Workshop Manual chassis SUPPLEMENT PRIERO '97 = oF; 4d al +S ae Ae oO 2 Pub. No, PWJE9086-HMITSUBISHI PRIERO WORKSHOP MANUAL SUPPLEMENT FOREWORD This Workshop Manual contains procedures for removal, disassembly, inspection, adjustment, reassembly and installation, etc. for service mechanics Use the following manuals in combination with this manual as required. TECHNICAL INFORMATION MANUAL. PYJE9002 WORKSHOP MANUAL ENGINE GROUP PWEEDIOO (Looseleaf edition) CHASSIS GROUP PWJE9086 (Looseleaf edition) PWJE9086-G (Supplement) ELECTRICAL WIRING — PHJE9026 (Looseleaf edition) PHJE9026-D (Supplement) PHJE9026-E (Supplement) PHJE9026-F (Supplement) PARTS CATALOGUE —_86035607AL] All information, illustrations and product desorip- tions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation. aha MISUBS Motors Corporation June 1096 General Intake and Exhaust... Service Brakes .. Chassis Electrical00-1 GENERAL CONTENTS VEHICLE IDENTIFICATION . Models Chassis Number .. SUPPORT LOCATIONS FOR LIFTING AND JACKING MAJOR SPECIFICATIONS ........-------0+5 500-2 GENERAL - Vehicle Identification VEHICLE IDENTIFICATION MODELS <2-DOOR MODELS> Model code Body style Engine model ‘Transmission model | Fuel supply system veac | NSFLE Canvas top 4D56 [2,477 mé]__| VSMT1 (SM/T) Injection with turbocharger | | and inter-cooler vesc | GNHVLE/R6 | Canvas top with | 6672 [2,972 me) TMP wide fender | GRHVLE/RE ‘VaAwa (407) Veew | NOFL6 | Wagon 4056 [2.477 mé)| VEMT1 (MT) | Injection | with turbocharger | NHFL6/R6 and inter-cooler V24wG NXFL6/R6- Wagon with wide | | fender veew | NHFL6 Wagon 4Ma0 (2,895 me]__| V5M3i (SMT) ——————~ with turbocharger V26WG NXFL6/R6 Wagon with wide and inter-cooler fender vew — NHVLG. Wagon 6G72 (2,972 me] | VSMT1 (SMT) | MPL [ewer | wepoe wan wa | | — fender GRXVLeRE Vaaws (4877) Fvasw | GNXMLE/MR6 | 6G74 (3,497 me] | VSM3t (SM/T) GRXMLE6/R6- V4AWS (4A/T)GENERAL - Vehicle Identification 00-3 <4-DOOR MODELS> Mode! code Body style Engine mode! Transmission model | Fuel supply system vaaw | NDFL6 Wagon 4056 [2.477 mé]__| VSMT1 (SMT) Injection ——— —— with turbocharger NDFCLS —_| Wagon without 3rd. and inter-cooler seat row | NHFL6 ‘Wagon vaawe | NXFL6/R6 | Wagon with wide fender vasw | NDFL6 Wagon 4Ma0 [2,835 mé] | V5M31 (SMT) ~ with turbocharger NDFCL6 —| Wagon without 3rd. and inter-cooler_ | seat row | NHFL6/R6 | Wagon | RHFR6 | Vaaws (4477) V46WG | NXFLE/R6 | Wagon with wide VsM31 (SM/T) ' fender -———___| RXFLE/RE V4AWS (4/7) vasw | NHVL/R6 | Wagon 6G72 [2,972 me] | VBMT1 (SM/T) MPI RHVLE/R6 AAW (4A/T) GNXVL6/R6_| Wagon with wide V5MT1 (5M/T) fender —_—____— GRXVLEIRE \V4AWS (4A/T) vasw | GNXML6/R6 6G74 [3,497 me] | VSM31 (SM/T) GRXMLE/RE I \VAAWS (44/7)00-4 GENERAL - Vehicle Identification CHASSIS NUMBER The chassis number is stamped on the side wall of the frame. near the right rear wheel. (Sx ‘O0E0022 N V. Oo Vv J 3 00001 A T TTTT TT 5 6 7 8 9 10 Ww 1. Asia 7. Body style 0: Frame 2. Japan 8. Model year Vv: 1997 3. MITSUBISHI A: Right hand drive for Europe B: Left hand drive for Europe 9. Plant JPY: Oye Plant of NAGOYA Motor Vehicle Works: 4. Sort 0: 4 or 2-door with tailgate (backdoor) A: 2-door semi-open (canvas top) 10. Engine specification 0: Without turbocharger, with catalyzer. 3: With turbocharger, without catalyzer. 5. Transmission N: 5 x 2-speed manual transmission R: 4 x 2-speed automatic transmission 11. Serial number 00001 ~ 6. Development order V23: 2,972 mé Petrol engine <2-door models> V24: 2,477 me Diesel engine <2-door models> V25: 3,497 me Petrol engine <2-door models> V26: 2,835 me Diesel engine <2-door models> v43: 2,972 me Petrol engine <4-door models> ‘V44: 2,477 me Diesel engine <4-door models> V45: 3,497 me Petrol engine <4-door models> V46: 2,835 me Diesel engine <4-door models>GENERAL ~ Major Specifications MAJOR SPECIFICATIONS CANVAS TOP [ \ ay WIT} Ie L 6 — Items: \V24CNSFLE V23CGNHVL6/RE V23CGRHVLE/R6 Dimensions mm Overall length © 4,075 4.145; Overall width @ 1,695 4,785 Overall height (unladen) @ 1,835, 1,845 Wheelbase ® 2,420 2,420 Track-front ® 1,420 | 1,465 Track-rear lo 1,435 1,480 Ground clearance (laden) jo 190 200 Overhang-front ® 675 720 Overhang-rear ® 980 1,005 Weight kg Kerb weight 1,655 - 1,800 1,725 - 1,855 1,735 ~ 1,865 Max. gross vehicle weight 2,510 2,510 2,510 Max. front axle load 1,100 or 1,200 or 1,200 or 1,070" 1,030"! 1,030" Max. rear axle load 1,650 or 1,650 or 1,650 or 1,565" 1,405"! 1,405" Seating capacity 4 Engine Model 4056 6a72 Total displacement me 2,477 2,972 Transmission Type S-speed manual S-speed manual ‘4-speed automatic Model VeMT1 VsMT1 vaaws NOTE "7: Vehicles for Belgium and France00-6 GENERAL — Major Specifications METAL TOP ® veooxe Items V23WNHVL6 | V23WGNXVLE/R6 | V23WGRXVLEIRG | V25WGNXMLE/RE V25WGRXMLE/RS Dimensions mm Overalllength | @ 4,120 4,145 4,145, ‘Overall width ® 1,695 1,785 1,785 Overall height | @ 1,835, 11845 11845 (unladen) Wheelbase @ 2,420 2,420 2,420 Track-front © 11420 1,465 1,465 Track-rear © 1,435 1,480 1,480 Ground clearance | @ 190 200 200 (laden) Overhang-tront. | © 720 720 720 Overhang-rear | @ 980 1,005 1,005 Weight kg Kerb weight 4,795 - 1,865, 1,760 - 1,875 1,770 — 1,885 1,810 - 1,925 Max. gross vehicle 2,510 2,510 2.510 2.510 weight Max.frontaxleload =| 1,200 or 1,200 or 1,200 or 1,200 or | 1/0301 1,030"! 1,030 *1 1,050 *" Max. rear axle load 1,650 or 1,650 or 1,650 or 1,780 or 1,405 *! or aos! | 1405 +1 1,345 °1 1,780 2 Seating capacity 5 Engine Model ec72 ea72 ea72 6a74 Total displacement _m / 2,972 2,972 2,972 3,497 Transmission ‘Type 5-speed manual 5-speed manual | 4-speed automatic | 5-speed manual or 4-speed automatic *° Model VsMT1 VEMTt VaAWs V5M31 or V4AWS “3 NOTES *': Vehicles for Belgium and France "2: Vehicles for Sweden *3: V2BWGRXMLE/REGENERAL — Major Specifications 00-7 ttems ] v2awnpFLe | V24wNHFL6 | \V24WGNXFL6/ | V26WNHFLS \V26WGNXFLE/RE iR6 RE Dimensions mm. | Overalllengh || 4,075 4,120 4,145 4,120 4.145 Overall width |@| 1,695 1,695 1,785 1,695 1,785 Overallheight (| 1,835 1,835 1,845 1,835 1,845 (unladen) | Wheelbase || 2.420 2,420 2,420 2,420 2,420 Track-front 9) 1,420 4,420 1,465 1,420 1,465 Track-rear ®) 1435 | 1,435 1,480 1,435 1,480 Ground clear- |® 190 | 190 200 180 195 ance (laden) Overnangtront |@| 675 720 720 | 720 720 Overhang-rear |@| 980 980 1.005 980 1,005 Weight kg | Kerb weight 1,680 - 1,820 | 1,730~1,900] 1,755-1,905 | 1,830-2,000 1,855 ~ 2,005 Max. gross vehicle 2,510 2,510 2,510 2,510 2,510 weight Max. front axle load | 1,100 or 4,100 or 1,100 or 1,200 or 1,200 or to70"t 4,070" 1,070" its 4,118"! Max. rear axle load | 1,650 or 1,650 or 1,650 or 1,780 or 1,780 or 4,565" 1,565*7 1,565"! 4,440%t 1,440"? Seating capacity Engine Model 4056 440 Total displacement 2,477 2,835 me Transmission Type S-speed manual S-speed manual Model V5MT1 V5M31 NOTE “1: Vehicles for Belgium and FranceGENERAL — Major Specifications Items \v43WNHVLE/R6 | \V43WRHVLE/RG ‘V43WGNXVLE/RE Dimensions mm Overall length @ 4,700 4725 Overall width ® 1,695 1,785 Overall height (unladen) | 1890 1,900 Wheelbase ® 2,725 21725 Track-front ® 4,420 11465 Track-rear ® 1,435 1,480 Ground clearance (laden) ® 190 200 ‘Overhang-front ® 720 720 Overhang-rear ® 1,255 1,280 Weight kg Kerb weight 1,925 - 2,085 1,920 ~ 2,105 or 1,955 — 2,115 1,920 ~ 2,080 “2 Max. gross vehicle weight 2,650 2,650 2,650 Max. front axle load 1,200 or 4,200 or 1,200 or 1,075") 4,075 * 11075 *! Max. rear axle load 4,650 41,650 4,650 ‘Seating capacity 7 | Engine Model ea72 Total displacement me 2,972 Transmission Type 5-speed manual 4-speed automatic 5-speed manual Model VeMTt V4AW3, V5MT1 NOTE “1: Vehicles for Belgium and France “2: Vehicles for SwedenGENERAL — Major Specifications 00-9 tems ‘VaSWGRXVLGIRG | VASWGNXMLO/R6 | V45WGRXMLE/RE Dimensions mm ‘Overall length ® 4725 4,725 Overall width ® 1,785 1,785 Overall height (unladen) |® 1900 1,900 Wheelbase ® 21725 2.725 Track-ront /® 11465 11465 Track-rear ® 1,480 1,480 Ground clearance (laden) ® 200 195 Overhang-front ® 720 720 Overhang-rear ® 4,280 4,280 Weight 7 kg a Kerb weight 1,955 — 2,115 1,955 — 2,150 1,990 - 2,145 Max. gross vehicle weight 2,650 2,720 2,720 Max. front axle load | 1,200 or 1,200 or 1,200 or 4075 "" 4,090 °1 11090" Max. rear axle load 4,650 1,780 or 1,780 or 1,670 *" 1,670"! ‘Seating capacity 7 Engine Model 6a72 6a74 Total displacement mt 2,972 3,497 Transmission Type 4-speed automatic 5-speed manual 4-speed automatic Model VAAW3 ‘V5M31 V4AWS NOTE “1: Vehicles for Belgium and France00-10 GENERAL — Major Specifications VA6WNOFCLE | Items ‘V46WNDFLS Vas WNHFLEIRG Dimensions mm ‘Overall length ® 4,655 4,700 Overall width ® 1,695, 11695 Overall height (unladen) | @ 11890 ‘890 Wheelbase ® 21725 21725 Track-tront © 11420 11420 Track-rear ® 1,435 4,435 Ground clearance (laden) | @) 180 180 Overhang-tront ® 675. 720 Overhang-rear ® 1.255 1,255 Weight "kg ~ | Kerb weight 1,960 - 2,095 1,920 — 2,085 2,010 - 2,180 Max. gross vehicle weight 2,720 2,720 Max. front axle load 41,200 or 1,200 or 145°! 4145°1 Max. rear axle load 11780 or 11780 or 11655*1 1655 *1 Seating capacity 7 8 7 Engine Mode! mao Total displacement mt 2,835 Transmission ~ — Type 5-speed manual Model V5M31 NOTE “1: Vehicles for Belgium and FranceGENERAL — Major Specifications 00-11 items \Va6WRHFRE VABWGNXFLER6 | V46WGRXFLERE Dimensions mm Overall length ® 4,700 4,725 Overall width @ 1,695 1,785 ‘Overall height (unladen) ® 1,890 1,900 Wheelbase ® 2,725 2,725 Track-front ® 1,420 1,465 Track-rear ® 1,435 1,480 Ground clearance (laden) a 180 195 Overhang-front ® 720 720 Overhang-rear ® 1,255 1,280 Weight ‘9 Kerb weight 2,005 - 2,175 2,045 - 2,180 2,050 - 2,185 Max. gross vehicle weight 2720 2,720 2,720 Max. front axle load 1,200 or 41,200 or 1,200 or 1,145" 41451 414541 Max. rear axle load 1,780 or 1,780 or 1,780 or 1,655 1,655" 1,655" Seating capacity 7 Engine Model 4m4o Total displacement me | 2,835 Transmission | - Type 4-speed automatic S:speed manual 4-speed automatic Model vaaws veM3t vaaws NOTE *T: Vehicles for Belgium and FranceGENERAL — Major Specifications V4aWNDFL6 ‘V44WNDFCLE V44WNHFL6 | V4a¥GNXFLO/RG Dimensions mm Overalllength | © 4,655 4,855 | 4,700 4,725 Overall width @ 1,695 4,695, | 4,695 | 1,785 Overall height ® 1,890 1,890 | 1,890 | 1,900 (unladen) Wheelbase ® 2,725 2,725 2,725 2,725 Track-front je 1,420 1,420 1,420 1,465 Track-rear ® 1,435 1,435 1,435 1,480 Ground clearance | ® 190 190 190 200 (laden) Overhang-front | ® 675 675 720 720 Overhang-rear | @ 1,255 1,255 1,255 1,280 Weight kg Kerb weight 1,885 ~ 2,000 1,840 - 1,975 1,915 -2,110 1,950 - 2,120 Max. gross vehicle 2,650 2,650 2,650 2,650 weight Max. front axle load 1,200 or 4,100 or 1,100 or 4,100 or 4,075"t 41,090" 1,090"1 1,090" Max. rear axle load 1,850 1,650 1,650 [1,650 Seating capacity 7 5 7 | 7 | Engine Model 4086 Total displacement me 2,477 Transmission a a Type Sspeed manual Model VeMT1 NoTE *T Vehicles for Belgium and FranceGENERAL - Major Support Locations for Lifting and Jacking 00-13 SUPPORT LOCATIONS FOR LIFTING AND JACKING Caution Do not support the vehicle at locations other than specified supporting points. If do so, this will cause damage etc... © Allifting and jacking point has been added to the No. 2 body mount of the vehicle frame. Lifting and jacking point (added) No. 2 body mount Litting and jacking points13-1 FUEL CONTENTS FUEL SYSTEM Cam Position Sensor <6G72-24 Valve Engine, 6G74 Engine> 2 Crank Angle Sensor... ee ‘Oxygen Sensor Outline of Changes ..... 2 Injectors Idle Speed Control Servo GENERAL INFORMATION ocsrcsssnenneee 2 (Stepper Motor Type) .... “ Variable Induction Control Solenoid ON-VEHICLE INSPECTION OF MPI Valve ee COMPONENTS . Purge Control Solenoid Valve Power Supply (Control Relay) and Ignition Switch-IG ... se . EG Control Solenoid Valve Fuel Pump Air Flow Sensor...yneral/General Information’ 13-2 FUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine> — Gn.ventle Inspection of MPI Compononte FUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine> GENERAL OUTLINE OF CHANGES The maintenance service points below have been established to correspond to the following changes. © Changes in the engine-ECU © Separation of the engine contro! relay and fuel pump control relay which were previously integrated GENERAL INFORMATION ttems | Specifications Engine ECU | Identification mode! No. SOHC | E2T37498 | £2T37499 "DOHC 2739987 £2T30088 ON-VEHICLE INSPECTION OF MPI COMPONENTS POWER SUPPLY (Control relay) AND IGNITION SWITCH-IG Battery Ignition switch rc — te) 2 + 3 4 & Equipment Control side connector relay = 1/2 i 7 z —+ 2s Ara Hoo 62 , Engine [y Engine cont Engine Y - unt Power Power ‘supply supply 7Fu1963 9FUOI0TFUEL SYSTEM <6G72-24 Valve Engine, 6G74 En: HARNESS INSPECTION ; Fc ‘Measure the ignition switch (1G) terminal input voltage ‘© Engine control unit connector: unit hamess side connector seine? kK) + ol re @ fa! OFF ont (ignition ON sv > switch - 2) weeae Sa ‘revi928 ‘Measure the power supply voltage of the control relay. © Ignition switch: OFF © Control relay connector: Disconnected _Vokage (V) sv Engine control unit harness side connector ‘Check for an open-circuit, or a short-circuit to earth, between the engine control unit and the control relay. © Engine control unit connector: ® connector jag | Disconnected rt © Control relay connector: |—-cjera | Disconnected Repair the | -HEB OK > hamess. (Biz ~ 8) @s~ reus9aa 2, 8) Measure power voltage tothe actuator cq '® Control relay connector: 9 Connected F8| |. ESomemaccmens OR) —> /\ ey O on 43 Engine Votage (V). lames Replace the Ter ee. ctor Cranking | BV oder higher OK te Fepiace ne Racing sv or defective engine Trui930 contol unit13-4 FUEL SYSTEM <6G72-24 Valve En: CONTROL RELAY INSPECTION | Contolrely SN, | equpmentside connector B 7u1931 FUEL PUMP Fuel pump relay NX a A, l r Fuel pum check S77 tem I] fe th Fuel pump (1) Disconnect the contro! relay. 6G74 Engine> — on-vehicle Inspection of MPI Components Battery Terminal No. voltage , 1 2 3 4 | Not supplied ‘Supplied ° | (2) Replace the control relay if faulty. lgnition switch i ® Equipment side connector (iG) t 4 a1 Fuel id pump 2 relay -E ® Equipment side connector 1 © Fuelpump ave’ | termina j Fuel pump att, 292 & Engine control unit connector ‘TFU1932 NOTE *-Vehicle without immobilizer system *2:Nehicles with immobilizer system sFuo101FUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine> - on-\ HARNESS INSPECTION Fuel pump drive terminal Li 7FUM93| a ‘Check the fuel pump ‘© Apply battery voltage to the fuel pump drive terminal and operate the pump ® Hamess side ‘connector Check for continuity ofthe fuel pump earthing line. Fuel pump connector: Disconnected TF u1945) pep the OK —> fe @i- + Earth) ween Check or pero or horeak Senween th ful pump and te el pump Shinto © | ihotermna connector ‘© Fuel pump connector: > [4] Dscomectes eK o Pual pump flay cornea: ) Disconnected Repair he OK > (@2- + ©7) wos ‘Measure the power supply voltage of the co fuel pump relay. Hamoss side a ‘¢ Fuel pump relay connector: 3 4 Dacomected + ety KC) Pepa the ranean 7% Ignition switch Voltage (V) (Ignition OFF o-1 OK > 35. ON. sv check for oven 7F 1928) switch, Engine control | Check for an open-circuit, or a short-circuit unithamess | to earth between the fuel pump relay and side connector | the engine control unit oul pump tly connector: ( ll J | ° diesoneces OK) —> Z|» nie sontol unt connector: ao2|” Bosomectes pepe he harness OK By (@2-2)?13-6 FUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine> — on-vehicie inspection of MP! Components [6] ‘Check for continuity between the fuel pump drive terminal and the fuel pump rolay. ‘© Fuel pump relay connector: @® Hamess side Disconnected ‘connector ‘Fuel pump connector: ott Disconnected als, ‘Check for an open-circuit, or a short-circuit to earth between the fuel pump relay and ‘© Fuel pump relay connector: + [3] cole 0K)-> & Ebi OK —> hex @i- ®2) nea co fuel pump. —— Fuel pump relay connector: ~~ <2} Connected | (SER ew- A fas ® Harness side Engine Voltage (V) Fuel $ engine 7Fu1930 is defective, FUEL PUMP RELAY INSPECTION Refer to P.13-4.FUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine> - On-Vehicle inspection of MPI Components 13-7 AIR FLOW SENSOR HARNESS INSPECTION }® Control relay hhamess sido connector reus906 ‘Check the continuity between the air flow ‘sensor and the control relay, ‘© Control relay connector: Disconnected © Air flow sensor connector: Disconnected NOTE Touch the circuit tester probes to both ends of the hamess. OK —> Repair the hamess. @ia- 81) ® Hames side connector Xa ‘Check for continuity of the earth circuit ‘© Connector: Disconnected OK) —> 3] unt harness 7eui222 between the air flow sensor and the engine control unit. © Air flow sensor connector: Disconnected © Engine control unit connector: Disconnected OK > ee (@is\-17%) srasy Repair the hamess. @3\-%) @ 719) Measure the applied voltage. © Air flow sensor connector: Disconnected ‘© Engine control unit connector: Connected © Ignition switch: ON Voltage (V) 48-52 Replace the engine control unit,13-8 FUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine> — On-Vehicie inspection of MPI Components CAM POSITION SENSOR HARNESS INSPECTION [J ‘Check for continuity between the cam connector ® postion sensor and control relay. Hamess side | © Cam position sensor connector: connector Disconnected 2] © Control relay connector: —- ATE Disconnected aie) NOTE ‘Touch ohmmeter probes to both ends of the Repair the Control relay hamess. > hamess. hamess side @s- connector ®7) 7Eu1947 [2] heck for continuity ofthe earth circuit ‘* Cam positon sensor connector: ® Hamess side eeepc 0K)—> I sepa OK —> fer side connector and the engine control unit. ‘© Engine control unit connector: Disconnected ‘® Cam position sensor connector: Disconnected @i- Earth) 6AFOOS7, Engine control ] Check for an open-circuit, ora short-circuit tunit harness | to earth between the cam position sensor > OK > AFO0S9 ‘Connected © Ignition switch: ON Li (@\2-@) wa a vee (eee resco OK > Se ‘control unit,FUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine> — on-vehicie inspection of MPI Components 13-9 CRANK ANGLE SENSOR HARNESS INSPECTION 1 TS eae ® ‘Check for continuity between the crank langle sensor and the control relay. ‘© Crank angle sensor connector: 60082 Garkardes an eK tt se ata nore ® Touch ohmmeter probes to both ends of the Repair the Control relay hamess_ — > hamess. genvel iy rane connector ®@N) [2] ‘Check for continuity of the earth circuit @ famess side Disconnected an —> B) Oe = repar ne OK —> tere: @in- Earth) Engine control unit harness. side connector 6.0063 ‘Check for an open-circuit, ora short-circuit to earth between the crank angle sensor and the engine control unit. ‘© Engine control unit connector: Disconnected © Crank angle sensor connector: Disconnected Hamess @ side connector ‘Measure the impressed voltage. © Crank angle sensor connector: Disconnected ‘© Engine control unit connector: Connected © Ignition switch: ON Voltage (V) 48-52 Replace the engine control unit.13-10 FUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine> - On-Vehicle inspection of MPI Components OXYGEN SENSOR HARNESS INSPECTION 1 ‘Check for continuity between the oxygen sensor and the control relay. 1 5 2 Goutal ay amracon PS Ile vamess so | * Setlolys + 2 ‘connector © Oxygen sensor connector: sh | o> ae So se al3 a3) NOTE Touch the ohmmeter probes to both ends of Repair the ® Control relay the hamess. > hamess hamess side @r- ‘connector en) 2Fui9e9 2 Engine control | Check for an open-circuit, or a short-circuit Unithamess | to earth, between the engine control unit and on , side connector | the oxygen sensor. > lamess side ‘© Oxygen sensor connector: [3] connector Bocomestd (OK) —> ‘Engine control unt connector: Disconnected L_ sense OK ee us) zrms2| Check for continuity of the earth circut '® Oxygen sensor connector: Disconnected ‘© Engine control unit connector: — Disconnected Ok) —> LdFUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine> — on-Vehicle Inspection of MPI Components 13-11 INJECTORS, HARNESS INSPECTION 1 Injector intermediate SD) hamess female ‘Check for continuity between the injectors and the control relay. I connector © Injector intermediate connector: @ Av Disconnected OK) —> (2] a ager © Control relay connector: 2 iets) Disconnected 24] | (=<, a NOTE Touch the ohmmete probes o both ends of OK ly Repair ino ® Contr relay the harness. on yamess side connector ) 2601950 D | pies intemadate ‘Check for an open-circuit, ora short-circuit hamess female to earth, between the engine control unit and ~ + cng conte uit comer OK Disconnected Repair the «Injector intermediate connector: hamess. Disconnected @1-2) OK P20) @s-1) @ 5%) (@e-3) (@ 115) IDLE SPEED CONTROL SERVO (STEPPER MOTOR TYPE) HARNESS INSPECTION 1 Check or continuity botwaon th We seed =) ® Harness side control servo and the control relay. PES] ” cemmestor | tte sea contel sone connector : Disconnected + B] = «Cont eay connector OK ath | (22 a Disconnected | 4 nore als) epi. Touch the chmmeter probes to both ends of Repair the © consi i ree fo Fenexs harness side J Oz s connector ®1) revtest heck ov an oporaroul ora shor-ereat {bath betneon fe engine cone! un and al the idle speed control servo. —~ = 6 Engh cont! unit connector: ) te +m) |* Semecte ° « lo spect eonl serve connector | Dsconneced Repairhe ramess Engine contol OK iE, AJ yf cnthissece Brn 9 ® Hamess side ‘side connector (@ia-\5) ‘connector cuss @i6-16)13-12 FUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine> — On-Vehicle inspection of MP! Components VARIABLE INDUCTION CONTROL SOLENOID VALVE HARNESS INSPECTION 1 ‘Check for continuity between variable = induction control solenoid vaive and control 11] = a ES Sles wanes eee |" snenscton conte sour Kk) + wy = connector |” valve connector. = 3) Disconnected ae 1 © Control relay connector: e 4 2] Disconnected Repair the Control relay, NOTE > hamess. harness side Touch the ohmmeter probes to both ends of @ii- connector the hamess. ®1) zeu1982 ‘Check for an open-circuit, or a short-circuit to earth, between the variable induction control Solenoid valve and the engine control unit © Variable induction control solenoid > Lod valve connector: [2] @ Hamess side connector ‘ars cones soa cont OK —> hem (2-8) ‘9£y0040 PURGE CONTROL SOLENOID VALVE HARNESS INSPECTION 1 heck for conn beeen he purge ® Hamess | Sci solenoid vave andthe conto ay. Sessector| © Purge contol solenoid "| * Take conto saneconnes [2 Disconnected e 43 NOTE harness side | the hamess. rere Engine to earth, between the purge control solenoid EI esos 22 — | tet cote ots tenes ee o Fuge cetera a Em eee OK)—> Ad sguecomee Sone nee sear ne OK > tee: @z-1)FUEL SYSTEM <6G72-24 Valve Engine, 6G74 Engine: spection of MPI Components 13-13 EGR CONTROL SOLENOID VALVE HARNESS INSPECTION ® Hamess Check for continuity between EGR control Side solenoid valve and control relay SI connector '® EGR control solenoid valve connector = 2 Disconnected —> 2 © Control relay connector: 2 Disconnected lal3| NOTE Repair the Memess sie ‘Touch the ohmmetr probes to oth ends of > hamess Jconnector the hamess @i- ®@1) 2FU2035, 2 Engine control unit] Check for an open-circuit, or a short-circuit hamess side connector to earth, between the EGR control solenoid valve and the engine control unit. @® Hamess side ‘connector © EGR control solenoid vaio connector OK) —> Disconnected '¢ Engine control unit connector: Soren separ ne OK —> ie @2-8)15-1 INTAKE AND EXHAUST - General/Exhaust Pipe and Muffler <4D56, 4M40> GROUP 15 INTAKE AND EXHAUST GENERAL OUTLINE OF CHANGES Maintenance service points have been established to correspond to the following changes to the exhaust system. © The front exhaust pipe has been changed from a spring-type ball joint to a flat joint, and a flexible pipe section has been added in vehicles with 4D56 engine. © Apre-muffler has been added to the tailpipe in all vehicle models. EXHAUST PIPE AND MUFFLER <4D56, 4M40> REMOVAL AND INSTALLATION | Pre-removal and Post.installation W | ‘Under Cover Removal and instal F— sanm td: “ —0e oe Removal steps Tail pipe Gasket Main muffler Pre muffier Gasket Front exhaust pipe Gasket . Dash panel heat protector 11. Front panel heat protector Heat protector 12. Rear heater heat protector Dash panel heat protector upper “@—25Nm — —_°£0097 Seenonseon=INTAKE AND EXHAUST - Exhaust Pipe and Muffler <4D56, 4M40> 15-2 <4M40> Removal steps 1. Tail pipe 7. Gasket 2. Gasket 8. Dash panel heat protector 3. Main muffler 9. Heat protector 4. Pre muttier 10. Dash panel heat protector upper 5. Gasket 11. Front panel heat protector 6. Front exhaust pipe 12, Rear heater heat protector ‘ INSPECTION Check the mufflers and pipes for corrosion or damage. © Check the rubber hangers and rubber suspenders for deterioration or damage. © Check for gas leakage from mufflers and pipes.15-3 INTAKE AND EXHAUST - Exhaust Pipe, Muffler and Catalytic Canverter <6G72-24 VALVE, 6G74> EXHAUST PIPE, MUFFLER AND CATALYTIC CONVERTER <6G72 — 24 VALVE, 6G74> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation | ‘© Under Cover Removal and Installation Removal steps 1. Tall pipe 8. Front exhaust pipe (L.H.) 2. Gasket 9. Gasket 3. Main muffler 10. Front exhaust pipe (R.H.) 4. Center exhaust pipe 11. Gasket 5. Gasket 12. Heat protector 6. Catalytic converter 13. Front panel heat protector 7. Oxygen sensor 14. Rear heater heat protector INSPECTION © Check the mutfers and pipes for corrosion or damage. © Check the rubber hangers and rubber suspenders for deterioration or damage, © Check for gas leakage from mufflers and pipes.35-1 SERVICE BRAKES CONTENTS GENERAL FRONT BRAKE HOSE ... Outline of Changes 2 WYDRAULIC UNIT SPECIFICATIONS .. Service Specitications .... WHEEL SPEED SENSOR ... SERVICE ADJUSTMENT PROCEDURES ... Hydraulic Unit Solenoid Valve Check Hydraulic Unit Motor Operation Check 335-2 SERVICE BRAKES - General/Specific: GENERAL OUTLINE OF CHANGES © The front brake hose has been changed from a double-hose type to a single-hose type. Maintenance service points have been established to correspond to this. © Maintenance service points have been established to correspond to changes in the ABS hydraulic unit. ‘© Maintenance service points have been established to correspond to changes in the ABS wheel speed sensors. Brake hose bracket Brake hose bracket (welded to upper arm) {(botted to upper arm) Brake hose (at body side) Brake hose (at brake caliper side) = — acozse aroase SPECIFICATIONS SERVICE SPECIFICATIONS tems Specifications Standard value ‘Speed sensor's intemal resistance kQ Front 4.47 = 1.35 Rear 13-15 Hydraulic unit solenoid valve internal resistance Q IN 4.29 + 0.25 OUT 854 +05SERVICE BRAKES - Service Adjustment Procedures 35-3 SERVICE ADJUSTMENT PROCEDURES HYDRAULIC UNIT SOLENOID VALVE CHECK Measure the resistance between terminals. Standard value: Solenoid Measurement | Resistance Terminals | between Terminals To front wheel cylinder 12-4 | 429+ 0.252 stozee (right side) To front wheel cylinder 12-5 (lett side) To rear wheel cylinder 12-6 From front wheel cylinder | 12-1 | 854 + 052 (tight side) From front wheel cylinder 12-2 (left side) From rear wheel cylinder 12-3 HYDRAULIC UNIT MOTOR OPERATION CHECK Connect the battery and check to be sure that the sound of the hydraulic unit motor operating can be heard. Caution hould not be applied for more than 135-4 SERVICE BRAKES - Front Brake Hose FRONT BRAKE HOSE REMOVAL AND INSTALLATION Pre-removel Operation — Post-installation Operation (© Brake Flud Draining © Brake Fluid Supplying © Air Bleeding from Brake Lines 14£0233 Removal steps 1. Hose clip 2. Front brake hoseSERVICE BRAKES ~ Hydraulic Unit 35-5 HYDRAULIC UNIT REMOVAL AND INSTALLATION Prevemoval peation Flare nut 15Nm conto a aro <4M40-LHD and 4D56-LHD> 14e0208 Removal steps 94 1. Brake tube connection 2. Hydraulic unit 3. ABS relay box 4, Hydraulic unit bracket Post-installation Operation ] ‘© Brake Fluid Supplying © Air Bleeding from Brake Lines © Checking by Using the MUT-II <6G72, 6G74, 4M40-RHD and 4D56-RHD> NOTE (1) RHD: R.H.drive vehicles (2) LHD: L.H.drive vehicles.35-6 SERVICE BRAKES — Hydraulic Unit REMOVAL SERVICE POINT ‘<6G72, 6G74, 4M40-RHD and 4D56-RHD> a4 4 -<4M40-LHD and 4D56-LHD> 3a 1 2 HYDRAULIC UNIT REMOVAL Caution 1 2. 3. 4. The hydraulic unit is heavy, and so care should be taken when removing It. . The hydraulic unit is not to be disassembled; its nuts and bolts should absolutely not be loosened. ‘The hydraulic unit must not be dropped or otherwise subjected to shocks. The hydraulic unit must not be turned upside down or laid on its side. INSTALLATION SERVICE POINT 1. BRAKE TUBE CONNECTION Install the brake tube as shown in the illustration. From master cylinder to hydraulic unit (to rear brake) From master cylinder to hydraulic unit (to front brake) From hydraulic unit to rear brake From hydraulic unit to front brake (LH) From hydraulic unit to front brake (RH) geensSERVICE BRAKES — Wheel Speed Sensor 35-7 WHEEL SPEED SENSOR REMOVAL AND INSTALLATION 3 Front speed sensor removal steps 1. Clip ” 2. Front speed sensor 3. Ci 4. Hamess bracket EY\A on & Rear speed sensor removal steps 5. Band « 6. Rear speed sensor 7. O-ring 8. Clip NOTE The clearance between the speed sensor and the rotor cannot be adjusted.35-8 SERVICE BRAKES - Wheel Speed Sensor REMOVAL SERVICE POINTS. 2. FRONT SPEED SENSOR/6. REAR SPEED SENSOR REMOVAL Caution Be careful when handling the pole piece at the tip of the speed sensor and the toothed edge of the rotor so as not to damage them by striking against other parts. INSPECTION Front Rear SPEED SENSOR (1) Check whether any metallic foreign material has adhered to the pole piece at the speed sensor tip, and, if so, remove it. Also check whether the pole piece is damaged, and, if so, replace it with a new one. NOTE The pole piece can become magnetized because of the Magnetic parts - —seweoes magnet built into the speed sensor, so that metallic foreign material easily adheres to it. Moreover, the pole piece may not be able to sense correctly the wheel ae rotation speed if it is damaged. (2) Measure the resistance between the speed sensor Ca terminals. Standard value: Front: 1.17 - 1.35 kQ x3 Rear: 1.3- 1.5 ko If the internal resistance of the speed sensor is not within the standard value, replace it with a new speed sensor. 40008 (3) Remove all connections from the speed sensor, and then measure the resistance between terminals (1) and (2) and the body of the speed sensor. Standard value: 100 k2 or more (4) If the speed sensor insulation resistance is outside the standard value range, replace with a new speed sensor. (5) Check the speed sensor cable for breakage, damage or disconnection; replace with a new one if a problem is found. 4N0208 NOTE When checking for cable damage, remove the cable clamp part from the body and then bend and pull the cable near the clamp to check whether or not temporary disconnection occurs.INTERIOR — General 52A-1 GROUP 52A INTERIOR GENERAL OUTLINE OF CHANGES © The seat cushion assembly for fixed mounting boss-type front seats has been integrated with the seat leg assembly. Disassembly service points have been established to correspond to this. © The suspension mechanism in front suspension seats has been changed from a shock absorber — spring mechanism to a rubber-moulded spring mechanism. Disassembly service points have been established to correspond to this. © Normal seats Seat cushion assembly. ‘Seat cushion assembly Seatieg 3 assomsy © Suspension seats 4 Oo, ve ge « Suspension assembly. assembly Rubber- moulded springs ‘Adjustment ‘Adjustment knob knob sotoze 196007052A-2 INTERIOR - Front Seat FRONT SEAT DISASSEMBLY AND REASSEMBLY Pre-removi stallation Operation lemoval and Installation of Front inner Seat Belt assembly Se 44m soeo248 Disassembly steps 1. Armrest assembly 9. Walk-in knob 2. Side support lever cap 10. Shield cover 3. Side support lever 11. Back pocket assembly 4, Lumbar support lever 12. Seatback assembly 5. Free hinge protector 18. Headrestraint guide o 6. Slide knob 14. Seat cushion assembly 7, Reclining knob 48. Suspension assembly 8. Reclining memory knob 16. Seat adjuster Yf DISASSEMBLY SERVICE POINT == 6. SLIDE KNOB REMOVAL / Pass a screwdriver through the shield cover hold and ol Y/ remove the slide knob mounting screw. 190255]SRS - General 52B-1 GROUP 52B SUPPLEMENTAL RESTRAINT SYSTEM (SRS) GENERAL OUTLINE OF CHANGES The following changes have been made to the SRS. Items other than these are the same as before. © The front impact sensors have been abolished. © The special tool has been changed and the removal procedures for the SRS-ECU connector have become simpler as a result of the SRS diagnosis unit being changed to a SRS-ECU. Lett front impact sensor (Abolished) Right front impact sensor (Abolished) SRS-ECU (Incorporated safing G-sensor and analog G-sensor) Lociclever > ‘SRS diagnosis unit | (L— tcgrarteesating . sero Se Flat-tipped (-) CR i Sctewciver ~ SRS-ECU side connector SDU side connector fle oPSSAlG Taps olf ia] 2] 1]213]4]516|718)9ojiaiiaii4] Tres (314 JCS Le lfishelis|ie]i7|:8[f19|20) fsfielin fsieor| ed 19x073952B-2 SRS — SRS Service Precautions SRS SERVICE PRECAUTIONS 1. In order to avoid injury to yourself or others from accidental deployment of the air bag during servicing, read and carefully follow all the precautions and procedures described in this, manual. 2. Do not use any electrical test equipment on or near SRS components, except those specified on basic manual. Never use an analog ohmmeter. 3. Never attempt to repair the following components: © SRS-ECU © Clock Spring © Air Bag Module (Driver's side or front passenger's side) If any of these components are diagnosed as faulty, they should only be replaced, in accordance with the — INDIVIDUAL COMPONENTS SERVICE procedures in basic manual. (Refer to PAJERO Workshop Manual Pub No. PWJE9086-F) Do not attempt to repair the wiring harness connectors of the SRS. If any of the connectors are diagnosed as faulty, replace the wiring harness. If the wires are diagnosed as faulty, replace or repair the wiring harness according to the following table. SRS-ECU| Hamess | Destination of Hamess | Corrective Action Terminal | Connector | No. (No. of | Terminals, Colour) 1104 | 2tpins, | _ - | | yellow a f 5 Dash wiring hamess — Clock spring Correct or replace |} — Air bag module (Driver's side) | dash wiring harness 6 Replace clock spring 7 Dash wiring harness — Air bag module (Front passenger's side) | Correct or replace 5 dash wiring harness 9, 10 - = - 1 Dash wiring hamiess —» Diagnosis connector Correct or replace each wiring harness 12 - |e 7 13 Dash wiring harness — Junction block (fuse No.18) Correct or replace —— | each wiring hamess 14 Dash wiring hamess > Junction block (fuse No.12) 18 Dash wiring hamess —> Instrument panel wiring harness > SRS warning lamp eee —___| — 1610 19 - 20 Dash wiring hamess — Earth | Correct or replace = dash wiring harnessSRS - Service Precautions 52B-3 Insulating tape oS Battery ————, 1970001 5. After disconnecting the negative battery cable, wait 60 seconds or more before proceeding with the following work. The SRS system is designed to retain enough voltage to deploy the air bag for short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected. 6. SRS components should not be subjected to heat over 93°C, so remove the SRS-ECU, air bag module and clock spring before drying or baking the vehicle after painting. 7. Whenever you finish servicing the SRS, check the SRS warning lamp operation to make sure that the system functions properly. (Refer to PAJERO Workshop Manual Pub. No. PWJE9086-F.) Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected . If you have any questions about the SRS, please contact your local distributor. NOTE SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL. 2 252B-4 SPECIAL TOOLS SRS — Special Tools / Test Equipment Too! Number Name Use MB901613, ‘SRS Check ‘© Checking the SRS electrical circuitry with Coe Hames a digital multi-meter (For both vehicles with driver's side air bag only and vehicles with both driver's side and front passenger's side air bags) | | mB991349 ‘SRS Check ‘© Checking the SRS electrical circuitry with =F Hamess 2 digital multimeter Pi / - MB991530 ‘SRS Check ‘© Checking the SRS electrical circuitry with | Hamess a digital multi-meter | TEST EQUIPMENT Tool Name Use Digital muit-meter Checking the SRS electrical circuitry [Use a muti-eter fr which he maxirum | Wat cunontiSiukor loc at ho en | are vungs cr venience neasscrontSRS - Troubleshooting 52B-5 TROUBLESHOOTING INSPECTION CHART FOR DIAGNOSIS CODES Inspect according to the inspection chart that is appropriate for the malfunction code. Code No. | Diagnosis item Reference page 44 | Analog G-sensor system inthe SRS-ECU 528-6 15,16 | Sating G-sensor system in the SRS-ECU 5286 21,22, | Diver's side air bag module (squib) system 528-6 24,25, | Font passongers side air bag module (squib) ~ 528-8 31,32 | SRS-ECU capacitor system - 528-9 34° Connector lock system - - "528-8 35 SRS-ECU (deployed air bag) system 528-9 1G, (A) power circuit system - - 52-10 | aa" 1G,(@)powercicutsysem == set | 43 SRS warring lamp drive cuit system ame Goes net laminate’ Se Lamp does not switch off 528-13 | 44 ‘SRS warning lamp drive circult system 7526-13 45 | SRS-ECU non-volatile memory (EEPROM) and AVD converter system | 528-13 51,52 _| Driver's side air bag module (squib ignition drive circuit) system ~ | sep-14 54, 55 _| Front passenger's sie airbag module (squib ignition crive cirult) system 528-14 NOTE (1)" If the vehicle condition returns to normal for a continuous period of 5 + 0.2 seconds, the diagnosis code will be automatically erased, and the SRS warning lamp will return to normal. (2) If the vehicle has a discharged battery it will store the fault codes 41 or 42. When these diagnosis codes are displayed, check the battery.52B-6 SRS - Troubleshooting INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No. 14 Analog G-sensor system inthe SRS-ECU _| Probable cause ‘The SAS-ECU monitors the output ofthe analog G-sensor inside the SRS-ECU. It] ¢ Malfunction of SRS-EQU ‘Sutputs this code when any of te folowing are detected. ‘* When the analog G-sensor is not operating ‘© When the characteristics of the analog G-sensor are abnormal ‘©_When the output from the analog G-sensor is abnormal Replace the Code No.15 or 16 Safing G-sensor system in the SRS-ECU | Probable cause ‘This code is output if there is a shor or open circuit between the terminals of the | « Malfunction of SRS-ECU safing G-sonsor inside the SAS-ECU. ‘The trouble causes for each diagnosis code No. are as follows. Code No, | Trouble Symptom 15 | Short circuit in the safing G-sensor 16 | Open circuit in the safing G-sensor Replace the SRS-ECU. Code No. 21, 22 or 61 Air bag module (driver's side | | squib) system Probable cause ‘© Maifuncton of clock spring ‘¢_Maituncton of SRS-ECU Maifunction of hamesses or connectors Mattunction of air bag module (orver's side squib)SRS - Troubleshooting 52B-7 ‘Code No. Trouble Symptom at © Short in air bag module (driver's side squib) or hamess short | © Short in clock spring 22 © Open ci air bag module (driver's side squib) or open hamess Open circuit in clock spring © Malfunction of connector contact 61 © Short in air bag module (driver's side squib) hamess leading to the power supply i ‘Check the clock spring [e+ Repair OK no [MS _, Repair MUTIISELF DIAG. CODE ing SRS check hamess (MB901613) | * Disconnect clock spring Sonnectors€'96 and Ar connec’ £56, Bag module connector 1 Gonnect SRS check harness ‘connector (1). 4 ‘OK ¢, Geeatnegaiv bar cable. | Erase siagnosis code memory rouble symptom, ‘re code Noo 21,22 oF 1 output? Cre voi sy [No 1 Replace the drivers air module. iad 19u0039 Dash wiring hamess [Check rouble symptom. [NG — No. ‘Check the harness between the —» Repair | SRBECUand dod spa feral | S*Bisconnect clock” spring ‘connector 656, Connect SAS check harness omecor (9) 1 Biasonnect SAS-ECU conndector oie 1 Connector SRS check hares Sonmecor (3) + Resistance between terminals =) IK: Approx. 32 ox. | —+| Replace the SRS-ECU.52B-8 SRS - Troubleshooting Code No. 24, 25 or 64 Air bag module (front passenger's | side squib) system Probable cause “These diagnosis codes are output i there i abnormal essiance between the input | © Malluncton of hamesses or connector terminals ofthe ar bag module (Rent passengers side sau), Malluncion of airbag mode (ront passenger's side ‘The trouble causes for each code No. are as follows. squib) ‘© Maltunction of SRS-ECU Code No. ‘Trouble Symptom 24 © Short in air bag module (front passenger's side squib) or harness short 25 © Open circuit in air bag module (front passengers side squib) or open harness Malfunction of connector contact 64 ‘Short in air bag module (front passenger's side squib) hamess leading to the power supply SRS check hamess | mur-u SELF o1AG. CODE "Ouacannes rent passengers ar (wpseie%s). ag module eomecior Ci # conmect SHS check harnoss onectot (3) * Connect negative baner cable Eraoe skagrosis code memory j econ a este = Repair tween the front passen- r9uo039 ‘gers. air bag module (Squib) and SRS-ECU, ‘OK 1 Replace the SRS-ECU,SRS — Troubleshooting 52B-9 Code. No. 31 or 32 SRS-ECU capacitor system ‘These dagnosis codes are ou Af the voltage at the SRS-ECU capacitor terminals Fiowoverf agrees cod Noe 1 and 42 are beng ov de toa Crop bain votage, code No, 82 wil not be detected. | Probable cause place the SAS-ECU. 7? Code No, 34 Connector lock system “This agnosis cadeis opulfa poor connesion ofthe SAS-ECUis detecod. However ite veticle conden relums to normal lagnosis code No. 94 wil be automatically fased, and the SAS warming lamp wil etch ff Probable cause ‘© Malfunction of connectors ‘© Malfunction of SRS-ECU. ‘Check the following connector. C128 1 the SASECU. Probable cause ‘© Maifunction of SRS-ECU52B-10 SRS - Troubleshooting Code No. 41 1G, (A) power circuit system ‘This diagnosis code is output the volage between the IG; (A) terminal and the arth is lower than the spactied value fora continuous period of § seconds or more, However, ifthe vehicle condition returns to normal, diagnosis code No. 41 will be automatically erased, and the SRS warning lamp will switch of | Probable cause '* Matfunction of Ramesses of connectors (© Malfunction of SRS-ECU po - Measure at SRS check hamoss [NG ‘SRS check harness connector (5) (MB991613), 1 Disconnect SAS-ECU connector © Connect SAS check hamess ‘connector (3) ‘© Continuity between terminals (20) <2) ‘OK: Continuty Connect SRS cheek hamees connector (3) E16, 0-107, C-77eL. -e{ Check the followin ‘own Repair connect, ee Jex Check tebe synetors id and repair it necessary. 1 re at SAS check hamess conocer G). (Check the following |\° repel Disconnect SAS-ECU connector O12 Sonnectors, ° mein Seecrenseatyeas font. i i a ete, eA Sean yo 1 OK ‘Check trouble symptom, - epac he SRS-EOU. ys Check the harness between the SRS-ECU and ignition switch | Gt, and repair it nacessarySRS - Troubleshooting 52B-11 Code No. 42 IG; (B) power circult system | Probable cause “This diagnosis code is output ifthe vottage between the IG, (B) terminal and the arti lower than the spectied value for a continuous period of § seconds or mare. However, it the vehicle condition retums to normal, diagnosis code No. 42 will be automatically erased, and the SAS waming lamp will switch of '@ Malfunction of hamesses or connectors "T Measure at SRS check ames |NG SRS check hamess | connector (5). (sosten9). | #Bissanect SRs-ECU comector ‘© Connect SRS check hamess Connector (3) + Sg Semen emia 20 oe | 2k contaty 19u0039 eT barbs ‘Measure at SRS check hamess connector (5). NS ‘Disconnect SAS-ECU connector 0-128, Connect SRS-ECU check harness conector (3). ‘© Connect negative battery cable. © Ignition swten: ON ( ® Votage between the terminal (13) and body earth. OK: SV ormore ‘conr | oK + —+!Check the following rnectors (C2116, C-102 and ¢-107 [Gresko ompiow NG Check the following |» Repair e128 ‘Check trouble symptom ~ NG. [ Grete arossbomean io SAS ECUandear | reeaaneetear NG qs Replace the SAS-EOU. ‘and repair necessary. (eee, the harness between the SRS-ECU and ignition oni]52B-12 SRS - Troubleshooting Code No. 43 SRS warning lamp drive circuit system (Lamp does not illuminate.) “This diagnosis code is output when an open circu occurs for a continuous period of 5 seconds while the SRS-ECU in monitoring the SRS warning lamp and the lamp 's OFF (transistor OFF) However, his code is output due to an open circuit, if the vehicle condition returns to normal, tis dagnosis code No. 43 wit be automatically erased, and the SRS warming lamp will return to normal Probable cause Maifunction of hamesses or connectors Blown bub Maifunction of SAS-ECU Maifunction of combination meter Measure at SRS. check hamess [NG ‘SRS check harness gonna (6). © "Disconnect SRS-ECU connector (8991613) ed © Gonnact SAS check hamess comecior (3) + Contnuty between terminals (20) =e) OK: "Continuity 190039 hai shalisli 1a pea No ‘ Dscomect SAS-ECU connect C- ' Gonnect negative battery cabie, Ropiace the SRS-ECU, bet ny NST check the following |"° > Repair | connector. e128 Jor jo 28, Connect SRS cheek harness connector (3), OK Na Check trouble symptom, NG. NG Check | And ignition switch (1G) Check wouble sympiom ———SSS~*d NG — ——— Ns Measure at SAS check hamess connector) | = —+Biown bulb inspection |-——» Repair * Ignition switen: ON’ Check the following} ———» Repair ' Connect terminal (15) tothe body ea connectors. inal (15) tothe body earth hector {° OK: Lamp ttuminates EME C-T0, 6-08 ana OK + OK hamess|~~——» Repair feen the SRS-ECU. FRopiace the combination meter OKSRS - Troubleshooting 52B-13 Code No. 43 SRS warning lamp drive circuit system (Lamp does not switch off. Probable cause “This dagnosis code is output when a shor fo earth occurs in the hamess between the lamp and the SRS-ECU while the SRS-ECU is monitoring ine SAS warning lamp and the lamp is ON, '@ Malfunction of hamesses or connectors ‘Malfunction of SRS-ECU ‘© Maiuncton of combination met No ng ‘SAS waming lamp inspection “Sf cheek the following | —» Repair Connect negatve beter cable connecter. Ig Nee as ecu > teat) mp smich of when SRS-ECU connector C-128 i eR Yes heck Wouble smptom: Replace the SRS ECU. je the _hamese ou Code No. 44 SRS warning lamp drive circuit system | Probable cause “This diagnosis code is output when a shor occurs in the lamp drive ccuit or a | ® Malfunction of hamesses or connectors ‘maitunction othe outputtransistorinside the SAS-ECUiscetectedwhilethe SRS-ECU | ¢ Malfunction of SAS-ECU is monitonng the SAS warring lamp drive circu. [Inspection of the SAS waming lamp drive crcult system. }°% | Roplaco tho SASECU. | Code No. 45 SRS-ECU non-volatile memory (EEPROM) and A/D converter system Probable cause ‘This diagnosis code is output if there is a malfunction in the SRS-ECU non-volatile memory (EEPROM) o° A/D converter '* Malfunction of SRS-ECU [Replace the SAS-ECU.52B-14 SRS — Troubleshos Code No. 51 or 52 Driver's side air bag module (squib ignition drive circuit) system Probable cause “This code output if a shor (NO. 51) or an open circuit (No. 52) Is detected in the croult for the divers seat ‘© Mallunction of SRS-ECU ce the SAS-ECU. ‘Code No. 54 or 55 Front passenger's side alr bag module (squib ignition drive circuit) system Probable cause | This code is output if a short (No. 54) or open circuit (No. 55) Is detected in the circut forthe passenger's seat ‘© Maiunction of SRS-ECU Replace the SASECU. SRS waming lamp __D50A129 SRS WARNING LAMP INSPECTION 1. Check to be sure that the SRS warning lamp il when the ignition switch is in the ON position. 2. Check to be sure that it illuminates for approximately 7 seconds and then switches off. 3. If the above is not the case, inspect the diagnosis codes.SRS - Troubleshooting 52B-15 INSPECTION CHART FOR TROUBLE SYMPTOMS Get an understanding of the trouble symptoms and check according to the inspection procedure chart. Trouble symptom Inspection | Reference Procedure | page No. ‘Communication with MUT-II | Communication with all systems is not possible. | 1 528-15 is not possible. — —| | Communication is not possible with SRS only 2 528-16 When the ignition key is tumed to “ON" (engine stopped), the SRS warning lamp | Refer to 528-43 | does nat iluminate diagnosis, code No. 43. f After the ignition switch is turned to ON, the SRS waming lamp is still on after | Refer to 528-13 approximately 7 seconds have passed. | diagnosis code No. 43. INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS. Inspection Procedure 1 Communication with MUT-II is not possible. (Communication with all system is not possible) ‘The caus is probably power supply system (including earth circuit) ofthe diagnosis | | Probable cause "© Maifunction of connectors #¢_Maitunction of hamess “Measure at the diagnosis connector C- 113 (1e-pn). /¢ Connect negative battery cable '* Vollage between 16 and earth tory vollage | OK No ‘Check trouble symptom, | +! Gheck the hamess wire betwoon the = ‘supply. and. lagi jotor (16-pin. Ne (Gospin.), and Measure at the diagnostic connector |»! Check the following connectors. (revessary 113 (16-pin). ens ‘Continuity betwoen 4 and earth Continuity between 5 and earth } (OK: Continuity = 04 jnptom. “ae (Check trouble sym jace the MUTA52B-16 SRS - Troubleshooting Inspection Procedure 2 ‘Communication with MUT-II is not possible. Tp | Pr (Communication is not possible with SRS only) | Probable cause If communication is not possible with the SRS only, the cause is probably an open | ¢ Malfunction of hamesses or connectors: Cheut n te Gagrose up eeu ofthe SAS on he power Grout (ecung | @ Maluncbon of SRG-ECU car owcu. Measure at SRS check ames NS "Check the following |\° + Repair SRS check harness connector (5). Ses chet e"Dacinect SASEU comer { + SEE ons cnt hanes le commer owe — «erly between terinas (20) [Check role symptom. —) Ok coninty iss * ‘Check the hamess between the SRS-ECUandearth, nd repair reuo0se rm fe] | eogosese x _ srs a SAS Gish names connor |X __.Teheck the following} °—» Repel Disconnect SAS-ECU connector C-128, connectors, on . enact Sh8 check hamese somsecer (. eae eee, c-r07 etc! ang Str cabe ExreL He vonos> Yona ‘between the terminal (13) and body earth CrecR Hive veticies> Berner ¢ venice | + Yaga Semen tho tia 16) and ody ea 1 ormere — Check wouble sympiom NG ‘heck the harness betweon the SAS-EGU and igilon ewich] 1G erigntion swicn it (3), and repair necessay. ck the harness between the 5 ‘anc jnosis | NG hesk he Fanessboiweon the BRS-ECU and dig opal OK place the SAS-ECU.CHASSIS ELECTRICAL — General/immobilizer System 54-1 GROUP 54 CHASSIS ELECTRICAL GENERAL OUTLINE OF CHANGES © The immobilizer-ECU has been changed. The service procedures except for those described below are the same as before. (1) A troubleshooting item (for diagnosis code No. 33) has been added for when the engine starting prevention mode is activated because the incorrect key has been used five times in succession. (2) Diagnosis code No. 11 is now erased automatically when the condition returns to normal (Previously it was erased using the MUT-II.) IMMOBILIZER SYSTEM SPECIAL TOOLS Too! Number Name Use MB991502 MUT-IIsub assembly | @ immobilizer system check (Diagnosis & display using the MUT-II) if ‘© Registration of the ID code. g ‘16x0807 ROM back54-2 CHASSIS ELECTRICAL — Immobilizer System TROUBLESHOOTING INSPECTION CHART FOR DIAGNOSIS CODES Diagnosis code No. _| Inspection items Reference page an ‘Transponder communication system Refer to '96 PAJERO Workshop Manual (PWJE9086-G) 12" ID code are not the same or are not registered Refer to '96 PAJERO Workshop Manual (PWJE9086-G) 21? ‘Communication system between MUT-II and engine-ECU. Refer to '96 PAJERO. Workshop Manual (PWJE9086-G) Communication system between fuel cut valve-ECU and Refer to '96 PAJERO immobilizer-ECU Workshop Manual (PWJE9086-G) 223 Fuel cut vaive-ECU system Refer to ‘96 PAJERO. Workshop Manual | (PWJE9086-G) 23° Starting permission codes are not identical Refer to '96 PAJERO Workshop Manual (PWJE9086-G) 31 EEPROM abnormality inside immobilizer-ECU Refer to '96 PAJERO Workshop Manual (PWJE9086-G) 322 Ignition switch IG signal circuit system. Refer to ‘96 PAJERO. Workshop Manual (PWJE9086-G) 33 Starting prevention system activated due to incorrect 542 operation NOTE (1) "2: Diagnosis code No.11 and No.12 are not recorded. (2) 2: Indicates vehicles with petrol engines. (3): Indicates vehicles with Diesel engines. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Code No. 33 Starting prevention system activated due to incorrect operation | Probable cause ithe ignition switch is tured on more than five mes in succession using an, ‘© The 0 code in he igniion key being used has not invalid kay woien doos not have an ID code registred, diagnosis code NO, 33's been propery vegtered rorted and sarin proverion mode e actvsled ‘© Mattuncton of te immobiizer-ECU {Winen stating preverion mode's activated, fe engine wil nt start even when a proper key s sed. This conotton wi contive unt staring prevention mode se Geared’ — “Tum te nin swish on or 20 minds ar mare and hen tum back of (This operation wil cause starting prevention mode tobe cleared.) eee tee ieee Wess th engine stated using a proper Key which already ad an IDicode rogetored? [Code No. 11 or No. 12 deplyed , 75 inspection Chan Cassifed by Diagnose Codes Gade No. 39 depiayes [Retro 0 PAIERO Workshop Maral (ON E086-6) RJST606005-60