MITSUBISHI MOTORS ae Workshop Manual chassis CARISMA 98 — aa TS, —— Ti < LTS Tie ses Gilg: CHF * Pub. No. PWDE9502-CCARISMA WORKSHOP MANUAL SUPPLEMENT FOREWORD This manual outlines changes in servicing procedures related to the chassis including vehicle inspections, adjustments and improvements in the newly equipped models. Use the following manuals in combination with this manual as required. TECHNICAL INFORMATION MANUAL PYGE9SE1 PYGESSE1-A (Supplement) PYGESSE1-B (Supplement) WORKSHOP MANUAL ENGINE GROUP PWEEOOOO (Looseleaf edition) PWDE9502 PWDE9502-A (Supplement) PWDE9502-8 (Supplement) PHDE9501 PHDE9501-A (Supplement) PHDE9501-8 (Supplement) PHDE9501-C (Supplement) PBGESSE1 PBGESSE1-A (Supplement) PARTS CATALOGUE NeosCoosD0] ‘All information, illustrations and product descriptions contained in this manual are current a at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation. ade MITSUBISHI MOTOR SALES Europe BV. CHASSIS GROUP ELECTRICAL WIRING BODY REPAIR MANUAL © Mitaubish! Motors Corporation 1907 General ... Engine Fuel .. Engine Cooling ....... Intake and Exhaust ... Engine Electrical ......... Engine and Emission Control .... Manual Transmission . . Automatic Transmission .. Service Brakes .. Steering ... Exterior . Chassis Electrical .. oy red Bt00-1 GENERAL — How to Use This Manual/Vel GROUP 00 GENERAL HOW TO USE THIS MANUAL MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. 1800: Indicates models equipped with the 1,834 me <4G93> petrol engine. MPI: Indicates the multipoint injection, or engines equipped with the multipoint injection. DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an engine. GDI: Indicates the gasoline direct injection VEHICLE IDENTIFICATION MODELS ‘Model code | Engine mode! ‘Transmission models _| Fuel supply system DAZA | LNPCLB/R6 | 4G93-D0HC-GDI (1894 me) | F5Ma2 (2WD-SM/T) | GDI LNJCLERG LNDCLEIRG | LRPCLE/RG Faaa2 (2WD ~ 47) LRICLEIRS LROCLEIRS J Model code Engine model “Tranemission models | Fuel supply system DA2A | SNPCLORS | 4693-D0HC-GDI (1834me) | Fsma2 2wo-SMmT) | GDI SNICLEMRE SNDCLE/RE ‘SRPCLE/RE F4A42 (2WD - 447) SRICLERG | SROCLE/RG00-2 GENERAL - Vehicle Identification THTTititt MODEL CODE No. | tems Contents 1 | Development DA: MITSUBISHI CARISMA 2 | Engine type | 2 1,894 me petrol engine 3 | Sort ‘A: Passenger car 4 | Body sve Si 4-door sedan Li S:door hatchback 5 | Transmission ype | N: 5-speed manual transmission R_4-speed automatic transmission | Trimievel DL ~ ex ” us 7 | Specitod onaine [6 MPL-DOHC-GOI_ @ | Steering whee! Left hand locaton Re Right hand @ | Destination For EuropeGENERAL — Major Specifications 00-3 MAJOR SPECIFICATIONS HATCHBACK -—— ems. DAZA [DAZA_ | DAZA | DAZA_— | DAZA | DA2A LNPCLs, | LNUCL6, | LNDCL6, | LAPCLE, | LRJCLE, | LRDCLE, LNPGRE | LNJGRE | LNDGRE | LAPCRE | LRJCR6 | LRDCRE Vehicie Overall length 1449s [4435 4435 4.435 [4.495 | 4,405) dimensions. mm Overall width 2\ 1605 [1695 [1695 [1,695 [1,695 | 1,695 Overall height 3] 1405 [1405 [1405 | 1,405 [1,405 | 1,405 (unladen) | Wheelbase 4/2550 | 2,550 2550 | 2550 | 2,550 Track-front 5 | 1,455 1455 [1,455 | 1,455 Track-rear [elias [1,475 1475«( 1,475 «| 1,475 (Overhang-front 7 | 880 380 880 880 | Overhangrear [8 | 1,005 | 1,005 1,005 | 4,005 | 1,005 Ground clearance | 9 | 155 155 150 150 150 (unladen) I Vehicle Kerb weight 1105 [4165 | 1160 [1,250 | 4,185 | 1,180 weight kg - Max. gross vehicle 1625 [1,620 [1615 | 1,645 = [1,640 | 1,695, weight rating Max. axle weight 851 846 846 876 ert [er rating-front | | Max. axle weight 774 774 769 769 769 764 | rating-rear ‘Seating capacity 5 Engine Model No. 4093 ‘Total displacement mé | 1,834 Transmis- | Model No. FeMaz Fanaa sion ‘Type 5-speed manual 4-speed automatic Fuel system | Fuel supply system Electronic controlled multipoint fuel injection (MP1)/Gasoline direct injection (ao!)00-4 GENERAL - Major Specifications SEDAN = ke rm? tems. DA2A|DA2A | DA2A | DA2A | DAZA__| DAA SNPCL6, | SNJCL6 | SNDCL6, | SRPCLE | SRUCLS, | SRDCLE SNPCR6 | SNJCR6 | SNDCRE | SRPCRE | SRJCRE | SRDCRE Vehicle ‘Overall length [1 | 4435 4,435 4495 | 4,495 4,435 4,435 dimensions T mm (Overall width [2| 1605 [1605 [1,695 | 1,605 | 1,605 ‘| 1,695, ‘Overall height 31405 | 1,405 | 1405 | 1,408 [1,405 | 1,405 (unladen) | Wheelbase 4|2ss |2ss0 [2550 |2550 | 2550 | 2.550 front s|iass [145s [1455 | 1.455 | 1,455 1,455, Trakt-rear elias [1475 | 147s | tars 1475 | 1,475 Overhang-tront | 7 | 880 880 880 880 880 (Overhang-rear 81,005 | 1,005 | 1,005 | 1,005 | 1,005 Ground clearance | 9 | 155 155 185 150 150 (unladen) Vehicle | Kerb weight ates [4ta5 [1140 [185 [4,165 | 1,160 weight kg Max. gross vehicle 1605 [1,600 [1595 | 1625 | 1,620 ‘| 1,615 weight rating Max. axle weight 856 851 851 381 876 876 rating-front Max. axle weight 749 749) 744 744 744 739 rating-rear Seating capacity 5 Engine | Model No. 4093 Total displacement me | 1,804 Transmis- | Model No. FeMaz Fanaa sion Type. 5-speed manual ‘4-speed automatic Fuel Fuel supply system Electronic controlled multipoint fuel injection (MPI)/Gasoline direct injection system (eo),11A-1 ENGINE CONTENTS GENERAL INFORMATION .. SERVICE SPECIFICATIONS ... SEALANTS . a2 SPECIAL TOOLS .........00:sesseeeeeeeeee 3 ON-VEHICLE SERVICE . Drive Belt Tension Check and Adjustment Ignition Timing Check Idle Speed Check Idle Mature Check Compression Pressure Check Manifold Vacuum Check 10 Lash Adjuster Check : 12 (CRANKSHAFT PULLEY 16 CAMSHAFT AND CAMSHAFT OIL SEAL ... 17 OIL PAN... CRANKSHAFT OIL SEAL... CYLINDER HEAD GASKET . TIMING BELT ........00eee005 ENGINE ASSEMBLY ...11A-2 ENGINE — General information/Service Specifications GENERAL INFORMATION Items 4693 Total displacement mé 1,834 | Bore x Stroke mm : 81.0890 ‘Compression ratio 26 ‘Combustion chamber [ Pentroof + ballinpiston ‘Camshaft arrangement DOHC a Number of valve intake 8 Exhaust 8 Vane timing Intake Opening BTDC 15" lasing ‘ABDC 56° Exhaust Opening BBDC 55" Closing TDC 15° Fuel system Electronically controlled multipoint fuel injection ‘Rocker arm Roller type ‘Auto-lash adjuster Equipped | SERVICE SPECIFICATIONS ttems ‘Standard value Limit | Alternator drive | Vibration When checked 151-195 = Betttension | feavency Hz When a used belts installed | 169-185 = | When a new bettis instaled | 195-230 = Tension N | When checked 204-480 - When a used baltis installed | 343-441 = When anew beltisinstaled | 490-686 = Deflection | When checked 80-105 = (Suclame | When a used bettis installed | 65-100 = When a new beltis installed | 7.08.0 = Power steering | TensionN | When checked 392-588 = Reem sesscr | ‘When a used beltis installed | 441539 = rive belt tension | When a new belts installed = Deflection | When checked 10.0-120 = “m ‘When a used bettis installed | 10.0-11.0 = ‘When a new beitis installed | 7.0-9.0 = Basic ignition timing 5° BTDO=3° = ignition timing ‘Approx. 18°BTDC | -ENGINE — Service Specifications/Sealants/Special Tools 11A-3 tems: ‘Standard value Limit Idle speed r/min | MIT 600 = 50-800 50" | — AT 650 = 50 = CO contents % 0.5 or less = HC contents ppm 100 or less, [= ‘Compression pressure kPa —rimin 1,569 — 300) 1,834 300 ‘Compression pressure difference of all cylinder kPa = Max. 100 Intake manifold vacuum kPa 7 - Min. 37 Cylinder head bolt shank length mm = 99.4 Timing batt tension torque Nm (Reference valve) 25 = ‘Auto-tensioner rod protrusion amount mm [38-45 = *: Varies depending on the transmission oil temperature. For details SEALANTS , fefer to P. 1189. Items ‘Specified sealants Remarks Oil pan - MITSUBISHI GENUINE PART | Semi-drying sealant ‘Thermostat case MD970389 oF equivalent | Cam poston sensor support SPECIAL TOOLS Too! Number Name Use 18901668 | Bett tension meter | Measuring the drive belt tension set (used together with the MUT-II) vormee MD998767 Tension pulley, ‘Timing belt tension adjustment socket wrench ~[weesisce | MoT au "Measuring the dive bel fonsion assembly ‘Checking the ignition timing | ‘© Checking the idle speed Ac: lege | Erasing diagnosis code - MD998713 Camshaft oll seal | Press-in of the camshaft oll seal installer11A-4 ENGINE — Special Tools wrench Too! ‘Number Name Use ‘MD998727 pan remover | Removal of oll pan MB991653 ‘Cylinder head bolt | Cylinder head bolt removal and installationENGINE - On-vehicle Service 11A-5 finger. Atemator pulley “Tap tightly with 7. mpest6s8 (Microphone) 10-20mm Crankshaft pulley SEN06s6 ‘Atemator pulley Bot tension gauge (Crankshaft pulloy senoese ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Check the drive belt tension by the following procedure. 1. Connect the special tool (belt tension meter kit) to the MUT-IL. 2. Connect the MUT-II to the diagnosis connector. 3. Turn the ignition switch to ON and select “Belt Tension Measurement” from the menu screen. 4, Hold the microphone to the middie of the drive belt between the pulleys (at the place indicated by the arrow), about 10 - 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of = 15°). 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 check that the vibration frequency of the belt is within the standard value. Caution (1) The temperature of the surface of the belt should be as close as possible to normal temperature. 2) Do not let any contaminants such as water or oll get onto the microphone. (@) If strong gusts of wind blow against the microphone or If there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. (4) If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. (6) Do not take the measurement while the vehicle's engine Is running. Use a belt tension gauge to check that the belt tension is within the standard value.ENGINE — On-vehicle Service ‘Alterdator Vibration frequency Hz pulley Tension N senoast Deflection (Reference value) mm Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check Cranisnat'| that the amount of deflection is within the standard value. Standard value: ‘Adjusting bolt Lock bot ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen the nut of the alternator pivot bolt. 2. Loosen the lock bolt. 3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. ‘Standard value: Tem ]Whenaused | When anew oot bot Botsinstaled _| bots ictalod aewoser Viraion feauency | 763-185 | Y05—200 Tension N aasaat | 400686 Deflection | 85-100 7.0-8.0 (Reference value) mm NOTE Refer to P.11A-5 concerning the measurement procedure of the alternator drive belt tension. 4, Tighten the nut of the alternator pivot bolt. Tightening torque: 44 Nm 5. Tighten the lock bolt. Tightening torque: 22 Nm 6. Tighten the adjusting bolt. Tightening torque: 10 NmENGINE - On-vehicle Service 11A-7 POWER STEERING OIL PUMP AND AIR CONDITIONER Sipump pulley COMPRESSOR DRIVE BELT TENSION CHECK AND ‘ll pump pulley — ADJUSTMENT man 1. Check the drive belt tension by the following procedure. Crankshat, 8 puley Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in ssor | the illustration, and check that the vibration frequency of the belt is within the standard value range. zono002 NOTE Refer to P.11A-5 for details on the method of measuring the vibration frequency using the MUT-IL. Use a belt tension gauge to check that the belt tension is within the standard value. Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value. Standard value: ems When | Whenaused | When anew checked _| belts installed | beltis installed Vibration 114199 [121-133 ‘| 145-166 frequency Hz TensionN | 992-588 | 441-539 | 637-833, Deflection mm | 10.0-120| 100-110 | 7.0-9.0 2. If outside the standard value, adjust by the following procedure. (1) Loosen the tensioner pulley fixing bolt A. (2) Adjust the amount of belt deflection using adjusting bolt B. (8) Tighten the fixing bolt A Tightening torque: 25 Nm (4) Check the belt deflection amount and tension, and readjust if necessary. Caution Check after turning the crankshaft once or more clockwise (right turn).11A-8 IGNITION TIMING CHECK (dle speed r/min 1. Before inspection, set the vehicle to the pre-inspection 900 condition. 800 2. Connect the MUT-II to the diagnosis connector. 700 3. Set up a timing light. coo 4. Start the engine and run at idle. - 5. Check that engine idle speed is within the standard value. “10 oon Standard valu temperature °C 2010084 Items Idle speed rimin MT 60050 - 80050" AT | 650250 NOTE (1) *:The idle speed in vehicles with manual transmission varies as shown in the table above in accordance with the transmission oil temperature. (2) After 4 minutes or more have passed in the idle running condition, the idle speed will become 750 1/ 6. Select No.17 of the MUT-II Actuator test. NOTE At this time, the engine speed will become approximately 750 r/min. 7. Check that basic ignition timing is within the standard value. Standard value: 5° BTDC:3° 8. If the basic ignition timing is outside the standard value, inspect the GDI system while referring to GROUP 13J = Troubleshooting 9. Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test. Caution If the test Is _not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engin 10. Check that ignition timing is at the standard value. Standard valu prox. 6°BTDCENGINE - On-vehicle Service 11A-9 Idle speed r/min 900 800 700 600 IDLE SPEED CHECK Before inspection, set the vehicle to the pre-inspection condition. Connect the MUT-II to the diagnosis connector. Check the basic ignition timing NOTE Refer to P.11A-8 concerning the check procedure of the basic ignition timing. Standard value: 5° BTDC=3° Run the engine at idle for 2 minutes. Check the idle speed. Select item No. 22 and take a reading of the idle speed. Standard value: items Ile speed rimin wT 60250-80050" AT 650250 NOTE (1) *:-The idle speed in vehicles with manual transmission varies as shown in the table above in accordance with the transmission oil temperature. (2) Alter 4 minutes or more have passed in the idle running condition, the idle speed will become 750 r/min. (@) The idle ‘speed is controlled automatically adjusted by the idle speed control (ISC) system. If the idle speed is outside the standard value, inspect the GDI components by referring to GROUP 13) — Troubleshooting. IDLE MIXTURE CHECK 1 2. 3. ome Before inspection, set the vehicle to the pre-inspection condition. Connect the MUT-II to the diagnosis connector. Check that the basic ignition timing is within the standard value. NOTE Refer to P.11A-8 concerning the check procedure of the basic ignition timing. Run the engine at 2,500 r/min for 2 minutes. Set the CO, HC tester. Check the CO contents and the HC contents at idle. NOTE This measurement should be performed in less than approximately 4 minutes since the engine speed become the idle speed. Standard value 1.5% or less 100 ppm or less11A-10 ENGINE — On-vehicle Service 7. Ws Compression gauge If there is a deviation from the standard value, check items: © Diagnosis output © Fuel pressure © Injector . Ignition coil, spark plug Leak in the EGR system and in the EGR control servo © Evaporative emission control system © Compression pressure NOTE Replace the three way catalyst when the CO and HC ‘contents are not within the standard value, even though the result of the inspection is normal on all items. COMPRESSION PRESSURE CHECK Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition. Remove all of the ignition coils and spark plugs. Disconnect the crank angle sensor connector. NOTE Doing this will prevent the engine-ECU from carrying out ignition and fuel injection. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel Caution (1) Keep away from the spark plug hole when cranking. (2) If compression Is measured with water, oll, fuel, te., 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. Set compression gauge to one of the spark plug holes. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 300 r/min): 1,569 kPa Limit (at engine Min, 1,334 kPa ed of 300 r/min):ENGINE — On-vehicle Service T1A-11 Vacuum gauge ‘eNoats 7. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 100 kPa 8. 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 6 and 7. (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket 9. Connect the crank angle sensor connector. 10, Install the spark plugs and ignition coils. 11. Use the MUT-II to erase the diagnosis codes. NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected. MANIFOLD VACUUM CHECK 1. Before inspection, set the vehicle to the pre-inspection ‘condition. 2. Connect the MUT-II to the diagnosis connector. 3. Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve, and then connect a ‘vacuum gauge to the ventilation hose. 4. Check that the idle speed is approximately 600 r/min or approximately 650 r/min . 5. Check the intake manifold negative pressure while the engine is idling. Limit: Min. 37 kPa11A-12 ENGINE - 01 ehicle Service LASH ADJUSTER CHECK If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE (1) The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load Because of this, if the noise does not occur immediately after the engine is started, if it does not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters. (2) If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick, Start the engine. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. Hf the noise does not occur immediately after the engine is started, or if it does not change in accordance with the engine speed, the problem is not being caused y the lash adjusters, so check for some other cause of the problem. Moreover, if the noise does not change in accordance with the engine speed, the cause of the problem is probably not with the engine. (In these cases, the lash adjusters are normal.) ‘While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N —> D). Hf the noise level changes, the cause of the noise is probably parts striking because of wom crankshaft ‘bearings or connecting rod bearings. (In such cases, the lash adjusters are normal.) After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or has disappeared, the cause of the noise was probably that oil sludge had caused the lash adjusters to become stuck. If this happens, carry out the following check. If the noise level does not change, go to step 5. (1) Let the engine cool down sufficiently. (2) Turn the crankshaft two full revolutions.ENGINE — On-vehic! 5. 6. Service 11A-13 (8) Carry out lash adjuster simple check. (Refer to P11A-414) ‘© If any of the rocker arms can be pushed down easily during the lash adjuster simple check, replace the corresponding lash adjusters. © Ifthe lash adjuster simple check has been carried out but all lash adjusters are normal (if none of the rocker arms could be pushed down easily), check for some other cause of the problem. NOTE You can check whether the lash adjusters are normal or not by carrying out a leak-down test. (Refer to the Engine Workshop Manual.) Caution Make sure that the air has been fully bled before Installation of a new lash adjuster. (Refer to the Engine Workshop Manué Bleed the air from the lash adjusters. (Refer to P.11A-14,) If the noise does not disappear even after the air has been bled from the lash adjusters, carry out the following check. Carry out lash adjuster simple check. (Refer to P.11A-1 © If one of the rocker arms can be pushed down easily during the lash adjuster simple check, replace the corresponding lash adjuster. © If two or more of the rocker arms can be pushed down easily during the lash adjuster simple check, the cause may be that the oil passage to the cylinder head is blocked. Check for blockages in the oil passage, and clear the blockages if any are found. if there are no blockages, replace the lash adjusters. © If the lash adjuster simple check has been carried out but all lash adjusters are normal (if none of the rocker arms could be pushed down easily), check for some other cause of the problem. NOTE ‘You can check whether the lash adjusters are normal ‘or not by carrying out a leak-down test. (Refer to the Engine Workshop Manual.) Caution Make sure that the alr has been fully bled before Installation of a new lash adjuster, (Refer to the Engine Workshop Manual.) Start the engine and check that the abnormal noise has disappeared. If necessary, bleed the air from the lash adjusters. (Refer to P.11A-14.)11A-14 ENGINE — On-vehicle Servi Timing bott side senoers Good 27€N0207 1. 2 3. 4 ‘Stop the engine. Remove the rocker cover. Set the No.1 cylinder to the compression top dead centre position. Check the rocker arms indicated by white arrows in the illustration by the procedures given below. Check whether the rocker arm moves downwards when the part of the rocker arm which touches the top of the lash adjuster is pushed. ‘© Ifthe rocker arm moves down easily when itis pushed, make a note of which is the corresponding lash adjuster. © Ifthe rocker arm feels extremely stiff when it is pushed and does not move down, the lash adjuster is normal, 80 check for some other cause of the problem. ‘Slowly turn the crankshaft 360° in the clockwise direction. Check the rocker arms indicated by black arrows in the istration in the same way as explained in step 4. NOTE (1) If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine. (2) After parking the vehicle for long periods, the oil drains ‘out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber. (8) If either of the above situations occur, the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters. Check the engine oil and replenish or replace the oil if necessary. NOTE (1) If there is a only small amount of cil, air will be drawn in through the oil screen and will get into the oi passage. (2) If the amount of oil is greater than normal, then the il will being mixed by the crankshaft and a large amount of air may get mixed into the oil. (8) If the oil is degenerated, air and oil will not separate easily in oll, and the amount of air mixed into the ol will increase.ENGINE - On-vehicle Service W1A-15 Highressure chamber ne ‘TENO393- S88 tan Ide speed Gradually open the thvottle valve Drive pattern for air bleeding Close the throttle valve. ‘7F 2059 3. 4, 5. (4) If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure ‘chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve closes. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal. Run the engine at idle for 1 — 3 minutes to let it warm up. With no load on the engine, repeat the drive pattern shown in the illustration at left and check if the abnormal noise disappears. (The noise should normally disappear after 10 ~ 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably ot due to air inside the lash adjusters.) After the noise has disappeared, repeat the drive pattern shown in the illustration at left a further 5 times. Run the engine at idle for 1-3 minutes and check that the noise has disappeared.11A-16 ENGINE — Crankshaft Pulley CRANKSHAFT PULLEY REMOVAL AND INSTALLATION Pre-removal and Post-nstallation Operation Under Cover (RH) Removal and' Installation Engine Ol so1mooss: Removal steps © Drive belt tension adjustment 4. Crankshaft pulley washer 1. Drive belt (Power steering and A/C) 5. Crankshaft pulley 2. Drive belt (Alternator) A> PA 3. Crankshaft pulley bolt NOTE Removal and installation service points are the same asENGINE ind Camshaft Oil S 11A-17 CAMSHAFT AND CAMSHAFT OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Postnetalation Operation 2°" Arrintake Hose Pemoval and instalation Timing Bet Removal and irtaaton Engine Coolant Orang and Supp Intake Manfola Removal and Ineakaion (Refer to GROUP 15.) © Fuel Pump Removal and installation ‘© Drive Belt Tension Adjustment 12-15 Nm. Removal steps 1. Connector bracket mounting bolt (injector harness) eather hose connection PCV hose connection Rocker cover Rocker cover gasket 3. Cam position sensor support Cam position sensing cylinder Camshatt sprocket, ——— Sp Apply engine oil to all sliding parts during installation. 9. Camshaft oil seal 10. Beam camshaft cap 11. Beam camshatt cap gasket Ad 12 Camshatt (exhaust side) DA 13. Camshaft (intake side) NOTE Removal and installation service points which are not listed in this manual are the same as before.11A-18 ENGINE — Camshaft and Camshaft Oil Seal Lubrication points ‘¢3mm___ ‘Sealant: 3M ATD Part No.8660 or equivalent Or... ‘Sealant: Engine oll MITSUBISHI GENUINE PART ‘or equivalent - “Sealant: SM ATD Part No.8660 or equivalentENGINE - Camshaft and Camshaft Oil Seal 11A-19 Intake side Approx. 10" Dowel pin Exhaust side 0998713 INSTALLATION SERVICE POINTS >B-4BEAM CAMSHAFT CAP INSTALLATION 1. Place the camshaft dowel pin as shown in the illustration. 2. Tighten the beam camshaft cap mounting bolts to the specified torque in the order shown in the illustration. Tightening torque: 0 — 12 Nm >C-4 CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the entire circumference of the oil seal lip. 2, Press-fit the oil seal as shown in the illustration. DD CAMSHAFT SPROCKET INSTALLATION Use the special tool to secure the camshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque. Tightening torque: 88 Nm$ § 11A-20 OIL PAN REMOVAL AND INSTALLATION Pre-removal and Post-nstallation Operation ¢°” Front Exhaust Pipe Removal and instalation ‘© Engine Oil Level Gauge Removal and Installation (Roter to GROUP 15) © Engine Oil Draining and Supplying ¢ Under Cover Removal and installation ENGINE — Oil Pan | Sealant; MITSUBISHI GENUINE PART MD970389 or equivalent 110008 Removal steps 1. Lower oil pan 6. Baffle plate 2. Drain plug Aq 3. Gasket NOTE 4. Cover Removal and installation service points which are not 5. Upper oil pan listed in this manual are the same as before.MD908727 ENGINE — Oil Pan 11A-21 REMOVAL SERVICE POINTS <4AD LOWER OIL PAN REMOVAL Caution Do not bend the flange of the lower oll pan or damage the upper oll pan. 48> UPPER OIL PAN REMOVAL ‘After removing all of the mounting bolts, screw the bolts into the places shown in the illustration and then remove the upper oil pan. Caution Because the upper oll pan used Is made from aluminium, ‘the oll pan remover (MB998727) should not be used.11A-22 ENGINE — Crankshaft Oil Seal CRANKSHAFT OIL SEAL ne SY ae, ; 4 gly, of /. 93-103.Nm g 93 “eh REMOVAL AND INSTALLATION 2 Crankshaft rankshat bp : ( ngine oft jn0 ok Scion ang Sehteent and ‘threaded hole) threaded nol) 8 11 10 ® a — ® Got teas) (Got thread) Up ue ono0ee ne rzooze oxz00% ‘Sealant: 3M Stud Locking 4170 or equivalent Engine oll i Crankshaft front oll seal removal steps Crankshaft rear oll seal removal steps. ‘© Timing bolt (refer to 114-27.) © Transmission assombi © Crank angle sensor © Glutch cover, disc 4. Crankshaft sprocket 6, Plate 2 Key Bd 7. Adaptor plate 3. Crankshaft sensing blade 8. Flywheel: assembly 4 Crankshaft spacer B-q_ 9. Adaptor plato 5. Crankshaft front oll seal Bq 10. Drive plato "Acq 11. Crankshaft rear ol! seal NOTE Removal and installation service points are the same as betore.ENGINE — Cylinder Head Gasket 11A-23 CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Prevention of fuel discharge Intake Manifold Removal and Installation Engine Coolant Draining and Supplying ter to GROUP 15.) Engine Ol Draining and Supping '¢ EGR Pipe Removal and Installation Airintake Hose Assembly Removal and Instalaion © Timing Belt Removal and installation Engine Cover Removal and Insialaion © Drive Bett Tension Adjustment ‘Thermostat Case Aacombly Removal and installation Fa pump ™ : , “um 4 ©. anaes aah Engine oll Removal steps 1, Brosther hose connection 6 PCV hose comection 2 Gam postion eonaor omnector 4, Power storing ol pomp brackst stay & Fuel pump connector 44>. Power steering ol pump brackat po 2 High precture Tel hose sssombyy 5. Fuel return hose11A-24 ENGINE — Cylinder Head Gasket 74 Nm -+ 0 Nm -+ 20 Nm -+ +90° Nm -+ +90° 12 10. 1 12, Beam 13, 14, 16. Connector bracket mounting bolt (injector harness) asket Engine coolant temperature sensor connector Water hose connection Idler pulley . Timing belt rear left cover 17. Timing belt rear right cover 18. Front exhaust pipe connection > PB 19. Cylinder head 20. Gylinder head assembly PA 21. Cylinder head gasket NOTE Removal and installation service points which are not listed in this manual are the same as before.ENGINE — Cylinder Head Gasket Intake side <> Frontot engine Exhaust sido ‘120008 007199 Cylinder head bolt Burred side er {Engine} Washi & A Cylinder head MB991653 Intake side <= Front of engine omo7sa7 11A-25 REMOVAL SERVICE POINT “48> CYLINDER HEAD BOLT REMOVAL Use the special tool to loosen the bolts in two or three stages in the order of the numbers shown in the illustration, and then remove the bolts. INSTALLATION SERVICE POINT B-4(CYLINDER HEAD BOLT INSTALLATION 1. ‘Check that the shank length of the cylinder head bolts are at or below the limit value. If the lengths are above the limit value, replace the bolts with new ones. Limit (A): 96.4 mm Install the cylinder head bolt washers so that the burrs caused by tapping the washers are facing upwards. Apply a small amount of engine oil to the threads of the cylinder head bolts and to the washers. Use the special tool to tighten the bolts by the following procedure (over the plastic region). (1) Tighten the bolts to 74 Nm in the order shown in the illustration, (2) Fully loosen the bolts in the reverse order to the order shown in the illustration. (8) Tighten the bolts to 20 Nm in the order shown in the illustration,Step 4 90 Paint mark ‘Step 5 0° Paint mark (4) Make paint marks on the heads of the oylinder head bolts and on the cylinder head, and then tighten the bolts a further 90° in the order shown in the illustration. (6) Tighten the bolts 90° in the order shown in the illustration and check that the paint marks on the bolt heads are in a straight line with the paint marks on the cylinder head. Caution (1) If the tightening angle for any bolt is less than 90°, that bolt will not be sufficiently tight. @) Ifitls more than 90°, remove all of the bolts and repeat the procedure from step (1).ENGINE — Timing Belt 11A-27 TIMING BELT REMOVAL AND INSTALLATION Pre-removal and Post-nstallation Operation ‘Under Cover Removal and Installation © Crankshaft Pulley Removal and Instalation © Drive Belt Tension Adjustment SB 9 Nm soniooro Removal steps 1. Alternator brace DPA 7. Auto tensioner 2! Timing belt front upper cover 8 Tensioner pulley and arm assembly 3. Timing belt tront lower cover 8. Idler pulley 4, Front flange 5. Engine support bracket NOTE ‘¢| Timing belt tension adjustment Removal and installation service points are the same as woe BSS 5. tng bor ere11A-28 ENGINE — Timing Belt INSTALLATION SERVICE POINT C4 TIMING BELT TENSION ADJUSTMENT 1. After turning the crankshaft a 1/4 turn anti-clockwise, turn it clockwise to the position where the timing marks are aligned. 2. Loosen the fixing bolt of the tensioner pulley and using the special tool and a torque wrench, apply tension to the timing belt; then tighten the fixing bolt at the specified torque. Standard Value: 2.5 Nm {timing belt tension torque (reference value)} Caution When tightening the fixing bolt, ensure that the tensioner pulley shaft doesn't rotate with the bolt. 3. Take out the 2 mm Allen wrench from the auto tensioner. 2mm Allen = wrench OY ‘At this time, check to be sure that 2 mm Allen wrench ~~ SS can be pulled out easily. | —S Turn the crankshaft clockwise 2 turns, and after leaving it in this position for 5 minutes or more, clock again to sorsooa? be sure that the auto tensioner 2 mm Allen wrench can be pulled out or inserted easily. NOTE Even if the 2 mm Allen wrench cannot be easily inserted, then it is satisfactory if the amount of protrusion of the auto tensioner rod is within the standard value. ‘Standard value (A): 3.8 - 4.5 mm If it is outside the standard value, repeat the operations in step 1 to 4. 4. Check to be sure that the timing marks on all sprockets are aligned. 0180042ENGINE — Engine Assembly ENGINE ASSEMBLY REMOVAL AND INSTALLATION 11A-29 Pre-removal and Post-installation Operation Prevention of fuel discharge Engine Coolant Draining and Supplying Hood Removal and installation Air Intake Hose Assembly Removal and Installation Radiator Assembly Removal and Installation ‘© Front Exhaust Pipe Removal and Installation eter to GAOL Engine Cover Removal and installation Under Cover Removal and Installation ‘Accelerator Cable Adjustment Be o-ring exo | Engine olf Removal steps 4. Accelerator cable 2 Ignition col connector 8. Throttle position sensor connector 4. Cam position sensor connector 5. Engine coolant temperature sensor ‘connector 6. Engine coolant temperature gauge unit connector 7. Fuel pump connector 8 Fue! return hose connection 8. ISC connector D>D-d 10. High-pressure fuel hose connection 11. Vacuum hose connection 12, Brake booster vacuum hose ‘connection 13, Purge solenoid valve connector11A-30 ENGINE Engine Assembly 96 - 18. Nm* groove 14, Crank angle sensor connector ‘© Transmission assembly 15. Injector harness connector 27. Engine mount bracket 16. Purge solenoid valve connector 28. Engine mount stopper 17. Air by-pass valve harness connector E> 28, Engine assembly 18, Heater hose connection 19. Oxygen sensor connector Caution 20. Alternator connector Mounting locations marked by * should be 21. Engine oil pressure switch connector _provisionally tightened, and then fully tightened '®| Drive belt tension adjustment ‘when the vehicle body Is supporting the full 22. Drive belt (for power steering oil pump, weight of the engine. AIC compressor) 23. Power stooring oil pump bracket stay NOTE > 24, Power steering oil pump bracket Removal and installation service points are the same as assembly before. << 25, AIC compressor mounting bolt 28. Oil pressure hose and pipe clamp: mounting boltFUEL CONTENTS MULTIPOINT FUEL INJECTION (MPI) ..... ELECTRONIC CONTROL TYPE CARBURETTOR ... 138 CONVENTIONAL TYPE CARBURETTOR .... 136 VARIABLE VENTURI TYPE CARBURETTOR ... ivamarode 19D: DIEGEL FUEL 0.2.0.6... csceesccesesseenees oy 13E FUEL SUPPLY 13F ++++1+ Referto GROUP 17 -AUTO-CRUISE CONTROL SYSTEM ... TRACTION CONTROL SYSTEM (TCL) .......++ GASOLINE DIRECT INJECTION (GDI) ... 130 NOTE THE GROUPS MARKED BY ARE NOTIN THIS MANUAL, 13-1FUEL SUPPLY — General/Fuel Tank GROUP 13F FUEL SUPPLY GENERAL OUTLINE OF CHANGES © Maintenance service procedures have been established for items which are different from before to correspond to the following changes. FUEL TANK REMOVAL AND INSTALLATION 1. Removal and installation of the fuel tank 2. Removal and installation of the fuel filter Pre-removal Operation Fuel Draining ‘© Fleducing the Inner Pressure of Fuel Line and Hose © Conter Exhaust Pipe Removal (Refer to GROUP 15.) Post-nstallation Operation "Center Exhaust Pipe Installation (Refer to GROUP 15.) © Fuel Refing © Fuel Leak Check Removal steps |. Hose connection Fuel return pipe 1 2 3. 4. Protector 5. Fuel tank assembly 6 Fuel main hose pcg 5 ue totam hose 9. Fuel pump module (0. Fuel vapour hose ooorsat 11. Fue! filer cap 12. Fuel rubber drain 18. fuel neck assembly 14, Leveling hose 16. Filler hose NOTE Removal and installation service points are the same as before.13F-2 FUEL SUPPLY - Fuel Filter FUEL FILTER REMOVAL AND INSTALLATION Pre-removal and Post.installation Operation ‘Air Cleaner Assembly Removal and Installation ‘Aosu0062 Removal steps 1. Fuel return hose 4. Fuel high pressure regulator 2: Fuel pressure regulator 5. Fuel main pipe 3, Fuel connector 6. Fuel high pressure filter13-1 GASOLINE DIRECT INJECTION (GDI) CONTENTS, GENERAL INFORMATION SERVICE SPECIFICATIONS SEALANT . SPECIAL TOOLS .......0.secseeeesseee 7 TROUBLESHOOTING .. ON-VEHICLE SERVICE .. 84 Tyre Body (Trott Valve Area) Cleaning... 84 Idle Position Switch and Throttle Position Sensor Adjustment 84 Fixed SAS Adjustment wie 85 Basic Idle Speed Adjustment 86 Fuel Pressure Test 87 Fuel Leakage Check 90 Fuel Pump Connector Disconnection row to Reduce the Fue! Pressure) 9 Fuel Pump Operation Check .......+ CT Component Location ...... 92 Gontrol Relay ana Fuel Pump Relay Contry, Check . Injector Driver Control Relay Continuity Check Intake Air Temperature Sensor Check . Engine Coolant Temperature Seneor Check... ‘Throttle Position Sensor Check cee 98 ee Idle Position Switch Check 94 ‘Oxygen Sensor Check 95 Injector Check . 96 Idle Speed Control (ISC) Servo (tener Motor) Check ....- 97 Ar By-pess Cot Slo Vave Purgo Contol Solenoid Valve Chock 98 EGR Control Servo Check ...........2+6+ 98 FUEL PUMP (HIGH PRESSURE) . INJECTOR .. THROTTLE BODY . INJECTOR DRIVER ..13J-2 Gopi General Information GENERAL INFORMATION ‘The Gasoline Direct Injection System consists of sensors which detect the engine conditions, the engine-ECU which controls the system based on signals from these sensors, and actuators which operate under the control of the engine-ECU. The engine-ECU carries out FUEL INJECTION CONTROL The injector drive times and injector timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continually-changing engine operation condi- tions. A single injector for each cylinder is mounted at the cylinder head. The fuel is sent under pressure from the fuel tank to the fuel pressure regulator (low pressure) by the fuel pump (low pressure). The pressure is regulated by the fuel pressure regulator (low pressure) and the fuel regulated is then sent to the fuel pump (high pressure). The fuel under increased pressure generated by the fuel pump (high Pressure) is then regulated by the fuel pressure regulator (high pressure) and is then distributed to each of the injectors via the delivery pipes. IDLE AIR CONTROL The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in accordance with changes in idling conditions and engine load during idling. The engine-ECU drives the idle speed control (ISC) motor to keep the engine running at the pre-set idle target speed in accordance with the engine coolant temperature and air IGNITION TIMING CONTROL The power transistor located in the ignition primary circuit turns ON and OFF to control the primary current flow to the ignition coil. This Controls the ignition timing in order to provide the optimum ignition timing with respect to the engine operating conditions. The ignition timing SELF-DIAGNOSIS FUNCTION © When an abnormality is detected in one of the sensors or actuators related to emission control, the engine warning lamp (check engine lamp) illuminates as a warning to the driver. © When an abnormality is detected in one of the sensors or actuators, a diagnosis activities such as fuel injection control, idle ‘speed control and ignition timing control. In addition, the engine-ECU is equipped with several diagnosis modes which simplify troubleshooting when a problem develops. Fue! injection is normally carried out once for each cylinder for every two rotations of the crankshatt. The firing order is 1-3-4-2. This is called sequential fuel injection. When the engine is cold or under a severe load, the “open-loop” control keeps the air/fuel ratio at a richer than usual level to maintain driveability. When the engine is under low or medium loads, the air/fuel ratio becomes leaner to reduce fuel consumption. When the engine is running at medium or high loads after having warmed up, the “closed-loop” control uses the signal from the oxygen sensor to keep the air/fuel ratio at the optimum theoretical level. conditioner load. In addition, when the air conditioner switch is turned off and on while the engine is idling, the ISC motor operates to adjust the throttle valve bypass air amount in accordance with the engine load conditions in order to avoid fluctuations in the engine speed. is determined by the engine-ECU from the engine speed, intake air volume, engine coolant temperature, atmospheric pressure and injection timing (intake stroke or compression stroke). code corresponding to the abnormality is output. © The RAM data inside the engine-ECU that is related to the sensors and actuators can bbe read by means of the MUT-II. In addition, the actuators can be force-driven under certain circumstances.GDI 13J-3 tion OTHER CONTROL FUNCTIONS 1. Fuel Pump Control Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running. condenser fan are controlled in response to the engine coolant temperature and vehicle speed. Purge Control Solenoid Valve Control 2. AIC Relay Control Refer to GROUP 17. Turns the compressor clutch of the A/C 8, EGR Control Servo Control ON and OFF. Refer to GROUP 17. 3, Fan Relay Control The revolutions of the radiator fan and GENERAL SPECIFICATIONS ttems_ ‘Specifications “Throttle body 54 ‘Thvottle position sensor ~~ | Variable resistor type Idle speed contol sono Stepper motor type (Stepper motor type by-pass ar control system) Ide position switch Rotary contact ype, within throtle postion sensor Engine-ECU_| Identification model No. 2768374 ~ ‘Sensors Air flow sensor Karman vortex type - Barometric pressure sensor ‘Semiconductor type —_ ~ Intake air temperature sensor —==S«| Thermistortype = Engine coolant temperature sensor | Thermistor type Oxygen sensor Zirconia type Vehicle speed sensor Magnetic resistive element type Inhibitor ewitch Contact switch ype Camshatt position sensor Halll element type Crank angle sensor ‘Hall element type. Detonation sensor Piezoelectric type Fuel pressure sensor Metallic membrane type Power steering fuid pressure switch Contact switch type13J-4 GDI — General information items Specifications Actuators | Control relay type Contact switch ype Fuel pump relay type Contact switch type Injector driver contro relay Contact switch type Injector type and number | Electromagnetic type, 4 Injector identification mark DIM 10006 ‘Air by-pass control solenoid valve | ON/OFF type solenoid vaive (ON/OFF) ‘ir by-pass control solenoid valve Duty cycle type solencid valve (oury) EGR control servo ‘Stopper motor type Purge control solenoid valve Duty cycle type solenoid valve Fuel pressure | Regulator pressure kPa 329 regulator (ow pressure) Fuel pres- | Regulator pressure MPa 5 sure regula- tor (high pressure)GDI — General Information 13J-5 GASOLINE DIRECT INJECTION SYSTEM DIAGRAM [sn =p [Engine ECU => [1 Injector driver (injector) | 2 ERI | $2 Ide. speed contra! servo 3 Intake ir temperature sensor 35 EGR contol servo (stepper motor) *4 Throttle postion sensor $4 Purge control solenoid valve %5. Idle postion switch $5 Air by-pass. control ‘solenoid valve %8 Gamshaft postion sensor (onote %7 Grank angio sensor ‘#6 Air by-pass control solenoid valve (OUTY)| %8 Baromotne pressure sensor ‘8 Engine coolant temperature sensor © Fuel pump relay “10 Dotonation sensor onto relay “11 Fuel pressure sensor | Injector ever conto relay - power relay Power supply vot Ignition switch — Engine waming lamp Diagnosis signal output Ignition switch — 1G Tgniion ‘col Vehicle speed sensor ‘Attemator G terminal AC switch ATECU Inhibitor switch Power steering fluid pressure switch ‘Atornator FR terminal MIT all temperature sensor Electrical toad switch Brake vacuum sensor Stop lamp switch lnyetor open creat chock signal From pump ponsane Tehillaok 45 avoypas “ana sonptne control solenoid PB Airby-pass §— 2 Idle sf Air flow sensor " SAeOES (Tome + eee *%8 Barometvic pressure "11 Fuel pressure me sensor +6 Camshaft (Out into ico Postion switch) ecto e— ier et ar “10 Detention sensor 4 ue ont os Onypn sence Fue! pump (igh pressure) "7 Crank ang sensor sFu0es713J-6 GDI — Service Specifications/Sealant SERVICE SPECIFICATIONS items Specifications Basic idle speed r/min 750250 Throttle position sensor adjusting voltage mV ‘400 1,000 Throtle position sensor resistance kA 35-65 Idle speed control servo coil resistance © 28 — 39 (at 20°C) Intake air temperature sensor | 20°C 23-30 resistance k& — 80°C. 0.90 -0.42 Engine coolant temperature | 20°C 24-27 sensor resistance k&. a 80°C 026-036 ‘Oxygen sensor output voltage V [08-10 Fuel pressure High pressure MPa 4-7 Low pressure KPa 324-343 - Injector coil resistance © 0.91.1 (at 20°C) Air by-pass control solenoid | ON/OFF 7.7 ~93 (at 20°C) valve coil resistance & DUTY 7.7 -9.3 (at 20°C) SEALANT tem Specified sealant Remark Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent | Drying sealant threaded portionGDI — Special Tools 13J-7 SPECIAL TOOLS Too! | Number Name Use a | meso1223 Harness set ‘© Fuel gauge simple inspection Ar MB981219 | A: Testhamess | Ai Connector pin contact pressure inspection B: MB991220 | B: LED hamess ‘ower circuit inspection C: Power circuit inspection C: MBs91221° | C: LED hamess | 5: Commercial tester connection D: MB991222 adapter D: Probe B c | > a comnans | ~ | MUTT sub |e Reading diagnosis code assembly ‘© GDI system inspection & — Test hamess set ee. 2 1MB991348, "© Measurement of voltage during ‘rouble- MB991658, shooting ‘© Inspection using an analyzer é 1MB991700 | Test harness MB991519 | Allemator hamess | Measurement of voltage during A connector | troubleshooting ~~ [wibee6463 | Test harness '* Inspection of idle speed control servo ‘e (pin, square) | © Inspection using an analyzer ‘MD998478 “Test harness: © Measurement of voltage during trouble- (B-pin, triangle) shooting © Inspection using an analyzer13J-8 GDI - Special Tools/Troubleshooting Engine warning lamp (check engine iamp) Ko) sruose4 Too! Number Name Use MD998708 ‘Adaptor hase ‘Measurement of fuel pressure 0988742 Hose adaptor MBsaT6s7 Fuel pressure gauge set TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW Refer to GROUP 00 — How to Use Troubleshooting/Inspection Service Points. DIAGNOSIS FUNCTION ENGINE WARNING LAMP (CHECK ENGINE LAMP) It an abnormality occurs in any of the following items related to the Gasoline Direct Injection (GDI) system, the engine warning lamp will illuminate, If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.GDI — Troubleshooting 13J-9 Engine warning lamp inspection Items Engine-ECU (Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor Engine coolant temperature sensor Crank angle sensor ‘Camshatt position sensor Barometric pressure sensor Detonation sensor Injector “Abnormal combustion Immobilizer system Fuel pressure sensor Excessive intake air amount Brake vacuum sensor METHOD OF READING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 — How to Use Troubleshooting/Inspection Service Points. INSPECTION USING MUT-II DATA LIST AND ACTUATOR TESTING 1. gee Carry out inspection by means of the data list and the actuator test function. If there is an abnormality, check and repair the chassis harnesses and components. After repairing, re-check using the MUT-II and check that the abnormal input and output have returned to normal as a result of the repairs. Erase the diagnosis code memory. Remove the MUT-II Start the engine again and carry out a road test to confirm that the problem has disappeared.13J-10 GDI — Troubleshooting 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) Lean fuel combustion driving and feedback control driving are prevented, (2) Basic injection drive timing and basic ignition timing are set by means of the mapping values from the throttle position sensor signal and the crank angle sensor signal. Intake air temperature | Control is carried out as if the intake air temperature is 25°C, sensor Throttle position (1) Lean fuel combustion driving is prevented. sensor (2) Dashpot compensation for the idle speed control is prevented. Engine coolant ‘Control is carried out as ifthe engine coolant temperature is 80°C. temperature sensor | Furthermore, this control will continue until the ignition switch is turned to OFF, even if the ‘sensor signal returns to normal Camshatt position | Control is carried out as if the conditions before the failure judgement ocourred are ‘sensor continuing Vehicle speed sensor | (1) Lean fuel combustion driving is prevented. However, this condition is cleared if the fengine speed is continuously at’ 1,500 r/min or more for @ certain length of time. (2) Lean fuel combustion during idling is prevented. Barometric pressure | Control is carried out as ifthe barometric pressure is 101 kPa (760 mmHg). ‘sensor Detonation sensor —_| Ignition timing is fixed to the timing for standard petrol Injector (1) Lean fuel combustion diving is prevented. | 2) EGR operation is cut ‘Abnormal combustion | Lean fuel combustion driving is prevented, Excessive intake air | When the air flow sensor output is compared with the throttle position sensor output and amount the air amount is judged to be excessive, compression stroke fuel injection and lean fuel ‘combustion driving are set. ‘Communication line | Ignition timing retarding control (engine and transmission total control) during with AT-ECU transmission gear shitting is prevented. ‘Alternator FR terminal | Alternator output suppression control under high electrical loads is prevented. (Alternator ‘works as a normal alternator) Fue! pressure sensor | Controls carried out as ifthe fuel prassure is 5 MPa.GDI — Troubleshooting 13J-11 INSPECTION CHART FOR DIAGNOSIS CODES ‘Code No. | Diagnosis item Reference page 1" ‘Oxygen sensor system FEET 12 ‘Ar flow sensor system 13013 13 Intake air temperature tayt4 14 Throttle position sensor system — 13545 | a Engine coolant temperature sensor system 13-16 22 Crank angie sensor system 1817 23 ‘Camshaft position sensor system 13-18 24 Vehicle speed sensor system AW-A19 25 Barometric pressure sensor system | 134-20 at Detonation sensor system 19-21 at Injector system 13-22 44 ‘Abnormal combustion 13-23 54 Immobilizer systern 1324 56 Fuel pressure sensor system 13-25 58 Excessive intake air amount 13-26 et ‘Communication wire with A/T-ECU system 13-26 64 Alternator FR terminal system 130-27, 66 Brake vacuum sensor system 13-2813J-12 GDI - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES ‘Code No. 11 Oxygen sensor system Probable cause ‘Range of chock 10°'3 minutos have passed after engine was started ‘© Engine coolant temperature i approx 80°C oF mare, Intake a tomperature le 20-50°C. Engine speed is approx. 2,000~3,000 r/min ‘2 Vohicie i¢ moving at constant speed on a fat, lvel road surtace ‘Set conations| 1” The oxygen sensor output voage is around 0.6 Vor 30 saconds (88 not cross 08 V for 30 seconds). '* When the range of check operations given abowe which accompany staring of ‘he engine are cared ou four bmo In succession a problems detected ater ‘each operator ‘© Mafuncion of the oxygen sensor {© Improper connector “contac, open cet or Short creuted harass wire ‘© Maituncson of tho engine-ECU ‘Check the oxygen sensor. (Reler to P.1GJ-95.) NG ee 4 Taare abe paper amos aaneay AE PRA Stee aaa Se 1. FE tn 9a ou Bron ete: ON) 2 Continuity between 2 and earth Replace ‘Measure at the engine ECU connecor 6-21 ‘© Disconnect the connector, and meacure at the | yg, hhamess sie, ~ ‘+ Vottage between 60 and earth (gntion switch: ON) OK: System wotape fox [heck the following connectore: - ie eT (Chea teste omsio ———d — Sig heck to harress wo boboon the ongind ECU and ">= Ropatr fhe onygon sur comectr jox Replace te ve) Check the harness wire batwoen the | ‘oxygen sensor and the contol ray connector and repair Wt neceseay. No [check the Tolowing connector: |S» Repate jez i eC 6a so [ek press wire boon ta J+ Rapa SrSim B20 be sen Sone 3x Replace he engine ECU NG ‘Check the folowing connector: |» Repalr nize ar (Check toute sion) NG Chock te Faas wo baboon to ‘ongine-ECU and the oxygen sansor connector. and repair necessary.GDI — Troubleshooting 13J-13 Code No.12 Air flow sensor system | Probable cause Tango of chock Te Matneson ofthe a tow saneor £° Ercna sped f 500 tn oF mre 3 Opener or shor creo Pamoss wre of ai Setconaions Sn sensor seat Sermo output haquancy & 9.9 He ot ns for 4 soond + Makan of enin-£CU ‘Naasre aio afow soneo‘comnedor}'~"° _ oasurattaaitowsensorconedar "© Chace hares wre between be a ie Sow sonar andthe cor oy, | 2 Sannect te connector 2 Daconeet he connector and | ie rapa nace {one eee arn oni70) | mesure ato hares 8 | ug “otage betwoon 3 ard arth 1. Mtge between anwar (22 NO ae {Eman ding) {gniton switch. ON) Bene folowing Sees Ry Sie Stor wo 2. Vonage bawaen 7 and earth 2 Votagebernaen ard oath on oor 2.no | onsen swiss ON) {Enon ia) P=) |, ove say 0K: 65) 2. Gontinaty between 5 and oath {Enain speed 4000 sn) OK Connon = Teck wok SmmpIom OK lOK _ ING — Check the folowing connector ‘heck te arvana wa boson ho x ‘ongine-ECU and the alr ow sensor, ‘nd repai if necessary. TS Pepatr (Rosia tre onan G00] ‘Measure a the engine ECU connector Bie | ‘Gonnec the connector [ Check the following connector: —) ey ‘Check the folowing connector: (ae13J-14 GDI — Troubleshooting Code No.13 Intake alr temperature sensor system Probable cause ange of chock ]¢ Matincion ot the intake ar temperature conser 12"Ater 60 seconds have passed since the engine have stated Open cit or shor-reuted harnoss wie ofthe Set conations Irth ai tomperatre sensor crc 2 Sensor resistance i 0.14 Ki oF less for 4 seconds | Matteson ofthe engine ECU cao tance 5 of ref 4 sx | —_ No. ‘Check the intake air terporature sensor. (Refer to P1083) Replace (OK No Mesaure at the a fow sensor connector A20. SS __. [check the following connector 6-22 1" Daceonac to connecter, and measur at the hares aS 7 seo T «+ Yotago between + and earn ' (ignition switch: ON) opel Sete sav — + Contnuty between 2 and earth Chek Woikle ego oe Cover pe OK i ‘heck the heros wa baboon hs ang ECU adhe rako (Check i Toiowing connector: AO? Sttonpeare sree OK 3 OK Te Repair epee [Chock rouble armpiom — No aie eg EUGDI — Troubleshooting 13J-15 Code No.14 Throttle position sensor system Probable cause Fango of check —— To attnction ofthe throtte poston eansor ‘2 Afr 60 seconds have passed since the engine have stated Open eeu or short orcuted hamess wire of the Set condtions ttrotle pestion sensor creat =" Sensor output voRage is 0.2 V or less for & seconds. | «le positon switch ON maituncton o ‘Shortcut in idle postion swich signal tne ‘late postion switch is ON and sensor output wage fs 2.0 V or mote for ¢ | @ Maltuncton of tw engine-ECU seconds. 6 ‘MUTT Bea iat |8° —-f check hoi positon switch sytem | 2 198 poston uth (Bote wes RSPECTON ERO: | Geter P1569) Seouie 28) OK Ne ‘Check the Hwotla postion soraar |S» Replace (ater to P1994) oR rreamnmna eee 0K ( Moasure ate fwotie postion sanaor + [ Eheck the following connector; | ef Check wouble sympiom: | somecior a6. su a 2 Dsconnect te connector, and re t measure atte hares sie ‘Ghoak te Faroas wir boon he © Volage batwaan 4 and each Repele fenaine-ECU and the tote postion (ignition switch: ON) OK ae 52 Continuity betweon 1 and art OK: Contnuty OK No 0K ‘Measure atthe engine ECU connector |“° | Check the following connector: |°“ | Gheck rouble symptom: B22. ey Connect the connector. Ne Ne '© Votage between 84 and earth ad Algniton switch: ON) ‘Chock the names wire batwoon tho OK: 0508 V Repair fongine-ECU and the tote posiven (Cheat vave: ale post | oy ton) [OK [Replace tha engine ECU. _ OK: 48 51V Feet 2 vn _(Theotio ave: Fully open) Replace the tet postion sensor13J-16 GDI — Troubleshooting Code No.21 Engine coolant temperature sensor system [ Probable caus ange of check (2 Aflor 60 seconds have passed since the engine have started ‘Sot conditions 1” Sonaor resistance ie 50 0 or lees fr 4 seconds. 1 Sonsor resistance is 72 kid or more for 4 seconds Range of check 2’ Ator engine stars ‘Set condone 1" 'Afor'5 minutes or more have passed since the engine coolant temperature ‘aler Merng has dropped from 40°C or moro to les than tis temperate aituncion of tie engine coolant temperature (pen rout or short-circuited hamoss wire ofthe ‘ongine coolant temperature sensor crcut Maftuncion ofthe engine-ECU ‘OK No ‘Check the engine coolant perature sensor (Refer toP 180-89) Replace a ng oan ae ogi al opr sr cones R76 © "Disconnect he conector, and moasure st the hamess ‘Check to harnass wire between to engine ECU and the engine coolant temperature sensor. (OK ye Repair \[Ropiace the engine-ECU.GDI — Troubleshooting 13J-17 ‘Code No.22 Crank angle sensor system Probable cause ‘Range of check 2 "Engine: During cranking ‘Sat conations| 18" Sensor output votlage does not chango for 4 seconds (no pulse signal i being input. ‘> Maluncion ofthe crank angle sensor ‘Open creat or shor-caates hamess wire ofthe ark angle sensor eat ‘© Maltinetion of te engine: ECU Tia aie arg sorcor |" + [Nanna cea | "= che ne Rares wie aon Noenae pea Slat sonsrsc become PSS camacor 2" Bechet he comectr, ent aia reese (ie ears aaron |e ug Wace +, Wage betwen 3 and sah sai Wa ing ‘© Voltage between 2 (biack op) {anion ewer ON) Bast fotowing ore oe Son va ne Ste crank) 2 Wage ate nd ears |. Na ad Sent oon es + Wage peters 2 ack ETE Y ral soe 2. Sarl betwen + and wah in (Engine: Iaing) ‘Ok: ‘Continuity Check trouble symptom. } Ser NR con = I ox fe ‘Check the following connector: | [Check the hamess wire between the a we [See Se eee acoso | OK NG rapt ([Repiace te engine E6U ‘Check the hamess wire between the crank angle sensor and the earth, and Lrepai necessary