.03 0.2
Cylinder head grinding limit of gasket surface mm (Total − 0.2
resurfacing depth of cylinder head and cylinder block)
Cylinder head overall height mm 120 −
Cylinder head bolt shank length mm − 99.4
Valve thickness of valve head Intake 1.0 Minimum 0.5
(margin) mm Exhaust 1.2 Minimum 0.7
Valve overall height mm Intake 111.33 Minimum 110.83
Valve stem outside diameter mm 6.0 −
Valve thickness to valve guide Intake 0.02 − 0.04 0.10
clearance mm Exhaust 0.04 − 0.06 0.15
Valve face angle mm 43.5° − 44° −
Valve spring free length mm Intake 54.8 Minimum 53.8
Valve spring load/installed height N/mm 267/44.2 −
Valve spring out-of-squareness 2° or less 4°
Valve seat valve contact width mm 0.9 − 1.3 −
Valve guide projection from cylinder head upper surface 14.0 −
mm

Valve stem projection mm Intake 48.33 48.83
Exhaust 48.34 48.84
Oil pan and oil pump
Oil pump side clearance mm Drive gear 0.08 − 0.14 −
Oil cooler by-pass valve mm Dimension (Normal 34.5 (1.358) −
temperature)
By-pass hole closing 40.0 (1.575) −
temperature 97 to
103°C
Oil pressure at curb idle speed kPa 78 or more −
[oil temperature is 75 to 90°]
Piston and connecting rod
Piston outside diameter mm 87 −
Piston ring side clearance mm No. 1 0.03 − 0.07 0.1
No. 2 0.02 − 0.06 0.1
No. 2 0.28− 0.43 0.8
Oil ring side rail 0.10 − 0.40 1.0
Piston pin press-in load N (Room temperature) 7,350 − 17,200 −
Crankshaft pin oil clearance mm 0.02 − 0.05 0.1
Connecting rod big end side clearance mm 0.10 − 0.25 0.4
Crankshaft and cylinder block
Crankshaft journal outside diameter mm 57.0 −
Crankshaft pin outside diameter mm 45.0 −
Oil clearance at crankshaft No. 1,2,4,5 journal 0.02 − 0.03 0.1
journals mm No. 3 journal 0.03 − 0.04 0.1
Bearing cap bolt shank length mm − 71.1
Piston to cylinder clearance mm 0.02 − 0.04 −
Cylinder block flatness of gasket surface mm 0.05 0.1
Cylinder block grinding limit of gasket surface mm (Total − 0.2
resurfacing depth of both cylinder head and cylinder block)
Cylinder block inside diameter mm 87.0 −
Cylindricity mm 0.01 −
REWORK DIMENSIONS
11F-5
REWORK DIMENSIONS
M1113024300413
Item Standard value

Cylinder head And valves
mm 0.6 oversize 35.60 − 35.63
0.6 oversize 33.60 − 33.63
0.25 oversize 11.25 − 11.27
0.50 oversize 11.50 − 11.52
M1113023401971
Item N⋅m
Alternator and ignition system
Auto-tensioner bracket bolt M10 44 ± 10
Auto-tensioner bracket bolt M8 22 ± 4
Camshaft position sensor bolt 11 ± 1
Camshaft position sensor support bolt 14 ± 1
Connector bracket bolt 11 ± 1
Crankshaft pulley bolt 25 ± 4
Alternator bolt 49 ± 9
Alternator pivot nut 44 ± 10
Ignition coil bolt 10 ± 2
Spark plugs 25 ± 5
Water pump pulley bolt 8.8 ± 1.0
Exhaust manifold
Exhaust manifold cover bolt 14 ± 1
Exhaust manifold bracket B bolt 59± 10
Exhaust manifold nut 49 ± 5
Exhaust manifold bracket A bolt 35 ± 6
Timing belt
Auto-tensioner bolt 23 ± 3
Camshaft sprocket bolt 89 ± 9
Item N⋅m
Crankshaft bolt 167
Crankshaft angle sensor bolt 8.5 ± 0.5
Engine support bracket bolt 49 ± 5
Generator bracket bolt 49 ± 9
Tensioner "B" bolt 19 ± 3
Timing belt cover bolt M6 (Bolt, washer assembly) 9.0 ± 1.0
Timing belt cover bolt M6 (Flange bolt and nut) 11 ± 1
Timing belt cover bolt M8 14 ± 1
Fuel and emission parts
EGR valve bolt 24 ± 3
Injectors and delivery pipe bolt 11 ± 1
Solenoid valve bracket bolt 11 ± 1
Solenoid valve nut 9.0 ± 1.0
Throttle body bolt 19 ± 3
Vacuum pipe and hose bolt 11 ± 1
Inlet manifold and water pump
Detonation sensor 23 ± 2
Engine coolant temperature gauge unit 11 ± 1
Harness bracket bolt 11 ± 1
Inlet manifold bolt 24 ± 3
Inlet manifold nut 20 ± 2
Inlet manifold stay bolt 31 ± 3
Manifold differential pressure sensor bolt 5.0 ± 1.0
Thermostat housing bolt 24 ± 4
Water inlet fitting bolt 13 ± 2
Water inlet pipe bolt 13 ± 2
Water outlet fitting bolt 13 ± 2
Water pump bolt 14 ± 1
Rocker arms and camshaft
Accumulator body bolt 44 ± 5
Oil feeder control valve bolt 11 ± 1
Rocker arms and rocker arm shaft bolt <exhaust side> 13 ± 1
11F-7
Item N⋅m
Rocker arms and rocker arm shaft bolt <intake side> 31 ± 3
Nut 9.0 ± 1.0
Rocker cover bolt 3.5 ± 0.5
Taper plug 47 ± 7
Cylinder head and valves
Cylinder head bolt 78 ± 2 → 0 → 20 ± 2 → +90° →
+90°
Oil pan and oil pump
Drain plug 39 ± 5
Flange bolt 36 ± 3
Front case bolt 23 ± 3
Oil cooler by-pass valve 54 ± 5
Oil filter bracket bolt 19 ± 3
Oil pan bolt 9.0 ± 3.0
Oil pump cover bolt 17 ± 1
Oil pump cover screw 10 ± 2
Oil screen bolt 19 ± 3
Plug 23 ± 3
Relief plug 44 ± 5
Transmission stay bolt 22 ± 4
Piston and connecting rod
Connecting rod cap nut 20 ± 2 → +90° to 94°
Crankshaft and cylinder block
Bearing cap bolt 25 ± 2 → +90°
Bell housing cover bolt 9.0 ± 1.0
Drive plate bolt 132 ± 5
Flywheel bolt 132 ± 5
Oil seal case bolt 11 ± 1
Rear plate bolt 11 ± 1
SEALANTS
SEALANTS
M1113000500725

Camshaft position sensor support* Mitsubishi Genuine Part No. MD970389 or equivalent
Engine support bracket seal bolt Mitsubishi Genuine Part No. MD970389 or equivalent
Engine coolant temperature sensor 3M ATD No.8660 or equivalent
Engine coolant temperature e gauge unit 3M Nut Locking Part No.4171 or equivalent
Water outlet fitting* Mitsubishi Genuine Part No. MD970389 or equivalent
Thermostat housing*
Thermostat housing seal bolt 3M™ AAD Part No. 8672 or equivalent
Oil pan* Mitsubishi Genuine Part No. MD970389 or equivalent
Rear oil seal case*
NOTE: *: Part to be sealed with a form-in-place gasket (FIPG)
ing it.
correct bead size.
ual.
to damage the mating surfaces. The oil pan remover
with an aluminum oil pan as it could damage the mat-
ing surfaces.
SPECIAL TOOLS
11F-9
SPECIAL TOOLS
M1113000601769

MD998781 Flywheel stopper Supporting drive plate
D998781
MB991883 Flywheel stopper Supporting flywheel
MB991883
MB991398 Spark plug wrench Removal and installation of

spark plug
MD998770 Oxygen sensor wrench Removal and installation of

oxygen sensor

puller
MD998785 Sprocket stopper Supporting counterbalance

shaft sprocket
MB990767 End yoke holder Holding camshaft sprocket

when loosening or torquing bolt
B990767
MD998719 Pins
D998719
SPECIAL TOOLS

MD998738 Adjusting screw • Holding the auto-tensioner
• Timing belt tension
adjustment
D998738
MD998767 Tension pulley wrench Adjustment of timing belt

tension
D998767

block>

installer
D998713

wrench (12) cylinder head bolt
B991654
MD998735 Valve spring compressor Compression of valve spring
MB991999 Valve steam seal Installation of valve steam seal

installer
B991999
SPECIAL TOOLS
11F-11
MD998162 Plug wrench Removal and installation of
front case cap plug
MD998783 Plug wrench retainer
MD998371 Silent shaft bearing Removal of counterbalance

puller shaft front bearing
MD998372 Silent shaft bearing Removal of counterbalance

puller shaft rear bearing
MB991603 Bearing installer stopper Removal and installation of rear

bearing
MD998705 Silent shaft bearing Installation of counterbalance

installer shaft bearing
MD998285 Crankshaft front oil seal Installation of crankshaft front

guide oil seal
D998285

installer
SPECIAL TOOLS

MD998780 Piston pin setting tool Removal and installation of
piston pin
MB992010 Bolt guide Removal and installation of

piston and connecting rod
assembly

seal

installer
D998776
11F-13
M1113001001395
11 ± 1 N·m
10 ± 2 N·m
25 ± 5 N·m 13 11 ± 1 N·m
1 10
11 14
15
16
13 ± 1 N·m 12
11 ± 1 N·m
14 ± 1 N·m
2
22 ± 4 N·m
3
8
6 44 ± 10 N·m
8.8 ± 1.0 N·m
22 ± 4 N·m
25 ± 4 N·m
7
49 ± 9 N·m
79 ± 5 N·m 9
5
44 ± 10 N·m
AK301540AD

1. Oil level gauge 9. Alternator
2. Oil level gauge guide 10. Ignition coil
3. O-ring <<A>> >>C<< 11. Spark plug
4. Auto tensioner 12. Connector bracket
5. Crankshaft pulley 13. Camshaft position sensor
6. Water pump pulley 14. O-ring
7. Idler pulley >>B<< 15. Camshaft position sensor support
8. Connector bracket <> >>A<< 16. Camshaft position sensing cylinder
REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> SPARK PLUG REMOVAL >>A<< CAMSHAFT POSITION SENSING
CYLINDER INSTALLATION
<A/T>
MB991398
AK300130 AD MD998781
Using special tool Spark plug wrench (MB991398), AK300135 AG
removal the spark plug.

<M/T>
MB991883
<> CAMSHAFT POSITION SENSING
CYLINDER REMOVAL
<A/T>
AK600660AB
1. Using special tool Flywheel stopper (MD998781),

MD998781
hold the drive plate.
• Flywheel stopper (MB991883)
AK300135 AG
• Flywheel stopper (MD998781)
<M/T> 2. Tighten the camshaft position sensing cylinder to
MB991883 the specified torque.
AK600659AB
1. Using special tool Flywheel stopper (MD998781),

hold the drive plate.
2. Removal the camshaft position sensing cylinder.
11F-15
>>B<< CAMSHAFT POSITION SENSOR >>C<< SPARK PLUG INSTALLATION
3 mm
MB991398
AK300130 AD
AK300004AE Using special tool Spark plug wrench (MB991398),

1. Remove completely the FIPG remaining on the tighten the spark plug to the specified torque.
camshaft position sensor support and cylinder Tightening torque: 25 ± 5 N⋅m
head.
indicated surface of the camshaft position sensor
support.
Specified sealant:
equivalent
EXHAUST MANIFOLD
EXHAUST MANIFOLD
M1113004900747
14 ± 1 N·m
14 ± 1 N·m
7
49 ± 5 N·m
6
1
2
44 ± 5 N·m 3
24 ± 3 N·m 5
44 ± 5 N·m
8
35 ± 6 N·m
59 ± 10 N·m
AK303751AD

1. Engine hanger >>A<< 5. Exhaust manifold bracket B
<<A>> >>B<< 2. Oxygen sensor 6. Exhaust manifold
<<A>> >>B<< 3. Oxygen sensor 7. Exhaust manifold gasket
>>B<< 4. Exhaust manifold cover 8. Exhaust manifold bracket A
EXHAUST MANIFOLD
11F-17
REMOVAL SERVICE POINT >>B<< EXHAUST MANIFOLD COVER /
<<A>> OXYGEN SENSOR REMOVE OXYGEN SENSOR INSTALLATION
1. Install the exhaust manifold cover to the exhaust
manifold.
2. Temporarily tighten the exhaust manifold cover
bolt.
MD998770
AK300132AD MD998770
Using special tool Oxygen sensor wrench
(MD998770), removal the oxygen sensor.
INSTALLATION SERVICE POINT AK300132AD
>>A<< EXHAUST MANIFOLD BRACKET 3. Using special tool Oxygen sensor wrench
"B" INSTALLATION (MD998770), install both of the oxygen sensors to
the exhaust manifold.
NOTE: Do not remove the special tool after the
oxygen sensor is installed.
4. Tighten the exhaust manifold cover bolt to the
specified torque of 14 ± 1N⋅m.
5. Remove the special tool.
AK300131
Check to ensure that the exhaust manifold bracket

"B" is in close contact with the exhaust manifold and
the cylinder block before tightening the respective
TIMING BELT
TIMING BELT
M1113001901525
2
14 ± 1 N·m
1 6
5
48 ± 5 N·m
23 ± 3 N·m
7
11 ± 1 N·m 21 ± 4 N·m
14 ± 1 N·m
14
13
12 22
11 ± 1 N·m 167 N·m
23
3
19
9.0 ± 1.0 N·m 4 18
45 ± 3 N·m
26
49 ± 9 N·m
89 ± 9 N·m
25 24
21
10
9
20 49 ± 9 N·m
8 49 ± 5 N·m 8.5 ± 0.5 N·m

16
35 ± 6 N·m
15 17
19 ± 3 N·m
54 ± 4 N·m
11 AK301538 AC

1. Connector bracket <<D>> >>G<< 14. Crankshaft sprocket
2. Timing belt front upper cover >>G<< 15. Crankshaft sensing blade
3. Timing belt front lower cover 16. Tensioner "B"
<<A>> >>K<< 4. Timing belt <<E>> >>F<< 17. Timing belt "B"
>>J<< 5. Tensioner pulley <<F>> >>E<< 18. Counterbalance shaft sprocket
6. Tensioner arm >>D<< 19. Spacer
>>I<< 7. Auto-tensioner <<G>> >>C<< 20. Crankshaft sprocket "B"
9. Bracket 22. Generator bracket
10. Crankshaft angle sensor >>B<< 23. Engine support bracket
<> >>H<< 11. Oil pump sprocket 24. Timing belt rear cover
<<C>> >>G<< 12. Crankshaft bolt <<H>> >>A<< 25. Camshaft sprocket bolt
>>G<< 13. Crankshaft pulley washer 26. Camshaft sprocket
TIMING BELT
11F-19
REMOVAL SERVICE POINTS <<C>> CRANKSHAFT BOLT LOOSENING
<<A>> TIMING BELT REMOVAL <M/T>
MB991883
AK600659AB
AK300133
<A/T>
CAUTION
Water or oil on the belt shortens its life drasti-
cally, so the removed timing belt, sprocket, and
tensioner must be washed or immersed in sol-
vent. Replace parts if contaminated.If there is oil
or water on any part, check the front case oil
seals, camshaft oil seal, and water pump for
leaks. MD998781
AK300135 AG
1. Mark the belt running direction for reinstallation.
2. Loosen the tensioner pulley bolt, and then remove 1. Install Flywheel stopper (MD998781) to hold the
the timing belt. drive plate or the flywheel.
<> OIL PUMP SPROCKET REMOVAL • Flywheel stopper (MD998781)
1. Remove the plug on the left side of the cylinder 2. Loosen and remove the crankshaft bolt and
block. washer.
<<D>> CRANKSHAFT SPROCKET

REMOVAL
AK300134
2. Insert a Phillips screwdriver (shank diameter 8

mm) through the plug hole to block the left MD998778 AK300136 AD
counterbalance shaft.
3. Loosen the nut, and then remove the oil pump 1. Set special tool Crankshaft sprocket puller
sprocket. (MD998778) as shown in the illustration.
2. Screw in the center bolt of the special tool to
remove the crankshaft sprocket.
TIMING BELT
<<E>> TIMING BELT "B" REMOVAL <<G>> CRANKSHAFT SPROCKET "B"

REMOVAL
AK300137
MD998778 AK300139AD
CAUTION
Water or oil on the belt shortens its life drasti- 1. Set special tool Crankshaft sprocket puller
cally, so the removed timing belt, sprocket, and (MD998778) as shown in the illustration.
tensioner must be free from oil and water. These
2. Screw in the center bolt of the special tool to
parts should not be washed or immersed in sol-
remove crankshaft sprocket "B."
vent. Replace parts if contaminated.If there is oil
or water on each part, check the front case oil
seals, camshaft oil seal and water pump for <<H>> CAMSHAFT SPROCKET
leaks. REMOVAL
1. Mark the belt running direction for reinstallation. MB990767
2. Loosen the tensioner "B" bolt, and then remove
the timing belt "B."
<<F>> COUNTERBALANCE SHAFT MD998719

SPROCKET REMOVAL
MD998785
AK300140 AD
1. Remove the camshaft sprocket.

2. Use the special tools to prevent the camshaft
sprocket from rotating.
• End yoke holder (MB990767)
• Pulley holder pin (MD998719)
AK300138 AD
1. Set special tool Sprocket stopper (MD998785) as

shown to prevent the counterbalance shaft
sprocket from turning together.
2. Loosen the bolt and remove the sprocket.
TIMING BELT
11F-21
INSTALLATION SERVICE POINTS >>C<< CRANKSHAFT SPROCKET "B"
>>A<< CAMSHAFT SPROCKET INSTAL- INSTALLATION
LATION
Sprocket "B"
Crankshaft
MB990767
Degrease
Front case AK301828AC
MD998719
AK300141 AD Clean and then degrease the front case of the front
case, crankshaft sprocket "B" and crankshaft surface
1. Use the special tools to prevent the camshaft
on which sprocket "B" is attached.
sprocket from rotating.
• End yoke holder (MB990767) NOTE: Degreasing is necessary to prevent decrease
• Pulley holder pin (MD998719) in the friction between contacting surfaces.
2. Tighten the camshaft sprocket bolt to the specified
torque. >>D<< SPACER INSTALLATION
Tightening torque: 89 ± 9 N⋅m Counter
Oil seal balance
shaft
>>B<< ENGINE SUPPORT BRACKET Spacer
INSTALLATION
Chamfered
AK301298AD
1. Apply a thin coat of clean engine oil to the lip area

of the oil seal.
2. Install the spacer with the chamfered end facing
toward the oil seal.
AK300142
1. Remove thoroughly the old sealant remaining on >>E<< COUNTERBALANCE SHAFT

SPROCKET INSTALLATION
it.
MD998785
Specified sealant:
equivalent
AK300138 AD
1. Install the counterbalance shaft sprocket and

screw on the bolt.
TIMING BELT
2. Install special tool Sprocket stopper (MD998785) 4. Move tensioner "B" in the direction of the arrow
as shown in the illustration to lock the while lifting with your finger to give sufficient
counterbalance shaft. tension to the tension side of timing belt. In this
3. Tighten the bolt, and then remove the special tool. condition, tighten the bolt to secure tensioner "B."
Tightening torque: 45 ± 3 N⋅m When the bolt is tightened, use care to prevent
the tensioner pulley shaft from turning with the
bolt. If the shaft is turned with the bolt, the belt will
>>F<< TIMING BELT "B" INSTALLATION be over tensioned.
Timing
mark
Timing
mark
AK300143 AD
1. Align timing marks on the crankshaft sprocket "B" AK300146

and counterbalance shaft sprocket with the marks
on the front case. 5. Check that timing marks on the sprockets are
aligned with the timing marks on the front case.
2. Install the timing belt "B" on the crankshaft
sprocket "B" and counterbalance shaft sprocket. 6. With your index finger, press the midway of span
There should be no slack on the tension side. on the tension side of timing belt "B." The bolt
must deflect 5 to 7 mm.
Tensioner "B" >>G<< CRANKSHAFT SENSING

BLADE/CRANKSHAFT
SPROCKET/CRANKSHAFT PULLEY
WASHER/CRANKSHAFT BOLT
INSTALLATION
Center of
bolt
Center of Sensing blade
tensioner pulley Crankshaft
AK300144 AD bolt
Sprocket Crankshaft
3. Make sure that the tensioner pulley center and the Clean
bolt center are positioned as shown in the
illustration.
Washer
Big chamfered side Degrease
AK301075AD
1. Clean and then degrease the contacting surfaces

of the crankshaft sprocket, sensing blade and
crankshaft.
NOTE: Degreasing is necessary to prevent
AK300145 decrease in the friction between contacting sur-
faces.
2. Clean the bolt hole in the crankshaft, the
crankshaft contacting surface of the crankshaft
sprocket, and the washer.
TIMING BELT
11F-23
3. Install the sensing blade and the crankshaft 2. Install the oil pump sprocket.
sprocket to the crankshaft. 3. Apply a thin coat of engine oil to the seating
4. Apply a small amount of engine oil to the threads surface of the nut.
and seating surface of the crankshaft bolt. 4. Tighten the nut to the specified torque.
5. Install the washer to the crankshaft bolt with the Tightening torque: 54 ± 5 N⋅m
larger chamfered side toward the bolt head.
<M/T> >>I<< AUTO-TENSIONER INSTALLATION
MB991883 If the auto-tensioner rod is fully extended, reset it as
follows:
AK600660AB
<A/T>
AK300154
1. Clamp the auto-tensioner in a vise with soft jaws.
MD998781 B
AK300135 AG
6. Lock the drive plate or the flywheel using the

special tool Flywheel stopper.
• Flywheel stopper (MD998781) AK301074AD
7. Tighten the crankshaft bolt to the specified torque.
2. Push in the rod little by little with the vise until the
Tightening torque: 167 N⋅m
set hole A in the rod is aligned with hole B in the
cylinder.
>>H<< OIL PUMP SPROCKET 3. Insert a wire (1.4 mm in diameter) into the set
INSTALLATION holes. This auto-tensioner setting wire will be
used during timing belt alignment.
4. Unclamp the auto-tensioner from the vise.
AK301073
1. Insert a Phillips head screwdriver (shank diameter

AK301832
8 mm) through the plug hole on the left side of the
cylinder block to block the left counterbalance
shaft.
TIMING BELT
CAUTION
Leave the wire installed in the auto-tensioner. Timing mark
5. Install the auto-tensioner onto the front case and
tighten to the specified torque.
>>J<< TENSIONER PULLEY

INSTALLATION
AK301076AD
3. Align the timing mark on oil pump sprocket with its

mating mark.
60 mm or more
Tensioner
pulley hole AK300147AD
Set the tensioner pulley so that the holes for attach-

Counter
ing a wrench may be positioned as shown in the illus- balance
tration. shaft AK301077 AD
4. Remove the plug on the cylinder block and insert

>>K<< TIMING BELT INSTALLATION
a Phillips head screwdriver (shank diameter 8
mm) through the hole.
Timing mark If it can be inserted as deep as 60 mm or more,
the timing marks are correctly aligned.
if the inserted depth is only 20 to 25 mm, turn the
oil pump sprocket one turn and realign the timing
marks. then check to ensure that the screwdriver
can be inserted 60 mm or more. keep the
screwdriver inserted until the timing belt is
AK300148 AD
completely installed.
1. Align the timing mark on the camshaft sprocket

with the timing mark on the rocker cover.
MD998738
AK300151 AD
Timing mark
5. Set the special tool Set screw (MD998738) as
AK300149 AD
shown and screw it in up to the position where the
wire inserted in the auto-tensioner when installing
2. Align the timing mark on the crankshaft sprocket it can be moved lightly.
with the timing mark on the front case. 6. Install the timing belt on the crankshaft sprocket,
oil pump sprocket, idler pulley, camshaft sprocket,
and tensioner pulley in that order.
TIMING BELT
11F-25
Auto tensioner
AK301295AD AK301836
7. Lift up the tensioner pulley in the direction of the 14. The wire inserted at the auto-tensioner
arrow and tighten the center bolt. installation is pulled out and then the special tool
8. Check that all timing marks are aligned. Set screw (MD998738) is removed by hand.
9. Remove the screwdriver inserted in step 5 and 15.Give two clockwise turns to the crankshaft. Wait
install the plug. for 15 minutes, then proceed with the following
10.Turn the crankshaft a quarter turn inspection steps.
counterclockwise. Then, turn it clockwise until the
timing marks are aligned again.
AK300152
MD998767 16.Check to see whether the metal wire (inserted

AK300150 AD
when the auto-tensioner was installed) can be
11.Install special tool Tension pulley socket wrench removed without any resistance.
(MD998767), socket wrench and torque wrench, If the metal wire can be removed without any
onto the tensioner pulley, and loosen the resistance, it means that the belt has a proper
tensioner pulley center bolt. tension. Therefore, remove the metal wire. In this
NOTE: Use a torque wrench that can measure 0 condition, check that the rod protrusion of the
to 5.0 N⋅m. auto-tensioner is within the standard value.
12.Torque to 3.5 N⋅m with the torque wrench. Standard value: 3.8 − 4.5 mm
13.Holding the tensioner pulley with special tool 17.If the metal wire offers resistance when removed,
Tension pulley socket wrench (MD998767) and repeat the previous steps 10 through 15 until the
torque wrench, tighten the center bolt to standard value is obtained as measured by the
specification. rod projection of the auto-tensioner rod.
TIMING BELT
INSPECTION
M1113002000481
TIMING BELT Rubber exposed
Tooth missing and

canvas fiber exposed
AKX00751AD
7. Abnormal wear on teeth.

AK202794 Initial stage:
Canvas worn (fluffy canvas fibers, rubbery
Replace the belt if any of the following conditions
texture gone, white discoloration, canvas
exist:
texture indistinct)
1. Hardening of rubber backing. Final stage:
Back side should be glossy without resilience and Canvas worn, exposing rubber (tooth width
leave no indent when pressed with fingernail. reduced)
Cracks Cracks
8. Missing tooth.
AUTO-TENSIONER
Peeling of canvas
Cracks in sides
12 mm
Cracks in tooth roots AK202793 AD
2. Cracks on rubber back.

3. Cracks or peeling of canvas.
4. Cracks at bottom of ribs. AK301307AD
5. Cracks on belt sides. 1. Check for oil leaks. If oil leaks are evident, replace
the auto-tensioner.
Rounded edge 2. Check the rod end for wear or damage and
replace the auto-tensioner if necessary.
3. Measure the rod protrusion. If it is out of
specification, replace the auto tensioner.
Standard value: 12 mm
98 TO 196 N
Abnormal wear
(fluffy strand) AK202795 AD
Movement
6. Abnormal wear of belt sides. Normal wear is
indicated if the sides are sharp as if cut by a knife.
Abnormal wear is indicated if the sides are
ragged.
AK301308AD
TIMING BELT
11F-27
4. Press the rod with a force of 98 to 196 N and 3. Measure the valve clearance marked with arrows
measure the movement of the rod. shown in the figure.
If the measured value is out of the standard value, White arrow mark: When No.1 cylinder is on the
replace the auto-tensioner. top dead center of compression stroke.
Standard value: 1.0 mm or less Black arrow mark: When No.4 cylinder is on the
top dead center of compression stroke.
VALVE CLEARANCE ADJUSTMENT
Perform the adjustment of the valve clearance in the
following procedure.
1. Remove the rocker cover.
Timing mark
AK300153
4. Using a thickness gauge, adjust the clearance

between the valve shaft end and the adjusting
screw.
AK300148 AE
Standard value (in cold state):
CAUTION Intake side: 0.11 mm
Rotate the crankshaft clockwise at any time. Exhaust side: 0.20 mm
NOTE: After the engine assembly is installed on
2. Rotate crankshaft clockwise and then align the
the vehicle, check the valve clearance again in
timing mark on the camshaft sprocket with the
the engine warm-up state. Adjust if necessary.
timing mark on the cylinder head. (Place No. 1
cylinder on the top dead center of compression 5. Hold the adjusting screw not rotating through a
stroke.) driver and then tighten the rock nut.
6. Rotate the crankshaft one time clockwise and
Intake valve side
then align the timing mark with the timing mark on
the crankshaft sprocket. (Place No. 4 cylinder on
the top dead center of compression stroke.)
7. Adjust the valve clearance for the rest of the
valves.
8. Install the rocker cover.
No. 1 No. 2 No. 3 No. 4

Exhaust valve side AK204362AE

M1113002200720
19 ± 3 N·m
24 ± 3 N·m
12 13
11 ± 1 N·m
11
9
10
6
8
14 2
1
7
11 ± 1 N·m
3 5
11 ± 1 N·m
9.0 ± 1.0 N·m
AK400854AB

1. Throttle body 8. Insulator
>>C<< 2. Throttle body gasket >>B<< 9. Injector
3. Vacuum pipe and hose 10. O-ring
4. Solenoid valve 11. Grommet
5. Solenoid valve bracket 12. Delivery pipe
6. Injector and delivery pipe 13. EGR valve
7. Insulator >>A<< 14. EGR gasket
11F-29
INSTALLATION SERVICE POINTS CAUTION
>>A<< EGR VALVE INSTALLATION Use care not to let engine oil enter the delivery
pipe.
1. Apply clean engine oil to the O-ring.
2. Insert the injector into the delivery pipe.
3. Make sure the injector rotates smoothly.
If not, remove the injector to check the O-ring for
damage, and replace the O-ring if necessary.
Then, reinstall the injector and check that it
rotates smoothly.
AK300578AD
Install a new gasket is positioned as shown in the INSTALLATION
illustration.
>>B<< INJECTORS INSTALLATION Projection
AK300579AD
A Install a new gasket so that the projection is posi-

tioned as shown in the illustration.
A
Inlet
manifold
Delivery pipe
Injector
AK300155AF
INLET MANIFOLD AND WATER PUMP

M1113025500164
11 ± 1 N·m
13 ± 2 N·m 11 ± 1 N·m
5.0 ± 1.0 N·m

9
2
13 14
16 24 ± 4 N·m
24 ± 3 N·m
1 10
11
13 ± 2 N·m 7 12
11 ± 1 N·m
30 ± 9 N·m
24 ± 3 N·m 19
19 ± 3 N·m
15 18 11 ± 1 N·m
13 ± 2 N·m
5
11 ± 1 N·m 20 ± 2 N·m
6
17 20
23 ± 2 N·m
4
8
31 ± 3 N·m
14 ± 1 N·m AK403249 AB

1. Water hose >>D<< 12. Thermostat housing
2. Water hose 13. Manifold differential pressure
3. Water pump sensor
4. Water pump gasket 14. Inlet manifold
>>H<< 5. O-ring 15. Inlet manifold gasket
>>H<< 6. Water inlet pipe 16. Engine hanger
>>H<< 7. O-ring 17. Detonation sensor
>>G<< 8. Inlet manifold stay <<A>> >>C<< 18 Oil pressure switch
>>F<< 9. Engine coolant temperature gauge >>B<< 19. Engine coolant temperature sensor
unit >>A<< 20. Water outlet fitting
10. Water inlet fitting
>>E<< 11. Thermostat
11F-31
REMOVAL SERVICE POINT >>B<< SEALANT APPLICATION TO
<<A>> OIL PRESSURE SWITCH ENGINE COOLANT TEMPERATURE
REMOVAL SENSOR
MD998012
AK300156 AF AK300712 AB
Using special tool Oil pressure switch wrench CAUTION

(MD998012), removal the oil pressure switch. When using a tool, avoid letting it touch the con-
nector portion which is made of plastic.
INSTALLATION SERVICE POINTS 1. Remove all old sealant remaining on the threads
>>A<< WATER OUTLET FITTING INSTAL- of the coolant temperature sensor and in the
LATION threaded hole in the thermostat housing.
2. Apply sealant to the coolant temperature sensor's
threads indicated in the drawing.
3 mm
Specified sealant:
AK301336AD
1. Apply a 3 mm diameter bead of FIPG to the

indicated surface of the water outlet fitting.
Specified sealant:
equivalent
2. Install the housing quickly (within 15 minutes)
while the sealant is wet and tighten the bolts to the
specified torque.
NOTE: . After installation, keep the sealed area away
from the coolant for approximately one hour.
>>C<< SEALANT APPLICATION TO OIL 2. Apply a 3 mm diameter bead of FIPG on the

PRESSURE SWITCH indicated surface of the thermostat housing.
Specified sealant:
equivalent
AK300715 AB

Specified Sealant: AK300158
it.
MD998012
Specified sealant:
4. Install the housing quickly (within 15 minutes)
while the sealant is wet and tighten the bolts to the
specified torque.
NOTE: After installation, keep the sealed area
AK300157 AF away from the coolant for approximately one hour.
2. Using special tool Oil pressure switch wrench
(MD998012), tighten the oil pressure switch to the >>E<< THERMOSTAT INSTALLATION
specified torque.
Tightening torque: 19 ± 3 N⋅m Jiggle valve
>>D<< THERMOSTAT HOUSING

INSTALLATION
Thermostat
housing
AK400855AC
1. Check that the rubber ring is undamaged and

seated correctly in the thermostat flange.
2. Install the thermostat as shown in the illustration.
3 mm The jiggle valve must be at the uppermost
position.
AK301337AD
1. Remove all old FIPG remaining on the thermostat

housing and cylinder head.
11F-33
>>F<< SEALANT APPLICATION TO >>G<< INLET MANIFOLD STAY
ENGINE COOLANT TEMPERATURE INSTALLATION
GAUGE UNIT
Inlet manifold
Cylinder block
AK301361AC
AK300711 AB
1. Install the inlet manifold stay and tighten the bolts
1. Remove all old sealant remaining on the threaded just finger tight.
hole in the coolant temperature gauge unit and 2. Check to ensure that the stay is in close contact
the thermostat housing. with the bosses of the inlet manifold and cylinder
NOTE: A new coolant temperature gauge unit is block.
coated with sealant. It does not require coating 3. First tighten the inlet manifold side bolts to the
with sealant before installation. specified torque, then the cylinder block side bolts
2. Apply sealant to the indicated threads of the to the specified torque.
coolant temperature gauge unit. Tightening torque: 31 ± 3 N⋅m
Specified sealant:
3M Nut Locking Part No.4171 or equivalent >>H<< WATER INLET PIPE/O-RING
INSTALLATION
CAUTION
Keep the O-ring free of oil or grease.
O-ring
Water inlet pipe

AK301861AC
1. Attach a new O-ring to each end of the water inlet

pipe.
2. Wet the O-ring with water.
3. Insert the rear end of the pipe into the thermostat
housing.

M1113005400875
5
Apply engine oil to
all moving parts 1
before installation. 2
3
4 6
31 ± 3 N·m 3.5 ± 0.5 N·m

8
7
13 ± 1 N·m
12 12
12
9.0 ± 1.0 N·m 12
12
12
12 11
12
13 18
16 17
13
13 28
13 15 12
13 13 16 17
10 14 13 12
11 ± 1 N·m
13 15 12 13
16 17 13
12 20 19 21
15 12 13
16 17 13 22
12 26
15 12 13 23
27
13 24
12 47 ± 7 N·m
13
13 25
44 ± 5 N·m
AK305650 AE

1. Breather hose <<A>> >>C<< 11. Rocker arms and rocker arm shaft
2. PCV hose (Exhaust side)
3. PCV valve 12.Nut
4. PCV valve gasket >>B<< 13.Adjusting screw
5. Oil filler cap 14.Rocker arm shaft assembly (Intake
6. Rocker cover side)
7. Rocker cover gasket 15.Rocker arm "C"
8. Oil seal 16.Piston arm assembly
>>D<< 9. Oil seal 17.Rocker arm "D"
<<A>> >>C<< 10.Rocker arms and rocker arm shaft 18.Rocker arm shaft (Exhaust side)
(Intake side) >>A<< 19.Oil feeder control valve
11F-35
Removal steps (Continued) >>B<< ADJUSTING SCREW
20.O-ring
INSTALLATION
21.Snap ring
22.Accumulator spring seat
23.Plunger spring
24.Accumulator plunger
25.Accumulator body
26.Taper plug
27.Oil feeder control valve filter
28.Camshaft
3 mm

AK301421 AD
<<A>> ROCKER ARMS AND ROCKER
Install provisionally the screw to rocker arm, insert it
ARM SHAFT REMOVAL so that end of the screw is flush with the edge of the
When the rocker arm is removed from the rocker rocker arm or projects slightly 3 mm.
shaft, keep them with the tags that show the installa-
tion location for the reinstallation of the rocker arm,
>>C<< ROCKER SHAFT
the T-lever, the piston arm assembly and so on.
SPRING/ROCKER ARMS AND ROCKER
ARM SHAFT INSTALLATION
INSTALLATION SERVICE POINTS 1. In accordance with the tags for the reinstallation,
>>A<< OIL FEEDER CONTROL VALVE install the rocker arm and so on to the rocker arm
shaft.
INSTALLATION
2. Install the rocker arm shaft with oil hole to the
CAUTION lower (cylinder head) side.
Do not reuse the O-ring.Install the O-ring after
wrap a tape not having adhesion (such as a seal Timing belt side
tape) round the notch on the oil passage of oil
feeder control valve to prevent it from damage.
The damaged O-ring may cause oil leakage.
Tape
AK301422 AD
3. Install the rocker arm, rocker arm shaft assembly

and intake temporarily.
4. Install the rocker arm, rocker arm shaft assembly
AK303651AE and exhaust temporarily.
5. Confirm the each rocker arm and rocker arm shaft
1. Apply a little amount of engine oil to the O-ring of
assembly are in position and then tighten to the
oil feeder control valve.
specified torque.
2. Install the oil feeder control valve to the cylinder
head. Tightening torque
M6: 13 ± 1 N⋅m
3. Tighten the oil feeder control valve to the specified M8: 31 ± 3 N⋅m
torque of 11 ± 1 N⋅m.
>>D<< CAMSHAFT OIL SEAL INSPECTION

M1113005500496
INSTALLATION
CAMSHAFT
MD998713
AK300160 AD
AK300161
1. Apply engine oil to the lip area of the oil seal and Measure the cam height. If it is below the limit,
the front end outside diameter of camshaft. replace the camshaft.
2. Using special tool Camshaft oil seal installer
(MD998713), install the camshaft oil seal.
A C B A C B A C B A C B
D D D D D D D D
AK301488AD
Standard Minimum
value limit
A: Intake low speed 33.84 mm 33.34 mm
cam A
B: Intake low speed 37.35 mm 36.85 mm
cam B
C: Intake high speed 37.21 mm 36.71 mm
cam
D: Exhaust cam 37.86 mm 37.36 mm
11F-37
M1113006900806
78 ± 2 N·m → 0 N·m → 20 ± 2 N·m → +90˚ → +90˚

8
1
9
10
20
14
4
5
15
6
17
12
13
16 19
11
18 2
7
3
Apply engine oil to

all moving parts
AK301262AE

<<A>> >>D<< 1. Cylinder head bolt >>A<< 12.Valve stem seal
2. Cylinder head assembly 13.Valve spring seat
3. Cylinder head gasket >>A<< 14.Valve stem seal
<> >>C<< 4. Retainer lock 15.Valve spring seat
5. Valve spring retainer 16.Intake valve guide
>>B<< 6. Valve spring 17.Exhaust valve guide
7. Intake valve 18.Intake valve seat
<> >>C<< 8. Retainer lock 19.Exhaust valve seat
9. Valve spring retainer 20.Cylinder head
>>B<< 10.Valve spring
11. Exhaust valve

<<A>> CYLINDER HEAD BOLTS >>A<< VALVE STEM SEAL INSTALLA-
REMOVAL TION
MB991999
MB991654
AK300162 AD AK300164 AF
Using special tool Cylinder head bolt wrench CAUTION

(MB991654), loosen the cylinder head bolts. Loosen The special tool must be used to install the valve
each bolt evenly, little by little, by two or three steps. stem seal. Improper installation could result in oil
leaking past the valve guide.
<> RETAINER LOCK REMOVAL 1. Install the valve spring seat.
2. Using special tool Valve stem seal installer
(MB991999), install a new valve stem seal.
MD998735
>>B<< VALVE SPRING INSTALLATION
Painted end
AK300163 AD
1. Set special tool Valve spring compressor

(MD998735) as illustrated to compress the valve
spring. Remove the retainer lock.
2. Relieve the spring tension and remove the valve, AK300717AB
retainer, spring, etc. Store removed valves, Install the valve spring with its identification color
springs, and other parts, tagged to indicate their painted end (larger pitch side) upward (toward the
cylinder number and location for assembly. valve spring retainer).
Identicifation:
<Intake> Light blue
<Exhaust> Orange
11F-39
>>C<< RETAINER LOCK INSTALLATION
MB991654
MD998735
AK300165 AD
AK300163 AD
CAUTION Timing belt side

Do not compress the valve spring excessively. It
can damage the stem seal.
1. Set special tool Valve spring compressor
8 6 1 3 9
(MD998735) as illustrated to compress the valve
spring. Install the retainer locks.
10 4 2 5 7
2. Relieve the spring tension. Check that the retainer
locks are seated correctly. AK306004AC
>>D<< CYLINDER HEAD BOLT 3. Using special tool Cylinder head bolt wrench
(MB991654) tighten the bolts to the specified
INSTALLATION
torque, using the tightening sequence shown.
4. Loosen all bolts fully in the reverse order of
tightening.
5. Retighten the loosened bolts to in the tightening
sequence shown.
Shank length
AK300591AB
1. When the removed cylinder head bolts are to be 90˚

reused, check that the shank length of each bolt
meets the limit. If it exceeds the limit, replace the
bolts.
90˚ Paint mark
Limit: 99.4 mm
2. Apply engine oil to the thread of the bolts and to AK300166 AD
the washers.
6. Make a paint mark across each bolt head and
cylinder head.
7. Tighten the cylinder head bolts 90 degrees in the
specified order.
CAUTION VALVE
• If the bolt is turned less than 90 degrees,
proper fastening performance may not be
achieved. Be careful to turn each bolt exactly
Contact
90 degrees. (Should be at
• If the bolt is overtightened, loosen the bolt centre of face)
completely and then retighten it by repeating Margin
the tightening procedure from step 1.
8. Tighten the bolts another 90 degrees in the same
order as in step 7, and check that the paint marks
on the cylinder head bolt are aligned with the paint AK300593AB
marks on the cylinder head. 1. Check the valve seat contact. Valve seat contact
should be uniform at the center of the valve face.
INSPECTION If incorrect, reface using a valve refacer.
M1113007000709
CYLINDER HEAD 2. If the margin is below the limit, replace the valve.
Standard value:
<Intake> 1.0 mm
<Exhaust> 1.2 mm
Minimum limit:
<Intake> 0.5 mm
<Exhaust> 1.0 mm
AK300167
1. Check the cylinder head gasket surface for

flatness by using a straight edge and feeler
gauge.
Standard value: 0.03 mm Total length
Limit: 0.2 mm
AK103808AC
2. If it exceeds the limit, correct to meet
specification. 3. Measure the valve's total length. If the
Grinding limit: *0.2 mm measurement is less than the limit, replace the
* Includes combined with cylinder block grind- valve.
ing. Standard value:
Cylinder head height (Specification when <Intake> 111.33 mm
new): 120 mm <Exhaust> 113.54 mm
Minimum limit:
<Intake> 110.83 mm
<Exhaust> 113.04 mm
11F-41
VALVE SPRING VALVE SEAT
Valve stem
end
Out of square
Valve stem
projection
Free height
Spring
seating
surface
AK300718AB AK300596 AB
1. Measure the free height of the spring. If it is less Assemble the valve, then measure the valve stem
than the limit, replace. projection between the end of the valve stem and the
spring seating surface. If the measurement exceeds
Standard value: the specified limit, replace the valve seat.
<Intake> 54.8 mm
<Exhaust> 56.1 mm Standard value:
<Intake> 48.33 mm
Minimum limit: <Exhaust> 48.34 mm
<Intake> 53.8 mm
<Exhaust> 55.1 mm Limit:
<Intake> 48.83 mm
2. Measure the squareness of the spring. If it <Exhaust> 48.84 mm
exceeds the limit, replace.
Standard value: 2 degrees or less VALVE SEAT RECONDITIONING PROCE-
Limit: 4 degrees DURE
Intake side Exhaust side
VALVE GUIDE 0.9 – 1.3 mm 0.9 – 1.3 mm
65˚ 65˚
20˚ 10˚
Valve
guide
43.5˚ – 44˚
AK300385AB
Stem diameter
Guide inside diameter AK300168 AE
1. Before correcting the valve seat, check for
clearance between the valve guide and valve and,
Measure the clearance between the valve guide and if necessary, replace the valve guide.
valve stem. If it exceeds the limit, replace the valve
2. Using the seat grinder, correct to obtain the
guide or valve, or both.
specified seat width and angle.
Standard value:
3. After correcting the valve seat, lap the valve and
<Intake> 0.02 − 0.04 mm
valve seat using lapping compound. Then, check
<Exhaust> 0.04 − 0.06 mm
the valve stem projection.
Limit:
<Intake> 0.10 mm
<Exhaust> 0.15 mm
VALVE SEAT REPLACEMENT PROCE- VALVE GUIDE REPLACEMENT PROCE-

DURE DURE
1. Using a press, remove the valve guide toward the
0.5 – 1 mm cylinder block.
CAUTION
Do not install a valve guide of the same size
again.
Cut 2. Rebore the valve guide hole of the cylinder head
so that it fits the press-fitted oversize valve guide.
0.5 – 1 mm
Valve guide hole diameters
AK300719AB
0.05 oversize 11.05 − 11.07 mm
0.25 oversize 11.25 − 11.27 mm
1. Cut the valve seat from the inside to thin the wall 0.50 oversize 11.50 − 11.52 mm
thickness. Then, remove the valve seat.
Valve seat
height
14.0 mm
Oversize hole diameter AK400856AB

AK300720AB
3. Press-fit the valve guide until it protrudes 14.0 mm
2. Rebore the valve seat hole in the cylinder head to from the cylinder head top surface as shown in
a selected oversize valve seat diameter. the illustration.
Intake seat ring hole diameters NOTE: When press-fitting the valve guide, work
0.3 oversize: 35.30 − 35.33 mm from the cylinder head top surface.
0.6 oversize: 35.60 − 35.63 mm NOTE: Pay attention to the difference in length of
Exhaust seat ring hole diameters the valve guides. (Intake side: 45.5 mm; exhaust
0.3 oversize: 33.30 − 33.33 mm side: 50.5 mm)
0.6 oversize: 33.60 − 33.63 mm NOTE: After installing the valve guides, insert new
3. Before fitting the valve seat, either heat the valves in them to check for smooth operation.
cylinder head up to approximately 250°C or cool
the valve seat in liquid nitrogen, to prevent the
cylinder head bore from galling.
4. Using a valve seat cutter, correct the valve seat to
the specified width and angle.
See "VALVE SEAT RECONDITIONING
PROCEDURE" on the previous page.
11F-43
M1113008101348
<M/T>
29
27
Apply engine oil to 30
all moving parts
31
19
10 ± 2 N·m
23 ± 3 N·m 28
25 21 8
54 ± 5 N·m 17 ± 1 N·m
13 7 19 ± 3 N·m
15
6
19 ± 3 N·m 22
24
23
14 26
18
17 23 ± 3 N·m
12 16 36 ± 3 N·m
11 4
10 23 ± 3 N·m 9.0 ± 3.0 N·m
9
44 ± 5 N·m
3 1 2
39 ± 5 N·m 22 ± 4 N·m
5 9.0 ± 3.0 N·m
AK400857 AB

1. Drain plug 17.O-ring
>>M<< 2. Drain plug gasket <<D>> >>I<< 18.Flange bolt
>>L<< 3. Oil filter >>H<< 19.Front case
4. Transmission stay 20.Front case gasket
<<A>> >>K<< 5. Oil pan lower 21.Oil pump cover
<> >>K<< 6. Oil pan upper >>G<< 22.Oil pump driven gear
7. Oil screen >>G<< 23.Oil pump drive gear
8. Oil screen gasket >>F<< 24.Crankshaft front oil seal
9. Relief plug >>E<< 25.Oil pump oil seal
10.Gasket >>D<< 26.Counterbalance shaft oil seal
11. Relief spring 27.Counterbalance shaft, left
12.Relief plunger 28.Counterbalance shaft, right
13.Oil cooler by-pass valve <M/T> <<E>> >>C<< 29.Counterbalance shaft, front bearing
14.Oil filter bracket <<F>> >>B<< 30.Counterbalance shaft, rear bearing,
15.Oil filter bracket gasket right
<<C>> >>J<< 16.Plug <<F>> >>A<< 31.Counterbalance shaft, rear bearing, left
<A/T>
28
26
Apply engine oil to 29
all moving parts
30
18
10 ± 2 N·m
23 ± 3 N·m
27
24 20 8
17 ± 1 N·m
7 19 ± 3 N·m
14
6
19 ± 3 N·m 21
23
22
13 25
17
16 23 ± 3 N·m
12 15 36 ± 3 N·m
11 4
10 23 ± 3 N·m 9.0 ± 3.0 N·m
9
44 ± 5 N·m
1
3 2
22 ± 4 N·m
39 ± 5 N·m
9.0 ± 3.0 N·m
5
AK600666 AB

1. Drain plug >>H<< 18.Front case
>>M<< 2. Drain plug gasket 19.Front case gasket
>>L<< 3. Oil filter 20.Oil pump cover
4. Transmission stay >>G<< 21.Oil pump driven gear
<<A>> >>K<< 5. Oil pan lower >>G<< 22.Oil pump drive gear
<> >>K<< 6. Oil pan upper >>F<< 23.Crankshaft front oil seal
7. Oil screen >>E<< 24.Oil pump oil seal
8. Oil screen gasket >>D<< 25.Counterbalance shaft oil seal
9. Relief plug 26.Counterbalance shaft, left
10.Gasket 27.Counterbalance shaft, right
11. Relief spring <<E>> >>C<< 28.Counterbalance shaft, front bearing
12.Relief plunger <<F>> >>B<< 29.Counterbalance shaft, rear bearing,
13.Oil filter bracket right
14.Oil filter bracket gasket <<F>> >>A<< 30.Counterbalance shaft, rear bearing, left
<<C>> >>J<< 15.Plug
16.O-ring
<<D>> >>I<< 17.Flange bolt
11F-45
REMOVAL SERVICE POINTS <<D>> FLANGE BOLT REMOVAL
<<A>> OIL PAN LOWER REMOVAL
CAUTION
Do not use a scraper or special tool MD998727 to
remove the oil pan.
Apply a wood block to the oil pan side and remove
the oil pan lower by tapping lightly on it with a plastic
hammer.
<> OIL PAN UPPER REMOVAL AK300172

1. Remove all bolts.
1. Remove the plug on the side of the cylinder block.
A 2. Insert a Phillips screwdriver (shank diameter 8
mm) into the plug hole to lock the counterbalance
shaft.
A
AK304400 AB
CAUTION
Do not use a scraper or special tool MD998727 to
remove the oil pan. AK300173
2. Screw a bolt into hole A shown to remove the oil
pan. 3. Loosen the flange bolt.
<<C>> PLUG REMOVAL <<E>> COUNTERBALANCE SHAFT

FRONT BEARING REMOVAL
MD998162
MD998783 AK300171 AD MD998371

Fit the teeth of the special tools in notches of the plug AK300174 AD
as shown in the drawing and support the tool with the CAUTION
special tool to loosen the plug. Be sure to remove the front bearing first. If it has
• Plug wrench (MD998162) not been removed, special tool Silent shaft bear-
• Plug wrench retainer (MD998783) ing puller (MD998372) cannot be used for rear
balance shaft bearing removal.
Using special tool Silent shaft bearing puller
(MD998371), remove the counterbalance shaft front
bearing from the cylinder block.
<<F>> COUNTERBALANCE SHAFT REAR INSTALLATION SERVICE POINTS

BEARING REMOVAL >>A<< LEFT COUNTERBALANCER
MB991603
MD998372
AK300175AD
MD998705
1. Use the special tool Silent shaft bearing puller AK300177 AF

rear bearings from the cylinder block.
MB991603
MD998705
MB991603
Rear bearing
AK300619AG
MD998372
AK300176 AD 1. Install special tool Silent shaft bearing installer
2. When removing the rear bearing of the left 2. Apply engine oil to the rear bearing outer surface
counterbalancer shaft, install the special tool and bearing hole in the cylinder block.
on the front of the cylinder block and use a special
tool Silent shaft bearing puller (MD998372) to pull
out the bearing. NOTE: The left rear bearing has no oil holes.

MD998705(Guide pin)
AK300178 AD

11F-47
>>C<< COUNTERBALANCE SHAFT
Ratchet ball
FRONT BEARING INSTALLATION
Oil hole
MD998705
Rear bearing right
AK300621AD
Rear bearing
installing portion
hole in the rear bearing to install the bearing of the AK300623AF
special tool. 1. Remove the rear bearing installing portion from

3. Apply engine oil to the bearing outer surface and the special tool Silent shaft bearing installer
bearing hole in the cylinder block. (MD998705).
MD998705
MD998705(Guide pin) MD998705(Guide pin)

AK300179 AG AK300178 AD

MD998705 installer (MD998705) in the threaded hole of the
AK300622AG

Front bearing right
that the oil hole of the bearing is aligned with the AK304592AB
hole in the rear bearing to install the bearing of the
special tool.
4. Apply engine oil to the front bearing outer surface
and bearing hole in the cylinder.
>>E<< OIL PUMP OIL SEAL

MD998705 INSTALLATION
Socket wrench
Oil seal
Front case
MD998705(Guide pin)
AK300179 AG
AK301070AD
Using a suitable socket wrench, install the oil pump

oil seal into the front case.
>>F<< CRANKSHAFT FRONT OIL SEAL

INSTALLATION
MD998375
AK300624

Oil seal
Front case
>>D<< COUNTERBALANCE SHAFT OIL

SEAL INSTALLATION AK301072AD
Using special tool Crankshaft front oil seal installer

Socket wrench (MD998375), install the crankshaft front oil seal into
the front case.
Front case
>>G<< OIL PUMP DRIVEN GEAR/OIL
Oil seal
AK301071AD
Using a suitable socket wrench, install the counter-

balance shaft oil seal into the front case.
Alignment
mark
AK300180 AD
Install the oil pump gears into the front case and
align the alignment marks.
11F-49
>>H<< OIL PUMP CASE INSTALLATION >>I<< FLANGE BOLT INSTALLATION
MD998285
AK300181AD AK300172
1. Set special tool Crankshaft front oil seal guide 1. Insert a Phillips head screwdriver (shank diameter
(MD998258) on the front end of crankshaft and 8 mm) into the hole in the left side of the cylinder
apply a thin coat of engine oil to the outer surface block to lock the counterbalance shaft.
of special tool.
2. Apply engine oil to the lip of the crankshaft front oil
seal.
AK300183
2. Secure the oil pump driven gear onto the left

MD998285
counterbalance shaft by tightening the flange bolt
AK300182 AD
3. Install the front case carefully not to damage the Tightening torque: 36 ± 3 N⋅m
oil seal. 3. Pull out the screwdriver and screw in the plug.
20 mm 40 mm
22 mm >>J<< PLUG INSTALLATION
25 mm
MD998162
32 mm
AK301520AD
MD998783
CAUTION
Carefully install the tightening bolts because of AK300184 AD
the different length respectively.
1. Install a new O-ring to the groove of the front
4. Tighten all flange bolts to the specified torque. case.
Tightening torque: 23 ± 3 N⋅m 2. Install the plug to the front case.
3. Use the special tools to tighten the plug to the
specified torque.
>>K<< OIL PAN UPPER/OIL PAN LOWER CAUTION

INSTALLATION Do not apply FIPG over remaining old FIPG.
CAUTION
Do not apply FIPG over remaining old FIPG. 4. Thoroughly remove old FIPG from the gasket
Doing so could result in oil leakage. surfaces of the oil pan upper and lower sections.
Timing belt side
and oil pan.
Bolt hole Bolt hole
Timing belt side area area
Grooved area AK304403 AB
Grooved CAUTION
area
AK304401 AB Too much FIPG will squeeze out, blocking cool-
CAUTION
result in leakage.
Too much FIPG will squeeze out, blocking cool-
ant or oil passages, while too thin a bead could 5. Apply a 4 mm diameter bead of FIPG to the flange
result in leakage. surface all around the oil pan.
2. Apply a 4 mm diameter bead of FIPG to the flange Specified sealant:
surface all around the oil pan. Mitsubishi Genuine Part No.MD970389 or
equivalent
Specified sealant:
Mitsubishi Genuine Part No.MD970389 or NOTE: In the grooved areas on the oil pan flange,
equivalent apply FIPG bead along the center of the groove.
NOTE: In the grooved areas on the oil pan flange, Timing belt side
apply FIPG bead along the center of the groove.
9 8
5 4 1
12 11
M6 × 16
3
2 6
7 10
AK304404 AB

AK304402 AB bolts in the indicated sequence.
in the drawing.
11F-51
>>L<< DRAIN PLUG GASKET
INSTALLATION
Drain plug
General service tool AK300186 AD
3. Using general service tool, Install the oil filter to

Oil pan the bracket and tighten it to the specified torque.
Gasket Tightening torque
Oil pan
side Part number MD356000 filter: 14 ± 2 N⋅m
Other Mitsubishi Genuine filter: 17 ± 3 N⋅m
4. If a torque wrench cannot be used use the
following procedure:
(1) Screw in the oil filter until its o-ring contacts
the oil filter bracket.
(2) Tighten the oil filter as follows:
Part number MD356000 filter: one turn
AK300601AB Other Mitsubishi Genuine filter: 3/4 turn
CAUTION INSPECTION
If the gasket is installed in the wrong direction, M1113008200290
oil leaks will occur. FRONT CASE
Install the drain plug gasket in the direction shown. 1. Check the oil passage for clogging. Clean if
necessary.
>>M<< OIL FILTER INSTALLATION 2. Check the left counterbalance shaft front bearing
1. Clean the installation surface of the filter bracket. for wear, damage and seizure. If the bearing is
damaged, replace the front case.
3. Check the front case for cracks and other
damage.
Replace cracked or damaged front case.
OIL SEAL
1. Check the oil seal lip for wear and damage.
Replace the oil seal if necessary.
AK301069AD 2. Check the oil seal lip for deterioration. Replace
the oil seal if necessary.
COUNTERBALANCE SHAFT OIL COOLER BYPASS VALVE
AK300187 Valve AK000032 AC
1. Check the oil holes for clogging and clean if 1. Make sure that valve moves smoothly.
necessary. 2. Ensure that the dimension L measures the
2. Check the journal for seizure, damage and standard value under normal temperature and
contact with bearing. If there is anything wrong humidity.
with the journal, replace the counterbalance shaft, Standard value: 34.5 mm
bearing or front case assembly if required.
3. The dimension must be the standard value when
measured after the valve has been dipped in 97 to
OIL PUMP 103°C oil.
1. Assemble the oil pump gears to the front case and
rotate it to ensure smooth rotation with no
looseness.
2. Ensure that there is no ridge wear on the contact
surface between the front case and the gear
surface of the oil pump cover.
AK300188
3. Check the side clearance.

Standard value:
11F-53
M1113008400885
6
7
8
10
9 4
12
11
Apply engine oil to

all moving parts
2
20 ± 2 N·m → +90º to 94º
1
AK306012 AC

>>G<< 1. Nut >>B<< 8. Oil ring
<<A>> >>F<< 2. Connecting rod cap <<C>> >>A<< 9. Piston pin
>>D<< 3. Connecting rod bearing 10.Piston
<> >>E<< 4. Piston and connecting rod assembly 11. Connecting rod
>>D<< 5. Connecting rod bearing 12.Bolt
>>C<< 6. Piston ring No. 1
>>C<< 7. Piston ring No. 2

<<A>>CONNECTING ROD CAP Guide A: 17.9 mm
REMOVAL Push
rod Guide B
Cylinder Guide A: 18.9 mm

number
Guide C
Guide A: 20.9 mm
AK202812 AB
Base
1. Mark the cylinder number on the side of the
connecting rod big end for correct reassembly.
Guide A: 21.9 mm
2. Keep the removed connecting rods, caps, and
bearings in that order according to the cylinder
number.
<> PISTON AND CONNECTING ROD AK301562 AB

ASSEMBLY REMOVAL
MB992010
Push rod
Front mark
Crank pin
Front
AK402310 AC mark

bolt. Guide C

Base
from the cylinder block.
AK202781 AB

11F-55
NOTE: Keep the disassembled pistons, piston 6. Insert the tool element, Guide B, into the tool
pins and connecting rods cylinder by cylinder. element, Guide A, with having 2.75 mm of the
clearance "L" between the tool element, Guide A
INSTALLATION SERVICE POINTS and B.
>>A<< PISTON PIN INSTALLATION

Push rod
Timing belt side
Crankshaft
bore size mark Piston pin
Front mark
Front
No.1 No.4 mark
No.2 No.3
AK301530 AD
Guide A
1. When replacing a piston, check the cylinder bore Base

replacement piston using the following table. Guide B
I A
II No mark AK202782 AB
III C 7. Place the piston and connecting rod assembly

NOTE: The piston size mark is located on the pis- onto the element, Piston setting base, with the
ton top surface. front marks facing up.
2. Insert the tool element, Push rod, into the piston 8. Install the piston pin using a press. If the required
pin and attach the element, Guide A, to the push press force is less than the standard value,
rod end. replace the piston and piston pin assembly or the
3. Assemble the connecting rod with the piston with connecting rod, or both.
their front marks facing in the same direction. Standard value: 7,350 − 17,100 N
piston pin.
5. Insert the assembly of piston pin, Push rod, and
Guide A (put together in step 4.) into the piston
holes from the front mark side.
AK301796
9. Check that the piston moves smoothly.
Guide B Guide A
AK301480 AD
>>B<< OIL RING INSTALLATION >>C<< PISTON RING NUMBER 2/PISTON

1. Fit the oil ring spacer into the piston ring groove. RING NUMBER 1 INSTALLATION
Side rail end Piston ring
expander
AK300190 AD AK300191 AD
1. Using the piston ring expander, fit number 2 into

Upper the number 2 groove of piston.
side rail
NOTE: Install piston rings with identification mark
facing up, to the piston crown side.
Spacer 2. Install the number 1 piston ring in the same
manner as step 1.
Lower
side rail
AK300395AE
No.1
CAUTION
Do not use a piston ring expander when install-
ing side rail.
2. Install the upper side rail. No.2
To install the side rail, first fit one end of the rail AK301452AD
portion into position by hand. See illustration. Identification mark
NOTE: The side rails and spacer may be installed <Number 1 ring> 1R
in either direction. <Number 2 ring> 2R
NOTE: New spacers and side rails are colored for NOTE: Confirm the profile for No.1 and No.2 pis-
identification of their sizes. ton rings carefully. Install them correctly by careful
attention to the direction of top and bottom.
Size Identification color
NOTE: The identification mark and the size mark
Standard None are stamped on the upper plane of the piston ring
0.50 mm oversize Red (piston top side).
diameter Size Size mark
3. Install the lower side rail in the same manner as Standard None
described in step 2.
0.50 mm oversize 50
4. Make sure that the side rails move smoothly in
diameter
both directions.
3. To prevent wrong installation, check the
identification mark of each piston ring. The
identification mark is stamped near the ring gap.
11F-57
>>D<< CONNECTING ROD BEARING >>E<< PISTON AND CONNECTING ROD
Locations of crankshaft pin diameter Side rail
marks
No. 1
No. 2
No. 1 No. 3
No. 2 Side rail
No. 4 AK304412 AB AK202730 AB
1. Apply engine oil on the circumference of the

piston, piston rings, and oil ring.
2. Arrange the piston ring and oil ring gaps (side rail
and spacer) as shown in the illustration.
3. Rotate the crankshaft so that the crank pin is on
the center of the cylinder bore.
Identification Bolt
color position Identification
mark position
AK400858AC
1. Measure the crankshaft pin diameter and confirm

its classification from the following table. On a MB992010
crankshaft supplied as a service part,
identification marks of its pins are stamped at the
positions shown in the illustration. Connecting rod
Crankshaft pin outside Connecting AK402300AC
diameter rod bearing
Identification Size mm Identification Bolt guide (MB992010), to the connecting rod
mark mark bolt.
I 44.995 − 45.000 1
II 44.985 − 44.995 2
III 44.980 − 44.985 3
2. If the crankshaft pin outside diameter identification
mark is "I," for example, select a bearing whose
identification mark is "1."
If there is no identification color paint on the
crankshaft, measure the pin outside diameter and
select a bearing appropriate for the measured AK300192
value.
3. Install the selected bearing in the big end and in 5. Use suitable thread protectors on the connecting
the cap of the connecting rod. rod bolts before inserting the piston and
connecting rod assembly into the cylinder block.
Care must be taken not to nick the crank pin.
6. Insert the piston and connecting rod assembly
into the cylinder with the front mark on the piston
crown pointing to the timing belt side.
7. Using a suitable piston ring compressor tool, 2. Before installing each nut, apply engine oil to the
install the piston and connecting rod assembly threaded portion and bearing surface of the nut.
into the cylinder block. 3. Loosely tighten each nut to the bolt.
4. Then tighten the nuts alternately to the specified
>>F<< CONNECTING ROD CAP torque to install the cap properly.
INSTALLATION Tightening torque: 20 ± 2 N⋅m
Cylinder 90˚ to 94˚ Paint mark

number Paint
mark
Bolt
Notches Nut
AK300193 AD AK301477AD
1. Verifying the mark made during disassembly, 5. Make a paint mark on the head of each nut.
install the bearing cap to the connecting rod. If the 6. Make a paint mark on the bolt end at the position
connecting rod is new with no index mark, make 90 to 94 degrees from the paint mark made on the
sure that the bearing locking notches are on the nut in the direction of tightening the nut.
same side as shown.
CAUTION
• If the nut is turned less than 90 degrees,
proper fastening performance may not be
achieved. Be careful to tighten the nut exactly
90 degrees.
• If the nut is overtightened (exceeding 94
degrees), loosen the nut completely and then
retighten it by repeating the tightening proce-
dure from step 3.
7. Turn the nut 90 to 94 degrees and make sure that
AK300194
the paint marks on the nut and bolt are aligned.
2. Make sure that the connecting rod big end side
clearance meets the specification. INSPECTION
M1113008500473
Standard value: 0.10 − 0.25 mm PISTON
Limit: 0.4 mm Replace the piston if scratches or seizure is evident
on its surfaces (especially the thrust surface).
>>G<< CONNECTING ROD CAP NUT Replace the piston if it is cracked.
TIGHTENING
PISTON PIN
1. The connecting rod bolts should be examined
1. Insert the piston pin into the piston pin hole with
before reuse. If the bolt threads are damaged, the
your thumb. You should feel a slight resistance.
bolt should be replaced.
Replace the piston pin if it can be easily inserted
Hand-thread the nut to the full length of the bolt or there is an excessive play.
threads. If the nut does not run down smoothly, 2. The piston and piston pin must be replaced as an
the bolt should be replaced. assembly.
11F-59
PISTON RING CRANKSHAFT PIN OIL CLEARANCE
1. Check the piston ring for damage, excessive <PLASTIGAGE METHOD>
wear, and breakage. Replace if defects are 1. Remove oil from the crankshaft pin and the
evident. If the piston has been replaced, the connecting rod bearing.
piston rings must also be replaced.
Plastigage
AK300196AE
AK300195
2. Cut plastigage to the same length as the width of
2. Check for clearance between the piston ring and the bearing and place it on the pin, parallel with its
ring groove. If it exceeds the limit, replace the ring axis.
or piston, or both. 3. Install the connecting rod cap carefully and tighten
Standard value: the nuts to the specified torque.
<Number 1> 0.03 − 0.07 mm 4. Carefully remove the connecting rod cap.
<Number 2> 0.02 − 0.06 mm
Limit: 0.1 mm
Push in by
piston
Plastigage
AK300197AE
Piston ring Piston ring gap

AK301481AD 5. Measure the width of the plastigage at its widest
part by using a scale printed on the plastigage
3. Insert the piston ring into the cylinder bore. Force package.
the ring down with a piston, the piston crown
being in contact with the ring, to correctly position
Limit: 0.1 mm
it at right angles to the cylinder wall. Then,
measure the end gap with a feeler gauge.
If the ring gap is excessive, replace the piston
ring.
Standard value:
<Number 1> 0.15 − 0.30 mm
<Number 2> 0.28 − 0.43 mm
<Oil> 0.10 − 0.40 mm
Limit:
<Number 1, Number 2> 0.8 mm
<Oil> 1.0 mm

M1113008701986
CAUTION
On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown
in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Remov-
ing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in
damage.
11 ± 1 N·m
13 6
12 7
9 132 ± 5 N·m
21
8
10
132 ± 5 N·m
11 ± 1 N·m 11
9.0 ± 1.0 N·m

1
20
19 4
2
18
A 3
5
17
16 Apply engine oil to

all moving parts
14 25 ± 2 N·m → +90˚
25 ± 2 N·m → +90˚
15 AK400859 AB

<<A> >>F<< 1.
> Flywheel bolt (M/T) 8. Drive plate (A/T)
2. Adapter plate (M/T) 9. Crankshaft bushing (A/T)
3. Flywheel (M/T) 10.Rear plate
4. Adapter plate (M/T) 11. Bell housing cover
5. Crankshaft bushing (M/T) >>E<< 12.Oil seal case
<<A> >>F<< 6.
> Drive plate bolt (A/T) >>D<< 13.Oil seal
7. Adapter plate (A/T) >>C<< 14.Bearing cap bolt (Head 17)
>>C<< 15.Bearing cap bolt (Head 14)
11F-61
>>C<< 16.Bearing cap
>>B<< 17.Crankshaft bearing (Lower)
18.Crankshaft
>>B<< 19.Crankshaft bearing (Upper)
>>A<< 20.Crankshaft thrust bearing
21 Cylinder block
REMOVE SERVICE POINTS Groove
<<A>>DRIVE PLATE BOLT AND FLY-

AK301467AD
WHEEL BOLT REMOVE
<M/T> 2. The thrust bearings must be installed with their
MB991883
groove side toward the crankshaft web.
>>B<< CRANKSHAFT BEARING

INSTALLATION
When bearing replacement is required, select and
install the correct bearing by the following procedure.
Location of crankshaft journal
diameter marks
AK600659AB
<A/T>
No. 2
No. 1 No. 3
No. 4 No. 5 AK304413 AB
1. Measure the crankshaft journal diameter and

MD998781
confirm its classification from the following table.
AK300135 AG
In the case of a crankshaft supplied as a service
1. Lock the drive plate or the flywheel using the part, identification marks of its journals are
special tool Flywheel stopper. stamped at the positions shown in the illustration.
Timing belt side
2. Remove the drive plate bolt or the flywheel bolt. No. 1 No. 2 No. 3 No. 4 No. 5

>>A<< CRANKSHAFT THRUST BEARING Cylinder bore
indentification
INSTALLATION mark
1. Install the two thrust bearings in the number 3
bearing bore in the cylinder block. For easier AK300198 AD
installation, apply engine oil to the bearings; this
will help hold them in position. 2. The cylinder block bearing bore diameter
identification marks are stamped at the position
shown in the illustration from left to right,
beginning at No.1.
Crankshaft journal outside diameter Cylinder block Crankshaft bearing Crankshaft bearing
bearing bore for No.3
Identification mark Size mm Identification mark Identification mark Identification mark
0 56.994 − 57.000 0 1 0
1 2 1
2 3 2
1 56.988 − 56.994 0 2 1
1 3 2
2 4 3
2 56.982 − 56.988 0 3 2
1 4 3
2 5 4
>>C<< BEARING CAP/BEARING CAP

BOLT INSTALLATION
1. Install the bearing caps so that the arrow points to
the timing belt side.
Identification
color position Identification
mark position
AK400858AC
For example, if the crankshaft journal outside diame-

ter identification mark is "0" and cylinder block bear- Shank length
ing bore identification mark is "1," select a bearing
whose identification mark is "2" for number 1, 2, 4 AK301471AD
and 5, and a bearing whose identification mark is "1"
for number 3. 2. Before installing the bearing cap bolts, check that
If there is no identification mark on the crankshaft, the shank length of each bolt meets the limit. If it
measure the journal outside diameter and select a exceeds the limit, replace the bolt.
bearing appropriate for the measured value. Limit: 71.1 mm
3. Apply engine oil to the threaded portion and
bearing surface of the bolt.
Groove
8 4 1 5 9
For upper
For lower
AK301466AD 7 3 2 6 10
3. Install the bearings having an oil groove to the

Arrow
cylinder block. AK300199 AD
4. Install the bearings having no oil groove to the 4. Tighten the bolts to the specified in the tightening
bearing cap. sequence shown.
11F-63
>>D<< OIL SEAL INSTALLATION
MB990938
MD998776
90˚
AK300200 AD
AK300202 AD
5. Make a paint mark on the head of each bolt.
6. Make a paint mark on the bearing cap 90 degrees Use the special tools to press-fit the rear oil seal in
from the paint mark made on the bolt in the the rear oil seal case.
direction of tightening the bolt. • Handle (MB990938)
CAUTION
• If the bolt is overtightened, loosen the bolt
completely and then retighten it by repeating >>E<< SEALANT APPLICATION TO OIL
the tightening procedure from step 4. SEAL CASE
• If the bolt is turned less than 90 degrees, 1. Remove completely old FIPG remaining on the
proper fastening performance may not be rear oil seal case and cylinder block.
achieved. Be sure to turn the bolt exactly 90
degrees.
7. Turn each bolt 90 degrees in the tightening
sequence specified in step 4, and make sure that
the paint marks on the bolt and cap are aligned.
AK300576AD

Specified sealant:
AK300201 Mitsubishi Genuine Part No.MD970389 or
equivalent
8. Make sure that the crankshaft turns smoothly and
NOTE: Be sure to install the case quickly while the
the end play is correct. If the end play exceeds the
sealant is wet (within 15 minutes).
limit, replace the number 3 crankshaft bearings.
3. Install the oil seal into the cylinder block after
Standard value: 0.05 − 0.25 mm applying an appropriate amount of engine oil to
Limit: 0.40 mm the entire circumference of its lip portion.
4. Install the rear oil seal case by tightening its bolts
to 11 ± 1 N⋅m.
NOTE: After installation, keep the sealed area away
from the oil for approximately one hour.
>>F<< DRIVE PLATE BOLT AND INSPECTION

M1113008800474
FLYWHEEL BOLT INSTALLATION
CRANKSHAFT JOURNAL OIL
1. Using the special tool Flywheel stopper secure
the drive plate or the flywheel. CLEARANCE <PLASTIGAGE METHOD>
1. Remove oil from the crankshaft journal and
<M/T>
crankshaft bearing.
MB991883
Plastigage
AK600660AB
<A/T>
AK300203AE
3. Cut the plastigage to the same length as the width

of bearing and place it on journal in parallel with
its axis.
4. Install the crankshaft bearing cap carefully and
tighten the bolts to the specified torque.
MD998781 5. Carefully remove the crankshaft bearing cap.
AK300135 AG
Plastigage
2. Tighten the flywheel bolt to the specified torque of
132 ± 5 N⋅m.
AK300204 AE
6. Measure the width of the plastigage at its widest

part by using a scale printed on the plastigage
package.
Standard value:
No.1,2,4,5 journal: 0.02 − 0.03 mm
No.3 journal: 0.03 − 0.04 mm
Limit: 0.1 mm
11F-65
CYLINDER BLOCK BORING CYLINDER
Piston outside Thrust

diameter direction
AK403250 AK300577AC
AD
1. Visually check for scratches, rust, and corrosion. 1. Oversize pistons to be used should be determined
Use also a flaw detecting agent for the check. If on the basis of the largest bore cylinder.
defects are evident, correct or replace. Piston size identification
2. Using a straightedge and feeler gauge, check the Size Identification mark
block top surface for warpage. Make sure that the 0.50 mm oversize 50
surface is free from gasket chips and other foreign diameter
matter.
Standard value: 0.05 mm NOTE: Size mark is stamped on the piston top.
Limit: 0.1 mm 2. Measure the outside diameter (OD) of the piston
to be used. Measure it in thrust direction as
3. If the distortion is excessive, correct within the
shown.
allowable limit or replace.
3. Based on the measured piston OD, calculate the
Grinding limit: 0.2 mm
boring finish dimension.
*Includes/combined with cylinder head
grinding Boring finish dimension = Piston OD +
Cylinder block height (when new): (clearance between piston OD and cylinder)
290 mm −0.02 mm (honing margin)
4. Check cylinder walls for scratches and seizure. If CAUTION
defects are evident, replace or bore to oversize To prevent distortion that may result from tem-
and replace pistons and piston rings. perature rise during honing, bore cylinders,
working from number 2 to number 4 to number 1
to number 3.
A 4. Bore all cylinders to the calculated boring finish
B dimension.
5. Hone to the final finish dimension (piston OD +
12mm clearance between piston OD and cylinder).
6. Check the clearance between the piston and
Center cylinder.
Bottom
Clearance between piston and cylinder:
0.02 − 0.04 mm
AK300206 AD
5. Using a cylinder gauge, measure the cylinder NOTE: When boring cylinders, finish all of four
bore and cylindrically. If worn badly, correct the cylinders to the same oversize. Do not bore only
cylinder to an oversize and replace the piston and one cylinder to an oversize.
piston rings. Measure at the points shown in the
illustration.
Standard value:
Cylinder inner diameter 87.0 mm
Cylindrically 0.01 mm or less
12-1
GROUP 12
ENGINE
LUBRICATION
CONTENTS
GENERAL INFORMATION . . . . . . . . 12-2 ON-VEHICLE SERVICE . . . . . . . . . . . 12-4

ENGINE OIL CHECK . . . . . . . . . . . . . . . . . 12-4
LUBRICANTS . . . . . . . . . . . . . . . . . . 12-3 ENGINE OIL REPLACEMENT . . . . . . . . . . 12-4
ENGINE OIL FILTER REPLACEMENT. . . . 12-5
SEALANT. . . . . . . . . . . . . . . . . . . . . . 12-3 OIL PRESSURE CHECK . . . . . . . . . . . . . . 12-6
SPECIAL TOOLS. . . . . . . . . . . . . . . . 12-3 ENGINE OIL COOLER . . . . . . . . . . . . 12-7

<4G63-Turbo, 4G69-M/T> . . . . . . . . . . . . . . 12-7
12-2 ENGINE LUBRICATION
GENERAL INFORMATION
GENERAL INFORMATION
M1121000100506
The lubrication method is a fully force-fed, full-flow fil- • Avoid contaminating clothes, particularly under-
tration type. The oil pump is a gear type which is pants, with oil.
driven by the crankshaft via the timing belt. • Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
ENGINE OILS • Do not wear heavily soiled clothing and
Health Warning oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separate from per-
Prolonged and repeated contact with mineral oil will
sonal clothing.
result in the removal of natural fats from the skin,
• Where there is a risk of eye contact, eye protec-
leading to dryness, irritation and dermatitis. In addi-
tion should be worn, for example, chemical gog-
tion, used engine oil contains potentially harmful con-
gles or face shields; in addition an eye wash
taminants which may cause skin cancer. Adequate
facility should be provided.
means of skin protection and washing facilities must
• Obtain first aid treatment immediately for open
be provided.
cuts and wounds.
Recommended Precautions • Wash regularly with soap and water to ensure all
oil is removed, especially before meals (skin
The most effective precaution is to adapt working
cleansers and nail brushes will help). After clean-
practices which prevent, as far as practicable, the
ing, the application of preparations containing
risk of skin contact with mineral oils, for example by
lanolin to replace the natural skin oils is advised.
using enclosed systems for handling used engine oil
• Do not use petrol, kerosine, diesel fuel, gas oil,
and by degreasing components, where practicable,
thinners or solvents for cleaning skin.
before handling them. Other precautions:
• Use barrier creams, applying them before each
• Avoid prolonged and repeated contact with oils,
work period, to help the removal of oil from the
particularly used engine oils.
skin after work.
• Wear protective clothing, including impervious
• If skin disorders develop, obtain medical advice
gloves where practicable.
without delay.
ENGINE LUBRICATION
LUBRICANTS
12-3
LUBRICANTS
M1121000401168
Item Specification
Non-turbo Engine oil ACEA classification A1/B1, A3/B3, A3/B4 or A5/B5
Engine oil API classification SG or higher
Turbo First Engine oil ACEA classification A1/B1, A3/B3, A3/B4 or A5/B5
Engine oil API classification SG or higher
Second and Engine oil ACEA classification A3/B3, A3/B4 or A5/B5
subsequent Engine oil API classification SG or higher
Engine oil quantity L 4G63-Non-Turbo, 4G69-A/T Oil filter 0.3
Total 4.3
4G63-Turbo, 4G69-M/T Oil filter 0.3
Oil cooler 0.3
Total 4.6
SEALANT
M1121000500258

Oil pressure switch 3M ATD Part No. 8660 or equivalent Semi-drying sealant
SPECIAL TOOLS
M1121000600619

MB991610 Oil filter wrench Removal and installation
of engine oil filter (When
using the oil filter of
MD356000)
MB991610
MD998012 Oil pressure switch Removal and installation

wrench of oil pressure switch
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
ENGINE OIL CHECK <Non-turbo>
M1121000900320
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 petrol mixed in, and that it
has sufficient viscosity.
ENGINE OIL REPLACEMENT

M1121001001271
1. Start the engine and allow it to warm up until the AC311073AC
temperature of the coolant reaches 80 °C to 90

<Turbo>
°C.
2. Remove the engine oil filler cap.
WARNING
Use care as oil could be hot.
3. Remove the drain plug to drain oil.
Drain plug
AC503670 AB
Drain plug
gasket 5. Refill with specified quantity of oil.
<Non-turbo>
Specified Engine Oil (ACEA and API classifica-
Oil pan side Oil pan tion): ACEA A1/B1, A3/B3, A3/B4 or A5/B5
API SG or higher
AC300837AB Total quantity (Includes volume inside engine
oil filter and oil cooler):
4. Install a new drain plug gasket so that it faces in 4.3 L <4G63, 4G69-A/T>
the direction shown in the illustration, and then 4.6 L <4G69-M/T>
tighten the drain plug to the specified torque.
<Turbo>
• First engine oil replacement
NOTE: Install the drain plug gasket so it faces in Specified Engine Oil (ACEA and API clas-
the direction shown in the illustration. sification): ACEA A1/B1, A3/B3, A3/B4
or A5/B5 API SG or higher
• Second and subsequent engine oil
replacements
Specified Engine Oil (ACEA and API clas-
sification): ACEA A3/B3, A3/B4 or
A5/B5 API SG or higher
Total quantity (Includes volume inside
engine oil filter and oil cooler): 4.6 L
NOTE: .
• Failure to use the specified type of engine oil
may cause the engine to malfunction. <Turbo>
• Use of additives is not recommended since
they may reduce the effectiveness of additives
already included in the engine oil. It may result
in failure of the mechanical assembly.
ENGINE LUBRICATION
ON-VEHICLE SERVICE
12-5
6. Install the engine oil filler cap. 5. Use the respective tool in the following table to
7. Check oil level. remove the engine oil filter.
6. Clean the filter bracket side mounting surface.
ENGINE OIL FILTER REPLACEMENT
M1121001100521
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.
WARNING
Use care as oil could be hot.
3. Remove the drain plug to drain oil. O-ring
AC103250AD
4. Remove the under cover.
7. Apply a small amount of engine oil to the O-ring of
the new oil filter.
8. Once the O-ring of the oil filter is touching the
MB991610 or
commercially- flange, use the respective tool in the following
available tool table to tighten to the specified torque.
9. Install the drain plug and refill the engine oil (Refer
to P.12-4).
10.Race the engine 2−3 times, and check to be sure
AC000093 AH that no engine oil leaks from installation section of
the oil filter.
Number Special tool Tightening torque

MD356000 Oil filter wrench (MB991610) Approximately 3/4 turn (14 ± 2 N⋅m)
or equivalent
MD136466, Commercially- available tool Approximately 3/4 turn (17 ± 3 N⋅m)
MD322508
ON-VEHICLE SERVICE
OIL PRESSURE CHECK 3. Install the oil pressure gauge.

M1121002300766
NOTE: Use an adapter of PT 1/8 thread.
1. Check engine oil quantity.
4. Run the engine to warm it.
CAUTION
5. After the engine has been warmed up, check that
<Non-turbo> oil pressure is within the standard value.
CYLINDER BLOCK Standard value:
At idle: 29 kPa or more
At 3,500 r/min: 294 − 686 kPa
6. Remove the oil pressure gauge.
OIL PRESSURE
SWITCH
AK000197AD
<Turbo>
Oil pressure
switch
AKX00295AD
Oil filter 7. Apply the specified sealant to the thread of oil

pressure switch.
Specified sealant: 3M ATD Part No. 8660 or
AK000878AG
equivalent
MD998012 CAUTION
MD998012
AKX00294 AF
Since sealant is applied to the thread of oil pres- AKX00294 AF

sure switch, take care not to damage the oil pres-
Do not start the engine within one hour after the
sure switch when removing it.
oil pressure switch has been installed.
2. Use the special tool Oil pressure switch wrench 8. Use the special tool Oil pressure switch wrench
(MD998012) to remove the oil pressure switch. (MD998012) to tighten the oil pressure switch to
NOTE: Remove the terminal of oil pressure switch the specified torque.
where the special tool Oil pressure switch wrench Tightening torque:
(MD998012) is not fitted. 19 ± 3 N⋅m <Non-turbo>
10 ± 2 N⋅m <Turbo>
ENGINE LUBRICATION
ENGINE OIL COOLER
12-7
ENGINE OIL COOLER
REMOVAL AND INSTALLATION <4G63-Turbo, 4G69-M/T>
M1121001300343

Front Under Cover (LH) Removal (Refer to GROUP 51, • Front Under Cover (LH) Installation (Refer to GROUP 51,
Under Cover P.51-31). Under Cover P.51-31).
• Engine Oil Refilling and Level Check (Refer to P.12-4).
12 ± 2 N·m 5.0 ± 1.0 N·m
12 ± 2 N·m
27
26 45 ± 5 N·m
21
12 ± 2 N·m
13
17 24
48 ± 7 N·m
1
14 20 22
2 N 33 ± 2 N·m
45 ± 5 N·m N 23
3 12 ± 2 N·m
12 ± 2 N·m
11
4N
15 10
4N 25
9 19 N
12
12 ± 2 N·m
9 16 12 ± 2 N·m
10 48 ± 7 N·m
8
18
7 12 ± 2 N·m
5 6
AC309226AB
Engine oil cooler removal steps Engine oil cooler removal steps
• Splash Shield Mounting Clips (LH) 9. Collar
(Refer to GROUP 51, Front Bumper 10. Bush
P.51-3). Engine oil cooler hose removal
1. Eye bolt steps (Engine oil cooler side)
2. Gasket 11. Engine oil cooler return hose
3. Eye bolt connection
4. Gasket 1. Eye bolt
5. Engine oil cooler assembly 2. Gasket
6. Bracket 12. Engine oil cooler return hose
7. Bracket 13. Bolt
8. Engine oil cooler
ENGINE OIL COOLER
Engine oil cooler hose removal Engine oil cooler hose removal
steps (Engine oil cooler side) steps (Engine side) (Continued)
• Reserve tank assembly (Refer to 23. Gasket
GROUP 14, Radiator P.14-35). 24. Engine oil cooler feed hose
14. Engine oil cooler feed hose 25. Bracket
connection Engine oil cooler feed and return
3. Eye bolt tube removal steps
4. Gasket • Front bumper beam (Refer to
15. Engine oil cooler feed hose GROUP 51, Front bumper assembly
Engine oil cooler hose removal P.51-3).
steps (Engine side) 11. Engine oil cooler return hose
• Side under cover (RH) (Refer to connection
GROUP 51, Under cover P.51-3). 14. Engine oil cooler feed hose
16. Clamp connection
17. Engine oil cooler return hose 17. Engine oil cooler return hose
18. Eye bolt 21. Engine oil cooler feed hose
19. Gasket connection
20. Engine oil cooler return hose 26. Engine oil cooler feed and return tube
21. Engine oil cooler feed hose 27. Clamp
connection
22. Eye bolt
13-1
GROUP 13
FUEL
CONTENTS
MULTIPORT FUEL INJECTION (MPI) <4G63-Non-Turbo> . . . 13A
MULTIPORT FUEL INJECTION (MPI) <4G63-Turbo> . . . . . . . 13B
MULTIPORT FUEL INJECTION (MPI) <4G69> . . . . . . . . . . . . . 13C
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13D

13A-1
GROUP 13A
MULTIPORT FUEL
INJECTION (MPI)
<4G63-Non-Turbo>
CONTENTS
GENERAL INFORMATION . . . . . . . . 13A-2 FUEL PRESSURE TEST . . . . . . . . . . . . . . 13A-316

FUEL PUMP CONNECTOR
SERVICE SPECIFICATIONS. . . . . . . 13A-5 DISCONNECTION (HOW TO REDUCE
PRESSURIZED FUEL LINES) . . . . . . . . . . 13A-318
FUEL PUMP OPERATION CHECK . . . . . . 13A-319
SEALANT. . . . . . . . . . . . . . . . . . . . . . 13A-5
COMPONENT LOCATION . . . . . . . . . . . . . 13A-320
SPECIAL TOOLS. . . . . . . . . . . . . . . . 13A-6 ENGINE CONTROL RELAY
CONTINUITY CHECK . . . . . . . . . . . . . . . . . 13A-321
FUEL PUMP RELAY CONTINUITY
TROUBLESHOOTING . . . . . . . . . . . . 13A-9 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-321
DIAGNOSIS TROUBLESHOOTING
INTAKE AIR TEMPERATURE SENSOR
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-9
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-321
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 13A-9
ENGINE COOLANT TEMPERATURE
INSPECTION CHART FOR DIAGNOSIS SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13A-322
CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-15
THROTTLE POSITION SENSOR
INSPECTION PROCEDURE FOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-322
DIAGNOSIS CODES . . . . . . . . . . . . . . . . . 13A-17
OXYGEN SENSOR CHECK . . . . . . . . . . . . 13A-323
INSPECTION CHART FOR TROUBLE
INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A-325
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13A-178
IDLE SPEED CONTROL (ISC) SERVO
SYMPTOM PROCEDURES . . . . . . . . . . . . 13A-182
(STEPPER MOTOR) CHECK . . . . . . . . . . . 13A-326
CHECK AT THE ECU TERMINALS . . . . . . 13A-300
INSPECTION PROCEDURE USING INJECTOR . . . . . . . . . . . . . . . . . . . . . 13A-328
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13A-305
ON-VEHICLE SERVICE. . . . . . . . . . . 13A-315

THROTTLE BODY ASSEMBLY . . . . . 13A-330
THROTTLE BODY (THROTTLE VALVE
AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13A-315
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13A-315 ENGINE-ECU . . . . . . . . . . . . . . . . . . . 13A-332
BASIC IDLE SPEED ADJUSTMENT . . . . . 13A-316 REMOVAL AND INSTALLATION . . . . . . . . 13A-332
13A-2 MULTIPORT FUEL INJECTION (MPI) <4G63-Non-Turbo>
GENERAL INFORMATION
GENERAL INFORMATION
M1131000101823
The Multipoint Fuel Injection System consists of sen- engine-ECU carries out activities such as fuel injec-
sors which detect the engine conditions, the tion control, idle speed control and ignition timing
engine-ECU which controls the system based on sig- control. In addition, the engine-ECU is equipped with
nals from these sensors, and actuators which oper- several diagnosis modes which simplify trouble-
ate under the control of the engine-ECU. The shooting when a problem develops.
FUEL INJECTION CONTROL

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

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

The power transistor located in the ignition primary
circuit turns ON and OFF to control the primary cur-
rent flow to the ignition coil. This controls the ignition
timing in order to provide the optimum ignition timing
with respect to the engine operating conditions. The
ignition timing is determined by the engine-ECU from
the engine speed, intake air volume, engine coolant
temperature and atmospheric pressure.
SELF-DIAGNOSIS FUNCTION
• When an abnormality is detected in one of the • The RAM data inside the engine-ECU that is
sensors or actuators related to emission control, related to the sensors and actuators can be read
the engine warning lamp (check engine lamp) by means of the M.U.T.-II/III. In addition, the actu-
illuminates as a warning to the driver. ators can be force-driven under certain circum-
• When an abnormality is detected in one of the stances.
sensors or actuators, a diagnosis code corre-
sponding to the abnormality is output.
MULTIPORT FUEL INJECTION (MPI) <4G63-Non-Turbo>
GENERAL INFORMATION
13A-3
OTHER CONTROL FUNCTIONS
1. Fuel Pump Control 4. Purge Control Solenoid Valve Control
Turns the fuel pump relay ON so that current is sup- (Refer to P.17-60, GROUP 17 − Engine And Emis-
plied to the fuel pump while the engine is crank- sion Control − Evaporative Emission Control Sys-
ing or running. tem).
2. A/C Relay Control 5. EGR Control Solenoid Valve Control
Turns the compressor clutch of the A/C ON and OFF. [Refer to P.17-67, GROUP 17 − Engine And Emis-
3. Fan Motor Control sion Control − Exhaust Gas Recirculation (EGR)
The revolutions of the radiator fan and condenser fan System].
are controlled in response to the engine coolant
temperature and vehicle speed.
Items Specifications
Throttle body Throttle bore mm 60
Throttle position sensor Variable resistor type
Idle speed control servo Stepper motor type
Engine-ECU Identification No. E6T38982
Sensors Air flow sensor Karman vortex type
Barometric pressure Sensor Semiconductor type
Intake air temperature sensor Thermistor type
Engine coolant temperature Thermistor type
Oxygen sensor Zirconia 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 Engine control relay type Contact switch type
Fuel pump relay type Contact switch type
Injector type and number Electromagnetic type, 4
Injector identification mark HDA 250E
EGR control solenoid valve Duty cycle type solenoid valve
Purge control solenoid valve Duty cycle type solenoid valve
Fuel pressure Regulator pressure kPa 329
regulator
GENERAL INFORMATION
MULTI-POINT FUEL INJECTION SYSTEM DIAGRAM
1 Oxygen sensor (front) Power supply 1 Injector Engine control relay

2 Oxygen sensor (rear) Ignition switch-IG Engine-ECU 2 Idle speed control Fuel pump relay
3 Air flow sensor Ignition switch-ST servo (Stepper motor) A/C compressor relay
4 Intake air temperature A/C switch 3 EGR control solenoid Ignition coil
sensor A/C load signal valve Fan controller
5 Throttle position sensor A/C pressure 4 Purge control solenoid Engine warning lamp
6 Camshaft position sensor valve Diagnosis output
sensor Power steering Alternator G terminal
7 Crank angle sensor fluid pressure switch Oxygen sensor heater
8 Barometric pressure Alternator FR Tachometer
sensor terminal
9 Engine coolant Vehicle speed
temperature sensor sensor
10 Detonation sensor
4 Intake air temperature sensor

2 Idle speed control servo
(Stepper motor) 3 Air flow sensor
8 Barometric
6 Camshaft position sensor 5 Throttle position pressure sensor
sensor
Fuel pressure Air

regulator M M A
To From
fuel tank fuel pump
EGR valve
1 Oxygen sensor Canister
(front)
1 Injector
Catalytic 9 Engine coolant 3 EGR control
converter temperature sensor solenoid valve
10 Detonation sensor 4 Purge control
solenoid valve
7 Crank angle sensor
2 Oxygen sensor (rear)
Catalytic
converter
AK204338 AB
13A-5
M1131000300772
Basic idle speed r/min 700 ± 50
Throttle position sensor adjusting voltage mV 535 − 735
Throttle position sensor resistance kΩ 3.5 − 6.5
Idle speed control servo coil resistance (at 20°C) Ω 28 − 33
Intake air temperature sensor −20°C 13 − 17
resistance kΩ 0°C 5.3 − 6.7
20°C 2.3 − 3.0
40°C 1.0 − 1.5
60°C 0.56 − 0.76
80°C 0.30 − 0.42
Engine coolant temperature −20°C 14 − 17
sensor resistance kΩ 0°C 5.1 − 6.5
20°C 2.1 − 2.7
40°C 0.9 − 1.3
60°C 0.48 − 0.68
80°C 0.26 − 0.36
Oxygen sensor output voltage (at racing) V 0.6 − 1.0
Oxygen sensor heater front 4.5 − 8.0
resistance (at 20°C) Ω rear 11 − 18
Fuel pressure kPa Vacuum hose disconnection 330 − 350 at curb idle
Vacuum hose connection Approximately. 270 at curb idle
Injector coil resistance (at 20°C) Ω 10.5 − 13.5
SEALANT
M1131000500505

Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent Drying sealant
Threaded portion
SPECIAL TOOLS
SPECIAL TOOLS
M1131000600728

MB991502 M.U.T.-II sub • Reading diagnosis code
assembly • MPI system inspection
B991502
MB991955 M.U.T.-III sub • Reading diagnosis code

A A: MB991824 assembly • MPI system inspection
B: MB991827 A: Vehicle • Measurement of fuel pressure
C: MB991910 communicatio
D: MB991911 n interface
MB991824 E: MB991825 (V.C.I.)
B F: MB991826 B: M.U.T.-III USB
cable
C: M.U.T.-III
main harness
MB991827 A (Vehicles
with CAN
C
communicatio
DO NOT USE n system)
D: M.U.T.-III
main harness
MB991910
B (Vehicles
D without CAN
communicatio
n system)
E: M.U.T.-III
MB991911 measurement
adapter
E F: M.U.T.-III
trigger harness
MB991825
MB991826
MB991955
MB991348 Test harness set • Measurement of voltage during

troubleshooting
• Inspection using an oscilloscope
MB991348
SPECIAL TOOLS
13A-7
MB991709 Test harness • Measurement of voltage during
troubleshooting
• Adjusting of idle speed control servo
MD998478 Test harness • Measurement of voltage during

(3-pin, triangle) Troubleshooting
MB991536 Check harness • Measurement of voltage during

for throttle Troubleshooting
position sensor • Adjusting of throttle position sensor
adjustment
MB991536

(4-pin, square) Troubleshooting
• Inspection of oxygen sensor (front)

Troubleshooting
• Inspection of oxygen sensor (rear)
MB991658
MB991223 Harness set • Check at the ECU terminals

A: MB991219 A: Test harness A: Connector pin contact inspection
B: MB991220 B: LED harness B: Power circuit inspection
C: MB991221 C: LED harness C: Power circuit inspection
D: MB991222 adapter D: Commercial tester connection
D: Probe
MB991223
SPECIAL TOOLS

MD998709 Adaptor hose Measurement of fuel pressure
MD998742 Hose adaptor
MB991637 Fuel pressure

gauge set
MB991637
MD998706 Injector test set Checking the spray condition of

injectors
MD998706
MB991607 Injector test

harness
MB991607
MD998741 Injector test

adaptor
MD998741
MB991608 Clip
MB991608
TROUBLESHOOTING
13A-9
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1131150000643
Refer to P.00-6, GROUP 00 − How to Use Trouble- DIAGNOSIS FUNCTION
shooting/Inspection Service Points. M1131155500290
NOTE: If the engine-ECU is replaced, the steering ENGINE WARNING LAMP (CHECK
lock cylinder and ignition key should be replaced ENGINE LAMP)
together with it.
Engine warning lamp

(check engine lamp)
AK300251AB
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 illumi-
nates while the engine is running, check the diagno-
sis code output.
ENGINE WARNING LAMP INSPECTION ITEMS

Code No. Diagnosis item
− Engine-ECU
P0100 Air flow sensor system
P0105 Barometric pressure sensor system
P0110 Intake air temperature sensor system
P0115 Engine coolant temperature sensor system
P0120 Throttle position sensor system
P0125* Feedback system monitor
P0130 Oxygen sensor (front) system <Sensor 1>
P0135 Oxygen sensor heater (front) system <Sensor 1>
P0136 Oxygen sensor (rear) system <Sensor 2>
P0141 Oxygen sensor heater (rear) system <Sensor 2>
P0170 Abnormal fuel system
P0201 No. 1 injector system
P0300 Random cylinder mis-fire detection system
P0301* No. 1 cylinder mis-fire detection system
TROUBLESHOOTING

P0325 Detonation sensor system
P0335 Crank angle sensor system
P0340 Camshaft position sensor system
P0403 EGR control solenoid valve system
P0420 Catalyst deterioration system
P0443 Purge control solenoid valve system
P0500 Vehicle speed sensor system
P0505 Idle speed control system
P0551* Power steering fluid pressure switch system
P1603* Battery back-up line system
P1610 Immobilizer system
NOTE: .
• If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication
between M.U.T.-II/III and the engine-ECU is impossible. In this case, the diagnosis code cannot be read.
• After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine is
next turned on and the same malfunction is re-detected.However, for items marked with a "*" in the diag-
nosis code number column, the engine warning lamp illuminates only on the first detection of the malfunc-
tion.
• After the engine warning lamp illuminates, it will be switched off under the following conditions.
• When the engine-ECU monitored the power train malfunction three times* met set condition require-
ments, it detected no malfunction.
*: In this case, "one time" indicates from engine start to stop.
• For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.)
are similar to those when the malfunction was first recorded.
• Sensor 1 indicates, the sensor mounted at a position closest to the engine, and sensor 2 indicates the
sensor mounted at the position second closest to the engine.
METHOD OF READING AND ERASING 5. Erase the diagnosis codes.

DIAGNOSIS CODES
Refer to P.00-6, GROUP 00 − How to Use Trouble- INSPECTION USING M.U.T.-II/III DATA
shooting/Inspection Service Points. LIST AND ACTUATOR TESTING
1. Carry out inspection by means of the data list and
DIAGNOSIS USING DIAGNOSIS 2 CODES the actuator test function, if there is an
1. Switch the diagnosis mode of the engine control abnormality, check and repair the chassis harness
unit to DIAGNOSIS 2 mode using the M.U.T.-II/III. and components.
2. Carry out a road test. 2. After repairing, re-check using the M.U.T.-II/III and
3. Take a reading of the diagnosis code and repair check that the abnormal input and output have
the problem location. returned to normal as a result of the repairs.
4. Turn the ignition switch to OFF and then back to 3. Erase the diagnosis code memory.
ON again. 4. Remove the M.U.T.-II/III, and then start the engine
NOTE: By turning the ignition switch to OFF, the again and carry out a road test to confirm that the
ENGINE-ECU will switch the diagnosis mode problem has disappeared.
from DIAGNOSIS 2 mode to DIAGNOSIS 1
mode.
TROUBLESHOOTING
13A-11
FREEZE FRAME DATA The display items of freeze frame data are shown
When the engine-ECU detects a malfunction and below.
stores a diagnosis code, it also stores a current sta-
tus of the engine. This function is called "Freeze
frame data". By analyzing this "Freeze frame" data
with the M.U.T.-II/III, an effective troubleshooting can
be performed.
DISPLAY ITEM LIST

Item No. Data Unit
21 Engine coolant temperature sensor °C
22 Engine speed r/min
24 Vehicle speed km/h
80 Long-term fuel compensation (long-term fuel trim) %
82 Short-term fuel compensation (short-term fuel trim) %
88 Fuel control condition Open loop OL
Closed loop CL
Open loop owing to drive condition OL-DRV.
Open loop owing to system malfunction OL-SYS.
Closed loop based on one oxygen sensor CL- H02S
87 Calculation load value %
Diagnosis code during data recording -
NOTE: If malfunctions have been detected in multi-
ple systems, store one malfunction only, which has
been detected first.
DRIVE CYCLE
By carrying out the test drive in the following three drive cycle patterns, the all monitoring can be accom-
plished for the diagnosis codes that is required by the vehicle driving to identify the fault. In other words,
doing such a drive allows to regenerate any kind of trouble which involves illuminating the engine warning
lamp (check engine lamp) and to verify the repair procedure has eliminated the trouble [the engine warning
lamp (check engine lamp) is no longer illuminated].
CAUTION
Two technicians should always be in the vehicle when carrying out a test drive.
NOTE: Check that the diagnosis code is not output before traveling in the Drive cycle pattern. Erase the diag-
nosis code if it has been output.
DRIVE CYCLE PATTERN LIST
Procedure Monitor item Diagnosis code
1 Catalytic converter monitor P0421
2 Oxygen sensor (front) monitor P0130
3 Other monitor P0136, P0201, P0202,
P0203, P0204, P0300,
P0301, P0302, P0303,
P0304, P0325, P0501,
P0551
TROUBLESHOOTING
Procedure 1
Catalytic converter monitor
Diagnosis P0421
code No.
Drive cycle One trip monitor [from start to ignition switch to "LOCK" (OFF) position] will be completed
pattern while traveling with the following drive cycle pattern. It will take 16 minutes or more.
6 minutes or more
90 km/h or more 10 minutes or more

(3)
(4) 55 - 80 km/h
Vehicle
speed (2) (5,6)
Stopping and braking

permitted
(1) (7)
Time
Engine Start Ignition switch :

"LOCK" (OFF)
position
AK301815 AB
Inspection • Atmospheric temperature: −10°C or more

condition
Test 1. Engine: start
procedure 2. Accelerate until the vehicle speed is 90 km/h or more.
3. Travel for 6 minutes or more while keeping the vehicle speed at 90 km/h or more.
4. Decelerate until the vehicle speed is within 80 km/h or less.
5. While traveling at 55 − 80 km/h for 10 minutes or more, fully close the throttle at least
once in 2 minutes and decelerate for 10 seconds or more.
• Do not repeat deceleration too often.
• Vehicle speed may go below 55 km/h after the deceleration.
• Stopping and braking are permitted. (If stopped or drive at 55 km/h or less for more
than 5 minutes the monitoring may be stopped. In this case please restart monitoring
from the beginning.)
6. After completing the above deceleration, bring the vehicle speed back to 55 − 80 km/h
and keep it in the range until starting the deceleration again.
• Repeat the above deceleration at least 5 times.
7. Return the vehicle to the shop, then turn the ignition switch to "LOCK" (OFF) position.
TROUBLESHOOTING
13A-13
Procedure 2
Oxygen sensor (front) monitor
Diagnosis P0130
code No.
16 minutes or more
55 - 80 km/h
(3)
Vehicle
speed (2) Stopping and braking
permitted
(1) (4)
Time

"LOCK" (OFF)
position
AK301816AB
Inspection • Engine coolant temperature: After engine warm up

conditions • Atmospheric temperature: −10°C or more
procedure 2. Accelerate until the vehicle speed is 55 − 80 km/h.
3. While keeping the acceleator pedal opening degree constant, keep the vehicle speed at
55 − 80km/h and travel for 16 minutes or more.
• Stopping and braking during this operation are permitted.
TROUBLESHOOTING
Procedure 3
Other monitor
Diagnosis P0136, P0201, P0202, P0203, P0204, P0300, P0301, P0302, P0303, P0304, P0325,
code No. P0500, P0551
16 minutes or more
55 km/h or more
(3)
Vehicle (2) 5 minutes or more

speed Engine: Idling
Transmission: Neutral
(1) (4) (5)

Time

"LOCK" (OFF)
position
AK301817AB

procedure 2. Accelerate until the vehicle speed is 55 km/h.
3. While keeping the acceleator pedal opening degree constant, keep the vehicle speed at
55 km/h and travel for 16 minutes or more.
4. Return the vehicle to the shop.
5. After stopping the vehicle, continue idling for 5 minutes, and then turn the ignition switch
to "LOCK" (OFF) position.
READINESS TEST STATUS In addition, if diagnosis codes are erased or the bat-
The engine-ECU monitors the following main diagno- tery cable is disconnected, this history will also be
sis items, judges if these items are in good condition erased (the memory will be reset).
or not, and the stores its history. this history can be • Catalyst: P0420
read out by using M.U.T.-II/III. (If the ECU has judged • Oxygen sensor: P0130
a item before, the M.U.T.-II/III displays "Complete"). • Oxygen sensor heater: P0135, P0141
TROUBLESHOOTING
13A-15
FAIL-SAFE FUNCTION REFERENCE TABLE
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 idle speed control 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
Barometric pressure Controls as if the barometric pressure is 101 kPa.
sensor
Throttle position sensor No increase in fuel injection amount during acceleration due to the throttle position
sensor signal.
Engine coolant Controls as if the engine coolant temperature is 80°C.
temperature sensor
Camshaft position Injectors fuel into the cylinders in the order 1-3-4-2 with irregular timing. (After the
sensor ignition switch is turned to the "ON" position, the No. 1 cylinder top dead center is
not detected at all)
Oxygen sensor (front) Air/fuel ratio feedback control (closed loop control) is not performed.
Oxygen sensor (rear) Performs the feedback control (closed loop control) of the air/fuel ratio by using
only the signal of the oxygen (front) installed on the front of the catalytic converter.
Detonation sensor Fixes the ignition timing as that for regular gasoline.
Ignition coil Cuts off the fuel supply to cylinders with an abnormal ignition.
(incorporating power
transistor)
Alternator FR terminal Does not control the output of the alternator according to an electrical load. (works
as a normal alternator)
Misfiring If the detected misfiring causes damage to the catalyst, the misfiring cylinder will be
shut down.
INSPECTION CHART FOR DIAGNOSIS CODE

M1131151000884
Code No. Diagnosis item Reference page

P0100 Air flow sensor system P.13A-17
P0105 Barometric pressure sensor system P.13A-27
P0110 Intake air temperature sensor system P.13A-36
P0115 Engine coolant temperature sensor system P.13A-42
P0120 Throttle position sensor system P.13A-49
P0125* Feedback system monitor P.13A-57
P0130 Oxygen sensor (front) system <Sensor 1> P.13A-61
P0135 Oxygen sensor heater (front) system <Sensor 1> P.13A-67
P0136 Oxygen sensor (rear) system <Sensor 2> P.13A-72
TROUBLESHOOTING

P0141 Oxygen sensor heater (rear) system <Sensor 2> P.13A-78
P0170 Abnormal fuel system P.13A-83
P0201 No.1 Injector system P.13A-87
P0300 Random cylinder mis-fire detection system P.13A-106
P0301* No.1 cylinder mis-fire detection system P.13A-110
P0325 Detonation sensor system P.13A-121
P0335 Crank angle sensor system P.13A-124
P0340 Camshaft position sensor system P.13A-134
P0403 EGR control solenoid valve system P.13A-142
P0420 Catalyst deterioration system P.13A-147
P0443 Purge control solenoid valve system P.13A-148
P0500 Vehicle speed sensor system P.13A-156
P0505 Idle speed control system P.13A-159
P0551* Power steering fluid pressure switch system P.13A-164
P0622 Alternator FR terminal system P.13A-169
P1603* Battery back-up line system P.13A-174
P1610 Immobilizer system P.13A-176
NOTE: .
• Do not replace the engine-ECU until a through terminal check reveals there are no short/open circuit.
• Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
• After the engine-ECU has detected a malfunction, a diagnosis code is recorded the next time the engine
is started and the same malfunction is re-detected. However, for items marked with "*", the diagnosis code
is recorded on the first detection of the malfunction.
• Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates the sen-
sor mounted at the position second closest to the engine.
TROUBLESHOOTING
13A-17
INSPECTION PROCEDURE FOR
DIAGNOSIS CODES
Code No. P0100 Air Flow Sensor System
Air flow sensor circuit
Battery
W-B
W-B
4 3
B-17X
1 2 Engine control relay

3 4
1 2
To engine-ECU
R
4
B-08
(MU802552)
1 2 3 4 5 6 7 Air flow sensor
7 5 3
B-W
20
J/C (1)
C-16 W-R C-135
G-B
17 31 32 33 34 35 36 37 38
B-W 39 40 41 42 43 44 45 46
19 40 90
C-137 C-134
71 72 73 74 75 76 77 78 79 80 81 1 2 3 4 5 6 7 8 9 10 11 12 13
82 83 84 85 86 87 88 89 90 9192 14 15 16 17 18 19 20 21 22 23 24 25 26
5V
Engine-ECU
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Gray
R: Red P: Pink V: Violet
AK401059 AB
TROUBLESHOOTING
OPERATION DIAGNOSIS PROCEDURE

• Power is supplied to the air flow sensor (terminal
No. 4) from the engine control relay (terminal No. STEP 1. M.U.T.-II/III data list
1) and earthed to the engine-ECU (terminal No. • Refer to Data list reference table P.13A-293.
40) from the air flow sensor (terminal No. 5).
a. Item 12: Air flow sensor
• A power voltage of 5 V is applied to the air flow
sensor output terminal (terminal No. 3) from the Q: Is the check result normal?
engine-ECU (terminal No. 90). YES : Intermittent malfunction (Refer to GROUP
• An air flow sensor filter reset signal is inputted to 00 − How to Use
the air flow sensor (terminal No. 7) from the Troubleshooting/Inspection Service Points
engine-ECU (terminal No. 19). P.00-6).
NO : Go to Step 2 .
FUNCTION
• Air flow sensor outputs a pulse signal propor- STEP 2. Connector check: B-08 air flow sensor
tional to the intake air flow rate. connector
• The engine-ECU determines the basic injection
timing of the injector using the pulse signal output Connector: B-08
from the air flow sensor and the engine speed
signal.
• When the throttle position sensor output is low,
the engine-ECU causes the power transistor in
the unit to be ON to send an air flow sensor filter B-08 (B)
reset signal to the air flow sensor. In response to
the reset signal, the air flow sensor resets the fil-
ter circuit to improve the ability of the air flow sen- 7 6 5 4 3 2 1
sor to measure the air flow rate in the area where Harness side connector AK300253 AB
the intake air flow rate is low.

Q: Is the check result normal?
YES : Go to Step 3 .
TROUBLE JUDGMENT NO : Repair.
Check Condition
• Engine speed is 500 r/min or more. STEP 3. Perform voltage measurement at B-08 air
Judgment Criterion flow sensor connector.
• Sensor output frequency of 3.3 Hz or less for 2 Connector: B-08
seconds.
PROBABLE CAUSE
• Failed air flow sensor
• Open/short circuit in air flow sensor circuit or
loose connector contact B-08 (B)
• Failed engine-ECU
7 6 5 4 3 2 1
Harness side connector AK300253 AB
• Disconnect connector, and measure at harness

side.
• Ignition switch: ON
• Voltage between terminal No. 3 and earth.
OK: 4.9 − 5.1 V
NO : Go to Step 4 .
TROUBLESHOOTING
13A-19
STEP 4. Perform voltage measurement at C-137 STEP 5. Connector check: C-137 engine-ECU
engine-ECU connector. connector
Connector: C-137 Connector: C-137
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
Harness side connector Harness side connector
AK300254 AC AK300254 AC
• Measure engine-ECU terminal voltage.

Connector: B-08
OK: 4.9 − 5.1 V
B-08 (B)
NO : Go to Step 6 .
7 6 5 4 3 2 1

YES : Check and repair harness between B-08
(terminal No. 3) air flow sensor connector
and C-137 (terminal No. 90) engine-ECU
connector.
• Check output line for open circuit.
NO : Repair.
TROUBLESHOOTING

STEP 6. Connector check: C-137 engine-ECU
connector. NO : Repair.
Connector: C-137
STEP 8. M.U.T.-II/III data list
• Refer to Data list reference table P.13A-293.
YES : Intermittent malfunction (Refer to GROUP
C-137
00 − How to Use
Troubleshooting/Inspection Service Points
P.00-6).
NO : Replace engine-ECU.
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Harness side connector STEP 9. Perform voltage measurement at B-08 air
AK300254 AC
flow sensor connector.
Connector: B-08
NO : Repair.
STEP 7. Check harness between B-08 (terminal

B-08 (B)
No. 3) air flow sensor connector and C-137
(terminal No. 90) engine-ECU connector.
7 6 5 4 3 2 1
Connector: B-08

side.
B-08 (B)
OK: System voltage
7 6 5 4 3 2 1
NO : Go to Step 10 .
Connector: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Harness side connector
AK300254 AC
• Check output line for short circuit.

TROUBLESHOOTING
13A-21
STEP 10. Connector check: B-17X engine control STEP 11. Perform resistance measurement at
relay connector B-08 air flow sensor connector.
Connector: B-17X Connector: B-08
Relay box’s B-17X
triangle marks
2 1 B-08 (B)
4 3
Harness side 7 6 5 4 3 2 1
connector AK300255 AC Harness side connector AK300253 AB
• Disconnect connector and measure at harness

Connector: B-08
side.
• Resistance between terminal No. 5 and earth.
OK: Continuity (2 Ω or less)
B-08 (B)
7 6 5 4 3 2 1
connector
Q: Is the check result normal? Connector: C-135
and B-17X (terminal No.1) engine control
relay connector.
• Check power supply line for
open/short circuit.
NO : Repair. C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

NO : Repair.
TROUBLESHOOTING
STEP 13. Check harness between B-08 (terminal STEP 14. Perform voltage measurement at B-08
No. 5) air flow sensor connector and C-135 air flow sensor connector.
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
7 6 5 4 3 2 1 Harness side connector AK300253 AB
• Use special tool test harness (MB991709) to con-
nect connector, and measure at pick-up harness.
Connector: C-135
OK: 7 − 8 V
C-135

connector
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 Connector: C-134
AK300256 AC
NOTE: Before checking harness, check intermediate

connector C-16, and repair if necessary.
• Check earthing line for open circuit and damage.
C-134
NO : Repair.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING
13A-23
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
Connector: C-134
• Transmission: Neutral
OK:
0 − 1 V (Engine: Idling)
6 − 9 V (Engine: 3,000 r/min)
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1 STEP 18. Connector check: C-134 engine-ECU

26 25 24 23 22 21 20 19 18 17 16 15 14
connector
Connector: C-134
AK300257 AC
• Check reset signal line for short circuit.

YES : Replace air flow sensor.
NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING
STEP 19. Check harness between B-08 (terminal STEP 20. Perform output wave pattern
No. 7) air flow sensor connector and C-134 measurement at B-08 air flow sensor connector
(terminal No. 19) engine-ECU connector. (Using an oscilloscope).
Connector: B-08 Connector: B-08
B-08 (B) B-08 (B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1
Harness side connector AK300253 AB Harness side connector AK300253 AB

Connector: C-134
• Engine: Idling
OK: Waveforms should be displayed on
inspection procedure using an oscilloscope
C-134 (Refer to P.13A-305) and noise should not be
displayed in the waveform.
13 12 11 10 9 8 7 6 5 4 3 2 1 YES : Go to Step 8 .
26 25 24 23 22 21 20 19 18 17 16 15 14 NO : Go to Step 21 .
AK300257 AC STEP 21. Replace air flow sensor.

• After replacing the air flow sensor, re-check the
• Check reset signal line for open circuit and dam-
trouble symptoms.
age.
NO : Check end.
NO : Repair.
STEP 22. Connector check: B-17X engine control

relay connector
Connector: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side
connector AK300255 AC

NO : Repair.
TROUBLESHOOTING
13A-25
STEP 23. Check harness between B-08 (terminal STEP 25. Check harness between B-08 (terminal
No. 4) air flow sensor connector and B-17X No. 3) air flow sensor connector and C-137
(terminal No. 1) engine control relay connector. (terminal No. 90) engine-ECU connector.
B-08 (B) B-08 (B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1
Connector: B-17X Connector: C-137

Relay box’s B-17X
triangle marks
2 1
4 3
C-137
Harness side
• Check power supply line for damage. 8180 79 78 77 76 75 74 73 72 71

92 91 90 89 88 87 86 85 84 83 82
NO : Repair. AK300254 AC
• Check output line for damage.

connector YES : Go to Step 26 .
CONNECTOR: C-134 NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.
TROUBLESHOOTING
STEP 26.Connector check: C-135 engine-ECU

connector
Connector: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC
Connector: B-08
B-08 (B)
7 6 5 4 3 2 1

YES : Check intermediate connector C-16, and
repair if necessary. If intermediate
connector is normal, check and repair
harness between B-08 (terminal No. 5) air
flow sensor connector and C-135 (terminal
No. 40) engine-ECU connector.
• Check earthing line for damage.
No : Repair.
TROUBLESHOOTING
13A-27
Code No. P0105: Barometric Pressure Sensor System
Barometric pressure sensor circuit
B-08
(MU802552)
Barometric pressure sensor
1 2 3 4 5 6 7 (Incorporated in air flow sensor)
1 2 5
B-W
20
Y-B G-W J/C (1)

C-16
17
B-W
81 85 40
C-135 C-137
31 32 33 34 35 36 37 38 71 72 73 74 75 76 77 78 79 80 81
39 40 41 42 43 44 45 46 82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code
AK401025 AB
OPERATION TROUBLE JUDGMENT

• A power voltage of 5 V is applied to the baromet-
Check Condition
ric pressure sensor power terminal (terminal No.
• 2 seconds later after the ignition switch has been
1) of the air flow sensor connector from the
in "ON" position or the engine has started up.
engine-ECU (terminal No. 81) and earthed to the
• The battery voltage is 8 V or more.
engine-ECU (terminal No. 40) from the air flow
sensor (terminal No. 5). Judgment Criterion
• The sensor signal is inputted to the engine-ECU • The sensor output voltage is 4.5 V or more (Baro-
(terminal No. 85) from the barometric pressure metric pressure of above 114 kPa or equivalent)
sensor output terminal (terminal No. 2) of the air for 2 seconds.
flow sensor connector. Or
• The sensor output voltage is 0.2 V or less (Baro-
FUNCTION metric pressure of below 53kpa or equivalent) for
• The barometric pressure sensor converts the bar- 2 seconds.
ometric pressure into a voltage signal and inputs
the signal to the engine-ECU. PROBABLE CAUSE
• In response to the signal, the engine-ECU cor- • Failed barometric pressure sensor
rects the fuel injection amount, etc. • Open/short circuit in barometric pressure sensor
circuit or loose connector contact
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Perform voltage measurement at B-08 air

STEP 1. M.U.T.-II/III data list Connector: B-08
a. Item 25: Barometric pressure sensor
00 − How to Use B-08 (B)
P.00-6).
NO : Go to Step 2 . 7 6 5 4 3 2 1
STEP 2. Connector check: B-08 air flow sensor • Disconnect connector, and measure at harness
side.
connector
Connector: B-08 • Voltage between terminal No. 1 and earth.
OK: 4.9 − 5.1 V
NO : Go to Step 4 .
B-08 (B)
STEP 4. Perform voltage measurement at C-137

7 6 5 4 3 2 1 engine-ECU connector.
Connector: C-137
NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

OK: 4.9 − 5.1 V
NO : Go to Step 6 .
TROUBLESHOOTING
13A-29
STEP 5. Connector check: C-137 engine-ECU STEP 6. Connector check: C-137 engine-ECU
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC
Connector: B-08 Q: Is the check result normal?

NO : Repair.
B-08 (B)
7 6 5 4 3 2 1

connector.
• Check power supply line for open
circuit.
NO : Repair.
TROUBLESHOOTING
STEP 7. Check harness between B-08 (terminal STEP 9. Perform resistance measurement at B-08
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
side.
Connector: C-137
C-137 STEP 10. Connector check: C-135 engine-ECU

connector
Connector: C-135
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC
• Check power supply line for short circuit.

C-135
NO : Repair.
38 37 36 35 34 33 32 31
STEP 8. M.U.T.-II/III data list 46 45 44 43 42 41 40 39
• Refer to Data list reference table P.13A-293. Harness side connector
a. Item No. 25: Barometric pressure sensor
AK300256 AC
YES : Intermittent malfunction (Refer to GROUP Q: Is the check result normal?
00 − How to Use YES : Go to Step 11 .
Troubleshooting/Inspection Service Points NO : Repair.
P.00-6).
TROUBLESHOOTING
13A-31
Connector: B-08
Connector: B-08
B-08 (B)
B-08 (B)
7 6 5 4 3 2 1
nect only terminal No. 1, No. 2 and No. 5, and
Connector: C-135
then measure at pick-up harness.
OK: 4.9 − 5.1 V
C-135 NO : Go to Step 13 .
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

• Check earthing line for open circuit or damage.
NO : Repair.
TROUBLESHOOTING
STEP 13. Connector check: C-137 engine-ECU STEP 14. Perform voltage measurement at B-08
connector air flow sensor connector.
Connector: C-137 Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
8180 79 78 77 76 75 74 73 72 71 • Use special tool test harness (MB991709) to con-

92 91 90 89 88 87 86 85 84 83 82 nect only terminal No. 1, No. 2 and No. 5, and
Harness side connector then measure at pick-up harness.
AK300254 AC
Connector: B-08 OK: 0.5 V or less
B-08 (B)
7 6 5 4 3 2 1

connector.
• Check power supply line for damage.
NO : Repair.
TROUBLESHOOTING
13A-33
B-08 (B)
C-135
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31 • Use special tool test harness (MB991709) to con-

46 45 44 43 42 41 40 39 nect only terminal No. 1, No. 2 and No. 5, and
AK300256 AC
Connector: B-08 OK:
Altitude 0m: 3.8 − 4.2 V
Altitude 600m: 3.5 − 3.9 V
Altitude 1,200m: 3.3 − 3.7 V
Altitude 1,800m: 3.0 − 3.4 V
B-08 (B) Q: Is the check result normal?
7 6 5 4 3 2 1
Q: Is the check result normal? connector
Connector: C-137
NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

NO : Repair.
TROUBLESHOOTING
STEP 18. Check harness between B-08 (terminal STEP 19. Perform voltage measurement at C-137
No. 2) air flow sensor connector and C-137 engine-ECU connector.
Connector: C-137
Connector: B-08
B-08 (B)
C-137
7 6 5 4 3 2 1
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Connector: C-137 Harness side connector
AK300254 AC

OK:
C-137 Altitude 0m: 3.8 − 4.2 V
Altitude 600m: 3.5 − 3.9 V
Altitude 1,200m: 3.3 − 3.7 V
8180 79 78 77 76 75 74 73 72 71 Altitude 1,800m: 3.0 − 3.4 V
92 91 90 89 88 87 86 85 84 83 82
Harness side connector Q: Is the check result normal?
AK300254 AC NO : Go to Step 20 .
• Check output line for short circuit and damage.
NO : Repair.
TROUBLESHOOTING
13A-35
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

NO : Repair.
B-08 (B)
7 6 5 4 3 2 1

connector.
• Check output line for open circuit and
damage.
NO : Repair.
TROUBLESHOOTING
Code No. P0110: Intake Air Temperature Sensor System
Intake air temperature sensor circuit
B-08
(MU802552)
Intake air temperature sensor
5 6
B-W
20
J/C (1)
C-16
Y-L
17
B-W
40 72
C-137 C-135
71 72 73 74 75 76 77 78 79 80 81 31 32 33 34 35 36 37 38
82 83 84 85 86 87 88 89 90 9192 39 40 41 42 43 44 45 46
5V
Engine-ECU
Wire colour code
AK401026 AB
OPERATION • The intake air temperature sensor is a kind of

• A power voltage of 5 V is applied to the intake air resistor, which has characteristics to reduce its
temperature sensor output terminal (terminal No. resistance as the intake air temperature rises.
6) of the air flow sensor connector from the Therefore, the sensor output voltage varies with
engine-ECU (terminal No. 72) the intake air temperature, and becomes lower as
• The power voltage is earthed to the engine-ECU the intake air temperature rises.
(terminal No. 40) from the air flow sensor (termi-
nal No. 5). TROUBLE JUDGMENT
Check Condition
FUNCTION • 2 seconds later after the ignition switch has been
• The intake air temperature sensor converts the in "ON" position or the engine has started up.
intake air temperature into a voltage and inputs
the voltage signal to the engine-ECU. Judgment Criterion
• In response to the signal, the engine-ECU cor- • The sensor output voltage is 4.6 V or more
rects the fuel injection amount, etc. (intake air temperature of below −45°C or equiva-
lent) for 2 seconds.
Or
• The sensor output voltage is 0.2 V or less (intake
air temperature above 125°C or equivalent) for 2
seconds.
TROUBLESHOOTING
13A-37
PROBABLE CAUSE STEP 4. Perform resistance measurement at B-08
• Failed intake air temperature sensor air flow sensor connector.
• Open/short circuit in intake air temperature sen-
sor circuit or loose connector contact Connector: B-08
DIAGNOSIS PROCEDURE
B-08 (B)
a. Item 13: Intake air temperature sensor 7 6 5 4 3 2 1
OK: At ambient temperature (atmospheric AK300253 AB
temperature) or equivalent. • Disconnect connector, and measure at harness

side.
YES : Intermittent malfunction (Refer to GROUP • Resistance between terminal No. 5 and earth.
00 − How to Use OK: Continuity (2 Ω or less)
Troubleshooting/Inspection Service Points Q: Is the check result normal?
P.00-6). YES : Go to Step 8 .
NO : Go to Step 2 . NO : Go to Step 5 .
STEP 2. Connector check: B-08 air flow sensor STEP 5. Connector check: C-135 engine-ECU
connector connector
Connector: B-08 Connector: C-135
B-08 (B)
C-135
7 6 5 4 3 2 1
Q: Is the check result normal? 38 37 36 35 34 33 32 31
YES : Go to Step 3 . 46 45 44 43 42 41 40 39
NO : Repair.
AK300256 AC
STEP 3. Check intake air temperature sensor

itself.
• Check intake air temperature sensor itself (Refer
NO : Repair.
to P.13A-321).
NO : Replace air flow sensor.
TROUBLESHOOTING
STEP 6. Check harness between B-08 (terminal STEP 7. M.U.T.-II/III data list
No. 5) air flow sensor connector and C-135 • Refer to Data list reference table P.13A-293.
(terminal No. 40) engine-ECU connector. a. Item 13: Intake air temperature sensor
Connector: B-08 OK: At ambient temperature (atmospheric
temperature) or equivalent.
00 − How to Use
B-08 (B) Troubleshooting/Inspection Service Points
P.00-6).
7 6 5 4 3 2 1
STEP 8. Perform voltage measurement at B-08 air
Connector: C-135 flow sensor connector.
Connector: B-08
C-135 B-08 (B)
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31 Harness side connector AK300253 AB
46 45 44 43 42 41 40 39
side.
AK300256 AC • Ignition switch: ON
connector C-16, and repair if necessary. OK: 4.5 − 4.9 V
• Check earthing line for open circuit and damage. Q: Is the check result normal?
YES : Go to Step 7 . NO : Go to Step 9 .
NO : Repair.
TROUBLESHOOTING
13A-39
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC
B-08 (B) B-08 (B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1
• Measure engine-ECU terminal voltage. Q: Is the check result normal?

• Disconnect B-08 air flow sensor connector. YES : Check and repair harness between B-08
• Ignition switch: ON (terminal No. 6) air flow sensor connector
• Voltage between terminal No. 72 and earth. and C-137 (terminal No. 72) engine-ECU
OK: 4.5 − 4.9 V connector.
Q: Is the check result normal? • Check output line for open circuit.
YES : Go to Step 10 . NO : Repair.
TROUBLESHOOTING

connector NO : Repair.
Connector: C-137
STEP 13. Perform voltage measurement at B-08
air flow sensor connector.
Connector: B-08
C-137
B-08 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Harness side connector 7 6 5 4 3 2 1
AK300254 AC
Q: Is the check result normal? nect only terminal No. 5 and No. 6, and then
YES : Go to Step 12 . measure at pick-up harness.
NO : Repair. • Ignition switch: ON
STEP 12. Check harness between B-08 (terminal OK:
No. 6) air flow sensor connector and C-137 Ambient temperature at −20°C: 3.8 − 4.4 V
(terminal No. 72) engine-ECU connector. Ambient temperature at 0°C: 3.2 − 3.8 V
Ambient temperature at 20°C: 2.3 − 2.9 V
Connector: B-08 Ambient temperature at 40°C: 1.5 − 2.1 V
B-08 (B) NO : Go to Step 14 .
7 6 5 4 3 2 1 STEP 14. Connector check: C-137 engine-ECU

Harness side connector AK300253 AB connector
Connector: C-137
Connector: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC
AK300254 AC
• Check output line for short circuit. Q: Is the check result normal?
NO : Repair.
TROUBLESHOOTING
13A-41
STEP 15. Check harness between B-08 (terminal STEP 16. Connector check: C-135 engine-ECU
No. 6) air flow sensor connector and C-137 connector
Connector: C-135
Connector: B-08
B-08 (B) C-135
7 6 5 4 3 2 1
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC
Connector: B-08
C-137
B-08 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
7 6 5 4 3 2 1
AK300254 AC
• Check output line for damage. YES : Check intermediate connector C-16 and
Q: Is the check result normal? repair if necessary. If intermediate
YES : Go to Step 16 . connector is normal, check and repair
NO : Repair. harness between B-08 (terminal No. 5) air
NO : Repair.
TROUBLESHOOTING
Code No. P0115: Engine Coolant Temperature Sensor System
Engine coolant temperature sensor circuit
B-108
(MU802406)
1 2 Engine coolant temperature sensor
2 1
BR Y-G
92 83
C-137
Engine-ECU
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192 5V
Wire colour code

R: Red P: Pink V:Violet
AK300260 AB
OPERATION • The engine coolant temperature sensor is a kind

• A power voltage of 5 V is applied to the engine of resistor, which has characteristics to reduce its
coolant temperature sensor output terminal (ter- resistance as the engine coolant temperature
minal No. 1) from the engine-ECU (terminal No. rises. Therefore, the sensor output voltage varies
83). with the engine coolant temperature, and
• The power voltage is earthed to the engine-ECU becomes lower as the engine coolant tempera-
(terminal No. 92) from the engine coolant temper- ture rises.
ature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION Check Condition
• The engine coolant temperature sensor converts • 2 seconds later after the ignition switch has been
the engine coolant temperature into a voltage sig- in "ON" position or just after the engine has
nal, and inputs the voltage to the engine-ECU. started up.
• In response to the signal, the engine-ECU con-
trols the fuel infection amount and the fast idle Judgment Criterion
speed when the engine is cold state. • The sensor output voltage is 4.6 V or more (water
temperature of below −45°C or equivalent) for 2
seconds.
Or
• The sensor output voltage of 0.1 V or less (water
temperature of above 140°C or equivalent) for 2
seconds.
TROUBLESHOOTING
13A-43
Check Condition STEP 3. Perform resistance measurement at
• After the engine has started up. B-108 engine coolant temperature sensor
Judging Conditions connector.
• The sensor output voltage rises 1.6 V or more Connector: B-108
(engine coolant temperature below 40°C or
2 1
equivalent) from 1.6 V or less (engine coolant
Harness side
temperature above 40°C or equivalent). connector
PROBABLE CAUSE
• Failed engine coolant temperature sensor
• Open/short circuit in engine coolant temperature
B-108 (B)
sensor circuit or loose connector contact
• Failed engine-ECU AK300261 AB
DIAGNOSIS PROCEDURE • Disconnect connector, and measure at sensor

side.
• Resistance between terminal No. 1 and No. 2.
STEP 1. M.U.T.-II/III data list OK:
• Refer to Data list reference table P.13A-293. Engine coolant temperature at −20°C: 14 − 17
a. Item 21: Engine coolant temperature sensor kΩ
OK: Engine coolant temperature at 0°C: 5.1 − 6.5
Engine cold state: At ambient temperature kΩ
(atmospheric temperature) or equivalent. Engine coolant temperature at 20°C: 2.1 − 2.7
Engine hot state: At 80 − 120°C kΩ
Engine coolant temperature at 40°C: 0.9 − 1.3
YES : Intermittent malfunction (Refer to GROUP kΩ
00 − How to Use Engine coolant temperature at 60°C: 0.48 −
Troubleshooting/Inspection Service Points 0.68 kΩ
Engine coolant temperature at 80°C: 0.26 −
P.00-6).
NO : Go to Step 2 .
0.36 kΩ
STEP 2. Connector check: B-108 engine coolant
NO : Replace engine coolant temperature
temperature sensor connector
sensor.
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK300261 AB

NO : Repair.
TROUBLESHOOTING
STEP 4. Perform voltage measurement at B-108 STEP 5. Perform voltage measurement at C-137
engine coolant temperature sensor connector. engine-ECU connector.
2 1
Harness side
connector
B-108 (B) C-137
AK300261 AB
• Disconnect connector, and measure at harness 8180 79 78 77 76 75 74 73 72 71

side. 92 91 90 89 88 87 86 85 84 83 82
• Ignition switch: ON Harness side connector

• Voltage between terminal No. 1 and earth. AK300254 AC
OK: 4.5 − 4.9 V
Connector: B-108
YES : Go to Step 10 . 2 1
NO : Go to Step 5 . Harness side
connector
B-108 (B)
AK300261 AB

• Disconnect B-108 engine coolant temperature
sensor.
OK: 4.5 − 4.9 V
NO : Go to Step 7 .
TROUBLESHOOTING
13A-45
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

2 1 YES : Go to Step 8 .
NO : Repair.
Harness side
connector
B-108 (B)
AK300261 AB

(terminal No. 1) engine coolant temperature
sensor connector and C-137 (terminal No.
83) engine-ECU connector.
NO : Repair.
TROUBLESHOOTING
STEP 8. Check harness between B-108 (terminal STEP 10. Perform resistance measurement at
No. 1) engine coolant temperature sensor B-108 engine coolant temperature sensor
connector and C-137 (terminal No. 83) connector.
engine-ECU connector. Connector: B-108
Connector: B-108 2 1
2 1 Harness side
connector
B-108 (B)
B-108 (B)
AK300261 AB
AK300261 AB
side.
Connector: C-137

connector
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 Connector: C-137
AK300254 AC

NO : Repair. C-137

• Refer to Data list reference table P.13A-293. 8180 79 78 77 76 75 74 73 72 71
a. Item 21: Engine coolant temperature sensor 92 91 90 89 88 87 86 85 84 83 82

OK:
Engine cold state: At ambient temperature AK300254 AC
(atmospheric temperature) or equivalent. YES : Go to Step 12 .
Engine hot state: At 80 − 120 °C NO : Repair.
00 − How to Use
P.00-6).
TROUBLESHOOTING
13A-47
No. 2) engine coolant temperature sensor engine coolant temperature sensor connector.
connector and C-137 (terminal No. 92) Connector: B-108
engine-ECU connector.
2 1
Connector: B-108 Harness side
2 1 connector
Harness side
connector
B-108 (B)
B-108 (B) AK300261 AB

AK300261 AB
Connector: C-137
OK:
Engine coolant temperature at −20°C: 3.9 − 4.5 V
Engine coolant temperature at 0°C: 3.2 − 3.8 V
C-137
8180 79 78 77 76 75 74 73 72 71 YES : Go to Step 9 .
92 91 90 89 88 87 86 85 84 83 82 NO : Go to Step 14 .
AK300254 AC STEP 14. Connector check: C-137 engine-ECU

connector
Connector: C-137
NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

NO : Repair.
TROUBLESHOOTING
No. 1) engine coolant temperature sensor connector
connector and C-137 (terminal No. 83)
Connector: C-137
Connector: B-108
2 1
Harness side
connector
C-137
B-108 (B)
8180 79 78 77 76 75 74 73 72 71
AK300261 AB 92 91 90 89 88 87 86 85 84 83 82
Connector: C-137
AK300254 AC
Connector: B-108
2 1
Harness side
connector
C-137
B-108 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300261 AB
AK300254 AC
YES : Check harness between B-108 (terminal
• Check output line for damage. No. 2) engine coolant temperature sensor
Q: Is the check result normal? connector and C-137 (terminal No. 92)
YES : Go to Step 16 . engine-ECU connector.
NO : Repair. • Check earthing line for damage.
NO : Repair.
TROUBLESHOOTING
13A-49
Code No. P0120: Throttle Position Sensor System
Throttle position sensor circuit
B-06
(MU802724)
Throttle position sensor
1 2 3 4
1 2 4
Y-B O BR
81 84 92
C-137
71 72 73 74 75 76 77 78 79 80 81
Engine-ECU
82 83 84 85 86 87 88 89 90 9192
5V
Wire colour code

AK300262 AB

• A power voltage of 5 V is applied to the throttle
Check Condition
position sensor (terminal No. 1) from the
engine-ECU (terminal No. 81).
Or
• The power voltage is earthed to the engine-ECU
• Excluding 2 seconds after the ignition switch has
(terminal No. 92) from the throttle position sensor
been in "ON" position or just after the engine has
(terminal No. 4).
started up.
• The sensor signal is inputted to the engine-ECU
(terminal No. 84) from the throttle position sensor Judgment Criteria
output terminal (terminal No. 2). • The sensor output voltage is 0.2 V or less for 2
seconds.
FUNCTION Or
• The throttle position sensor converts the opening • When the engine speed is 1,000 r/min or less and
of the throttle valve into a voltage and inputs the the charging efficiency is 40% or less, the throttle
voltage signal to the engine-ECU. position sensor output voltage is 4.4 V or more for
• In response to the signal, the engine-ECU checks 2 seconds.
the opening of the throttle valve.
TROUBLESHOOTING
PROBABLE CAUSE STEP 4. Perform voltage measurement at B-06

• Failed throttle position sensor throttle position sensor connector.
• Open/short circuit in throttle position sensor cir-
cuit or loose connector contact Connector: B-06
• Failed engine-ECU B-06 (B)
DIAGNOSIS PROCEDURE

a. Item 14: Throttle position sensor 4 3 2 1
YES : Intermittent malfunction (Refer to GROUP • Disconnect connector, and measure at harness
00 − How to Use side.
Troubleshooting/Inspection Service Points • Ignition switch: ON
P.00-6). • Voltage between terminal No. 1 and earth.
NO : Go to Step 2 . OK: 4.9 − 5.1 V
STEP 2. Connector check: B-06 throttle position YES : Go to Step 10 .
sensor connector NO : Go to Step 5 .
Connector: B-06
B-06 (B) STEP 5. Perform voltage measurement at C-137
Connector: C-137
4 3 2 1
Q: Is the check result normal? C-137

NO : Repair.
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
STEP 3. Check throttle position sensor itself.
• Check throttle position sensor itself (Refer to
P.13A-322). AK300254 AC
Q: Is the check result normal? • Measure engine-ECU terminal voltage.

YES : Go to Step 4 . • Ignition switch: ON
NO : Replace throttle position sensor. • Voltage between terminal No. 81 and earth.
OK: 4.9 − 5.1 V
NO : Go to Step 7 .
TROUBLESHOOTING
13A-51
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

B-06 (B) YES : Go to Step 8 .
NO : Repair.
4 3 2 1

(terminal No. 1) throttle position sensor
circuit.
NO : Repair.
TROUBLESHOOTING
No. 1) throttle position sensor connector and B-06 throttle position sensor connector.
C-137 (terminal No. 81) engine-ECU connector.
Connector: B-06
Connector: B-06 B-06 (B)
B-06 (B)
4 3 2 1
4 3 2 1 Harness side connector AK300263 AB
side.
Connector: C-137

connector
Connector: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

YES : Go to Step 9 . C-137
NO : Repair.
8180 79 78 77 76 75 74 73 72 71
STEP 9. M.U.T.-II/III data list 92 91 90 89 88 87 86 85 84 83 82
• Refer to Data list reference table P.13A-293. Harness side connector
a. Item 14: Throttle position sensor
AK300254 AC
Troubleshooting/Inspection Service Points NO : Repair.
P.00-6).
TROUBLESHOOTING
13A-53
No. 4) throttle position sensor connector and NO : Go to Step 14 .
Connector: B-06 STEP 14. Connector check: C-137 engine-ECU
B-06 (B) connector
Connector: C-137
4 3 2 1
C-137
Connector: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC
C-137
Connector: B-06
B-06 (B)
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC
• Check earthing line for open circuit and damage. 4 3 2 1

Q: Is the check result normal? Harness side connector AK300263 AB
NO : Repair. Q: Is the check result normal?
throttle position sensor connector.
Connector: B-06 • Check power supply line for damage.
B-06 (B) NO : Repair.
4 3 2 1

OK: 4.9 − 5.1 V
TROUBLESHOOTING

Connector: B-06 connector and C-137 (terminal No. 92)
B-06 (B) engine-ECU connector.
NO : Repair.

4 3 2 1 Connector: B-06
Harness side connector AK300263 AB B-06 (B)
OK: 0.5 V or less
Q: Is the check result normal? 4 3 2 1
YES : Go to Step 17 . Harness side connector AK300263 AB
NO : Go to Step 16 . • Use special tool test harness (MB991536) to con-
STEP 16. Connector check: C-137 engine-ECU • Ignition switch: ON
connector • Voltage between terminal No. 2 and earth.
Connector: C-137
OK:
Accelerator pedal fully released: 0.535 − 0.735
V
Accelerator pedal fully depressed: 4.5 − 5.0 V
C-137
STEP 18. Adjust throttle position sensor
• Adjust throttle position sensor (Refer to
8180 79 78 77 76 75 74 73 72 71 P.13A-315).
92 91 90 89 88 87 86 85 84 83 82
Harness side connector Q: Is the adjusted value normal?
AK300254 AC NO : Adjust throttle position sensor.
Connector: B-06
B-06 (B)
4 3 2 1
TROUBLESHOOTING
13A-55
STEP 19. Connector check: C-137 engine-ECU STEP 20. Perform voltage measurement at C-137
connector engine-ECU connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

Connector: B-06
B-06 (B)
OK:
Accelerator pedal fully released: 0.535 − 0.735
V
Accelerator pedal fully depressed: 4.5 − 5.0 V
4 3 2 1 YES : Go to Step 22 .
Harness side connector AK300263 AB NO : Go to Step 21 .

• Check output line for short circuit and
damage.
NO : Repair.
TROUBLESHOOTING
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

NO : Repair.
4 3 2 1

damage.
NO : Repair.
TROUBLESHOOTING
13A-57
Code No. P0125: Feedback system monitor
OPERATION • Failed fuel system

• Refer to P0201 injector circuit P.13A-87. • Failed exhaust system
Refer to P0202 injector circuit P.13A-92. • Failed engine-ECU
Refer to P0203 injector circuit P.13A-97.
Refer to P0204 injector circuit P.13A-102. DIAGNOSIS PROCEDURE
• Refer to P0130 Oxygen sensor (front) circuit
P.13A-61. STEP 1. M.U.T.-II/III diagnosis code
FUNCTION Q: Is any other diagnosis code than P0170 output?
YES : Inspection chart for diagnosis code (Refer
• The engine-ECU effects air-fuel ratio feedback
to P.13A-15).
control in accordance with the signals from the
NO : Go to Step 2 .
heater oxygen sensor (front).
• If the heated oxygen sensor (front) has deterio-
rated, corrections will be made by the heated STEP 2.M.U.T.-II/III data list
oxygen sensor (rear). • Refer to Data list reference table P.13A-293.
• diagnosis code P0125 becomes stored in mem- a. Item 12: Air flow sensor
ory if a failure is detected in the above air/fuel b. Item 21: Engine coolant temperature sensor
ratio feedback control system. c. Item 25: Barometric pressure sensor
d. Item 69: Oxygen sensor (rear)
TROUBLE JUDGMENT
Q: Are the check results normal?
Check Conditions YES : Go to Step 3 .
• The engine coolant temperature approximately. NO : Perform the diagnosis code classified check
82°C or more. procedure for the sensor that has shown an
• Within the range of air-fuel ratio feedback opera- abnormal data valve (Refer to Inspection
tion. Chart for Diagnosis Codes P.13A-15).
• Not in low speed operation.
Judgment Criteria STEP 3.Check for intake of air from intake hose
• The oxygen sensor output voltage is not deviated and inlet manifold.
from 0.5 V for 30 seconds.
PROBABLE CAUSE
NO : Repair.
• Failed oxygen sensor (front)
• Harness damage in oxygen sensor (front) circuit
or loose connector contact STEP 4.Check for leakage of exhaust emission
• Failed oxygen sensor (rear) from exhaust manifold.
NOTE: When the oxygen sensor (front) begins to Q: Is the check result normal?
deteriorate, the oxygen sensor output voltage will YES : Go to Step 5 .
deviate from the voltage when the sensor was new NO : Repair.
(normally 0.5 volt at stoichiometric ratio). This devia-
tion will be corrected by the oxygen sensor (rear).If STEP 5.Check throttle body (throttle valve
the oxygen sensor (rear) responds poorly because it portion) for contamination.
has deteriorated, it will improperly correct the oxygen
sensor (front). Thus, even when closed loop control Q: Is the check result normal?
is being effected, the fluctuation of the oxygen sen- YES : Go to Step 6 .
NO : Clean throttle body (throttle valve portion)
sor (front) output voltage decreases, without inter-
(Refer to P.13A-315).
secting with 0.5 volt. As a result, there is a possibility
of diagnosis code P0125 becoming registered.
TROUBLESHOOTING
STEP 6. Connector check: B-112 oxygen sensor STEP 8. Check harness between B-112 oxygen
(front) connector, C-137 engine-ECU connector sensor (front) connector and C-137 engine-ECU
connector.
Connector: B-112
Oxygen sensor (front) Connector: B-112
Oxygen sensor (front)
B-112 (B)
B-112 (B)
2 1
4 3 2 1
4 3
Connector: C-137
Connector: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 8180 79 78 77 76 75 74 73 72 71
Harness side connector 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC
AK300254 AC
YES : Go to Step 7 . • Check output line for damage.
NO : Repair.
STEP 7. Check oxygen sensor (front) itself.
• Check oxygen sensor (front) itself (Refer to
P.13A-323).
NO : Replace oxygen sensor (front).
TROUBLESHOOTING
13A-59
STEP 9. Connector check: Injector connector STEP 11. Connector check: B-17X engine control
relay connector and C-134 engine-ECU
Connector: B-01, B-02, B-04, B-05
connector.
Connector: B-17X
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR) Relay box’s B-17X
triangle marks
M 2 1
2 1
Harness side connector AK300265 AB 4 3
Harness side
a. B-01 (No.1 injector connector) connector AK300255 AC
b. B-02 (No.2 injector connector)
c. B-04 (No.3 injector connector) Connector: C-134
d. B-05 (No.4 injector connector)
NO : Repair.
STEP 10. Check injector itself. C-134

• Check Injector itself (Refer to P.13A-325).
YES : Go to Step 11 . 13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Replace injector. 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING
STEP 12. Check harness between B-17X engine STEP 13. Check harness between injector
control relay connector and injector connector. connector and C-134 engine-ECU connector.
Connector: B-17X Connector: B-01, B-02, B-04, B-05
Relay box’s B-17X
triangle marks
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
2 1
4 3
M
Harness side 2 1
Connector: B-01, B-02, B-04, B-05 Connector: C-134
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
C-134
M
2 1
a. Check harness between B-17X (terminal No. 1) 13 12 11 10 9 8 7 6 5 4 3 2 1

engine control relay connector and B-01 (terminal 26 25 24 23 22 21 20 19 18 17 16 15 14
No. 1) No. 1 injector connector. Harness side connector

b. Check harness between B-17X (terminal No. 1) AK300257 AC
engine control relay connector and B-02 (terminal
No. 1) No. 2 injector connector. a. Check harness between B-01 (terminal No. 2)
No. 1injector connector and C-134 (terminal No.
c. Check harness between B-17X (terminal No. 1)
No. 1) No. 3 injector connector. b. Check harness between B-02 (terminal No. 2)
No. 2 injector connector and C-134 (terminal No.
d. Check harness between B-17X (terminal No. 1)
No. 1) No. 4 injector connector. c. Check harness between B-04 (terminal No. 2)
• Check power supply line for damage. No. 3 injector connector and C-134 (terminal No.
Q: Are the check results normal? d. Check harness between B-05 (terminal No. 2)
NO : Repair.
NO : Repair.
STEP 14. Fuel pressure measurement.

• Fuel pressure measurement (Refer to
P.13A-316).
YES : Repair.
NO : Replace engine-ECU
TROUBLESHOOTING
13A-61
Code No. P0130: Oxygen Sensor (Front) System <sensor 1>
Oxygen sensor (front) circuit
B-121
MU802605

1 2
3 4
1 3 2 4
From Engine control relay
To engine-ECU
B
2
B W J/C (2)
C-17
92 76 1
B
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
Wire colour code
AK401027 AB

Check Condition
(terminal No. 76) from the oxygen sensor output
• Above 3 minutes later after the engine has
terminal (terminal No. 4).
started up.
• The oxygen sensor (terminal No. 2) is earthed
• The engine coolant temperature approximately
with engine-ECU (terminal No. 92).
82°C or more.
FUNCTION • The engine speed is 1,200 r/min or more.
• The volumetric efficiency 25% or more.
• The oxygen sensor converts the concentration of
• The monitoring time is 5 seconds.
oxygen in the exhaust emission into a voltage
and inputs the signal to the engine-ECU. Judgment Criteria
• When the air-fuel ratio is richer than the theoreti- • When the oxygen sensor (front) output voltage is
cal air-fuel ratio, the oxygen sensor outputs a 0.2 V or less and a power voltage of 5 V is
voltage of about 1 V. When it is leaner than the applied to the oxygen sensor (front) in the
theoretical air-fuel ratio, it outputs a voltage of engine-ECU, the sensor output voltage is 4.5 V or
about 0 V. more.
• In response to the signal, the engine-ECU con- Check Condition
trols the fuel infection amount so that the air-fuel • The engine speed is 1,000 − 3,000 r/min.
ratio can be equivalent to the theoretical air-fuel • During the air-fuel ratio feedback control
ratio.
TROUBLESHOOTING
Judgment Criteria STEP 3. Perform resistance measurement at

• When the oxygen sensor (front) output frequency B-121 oxygen sensor (front) connector.
is 6 or less for 10 seconds on the average.
Connector: B-121
PROBABLE CAUSE Oxygen sensor (front)
• Failed oxygen sensor
• Open/short circuit in oxygen sensor (front) circuit B-121 (B)
or loose connector contact
2 1
DIAGNOSIS PROCEDURE 4 3
Harness side connector AK300264 AC
side.
a. Item 11: Oxygen sensor (front)
Q: Is the check result normal? OK: Continuity (2 Ω or less)
00 − How to Use Q: Is the check result normal?
Troubleshooting/Inspection Service Points YES : Go to Step 7 .
NO : Go to Step 4 .
P.00-6).
NO : Go to Step 2 .
STEP 2. Connector check: B-121 oxygen sensor connector
(front) connector Connector: C-137
Connector: B-121
B-121 (B)
C-137
2 1
4 3
Harness side connector AK300264 AC 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Q: Is the check result normal? Harness side connector

NO : Repair.
TROUBLESHOOTING
13A-63
No. 2) oxygen sensor (front) connector and C-137 • Refer to Data list reference table P.13A-293.
(terminal No. 92) engine-ECU connector. a. Item 11: Oxygen sensor (front)
Oxygen sensor (front) YES : Intermittent malfunction (Refer to GROUP
00 − How to Use
B-121 (B) Troubleshooting/Inspection Service Points
P.00-6).
2 1
4 3 STEP 7. Perform voltage measurement at B-121
Harness side connector oxygen sensor (front) connector.
AK300264 AC
Connector: B-121
Connector: C-137 Oxygen sensor (front)
B-121 (B)
2 1
4 3
C-137
• Use special tool test harness (MD998464) to con-

8180 79 78 77 76 75 74 73 72 71 nect connector, and measure at pick-up harness.
92 91 90 89 88 87 86 85 84 83 82
• Engine: After warm-up
AK300254 AC • Voltage between terminal No. 2 and earth.
• Check earthing line for open circuit and damage. OK: 0.5 V or less
Q: Is the check result normal? Q: Is the check result normal?

YES : Go to Step 6 . YES : Go to Step 9 .
NO : Repair. NO : Go to Step 8 .
TROUBLESHOOTING
connector oxygen sensor (front) connector.
B-121 (B)
2 1
C-137
4 3
8180 79 78 77 76 75 74 73 72 71 • Use special tool test harness (MD998464) to con-

92 91 90 89 88 87 86 85 84 83 82 nect connector, and measure at pick-up harness.
Harness side connector • Engine: After warm-up
AK300254 AC
OK:
Connector: B-121 600 − 1,000 mV when 200 mV or lower abrupt
Oxygen sensor (front) racing is done a few seconds after abrupt
deceleration from 4,000 r/min.
B-121 (B)
2 1
4 3 STEP 10. Check oxygen sensor (front) itself
Harness side connector AK300264 AC • Check oxygen sensor (front) itself (Refer to
P.13A-323).
YES : Check and repair harness between B-121 Q: Is the check result normal?
(terminal No. 2) oxygen sensor (front)
NO : Repair.
TROUBLESHOOTING
13A-65
connector engine-ECU connector.
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

Connector: B-121
B-121 (B)
OK:
600 − 1,000 mV when 200 mV or lower abrupt
racing is done a few seconds after abrupt
2 1 deceleration from 4,000 r/min.
4 3
Harness side connector AK300264 AC YES : Go to Step 14 .
NO : Repair.
TROUBLESHOOTING
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

Oxygen sensor (front) YES : Go to Step 6 .
NO : Repair.
B-121 (B)
2 1
4 3

NO : Repair.
TROUBLESHOOTING
13A-67
Code No. P0135: Oxygen Sensor Heater (Front) System <Sensor 1>
Oxygen sensor (front) heater circuit
Battery
W-B
W-B
4 3 Oxygen sensor (front)

B-17X
B-121
Engine MU8026053
1 2
control
3 4 relay 1 2
3 4
1 2
To engine-ECU 1 3 2 4
To engine-ECU
R
Y-R
60
C-136
51 52 53 54 55 56
Engine-ECU
57 58 59 60 61 62
Wire colour code

AK401028 AB
OPERATION FUNCTION
• Power is supplied to the heater power terminal • The power supply to the oxygen sensor heater
(terminal No. 1) of the oxygen sensor (front) con- (front) is controlled by the ON/OFF control of the
nector from the engine control relay (terminal No. power transistor in the engine-ECU.
1). • Heating the oxygen sensor heater (front) enables
• The heater (terminal No. 3) of the oxygen sensor the oxygen sensor to provide good response
(front) connector is controlled by the power tran- even when the exhaust emission temperature is
sistor in the engine-ECU (terminal No. 60). low.
TROUBLESHOOTING
TROUBLE JUDGMENT STEP 2. Perform resistance measurement at

Check Conditions B-121 oxygen sensor (front) connector.
• The engine coolant temperature is approximately. Connector: B-121
20°C or higher. Oxygen sensor (front)
• The oxygen sensor heater (front) is in "ON" posi-
tion. B-121 (B)
• The engine speed is 50 r/min or more.
• The battery voltage is 11 − 16 V.
Judgment Criteria 2 1
• The heater current of oxygen sensor heater 4 3
(front) is below 0.15 A or above 7.5 A for 1 sec-
ond. AK300264 AC
• Disconnect connector, and measure at sensor

PROBABLE CAUSE side.
• Failed oxygen sensor heater • Resistance between terminal No. 1 and No. 3.
• Open/short circuit in oxygen sensor (front) circuit OK: 4.5 − 8.0 Ω
• Failed engine-ECU Q: Is the check result normal?
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-121 oxygen sensor oxygen sensor (front) connector.
(front) connector
Connector: B-121
Connector: B-121
B-121 (B)
B-121 (B)
2 1
2 1
4 3
4 3
Q: Is the check result normal? side.
YES : Go to Step 2 . • Ignition switch: ON
NO : Repair. • Voltage between terminal No. 1 and earth.
OK: System voltage
NO : Go to Step 4 .
TROUBLESHOOTING
13A-69
STEP 4. Connector check: B-17X engine control STEP 5. Perform voltage measurement at C-136
relay connector engine-ECU connector.
Relay box’s B-17X
triangle marks
2 1
4 3 C-136
Harness side
56 55 54 53 52 51
Connector: B-121 62 61 60 59 58 57
Oxygen sensor (front) Harness side connector
B-121 (B) AK300268 AC

2 1 • Voltage between terminal No. 60 and earth.
4 3 OK: System voltage
Harness side connector AK300264 AC Q: Is the check result normal?
Q: Is the check result normal? NO : Go to Step 6 .
(terminal No. 1) oxygen sensor connector
and B-17X (terminal No. 1) engine control STEP 6. Connector check: C-136 engine-ECU
relay connector. connector
• Check power supply line for Connector: C-136
open/short circuit.
NO : Repair.
C-136
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AC

NO : Repair.
TROUBLESHOOTING
No. 3) oxygen sensor (front) connector and C-136 connector
Connector: C-136
Connector: B-121
B-121 (B)
C-136
2 1
4 3
56 55 54 53 52 51
62 61 60 59 58 57
Connector: C-136
AK300268 AC

NO : Repair.
C-136
No. 1) oxygen sensor (front) connector and
56 55 54 53 52 51
B-17X (terminal No. 1) engine control relay
62 61 60 59 58 57 connector.
Harness side connector Connector: B-121
AK300268 AC Oxygen sensor (front)
• Check earthing line for open/short circuit. B-121 (B)

YES : Replace engine-ECU.
NO : Repair.
2 1
4 3
Connector: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
13A-71
STEP 10. Check harness between B-121 (terminal STEP 11. Check the trouble symptoms.
No. 3) oxygen sensor (front) connector and C-136 Q: Does trouble symptom persist?
(terminal No. 60) engine-ECU connector. YES : Replace engine-ECU.
Connector: B-121 NO : Intermittent malfunction (Refer to GROUP
Oxygen sensor (front) 00 − How to Use
B-121 (B) P.00-6).
2 1
4 3
Connector: C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AC

NO : Repair.
TROUBLESHOOTING
Code No. P0136: Oxygen Sensor (Rear) System <Sensor 2>
Oxygen sensor (rear) circuit
C-18
MU801688
1 2 Oxygen sensor (rear)

3 4
2 1 3 4
From engine control relay
To engine-ECU B
3
P L
J/C (2)
C-17
92 75 1
B
C-137
71 72 73 74 75 76 77 78 79 80 81
82 83 84 85 86 87 88 89 90 9192
Engine-ECU
Wire colour code
AK401029 AB

Check Conditions
(terminal No. 75) from the oxygen sensor (rear)
output terminal (terminal No. 4).
started up.
• The oxygen sensor (rear) (terminal No. 3) is
• The engine coolant temperature is approximately.
earthed with engine-ECU (terminal No. 92).
82°C or higher.
FUNCTION • The engine speed is 1,200 r/min or more.
• The volumetric efficiency is 25% or more.
• The oxygen sensor (rear) converts the concentra-
tion of oxygen in the exhaust emission into a volt-
age signal and inputs the voltage signal to the Judgment Criteria
engine-ECU. • When the oxygen sensor (rear) output voltage is
• When the air-fuel ratio is richer than the theoreti- 0.15 V or less and a power voltage of 5 V is
cal air-fuel ratio, the oxygen sensor (rear) outputs applied to the oxygen sensor (rear) in the
a voltage of about 1 V. When it is leaner than the engine-ECU, the sensor output voltage is 4.5 V or
theoretical air-fuel ratio, it outputs a voltage of more.
about 0 V.
• In response to the signal, the engine-ECU con- PROBABLE CAUSE
trols the fuel infection amount so that the air-fuel • Failed oxygen sensor
ratio can be equivalent to the theoretical air-fuel • Open/short circuit in oxygen sensor (rear) circuit
ratio. or loose connector contact
TROUBLESHOOTING
13A-73
DIAGNOSIS PROCEDURE STEP 3. Perform resistance measurement at C-18
oxygen sensor (rear) connector.
STEP 1. M.U.T.-II/III data list Connector: C-18
a. Item 59: Oxygen sensor (rear) 1 2
3 4
YES : Intermittent malfunction (Refer to GROUP Harness side
connector
00 − How to Use
Troubleshooting/Inspection Service Points C-18
P.00-6).
NO : Go to Step 2 .
Oxygen sensor (rear)
STEP 2. Connector check: C-18 oxygen sensor

(rear) connector
Connector: C-18
AK300270 AB
1 2
3 4
side.
Harness side • Resistance between terminal No. 3 and earth.
connector
C-18
Oxygen sensor (rear) NO : Go to Step 4 .

connector
Connector: C-137
AK300270 AB

NO : Repair.
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

NO : Repair.
TROUBLESHOOTING
STEP 5. Check harness between C-18 (terminal STEP 6. M.U.T.-II/III data list
No. 3) oxygen sensor (rear) connector and C-137 • Refer to Data list reference table P.13A-293.
(terminal No. 92) engine-ECU connector. a. Item 59: Oxygen sensor (rear)
Connector: C-18 Q: Is the check result normal?
1 2 00 − How to Use
3 4 Troubleshooting/Inspection Service Points
Harness side P.00-6).
connector
C-18
Oxygen sensor (rear) oxygen sensor (rear) connector.
Connector: C-18
1 2
3 4
AK300270 AB Harness side

connector
Connector: C-137 C-18
C-137
AK300270 AB

8180 79 78 77 76 75 74 73 72 71 nect connector, and measure at pick-up harness.
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC • Voltage between terminal No. 3 and earth.

TROUBLESHOOTING
13A-75
connector oxygen sensor (rear) connector.
1 2
3 4
Harness side
connector
C-18
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC
AK300270 AB
Connector: C-18 • Use special tool test harness (MB991658) to con-

1 2 • Engine: After warm-up
Harness side OK:
connector
C-18 racing is done a few seconds after abrupt
Oxygen sensor (rear) Q: Is the check result normal?
STEP 10. Check oxygen sensor (rear) itself.

AK300270 AB • Check oxygen sensor (rear) itself (Refer to
P.13A-323).
YES : Check and repair harness between C-18 Q: Is the check result normal?
NO : Replace oxygen (rear) sensor.
connector.
NO : Repair.
TROUBLESHOOTING
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

Connector: C-18
1 2 • Engine: After warm-up
Harness side OK:
connector 600 − 1,000 mV when 200 mV or lower abrupt
C-18
AK300270 AB

YES : Check and repair harness between C-18
connector.
NO : Repair.
TROUBLESHOOTING
13A-77
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

1 2 NO : Repair.
3 4
Harness side
connector
C-18
AK300270 AB

(terminal No. 4) oxygen sensor (rear)
NO : Repair.
TROUBLESHOOTING
Code No. P0141: Oxygen Sensor Heater (Rear) System <Sensor 2>
Oxygen sensor (rear) heater circuit
Battery
W-B
W-B

B-17X
1 2 Engine C-18
control MU801688
3 4 relay
1 2
3 4
1 2
R
R To engine-ECU
4
J/C (2)
C-17
11
Y-L
54
C-136
51 52 53 54 55 56 Engine-ECU
57 58 59 60 61 62
Wire colour code

AK401030 AB
OPERATION FUNCTION
(terminal No. 2) of the oxygen sensor (rear) con- (rear) is controlled by the ON/OFF control of the
1). • Heating the oxygen sensor heater (rear) enables
(rear) connector is controlled by the power tran- even when the exhaust emission temperature is
TROUBLESHOOTING
13A-79
TROUBLE JUDGMENT STEP 2. Perform resistance measurement at C-18
Check Conditions oxygen sensor (rear) connector.
• The engine coolant temperature is approximately. Connector: C-18
20 °C or higher.
• The oxygen sensor heater (rear) is in "ON" posi- 1 2
tion. 3 4
• The engine speed is 50 r/min or more. Harness side
• The battery voltage is 11 − 16 V. connector
Judgment Criterion C-18

• The heater current of front oxygen sensor heater
(rear) is below 0.15 A or above 5.0 A for 6 sec- Oxygen sensor (rear)
onds.
PROBABLE CAUSE
• Failed oxygen sensor heater (rear)
• Open/short circuit in oxygen sensor (rear) circuit
or loose connector contact AK300270 AB
• Failed engine-ECU • Disconnect connector, and measure at sensor

side.
DIAGNOSIS PROCEDURE • Resistance between terminal No. 1 and No. 2.
OK: 11 − 18 Ω
STEP 1. Connector check: C-18 oxygen sensor Q: Is the check result normal?
(rear) connector YES : Go to Step 3 .
Connector: C-18
1 2 STEP 3. Perform voltage measurement at C-18

3 4 oxygen sensor (rear) connector.
Harness side
connector Connector: C-18
C-18 1 2
3 4
Harness side
Oxygen sensor (rear) connector
C-18

AK300270 AB

NO : Repair.
AK300270 AB

side.
OK: System voltage
NO : Go to Step 4 .
TROUBLESHOOTING
C-137 C-136
8180 79 78 77 76 75 74 73 72 71 56 55 54 53 52 51
92 91 90 89 88 87 86 85 84 83 82 62 61 60 59 58 57
AK300254 AC AK300268 AC

Connector: C-18
3 4 OK: System voltage
Harness side Q: Is the check result normal?
connector
C-18 NO : Go to Step 6 .
Oxygen sensor (rear) STEP 6. Connector check: C-136 engine-ECU

connector
Connector: C-136
AK300270 AB

repair if necessary. If intermediate C-136
harness between C-18 (terminal No. 2)
oxygen sensor (rear) connector and B-17X
56 55 54 53 52 51
(terminal No. 1) engine control relay 62 61 60 59 58 57
connector.
open/short circuit. AK300268 AC
NO : Repair.
NO : Repair.
TROUBLESHOOTING
13A-81
STEP 7. Check harness between C-18 (terminal STEP 8. Connector check: C-136 engine-ECU
No. 1) oxygen sensor connector and C-136 connector
Connector: C-136
Connector: C-18
1 2
3 4
Harness side
connector
C-18 C-136

56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AC
AK300270 AB
Connector: C-136
NO : Repair.
C-136
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AC
• Check earthing line for open/short circuit.

NO : Repair.
TROUBLESHOOTING
STEP 9. Check harness between C-18 (terminal STEP 10. Check harness between C-18 (terminal
No. 2) oxygen sensor connector and B-17X No. 1) oxygen sensor connector and C-136
1 2 1 2
3 4 3 4
Harness side Harness side
connector connector
C-18 C-18
Oxygen sensor (rear) Oxygen sensor (rear)
AK300270 AB AK300270 AB

Relay box’s B-17X
triangle marks
2 1
4 3 C-136
Harness side
NOTE: Before checking harness, check intermediate 56 55 54 53 52 51

62 61 60 59 58 57
• Check power supply line for damage. Harness side connector
Q: Is the check result normal? AK300268 AC
YES : Go to Step 10 . • Check earthing line for damage.

NO : Repair.
NO : Repair.
STEP 11. Check the trouble symptoms.

Q: Does trouble symptom persist?
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use
P.00-6).
TROUBLESHOOTING
13A-83
Code No. P0170: Abnormal Fuel System
OPERATION STEP 2. M.U.T.-II/III data list

• Refer to P0201 injector circuit P.13A-87. • Refer to Data list reference table P.13A-293.
• Refer to P0202 injector circuit P.13A-92. a. Item 12: Air flow sensor
• Refer to P0203 injector circuit P.13A-97. b. Item 13: Intake air temperature sensor
• Refer to P0204 injector circuit P.13A-102.
c. Item 21: Engine coolant temperature sensor
FUNCTION d. Item 25: Barometric pressure sensor
• If the fuel system goes out of order, the fuel cor- Q: Are the check results normal?
rection value will become larger. YES : Go to Step 3 .
• The engine-ECU checks whether the fuel correc- NO : Perform the diagnosis code classified check
tion value is within the standard limits. procedure for the sensor that has shown an
abnormal data value (Refer to Inspection
TROUBLE JUDGMENT Chart for Diagnosis Codes P.13A-15).
Check Conditions
• In learning air-fuel ratio STEP 3. Check for intake of air from intake hose
and inlet manifold.
Judgment Criteria
• The compensation value of fuel injection amount Q: Is the check result normal?
is too low for 2 seconds or more. YES : Go to Step 4 .
Or NO : Repair.
• The compensation value of fuel injection amount
is too high for 2 seconds or more. STEP 4. Check for leakage of exhaust emission
from exhaust manifold.
PROBABLE CAUSE
• Failed fuel supply system
• Failed oxygen sensor (front) NO : Repair.
• Failed intake air temperature sensor
• Failed purge control solenoid valve STEP 5. Check throttle body (throttle valve
• Failed engine-ECU portion) for contamination.
DIAGNOSIS PROCEDURE YES : Go to Step 6 .
STEP 1. M.U.T.-II/III diagnosis code
Q: Is any other diagnosis code than P0170 output?
to P.13A-15). • Refer to Data list reference table P.13A-293.
NO : Go to Step 2 . a. Item 11: Oxygen sensor (front).
NO : Check oxygen sensor (front) system (Refer
toP.13A-61, Code No. P0130).
TROUBLESHOOTING
STEP 7. Connector Check: Injector connector STEP 9. Connector check: B-17X engine control
relay connector and B-134 engine-ECU
Connector: B-01, B-02, B-04, B-05
connector
Connector: B-17X
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR) Relay box’s B-17X
triangle marks
M 2 1
2 1
Harness side
a. B-01 (No.1 injector connector). connector AK300255 AC
b. B-02 (No.2 injector connector).
c. B-04 (No.3 injector connector). Connector: C-134
d. B-05 (No.4 injector connector).
NO : Repair.
STEP 8. Check injector itself. C-134

YES : Go to Step 9 . 13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Replace injector. 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING
13A-85
Connector: B-01, B-02, B-04, B-05 Connector: B-01, B-02, B-04, B-05
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR) B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
M M
2 1 2 1

Relay box’s B-17X
triangle marks
2 1
4 3 C-134
Harness side
a. Check harness between B-17X (terminal No. 1) 13 12 11 10 9 8 7 6 5 4 3 2 1

engine control relay connector and B-01 (terminal 26 25 24 23 22 21 20 19 18 17 16 15 14

b. Check harness between B-17X (terminal No. 1) AK300257 AC
c. Check harness between B-17X (terminal No. 1)
Q: Are the check results normal? d. Check harness between B-05 (terminal No. 2)
NO : Replace.
NO : Replace.
TROUBLESHOOTING
STEP 12. Check purge control solenoid valve STEP 13. Fuel pressure measurement.
itself. • Fuel pressure measurement (Refer to
• Check purge control solenoid valve itself (Refer P.13A-316).
to GROUP 17 − Emission Control System −
Evaporative Emission Control System P.17-65).
Q: Is the check result normal? NO : Repair.
NO : Replace purge control solenoid valve.
TROUBLESHOOTING
13A-87
Code No. P0201: No. 1 Injector System
Injector circuit
Battery
W-B
W-B
4 3
B-17X
1 2
Engine control relay
3 4
1 2
R
To engine-ECU
R R R R
Injector Injector Injector Injector

No. 1 1 No. 2 1 No. 3 1 No. 4 1
B-01 B-02 B-04 B-05
(MU802062) (MU802062) (MU802062) (MU802062)
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 14 2 15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code
AK401031 AB
OPERATION
• Power is supplied to the injector (terminal No. 1)
from the engine control relay (terminal No. 1).
TROUBLESHOOTING
• The engine-ECU (terminal No. 1) makes the STEP 2. Connector check: B-01 No. 1 injector
power transistor in the unit be in "ON" position, connector
and that makes currents go on the injector (termi-
nal No. 2). Connector: B-01
FUNCTION
• The engine-ECU controls the power supply inter- B-01 (GR)
val of the injector.
• The fuel injection amount of the injector depends
on the power supply interval.
M
TROUBLE JUDGMENT 2 1
Check Conditions
• The engine speed is 50 − 8,000 r/min. Q: Is the check result normal?
• The throttle position sensor output voltage is 5 V YES : Go to Step 3 .
or less. NO : Repair.
• Injector not in forced drive (actuator test) mode
Judgment Criterion STEP 3. Perform resistance measurement at B-01
• No surge voltage of the injector coil is detected No. 1 injector connector.
for 2 seconds.
Connector: B-01
PROBABLE CAUSE
• Failed No. 1 injector
• Open/short circuit in injector circuit or loose con- B-01 (GR)
nector contact
M
STEP 1. M.U.T.-II/III actuator test • Disconnect connector, and measure at injector

• Refer to Actuator test reference table list side.
P.13A-299. • Resistance between terminal No. 1 and No. 2.
a. Item 01: No. 1 injector OK: 10.5 − 13.5 Ω
OK: Idling state varies. Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 4 .
YES : Intermittent malfunction (Refer to GROUP NO : Replace No. 1 injector.
00 − How to Use
P.00-6).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-89
STEP 4. Perform voltage measurement at B-01 STEP 5. Connector check: B-17X engine control
No. 1 injector connector. relay connector
Connector: B-01 CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
B-01 (GR)
2 1
4 3
M
2 1 Harness side
connector AK300255 AB

Connector: B-01
side.
B-01 (GR)
OK: System voltage
NO : Go to Step 5 . M
2 1

YES : Check and repair harness between B-17X
(terminal No. 1) engine control relay
connector and B-01 (terminal No. 1) No. 1
injector connector.
open/short circuit.
NO : Repair.

relay connector
CONNECTOR: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
STEP 7. Check harness between B-17X (terminal STEP 9. Check harness between B-01 (terminal
No. 1) engine control relay connector and B-01 No. 2) No.1 injector connector and C-134
(terminal No. 1) No. 1 injector connector. (terminal No. 1) engine-ECU connector.
CONNECTOR: B-17X Connector: B-01
Relay box’s B-17X
triangle marks
B-01 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AB Harness side connector AK300265 AC
Connector: B-01 CONNECTOR: C-134
B-01 (GR)
C-134
M
2 1
• Check power supply line for damage. 13 12 11 10 9 8 7 6 5 4 3 2 1

26 25 24 23 22 21 20 19 18 17 16 15 14
NO : Repair. AK300257 AB
• Check output line for open/short circuit and dam-

STEP 8. Connector check: C-134 engine-ECU age.
connector
CONNECTOR: C-134 YES : Go to Step 10 .
NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB

NO : Repair.
TROUBLESHOOTING
13A-91
STEP 10. Perform signal wave pattern
measurement at C-134 engine-ECU connector
(Using an oscilloscope).
CONNECTOR: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AB
• Engine: Idling
OK: Waveforms should be display on
Inspection procedure using an oscilloscope
00 − How to Use
P.00-6).
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
4 3
B-17X
1 2
3 4
1 2
R
To engine-ECU
R R R R

No. 1 1 No. 2 1 No. 3 1 No. 4 1
B-01 B-02 B-04 B-05
(MU802062) (MU802062) (MU802062) (MU802062)
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 14 2 15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code
AK401031 AB
TROUBLESHOOTING
13A-93
OPERATION STEP 2. Connector check: B-02 No. 2 injector
• Power is supplied to the injector (terminal No. 1) connector
• The engine-ECU (terminal No. 14) makes the Connector: B-02
power transistor in the unit be in "ON" position,
nal No. 2). B-02 (GR)
FUNCTION
• The engine-ECU controls the power supply inter-
val of the injector. M
2 1
Harness side connector AK300265 AD
TROUBLE JUDGMENT YES : Go to Step 3 .
Check Conditions NO : Repair.
• The engine speed is 50 − 8,000 r/min.
• The throttle position sensor output voltage 5 V or STEP 3. Perform resistance measurement at
less. resistance B-02 No. 2 injector connector.
Connector: B-02
Judgment Criterion
• No surge voltage of the injector coil is detected
for 2 seconds.
B-02 (GR)
PROBABLE CAUSE
• Open/short circuit in No. 2 injector circuit or loose
M
connector contact 2 1
• Failed engine-ECU Harness side connector AK300265 AD
• Disconnect connector, and measure at injector

DIAGNOSIS PROCEDURE side.
STEP 1. M.U.T.-II/III actuator test OK: 10.5 − 13.5 Ω
• Refer to Actuator test reference table list
P.13A-299. YES : Go to Step 4 .
a. Item 02: No. 2 injector NO : Replace No. 2 injector.
OK: Idling state varies.
00 − How to Use
P.00-6).
NO : Go to Step 2 .
TROUBLESHOOTING
Connector: B-02 Connector: B-17X
Relay box’s B-17X

triangle marks
B-02 (GR)
2 1
4 3
M
2 1 Harness side

Connector: B-02
side.
B-02 (GR)
OK: System voltage
2 1

injector connector.
open/short circuit and damage.
NO : Repair.

relay connector
Connector: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
13A-95
No. 1) engine control relay connector and B-02 No. 2) No. 2 injector connector and C-134
Relay box’s B-17X
triangle marks
B-02 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AC Harness side connector AK300265 AD
B-02 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

connector
Connector: C-134 YES : Go to Step 10 .
NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING

Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC
• Engine: Idling
OK: Waveform should be display on Inspec-
tion procedure using an oscilloscope (Refer
to P.13A-305).
00 − How to Use
P.00-6).
TROUBLESHOOTING
13A-97
Injector circuit
Battery
W-B
W-B
4 3
B-17X
1 2
3 4
1 2
R
To engine-ECU
R R R R

No. 1 1 No. 2 1 No. 3 1 No. 4 1
B-01 B-02 B-04 B-05
(MU802062) (MU802062) (MU802062) (MU802062)
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 14 2 15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code
AK401031 AB
TROUBLESHOOTING

nal No. 2). B-04 (GR)
FUNCTION
2 1
Harness side connector AK300265 AE
• The throttle position sensor output voltage is 5 V STEP 3. Perform resistance measurement at B-04
or less. No. 3 injector connector.
Connector: B-04
Judgment Criterion
for 2 seconds.
B-04 (GR)
PROBABLE CAUSE
M
• Failed engine-ECU Harness side connector AK300265 AE

00 − How to Use
P.00-6).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-99
Relay box’s B-17X

triangle marks
B-04 (GR)
2 1
4 3
M
2 1 Harness side

Connector: B-04
side.
B-04 (GR)
OK: System voltage
2 1

injector connector.
open/short circuit.
NO : Repair.

relay connector
Connector: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
Relay box’s B-17X
triangle marks
B-04 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AC Harness side connector AK300265 AE
B-04 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

connector
NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING
13A-101
Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC
• Engine: Idling
to P.13A-305).
00 − How to Use
P.00-6).
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
4 3
B-17X
1 2
3 4
1 2
R
To engine-ECU
R R R R

No. 1 1 No. 2 1 No. 3 1 No. 4 1
B-01 B-02 B-04 B-05
(MU802062) (MU802062) (MU802062) (MU802062)
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 14 2 15
Engine-ECU
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code
AK401031 AB
TROUBLESHOOTING
13A-103
nal No. 2). B-05 (GR)
FUNCTION
2 1
Harness side connector AK300265 AF
• The throttle position sensor output voltage is 5 V STEP 3. Perform resistance measurement at B-05
or less. No. 4 injector connector.
Connector: B-05
Judgment Criterion
for 2 seconds
B-05 (GR)
PROBABLE CAUSE
M
• Failed engine-ECU Harness side connector AK300265 AF

00 − How to Use
P.00-6).
NO : Go to Step 2 .
TROUBLESHOOTING
Relay box’s B-17X

triangle marks
B-05 (GR)
2 1
4 3
M
2 1 Harness side

Connector: B-05
side.
B-05 (GR)
OK: System voltage
2 1

injector connector.
open/short circuit and damage.
NO : Repair.

relay connector
Connector: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

YES : Go to Step 7.
NO : Repair.
TROUBLESHOOTING
13A-105
Relay box’s B-17X
triangle marks
B-05 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AC Harness side connector AK300265 AF
B-05 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

connector
NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING

Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC
• Engine: Idling
to P.13A-305).
00 − How to Use
P.00-6).
Code No. P0300: Random cylinder mis-fire detected
OPERATION • The engine coolant temperature is −10°C or

• Refer to P0201 injector circuit P.13A-87. higher.
• Refer to P0202 injector circuit P.13A-92. • The intake air temperature is −10°C or higher.
• Refer to P0203 injector circuit P.13A-97. • The barometric pressure is 72 kPa or more.
• Refer to P0204 injector circuit P.13A-102. • The volumetric efficiency is 30 − 55%.
• The adaptive learning has been completed with
FUNCTION the vane that generates the crankshaft position
• If a misfire occurs while the engine is running, the signals.
engine speed changes for an instant. • During the engine operation except the shift
• The engine-ECU checks for such changes in change or low speed driving and rapid accelera-
engine speed. tion and deceleration, also intermittent operation
of air compressor (A/C: within the 3 seconds after
TROUBLE JUDGMENT changing to ON from OFF or to OFF from ON).
• The throttle deviation is within the range of
Check Conditions −0.059 V/10ms to 0.059 V/10ms.
• 5 seconds later after the engine has started up.
TROUBLESHOOTING
13A-107
Judgment Criteria STEP 3.Check ignition secondary voltage
• The number of misfiring (in the catalyst tempera- waveform using an oscilloscope.
ture of above 950°C) is beyond the specified • Check ignition secondary voltage waveform
number (of 4.5% on more than the two cylinders) (Refer to GROUP 16 − Ignition System −
with the engine speed of 200 r/min. On-vehicle Service P.16-41)
Or
• The number of misfiring (that is 1.5 times the Q: Is the check result normal?
emission standard limit) is beyond the specified YES : Go to Step 4 .
number (of 2% on more than the two cylinders) NO : Check ignition circuit system (Refer to
with the engine speed of 1000 r/min. Inspection procedure 30 P.13A-286).
PROBABLE CAUSE STEP 4.Connector check: Injector connector

• Ignition system related part(s) failed
Connector: B-01, B-02, B-04, B-05
• Failed crank angle sensor
• Incorrect air-fuel ratio
• Low compression pressure
• Failed coolant temperature sensor B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
• Skipping of timing belt teeth.
• EGR system and EGR valve failed
M
2 1
DIAGNOSIS PROCEDURE Harness side connector AK300265 AB
a. B-01 (No.1 injector connector)

STEP 1.M.U.T.-II/III data list
• Item 22: Crank angle sensor
c. B-04 (No.3 injector connector)
OK: Keep the engine speed constant to make
the pulse width of output waveform con-
stant. Q: Are the check results normal?
NO : Check crank angle sensor system (Refer to
Code No. P0335 P.13A-124). STEP 5.Check injector itself.
STEP 2.M.U.T.-II/III data list Q: Is the check result normal?
• Refer to Data list reference table P.13A-293. YES : Go to Step 6 .
a. Item 21: Engine coolant temperature sensor NO : Replace injector.
b. Item 81: Long-term fuel compensation
c. Item 82: Short-term fuel compensation
NO : Perform the diagnosis code classified check
procedure for the sensor that has shown an
abnormal data valve (Refer to, Inspection
Chart for Diagnosis Codes P.13A-15).
TROUBLESHOOTING
STEP 6.Connector check: B-17X engine control STEP 7. Check harness between B-17X engine
relay connector and C-134 engine-ECU control relay connector and injector connector.
connector
Connector: B-17X
Connector: B-17X B-17X
Relay box’s
Relay box’s B-17X triangle marks
triangle marks
2 1
2 1 4 3
4 3 Harness side
Connector: B-01, B-02, B-04, B-05
Connector: C-134
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
M
C-134 2 1
a. Check harness between B-17X (terminal No. 1)

13 12 11 10 9 8 7 6 5 4 3 2 1 engine control relay connector and B-01 (terminal
26 25 24 23 22 21 20 19 18 17 16 15 14 No. 1) No. 1 injector connector.
Harness side connector b. Check harness between B-17X (terminal No. 1)
AK300257 AC engine control relay connector and B-02 (terminal
No. 1) No. 2 injector connector.
Q: Is the check result normal? c. Check harness between B-17X (terminal No. 1)
YES : Go to Step 7 . engine control relay connector and B-04 (terminal
NO : Repair. No. 1) No. 3 injector connector.
NO : Repair.
TROUBLESHOOTING
13A-109
STEP 8. Check harness between injector STEP 9. Fuel pressure measurement.
connector and C-134 engine-ECU connector. • Fuel pressure measurement (Refer to fuel pres-
sure test P.13A-316)
Connector: B-01, B-02, B-04, B-05
NO : Repair.
B-01 (GR) B-02 (GR) B-04 (GR) B-05 (GR)
STEP 10. Check for intake of air from intake hose

and inlet manifold.
M
2 1 Q: Is the check result normal?
NO : Repair.
Connector: C-134
STEP 11. Check for skipped timing belt teeth.
NO : Repair.
C-134 STEP 12. Exhaust gas recirculation system

check.
• Exhaust gas recirculation system check [Refer to
GROUP 17 − Exhaust gas recirculation (EGR)
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 system P.17-70].
YES : Replace engine-ECU
AK300257 AC
NO : Repair.
a. Check harness between B-01 (terminal No. 2)
b. Check harness between B-02 (terminal No. 2)
c. Check harness between B-04 (terminal No. 2)
d. Check harness between B-05 (terminal No. 2)
NO : Repair.
TROUBLESHOOTING
Code No. P0301: No. 1 cylinder mis-fire detection system
OPERATION PROBABLE CAUSE

• Refer to P0201 injector circuit P.13A-87. • Ignition system related part(s) failed
FUNCTION • Failed engine-ECU
• If a misfire occurs while the engine is running, the
engine speed changes for an instant. DIAGNOSIS PROCEDURE
• The engine-ECU checks for such changes in
engine speed.
STEP 1.Check ignition secondary voltage
TROUBLE JUDGMENT waveform using an oscilloscope.
• Check ignition secondary voltage waveform
Check Conditions (Refer to GROUP 16 − Ignition System −
• 5 seconds later after the engine has started up. On-vehicle Service P.16-41)
• The engine coolant temperature is −10°C or
higher. NO : Check ignition Circuit System (Refer to
• The intake air temperature is −10°C or higher. Inspection procedure 30 P.13A-286)
• The barometric pressure is 72 kPa or more.
• The volumetric efficiency is 30 − 55%.
• The adaptive learning has been completed with STEP 2.Connector check: B-01 No.1 injector
the vane that generates the crankshaft position connector
signals. Connector: B-01
• During the engine operation except the shift
change or low speed driving and rapid accelera-
tion and deceleration, also intermittent operation
B-01 (GR)
changing to ON from OFF or to OFF from ON).
• The throttle deviation is within the range of
−0.059 V/10ms to 0.059 V/10ms.
M
2 1
Judgment Criteria
• The number of misfiring (in the catalyst tempera- AK300265 AC
ture of above 950°C) is beyond the specified Q: Is the check result normal?
number (of 4.5% on more than the two cylinders) YES : Go to Step 3 .
with the engine speed of 200 r/min. NO : Repair.
Or
• The number of misfiring (that is 1.5 times the
emission standard limit) is beyond the specified STEP 3.Check No.1 injector itself.
number (of 2% on more than the two cylinders) • Check Injector itself (Refer to P.13A-325).
with the engine speed of 1,000 r/min. Q: Is the check result normal?
NO : Replace No.1 injector.
TROUBLESHOOTING
13A-111
STEP 4.Connector check: B-17X engine control STEP 5.Check harness between B-17X (terminal
relay connector and B-134 engine-ECU No. 1) engine control relay connector and B-01
connector (terminal No. 1) No.1 injector connector.
Connector: B-17X Connector: B-17X
Relay box’s B-17X Relay box’s B-17X

triangle marks triangle marks
2 1 2 1
4 3 4 3
connector AK300255 AC connector AK300255 AC
B-01 (GR)
C-134
M
2 1
13 12 11 10 9 8 7 6 5 4 3 2 1 • Check power supply line for damage.

26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC NO : Repair.

NO : Repair.
TROUBLESHOOTING
STEP 6. Check harness between B-01(terminal STEP 7. Fuel pressure measurement.

No. 2) No.1 injector connector and C-134 • Fuel pressure measurement (Refer to fuel pres-
(terminal No. 1) engine-ECU connector sure test P.13A-316).
NO : Repair.
B-01 (GR)
M
2 1
Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
OPERATION • The engine coolant temperature is −10°C or

• Refer to P0202 injector circuit P.13A-92. higher.
• The intake air temperature is −10°C or higher.
FUNCTION • The barometric pressure is 72 kPa or more.
• If a misfire occurs while the engine is running, the • The volumetric efficiency is 30 − 55%.
engine speed changes for an instant. • The adaptive learning has been completed with
• The engine-ECU checks for such changes in the vane that generates the crankshaft position
engine speed. signals.
TROUBLE JUDGMENT change or low speed driving and rapid accelera-
Check Conditions of air compressor (A/C: within the 3 seconds after
• 5 seconds later after the engine has started up. changing to ON from OFF or to OFF from ON).
• The engine speed is 500 − 4,500 r/min. • The throttle deviation is within the range of −
0.059 V/10ms to 0.059 V/10ms.
TROUBLESHOOTING
13A-113
Judgment Criteria STEP 3.Check No.2 injector itself.
• The number of misfiring (in the catalyst tempera- • Check Injector itself (Refer to P.13A-325).
ture of above 950°C) is beyond the specified
number (of 4.5% on more than the two cylinders) Q: Is the check result normal?
with the engine speed of 200 r/min. YES : Go to Step 4 .
or NO : Replace No.2 injector.
emission standard limit) is beyond the specified STEP 4.Connector check: B-17X engine control
number (of 2% on more than the two cylinders) relay connector and B-134 engine-ECU
with the engine speed of 1,000 r/min. connector
PROBABLE CAUSE Connector: B-17X
• Ignition system related part(s) failed Relay box’s B-17X

• Low compression pressure triangle marks
4 3
STEP 1.Check ignition secondary voltage Harness side
waveform using an oscilloscope. connector AK300255 AC

(Refer to GROUP 16 − Ignition System − Connector: C-134
On-vehicle Service P.16-41)
NO : Check ignition circuit system (Refer to
Inspection procedure 30 P.13A-286).
C-134
STEP 2.Check connector: B-02 No.2 injector
connector
Connector: B-02 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
B-02 (GR) AK300257 AC

NO : Repair.
M
2 1

NO : Repair.
TROUBLESHOOTING
STEP 5.Check harness between B-17X (terminal STEP 6. Check harness between B-02 (terminal
No. 1) engine control relay connector and No. 2) No.2 injector connector and C-134
B-02(terminal No. 1) No.2 injector connector. (terminal No. 14) engine-ECU connector
Relay box’s B-17X
triangle marks
B-02 (GR)
2 1
4 3
M
Harness side 2 1
connector AK300255 AC Harness side connector AK300265 AD
B-02 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.

• Fuel pressure measurement (Refer to fuel pres-
sure test P.13A-316)
NO : Repair.
TROUBLESHOOTING
13A-115

engine speed.
higher. NO : Check ignition circuit system (Refer to
• The intake air temperature is −10°C or higher. Inspection procedure 30 P.13A-286).
B-04 (GR)
• The throttle deviation is within the range of −
0.059 V/10ms to 0.059 V/10ms.
M
• The number of misfiring (in the catalyst tempera- AK300265 AE

or
TROUBLESHOOTING
relay connector, B-134 engine-ECU connector No. 1) engine control relay connector and B-04
(terminal No. 1) No.3 injector connector.
Connector: B-17X
B-17X Connector: B-17X
Relay box’s
triangle marks Relay box’s B-17X
triangle marks
2 1
4 3 2 1
Harness side 4 3
connector AK300255 AC Harness side
Connector: C-134
Connector: B-04
B-04 (GR)
C-134
M
2 1
13 12 11 10 9 8 7 6 5 4 3 2 1
AK300257 AC YES : Go to Step 6 .
NO : Repair.
NO : Repair.
TROUBLESHOOTING
13A-117
STEP 6. Check harness between B-04 (terminal STEP 7. Fuel pressure measurement.
(terminal No. 2) engine-ECU connector sure test P.13A-316)
NO : Repair.
B-04 (GR)
M
2 1
Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING

engine speed.
STEP 1. Check ignition secondary voltage
higher. NO : Check ignition Circuit System (Refer to
• The intake air temperature is −10°C or higher. Inspection procedure 30 P.13A-286).
B-05 (GR)
• The throttle deviation is within the range of −
0.059 V/10ms to 0.059 V/10ms.
M
• The number of misfiring (in the catalyst tempera- AK300265 AF

or
TROUBLESHOOTING
13A-119
relay connector and B-134 engine-ECU No. 1) engine control relay connector and B-05
Relay box’s B-17X Relay box’s B-17X

2 1 2 1
4 3 4 3
B-05 (GR)
C-134
M
2 1

26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.
TROUBLESHOOTING
(terminal No. 15) engine-ECU connector. sure test P.13A-316)
NO : Repair.
B-05 (GR)
M
2 1
Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING
13A-121
Code No. P0325: Detonation Sensor System
Detonation sensor circuit
C-137
71 72 73 74 75 76 77 78 79 80 81 Engine-ECU
82 83 84 85 86 87 88 89 90 9192
78
B B
B B-102
MU802661
2 1 1 2
Detonation sensor
Wire colour code

AK401196 AB

Check Condition
(terminal No. 78) from the detonation sensor (ter-
• 2 seconds later after the engine has started up.
minal No. 1).
Judgment Criteria
FUNCTION • The change amount of the detonation sensor out-
• The detonation sensor detects the vibration of the put voltage (the detonation sensor peak voltage
cylinder block caused by detonation waves, and in every one third a turn of the crankshaft) is
inputs a signal to the engine-ECU. below 0.08 V in 200 consecutive times.
• In response to the signal, the engine-ECU pro-
vides controls to retard the ignition timing when
the detonation occurs.
TROUBLESHOOTING
PROBABLE CAUSE STEP 2. Perform resistance measurement at

• Failed detonation sensor B-102 detonation sensor connector.
• Open/short circuit in detonation sensor circuit or
Connector: B-102
loose connector contact
2 1
DIAGNOSIS PROCEDURE Harness side
connector
B-102 (GR)
STEP 1. Connector check: B-102 detonation
sensor connector
Connector: B-102
2 1
Harness side
connector
B-102 (GR)
Detonation sensor
Alternator
AK300274 AC

side.
Detonation sensor
Alternator YES : Go to Step 3 .
NO : Check and repair harness between B-102
AK300274 AC
(terminal No. 2) detonation sensor
Q: Is the check result normal? connector and body earth.
YES : Go to Step 2 . • Check earthing line for open circuit
NO : Repair. and damage.
TROUBLESHOOTING
13A-123
STEP 3. Connector check: C-137 engine-ECU Connector: C-137
connector
Connector: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 AK300254 AC
AK300254 AC age.
NO : Repair.
NO : Repair.
No. 1) detonation sensor connector and C-137 Q: Does trouble symptom persist?
(terminal No.78) engine-ECU connector. YES : Go to Step 6 .
Connector: B-102
00 − How to Use
2 1
P.00-6).
Harness side
connector
B-102 (GR) STEP 6. Replace detonation sensor.
• After replacing the detonation sensor, re-check
the trouble symptoms.
NO : Check end.
Detonation sensor
Alternator
AK300274 AC
TROUBLESHOOTING
Code No. P0335: Crank Angle Sensor System
Crank angle sensor circuit
Battery
W-B
W-B
4 3
B-17X

3 4
1 2
R
To engine-ECU
B-29 3
MU802603
1 2
Crank angle sensor
3
1 2
B-W
18
J/C(1) G-R
C-16
17
B-W
40 89
C-135 C-137
31 32 33 34 35 36 37 38 71 72 73 74 75 76 77 78 79 80 81
39 40 41 42 43 44 45 46 82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code
AK401032 AB
TROUBLESHOOTING
13A-125
• Power is supplied to the crank angle sensor (ter-
minal No. 3) from the engine control relay (termi- STEP 1. M.U.T.-II/III data list
nal No. 1) and is earthed to the engine-ECU • Refer to Data list reference table P.13A-293.
(terminal No. 40) from the crank angle sensor
a. Item 22: Crank angle sensor
(terminal No. 1).
• A power voltage of 5 V is applied to the crank Q: Is the check result normal?
angle sensor output terminal (terminal No. 2) YES : Intermittent malfunction (Refer to GROUP
from the engine-ECU (terminal No. 89). 00 − How to Use
FUNCTION P.00-6).
• The crank angle sensor detects the crank angle NO : Go to Step 2 .
(position) and inputs a pulse signal to the
engine-ECU. STEP 2. Connector check: B-29 crank angle
• In response to the signal, the engine-ECU con- sensor connector
trols the injector, etc.
Connector: B-29
TROUBLE JUDGMENT
2 1
Check Condition 3
• Engine in cranking state. Harness side B-29 (B)
connector
Judgment Criterion
• The sensor output voltage remains unchanged
(no pulse signal is inputted) for 2 seconds.
PROBABLE CAUSE
• Open/short circuit in crank angle sensor circuit or
Crank angle sensor
AK300276 AB

NO : Repair.
TROUBLESHOOTING
crank angle sensor connector. engine-ECU connector.
2 1
3
Harness side B-29 (B)
connector
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC
Connector: B-29
2 1
Crank angle sensor
3
AK300276 AB
connector
side.
OK: 4.9 − 5.1 V
NO : Go to Step 4 .
Crank angle sensor
AK300276 AB

• Disconnect B-29 crank angle sensor connector.
OK: 4.9 − 5.1 V
NO : Go to Step 6 .
TROUBLESHOOTING
13A-127
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

2 1 NO : Repair.
3
connector
Crank angle sensor
AK300276 AB

(terminal No. 2) crank angle sensor
NO : Repair.
TROUBLESHOOTING
No. 2) crank angle sensor connector and C-137 • Refer to Data list reference table P.13A-293.
(terminal No. 89) engine-ECU connector. a. Item 22: Crank angle sensor
2 1 00 − How to Use
3 Troubleshooting/Inspection Service Points
connector
P.00-6).

crank angle sensor connector.
Connector: B-29
2 1
3
connector
Crank angle sensor
AK300276 AB
Connector: C-137
Crank angle sensor

C-137
AK300276 AB

8180 79 78 77 76 75 74 73 72 71 side.
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC OK: System voltage
NO : Repair.
TROUBLESHOOTING
13A-129
relay connector B-29 crank angle sensor connector.
Relay box’s B-17X

triangle marks 2 1
3
connector
2 1
4 3
Harness side
Connector: B-29
2 1
3
connector
Crank angle sensor
AK300276 AB

side.
Crank angle sensor

AK300276 AB
connector
connector and B-17X (terminal No. 1)
engine control relay connector.
open/short circuit.
NO : Repair. C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

NO : Repair.
TROUBLESHOOTING
No. 1) crank angle sensor connector and C-135 measurement at B-29 crank angle sensor
(terminal No. 40) engine-ECU connector. connector (Using an oscilloscope).
2 1 2 1
3 3
Harness side B-29 (B) Harness side B-29 (B)
connector connector
Crank angle sensor Crank angle sensor
AK300276 AB AK300276 AB

Connector: C-135
• Engine: Idling
C-135 (Refer to P.13A-305), its maximum value
should be 4.8 V or more, and its minimum
value should be 0.6 V or less with no noise in
waveform.
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 Q: Is the check result normal?
Harness side connector YES : Go to Step 8 .
AK300256 AC

NO : Repair.
TROUBLESHOOTING
13A-131
STEP 15. Connector check: B-17X engine control STEP 16. Check harness between B-29 (terminal
relay connector No. 3) crank angle sensor connector and B-17X
(terminal No. 1) engine control relay connector.
Connector: B-17X
B-17X Connector: B-29
Relay box’s
triangle marks
2 1
3
2 1 connector
4 3
Harness side

NO : Repair.
Crank angle sensor
AK300276 AB
Connector: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
STEP 17. Connector check: C-135 and C-137 STEP 18. Check harness between B-29 (terminal
engine-ECU connectors No. 2) crank angle sensor connector and C-137
Connectors: C-135, C-137
Connector: B-29
2 1
3
connector
C-135
C-137
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
C-135 Harness side connector
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300277 AC Crank angle sensor
Q: Is the check result normal? AK300276 AB

NO : Repair. Connector: C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

NO : Repair.
TROUBLESHOOTING
13A-133
STEP 19. Check harness between B-29 (terminal STEP 20. Check the crankshaft sensing blade.
No. 1) crank angle sensor connector and C-135 Q: Is the check result normal?
(terminal No. 40) engine-ECU connector. YES : Go to Step 21 .
Connector: B-29 NO : Replace the crankshaft sensing blade.
2 1 STEP 21: M.U.T.-II/III data list

3
B-29 (B) • Refer to Data list reference table P.13A-293.
Harness side
connector a. Item 22: Crank angle sensor
00 − How to Use
P.00-6).
NO : Replace crank angle sensor.
Crank angle sensor
AK300276 AB
Connector: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

NO : Repair.
TROUBLESHOOTING
Code No. P0340: Camshaft Position Sensor System
Camshaft position sensor circuit
Battery
W-B
W-B
4 3
B-17X

3 4
1 2
R
B-106 3 To engine-ECU
MU802337
1 2 3 Camshaft position sensor
1 2
B-W
19
J/C (1)
C-16 L-Y
17
B-W
40 88
C-135 C-137
31 32 33 34 35 36 37 38 71 72 73 74 75 76 77 78 79 80 81
39 40 41 42 43 44 45 46 82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code
AK401033 AB
OPERATION FUNCTION
• Power is supplied to the camshaft position sensor • The camshaft position sensor detects the top
(terminal No. 3) from the engine control relay (ter- dead center on the compression stroke of the No.
minal No. 1) and is earthed to the engine-ECU 1 cylinder and inputs a pulse signal to the
(terminal No. 40) from the camshaft position sen- engine-ECU.
sor (terminal No. 1).
• A power voltage of 5 V is applied to the camshaft TROUBLE JUDGMENT
position sensor output terminal (terminal No. 2)
from the engine-ECU (terminal No. 88). Check Condition
• After the engine has started up.
TROUBLESHOOTING
13A-135
Judgment Criterion STEP 3. Connector check: B-17X engine control
• The sensor output voltage remains unchanged relay connector
Connector: B-17X
PROBABLE CAUSE Relay box’s B-17X
• Failed camshaft position sensor triangle marks
• Open/short circuit in camshaft position sensor cir-
cuit or loose connector contact
• Failed engine-ECU 2 1
4 3
DIAGNOSIS PROCEDURE
Harness side
STEP 1. Connector check: B-106 camshaft
position sensor connector Connector: B-106
Connector: B-106
3 2 1
3 2 1 Harness side
connector
Harness side
connector
B-106 (B)
B-106 (B)
AK300279 AB
AK300279 AB
(terminal No. 3) camshaft position sensor
NO : Repair. connector and B-17X (terminal No. 1)
STEP 2. Perform voltage measurement at B-106 open/short circuit.
camshaft position sensor connector. NO : Repair.
Connector: B-106
3 2 1
Harness side
connector
B-106 (B)
AK300279 AB

side.
OK: System voltage
NO : Go to Step 3 .
TROUBLESHOOTING
camshaft position sensor connector. engine-ECU connector.
3 2 1
Harness side
connector
B-106 (B)
C-137
AK300279 AB
• Disconnect connector, and measure at harness 8180 79 78 77 76 75 74 73 72 71

side. 92 91 90 89 88 87 86 85 84 83 82

OK: 4.9 − 5.1 V
Connector: B-106
3 2 1
NO : Go to Step 5 .
Harness side
connector
B-106 (B)
AK300279 AB

• Disconnect B-106 camshaft position sensor con-
nector.
OK: 4.9 − 5.1 V
NO : Go to Step 7 .
TROUBLESHOOTING
13A-137
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC

3 2 1 NO : Repair.
Harness side
connector
B-106 (B)
AK300279 AB

NO : Repair.
TROUBLESHOOTING
No. 2) camshaft position sensor connector and B-106 camshaft position sensor connector.
Connector: B-106
Connector: B-106
3 2 1
3 2 1 Harness side
connector
B-106 (B)
B-106 (B)
AK300279 AB
AK300279 AB
side.
Connector: C-137

connector
Connector: C-135
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

C-135
NO : Repair.
38 37 36 35 34 33 32 31
STEP 9. Check the trouble symptoms. 46 45 44 43 42 41 40 39
Q: Does trouble symptom persist? Harness side connector

NO : Intermittent malfunction (Refer to GROUP AK300256 AC

P.00-6). NO : Repair.
TROUBLESHOOTING
13A-139
No. 1) camshaft position sensor connector and measurement at B-106 camshaft position sensor
C-135 (terminal No. 40) engine-ECU connector. connector (Using an oscilloscope).
3 2 1 3 2 1
connector connector
B-106 (B) B-106 (B)
AK300279 AB AK300279 AB

Connector: C-135
• Engine: Idling
C-135 (Refer to P.13A-305), its maximum value
waveform.
38 37 36 35 34 33 32 31
AK300256 AC
NOTE: Before checking harness, check intermediate STEP 14. Connector check: B-17X engine control
connector C-16, and repair if necessary. relay connector.
Connector: B-17X
Q: Is the check result normal? B-17X
YES : Go to Step 9 . Relay box’s
triangle marks
NO : Repair.
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
STEP 15. Check harness between B-106 (terminal STEP 16. Connector check: C-135 and C-137
No. 3) camshaft position sensor connector and engine-ECU connectors
connector.
Connector: B-106
3 2 1
Harness side
connector
C-135
C-137
B-106 (B)
38 37 36 35 34 33 32 31
AK300279 AB 46 45 44 43 42 41 40 39

Connector: B-17X
Relay box’s B-17X

triangle marks
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
2 1
AK300277 AC
4 3
connector AK300255 AC YES : Go to Step 17 .
NO : Repair.
NO : Repair.
TROUBLESHOOTING
13A-141
No. 2) camshaft position sensor connector and No. 1) camshaft position sensor connector and
C-137 (terminal No. 88) engine-ECU connector. C-135 (terminal No. 40) engine-ECU connector.
3 2 1 3 2 1
connector connector
B-106 (B) B-106 (B)
AK300279 AB AK300279 AB
C-137 C-135
8180 79 78 77 76 75 74 73 72 71 38 37 36 35 34 33 32 31
92 91 90 89 88 87 86 85 84 83 82 46 45 44 43 42 41 40 39
AK300254 AC AK300256 AC
• Check output line for damage. NOTE: Before checking harness, check intermediate
Q: Is the check result normal? connector C-16, and repair if necessary.
NO : Repair.
STEP 19. Check camshaft position sensing

cylinder.
NO : Replace camshaft position sensing cylinder.

YES : Replace camshaft position sensor.
00 − How to Use
P.00-6).
TROUBLESHOOTING
Code No. P0403: EGR Control Solenoid Valve System
EGR control solenoid valve circuit
Battery
W-B
W-B
4 3
B-17X

3 4
1 2
To engine-ECU
R
1
B-119
1 2 EGR control solenoid valve
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK401034 AB
OPERATION • The engine-ECU (terminal No. 6) makes the

• Power is supplied to the EGR control solenoid power transistor in the unit be in "ON", and that
valve (terminal No. 1) from the engine control makes currents go on the EGR control solenoid
relay (terminal No. 1). valve (terminal No. 2).
TROUBLESHOOTING
13A-143
FUNCTION STEP 3. Perform resistance measurement at
• In response to the signal from the engine-ECU, B-119 EGR control solenoid valve connector.
the EGR control solenoid valve controls the oper-
Connector: B-119
ation of the EGR valve. 2 1
Harness side
TROUBLE JUDGMENT connector
Check Conditions
• Except the engine stalling
• The battery voltage is 10 − 16 V. B-119 (BR)
Judgment Criteria
• If the off surge voltage from the motor coil is not
generated when the EGR valve control motor is AK300281 AC
driven. • Disconnect connector, and measure at solenoid

valve side.
PROBABLE CAUSE • Resistance between terminal No. 1 and No. 2.
• Failed EGR control solenoid valve OK: 29 − 35 Ω (at 20°C)
• Open/short circuit in EGR control solenoid valve
circuit or loose connector contact Q: Is the check result normal?
NO : Replace EGR control solenoid valve.
DIAGNOSIS PROCEDURE
EGR control solenoid valve connector.
STEP 1. M.U.T.-II/III actuator test
• Refer to Actuator test reference table P.13A-299. Connector: B-119
2 1
a. Item 10: EGR control solenoid valve Harness side
OK: Operating sound can be heard and the connector
valve vibrates.
YES : Intermittent malfunction (Refer to GROUP B-119 (BR)
00 − How to Use
P.00-6). AK300281 AC
NO : Go to Step 2 . • Disconnect connector, and measure at harness
side.
STEP 2. Connector check: B-119 EGR control • Ignition switch: ON
solenoid valve connector • Voltage between terminal No. 1 and earth.
Connector: B-119 OK: System voltage
2 1
Harness side
NO : Go to Step 5 .
B-119 (BR)
AK300281 AC

NO : Repair.
TROUBLESHOOTING
Relay box’s B-17X
triangle marks
2 1
4 3 C-134
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1
Connector: B-119
2 1 26 25 24 23 22 21 20 19 18 17 16 15 14
Harness side Harness side connector

connector
AK300257 AC

side.
B-119 (BR)
OK: System voltage
AK300281 AC
YES : Check and repair harness between B-119 NO : Go to Step 7 .
(terminal No. 1) EGR control solenoid valve
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13A-145
connector connector
C-134 C-134
13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC AK300257 AC

2 1
Harness side NO : Repair.
connector
B-119 (BR)
AK300281 AC

• Check output line for open/short
circuit.
NO : Repair.
TROUBLESHOOTING
No. 2) EGR control solenoid valve connector and No. 1) EGR control solenoid valve connector and
C-134 (terminal No. 6) engine-ECU connector. B-17X (terminal No. 1) engine control relay
Connector: B-119
connector.
2 1
Connector: B-119
Harness side 2 1
connector Harness side
connector
B-119 (BR)
B-119 (BR)
AK300281 AC
AK300281 AC
Connector: C-134
Connector: B-17X
Relay box’s B-17X

triangle marks
2 1
C-134
4 3
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Repair.
YES : Go to Step 10 . STEP 11. M.U.T.-II/III actuator test
NO : Repair. • Refer to actuator test reference table list
P.13A-299.
• Item 10: EGR control solenoid valve
OK: Operating sound can be heard and the
valve vibrates.
00 − How to Use
P.00-6).
TROUBLESHOOTING
13A-147
Code No. P0420: Catalyst malfunction
FUNCTION STEP 2.M.U.T.-II/III data list

• The signal from the heated oxygen sensor (rear) • Refer to Data list reference table P.13A-293.
differs from the heated oxygen sensor (front). a. Item 11: Oxygen sensor (front)
That is because the catalytic converter purifies b. Item 59: Oxygen sensor (rear)
exhaust gas. When the catalytic converter has
deteriorated, the signal from the heated oxygen Q: Is the check result normal?
sensor (front) becomes similar to the heated oxy- YES : Go to Step 3 .
gen sensor (rear). NO : Perform the diagnosis code classified check
• The engine-ECU compares the output of the front procedure for the sensor that has shown an
and rear heated oxygen sensor signals. abnormal data valve (Refer to Inspection
TROUBLE JUDGMENT
Check Conditions STEP 3.M.U.T.-II/III data list
• Engine speed: 3,000 r/min or less. a. Item 11: Oxygen sensor (front)
• During the driving. OK: 0 − 0.4 and 0.6 − 1.0 volt should alternate
• During the air-fuel ratio feedback control. 15 times or more within 10 seconds (engine
speed at 2,000 r/min).
Judgment Criterion
• When the output frequency ratio of the oxygen Q: Is the check result normal?
sensor (rear) vs. The oxygen sensor (front) is 0.8 YES : Go to Step 4 .
or more on the average for 10 seconds. NO : Replace the oxygen sensor (front).
PROBABLE CAUSE STEP 4.Replace the oxygen sensor (rear).

• Catalytic converter deteriorated • After replacing the oxygen sensor (rear),
• Failed oxygen sensor (front) re-check the trouble symptoms.
• Failed oxygen sensor (rear)
YES : Check end.
NO : Go to Step 5 .
DIAGNOSIS PROCEDURE
STEP 5.Replace the catalytic converter.
STEP 1.Check for leakage of exhaust emission • After replacing the catalytic converter, re-check
from exhaust manifold. the trouble symptoms.
YES : Go to Step 2 . YES : Replacing engine-ECU.
NO : Repair. NO : Check end.
TROUBLESHOOTING
Code No. P0443: Purge Control Solenoid Valve System
Purge control solenoid valve circuit
Battery
W-B
W-B
4 3
B-17X

3 4
1 2
To engine-ECU
R
2
B-101
MU802779
1 2 Purge control solenoid valve
BR
9
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
Engine-ECU
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK401035 AB

• Power is supplied to the purge control solenoid power transistor in the unit be in "ON" position,
valve (terminal No. 2) from the engine control and that makes currents go on the purge control
relay (terminal No. 1). solenoid valve (terminal No. 1).
TROUBLESHOOTING
13A-149
FUNCTION STEP 3: Perform resistance measurement at
• In response to a signal from the engine-ECU, the B-101 purge control solenoid valve connector.
purge control solenoid valve controls the flow rate
of the purge air to be introduced into the surge Connector: B-101
2 1
tank.
Harness side
connector
TROUBLE JUDGMENT
Check Conditions
• Ignition switch: ON B-101 (B)
Judgment Criteria
• The surge voltage (system voltage + 2 V) of sole- AK300283AB
noid coil is not detected when the purge control • Disconnect connector, and measure at solenoid
solenoid valve is turned in OFF position from ON. valve side.
• The battery voltage is 10 V or more. • Resistance between terminal No. 1 and No. 2.
OK: 30 − 34 Ω (at 20°C)
PROBABLE CAUSE
• Failed purge control solenoid valve
• Open/short circuit in purge control solenoid value NO : Replace purge control solenoid valve.
DIAGNOSIS PROCEDURE purge control solenoid valve connector.
Connector: B-101
2 1
• Item 08: Purge control solenoid valve Harness side
connector
valve vibrates
Q: Is the check result normal? B-101 (B)
00 − How to Use
Troubleshooting/Inspection Service Points AK300283AB
P.00-6). • Disconnect connector, and measure at harness
NO : Go to Step 2 . side.
STEP 2. Connector check: B-101 purge control • Voltage between terminal No. 2 and earth.
solenoid valve connector OK: System voltage
Harness side NO : Go to Step 5 .
connector
B-101 (B)
AK300283AB

NO : Repair.
TROUBLESHOOTING
Relay box’s B-17X
triangle marks
2 1
4 3 C-134
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1
Connector: B-101
26 25 24 23 22 21 20 19 18 17 16 15 14
2 1
Harness side

side.
B-101 (B) • Ignition switch: ON
AK300283AB
OK: System voltage
YES : Check and repair harness between B-101 NO : Go to Step 7 .
(terminal No. 2) purge control solenoid valve
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13A-151
connector connector
C-134 C-134
13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC AK300257 AC

connector
B-101 (B)
AK300283AB

• Check output line for open and short
circuit.
NO : Repair.
TROUBLESHOOTING
No. 1) purge control solenoid valve connector No. 2) purge control solenoid valve connector
and C-134 (terminal No. 9) engine-ECU and B-17X (terminal No. 1) engine control relay
connector. connector.
2 1 2 1
connector connector
B-101 (B) B-101 (B)
AK300283AB AK300283AB
Connector: C-134 Connector: B-17X
Relay box’s B-17X

triangle marks
2 1
C-134 4 3
Harness side

26 25 24 23 22 21 20 19 18 17 16 15 14
YES : Go to Step 10 . • Item 08: purge control solenoid valve
NO : Repair. OK: Operating sound can be heard and the
valve vibrates
00 − How to Use
P.00-6).
TROUBLESHOOTING
13A-153
Code No. P0500: Vehicle speed sensor system
Vehicle speed sensor circuit
Ignition switch Engine-ECU

C-137
C-303
R LOCK
71 72 73 74 75 76 77 78 79 80 81
1 2 3 ST ACC 82 83 84 85 86 87 88 89 90 9192
IG1 IG2
4 5 6
2
L-B 86
C-203
6
W-L
2 J/B
7.5A
3
C-202 J/C (1)
C-16 Meter and gauge
11 1
B-W 2
C-106
3
W-L
B-W
1 3
B-115
1 2 3 Vehicle speed sensor
2
B
8
J/C (2)
C-17
B 1
Wire colour code

AK401036 AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the vehicle • The vehicle speed sensor converts the vehicle
speed sensor (terminal No. 3) from the speed to the voltage, and then input it into the
engine-ECU (terminal No. 86). engine-ECU
TROUBLESHOOTING
TROUBLE JUDGMENT STEP 2.M.U.T.-II/III data list

Check Conditions • Refer to Data list reference table P.13A-293.
• 2 seconds later after the engine has started up. a. Item 24: Vehicle speed sensor
• Engine speed: 2,000 r/min or more. Q: Is the check result normal?
• Under the high load operation (The volumetric YES : Go to Step 3 .
efficiency is 50 − 60%). NO : Intermittent malfunction (Refer to GROUP
Judgment Criterion 00 - How to Use Troubleshooting/Inspection
• The sensor output voltage remains unchanged Service Points P.00-6).
STEP 3.Check connector: C-137 engine-ECU
PROBABLE CAUSE connector
• Failed Vehicle speed sensor
Connector: C-137
• Open/short circuit in vehicle speed sensor circuit
DIAGNOSIS PROCEDURE
STEP 1.Check the speedometer C-137

NO : Check the speedometer (Refer to GROUP 8180 79 78 77 76 75 74 73 72 71
54A −Combination Meter Assembly and 92 91 90 89 88 87 86 85 84 83 82
Vehicle speed sensor − On-vehicle Service Harness side connector

P.54A-57). AK300254 AC

NO : Repair.
TROUBLESHOOTING
13A-155
STEP 4.Check harness between C-137 (terminal STEP 5.Check the trouble symptoms.
No. 86) engine-ECU connector and B-115 Q: Does trouble symptom persist?
(terminal No. 3) Vehicle speed sensor connector. YES : Replacing engine-ECU.
Connector: C-137 NO : Intermittent malfunction (Refer to GROUP
00 - How to Use Troubleshooting/Inspection
Service Points P.00-6).
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC
Connector: B-115
3 2 1
B-115 (B) Harness side
connector
AK300285AC

• Check output line for open circuit and damage.
NO : Repair.
TROUBLESHOOTING
Code No. P0500: Vehicle speed sensor system

C-137
C-303
R LOCK
71 72 73 74 75 76 77 78 79 80 81
1 2 3 ST ACC 82 83 84 85 86 87 88 89 90 9192
IG1 IG2
4 5 6
2
L-B 86
C-203
6
W-L
2 J/B
7.5A
3
C-202 J/C (1)
11 1
B-W 2
C-106
3
W-L
B-W
1 3
B-115
2
B
8
J/C (2)
C-17
B 1
Wire colour code

AK401036 AB
OPERATION FUNCTION
TROUBLESHOOTING
13A-157
Check Conditions • Refer to Data list reference table P.13A-293.
• Under the high load operation (The volumetric YES : Go to Step 3 .
efficiency is 40 − 75%). NO : Intermittent malfunction (Refer to GROUP
Connector: C-137
DIAGNOSIS PROCEDURE
STEP 1.Check the speedometer C-137

NO : Check the speedometer (Refer to GROUP 8180 79 78 77 76 75 74 73 72 71
54A −Combination Meter Assembly and 92 91 90 89 88 87 86 85 84 83 82
Vehicle speed sensor − On-vehicle Service Harness side connector

P.54A-57). AK300254 AC

NO : Repair.
TROUBLESHOOTING
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC
Connector: B-115
3 2 1
connector
AK300285AC

NO : Repair.
TROUBLESHOOTING
13A-159
Code No. P0505: Idle Speed Control Servo System
Idle speed control servo circuit
Battery
W-B
W-B
4 3
B-17X

3 4
1 2
R
To engine-ECU
R R
2 5
B-120
1 2 3
Idle speed control servo
4 5 6
1 3 4 6
L-Y Y-L W G-Y
4 17 5 18
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13 Engine-ECU
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK401037 AB
TROUBLESHOOTING
OPERATION Judgment Criteria

• The power is supplied to the idle speed control • The actual idle speed is higher than the target
servo (terminal No. 2 and No. 5) from the engine idle speed by 100 r/min or more for 10 seconds.
control relay (terminal No. 1).
• The engine-ECU (terminal No. 4, No. 5, No. 17 PROBABLE CAUSE
and No. 18) makes power transistor in the unit be • Failed idle speed control servo
in "ON" position in order, and that makes currents • Open/short circuit in idle speed control servo cir-
go on the idle speed control servo (terminal No. cuit or loose connector contact
1, No. 3, No. 4 and No. 6). • Failed engine-ECU
FUNCTION DIAGNOSIS PROCEDURE

• The idle speed control servo opens and closes
the servo valve in response to a signal from the STEP 1. M.U.T.-II/III Data List
engine-ECU to control the intake air flow rate dur- • Refer to Data list reference table P.13A-293.
ing idling.
a. Item 45: Idle speed control position
TROUBLE JUDGMENT Q: Is the check result normal?
Check conditions 00 − How to Use
• The vehicle speed has reached 1.5 km/h or more Troubleshooting/Inspection Service Points
at least once.
P.00-6).
• During the closed-loop idle speed control. NO : Go to Step 2 .
Judgment Criteria
• The actual idle speed is higher than the target STEP 2. Connector check: B-120 idle speed
idle speed by 300 r/min or more for 10 seconds. control servo connector
Check conditions Connector: B-120
• The vehicle speed has reached 1.5 km/h or more
at least once.
3 2 1
• During the closed-loop idle speed control.
6 5 4
• The highest ambient temperature at the last drive
Harness side
is 45 °C or less. connector
• The engine coolant temperature is approximately.
82°C or higher.
• The battery voltage is 10 V or more. B-120 (B)
• The intake air temperature is −10°C or higher. AK300287 AD
Judgment Criteria
• The actual idle speed is higher than the target YES : Go to Step 3 .
idle speed by 200 r/min or more for 10 seconds. NO : Repair.
Check conditions
• During the closed-loop idle speed control. STEP 3. Check idle speed control servo itself.
• The engine coolant temperature is approximately. • Check idle speed control servo itself (Refer to
82°C or higher. P.13A-326).
• The power steering switch is in OFF position. Q: Is the check result normal?
• The charging efficiency is 40 % or less. YES : Go to Step 4 .
• The intake air temperature is −10°C or higher. NO : Replace idle speed control servo.
TROUBLESHOOTING
13A-161
STEP 4. Perform voltage measurement at B-120 STEP 5. Check connector: B-17X engine control
idle speed control servo connector. relay connector
Relay box’s B-17X

3 2 1 triangle marks
6 5 4
Harness side
connector
2 1
4 3
AK300287 AD connector AK300255 AC

Connector: B-120
side.
• Voltage between terminal No. 2 and earth, also 3 2 1
between terminal No. 5 and earth. 6 5 4
Harness side
OK: System voltage connector
NO : Go to Step 5 . B-120 (B)
AK300287 AD

(terminal No. 2 or No. 5) idle speed control
servo connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
TROUBLESHOOTING
STEP 6. Perform voltage measurement at C-134 4. Harness between idle speed control
engine-ECU connector. servo terminal No. 6 and
engine-ECU connector terminal No.
Connector: C-134 18
open/short circuit.

connector
C-134
Connector: C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC C-134
Connector: B-120
3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
6 5 4
Harness side
connector
AK300257 AC

AK300287 AD NO : Repair.
side.
• Voltage between terminal No. 4 and earth,
between terminal No. 5 and earth, between termi-
nal No. 17 and earth, also voltage between termi-
nal No. 18 and earth.
OK: System voltage
idle speed control servo and C-134
engine-ECU.
1. Harness between idle speed control
servo terminal No. 1 and
4
17
5
TROUBLESHOOTING
13A-163
STEP 8. Check harness between B-120 idle STEP 9. Check harness between B-120 (terminal
speed control servo and C-134 engine-ECU. No. 2 or No. 5) idle speed control servo
Connector: B-120
connector and B-17X (terminal No. 1) engine
control relay connector.
3 2 1 Connector: B-120
6 5 4
Harness side 3 2 1
connector 6 5 4
Harness side
connector
B-120 (B)
AK300287 AD
B-120 (B)
Connector: C-134 AK300287 AD
Connector: B-17X
Relay box’s B-17X

triangle marks
C-134
2 1
4 3
13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side
26 25 24 23 22 21 20 19 18 17 16 15 14
Harness side connector • Check power supply line for damage.
AK300257 AC Q: Is the check result normal?
1. Harness between idle speed control servo termi-
NO : Repair.
nal No. 1 and engine-ECU connector terminal
No. 4
2. Harness between idle speed control servo termi- STEP 10. M.U.T.-II/III Data List
nal No. 3 and engine-ECU connector terminal • Refer to Data list reference table P.13A-293.
No. 17 a. Item 45: Idle speed control position
3. Harness between idle speed control servo termi- Q: Is the check result normal?
nal No. 4 and engine-ECU connector terminal YES : Intermittent malfunction (Refer to GROUP
No. 5 00 − How to Use
4. Harness between idle speed control servo termi- Troubleshooting/Inspection Service Points
nal No. 6 and engine-ECU connector terminal P.00-6).
No. 18 NO : Replace engine-ECU.
NO : Repair.
TROUBLESHOOTING
Code No. P0551: Power Steering Fluid Pressure Switch System
Power steering fluid pressure switch circuit
C-135
31 32 33 34 35 36 37 38
Engine-ECU
39 40 41 42 43 44 45 46
37
B-28 1
(MU801211)
1
Power steering fluid pressure switch
Wire colour code

AK401204 AC
CONDITION PROBABLE CAUSE

• The battery voltage is applied to the power steer- • Failed power steering fluid pressure switch
ing fluid pressure switch (terminal No. 1) from the • Open/short circuit in power steering fluid pres-
engine-ECU (terminal No. 37). sure switch circuit or loose connector contact
FUNCTION
• It is detected whether a load is applied on the DIAGNOSIS PROCEDURE
power steering fluid pump by steering or not, and
the signal is inputted to the engine-ECU. When
STEP 1. Connector check: B-28 power steering
the power steering fluid pressure switch "ON" sig-
fluid pressure switch connector
nal (a large load on the power steering fluid
pump) is inputted, the engine-ECU provides the Connector: B-28
idle-up control.
TROUBLE JUDGMENT
Check Conditions B-28 (B)
• The engine coolant temperature is approximately
1
20°C or higher.
Harness side
Judgment Criterion connector AK300289 AC
• A power steering pressure switch in the ON posi-
tion is detected 10 times for 4 seconds at a vehi- Q: Is the check result normal?
cle speed of 50 km/h or more. YES : Go to Step 2 .
NO : Repair.
TROUBLESHOOTING
13A-165
STEP 2. Perform voltage measurement at B-28 STEP 4. Connector check: C-135 engine-ECU
power steering fluid pressure switch connector. connector
B-28 (B)
1 C-135
Harness side
• Disconnect connector, and measure at harness 38 37 36 35 34 33 32 31

side. 46 45 44 43 42 41 40 39

OK: System voltage
Connector: B-28
NO : Go to Step 3 .
STEP 3. Perform voltage measurement at C-135 B-28 (B)

1
Connector: C-135
Harness side

(terminal No. 1) power steering fluid
pressure switch connector and C-135
C-135
NO : Repair.
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
STEP 5. Connector check: C-135 engine-ECU STEP 6. Check harness between B-28 (terminal
connector No. 1) power steering fluid pressure switch
Connector: C-135
Connector: B-28
C-135 B-28 (B)
38 37 36 35 34 33 32 31 Harness side
46 45 44 43 42 41 40 39 connector AK300289 AC

Connector: C-135
AK300256 AC

NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

NO : Repair.
STEP 7. M.U.T.-II/III Data List

a. Item 27: Power steering fluid pressure switch
00 − How to Use
P.00-6).
TROUBLESHOOTING
13A-167
STEP 8. Perform voltage measurement at C-135 STEP 10. Check harness between B-28 (terminal
engine-ECU connector. No. 1) power steering fluid pressure switch
Connector: C-135
Connector: B-28
C-135 B-28 (B)
38 37 36 35 34 33 32 31 Harness side
46 45 44 43 42 41 40 39 connector AK300289 AC

Connector: C-135
AK300256 AC

• Engine: Idling
OK:
System voltage (Steering wheel: Stationary) C-135
1 V or less (Steering wheel: Turned)
38 37 36 35 34 33 32 31
NO : Go to Step 9 . 46 45 44 43 42 41 40 39
AK300256 AC
connector
Connector: C-135
YES : Replace power steering fluid pressure
switch.
NO : Repair.
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

NO : Repair.
TROUBLESHOOTING

connector
Connector: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

NO : Repair.
TROUBLESHOOTING
13A-169
Code No. P0622: Alternator FR Terminal System
Alternator circuit
C-135
31 32 33 34 35 36 37 38 Engine-ECU
39 40 41 42 43 44 45 46
41
Y-B
B-19
1
Y-B
B-30 4
(MU802046)
1 2 3 4 IC Voltage
regulator Alternator
Wire colour code

AK300290 AB

• The energized state of the alternator field coil is
Check Condition
inputted from the alternator (terminal No. 4) to the
• Engine speed is 50 r/min or more.
Judgment Criterion
FUNCTION • Input voltage from alternator FR terminal is the
• A signal of the power supply duty ratio for the system voltage or more for 20 seconds.
alternator field coil is inputted to the engine-ECU.
• In response to the signal, the engine-ECU PROBABLE CAUSE
detects the alternator output current and controls • Alternator FR terminal circuit open circuited
the idling speed according to the output current • Failed engine-ECU
(electric load).
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Connector check: C-135 engine-ECU

connector
STEP 1. Connector check: B-19 intermediate Connector: C-135
connector
Connector: B-19
B-19 (B)
C-135
3 2 1
6 5 4
Female side 38 37 36 35 34 33 32 31
connector AK300294 AC 46 45 44 43 42 41 40 39
YES : Go to Step 2 . AK300256 AC
NO : Repair.
STEP 2. Perform voltage measurement at B-19 NO : Repair.
intermediate connector.
Connector: B-19
B-19 (B)
1 2 3
4 5 6
Male side
• Disconnect connector, and measure at male con-

nector side.
OK: System voltage
NO : Go to Step 3 .
TROUBLESHOOTING
13A-171
No. 1) intermediate connector and C-135 intermediate connector.
Connector: B-19
Connector: B-19
B-19 (B)
B-19 (B)
3 2 1
1 2 3 6 5 4
4 5 6 Female side
Male side connector AK300294 AC
Connector: C-135
OK: System voltage
NO : Go to Step 7 .
C-135
STEP 7. Connector check: B-30 alternator

connector
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 Connector: B-30
AK300256 AC
• Check output line for short circuit. B-30 (GR)

4 3 2 1
NO : Repair.
Harness side
NO : Repair.
00 − How to Use
P.00-6).
TROUBLESHOOTING
No. 4) alternator connector and B-19 (terminal intermediate connector.
No. 1) intermediate connector.
Connector: B-19
Connector: B-30
B-19 (B)
B-30 (GR)
3 2 1
6 5 4
4 3 2 1 Female side
Connector: B-19
• Engine: Idle after warm-up
• Radiator fan: Inactive
B-19 (B) • Voltage between terminal No. 1 and earth.
OK: Switching the headlamps to ON from
3 2 1 OFF causes the voltage to fall.
6 5 4 Q: Is the check result normal?
Female side YES : Go to Step 5 .
connector AK300294 AC NO : Go to Step 10 .
Q: Is the check result normal? STEP 10. Connector check: B-30 alternator
YES : Replace alternator. connector
NO : Repair.
Connector: B-30
B-30 (GR)
4 3 2 1
Harness side

NO : Repair.
TROUBLESHOOTING
13A-173
No. 4) alternator connector and B-19 (terminal No. 1) intermediate connector and C-135
No. 1) intermediate connector pin No. 1. (terminal No. 41) engine-ECU connector.
B-19 (B)
B-30 (GR)
1 2 3
4 3 2 1 4 5 6
Harness side Male side
B-19 (B)
3 2 1
6 5 4 C-135
Female side
• Check output line for damage. 38 37 36 35 34 33 32 31

46 45 44 43 42 41 40 39

NO : Repair.
STEP 13. Check trouble symptom.

Q: Same symptoms regenerated?
YES : Replace alternator.
NO : Intermittent malfunction (Refer to Group 00
− How to Use troubleshooting/Inspection
TROUBLESHOOTING
Code No. P1603: Battery Backup Line System
Battery backup circuit
Battey
Relay box 9
20A
W-B
A-14
5
W-B
80
C-137
Battery Engine-ECU
71 72 73 74 75 76 77 78 79 80 81
backup
82 83 84 85 86 87 88 89 90 9192
Wire colour code

AK300297 AB

• Power is directly supplied to the engine-ECU (ter-
Check Condition
minal No. 80) from the battery.
FUNCTION Judgment Criterion
• The engine-ECU is check the open circuit of bat- • The battery backup line voltage 6 V or less.
tery backup line.
PROBABLE CAUSE
• Open/short circuit in battery backup line circuit or
TROUBLESHOOTING
13A-175
connector
STEP 1 M.U.T.-II/III diagnosis code Connector: C-137
• Temporarily place the ignition switch in "LOCK"
(OFF) position, and 10 seconds after that, place it
in "ON" position again.
Q: Is the diagnosis code P1603 set?
00 − How to use Troubleshooting/Inspection C-137
STEP 2. Perform voltage measurement at C-137 8180 79 78 77 76 75 74 73 72 71
engine-ECU connector. 92 91 90 89 88 87 86 85 84 83 82
Connector: C-137
AK300254 AC

NO : Repair.

C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 00 − How to Use
Harness side connector Troubleshooting/Inspection Service
PointsP.00-6).
AK300254 AC

side.
OK: System voltage
NO : Check intermediate connector A-14, and
harness between battery and C-137
open/short circuit.
TROUBLESHOOTING
Code No. P1610: Immobilizer System
Immobilizer-ECU circuit
Signal
transmission Immobilizer-ECU
circuit
C-304-1 3
1 2 C-304
7 3 4 5 6 7 MU801547
V
C-104
11
V
51
C-136
51 52 53 54 55 56 Engine-ECU
57 58 59 60 61 62
Wire colour code

AK300298 AD

• The signals are sent and received between
Check Condition
engine-ECU (terminal No. 51) and immobi-
lizer-ECU (terminal No. 7).
Judgment Criterion
FUNCTION • Improper communication problems between the
• Engine-ECU sends or receives the control sig- engine-ECU and the immobilizer-ECU are
nals to or from immobilizer-ECU to certify the detected.
ignition key.
NOTE: .
PROBABLE CAUSE
• If the registered ignition keys are close each • Open/short circuit in immobilizer system circuit or
other when starting the engine, radio interfer- loose connector contact
ence may cause this code to be displayed. • Failed immobilizer-ECU
• This code may be displayed when registering • Failed engine-ECU
the key encrypted code.
TROUBLESHOOTING
13A-177
DIAGNOSIS PROCEDURE STEP 2. Check harness between C-304 (terminal
No. 7) immobilizer-ECU connector and C-136
STEP 1. Connector check: C-304 (terminal No. 51) engine-ECU connector.
immobilizer-ECU connector and C-136 Connector: C-304
engine-ECU connector Harness side
connector
Connector: C-304 2 1
Harness side 76543
connector
2 1
76543
C-304
C-304
AK203418 AC
Connector: C-136
AK203418 AC
Connector: C-136
C-136
C-136
56 55 54 53 52 51
62 61 60 59 58 57
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AC
AK300268 AC
YES : Go to Step 2 . age.
NO : Repair.

00 − How to Use
P.00-6).
STEP 4. After replacing the immobilizer-ECU,

re-check the trouble symptoms.
NO : Check end.
TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOMS

M1131151500823
Items Trouble symptom Inspection

procedure
No.
Communication Communication with all system is not possible 1
with M.U.T.-II/III is Communication with engine-ECU only is not possible 2
impossible
Engine warning The engine warning lamp does not illuminate right after the ignition switch 3
lamp is turned the "ON" position
The engine warning lamp remains illuminating and never goes out 4
Starting Starting impossible The starter is impossible to operate. 5
(No initial combustion)
Starting impossible The starter is operative and cranks 6
(Starter operative but no initial the engine, but none of initial
combustion) combustion is in the cylinders and
the engine is not started.
Starting impossible The initial combustion occurs, but 7
(Initial combustion but no complete the engine stalls soon due to the
combustion) incomplete combustion.
Improper starting It is long cranking to start the engine.
(Long time to start)
Improper idling Unstable idling The engine speed is not constant 8
(Rough idling, hunting) and changeable during the idling.
Usually, the judgment can be based
on the movement of the tachometer
pointer, also on the vibration
transmitted to the steering wheel, sift
lever, vehicle body and so on.
Improper idling speed The proper idling speed is not
satisfied.
Engine stalled during idling The engine stalls during the idling in
(Die out) no relation to the vehicle movement.
Engine stalls The engine stalls when starting the The engine stalls during the 9
car operation, or when the accelerator
(Pass out) pedal is depressed from the idling.
The engine stalls when The engine stalls at the deceleration. 10
decelerating
TROUBLESHOOTING
13A-179
procedure
No.
Driving Engine does not revolve up The engine speed is not higher when 11
the accelerator pedal is depressed.
Hesitation, sag The response of vehicle speed 12
(engine speed) is delayed when the
accelerator pedal is depressed, or
the vehicle speed (engine speed) is
temporarily dropped during the
acceleration. These phenomena are
called "hesitation" and the serious
hesitation is called "sag".
Poor acceleration The engine cannot obtain the
acceleration corresponding to the
degree of throttle opening although
the engine is smooth at the constant
speed.
Stumble The engine speed increase is
delayed when the accelerator pedal
is initially depressed at the starting.
Surge The vehicle body is repeated to
vibrate jollity in the forward and
backward directions at the constant
speed or acceleration.
The feeling of impact or vibration The large impact feeling occurs at 13
when accelerating the acceleration.
when decelerating the deceleration.
Knocking Sharp sound like a hammer striking 15
on the cylinder walls during the
driving can be heard and wrongly
affects the driving.
Ignition timing offset The basic ignition timing is deviated 16
from the datum value.
Stopping Run on (Dieseling) The engine continues to run after the 17
ignition switch is in "LOCK (OFF)"
position.
Exhaust gas Odor, white smoke, black smoke, The exhaust gas is extremely rank 18
high-concentration CO/HC during odor, white smoke or black smoke.
idling The concentration of CO & HC is
high during the idling.
Charging Battery rundown The battery is soon rundown or the 19
performance charging ability of battery is small.
TROUBLESHOOTING

procedure
No.
Cooling Overheating The temperature of engine cooling 20
performance water is extremely high.
Abnormal rotation of fan Motor The fan motor is abnormally rotated 21
when the ignition switch is in "ON"
position in no relation to the engine
cooling water temperature.
A/C performance Poor A/C Performance The temperature of air cooling from 22
A/C is not efficient or very far from
the target temperature.
TROUBLESHOOTING
13A-181
PROBLEM SYMPTOMS TABLE
Inspection Trouble symptom Reference
procedure No. page
1 Communication with all system is not possible P.13A-182
2 Communication with engine-ECU only is not possible P.13A-185
3 The engine warning lamp does not illuminate right after the ignition switch is P.13A-187
turned the "ON" position
4 The engine warning lamp remains illuminating and never goes out P.13A-193
5 Starting impossible (No initial combustion) P.13A-195
6 Starting impossible (Starter operative but no initial combustion) P.13A-200
7 Starting impossible (Initial combustion but no complete combustion) P.13A-204
Starting impossible (Long time to start)
8 Unstable idling (Rough idling, hunting) P.13A-207
Improper idling speed (Too high or too low)
Engine stalls during idling (Die out)
9 The engine stalls when starting the car (pass out) P.13A-214
10 The engine stalls when decelerating P.13A-216
11 Engine does not revolve up P.13A-218
12 Hesitation, sag P.13A-220
Poor acceleration
Stumble
Surge
13 The feeling of impact or vibration when accelerating P.13A-222
14 The feeling of impact or vibration when decelerating P.13A-224
15 Knocking P.13A-224
16 Ignition timing offset P.13A-225
17 Run on (Dieseling) P.13A-227
18 Odor, white smoke, black smoke, high-concentration CO/HC during idling P.13A-227
19 Battery rundown P.13A-229
20 Overheating P.13A-234
21 Abnormal rotation of fan motor P.13A-235
22 Poor A/C performance P.13A-237
23 Engine-ECU power supply, engine control relay, ignition switch-IG1 system P.13A-239
24 Fuel pump system P.13A-247
25 Fan control relay system P.13A-256
26 A/C switch system P.13A-262
27 A/C compressor relay system P.13A-266
28 A/C load signal system P.13A-273
29 A/C pressure sensor system P.13A-277
30 Ignition circuit system P.13A-286
TROUBLESHOOTING
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with All System is not Possible
Data link connector circuit
Fusible link (1)
C-116
15
R
C-204
1
15 J/B
15A
12
C-205
W-B
C-24 16
1 2 3 4 5 6 7 8 Data link connector
9 10 1112 13 14 1516
4 5
B B
Wire colour code

AK300300 AD
OPERATION COMMENT ON TROUBLE SYMPTOM

• Battery voltage is applied to diagnosis connector • Failure is possibly caused by failed power supply
(terminal No.16). circuit or failed earthing circuit of diagnosis con-
• Diagnosis connector (terminals No. 4 and 5) are nector.
earthed to the vehicle body.
PROBABLE CAUSE
• Failed diagnosis connector
• Open/short circuit in diagnosis connector circuit
• Failed M.U.T.-II/III
TROUBLESHOOTING
13A-183
DIAGNOSIS PROCEDURE STEP 3: Perform voltage measurement at C-24
STEP 1: Check connector: C-24 diagnosis Connector: C-24
connector
Connector: C-24
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
C-24 (B)
1 2 3 4 5 6 7 8 Harness side connector
AK203424 AE
9 10 1112 13 14 1516
Harness side connector • Disconnect connector, and measure at the har-
AK203424 AE ness side.
YES : Go to Step 2 . OK: System voltage
NO : Check intermediate connectors C-116, C-204
STEP 2: Perform resistance measurement at C-24
diagnosis connector. and C-205, and repair if necessary. If
connectors are normal, check and repair
Connector: C-24 harness between C-24 (terminal No. 16)
diagnosis connector and battery.
open/short circuit.
C-24 (B) STEP 4: Replace M.U.T.-II/III

1 2 3 4 5 6 7 8
• After replacing the M.U.T.-II/III, re-check the trou-
9 10 1112 13 14 1516
ble symptoms.
AK203424 AE Q: Does trouble symptom persist?
NO : Check end
side.
• Resistance between terminal No. 4 and earth,
also between terminal No. 5 and earth.
NO : Check and repair harness between C-24
(terminal No. 4) diagnosis connector and
body earth, also between C-24 (terminal No.
5) diagnosis connector and body earth.
• Check earthing line for open circuit
and damage.
TROUBLESHOOTING
STEP 5: Check harness between C-24 (terminal

No. 16) diagnosis connector and battery.
Connector: C-24
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
AK203424 AE

connectors C116, C-204 and C-205, and repair if
necessary.
(terminal No. 4 and No. 5) diagnosis
connector and body earth.
NO : Repair.
TROUBLESHOOTING
13A-185
Inspection Procedure 2: Communication with Engine-ECU only is not Possible.
C-136
Engine-ECU
51 52 53 54 55 56
57 58 59 60 61 62
62
O-W
C-105
5
C-04 O-L
37
31 32 33 34 35 36 37 38 39 40 41 Combination
Control
42 43 44 45 46 47 48 49 50 51 52 mater
circuit
G G
36
O-W
32
J/C (3)
C-02
29
O-L
C-24
(MU803797) 7
9 10 1112 13 14 1516
Wire colour code

AK401207 AB

• There is data communication between diagnosis
connector output terminal (terminal No. 7) and STEP 1: Check engine warning lamp.
engine-ECU (terminal No. 62). • Ignition switch: OFF → ON
COMMENT ON TROUBLE SYMPTOM Q: Is lamp illuminating for few seconds?
• Failure is possibly caused by failed power supply YES : Go to Step 2 .
circuit or failed earthing circuit of engine-ECU. NO : Check engine-ECU power supply, engine
control relay and ignition switch IG1 system
PROBABLE CAUSE (Refer to Inspection Procedure 23
• Open/short circuit in engine-ECU power circuit P.13A-239).
• Between engine-ECU and diagnosis connector
for short circuit
TROUBLESHOOTING
STEP 2: Connector check: C-136 engine-ECU STEP 3: Check harness between C-24 (terminal
connector No. 7) diagnosis connector and C-136 (terminal
Connector: C-136
Connector: C-24
C-24 (B)
C-136 1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
AK203424 AE
56 55 54 53 52 51
62 61 60 59 58 57
Connector: C-136
AK300268 AC

NO : Repair.
C-136
56 55 54 53 52 51
62 61 60 59 58 57
AK300268 AC
NOTE: Before Checking harness, check intermedi-

ate connectors C-105, C-02 and C-04 and repair if
necessary.
• Check communication line for open/short circuit
and damage.
NO : Repair.
STEP 4: Check the trouble symptom.

00 − How to Use
P.00-6).
TROUBLESHOOTING
13A-187
Inspection Procedure 3: The Engine Warning Lamp Does not Illuminate Right after the Ignition Switch
is Turned The "ON" Position
Malfunction indicator lamp (Engine warning lamp) circuit
C-303
R LOCK
1 2 3 ST
Ignition switch
ACC
4 5 6 IG1 IG2
L-B
C-203
6
2 J/B
7.5A
25
C-205
C-04
B-W
42 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G G
C-05 Malfunction indicator lamp

(Engine warning lamp)
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122 14
G G
R-W
7
C-105
R-W
36
C-135
Engine-ECU
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Wire colour code

AK401039 AB
OPERATION • Engine-ECU (terminal No. 36) makes power tran-

• Battery voltage is applied to engine warning lamp sistor in unit be in "ON" position, and that makes
of combination meter connector (terminal No. 42) currents go on engine warning lamp of combina-
from ignition switch. tion meter connector (terminal No. 14).
TROUBLESHOOTING
COMMENTS ON TROUBLE SYMPTOM STEP 3: Connector check: C-04 combination

• Engine-ECU turns on engine warning lamp for 5 meter connector
seconds to check for burnt-out bulb immediately
after ignition switch is turned to ON. Connector: C-04
• If engine warning lamp is not lit just after turning C-04
ignition switch to "ON" position, failure is possibly
caused by burn-out bulb, open/short circuit or
other faults.
PROBABLE CAUSE
• Engine warming lamp bulb burnt out
• Failed ignition switch
• Open/short circuit in engine warning lamp circuit
for or loose connector contact
• Failed engine-ECU 41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
DIAGNOSIS PROCEDURE G G
STEP 1: Check engine start-up. AK300303AC
Q: Is engine started? Q: Is the check result normal?

NO : Check engine-ECU power supply, engine NO : Repair.
(Refer to Inspection Procedure 23 STEP 4: Perform voltage measurement at C-04
P.13A-239). combination meter connector.
Connector: C-04
STEP 2: Check engine warning lamp for
burnt-out bulb. C-04
NO : Replace engine warning lamp.
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G G
AK300303AC
• Disconnect connector, and measure at the har-

ness side.
OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
13A-189
STEP 5: Connector check: C-303 ignition switch STEP 6: Connector check: C-135 engine-ECU
connector connector
C-303
3 2 1
6 5 4
C-135
Harness side
connector
AK300304 AC
38 37 36 35 34 33 32 31
Connector: C-04 46 45 44 43 42 41 40 39
C-04
AK300256 AC

NO : Repair.
STEP 7: Perform voltage measurement at C-135

41 40 39 38 37 36 35 34 33 32 31 Connector: C-135
52 51 50 49 48 47 46 45 44 43 42
G G
AK300303AC

YES : Check intermediate connectors C-203 and C-135
C-205, and repair if necessary. If
intermediate connectors are normal, check
and repair harness between C-04 (terminal
38 37 36 35 34 33 32 31
No. 42) combination meter connector and 46 45 44 43 42 41 40 39
C-303 (terminal No. 2) ignition switch Harness side connector
connector.
• Check power supply line for AK300256 AC
open/short circuit. • Disconnect connector, and measure at the har-

NO : Repair. ness side.
OK: System voltage
NO : Go to Step 8 .
TROUBLESHOOTING
STEP 8: Check connector: C-05 combination STEP 9: Connector check: C-303 ignition switch
meter connector connector
C-05 (L)
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AC

11 10 9 8 7 6 5 4 3 2 1 YES : Go to Step 10 .
22 2120 19 18 17 16 15 14 1312
NO : Repair.
G G
AK300305 AC
Connector: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

combination meter connector and C-135
circuit.
NO : Repair.
TROUBLESHOOTING
13A-191
STEP 10: Check harness between C-04 (terminal STEP 11: Connector check: C-05 ignition switch
No. 42) combination meter connector and C-303 connector
(terminal No. 2) ignition switch connector.
Connector: C-05
Connector: C-04
C-05 (L)
C-04
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G G
G G Harness side connector
AK300305 AC
AK300303AC
Connector: C-303
NO : Repair.
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AC

connectors C-203 and C-205, and repair if neces-
sary.
NO : Repair.
TROUBLESHOOTING
STEP 12: Check harness between C-05 (terminal STEP 13: Check the trouble symptoms.
No. 14) combination meter connector and C-135 Q: Does trouble symptom persist?
00 − How to Use
C-05 (L) Troubleshooting/Inspection Service Points
P.00-6).
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G G
AK300305 AC
Connector: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

NO : Repair.
TROUBLESHOOTING
13A-193
Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and never goes out
C-303
R LOCK
1 2 3 ST
Ignition switch
ACC
4 5 6 IG1 IG2
L-B
C-203
6
2 J/B
7.5A
25
C-205
C-04
B-W
42 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G G

1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122 14
G G
R-W
7
C-105
R-W
36
C-135
Engine-ECU
31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46
Wire colour code

AK401039 AB
OPERATION • Engine-ECU (terminal No. 36) makes power tran-

• Battery voltage is applied to engine warning lamp sistor in unit be in "ON" position, and that makes
(terminal No. 42) from ignition switch. currents go on engine warning lamp (terminal No.
14).
TROUBLESHOOTING
COMMENT ON TROUBLE SYMPTOM STEP 3: Perform voltage measurement at C-135

• Engine-ECU has detected failed sensor or failed engine-ECU connector.
actuator. Or failure is possibly caused by short
circuit or other faults. Connector: C-135
PROBABLE CAUSE
• Short circuit in between engine warning lamp and
engine-ECU circuit.
C-135
DIAGNOSIS PROCEDURE
STEP 1: M.U.T.-II/III diagnosis code 38 37 36 35 34 33 32 31

Q: Diagnosis code set? 46 45 44 43 42 41 40 39
YES : Inspection chart for diagnosis code (Refer Harness side connector
to P.13A-15.)
AK300256 AC
NO : Go to Step 2 .
Connector: C-05
STEP 2: Connector check: C-135 engine-ECU
connector C-05 (L)
Connector: C-135
C-135
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G G
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300305 AC
AK300256 AC ness side.
NO : Repair. OK: System voltage
NO : Check intermediate connector C-105, and
TROUBLESHOOTING
13A-195
STEP 4: Check the trouble symptoms.
00 − How to Use
P.00-6).
Inspection Procedure 5: Starting impossible (No Initial Combustion)
COMMENT ON TROUBLE SYMPTOM STEP 2: M.U.T.-II/III data list

• Failure is possibly caused by failed starter itself • Item 18: Cranking signal
or failed related circuit. OK:
ON (Ignition switch: ST)
PROBABLE CAUSE
OFF (Ignition switch: ON)
• Failed battery
• Failed starter motor Q: Is the check result normal?
• Open/short circuit in starter associated circuit or YES : Go to Step 8 .
loose connector contact NO : Go to Step 3 .
DIAGNOSIS PROCEDURE STEP 3: Connector check: C-137 engine-ECU

connector
STEP 1: Check battery voltage. Connector: C-137
• Measure battery voltage at cranking.
OK: 8 V or higher
NO : Check battery (Refer to GROUP 54A −
Battery − On-vehicle Service − Battery Test
C-137
P.54A-7).
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

NO : Repair.
TROUBLESHOOTING
STEP 4: Perform voltage measurement at C-137 STEP 6: Check ignition switch.

Connector: C-137
Connector: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
8180 79 78 77 76 75 74 73 72 71 92 91 90 89 88 87 86 85 84 83 82
92 91 90 89 88 87 86 85 84 83 82 Harness side connector
AK300254 AC
AK300254 AC
Connector: C-303
ness side.
• Ignition switch: ST
C-303
OK: System voltage
3 2 1
Q: Is the check result normal? 6 5 4
YES : Go to Step 7 . Harness side
NO : Go to Step 5 . connector
AK300304 AC
STEP 5: Connector check: C-303 ignition switch • Check ignition switch (Refer to GROUP 54A −
connector Ignition Switch − Ignition Switch P.54A-30).
YES : Check intermediate connectors C-106 and
B-19, and repair if necessary. If intermediate
connector are normal, check and repair
C-303 inhibitor switch connector and C-303
3 2 1
6 5 4
Harness side open/short circuit.
connector
AK300304 AC NO : Replace ignition switch.

NO : Repair.
TROUBLESHOOTING
13A-197
STEP 7: Connector check: C-303 ignition switch STEP 8: Check connector: B-26 starter connector
connector and B-26 starter connector
Connector: B-26
Connector: C-303
C-303 B-26 (B)

3 2 1
6 5 4 1

connector connector AK300306 AC
AK300304 AC
Connector: B-26 YES : Go to Step 9 .
NO : Repair.
STEP 9: Perform voltage measurement at B-26

starter connector.
B-26 (B)
Connector: B-26
1
Harness side

B-19, and repair if necessary. If intermediate 1
connectors are normal, check and repair Harness side
harness between C-303 (terminal No. 5) connector AK300306 AC
ignition switch connector and B-26 (terminal • Disconnect connector, and measure at the har-
No. 1) starter connector. ness side.
• Check output line for short circuit. • Ignition switch: ST
NO : Repair.
OK: System voltage
TROUBLESHOOTING
STEP 10: Connector check: C-303 ignition switch STEP 11: Connector check: B-25 starter
connector connector
C-303
3 2 1 B-25
6 5 4 1
Harness side
AK300304 AC connector AK300307 AC

NO : Repair.
STEP 12: Perform voltage measurement at B-25

B-26 (B) starter connector.
1 Connector: B-25
Harness side

YES : Check intermediate connectors B-19 and B-25
C-106, and repair if necessary. If 1
and repair harness between C-303 (terminal Harness side
No. 5) ignition switch connector and B-26 connector AK300307 AC
(terminal No. 1) starter connector. • Disconnect connector, and measure at the har-
• Check output line for open circuit and ness side.
damage. • Voltage between terminal No. 1 and earth.
NO : Repair.
OK: System voltage
(terminal No. 1) starter connector and
battery.
open/short circuit.
TROUBLESHOOTING
13A-199
STEP 13: Check harness between C-303 (terminal STEP 14: Check harness between B-25 (terminal
No. 5) ignition switch connector and B-26 No. 1) starter connector and battery.
(terminal No. 1) starter connector.
Connector: B-25
Connector: C-303
C-303 B-25
3 2 1 1
6 5 4
connector connector AK300307 AC
AK300304 AC
YES : Replace starter.
NO : Repair.
B-26 (B)
1
Harness side

connectors B-19 and C-106, and repair if necessary.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 6: Starting impossible (Starter Operative but No Initial Combustion)
COMMENT ON TROUBLE SYMPTOM STEP 4: M.U.T.-II/III actuator test

• Failure is possibly caused by failed ignition cir- • Item 07: Fuel pump
cuit, failed fuel feed or other faults. OK: Operating sound of fuel pump can be
heard.
PROBABLE CAUSE
• Failed battery Q: Is the check result normal?
• Timing belt broken YES : Go to Step 5 .
• Failed idle speed control NO : Check fuel pump system (Refer to
• Throttle valve fouled around Inspection Procedure 24 P.13A-247)
• Failed ignition system
• Failed fuel system STEP 5. Check timing belt for breakage.
• Failed immobilizer system • Engine: Cranking
• Failed engine-ECU OK: Camshaft rotates.
DIAGNOSIS PROCEDURE Q: Is the check result normal?

NO : Replace timing belt.
STEP 1: Check battery voltage.
STEP 6. Check the engine start ability.
OK: 8 V or higher • With depressing the accelerator pedal slightly,
Q: Is the check result normal? and start the engine.
YES : Go to STEP 2 . Q: Is the start ability good?
NO : Check battery (Refer to GROUP 54 − YES : Go to Step 7 .
Battery − On-vehicle Service − Battery test NO : Go to Step 8 .
P.54A-7).
STEP 7: Check idling speed control for operating
STEP 2: Check engine warning lamp for burnt out sound.
bulb. • Check idle speed control servo for operating
Q: Is the check result normal? sound (Refer to P.13A-326).
YES : Go to Step 3 . Q: Is the check result normal?
NO : Check engine-ECU power supply, engine YES : Clean throttle body (throttle valve portion)
control relay and ignition switch IG1 system (Refer to P.13A-315).
(Refer to Inspection Procedure 23 NO : Check idle speed control servo system
P.13A-239). (Refer to code No. P0505 P.13A-159).
STEP 3: M.U.T.-II/III diagnosis code STEP 8: M.U.T.-II/III data list

Q: Diagnosis code set?
• Item 18: Cranking signal
YES : Inspection chart for diagnosis codes (Refer OK:
to P.13A-15) ON (Ignition switch: ST)
NO : Go to Step 4 . OFF (Ignition switch: ON)
NO : Go to Step 9 .
TROUBLESHOOTING
13A-201
STEP 9: Connector check: C-137 engine-ECU STEP 10: M.U.T.-II/III data list
connector • Refer to Data list reference table P.13A-293.
Connector: C-137
Code No. P0335 P.13A-124).
STEP 11: Check injector for operating sound.

C-137 • Check injector for operating sound (Refer to
P.13A-325).
Q: Can operating sound be heard?
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
NO : Check the injector system of the defective
cylinder.
AK300254 AC (Refer to Code No. P0201: No. 1 injector
system P.13A-87.)
Connector: C-303 (Refer to Code No. P0202: No. 2 injector
system P.13A-92.)
(Refer to Code No. P0203: No. 3 injector
system P.13A-97.)
C-303 (Refer to Code No. P0204: No. 4 injector
3 2 1 system P.13A-102.)
6 5 4
Harness side STEP 12: Connector check: B-110 and B-111
connector
AK300304 AC ignition coil connectors
Connector: B-110, B-111
YES : Check intermediate connectors B-19 and 3 2 1
C-106, and repair if necessary. If Harness side
intermediate connectors are normal, check connector
B-111 (GR)
No. 5) ignition switch connector and C-137
• Check output line for open/short B-110 (GR)
circuit.
AK300308 AB
NO : Repair.
NO : Repair.
TROUBLESHOOTING
STEP 13: Perform voltage measurement at each STEP 14: Connector check: C-303 ignition switch
of B-110 and B-111 ignition coil connectors. connector
Connector: B-110, B-111 Connector: C-303
3 2 1
Harness side
connector
B-111 (GR)
C-303
3 2 1
6 5 4
B-110 (GR) Harness side

connector
AK300308 AB AK300304 AC

ness side.
• Ignition switch: ON 3 2 1
• Voltage between terminal No. 1 and earth. Harness side
connector
OK: System voltage B-111 (GR)
B-110 (GR)
AK300308 AB

YES : Check intermediate connectors A-14,
C-116, C-203 and C-205, and repair if
necessary. Check and repair harness
between C-303 (terminal No. 2) ignition
switch connector and (terminal No. 1)
affected cylinders ignition coil connector.
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13A-203
STEP 15: Check harness between C-303 (terminal STEP 16: Check ignition secondary voltage
No. 2) ignition switch connector and (terminal waveform using an oscilloscope.
No. 1) affected cylinders ignition coil connector. • Check ignition secondary voltage waveform
NOTE: Before checking harness, check intermediate (Refer to GROUP 16 − Ignition System −
connectors A-14, C-116, C-203 and C-205, and On-vehicle Service P.16-41)
repair if necessary. Q: Is the check result normal?
. YES : Go to Step 18 .
• Check power supply line for damage. NO : Go to Step 17 .
Connector: C-303
STEP 17: Check spark plug.
• Check spark plug (Refer to GROUP 16 − Ignition
System − On-vehicle Service P.16-40)
C-303 Q: Is the check result normal?
3 2 1 YES : Go to Step 18 .
6 5 4 NO : Replace spark plug.
Harness side
connector
AK300304 AC
STEP 18: Replace engine-ECU
• After replacing the engine-ECU, re-check the
Connector: B-110, B-111 trouble symptoms.
3 2 1
YES : Check for foreign matters (water, kerosene,
Harness side
connector etc.) in fuel and replace if necessary.
B-111 (GR) NO : Check end.
B-110 (GR)
AK300308 AB

NO : Repair.
TROUBLESHOOTING
Inspection Procedure 7: Starting Impossible (Initial Combustion But no Complete Combustion),

Improper Starting (Long time to Start)

• Failure is possibly caused by poor ignition, incor- • Refer to Data list reference table P.13A-293.
rect air-fuel ratio at cranking, improper fuel pres- a. Item 13: Intake air temperature sensor
sure or other faults. b. Item 21: Engine coolant temperature sensor
PROBABLE CAUSE c. Item 25: Barometric pressure sensor
• Failed battery Q: Are the check results normal?
• Failed ignition system YES : Go to Step 5 .
• Failed fuel system NO : Perform the diagnosis code classified check
• Air-fuel ratio control procedure for the sensor that has shown an
• Failed idle speed control system abnormal data value (Refer to Inspection
• Failed intake system Chart for Diagnosis Codes P.13A-15).
• Failed exhaust gas cleaning system
• Throttle valve fouled around STEP 5: Check start ability.
• Timing belt not in place • With depressing the accelerator pedal slightly,
• Compression pressure improper and start the engine.
Q: Is the start ability good?
DIAGNOSIS PROCEDURE NO : Go to Step 7 .
STEP 1: Check battery condition. STEP 6: Check idle speed control servo for
Q: Have the battery terminal been disconnected? operating sound.
YES : After warm-up engine, idle for about 10 • Check idle speed control servo for operating
minutes. sound (Refer to P.13A-326).
NO : Go to Step 2 .
YES : Clean throttle body (throttle valve portion)
STEP 2: Check battery voltage. (Refer to P.13A-315).
• Measure battery voltage at cranking. NO : Check idle speed control servo system
OK: 8 V or higher (Refer to Code No. P0505 P.13A-159).

YES : Go to Step 3 . STEP 7: M.U.T.-II/III actuator test
NO : Check battery (Refer to GROUP 54 − • Item 07: Fuel pump
Battery − On-vehicle Service − Battery Test OK: Operating sound of fuel pump can be
P.54A-7). heard.
STEP 3: M.U.T.-II/III diagnosis code YES : Go to Step 8 .
NO : Check fuel pump system (Refer to
Inspection Procedure 24 P.13A-247).
YES : Inspection chart for diagnosis codes (Refer
to P.13A-15)
NO : Go to Step 4 . STEP 8: Check air intake from intake hose and
inlet manifold.
NO : Repair.
TROUBLESHOOTING
13A-205
STEP 9: Check injector for operating sound. STEP 12: Connector check: C-134 engine-ECU
• Check injector for operating sound at engine connector
cranking (Refer to P.13A-325).
Connector: C-134
cylinder.
(Refer to Code No. P0201: No.1 injector system
P.13A-87.)
(Refer to Code No. P0202: No.2 injector system C-134
P.13A-92.)
(Refer to Code No. P0203: No.3 injector system
P.13A-97.) 13 12 11 10 9 8 7 6 5 4 3 2 1
(Refer to Code No. P0204: No.4 injector system 26 25 24 23 22 21 20 19 18 17 16 15 14
P.13A-102.) Harness side connector
AK300257 AC
STEP 10. Check timing marks of timing belt.
Q: Is the check result normal? YES : Check and repair harness between C-134
YES : Go to Step 11 . (terminal No. 13 and No. 26) engine-ECU
NO : Align timing marks. connector and body earth.
STEP 11: Perform voltage measurement at C-134 and damage.
engine-ECU connector. NO : Repair.
Connector: C-134
STEP 13: Connector check: B110 and B-111
ignition coil connectors
3 2 1
Harness side
C-134 connector
B-111 (GR)
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 B-110 (GR)
AK300257 AC
• Measure engine-ECU terminal voltage. YES : Go to Step 14 .
• Ignition switch: ON NO : Repair.
• Voltage between terminal No. 13 and earth, also
between terminal No. 26 and earth. STEP 14: Check ignition secondary voltage
OK: 0.5 V or less waveform using an oscilloscope.
Q: Is the check result normal? • Check ignition secondary voltage waveform
YES : Go to Step 13 . (Refer to GROUP 16 − Ignition System −
NO : Go to Step 12 . On-vehicle Service P.16-41)
TROUBLESHOOTING
STEP 15: Check spark plug. STEP 18: Check harness between terminal No. 2
• Check spark plug (Refer to GROUP 16 − Ignition of each cylinder’s ignition coil connector and
System − On-vehicle Service P.16-40) vehicle body earth.
Q: Is the check result normal? Connector: B-110, B-111
NO : Replace spark plug. 3 2 1
Harness side
connector
STEP 16: Check spark plug cable itself. B-111 (GR)
• Check spark plug cable itself (Refer to GROUP
16 − Ignition System − On-vehicle Service
P.16-40). B-110 (GR)
NO : Replace spark plug cable. Connector: C-134
STEP 17: Check ignition coil itself.

• Check ignition coil itself (Refer to GROUP 16 −
Ignition System − On-vehicle Service P.16-38).
NO : Replace ignition coil.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

YES : Check and repair harness between terminal
No. 3 of each cylinder’s ignition coil
connector and C-134 engine-ECU
connector.
• Check signal line for open/short
circuit and damage.
NO : Repair.
STEP 19: Check spray condition of injector.

• Check each injector for spray condition (Refer to
P.13A-325).
NO : Replace injector.
STEP 20: Check compression pressure.

• Check compression pressure (Refer to GROUP
11A − On-vehicle Service P.11A-13).
NO : Repair.
TROUBLESHOOTING
13A-207
STEP 21: Check EGR control solenoid valve STEP 22: Check EGR valve itself.
itself. • Check EGR valve itself [Refer to GROUP 17 −
• Check EGR control solenoid valve itself [Refer to Emission Control System − Exhaust Gas Recir-
GROUP 17 − Emission Control System − culation (EGR) System P.17-71].
Exhaust Gas Recirculation (EGR) System Q: Is the check result normal?
P.17-72]. YES : Go to Step 23 .
Q: Is the check result normal? NO : Replace EGR valve.
NO : Replace EGR control solenoid valve. STEP 23: Replace engine-ECU.
trouble symptoms.
etc.) in fuel and replace if necessary.
NO : Check end.
Inspection Procedure 8: Unstable idling (Rough idling, hunting), Improper idling speed (Too high or
too low), Engine stalls during idling (Die out)
COMMENT ON TROUBLE SYMPTOM STEP 2: M.U.T.-II/III diagnosis code

• Probable causes can be widely found in ignition
system, air-fuel ratio control system, idle speed
control system, fuel system, etc. A sudden
to P.13A-15).
engine stall is possibly caused by poor connector
NO : Go to Step 3 .
contact.
PROBABLE CAUSE STEP 3: M.U.T.-II/III data list

• Failed ignition system • Refer to Data list reference table P.13A-293.
• Failed fuel system a. Item 12: Air flow sensor
• Failed air-fuel ratio control system b. Item 13: Intake air temperature sensor
• Failed idle speed control system c. Item 14: Throttle position sensor
• Failed intake/exhaust system d. Item 21: Engine coolant temperature sensor
• Failed emission gas cleaning system
e. Item 25: Barometric pressure sensor
• Throttle valve body fouled
• Timing belt out of place Q: Are the check results normal?
• Compression pressure improper YES : Go to Step 4 .
• Failed engine-ECU NO : Perform the diagnosis code classified check
DIAGNOSIS PROCEDURE abnormal data value (Refer to Inspection
STEP 1: Check battery condition.

STEP 4: M.U.T.-II/III data list
Q: Has the battery terminal been disconnected? • Refer to Data list reference table P.13A-293.
YES : After warm-up engine, idle for about 10 a. Item 27: Power steering fluid pressure switch
minutes.
NO : Go to Step 2 . Q: Is the check result normal?
NO : Check power steering fluid pressure switch
system (Refer to Code No. P0551
P.13A-164).
TROUBLESHOOTING
STEP 5: Check idle speed control servo for STEP 11: Perform voltage measurement at C-134
operating sound. engine-ECU connector.
• Check idle speed control servo for operating
Connector: C-134
sound (Refer to P.13A-326).
NO : Check idle speed control servo system
(Refer to Code No. P505 P.13A-159).
C-134
STEP 6: Check throttle body (throttle valve
portion) for contamination.
YES : Go to Step 7 . 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
(Refer to P.13A-315). Harness side connector
AK300257 AC
STEP 7: Check air intake from intake hose and • Measure engine-ECU terminal voltage.
inlet manifold. • Ignition switch: ON
Q: Is the check result normal? • Voltage between terminal No. 13 and earth, also
YES : Go to Step 8 . between terminal No. 26 and earth.
NO : Repair. OK: 0.5 V or less
STEP 8: Check injector for operating sound. YES : Go to Step 13 .
• Check injector for operating sound (Refer to NO : Go to Step 12 .
P.13A-325).
Q: Can operating sound be heard? STEP 12: Connector check: C-134 engine-ECU
YES : Go to Step 9 . connector
Connector: C-134
cylinder.
system P.13A-87.)
system P.13A-92.)
system P.13A-97.) C-134
system P.13A-102.)
13 12 11 10 9 8 7 6 5 4 3 2 1
STEP 9: Check timing marks of timing belt. 26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Align timing marks.
• Refer to Data list reference table P.13A-293. (terminal No. 13 and No. 26) engine-ECU
Q: Is the check result normal? and damage.
to Code No. P0130 P.13A-61).
TROUBLESHOOTING
13A-209
engine-ECU connector. connector and B-30 alternator connector
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AC AK300256 AC

Connector: B-30
• Engine: Idling after warm-up
• Radiator fan: Not operating
B-30 (GR)
OFF causes the voltage to increase by 0.2 −
3.5 V. 4 3 2 1
Q: Is the check result normal? Harness side
connector
NO : Repair.
TROUBLESHOOTING
STEP 15. Check harness between C-135 (terminal STEP 16. Perform voltage measurement at C-135
No. 33) engine-ECU connector and B-30 (terminal engine-ECU connector.
No. 1) alternator connector.
Connector: C-135
Connector: C-135
C-135
C-135
38 37 36 35 34 33 32 31
38 37 36 35 34 33 32 31 46 45 44 43 42 41 40 39
AK300256 AC
AK300256 AC
Connector: B-30
B-30 (GR) OK: Switching the headlamps to ON from
OFF causes the voltage to fall.
4 3 2 1 YES : Go to Step 20 .

connector B-19, and repair if necessary.
age.
NO : Repair.
TROUBLESHOOTING
13A-211
STEP 17. Connector check: C-135 engine-ECU STEP 18. Check harness between C-135 (terminal
connector and B-30 alternator connector No. 41) engine-ECU connector and B-30 (terminal
Connector: C-135
Connector: C-135
C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31
Harness side connector 46 45 44 43 42 41 40 39
AK300256 AC
AK300256 AC
Connector: B-30
Connector: B-30
B-30 (GR)
B-30 (GR)
4 3 2 1
Harness side 4 3 2 1
connector AK300296 AC Harness side
YES : Go to Step 18 . NOTE: Before checking harness, check intermediate
NO : Repair. connector B-19, and repair if necessary.
age.
NO : Repair.

00 − How to Use
P.00-6).
TROUBLESHOOTING
STEP 20. Perform voltage measurement at C-134 STEP 21. Connector check: B-110 and B-111
engine-ECU connector. ignition coil connectors
Connector: C-134 Connector: B-110, B-111
3 2 1
Harness side
connector
B-111 (GR)
C-134
B-110 (GR)
AK300308 AB
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
NO : Repair.
AK300257 AC
• Measure engine-ECU terminal voltage. STEP 22. Check ignition secondary voltage
• Engine: Idling waveform using an oscilloscope.
• A/C switch: ON (A/C compressor ON) • Check ignition secondary voltage waveform
• Voltage between terminal No. 24 and earth. (Refer to GROUP 16 − Ignition System −
OK: On-vehicle Service P.16-41)
1 V or less (with outside air temperature sen- Q: Is the check result normal?
sor ambient temperature at 18°C or higher YES : Go to Step 27 .
and A/C set for maximum air flow at mini- NO : Go to Step 23 .
mum temperature)
System voltage (with A/C set for minimum air
STEP 23. Check spark plug.
flow at room temperature) • Check spark plug (Refer to GROUP 16 − Ignition
Q: Is the check result normal? System − On-vehicle Service P.16-40)
NO : Check A/C load signal system (Refer to
Inspection Procedure 28 P.13A-273). NO : Replace spark plug.
STEP 24. Check individual spark plug cable

P.16-40).
Q: Q: Is the check result normal?
NO : Replace spark plug cable.
STEP 25. Check ignition coil itself.

TROUBLESHOOTING
13A-213
STEP 26. Check harness between terminal No. 2 STEP 29. Check purge control solenoid valve
of ignition coil connector of each cylinder and itself.
body earth. • Check purge control solenoid valve itself (Refer
Evaporative Emission Control System P.17-65)
Harness side YES : Go to Step 30 .
connector
B-111 (GR) NO : Replace purge control solenoid valve.
STEP 30. Check EGR control solenoid valve

B-110 (GR)
itself.
• Check EGR control solenoid valve itself [Refer to
AK300308 AB
GROUP 17 − Emission Control System −
Exhaust Gas Recirculation (EGR) System
Connector: C-134
P.17-72].

C-134
itself.
13 12 11 10 9 8 7 6 5 4 3 2 1 Exhaust Gas Recirculation (EGR) System
26 25 24 23 22 21 20 19 18 17 16 15 14
P.17-71].
• Check earthing line for open/short circuit and NO : Replace EGR valve.
damage.
Q: Is the check result normal? STEP 32. M.U.T.-II/III actuator test
YES : Check and repair harness between terminal • Item 07: Fuel pump
No. 3 of ignition coil connector of each OK: Operating sounds of fuel pump can be
cylinder and C-134 engine-ECU heard.
• Check signal line for open/short and
damage. YES : Go to Step 33 .
NO : Repair. NO : Check fuel pump system (Refer to
inspection Procedure 24 P.13A-247).
STEP 27. Check injector for spray condition.
• Check each injector for spray condition (Refer to STEP 33. Replace engine-ECU.
P.13A-325). • After engine-ECU is replaced, re-check for trou-
Q: Is the check result normal? ble symptom.
YES : Go to Step 28 . Q: Does trouble system persist?
NO : Replace injector. YES : Check for foreign matters (water, kerosene,
STEP 28. Check compression pressure. NO : Check end.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 9: The Engine Stalls when Starting the Car (Pass Out)
COMMENT ON TROUBLE SYMPTOM STEP 5. Connector check: B-110 and B-111

• Engine stall on starting is possibly caused by mis- ignition connectors.
fire due to failed spark plug, improper air-fuel
ratio at accelerator pedal depression or other Connector: B-110, B-111
faults. 3 2 1
Harness side
• Failed ignition system B-111 (GR)
• Failed intake system
• Failed engine-ECU B-110 (GR)
DIAGNOSIS PROCEDURE AK300308 AB

STEP 1. M.U.T.-II/III diagnosis code YES : Go to Step 6 .
NO : Repair.
to P.13A-15). STEP 6. Check ignition secondary voltage
NO : Go to Step 2 . waveform using an oscilloscope.
(Refer to GROUP 16 − Ignition System −
STEP 2. Check EGR control solenoid valve itself. On-vehicle Service P.16-41)
GROUP 17 − Emission Control System − Q: Is the check result normal?
Exhaust Gas Recirculation (EGR) System YES : Replace engine-ECU.
NO : Go to Step 7 .
P.17-72].
NO : Replace EGR control solenoid valve. • Check spark plug (Refer to GROUP 16 − Ignition
STEP 3. Check EGR valve itself. Q: Is the check result normal?

• Check EGR valve itself [Refer to GROUP 17 −
NO : Replace spark plug.
Emission Control System − Exhaust Gas Recir-
culation (EGR) System P.17-71].
STEP 8.Check spark plug cable itself.
NO : Replace EGR valve. 16 − Ignition System − On-vehicle Service
P.16-40).
STEP 4. Check air intake from intake hose and Q: Is the check result normal?
inlet manifold. YES : Go to Step 9 .
NO : Repair. STEP 9. Check ignition coil itself.
TROUBLESHOOTING
13A-215
STEP 10. Check harness between terminal No. 2
of ignition coil connector of each cylinder and
body earth.
3 2 1
Harness side
connector
B-111 (GR)
B-110 (GR)
AK300308 AB
Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

No. 3 of ignition coil connector of each
cylinder and C-134 engine-ECU.
circuit and damage.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 10. The Engine Stalls when Decelerating
COMMENT ON TROUBLE SYMPTOM STEP 5. Check EGR valve itself.

• Engine stall on deceleration is possibly caused by • Check EGR valve itself [Refer to GROUP 17 −
insufficient air intake, improper air-fuel ratio due Emission Control System − Exhaust Gas Recir-
to failed exhaust gas recirculation system or culation (EGR) System P.17-71].
other faults.
PROBABLE CAUSE YES : Go to Step 6 .
NO : Replace EGR valve.
• Failed idle speed control system
• Failed emission control system STEP 6. Check throttle body (throttle valve
• Throttle valve fouled portion) for contamination.
DIAGNOSIS PROCEDURE NO : Clean throttle body (throttle valve portion)
STEP 7. Connector check: B-110 and B-111
YES : Inspection chart for diagnosis code (Refer ignition coil connectors
to P.13A-15). Connector: B-110, B-111
NO : Go to Step 2 .
3 2 1
Harness side
STEP 2. M.U.T.-II/III data list connector
• Refer to Data list reference table P.13A-293. B-111 (GR)
a. Item 14: Throttle position sensor
YES : Go to Step 3 . B-110 (GR)
NO : Check throttle position sensor system AK300308 AB
NO : Repair.
• Item 45: Idle speed control servo position
OK: Idle speed control servo drops to 0 − 2
Steps at deceleration (engine at 1,000 r/min STEP 8. Check ignition secondary voltage
or higher). waveform using an oscilloscope.
Q: Is the check result normal? (Refer to GROUP 16 − Ignition System −
YES : Go to Step 4 . On-vehicle Service P.16-41)
(Refer to Code No. P0505 P.13A-159). Q: Is the check result normal?
NO : Go to Step 9 .
STEP 4. Check EGR control solenoid valve itself.
GROUP 17 − Emission Control System − STEP 9. Check spark plug.
Exhaust Gas Recirculation (EGR) System • Check spark plug (Refer to GROUP 16 − Ignition
P.17-72]. System − On-vehicle Service P.16-40)
TROUBLESHOOTING
13A-217
STEP 10. Check spark plug cable itself. STEP 12. Check harness between terminal No. 2
• Check spark plug cable itself (Refer to GROUP of ignition coil connector of each cylinder and
16 − Ignition System − On-vehicle Service body earth.
P.16-40).
YES : Go to Step 11 . 3 2 1
NO : Replace spark plug cable. Harness side
connector
B-111 (GR)
Ignition System − On-vehicle Service P.16-38). B-110 (GR)
NO : Replace ignition coil. Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

circuit and damage.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 11: Engine does not Revole Up
COMMENT ON TROUBLE SYMPTOM STEP 4. Check ignition secondary voltage

• Failure is possibly caused by failed fuel system, waveform using an oscilloscope.
ignition system or other faults. • Check ignition secondary voltage waveform
PROBABLE CAUSE On-vehicle Service P.16-41)
• Failed fuel system
• Timing belt out of place
NO : Go to Step 5 .
DIAGNOSIS PROCEDURE STEP 5. Check spark plug.

Q: Diagnosis code set? YES : Go to Step 6 .
YES : Inspection chart for diagnosis code (Refer NO : Replace spark plug.
to P.13A-15).
NO : Go to Step 2 .
STEP 6. Check spark plug cable itself.
STEP 2. Check timing marks of timing belt. 16 − Ignition System − On-vehicle Service
Q: Is the check result normal? P.16-40).
NO : Align match marks.
STEP 3. Connector check: B-110 and B-111
ignition coil connectors STEP 7. Check ignition coil itself.
Connector: B-110, B-111 • Check ignition coil itself (Refer to GROUP 16 −
3 2 1
B-111 (GR) NO : Replace ignition coil.
B-110 (GR)
AK300308 AB

NO : Repair.
TROUBLESHOOTING
13A-219
STEP 8. Check harness between terminal No. 2 of STEP 9. Fuel pressure measurement.
ignition coil connector of each cylinder and body • Fuel pressure measurement (Refer to
earth. P.13A-316).
Connector: B-110, B-111 Q: Is the check result normal?
3 2 1 NO : Repair.
Harness side
connector
B-111 (GR)
B-110 (GR)
AK300308 AB
Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

circuit and damage.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 12: Hesitation, sag,poor acceleration, stumble, surge
COMMENT ON TROUBLE SYMPTOM STEP 3. M.U.T.-II/III data list

• Failure is possibly caused by failed ignition sys- • Refer to Data list reference table P.13A-293.
tem, improper air-fuel ratio, improper compres- a. Idem 13: Intake air temperature sensor
sion pressure or other faults. b. Item 14: Throttle position sensor
PROBABLE CAUSE c. Item 21: Engine coolant temperature sensor
• Failed air-fuel ratio control system d. Item 25: Barometric pressure sensor
• Failed ignition system Q: Are the check results normal?
• Failed fuel system YES : Go to Step 4 .
• Failed intake and exhaust system NO : Perform the diagnosis code classified check
• Failed emission control system Procedure for the sensor that has shown an
• Throttle valve fouled abnormal data value (Refer to Inspection
• Improper compression pressure Chart for Diagnosis Codes P.13A-15).
STEP 4. Check purge control solenoid valve
DIAGNOSIS PROCEDURE itself.
• Check purge control solenoid valve itself (Refer
STEP 1. M.U.T.-II/III diagnosis code to GROUP 17 − Emission Control System −
YES : Inspection chart for diagnosis code (Refer Q: Is the check result normal?
to P.13A-15). YES : Go to Step 5 .
NO : Go to Step 2 . NO : Replace purge control solenoid valve.
STEP 2. Check injector for operating sound. STEP 5. Check EGR control solenoid valve itself.
• Check injector for operating sound (Refer to • Check EGR control solenoid valve itself [Refer to
P.13A-325). GROUP 17 − Emission Control System −
Exhaust Gas Recirculation (EGR) System
Q: Can operating sound be heard? P.17-72].
NO : Check the injector system of the defective Q: Is the check result normal?
cylinder. YES : Go to Step 6 .
(Refer to code No. P0201: No. 1 injector system NO : Replace EGR control solenoid valve.
P.13A-87).
(Refer to code No. P0202: No. 2 injector system STEP 6. Check EGR valve itself.
P.13A-92). • Check EGR itself [Refer to GROUP 17 − Emis-
(Refer to code No. P0203: No. 3 injector system sion Control System − Exhaust Gas Recirculation
P.13A-97). (EGR) System P.17-71].
(Refer to code No. P0204: No. 4 injector system Q: Is the check result normal?
P.13A-102). YES : Go to Step 7 .

NO : Check oxygen sensor system (Refer to
Code No. P0130 P.13A-61).
TROUBLESHOOTING
13A-221
STEP 8. Connector check: B-110 and B-111 STEP 13. Check harness between terminal No. 2
ignition coil connectors of ignition coil connector of each cylinder and
body earth.
3 2 1
Harness side 3 2 1
B-111 (GR) connector
B-111 (GR)
B-110 (GR)
B-110 (GR)
AK300308 AB
AK300308 AB
YES : Go to Step 9 . Connector: C-134
NO : Repair.

waveform using an oscilloscope.
C-134
NO : Go to Step 10 . 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
• Check spark plug (Refer to GROUP 16 − Ignition AK300257 AC
System − On-vehicle Service P.16-40) • Check earthing line for open circuit and damage.
YES : Go to Step 11 . YES : Check and repair harness between terminal
NO : Replace spark plug. No. 3 of ignition coil connector of each
cylinder and C-134 engine-ECU
STEP 11. Check spark plug cable itself. • Check signal line for open/short
• Check spark plug cable itself (Refer to GROUP circuit and damage.
16 − Ignition System − On-vehicle Service NO : Repair.
P.16-40).
STEP 14. Check throttle body (throttle valve
YES : Go to Step 12 . portion) for contamination.
NO : Replace spark plug cable. Q: Is the check result normal?
YES : Go to Step 13 . • Fuel pressure measurement (Refer to
NO : Replace ignition coil. P.13A-316).
NO : Repair.
TROUBLESHOOTING
STEP 16. Check compression pressure.

NO : Repair.
Inspection Procedure 13. The Feeling of Impact or Vibration when Accelerating
COMMENT ON TROUBLE SYMPTOM STEP 3. Check ignition secondary voltage

• Failure is possibly caused by failed ignition leak waveform using an oscilloscope.
with rise in spark plug-required voltage at accel- • Check ignition secondary voltage waveform
eration. (Refer to GROUP 16 − Ignition System −
PROBABLE CAUSE
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code System − On-vehicle Service P.16-40)
Q: Diagnosis code set? Q: Is the check result normal?
YES : Inspection chart for diagnosis code (Refer YES : Go to Step 5 .
to P.13A-15). NO : Replace spark plug.
NO : Go to Step 2 .

STEP 2. Check connector: B-110 and B-111 • Check spark plug cable itself (Refer to GROUP
ignition coil connectors 16 − Ignition System − On-vehicle Service
Connector: B-110, B-111 P.16-40).

Harness side
connector NO : Replace spark plug cable.
B-111 (GR)

B-110 (GR) Ignition System − On-vehicle Service P.16-38).
AK300308 AB Q: Is the check result normal?
Q: Is the check result normal? NO : Replace ignition coil.
NO : Repair.
TROUBLESHOOTING
13A-223
STEP 7. Check harness between terminal No. 2 of
ignition coil connector of each cylinder and body
earth.
3 2 1
Harness side
connector
B-111 (GR)
B-110 (GR)
AK300308 AB
Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

3 of ignition coil connector of each cylinder
and C-134 engine-ECU
circuit and damage.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 14: The feeling of impact or vibration when decelerating
COMMENT ON TROUBLE SYMPTOM STEP 2. Check idle speed control servo for
• Failure is possibly caused by insufficient air operating sound.
intake due to failed idle speed control system. • Check idle speed control servo for operating
sound (Refer to P.13A-326).
PROBABLE CAUSE
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code a. Item 14: Throttle position sensor
to P.13A-15). NO : Check throttle position sensor system
NO : Go to Step 2 .

Inspection Procedure 15: Knocking

• Failure is possibly caused by failed detonation ignition coil connectors
control, improper thermal value of spark plug or
other faults. Connector: B-110, B-111
3 2 1
PROBABLE CAUSE Harness side
• Defective detonation sensor connector
• Failed detonation control system B-111 (GR)
• Defective spark plug
• Failed engine-ECU B-110 (GR)

NO : Repair.
to P.13A-15).
NO : Go to Step 2 .
TROUBLESHOOTING
13A-225
STEP 3. Check ignition secondary voltage STEP 7. Check harness between ignition coil
waveform using an oscilloscope. connector terminal No. 2 of each cylinder and
• Check ignition secondary voltage waveform body earth.
YES : Check detonation sensor (Refer to Code Harness side
connector
No. P0325 P.13A-121). B-111 (GR)
NO : Go to Step 4 .
STEP 4. Check spark plug. B-110 (GR)

System − On-vehicle Service P.16-40) AK300308 AB


16 −Ignition System − On-vehicle Service
C-134
P.16-40).
NO : Replace spark plug cable. 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
• Check ignition coil itself (Refer to GROUP 16 − AK300257 AC
Ignition System − On-vehicle Service P.16-38). • Check earthing line for open circuit and damage.
YES : Go to Step 7 . YES : Check and repair harness between ignition
NO : Replace ignition coil. coil connector terminal No. 3 of each
cylinder and C-134 engine-ECU connector.
• Check signal line for open circuit,
short circuit and damage.
NO : Repair.
Inspection Procedure 16: Ignition Timing Offset
COMMENT ON TROUBLE SYMPTOM DIAGNOSIS PROCEDURE

• Failure is possibly caused by failed crank angle
sensor, failed camshaft position sensor, improper STEP 1. M.U.T.-II/III diagnosis code
installed timing belt or other faults.
PROBABLE CAUSE YES : Inspection chart for diagnosis code (Refer
• Failed crank angle sensor to P.13A-15).
• Failed camshaft position sensor NO : Go to Step 2 .
• Improperly installed timing belt
TROUBLESHOOTING
STEP 2. Perform output wave pattern • Voltage between terminal No. 2 and earth.
measurement of crank angle sensor and OK: Output waveform timings of both sen-
camshaft position sensor (Using an sors are the same as the check procedure
oscilloscope). (Refer to P.13A-305) using an oscilloscope.
2 1 NO : Go to Step 4 .
3
B-29 (B)
Harness side STEP 3. Check the trouble symptoms.
connector
00 − How to Use
P.00-6).
STEP 4. Check crank angle sensor and camshaft

position sensor mounted conditions.
NO : Repair.
Crank angle sensor
AK300276 AB STEP 5. Check timing marks of timing belt.

Connector: B-106
3 2 1
Harness side
connector STEP 6. Check crank angle sensor vane.
B-106 (B)
NO : Replace crank angle sensor vane.
AK300279 AB
Crank Angle Sensor cylinder.
• Use special tool test harness (MB998478) to con- Q: Is the check result normal?
nect B-29 crank angle sensor connector, and YES : Go to Step 8 .
measure at pick-up harness. NO : Replace camshaft position sensing cylinder.
• Engine: Idling
• Transmission: Neutral STEP 8. Replace crank angle sensor.
• Voltage between terminal No. 2 and earth. • After replacing the crank angle sensor, re-check
Camshaft Position Sensor the trouble symptoms.
• Use special tool test harness (MD991709) to con- Q: Does trouble symptom persist?
nect B-106 camshaft position sensor connector, YES : Go to Step 9 .
and measure at pick-up harness. NO : Check end.
• Engine: Idling
TROUBLESHOOTING
13A-227
STEP 9. Replace camshaft position sensor.
• After replacing the camshaft position sensor,
00 − How to Use
P.00-6).
Inspection Procedure 17: Run on (Dieseling)

• Failure is possibly caused by leakage from injec-
tor. STEP 1. Check injector for spray condition.
PROBABLE CAUSE
P.13A-325).
• Failed injector
• Failed engine-ECU Q: Does trouble symptom persist?
Inspection Procedure 18: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC during
Idling
COMMENT ON TROUBLE SYMPTOM STEP 2. Check injector for operating sound.

• Failure is possibly caused by improper air-fuel • Check injector for operating sound (Refer to
ratio, deteriorated catalyst, failed ignition system, P.13A-325).
failed fuel system, failed compression pressure or
other faults. Q: Can operating sound be heard?
PROBABLE CAUSE NO : Check the injector system of the defective
cylinder.
• Incorrect air/fuel ratio
(Refer to P.13A-87, Code P0201: No. 1 injector
System)
• Failed intake and exhaust system
System)
• Failed emission control system
• Failed compression pressure
System)
• Failed catalytic converter
(Refer to P.13A-102, Code P0204: No. 4
injector System)
DIAGNOSIS PROCEDURE
STEP 3. Check ignition timing.
• Check ignition timing. (Refer to GROUP 11A −
STEP 1. M.U.T.-II/III diagnosis code On-vehicle Service P.11A-11).
to P.13A-15). NO : Check for offset ignition timing (Refer to
NO : Go to Step 2 .
TROUBLESHOOTING
STEP 4. M.U.T.-II/III data list STEP 10. Check EGR control solenoid valve
• Refer to Data list reference table P.13A-293. itself.
a. Item 12: Air flow sensor • Check EGR control solenoid valve itself [Refer to
b. Item 13: Intake air temperature sensor GROUP 17 − Emission Control System −
c. Item 21: Engine coolant temperature sensor Exhaust Gas Recirculation (EGR) System
d. Item 25: Barometric pressure sensor P.17-72].
Q: Are the check results normal? Q: Is the check result normal?

NO : Perform the diagnosis code classified check NO : Replace EGR control solenoid valve.
Procedure for the sensor that has shown an
abnormal data value (Refer to Inspection STEP 11. Check EGR valve itself.
Chart for Diagnosis Codes P.13A-15). • Check EGR valve itself [Refer to GROUP 17 −
STEP 5. Check air intake from intake hose and culation (EGR) System P.17-71].
inlet manifold. Q: Is the check result normal?
NO : Repair.
STEP 6. Check for emission leakage from • Fuel pressure measurement (Refer to
exhaust manifold. P.13A-316).
NO : Repair. NO : Repair.
STEP 7. Check throttle body (throttle valve STEP 13. Check positive crankcase ventilation
portion) for contamination. valve itself.
• Check positive crankcase ventilation valve itself
Q: Is the check result normal? (Refer to GROUP 17 − Emission Control System
− crankcase Emission Control System P.17-60).
(Refer to P.13A-315). Q: Is the check result normal?
NO : Replace positive crankcase ventilation
valve.
Q: Is the check result normal? • Check spark plug (Refer to GROUP 16 − Ignition
to Code No. P0130 P.13A-61). Q: Is the check result normal?
STEP 9. Check Purge control solenoid valve
itself.
• Check purge control solenoid valve itself (Refer STEP 15. Check spark plug cable itself.
to GROUP 17 − Emission Control System − • Check spark plug cable itself (Refer to GROUP
Evaporative Emission Control System P.17-65). 16 − Ignition System − On-vehicle Service
P.16-40).
NO : Replace purge control solenoid valve. YES : Go to Step 16 .
TROUBLESHOOTING
13A-229
STEP 16. Check ignition coil itself. STEP 18. Check injector for spray condition.
• Check ignition coil itself (Refer to GROUP 16 − • Check each injector for spray condition (Refer to
Ignition System − On-vehicle Service P.16-38). P.13A-325).
Q: Is the check result normal? Q: Does trouble symptom persist?
NO : Replace ignition coil. NO : Replace injector.
STEP 17. Check compression pressure. STEP 19. Replace catalytic converter.
• Check compression pressure (Refer to GROUP • After replacing the catalytic converter, re-check
11A − On-vehicle Service P.11A-13). the trouble symptoms.
YES : Go to Step 18 . YES : Replace engine-ECU.
NO : Repair. NO : Check end
Inspection Procedure 19: Battery Rundown
COMMENT ON TROUBLE SYMPTOM STEP 2. Connector check: B-19 intermediate

• Failure is possibly caused by failed alternator, connector
failed generation control circuit or other faults.
Connector: B-19
PROBABLE CAUSE
• Failed battery
• Alternator G terminal short-circuited B-19 (B)
• Failed alternator
3 2 1
DIAGNOSIS PROCEDURE 6 5 4
Female side
STEP 1. Check battery voltage.
• Measure battery voltage during cranking. Q: Is the check result normal?
OK: 8 V or more NO : Repair.
NO : Check battery (Refer to GROUP 54 −
Battery − On-vehicle Service − Battery test
P.54A-7).
TROUBLESHOOTING
STEP 3. Perform voltage measurement at B-19 STEP 4. Connector check: C-303 ignition switch
intermediate connector. connector
B-19 (B)
C-303
3 2 1
1 2 3 6 5 4
4 5 6
Harness side
Male side connector
connector AK300295 AC AK300304 AC

Connector: B-19
nector side.
B-19 (B)
OK: System voltage
NO : Go to Step 4 . 4 5 6
Male side

YES : Check intermediate connectors C-04, C-05,
necessary. If intermediate connectors are
normal, check and repair harness between
B-19 (terminal No. 5) intermediate
ignition switch connector.
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13A-231
STEP 5. Perform voltage measurement at B-19 STEP 7. Check harness between B-19 (terminal
intermediate connector. No. 4) intermediate connector and B-30 (terminal
Connector: B-19
Connector: B-19
B-19 (B)
B-19 (B)
3 2 1
6 5 4 3 2 1
Female side 6 5 4
connector AK300294 AC Female side
connector
• Disconnect connector, and measure at female AK300294 AC
connector side.
Connector: B-30
OK: System voltage
Q: Is the check result normal? B-30 (GR)
NO : Go to Step 6 .
4 3 2 1
Harness side
STEP 6. Connector check: B-30 alternator connector AK300296 AC
connector
Connector: B-30
NO : Repair.
B-30 (GR)
4 3 2 1
Harness side

NO : Repair.
TROUBLESHOOTING
No. 5) intermediate connector and B-30 (terminal No. 3) alternator connector and C-303 (terminal
No. 3) alternator connector. No. 2) ignition switch connector.
B-19 (B)
B-30 (GR)
3 2 1
6 5 4 4 3 2 1
Female side Harness side
B-30 (GR)
C-303
3 2 1
6 5 4
4 3 2 1
Harness side
connector AK300296 AC AK300304 AC
• Check power supply line for open/short circuit. NOTE: Before checking harness, check intermediate
Q: Is the check result normal? connectors C-04, C-05, C-105, C-203 and C-205 and
YES : Go to Step 9 . repair if necessary.
NO : Repair. • Check power supply line for damage.
NO : Repair.

connector
Connector: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

NO : Repair.
TROUBLESHOOTING
13A-233
STEP 11. Perform voltage measurement at C-135 STEP 12. Perform voltage measurement at C-135
engine-ECU connector. engine-ECU connector.
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AC AK300256 AC

Connector: B-19
1 2 3 OFF causes the voltage to increase by 0.2 −
4 5 6 3.5 V.
Male side Q: Is the check result normal?
connector AK300295 AC YES : Go to Step 13 .
• Disconnect connector, and measure at harness NO : Check alternator.
side.
• Ignition switch: ON STEP 13. Check the trouble symptoms.
OK: System voltage YES : Replace engine-ECU.
Q: Is the check result normal? NO : Intermittent malfunction (Refer to GROUP
YES : Go to Step 12 . 00 − How to Use
NO : Check and repair harness between B-19 Troubleshooting/Inspection Service Points
(terminal No. 4) intermediate connector and P.00-6).
C-135 (terminal No. 33) engine-ECU
connector.
TROUBLESHOOTING
Inspection Procedure 20: Overheating
COMMENT ON TROUBLE SYMPTOM STEP 3. M.U.T.-II/III actuator test

• Failure is possibly caused by failed engine cool- • Item 21: Fan controller
ing system, failed fan controller, failed engine OK: Fan motor rotating
coolant temperature sensor or other faults.
• Insufficient or deteriorated engine coolant NO : Check fan control relay system (Refer to
• Failed fan controller Inspection Procedure 25 P.13A-256).
• Failed thermostat STEP 4. M.U.T.-II/III data list
• Failed water pump • Item 21: Engine coolant temperature sensor
• Failed radiator core OK:
• Failed engine-ECU Engine cold state: At ambient temperature
(atmospheric temperature) or equivalent.
DIAGNOSIS PROCEDURE Engine hot state: At 80 − 120°C
Q: Diagnosis code set? NO : Check engine coolant temperature sensor
YES : Inspection chart for diagnosis code (Refer system (Refer to Code No. P0115
to P.13A-15). P.13A-42).
NO : Go to Step 2 .
STEP 5. Check thermostat.
STEP 2. Check engine coolant • Check thermostat (Refer to GROUP 14 − Ther-
NOTE: If engine coolant level falls too early, check mostat P.14-24).
for leaky spots, and repair if necessary. Q: Is the check result normal?
• Check engine coolant (Refer to GROUP 14 − YES : Go to Step 6 .
On-vehicle Service P.14-17). NO : Replace thermostat.
YES : Go to Step 3 . STEP 6. Check water pump.
NO : Replace or add engine coolant. • Check water pump.
YES : Replace radiator.
NO : Replace water pump.
TROUBLESHOOTING
13A-235
Inspection Procedure 21: Abnormal Rotation of Fan Motor
Fan controller (Radiator fan, A/C condensor fan) Circuit
5V
A-20
(MU802322)
1 2 3
Fan controller
L-W
7
A-14
L-W
21
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300309 AB

• The control (duty) signal is inputted to the fan • Failed fan controller
controller (terminal No. 2) from the engine-ECU • Open/short circuit in fan controller circuit or loose
(terminal No. 21). connector contact
FUNCTION
• The engine-ECU inputs a duty signal suitable for
the engine coolant temperature, vehicle speed
and A/C switch position to the fan controller. In
response to the signal, the fan controller controls
the rotating speeds of the radiator fan and A/C
condenser fan (The fan speed becomes higher
as the average voltage of the terminal comes
nearer to 5V).
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Check the trouble symptoms.

STEP 1. Connector check: C-134 engine-ECU YES : Replace engine-ECU.
connector NO : Intermittent malfunction (Refer to GROUP
00 − How to Use
Connector: C-134
P.00-6).

C-134 Connector: C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
C-134
AK300257 AC

13 12 11 10 9 8 7 6 5 4 3 2 1
NO : Repair.
26 25 24 23 22 21 20 19 18 17 16 15 14
STEP 2. Check at C-134 engine-ECU connector.
AK300257 AC
Connector: C-134
side.
OK: 4.9 − 5.1 V
C-134 YES : Replace fan controller.
NO : Go to Step 5 .
13 12 11 10 9 8 7 6 5 4 3 2 1 STEP 5. Connector check: A-20 fan controller

26 25 24 23 22 21 20 19 18 17 16 15 14 connector
Connector: A-20
AK300257 AC

side.
• Ignition switch: ON A-20 (GR)
• Short-circuit terminal No. 21 to earth.
OK: Fan motor stops rotating.
3 2 1
YES : Go to Step 3 . connector AK203423 AC
NO : Go to Step 4 .
NO : Repair.
TROUBLESHOOTING
13A-237
STEP 6. Check harness between A-20 (terminal
No. 2) fan controller connector and C-134
Connector: A-20
A-20 (GR)
3 2 1
Harness side
Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

connector A-14, and repair if necessary.
YES : Replace fan controller.
NO : Repair.
Inspection Procedure 22: Poor A/C Performance

• Failure is possibly caused by short /overcharged
A/C refrigerant, failed A/C control system, failed STEP 1. M.U.T.-II/III diagnosis code
fan control system or other faults.
• Short or overcharged A/C refrigerant to P.13A-15).
• Failed A/C compressor relay NO : Go to Step 2 .
• Failed fan controller
• Failed A/C-ECU
TROUBLESHOOTING
STEP 2. A/C compressor magnet clutch STEP 4. M.U.T.-II/III data list

operation check. • Item 49: A/C relay
• Engine: Idling a. Engine: Running at idle
• A/C set temperature: b. A/C set temperature:
Maximum Cool when temperature in cabin is Maximum Cool when temperature in cabin is
25°C or more 25°C or more.
Maximum Hot when temperature in cabin is 25°C Maximum Hot when temperature in cabin is
or less 25°C or less.
OK: OK:
Magnet clutch active (when A/C is ON) ON (when A/C is ON)
Magnet clutch inactive (when A/C is OFF) OFF (when A/C is OFF)
YES : Go to Step 5 . YES : Check A/C system (Refer to GROUP 55A −
NO : Go to Step 3 . Troubleshooting P.55A-5).
NO : Check A/C compressor relay (Refer to
STEP 3. M.U.T.-II/III data list inspection procedure 27 P.13A-266).
• Item 28: A/C switch
a. Engine: Idling STEP 5. Check charged amount of A/C
b. A/C set temperature: refrigerant.
Maximum Cool when temperature in cabin is • Check charged amount of A/C refrigerant (Refer
25°C or more to GROUP 55A − On-vehicle Service P.55A-49).
Maximum Hot when temperature in cabin is Q: Is the check result normal?
25°C or less YES : Go to Step 6 .
OK: NO : Adjust charged amount of A/C refrigerant.
ON (when A/C is ON)
OFF (when A/C is OFF)
Q: Is the check result normal? • Item 21: Fan controller
YES : Go to Step 4 . OK: Fan motor rotates.
NO : Check A/C switch (Refer to Inspection
Procedure 26 P.13A-262). Q: Is the check result normal?
YES : Check A/C load signal system (Refer to
NO : Check fan control relay system (Refer to
Inspection Procedure 25P.13A-256).
TROUBLESHOOTING
13A-239
Inspection Procedure 23: Engine-ECU Power Supply, Engine Control Relay, Ignition Switch-IG1
System
Power supply and ignition switch-IG circuit
Battery
9
20A Relay box
C-303 LOCK
R
123 ST ACC Ignition switch
W-B 456
IG1 IG2
A-14
5 2
W-B L-B
C-203
6
W-B
W-B 8
J/B
7.5A
4 3
B-17X
1
Engine C-202
1 2 control
relay
3 4 L-B
1 2
2 C-106
10
J/C (2) Y-G W-B
C-17
L-B
10 9
R R
12 25 38 80 82
Power Battery
source backup Engine-ECU
C-134 C-135 C-137
1 2 3 4 5 6 7 8 9 10 11 12 13 31 32 33 34 35 36 37 38 71 72 73 74 75 76 77 78 79 80 81
14 15 16 17 18 19 20 21 22 23 24 25 26 39 40 41 42 43 44 45 46 82 83 84 85 86 87 88 89 90 9192
Wire colour code

R: Red P: Pink V: Violet AK401040 AC
TROUBLESHOOTING
OPERATION STEP 2. Connector check: B-17X engine control

• The battery voltage is applied to the engine con- relay connector
trol relay (terminal No. 3 and 4).
• The engine-ECU (terminal No. 38) makes the Connector: B-17X
power transistor in the unit be in "ON" position Relay box’s B-17X
and makes currents go on the engine control triangle marks
relay coil, and that makes the relay be in "ON"
position.
• When the engine control relay is in "ON" position, 2 1
the battery voltage is supplied to the 4 3
engine-ECU, the sensor and the actuator from
Harness side
the engine control relay (terminal No. 1). connector AK300255 AC
FUNCTION Q: Is the check result normal?

• When the ignition switch ON signal is input to the YES : Go to Step 3 .
engine-ECU, the engine-ECU places the engine NO : Repair.
control relay in the ON position. Accordingly, the
battery voltage is supplied to the engine-ECU,
sensor and actuator. STEP 3. Check engine control relay.
• Check engine control relay (Refer to P.13A-321).
PROBABLE CAUSE Q: Is the check result normal?
• Failed engine control relay YES : Go to Step 4 .
• Open/short circuit in engine control relay circuit or NO : Replace engine control relay.
• Failed engine-ECU STEP 4. Perform voltage measurement at B-17X
DIAGNOSIS PROCEDURE
Connector: B-17X
Relay box’s B-17X

STEP 1. Check battery voltage. triangle marks
• Measure battery voltage during cranking.
OK: 8 V or more
Q: Is the check result normal? 2 1
NO : Check battery (Refer to GROUP 54 −
Battery − On-vehicle Service − Battery test Harness side
P.54A-7).
• Remove relay, and measure at relay box side.
between terminal No. 4 and earth.
OK: System voltage
harness between B-17X (terminal No. 4)
engine control relay connector and battery.
open/short circuit.
TROUBLESHOOTING
13A-241
C-134
C-137
13 12 11 10 9 8 7 6 5 4 3 2 1 8180 79 78 77 76 75 74 73 72 71
26 25 24 23 22 21 20 19 18 17 16 15 14 92 91 90 89 88 87 86 85 84 83 82
AK300257 AC AK300254 AC
• Measure engine-ECU terminal voltage. • Measure engine-ECU terminal voltage.

• Ignition switch: ON • Ignition switch: ON
• Voltage between terminal No. 12 and earth, also • Voltage between terminal No. 82 and earth.
between terminal No. 25 and earth. OK: System voltage
OK: System voltage Q: Is the check result normal?
YES : Check and repair C-134 engine-ECU NO : Go to Step 8 .
connector.
NO : Go to Step 6 .
connector
Connector: C-137
connector
Connector: C-137
C-137
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
8180 79 78 77 76 75 74 73 72 71 Harness side connector

92 91 90 89 88 87 86 85 84 83 82
AK300254 AC
AK300254 AC
NO : Repair.
TROUBLESHOOTING
STEP 9. Check ignition switch. STEP 11. Check harness between C-303 (terminal
• Check ignition switch (Refer to GROUP 54A − No. 2) ignition switch connector and C-137
Ignition Switch − Ignition Switch P.54A-96). (terminal No. 82) engine-ECU connector.
NO : Replace ignition switch.
STEP 10. Connector check: C-303 ignition switch C-303

connector 3 2 1
6 5 4
Connector: C-303
Harness side
connector
AK300304 AC

3 2 1
6 5 4
Harness side
connector
AK300304 AC

C-137
NO : Repair.
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

connectors C-106, C-202 and C-203, and repair if
necessary.
• Check output line for open/short circuit.
YES : Check and repair ignition switch IG1 power
supply line harness and connector.
• Check power supply line for short
circuit.
NO : Repair.
TROUBLESHOOTING
13A-243
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AC AK300256 AC

Connector: B-17X
B-17X
Relay box’s • Voltage between terminal No. 38 and earth.
triangle marks
OK: 1 V or less
4 3
Harness side

• Ignition switch: OFF
OK: System voltage
NO : Check and repair harness between B-17X
• Check earthing line for open/short
circuit.
TROUBLESHOOTING
connector, C-303 ignition switch connector No. 2) ignition switch connector and C-137
Connector: C-137
Connector: C-303
C-303
3 2 1
C-137 6 5 4
Harness side
connector
AK300304 AC
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
Harness side connector Connector: C-137
AK300254 AC
CONNECTOR: C-303
C-137
C-303
3 2 1
6 5 4
8180 79 78 77 76 75 74 73 72 71
Harness side 92 91 90 89 88 87 86 85 84 83 82
connector Harness side connector
AK300304 AB
AK300254 AC
NO : Repair. connectors C-106, C-202 and C-203 and repair if
necessary.
NO : Repair.

00 − How to Use
P.00-6).
TROUBLESHOOTING
13A-245
STEP 17. Check harness between B-17X STEP 18. Check engine control relay output
(terminal No. 1) engine control relay connector power supply harness and connector for short
and C-134 (terminal No. 12 and No. 25) circuit.
engine-ECU connector. Q: Is the check result normal?
Connector: B-17X YES : Go to Step 19 .
B-17X NO : Repair.
Relay box’s
triangle marks
STEP 19. Check harness between B-17X
(terminal No. 3 and No. 4) engine control relay
2 1 connector and battery.
4 3 Connector: B-17X
Harness side Relay box’s B-17X
connector AK300255 AC triangle marks
Connector: C-134
2 1
4 3
Harness side
C-134 NOTE: Before checking harness, check intermediate

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
NO : Repair.
AK300257 AC

age.
NO : Repair.
TROUBLESHOOTING

(terminal No. 2) engine control relay connector
connector.
Connector: B-17X
Relay box’s B-17X

triangle marks
2 1
4 3
Harness side
Connector: C-135
C-135
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

NO : Repair.
TROUBLESHOOTING
13A-247
Inspection Procedure 24: Fuel Pump System
Fuel pump circuit
Battery
C-303
W R LOCK
123 Ignition switch
456 ST ACC
IG1 IG2
24
Relay box
15A 2
W
L-B
C-116
41
W
C-202 C-203
2 6
4 3 1 3 8
7.5A
C-215 C-213
1 2 1 2 OFF ON OFF ON J/B
Fuel Fuel
3 4 3 4 pump 1 2 pump 4 2
relay (1) relay (2)
C-215 C-213
C-205 11 C-209 1 C-205

14
B-L
D-24 6
B
G
B-L
Fuel pump <2WD> 5
Fuel pump and
gauge unit (main)
<4WD>
M
D-16
(MU802058)
C-106
4 8
1 2 3
4 5 B
D-24 4
G
B
22
C-134
Engine-ECU
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK401041 AC
TROUBLESHOOTING
OPERATION STEP 2. Check fuel pump relay.

• The battery voltage is applied to the fuel pump • Fuel pump relay, continuity check (Refer to
relay (1) (terminal No. 3) form the ignition switch P.13A-321).
and is earthed to the vehicle body from the fuel
pump relay (1) (terminal No. 2). Q: Is the check result normal?
• The battery voltage is applied to the fuel pump YES : Go to Step 3 .
NO : Replace fuel pump relay.
relay (1) (terminal No. 4) and to the fuel pump
relay (2) (terminal No. 1) from the fuel pump relay
(1) (terminal No. 1). STEP 3. Perform resistance measurement at
• The battery voltage is applied to the fuel pump C-215 fuel pump relay (1) connector.
relay (2) (terminal No. 3) from the ignition switch. Connector: C-215
The engine-ECU (terminal No. 22) makes the Junction block’s
triangle marks
power transistor in the unit be in "ON" position
and makes currents go on the fuel pump relay (2) C-215
coil, and that makes the relay be in "ON" position. 2 1
• When the fuel pump relay (2) is in "ON" position, 4 3
the battery voltage is supplied to the fuel pump Harness side
(low pressure) from the fuel pump relay (2) (ter- connector
minal No. 4).
FUNCTION AK300313 AC
• When the ignition switch ON signal is input to the • Remove relay, and measure at junction block
engine-ECU, the engine-ECU places the fuel side.
pump relay in the "ON" position. Accordingly, the • Resistance between terminal No. 2 and earth.
battery voltage is supplied to the fuel pump. OK: Continuity (2 Ω or less)
• Failed fuel pump relay NO : Check intermediate connector C-205, and
• Failed fuel pump repair if necessary. If intermediate
• Open/short circuit in fuel pump drive circuit or connector is normal, check and repair
loose connector contact harness between C-215 (terminal No. 2)
• Failed engine-ECU fuel pump relay (1) connector and body
earth.
DIAGNOSIS PROCEDURE • Check earthing line for open circuit
and damage.
STEP 1. Connector check: C-215 fuel pump relay
(1) connector and C-213 fuel pump relay (2)
connector
Junction block’s
triangle marks
C-215
2 1
C-213
4 3
Harness side
connector
AK300312 AC

NO : Repair.
TROUBLESHOOTING
13A-249
STEP 4. Perform voltage measurement at C-215 STEP 5. Connector check: C-303 ignition switch
fuel pump relay (1) connector. connector
Junction block’s
triangle marks
C-215
2 1
4 3 C-303
3 2 1
Harness side
connector 6 5 4
Harness side
connector
AK300313 AC AK300304 AC
• Remove relay, and measure at junction block Connector: C-215

side. Junction block’s
triangle marks
• Voltage between terminal No. 3 and earth. C-215
OK: System voltage 2 1
4 3
Harness side
NO : Go to Step 5 .
AK300313 AC

fuel pump relay (1) connector and C-303
circuit and damage.
NO : Repair.
TROUBLESHOOTING
Junction block’s
triangle marks
C-215
2 1
4 3 C-303
3 2 1
Harness side
connector 6 5 4
Harness side
connector
AK300313 AC AK300304 AC
• Remove relay, and measure at junction block Connector: C-213

side. Junction block’s
triangle marks
OK: System voltage
2 1
4 3
Harness side
NO : Check intermediate connectors C-116 and connector
and repair harness between C-215 (terminal AK300321 AC
No. 4) fuel pump relay (1) connector and

battery. Q: Is the check result normal?
open/short circuit.
STEP 7. Perform voltage measurement at C-213 ignition switch connector and C-213
fuel pump relay (2) connector. (terminal No. 3) fuel pump relay (2)
Connector: C-213 connector.
Junction block’s
triangle marks • Check power supply line for
open/short circuit.
NO : Repair.
2 1
C-213
4 3
Harness side
connector
AK300321 AC
• Remove relay, and measure at junction block

side.
OK: System voltage
NO : Go to Step 8 .
TROUBLESHOOTING
13A-251
C-134 C-134
13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC AK300257 AC

Junction block’s
YES : Go to Step 10 . triangle marks
NO : Repair.
2 1
C-213
4 3
Harness side
connector
AK300321 AC

side.
OK: System voltage
NO : Check intermediate connectors C-106 and
connector.
circuit.
TROUBLESHOOTING
STEP 11. Connector check: D-16 fuel pump STEP 12. Perform voltage measurement at D-16
connector fuel pump connector.
Connector: D-16 Connector: D-16
D-16 (GR) D-16 (GR)

3 2 1 3 2 1
5 4 5 4
connector AK203431AC connector AK203431AC

NO : Repair.
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

side.
• Using a jumper wire, connect C-134 (terminal No.
22) engine-ECU connector and earth.
OK: System voltage
TROUBLESHOOTING
13A-253
STEP 13. Check harness between C-213 (terminal STEP 14. Perform resistance measurement at
No. 4) fuel pump relay (2) connector and D-16 D-16 fuel pump connector.
(terminal No. 5) fuel pump connector.
Connector: D-16
Connector: C-213
Junction block’s
triangle marks
2 1
C-213 D-16 (GR)
4 3
Harness side 3 2 1
connector 5 4
Harness side
connector AK203431AC
AK300321 AC
side.
Connector: D-16
D-16 (GR) NO : Check intermediate connector D-24, and
3 2 1 repair if necessary. If intermediate
5 4 connector is normal, check and repair
Harness side harness between D-16 (terminal No. 4) fuel
connector AK203431AC pump connector and body earth.
and damage.
connectors C-209 and D-24, and repair if necessary.
age. STEP 15. Connector check: C-303 ignition switch
connector
YES : Replace engine-ECU. Connector: C-303
NO : Repair.
C-303
3 2 1
6 5 4
Harness side
connector
AK300304 AC

NO : Repair.
TROUBLESHOOTING
No. 2) ignition switch connector and C-215 No. 1) fuel pump relay (1) connector and C-213
(terminal No. 3) fuel pump relay (1) connector. (terminal No. 1) fuel pump relay (2) connector.
Connector: C-303 Connectors: C-213, C-215
Junction block’s
triangle marks
C-215
2 1
C-303 C-213
4 3
3 2 1
Harness side
6 5 4 connector
Harness side
connector
AK300304 AC AK300312 AC
Connector: C-215
Junction block’s
triangle marks Q: Is the check result normal?
C-215 NO : Repair.
2 1
4 3
STEP 19. Check harness between C-303 (terminal
Harness side
connector No. 2) ignition switch connector and C-213
(terminal No. 3) fuel pump relay (2) connector.
AK300313 AC Connector: C-303

C-303
YES : Go to Step 17. 6 5 4
NO : Repair. Harness side
connector
AK300304 AC
STEP 17. Check harness between battery and
C-215 (terminal No. 4) fuel pump relay (1) Connector: C-213
Junction block’s
connector. triangle marks
Connector: C-215
Junction block’s
triangle marks
2 1
C-213
4 3
C-215
2 1 Harness side
connector
4 3
Harness side

AK300313 AC
NOTE: Before checking harness, check intermediate YES : Go to Step 20 .
connectors C-116 and C-202, and repair if neces- NO : Repair.
sary.
NO : Repair.
TROUBLESHOOTING
13A-255
No. 2) fuel pump relay (2) connector and C-134 No. 4) fuel pump relay (2) connector and D-16
(terminal No. 22) engine-ECU connector. (terminal No.5) fuel pump connector.
Junction block’s Junction block’s
2 1 2 1
C-213 C-213
4 3 4 3
connector connector
AK300321 AC AK300321 AC
Connector: C-134 Connector: D-16
D-16 (GR)
3 2 1
C-134
5 4
Harness side
connector AK203431AC
13 12 11 10 9 8 7 6 5 4 3 2 1 NOTE: Before checking harness, check intermediate

26 25 24 23 22 21 20 19 18 17 16 15 14
connectors D-24 and C-209, and repair if necessary.
Harness side connector • Check output line for open/short circuit.
YES : Replace fuel pump.
NO : Repair.
sary.
YES : Go to Step 21.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 25: Fan Control Relay System
Fan control relay Circuit
Battery
9
Relay box
20A
W-B
A-14
5
W-B
W-B
4 3
B-17X

3 4
1 2
Engine control system R
4 To engine-ECU
Fusible link (2) J/C (2)
C-17
5
R
L-W A-14
11
R
4 3
A-10X
2 Fan control relay
1 3
4
2 1
B
L
A-20
(MU802322)
Smoothing Fan controller
1 2 3 circuit
Wire colour code

AK401042 AB
TROUBLESHOOTING
13A-257
OPERATION STEP 2. Check fan control relay.
• The battery voltage is applied to the fan control • Check fan control relay (Refer to GROUP 14 −
relay (terminal No. 3) from the engine control On−vehicle Service P.14-19).
relay (terminal No. 1) and is earthed to the vehi-
cle body from the fan control relay (terminal No.
1).
NO : Replace fan control relay.
• The battery voltage is applied to the fan control
relay (terminal No. 4).
• When the fan control relay is in "ON" position, the STEP 3. Perform resistance measurement at
battery voltage is supplied to the fan controller A-10X fan control relay connector.
(terminal No. 3) from the fan control relay (termi- Connector: A-10X
nal No. 2).
FUNCTION
A-10X
• When the engine control relay is in "ON" position,
the fan control relay is also simultaneously placed
in "ON" position. Accordingly, the battery voltage 2
is supplied to the fan controller. 3 1
4
Harness side
PROBABLE CAUSE connector AK300324 AC
• Failed fan control relay
• Failed fan controller • Remove relay and measure at relay box side.
• Failed radiator fan motor • Resistance between terminal No. 1 and earth.
• Failed condenser fan motor OK: Continuity (2 Ω or less)
• Open/short circuit in fan control relay circuit or Q: Is the check result normal?
loose connector contact YES : Go to Step 4 .
• Failed engine-ECU NO : Check and repair harness between A-10X
(terminal No. 1) fan control relay connector
DIAGNOSIS PROCEDURE and body earth.
and damage.
STEP 1. Connector check: A-10X fan control
relay connector
STEP 4. Perform voltage measurement at A-10X
Connector: A-10X
fan control relay connector.
Connector: A-10X
A-10X
A-10X
2
3 1
4
Harness side 2
connector 3 1
AK300324 AC
4
Harness side
Q: Is the check result normal? connector AK300324 AC
NO : Repair. • Remove relay and measure at relay box side.
OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
STEP 5. Connector check: B-17X engine control STEP 6. Perform voltage measurement at A-10X
relay connector fan control relay connector.
Connector: B-17X Connector: A-10X
Relay box’s B-17X

triangle marks
A-10X
2 1
2
4 3 3 1
4

Connector: A-10X
• Voltage between terminal No. 4 and earth
OK: System voltage
A-10X Q: Is the check result normal?
NO : Check and repair harness between battery
2 and A-10X (terminal No. 4) fan control relay
3 1
4 connector.
Harness side • Check power supply line for
connector AK300324 AC open/short circuit.
YES : Check intermediate connectors A-14 and STEP 7. Connector check: A-20 fan controller
C-17, and repair if necessary. If intermediate connector
connectors are normal, check and repair Connector: A-20
engine control relay connector and A-10X
(terminal No. 3) fan control relay connector.
open/short circuit. A-20 (GR)
NO : Repair.
3 2 1
Harness side

NO : Repair.
TROUBLESHOOTING
13A-259
STEP 8. Perform voltage measurement at A-20 STEP 10. Connector check: B-17X engine control
fan controller connector. relay connector
Connector: A-20 Connector: B-17X
Relay box’s B-17X

triangle marks
A-20 (GR)
2 1
4 3
3 2 1
• Disconnect connector, and measure at harness Q: Is the check result normal?

side. YES : Go to Step 11 .
OK: System voltage
STEP 11. Check harness between B-17X (terminal
Q: Is the check result normal? No. 1) engine control relay connector and A-10X
YES : Go to Step 12 . (terminal No. 3) fan control relay connector.
NO : Go to Step 9 .
Connector: B-17X
Relay box’s B-17X

STEP 9. Check harness between A-10X (terminal triangle marks
No. 2) fan control relay connector and A-20
(terminal No. 3) fan controller connector.
Connector: A-10X 2 1
4 3
Harness side
A-10X connector AK300255 AC
Connector: A-10X
2
3 1
4
Harness side
connector AK300324 AC A-10X
Connector: A-20
2
3 1
4
Harness side
A-20 (GR)
connectors A-14 and C-17, and repair if necessary.
3 2 1 • Check power supply line for damage.
Harness side
YES : Check and repair harness between A-10X
• Check output line for open/short circuit. (terminal No. 1) fan control relay connector
Q: Is the check result normal? and body earth.
TROUBLESHOOTING
STEP 12. Connector check: C-134 engine-ECU STEP 14. M.U.T.-II/III actuator test
connector • Item 21: Fan controller
Connector: C-134 OK: Fan motor rotates.
00 − How to Use
P.00-6).
C-134

13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 Connector: C-134
AK300257 AC

NO : Repair.
C-134
STEP 13. Fan motor drive test.

Connector: C-134 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

side.
C-134 • Ignition switch: ON
OK: 4.9 − 5.1 V
13 12 11 10 9 8 7 6 5 4 3 2 1 Q: Is the check result normal?
26 25 24 23 22 21 20 19 18 17 16 15 14
Harness side connector NO : Go to Step 18 .
AK300257 AC
• Disconnect C-134 engine-ECU connector.

OK: Fan motor rotates.
TROUBLESHOOTING
13A-261
STEP 16. Check harness between A-10X STEP 18. Check harness between A-20 (terminal
(terminal No. 4) fan control relay connector and No. 2) fan controller connector and C-134
battery. (terminal No. 21) engine-ECU connector.
Connector: A-10X Connector: A-20
A-10X
A-20 (GR)
2
3 1
4 3 2 1

Connector: C-134
NO : Repair.
STEP 17. Check harness between A-10X

(terminal No. 2) fan control relay connector and
C-134
A-20 (terminal No. 3) fan controller connector.
Connector: A-10X
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
A-10X Harness side connector
AK300257 AC
2
3 1 NOTE: Before checking harness, check intermediate
4 connector A-14, and repair if necessary.
Harness side
Connector: A-20 YES : Replace fan motor and fan controller.
NO : Repair.
A-20 (GR)
3 2 1
Harness side

YES : Replace fan motor and fan controller.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 26: A/C Switch System
A/C Switch circuit

C-06
(MU801584)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A/C-ECU
C-26
(MU801584)
21 22 23 24 25 26 27 28 4 <Manual A/C>
29 30 31 32 33 34 35 36 34 <Auto A/C>
G-B
C-104
7
G-B
45
C-135
31 32 33 34 35 36 37 38 Engine-ECU
39 40 41 42 43 44 45 46
Wire colour code

AK401060 AB

• The battery voltage is applied to the engine-ECU • Failed A/C
(terminal No. 45) from the A/C-ECU (terminal No. • Failed A/C system
4) <Manual A/C> or A/C-ECU (terminal No. 34) • Open/short circuit in A/C circuit or loose connec-
<Auto A/C>. tor contact
FUNCTION
• When the A/C switch is in "ON" position, A/C
switch ON signal is inputted to the engine-ECU
from the A/C-ECU. In response to the signal, the
engine-ECU controls the A/C compressor relay.
TROUBLESHOOTING
13A-263
DIAGNOSIS PROCEDURE STEP 2. Perform voltage measurement at C-06
A/C-ECU connector <Manual A/C> or C-26
STEP 1. Perform voltage measurement at C-135 A/C-ECU connector <Auto A/C>.
engine-ECU connector. Connector: C-06
<Manual A/C>
Connector: C-135
C-06 (B)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
C-135 Harness side
Connector: C-26
38 37 36 35 34 33 32 31 <Auto A/C>
46 45 44 43 42 41 40 39
AK300256 AC

• Engine: Running at idle 28 27 26 25 24 23 22 21
C-26 (B)
• A/C set temperature: 36 35 34 33 32 31 30 29
Harness side
Maximum Cool when temperature in cabin is connector
AK300327AB
25°C or more
Maximum Hot when temperature in cabin is 25°C • Measure engine-ECU terminal voltage.
or less • Engine: Idling
• Voltage between terminal No. 45 and earth. • A/C set temperature:
OK: Maximum Cool when temperature in cabin is
System voltage (when A/C is ON) 25°C or more
0.5 V or less (when A/C is OFF) Maximum Hot when temperature in cabin is 25°C
or less
Q: Is the check result normal? • Voltage between terminal No. 4 and earth <Man-
YES : Go to Step 6 . ual A/C>
NO : Go to Step 2 . • Voltage between terminal No. 34 and earth <Auto
A/C>
OK: System voltage
NO : Go to Step 3 .
TROUBLESHOOTING
STEP 3. Connector check: C-06 A/C-ECU STEP 4. Check harness between C-06 A/C-ECU
connector <Manual A/C> or C-26 A/C-ECU connector <Manual A/C> or C-26 A/C-ECU
connector <Auto A/C> C-135 engine-ECU connector <Auto A/C> and C-135 (terminal No.
connector 45) engine-ECU connector.
<Manual A/C> <Manual A/C>
C-06 (B) C-06 (B)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9
connector AK300326 AB connector AK300326 AB

<Auto A/C> <Auto A/C>
28 27 26 25 24 23 22 21 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29 C-26 (B) 36 35 34 33 32 31 30 29 C-26 (B)
connector connector
AK300327AB AK300327AB
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AC AK300256 AC
Q: Is the check result normal? NOTE: Before checking harness, check intermediate
YES : Go to Step 4 . connector C-104, and repair if necessary.
NO : Repair. • Check output line for short circuit.
YES : Check A/C system (Refer to GROUP 55A −
Troubleshooting P.55A-5).
NO : Repair.
TROUBLESHOOTING
13A-265
STEP 5. Connector check: C-06 A/C-ECU STEP 6. Connector check: C-135 engine-ECU
connector <Manual A/C> or C-26 A/C-ECU connector
connector <Auto A/C> and C-135 engine-ECU
Connector: C-135
connector
Connector: C-06
<Manual A/C>
C-06 (B)
C-135
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Harness side 38 37 36 35 34 33 32 31
connector AK300326 AB 46 45 44 43 42 41 40 39
Connector: C-26
<Auto A/C>
AK300256 AC

NO : Repair.
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29 C-26 (B) STEP 7. M.U.T.-II/III data list
Harness side • Item 28: A/C switch
connector
AK300327AB a. Engine: Idling
b. A/C set temperature:
Connector: C-135 Maximum Cool when temperature in cabin is
25°C or more.
Maximum Hot when temperature in cabin is
25°C or less.
OK:
ON (when A/C is ON)
C-135 OFF (when A/C is OFF)
38 37 36 35 34 33 32 31
00 − How to Use
46 45 44 43 42 41 40 39 Troubleshooting/Inspection Service Points
Harness side connector P.00-6).
AK300256 AC

harness between C-06 (terminal No. 4) or
C-26 (terminal No. 34) A/C-ECU connector
connector.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 27: A/C Compressor Relay System
A/C compressor relay Circuit
Ignition switch
C-303
R LOCK
1 2 3
4 5 6 ST ACC
IG1 IG2
4
L-R
C-203
2
Battery
W 5 J/B
7.5A
10 C-205
Relay box
10A 16
L-R
B-R
A-14 C-106
9 11
B-R L-R
4 3
B-18X
1 2 A/C compressor relay

3 4
1 2
A/C-ECU
B-W G
1 8
Engine-ECU
A/C compressor
assembly A/C refrigerant
temperature
switch
B-27
MU802653
1 Magnetic C-134
clutch
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK401206 AB
TROUBLESHOOTING
13A-267
OPERATION STEP 2. A/C compressor relay check.
• The battery voltage is applied to the A/C com- • Check A/C compressor relay (Refer to GROUP
pressor relay (terminal No. 4). 55A − On-vehicle Service P.55A-55).
• The battery voltage is applied to the A/C com-
pressor relay (terminal No. 3) from the ignition
switch. The engine-ECU (terminal No. 8) makes
NO : Replace A/C compressor relay.
the power transistor in the unit be in "ON" posi-
tion and makes currents go on the A/C compres-
sor relay coil, and that makes the relay be in "ON" STEP 3. Perform voltage measurement at B-18X
position. A/C compressor relay connector.
• When the A/C compressor is in "ON" position, the Connector: B-18X
battery voltage is supplied to the A/C compressor B-18X
(terminal No. 1) from the A/C compressor relay Relay box’s
triangle marks
(terminal No. 1).
FUNCTION
• When the A/C switch "ON" signal is input to the 2 1
engine-ECU, the engine-ECU places the A/C 4 3
compressor relay in the "ON" position. Accord-
Harness side
ingly, the battery voltage supplied to the A/C com- connector AK300329 AC
pressor operates the magnet clutch.
PROBABLE CAUSE • Ignition switch: ON
• Failed A/C compressor relay • Voltage between terminal No. 3 and earth.
• Failed A/C compressor magnet clutch OK: System voltage
• Open/short circuit in A/C compressor relay circuit Q: Is the check result normal?
or loose connector contact YES : Go to Step 5 .
• Failed engine-ECU NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-18X A/C

compressor relay connector
Connector: B-18X
B-18X
Relay box’s
triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
STEP 4. Connector check: C-303 ignition switch STEP 5. Perform voltage measurement at B-18X
connector A/C compressor relay connector.
B-18X
Relay box’s
triangle marks
C-303
3 2 1 2 1
6 5 4
4 3
Harness side
AK300304 AC connector AK300329 AC

Connector: B-18X
B-18X
Relay box’s OK: System voltage
triangle marks
2 1
Harness side harness between B-18X (terminal No. 4)
connector AK300329 AC A/C compressor relay connector and
battery.
Q: Is the check result normal? • Check power supply line for
YES : Check intermediate connectors C-106,
open/short circuit.
C-203 and C-205, and repair if necessary. If
and repair harness between B-18X (terminal STEP 6. Connector check: B-27 A/C compressor
No. 3) A/C compressor relay connector and connector
C-303 (terminal No. 4) ignition switch Connector: B-27
connector.
open/short circuit.
NO : Repair.
B-27 (B)
1
Harness side

NO : Repair.
TROUBLESHOOTING
13A-269
A/C compressor connector. engine-ECU connector.
B-27 (B)
1 C-134
Harness side
13 12 11 10 9 8 7 6 5 4 3 2 1
Connector: B-18X
26 25 24 23 22 21 20 19 18 17 16 15 14
B-18X
Relay box’s Harness side connector
triangle marks
AK300257 AC

2 1 • Ignition switch: ON
4 3
OK: System voltage
Harness side
connector AK300329 AC Q: Is the check result normal?
NO : Go to Step 9 .
side.
• Remove B-18X (terminal No. 1 and No. 4) A/C
compressor relay and short-circuit of harness STEP 9. Connector check: C-134 engine-ECU
side connector. connector
Connector: C-134
OK: System voltage
(terminal No. 1) A/C compressor connector
C-134
and B-18X (terminal No. 1) A/C compressor
relay connector.
circuit. 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING
STEP 10. Check harness between B-18X STEP 11. M.U.T.-II/III data list
(terminal No. 2) A/C compressor relay connector • Item 49: A/C relay
and C-134 (terminal No. 8) engine-ECU a. Engine: Idling
connector. b. A/C set temperature:
Connector: B-18X Maximum Cool when temperature in cabin is
B-18X 25°C or more
Relay box’s Maximum Hot when temperature in cabin is
triangle marks
25°C or less
OK:
ON (when A/C is ON)
2 1
4 3
Harness side YES : Intermittent malfunction (Refer to GROUP
connector
00 − How to Use
AK300329 AC

Connector: C-134
P.00-6).

connector
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
C-134
AK300257 AC

13 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 11 . 26 25 24 23 22 21 20 19 18 17 16 15 14
NO : Repair.
AK300257 AC

NO : Repair.
TROUBLESHOOTING
13A-271
STEP 13. Check harness between B-18X STEP 15. Check harness between C-303 (terminal
(terminal No. 2) A/C compressor relay connector No. 4) ignition switch connector and B-18X
and C-134 (terminal No. 8) engine-ECU (terminal No. 3) A/C compressor relay connector.
connector.
Connector: C-303
Connector: B-18X
B-18X
Relay box’s
triangle marks
C-303
3 2 1
2 1 6 5 4
Harness side
4 3 connector
Harness side AK300304 AC
Connector: B-18X
Connector: C-134 B-18X
Relay box’s
triangle marks
2 1
4 3
C-134
Harness side

13 12 11 10 9 8 7 6 5 4 3 2 1 connectors C-106, C-203 and C-205, and repair if
26 25 24 23 22 21 20 19 18 17 16 15 14
necessary.
• Check earthing line for damage. YES : Go to Step 16 .
NO : Repair.
NO : Repair. STEP 16. Check harness between battery and
B-18X (terminal No. 4) A/C compressor relay
connector.
STEP 14. Connector check: C-303 ignition switch
connector Connector: B-18X
B-18X
Connector: C-303 Relay box’s
triangle marks
2 1
C-303
3 2 1 4 3
6 5 4
Harness side
connector
AK300304 AC NOTE: Before checking harness, check intermediate
Q: Is the check result normal? • Check power supply line for damage.
NO : Repair.
TROUBLESHOOTING

(terminal No. 1) A/C compressor relay connector
and B-27 (terminal No. 1) A/C compressor relay
connector.
Connector: B-18X
B-18X
Relay box’s
triangle marks
2 1
4 3
Harness side
Connector: B-27
B-27 (B)
1
Harness side

YES : Replace A/C compressor magnet clutch.
NO : Repair.
TROUBLESHOOTING
13A-273
Inspection Procedure 28: A/C Load Signal System
A/C load signal circuit

C-06
(MU801584)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A/C-ECU
C-26
(MU801584)
21 22 23 24 25 26 27 28
5 <Manual A/C>
29 30 31 32 33 34 35 36
32 <Auto A/C>
L-W
C-104
6
L-W
24
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13 Engine-ECU
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK401061 AB

• The A/C load signal is inputted to the • Failed A/C-ECU
engine-ECU (terminal No. 24) from the A/C-ECU • Open/short circuit in A/C load signal circuit or
(terminal No. 5). <Manual A/C> or (terminal No. loose connector contact
32) <Auto A/C> • Failed engine-ECU
FUNCTION
• The magnitude of the A/C compressor load is
detected and input to the engine-ECU. The
engine-ECU provides A/C idle up control accord-
ing to the A/C compressor load condition.
TROUBLESHOOTING

connector
STEP 1. Perform voltage measurement at C-134 Connector: C-134
Connector: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC
AK300257 AC
• Measure engine-ECU terminal voltage. NO : Repair.
• Engine: Idling
• A/C switch: ON (A/C compressor in driven state)
OK: Q: Does trouble symptom persist?
1 V or less (when the temperate around the
atmospheric air temperature sensor is 18°C
00 − How to Use
or more, and the A/C is set to the lowest tem-
perature and the maximum air flow rate)
System voltage (when the A/C is set to the P.00-6).
temperature in the cabin and the minimum
air flow rate) STEP 4. Connector check: C-134 engine-ECU
NO : Go to Step 4 .
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING
13A-275
STEP 5. Perform voltage measurement at C-06 STEP 6. Connector Check: C-06 A/C-ECU
A/C-ECU connector <Manual A/C> or C-26 connector <Manual A/C> or C-26 A/C-ECU
A/C-ECU connector <Auto A/C>. connector <Auto A/C>
<Manual A/C> <Manual A/C>
C-06 (B) C-06 (B)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9

<Auto A/C> <Auto A/C>
28 27 26 25 24 23 22 21 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29 C-26 (B) 36 35 34 33 32 31 30 29 C-26 (B)
connector connector
AK300327AB AK300327AB
• Measure A/C-ECU terminal voltage. Q: Is the check result normal?

• Engine: Idling YES : Go to Step 7 .
• A/C set temperature: NO : Repair.
Maximum Cool when temperature in cabin is
25°C or more
Maximum Hot when temperature in cabin is 25°C
or less
• Voltage between terminal No. 5 and earth <Man-
ual A/C>
• Voltage between terminal No. 32 and earth <Auto
A/C>
OK: System voltage
NO : Go to Step 6 .
TROUBLESHOOTING
STEP 7. Check harness between C-06 (terminal STEP 8. Check connector: C-06 A/C-ECU
No. 5) or C-26 (terminal No. 32) A/C-ECU connector <Manual A/C> or C-26 A/C-ECU
connector and C-134 (terminal No. 24) connector <Auto A/C>
engine-ECU connector. Connector: C-06
Connector: C-06 <Manual A/C>
<Manual A/C>
C-06 (B)
C-06 (B)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 Harness side
Connector: C-26
Connector: C-26 <Auto A/C>
<Auto A/C>
28 27 26 25 24 23 22 21
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29 C-26 (B)
36 35 34 33 32 31 30 29 C-26 (B) Harness side
AK300327AB
connector
AK300327AB
Connector: C-134
Connector: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14
26 25 24 23 22 21 20 19 18 17 16 15 14 Harness side connector
AK300257 AC
AK300257 AC
NOTE: Before checking harness, check intermediate YES : Check intermediate connector C-104, and
connector C-104, and repair if necessary. repair if necessary. If intermediate
• Check output line for short circuit. connector is normal, check and repair
Q: Is the check result normal? harness between C-06 (terminal No. 5) or
YES : Check A/C system (Refer to GROUP 55A − C-26 (terminal No. 32) A/C-ECU connector
Troubleshooting P.55A-5). and C-134 (terminal No. 24) engine-ECU
NO : Repair. connector.
NO : Repair.
TROUBLESHOOTING
13A-277
Inspection Procedure 29: A/C Pressure Sensor System
A/C Pressure sensor circuit
A-02
(MU802509) A/C Pressure sensor
1 2 3
3 1 2
G-Y BR G-R
C-116
17 5
A-14
17 BR G-R
C-105 C-104
21 4
G-Y
A/C-ECU
BR G-R
81 92 42
C-135 C-137
31 32 33 34 35 36 37 38 71 72 73 74 75 76 77 78 79 80 81
39 40 41 42 43 44 45 46 82 83 84 85 86 87 88 89 90 9192
5V
Engine-ECU
Wire colour code

AK300339 AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the A/C pres- • The A/C pressure sensor detects the A/C refriger-
sure sensor power terminal (terminal No. 3) from ant pressure and inputs the pressure signal to the
the engine-ECU (terminal No. 81) and is earthed engine-ECU. The engine-ECU uses the signal for
to the engine-ECU (terminal No. 92) from the A/C ON/OFF control of the magnet clutch of the A/C
pressure sensor (terminal No. 1). compressor.
(terminal No. 42) from the A/C pressure sensor PROBABLE CAUSE
output terminal (terminal No. 2). • Failed A/C pressure sensor
• Open/short circuit in A/C pressure sensor circuit
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Perform voltage measurement at A-02

A/C pressure sensor connector.
STEP 1. M.U.T.-II/III data list Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
3 2 1 Harness side
connector
Harness side AK300340AB
connector
AK300340AB • Disconnect connector, and measure at harness
• Refer to Data list reference table P.13A-293. side.
a. Item 3A: A/C pressure sensor • Ignition switch: ON
OK: 4.9 − 5.1 V
P.00-6). NO : Go to Step 4 .
NO : Go to Step 2 .
STEP 2. Connector check: A-02 A/C pressure engine-ECU connector.
sensor connector Connector: C-137
Connector: A-02
A-02 (B)
C-137
3 2 1
Harness side
connector
AK300340AB 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82

OK: 4.9 − 5.1 V
NO : Go to Step 5 .
TROUBLESHOOTING
13A-279
connector connector
C-137 C-137
8180 79 78 77 76 75 74 73 72 71 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82 92 91 90 89 88 87 86 85 84 83 82
AK300254 AC AK300254 AC
Connector: A-02 Q: Is the check result normal?

NO : Repair.
A-02 (B)
3 2 1
Harness side
connector
AK300340AB

YES : Check intermediate connector A-14, and
harness between A-02 (terminal No. 3) A/C
pressure sensor connector and C-137
circuit.
NO : Repair.
TROUBLESHOOTING
STEP 7. Check harness between A-02 (terminal STEP 9. Perform resistance measurement at A-02
No. 3) A/C pressure sensor connector and C-137 A/C pressure sensor connector.
Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
3 2 1 Harness side
connector AK300340AB
AK300340AB
side.
Connector: C-137
• Resistance between terminal No. 1 and earth

connector
Connector: C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

• Check power supply line for short circuit. C-137

NO : Repair. 8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
• Refer to Data list reference table P.13A-293. AK300254 AC
a. Item 3A: A/C pressure sensor Q: Is the check result normal?

YES : Intermittent malfunction (Refer to GROUP NO : Repair.
00 − How to Use
P.00-6).
TROUBLESHOOTING
13A-281
STEP 11. Check harness between A-02 (terminal STEP 12. Perform voltage measurement at A-02
Connector: A-02
Connector: A-02
A-02 (B)
A-02 (B)
3 2 1
3 2 1 Harness side
AK300340AB
Connector: C-137
OK: 4.9 − 5.1 V
C-137
8180 79 78 77 76 75 74 73 72 71
92 91 90 89 88 87 86 85 84 83 82
AK300254 AC

sary.
NO : Repair.
TROUBLESHOOTING
STEP 13. Connector check: C-137 engine-ECU STEP 14. Perform voltage measurement at A-02
connector A/C pressure sensor connector.
Connector: C-137 Connector: A-02
A-02 (B)
3 2 1
C-137 Harness side
connector
AK300340AB

Harness side connector • Ignition switch: ON
AK300254 AC
OK: 0.5 or less
Connector: A-02
A-02 (B)
3 2 1
Harness side
connector
AK300340AB

NO : Repair.
TROUBLESHOOTING
13A-283
Connector: C-137 Connector: A-02
A-02 (B)
3 2 1
C-137 Harness side
connector
AK300340AB

Harness side connector • Engine: Running at idle
AK300254 AC
• A/C switch: ON
Connector: A-02 OK:
1.8 − 2.0 V (A/C refrigerant pressure: 1 kPa)
A-02 (B)
3 2 1
Harness side STEP 17. Connector check: C-135 engine-ECU
connector
AK300340AB connector
Connector: C-135
and repair harness between A-02 (terminal
No. 1) A/C pressure sensor connector and
C-135
connector.
NO : Repair.
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

NO : Repair.
TROUBLESHOOTING
STEP 18. Check harness between A-02 (terminal STEP 19. Perform voltage measurement at C-135
No. 2) A/C pressure sensor connector and C-135 engine-ECU connector.
(terminal No. 42) engine-A/T-ECU connector.
Connector: C-135
Connector: A-02
A-02 (B)
C-135
3 2 1
Harness side
connector
AK300340AB
38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39
AK300256 AC

• Engine: Running at idle
• A/C switch: ON
C-135
OK:
38 37 36 35 34 33 32 31
AK300256 AC

sary.
YES : Replace A/C pressure sensor.
NO : Repair.
TROUBLESHOOTING
13A-285
connector connector
C-135 C-135
38 37 36 35 34 33 32 31 38 37 36 35 34 33 32 31
46 45 44 43 42 41 40 39 46 45 44 43 42 41 40 39
AK300256 AC AK300256 AC

NO : Repair.
A-02 (B)
3 2 1
Harness side
connector
AK300340AB

connector.
circuit and damage.
NO : Repair.
TROUBLESHOOTING
Inspection Procedure 30: Ignition Circuit System
Ignition circuit
Ignition switch
C-303
R LOCK
1 2 3 ST
4 5 6 ACC
IG1 IG2
2
L-B
C-203
6
J/B 1
10A
10
W C-205
C-116
26
W
A-14
16
W W
W
1 1
Ignition coil 1 Ignition coil 2 1

B-110 B-111
(MU802064) (MU802064) Capacitor
B-107
1 2 3 1 2 3 (MU801211)
1
3 2 Spark 2 3
plug
B B
B-L W-L
B
10 23
C-134
1 2 3 4 5 6 7 8 9 10 11 12 13
Engine-ECU 14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK401144 AC
TROUBLESHOOTING
13A-287
OPERATION STEP 3. Connector check: B-111 and B-110
• The battery voltage is applied to the ignition coil ignition coil connectors
(terminal No. 1) from the ignition switch and is
earthed to the vehicle body from the ignition coil Connector: B-110, B-111
(terminal No. 2). 3 2 1
• A power voltage of 12 V is applied to the ignition Harness side
coil output terminal (terminal No. 3) from the connector
B-111 (GR)
engine-ECU (terminal No. 10 and No. 23).
FUNCTION
• When the engine-ECU makes the power transis- B-110 (GR)
tor in the unit be in "OFF" position, the battery
AK300308 AB
voltage in the unit is applied to the power transis-
tor unit, and that makes the power transistor unit Q: Is the check result normal?
be in "ON" position. The engine-ECU makes the YES : Go to Step 4 .
power transistor in the unit be in "ON", and that NO : Repair.
makes the power transistor unit be in "OFF" posi-
tion.
• In response to the signal from the engine-ECU, STEP 4. Check ignition coil itself.
the power transistor unit is in "ON" position. The • Check ignition coil itself (Refer to GROUP 16 −
primary current is going to the ignition coil. When Ignition System − On-vehicle Service P.16-38).
the power transistor unit is in "OFF" position, the Q: Is the check result normal?
primary current is interrupted and high voltage is YES : Go to Step 5 .
generated in the secondary coil. NO : Replace ignition coil.

• Failed ignition coil and B-110 ignition coil connectors.
• Failed spark plug
• Failed spark plug cable Connector: B-110, B-111
• Open/short circuit in ignition primary circuit or
3 2 1
loose connector contact Harness side
• Failed engine-ECU connector
B-111 (GR)
DIAGNOSIS PROCEDURE
STEP 1. Check spark plug cable itself. B-110 (GR)

• Check spark plug cable itself (Refer to GROUP AK300308 AB
P.16-40). side.
Q: Is the check result normal? • Ignition switch: ON
YES : Go to Step 2 . • Voltage between terminal No. 1 and earth.
NO : Replace spark plug cable. OK: System voltage
STEP 2. Check spark plug. YES : Go to Step 7 .
• Check spark plug (Refer to GROUP 16 − Ignition NO : Go to Step 6 .
TROUBLESHOOTING
STEP 6. Connector check: C-303 ignition switch STEP 7. Perform voltage measurement at B-111
connector and B-110 ignition coil connectors.
Connector: C-303 Connector: B-110, B-111
3 2 1
Harness side
connector
B-111 (GR)
C-303
3 2 1
6 5 4
Harness side B-110 (GR)
connector
AK300304 AC AK300308 AB

side.
3 2 1 • Engine: Cranking
Harness side • Voltage between terminal No. 3 and earth.
connector
B-111 (GR) OK: 0.5 − 4.0 V
NO : Go to Step 8 .
B-110 (GR)
AK300308 AB

C-303 (terminal No. 2) ignition switch
connector and B-111 (terminal No. 1)
ignition coil connector, also between C-303
(terminal No. 2) ignition switch connector
and B-110 (terminal No. 1) ignition coil
connector.
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13A-289
C-134 C-134
13 12 11 10 9 8 7 6 5 4 3 2 1 13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC AK300257 AC
Connector: B-110, B-111 Connector: B-110, B-111
3 2 1 3 2 1
connector connector
B-111 (GR) B-111 (GR)
B-110 (GR) B-110 (GR)

AK300308 AB AK300308 AB

• Disconnect B-111 and B-110 ignition coil connec- YES : Check and repair harness between B-111
tors. (terminal No. 3) ignition coil connector and
• Engine: Cranking C-134 (terminal No. 23) engine-ECU
• Voltage between terminal No. 10 and earth, also connector, also between B-110 (terminal
between terminal No. 23 and earth. No. 3) ignition coil connector and C-134
OK: 0.5 − 4.0 V (terminal No. 10) engine-ECU connector.
TROUBLESHOOTING
connector No. 3) ignition coil connector and C-134 (terminal
No. 23) engine-ECU connector, also between
Connector: C-134
B-110 (terminal No. 3) ignition coil connector and
Connector: C-134
C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
13 12 11 10 9 8 7 6 5 4 3 2 1
AK300257 AC
26 25 24 23 22 21 20 19 18 17 16 15 14

NO : Repair.
3 2 1
Harness side
connector
B-111 (GR)
B-110 (GR)
AK300308 AB

NO : Repair.

00 − How to Use
P.00-6).
TROUBLESHOOTING
13A-291
STEP 13. Perform resistance measurement at STEP 14. Check harness between C-303 (terminal
B-111 and B-110 ignition coil connectors. No. 2) ignition switch connector and B-111
(terminal No. 1) ignition coil connector, also
between C-303 (terminal No. 2) ignition switch
3 2 1 connector and B-110 (terminal No. 1) ignition coil
Harness side connector.
connector
B-111 (GR) Connector: C-303
B-110 (GR)
C-303
AK300308 AB
3 2 1
• Disconnect connector, and measure at harness 6 5 4
side. Harness side
• Resistance between terminal No. 2 and earth. connector
AK300304 AC
Q: Is the check result normal? Connector: B-110, B-111
3 2 1
Harness side
(terminal No. 2) ignition coil connector and connector
body earth, also between B-110 (terminal B-111 (GR)
No. 2) ignition coil connector and body
earth.
B-110 (GR)
and damage.
AK300308 AB

connectors A-14, C-116, C-203 and C-205, and
repair if necessary.
NO : Repair.
TROUBLESHOOTING

No. 3) ignition coil connector and C-134 (terminal
3 2 1
Harness side
connector
B-111 (GR)
B-110 (GR)
AK300308 AB
Connector: C-134
C-134
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 24 23 22 21 20 19 18 17 16 15 14
AK300257 AC

NO : Repair.
TROUBLESHOOTING
13A-293
Data List Reference Table
M1131152002753
Item Inspection Inspection condition Normal condition Inspection Reference

No. item procedure page
No.
11 Oxygen Engine: After Excessive deceleration 200 mV or less Code No. P.13A-61
sensor warm-up (leaner by from 4,000 r/min P0130
(front) deceleration, richer At excessive 600 − 1,000 mV
by acceleration) acceleration
Engine: After Idle operation 400 mV or less
warm-up (using 2,500 r/min ⇔ 600 −
oxygen sensor, 1,000 mV
check air-fuel ratio (altered)
as well as control
status by
engine-ECU.
12 Air flow • Engine coolant Idle operation 16 − 24 Hz − −
sensor *1 temperature: 80 2,500 r/min 72 − 112 Hz
− 95°C
Acceleration According to
• Lamps, electric
acceleration,
cooling fan and
frequency is
all accessories:
amplified.
OFF
• Transmission:
Neutral
13 Intake air Ignition switch: Intake air temperature: −20°C Code No. P.13A-36
temperature “ON” or engine −20°C P0110
sensor running Intake air temperature: 0°C
0°C
Intake air temperature: 20°C
20°C
40°C
Intake air temperature: 80° C
80°C
14 Throttle Ignition switch: Set to Idle position 535 − 735 mV Code No. P.13A-49
position “ON” Release accelerator Increased P0120
sensor pedal gradually according to
accelerator pedal
stroke
Release accelerator 4,500 −
pedal fully 5,000 mV
16 Power Ignition switch: “ON” System voltage Procedure P.13A-239
supply No. 23
voltage
18 Cranking Ignition switch: Engine: Stopped OFF Procedure P.13A-239
signal “ON” Engine: Cranking ON No. 23
(ignition
switch-ST)
TROUBLESHOOTING

No.
21 Engine Ignition switch: Coolant temperature: −20°C Code No. P.13A-42
coolant “ON” or engine −20°C P0115
temperature running Coolant temperature: 0°C
sensor 0°C
Coolant temperature: 20°C
20°C
40°C
80°C
22 Crank angle • Engine: Compare engine speed Matched Code No. P.13A-124
sensor Cranking on tachometer with the P0335
• Tachometer: value displayed on
Connected M.U.T.-II/III
Engine: Idle Coolant temperature: 1,100 −
operation −20°C 1,300 r/min
Coolant temperature: 1,100 −
0°C 1,300 r/min
20°C 1,300 r/min
Coolant temperature: 940 − 1,140 r/min
40°C
Coolant temperature: 650 − 850 r/min
80°C
25 Barometric Ignition switch: Altitude: 0m 101 kPa Code No. P.13A-27
pressure “ON” Altitude: 600m 95 kPa P0105
sensor
Altitude: 1,200m 88 kPa
27 Power Engine: Idle Steering wheel: Not OFF Code No. P.13A-164
steering operation operated P0551
fluid Steering wheel: ON
pressure Operated
switch
28 A/C switch Engine: Idle AC switch: OFF OFF Procedure P.13A-262
AC A/C OFF No. 26
switch: compressor is
ON not driven
A/C ON
compressor is
driven
TROUBLESHOOTING
13A-295
No.
37 Volumetric • Engine coolant Idle operation 13 − 33% − −
efficiency temperature: 80 2,500 r/min 12 − 32%
− 95°C
Excessive acceleration According to
• Lamps, electric
acceleration,
cooling fan and
volumetric
all accessories:
efficiency is
OFF
increased.
3A A/C • After engine A/C in MAX COOL state 2,200 mV or Procedure P.13A-277
pressure warm-up, idle (under high load) more No. 29
sensor operation A/C in MAX HOT state 1,800 mV or less
• A/C switch: ON (under low load)
41 Injectors *2 Engine: Cranking Coolant temperature: 5.6 − 8.4 ms − −
0°C (all cylinders in
simultaneous injecting
operation)
Coolant temperature: 5.6 − 8.4 ms
20°C
80°C
Injectors*3 • Engine coolant Idle operation 2.0 − 3.2 ms
temperature: 80 2,500 r/min 2.2 − 3.4 ms
− 95°C
Excessive acceleration Increased
• Lamps, electric
cooling fan and
all accessories:
OFF
• Transmission:
Neutral
44 Ignition • Engine: After Idle operation 2 − 18°BTDC Procedure P.13A-286
advance warm-up 2,500 r/min 18 − 38°BTDC No. 30
• Install timing
light (for use to
measure actual
ignition timing)
TROUBLESHOOTING

No.
45 ISC • Engine coolant A/C switch: OFF 2 − 25 steps − −
(stepper temperature: 80 A/C switch: OFF → ON Increased 10 −
motor) − 95°C 70 steps
servo • Lighting, electric
position*4 cooling fan and
accessories:
OFF
• Transmission:
Neutral
• Engine: Idle
operation (When
A/C switch is
ON, A/C
compressor
must be ON)
49 A/C relay Engine: After A/C switch: OFF OFF Procedure P.13A-273
warm-up, idle A/C A/C OFF No. 27
operation after switch: compressor is
warm-up ON not driven
A/C ON
compressor is
driven
59 Oxygen Engine: After At excessive 0 mV or less ⇔ Code No. P.13A-72
sensor warm-up acceleration 600 - 1,000 mV P0136
(rear) (altered)
12 Air flow • Engine coolant Idle operation 0.9 − 4.9 g/s − −
*5 sensor temperature: 80 2,500 r/min 7.2 − 13.2 g/s
− 95°C
• Lamps, electric
acceleration,
cooling fan and
frequency is
all accessories:
amplified.
OFF
• Transmission:
Neutral
13 Intake air Ignition switch: Intake air temperature: −20°C Code No. P.13A-36
*5 temperature “ON” or engine −20°C P0110
0°C
20°C
40°C
80°C
TROUBLESHOOTING
13A-297
No.
21 Engine Ignition switch: Coolant temperature: −20°C Code No. P.13A-42
*5 coolant “ON” or engine −20°C P0115
sensor 0°C
20°C
40°C
80°C
22 Crank angle • Engine: Compare engine speed Matched − −
*5 sensor Cranking on tachometer with the
0°C 1,300 r/min
20°C 1,300 r/min
40°C
80°C
24 Vehicle Drive 40 km/h Approximately 40 Code No. P.13A-156
*5 speed km/h P0500
sensor
44 Ignition • Engine: After Idle operation 2 − 18 deg − −
*5 advance warm-up 2,500 r/min 18 − 38 deg
• Install timing
light (for use to
measure actual
ignition timing)
81 Long-term Engine: After warm-up, 2,500 r/min without −12.5 − 12.5% Code No. P.13A-83
*5 fuel any load (during closed loop) P0170
compensati
on
82 Shot-term Engine: After warm-up, 2,500 r/min without −25 − 25% Code No. P.13A-83
compensati
on
87 Calculation Engine: After Idle operation 13 − 33% − −
*5 losd value warm-up 2,500 r/min 12 − 32%
TROUBLESHOOTING

No.
88 Fuel control Engine: After 2,500 r/min Closed loop − −
*5 condition warm-up Acceleration Open loop-drive
condition
8A Throttle Ignition switch: Set to Idle position 0 − 10% Code No. P.13A-49
*5 position “ON” Release accelerator Increased P0120
sensor pedal gradually according to
(Throttle accelerator pedal
opening stroke
angle)
Release accelerator 80 − 100%
pedal fully
A1 Oxygen Engine: After Excessive deceleration 0.2 V or less ⇔ Code No. P.13A-61
*5 sensor warm-up (leaner by from 4,000 r/min 0.6 − 1 V P0130
(front) deceleration, richer (altered)
by acceleration)
Engine: After Idle operation 0.4 V or less ⇔
warm-up (using 2,500 r/min 0.6 − 1 V
oxygen sensor, (altered)
check air-fuel ratio
as well as control
status by
engine-ECU.
A1 Oxygen Engine: After At excessive 0 V or less ⇔ 0.6 Code No. P.13A-72
*5 sensor warm-up acceleration − 1 V (altered) P0136
(rear)
CAUTION
When shifting the select lever to D range, the brakes should be applied so that the vehicle does not
move forward
NOTE: *1: On the new vehicle (mileage: 500 km or less), air flow sensor output frequency may be higher by
approx. 10%.
NOTE: *2: Injector drive time ranges shown are when power voltage is 11 V and the cranking speed is 250
r/min. or less.
NOTE: *3: On the new vehicle (mileage: 500 km or less), injector drive time may be longer by approx. 10%.
NOTE: *4: On the new vehicle (mileage: 500 km or less), the number of steps of stepper motor may be larger
by approx. 30 steps.
NOTE: *5: When service data in check mode is selected, the data is not displayed.
TROUBLESHOOTING
13A-299
Actuator Test Reference Table
M1131152500644
Item Inspection Drive content Inspection conditions Normal Code No. Reference
No. item condition /Inspection page
procedure
No.
01 Injector Cut off No. 1 Engine: After warm-up, Engine is Code No. P.13A-87
injector idle operation (Cut off changed P0201
02 Cut off No. 2 injectors sequentially to (becomes Code No. P.13A-92
injector check for a cylinder that unstable or P0202
does not change engine in stalled)
03 Cut off No. 3 idle status. Code No. P.13A-97
injector P0203
04 Cut off No. 4 Code No. P.13A-102
injector P0204
07 Fuel pump Drive fuel pump Ignition Hold return Pulse is felt Procedure P.13A-247
to circulate fuel switch: "ON" hose with No. 24
fingers to
feel pulse of
fuel flowing
Check for Operating
pump noise audible
operating
noise near
fuel tank
08 Purge Switch solenoid Ignition switch: "OFF" When the valve Code No. P.13A-148
control valve from OFF is actuated, P0443
solenoid to ON operating noise
valve is audible
10 EGR control Switch solenoid Ignition switch: "ON" When the valve Code No. P.13A-142
solenoid valve from OFF is actuated, P0403
valve to ON operating noise
is audible.
17 Basic ignition Switch • Engine: Idle operation 5° BTDC − −
timing engine-ECU to • Install timing light
ignition timing
adjusting mode
21 Fan Actuate fan • Ignition switch: "ON" Fan motor is Procedure P.13A-235
controller motor • A/C switch: ON rotated No. 21
TROUBLESHOOTING
CHECK AT THE ECU TERMINALS NOTE: .

M1131153500960 1. Make the voltage measurement with the
TERMINAL VOLTAGE CHECK CHART engine-ECU connector connected.
2. You may find it convenient to pull out the
Needle-nosed wire probe 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
AK201749AB them. Be careful to prevent this!
1. Connect a needle-nosed wire probe to a voltmeter 3. If voltmeter shows any division from standard
probe. value, check the corresponding sensor, actuator
and related electrical wiring, then repair or
2. Insert the needle-nosed wire probe into each of
replace.
the engine-ECU connector terminals from the wire
side, and measure the voltage while referring to 4. After repair or replacement, recheck with the
the check chart. voltmeter to confirm that the repair has corrected
the problem.
Engine-ECU Connector Terminal Arrangement

Engine-ECU Connector
C-134 C-135 C-136 C-137
1 2 3 4 5 6 7 8 9 10 11 12 13 31 32 33 34 35 36 37 38 51 52 53 54 55 56 71 72 73 74 75 76 77 78 79 80 81
14 15 16 17 18 19 20 21 22 23 24 25 26 39 40 41 42 43 44 45 46 57 58 59 60 61 62 82 83 84 85 86 87 88 89 90 9192
AK300342 AB
Terminal Check item Check condition (Engine condition) Normal condition

No.
1 No. 1 injector While engine is idling after having warmed From 11 − 14 V,
14 No. 2 injector up, suddenly depress the accelerator pedal. momentarily drops slightly
2 No. 3 injector
15 No. 4 injector
4 Stepper motor coil • Engine: Soon after the warmed up engine System voltage ⇔ 1 V or
<A1> is star less (Changes repeatedly)
17 Stepper motor coil • A/C switch: OFF → ON (A/C compressor
<A2> is operating)
5 Stepper motor coil
<B1>
18 Stepper motor coil
<B2>
6 EGR control Ignition switch: "ON" System Voltage
solenoid Valve While engine is idling, suddenly depress the From system voltage,
accelerator pedal. momentarily drops
TROUBLESHOOTING
13A-301
No.
8 A/C relay • Engine: Idle speed System voltage or
• A/C switch: OFF → ON (A/C compressor Momentarily 6V or more →
is operating) 1 V or less
9 Purge control Ignition switch: "ON" System voltage
solenoid valve Running at 3,500 r/min while engine is 1 V or less
warming up after having been started.
10 Ignition coil − No. 1, Engine r/min: 3,000 r/min 0.3 − 3.0 V
No. 4
23 Ignition coil − No. 2,
No. 3
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 and condenser fan is not operating 0 − 0.3 V
Radiator and condenser fan is operating 0.7 V or more
22 Fuel pump relay Ignition switch: ON System voltage
Engine: Idle speed 1 V or less
24 A/C load signal Refer to GROUP 55 - Troubleshooting (Inspection at the Automatic
compressor - ECU Terminal)
33 Alternator G terminal • Engine: Warm, idle (radiator fan: OFF) Voltage increases by 0.2 −
• Headlamp: OFF → ON 3.5 V
• Stop lamp: OFF → ON
• Rear defogger switch: OFF → ON
36 Engine warming Ignition switch: "LOCK" (OFF) → "ON" 1 V or less → System
lamp voltage (After several
seconds have elapsed)
37 Power steering fluid Engine: Idling after When steering wheel System voltage
pressure switch warming up is Stationary
When steering wheel 1 V or less
is turned
38 Control relay (Power Ignition switch: "LOCK" (OFF) System voltage
supply) Ignition switch: "ON" 1 V or less
41 Alternator FR • Engine: Warm, idle (radiator fan: OFF) Voltage decreases
terminal • Headlamp: OFF → ON
42 A/C pressure sensor • Engine: Idling When A/C is "MAX, 2.2 V or more
• A/C switch: ON COOL" condition
(when the load by
A/C is high)
When A/C is "MAX, 1.8 V or less
HOT" condition (when
the load by A/C is
low)
TROUBLESHOOTING

No.
45 A/C switch Engine: Idle speed Turn the A/C switch 0.5 V or less
OFF
Turn the A/C switch System voltage
ON (A/C compressor
is operating)
54 Oxygen sensor Engine: Idling after warming up 1 V or less
heater (rear) Engine:Racing System voltage
58 Tachometer signal Engine: 3,000 r/min 0.3 − 3.0 V
heater (front) Engine:5,000 r/min System voltage
71 Ignition switch − ST Engine: Cranking 8 V or more
72 Intake air Ignition switch: "ON" When intake air 3.8 − 4.4 V
temperature sensor temperature is
−20°C
When intake air 3.2 − 3.8 V
temperature is
0°C
temperature is
20°C
temperature is
40°C
temperature is
60°C
temperature is 80°C
75 Oxygen sensor Engine: Idling after warmed up (Check using 0 ⇔ 0.6 V (Changes
(rear) a digital type voltmeter) repeatedly)
76 Oxygen sensor Engine: Running at 2,500 r/min after warmed 0 ⇔ 0.8 V (Changes
(front) up (Check using a digital type voltmeter) repeatedly)
80 Backup power Ignition switch: "LOCK" (OFF) System voltage
supply
81 Sensor impressed Ignition switch: "ON" 4.9 − 5.1 V
voltage
82 Ignition switch − IG Ignition switch: "ON" System voltage
TROUBLESHOOTING
13A-303
No.
83 Engine coolant Ignition switch: "ON" When engine coolant 3.9 − 4.5 V
temperature sensor temperature is
−20°C
When engine coolant 3.2 − 3.8 V
temperature is
0°C
temperature is
20°C
temperature is
40°C
temperature is
60°C
temperature is
80°C
84 Throttle position Ignition switch: "ON" Set throttle valve to 0.535 − 0.735 V
sensor idle Position
Fully open throttle 4.4 − 5.3 V
valve
85 Barometric pressure Ignition switch: "ON" Altitude: 0 m 3.8 − 4.2 V
sensor Altitude: 600 m 3.5 − 3.9 V
Altitude: 1,200 m 3.3 − 3.7 V
Altitude: 1,800 m 3.0 − 3.4 V
86 Vehicle speed • Ignition switch: "ON" 0 ⇔ 5 V Changes
sensor • Move the vehicle forword slowly repeatedly
88 Camshaft position Engine: Cranking 0.4 − 3.0 V
sensor Engine: Idling 1.5 − 3.0 V
89 Crank angle sensor Engine: Cranking 0.4 − 4.0 V
Engine: Idling speed 1.5 − 2.5 V
90 Air flow sensor Engine: Idle speed 2.2 − 3.2 V
Engine: 2,500 r/min
TROUBLESHOOTING
CHECK CHART FOR RESISTANCE AND CAUTION

CONTINUITY BETWEEN TERMINALS If the terminals that should be checked are mis-
1. Turn the ignition switch to "LOCK" (OFF) position. taken, or if connector terminals are not correctly
shorted to earth, damage may be caused to the
2. Disconnect the engine-ECU connector.
vehicle wiring, sensors, engine-ECU and/or ohm-
3. Measure the resistance and check for continuity meter. Be careful to prevent this!
between the terminals of the engine-ECU
4. If the ohmmeter shows any deviation from the
harness-side connector while referring to the
standard value, check the corresponding sensor,
check chart.
actuator and related electrical wiring, and the
NOTE: . repair or replace.
1. When measuring resistance and checking 5. After repair or replacement, recheck with the
continuity, a harness for checking contact pin ohmmeter to confirm that the repair or
pressure should be used instead of inserting a replacement has corrected the problem.
test probe.
2. Checking need not be carried out in the order
given in the chart.
Engine-ECU Harness Side Connector Terminal Arrangement

Engine-ECU Harness Side Connector
C-137 C-136 C-135 C-134
8180 79 78 77 76 75 74 73 72 71 56 55 54 53 52 51 38 37 36 35 34 33 32 31 13 12 11 10 9 8 7 6 5 4 3 2 1
92 91 90 89 88 87 86 85 84 83 82 62 61 60 59 58 57 46 45 44 43 42 41 40 39 26 25 24 23 22 21 20 19 18 17 16 15 14
AK300343 AB
Terminal Inspection item Normal condition (Check condition)

No.
1 − 12 No. 1 injector 13 − 16 Ω (At 20°C)
12 − 14 No. 2 injector
4 − 12 Stepper motor coil (A1) 26 − 33 Ω (At 20°C)
12 − 17 Stepper motor coil (A2)
5 − 12 Stepper motor coil (B1)
12 − 18 Stepper motor coil (B2)
6 − 12 EGR control solenoid valve 29 − 35 Ω (At 20°C)
9 − 12 Purge control solenoid valve 29 − 35 Ω (At 20°C)
12 − 54 Oxygen sensor heater(rear) 11 − 18 Ω (At 20°C)
12 − 60 Oxygen sensor heater(front) 4.5 − 8.0 Ω (At 20°C)
13 − Body ECU earth Continuity (2 Ω or less)
earth
26 − Body
earth
TROUBLESHOOTING
13A-305
No.
81 − 83 Engine coolant temperature sensor 14 − 17 kΩ (When coolant temperature is −20°C)
5.1 − 6.5 kΩ (When coolant temperature is 0°C)
72 − 81 Intake air temperature sensor 13 − 17 kΩ (When intake air temperature is −20°C)
5.3 − 6.7 kΩ (When intake air temperature is 0°C)
INSPECTION PROCEDURE USING AIR FLOW SENSOR

OSCILLOSCOPE Measurement Method
M1131154500736
The output signals of the sensors and the conditions
Oscilloscope
of the actuation signals of the actuators can be
inspected visually by observing the waveforms on 1 2 3 4 5 6 7
the oscilloscope.
Special
patterns
pickup
AK000786 AE
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 oscilloscope special patterns pickup
to air flow sensor connector terminal No. 3.
Alternate Method (Test harness not

available)
to engine-ECU terminal No. 90.
TROUBLESHOOTING
Standard Wave Pattern

Observation conditions
Function Special patterns
Pattern height Low
Pattern selector Display
Engine Idle
Standard wave pattern

(V)
10 The time (cycle time) T is reduced when
T the amount of intake air increases.
T1 T2 Times T1 and T2 are equal.
Time
0
AK202334 AB
Observation conditions (from conditions above engine is increased by racing.)

(V)
10
T
Time
0
AK202335 AB
Wave Pattern Observation Points

Check that cycle time T becomes shorter and the fre-
quency increases when the engine speed is
increased.
TROUBLESHOOTING
13A-307
Examples of Abnormal Wave Patterns CAMSHAFT POSITION SENSOR AND
CRANK ANGLE SENSOR
Measurement Method
Camshaft position Oscilloscope
sensor connector
1 2 3 Special patterns
pick-up
AKX01597
1 2
• Example 1 3 Crank angle
Cause of problem sensor connector
AK000840AC
Sensor interface malfunction
1. Disconnect the camshaft position sensor
Wave pattern characteristics connector and connect the special tool Test
Rectangular wave pattern is output even when harness (MB991709) in between (All terminals
the engine is not started. should be connected).
• Example 2
2. Connect the oscilloscope special pattern pickup to
Cause of problem camshaft position sensor terminal No. 2.
Damaged rectifier or vortex generation column
3. Disconnect the crank angle sensor connector and
Wave pattern characteristics connect the special tool Test harness
Unstable wave pattern with non-uniform fre- (MD998478) in between.
quency. However, when an ignition leak
occurs during acceleration, the wave pattern
to crank angle sensor terminal No. 2.
will be distorted temporarily, even if the air
flow sensor is normal. Alternate Method (Test harness not
available)
to engine-ECU terminal No. 88 (When checking
the camshaft position sensor signal wave pattern).
the crank angle sensor signal wave pattern).
TROUBLESHOOTING

Observation condition
Pattern height Low
Engine speed Idle
Standard Wave Pattern 2 engine revolutions

(V) (1 camshaft revolution)
The time (cycle time)
75˚ BTDC T is reduced when the
5˚ BTDC
engine speed increases
Crank angle
sensor output
wave pattern
Camshaft position
sensor output
wave pattern
Time
0
TDC: Top dead centre No.1 TDC No.3 TDC No.4 TDC No.2 TDC
AK202336 AB
Wave Pattern Observation Points Wave pattern characteristics

Check that cycle time T becomes shorter when the Rectangular wave pattern is output even when
engine speed increases. the engine is not started.
•
Examples of Abnormal Wave Patterns

•
AKX01602
Example 2
AKX01597
Cause of problem
Example 1 Loose timing belt
Cause of problem Abnormality in sensor disk
Sensor interface malfunction Wave pattern characteristics
Wave pattern is displaced to the left or right.
TROUBLESHOOTING
13A-309
INJECTOR Alternate Method (Test harness not
Measurement Method available)
Oscilloscope to engine- ECU terminal No. 1 (When checking
the No. 1 cylinder).
1 2 to engine-ECU terminal No. 14 (When checking
Special
patterns 3. Connect the oscilloscope special patterns pickup
pickup to engine-ECU terminal No. 2 (When checking the
No. 3 cylinder).
AK101807AC 4. Connect the oscilloscope special patterns pickup
1. Disconnect the injector connector, and then the No. 4 cylinder).
connect the special tool Test harness set
(MB991348) in between (All terminals should be
connected).
to terminal No. 2 of the injector connector.

Pattern height Variable
Variable knob Adjust while viewing the
wave pattern
Engine Idle
(V) Point A.
Solenoid back
50 electromotive
force
(Approx.7×10V)
Point B
Injector drive
time
Time
Power
voltage
0 Drive signal: ON Drive signal: OFF
AK202347AB
TROUBLESHOOTING
Wave Pattern Observation Points IDLE SPEED CONTROL (ISC) SERVO

Point A: Height of solenoid back electromotive force (STEPPER MOTOR)
Contrast with standard wave Probable Measurement Method
pattern cause
Solenoid coil back electromotive Short in the Oscilloscope
force is low or doesn’t appear at injector solenoid
all. 1 2 3
4 5 6
Point B: Injector drive time
•
Special
patterns
pickup
AK300344AB
1. Disconnect the ISC servo connector, and connect

the special tool Test harness (MB991709) in
between.
When idling 2. Connect the oscilloscope special patterns pickup
When racing AKX01605AE
to the ISC servo-side connector terminal No. 1,
The injector drive time will be synchronized with the No. 3, No. 4 and No. 6 respectively.
M.U.T.-II/III tester display.
• When the engine is suddenly raced, the drive Alternate Method (Test harness not
time will be greatly extended at first, but the drive available)
time will soon match the engine speed. 1. Connect the oscilloscope special patterns pickup
to engine-ECU terminal No. 4, connection
terminal No. 5, connection terminal No. 17, and
connection terminal No. 18 respectively.
TROUBLESHOOTING
13A-311
Pattern height High
Engine condition When the engine coolant
temperature is 20°C or
below, turn the ignition
switch from LOCK (OFF)
position 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
instant, but soon Point B
Point A
disappears. Coilreverse electromotive
30 Induced electromotive force
force (Approx.3x10V)
from the motor turning
Stepper 20
motor
control
signal
wave 10
pattern
Time
AK201857 AB
Wave pattern Observation Points

Check that the standard wave pattern appears when Point B: Height of coil reverse electromotive force
the stepper motor is operating. Contrast with standard wave Probable
Point A: Presence or absence of induced electromo- pattern cause
tive force from the motor turning (Refer to the abnor-
mal wave pattern). Coil reverse electromotive force Short in the
does not appear or is extremely coil
Contrast with standard wave Probable small.
pattern cause
Induced electromotive force does Motor is
not appear or is extremely small. malfunctioning
TROUBLESHOOTING
Examples of Abnormal Wave Pattern Wave pattern characteristics

•
Current is not supplied to the motor coil on the
open circuit side (Voltage does not drop to 0
V).
Furthermore, the induced electromotive force
waveform at the normal side is slightly differ-
ent from the normal waveform.
IGNITION COIL AND POWER TRANSIS-

TOR
AKX01608AE Measurement Method
Example 1
Oscilloscope
Cause of problem
Motor is malfunctioning. (Motor is not operating.)
Wave pattern characteristics 1 2 3
Induced electromotive force from the motor turn- Special
ing does not appear. patterns
•
pickup
Open
circuit
side AK300345 AB
1. Disconnect the ignition coil connector, and

(MB991348) in between (All terminals should be
connected).
Normal
side 2. Connect the oscilloscope special patterns pickup
AKX01609AF to terminal No. 3 of each ignition coil connector in
Example 2 turn.
Cause of problem
Open circuit in the line between the stepper
motor and the engine-ECU. available)
to engine-ECU terminal No. 10 (No. 1 − No. 4),
connection terminal No. 23 (No. 2 − No.3)
respectively.
TROUBLESHOOTING
13A-313
Pattern height Low
Engine Approximately. 1,200
r/min
(V)
6 T
5˚ BTDC
4 75˚ BTDC
Crank angle Compression top dead center
sensor output 2
wave pattern
0
Power transistor T1
2 Ignition period
control signal
wave pattern
0
OFF ON
Dwell section
T : Revolution time corresponding to a crank angle of 180˚

T1 : Time computed by the engine-ECU
: Spark advance angle
AK204435 AC
Wave Pattern Observation Points Examples of Abnormal Wave Patterns

Point: Condition of wave pattern build-up section and
•
maximum voltage (Refer to abnormal wave pattern

examples 1 and 2). Normal wave pattern
Condition of wave pattern Probable cause
build-up section and
maximum voltage
Rises from approximately. 2 V Normal 2V
to approximately 4.5 V at the
top-right
AKX01612AD
2 V rectangular wave Open-circuit in
ignition primary Example 1
circuit Wave pattern during engine cranking
Rectangular wave at power Power transistor Cause of problem
voltage malfunction Open-circuit in ignition primary circuit
Wave pattern characteristics
Top-right part of the build-up section cannot be
seen, and voltage value is approximately 2 V
too low.
TROUBLESHOOTING
•
Normal wave pattern

VB
AKX01613AD
Example 2
Wave pattern during engine cranking
Cause of problem
Malfunction in power transistor
Power voltage results when the power transistor
is ON.
ON-VEHICLE SERVICE
13A-315
ON-VEHICLE SERVICE
AREA) CLEANING
M1131001000837
1. Remove the air intake hose from the throttle body. Throttle position
sensor
2. Spray cleaning fluid on a clean cloth.
CAUTION
• Do not spray the cleaning fluid directly to the
MB991536
throttle valve.
• Make sure the cleaning fluid does not enter
the motor from the bypass line. Also make AK201752AB
sure it does not enter the sensor through the (1) Disconnect the throttle position sensor
shaft. connector and connect the special tool Test
• Be careful not to rub off the molybden applied harness (MB991536) between the
around the throttle valve shaft. disconnected connector taking care not to
confuse the terminal to be connected.
(2) Connect digital voltmeter between the terminal
No. 2 (special tool's yellow clip on the sensor
15 mm output) and the terminal No. 4 (special tool's
red clip on the sensor earth) of the throttle
15 mm position sensor connector.
2. Turn the ignition switch to "ON" position (but do
not start the engine).
Areas on throttle valve to 3. Check the output voltage of the throttle position
apply molybdenum disulfide AK000833AD sensor.
Standard value: 535 − 735 mV
3. Wipe off the dirt around the throttle valve with the
cloth sprayed with cleaning fluid.
4. Attach the air intake hose.
5. Adjust the basic idle speed (Refer to P.13A-316).

ADJUSTMENT
M1131001100588
Throttle position
sensor AK300347AB
4. If not within the standard value, loosen the throttle

position sensor mounting bolts. Then rotate the
sensor body to adjust.
5. Turn the ignition switch to "LOCK" (OFF) position.
1 2 3 4 6. Remove the M.U.T.-II/III. If the M.U.T.-II/III is not
Equipment side connector AK300346 AB used, remove the special tool, and then connect
the throttle position sensor connector.
1. Connect the M.U.T.-II/III to the diagnosis 7. If a diagnosis code is displayed, erase the
connector. diagnosis code by using the M.U.T.-II/III or
When not using the M.U.T.-II/III, proceed as disconnect the negative battery cable from the
follows. battery terminal and then leave it for at least 10
seconds. After that, reconnect the battery cable,
and then let the engine run at idle for
approximately 10 minutes.
ON-VEHICLE SERVICE
BASIC IDLE SPEED ADJUSTMENT 6. If not within the standard value range, turn the
M1131001800640 speed adjusting screw (SAS) to make the
CAUTION necessary adjustment.
• The standard idling speed has been adjusted NOTE: If the idling speed is higher than the stand-
by the speed adjusting screw (SAS) by the ard value range even when the SAS is fully
manufacturer, and there should usually be no closed, check whether or not there is any indica-
need for readjustment. tion that the fixed SAS has been moved. If there is
• If the adjustment has been changed by mis- an indication that it has been moved, adjust the
take, the idle speed may become too high or fixed SAS.
the idle speed may drop too low when loads 7. Press the M.U.T.-II/III clear key, and release the
from components such as the A/C are placed ISC servo from the Actuator test mode.
on the engine. If this occurs, adjust by the fol-
lowing procedure. NOTE: Unless the ISC servo is released, the
Actuator test mode will continue 27 minutes.
• The adjustment, if made, should be made
after first confirming that the spark plugs, the 8. Turn the ignition switch to "LOCK" (OFF) position.
injectors, the idle speed control servo, the 9. Disconnect the M.U.T.-II/III.
compression pressure, etc., are all normal. 10.Start the engine again and let it run at idle speed
1. Before inspection and adjustment, set the vehicle for about 10 minutes; check that the idling
to the pre-inspection condition. condition is normal.
connector (16-pin). FUEL PRESSURE TEST
M1131001900960
NOTE: When the M.U.T.-II/III is connected, the 1. Release residual pressure from the fuel pipe line
diagnosis control terminal should be earthed. to prevent fuel gush out (Refer to P.13A-318).
3. Start the engine and run at idle. CAUTION
4. Select the item No. 30 of the M.U.T.-II/III Actuator Cover the hose connection with rags to prevent
test. splash of fuel that could be caused by some
NOTE: This holds the ISC servo at the basic step residual pressure in the fuel pipe line.
to adjust the basic idle speed.
NOTE: .
• 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.
• If the engine stalls or the engine speed is low
even though the vehicle has been driven AK300349AB
approximately 500 km or more, it is probable 2. Disconnect the high-pressure fuel hose at the
that deposits are adhered to the throttle valve, delivery pipe side.
so clean it (Refer to P.13A-315).
MB 991637
Gasket
MD 998709
Delivery
pipe MD 998742
High-pressure
fuel hose
AKX01458AG
AK300348
3. Assemble the fuel pressure measurement tools
as follows.
ON-VEHICLE SERVICE
13A-317
<When using the fuel pressure gauge set (special CAUTION
tool)> To prevent damage to the M.U.T.-II/III, always turn
a. Remove the union joint and bolt from the special the ignition switch to the "LOCK" (OFF) position
tool Adaptor hose (MD998709) and attach the before connecting or disconnecting the
special tool Hose adaptor (MD998742) to the M.U.T.-II/III.
adaptor hose. 5. Connect the M.U.T.-II/III to the diagnosis
b. Via a gasket, install the special tool Fuel pressure connector.
gauge set (MB991637 or MB991981) into the
6. Turn the ignition switch to "ON" position (But do
special tool that has already assembled as
described in (a) above.
7. Select "Item No. 07" from the M.U.T.-II/III Actuator
test to drive the fuel pump. Check that there are
MB 991981
no fuel leaks from any parts.
8. Finish the actuator test or turn the ignition switch
Gasket to "LOCK" (OFF) position.
MD 998709 9. Start the engine and run at idle.
Delivery 10.Fuel pressure measurement while the engine is
pipe MD 998742 running at idle.
High-pressure Standard value: Approximately. 270 kPa at
fuel hose
cerb idle
AK305430AB
<When using the fuel pressure gauge>

a. Remove the union joint and bolt from special tool
Adaptor hose (MD998709) and attach the special
tool Hose adaptor (MD998742) to the adaptor
hose.
b. Via a suitable O-ring or gasket, install the fuel
pressure gauge to the special tool that has
already assembled as described in (a) above.
AK300349AB
Fuel pressure
gauge set 11.Disconnect the vacuum hose from the fuel
O-ring or gasket pressure regulator and measure fuel pressure
with the hose end closed by a finger.
MD 998709
Standard value: 330 − 350 kPa at cerb idle
Delivery
pipe
MD 998742 12.Check to see that fuel pressure at idle does not
High-pressure drop even after the engine has been raced
fuel hose several times.
13.Racing the engine repeatedly, hold the fuel return
AKX01457AF
hose lightly with fingers to feel that fuel pressure
4. Install the assembled fuel pressure measurement is present in the return hose.
tools between the fuel rail and fuel high-pressure NOTE: If the fuel flow rate is low, there will be no
hose. fuel pressure in the return hose.
14.If any of fuel pressure measured in steps 10 to 13
is out of specification, troubleshoot and repair
according to the table below.
ON-VEHICLE SERVICE
Symptom Probable cause Remedy

• Fuel pressure too low Clogged fuel filter Replace fuel filter
• Fuel pressure drops after racing Fuel leaking to return side due to Replace fuel pressure regulator
• No fuel pressure in fuel return poor fuel regulator valve seating or
hose 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 Replace vacuum hose or clean
hose is connected and when Clogged nipple nipple
disconnected
15.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
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 Replace fuel pump
immediately after engine is open
stopped
16.Release residual pressure from the fuel pipe line FUEL PUMP CONNECTOR
(Refer to P.13A-318). DISCONNECTION (HOW TO REDUCE
CAUTION PRESSURIZED FUEL LINES)
Cover the hose connection with rags to prevent M1131000900558
splash of fuel that could be caused by some WARNING

residual pressure in the fuel pipe line. When removing the fuel pipe, etc., release
17.Remove the fuel pressure gauge and special tool fuel pressure to prevent fuel spray.
from the delivery pipe. 1. Remove the rear seat assembly (Refer to GROUP
18.Replace the O-ring at the end of the fuel high 52A − Rear Seat Assembly P.52A-26).
pressure hose with a new one. Furthermore,
Service hole cover
apply engine oil to the new O-ring before
replacement.
19.Fit the fuel high pressure hose over the delivery
pipe and tighten the bolt to specified toque.
20.Check for any fuel leaks by following the
procedure in step 7.
21.Disconnect the M.U.T.-II/III. AC102784 AB
2. Remove the service hole cover.

ON-VEHICLE SERVICE
13A-319
Fuel pump assembly <2WD> or Fuel pump assembly <2WD>

fuel tank pump and gauge assembly <4WD>
or fuel tank pump and gauge assembly <4WD>
connector
AC101011AD connector AC101011AE
3. Disconnect the fuel pump assembly connector (4) Disconnect the fuel pump assembly <2WD> or
<2WD> or fuel tank pump and gauge assembly the fuel tank pump and gauge assembly
connector <4WD>. <4WD> connector.
4. After starting the engine and letting it run until it
stops naturally, turn the ignition switch to the 1 2 3
"LOCK" (OFF) position. 4 5
5. Connect the fuel pump assembly connector
<2WD> or fuel tank pump and gauge assembly
connector <4WD>.
6. Install the service hole cover and rear seat
assembly (Refer to GROUP 52A − Rear Seat
Assembly P.52A-26).
AC101012 AD
FUEL PUMP OPERATION CHECK (5) When the fuel pump drive connector is
M1131002000982
attached directly to the battery, check if the
1. Check the operating of the fuel pump by
sound of the fuel pump operation can be
M.U.T.-II/III to force-drive the fuel pump.
heard. If no operating sound is heard, replace
2. If the fuel pump will not operate, check by using the fuel tank pump (Refer to GROUP 13D,
the following procedure. If normal, check the fuel Fuel Pump Module Disassembly and
pump drive circuit. Assembly P.13D-15 <2WD>, P.13D-16
(1) Turn the ignition switch to the "LOCK" (OFF) <4WD>).
position. NOTE: As the fuel pump is an in-tank type, the
(2) Remove the rear seat assembly (Refer to fuel pump sound is hard to hear. Remove the
GROUP 52A, Rear Seat Assembly Removal fuel tank filler tube cap and check from the tank
and Installation P.52A-26). inlet.
Service hole cover (6) Check for fuel pressure by pinching the fuel
hose with fingertips.
(7) Connect the fuel pump assembly <2WD> or
the fuel tank pump and gauge assembly
<4WD> connector.
(8) Install the service hole cover and rear seat
assembly (Refer to GROUP 52A, Rear Seat
Assembly Removal and Installation P.52A-26).
AC102784 AB
(3) Remove the service hole cover.

ON-VEHICLE SERVICE
COMPONENT LOCATION
M1131002100912
Name Symbol Name Symbol

Air flow sensor G Engine-ECU T
(with intake air temperature sensor and Engine warming lamp Q
barometric pressure sensor) (check engine lamp)
A/C relay O Fuel pump relay (1) and (2) P
A/C switch S Idle speed control servo F
A/C pressure sensor A Ignition coil I
Camshaft position sensor L Injector D
Crank angle sensor C Oxygen sensor (front) K
Detonation sensor H Oxygen sensor (rear) U
Diagnosis connector R Power steering fluid pressure switch B
EGR control solenoid valve J Purge control solenoid valve J
Engine control relay O Throttle position sensor E
Engine coolant temperature sensor M Vehicle speed sensor N
A B C D E F G
H I J K L M N O
P Q R S T U
AK300351AB
ON-VEHICLE SERVICE
13A-321
ENGINE CONTROL RELAY CONTINUITY INTAKE AIR TEMPERATURE SENSOR
CHECK CHECK
M1131050000981 M1131002800632
Intake air
Relay box’s temperature
triangle marks Engine control relay sensor
1 2
3 4
1 2 3 4 5 6 7
Equipment side Equipment side connector
connector AK300352 AB AK300354 AB
Tester Battery Voltage Normal State 1. Disconnect the air flow sensor connector.
Connection 2. Measure resistance between terminals No. 5 and
Terminal No. 6.
2−3 No Voltage Continuity Standard value:
1−4 No Voltage No continuity 13 − 17 kΩ (at −20°C)
Voltage (Connect Continuity (2 5.3 − 6.7 kΩ (at 0°C)
positive (+) terminal of Ω or less) 2.3 − 3.0 kΩ (at 20°C)
battery to terminal No. 3 1.0 − 1.5 kΩ (at 40°C)
and negative (−) 0.56 − 0.76 kΩ (at 60°C)
terminal of battery to 0.30 − 0.42 kΩ (at 80°C)
terminal No. 2.) 3. Remove the air flow sensor
FUEL PUMP RELAY CONTINUITY CHECK

M1131033000988
Intake air temperature
Junction block’s sensor
triangle marks
Fuel pump
relay (1)
1 2
Fuel pump 3 4
relay (2)
Equipment side AKX01621AD
connector
4. Measure resistance while heating the sensor

AK300353 AB
using a hair drier.
Tester Battery Voltage Normal State Normal condition:
Connection Temperature (°C) Resistance (kΩ)
Terminal
Higher Smaller
2-3 No Voltage Continuity
5. If the value deviates from the standard value or
1-4 No Voltage No continuity
the resistance remains unchanged, replace the air
Voltage (Connect Continuity (2 flow sensor assembly.
positive (+) terminal of Ω or less) 6. Install the air flow sensor and tighten it to the
battery to terminal No. 3 specified torque.
and negative (−)
terminal of battery to Tightening torque: 8.8 ± 1 N⋅m
terminal No. 2.)
ON-VEHICLE SERVICE

SENSOR CHECK
M1131003101059
CAUTION
Be careful not to touch the connector (resin sec-
tion) with the tool when removing and installing.
1 2
AKX01623AD
Equipment
side connector
4. Apply sealant to threaded portion.
Specified sealant:
Engine coolant 3M NUT Locking Part No. 4171 or equivalent
temperature
sensor 5. Install the engine coolant temperature sensor and
AK501636 AB tighten it to the specified torque.
1. Remove the engine coolant temperature sensor.
THROTTLE POSITION SENSOR CHECK
M1131003200729
Throttle position
sensor
AKX01622
1 2 3 4
2. With temperature sensing portion of engine Equipment side connector AK300346 AB
coolant temperature sensor immersed in hot
water, check resistance. 1. Disconnect the throttle position sensor connector.
Standard value: 2. Measure the resistance between the throttle
14 − 17 kΩ (at −20°C) position sensor side connector terminal No. 1 and
5.1 − 6.5 kΩ (at 0°C) terminal No. 4.
2.1 − 2.7 kΩ (at 20°C) Standard value: 3.5 − 6.5 kΩ
0.9 − 1.3 kΩ (at 40°C)
3. Measure the resistance between the throttle
0.48 − 0.68 kΩ (at 60°C)
position sensor side connector terminal No. 2 and
0.26 − 0.36 kΩ (at 80°C)
terminal No. 4.
3. If the resistance deviates from the standard value Normal condition:
greatly, replace the sensor.
Throttle valve slowly Changes smoothly in
open until fully open from proportion to the opening
the idle 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-315.
ON-VEHICLE SERVICE
13A-323
OXYGEN SENSOR CHECK 7. While repeatedly racing the engine, measure the
M1131005000776 oxygen sensor output voltage.
Oxygen sensor (front) Standard value:
Engine Oxygen Remarks
sensor
output
Oxygen sensor (front) voltage
When 0.6 − 1.0 V If you make the air-fuel
racing the ratio rich by racing the
1 2 engine engine repeatedly, a
3 4 normal oxygen sensor
will output a voltage of
Equipment side connector AK300356 AB 0.6 − 1.0 V.
1. Disconnect the oxygen sensor connector and CAUTION
connect the special tool Test harness • Be very careful when connecting the jumper
(MD998464) to the connector on the oxygen wire; incorrect connection can damage the
sensor side. oxygen sensor.
2. Make sure that there is continuity (4.5 − 8.0 Ω at • Be careful the heater is broken when voltage
20°C) between terminal No. 1 (red clip of special of beyond 8V is applied to the oxygen sensor
tool) and No. 3 (blue clip of special tool) on the heater.
oxygen sensor connector. NOTE: If the sufficiently high temperature (of
3. If there is no continuity, replace the oxygen approximate 400°C or more) is not reached
sensor. although the oxygen sensor is normal, the output
4. Warm up the engine until engine coolant is 80°C voltage would be possibly low although the rich
or higher. air-fuel ratio. Therefore, if the output voltage is
5. Perform a tracing for 5 minutes or more with the low, use a jumper wire to connect the terminal
engine speed of 4,500 r/min. No.1 (red clip of special tool) and the terminal No.
3 (blue clip of special tool) of the oxygen sensor
with a (+) terminal and (-) terminal of 8 V power
supply respectively, then check again.
Black
Oxygen 8. If the sensor is defective, replace the oxygen
sensor
equipment sensor.
side connector NOTE: For removal and installation of the oxygen
White sensor, refer to GROUP 15 − Exhaust Manifold.
P.15-18.
AKX01624 AF
MD998464
6. Connect a digital voltage meter between terminal

No. 2 (black clip of special tool) and No. 4 (white
clip of special tool).
ON-VEHICLE SERVICE
Oxygen sensor (rear) 6. Connect a digital voltage meter between terminal

No. 3 and No. 4.
7. While repeatedly racing the engine, measure the
oxygen sensor output voltage.
2 1
4 3 Standard value:
Equipment side Engine Oxygen Remarks
connector sensor
output
voltage
Oxygen sensor
connector (rear) When 0.6 − 1.0 V If you make the air-fuel
Oxygen sensor (rear) engine engine repeatedly, a
normal oxygen sensor
0.6 − 1.0 V.
AK300357 AB
CAUTION
1. Disconnect the oxygen sensor connector and • Be very careful when connecting the jumper
connect the special tool Test harness (MB991658) wire; incorrect connection can damage the
to the connector on the oxygen sensor side. oxygen sensor.
2. Make sure that there is continuity (11 − 18 Ω at • Be careful the heater is broken when voltage
20°C) between terminal No. 1 and No. 2 on the of beyond 8V is applied to the oxygen sensor
oxygen sensor connector. heater.
3. If there is no continuity, replace the oxygen NOTE: If the sufficiently high temperature (of
sensor. approximate 400°C or more) is not reached
4. Warm up the engine until engine coolant is 80°C although the oxygen sensor is normal, the output
or higher. voltage would be possibly low although the rich
5. Perform a tracing for 5 minutes or more with the air-fuel ratio. Therefore, if the output voltage is
engine speed of 4,500 r/min. low, use a jumper wire to connect the terminal
No.2 and the terminal No. 1 of the oxygen sensor
Oxygen sensor
supply respectively, then check again.
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 P.15-25.
MB991658
AK000121 AC
ON-VEHICLE SERVICE
13A-325
INJECTOR CHECK NOTE: If the operating sound cannot be heard,
M1131005200628 inspect the injector actuation circuit.
Check the Operation Sound
Measurement of Resistance between Ter-
minals
Injector
1 2 1. Disconnect the injector connector.
Equipment side 2. Measure the resistance between terminals.
connector
Standard value: 10.5 − 13.5 Ω (at 20°C)
3. Connect the injector connector.
Check the Injection Condition

AK300358 AB 1. Following the steps below, bleed out the residual
pressure within the fuel pipe line to prevent flow of
1. Use a stethoscope to listen to the operation sound the fuel (Refer to P.13A-318).
(clicking) of the injectors while the engine is idling
2. Remove the injector.
or cranking.
3. Assemble the following special tools as shown in
CAUTION
Fig.
Beware that the operation sounds of other injec-
• Injector test set (MD998706)
tors can be heard even if the injector that is being
• Injector test harness (MB991607)
inspected might not be operating.
• Injector test adaptor (MD998741)
2. Verify that the operation sound increases with the • Clip (MB991608)
engine speed.
High-pressure fuel hose
MD998741
Return hose
MB991607
Pressure regulator
Clip (MB991608) MD998706
Injector
Battery
AK101794 AD
4. Connect the M.U.T.-II/III to the diagnosis Mainhose

connector.
6. Select "Item No. 07" from the M.U.T.-II/III Actuator Return hose
test to drive the fuel pump.
Injector
Battery AK101795 AC
7. Activate the injector and check the atomized

spray condition of the fuel.
ON-VEHICLE SERVICE
The condition can be considered satisfactory Check the Coil Resistance

unless it is extremely poor.
8. Stop the actuation of the injector, and check for
leakage from the injector's nozzle.
Standard value: 1 drop or less per minute
9. 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.
1 2 3
10.Disconnect the M.U.T.-II/III. 4 5 6
IDLE SPEED CONTROL (ISC) SERVO

(STEPPER MOTOR) CHECK
M1131005400611
Check the Operation Sound

1 2 3
4 5 6
1 2 3
4 5 6
Equipment side
connector
AKX01561AE
Idle speed 1. Disconnect the idle speed control servo

control servo connector.
AK300359 AB
2. Measure the resistance between terminal No. 2
1. Check that the engine coolant temperature is and either terminal No. 1 or terminal No. 3 of the
20°C or below. connector at the idle speed control servo side.
NOTE: Disconnecting the engine coolant temper- Standard value: 28 − 33 Ω (at 20°C)
ature sensor connector and connecting the har- 3. Measure the resistance between terminal No. 5
ness-side of the connector to another engine and either terminal No. 6 or terminal No. 4 of the
coolant temperature sensor that is at 20°C or connector at the idle speed control servo side.
below is also okay. Standard value: 28 − 33 Ω (at 20°C)
2. Check that the operation sound of the stepper
motor can be heard after the ignition is turned to
the "ON" position (but without starting the engine).
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-ECU.
ON-VEHICLE SERVICE
13A-327
Operation Check 5. With the idle speed control servo as shown in the
illustration, connect the negative (−) terminal of
the power supply to each clip as described in the
following steps, and check whether or not a
vibrating feeling (a feeling of very slight vibration
of the stepper motor) is generated as a result of
the activation of the stepper motor.
(1) Connect the negative (−) terminal of the power
supply to the terminal No. 1 and terminal No.
4.
AKX01626 (2) Connect the negative (−) terminal of the power
1. Remove the throttle body. 4.
2. Remove the stepper motor. (3) Connect the negative (−) terminal of the power
3. Connect the special tool Test harness supply to the terminal No. 3 and terminal No.
(MB991709) to the idle speed control servo 6.
connector. (4) Connect the negative (−) terminal of the power
4. Connect the positive (+) terminal of a power supply to the terminal No. 1 and terminal No.
supply (approximately 6 V) to the terminals No. 2 6.
and No. 5. (5) Connect the negative (−) terminal of the power
4.
(6) Repeat the tests in sequence from (5) to (1).
6. If vibration is detected during the test, the stepper
motor can be considered to be normal.
INJECTOR
INJECTOR
M1131007101880
CAUTION
When the fuel injector replacement is performed, use the M.U.T.-II/III to initialise the learning value
(Refer to GROUP 00, Precautions Before Service − Initialisation Procedure for Learning Value in MPI
Engine P.00-21).
• Fuel Discharge Prevention (Refer to P.13A-318). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner P.15-6).
P.15-6). • Fuel Leakage Inspection.
AC300484
3 8.9 ± 1.9 N·m 11 ± 1 N·m

4 8
9
7N
5
6
5.0 ± 1.0 N·m
10 15 N
N 11 17 14
16
2 12
13
18

moving parts before 1
installation.
AC604915AB

1. PCV hose connection 11. O-ring
2. Injector connector <<A>> >>B<< 12. Fuel delivery pipe and fuel injector
3. Idle speed control servo connector assembly
4. Throttle position sensor connector 13. Insulators
5. Emission control equipment hose >>A<< 14. Fuel injector assembly
connector 15. O-ring
>>A<< 6. Fuel high-pressure hose 16. Insulators
connection 17 Fuel injectors
7. O-ring 18. Fuel delivery pipe
8. Fuel return hose connection
9. Fuel hose
>>A<< 10. Delivery pipe pressure regulator
INJECTOR
13A-329
REMOVAL SERVICE POINT 4. Tighten the delivery pipe pressure regulator and
<<A>> FUEL DELIVERY PIPE AND FUEL fuel high-pressure hose to the specified torque.
INJECTOR ASSEMBLY REMOVAL Tightening torque:
8.9 ± 1.9 N⋅m <Delivery pipe pressure regula-
CAUTION tor>
Do not drop the injector. 5.0 ± 1.0 N⋅m <Fuel high-pressure hose>
Remove the fuel delivery pipe with the fuel injector
assembly attached to it.
>>B<< FUEL DELIVERY PIPE AND FUEL
INSTALLATION SERVICE POINT INJECTOR ASSEMBLY INSTALLATION
>>A<< FUEL INJECTOR ASSEM- CAUTION
BLY/DELIVERY PIPE PRESSURE REGU- Securely bring the insulator into contact with the
injector to prevent air leak from the insulator
LATOR/FUEL HIGH-PRESSURE HOSE area.
INSTALLATION
CAUTION
Do not let the engine oil get into the delivery pipe
will be damaged. Injector
1. Apply a drop of new engine oil to the O-ring.
2. Turn the fuel injector assembly. To the right and Insulator
left to install to the fuel delivery pipe. Repeat for
delivery pipe pressure regulator and fuel
high-pressure hose. Be careful not to damage the
O-ring. After installing, check that the item turns AC601239AB
smoothly. Be sure that there is no clearance between the insu-

3. If it does not turn smoothly, the O-ring may be lator area and the injector, and install them to the cyl-
trapped, remove the item, re-install it into the fuel inder head.
delivery pipe and check again.
THROTTLE BODY ASSEMBLY

M1131007701354
CAUTION
When the throttle body assembly replacement is performed, use the M.U.T.-II/III to initialise the learn-
ing value (Refer to GROUP 00, Precautions Before Service − Initialisation Procedure for Learning
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Engine Coolant Supplying (Refer to GROUP 14, On-vehi-
P.15-6). cle Service − Engine Coolant Replacement P.14-17).
On-vehicle Service − Accelerator Cable Adjustment
P.17-6).
7
2
5.0 ± 1.0 N·m

1 19 ± 3 N·m
N8
3
4
5 AC300416AB

1. Accelerator cable connection 6. Emission vacuum hose
2. Throttle position sensor connector connection
3. Idle speed control servo connector 7. Throttle body assembly
4. Water return hose connection >>A<< 8. Throttle body gasket
5. Water feed hose connection
13A-331
INSTALLATION SERVICE POINT
>>A<< THROTTLE BODY GASKET
INSTALLATION
CAUTION
Poor idling etc. may result if the throttle body
gasket is installed incorrectly.
Up
Towards front
of vehicle AC200313AB
Install the throttle body gasket as shown in the illus-

tration.
ENGINE-ECU
ENGINE-ECU
M1131033800445
CAUTION
• When the engine-ECU replacement is performed, always refer to GROUP 54A, On-vehicle Service -
How to Register Encrypted Code P.54A-22.
• After the engine-ECU is replaced, idling speed may be unstable because the MPI engine learning
is not completed. To make it stable, make the system learn the idling (Refer to GROUP 00 − Pre-
cautions before Service, Learning Procedure for Idling in MPI Engine P.00-21).
Pre-removal and Post-installation Operation
Cowl Side Trim (RH) Removal and Installation (Refer to
GROUP 52A, Trim P.52A-10).
3
5.0 ± 1.0 N·m
1
9.0 ± 2.0 N·m
AC300630AC
REMOVAL STEPS REMOVAL STEPS (Continued)

1. Engine-ECU connector 2. Engine-ECU
3. Engine-ECU bracket
13B-1
GROUP 13B
MULTIPORT FUEL
INJECTION (MPI)
<4G63-Turbo>
CONTENTS
GENERAL INFORMATION . . . . . . . . 13B-3 ON-VEHICLE SERVICE . . . . . . . . . . . 13B-390

SERVICE SPECIFICATIONS. . . . . . . 13B-7 AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13B-390
ACCELERATOR PEDAL POSITION SWITCH
SEALANT. . . . . . . . . . . . . . . . . . . . . . 13B-7 AND ACCELERATOR PEDAL POSITION
SENSOR (APS) ADJUSTMENT . . . . . . . . . 13B-390
FUEL PRESSURE TEST . . . . . . . . . . . . . . 13B-391
SPECIAL TOOLS. . . . . . . . . . . . . . . . 13B-8
FUEL PUMP CONNECTOR
DISCONNECTION (HOW TO REDUCE
TROUBLESHOOTING . . . . . . . . . . . . 13B-11 PRESSURIZED FUEL LINES) . . . . . . . . . . 13B-393
DIAGNOSIS TROUBLESHOOTING FUEL PUMP OPERATION CHECK . . . . . . 13B-393
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-11
COMPONENT LOCATION . . . . . . . . . . . . . 13B-394
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 13B-11
ENGINE CONTROL RELAY CONTINUITY
INSPECTION CHART FOR DIAGNOSIS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-395
CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-20
FUEL PUMP RELAY CONTINUITY
INSPECTION PROCEDURE FOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-395
DIAGNOSIS CODES . . . . . . . . . . . . . . . . . 13B-22
INTAKE AIR TEMPERATURE SENSOR
INSPECTION CHART FOR TROUBLE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-396
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13B-248
INSPECTION CHART FOR TROUBLE SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13B-396
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13B-252
ACCELERATOR PEDAL POSITION
CHECK AT THE ECU TERMINALS . . . . . . 13B-376 SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13B-397
INSPECTION PROCEDURE USING ACCELERATOR PEDAL POSITION
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13B-383 SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . 13B-397
OXYGEN SENSOR CHECK . . . . . . . . . . . . 13B-398
INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13B-400
THROTTLE VALVE CONTROL SERVO
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-400
FUEL PRESSURE SOLENOID VALVE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13B-401
Continued on next page

13B-2
INJECTOR . . . . . . . . . . . . . . . . . . . . . 13B-402 ENGINE-ECU . . . . . . . . . . . . . . . . . . . 13B-406

REMOVAL AND INSTALLATION . . . . . . . . 13B-402 REMOVAL AND INSTALLATION . . . . . . . . 13B-406
THROTTLE BODY ASSEMBLY . . . . 13B-404

MULTIPORT FUEL INJECTION (MPI) <4G63-Turbo>
GENERAL INFORMATION
13B-3
GENERAL INFORMATION
M1131000101782
The Multipoint Fuel Injection System consists of sen- engine-ECU carries out activities such as fuel injec-
sors which detect the engine conditions, the tion control, idle speed control and ignition timing
engine-ECU which controls the system based on sig- control. In addition, the engine-ECU is equipped with
nals from these sensors, and actuators which oper- several diagnosis modes which simplify trouble-
ate under the control of the engine-ECU. The shooting when a problem develops.

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

This system electrically controls the opening of the
throttle valve. The engine-ECU detects the amount
of travel of the accelerator pedal via the accelerator
pedal position sensor, and controls the actuation of
the throttle valve control servo motor, which is
mounted on the throttle body, in order to attain the
target throttle valve opening that has been predeter-
mined in accordance with driving conditions.
IDLE SPEED CONTROL

The idle speed is kept at the optimum speed by con- air conditioner load. In addition, when the air condi-
trolling the amount of air that bypasses the throttle tioner switch is turned off and on while the engine is
valve in accordance with changes in idling conditions idling, the idle speed control motor operates to adjust
and engine load during idling. The engine-ECU the throttle valve bypass air amount in accordance
drives the idle speed control motor to keep the with the engine load conditions in order to avoid fluc-
engine running at the pre-set idle target speed in tuations in the engine speed.

The power transistor located in the ignition primary
circuit turns ON and OFF to control the primary cur-
rent flow to the ignition coil. This controls the ignition
timing in order to provide the optimum ignition timing
ignition timing is determined by the engine-ECU from
the engine speed, intake air volume, engine coolant
temperature and atmospheric pressure.
13B-4 MULTIPORT FUEL INJECTION (MPI) <4G63-Turbo>
GENERAL INFORMATION
• When an abnormality is detected in one of the • The RAM data inside the engine-ECU that is
sensors or actuators related to emission control, related to the sensors and actuators can be read
the engine warning lamp (check engine lamp) by means of the M.U.T.-II/III. In addition, the actu-
illuminates as a warning to the driver. ators can be force-driven under certain circum-
• When an abnormality is detected in one of the stances.

1. Fuel Pump Control Prevents alternator output current from increasing
Turns the fuel pump relay ON so that current is sup- suddenly and idle speed from dropping at times
plied to the fuel pump while the engine is crank- such as when the headlamp are turned on.
ing or running. 5. Purge Control Solenoid Valve Control
2. A/C Relay Control (Refer to GROUP 17 − Engine And Emission Control
Turns the compressor clutch of the A/C ON and OFF. − Evaporative Emission Control System
3. Fan Motor Control P.17-60).
The revolutions of the radiator fan and condenser fan 6. EGR Control Solenoid Valve Control
are controlled in response to the engine coolant (Refer to GROUP 17 − Engine And Emission Control
temperature and vehicle speed. − Exhaust Gas Recirculation (EGR) System
4. Alternator Output Current Control P.17-67).
GENERAL INFORMATION
13B-5
Throttle position sensor Hall element type
Throttle valve control servo DC motor type, having broshes
Sensors Air flow sensor Karman vortex type
Barometric pressure sensor Semiconductor type
Engine coolant temperature Thermistor type
Accelerator pedal position sensor Variable resistor type
Accelerator pedal position switch Contact switch type
Vehicle speed sensor Magnetic resistive element type
Camshaft position sensor Hall element type
Crank angle sensor Hall element type
Clutch oil pressure sensor Semiconductor type
Injector identification mark CDH450
Throttle valve control servo relay Contact switch type
EGR control solenoid valve Duty cycle type solenoid valve
Fuel pressure control solenoid valve ON/OFF type solenoid valve
Waste gate solenoid valve Duty cycle type solenoid valve
regulator
GENERAL INFORMATION
1 Oxygen sensor (front) Power supply Engine- 1 Injector Engine control relay
2 Oxygen sensor (rear) Ignition switch-IG ECU 2 Throttle valve Fuel pump relay
3 Air flow sensor Ignition switch-ST control servo A/C compressor relay
4 Intake air temperature A/C switch 3 Fuel pressure Ignition coil
sensor A/C load signal control solenoid Fan controller
5 Camshaft position Power steering valve Engine warning lamp
sensor fluid pressure 4 Waste gate Diagnosis output
6 Crank angle sensor switch solenoid valve Alternator G terminal
7 Barometric pressure Alternator FR 5 EGR control Air flow sensor reset
sensor terminal solenoid valve signal
8 Engine coolant Accelerator pedal 6 Purge control Oxygen sensor heater
temperature sensor position switch solenoid valve (front)
9 Detonation sensor Accelerator pedal Oxygen sensor heater
10 Throttle position position sensor (rear)
sensor(main) (main) Tachometer
11 Throttle position Accelerator pedal
sensor(sub) position sensor
(sub)
Vehicle speed
sensor
Clutch oil pressure
sensor
10 Throttle position sensor (main)

Canister From 11 Throttle position sensor (sub)
fuel tank
2 Throttle valve control servo
Check valve By-pass

valve
5 EGR control
3 Fuel pressure solenoid valve
6 Purge control control solenoid valve
solenoid valve
5 Camshaft
Fuel pressure position sensor
7 Barometric regulator
pressure sensor From
To fuel fuel pump
4 Intake air tank
3 Air flow temperature EGR
sensor sensor valve
1 Injector
Air 8 Engine coolant temperature sensor
inlet
Waste gate actuator 9 Detonation sensor
4 Waste gate solenoid valve Catalytic converter Catalytic converter

1 Oxygen sensor (front) 2 Oxygen sensor (rear)
AK306145 AB
13B-7
M1131000301140
Accelerator pedal position sensor adjusting voltage V 0.5 − 0.9
Accelerator pedal position sensor resistance kΩ 3.5 − 6.5
20°C 2.3 − 3.0
40°C 1.0 − 1.5
60°C 0.56 − 0.76
80°C 0.30 − 0.42
20°C 2.1 − 2.7
40°C 0.9 − 1.3
60°C 0.48 − 0.68
80°C 0.26 − 0.36
Oxygen sensor heater Front 4.5 − 8.0
resistance (at 20°C) Ω Rear 11 − 18
Fuel pressure kPa Vacuum hose disconnection 289 − 309 at curb idle
Vacuum hose connection Approximately 230 at curb idle
Fuel pressure control solenoid valve resistance (at 20°C) Ω 28 − 36
Injector coil resistance (at 20°C) Ω 13 − 16
Injector fuel leakage rate Drop/minute 1 or less
Throttle valve control servo coil resistance (at 20°C) Ω 0.3 − 100
SEALANT
M1131000500765

Threaded portion
SPECIAL TOOLS
SPECIAL TOOLS
M1131000601259

• Measurement of fuel pressure
B991502

MB991824 E: MB991825 (V.C.I.)
cable
C: M.U.T.-III
main harness
with CAN
C
communicatio
D: M.U.T.-III
main harness
MB991910
B (Vehicles
D without CAN
communicatio
n system)
E: M.U.T.-III
adapter
E F: M.U.T.-III
trigger harness
MB991825
MB991826
MB991955

troubleshooting
MB991348
SPECIAL TOOLS
13B-9
troubleshooting

(3-pin, triangle) Troubleshooting

• Inspection of oxygen sensor (front)

Troubleshooting
• Inspection of data list
MB991658

D: Probe
MB991223
SPECIAL TOOLS


gauge set
MB991637

gauge set
MB991981

injectors
MD998706

harness
MB991607

adaptor
MD998741

holder assembly
MB991976
TROUBLESHOOTING
13B-11
TROUBLESHOOTING
M1131150001260
NOTE: If the engine-ECU is replaced, the steering ENGINE WARNING LAMP (CHECK
lock cylinder and ignition key should be replaced ENGINE LAMP)
together with it.
Engine warning lamp

(check engine lamp)
AK300251AB

sis code output.

− Engine-ECU
P0090 Fuel pressure control valve system
P0122* Throttle position sensor (main) circuit low input
P0123* Throttle position sensor (main) circuit high input
P0130 Oxygen sensor (front) system
P0135 Oxygen sensor heater (front) system
P0136 Oxygen sensor (rear) system
P0141 Oxygen sensor heater (rear) system
P0170 Abnormal fuel system
P0222* Throttle position sensor (sub) circuit low input
P0223* Throttle position sensor (sub) circuit high input
TROUBLESHOOTING

P0243 Waste gate solenoid valve system
P0300 Random cylinder misfire detection system
P0301* No. 1 cylinder misfire detection system
P0403 EGR control solenoid valve system
P0421 Warm up Catalyst malfunction
P0500 Vehicle speed sensor system
P0638* Throttle actuator control servo circuit range/performance/problem
P0642* Throttle position sensor power supply
P0657* Throttle actuator control servo relay circuit malfunction
P0805 Clutch oil pressure sensor system
P1603* Battery back-up line system
P2100* Throttle actuator control servo circuit (open)
P2101* Throttle valve control magneto malfunction
P2102* Throttle valve control servo circuit (shorted low)
P2103* Throttle valve control servo circuit (shorted high)
P2121* Accelerator pedal position sensor (main) circuit range/performance problem
P2122* Accelerator pedal position sensor (main) circuit low input
P2123* Accelerator pedal position sensor (main) circuit high input
P2126* Accelerator pedal position sensor (sub) circuit range/Performance problem
P2127* Accelerator pedal position sensor (sub) circuit low input
P2128* Accelerator pedal position sensor (sub) circuit high input
P2135* Throttle position sensor (main and sub) range/performance problem
P2138* Accelerator pedal position sensor (main and sub) range/performance problem
TROUBLESHOOTING
13B-13
NOTE: .
• If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication
between M.U.T.-II/III and the engine-ECU is impossible. In this case, the diagnosis code cannot be read.
• After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine is
next turned on and the same malfunction is re-detected. However, for items marked with a "*" in the diag-
nosis code number column, the engine warning lamp illuminates only on the first detection of the malfunc-
tion.
• When the engine-ECU monitored the power train malfunction three times* met set condition require-
ments, it detected no malfunction.
METHOD OF READING AND ERASING INSPECTION USING M.U.T.-II/III DATA

DIAGNOSIS CODES LIST AND ACTUATOR TESTING
Refer to P.00-6, GROUP 00 − How to Use Trouble- 1. Carry out inspection by means of the data list and
shooting/Inspection Service Points. the actuator test function, if there is an
abnormality, check and repair the chassis harness
DIAGNOSIS USING DIAGNOSIS 2 MODE and components.
1. Switch the diagnosis mode of the engine control 2. After repairing, re-check using the M.U.T.-II/III and
unit to DIAGNOSIS 2 mode using the M.U.T.-II/III. check that the abnormal input and output have
2. Carry out a road test. returned to normal as a result of the repairs.
3. Take a reading of the diagnosis code and repair 3. Erase the diagnosis code memory.
the problem location. 4. Remove the M.U.T.-II/III, and then start the engine
4. Turn the ignition switch to "LOCK" (OFF) position again and carry out a road test to confirm that the
and then back to "ON" position again. problem has disappeared.
NOTE: By turning the ignition switch to "LOCK"
(OFF) position, the ENGINE-ECU will switch the FREEZE FRAME DATA
diagnosis mode from DIAGNOSIS 2 mode to When the engine-ECU detects a malfunction and
DIAGNOSIS 1 mode. stores a diagnosis code, it also stores a current sta-
5. Erase the diagnosis codes. tus of the engine. This function is called "Freeze
frame data". By analyzing this "Freeze frame" data
with the M.U.T.-II/III, an effective troubleshooting can
be performed.
The display items of freeze frame data are shown
below.
TROUBLESHOOTING
DISPLAY ITEM LIST

Item No. Data Unit
12 Air flow sensor °C
13 Intake air temperature sensor r/min
22 Crank angle sensor r/min
44 Ignition advance km/h
81 Long-term fuel compensation %
82 Short-term fuel compensation %
Closed loop CL
8A Throttle position sensor (main) %
− Diagnosis code during data recording -
DRIVE CYCLE
By carrying out the test drive in the following three drive cycle patterns, the all monitoring can be accom-
plished for the diagnosis codes that is required by the vehicle driving to identify the fault. In other words,
doing such a drive allows to regenerate any kind of trouble which involves illuminating the engine warning
lamp (check engine lamp) and to verify the repair procedure has eliminated the trouble [the engine warning
lamp (check engine lamp) is no longer illuminated].
CAUTION
1 Catalytic converter monitor P0421
2 Oxygen sensor (front) monitor P0130
P0203, P0204, P0300,
P0301, P0302, P0303,
P0304, P0325, P0500,
P0551
TROUBLESHOOTING
13B-15
Procedure 1
Diagnosis P0421
code No.
6 minutes or more

(3)
(4) 55 - 80 km/h
Vehicle
speed (2) (5,6)

permitted
(1) (7)
Time

"LOCK" (OFF)
position
AK301815 AB

condition
TROUBLESHOOTING
Procedure 2
Diagnosis P0130
code No.
16 minutes or more
55 - 80 km/h
(3)
Vehicle
permitted
(1) (4)
Time

"LOCK" (OFF)
position
AK301816AB

3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at
TROUBLESHOOTING
13B-17
Procedure 3
Other monitor
code No. P0500, P0551
16 minutes or more
55 km/h or more
(3)

(1) (4) (5)

Time

"LOCK" (OFF)
position
AK301817AB

The engine-ECU monitors the following main diagno- tery cable is disconnected, this history will also be
sis items, judges if these items are in good condition erased (the memory will be reset).
or not, and the stores its history. This history can be • Catalyst: P0421
read out by using M.U.T.-II/III. (If the ECU has judged • Oxygen sensor: P0130
a item before, the M.U.T.-II/III displays "Complete"). • Oxygen sensor heater: P0135, P0141
TROUBLESHOOTING


Air flow sensor 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.
sensor
sensor
Throttle position sensor • Controls the throttle valve position through the use of the throttle position sensor
(main) (sub) signal.
• Renders the amount of accelerator pedal travel as being approximately one-half
the normal opening angle.
• Prohibits the operation of the engine speed feedback control.
• Cuts off fuel when the engine speed exceeds 3,000 r/min.
• Suppresses the engine output by stopping the electronically controlled throttle
valve system if the throttle position sensor (sub) is also malfunctioning.
(sub) (main) signal.
valve system if the throttle position sensor (main) is also malfunctioning.
Accelerator pedal • Detects the amount of the accelerator pedal travel through the use of the
position sensor (main) accelerator pedal position sensor (sub) signal, but rendering it only as being
approximately one-half the normal opening angle.
valve system if the accelerator position sensor (sub) is also malfunctioning.
position sensor (sub) accelerator pedal position sensor (main) signal, but rendering it only as being
valve system if the accelerator position sensor (main) is also malfunctioning.
Engine coolant Controls as if the engine coolant temperature is 80°C.
temperature sensor
Camshaft position Injectors fuel into the cylinders in the order 1-3-4-2 with irregular timing. (After the
not detected at all)
Oxygen sensor (front) Air-fuel ratio feedback control (closed loop control) is not performed.
Oxygen sensor (rear) Performs the feedback control (closed loop control) of the air-fuel ratio by using
only the signal of the oxygen (front) installed on the front of the catalytic converter.
Detonation sensor Fixes the ignition timing as that for regular gasoline.
TROUBLESHOOTING
13B-19
transistor)
shut down
Throttle valve position • Suppresses the engine output by stopping the electronically controlled throttle
feedback valve system.
Throttle valve control • Suppresses the engine output by stopping the electronically controlled throttle
servo valve system.
Engine-ECU main • Suppresses the engine output by stopping the electronically controlled throttle
processor valve system.
Communication • Renders the amount of accelerator pedal travel as being approximately one-half
between powertrain the normal opening angle.
control module main • Prohibits the operation of the engine speed feedback control.
processor and system • Cuts off fuel when the engine speed exceeds 3,000 r/min.
LSI
Intake air monitor • Suppresses the engine output by stopping the electronically controlled throttle
valve system.
TROUBLESHOOTING

M1131151001382

P0090 Fuel pressure control solenoid valve system P.13B-22
P0100 Air flow sensor system P.13B-28
P0105 Barometric pressure sensor system P.13B-38
P0110 Intake air temperature sensor system P.13B-47
P0115 Engine coolant temperature sensor system P.13B-54
P0122* Throttle position sensor (main) circuit low input P.13B-61
P0123* Throttle position sensor (main) circuit high input P.13B-65
P0125* Feedback system monitor P.13B-68
P0130 Oxygen sensor (front) system P.13B-72
P0135 Oxygen sensor heater (front) system P.13B-78
P0136 Oxygen sensor (rear) system P.13B-84
P0141 Oxygen sensor heater (rear) system P.13B-90
P0170 Abnormal fuel system P.13B-96
P0201 No.1 Injector system P.13B-100
P0222* Throttle position sensor (sub) circuit low input P.13B-116
P0223* Throttle position sensor (sub) circuit high input P.13B-120
P0243 Waste gate solenoid valve system P.13B-123
P0300 Random cylinder misfire detection system P.13B-128
P0301* No.1 cylinder misfire detection system P.13B-131
P0325 Detonation sensor system P.13B-141
P0335 Crank angle sensor system P.13B-145
P0340 Camshaft position sensor system P.13B-155
P0403 EGR control solenoid valve system P.13B-162
P0421 Warm up catalyst malfunction P.13B-167
P0443 Purge control solenoid valve system P.13B-168
P0500 Vehicle speed sensor system P.13B-173
P0513 Immobilizer system P.13B-176
P0551* Power steering fluid pressure switch system P.13B-178
P0622 Alternator FR terminal system P.13B-183
P0638* Throttle valve control servo circuit range/performance/problem P.13B-188
TROUBLESHOOTING
13B-21
P0642* Throttle position sensor power supply P.13B-190
P0657* Throttle valve control servo relay circuit malfunction P.13B-191
P0805 Clutch oil pressure sensor system P.13B-197
P1603* Battery back-up line system P.13B-205
P2100* Throttle valve control servo circuit (open) P.13B-207
P2101* Throttle valve control magneto malfunction P.13B-210
P2102* Throttle valve control servo circuit (shorted low) P.13B-213
P2103* Throttle valve control servo circuit (shorted high) P.13B-216
P2121* Accelerator pedal position sensor (main) circuit range/performance P.13B-219
problem
P2122* Accelerator pedal position sensor (main) circuit low input P.13B-222
P2123* Accelerator pedal position sensor (main) circuit high input P.13B-226
P2126* Accelerator pedal position sensor (sub) circuit range/Performance P.13B-229
problem
P2127* Accelerator pedal position sensor (sub) circuit low input P.13B-232
P2128* Accelerator pedal position sensor (sub) circuit high input P.13B-236
P2135* Throttle position sensor (main and sub) range/performance problem P.13B-239
P2138* Accelerator pedal position (main and sub) range/performance P.13B-241
problem
P2173* Abnormal intake air amount P.13B-247
NOTE: .
• Do not replace the engine-ECU until a through terminal check reveals there are no short/open circuit.
• Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
• After the engine-ECU has detected a malfunction, a diagnosis code is recorded the next time the engine
is started and the same malfunction is re-detected. However, for items marked with "*", the diagnosis code
is recorded on the first detection of the malfunction.
• Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates the sen-
sor mounted at the position second closest to the engine.
TROUBLESHOOTING

DIAGNOSIS CODES
Code No. P0090: Fuel Pressure Control Solenoid Valve System
Fuel pressure control solenoid valve circuit
Battery
W-B A-14
5
W-B W-B
4 3
B-17X
1 2
3 4
1 2
R To engine-ECU
4
J/C(2)
C-17
13
B-122 R 2
(MU802722)
1 2 Fuel pressure control solenoid valve
BR
4
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213 Engine-ECU
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK400800 AB
TROUBLESHOOTING
13B-23
OPERATION STEP 2. Connector check: B-122 fuel pressure
• Power is supplied from the engine control relay control solenoid valve connector
(terminal No. 1) to the fuel pressure control sole-
Connector : B-122
noid valve (terminal No. 2).
• The engine-ECU (terminal No. 4) causes the
power transistor in the unit to be ON to supply
power to the fuel pressure control solenoid valve
(terminal No. 1).
B-122(B)
FUNCTION
2 1
• In response to a signal from the engine-ECU, the
Harness side
fuel pressure control solenoid valve switches the connector AK400929 AB
pressure to be introduced into the fuel pressure
regulator between the intake manifold negative Q: Is the check result normal?
pressure and atmospheric pressure. YES : Go to Step 3 .
NO : Repair or replace.
TROUBLE JUDGMENT
• Battery voltage is 10 V or more. B-122 fuel pressure control solenoid valve
connector.
Judgment Criterion
• Surge voltage cannot be detected within 1 sec- Connector : B-122
onds from the time when the fuel pressure control
solenoid valve has changed from ON to OFF.
PROBABLE CAUSE
• Failed fuel pressure control solenoid valve
B-122(B)
• Open/short circuit in fuel pressure control sole-
noid valve circuit or loose connector contact 2 1
• Failed engine-ECU Harness side
DIAGNOSIS PROCEDURE • Disconnect connector, and measure at solenoid

valve side.
• Item 09: Fuel pressure control solenoid valve OK: 28 − 36 Ω (at 20°C)
OK: Operating sound can be heard and the Q: Is the check result normal?
valve vibrates. YES : Go to Step 4 .
NO : Replace fuel pressure control solenoid
Q: Is the check result normal? valve.
00 − How to Use
Troubleshooting/Inspection Service
PointsP.00-6) .
NO : Go to Step 2 .
TROUBLESHOOTING
fuel pressure control solenoid valve connector. relay connector
Connector : B-122 Connector : B-17X
B-17X
Relay box's
triangle marks
B-122(B) 2 1
2 1 4 3
• Disconnect connector, and measure at harness Connector : B-122

side.
• Ignition switch: "ON"
OK: System voltage
B-122(B)
NO : Go to Step 5 . 2 1
Harness side

harness between B-122 (terminal No. 2) fuel
pressure control solenoid valve connector
and B-17X (terminal No. 1) engine control
relay connector.
open/short circuit.
TROUBLESHOOTING
13B-25
C-139(GR) C-139(GR)
4 3 2 1 4 3 2 1
13 12 1110 9 8 7 6 5 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2019 18 17 16 15 14
2726 2524 23 22 21 2726 2524 23 22 21
AK400931 AB AK400931 AB
• Disconnect connector, and measure at harness Connector : B-122

side.
OK: System voltage
B-122(B)
Harness side

(terminal No. 1) fuel pressure control
solenoid valve connector and C-139
circuit.
TROUBLESHOOTING
connector No. 1) fuel pressure control solenoid valve
connector and C-139 (terminal No. 4) engine-ECU
Connector: C-139
connector.
Connector : B-122
C-139(GR)
B-122(B)
2 1
4 3 2 1 Harness side
13 12 1110 9 8 7 6 5 connector
2019 18 17 16 15 14 AK400929 AB
2726 2524 23 22 21
AK400931 AB

C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

NO : Repair.
TROUBLESHOOTING
13B-27
STEP 10. Check harness between B-122 (terminal STEP 11. M.U.T.-II/III actuator test
No. 2) fuel pressure control solenoid valve • Item 09: Fuel pressure control solenoid valve
connector and B-17X (terminal No. 1) engine OK: Operating sound can be heard and the
control relay connector. valve vibrates.
Connector : B-122 Q: Is the check result normal?
00 − How to Use
P.00-6).
B-122(B)
2 1
Harness side
Connector : B-17X
B-17X
Relay box's
triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
Code No. P0100: Air Flow Sensor System
Battery
W-B A-14
5
W-B W-B
4 3
B-17X
1 2
3 4
1 2
To engine-ECU
R
4
B-08
(MU802552)
Air flow sensor
1 2 3 4 5 6 7
7 5 3
B-W
20
G-B J/C(1) W-R
C-16
17
B-W
37 88 63
C-140 C-141
(MU803803) (MU803804)
3132 33 34 6162 6364
35363738394041 42 43 656667686970717273
444546474849 50 51 747576777879808182
5253 545556 57 58 5V 8384 858687 8889
Engine-ECU
Wire colour code

AK400801 AB
OPERATION • A power voltage of 5 V is applied to the air flow

• Power is supplied to the air flow sensor (terminal sensor output terminal (terminal No. 3) from the
No. 4) from the engine control relay (terminal No. engine-ECU (terminal No. 63).
1) and earthed to the engine-ECU (terminal No.
88) from the air flow sensor (terminal No. 5).
TROUBLESHOOTING
13B-29
• An air flow sensor filter reset signal is inputted to STEP 2. Connector check: B-08 air flow sensor
the air flow sensor (terminal No. 7) from the connector
Connector : B-08
FUNCTION
• Air flow sensor outputs a pulse signal propor-
tional to the intake air flow rate.
• The engine-ECU determines the basic injection
timing of the injector using the pulse signal output
from the air flow sensor and the engine speed
signal. B-08(B)
7 6 5 4 3 2 1
• When the throttle position sensor output is low,
the engine-ECU causes the power transistor in
the unit to be ON to send an air flow sensor filter Q: Is the check result normal?
reset signal to the air flow sensor. In response to YES : Go to Step 3 .
the reset signal, the air flow sensor resets the fil- NO : Repair or replace.
ter circuit to improve the ability of the air flow sen-
sor to measure the air flow rate in the area where
the intake air flow rate is low. STEP 3. Perform voltage measurement at B-08 air
TROUBLE JUDGMENT Connector : B-08
Check Condition
• Engine speed of 500 r/min or more.
Judgment Criterion
• The sensor output frequency of 3.3 Hz or more
for 2 seconds.
B-08(B)
PROBABLE CAUSE 7 6 5 4 3 2 1
• Failed air flow sensor Harness side connector AK400932 AB
• Open/short circuit in air flow sensor circuit or • Disconnect connector, and measure at harness
loose connector contact side.
• Failed engine-ECU • Ignition switch: "ON"
DIAGNOSIS PROCEDURE
OK: 4.9 − 5.1 V
STEP 1. M.U.T.-II/III data list YES : Go to Step 9 .
• Refer to Data List Reference Table P.13B-368. NO : Go to Step 4 .
00 − How to Use
P.00-6).
NO : Go to Step 2 .
TROUBLESHOOTING
C-141(GR) C-141(GR)
6463 62 61 6463 62 61
7372 7170 69 6867 6665 7372 7170 69 6867 6665
82 818079 78 7776 7574 82 818079 78 7776 7574
8988 87 86 85 8483 8988 87 86 85 8483
AK400933 AB AK400933 AB
• Measure engine-ECU terminal voltage. Connector : B-08

OK: 4.9 − 5.1 V
NO : Go to Step 6 .
B-08(B)
7 6 5 4 3 2 1

connector.
TROUBLESHOOTING
13B-31
connector No. 3) air flow sensor connector and C-141
Connector: C-141
Connector : B-08
C-141(GR)
B-08(B)
7 6 5 4 3 2 1
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483 Connector: C-141
AK400933 AB

C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

NO : Repair.

• Refer to Data List Reference Table P.13B-368.
00 − How to Use
P.00-6).
TROUBLESHOOTING
STEP 9. Perform voltage measurement at B-08 air STEP 11. Perform resistance measurement at
flow sensor connector. B-08 air flow sensor connector.
Connector : B-08 Connector : B-08
B-08(B) B-08(B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1
• Disconnect connector, and measure at harness • Disconnect and measure at harness side.
side. • Resistance between terminal No. 5 and earth.
• Ignition switch: "ON" OK: Continuity (2 Ω or less)
OK: System voltage YES : Go to Step 14 .
connector
Connector: C-141
relay connector
Connector : B-17X
B-17X
Relay box's
triangle marks
C-141(GR)
2 1
4 3
Harness side 6463 62 61
connector AK400930 AB 7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
Connector : B-08 Harness side connector
AK400933 AB

B-08(B)
7 6 5 4 3 2 1

and B-17X (terminal No. 1) engine control
relay connector.
open/short circuit.
TROUBLESHOOTING
13B-33
(terminal No. 88) engine-ECU connector. Connector : B-08
Connector : B-08
B-08(B)
B-08(B) 7 6 5 4 3 2 1
Connector: C-141
OK: 6 − 9 V
C-141(GR)

6463 62 61
connector
7372 7170 69 6867 6665
82 818079 78 7776 7574 Connector: C-140
8988 87 86 85 8483
AK400933 AB

C-140(GR)
NO : Repair. 34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

TROUBLESHOOTING
Connector : B-08
B-08(B)
B-08(B) 7 6 5 4 3 2 1
Connector: C-140
OK:
0 − 1 V (Engine: Idling)
6 − 9 V (Engine: 3,000 r/min.)
C-140(GR) YES : Go to Step 20 .
34 33 32 31
43 42 4140 39 38 37 36 35 STEP 18. Connector check: C-140 engine-ECU
51 50 49 4847 46 4544
58 57 5655 54 5352 connector
Connector: C-140
AK400934 AB
• Check reset signal line for short circuit.

NO : Repair.
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

TROUBLESHOOTING
13B-35
No. 7) air flow sensor connector and C-140 measurement at B-08 air flow sensor connector
(terminal No. 37) engine-ECU connector. (Using oscilloscope).
B-08(B) B-08(B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1

Connector: C-140
• Engine: Idling
inspection procedure using an oscilloscope
C-140(GR) (Refer to P.13B-383) and noise should not be
displayed in the waveform.
34
43
33 32 31
42 4140 39 38 37 36 35
51 50 49 4847 46 4544 NO : Go to Step 21 .
58 57 5655 54 5352
AK400934 AB STEP 21. Replace air flow sensor.
• After replacing the air flow sensor, re-check the
• Check reset signal line for open circuit and dam-
trouble symptoms.
age.
NO : Check end.
NO : Repair.

relay connector
Connector : B-17X
B-17X
Relay box's
triangle marks
2 1
4 3
Harness side

TROUBLESHOOTING
No. 4) air flow sensor connector and B-17X No. 3) air flow sensor connector and C-141
B-08(B) B-08(B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1
Connector : B-17X Connector: C-141

B-17X
Relay box's
triangle marks
2 1
4 3 C-141(GR)
Harness side
• Check power supply line for damage. 6463 62 61

7372 7170 69 6867 6665
82 818079 78 7776 7574
Q: Is the check result normal? 8988 87 86 85 8483
YES : Go to Step 24 . Harness side connector

connector Q: Is the check result normal?
Connector: C-141 NO : Repair.
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

TROUBLESHOOTING
13B-37
connector
Connector: C-141
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB
Connector : B-08
B-08(B)
7 6 5 4 3 2 1

No : Repair or replace.
TROUBLESHOOTING
Barometric pressure sensor circuit
B-08
(MU802552)
Barometric pressure sensor
1 2 5
B-W
20
Y-R G-W J/C(1)
C-16
17
B-W
97 100 88
C-142 C-141
(MU803805) (MU803804)
9192 939495 6162 6364
96979899100 101102103 104 656667686970717273
105106 107108109 110111112 747576777879808182
113114 115116117 118119120 8384 858687 8889
5V
Engine-ECU
Wire colour code
AK400802 AB

• A power voltage of 5 V is applied to the baromet-
Check Condition
ric pressure sensor power terminal (terminal No.
• 2 seconds after the ignition switch has been
1) of the air flow sensor connector from the
placed in the "ON" position or the engine has
engine-ECU (terminal No. 97) and earthed to the
started up.
engine-ECU (terminal No. 88) from the air flow
sensor (terminal No. 5). Judgment Criterion
• The sensor signal is inputted to the engine-ECU • The sensor output voltage of 4.5 V or more (Baro-
(terminal No. 100) from the barometric pressure metric pressure above 114 kPa or equivalent) for
sensor output terminal (terminal No. 2) of the air 2 seconds.
flow sensor connector. or
• The sensor output voltage 0.2 V or less (Baro-
FUNCTION metric pressure below 53 kPa or equivalent) for 2
• The barometric pressure sensor converts the bar- seconds.
ometric pressure into a voltage signal and inputs
the signal to the engine-ECU. PROBABLE CAUSE
• In response to the signal, the engine-ECU cor- • Failed barometric pressure sensor
rects the fuel injection amount, etc. • Open/short circuit in barometric pressure sensor
TROUBLESHOOTING
13B-39
DIAGNOSIS PROCEDURE STEP 3. Perform voltage measurement at B-08 air
STEP 1. M.U.T.-II/III data list Connector : B-08
00 − How to Use
P.00-6). B-08(B)
7 6 5 4 3 2 1
NO : Go to Step 2 . Harness side connector AK400932 AB

STEP 2. Connector check: B-08 air flow sensor
side.
connector
Connector : B-08 • Voltage between terminal No. 1 and earth.
OK: 4.9 − 5.1 V
NO : Go to Step 4 .
B-08(B) STEP 4. Perform voltage measurement at C-142

7 6 5 4 3 2 1 engine-ECU connector.
Connector: C-142
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

OK: 4.9 − 5.1 V
NO : Go to Step 6 .
TROUBLESHOOTING
connector connector
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB

B-08(B)
7 6 5 4 3 2 1

connector.
circuit.
TROUBLESHOOTING
13B-41
STEP 7. Check harness between B-08 (terminal STEP 9. Perform resistance measurement at B-08
Connector : B-08
B-08(B)
B-08(B) 7 6 5 4 3 2 1
side.
Connector: C-142
C-142(GR) STEP 10. Connector check: C-141 engine-ECU

connector
959493 92 91 Connector: C-141
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

C-141(GR)
NO : Repair.
6463 62 61
STEP 8. M.U.T.-II/III data list 7372 7170 69 6867 6665
82 818079 78 7776 7574
• Refer to Data List Reference Table P.13B-368. 8988 87 86 85 8483
a. Item No. 25: Barometric pressure sensor
AK400933 AB
Troubleshooting/Inspection Service Points NO : Repair or replace.
P.00-6).
TROUBLESHOOTING
Connector : B-08
B-08(B)
B-08(B) 7 6 5 4 3 2 1
Connector: C-141
then measure at pick-up harness.
OK: 4.9 − 5.1 V
C-141(GR) NO : Go to Step 13 .
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

NO : Repair.
TROUBLESHOOTING
13B-43
Connector: C-142 Connector : B-08
C-142(GR) B-08(B)
7 6 5 4 3 2 1
959493 92 91
104 103102 101100 99 98 97 96
112111110
120119118
109108107
117116115
106105
114113
AK400935 AB
Connector : B-08 OK: 0.5 V or less

B-08(B)
7 6 5 4 3 2 1

connector.
TROUBLESHOOTING
C-141(GR) B-08(B)
7 6 5 4 3 2 1
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574 nect only terminal No. 1, No. 2 and No. 5, and
8988 87 86 85 8483
AK400933 AB
Connector : B-08 OK:

Altitude 0 m: 3.8 − 4.2 V
Altitude 600 m: 3.5 − 3.9 V
Altitude 1,200 m: 3.3 − 3.7 V
Altitude 1,800 m: 3.0 − 3.4 V
B-08(B) NO : Go to Step 17 .
7 6 5 4 3 2 1
Connector: C-142
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
13B-45
No. 2) air flow sensor connector and C-142 engine-ECU connector.
Connector: C-142
Connector : B-08
C-142(GR)
B-08(B)
7 6 5 4 3 2 1
Harness side connector AK400932 AB 959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
Connector: C-142 120119118 117116115 114113

AK400935 AB

OK:
C-142(GR)
Altitude 0 m: 3.8 − 4.2 V
Altitude 600 m: 3.5 − 3.9 V
959493 92 91 Altitude 1,200 m: 3.3 − 3.7 V
104 103102 101100 99 98 97 96
112111110 109108107 106105
Altitude 1,800 m: 3.0 − 3.4 V
120119118 117116115 114113

AK400935 AB NO : Go to Step 20 .
NO : Repair.
TROUBLESHOOTING
connector connector
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB

B-08(B)
7 6 5 4 3 2 1

connector.
damage.
TROUBLESHOOTING
13B-47
B-08
(MU802552)
1 2 3 4 5 6 7 Intake air temperature sensor

(Incorporated in air flow sensor)
5 6
B-W
20
J/C(1)
C-16 Y-L
17
B-W
88 99
C-141 C-142
(MU803804) (MU803805)
6162 6364 9192 939495
656667686970717273 96979899100 101102103 104
747576777879808182 105106 107108109 110111112
8384 858687 8889 113114 115116117 118119120
5V
Engine-ECU
Wire colour code
AK400803 AB

engine-ECU (terminal No. 99) the intake air temperature, and becomes lower as
• The power voltage is earthed to the engine-ECU the intake air temperature rises.
(terminal No. 88) from the air flow sensor (termi-
nal No. 5). TROUBLE JUDGMENT
Check Condition
• The intake air temperature sensor converts the in "ON" position or the engine has started up.
the voltage signal to the engine-ECU. Judgment Criterion
• In response to the signal, the engine-ECU cor- • The sensor output voltage of 4.6 V or more
rects the fuel injection amount, etc. (intake air temperature below −45°C or equiva-
lent) for 2 seconds.
or
• The sensor output voltage of 0.2 V or loss (intake
air temperature above 125 °C or equivalent) for 2
seconds.
TROUBLESHOOTING

Connector : B-08
sor circuit or loose connector contact
DIAGNOSIS PROCEDURE

• Item 13: Intake air temperature sensor B-08(B)
7 6 5 4 3 2 1
OK: At ambient temperature (atmospheric Harness side connector AK400932 AB
temperature) or equivalent.
YES : Intermittent malfunction (Refer to GROUP side.
00 − How to Use • Resistance between terminal No. 5 and earth.
Troubleshooting/Inspection Service Points OK: Continuity (2 Ω or less)
P.00-6). Q: Is the check result normal?
NO : Go to Step 2 . YES : Go to Step 8 .
NO : Go to Step 5 .
STEP 2. Connector check: B-08 air flow sensor
connector STEP 5. Connector check: C-141 engine-ECU
Connector : B-08 connector
Connector: C-141
B-08(B)
7 6 5 4 3 2 1
C-141(GR)

6463 62 61
YES : Go to Step 3 . 7372 7170 69 6867 6665
NO : Repair or replace. 82 818079 78 7776 7574
8988 87 86 85 8483
STEP 3. Check intake air temperature sensor AK400933 AB
itself.
• Check intake air temperature sensor itself (Refer Q: Is the check result normal?
to P.13B-396).
NO : Replace air flow sensor.
TROUBLESHOOTING
13B-49
No. 5) air flow sensor connector and C-141 • Item 13: Intake air temperature sensor
(terminal No. 88) engine-ECU connector. OK: At ambient temperature (atmospheric
Connector : B-08 temperature) or equivalent.
00 − How to Use
P.00-6).
B-08(B)
7 6 5 4 3 2 1
Harness side connector AK400932 AB STEP 8. Perform voltage measurement at B-08 air
C-141(GR)
B-08(B)
7 6 5 4 3 2 1
6463 62 61
7372 7170 69 6867 6665 • Disconnect connector, and measure at harness
82 818079 78 7776 7574
8988 87 86 85 8483 side.
Harness side connector • Ignition switch: "ON"
AK400933 AB • Voltage between terminal No. 6 and earth.
OK: 4.5 − 4.9 V
connector C-16, and repair if necessary. Q: Is the check result normal?
• Check earthing line for open circuit and damage. YES : Go to Step 13 .
NO : Go to Step 9 .
NO : Repair.
TROUBLESHOOTING
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB
B-08(B) B-08(B)
7 6 5 4 3 2 1 7 6 5 4 3 2 1

• Disconnect B-08 air flow sensor connector. YES : Check and repair harness between B-08
• Ignition switch: "ON" (terminal No. 6) air flow sensor connector
• Voltage between terminal No. 99 and earth. and C-142 (terminal No. 99) engine-ECU
YES : Go to Step 10 . NO : Repair or replace.
TROUBLESHOOTING
13B-51
connector No. 6) air flow sensor connector and C-142
Connector: C-142
Connector : B-08
C-142(GR)
B-08(B)
7 6 5 4 3 2 1
959493 92 91 Harness side connector AK400932 AB
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
Connector: C-142
AK400935 AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.
TROUBLESHOOTING
air flow sensor connector. No. 6) air flow sensor connector and C-142
Connector : B-08
Connector : B-08
B-08(B)
7 6 5 4 3 2 1 B-08(B)
Harness side connector AK400932 AB 7 6 5 4 3 2 1
• Use special tool test harness (MB991709) to con- AK400932 AB
nect only terminal No. 5 and No. 6, and then

Connector: C-142
measure at pick-up harness.
OK:
Ambient temperature at −20°C: 3.8 − 4.4 V
Ambient temperature at 20°C: 2.3 − 2.9 V C-142(GR)
Ambient temperature at 80°C: 0.4 − 1.0 V 959493 92 91
104 103102 101100 99 98 97 96
Q: Is the check result normal? 112111110

120119118
109108107
117116115
106105
114113
AK400935 AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
13B-53
connector
Connector: C-141
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB
Connector : B-08
B-08(B)
7 6 5 4 3 2 1

TROUBLESHOOTING
B-108
(MU802406)
1 2 Engine coolant temperature sensor
2 1
BR Y-G
96 98
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112 Engine-ECU
113114 115116117 118119120
5V
Wire colour code

AK400804 AB

minal No. 1) from the engine-ECU (terminal No. rises. Therefore, the sensor output voltage varies
98). with the engine coolant temperature, and
(terminal No. 96) from the engine coolant temper- ture rises.
ature sensor (terminal No. 2).
TROUBLE JUDGMENT
FUNCTION Check Condition
• The engine coolant temperature sensor converts • 2 seconds later after the ignition switch has been
the engine coolant temperature into a voltage sig- in "ON" position or the engine has started up.
nal, and inputs the voltage to the engine-ECU.
• In response to the signal, the engine-ECU con- Judgment Criterion
trols the fuel infection amount and the fast idle • The sensor output voltage of 4.6 V or more
speed when the engine is cold state. (engine coolant temperature of −45°C or equiva-
lent) for 2 seconds,
or
• The sensor output voltage of 0.1 V or less
(engine coolant temperature of 140°C or more, or
equivalent) for 2 seconds.
TROUBLESHOOTING
13B-55
• Ignition switch: "ON" B-108 engine coolant temperature sensor
• Engine speed of 50 r/min. or more connector.
Judging Conditions Connector : B-108
• The sensor output voltage rises 1.6 V or more
2 1
(engine coolant temperature below 40°C or
Harness side
equivalent) from 1.6 V or less (engine coolant connector
temperature above 40°C or equivalent).
• Thereafter, the sensor output voltage is 1.6 V or
more for 5 minutes.
PROBABLE CAUSE B-108(B)

• Failed engine coolant temperature sensor AK400936 AB
• Open/short circuit in engine coolant temperature
side.
DIAGNOSIS PROCEDURE OK:
Engine coolant temperature at −20°C: 14 − 17
kΩ
STEP 1. M.U.T.-II/III data list Engine coolant temperature at 0°C: 5.1 − 6.5
• Item 21: Engine coolant temperature sensor kΩ
0.68 kΩ
00 − How to Use
0.36 kΩ
sensor.
STEP 2. Connector check: B-108 engine coolant
Connector : B-108
2 1
Harness side
connector
B-108(B)
AK400936 AB

TROUBLESHOOTING
engine coolant temperature sensor connector. engine-ECU connector.
Connector : B-108 Connector: C-142
2 1
Harness side
connector
B-108(B) C-142(GR)
AK400936 AB

104 103102 101100 99 98 97 96
side. 112111110
120119118
109108107
117116115
106105
114113
• Ignition switch: "ON" Harness side connector
AK400935 AB
OK: 4.5 − 4.9 V
Q: Is the check result normal? Connector : B-108
connector
B-108(B)
AK400936 AB

sensor.
OK: 4.5 − 4.9 V
NO : Go to Step 7 .
TROUBLESHOOTING
13B-57
connector connector
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB

Harness side
connector
B-108(B)
AK400936 AB

TROUBLESHOOTING
No. 1) engine coolant temperature sensor B-108 engine coolant temperature sensor
engine-ECU connector. Connector : B-108
Connector : B-108 2 1
2 1 Harness side
connector
B-108(B)
B-108(B) AK400936 AB
AK400936 AB
side.
Connector: C-142

connector
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113 Connector: C-142
AK400935 AB

NO : Repair. C-142(GR)
STEP 9. M.U.T.-II/III data list 959493 92 91

• Item 21: Engine coolant temperature sensor 104 103102 101100 99 98 97 96
112111110 109108107 106105
OK: 120119118 117116115 114113
Engine cold state: At ambient temperature Harness side connector

(atmospheric temperature) or equivalent. AK400935 AB
Engine hot state: At 80 − 120°C YES : Go to Step 12 .
Q: Is the check result normal? NO : Repair or replace.
00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-59
connector and C-142 (terminal No. 96) Connector : B-108
2 1
Connector : B-108 Harness side
2 1 connector
Harness side
connector
B-108(B)
AK400936 AB
B-108(B)
AK400936 AB
Connector: C-142
OK:
Engine coolant temperature at −20°C: 3.9 − 4.5
V
C-142(GR)
V
V
959493 92 91 Engine coolant temperature at 60°C: 0.7 − 1.3
104 103102 101100 99 98 97 96
112111110 109108107 106105 V
120119118 117116115 114113
V
AK400935 AB
• Check earthing line for open circuit and damage. YES : Go to Step 9 .
NO : Repair. STEP 14. Connector check: C-142 engine-ECU
connector
Connector: C-142
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
No. 1) engine coolant temperature sensor connector
Connector: C-142
Connector : B-108
2 1
Harness side
connector
C-142(GR)
B-108(B)
959493 92 91
104 103102 101100 99 98 97 96
AK400936 AB 112111110 109108107 106105
120119118 117116115 114113

AK400935 AB
Connector : B-108
2 1
Harness side
connector
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96 B-108(B)
112111110 109108107 106105
120119118 117116115 114113 AK400936 AB
AK400935 AB
• Check output line for damage. No. 2) engine coolant temperature sensor
TROUBLESHOOTING
13B-61
Code No. P0122: Throttle Position Sensor (main) Circuit Low Input
Throttle position sensor (main) circuit
(main)
B-06 Hall IC
Electronically
1 2 3 4 5 6 controlled
throttle valve
2 1 4
R W B
106 115 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU
Wire colour code

AK304122 AD

• A power voltage of 5 V is applied to the electroni-
Check Conditions
cally controlled throttle valve (terminal No. 2)
• Ignition switch is in "ON" position.
from the engine-ECU (terminal No. 106).
• The power voltage is earthed to the engine-ECU Judgment Criteria
(terminal No. 105) from the electronically control- • Throttle position sensor (main) output voltage is
led throttle valve (terminal No. 4). 0.35 V or less for 0.5 second.
(terminal No. 115) from the electronically control- PROBABLE CAUSE
led throttle valve output terminal (terminal No. 1). • Failed throttle position sensor (main)
FUNCTION cuit or loose connector contact
• The throttle position sensor converts the throttle • Failed engine-ECU
valve position into voltage and inputs it into the
Engine-ECU.
• The Engine-ECU controls the throttle valve posi-
tion.
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Perform voltage measurement at B-06

electronically controlled throttle valve connector.
a. Item 79: Throttle position sensor (main)
00 − How to Use
P.00-6). 6 5 4 3 2 1 B-06(B)
NO : Go to Step 2 . Harness side connector AK400937AB

STEP 2. Connector check: B-06 electronically side.
controlled throttle valve connector • Ignition switch: ON
OK: 4.9 − 5.1 V
NO : Go to Step 4 .

6 5 4 3 2 1 B-06(B) connector
Harness side connector AK400937AB
Connector: C-142
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
13B-63
No. 2) electronically controlled throttle valve • Refer to Data List Reference Table P.13B-368.
connector and C-142 (terminal No. 106) a. Item 79: Throttle position sensor (main)
Connector : B-06 YES : Intermittent malfunction (Refer to GROUP
00 − How to Use
P.00-6).

6 5 4 3 2 1 B-06(B) connector
Connector: C-142
Connector: C-142
C-142(GR)
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
959493 92 91 120119118 117116115 114113
104 103102 101100 99 98 97 96
112111110 109108107 106105 Harness side connector
120119118 117116115 114113

• Check power supply line for open/short circuit. YES : Go to Step 8 .
NO : Repair.
TROUBLESHOOTING
No. 2) electronically controlled throttle valve No. 1) electronically controlled throttle valve
connector and C-142 (terminal No. 106) connector and C-142 (terminal No. 115)
6 5 4 3 2 1 B-06(B) 6 5 4 3 2 1 B-06(B)
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB
• Check power supply line for damage. • Check output line for open/short circuit and dam-
age.
NO : Repair. YES : Go to Step 10 .
NO : Repair.
STEP 10. Replace the electronically controlled

throttle valve
• After replacing the electronically controlled throt-
tle valve, re-check the trouble symptoms.
YES : Check end.
TROUBLESHOOTING
13B-65
Code No. P0123: Throttle Position Sensor (main) Circuit High Input
(main)
B-06 Hall IC
Electronically
throttle valve
2 1 4
R W B
106 115 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU
Wire colour code

AK304122 AD

Check Conditions
(terminal No. 105) from the electronically control- • Throttle position sensor (main) output voltage is
led throttle valve (terminal No. 4). 4.8 V or more for 0.5 second.
led throttle valve output terminal (terminal No. 1). • Failed throttle position sensor (main)
FUNCTION cuit or loose connector contact
Engine-ECU.
tion.
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 3. Perform resistance measurement at B-06

a. Item 79: Throttle position sensor (main)
00 − How to Use
P.00-6). 6 5 4 3 2 1 B-06(B)

controlled throttle valve connector • Resistance between terminal No. 4 and earth.
Connector : B-06 OK: Continuity (2 Ω or less)
NO : Go to Step 4 .

connector
6 5 4 3 2 1 B-06(B)
AK400937AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
13B-67
00 − How to Use
P.00-6).

6 5 4 3 2 1 B-06(B) throttle valve
Harness side connector AK400937AB • After replacing the electronically controlled throt-
YES : Check end.
NO : Replace the engine-ECU.
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.
TROUBLESHOOTING
Code No. P0125: Feedback system monitor
OPERATION • Failed fuel system

• Refer to P0201 injector circuit P.13B-100. • Failed exhaust system
Refer to P0202 injector circuit P.13B-104. • Failed engine-ECU
Refer to P0203 injector circuit P.13B-108.
Refer to P0204 injector circuit P.13B-112. DIAGNOSIS PROCEDURE
• Refer to P0130 Oxygen sensor (front) circuit
P.13B-72. STEP 1. M.U.T.-II/III diagnosis code
FUNCTION Q: Is any other diagnosis code than P0170 output?
• The engine-ECU effects air-fuel ratio feedback
to P.13B-20).
control in accordance with the signals from the
NO : Go to Step 2 .
oxygen sensor (front).
• If the heated oxygen sensor (front) has deterio-
rated, corrections will be made by the oxygen STEP 2. M.U.T.-II/III data list
sensor (rear). • Refer to Data List Reference Table P.13B-368.
• Diagnosis code P0125 becomes stored in mem- a. Item 12: Air flow sensor
ory if a failure is detected in the above air-fuel b. Item 21: Engine coolant temperature sensor
ratio feedback control system. c. Item 25: Barometric pressure sensor
d. Item 59: Oxygen sensor (rear)
TROUBLE JUDGMENT
• The engine coolant temperature is approximately NO : Perform the diagnosis code classified check
76°C or more. procedure for the sensor that has shown an
• Within the range of air-fuel ratio feedback opera- abnormal data valve (Refer to Inspection
tion. Chart for Diagnosis Codes P.13B-20).
• Not in slowing down operation.
Judgment Criterion STEP 3. Check for intake of air from intake hose
• The oxygen sensor output voltage is not deviated and inlet manifold.
from 0.5 V for 30 seconds.
PROBABLE CAUSE
NO : Repair.
• Failed oxygen sensor (front)
• Harness damage in oxygen sensor (front) circuit
or loose connector contact STEP 4. Check for leakage of exhaust emission
• Failed oxygen sensor (rear) from exhaust manifold.
NOTE: When the oxygen sensor (front) begins to Q: Is the check result normal?
deteriorate, the oxygen sensor output voltage will YES : Go to Step 5 .
deviate from the voltage when the sensor was new NO : Repair.
(normally 0.5 volt at stoichiometric ratio). This devia-
tion will be corrected by the oxygen sensor (rear). If STEP 5. Check throttle body (throttle valve
the oxygen sensor (rear) responds poorly because it portion) for contamination.
sensor (front). Thus, even when closed loop control Q: Is the check result normal?
is being effected, the fluctuation of the oxygen sen- YES : Go to Step 6 .
sor (front) output voltage decreases, without inter-
(Refer to P.13B-390).
secting with 0.5 volt. As a result, there is a possibility
TROUBLESHOOTING
13B-69
STEP 6. Connector check: B-121 oxygen sensor STEP 8. Check harness between B-121 oxygen
(front) connector and C-142 engine-ECU sensor (front) connector and C-142 engine-ECU
connector connector.
Oxygen sensor (front) Oxygen sensor (front)
2 1 2 1
4 3 B-121(B) 4 3 B-121(B)
Harness Harness
side connector side connector
AK400938AB AK400938AB
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB

NO : Repair or replace. YES : Go to Step 9 .
NO : Repair.
STEP 7. Check oxygen sensor (front) itself.
• Check oxygen sensor (front) itself (Refer to
P.13B-398).
TROUBLESHOOTING
Connector : B-01,B-02,B-04,B-05
connector.
Connector : B-17X
B-01 B-02 B-04 B-05 B-17X
(GR) (GR) (GR) (GR)
Relay box's
triangle marks
M
2 1 2 1
a. B-01 (No. 1 injector connector) Harness side
b. B-02 (No. 2 injector connector)
c. B-04 (No. 3 injector connector) Connector: C-139
d. B-05 (No. 4 injector connector)
STEP 10. Check injector itself. C-139(GR)

• Check Injector itself (Refer to P.13B-400).
13 12 1110 9 8 7
2
6
1
5
NO : Replace injector. 2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

TROUBLESHOOTING
13B-71
Connector : B-17X Connector : B-01,B-02,B-04,B-05
B-17X
Relay box's
triangle marks B-01 B-02 B-04 B-05
(GR) (GR) (GR) (GR)
2 1
4 3 M
Harness side 2 1
connector AK400930 AB Harness side connector AK400940 AB
Connector : B-01,B-02,B-04,B-05 Connector: C-139
B-01 B-02 B-04 B-05

(GR) (GR) (GR) (GR)
C-139(GR)
M
2 1
4 3 2 1
a. Check harness between B-17X (terminal No. 1) 13 12 1110 9 8 7 6 5
engine control relay connector and B-01 (terminal 2019 18 17 16
2726 2524 23
15
22
14
21
b. Check harness between B-17X (terminal No. 1)
AK400931 AB
c. Check harness between B-17X (terminal No. 1) No. 1 injector connector and C-139 (terminal No.
engine control relay connector and B-04 (terminal 1) engine-ECU connector.
d. Check harness between B-17X (terminal No. 1) No. 2 injector connector and C-139 (terminal No.
YES : Go to Step 13 . d. Check harness between B-05 (terminal No. 2)
NO : Repair. No. 4 injector connector and C-139 (terminal No.
NO : Repair.

P.13B-391).
NO : Repair.
TROUBLESHOOTING
Code No. P0130: Oxygen Sensor (front) System
Oxygen sensor (front) circuit
B-121
MU802605
1 2
1 3 2 4
From Engine control relay
To engine-ECU
B
2
B W J/C (2)
C-17
96 108 1
C-142
(MU803805)
B
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120
Engine-ECU
Wire colour code
AK400805 AB

Check Conditions
(terminal No. 108) from the oxygen sensor (front)
started up.
• The oxygen sensor (front) (terminal No. 2) is
earthed with engine-ECU (terminal No. 96).
80°C or more.
FUNCTION • The volumetric efficiency 25% or more.
• The engine speed of 1,200 r/min. or more.
• The oxygen sensor (front) converts the concen-
tration of oxygen in the exhaust emission into a Judgment Criterion
voltage and inputs the signal to the engine-ECU. • When the oxygen sensor (front) output voltage is
• When the air-fuel ratio is richer than the theoreti- 0.2 V or less, and a power voltage of 5 V is
cal air-fuel ratio, the oxygen sensor (front) out- applied to the oxygen sensor (front) in the
puts a voltage of about 1 V. When it is leaner than engine-ECU, the sensor output voltage is 4.5 V or
the theoretical air-fuel ratio, it outputs a voltage of more.
about 0 V.
• In response to the signal, the engine-ECU con- PROBABLE CAUSE
trols the fuel infection amount so that the air-fuel • Failed oxygen sensor (front)
ratio can be equivalent to the theoretical air-fuel • Open/short circuit in oxygen sensor (front) circuit
ratio. or loose connector contact
TROUBLESHOOTING
13B-73
DIAGNOSIS PROCEDURE STEP 3. Perform resistance measurement at
B-121 oxygen sensor (front) connector
STEP 1. M.U.T.-II/III data list Connector: B-121
00 − How to Use
Troubleshooting/Inspection Service Points Oxygen sensor (front)
P.00-6).
NO : Go to Step 2 .
STEP 2. Connector check: B-121 oxygen sensor

(front) connector
Connector: B-121
2 1
4 3 B-121(B)
Harness
Oxygen sensor (front) side connector
AK400938AB

side.
NO : Go to Step 4 .
2 1
B-121(B)
4 3
connector
Harness
side connector Connector: C-142
AK400938AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
No. 2) oxygen sensor connector and C-142 • Refer to Data List Reference Table P.13B-368.
(terminal No. 96) engine-ECU connector. a. Item 11: Oxygen sensor (front)
00 − How to Use
P.00-6).

oxygen sensor (front) connector.
Connector: B-121

2 1
4 3 B-121(B)
Harness
side connector
AK400938AB
Connector: C-142
2 1
4 3 B-121(B)
C-142(GR) Harness
side connector
AK400938AB
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113 • Engine: After warm-up
• Check earthing line for open circuit and damage. OK: 0.5V or less

TROUBLESHOOTING
13B-75
connector oxygen sensor (front) connector.

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB
Connector: B-121
2 1
4 3 B-121(B)
Harness
side connector
AK400938AB

OK:
4 3 B-121(B)
Harness STEP 10. Check oxygen sensor (front) itself

side connector
AK400938AB • Check oxygen sensor itself (Refer to P.13B-398).
TROUBLESHOOTING
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB
Connector: B-121
OK:
Oxygen sensor (front) deceleration from 4,000 r/min.
2 1
4 3 B-121(B)
Harness
side connector
AK400938AB

TROUBLESHOOTING
13B-77
connector connector
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB

2 1
4 3 B-121(B)
Harness
side connector
AK400938AB

TROUBLESHOOTING
Code No. P0135: Oxygen Sensor Heater (front) System
Oxygen sensor heater (front) circuit
Battery
W-B
A-14
5
W-B W-B
4 3 Oxygen sensor (front) B-121
B-17X
MU802605
1 2 Engine
control
3 4 relay 1 2
3 4
1 2
To engine-ECU
R
Y-R
10
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Engine-ECU
Wire colour code

AK400806 AB
OPERATION FUNCTION
(terminal No. 1) of the oxygen sensor (front) con- (front) is controlled by the ON/OFF control of the
1). • Heating the oxygen sensor heater (front) enables
(front) connector is controlled by the power tran- even when the exhaust emission temperature is
TROUBLESHOOTING
13B-79
Check Conditions B-121 oxygen sensor (front) connector.
• The engine coolant temperature is 20°C or Connector: B-121
higher.
• The oxygen sensor heater: (front) is ON.
• The engine speed of 50 r/min. or more.
• A/C relay: OFF
• Radiator fan: OFF
• The system voltage is 11 − 16 V.
Judging Criterion
• The heater current of oxygen sensor heater
(front) 0.2 A or less or 3.5 A or more for 4 sec-
onds.
PROBABLE CAUSE
• Failed oxygen sensor heater (front)
• Open/short circuit in oxygen sensor heater (front)
2 1
B-121(B)
Harness
side connector
AK400938AB
STEP 1. Connector check: B-121 oxygen sensor
(front) connector • Disconnect connector, and measure at sensor
side.
Connector: B-121 • Resistance between terminal No. 1 and No. 3.
OK: 4.5 − 8.0 Ω
2 1
4 3 B-121(B)
Harness
side connector
AK400938AB

TROUBLESHOOTING
oxygen sensor (front) connector. relay connector
Connector: B-121 Connector : B-17X
B-17X
Relay box's
triangle marks
2 1
Oxygen sensor (front) 4 3
Harness side
Connector: B-121

4 3 B-121(B)
Harness
side connector
AK400938AB

side.
OK: System voltage
YES : Go to Step 5 . 4 3 B-121(B)
NO : Go to Step 4 .
Harness
side connector
AK400938AB

open/short circuit.
TROUBLESHOOTING
13B-81
STEP 5. Perform voltage measurement at C-139 STEP 7. Check harness between B-121 (terminal
engine-ECU connector. No. 3) oxygen sensor connector and C-139
Connector: C-139
Connector: B-121
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

4 3 B-121(B)
Harness
YES : Go to Step 8 . side connector
NO : Go to Step 6 . AK400938AB
Connector: C-139
connector
Connector: C-139
C-139(GR)
4 3 2 1
C-139(GR) 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
4 3 2 1
13 12 1110 9 8 7 6 5 AK400931 AB
2019 18 17 16 15 14
2726 2524 23 22 21 • Check earthing line for open/short circuit.
AK400931 AB
NO : Repair.
TROUBLESHOOTING
connector No. 1) oxygen sensor (front) connector and
Connector: C-139
connector.
Connector: B-121
C-139(GR)

4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

2 1
4 3 B-121(B)
Harness
side connector
AK400938AB
Connector : B-17X
B-17X
Relay box's
triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
13B-83
No. 3) oxygen sensor (front) connector and C-139 Q: Does trouble symptom persist?
00 − How to Use
P.00-6).
2 1
4 3 B-121(B)
Harness
side connector
AK400938AB
Connector: C-139
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

NO : Repair.
TROUBLESHOOTING
Code No. P0136: Oxygen Sensor (rear) System
Oxygen sensor (rear) circuit
C-18
MU801688
2 1
4 3
2 1 3 4
To engine-ECU B
3
P L J/C (2)
C-17
C-142 96 116 1
(MU803805) B
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120
Engine-ECU
Wire colour code

AK400807AB
OPERATION • In response to the signal, the engine-ECU con-

• The sensor signal is inputted to the engine-ECU trols the fuel infection amount so that the air-fuel
(terminal No. 116) from the oxygen sensor (rear) ratio can be equivalent to the theoretical air-fuel
output terminal (terminal No. 4). ratio.
• The oxygen sensor (rear) (terminal No. 3) is
earthed with engine-ECU (terminal No. 96). TROUBLE JUDGMENT
Check Conditions
FUNCTION • Above 3 minutes later after the engine has
• The oxygen sensor (rear) converts the concentra- started up.
tion of oxygen in the exhaust emission into a volt- • The engine coolant temperature is approximately
age signal and inputs the voltage signal to the 80°C or higher.
engine-ECU. • The volumetric efficiency is 25% or more.
• When the air-fuel ratio is richer than the theoreti- • The engine speed is 1,200 r/min. or more.
cal air-fuel ratio, the oxygen sensor (rear) outputs
a voltage of about 1 V. When it is leaner than the
theoretical air-fuel ratio, it outputs a voltage of
about 0 V.
TROUBLESHOOTING
13B-85
Judgment Criterion STEP 3. Perform resistance measurement at C-18
• When the oxygen sensor (rear) output voltage is oxygen sensor (rear) connector.
0.2 V or less, and a power voltage of 5 V is
applied to the oxygen sensor (rear) in the Connector : C-18
engine-ECU, the sensor output voltage is 4.5 V or Oxygen Sensor(rear)
more.
PROBABLE CAUSE
DIAGNOSIS PROCEDURE

a. Item 59: Oxygen sensor (rear)
1 2
3 4
00 − How to Use C-18
Troubleshooting/Inspection Service Points Harness side
connector
P.00-6). AK400939AB
side.
STEP 2. Connector check: C-18 oxygen sensor • Resistance between terminal No. 3 and earth.
(rear) connector OK: Continuity (2 Ω or less)
Connector : C-18 Q: Is the check result normal?
Oxygen Sensor(rear) YES : Go to Step 7 .
NO : Go to Step 4 .

connector
Connector: C-142
C-142(GR)
1 2 959493 92 91
104 103102 101100 99 98 97 96
3 4 112111110 109108107 106105
C-18 120119118 117116115 114113
Harness side Harness side connector
connector
AK400939AB
AK400935 AB

NO : Repair or replace. NO : Repair or replace.
TROUBLESHOOTING
STEP 5. Check harness between C-18 (terminal STEP 6. M.U.T.-II/III data list
No. 3) oxygen sensor (rear) connector and C-142 • Refer to Data List Reference Table P.13B-368.
(terminal No. 96) engine-ECU connector. a. Item 59: Oxygen sensor (rear)
Connector : C-18 Q: Is the check result normal?
Oxygen Sensor(rear) YES : Intermittent malfunction (Refer to GROUP
00 − How to Use
P.00-6).

oxygen sensor (rear) connector.
Connector : C-18
Oxygen Sensor(rear)
1 2
3 4
C-18
Harness side
connector
AK400939AB
Connector: C-142
1 2
3 4
C-18
C-142(GR) Harness side
connector
AK400939AB
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113 • Engine: After warm-up

TROUBLESHOOTING
13B-87
connector oxygen sensor (rear) connector.
Connector: C-142 Connector : C-18
Oxygen Sensor(rear)
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB
Connector : C-18
Oxygen Sensor(rear) 1 2
3 4
C-18
Harness side
connector
AK400939AB

OK:
3 4
C-18
Harness side STEP 10. Check oxygen sensor (rear) itself
connector
AK400939AB • Check oxygen sensor (rear) itself (Refer to
P.13B-398).
YES : Check and repair harness between C-18 Q: Is the check result normal?
TROUBLESHOOTING
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB

Connector : C-18
Oxygen Sensor(rear)
OK:
1 2
3 4
C-18
Harness side
connector
AK400939AB

TROUBLESHOOTING
13B-89
connector connector
Connector : C-18 Connector: C-142
Oxygen Sensor(rear)
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

3 4 NO : Repair or replace.
C-18
Harness side
connector
AK400939AB
Connector: C-142
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
Code No. P0141: Oxygen Sensor Heater (rear) System
Oxygen sensor heater (rear) circuit
Battery
W-B
A-14
5
W-B W-B
B-17X C-18
MU801688
1 2 Engine
control 2 1
3 4 relay
4 3
1 2
R
To engine-ECU
4
R
J/C (2)
C-17
11
Y-L
18
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Engine-ECU
Wire colour code

AK400808 AB
OPERATION FUNCTION
(terminal No. 2) of the oxygen sensor (rear) con- (rear) is controlled by the ON/OFF control of the
1). • Heating the oxygen sensor heater (rear) enables
(rear) connector is controlled by the power tran- even when the exhaust emission temperature is
TROUBLESHOOTING
13B-91
TROUBLE JUDGMENT STEP 2. Perform resistance measurement at C-18
Check Conditions oxygen sensor (rear) connector.
• The engine coolant temperature is 20°C or Connector : C-18
higher. Oxygen Sensor(rear)
• The oxygen sensor heater (rear) is ON.
• The engine speed is 50 r/min. or more.
• A/C relay: OFF
• Radiator fan: OFF
• The system voltage is 11 − 16 V.
Judgment Criterion
• The heater current of oxygen sensor heater (rear)
0.2 A or less or 3.5 A or more for 4 seconds.
PROBABLE CAUSE
• Failed oxygen sensor heater (rear)
1 2
C-18
Harness side
STEP 1. Connector check: C-18 oxygen sensor connector
AK400939AB
(rear) connector
Connector : C-18 side.
Oxygen Sensor(rear) • Resistance between terminal No. 1 and No. 2.
OK: 11 − 18 Ω
1 2
3 4
C-18
Harness side
connector
AK400939AB

TROUBLESHOOTING
STEP 3. Perform voltage measurement at C-18 STEP 4. Connector check: B-17X engine control
oxygen sensor (rear) connector. relay connector
Connector : C-18 Connector : B-17X
Oxygen Sensor(rear) B-17X
Relay box's
triangle marks
2 1
4 3
Harness side
Connector : C-18
Oxygen Sensor(rear)
1 2
3 4
C-18
Harness side
connector
AK400939AB

side.
OK: System voltage
NO : Go to Step 4 . C-18
Harness side
connector
AK400939AB

oxygen sensor (rear) connector and B-17X
connector.
open/short circuit.
TROUBLESHOOTING
13B-93
STEP 5. Perform voltage measurement at C-139 STEP 7. Check harness between C-18 (terminal
engine-ECU connector. No. 1) oxygen sensor connector and C-139
Connector: C-139
Connector : C-18
Oxygen Sensor(rear)
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

1 2
Harness side
NO : Go to Step 6 . AK400939AB
Connector: C-139
connector
Connector: C-139
C-139(GR)
4 3 2 1
C-139(GR) 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
4 3 2 1
13 12 1110 9 8 7 6 5 AK400931 AB
2019 18 17 16 15 14
2726 2524 23 22 21 • Check earthing line for open/short circuit.
AK400931 AB
NO : Repair.
TROUBLESHOOTING
connector No. 2) oxygen sensor (rear) connector and B-17X
Connector: C-139
Connector : C-18
Oxygen Sensor(rear)
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

NO : Repair or replace. 1 2
3 4
C-18
Harness side
connector
AK400939AB
Connector : B-17X
B-17X
Relay box's
triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
13B-95
STEP 10. Check harness between C-18 (terminal STEP 11. Check the trouble symptoms.
No. 1) oxygen sensor (rear) connector and C-139 Q: Does trouble symptom persist?
Connector : C-18 NO : Intermittent malfunction (Refer to GROUP
Oxygen Sensor(rear) 00 − How to Use
P.00-6).
1 2
3 4
C-18
Harness side
connector
AK400939AB
Connector: C-139
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

NO : Repair.
TROUBLESHOOTING
Code No. P0170: Abnormal Fuel System
OPERATION STEP 2. M.U.T.-II/III data list

• Refer to P0201 injector circuit P.13B-100. • Refer to Data List Reference Table P.13B-368.
• Refer to P0202 injector circuit P.13B-104. a. Item 12: Air flow sensor
• Refer to P0203 injector circuit P.13B-108. b. Item 13: Intake air temperature sensor
• Refer to P0204 injector circuit P.13B-112.
FUNCTION d. Item 25: Barometric pressure sensor
• If the fuel system goes out of order, the fuel cor- Q: Are the check results normal?
rection value will become larger. YES : Go to Step 3 .
• The engine-ECU checks whether the fuel correc- NO : Perform the diagnosis code classified check
tion value is within the standard limits. procedure for the sensor that has shown an
TROUBLE JUDGMENT Chart for Diagnosis Codes P.13B-20).
Check Condition
• In learning air-fuel ratio STEP 3. Check for intake of air from intake hose
and intake manifold.
Judgment Criterion
• Fuel injection amount correction value remains Q: Is the check result normal?
unusually low for more than 5 seconds. YES : Go to Step 4 .
or NO : Repair.
• Fuel injection amount correction value remains
unusually high for more than 5 seconds. STEP 4. Check for leakage of exhaust emission
PROBABLE CAUSE
• Failed fuel supply system
• Failed oxygen sensor (front) NO : Repair.
• Failed intake air temperature sensor
• Failed purge control solenoid valve STEP 5. Check throttle body (throttle valve
YES : Inspection Chart for Diagnosis Code (Refer
to P.13B-20). • Refer to Data List Reference Table P.13B-368.
NO : Go to Step 2 . a. Item 11: Oxygen sensor (front)
to Code No. P0130 P.13B-72).
TROUBLESHOOTING
13B-97
STEP 7. Connector Check: Injector connector STEP 9. Connector check: B-17X engine control
connector
Connector : B-17X
B-01 B-02 B-04 B-05 B-17X
(GR) (GR) (GR) (GR)
Relay box's
triangle marks
M
2 1 2 1
a. B-01 (No.1 injector connector). Harness side
b. B-02 (No.2 injector connector).
c. B-04 (No.3 injector connector). Connector: C-139
d. B-05 (No.4 injector connector).
STEP 8. Check injector itself. C-139(GR)

13 12 1110 9 8 7
2
6
1
5
2726 2524 23 22 21
AK400931 AB

TROUBLESHOOTING
B-17X
Relay box's
(GR) (GR) (GR) (GR)
2 1
4 3 M
Harness side 2 1
B-01 B-02 B-04 B-05

(GR) (GR) (GR) (GR)
C-139(GR)
M
2 1
4 3 2 1
2726 2524 23
15
22
14
21
AK400931 AB
c. Check harness between B-17X (terminal No. 1) No. 1 injector connector and C-139 (terminal No.
NO : Repair.
STEP 12. Check purge control solenoid valve

itself.
• Check purge control solenoid valve itself (Refer
TROUBLESHOOTING
13B-99
STEP 13. Fuel pressure measurement
P.13B-391).
NO : Repair.
TROUBLESHOOTING
Injector circuit
Battery
W-B
A-14
5
W-B
W-B
4 3
B-17X
1 2
3 4
1 2
R
To engine-ECU
R R R R
No. 1 No. 2 No. 3 No. 4
1 1 1 1
B-01 B-02 B-04 B-05
(MU802062) (MU802062) (MU802062) (MU802062)
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 5 14 21
Engine-ECU
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code
AK400809 AB
TROUBLESHOOTING
13B-101
Connector : B-01
• The engine-ECU (terminal No. 1) makes the
nal No. 2). B-01
(GR)
FUNCTION
2 1
• The fuel injection amount of the injector depends Harness side connector AK400940 AC
Check Conditions
• The throttle position sensor output voltage is 1.15 STEP 3. Check No. 1 injector itself.
V or less. • Check No. 1 Injector itself (Refer to P.13B-400).
• Injector not in forced drive (actuator test) mode. Q: Is the check result normal?
Judgment Criteria YES : Go to Step 4 .
• No surge voltage of the injector coil is detected NO : Replace No. 1 injector.
for 2 seconds.
PROBABLE CAUSE No. 1 injector connector.
Connector : B-01
• Open/short circuit in injector circuit or loose con-
nector contact
B-01
(GR)
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III actuator test M

• Item 01: No. 1 injector 2 1
side.
00 − How to Use
P.00-6). OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
STEP 5. Connector check: B-17X engine control STEP 7. Check harness between B-17X (terminal
relay connector No. 1) engine control relay connector and B-01
Connector : B-17X (terminal No. 1) No. 1 injector connector.
B-17X Connector : B-17X
B-17X
Relay box's
triangle marks Relay box's
triangle marks
2 1
4 3 2 1
Harness side 4 3
Harness side
Connector : B-01
Connector : B-01
B-01
(GR) B-01
(GR)
M
2 1 M
Harness side connector AK400940 AC 2 1
YES : Check and repair harness between B-17X • Check power supply line for damage.
(terminal No. 1) engine control relay Q: Is the check result normal?
connector and B-01 (terminal No. 1) No. 1 YES : Go to Step 8 .
injector connector. NO : Repair.
open/short circuit. STEP 8. Connector check: C-139 engine-ECU
connector
Connector: C-139
relay connector
Connector : B-17X
B-17X
Relay box's
triangle marks
C-139(GR)
2 1
4 3 4 3 2 1
13 12 1110 9 8 7 6 5
Harness side 2019 18 17 16 15 14
connector AK400930 AB 2726 2524 23 22 21
NO : Repair or replace. Q: Is the check result normal?
TROUBLESHOOTING
13B-103
STEP 9. Check harness between B-01 (terminal STEP 10. Perform signal wave pattern
No. 2) No. 1 injector connector and C-139 measurement at C-139 engine-ECU connector
B-01
(GR)
C-139(GR)
M
2 1
4 3 2 1
Connector: C-139 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB
• Engine: Idling
C-139(GR) • Voltage between terminal No. 1 and earth.
4 3 2 1 (Refer to P.13B-383).
13 12 1110 9 8 7 6 5
2019 18 17 16
2726 2524 23
15
22
14
21
Harness side connector YES : Intermittent malfunction (Refer to GROUP
00 − How to Use
AK400931 AB
• Check output line for open/short circuit and dam- P.00-6).
age. NO : Replace engine-ECU.
NO : Repair.
TROUBLESHOOTING
Injector circuit
Battery
W-B
A-14
5
W-B
W-B
4 3
B-17X
1 2
3 4
1 2
R
To engine-ECU
R R R R
No. 1 No. 2 No. 3 No. 4
1 1 1 1
B-01 B-02 B-04 B-05
(MU802062) (MU802062) (MU802062) (MU802062)
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 5 14 21
Engine-ECU
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code
AK400809 AB
TROUBLESHOOTING
13B-105
Connector : B-02
• The engine-ECU connector (terminal No. 5)
makes the power transistor in the unit be in "ON"
position, and that makes currents go on the injec-
tor (terminal No. 2). B-02
(GR)
FUNCTION
2 1
• The fuel injection amount of the injector depends Harness side connector AK400940 AD
Check Conditions
for 2 seconds.
Connector : B-02
connector contact
B-02
(GR)
DIAGNOSIS PROCEDURE

side.
00 − How to Use
NO : Go to Step 5 .
TROUBLESHOOTING
B-17X
Relay box's
triangle marks
2 1
4 3 2 1
Harness side 4 3
Harness side
Connector : B-02
Connector : B-02
B-02
(GR) B-02
(GR)
M
2 1 M
Harness side connector AK400940 AD 2 1
open/short circuit and damage. STEP 8. Connector check: C-139 engine-ECU
connector
Connector: C-139
relay connector
Connector : B-17X
B-17X
Relay box's
triangle marks
C-139(GR)
2 1
4 3 4 3 2 1
13 12 1110 9 8 7 6 5
Harness side 2019 18 17 16 15 14
connector AK400930 AB 2726 2524 23 22 21
TROUBLESHOOTING
13B-107
B-02
(GR)
C-139(GR)
M
2 1
4 3 2 1
Connector: C-139 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB
• Engine: Idling
4 3 2 1 to P.13B-383).
13 12 1110 9 8 7 6 5
2019 18 17 16
2726 2524 23
15
22
14
21
00 − How to Use
AK400931 AB
NO : Repair.
TROUBLESHOOTING
Injector circuit
Battery
W-B
A-14
5
W-B
W-B
4 3
B-17X
1 2
3 4
1 2
R
To engine-ECU
R R R R
No. 1 No. 2 No. 3 No. 4
1 1 1 1
B-01 B-02 B-04 B-05
(MU802062) (MU802062) (MU802062) (MU802062)
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 5 14 21
Engine-ECU
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code
AK400809 AB
TROUBLESHOOTING
13B-109
Connector : B-04
B-04
nal No. 2). (GR)
FUNCTION
2 1
• The fuel injection amount of the injector depends Harness side connector AK400940 AE
Check Conditions
for 2 seconds.
Connector : B-04
connector contact
• Failed engine-ECU B-04
(GR)
DIAGNOSIS PROCEDURE

side.
00 − How to Use
NO : Go to Step 5 .
TROUBLESHOOTING
B-17X
Relay box's
triangle marks
2 1
4 3 2 1
Harness side 4 3
Harness side
Connector : B-04
Connector : B-04
B-04
(GR) B-04
(GR)
M
2 1 M
Harness side connector AK400940 AE 2 1
open/short circuit. STEP 8. Connector check: C-139 engine-ECU
connector
Connector: C-139
relay connector
Connector : B-17X
B-17X
Relay box's
triangle marks
C-139(GR)
2 1
4 3 4 3 2 1
13 12 1110 9 8 7 6 5
Harness side 2019 18 17 16 15 14
connector AK400930 AB 2726 2524 23 22 21
TROUBLESHOOTING
13B-111
(terminal No. 14) engine-ECU connector. (Using on oscilloscope).
B-04
(GR)
C-139(GR)
M
2 1
4 3 2 1
Connector: C-139 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB
• Engine: Idling
4 3 2 1 to P.13B-383).
13 12 1110 9 8 7 6 5
2019 18 17 16
2726 2524 23
15
22
14
21
00 − How to Use
AK400931 AB
NO : Repair.
TROUBLESHOOTING
Injector circuit
Battery
W-B
A-14
5
W-B
W-B
4 3
B-17X
1 2
3 4
1 2
R
To engine-ECU
R R R R
No. 1 No. 2 No. 3 No. 4
1 1 1 1
B-01 B-02 B-04 B-05
(MU802062) (MU802062) (MU802062) (MU802062)
1 2 1 2 1 2 1 2
2 2 2 2
Y Y-R Y-G L
1 5 14 21
Engine-ECU
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code
AK400809 AB
TROUBLESHOOTING
13B-113
Connector : B-05
B-05
nal No. 2). (GR)
FUNCTION
• The engine-ECU connector controls the power
supply interval of the injector. M
2 1
• The fuel injection amount of the injector depends Harness side connector AK400940 AF
Check Conditions
V or less. • Check No. 4 Injector (Refer to P.13B-400) itself.
for 2 seconds.
Connector : B-05
connector contact
B-05
(GR)
DIAGNOSIS PROCEDURE

side.
00 − How to Use
NO : Go to Step 5 .
TROUBLESHOOTING
B-17X
Relay box's
triangle marks
2 1
4 3 2 1
Harness side 4 3
Harness side
Connector : B-05
Connector : B-05
B-05
(GR) B-05
(GR)
M
2 1 M
Harness side connector AK400940 AF 2 1
open/short circuit and damage. STEP 8. Connector check: C-139 engine-ECU
connector
Connector: C-139
relay connector
Connector : B-17X
B-17X
Relay box's
triangle marks
C-139(GR)
2 1
4 3 4 3 2 1
13 12 1110 9 8 7 6 5
Harness side 2019 18 17 16 15 14
connector AK400930 AB 2726 2524 23 22 21
YES : Go to Step 7.
TROUBLESHOOTING
13B-115
B-05
(GR)
C-139(GR)
M
2 1
4 3 2 1
Connector: C-139 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB
• Engine: Idling
4 3 2 1 to P.13B-383).
13 12 1110 9 8 7 6 5
2019 18 17 16
2726 2524 23
15
22
14
21
00 − How to Use
AK400931 AB
NO : Repair.
TROUBLESHOOTING
Code No. P0222: Throttle Position Sensor (Sub) Circuit Low Input
Throttle position sensor (sub) circuit
(sub)
B-06 Hall IC Electronically
controlled
1 2 3 4 5 6 throttle valve
2 3 4
R G B
106 113 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU
Wire colour code

AK304122AE

Check Conditions
(terminal No. 105) from the electronically control- • Throttle position sensor (sub) output voltage is
led throttle valve (terminal No. 4). 2.25 V or less for 0.5 second.
led throttle valve output terminal (terminal No. 3). • Failed throttle position sensor (sub)
• Open/short circuit in throttle position sensor (sub)
FUNCTION circuit or loose connector contact
Engine-ECU.
tion.
TROUBLESHOOTING
13B-117
• Refer to Data list reference table P.13B-368.
a. Item 14: Throttle position sensor (sub)
00 − How to Use
P.00-6). 6 5 4 3 2 1 B-06(B)

controlled throttle valve connector • Ignition switch: ON
OK: 4.9 − 5.1 V
NO : Go to Step 4 .

6 5 4 3 2 1 B-06(B) connector
Connector: C-142
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
00 − How to Use
P.00-6).

6 5 4 3 2 1 B-06(B) connector
Connector: C-142
Connector: C-142
C-142(GR)
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
959493 92 91 120119118 117116115 114113
104 103102 101100 99 98 97 96
120119118 117116115 114113

• Check power supply line for open/short circuit. YES : Go to Step 8 .
NO : Repair.
TROUBLESHOOTING
13B-119
6 5 4 3 2 1 B-06(B) 6 5 4 3 2 1 B-06(B)
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB
age.
NO : Repair.

throttle valve
YES : Check end.
TROUBLESHOOTING
Code No. P0223: Throttle Position Sensor (Sub) Circuit High Input
(sub)
controlled
2 3 4
R G B
106 113 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU
Wire colour code

AK304122AE

Check Conditions
(terminal No. 105) from the electronically control- • Throttle position sensor (sub) output voltage is
led throttle valve (terminal No. 4). 4.8 V or more for 0.5 second.
led throttle valve output terminal (terminal No. 3). • Failed throttle position sensor (sub)
FUNCTION circuit or loose connector contact
Engine-ECU.
tion.
TROUBLESHOOTING
13B-121
DIAGNOSIS PROCEDURE STEP 3. Perform resistance measurement at B-06
00 − How to Use
P.00-6). 6 5 4 3 2 1 B-06(B)

controlled throttle valve connector • Resistance between terminal No. 4 and earth.
Connector : B-06 OK: Continuity (2 Ω or less)
NO : Go to Step 4 .

connector
6 5 4 3 2 1 B-06(B)
AK400937AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
connector and C-142 (terminal No. 105) a. Item 14: Throttle position sensor (sub)
00 − How to Use
P.00-6).

6 5 4 3 2 1 B-06(B) throttle valve
Harness side connector AK400937AB • After replacing the electronically controlled throt-
YES : Check end.
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.
TROUBLESHOOTING
13B-123
Code No. P0243: Waste Gate Solenoid Valve System
Waste gate solenoid valve circuit
Battery
W-B A-14
5
W-B W-B
4 3
B-17X
1 2
3 4
1 2
R To engine-ECU
4
J/C(2)
C-17
13
R
1
B-123
Waste gate solenoid valve
1 2
BR-W
126
C-138
(MU803801)
121122 123 124
125126127128129 130 131 132 133
Engine-ECU
134135 136137 138 139 140 141
142143 144 145 146
Wire colour code

AK400810 AB
OPERATION • The engine-ECU (terminal No. 126) causes the

• Power is supplied from the engine control relay power transistor in the unit to be ON to supply
(terminal No. 1) to the waste gate solenoid valve power to the waste gate solenoid valve (terminal
(terminal No. 1). No. 2).
TROUBLESHOOTING

• In response to a signal from the engine-ECU, the B-123 waste gate solenoid valve connector.
waste gate solenoid valve controls the turbo
Connector : B-123
charge pressure to be introduced into the waste
gate actuator of the turbo charger.
TROUBLE JUDGMENT
Check Condition
B-123(GR)
• Battery voltage is 10 V or more.
2 1
Judgment Criterion
Harness side
• Surge voltage cannot be detected within 1 sec- connector AK400941 AB
onds from the time when the waste gate solenoid
valve has changed from ON to OFF. • Disconnect connector, and measure at solenoid
valve side.
• Failed waste gate solenoid valve OK: 29 − 35 Ω (at 20°C)
• Open/short circuit in waste gate solenoid valve Q: Is the check result normal?
sensor circuit or loose connector contact YES : Go to Step 4 .
• Failed engine-ECU NO : Replace waste gate solenoid valve.
DIAGNOSIS PROCEDURE
waste gate solenoid valve connector.
Connector : B-123
• Item 12: Waste gate solenoid valve
valve vibrates.
B-123(GR)
00 − How to Use
2 1
Harness side
P.00-6). connector AK400941 AB
NO : Go to Step 2 .
STEP 2.Connector check: B-123 waste gate side.
solenoid valve connector
Connector : B-123
OK: System voltage
NO : Go to Step 5 .
B-123(GR)
2 1
Harness side

TROUBLESHOOTING
13B-125
B-17X
Relay box's
triangle marks
2 1
4 3 C-138(GR)
Harness side
124 123 122121

Connector : B-123 133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142

AK400953 AB

B-123(GR) side.
2 1 • Ignition switch: "ON"
connector AK400941 AB OK: System voltage

YES : Check intermediate connector C-17, and YES : Go to Step 8 .
repair if necessary. If intermediate NO : Go to Step 7 .
harness between B-123 (terminal No. 1)
waste gate solenoid valve connector and
connector.
open/short circuit.
TROUBLESHOOTING
connector connector
C-138(GR) C-138(GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142

AK400953 AB AK400953 AB

B-123(GR)
2 1
Harness side

(terminal No. 2) waste gate solenoid valve
circuit.
TROUBLESHOOTING
13B-127
No. 2) waste gate solenoid valve connector and No. 1) waste gate solenoid valve connector and
Connector : B-123 connector.
Connector : B-123
B-123(GR)
2 1 B-123(GR)
Harness side 2 1
connector AK400941 AB Harness side
Connector: C-138
Connector : B-17X
B-17X
Relay box's
triangle marks
2 1
C-138(GR)
4 3
Harness side
124 123 122121 connector AK400930 AB
133 132 131 130 129128127126125
141 140 139 138 137136
146 145 144
135134
143142
Harness side connector connector C-17, and repair if necessary.
AK400953 AB
• Check output line for damage. Q: Is the check result normal?

NO : Repair.
• Item 12: Waste gate solenoid valve
valve vibrates.
00 − How to Use
P.00-6).
TROUBLESHOOTING
Code No. P0300: Random cylinder mis-fire detected

• Refer to P0201 injector circuit P.13B-100. • Ignition system related part(s) failed
• Refer to P0202 injector circuit P.13B-104. • Failed crank angle sensor
• Refer to P0203 injector circuit P.13B-108. • Incorrect air-fuel ratio
• Refer to P0204 injector circuit P.13B-112. • Low compression pressure
• Failed coolant temperature sensor
FUNCTION • Skipping of timing belt teeth.
• If a misfire occurs while the engine is running, the • EGR system and EGR valve failed
engine speed changes for an instant. • Failed engine-ECU
engine speed. DIAGNOSIS PROCEDURE
TROUBLE JUDGMENT
Check Conditions • Item 22: Crank angle sensor
• The engine speed is 500 − 6,500 r/min. OK: Keep the engine speed constant to make
• The engine coolant temperature is −10°C or the pulse width of output waveform con-
higher. stant.
• The barometric pressure is 76 kPa or more. Q: Is the check result normal?
• The volumetric efficiency is 30 − 55%. YES : Go to Step 2 .
the vane that generates the crankshaft position Code No. P0335 P.13B-145).
signals.
• During the engine operation except the shift STEP 2.M.U.T.-II/III data list
change or low speed driving and rapid accelera- • Refer to Data list reference table P.13B-368.
tion and deceleration, also intermittent operation a. Item 21: Engine coolant temperature sensor
of air compressor (A/C: within the 3 seconds after b. Item 81: Long-term fuel compensation
changing to ON from OFF or to OFF from ON). c. Item 82: Short-term fuel compensation
• The throttle deviation is within the range of −0.06
V/10ms to 0.06 V/10ms. Q: Are the check results normal?
Judgment Criteria NO : Perform the diagnosis code classified check
• Misfire has occurred more frequently than procedure for the sensor that has shown an
allowed during the last 200 revolutions (When the abnormal data valve (Refer to, Inspection
catalyst temperature is higher than 950°C). Chart for Diagnosis Codes P.13B-20).
or
• Misfire has occurred in 15 or more of the last
1,000 revolutions (corresponding to 1.5 times the STEP 3. Check ignition secondary voltage
limit of emission standard). waveform using an oscilloscope.
Inspection procedure 30 P.13B-355).
TROUBLESHOOTING
13B-129
STEP 4.Connector check: Injector connector STEP 6.Connector check: B-17X engine control
connector
Connector : B-17X
B-01 B-02 B-04 B-05 B-17X
(GR) (GR) (GR) (GR)
Relay box's
triangle marks
M
2 1 2 1
a. B-01 (No.1 injector connector) Harness side
STEP 5.Check injector itself. C-139(GR)

13 12 1110 9 8 7
2
6
1
5
2726 2524 23 22 21
AK400931 AB

TROUBLESHOOTING
B-17X
Relay box's
(GR) (GR) (GR) (GR)
2 1
4 3 M
Harness side 2 1
B-01 B-02 B-04 B-05

(GR) (GR) (GR) (GR)
C-139(GR)
M
2 1
4 3 2 1
2726 2524 23
15
22
14
21
AK400931 AB
c. Check harness between B-17X (terminal No. 1) No. 1injector connector and C-139 (terminal No.
NO : Repair.

sure test P.13B-391)
NO : Repair.
TROUBLESHOOTING
13B-131
STEP 10. Check for intake of air from intake hose STEP 12. Exhaust gas recirculation system
and inlet manifold. check.
• Exhaust gas recirculation system check [Refer to
YES : Go to Step 11 . GROUP 17 − Exhaust gas recirculation (EGR)
NO : Repair. system P.17-70].
STEP 11. Check for skipped timing belt teeth. YES : Replace engine-ECU
NO : Repair.
NO : Repair.

engine speed.
• The engine speed is 500 − 6,500 r/min. On-vehicle Service P.16-41)
higher.
• The intake air temperature is −10°C or higher. NO : Check ignition Circuit System (Refer to
• The barometric pressure is 76 kPa or more. Inspection procedure 30 P.13B-355)
the vane that generates the crankshaft position STEP 2.Connector check: B-01 No.1 injector
signals. connector
• During the engine operation except the shift Connector : B-01
of air compressor (A/C: within the 3 seconds after B-01
changing to ON from OFF or to OFF from ON). (GR)
• The throttle deviation is within the range of −0.06
V/10ms to 0.06 V/10ms.
Judgment Criterion M
2 1
• Misfire has occurred more frequently than Harness side connector AK400940 AC
allowed during the last 200 revolutions (When the
catalyst temperature is higher than 950°C). Q: Is the check result normal?
or YES : Go to Step 3 .
• Misfire has occurred in 15 or more of the last NO : Repair or replace.
1,000 revolutions (corresponding to 1.5 times the
limit of emission standard).
TROUBLESHOOTING
STEP 3.Check No.1 injector itself. STEP 5.Check harness between B-17X (terminal
• Check Injector itself (Refer to P.13B-400). No. 1) engine control relay connector and B-01
(terminal No. 1) No.1 injector connector.
YES : Go to Step 4 . Connector : B-17X
NO : Replace No.1 injector. B-17X
Relay box's
STEP 4.Connector check: B-17X engine control triangle marks
connector 2 1
Connector : B-17X 4 3
B-17X
Harness side
Relay box's
triangle marks
Connector : B-01
2 1
4 3 B-01
(GR)
Harness side
Connector: C-139 M
2 1

C-139(GR) NO : Repair.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

TROUBLESHOOTING
13B-133
(terminal No. 1) engine-ECU connector sure test P.13B-391).
NO : Repair.
B-01
(GR)
M
2 1
Connector: C-139
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

NO : Repair.
OPERATION • The intake air temperature is −10°C or higher.

• Refer to P0202 injector circuit P.13B-104. • The barometric pressure is 76 kPa or more.
FUNCTION • The adaptive learning has been completed with
• If a misfire occurs while the engine is running, the the vane that generates the crankshaft position
engine speed changes for an instant. signals.
• The engine-ECU checks for such changes in • During the engine operation except the shift
engine speed. change or low speed driving and rapid accelera-
TROUBLE JUDGMENT of air compressor (A/C: within the 3 seconds after
Check Conditions • The throttle deviation is within the range of −0.06
• The engine speed is 500 − 6,500 r/min. V/10ms to 0.06 V/10ms.
higher.
TROUBLESHOOTING
Judgment Criterion STEP 3.Check No.2 injector itself.

• Misfire has occurred more frequently than • Check Injector itself (Refer to P.13B-400).
• Misfire has occurred in 15 or more of the last NO : Replace No.2 injector.
limit of emission standard). STEP 4.Connector check: B-17X engine control
Connector : B-17X
B-17X
Relay box's
DIAGNOSIS PROCEDURE triangle marks
2 1
waveform using an oscilloscope. 4 3
• Check ignition secondary voltage waveform Harness side
(Refer to GROUP 16 − Ignition System − connector AK400930 AB

Connector: C-139
STEP 2.Check connector: B-02 No.2 injector

C-139(GR)
connector
Connector : B-02
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
B-02
(GR) Harness side connector
AK400931 AB
M
Harness side connector AK400940 AD NO : Repair or replace.

TROUBLESHOOTING
13B-135
No. 1) engine control relay connector and No. 2) No.2 injector connector and C-139
B-02(terminal No. 1) No.2 injector connector. (terminal No. 5) engine-ECU connector
Connector : B-17X Connector : B-02
B-17X
Relay box's
triangle marks B-02
(GR)
2 1
4 3 M
Harness side 2 1
connector AK400930 AB Harness side connector AK400940 AD
B-02
(GR)
C-139(GR)
M
2 1
• Check power supply line for damage. 4 3

13 12 1110 9 8 7
2
6
1
5
2019 18 17 16 15 14

NO : Repair.

NO : Repair.
TROUBLESHOOTING

engine speed.
• The engine speed is 500 − 6,500 r/min. On-vehicle Service P.16-41)
higher.
• The intake air temperature is −10°C or higher. NO : Check ignition circuit system (Refer to
• The barometric pressure is 76 kPa or more. Inspection procedure 30 P.13B-355).
the vane that generates the crankshaft position STEP 2.Connector check: B-04 No.3 injector
signals. connector
• During the engine operation except the shift Connector : B-04
of air compressor (A/C: within the 3 seconds after B-04
changing to ON from OFF or to OFF from ON). (GR)
• The throttle deviation is within the range of − 0.06
V/10ms to 0.06 V/10ms.
Judgment Criterion M
2 1
• Misfire has occurred more frequently than Harness side connector AK400940 AE
• Misfire has occurred in 15 or more of the last NO : Repair or replace.
limit of emission standard).
STEP 3.Check No.3 injector itself.
TROUBLESHOOTING
13B-137
relay connector and C-139 engine-ECU No. 1) engine control relay connector and B-04
Connector : B-17X Connector : B-17X
B-17X B-17X
Relay box's Relay box's

2 1 2 1
4 3 4 3
B-04
(GR)
C-139(GR)
M
2 1
4 3
13 12 1110 9 8 7
2
6
1
5
2019 18 17 16 15 14
2726 2524 23 22 21 Q: Is the check result normal?
AK400931 AB
NO : Repair.

TROUBLESHOOTING
(terminal No. 14) engine-ECU connector sure test P.13B-391)
NO : Repair.
B-04
(GR)
M
2 1
Connector: C-139
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

NO : Repair.
OPERATION • The intake air temperature is −10°C or higher.

• Refer to P0204 injector circuit P.13B-112. • The barometric pressure is 76 kPa or more.
FUNCTION • The adaptive learning has been completed with
• If a misfire occurs while the engine is running, the the vane that generates the crankshaft position
engine speed changes for an instant. signals.
• The engine-ECU checks for such changes in • During the engine operation except the shift
engine speed. change or low speed driving and rapid accelera-
TROUBLE JUDGMENT of air compressor (A/C: within the 3 seconds after
Check Conditions • The throttle deviation is within the range of −0.06
• The engine speed is 500 − 6,500 r/min. V/10ms to 0.06 V/10ms.
higher.
TROUBLESHOOTING
13B-139
Judgment Criterion STEP 3.Check No.4 injector itself.
• Misfire has occurred more frequently than • Check Injector itself (Refer to P.13B-400).
• Misfire has occurred in 15 or more of the last NO : Replace No.4 injector.
limit of emission standard). STEP 4.Connector check: B-17X engine control
Connector : B-17X
B-17X
Relay box's
2 1
waveform using an oscilloscope. 4 3
• Check ignition secondary voltage waveform Harness side
(Refer to GROUP 16 − Ignition System − connector AK400930 AB

Connector: C-139
NO : Check ignition Circuit System (Refer to
STEP 2.Connector check: B-05 No.4 injector

C-139(GR)
connector
Connector : B-05
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
B-05 2726 2524 23 22 21
(GR) Harness side connector
AK400931 AB
M
Harness side connector AK400940 AF NO : Repair or replace.

TROUBLESHOOTING
No. 1) engine control relay connector and B-05 No. 2) No.4 injector connector and C-139
(terminal No. 1) No.4 injector connector. (terminal No. 21) engine-ECU connector.
Connector : B-17X Connector : B-05
B-17X
Relay box's
triangle marks B-05
(GR)
2 1
4 3 M
Harness side 2 1
connector AK400930 AB Harness side connector AK400940 AF
B-05
(GR)
C-139(GR)
M
2 1
• Check power supply line for damage. 4 3

13 12 1110 9 8 7
2
6
1
5
2019 18 17 16 15 14

NO : Repair.

NO : Repair.
TROUBLESHOOTING
13B-141
C-141
(MU803804)
6162 6364
656667686970717273
747576777879808182 Engine-ECU
8384 858687 8889
89
B B
B B-102
MU802661
2 1 1 2
Detonation sensor
Wire colour code

AK400811 AB

Check Conditions
(terminal No. 89) from the detonation sensor (ter-
minal No. 1).
• Excluding for 2 seconds after ignition switch is set
FUNCTION to "ON" position or 2 seconds after engine start is
completed.
• The detonation sensor detects the vibration of the
• The engine speed is 2,000 r/min. or more.
cylinder block caused by detonation waves, and
• The volumetric efficiency is 30% or more.
inputs a signal to the engine-ECU.
• In response to the signal, the engine-ECU pro-
vides controls to retard the ignition timing when
the detonation occurs.
TROUBLESHOOTING
Judgment Criterion STEP 2. Perform resistance measurement at

• The change amount of the detonation sensor out- B-102 detonation sensor connector.
put voltage (the detonation sensor peak voltage
in every half a turn of the crankshaft) is below Connector : B-102
0.06 V or less in 200 consecutive times.
PROBABLE CAUSE
• Failed detonation sensor
• Open/short circuit in detonation sensor circuit or Detonation sensor
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-102 detonation 2 1

sensor connector Harness side
connector
Connector : B-102
B-102(GR)
Detonation sensor
AK400942 AB

side.
2 1
connector
B-102(GR) (terminal No. 2) detonation sensor
and damage.
AK400942 AB

TROUBLESHOOTING
13B-143
connector No. 1) detonation sensor connector and C-141
Connector: C-141
Connector : B-102
Detonation sensor
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
Harness side connector 2 1
AK400933 AB Harness side
connector
YES : Go to Step 4 . B-102(GR)
AK400942 AB
Connector: C-141
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

age.
NO : Repair.
TROUBLESHOOTING
STEP 5. Check the trouble symptoms. STEP 6. Replace detonation sensor.

YES : Go to Step 6 . the trouble symptoms.
NO : Intermittent malfunction (Refer to GROUP Q: Does trouble symptom persist?
00 − How to Use YES : Replace engine-ECU.
Troubleshooting/Inspection Service Points NO : Check end.
P.00-6).
TROUBLESHOOTING
13B-145
Battery
W-B
A-14
5
W-B
W-B
4 3
B-17X

3 4
1 2
R To engine-ECU
B-29 3
MU802603
1 2
Crank angle sensor
3
1 2
B-W
18
J/C(1) G-R
C-16
17
B-W
C-141 88 70
(MU803804)
6162 6364
656667686970717273
747576777879808182 Engine-ECU
8384 858687 8889
5V
Wire colour code

AK400812 AB
TROUBLESHOOTING

• Power is supplied to the crank angle sensor (ter-
minal No. 3) from the engine control relay (termi- STEP 1. M.U.T.-II/III data list
nal No. 1) and is earthed to the engine-ECU • Refer to Data List Reference Table P.13B-368.
(terminal No. 88) from the crank angle sensor
(terminal No. 1).
• A power voltage of 5 V is applied to the crank Q: Is the check result normal?
angle sensor output terminal (terminal No. 2) YES : Intermittent malfunction (Refer to GROUP
from the engine-ECU (terminal No. 70). 00 − How to Use
FUNCTION P.00-6).
• The crank angle sensor detects the crank angle NO : Go to Step 2 .
(position) and inputs a pulse signal to the
engine-ECU. STEP 2. Connector check: B-29 crank angle
• In response to the signal, the engine-ECU con- sensor connector
trols the injector, etc.
Connector: B-29
TROUBLE JUDGMENT
Check Condition
• Engine in cranking state.
Judgment Criterion
• The sensor output voltage remains unchanged
Crank angle sensor
PROBABLE CAUSE
• Open/short circuit in crank angle sensor circuit or
2 1 B-29 (B)
3
Harness side
connector
AK400943AB

TROUBLESHOOTING
13B-147
crank angle sensor connector. engine-ECU connector.
C-141(GR)
Crank angle sensor
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB
Connector: B-29
2 1 B-29 (B)
3
Harness side
connector
AK400943AB

side.
• Ignition switch: "ON" Crank angle sensor
OK: 4.9 − 5.1 V
NO : Go to Step 4 .
2 1 B-29 (B)
3
Harness side
connector
AK400943AB

• Disconnect B-29 crank angle sensor connector.
OK: 4.9 − 5.1 V
NO : Go to Step 6 .
TROUBLESHOOTING
connector connector
C-141(GR) C-141(GR)
6463 62 61 6463 62 61
7372 7170 69 6867 6665 7372 7170 69 6867 6665
82 818079 78 7776 7574 82 818079 78 7776 7574
8988 87 86 85 8483 8988 87 86 85 8483
AK400933 AB AK400933 AB

Crank angle sensor
2 1 B-29 (B)
3
Harness side
connector
AK400943AB

TROUBLESHOOTING
13B-149
No. 2) crank angle sensor connector and C-141 • Refer to Data List Reference Table P.13B-368.
(terminal No. 70) engine-ECU connector. a. Item 22: Crank angle sensor
00 − How to Use
P.00-6).
Crank angle sensor

Connector: B-29
2 1 B-29 (B)
Harness side
connector
AK400943AB
Connector: C-141
2 1 B-29 (B)
3
Harness side
C-141(GR) connector
AK400943AB
6463 62 61
7372 7170 69 6867 6665 side.
82 818079 78 7776 7574
8988 87 86 85 8483
Harness side connector • Voltage between terminal No. 3 and earth.
AK400933 AB OK: System voltage
NO : Repair.
TROUBLESHOOTING
relay connector B-29 crank angle sensor connector.
Connector : B-17X Connector: B-29
B-17X
Relay box's
triangle marks
2 1
4 3
Harness side Crank angle sensor
Connector: B-29
2 1 B-29 (B)
3
Crank angle sensor Harness side
connector
AK400943AB

side.
2 1 B-29 (B) YES : Go to Step 14 .
3 NO : Go to Step 12 .
Harness side
connector
AK400943AB STEP 12. Connector check: C-141 engine-ECU
connector
Connector: C-141
open/short circuit.
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

TROUBLESHOOTING
13B-151
No. 1) crank angle sensor connector and C-141 measurement at B-29 crank angle sensor
(terminal No. 88) engine-ECU connector. connector (Using oscilloscope).
Crank angle sensor Crank angle sensor
2 1 B-29 (B) 2 1 B-29 (B)

3 3
connector connector
AK400943AB AK400943AB

Connector: C-141
• Engine: Idling
C-141(GR) (Refer to P.13B-383), its maximum value
6463 62 61 waveform.
7372 7170 69 6867 6665
8988 87 86 85 8483
AK400933 AB

NO : Repair.
TROUBLESHOOTING
STEP 15. Connector check: B-17X engine control STEP 16. Check harness between B-29 (terminal
relay connector No. 3) crank angle sensor connector and B-17X
Connector : B-17X (terminal No. 1) engine control relay connector.
B-17X Connector: B-29
Relay box's
triangle marks
2 1
4 3
Harness side
connector AK400930 AB Crank angle sensor

2 1 B-29 (B)
3
Harness side
connector
AK400943AB
Connector : B-17X
B-17X
Relay box's
triangle marks
2 1
4 3
Harness side

NO : Repair.
TROUBLESHOOTING
13B-153
connectors No. 2) crank angle sensor connector and C-141
Connector: C-141
Connector: B-29
C-141(GR)
Crank angle sensor

6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

2 1 B-29 (B)
3
Harness side
connector
AK400943AB
Connector: C-141
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

NO : Repair.
TROUBLESHOOTING
STEP 19. Check harness between B-29 (terminal STEP 20. Check the crankshaft sensing blade
No. 1) crank angle sensor connector and C-141 Q: Is the check result normal?
(terminal No. 88) engine-ECU connector. YES : Go to Step 21 .
Connector: B-29 NO : Replace the crankshaft sensing blade.

Crank angle sensor 00 − How to Use
P.00-6).
2 1 B-29 (B)
3
Harness side
connector
AK400943AB
Connector: C-141
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

NO : Repair.
TROUBLESHOOTING
13B-155
Battery
W-B
A-14
5
W-B
W-B
4 3
B-17X

3 4
1 2
R
To engine-ECU
B-106 3
MU802337
1 2 3 Camshaft position sensor
1 2
B-W
19
J/C (1)
C-16 L-Y
17
B-W
88 71
C-141
(MU803804)
6162 6364
656667686970717273 Engine-ECU
747576777879808182
8384 858687 8889
5V
Wire colour code

AK400813 AB
OPERATION FUNCTION
• Power is supplied to the camshaft position sensor • The camshaft position sensor detects the top
(terminal No. 3) from the engine control relay (ter- dead center on the compression stroke of the No.
minal No. 1) and is earthed to the engine-ECU 1 cylinder and inputs a pulse signal to the
(terminal No. 88) from the camshaft position sen- engine-ECU.
sor (terminal No. 1).
• A power voltage of 5 V is applied to the camshaft TROUBLE JUDGMENT
position sensor output terminal (terminal No. 2) Check Conditions
from the engine-ECU (terminal No. 71). • Ignition switch: "ON"
• Engine speed of 50 r/min. or more.
TROUBLESHOOTING
Judgment Criterion STEP 3. Connector check: B-17X engine control

• The sensor output voltage remains unchanged relay connector
Connector : B-17X
PROBABLE CAUSE B-17X
• Failed camshaft position sensor Relay box's
• Open/short circuit in camshaft position sensor cir- triangle marks
• Failed engine-ECU 2 1
Harness side
position sensor connector Connector : B-106
Connector : B-106 3 2 1
B-106(B)
Harness side
3 2 1 connector
B-106(B)
Harness side
connector
AK400944 AB

Q: Is the check result normal? (terminal No. 3) camshaft position sensor
YES : Go to Step 2 . connector and B-17X (terminal No. 1)
STEP 2. Perform voltage measurement at B-106 open/short circuit.
camshaft position sensor connector. NO : Repair or replace.
Connector : B-106
3 2 1
B-106(B) camshaft position sensor connector.
Harness side
connector Connector : B-106
3 2 1
B-106(B)
Harness side
connector
AK400944 AB

side.
• Ignition switch: "ON" AK400944 AB
• Voltage between terminal No. 3 and earth. • Disconnect connector, and measure at harness
OK: System voltage side.
Q: Is the check result normal? • Ignition switch: "ON"
NO : Go to Step 3 . OK: 4.9 − 5.1 V
NO : Go to Step 5 .
TROUBLESHOOTING
13B-157
C-141(GR) C-141(GR)
6463 62 61 6463 62 61
7372 7170 69 6867 6665 7372 7170 69 6867 6665
82 818079 78 7776 7574 82 818079 78 7776 7574
8988 87 86 85 8483 8988 87 86 85 8483
AK400933 AB AK400933 AB
3 2 1 3 2 1
B-106(B) B-106(B)
connector connector
AK400944 AB AK400944 AB

• Disconnect B-106 camshaft position sensor con- YES : Check and repair harness between B-106
nector. (terminal No. 2) camshaft position sensor
• Ignition switch: "ON" connector and C-141 (terminal No. 71)
• Voltage between terminal No. 71 and earth. engine-ECU connector.
OK: 4.9 − 5.1 V • Check output line for open circuit.
NO : Go to Step 7 .
TROUBLESHOOTING
connector No. 2) camshaft position sensor connector and
Connector: C-141
Connector : B-106
3 2 1
B-106(B)
Harness side
connector
C-141(GR)
6463 62 61 AK400944 AB
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483 Connector: C-141
AK400933 AB

C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

NO : Repair.

00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-159
STEP 10. Perform resistance measurement at STEP 12. Check harness between B-106 (terminal
B-106 camshaft position sensor connector. No. 1) camshaft position sensor connector and
Connector : B-106
Connector : B-106
3 2 1
B-106(B)
Harness side 3 2 1
connector B-106(B)
Harness side
connector
AK400944 AB
• Disconnect connector, and measure at harness AK400944 AB
side.
Connector: C-141
C-141(GR)
connector
Connector: C-141 6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

C-141(GR) • Check earthing line for open circuit and damage.
6463 62 61 YES : Go to Step 9 .
7372 7170 69 6867 6665 NO : Repair.
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

TROUBLESHOOTING
STEP 13. Perform output wave pattern STEP 15. Check harness between B-106 (terminal
measurement at B-106 camshaft position sensor No. 3) camshaft position sensor connector and
connector (Using oscilloscope). B-17X (terminal No. 1) engine control relay
Connector : B-106 connector.
Connector : B-106
3 2 1
B-106(B)
Harness side 3 2 1
connector B-106(B)
Harness side
connector
AK400944 AB
nect connector, and measure at pick-up harness. Connector : B-17X

• Engine: Idling B-17X
• Voltage between terminal No. 2 and earth. Relay box's
triangle marks
(Refer to P.13B-383), its maximum value 2 1
should be 4.8 V or more, and its minimum 4 3
value should be 0.6 V or less with no noise in Harness side
waveform. connector AK400930 AB
NO : Repair.
relay connector. STEP 16. Connector check: C-141 engine-ECU
Connector : B-17X connectors
B-17X
Connector: C-141
Relay box's
triangle marks
2 1
4 3
Harness side C-141(GR)

YES : Go to Step 15 . 6463 62 61
7372 7170 69 6867 6665
NO : Repair or replace. 82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

TROUBLESHOOTING
13B-161
No. 2) camshaft position sensor connector and No. 1) camshaft position sensor connector and
C-141 (terminal No. 71) engine-ECU connector. C-141 (terminal No. 88) engine-ECU connector.
3 2 1 3 2 1
B-106(B) B-106(B)
connector connector
AK400944 AB AK400944 AB
C-141(GR) C-141(GR)
6463 62 61 6463 62 61
7372 7170 69 6867 6665 7372 7170 69 6867 6665
82 818079 78 7776 7574 82 818079 78 7776 7574
8988 87 86 85 8483 8988 87 86 85 8483
AK400933 AB AK400933 AB
• Check output line for damage. NOTE: Before checking harness, check intermediate
Q: Is the check result normal? connector C-16, and repair if necessary.
NO : Repair.

cylinder.

00 − How to Use
P.00-6).
TROUBLESHOOTING
Code No. P0403: Exhaust Gas Recirculation (EGR) Control Solenoid Valve
EGR control solenoid valve circuit
Battery
W-B
A-14
5
W-B
W-B
4 3
B-17X

3 4
1 2
To engine-ECU
R
1
B-119
1 2 EGR control solenoid valve
C-139 20
(MU803802)
1 2 3 4
5 6 7 8 9 10111213 Engine-ECU
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK400814 AB

• Power is supplied to the EGR control solenoid power transistor in the unit be in "ON", and that
valve (terminal No. 1) from the engine control makes currents go on the EGR control solenoid
relay (terminal No. 1). valve (terminal No. 2).
TROUBLESHOOTING
13B-163
• In response to the signal from the engine-ECU, B-119 EGR control solenoid valve connector.
the EGR control solenoid valve controls the oper-
Connector : B-119
ation of the EGR valve.
TROUBLE JUDGMENT
Check Condition
B-119(BR)
Judgment Criterion 2 1
• When the EGR control solenoid valve is turned to Harness side
"LOCK" (OFF) position from "ON" position, none connector
AK400945AB
of solenoid coil surge voltage (system voltage of
+2 V) is detected. • Disconnect connector, and measure at solenoid
valve side.
• Failed EGR control solenoid valve OK: 29 − 35 Ω (at 20°C)
• Open/short circuit in EGR control solenoid valve Q: Is the check result normal?
circuit or loose connector contact YES : Go to Step 4 .
• Failed engine-ECU NO : Replace EGR control solenoid valve.
DIAGNOSIS PROCEDURE
EGR control solenoid valve connector.
Connector : B-119
valve vibrates.
00 − How to Use B-119(BR)
2 1
Harness side
P.00-6). connector
AK400945AB
NO : Go to Step 2 .
STEP 2. Connector check: B-119 EGR control side.
solenoid valve connector
Connector : B-119
OK: System voltage
NO : Go to Step 5 .
B-119(BR)
2 1
Harness side
connector
AK400945AB

TROUBLESHOOTING
B-17X
Relay box's
triangle marks
2 1
4 3 C-139(GR)
Harness side
4 3 2 1
Connector : B-119 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

B-119(BR) side.
connector
AK400945AB OK: System voltage

YES : Check and repair harness between B-119 YES : Go to Step 8 .
(terminal No. 1) EGR control solenoid valve NO : Go to Step 7 .
open/short circuit.
TROUBLESHOOTING
13B-165
connector connector
C-139(GR) C-139(GR)
4 3 2 1 4 3 2 1
13 12 1110 9 8 7 6 5 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2019 18 17 16 15 14
2726 2524 23 22 21 2726 2524 23 22 21
AK400931 AB AK400931 AB

B-119(BR)
2 1
Harness side
connector
AK400945AB

circuit.
TROUBLESHOOTING
No. 2) EGR control solenoid valve connector and No. 1) EGR control solenoid valve connector and
Connector : B-119
connector.
Connector : B-119
B-119(BR)
2 1 B-119(BR)
Harness side 2 1
AK400945AB
connector
AK400945AB
Connector: C-139
Connector : B-17X
B-17X
Relay box's
triangle marks
C-139(GR) 2 1
4 3
Harness side
4 3 2 1 connector AK400930 AB
13 12 1110 9 8 7 6 5
2019 18 17 16
2726 2524 23
15
22
14
21
AK400931 AB
NO : Repair.
Q: Is the check result normal? STEP 11. M.U.T.-II /III actuator test
NO : Repair.
valve vibrates.
00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-167
Code No. P0421: Warm up Catalyst Malfunction

• The signal from the oxygen sensor (rear) differs
from the oxygen sensor (front). That is because STEP 1. Check for leakage of exhaust emission
the catalytic converter purifies exhaust gas. from exhaust manifold.
When the catalytic converter has deteriorated,
the signal from the oxygen sensor (front) Q: Is the check result normal?
becomes similar to the oxygen sensor (rear). YES : Go to Step 2 .
• The engine-ECU compares the output of the front NO : Repair.
and rear oxygen sensor signals.
TROUBLE JUDGMENT • Refer to Data List Reference Table P.13B-368.
Check Conditions a. Item 11: Oxygen sensor (front)
• The engine speed is 3,000 r/min. or less. b. Item 59: Oxygen sensor (rear)
• The accelerator pedal is fully depressed. Q: Is the check result normal?
• Airflow sensor output is 8 g/s or higher. YES : Go to Step 3 .
• 3 seconds or longer has elapsed after the NO : Perform the diagnosis code classified check
above-mentioned conditions have been met. procedure for the sensor that has shown an
• Engine running, intake air temperature is −10°C abnormal data valve (Refer to Inspection
or higher. Chart for Diagnosis Codes P.13B-20).
• Under the closed-loop control.
• Vehicle speed is 1.5 km/h or more.
• The engine-ECU monitors for this condition for 7
• Item 11: Oxygen sensor (front)
cycles of 10 seconds each during the drive cycle.
• Short-term fuel trim is higher than −25% or lower OK: 0 − 0.4 and 0.6 − 1.0 volt should alternate
than +25%. 15 times or more within 10 seconds (engine
• Accumulated air flow sensor output is 2,931 g or speed at 2,000 r/min.).
higher. Q: Is the check result normal?
Judgment Criterion YES : Go to Step 4 .
NO : Replace the oxygen sensor (front).
• The oxygen sensor (rear) signal frequency
divided by oxygen sensor (front) signal frequency
= 0.8 or more. STEP 4. Replace the oxygen sensor (rear).
• After replacing the oxygen sensor (rear),
PROBABLE CAUSE re-check the trouble symptoms.
• Catalytic converter deteriorated
• Failed oxygen sensor (front) YES : Check end.
• Failed oxygen sensor (rear) NO : Go to Step 5 .
STEP 5. Replace the catalytic converter.

• After replacing the catalytic converter, re-check
YES : Check end.
NO : Replacing engine-ECU.
TROUBLESHOOTING
Battery
W-B
A-14
5
W-B W-B
4 3
B-17X

3 4
1 2
To engine-ECU
R
2
B-101
MU802779
1 2 Purge control solenoid valve
BR
23
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213 Engine-ECU
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK400815 AB

• Power is supplied to the purge control solenoid power transistor in the unit be in "ON" position,
valve (terminal No. 2) from the engine control and that makes currents go on the purge control
relay (terminal No. 1). solenoid valve (terminal No. 1).
TROUBLESHOOTING
13B-169
• In response to a signal from the engine-ECU, the B-101 purge control solenoid valve connector.
purge control solenoid valve controls the flow rate
Connector : B-101
of the purge air to be introduced into the surge
tank.
TROUBLE JUDGMENT B-101(B)
Check Conditions
2 1
Harness side
Judgment Criterion connector AK400946AB
• The surge voltage (system voltage +2 V) of sole-
solenoid valve is turned to OFF from ON. valve side.
PROBABLE CAUSE OK: 30 − 34 Ω (at 20°C)
• Failed purge control solenoid valve Q: Is the check result normal?
• Open/short circuit in purge control solenoid value YES : Go to Step 4 .
circuit or loose connector contact NO : Replace purge control solenoid valve.

purge control solenoid valve connector.
Connector : B-101
• Item 08: Purge control solenoid valve
OK: Operating sound can be heard and the B-101(B)
valve vibrates
2 1
00 − How to Use
Troubleshooting/Inspection Service Points Harness side
P.00-6).
side.
STEP 2. Connector check: B-101 purge control
solenoid valve connector • Voltage between terminal No. 2 and earth.
OK: System voltage
Connector : B-101
2 1
Harness side

TROUBLESHOOTING
relay connector. engine-ECU connector.
B-17X
Relay box's
triangle marks
2 1
4 3 C-139(GR)
Harness side
4 3 2 1
Connector : B-101 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
B-101(B) AK400931 AB

side.
connector AK400946AB OK: System voltage

YES : Check and repair harness between B-101 YES : Go to Step 8 .
(terminal No. 2) purge control solenoid valve NO : Go to Step 7 .
• Check power line for open/short
circuit.
TROUBLESHOOTING
13B-171
connector connector
C-139(GR) C-139(GR)
4 3 2 1 4 3 2 1
13 12 1110 9 8 7 6 5 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2019 18 17 16 15 14
2726 2524 23 22 21 2726 2524 23 22 21
AK400931 AB AK400931 AB

B-101(B)
2 1
Harness side

circuit.
TROUBLESHOOTING
and C-139 (terminal No. 23) engine-ECU and B-17X (terminal No. 1) engine control relay
B-101(B) B-101(B)
2 1 2 1
Connector: C-139 Connector : B-17X

B-17X
Relay box's
triangle marks
2 1
C-139(GR) 4 3
Harness side
4 3
13 12 1110 9 8 7
2
6
1
5
2019 18 17 16 15 14
AK400931 AB
NO : Repair.

Q: Is the check result normal? • Item 08: purge control solenoid valve
NO : Repair. OK: Operating sound can be heard and the
valve vibrates.
00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-173
Code No. P0500: Vehicle Speed Sensor System

C-303 C-141
R LOCK (MU803804)
1 2 3
4 5 6 ST ACC 6162 6364
IG1 IG2 656667686970717273
747576777879808182
8384 858687 8889
2
L-B 79
C-203
6
W-L
2 J/B
7.5A
3
C-202 J/C (1) W-L
11 1
B-W 2
W-L
B-19
9 B-19
4
B-W
W-L
1 3
B-115
(MU802723)
Vehicle speed sensor
1 2 3
B 2
B-19
5
B 8
J/C (2)
C-17
B 1
Wire colour code

AK400816 AB
OPERATION FUNCTION
engine-ECU (terminal No. 79). engine-ECU.
TROUBLESHOOTING
TROUBLE JUDGMENT STEP 2. M.U.T.-II/III data list

Check Conditions • Refer to Data List Reference Table P.13B-368.
• The engine speed is 2,000 − 4,000 r/min. Q: Is the check result normal?
• The volumetric efficiency is 60 − 80%. YES : Go to Step 3 .
Judgment Criterion NO : Intermittent malfunction (Refer to GROUP
• The sensor output voltage remains unchanged 00 - How to Use Troubleshooting/Inspection
(no pulse signal is inputted) for 2 seconds. Service Points P.00-6).
PROBABLE CAUSE STEP 3. Check connector: C-141 engine-ECU

• Failed Vehicle speed sensor connector
Connector: C-141
DIAGNOSIS PROCEDURE
STEP 1. Check the speedometer

C-141(GR)
NO : Check the speedometer (Refer to GROUP
54A −Combination Meter Assembly −
6463 62 61
7372 7170 69 6867 6665
On-vehicle Service P.54A-57). 82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

TROUBLESHOOTING
13B-175
STEP 4. Check harness between C-141 (terminal STEP 5. Check the trouble symptoms.
(terminal No. 3) vehicle speed sensor connector. YES : Replacing engine-ECU.
00 − How to Use
P.00-6).
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB
Connector : B-115
B-115(B)
3 2 1
Harness side
connector
AK400947AB

connector B-19 and C-16, and repair if necessary.
NO : Repair.
TROUBLESHOOTING
Code No. P0513: Immobilizer System
Signal
circuit
C-304-1 3
1 2 C-304
7 3 4 5 6 7 MU801547
V
C-104
11
V
65
C-141
(MU803804)
6162 6364
656667686970717273 Engine-ECU
747576777879808182
8384 858687 8889
Wire colour code

AK400817 AB

Check Condition
engine-ECU (terminal No. 65) and immobi-
lizer-ECU (terminal No. 7).
Judgment Criterion
FUNCTION • When the communication error between the
• Engine-ECU sends or receives the control sig- engine-ECU and the immobilizer-ECU continues
nals to or from immobilizer-ECU to certify the for 2 seconds or more.
ignition key.
NOTE: .
PROBABLE CAUSE
• This code may be displayed when registering • Failed engine-ECU
the key encrypted code.
TROUBLESHOOTING
13B-177
STEP 1. Connector check: C-304 (terminal No. 65) engine-ECU connector.
immobilizer-ECU connector and C-141 Connector : C-304
engine-ECU connector
Connector : C-304 C-304
C-304
2 1
7 6 5 4 3
Harness side
2 1 connector
7 6 5 4 3 AK400948 AB
Harness side
AK400948 AB
Connector: C-141
C-141(GR)
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
6463 62 61
7372 7170 69 6867 6665 Harness side connector
82 818079 78 7776 7574
8988 87 86 85 8483 AK400933 AB
AK400933 AB
NO : Repair.

00 − How to Use
P.00-6).

NO : Check end.
TROUBLESHOOTING
C-140
(MU803803)
3132 33 34
35363738394041 42 43 Engine-ECU
444546474849 50 51
5253 545556 57 58
47
B-28 1
(MU801211)
1
Power steering fluid pressure switch
Wire colour code

AK400818 AB
CONDITION TROUBLE JUDGMENT

• The battery voltage is applied to the power steer-
Check Conditions
ing fluid pressure switch (terminal No. 1) from the
• The engine coolant temperature is 30°C or
FUNCTION higher.
• Drive for 4 seconds or more with the vehicle
• It is detected whether a load is applied on the
speed is 50 km/h or more. Stop the vehicle (vehi-
power steering fluid pump by steering or not, and
cle speed is 1.5 km/h or less). Repeat 10 times is
the signal is inputted to the engine-ECU. When
more.
the power steering fluid pressure switch "ON" sig-
nal (a large load on the power steering fluid Judgment Criterion
pump) is inputted, the engine-ECU provides the • The power steering fluid pressure switch remains
idle-up control. in "ON" position.
PROBABLE CAUSE
• Failed power steering fluid pressure switch
• Open/short circuit in power steering fluid pres-
sure switch circuit or loose connector contact
TROUBLESHOOTING
13B-179
STEP 1. Connector check: B-28 power steering Connector: C-140
Connector: B-28
B-28 (B) C-140(GR)
1
34 33 32 31
Harness side 43 42 4140 39 38 37 36 35
connector AK400949AB 51 50 49 4847 46 4544
58 57 5655 54 5352
YES : Go to Step 2 . AK400934 AB
NO : Repair or replace. • Measure engine-ECU terminal voltage.

STEP 2. Perform voltage measurement at B-28 • Voltage between terminal No. 47 and earth.
power steering fluid pressure switch connector. OK: System voltage
NO : Go to Step 5 .
B-28 (B)
1
Harness side

side.
OK: System voltage
NO : Go to Step 3 .
TROUBLESHOOTING
connector connector
C-140(GR) C-140(GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK400934 AB AK400934 AB

B-28 (B)
1
Harness side

TROUBLESHOOTING
13B-181
No. 1) power steering fluid pressure switch engine-ECU connector.
Connector: C-140
Connector: B-28
B-28 (B)
C-140(GR)
1
43 42 4140 39 38 37 36 35
connector AK400949AB 51 50 49 4847 46 4544
58 57 5655 54 5352
Connector: C-140
AK400934 AB

• Engine: Idling
OK:
C-140(GR)
System voltage (Steering wheel: Stationary)
34 33 32 31 YES : Go to Step 11 .
43
51
42 4140 39 38 37 36 35
50 49 4847 46 4544 NO : Go to Step 9 .
58 57 5655 54 5352
AK400934 AB
connector
Connector: C-140
NO : Repair.

a. Item 27: Power steering fluid pressure switch C-140(GR)

34 33 32 31
00 − How to Use 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
Troubleshooting/Inspection Service Points 58 57 5655 54 5352
P.00-6). Harness side connector
NO : Replace engine-ECU. AK400934 AB

TROUBLESHOOTING
No. 1) power steering fluid pressure switch connector
Connector: C-140
Connector: B-28
B-28 (B)
C-140(GR)
1
43 42 4140 39 38 37 36 35
connector AK400949AB 51 50 49 4847 46 4544
58 57 5655 54 5352
Connector: C-140
AK400934 AB

C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

switch.
NO : Repair.
TROUBLESHOOTING
13B-183
Alternator FR terminal circuit
C-141
(MU803804)
6162 6364
656667686970717273 Engine-ECU
747576777879808182
8384 858687 8889
86
Y-B
B-19
1
Y-B
B-30 4
(MU802046)
1 2 3 4 IC Voltage
Wire colour code

AK400819 AB

Check Condition
• Engine speed is 50 r/min or more.
Judgment Criterion
FUNCTION • Input voltage from alternator FR terminal is the
• A signal of the power supply duty ratio for the system voltage or more for 20 seconds.
alternator field coil is inputted to the engine-ECU.
• In response to the signal, the engine-ECU PROBABLE CAUSE
detects the alternator output current and controls • Open circuit in alternator FR terminal circuit
the idling speed according to the output current • Failed engine-ECU
(electric load).
TROUBLESHOOTING

connector
STEP 1. Connector check: B-19 intermediate Connector: C-141
connector
Connector: B-19
B-19 (B)
C-141(GR)
3 2 1
6 5 4
6463 62 61
Female side 7372 7170 69 6867 6665
connector AK400950AB 82 818079 78 7776 7574
8988 87 86 85 8483
STEP 2. Perform voltage measurement at B-19 NO : Repair or replace.
intermediate connector.
Connector: B-19
B-19 (B)
1 2 3
4 5 6
Male side
connector
AK401530 AB

nector side.
OK: System voltage
NO : Go to Step 3 .
TROUBLESHOOTING
13B-185
No. 1) intermediate connector and C-141 intermediate connector.
Connector: B-19
Connector: B-19
B-19 (B)
B-19 (B)
3 2 1
1 2 3 6 5 4
4 5 6 Female side
Male side connector AK400950AB
connector
AK401530 AB
Connector: C-141
OK: System voltage
NO : Go to Step 7 .
C-141(GR)
STEP 7. Connector check: B-30 alternator

6463 62 61
connector
7372 7170 69 6867 6665
82 818079 78 7776 7574 Connector: B-30
8988 87 86 85 8483
AK400933 AB
• Check output line for short circuit. B-30 (GR)

NO : Repair. 4 3 2 1
Harness side
00 − How to Use
P.00-6).
TROUBLESHOOTING
No. 4) alternator connector and B-19 (terminal intermediate connector.
No. 1) intermediate connector.
Connector: B-19
Connector: B-30
B-19 (B)
B-30 (GR)
3 2 1
6 5 4
4 3 2 1 Female side
Harness side
Connector: B-19
• Engine: Idle after warm-up
3 2 1 OFF causes the voltage to fall.
Female side YES : Go to Step 5 .
connector AK400950AB NO : Go to Step 10 .
Q: Is the check result normal? STEP 10. Connector check: B-30 alternator
YES : Replace alternator. connector
NO : Repair. Connector: B-30
B-30 (GR)
4 3 2 1
Harness side

TROUBLESHOOTING
13B-187
No. 4) alternator connector and B-19 (terminal No. 1) intermediate connector and C-141
No. 1) intermediate connector. (terminal No. 86) engine-ECU connector.
B-19 (B)
B-30 (GR)
1 2 3
4 5 6
4 3 2 1
Harness side Male side
connector
AK401530 AB
B-19 (B)
3 2 1
6 5 4 C-141(GR)
Female side
• Check output line for damage. 6463 62 61

7372 7170 69 6867 6665
82 818079 78 7776 7574

NO : Repair.

NO : Intermittent malfunction (Refer to Group 00
− How to Use troubleshooting/Inspection
TROUBLESHOOTING
DTC P0638: Throttle Valve Control Servo Circuit Range/Performance Problem
OPERATION STEP 2. Check the throttle valve control servo

• Refer to P2101 − Throttle valve control servo cir- itself.
cuit P.13B-210. • Check the throttle valve control servo control
motor itself (Refer to P.13C-436)
FUNCTION
• engine-ECU checks the electronic controlled
throttle system for abnormal conditions.
NO : Replace electronically controlled throttle
TROUBLE JUDGMENT valve.
Check Conditions STEP 3. Connector check: B-06 electronically

• Battery positive voltage is 8.3 V or higher. controlled throttle valve connector and C-138
• Throttle position sensor (main) output voltage is engine-ECU connector
0.35 − 4.8 V.
• Drop of throttle position sensor (main) output volt- Connector : B-06
age per 100 milliseconds is 0.04 V or more.
Judgement Criteria
• Throttle position sensor (main) output voltage has
continued to be above 0.5 V higher than the tar-
get throttle position sensor (main) voltage for 0.5
second.
6 5 4 3 2 1 B-06(B)
Check Conditions Harness side connector
• Battery positive voltage is 8.3 V or higher. AK400937AB
• Throttle position sensor (main) output voltage is

Connector: C-138
0.35 − 4.8 V.
Judgement Criteria
• Difference between throttle position sensor
(main) output voltage and target throttle position
sensor (main) voltage is 1 V or higher for 4 sec-
onds.
C-138(GR)
PROBALE CAUSE
• Failed throttle valve return spring.
• Failed throttle valve operation. 124 123 122121
133 132 131 130 129128127126125
• Failed throttle valve control servo. 141 140 139 138 137136 135134
• Open/short circuit in throttle valve control servo

146 145 144 143142

connector contact.
• Failed engine-ECU. AK400953 AB

DIAGNOSIS YES : Go to Step 4 .
a. Item 9A: Throttle position sensor (main) mid
opening learning value
NO : Replace throttle body assembly.
TROUBLESHOOTING
13B-189
6 5 4 3 2 1 B-06(B) 6 5 4 3 2 1 B-06(B)
C-138(GR) C-138(GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142

AK400953 AB AK400953 AB
• Check output line for short circuit and damage. • Check output line for short circuit and damage.

00 − How to Use
P.00-6).
TROUBLESHOOTING
DTC P0642: Throttle Position Sensor Power Supply
FUNCTION PROBALE CAUSE

• engine-ECU checks the throttle position sensor • Failed engine-ECU
power voltage for abnormal conditions.
DIAGNOSIS
TROUBLE JUDGMENT
Check Conditions STEP 1. Check the trouble symptoms.
• Battery positive voltage is 6.3 V or higher.
Judgement Criteria YES : Replace engine-ECU.
• Throttle position sensor power voltage is 4.1 V or NO : Intermittent malfunction (Refer to GROUP
less for 0.5 second. 00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-191
DTC P0657: Throttle Valve Control Servo Relay Circuit Malfunction
Throttle valve control servo relay circuit

Battery
W-B
A-14
5
W-B
W-B
4 3
B-17X
Engine W
1 2 control
relay
3 4
1 2
R Y-G W R
4 3
Throttle B-14X
To engine-ECU valve
control 1 2
servo
relay 3 4
1 2
R-W L
132 15
C-138 C-139
(MU803801) (MU803802)
121122 123 124
Power source 1 2 3 4
125126127128129 130 131 132 133 5 6 7 8 9 10111213
134135 136137 138 139 140 141 14 15 16 1718 19 20
142143 144 145 146 21 22 232425 2627
Engine-ECU
Wire colour code

B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
AK400820AB
OPERATION • Engine-ECU (terminal No. 15) applies current to

• Battery voltage is applied to the Throttle valve the throttle valve control servo relay coil by turn-
control servo relay terminal (terminal No. 4). ing ON the power transistor in the unit in order to
• Battery voltage is applied to the Throttle valve turn the relay ON.
control servo relay terminal (terminal No. 3) from
the engine control relay (terminal No. 1).
TROUBLESHOOTING
• When the throttle valve control servo relay turns STEP 3. Perform voltage measurement at B-14X
ON, battery voltage is supplied by the throttle throttle valve control servo relay connector.
valve control servo relay (terminal No. 1) to the
engine-ECU (terminal No. 132). Connector : B-14X
FUNCTION Relay box's

• When the ignition switch ON signal is input into triangle marks
the engine-ECU, the engine-ECU turns ON the
Throttle valve control servo. 2 1
TROUBLE JUDGMENT 4 3 B-14X

Harness side
Check Condition connector AK400952AB
Judgement Criteria • Voltage between terminal No. 4 and earth.
• The power line voltage of the electronic controlled OK: System voltage
throttle system is 4.0 V or less for 1 second.
PROBALE CAUSE YES : Go to Step 4 .
• Failed throttle valve return spring
circuit or loose connector contact.
throttle valve control servo relay connector
and battery.
DIAGNOSIS • Check power supply line for
open/short circuit.
STEP 1. Connector check: B-14X throttle valve
control servo relay connector STEP 4. Perform voltage measurement at B-14X
Connector : B-14X throttle valve control servo relay connector.
Connector : B-14X
Relay box's
triangle marks
Relay box's
triangle marks
2 1
4 3 B-14X 2 1
Harness side 4 3 B-14X
Harness side
YES : Go to Step 2 . • Remove relay, and measure at relay box side.
NO : Repair or replace. • Ignition switch: ON
STEP 2. Check throttle valve control servo relay OK: System voltage
itself. Q: Is the check result normal?
• Check throttle valve control servo relay (Refer to YES : Go to Step 5 .
P.13C-430). NO : Go to Step 6 .
NO : Repair.
TROUBLESHOOTING
13B-193
B-17X
Relay box's
triangle marks
2 1
4 3 C-139(GR)
Harness side
4 3 2 1
Connector : B-14X 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
Relay box's
triangle marks AK400931 AB
Connector : B-14X
2 1
4 3 B-14X
Relay box's
Harness side triangle marks

YES : Check and repair harness between B-17X 4 3 B-14X
Harness side
connector and B-14X (terminal No. 3) connector AK400952AB
throttle valve control servo relay connector.
• Check power supply line for • Disconnect connector, and measure at harness
open/short circuit. side.
NO : Repair or replace. • Ignition switch: ON
OK: System voltage
(terminal No. 2) throttle valve control servo
relay connector and C-139 (terminal No. 15)
circuit.
NO : Go to Step 7 .
TROUBLESHOOTING
STEP 7. Perform voltage measurement at C-138 STEP 8. Check harness between B-14X (terminal
engine-ECU connector. No. 1) throttle valve control servo relay
Connector: C-138
Connector : B-14X
Relay box's
triangle marks
C-138(GR)
2 1
4 3 B-14X
124 123 122121 Harness side
133 132 131 130 129128127126125 connector AK400952AB
141 140 139 138 137136 135134
146 145 144 143142

AK400953 AB

side.
OK: System voltage C-138(GR)
NO : Go to Step 8 . 124 123 122121
133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142

AK400953 AB

NO : Repair.
TROUBLESHOOTING
13B-195
STEP 9. Check harness between B-17X (terminal STEP 10. Connector check: C-138 engine-ECU
No. 1) engine control relay connector and B-14X connector
(terminal No. 3) throttle valve control servo relay
Connector: C-138
connector.
Connector : B-17X
B-17X
Relay box's
triangle marks
C-138(GR)
2 1
4 3
133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
Connector : B-14X Harness side connector

AK400953 AB
Relay box's
2 1
00 − How to Use
4 3 B-14X Troubleshooting/Inspection Service Points
Harness side P.00-6).
Connector: C-139 STEP 11. Check and repair harness between

B-14X (terminal No. 4) throttle valve control servo
relay connector and battery.
Connector : B-14X
Relay box's
triangle marks
C-139(GR)
2 1
4 3 2 1 4 3
13 12 1110 9 8 7 6 5
B-14X
2019 18 17 16 15 14
2726 2524 23 22 21 Harness side
AK400931 AB
• Check output line for damage. Q: Is the harness connector in good condition?
YES : Check and repair harness between B-14X 00 − How to Use
(terminal No. 2) throttle valve control servo Troubleshooting/Inspection Service Points
relay connector and C-139 (terminal No. 15) P.00-6).
circuit.
NO : Repair.
TROUBLESHOOTING
STEP 12. Check and repair harness between STEP 13. Check the trouble symptoms.
B-14X (terminal No. 1) throttle valve control servo Q: Does trouble symptom persist?
relay connector and C-138 (terminal No. 132) YES : Replace engine-ECU.
engine-ECU connector. NO : Intermittent malfunction (Refer to GROUP
Connector : B-14X 00 − How to Use
Relay box's P.00-6).
triangle marks
2 1
4 3 B-14X
Harness side
Connector: C-138
C-138(GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142

AK400953 AB

Q: Is the harness connector in good condition?
00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-197
Code No. P0805: Clutch Oil Pressure Sensor System
Clutch oil pressure sensor circuit
B-124
(MU802408)
1 2 3 Clutch oil pressure sensor
3 1 2
Y-B BR L-W
97 96 84
C-142
(MU803805) C-141
(MU803803)
9192 939495
96979899100 101102103 104 6162 6364
105106 107108109 110111112 656667686970717273
113114 115116117 118119120 747576777879808182
8384 858687 8889
5V
Engine-ECU
Wire colour code

AK400916 AB

• A power voltage of 5 V is applied to the clutch oil
Check Condition
pressure sensor power terminal (terminal No. 3)
from the engine-ECU (terminal No. 97) and
• Engine speed of 50 r/min or more.
earthed to the engine-ECU (terminal No. 96) from
the clutch oil pressure sensor (terminal No. 2) Judgment Criterion
• The sensor signal is inputted to the engine-ECU • The misjudgment for the clutch connecting/dis-
(terminal No. 101) from the clutch position sensor connecting is not detected at all.
PROBABLE CAUSE
FUNCTION • Failed clutch oil pressure sensor
• The clutch oil pressure sensor converts the clutch • Open/short circuit in clutch oil pressure sensor
position into a voltage signal and inputs the signal circuit or loose connector contact
to the engine-ECU. • Failed engine-ECU
• In response to the signal, the engine-ECU cor-
rects the fuel injection amount, etc.
TROUBLESHOOTING

STEP 1. Connector check: B-124 clutch oil Connector: C-142
pressure sensor connector.
Connector : B-124
B-124(B)
C-142(GR)
1 2 3

104 103102 101100 99 98 97 96
connector AK400954 AB 112111110 109108107 106105
120119118 117116115 114113

• Ignition switch: ON.
STEP 2. Perform voltage measurement at B-124 • Voltage between terminal No. 97 and earth.
clutch oil pressure sensor connector. OK: 4.9 − 5.1 V
Connector : B-124
1 2 3
Harness side
• Disconnect and measure at harness side.

• Ignition switch: ON.
OK: 4.9 − 5.1 V
NO : Go to Step 3 .
TROUBLESHOOTING
13B-199
connector connector
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB

B-124(B) NO : Repair or replace.
1 2 3
Harness side

(terminal No. 3) clutch oil pressure sensor
TROUBLESHOOTING
No. 3) clutch oil pressure sensor connector and B-124 clutch oil pressure sensor connector.
C-142 (terminal No. 97) engine-ECU connector. Connector : B-124
Connector : B-124
B-124(B)
B-124(B)
1 2 3
1 2 3
Harness side
Connector: C-142
NO : Go to Step 9 .

connector
959493 92 91 Connector: C-142
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

YES : Go to Step 7 . C-142(GR)
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
STEP 7. Check the trouble symptoms. 112111110 109108107 106105
120119118 117116115 114113
Q: Does trouble symptom persist? Harness side connector
NO : Intermittent malfunction (Refer to GROUP AK400935 AB

P.00-6). NO : Repair or replace.
TROUBLESHOOTING
13B-201
No. 2) clutch oil pressure sensor connector and clutch oil pressure sensor connector.
C-142 (terminal No. 96) engine-ECU connector. Connector : B-124
Connector : B-124
B-124(B)
B-124(B)
1 2 3
1 2 3
Harness side
nect connector and measure at pick-up harness.
Connector: C-142
OK: 4.9 − 5.1 V
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.
TROUBLESHOOTING
connector. clutch oil pressure sensor connector.
B-124(B)
1 2 3
C-142(GR)
Harness side
959493 92 91
104 103102 101100 99 98 97 96
112111110
120119118
109108107
117116115
106105
114113
AK400935 AB
OK:
Connector : B-124 Release the clutch pedal: 1.3 V or less
Depress the clutch pedal: 1.9 V or more
B-124(B) Q: Is the check result normal?
1 2 3 STEP 14. Connector check: C-142 engine-ECU

Connector: C-142

YES : • Check and repair harness between
B-124 (terminal No. 3) clutch oil
(terminal No. 97) engine-ECU
connector.
• Check power supply line for damage. C-142(GR)
NO : Repair or replace
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
13B-203
No. 2) clutch oil pressure sensor connector and engine-ECU connector.
Connector: C-142
Connector : B-124
B-124(B)
1 2 3 C-142(GR)
Harness side
connector AK400954 AB 959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
Connector: C-142 120119118 117116115 114113

AK400935 AB
• Measure engine-ECU.
C-142(GR)
OK:
Release the clutch pedal: 1.3 V or less
Depress the clutch pedal: 1.9 V or more
959493 92 91
104 103102 101100 99 98 97 96 Q: Is the check result normal?
112111110
120119118
109108107
117116115
106105
114113
AK400935 AB

YES : Replace clutch oil pressure sensor
NO : Repair.
TROUBLESHOOTING
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB

B-124(B) NO : Repair or replace
1 2 3
Harness side

YES : • Check and repair harness between
B-124 (terminal No. 2) clutch oil
(terminal No. 84) engine-ECU
connector.
damage.
NO : Repair or replace
TROUBLESHOOTING
13B-205
Code No. P1603: Battery Back-up Line System
Battery
Relay box 9
20A
W-B
A-14
5
W-B
58
C-140
(MU803803)
3132 33 34 Battery Engine-ECU
35363738394041 42 43 backup
444546474849 50 51
5253 545556 57 58
Wire colour code

AK400821AB

• Power is directly supplied to the engine-ECU (ter-
Check Condition
minal No. 58) from the battery.
• The engine-ECU is check the open circuit of bat- • The battery back-up line voltage 6 V or less.
tery back-up line.
PROBABLE CAUSE
• Open/short circuit in battery back-up line circuit or
TROUBLESHOOTING

connector
STEP 1. M.U.T.-II/III diagnosis code Connector: C-140
Q: Is the diagnosis code P1603 set?
00 − How to use Troubleshooting/Inspection C-140(GR)
34 33 32 31
STEP 2. Perform voltage measurement at C-140 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
engine-ECU connector. 58 57 5655 54 5352
Connector: C-140
AK400934 AB

C-140(GR) STEP 4. Check the trouble symptoms.

34 33 32 31 NO : Intermittent malfunction (Refer to GROUP
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 00 − How to Use
58 57 5655 54 5352
Harness side connector Troubleshooting/Inspection Service Points
P.00-6).
AK400934 AB

side.
OK: System voltage
open/short circuit.
TROUBLESHOOTING
13B-207
DTC P2100: Throttle Valve Control Servo Circuit (open)
Throttle valve control servo circuit
B-06 Electronically
controlled
6 5
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
125126127128129 130 131 132 133
134135 136137 138 139 140 141
GND GND 142143 144 145 146
145 144 Engine-ECU
Wire colour code

AK304136 AC
OPERATION FUNCTION
• Controls the current that is applied from the • Engine-ECU varies the direction and the amper-
engine-ECU (terminals No. 133, No. 141) to the age of the current that is applied to the throttle
electronically controlled throttle valve (terminals valve control servo in order to control the opening
No. 5, No. 6). of the throttle valve.
TROUBLESHOOTING
TROUBLE JUDGMENT STEP 3. Connector check: C-138 engine-ECU

Check Condition connector
• Battery positive voltage is 8.3 V or higher. Connector: C-138
Judgement Criteria
• Throttle actuator control motor current is 0.1 A or
less for 0.72 second.
PROBABLE CAUSE
• Failed throttle valve control servo.
• Open/short circuit in throttle valve control servo C-138(GR)
circuit or lose connector contact.
124 123 122121
133 132 131 130 129128127126125
DIAGNOSIS PROCEDURE 141

146
140 139 138 137136 135134
145 144 143142
STEP 1. Connector check: B-06 electronically AK400953 AB
controlled throttle valve connector

Connector : B-06 YES : Go to Step 4 .
STEP 4. Perform resistance measurement at

C-138 engine-ECU connector.
Connector: C-138
6 5 4 3 2 1 B-06(B)

C-138(GR)
STEP 2. Perform resistance measurement at B-06

electronically controlled throttle valve connector. 124 123 122121
133 132 131 130 129128127126125
141 140 139 138 137136 135134
Connector : B-06 146 145 144 143142

AK400953 AB

side.
or terminal No. 145 and earth.
6 5 4 3 2 1 B-06(B) OK: Continuity (2 Ω or less)
• Disconnect connector, and measure at electroni- YES : Go to Step 5 .
cally controlled throttle valve side. NO : Check harness between C-138 (terminal
• Resistance between terminal No. 5 and No. 6. No. 144 or No. 145) engine-ECU and earth.
OK: 0.3 − 80 kΩ (at 20°C)
TROUBLESHOOTING
13B-209
6 5 4 3 2 1 B-06(B) 6 5 4 3 2 1 B-06(B)
C-138(GR) C-138(GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142

AK400953 AB AK400953 AB

00 − How to Use
P.00-6).
TROUBLESHOOTING
DTC P2101: Throttle Valve Control Servo Magneto Malfunction
B-06 Electronically
controlled
6 5
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
Engine-ECU
125126127128129 130 131 132 133
134135 136137 138 139 140 141
142143 144 145 146
Wire colour code

AK304137AE

• Controls the current that is applied from the
Check Condition
engine-ECU (terminals No. 133, No. 141) to the
electronically controlled throttle valve (terminals
No. 5, No. 6). Judgement Criteria
• The coil temperature of the throttle actuator con-
FUNCTION trol motor is 180°C or higher for 0.8 second.
• Engine-ECU check whether the throttle valve
control servo magneto failed. PROBABLE CAUSE
TROUBLESHOOTING
13B-211
connector
STEP 1. Connector check: B-06 electronically Connector: C-138
Connector : B-06
C-138(GR)
6 5 4 3 2 1 B-06(B) 124 123 122121

133 132 131 130 129128127126125
Harness side connector AK400937AB 141 140 139 138 137136 135134
146 145 144 143142

STEP 2. Perform resistance measurement at B-06 NO : Repair or replace.
Connector : B-06
6 5 4 3 2 1 B-06(B)
• Disconnect connector, and measure at electroni-

cally controlled throttle valve side.
OK: 0.3 − 80 kΩ (at 20 °C)
TROUBLESHOOTING
6 5 4 3 2 1 B-06(B) 6 5 4 3 2 1 B-06(B)
C-138(GR) C-138(GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142

AK400953 AB AK400953 AB

00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-213
DTC P2102: Throttle Valve Control Servo Circuit (Shorted Low)
B-06 Electronically
controlled
6 5
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
Engine-ECU
125126127128129 130 131 132 133
134135 136137 138 139 140 141
142143 144 145 146
Wire colour code

AK304137AE

Check Condition
• Throttle valve control servo current is 12 A or
FUNCTION higher for 0.8 second.
• Engine-ECU varies the direction and the amper-
age of the current that is applied to the throttle PROBABLE CAUSE
valve control servo in order to control the opening • Failed throttle valve control servo.
of the throttle valve. • Short circuit in throttle valve control servo circuit
or lose connector contact.
TROUBLESHOOTING

connector
Connector : B-06
C-138(GR)
6 5 4 3 2 1 B-06(B) 124 123 122121

133 132 131 130 129128127126125
146 145 144 143142

Connector : B-06
6 5 4 3 2 1 B-06(B)

OK: 0.3 − 80 Ω (at 20 °C)
TROUBLESHOOTING
13B-215
6 5 4 3 2 1 B-06(B) 6 5 4 3 2 1 B-06(B)
C-138(GR) C-138(GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142

AK400953 AB AK400953 AB
• Check output line for short circuit. • Check output line for short circuit.

00 − How to Use
P.00-6).
TROUBLESHOOTING
DTC P2103: Throttle Valve Control Servo Circuit (Shorted High)
B-06 Electronically
controlled
6 5
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
Engine-ECU
125126127128129 130 131 132 133
134135 136137 138 139 140 141
142143 144 145 146
Wire colour code

AK304137AE

Check Condition
• Throttle actuator control motor current is 8 A or
• Engine-ECU varies the direction and the amper-
age of the current that is applied to the throttle PROBABLE CAUSE
valve control servo in order to control the opening • Failed throttle valve control servo.
of the throttle valve. • Short circuit in throttle valve control servo circuit
or loose connector contact.
TROUBLESHOOTING
13B-217
connector
Connector : B-06
C-138(GR)
6 5 4 3 2 1 B-06(B) 124 123 122121

133 132 131 130 129128127126125
146 145 144 143142

Connector : B-06
6 5 4 3 2 1 B-06(B)

OK: 0.3 − 80 Ω (at 20°C)
NO : Replace the throttle body assembly.
TROUBLESHOOTING
6 5 4 3 2 1 B-06(B) 6 5 4 3 2 1 B-06(B)
C-138(GR) C-138(GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142

AK400953 AB AK400953 AB

00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-219
Code No. P2121: Accelerator Pedal Position Sensor (main) Circuit Range/Performance Problem
OPERATION STEP 2. Check accelerator pedal position sensor

• Refer to P2122 accelerator pedal position sensor itself.
(main) circuit P.13B-222. • Check accelerator pedal position sensor itself
• Refer to inspection procedure 31 accelerator (Refer to P.13C-431).
pedal position switch circuit P.13B-362.
FUNCTION YES : Go to Step 3 .
NO : Replace accelerator pedal position sensor.
• Engine-ECU checks the accelerator pedal posi-
tion sensor (main) output signal characteristics
for abnormal conditions. STEP 3. Perform resistance measurement at
B-116 accelerator pedal position sensor
TROUBLE JUDGMENT connector.
Check Condition Connector : B-116
• Ignition switch is in "ON" position
• Closed throttle position switch: ON B-116(GR)
• Accelerator pedal position sensor (sub) output
voltage is 1.88 V or less.
Judgment Criteria
• Accelerator pedal position sensor (main) output
voltage is 1.88 V or higher for 1 second. 8 7 6 5 4 3 2 1
PROBABLE CAUSE
• Failed accelerator pedal position sensor
side.
• Open/short circuit in accelerator pedal position
• Failed accelerator pedal position switch OK: Continuity (2 Ω or less)
• Open/short circuit in accelerator pedal position Q: Is the check result normal?
switch circuit or loose connector contact YES : Go to Step 7 .
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-116 accelerator

pedal position sensor connector
Connector : B-116
B-116(GR)
8 7 6 5 4 3 2 1

TROUBLESHOOTING
connector No. 1) accelerator pedal position sensor
Connector: C-142
Connector : B-116
B-116(GR)
C-142(GR)
959493 92 91 8 7 6 5 4 3 2 1
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.

00 − How to Use Trouble
shooting/Inspection Service Points P.00-6).
STEP 7. Check accelerator pedal position switch

itself.
• Check accelerator pedal position switch itself
TROUBLESHOOTING
13B-221
Connector: C-140
Connector : B-116
B-116(GR)
C-140(GR)
8 7 6 5 4 3 2 1
34 33 32 31
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

NO : Repair.
TROUBLESHOOTING
Code No. P2122: Accelerator Pedal Position Sensor (main) Circuit Low Input
Accelerator pedal position sensor (main) circuit
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(main)
2 3 1
L-W GR BR-W
92 114 91
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU
Wire colour code

AK304133 AD
OPERATION FUNCTION
• A power voltage of 5 V is applied to the accelera- • The accelerator pedal position sensor (main) out-
tor pedal position sensor (terminal No. 2) from the puts voltage which corresponds to the accelera-
engine-ECU (terminal No. 92). tor pedal depression.
• The power voltage is earthed to the engine-ECU • The engine-ECU checks whether the voltage is
(terminal No. 91) from the accelerator pedal posi- within a specified range.
tion sensor (terminal No. 1).
• The sensor signal is inputted to the engine-ECU TROUBLE JUDGMENT
(terminal No. 114) from the accelerator pedal
Check Condition
position sensor output terminal (terminal No. 3).
Judgment Criteria
voltage is 0.2 volt or less for 0.3 second.
TROUBLESHOOTING
13B-223
• Failed accelerator pedal position sensor accelerator pedal position sensor connector.
Connector : B-116
B-116(GR)
DIAGNOSIS PROCEDURE

8 7 6 5 4 3 2 1
a. Item 78: Accelerator pedal position sensor Harness side connector
(main) AK400955 AB

00 − How to Use • Ignition switch: ON
Troubleshooting/Inspection Service Points • Voltage between terminal No. 2 and earth.
P.00-6). OK: 4.9 − 5.1 V
STEP 2. Connector check: B-116 accelerator NO : Go to Step 5 .
Connector : B-116 STEP 5. Connector check: C-142 engine-ECU
connector
B-116(GR) Connector: C-142
8 7 6 5 4 3 2 1
C-142(GR)
959493 92 91
NO : Repair or replace. 104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
STEP 3. Check accelerator pedal position sensor Harness side connector

itself. AK400935 AB
• Check accelerator pedal position sensor itself
(Refer to P.13C-431). Q: Is the check result normal?
TROUBLESHOOTING
No. 2) accelerator pedal position sensor • Refer to Data List Reference Table P.13B-368.
connector and C-142 (terminal No. 92) a. Item 78: Accelerator pedal position sensor
engine-ECU connector. (main)
B-116(GR) 00 − How to Use
P.00-6).

Connector: C-142
Connector: C-142
C-142(GR)
C-142(GR)
959493 92 91
959493 92 91 104 103102 101100 99 98 97 96
104 103102 101100 99 98 97 96 112111110 109108107 106105
112111110 109108107 106105 120119118 117116115 114113
120119118 117116115 114113
AK400935 AB
AK400935 AB

NO : Repair.
TROUBLESHOOTING
13B-225
No. 2) accelerator pedal position sensor No. 3) accelerator pedal position sensor
B-116(GR) B-116(GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB
• Check power supply line for damage. • Check earthing line for damage.
TROUBLESHOOTING
Code No. P2123: Accelerator Pedal Position Sensor (main) Circuit High Input
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(main)
2 3 1
L-W GR BR-W
92 114 91
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU
Wire colour code

AK304133 AD
OPERATION FUNCTION
Check Condition
voltage is 0.2 − 2.5 V.
TROUBLESHOOTING
13B-227
Judgment Criteria STEP 3. Check accelerator pedal position sensor
• Accelerator pedal position sensor (main) output itself.
voltage is 4.5 V or higher for is 1 second. • Check accelerator pedal position sensor itself
(Refer to P.13C-431).
PROBABLE CAUSE
• Failed accelerator pedal position sensor Q: Is the check result normal?
• Open/short circuit in accelerator pedal position YES : Go to Step 4 .
sensor circuit or loose connector contact NO : Replace accelerator pedal position sensor.
DIAGNOSIS PROCEDURE B-116 accelerator pedal position sensor
connector.
a. Item 78: Accelerator pedal position sensor B-116(GR)
(main)
00 − How to Use
Troubleshooting/Inspection Service Points 8 7 6 5 4 3 2 1
P.00-6). Harness side connector AK400955 AB
NO : Go to Step 2 .
side.
STEP 2. Connector check: B-116 accelerator • Resistance between terminal No. 1 and earth.
pedal position sensor connector OK: Continuity (2 Ω or less)
Connector : B-116
B-116(GR) NO : Go to Step 6 .

a. Item 78: Accelerator pedal position sensor
8 7 6 5 4 3 2 1 (main)
NO : Repair or replace. Troubleshooting/Inspection Service Points
P.00-6).
TROUBLESHOOTING
Connector: C-142
Connector : B-116
B-116(GR)
C-142(GR)
959493 92 91 8 7 6 5 4 3 2 1
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.
TROUBLESHOOTING
13B-229
Code No. P2126: Accelerator Pedal Position Sensor (sub) Circuit Range/Performance Problem
OPERATION STEP 2. Check accelerator pedal position sensor

• Refer to Code No. P2127 Accelerator Pedal Cir- itself.
cuit Position Sensor (sub) Circuit P.13B-232. • Check accelerator pedal position sensor itself
• Refer to Inspection Procedure 31: Accelerator (Refer to P.13C-431).
Pedal Position Switch Circuit P.13B-362.
tion sensor (sub) output signal characteristics for
abnormal conditions. STEP 3. Perform resistance measurement at
TROUBLE JUDGMENT connector.
Check Condition Connector : B-116
• Closed throttle position switch: ON B-116(GR)
• Accelerator pedal position sensor (main) failure is
detected.
Judgment Criteria
voltage is 2.5 V or higher for 1 second. 8 7 6 5 4 3 2 1
PROBABLE CAUSE
side.
• Failed accelerator pedal position switch OK: Continuity (2 Ω or less)
• Open/short circuit in accelerator pedal position Q: Is the check result normal?
switch circuit or loose connector contact YES : Go to Step 7 .
DIAGNOSIS PROCEDURE

Connector : B-116
B-116(GR)
8 7 6 5 4 3 2 1

TROUBLESHOOTING
Connector: C-142
Connector : B-116
B-116(GR)
C-142(GR)
959493 92 91 8 7 6 5 4 3 2 1
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.

STEP 7. Check accelerator pedal position switch

itself.
TROUBLESHOOTING
13B-231
Connector: C-140
Connector : B-116
B-116(GR)
C-140(GR)
8 7 6 5 4 3 2 1
34 33 32 31
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

NO : Repair.
TROUBLESHOOTING
Code No. P2127: Accelerator Pedal Position Sensor (sub) Circuit Low Input
Accelerator pedal position sensor (sub) circuit
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(sub)
8 6 7
Y-R L B
97 107 96
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU
Wire colour code

AK304133 AE
OPERATION FUNCTION
• A power voltage of 5 V is applied to the accelera- • The accelerator pedal position sensor (sub) out-
Check Condition
Judgment Criteria
voltage is 0.2 volt or less for 1 second.
TROUBLESHOOTING
13B-233
Connector : B-116
B-116(GR)
DIAGNOSIS PROCEDURE

8 7 6 5 4 3 2 1
a. Item 77: Accelerator pedal position sensor Harness side connector
(sub) AK400955 AB

P.00-6). OK: 4.9 − 5.1 V
STEP 2. Connector check: B-116 accelerator NO : Go to Step 5 .
Connector : B-116 STEP 5. Connector check: C-142 engine-ECU
connector
8 7 6 5 4 3 2 1
C-142(GR)
959493 92 91
NO : Repair or replace. 104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
STEP 3. Check accelerator pedal position sensor Harness side connector

itself. AK400935 AB
(Refer to P.13C-431). Q: Is the check result normal?
TROUBLESHOOTING
No. 8) accelerator pedal position sensor • Refer to Data List Reference Table P.13B-368.
engine-ECU connector. (sub)
B-116(GR) 00 − How to Use
P.00-6).

Connector: C-142
Connector: C-142
C-142(GR)
C-142(GR)
959493 92 91
959493 92 91 104 103102 101100 99 98 97 96
104 103102 101100 99 98 97 96 112111110 109108107 106105
112111110 109108107 106105 120119118 117116115 114113
120119118 117116115 114113
AK400935 AB
AK400935 AB
• Check power supply line for open/short circuit. Q: Is the check result normal?
NO : Repair.
TROUBLESHOOTING
13B-235
B-116(GR) B-116(GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB
TROUBLESHOOTING
Code No. P2128: Accelerator Pedal Position Sensor (sub) Circuit High Input
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(sub)
8 6 7
Y-R L B
97 107 96
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU
Wire colour code

AK304133 AE
OPERATION • The engine-ECU checks whether the voltage is

• A power voltage of 5 V is applied to the accelera- within a specified range.
tor pedal position sensor (terminal No. 8) from the
engine-ECU (terminal No. 97). TROUBLE JUDGMENT
• The power voltage is earthed to the engine-ECU Check Condition
(terminal No. 96) from the accelerator pedal posi- • Ignition switch is in "ON" position.
tion sensor (terminal No. 7). • Accelerator pedal position sensor (main) output
• The sensor signal is inputted to the engine-ECU voltage is 0.2 − 2.5 V.
position sensor output terminal (terminal No. 6). Judgment Criteria
FUNCTION voltage is 4.5 V or higher for 1 second.
• The accelerator pedal position sensor (sub) out-
puts voltage which corresponds to the accelera-
tor pedal depression.
TROUBLESHOOTING
13B-237
PROBABLE CAUSE STEP 3. Check accelerator pedal position sensor
• Failed accelerator pedal position sensor itself.
• Open/short circuit in accelerator pedal position • Check accelerator pedal position sensor itself
sensor circuit or loose connector contact (Refer to P.13C-431).
DIAGNOSIS PROCEDURE NO : Replace accelerator pedal position sensor.
STEP 1. M.U.T.-II/III data list STEP 4. Perform resistance measurement at

• Refer to Data List Reference Table P.13B-368. B-116 accelerator pedal position sensor
a. Item 77: Accelerator pedal position sensor connector.
(sub)
Connector : B-116
B-116(GR)
00 − How to Use
P.00-6).
NO : Go to Step 2 .
8 7 6 5 4 3 2 1
STEP 2. Connector check: B-116 accelerator Harness side connector AK400955 AB
Connector : B-116
side.
B-116(GR)
NO : Go to Step 6 .
8 7 6 5 4 3 2 1
Q: Is the check result normal? a. Item 77: Accelerator pedal position sensor
YES : Go to Step 3 . (sub)
00 − How to Use
P.00-6).
TROUBLESHOOTING
Connector: C-142
Connector : B-116
B-116(GR)
C-142(GR)
959493 92 91 8 7 6 5 4 3 2 1
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.
TROUBLESHOOTING
13B-239
Code No. P2135: Throttle Position Sensor (main and sub) Range/Performance Problem

• Refer to Code No. P0122: Throttle Position Sen-
sor (main) Circuit Low Input P.13B-61. STEP 1. Connector check: C-142 engine-ECU
• Refer to Code No. P0222: Throttle Position Sen- connector and B-06 electronically controlled
sor (sub) Circuit Low Input P.13B-116. throttle valve connector
FUNCTION Connector: C-142
• engine-ECU checks the throttle position sensor
output signal characteristics for abnormal condi-
tions.
TROUBLE JUDGMENT
Check Condition
C-142(GR)
0.35 − 2.5 V. 959493 92 91
• Throttle position sensor (sub) output voltage is 104 103102 101100 99 98 97 96
112111110 109108107 106105
2.25 − 4.8 V 120119118 117116115 114113

Judgment Criteria
• Using the formula given below, the voltage of 0.3 AK400935 AB
V or higher is obtained for 0.5 second: V* − V** − Connector : B-06

2V
V*: throttle position sensor (main) output voltage
V**: throttle position sensor (sub) output voltage.
PROBABLE CAUSE
• Failed throttle position sensor
cuit or loose connector contact 6 5 4 3 2 1 B-06(B)

TROUBLESHOOTING
6 5 4 3 2 1 B-06(B) 6 5 4 3 2 1 B-06(B)
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB
STEP 4. Replace throttle body assembly.

• After throttle body assembly is replaced, re-check
for trouble symptom.
Q: Does trouble system persist?
NO : Check end.
TROUBLESHOOTING
13B-241
Code No. P2138: Accelerator Pedal Position Sensor (main and sub) Range/Performance Problem

• Refer to Code No. P2122: Accelerator Pedal
Position Sensor (main) Circuit Low Input STEP 1. Connector check: B-116 accelerator
P.13B-222. pedal position connector
Connector : B-116
Position Sensor (sub) Circuit Low Input
P.13B-232.
B-116(GR)
FUNCTION
tion sensor output signal characteristics for
abnormal conditions.
8 7 6 5 4 3 2 1
TROUBLE JUDGMENT Harness side connector AK400955 AB
Check Condition
• Ignition switch is in "ON" position Q: Is the check result normal?
voltage is 0.2 − 4.5 V. STEP 2. Check accelerator pedal position sensor
itself.
Judgment Criteria
voltage minus Accelerator pedal position sensor
(main) output voltage is 1 volt or higher for 1 sec- Q: Is the check result normal?
ond. YES : Go to Step 3 .
• Accelerator pedal position sensor (main) output NO : Replace accelerator pedal position sensor.
(sub) output voltage is 1 volt or higher for 0.2 sec- STEP 3. Perform resistance measurement at
onds. B-116 accelerator pedal position sensor
connector.
PROBABLE CAUSE
Connector : B-116
sensor circuit or loose connector contact B-116(GR)
8 7 6 5 4 3 2 1

side.
NO : Go to Step 4 .
TROUBLESHOOTING
Connector: C-142
Connector : B-116
B-116(GR)
C-142(GR)
959493 92 91 8 7 6 5 4 3 2 1
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.
STEP 6. Check the trouble symptoms

00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-243
B-116 accelerator pedal position sensor No. 7) accelerator pedal position sensor
connector. connector and C-142 (terminal No. 96)
Connector : B-116 engine-ECU connector.
Connector : B-116
B-116(GR)
B-116(GR)
8 7 6 5 4 3 2 1
Harness side connector AK400955 AB 8 7 6 5 4 3 2 1
side.
Connector: C-142
NO : Go to Step 8 .
STEP 8. Connector check: C-142 engine-ECU C-142(GR)

connector
Connector: C-142 959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
Connector: C-142
Connector : B-116
B-116(GR)
C-142(GR)
959493 92 91 8 7 6 5 4 3 2 1
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.
TROUBLESHOOTING
13B-245
B-116(GR) B-116(GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB
• Check power supply line for damage. • Check output line for damage.
TROUBLESHOOTING

No. 6) accelerator pedal position sensor
Connector : B-116
B-116(GR)
8 7 6 5 4 3 2 1
Connector: C-142
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

NO : Repair.
TROUBLESHOOTING
13B-247
DTC P2173: Abnormal Intake Air Amount
FUNCTION DIAGNOSIS
• Engine-ECU decides the allowable intake air
amount in accordance with the engine speed and STEP 1. M.U.T.-II/III diagnosis code
the target opening angle of throttle valve.
• Engine-ECU checks whether the actual intake air Q: Diagnosis code set?
amount is more than the allowable intake air YES : Inspection chart for diagnosis code (Refer
amount. to P.13B-20).
NO : Go to Step 2 .
TROUBLE JUDGMENT
Check Conditions STEP 2. Replace the air flow sensor.
• While engine is running. • After replacing the air flow sensor, re-check the
trouble symptoms.
Judgment Criteria
• The actual intake air amount is more than the
allowable in take air amount for 1.5 seconds.
NO : Check end.
TROUBLESHOOTING HINTS (The most
likely causes for this code to be set are:) STEP 3. Replace the throttle body assembly.
• Failed air flow sensor. • After replacing the throttle body assembly,
• Throttle valve faulty operation. re-check the trouble symptoms.
• Failed throttle position sensor Q: Is the check result normal?
• Failed engine-ECU YES : Replacing engine-ECU.
NO : Check end.
TROUBLESHOOTING

M1131151501224

procedure
No.
with M.U.T.-II/III is Communication with engine-ECU only is not possible 2
impossible
lamp is turned to the "ON" position
Starting Starting impossible The starter is impossible to operate. 5
(starter inoperative)
satisfied.
decelerating
TROUBLESHOOTING
13B-249
procedure
No.
Driving Hesitation, sag The response of vehicle speed 12
speed.
position.
TROUBLESHOOTING

procedure
No.
procedure No. page
1 Communication with all system is not possible P.13B-252
2 Communication with engine-ECU only is not possible P.13B-255
3 The engine warning lamp does not illuminate right after the ignition switch is P.13B-257
turned "ON" position
4 The engine warning lamp remains illuminating and never goes out P.13B-263
5 Starting impossible (No initial combustion) P.13B-266
6 Starting impossible (Starter operative but no initial combustion) P.13B-271
7 Starting impossible (Initial combustion but no complete combustion) P.13B-273
8 Unstable idling (Rough idling, hunting) P.13B-276
9 The engine stalls when starting the car (pass out) P.13B-283
10 The engine stalls when decelerating P.13B-285
11 Engine does not revolve up P.13B-287
12 Hesitation, sag P.13B-289
Poor acceleration
Stumble
Surge
13 The feeling of impact or vibration when accelerating P.13B-291
14 The feeling of impact or vibration when decelerating P.13B-293
15 Knocking P.13B-293
16 Ignition timing offset P.13B-294
17 Run on (Dieseling) P.13B-296
18 Odor, white smoke, black smoke, high-concentration CO/HC during idling P.13B-296
19 Battery rundown P.13B-298
20 Overheating P.13B-303
TROUBLESHOOTING
13B-251
procedure No. page
21 Abnormal rotation of fan motor P.13B-304
22 Poor A/C performance P.13B-307
23 Engine-ECU power supply, engine control relay, ignition switch-IG1 system P.13B-308
24 Fuel pump system P.13B-316
25 Fan control relay system P.13B-325
26 A/C switch system P.13B-331
27 A/C compressor relay system P.13B-335
28 A/C load signal system P.13B-342
29 A/C pressure sensor system P.13B-346
30 Ignition circuit system P.13B-355
31 Accelerator pedal position switch circuit system P.13B-362
TROUBLESHOOTING

SYMPTOMS
Inspection Procedure 1: Communication with All System is not Possible
Fusible link (1)
C-116
15
R
C-204
1
15 J/B
15A
12
C-205
W-B
C-24 16
9 10 1112 13 14 1516
4 5
B B
Wire colour code

AK300300 AD
OPERATION COMMENTS ON TROUBLE SYMPTOM

PROBABLE CAUSE
• Failed diagnosis connector
• Open/short circuit in diagnosis connector circuit.
• Failed M.U.T.-II/III
TROUBLESHOOTING
13B-253
STEP 1: Connector check: C-24 diagnosis Connector: C-24
connector
Connector: C-24
C-24 (B)
1 2 3 4 5 6 7 8
C-24 (B) 9 10 1112 13 14 1516

9 10 1112 13 14 1516 • Disconnect connector, and measure at the har-
Harness side connector AK400956 AB ness side.
YES : Go to Step 2 . OK: System voltage
NO : Check intermediate connectors C-116, C-204
STEP 2: Perform resistance measurement at C-24
diagnosis connector. and C-205, and repair if necessary. If
Connector: C-24 harness between C-24 (terminal No. 16)
diagnosis connector and battery.
open/short circuit.
C-24 (B) STEP 4: Replace M.U.T.-II/III.

1 2 3 4 5 6 7 8
• After replacing the M.U.T.-II/III, re-check the trou-
9 10 1112 13 14 1516 ble symptoms.
Harness side connector AK400956 AB Q: Does trouble symptom persist?
NO : Check end.
side.
body earth, also between C-24 (terminal No.
and damage.
TROUBLESHOOTING

Connector: C-24
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516

necessary.
NO : Repair.
TROUBLESHOOTING
13B-255
Inspection Procedure 2: Communication with Engine-ECU Only is Not Possible.
Diagnosis connector circuit
C-141
(MU803804)
6162 6364 Engine-ECU
656667686970717273
747576777879808182
8384 858687 8889
74
O-W
C-105
5
O-L C-04
37
Control 31 32 33 34 35 36 37 38 39 40 41
Combination mater 42 43 44 45 46 47 48 49 50 51 52
circuit
G G
36
O-W
32
J/C (3)
C-02
29
O-L
C-24 7
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
Wire colour code

AK400822 AB

• There is data communication between diagnosis
connector output terminal (terminal No. 7) and STEP 1: Check engine warning lamp.
engine-ECU (terminal No. 74). • Ignition switch: OFF → ON
COMMENT ON TROUBLE SYMPTOM Q: Is lamp illuminating for few seconds?
• Failure is possibly caused by failed power supply YES : Go to Step 2 .
circuit or failed earthing circuit of engine-ECU. NO : Check engine-ECU power supply, engine
PROBABLE CAUSE (Refer to Inspection Procedure 24
• Open/short circuit in engine-ECU power circuit P.13C-339).
• Between engine-ECU and diagnosis connector
for short circuit
• Failed combination meter
TROUBLESHOOTING
STEP 2: Connector check: C-141 engine-ECU STEP 3: Check harness between C-24 (terminal
connector No. 7) diagnosis connector and C-141 (terminal
Connector: C-141
Connector: C-24
C-141(GR) C-24 (B)

1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
6463 62 61 Harness side connector AK400956 AB
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483 Connector: C-141
AK400933 AB

C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

necessary.
and damage.
NO : Repair.
STEP 4: Replace the combination meter

• After replacing the combination meter, re-check
NO : Check end.

00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-257
Inspection Procedure 3: The Engine Warning Lamp Does not Illuminate Right after the Ignition Switch
is Turned The "ON" Position
Ignition switch
C-303
R LOCK
1 2 3
4 5 6 ST ACC
IG1 IG2
L-B
C-203
6
2 J/B
7.5A
25
C-205
C-04
B-W
42 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G G

1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122 14
G G
R-W
7
C-105
R-W
7
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20 Engine-ECU
21 22 232425 2627
Wire colour code

AK400823 AB
TROUBLESHOOTING
OPERATION STEP 3: Connector check: C-04 combination

• Battery voltage is applied to engine warning lamp meter connector
of combination meter connector (terminal No. 42)
Connector: C-04
from ignition switch.
• Engine-ECU (terminal No. 7) makes power tran- C-04
sistor in unit be in "ON" position, and that makes
currents go on engine warning lamp of combina-
tion meter connector (terminal No. 14).
COMMENTS ON TROUBLE SYMPTOM

• Engine-ECU turns on engine warning lamp for 5
seconds to check for burnt-out bulb immediately
after ignition switch is turned to ON.
• If engine warning lamp is not lit just after turning
ignition switch to "ON" position, failure is possibly 41 40 39 38 37 36 35 34 33 32 31
caused by burn-out bulb, open/short circuit or 52 51 50 49 48 47 46 45 44 43 42
other faults. G G

PROBABLE CAUSE AK400957AB
• Failed ignition switch Q: Is the check result normal?
• Open/short circuit in engine warning lamp circuit YES : Go to Step 4 .
for or loose connector contact NO : Repair or replace.
DIAGNOSIS PROCEDURE combination meter connector.
Connector: C-04
STEP 1: Check engine start-up.
C-04
Q: Is engine started?
NO : Check engine-ECU power supply, engine
(Refer to Inspection Procedure 23
P.13B-308).
STEP 2: Check engine warning lamp for

burnt-out bulb.
41 40 39 38 37 36 35 34 33 32 31
Q: Is the check result normal? 52 51 50 49 48 47 46 45 44 43 42
NO : Replace engine warning lamp. G G

AK400957AB

ness side.
OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
13B-259
STEP 5: Connector check: C-303 ignition switch STEP 6: Connector check: C-139 engine-ECU
connector connector
C-303
3 2 1
6 5 4
C-139(GR)
Harness side
connector
AK400958 AB
4 3 2 1
13 12 1110 9 8 7 6 5
Connector: C-04 2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB


41 40 39 38 37 36 35 34 33 32 31 Connector: C-139
52 51 50 49 48 47 46 45 44 43 42
G G

AK400957AB

YES : Check intermediate connectors C-203 and C-139(GR)
and repair harness between C-04 (terminal 4 3 2 1
13 12 1110 9 8 7 6 5
No. 42) combination meter connector and 2019 18 17 16 15 14
2726 2524 23 22 21
connector.
• Check power supply line for AK400931 AB
open/short circuit. • Disconnect connector, and measure at the har-

NO : Repair or replace. ness side.
OK: System voltage
NO : Go to Step 8 .
TROUBLESHOOTING
STEP 8: Check connector: C-05 combination STEP 9: Connector check: C-303 ignition switch
meter connector connector
C-05 (L)
C-303
3 2 1
6 5 4
Harness side
connector
AK400958 AB

11 10 9 8 7 6 5 4 3 2 1 YES : Go to Step 10 .
22 2120 19 18 17 16 15 14 1312
G G

AK400959 AB
Connector: C-139
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

circuit.
TROUBLESHOOTING
13B-261
STEP 10: Check harness between C-04 (terminal STEP 11: Connector check: C-05 combination
No. 42) combination meter connector and C-303 meter connector
(terminal No. 2) ignition switch connector. Connector: C-05
Connector: C-04
C-05 (L)
C-04
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G G
AK400957AB
C-303
3 2 1
6 5 4
Harness side
connector
AK400958 AB

sary.
NO : Repair.
TROUBLESHOOTING
STEP 12: Check harness between C-05 (terminal STEP 13: Check the trouble symptoms.
No. 14) combination meter connector and C-139 Q: Does trouble symptom persist?
00 − How to Use
C-05 (L) Troubleshooting/Inspection Service Points
P.00-6).
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G G

AK400959 AB
Connector: C-139
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

NO : Repair.
TROUBLESHOOTING
13B-263
Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and never goes out
Ignition switch
C-303
R LOCK
1 2 3
4 5 6 ST ACC
IG1 IG2
L-B
C-203
6
2 J/B
7.5A
25
C-205
C-04
B-W
42 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
G G

1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122 14
G G
R-W
7
C-105
R-W
7
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213
14 15 16 1718 19 20 Engine-ECU
21 22 232425 2627
Wire colour code

AK400823 AB
TROUBLESHOOTING
OPERATION STEP 3: Perform voltage measurement at C-139

• Battery voltage is applied to engine warning lamp engine-ECU connector.
(terminal No. 42) from ignition switch.
• Engine-ECU (terminal No. 7) makes power tran- Connector: C-139
sistor in unit be in "ON" position, and that makes
currents go on engine warning lamp (terminal No.
14).
COMMENT ON TROUBLE SYMPTOM

• Engine-ECU has detected failed sensor or failed C-139(GR)
actuator. Or failure is possibly caused by short
circuit or other faults.
PROBABLE CAUSE
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
• Short circuit in between engine warning lamp and 2726 2524 23 22 21
engine-ECU circuit. Harness side connector
• Failed engine-ECU AK400931 AB
DIAGNOSIS PROCEDURE Connector: C-05
C-05 (L)
STEP 1: M.U.T.-II/III diagnosis code
to P.13B-20.)
NO : Go to Step 2 .

connector
Connector: C-139 11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G G

AK400959 AB

C-139(GR)
ness side.
4 3 2 1 OK: System voltage
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 Q: Is the check result normal?
2726 2524 23 22 21
AK400931 AB repair if necessary. If intermediate
TROUBLESHOOTING
13B-265
00 − How to Use
P.00-6).
TROUBLESHOOTING
Inspection Procedure 5: Starting Impossible (No Initial Combustion)
Stating impossible (no initial combustion)
Ignition switch
C-303
R LOCK
1 2 3
ST ACC
IG1 IG2 4 5 6
Battery
5
B-Y
C-106
16
B-R
B-L
B-19
3 B-Y
C-140
51 (MU803083)
B-R 3132 33 34
35363738394041 42 43
444546474849 50 51
5253 545556 57 58
1 1
1 Engine-ECU
1
ON
OFF
B-26
B-25 M
(MU801215)
Starter
Wire colour code

AK304155 AC
OPERATION • If the ignition switch is turned to "START" posi-

• If the ignition switch is turned to "START" position, battery voltage is applied to engine-ECU
tion, battery voltage is applied to starter (terminal (terminal No. 51) from ignition switch. Because of
No. 1). this, engine-ECU detects that the engine is
cranked.
TROUBLESHOOTING
13B-267
COMMENT ON TROUBLE SYMPTOM STEP 4. Perform voltage measurement at C-140
• Failure is possibly caused by failed starter itself engine-ECU connector.
or failed related circuit.
Connector: C-140
PROBABLE CAUSE
• Failed battery
• Failed starter motor
• Open/short circuit in starter associated circuit or
C-140(GR)
DIAGNOSIS PROCEDURE
STEP 1. Check battery voltage. 34 33 32 31

43 42 4140 39 38 37 36 35
• Measure battery voltage at cranking. 51 50 49 4847 46 4544
58 57 5655 54 5352
OK: 8 V or higher Harness side connector
ness side.
P.54A-7).
OK: System voltage
• Item 18: Cranking signal Q: Is the check result normal?
OK: NO : Go to Step 5 .
ON (Ignition switch: ST)
NO : Go to Step 3 . Connector: C-303

connector
C-303
Connector: C-140 3 2 1
6 5 4
Harness side
connector
AK400958 AB

34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

TROUBLESHOOTING
STEP 6. Check ignition switch. STEP 7. Connector check: C-303 ignition switch
Connector: C-140
Connector: C-303
C-303
3 2 1
C-140(GR) 6 5 4
Harness side
connector
34 33 32 31 AK400958 AB
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352 Connector: B-26
AK400934 AB
Connector: C-303
B-26 (B)
1
C-303 Harness side
3 2 1
6 5 4
Harness side
connector YES : Check intermediate connectors B-19 and
AK400958 AB C-106, and repair if necessary. If
• Check ignition switch (Refer to GROUP 54A −
Ignition Switch − Ignition Switch − Inspection and repair harness between C-303 (terminal
No. 5) ignition switch connector and B-26
P.54A-30).
Q: Is the check result normal? • Check output line for short circuit.
YES : Check intermediate connectors B-19 and NO : Repair or replace.
STEP 8. Check connector: B-26 starter connector
No. 51) inhibitor switch connector and Connector: B-26
connector.
open/short circuit.
NO : Replace ignition switch. B-26 (B)
1
Harness side

TROUBLESHOOTING
13B-269
starter connector. connector
C-303
B-26 (B) 3 2 1
6 5 4
1
Harness side
connector AK400960AB AK400958 AB

Connector: B-26
ness side.
OK: System voltage
NO : Go to Step 10 . 1
Harness side

YES : Check intermediate connectors B-19 and
damage.
STEP 11. Connector check: B-25 starter

connector
Connector: B-25
B-25
1
Harness side
connector
AK400961AB

TROUBLESHOOTING
STEP 12. Perform voltage measurement at B-25 STEP 13. Check harness between C-303 (terminal
starter connector. No. 5) ignition switch connector and B-26
Connector: B-25
Connector: C-303
B-25 C-303
1
3 2 1
6 5 4
Harness side
AK400961AB connector
• Disconnect connector, and measure at the har- AK400958 AB
ness side.
Connector: B-26
OK: System voltage
NO : Check and repair harness between B-25 B-26 (B)
battery. 1
• Check power supply line for Harness side
connector
open/short circuit. AK400960AB

NO : Repair.

No. 1) starter connector and battery.
Connector: B-25
B-25
1
Harness side
connector
AK400961AB

NO : Repair.
TROUBLESHOOTING
13B-271
Inspection Procedure 6: Starting impossible (Starter Operative but No Initial Combustion)
OPERATION STEP 3: M.U.T.-II/III diagnosis code

• Refer to inspection procedure, ignition circuit sys-
tem P.13B-355.
COMMENTS ON TROUBLE SYMPTOM to P.13B-20).
NO : Go to Step 4 .
• Failure is possibly caused by failed ignition cir-
cuit, failed fuel feed or other faults.
STEP 4: M.U.T.-II/III actuator test
PROBABLE CAUSE • Item 07: Fuel pump
• Failed battery OK: Operating sound of fuel pump can be
• Timing belt broken heard.
• Throttle valve fouled around
• Failed fuel system NO : Check fuel pump system (Refer to
• Failed immobilizer system Inspection Procedure 24 P.13B-316).
DIAGNOSIS PROCEDURE STEP 5. Check timing belt for breakage.

• Engine: Cranking
OK: Camshaft rotates.
• Measure battery voltage at cranking. Q: Is the check result normal?
OK: 8 V or higher
NO : Replace timing belt.
NO : Check battery (Refer to GROUP 54A − STEP 6. Check throttle body (throttle valve
Battery − On-vehicle Service − Battery test portion) contamination.
P.54A-7). Q: Is the start ability good?
STEP 2: Check engine warning lamp for burnt out (Refer to P.13B-390).
bulb
NO : Check engine-ECU power supply, engine
control relay and ignition switch IG1 system OK:
(Refer to Inspection Procedure 23 ON (Ignition switch: ST)
P.13B-308). OFF (Ignition switch: ON)
NO : Go to Step 8 .
TROUBLESHOOTING
STEP 8: Connector check: C-140 engine-ECU STEP 9: M.U.T.-II/III data list

connector • Refer to Data List Reference Table P.13B-368.
Connector: C-140
Code No. P0335 P.13B-145).

C-140(GR)
• Check injector for operating sound (Refer to
P.13B-400).
34 33 32 31 Q: Can operating sound be heard?
43
51
42 4140 39 38 37 36 35
50 49 4847 46 4544 YES : Go to Step 11 .
58 57 5655 54 5352 NO : Check the injector system of the defective
cylinder
AK400934 AB (Refer to Code No. 0201: No. 1 injector system
P.13B-100).
Connector: C-303
(Refer to Code No. 0202: No. 2 injector system
P.13B-104).
P.13B-108).
C-303 (Refer to Code No. 0204: No. 4 injector system
3 2 1
P.13B-112).
6 5 4
Harness side
connector STEP 11: Check ignition secondary voltage
AK400958 AB waveform using an oscilloscope.
intermediate connector is normal, check and Q: Is the check result normal?
repair harness between C-303 (terminal No. YES : Go to Step 12 .
5) ignition switch connector and C-140 NO : Check ignition circuit system (Refer to
(terminal No. 51) engine-ECU connector. inspection procedure 30 P.13B-355).
circuit. STEP 12: Replace engine-ECU.
NO : Repair or replace. • After replacing the engine-ECU, re-check the
trouble symptoms.
NO : Check end.
TROUBLESHOOTING
13B-273
Inspection Procedure 7: Starting Impossible (Initial Combustion but no Complete Combustion),

Starting (Long Time to Start)
COMMENTS ON TROUBLE SYMPTOM STEP 4: M.U.T.-II/III data list

• Failure is possibly caused by poor ignition, incor- • Refer to Data List Reference Table P.13B-368.
rect air-fuel ratio at cranking, improper fuel pres- a. Item 13: Intake air temperature sensor
sure or other faults. b. Item 21: Engine coolant temperature sensor
PROBABLE CAUSE c. Item 25: Barometric pressure sensor
• Failed battery Q: Are the check results normal?
• Failed ignition system YES : Go to Step 5 .
• Failed fuel system NO : Perform the diagnosis code classified check
• Failed air-fuel ratio control system procedure for the sensor that has shown an
• Failed intake system abnormal data value (Refer to Inspection
• Failed exhaust gas cleaning system Chart for Diagnosis Codes P.13B-20).
• Timing belt not in place STEP 5: Check throttle body (throttle valve
• Improper compression pressure portion) contamination.
Q: Have the battery terminal been disconnected? STEP 6: M.U.T.-II/III actuator test
YES : After warm-up engine, idle for about 10 • Item 07: Fuel pump
minutes. OK: Operating sound of fuel pump can be
NO : Go to Step 2 . heard.
STEP 2: Check battery voltage. YES : Go to Step 7 .
• Measure battery voltage at cranking. NO : Check fuel pump system (Refer to
OK: 8 V or higher Inspection Procedure 24 P.13B-316).
YES : Go to Step 3 . STEP 7: Check air intake from intake hose and
NO : Check battery (Refer to GROUP 54A − intake manifold.
P.54A-7). YES : Go to Step 8 .
NO : Repair.
STEP 3: M.U.T.-II/III diagnosis code
to P.13B-20).
NO : Go to Step 4 .
TROUBLESHOOTING
STEP 8: Check injector for operating sound. STEP 11: Connector check: C-138 engine-ECU
• Check injector for operating sound at engine connector
cranking (Refer to P.13B-400).
Connector: C-138
cylinder
P.13B-100).
(Refer to Code No. 0202: No. 2 injector system C-138(GR)
P.13B-104).
P.13B-108). 124
133
123 122121
132 131 130 129128127126125
(Refer to Code No. 0204: No. 4 injector system 141
146
140 139 138 137136 135134
145 144 143142
P.13B-112). Harness side connector
AK400953 AB
Q: Is the check result normal? YES : Check and repair harness between C-138
YES : Go to Step 10 . (terminal No. 144 and No. 145) engine-ECU
NO : Align timing marks. connector and body earth.
• Check earth line for open circuit and
STEP 10: Perform voltage measurement at C-138 damage.
engine-ECU connector. NO : Repair or replace.
Connector: C-138
STEP 12: Connector check: B-110 and B-111
ignition coil connectors.
Connector : B-110,B-111
3 2 1
Harness side
connector
C-138(GR) B-111(GR)
124 123 122121

133 132 131 130 129128127126125 B-110(GR)
141 140 139 138 137136 135134
146 145 144 143142
AK400962 AB
• Measure engine-ECU terminal voltage. YES : Go to Step 13 .
• Voltage between terminal No. 144 and earth also NO : Repair or replace.
OK: System voltage STEP 13: Check ignition secondary voltage
TROUBLESHOOTING
13B-275
STEP 14: Check spark plug. STEP 17: Check harness between ignition coil
• Check spark plug (Refer to GROUP 16 − Ignition connector terminal No. 2 of each cylinder and
System − On-vehicle Service P.16-40) body earth.
Q: Is the check result normal? Connector : B-110,B-111
NO : Replace spark plug. Harness side
connector
B-111(GR)
STEP 15: Check spark plug cable itself.
P.16-39). B-110(GR)

NO : Replace spark plug cable. Connector: C-140
STEP 16: Check ignition coil itself.

YES : Go to Step 17 . C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

YES : Check and repair harness between ignition
coil connector terminal No. 3 of each
circuit and damage.
NO : Repair.
STEP 18: Check spray condition of injector.

P.13B-400).

11C − On-vehicle Service P.11C-13).
NO : Repair.
TROUBLESHOOTING
STEP 20: Check EGR control solenoid valve STEP 21: Check EGR valve itself.
itself. • Check EGR valve itself (Refer to GROUP 17 −
• Check EGR control solenoid valve itself (Refer to Emission Control System − Exhaust Gas Recir-
GROUP 17 − Emission Control System − culation (EGR) System P.17-71).
Exhaust Gas Recirculation (EGR) System Q: Is the check result normal?
P.17-72). YES : Go to Step 22 .
Q: Is the check result normal? NO : Replace EGR valve.
NO : Replace EGR control solenoid valve. STEP 22: Replace engine-ECU.
trouble symptoms.
NO : Check end.
Inspection Procedure 8: Unstable Idling (Rough Idling, hunting), Improper Idling Speed (Too High or
too Low), Engine Stalls During Idling (Die Out)
COMMENTS ON TROUBLE SYMPTOM STEP 2: M.U.T.-II/III diagnosis code

• Probable causes can be widely found in ignition
system, air-fuel ratio control system, idle speed
control system, fuel system, etc. A sudden
to P.13B-20).
NO : Go to Step 3 .
contact.
PROBABLE CAUSE STEP 3: M.U.T.-II/III data list

• Failed ignition system • Refer to Data List Reference Table P.13B-368.
• Failed fuel system a. Item 12: Air flow sensor
• Failed air-fuel ratio control system b. Item 13: Intake air temperature sensor
• Failed intake/exhaust system c. Item 14: Throttle position sensor (sub)
• Failed emission gas cleaning system d. Item 21: Engine coolant temperature sensor
e. Item 25: Barometric pressure sensor
f. Item 77: Accelerator pedal position sensor
• Improper compression pressure
(sub)
g. Item 78: Accelerator pedal position sensor
DIAGNOSIS PROCEDURE (main)
h. Item 79: Throttle position sensor (main)
STEP 1: Check battery condition. Q: Are the check results normal?

Q: Has the battery terminal been disconnected? NO : Perform the diagnosis code classified check
YES : After warm-up engine, idle for about 10 Procedure for the sensor that has shown an
minutes. abnormal data value (Refer to Inspection
NO : Go to Step 2 . Chart for Diagnosis Codes P.13B-20).
TROUBLESHOOTING
13B-277
STEP 4: M.U.T.-II/III data list STEP 10: Perform voltage measurement at C-138
• Refer to Data List Reference Table P.13B-368. engine-ECU.
a. Item 27: Power steering fluid pressure switch Connector: C-138
system (Refer to Code No. P0551
P.13B-178).
C-138(GR)
STEP 5: Check throttle body (throttle valve
133 132 131 130 129128127126125
141 140 139 138 137136 135134
NO : Clean throttle body (throttle valve portion) 146 145 144 143142

AK400953 AB
STEP 6: Check air intake from intake hose and • Measure engine-ECU terminal voltage.
intake manifold. • Ignition switch: "ON"
NO : Repair. OK: 0.5 V or less
STEP 7: Check injector for operating sound. YES : Go to Step 12 .
• Check injector for operating sound (Refer to NO : Go to Step 11 .
P.13B-400).
NO : Check the injector system of the defective Connector: C-138
cylinder.
system P.13B-100)
system P.13B-104)
system P.13B-108) C-138(GR)
system P.13B-112)
124 123 122121
133 132 131 130 129128127126125
STEP 8: Check timing marks of timing belt. 141

146
140 139 138 137136 135134
145 144 143142

STEP 9. M.U.T.-II/III data list (terminal No. 144 and No. 145) engine-ECU
• Refer to Data List Reference Table P.13B-368. connector and body earth.
a. Item 11: Oxygen sensor (front) • Check earthing line for open circuit
Q: Is the check result normal? and damage.
NO : Check the oxygen sensor (front) system
(Refer to Code No. P0130 P.13B-72)
TROUBLESHOOTING
engine-ECU connector. connector and B-30 alternator connector.
C-140(GR) C-140(GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK400934 AB AK400934 AB
• Measure engine-ECU terminal voltage. Connector: B-30

B-30 (GR)
OK: Switching the head lamps to ON from
OFF causes the voltage to increase by 0.2 −
3.5 V. 4 3 2 1
YES : Go to Step 15 . connector AK400951 AB
TROUBLESHOOTING
13B-279
STEP 14. Check harness between C-140 (terminal STEP 15. Perform voltage measurement at C-140
No. 45) engine-ECU connector and B-30 (terminal engine-ECU connector.
Connector: C-140
Connector: C-140
C-140(GR)
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
34 33 32 31 51 50 49 4847 46 4544
43 42 4140 39 38 37 36 35 58 57 5655 54 5352
51 50 49 4847 46 4544
AK400934 AB
Connector: B-30
B-30 (GR) OK: Switching the head lamps to ON from
4 3 2 1 YES : Go to Step 19 .

connector B-19 and repair if necessary.
age.
NO : Repair.
TROUBLESHOOTING
connector and B-30 alternator connector. No. 86) engine-ECU connector and B-30 (terminal
Connector: C-140
Connector: C-141
C-140(GR)
C-141(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 6463 62 61
58 57 5655 54 5352 7372 7170 69 6867 6665
82 818079 78 7776 7574
Harness side connector 8988 87 86 85 8483
AK400934 AB Harness side connector

AK400933 AB
Connector: B-30
Connector: B-30
B-30 (GR)
B-30 (GR)
4 3 2 1
connector AK400951 AB Harness side
NO : Repair or replace. connector B-19, and repair if necessary.
age.
NO : Repair.

00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-281
STEP 19. Perform voltage measure at C-141 STEP 20. Connector check: B-110 and B-111
engine-ECU connector. ignition coil connectors.
Connector: C-141 Connector : B-110,B-111
3 2 1
Harness side
connector
B-111(GR)
C-141(GR) B-110(GR)
AK400962 AB
6463 62 61
82 818079 78 7776 7574
8988 87 86 85 8483 YES : Go to Step 21 .
Harness side connector NO : Repair or replace.
AK400933 AB
• Measure engine-ECU terminal voltage. STEP 21. Check ignition secondary voltage
• Engine: Idling waveform using an oscilloscope.
• A/C switch: ON (A/C compressor ON) • Check ignition secondary voltage waveform
• Voltage between terminal No. 78 and earth. (Refer to GROUP 16 − Ignition System −
OK:
1 V or less (with outside air temperature sen- Q: Is the check result normal?
sor ambient temperature at 18° C or higher YES : Go to Step 26 .
and A/C set for maximum air flow at mini- NO : Go to Step 22 .
mum temperature)
System voltage (with A/C set for minimum air STEP 22. Check spark plug.
flow at room temperature) • Check spark plug (Refer to GROUP 16 − Ignition
Q: Is the check result normal? System − On-vehicle Service P.16-40)
NO : Check A/C load signal system (Refer to YES : Go to Step 23 .
Inspection Procedure 28 P.13B-342). NO : Replace spark plug.
STEP 23. Check spark plug cable.

P.16-39).
Q: Q: Is the check result normal?

TROUBLESHOOTING
STEP 25. Check harness between ignition coil STEP 28. Check purge control solenoid valve
connector terminal No. 2 of each cylinder and itself.
body earth. • Check purge control solenoid valve itself (Refer
Connector : B-110,B-111 to GROUP 17 − Emission Control System −
3 2 1
B-111(GR) NO : Replace purge control solenoid valve.

B-110(GR) itself.
• Check EGR control solenoid valve itself (Refer to
AK400962 AB
Connector: C-140 Exhaust Gas Recirculation (EGR) System
P.17-72).
C-140(GR)
STEP 30. Check EGR valve itself.
• Check EGR valve itself (Refer to GROUP 17 −
34 33 32 31
culation (EGR) System P.17-71).
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 Q: Is the check result normal?
58 57 5655 54 5352
AK400934 AB
• Check earthing line for open/short circuit and STEP 31. M.U.T.-II/III actuator test
damage. • Item 07: Fuel pump
Q: Is the check result normal? OK: Operating sounds of fuel pump can be
YES : Check and repair harness between ignition heard.
• Check signal line for open/short and NO : Check fuel pump system (Refer to
damage. inspection Procedure 24 P.13B-316).
NO : Repair.
STEP 32. Replace engine-ECU

STEP 26. Check injector for spray condition.
• After engine-ECU is replaced, re-check for trou-
ble symptoms.
P.13B-400).
Q: Is the check result normal? YES : Check for foreign matters (water, kerosene,
YES : Go to Step 27 . etc.) in fuel and replace if necessary.
NO : Replace injector. NO : Check end.

11C − On-vehicle Service P.11C-13).
NO : Repair.
TROUBLESHOOTING
13B-283

• Engine stall on starting is possibly caused by mis- ignition connectors
fire due to failed spark plug, improper air-fuel
ratio at accelerator pedal depression or other
3 2 1
faults.
Harness side
connector
PROBABLE CAUSE B-111(GR)
• Failed engine-ECU B-110(GR)
AK400962 AB
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code NO : Repair or replace.
to P.13B-20).
NO : Go to Step 2 .
Exhaust Gas Recirculation (EGR) System NO : Go to Step 7 .
P.17-72).
Q: Is the check result normal? STEP 7. Check spark plug.
YES : Go to Step 3 . • Check spark plug (Refer to GROUP 16 − Ignition
STEP 3. Check EGR valve itself. YES : Go to Step 8 .
• Check EGR valve itself (Refer to GROUP 17 − NO : Replace spark plug.
STEP 8.Check spark plug cable itself.
Q: Is the check result normal? • Check spark plug cable itself (Refer to GROUP
YES : Go to Step 4 . 16 − Ignition System − On-vehicle Service
P.16-39).
STEP 4. Check air intake from intake hose and
intake manifold. NO : Replace spark plug cable.
NO : Repair.
TROUBLESHOOTING
STEP 10. Check harness between ignition coil

connector terminal No. 2 of each cylinder and
body earth.
3 2 1
Harness side
connector
B-111(GR)
B-110(GR)
AK400962 AB
Connector: C-140
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

circuit and damage.
NO : Repair.
TROUBLESHOOTING
13B-285
Inspection Procedure 10: The Engine Stalls when Decelerating
COMMENT ON TROUBLE SYMPTOM STEP 4. Check EGR valve itself.

• Engine stall on deceleration is possibly caused by • Check EGR valve itself (Refer to GROUP 17 −
insufficient air intake, improper air-fuel ratio due Emission Control System − Exhaust Gas Recir-
to failed exhaust gas recirculation system or culation (EGR) System P.17-71).
other faults.
• Throttle valve fouled STEP 5. Check throttle body (throttle valve
STEP 1. M.U.T.-II/III diagnosis code (Refer to P.13B-390).

YES : Inspection chart for diagnosis code (Refer STEP 6. Connector check: B-110 and B-111
to P.13B-20). ignition coil connectors
NO : Go to Step 2 . Connector : B-110,B-111
3 2 1
Harness side
STEP 2. M.U.T.-II/III data list connector
B-111(GR)
b. Item 77: Accelerator pedal position sensor
(sub)
B-110(GR)
c. Item 78: Accelerator pedal position sensor
(main) AK400962 AB
d. Item 79: Throttle position sensor (main)
abnormal data value (Refer to Inspection STEP 7. Check ignition secondary voltage
Chart for Diagnosis Code P.13B-20) waveform using an oscilloscope.
GROUP 17 − Emission Control System − Q: Is the check result normal?
Exhaust Gas Recirculation (EGR) System YES : Replace engine-ECU.
NO : Go to Step 8 .
P.17-72).
NO : Replace EGR control solenoid valve. • Check spark plug (Refer to GROUP 16 − Ignition
TROUBLESHOOTING
STEP 9. Check spark plug cable itself. STEP 11. Check harness between ignition coil
• Check spark plug cable itself (Refer to GROUP connector terminal No. 2 of each cylinder and
16 − Ignition System − On-vehicle Service body earth.
P.16-39). Connector : B-110,B-111
YES : Go to Step 10 . Harness side
connector
B-111(GR)

Ignition System − On-vehicle Service P.16-38). B-110(GR)

NO : Replace ignition coil. Connector: C-140
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

circuit and damage.
NO : Repair.
TROUBLESHOOTING
13B-287
Inspection Procedure 11: Engine does not Revole Up
COMMENTS ON TROUBLE SYMPTOM STEP 4. Connector check: B-110 and B-111

• Failure is possibly caused by failed fuel system, ignition coil connectors
ignition system or other faults.
PROBABLE CAUSE 3 2 1
Harness side
• Failed ignition system connector
• Failed fuel system B-111(GR)
• Failed throttle valve opening control system
B-110(GR)

Q: Diagnosis code set? NO : Repair or replace.
to P.13B-20).
NO : Go to Step 2 .
STEP 2. M.U.T.-II/III data list (Refer to GROUP 16 − Ignition System −
• Refer to Data list reference table P.13B-368 On-vehicle Service P.16-41)
a. Item 14: Throttle position sensor (sub) Q: Is the check result normal?
b. Item 77: Accelerator pedal position sensor YES : Go to Step 10 .
(sub) NO : Go to Step 6 .
(main)
d. Item 79: Throttle position sensor (main) • Check spark plug (Refer to GROUP 16 − Ignition
Q: Are the check results normal? System − On-vehicle Service P.16-40)
procedure for the sensor that has shown an NO : Replace spark plug.
Chart for Diagnosis Code P.13B-20).
STEP 3. Check timing marks of timing belt. 16 − Ignition System − On-vehicle Service
NO : Align match marks.

TROUBLESHOOTING
STEP 9. Check harness between ignition coil STEP 10. Fuel pressure measurement.
connector terminal No. 2 of each cylinder and • Fuel pressure measurement (Refer to
body earth. P.13B-391).
Connector : B-110,B-111 Q: Is the check result normal?
3 2 1 YES : Replace engine-ECU.
connector
B-111(GR)
B-110(GR)
AK400962 AB
Connector: C-140
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

circuit and damage.
NO : Repair.
TROUBLESHOOTING
13B-289
Inspection Procedure 12: Hesitation, Sag,Poor Acceleration, Stumble or Surge
COMMENTS ON TROUBLE SYMPTOM STEP 3. M.U.T.-II/III data list

• Failure is possibly caused by failed ignition sys- • Refer to Data List Reference Table P.13B-368.
tem, improper air-fuel ratio, improper compres- a. Item 13: Intake air temperature sensor
sion pressure or other faults. b. Item 14: Throttle position sensor (sub)
• Failed air-fuel ratio control system d. Item 25: Barometric pressure sensor
• Failed ignition system e. Item 77: Accelerator pedal position sensor
• Failed fuel system (sub)
• Failed intake and exhaust system f. Item 78: Accelerator pedal position sensor
• Failed emission control system (main)
• Failed throttle valve opening control system g. Item 79: Throttle position sensor (main)
• Failed turbocharger system Q: Are the check results normal?
• Throttle valve fouled YES : Go to Step 4 .
• Improper compression pressure NO : Perform the diagnosis code classified check
• Failed engine-ECU procedure for the sensor that has shown an
DIAGNOSIS PROCEDURE Chart for Diagnosis Codes P.13B-20).
STEP 1. M.U.T.-II/III diagnosis code STEP 4. Check Purge control solenoid valve
Q: Diagnosis code set? itself.
YES : Inspection chart for diagnosis code (Refer • Check Purge control solenoid valve itself (Refer
to P.13B-20). to GROUP 17 − Emission Control System −
NO : Go to Step 2 . Evaporative Emission Control System P.17-65).
STEP 2. Check injector for operating sound. YES : Go to Step 5 .
• Check injector for operating sound (Refer to NO : Replace purge control solenoid valve.
P.13B-400).
STEP 5. Check EGR control solenoid valve itself.
YES : Go to Step 3 . • Check EGR control solenoid valve itself (Refer to
NO : Check the injector system of the defective GROUP 17 − Emission Control System −
cylinder. Exhaust Gas Recirculation (EGR) Sys-
(Refer to code No. P0201: No. 1 injector system temP.17-72).
P.13B-100) Q: Is the check result normal?
(Refer to code No. P0202: No. 2 injector system YES : Go to Step 6 .
P.13B-104) NO : Replace EGR control solenoid valve.
(Refer to code No. P0203: No. 3 injector system
P.13B-108) STEP 6. Check EGR valve itself.
(Refer to code No. P0204: No. 4 injector system • Check EGR valve itself (Refer to GROUP 17 −
P.13B-112) Emission Control System − Exhaust Gas Recir-
TROUBLESHOOTING
STEP 7. M.U.T.-II/III data list STEP 12. Check ignition coil itself.
• Refer to Data List Reference Table P.13B-368. • Check ignition coil itself (Refer to GROUP 16 −
a. Item 11: Oxygen sensor (front) Ignition System − On-vehicle Service P.16-38).
NO : Check oxygen sensor (front) system (Refer NO : Replace ignition coil.
to Code No. P0130 P.13B-72).
STEP 8. Connector check: B-110 and B-111 connector terminal No. 2 of each cylinder and
ignition coil connectors body earth.
Connector : B-110,B-111 Connector : B-110,B-111
3 2 1 3 2 1
connector connector
B-111(GR) B-111(GR)
B-110(GR) B-110(GR)
AK400962 AB AK400962 AB


C-140(GR)
YES : Go to Step 14 . 43
51
42 4140 39 38 37 36 35
50 49 4847 46 4544
NO : Go to Step 10 . 58 57 5655 54 5352
STEP 10. Check spark plug. AK400934 AB
• Check spark plug (Refer to GROUP 16 − Ignition • Check earthing line for open circuit and damage.
System − On-vehicle Service P.16-40) Q: Is the check result normal?
Q: Is the check result normal? YES : Check and repair harness between ignition
YES : Go to Step 11 . coil connector terminal No. 3 of each
NO : Replace spark plug. cylinder and C-140 engine-ECU connector.
• Check signal line for open or short
STEP 11. Check spark plug cable itself. circuit or damage.
NO : Repair.
P.16-39). STEP 14. Check throttle body (throttle valve
NO : Replace spark plug cable. YES : Go to Step 15 .
TROUBLESHOOTING
13B-291
STEP 15. M.U.T.-II/III actuator test. STEP 18. M.U.T.-II/III actuator test.
• Item 12: Waste gate solenoid valve • Item 09: Fuel pressure control solenoid valve
OK: Operating sound is audible on actua- OK: Operating sound is audible on actua-
tion. tion.
NO : Check waste gate solenoid valve system NO : Check fuel pressure control solenoid valve
(Refer to Code No. P0243 P.13B-123). system (Refer to Code No. P0443
P.13B-168).
STEP 16. Check turbo charger supercharging
pressure. STEP 19.Fuel pressure measurement.
• Check turbo charger output pressure (Refer to • Fuel pressure measurement (Refer to
GROUP 15 −Intake Exhaust −On-vehicle Service P.13B-391).
P.15-3).
NO : Repair.
STEP 17. Check supercharging pressure control • Check compression pressure (Refer to GROUP
system. 11C − On-vehicle Service P.11C-13).
• Check supercharging pressure control system
(Refer to GROUP 15 −Intake Exhaust
−On-vehicle Service P.15-3). NO : Repair.
NO : Repair.
Inspection Procedure 13: The Feeling of Impact or Vibration when Accelerating

• Failure is possibly caused by failed ignition leak • Refer to Data List Reference Table P.13B-368
with rise in spark plug-required voltage at accel- a. Item 14: Throttle position sensor (sub)
eration, throttle valve opening control system. b. Item 77: Accelerator pedal position sensor
(sub)
PROBABLE CAUSE
(main)
• Failed engine-ECU d. Item 79: Throttle position sensor (main)
STEP 1. M.U.T.-II/III diagnosis code abnormal data value (Refer to Inspection
Q: Diagnosis code set? Chart for Diagnosis Code P.13B-20).
to P.13B-20).
NO : Go to Step 2 .
TROUBLESHOOTING
STEP 3. Connector check: B-110 and B-111 STEP 7. Check ignition coil itself.
ignition coil connectors • Check ignition coil itself (Refer to GROUP 16 −
Connector : B-110,B-111 Ignition System − On-vehicle Service P.16-38).
connector NO : Replace ignition coil.
B-111(GR)

connector terminal No. 2 of each cylinder and
B-110(GR) body earth.
AK400962 AB Connector : B-110,B-111
3 2 1
NO : Repair or replace. B-111(GR)

waveform using an oscilloscope. B-110(GR)
(Refer to GROUP 16 − Ignition System − AK400962 AB

Connector: C-140
NO : Go to Step 5 .

System − On-vehicle Service P.16-40) C-140(GR)

YES : Go to Step 6 . 34 33 32 31
NO : Replace spark plug. 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
16 − Ignition System − On-vehicle Service • Check earthing line for open circuit and damage.
Q: Is the check result normal? YES : Check and repair harness between ignition
YES : Go to Step 7 . coil connector terminal No. 3 of each
NO : Replace spark plug cable. cylinder and C-140 engine-ECU connector.
circuit and damage.
NO : Repair.
TROUBLESHOOTING
13B-293
Inspection Procedure 14: The Feeling of Impact or Vibration when Decelerating

• Failure is possibly caused by insufficient air • Refer to Data List Reference Table P.13B-368.
intake due to failed throttle valve opening control a. Item 14: Throttle position sensor (sub)
system. b. Item 77: Accelerator pedal position sensor
(sub)
PROBABLE CAUSE
(main)
• Failed engine-ECU d. Item 79: Throttle position sensor (main)
Q: Diagnosis code set? Chart for Diagnosis Code P.13B-20).
to P.13B-20).
NO : Go to Step 2 .
portion) contamination.

• Failure is possibly caused by failed detonation ignition coil connectors
control, improper thermal value of spark plug or
other faults.
3 2 1
connector
• Defective detonation sensor B-111(GR)
• Failed detonation control system
AK400962 AB
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code NO : Repair or replace.
to P.13B-20).
NO : Go to Step 2 .
TROUBLESHOOTING
STEP 3. Check ignition secondary voltage STEP 7. Check harness between ignition coil
waveform using an oscilloscope. connector terminal No. 2 of each cylinder and
• Check ignition secondary voltage waveform body earth.
(Refer to GROUP 16 − Ignition System − Connector : B-110,B-111
On-vehicle Service P.16-41) 3 2 1
YES : Check detonation sensor (Refer to Code connector
No. P0325 P.13B-141). B-111(GR)
NO : Go to Step 4 .
STEP 4. Check spark plug. B-110(GR)

AK400962 AB

16 −Ignition System − On-vehicle Service
C-140(GR)
P.16-39).
YES : Go to Step 6 . 34 33 32 31
43 42 4140 39 38 37 36 35
NO : Replace spark plug cable. 51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB
Ignition System − On-vehicle Service P.16-38). • Check earthing line for open circuit or damage.
YES : Go to Step 7 . YES : Check and repair harness between ignition
NO : Replace ignition coil. coil connector terminal No. 3 of each
circuit and damage.
NO : Repair.

• Failure is possibly caused by failed crank angle
sensor, failed camshaft position sensor, improper STEP 1. M.U.T.-II/III diagnosis code
• Failed crank angle sensor to P.13B-20).
• Failed camshaft position sensor NO : Go to Step 2 .
• Improperly installed timing belt
TROUBLESHOOTING
13B-295
STEP 2. Perform output wave pattern
measurement of crank angle sensor and NO : Go to Step 4 .
camshaft position sensor (Using oscilloscope).
Connector: B-29 STEP 3. Check the trouble symptoms.
00 − How to Use
P.00-6).
Crank angle sensor
STEP 4. Check crank angle sensor and camshaft
position sensor mounted conditions.
NO : Repair.

2 1 B-29 (B)
3
Harness side
connector NO : Align timing marks.
AK400943AB
Connector : B-106
STEP 6. Check crank angle sensor vane.
3 2 1
B-106(B) YES : Go to Step 7 .
Harness side NO : Replace crank angle sensor vane.
connector

cylinder.
AK400944 AB YES : Go to Step 8 .
Crank Angle Sensor
• Use special tool test harness (MD998478) to con- STEP 8. Replace crank angle sensor.
nect B-29 crank angle sensor connector, and • After replacing the crank angle sensor, re-check
measure at pick-up harness. the trouble symptoms.
• Engine: Idling
• Transmission: Neutral Q: Does trouble symptom persist?
• Voltage between terminal No. 2 and earth. YES : Go to Step 9 .
NO : check end.
Camshaft Position Sensor
nect B-106 camshaft position sensor connector,
and measure at pick-up harness.
• Engine: Idling
OK: Output waveform timings of both sen-
sors are the same as the check procedure
(Refer to P.13B-383) using an oscilloscope.
TROUBLESHOOTING
STEP 9. Replace camshaft position sensor.

00 − How to Use
P.00-6).
Inspection Procedure 17: Run on (Dieseling)

PROBABLE CAUSE
P.13B-400).
• Failed injector
• Failed engine-ECU Q: Does trouble symptom persist?
Inspection Procedure 18: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC During
Idling
COMMENT ON TROUBLE SYMPTOM STEP 2. Check injector for operating sound.

• Failure is possibly caused by improper air-fuel • Check injector for operating sound (Refer to
ratio, deteriorated catalyst, failed ignition system, P.13B-400).
failed fuel system, failed compression pressure or
other faults. Q: Can operating sound be heard?
PROBABLE CAUSE NO : Check the injector system of the defective
cylinder.
• Failed air-fuel control system
system P.13B-100).
• Failed intake and exhaust system
system P.13B-104).
• Failed compression pressure
system P.13B-108).
• Failed catalytic converter
system P.13B-112).
DIAGNOSIS PROCEDURE
STEP 3. Check ignition timing.
• Check ignition timing (Refer to GROUP 11C −
STEP 1. M.U.T.-II/III diagnosis code On-vehicle Service P.11C-11).
to P.13B-20). NO : Check for offset ignition timing (Refer to
NO : Go to Step 2 .
Inspection Procedure 16 P.13B-294).
TROUBLESHOOTING
13B-297
STEP 4. M.U.T.-II/III data list STEP 10. Check EGR control solenoid valve
• Refer to Data List Reference Table P.13B-368. itself.
a. Item 12: Air flow sensor • Check EGR control solenoid valve itself (Refer to
b. Item 13: Intake air temperature sensor GROUP 17 − Emission Control System −
c. Item 21: Engine coolant temperature sensor Exhaust Gas Recirculation (EGR) System
d. Item 25: Barometric pressure sensor P.17-72).
Q: Are the check results normal? Q: Is the check result normal?

NO : Perform the diagnosis code classified check NO : Replace EGR control solenoid valve.
abnormal data value (Refer to Inspection STEP 11. Check EGR valve itself.
Chart for Diagnosis Codes P.13B-20). • Check EGR valve itself (Refer to GROUP 17 −
STEP 5. Check air intake from intake hose and culation (EGR) System P.17-71).
intake manifold. Q: Is the check result normal?
NO : Repair.
STEP 6. Check for emission leakage from • Fuel pressure measurement (Refer to
exhaust manifold. P.13B-391).
Q: Is the check result normal? (Refer to GROUP 17 − Emission Control System
− Evaporative Emission Control System
(Refer to P.13B-390). P.17-60).
STEP 8. M.U.T.-II/III data list YES : Go to Step 14 .
NO : Replace positive crankcase ventilation
valve.
to Code No. P0130 P.13B-72). System − On-vehicle Service P.16-40)
STEP 9. Check Purge control solenoid valve
itself.
• Check Purge control solenoid valve itself (Refer
TROUBLESHOOTING
STEP 15. Check spark plug cable itself. STEP 17. Check compression pressure.
• Check spark plug cable itself (Refer to GROUP • Check compression pressure (Refer to GROUP
16 − Ignition System − On-vehicle Service 11C − On-vehicle Service P.11C-13).
STEP 18. Check injector for spraying condition.
STEP 16. Check ignition coil itself. • Check each injector for spray condition (Refer to
• Check ignition coil itself (Refer to GROUP 16 − P.13B-400).
Ignition System − On-vehicle Service P.16-38). Q: Does trouble symptom persist?
YES : Go to Step 17 . NO : Replace injector.
STEP 19. Replace catalytic converter.
• After replacing the catalytic converter re-check
NO : Check end.
Inspection Procedure 19: Battery Rundown
COMMENT ON TROUBLE SYMPTOM STEP 2. Connector check: B-19 intermediate

Connector: B-19
PROBABLE CAUSE
• Failed battery
• Alternator G terminal short-circuit B-19 (B)
3 2 1
6 5 4
DIAGNOSIS PROCEDURE
Female side
STEP 1. Check battery voltage.
• Measure battery voltage during cranking. Q: Is the check result normal?
OK: 8 V or more NO : Repair or replace.
Battery − On-vehicle Service − Battery test
P.54A-7).
TROUBLESHOOTING
13B-299
intermediate connector. connector
B-19 (B)
C-303
3 2 1
1 2 3
6 5 4
4 5 6
Harness side
Male side connector
AK401530 AB

Connector: B-19
nector side.
B-19 (B)
OK: System voltage
1 2 3
4 5 6
NO : Go to Step 4 .
Male side
connector
AK401530 AB

YES : Check intermediate connectors C-04, C-05,
B-19 (terminal No. 7) intermediate
ignition switch connector.
open/short circuit.
TROUBLESHOOTING
intermediate connector. No. 6) intermediate connector and B-30 (terminal
Connector: B-19
Connector: B-19
B-19 (B)
B-19 (B)
3 2 1
6 5 4 3 2 1
Female side 6 5 4
connector AK400950AB Female side
connector
• Disconnect connector, and measure at female AK400950AB
connector side. Connector: B-30

OK: System voltage
NO : Go to Step 6 .
4 3 2 1
STEP 6. Connector check: B-30 alternator Harness side
connector
Connector: B-30
NO : Repair.
B-30 (GR)
4 3 2 1
Harness side

TROUBLESHOOTING
13B-301
No. 7) intermediate connector and B-30 (terminal No. 3) alternator connector and C-303 (terminal
No. 3) alternator connector. No. 2) ignition switch connector.
B-19 (B)
B-30 (GR)
3 2 1
6 5 4 4 3 2 1
Female side Harness side
connector AK400950AB connector AK400951 AB
B-30 (GR) C-303

3 2 1
6 5 4
4 3 2 1 Harness side
• Check power supply line for open/short circuit. NOTE: Before checking harness, check intermediate
Q: Is the check result normal? connectors C-04, C-05, C-105, C-203 and C-205,
YES : Go to Step 9 . and repair if necessary.
NO : Repair. • Check power supply line for damage.
NO : Repair.

connector
Connector: C-140
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

TROUBLESHOOTING
C-140(GR) C-140(GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK400934 AB AK400934 AB

Connector: B-19
OK: Switching the head lamps to ON from
1 2 3 OFF causes the voltage to increase by 0.2 −
4 5 6 3.5 V.
Male side Q: Is the check result normal?
connector
• Disconnect connector, and measure at harness NO : Check alternator.
side.
• Ignition switch: "ON" STEP 13. Check the trouble symptoms.
OK: System voltage YES : Replace engine-ECU.
NO : Check and repair harness between B-19 Troubleshooting/Inspection Service Points
(terminal No. 6) intermediate connector and P.00-6).
connector.
TROUBLESHOOTING
13B-303

• Failed fan controller Inspection Procedure 25 P.13B-325).
• Failed engine-ECU Engine cold state: At ambient temperature
DIAGNOSIS PROCEDURE Engine hot state: At 80 − 120 ° C
Q: Diagnosis code set? NO : Check engine coolant temperature sensor
YES : Inspection chart for diagnosis code (Refer system (Refer to Code No. P0115
to P.13B-20). P.13B-54).
NO : Go to Step 2 .
STEP 5. Check thermostat.
STEP 2. Check engine coolant. • Check thermostat (Refer to GROUP 14 − Ther-
NOTE: If engine coolant level falls too early, check mostat P.14-24).
for leaky spots, and repair if necessary. Q: Is the check result normal?
• Check engine coolant (Refer to GROUP 14 − YES : Go to Step 6 .
On-vehicle Service P.14-17). NO : Replace thermostat.
YES : Go to Step 3 . STEP 6. Check water pump.
NO : Replace or add engine coolant. • Check water pump.
YES : Replace radiator.
TROUBLESHOOTING
A-20 5V
(MU802322)
1 2 3
Fan controller
L-W
7
A-14
L-W
17
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213 Engine-ECU
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK400824 AB

(terminal No. 17). connector contact
FUNCTION
• The engine-ECU inputs a duty signal suitable for
the engine coolant temperature, vehicle speed
and A/C switch position to the fan controller. In
response to the signal, the fan controller controls
the rotating speeds of the radiator fan and A/C
condenser fan. (The fan speed becomes higher
as the average voltage of the terminal comes
nearer to 5 V.)
TROUBLESHOOTING
13B-305
DIAGNOSIS PROCEDURE STEP 3. Check the trouble symptoms.
STEP 1. Connector check: C-139 engine-ECU YES : Replace engine-ECU.
connector NO : Intermittent malfunction (Refer to GROUP
00 − How to Use
Connector: C-139
P.00-6).

C-139(GR) Connector: C-139
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
C-139(GR)
AK400931 AB

YES : Go to Step 2 . 4 3 2 1
13 12 1110 9 8 7 6 5
NO : Repair or replace. 2019 18 17 16 15 14
2726 2524 23 22 21
STEP 2. Check at C-139 engine-ECU connector.
AK400931 AB
Connector: C-139
side.
• Voltage between terminal No.17 and earth.
OK: 4.9 − 5.1 V
C-139(GR) YES : Replace fan controller.
NO : Go to Step 5 .
4 3 2 1
13 12 1110 9 8 7 6 5 STEP 5. Connector check: A-20 fan controller
2019 18 17 16 15 14
2726 2524 23 22 21 connector
Connector : A-20
AK400931 AB

side.
• Short-circuit terminal No.17 to earth. A-20(GR)
OK: Fan motor stops rotating. 3 2 1
Harness side
NO : Go to Step 4 .
TROUBLESHOOTING

Connector : A-20
A-20(GR)
3 2 1
Harness side
connector
AK400963 AB
Connector: C-139
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

NO : Repair.
TROUBLESHOOTING
13B-307
COMMENT ON TROUBLE SYMPTOM Q: Is the check result normal?

• Failure is possibly caused by short /overcharged YES : Go to Step 4 .
A/C refrigerant, failed A/C control system, failed
fan control system or other faults. Procedure 26 P.13B-331).
PROBABLE CAUSE STEP 4. M.U.T.-II/III data list

• Short or overcharged A/C refrigerant • Item 49: A/C relay
• Failed A/C compressor a. Engine: Idling
• Failed fan controller b. A/C set temperature:
• Failed A/C-ECU Maximum Hot when temperature in cabin is
• Failed engine-ECU 25°C or less
DIAGNOSIS PROCEDURE 25°C or more
OK:
STEP 1. M.U.T.-II/III diagnosis code ON (when A/C is ON)
YES : Inspection chart for diagnosis code (Refer Q: Is the check result normal?
to P.13B-20). YES : Check A/C system (Refer to GROUP 55 −
NO : Go to Step 2 . Troubleshooting P.55A-5).
STEP 2. A/C compressor magnet clutch
operation check.
• Engine: Idling STEP 5. Check charged amount of A/C
• A/C set temperature: refrigerant.
Maximum Cool when temperature in cabin is • Check charged amount of A/C refrigerant (Refer
25°C or more to GROUP 55 − On-vehicle Service P.55A-49).
Maximum Hot when temperature in cabin is 25°C Q: Is the check result normal?
or less YES : Go to Step 6 .
OK: NO : Adjust charged amount of A/C refrigerant.
Magnet clutch active (when A/C is ON)
Magnet clutch inactive (when A/C is OFF) STEP 6. M.U.T.-II/III actuator test
Q: Is the check result normal? • Item 21: Fan controller
NO : Go to Step 3 .
STEP 3. M.U.T.-II/III data list Inspection Procedure 28 P.13B-342).
• Item 28: A/C switch NO : Check fan control relay system (Refer to
a. Engine: Idling Inspection Procedure 25 P.13B-325).
25°C or more
25°C or less
OK:
ON (when A/C is ON)
TROUBLESHOOTING
Inspection Procedure 23: Engine-ECU Power Supply, Engine Control Relay, Ignition Switch-IG1
System
Battery
9
Relay box
20A Ignition switch
LOCK C-303
R
ST ACC 123
W-B 456
IG1 IG2
A-14
5
2
L-B
C-203
6
W-B
W-B 8
J/B
7.5A
4 3
B-17X 1
Engine C-202
1 2 control
relay
3 4
L-B
1 2
4 C-106
10
J/C (2) Y-G W-B
C-17
9 10 L-B
R
42 33 34 43 57 58 50
B B
GND GND Power Battery
source backup Engine-ECU
C-140
(MU803803)
3132 33 34
353637383940 41 42 43
444546474849 50 51
5253 545556 57 58
Wire colour code

AK400825 AB
TROUBLESHOOTING
13B-309
trol relay (terminal No. 3 and No. 4).
Connector : B-17X
B-17X
power transistor in the unit be in "ON" position
and makes currents go on the engine control Relay box's
relay coil, and that makes the relay be in "ON" triangle marks
position.
the battery voltage is supplied to the
4 3
engine-ECU, the sensor and the actuator from
Harness side
the engine control relay (terminal No. 1). connector AK400930 AB
FUNCTION Q: Is the check result normal?

• When the ignition switch ON signal is input to the YES : Go to Step 3 .
engine-ECU, the engine-ECU places the engine NO : Repair or replace.
control relay in the ON position. Accordingly, the
battery voltage is supplied to the engine-ECU, STEP 3. Check engine control relay.
sensor and actuator. • Check engine control relay (Refer to P.13B-395).
• Failed engine control relay YES : Go to Step 4 .
• Open/short circuit in engine control relay circuit or NO : Replace engine control relay.
• Failed engine-ECU STEP 4. Perform voltage measurement at B-17X
DIAGNOSIS PROCEDURE Connector : B-17X
B-17X
STEP 1. Check battery voltage. Relay box's
• Measure battery voltage during cranking. triangle marks
OK: 8 V or more
Harness side
Battery − On-vehicle Service − Battery test connector AK400930 AB
P.54A-7). • Remove relay, and measure at relay box side.
OK: System voltage
harness between B-17X (terminal No. 3, No.
4) engine control relay connector and
battery.
open/short circuit.
TROUBLESHOOTING
C-140(GR) C-140(GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK400934 AB AK400934 AB

YES : Go to Step 6 . side.
NO : Repair or replace. • Ignition switch: "ON"
OK: System voltage
NO : Go to Step 7 .

connector
Connector: C-303
C-303
3 2 1
6 5 4
Harness side
connector
AK400958 AB

TROUBLESHOOTING
13B-311
STEP 8. Check ignition switch. STEP 9. Perform voltage measurement at C-140
Connector: C-140
Connector: C-140
C-140(GR)
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 34 33 32 31
58 57 5655 54 5352 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
AK400934 AB
AK400934 AB
Connector: C-303
side.
OK: System voltage
C-303
Harness side NO : • Check intermediate connector A-14 and
connector repair if necessary. If intermediate
AK400958 AB connector is normal, check and repair
• Check ignition switch (Refer to GROUP 54A − harness between C-140 (terminal No.
Ignition Switch − Ignition Switch − Inspection 58) engine-ECU connector and battery.
P.54A-30). • Check power supply line for short
circuit.
YES : • Check intermediate connectors C-106,
C-202 and C-203, then repair if STEP 10. Connector check: C-140 engine-ECU
necessary. If intermediate connectors connector
are normal, check and repair harness Connector: C-140
between C-140 (terminal No. 50)
engine-ECU connector and C-303
(terminal No. 2) ignition switch
connector.
open/short circuit.
NO : Replace ignition switch. C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

TROUBLESHOOTING
STEP 11. Perform resistance measurement at STEP 13. Perform voltage measurement at C-140
C-140 engine-ECU connector. engine-ECU connector.
C-140(GR) C-140(GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK400934 AB AK400934 AB
• Disconnect connector, and measure at harness Connector : B-17X

side. B-17X
and No. 42 and earth. Relay box's
triangle marks
NO : Check and repair harness between C-140 4 3
(terminal No. 33, No. 42) engine-ECU Harness side
• Check earthing line for open circuit • Disconnect connector, and measure at harness
and damage. side.
STEP 12. Connector check: C-140 engine-ECU OK: System voltage
Connector: C-140
circuit.
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

TROUBLESHOOTING
13B-313
engine-ECU connector. No. 2) ignition switch connector and C-140
Connector: C-140
Connector: C-303
C-303
3 2 1
C-140(GR) 6 5 4
Harness side
connector
34 33 32 31 AK400958 AB
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352 Connector: C-140
AK400934 AB
Connector : B-17X
B-17X
Relay box's
triangle marks C-140(GR)
2 1
34 33 32 31
4 3 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
Harness side 58 57 5655 54 5352
connector AK400930 AB Harness side connector
side.
• Using jumper wire, connect C-140 (terminal No.
necessary.
• Voltage between terminal No. 34 and earth, and
No. 43 and earth.
NO : Check intermediate connector C-17 and
harness between C-140 (terminal No. 34,
No. 43) engine-ECU connector and B-17X
(terminal No. 1) engine control relay.
TROUBLESHOOTING
STEP 16. Check harness between B-17X STEP 17. Check harness between B-17X
(terminal No. 3, No. 4) engine control relay (terminal No. 2) engine control relay connector
connector and battery. and C-140 (terminal No. 57) engine-ECU
Connector : B-17X connector.
B-17X
Relay box's
triangle marks
2 1
4 3 2 1
Harness side 4 3
Harness side
connector A-14, and repair if necessary. Connector: C-140
NO : Repair.
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

NO : Repair.
TROUBLESHOOTING
13B-315
STEP 18. Check harness between B-17X STEP 19. Check the trouble symptoms.
(terminal No. 1) engine control relay connector Q: Does trouble symptom persist?
and C-140 (terminal No. 34, No. 43) engine-ECU YES : Replace engine-ECU.
connector. NO : Intermittent malfunction (Refer to GROUP
Connector : B-17X 00 − How to Use
B-17X Troubleshooting/Inspection Service Points
P.00-6).
Relay box's
triangle marks
2 1
4 3
Harness side
Connector: C-140
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

NO : Repair.
TROUBLESHOOTING
Fuel pump circuit
Battery
C-303
W R LOCK
123 Ignition switch
456 ST ACC
IG1 IG2
24
Reray box
15A 2
W
L-B
C-116
41
W
C-202 C-203
2 6
4 3 1 3 8
7.5A
C-215 C-213
Fuel Fuel
3 4 3 4 pump 1 2 pump 4 2
relay (1) relay (2)
C-215 C-213
C-205 11 C-209 1 C-205

14
B-L
D-24 6
B
G
B-L
Fuel pump
and gauge 5
unit (main)
D-16
(MU802058) M
C-106
1 2 3 8
4 5 4
B
D-24 4
G
B
16
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213 Engine-ECU
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK400826 AB
TROUBLESHOOTING
13B-317
OPERATION STEP 2. Check fuel pump relay.
• The battery voltage is applied to the fuel pump • Fuel pump relay, continuity check (Refer to
relay (1) (terminal No. 3) form the ignition switch P.13B-395).
and is earthed to the vehicle body from the fuel
pump relay (1) (terminal No. 2). Q: Is the check result normal?
• The battery voltage is applied to the fuel pump YES : Go to Step 3 .
relay (1) (terminal No. 4) and to the fuel pump
(1) (terminal No. 1). STEP 3. Perform resistance measurement at
• The battery voltage is applied to the fuel pump C-215 fuel pump relay (1) connector.
relay (2) (terminal No. 3) from the ignition switch. Connector : C-215
The engine-ECU (terminal No. 16) makes the
power transistor in the unit be in "ON" position Junction block's
triange marks
and makes currents go on the fuel pump relay (2) C-215
coil, and that makes the relay be in "ON" position.
• When the fuel pump relay (2) is in "ON" position, 2 1
the battery voltage is supplied to the fuel pump 4 3
(low pressure) from the fuel pump relay (2) (ter- Harness side
connector
minal No. 4).
AK400965AB
FUNCTION
• When the ignition switch ON signal is input to the
side.
engine-ECU, the engine-ECU places the fuel
pump relay in the "ON" position. Accordingly, the
battery voltage is supplied to the fuel pump. OK: Continuity (2 Ω or less)
• Failed fuel pump relay NO : Check intermediate connector C-205, and
• Failed fuel pump repair if necessary. If intermediate
• Open/short circuit in fuel pump drive circuit or connector is normal, check and repair
loose connector contact harness between C-215 (terminal No. 2)
• Failed engine-ECU fuel pump relay (1) connector and body
earth.
DIAGNOSIS PROCEDURE • Check earthing line for open circuit
and damage.
connector
Connector : C-213,C-215
Junction block's
triange marks
C-215
2 1
4 3
C-213
Harness side
connector
AK400964AB

TROUBLESHOOTING
Junction block's
triange marks
C-215
2 1 C-303
4 3 3 2 1
Harness side 6 5 4
connector
AK400965AB AK400958 AB

Connector : C-215
side.
• Ignition switch: ON Junction block's
• Voltage between terminal No. 3 and earth. triange marks
C-215
OK: System voltage
2 1
4 3
connector
AK400965AB

fuel pump relay (1) connector and C-303
circuit and damage.
TROUBLESHOOTING
13B-319
Junction block's
triange marks
C-215
2 1 C-303
4 3 3 2 1
Harness side 6 5 4
connector
AK400965AB AK400958 AB

Connector : C-213
side.
• Voltage between terminal No. 4 and earth. Junction block's
triange marks
OK: System voltage
2 1
NO : Check intermediate connectors C-116 and 4 3
C-213
C-202, and repair if necessary. If Harness side
connector
and repair harness between C-215 (terminal AK400966AB

open/short circuit.
Connector : C-213 connector.
Junction block's circuit.
triange marks
2 1
4 3
C-213
Harness side
connector
AK400966AB

side.
OK: System voltage
NO : Go to Step 8 .
TROUBLESHOOTING
C-139(GR) C-139(GR)
4 3 2 1 4 3 2 1
13 12 1110 9 8 7 6 5 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2019 18 17 16 15 14
2726 2524 23 22 21 2726 2524 23 22 21
AK400931 AB AK400931 AB
Q: Is the check result normal? Connector : C-213

Junction block's
NO : Repair or replace. triange marks
2 1
4 3
C-213
Harness side
connector
AK400966AB

side.
OK: System voltage
connector.
circuit.
TROUBLESHOOTING
13B-321
STEP 11. Connector check: D-16 fuel pump STEP 13. Check harness between C-215 (terminal
connector No. 1) fuel pump relay (1) connector and C-213
Connector: D-16
Connector : C-213,C-215
Junction block's
triange marks
C-215
D-16 (GR) 2 1
3 2 1 4 3
5 4 C-213
Harness side
AK400964AB
Q: Is the check result normal? • Check power supply line for open/short circuit.
YES : Go to Step 14
NO : Repair.
STEP 12. Perform voltage measurement at D-16
fuel pump connector.
Connector: D-16 No. 4) fuel pump relay (2) connector and D-16
(terminal No. 5) fuel pump connector.
Connector : C-213
Junction block's
D-16 (GR) triange marks
3 2 1
5 4 2 1
Harness side 4 3
connector AK400967AB C-213
Harness side
• Disconnect connector, and measure at harness connector
side. AK400966AB
• Using a jumper wire, connect C-139 (terminal No. Connector: D-16
OK: System voltage
D-16 (GR)
NO : Go to Step 13 . 3 2 1
5 4
Harness side

connectors D-209 and D-24, and repair if necessary.
age.
NO : Repair.
TROUBLESHOOTING
D-16 fuel pump connector. No. 2) ignition switch connector and C-215
Connector: D-16
Connector: C-303
D-16 (GR) C-303

3 2 1 3 2 1
5 4 6 5 4
connector AK400967AB connector
side. Connector : C-215

Junction block's
OK: Continuity (2 Ω or less) triange marks
C-215
2 1
NO : Check intermediate connector D-24, and
4 3
Harness side
connector is normal, check and repair connector
harness between D-16 (terminal No. 4) fuel
AK400965AB
pump connector and body earth.
• Check earthing line for open circuit NOTE: Before checking harness, check intermediate
and damage. connector C-203, and repair if necessary.
STEP 16. Connector check: C-303 ignition switch Q: Is the check result normal?

C-215 (terminal No. 4) fuel pump relay (1)
C-303
connector.
3 2 1 Connector : C-215
6 5 4
Junction block's
Harness side triange marks
connector C-215
AK400958 AB
2 1
Harness side
NO : Repair or replace. connector
AK400965AB

NO : Repair.
TROUBLESHOOTING
13B-323
No. 1) fuel pump relay (1) connector and C-213 No. 4) fuel pump relay (2) connector and D-16
(terminal No. 1) fuel pump relay (2) connector. (terminal No. 5) fuel pump connector.
Connector : C-213,C-215 Connector : C-213
Junction block's Junction block's

triange marks triange marks
C-215
2 1 2 1
4 3 4 3
C-213 C-213
connector connector
AK400964AB AK400966AB

Connector: D-16
NO : Repair.
STEP 20. Check harness between C-303 (terminal D-16 (GR)

No. 2) ignition switch connector and C-213 3 2 1
(terminal No. 3) fuel pump relay (2) connector. 5 4
Harness side
Connector: C-303 connector AK400967AB

C-303
6 5 4 YES : Replace fuel pump.
connector
AK400958 AB
Connector : C-213
Junction block's
triange marks
2 1
4 3
C-213
Harness side
connector
AK400966AB

NO : Repair.
TROUBLESHOOTING

No. 2) fuel pump relay (2) connector and C-139
Connector : C-213
Junction block's
triange marks
2 1
4 3
C-213
Harness side
connector
AK400966AB
Connector: C-139
C-139(GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

sary.
YES : Replace fuel pump
NO : Repair.
TROUBLESHOOTING
13B-325
Battery
9
20A
W-B A-14
5 (*1)
16 (*2)
W-B
W-B
4 3
B-17X

3 4
1 2
4 To engine-ECU
C-17
5
R
L-W A-14
11
R
4 1
A-10X
2 Fan control relay
1 3
4
2 3
B
L
A-20
(MU802322)
1 2 3 circuit
Wire colour code

AK304147 AC
TROUBLESHOOTING

relay (terminal No. 3) from the engine control On−vehicle Service − Fan Control Relay Continu-
relay (terminal No. 1) and is earthed to the vehi- ity Check P.14-19).
1).
• When the fan control relay is in "ON" position, the
battery voltage is supplied to the fan controller STEP 3. Perform resistance measurement at
(terminal No. 3) from the fan control relay (termi- A-10X fan control relay connector.
nal No. 2). Connector : A-10X
FUNCTION
B-10X
the fan control relay is also simultaneously placed
in "ON" position. Accordingly, the battery voltage
is supplied to the fan controller. 2
3 1
4
connector
• Failed fan control relay AK400968 AB
• Failed fan controller • Remove relay and measure at relay box side.
• Failed radiator fan motor • Resistance between terminal No. 1 and earth.
• Failed condenser fan motor
• Open/short circuit in fan control relay circuit or OK: Continuity (2 Ω or less)
loose connector contact Q: Is the check result normal?
• Failed engine-ECU YES : Go to Step 4 .
NO : Check and repair harness between A-10X
DIAGNOSIS PROCEDURE (terminal No. 1) fan control relay connector
and body earth.
STEP 1. Connector check: A-10X fan control and damage.
relay connector
Connector : A-10X
Connector : A-10X
B-10X
2
3 1 B-10X
4
Harness side
connector 2
AK400968 AB 3 1
4
connector
• Remove relay and measure at relay box side.
OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
13B-327
Connector : B-17X Connector : A-10X
B-17X
Relay box's
triangle marks B-10X
2 1 2
3 1
4 3 4
Harness side
Connector : A-10X • Remove relay, and measure at relay box side.

OK: System voltage
B-10X Q: Is the check result normal?
2 NO : Check and repair harness between battery
3 1 and A-10X (terminal No. 4) fan control relay
4
connector • Check power supply line for
AK400968 AB
open/short circuit.
Connector : A-20
open/short circuit.
NO : Repair or replace. A-20(GR)
3 2 1
Harness side
connector
AK400963 AB

TROUBLESHOOTING
Connector : A-20 Connector : B-17X
B-17X
Relay box's
triangle marks
A-20(GR) 2 1
3 2 1 4 3
Harness side
AK400963 AB connector AK400930 AB

• Ignition switch: ON NO : Repair or replace.
OK: System voltage
NO : Go to Step 9 .
Connector : B-17X
B-17X
STEP 9. Check harness between A-10X (terminal
Relay box's
No. 2) fan control relay connector and A-20 triangle marks
Connector : A-10X
2 1
4 3
Harness side
B-10X connector AK400930 AB
2 Connector : A-10X
3 1
4
Harness side
connector
AK400968 AB B-10X
Connector : A-20 2
3 1
4
Harness side
connector
AK400968 AB
A-20(GR) NOTE: Before checking harness, check intermediate

3 2 1
Harness side
AK400963 AB
TROUBLESHOOTING
13B-329
STEP 12. Connector check: C-139 engine-ECU STEP 14. M.U.T.-II/III actuator test
connector • Item 21: Fan controller
Connector: C-139 OK: Fan motor rotates.
00 − How to Use
P.00-6).
C-139(GR)

4 3 2 1 engine-ECU connector.
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 Connector: C-139
2726 2524 23 22 21
AK400931 AB

C-139(GR)
STEP 13. Fan motor drive test.

4 3 2 1
Connector: C-139 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

side.
C-139(GR) • Ignition switch: ON
OK: 4.9 − 5.1 V
4 3 2 1
13 12 1110 9 8 7
2019 18 17 16
6
15
5
14
2726 2524 23 22 21 YES : Go to Step 16 .
AK400931 AB
• Disconnect C-139 engine-ECU connector.

TROUBLESHOOTING
STEP 16. Check harness between A-10X STEP 18. Check harness between A-20 (terminal
(terminal No. 4) fan control relay connector and No. 2) fan controller connector and C-139
battery. (terminal No. 17) engine-ECU connector.
Connector : A-10X Connector : A-20
B-10X
2 A-20(GR)
3 1
4 3 2 1
connector connector
AK400968 AB AK400963 AB

Connector: C-139
NO : Repair.
STEP 17. Check harness between A-10X

C-139(GR)
A-20 (terminal No. 3) fan controller connector.
Connector : A-10X
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
B-10X
AK400931 AB
2
3 1
4 NOTE: Before checking harness, check intermediate
Harness side connector A-14, and repair if necessary.
connector
AK400968 AB • Check output line for short circuit.
Connector : A-20
NO : Repair.
A-20(GR)
3 2 1
Harness side
connector
AK400963 AB

NO : Repair.
TROUBLESHOOTING
13B-331
A/C Switch circuit
C-26
(MU801584)
21 22 23 24 25 26 27 28 A/C-ECU
29 30 31 32 33 34 35 36
34
G-B
C-104
7
G-B
69
C-141
(MU803804)
656667686970717273
747576777879808182
8384 858687 8889
Wire colour code

AK400827AB

(terminal No. 69) from the A/C-ECU (terminal No. • Failed A/C system
34). • Open/short circuit in A/C circuit or loose connec-
tor contact
from the A/C-ECU. In response to the signal, the
engine-ECU controls the A/C compressor relay.
TROUBLESHOOTING

A/C-ECU connector.
STEP 1. Perform voltage measurement at C-141 Connector : C-26
Connector: C-141
28 27 26 25 24 23 22 21 C-26(B)
36 35 34 33 32 31 30 29
Harness side
C-141(GR)
• Measure A/C-ECU terminal voltage.
• Engine: Idling
6463 62 61 • A/C set temperature:
7372 7170 69 6867 6665
82 818079 78 7776 7574 Maximum Cool when temperature in cabin is
8988 87 86 85 8483 25°C or more
AK400933 AB or less
• Measure engine-ECU terminal voltage. • Voltage between terminal No. 34 and earth
• Engine: Running at idle OK: System voltage
• A/C set temperature:
Maximum Cool when temperature in cabin is YES : Go to Step 5 .
25°C or more NO : Go to Step 3 .
or less
OK:
System voltage (when A/C is ON)
0.5 V or less (when A/C is OFF)
NO : Go to Step 2 .
TROUBLESHOOTING
13B-333
STEP 3. Connector check: C-26 A/C-ECU STEP 4. Check harness between C-26 (terminal
connector and C-141 engine-ECU connector No. 34) A/C-ECU connector and C-141 (terminal
Connector : C-26 No. 69) engine-ECU connector.
Connector : C-26
28 27 26 25 24 23 22 21 C-26(B)
36 35 34 33 32 31 30 29 C-26(B)
28 27 26 25 24 23 22 21
Harness side 36 35 34 33 32 31 30 29
connector AK400969AB Harness side
Connector: C-141
Connector: C-141
C-141(GR)
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574 6463 62 61
8988 87 86 85 8483 7372 7170 69 6867 6665
82 818079 78 7776 7574

AK400933 AB
NO : Repair or replace. connector C-104, and repair if necessary.
Troubleshooting − Check Chart for Trouble
Symptoms P.55A-5).
NO : Repair.
TROUBLESHOOTING
STEP 5. Connector check: C-26 A/C-ECU STEP 6. Connector check: C-141 engine-ECU
connector and C-141 engine-ECU connector connector
28 27 26 25 24 23 22 21 C-26(B)
36 35 34 33 32 31 30 29
C-141(GR)
Harness side
6463 62 61
Connector: C-141 7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

C-141(GR) NO : Repair or replace.

6463 62 61
7372 7170 69 6867 6665 • Item 28: A/C switch
82 818079 78 7776 7574
8988 87 86 85 8483 a. Engine: Idling
Harness side connector b. A/C set temperature:
AK400933 AB
25°C or more.
Q: Is the check result normal? Maximum Hot when temperature in cabin is
YES : Check intermediate connector C-104, and 25°C or less.
repair if necessary. If intermediate OK:
connector is normal, check and repair ON (when A/C is ON)
harness between C-26 (terminal No. 34) OFF (when A/C is OFF)
A/C-ECU connector and C-141 (terminal
No. 69) engine-ECU connector. Q: Is the check result normal?
• Check output line for open circuit. YES : Intermittent malfunction (Refer to GROUP
NO : Repair or replace. 00 − How to Use
P.00-6).
TROUBLESHOOTING
13B-335
Ignition switch
C-303
R LOCK
1 2 3
4 5 6 ST ACC
IG1 IG2
4
L-R
C-203
2
Battery
W 5 J/B
7.5A
10 C-205
Relay box
10A 16
L-R
B-R
A-14 C-106
9 11
B-R L-R
4 3
B-18X

3 4
1 2
A/C-ECU
B-W G
1 8
Engine-ECU
A/C compressor
temperature
switch
B-27
(MU802653)
1 Magnetic C-134
clutch
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Wire colour code

AK300328 AB
TROUBLESHOOTING
OPERATION STEP 2. A/C compressor relay check.

• The battery voltage is applied to the A/C com- • Check A/C compressor relay (Refer to GROUP
pressor relay (terminal No. 4). 55A − On-vehicle Service P.55A-55).
• The battery voltage is applied to the A/C com-
pressor relay (terminal No. 3) from the ignition
switch. The engine-ECU (terminal No. 8) makes
NO : Replace A/C compressor relay.
tion and makes currents go on the A/C compres-
sor relay coil, and that makes the relay be in "ON" STEP 3. Perform voltage measurement at B-18X
position. A/C compressor relay connector.
• When the A/C compressor is in "ON" position, the Connector : B-18X
battery voltage is supplied to the A/C compressor B-18X
(terminal No. 1) from the A/C compressor relay
assembly (terminal No. 1). Relay box's
triangle marks
FUNCTION
• When the A/C switch "ON" signal is input to the 2 1
engine-ECU, the engine-ECU places the A/C 4 3
compressor relay in the "ON" position. Accord- Harness side
ingly, the battery voltage supplied to the A/C com- connector AK400970 AB
pressor operates the magnet clutch. • Remove relay, and measure at relay box side.
PROBABLE CAUSE
• Failed A/C compressor relay
• Failed A/C compressor magnet clutch OK: System voltage
• Open/short circuit in A/C compressor relay circuit Q: Is the check result normal?
or loose connector contact YES : Go to Step 5 .
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-18X A/C

compressor relay connector
Connector : B-18X
B-18X
Relay box's
triangle marks
2 1
4 3
Harness side

TROUBLESHOOTING
13B-337
Connector: C-303 Connector : B-18X
B-18X
Relay box's
triangle marks
C-303
3 2 1 2 1
6 5 4
4 3
Harness side
AK400958 AB

Connector : B-18X
B-18X
OK: System voltage
Relay box's
2 1
Harness side harness between B-18X (terminal No. 4)
connector AK400970 AB A/C compressor relay connector and
battery.
open/short circuit.
and repair harness between B-18X (terminal STEP 6. Connector check: B-27 A/C compressor
No. 3) A/C compressor relay connector and assembly connector
C-303 (terminal No. 4) ignition switch Connector: B-27
connector.
open/short circuit.
B-27 (B)
1
Harness side

TROUBLESHOOTING
A/C compressor assembly connector. engine-ECU connector.
B-27 (B)
C-139(GR)
1
Harness side
4 3 2 1
13 12 1110 9 8 7 6 5
Connector : B-18X 2019 18 17 16 15 14
B-18X 2726 2524 23 22 21
Relay box's
triangle marks AK400931 AB

2 1 side.
4 3
Harness side
connector AK400970 AB OK: System voltage
• Remove B-18X (terminal No. 1 and No. 4) A/C NO : Go to Step 9 .
compressor relay and short-circuit of harness
side connector. STEP 9. Connector check: C-139 engine-ECU
• Ignition switch: ON connector
Connector: C-139
OK: System voltage
(terminal No. 1) A/C compressor assembly
connector and B-18X (terminal No. 1) A/C
compressor relay connector. C-139(GR)
circuit.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB

TROUBLESHOOTING
13B-339
STEP 10. Check harness between B-18X STEP 11. M.U.T.-II/III data list
(terminal No. 2) A/C compressor relay connector • Item 49: A/C relay
and C-139 (terminal No. 8) engine-ECU a. Engine: Idling
connector. b. A/C set temperature:
Connector : B-18X Maximum Cool when temperature in cabin is
B-18X 25°C or more
Relay box's
triangle marks 25°C or less
OK:
2 1
ON (when A/C is ON)
4 3
Harness side
00 − How to Use
Connector: C-139 Troubleshooting/Inspection Service Points
P.00-6).

connector
C-139(GR) Connector: C-139
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK400931 AB
C-139(GR)

YES : Go to Step 11 . 13 12 1110 9 8 7
2019 18 17 16
6
15
5
14
NO : Repair. 2726 2524 23 22 21
AK400931 AB

TROUBLESHOOTING
STEP 13. Check harness between B-18X STEP 15. Check harness between C-303 (terminal
(terminal No. 2) A/C compressor relay connector No. 4) ignition switch connector and B-18X
and C-139 (terminal No. 8) engine-ECU (terminal No. 3) A/C compressor relay connector.
connector. Connector: C-303
Connector : B-18X
B-18X
Relay box's
triangle marks C-303
3 2 1
2 1 6 5 4
4 3 Harness side
connector
Harness side AK400958 AB
Connector : B-18X
Relay box's
triangle marks
2 1
4 3
C-139(GR)
Harness side
4 3 2 1 NOTE: Before checking harness, check intermediate

13 12 1110 9 8 7
2019 18 17 16
6
15
5
14
2726 2524 23 22 21 necessary.
• Check earthing line for damage. YES : Go to Step 16 .
NO : Repair.
NO : Repair. STEP 16. Check harness between battery and
B-18X (terminal No. 4) A/C compressor relay
connector.
connector Connector : B-18X
B-18X
Connector: C-303
Relay box's
triangle marks
2 1
C-303
3 2 1 4 3
6 5 4 Harness side
Harness side
connector
AK400958 AB NOTE: Before checking harness, check intermediate
NO : Repair.
TROUBLESHOOTING
13B-341
and B-27 (terminal No. 1) A/C compressor
assembly connector.
Connector : B-18X
B-18X
Relay box's
triangle marks
2 1
4 3
Harness side
Connector: B-27
B-27 (B)
1
Harness side

NO : Repair.
TROUBLESHOOTING
A/C load signal circuit
C-26
(MU801584)
21 22 23 24 25 26 27 28
A/C-ECU
29 30 31 32 33 34 35 36
32
L-W
C-106
6
L-W
78
C-141
(MU803804)
656667686970717273
747576777879808182
8384 858687 8889
Wire colour code

AK400829AB

engine-ECU (terminal No. 78) from the A/C-ECU • Open/short circuit in A/C load signal circuit or
(terminal No. 32). loose connector contact
FUNCTION
detected and input to the engine-ECU. The
engine-ECU provides A/C idle up control accord-
ing to the A/C compressor load condition.
TROUBLESHOOTING
13B-343
connector
STEP 1. Perform voltage measurement at C-141 Connector: C-141
Connector: C-141
C-141(GR)
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
6463 62 61
82 818079 78 7776 7574
8988 87 86 85 8483 AK400933 AB
AK400933 AB
• Measure engine-ECU terminal voltage. NO : Repair.
• Engine: Idling
OK: Q: Does trouble symptom persist?
00 − How to Use
air flow rate) STEP 4. Connector check: C-141 engine-ECU
NO : Go to Step 4 .
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

TROUBLESHOOTING
A/C-ECU connector. No. 32) A/C-ECU connector and C-141 (terminal
Connector : C-26 No. 78) engine-ECU connector.
Connector : C-26
28 27 26 25 24 23 22 21 C-26(B)
36 35 34 33 32 31 30 29 C-26(B)
28 27 26 25 24 23 22 21
Harness side 36 35 34 33 32 31 30 29
connector
• Measure A/C-ECU terminal voltage. AK400969AB
• Engine: Idling
Connector: C-141
25°C or more
or less
OK: System voltage C-141(GR)
NO : Go to Step 6 . 6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
STEP 6. Connector Check: C-26 A/C-ECU Harness side connector
Connector : C-26
connector C-106 and repair if necessary.
28 27 26 25 24 23 22 21 C-26(B) Troubleshooting − Check Chart for Trouble
36 35 34 33 32 31 30 29 Symptoms P.55A-5).

TROUBLESHOOTING
13B-345
STEP 8. Check connector: C-26 A/C-ECU
connector
Connector : C-26
28 27 26 25 24 23 22 21 C-26(B)
36 35 34 33 32 31 30 29
Harness side
Connector: C-141
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK400933 AB

A/C-ECU connector and C-141 (terminal
TROUBLESHOOTING
A-02
(MU802509)
A/C Pressure sensor
1 2 3
3 1 2
G-Y BR G-R
C-116
17 5
A-14 BR G-R
17
C-105 C-104
21 4
G-Y
A/C-ECU
BR G-R
97 96 118
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU
Wire colour code

AK304330AC
OPERATION FUNCTION
the engine-ECU (terminal No. 97) and is earthed engine-ECU. The engine-ECU uses the signal for
to the engine-ECU (terminal No. 96) from the A/C ON/OFF control of the magnet clutch of the A/C
pressure sensor (terminal No. 1). compressor.
(terminal No. 118) from the A/C pressure sensor PROBABLE CAUSE
output terminal (terminal No. 2). • Failed A/C pressure sensor
• Open/short circuit in A/C pressure sensor circuit
TROUBLESHOOTING
13B-347
STEP 1. Connector check: A-02 A/C pressure Connector: C-142
sensor connector
Connector : A-02
3 2 1
Harness side
B-02(B) connector
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
AK400972 AB 112111110 109108107 106105
120119118 117116115 114113

STEP 2. Perform voltage measurement at A-02 • Voltage between terminal No. 97 and earth.
A/C pressure sensor connector. OK: 4.9 − 5.1 V
Connector : A-02
3 2 1
NO : Go to Step 5 .
Harness side
B-02(B) connector
AK400972 AB

side.
OK: 4.9 − 5.1 V
NO : Go to Step 3 .
TROUBLESHOOTING
connector connector
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB
Connector : A-02 Q: Is the check result normal?

3 2 1 NO : Repair or replace.
Harness side
B-02(B) connector
AK400972 AB

circuit.
TROUBLESHOOTING
13B-349
(terminal No. 97) engine-ECU connector. Connector : A-02
Connector : A-02
3 2 1
3 2 1 Harness side
Harness side B-02(B) connector
B-02(B) connector
AK400972 AB
AK400972 AB
side.
Connector: C-142
NO : Go to Step 9 .

connector
959493 92 91 Connector: C-142
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

• Check power supply line for short circuit. C-142(GR)

YES : Go to Step 7 . 959493 92 91
NO : Repair. 104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB
YES : Replace engine-ECU. Q: Is the check result normal?
NO : Intermittent malfunction (Refer to GROUP YES : Go to Step 10 .
00 − How to Use NO : Repair or replace.
P.00-6).
TROUBLESHOOTING
(terminal No. 96) engine-ECU connector. Connector : A-02
Connector : A-02
3 2 1
3 2 1 Harness side
Harness side B-02(B) connector
B-02(B) connector
AK400972 AB
AK400972 AB
Connector: C-142
OK: 4.9 − 5.1 V
C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

sary.
NO : Repair.
TROUBLESHOOTING
13B-351
Connector: C-142 Connector : A-02
3 2 1
Harness side
B-02(B) connector
C-142(GR)
AK400972 AB
959493 92 91
104 103102 101100 99 98 97 96
112111110
120119118
109108107
117116115
106105
114113
AK400935 AB
OK: 0.5 or less
Connector : A-02
3 2 1
Harness side
B-02(B) connector
AK400972 AB

TROUBLESHOOTING
Connector: C-142 Connector : A-02
3 2 1
Harness side
B-02(B) connector
C-142(GR)
AK400972 AB
959493 92 91
104 103102 101100 99 98 97 96
112111110
120119118
109108107
117116115
106105
114113
Harness side connector • Engine: Running at idle
• A/C switch: ON
AK400935 AB
Connector : A-02 OK:
2.2 V or more (When A/C is "MAX, COOL" con-
3 2 1 dition)
Harness side 1.8 V or less (When A/C is "MAX, HOT" condi-
B-02(B) connector
tion)
AK400972 AB
Connector: C-142
connector.
NO : Repair or replace. C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB

TROUBLESHOOTING
13B-353
STEP 17. Check harness between A-02 (terminal STEP 18. Perform voltage measurement at C-142
No. 2) A/C pressure sensor connector and C-142 engine-ECU connector.
Connector: C-142
Connector : A-02
3 2 1
Harness side
B-02(B) connector
C-142(GR)
AK400972 AB 959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
Connector: C-142 120119118 117116115 114113

AK400935 AB

• A/C switch: ON
C-142(GR)
OK:
959493 92 91 dition)
104 103102 101100 99 98 97 96
112111110 109108107 106105 1.8 V or more (When A/C is "MAX, HOT" condi-
120119118 117116115 114113
tion)
AK400935 AB
NOTE: Before checking harness, check intermediate NO : Go to Step 19 .
sary.
NO : Repair.
TROUBLESHOOTING
connector connector
C-142(GR) C-142(GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK400935 AB AK400935 AB
Connector : A-02 Q: Is the check result normal?

3 2 1 NO : Repair or replace.
Harness side
B-02(B) connector
AK400972 AB

connector.
• Check power supply line for short
circuit and damage.
TROUBLESHOOTING
13B-355
Ignition circuit
Ignition switch
C-303
R LOCK
1 2 3 ST
4 5 6 ACC
IG1 IG2
2
L-B
C-203
6
J/B 1
10A
10
W C-205
C-116
26
W
A-14
16
W W
W
1 1
Ignition coil 1 Ignition coil 2 1

B-110 B-111
B-107
Capacitor
1 2 3 1 2 3
3 2 Spark 2 3
plug
B B
B-L W-L
B
31 35
C-140
(MU803803)
3132 33 34
Engine-ECU 35363738394041 42 43
444546474849 50 51
5253 545556 57 58
Wire colour code

AK400869AB
TROUBLESHOOTING
OPERATION STEP 3. Connector check: B-111 and B-110

• The battery voltage is applied to the ignition coil ignition coil connectors
earthed to the vehicle body from the ignition coil
3 2 1
(terminal No. 2).
Harness side
• A power voltage of 12 V is applied to the ignition connector
coil output terminal (terminal No. 3) from the B-111(GR)
engine-ECU (terminal No. 31 and No. 35).
FUNCTION
• When the engine-ECU makes the power transis- B-110(GR)
tor in the unit be in "OFF" position, the battery AK400962 AB
voltage in the unit is applied to the power transis-
tor unit, and that makes the power transistor unit Q: Is the check result normal?
be in "ON" position. The engine-ECU makes the YES : Go to Step 4 .
power transistor in the unit be in "ON", and that NO : Repair or replace.
makes the power transistor unit be in "OFF" posi-
tion. STEP 4. Check ignition coil itself.
• In response to the signal from the engine-ECU, • Check ignition coil itself (Refer to GROUP 16 −
the power transistor unit is in "ON" position. The Ignition System − On-vehicle Service P.16-38).
primary current is going to the ignition coil. When
the power transistor unit is in "OFF" position, the Q: Is the check result normal?
primary current is interrupted and high voltage is YES : Go to Step 5 .
generated in the secondary coil. NO : Replace ignition coil.

• Failed ignition coil and B-110 ignition coil connectors.
• Failed spark plug Connector : B-110,B-111
• Failed spark plug cable
3 2 1
• Open/short circuit in ignition primary circuit or Harness side
loose connector contact connector
DIAGNOSIS PROCEDURE
B-110(GR)
16 − Ignition System − On-vehicle Service • Disconnect connector, and measure at harness

P.16-40). side.
NO : Replace spark plug cable. OK: System voltage
STEP 2. Check spark plug. YES : Go to Step 7 .
• Check spark plug (Refer to GROUP 16 − Ignition NO : Go to Step 6 .
TROUBLESHOOTING
13B-357
STEP 6. Connector check: C-303 ignition switch STEP 7. Perform voltage measurement at B-111
connector and B-110 ignition coil connectors.
Connector: C-303 Connector : B-110,B-111
3 2 1
Harness side
connector
B-111(GR)
C-303
3 2 1
6 5 4
Harness side B-110(GR)
connector
AK400958 AB AK400962 AB

side.
3 2 1
Harness side
connector • Voltage between terminal No. 3 and earth.
B-111(GR) OK: 0.5 − 4.0 V
B-110(GR) NO : Go to Step 8 .
AK400962 AB

ignition coil connector, also between C-303
(terminal No. 2) ignition switch connector
and B-110 (terminal No. 1) ignition coil
connector.
open/short circuit.
TROUBLESHOOTING
C-140(GR) C-140(GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK400934 AB AK400934 AB
Connector : B-110,B-111 Connector : B-110,B-111

3 2 1 3 2 1
connector connector
B-111(GR) B-111(GR)
B-110(GR) B-110(GR)
AK400962 AB AK400962 AB

• Disconnect B-111 and B-110 ignition coil connec- YES : Check and repair harness between B-111
tors. (terminal No. 3) ignition coil connector and
• Engine: Cranking C-140 (terminal No. 35) engine-ECU
• Voltage between terminal No. 31 and earth, also connector, also between B-110 (terminal
between terminal No. 35 and earth. No. 3) ignition coil connector and C-140
OK: 0.5 − 4.0 V (terminal No. 31) engine-ECU connector.
TROUBLESHOOTING
13B-359
connector No. 3) ignition coil connector and C-140 (terminal
Connector: C-140
3 2 1
Harness side
connector
C-140(GR) B-111(GR)
34 33 32 31 B-110(GR)
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352 AK400962 AB
AK400934 AB Connector: C-140

C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

NO : Repair.

00 − How to Use
P.00-6).
TROUBLESHOOTING
B-111 and B-110 ignition coil connectors. No. 2) ignition switch connector and B-111
Connector : B-110,B-111 (terminal No. 1) ignition coil connector, also
3 2 1
between C-303 (terminal No. 2) ignition switch
Harness side connector and B-110 (terminal No. 1) ignition coil
connector connector.
B-110(GR)
AK400962 AB
C-303
3 2 1
side. Harness side
• Resistance between terminal No. 2 and earth. connector
OK: Continuity (2 Ω or less) AK400958 AB
Q: Is the check result normal? Connector : B-110,B-111

NO : Check and repair harness between B-111 Harness side
(terminal No. 2) ignition coil connector and connector
body earth, also between B-110 (terminal B-111(GR)
No. 2) ignition coil connector and body
earth.
• Check earthing line for open circuit B-110(GR)
and damage.
AK400962 AB

connectors A-14, C-116, C-203 and C-205, and
NO : Repair.
TROUBLESHOOTING
13B-361
No. 3) ignition coil connector and C-140 (terminal
3 2 1
Harness side
connector
B-111(GR)
B-110(GR)
AK400962 AB
Connector: C-140
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

NO : Repair.
TROUBLESHOOTING
Inspection Procedure 31: Accelerator Pedal Position Switch Circuit System
Accelerator pedal position switch circuit
B-116
(MU802073)
OFF Accelerator pedal
1 2 3 4 5 6 7 8 ON position sensor
4 5
BR-G B
38 96
C-140 C-142
(MU803803) (MU803805)
3132 33 34 9192 939495
35363738394041 42 43 96979899100 101102103 104
444546474849 50 51 105106 107108109 110111112
5253 545556 57 58 113114 115116117 118119120
Engine-ECU
Wire colour code
AK304332 AC

• A power voltage of 5 V is applied to the accelera-
tor pedal position switch output terminal (terminal STEP 1. Connector check: B-116 accelerator
No. 4) from the engine-ECU (terminal No. 38). pedal position sensor connector
(terminal No. 92) from the Accelerator pedal posi- Connector : B-116
tion switch (terminal No. 5).
B-116(GR)
COMMENT ON TROUBLE SYMPTOM
• Accelerator pedal position switch turns OFF
when amount of travel of the accelerator pedal
exceeds the prescribed value.
• Engine-ECU uses the signal that is input by the 8 7 6 5 4 3 2 1
accelerator pedal position switch for determining Harness side connector AK400955 AB
the abnormal characteristics of the accelerator
pedal position sensor (sub). Q: Is the check result normal?
PROBABLE CAUSE NO : Repair or replace.
• Failed accelerator pedal position switch.
switch circuit or loose connector contact.
TROUBLESHOOTING
13B-363
STEP 2. Check accelerator pedal position switch STEP 4. Perform voltage measurement at C-140
itself engine-ECU connector.
Connector: C-140

accelerator pedal position sensor connector. C-140(GR)
Connector : B-116
34 33 32 31
43 42 4140 39 38 37 36 35
B-116(GR) 51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB
Connector : B-116
8 7 6 5 4 3 2 1
B-116(GR)
side.
OK: 4.9 − 5.1 V 8 7 6 5 4 3 2 1
YES : Go to Step 8 . • Measure engine-ECU terminal voltage.

NO : Go to Step 4 . • Disconnect B-116 accelerator pedal position sen-
sor
OK: 4.9 − 5.1 V
NO : Go to Step 6 .
TROUBLESHOOTING
connector connector
C-140(GR) C-140(GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK400934 AB AK400934 AB

B-116(GR)
8 7 6 5 4 3 2 1

(terminal No. 4) accelerator pedal position
TROUBLESHOOTING
13B-365
No. 4) accelerator pedal position sensor B-116 accelerator pedal position sensor
engine-ECU connector. Connector : B-116
Connector : B-116
B-116(GR)
B-116(GR)
8 7 6 5 4 3 2 1
side.
Connector: C-140
NO : Go to Step 9 .
C-140(GR)
connector
34 33 32 31 Q: Is the check result normal?
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352 Connector: C-142
AK400934 AB

NO : Repair. C-142(GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK400935 AB
TROUBLESHOOTING
No. 5) accelerator pedal position sensor engine-ECU connector
Connector: C-140
Connector : B-116
B-116(GR)
C-140(GR)
8 7 6 5 4 3 2 1
34 33 32 31
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

OK:
C-142(GR)
0 − 1 V (Release the accelerator pedal)
4 V or more (Depress the accelerator pedal)
959493
104
92 91
103102 101100 99 98 97 96
112111110 109108107 106105 NO : Go to Step 12 .
120119118 117116115 114113

AK400935 AB STEP 12. Connector check: C-140 engine-ECU
connector
Connector: C-140
NO : Repair.
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB

TROUBLESHOOTING
13B-367
No. 4) accelerator pedal position sensor connector
Connector: C-140
Connector : B-116
B-116(GR)
C-140(GR)
8 7 6 5 4 3 2 1
34 33 32 31
51 50 49 4847 46 4544
58 57 5655 54 5352
AK400934 AB
Connector : B-116
B-116(GR)
C-140(GR)
34 33 32 31
43 42 4140 39 38 37 36 35 8 7 6 5 4 3 2 1
51 50 49 4847 46 4544
58 57 5655 54 5352 Harness side connector AK400955 AB
AK400934 AB
• Check output line for damage. No. 5) accelerator pedal position sensor
TROUBLESHOOTING

M1131152001471

No.
11 Oxygen Engine: After Excessive deceleration 200 mV or less Code No. P.13B-72
sensor warm-up (leaner by from 4,000 r/min P0130
(front) deceleration, richer At excessive 600 − 1,000 mV
by acceleration) acceleration
as well as control
status by
engine-ECU.
12 Air flow • Engine coolant Idle operation 18 − 44 Hz − −
sensor *1 temperature: 85 2,500 r/min 40 − 100 Hz
− 95°C
• Lamps, electric
acceleration,
cooling fan and
frequency is
all accessories:
amplified.
OFF
• Transmission:
Neutral
13 Intake air Ignition switch: Intake air temperature: −20°C Code No. P.13B-47
temperature "ON" or engine −20°C P0110
0°C
20°C
40°C
80°C
14 Throttle • Remove the Fully close the throttle 2,200 − Code No. P.13B-116
position intake air hose valve with your finger 2,800 mV P0222, P.13B-120
sensor (sub) at the throttle Fully open the throttle 4,600 mV or P0223
*4 body valve with your finger more
• Disconnect the
throttle position
sensor, and the
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the
use of the
special tool:
MB991658.
• Ignition switch:
ON
TROUBLESHOOTING
13B-369
No.
16 Power Ignition switch: "ON" System voltage Procedure P.13B-308
supply No. 23
voltage
18 Cranking Ignition switch: Engine: Stopped OFF Procedure P.13B-308
signal "ON" Engine: Cranking ON No. 23
(ignition
switch-ST)
21 Engine Ignition switch: Coolant temperature: −20°C Code No. P.13B-54
coolant "ON" or engine −20°C P0115
sensor 0°C
20°C
40°C
80°C
22 Crank angle • Engine: Compare engine speed Matched Code No. P.13B-145
0°C 1,500 r/min
20°C 1,500 r/min
40°C 1,350 r/min
80°C
25 Barometric Ignition switch: Altitude: 0m 101 kPa Code No. P.13B-38
pressure "ON" Altitude: 600m 95 kPa P0105
sensor
26 Accelerator Ignition switch: Release the accelerator ON Procedure P.13B-362
pedal "ON" pedal No. 31
position Depress the accelerator OFF
switch pedal
27 Power Engine: Idle Steering wheel: Not OFF Code No. P.13B-178
steering fluid operation operated P0551
pressure Steering wheel: ON
switch Operated
TROUBLESHOOTING

No.
28 A/C switch Engine: Idle AC switch: OFF OFF Procedure P.13B-331
AC A/C OFF No. 26
ON not driven
A/C ON
compressor is
driven
34 Air flow Engine: After Idle operation ON Code No. P.13B-28
sensor reset engine warm-up 3,000 r/min OFF P0100
signal
− 95°C
• Lamps, electric
acceleration,
cooling fan and
volumetric
all accessories:
efficiency is
OFF
increased.
• Transmission:
Neutral
41 Injectors *2 Engine: Cranking Coolant temperature: 22 − 34 ms − −
operation)
Coolant temperature: 5 − 11 ms
20°C
80°C
− 95°C
• Lamps, electric
cooling fan and
all accessories:
OFF
• Transmission:
Neutral
44 Ignition • Engine: After Idle operation 0 − 13°BTDC Procedure P.13B-355
• Install timing
light (for use to
measure actual
ignition timing)
TROUBLESHOOTING
13B-371
No.
49 A/C relay Engine: After A/C switch: OFF OFF Procedure P.13B-335
A/C ON
compressor is
driven
59 Cylinder 1,4 Engine: After At excessive 0 mV or less ⇔ Code No. P.13B-84
Oxygen warm-up acceleration 600 − 1,000 mV P0136
Sensor (altered)
(rear)
77 Accelerator Ignition switch: ON Release the accelerator 335 − 935 mV Code No. P.13B-229
pedal pedal P2126, P.13B-232
position Depress the accelerator Increases in P2127, P.13B-236
sensor (sub) pedal gradually response to the P2128
pedal depression
stroke
Depress the accelerator 4,000 mV or
pedal fully more
78 Accelerator Ignition switch: ON Release the accelerator 335 − 935 mV Code No. P.13B-219
pedal pedal P2121, P.13B-222
position Depress the accelerator Increases in P2122, P.13B-226
sensor pedal gradually response to the P2123
(main) pedal depression
stroke
Depress the accelerator 4,000 mV or
pedal fully more
79 Throttle • Remove the Fully close the throttle 300 − 700 mV Code No. P.13B-61
position intake air hose valve with your finger P0122, P.13B-65
sensor at the throttle Fully open the throttle 4,000 mV or P0123
(main) body valve with your finger more
• Disconnect the
throttle position
sensor, and then
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the
use of the
special tool:
MB991658.
ON
No load 520 − 620 mV
TROUBLESHOOTING

No.
9A Throttle Ignition switch: ON 600 − 1,200 mV Code No. P.13B-61
position P0122, P.13B-65
sensor P0123
(main) mid
opening
learning
value
13 Intake air Ignition switch: Intake air temperature: −20°C Code No. P.13B-47
*5 temperature "ON" or engine −20°C P0110
0°C
20°C
40°C
80°C
21 Engine Ignition switch: Coolant temperature: −20°C Code No. P.13B-54
*5 coolant "ON" or engine −20°C P0115
sensor 0°C
20°C
40°C
80°C
0°C 1,500 r/min
20°C 1,500 r/min
40°C 1,350 r/min
80°C
24 Vehicle Drive 40 km/h Approximately − −
*5 speed 40 km/h
sensor
TROUBLESHOOTING
13B-373
No.
• Install timing
light (for use to
measure actual
ignition timing)
81 Long-term Engine: After warm-up, 2,500 r/min without −12.5 to 12.5% Code No. P.13B-96
compensati
on cylinder
1, 4
82 Shot-term Engine: After warm-up, 2,500 r/min without −20 to 20% Code No. P.13B-96
compensati
on cylinder
1, 4
8A Throttle • Remove the Fully close the throttle 0 − 5% Code No. P.13B-61
*5 position intake air hose valve with your finger P0122, P.13B-65
sensor at the throttle Fully open the throttle 88% or more P0123
(main) *4 body valve with your finger
• Disconnect the
throttle position
sensor, and then
connect terminal
numbers No. 3,
and No. 4, No. 5
and No. 6 with
the use of the
special tool:
MB991658.
ON
TROUBLESHOOTING

No.
A1 Oxygen Engine: After Excessive deceleration 0.2 V or less ⇔ Code No. P.13B-72
*5 sensor warm-up (leaner by from 4,000 r/min 0.6 − 1 V P0130
(front) deceleration, richer (altered)
by acceleration)
as well as control
status by
engine-ECU
A2 Oxygen Engine: After At excessive 0 V or less ⇔ 0.6 Code No. P.13B-84
*5 sensor warm-up acceleration − 1 V (altered) P0136
(rear)
A9 Engine Running distance in the engine warning lamp on − −
*5 warning
lamp
distance
CAUTION
move forward
approximately 10%.
r/min. or less.
NOTE: *3: On the new vehicle (mileage: 500 km or less), injector drive time may be longer by approximately
10%.
NOTE: *4: After the inspection has been completed, disconnect the throttle actuator control motor connector,
and then use the M.U.T.-II/III to delete the diagnosis code that was recorded during the inspection.
TROUBLESHOOTING
13B-375
M1131152500912
procedure
No.
01 Injector Cut off No. 1 Engine: After warm-up, Engine is Code No. P.13B-100
02 Cut off No. 2 injectors sequentially to (becomes Code No. P.13B-104
03 Cut off No. 3 idle status. Code No. P.13B-108
injector P0203
04 Cut off No. 4 Code No. P.13B-112
injector P0204
07 Fuel pump Drive fuel pump Ignition Check for Operating Procedure P.13B-316
to circulate fuel switch: "ON" pump noise audible No. 25
operating
noise near
fuel tank
08 Purge Switch solenoid Ignition switch: "OFF" When the valve Code No. P.13B-168
valve is audible
09 Fuel Switch solenoid Ignition switch: "ON" When the valve Code No. P.13B-22
pressure valve from OFF is actuated, P0090
control to ON operating noise
solenoid is audible
valve
10 EGR control Switch solenoid Ignition switch: "ON" When the valve Code No. P.13B-162
is audible.
12 Waste gate Switch solenoid Ignition switch: "ON" When the valve Code No. P.13B-123
is audible
timing engine-ECU to • Install timing light
ignition timing
adjusting mode
21 Fan Actuate fan • Ignition switch: "ON" Fan motor is Procedure P.13B-304
34 Throttle Stop the throttle Ignition switch: "ON" Throttle valve Code No. P.13B-207
valve control valve control is open P2100, P.13B-210
servo servo P2101, P.13B-213
P2102,
P.13B-216
P2103
TROUBLESHOOTING

TERMINAL VOLTAGE CHECK CHART engine-ECU connector connected.
2. You may find it convenient to pull out the
Needle-nosed wire probe engine-ECU to make it easier to reach the
given in the chart.
CAUTION
Short-circulating the positive (+) probe between
a connector terminal and earth could damage the
vehicle wiring, the sensor, engine-ECU or all of
AK201749AB them. Be careful to prevent this!
1. Connect a needle-nosed wire probe to a voltmeter 3. If voltmeter shows any division from standard
probe. value, check the corresponding sensor, actuator
replace.
the engine-ECU connector terminals from the wire
side, and measure the voltage while referring to 4. After repair or replacement, recheck with the
the check chart. voltmeter to confirm that the repair has corrected
the problem.
Engine-ECU Connector Terminal Arrangement

Engine-ECU Connector
C-139 C-140 C-141 C-142 C-138
121 125 134

122 126 135
123 132 140

124 133 141
31
32
33
34
61
62
63
64
91
92
93
94
95
1
2
3
4
127
128 136
129 137
130 138
131 139
100
101
102
103
104 112 120

10
71
11
12
13
35
36
37
38
39
40
41
42
43
65
66
67
68
69
70
72
73
96
97
98
99
5
6
7
8
9
105 113
106 114
107 115
108 116
109 117
110 118
111 119
44
45
46
47
48
49
50
51
74
75
76
78
79
80
81
82
77
14
15
16
17
18
19
20
142
143
144
145
146
83
84
85
86
87
88
89
52
53
54
55
56
57
58
21
22
23
24
25
26
27
AK303309 AE

No.
1 No. 1 injector While engine is idling after having warmed From 9 − 13 V*,
14 No. 3 injector
21 No. 4 injector
3 Fuel pressure Ignition switch: ON System voltage
control solenoid Engine: Cranking → Idle operation (within 1V or less → System
valve approximately 2 minutes or less) voltage
7 Engine warning lamp Ignition switch: "LOCK" (OFF) → "ON" 1 V or less → System
voltage (After several
8 A/C relay • Engine: Idle speed System voltage → 1 V or
• A/C switch: OFF → ON (A/C compressor less
is operating)
10 Oxygen sensor Engine: Idling after warming up 9 − 11 V
heater (front) Engine: 5,000 r/min System voltage
TROUBLESHOOTING
13B-377
No.
15 Throttle valve control Ignition switch: "ON" System voltage
servo relay Running at 3,500 r/min while engine is 1 V or less
17 Fan controller Radiator and condenser fan is not operating 0 − 0.3 V*
Radiator and condenser fan is operating 0.7 V* or more
heater (rear) Engine: Racing System voltage
20 EGR control Ignition switch: "ON" System voltage
solenoid valve While engine is idling, suddenly depress the From system voltage,
accelerator pedal momentarily drops.
23 Purge control Ignition switch: "ON" Decreases Voltage
31 Ignition coil − No. 1, Engine r/min: 3,000 r/min 0.3 − 3.0 V*
No. 4
35 Ignition coil − No. 2,
No. 3
43
38 Accelerator pedal Ignition switch: "ON" Release the 0−1V
position switch accelerator pedal
Depress the 4 V or more
accelerator pedal
45 Alternator G terminal • Engine: Warm, idle (radiator fan: OFF) Voltage increases
• Headlamp: OFF → ON
is turned
57 Engine control relay Ignition switch: "LOCK" (OFF) System voltage
(Power supply) Ignition switch: "ON" 1 V or less
supply
63 Air flow sensor Engine: Idle speed. 2.2 − 3.2V
Engine r/min: 2,500 r/min speed
TROUBLESHOOTING

No.
OFF
ON (A/C compressor
is operating)
Engine: Idling 2.0 − 3.0 V
78 A/C load signal Refer to GROUP 55 − Troubleshooting (Inspection at the Automatic
compressor − ECU Terminal)
79 Vehicle speed • Ignition switch: "ON" 0 ⇔ 5 V Changes
sensor • Move the vehicle forward slowly repeatedly
84 Clutch oil pressure Ignition switch: "ON" Release the clutch 1.3V or less
sensor pedal
Depress the clutch 1.9 V or more
pedal
92 Power supply Ignition switch: "ON" 4.5 − 5.5 V
voltage applied to
accelerator pedal
position sensor
voltage
temperature sensor temperature is −20°C
temperature is 0°C
TROUBLESHOOTING
13B-379
No.
temperature is 0°C
100 Barometric pressure Ignition switch: "ON" Altitude: 0m 3.8 − 4.2V
sensor Altitude: 600m 3.5 − 3.9V
Altitude: 1,200m 3.3 − 3.7V
Altitude: 1,800m 3.0 − 3.4V
voltage applied to
throttle position
sensor
107 Accelerator pedal Ignition switch: "ON" Release the 0.335 − 0.935 V
position sensor (sub) accelerator pedal
Depress the 4.0 V or more
accelerator pedal fully
108 Oxygen sensor Engine: Running at 2,500 r/min after warmed 0 ⇔ 0.8 V (Changes
(front) up (Check using a digital type voltmeter) repeatedly)
113 Throttle position • Remove the intake Fully close the throttle 2.2 − 2.8 V
sensor (sub) air hose at the valve with your finger
throttle body Fully open the throttle 4.6 V or more
• Disconnect the valve with your finger
throttle position
sensor, and then
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the use
of the special tool
(MB991658).
"ON"
position sensor accelerator pedal
(main) Depress the 4.0 V or more
TROUBLESHOOTING

No.
sensor (main) air hose at the valve with your finger
throttle position
sensor, and then
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the use
of the special tool
(MB991658).
"ON"
116 Oxygen sensor Engine: Idling after warmed up (Check using 0 ⇔ 0.6 V (Changes
(rear) a digital type voltmeter) repeatedly)
(when the load by
A/C is high)
the load by A/C is
low)
126 Waste gate solenoid Ignition switch: "ON" System voltage
valve Engine: After warm-up, idle operation (When 1 V or less
using premium gasoline)
voltage applied to
throttle valve control
servo
133 Throttle valve control • Ignition switch: "ON" Decreases slightly
servo (+) • Accelerator pedal: fully opened → fully (approximately 2 V) from
closed battery voltage.
servo (−) • Accelerator pedal: fully closed → fully (approximately 2 V) from
opened battery voltage.
NOTE: The average voltage is shown when an ana-
log voltmeter is used (because the average voltage
might not be shown stably when digital voltmeter is
used).
TROUBLESHOOTING
13B-381
2. Disconnect the engine-ECU connector.
vehicle wiring, sensors, engine-ECU and/or ohm-
3. Measure the resistance and check for continuity meter. Be careful to prevent this!
between the terminals of the engine-ECU
harness-side connector while referring to the
check chart.
test probe.
given in the chart.
Engine-ECU Harness Side Connector Terminal Arrangement

Engine-ECU Harness Side Connector
C-138 C-142 C-141 C-140 C-139
124 133 141
123 132 140
122 126 135

121 125 134
34
33
32
31
64
63
62
61
95
94
93
92
91
4
3
2
1
131 139
130 138
129 137
128 136
127
104 112
103 110
102
101 109
100 108
10
71
11
13
12
43
42
41
40
39
38
37
36
35
73
72
70
69
68
67
66
65
99 107
98
97 106
96 105
6
5
8
7
9
111
51
50
49
48
47
46
45
44
82
81
80
79
78
76
75
74
77
20
19
18
17
16
15
14
146
145
144
143
142
120
119
118
117
116
115
114
113
89
88
87
86
85
84
83
58
57
56
55
54
53
52
27
26
25
24
23
22
21
AK303310 AE

No.
1 − 34 No. 1 injector 13 − 16 Ω (At 20°C)
3 − 34 Fuel pressure control solenoid valve 28 − 36 Ω (at 20°C)
10 − 34 Oxygen sensor heater (front) 4.5 − 8.0 Ω (at 20°C)
18 − 34 Oxygen sensor heater (rear) 11 − 18 Ω (at 20°C)
20 − 34 EGR control solenoid valve 29 − 35Ω (at 20°C)
earth
42 − Body
earth
144 −
Body
earth
145 −
Body
earth
TROUBLESHOOTING

No.
34 − 126 Waste gate solenoid valve 29 − 35 Ω (at 20°C)
133 − 141 Throttle actuator control motor 0.3 − 80 Ω (at 20°C)
TROUBLESHOOTING
13B-383
INSPECTION PROCEDURE USING 1. Disconnect the air flow sensor connector, and
OSCILLOSCOPE connect the special tool test harness (MB991709)
M1131154501030 in between (All terminals should be connected).
The output signals of the sensors and the conditions 2. Connect the oscilloscope special patterns pickup
of the actuation signals of the actuators can be to air flow sensor connector terminal No. 3.
inspected visually by observing the waveforms on
the oscilloscope. Alternate Method (Test harness not
AIR FLOW SENSOR (AFS) available)
Measurement Method 1. Connect the oscilloscope special patterns pickup
to engine-ECU terminal No. 63.
Oscilloscope
1 2 3 4 5 6 7
Special
patterns Function Special patterns
pickup
Pattern height Low
Engine speed Idle
AK000786 AE

(V)
10 The time (cycle time) T is reduced when
T the amount of intake air increases.
T1 T2 Times T1 and T2 are equal.
Time
0
AK202334 AC
Observation conditions (from conditions above engine is increased by racing.)

(V)
10
T
Time
0
AK202335 AB
TROUBLESHOOTING
Wave Pattern Observation Points CAMSHAFT POSITION SENSOR AND

Check that cycle time T becomes shorter and the fre- CRANK ANGLE SENSOR
quency increases when the engine speed is
Measurement Method
increased.
Camshaft position Oscilloscope
Examples of Abnormal Wave Patterns sensor connector
1 2 3 Special patterns
pick-up
1 2
3 Crank angle
sensor connector
AK000840AC
1. Disconnect the camshaft position sensor

AKX01597
connector and connect the special tool test
• Example 1 harness (MB991709) in between (All terminals
Cause of problem should be connected).
Sensor interface malfunction 2. Connect the oscilloscope special pattern pickup to
Wave pattern characteristics camshaft position sensor terminal No. 2.
Rectangular wave pattern is output even when 3. Disconnect the crank angle sensor connector and
the engine is not started. connect the special tool test harness (MD998478)
• Example 2 in between.
Cause of problem 4. Connect the oscilloscope special patterns pickup
Damaged rectifier or vortex generation column to crank angle sensor terminal No. 2.
Wave pattern characteristics Alternate Method (Test harness not
Unstable wave pattern with non-uniform fre-
quency. However, when an ignition leak available)
occurs during acceleration, the wave pattern 1. Connect the oscilloscope special patterns pickup
will be distorted temporarily, even if the air to engine-ECU terminal No. 71 (When checking
flow sensor is normal. the camshaft position sensor signal wave pattern).
the crank angle sensor signal wave pattern).
TROUBLESHOOTING
13B-385
Pattern height Low
Engine speed Idle
Standard Wave Pattern 2 engine revolutions

The time (cycle time)
75˚ BTDC T is reduced when the
5˚ BTDC
engine speed increases
Crank angle
sensor output
wave pattern
Camshaft position
sensor output
wave pattern
Time
0
TDC: Top dead centre No.1 TDC No.3 TDC No.4 TDC No.2 TDC
AK202336 AB
Wave Pattern Observation Points Wave pattern characteristics

Check that cycle time T becomes shorter when the Rectangular wave pattern is output even when
engine speed increases. the engine is not started.
•

•
AKX01602
Example 2
AKX01597
Cause of problem
Example 1 Loose timing belt
Cause of problem Abnormality in sensor disk
Sensor interface malfunction Wave pattern characteristics
Wave pattern is displaced to the left or right.
TROUBLESHOOTING
INJECTOR Alternate Method (Test harness not

Oscilloscope to engine-ECU terminal No. 1 (When checking the
No. 1 cylinder).
1 2 to engine-ECU terminal No. 5 (When checking the
No. 2 cylinder).
Special
patterns 3. Connect the oscilloscope special patterns pickup
pickup to engine-ECU terminal No. 14 (When checking
AK101807AC 4. Connect the oscilloscope special patterns pickup
1. Disconnect the injector connector, and then the No. 4 cylinder).
connect the special tool test harness (MB991348)
in between (All terminals should be connected). Standard Wave Pattern
wave pattern
Engine speed Idle
(V) Point A.
Solenoid back
50 electromotive
force
(Approx.7×10V)
Point B
Injector drive
time
Time
Power
voltage
AK202347AB
TROUBLESHOOTING
13B-387
Wave Pattern Observation Points IGNITION COIL AND POWER TRANSIS-
Point A: Height of solenoid back electromotive force TOR
Contrast with standard Probable cause Measurement Method
wave pattern
Solenoid coil back Short in the injector Oscilloscope
electromotive force is solenoid
low or does not appear
at all. 1 2 3

• Special
patterns
pickup
CH1
AK201750 AB

connect the special tool test harness (MB991348)
When idling to terminal No. 3 of each ignition coil connector in
turn.
The injector drive time will be synchronized with the
M.U.T.-II/III tester display. Alternate Method (Test harness not
• When the engine is suddenly raced, the drive available)
time will be greatly extended at first, but the drive 1. Connect the oscilloscope special patterns pickup
time will soon match the engine speed. to engine-ECU terminal No. 31 (No. 1 − No. 4),
connection terminal No. 35 (No. 2 − No.3)
respectively.
TROUBLESHOOTING

Pattern height Low
Engine r/min Approximately 1,200
r/min
(V)
6 T
5˚ BTDC
4 75˚ BTDC
Crank angle Compression top dead center
sensor output 2
wave pattern
0
Power transistor T1
2 Ignition period
control signal
wave pattern
0
OFF ON
Dwell section
T : Revolution time corresponding to a crank angle of 180˚

T1 : Time computed by the engine-ECU
: Spark advance angle
AK204435 AC
Wave Pattern Observation Points Condition of wave pattern Probable cause

Point: Condition of wave pattern build-up section and build-up section and maximum
maximum voltage (Refer to abnormal wave pattern voltage
examples 1 and 2).
Rises from approximately 2 V Normal
to approximately 4.5 V at the
top-right
2 V rectangular wave Open-circuit in
ignition primary
circuit
Rectangular wave at power Power transistor
voltage malfunction
TROUBLESHOOTING
13B-389
•
Normal wave pattern

VB
Normal wave pattern
2V
AKX01613AD
AKX01612AD Example 2
Example 1 Wave pattern during engine cranking
Wave pattern during engine cranking Cause of problem
Cause of problem Malfunction in power transistor
Open-circuit in ignition primary circuit Wave pattern characteristics
Wave pattern characteristics Power voltage results when the power transistor
Top-right part of the build-up section cannot be is ON.
too low.
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
AREA) CLEANING
M1131001000804
1. Remove the air intake hose from the throttle body.
2. Remove the throttle body assembly.
CAUTION
• Do not spray the cleaning fluid directly to the
throttle valve. 16 PIN
MB991502
the motor from the bypass line. Also make AK303691AG
sure it does not enter the sensor through the

shaft.
cloth sprayed with cleaning fluid. 16-PIN
5. Install the throttle body assembly.
6. Attach the air intake hose.

SWITCH AND ACCELERATOR PEDAL
MB991911
POSITION SENSOR (APS) ADJUSTMENT
M1131053400052
MB991824
CAUTION
1. The accelerator pedal position sensor should
not be moved unnecessarily; it has been pre-
cisely adjusted by the manufacture.
2. If the adjustment is disturbed for any reason,
readjust as follows.
MB991827 AK303690AB

connector.
ON-VEHICLE SERVICE
13B-391
FUEL PRESSURE TEST
M1131001900959
Accelerator pedal 1. Release residual pressure from the fuel pipe line
position sensor to prevent fuel gush out (Refer to P.13B-393).
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.
1 2 3 4 5 6 7 8
Equipment side connector AK400227 AB
Accelerator lever
Stopper (full
stop position)
AK400228 AB
A 2. Disconnect the high-pressure fuel hose at the

AK303650AB delivery pipe side.
2. Remove the accelerator pedal position sensor
(main and sub) assembly mounting bolts, and MB 991637
then insert a thickness gauge with a thickness of Gasket
0.60 mm in between the accelerator lever and the MD 998709
fully-closed stopper (i.e. into area "A" shown in
Fig). Delivery
pipe MD 998742
3. Turn the ignition switch to the "ON" position
High-pressure
(without starting the engine). fuel hose
4. Loosen the accelerator pedal position sensor
mounting bolt, and then turn the accelerator pedal AKX01458AG
position sensor anti-clockwise as far as it will go.

5. Check that the accelerator pedal position switch MB 991981
turns on at this time.
6. Turn the accelerator pedal position sensor Gasket
clockwise until the point is found where the
MD 998709
accelerator pedal position switch turns off.
Securely tighten the accelerator pedal position Delivery
pipe
sensor mounting bolt at this point. MD 998742
7. Check that the accelerator pedal position sensor High-pressure
fuel hose
(main) output at this time is within the standard
value range. AK305430AB
Standard value: 0.5 − 0.9 V 3. Assemble the fuel pressure measurement tools
8. Turn the ignition switch to the "LOCK" (OFF) as follows.
position.
<When using the fuel pressure gauge set (special
9. Remove the thickness gauge and then install the tool)>
accelerator pedal position sensor assembly. a. Remove the union joint and bolt from the special
10.Remove the M.U.T.-II/III. tool adaptor hose (MD998709) and attach the
special tool hose adaptor (MD998742) to the
adaptor hose.
ON-VEHICLE SERVICE
b. Via a gasket, install the special tool fuel pressure 7. Select "Item No. 07" from the M.U.T.-II/III Actuator
gauge set (MB991637 or MB991981) into the test to drive the fuel pump. Check that there are
special tool that has already assembled as no fuel leaks from any parts.
described in (a) above. 8. Finish the actuator test or turn the ignition switch
Fuel pressure to "LOCK" (OFF) position.
gauge set 9. Start the engine and run at idle.
O-ring or gasket 10.Measure fuel pressure while the engine is running
MD 998709 at idle.
Delivery Standard value: Approximately 230 kPa
pipe
MD 998742
High-pressure Vacuum hose
fuel hose
AKX01457AF Fuel pressur

regulator
adaptor hose (MD998709) and attach the special
tool hose adaptor (MD998742) to the adaptor
hose. AK400229AB
b. Via a suitable O-ring or gasket, install the fuel 11.Disconnect the vacuum hose from the fuel
pressure gauge to the special tool that has pressure regulator and measure fuel pressure
already assembled as described in (a) above. with the hose end closed by a finger.
4. Install the assembled fuel pressure measurement
Standard value: 289 − 309 kPa
tools between the fuel rail and fuel high-pressure
hose. 12.Check to see that fuel pressure at idle does not
drop even after the engine has been raced
CAUTION
several times.
To prevent damage to the M.U.T.-II/III, always turn
the ignition switch to the "LOCK" (OFF) position 13.Racing the engine repeatedly, hold the fuel return
before connecting or disconnecting the hose lightly with fingers to feel that fuel pressure
M.U.T.-II/III. is present in the return hose.
5. Connect the M.U.T.-II/III to the diagnosis NOTE: If the fuel flow rate is low, there will be no
connector. fuel pressure in the return hose.
6. Turn the ignition switch to "ON" position (But do 14.If any of fuel pressure measured in steps 10 to 13
not start the engine). is out of specification, troubleshoot and repair
• No fuel pressure in fuel return poor fuel regulator valve seating or
hose settled spring
regulator
Same fuel pressure when vacuum Damaged vacuum hose or Replace vacuum hose or clean
hose is connected and when Clogged nipple nipple
disconnected
ON-VEHICLE SERVICE
13B-393
stopped
16.Release residual pressure from the fuel pipe line 20.Check for any fuel leaks by following the
(Refer to P.13B-393). procedure in step 7.
CAUTION 21.Disconnect the M.U.T.-II/III.
Cover the hose connection with rags to prevent
splash of fuel that could be caused by some FUEL PUMP CONNECTOR
residual pressure in the fuel pipe line. DISCONNECTION (HOW TO REDUCE
17.Remove the fuel pressure gauge and special tool PRESSURIZED FUEL LINES)
from the delivery pipe. M1131000900804
The service procedure is the same as the vehicles
18.Replace the O-ring at the end of the fuel high with 4G63-Non-Turbo- engine. (Refer to GROUP
pressure hose with a new one. Furthermore, 13A - On-vehicle Service P.13A-318).
apply engine oil to the new O-ring before
replacement. FUEL PUMP OPERATION CHECK
19.Fit the fuel high pressure hose over the delivery M1131002000915
pipe and tighten the bolt to specified toque. The service procedure is the same as the vehicles
with 4G63-Non-Turbo engine. (Refer to GROUP 13A
- On-vehicle Service P.13A-319).
ON-VEHICLE SERVICE
COMPONENT LOCATION
M1131002101205

A/C relay H Engine-ECU S
A/C switch Q Engine warming lamp (check engine lamp) O
Accelerator pedal position sensor (with A Fan control relay H
accelerator pedal position switch)
Air flow sensor (with intake air N Fuel pressure control solenoid valve G
temperature sensor and barometric Fuel pump relay (1) and (2) P
pressure sensor)
Camshaft position sensor M Ignition coil (integrated power transistor) J
Clutch oil pressure sensor T
Crank angle sensor C Injector D
Detonation sensor K Oxygen sensor (front) L
Diagnosis connector Q Oxygen sensor (rear) U
EGR control solenoid valve I Power steering fluid pressure switch B
Electronic-controlled throttled valve E Purge control solenoid valve I
(Throttle position sensor and throttle
valve control servo)
Engine control relay H Vehicle speed sensor F
Engine coolant temperature sensor M Waste gate solenoid valve G
A B C D E F G H
I J K L M N
P Q R S T U
AK400230 AB
ON-VEHICLE SERVICE
13B-395
ENGINE CONTROL RELAY CONTINUITY FUEL PUMP RELAY CONTINUITY CHECK
M1131033000999
CHECK
M1131050000992
Fuel pump
Engine control relay relay(1) Relay box's
triangle marks
Relay box's
triangle marks 2 1
Fuel pump 4 3
2 1 relay(2) Equipment side
connector
4 3
AK400232 AB
Equipment side
Fuel pump relay (1) and (2)
Tester Battery Normal State Tester Battery Normal State
Connection Voltage Connection Voltage
Terminal Terminal
2−3 No Voltage Continuity 1−4 No Voltage Continuity
1−4 No Voltage No continuity 2−3 No Voltage No continuity
Voltage Continuity (2 Ω Voltage Continuity (2 Ω
(Connect or less) (Connect or less)
positive (+) positive (+)
terminal of terminal of
battery to battery to
terminal No. 2 terminal No. 1
and negative (−) and negative (−)
terminal of terminal of
battery to battery to
terminal No. 3.) terminal No. 4.)
ON-VEHICLE SERVICE
INTAKE AIR TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE

CHECK SENSOR CHECK
M1131002800858 M1131003100818
CAUTION
1 2
Equipment side
connector
1 2 3 4 5 6 7 Air flow sensor
Equipment side connector
AK400234 AB
1. Disconnect the air flow sensor connector.

Engine coolant
2. Measure resistance between terminals No. 5 and temperature sensor
AK400233 AB
No. 6.
Standard value: 1. Remove the engine coolant temperature sensor.
13 − 17 kΩ (at −20°C)
5.3 − 6.7 kΩ (at 0°C)
2.3 − 3.0 kΩ (at 20°C)
1.0 − 1.5 kΩ (at 40°C)
0.56 − 0.76 kΩ (at 60°C)
0.30 − 0.42 kΩ (at 80°C)
Intake air temperature

sensor AKX01622
2. With temperature sensing portion of engine

coolant temperature sensor immersed in hot
water, check resistance.
Standard value:
AKX01621AD 14 − 17 kΩ (at −20°C)
5.1 − 6.5 kΩ (at 0°C)
2.1 − 2.7 kΩ (at 20°C)
3. Measure resistance while heating the sensor
0.9 − 1.3 kΩ (at 40°C)
using a hair drier.
0.48 − 0.68 kΩ (at 60°C)
Normal condition: 0.26 − 0.36 kΩ (at 80°C)
Temperature (°C) Resistance (kΩ)
3. If the resistance deviates from the standard value
Higher Smaller greatly, replace the sensor.
the resistance remains unchanged, replace the air
flow sensor assembly.
ON-VEHICLE SERVICE
13B-397
4. If not within the standard value, or resistance
value does not change smoothly, replace the
accelerator pedal position sensor.
NOTE: After replacement, adjust the accelerator
pedal position sensor. (Refer to P.13B-390.)

SWITCH CHECK
M1131052500131
AKX01623AD
4. Apply sealant to threaded portion. Accelerator pedal

position sensor
Specified sealant:
3M NUT Locking Part No. 4171 or equivalent
5. Install the engine coolant temperature sensor and
tighten it to the specified torque.
Tightening torque: 29 ± 10 N⋅m 1 2 3 4 5 6 7 8
Equipment side connector AK400227 AB
SENSOR CHECK 1. Disconnect the accelerator pedal position sensor
M1131003400110 connector.
2. Check continuity between terminal No. 4
(accelerator pedal position switch) and No. 5
Accelerator pedal
position sensor (earth) of the connector.
Normal condition:
Accelerator pedal Continuity
Depressed No continuity
1 2 3 4 5 6 7 8
Released Continuity (0 Ω)
Equipment side connector AK400227 AB 3. If defective, replace the accelerator pedal position
sensor.
1. Disconnect the accelerator pedal position sensor NOTE: After replacement, adjust the accelerator
connector. pedal position sensor. (Refer to P.13B-390.)
2. Measure resistance between terminal No. 2 (main
power supply) and No. 1 (main earth) as well as
between terminal No. 8 (sub power supply) and
terminal No. 7 (sub earth) of the sensor
connector.
Standard valve: 3.5 − 6.5 kΩ
power supply) and No. 3 (main output) as well as
No. 6 (sub output) of the sensor connector.
Normal condition:
Depress the accelerator Resistance value
pedal slowly. changes in accordance
with the accelerator
pedal depression
smoothly.
ON-VEHICLE SERVICE
OXYGEN SENSOR CHECK 6. Connect a digital voltage meter between terminal

M1131005001069 No. 2 (black clip of special tool) and No. 4 (white
Oxygen sensor (front) clip of special tool).
Standard value:
sensor
output
voltage
engine engine repeatedly, a
connector 0.6 − 1.0 V.
CAUTION
• Be very careful when connecting the jumper
wire; incorrect connection can damage the
1 2
oxygen sensor.
3 4
• Be careful the heater is broken when voltage
Equipment of beyond 8 V is applied to the oxygen sensor
side connector
AK400235 AB heater.
NOTE: If the sufficiently high temperature (of
1. Disconnect the oxygen sensor connector and approximate 400°C or more) is not reached
connect the special tool test harness (MD998464) although the oxygen sensor is normal, the output
to the connector on the oxygen sensor side. voltage would be possibly low although the rich
2. Make sure that there is continuity (4.5 − 8.0 Ω at air-fuel ratio. Therefore, if the output voltage is
20°C) between terminal No. 1 (red clip of special low, use a jumper wire to connect the terminal No.
tool) and No. 3 (blue clip of special tool) on the 1 (red clip of special tool) and the terminal No. 3
oxygen sensor connector. (blue clip of special tool) of the oxygen sensor
3. If there is no continuity, replace the oxygen with a (+) terminal and (−) terminal of 8 V power
sensor. supply respectively, then check again.
4. Warm up the engine until engine coolant is 80°C 8. If the sensor is defective, replace the oxygen
or higher. sensor.
5. Perform a tracing for 5 minutes or more with the NOTE: For removal and installation of the oxygen
engine speed of 4,500 r/min. sensor, refer to GROUP 15 − Exhaust Manifold
and turbocharger. P.15-22.
Oxygen
Black sensor
equipment
side connector
White
MD998464 AK305450 AB
ON-VEHICLE SERVICE
13B-399
Oxygen sensor (rear) 6. Connect a digital voltage meter between terminal
No. 1 and No. 2.
Standard value:
sensor
Oxygen sensor(rear) output
sensor voltage
1 2 normal oxygen sensor
3 4 will output a voltage of
Equipment 0.6 − 1.0 V.
side connector
CAUTION
• Be very careful when connecting the jumper
wire; incorrect connection can damage the
oxygen sensor.
Oxygen sensor(rear) • Be careful the heater is broken when voltage
connector
AK400236 AB
of beyond 12 V is applied to the oxygen sen-
sor heater.
1. Disconnect the oxygen sensor connector and NOTE: If the sufficiently high temperature (of
connect the special tool test harness (MB991658) approximately 400°C or more) is not reached
to the connector on the oxygen sensor side. although the oxygen sensor is normal, the output
2. Make sure that there is continuity (11 − 18 Ω at voltage would be possibly low although the rich
20°C) between terminal No. 3 and No. 4 on the air-fuel ratio. Therefore, if the output voltage is
oxygen sensor connector. low, use a jumper wire to connect the terminal No.
3. If there is no continuity, replace the oxygen 3 and the terminal No. 4 of the oxygen sensor with
sensor. a (+) terminal and (−) terminal of 12 V power sup-
4. Warm up the engine until engine coolant is 80°C ply respectively, then check again.
or higher. 8. If the sensor is defective, replace the oxygen
5. Perform a tracing for 5 minutes or more with the sensor.
engine speed of 4,500 r/min. NOTE: For removal and installation of the oxygen
Oxygen sensor
MB991658 AK301808 AB
ON-VEHICLE SERVICE
INJECTOR CHECK 3. Assemble the following special tools as shown in

M1131005200929 Fig.
Check the Operation Sound • Injector test set (MD998706)
• Injector test harness (MB991607)
• Injector test adaptor (MD998741)
Injector • Injector test holder assembly (MB991976)
connector.
1 2 6. Select "Item No. 07" from the M.U.T.-II/III actuator
test to drive the fuel pump.
Equipment side connector AK400237AB
Fuel pressure
1. Use a stethoscope to listen to the operation sound regulator
(clicking) of the injectors while the engine is idling
or cranking.
High-pressure
CAUTION fuel hose
tors can be heard even if the injector that is being Return hose
inspected might not be operating.
2. Verify that the operation sound increases with the
engine speed. Battery
Injector
NOTE: If the operating sound cannot be heard, AK301465AC
inspect the injector actuation circuit.

7. Activate the injector and check the atomized
spray condition of the fuel.
Measurement of Resistance between Ter-
minals The condition can be considered satisfactory
unless it is extremely poor.
1. Disconnect the injector connector.
8. Stop the actuation of the injector, and check for
2. Measure the resistance between terminals. leakage from the injector’s nozzle.
Standard value: 13 − 16 Ω (at 20°C) Standard value: 1 drop or less per minute
3. Connect the injector connector. 9. Without the fuel pump operation, operate the
injector to draw the fuel out.
Check the Injection Condition
10.If the spraying is extremely poor or the fuel
1. Following the steps below, bleed out the residual leakage from the injector nozzle deviates from the
pressure within the fuel pipe line to prevent flow of standard value, replace the injector.
the fuel (Refer to P.13B-393).
11.Disconnect the M.U.T.-II/III.
Fuel pressure THROTTLE VALVE CONTROL SERVO
regulator CHECK
M1131051000230
MD998741 OPERATION CHECK

High-pressure 1. Remove the air intake hose from the throttle body.
fuel hose MD998706
MB991607 2. Turn the ignition switch to "ON" position.
Return hose
3. Operate the accelerator pedal and confirm that
MB991976 the throttle valve is opening and closing
accordingly.
Battery Injector
AK301464 AC
ON-VEHICLE SERVICE
13B-401
CHECK THE COIL RESISTANCE
B nipple
Electronically
controlled
throttle valve
1 2 3 4 5 6
Battery
Equipment AK202416 AC
side connector AK400238 AB
3. Connect a hand vacuum pump to the solenoid
1. Disconnect the electronically controlled throttle valve’s A nipple.
valve connector. 4. Connect the solenoid valve terminal and battery
2. Measure the resistance between terminals No. 1 terminal with a jumper wire.
and No. 2 at the throttle valve control servo 5. Disconnect the jumper wire between the battery’s
connector. (−) terminals, apply a negative pressure, and
Standard value: 0.3 − 80 Ω (at 20°C) inspect the tightness.
3. If resistance is outside the standard value, replace Standard valve:
the throttle body assembly. Battery voltage B nipple Normal
condition
FUEL PRESSURE SOLENOID VALVE No applied Open Vacuum leak
CHECK Close Vacuum
M1131005800084
OPERATION CHECK maintained

Applied Open Vacuum
maintained
1 2
Equipment
side connector
COIL RESISTANCE CHECK
Fuel pressure
solenoid valve AK400239 AB
1. Remove the vacuum hose from the solenoid

valve.
2. Disconnect the harness connector.
AK304596
1. Measure the resistance between the terminals of

the solenoid valve.
Standard value: 28 − 36 Ω (at 20°C)
INJECTOR
INJECTOR
M1131007101482
CAUTION
Engine P.00-21).
• Fuel Discharge Prevention (Refer to P.13B-393). • Intercooler Assembly and Intercooler Outlet Air Hose
• Intercooler Assembly and Intercooler Outlet Air Hose A Installation (Refer to GROUP 15, Intercooler P.15-9).
Removal (Refer to GROUP 15, Intercooler P.15-9). • Fuel Leakage Inspection.
5.0 ± 1.0 N·m

12 2
7 19 14
8N
13 N 15 16 18 17
N 11
9 13 5
4
10 11 ± 1 N·m 3
6
8.9 ± 1.9 N·m 1

moving parts before
installation.
AC400839AB

2. Injector connector <<A>> 12. Fuel delivery pipe and fuel injector
3. Detonation sensor connector assembly
4. Purge control solenoid valve 13. Insulators
connector >>A<< 14. Fuel injector assembly
5. EGR solenoid valve connector 15. O-ring
6. Emission control equipment hose 16. Fuel injector sheets
connector 17. Insulators
>>A<< 7. Fuel high-pressure hose 18 Fuel injectors
connection 19. Fuel delivery pipe
8. O-ring
9. Fuel return hose connection
>>A<< 10. Delivery pipe pressure regulator
INJECTOR
13B-403
<<A>> FUEL DELIVERY PIPE AND FUEL >>A<< FUEL INJECTOR ASSEM-
INJECTOR ASSEMBLY REMOVAL BLY/DELIVERY PIPE PRESSURE REGU-
CAUTION LATOR/FUEL HIGH-PRESSURE HOSE
Do not drop the injector. INSTALLATION
Remove the fuel delivery pipe with the fuel injector
CAUTION
assembly attached to it.
Do not let the engine oil get into the delivery pipe
will be damaged.
2. Turn the fuel injector assembly. To the right and
left to install to the fuel delivery pipe. Repeat for
delivery pipe pressure regulator and fuel
O-ring. After installing, check that the item turns
smoothly.
3. If it dose not turn smoothly, the O-ring may be
trapped, remove the item, re-install it into the fuel
4. Tighten the delivery pipe pressure regulator and
fuel high-pressure hose to the specified torque.
Tightening torque:
8.9 ± 1.9 N⋅m <Delivery pipe pressure regula-
tor>
5.0 ± 1.0 N⋅m <Fuel high-pressure hose>

M1131007701365
CAUTION
• When the throttle body assembly replacement is performed, use the M.U.T.-II/III to initialise the
learning value (Refer to GROUP 00, Precautions Before Service − Initialisation Procedure for
Learning Value in MPI Engine P.00-21).
• Do not loosen the fixing screws for the resin cover of throttle body assembly. If the screws are
loosened, the sensor incorporated in the resin cover becomes misaligned and the throttle body
can not work normally.
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Engine Coolant Supplying (Refer to GROUP 14, On-vehi-
Service − Engine Coolant Replacement P.14-17). cle Service − Engine Coolant Replacement P.14-17).
• Intercooler Assembly and Intercooler Outlet Air Hose • Intercooler Assembly and Intercooler Outlet Air Hose
Removal (Refer to GROUP 15, Intercooler P.15-9). Installation (Refer to GROUP 15, Intercooler P.15-9).
5N
4
13 ± 2 N·m
1
3 2
AC400809 AB

>>B<< • Initialisation procedure (installation 3. Water feed hose connection
only) 4. Throttle body assembly
1. Throttle position sensor connector >>A<< 5. Throttle body gasket
2. Water return hose connection
13B-405
INSTALLATION SERVICE POINT >>B<< INITIALISATION PROCEDURE
>>A<< THROTTLE BODY GASKET Turn the ignition switch on then off, and keep it off for
at least 10 seconds.
INSTALLATION
CAUTION
Projection
AC400885AB
Install the throttle body gasket as its protrusion is in

the direction shown.
ENGINE-ECU
ENGINE-ECU
M1131033800456
CAUTION
• When the engine-ECU replacement is performed, always refer to GROUP 54A, On-vehicle Service -
How to Register Encrypted Code P.54A-22.
• After the engine-ECU is replaced, idling speed may be unstable because the MPI engine learning
is not completed. To make it stable, make the system learn the idling (Refer to GROUP 00 − Pre-
cautions before Service, Learning Procedure for Idling in MPI Engine P.00-21).
3
5.0 ± 1.0 N·m
1 9.0 ± 2.0 N·m
AC309335AB
Removal steps INSTALLATION SERVICE POINT

>>A<< • Initialisation procedure (installation
>>A<< INITIALISATION PROCEDURE
only)
1. Engine-ECU connector Turn the ignition switch on then off, and keep it off for
2. Engine-ECU at least 10 seconds.
3. Engine-ECU bracket
13C-1
GROUP 13C
MULTIPORT FUEL
INJECTION (MPI)
<4G69>
CONTENTS
GENERAL INFORMATION . . . . . . . . 13C-3 ACCELERATOR PEDAL POSITION

SWITCH AND ACCELERATOR
PEDAL POSITION SENSOR (APS)
SERVICE SPECIFICATIONS. . . . . . . 13C-7 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 13C-427
FUEL PUMP CONNECTOR
SEALANT. . . . . . . . . . . . . . . . . . . . . . 13C-7 DISCONNECTION (HOW TO REDUCE
PRESSURIZED FUEL LINES) . . . . . . . . . . 13C-428
SPECIAL TOOLS. . . . . . . . . . . . . . . . 13C-8 FUEL PUMP OPERATION CHECK . . . . . . 13C-428
COMPONENT LOCATION . . . . . . . . . . . . . 13C-428
TROUBLESHOOTING . . . . . . . . . . . . 13C-11 ENGINE CONTROL RELAY CONTINUITY
DIAGNOSIS TROUBLESHOOTING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-429
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-11 FUEL PUMP RELAY CONTINUITY
DIAGNOSIS FUNCTION. . . . . . . . . . . . . . . 13C-11 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-430
INSPECTION CHART FOR DIAGNOSIS THROTTLE VALVE CONTROL SERVO
CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-21 RELAY CONTINUITY CHECK . . . . . . . . . . 13C-430
INSPECTION PROCEDURE FOR INTAKE AIR TEMPERATURE SENSOR
DIAGNOSIS CODES . . . . . . . . . . . . . . . . . 13C-24 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-430
INSPECTION CHART FOR TROUBLE ENGINE COOLANT TEMPERATURE
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13C-278 SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13C-431
CHECK AT THE ECU TERMINALS . . . . . . 13C-412 ACCELERATOR PEDAL POSITION
INSPECTION PROCEDURE USING SENSOR CHECK . . . . . . . . . . . . . . . . . . . . 13C-431
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13C-419 ACCELERATOR PEDAL POSITION
SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . 13C-432
ON-VEHICLE SERVICE. . . . . . . . . . . 13C-425 OXYGEN SENSOR CHECK . . . . . . . . . . . . 13C-432
THROTTLE BODY (THROTTLE VALVE INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13C-435
AREA) CLEANING . . . . . . . . . . . . . . . . . . . 13C-425 THROTTLE VALVE CONTROL SERVO
FUEL PRESSURE TEST . . . . . . . . . . . . . . 13C-425 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C-436
OIL CONTROL VALVE CHECK . . . . . . . . . 13C-436

13C-2
INJECTOR . . . . . . . . . . . . . . . . . . . . . 13C-437 ENGINE-ECU AND

REMOVAL AND INSTALLATION . . . . . . . . 13C-437 ENGINE-A/T-ECU . . . . . . . . . . . . . . . . 13C-441
THROTTLE BODY ASSEMBLY . . . . 13C-439
MULTIPORT FUEL INJECTION (MPI) <4G69>
GENERAL INFORMATION
13C-3
GENERAL INFORMATION
M1131000101845
The Multipoint Fuel Injection System consists of sen- <A/T> carries out activities such as fuel injection con-
sors which detect the engine conditions, the trol, idle speed control and ignition timing control. In
engine-ECU <M/T> or engine-A/T-ECU <A/T> which addition, the engine-ECU <M/T> or engine-A/T-ECU
controls the system based on signals from these <A/T> is equipped with several diagnosis modes
sensors, and actuators which operate under the con- which simplify troubleshooting when a problem
trol of the engine-ECU <M/T> or engine-A/T-ECU develops.
<A/T>. The engine-ECU <M/T> or engine-A/T-ECU

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

This system electrically controls the opening of the
throttle valve. The engine-ECU <M/T> or
engine-A/T-ECU <A/T> detects the amount of travel
of the accelerator pedal via the accelerator pedal
position sensor, and controls the actuation of the
throttle actuator control motor, which is mounted on
the throttle body, in order to attain the target throttle
valve opening that has been predetermined in
accordance with driving conditions.
IDLE SPEED CONTROL

The idle speed is kept at the optimum speed by con- air conditioning switch is turned off and on while the
trolling the amount of air that passes through the engine is idling, the throttle valve control servo
throttle valve in accordance with changes in idling adjusts the throttle valve passes through air amount
conditions and engine load during idling. according to the engine load conditions to avoid fluc-
The engine-ECU <M/T> or engine-A/T-ECU <A/T> tuations in the engine speed.
drives the throttle valve control servo to keep the
engine running at the pre-set idle target speed in
A/C and other electrical load. In addition, when the

The power transistor located in the ignition primary ignition timing is determined by the engine-ECU
circuit turns ON and OFF to control the primary cur- <M/T> or engine-A/T-ECU <A/T> from the engine
rent flow to the ignition coil. This controls the ignition speed, intake air volume, engine coolant tempera-
timing in order to provide the optimum ignition timing ture and atmospheric pressure.
13C-4 MULTIPORT FUEL INJECTION (MPI) <4G69>
GENERAL INFORMATION
• When an abnormality is detected in one of the • The RAM data inside the engine-ECU <M/T> or
sensors or actuators related to emission control, engine-A/T-ECU <A/T> that is related to the sen-
the engine warning lamp (check engine lamp) sors and actuators can be read by means of the
illuminates as a warning to the driver. M.U.T.-II/III. In addition, the actuators can be
• When an abnormality is detected in one of the force-driven under certain circumstances.

1. Fuel Pump Control The revolutions of the radiator fan and condenser fan
Turns the fuel pump relay ON so that current is sup- are controlled in response to the engine coolant
plied to the fuel pump while the engine is crank- temperature and vehicle speed.
ing or running. 5. Alternator Output Current Control
2. A/C Relay Control Prevents alternator output current from increasing
Turns the compressor clutch of the A/C ON and OFF. suddenly and idle speed from dropping at times
3. Oil Control Valve Control such as when the headlamp are turned on.
The engine-ECU <M/T> or engine-A/T-ECU <A/T> 6. Purge Control Solenoid Valve Control
effects duty cycle control on the engine oil control (Refer to P.17-60, GROUP 17 − Engine And Emis-
valve, in accordance with the engine speed. This sion Control − Evaporative Emission Control Sys-
regulates the supply of engine oil to the intake tem).
rocker shaft, which switches the cams. 7. EGR Control Solenoid Valve Control
4. Fan Motor Control [Refer to P.17-67, GROUP 17 − Engine And Emis-
sion Control − Exhaust Gas Recirculation (EGR)
System].
GENERAL INFORMATION
13C-5
Throttle position sensor Hall element type
Throttle valve control servo DC motor type, having broshes
<M/T>
Engine-A/T-E Identification No. E6T44480
CU <A/T>
Sensors Air flow sensor Heat sensitizing type
Barometric pressure sensor Semiconductor type
Engine coolant temperature sensor Thermistor type
Accelerator pedal position sensor Variable resistor type
Accelerator pedal position switch Contact switch type
Vehicle speed sensor <M/T> Magnetic resistive element type
Inhibitor switch <A/T> Contact switch type
Camshaft position sensor Magneto resistance element type
Crank angle sensor Magneto resistance element type
Manifold absolute pressure sensor Semiconductor type
Injector identification mark IDH322S
Throttle actuator control motor relay Contact switch type
Oil control valve Duty cycle type solenoid valve
EGR valve Stepper motor
regulator
GENERAL INFORMATION

1 Cylinder 1, 4 oxygen Power supply Engine-ECU 1 Oil control valve Engine control relay
sensor (front) Ignition switch-IG <M/T> or 2 Throttle valve Fuel pump relay
2 Cylinder 2, 3 oxygen Ignition switch-ST Engine-A/T- control servo A/C compressor relay
sensor (front) A/C switch ECU <A/T> 3 Injector Throttle valve control
3 Cylinder 1, 4 oxygen A/C load signal Barometric 4 EGR valve servo relay
sensor (rear) A/C pressure pressure (Stepper motor) Ignition coil
4 Cylinder 2, 3 oxygen sensor sensor 5 Purge control solenoid Fan controller
sensor (rear) Power steering valve Engine warning lamp
5 Camshaft position fluid pressure switch Diagnosis output
sensor Alternator FR Alternator G terminal
6 Engine coolant terminal Tachometer
temperature sensor Accelerator pedal Cylinder 1, 4 oxygen
7 Crank angle sensor position switch sensor (front)
8 Detonation sensor Accelerator pedal
9 Throttle position sensor position sensor Cylinder 2, 3 oxygen
(main) (main) sensor (front)
10 Throttle position sensor Accelerator pedal
(sub) position sensor Cylinder 1, 4 oxygen
11 Intake air temperature (sub) sensor (rear)
sensor Vehicle speed
12 Air flow sensor sensor <M/T> Cylinder 2, 3 oxygen
13 Manifold absolute Inhibitor switch sensor (rear)
pressure sensor <A/T>
9 Throttle position sensor (main)

10 Throttle position sensor (sub)
5 Camshaft position sensor
2 Throttle valve 11 Intake air temperature sensor
control servo
2 Cylinder 2, 3 oxygen 13 Manifold absolute
pressure sensor 12 Air flow sensor
sensor (front)
1 Cylinder 1, 4 oxygen
sensor (front)
Air
1 Oil control valve
M
From
fuel pump
4 EGR valve
(stepper motor)
Canister
Catalytic 3 Injector
converter 6 Engine coolant
temperature sensor 5 Purge control
solenoid valve
8 Detonation sensor
Catalytic
3 Cylinder 1, 4 oxygen converter
sensor (rear)
4 Cylinder 2, 3 oxygen
sensor (rear) AK302916 AB
13C-7
M1131000300675
20°C 2.3 − 3.0
40°C 1.0 − 1.5
60°C 0.56 − 0.76
80°C 0.30 − 0.42
20°C 2.1 − 2.7
40°C 0.9 − 1.3
60°C 0.48 − 0.68
80°C 0.26 − 0.36
Oxygen sensor heater front 4.5 − 8.0
resistance (at 20°C) Ω rear 11 − 18
Fuel pressure kPa Approximately. 324 at curb idle
Injector coil resistance (at 20°C) Ω 10.5 − 13.5
Throttle valve control servo coil resistance (at 20°C) Ω 0.3 − 80
Oil control valve (at 20°C) Ω 6.9 − 7.9
SEALANT
M1131000500419

Threaded portion
SPECIAL TOOLS
SPECIAL TOOLS
M1131000600580

• Measurement of fuel pressure
B991502

MB991824 E: MB991825 (V.C.I.)
cable
C: M.U.T.-III
main harness
with CAN
C
communicatio
D: M.U.T.-III
main harness
MB991910
B (Vehicles
D without CAN
communicatio
n system)
E: M.U.T.-III
adapter
E F: M.U.T.-III
trigger harness
MB991825
MB991826
MB991955

troubleshooting
MB991348
SPECIAL TOOLS
13C-9
troubleshooting

MB991316


Troubleshooting
• Inspection of data list
MB991658

D: Probe
MB991223
SPECIAL TOOLS


gauge set
MB991637

injectors
MD998706

harness
MB991607

adaptor
MD998741

holder assembly
MB991976
TROUBLESHOOTING
13C-11
TROUBLESHOOTING
M1131150000568
ENGINE WARNING LAMP (CHECK

ENGINE LAMP)
Engine warning lamp

(check engine lamp)
AK300251AB

sis code output.

− Engine-ECU <M/T> or engine-A/T-ECU <A/T>
P0105 Manifold absolute pressure sensor system
P0122* Throttle position sensor (main) circuit low input
P0123* Throttle position sensor (main) circuit high input
P0130 Cylinder 1, 4 oxygen sensor (front) system
P0135 Cylinder 1, 4 oxygen sensor (front) heater system
P0136 Cylinder 1, 4 oxygen sensor (rear) system
P0141 Cylinder 1, 4 oxygen sensor (rear) heater system
P0150 Cylinder 2, 3 oxygen sensor (front) system
P0155 Cylinder 2, 3 oxygen sensor (front) heater system
P0156 Cylinder 2, 3 oxygen sensor (rear) system
P0161 Cylinder 2, 3 oxygen sensor (rear) heater system
P0170 Abnormal fuel system (cylinder 1, 4)
P0173 Abnormal fuel system (cylinder 2, 3)
TROUBLESHOOTING

P0222* Throttle position sensor (sub) circuit low input
P0223* Throttle position sensor (sub) circuit high input
P0300* Random/multiple cylinder misfire detected
P0301* No. 1 cylinder misfire detected
P0403 Exhaust gas recirculation control system
P0421 Warm up catalyst malfunction (cylinder 1, 4)
P0431 Warm up catalyst malfunction (cylinder 2, 3)
P0500 Vehicle speed sensor system <M/T>
P0513 Immobilizer malfunction
P0606* Engine-ECU <M/T> or engine-A/T-ECU <A/T> main processor malfunction
P0622 Alternator FR terminal system
P0638* Throttle valve control servo circuit range/performance problem
P0642* Throttle position sensor power supply
P0657* Throttle valve control servo relay circuit malfunction
P0705 Inhibitor switch system
P0710 A/T fluid temperature sensor system
P0715* Input shaft speed sensor system
P0720* Output shaft speed sensor system
P0740* Torque converter clutch solenoid valve system
P0750* Low-reverse solenoid valve system
P0755* Underdrive solenoid valve system
P0760* Second solenoid valve system
P0765* Overdrive solenoid valve system
P1010 Oil control valve system
P1602* Communication malfunction (between engine-ECU <M/T> or engine-A/T-ECU <A/T>
main processor and system LSI)
P1603* Battery backup circuit malfunction
P1751* A/T control relay system
P2100* Throttle valve control servo circuit (open)
P2101* Throttle valve control servo magneto malfunction
TROUBLESHOOTING
13C-13
P2102* Throttle valve control servo circuit (shorted low)
P2103* Throttle valve control servo circuit (shorted high)
P2121* Accelerator pedal position sensor (main) circuit range/performance problem
P2122* Accelerator pedal position sensor (main) circuit low input
P2123* Accelerator pedal position sensor (main) circuit high input
P2126* Accelerator pedal position sensor (sub) circuit range/performance problem
P2127* Accelerator pedal position sensor (sub) circuit low input
P2128* Accelerator pedal position sensor (sub) circuit high input
P2135* Throttle position sensor (main and sub) range/performance problem
P2138* Accelerator pedal position sensor (main and sub) range/performance problem
P2173* Abnormal intake air amount
NOTE: .
• If the engine warning lamp illuminates because of a malfunction of the engine-ECU <M/T> or
engine-A/T-ECU <A/T>, communication between M.U.T.-II/III and the engine-ECU <M/T> or
engine-A/T-ECU <A/T> is impossible. In this case, the diagnosis code cannot be read.
• After the engine-ECU <M/T> or engine-A/T-ECU <A/T> has detected a malfunction, the engine warning
lamp illuminates when the engine is next turned on and the same malfunction is re-detected.However, for
items marked with a "*" in the diagnosis code number column, the engine warning lamp illuminates only
on the first detection of the malfunction.
• When the engine-ECU <M/T> or engine-A/T-ECU <A/T> monitored the power train malfunction three
times* met set condition requirements, it detected no malfunction.
METHOD OF READING AND ERASING 5. Erase the diagnosis codes.

DIAGNOSIS CODES
Refer to P.00-6, GROUP 00 − How to Use Trouble- INSPECTION USING M.U.T.-II/III DATA
shooting/Inspection Service Points. LIST AND ACTUATOR TESTING
1. Carry out inspection by means of the data list and
DIAGNOSIS USING DIAGNOSIS 2 CODES the actuator test function, if there is an
1. Switch the diagnosis mode of the engine control abnormality, check and repair the chassis harness
unit to DIAGNOSIS 2 mode using the M.U.T.-II/III. and components.
2. Carry out a road test. 2. After repairing, re-check using the M.U.T.-II/III and
3. Take a reading of the diagnosis code and repair check that the abnormal input and output have
the problem location. returned to normal as a result of the repairs.
4. Turn the ignition switch to OFF and then back to 3. Erase the diagnosis code memory.
ON again. 4. Remove the M.U.T.-II/III, and then start the engine
NOTE: By turning the ignition switch to OFF, the again and carry out a road test to confirm that the
ENGINE-ECU <M/T> or ENGINE-A/T-ECU problem has disappeared.
<A/T> will switch the diagnosis mode from DIAG-
NOSIS 2 mode to DIAGNOSIS 1 mode.
TROUBLESHOOTING
FREEZE FRAME DATA The display items of freeze frame data are shown
When the engine-ECU <M/T> or engine-A/T-ECU below.
<A/T> detects a malfunction and stores a diagnosis
code, it also stores a current status of the engine.
This function is called "Freeze frame data". By ana-
lyzing this "Freeze frame" data with the M.U.T.-II/III,
an effective troubleshooting can be performed.
DISPLAY ITEM LIST

Item No. Data Unit
12 Air flow sensor °C
13 Intake air temperature sensor r/min
22 Crank angle sensor r/min
44 Ignition advance km/h
81 Long-term fuel compensation (cylinder 1, 4) %
82 Short-term fuel compensation (cylinder 1, 4) %
83 Long-term fuel compensation (cylinder 2, 3) %
84 Short-term fuel compensation (cylinder 2, 3) %
(cylinder 1, 4) Closed loop CL
(cylinder 2, 3) Closed loop CL
8A Throttle position sensor (main) %
− Diagnosis code during data recording -
TROUBLESHOOTING
13C-15
DRIVE CYCLE
The following five drive cycle patterns are performed on the diagnosis codes monitored during the vehicle
driving. The vehicle driving requires the patterns to identify the fault. In other words, doing such a drive allows
to regenerate any kind of trouble which involves illuminating the engine warming lamp (check engine lamp)
and to verify the repair procedure has eliminated the trouble [the engine warming lamp (check engine lamp) is
no longer illuminated].
CAUTION
1 Catalytic converter monitor P0421, P0431
2 Oxygen sensor (front) monitor P0130, P0150
P0155, P0156, P0161,
P0201, P0202, P0203,
P0204, P0300, P0301,
P0302, P0303, P0304,
P0325, P0551, P0638
TROUBLESHOOTING
Procedure 1
Diagnosis P0421, P0431
code No.
6 minutes or more

(3)
(4) 55 - 80 km/h
Vehicle
speed (2) (5,6)

permitted
(1) (7)
Time

"LOCK" (OFF)
position
AK301815 AB

condition
TROUBLESHOOTING
13C-17
Procedure 2
Diagnosis P0130, P0150
code No.
16 minutes or more
55 - 80 km/h
(3)
Vehicle
permitted
(1) (4)
Time

"LOCK" (OFF)
position
AK301816AB

TROUBLESHOOTING
Procedure 3
Other monitor
code No. P0301, P0302, P0303, P0304, P0325, P0551, P0638
16 minutes or more
55 km/h or more
(3)

(1) (4) (5)

Time

"LOCK" (OFF)
position
AK301817AB

The engine-ECU <M/T> or engine-A/T-ECU <A/T> tery cable is disconnected, this history will also be
monitors the following main diagnosis items, judges erased (the memory will be reset).
if these items are in good condition or not, and the • Catalyst: P0421, P0431
stores its history. this history can be read out by • Oxygen sensor: P0130, P0136, P0150, P0156
using M.U.T.-II/III. (If the ECU has judged a item • Oxygen sensor heater: P0135, P0141, P0155,
before, the M.U.T.-II/III displays "Complete"). P0161
TROUBLESHOOTING
13C-19

Air flow sensor Uses the throttle position sensor signal and engine speed signal (crankshaft
position sensor signal) for basic injector drive time and basic ignition timing from
the pre-set mapping.
sensor
sensor
(main) (sub) signal.
valve system if the throttle position sensor (sub) is also malfunctioning.
(sub) (main) signal.
valve system if the throttle position sensor (main) is also malfunctioning.
position sensor (main) accelerator pedal position sensor (sub) signal, but rendering it only as being
valve system if the accelerator pedal position sensor (sub) is also
malfunctioning.
position sensor (sub) accelerator pedal position sensor (main) signal, but rendering it only as being
valve system if the accelerator pedal position sensor (main) is also
malfunctioning.
Engine coolant Controls as if the engine coolant temperature is 80°C. (This control will be
temperature sensor continued until the ignition switch is turned to the "LOCK" (OFF) position even
though the sensor signal returns to normal.)
Camshaft position Injects fuel into the cylinders in the order 1-3-4-2 with irregular timing. (After the
not detected at all.)
Oxygen sensor <front> Air/fuel ratio closed loop control is not performed.
Oxygen sensor <rear> Performs the closed loop control of the air/fuel ratio by using only the signal of the
oxygen sensor (front) installed on the front side of the catalytic converter.
TROUBLESHOOTING

Detonation sensor Switches the ignition timing from ignition timing for high octane to ignition timing for
standard octane fuel.
transistor)
shut down.
Throttle valve position • Suppresses the engine output by stopping the electronically controlled throttle
feedback valve system.
Throttle valve control • Suppresses the engine output by stopping the electronically controlled throttle
servo valve system.
Engine-ECU <M/T> or • Suppresses the engine output by stopping the electronically controlled throttle
engine-A/T-ECU <A/T> valve system.
main processor • Prohibits the operation of the engine speed feedback control.
Communication • Renders the amount of accelerator pedal travel as being approximately one-half
between powertrain the normal opening angle.
control module main • Prohibits the operation of the engine speed feedback control.
processor and system • Cuts off fuel when the engine speed exceeds 3,000 r/min.
LSI
Intake air monitor • Suppresses the engine output by stopping the electronically controlled throttle
valve system.
• Prohibits the operation of engine speed feedback.
Oil control valve • Do not switch to high-speed cam.
• Cut off fuel when the engine speed exceeds 5,000 r/min.
TROUBLESHOOTING
13C-21
M1131151001412

P0100 Air flow sensor system P.13C-24
P0105 Manifold absolute pressure sensor system P.13C-30
P0110 Intake air temperature sensor system P.13C-40
P0115 Engine coolant temperature sensor system P.13C-47
P0122* Throttle position sensor (main) circuit low input P.13C-54
P0123* Throttle position sensor (main) circuit high input P.13C-58
P0125* Feedback system monitor P.13C-61
P0130 Cylinder 1, 4 oxygen sensor (front) system P.13C-67
P0135 Cylinder 1, 4 oxygen sensor (front) heater system P.13C-73
P0136 Cylinder 1, 4 oxygen sensor (rear) system P.13C-79
P0141 Cylinder 1, 4 oxygen sensor (rear) heater system P.13C-86
P0150 Cylinder 2, 3 oxygen sensor (front) system P.13C-93
P0155 Cylinder 2, 3 oxygen sensor (front) heater system P.13C-100
P0156 Cylinder 2, 3 oxygen sensor (rear) system P.13C-106
P0161 Cylinder 2, 3 oxygen sensor (rear) heater system P.13C-113
P0170 Abnormal fuel system (cylinder 1, 4) P.13C-119
P0173 Abnormal fuel system (cylinder 2, 3) P.13C-122
P0201 No. 1 injector system P.13C-126
P0222* Throttle position sensor (sub) circuit low input P.13C-146
P0223* Throttle position sensor (sub) circuit high input P.13C-150
P0300* Random/multiple cylinder misfire detected P.13C-153
P0301* No. 1 cylinder misfire detected P.13C-155
P0325 Detonation sensor system P.13C-167
P0335 Crank angle sensor system P.13C-170
P0340 Camshaft position sensor system P.13C-180
P0403 Exhaust gas recirculation control system P.13C-189
P0421 Warm Up Catalyst Malfunction (cylinder 1, 4) P.13C-194
P0431 Warm Up Catalyst Malfunction (cylinder 2, 3) P.13C-195
P0443 Purge control solenoid valve system P.13C-196
P0500 Vehicle speed sensor system <M/T> P.13C-201
TROUBLESHOOTING

P0513 Immobilizer malfunction P.13C-204
P0551* Power steering fluid pressure switch system P.13C-206
P0606* Engine-ECU <M/T> or engine-A/T-ECU <A/T> main processor P.13C-211
malfunction
P0622 Alternator FR terminal system P.13C-212
P0638* Throttle valve control servo circuit range/performance problem P.13C-216
P0642* Throttle position sensor power supply P.13C-219
P0657* Throttle valve control servo relay circuit malfunction P.13C-220
P0705 Inhibitor switch system • A/T DTC No. 27 (Inhibitor switch P.23A-50,
system: open circuit) P.23A-55
• A/T DTC No. 28 (Inhibitor switch
system: short circuit)
P0710 A/T fluid temperature • A/T DTC No. 15 (A/T fluid temperature P.23A-19,
sensor system sensor system: open circuit) P.23A-25
• A/T DTC No. 16 A/T (fluid temperature
sensor system: short circuit)
P0715* Input shaft speed sensor • A/T DTC No. 22 (Input shaft speed P.23A-28
system sensor system)
P0720* Output shaft speed • A/T DTC No. 23 (Output shaft speed P.23A-37
sensor system sensor system)
P0740* Torque converter clutch • A/T DTC No. 36 (Torque converter P.23A-73
solenoid valve system clutch solenoid valve system)
P0750* Low-reverse solenoid • A/T DTC No. 31 (Low-reverse solenoid P.23A-58
valve system valve system)
P0755* Underdrive solenoid valve • A/T DTC No. 32 (Underdrive solenoid P.23A-62
system valve system)
P0760* Second solenoid valve • A/T DTC No. 33 (Second solenoid P.23A-66
P0765* Overdrive solenoid valve • A/T DTC No. 34 (Overdrive solenoid P.23A-69
P1010 Oil control valve circuit P.13C-227
P1602* Communication malfunction (between engine-ECU <M/T> or P.13C-232
engine-A/T-ECU <A/T> main processor and system LSI)
P1603* Battery backup circuit malfunction P.13C-233
P1751* A/T control relay system • A/T DTC No. 54 (A/T control relay P.23A-80
system)
P2100* Throttle valve control servo circuit (open) P.13C-236
P2101* Throttle valve control servo magneto malfunction P.13C-240
P2102* Throttle valve control servo circuit (shorted low) P.13C-243
P2103* Throttle valve control servo circuit (shorted high) P.13C-246
P2121* Accelerator pedal position sensor (main) circuit range/performance P.13C-249
problem
P2122* Accelerator pedal position sensor (main) circuit low input P.13C-252
TROUBLESHOOTING
13C-23
P2123* Accelerator pedal position sensor (main) circuit high input P.13C-256
P2126* Accelerator pedal position sensor (sub) circuit range/performance P.13C-259
problem
P2127* Accelerator pedal position sensor (sub) circuit low input P.13C-262
P2128* Accelerator pedal position sensor (sub) circuit high input P.13C-266
P2135* Throttle position sensor (main and sub) range/performance problem P.13C-269
P2138* Accelerator pedal position sensor (main and sub) range/performance P.13C-271
problem
P2173* Abnormal intake air amount P.13C-277
P2226 Barometric pressure sensor system P.13C-277
NOTE: .
• Do not replace the engine-ECU <M/T> or engine-A/T-ECU <A/T> until a through terminal check reveals
there are no short/open circuit.
• Check that the engine-ECU <M/T> or engine-A/T-ECU <A/T> earth circuit is normal before checking for
the cause of the problem.
• After the engine-ECU <M/T> or engine-A/T-ECU <A/T> has detected a malfunction, a diagnosis code is
recorded the next time the engine is started and the same malfunction is re-detected. However, for items
marked with "*", the diagnosis code is recorded on the first detection of the malfunction.
TROUBLESHOOTING

DIAGNOSIS CODES
Code No. P0100: Air Flow Sensor System
Battery
W-B W-B
4 3
B-17X
1 2 Engine
control
3 4 relay
1 2
R
To engine-ECU <M/T>
4 To engine-A/T-ECU <A/T>
J/C (2)
C-17
12
R
2
B-08
Heat Air flow
sensitizing sensor
1 2 3 4
resistance
3 4
BR
1
J/C (1)
W-R
C-16
6
BR
C-141 63 96 C-142
(MU803804) (MU803805)
6162 6364 9192 939495
656667686970717273 96979899100 101102103 104
747576777879808182 105106 107108109 110111112
8384 858687 8889 113114 115116117 118119120
5V
Engine-ECU <M/T>
Engine-A/T-ECU <A/T>
Wire colour code

AK401167AB
TROUBLESHOOTING
13C-25
OPERATION STEP 2. Connector check: B-08 air flow sensor
• Power is supplied by the engine control relay (ter- connector
minal No. 1) to the air flow sensor (terminal No.
2), and the air flow sensor (terminal No. 4) is Connector: B-08
grounded through the engine-ECU <M/T> or
engine-A/T-ECU <A/T> (terminal No. 96). B-08 (B)
• The air flow sensor (terminal No. 3) outputs a
sensor signal, which is input into the engine-ECU
<M/T> or engine-A/T-ECU <A/T> (terminal No.
63).
4 3 2 1
FUNCTION Harness
side connector
• The air flow sensor outputs amperage that varies
AK303649 AB
in accordance with the intake air volume. Q: Is the check result normal?
• The engine-ECU <M/T> or engine-A/T-ECU YES : Go to Step 3 .
<A/T> uses the amperage output by the air flow NO : Repair.
sensor and the engine speed signal in order to
determine the basic injection duration of the
injector. STEP 3. Perform voltage measurement at B-08 air
TROUBLE JUDGMENT Connector: B-08
Check Conditions
• After 3 seconds have passed since the ignition B-08 (B)
switch was turned to "ON" position.
Judgment Criteria
• Air flow sensor output voltage has continued to
be 0.2 V or lower for 2 seconds. 4 3 2 1
Or Harness
• Air flow sensor output voltage has continued to side connector AK303649 AB
be 4.9 V or higher for 2 seconds. • Disconnect connector, and measure at harness
side.
PROBABLE CAUSE
• Failed air flow sensor • Voltage between terminal No. 2 and earth.
• Open/short circuit in air flow sensor circuit or
loose connector contact OK: System voltage
• Failed engine-ECU <M/T> Q: Is the check result normal?
• Failed engine-A/T-ECU <A/T> YES : Go to Step 5 .
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE

• Refer to Data list reference table P.13C-402.
00 − How to Use
P.00-6).
NO : Go to Step 2 .
TROUBLESHOOTING
STEP 4. Connector check: B-17X engine control STEP 5. Perform resistance measurement at B-08
relay connector air flow sensor connector.
B-17X
Relay box’s B-08 (B)
triangle marks
2 1
4 3 4 3 2 1
Harness Harness
side connector AK304152 AB side connector AK303649 AB

Connector: B-08
side.
B-08 (B) OK: Continuity (2 Ω or less)
NO : Go to Step 6 .
4 3 2 1
Harness STEP 6. Connector check: C-142 engine-ECU
<M/T> connector or engine-A/T-ECU <A/T>
Connector: C-142
connector is normal, check and repair <L. H. Drive Vehicle>
flow sensor connector and B-17X (terminal
No. 1) engine control relay connector.
• Check power supply line for C-142 (GR)
open/short circuit.
NO : Repair.
<R. H. Drive Vehicle>
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-27
No. 4) air flow sensor connector and C-142 • Refer to Data List Reference Table P.13C-402.
(terminal No. 96) engine-ECU <M/T> connector or a. Item 12: Air flow sensor
engine-A/T-ECU <A/T> connector.
Connector: B-08 YES : Intermittent malfunction (Refer to GROUP
00 − How to Use
B-08 (B)
P.00-6).
NO : Replace engine-ECU <M/T> or
engine-A/T-ECU <A/T>.
4 3 2 1
Harness <M/T> connector or engine-A/T-ECU <A/T>
connector.
<L. H. Drive Vehicle> <L. H. Drive Vehicle>
C-142 (GR) C-141(GR)
<R. H. Drive Vehicle> <R. H. Drive Vehicle>

C-142 (GR) C-141 (GR)
959493 92 91 6463 62 61
104 103102 101100 99 98 97 96 7372 7170 69 6867 6665
112111110 109108107 106105 82 818079 78 7776 7574
120119118 117116115 114113 8988 87 86 85 8483
AK304153 AB AK304154 AB
NOTE: Before checking harness, check intermediate Q: Is the check result normal?
connector C-16, and repair if necessary. YES : Go to Step 10 .
• Check earthing line for open circuit. NO : Repair.
NO : Repair.
TROUBLESHOOTING
STEP 10. Check harness between B-08 (terminal STEP 11. Connector check: B-17X engine control
No. 3) air flow sensor connector and C-141 relay connector
(terminal No. 63) engine-ECU <M/T> connector or
Connector: B-17X
B-17X
Connector: B-08
Relay box’s
triangle marks
B-08 (B)
2 1
4 3
Harness
4 3 2 1 side connector AK304152 AB
Harness
side connector AK303649 AB Q: Is the check result normal?
NO : Repair.
Connector: C-141
<L. H. Drive Vehicle>
No. 2) air flow sensor connector and B-17X
C-141(GR)
Connector: B-08
B-08 (B)
C-141 (GR)
4 3 2 1
Harness
6463 62 61 Connector: B-17X

7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483 B-17X
Harness side connector Relay box’s
triangle marks
AK304154 AB

2 1
age.
4 3
YES : Go to Step 11 . Harness
side connector

NO : Repair.
TROUBLESHOOTING
13C-29
STEP 13. M.U.T.-II/III data list STEP 14. Replace air flow sensor.
• Refer to Data List Reference Table P.13C-402. • After replacing the air flow sensor, re-check the
a. Item 12: Air flow sensor trouble symptoms.
YES : Intermittent malfunction (Refer to GROUP YES : Replace the engine-ECU <M/T> or
00 − How to Use engine-A/T-ECU <A/T>.
Troubleshooting/Inspection Service Points NO : Check end.
P.00-6).
TROUBLESHOOTING
Code No. P0105: Manifold Absolute Pressure Sensor System
Manifold absolute pressure sensor circuit
B-103
(MU802723)
Manifold absolute
1 2 3 pressure sensor
3 1 2
Y-B L-B BR
97 101 96
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120
5V
Engine-ECU <M/T>
Wire colour code

AK304119AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the manifold • The manifold absolute pressure sensor converts
absolute pressure sensor power terminal (termi- the manifold absolute pressure into a voltage sig-
nal No. 3) from the engine-ECU <M/T> or nal and inputs the signal to the engine-ECU
engine-A/T-ECU <A/T> (terminal No. 97) and <M/T> or engine-A/T-ECU <A/T>.
earthed to the engine-ECU <M/T> or • In response to the signal, the engine-ECU <M/T>
engine-A/T-ECU <A/T> (terminal No. 96) from the or engine-A/T-ECU <A/T> corrects the fuel injec-
manifold absolute pressure sensor (terminal No. tion amount, etc.
2).
Check Conditions
101) from the manifold absolute pressure sensor
in "ON" position or the engine has started up
TROUBLESHOOTING
13C-31
Judgment Criteria STEP 2. Connector check: B-103 Manifold
• The sensor output voltage is 4.5V or more (baro- absolute pressure sensor connector
metric pressure above 114 kPa or equivalent) for
4 seconds. Connector: B-103
Or
• The sensor output voltage is 0.2 V or less (baro-
metric pressure below 53 kPa or equivalent) for 4 C-103 (B)
seconds.
PROBABLE CAUSE
3 2 1
• Failed Manifold absolute pressure sensor
• Open/short circuit in Manifold absolute pressure Harness side
connector
sensor circuit or loose connector contact AK304038AB
• Failed engine-ECU <M/T>

• Failed engine-A/T-ECU <A/T>
NO : Repair.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list manifold absolute pressure sensor connector.
• Refer to Data List Reference Table P.13C-402.
Connector: B-103
a. Item 95: Manifold absolute pressure sensor
C-103 (B)
00 − How to Use
P.00-6).
Harness side
connector
AK304038AB

OK: 4.9 − 5.1 V
NO : Go to Step 4 .
TROUBLESHOOTING
engine-ECU <M/T> connector or engine-A/T-ECU <M/T> connector or engine-A/T-ECU <A/T>
<A/T> connector. connector
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
• Measure engine-ECU <M/T> or engine-A/T-ECU

Connector: B-103
<A/T> terminal voltage.
C-103 (B)
OK: 4.9 − 5.1 V
Harness side
connector
AK304038AB

(terminal No. 3) manifold absolute pressure
97) engine-ECU <M/T> connector or
circuit.
NO : Repair.
TROUBLESHOOTING
13C-33
<M/T> connector or engine-A/T-ECU <A/T> No. 3) manifold absolute pressure sensor
connector connector and C-142 (terminal No. 97)
engine-ECU <M/T> connector or engine-A/T-ECU
Connector: C-142 <A/T> connector.
Connector: B-103
C-103 (B)
C-142 (GR)
3 2 1
Harness side
C-142 (GR) connector
AK304038AB
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB
Q: Is the check result normal? <R. H. Drive Vehicle>

NO : Repair. C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 8. M.U.T.-II/III data list STEP 10. Connector check: C-142 engine-ECU
• Refer to Data List Reference Table P.13C-402. <M/T> connector or engine-A/T-ECU <A/T>
a. Item No. 95: Manifold absolute pressure sen- connector
sor
Connector: C-142
Q: Is the check result normal? <L. H. Drive Vehicle>
00 − How to Use
P.00-6). C-142 (GR)
STEP 9. Perform resistance measurement at <R. H. Drive Vehicle>

B-103 manifold absolute pressure sensor C-142 (GR)
connector.
Connector: B-103
C-103 (B) 959493 92 91

104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

3 2 1
AK304153 AB
Harness side
AK304038AB
NO : Repair.
TROUBLESHOOTING
13C-35
No. 2) manifold absolute pressure sensor manifold absolute pressure sensor connector.
Connector: B-103
<A/T> connector.
Connector: B-103 C-103 (B)
C-103 (B)
3 2 1
Harness side
connector
AK304038AB
3 2 1
Harness side
connector nect connector and measure at pick-up harness.
AK304038AB
Connector: C-142
OK: 4.9 − 5.1 V
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> manifold absolute pressure sensor connector.
connector
Connector: B-103
Connector: C-142
C-103 (B)
C-142 (GR) 3 2 1
Harness side
connector
AK304038AB
<R. H. Drive Vehicle> • Use special tool test harness (MB991348) to con-
C-142 (GR)
OK:
Altitude 600m: 3.4 − 4.0 V
959493 92 91
104 103102 101100 99 98 97 96
Altitude 1,200m: 3.2 − 3.8 V
112111110 109108107 106105 Altitude 1,800m: 2.9 − 3.5 V
120119118 117116115 114113

Connector: B-103
C-103 (B)
3 2 1
Harness side
connector
AK304038AB

(terminal No. 3) manifold absolute pressure
NO : Repair.
TROUBLESHOOTING
13C-37
<M/T> connector or engine-A/T-ECU <A/T> No. 1) manifold absolute pressure sensor
Connector: B-103
C-103 (B)
C-142 (GR)
3 2 1
Harness side
C-142 (GR) connector
AK304038AB
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

YES : Replace manifold absolute pressure sensor.
NO : Repair.
TROUBLESHOOTING
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

Connector: B-103
C-103 (B)
OK:
Altitude 600m: 3.4 − 4.0 V
Altitude 1,200m: 3.2 − 3.8 V 3 2 1
Altitude 1,800m: 2.9 − 3.5 V Harness side
connector
Q: Is the check result normal? AK304038AB
YES : Check and repair check harness between
B-103 (terminal No. 1) manifold absolute
(terminal No. 101) engine-ECU <M/T>
connector or engine-A/T-ECU <A/T>
connector.
damage.
NO : Repair.
TROUBLESHOOTING
13C-39
connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
B-08
Intake air temperature sensor
(Integrated in air flow sensor)
1 2 3 4
4 1
BR
11
J/C/ (1)
C-16 Y-L
6
BR
96 99
C-142
(MU803805)
9192 939495 Engine-ECU <M/T>
96979899100 101102103 104 Engine-A/T-ECU <A/T>
105106 107108109 110111112
113114 115116117 118119120
5V
Wire colour code

AK401168AB

engine-ECU <M/T> or engine-A/T-ECU <A/T> the intake air temperature, and becomes lower as
(terminal No. 99). the intake air temperature rises.
<M/T> or engine-A/T-ECU (terminal No. 96) from TROUBLE JUDGMENT
the air flow sensor (terminal No. 4). Check Conditions
FUNCTION in "ON" position or the engine has started up.
• The intake air temperature sensor converts the • The battery voltage is 8 V or more.
the voltage signal to the engine-ECU <M/T> or Judgment Criteria
engine-A/T-ECU <A/T>. • The sensor output voltage is 4.6V or more (intake
• In response to the signal, the engine-ECU <M/T> air temperature of below -45°C or equivalent) for
or engine-A/T-ECU <A/T> corrects the fuel injec- 4 seconds.
tion amount, etc. Or
• The sensor output voltage is 0.2V or less (intake
air temperature of above 125°C or equivalent) for
4 seconds.
TROUBLESHOOTING
13C-41
sor circuit or loose connector contact Connector: B-08
• Failed engine-A/T-ECU <A/T> B-08 (B)
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list 4 3 2 1

• Item 13: Intake air temperature sensor Harness
OK: At ambient temperature (atmospheric side connector AK303649 AB
temperature) or equivalent. • Disconnect connector, and measure at harness

YES : Intermittent malfunction (Refer to GROUP • Resistance between terminal No. 4 and earth.
00 − How to Use OK: Continuity (2 Ω or less)
Troubleshooting/Inspection Service Points Q: Is the check result normal?
P.00-6). YES : Go to Step 8 .
NO : Go to Step 2 . NO : Go to Step 5 .
STEP 2. Connector check: B-08 air flow sensor STEP 5. Connector check: C-142 engine-ECU
connector <M/T> connector or engine-A/T-ECU <A/T>
Connector: B-08 connector
Connector: C-142
B-08 (B) <L. H. Drive Vehicle>
C-142 (GR)
4 3 2 1
Harness

YES : Go to Step 3 . C-142 (GR)
NO : Repair.
STEP 3. Check intake air temperature sensor

itself.
• Check intake air temperature sensor itself (Refer
959493 92 91
to P.13C-430). 104 103102 101100 99 98 97 96
112111110 109108107 106105

NO : Replace air flow sensor. AK304153 AB

NO : Repair.
TROUBLESHOOTING
No. 4) air flow sensor connector and C-142 • Item No. 13: Intake air temperature sensor
(terminal No. 96) engine-ECU <M/T> connector or OK: At ambient temperature (atmospheric
engine-A/T-ECU <A/T> connector. temperature) or equivalent.
B-08 (B)
00 − How to Use
P.00-6).
4 3 2 1
Harness
STEP 8. Perform voltage measurement at B-08 air
B-08 (B)
C-142 (GR)
4 3 2 1
Harness
<R. H. Drive Vehicle> side connector AK303649 AB
C-142 (GR) • Disconnect connector, and measure at harness

side.
OK: 4.5 − 4.9 V
104 103102 101100 99 98 97 96
112111110 109108107 106105
YES : Replace engine-ECU <M/T> or
120119118 117116115 114113 engine-A/T-ECU <A/T>.
AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-43
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
B-08 (B) B-08 (B)
4 3 2 1 4 3 2 1
Harness Harness
• Measure engine-ECU <M/T> or engine-A/T-ECU Q: Is the check result normal?

<A/T> terminal voltage. YES : Check and repair harness between B-08
• Disconnect B-08 air flow sensor connector. (terminal No. 1) air flow sensor connector
• Ignition switch: ON and C-142 (terminal No. 99) engine-ECU
• Voltage between terminal No. 99 and earth. <M/T> connector or engine-A/T-ECU <A/T>
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 1) air flow sensor connector and C-142
connector (terminal No. 99) engine-ECU <M/T> connector or
Connector: C-142 • Check output line for short circuit.
Connector: B-08
B-08 (B)
C-142 (GR)
<R. H. Drive Vehicle> 4 3 2 1

Harness
C-142 (GR) side connector AK303649 AB
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-45
STEP 13. Perform voltage measurement at B-08 STEP 14. Connector check: C-142 engine-ECU
air flow sensor connector. <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: B-08
Connector: C-142
C-142 (GR)
4 3 2 1
Harness
• Use special tool test harness (MB991709) to con- <R. H. Drive Vehicle>
nect only terminal No. 1 and No. 4, and then C-142 (GR)
measure at pick-up harness.
OK:
Ambient temperature at −20°C: 3.8 − 4.4 V
104 103102 101100 99 98 97 96

120119118 117116115 114113

AK304153 AB

NO : Go to Step 14 . NO : Repair.
TROUBLESHOOTING

No. 1) air flow sensor connector and C-142
Connector: B-08
B-08 (B)
4 3 2 1
Harness
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-47
B-108
(MU802406)
Engine coolant
temperature sensor
1 2
2 1
BR Y-G
96 98
C-142
(MU803805)
Engine-ECU <M/T>
9192 939495
96979899100 101102103 104 Engine-A/T-ECU <A/T>
105106 107108109 110111112
113114 115116117 118119120 5V
Wire colour code

AK304121AB

minal No. 1) from the engine-ECU <M/T> or rises. Therefore, the sensor output voltage varies
engine-A/T-ECU <A/T> (terminal No. 98). with the engine coolant temperature, and
<M/T> or engine-A/T-ECU <A/T> (terminal No. ture rises.
96) from the engine coolant temperature sensor
(terminal No. 2). TROUBLE JUDGMENT
Check Conditions
• The engine coolant temperature sensor converts in "ON" position or just after the engine has
the engine coolant temperature into a voltage sig- started up.
nal, and inputs the voltage to the engine-ECU
<M/T> or engine-A/T-ECU <A/T>. Judgment Criteria
• In response to the signal, the engine-ECU <M/T> • The sensor output voltage is 4.6V or more (water
or engine-A/T-ECU <A/T> controls the fuel infec- temperature of below -45°C or equivalent) for 4
tion amount and the fast idle speed when the seconds.
engine is cold state. Or
• The sensor output voltage is 0.1V or less (water
temperature of above 140°C or equivalent) for 4
seconds.
TROUBLESHOOTING
Check Conditions STEP 3. Perform resistance measurement at

• After the engine has started up. B-108 engine coolant temperature sensor
Judgment Criteria connector.
• The sensor output voltage rises 1.6V or more
Connector: B-108
(engine coolant temperature below 40°C or 2 1
equivalent) from 1.6V or less (engine coolant
Harness side
temperature above 40°C or equivalent). connector
PROBABLE CAUSE
• Open/short circuit in engine coolant temperature B-108 (B)
• Failed engine-ECU <M/T> AK304156 AB
OK:
STEP 1. M.U.T.-II/III data list Engine coolant temperature at −20°C: 14 − 17
• Item 21: Engine coolant temperature sensor kΩ
Q: Is the check result normal? Engine coolant temperature at 40°C: 0.9 − 1.3
YES : Intermittent malfunction (Refer to GROUP kΩ
00 − How to Use Engine coolant temperature at 60°C: 0.48 −
Troubleshooting/Inspection Service Points 0.68 kΩ
P.00-6). Engine coolant temperature at 80°C: 0.26 −
NO : Go to Step 2 . 0.36 kΩ
STEP 2. Connector check: B-108 engine coolant YES : Go to Step 4 .
sensor.
Connector: B-108
2 1
Harness side
connector
B-108 (B)
AK304156 AB

NO : Repair.
TROUBLESHOOTING
13C-49
B-108 engine coolant temperature sensor No. 2) engine coolant temperature sensor
Connector: B-108
<A/T> connector.
2 1
Harness side Connector: B-108
connector 2 1
Harness side
connector
B-108 (B)
B-108 (B)
AK304156 AB

side. AK304156 AB

Connector: C-142
NO : Go to Step 5 .
C-142 (GR)
connector
C-142 (GR)
Connector: C-142
959493 92 91
C-142 (GR) 104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
C-142 (GR)
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
NO : Repair.
TROUBLESHOOTING
STEP 7. M.U.T.-II/III data list STEP 9. Perform voltage measurement at C-142

• Item 21: Engine coolant temperature sensor engine-ECU <M/T> connector or engine-A/T-ECU
OK: <A/T> connector.
Engine cold state: At ambient temperature
Connector: C-142
Engine hot state: At 80 − 120 °C <L. H. Drive Vehicle>

00 − How to Use C-142 (GR)
P.00-6).
engine-A/T-ECU <A/T>. <R. H. Drive Vehicle>
C-142 (GR)
engine coolant temperature sensor connector.
Connector: B-108
2 1
connector 104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
B-108 (B)
Connector: B-108
AK304156 AB 2 1
• Disconnect connector, and measure at harness Harness side

connector
side.
OK: 4.5 − 4.9 V B-108 (B)

NO : Go to Step 9 . • Measure engine-ECU <M/T> or engine-A/T-ECU
sensor.
OK: 4.5 − 4.9 V
TROUBLESHOOTING
13C-51
<M/T> connector or engine-A/T-ECU <A/T> <M/T> connector or engine-A/T-ECU <A/T>
connector connector
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

connector
B-108 (B)
AK304156 AB

NO : Repair.
TROUBLESHOOTING
Connector: B-108
2 1
<A/T> connector
Harness side
Connector: B-108 connector
2 1
Harness side
connector
B-108 (B)
AK304156 AB
B-108 (B)
AK304156 AB
Connector: C-142
OK:
Engine coolant temperature at −20°C: 3.9 − 4.5
V
C-142 (GR) V
V
V
C-142 (GR) Engine coolant temperature at 80°C: 0.3 − 0.9
V
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-53
<M/T> connector or engine-A/T-ECU <A/T> No. 1) engine coolant temperature sensor
Connector: B-108
2 1
Harness side
connector
C-142 (GR)
B-108 (B)
C-142 (GR) AK304156 AB
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Code No. P0122: Throttle Position Sensor (Main) Circuit Low Input
(main)
B-06 Hall IC
Electronically
throttle valve
5 4 3
R W B
106 115 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU <M/T>
Wire colour code

AK304122 AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the electroni- • The throttle position sensor converts the throttle
cally controlled throttle valve (terminal No. 5) valve position into voltage and inputs it into the
from the engine-ECU <M/T> or engine-A/T-ECU engine-ECU <M/T> or engine-A/T-ECU <A/T>.
<A/T> (terminal No. 106). • The engine-ECU <M/T> or engine-A/T-ECU
• The power voltage is earthed to the engine-ECU <A/T> controls the throttle valve position.
105) from the electronically controlled throttle TROUBLE JUDGMENT
valve (terminal No. 3).
Check Conditions
115) from the electronically controlled throttle Judgment Criteria
valve output terminal (terminal No. 4). • Throttle position sensor (main) output voltage is
0.35 V or less for 0.5 second.
TROUBLESHOOTING
13C-55
• Failed throttle position sensor (main) electronically controlled throttle valve connector.
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III data list B-06 (B)

• Refer to Data List Reference Table P.13C-402. 6 5 4 3 2 1
a. Item 79: Throttle position sensor (main) Harness side connector AK304259 AB
Q: Is the check result normal? • Disconnect connector, and measure at harness

P.00-6). OK: 4.9 − 5.1 V
NO : Go to Step 2 .
STEP 2. Connector check: B-06 electronically NO : Go to Step 4 .
connector
Connector: C-142
B-06 (B)
6 5 4 3 2 1
Harness side connector AK304259 AB C-142 (GR)

NO : Repair. <R. H. Drive Vehicle>
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
No. 5) electronically controlled throttle valve • Refer to Data List Reference Table P.13C-402.
<A/T> connector.
Connector: B-06 00 − How to Use
P.00-6).
B-06 (B)
6 5 4 3 2 1 <M/T> connector or engine-A/T-ECU <A/T>
Harness side connector connector
AK304259 AB
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)

C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
959493 92 91
112111110 109108107 106105
104 103102 101100 99 98 97 96
120119118 117116115 114113
112111110 109108107 106105
AK304153 AB
• Check power supply line for open/short circuit.
NO : Repair.
TROUBLESHOOTING
13C-57
engine-ECU <M/T> connector or engine-A/T-ECU engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector. <A/T> connector.
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
age.
NO : Repair.

throttle valve
YES : Check end.
TROUBLESHOOTING
Code No. P0123: Throttle Position Sensor (Main) Circuit High Input
(main)
B-06 Hall IC
Electronically
throttle valve
5 4 3
R W B
106 115 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU <M/T>
Wire colour code

AK304122 AB
OPERATION FUNCTION
Check Conditions
valve output terminal (terminal No. 4). • Throttle position sensor (main) output voltage is
4.8 V or more for 0.5 second.
TROUBLESHOOTING
13C-59
• Failed throttle position sensor (main) electronically controlled throttle valve connector.
DIAGNOSIS PROCEDURE

a. Item 79: Throttle position sensor (main) Harness side connector AK304259 AB

P.00-6).
NO : Go to Step 2 .
NO : Go to Step 4 .
STEP 2. Connector check: B-06 electronically
controlled throttle valve connector STEP 4. Connector check: C-142 engine-ECU
Connector: B-06 <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-142
B-06 (B)
6 5 4 3 2 1 C-142 (GR)

YES : Go to Step 3 . <R. H. Drive Vehicle>
NO : Repair.
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
<A/T> connector.
P.00-6).
B-06 (B)
Harness side connector • After replacing the electronically controlled throt-
AK304259 AB
YES : Check end.
NO : Replace the engine-ECU <M/T> or
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-61
Code No. P0125: Feedback System Monitor
OPERATION sensor (front). Thus, even when closed loop control

• Refer to Code No. P0201 No. 1 Injector System is being effected, the fluctuation of the oxygen sen-
P.13C-126. sor (front) output voltage decreases, without inter-
Refer to Code No. P0202 No. 2 Injector System secting with 0.5 volt. As a result, there is a possibility
P.13C-131.
Refer to Code No. P0203 No. 3 Injector System
• Failed exhaust system
P.13C-136.
Refer to Code No. P0204 No. 4 Injector System
P.13C-141.
• Refer to Code No. P0130 Cylinder 1, 4 Oxygen DIAGNOSIS PROCEDURE
Sensor (Front) Circuit P.13C-67.
• Refer to P0150 Cylinder 2, 3 Oxygen Sensor
(Front) Circuit P.13C-93. STEP 1. M.U.T.-II/III diagnosis code
Q: Is any other diagnosis code than P0170 or P0173
FUNCTION output?
• The engine-ECU <M/T> or engine-A/T-ECU YES : Inspection chart for diagnosis code (Refer
<A/T> effects air-fuel ratio feedback control in to P.13C-21).
accordance with the signals from the oxygen sen- NO : Go to Step 2 .
sor (front).
• If the oxygen sensor (front) has deteriorated, cor-
rections will be made by the oxygen sensor
(rear).
• Diagnosis code P0125 becomes stored in mem- a. Item 12: Air flow sensor
ory if a failure is detected in the above air/fuel b. Item 21: Engine coolant temperature sensor
ratio feedback control system. c. Item 59: Cylinder 1, 4 oxygen sensor (front)
d. Item 69: Cylinder 2, 3 oxygen sensor (rear)
TROUBLE JUDGMENT e. Item 95: Manifold absolute pressure sensor
Check Conditions Q: Are the check results normal?
• The engine coolant temperature approximately. YES : Go to Step 3 .
82°C or more. NO : Perform the diagnosis code classified check
• Within the range of air-fuel ratio feedback opera- procedure for the sensor that has shown an
tion. abnormal data valve (Refer to Inspection
• Not in low speed operation. Chart for Diagnosis Code P.13C-21).
Judgment Criterion
• The oxygen sensor output voltage is not deviated STEP 3: M.U.T.-II/III data list
from 0.5 V for 30 seconds. • Refer to Data List Reference Table P.13C-402.
PROBABLE CAUSE Q: Are the check results normal?
• Failed oxygen sensor (front) YES : Go to Step 4 .
• Harness damage in oxygen sensor (front) circuit NO : Replace engine-ECU <M/T> or
or loose connector contact engine-A/T-ECU <A/T>.
NOTE: When the oxygen sensor (front) begins to STEP 4.Check for intake of air from intake hose
deteriorate, the oxygen sensor output voltage will and inlet manifold.
deviate from the voltage when the sensor was new
(normally 0.5 volt at stoichiometric ratio). This devia- Q: Is the check result normal?
tion will be corrected by the oxygen sensor (rear).If YES : Go to Step 5 .
the oxygen sensor (rear) responds poorly because it NO : Repair.
TROUBLESHOOTING
STEP 5.Check for leakage of exhaust emission STEP 7. Connector check: B-39 cylinder 1, 4
from exhaust manifold. oxygen sensor (front) connector, C-142
YES : Go to Step 6 . <A/T> connector.
NO : Repair. Connector: B-39
STEP 6.Check throttle body (throttle valve

NO : Clean throttle body (throttle valve portion) 2 1
Cylinder 1, 4 oxygen
(Refer to P.13C-425). 4 3
B-39 (GR) sensor (front)
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
STEP8. Check cylinder 1, 4 oxygen sensor (front)

itself.
• Check cylinder 1, 4 oxygen sensor (front) itself
NO : Replace cylinder 1, 4 oxygen sensor (front).
TROUBLESHOOTING
13C-63
STEP 9. Check harness between B-39 (terminal STEP 10. Connector check: B-112 cylinder 2, 3
No. 4) cylinder 1, 4 oxygen sensor (front) oxygen sensor (front) connector, C-142
connector and C-142 (terminal No. 109) engine-ECU <M/T> connector or engine-A/T-ECU
engine-ECU <M/T> connector or engine-A/T-ECU <A/T> connector.
<A/T> connector.
Connector: B-112
Connector: B-39
sensor (front)
2 1
4 3 sensor (front)
B-39 (GR)
Connector: C-142
C-142 (GR) 2 1
4 3
Harness
side connector B-112 (GR)
AK304264 AB
C-142 (GR) Connector: C-142

C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
C-142 (GR)
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 11. Check cylinder 2, 3 oxygen sensor STEP 12. Check harness between B-112 (terminal
(front) itself. No. 4) cylinder 2, 3 oxygen sensor (front)
• Check cylinder 2, 3 oxygen sensor (front) itself connector and C-142 (terminal No. 108)
(Refer to P.13C-432). engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
YES : Go to Step 12 . Connector: B-112
sensor (front)
2 1
4 3
Harness
AK304264 AB
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-65
relay connector and C-139 engine-ECU <M/T>
Connectors: B-01, B-02, B-04, B-05
connector or engine-A/T-ECU <A/T> connector.
B-05 (GR)
B-01 (GR) B-02 (GR) B-04 (GR) Connector: B-17X
B-17X
Relay box’s
triangle marks
M
2 1 2 1
Harness
side connector AK304261 AB 4 3
a. B-01 (No.1 injector connector) Harness

NO : Repair.
C-139 (GR)
STEP 14. Check injector itself.

• Check Injector itself (Refer to P.13C-435).
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
Connector: B-17X Connectors: B-01, B-02, B-04, B-05
B-17X B-05 (GR)
B-01 (GR) B-02 (GR) B-04 (GR)
Relay box’s
triangle marks
2 1
M
4 3
2 1
Harness Harness
Connectors: B-01, B-02, B-04, B-05 Connector: C-139
B-05 (GR) <L. H. Drive Vehicle>

B-01 (GR) B-02 (GR) B-04 (GR)
C-139 (GR)
M
2 1
Harness
side connector AK304261 AB <R. H. Drive Vehicle>
a. Check harness between B-17X (terminal No. 1)

engine control relay connector and B-01 (terminal C-139 (GR)
No. 1) No. 2 injector connector. 4 3 2 1
c. Check harness between B-17X (terminal No. 1) 13 12 1110 9 8 7
2019 18 17 16
6
15
5
14
engine control relay connector and B-04 (terminal 2726 2524 23 22 21

d. Check harness between B-17X (terminal No. 1) AK304262 AB
Q: Are the check results normal? engine-A/T-ECU <A/T> connector.
YES : Go to Step 17 . b. Check harness between B-02 (terminal No. 2)
NO : Repair.
TROUBLESHOOTING
13C-67
P.13C-425).
YES : Repair.
Code No. P0130: Cylinder 1, 4 Oxygen Sensor (Front) System
Cylinder 1, 4 oxygen sensor (front) circuit
B-39
MU802665
1 2 sensor (front)
3 4
1 3 2 4
R G
To engine-ECU <M/T>
To engine-A/T-ECU <A/T>
B
12
9
J/C (2)
J/C (1)
C-17
C-16
1
6
B
BR
96 109
C-142
(MU803805)
9192 939495 Engine-ECU <M/T>
96979899100 101102103 104 Engine-A/T-ECU <A/T>
105106 107108109 110111112
113114 115116117 118119120
Wire colour code

AK401169 AB
OPERATION • The cylinder 1, 4 oxygen sensor (front) (terminal

• The sensor signal is inputted to the engine-ECU No. 2) is earthed with engine-ECU <M/T> or
<M/T> or engine-A/T-ECU <A/T> (terminal No. engine-A/T-ECU <A/T> (terminal No. 96).
109) from the cylinder 1, 4 oxygen sensor (front)
TROUBLESHOOTING

• The cylinder 1, 4 oxygen sensor (front) converts
the concentration of oxygen in the exhaust emis- STEP 1. M.U.T.-II/III data list
sion into a voltage and inputs the signal to the • Refer to Data List Reference Table P.13C-402.
engine-ECU <M/T> or engine-A/T-ECU <A/T>.
a. Item 11: Cylinder 1, 4 oxygen sensor (front)
• When the air-fuel ratio is richer than the theoreti-
cal air-fuel ratio, the cylinder 1, 4 oxygen sensor Q: Is the check result normal?
(front) outputs a voltage of about 1 V. When it is YES : Intermittent malfunction (Refer to GROUP
leaner than the theoretical air-fuel ratio, it outputs 00 − How to Use
a voltage of about 0 V. Troubleshooting/Inspection Service Points
• In response to the signal, the engine-ECU <M/T> P.00-6).
or engine-A/T-ECU <A/T> controls the fuel infec- NO : Go to Step 2 .
tion amount so that the air-fuel ratio can be equiv-
alent to the theoretical air-fuel ratio. STEP 2. Connector check: B-39 cylinder 1, 4
oxygen sensor (front) connector
TROUBLE JUDGMENT
Connector: B-39
Check Conditions
started up.
82°C or higher.
2 1
• The monitoring time is 5 seconds. Cylinder 1, 4 oxygen
4 3 sensor (front)
B-39 (GR)
Judgment Criteria
• When the cylinder 1, 4 oxygen sensor (front) out- AK304260 AB
put voltage is 0.2 V or less and a power voltage of

5 V is applied to the cylinder 1, 4 oxygen sensor
(front) in the engine-ECU <M/T> or NO : Repair.
engine-A/T-ECU <A/T>, the sensor output volt-
age is 4.5V or more.
• To be monitored once per driving cycle. STEP 3. Perform resistance measurement at B-39
cylinder 1, 4 oxygen sensor (front) connector.
Check Conditions
• The engine speed is 1200 − 3000 r/min. Connector: B-39
60°C or higher.
• Volumetric efficiency is 20 − 60%.
• During the air-fuel ratio feedback control
Judgment Criteria
2 1
• When the cylinder 1, 4 oxygen sensor (front) out- Cylinder 1, 4 oxygen
4 3
put frequency is 6 or less for 10 seconds on the B-39 (GR) sensor (front)
average. Harness side connector AK304260 AB
PROBABLE CAUSE • Disconnect connector, and measure at harness

• Failed cylinder 1, 4 oxygen sensor (front) side.
• Open/short circuit in cylinder 1, 4 oxygen sensor • Resistance between terminal No. 2 and earth.
(front) circuit or loose connector contact OK: Continuity (2 Ω or less)
NO : Go to Step 4 .
TROUBLESHOOTING
13C-69
<M/T> connector or engine-A/T-ECU <A/T> No. 2) cylinder 1, 4 oxygen sensor (front)
Connector: B-39
C-142 (GR)
2 1
<R. H. Drive Vehicle> 4 3 sensor (front)
B-39 (GR)
C-142 (GR) Harness side connector AK304260 AB
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
STEP 6. M.U.T.-II/III data list STEP 9. Connector check: C-142 engine-ECU

• Refer to Data List Reference Table P.13C-402. <M/T> connector or engine-A/T-ECU <A/T>
a. Item 11: Cylinder 1, 4 oxygen sensor (front) connector
00 − How to Use
P.00-6).
C-142 (GR)

cylinder 1, 4 oxygen sensor (front) connector. <R. H. Drive Vehicle>
Connector: B-39 C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
2 1
Cylinder 1, 4 oxygen 112111110 109108107 106105
4 3 sensor (front) 120119118 117116115 114113
B-39 (GR)
Harness side connector AK304260 AB AK304153 AB

nect connector, and measure at pick-up harness. Connector: B-39
• Transmission: Neutral <M/T> or P range <A/T>.
OK:
When the engine is 2,500 r/min, the output
voltage should repeat 0 to 0.8 V alternately. 2 1
4 3 sensor (front)
YES : Go to Step 10 . Harness side connector AK304260 AB
NO : Go to Step 8 .
STEP 8. Check cylinder 1, 4 oxygen sensor (terminal No. 4) Cylinder 1, 4 oxygen sensor
(front) itself. (front) connector and C-142 (terminal No.
• Check cylinder 1, 4 oxygen sensor (front) itself 109) engine-ECU <M/T> connector or
(Refer to P.13C-432). engine-A/T-ECU <A/T> connector.
Q: Is the check result normal? • Check output line for damage.
TROUBLESHOOTING
13C-71
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

Connector: B-39
• Transmission: Neutral <M/T> or P range <A/T>
OK:
2 1
voltage should repeat 0 to 0.8 V alternately. Cylinder 1, 4 oxygen
4 3 sensor (front)
B-39 (GR)
engine-ECU <M/T> connector or
NO : Repair.
TROUBLESHOOTING

connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-73
Code No. P0135: Cylinder 1, 4 Oxygen Sensor (Front) Heater System
Cylinder 1, 4 oxygen sensor (front) heater circuit
Battery
W-B
W-B
4 3 Cylinder 1, 4 oxygen sensor (front)

B-17X B-39
Engine MU802665
1 2 control
relay
3 4 1 2
3 4
1 2
To engine-ECU <M/T> 1 3 2 4
R
To engine-ECU <M/T>
P-L
25
C-139
(MU803802)
1 2 3 4
Engine-ECU <M/T>
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401170AB
OPERATION FUNCTION
• Power is supplied to the heater power terminal • The power supply to the cylinder 1, 4 oxygen
(terminal No. 1) of the Cylinder 1, 4 oxygen sen- sensor (front) heater is controlled by the ON/OFF
sor (front) connector from the engine control relay control of the power transistor in the engine-ECU
(terminal No. 1). <M/T> or engine-A/T-ECU <A/T>.
• The heater (terminal No. 3) of the Cylinder 1, 4 • Heating the cylinder 1, 4 oxygen sensor (front)
oxygen sensor (front) connector is controlled by heater enables the cylinder 1, 4 oxygen sensor
the power transistor in the engine-ECU <M/T> or (front) to provide good response even when the
engine-A/T-ECU <A/T> (terminal No. 25). exhaust emission temperature is low.
TROUBLESHOOTING
TROUBLE JUDGMENT STEP 2. Perform resistance measurement at B-39

Check Conditions cylinder 1, 4 oxygen sensor (front) connector.
• 60 seconds have elapsed since the previous Connector: B-39
monitoring started.
• Engine coolant temperature is 20°C or higher.
• While cylinder 1, 4 oxygen sensor (front) heater is
on.
• Battery positive voltage is 11 − 16 V.
• Cylinder 1, 4 oxygen sensor (front) heater current 4 3
B-39 (GR) sensor (front)
has continued to be 0.16 A or lower, or 7.5 A or
higher for 4 seconds. AK304260 AB

• Failed cylinder 1, 4 oxygen sensor (front) heater • Resistance between terminal No. 1 and No. 3.
• Open/short circuit in cylinder 1, 4 oxygen sensor OK: 4.5 − 8.0 Ω
(front) circuit or loose connector contact
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-39 cylinder 1, 4
oxygen sensor (front) connector Connector: B-39
Connector: B-39
2 1
4 3 sensor (front)
2 1 B-39 (GR)
Cylinder 1, 4 oxygen Harness side connector
4 3 sensor (front) AK304260 AB
B-39 (GR)
side.
Q: Is the check result normal? • Ignition switch: ON
NO : Repair. OK: System voltage
NO : Go to Step 4 .
TROUBLESHOOTING
13C-75
relay connector engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
Connector: B-17X
B-17X Connector: C-139
Relay box’s <L. H. Drive Vehicle>
triangle marks
2 1
C-139 (GR)
4 3
Harness

Connector: B-39
C-139 (GR)
2 1 4 3 2 1
Cylinder 1, 4 oxygen 13 12 1110 9 8 7 6 5
4 3 sensor (front) 2019 18 17 16 15 14
B-39 (GR)
2726 2524 23 22 21
Harness side connector AK304260 AB Harness side connector
AK304262 AB
YES : Check and repair harness between B-39 • Measure engine-ECU <M/T> or engine-A/T-ECU
(terminal No. 1) cylinder 1, 4 oxygen sensor <A/T> terminal voltage.
(front) connector and B-17X (terminal No. 1) • Ignition switch: ON
engine control relay connector. • Voltage between terminal No. 25 and earth.
• Check power supply line for OK: System voltage
open/short circuit.
NO : Go to Step 6 .
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 3) cylinder 1, 4 oxygen sensor (front)
Connector: B-39
C-139 (GR)
2 1
<R. H. Drive Vehicle> 4 3 sensor (front)
B-39 (GR)
C-139 (GR)
Connector: C-139
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21 C-139 (GR)
AK304262 AB

NO : Repair.
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-77
<M/T> connector or engine-A/T-ECU <A/T> No. 1)cylinder 1, 4 oxygen sensor (front)
connector connector and B-17X (terminal No. 1) engine
Connector: C-139
Connector: B-39
C-139 (GR)
2 1
4 3 sensor (front)
B-39 (GR)
C-139 (GR) Connector: B-17X

B-17X
Relay box’s
triangle marks
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2 1
2726 2524 23 22 21
Harness side connector 4 3
AK304262 AB Harness
NO : Repair.
TROUBLESHOOTING
No. 3) cylinder 1, 4 oxygen sensor (front) Q: Does trouble symptom persist?
connector and C-139 (terminal No. 25) YES : Replace engine-ECU <M/T> or
engine-ECU <M/T> connector or engine-A/T-ECU engine-A/T-ECU <A/T>.
<A/T> connector. NO : Intermittent malfunction (Refer to GROUP
P.00-6).
2 1
4 3 sensor (front)
B-39 (GR)
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-79
Code No. P0136: Cylinder 1, 4 Oxygen Sensor (Rear) System
Cylinder 1, 4 oxygen sensor (rear) circuit
B-38
MU802605
1 2 sensor (rear)
3 4
1 3 2 4
BR Y
To engine-ECU <M/T>
B
8
10
J/C (2)
J/C (1)
C-17
C-16
1
6
B
BR
96 117
C-142
(MU803805)
9192 939495 Engine-ECU <M/T>
96979899100 101102103 104 Engine-A/T-ECU <A/T>
105106 107108109 110111112
113114 115116117 118119120
Wire colour code

AK401171 AB
OPERATION FUNCTION
• The sensor signal is inputted to the engine-ECU • The cylinder 1, 4 oxygen sensor (rear) converts
<M/T> or engine-A/T-ECU <A/T> (terminal No. the concentration of oxygen in the exhaust emis-
117) from the cylinder 1, 4 oxygen sensor (rear) sion into a voltage and inputs the signal to the
output terminal (terminal No. 4). engine-ECU <M/T> or engine-A/T-ECU <A/T>.
• The cylinder 1, 4 oxygen sensor (rear) (terminal • When the air-fuel ratio is richer than the theoreti-
No. 2) is earthed with engine-ECU <M/T> or cal air-fuel ratio, the cylinder 1, 4 oxygen sensor
engine-A/T-ECU <A/T> (terminal No. 96). (rear) outputs a voltage of about 1 V. When it is
leaner than the theoretical air-fuel ratio, it outputs
a voltage of about 0 V.
• Based on this signal, the engine-ECU <M/T> or
engine-A/T-ECU <A/T> corrects the deviation in
the signal that is output by the cylinder 1, 4 oxy-
gen sensor (rear).
TROUBLESHOOTING
TROUBLE JUDGMENT DIAGNOSIS PROCEDURE

Check Conditions
• Above 3 minutes later after the engine has STEP 1. M.U.T.-II/III data list
started up. • Refer to Data List Reference Table P.13C-402.
• The engine coolant temperature is approximately a. Item 59: Cylinder 1, 4 oxygen sensor (rear)
82°C or higher.
• The engine speed is 1200 r/min or more. YES : Intermittent malfunction (Refer to GROUP
• The monitoring time is 5 seconds. 00 − How to Use
Judgment Criteria Troubleshooting/Inspection Service Points
• When the cylinder 1, 4 oxygen sensor (rear) out- P.00-6).
put voltage is 0.2V or less and a power voltage of NO : Go to Step 2 .
5V is applied to the cylinder 1, 4 oxygen sensor
(rear) in the engine-ECU <M/T> or STEP 2. Connector check: B-38 cylinder 1, 4
engine-A/T-ECU <A/T>, the sensor output volt- oxygen sensor (rear) connector
• To be monitored once per driving cycle. Connector: B-38
Check Conditions
• 2 seconds later after lack of circuit continuity is
detected.
• When the front oxygen sensor is normally oper- Cylinder 1, 4 oxygen
ated. sensor (rear)
Judgment Criteria
• When the air-fuel ratio is rich, the cylinder 1, 4
oxygen sensor (front) output voltage is 0.5 V or
more.
• The cylinder 1, 4 oxygen sensor (rear) output
voltage is less than 0.1 V.
• The maximum and maximum of the cylinder 1, 4
oxygen sensor (rear) output is 0.078 V or less.
PROBABLE CAUSE
• Failed cylinder 1, 4 oxygen sensor (rear) 2 1
• Open/short circuit in cylinder 1, 4 oxygen sensor 4 3 B-38 (B)
(rear) circuit or loose connector contact Harness
• Failed engine-ECU <M/T> side connector AK304263 AB
NO : Repair.
TROUBLESHOOTING
13C-81
STEP 3. Perform resistance measurement at B-38 STEP 4. Connector check: C-142 engine-ECU
cylinder 1, 4 oxygen sensor (rear) connector. <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: B-38
Connector: C-142
sensor (rear)
C-142 (GR)
C-142 (GR)
2 1 959493 92 91
104 103102 101100 99 98 97 96
4 3 B-38 (B) 112111110 109108107 106105
120119118 117116115 114113
Harness
side connector AK304263 AB Harness side connector
AK304153 AB
side. Q: Is the check result normal?
• Resistance between terminal No. 2 and earth. YES : Go to Step 5 .
OK: Continuity (2 Ω or less) NO : Repair.
NO : Go to Step 4 .
TROUBLESHOOTING

No. 2) cylinder 1, 4 oxygen sensor (rear) NO : Repair.
<A/T> connector. STEP 6. M.U.T.-II/III data list
Connector: B-38
a. Item 59: Cylinder 1, 4 oxygen sensor (rear)
00 − How to Use
Cylinder 1, 4 oxygen Troubleshooting/Inspection Service Points
sensor (rear) P.00-6).

cylinder 1, 4 oxygen sensor (rear) connector.
Connector: B-38
2 1 Cylinder 1, 4 oxygen
4 3 B-38 (B) sensor (rear)
Harness
Connector: C-142
C-142 (GR)
2 1
<R. H. Drive Vehicle> 4 3 B-38 (B)
Harness

959493 92 91 • Voltage between terminal No. 4 and earth.
104 103102 101100 99 98 97 96
112111110 109108107 106105 OK:
120119118 117116115 114113
voltage should repeat 0 to 0.8 V alternately
AK304153 AB
connector C-16, and repair if necessary. NO : Go to Step 8 .
• Check earthing line for open circuit.
TROUBLESHOOTING
13C-83
STEP 8. Check Cylinder 1, 4 oxygen sensor (rear) Connector: B-38
itself.
• Check cylinder 1, 4 oxygen sensor (rear) itself
YES : Go to Step 9 . sensor (rear)
NO : Replace cylinder 1, 4 oxygen (rear) sensor.

connector
Connector: C-142
C-142 (GR) 2 1
4 3 B-38 (B)
Harness

C-142 (GR) YES : Check and repair harness between B-38
(terminal No. 4) cylinder 1, 4 oxygen sensor
(rear) connector and C-142 (terminal No.
959493 92 91
104 103102 101100 99 98 97 96 NO : Repair.
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
TROUBLESHOOTING
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

Connector: B-38
OK: Cylinder 1, 4 oxygen
When the engine is 2,500 r/min, the output sensor (rear)
voltage should repeat 0 to 0.8 V alternately.
2 1
4 3 B-38 (B)
Harness
TROUBLESHOOTING
13C-85
connector
117) engine-ECU <M/T> connector or Connector: C-142
NO : Repair.
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Code No. P0141: Cylinder 1, 4 Oxygen Sensor (Rear) Heater System
Cylinder 1,4 oxygen sensor (rear) heater circuit
Battery
W-B
W-B
4 3 Cylinder 1, 4 oxygen sensor (rear)

B-17X
Engine B-38
1 2 control MU802605
relay
3 4
1 2
1 2 3 4
R
To engine-ECU <M/T>
V-W
24
C-139
(MU803802)
1 2 3 4 Engine-ECU <M/T>
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401172 AB
OPERATION • The heater (terminal No. 3) of the cylinder 1, 4

• Power is supplied to the heater power terminal oxygen sensor (rear) connector is controlled by
(terminal No. 1) of the cylinder 1, 4 oxygen sen- the power transistor in the engine-ECU <M/T> or
sor (rear) connector from the engine control relay engine-A/T-ECU <A/T> (terminal No. 24).
(terminal No. 1).
TROUBLESHOOTING
13C-87
• The power supply to the cylinder 1, 4 oxygen
sensor (rear) heater is controlled by the ON/OFF STEP 1. Connector check: B-38 cylinder 1, 4
control of the power transistor in the engine-ECU oxygen sensor (rear) connector
<M/T> or engine-A/T-ECU <A/T>.
• Heating the cylinder 1, 4 oxygen sensor (rear) Connector: B-38
heater enables the cylinder 1, 4 oxygen sensor
(rear) to provide good response even when the
exhaust emission temperature is low.
TROUBLE JUDGMENT Cylinder 1, 4 oxygen

sensor (rear)
Check Conditions
• 60 seconds have elapsed since the previous
monitoring started.
• While cylinder 1, 4 oxygen sensor (rear) heater is
on.
Judgment Criteria
• Cylinder 1, 4 oxygen sensor (rear) heater cur-
rents have continued to be 0.16 A or lower, or 5.0
A or higher for 4 seconds. 2 1
4 3
PROBABLE CAUSE B-38 (B)
Harness
• Failed cylinder 1, 4 oxygen sensor (rear) heater side connector AK304263 AB
• Open/short circuit in cylinder 1, 4 oxygen sensor
(rear) circuit or loose connector contact Q: Is the check result normal?
• Failed engine-ECU <M/T> YES : Go to Step 2 .
• Failed engine-A/T-ECU <A/T> NO : Repair.
TROUBLESHOOTING
STEP 2. Perform resistance measurement at B-38 STEP 3. Perform voltage measurement at B-38
cylinder 1, 4 oxygen sensor (rear) connector. cylinder 1, 4 oxygen sensor (rear) connector.
Cylinder 1, 4 oxygen Cylinder 1, 4 oxygen

sensor (rear) sensor (rear)
2 1 2 1
4 3 B-38 (B) 4 3 B-38 (B)
Harness Harness
• Disconnect connector, and measure at sensor • Disconnect connector, and measure at harness
side. side.
• Resistance between terminal No. 1 and No. 3. • Ignition switch: ON
OK: 11 − 18 Ω • Voltage between terminal No. 1 and earth.
OK: System voltage
NO : Replace cylinder 1, 4 oxygen sensor (rear). YES : Go to Step 5 .
NO : Go to Step 4 .
TROUBLESHOOTING
13C-89
<A/T> connector.
Connector: B-17X
triangle marks
2 1
C-139 (GR)
4 3
Harness

Connector: B-38
C-139 (GR)
sensor (rear)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

OK: System voltage
4 3 B-38 (B) YES : Go to Step 8 .
Harness NO : Go to Step 6 .

(rear) connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 3) cylinder 1, 4 oxygen sensor (rear)
Connector: B-38
C-139 (GR)
sensor (rear)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1
AK304262 AB
4 3 B-38 (B)
Harness
Q: Is the check result normal? side connector AK304263 AB
NO : Repair.
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-91
<M/T> connector or engine-A/T-ECU <A/T> No. 1) cylinder 1, 4 oxygen sensor (rear)
connector connector and B-17X (terminal No. 1) engine
Connector: C-139
Connector: B-38
C-139 (GR)
sensor (rear)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1
4 3 B-38 (B)
AK304262 AB
Harness
YES : Go to Step 9 . Connector: B-17X
NO : Repair.
B-17X
Relay box’s
triangle marks
2 1
4 3
Harness

NO : Repair.
TROUBLESHOOTING
No. 3) cylinder 1, 4 oxygen sensor (rear) Q: Does trouble symptom persist?
P.00-6).
sensor (rear)
2 1
4 3 B-38 (B)
Harness
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-93
Code No. P0150: Cylinder 2, 3 Oxygen Sensor (Front) System
Cylinder 2, 3 oxygen sensor (front) circuit
B-112
MU802665
1 2 sensor (front)
3 4
1 3 2 4
B W
To engine-ECU <M/T>
B
2
7
J/C (2)
J/C (1)
C-17
C-16
1
6
B
BR
96 108
C-142
(MU803805)
9192 939495 Engine-ECU <M/T>
96979899100 101102103 104 Engine-A/T-ECU <A/T>
105106 107108109 110111112
113114 115116117 118119120
Wire colour code

AK401173 AB
OPERATION • When the air-fuel ratio is richer than the theoreti-

• The sensor signal is inputted to the engine-ECU cal air-fuel ratio, the cylinder 2, 3 oxygen sensor
<M/T> or engine-A/T-ECU <A/T> (terminal No. (front) outputs a voltage of about 1 V. When it is
108) from the cylinder 2, 3 oxygen sensor (front) leaner than the theoretical air-fuel ratio, it outputs
output terminal (terminal No. 4). a voltage of about 0 V.
• The front cylinder 2, 3 oxygen sensor (front) (ter- • In response to the signal, the engine-ECU <M/T>
minal No. 2) is earthed with engine-ECU <M/T> or engine-A/T-ECU <A/T> controls the fuel infec-
or engine-A/T-ECU <A/T> (terminal No. 96). tion amount so that the air-fuel ratio can be equiv-
alent to the theoretical air-fuel ratio.
FUNCTION
• The cylinder 2, 3 oxygen sensor (front) converts TROUBLE JUDGMENT
the concentration of oxygen in the exhaust emis- Check Conditions
sion into a voltage and inputs the signal to the • Above 3 minutes later after the engine has
engine-ECU <M/T> or engine-A/T-ECU <A/T>. started up.
82°C or higher.
TROUBLESHOOTING
Judgment Criteria STEP 2. Connector check: B-112 cylinder 2, 3

• When the cylinder 2, 3 oxygen sensor (front) out- oxygen sensor (front) connector
put voltage is 0.2V or less and a power voltage of
5 V is applied to the cylinder 2, 3 oxygen sensor Connector: B-112
(front) in the engine-ECU <M/T> or
• To be monitored once per driving cycle.
Check Conditions Cylinder 2, 3 oxygen
• The engine speed is 1200 − 3000 r/min. sensor (front)
60°C or higher.
• Volumetric efficiency is 20 − 60%.
• During the air-fuel ratio feedback control.
Judgment Criteria
• When the cylinder 2, 3 oxygen sensor (front) out-
put frequency is 6 or less for 10 seconds on the
average
PROBABLE CAUSE 2 1
• Failed cylinder 2, 3 oxygen sensor (front) 4 3
• Open/short circuit in cylinder 2, 3 oxygen sensor Harness
(front) circuit or loose connector contact side connector B-112 (GR)
AK304264 AB
• Failed engine-A/T-ECU <A/T> Q: Is the check result normal?
DIAGNOSIS PROCEDURE NO : Repair.

00 − How to Use
P.00-6).
NO : Go to Step 2 .
TROUBLESHOOTING
13C-95
STEP 3. Perform resistance measurement at STEP 4. Connector check: C-142 engine-ECU
B-112 cylinder 2, 3 oxygen sensor (front) <M/T> connector or engine-A/T-ECU <A/T>
connector. connector
Cylinder 2, 3 oxygen C-142 (GR)

sensor (front)
C-142 (GR)
959493 92 91
2 1 104 103102 101100 99 98 97 96
112111110 109108107 106105
4 3 120119118 117116115 114113

Harness
side connector B-112 (GR) AK304153 AB
AK304264 AB

• Resistance between terminal No. 2 and earth. NO : Repair.
NO : Go to Step 4 .
TROUBLESHOOTING

No. 2) cylinder 2, 3 oxygen sensor (front) NO : Repair.
Connector: B-112
00 − How to Use
Cylinder 2, 3 oxygen P.00-6).
sensor (front)

Connector: B-112
2 1
sensor (front)
Harness
AK304264 AB
Connector: C-142
C-142 (GR)
2 1
4 3
Harness
C-142 (GR) side connector B-112 (GR)
AK304264 AB

104 103102 101100 99 98 97 96
112111110 109108107 106105 OK:
120119118 117116115 114113
AK304153 AB
TROUBLESHOOTING
13C-97
STEP 8. Check cylinder 2, 3 oxygen sensor Connector: B-112
(front) itself
• Check cylinder 2, 3 oxygen sensor (front) itself
YES : Go to Step 9 . Cylinder 2, 3 oxygen
NO : Replace cylinder 2, 3 oxygen sensor (front). sensor (front)

connector
Connector: C-142
2 1
C-142 (GR)
4 3
Harness
AK304264 AB

(front) connector and C-142 (terminal No.
959493 92 91
104 103102 101100 99 98 97 96
NO : Repair.
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
TROUBLESHOOTING
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

Connector: B-112
OK:
When the engine is 2,500 r/min, the output Cylinder 2, 3 oxygen
sensor (front)
2 1
4 3
Harness
AK304264 AB
TROUBLESHOOTING
13C-99
connector
(front) connector and C-142 (terminal No.
NO : Repair.
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Code No. P0155: Cylinder 2, 3 Oxygen Sensor (Front) Heater System
Cylinder 2, 3 oxygen sensor (front) heater circuit
Battery
W-B
W-B
4 3 Cylinder 2, 3 oxygen sensor (front)

B-17X B-112
Engine MU802665
1 2 control
relay
3 4 1 2
3 4
1 2
R
To engine-ECU <M/T>
Y-R
10
C-139
(MU803802)
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401174 AB
OPERATION FUNCTION
(terminal No. 1) of the cylinder 2, 3 oxygen sen- sensor (front) heater is controlled by the ON/OFF
sor (front) connector from the engine control relay control of the power transistor in the engine-ECU
• The heater (terminal No. 3) of the cylinder 2, 3 • Heating the cylinder 2, 3 oxygen sensor (front)
oxygen sensor (front) connector is controlled by heater enables the cylinder 2, 3 oxygen sensor
the power transistor in the engine-ECU <M/T> or (front) to provide good response even when the
TROUBLESHOOTING
13C-101
Check Conditions B-112 cylinder 2, 3 oxygen sensor (front)
• 60 seconds have elapsed since the previous connector.
monitoring started. Connector: B-112
• While cylinder 2, 3 oxygen sensor (front) heater is
on.
Judgment Criteria Cylinder 2, 3 oxygen
• Cylinder 2, 3 oxygen sensor (front) heater cur- sensor (front)
rents has continued to be 0.16 A or lower, or 7.5
A or higher for 4 seconds.
PROBABLE CAUSE
• Failed oxygen sensor heater
(front) circuit or loose connector contact
4 3
Harness
STEP 1. Connector check: B-112 cylinder 2, 3 side connector B-112 (GR)
AK304264 AB
oxygen sensor (front) connector
Connector: B-112 side.
OK: 4.5 − 8.0 Ω
Cylinder 2, 3 oxygen NO : Replace cylinder 2, 3 oxygen sensor (front).
sensor (front)
2 1
4 3
Harness
AK304264 AB

NO : Repair.
TROUBLESHOOTING
cylinder 2, 3 oxygen sensor (front) connector. relay connector
B-17X
Relay box’s
triangle marks
Cylinder 2, 3 oxygen 2 1
sensor (front)
4 3
Harness
Connector: B-112
2 1 sensor (front)
4 3
Harness
AK304264 AB

side.
OK: System voltage
Harness
AK304264 AB

(front) connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13C-103
C-139 (GR) C-139 (GR)
C-139 (GR) C-139 (GR)
4 3 2 1 4 3 2 1
13 12 1110 9 8 7 6 5 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2019 18 17 16 15 14
2726 2524 23 22 21 2726 2524 23 22 21
AK304262 AB AK304262 AB

<A/T> terminal voltage. YES : Go to Step 7 .
OK: System voltage
NO : Go to Step 6 .
TROUBLESHOOTING
No. 3) cylinder 2, 3 oxygen sensor (front) <M/T> connector or engine-A/T-ECU <A/T>
connector and C-139 (terminal No. 10) connector
<A/T> connector. Connector: C-139
Connector: B-112
C-139 (GR)
sensor (front)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1 Harness side connector

4 3 AK304262 AB
Harness
AK304264 AB
NO : Repair.
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-105
No. 1) cylinder 2, 3 oxygen sensor (front) No. 3) cylinder 2, 3 oxygen sensor (front)
connector and B-17X (terminal No. 1) engine connector and C-139 (terminal No. 10)
control relay connector. engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
Connector: B-112
Connector: B-112
sensor (front) Cylinder 2, 3 oxygen
sensor (front)
2 1
4 3 2 1
Harness 4 3
AK304264 AB Harness
AK304264 AB
Connector: B-17X
triangle marks
2 1
C-139 (GR)
4 3
Harness
• Check power supply line for damage. <R. H. Drive Vehicle>

C-139 (GR)
NO : Repair.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING

00 − How to Use
P.00-6).
Code No. P0156: Cylinder 2, 3 Oxygen Sensor (Rear) System
Cylinder 2, 3 oxygen sensor (rear) circuit
B-113
MU802605
1 2 sensor (rear)
3 4
1 3 2 4
P L
To engine-ECU <M/T>
B
3
10
J/C (2)
J/C (1)
C-17
C-16
1
6
B
BR
96 116
C-142
(MU803805)
9192 939495 Engine-ECU <M/T>
96979899100 101102103 104 Engine-A/T-ECU <A/T>
105106 107108109 110111112
113114 115116117 118119120
Wire colour code

AK401175 AB
OPERATION • The cylinder 2, 3 oxygen sensor (rear) (terminal

• The sensor signal is inputted to the engine-ECU No. 2) is earthed with engine-ECU <M/T> or
<M/T> or engine-A/T-ECU <A/T> (terminal No. engine-A/T-ECU <A/T> (terminal No. 96).
116) from the cylinder 2, 3 oxygen sensor (rear)
TROUBLESHOOTING
13C-107
FUNCTION PROBABLE CAUSE
• The cylinder 2, 3 oxygen sensor (rear) converts • Failed cylinder 2, 3 oxygen sensor (rear)
the concentration of oxygen in the exhaust emis- • Open/short circuit in cylinder 2, 3 oxygen sensor
sion into a voltage and inputs the signal to the (rear) circuit or loose connector contact
engine-ECU <M/T> or engine-A/T-ECU <A/T>. • Failed engine-ECU <M/T>
• When the air-fuel ratio is richer than the theoreti- • Failed engine-A/T-ECU <A/T>
cal air-fuel ratio, the cylinder 2, 3 oxygen sensor
(rear) outputs a voltage of about 1 V. When it is DIAGNOSIS PROCEDURE
leaner than the theoretical air-fuel ratio, it outputs
a voltage of about 0 V.
• Based on this signal, the engine-ECU <M/T> or
engine-A/T-ECU <A/T> corrects the deviation in
the signal that is output by the cylinder 2, 3 oxy- a. Item 69: Cylinder 2, 3 oxygen sensor (rear)
gen sensor (front). Q: Is the check result normal?
TROUBLE JUDGMENT 00 − How to Use
Check Conditions
• Above 3 minutes later after the engine has P.00-6).
NO : Go to Step 2 .
started up.
82°C or higher. STEP 2. Connector check: B-113 cylinder 2, 3
• The engine speed is 1200 r/min or more. oxygen sensor (rear) connector
Connector: B-113
Judgment Criteria
• When the cylinder 2, 3 oxygen sensor (rear) out-
put voltage is 0.2V or less and a power voltage of
5V is applied to the cylinder 2, 3 oxygen sensor
(rear) in the engine-ECU <M/T> or
age is 4.5V or more. Cylinder 2, 3 oxygen
sensor (rear)
• To be monitored once per driving cycle.
Check Conditions
• 2 seconds later after lack of circuit continuity is
detected.
• When the cylinder 2, 3 oxygen sensor (rear) is
normally operated. B-113 (B)
Judgment Criteria
• When the air-fuel ratio is rich, the cylinder 1, 4
oxygen sensor (front) output voltage is 0.5 V or 2 1
more. 4 3
• The cylinder 1, 4 oxygen sensor (rear) output
Harness
voltage is less than 0.1 V. side connector AK304265 AB
• The maximum and maximum of the cylinder 1, 4
oxygen sensor (rear) output is 0.078 V or less. Q: Is the check result normal?
NO : Repair.
TROUBLESHOOTING
STEP 3. Perform resistance measurement at STEP 4. Connector check: C-142 engine-ECU

B-113 cylinder 2, 3 oxygen sensor (rear) <M/T> connector or engine-A/T-ECU <A/T>
C-142 (GR)
sensor (rear)
C-142 (GR)
B-113 (B)
959493 92 91
104 103102 101100 99 98 97 96
2 1 112111110 109108107 106105
120119118 117116115 114113
4 3
Harness
side connector AK304265 AB AK304153 AB

• Resistance between terminal No. 2 and earth. NO : Repair.
NO : Go to Step 4 .
TROUBLESHOOTING
13C-109
No. 2) cylinder 2, 3 oxygen sensor (rear) NO : Repair.
Connector: B-113
a. Item 69: Cylinder 2, 3 oxygen sensor (rear)
00 − How to Use
P.00-6).
Cylinder 2, 3 oxygen NO : Replace engine-ECU <M/T> or
sensor (rear)

cylinder 2, 3 oxygen sensor (rear) connector.
Connector: B-113
B-113 (B)
2 1
4 3
Harness Cylinder 2, 3 oxygen
side connector AK304265 AB sensor (rear)
Connector: C-142
B-113 (B)
C-142 (GR)
2 1
<R. H. Drive Vehicle> 4 3
Harness

104 103102 101100 99 98 97 96
112111110 109108107 106105 OK:
120119118 117116115 114113
AK304153 AB
TROUBLESHOOTING
STEP 8. Check cylinder 2, 3 oxygen sensor (rear) Connector: B-113

itself
• Check cylinder 2, 3 oxygen sensor (rear) itself
NO : Replace cylinder 2, 3 oxygen sensor (rear).
sensor (rear)
connector
Connector: C-142
<L. H. Drive Vehicle> B-113 (B)
2 1
C-142 (GR)
4 3
Harness

959493 92 91
104 103102 101100 99 98 97 96
NO : Repair.
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
TROUBLESHOOTING
13C-111
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

Connector: B-113
OK:
voltage should repeat 0 to 0.8 V alternately. Cylinder 2, 3 oxygen
sensor (rear)
B-113 (B)
2 1
4 3
Harness
TROUBLESHOOTING

connector
NO : Repair.
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-113
Code No. P0161: Cylinder 2, 3 Oxygen Sensor (Rear) heater System
Cylinder 2,3 oxygen sensor (rear) heater circuit
Battery
W-B
W-B
4 3 Cylinder 2, 3 oxygen sensor (rear)

B-17X
B-113
Engine MU802605
1 2 control
relay
3 4 1 2
3 4
1 2
R
To engine-ECU <M/T>
Y-L
18
C-139
(MU803802)
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401176 AB
OPERATION FUNCTION
(terminal No. 1) of the cylinder 2, 3 oxygen sen- sensor (rear) heater is controlled by the ON/OFF
sor (rear) connector from the engine control relay control of the power transistor in the engine-ECU
• The heater (terminal No. 3) of the cylinder 2, 3 • Heating the cylinder 2, 3 oxygen sensor (rear)
oxygen sensor (rear) connector is controlled by heater enables the cylinder 2, 3 oxygen sensor
the power transistor in the engine-ECU <M/T> or (rear) to provide good response even when the
TROUBLESHOOTING

Check Conditions B-113 cylinder 2, 3 oxygen sensor (rear)
• 60 seconds have elapsed since the previous connector.
monitoring started. Connector: B-113
• While cylinder 2, 3 oxygen sensor (rear) heater is
on.
Judgment Criteria
• Cylinder 2, 3 oxygen sensor (rear) heater cur-
rents have continued to be 0.16 A or lower, or 5.0 sensor (rear)
A or higher for 4 seconds.
PROBABLE CAUSE
• Failed cylinder 2, 3 oxygen sensor (rear) heater
(rear) circuit or loose connector contact B-113 (B)
4 3
Harness
STEP 1. Connector check: B-113 cylinder 2, 3 side connector AK304265 AB
oxygen sensor (rear) connector
Connector: B-113 side.
OK: 11 − 18 Ω
NO : Replace cylinder 2, 3 oxygen sensor (rear).
sensor (rear)
B-113 (B)
2 1
4 3
Harness

NO : Repair.
TROUBLESHOOTING
13C-115
cylinder 2, 3 oxygen sensor (rear) connector. relay connector
B-17X
Relay box’s
triangle marks
2 1
Cylinder 2, 3 oxygen 4 3
sensor (rear)
Harness
Connector: B-113
B-113 (B)
4 3 sensor (rear)
Harness

side.
• Voltage between terminal No. 1 and earth. B-113 (B)
OK: System voltage

Harness

(rear) connector and B-17X (terminal No. 1)
open/short circuit.
NO : Repair.
TROUBLESHOOTING
C-139 (GR) C-139 (GR)
C-139 (GR) C-139 (GR)
4 3 2 1 4 3 2 1
13 12 1110 9 8 7 6 5 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2019 18 17 16 15 14
2726 2524 23 22 21 2726 2524 23 22 21
AK304262 AB AK304262 AB

OK: System voltage
NO : Go to Step 6 .
TROUBLESHOOTING
13C-117
No. 3) cylinder 2, 3 oxygen sensor (rear) <M/T> connector or engine-A/T-ECU <A/T>
connector and C-139 (terminal No. 18) connector
Connector: B-113
C-139 (GR)
sensor (rear) <R. H. Drive Vehicle>
C-139 (GR)
B-113 (B)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
2 1
4 3 AK304262 AB
Harness
NO : Repair.
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
No. 1) cylinder 2, 3 oxygen sensor (rear) No. 3) cylinder 2, 3 oxygen sensor (rear)
connector and B-17X (terminal No. 1) engine connector and C-139 (terminal No. 18)
control relay connector. engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
Connector: B-113
Connector: B-113
sensor (rear) Cylinder 2, 3 oxygen
sensor (rear)
B-113 (B)
B-113 (B)
2 1
4 3 2 1
Harness 4 3
Harness
Connector: B-17X
triangle marks
2 1
C-139 (GR)
4 3
Harness
• Check power supply line for damage. <R. H. Drive Vehicle>

C-139 (GR)
NO : Repair.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-119
00 − How to Use
P.00-6).
Code No. P0170: Abnormal Fuel System (Cylinder 1,4)

• Refer to Code No. P0201: No. 1 Injector System
P.13C-126. STEP 1. M.U.T.-II/III diagnosis code
P.13C-141.
FUNCTION to P.13C-21).
NO : Go to Step 2 .
• If the fuel system goes out of order, the fuel cor-
rection valve will become larger.
• The engine-ECU <M/T> or engine-A/T-ECU STEP 2. M.U.T.-II/III data list
<A/T> checks whether the fuel trim value is within • Refer to Data List Reference Table P.13C-402.
a specified range. a. Item 12: Air flow sensor
b. Item 13: Intake air temperature sensor
TROUBLE JUDGMENT c. Item 21: Engine coolant temperature sensor
Check Conditions d. Item 95: Manifold absolute pressure sensor
• In learning the air-fuel ratio. Q: Are the check results normal?
• Long-term fuel trim has continued to be +12.5% NO : Perform the diagnosis code classified check
or higher for 10 seconds. procedure for the sensor that has shown an
Or abnormal data value (Refer to Inspection
• Long-term fuel trim has continued to be -12.5% or Chart for Diagnosis Code P.13C-21).
higher for 10 seconds.
PROBABLE CAUSE • Refer to Data List Reference Table P.13C-402.
• Failed intake air temperature sensor a. Item 25: Barometric pressure sensor
• Failed purge control solenoid valve Q: Are the check results normal?
• Failed injector
• Air drawn in from gaps in gasket, seals, etc.
• Failed manifold absolute pressure sensor
• Failed barometric pressure sensor STEP 4. Check throttle body (throttle valve
• Exhaust leak portion) for contamination.
• Incorrect fuel pressure Q: Is the check result normal?
• Failed engine-A/T-ECU <A/T> NO : Clean throttle body (throttle valve portion)
TROUBLESHOOTING
STEP 5. Check for intake of air from intake hose STEP 9. Connector check: B-17X engine control
and inlet manifold. relay connector and C-139 engine-ECU <M/T>
connector or engine-A/T-ECU <A/T> connector
NO : Repair.
B-17X
Relay box’s
STEP 6. Check for leakage of exhaust emission triangle marks
NO : Repair.
Harness
STEP 7. Connector Check: Injector connector
Connector: C-139
Connectors: B-01, B-05
B-05 (GR)
B-01 (GR)
C-139 (GR)
M
2 1
Harness
side connector AK304261 AG
a. B-01 (No. 1 injector connector).

b. B-05 (No. 4 injector connector). C-139 (GR)

NO : Replace.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
STEP 8. Check injector itself. 2726 2524 23 22 21
• Check Injector itself (Refer to P.13C-435). Harness side connector
NO : Replace injector. Q: Is the check result normal?
NO : Repair.
TROUBLESHOOTING
13C-121
control relay connector and injector connector. connector and C-139 engine-ECU <M/T>
Connector: B-17X
triangle marks
2 1
C-139 (GR)
4 3
Harness

B-05 (GR)
B-01 (GR)
C-139 (GR)
M 4 3 2 1
13 12 1110 9 8 7 6 5
2 1 2019 18 17 16 15 14
Harness 2726 2524 23 22 21
side connector AK304261 AG Harness side connector
a. Check harness between B-17X (terminal No. 1) AK304262 AB
No. 1) No. 1 injector connector. Connectors: B-01, B-05
b. Check harness between B-17X (terminal No. 1) B-05 (GR)
B-01 (GR)
YES : Go to Step 11 . M
2 1
NO : Repair.
Harness
side connector AK304261 AG

NO : Repair.
TROUBLESHOOTING
• Check purge control solenoid valve itself (Refer P.13C-425).
Evaporative Emission Control System− Purge
Control Solenoid Valve P.17-65).
Code No. P0173: Abnormal Fuel System (cylinder 2, 3)

• Refer to Code No. P0202 No. 2 Injector System
P.13C-131. STEP 1. M.U.T.-II/III diagnosis code
P.13C-136.
FUNCTION to P.13C-21).
NO : Go to Step 2 .
• If the fuel system goes out of order, the fuel cor-
rection valve will become larger.
• The engine-ECU <M/T> or engine-A/T-ECU STEP 2. M.U.T.-II/III data list
<A/T> checks whether the fuel trim value is within • Refer to Data List Reference Table P.13C-402.
a specified range. a. Item 12: Air flow sensor
b. Item 13: Intake air temperature sensor
TROUBLE JUDGMENT c. Item 21: Engine coolant temperature sensor
Check Conditions d. Item 95: Manifold absolute sensor
• In learning the air-fuel ratio. Q: Are the check results normal?
• Long-term fuel trim has continued to be +12.5% NO : Perform the diagnosis code classified check
or higher for 10 seconds. procedure for the sensor that has shown an
Or abnormal data value (Refer to Inspection
• Long-term fuel trim has continued to be -12.5% or Chart for Diagnosis Code P.13C-21).
higher for 10 seconds.
PROBABLE CAUSE • Refer to Data List Reference Table P.13C-402.
• Failed intake air temperature sensor a. Item 25: Barometric pressure sensor
• Failed purge control solenoid valve Q: Are the check results normal?
• Failed injector
• Air drawn in from gaps in gasket, seals, etc.
• Failed manifold absolute pressure sensor
• Failed barometric pressure sensor STEP 4. Check throttle body (throttle valve
• Exhaust leak portion) for contamination.
• Incorrect fuel pressure Q: Is the check result normal?
• Failed engine-A/T-ECU <A/T> NO : Clean throttle body (throttle valve portion)
TROUBLESHOOTING
13C-123
STEP 5. Check for intake of air from intake hose STEP 9. Connector check: B-17X engine control
and inlet manifold. relay connector and C-139 engine-ECU <M/T>
NO : Repair.
B-17X
Relay box’s
STEP 6. Check for leakage of exhaust emission triangle marks
NO : Repair.
Harness
STEP 7. Connector Check: Injector connector
Connector: C-139
B-02 (GR) B-04 (GR)
C-139 (GR)
M
2 1
Harness
side connector AK304261 AH
a. B-02 (No. 2 injector connector).

b. B-04 (No. 3 injector connector). C-139 (GR)

NO : Replace.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
STEP 8. Check injector itself. 2726 2524 23 22 21
• Check Injector itself (Refer to P.13C-435). Harness side connector
NO : Replace injector. Q: Is the check result normal?
NO : Repair.
TROUBLESHOOTING
control relay connector and injector connector. connector and C-139 engine-ECU <M/T>
Connector: B-17X
triangle marks
2 1
C-139 (GR)
4 3
Harness

B-02 (GR) B-04 (GR)

C-139 (GR)
M 4 3 2 1
13 12 1110 9 8 7 6 5
2 1 2019 18 17 16 15 14
Harness 2726 2524 23 22 21
side connector AK304261 AH Harness side connector
a. Check harness between B-17X (terminal No. 1) AK304262 AB
No. 1) No. 2 injector connector. Connectors: B-02, B-04
b. Check harness between B-17X (terminal No. 1) B-02 (GR) B-04 (GR)
YES : Go to Step 11 . M
2 1
NO : Repair.
Harness
side connector AK304261 AH

NO : Repair.
TROUBLESHOOTING
13C-125
• Check purge control solenoid valve itself (Refer P.13C-425).
Evaporative Emission Control System − Purge
Control Solenoid Valve P.17-65).
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
R To engine-ECU <M/T>
R R R R
No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
(MU802062) 1 (MU802062) 1 (MU802062) 1 (MU802062) 1
1 2 1 2 1 2 1 2
2 2 2 2
O W-G R-W R-B
1 5 14 21
C-139
(MU803802)
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401177 AB
TROUBLESHOOTING
13C-127
• The engine-ECU <M/T> or engine-A/T-ECU Connector: B-01
<A/T> (terminal No. 1) makes the power transis-
B-01 (GR)
tor in the unit be in "ON" position, and that makes
currents go on the injector (terminal No. 2).
FUNCTION
• The engine-ECU <M/T> or engine-A/T-ECU M
<A/T> controls the power supply interval of the 2 1
injector. Harness
side connector
AK304261 AC
on the power supply interval. Q: Is the check result normal?

Check Conditions
• While engine is running. STEP 3. Check No. 1 injector itself.
Judgment Criteria • Check No. 1 Injector itself (Refer to P.13C-435).
• Injector coil surge voltage (battery positive volt- Q: Is the check result normal?
age + 2 V) has not been detected for 2 seconds. YES : Go to Step 4 .
NO : Replace No. 1 injector.
PROBABLE CAUSE
• Failed No. 1 injector STEP 4. Perform voltage measurement at B-01
• Open/short circuit in injector circuit or loose con- No. 1 injector connector.
nector contact
• Failed engine-ECU <M/T> Connector: B-01
B-01 (GR)
DIAGNOSIS PROCEDURE

• Item 01: No. 1 injector M
2 1
OK: Idling state varies. Harness
side connector AK304261 AC
NO : Go to Step 2 . OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
STEP 5. Connector check: B-17X engine control STEP 6. Connector check: B-17X engine control
relay connector relay connector
B-17X B-17X
Relay box’s Relay box’s
2 1 2 1
4 3 4 3
Harness Harness

B-01 (GR) NO : Repair.

No. 1) engine control relay connector and B-01
M
(terminal No. 1) No. 1 injector connector.
2 1
Connector: B-17X
Harness
side connector AK304261 AC B-17X
Relay box’s
Q: Is the check result normal? triangle marks
connector and B-01 (terminal No. 1) No. 1 2 1
injector connector. 4 3
• Check power supply line for Harness
open/short circuit. side connector AK304152 AB
NO : Repair.
Connector: B-01
B-01 (GR)
M
2 1
Harness

NO : Repair.
TROUBLESHOOTING
13C-129
<M/T> connector or engine-A/T-ECU <A/T> No. 2) No. 1 injector connector and C-139
Connector: C-139
Connector: B-01
B-01 (GR)
C-139 (GR)
M
2 1
<R. H. Drive Vehicle> Harness

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

age.
NO : Repair.
TROUBLESHOOTING

measurement at C-139 engine-ECU <M/T>
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
• Engine: Idling
00 − How to Use
P.00-6).
TROUBLESHOOTING
13C-131
Injector circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
R R R R
No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
(MU802062) 1 (MU802062) 1 (MU802062) 1 (MU802062) 1
1 2 1 2 1 2 1 2
2 2 2 2
O W-G R-W R-B
1 5 14 21
C-139
(MU803802)
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401177 AB
TROUBLESHOOTING

<A/T> connector (terminal No. 5) makes the B-02 (GR)
nal No. 2).
FUNCTION M
• The engine-ECU <M/T> or engine-A/T-ECU 2 1
<A/T> controls the power supply interval of the Harness
side connector AK304261 AD
injector.
• The fuel injection amount of the injector depends Q: Is the check result normal?
on the power supply interval. YES : Go to Step 3 .
NO : Repair.
TROUBLE JUDGMENT
Check Conditions STEP 3. Check No. 2 injector itself.
• While engine is running. • Check No. 2 Injector itself (Refer to P.13C-435).
Judgment Criteria Q: Is the check result normal?
• Injector coil surge voltage (battery positive volt- YES : Go to Step 4 .
age + 2 V) has not been detected for 2 seconds. NO : Replace No. 2 injector.

• Failed No. 2 injector No. 2 injector connector.
connector contact Connector: B-02
B-02 (GR)
DIAGNOSIS PROCEDURE

2 1
• Item 02: No. 2 injector
Harness
OK: Idling state varies. side connector AK304261 AD

NO : Go to Step 2 .
NO : Go to Step 5 .
TROUBLESHOOTING
13C-133
B-17X B-17X
2 1 2 1
4 3 4 3
Harness Harness


M
2 1
Connector: B-17X
Harness
side connector AK304261 AD B-17X
Relay box’s
open/short circuit and damage. side connector AK304152 AB
NO : Repair.
Connector: B-02
B-02 (GR)
M
2 1
Harness

NO : Repair.
TROUBLESHOOTING
Connector: C-139
Connector: B-02
B-02 (GR)
C-139 (GR)
M
2 1

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

age.
NO : Repair.
TROUBLESHOOTING
13C-135
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
• Engine: Idling
to P.13C-419).
00 − How to Use
P.00-6).
TROUBLESHOOTING
Injector circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
R R R R
No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
(MU802062) 1 (MU802062) 1 (MU802062) 1 (MU802062) 1
1 2 1 2 1 2 1 2
2 2 2 2
O W-G R-W R-B
1 5 14 21
C-139
(MU803802)
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401177 AB
TROUBLESHOOTING
13C-137
<A/T> (terminal No. 14) makes the power transis- B-04 GR)
FUNCTION
<A/T> controls the power supply interval of the 2 1
injector. Harness
side connector
AK304261 AE

Check Conditions
Judgment Criteria • Check No. 3 Injector itself (Refer to P.13C-435).
PROBABLE CAUSE
• Open/short circuit in No. 3 injector circuit or loose No. 3 injector connector.
connector contact
• Failed engine-ECU<M/T> Connector: B-04
• Failed engine-A/T-ECU<A/T> B-04 GR)
DIAGNOSIS PROCEDURE

2 1
side connector AK304261 AE
NO : Go to Step 5 .
TROUBLESHOOTING
B-17X B-17X
2 1 2 1
4 3 4 3
Harness Harness

B-04 GR) NO : Repair.

M
2 1
Connector: B-17X
Harness
side connector AK304261 AE B-17X
Relay box’s
open/short circuit. side connector AK304152 AB
NO : Repair.
Connector: B-04
B-04 GR)
M
2 1
Harness

NO : Repair.
TROUBLESHOOTING
13C-139
Connector: C-139
Connector: B-04
B-04 GR)
C-139 (GR)
M
2 1

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
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AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

age.
NO : Repair.
TROUBLESHOOTING

(Using on oscilloscope).
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
• Engine: Idling
to P.13C-419).
00 − How to Use
P.00-6).
TROUBLESHOOTING
13C-141
Injector circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
R R R R
No. 1 No. 2 No. 3 No. 4
B-01 B-02 B-04 B-05
(MU802062) 1 (MU802062) 1 (MU802062) 1 (MU802062) 1
1 2 1 2 1 2 1 2
2 2 2 2
O W-G R-W R-B
1 5 14 21
C-139
(MU803802)
5 6 7 8 9 10111213
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401177 AB
TROUBLESHOOTING

<A/T> (terminal No. 21) makes the power transis- B-05 (GR)
FUNCTION
<A/T> connector controls the power supply inter- 2 1
val of the injector. Harness
side connector
AK304261 AF

Check Conditions
Judgment Criteria • Check No. 4 Injector (Refer to P.13C-435) itself.
PROBABLE CAUSE
• Open/short circuit in No. 4 injector circuit or loose No. 4 injector connector.
connector contact
• Failed engine-ECU <M/T> Connector: B-05
• Failed engine-A/T-ECU <A/T> B-05 (GR)
DIAGNOSIS PROCEDURE

2 1
side connector AK304261 AF
NO : Go to Step 5 .
TROUBLESHOOTING
13C-143
B-17X B-17X
2 1 2 1
4 3 4 3
Harness Harness

YES : Go to Step 7.
B-05 (GR)
NO : Repair.

M
2 1
Connector: B-17X
Harness
side connector AK304261 AF B-17X
Relay box’s
open/short circuit and damage. side connector AK304152 AB
NO : Repair.
Connector: B-05
B-05 (GR)
M
2 1
Harness

NO : Repair.
TROUBLESHOOTING
Connector: C-139
Connector: B-05
B-05 (GR)
C-139 (GR)
M
2 1

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
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AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
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AK304262 AB

age.
NO : Repair.
TROUBLESHOOTING
13C-145
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
• Engine: Idling
to P.13C-419).
00 − How to Use
P.00-6).
TROUBLESHOOTING
Code No. P0222: Throttle Position Sensor (Sub) Circuit Low Input
(sub)
controlled
5 6 3
R G B
106 113 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU <M/T>
Wire colour code

AK304122AC
OPERATION FUNCTION
Check Conditions
valve output terminal (terminal No. 6). • Throttle position sensor (sub) output voltage is
2.25 V or less for 0.5 second.
TROUBLESHOOTING
13C-147
• Failed throttle position sensor (sub) electronically controlled throttle valve connector.
circuit or loose connector contact Connector: B-06
DIAGNOSIS PROCEDURE

• Refer to Data list reference table P.13C-402. 6 5 4 3 2 1
a. Item 14: Throttle position sensor (sub) Harness side connector AK304259 AB

P.00-6). OK: 4.9 − 5.1 V
NO : Go to Step 2 .
STEP 2. Connector check: B-06 electronically NO : Go to Step 4 .
connector
Connector: C-142
B-06 (B)
6 5 4 3 2 1
Harness side connector AK304259 AB C-142 (GR)

NO : Repair. <R. H. Drive Vehicle>
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
<A/T> connector.
P.00-6).
B-06 (B)
6 5 4 3 2 1 <M/T> connector or engine-A/T-ECU <A/T>
Harness side connector connector
AK304259 AB
Connector: C-142
Connector: C-142
C-142 (GR)
C-142 (GR)

C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
959493 92 91
112111110 109108107 106105
104 103102 101100 99 98 97 96
120119118 117116115 114113
112111110 109108107 106105
AK304153 AB
NO : Repair.
TROUBLESHOOTING
13C-149
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
age.
NO : Repair.

throttle valve
YES : Check end.
TROUBLESHOOTING
Code No. P0223: Throttle Position Sensor (Sub) Circuit High Input
(sub)
controlled
5 6 3
R G B
106 113 105
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU <M/T>
Wire colour code

AK304122AC
OPERATION FUNCTION
Check Conditions
valve output terminal (terminal No. 6). • Throttle position sensor (sub) output voltage is
4.8 V or more for 0.5 second.
TROUBLESHOOTING
13C-151
• Failed throttle position sensor (sub) electronically controlled throttle valve connector.
circuit or loose connector contact Connector: B-06
DIAGNOSIS PROCEDURE

a. Item 14: Throttle position sensor (sub) Harness side connector AK304259 AB

P.00-6).
NO : Go to Step 2 .
NO : Go to Step 4 .
STEP 2. Connector check: B-06 electronically
controlled throttle valve connector STEP 4. Connector check: C-142 engine-ECU
connector
Connector: C-142
B-06 (B)
6 5 4 3 2 1 C-142 (GR)

NO : Repair.
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
connector and C-142 (terminal No. 105) a. Item 14: Throttle position sensor (sub)
<A/T> connector.
P.00-6).
B-06 (B)
Harness side connector • After replacing the electronically controlled throt-
AK304259 AB
YES : Check end.
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-153
Code No. P0300: Random/Multiple Cylinder Misfire Detected
OPERATION • Failed engine-ECU <M/T>

• Refer to Code No. P0201: No. 1 injector system • Failed engine-A/T-ECU <A/T>
P.13C-126.
• Refer to Code No. P0202: No. 2 injector system DIAGNOSIS PROCEDURE
P.13C-131.
• Refer to Code No. P0203: No. 3 injector system STEP 1.M.U.T.-II/III data list
P.13C-136. • Item 22: Crank angle sensor
• Refer to Code No. P0204: No. 4 injector system OK: Keep the engine speed constant to make
P.13C-141. the pulse width of output waveform con-
stant.
FUNCTION
engine speed changes for an instant. NO : Check crank angle sensor system (Refer to
• The engine-ECU <M/T> or engine-A/T-ECU Code No. P0335 P.13C-170).
<A/T> checks for such changes in engine speed.
TROUBLE JUDGMENT STEP 2. M.U.T.-II/III data list

Check Conditions
a. Item 21: Engine coolant temperature sensor
• Engine speed is 500 − 6,500 r/min.
b. Item 81: Long-term fuel compensation
• Engine coolant temperature is −10°C or higher.
• Barometric pressure is 76 kPa or higher. c. Item 82: Short-term fuel compensation
• Volumetric efficiency is between 30% and 55 %. Q: Are the check results normal?
• Adaptive learning is complete for the vane which YES : Go to Step 3 .
generates a crankshaft position signal. NO : Perform the diagnosis code classified check
• While the engine is running, excluding gear shift- procedure for the sensor that has shown an
ing, deceleration, sudden acceleration/decelera- abnormal data valve (Refer to Inspection
tion and A/C compressor switching. Chart for Diagnosis Code P.13C-21).
• The throttle deviation is −0.06 V/10 ms to +0.06
V/10 ms. STEP 3. Visual check of ignition spark.
Judgment Criteria (change in the angular accel- • Remove the spark plug and install it to the ignition
eration of the crankshaft is used for misfire coil.
detection). • Connect the ignition coil connector.
• Misfire has occurred more frequently than the • Remove all injector connectors.
limit during the last 200 revolutions (when the cat- • At the engine start, check each spark plug pro-
alyst temperature has been 950°C or higher). duces a spark.
Or Q: Is the check result normal?
• Misfire has occurred 15 times or more in the last YES : Go to Step 5 .
1,000 revolutions (that has been equivalent to NO : Go to Step 4 .
approximately 1.5 times the emission standard).
PROBABLE CAUSE STEP 4. Check spark plug.

• Ignition system related part(s) failed • Check spark plug itself (Refer to GROUP 16 −
• Failed crank angle sensor Ignition System − On-vehicle Service P.16-40).
• Incorrect air-fuel ratio Q: Is the check result normal?
• Low compression pressure YES : Check ignition circuit system (Refer to
• Failed engine coolant temperature sensor Inspection Procedure 31 P.13C-388).
• Skipping of timing belt teeth. NO : Replace the spark plug.
• EGR system and EGR valve failed
TROUBLESHOOTING
STEP 5. Connector check: Injector connector STEP 8. Check for intake of air from intake hose
and inlet manifold.
Connectors: B-01, B-02, B-04, B-05
B-05 (GR)
B-01 (GR) B-02 (GR) B-04 (GR) YES : Go to Step 9 .
NO : Repair.
STEP 9. Check for skipped timing belt teeth.

M Q: Is the check result normal?
Harness NO : Repair.
a. B-01 (No. 1 injector connector)

STEP 10. Check EGR valve (stepper motor) itself.
b. B-02 (No. 2 injector connector)
• Check EGR valve (stepper motor) itself [Refer to
c. B-04 (No. 3 injector connector) GROUP 17 − Exhaust Gas Recirculation (EGR)
d. B-05 (No. 4 injector connector) System − EGR Valve (Stepper Motor) Check
Q: Are the check results normal? <4G69> P.17-72].
NO : Replace EGR valve (stepper motor)
STEP 6. Check injector itself.
• Check Injector itself (Refer to P.13C-435). STEP 11. Check the trouble symptoms.
YES : Go to Step 7 . YES : Replace engine-ECU <M/T> or
NO : Replace injector. engine-A/T-ECU <A/T>.
STEP 7. Fuel pressure measurement. 00 − How to Use
• Fuel pressure measurement (Refer to Fuel Pres- Troubleshooting/Inspection Service
sure Test P.13C-425) PointsP.00-6).
NO : Repair.
TROUBLESHOOTING
13C-155
Code No. P0301: No. 1 Cylinder Misfire Detected

P.13C-126. STEP 1. Visual check of ignition spark.
• Remove the spark plug and install it to the ignition
FUNCTION coil.
• If a misfire occurs while the engine is running, the • Connect the ignition coil connector.
engine speed changes for an instant. • Remove all injector connectors.
• The engine-ECU <M/T> or engine-A/T-ECU • At the engine start, check each spark plug pro-
<A/T> checks for such changes in engine speed. duces a spark.
Check Conditions NO : Go to Step 2 .
• Barometric pressure is 76 kPa or higher.
• Check spark plug itself (Refer to GROUP 16 −
• Volumetric efficiency is between 30% and 55 %.
• Adaptive learning is complete for the vane which
generates a crankshaft position signal. Q: Is the check result normal?
• While the engine is running, excluding gear shift- YES : Check ignition circuit system (Refer to
ing, deceleration, sudden acceleration/decelera- Inspection Procedure 31 P.13C-388).
tion and A/C compressor switching. NO : Replace the spark plug.
V/10 ms. STEP 3.Connector check: B-01 No. 1 injector
Judgment Criteria (change in the angular accel- connector
eration of the crankshaft is used for misfire Connector: B-01
detection).
• Misfire has occurred more frequently than the B-01 (GR)
limit during the last 200 revolutions (when the cat-
alyst temperature has been 950°C or higher).
Or
• Misfire has occurred 15 times or more in the last
1,000 revolutions (that has been equivalent to M
2 1
Harness
PROBABLE CAUSE
• Ignition system related part(s) failed Q: Is the check result normal?
• Low compression pressure YES : Go to Step 4 .
• Failed engine-ECU <M/T> NO : Repair.
STEP 4.Check No. 1 injector itself.
TROUBLESHOOTING
relay connector and C-139 engine-ECU <M/T> No. 1) engine control relay connector and B-01
connector or engine-A/T-ECU <A/T> connector (terminal No. 1) No. 1 injector connector.
B-17X B-17X
2 1 2 1
4 3 4 3
Harness Harness
<L. H. Drive Vehicle> B-01 (GR)
C-139 (GR)
M
2 1
Harness
C-139 (GR)
NO : Repair.
4 3 2 1
13 12 1110 9 8 7 6 5
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AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-157
No. 2) No. 1 injector connector and C-139 • Fuel pressure measurement (Refer to fuel pres-
(terminal No. 1) engine-ECU <M/T> connector or sure test P.13C-425).
engine-A/T-ECU <A/T> connector Q: Is the check result normal?
Connector: B-01 YES : Go to Step 9
NO : Repair.
B-01 (GR)

M engine-A/T-ECU <A/T>.
2 1 NO : Intermittent malfunction (Refer to GROUP
Harness
00 − How to Use
Connector: C-139 P.00-6).
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING

FUNCTION coil.
V/10 ms. STEP 3. Check connector: B-02 No. 2 injector
detection).
• Misfire has occurred more frequently than the B-02 (GR)
Or
2 1
Harness
PROBABLE CAUSE
STEP 4. Check No. 2 injector itself.
TROUBLESHOOTING
13C-159
relay connector and C-139 engine-ECU <M/T> No. 1) engine control relay connector and
connector or engine-A/T-ECU <A/T> connector B-02(terminal No. 1) No. 2 injector connector.
B-17X B-17X
2 1 2 1
4 3 4 3
Harness Harness
C-139 (GR)
M
2 1
Harness
C-139 (GR)
NO : Repair.
4 3 2 1
13 12 1110 9 8 7 6 5
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AK304262 AB

NO : Repair.
TROUBLESHOOTING
(terminal No. 5) engine-ECU <M/T> connector or sure test P.13C-425)
NO : Repair.
B-02 (GR)

Harness
00 − How to Use
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
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AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-161

FUNCTION coil.
V/10 ms. STEP 3. Connector check: B-04 No. 3 injector
detection).
• Misfire has occurred more frequently than the B-04 GR)
Or
2 1
Harness
PROBABLE CAUSE
• Failed engine-A/T-ECU
TROUBLESHOOTING
STEP 5. Connector check: B-17X engine control STEP 6.Check harness between B-17X (terminal
B-17X B-17X
2 1 2 1
4 3 4 3
Harness Harness
<L. H. Drive Vehicle> B-04 GR)
C-139 (GR)
M
2 1
Harness
C-139 (GR)
NO : Repair.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-163
(terminal No. 14) engine-ECU <M/T> connector or sure test P.13C-425)
NO : Repair.
B-04 GR)

Harness
00 − How to Use
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING

FUNCTION coil.
V/10 ms. STEP 3. Connector check: B-05 No. 4 injector
detection).
B-05 (GR)
• Misfire has occurred more frequently than the
Or
2 1
Harness
PROBABLE CAUSE
TROUBLESHOOTING
13C-165
B-17X B-17X
2 1 2 1
4 3 4 3
Harness Harness
C-139 (GR)
M
2 1
Harness
C-139 (GR)
NO : Repair.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
No. 2) No. 4 injector connector and C-139 • Fuel pressure measurement (Refer to Fuel Pres-
(terminal No. 21) engine-ECU <M/T> connector or sure Test P.13C-425)
engine-A/T-ECU <A/T> connector. Q: Is the check result normal?
NO : Repair.
B-05 (GR)

Harness
00 − How to Use
Connector: C-139
PointsP.00-6).
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-167
C-141
(MU803804)
6162 6364 Engine-ECU <M/T>
656667686970717273 Engine-A/T-ECU <A/T>
747576777879808182
8384 858687 8889
89
B B
B-102
MU802661
2 1 1 2
Detonation sensor
Wire colour code

AK304128 AB

Check Conditions
• After 2 seconds have passed since the engine
89) from the detonation sensor (terminal No. 1).
starting sequence was completed.
FUNCTION • Engine speed is 2,500 r/min or higher.
• The detonation sensor detects the vibration of the Judgment Criteria
cylinder block caused by detonation waves, and • Change of detonation sensor output voltage (det-
inputs a signal to the engine-ECU <M/T> or onation sensor peak voltage in each 1/2 turn of
engine-A/T-ECU <A/T>. the crankshaft) has not been 0.06 V or more in
• In response to the signal, the engine-ECU <M/T> the last consecutive 200 periods.
or engine-A/T-ECU <A/T> provides controls to
retard the ignition timing when the detonation
occurs.
TROUBLESHOOTING
PROBABLE CAUSE STEP 3. Connector check: C-141 engine-ECU

• Failed detonation sensor <M/T> connector or engine-A/T-ECU <A/T>
• Open/short circuit in detonation sensor circuit or connector
• Failed engine-ECU <M/T> Connector: C-141
• Failed engine-A/T-ECU <A/T> <L. H. Drive Vehicle>
DIAGNOSIS PROCEDURE
C-141(GR)
STEP 1. Connector check: B-102 detonation
sensor connector
Connector: B-102
C-141 (GR)
B-102 (GR)
2 1 Detonation sensor
6463 62 61
Harness 7372 7170 69 6867 6665
side connector AK304266 AB 82 818079 78 7776 7574
8988 87 86 85 8483

NO : Repair.
STEP 2. Perform resistance measurement at NO : Repair.
B-102 detonation sensor connector.
Connector: B-102
B-102 (GR)
Harness

side.
(terminal No. 2) detonation sensor
and damage.
TROUBLESHOOTING
13C-169
No. 1) detonation sensor connector and C-141 Q: Does trouble symptom persist?
(terminal No. 89) engine-ECU <M/T> connector or YES : Go to Step 6 .
engine-A/T-ECU <A/T> connector. NO : Intermittent malfunction (Refer to GROUP
P.00-6).
B-102 (GR)
STEP 6. Replace detonation sensor.
Harness
side connector AK304266 AB YES : Replace engine-ECU <M/T> or
Connector: C-141 NO : Check end.
C-141(GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

age.
NO : Repair.
TROUBLESHOOTING
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
relay
3 4
1 2
1 B-29
B-29 1 B-29-1
(MU802064)
Crank
1 2 3 angle
sensor
B-29-1
1 2 3
3 2
3 2
B-W
18
J/C (1)
G-R
C-16
17
B-W
88 70
C-141
(MU803804)
Engine-ECU <M/T>
6162 6364
656667686970717273 Engine-A/T-ECU <A/T>
747576777879808182
8384 858687 8889 5V
Wire colour code

AK401178 AB
TROUBLESHOOTING
13C-171
OPERATION STEP 2. Connector check: B-29 crank angle
• Power is supplied to the crank angle sensor (ter- sensor intermediate connector
minal No. 1) from the engine control relay (termi-
nal No. 1) and is earthed to the engine-ECU Connector: B-29
88) from the crank angle sensor (terminal No. 3).
• A power voltage of 5 V is applied to the crank
angle sensor output terminal (terminal No. 2) B-29 (GR)
from the engine-ECU <M/T> or engine-A/T-ECU
<A/T> (terminal No. 70).
3 2 1
FUNCTION Harness
side connector
• The crank angle sensor detects the crank angle
AK304267 AB
(position) and inputs a pulse signal to the Q: Is the check result normal?
engine-ECU <M/T> or engine-A/T-ECU <A/T>. YES : Go to Step 3 .
• In response to the signal, the engine-ECU <M/T> NO : Repair.
or engine-A/T-ECU <A/T> controls the injector,
etc.
TROUBLE JUDGMENT crank angle sensor intermediate connector.
Check Conditions Connector: B-29

• While engine is being cranked.
Judgment Criteria
• Crank angle sensor output voltage has not been B-29 (GR)
changed (no pulse signal has been input) for 2
seconds.
3 2 1
PROBABLE CAUSE Harness
• Failed crank angle sensor side connector AK304267 AB
• Open/short circuit in crank angle sensor circuit or • Disconnect connector, and measure at harness
loose connector contact side.
• Failed engine-ECU <M/T> • Ignition switch: ON
• Failed engine-A/T-ECU <A/T> • Voltage between terminal No. 2 and earth.
DIAGNOSIS PROCEDURE OK: 4.9 − 5.1 V
STEP 1. M.U.T.-II/III data list NO : Go to Step 4 .
00 − How to Use
P.00-6).
NO : Go to Step 2 .
TROUBLESHOOTING
engine-ECU connector. <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-141
<L. H. Drive Vehicle> Connector: C-141
C-141(GR)
C-141(GR)

C-141 (GR) <R. H. Drive Vehicle>
C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574 6463 62 61
8988 87 86 85 8483 7372 7170 69 6867 6665
82 818079 78 7776 7574

AK304154 AB
Connector: B-29
Connector: B-29
B-29 (GR)
B-29 (GR)
3 2 1
Harness 3 2 1
Harness
side connector
• Measure engine-ECU <M/T> or engine-A/T-ECU AK304267 AB
<A/T> terminal voltage. Q: Is the check result normal?

• Disconnect B-29 crank angle sensor intermediate YES : Check and repair harness between B-29
connector. (terminal No. 2) crank angle sensor
• Ignition switch: ON intermediate connector and C-141 (terminal
• Voltage between terminal No. 70 and earth. No. 70) engine-ECU <M/T> connector or
OK: 4.9 − 5.1 V engine-A/T-ECU <A/T> connector.
NO : Go to Step 6 .
TROUBLESHOOTING
13C-173
<M/T> connector or engine-A/T-ECU <A/T> No. 2) crank angle sensor intermediate connector
connector and C-141 (terminal No. 70) engine-ECU <M/T>
Connector: C-141
Connector: B-29
C-141(GR) B-29 (GR)
3 2 1
Connector: C-141
6463 62 61
7372 7170 69 6867 6665 C-141(GR)
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
Q: Is the check result normal? C-141 (GR)
NO : Repair.
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.

00 − How to Use
P.00-6).
TROUBLESHOOTING
crank angle sensor intermediate connector. relay connector
B-17X
Relay box’s
triangle marks
B-29 (GR)
2 1
3 2 1 4 3
Harness Harness

Connector: B-29
side.
OK: System voltage B-29 (GR)
NO : Go to Step 10 . 3 2 1
Harness

intermediate connector and B-17X (terminal
open/short circuit.
NO : Repair.

B-29 crank angle sensor intermediate connector.
Connector: B-29
B-29 (GR)
3 2 1
Harness

side.
TROUBLESHOOTING
13C-175
<M/T> connector or engine-A/T-ECU <A/T> No. 3) crank angle sensor intermediate connector
Connector: C-141
Connector: B-29
C-141(GR) B-29 (GR)
3 2 1
Connector: C-141
6463 62 61
7372 7170 69 6867 6665 C-141(GR)
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
NO : Repair.
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING
measurement at B-29 crank angle sensor No. 1) crank angle sensor intermediate connector
intermediate connector (Using an oscilloscope). and B-17X (terminal No. 1) engine control relay
connector.
Connector: B-29
Connector: B-29
B-29 (GR)
B-29 (GR)
3 2 1
Harness 3 2 1
Harness
side connector

Connector: B-17X
• Engine: Idling
• Transmission: Neutral <M/T> or P range <A/T> B-17X
• Voltage between terminal No. 2 and earth. Relay box’s
triangle marks
(Refer to P.13C-419), its maximum value 2 1
value should be 0.6 V or less with no noise in Harness
waveform. side connector AK304152 AB
NO : Repair.
relay connector
Connector: B-17X
B-17X
Relay box’s
triangle marks
2 1
4 3
Harness

NO : Repair.
TROUBLESHOOTING
13C-177
<M/T> connectors or engine-A/T-ECU <A/T> No. 2) crank angle sensor intermediate connector
Connector: C-141
Connector: B-29
C-141(GR) B-29 (GR)
3 2 1
Connector: C-141
6463 62 61
7372 7170 69 6867 6665 C-141(GR)
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
NO : Repair.
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING
STEP 19. Check harness between B-29 (terminal STEP 20. Connector check: B-29-1 crank angle
No. 3) crank angle sensor intermediate connector sensor connector
and C-141 (terminal No. 88) engine-ECU <M/T>
Connector: B-29-1
Connector: B-29
B-29-1 (B)
B-29 (GR)
3 2 1
Harness
3 2 1 side connector AK304268 AB
Harness
side connector AK304267 AB Q: Is the check result normal?
NO : Repair.
Connector: C-141
STEP 21. Check harness between B-29 crank
angle sensor intermediate connector and B-29-1
C-141(GR)
Connector: B-29

C-141 (GR) B-29 (GR)
3 2 1
Harness
6463 62 61 Connector: B-29-1

7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB B-29-1 (B)
• Check earthing line for damage. 3 2 1
Harness
NO : Repair. • Check power supply line open/short circuit and
damage.
• Check output line open/short circuit and damage.
• Check earthing line for open/short circuit and
damage.
NO : Replace the timing belt cover.
TROUBLESHOOTING
13C-179
STEP 22. Check the crankshaft sensing blade. STEP 23: M.U.T.-II/III data list
YES : Go to Step 23 . a. Item 22: Crank angle sensor
NO : Replace the crankshaft sensing blade. Q: Is the check result normal?
00 − How to Use
P.00-6).
TROUBLESHOOTING
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
relay
3 4
1 2
3 To engine-A/T-ECU <A/T>
B-106
MU802337 Camshaft
position
sensor
1 2 3
1 2
B-W
19
J/C (1)
L-Y
C-16
17
B-W
88 71
C-141
(MU803804)
6162 6364
Engine-ECU <M/T>
656667686970717273 Engine-A/T-ECU <A/T>
747576777879808182
8384 858687 8889 5V
Wire colour code

AK401179 AB
OPERATION • A power voltage of 5 V is applied to the camshaft

• Power is supplied to the camshaft position sensor position sensor output terminal (terminal No. 2)
(terminal No. 3) from the engine control relay (ter- from the engine-ECU <M/T> or engine-A/T-ECU
minal No. 1) and is earthed to the engine-ECU <A/T> (terminal No. 71).
88) from the camshaft position sensor (terminal
No. 1).
TROUBLESHOOTING
13C-181
FUNCTION STEP 2. Perform voltage measurement at B-106
• The camshaft position sensor detects the top camshaft position sensor connector.
dead center on the compression stroke of the No.
1 cylinder and inputs a pulse signal to the Connector: B-106
TROUBLE JUDGMENT B-106 (B)
Check Conditions
• Engine speed is 50 r/min or higher. 3 2 1
Judgment Criteria Harness
• Camshaft position sensor output voltage has not side connector
been changed (no pulse signal is has been input) AK304269 AB
for 2 seconds. • Disconnect connector, and measure at harness

side.
PROBABLE CAUSE • Ignition switch: ON
• Failed camshaft position sensor • Voltage between terminal No. 3 and earth.
• Open/short circuit in camshaft position sensor cir- OK: System voltage
NO : Go to Step 3 .
DIAGNOSIS PROCEDURE

position sensor connector
Connector: B-106
B-106 (B)
3 2 1
Harness
side connector
AK304269 AB

NO : Repair.
TROUBLESHOOTING
STEP 3. Connector check: B-17X engine control STEP 4. Perform voltage measurement at B-106
relay connector camshaft position sensor connector.
B-17X
Relay box’s
triangle marks B-106 (B)
2 1
3 2 1
4 3
Harness
side connector AK304152 AB AK304269 AB

Connector: B-106
side.
B-106 (B)
OK: 4.9 − 5.1 V
Harness NO : Go to Step 5 .
side connector
AK304269 AB

open/short circuit.
NO : Repair.
TROUBLESHOOTING
13C-183
C-141(GR) C-141(GR)

C-141 (GR) C-141 (GR)
6463 62 61 6463 62 61
7372 7170 69 6867 6665 7372 7170 69 6867 6665
82 818079 78 7776 7574 82 818079 78 7776 7574
8988 87 86 85 8483 8988 87 86 85 8483
AK304154 AB AK304154 AB
B-106 (B) B-106 (B)
3 2 1 3 2 1
Harness Harness
side connector side connector
AK304269 AB AK304269 AB

<A/T> terminal voltage. YES : Check and repair harness between B-106
• Disconnect B-106 camshaft position sensor con- (terminal No. 2) camshaft position sensor
nector. connector and C-141 (terminal No. 71)
• Ignition switch: ON engine-ECU <M/T> connector or
• Voltage between terminal No. 71 and earth. engine-A/T-ECU <A/T> connector.
OK: 4.9 − 5.1 V • Check output line for open circuit.
NO : Go to Step 7 .
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 2) camshaft position sensor connector and
connector C-141 (terminal No. 71) engine-ECU <M/T>
Connector: C-141
Connector: B-106
B-106 (B)
C-141(GR)
3 2 1
Harness
<R. H. Drive Vehicle> side connector
C-141 (GR) AK304269 AB
Connector: C-141
6463 62 61
7372 7170 69 6867 6665 C-141(GR)
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
NO : Repair.
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.

00 − How to Use
P.00-6).
TROUBLESHOOTING
13C-185
B-106 camshaft position sensor connector. No. 1) camshaft position sensor connector and
C-141 (terminal No. 88) engine-ECU <M/T>
Connector: B-106
Connector: B-106
B-106 (B)
B-106 (B)
3 2 1
Harness
side connector 3 2 1
AK304269 AB
Harness
• Disconnect connector, and measure at harness side connector
side. AK304269 AB

Connector: C-141
C-141(GR)
connector
Connector: C-141 C-141 (GR)
C-141(GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
<R. H. Drive Vehicle> Harness side connector

C-141 (GR) AK304154 AB

6463 62 61 YES : Go to Step 9 .
7372 7170 69 6867 6665 NO : Repair.
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING
measurement at B-106 camshaft position sensor No. 3) camshaft position sensor connector and
connector (Using an oscilloscope). B-17X (terminal No. 1) engine control relay
connector.
Connector: B-106
Connector: B-106
B-106 (B)
B-106 (B)
3 2 1
Harness 3 2 1
side connector Harness
AK304269 AB side connector

Connector: B-17X
• Engine: Idling
• Transmission: Neutral <M/T> or P range <A/T> B-17X
• Voltage between terminal No. 2 and earth. Relay box’s
triangle marks
(Refer to P.13C-419), its maximum value 2 1
value should be 0.6 V or less with no noise in Harness
waveform. side connector AK304152 AB
NO : Repair.
relay connector.
Connector: B-17X
B-17X
Relay box’s
triangle marks
2 1
4 3
Harness

NO : Repair.
TROUBLESHOOTING
13C-187
<M/T> connector or engine-A/T-ECU <A/T> No. 2) camshaft position sensor connector and
connector C-141 (terminal No. 71) engine-ECU <M/T>
Connector: C-141
Connector: B-106
B-106 (B)
C-141(GR)
3 2 1
Harness
<R. H. Drive Vehicle> side connector
C-141 (GR) AK304269 AB
Connector: C-141
6463 62 61
7372 7170 69 6867 6665 C-141(GR)
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB
NO : Repair.
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING
STEP 18. Check harness between B-106 (terminal STEP 19. Check camshaft position sensing
No. 1) camshaft position sensor connector and cylinder.
C-141 (terminal No. 88) engine-ECU <M/T> Q: Is the check result normal?
connector or engine-A/T-ECU <A/T> connector. YES : Go to Step 20 .
Connector: B-106 NO : Replace camshaft position sensing cylinder.

B-106 (B)
3 2 1
00 − How to Use
Harness Troubleshooting/Inspection Service Points
side connector
AK304269 AB
P.00-6).
Connector: C-141
C-141(GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING
13C-189
Code No. P0403: Exhaust Gas Recirculation Control System
EGR valve circuit
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
R
To engine-ECU <M/T>
R R
2 5
B-105
(MU802056)
Exhaust gas
recirculation
1 2 3 (EGR) valve
4 5 6
1 3 4 6
L-B Y L-Y L-R
3 12 19 26
C-139
(MU803802)
1 2 3 4
Engine-ECU <M/T>
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401180 AB
TROUBLESHOOTING
OPERATION STEP 2. Check EGR valve itself.

• Power is supplied to the EGR valve (terminal No. • Check EGR control solenoid valve itself [Refer to
2 and No. 5) from the engine control relay (termi- GROUP 17 − Emission Control System −
nal No. 1). Exhaust Gas Recirculation (EGR) System − EGR
• The engine-ECU <M/T> or engine-A/T-ECU Valve (stepper motor) Check <4G69>P.17-72.
<A/T> (terminal No. 3, No. 12, No. 19 and No. 26)
makes the power transistor in the unit be in "ON",
and that makes currents go on the EGR valve
NO : Replace EGR valve (stepper motor).
(terminal No. 1, No. 3, No. 4 and No. 6).
FUNCTION STEP 3. Perform voltage measurement at B-105

• Based on the signal from engine-ECU <M/T> or EGR valve connector.
engine-A/T-ECU <A/T>, the EGR valve (stepper Connector: B-105
motor) controls the EGR rate.
TROUBLE JUDGMENT
Check Conditions
• Battery positive voltage is 10.3 V or higher. B-105 (GR)
3 2 1
Judgment Criteria
6 5 4
• The EGR valve motor coil surge voltage (battery
Harness
positive voltage +2 V) is not detected for 3 sec- side connector AK304270 AB
onds.
• Failed EGR valve • Ignition switch: ON
• Open/short circuit in EGR valve circuit or loose • Voltage between terminal No. 2, No. 5 and earth.
connector contact OK: System voltage
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
STEP 1. Connector check: B-105 EGR valve

connector
Connector: B-105
B-105 (GR)
3 2 1
6 5 4
Harness

NO : Repair.
TROUBLESHOOTING
13C-191
relay connector engine-ECU connector or engine-A/T-ECU <A/T>
connector.
Connector: B-17X
triangle marks
2 1
C-139 (GR)
4 3
Harness

Connector: B-105
C-139 (GR)
B-105 (GR)
3 2 1 4 3 2 1
6 5 4 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
Harness 2726 2524 23 22 21
AK304262 AB
YES : Check and repair harness between B-105 • Disconnect connector, and measure at harness
(terminal No. 2, No. 5) EGR valve connector side.
and B-17X (terminal No. 1) engine control • Ignition switch: ON
relay connector. • Voltage between terminal No. 3, No. 12, No. 19,
• Check power supply line for No. 26 and earth.
open/short circuit. OK: System voltage
NO : Repair.
NO : Go to Step 6 .
TROUBLESHOOTING
STEP 6. Connector check: C-139 engine-ECU c. Check harness between B-105

<M/T> connector or engine-A/T-ECU <A/T> (terminal No. 4) EGR valve
connector connector and C-139 (terminal No.
Connector: C-139 engine-A/T-ECU <A/T> connector
<L. H. Drive Vehicle> d. Check harness between B-105
(terminal No. 6) EGR valve
connector and C-139 (terminal No.
C-139 (GR) engine-A/T-ECU <A/T> connector
open/short circuit.
NO : Repair.

C-139 (GR) <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-139
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
C-139 (GR)
AK304262 AB
Connector: B-105
C-139 (GR)
B-105 (GR)
3 2 1
6 5 4
Harness 4 3 2 1
side connector AK304270 AB 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
EGR valve connector and C-139 AK304262 AB

engine-A/T-ECU <A/T> connector
a. Check harness between B-105 NO : Repair.
b. Check harness between B-105
connector and C-139 (terminal No.
TROUBLESHOOTING
13C-193
STEP 8. Check harness between B-105 EGR
valve connector and C-139 engine-ECU <M/T> NO : Repair.
Connector: B-105 STEP 9. Check harness between B-105 (terminal
No. 2, No. 5) EGR valve connector and B-17X
Connector: B-105
B-105 (GR)
3 2 1
6 5 4
Harness
side connector AK304270 AB B-105 (GR)
3 2 1
Connector: C-139 6 5 4
<L. H. Drive Vehicle> Harness
Connector: B-17X
C-139 (GR) B-17X
Relay box’s
triangle marks
<R. H. Drive Vehicle> 2 1

4 3
C-139 (GR) Harness

4 3
13 12 1110 9 8 7
2
6
1
5
2019 18 17 16
2726 2524 23
15
22
14
21
NO : Repair.
AK304262 AB

EGR valve connector and C-139 (terminal No. 3)
EGR valve connector and C-139 (terminal No.
TROUBLESHOOTING
Code No. P0421: Warm Up Catalyst Malfunction (cylinder 1,4)

• The signal from the cylinder 1, 4 oxygen sensor
(rear) differs from the cylinder 1, 4 oxygen sensor STEP 1. Check for leakage of exhaust emission
(front). That is because the catalytic converter from exhaust manifold.
purifies exhaust gas. When the catalytic con-
verter has deteriorated, the signal from the cylin- Q: Is the check result normal?
der 1, 4 oxygen sensor (front) becomes similar to YES : Go to Step 2 .
the cylinder 1, 4 oxygen sensor (rear). NO : Repair.
• The engine-ECU <M/T> or engine-A/T-ECU
<A/T> compares the output of the cylinder 1, 4 STEP 2. M.U.T.-II/III data list
oxygen sensor signals (front and rear). • Refer to Data List Reference Table P.13C-402.
TROUBLE JUDGMENT b. Item 59: Cylinder 1, 4 oxygen sensor (rear)
Check Conditions Q: Is the check result normal?
• Engine speed is 3,000 r/min or lower. YES : Go to Step 3 .
• The accelerator pedal is open. NO : Perform the diagnosis code classified check
• Air flow sensor output is 8 g/s or higher. procedure for the sensor that has shown an
• 3 seconds or more elapsed after the abovemen- abnormal data valve (Refer to Inspection
tioned conditions were satisfied. Chart for Diagnosis Code P.13C-21).
• Intake air temperature is −10°C or higher after the
engine is started.
• Under the closed loop air/fuel ratio control. a. Item 11: Cylinder 1, 4 oxygen sensor (front)
• Vehicle speed is 1.5 km/h or higher. OK: 0 − 0.4 and 0.6 − 1.0 volt should alternate
• For 10 seconds per cycle, the engine-ECU 15 times or more within 10 seconds (engine
<M/T> or engine-A/T-ECU <A/T> monitors 7 speed at 2,000 r/min).
cycles of this condition during the drive cycle. Q: Is the check result normal?
• Short-term fuel trim is between −25% or higher YES : Go to Step 4 .
and +25% or lower. NO : Replace the cylinder 1, 4 oxygen sensor
• The cumulative air flow sensor output is 2,931 g (front).
or higher.
Judgment Criteria STEP 4. Replace the cylinder 1, 4 oxygen sensor
• The cylinder 1, 4 oxygen sensor (rear) signal fre- (rear).
quency divided by cylinder 1, 4 oxygen sensor • After replacing the cylinder 1, 4 oxygen sensor
(front) signal frequency is 0.8 or more. (rear), re-check the trouble symptoms.

YES : Check end.
• Catalytic converter deteriorated NO : Go to Step 5 .
• Failed cylinder 1, 4 oxygen sensor (front)
• Failed cylinder 1, 4 oxygen sensor (rear)
• Failed engine-ECU <M/T> STEP 5. Replace the catalytic converter (cylinder
• Failed engine-A/T-ECU <A/T> 1, 4).
• After replacing the catalytic converter (cylinder 1,
4), re-check the trouble symptoms.
NO : Check end.
TROUBLESHOOTING
13C-195
Code No. P0431: Warm Up Catalyst Malfunction (Cylinder 2, 3)

• The signal from the cylinder 2, 3 oxygen sensor
(rear) differs from the cylinder 2, 3 oxygen sensor STEP 1. Check for leakage of exhaust emission
(front). That is because the catalytic converter from exhaust manifold.
purifies exhaust gas. When the catalytic con-
verter has deteriorated, the signal from the cylin- Q: Is the check result normal?
der 2, 3 oxygen sensor (front) becomes similar to YES : Go to Step 2 .
the cylinder 2, 3 oxygen sensor (rear). NO : Repair.
<A/T> compares the output of the cylinder 2, 3 STEP 2. M.U.T.-II/III data list
oxygen sensor signals (front and rear). • Refer to Data List Reference Table P.13C-402.
TROUBLE JUDGMENT b. Item 69: Cylinder 2, 3 oxygen sensor (rear)
Check Conditions Q: Is the check result normal?
• Engine speed is 3,000 r/min or lower. YES : Go to Step 3 .
• The accelerator pedal is open. NO : Perform the diagnosis code classified check
• Air flow sensor output is 8 g/s or higher. procedure for the sensor that has shown an
• 3 seconds or more elapsed after the abovemen- abnormal data valve (Refer to Inspection
tioned conditions were satisfied. Chart for Diagnosis Code P.13C-21).
• Intake air temperature is −10°C or higher after the
engine is started.
• Under the closed loop air/fuel ratio control. a. Item 39: Cylinder 2, 3 oxygen sensor (front)
• Vehicle speed is 1.5 km/h or higher. OK: 0 − 0.4 and 0.6 − 1.0 volt should alternate
• For 10 seconds per cycle, the engine-ECU 15 times or more within 10 seconds (engine
<M/T> engine-A/T-ECU <A/T> monitors 7 cycles speed at 2,000 r/min).
of this condition during the drive cycle. Q: Is the check result normal?
• Short-term fuel trim is between −25% or higher YES : Go to Step 4 .
and +25% or lower. NO : Replace the cylinder 2, 3 oxygen sensor
• The cumulative air flow sensor output is 2,931 g (front).
or higher.
Judgment Criteria STEP 4. Replace the cylinder 2, 3 oxygen sensor
• The cylinder 2, 3 oxygen sensor (rear) signal fre- (rear).
quency divided by cylinder 2, 3 oxygen sensor • After replacing the cylinder 2, 3 oxygen sensor
(front) signal frequency is 0.8 or more. (rear), re-check the trouble symptoms.

YES : Check end.
• Catalytic converter deteriorated NO : Go to Step 5 .
• Failed cylinder 2, 3 oxygen sensor (front)
• Failed cylinder 2, 3 oxygen sensor (rear)
• Failed engine-ECU <M/T> STEP 5. Replace the catalytic converter (cylinder
• Failed engine-A/T-ECU <A/T> 2, 3).
• After replacing the catalytic converter (cylinder 2,
3), re-check the trouble symptoms.
NO : Check end.
TROUBLESHOOTING
Battery
W-B
W-B
4 3
B-17X
Engine
1 2 control
3 4 relay
1 2
To engine-ECU <M/T>
R To engine-A/T-ECU <A/T>
2
B-101 Purge
MU802779 control
solenoid
1 2 valve
1
BR
23
C-139
(MU803802)
1 2 3 4
Engine-ECU <M/T>
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401181 AB
OPERATION • The engine-ECU <M/T> or engine-A/T-ECU

• Power is supplied to the purge control solenoid <A/T> (terminal No. 23) makes the power transis-
valve (terminal No. 2) from the engine control tor in the unit be in "ON" position, and that makes
relay (terminal No. 1). currents go on the purge control solenoid valve
(terminal No. 1).
TROUBLESHOOTING
13C-197
• In response to a signal from the engine-ECU B-101 purge control solenoid valve connector.
<M/T> or engine-A/T-ECU <A/T>, the purge con-
trol solenoid valve controls the flow rate of the Connector: B-101
purge air to be introduced into the surge tank.
TROUBLE JUDGMENT
Check Conditions
• Battery positive voltage is 10 V or higher. 2 1 B-101 (B)
Judgment Criteria Harness
side connector
• The surge voltage (system voltage +2 V) of sole- AK304271 AB
solenoid valve is turned in OFF position from ON. valve side.
PROBABLE CAUSE OK: 30 − 34 Ω (at 20°C)
• Failed purge control solenoid valve
• Open/short circuit in purge control solenoid value Q: Is the check result normal?
DIAGNOSIS PROCEDURE purge control solenoid valve connector.
Connector: B-101
• Item 08: Purge control solenoid valve
valve vibrates
YES : Intermittent malfunction (Refer to GROUP 2 1 B-101 (B)
00 − How to Use Harness
Troubleshooting/Inspection Service Points side connector AK304271 AB
P.00-6). • Disconnect connector, and measure at harness
NO : Go to Step 2 .
side.
STEP 2. Connector check: B-101 purge control • Voltage between terminal No. 2 and earth.
solenoid valve connector OK: System voltage
NO : Go to Step 5 .
2 1 B-101 (B)
Harness

NO : Repair.
TROUBLESHOOTING
<A/T> connector.
Connector: B-17X
triangle marks
2 1
C-139 (GR)
4 3
Harness

Connector: B-101
C-139 (GR)
4 3 2 1
2 1 B-101 (B) 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
Harness 2726 2524 23 22 21
AK304262 AB
YES : Check and repair harness between B-101 • Disconnect connector, and measure at harness
(terminal No. 2) purge control solenoid valve side.
connector and B-17X (terminal No. 1) • Ignition switch: ON
engine control relay connector. • Voltage between terminal No. 23 and earth.
• Check power line for open/short OK: System voltage
circuit.
NO : Go to Step 7 .
TROUBLESHOOTING
13C-199
connector connector
C-139 (GR) C-139 (GR)
C-139 (GR) C-139 (GR)
4 3 2 1 4 3 2 1
13 12 1110 9 8 7 6 5 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2019 18 17 16 15 14
2726 2524 23 22 21 2726 2524 23 22 21
AK304262 AB AK304262 AB

NO : Repair.
2 1 B-101 (B)
Harness

circuit.
NO : Repair.
TROUBLESHOOTING
and C-139 (terminal No. 23) engine-ECU <M/T> and B-17X (terminal No. 1) engine control relay
connector or engine-A/T-ECU <A/T> connector. connector.
2 1 B-101 (B) 2 1 B-101 (B)

Harness Harness
<L. H. Drive Vehicle> B-17X

Relay box’s
triangle marks
C-139 (GR)
2 1
4 3
Harness
• Check power line for damage.
C-139 (GR)
NO : Repair.
4 3 2 1 STEP 11. M.U.T.-II/III actuator test

13 12 1110 9 8 7
2019 18 17 16
6
15
5
14
• Item 08: purge control solenoid valve
2726 2524 23 22 21
valve vibrates
AK304262 AB
• Check output line for damage. YES : Intermittent malfunction (Refer to GROUP
Q: Is the check result normal? 00 − How to Use
YES : Go to Step 10 . Troubleshooting/Inspection Service Points
NO : Repair. P.00-6).
TROUBLESHOOTING
13C-201
Code No. P0500: Vehicle Speed Sensor System <M/T>

C-141
C-303 (MU803804)
R LOCK
1 2 3 6162 6364
4 5 6 ST ACC 656667686970717273
IG1 IG2 747576777879808182
8384 858687 8889
2
L-B 79
C-203
6
W-L
2 J/B
W-L
7.5A Meter and gauge
C-202
11
B-W C-105
22
C-106
3
W-L
B-W
1 3
B-115
(MU802723)
2
B 13
J/C (2)
C-17
5
B
Wire colour code

AK401182 AB
OPERATION FUNCTION
TROUBLESHOOTING

Check Conditions • Refer to Data list reference table P.13C-402.
• Idle switch: OFF YES : Go to Step 3 .
• Under the high load operation. NO : Intermittent malfunction (Refer to GROUP
• Open/short circuit in vehicle speed sensor circuit Connector: C-141
DIAGNOSIS PROCEDURE
C-141 (GR)
STEP 1.Check the speedometer

YES : Go to Step 2 . 6463 62 61
7372 7170 69 6867 6665
NO : Check the speedometer (Refer to GROUP 82 818079 78 7776 7574
8988 87 86 85 8483
54A −Combination Meter Assembly −
On-vehicle Service − Speedmeter Check AK304536 AB
P.54A-57).
NO : Repair.
TROUBLESHOOTING
13C-203
Connector: C-141
C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304536 AB
Connector: B-115
C-115 (B)
3 2 1
Harness side
connector
AK304537AB

NO : Repair.
TROUBLESHOOTING
Code No. P0513: Immobilizer Malfunction
Signal
circuit
C-304-1 3
1 2 C-304
7 3 4 5 6 7 MU801547
V
C-104
11
V
65
C-141
(MU803804)
656667686970717273 Engijne-A/T-ECU <A/T>
747576777879808182
8384 858687 8889
Wire colour code

AK304151AC

Check Condition
engine-ECU <M/T> or engine-A/T-ECU <A/T>
(terminal No. 65) and immobilizer-ECU (terminal
No. 7). Judgment Criterion
• When the communication error between
FUNCTION engine-ECU <M/T> or engine-A/T-ECU <A/T>
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> and the immobilizer-ECU continues for 2 seconds
sends or receives the control signals to or from or more.
immobilizer-ECU to certify the ignition key.
NOTE: .
PROBABLE CAUSE
• This code may be displayed when registering • Failed engine-ECU <M/T>
the key encrypted code. • Failed engine-A/T-ECU <A/T>
TROUBLESHOOTING
13C-205
STEP 1. Connector check: C-304 (terminal No. 65) engine-ECU <M/T> connector or
immobilizer-ECU connector and C-141 engine-A/T-ECU <A/T> connector.
engine-ECU <M/T> connector or engine-A/T-ECU Connector: C-304
<A/T> connector. Harness side
connector
Connector: C-304 2 1
Harness side 76543
connector
2 1
76543
C-304
C-304
AK203418 AC
AK203418 AC Connector: C-141

Connector: C-141
C-141(GR)
C-141(GR)

C-141 (GR)
C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
6463 62 61
82 818079 78 7776 7574
8988 87 86 85 8483 AK304154 AB

AK304154 AB
NO : Repair.

00 − How to Use
P.00-6).
TROUBLESHOOTING

NO : Check end.
C-140
(MU803803)
3132 33 34 Engine-ECU <M/T>
353637383940 41 42 43 Engine-A/T-ECU <A/T>
444546474849 50 51
5253 545556 57 58
47
Y
B-19
1
Y
B-28
(MU801215) 1
1 Power steering fluid

OFF pressure switch
ON
Wire colour code

AK304134 AC
CONDITION TROUBLE JUDGMENT

• The battery voltage is applied to the power steer-
Check Conditions
ing fluid pressure switch (terminal No. 1) from the
• Drive the vehicle of 50 km/h or more for 4 sec-
(terminal No. 47).
onds or more. Stop the vehicle (of 1.5 km/h or
FUNCTION less). Repeat 10 times or more.
• It is detected whether a load is applied on the Judgment Criteria
power steering fluid pump by steering or not, and • Power steering pressure switch continues to be
the signal is inputted to the engine-ECU <M/T> or in "ON".
engine-A/T-ECU <A/T>. When the power steer-
ing fluid pressure switch "ON" signal (a large load
on the power steering fluid pump) is inputted, the
provides the idle-up control.
TROUBLESHOOTING
13C-207
PROBABLE CAUSE STEP 3. Perform voltage measurement at C-140
• Failed power steering fluid pressure switch engine-ECU <M/T> connector or engine-A/T-ECU
• Open/short circuit in power steering fluid pres- <A/T> connector.
sure switch circuit or loose connector contact
• Failed engine-ECU <M/T> Connector: C-140
• Failed engine-A/T-ECU <A/T> <L. H. Drive Vehicle>
DIAGNOSIS PROCEDURE
C-140 (GR)
STEP 1. Connector check: B-28 power steering
Connector: B-28
C-140 (GR)
B-28 (B)
1 34 33 32 31
43 42 4140 39 38 37 36 35
Harness side connector 51 50 49 4847 46 4544
AK304273 AC 58 57 5655 54 5352

NO : Repair.
STEP 2. Perform voltage measurement at B-28 • Ignition switch: ON
power steering fluid pressure switch connector. • Voltage between terminal No. 47 and earth.
Connector: B-28 OK: System voltage
NO : Go to Step 5 .
B-28 (B)
1

side.
OK: System voltage
NO : Go to Step 3 .
TROUBLESHOOTING
connector connector
C-140 (GR) C-140 (GR)
C-140 (GR) C-140 (GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK304274 AB AK304274 AB

NO : Repair.
B-28 (B)
1

connector.
NO : Repair.
TROUBLESHOOTING
13C-209
STEP 6. Check harness between B-28 (terminal STEP 7. M.U.T.-II/III data List
No. 1) power steering fluid pressure switch • Refer to Data list reference table P.13C-402.
connector and C-140 (terminal No. 47) a. Item 27: Power steering fluid pressure switch
<A/T> connector.
P.00-6).
B-28 (B) STEP 8. Perform voltage measurement at C-140

1 engine-ECU <M/T> connector or engine-A/T-ECU
Harness side connector <A/T> connector.
AK304273 AC
Connector: C-140
Connector: C-140
C-140 (GR)
C-140 (GR)

C-140 (GR)
C-140 (GR)
34 33 32 31
34 33 32 31 43 42 4140 39 38 37 36 35
43 42 4140 39 38 37 36 35 51 50 49 4847 46 4544
51 50 49 4847 46 4544 58 57 5655 54 5352
58 57 5655 54 5352
AK304274 AB
AK304274 AB
• Check output line for short circuit. <A/T> terminal voltage.
Q: Is the check result normal? • Engine: Idling
NO : Repair. OK:
System voltage (Steering wheel: Stationary)
NO : Go to Step 9 .
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 1) power steering fluid pressure switch
Connector: B-28
C-140 (GR)
B-28 (B)
<R. H. Drive Vehicle> 1

34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
C-140 (GR)
AK304274 AB

NO : Repair.
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

switch.
NO : Repair.
TROUBLESHOOTING
13C-211
connector
Connector: C-140
C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

NO : Repair.
DTC P0606: Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Main Processor Malfunction
FUNCTION DIAGNOSIS
• System LSI checks the engine-ECU <M/T> or
engine-A/T-ECU <A/T> for abnormal conditions. STEP 1. Check the trouble symptoms.
TROUBLE JUDGMENT Q: Does trouble symptom persist?
Check Conditions engine-A/T-ECU <A/T>.
• Ignition switch is "ON" position. NO : Intermittent malfunction (Refer to GROUP
Judgement Criteria 00 − How to Use
• No surveillance pulse signals is input for 0.5 sec- Troubleshooting/Inspection Service Points
ond. P.00-6).
PROBABLE CAUSE
• Failed the engine-ECU <M/T>
• Failed the engine-A/T-ECU <A/T>
TROUBLESHOOTING
Alternator circuit
C-141
(MU803804)
656667686970717273 Engine-A/T-ECU <A/T>
747576777879808182
8384 858687 8889
86
Y-B
B-19
2
Y-B
B-30
(MU802046) 4
1 2 3 4
IC voltage
Wire colour code

AK304135 AB

Check Condition
• Engine speed is 50 r/min or higher.
(terminal No. 86). Judgment Criterion
• Input voltage from the alternator FR terminal has
FUNCTION continued to be approximately battery positive
• A signal of the power supply duty ratio for the voltage for 20 seconds.
alternator field coil is inputted to the engine-ECU
<M/T> or engine-A/T-ECU <A/T>. PROBABLE CAUSE
• In response to the signal, the engine-ECU <M/T> • Failed alternator
or engine-A/T-ECU <A/T> detects the alternator • Open/short circuit in alternator FR terminal circuit
output current and controls the idling speed or loose connector
according to the output current (electric load). • Failed engine-ECU <M/T>
TROUBLESHOOTING
13C-213
STEP 1. Connector check: B-30 alternator connector.
connector
Connector: C-141
Connector: B-30 <L. H. Drive Vehicle>
B-30 (GR) C-141(GR)
4 3 2 1
Harness side <R. H. Drive Vehicle>
connector AK304037AB C-141 (GR)

NO : Repair.
STEP 2. Perform voltage measurement at B-30 6463 62 61

alternator connector. 7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
Connector: B-30 Harness side connector
AK304154 AB

B-30 (GR) YES : Go to Step 4 .
NO : Repair.
4 3 2 1
Harness side

nector side.
OK: System voltage
NO : Go to Step 3 .
TROUBLESHOOTING
No. 4) alternator connector and C-141 (terminal Q: Does trouble symptom persist?
No. 86) engine-ECU <M/T> connector or YES : Replace engine-ECU <M/T> or
engine-A/T-ECU <A/T> connector. engine-A/T-ECU <A/T>.
00 − How to Use
P.00-6).
B-30 (GR)

4 3 2 1
<A/T> connector.
Harness side
connector AK304037AB Connector: C-141
Connector: C-141
C-141(GR)
C-141(GR)

C-141 (GR)
C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
6463 62 61 8988 87 86 85 8483
82 818079 78 7776 7574
8988 87 86 85 8483 AK304154 AB
AK304154 AB
• Check output line for open/short circuit. • Engine: Idle after warm-up
Q: Is the check result normal? • Transmission: Neutral <M/T> or P range <A/T>
YES : Go to Step 5 . • Radiator fan: Inactive
NO : Repair. • Voltage between terminal No. 86 and earth.
NO : Go to Step 5 .
TROUBLESHOOTING
13C-215
STEP 7. Check harness between B-30 (terminal STEP 8. Check trouble symptom.
No. 4) alternator connector and C-141 (terminal Q: Same symptoms regenerated?
No. 86) engine-ECU <M/T> connector or YES : Replace alternator.
engine-A/T-ECU <A/T> connector. NO : Intermittent malfunction (Refer to Group 00
Connector: B-30 − How to Use troubleshooting/Inspection
B-30 (GR)
4 3 2 1
Harness side
Connector: C-141
C-141(GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING
DTC P0638: Throttle Valve Control Servo Circuit Range/Performance Problem
OPERATION PROBALE CAUSE

• Refer to P2101 − Throttle valve control servo cir- • Failed throttle valve return spring.
cuit P.13C-240. • Failed throttle valve operation.
FUNCTION • Open/short circuit in throttle valve control servo
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> connector contact.
checks the electronic controlled throttle system • Failed engine-ECU <M/T>.
for abnormal conditions. • Failed engine-A/T-ECU <A/T>.
TROUBLE JUDGMENT DIAGNOSIS

Check Conditions
• Battery positive voltage is 8.3 V or higher. STEP 1. M.U.T.-II/III data list
• Throttle position sensor (main) output voltage is • Refer to Data list reference table P.13C-402.
0.35 − 4.8 V.
a. Item 9A: Throttle position sensor (main) mid
• Drop of throttle position sensor (main) output volt-
opening learning value
age per 100 milliseconds is 0.04 V or more.
Judgement Criteria YES : Go to Step 2 .
• Throttle position sensor (main) output voltage has NO : Replace throttle body assembly.
continued to be above 0.5 V higher than the tar-
get throttle position sensor (main) voltage for 0.5
second. STEP 2. Check the throttle valve control servo
itself.
Check Conditions • Check the throttle valve control servo control
• Battery positive voltage is 8.3 V or higher. motor itself (Refer to P.13C-436)
0.35 − 4.8 V. Q: Is the check result normal?
Judgement Criteria NO : Replace electronically controlled throttle
• Difference between throttle position sensor valve.
(main) output voltage and target throttle position
sensor (main) voltage is 1 V or higher for 4 sec-
onds.
TROUBLESHOOTING
13C-217
STEP 3. Connector check: B-06 electronically STEP 4. Check harness between B-06 (terminal
controlled throttle valve connector and C-138 No. 1) electronically controlled throttle valve
engine-ECU <M/T> connector or engine-A/T-ECU connector and C-138 (terminal No. 133)
<A/T> connector engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
Connector: B-06
Connector: B-06
B-06 (B)
6 5 4 3 2 1 B-06 (B)
6 5 4 3 2 1
Connector: C-138
C-138 (GR)
C-138 (GR)

C-138 (GR)
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134 124 123 122121
146 145 144 143142 133 132 131 130 129128127126125
141 140 139 138 137136 135134
Harness side connector 146 145 144 143142

AK304275 AB
AK304275 AB
YES : Go to Step 4 . • Check output line for short circuit and damage.
NO : Repair.
TROUBLESHOOTING
No. 2) electronically controlled throttle valve Q: Does trouble symptom persist?
P.00-6).
B-06 (B)
6 5 4 3 2 1
Connector: C-138
C-138 (GR)
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

NO : Repair.
TROUBLESHOOTING
13C-219
DTC P0642: Throttle Position Sensor Power Supply

• Engine-ECU <M/T> or engine-A/T-ECU <A/T> • Failed engine-ECU <M/T>
checks the throttle position sensor power voltage • Failed engine-A/T-ECU <A/T>
for abnormal conditions.
DIAGNOSIS
TROUBLE JUDGMENT
Judgement Criteria YES : Replace engine-ECU <M/T> or
• Throttle position sensor power voltage is 4.1 V or engine-A/T-ECU <A/T>.
less for 0.5 second. NO : Intermittent malfunction (Refer to GROUP
00 − How to Use
P.00-6).
TROUBLESHOOTING
DTC P0657: Throttle Valve Control Servo Relay Circuit Malfunction
Throttle valve control srvo relay circuit

Battery
W-B
A-14
5 (*1) or
16 (*2)
W-B
W-B
4 3
B-17X
Engine
1 2 control
relay
3 4
1 2
W-B R
4
R Y-G
J/C (2)
C-17
12
4 3
Throrrle B-14X
valve
control 1 2
servo
relay 3 4
To engine-ECU <M/T>
1 2
R-W L
132 15
C-138 C-139
(MU803801) (MU803802)
121122 123 124
Power source 1 2 3 4
125126127128129 130 131 132 133 5 6 7 8 9 10111213
134135 136137 138 139 140 141 14 15 16 1718 19 20
142143 144 145 146 21 22 232425 2627
NOTE
*1: L.H. drive vehicles Engine-ECU <M/T>
*2: R.H. drive vehicles Engine-A/T-ECU <A/T>
Wire colour code

AK401183 AB
OPERATION • Engine-ECU <M/T> or engine-A/T-ECU <A/T>

• Battery voltage is applied to the Throttle valve (terminal No. 15) applies current to the throttle
control servo relay terminal (terminal No. 4). valve control servo relay coil by turning ON the
• Battery voltage is applied to the Throttle valve power transistor in the unit in order to turn the
control servo relay terminal (terminal No. 3) from relay ON.
TROUBLESHOOTING
13C-221
• When the throttle valve control servo relay turns STEP 2. Check throttle valve control servo relay
ON, battery voltage is supplied by the throttle itself.
valve control servo relay (terminal No. 1) to the • Check throttle valve control servo relay (Refer to
P.13C-430).
(terminal No. 132).
• When the ignition switch ON signal is input into NO : Repair.
the engine-ECU <M/T> or engine-A/T-ECU
<A/T>, the engine-ECU <M/T> or STEP 3. Perform voltage measurement at B-14X
engine-A/T-ECU <A/T> turns ON the Throttle throttle valve control servo relay connector.
valve control servo.
Connector: B-14X
TROUBLE JUDGMENT
Check Condition Relay box’s
Judgement Criteria 2 1
• The power line voltage of the electronic controlled
throttle system is 4.0 V or less for 1 second. 4 3
Harness
PROBALE CAUSE side connector AK304276 AB
• Failed throttle valve return spring • Remove relay, and measure at relay box side.
• Open/short circuit in throttle valve control servo • Voltage between terminal No. 4 and earth.
circuit or loose connector contact. OK: System voltage
DIAGNOSIS
STEP 1. Connector check: B-14X throttle valve harness between B-14X (terminal No. 4)
control servo relay connector throttle valve control servo relay connector
and battery.
Connector: B-14X
open/short circuit.
Relay box’s
2 1
4 3
Harness

NO : Repair.
TROUBLESHOOTING
STEP 4. Perform voltage measurement at B-14X STEP 5. Connector check: B-17X engine control
throttle valve control servo relay connector. relay connector
B-17X
triangle marks B-14X triangle marks
2 1 2 1
4 3 4 3
Harness Harness

Connector: B-14X
OK: System voltage Relay box’s
2 1
NO : Go to Step 6 .
4 3
Harness

engine control relay connector and B-14X
relay connector.
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13C-223
C-139 (GR)
C-138 (GR)
C-138 (GR)
C-139 (GR)
124 123 122121

4 3 2 1 133 132 131 130 129128127126125
13 12 1110 9 8 7 6 5 141 140 139 138 137136 135134
2019 18 17 16 15 14 146 145 144 143142
AK304262 AB AK304275 AB

Connector: B-14X
side.
Relay box’s • Voltage between terminal No. 132 and earth.
OK: System voltage
2 1
Harness

side.
OK: System voltage
circuit.
NO : Go to Step 7 .
TROUBLESHOOTING
STEP 8. Check harness between B-14X (terminal STEP 9. Check harness between B-17X (terminal
No. 1) throttle valve control servo relay No. 1) engine control relay connector and B-14X
connector and C-138 (terminal No. 132) (terminal No. 3) throttle valve control servo relay
engine-ECU <M/T> connector or engine-A/T-ECU connector.
<A/T> connector.
Connector: B-17X
Connector: B-14X B-17X
Relay box’s
Relay box’s triangle marks
2 1
2 1 4 3
4 3 Harness
Connector: B-14X
Connector: C-138
<L. H. Drive Vehicle> Relay box’s
2 1
C-138 (GR) 4 3
Harness

Connector: C-139
C-138 (GR) <L. H. Drive Vehicle>
C-139 (GR)
124 123 122121
133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142

AK304275 AB
• Check output line for open/short circuit. C-139 (GR)

NO : Repair.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING
13C-225
STEP 11. Check and repair harness between
B-14X (terminal No. 4) throttle valve control servo
relay connector and battery.
engine-ECU <M/T> connector or Connector: B-14X
Relay box’s
circuit. triangle marks B-14X
NO : Repair.
2 1
STEP 10. Connector check: C-138 and C-139
4 3
<A/T> connector Harness
Connectors: C-138, C-139 • Check power supply line for damage.

00 − How to Use
C-139 (GR)
C-138 (GR) Troubleshooting/Inspection Service Points
P.00-6).
C-139 (GR)
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304277 AB

00 − How to Use
P.00-6).
TROUBLESHOOTING
STEP 12. Check and repair harness between STEP 13. Check the trouble symptoms.
B-14X (terminal No. 1) throttle valve control servo Q: Does trouble symptom persist?
relay connector and C-138 (terminal No. 132) YES : Replace engine-ECU <M/T> or
Connector: B-14X 00 − How to Use
P.00-6).
Relay box’s
2 1
4 3
Harness
Connector: C-138
C-138 (GR)
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

00 − How to Use
P.00-6).
TROUBLESHOOTING
13C-227
Code No. P1010: Oil Control Valve Circuit
Engine oil control valve circuit
Battery
W-B
W-B
4 3
B-17X
1 2 Engine
control
3 4 relay
1 2
4
J/C (2)
C-17
11
R
B-104 1
MU802779
Oil control
1 2 valve
P-B
C-142 95
(MU803805)
9192 939495
96979899100 101102103 104 Engine-ECU <M/T>
105106 107108109 110111112 Engine-A/T-ECU <A/T>
113114 115116117 118119120
Wire colour code

AK401184AB
TROUBLESHOOTING
OPERATION STEP 2: Perform resistance measurement at

• Power is supplied to the oil control valve (terminal B-104 oil control valve connector.
No. 1) from the engine control relay (terminal No.
1). Connector: B-104
currents go on the oil control valve (terminal No.
2).
B-104 (B)
FUNCTION 2 1
• The oil control valve switches the cams to oper- Harness

ate the MIVEC system in the low-speed or
high-speed mode in accordance with the signals • Disconnect connector, and measure at oil control
from the engine-ECU <M/T> or engine-A/T-ECU valve side.
<A/T>. • Resistance between terminal No. 1 and No. 2.
OK: 6.9 − 7.9 Ω (at 20°C)
TROUBLE JUDGMENT
• Ignition switch is "ON" position NO : Replace oil control valve.
• Battery positive voltage is higher than 10 V.
• MIVEC operating in the low-speed mode. STEP 3. Perform voltage measurement at B-104
Judgment Criteria oil control valve connector.
<A/T> terminal voltage of oil control valve circuit
is less than 1.5 V for 2 seconds.
PROBABLE CAUSE
• Failed oil control valve
• Open/short circuit in oil control valve circuit or
loose connector contact 2 1 B-104 (B)
Harness
• Failed engine-A/T-ECU <A/T> side connector AK304278 AB
DIAGNOSIS PROCEDURE • Disconnect connector, and measure at harness

side.
STEP 1. Connector check: B-104 oil control valve • Voltage between terminal No. 1 and earth.
connector OK: System voltage
NO : Go to Step 4 .
2 1 B-104 (B)
Harness

NO : Repair.
TROUBLESHOOTING
13C-229
<A/T> connector.
Connector: B-17X
triangle marks
2 1
C-142 (GR)
4 3
Harness

Connector: B-104
C-142 (GR)
B-104 (B) 959493 92 91

2 1 104 103102 101100 99 98 97 96
112111110 109108107 106105
Harness 120119118 117116115 114113
AK304153 AB
YES : Check intermediate connector C-17, and • Disconnect connector, and measure at harness
repair if necessary. If intermediate side.
connector is normal, check and repair • Ignition switch: ON
harness between B-104 (terminal No. 1) oil • Voltage between terminal No. 95 and earth.
control valve connector and B-17X (terminal OK: System voltage
• Check power line for open/short Q: Is the check result normal?
circuit. YES : Go to Step 7 .
TROUBLESHOOTING
connector connector
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

NO : Repair.
2 1 B-104 (B)
Harness

(terminal No. 2) oil control valve connector
connector.
circuit.
NO : Repair.
TROUBLESHOOTING
13C-231
No. 2) oil control valve connector and C-142 No. 1) oil control valve connector and B-17X
(terminal No. 95) engine-ECU <M/T> connector or (terminal No. 1) engine control relay connector.
Connector: B-104
Connector: B-104
2 1 B-104 (B)
2 1 B-104 (B)
Harness
Connector: B-17X
<L. H. Drive Vehicle> Relay box’s
triangle marks
2 1
C-142 (GR)
4 3
Harness
<R. H. Drive Vehicle> NOTE: Before checking harness, check intermediate

C-142 (GR) connector C-17, and repair if necessary.
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
• Check output line for damage. NO : Intermittent malfunction (Refer to GROUP
Q: Is the check result normal? 00 − How to Use
TROUBLESHOOTING
DTC P1602: Communication Malfunction (between Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Main
Processor and System LSI)

• Engine-ECU <M/T> or engine-A/T-ECU <A/T> • Failed engine-ECU <M/T>
checks the communication status for abnormal • Failed engine-A/T-ECU <A/T>
conditions.
DIAGNOSIS
TROUBLE JUDGMENT
• Ignition switch is "ON" position.
Judgement Criteria YES : Replace engine-ECU <M/T> or
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> engine-A/T-ECU <A/T>.
detects an error in communication with the throt- NO : Intermittent malfunction (Refer to GROUP
tle actuator control module for 0.07 second. 00 − How to Use
P.00-6).
TROUBLESHOOTING
13C-233
Code No. P1603: Battery Backup Circuit Malfunction
Battery
Relay 9
box 20A
W-B
A-14
5 (*1) or
16 (*2)
W-B
58
C-140
(MU803803)
3132 33 34
Battery Engine-ECU <M/T>
35363738394041 42 43 backup Engine-A/T-ECU <A/T>
444546474849 50 51
5253 545556 57 58
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
AK304139AB

• Power is directly supplied to the engine-ECU
Check Condition
• After engine starting sequence is completed.
58) from the battery.
• Battery positive voltage is 10 V or higher.
• The engine-ECU <M/T> or engine-A/T-ECU • Battery backup line voltage is 6 V or lower for 2
<A/T> is check the open circuit of battery backup seconds.
line.
TROUBLESHOOTING
PROBABLE CAUSE STEP 2. Perform voltage measurement at C-140

• Open/short circuit in battery backup line circuit or engine-ECU <M/T> connector or engine-A/T-ECU
loose connector contact <A/T> connector.
• Failed engine-A/T-ECU <A/T> Connector: C-140
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code C-140 (GR)

Q: Is the diagnosis code P1603 set? <R. H. Drive Vehicle>
00 − How to use Troubleshooting/Inspection
Service Points P.00-6). C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

side.
OK: System voltage
connector.
open/short circuit.
TROUBLESHOOTING
13C-235
STEP 3. Check harness between battery and STEP 4. Connector check: C-140 engine-ECU
C-140 (terminal No. 58) engine-ECU <M/T> <M/T> connector or engine-A/T-ECU <A/T>
connector or engine-A/T-ECU <A/T> connector. connector.
Connector: C-140
Connector: C-140
C-140 (GR)
C-140 (GR)
C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
34 33 32 31
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB
AK304274 AB
• Check earthing line for damage. NO : Repair.
YES : Go to Step 4 . STEP 5. Check the trouble symptoms.
NO : Repair.
00 − How to Use
PointsP.00-6).
TROUBLESHOOTING
DTC P2100: Throttle Valve Control Servo Circuit (open)
B-06 Electronically
controlled
1 2
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
125126127128129 130 131 132 133
134135 136137 138 139 140 141
GND GND 142143 144 145 146

B
Wire colour code

AK401165 AB
OPERATION FUNCTION
• Controls the current that is applied from the • Engine-ECU <M/T> or engine-A/T-ECU <A/T>
engine-ECU <M/T> or engine-A/T-ECU <A/T> varies the direction and the amperage of the cur-
(terminals No. 133, No. 141) to the electronically rent that is applied to the throttle valve control
controlled throttle valve (terminals No. 1, No. 2). servo in order to control the opening of the throt-
tle valve.
TROUBLESHOOTING
13C-237
TROUBLE JUDGMENT STEP 2. Perform resistance measurement at B-06
Check Condition electronically controlled throttle valve connector.
• Battery positive voltage is 8.3 V or higher. Connector: B-06
Judgement Criteria
• Throttle actuator control motor current is 0.1 A or
less for 0.72 second.
PROBABLE CAUSE
B-06 (B)
• Open/short circuit in throttle valve control servo 6 5 4 3 2 1
• Failed engine-ECU <M/T> AK304259 AB
• Failed engine-A/T-ECU <A/T> • Disconnect connector, and measure at electroni-

DIAGNOSIS PROCEDURE • Resistance between terminal No. 1 and No. 2.
OK: 0.3 − 80 kΩ (at 20 °C)
STEP 1. Connector check: B-06 electronically Q: Is the check result normal?
controlled throttle valve connector YES : Go to Step 3 .
Connector: B-06

connector
Connector: C-138
6 5 4 3 2 1

NO : Repair.
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

NO : Repair.
TROUBLESHOOTING
C-138 engine-ECU <M/T> connector or No. 1) electronically controlled throttle valve
engine-A/T-ECU <A/T> connector. connector and C-138 (terminal No. 133)
Connector: B-06
C-138 (GR)
B-06 (B)
6 5 4 3 2 1
Connector: C-138
124 123 122121
133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142

C-138 (GR)
AK304275 AB

side.
• Resistance between terminal No. 144 and earth C-138 (GR)
or terminal No. 145 and earth.
YES : Go to Step 5 . 124 123 122121
NO : Check harness between C-138 (terminal 133 132 131 130 129128127126125
141 140 139 138 137136 135134
No. 144 or No. 145) engine-ECU <M/T> or 146 145 144 143142
engine-A/T-ECU <A/T> and earth. Harness side connector
AK304275 AB

NO : Repair.
TROUBLESHOOTING
13C-239
No. 2) electronically controlled throttle valve Q: Is the check result normal?
P.00-6).
B-06 (B)
6 5 4 3 2 1
Connector: C-138
C-138 (GR)
C-138 (GR)
124 123 122121

133 132 131 130 129128127126125
141 140 139 138 137136 135134
146 145 144 143142
AK304275 AB

NO : Repair.
TROUBLESHOOTING
DTC P2101: Throttle Valve Control Servo Magneto Malfunction
B-06 Electronically
controlled
1 2
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
Engine-ECU <M/T>
125126127128129 130 131 132 133 Engine-A/T-ECU <A/T>
134135 136137 138 139 140 141
142143 144 145 146
Wire colour code

AK401166AB

Check Condition
(terminals No. 133, No. 141) to the electronically
controlled throttle valve (terminals No. 1, No. 2). Judgement Criteria
• The coil temperature of the throttle actuator con-
FUNCTION trol motor is 180°C or higher for 0.8 second.
• Engine-ECU <M/T> or engine-A/T-ECU <A/T>
check whether the throttle valve control servo PROBABLE CAUSE
magneto failed. • Failed throttle valve control servo.
TROUBLESHOOTING
13C-241
STEP 1. Connector check: B-06 electronically connector
Connector: C-138
C-138 (GR)
B-06 (B)
6 5 4 3 2 1
C-138 (GR)
NO : Repair.
124 123 122121
STEP 2. Perform resistance measurement at B-06 133 132 131 130 129128127126125
141 140 139 138 137136 135134
electronically controlled throttle valve connector. 146 145 144 143142

Connector: B-06
AK304275 AB

NO : Repair.
B-06 (B)
6 5 4 3 2 1

OK: 0.3 − 80 kΩ (at 20 °C)
TROUBLESHOOTING
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-138 (GR) C-138 (GR)
C-138 (GR) C-138 (GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142
AK304275 AB AK304275 AB

00 − How to Use
P.00-6).
TROUBLESHOOTING
13C-243
DTC P2102: Throttle Valve Control Servo Circuit (Shorted Low)
B-06 Electronically
controlled
1 2
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
Engine-ECU <M/T>
125126127128129 130 131 132 133 Engine-A/T-ECU <A/T>
134135 136137 138 139 140 141
142143 144 145 146
Wire colour code

AK401166AB

Check Condition
• Throttle valve control servo current is 12 A or
varies the direction and the amperage of the cur- PROBABLE CAUSE
rent that is applied to the throttle valve control • Failed throttle valve control servo
servo in order to control the opening of the throt- • Short circuit in throttle valve control servo circuit
tle valve. or lose connector contact
TROUBLESHOOTING

Connector: C-138
C-138 (GR)
B-06 (B)
6 5 4 3 2 1
C-138 (GR)
NO : Repair.
124 123 122121
141 140 139 138 137136 135134

Connector: B-06
AK304275 AB

NO : Repair.
B-06 (B)
6 5 4 3 2 1

OK: 0.3 − 80 Ω (at 20 °C)
TROUBLESHOOTING
13C-245
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-138 (GR) C-138 (GR)
C-138 (GR) C-138 (GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142
AK304275 AB AK304275 AB

00 − How to Use
P.00-6).
TROUBLESHOOTING
DTC P2103: Throttle Valve Control Servo Circuit (Shorted High)
B-06 Electronically
controlled
1 2
L-R L-Y
133 141
C-138
(MU803801)
121122 123 124
Engine-ECU <M/T>
125126127128129 130 131 132 133 Engine-A/T-ECU <A/T>
134135 136137 138 139 140 141
142143 144 145 146
Wire colour code

AK401166AB

Check Condition
• Throttle actuator control motor current is 8 A or
varies the direction and the amperage of the cur- PROBABLE CAUSE
rent that is applied to the throttle valve control • Failed throttle valve control servo
servo in order to control the opening of the throt- • Short circuit in throttle valve control servo circuit
tle valve. or loose connector contact
TROUBLESHOOTING
13C-247
Connector: C-138
C-138 (GR)
B-06 (B)
6 5 4 3 2 1
C-138 (GR)
NO : Repair.
124 123 122121
141 140 139 138 137136 135134

Connector: B-06
AK304275 AB

NO : Repair.
B-06 (B)
6 5 4 3 2 1

OK: 0.3 − 80 Ω (at 20 °C)
NO : Replace the throttle body assembly.
TROUBLESHOOTING
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-138 (GR) C-138 (GR)
C-138 (GR) C-138 (GR)
124 123 122121 124 123 122121

133 132 131 130 129128127126125 133 132 131 130 129128127126125
141 140 139 138 137136 135134 141 140 139 138 137136 135134
146 145 144 143142 146 145 144 143142
AK304275 AB AK304275 AB

00 − How to Use
P.00-6).
TROUBLESHOOTING
13C-249
Code No. P2121: Accelerator Pedal Position Sensor (Main) Circuit Range/Performance Problem

• Refer to P2122 accelerator pedal position sensor
(main) circuit P.13C-395. STEP 1. Connector check: B-116 accelerator
• Refer to inspection procedure 32 accelerator pedal position sensor connector
pedal position switch circuit P.13C-395.
Connector: B-116
FUNCTION
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> B-116 (GR)
checks the accelerator pedal position sensor
(main) output signal characteristics for abnormal
conditions.
TROUBLE JUDGMENT
8 7 6 5 4 3 2 1
Check Condition Harness side connector AK304279 AB
• Closed throttle position switch: ON Q: Is the check result normal?
• Accelerator pedal position sensor (sub) output YES : Go to Step 2 .
voltage is 1.88 V or less. NO : Repair.
Judgment Criteria
• Accelerator pedal position sensor (main) output STEP 2. Check accelerator pedal position sensor
voltage is 1.88 V or higher for 1 second. itself.
PROBABLE CAUSE (Refer to P.13C-431).
• Failed accelerator pedal position switch
switch circuit or loose connector contact STEP 3. Perform resistance measurement at
• Failed engine-ECU <M/T> B-116 accelerator pedal position sensor
• Failed engine-A/T-ECU <A/T> connector.
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1

side.
NO : Go to Step 4 .
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 1) accelerator pedal position sensor
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.

TROUBLESHOOTING
13C-251
STEP 7. Check accelerator pedal position switch STEP 9. Check harness between B-116 (terminal
itself. No. 4) accelerator pedal position sensor
• Check accelerator pedal position switch itself connector and C-140 (terminal No. 38)
<A/T> connector.
B-116 (GR)
connector
Connector: C-140
<L. H. Drive Vehicle> 8 7 6 5 4 3 2 1
Connector: C-140
<R. H. Drive Vehicle> C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 C-140 (GR)
58 57 5655 54 5352

34 33 32 31
AK304274 AB
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
NO : Repair.
AK304274 AB

NO : Repair.
TROUBLESHOOTING
Code No. P2122: Accelerator Pedal Position Sensor (Main) Circuit Low Input
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(main)
2 3 1
L-W GR BR-W
92 114 91
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code

AK304133AB
OPERATION FUNCTION
engine-ECU <M/T> or engine-A/T-ECU <A/T> tor pedal depression.
(terminal No. 92). • The engine-ECU <M/T> or engine-A/T-ECU
• The power voltage is earthed to the engine-ECU <A/T> checks whether the voltage is within a
<M/T> or engine-A/T-ECU <A/T> (terminal No. specified range.
91) from the accelerator pedal position sensor
Check Condition
output terminal (terminal No. 3). Judgment Criteria
voltage is 0.2 volt or less for 0.3 second.
TROUBLESHOOTING
13C-253
sensor circuit or loose connector contact Connector: B-116
B-116 (GR)
DIAGNOSIS PROCEDURE

• Refer to Data List Reference Table P.13C-402. 8 7 6 5 4 3 2 1
a. Item 78: Accelerator pedal position sensor Harness side connector AK304279 AB
(main) • Disconnect connector, and measure at harness

YES : Intermittent malfunction (Refer to GROUP • Ignition switch: ON
00 − How to Use • Voltage between terminal No. 2 and earth.
Troubleshooting/Inspection Service Points OK: 4.9 − 5.1 V
P.00-6).
NO : Go to Step 2 .
NO : Go to Step 5 .
pedal position sensor connector STEP 5. Connector check: C-142 engine-ECU
connector
B-116 (GR)
Connector: C-142
8 7 6 5 4 3 2 1 C-142 (GR)

NO : Repair.
C-142 (GR)
STEP 3. Check accelerator pedal position sensor

itself.
959493 92 91
Q: Is the check result normal? 104 103102 101100 99 98 97 96
112111110 109108107 106105
YES : Go to Step 4 . 120119118 117116115 114113
NO : Replace accelerator pedal position sensor. Harness side connector

AK304153 AB

NO : Repair.
TROUBLESHOOTING
No. 2) accelerator pedal position sensor • Refer to Data List Reference Table P.13C-402.
engine-ECU <M/T> connector or engine-A/T-ECU (main)
<A/T> connector.
00 − How to Use
B-116 (GR) Troubleshooting/Inspection Service Points
P.00-6).
8 7 6 5 4 3 2 1
AK304279 AB
connector
C-142 (GR) C-142 (GR)

C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

TROUBLESHOOTING
13C-255
B-116 (GR) B-116 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
TROUBLESHOOTING
Code No. P2123: Accelerator Pedal Position Sensor (Main) Circuit High Input
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(main)
2 3 1
L-W GR BR-W
92 114 91
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code

AK304133AB
OPERATION FUNCTION
Check Condition
voltage is 0.2 - 2.5 V.
TROUBLESHOOTING
13C-257
voltage is 4.5 V or higher for is 1 second. • Check accelerator pedal position sensor itself
PROBABLE CAUSE
• Failed engine-A/T-ECU <A/T> STEP 4. Perform resistance measurement at
DIAGNOSIS PROCEDURE connector.
Connector: B-116
• Refer to Data List Reference Table P.13C-402. B-116 (GR)
(main)
00 − How to Use 8 7 6 5 4 3 2 1
Troubleshooting/Inspection Service Points Harness side connector AK304279 AB
P.00-6).
side.
Connector: B-116
NO : Go to Step 6 .
B-116 (GR)

(main)
8 7 6 5 4 3 2 1
00 − How to Use
TROUBLESHOOTING
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-259
Code No. P2126: Accelerator Pedal Position Sensor (Sub) Circuit Range/Performance Problem

• Refer to Code No. P2127 Accelerator Pedal Cir-
cuit Position Sensor (sub) Circuit P.13C-262. STEP 1. Connector check: B-116 accelerator
• Refer to Inspection Procedure 32: Accelerator pedal position sensor connector
Pedal Position Switch Circuit P.13C-395.
Connector: B-116
FUNCTION
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> B-116 (GR)
checks the accelerator pedal position sensor
(sub) output signal characteristics for abnormal
conditions.
TROUBLE JUDGMENT
8 7 6 5 4 3 2 1
Check Condition Harness side connector AK304279 AB
• Closed throttle position switch: ON Q: Is the check result normal?
• Accelerator pedal position sensor (main) failure is YES : Go to Step 2 .
detected. NO : Repair.
Judgment Criteria
• Accelerator pedal position sensor (sub) output STEP 2. Check accelerator pedal position sensor
voltage is 2.5 V or higher for 1 second. itself.
PROBABLE CAUSE (Refer to P.13C-431).
• Failed accelerator pedal position switch
switch circuit or loose connector contact STEP 3. Perform resistance measurement at
• Failed engine-ECU <M/T> B-116 accelerator pedal position sensor
• Failed engine-A/T-ECU <A/T> connector.
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1

side.
NO : Go to Step 4 .
TROUBLESHOOTING
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.

TROUBLESHOOTING
13C-261
STEP 7. Check accelerator pedal position switch STEP 9. Check harness between B-116 (terminal
itself. No. 4) accelerator pedal position sensor
• Check accelerator pedal position switch itself connector and C-140 (terminal No. 38)
<A/T> connector.
B-116 (GR)
connector
Connector: C-140
<L. H. Drive Vehicle> 8 7 6 5 4 3 2 1
Connector: C-140
<R. H. Drive Vehicle> C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 C-140 (GR)
58 57 5655 54 5352

34 33 32 31
AK304274 AB
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
NO : Repair.
AK304274 AB

NO : Repair.
TROUBLESHOOTING
Code No. P2127: Accelerator Pedal Position Sensor (Sub) Circuit Low Input
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(sub)
8 6 7
Y-R L B
97 107 96
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code

AK304133AC
OPERATION FUNCTION
Check Condition
output terminal (terminal No. 6). Judgment Criteria
voltage is 0.2 volt or less for 1 second.
TROUBLESHOOTING
13C-263
sensor circuit or loose connector contact Connector: B-116
B-116 (GR)
DIAGNOSIS PROCEDURE

• Refer to Data List Reference Table P.13C-402. 8 7 6 5 4 3 2 1
a. Item 77: Accelerator pedal position sensor Harness side connector AK304279 AB
(sub) • Disconnect connector, and measure at harness

YES : Intermittent malfunction (Refer to GROUP • Ignition switch: ON
00 − How to Use • Voltage between terminal No. 8 and earth.
Troubleshooting/Inspection Service Points OK: 4.9 − 5.1 V
P.00-6).
NO : Go to Step 2 .
NO : Go to Step 5 .
pedal position sensor connector STEP 5. Connector check: C-142 engine-ECU
connector
B-116 (GR)
Connector: C-142
8 7 6 5 4 3 2 1 C-142 (GR)

NO : Repair.
C-142 (GR)
STEP 3. Check accelerator pedal position sensor

itself.
959493 92 91
Q: Is the check result normal? 104 103102 101100 99 98 97 96
112111110 109108107 106105
YES : Go to Step 4 . 120119118 117116115 114113
NO : Replace accelerator pedal position sensor. Harness side connector

AK304153 AB

NO : Repair.
TROUBLESHOOTING
No. 8) accelerator pedal position sensor • Refer to Data List Reference Table P.13C-402.
engine-ECU <M/T> connector or engine-A/T-ECU (sub)
<A/T> connector.
00 − How to Use
B-116 (GR) Troubleshooting/Inspection Service Points
P.00-6).
8 7 6 5 4 3 2 1
AK304279 AB
connector
C-142 (GR) C-142 (GR)

C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-265
B-116 (GR) B-116 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
TROUBLESHOOTING
Code No. P2128: Accelerator Pedal Position Sensor (Sub) Circuit High Input
Accelerator B-116
pedal (MU802073)
position
sensor 1 2 3 4 5 6 7 8
(sub)
8 6 7
Y-R L B
97 107 96
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
5V 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code

AK304133AC
OPERATION FUNCTION
Check Condition
TROUBLESHOOTING
13C-267
voltage is 4.5 V or higher for 1 second. • Check accelerator pedal position sensor itself
PROBABLE CAUSE
• Failed engine-A/T-ECU <A/T> STEP 4. Perform resistance measurement at
DIAGNOSIS PROCEDURE connector.
Connector: B-116
• Refer to Data List Reference Table P.13C-402. B-116 (GR)
(sub)
00 − How to Use 8 7 6 5 4 3 2 1
Troubleshooting/Inspection Service Points Harness side connector AK304279 AB
P.00-6).
side.
Connector: B-116
NO : Go to Step 6 .
B-116 (GR)

(sub)
8 7 6 5 4 3 2 1
00 − How to Use
TROUBLESHOOTING
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-269
Code No. P2135: Throttle Position Sensor (Main and Sub) Range/Performance Problem

• Refer to Code No. P0122: Throttle Position Sen-
sor (main) Circuit Low Input P.13C-54. STEP 1. Connector check: C-142 engine-ECU
• Refer to Code No. P0222: Throttle Position Sen- <M/T> connector or engine-A/T-ECU <A/T>
sor (sub) Circuit Low Input P.13C-146. connector and B-06 electronically controlled
throttle valve connector
FUNCTION
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> Connector: C-142
checks the throttle position sensor output signal <L. H. Drive Vehicle>
characteristics for abnormal conditions.
TROUBLE JUDGMENT
Check Condition C-142 (GR)
0.35 − 2.5 V.
• Throttle position sensor (sub) output voltage is
2.25 − 4.8 V C-142 (GR)
Judgment Criteria
• Using the formula given below, the voltage of 0.3
V or higher is obtained for 0.5 second: V* − V** −
2V
V*: throttle position sensor (main) output voltage 959493 92 91
V**: throttle position sensor (sub) output voltage. 104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
PROBABLE CAUSE Harness side connector

• Failed throttle position sensor AK304153 AB
B-06 (B)
6 5 4 3 2 1

NO : Repair.
TROUBLESHOOTING
B-06 (B) B-06 (B)

6 5 4 3 2 1 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
STEP 4. Replace throttle body assembly.

• After throttle body assembly is replaced, re-check
for trouble symptom.
NO : Check end.
TROUBLESHOOTING
13C-271
Code No. P2138: Accelerator Pedal Position Sensor (Main and Sub) Range/Performance Problem

Position Sensor (main) Circuit Low Input STEP 1. Connector check: B-116 accelerator
P.13C-252. pedal position connector
Position Sensor (sub) Circuit Low Input Connector: B-116
P.13C-262.
B-116 (GR)
FUNCTION
checks the accelerator pedal position sensor out-
put signal characteristics for abnormal conditions.
TROUBLE JUDGMENT 8 7 6 5 4 3 2 1
Check Condition
• Ignition switch is in "ON" position Q: Is the check result normal?
• Accelerator pedal position sensor (main) output YES : Go to Step 2 .
voltage is 0.2 − 4.5 V. NO : Repair.
voltage is 0.2 − 4.5 V. STEP 2. Check accelerator pedal position sensor
Judgment Criteria itself.
• Accelerator pedal position sensor (sub) output • Check accelerator pedal position sensor itself
voltage minus Accelerator pedal position sensor (Refer to P.13C-431).
(main) output voltage is 1 volt or higher for 1 sec- Q: Is the check result normal?
ond. YES : Go to Step 3 .
• Accelerator pedal position sensor (main) output NO : Replace accelerator pedal position sensor.
(sub) output voltage is 1 volt or higher for 0.2 sec- STEP 3. Perform resistance measurement at
onds. B-116 accelerator pedal position sensor
connector.
PROBABLE CAUSE
• Failed accelerator pedal position sensor Connector: B-116
sensor circuit or loose connector contact B-116 (GR)
8 7 6 5 4 3 2 1

side.
NO : Go to Step 4 .
TROUBLESHOOTING
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
STEP 6. Check the trouble symptoms

00 − How to Use
P.00-6).
TROUBLESHOOTING
13C-273
B-116 accelerator pedal position sensor No. 7) accelerator pedal position sensor
Connector: B-116
<A/T> connector.
B-116 (GR) Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
side. AK304279 AB

Connector: C-142
NO : Go to Step 8 .
C-142 (GR)
connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
<R. H. Drive Vehicle> Harness side connector

AK304153 AB
C-142 (GR)
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Connector: B-116
B-116 (GR)
C-142 (GR)

8 7 6 5 4 3 2 1
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
C-142 (GR)
AK304153 AB

959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-275
B-116 (GR) B-116 (GR)
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB
• Check power supply line for damage. • Check output line for damage.
TROUBLESHOOTING

<A/T> connector.
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
13C-277
DTC P2173: Abnormal Intake Air Amount
FUNCTION DIAGNOSIS
decides the allowable intake air amount in STEP 1. M.U.T.-II/III diagnosis code
accordance with the engine speed and the target
opening angle of throttle valve. Q: Diagnosis code set?
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> YES : Inspection chart for diagnosis code (Refer
checks whether the actual intake air amount is to P.13C-21).
more than the allowable intake air amount. NO : Go to Step 2 .
TROUBLE JUDGMENT STEP 2. Replace the air flow sensor.

Check Conditions • After replacing the air flow sensor, re-check the
• While engine is running. trouble symptoms.
Judgment Criteria
• The actual intake air amount is more than the
NO : Check end.
allowable in take air amount for 1.5 seconds.
TROUBLESHOOTING HINTS (The most STEP 3. Replace the throttle body assembly.
likely causes for this code to be set are: ) • After replacing the throttle body assembly,
• Failed air flow sensor. re-check the trouble symptoms.
• Throttle valve faulty operation. Q: Is the check result normal?
• Failed throttle position sensor YES : Replacing engine-ECU <M/T> or
• Failed engine-ECU <M/T> engine-A/T-ECU <A/T>.
• Failed engine-A/T-ECU <A/T> NO : Check end.
FUNCTION or
• The barometric pressure sensor converts the bar- • The sensor output voltage is 0.2 V or less (Baro-
ometric pressure into a voltage signal and inputs matric pressure of below 53 kPa or equivalent)
the signal to the engine-ECU <M/T> or for 4 seconds.
• In response to the signal, the engine-ECU <M/T> PROBABLE CAUSE
or engine-A/T-ECU <A/T>. corrects the fuel injec- • Failed barometric pressure sensor
tion amount, etc.
DIAGNOSIS PROCEDURE
TROUBLE JUDGMENT
Check Conditions STEP 1. M.U.T.-II/III diagnosis code
• 2 seconds later after the ignition switch has been Q: Diagnosis code set?
in "ON" position or the engine has started up. YES : Replace engine-ECU <M/T> or
• The battery voltage is 8 V or more. engine-A/T-ECU <A/T>.
Judgment Criteria NO : Inspection chart for diagnosis code (Refer to
• The sensor output voltage is 4.5 V or more (Baro- P.13C-21).
matric pressure of above 114 kPa or equivalent)
for 4 seconds.
TROUBLESHOOTING

M1131151501150

procedure
No.
with M.U.T.-II/III is Communication with engine-ECU <M/T> or engine-A/T-ECU <A/T> only 2
impossible is not possible
lamp is turned the "ON" position
Starting Starting impossible The starter is impossible to operate. 5 <M/T>,
(No initial combustion) 6 <A/T>
satisfied.
decelerating
TROUBLESHOOTING
13C-279
procedure
No.
Driving Engine does not revolve up The engine speed is not higher when 12
the accelerator pedal is depressed.
Hesitation, sag The response of vehicle speed 13
speed.
position.
TROUBLESHOOTING

procedure
No.
procedure page
No.
1 Communication with all system is not possible P.13C-282
2 Communication with engine-ECU <M/T> or engine-A/T-ECU <A/T> only is not P.13C-285
possible
3 The engine warning lamp does not illuminate right after the ignition switch is P.13C-288
turned the "ON" position
4 The engine warning lamp remains illuminating and never goes out P.13C-295
5 Starting impossible (No initial combustion) <M/T> P.13C-298
6 Starting impossible (No initial combustion) <A/T> P.13C-303
7 Starting impossible (Starter operative but no initial combustion) P.13C-309
8 Starting impossible (Initial combustion but no complete combustion) P.13C-312
9 Unstable idling (Rough idling, hunting) P.13C-314
10 The engine stalls when starting the car (pass out) P.13C-318
11 The engine stalls when decelerating P.13C-319
12 Engine does not revolve up P.13C-320
13 Hesitation, sag P.13C-321
Poor acceleration
Stumble
Surge
14 The feeling of impact or vibration when accelerating P.13C-323
15 The feeling of impact or vibration when decelerating P.13C-324
16 Knocking P.13C-324
17 Ignition timing offset P.13C-325
18 Run on (Dieseling) P.13C-326
TROUBLESHOOTING
13C-281
procedure page
No.
19 Odor, white smoke, black smoke, high-concentration CO/HC during idling P.13C-327
20 Battery rundown P.13C-329
21 Overheating P.13C-333
22 Abnormal rotation of fan motor P.13C-334
23 Poor A/C performance P.13C-337
24 Engine-ECU <M/T> or engine-A/T-ECU <A/T> power supply, engine control P.13C-339
relay, ignition switch-IG1 system
25 Fuel pump system P.13C-345
26 Fan control relay system P.13C-354
27 A/C switch system P.13C-361
28 A/C compressor relay system P.13C-366
29 A/C load signal system P.13C-373
30 A/C pressure sensor system P.13C-378
31 Ignition circuit system P.13C-388
32 Accelerator pedal position switch circuit system P.13C-395
TROUBLESHOOTING
SYMPTOM PROCEDURES
Inspection Procedure 1: Communication with All System is Not Possible
Fusible link (1)
R C-116
15 (*1) or
A-14
14 (*2)
R
C-122
2 (*2)
R
C-204
1
15 J/B
15A
12
C-205
W-B
C-24
MU803797 16
1 2 3 4 5 6 7 8
Diagnosis connector
9 10 1112 13 14 1516
4 5
B B
NOTE
Wire colour code
AK304141 AC
OPERATION COMMENT ON TROUBLE SYMPTOM

TROUBLESHOOTING
13C-283
PROBABLE CAUSE STEP 2: Perform resistance measurement at C-24
• Failed diagnosis connector diagnosis connector.
• Open/short circuit in diagnosis connector circuit
• Failed M.U.T.-II/III Connector: C-24
<L. H. drive vehicle>
DIAGNOSIS PROCEDURE
NOTE: .
*1
: L.H. drive vehicles
*2: R.H. drive vehicles C-24 (B)
1 2 3 4 5 6 7 8
STEP 1: Check connector: C-24 diagnosis 9 10 1112 13 14 1516
connector
<R. H. drive vehicle> Harness side
Connector: C-24 connector
C-24 (B)
C-24 (B)
1 2 3 4 5 6 7 8
AK304280 AB
9 10 1112 13 14 1516
connector side.
C-24 (B) Q: Is the check result normal?
AK304280 AB body earth, also between C-24 (terminal No.
Q: Is the check result normal? • Check earthing line for open circuit
YES : Go to Step 2 . and damage.
NO : Repair.
TROUBLESHOOTING
STEP 3: Perform voltage measurement at C-24 STEP 4: Replace M.U.T.-II/III

diagnosis connector. • After replacing the M.U.T.-II/III, re-check the trou-
ble symptoms.
Connector: C-24
<L. H. drive vehicle> Q: Does trouble symptom persist?
NO : Check end

C-24 (B)
Connector: C-24
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
connector
C-24 (B)
C-24 (B) 1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
connector
AK304280 AB

ness side.
C-24 (B)
OK: System voltage
NO : Check intermediate connectors C-116*1, AK304280 AB
*2 C-122*2,
A-14 C-204 and C-205 and repair NOTE: Before checking harness, check intermediate
if necessary. If connectors are normal, connectors C116*1, A-14*2, C-122*2, C-204 and
check and repair harness between C-24 C-205, and repair if necessary.
(terminal No. 16) diagnosis connector and • Check power supply line for damage.
battery.
• Check power supply line for Q: Is the check result normal?
open/short circuit. YES : Check and repair harness between C-24
NO : Repair.
TROUBLESHOOTING
13C-285
Inspection Procedure 2: Communication with Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Only is

Not Possible.
C-141
(MU803804)
656667686970717273
747576777879808182 Engine-A/T-ECU <A/T>
8384 858687 8889
74
O-W
C-04 (*1)
C-105
5
31 32 33 34 35 36 37 38 39 40 41
O-L 42 43 44 45 46 47 48 49 50 51 52
37
G G
Combination mater Control C-04 (*2)

circuit
36 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 5152
O-W (*1) or 32 (*1) or
O-L (*2) 20 (*2)
J/C (3)
C-02
29 (*1) or
18 (*2)
O-L
C-24 7
MU803797
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
NOTE
Wire colour code
AK401079 AC

• There is data communication between diagnosis • Open/short circuit in engine-ECU <M/T> or
connector output terminal (terminal No. 7) and engine-A/T-ECU <A/T> power circuit
engine-ECU <M/T> or engine-A/T-ECU <A/T> • Between engine-ECU <M/T> or engine-A/T-ECU
(terminal No. 74). <A/T> and diagnosis connector for short circuit
• Failed combination meter
COMMENT ON TROUBLE SYMPTOM • Failed engine-ECU <M/T>
• Failure is possibly caused by failed power supply • Failed engine-A/T-ECU <A/T>
circuit or failed earthing circuit of engine-ECU
<M/T> or engine-A/T-ECU <A/T>.
TROUBLESHOOTING
DIAGNOSIS PROCEDURE STEP 2: Connector check: C-141 engine-ECU

STEP 1: Check engine warning lamp. connector
• Ignition switch: OFF → ON
Connector: C-141
Q: Is lamp illuminating for few seconds? <L. H. Drive Vehicle>
NO : Check engine-ECU <M/T> or
engine-A/T-ECU <A/T> power supply,
engine control relay and ignition switch IG1 C-141(GR)
system (Refer to Inspection Procedure 24
P.13C-339).

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING
13C-287
No. 7) diagnosis connector and C-141 (terminal NO : Repair.
No. 74) engine-ECU <M/T> connector or
STEP 4: Replace the combination meter
Connector: C-24 • After replacing the combination meter, re-check
NO : Check end.
C-24 (B)
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
<R. H. drive vehicle> Harness side engine-A/T-ECU <A/T>.
connector
00 − How to Use
P.00-6).
C-24 (B)
AK304280 AB
Connector: C-141
C-141(GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

necessary.
and damage.
TROUBLESHOOTING
Inspection Procedure 3: The Engine Warning Lamp Does Not Illuminate Right after the Ignition Switch
is Turned the "ON" Position
Combination meter circuit
Ignition switch
C-303 R LOCK
1 2 3 ST ACC
4 5 6 IG1 IG2
L-B
C-203
6
2
J/B
7.5A
25
C-205 C-04 (*1)
B-W
C-04
42 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
Combination meter
G G
C-05 (*1)
C-04 (*2)
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 5152
G G C-05
14
R-W
C-05 (*2)
1 2 3 4 5 6 7 8 9 10 11 7
12 13 14 15 16 17 18 19 20 2122 C-105
R-W
7
C-139
(MU803802)
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
NOTE 14 15 16 1718 19 20
*1: L.H. drive vehicles 21 22 232425 2627
Wire colour code

AK401087 AB
TROUBLESHOOTING
13C-289
OPERATION STEP 2: Check engine warning lamp for
• Battery voltage is applied to engine warning lamp burnt-out bulb.
of combination meter connector (terminal No. 42)
from ignition switch.
NO : Replace engine warning lamp.
(terminal No. 7) makes power transistor in unit be
in "ON" position, and that makes currents go on
engine warning lamp of combination meter con- STEP 3: Connector check: C-04 combination
nector (terminal No. 14). meter connector
Connector: C-04
COMMENTS ON TROUBLE SYMPTOM
• Engine-ECU <M/T> or engine-A/T-ECU <A/T> C-04
turns on engine warning lamp for 5 seconds to
check for burnt-out bulb immediately after ignition
switch is turned to ON.
• If engine warning lamp is not lit just after turning
ignition switch to "ON" position, failure is possibly
caused by burn-out bulb, open/short circuit or
other faults.
<L. H. Drive Vehicles>
PROBABLE CAUSE
• Failed ignition switch 41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
• Open/short circuit in engine warning lamp circuit
for or loose connector contact G G
• Failed engine-ECU <M/T> Harness side connector

<R. H. Drive Vehicles>
DIAGNOSIS PROCEDURE 41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 4342
STEP 1: Check engine start-up. Harness side connector

Q: Is engine started? AK304333 AB
NO : Check engine-ECU <M/T> or Q: Is the check result normal?
engine-A/T-ECU <A/T> power supply, YES : Go to Step 4 .
engine control relay and ignition switch IG1 NO : Repair.
system (Refer to Inspection Procedure 24
P.13C-339).
TROUBLESHOOTING
STEP 4: Perform voltage measurement at C-04 STEP 5: Connector check: C-303 ignition switch
combination meter connector. connector
C-04
C-303
3 2 1
6 5 4

Connector: C-04
41 40 39 38 37 36 35 34 33 32 31 C-04
52 51 50 49 48 47 46 45 44 43 42
G G
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 4342
AK304333 AB
41 40 39 38 37 36 35 34 33 32 31
• Disconnect connector, and measure at the har- 52 51 50 49 48 47 46 45 44 43 42
ness side. G G
OK: System voltage <R. H. Drive Vehicles>
Q: Is the check result normal? 41 40 39 38 37 36 35 34 33 32 31

YES : Go to Step 6 . 52 51 50 49 48 47 46 45 44 4342
NO : Go to Step 5 .
AK304333 AB

No. 42) combination meter connector and
connector.
open/short circuit.
NO : Repair
TROUBLESHOOTING
13C-291
STEP 6: Connector check: C-139 engine-ECU STEP 7: Perform voltage measurement at C-139
<M/T> connector or engine-A/T-ECU <A/T> engine-ECU <M/T> connector or engine-A/T-ECU
connector <A/T> connector.
C-139 (GR) C-139 (GR)
C-139 (GR) C-139 (GR)
4 3 2 1 4 3 2 1
13 12 1110 9 8 7 6 5 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2019 18 17 16 15 14
2726 2524 23 22 21 2726 2524 23 22 21
AK304262 AB AK304262 AB

YES : Go to Step 7 . ness side.
NO : Repair. • Ignition switch: ON
OK: System voltage
NO : Go to Step 8 .
TROUBLESHOOTING

STEP 8: Check connector: C-05 combination
meter connector
Connector: C-05 connector is normal, check and repair
C-05 (L) combination meter connector and C-139
connector.
circuit.
NO : Repair
<L. H. Drive Vehicles> STEP 9: Connector check: C-303 ignition switch

connector
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312 Connector: C-303
G G
Harness side connector C-303

11 10 9 8 7 6 5 4 3 2 1 3 2 1
22 21 20 19 18 17 16 15 14 13 12
6 5 4
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
TROUBLESHOOTING
13C-293
STEP 10: Check harness between C-04 (terminal STEP 11: Connector check: C-05 ignition switch
No. 42) combination meter connector and C-303 connector
Connector: C-05
Connector: C-04
C-05 (L)
C-04

11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
41 40 39 38 37 36 35 34 33 32 31
52 51 50 49 48 47 46 45 44 43 42
G G
11 10 9 8 7 6 5 4 3 2 1
41 40 39 38 37 36 35 34 33 32 31 22 21 20 19 18 17 16 15 14 13 12
52 51 50 49 48 47 46 45 44 4342

AK304335 AB
AK304333 AB

Connector: C-303
NO : Repair.
C-303
3 2 1
6 5 4

sary.
NO : Repair.
TROUBLESHOOTING

No. 14) combination meter connector and C-139 NO : Repair.
Connector: C-05
C-05 (L)
00 − How to Use
P.00-6).
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G G
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12

AK304335 AB
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

TROUBLESHOOTING
13C-295
Inspection Procedure 4: The Engine Warning Lamp Remains Illuminating and Never Goes Out
Combination meter circuit
Ignition switch
C-303 R LOCK
1 2 3 ST ACC
4 5 6 IG1 IG2
L-B
C-203
6
2
J/B
7.5A
25
C-205 C-04 (*1)
B-W
C-04
42 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 51 52
Combination meter
G G
C-05 (*1)
C-04 (*2)
1 2 3 4 5 6 7 8 9 10 11
12 1314 15 16 17 18 19 20 2122 31 32 33 34 35 36 37 38 39 40 41
42 43 44 45 46 47 48 49 50 5152
G G C-05
14
R-W
C-05 (*2)
1 2 3 4 5 6 7 8 9 10 11 7
12 13 14 15 16 17 18 19 20 2122 C-105
R-W
7
C-139
(MU803802)
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
NOTE 14 15 16 1718 19 20
Wire colour code

AK401087 AB

• Battery voltage is applied to engine warning lamp (terminal No. 7) makes power transistor in unit be
of combination meter connector (terminal No. 42) in "ON" position, and that makes currents go on
from ignition switch. engine warning lamp (terminal No. 14).
TROUBLESHOOTING
COMMENT ON TROUBLE SYMPTOM STEP 2: Connector check: C-139 engine-ECU

• Engine-ECU <M/T> or engine-A/T-ECU <A/T> <M/T> connector or engine-A/T-ECU <A/T>
has detected failed sensor or failed actuator. Or connector.
failure is possibly caused by short circuit or other
faults. Connector: C-139
PROBABLE CAUSE
• Short circuit in between engine warning lamp and
circuit. C-139 (GR)
• Failed engine-ECU <A/T>
DIAGNOSIS PROCEDURE <R. H. Drive Vehicle>
STEP 1: M.U.T.-II/III diagnosis code C-139 (GR)

to P.13C-21.)
NO : Go to Step 2 . 4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair
TROUBLESHOOTING
13C-297
STEP 3: Perform voltage measurement at C-139 • Voltage between terminal No. 7 and earth.
engine-ECU <M/T> connector or engine-A/T-ECU OK: System voltage
<A/T> connector. Q: Is the check result normal?
Connector: C-139
<L. H. Drive Vehicle> repair if necessary. If intermediate
C-139 (GR)
connector.

C-139 (GR)
4 3
13 12 1110 9 8 7
2
6
1
5
00 − How to Use
2019 18 17 16 15 14 Troubleshooting/Inspection Service Points
2726 2524 23 22 21
Harness side connector P.00-6).
AK304262 AB
Connector: C-05
C-05 (L)
11 10 9 8 7 6 5 4 3 2 1
22 2120 19 18 17 16 15 14 1312
G G
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12

AK304335 AB

ness side.
TROUBLESHOOTING
Inspection Procedure 5: Starting Impossible (No Initial Combustion) <M/T>
Stating impossible (no initial combustion) <M/T>
Ignition switch
C-303
R LOCK
1 2 3
ST ACC
IG1 IG2 4 5 6
Battery
5
B-Y
C-106
16
B-Y
B-L
B-19
4 B-Y
C-140
51 (MU803083)
B-R 3132 33 34
35363738394041 42 43
444546474849 50 51
5253 545556 57 58
1 1
1 Engine-ECU
1
ON
OFF
B-26
B-25 M
(MU801215)
Starter
Wire colour code

AK304155 AD
COMMENT ON TROUBLE SYMPTOM PROBABLE CAUSE

• Failure is possibly caused by failed starter itself • Failed battery
or failed related circuit. • Failed starter motor
TROUBLESHOOTING
13C-299
Connector: C-140
OK: 8 V or higher
NO : Check battery (Refer to GROUP 54A − C-140 (GR)
P.54A-7).
34 33 32 31
STEP 2: M.U.T.-II/III data list 43 42 4140 39 38 37 36 35
• Item 18: Cranking signal 51
58
50 49 4847 46 4544
57 5655 54 5352
OK: Harness side connector
ON (Ignition switch: ST) AK304455 AB
OFF (Ignition switch: ON) • Disconnect connector, and measure at the har-
Q: Is the check result normal? ness side.
YES : Go to Step 8 . • Ignition switch: ST
NO : Go to Step 3 . • Voltage between terminal No. 51 and earth.
OK: System voltage
STEP 3: Connector check: C-140 engine-ECU Q: Is the check result normal?
NO : Go to Step 5 .
Connector: C-140
STEP 5: Connector check: C-303 ignition switch

connector
Connector: C-303
C-140 (GR)
C-303
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 3 2 1
58 57 5655 54 5352
Harness side connector 6 5 4
AK304455 AB

NO : Repair.
NO : Repair.
TROUBLESHOOTING
STEP 6: Check ignition switch. STEP 7: Connector check: C-303 ignition switch
Connector: C-140
Connector: C-303
C-303
C-140 (GR)
3 2 1
6 5 4
34 33 32 31
51 50 49 4847 46 4544
58 57 5655 54 5352
Harness side connector Connector: B-26
AK304455 AB
Connector: C-303
B-26(B)
C-303
1
3 2 1
6 5 4
Harness side connector AK304334 AB YES : Check intermediate connectors C-106 and
B-19, and repair if necessary. If intermediate
Ignition Switch − Ignition Switch − Inspection
P.54A-30). ignition switch connector and B-26 (terminal
Q: Is the check result normal? No. 1) starter connector.
YES : Check intermediate connectors C-106 and • Check output line for short circuit.
B-19, and repair if necessary. If intermediate NO : Repair.
STEP 8: Check connector: B-26 starter connector
engine-ECU connector and C-303 (terminal
No. 5) ignition switch connector. Connector: B-26
open/short circuit.
B-26(B)
1

NO : Repair.
TROUBLESHOOTING
13C-301
STEP 9: Perform voltage measurement at B-26 STEP 10: Connector check: C-303 ignition switch
C-303
B-26(B)
3 2 1
1 6 5 4

Connector: B-26
ness side.
OK: System voltage
Q: Is the check result normal? B-26(B)
1

damage.
NO : Repair.
STEP 11: Connector check: B-25 starter

connector
Connector: B-25
B-25
1

NO : Repair.
TROUBLESHOOTING
STEP 12: Perform voltage measurement at B-25 STEP 13: Check harness between C-303 (terminal
starter connector. No. 5) ignition switch connector and B-26
Connector: B-25
Connector: C-303
C-303
B-25
1
3 2 1
Harness side connector 6 5 4
AK304337 AB
ness side.
Connector: B-26
OK: System voltage
NO : Check and repair harness between B-25 B-26(B)
battery.
1
open/short circuit. Harness side connector AK304336 AB

NO : Repair.
STEP 14: Check harness between B-25 (terminal

Connector: B-25
B-25
1

NO : Repair.
TROUBLESHOOTING
13C-303
Inspection Procedure 6: Starting Impossible (No Initial Combustion) <A/T>
Stating impossible (no initial combustion) <A/T>
Ignition switch
C-303
R LOCK
1 2 3
ST ACC
IG1 IG2 4 5 6
Battery
5
B-Y
C-106
16
B-Y
10 B-35
MU802355
Inhibitor
switch 1 2 3 4 5 6
7 8 9 10
B-L 9
B-R
B-Y
B-19 C-140
4 51 (MU803803)
3132 33 34
B-R 35363738394041 42 43
444546474849 50 51
5253 545556 57 58
1 1
Engine-A/T-ECU
1 ON
OFF
1
M
B-25 B-26
(MU801215)
Starter
Wire colour code

AK401208 AB
COMMENT ON TROUBLE SYMPTOM PROBABLE CAUSE

• Failure is possibly caused by failed starter itself • Failed battery
or failed related circuit. • Failed inhibitor switch
• Failed starter motor
TROUBLESHOOTING

engine-A/T-ECU connector.
Connector: C-140
OK: 8 V or higher
NO : Check battery (Refer to GROUP 54A − C-140 (GR)
Battery-On-vehicle Service − Battery Test
P.54A-7).

OK:
ON (Ignition switch: ST) C-140 (GR)
YES : Go to Step 11 . 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
NO : Go to Step 3 . 58 57 5655 54 5352

STEP 3: Connector check: C-140 engine-A/T-ECU AK304274 AB
connector
Connector: C-140 ness side.
<L. H. Drive Vehicle> • Ignition switch: ST
OK: System voltage
C-140 (GR)
NO : Go to Step 5 .
<R. H. Drive Vehicle> STEP 5: Connector check: B-35 inhibitor switch

connector
Connector: B-35
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352 B-35 (B)
Harness side connector 6 5 4 3 2 1
10 9 8 7
AK304274 AB

NO : Repair.
NO : Repair.
TROUBLESHOOTING
13C-305
STEP 6: Perform voltage measurement at B-35 STEP 8: Check ignition switch
inhibitor switch connector
Connector: B-35
Connector: B-35
B-35 (B)
B-35 (B) 6 5 4 3 2 1
6 5 4 3 2 1 10 9 8 7
10 9 8 7 Harness side connector AK304338 AB
Connector: C-303
ness side.
• Ignition switch: ST C-303
OK: System voltage
NO : Go to Step 7 .
STEP 7: Connector check: C-303 ignition switch • Check ignition switch (Refer to GROUP 54A −
connector Ignition switch − Ignition Switch − Inspection
P.54A-30).
Connector: C-303
YES : Check intermediate connector C-106 and
C-303 repair if necessary. If intermediate
inhibitor switch connector and C-303
3 2 1 (terminal No. 5) ignition switch connector.
6 5 4 • Check power supply line for
Harness side connector AK304334 AB open/short circuit.
NO : Repair.
TROUBLESHOOTING
STEP 9: Check inhibitor switch. STEP 10: Connector check: B-35 inhibitor switch
Connector: B-35
Connector: B-35
B-35 (B)
6 5 4 3 2 1 B-35 (B)
10 9 8 7 6 5 4 3 2 1
Harness side connector 10 9 8 7
AK304338 AB
Connector: C-140
Connector: B-26
C-140 (GR)
B-26(B)
1

C-140 (GR) YES : Check intermediate connectors B-19, and
34 33 32 31 harness between B-35 (terminal No. 9)
43
51
42 4140 39 38 37 36 35
50 49 4847 46 4544
inhibitor switch connector and B-26
58 57 5655 54 5352 (terminal No. 1) starter connector.
Harness side connector • Check output line for short circuit.
NO : Repair.
AK304274 AB
• Check ignition switch (Refer to GROUP 23A − On

STEP 11: Check connector: B-26 starter
− vehicle Service − A/T Control Component
connector
Check − Inhibitor Switch Check P.23A-126).
Connector: B-26
YES : Check intermediate connectors B-19, and
B-26(B)
(terminal No. 51) engine-A/T-ECU
connector. 1
• Check power supply line for Harness side connector AK304336 AB
open/short circuit.
NO : Replace ignition switch. Q: Is the check result normal?
NO : Repair.
TROUBLESHOOTING
13C-307
STEP 12: Perform voltage measurement at B-26 STEP 13: Connector check: B-35 inhibitor switch
B-26(B)
B-35 (B)
6 5 4 3 2 1
1 10 9 8 7

Connector: B-26
ness side.
OK: System voltage
Q: Is the check result normal? B-26(B)
1

YES : Check intermediate connectors B-19, and
inhibitor switch connector and B-26
damage.
NO : Repair.
STEP 14: Connector check: B-25 starter

connector
Connector: B-25
B-25
1

NO : Repair.
TROUBLESHOOTING
STEP 15: Perform voltage measurement at B-25 STEP 16: Check harness between B-35 (terminal
starter connector. No. 9) inhibitor switch connector and B-26
Connector: B-25
Connector: B-35
B-25
1
B-35 (B)
6 5 4 3 2 1
10 9 8 7
ness side.
Connector: B-26
OK: System voltage
NO : Check and repair harness between B-25 B-26(B)
battery.
1
open/short circuit. Harness side connector AK304336 AB

connectors B-19 and repair if necessary.
NO : Repair.
STEP 17: Check harness between B-25 (terminal

Connector: B-25
B-25
1

NO : Repair.
TROUBLESHOOTING
13C-309
Inspection Procedure 7: Starting Impossible (Starter Operative but No Initial Combustion)
COMMENT ON TROUBLE SYMPTOM STEP 3: M.U.T.-II/III diagnosis code

• Failure is possibly caused by failed ignition cir-
cuit, failed fuel feed or other faults.
PROBABLE CAUSE to P.13C-21)
NO : Go to Step 4 .
• Failed battery
• Timing belt broken
• Failed idle speed control STEP 4: M.U.T.-II/III actuator test
• Throttle valve fouled around • Item 07: Fuel pump
• Failed ignition system OK: Operating sound of fuel pump can be
• Failed fuel system heard.
• Failed immobilizer system
• Failed inhibitor-switch <A/T>
• Failed engine-ECU <M/T> NO : Check fuel pump system (Refer to
• Failed engine-A/T-ECU <A/T> Inspection Procedure 25 P.13C-345)
DIAGNOSIS PROCEDURE
STEP 5. Check timing belt for breakage.
NOTE: . • Engine: Cranking
*1
: L.H. drive vehicles OK: Camshaft rotates.
STEP 1: Check battery voltage. NO : Replace timing belt.
OK: 8 V or higher STEP 6. Check throttle body (throttle valve)
Q: Is the check result normal? contamination.
YES : Go to STEP 2 . Q: Is the check result normal?
NO : Check battery (Refer to GROUP 54 − YES : Go to Step 7 .
Battery − On-vehicle Service − Battery Test NO : Clean throttle body (throttle valve portion)
P.54A-7). (Refer to P.13C-425).
STEP 2: Check engine warning lamp for burnt out STEP 7: M.U.T.-II/III data list
bulb. • Item 18: Cranking signal
Q: Is the check result normal? OK:
YES : Go to Step 3 . ON (Ignition switch: ST)
NO : Check engine-ECU <M/T> or OFF (Ignition switch: ON)
engine-A/T-ECU <A/T> power supply,
engine control relay and ignition switch IG1 YES : Go to Step 10 .
system (Refer to Inspection Procedure 24 NO : Go to Step 8 <M/T> , Go to Step 9 <A/T> .
P.13C-339).
TROUBLESHOOTING
STEP 8: Connector check: C-140 engine-ECU STEP 9: Connector check: C-140 engine-A/T-ECU
connector connector
C-140 (GR) C-140 (GR)
34 33 32 31 <R. H. Drive Vehicle>

43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304455 AB C-140 (GR)
Connector: C-303
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
C-303 58 57 5655 54 5352
AK304274 AB
3 2 1
6 5 4 Connector: B-35

intermediate connectors are normal, check B-35 (B)
6 5 4 3 2 1
and repair harness between C-303 (terminal 10 9 8 7
No. 5) ignition switch connector and C-140
(terminal No. 51) engine-ECU connector. AK304338 AB
• Check output line for open/short Q: Is the check result normal?

circuit. YES : Check intermediate connectors B-19, and
NO : Repair. repair if necessary. If intermediate
(terminal No. 51) engine-A/T-ECU
connector.
circuit.
NO : Repair.
TROUBLESHOOTING
13C-311
STEP 10: M.U.T.-II/III data list STEP 13. Check spark plug.
• Refer to Data list reference table P.13C-402. • Check spark plug itself (Refer to GROUP 16 −
a. Item 22: Crank angle sensor Ignition System − On-vehicle Service P.16-40).
YES : Go to Step 11 . YES : Check ignition circuit system (Refer to
NO : Check crank angle sensor system (Refer to Inspection Procedure 31 P.13C-388).
Code No. P0335 P.13C-170). NO : Replace the spark plug.
STEP 11: Check injector for operating sound. STEP 14: Fuel pressure measurement.
• Check injector for operating sound (Refer to • Fuel pressure measurement (Refer to
P.13C-435). P.13C-425).
Q: Can operating sound be heard? Q: Is the check result normal?
NO : Check the injector system of the defective NO : Repair.
cylinder.
(Refer to Code No. P0201: No. 1 injector STEP 15: Replace engine-ECU <M/T> or
system P.13C-126.) engine-A/T-ECU <A/T>
(Refer to Code No. P0202: No. 2 injector • After replacing the engine-ECU <M/T> or
system P.13C-131.) engine-A/T-ECU <A/T>, re-check the trouble
(Refer to Code No. P0203: No. 3 injector symptoms.
system P.13C-136.)
(Refer to Code No. P0204: No. 4 injector Q: Does trouble symptom persist?
system P.13C-141.) YES : Check for foreign matters (water, kerosene,
NO : Check end.
STEP 12. Visual check of ignition spark.
coil.
• Connect the ignition coil connector.
• Remove all injector connectors.
• At the engine start, check each spark plug pro-
duces a spark.
TROUBLESHOOTING
Inspection Procedure 8: Starting Impossible (Initial Combustion But No Complete Combustion),

Improper Starting (Long Time to Start)

• Failure is possibly caused by poor ignition, incor- • Refer to Data list reference table P.13C-402.
rect air-fuel ratio at cranking, improper fuel pres- a. Item 12: Air flow sensor
sure or other faults. b. Item 13: Intake air temperature sensor
• Failed battery d. Item 95: Manifold absolute pressure sensor
• Failed ignition system Q: Are the check results normal?
• Failed fuel system YES : Go to Step 5 .
• Air-fuel ratio control NO : Perform the diagnosis code classified check
• Failed idle speed control system procedure for the sensor that has shown an
• Failed intake system abnormal data value (Refer to Inspection
• Failed exhaust gas cleaning system Chart for Diagnosis Code P.13C-21).
• Timing belt not in place STEP 5: M.U.T.-II/III data list
• Compression pressure improper • Refer to Data list reference table P.13C-402.
Q: Have the battery terminal been disconnected? STEP 6: Check throttle body (throttle valve)
YES : After warm-up engine, idle for about 10 contamination.
minutes.
STEP 2: Check battery voltage. (Refer to P.13C-425).
OK: 8 V or higher STEP 7: M.U.T.-II/III actuator test
Q: Is the check result normal? • Item 07: Fuel pump
YES : Go to Step 3 . OK: Operating sound of fuel pump can be
NO : Check battery (Refer to GROUP 54 − heard.
P.54A-7).
NO : Check fuel pump system (Refer to
STEP 3: M.U.T.-II/III diagnosis code Inspection Procedure 25 P.13C-345).
YES : Inspection chart for diagnosis codes (Refer STEP 8: Check air intake from intake hose and
to P.13C-21). inlet manifold.
NO : Go to Step 4 .
NO : Repair.
TROUBLESHOOTING
13C-313
STEP 9: Check injector for operating sound. STEP 13: Check spray condition of injector.
• Check injector for operating sound at engine • Check each injector for spray condition (Refer to
cranking (Refer to P.13C-435). P.13C-435).
Q: Can operating sound be heard? Q: Is the check result normal?
NO : Check the injector system of the defective NO : Replace injector.
cylinder.
(Refer to Code No. P0201: No.1 Injector
System P.13C-126).
11E − On-vehicle Service − Compression Pres-
System P.13C-131).
sure Check P.11E-15).
System P.13C-136). Q: Is the check result normal?
(Refer to Code No. P0204: No.4 Injector YES : Go to Step 15 .
System P.13C-141). NO : Repair.
STEP 10. Check timing marks of timing belt. STEP 15: Check EGR valve (stepper motor) itself.
Exhaust Gas Recirculation (EGR) System − EGR
Valve (stepper motor) Check <4G69>P.17-72].
• Remove the spark plug and install it to the ignition NO : Replace EGR valve (stepper motor).
coil.
• Connect the ignition coil connector.
• Remove all injector connectors. STEP 16: Replace engine-ECU <M/T> or
• At the engine start, check each spark plug pro- engine-A/T-ECU <A/T>.
duces a spark. • After replacing the engine-ECU <M/T> or
engine-A/T-ECU <A/T>, re-check the trouble
symptoms.
NO : Go to Step 12 . Q: Does trouble symptom persist?
STEP 12. Check spark plug. NO : Check end.
YES : Check ignition circuit system (Refer to
Inspection Procedure 31 P.13C-388).
NO : Replace the spark plug.
TROUBLESHOOTING
Inspection Procedure 9: Unstable Idling (Rough Idling, Hunting), Improper Idling Speed (Too High or
too Low), Engine Stalls during Idling (Die Out)

• Probable causes can be widely found in ignition • Refer to Data List Reference Table P.13C-402.
system, air-fuel ratio control system, idle speed a. Item 12: Air flow sensor
control system, fuel system, etc. A sudden b. Item 13: Intake air temperature sensor
c. Item 14: Throttle position sensor (sub)
contact.
d. Item 21: Engine coolant temperature sensor
PROBABLE CAUSE e. Item 77: Accelerator pedal position sensor
• Failed ignition system (sub)
• Failed fuel system f. Item 78: Accelerator pedal position sensor
• Failed air-fuel ratio control system (main)
• Failed idle speed control system g. Item 79: Throttle position sensor (main)
• Failed intake/exhaust system h. Item 95: Manifold absolute pressure sensor
• Throttle valve body fouled YES : Go to Step 4 .
• Timing belt out of place NO : Perform the diagnosis code classified check
• Compression pressure improper procedure for the sensor that has shown an
• Failed engine-ECU <M/T> abnormal data value (Refer to Inspection
• Failed engine-A/T-ECU <A/T> Chart for Diagnosis Code P.13C-21).
DIAGNOSIS PROCEDURE
STEP 1: Check battery condition. a. Item 25: Barometric pressure sensor
Q: Has the battery terminal been disconnected? Q: Are the check results normal?
YES : After warm-up engine, idle for about 10 YES : Go to Step 5 .
minutes. NO : Replace engine-ECU <M/T> or
NO : Go to Step 2 . engine-A/T-ECU <A/T>.
STEP 2: M.U.T.-II/III diagnosis code STEP 5: M.U.T.-II/III data list

Q: Diagnosis code set? • Refer to Data List Reference Table P.13C-402.
YES : Inspection chart for diagnosis code (Refer a. Item 27: Power steering fluid pressure switch
to P.13C-21).
NO : Go to Step 3 .
circuit (Refer to Code No. P0551
P.13C-206).
STEP 6: Check throttle body (throttle valve)

contamination.
TROUBLESHOOTING
13C-315
STEP 7: Check air intake from intake hose and STEP 11. Perform voltage measurement at C-140
inlet manifold. engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
NO : Repair.

• Check injector for operating sound (Refer to
P.13C-435). C-140 (GR)

cylinder.
(Refer to Code No. P0201: No. 1 Injector
System P.13C-126).
(Refer to Code No. P0202: No. 2 Injector C-140 (GR)
System P.13C-131).
System P.13C-136). 34 33 32 31
(Refer to Code No. P0204: No. 4 Injector 43
51
42 4140 39 38 37 36 35
50 49 4847 46 4544
System P.13C-141). 58 57 5655 54 5352
STEP 9: Check timing marks of timing belt. AK304274 AB
Q: Is the check result normal? • Measure engine-ECU <M/T> or engine-A/T-ECU

YES : Go to Step 10 . <A/T> terminal voltage.
NO : Align timing marks. • Engine: Idling after warm-up
STEP 10. M.U.T.-II/III data list • Radiator fan: Not operating
• Refer to Data List Reference Table P.13C-402. • Voltage between terminal No. 45 and earth.
a. Item 11: Cylinder 1, 4 oxygen sensor (front) OK: Switching the headlamps to ON from
b. Item 39: Cylinder 2, 3 oxygen sensor (front) OFF causes the voltage to increase.
c. Item 59: Cylinder 1, 4 oxygen sensor (rear) Q: Is the check result normal?
d. Item 69: Cylinder 2, 3 oxygen sensor (rear) YES : Go to Step 15 .
Chart for Diagnosis Code P.13C-21).
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> No. 45) engine-ECU <M/T> connector or
connector and B-30 alternator connector engine-A/T-ECU <A/T> connector and B-30
(terminal No. 1) alternator connector.
Connector: C-140
C-140 (GR)
C-140 (GR)

C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 34 33 32 31
58 57 5655 54 5352 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544

AK304274 AB
AK304274 AB
Connector: B-30
Connector: B-30
B-30 (GR)
B-30 (GR)
4 3 2 1
NO : Repair. connector B-19, and repair if necessary.
age.
NO : Repair.
STEP 14. Replace alternator

• After alternator is replaced, re-check for trouble
symptom.
NO : Check end.
TROUBLESHOOTING
13C-317
STEP 15. Perform voltage measurement at C-141 STEP 17. Check spark plug.
engine-ECU <M/T> connector or engine-A/T-ECU • Check spark plug itself (Refer to GROUP 16 −
<A/T> connector. Ignition System − On-vehicle Service P.16-40).
C-141(GR) STEP 18. Check injector for spray condition.

P.13C-435).
C-141 (GR)

6463 62 61 sure Check P.11E-15).
7372 7170 69 6867 6665
8988 87 86 85 8483
NO : Repair.
AK304154 AB
• Measure engine-ECU <M/T> or engine-A/T-ECU STEP 20. Check purge control solenoid valve
<A/T> terminal voltage. itself.
• Engine: Idling • Check purge control solenoid valve itself (Refer
• A/C switch: ON (A/C compressor ON) to GROUP 17 − Emission Control System −
• Voltage between terminal No. 78 and earth. Evaporative Emission Control System− Purge
OK: Control Solenoid Valve Check P.17-65).
1 V or less (with outside air temperature sen-
sor ambient temperature at 18°C or higher
and A/C set for maximum air flow at mini- NO : Replace purge control solenoid valve.
mum temperature)
System voltage (with A/C set for minimum air
flow at room temperature) STEP 21. Check EGR valve (stepper motor) itself.
Q: Is the check result normal? GROUP 17 − Emission Control System −
NO : Check A/C load signal system (Refer to
Valve (Stepper Motor) Check <4G69>P.17-72].
STEP 16. Visual check of ignition spark. NO : Replace EGR valve (stepper motor).
coil.
• Connect the ignition coil connector. STEP 22. M.U.T.-II/III actuator test
• Remove all injector connectors. • Item 07: Fuel pump
• At the engine start, check each spark plug pro- OK: Operating sounds of fuel pump can be
duces a spark. heard.
NO : Go to Step 17 . NO : Check fuel pump system (Refer to
inspection Procedure 25 P.13C-345).
TROUBLESHOOTING
STEP 23. Replace engine-ECU <M/T> or

• After engine-ECU <M/T> or engine-A/T-ECU
<A/T> is replaced, re-check for trouble symptom.
NO : Check end.
COMMENT ON TROUBLE SYMPTOM STEP 3. Check EGR valve (stepper motor) itself.
• Engine stall on starting is possibly caused by mis- • Check EGR valve (stepper motor) itself [Refer to
fire due to failed spark plug, improper air-fuel GROUP 17 − Emission Control System −
ratio at accelerator pedal depression or other Exhaust Gas Recirculation (EGR) System − EGR
faults. Valve (Stepper Motor) Check <4G69> P.17-72].

• Failed engine-ECU <M/T> STEP 4. Check air intake from intake hose and
• Failed engine-A/T-ECU <A/T> inlet manifold.
NO : Repair.
YES : Inspection chart for diagnosis code (Refer • Remove the spark plug and install it to the ignition
to P.13C-21). coil.
NO : Go to Step 2 . • Connect the ignition coil connector.
STEP 2. M.U.T.-II/III data list duces a spark.
b. Item 77: Accelerator pedal position sensor engine-A/T-ECU <A/T>.
(main)
Q: Are the check results normal? Ignition System − On-vehicle Service P.16-40).
NO : Perform the diagnosis code classified check Q: Is the check result normal?
abnormal data value (Refer to Inspection Inspection Procedure 31 P.13C-388).
TROUBLESHOOTING
13C-319
Inspection Procedure 11. The Engine Stalls when Decelerating
COMMENT ON TROUBLE SYMPTOM STEP 3. Check EGR valve (stepper motor) itself.
• Engine stall on deceleration is possibly caused by • Check EGR valve (stepper motor) itself [Refer to
insufficient air intake, improper air-fuel ratio due GROUP 17 − Emission Control System −
to failed exhaust gas recirculation system or Exhaust Gas Recirculation (EGR) System − EGR
other faults. Valve (Stepper Motor) Check <4G69> P.17-72].

• Throttle valve fouled STEP 4. Check throttle body (throttle valve
• Failed engine-ECU <M/T> portion) for contamination.
YES : Inspection chart for diagnosis code (Refer • Remove the spark plug and install it to the ignition
to P.13C-21). coil.
NO : Go to Step 2 . • Connect the ignition coil connector.
STEP 2. M.U.T.-II/III data list duces a spark.
(main)
Q: Is the check result normal? Ignition System − On-vehicle Service P.16-40).
abnormal data value (Refer to Inspection Inspection Procedure 31 P.13C-388).
TROUBLESHOOTING
Inspection Procedure 12: Engine Does Not Revole Up
COMMENT ON TROUBLE SYMPTOM STEP 3. Visual check of ignition spark.

• Failure is possibly caused by failed fuel system, • Remove the spark plug and install it to the ignition
throttle valve opening control system ignition sys- coil.
tem or other faults. • Connect the ignition coil connector.
PROBABLE CAUSE • At the engine start, check each spark plug pro-
• Failed ignition system duces a spark.
NO : Go to Step 4 .

Q: Diagnosis code set? YES : Check ignition circuit system (Refer to
YES : Inspection chart for diagnosis code (Refer Inspection Procedure 31 P.13C-388).
to P.13C-21). NO : Replace the spark plug.
NO : Go to Step 2 .

STEP 2. M.U.T.-II/III data list • Fuel pressure measurement P.13C-425).
(sub) NO : Repair.
(main)
TROUBLESHOOTING
13C-321
Inspection Procedure 13: Hesitation, Sag, Poor Acceleration, Stumble, Surge

• Failure is possibly caused by failed ignition sys- • Refer to Data list reference table P.13C-402.
tem, improper air-fuel ratio, throttle valve opening a. Idem 13: Intake air temperature sensor
control system improper compression pressure b. Item 14: Throttle position sensor (sub)
or other faults.
PROBABLE CAUSE d. Item 77: Accelerator pedal position sensor
• Failed air-fuel ratio control system (sub)
• Failed ignition system e. Item 78: Accelerator pedal position sensor
• Failed fuel system (main)
• Failed intake and exhaust system f. Item 79: Throttle position sensor (main)
• Failed emission control system g. Item 95: Manifold absolute pressure sensor
• Failed throttle valve opening control system Q: Are the check results normal?
• Throttle valve fouled YES : Go to Step 4 .
• Improper compression pressure NO : Perform the diagnosis code classified check
• Failed engine-ECU <M/T> Procedure for the sensor that has shown an
• Failed engine-A/T-ECU <A/T> abnormal data value (Refer to Inspection
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code • Refer to Data List Reference Table P.13C-402.
Q: Diagnosis code set? a. Item 25: Barometric pressure sensor
YES : Inspection chart for diagnosis code (Refer Q: Are the check results normal?
to P.13C-21). YES : Go to Step 5 .
NO : Go to Step 2 . NO : Replace engine-ECU <M/T> or
STEP 2. Check injector for operating sound.
• Check injector for operating sound (Refer to STEP 5. Check purge control solenoid valve
P.13C-435). itself.
Q: Can operating sound be heard? • Check purge control solenoid valve itself (Refer
YES : Go to Step 3 . to GROUP 17 − Emission Control System −
NO : Check the injector system of the defective Evaporative Emission Control System− Purge
cylinder. Control Solenoid Valve Check P.17-65).
(Refer to Code No. P0201: No. 1 Injector Q: Is the check result normal?
System P.13C-126). YES : Go to Step 6 .
(Refer to Code No. P0202: No. 2 Injector NO : Replace purge control solenoid valve.
System P.13C-131).
STEP 6. Check EGR valve (stepper motor) itself.
System P.13C-136).
System P.13C-141).
TROUBLESHOOTING
STEP 7. M.U.T.-II/III data list STEP 9. Check spark plug.

• Refer to Data List Reference Table P.13C-402. • Check spark plug itself (Refer to GROUP 16 −
a. Item 11: Cylinder 1, 4 oxygen sensor (front) Ignition System − On-vehicle Service P.16-40).
b. Item 39: Cylinder 2, 3 oxygen sensor (front) Q: Is the check result normal?
c. Item 59: Cylinder 1, 4 oxygen sensor (rear) YES : Check ignition circuit system (Refer to
d. Item 69: Cylinder 2, 3 oxygen sensor (rear) Inspection Procedure 31 P.13C-388).
NO : Perform the diagnosis code classified check STEP 10. Check throttle body (throttle valve
Procedure for the sensor that has shown an portion) for contamination.
abnormal data value (Refer to Inspection Q: Is the check result normal?
Chart for Diagnosis Code P.13C-21). YES : Go to Step 11 .
STEP 8. Visual check of ignition spark. (Refer to P.13C-425).
coil. STEP 11. Measure fuel pressure.
• Connect the ignition coil connector. • Measure fuel pressure (Refer to P.13C-425).
• At the engine start, check each spark plug pro- Q: Is the check result normal?
duces a spark.
NO : Repair.
NO : Go to Step 9 . STEP 12. Check compression pressure.
sure Check P.11E-15).
NO : Repair.
TROUBLESHOOTING
13C-323
Inspection Procedure 14. The Feeling of Impact or Vibration when Accelerating

• Failure is possibly caused by failed ignition leak • Remove the spark plug and install it to the ignition
with rise in spark plug-required voltage at accel- coil.
eration, throttle valve opening control system. • Connect the ignition coil connector.
• Failed ignition system duces a spark.
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code • Check spark plug itself (Refer to GROUP 16 −
Q: Diagnosis code set? Ignition System − On-vehicle Service P.16-40).
to P.13C-21). YES : Check ignition circuit system (Refer to
NO : Go to Step 2 . Inspection Procedure 31 P.13C-388).
(sub)
(main)
TROUBLESHOOTING
Inspection Procedure 15: The Feeling of Impact or Vibration when Decelerating

• Failure is possibly caused by insufficient air • Refer to Data List Reference Table P.13C-402.
intake due to failed idle speed control system. a. Item 14: Throttle position sensor (sub)
PROBABLE CAUSE
(sub)
(main)
• Failed engine-A/T-ECU <A/T> d. Item 79: Throttle position sensor (main)
Q: Diagnosis code set? Chart for Diagnosis Code P.13C-21).
to P.13C-21).
STEP 3. Check throttle body (throttle valve)
NO : Go to Step 2 .
contamination.

• Failure is possibly caused by failed detonation • Remove the spark plug and install it to the ignition
control, improper thermal value of spark plug or coil.
other faults. • Connect the ignition coil connector.
• Defective detonation sensor duces a spark.
• Failed detonation control system
YES : Check detonation sensor system (Refer to
Code No. P0325 P.13C-167).
NO : Go to Step 3 .

Q: Diagnosis code set? YES : Check ignition circuit system (Refer to
YES : Inspection chart for diagnosis code (Refer Inspection Procedure 31 P.13C-388).
to P.13C-21). NO : Replace the spark plug.
NO : Go to Step 2 .
TROUBLESHOOTING
13C-325
COMMENT ON TROUBLE SYMPTOM STEP 2. Measure output waveforms of crank

• Failure is possibly caused by failed crank angle angle sensor and camshaft position sensor (Use
sensor, failed camshaft position sensor, improper oscilloscope).
Connector: B-29
PROBABLE CAUSE
• Failed camshaft position sensor
• Improperly installed timing belt B-29 (GR)
3 2 1
DIAGNOSIS PROCEDURE Harness
STEP 1. M.U.T.-II/III diagnosis code Connector: B-106

B-106 (B)
to P.13C-21).
NO : Go to Step 2 .
3 2 1
Harness
side connector
AK304269 AB
Crank Angle Sensor

nect B-29 crank angle sensor intermediate con-
nector, and measure at pick-up harness.
• Engine: Idling
Camshaft Position Sensor
nect B-106 camshaft position sensor connector,
and measure at pick-up harness.
• Engine: Idling
OK: Output waveform timings of both sen-
sors are the same as the check procedure
(Refer to P.13C-419) using an oscilloscope.
NO : Go to Step 4 .
TROUBLESHOOTING
STEP 3. Check the trouble symptoms. STEP 7. Check camshaft position sensing
cylinder.
YES : Replace engine-ECU <M/T> or Q: Is the check result normal?
engine-A/T-ECU <A/T>. YES : Go to Step 8 .
NO : Intermittent malfunction (Refer to GROUP NO : Replace camshaft position sensing cylinder.
00 − How to Use
Troubleshooting/Inspection Service Points STEP 8. Replace crank angle sensor.
P.00-6). • After replacing the crank angle sensor, re-check
STEP 4. Check crank angle sensor and camshaft Q: Does trouble symptom persist?
position sensor mounted conditions. YES : Go to Step 9 .
Q: Is the check result normal? NO : Check end.
NO : Repair. STEP 9. Replace camshaft position sensor.
STEP 5. Check timing marks of timing belt. re-check the trouble symptoms.
YES : Go to Step 6 . YES : Replace engine-ECU <M/T> or
NO : Align timing marks. engine-A/T-ECU <A/T>.
00 − How to Use
STEP 6. Check crank shaft sensing blead.
NO : Replace crank shaft sensing blead.
Inspection Procedure 18: Run On (Dieseling)

PROBABLE CAUSE
P.13C-435).
• Failed injector
• Failed engine-ECU <M/T> Q: Does trouble symptom persist?
• Failed engine-A/T-ECU <A/T> YES : Replace engine-ECU <M/T> or
TROUBLESHOOTING
13C-327
Inspection Procedure 19: Odor, White Smoke, Black Smoke, and High-Concentration CO/HC during
Idling
COMMENT ON TROUBLE SYMPTOM STEP 3. Check ignition timing.

• Failure is possibly caused by improper air-fuel • Check ignition timing. (Refer to GROUP 11E −
ratio, deteriorated catalyst, failed ignition system, On-vehicle Service − Ignition Timing Check
failed fuel system, failed compression pressure or P.11E-12).
other faults.
NO : Check for offset ignition timing (Refer to
• Incorrect air/fuel ratio
• Failed intake and exhaust system STEP 4. M.U.T.-II/III data list
• Failed emission control system • Refer to Data List Reference Table P.13C-402.
• Failed compression pressure a. Item 12: Air flow sensor
• Failed catalytic converter b. Item 13: Intake air temperature sensor
• Failed engine-ECU <M/T> c. Item 21: Engine coolant temperature sensor
d. Item 95: Manifold absolute pressure sensor
DIAGNOSIS PROCEDURE Q: Are the check results normal?
STEP 1. M.U.T.-II/III diagnosis code Procedure for the sensor that has shown an
Q: Diagnosis code set? abnormal data value (Refer to Inspection
YES : Inspection chart for diagnosis code (Refer Chart for Diagnosis Code P.13C-21).
to P.13C-21).
NO : Go to Step 2 . STEP 5: M.U.T.-II/III data list
STEP 2. Check injector for operating sound. a. Item 25: Barometric pressure sensor
• Check injector for operating sound (Refer to Q: Are the check results normal?
P.13C-435). YES : Go to Step 6 .
Q: Can operating sound be heard? NO : Replace engine-ECU <M/T> or
YES : Go to Step 3 . engine-A/T-ECU <A/T>.
cylinder. STEP 6. Check air intake from intake hose and
(Refer to, Code No. P0201: No. 1 injector inlet manifold.
system P.13C-126).
(Refer to, Code No. P0202: No. 2 injector Q: Is the check result normal?
system P.13C-131).
NO : Repair.
(Refer to, Code No. P0203: No. 3 injector
system P.13C-136).
(Refer to, Code No. P0204: No. 4 injector STEP 7. Check for emission leakage from
system P.13C-141). exhaust manifold.
NO : Repair.
TROUBLESHOOTING
YES : Go to Step 9 . (Refer to GROUP 17 − Emission Control System
NO : Clean throttle body (throttle valve portion) − crankcase Emission Control System − Positive
(Refer to P.13C-425). Crankcase Ventilation (PCV) Valve Check
P.17-60).
STEP 9. M.U.T.-II/III data list Q: Is the check result normal?
• Refer to Data list reference table P.13C-402. YES : Go to Step 14 .
a. Item 11: Cylinder 1, 4 oxygen sensor (front) NO : Replace positive crankcase ventilation
b. Item 39: Cylinder 2, 3 oxygen sensor (front) valve.
c. Item 59: Cylinder 1, 4 oxygen sensor (rear)
d. Item 69: Cylinder 2, 3 oxygen sensor (rear) STEP 14. Check spark plug.
Q: Is the check result normal? Ignition System − On-vehicle Service P.16-40).
Procedure for the sensor that has shown an YES : Go to Step 15 .
abnormal data value (Refer to Inspection NO : Replace spark plug.
STEP 10. Check Purge control solenoid valve • Check ignition coil itself (Refer to GROUP 16 −
itself. Ignition System − On-vehicle Service − Ignition
• Check purge control solenoid valve itself (Refer Coil Check <4G69>P.16-39).
to GROUP 17 − Emission Control System − Q: Is the check result normal?
Evaporative Emission Control System − Purge YES : Go to Step 16 .
Control Solenoid Valve Check P.17-65). NO : Replace ignition coil.
YES : Go to Step 11 . STEP 16. Check compression pressure.
NO : Replace purge control solenoid valve. • Check compression pressure (Refer to GROUP
STEP 11. Check EGR valve (stepper motor) itself. sure Check P.11E-15).
• Check EGR valve (stepper motor) itself [Refer to Q: Is the check result normal?
GROUP 17 − Emission Control System − YES : Go to Step 17 .
Exhaust Gas Recirculation (EGR) System − EGR NO : Repair.
Q: Is the check result normal? STEP 17. Check injector for spraying condition.
YES : Go to Step 12 . • Check each injector for spray condition (Refer to
NO : Replace EGR valve (stepper motor). P.13C-435).
STEP 12. Measure fuel pressure. YES : Go to Step 18 .
• Measure fuel pressure (Refer to P.13C-425). NO : Replace injector.
YES : Go to Step 13 . STEP 18. Replace catalytic converter.
NO : Repair. • After replacing the catalytic converter, re-check
NO : Check end.
TROUBLESHOOTING
13C-329
Inspection Procedure 20: Battery Run Down
COMMENT ON TROUBLE SYMPTOM STEP 2. Connector check: B-30 alternator

Connector: B-30
PROBABLE CAUSE
• Failed battery
• Alternator G terminal short-circuited
B-30 (GR)
4 3 2 1
DIAGNOSIS PROCEDURE Harness side

STEP 1. Check battery voltage. Q: Is the check result normal?

• Measure battery voltage during cranking. YES : Go to Step 3 .
NO : Repair.
OK: 8 V or more
alternator connector.
Battery − On-vehicle Service − Battery Test Connector: B-30
P.54A-7).
B-30 (GR)
4 3 2 1
Harness side

side.
OK: System voltage
NO : Go to Step 4 .
TROUBLESHOOTING
STEP 4. Connector check: C-303 ignition switch STEP 5. Connector check: C-140 engine-ECU
connector <M/T> connector or engine-A/T-ECU <A/T>
connector
Connector: C-303
Connector: C-140
C-303 <L. H. Drive Vehicle>
3 2 1 C-140 (GR)
6 5 4

Connector: B-30
C-140 (GR)
B-30 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
4 3 2 1 51 50 49 4847 46 4544
58 57 5655 54 5352
Harness side
connector AK304037AB Harness side connector
AK304274 AB
YES : Check intermediate connectors B-19, C-04,
C-05, C-105, C-203 and C-205, and repair if YES : Go to Step 6 .
necessary. If intermediate connectors are NO : Repair.
B-30 (terminal No. 3) alternator connector
and C-303 (terminal No. 2) ignition switch
connector.
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13C-331
engine-ECU <M/T> connector or engine-A/T-ECU No. 45) engine-ECU <M/T> connector or
<A/T> connector engine-A/T-ECU <A/T> connector and B-30
(terminal No. 1) alternator connector.
Connector: C-140
C-140 (GR)
C-140 (GR)

C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 34 33 32 31
58 57 5655 54 5352 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544

AK304274 AB
side.
Connector: B-30
OK: System voltage
NO : Go to Step 7 .
4 3 2 1
Harness side

YES : replace alternator.
NO : Repair.
TROUBLESHOOTING
STEP 8. Perform voltage measurement at C-140 STEP 9. Check the trouble symptoms.
engine-ECU <M/T> connector or engine-A/T-ECU Q: Does trouble symptom persist?
<A/T> connector. YES : Replace engine-ECU <M/T> or
Connector: C-140 engine-A/T-ECU <A/T>.
<L. H. Drive Vehicle> 00 − How to Use
P.00-6).
C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

OFF causes the voltage to increase.
NO : Replace alternator.
TROUBLESHOOTING
13C-333

• Failed fan controller Inspection Procedure 26 P.13C-354).
• Failed engine-ECU <M/T> Engine cold state: At ambient temperature
• Failed engine-A/T-ECU <A/T> (atmospheric temperature) or equivalent.
Engine hot state: At 80 − 120°C
DIAGNOSIS PROCEDURE
STEP 1. M.U.T.-II/III diagnosis code NO : Check engine coolant temperature sensor
Q: Diagnosis code set? system (Refer to Code No. P0115
YES : Inspection chart for diagnosis code (Refer P.13C-47).
to P.13C-21).
NO : Go to Step 2 . STEP 5. Check thermostat.
• Check thermostat (Refer to GROUP 14 − Ther-
STEP 2. Check engine coolant mostat − Thermostat Inspection P.14-24).
NOTE: If engine coolant level falls too early, check Q: Is the check result normal?
for leaky spots, and repair if necessary. YES : Go to Step 6 .
• Check engine coolant (Refer to GROUP 14 − NO : Replace thermostat.
On-vehicle Service − Engine Coolant Leak Check
P.14-17). STEP 6. Check water pump.
Q: Is the check result normal? • Check water pump.
NO : Replace or add engine coolant. YES : Replace radiator.
TROUBLESHOOTING
5V
A-20
(MU802322)
Fan controller
1 2 3
L-W
7
A-14
L-W
17
C-139
(MU803802)
5 6 7 8 9 10111213 Engine-A/T-ECU <A/T>
14 15 16 1718 19 20
21 22 232425 2627
Wire colour code

AK401090 AC

<M/T> or engine-A/T-ECU <A/T> (terminal No. connector contact
17). • Failed engine-ECU <M/T>
FUNCTION
<A/T> inputs a duty signal suitable for the engine
coolant temperature, vehicle speed and A/C
switch position to the fan controller. In response
to the signal, the fan controller controls the rotat-
ing speeds of the radiator fan and A/C condenser
fan (The fan speed becomes higher as the aver-
age voltage of the terminal comes nearer to 5V).
TROUBLESHOOTING
13C-335
DIAGNOSIS PROCEDURE STEP 2. Check at C-139 engine-ECU <M/T>
Connector: C-139
connector. <L. H. Drive Vehicle>
Connector: C-139
C-139 (GR)
C-139 (GR)
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
4 3 2 1
13 12 1110 9 8 7 6 5 AK304262 AB
2019 18 17 16 15 14
2726 2524 23 22 21
side.
AK304262 AB • Ignition switch: ON
• Short-circuit terminal No. 17 to earth.
YES : Go to Step 2 . OK: Fan motor stops rotating.
NO : Go to Step 4 .

00 − How to Use
P.00-6).
TROUBLESHOOTING
STEP 4. Perform voltage measurement at C-139 STEP 6. Check harness between A-20 (terminal
engine-ECU <M/T> connector or engine-A/T-ECU No. 2) fan controller connector and C-139
<A/T> connector. (terminal No. 17) engine-ECU <M/T> connector or
Connector: C-139
Connector: A-20
C-139 (GR) A-20 (GR)
3 2 1
<R. H. Drive Vehicle> Harness side

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
side.
• Ignition switch: ON C-139 (GR)
OK: 4.9 − 5.1 V
YES : Replace fan controller. 4 3 2 1
13 12 1110 9 8 7 6 5
NO : Go to Step 5 . 2019 18 17 16 15 14
2726 2524 23 22 21
STEP 5. Connector check: A-20 fan controller
AK304262 AB
connector
Connector: A-20
A-20 (GR)
NO : Repair.
3 2 1
Harness side

NO : Repair.
TROUBLESHOOTING
13C-337

• Failure is possibly caused by short /overcharged • Item 28: A/C switch
A/C refrigerant, failed A/C control system, failed a. Engine: Idling
fan control system or other faults. b. A/C set temperature:
PROBABLE CAUSE
25°C or more
• Short or overcharged A/C refrigerant Maximum Hot when temperature in cabin is
• Failed A/C compressor relay 25°C or less
• Failed A/C-ECU OK:
• Failed engine-ECU <M/T> ON (when A/C is ON)
• Failed engine-A/T-ECU <A/T> OFF (when A/C is OFF)
Procedure 27 P.13C-361).
Q: Diagnosis code set? STEP 4. M.U.T.-II/III data list
• Item 49: A/C relay
to P.13C-21).
NO : Go to Step 2 .
a. Engine: Running at idle
STEP 2. A/C compressor magnet clutch 25°C or more.
operation check. Maximum Hot when temperature in cabin is
• Engine: Idling 25°C or less.
OK:
ON (when A/C is ON)
25°C or more
or less Q: Is the check result normal?
OK: YES : Check A/C system (Refer to GROUP 55A −
Magnet clutch active (when A/C is ON) Troubleshooting check chart for trouble
Magnet clutch inactive (when A/C is OFF) symptoms P.55A-5).
Q: Is the check result normal? Inspection Procedure 28 P.13C-366).
NO : Go to Step 3 .
STEP 5. Check charged amount of A/C
refrigerant.
• Check charged amount of A/C refrigerant (Refer
to GROUP 55A − On-vehicle Service − Sight
Glass Refrigerant Level Test P.55A-49).
NO : Adjust charged amount of A/C refrigerant.
TROUBLESHOOTING

• Item 21: Fan controller
NO : Check fan control relay system (Refer to
TROUBLESHOOTING
13C-339
Inspection Procedure 24: Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Power Supply, Engine Control
Relay, Ignition Switch-IG1 System
Battery
Ignition switch
9 Relay box LOCK C-303
20A R
ST ACC 123
IG1 IG2 456
W-B
2
A-14
L-B
5 (*1)
6 (*2) C-203
6
W-B
W-B 8
J/B
7.5A
4 3
B-17X 1
Engine C-202
1 2 control
relay
3 4
L-B
1 2
4 C-106
10
J/C (2) Y-G W-B
C-17
9 10 L-B
R R
42 33 34 43 57 58 50
B B Power Battery Engine-ECU <M/T>

source backup Engine-A/T-ECU <A/T>
C-140
(MU803803)
NOTE 3132 33 34
*2: R.H. drive vehicles 444546474849 50 51
5253 545556 57 58
Wire colour code
AK401081 AC
TROUBLESHOOTING

trol relay (terminal No. 3 and 4).
• The engine-ECU <M/T> or engine-A/T-ECU Connector: B-17X
<A/T> (terminal No. 57) makes the power transis- B-17X
tor in the unit be in "ON" position and makes cur- Relay box’s
rents go on the engine control relay coil, and that triangle marks
makes the relay be in "ON" position.
the battery voltage is supplied to the engine-ECU
4 3
34 and No. 43), the sensor and the actuator from Harness
• When the ignition switch ON signal is input to the NO : Repair.
engine-ECU <M/T> or engine-A/T-ECU <A/T>,
<A/T> places the engine control relay in the ON STEP 3. Check engine control relay.
position. Accordingly, the battery voltage is sup- • Check engine control relay (Refer to P.13C-429).
plied to the engine-ECU <M/T> or Q: Is the check result normal?
engine-A/T-ECU <A/T>, sensor and actuator. YES : Go to Step 4 .
NO : Replace engine control relay.
PROBABLE CAUSE
• Failed engine control relay STEP 4. Perform voltage measurement at B-17X
• Open/short circuit in engine control relay circuit or engine control relay connector.
• Failed engine-ECU <M/T> Connector: B-17X
• Failed engine-A/T-ECU <A/T> B-17X
Relay box’s
STEP 1. Check battery voltage. 2 1

• Measure battery voltage during cranking. 4 3
OK: 8 V or more Harness
YES : Go to Step 2 . • Remove relay, and measure at relay box side.
NO : Check battery (Refer to GROUP 54A − • Voltage between terminal No. 3 and earth, also
Battery − On-vehicle Service − Battery test between terminal No. 4 and earth.
P.54A-7). OK: System voltage
harness between B-17X (terminal No. 3 and
terminal No. 4) engine control relay
connector and battery.
open/short circuit.
TROUBLESHOOTING
13C-341
C-140 (GR) C-140 (GR)
C-140 (GR) C-140 (GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK304274 AB AK304274 AB

OK: System voltage
YES : Check and repair C-140 engine-ECU <M/T>
connector.
NO : Go to Step 6 .
TROUBLESHOOTING
STEP 7. Perform voltage measurement at C-140 STEP 9. Check ignition switch.

Connector: C-303
<A/T> connector.
Connector: C-140
C-303
3 2 1
C-140 (GR) 6 5 4
<R. H. Drive Vehicle> Connector: C-140

C-140 (GR)
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB
• Measure engine-ECU <M/T> or engine-A/T-ECU C-140 (GR)

• Voltage between terminal No. 50 and earth. 34 33 32 31
43 42 4140 39 38 37 36 35
OK: System voltage 51 50 49 4847 46 4544
58 57 5655 54 5352
NO : Go to Step 8 . AK304274 AB

STEP 8. Connector check: C-303 ignition switch Ignition Switch − Ignition Switch − Inspection
connector P.54A-30).
YES : Check intermediate connector C-106,
C-303 intermediate connector is normal, check and
repair harness between C-303 (terminal No.
2) ignition switch connector and C-140
3 2 1 connector or engine-A/T-ECU <A/T>
6 5 4 connector.
Harness side connector AK304334 AB • Check output line for open/short
circuit and damage.
Q: Is the check result normal? NO : Replace ignition switch.
NO : Repair.
TROUBLESHOOTING
13C-343
STEP 10. Perform voltage measurement at C-140 STEP 11. Check harness between B-17X (terminal
engine-ECU <M/T> connector or engine-A/T-ECU No. 3 and No. 4) engine control relay connector
<A/T> connector. and battery.
<L. H. Drive Vehicle> B-17X

Relay box’s
triangle marks
C-140 (GR)
2 1
4 3
Harness
C-140 (GR)
34 33 32 31 NO : Repair.
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB
Connector: B-17X
B-17X
Relay box’s
triangle marks
2 1
4 3
Harness

• Ignition switch: OFF
OK: System voltage
circuit.
TROUBLESHOOTING
No. 2) ignition switch connector and C-140 No. 33 and No. 42) engine-ECU <M/T> connector
(terminal No. 50) engine-ECU <M/T> connector or or engine-A/T-ECU <A/T> connector and body
engine-A/T-ECU <A/T> connector. earth.
C-303
C-140 (GR)
3 2 1
6 5 4
Connector: C-140
C-140 (GR)
C-140 (GR) 34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
<R. H. Drive Vehicle> AK304274 AB

C-140 (GR) YES : Replace engine-ECU <M/T> or
engine-A/T-ECU <A/T>
NO : Repair.
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

connectors C-106, C-202 and C-203 and repair if
necessary.
NO : Repair.
TROUBLESHOOTING
13C-345
Fuel pump and gauge unit (main) circuit
Battery
C-303
W R LOCK
123 Ignition switch
456 ST ACC
IG1 IG2
24
Relay box
15A 2
W
L-B
C-116
41
W
C-202 C-203
2 6
4 3 1 3 8
7.5A
C-215 C-213
Fuel Fuel
3 4 3 4 pump 1 2 pump 4 2
relay (1) relay (2)
C-215 C-213
C-205 11 C-209 1 C-205

14
B-L
D-24 6
B
B-L G
Fuel pump
and gauge 5
unit (main)
D-16
(MU802058) M
C-106
1 2 3 8
4 5 4
B
D-24 4
G
B
16
C-139
(MU803802)
1 2 3 4
5 6 7 8 9 10111213 Engine-ECU <M/T>
14 15 16 1718 19 20 Engine-A/T-ECU <A/T>
21 22 232425 2627
Wire colour code

AK401082 AC
TROUBLESHOOTING

• The battery voltage is applied to the fuel pump • Failed fuel pump relay
relay (1) (terminal No. 3) form the ignition switch • Failed fuel pump
and is earthed to the vehicle body from the fuel • Open/short circuit in fuel pump drive circuit or
pump relay (1) (terminal No. 2). loose connector contact
• The battery voltage is applied to the fuel pump • Failed engine-ECU <M/T>
relay (1) (terminal No. 4) and to the fuel pump • Failed engine-A/T-ECU <A/T>
(1) (terminal No. 1). DIAGNOSIS PROCEDURE
• The battery voltage is applied to the fuel pump
relay (2) (terminal No. 3) from the ignition switch.
The engine-ECU <M/T> or engine-A/T-ECU
connector
tor in the unit be in "ON" position and makes cur-
rents go on the fuel pump relay (2) coil, and that Connectors: C-213, C-215
makes the relay be in "ON" position.
• When the fuel pump relay (2) is in "ON" position,
Junction block’s
the battery voltage is supplied to the fuel pump triangle marks C-215
(low pressure) from the fuel pump relay (2) (ter-
minal No. 4). C-213
2 1
FUNCTION 4 3
• When the ignition switch ON signal is input to the Harness side
engine-ECU <M/T> or engine-A/T-ECU <A/T>, connector AK304339 AB
<A/T> places the fuel pump relay in the "ON" Q: Is the check result normal?
position. Accordingly, the battery voltage is sup- YES : Go to Step 2 .
NO : Repair.
plied to the fuel pump.
STEP 2. Check fuel pump relay.

• Fuel pump relay, continuity check (Refer to
P.13C-430).
TROUBLESHOOTING
13C-347
STEP 3. Perform resistance measurement at STEP 5. Connector check: C-303 ignition switch
C-215 fuel pump relay (1) connector. connector
Connectors: C-215 Connector: C-303
Junction block’s C-303

2 1
3 2 1
4 3
6 5 4
Harness side

Connectors: C-215
side.
OK: Continuity (2 Ω or less) Junction block’s
NO : Check intermediate connector C-205, and 2 1
repair if necessary. If intermediate 4 3
connector is normal, check and repair Harness side
connector
harness between C-215 (terminal No. 2) AK304339 AC
fuel pump relay (1) connector and body

earth. Q: Is the check result normal?
and damage.
STEP 4. Perform voltage measurement at C-215 fuel pump relay (1) connector and C-303
fuel pump relay (1) connector. (terminal No. 2) ignition switch connector.
Connectors: C-215
circuit and damage.
NO : Repair.
Junction block’s
2 1
4 3
Harness side

side.
OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
Connectors: C-215 Connector: C-303
Junction block’s C-303

2 1
3 2 1
4 3
6 5 4
Harness side

Connectors: C-213
side.
OK: System voltage Junction block’s
triangle marks
NO : Check intermediate connectors C-116 and 2 1
C-202, and repair if necessary. If 4 3
intermediate connectors are normal, check Harness side
connector
and repair harness between C-215 (terminal AK304339 AD

open/short circuit.
Connectors: C-213
connector.
circuit.
Junction block’s NO : Repair.
triangle marks
C-213
2 1
4 3
Harness side
connector AK304339 AD

side.
OK: System voltage
NO : Go to Step 8 .
TROUBLESHOOTING
13C-349
<M/T> connector or engine-A/T-ECU <A/T> engine-ECU <M/T> connector or engine-A/T-ECU
connector <A/T> connector.
C-139 (GR) C-139 (GR)
C-139 (GR) C-139 (GR)
4 3 2 1 4 3 2 1
13 12 1110 9 8 7 6 5 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14 2019 18 17 16 15 14
2726 2524 23 22 21 2726 2524 23 22 21
AK304262 AB AK304262 AB
Q: Is the check result normal? Connectors: C-213

NO : Repair.
Junction block’s
triangle marks
C-213
2 1
4 3
Harness side

side.
OK: System voltage
connector.
circuit.
TROUBLESHOOTING
STEP 11. Connector check: D-16 fuel pump STEP 12. Perform voltage measurement at D-16
connector fuel pump connector.
Connector: D-16 Connector: D-16
D-16 (GR) D-16 (GR)

3 2 1 3 2 1
5 4 5 4
connector AK203431AC connector AK203431AC

NO : Repair. <L. H. Drive Vehicle>
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

side.
• Using a jumper wire, connect C-139 (terminal No.
engine-A/T-ECU <A/T> connector and earth.
OK: System voltage
TROUBLESHOOTING
13C-351
STEP 13. Check harness between C-215 (terminal STEP 15. Perform resistance measurement at
No. 1) fuel pump relay (1) connector and C-213 D-16 fuel pump connector.
Connector: D-16
Junction block’s
D-16 (GR)
C-213 3 2 1
2 1 5 4
4 3 Harness side
Harness side connector AK203431AC
• Check power supply line for open/short circuit. side.
YES : Go to Step 14 OK: Continuity (2 Ω or less)
STEP 14. Check harness between C-213 (terminal NO : Check intermediate connector D-24, and
No. 4) fuel pump relay (2) connector and D-16 repair if necessary. If intermediate
(terminal No. 5) fuel pump connector. connector is normal, check and repair
harness between D-16 (terminal No. 4) fuel
Connectors: C-213 pump connector and body earth.
Junction block’s and damage.
triangle marks

C-213
2 1 connector
4 3
Connector: C-303
Harness side
C-303
Connector: D-16
3 2 1
6 5 4
D-16 (GR) Harness side connector AK304334 AB
3 2 1
connector AK203431AC NO : Repair.
connectors D-209 and D-24, and repair if necessary.
age.
NO : Repair.
TROUBLESHOOTING
No. 2) ignition switch connector and C-215 No. 1) fuel pump relay (1) connector and C-213
(terminal No. 3) fuel pump relay (1) connector. (terminal No. 1) fuel pump relay (2) connector.
Connector: C-303 Connectors: C-213, C-215
C-303 Junction block’s

C-213
2 1
3 2 1
4 3
6 5 4
Harness side
Harness side connector AK304334 AB connector AK304339 AB

Connectors: C-215
Junction block’s NO : Repair.

2 1 No. 2) ignition switch connector and C-213
4 3 (terminal No. 3) fuel pump relay (2) connector.
Harness side
connector AK304339 AC Connector: C-303

connector C-203, and repair if necessary. C-303
NO : Repair. 6 5 4
C-215 (terminal No. 4) fuel pump relay (1) Connectors: C-213
connector.
Connectors: C-215 Junction block’s
triangle marks
Junction block’s
C-215 2 1
4 3
2 1 Harness side
4 3
Harness side • Check power supply line for damage.
connectors C-116 and C-202, and repair if neces- NO : Repair.
sary.
NO : Repair.
TROUBLESHOOTING
13C-353
No. 4) fuel pump relay (2) connector and D-16 No. 2) fuel pump relay (2) connector and C-139
(terminal No. 5) fuel pump connector. (terminal No. 16) engine-ECU <M/T> connector or
Connectors: C-213
Connectors: C-213
Junction block’s
triangle marks Junction block’s
triangle marks
C-213
2 1
C-213
4 3 2 1
Harness side 4 3
connector AK304339 AD Harness side
CONNECTOR: C-303
Connector: C-139
C-303
3 2 1
6 5 4 C-139 (GR)
Harness side
connector
AK300304 AB
NOTE: Before checking harness, check intermediate <R. H. Drive Vehicle>

C-139 (GR)
YES : Replace fuel pump.
NO : Repair.
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

sary.
YES : Replace fuel pump
NO : Repair.
TROUBLESHOOTING
Battery
9
Relay box
20A
W-B A-14
5 (*1)
16 (*2)
W-B
W-B
4 3
B-17X

3 4
1 2
4 To engine-ECU <M/T>
C-17
5
R
L-W A-14
11
R
4 3
A-10X
2 Fan control relay
1 3
4
2 1
B
L
A-20
(MU802322) NOTE
circuit *1: L.H. drive vehicles
1 2 3 *2: R.H. drive vehicles
Wire colour code

AK401083 AB
TROUBLESHOOTING
13C-355
relay (terminal No. 3) from the engine control On−vehicle Service − Fan Control Relay Continu-
relay (terminal No. 1) and is earthed to the vehi- ity Check P.14-19).
1).
• When the fan control relay is in "ON" position, the
battery voltage is supplied to the fan controller STEP 3. Perform resistance measurement at
(terminal No. 3) from the fan control relay (termi- A-10X fan control relay connector.
nal No. 2). Connector: A-10X
FUNCTION
the fan control relay is also simultaneously placed A-10X
in "ON" position. Accordingly, the battery voltage
is supplied to the fan controller. 2
3 1
PROBABLE CAUSE 4
Harness
• Failed fan control relay side connector AK304340 AB
• Failed radiator fan motor • Remove relay and measure at relay box side.
• Failed condenser fan motor • Resistance between terminal No. 1 and earth.
• Open/short circuit in fan control relay circuit or OK: Continuity (2 Ω or less)
loose connector contact Q: Is the check result normal?
• Failed engine-A/T-ECU <A/T> NO : Check and repair harness between A-10X
(terminal No. 1) fan control relay connector
DIAGNOSIS PROCEDURE and body earth.
and damage.
STEP 1. Connector check: A-10X fan control
relay connector
Connector: A-10X
Connector: A-10X
A-10X
A-10X
2
3 1
4
Harness 2
3 1
4
Harness
NO : Repair. • Remove relay and measure at relay box side.
OK: System voltage
NO : Go to Step 5 .
TROUBLESHOOTING
Connector: B-17X Connector: A-10X
B-17X
Relay box’s
triangle marks A-10X
2 1
2
3 1
4 3
4
Harness Harness

Connector: A-10X
OK: System voltage
A-10X Q: Is the check result normal?
NO : Check and repair harness between battery
2 and A-10X (terminal No. 4) fan control relay
3 1
4 connector.
Harness • Check power supply line for
side connector AK304340 AB open/short circuit.
connectors are normal, check and repair Connector: A-20
open/short circuit. A-20 (GR)
NO : Repair.
3 2 1
Harness side

NO : Repair.
TROUBLESHOOTING
13C-357
Connector: A-20 Connector: B-17X
B-17X
Relay box’s
triangle marks
A-20 (GR)
2 1
3 2 1 4 3
Harness side Harness
connector AK203423 AC side connector AK304152 AB

OK: System voltage
NO : Go to Step 9 .
Connector: B-17X
B-17X
STEP 9. Check harness between A-10X (terminal
No. 2) fan control relay connector and A-20 Relay box’s
triangle marks
Connector: A-10X 2 1
4 3
Harness
A-10X side connector AK304152 AB
Connector: A-10X
2
3 1
4
Harness
side connector AK304340 AB A-10X
Connector: A-20
2
3 1
4
Harness
A-20 (GR)
3 2 1 • Check power supply line for damage.
Harness side
TROUBLESHOOTING
STEP 12. Connector check: C-139 engine-ECU STEP 13. Fan motor drive test.
Connector: C-139
C-139 (GR)
C-139 (GR)

C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
4 3 2 1
2019 18 17 16 15 14
2726 2524 23 22 21 AK304262 AB
• Disconnect C-139 engine-ECU <M/T> connector
AK304262 AB
or engine-A/T-ECU <A/T> connector.

• Item 21: Fan controller
00 − How to Use
P.00-6).
TROUBLESHOOTING
13C-359
STEP 15. Perform voltage measurement at C-139 STEP 16. Check harness between A-10X
engine-ECU <M/T> connector or engine-A/T-ECU (terminal No. 4) fan control relay connector and
<A/T> connector. battery.
Connector: C-139 Connector: A-10X
A-10X
C-139 (GR)
2
3 1
4
Harness
C-139 (GR)
NO : Repair.
4 3 2 1 STEP 17. Check harness between A-10X

13 12 1110 9 8 7
2019 18 17 16
6
15
5
14
2726 2524 23 22 21 A-20 (terminal No. 3) fan controller connector.
Connector: A-10X
AK304262 AB

side. A-10X
OK: 4.9 − 5.1 V 3
2
1
Q: Is the check result normal? 4
Harness
YES : Go to Step 16 . side connector AK304340 AB
Connector: A-20
A-20 (GR)
3 2 1
Harness side

NO : Repair.
TROUBLESHOOTING

Connector: A-20
A-20 (GR)
3 2 1
Harness side
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-361
A/C Switch circuit

C-06
(MU801584)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A/C-ECU
C-26
(MU801584)
21 22 23 24 25 26 27 28
29 30 31 32 33 34 35 36
C-06
4 <Manual A/C>
G-B C-26
34 <Auto A/C>
C-104
7
G-B
69
C-141
(MU803804)
6162 6364
656667686970717273 Engine-ECU <M/T>
747576777879808182 Engine-A/T-ECU <A/T>
8384 858687 8889
Wire colour code

AK401088 AB

<M/T> or engine-A/T-ECU <A/T> (terminal No. • Failed A/C system
69) from the A/C-ECU (terminal No. 4) <Manual • Open/short circuit in A/C circuit or loose connec-
A/C> or A/C-ECU (terminal No. 34) <Auto A/C>. tor contact
FUNCTION • Failed engine-A/T-ECU <A/T>
<M/T> or engine-A/T-ECU <A/T> from the
A/C-ECU. In response to the signal, the
controls the A/C compressor relay.
TROUBLESHOOTING

A/C-ECU <Manual A/C> connector or C-26
STEP 1. Perform voltage measurement at C-141 A/C-ECU <Auto A/C> connector.
<A/T> connector.
Connector: C-141
10 9 8 7 6 5 4 3 2 1
C-141(GR) 20 19 18 17 16 15 14 13 12 11
AK304341
Connector: C-26
<R. H. Drive Vehicle> <Auto A/C>
C-141 (GR)
C-26 (B)
28 27 26 25 24 23 22 21
6463 62 61 36 35 34 33 32 31 30 29
7372 7170 69 6867 6665
82 818079 78 7776 7574 Harness side connector AK304342 AB
8988 87 86 85 8483
Harness side connector • Measure A/C-ECU terminal voltage.
AK304154 AB • Engine: Idling
• Measure engine-ECU <M/T> or engine-A/T-ECU Maximum Cool when temperature in cabin is
<A/T> terminal voltage. 25°C or more
• Engine: Running at idle Maximum Hot when temperature in cabin is 25°C
• A/C set temperature: or less
Maximum Cool when temperature in cabin is • Voltage between terminal No. 4 and earth <Man-
25°C or more ual A/C>
Maximum Hot when temperature in cabin is 25°C • Voltage between terminal No. 34 and earth <Auto
or less A/C>
OK: System voltage
OK:
System voltage (when A/C is ON) Q: Is the check result normal?
0.5 V or less (when A/C is OFF) YES : Go to Step 5 .
NO : Go to Step 3 .
NO : Go to Step 2 .
TROUBLESHOOTING
13C-363
STEP 3. Connector check: C-06 A/C-ECU STEP 4. Check harness between C-06 (terminal
<Manual A/C> connector or C-26 A/C-ECU <Auto No. 4) A/C-ECU <Manual A/C> connector or C-26
A/C> connector and C-141 engine-ECU <M/T> (terminal No. 34) A/C-ECU <Auto A/C> connector
connector or engine-A/T-ECU <A/T> connector and C-141 (terminal No. 69) engine-ECU <M/T>
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
AK304341
AK304341
Connector: C-26
<Auto A/C> Connector: C-26
<Auto A/C>
C-26 (B)
C-26 (B)
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
28 27 26 25 24 23 22 21
Connector: C-141
C-141(GR)

C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING

<Auto A/C>
C-26 (B)
C-141(GR)
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-141 (GR)
Connector: C-141
6463 62 61 C-141(GR)
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB <R. H. Drive Vehicle>
C-141 (GR)
Troubleshooting − Check Chart for Trouble 6463 62 61
Symptoms P.55A-5). 7372 7170 69 6867 6665
82 818079 78 7776 7574
NO : Repair. 8988 87 86 85 8483
AK304154 AB
STEP 5. Connector check: C-06 A/C-ECU
<Manual A/C> connector or C-26 A/C-ECU <Auto Q: Is the check result normal?
A/C> connector and C-141 engine-ECU <M/T> YES : Check intermediate connector C-104, and
connector or engine-A/T-ECU <A/T> connector repair if necessary. If intermediate
<Manual A/C> or C-26 (terminal No. 34)
<Auto A/C> A/C-ECU connector and C-141
connector.
10 9 8 7 6 5 4 3 2 1 • Check output line for open circuit.
20 19 18 17 16 15 14 13 12 11 NO : Repair.
AK304341
TROUBLESHOOTING
13C-365
STEP 6. Connector check: C-141 engine-ECU STEP 7. M.U.T.-II/III data list
<M/T> connector or engine-A/T-ECU <A/T> • Item 28: A/C switch
connector a. Engine: Idling
Connector: C-141
<L. H. Drive Vehicle> 25°C or more.
25°C or less.
C-141(GR) OK:
ON (when A/C is ON)
<R. H. Drive Vehicle> YES : Intermittent malfunction (Refer to GROUP
C-141 (GR) 00 − How to Use
P.00-6).
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB

NO : Repair.
TROUBLESHOOTING
Ignition switch
C-303
R LOCK
1 2 3
4 5 6 ST ACC
IG1 IG2
4
L-R
C-203
2
Battery
W 5 J/B
7.5A
10 C-205
Relay box 16 (*1) or
10A C-202
L-R 13 (*2)
B-R
A-14 C-106
9 11
B-R L-R
4 3
B-18X

3 4
1 2
A/C-ECU
B-W G
1 8
Engine-ECU <M/T>
A/C compressor
temperature
switch C-139
B-27 (MU803802)
MU802653
1 2 3 4
5 6 7 8 9 10111213
1 14 15 16 1718 19 20
Magnetic 21 22 232425 2627
clutch
NOTE
Wire colour code
AK401209 AC
TROUBLESHOOTING
13C-367
OPERATION STEP 1. Connector check: B-18X A/C
• The battery voltage is applied to the A/C com- compressor relay connector
pressor relay (terminal No. 4).
• The battery voltage is applied to the A/C com- Connector: B-18X
pressor relay (terminal No. 3) from the ignition B-18X
switch. The engine-ECU <M/T> or Relay box’s
engine-A/T-ECU <A/T> (terminal No. 8) makes triangle marks
tion and makes currents go on the A/C compres- 2 1
sor relay coil, and that makes the relay be in "ON"
4 3
position.
• When the A/C compressor is in "ON" position, the Harness
battery voltage is supplied to the A/C compressor
(terminal No. 1) from the A/C compressor relay Q: Is the check result normal?
assembly (terminal No. 1). YES : Go to Step 2 .
NO : Repair.
FUNCTION
• When the A/C switch "ON" signal is input to the
engine-ECU <M/T> or engine-A/T-ECU <A/T>, STEP 2. A/C compressor relay check.
the engine-ECU <M/T> or engine-A/T-ECU • Check A/C compressor relay (Refer to GROUP
<A/T> places the A/C compressor relay in the 55A − On-vehicle Service P.55A-55).
"ON" position. Accordingly, the battery voltage Q: Is the check result normal?
supplied to the A/C compressor operates the YES : Go to Step 3 .
magnet clutch. NO : Replace A/C compressor relay.
PROBABLE CAUSE STEP 3. Perform voltage measurement at B-18X

• Failed A/C compressor relay A/C compressor relay connector.
• Failed A/C compressor magnet clutch
• Open/short circuit in A/C compressor relay circuit Connector: B-18X
or loose connector contact B-18X
• Failed engine-ECU <M/T> Relay box’s
• Failed engine-A/T-ECU <A/T> triangle marks
NOTE: . 4 3
*1
: L.H. drive vehicles Harness
*2: R.H. drive vehicles side connector AK304343 AB

OK: System voltage
NO : Go to Step 4 .
TROUBLESHOOTING
B-18X
C-303 Relay box’s

triangle marks
2 1
3 2 1
4 3
6 5 4
Harness
Harness side connector AK304334 AB side connector AK304343 AB

Connector: B-18X
B-18X
OK: System voltage
Relay box’s
2 1
Harness harness between B-18X (terminal No. 4)
side connector AK304343 AB A/C compressor relay connector and
battery.
open/short circuit.
C-202*2, C-203 and C-205 *1, and repair if
normal, check and repair harness between STEP 6. Connector check: B-27 A/C compressor
B-18X (terminal No. 3) A/C compressor assembly connector
relay connector and C-303 (terminal No. 4) Connector: B-27
ignition switch connector. Harness 1
• Check power supply line for side connector
open/short circuit.
NO : Repair.
B-27(B)
AK304344 AB

NO : Repair.
TROUBLESHOOTING
13C-369
A/C compressor assembly connector. engine-ECU <M/T> connector or engine-A/T-ECU
<A/T> connector.
Connector: B-27
Harness 1
Connector: C-139
side connector
B-27(B) C-139 (GR)
AK304344 AB

Connector: B-18X
B-18X
Relay box’s C-139 (GR)

triangle marks
2 1
4 3 2 1
4 3 13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
Harness 2726 2524 23 22 21
side. • Disconnect connector, and measure at harness
• Remove B-18X (terminal No. 1 and No. 4) A/C side.
compressor relay and short-circuit of harness • Ignition switch: ON
side connector. • Voltage between terminal No. 8 and earth.
• Voltage between terminal No. 1 and earth. OK: System voltage
(terminal No. 1) A/C compressor assembly
connector and B-18X (terminal No. 1) A/C
compressor relay connector.
circuit.
TROUBLESHOOTING
STEP 9. Connector check: C-139 engine-ECU STEP 10. Check harness between B-18X
<M/T> connector or engine-A/T-ECU <A/T> (terminal No. 2) A/C compressor relay connector
Connector: C-139
Connector: B-18X
B-18X
Relay box’s
triangle marks
C-139 (GR)
2 1
4 3

4 3 2 1
13 12 1110 9 8 7 6 5 C-139 (GR)
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
13C-371
STEP 11. M.U.T.-II/III data list STEP 13. Check harness between B-18X
• Item 49: A/C relay (terminal No. 2) A/C compressor relay connector
a. Engine: Idling and C-139 (terminal No. 8) engine-ECU <M/T>
b. A/C set temperature: connector or engine-A/T-ECU <A/T> connector.
Maximum Cool when temperature in cabin is Connector: B-18X
25°C or more B-18X
25°C or less Relay box’s
triangle marks
OK:
ON (when A/C is ON)
2 1
4 3
YES : Intermittent malfunction (Refer to GROUP Harness
side connector
00 − How to Use AK304343 AB

Connector: C-139
P.00-6).
NO : Replace engine-ECU <M/T> or <L. H. Drive Vehicle>
STEP 12. Connector check: C-139 engine-ECU C-139 (GR)

connector
Connector: C-139
C-139 (GR)
C-139 (GR)
4 3 2 1
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
<R. H. Drive Vehicle> 2726 2524 23 22 21
AK304262 AB
C-139 (GR)
4 3 2 1 NO : Repair.
13 12 1110 9 8 7 6 5
2019 18 17 16 15 14
2726 2524 23 22 21
AK304262 AB

NO : Repair.
TROUBLESHOOTING
STEP 14. Connector check: C-303 ignition switch STEP 16. Check harness between battery and
connector B-18X (terminal No. 4) A/C compressor relay
connector.
Connector: C-303
Connector: B-18X
B-18X
C-303
Relay box’s
triangle marks
3 2 1 2 1
6 5 4
4 3
Harness side connector AK304334 AB Harness
NO : Repair. connector A-14, and repair if necessary.
STEP 15. Check harness between C-303 (terminal Q: Is the check result normal?
No. 4) ignition switch connector and B-18X YES : Go to Step 17 .
(terminal No. 3) A/C compressor relay connector. NO : Repair.
Connector: C-303
C-303 and B-27 (terminal No. 1) A/C compressor
assembly connector.
Connector: B-18X
3 2 1 B-18X
6 5 4 Relay box’s
Harness side connector triangle marks
AK304334 AB
Connector: B-18X 2 1
B-18X 4 3
Relay box’s Harness
triangle marks side connector AK304343 AB
Connector: B-27
2 1 1
Harness
4 3 side connector
Harness

B-27(B)
connectors C-106, C-202*2, C-203 and C-205*1, and
• Check power supply line for damage. AK304344 AB
Q: Is the check result normal? • Check output line for damage.
NO : Repair.
TROUBLESHOOTING
13C-373
A/C Load Signal System

C-06
(MU801584)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A/C-ECU
C-26
(MU801584)
21 22 23 24 25 26 27 28
29 30 31 32 33 34 35 36
C-06
5 <Manual A/C>
L-W C-26
32 <Auto A/C>
C-104
6
L-W
78
C-141
(MU803804)
6162 6364
656667686970717273 Engine-ECU <M/T>
747576777879808182 Engine-A/T-ECU <A/T>
8384 858687 8889
Wire colour code

AK401089 AB

engine-ECU <M/T> or engine-A/T-ECU <A/T> • Open/short circuit in A/C load signal circuit or
(terminal No. 78) from the A/C-ECU (terminal No. loose connector contact
5). <Manual A/C> or (terminal No. 32) <Auto • Failed engine-ECU <M/T>
A/C> • Failed engine-A/T-ECU <A/T>
FUNCTION
detected and input to the engine-ECU <M/T> or
engine-A/T-ECU <A/T>. The engine-ECU <M/T>
or engine-A/T-ECU <A/T> provides A/C idle up
control according to the A/C compressor load
condition.
TROUBLESHOOTING

STEP 1. Perform voltage measurement at C-141 connector
Connector: C-141
<A/T>.
Connector: C-141
C-141(GR)
C-141(GR)

C-141 (GR)
C-141 (GR)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
6463 62 61
82 818079 78 7776 7574
8988 87 86 85 8483 AK304154 AB

AK304154 AB
• Measure engine-ECU <M/T> or engine-A/T-ECU NO : Repair.
• Engine: Idling
• Voltage between terminal No. 78 and earth Q: Does trouble symptom persist?
OK:
00 − How to Use
air flow rate)
NO : Go to Step 4 .
TROUBLESHOOTING
13C-375
<M/T> connector or engine-A/T-ECU <A/T> A/C-ECU <Manual A/C> connector or C-26
connector A/C-ECU <Auto A/C> connector.
Connector: C-141
C-141(GR)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
AK304341
C-141 (GR)
Connector: C-26
<Auto A/C>
C-26 (B)
6463 62 61
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483 28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
AK304154 AB
• Measure A/C-ECU terminal voltage.
Q: Is the check result normal? • Engine: Idling
YES : Go to Step 5 . • A/C set temperature:
NO : Repair. Maximum Cool when temperature in cabin is
25°C or more
or less
• Voltage between terminal No. 5 and earth <Man-
ual A/C>
• Voltage between terminal No. 32 and earth <Auto
A/C>
OK: System voltage
NO : Go to Step 6 .
TROUBLESHOOTING
STEP 6. Connector Check: C-06 A/C-ECU STEP 7. Check harness between C-06 (terminal
<Manual A/C> connector or C-26 A/C-ECU <Auto No. 5) or C-26 (terminal No. 32) A/C-ECU
A/C> connector connector and C-141 (terminal No. 78)
<A/T> connector.
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
AK304341 10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Connector: C-26 AK304341

<Auto A/C>
C-26 (B) Connector: C-26

<Auto A/C>
C-26 (B)
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
36 35 34 33 32 31 30 29
Q: Is the check result normal? Harness side connector AK304342 AB
NO : Repair.
TROUBLESHOOTING
13C-377

<Auto A/C>
C-26 (B)
C-141(GR)
28 27 26 25 24 23 22 21
36 35 34 33 32 31 30 29
C-141 (GR)
Connector: C-141
6463 62 61 C-141(GR)
7372 7170 69 6867 6665
82 818079 78 7776 7574
8988 87 86 85 8483
AK304154 AB <R. H. Drive Vehicle>
C-141 (GR)
Troubleshooting − Check Chart for Trouble 6463 62 61
Symptoms P.55A-5). 7372 7170 69 6867 6665
82 818079 78 7776 7574
NO : Repair. 8988 87 86 85 8483
AK304154 AB
STEP 8. Check connector: C-06 A/C-ECU
connector <Manual A/C> or C-26 A/C-ECU Q: Is the check result normal?
connector <Auto A/C> YES : Check intermediate connector C-104, and
harness between C-06 (terminal No. 5) or
C-26 (terminal No. 32) A/C-ECU connector
connector.
10 9 8 7 6 5 4 3 2 1 • Check output line for open circuit.
20 19 18 17 16 15 14 13 12 11 NO : Repair.
AK304341
TROUBLESHOOTING
A-02
(MU802509) A/C Pressure sensor
1 2 3
3 1 2
G-Y BR G-R
C-116
17 5
A-14 BR G-R
17
C-105 C-104
21 4
G-Y
A/C-ECU
BR G-R
97 96 118
C-142
(MU803805)
9192 939495
96979899100 101102103 104
105106 107108109 110111112
113114 115116117 118119120 5V
Engine-ECU <M/T>
Wire colour code

AK304330AB
OPERATION FUNCTION
the engine-ECU <M/T> or engine-A/T-ECU engine-ECU <M/T> or engine-A/T-ECU <A/T>.
<A/T> (terminal No. 97) and is earthed to the The engine-ECU uses the signal for ON/OFF
engine-ECU <M/T> or engine-A/T-ECU <A/T> control of the magnet clutch of the A/C compres-
(terminal No. 96) from the A/C pressure sensor sor.
(terminal No. 1).
• The sensor signal is inputted to the engine-ECU PROBABLE CAUSE
<M/T> or engine-A/T-ECU <A/T> (terminal No. • Failed A/C pressure sensor
118) from the A/C pressure sensor output termi- • Open/short circuit in A/C pressure sensor circuit
nal (terminal No. 2). or loose connector contact
TROUBLESHOOTING
13C-379
STEP 1. Connector check: A-02 A/C pressure <A/T> connector.
sensor connector
Connector: C-142
Connector: A-02 <L. H. Drive Vehicle>
A-02 (B)
C-142 (GR)
3 2 1 <R. H. Drive Vehicle>

C-142 (GR)
NO : Repair.
STEP 2. Perform voltage measurement at A-02 959493 92 91

A/C pressure sensor connector. 104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
Connector: A-02 Harness side connector
A-02 (B)
AK304153 AB

OK: 4.9 − 5.1 V
3 2 1
• Disconnect connector, and measure at harness NO : Go to Step 5 .
side.
OK: 4.9 − 5.1 V
NO : Go to Step 3 .
TROUBLESHOOTING
connector connector
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

A-02 (B) YES : Go to Step 6 .
NO : Repair.
3 2 1

connector.
• Check power line for open circuit.
NO : Repair.
TROUBLESHOOTING
13C-381
Connector: A-02
engine-A/T-ECU <A/T> connector. A-02 (B)
Connector: A-02
A-02 (B)
3 2 1
3 2 1
side.
Connector: C-142
NO : Go to Step 9 .
C-142 (GR)
connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
Harness side connector <R. H. Drive Vehicle>

AK304153 AB
C-142 (GR)
• Check power line for short circuit.
YES : Go to Step 7 . 959493 92 91
NO : Repair. 104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
YES : Replace engine-ECU <M/T> or Q: Is the check result normal?
engine-A/T-ECU <A/T>. YES : Go to Step 10 .
NO : Intermittent malfunction (Refer to GROUP NO : Repair.
00 − How to Use
P.00-6).
TROUBLESHOOTING
Connector: A-02
engine-A/T-ECU <A/T> connector. A-02 (B)
Connector: A-02
A-02 (B)
3 2 1
3 2 1
Connector: C-142 • Voltage between terminal No. 3 and earth.
OK: 4.9 − 5.1 V
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

sary.
NO : Repair.
TROUBLESHOOTING
13C-383
<M/T> connector or engine-A/T-ECU <A/T> A/C pressure sensor connector.
connector
Connector: A-02
A-02 (B)
Connector: C-142
C-142 (GR)
3 2 1
C-142 (GR)
OK: 0.5 V or less
959493 92 91
104 103102 101100 99 98 97 96 NO : Go to Step 14 .
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
Connector: A-02
A-02 (B)
3 2 1

connector.
• Check power line for damage.
NO : Repair.
TROUBLESHOOTING
<M/T> connector or engine-A/T-ECU <A/T> A/C pressure sensor connector.
connector
Connector: A-02
A-02 (B)
Connector: C-142
C-142 (GR)
3 2 1
C-142 (GR)
• A/C switch: ON
OK:
959493 92 91
104 103102 101100 99 98 97 96
dition)
112111110 109108107 106105 1.8 V or less (When A/C is "MAX, HOT" condi-
120119118 117116115 114113
tion)
Connector: A-02 NO : Go to Step 16 .
A-02 (B)
3 2 1

connector.
NO : Repair.
TROUBLESHOOTING
13C-385
STEP 16. Connector check: C-142 engine-ECU STEP 17. Check harness between A-02 (terminal
<M/T> connector or engine-A/T-ECU <A/T> No. 2) A/C pressure sensor connector and C-142
connector (terminal No. 118) engine-ECU <M/T> or
Connector: C-142
<L. H. Drive Vehicle> Connector: A-02
A-02 (B)
C-142 (GR)
3 2 1
C-142 (GR)
Connector: C-142
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
C-142 (GR)
120119118 117116115 114113

AK304153 AB
C-142 (GR)
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

sary.
NO : Repair.
TROUBLESHOOTING
C-142 (GR) C-142 (GR)
C-142 (GR) C-142 (GR)
959493 92 91 959493 92 91
104 103102 101100 99 98 97 96 104 103102 101100 99 98 97 96
112111110 109108107 106105 112111110 109108107 106105
120119118 117116115 114113 120119118 117116115 114113

AK304153 AB AK304153 AB

Connector: A-02
<A/T> terminal voltage. A-02 (B)
• A/C switch: ON
OK:
dition)
1.8 V or more (When A/C is "MAX, HOT" condi- 3 2 1
tion) Harness side connector AK304345 AB

connector.
• Check power line for short circuit and
damage.
NO : Repair.
TROUBLESHOOTING
13C-387
connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB

NO : Repair.
TROUBLESHOOTING
Ignition circuit
Ignition switch
C-303
R LOCK
ST 1 2 3
ACC 4 5 6
IG1 IG2
2
L-B
C-203
6
J/B 1
W 10A
C-116 (*1)
26 10
C-205
W
A-14 (*1)
16
C-124 (*2)
1
B-110 B-111 B-117 B-118

(MU802064) (MU802064) (MU802064) (MU802064)
W W W W W
1 2 3 1 2 3 1 2 3 1 2 3
Ignition coil 1 1 Ignition coil 2 1 Ignition coil 3 1 Ignition coil 4 1 1
B-107
3 2 3 2 3 2 3 2 Capacitor
B Spark B Spark B Spark B Spark

plug plug plug Y-L plug
Y-B
B-L W-L
NOTE
31 32 35 52
C-140
(MU803803)
3132 33 34
35363738394041 42 43
444546474849 50 51
5253 545556 57 58
Engine-ECU <M/T>
Wire colour code
AK401086 AC
TROUBLESHOOTING
13C-389
OPERATION STEP 2. Connector check: B-110, B-111, B-117
• The battery voltage is applied to the ignition coil and B-118 ignition coil connectors
earthed to the vehicle body from the ignition coil Connectors: B-110, B-111, B-117, B118
B-118 (B)
(terminal No. 2). B-117 (B)
• A power voltage of 12 V is applied to the ignition B-111 (B)
coil output terminal (terminal No. 3) from the
B-110 (B)
(terminal No. 31, No. 32, No. 35 and No. 52).
3 2 1
FUNCTION Harness side
connector
• When the engine-ECU <M/T> or engine-A/T-ECU
AK304346 AB
<A/T> makes the power transistor in the unit be
in "OFF" position, the battery voltage in the unit is Q: Is the check result normal?
applied to the power transistor unit, and that YES : Go to Step 3 .
makes the power transistor unit be in "ON" posi- NO : Repair.
tion. The engine-ECU <M/T> or engine-A/T-ECU
<A/T> makes the power transistor in the unit be
in "ON", and that makes the power transistor unit STEP 3. Check ignition coil itself.
be in "OFF" position. • Check ignition coil itself (Refer to GROUP 16 −
• In response to the signal from the engine-ECU Ignition System − On-vehicle Service − Ignition
<M/T> or engine-A/T-ECU <A/T>, the power tran- coil check <4G69>P.16-39).
sistor unit is in "ON" position. The primary current Q: Is the check result normal?
is going to the ignition coil. When the power tran- YES : Go to Step 4 .
sistor unit is in "OFF" position, the primary current NO : Replace ignition coil.
is interrupted and high voltage is generated in the
secondary coil. STEP 4. Perform voltage measurement at B-110,
B-111, B-117 and B-118 ignition coil connectors.
PROBABLE CAUSE
• Failed ignition coil Connectors: B-110, B-111, B-117, B118
• Failed spark plug B-118 (B)
B-117 (B)
• Failed spark plug cable
B-111 (B)
• Open/short circuit in ignition primary circuit or
loose connector contact B-110 (B)
• Failed engine-A/T-ECU <A/T> 3 2 1
Harness side
DIAGNOSIS PROCEDURE connector
AK304346 AB
NOTE: .
*1: L.H. drive vehicle • Disconnect connector, and measure at harness
side.
*2: R.H. drive vehicle
STEP 1. Check spark plug. OK: System voltage
• Check spark plug itself (Refer to GROUP 16 − Q: Is the check result normal?
Ignition System − On-vehicle Service P.16-40). YES : Go to Step 6 .
TROUBLESHOOTING
STEP 5. Connector check: C-303 ignition switch STEP 6. Perform voltage measurement at B-110,
connector B-111, B-117 and B-118 ignition coil connectors.
Connector: C-303 Connectors: B-110, B-111, B-117, B118
B-118 (B)
B-117 (B)
C-303 B-111 (B)
B-110 (B)
3 2 1 3 2 1
6 5 4 Harness side
connector
Harness side connector AK304334 AB AK304346 AB

Connectors: B-110, B-111, B-117, B118
side.
B-118 (B)
B-117 (B) • Engine: Cranking
B-110 (B) OK: 0.5 − 4.0 V
connector
AK304346 AB

YES : Check intermediate connectors A-14*1,
C-116*1, C-124*2, C-203 and C-205, and
harness between ignition switch connector
and ignition coil connector
a. Check and repair harness between
No. 1 ignition coil connector
b. Check and repair harness between
c. Check and repair harness between
d. Check and repair harness between
open/short circuit.
NO : Repair.
TROUBLESHOOTING
13C-391
<A/T>. connector
C-140 (GR) C-140 (GR)
C-140 (GR) C-140 (GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK304274 AB AK304274 AB
Connectors: B-110, B-111, B-117, B118 Connectors: B-110, B-111, B-117, B118
B-118 (B) B-118 (B)
B-117 (B) B-117 (B)
B-111 (B) B-111 (B)
B-110 (B) B-110 (B)
3 2 1 3 2 1
connector connector
AK304346 AB AK304346 AB

• Disconnect B-110, B-111, B-117 and B-118 igni-
tion coil connectors.
a. Voltage between terminal No. 31 and earth
(No. 1 Ignition coil).
b. Voltage between terminal No. 32 and earth
c. Voltage between terminal No. 35 and earth
d. Voltage between terminal No. 52 and earth
OK: 0.5 − 4.0 V
NO : Go to Step 9 .
TROUBLESHOOTING

coil connector and engine-ECU <M/T>
connector
a. Check and repair harness between <L. H. Drive Vehicle>
B-110 (terminal No. 3) No. 1 ignition
coil connector and C-140 (terminal
No. 31) engine-ECU <M/T> or
connector engine-A/T-ECU <A/T> C-140 (GR)
connector.
b. Check and repair harness between
coil connector and C-140 (terminal <R. H. Drive Vehicle>
No. 32) engine-ECU <M/T> or
connector engine-A/T-ECU <A/T>
connector.
C-140 (GR)
c. Check and repair harness between
coil connector and C-140 (terminal 34 33 32 31
No. 35) engine-ECU <M/T> or 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
connector engine-A/T-ECU <A/T> 58 57 5655 54 5352
connector. Harness side connector
d. Check and repair harness between
AK304274 AB
coil connector and C-140 (terminal Q: Is the check result normal?
No. 52) engine-ECU <M/T> or YES : Go to Step 10 .
connector engine-A/T-ECU <A/T> NO : Repair.
connector.
NO : Repair.
TROUBLESHOOTING
13C-393
connector and engine-ECU <M/T> connector or NO : Repair.
Connector: C-140 STEP 11. Check the trouble symptoms.
<L. H. Drive Vehicle> Q: Does trouble symptom persist?
C-140 (GR)
00 − How to Use
P.00-6).
B-110, B-111, B-117 and B-118 ignition coil
connectors.
C-140 (GR)
Connectors: B-110, B-111, B-117, B118
B-118 (B)
B-117 (B)
34 33 32 31
43 42 4140 39 38 37 36 35 B-111 (B)
51 50 49 4847 46 4544
58 57 5655 54 5352 B-110 (B)
AK304274 AB 3 2 1
Harness side
Connectors: B-110, B-111, B-117, B118 connector
AK304346 AB
B-118 (B)
B-117 (B) • Disconnect connector, and measure at harness
B-111 (B) side.
B-110 (B) • Resistance between terminal No. 2 and earth.
Harness side YES : Go to Step 13.
connector
NO : Check and repair harness between ignition
AK304346 AB
coil connector and body earth
a. Check and repair harness between B-110 (termi- a. Check and repair harness between
nal No. 3) No. 1 ignition coil connector and C-140 B-110 (terminal No. 2) No. 1 ignition
(terminal No. 31) engine-ECU <M/T> connector coil connector and body earth
or engine-A/T-ECU <A/T> connector. b. Check and repair harness between
b. Check and repair harness between B-111 (termi- B-111 (terminal No. 2) No. 2 ignition
nal No. 3) No. 2 ignition coil connector and C-140 coil connector and body earth
(terminal No. 32) engine-ECU <M/T> connector c. Check and repair harness between
or engine-A/T-ECU <A/T> connector. B-117 (terminal No. 2) No. 3 ignition
c. Check and repair harness between B-117 (termi- coil connector and body earth
nal No. 3) No. 3 ignition coil connector and C-140 d. Check and repair harness between
(terminal No. 35) engine-ECU <M/T> connector B-118 (terminal No. 2) No. 4 ignition
or engine-A/T-ECU <A/T> connector. coil connector and body earth
d. Check and repair harness between B-118 (termi- • Check earthing line for open
nal No. 3) No. 4 ignition coil connector and C-140 circuit and damage.
(terminal No. 52) engine-ECU <M/T> connector
or engine-A/T-ECU <A/T> connector.
TROUBLESHOOTING
STEP 13. Check harness between ignition switch STEP 14. Check harness between ignition coil
connector and ignition coil connector. connector and engine-ECU <M/T> connector or
Connector: C-303
Connectors: B-110, B-111, B-117, B118
B-118 (B)
C-303 B-117 (B)
B-111 (B)
B-110 (B)
3 2 1
6 5 4 3 2 1
Harness side
AK304346 AB
Connectors: B-110, B-111, B-117, B118
B-118 (B) Connector: C-140
B-117 (B)
B-110 (B)
3 2 1 C-140 (GR)
Harness side
connector
AK304346 AB
a. Check and repair harness between C-303 (termi- <R. H. Drive Vehicle>
nal No. 2) ignition switch connector and B-110
(terminal No. 1) No. 1 ignition coil connector
b. Check and repair harness between C-303 (termi- C-140 (GR)
nal No. 2) ignition switch connector and B-111
c. Check and repair harness between C-303 (termi- 34 33 32 31
nal No. 2) ignition switch connector and B-117 43
51
42 4140 39 38 37 36 35
50 49 4847 46 4544
(terminal No. 1) No. 3 ignition coil connector 58 57 5655 54 5352
d. Check and repair harness between C-303 (termi- Harness side connector
nal No. 2) ignition switch connector and B-118 AK304274 AB
a. Check and repair harness between B-110 (termi-
nal No. 3) No. 1 ignition coil connector and C-140
connectors A-14*1, C-116*1, C-124*2, C-203 and (terminal No. 31) engine-ECU <M/T> or
C-205, and repair if necessary. engine-A/T-ECU <A/T> connector.
b. Check and repair harness between B-111 (termi-
Q: Is the check result normal? nal No. 3) No. 2 ignition coil connector and C-140
YES : Go to Step 14 . (terminal No. 32) engine-ECU <M/T> or
NO : Repair. engine-A/T-ECU <A/T> connector.
c. Check and repair harness between B-117 (termi-
(terminal No. 35) engine-ECU <M/T> or
d. Check and repair harness between B-118 (termi-
(terminal No. 52) engine-ECU <M/T> or
TROUBLESHOOTING
13C-395
NO : Repair.
Inspection Procedure 32: Accelerator Pedal Position Switch Circuit System
Accelerator pedal position switch circuit
B-116
(MU802073)
OFF Accelerator pedal
1 2 3 4 5 6 7 8 ON position sensor
4 5
BR-G B
38 96
C-140 C-142
(MU803803) (MU803805)
3132 33 34 9192 939495
35363738394041 42 43 96979899100 101102103 104
444546474849 50 51 105106 107108109 110111112
5253 545556 57 58 113114 115116117 118119120
Engine-ECU <M/T>
Wire colour code
AK304332 AB

• A power voltage of 5 V is applied to the accelera- uses the signal that is input by the accelerator
tor pedal position switch output terminal (terminal pedal position switch for determining the abnor-
No. 4) from the engine-ECU <M/T> or mal characteristics of the accelerator pedal posi-
engine-A/T-ECU <A/T> (terminal No. 38). tion sensor (sub).
<M/T> or engine-A/T-ECU <A/T> (terminal No. PROBABLE CAUSE
96) from the Accelerator pedal position switch • Failed accelerator pedal position switch.
(terminal No. 5). • Open/short circuit in accelerator pedal position
switch circuit or loose connector contact.
COMMENT ON TROUBLE SYMPTOM • Failed engine-ECU <M/T>
• Accelerator pedal position switch turns OFF • Failed engine-A/T-ECU <A/T>
when amount of travel of the accelerator pedal
exceeds the prescribed value.
TROUBLESHOOTING

STEP 1. Connector check: B-116 accelerator <A/T> connector.
Connector: C-140
B-116 (GR)
C-140 (GR)
8 7 6 5 4 3 2 1 <R. H. Drive Vehicle>


YES : Go to Step 2 . C-140 (GR)
NO : Repair.
34 33 32 31
STEP 2. Check accelerator pedal position switch 43 42 4140 39 38 37 36 35
itself 51
58
50 49 4847 46 4544
57 5655 54 5352
• Check accelerator pedal position switch itself Harness side connector
AK304274 AB
Connector: B-116
B-116 (GR)
accelerator pedal position sensor connector.
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1

• Disconnect B-116 accelerator pedal position sen-
8 7 6 5 4 3 2 1 sor
Harness side connector AK304279 AB • Ignition switch: ON
side. OK: 4.9 − 5.1 V
• Ignition switch: ON Q: Is the check result normal?
• Voltage between terminal No. 4 and earth. YES : Go to Step 5 .
OK: 4.9 − 5.1 V NO : Go to Step 6 .

NO : Go to Step 4 .
TROUBLESHOOTING
13C-397
C-140 (GR) C-140 (GR)
C-140 (GR) C-140 (GR)
34 33 32 31 34 33 32 31
43 42 4140 39 38 37 36 35 43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 51 50 49 4847 46 4544
58 57 5655 54 5352 58 57 5655 54 5352
AK304274 AB AK304274 AB

8 7 6 5 4 3 2 1

(terminal No. 4) accelerator pedal position
NO : Repair.
TROUBLESHOOTING
No. 4) accelerator pedal position sensor B-116 accelerator pedal position sensor
Connector: B-116
<A/T> connector.
Connector: B-116 B-116 (GR)
B-116 (GR)
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
side.
Connector: C-140
NO : Go to Step 9 .
C-140 (GR)
connector
Connector: C-142
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544 C-142 (GR)
58 57 5655 54 5352
AK304274 AB
C-142 (GR)
NO : Repair.
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
NO : Repair.
TROUBLESHOOTING
13C-399
No. 5) accelerator pedal position sensor engine-ECU <M/T> connector or engine-A/T-ECU
connector and C-142 (terminal No. 96) <A/T> connector
Connector: B-116
B-116 (GR)
C-140 (GR)

8 7 6 5 4 3 2 1
Connector: C-142 C-140 (GR)

34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
C-142 (GR) Harness side connector
AK304274 AB

C-142 (GR) • Ignition switch: ON
OK:
0 − 1 V (Release the accelerator pedal)
4 V or more (Depress the accelerator pedal)
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113
AK304153 AB

NO : Repair.
TROUBLESHOOTING
Connector: B-116
B-116 (GR)
C-140 (GR)

8 7 6 5 4 3 2 1

34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
C-140 (GR)
AK304274 AB

NO : Repair.
C-140 (GR)
34 33 32 31
43 42 4140 39 38 37 36 35
51 50 49 4847 46 4544
58 57 5655 54 5352
AK304274 AB

NO : Repair.
TROUBLESHOOTING
13C-401
connector
Connector: C-142
C-142 (GR)
C-142 (GR)
959493 92 91
104 103102 101100 99 98 97 96
112111110 109108107 106105
120119118 117116115 114113

AK304153 AB
Connector: B-116
B-116 (GR)
8 7 6 5 4 3 2 1

NO : Repair.
TROUBLESHOOTING

M1131152002764

No.
11 Cylinder 1,4 Engine: After Excessive deceleration 200 mV or less Code No. P.13C-67
oxygen warm-up (leaner by from 4,000 r/min P0130
sensor deceleration, richer At excessive 600 − 1,000 mV
(front) by acceleration) acceleration
as well as control
status by
engine-ECU <M/T>
or engine-A/T-ECU
<A/T>.
sensor *1 temperature: 85 2,500 r/min 6.0 − 16.0 g/s
− 95°C
• Lamps, electric
acceleration,
cooling fan and
frequency is
all accessories:
amplified.
OFF
• Transmission:
Neutral <M/T>,
"P" range <A/T>
13 Intake air Ignition switch: Intake air temperature: −20°C Code No. P.13C-40
temperature "ON" or engine −20°C P0110
0°C
20°C
40°C
80°C
TROUBLESHOOTING
13C-403
No.
14 Throttle • Remove the Fully close the throttle 2,200 − Code No. P.13C-146
position intake air hose valve with your finger 2,800 mV P0222, P.13C-150
sensor (sub) at the throttle Fully open the throttle 4,600 mV or P0223
*4 body valve with your finger more
• Disconnect the
throttle position
sensor, and the
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the
use of the
special tool:
MB991658.
ON
16 Power Ignition switch: "ON" System voltage Procedure P.13C-339
supply No. 24
voltage
18 Cranking Ignition switch: Engine: Stopped OFF Procedure P.13C-339
signal "ON" Engine: Cranking ON No. 24
(ignition
switch-ST)
21 Engine Ignition switch: Coolant temperature: −20°C Code No. P.13C-47
coolant "ON" or engine −20°C P0115
sensor 0°C
20°C
40°C
80°C
TROUBLESHOOTING

No.
22 Crank angle • Engine: Compare engine speed Matched Code No. P.13C-170
0°C 1,420 r/min
20°C 1,300 r/min
40°C
80°C
25 Barometric Ignition switch: Altitude: 0m 101 kPa Code No. P.13C-277
pressure "ON" Altitude: 600m 95 kPa P2226
sensor
26 Accelerator Ignition switch: Release the ON Procedure P.13C-395
pedal "ON" accelerator pedal No. 32
position Depress the OFF
switch accelerator pedal
27 Power Engine: Idle Steering wheel: Not OFF Code No. P.13C-206
steering fluid operation operated P0551
pressure Steering wheel: ON
switch Operated
28 A/C switch Engine: Idle AC switch: OFF OFF Procedure P.13C-361
AC A/C OFF No. 27
ON not driven
A/C ON
compressor is
driven
− 95°C
• Lamps, electric
acceleration,
cooling fan and
volumetric
all accessories:
efficiency is
OFF
increased.
• Transmission:
Neutral <M/T>,
"P" range <A/T>
TROUBLESHOOTING
13C-405
No.
39 Cylinder 2,3 Engine: After Excessive deceleration 200 mV or less Code No. P.13C-93
oxygen warm-up (leaner by from 4,000 r/min P0150
sensor deceleration, richer At excessive 600 − 1,000 ms
(front) acceleration) acceleration
as well as control
status by
engine-ECU
41 Injectors *2 Engine: Cranking Coolant temperature: 60.5 − 80.5 ms − −
operation)
20°C
80°C
− 95°C
• Lamps, electric
cooling fan and
all accessories:
OFF
• Transmission:
Neutral <M/T>,
"P" range <A/T>
44 Ignition • Engine: After Idle operation 2 − 18°BTDC Procedure P.13C-388
• Install timing
light (for use to
measure actual
ignition timing)
49 A/C relay Engine: After A/C switch: OFF OFF Procedure P.13C-366
A/C ON
compressor is
driven
59 Cylinder 1,4 Engine: After At excessive 0 mV or less ⇔ Code No. P.13C-79
Oxygen warm-up acceleration 600 − 1,000 mV P0136
Sensor (altered)
(rear)
TROUBLESHOOTING

No.
68 EGR valve • Engine coolant Idling 2 − 8 STEP Code No. P.13C-189
temperature: 85 2,500 r/min 2 − 8 STEP P0403
− 95°C
• Lights and all
accessories:
"OFF"
• Transmission:
Neutral <M/T>,
"P" range <A/T>
69 Cylinder 2,3 Engine: After At excessive 0 mV or less ⇔ Code No. P.13C-106
oxygen warm-up acceleration 600 − 1,000 mV P0156
sensor (altered)
(rear)
77 Accelerator Ignition switch: ON Release the 335 − 935 mV Code No. P.13C-259
pedal accelerator pedal P2126, P.13C-262
position Depress the Increases in P2127, P.13C-266
sensor (sub) accelerator pedal response to the P2128
gradually pedal depression
stroke
Depress the 4,000 mV or
accelerator pedal fully more
78 Accelerator Ignition switch: ON Release the 335 − 935 mV Code No. P.13C-249
pedal accelerator pedal P2121, P.13C-252
position Depress the Increases in P2122, P.13C-256
sensor accelerator pedal response to the P2123
(main) gradually pedal depression
stroke
Depress the 4,000 mV or
accelerator pedal fully more
79 Throttle • Remove the Fully close the throttle 300 − 700 mV Code No. P.13C-54
position intake air hose valve with your finger P0122, P.13C-58
sensor at the throttle Fully open the throttle 4,000 mV or P0123
(main) body valve with your finger more
• Disconnect the
throttle position
sensor, and then
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the
use of the
special tool:
MB991658.
ON
No load 520 − 620 mV
• Shift lever: "N" → "D" <A/ T> 540 − 640 mV
TROUBLESHOOTING
13C-407
No.
95 Manifold Ignition switch: ON Altitude: 0 m 101 kPa Code No. P.13C-30
absolute Altitude: 600 m 95 kPa P0105
pressure
sensor Altitude: 1,200 m 88 kPa
Altitude: 1,800 m 81 kPa
• Engine coolant Idle operation 16 − 36 kPa
temperature: 85 When engine is Increased
− 95°C suddenly raced
• Lights and all
accessories:
"OFF"
• Transmission:
Neutral <M/T>,
"P" range <A/ T>
9A Throttle Ignition switch: ON 600 − 1,200 mV Code No. P.13C-54
position P0122, P.13C-58
sensor P0123
(main) mid
opening
learning
value
*5 sensor temperature: 85 2,500 r/min 8.0 − 16.0 g/s
− 95°C
• Lamps, electric
acceleration,
cooling fan and
frequency is
all accessories:
amplified.
OFF
• Transmission:
Neutral <M/T>,
"P" range <A/T>
13 Intake air Ignition switch: Intake air temperature: −20°C Code No. P.13C-40
*5 temperature "ON" or engine −20°C P0110
0°C
20°C
40°C
80°C
TROUBLESHOOTING

No.
21 Engine Ignition switch: Coolant temperature: −20°C Code No. P.13C-47
*5 coolant "ON" or engine −20°C P0115
sensor 0°C
20°C
40°C
80°C
0°C 1,420 r/min
20°C 1,300 r/min
40°C
80°C
24 Vehicle Drive 40 km/h Approximately 40 − −
*5 speed km/h
sensor
• Install timing
light (for use to
measure actual
ignition timing)
81 Long-term Engine: After warm-up, 2,500 r/min without −12.5 to 12.5% Code No. P.13C-119
compensati
on cylinder
1, 4
82 Shot-term Engine: After warm-up, 2,500 r/min without −25 to 25% Code No. P.13C-119
compensati
on cylinder
1, 4
TROUBLESHOOTING
13C-409
No.
83 Long-term Engine: After warm-up, 2,500 r/min without −12.5 to 12.5% Code No. P.13C-122
compensati
on cylinder
2, 3
84 Short-term Engine: After warm-up, 2,500 r/min without −25 to 25% Code No. P.13C-122
compensati
on cylinder
2, 3
cylinder 1, 4 condition
cylinder 2, 3 condition
8A Throttle • Remove the Fully close the throttle 0 − 5% Code No. P.13C-54
*5 position intake air hose valve with your finger P0122, P.13C-58
sensor at the throttle Fully open the throttle 88% or more P0123
(main) *4 body valve with your finger
• Disconnect the
throttle position
sensor, and then
connect terminal
numbers No. 3,
and No. 4, No. 5
and No. 6 with
the use of the
special tool:
MB991658.
ON
A1 Cylinder 1, 4 Engine: After Excessive deceleration 0.2 V or less ⇔ Code No. P.13C-67
*5 oxygen warm-up (leaner by from 4,000 r/min 0.6 − 1 V P0130
sensor deceleration, richer (altered)
(front) by acceleration)
as well as control
status by
engine-ECU <M/T>
or engine-A/T-ECU
<A/T>)
TROUBLESHOOTING

No.
A2 Cylinder 1, 4 Engine: After At excessive 0 V or less ⇔ Code No. P.13C-79
*5 oxygen warm-up acceleration 0.6 − 1 V P0136
sensor (altered)
(rear)
A3 Cylinder 2,3 Engine: After Excessive deceleration 0.2 V or less ⇔ Code No. P.13C-93
*5 oxygen warm-up (leaner by from 4,000 r/min 0.6 − 1 V P0150
sensor deceleration, richer (altered)
(front) by acceleration)
warm-up (using 2,500 r/min 0.6 − 1V (altered)
oxygen sensor,
as well as control
status by
engine-ECU <M/T>
or engine-A/T-ECU
<A/T>)
A4 Cylinder 2,3 Engine: After At excessive 0 V or less ⇔ 0.6 Code No. P.13C-106
*5 oxygen warm-up acceleration − 1 V (altered) P0156
sensor
(rear)
A9 Engine Running distance in the engine warning lamp on − −
*5 warning
lamp
distance
CAUTION
move forward
approx. 10%.
r/min. or less.
NOTE: *3: On the new vehicle (mileage: 500 km or less), injector drive time may be longer by approx. 10%.
NOTE: *4: After the inspection has been completed, disconnect the throttle actuator control motor connector,
and then use the M.U.T.-II/III to delete the diagnosis code that was recorded during the inspection.
TROUBLESHOOTING
13C-411
M1131152500978
procedure
No.
01 Injector Cut off No. 1 Engine: After warm-up, Engine is Code No. P.13C-126
02 Cut off No. 2 injectors sequentially to (becomes Code No. P.13C-131
03 Cut off No. 3 idle status. Code No. P.13C-136
injector P0203
04 Cut off No. 4 Code No. P.13C-141
injector P0204
07 Fuel pump Drive fuel pump Ignition Check for Operating Procedure P.13C-345
to circulate fuel switch: "ON" pump noise audible No. 25
operating
noise near
fuel tank
08 Purge Switch solenoid Ignition switch: "OFF" When the valve Code No. P.13C-196
valve is audible
timing engine-ECU • Install timing light
<M/T> or
engine-A/T-ECU
<A/T> to ignition
timing adjusting
mode
21 Fan Actuate fan • Ignition switch: "ON" Fan motor is Procedure P.13C-334
22 Oil control Oil control valve Engine: Warming up, Engine speed Code No. P.13C-227
valve turns from OFF 2,000 r/min is changed P1010
the ON
34 Throttle Stop the throttle Ignition switch: "ON" Throttle valve Code No. P.13C-236
valve control valve control is open P2100, P.13C-240
servo servo P2101, P.13C-243
P2102,
P.13C-246
P2103
TROUBLESHOOTING

TERMINAL VOLTAGE CHECK CHART engine-ECU <M/T> or engine-A/T-ECU <A/T>
connector connected.
Needle-nosed wire probe 2. You may find it convenient to pull out the
to make it easier to reach the connector termi-
nals.
given in the chart.
CAUTION
Short-circuiting the positive (+) probe between a
AK201749AB connector terminal and earth could damage the
vehicle wiring, the sensor, engine-ECU <M/T> or
1. Connect a needle-nosed wire probe to a voltmeter
engine-A/T-ECU <A/T> or all of them. Be careful
probe.
to prevent this!
3. If voltmeter shows any division from standard
the engine-ECU <M/T> or engine-A/T-ECU <A/T>
value, check the corresponding sensor, actuator
connector terminals from the wire side, and
measure the voltage while referring to the check
replace.
chart.
4. After repair or replacement, recheck with the
voltmeter to confirm that the repair has corrected
the problem.
Engine-ECU <M/T> or engine-A/T-ECU <A/T> Connector Terminal Arrangement

Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Connector
C-139 C-140 C-141 C-142 C-138
121 125 134
122 126 135
123 132 140

124 133 141
31
32
33
34
61
62
63
64
91
92
93
94
95
1
2
3
4
127
128 136
129 137
130 138
131 139
100
101
102
103
104 112 120

10
71
11
12
13
35
36
37
38
39
40
41
42
43
65
66
67
68
69
70
72
73
96
97
98
99
5
6
7
8
9
105 113
106 114
107 115
108 116
109 117
110 118
111 119
44
45
46
47
48
49
50
51
74
75
76
78
79
80
81
82
77
14
15
16
17
18
19
20
142
143
144
145
146
83
84
85
86
87
88
89
52
53
54
55
56
57
58
21
22
23
24
25
26
27
AK303309 AB

No.
1 No. 1 injector While engine is idling after having warmed From 9 − 13 V*,
14 No. 3 injector
21 No. 4 injector
3 EGR valve (A) Ignition switch: Immediately after turning ON 5 − 8 V* (fluctuates for
12 EGR valve (B) approximately 3 seconds)
19 EGR valve (C)
26 EGR valve (D)
7 Engine warning lamp Ignition switch: "LOCK" (OFF) → "ON" 1 V or less → System
voltage (After several
TROUBLESHOOTING
13C-413
No.
8 A/C relay • Engine: Idle speed System voltage → 1 V or
• A/C switch: OFF → ON (A/C compressor less
is operating)
10 Cylinder 2,3 oxygen Engine: Idling after warming up 9 − 11 V
sensor heater (front) Engine: 5,000 r/min System voltage
15 Throttle valve control Ignition switch: "ON" System voltage
servo relay Running at 3,500 r/min while engine is 1 V or less
17 Fan controller Radiator and condenser fan is not operating 0 − 0.3 V*
Radiator and condenser fan is operating 0.7 V* or more
18 Cylinder 2,3 oxygen Engine: Idling after warming up 1 V or less
sensor heater (rear) Engine: Racing System voltage
23 Purge control Ignition switch: "ON" Decreases Voltage
24 Cylinder 1,4 oxygen Engine: Idling after warming up 1 V or less
sensor heater (rear) Engine: 5,000 r/min System voltage
25 Cylinder 1,4 oxygen Engine: Idling after warming up 9 − 11 V
sensor heater (front) Engine: Racing System voltage
31 Ignition coil − No. 1 Engine r/min: 3,000 r/min 0.3 − 3.0 V*
32 Ignition coil − No. 2
43
38 Accelerator pedal Ignition switch: "ON" Release the 0−1V
position switch accelerator pedal
Depress the 4 V or more
accelerator pedal
45 Alternator G terminal • Engine: Warm, idle (radiator fan: OFF) Voltage increases
• Headlamp: OFF → ON
is turned
TROUBLESHOOTING

No.
57 Engine control relay Ignition switch: "LOCK" (OFF) System voltage
(Power supply) Ignition switch: "ON" 1 V or less
supply
63 Air flow sensor Engine: Gradually increase the speed. Voltage increase in
response to revving
OFF
ON (A/C compressor
is operating)
Engine: Idling 2.0 − 3.0 V
78 A/C load signal Refer to GROUP 55 − Troubleshooting (Inspection at the Automatic
compressor − ECU Terminal)
79 <M/T> Vehicle speed • Ignition switch: "ON" 0 ⇔ 5 V Changes
sensor • Move the vehicle forword slowly repeatedly
voltage applied to
accelerator pedal
position sensor
95 Oil control valve Ignition switch: "ON" System voltage
Engine: warming up, 4,500 r/min 4.0 − 10 V*
voltage
temperature is 0°C
TROUBLESHOOTING
13C-415
No.
temperature is 0°C
101 Manifold absolute Engine: idling 0.8 − 2.4 V
pressure sensor • Engine: idling Rises from 0.8 − 2.4 V
• Revving (momentary wide open throttle) suddenly
voltage applied to
throttle position
sensor
position sensor (sub) accelerator pedal
Depress the 4.0 V or more
108 Cylinder 2,3 oxygen Engine: Running at 2,500 r/min after warmed 0 ⇔ 0.8 V (Changes
sensor (front) up (Check using a digital type voltmeter) repeatedly)
109 Cylinder 1,4 oxygen Engine: Running at 2,500 r/min after warmed 0 ⇔ 0.8 V (Changes
sensor (front) up (Check using a digital type voltmeter) repeatedly)
sensor (sub) air hose at the valve with your finger
throttle position
sensor, and then
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the use
of the special tool
(MB991658).
"ON"
position sensor accelerator pedal
(main) Depress the 4.0 V or more
TROUBLESHOOTING

No.
sensor (main) air hose at the valve with your finger
throttle position
sensor, and then
connect terminal
numbers No. 3,
No. 4, No. 5 and
No. 6 with the use
of the special tool
(MB991658).
"ON"
116 Cylinder 2,3 oxygen Engine: Idling after warmed up (Check using 0 ⇔ 0.6 V (Changes
sensor (rear) a digital type voltmeter) repeatedly)
117 Cylinder 1,4 oxygen Engine: Idling after warmed up (Check using 0 ⇔ 0.6 V (Changes
sensor (rear) a digital type voltmeter) repeatedly)
(when the load by
A/C is high)
the load by A/C is
low)
voltage applied to
throttle valve control
servo
servo (+) • Accelerator pedal: fully opened → fully (approximately 2 V) from
closed battery voltage.
servo (−) • Accelerator pedal: fully closed → fully (approximately 2 V) from
opened battery voltage.
NOTE: *:The average voltage is shown when an
analog voltmeter is used (because the average volt-
age might not be shown stably when digital voltmeter
is used).
TROUBLESHOOTING
13C-417
2. Disconnect the engine-ECU <M/T> or
vehicle wiring, sensors, engine-ECU <M/T> or
engine-A/T-ECU <A/T> and/or ohmmeter. Be
3. Measure the resistance and check for continuity careful to prevent this!
between the terminals of the engine-ECU <M/T>
or engine-A/T-ECU <A/T> harness-side connector
while referring to the check chart.
test probe.
given in the chart.
Engine-ECU <M/T> or engine-A/T-ECU <A/T> Harness Side Connector Terminal

Arrangement
Engine-ECU <M/T> or Engine-A/T-ECU <A/T> Harness Side Connector
C-138 C-142 C-141 C-140 C-139
124 133 141
123 132 140
122 126 135

121 125 134
34
33
32
31
64
63
62
61
95
94
93
92
91
4
3
2
1
131 139
130 138
129 137
128 136
127
104 112
103 110
102
101 109
100 108
10
71
11
13
12
43
42
41
40
39
38
37
36
35
73
72
70
69
68
67
66
65
99 107
98
97 106
96 105
6
5
8
7
9
111
51
50
49
48
47
46
45
44
82
81
80
79
78
76
75
74
77
20
19
18
17
16
15
14
146
145
144
143
142
120
119
118
117
116
115
114
113
89
88
87
86
85
84
83
58
57
56
55
54
53
52
27
26
25
24
23
22
21
AK303310 AB

No.
1 − 34 No. 1 injector 10.5 − 13.5 Ω (At 20°C)
3 − 34 EGR valve (A) 20 − 24 Ω (at 20°C)
12 − 34 EGR valve (B)
19 − 34 EGR valve (C)
26 − 34 EGR valve (D)
10 − 34 Cylinder 2,3 oxygen sensor heater 4.5 − 8.0 Ω (at 20°C)
(front)
25 − 34 Cylinder 1,4 oxygen sensor heater
(front)
18 − 34 Cylinder 2,3 oxygen sensor heater 11 − 18 Ω (at 20°C)
(rear)
24 − 34 Cylinder 1,4 oxygen sensor heater
(rear)
TROUBLESHOOTING

No.
earth
42 − Body
earth
144 −
Body
earth
145 −
Body
earth
34 − 95 Oil control valve 6.9 − 7.9 Ω (at 20°C)
133 − 141 Throttle actuator control motor 0.3 − 80 Ω (at 20°C)
TROUBLESHOOTING
13C-419
INSPECTION PROCEDURE USING 2. Connect the oscilloscope special pattern pickup to
OSCILLOSCOPE camshaft position sensor terminal No. 2.
M1131154500639 3. Disconnect the crank angle sensor intermediate
The output signals of the sensors and the conditions connector and connect the special tool Test
of the actuation signals of the actuators can be harness (MB991658) in between.
inspected visually by observing the waveforms on
the oscilloscope.
to crank angle sensor terminal No. 2.
CAMSHAFT POSITION SENSOR AND
CRANK ANGLE SENSOR Alternate Method (Test harness not
Camshaft position to engine-ECU <M/T> or engine-A/T-ECU <A/T>
sensor connector
terminal No. 71 (When checking the camshaft
Special patterns
1 2 3 pick-up
position sensor signal wave pattern).
Oscilloscope
to engine-ECU <M/T> or engine-A/T-ECU <A/T>
terminal No. 70 (When checking the crank angle
sensor signal wave pattern).
1 2 3
Crank angle sensor

intermediate
connector Observation condition
AK304513AB Pattern height Low
1. Disconnect the camshaft position sensor Pattern selector Display
connector and connect the special tool Test Engine speed Idle
harness (MB991709) in between (All terminals
should be connected).
2 engine revolutions
No.1 TDC No.3 TDC No.4 TDC No.2 TDC

Crank angle
sensor output 5
wave pattern
5
Camshaft position
sensor output
wave pattern
0 Time
TDC: Top dead centre

AK304514 AB
Wave Pattern Observation Points

Check that cycle time T becomes shorter when the
engine speed increases.
TROUBLESHOOTING
Examples of Abnormal Wave Patterns INJECTOR

Measurement Method
•
Oscilloscope
1 2
Special
patterns
pickup
AK304525
Example 1 AK101807AC
Cause of problem
1. Disconnect the injector connector, and then
Sensor interface malfunction
Wave pattern characteristics (MB991658) in between (All terminals should be
Rectangular wave pattern is output even when connected).
• 2. Connect the oscilloscope special patterns pickup

available)
terminal No. 1 (When checking the No. 1
cylinder).
AK203244
Example 2 terminal No. 5 (When checking the No. 2
Cause of problem cylinder).
Loose timing belt 3. Connect the oscilloscope special patterns pickup
Abnormality in sensor disk to engine-ECU <M/T> or engine-A/T-ECU <A/T>
Wave pattern characteristics terminal No. 14 (When checking the No. 3
Wave pattern is displaced to the left or right. cylinder).
terminal No. 21 (When checking the No. 4
cylinder).
TROUBLESHOOTING
13C-421
wave pattern
Engine Idle
Point A.
Standard wave pattern (V)
50
Solenoid back
electromotive force
(Approximately 7×10V)
Point B
Injector drive
time
Power
voltage
Time
AK301250AC
Wave Pattern Observation Points IGNITION COIL AND POWER TRANSIS-

Point A: Height of solenoid back electromotive force TOR
Contrast with standard wave Probable Measurement Method
pattern cause
Solenoid coil back electromotive Short in the Oscilloscope
force is low or doesn’t appear at injector solenoid
all.
1 2 3
• Special
patterns
pickup
AK300345 AB

When idling 2. Connect the oscilloscope special patterns pickup
to terminal No. 3 of each ignition coil connector in
The injector drive time will be synchronized with the turn.
M.U.T.-II tester display.
• When the engine is suddenly raced, the drive Alternate Method (Test harness not
time will be greatly extended at first, but the drive available)
time will soon match the engine speed. 1. Connect the oscilloscope probe to engine-ECU
<M/T> or engine-A/T-ECU <A/T> terminal No. 31.
(When checking the number 1 cylinder.)
TROUBLESHOOTING
2. Connect the oscilloscope probe to engine-ECU Standard Wave Pattern

<M/T> or engine-A/T-ECU <A/T> terminal No. 32.
3. Connect the oscilloscope probe to engine-ECU
<M/T> or engine-A/T-ECU <A/T> terminal No. 35. Pattern height Low
(When checking the number 3 cylinder.) Pattern selector Display
4. Connect the oscilloscope probe to engine-ECU Engine Approximately. 1,200
<M/T> or engine-A/T-ECU <A/T> terminal No. 52. r/min
(V) 2 engine revolutions

(1 camshaft revolution)
5˚ BTDC
TDC
Crank angle 10
sensor output
wave pattern
0
Ignition timing
Power transistor
control signal 10
wave pattern
0
OFF ON
Dwell section
TDC: Top dead centre AK203245AC
Wave Pattern Observation Points Example

Point: When the engine speed increases, verify that Wave pattern during engine cranking
the power transistor control signal (ignition timing) Cause of problem
advances. Open-circuit in ignition primary circuit
Examples of Abnormal Wave Patterns Top-right part of the build-up section cannot be
•

too low.
Normal wave pattern
AK203246 AD
TROUBLESHOOTING
13C-423
EGR VALVE (STEPPER MOTOR) Alternate Method (Test Harness not
Measurement Method Available)
1. Connect the oscilloscope probe to engine-ECU
Oscilloscope <M/T> or engine-A/T-ECU <A/T> terminal No. 3,
connection terminal No. 12, connection terminal
1 2 3
No. 19, and connection terminal No. 26 respec-
4 5 6
tively.
Special
patterns
pickup Standard Wave Pattern
AK303311AB Pattern height High
1. Disconnect the EGR valve connector, and con- Pattern selector Display
nect the special tool test harness (MB991658) in Engine Ignition switch: OFF →
between. ON
2. Connect the oscilloscope probe to the EGR
valve-side connector terminal 1, terminal 3, termi-
nal 4 and terminal 6 respectively.
(V)
The wave pattern

appears for an
instant, but soon
40 disappears.
Point A
Induced electromotive force
from the motor turning
Point B
Coil reverse electromotive
20 force (Approximately. 40V)
Stepper
motor
control
signal
wave
pattern 0
Time
AK301251AB
Wave pattern Observation Points

Check that the standard wave pattern appears when Point B: Height of coil reverse electromotive force
the EGR control servo is operating. Contrast with standard wave Probable
Point A: Presence or absence of induced electromo- pattern cause
tive force from the motor turning. (Refer to the abnor-
mal wave pattern.) Coil reverse electromotive force Short in the
does not appear or is extremely coil
Contrast with standard wave Probable small.
pattern cause
Induced electromotive force does Motor is
not appear or is extremely small. malfunctioning
TROUBLESHOOTING

•
Open
circuit
side
Normal
side
AKX01609AF
AKX01608AE Example 2
Example 1 Cause of problem
Cause of problem Open circuit in the line between the EGR valve
Sensor interface malfunction. (Motor is not oper- and the engine-ECU <M/T> or
ating) engine-A/T-ECU <A/T>.
Wave pattern characteristics Wave pattern characteristics
Induced electromotive force from the motor turn- Current is not supplied to the motor coil on the
ing dose not appear. open circuit side. (Voltage dose not drop to 0
V.)
Furthermore, the induced electromotive force
waveform at the normal side is slightly differ-
ent from the normal waveform.
ON-VEHICLE SERVICE
13C-425
ON-VEHICLE SERVICE
AREA) CLEANING MB 991637
M1131001000484
Gasket
1. Remove the air intake hose from the throttle body.
MD 998709
2. Remove the throttle body assembly.
CAUTION Delivery
pipe
• Do not spray the cleaning fluid directly to the MD 998742
throttle valve. High-pressure
fuel hose
the motor from the bypass line. Also make AKX01458AG
sure it does not enter the sensor through the

shaft. MB 991981
Gasket
cloth sprayed with cleaning fluid.
MD 998709
5. Install the throttle body assembly.
6. Attach the air intake hose. Delivery
pipe MD 998742
FUEL PRESSURE TEST High-pressure
M1131001900971 fuel hose
1. Release residual pressure from the fuel pipe line AK305430AB
to prevent fuel gush out (Refer to P.13C-428).
CAUTION <When using the fuel pressure gauge set (special
Cover the hose connection with rags to prevent tool)>
splash of fuel that could be caused by some a. Remove the union joint and bolt from the special
residual pressure in the fuel pipe line. tool Adaptor hose (MD998709) and attach the
special tool Hose adaptor (MD998742) to the
adaptor hose.
b. Via a gasket, install the special tool Fuel pressure
gauge set (MB991637 or MB991981) into the
special tool that has already assembled as
described in (a) above.
Fuel pressure
gauge set
O-ring or gasket
AK303313AB MD 998709
2. Disconnect the high-pressure fuel hose at the Delivery

pipe
delivery pipe side. MD 998742
3. Assemble the fuel pressure measurement tools High-pressure
fuel hose
as follows.
AKX01457AF

Adaptor hose (MD998709) and attach the special
tool Hose adaptor (MD998742) to the adaptor
hose.
b. Via a suitable O-ring or gasket, install the fuel
pressure gauge to the special tool that has
already assembled as described in (a) above.
ON-VEHICLE SERVICE
4. Install the assembled fuel pressure measurement 8. Finish the actuator test or turn the ignition switch
tools between the fuel rail and fuel high-pressure to "LOCK" (OFF) position.
hose. 9. Start the engine and run at idle.
CAUTION 10.Measure fuel pressure while the engine is running
To prevent damage to the M.U.T.-II/III, always turn at idle.
the ignition switch to the "LOCK" (OFF) position Standard value: Approximately. 324 kPa at
before connecting or disconnecting the cerb idle
M.U.T.-II/III.
11.Check to see that fuel pressure at idle does not
drop even after the engine has been raced
connector.
several times.
12.If any of fuel pressure measured in steps 10 to 11
is out of specification, troubleshoot and repair
7. Select "Item No. 07" from the M.U.T.-II/III Actuator according to the table below.
test to drive the fuel pump. Check that there are
no fuel leaks from any parts.
poor fuel regulator valve seating or
settled spring
regulator
stopped
14.Release residual pressure from the fuel pipe line 16.Replace the O-ring at the end of the fuel high
(Refer to P.13C-428). pressure hose with a new one. Furthermore,
CAUTION apply engine oil to the new O-ring before
Cover the hose connection with rags to prevent replacement.
splash of fuel that could be caused by some 17.Fit the fuel high pressure hose over the delivery
residual pressure in the fuel pipe line. pipe and tighten the bolt to specified toque.
15.Remove the fuel pressure gauge and special tool Tightening torque: 8.8 ± 1.9 N⋅m
from the delivery pipe. 18.Check for any fuel leaks by following the
procedure in step 7.
19.Disconnect the M.U.T.-II/III.
ON-VEHICLE SERVICE
13C-427
SWITCH AND ACCELERATOR PEDAL Accelerator pedal 1 2 3 4 5 6 7 8
position sensor
POSITION SENSOR (APS) ADJUSTMENT Equipment
side connector
M1131053400041
CAUTION
1. The accelerator pedal position sensor should
not be moved unnecessarily; it has been pre-
cisely adjusted by the manufacture.
2. If the adjustment is disturbed for any reason,
readjust as follows. AK303330AB
Accelerator lever
Stopper (full
stop position)
16 PIN A
MB991502 AK303650AB
AK303691AG
2. Remove the accelerator pedal position sensor
(main and sub) assembly mounting bolts, and
then insert a thickness gauge with a thickness of
0.60 mm in between the accelerator lever and the
fully-closed stopper (i.e. into area "A" shown in
16-PIN Fig).
3. Turn the ignition switch to the "ON" position
(without starting the engine).
4. Loosen the accelerator pedal position sensor
mounting bolt, and then turn the accelerator pedal
position sensor anti-clockwise as far as it will go.
MB991911
5. Check that the accelerator pedal position switch
turns on at this time.
MB991824
6. Turn the accelerator pedal position sensor
clockwise until the point is found where the
accelerator pedal position switch turns off.
Securely tighten the accelerator pedal position
sensor mounting bolt at this point.
7. Check that the accelerator pedal position sensor
MB991827 AK303690AB
(main) output at this time is within the standard
value range.
1. Connect the M.U.T.-II/III to the diagnosis Standard value: 0.5 − 0.9 V
connector.
position.
9. Remove the thickness gauge and then install the
accelerator pedal position sensor assembly.
10.Remove the M.U.T.-II/III.
ON-VEHICLE SERVICE
FUEL PUMP CONNECTOR FUEL PUMP OPERATION CHECK

M1131002000959
DISCONNECTION (HOW TO REDUCE The service procedure is the same as the vehicles
PRESSURIZED FUEL LINES) with 4G63-Non-Turbo engine. (Refer to GROUP 13A
M1131000900848
- On-vehicle Service P.13A-319).
The service procedure is the same as the vehicles
with 4G63-Non-Turbo- engine. (Refer to GROUP
13A - On-vehicle Service P.13A-318).
COMPONENT LOCATION
M1131002100815

Accelerator pedal position sensor (with A A/C relay I
accelerator pedal position switch)
A/C pressure sensor A Engine control relay I
Throttle valve control servo relay I
Crank angle sensor B Cylinder 1,4 oxygen sensor (front) J
Detonation sensor C Cylinder 1,4 oxygen sensor (rear) K
Manifold absolute pressure sensor C Ignition coil L
Purge control solenoid valve C Cylinder 2,3 oxygen sensor (rear) M
Injector D Cylinder 2,3 oxygen sensor (front) N
EGR valve E Inhibitor switch <A/T> O
Electronic-controled throttle valve F Power steering fluid pressure switch O
(Throttle position sensor and throttle Fuel pump relay (1) and (2) P
valve control servo)
Vehicle speed sensor <M/T> F Engine warning lamp Q
(check engine lamp)
Camshaft position sensor G Diagnosis connector R
Oil control valve G A/C switch S
Engine coolant temperature sensor G Engine-ECU <M/T> or engine-A/T-ECU T
Air flow sensor H <A/T> (with barometric pressure sensor)
(with intake air temperature sensor)
ON-VEHICLE SERVICE
13C-429
A B C D E F G H I P Q R S T
T S R Q P
J K L M N O
AK303314 AB
ENGINE CONTROL RELAY CONTINUITY Tester Battery Voltage Normal State

CHECK Connection
M1131050001003 Terminal
Engine control relay Relay box’s 2−3 No Voltage Continuity
triangle marks
1−4 No Voltage No continuity
Voltage (Connect Continuity (2
1 2 positive (+) terminal of Ω or less)
battery to terminal No. 3
3 4
and negative (−)
Equipment terminal of battery to
side connector
terminal No. 2.)
AK303315 AB
ON-VEHICLE SERVICE
FUEL PUMP RELAY CONTINUITY CHECK INTAKE AIR TEMPERATURE SENSOR

M1131033001000
CHECK
Fuel pump relay(1) M1131002800535
Junction block’s
triangle marks Air flow sensor
1 2
3 4 Fuel pump relay(2)
Equipment 1 2 3 4
Equipment
side connector AK303318AB
Tester Battery Voltage Normal State
Connection 1. Disconnect the air flow sensor connector.
Terminal
2. Measure resistance between terminals No. 1 and
2-3 No Voltage Continuity No. 4.
1-4 No Voltage No continuity Standard value:
Voltage (Connect Continuity (2 13 − 17 kΩ (at −20°C)
positive (+) terminal of Ω or less) 5.3 − 6.7 kΩ (at 0°C)
battery to terminal No. 3 2.3 − 3.0 kΩ (at 20°C)
and negative (−) 1.0 − 1.5 kΩ (at 40°C)
terminal of battery to 0.56 − 0.76 kΩ (at 60°C)
terminal No. 2.) 0.30 − 0.45 kΩ (at 80°C)
3. Remove the air flow sensor
RELAY CONTINUITY CHECK
M1131053500305
Relay box’s
triangle marks
Intake air
1 2 temperature
sensor
3 4
Equipment AK203040 AD
Throttle valve control side connector
servo relay 4. Measure resistance while heating the sensor
AK303317AB
using a hair drier.
Tester Battery Voltage Normal State Normal condition:
Connection Temperature (°C) Resistance (kΩ)
Terminal
Higher Smaller
2−3 No Voltage Continuity
1−4 No Voltage No continuity the resistance remains unchanged, replace the air
Voltage (Connect Continuity (2 flow sensor assembly.
positive (+) terminal of Ω or less) 6. Install the air flow sensor and tighten it to the
battery to terminal No. 3 specified torque.
and negative (−)
terminal of battery to
terminal No. 2.)
ON-VEHICLE SERVICE
13C-431
ENGINE COOLANT TEMPERATURE 4. Apply sealant to threaded portion.
SENSOR CHECK Specified sealant:
M1131003100506 3M NUT Locking Part No. 4171 or equivalent
CAUTION
5. Install the engine coolant temperature sensor and
tighten it to the specified torque.

SENSOR CHECK
Engine coolant M1130503400093
temperature sensor
Accelerator pedal 1 2 3 4 5 6 7 8
1 2
position sensor Equipment
Equipment side connector
side connector
AK303319 AB
1. Remove the engine coolant temperature sensor.
AK303330AB
1. Disconnect the accelerator pedal position sensor

connector.
power supply) and No. 1 (main earth) as well as
terminal No. 7 (sub earth) of the sensor
AKX01622
connector.
2. With temperature sensing portion of engine Standard valve: 3.5 − 6.5 kΩ
coolant temperature sensor immersed in hot 3. Measure resistance between terminal No. 2 (main
water, check resistance. power supply) and No. 3 (main output) as well as
Standard value: between terminal No. 8 (sub power supply) and
14 − 17 kΩ (at −20°C) No. 6 (sub output) of the sensor connector.
5.1 − 6.5 kΩ (at 0°C) Normal condition:
2.1 − 2.7 kΩ (at 20°C) Depress the accelerator Resistance value
0.9 − 1.3 kΩ (at 40°C) pedal slowly. changes in accordance
0.48 − 0.68 kΩ (at 60°C) with the accelerator
0.26 − 0.36 kΩ (at 80°C) pedal depression
3. If the resistance deviates from the standard value smoothly.
greatly, replace the sensor. 4. If not within the standard value, or resistance
value does not change smoothly, replace the
accelerator pedal position sensor.
NOTE: After replacement, adjust the accelerator
pedal position sensor. (Refer to P.13C-427.)
AKX01623AD
ON-VEHICLE SERVICE
ACCELERATOR PEDAL POSITION OXYGEN SENSOR CHECK

M1131005000679
SWITCH CHECK
M1131052500045 OXYGEN SENSOR (FRONT)
Accelerator pedal 1 2 3 4 5 6 7 8 sensor (front)
position sensor Equipment
side connector
1 2
3 4
Equipment
Cylinder 1, 4 oxygen side connector
AK303330AB sensor (front) connector AK303320AB
1. Disconnect the accelerator pedal position sensor

connector.
2. Check continuity between terminal No. 4
(accelerator pedal position switch) and No. 5
(earth) of the connector.
Normal condition:
Accelerator pedal Continuity Cylinder 2, 3 oxygen
sensor (front)
Depressed No continuity
Released Continuity (0 Ω)
1 2
3. If defective, replace the accelerator pedal position 3 4
sensor.
Equipment
NOTE: After replacement, adjust the accelerator side connector
pedal position sensor. (Refer to P.13C-427.)
sensor (front) connector
AK303321 AB
1. Disconnect the oxygen sensor connector and

to the connector on the oxygen sensor side.
ON-VEHICLE SERVICE
13C-433
Oxygen Standard value:
Red sensor Engine Oxygen Remarks
equipment
side connector sensor
Blue
output
voltage
AKX01624 AR
MB991316
0.6 − 1.0 V.
Oxygen
Red sensor CAUTION
equipment
side connector • Be very careful when connecting the jumper
Blue wire; incorrect connection can damage the
oxygen sensor.
AKX01624 AF
of beyond 8V is applied to the oxygen sensor
MD998464 heater.
2. Make sure that there is continuity (4.5 − 8.0 Ω at NOTE: If the sufficiently high temperature (of
20°C) between terminal No. 1 (red clip of special approximate 400°C or more) is not reached
tool) and No. 3 (blue clip of special tool) on the although the oxygen sensor is normal, the output
oxygen sensor connector. voltage would be possibly low although the rich
3. If there is no continuity, replace the oxygen air-fuel ratio. Therefore, if the output voltage is
sensor. low, use a jumper wire to connect the terminal No.
1 (red clip of special tool) and the terminal No. 3
4. Warm up the engine until engine coolant is 80°C
(blue clip of special tool) of the oxygen sensor
or higher.
5. Perform a tracing for 5 minutes or more with the supply respectively, then check again.
engine speed of 4,500 r/min.
8. If the sensor is defective, replace the oxygen
sensor.
NOTE: For removal and installation of the oxygen
Oxygen sensor, refer to GROUP 15 − Exhaust Manifold.
Black sensor
equipment
P.15-20.
side connector
White
AKX01624 AP
MB991316

No. 2 (black clip of special tool) and No. 4 (white
clip of special tool).
ON-VEHICLE SERVICE
OXYGEN SENSOR (REAR)
Oxygen
Red sensor
equipment
side connector
Blue
sensor (rear)
AKX01624 AF
MD998464
1 2
2. Make sure that there is continuity (11 − 18 Ω at
3 4
20°C) between terminal No.1 (red clip of special
Equipment tool) and No. 3 (blue clip of special tool) on the
side connector
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.
5. Perform a tracing for 5 minutes or more with the
Cylinder 1, 4 oxygen engine speed of 4,500 r/min.
sensor (rear) connector
AK303322 AB
Oxygen
Black sensor
equipment
side connector
White
Cylinder 2, 3 oxygen MD998464

AKX01624 AS
sensor (rear)
No.2 (black clip of special tool) and No. 4 (white
1 2 clip of special tool).
Cylinder 2, 3 oxygen 3 4 7. While repeatedly racing the engine, measure the
sensor (rear) connector
Equipment oxygen sensor output voltage.
side connector
Standard value:
sensor
output
voltage
AK303323AB
1. Disconnect the oxygen sensor connector and engine engine repeatedly, a
connect the special tool Test harness normal oxygen sensor
(MD998464) to the connector on the oxygen will output a voltage of
sensor side. 0.6 − 1.0 V.
ON-VEHICLE SERVICE
13C-435
CAUTION MEASUREMENT OF RESISTANCE
• Be very careful when connecting the jumper BETWEEN TERMINALS
wire; incorrect connection can damage the 1. Disconnect the injector connector.
oxygen sensor.
2. Measure the resistance between terminals.
of beyond 12 V is applied to the oxygen sen-
sor heater. 3. Connect the injector connector.
NOTE: If the sufficiently high temperature (of
approximate 400°C or more) is not reached CHECK THE INJECTION CONDITION
although the oxygen sensor is normal, the output 1. Carry out the procedure to prevent flow of the fuel
voltage would be possibly low although the rich (Refer to P.13C-428).
air-fuel ratio. Therefore, if the output voltage is CAUTION
low, use a jumper wire to connect the terminal Do not make fuel splash by covering fuel with
No.2 and the terminal No. 1 of the oxygen sensor waste and so on because the residual pressure is
with a (+) terminal and (-) terminal of 12 V power in the fuel pipeline.
supply respectively, then check again. 2. Remove the fuel high-pressure hose at the
8. If the sensor is defective, replace the oxygen delivery pipe side.
sensor.
NOTE: For removal and installation of the oxygen Tie up band
MD998741
MB991976
INJECTOR CHECK
M1131005200509
CHECK THE OPERATION SOUND

Injector
Injector AK303686AC

4. Assemble Injector Test Set (MD998706) of the
special tool as shown in Fig.
1 2 a. Install the injector to the installation hose for the
Equipment injector and then fix it using Injector Holder
side connector (MB991976) of the special tool.
AK303324 AB
b. Install Injector Test Adaptor (MD998741) of the
1. Use a stethoscope to listen to the operation sound special tool to another hose connected with the
(clicking) of the injectors while the engine is idling installation hose for the injector.
or cranking. c. Fold, band and tie up the rest of hose completely
in order to prevent from fuel leakage because it is
CAUTION
not used.
tors can be heard even if the injector that is being 5. Install Injector Test Set (MD998706) of the special
inspected might not be operating. tool to the fuel high-pressure hose.
2. Verify that the operation sound increases with the 6. Connect the M.U.T.-III to the diagnosis connector.
engine speed. 7. Turn the ignition switch to "ON" position (but do
NOTE: If the operating sound cannot be heard, not start the engine).
inspect the injector actuation circuit. 8. Select "Item No. 07" from M.U.T.-III actuator test
and drive the fuel pump.
ON-VEHICLE SERVICE
High-pressure CHECK THE COIL RESISTANCE

fuel hose
MB991607 Electronically
AK303687AC throttle valve
Equipment
9. Connect Injector Test Harness (MB991607) of the side connector AK303325AB
special tool between the injector and battery, and 1. Disconnect the electronically controlled throttle
then actuate the injector. valve connector.
10.Check the fuel spray condition. The condition can 2. Measure the resistance between terminals No. 1
be considered satisfactory unless it is extremely and No. 2 at the throttle valve control servo
poor. connector.
11.Stop actuating the injector. Check leakage from Standard value: 0.3 − 80 Ω (at 20°C)
the injector nozzle. Turn the ignition switch to
"LOCK OFF" position and then disconnect 3. If resistance is outside the standard value, replace
M.U.T.-III. the throttle body assembly.
12.Actuate the injector until the fuel cannot flow. OIL CONTROL VALVE CHECK
Draw the fuel out from the special tool. M1131053200058
13.Remove the special tool. OPERATION CHECK

14.If the fuel spray condition is extremely poor or if
there is the fuel leakage from the injector nozzle,
replace the injector. 1 2
15.Install the injector and fuel high-pressure hose. Equipment
side connector
CHECK
M1130532400037
OPERATION CHECK Oil control valve

1. Remove the air intake hose from the throttle body. AK303326 AB
2. Turn the ignition switch to "ON" position. 1. Disconnect the oil control valve connector.
3. Operate the accelerator pedal and confirm that
CAUTION
the throttle valve is opening and closing
To prevent the coil from burning, keep the dura-
accordingly.
tion of the voltage application as short as possi-
ble.
2. Apply battery voltage to the terminals of the
connector at the oil control valve, and make sure
the oil control valve makes a clicking sound.
MEASUREMENT OF RESISTANCE
BETWEEN TERMINALS
1. Disconnect the oil control valve connector.
2. Measure the resistance between the terminals of
the connector at the oil control valve.
3. If resistance is outside the standard value, replace
the oil control valve.
INJECTOR
13C-437
INJECTOR
M1131007101493
CAUTION
Engine P.00-21).
• Fuel Discharge Prevention (Refer to P.13C-428). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner P.15-8).
P.15-8). • Fuel Leakage Inspection.
11 ± 1 N·m
11 ± 1 N·m
3
N 87 5.0 ± 1.0 N·m
6 2
12
13 N 9
5
15 11
16
10
14
4 1

moving parts before
installation.
AC309314 AB

2. Capacitor connector <<A>> 9. Fuel delivery pipe and fuel injector
3. Ignition coil connector assembly
4. Injector connector 10. Insulators
5. EGR valve connector >>A<< 11. Fuel injector assembly
6. Rocker cover bracket installation 12. Fuel delivery pipe
bolts 13. O-ring
>>A<< 7. Fuel high-pressure hose 14. Insulators
connection 15. Grommets
16 Fuel injectors
INJECTOR

<<A>> FUEL DELIVERY PIPE AND FUEL >>A<< FUEL INJECTOR ASSEM-
INJECTOR ASSEMBLY REMOVAL BLY/FUEL HIGH-PRESSURE HOSE
CAUTION INSTALLATION
Do not drop the injector. CAUTION
Remove the fuel delivery pipe with the fuel injector Do not let the engine oil get into the delivery pipe
assembly attached to it. will be damaged.
2. Turn the fuel injector assembly to the right and left
to install to the fuel delivery pipe. Repeat for fuel
O-ring. After installing, check that the item turns
smoothly.
3. If it dose not turn smoothly, the O-ring may be
4. Tighten the fuel high-pressure hose to the
specified torque.
13C-439
M1131007701376
CAUTION
• When the throttle body assembly replacement is performed, use the M.U.T.-II/III to initialise the
learning value (Refer to GROUP 00, Precautions Before Service − Initialisation Procedure for
Learning Value in MPI Engine P.00-21).
• Do not loosen the fixing screws for the resin cover of throttle body assembly. If the screws are
loosened, the sensor incorporated in the resin cover becomes misaligned and the throttle body
can not work normally.
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner • Engine Coolant Supplying (Refer to GROUP 14, On-vehi-
P.15-8). cle Service − Engine Coolant Replacement P.14-17).
5N
19 ± 3 N·m
1
AC304161AE

>>B<< • Initialisation procedure (installation 3. Water feed hose connection
only) 4. Throttle body assembly
1. Throttle position sensor connector >>A<< 5. Throttle body gasket
2. Water return hose connection
INSTALLATION SERVICE POINTS >>B<< INITIALISATION PROCEDURE

>>A<< THROTTLE BODY GASKET Turn the ignition switch on then off, and keep it off for
at least 10 seconds.
INSTALLATION
CAUTION
Projection
AC304212AC
Install the throttle body gasket as its protrusion is in

the direction shown.
ENGINE-ECU AND ENGINE-A/T-ECU
13C-441
ENGINE-ECU AND ENGINE-A/T-ECU
M1131022500268
CAUTION
• When the engine-ECU <M/T> or the engine-A/T-ECU <A/T> replacement is performed, always refer
to GROUP 54A, On-vehicle Service - How to Register Encrypted Code P.54A-22.
• After the engine-ECU <M/T> or the engine-A/T-ECU <A/T> is replaced, idling speed may be unsta-
ble because the MPI engine learning is not completed. To make it stable, make the system learn
the idling (Refer to GROUP 00 − Precautions before Service, Learning Procedure for Idling in MPI
Engine P.00-21).
3
5.0 ± 1.0 N·m
1 9.0 ± 2.0 N·m
AC309335AB
Removal Steps INSTALLATION SERVICE POINT

>>A<< • Initialisation procedure (installation
>>A<< INITIALISATION PROCEDURE
only)
1. Engine-ECU connector <M/T> or Turn the ignition switch on then off, and keep it off for
Engine-A/T-ECU connector <A/T> at least 10 seconds.
2. Engine-ECU <M/T> or
3. Engine-ECU bracket <M/T> or
Engine-A/T-ECU bracket <A/T>
13D-1
GROUP 13D
FUEL SUPPLY
CONTENTS
GENERAL INFORMATION . . . . . . . . 13D-2 FUEL TANK GAUGE UNIT

REPLACEMENT <4WD> . . . . . . . . . . . . . . 13D-5
SEALANT. . . . . . . . . . . . . . . . . . . . . . 13D-2 FUEL LEAK CHECK OF FUEL TANK . . . . . 13D-7
SPECIAL TOOL . . . . . . . . . . . . . . . . . 13D-2 FUEL TANK . . . . . . . . . . . . . . . . . . . . 13D-8

<4G63-Non-Turbo, 4G63-Turbo> . . . . . . . . 13D-8
ON-VEHICLE SERVICE. . . . . . . . . . . 13D-3
REMOVAL AND INSTALLATION <4G69> . 13D-12
FUEL PUMP OPERATION CHECK . . . . . . 13D-3
FUEL PUMP ASSEMBLY DISASSEMBLY
FUEL GAUGE UNIT CHECK . . . . . . . . . . . 13D-3
AND REASSEMBLY <2WD> . . . . . . . . . . . 13D-15
FUEL PUMP ASSEMBLY <2WD>,
FUEL TANK PUMP AND GAUGE
ASSEMBLY DISASSEMBLY AND
ASSEMBLY <4WD> REPLACEMENT . . . . 13D-3
REASSEMBLY <4WD> . . . . . . . . . . . . . . . . 13D-16
FUEL TANK GAUGE UNIT
FUEL TANK GAUGE UNIT DISASSEMBLY
REPLACEMENT <2WD> . . . . . . . . . . . . . . 13D-4
AND REASSEMBLY . . . . . . . . . . . . . . . . . . 13D-17
13D-2 FUEL SUPPLY
GENERAL INFORMATION
GENERAL INFORMATION
M1135000100457
• The fuel tank is located under the floor of the rear • A fuel pump assembly <2WD>, fuel pump and
seats to provide increased protection and a more gauge assembly <4WD> including fuel pump,
luggage space. fuel filter, reservoir and fuel gauge unit, has been
• A fuel tank safety valve assembly has been adopted to lighten weight and improve servicea-
adopted to prevent fuel from leaking out in case bility.
of a collision.
SEALANT
M1135005200039

Service hole cover and floor pan <2WD> 3M 8513 Grommets windshield sealer (Black)
SPECIAL TOOL
M1135000600526

MB992145 Fuel leak check cap Fuel leak check
B992145
FUEL SUPPLY
ON-VEHICLE SERVICE
13D-3
ON-VEHICLE SERVICE
FUEL PUMP OPERATION CHECK Fuel pump assembly <2WD>
M1135001000260
<4G63-Non-Turbo>: Refer to GROUP 13A - or fuel tank pump and gauge assembly <4WD>
connector
On-vehicle Service, Fuel Pump Operation Check
P.13A-319.
<4G63-Turbo>: Refer to GROUP 13B - On-vehicle Fuel suction
Service, Fuel Pump Operation Check P.13B-393. tube <4WD>
<4G69>: Refer to GROUP 13C - On-vehicle Service,
Fuel Pump Operation Check P.13C-428.
FUEL GAUGE UNIT CHECK

M1135003100371
Refer to GROUP 54A − Combination Meter, On-vehi-
cle Service, Fuel Gauge Unit Check P.54A-58
<2WD>, P.54A-58 <4WD>.
FUEL PUMP ASSEMBLY <2WD>, FUEL

TANK PUMP AND GAUGE ASSEMBLY
<4WD> REPLACEMENT
M1135004900433 Fuel return hose
1. Remove the rear seat cushion assembly (Refer to <4G63-Non-Turbo, Fuel high-pressure
GROUP 52A − Rear seat assembly P.52A-26). 4G63-Turbo> hose
AC309286AE
Service hole cover

3. Disconnect the fuel pump assembly <2WD> or
fuel tank pump and gauge assembly <4WD>
connector, fuel return hose, fuel high-pressure
hose and fuel suction tube <4WD>.
CAUTION
Fuel tank pump and
gauge assembly
AC102784 AB
2. Remove the service hole cover mounting screws Service hole

and remove the service hole cover.
Float
AC107193AC
For 4WD: Pay attention not to damage the float

when removing and installing fuel tank pump and
gauge assembly through the service hole.
4. Remove the mounting nuts and fuel pump bracket
plate, and remove the fuel pump assembly
<2WD>, fuel tank pump and gauge assembly
<4WD> from the service hole.
5. Install the fuel pump assembly <2WD>, fuel tank
pump and gauge assembly <4WD> to the fuel
tank through the service hole.
13D-4 FUEL SUPPLY
ON-VEHICLE SERVICE
Fuel pump bracket plate 7. Connect the fuel pump assembly <2WD> or fuel
tank pump and gauge assembly <4WD>
connector, fuel return hose, fuel high-pressure
hose and fuel suction tube <4WD>.
Service hole cover
2.5 ± 0.4 N·m
AC107194AC
6. Install the fuel pump bracket plate to the fuel tank

and tighten the mounting nuts to the specified
torque.
AC102784 AB
8. Tighten the service hole cover mounting screws
CAUTION and install the service hole cover.
9. Install the rear seat cushion assembly. (Refer to
GROUP 52A − Rear seat assembly P.52A-26).
Corresponding side
Fuel high-pressure hose or FUEL TANK GAUGE UNIT
fuel pump suction tube <4WD> REPLACEMENT <2WD>
M1135001400398
1. Remove the rear seat cushion assembly (Refer to
GROUP 52A − Rear Seat Assembly P.52A-26).
3 mm
Quick connector Flat-tipped screwdriver
AC300047AC
After connecting the fuel high-pressure hose or

fuel pump suction tube <4WD>, slightly pull it to
ensure that it is installed securely. Also confirm
that there is a play approximately 3 mm.
Fuel pump assembly <2WD>
or fuel tank pump and gauge assembly <4WD>
connector
Service hole cover AC107600AC
Fuel suction 2. Pry off the service hole cover using a flat-tipped
tube <4WD> screwdriver, etc.
Fuel tank gauge unit

harness connector AC107601AC
3. Disconnect the fuel tank gauge unit harness

Fuel return hose
<4G63-Non-Turbo, Fuel high-pressure connector.
4G63-Turbo> hose
AC309286AE
FUEL SUPPLY
ON-VEHICLE SERVICE
13D-5
CAUTION Fuel tank gauge unit
Gauge unit

harness connector AC107601AC
Service hole AC107188AD

6. Connect the fuel tank gauge unit harness
Pay attention not to damage the gauge unit and connector.
the float of the fuel tank gauge unit when with-
drawing it from the service hole.
4. Remove the fuel tank gauge unit mounting nuts Service hole cover
and remove the fuel tank gauge unit from service
hole.
CAUTION
Fuel tank gauge unit Floor pan
AC100961AD
7. Apply the specified sealant to the contact surfaces

Gauge unit
of the service hole cover and the floor pan, and
install the service hole cover.
Specified sealant: 3M 8513 Grommets Wind-
shield Sealer (Black)
Service hole AC107188AE
8. Install the rear seat cushion assembly (Refer to
Pay attention not to damage the gauge unit and GROUP 52A − Rear Seat Assembly P.52A-26).
the float of the fuel tank gauge unit when insert-
ing it from the service hole. FUEL TANK GAUGE UNIT
2.5 ± 0.4 N·m
REPLACEMENT <4WD>
M1135001400406
1. Remove the rear seat cushion assembly (Refer to
GROUP 52A − Rear Seat Assembly P.52A-26).
Service hole cover
AC107602 AC
5. Install the fuel tank gauge unit to the fuel tank

through the service hole, and tighten the mounting
nuts to the specified torque.
AC107603AC
2. Remove the service hole cover mounting screws
and remove the service hole cover.
13D-6 FUEL SUPPLY
ON-VEHICLE SERVICE
Fuel pump suction tube 2.5 ± 0.4 N·m
Fuel tank gauge

unit harness
connector
AC107189AC AC107618AC
3. Disconnect the fuel tank gauge unit harness 5. Install the fuel tank gauge unit to the fuel tank
connector and fuel pump suction tube. through the service hole, and tighten the mounting
CAUTION nuts to the specified torque.
CAUTION
Gauge unit
Main pipe nozzle or
fuel main pipe
Service hole Fuel high-pressure hose or

fuel pump suction tube
Float
AC107190AD
Pay attention not to damage the gauge unit and 3 mm

Quick connector
the float of the fuel tank gauge unit when with- AC300047AB
drawing it from the service hole. After connecting the fuel high-pressure hose or
4. Remove the fuel tank gauge unit mounting nuts fuel pump suction tube, slightly pull it to ensure
and remove the fuel tank gauge unit from service that it is installed securely. Also confirm that
hole. there is a play approximately 3 mm.
CAUTION Fuel pump suction tube

Gauge unit
Service hole Fuel tank gauge
unit harness
connector
AC107189AC
Float
AC107190 AE
6. Connect the fuel tank pump gauge unit harness
Pay attention not to damage the gauge unit and connector and fuel suction tube.
the float of the fuel tank gauge unit when insert-
ing it from the service hole.
FUEL SUPPLY
ON-VEHICLE SERVICE
13D-7
Service hole cover
MB992145 Pressure
gauge
AC107603AC
7. Tighten the service hole cover mounting screws Trigonal joint

and install the service hole cover.
8. Install the rear seat cushion assembly (Refer to
GROUP 52A − Rear Seat Assembly P.52A-26). Air gun
FUEL LEAK CHECK OF FUEL TANK

M1135005900038
CAUTION Hose blocking plier

Always check the fuel leak of fuel tank with the
vehicle loaded. If it is checked with the fuel tank AC600150AB
removed, the fuel tank may be damaged.
2. Install the hose and pressure gauge to the special
MB992145 tool as shown.
Vapour hose
AC600149 AC Hose blocking plier
1. Remove the fuel tank cap, install special tool fuel AC605625 AB
leak check cap (MB992145).
3. Block the canister vapour hose (fuel tank side).
CAUTION
• Do not pressurise suddenly.
• Do not pressurise 11.76 kPa or more to pre-
vent the damage of components.
4. Pressurize while checking the pressure gauge
and hold if it reaches from 9.80 to 11.76 kPa.
5. Leave it for approximately 3 minutes and check
that the pressure is not weakened.
6. If the pressure is weakened, apply soapy water to
each part with pressurised state and check the
leak while confirming if air bubbles are seen.
13D-8 FUEL SUPPLY
FUEL TANK
FUEL TANK
<4G63-Non-Turbo, 4G63-Turbo>
M1135001900702

• Draining Fuel • Propeller Shaft Installation <4WD> (Refer to GROUP 25,
• Fuel Pump Connector Disconnection (How to Reduce Propeller Shaft P.25-3).
Fuel Pressure) (Refer to GROUP 13A − On-vehicle Serv- • Centre Exhaust Pipe Installation (Refer to GROUP 15,
ice P.13A-318 <4G63-Non-Turbo>) (Refer to GROUP Exhaust Pipe and Main Muffler P.15-25
13B − On-vehicle Service P.13B-393 <4G63-Turbo>). <4G63-Non-Turbo>) (Refer to GROUP 15, Exhaust Pipe
• Centre Exhaust Pipe Removal (Refer to GROUP 15, and Main Muffler P.15-27 <4G63-Turbo>).
Exhaust Pipe and Main Muffler P.15-25 • Refilling Fuel
<4G63-Non-Turbo>) (Refer to GROUP 15, Exhaust Pipe • Checking for Fuel Leaks
and Main Muffler P.15-27 <4G63-Turbo>).
• Propeller Shaft Removal <4WD> (Refer to GROUP 25,
Propeller Shaft P.25-3).
<2WD>
8
2.5 ± 0.4 N·m
21
11
8 2.5 ± 0.4 N·m 12
5
15 13
13 15 13
17 22
18 N
2.5 ± 0.4 N·m 4 3
20 N 19
20 N 19
9 2.5 ± 0.4 N·m 13 24 2
14 13
25
1
23
6
26 ± 5 N·m
23 ± 4 N·m
26 ± 5 N·m 7
AC212356 AB
FUEL SUPPLY
FUEL TANK
13D-9
<4WD>
8
2.5 ± 0.4 N·m
2.5 ± 0.4 N·m 21

16 11
8 12
2.5 ± 0.4 N·m 13 5
15
13 15 13
22
17 N 18 2.5 ± 0.4 N·m
4 3
13 20 N
20 N 19 14 19
13 2
24
10
25 1
23
23 ± 4 N·m
26 ± 5 N·m 7 AC212516AB
Fuel tank assembly removal Fuel tank assembly removal

steps steps (Continued)
1. Fuel filler hose connection <Fuel >>A<< 11. Fuel high-pressure hose
filler neck side> 12. Fuel return hose
2. Fuel filler neck breather hose 13. Fuel tank hose
connection <Fuel filler neck side> 14. Fuel tank vapour hose 2way valve
3. Main pipe connection 15. Fuel vapour pipe
4. Return pipe >>A<< 16. Fuel pump suction tube <4WD>
5. Fuel vapour pipe <> 17. Fuel tank gauge unit
6. Parking brake cable clamp 18. Gasket
connection <RH side> 19. Fuel tank safety valve
7. Wiring harness clamp connection 20. Gasket
8. Fuel tank gauge unit assembly, fuel 21. Fuel pump bracket plate
pump assembly <2WD>, fuel tank <> 22. Fuel pump assembly <2WD>, fuel
pomp and gauge assembly <4WD> tank pump and gauge assembly
connector connection <4WD>
<<A>> • Rear differential support member 23. Fuel filler hose
installation nuts and bolts <4WD> 24. Fuel filler neck breather hose
(Refer to GROUP 27B − Rear 25. Fuel tank
Differential Carrier Assembly
P.27B-16).
9. Fuel tank assembly <2WD>
<<A>> 10. Fuel tank assembly <4WD>
13D-10 FUEL SUPPLY
FUEL TANK
<FUEL FILLER NECK>
30
27
28
29
1
26
AC300410AB
Fuel filler neck removal steps Fuel filler neck removal steps
1. Fuel filler hose connection <Fuel 27. Fuel tank cap
filler neck side> 28. Fuel filler neck
2. Fuel filler neck breather hose 29. Fuel filler neck valve
connection <Fuel filler neck side> 30. Gasket
26. Fuel filler neck protector
FUEL SUPPLY
FUEL TANK
13D-11
REMOVAL SERVICE POINTS CAUTION

<<A>> REAR DIFFERENTIAL SUPPORT Support the fuel tank assembly securely so that
MEMBER INSTALLATION NUTS AND it does not fall off from the transmission jack.
BOLTS <4WD>/FUEL TANK ASSEMBLY 3. Tilt the fuel tank assembly to disconnect the
connectors.
<4WD> REMOVAL
Towards front Rear differential
Rear differential of vehicle
Fuel tank assembly carrier assembly
carrier assembly
Tilt
Towards front Lower
Fuel tank assembly AC300043AB
4. Remove the fuel tank assembly to the direction
1. Remove the rear differential support member
shown, being careful not to strike it against the
installation nuts and bolts, and then tilt the rear
rear differential carrier assembly.
differential carrier assembly (Refer to GROUP
27B − Rear Differential Carrier Assembly <> FUEL TANK GAUGE UNIT/FUEL
P.27B-16). PUMP ASSEMBLY <2WD>, FUEL TANK
PUMP AND GAUGE ASSEMBLY <4WD>
REMOVAL
CAUTION
When withdrawing the fuel tank gauge unit, fuel
tank pump and gauge assembly from the fuel
tank, be careful not damage the module unit and
the float.
Fuel tank assembly
Transaxle jack AC107196 AD INSTALLATION SERVICE POINTS
2. Raise and support the fuel tank assembly with a >>A<< FUEL PUMP SUCTION TUBE
transmission jack, and remove the mounting nuts <4WD>/FUEL HIGH-PRESSURE HOSE
and bolts. INSTALLATION
Towards front CAUTION
of vehicle Rear differential
Corresponding side
Fuel high-pressure hose or
fuel pump suction tube <4WD>
Tilt
AC300040AB 3 mm
Quick connector
AC300047AC

fuel pump suction tube <4WD>, slightly pull it to
ensure that it is installed securely. Also confirm
that there is a play approximately 3 mm.
13D-12 FUEL SUPPLY
FUEL TANK
REMOVAL AND INSTALLATION <4G69>

M1135001900542

• Draining Fuel • Propeller Shaft Installation (Refer to GROUP 25, Propeller
• Fuel Pump Connector Disconnection (How to Reduce Shaft P.25-3).
Fuel Pressure) (Refer to GROUP 13C − On-vehicle Serv- • Centre Exhaust Pipe Installation (Refer to GROUP 15,
ice P.13C-428). Exhaust Pipe and Main Muffler P.15-25).
• Centre Exhaust Pipe Removal (Refer to GROUP 15, • Refilling Fuel
Exhaust Pipe and Main Muffler P.15-25). • Checking for Fuel Leaks
• Propeller Shaft Removal (Refer to GROUP 25, Propeller
Shaft P.25-3).
7
2.5 ± 0.4 N·m
2.5 ± 0.4 N·m 18

13
9
7
4
2.5 ± 0.4 N·m 10
12
10 12 10 19
14 N 15 2.5 ± 0.4 N·m 3
10 17 N 16
17 N 16 11
10 2
21
8
22 1
20
23 ± 4 N·m
26 ± 5 N·m
6 AC309122AB
Fuel tank assembly removal Fuel tank assembly removal

1. Fuel filler hose connection <Fuel <<A>> • Rear differential support member
filler neck side> installation nuts and bolts (Refer to
2. Fuel filler neck breather hose GROUP 27B − Rear Differential
connection <Fuel filler neck side> Carrier Assembly P.27B-16).
3. Main pipe connection <<A>> 8. Fuel tank assembly
4. Fuel vapour pipe >>A<< 9. Fuel high-pressure hose
5. Parking brake cable clamp 10. Fuel tank hose
connection <RH side> 11. Fuel tank vapour hose 2way valve
6. Wiring harness clamp connection 12. Fuel vapour pipe
7. Fuel tank gauge unit assembly, fuel >>A<< 13. Fuel pump suction tube
tank pomp and gauge assembly <> 14. Fuel tank gauge unit
connector connection 15. Gasket
16. Fuel tank safety valve
FUEL SUPPLY
FUEL TANK
13D-13
Fuel tank assembly removal
steps (Continued)
17. Gasket
18. Fuel pump bracket plate
<> 19. Fuel tank pump and gauge
assembly
20. Fuel filler hose
21. Fuel filler neck breather hose
22. Fuel tank
<FUEL FILLER NECK>
27
24
25
26
1
23
AC300410AC
Fuel filler neck removal steps Fuel filler neck removal steps
1. Fuel filler hose connection <Fuel 24. Fuel tank cap
filler neck side> 25. Fuel filler neck
2. Fuel filler neck breather hose 26. Fuel filler neck valve
connection <Fuel filler neck side> 27. Gasket
23. Fuel filler neck protector
13D-14 FUEL SUPPLY
FUEL TANK
REMOVAL SERVICE POINTS CAUTION

<<A>> REAR DIFFERENTIAL SUPPORT Support the fuel tank assembly securely so that
MEMBER INSTALLATION NUTS AND it does not fall off from the transmission jack.
BOLTS/FUEL TANK ASSEMBLY 3. Tilt the fuel tank assembly to disconnect the
connectors.
REMOVAL
Towards front Rear differential
Rear differential of vehicle
carrier assembly
Tilt
Towards front Lower
Fuel tank assembly AC300043AB
4. Remove the fuel tank assembly to the direction
1. Remove the rear differential support member
shown, being careful not to strike it against the
installation nuts and bolts, and then tilt the rear
rear differential carrier assembly.
differential carrier assembly (Refer to GROUP
27B − Rear Differential Carrier Assembly <> FUEL TANK GAUGE UNIT/FUEL
P.27B-16). TANK PUMP AND GAUGE ASSEMBLY
REMOVAL
CAUTION
When withdrawing the fuel tank gauge unit, fuel
tank pump and gauge assembly from the fuel
tank, be careful not damage the module unit and
the float.
Fuel tank assembly INSTALLATION SERVICE POINTS

Transaxle jack AC107196 AD >>A<< FUEL PUMP SUCTION TUBE
2. Raise and support the fuel tank assembly with a <4WD>/FUEL HIGH-PRESSURE HOSE
transmission jack, and remove the mounting nuts INSTALLATION
and bolts. CAUTION
Towards front
of vehicle Rear differential
Corresponding side
Fuel high-pressure hose or
fuel pump suction tube
Tilt 3 mm
Quick connector
AC300040AB AC300047AE

fuel pump suction tube, slightly pull it to ensure
that it is installed securely. Also confirm that
there is a play approximately 3 mm.
FUEL SUPPLY
FUEL TANK
13D-15
FUEL PUMP ASSEMBLY DISASSEMBLY
AND REASSEMBLY <2WD>
M1135004600380
3
2
10
1N
N5 8
6
N5 4
9
11 7
AC309295 AB
Disassembly steps Disassembly steps (Continued)

1. Gasket >>A<< 10. Fuel tank grommet
2. Fuel tank pump connector 11. Fuel tank filter assembly
connection
3. Fuel pump bracket REASSEMBLY SERVICE POINT
4. Fuel pump hose
>>A<< FUEL TANK GROMMET/O-RING
>>A<< 5. O-ring
6. Fuel pump tube INSTALLATION
7. Fuel pump bracket Apply gasoline on the grommet and the O-ring before
8. Fuel tank pump mounting them to prevent damage or twisting.
9. Fuel tank pump cushion
13D-16 FUEL SUPPLY
FUEL TANK

ASSEMBLY DISASSEMBLY AND
REASSEMBLY <4WD>
M1135004600476
<4G63-Non-Turbo, 4G63-Turbo> <4G69>
5 5
4
14 4
2 1N 2 1N 14
3 N 10
12 3 N 10
8 9 6
N 10
12
6 N 10
7 13
13
11
15 15 11
AC309123 AC309123
AC309296 AC

1. Gasket 11. Fuel pump bracket
2. Fuel tank gauge unit connector 12. Fuel tank pump
connection 13. Fuel tank pump cushion
3. Fuel tank gauge unit >>A<< 14. Fuel tank grommet
4. Fuel tank pump connector 15. Fuel tank filter assembly
connection
5. Fuel pump bracket REASSEMBLY SERVICE POINT
6. Fuel pump hose >>A<< FUEL TANK GROMMET/O-RING
7. Fuel tank assist pump
<4G63-Non-Turbo, 4G63-Turbo> INSTALLATION
8. Fuel pump tube Apply gasoline on the grommet and the O-ring before
<4G63-Non-Turbo, 4G63-Turbo> mounting them to prevent damage or twisting.
9. Fuel pump pressure regulator
<4G69>
>>A<< 10. O-ring
FUEL SUPPLY
FUEL TANK
13D-17
FUEL TANK GAUGE UNIT DISASSEMBLY AND REASSEMBLY
M1135051100068
<2WD> <4WD>
3
3
1
1
2
AC102461 AD

1. Gasket 2. Fuel in tank filter <4WD>
3. Fuel tank gauge unit
14-1
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . . 14-2 THERMOSTAT . . . . . . . . . . . . . . . . . . 14-21

REMOVAL AND INSTALLATION . . . . . . . . 14-21
SERVICE SPECIFICATION . . . . . . . . 14-2 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-24
LUBRICANT. . . . . . . . . . . . . . . . . . . . 14-2 WATER PUMP . . . . . . . . . . . . . . . . . . 14-25

SEALANT. . . . . . . . . . . . . . . . . . . . . . 14-2 <4G63-NON-TURBO>. . . . . . . . . . . . . . . . . 14-25
SPECIAL TOOL . . . . . . . . . . . . . . . . . 14-3 <4G63-TURBO> . . . . . . . . . . . . . . . . . . . . . 14-26
TROUBLESHOOTING . . . . . . . . . . . . 14-3 <4G69> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27

SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 14-3 WATER HOSE AND
INSPECTION PROCEDURE FOR WATER PIPE . . . . . . . . . . . . . . . . . . . 14-28
TROUBLE SYMPTOMS . . . . . . . . . . . . . . . 14-4 REMOVAL AND INSTALLATION
<4G63-NON-TURBO>. . . . . . . . . . . . . . . . . 14-28
ON-VEHICLE SERVICE. . . . . . . . . . . 14-17 REMOVAL AND INSTALLATION
<4G63-TURBO> . . . . . . . . . . . . . . . . . . . . . 14-30
ENGINE COOLANT LEAK CHECK . . . . . . 14-17
RADIATOR CAP VALVE OPENING
<4G69> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-32
PRESSURE CHECK. . . . . . . . . . . . . . . . . . 14-17
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 14-34
ENGINE COOLANT REPLACEMENT . . . . 14-17
CONCENTRATION MEASUREMENT . . . . 14-18
RADIATOR . . . . . . . . . . . . . . . . . . . . . 14-35
FAN CONTROLLER CHECK . . . . . . . . . . . 14-19
FAN CONTROL RELAY CONTINUITY
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19
RADIATOR FAN MOTOR CHECK . . . . . . . 14-20
14-2 ENGINE COOLING
GENERAL INFORMATION
GENERAL INFORMATION
M1141000100951
The cooling system is designed to keep every part of ature, the thermostat opens to circulate the coolant
the engine at appropriate temperature in whatever through the radiator as well so that the heat
condition the engine may be operated. The cooling absorbed by the coolant may be radiated into the air.
method is of the water-cooled, pressure forced circu- The water pump is of the centrifugal type and is
lation type in which the water pump pressurizes cool- driven by the drive belt from the crankshaft. The radi-
ant and circulates it throughout the engine. If the ator is the corrugated fin, down flow type.
coolant temperature exceeds the prescribed temper-
Item Specification
Radiator Performance kJ/h 4G63-Non-Turbo 194,000
4G63-Turbo 237,600
4G69 208,800
Built-in transmission fluid cooler Performance kJ/h 5,700
<4G69-A/T>
SERVICE SPECIFICATION
M1141000300461

Fan controller V A/C OFF 1 or less -
A/C ON Repeat -
8.2 ± 2.6
System voltage ± 2.6
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 mm 8.5 or more -
LUBRICANT
M1141000400394
Item Specified coolant Quantity L

Engine coolant DIAQUEEN SUPER LONG LIFE COOLANT or an 7.0
(including condense equivalent
tank)
SEALANT
M1141000500391

Thermostat case, Water outlet fitting MITSUBISHI GENUINE Part No.MD970389 or equivalent
Thermostat case assembly bolt 3M Stud Locking 4170 or equivalent
Cylinder block drain plug 3M Nut Locking Part No.4171 or equivalent
ENGINE COOLING
SPECIAL TOOL
14-3
SPECIAL TOOL
M1141000600525

MB991871 LLC changer Coolant refilling
MB991871
MB991223 Harness set Making voltage and

A
A: MB991219 A: Test harness resistance measurement
B: MB991220 B: LED harness during troubleshooting
C: MB991221 C: LED harness A: Connector pin contact
D: MB991222 adapter pressure inspection
B D: Probe B: Power circuit inspection
C: Power circuit inspection
D: Commercial tester
connection
C
D DO NOT USE
MB991223 AZ
MB992006 Extra fine probe Making voltage and

resistance measurement
during troubleshooting
MB992006
TROUBLESHOOTING
SYMPTOMS
M1141005600412
Trouble symptom Inspection Reference page

procedure No.
Radiator fan and condenser fan do not operate 1 P.14-4
Radiator fan and condenser fan do not change speed or stop 2 P.14-13
Radiator fan does not operate 3 P.14-16
Condenser fan does not operate 4 P.14-16
14-4 ENGINE COOLING
TROUBLESHOOTING

TROUBLE SYMPTOMS
Inspection Procedure 1: Radiator Fan and Condenser Fan do not Operate
Radiator Fan and Condenser Fan Drive Circuit
ENGINE-ECU <M/T> OR
ENGINE-A/T-ECU <A/T> FUSIBLE
LINK No.2
ENGINE CONTROL
RELAY
FAN CONTROL
RELAY
FAN
CONTROLLER
NOTE
4G63-NON-TURBO
4G63-TURBO AND 4G69
Wire colour code

B : Black LG : Light green
G : Green L : Blue
W : White Y : Yellow
SB : Sky blue BR : Brown
CONDENSER RADIATOR O : Orange GR : Grey
FAN MOTOR FAN MOTOR R : Red P : Pink V : Violet
AC605204
CIRCUIT OPERATION • The engine-ECU <M/T> or engine-A/T-ECU

• The fan controller is powered from fusible link <A/T> uses input signals from the A/C switch, the
No.2. water temperature sensor unit and the vehicle
speed sensor <M/T> or the output shaft speed
sensor <A/T> to control the speed of the radiator
fan motor and the condenser fan motor.
<A/T> controls the fan controller to activate the
radiator fan motor and the condenser fan motor.
ENGINE COOLING
TROUBLESHOOTING
14-5
TECHNICAL DESCRIPTION (2) Turn the ignition switch to the "ON" position.
• The cause could be a malfunction of the fan con-
troller power supply or earth circuit.
• If the communication line wiring harness between Connector A-20
the fan controller and the engine-ECU <M/T> or (Component side)
engine-A/T-ECU <A/T> is short-circuited to earth, 3 2 1
the radiator fan motor and the condenser fan
motor will not rotate.
• The cause could also be a malfunction of input
signal from the A/C switch, the water temperature
sensor unit and the vehicle speed sensor <M/T> AC201418 AF
or the output shaft speed sensor <A/T> to the
(3) Measure the voltage between fan controller
connector A-20 terminal 3 and body earth.
• The cause could also be a malfunction of the fan
• The voltage should measure system voltage.
controller or the engine-ECU <M/T> or
(4) Turn the ignition switch to the "LOCK" (OFF)
position.
(5) Connect fan controller connector A-20.
TROUBLESHOOTING HINTS
• Malfunction of fusible link No.2 Q: Is the measured voltage system voltage?
• Malfunction of fan control relay YES : Go to Step 17.
• Malfunction of cooling fan motor NO : Go to Step 3.
• Malfunction of fan controller
• Malfunction of engine-ECU <M/T> or STEP 3. Check the fan controller connector A-20.
Connector: A-20
• Damaged wiring harness or connector
DIAGNOSIS PROCEDURE
A-20
STEP 1. Check the radiator fan motor. 3 2 1
Refer to P.14-20.
Q: Is the radiator fan motor in good condition?
YES : Go to Step 2.
AC301902 AB
NO : Replace the radiator fan motor (Refer to
P.14-35). Then go to Step 24. Q: Is the connector in good condition?
YES : Go to Step 4.
NO : Repair or replace the connector. Then go to
STEP 2. Measure the power supply voltage at fan
controller connector A-20. Step 24.
Connector: A-20
A-20
3 2 1
AC301902 AB
(1) Disconnect fan controller connector A-20 and

measure wiring harness side connector.
14-6 ENGINE COOLING
TROUBLESHOOTING
Q: Is the measured voltage system voltage?

STEP 4. Check the fusible link No.2.
YES : Go to Step 8.
NO : Go to Step 6.
Relay box
STEP 6. Check the fan control relay connector

A-10X.
Connector: A-10X
Relay box
Fusible link Fan control relay

No.2 AC309505 AB
Q: Is the fusible link No.2 in good condition?

YES : Go to Step 5. A-10X
NO : Replace the fusible link No.2. Then go to
Step 24. AC309505 AC
Q: Is the connector in good condition?

STEP 5. Measure the power supply voltage at fan
YES : Go to Step 7.
control relay connector A-10X. NO : Repair the connector or replace the relay
Connector: A-10X box. Then go to Step 24.
Relay box
STEP 7. Check the harness wire between fusible

Fan control relay link No.2 and fan control relay connector A-10X
terminal 4.
A-10X Relay box
AC309505 AC
(1) Disconnect fan control relay connector A-10X

(remove the fan control relay) and measure relay
box side connector.
(2) Turn the ignition switch to the "ON" position. Fusible link
No.2 AC309505 AB
A-10X Connector
(Relay box side) Connector: A-10X
Relay box
Fan control relay
A-10X
AC303511AD
(3) Measure the voltage between fan control relay

AC309505 AC
connector A-10X terminal 4 and body earth.
• The voltage should measure system voltage. Q: Is the harness wire in good condition?
(4) Turn the ignition switch to the "LOCK" (OFF) YES : An intermittent malfunction is suspected
position. (Refer to GROUP 00 - How to use
(5) Connect fan control relay connector A-10X troubleshooting P.00-6).
(install the fan control relay). NO : Repair the damaged harness wire. Then go
to Step 24.
ENGINE COOLING
TROUBLESHOOTING
14-7
STEP 8. Check the fan control relay. STEP 10. Check the harness wire between fan
Refer to P.14-19. control relay connector A-10X terminal 2 and fan
Q: Is the fan control relay in good condition?
controller connector A-20 terminal 3.
YES : Go to Step 9. Connector: A-10X
Relay box
NO : Replace the fan control relay. Then go to
Step 24.
Fan control relay
A-10X.
Connector: A-10X A-10X
Relay box
AC309505 AC
Fan control relay
Connector: A-20
A-10X
A-20
AC309505 AC 3 2 1
Q: Is the connector in good condition?

NO : Repair the connector or replace the relay
AC301902 AB
box. Then go to Step 24.
Q: Is the harness wire in good condition?
NO : Repair the damaged harness wire. Then go
to Step 24.
14-8 ENGINE COOLING
TROUBLESHOOTING
STEP 11. Measure the terminal voltage at fan STEP 12. Check the J/C No.2 C-17, intermediate
control relay connector A-10X. connector A-14 and fan control relay connector
A-10X.
Connector: A-10X
Relay box
Connector: C-17
Fan control relay
C-17 (GR)
A-10X
AC309505 AC
(1) Disconnect fan control relay connector A-10X AC309507AC
(remove the fan control relay) and measure relay Connector: A-14
box side connector.
(2) Turn the ignition switch to the "ON" position.
A-14(GR)
A-10X Connector
(Relay box side)
A-14(GR)
AC309506AB
Connector: A-10X
Relay box
AC303517AC
(3) Measure the voltage between fan control relay

connector A-10X terminal 1 and body earth. Fan control relay
• The voltage should measure system voltage.
(4) Turn the ignition switch to the "LOCK" (OFF)
position. A-10X
(5) Connect fan control relay connector A-10X
(install the fan control relay).
AC309505 AC
Q: Is the measured voltage system voltage?
YES : Go to Step 14. Q: Are there connectors in good condition?
NO : Go to Step 12. YES : Go to Step 13.
Step 24.
ENGINE COOLING
TROUBLESHOOTING
14-9
STEP 13. Check the harness wire between J/C
No.2 C-17 terminal 5 and fan control relay A-10X Connector
connector A-10X terminal 1. (Relay box side)
Connector: C-17
C-17 (GR)
AC303533AC
(2) Check that there is continuity between fan control

relay connector A-10X terminal 3 and body earth.
AC309507AC • Continuity (less than 2 Ω).
(3) Connect fan control relay connector A-10X
Connector: A-10X
Relay box (install the fan control relay).
Q: Does the continuity exist?
YES : An intermittent malfunction is suspected
Fan control relay (Refer to GROUP 00 - How to use
troubleshooting P.00-6).
NO : Go to Step 15.
A-10X
AC309505 AC A-10X.
Connector: A-10X
Q: Are these harness wires in good condition? Relay box
(Refer to GROUP 00 - How to use
troubleshooting P.00-6). Fan control relay
to Step 24.
A-10X
STEP 14. Check the continuity between fan
control relay connector A-10X and body earth. AC309505 AC
Connector: A-10X
Relay box Q: Is the connector in good condition?
NO : Repair the connector or replace the relay
Fan control relay box. Then go to Step 24.
A-10X
AC309505 AC
(1) Disconnect fan control relay connector A-10X

(remove the fan control relay) and measure relay
box side connector.
14-10 ENGINE COOLING
TROUBLESHOOTING
Q: Does the continuity exist?

STEP 16. Check the harness wire between fan
control relay connector A-10X terminal 3 and NO : Go to Step 18.
body earth.
Connector: A-10X STEP 18. Check the fan controller connector
Relay box
A-20.
Connector: A-20
Fan control relay
A-10X A-20
3 2 1
AC309505 AC

YES : An intermittent malfunction is suspected AC301902 AB
(Refer to GROUP 00 - How to use
troubleshooting P.00-6). Q: Is the connector in good condition?
NO : Repair the damaged harness wire. Then go YES : Go to Step 19.
to Step 24. NO : Repair or replace the connector. Then go to
Step 24.
STEP 17. Check the continuity between fan
controller connector A-20 and body earth. STEP 19. Check the harness wire between fan
controller connector A-20 terminal 1 and body
Connector: A-20
earth.
Connector: A-20
A-20
3 2 1
A-20
3 2 1
AC301902 AB
(1) Disconnect fan controller connector A-20 and

AC301902 AB
measure wiring harness side connector.
A-20 Connector (Refer to GROUP 00 - How to use
(Wiring harness side) troubleshooting P.00-6).
to Step 24.
AC303534 AC
(2) Check that there is continuity between fan

controller connector A-20 terminal 1 and body
earth.
• Continuity (less than 2 Ω).
(3) Connect fan controller connector A-20.
ENGINE COOLING
TROUBLESHOOTING
14-11
STEP 20. Check the fan controller connector STEP 21. Check the harness wire between fan
A-20, intermediate connector A-14 and controller connector A-20 terminal 2 and
engine-ECU connector or engine-A/T-ECU engine-ECU or engine-A/T-ECU connector C-134
connector C-134 <4G63-Non-turbo> or C-139 terminal 21 <4G63-Non-turbo> or C-139 terminal
<4G63-Turbo and 4G69>. 17 <4G63-Turbo and 4G69>.
Connector: A-20 Connector: A-20
A-20 A-20
3 2 1 3 2 1
AC301902 AB AC301902 AB
Connector: A-14 Connectors: C-134 , C-139
A-14(GR)
A-14(GR) C-134
C-139 (GR)
AC309506AB
C-134 Harness side

Connectors: C-134 , C-139
C-139 (GR) Harness side
C-134
C-139 (GR) : 4G63-Non-turbo
: 4G63-Turbo and 4G69
AC605257AB
C-134 Harness side

Q: Are these harness wires in good condition?
C-139 (GR) Harness side NO : Repair the damaged harness wire. Then go
to Step 24.
: 4G63-Non-turbo
AC605257AB
Q: Are these connectors in good condition?

Step 24.
TROUBLESHOOTING
STEP 22. Check the fan controller. (5) Check for the cooling fan operation.
• The cooling fan rotates. (with connector termi-
Connectors: C-134 , C-139 nal pin 21 <4G63-Non-turbo> or 17
<4G63-Turbo and 4G69> disconnected)
• The cooling fan stops. (When connector ter-
minal pin 21 <4G63-Non-turbo> or 17
<4G63-Turbo and 4G69> is connected to the
body earth.)
C-134 (6) Turn the ignition switch to the "OFF" position.
C-139 (GR)
(7) Disconnect engine-ECU connector or
engine-A/T-ECU connector C-134
<4G63-Non-turbo> or C-139 <4G63-Turbo and
4G69>, and push in connector terminal pin 21
C-134 Harness side
<4G63-Non-turbo> or 17 <4G63-Turbo and
4G69> to disconnect connector.
C-139 (GR) Harness side (8) Reconnect the connector with connector terminal
pin still installed.
Q: Does the cooling fan rotate? And when the
connector terminal pin is connected to the body
: 4G63-Non-turbo earth, does the cooling fan stop?
: 4G63-Turbo and 4G69 YES : Go to Step 23.
NO : Replace the fan controller (Refer to
AC605257AB P.14-35). Then go to Step 24.
engine-A/T-ECU connector C-134 STEP 23. M.U.T.-II/III self-diag code
<4G63-Non-turbo> or C-139 <4G63-Turbo and Check if an MPI system self-diag code is set. (Refer
4G69>. to GROUP 13A - Troubleshooting P.13A-9)
<4G63-Non-Turbo>, (Refer to GROUP 13B - Trou-
C-134 connector <4G63-Non-turbo> bleshooting P.13B-11) <4G63-Turbo> or (Refer to
(Harness side connector: ECU side view)
GROUP 13C - Troubleshooting P.13C-11) <4G69>.
C-139 connector <4G63-Turbo AND 4G69> to GROUP 13A - Troubleshooting
P.13A-15) <4G63-Non-Turbo>, (Refer to
GROUP 13B - Troubleshooting P.13B-20)
<4G63-Turbo> or (Refer to GROUP 13C -
AC309522 AC
Troubleshooting P.13C-21) <4G69>.
(2) Pull out connector terminal pin 21 NO : Replace the engine-ECU <M/T> or
<4G63-Non-turbo> or 17 <4G63-Turbo and engine-A/T-ECU <A/T> (Refer to GROUP
4G69> to disconnect connector. 13A, Engine-ECU P.13A-332)
(3) Reconnect the connector with connector terminal <4G63-Non-Turbo>, (Refer to GROUP 13B,
pin still removed. Engine-ECU P.13B-406) <4G63-Turbo> or
(4) Turn the ignition switch to the "ON" position. (Refer to GROUP 13C, Engine-ECU and
Engine-A/T-ECU P.13C-441) <4G69>. Then
go to Step 24.
STEP 24. Check the symptoms.

Q: Does the radiator fan motor and the condenser fan
motor operate correctly?
YES : This symptoms is complete.
NO : Return to Step 1.
ENGINE COOLING
TROUBLESHOOTING
14-13
Inspection Procedure 2: Radiator Fan and Condenser Fan do not Change Speed or Stop
RADIATOR FAN AND CONDENSER FAN STEP 2. Check the fan control relay connector
DRIVE CIRCUIT A-10X.
Refer to P.14-4.
Connector: A-10X
Relay box
TECHNICAL DESCRIPTION
• The cause could be a malfunction of the fan con-
troller power supply or earth circuit. Fan control relay
• If the communication line wiring harness between
the fan controller and the engine-ECU <M/T> or
engine-A/T-ECU <A/T> is short-circuited to earth, A-10X
the radiator fan motor and the condenser fan
motor will not rotate.
AC309505 AC
• The cause could also be a malfunction of input
signal from the A/C switch, the water temperature Q: Is the connector in good condition?
sensor unit and the vehicle speed sensor <M/T> YES : Go to Step 3.
or the output shaft speed sensor <A/T> to the NO : Repair the connector or replace the relay
engine-ECU <M/T> or engine-A/T-ECU <A/T>. box. Then go to Step 8.
• The cause could also be a malfunction of the fan
controller or the engine-ECU <M/T> or STEP 3. Check the harness wire between fan
engine-A/T-ECU <A/T>. control relay connector A-10X terminal 2 and fan
controller connector A-20 terminal 3.
TROUBLESHOOTING HINTS
• Malfunction of fusible link No.2 Connector: A-10X
Relay box
• Malfunction of fan control relay
• Malfunction of cooling fan motor
• Malfunction of fan controller Fan control relay
• Malfunction of engine-ECU <M/T> or
• Damaged wiring harness or connector A-10X
DIAGNOSIS PROCEDURE
AC309505 AC
STEP 1. Check the fan control relay. Connector: A-20

Refer to P.14-19.
Q: Is the fan control relay in good condition?
YES : Go to Step 2. A-20
NO : Replace the fan control relay. Then go to
Step 8. 3 2 1
AC301902 AB

YES : Go to Step 4.
to Step 8.
TROUBLESHOOTING
STEP 4. Check the fan controller connector A-20, STEP 5. Check the harness wire between fan
intermediate connector A-14 and engine-ECU controller connector A-20 terminal 2 and
connector or engine-A/T-ECU connector C-134 engine-ECU connector or engine-A/T-ECU
<4G63-Non-turbo> or C-139 <4G63-turbo and connector C-134 terminal 21 <4G63-Non-turbo>
4G69>. or C-139 terminal 17 <4G63-turbo and 4G69>.
Connector: A-20 Connector: A-20
A-20 A-20
3 2 1 3 2 1
AC301902 AB AC301902 AB
Connector: A-14 Connectors: C-134 , C-139
A-14(GR)
A-14(GR) C-134
C-139 (GR)
AC309506AB
C-134 Harness side

Connectors: C-134 , C-139
C-139 (GR) Harness side
C-134
C-139 (GR) : 4G63-Non-turbo
AC605257AB
C-134 Harness side

Q: Are these harness wires in good condition?
YES : Go to Step 6.
C-139 (GR) Harness side NO : Repair the damaged harness wire. Then go
to Step 8.
: 4G63-Non-turbo
AC605257AB
Q: Are these connectors in good condition?

YES : Go to Step 5.
Step 8.
ENGINE COOLING
TROUBLESHOOTING
14-15
STEP 6. Check the fan controller. (5) Check for the cooling fan operation.
• The cooling fan rotates. (with connector termi-
Connectors: C-134 , C-139 nal pin 21 <4G63-Non-turbo> or 17
<4G63-Turbo and 4G69> disconnected)
• The cooling fan stops. (When connector ter-
minal pin21 <4G63-Non-turbo> or 17
<4G63-Turbo and 4G69> is connected to the
body earth.)
C-134 (6) Turn the ignition switch to the "OFF" position.
C-139 (GR)
engine-A/T-ECU connector C-134
<4G63-Non-turbo> or C-139 <4G63-Turbo and
4G69>, and push in connector terminal pin 21
C-134 Harness side
<4G63-Non-turbo> or 17 <4G63-Turbo and
4G69> to disconnect connector.
C-139 (GR) Harness side (8) Reconnect the connector with connector terminal
pin still installed.
Q: Does the cooling fan rotate? And when the
connector terminal pin is connected to the body
: 4G63-Non-turbo earth, does the cooling fan stop?
: 4G63-Turbo and 4G69 YES : Go to Step 7.
NO : Replace the fan controller (Refer to
AC605257AB P.14-35). Then go to Step 8.
engine-A/T-ECU connector C-134 STEP 7. M.U.T.-II/III self-diag code
<4G63-Non-turbo> or C-139 <4G63-Turbo and Check if an MPI system self-diag code is set. (Refer
4G69>. to GROUP 13A - Troubleshooting P.13A-9)
<4G63-Non-Turbo>, (Refer to GROUP 13B - Trou-
C-134 connector <4G63-Non-turbo> bleshooting P.13B-11) <4G63-Turbo> or (Refer to
GROUP 13C - Troubleshooting P.13C-11) <4G69>.
C-139 connector <4G63-Turbo AND 4G69> to GROUP 13A - Troubleshooting
P.13A-15) <4G63-Non-Turbo>, (Refer to
GROUP 13B - Troubleshooting P.13B-20)
<4G63-Turbo> or Inspection chart for
AC309522 AC
diagnosis code (Refer to GROUP 13C -
(2) Pull out connector terminal pin 21 Troubleshooting P.13C-21) <4G69>.
<4G63-Non-turbo> or 17 <4G63-Turbo and NO : Replace the engine-ECU <M/T> or
4G69> to disconnect connector. engine-A/T-ECU <A/T> (Refer to GROUP
(3) Reconnect the connector with connector terminal 13A P.13A-332) <4G63-Non-Turbo>, (Refer
pin still removed. to GROUP 13B, Engine-ECU P.13B-406)
(4) Turn the ignition switch to the "ON" position. <4G63-Turbo> or (Refer to GROUP 13C,
Engine-ECU and Engine-A/T-ECU
P.13C-441) <4G69>. Then go to Step 8.

Q: Does the radiator fan motor and the condenser fan
motor operate correctly?
YES : This symptoms is complete.
TROUBLESHOOTING
Inspection Procedure 3: Radiator Fan does not Operate
RADIATOR FAN AND CONDENSER FAN STEP 2. Check the fan controller.
DRIVE CIRCUIT Refer to P.14-19.
Refer to P.14-4. Q: Is the fan controller in good condition?
YES : Go to Step 3.
TECHNICAL DESCRIPTION NO : Replace the fan controller (Refer to
The cause could be a malfunction of the radiator fan P.14-35). Then go to Step 3.
motor or an open circuit between the fan controller
and the radiator fan motor.
TROUBLESHOOTING HINTS Q: Does the radiator fan operate?
Malfunction of radiator fan motor YES : This symptoms is complete.
DIAGNOSIS PROCEDURE
STEP 1. Check the radiator fan motor.

Refer to P.14-20.
Q: Is the radiator fan motor in good condition?
YES : Go to Step 2.
NO : Replace the radiator fan motor (Refer to
P.14-35). Then go to Step 3.
Inspection Procedure 4: Condenser Fan does not Operate
RADIATOR FAN AND CONDENSER FAN STEP 2. Check the fan controller.
DRIVE CIRCUIT Refer to P.14-19.
Refer to P.14-4. Q: Is the fan controller in good condition?
YES : Go to Step 3.
TECHNICAL DESCRIPTION NO : Replace the fan controller (Refer to
The cause could be a malfunction of the condenser P.14-35). Then go to Step 3.
fan motor or fan controller.
TROUBLESHOOTING HINTS STEP 3. Check the symptoms.

• Malfunction of condenser fan motor Q: Does the condenser fan operate?
• Malfunction of fan controller YES : This symptoms is complete.
DIAGNOSIS PROCEDURE
STEP 1. Check the condenser fan motor.

Condenser fan motor check. (Refer to GROUP 55,
Condenser and Condenser Fan Motor P.55A-76).
Q: Is the condenser fan motor in good condition?
YES : Go to Step 2.
NO : Replace the condenser fan motor, then go
to Step 3.
ENGINE COOLING
ON-VEHICLE SERVICE
14-17
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK 2. Increase the pressure until the indicator of the
M1141001000355 gauge stops moving.
WARNING Minimum limit: 83 kPa
When pressure testing the cooling system, Standard value: 93 − 123 kPa
slowly release cooling system pressure to
3. Replace the radiator cap if the reading does not
avoid getting burned by hot coolant.
remain at or above the limit.
CAUTION
• Be sure to completely clean away any mois- ENGINE COOLANT REPLACEMENT
ture from the places checked. M1141001200520
• When the tester is taken out, be careful not to WARNING

spill any coolant. When removing the radiator cap, use care to
• Be careful when installing and removing the avoid contact with hot coolant or steam.
tester and when testing not to deform the Place a shop towel over the cap and turn the
filler neck of the radiator. cap counterclockwise a little to let the pres-
sure escape through the vinyl tube. After
relieving the steam pressure, remove the cap
Cap adapter by slowly turning it counterclockwise.
1. Drain the water from the radiator, heater core and
Adapter
engine after unplugging the radiator drain plug
and removing the radiator cap.
<2WD>
ACX01844 AC
1. Check that the coolant level is up to the filler neck.

Install a radiator tester and apply 160 kPa
pressure, and then check for leakage from the
Intake manifold
radiator hose or connections. Cylinder block
2. If there is leakage, repair or replace the drain plug
AC200630AD
appropriate part.
<4WD>
RADIATOR CAP VALVE OPENING
PRESSURE CHECK
M1141001300431
NOTE: Be sure that the cap is clean before test-
ing. Rust or other foreign material on the cap seal 30 ± 3 N·m
will cause an improper reading.
Water return tube assembly
AC301654 AC
Cap adapter
2. Drain the water in the water jacket by unplugging
the drain plug of the cylinder block. On 4WD,
drain engine coolant from the water return tube
assembly of the transfer.
3. Remove the reserve tank and drain the coolant.
AC211643 AB 4. Drain the coolant then clean the path of the
coolant by injecting water into the radiator from
1. Use a cap adapter to attach the cap to the tester. the radiator cap area.
ON-VEHICLE SERVICE
9. Reinstall the radiator cap.

10.Start the engine and let it warm up until the
thermostat opens.
Cylinder block
11.After repeatedly revving the engine up to 3,000
drain plug
r/min several times, then stop the engine.
12.Remove the radiator cap after the engine has
become cold, and pour in coolant up to the brim.
Reinstall the cap.
CAUTION
AC304677 AE
Do not overfill the reserve tank.
5. Apply the designated sealant to the screw area of 13.Add coolant to the reserve tank between the
the cylinder block drain plug, and then tighten to "FULL" and "LOW" mark if necessary.
the standard torque.
Specified sealant: 3M Nut Locking Part CONCENTRATION MEASUREMENT
No.4171 or equivalent M1141001100426
Measure the temperature and specific gravity of the
engine coolant to check the antifreeze concentration.
6. Securely tighten the drain plug of the radiator.
Standard value: 30 − 60 % (allowable concen-
7. Assemble the reserve tank. tration range)
CAUTION Recommended antifreeze: DIAQUEEN SUPER
Do not use alcohol or methanol anti-freeze or any LONG LIFE COOLANT or equivalent
engine coolants mixed with alcohol or methanol CAUTION
anti-freeze. The use of an improper anti-freeze
If the concentration of the anti-freeze is below 30
can cause corrosion of the aluminium compo-
%, the anti-corrosion property will be adversely
nents.
affected. In addition, if the concentration is
above 60 %, both the anti-freezing and engine
cooling properties will decrease, affecting the
MB991871 engine adversely. For these reasons, be sure to
maintain the concentration level within the speci-
fied range.
Air hose
AC200579AC
8. By referring to the section on coolant, select an

appropriate concentration for safe operating
temperature within the range of 30 to 60 %. Use
special tool LLC changer (MB991871) to refill the
coolant. A convenient mixture is a 50 % water and
50 % antifreeze solution (freezing point: −31°C).
Recommended antifreeze: DIAQUEEN SUPER
LONG LIFE COOLANT or equivalent
Quantity: 7.0 L
NOTE: . For how to use special tool MB991871,
refer to its manufacturer’s instructions.
ENGINE COOLING
ON-VEHICLE SERVICE
14-19
FAN CONTROLLER CHECK FAN CONTROL RELAY CONTINUITY
M1141007400083
CHECK
M1141006200677
Fan control relay
3 2 1
Fan controller
AC103011AD
1. Remove the fan controller connector. AC308060

2. Turn the ignition switch to the "ON" position, and
measure the voltage between the harness-side
Standard value: System voltage 4
2
2
Fan controller 1 3
4 3 1
AC309492 AB
1 2
Battery Terminal No.to Continuity test
voltage be connected to results
tester
AC103010 AD
Not applied 4−2 Open circuit
3. Connect the fan controller connector, and Connect 4−2 Continuity (less
disconnect the condenser fan motor connector. terminal than 2 Ω)
4. Ensure that the A/C switch is off, and start the No.1 and
engine and run it at idle. battery (−)
5. Measure the voltage between the fan terminal.
controller-side connector terminals. Connect
Standard value: 1V or less terminal
No.3 and
WARNING battery (+)
Stay clear of the fan when the fan starts run- terminal.
ning.
6. Turn the A/C switch to the "ON" position.
7. Measure the voltage between the fan
controller-side connector terminals while the fan is
running. The voltage should repeat the values
below.
Standard value:
8.2 ± 2.6 V
System voltage ± 2.6 V
8. If the voltage does not repeatedly change as
indicated, replace the fan controller.
ON-VEHICLE SERVICE
RADIATOR FAN MOTOR CHECK 1. Remove the radiator fan motor connector.
M1141007100112
2. Check to see that the fan motor of the radiator
turns when applying battery power between the
2 1 connector terminals of the radiator fan motor. Also
check to see that there is no abnormal sound
coming from the radiator fan motor at this time.
3. If the radiator fan motor is defective, replace it.
Radiator
fan motor
AC103006AE
ENGINE COOLING
THERMOSTAT
14-21
THERMOSTAT
M1141002400613

• Engine Coolant Draining and Refilling (Refer to P.14-17).
• Air Cleaner Removal and Installation (Refer to GROUP
15, Air Cleaner P.15-6<4G63-Non-Turbo>,
P.15-7<4G63-Turbo>, P.15-8<4G69>).
• Battery Removal and Installation
<4G63-Non-Turbo>
1
13 ± 2 N·m
2 4
3 AC301429 AB

1. Engine coolant temperature gauge <<A>> >B<< 3. Radiator lower hose connection
unit connector 4. Water inlet fitting
2. Engine coolant temperature sensor >>A<< 5. Thermostat
connector
THERMOSTAT
<4G63-Turbo>
1
2
5
3
9
4 6 13 ± 2 N·m
8
7
AC202401 AC

1. Fuel pressure control solenoid 4. Engine coolant temperature
valve connector sensor connector
2. Waste gate solenoid valve 5. Control wiring harness connection
connector 6. Harness bracket
3. Engine coolant temperature gauge <<A>> >>B<< 7. Radiator lower hose connection
unit connector 8. Water inlet fitting
>>A<< 9. Thermostat
ENGINE COOLING
THERMOSTAT
14-23
<4G69>
11 ± 1 N·m
2
3
11 ± 1 N·m
5
2
4 13 ± 2 N·m
1
AC309324AB

<<A>> >>B<< 1. Radiator lower hose connection 4. Water inlet fitting
2. Control wiring harness connection >>A<< 5. Thermostat
3. Control wiring harness connection
bracket
THERMOSTAT
REMOVAL SERVICE POINT 2. Align the mating marks on the radiator hose and
<<A>> RADIATOR LOWER HOSE DIS- hose clamp, and then connect the radiator hose.
CONNECTION INSPECTION
M1141002500472
THERMOSTAT CHECK
Mating marks
AC200641AC
hose clamp. Disconnect the radiator hose. ACX00400AB
INSTALLATION SERVICE POINTS 1. Immerse the thermostat in water, and heat the
water while stirring. Check the thermostat valve
>>A<< THERMOSTAT INSTALLATION opening temperature.
Make absolutely sure that no oil adheres to the Valve opening temperature: 82 ± 1.5°C
rubber ring of the thermostat. Also do not fold or
scratch the rubber ring during installation.
Jiggle valve
Valve lift
ACX00401AC
Rubber ring
AC000279 AB 2. Check that the amount of valve lift is at the
Install the thermostat so that the jiggle valve is facing standard value when the water is at the
straight up. Be careful not to fold or scratch the rub- full-opening temperature.
ber ring. NOTE: Measure the valve height when the ther-
mostat is fully closed, and use this measurement
>>B<< RADIATOR LOWER HOSE to compare the valve height when the thermostat
CONNECTION is fully open.
Standard value:
Full-opening temperature: 95°C
Projection
Amount of valve lift: 8.5 mm or more
Water inlet fitting Mating marks
AC200642 AE
1. Insert each hose as far as the projection of the

water inlet fitting.
ENGINE COOLING
WATER PUMP
14-25
WATER PUMP
<4G63-NON-TURBO>
M1141002700700

• Engine Coolant Draining (Refer to P.14-17). • Timing Belt Installation (Refer to GROUP 11A, Timing Belt
• Timing Belt Removal (Refer to GROUP 11A, Timing Belt P.11A-40).
P.11A-40). • Engine Coolant Refilling (Refer to P.14-17).
N4
2
1
22 ± 4 N·m Bolt specifications

8 × 70 8 × 22
2
3N 8 × 14
23 ± 3 N·m 14 ± 1 N·m 8 × 25
8 × 22
Screw diameter × length mm
AC301467AB

1. Alternator brace
>>A<< O-RING INSTALLATION
2. Water pump
Water pump
>>A<< 4. O-ring
O-ring
Water inlet pipe

AC103005AD
Fit the O-ring to the groove in the water inlet pipe.

Then lubricate the O-ring and the inside of the water
pump with water, and then insert the pipe to the
water pump.
WATER PUMP

<4G63-TURBO>
M1141002700670

• Engine Coolant Draining (Refer to P.14-17). • Timing Belt Installation (Refer to GROUP 11C, Timing Belt
• Timing Belt Removal (Refer to GROUP 11C, Timing Belt P.11C-34).
P.11C-34). • Engine Coolant Refilling (Refer to P.14-17).
N 4
1 2
Bolt specifications
8 × 22
8 × 70
8 × 14
22 ± 4 N·m
3N
2
23 ± 3 N·m
8 × 55
14 ± 1 N·m
8 × 22
Nominal diameter × Nominal length mm
AC202463 AE

1. Alternator brace
2. Water pump
Water pump
>>A<< 4. O-ring
O-ring
Water inlet pipe

AC103005AD

water pump.
ENGINE COOLING
WATER PUMP
14-27
M1141002700681

• Engine Coolant Draining (Refer to P.14-17). • Timing Belt Installation (Refer to GROUP 11E, Timing Belt
• Timing Belt Removal (Refer to GROUP 11E, Timing Belt P.11E-36).
P.11E-36). • Engine Coolant Refilling (Refer to P.14-17).
N3
Bolt specifications
8 × 55 8 × 22
N2
1
1
8 × 14
8 × 55
Screw diameter × length mm 8 × 22
14 ± 1 N·m
AC309459 AB

1. Water pump
>>A<< 3. O-ring
Water pump
O-ring
Water inlet pipe

AC103005AD

water pump.
WATER HOSE AND WATER PIPE

<4G63-NON-TURBO>
M1141003300738

• Engine Coolant Draining and Supplying (Refer to
P.14-17).
15, Air Cleaner P.15-6).
• Thermostat Removal and Installation (Refer to P.14-21).
N 9
8 N 9 13 ± 2 N·m
13 ± 2 N·m
2
23 ± 4 N·m
1 5
5
Ø3 mm
2 Ø3 mm
Sealant: Mitsubishi Genuine Part No. MD970839 or equivalent

AC301428 AB

<<A>> >>C<< 1. Radiator upper hose connection 6. Heater hose connection
>>B<< 2. Water outlet fitting 7. Transfer water return hose
3. Water hose connection <4WD>
4. Water hose 8. Water inlet pipe assembly
>>B<< 5. Thermostat case assembly >>A<< 9. O-ring
ENGINE COOLING
14-29
<<A>> RADIATOR UPPER HOSE DISCON- >>B<< THERMOSTAT CASE
NECTION ASSEMBLY/WATER OUTLET FITTING
INSTALLATION
1. Use a gasket scraper or wire brush to completely
eliminate all gasket material on the gasket
mounting surface.
2. Apply a bead of the specified sealant.
Specified Sealant: MITSUBISHI GENUINE
PART No.MD970389 or equivalent
Mating marks
3. With the sealant still wet (within 15 minutes after
the sealant is applied), install the thermostat case
AC200641AC
or water outlet fitting. Do not apply the sealant in
After making mating marks on the radiator hose and an area more than the required.
hose clamp, disconnect the radiator hose.
>>C<< RADIATOR UPPER HOSE
CONNECTION
CAUTION Projection
Water pump or thermostat case
O-ring
Water inlet pipe, Mating marks
water outlet fitting
or radiator AC200642 AC
Water inlet pipe

AC200644 AC 1. Insert each hose as far as the projection of the
water outlet fitting.
Do not allow engine oil or other grease to adhere
2. Align the mating marks on the radiator hose and
to the O-ring
hose clamp, and then connect the radiator hose.
Insert the O-ring to the water pipe, and coat the outer
portion of the O-ring with water or engine coolant.

<4G63-TURBO>
M1141003300716

P.14-17).
• Intercooler Removal and Installation (Refer to GROUP
15, Intercooler P.15-9).
N 16
15 13 ± 2 N·m
14
16 N
48 ± 6 N·m
6
13 ± 2 N·m
27 ± 5 N·m
N 13 2 5
11 19 ± 3 N·m
1
36 ± 6 N·m
12 4
10 ± 1 N·m
10 ± 1 N·m
3
10 23 ± 4 N·m 11 ± 1 N·m
7
27 ± 5 N·m
8 23 ± 4 N·m
23 ± 4 N·m
9N
10
Ø3 mm
2 Ø3 mm
Sealant: Mitsubishi Genuine Part No. MD970839 or equivalent

AC401071AB
ENGINE COOLING
14-31
<<A>> >>C<< 1. Radiator upper hose connection >>B<< 10. Thermostat case assembly
>>B<< 2. Water outlet fitting 11. Water hose
3. Vacuum hose • Turbocharger assembly (Refer to
4. Fuel pressure control solenoid GROUP 15, Exhaust manifold and
valve and waste gate solenoid turbocharger P.15-22).
valve assembly 12. Turbocharger water return pipe
5. Water hose 13. Gasket
6. Water hose 14. Heater hose connection
7. Water hose 15. Water inlet pipe assembly
8. Turbocharger water feed pipe >>A<< 16. O-ring
9. Gasket

<<A>> RADIATOR UPPER HOSE DISCON- >>B<< THERMOSTAT CASE
NECTION ASSEMBLY/WATER OUTLET FITTING
INSTALLATION
mounting surface.
2. Apply a bead of the specified sealant.
Mating marks
the sealant is applied), install the thermostat case
AC200641AC
or water outlet fitting. Do not apply the sealant in
After making mating marks on the radiator hose and an area more than the required.
>>C<< RADIATOR UPPER HOSE
CONNECTION
CAUTION Projection
O-ring
Water inlet pipe

AC200644 AC 1. Insert each hose as far as the projection of the
to the O-ring

M1141003300567

P.14-17).
N 14
24 ± 4 N·m
11
13 ± 2 N·m
13
14 N
12 10
8
6
24 ± 4 N·m
7 5.0 ± 1.0 N·m

4
1 13 ± 2 N·m 3 2
11 ± 1 N·m
AC309470 AB

<<A>> >>C<< 1. Radiator upper hose connection >>B<< 8. Thermostat case assembly
2. Radiator hose clamp 9. Heater hose connection
3. Control wiring harness connection 10. Harness clamp
bracket 11. Water feed hose
>>B<< 4. Water outlet fitting 12. Transfer water return hose
5. Heater hose connection connection
6. Water return hose 13. Water inlet pipe assembly
7. Engine coolant temperature gauge >>A<< 14. O-ring
unit
ENGINE COOLING
14-33
REMOVAL SERVICE POINT >>B<< THERMOSTAT CASE
<<A>> RADIATOR UPPER HOSE DISCON- ASSEMBLY/WATER OUTLET FITTING
NECTION INSTALLATION
mounting surface.
Water outlet Thermostat case

fitting assembly
Mating marks
AC200641AC
After making mating marks on the radiator hose and

Ø3 mm
AC305204 AF
INSTALLATION SERVICE POINTS 2. Apply a bead of the sealant to the cylinder head
>>A<< O-RING INSTALLATION mating surface of the thermostat case as shown.
Specified Sealant: Mitsubishi Genuine Part
No.MD970389 or equivalent
Thermostat case assembly
O-ring
Water inlet pipe

AC200644 AC
CAUTION
AC303724AE
to the O-ring
3. Apply sealant to the thread of the thermostat case
assembly bolts as shown.
Specified Sealant: 3M Stud Locking 4170 or
equivalent
the sealant is applied), install the thermostat case.
Do not apply the sealant in an area more than the
required.
>>C<< RADIATOR UPPER HOSE INSPECTION

M1141003400274
CONNECTION
WATER PIPE AND HOSE CHECK
Check the water pipe and hose for cracks, damage
Projection and clogs. Replace them if necessary.


ENGINE COOLING
RADIATOR
14-35
RADIATOR
M1141001501580

• Engine Coolant Draining (Refer to P.14-17). • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner P.15-6<4G63-Non-Turbo>, P.15-7<4G63-Turbo>,
P.15-6<4G63-Non-Turbo>, P.15-7<4G63-Turbo>, P.15-8<4G69>).
P.15-8<4G69>). • Engine Coolant Refilling and Level Check (Refer to
P.14-17).
<4G63-Non-Turbo>
12 ± 2 N·m
12 ± 2 N·m
3 9
9
4 10
5 7 12
6
11 N 2 1
11
8
14
16
13 15
AC309199AB
Radiator removal steps Radiator removal steps

1. Drain plug 12. Fan controller
2. O-ring 13. Cooling fan assembly
3. Radiator cap Radiator fan motor removal
4. Rubber hose steps
5. Reserve tank assembly 4. Rubber hose
6. Fan controller connector 6. Fan controller connector
<<A>> >>A<< 7. Radiator upper hose <<A>> >>A<< 7. Radiator upper hose
<<A>> >>A<< 8. Radiator lower hose 13. Cooling fan assembly
9. Upper insulator 14. Radiator fan
10. Radiator assembly 15. Radiator fan motor
11. Lower insulator 16. Shroud assembly
RADIATOR
<4G63-Turbo>
12 ± 2 N·m
12 ± 2 N·m 9
3
9
10
4
7
6 13
5
1
11 2N
11
12
8
15
17
16
14
AC400834AB

1. Drain plug 13. Fan controller
2. O-ring 14. Radiator fan assembly
3. Radiator cap Radiator fan motor removal
4. Rubber hose steps
5. Reserve tank assembly 4. Rubber hose
6. Fan controller connector 6. Fan controller connector
<<A>> >>A<< 7. Radiator upper hose <<A>> >>A<< 7. Radiator upper hose
<<A>> >>A<< 8. Radiator lower hose 12. Condenser fan assembly
9. Upper insulator 13. Fan controller
10. Radiator assembly 14. Radiator fan assembly
11. Lower insulator 15. Radiator fan
12. Condenser fan assembly 16. Radiator fan motor
17. Shroud assembly
ENGINE COOLING
RADIATOR
14-37
<4G69>
12 ± 2 N·m
12 ± 2 N·m 10
3
10
11
4
7
5
15
6
2N 1
17
12
18 9
8 14
5.0 ± 1.0 N·m
13
5.0 ± 1.0 N·m 5.0 ± 1.0 N·m
19
21
20
16
AC504333 AB

1. Drain plug 16. Radiator fan assembly
2. O-ring 17. Transmission fluid cooler hose
3. Radiator cap <A/T>
4. Rubber hose 18. Transmission fluid cooler tube
5. Reserve tank assembly assembly <A/T>
6. Fan controller connector Radiator fan motor removal
<<A>> >>A<< 7. Radiator upper hose steps
<<A>> >>A<< 8. Radiator lower hose 4. Rubber hose
<> 9. Transmission fluid cooler hose 6. Fan controller connector
connection <A/T> <<A>> >>A<< 7. Radiator upper hose
10. Upper insulator 14. Condenser fan assembly
11. Radiator assembly 15. Fan controller
12. Lower insulator 16. Radiator fan assembly
13. Transmission fluid cooler hose 19. Radiator fan
assembly <A/T> 20. Radiator fan motor
14. Condenser fan assembly 21. Shroud assembly
15. Fan controller
RADIATOR
REMOVAL SERVICE POINTS INSTALLATION SERVICE POINT

<<A>> RADIATOR UPPER HOSE/RADIA- >>A<< RADIATOR LOWER HOSE/RADIA-
TOR LOWER HOSE DISCONNECTION TOR UPPER HOSE CONNECTION
Projection
Mating marks
AC200641AC or radiator AC200642 AC
Make mating marks on the radiator hose and the 1. Insert each hose as far as the projection of the
hose clamp. Disconnect the radiator hose. water inlet pipe, water outlet fitting or radiator.
<> TRANSMISSION FLUID COOLER hose clamp, and then connect the radiator hose.
HOSE DISCONNECTION
After disconnecting the hose, plug it to avoid entry of
dust or foreign material.
15-1
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL INFORMATION . . . . . . . . 15-2 INTERCOOLER <4G63-Turbo> . . . . . 15-9

SERVICE SPECIFICATIONS. . . . . . . 15-2
INLET MANIFOLD . . . . . . . . . . . . . . . 15-10
SEALANT. . . . . . . . . . . . . . . . . . . . . . 15-2 REMOVAL AND INSTALLATION
<4G63-NON-TURBO>. . . . . . . . . . . . . . . . . 15-10
SPECIAL TOOL . . . . . . . . . . . . . . . . . 15-2 REMOVAL AND INSTALLATION
<4G63-TURBO> . . . . . . . . . . . . . . . . . . . . . 15-12
ON-VEHICLE SERVICE. . . . . . . . . . . 15-3 REMOVAL AND INSTALLATION
<4G69> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15
TURBOCHARGER SUPERCHARGING
PRESSURE CHECK <Turbo> . . . . . . . . . . 15-3 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-17
SUPERCHARGING PRESSURE CONTROL
SYSTEM CHECK <Turbo> . . . . . . . . . . . . . 15-3 EXHAUST MANIFOLD . . . . . . . . . . . . 15-18
WASTE GATE ACTUATOR CHECK REMOVAL AND INSTALLATION
<Turbo> . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4 <4G63-NON-TURBO>. . . . . . . . . . . . . . . . . 15-18
WASTE GATE SOLENOID VALVE CHECK REMOVAL AND INSTALLATION
<Turbo> . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4 <4G69> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20
AIR BY-PASS VALVE CHECK <Turbo>. . . 15-5 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-21
INTAKE MANIFOLD VACUUM CHECK
<Turbo> . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5 EXHAUST MANIFOLD AND
TURBOCHARGER <4G63-Turbo> . . 15-22
AIR CLEANER . . . . . . . . . . . . . . . . . . 15-6 REMOVAL AND INSTALLATION . . . . . . . . 15-22
REMOVAL AND INSTALLATION INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 15-24
<4G63-NON-TURBO> . . . . . . . . . . . . . . . . 15-6
REMOVAL AND INSTALLATION EXHAUST PIPE AND
<4G63-TURBO> . . . . . . . . . . . . . . . . . . . . . 15-7 MAIN MUFFLER . . . . . . . . . . . . . . . . . 15-25
<4G69> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8
<4G63-NON-TURBO, 4G69> . . . . . . . . . . . 15-25
<4G63-TURBO> . . . . . . . . . . . . . . . . . . . . . 15-27
15-2 INTAKE AND EXHAUST
GENERAL INFORMATION
GENERAL INFORMATION
M1151000100468
The exhaust pipe is divided into three parts.
M1151000300569

Turbocharger supercharging pressure 84 − 112 −
(waste gate solenoid valve not operating) kPa
Initial activation pressure of waste gate actuator Approximately 80 −
(at the stroke of approximately 1 mm) kPa
Waste gate solenoid valve coil resistance (at 20°C) Ω 29 − 35 −
Initial activation pressure of air bypass valve kPa Approximately 53 −
Manifold distortion of the installation surface mm 0.15 or less 0.20
SEALANT
M1151000500217

Thermostat case MITSUBISHI GENUINE Part No.MD970389 or equivalent
Thermostat case assembly bolt 3M Stud Locking 4170 or equivalent
SPECIAL TOOL
M1151000600441

MD998770 Oxygen sensor wrench Removal and installation of
oxygen sensor
INTAKE AND EXHAUST
ON-VEHICLE SERVICE
15-3
ON-VEHICLE SERVICE
TURBOCHARGER SUPERCHARGING SUPERCHARGING PRESSURE
PRESSURE CHECK <Turbo> CONTROL SYSTEM CHECK <Turbo>
M1151001000215 M1151001100193
CAUTION
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.
Turbocharger waste
gate solenoid valve
Plug
AK401193 AB
1. Disconnect the hose (black) from the

turbocharger waste gate solenoid valve and
Turbocharger waste connect a three-way joint between the hose and
gate solenoid valve
the solenoid valve.
AK401192 AB
2. Connect a hand vacuum pump to the three-way
1. Disconnect the hose (black) from the joint.
turbocharger waste gate solenoid valve, and
connect the pressure gauge to the hose. Plug the
nipple of the solenoid valve from which the hose
(black) has been disconnected.
2. Drive at full-throttle acceleration in L range and
then measure the supercharging pressure when
the engine speed in about 3,000 r/min.
Standard value: 84 − 112 kPa
3. If the supercharging pressure deviates from the Boost hose
Nipple AK200366 AC
standard value, check the following items for
possible cause. 3. Disconnect the hose from the turbocharger waste
• Malfunction of the waste gate actuator gate actuator control boost nipple and plug the
• Leakage of supercharging pressure nipple.
• Malfunction of the turbocharger
4. Applying a negative pressure with the hand
4. When the indicated supercharging is more than vacuum pump, check tightness both when the
standard value, supercharging control may be hose end is closed and when it is open.
faulty, therefore check the followings.
• Malfunction of the waste gate actuator Engine state Hose end Normal state
• Malfunction of waste gate valve Stop Opened Negative
• Disconnection or cracks of the waste gate actua- (Ignition switch: ON) pressure leaks.
tor rubber hose Closed Negative
pressure is
maintained.
Idling (after Negative
warm-up) pressure leaks.
NOTE: If this check indicates an abnormal condi-
tion; the turbocharger waste gate actuator, turbo-
charger waste gate solenoid or hose is broken.
ON-VEHICLE SERVICE
WASTE GATE ACTUATOR CHECK WASTE GATE SOLENOID VALVE CHECK

<Turbo> <Turbo>
M1151001200156 M1151001300142
OPERATION CHECK
A
B
AK200367
Battery
1. Connect a manual pump (pressure-application AK200441AC
type) to nipple. 1. Connect a hand vacuum pump to the solenoid

CAUTION valve nipple A.
In order to avoid damage to the diaphragm, do 2. Using a jumper wire, connect between the
not apply a pressure of 94 kPa or higher. solenoid valve terminal and battery terminal.
2. While gradually applying pressure, check the 3. Connecting and disconnecting the jumper wire at
pressure that begins to activate (approximately 1 the battery negative terminal to apply a negative
mm stroke) the waste gate actuator rod. pressure, check tightness.
Standard value: Approximately 80 kPa
Jumper wire B nipple Normal condition
3. If there is a significant deviation from the standard condition
value, check the actuator or the waste gate valve:
Connected Opened Negative pressure
replace actuator or turbocharger assembly if
leaks.
necessary.
Closed Negative pressure is
held.
Disconnected Opened Negative pressure is
held.
INTAKE AND EXHAUST
ON-VEHICLE SERVICE
15-5
COIL RESISTANCE CHECK AIR BY-PASS VALVE CHECK <Turbo>
M1151001600132
AK200442
AK200443
Measure the resistance between solenoid valve ter-
minals 1. Remove the air bypass valve.
Standard value: 29 − 35 Ω (at 20°C) 2. Connect the hand vacuum pump to the nipple of
the air bypass valve.
3. Apply a negative pressure of approximately 93
kPa, and check that air tightness is maintained.
4. Also check operation of the valve.
Standard value:
Negative pressure Valve operation
Approximately 53 kPa It starts opening
INTAKE MANIFOLD VACUUM CHECK

<Turbo>
M1151001800211
Refer to GROUP 11C − On-vehicle Service
P.11C-14.
AIR CLEANER
AIR CLEANER
<4G63-NON-TURBO>
M1151002100710
CAUTION
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following pre-
cautions.
• Avoid any shock or load to these parts when removing and installing them.
• When installing, securely set the air cleaner cover and the resonator clamp to the air cleaner body.
NOTE: Parts marked by * are made of recycled-paper mixed plastic material. Dispose of according to state
and local laws
3.9 ± 1.0 N·m

6
11
12
1* 5
Clamp 3.9 ± 1.0 N·m
8.8 ± 1.0 N·m

N 9
3*
8.8 ± 1.0 N·m
8
4* 10*
2* 7
11 ± 1 N·m
8.8 ± 1.0 N·m
13 22 ± 4 N·m
AC203703 AB

1. Resonator 8. Air flow sensor assembly
2. Air cleaner element 9. Gasket
3. Air duct 10. Air cleaner cover
4. Air cleaner body 11. Resonator
5. Air flow sensor connector 12. Air intake hose
6. Breather hose connection 13. Air cleaner bracket
7. Air cleaner cover and air flow sensor
assembly
INTAKE AND EXHAUST
AIR CLEANER
15-7
<4G63-TURBO>
M1151002100691
CAUTION
cautions.
• When installing, securely set the air cleaner body assembly clamp to the air cleaner cover.
and local laws
2*
10
5.9 ± 1.0 N·m
9
8.8 ± 1.0 N·m 3*
11 Clamp
8.8 ± 1.0 N·m
3.9 ± 1.0 N·m
3.9 ± 1.0 N·m 4

8.8 ± 1.0 N·m
6
N 7
8*
5 8.8 ± 1.0 N·m
12
AC400870 AB

1. Air duct 8. Air cleaner body assembly
2. Air cleaner cover • Air by-pass valve and intercooler
3. Air cleaner element outlet air hose B assembly
4. Air flow sensor connector 9. Breather hose connection
5. Air cleaner body and air flow sensor 10. Vacuum hose connection
assembly 11. Air intake hose
6. Air flow sensor assembly 12. Air cleaner bracket
7. Gasket
AIR CLEANER

M1151002100561
CAUTION
cautions.
• When installing, securely set the air cleaner cover and the resonator clamp to the air cleaner body.
and local laws
9 3.0 ± 0.5 N·m

3.0 ± 0.5 N·m
4.0 ± 1.0 N·m

1.6 ± 0.6 N·m
1* 3.9 ± 1.0 N·m
5
6
Clamp 3.9 ± 1.0 N·m

8.8 ± 1.0 N·m 7
3
10
8*
2*
11 ± 1 N·m 4*
8.8 ± 1.0 N·m
11 22 ± 4 N·m
AC304211AC

1. Resonator 7. Air flow sensor assembly
2. Air cleaner element 8. Air cleaner cover
3. Air duct 9. Resonator
4. Air cleaner body 10. Air intake hose
5. Air flow sensor connector 11. Air cleaner bracket
6. Breather hose connection
INTAKE AND EXHAUST
INTERCOOLER <4G63-Turbo>
15-9
INTERCOOLER <4G63-Turbo>
M1151002400067
8.8 ± 1.0 N·m
5.9 ± 1.0 N·m

5.9 ± 1.0 N·m
8.8 ± 1.0 N·m
5.9 ± 1.0 N·m
5.9 ± 1.0 N·m
5.9 ± 1.0 N·m
3
4 10
6 8.8 ± 1.0 N·m 7
1
5
5.9 ± 1.0 N·m

8.8 ± 1.0 N·m
9.0 ± 1.0 N·m
8 9
8.8 ± 1.0 N·m
5.9 ± 1.0 N·m
11 AC400869AB

1. Intercooler, intercooler cover, 6. Intercooler
intercooler bracket, intercooler • Air duct (Refer to P.15-7)
outlet air hose A and intercooler • Battery and battery tray
intake air hose assembly 7. Intercooler outlet air hose B
2. Intercooler outlet air hose A 8. Vacuum hose connection
3. Intercooler intake air hose 9. Air by-pass valve assembly
4. Intercooler cover 10. Rear bracket
5. Intercooler bracket 11. Front bracket
INLET MANIFOLD
INLET MANIFOLD
<4G63-NON-TURBO>
M1151003001173

• Fuel Line Pressure Reduction [Refer to GROUP 13A, • Fuel Delivery Pipe and Fuel Injector assembly Installation
On-vehicle Service − Fuel Pump Connector Disconnec- (Refer to GROUP 13A, Injector P.13A-328).
tion (How to Reduce Pressurized Fuel Lines) P.13A-318.] • Throttle Body Installation (Refer to GROUP 13A, Throttle
• Throttle Body Removal (Refer to GROUP 13A, Throttle Body P.13A-330).
Body P.13A-330). • Accelerator Cable Adjustment (Refer to GROUP 17,
• Fuel Delivery Pipe and Fuel Injector assembly Removal On-vehicle Service − Accelerator Cable Check and
(Refer to GROUP 13A, Injector P.13A-328). Adjustment P.17-6).
• Fuel Leak Check
2
1 5.0 ± 1.0 N·m
3
5.0 ± 1.0 N·m
4
5
11 ± 1 N·m
10 6
13 ± 1 N·m
7
N9
(Engine oil) AC301313 AB

1. Purge control solenoid valve 5. Earth cable connection
connector 6. Emission control equipment hose
2. EGR control solenoid valve 7. PCV hose
connector 8. Oil level gauge and guide
3. Detonation sensor connector 9. O-ring
4. Accelerator cable connection 10. Detonation sensor connector clamp
INTAKE AND EXHAUST
INLET MANIFOLD
15-11
11 ± 1 N·m
11
9.0 ± 1.0 N·m

14
20 ± 2 N·m 36 ± 6 N·m
20 ± 2 N·m
16
36 ± 6 N·m
12
36 ± 6 N·m 13 N
17 N
20 ± 2 N·m
15
31 ± 3 N·m
AC301314 AB

11. Vacuum hose and pipe assembly 15. Intake manifold stay
12. EGR valve 16. Intake manifold assembly
13. EGR valve gasket 17. Intake manifold gasket
14. Brake booster vacuum hose
connection
INLET MANIFOLD

<4G63-TURBO>
M1151003001151

• Fuel Line Pressure Reduction [Refer to GROUP 13B, • Throttle Body Installation (Refer to GROUP 13B, Throttle
On-vehicle Service − Fuel Pump Connector Disconnec- Body P.13B-404).
tion (How to Reduce Pressurized Fuel Lines) P.13B-393]. • Accelerator Cable Adjustment (Refer to GROUP 17,
• Throttle Body Removal (Refer to GROUP 13B, Throttle On-vehicle Service − Accelerator Cable Check and
Body P.13B-404). Adjustment P.17-6).
• Fuel Leak Check
9.0 ± 2.0 N·m
11 ± 1 N·m
2 10 5.0 ± 1.0 N·m
1 6
3 5
4
8
11
9N
11 ± 1 N·m
7
14
12
13
13 ± 1 N·m
16
11 ± 1 N·m
N 15
(Engine oil) AC401381AB

1. Purge control solenoid valve 7. Emission control equipment hose
connector connection
2. EGR control solenoid valve >>A<< 8. Fuel high-pressure hose
connector connection
3. Detonation sensor connector 9. O-ring
4. Injector connectors 10. Fuel return line hose connection
5. Waste gate solenoid valve <<A>> 11. Fuel delivery pipe and fuel injector
connector assembly
6. Fuel pressure control solenoid 12. Insulators
valve connector 13. Vacuum hose connection
14. Oil level gauge and guide
INTAKE AND EXHAUST
INLET MANIFOLD
15-13
15. O-ring
16. Detonation sensor connector clamp
11 ± 1 N·m
17
9.0 ± 1.0 N·m

18
11 ± 1 N·m
20 ± 2 N·m
19 ± 3 N·m
25 36 ± 6 N·m
20 ± 2 N·m
21
19
36 ± 6 N·m
20 ± 2 N·m 22 20 N
26 N
24
22 ± 4 N·m 20 ± 2 N·m
23
31 ± 3 N·m
AC400871AB

17. Vacuum hose and pipe assembly 22. PCV hose
18. Solenoid valve assembly 23. Intake manifold stay
19. EGR valve 24. Alternator brace stay
20. EGR valve gasket 25. Intake manifold assembly
21. Brake booster vacuum hose 26. Intake manifold gasket
connection
INLET MANIFOLD

<<A>> FUEL DELIVERY PIPE AND FUEL >>A<< FUEL HIGH-PRESSURE HOSE
INJECTOR ASSEMBLY REMOVAL INSTALLATION
CAUTION 1. Apply a drop of new engine oil to the O-ring.
Do not drop the injector. 2. Turn the fuel high-pressure hose to the right and
Remove the fuel delivery pipe with the fuel injector left to install to the fuel delivery pipe. Be careful
assembly attached to it. not to damage the O-ring. After installing, check
that the item turns smoothly.
3. If it does not turn smoothly, the O-ring may be
4. Tighten the fuel high-pressure hose to the
specified torque.
INTAKE AND EXHAUST
INLET MANIFOLD
15-15
M1151003001935

• Fuel Line Pressure Reduction [Refer to GROUP 13C, • Delivery Pipe and Injector Assembly Installation (Refer to
On-vehicle Service − Fuel Pump Connector Disconnec- GROUP 13C, Injector P.13C-437).
tion (How to Reduce Pressurized Fuel Lines) P.13C-428]. • Throttle Body Installation (Refer to GROUP 13C, Throttle
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle Body P.13C-439).
Service − Engine Coolant Replacement P.14-17). • Air Cleaner Cover and Air Intake Hose Installation (Refer
• Air Cleaner Cover and Air Intake Hose Removal (Refer to to P.15-8).
P.15-8). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Throttle Body Removal (Refer to GROUP 13C, Throttle Service − Engine Coolant Replacement P.14-17).
Body P.13C-439).
• Delivery Pipe and Injector Assembly Removal (Refer to
GROUP 13C, Injector P.13C-437).
4
3
5
20 17
6 21
11 ± 1 N·m 19
7 24 ± 3 N·m
8 1
5.0 ± 1.0 N·m 24 ± 4 N·m
27
2N 18
24 22 N
29 12 9
11
28 N
10
13
11 ± 1 N·m
23 24 ± 3 N·m
14 20 ± 2 N·m
26
25
13 ± 1 N·m
15
N 16
31 ± 3 N·m
(Engine oil)
AC605268 AB

1. EGR valve 7. Brake booster vacuum hose
>>C<< 2. EGR valve gasket 8. Evaporative emission vacuum hose
3. Capacitor connector connection
4. Brake booster vacuum hose 9. Manifold absolute pressure sensor
5. Capacitor connector
6. Brake booster vacuum pipe 10. Detonation sensor connector
INLET MANIFOLD

11. Evaporative emission purge solenoid >>A<< 21. Thermostat case assembly
valve connector 22. O-ring
12. Harness clamp 23. Detonation sensor harness clamp
13. Detonation sensor connector clamp 24. Manifold absolute pressure sensor
14. Harness clamp 25. Harness clamp
15. Oil level gauge and guide 26. Intake manifold stay
16. O-ring 27. Intake manifold
17. Harness clamp 28. Intake manifold gasket
<<A>> >>B<< 18. Radiator lower hose connection 29. Evaporative emission purge solenoid
19. Heater water hose connection valve, evaporative emission vacuum
20. Engine coolant temperature gauge hose and pipe assembly
unit connector

<<A>> RADIATOR LOWER HOSE DIS- >>A<< THERMOSTAT CASE ASSEMBLY
CONNECTION INSTALLATION
mounting surface.
Mating marks
AC200641AC
Make mating marks on the radiator hose and the Ø3 mm

AC305212 AD
2. Apply a bead of the sealant to the cylinder head

mating surface of the thermostat case assembly
as shown.
AC303724AE
3. Apply sealant to the thread of the thermostat case

assembly bolts as shown.
Specified Sealant: 3M Stud Locking 4170 or
equivalent
INTAKE AND EXHAUST
INLET MANIFOLD
15-17
4. With the sealant still wet (within 15 minutes after INSPECTION
the sealant is applied), install the thermostat case M1151003100553
assembly. Do not apply the sealant in an area Check the following points; replace the part if a prob-
more than the required. lem is found.
Intake Manifold Check
>>B<< RADIATOR LOWER HOSE 1. Check for damage or cracking of any part.
CONNECTION 2. Clogging of the negative pressure (vacuum) outlet
port, or clogging of the exhaust gas recirculation
passages.
Projection
3. Using a straight edge and feeler gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
Water inlet fitting Mating marks
AC200642 AE

water inlet fitting.
>>C<< EGR VALVE GASKET

INSTALLATION
Notched
part
Gasket
Notched
part AC302358AE
Install the EGR valve gasket as shown in the illustra-

tion.
EXHAUST MANIFOLD
EXHAUST MANIFOLD
<4G63-NON-TURBO>
M1151003301011
8N
7 29 ± 3 N·m
14 ± 1 N·m 1
6 44 ± 5 N·m
29 ± 3 N·m
49 ± 5 N·m 14 ± 1 N·m
35 ± 6 N·m
5 2
44 ± 5 N·m
4N
49 ± 10 N·m
3 AC301312 AB

<<A>> >>A<< 1. Oxygen sensor 5. Exhaust manifold bracket
2. Exhaust manifold cover 6. Engine hanger
3. Front exhaust pipe connection 7. Exhaust manifold
4. Exhaust pipe gasket 8. Exhaust manifold gasket
INTAKE AND EXHAUST
EXHAUST MANIFOLD
15-19
<<A>> OXYGEN SENSOR REMOVAL >>A<< OXYGEN SENSOR INSTALLATION
MD998770 MD998770
Oxygen sensor Oxygen sensor
AC212566AB AC212566AB
Use special tool oxygen sensor wrench (MD998770) Use special tool oxygen sensor wrench (MD998770)
to remove the oxygen sensor. to install the oxygen sensor.
EXHAUST MANIFOLD

M1151003300728
14 ± 1 N·m
1
1
44 ± 5 N·m
14 ± 1 N·m
44 ± 5 N·m
N 5 4
49 ± 5 N·m
3
35 ± 6 N·m
44 ± 5 N·m AC309280AC

<<A>> >>A<< 1. Oxygen sensor 4. Exhaust manifold
2. Exhaust manifold cover 5. Exhaust manifold gasket
• Front exhaust pipe (Refer to P.15-25.) 6. Exhaust manifold bracket A
3. Exhaust manifold bracket B
INTAKE AND EXHAUST
EXHAUST MANIFOLD
15-21
MD998770 MD998770
AC212566AB AC212566AB
INSPECTION
M1151003400480
Check the following points; replace the part if a prob-
lem is found.
EXHAUST MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Using a straight edge and a thickness gauge,
check for distortion of the cylinder head
installation surface.
Limit: 0.20 mm
EXHAUST MANIFOLD AND TURBOCHARGER <4G63-Turbo>
EXHAUST MANIFOLD AND TURBOCHARGER

<4G63-Turbo>
M1151008900082

• Engine Oil Draining (Refer to GROUP 12, On-vehicle • Starter Assembly Installation (Refer to GROUP 16, Starter
Service − Engine Oil Replacement P.12-4). Motor Assembly P.16-26).
• Engine Coolant Draining (Refer to GROUP 14, On-vehicle • Front Exhaust Pipe Installation (Refer to P.15-27).
Service − Engine Coolant Replacement P.14-17). • Rocker Cover Centre Cover Installation (Refer to GROUP
• Intercooler and Intercooler Bracket Assembly Removal 11C, Camshaft and Valve Stem Seal P.11C-17).
(Refer to P.15-9). • Intercooler and Intercooler Bracket Assembly Installation
• Rocker Cover Centre Cover Removal (Refer to GROUP (Refer to P.15-9).
11C, Camshaft and Valve Stem Seal P.11C-17). • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle
• Front Exhaust Pipe Removal (Refer to P.15-27). Service − Engine Coolant Replacement P.14-17).
• Starter Assembly Removal (Refer to GROUP 16, Starter • Engine Oil Refilling (Refer to GROUP 12, On-vehicle
Motor Assembly P.16-26). Service − Engine Oil Replacement P.12-4).
59 ± 5 N·m
23 ± 3 N·m 29 ± 3 N·m
N 31
49 ± 5 N·m
16 17 N
23 ± 3 N·m 30
19 ± 1 N·m 18
N 22 17 ± 2 N·m
59 ± 5 N·m
21
49 ± 5 N·m 11 ± 1 N·m
N 27 29
26 3 17 N 10 ± 1 N·m
2 28 ± 5 N·m
8
28 ± 5 N·m 4N 24 N
15 23
6 13
12 ± 1 N·m
20 12 N 19
1 14 N
10 ± 1 N·m
59 ± 5 N·m 9.0 ± 1.0 N·m
7 25
59 ± 5 N·m 9
28 11 N
44 ± 5 N·m
10
35 ± 6 N·m
14 ± 1 N·m AC400919 AB

1. Oxygen sensor connector 6. Turbocharger protector
2. Vacuum hose connection 7. Vacuum hose connection
3. Turbocharger air outlet fitting 8. Turbocharger pin
>>D<< 4. Turbocharger air outlet fitting 9. Turbocharger waste gate actuator
gasket 10. Turbocharger oil return tube
5. Exhaust manifold cover 11. Turbocharger oil return tube gasket
12. Turbocharger oil return tube gasket
INTAKE AND EXHAUST
15-23
13. Eye bolt 22. Turbocharger exhaust gas inlet
14. Gaskets hole gasket
15. Turbocharger water feed pipe 23. Eye bolt
clamp 24. Gaskets
16. Eye bolts 25. Turbocharger water return pipe
17. Gaskets 26. Turbocharger exhaust outlet fitting
<<A>> 18. Turbocharger oil feed tube 27. Turbocharger exhaust outlet gasket
19. Turbocharger water return hose <> >>C<< 28. Oxygen sensor
connection >>B<< 29. Turbocharger assembly
20. Turbocharger exhaust outlet fitting >>A<< 30. Exhaust manifold
stay 31. Exhaust manifold gasket
21. Turbocharger, turbocharger water
return pipe and turbocharger
exhaust outlet fitting assembly

<<A>> TURBOCHARGER OIL FEED TUBE >>A<< EXHAUST MANIFOLD INSTALLA-
REMOVAL TION
CAUTION 1. Tighten the exhaust manifold mounting nuts in the
After removing the turbocharger oil feed tube, be order below.
careful that any foreign materials do not get into
the oil passages of the turbocharger. Engine front
<> OXYGEN SENSOR REMOVAL
MD998770 1 2
AC401466AB
(1) Finger-tighten the shown nuts in numerical

Oxygen sensor order in two stages.
AC212566AB
Engine front
Use special tool oxygen sensor wrench (MD998770)
to remove the oxygen sensor.
1 2 3 4
5 7 6
AC401467AB
(2) Finger-tighten the shown nuts in numerical

order.
>>C<< OXYGEN SENSOR INSTALLATION

Engine front
1 2 3 4 MD998770
5 7 6
Oxygen sensor
AC401467AB
(3) Tighten the nuts shown in numerical order to AC212566AB
the specified torque. Use special tool oxygen sensor wrench (MD998770)
Tightening torque: 29 ± 3 N⋅m to install the oxygen sensor.
>>D<< TURBOCHARGER AIR OUTLET

Engine front
FITTING GASKET INSTALLATION
1 2 projection
AC401466AB
(4) Tighten the nuts shown in numerical order to

AC401319AB
Install the gasket as its protrusion is in the direction
>>B<< TURBOCHARGER ASSEMBLY shown.
INSTALLATION INSPECTION
M1151003400639
Check the following points; replace the part if a prob-
lem is found.
EXHAUST MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Using a straight edge and a feeler gauge, check
for distortion of the cylinder head installation
surface.
AC201818AC
Limit: 0.20 mm
1. Clean the turbocharger oil feed tube, water feed
pipe and water return pipe fitting, the inside of eye TURBOCHARGER ASSEMBLY CHECK
bolts, and individual pipe for clogs. 1. Visually check the turbine wheel and the
compressor wheel for cracking or other damage.
CAUTION
Be careful that any foreign materials do not get 2. Check whether the turbine wheel and the
into the turbocharger. compressor wheel can be easily turned by hand.
3. Check for oil leakage from the turbocharger
2. Clean or blow the air if carbon residues are stuck
assembly.
to the oil passages of turbocharger assembly.
4. Check whether or not the turbocharger wastegate
3. Add new engine oil through the turbocharger oil
regulating valve remains open. If any problem is
feed tube of turbocharger assembly.
found, replace the part after disassembly.
INTAKE AND EXHAUST
EXHAUST PIPE AND MAIN MUFFLER
15-25
<4G63-NON-TURBO, 4G69>
M1151008700550
<4G63-Non-Turbo>
13 ± 2 N·m
6
13 ± 2 N·m
7
1
13 ± 2 N·m 9 6
13 ± 2 N·m
11 N 12
4 N 5
2 45 ± 5 N·m
8N 59 ± 10 N·m
10 N
49 ± 10 N·m
49 ± 10 N·m
AC301054 AC
<4G69>
13 ± 2 N·m
6
13 ± 2 N·m
7
13 ± 2 N·m 1
13 ± 2 N·m 9 6
12 N 10 5N
N 11 4
2 45 ± 5 N·m
N 8 59 ± 10 N·m
3 3 49 ± 10 N·m
49 ± 10 N·m
AC309215 AB
44 ± 5 N·m 44 ± 5 N·m
Exhaust main muffler removal Centre exhaust pipe removal
steps steps
1. Exhaust main muffler 2. Centre exhaust pipe
5. Exhaust pipe gasket 5. Exhaust pipe gasket
6. Hanger 8. Exhaust pipe gasket
7. Exhaust pipe damper 9. Hanger
Front exhaust pipe removal Front exhaust pipe removal

• Centre under cover (front) (Refer to 10. Exhaust pipe gasket
GROUP 51, Under Cover P.51-31). 11. Exhaust pipe gasket
<<A>> >>A<< 3. Oxygen sensor <4G69> 12. Hanger
4. Front exhaust pipe

MD998770 MD998770
AC212566AB AC212566AB
INTAKE AND EXHAUST
15-27
<4G63-TURBO>
M1151008700549
13 ± 2 N·m
5
13 ± 2 N·m
1
13 ± 2 N·m 8
6
5
13 ± 2 N·m 7N
10 N 11 N9 4N
45 ± 5 N·m
2
59 ± 10 N·m
3 11
49 ± 10 N·m
13 ± 2 N·m
50 ± 5 N·m AC400860AB
Exhaust main muffler removal Front exhaust pipe removal

steps steps
1. Exhaust main muffler • Centre under cover (front) (Refer to
4. Exhaust pipe gasket GROUP 51, Under Cover P.51-31).
5. Hanger 3. Front exhaust pipe
6. Exhaust pipe damper 9. Exhaust pipe gasket
Centre exhaust pipe removal 10. Seal ring
steps 11. Hanger
2. Centre exhaust pipe
4. Exhaust pipe gasket
7. Exhaust pipe gasket
8. Exhaust pipe damper
16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . . 16-3 STARTING SYSTEM . . . . . . . . 16-23
GENERAL INFORMATION . . . . . . 16-3 GENERAL INFORMATION . . . . . . 16-23
SERVICE SPECIFICATIONS. . . . . 16-4 SERVICE SPECIFICATIONS . . . . . 16-24
SPECIAL TOOLS. . . . . . . . . . . . . . 16-5 STARTER MOTOR ASSEMBLY . . 16-25

ON-VEHICLE SERVICE. . . . . . . . . 16-6 <4G63-NON-TURBO> . . . . . . . . . . . . . . 16-25
ALTERNATOR OUTPUT LINE
<4G63-TURBO>. . . . . . . . . . . . . . . . . . . 16-26
VOLTAGE DROP TEST . . . . . . . . . . . . 16-6
OUTPUT CURRENT TEST . . . . . . . . . . 16-7
<4G69>. . . . . . . . . . . . . . . . . . . . . . . . . . 16-27
REGULATED VOLTAGE TEST. . . . . . . 16-9
STARTER MOTOR ASSEMBLY
WAVEFORM CHECK USING AN
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-28
OSCILLOSCOPE. . . . . . . . . . . . . . . . . . 16-11
DISASSEMBLY AND REASSEMBLY . . 16-31
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-33
ALTERNATOR ASSEMBLY . . . . . 16-13
<4G63-NON-TURBO> . . . . . . . . . . . . . . 16-13
<4G63-TURBO> . . . . . . . . . . . . . . . . . . 16-15
<4G69> . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
DISASSEMBLY AND REASSEMBLY . . 16-18
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-21
16-2
IGNITION SYSTEM . . . . . . . . . . 16-35 IGNITION COIL. . . . . . . . . . . . . . . . 16-45

<4G63-NON-TURBO> . . . . . . . . . . . . . . 16-45
GENERAL INFORMATION REMOVAL AND INSTALLATION
<4G63> . . . . . . . . . . . . . . . . . . . . . 16-35 <4G63-TURBO>. . . . . . . . . . . . . . . . . . . 16-46
GENERAL INFORMATION <4G69>. . . . . . . . . . . . . . . . . . . . . . . . . . 16-47
<4G69> . . . . . . . . . . . . . . . . . . . . . 16-36
CAMSHAFT POSITION
SERVICE SPECIFICATIONS. . . . . 16-37 SENSOR . . . . . . . . . . . . . . . . . . . . . 16-48
REMOVAL AND INSTALLATION. . . . . . 16-48
SPECIAL TOOL . . . . . . . . . . . . . . . 16-37
CRANKSHAFT POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . 16-50
ON-VEHICLE SERVICE. . . . . . . . . 16-38
IGNITION COIL (WITH BUILT-IN POWER
<4G63-NON-TURBO> . . . . . . . . . . . . . . 16-50
TRANSISTOR) CHECK <4G63> . . . . . . 16-38
IGNITION COIL (WITH BUILT-IN POWER
<4G63-TURBO>. . . . . . . . . . . . . . . . . . . 16-51
TRANSISTOR) CHECK <4G69> . . . . . . 16-39
RESISTIVE CORD CHECK <4G63> . . . 16-39
<4G69>. . . . . . . . . . . . . . . . . . . . . . . . . . 16-52
SPARK PLUG CHECK AND
CLEANING. . . . . . . . . . . . . . . . . . . . . . . 16-40
CAMSHAFT POSITION SENSOR DETONATION SENSOR . . . . . . . . 16-53
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . 16-40 REMOVAL AND INSTALLATION
CRANK ANGLE SENSOR CHECK . . . . 16-40 <4G63-NON-TURBO, 4G63-TURBO> . . 16-53
DETONATION SENSOR CHECK . . . . . 16-41 REMOVAL AND INSTALLATION
IGNITION SECONDARY VOLTAGE <4G69>. . . . . . . . . . . . . . . . . . . . . . . . . . 16-54
WAVEFORM CHECK USING AN
OSCILLOSCOPE <4G63>. . . . . . . . . . . 16-41
ENGINE ELECTRICAL
CHARGING SYSTEM
16-3
CHARGING SYSTEM
GENERAL INFORMATION
M1161000100566
The charging system uses the alternator output to The average output voltage fluctuates slightly with
keep the battery charged at a constant level under the alternator load condition.
various electrical loads. When the ignition switch is turned on, current flows in
OPERATION the field coil and initial excitation of the field coil
occurs.
Voltage
When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
output current of the stator coil.
The alternator output voltage rises as the field cur-
Approximately rent increases and it falls as the field current
14.4 V decreases. When the battery voltage (alternator "S"
terminal voltage) reaches a regulated voltage of
approximately 14.4 V, the field current is cut off.
Time When the battery voltage drops below the regulated
AKX00183 AC voltage, the voltage regulator regulates the output
Rotation of the excited field coil generates AC volt- voltage to a constant level by controlling the field cur-
age in the stator. rent.
This alternating current is rectified through diodes to In addition, when the field current is constant, the
DC voltage having a waveform shown in the illustra- alternator output voltage rises as the engine speed
tion. increases.
SYSTEM DIAGRAM
Alternator
Startor
coil
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
Field coil
G
S
+
L
FR Ignition
switch Battery
Charging
Voltage regulator warning
light –
AK301529 AG
16-4 ENGINE ELECTRICAL
CHARGING SYSTEM
ALTERNATOR SPECIFICATIONS
Item Specifications
Type Battery voltage sensing
Rated output V/A 12/110
Voltage regulator Electronic built-in type

2003-2006 Mitsubishi Outlander Service Manual

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2003-2006 Mitsubishi Outlander Service Manual

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2003 - 2006 GROUP INDEX

GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00E

HOW TO USE THIS MANUAL. . . . . . 00-2 SUPPLEMENTAL RESTRAINT

VEHICLE IDENTIFICATION . . . . . . . 00-16 SUPPORT LOCATIONS FOR

HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR AND REFERENCE VALUE

EXPLANATION OF MANUAL CONTENTS

Indicates the page number.

Indicates procedures to be performed be-

Mark N denotes nonreusable part.

Repair kit or parts sets are shown.

Maintenance and servicing procedures

Classifications of major maintenance / service points

The title of the page

Indicates (by symbols) where

Symbols for lubrication, sealants and adhesives

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE

1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING

Check trouble symptom.

Read the diagnosis code. Read the diagnosis code.

After taking note of the

Read the diagnosis codes.

2. SYSTEM OPERATION AND SYMPTOM 4. DIAGNOSIS CODE CHART

8. SERVICE DATA REFERENCE TABLE MB991911

9. CHECK AT ECU TERMINALS

10. INSPECTION PROCEDURE BY USING

<Using the MUT-III>

Connect the M.U.T.-II/III to the diagnosis connector,

M.U.T.-II 1. Use the special tool diagnosis code check

1. Connect the M.U.T.-II/III to the diagnosis

HOW TO USE THE INSPECTION PROCE-

Relevant circuit(s) of the component which

Start of diagnosis Describes

HARNESS CHECK MEASURES TO TAKE AFTER

IF INSPECTING WITH THE CONNECTOR IF INSPECTING WITH THE CONNECTOR

<When Inspecting a Male Pin>

Inspect by inserting a test probe from the harness

If the connector pin stopper is damaged, the terminal

Harness wire breakage

Use the special tool inspection harness (MB991219)

The chassis number is stamped on the toeboard

No. Item Content

1 Fixed figure J Asia

Front of the vehicle

GENERAL DATA AND SPECIFICATIONS

Items CU2W CU5W

INITIALIZATION PROCEDURE FOR Learning Procedure

Before replacing a component related to the electri-

M.U.T.-III sub assembly

MB991824 MB991827 MB991910

M.U.T.-III main harness B M.U.T.-III measurement adapter M.U.T.-III trigger harness

MB991911 MB991825 MB991826

Refer to the "M.U.T.-II REFERENCE MANUAL",

AC300830AG Recommended Precautions

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

SRS warning lamp

Seat belt with pre-tensioner

Driver's air bag

Side air bag module

Side impact sensor

Side air bag module

Front impact sensor

SRS-ECU terminal No. Destination of harness Remedy

DANGER retain enough voltage to deploy the air bag