d

BackupServiceManual General
3OOOGl-

GROUP INDEX
.........................

Engine . . . . . . . . . . . . . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Cooling . . . . . . . . . . . . . . . . .

1992-l996 Volume 1
FOREWORD
This Service Manual has been prepared with the latest service information available at the time of publication. It is subdivided into various group categories and each section contains diagnosis, disassembly, repair, and installation procedures along with complete specifications and tightening references. Use of this manual will aid in properly performing any servicing necessary to maintain or restore the high levels of performance and reliability designed into these outstanding vehicles.

Intake and Exhaust

............ ...

Engine and Emission Control

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transaxle .............. ...........

Automatic Transaxle

Propeller Shaft . . . . . . . . . . . . . . . . . Front Axle . . . . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . Wheel and Tire . . . . . . . . . . . . . . . . . Power Plant Mount . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . Rear Suspension .............. ................ ................

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A . I 4iB
WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH
Nat,Onal inmtute for

Service Brakes Parking Brakes

Steering . . . . . . . . . . . . . . . . . . . . . . . Body . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior . . . . . . . . . . . . . . . . . . . . . . . Interior and Supplemental Restraint System (SRS) . . . . . . . . Heater, Air Conditioning and Ventilation .. :. . . . . . . . . . . . . . . . . Alphabetical Index . . . . . . . . . . . . .
NOTE: Electrial system information is contained in Volume 2 “Electrical” of this paired Service Manual. For overhaul procedures of engines or transmissions, refer to the separately issued Engine Service Manual or Manual/Automatic Transmission Service Manual.

AUTOMOTIVE SERVICE EXCELLENCE

MITSUBISHI

MOTOR SALES OF AMERICA Inc

Mitsubishi Motors Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufactured.

c

0 1995 Mitsubishi Motors Corporation

Reprintdin USA

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES
WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from rendering the SRS inoperative). (2) If it is possible that the SRS components are subjected to heat over 93°C (200°F) in baking or in drying after painting, remove the SRS components (air bag module, SRS diagnosis unit, front impact sensors) beforehand. (3) Service or maintenance of any SRS component or SRS-related component must’be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS) and GROUP 00 - Maintenance Service, before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.

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GENERAL
CONTENTS
GENERAL DATA AND SPECIFICATIONS . . . 26 HOW TO USE THIS MANUAL . . . . . . . . . . . . . . 2
Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . Explanation of Circuit Diagrams . . . . . . . . . . . . . . . Explanation of Manual Contents . . . . . . . . . . . . . . . Explanation of the Troubleshooting Guide . . . . . . Maintenance, Repair and Servicing Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tool Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 4 6 2 2 2 2 Fuel Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System (Tank, Pipe Line, Connections and Fuel Tank Filler Tube Cap) . . . . . . . . . . . . . . Ignition Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transmission Oil . . . . . . . . . . . . . . . . . . . . Rear Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRS Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 45 46 48 52 46 53 46 51

MASTER TROUBLESHOOTING . . . . . . . . . . . . 29 PRECAUTIONS BEFORE SERVICE . . . . . . . . 18 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE . . . . . . . . . . 38 SCHEDULED MAINTENANCE TABLE . . . . . .41 SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELS . . . . . . . . . . . . . . . . . . . . . . . 25 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . a .. 28 TOWING AND HOISTING . . . . . . . . . . . . . . . . . . 21 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . 11
Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Model Stamping . . . . . . . . . . . . . . . . . . . . . Theft Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Identification Code Chart Plate . . . . . . . . Vehicle Identification Number List . . . . . . . . . . . . Vehicle Identification Number Location . . . . . . . . . Vehicle Information Code Plate . . . . . . . . . . . . . . . Vehicle Safety Certification Label . . . . . . . . . . . . . 14 14 15 11 12 11 13 14

HOW TO USE TROUBLESHOOTING/ INSPECTION SERVICE POINTS . . . . . . . . . . . . . 7 LUBRICATION AND MAINTENANCE . . . . . . . 36 MAIN SEALANT AND ADHESIVE TABLE .. .61 MAINTENANCE SERVICE . . . . . . . . . . . . . . . . . . 45
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . Automatic Transmission Fluid . . . . . . . . . . . . . . . . Ball Joint and Steering Linkage Seals . . . . . . . . Brake Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belt (For Generator, Water Pump, Power Steering Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Shaft Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporative Emission Control System . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . / 45 49 52 52 52 47 52 51 47 48 46 60

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GENERAL - How to Use This Manual

HOW TO USE THIS MANUAL
MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Unless otherwise specified, each service procedure covers all models. Procedures covering specific models are identified by the model codes, or similar designation (engine type, transaxle type, etc.). A description of these designations is covered in this manual under “VEHICLE IDENTIFICATION”. SERVICE ADJUSTMENT PROCEDURES “Service Adjustment Procedures” are procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspections (for looseness, play, cracking, damage, etc.) must also be performed. SERVICE PROCEDURES The service steps are arranged in numerical order and attention must be paid in performing vehicle service are described in detail in SERVICE POINTS. or the value to which the part or assembly is corrected and adjusted. It is given by tolerance. LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in strength. It is a value established outside the range of standard value. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time). CAUTION Indicates the presentation of information particularly vital to the worker during the performance of maintenance and servicing procedures in order to avoid the possibility of injury to the worker; or damage to component parts, or a reduction of component or vehicle function or performance, etc. INDICATION OF TIGHTENING TORQUE The tightening torque shown in this manual is a basic value with a tolerance of +lO% except the following cases when the upper and lower limits of tightening torque are given. (1) The tolerance for the basic value is within +lO%. (2) Special bolts or the like are in use. (3) Special tightening methods are used.

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TROUBLESHOOTING

Troubleshootings are classified into master troubleshooting and group troubleshooting and located as follows: The master troubleshooting is prepared when the trouble symptom relates to two or more groups and given in MASTER TROUBLESHOOTING. The group troubleshooting guide is prepared for ’ SPECIAL TOOL NOTE causes of problems related to that individual group only; a troubleshooting guide is prepared for each Only MMC special tool part numbers are called appropriate group. out in the repair sections of this manual. Please refer to the special tool cross reference chart, which DEFINITION OF TERMS is located in the service manual at the beginning of each group, for a cross reference from the MMC STANDARD VALUE special tool number to the special tool number that Indicates the value used as the standard for judging is available in your market. the quality of a part or assembly on inspection MODEL INDICATIONS The following abbreviations are used in this manual for classification of model types. Indicates the manual transaxle, or models equipped with the manual transaxle. M/TI Indicates the automatic transaxle, or models equipped with the automatic transaxle. A/T: Indicates the multiport fuel injection, or engines equipped with the multiport fuel injection. MFI: Turbo: Indicates an engine with turbocharger, or a model equipped with such an engine. Non-Turbo: Indicates an engine without turbocharger, or a model equipped with such an engine. FWD: Indicates the front wheel drive vehicles. AWD: Indicates the all wheel drive vehicles. ABS: Indicates the anti-lock braking system or models equipped with the anti-lock braking system. ECS: Indicates the electronic control suspension or models equipped with the electronic control suspension. 4WS: Indicates the 4-wheel steering system or models equipped with the 4-wheel steering system. ( TSB Revision

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vi;

GENERAL - How to Use This Manual EXPLANATION OF CIRCUIT DIAGRAMS I b
The symbols used in circuit diagrams are used as described below.

00-3

NOTE For detailed information concerning the reading of circuit diagrams, refer to Volume 2 - Circuit Diagrams. The input/output (direction of current flow) relative to the electronic control unit is indicated by symbols. output input \ Input/output

r

Indicates a connector.

\

/

\

The broken( ----)line inc cates the same connector.

The connector symbol indicates the device side connector (for an intermediate connector, the male side connector) as seen from the terminal front (the connecI tor’s connection face).

The direction of current flow is indicated by the In this instance, the current flow is in both directions, up or down.

I

i. Ita.

\

Indicates the branch point of a harness of a different line diameter or line color. I

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GENERAL - How to Use This Manual EXPLANATION OF MANUAL CONTENTS
Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. I

-

-

-

-

-

Component Diagram A diagram of the component parts is provided near the front of each section in order to give the reader a better understanding of the installed condition of component parts.

Indicates (by symbols) where lubrication is necessary.

Maintenance and Servicing Procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. l Removal steps: The part designation number corresponds to the number in the illustration to indicate removal steps. l Disassembly steps: The part designation number corresponds to the number in the illustration to indicate disassembly steps.
l

l

Installation steps: Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. Reassembly steps: Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted if reassembly is possible in reverse order of disassembly steps.

Classifications of Major Maintenance I Service Points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.), these are arranged together as major maintenance and service points and explained in detail. +A,: .A+: Indicates that there are essential points for removal or disassembly. Indicates that there are essential points for installation 8r reassembly.

. . _. __
Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication and a: Grease (multipurpose grease unless there is a for application of sealants and adhesives is provided, by brand or type specified) using symbols, in the diagram of component parts or on the page following the component parts page, and ex~_ plained. .; 4 : Sealant or adhesive : * : : Brake fluid or automatic transmission fluid Engine oil, gear oil or air conditioning compressor oil Adhesive tape or butyl rubber tape

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GENERAL - How to Use This Manual

STEERING - Power Steering Gear Box

37A-23 ll-

POWER STEERtNG GEAR BOX

Denotes
* ZL \. r, c ?t?/ /

tightening

Repair kit or set parts are shown. ~OJyL,“A~ frequently used parts

~Rnnovalstspr l.&iiassemblyandgfWboXcwnsctingbog 2. s&mid v&e OLxIlieEmr <VeNc!es wiU~ EPS>

2

EenthenutbutdonatremoveK ,<l

FOG lJGl+l RELAY coNnNulTY CHECX

~

0-0 indicates that there is continuity between the terminals. 0-0 indicates terminals to which battery voltage is applied.

The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of l$riition and sealing proce-

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GENERAL - How to Use This Manual

EXPLANATION OF THE TROUBLESHOOTING GUIDE

diagram for checking (including the interface of the air conditioning control unit).

Indicates the connector number. - Numbers are used in the operation descriptions only as necessary, and these numbers correspond to the numbers used in harness

ti?emiSIM is mYwed f o r & myY in csder w eclmen ms amian ti?Mnsorplt10resi?asrre. ?#-wpphl @.$V) at the airsonddiormr ccmol unit is applied 10 each sewor. and the ntis (16). IX% 1171 and f51 am diitded by the reys- values of each sensor. and

11. The passerqet CMPanmenr~~ture smsw ityin SQnal rS held to 25-C v7-3. ..-. ,_. The olmfde.aw Ulnscu Input JiaMl is held to 15-c f5PFl. N O . 13. Tb ahthermo~ - imut WMI is hdd to SC l3SW.

a.“. 5 IV

s I OUtSdbWsenrorpwrsusDfv RdrigQsm-rapanue SmsoOr . ,‘4.< k passewm --w* NRI saaar pa *- 25-c 177-n. i 4kn ^ At~wnes 1 SaM Pm temosmun 2% (77-I y$se~c++%i~nonnaOFF:BOD SmawPmtarmaM * 25% f77-F) 4ko

TzmiW w&age m-l.sv f 2.45-2 55v 0 1511 Iv-tsv
-1

Indicates the check to be made. t I8

15 16

1

7 p-t‘_

crt 6% _ _. smxmtampcrmrre2 5~7~ ~~ --. I whmarc.mdlt?amrroF :F 8161.

” t

I

~a*C‘,
Indicates the termiIndicates the conditions underwhich the check should be

Indicates the specification to be used for judgement of the check results. If there is no particular mention of conditionsin the”Conditions”column, thecolumn Shows the specification under normal conditions.

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GENERAL - How to Use Troubleshooting/Inspection Service Point

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HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINT
c

Troubleshooting of electronic control systems for which the scan tool can be used follows the basic outline described below. Furthermore, even in systems for which the scan tool cannot be used, part of these systems still follow this outline.

TROUBLESHOOTING CONTENTS
1. 2. STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING The main procedures for diagnostic troubleshooting are shown. SYSTEM OPERATION AND SYMPTOM VERtFICATION TESTS If verification of the trouble symptoms is difficult, procedures for checking operation and verifying trouble symptoms are shown. DIAGNOSTIC FUNCTION The following diagnostic functions are shown. 0 Method of reading diagnostic trouble codes 0 Method of erasing diagnostic trouble codes 0 Input inspection service points INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES Indicates the inspection procedures corresponding to each diagnostic trouble code. (Refer to P.OO-9 - how to use the inspection procedures.) INSPECTION CHART FOR TROUBLE SYMPTOMS If there are trouble symptoms, even though the results of inspection using the scan tool show that all diagnostic trouble codes are normal, inspection procedures for each trouble symptom will be found by means of this chart. INSPECTION PROCEDURE FOR DIAGNOSTIC SYMPTOM Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection Chart for Trouble Symptoms. (Refer to P.OO-9 - how to use the inspection procedures.) SERVICE DATA REFERENCE TABLE Inspection items and normal judgement values have been provided in this chart as reference information. . : . .“L .., CHECK AT ECU TERMINALS ‘, Y. 0. Terminal numbers for the ECU connectors, inspectl~n itemsandstandard values have been provided ‘i’ ‘i, ?i.> .$ in this chart as reference information. Terminal Voltage Checks 1. Connect a needle-nosed wire probe or paper clip to a voltmeter probe. 2. Insert the needle-nosed wire probe into each of the ECU connector terminals from the wire side, and measure the voltage while referring to the check chart. NOTE 1. Measure voltage with the ECU connectors connected. 2. You may find it convenient to pull out the ECU to make it easier to reach the connector terminals. 3. Checks don’t have to be carried out in the order given in the chart. Caution Short-circuiting the positive (+) probe between a connector terminal and ground could damage the vehicle wiring, the sensor, the ECU, or all three. Use care to prevent this! 3. If voltage readings differ from Normal Condition values, check related sensors, actuators, and wiring, then replace or repair. 4. After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem. TSB Revision

3.

4. 5.

6.

00-8

GENERAL - How to Use Troubleshooting/Inspection Service Point

Terminal Resistance and Continuity Checks 1. Turn off the ignition switch. 2. Disconnect the ECU connector. 3. Measure the resistance and check for continuity between the terminals of the ECU harness-side connector while referring to the check chart. NOTE Checks don’t have to be carried out in the order given in the chart. Caution If resistance and continuity checks are performed on the wrong terminals, damage to the vehicle wiring, sensors, ECU, and/or ohmmeter may occur. Use care to prevent this! 4. If the ohmmeter shows any deviation from the Normal Condition value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace. 5. After repair or replacement, recheck with the ohmmeter to confirm that the repair has corrected the problem. 10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are listed here.

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GENERAL - How to Use Troubleshooting/inspection HOW TO USE THE INSPECTION PROCEDURES
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Service Point

00-9

The causes of a high frequency of problems occurring in electronic circuitry are generally the connectors, components, the ECU and the harnesses between connectors, in that order. These inspection procedures follow this order, and they first try to discover a problem with a connector or a defective component.

a.

?d is

In the above cases, the ECS switch circuit is defective orthe indicator
circuit is defective.

-

-

-

l

0

Indicates inspection carried out using the scan tool. Indicates the operation and inspection procedures. Indicates the OK judgement conditions. I I /I 2. Thick box lines: Detailed inspection procedures (methods) such as component inspection and circuit inspection are listed on a separate page, and are given here for reference.

1.

Indicates voltage and resistance to be measured at a particular con- 1 nectar. (Refer to “Connector Measurement Service Points”.) The connector position can be located in the wiring diagram in Volume -2 manual by means of this symbol. Indicates ooeration and inspection procedures, inspection terminals
0
l

yisynecttne connector, ana measure at me namess 2 suxz. ~oftagq between terminal 6 - earth and terminal 8 -

Indicates the OK judgement conditions.

I

ground OI<: Approx. 5V

UK

Check trouble symptom. _’ ) Replace the ECS-ECU.

Inspect the contact condition at each connector terminal. (Refer to “Connector Inspection Service Points”.) The connector position can be located in the wiring diagram in Vol\ ume-2 manual by means of this symbol. Caution \ After carrying out connector inspection, always be sure to reconnect the connector as it was before. I 5. Confirm that there are trouble symptoms. If trouble symptoms have disappeared, the connector may have been inserted incorrectly and the trouble symptom may have disappeared during inspection. If it seemsthat trouble symptoms still remain, proceed to the next stage of instructions. 1 6. If trouble symptoms still remain up to this stage, there is a possibility that there is an open or short circuit in the harness between the connectors, so check the harness. Alternatively, the cause may be a defective ECU, so try replacing the ECU and check if the trouble symptom disappears.

4.

HARNESS INSPECTION Check for an open or short circuit in the harness between the terminals which were defective according to the connector measurements. Carry out this inspection while referring to Volume 2 Electrical manual. Here, “Check harness between power supply and terminal xx” also includes checking for blown fuses. For inspection service points when there is a blown fuse, refer to “Inspection Service Points for a Blown Fuse”.

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MEASURES TO TAKE AFTER REeLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure from the beginning.

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00-10

GENERAL - How to Use Troubleshooting/inspection

Service Point

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS
Most intermittent malfunctions occur under certain conditions. If those conditions can be identified, the cause will be easier to find. TO COPE WITH INTERMIITENT MALFUNCTION; 1. Ask the customer about the malfunction Ask what it feels like, what it sounds like, etc. Then ask about driving conditions, weather, frequency of occurrence, and so on. 2. Determine the conditions from the customer’s responses Typically, almost all intermittent malfunctions occur from conditions like vibration, temperature and/or moisture change, poor connections. From the customer’s replies, it should be reasoned which condition is influenced.

duplicate the customer’s complaint. Determine the most likely circuit(s) and perform the simulation tests on the connectors and parts of that circuit(s). Be sure to use the inspection procedures provided for diagnostic trouble codes and trouble symptoms. For temperature and/or moisture conditions related intermittent malfunctions, using common sense, try to change the conditions of the suspected circuit components, then use the simulation tests below. 4. Verify the intermittent malfunction is eliminated Repair the malfunctioning part and try to duplicate the condition(s) again to verify the intermittent malfunction has been eliminated.

3. Use simulation test In the cases of vibration or poor connections, use the simulation tests below to attempt to

SIMULATION TESTS For these simulation tests, shake, then gently bend, pull, and twist the wiring of each of these examples to duplicate the intermittent malfunction. l Shake the connector up-and-down, and right-and-left. l Shake the wiring harness up-and-down, and right-and-left. l Vibrate the part or sensor. NOTE In case of difficulty in finding the cause of the intermittent malfunction, the data recorder function in the scan tool (MUT-II) is effective.

00003705

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GENERAL - Vehicle Identification

00-l 1

VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER LOCATION
The vehicle identification number (V.I.N.) is located on a plate attached to the left top side of the instrument panel.

VEHICLE IDENTIFICATION CODE CHART PLATE
All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc. Contents Item J : Japan 1 Country -

<Up to 1993 models>

vo.

2 3 4

Make Vehicle

type

A: Mitsubishi 3: Passenger Car

Others

1234567891011 12 0020009 <From 1994 modek5 Line

X: (1992 models) ~ Driver Air Bag, Passenger B: (1993 models) Manual Seat Belt A: (From 1994 Driver and Passenger Air models) 1 Bag 1 D: 3000GTFWD 11992 models

1234567891011 12

6

Price class

0020009 t 00004107

7 8

Body Engine

I

Convertible models W: 3000GT AWD Convertible 4: High 5: Sports (1994 models only), Premium 6: Premium (1994 models only), Special 7: Ultimate 8: Sports (1995 and 1996 models) 4: 3-door Hatchback 5: 2-door Convertible up to 1993 B: 3.0 dm3 (181.4 cu.in.) models <DOHC-MFI> C: 3.0 dm3 (181.4 cu.in.) <DOHC-MFI-Turbo> From 1994 J: 3.0 dm3 (181.4 cu.in.) models <DOHC-MFI> K: 3.0 dm3 (181.4 cu.in.) <DOHC-MFI-Turbo>

9 10

Check digits* N: 1992 Year Model year P: 1993 Year

11 12

Plant Serial number

Y: Nagoya-l Plant 000001 to 999999

NOTE
*: Check digit means a single number or letter X used to verify the accuracy of transcription of vehicle identification number.

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00-12
cl 992 MODELS> cl 993 MODELS> VEHICLES FOR FEDERAL

GENERAL - Vehicle Identification

VEHICLE IDENTIFICATION NUMBER LIST

1 V.I.N. (except sequence number) 1 Brand JA3BM54JClPY (1993 model) JA3XD54BClNY (1992 model)

1Engine displacement

1 Models code

I

Mitsubishi 3000GT 3.0 dm3 (181.4 cu.in.) ZltAMNXML2M Zll AMRXML2M <FWD> [DOHC-MFI1

JA3BN74KOPY (1993 model) JA3XE74CONY (1992 model)

Mitsubishi 3000GT 3.0 dm3 (181.4 cu.in.) Z15AMNGFL2M <AWD> ZlGAMNGFL2M [DOHC-MFI-Turbo]

VEHICLES FOR CALIFORNIA
V.I.N. (except sequence number) JA3BM54JlIlPY (1993 model) JA3XD54BONY (1992 model) JA3BM64JClPY (1993 model) JA3XD64BElNY (1992 model) JA3BN74KOPY* (1993 model) JA3XE74CClNY’ (1992 model) Brand Engine displacement Models code

Mitsubishi 3000GT 3.0 dm3 (181.4 cu.in.) ZllAMNXML7M ZllAMRXML7M cFWD> [DOHC-MFI] ZllAMNPML7M Zl lAMRPML7M Mitsubishi 3000GT 3.0 dm3 (181.4 cu.in.) Z15AMNGFL7M <AWD> [DOHC-MFI-Turbo] ZlGAMNGFL7M

NOTE AWD marked with can also be sold in Federal States.
l

cl 994 MODELS> VEHICLES FOR FEDERAL
1 V.I.N. (except sequence number) 1 Brand 1::~~~~~~~:: 1 y;;t&shi 3 0 0 0 G T Engine displacement Models code I

3.0 dm3 (181.4 cu.in.) ZllAMNXML2M 1 ZllAMRXML2M [DOHC-MFI] ZllAMNPML2M Zl lAMRPML2M

JA3AN74KClRY

Mitsubishi ,300OGT <AWD> I

3.0 dm3 (181.4 cu.in.) ZlGAMJGFL2M [DOHC-MFI-Turbo]

VEHICLES FOR CALIFORNIA
V.I.N. (except sequence number) / Brand .I lVl;‘vl;shi 3 ~~~~~~~~~ 0 0 0 G T Engine displacement 1 Models code I

3.0 dm3 (181.4 cu.in.) ZltAMNXML7M j ZllAMRXML7M [DOHC-MFI] ZliAMNPML7M ZllAMRPML-IM

JA3AN74KORY

Mitsubishi 3000GT <AWD>

3.0 dm3 (181.4 cu.in.) ZlGAMJGFL7M [DOHC-MFI-Turbo]

) TSB Revision

GENERAL - Vehicle Identification
cl 995 MODELS> cl996 MODELS> VEHICLES FOR FEDERAL
V.I.N. (except sequence number) JA3AM54JOSY JA3AM84JCISY JA3AN74KOSY AWD Brand Mitsubishi 3000GT FWD Engine displacement Models code

00-l

3

3.0 dm3 (181.4 cu.in.) f~:~~~~~~~~ [DOHC-MFI] ZllAMNXML2M Zl lAMRXML2M 3.0 dm3 (181.4 cu.in.) ZlGAMJGFL2M [DOHC-MFI-Turbo]

VEHICLES FOR CALIFORNIA
I

V.I.N. (except sequence number) JA3AM54JOSY JA3AM84JOSY JA3AV65JOSY JA3AN74KOSY JA3AW75KOSY
c

Brand Mitsubishi 3000GT <FWD>

T
i

1 Engine displacement Hatchback 3.0 dm3 (181.4 cu.in.) [DOHC-MFI]

T Models code
ZllAMNPML7M ZllAMRPML7M

Convertible Mitsubishi 3000GT <AWD> Convertible 3.0 dm3 (181.4 cuin.) [DOHC-MFI-Turbo]

VEHICLE INFORMATION CODE PLATE
Vehicle information code plate is riveted onto the bulkhead in the engine compartment. The place shows model code, engine model, transaxle model, and body color. code.
1 No. 1 Items 1 Contents I

/ i 1 MODEL
2 3 4 ENGINE EXT TRANSAXLE COLOR, INT OPT

/ ;;;EM
6672 CAGA F5M33 3307 I R25 87V 03V

1

;;;;;;;;en0d3eis
Engine model Exterior code F5M33: Transaxle model 3307: Rear differential reduction R25: Body color code 87V: Interior code 03V: Equipment code

1

I

I

5

TSB Revision

GENERAL - Vehicle Identification CHASSIS NUMBER
STAMPING LOCATION The chassis number is stamped on the top center of the firewall located in the engine compartment. CHASSIS NUMBER CODE CHART
Chassis number code Zl q A RYOOOOOl Contents Zl CIA: Indicates 3000GT-series. RYOOOOOl : Refer to 10th thru 17th digits of V.I.N. plate.

‘, a

VEHICLE SAFETY CERTIFICATION LABEL
1. The vehicle safety certification label is attached to the

2.

face of left door pillar. This label indicates the month and year of manufacture, Gross Vehicle Weight Rating (G.V.W.R.), and Gross Axle Weight Rating (G.A.W.R.), front and rear, and Vehicle Identification Number (V.I.N.).

d

ENGINE MODEL STAMPING
1. The engine model number is stamped at the front side on the top edge of the cylinder block as shown in the following:
Engine model 6672 Engine displacement 3.0 dm3 (181.4 cu.in.)

2. The engine serial number is stamped near the engine model number.
1 Enaine serial number 1 AA0201 to YY9990 I

TSB Revision

GENERAL - Vehicle Identification
Theft protection label

00-15

i

THEFT PROTECTION
In order to protect against theft, a Vehicle Identification Number (VIN) is stamped in, or attached as a label to, the following major parts of the engine and transaxle, as well as main outer panels: Engine cylinder block, Transaxle housing, Fender, Door, Quarter panel, Hood, Liftgate, Bumpers In addition, a theft-protection label is attached to replacement parts for the body outer panel main components, and the same data are stamped into replacement parts for the engine and the transaxle. Cautions regarding panel repairs: 1. When repainting original parts, do so after first masking the theft-protection label, and, after painting, be sure to peel off the masking tape. 2. The theft-protection label for replacement parts is covered by masking tape, so such parts can be painted as is. The masking tape should be removed after painting is finished. 3. The theft-protection label should not be removed from original parts or replacement parts.

b

For original parts

00*61s

For replacement parts

OOK621 00002280

c

1 TSB Revision

00-16
LOCATIONS

GENERAL - Vehicle Identification

Target area (A: for original equipment parts, B: for replacement parts) Engine Automatic transaxle

ZOOFOOS3

ZOOFOO16

Manual transaxle cF5M33>

Manual transaxle cW!SMGl> (Up to 1993 models) cWGMGl> (From 1994 models)

Fender

Door

231FOO70

Z31FWJ71

the illustration indicates left hand side, outer. Right hand side is symmetrically opposite.

The illustration indicates right hand side, outer. Left hand side is symmetrically opposite.

TSB Revision

GENERAL - Vehicle Identification
Target area (A: for original equipment parts, B: for replacement parts) Quarter panel
The replacement part label is attached to the inner side of the part

00-17

1

Hood

shown in the illustration.

The illustration indicates left hand side, outer. Right hand side is symmetrically opposite. Liftgate Front bumper

231FOO74

3ear bumper

1 TSB Revision

00-l 8

GENERAL - Precautions before Service

PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
1. Items to follow when servicing SRS (1) Be sure to be read GROUP 528 - Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) Always use the designated special tools and test equipment. (3) Wait at least 60 seconds after disconnecting the battery cable before doing any further work. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected. (4) Never attempt to disassemble or repair the SRS components (front impact sensors, SRS diagnosis unit, air bag module and clock spring). If faulty, replace it. (5) Warning labels must be heeded when servicing or handling SRS components. Warning labels are located in the following locations. . Hood 0. Sun visor l Glove box l SRS diagnosis unit l Steering wheel l Air bag module l Clock spring l Steering gear and linkage clamp (6) Store components removed from the SRS in a clean and dry place. The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward. Do not place anything on top of it. (7) Be sure to deploy the air bag before disposing of the air bag module or disposing of a vehicle equipped with an air bag. (Refer to GROUP 52B - Air Bag Module Disposal Procedures.) (8) Whenever you finish servicing the SRS, check the SRS warning light operation to make sure that the system functions properly. 2. Observe the following when carrying out operations on places where SRS components are installed, including operations not directly related to the SRS air bag. (1) When removing or installing parts do not allow any impact or shock to the SRS components. (2) SRS components should not be subjected to heat over 93°C (2OO”F), so remove the SRS components before drying or baking the vehicle after painting. After re-installing them, check the SRS warning light operation to make sure that the system functions properly.

1 TSB Revision

GENERAL - Precautions before Service SERVICING ELECTRICAL SYSTEM

00-I

9

1. Note the following before proceeding with work on the electrical system. Note that the following must never be done: Unauthorized modifications of any electrical device or wiring, because such modifications might lead to a vehicle malfunction, over-capacity or short-circuit that could result in a fire in the vehicle. 2. When servicing the electrical system, disconnect the negative cable terminal from the battery. Caution 1. Before connecting or disconnecting the negative cable, be sure to turn off the ignition switch and the lighting switch. (If this is not done, there is the possibility of semiconductor parts being damaged.) 2. After completion of the work steps [when the battery’s negative (-) terminal is connected], warm up the engine and allow it to idle for approximately ten minutes under the conditions described below, in order to stabilize the engine control conditions, and then check to be sure that the idling is satisfactory. Engine coolant temperature: 80-95X (176-203OF) Lights, electric fans, accessories: OFF Transaxle: Neutral position (A/T models: “N” or “P”) Steering wheel: neutral (center) position

VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to maintain the spray nozzle at a distance of at least 300 mm (12 in.) from any plastic parts and all opening parts (doors, luggage compartment, etc.).

mm (in.)

ZS0005E

J

APPLYING RUST PREVENTIVES, UNDERCOAT, ETC.
Heated oxygen sensors have their functional efficiency decreased if they are smeared with oil or grease. When applying rust preventives, undercoat, etc., be sure to protect the heated oxygen sensor with a protective cover or the like.
/ i

TSB Revision

00-20

GENERAL - Precautions before Service SCAN TOOL (MUT) <Up to 1993 models>
(1) To operate the scan tool, refer to the“MULTI-USE TESTER OPERATION INSTRUCTIONS”. Caution Connection and disconnection of the scan tool should always be made with the ignition switch in the OFF position. (2) Always use a ROM pack that is appropriate for the vehicle.
ROM Pack 1 MB991423 1 MB991466 Applicable Model 1 1992 model 1 1992.1993 model 1

Scan tool (Multi-Use Tester <MUT>)

3OM pack

00002282

Scan tool cMUT-If>

SCAN TOOL (MUT-II) <From 1994 models> <All models>
To operate the scan tool, refer to the “MUT-II OPERATING INSTRUCTIONS”. Caution Connection and disconnection of the scan tool should always be made with the ignition switch in the OFF position.
Z16XO606

ROM pack

ZI

6x0607

00002281

TSB Revision

GENERAL - Towing and Hoisting
Sling type

00-21

NO

TOWING AND HOISTING
WRECKER TOWING RECOMMENDATION
<FWD> FRONT TOWING PICKUP Caution This vehicle cannot be towed by a wrecker using slingtype equipment to prevent the bumper from deformation. If this vehicle is towed, use wheel lift or flat bed equipment. The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released. It is recommended that vehicles be towed using the front pickup whenever possible.

Yheel lift type

:lat bed type

zooFoo17 44 type

NO

ieel lift type &&A

It bed type

REAR TOWING PICKUP Caution This vehicle cannot be towed by a wrecker using slingtype equipment to prevent the bumper from deformation. If this vehicle is towed, use wheel lift or flat bed equipment. Manual transaxle vehicles may be towed on the front wheels, provided the transaxle is in neutral and the drive-line has not been damaged. The steering wheel must be clamped in the straight-ahead position with a steering wheel clamping device designed for towing service use. Caution 1. Do not use steering column lock to secure front wheel position for towing. *2. Make sure the transaxle is in Neutral if vehicle will be with drive wheels on the ground. Automatic transaxle vehicle may be towed on the front wheels at speeds not to exceed 50 km/h (30 mph) for distances not to exceed 30 km (18 miles). Caution If these limits cannot be met, the front wheels must be placed on a tow dolly. NOTE *: <From 1994 models> TOWING WHEN KEYS ARE NOT AVAILABLE When a locked vehicle must be towed and keys are not available, the vehicle may be lifted and towed from the front, provided the parking brake is released. If not released, the rear wheels should be placed on a tow dolly.

1 TSB Revision

00-22

GENERAL - Towing and Hoisting SAFETY PRECAUTIONS
The following precautions should be taken when towing the vehicle. 1. DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO OR WRAPPING AROUND THE BUMPER. 2. Any loose or protruding parts of damaged vehicle’such as hoods, doors, fenders, trim, etc., should be secured or removed prior to moving the vehicle. 3. Operator should refrain from going under a vehicle while it is lifted by the towing equipment, unless the vehicle is adequately supported by safety stands. 4. Never allow passengers to ride in a towed vehicle. 5. State and local rules and regulations must be followed when towing a vehicle. , ’ ‘d

Sling type

<AWD>
Caution 1. If only the front wheels or only the rear wheels are lifted for towing, the bumper will be damaged. In addition, lifting of the rear wheels causes the oil to flow forward, and may result in heat damage to the rear bushing of the transfer, and so should never be done. 2. The vehicle must not be towed by placing only its front wheels or only the rear wheels on a rolling dolly, because to do so will result in deterioration of the viscous coupling and in the viscous coupling causing the vehicle to jump forward suddenly. 3. If this vehicle is towed, use flat bed equipment.

’ Ij

Wheel lift type

Flat bed type

I TSB ~~~

Revision

0 in. 2. place a piece of cloth on the jack’s contact surface (to prevent corrosion caused by damage to the coating). spare tire and liftgate. Caution cAWD>: 1. Front: Under the mid point of No. 4.GENERAL . In order to prevent scarring the crossmember.Towing and Hoisting Frame contact support location 00-23 ~ HOISTING POST TYPE Special care should be taken when raising the vehicle on a frame contact type hoist. The hoist must be equipped with the proper adapters in order to support the vehicle at the proper locations. 1 crossmember NOTE On vehicles with active-aero system. Be sure to reinstall the center cover panel after jack-up operation.) zooFoo3 When service procedures require removing rear suspension. A floor jack must never be used on any part of the underbody. FLOOR JACK The usual type of floor jack is used at the following locations. This practice may result in permanent damage to the body. Do not attempt to raise one entire side of the vehicle by placing a jack midway between front and rear wheels. When lifting the No. do not allow jack lifting plate to contact under cover. 1 crossmember. Front <FWD> Rear <AWD> TSB Revision . place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of center of gravity changes. fuel tank. 3. Rear: <FWD> Under the jack up bracket of crossmember cAWD> Under the rear differential Caution 1. the front jacking point can be accessed by removing the center cover panel from the under cover.130 mm (44.

TSB Revision .00-24 GENERAL .Towing and Hoisting ‘LIFTING. Always block opposite wheels and jack on level surface. JACKING SUPPORT LOCATION <MID> <AWD> ZOOFOO19 00002285 %?8 Floor jack locations $ Approximate center of gravity @ Frame contact hoist. twin post hoist or scissors jack (emergency) locati&s EMERGENCY JACKING Jack receptacles are located at the body sills to accept the scissors jack supplied with the vehicle for emergency road service.

3. Caution The rear wheels should remain on the ground.GENERAL . so jack up the front wheels and check the rotation condition of the wheels in this state for no effect by the viscous coupling’s dragging force. Caution 1. follow the same procedure as for front wheel measurements. Balancing machine OOA0046 w e Pick-up stand TSB Revision . the brake test should always be conducted after the speedometer test. Jack up the rear wheels. Rotate each wheel manually and check to be sure that there is no dragging. after setting a pick-up stand and balancing machine in place. If an error is indicated in the state of engine drive. or increase or reduce speed suddenly during the work. 2. motor drive can be used concurrently. OOPO036 00002266 WHEEL BALANCE i FRONT WHEEL MEASUREMENTS 1. the cause may be the effect of the viscous coupling’s dragging force. Set so that the front and rear of the vehicle are at the same height. 3. Do not operate the clutch suddenly. and place an axle stand at the designated part of the side sill. and then. and place an axle stand at the designated part of the side sill. REAR WHEEL MEASUREMENTS 1. 2.Special Handling Instructions for AWD Models 00-25 SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELS BRAKE TEST In order to stabilize the viscous coupling’s dragging force. 2. 2. FRONT WHEEL MEASUREMENTS 1. 3. NOTE If the brake dragging force exceeds the specified value. Caution 1. Release the parking brake. If the brake dragging force exceeds the specified value. Perform the brake test. Jack up the front wheels and set a pick-up stand and balancing machine in place. REAR WHEEL MEASUREMENTS After placing the rear wheels on the brake tester. and then make the measurements. 2. jack up the vehicle and manually rotate each wheel to check the rotation condition of each wheel. Jack up the rear wheels. Jack up the front wheels. follow the same procedures as for the front wheel measurements. Place the front wheels on the brake tester. Use the engine to drive the tires.

General Data and Specifications GENERAL DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS ZOOFOO15 I NOTE l 1: 1993 model 2: 1992 *3: ‘4: <4ws> 1994 model l 5: l 6: 1995 model <Hatchback> 1995 model <Convertible> l 7: l 8: 1996 model <Hatchback> 1996 model <Convertible> TSB Revision .00-26 GENERAL .

GENERAL . Piston displacement cm3 (cu.General Data and Specifications items 3000GT <DOHC> (Non-Turbo) Model No.814 0.4) F5M335-speed manual 3000GT SL <DOHC> (Non-Turbo) 6G72-(DOHC) 2. *l: Up to 1993 models NOTE *2: From 1994 models -1 TSB Revision .972 (181.) Transaxle Model No.972 (181.972 (181.4) F5M335-speed manual 00-27 3000GT VR-4 <DOHC> (Turbo) 6G72-(DOHC) 2.-Type (Manual transaxle) 6G72-(DOHC) 2.4) W5MGl” 5-speed manual W6MGl *2 6-speed manual Engine Model No.in.958 L.speed automatic Multiport fuel injection system <MFI system> Multiport fuel injection system <MFI system> NOTE *l: Up to 1993 models ‘2: From 1994 models ENGINE SPECIFICATIONS I TRANSAXLE SPECIFICATIONS I- I F5M33 1 W5MGl*’ 1 WGMGl*’ 1 F4A33 1 Gear ratio Final reduction ratio I I I I / L Transfer - 0.-Type Automatic transaxle Fuel system Fuel supply system F4A33-4-speed automatic Multiport fuel injection system cMFI system> F4A33-4 .

2) 24 (17) 49 (36) 44 (33) 93 (69) 81 (60) Head mark “8” 1 12 (8.5 (1. nuts and washers are all made of steel and plated with zinc. Standard bolt and nut tightening torque Bolt nominal diameter (mm) Pitch (mm) Head mark “4” 1 2.8 (7.25 1.8 (7.75 1 4.25 1.00-28 GENERAL . (4) If self-tapping screws or self-locking nuts are used.8) 1.8 (6.lbs. (3) If bolts are tightened to plastic or die-cast inset-ted nuts.6) 12 (8.4) 26 (19) 24 (17) 46 (34 42 (31) Head mark “7” 1 9.5) 22 (16) 9. (1) Bolts.5 I 72 (53) I 137(101) 1 206 (152) / 167(123) 1 304 (224) 412 (304) / 559 (412) 1 735 (542) 1 157(116) 1 235(174) 1 343 (253) / 481 (354) 647 (477) 1 853 (629) 1 M20 1 M22 / 1.) Pitch (mm) Head mark “4” 1 1. Torque Nm (ft.) Head mark “7” 1 4.7) The values in the table are not applicable: (1) If toothed washers are inserted.lbs.9 (3.5 / 1.5 1.7) 28 (20) 57 (42) 54 (40) 103 (76) 96 (71) I M6 I M8 Ml0 Ml0 Ml2 Ml2 TSB Revision . (2) The threads and bearing surface of bolts and nuts are all in dry condition.9 (3.5 / 226 (166) 304 (224) 1 392 (289) Flange bolt and nut tightening torque Bolt nominal diameter (mm) Torque Nm (ft.6) 13 (9.25 / 4.9 (3.0 1.Tightening Torque TIGHTENING TORQUE Each torque value in the table is a standard value for tightening under the following conditions. (2) If plastic parts are fastened.2) 25 (18) Head mark “8” I I Ml2 Ml4 / 1.25 1.0 M8 1.6) 8.

Master Troubleshooting 00-29 MASTER TROUBLESHOOTING ENGINE OVERHEATS Symptom Engine overheats Probable cause Cooling system faulty Incorrect ignition timing Reference page 14-3 11-9 ENGINE WILL NOT CRANK OR CRANKS SLOWLY Symptom Engine will not crank or cranks slowly Probable cause Starting system faulty Reference page 16-19 ENGINE WILL NOT START OR HARD TO START (CRANKS OK) Symptom Engine will not start or hard to start (Cranks OK) Probable cause No fuel supply to injector Injection system problems Ignition system problems Vacuum leaks Evaporative emission purge control valve l hose l Vacuum hoses 0 Intake manifold 0 Intake manifold plenum l Throttle body l EGR valve Compression too low Reference page 13A-72.200 13A-52 16-31 17-42 i 11-14 TSB Revision .GENERAL .

00-30 GENERAL .Master Troubleshooting ROUGH IDLE OR ENGINE STALLS rative emission purge control valve ENGINE HESITATES OR POOR ACCELERATION vaporative emission purge control valve l Vacuum hoses TSB Revision .

GENERAL .Master Troubleshooting ENGINE DIESELING Symptom Probable cause Incorrect ignition timing Reference page 11-9 00-31 L Engine dieseling (runs after ignition switch is turned off) EXCESSIVE OIL CONSUMPTION Symptom Excessive oil consumption 1 Probable cause Oil leak Positive crankcase ventilation line clogged Valve stem seal worn or damaged Valve stem worn Piston ring worn or damaged Reference page or remedy Repair as necessary 17-56 Repair as necessary Repair as necessary Repair as necessary POOR FUEL MILEAGE Symptom Poor fuel mileage Probable cause Fuel leak I Air cleaner clogged Ignition system problems Fuel injection system problems i Compression too low Tires improperly inflated Clutch slips Brakes drag Reference page or remedy Repair as necessary j 15-9 16-30 13A-52 11-14 31-3 21-3 35-6 I I I NOISE Symptom Noise Probable cause Loose bolts and nuts Engine noise Reference page or remedy Retighten as necessary 11-6 TSB Revision .

Master Troubleshooting Probable cause Loose power steering oil pump belt Low fluid level Air in power steering system Low tire pressure Excessive turning resistance of lower arm ball joint Excessively tightened steering gear box rack support cover Improper front wheel alignment Excessive turning resistance of tie-rod ball joint Sticky flow control valve Bent rack in steering gear box Reference page or remedy 37A-9 Replenish 37A-11 I 31-3 33A-10 37A-20 33A-6 37A-7 37A-30 37A-20 POOR RETURN OF STEERING WHEEL TO CENTER Symptom Poor return of steering wheel to center Probable cause Improper front wheel alignment Improper tire pressure Excessive tightened rack support cover Damaged front wheel bearing Reference page 33A-6 31-3 37A-20 26-9 TSB Revision .00-32 HARD STEERING Symptom Hard steering GENERAL .

36 Reference page 33A-6 34-5. 12 34-13.25. 36.GENERAL .7 34-5. 25 31-3 ROAD WANDER Symptom Road wander Probable cause Improper front or rear wheel alignment Excessive play of steering wheel Poor turning resistance of lower arm ball joint Improper tire pressure Loose or worn lower arm bushing Loose or worn wheel bearings Loose rack support cover in steering gear box 37A-20 Reference page 33A-6 34-525 37A-6 33A-11 31-3 33A-10 TSB Revision . 36 ABNORMAL TIRE WEAR Symptom Abnormal tire wear Probable cause Improper front or rear wheel alignment Improper tire pressure lmbalanced wheels c Loose wheel bearings Malfunctioning shock absorber 34-6 33A-7 34-13. 38 Reference page or remedy 31-3 Repair 33A-6. 16. 13.Master Troubleshootina POOR RIDING Symptom Poor riding Probable cause Improper tire pressure lmbalanced wheels Improper front or rear wheel alignment Malfunctioning shock absorber Broken or worn stabilizer Broken or worn coil spring Loose suspension securing bolt(s) Worn lower arm bushing Worn suspension arm bushing Retighten 33A-10 33A-10 33A-7.

36 TSB Revision . play. or seizure of drive shaft ball joint BOlTOMlNG Symptom Bottoming Probable cause Overloaded vehicle Broken or weak coil spring Malfunctioning shock absorber Reference page or remedy Correct 33A-7 34-13.Master Troubleshooting VEHICLE PULLS TO ONE SIDE Symptom Vehicle pulls to one side Probable cause Improper front or rear wheel alignment lmbalanced or worn tires Uneven tire pressure Excessive turning resistance of lower arm ball joint Wheel bearing seizure Broken or worn coil spring Bent front or rear axle drive shaft Deformed lower arm 33A-11 Replace 33A-7 26-12 33A-10 Reference page or remedy 33A-6 34-525 31-3 STEERING WHEEL SHIMMY lmbalanced wheels Wear.00-34 GENERAL .

GENERAL . forming indentations Probable cause Excessive bearing preload Excessive load End of bearing life Improper bearing assembly 00-35 Impact when bearing was installed (such as being hit with a hammer) Excessive bearing preload Excessive load Vibration when bearings are not used. corrosion / i Wear Wear of surface areas caused by friction Discoloration Grease discoloration results from grease deterioration which causes particles of pigment contained in grease to adhere to surfaces Heat discoloration will appear as a deep brown or purple 1 TSB Revision . race and roller contact surfaces compress. Insufficient grease Excessive bearing preload Excessive load Faulty oil seal Excessive variation of loads on bearings Use of grease other than that specified lnsuff icient grease Use of grease otherthan that specified Faulty oil seal Presence of water or moisture Insufficient grease Foreign matter Rust or corrosion due to moisture Use of grease other than that specified Faulty oil seal Use of grease other than that specified Faulty oil seal Excessive bearing preload Excessive load Nicks Instead of rolling along race surface. rollers slide.Master Troubleshootina WHEEL BEARING TROUBLESHOOTING Trouble i Pitting Flaking Cracking Flat spotting Symptom Pitting occurs because of uneven rotation of race and bearing surfaces The surface peels because of uneven rotation of the race and bearing surfaces Chipping or cracking of cage or roller edges When large load is applied. such as during shipment on freight cars. thus damaging surface Smearing i Damage or wear caused by minute particles adhering to surfaces results in rough movement and such high temperatures that parts of surface melt Appears on various areas of the bearing Rust. etc. transport trucks.

GEAR LUBRICANTS The SAE grade number also indicates the viscosity of Multi-Purpose Gear Lubricants. SG ECII or SGKD EC11 For further details. Caution Using leaded gasoline in your car will damage the catalytic converters and the oxygen sensors. the performance and fuel consumption will suffer a little degradation. thinners. Your car is designed to operate on premium unleaded gasoline having a minimum octane rating of 91 or 95 RON (Research Octane Number). Three schedules are provided. when changing engine oil. the potential exists for humans to develop a number of skin disorders. Since these conditions vary with the individual vehicle owner’s driving habits. and will void warranty coverage of the catalytic converters and the oxygen sensors. Care should be taken. one for “General Maintenance” and one for “Severe Usage Service”. Accordingly. should be used. it is necessary to prescribe lubrication and maintenance service on a time frequency as well as mileage interval basis. Trailer towing or police. that cannot be penetrated by oil. Protective clothing and gloves.00-36 GENERAL . refer to “LUBRICANTS SELECTION” section. 3 etc. the American Petroleum Institute (API) and the National Lubricating Grease Institute (NLGI). one for “Required Maintenance”. Operation of Vehicle (1) Short-trip operation at freezing temperature (engine not thoroughly warmed up) (2) More than 50% operation in heavy city traffic during hot weather above 32°C (90°F) (3) Extensive idling (4) Driving in sandy areas (5) Driving in salty areas (6) Driving in dusty conditions FUEL USAGE STATEMENT Your car must use unleaded gasoline only.Lubrication and Maintenance Caution Test results submitted to EPA have shown that laboratory animals develop skin cancer after prolonged contact with used engine oil. Component service information is included in appropriate units for vehicles operating under one or more of the following conditions: 1. Whenever “Chassis Lubricant” is specified. TSB Revision . 2. including cancer. It is illegal. from such exposure to used engine oil. should be worn. or solvents. Oils. or commercial type operation 2. Item numbers in the “SCHEDULED MAINTENANCE TABLE” correspond to the item numbers in the “MAINTENANCE SERVICE” section. to minimize the amount and length of exposure time to used engine oil on your skin. 1. unleaded gasoline having a octane rating of 87 or 91 RON (Research Octane Number) may be used. therefore. lubricants and greases are classified and graded according to standards recommended by the Society of Automotive Engineers (SAE). MAINTENANCE SCHEDULES Information for service maintenance is provided under “SCHEDULED MAINTENANCE TABLE”. LUBRICANTS . the area in which the vehicle is operated and the type of driving to which the vehicle is subjected.. If premium unleaded gasoline is not available. LUBRICATION AND MAINTENANCE Maintenance and lubrication service recommendations have been compiled to provide maximum protection for the vehicle owner’s investment against all reasonable types of driving conditions. NLGI grade 2. d SEVERE SERVICE Vehicles operating under severe service conditions will require more frequent service. taxi. ENGINE OIL Either of the following engine oils should be used: (1) Engine oil displaying EOLCS certification mark (2) Engine oil conforming to the API classification SH ECII. or use waterless hand cleaner. Typically gear lubricants conforming to API GL-4 or GL-5 with a viscosity of SAE 75W-85W or 75W-90 are recommended for manual transaxle. MultiPurpose Grease. The API classification system defines gear lubricants in terms of usage. This car has a fuel tank filler tube especially designed to accept only the smaller-diameter unleaded gasoline dispensing nozzle. to remove any used engine oil. Do not use gasoline. In this case. SH/CD ECII. The skin should be thoroughly washed with soap and water.GREASES ‘i Semi-solid lubricants bear the NLGI designation and are further classified as grades 0.

A mixture of 10% ethanol (grain alcohol) and 90% unleaded gasoline may be used in your car. although they may not be so identified.GENERAL . Many of these materials inL’ tended for gum and varnish removal may contain highly active solvents or similar ingredients that can be harmful to gasket and diaphragm materials used in fuel system component parts.Lubrication and Maintenance MATERIALS ADDED TO FUEL Indiscriminate use of fuel system cleaning agents should be avoided. may cause reduced engine performance and produce vapor lock or hard starting. Fuel system damage and performance problems. Gasolines containing MTBE (Methyl Tertiary Butyl Ether) _’ L/ Unleaded gasoline containing 15% or less MTBE may be used in your car. Fuel containing MTBE over 15% vol. Gasolines Containing Alcohol Some gasolines sold at service stations contain alcohol. may not be covered by the new car warranty. Gasohol . Metanol . 00-37 TSB Revision . it is recommended that the car be operated on gasoline. Use of fuels containing alcohol is not recommended unless the nature of the blend can be determined as being satisfactory.Do not use gasolines containing methanol (wood alcohol). If driveability problems are experienced as a result of using gasohol. resulting from the use of gasolines containing methanol. Use of this type of alcohol can result in vehicle performance deterioration and damage critical parts in the fuel system components.

3 dm3 0. measure 4. 1 1.3 dm3 4. 8.5 qts.27 dm3 0. Metric measure 4.5 qts. 8OW-90 LUBRICANT CAPACITIES TABLE Description Engine oil Crankcase Oil filter Oil cooler <Turbo> Total <Non-Turbo> Total <Turbo> Cooling system (including heater and coolant reserve system) Manual transaxle FWD AWD Transfer 5M1-f GM/-r Automatic transaxle Rear axle cAWD> Power steering 1.45 dm3 Fuel tank 75 dm3 1 TSB Revision 1. .32 qt.29 qt.2 qts. 19.4 qts.CaDacities Table necommenaea Lubrtcams ana LuDrlcant RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE RECOMMENDED LUBRICANTS Differential (rear axle) Hypoid Gear Oil API classification GL-5 or high Above -23°C (-10°F) SAESO. 2. .S.8OW From -34°C (-30°F) to -23°C (-10°F) SAE 8OW.9 qts.1 dm3 U. . 2.5 dm3 / 1. .4 dm3 0.8 gals.59 qts. 7. .0 dm3 0. 85W-90.16qts.3 dm3 2.32 qt. 4. 4.9 qts.5 qts.3 dm3 4.6 dms 8 o dm3 2.30 dms 7.00-38 GENERAL .32 qt.

an API classification SH ECII. M03A014 / . NOTE *: SAE 5W-30 may be used for operation in very cold weather areas where the lowest atmospheric temperature is below -10°F (-23°C).L Oil Viscosity The SAE grade number indicates the viscosity of the oil. M03A015 L If these oils are not available. Turbo 003BOO9 REAR AXLE I i Lubricant Anticipated temperature range API classification GL-5 or higher I ~ 1 Below -34°C (-30°F) TSB Revision 1 SAE 75W I . SG EC11 or SG/CD EC11 can be used. Oil Identification Symbol Use only engine oils displaying the EOLCS certification mark on the container.GENERAL .Capacities Table EOLCS certification mark necommenaea woncams ana wwcanx 00-39 LUBRICANTS SELECTION ENGINE OIL Caution Never use nondetergent or straight mineral oil. A proper SAE grade number should be selected according to ambient temperature. SH/CD ECII.

specified range.Capacities Table SELECTION OF COOLANT COOLANT Relation between Antifreeze Concentration and Specific Gravity Engine coolant temperature “C (OF) and specific gravity Freezing temperature Safe operating temperature Engine coolant concentration (Specific volume) % ‘L/j 50 55 60 Example The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.necommenaea LuDrlcants ana LuDricant GENERAL . In addition. be sure to maintain the concentration level within the. if the concentration is above 60%. 2.058 at the coolant temperature of 20°C (68°F). the anti-corrosion property will be adversely affected. Caution 1. If the concentration of the coolant is below 30%. \- 1 TSB Revision . For these reasons. Do not use a mixture of different brands of anti-freeze. affecting the engine adversely. both the anti-freeze and engine cooling properties will decrease.

No. Retain receipts for all vehicle emission services to protect your emission warranty. and fuel tank filler tube cap)* Fuel hoses Air cleaner element 4 Evaporative emission control system (except evaporative emission canister)* Sparks plugs Service to be performed Kilometers in thousands Mileage in thousands 24 15 48 30 72 45 96 60 X 120 144 168 75 90 105 Check for leaks Every 5 years or Check condition Every 2 years or Replace at Check for leaks and clogging Every 5 years or Replace except platinum plugs platinum plugs only I I4 I4 I4 X X X X X X X X X Ignition cables* NOTE ‘: Except for Federal / Replace Every 5 years or GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE eneral maintenance NOTE *: For California.Scheduled Maintenance Table 00-41 ~ ~ ~ SCHEDULED MAINTENANCE TABLE <Up to 1994 models> SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PROPER i \i VEHICLE PERFORMANCE Inspection and services should be performed any time a malfunction is observed or suspected.GENERAL . pipe line and connection. this maintenance is recommended but not required. 1 TSB Revision . Emission control system maintenance Fuel system (tank.

Replace at ment Replace at Change Every 3 months or Replace Every 6 months or Inspect for wear More frequently / x x I x I x I x / x I x x x X X X Severe usage conditions A B C D E F G VO.600 km (6. - Maintenance Item Service to be performed 96 120 144 168 (60) (75) (90) (105) X 3 X 5 Spark plugs Engine oil 9 Every 4. General maintenance Service to be performed Kilometers in thousands Mileage in thousands 24 15 48 30 72 45 96 60 120 144 168 75 90 105 15 16 17 Brake hoses ‘Ball joint and steering linkage seals Drive shaft boots Check for deterioration or leaks Every year or Inspect for grease leaks and damage Every 2 years or Inspect for grease leaks and damage Every year or / Check oil level Inspect system Check and service as required Every 2 years or I x X X X x /xl x x Ix1 x x Ix/ x 18 / Rear axle oil <AWD> 19 SRS airbag Exhaust system (connection portion of muffler.000 Miles) Every 9.800 km (3.000 Miles) More frequently x x x x x x X X 10 Engine oil filter t 14 t Disc brake pads X Severe usage conditions ADriving in dusty conditions BTrailer towing or police.Scheduled Maintenance Table I\lo. pip20 ings and converter heat shields) At 10 years X X X NOTE SRS: Supplemental Restraint System SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS The maintenance items should be performed according to the following table: 1Mileage intervals kilometers in thousands (Miles in thousands) (::) (ii) (i:) Air cleaner ele. or commercial type operation Extensive idling CDShort trip operation at freezing temperatures (engine not thoroughly warmed up) EFG- Driving in sandy areas Driving in salty areas More than 50% operation in heavy city traffic during hot weather above 32°C (90°F) 1 TSB Revision 1 . taxi.GENERAL .

500 miles) each year. Emission control system maintenance Fuel system (tank. the oil filter should be replaced at every oil change. Power steering pump) Check condition at X X Change Every year or Change Every 6 months or Every 12.000 km (10.Scheduled Maintenance Table 00-43 SCHEDULED MAINTENANCE TABLE <From 1995 models> SCHEDULED MAINTENANCE SERVICES FOR EMISSION CONTROL AND PROPER i VEHICLE PERFORMANCE Inspection and services should be performed any time a malfunction is observed or suspected. Water pump. No. this maintenance is recommended but not required. 105 Check for leaks Every 5 years or t Check condition Every 2 years or L Replace at Evaporative emission con. and fuel tank filler tube cap)*’ Fuel hoses 3 4 Air cleaner element Service to be performed Kilometers in thousands Mileage in thousands 24 15 48 30 72 45 96 60 X I I X X I I X X X I I X X I 120 144 168 75 90.Every 5 years or rative emission canister)*’ Sparks plugs Replace except platinum plugs platinum plugs only Ignition cables*’ Replace Every 5 years or X X X X X NOTE *I: Except for Federal i GENERAL MAINTENANCE SERVICE FOR PROPER VEHICLE PERFORMANCE - Service to be I10.t Check for leaks and clogging trol system (except evapo.000 miles) X X X I 11 12 Manual transmission oil Automatic fluid transmission Check oil level at Check fluid level Every year or Change fluid at I x 1x1 /XI Ix/ x x x x x x I NisiE For California. Retain receipts for all vehicle emission services to protect your emission warranty.000 km (5.000 miles) X 8 9 Drive belt (for Generator. *I -: TSB Revision .GENERAL. pipe line and connection.000 km*2 (100.500 miles) Every 8. . 7 General maintenance Timing belt performed Replace at Kilometers in thousands Mileage in thousands 24 15 48 30 72 45 96 60 120 144 168 75 90 105 X’ At 160. *3: If the mileage is less than 12.000 km (7.000 km (7.000 miles) I I 10 Replace Every year*3 or Replace Every year or Every 16. ii*? Not required if belt was previously changed.

000 Miles) 11 Manual transmission oil I 13 Transfer oil 15 Disc brake pads X X X X Every 9.800 km (3. 1 Maintenance Item Service to be performed Mileage intervals kilometers in thousands (Miles in thousands) (::) (ii) (i:) 96 120 144 168 (60) (75) (90) (105) x x x x x x x x x Severe usage conditions A B c I \ ‘d 3 Air cleaner element 5 Spark plugs 9 Engine oil 10 Engine oil filter Replace at Replace at Change Every 3 months or Replace Every 6 months or Change at Change at inspect for wear Every6 months or x x x x xx X Every 4.Scheduled Maintenance Table 15 Disc brake pads Inspect for wear Every year or Check or for deterioration or leaks x x Every x year X’X x x 16 Brake hoses 17 18 19 Ball joint and steering linkage seals Drive shaft boots Rear axle oil cAWD> xxxxxxx Inspect for grease leaks and damage Every 2 years or Inspect for grease leaks and damage Every year or inspect oil level Inspect system Check and service as required Every 2 years or x X x x X x x X x x X At 10 years X X 20 SRS airbag 21 Exhaust system (connection portion of muffler.GENERAL .000 Miles) Every 9. piplngs and converter heat shields) X X X NOTE SRS: Supplemental Restraint System SCHEDULED MAINTENANCE UNDER SEVERE USAGE CONDITIONS The maintenance items should be performed according to the following table: No.600 km (6.000 Miles) Every 48.000 km (30. driving in stop and go traffic DShort trip operation at freezing temperatures (engine not thoroughly warmed up) EFGH- Driving in sandy areas Driving in salty areas More than 50% operation in heavy city traffic or at sustained high speeds during hot weather above 32°C (90°F) Driving on off -road d TSB Revision .600 km (6. or commercial type operation cExtensive idling. taxi.000 Miles) Severe usage conditions ADriving in dusty conditions BTrailer towing or police.

(6) Be sure to close the air cleaner cover completely when clamping it. AIR CLEANER ELEMENT (Replace) The air cleaner element will become dirty and loaded with dust during use. (6) Take out the air cleaner element and install a new one.Maintenance Service 00-45 MAINTENANCE SERVICE 1. (4) Unclamp the air cleaner cover. abrasions and excessive swelling indicate deterioration of the rubber. FUEL HOSES (Check condition) Inspect the surface of fuel hoses for heat and mechanical damage. (5) Remove the air cleaner cover and volume air-flow sensor. (3) Unclamp the ‘air cleaner cover. 3. checking. 1. (2) Remove the air intake hose from the volume air-flow sensor. the hoses should be changed. Hard and brittle rubber. FUEL SYSTEM (TANK. (5) Take out the air cleaner element and install a new one. If the fabric casing of the rubber hose is exposed by cracks and abrasions in the fuel system. and the filtering effect will be substantially reduced. tears. cracking. <Non-Turbo> (1) Disconnect the volume air-flow sensor connector.GENERAL . PIPE LINE. 2. (2) Disconnect the volume air-flow sensor connector.TSB Revision . CONNECTIONS AND FUEL TANK FILLER TUBE CAP) (Check for leak) Check for damage or leakage in the fuel lines and connections and looseness of the fuel tank filler tube cap. (3) Remove air intake hose A from the volume air-flow sensor. Replace it with a new one. t. Cautidn Remove the air cleaner cover with care not to give shock to the volume air-flow sensor. cuts. (4) Remove the air cleaner cover and volume air-flow sensor. Caution Remove the air cleaner cover with care not to give shock to the volume air-flow sensor. 2. (7) Be sure to close the air cleaner cover completely when clamping it. <Turbo> (1) Remove the clutch booster vacuum pipe mounting bolt.

7.Timing Belt. For removal and installation procedures. Remove the fuel tank filler tube cap from the fuel tank filler tube and check to see if there is evidence that the packing makes improper contact to the fuel tank filler tube. an open circuit might result. Disconnect the line at both ends.0-1. 1._ .) NOTE For the platinum plug. SPARK PLUGS (Replace) The spark plugs must fire properly to assure proper engine performance and emission-control. If the cable is disconnected by pulling on the cable alone.) +Jti!l Correct \ . IGNITION CABLES (Replace) The ignition cables should be replaced periodically with new ones.043 in. and blow it clean with compressed air. [ TSB Revision . use care not to damage the platinum tip. After replacing. TIMING BELT (Replace) Replace the belt with a new one periodically to assure proper engine performance. refer to GROUP 11 . Therefore. .lbs.except evaporative emission canister If the fuel-vapor vent line is clogged or damaged.00-46 GENERAL .039-. 2. Spark plug NGK NIPPON DENS0 PFRGJ-11 PK20PRPll Spark plug gap: 1. Do not try to adjust the plug gap. NOTE When disconnecting an ignition cable.-e 6. The fuel tank pressure control valve installed on the vapor line should be checked for correct operation.1 mm (.Maintenance Service 4. be sure to hold cable cap. EVAPORATIVE EMISSION CONTROL SYSTEM (Check for leaks and clogging) . Specified torque: 25 Nm (15 ft. make sure that the ignition cables and terminals are properly connected and full seated. a fuel vapor mixture escapes into the atmosphere causing excessive emissions. they should be replaced periodically with new ones. 5.

0-5.16-.) <Reference value> For P/S pump Tension N (Ibs.OO-38) Caution Never use nondetergent or straight mineral oil.22) 250-500 (55-l 10) 9.) <Turbo> 4.9 qts.) applied to belt mid-point between pulleys shown in the illustration. 2.53) For generator Idler pulley Tension pulley / Tension A pulley Crankshaft pulley 01 FOO07 <Vehicle with air conditioning> Power steering Tenzion pulley pump pulley \ Air conditioning Crankshaft compressor pulley OlFOO84 pulley 00002532 I <Vehicle with air conditioning> 1 Items 1 For generator and A/C compressor For P/S pump / Tension N (Ibs.6 dm3 (4.) Deflection mm (in.) <Reference value> 350-600 (77. make adjustment. Cover the generator with shop towel before filling engine oil to make sure that even if oil is spilt.3 dm3 (4. remove the oil filler cap.Maintenance Service <Vehicle without air conditioning> Generator I 00-47 8. ENGINE OIL (Change) Always use the specified oil. Water Pump. it may not drop on the generator.16-. (2) Remove the drain plug and drain the engine oil.GENERAL . If the standard value is not obtained. Caution 1.5 (. and replace it if defective. (4) Pour new engine oil through the oil filler. (3) Tighten the drain plug to 40 Nm (29 ftlbs. Standard value: <Vehicle without air conditioning> items Specification Tension N (Ibs. Use an oil mug or a funnel to fill oil. (Refer to P.0-5.22) 250-500 (55-110) 9.5 (. (2) On vehicles without air conditioning.5-l 3.) Deflection mm (in.) (5) Check to ensure that the engine oil level is within the level range indicated on the oil dip stick. Inspect the drive belt for evidence of cuts and cracks.5 (.) <Reference value> Specification I 1 350-600 (77-132) 4. Engine oil total capacity: [including oil filter and oil cooler] <Non-Turbo> 4. DRIVE BELT (For Generator. set a tension gauge at a position maked with arrow A in the illustration to measure the belt tension.5 qts.) Deflection mm (in.). (1) Measure the deflection with a force of 100 N (22 Ibs. Power Steering Pump) (Check condition) Check the tension of the drive belt.132) 4.5 (.) Deflection mm (in.53) I 1 9. (1) After warming up the engine.37-.37-.) <Reference value> Tension N (Ibs.5-13. TSB Revision .

(6) After stopping engine. You should be sure that any replacement filter used on this vehicle is a high-quality filter and is capable of withstanding a pressure of 256 psi (1. Oil Filter Part No. and check the oil level by removing the filler plug. Genuine oil filters are high quality filters being capable of withstanding a pressure of 256 psi and are strongly recommended for use on this vehicle. ‘d 11. ENGINE OIL FILTER (Replace) The quality of replacement filters varies considerably. (1) Remove the engine oil filter by using the oil filter wrench. TSB Revision .00-48 GENERAL . (1) With the vehicle parked at a level place. (2) Clean the oil filter mounting surface of the oil filter bracket. If the oil is contaminated. (3) Coat engine oil to the O-ring of new oil filter. ENGINE OIL FILTER SELECTION This vehicle is equipped with a full-flow.765 kPa) (manufacturer’s specifications) to avoid filter and engine damage. It is possible. MITSUBISHI Genuine Parts: MD136790 or equivalent.L/ I ~ Any replacement oil filter should be installed in accordance with the oil filter manufacturer’s installation instructions. particularly in cold weather. and after the O-ring contacts the flange surface. . NOTE The oil filter tightening torque is 14 Nm (11 ft. throw-away oil filter. (4) Screw in the oil filter by hand.). check oil level and refill as necessary. tighten it another 3/4 turns with a filter wrench.lbs. The same type of replacement filter is recommended as a replacement filter for this vehicle. (5) Start and run engine and check for engine oil leaks. remove the filler plug. that this vehicle may develop high oil pressure for a short duration. it is necessary to replace it with new oil. MANUAL TRANSMISSION OIL (Check oil level) Inspect each component for evidence of leakage. etc.Maintenance Service 10. Only high quality filters should be used to assure most efficient service.

Maintenance Service 00-49 1 PhiI (2) Check that the transaxle oil level is at the lower portion of the filler plug hole. The transaxle should be overhauled under the following conditions. (3) Check to be sure that the transmission oil is not noticeably dirty. Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid. l If there is a “burning” odor. Before removing dipstick. 4.GENERAL . 2. and that it has a suitable viscosity. 1. id TSB Revision . Place vehicle on level floor. l If there is a noticeably great amount of metal particles in the fluid. 3. ZO9FO12 Transfer 4 9 9 2 model> I Transfer <From 1993 model> 12. l If the fluid color has become noticeably blacker. wipe all dirt from area around dipstick. check that the transfer oil level is at the portion shown in the illustration. For AWD-vehicles. Then take out the dipstick and check the condition of the fluid. then place lever in “N” Neutral position. This operation is necessary to be sure that fluid level check is accurate. AUTOMATIC TRANSMISSION FLUID (Check fluid level) Drive until the fluid temperature reaches the usual temperature [70-80°C (160-18O”F)].

5 dm3 (4. 4.lbs. Air trapped in hydraulic circuit forms bubbles which make fluid spongy. approx. resulting in accelerated deterioration of ATF transmission fluid.8 qts. Low fluid level can cause a variety of conditions because it allows pump to take in air along with fluid.). (1) Remove drain plug at transaxle case bottom to let fluid drain. Replenish with new fluid after the cause of any contamination has been corrected. clutch.5 ft. (Change fluid) Drain the fluid and check whether there is any evidence of contamination. pressures will be erratic. with parking brake on. (4) Check the oil filter for clogging and damage and replace if necessary. Foaming can also result in fluid escaping from transaxle vent where it may be mistaken for a leak. then remove oil pan.) of specified ATF into case through dipstick hole.) of fluid can be replaced because rest of fluid remains in torque converter. In either case. air bubbles can cause overheating.5-8. ending in “N” Neutral position. . Then. TSB Revision . 7. Be sure to examine fluid on dipstick closely. Oil pan bolt: lo-12 Nm (7.) (6) Clean both gasket surfaces of transaxle case and oil pan.00-50 GENERAL . Drain pulg: 30-35 Nm (22-25 ft. 6. (7) Install oil pan with new gasket and tighten oil pan bolts. which can interfere with normal valve. Therefore.] Transmission fluid: DIAMOND ATF SP or equivalent (9) Start engine and allow to idle for at least two minutes. If fluid level is low.8 qts. (5) Clean drain plug and tighten drain plug with gasket. and servo operation. (3) Loosen oil pan bolts and tap pan at one corner to break it loose allowing fluid to drain. rotal quantity of ATF required is approx. add ATF until level reaches “HOT range.lbs.Maintenance Service Check to see if fluid level is in “HOT’ range on dipstick.) (8) Pour 4. move selector lever momentarily to each position.5 dm3 (7.5 dm3 (4.9 qts. Actually however. gears churn up foam and cause same conditions which occur with low fluid level. fluid oxidation. When transaxle has too much fluid. 5. (2) Place a drain container with large opening under the transaxle oil pan. Improper filling can also raise fluid level too high.

10. Mount the reserve tank. ENGINE COOLANT (Change) Check the cooling system parts. If the oil is contaminated. 2.. it is necessary to replace it with new oil. Rear bank 1 Y /.+ 0y.TRANSFER OIL (Check oil level) Inspect each components for evidence of leakage. 4171 or equivalent Tightening torque: 40 Nm (29 ft. Install the radiator cap securely.lbs. and check the oil level by removing the filler plug. Coat the threads of the engine drain plugs with the specified sealant and tighten the plugs to specification. Remove the reservoir tank and discharge coolant. Race the engine up to around 3.) 6. When the engine has cooled down. 12. 7. Fit the radiator drain plug securely. remove the radiator cap and add coolant up to the brim. Remove the heat protectors (front and rear) from the exhaust manifold. and oil cooler hoses. Slowly pour coolant into the radiator to the brim and also into the reserve tank up to the FULL line. Lift up the vehicle. Loosen the radiator drain plug. 4.GENERAL . 13. 2.3 <Turbo> 1. 5. Start the engine and warm up until the thermostat opens. Follow the same steps 3 to 12 above. Recheck fluid level after transaxle is at normal operating temperature. CHANGING COOLANT <Non-Turbo> 1. Fluid level should be between upper and lower marks of “HOT’ range. heater. then stop the engine. 3. When coolant has been discharged. 3.000 rpm several times. Add coolant to the reserve tank up to the FULL line. 9. 11. such as radiator. 14. Insert dipstick fully to prevent dirt from entering transaxle. remove two drain plugs from the engine block (one for each bank) and remove the radiator cap to discharge coolant. pour water through the filler port to flush coolant passage.Maintenance Service 00-51 (lO)Add sufficient ATF to bring fluid level to lower mark. Specified sealant: 3M Nut Locking Part No. 8. remove the drain plug from the rear bank of the engine and remove the radiator cap to discharge coolant. 1 TSB Revision I . Loosen the radiator drain plug. thermostat and connections for leakage and damage.

Thickness of lining: Limit 2. 2. it is in satisfactory condition. leakage and damage. scuffing or worn spots. tire or chassis. do not require periodic lubrication. Replace them if defective. 19. 2. Replace complete set of pads if defective.) 2.DRlVE SHAFT BOOTS (Inspect for grease leaks and damage) 1. do not require periodic lubrication. If the oil level is slightly below the filler hole. severe surface cracking. leakage and damage. Inspect the dust cover and boots for proper sealing. (If the fabric casing of the hoses is exposed by cracks or abrasion in the rubber hose cover. These components. Caution The pads for the right and left wheels should be replaced at the same time. Never “split” or intermix brake pad sets.08 in. Faulty installation. 18. which are permanently lubricated at the factory. Eventual deterioration of the hose may occur with possible bursting failure. Correct length. casing twisting or interference with wheel. Damaged seals and boots should be replaced to prevent leakage or contamination of the grease. which are permanently lubricated at the factory. The hoses should be checked for: 1.00-52 GENERAL . These components. 17. TSB Revision . BRAKE HOSES (Check for deterioration or leaks) Inspection of brake hoses and tubing should be included in all brake service operations. Damaged boots should be replaced to prevent leakage or contamination of the grease.Maintenance Service 15.DlSC BRAKE PADS (Inspect for wear) Check for fluid contamination and wear.0 mm (. REAR AXLE OIL (LIMITED-SLIP DIFFERENTIAL) (Check oil level) . the hoses should be replaced. Replace it if defective.) 14woo95 16. Inspect the boots for proper sealing.AWD Remove the filler plug and inspect the oil level at bottom of filler hole. pulling. All four pads must be replaced as a complete set.BALL JOINT AND STEERING LINKAGE SEALS (Inspect for grease leaks and damage) 1.

“SRS” WARNING LIGHT CHECK When the ignition key is turned to “ON” or engine started. and push the spring horizontally toward the inside of the unit.gs3 GW LSS GAWR L8S KG FR.. (2) Remove the rear console assembly.. function. I. etc.PATERN-OlI.) The SRS must be inspected by an authorized dealer 10 years after the car manufacture date shown on the certification label located on left front door latch post.LSL-0. Do not use excessive force to raise the lock lever. (Refer to GROUP 52A .PIND THEFY PREVENTION STANDARDS IN EEFECT C. connection to wiring harness. %YR KG kF T”. SRS COMPONENTS VISUAL CHECK (1) Turn the ignition key to the “LOCK” position. This means that the system is functioning properly.~. The SRS system is designed to retain enough voltage to deploy the air bag even after the battery has been disconnected.S “E”lCLE CONKWS T O I\LL APPLlCABLE FEDERAL MOTOR VEHICLE S FETY BUMPER. : 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Y. . Caution 1. Caution Wait at least 60 seconds after disconnecting the battery cable before doing any further work.Floor Console. BY MITsuslsHI MOTCSIS coi?PoFsAnoN LPR . YEHICLE TYPE:PASSENGER CAR ~--___ ~900122 oOFOOI 00002289 Maintenance Items SRS warnina liaht Battery 219FOlO 1.Maintenance Service 20.GENERAL . TSB Revision . 2..N. THE DATE OF MNUFACTURE SHOWN A8O”E. disconnect the negative battery cable and tape the terminal. SRS MAINTENANCE (SRS component check: damage. Serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cable is disconnected.~ {MFD. 2. the “SRS” warning light will illuminate for about 7 seconds and then turn off.) (3) Release the lock of SDU connector in accordance with the following procedure: In case that there is no notch on the lock lever (Type 1) Place a flat tip screwdriver against the lock spring (metal section) of the connector lock lever as shown in the illustration. Manufacture date Certification label \ . Do not insert the screwdriver into the gap between the lock lever and the lock spring.

(2) Check front upper frame lower and sensor brackets for deformities or rust. Replace sensor and/or wiring harness if it fails visual check. Caution The SRS may not activate properly if SRS diagnosis unit is not installed properly.) 7 / 2-2 SRS Diagnosis Unit (SDU) (1) Check SDU case and brackets for dents.Maintenance Service In case that there is a notch on the lock lever (Type 2) Place a flat tip screwdriver against the lock spring (metal section) at the lock lever notch as shown in the illustration.] TSB Revision I . cracks. (3) Check wiring harness (for front impact sensor) for binds.SRS Diagnosis Unit (SDU).GENERAL . (2) Check connectors and lock lever for damage. [Refer to GROUP 528 . deformities or rust. Check sensors to ensure the arrow marks face the front of the vehicle. (Refer to GROUP 52B . Replace SDU if it fails visual check. connector for damage. 2-1 Front Impact Sensors (1) Remove right and left front splash shield extensions. (4) Disconnect the red 14-pin connector from the SDU. Caution The SRS may not activate properly if a front impact sensor is not installed properly. which could result in serious injury or death to the vehicle’s driver and passenger.Service Precautions and Front Impact Sensors. Caution Do not use excessive force to raise the lock lever. and terminals for deformities. and push the spring toward the unit. and terminals for deformities or rust. which could result in serious injury or death to the vehicle’s driver and passenger.

Maintenance Service 2-3 Air Bag Module. Steering Wheel and Clock Spring 00-55 L <Up to 1993 models> Ring gear Rotor Screw Caution label <Driver’s side> To cruis cvitch mote control itch (radio) b remote control switch To air bag module <From 1994 models> LJ Ring gear Flat c Rotor Screw SRS diagnosis unit Air bag module \ <Driver’s side> Gv’--$k&ibration Cable end support t19F0-246 00002290 TSB Revision .GENERAL .

Maintenance Service <Passenger’s side> Air bag module Glove b& assembly Z19FO250 (1) Remove air bag module from steering wheel. . cracks or deformities.00-56 <From 1994 models> GENERAL .) Caution When disconnecting the air bag module-clock spring connector. Caution The removed air bag module should be stored in a clean.cup to 1993 models> Pad cover (2) Check pad cover for dents. (Refer to GROUP 52Ei3 . TSB Revision .Air Bag Module and Clock Spring. dry place with the pad cover face up. take care not to apply excessive force to it.

(5) Check harness (built into steering wheel) and connectors for damage. _.\\ \ \i I3 Pad cover Pad cover :Passenger’s side> Z19FO250 00002291 (3) Check hooks and connectors for damage. cracks or deformities. and harness for binds. . terminals deformities.Maintenance Service :From 1994 models> :Driver’s side> 00-57 -T. and terminals for deformities. (4) Check air bag inflator case for dents.GENERAL . :From 1994 models> :Driver’s side> Inflator case <Passenger’s side> TSB Revision . \_ . Conli.

Air Bag Module and Clock Spring. Doing so may damage the collapsible column mechanism. 1 TSB Revision . Caution If the clock spring’s mating mark is not properly aligned. 6 SRS diagnosis unit Z19FO109 <From 1994 models> To aicbag module To SRS diagnosis unit (10)Visually check the clock spring case and the gears for damage. obstructing normal operation of the SRS and possibly leading to serious injury to the vehicle’s driver and passenger. Caution Do not hammer on the steering wheel. (Refer to GROUP 52B . (7) Remove the steering column covers. the steering wheel may not be completely rotational during a turn.Instrument Panel.Maintenance Service (6) Remove the steering wheel by using special tool. or the flat cable within the clock spring may be severed. install the clock spring to the column switch.) (8) Remove the clock spring.) :Up to 1993 models> To air bag module (9) Check clock spring connectors and protective tube for damage. (Refer to GROUP 52A .00-58 GENERAL . after turning the vehicle’s front wheels to straightahead position. (11)Align the mating mark and “NEUTRAL” position indicator and. and terminals for deformities.

(Refer to GROUP 52B . which could result in serious injury or death to the vehicle’s driver and passenger.) Caution The SRS may not activate properly if any of the above components is not installed properly.) Caution The SRS may not activate properly if SRS harnesses or connectors are damaged or improperly connected. 2-4 Front Wiring Harness and Body Wiring Harness i 236FOO19 L (1) Check connectors for poor connections. (2) Check harnesses for binds. connectors for damage. REPLACE ANY CONNECTORS OR HARNESS THAT FAIL THE VISUAL INSPECTION. steering column covers and the air bag module. and terminals for deformities. (13)Check steering wheel for noise.Air Bag Module and Clock Spring. REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION.GENERAL . (14)Check steering wheel for excessive free play.Service Precautions. binds or difficult operation. which could result in serious injury or death to the vehicle’s driver and passenger. (Refer to GROUP 52B . TSB Revision .Maintenance Service <Up to 1993 models> 00-59 <UP to 1994 models> (12)lnstall the steering wheel.

d TSB Revision I . 2. Check the hanger rubber and brackets for damage.00-60 GENERAL . corrqsion. Check the joints and connections for looseness and gas leaks.Maintenance Service 21. EXHAUST SYSTEM (CONNECTION PORTION OF MUFFLER. PIPINGS AND CONVERTER HEAT SHIELDS) (Check and service as required) Check for holes and gas leaks due to damage. etc. 3. 1.

4G9 engine) 3M Nut Locking Part No. 8625 or equivalent ADHESIVES FOR INTERIOR TRIM Application Adhesion of polyvinylchloride sheet Adhesion of door weatherstrip to body Sealing between grommet or packing and metal seal Adhesion of headlining and other interior trim materials Adhesion of fuel tank to pad Recommended brand 3M Part No. Joints. 8513 or equivalent 3M Part No. 8660 or equivalent 3M ATD Part No. front panel and the like joints i+. 8080 or equivalent BODY SEALANT Application Sealing of sheet metal. body side panel. 8531 or 3M ATD Part No. Fender panel.Main Sealant and Adhesive Table 00-6 1 MAIN SEALANT AND ADHESIVE TABLE Li I SEALANTS FOR ENGINE ACCESSORIES Application Sealing between rocker cover and camshaft bearing cap (4G6 DOHC and 6G7 engines only) Sealing between semi-circular packing and rocker cover and between semi-circular packing and cylinder head Oil pressure switch Engine coolant temperature switch. trunk. 8011 or equivalent 3M ATD Part No. 8513 or equivalent 3M ATD Part No. drip rail. Water pump. 4171 or equivalent Recommended brand 3M ATD Part No.Sealing of tailgate hinges Recommended brand 3M ATD Part No. Engine coolant temperature gauge unit (large size) Engine coolant temperature gauge unit (small size. MD091056 only) Oil pan (except 4G5. Rear combination lamp Recommended brand 3M ATD Part No. Therm0 valve. 8509 or equivalent ADHESION WITH RIBBON SEALER Application Waterproof film for door. 4G6. 8646 or equivalent 1 TSB Revision . 8660 or equivalent MITSUBISHI GENUINE Part No.GENERAL . Mud guard. floor. EC-l 368 or equivalent 3M ATD Part No. 8001 or 3M ATD Part No. Engine coolant temperature sensor. Splash shield. Thermostat case (4G9. 6Al engine only) SEALING BETWEEN GLASS AND WEATHERSTRIP Application Sealing between tempered glass and weatherstrip Sealing between body flange and weatherstrip Sealing between laminated glass and weatherstrip Recommended brand 3M ATD Part No. EC-1368 or 3M ATD Part No. MD970389 or equivalent I Oil pan. Therm0 switch.

fan. 8864 or equivalent TSB Revision . pulley and gear connections Sealing of small recess or flange surface Steering angle stopper bolt (jeep) 3M Nut locking Part No. 4170 or equivalent UNDERCOAT Application Undercoat Recommended brand 3M ATD Part No.00-62 GENERAL . 4171 or equivalent Recommended brand 3M Stud locking Part No. 8155 or equivalent ANAEROBIC FAST BONDING ADHESIVE Application Fixing of bolts and screws Tightening of drive gear to differential case l l Bolts for coupling tilt steering upper column with lower column Fixing of bearing.Main Sealant and Adhesive Table CHASSIS SEALANT ball joint and linkage ox packing and shims ousing rack support cover and top cover of knuckle arm flange FAST BONDING ADHESIVE Application Adhesion of all materials except polyethylene. fluorocarbon resin or other materials with highly absorbent surface Recommended brand 3M ATD Part No. polypropylene.

. . . . . . . . . .. . . 7 Basic Idle Speed Adjustment . .. . . .. . . . . . .. ... . . . . .. . . . . ..*. . . . . . . . . 15 . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . .. . 3 Service Specifications . . . . 4 SPECIFICATIONS . . . . . . . . . . .. . ... . . . . . .. . . . . . . .. . . . .. . . 13 7 Idle Mixture Check . . . . . . . . .. . . . . . . . . 31 TROUBLESHOOTING . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . ... .. . . .. . . . . .. .. . . . . . . . . 2 TIMING BELT . .. . . . . . . .. . . . . . . . . . . . . . 12 Ignition Timing Check . .. . . .. .. . . .. . . .26 CYLINDER HEAD GASKET .. 28 ENGINE ASSEMBLY . .. . . .. . . . . .. . . . . ..ENGINE CONTENTS CAMSHAFT OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 6 / Li OIL PAN AND OIL SCREEN . . . . 9 Lash Adjuster Check .. . . . . . . Refer to GROUP 13A Compression Pressure Check .. . . .. . . . . .. . . . . . . . . . . . . . . .. .. . . . . . . . .. . 18 ENGINE OIL COOLER . . 11 Dashpot Check and Adjustment . . . id . . . . . .. . ~. . . . . . 2 General Specifications . . . . . 15 Lash Adjuster Replacement . .. . . Drive Belts Tension Adjustment . . 25 CRANKSHAFT REAR OIL SEAL . . . . . . . .. .. . -23 ON-VEHICLE SERVICE . . . . 17 Manifold Vacuum Check . . . . . . . . . . . . m . . . . . .. .. . . . . . . . ... . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . .*. .. . . . . . 36 SPECIAL TOOLS . .. . m . . . . . . . . 21 CRANKSHAFT FRONT OIL SEAL . . . . 14 Curb idle Speed Check .. . . . . . .*. . . .. . . .. . 2 Sealants . . . ..

) ENGINE . DOHC 6 91 .Specifications Non-Turbo V-type.) Stroke mm (in.4) Turbo V-type.0 (2. DOHC 6 91 .in.4) SERVICE SPECIFICATIONS HC concentration ppm NOTE *I: 1992 models *2: From 1993 models 100 or less TSB Revision .) Piston displacement cc (cu.992) 2.587) 76.11-2 SPECIFICATIONS GENERAL SPECIFICATIONS Items Type Number of cylinders Bore mm (in.l (3.992) 2.l (3.587) 76.0 (2.972 (181.972 (181.

MD970389 or equivalent 3M ATD Part No.0 (.5-12.149-.5-9.0 (.0-5.37-.5 (.5 (.22) 3.20) 4.41-.) / L Timing belt For power steering pump Inspection New belt Used belt Amount of projection of auto tensioner rod mm (in.53) 7.16-.14-.l6-.16) 4.5 (.) (distance between the tensioner arm and auto tensioner body) SEALANTS I Items Oil pan Rocker cover Specified sealant MITSUBISHI GENUINE Part No.5-4.5 (.0-5.14-.20) 9.5-4. 8660 or equivalent I TSB Revision .49) 3.35) 10.177) Limit 11-3 - L Drive belt tension N (Ibs.0 (.0-5.Specifications Items Standard value For generator (Vehicle without air Inspection conditioning) New belt Used belt For generator and air conditioning compressor Inspection New belt Used belt For power steering pump Inspection New belt Used belt Drive belt deflection mm (in.16) 4.22) 3.30-.5-l 3.ENGINE .8-4.0 (.0-5.) <Reference value> For generator (Vehicle without air Inspection conditioning) New belt Used belt For generator and air conditioning compressor Inspection New belt Used belt 350-600 (77-132) 650-850 (143-187) 450-600 (99-132) 350-600 (77-132) 650-850 (143-187) 450-600 (99-132) 250-500 (55-110) 500-700 (110-154) 350-400 (77-88) 4.0 (.16-.5 (.16-.

I ENGINE . refer to GROUP 00 .Special Tools SPECIAL TOOLS Tool Tool number and name MB991341 Scan tool (Multi-use tester cMUT>) ROM pack (For the number.Precautions before service.) MB991 502 Scan tool (MUT-II) Supersession MB991 341 Application Up to 1993 models Idle speed check d I ~ - MB991502 All models Idle speed check I pack - ROM MD998051 Cylinder head bolt wrench MD998051 -01 Loosening and tightening of cylinder head bolt L/ I T MD998727 oil pan remover service General tool We a scraper and exercise care) Removal of the oil pan MD998761 Camshaft oil seal installer Installation of camshaft oil seal MD998782 Valve lifter set - Removal of rash adjuster TSB Revision .

ENGINE . together with the crankshaft pulley bolt. Adjustment of timing belt M D998767 \ vI’ Q I Q MD99871 7 Tensioner pulley socket wrench Installation of crankshaft front oil seal L I @fQ Crankshaft front oil seal installer MD99871 8 Crankshaft rear oil seal installer Installation of crankshaft rear oil seal 1 TSB Revision . etc.. Use only the large nut included in MB990998. when the piston and connecting rod assembly is assembled. P MD998754 Crank pulley holder Supersession MB990767-01 Application 11-5 -l L Supporting the sprocket and shaft pulley when attaching or detaching them Supporting the crankshaft pulley when crankshaft bolt and pulley are removed or reinstalled. <SOHC> *. I 1 fJ!s Fl fB MB990998* Crankshaft wrench Q Used if the crankshaft needs to be rotated to attach the timing belt.Special Tools Tool Tool number and name MB990767 End yoke holder ..

Troubleshooting Oil relief valve stuck (opened) Excessive bearing clearance Oil pressure too high Noisy valves Oil relief valve stuck (closed) Incorrect lash adjuster Repair relief valve Replace bearings Repair relief valve Replace lash adjuster Connecting rod noise/ main bearing noise TSB Revision I .11-6 TROUBLESHOOTING ENGINE .

0-5.49) (55-110) 9.5-4. Standard value: <Vehicle without air conditioning> Items <Vehicle without air conditioner> Ge. Check that the V-ribbed belt is not resting on the tension pulley or idler pulley flange.5 (.5-9. check the belt tension for standard value.53) 350-400 500-700 (110-154) ( 7 7 . check that the V-ribs are properly fit without misalignment.used belt 450-600 650-850 (143-187) (99-132) Eior . 2.N (lb.0 (.22) Adjustment value .49) Tension Pulley Crankshaft pulley OlFOOO7 ing pump mm (in) <Reference value> <Vehicle with air conditioner> <Vehicle with air conditioning> Adjust- Items Tension For genera.) 250-500 500-700 7.0 (.14-.erator Idler pulley Tens$. Air conditioning compressor pulley Crankshaft pulley OlFOO84 00002117 For power Tension N (Ibs.used belt Tension For genera.8 8 ) 7.5-13..41-.16-.%) tor Deflection mm (in.53) (110-154) (77-88) steering Deflection pump mm (in.35) 10.on pulley Check value 350-600 (77-132) 4.16) 4.37-.) to the belt to check the deflection for standard value.0 (.ENGINE .) tar and Check value 350-600 (77-l 32) ment value .5-9. Caution 1.0-5. check the pulley for scoring. When installing the V-ribbed belt. If creaking or slippage is observed.Deflection For 450-600 650-850 (143-187) (99-132) 3.N (Ibs.) <Reference value> Tension power N (Ibs.5 (.5 (.0 (.) s t e e r . check the belt for wear.On-vehicle Service 11-7 ON-VEHICLE SERVICE DRIVE BELTS TENSION ADJUSTMENT (1) Check that the belts are not damaged and are properly fit into the pulley grooves. (2) With belt tension gauge set to the belt midway between the pulleys as shown in the illustration. 3.30-.) <Reference value> [sion I .37.5 (.5 (. in addition to sag inspection.new belt Adjustment value . damage.5-12. or breakage on the pulley contact surface.new belt Adjust- ment value .20) 250-500 (55-110) 9.41-.5-12.5-13.16-. Or apply a force of 98 N (22 Ibs.30-.35) 350-400 10.

(8) Install under covers. if necessary. (2) Loosen the tension pulley fixing bolts in the order of B and A. (7) Check the belt tension. ‘d Crankshaft pulley ZOlN0074 00002096 TSB Revision . into the opening at the end of the tension pulley bracket. Readjust.. Readjust.).). Readjust.H. (4) Adjust belt deflection with adjusting bolt. ey Adju bolt Li I Fixing nut 201F0008 I Generatormllev POWER STEERING PUMP DRIVE BELT DEFLECTION ADJUSTMENT (1) Insert an extension bar (insertion depth 12. (3) Use straight handle box wrench to tighten fixing nut.) (5) Give the crankshaft two turns in normal direction (clockwise) to run in the belt. (4) Tighten the tension pulley fixing bolts in the order of A and B. (2) Adjust belt deflection with adjusting bolt. Tightening torque: 42 Nm (30 ft. (5) Tighten fixing bolt. if necessary. (4) Run the engine one time or more. (6) Check the belt deflection.11-8 Generatorpullev ENGINE .lbs. side L. (6) Run the engine one time or more. (3) Move the extension bar installed to the tension pulley in the direction of arrow to adjust the belt tension. etc.H. GENERATOR AND AIR CONDITIONING COMPRESSOR DRIVE BELT DEFLECTION ADJUSTMENT <Vehicle with air conditioning> (1) Use straight handle box wrench to loosen tension pulley fixing nut.On-vehicle Service GENERATOR DRIVE BELT TENSION ADJUSTMENT <Vehicle without air conditioning> (1) Remove front under cover panel <Vehicle with active aero> (Refer to GROUP 51 . (3) Loosen tension pulley fixing nut.Aero Parts.7 mm). (5) Check the belt deflection. if necessary. (2) Remove under covers (front L.

(14)Disconnect the jumper wire connected at step (8). ground the ignition timing adjusting terminal.ENGINE . the ignition timing will not be the basic timing but be ordinary timing. l Engine coolant temperature: 80-95°C (176-203°F) l Lights. tighten mounting nut taking care not to move the crank angle sensor. electric cooling fan and accessories: OFF l Transaxle: neutral (P for AIT) (2) Insert a paper clip to the engine speed detection connector (blue). (5) Check curb idle speed. (6) Turn OFF the ignition switch. Curb idle speed: 700 f 100 rpm NOTE The engine speed indicated is a third of actual speed. (7) Remove the water-proof female connector from the ignition timing adjustment connector (brown). (9) Start the engine and run at idle. (13)Turn OFF the ignition switch. NOTE Grounding this terminal sets the engine to the basic ignition timing. \/4-l ii Basic ignition timing: 5” BTDC f 2“ (1l)lf not within the standard value range. (8) Using a jumper wire. (1O)Check basic ignition timing. (4) Start the engine and run at idle. In other words. the reading of the tachometer times 3 is actual speed. and to the clockwise advances it. NOTE Do not use the scan tool. Turning it to the counterclockwise retards timing. (3) Set the timing light.On-vehicle Service IGNITION TIMING CHECK 11-9 4992 models> (1) The vehicle should be prepared as follows before the inspection and adjustment. - 27F1109371 1 TSB Revision . (12)After adjustment. If tested with the scan tool connected to the data link connector. and connect a tachometer to the paper clip. loosen the crank angle sensor mounting nut and adjust by turning the crank angle sensor.

Actual ignition timing: Approx.On-vehicle Service (15)Check to be sure that the idling ignition timing is the correct timing. (7) Disconnect the waterproof female connector from the ignition timing adjusting connector (brown). NOTE Do not use the scan tool. ground the ignition timing adjusting terminal. NOTE Grounding this terminal sets the engine to the basic ignition timing. (9) Start the engine and run at idle. l Engine coolant temperature: 80-95°C (176-203°F) l Lights. electric cooling fan and accessories: OFF l Transaxle: neutral (P for A/T) (2) Insert a paper clip to the engine speed detection connector Engines speed detection # connec_ t tor (blue) 7 (blue). even-under normal operation. IGNITION TIMING CHECK <From 1993 models> (1) The vehicle should be prepared as follows before the inspection and adjustment. (6) Turn OFF the ignition switch. (5) Check curb idle speed. If tested with the scan tool connected to the data link connector. In other words. (3) Set the timing light. the reading of the tachometer times 3 is actual speed. (4) Start the engine and run at idle. (8) Using a jumper wire. (10)Check basic ignition timing. the ignition timing will not be the basic timing but be ordinary timing. and connect a tachometer to the paper clip.II-IO ENGINE . (2) And it is automatically further advanced by about 5 from 15” BTDC at higher altitudes. 15” BTDC NOTE (1) Ignition timing is variable within about +7”. Basic ignition timing: PBTDC rt 3” TSB Revision . Curb idle speed: 700 + 100 rpm NOTE The engine speed indicated is a third of actual speed.

and check the MFI components. In other words.Chart Classified by Problem Symptoms.On-vehicle Service II-II (1l)lf basic ignition timing is not within the standard range. refer to GROUP 13A . electric cooling fan and accessories: OFF l Transaxle: neutral (P for A/T) (2) Connect a tachometer. Standard value: 5” BTDC + 2” 4992 models> 5” BTDC f 3” <from 1993 models> NOTE Check the ignition timing with the scan tool not connected to the data link connector. (10)Check the idle speed. if not. TSB Revision . Curb idle speed: 700 f 100 rpm NOTE (1) The idling speed is automatically regulated by the idle-speed control system.On-vehicle Inspection of MFI Components. (5) Start the engine and let it idle. even under normal operating.) (3) Set a timing light. (6) Check the ignition timing is the standard value. the reading of the tachometer times 3 is actual speed. (2) The engine speed indicated is a third of actual speed. (12)Disconnect the jumper wire connected at step (8). (7) Remove the jumper wire from the ignition timing adjusting terminal.ll-9. (8) When using the scan tool. (9) Idle the engine for two minutes. ground the ignition timing adjusting terminal. (Refer to P. (4) Using a jumper wire. (2) And it is automatically further advanced by about 5” from 15”BTDC at higher altitudes. check the crankshaft position sensor by reference to GROUP 13A . 15” BTDC NOTE (1) Ignition timing is variable within about *7”. Actual ignition timing: Approx. CURB IDLE SPEED CHECK (1) The vehicle should be prepared as follows before the inspection. (1l)lf there is a deviation from the standard value. l Engine coolant temperature: 80-95°C (176-203°F) l Lights. (13)Check to be sure that the idling ignition timing is the correct timing.ENGINE . turn OFF the ignition switch and connect the tester to the data link connector. adjust.

set a tachometer or connect the scan tool to the data link connector. electric cooling fan and accessories: OFF l Transaxle: P range (2) Make sure that the basic ignition timing is of a standard value.000 mV range. 2 minutes. replace the three-way catalyst. Standard value: 5”BTDC f 2” cl992 models> 5”BTDC 4 3” <from 1993 models> (3) After turning the ignition switch OFF.ll -9. NOTE For tachometer setting procedure.) l Fuel pressure 0 Injectors l Ignition coil. set the vehicle in the following condition. check the following items. 1 TSB Revision . l Engine coolant temperature: 80-95°C (176-203°F) l Lights. (6) Check the CO concentration and HC concentration with the engine at idle. spark plug cables and spark plugs l Leaks in EGR svstem and EGR valve l Evaporative emission control system 0 Compression pressure NOTE If CO and HC concentrations exceed the respective standard values despite the fact that the results of the inspection made on all items are normal.500 rpm for approx.II-12 ENGINE . heated oxygen sensor output signals change within a O-400 mV range and a 600-l . (4) Start the engine and run at 2. l Diagnostic output l Closed loop control (if closed loop control is performed normally. Standard value: CO concentration: 0. (5) Set the CO tester and HC tester.On-vehicle Service IDLE MIXTURE CHECK (1) Before inspection. refer to P.5 % or less HC concentration: 100 ppm or less (7) If the standard value is exceeded.

TSB Revision . Standard value: 2. rom 1994 Non Turbo M/T model or California> (5) Open the throttle valve until the dashpot rod makes a full stroke.ENGINE . (9) Release the throttle valve to make sure that the engine speed slowly drops to the idle speed.ll-9. refer to P. (2) Set the vehicle in the following conditions before dashpot inspection and adjustment.On-vehicle Service II-13 DASHPOT CHECK AND ADJUSTMENT <Turbo and From 1994 Non Turbo M/T model for California> (1) Inspect the idle speed before inspection and adjustment of the dashpot. loosen the lock nut on the rod and turn the rod to make adjustment for proper dashpot starting engine speed.200 k 200 rpm from 1994 Non Turbo for California> (8) If the engine speed is not within the specified limit. (4) Start the engine. l Engine coolant temperature: 80-95°C (176-203°F) l Lights. electrical cooling fan and accessories: OFF l Transaxle: neutral (3) Set the tachometer or connect the scan tool to the data link connector (white). (6) Close the throttle valve slowly to find a point where the throttle lever contacts the dashpot rod (a point where the dashpot starts to contract). NOTE For the tachometer setting procedure. Hold the throttle valve at this point. (7) Check the engine speed (at which the dashpot starts to operate).

in the cylinder due to the cracks in the cylinders. electric cooling fan and accessories: OFF l Transaxle: Neutral (P for A/T) (2) Remove the spark plug cables. If a compression measurement is performed with water. these substances heated to a very high temperature will blow off the spark plug mounting holes and could be dangerous. 959 kPa (139 psi) [250-400 rpm] <Turbo> min. l Engine coolant temperature: 80-95°C (176-203°F) l Lights. and then check for foreign substances deposited on the shop towel. Place the vehicle in the following conditions. 792 kPa (115 psi) [250-400 rpm] (8) Measure the compression pressure in each of the cylinders and check that the difference in compression pressure between the individual cylinders is less than the limit value.11-14 ENGINE .270 kPa (185 psi) [250-400 rpm] <Turbo> 1. and crank the engine to measure the compression pressure. 2. (3) Remove all of the spark plugs.080 kPa (156 psi) [250-400 rpm] Limit: <Non-Turbo> min. Caution 1. NOTE By so doing the engine control module stops performing ignition and fuel injection. oil. 98 kPa (14 psi) 1 TSB Revision .On-vehicle Service COMPRESSION PRESSURE CHECK (1) Prior to inspection. (4) Disconnect the crankshaft position sensor connector.II a compression gauge in a spark plug mounting (7) Set the throttle valve in a fully opened position. Limit: max. fuel. etc. keep away from the spark plug mounting holes. (6) ~I. When you crank the engine. crank the engine. check to ensure that the engine oil. starter motor and battery are in proper condition. Standard value: <Non-Turbo> 1. (5) Cover the spark plug mounting holes with a shop towel.

NOTE This erases the trouble code due to the disconnection of the crankshaft position sensor connector.ll-9. pour in a small amount of engine oil through the spark plug mounting hole. and repeat Steps (7) through (8). (4) Start the engine and check that idle speed is within the standard value range. (5) Check the manifold vacuum. then it is likely that either the piston ring.Hg) LASH ADJUSTER CHECK NOTE If the clanging noise due to the lash adjuster produced immediately after the engine has started or during operation persists. cylinder wall surface or both are worn or damaged. and then re-connect it. Limit: 450 mmHg (18 in. l Engine coolant temperature: 80-95°C (176-203°F) l Lights. perform the following checks. poor valve contact. 2) <Turbo> Install a three-way joint to the vacuum hose connected between the air intake plenum and the fuel pressure solenoid valve and connect a vacuum gauge. (iO)Re-connect the crankshaft position sensor connector.ENGINE . 2) If the small amount of oil poured in does not cause the compression pressure to rise. and accessories: OFF l Transaxle: Neutral (P for A/T) (2) Connect a tachometer.) (3) 1) <Non-Turbo> Install a three-way joint to the vacuum hose connected between the air intake plenum and the fuel pressure regulator and connect a vacuum gauge to the joint. NOTE (1) If the engine oil level is low.On-vehicle Service II-15 (9) If there is a cylinder in which the compression pressure or pressure difference is beyond the limit value. electric cooling fan. MANIFOLD VACUUM CHECK (1) The vehicle should be repaired as follows before the inspection. leave it disconnected for more than 10 seconds. (12)Erase the diagnostic trouble code using the scan tool or disconnect the negative (-) terminal of the battery. (11) Re-mount the spark plugs and spark plug cables. then valve seizure. 1) If the small amount of oil poured in causes the compression pressure to rise. (1) Check the engine oil. and add or replace if necessary. / TSB Revision . or leakage from the gasket is suspected. (Refer to P. the air drawn in from the oil strainer will be trapped in the oil passage.

This is the same phenomenon that occurs when the valve clearance is adjusted to an excessive dimension. (2) After a long period of parking during which the oil in the oil passage goes away. 1 is positioned at the top dead center of the compression. 5) In the same procedure as Step (3). Then perform inspection in accordance with steps (1) through (5) to make sure that there is no abnormality. No.4 No. The lash adjuster will be drawn too far in. 2) Set the engine so that cylinder No. In addition. check the lash adjuster. the air could enter the high pressure chamber. agitation of the oil by the crankshaft could cause a large amount of air to enter the oil. when replacing the lash adjuster. the normal condition will be.3 No. If the rocker arm goes down readily.000 rpm slowly (in 30 seconds) and then decelerate it to the idling speed slowly (in 30 seconds). once trapped. the air in the high pressure chamber will be compressed while the valve is in the opened position. it will take some time before the oil is re-supplied to the lash adjuster. it means that the air has escaped from the high pressure chamber of the lash adjuster and that the lash adjuster has regained its normal functions. is not readily separated from the oil. and will produce noise when the valve closes. Therefore. In this case. check the rocker arm at the area indicated by the black arrow mark.II-16 ENGINE .On-vehicle Service (2) If the engine oil level is higher than the specified level. 6) Push down the rocker arm at a portion located right above the lash adjuster. (3) A deteriorated oil contains a large amount of air. Replace it with a new one in accordance with step (4). (2) Start the engine and slowly race* it several times (less than 10 times).6 27EN0530 TSB Revision . (3) If any abnormal noise is not eliminated by racing. If racing the engine causes the noise to die away. 4) Slowly turn the crankshaft 360 degrees clockwise. because the air. 3) Press the rocker arm at the area indicated by the white arrow mark to check whether the rocker arm is lowered or not. When the engine is started. the air might enter the high pressure chamber. be sure to remove air positively from the lash adjuster before installation. * Accelerate the engine from the idling speed to 3. the lash adjuster is defective.2 No.1 No. the oil in the lash adjuster will decrease. 1) Stop the engine.5 No. restored if the air escapes from the lash adjuster. NOTE (1) When the vehicle is parked on a slope for a long period. If the air trapped due to these causes enters the high pressure chamber in the lash adjuster.

Using the special tool. place the pivot side of the rocker arm on the lash adjuster. Therefore. Therefore. the lash adjuster is in the normal condition. the piston interferes with the valve when the valve is pushed down. LASH ADJUSTER REPLACEMENT Refer to LASH ADJUSTER CHECK. the rocker arm located at the valve lifted by the cam cannot be removed. refer to the Engine Service Manual. 4. if the rocker arm is felt very stiff or cannot be pushed down when it is pushed. Therefore. Install a new lash adjuster having air removed to the cylinder head. TSB Revision I . install the roller rocker arm. (4) Lash Adjuster Replacement Procedure Caution In the cylinder from which the lash adjuster is removed. the lash adjuster can be judged accurately to be defective or not.On-vehicle Service 11-17 NOTE (1) If the leak-down test is performed. ‘push down the valve and place the slipper side of the rocker arm on the valve stem end. 1. turn the crankshaft to keep the piston position down.ENGINE . check for other cause of noise. (2) For the leak-down test procedure or the procedure for removing air from the lash adjuster. NOTE When the roller rocker arm is installed. In addition. With the valve pressed down by the special tool. Then. 2. 3. press the valve down and remove the roller rocker arm. In addition. turn the crankshaft to keep the cam from lifting the valve before removal of the rocker arm. Pull out the lash adjuster from the cylinder head.

Cruise Control. LA5 Nm . Vapor hose connection 9.) l Hood Installation (Refer to GROUP 42 .) 12.) (AIT: Refer to GROUP 23 .) l Radiator Removal (Refer to GROUP 14 .Transaxle Assembly.) 0 Cruise Control Pump and Link Assembly Installation (Refer to GROUP 13G . Accelerator cable connection 2. EGR temperature sensor connector <Vehicles for California> 11.Charge Air Cooler.lt 13. Air conditioning compressor 16.Transaxle Assembly. Generator harness connection 14.) l Engine Oil Supplying (Refer to GROUP 00 .Transaxle Assembly.Maintenance Service.) IV I 5 Nm 4 ft.II-18 ENGINE ASSEMBLY ENGINE . Brake booster vacuum hose connection 3.) l Transaxle Assembly Installation (M/T Refer to GROUP 22 .Exhaust Pipe and Main Muffler.Radiator.Hood.) (A/TI Refer to GROUP 23 .Engine Control.Exhaust Pipe and Main Muffler.) l Accelerator Cable Adjustment (Refer to GROUP 13F . Booster vacuum hose connection <Turbo> 4. Heater hose connection 10.lbs.) l Transaxle Assembly Removal (M/TI Refer to GROUP 22 . - ZOlFOO43 Removal steps 1. Oil cooler pipes connection <Turbo> :i: TSB Revision . Oil pressure switch connector (Power steering) 18. 40-45Nm 29-33 ft. Solenoid valve assembly 8.Charge Air Cooler. Drive belt (Power steering) (Refer to P. Ground cable connection ( 7.Cruise Control. Fuel high pressure hose connection 6.) l Air Hose and Air Pipe <Turbo> Installation (Refer to GROUP 14 .) 13.ll-7.) l Hood Removal (Refer to GROUP 42 .) l Cruise Control Pump and Link Assembly Removal (Refer to GROUP 13G .) l Post-installation Operation l Radiator installation (RefertoGROUP 14-Radiator. Power steering oil pump 17.Transaxle Assembly.) l Front Exhaust Pipe Installation (Refer to GROUP 15 .Hood.) l Front Exhaust Pipe Removal (Refer to GROUP 15 .lbs. Drive belt (Generator and air conditioning) (Refer to P-1 l-7.Engine Assembly REMOVAL AND INSTALLATION Pre-removal Operation High Pressure Fuel Hose Release of Residual Pressure(RefertoGROUP 13A-ServiceAdjustment Procedures. Heated oxygen sensor connector <Tu rho> 15.) l Air Hose and Air Pipe <Turbo> Removal (Refer to GROUP 15 . Fuel return hose connection 5.4 ft.

Engine assembly YOTE 1992 model 1: 1993 model 1994 model TSB Revision . Olt-““. \ 36 \ 36. Variable induction motor connector <Non-Turbo> 34.lbs. Front roll stopper bracket and engine connection bolt 38.lb.A( 37.Engine Assembly II-19 loo-120 Nm zo. / f-j /- 70 Nm 51 ft. Engine coolant temperature switch connector (Air conditioning)*2 27. Iii&$. Crankshaft position sensor and camshaft position sensor connector*2 26. Ignition power transistor connector 32.8 7 ft. Rear roll stopper bracket and engine connection bolt 4C.Foo58 7 2 . Engine coolant temperature sensor connector 28. . Crankshaft position sensor connector*’ 25. Fuel injector harness connector 23.lbs. 51-58 ft. Oil pressure switch and oil pressure gauge unit connector 22. Engine mounting bracket 36.s. 00002118 19.ENGINE . Fuel injector connector 33. Ignition coil connector 31. Knock sensor connector 24. .Bd 35. TPS connector 21. Idle air control motor connector 20. Engine coolant temperature gauge unit connector 29.z3 \\g--4 i ’ g-g p& . Condenser connector 30. oxygen sensor connector (B. .

Engine Assembly REMOVAL SERVICE POINTS +A. +B. hoses. +C. ENGINE ASSEMBLY REMOVAL After checking that the cables.A( ENGINE ASSEMBLY INSTALLATION When mounting the engine. AIR CONDITIONING COMPRESSOR / POWER STEERING OIL PUMP DISCONNECTION Disconnect air conditioning compressor and power steering oil pump (with the hose). NOTE The removed air conditioning compressor and power steering oil pump should be fastened (by using rope. harness connectors. INSTALLATION SERVICE POINTS . are all removed. slowly raise the chain block to lift the engine assembly upward out of the engine compartment. check to be sure that the cables. harness connectors.) in a position that will not interfere with the removal/installation of the engine assembly. use a chain block or similar arrangement to suspend the engine assembly (to the extent that there is no looseness of the chain).II-20 ENGINE . . are all in the correct position. etc. hoses. ‘L/J Eng/ine mount bracket'4OlN0052 Engine mount bracket - ZOlFOO72 1 TSB Revision . ENGINE MOUNT BRACKET REMOVAL Before removing the engine mount bracket installation bolt. etc.B( ENGINE MOUNT BRACKET INSTALLATION Attach the engine mounting bracket so that the arrow mark on the mounting stopper is in the direction as shown in the illustration. etc.

) l Accelerator Cable Adjustment (Refer to GROUP 13F . bB+ 6.) l 3 Nm 2.) l Intake Manifold Installation (Refer to GROUP 15 .) l Camshaft Position Sensor Removal (Refer to GROUP 16 .li-31.lbs. PCV hose connection . Breather hose connection 4.lbs.C+ 5.) l Timing Belt Installation (Refer to P.Nm 65 ft. Center cover (front bank) 2. .Cam Position Sensor and Crankshaft Position Sensor. Camshaft oil seals TSB Revision .Intake Manifold.ENGINE . 8660 or squivalent Removal steps 1.Intake Manifold.ll-31. 3 Nm 20 i NO&l? I Rocker cover 90’.A( 7. Spark plug cables connection 3.2 ft.) Post-installation Operation Camshaft Position Sensor installation (Refer to GROUP 16 .Cam Position Sensor and Crankshaft Position Sensor. Rocker cover +A.Engine Control. Sealant: 3M ATD Part No.Camshaft Oil Seals II-21 CAMSHAFT OIL SEALS f ki REMOVAL AND INSTALLATION Pre-removal Operation l Timing Belt Removal (Refer to P. Camshaft sprocket +B.) l Intake Manifold Removal (Refer to GROUP 15 .

C+ ROCKER COVER INSTALLATION Tighten the rocker cover bolts in the order shown in the illustration. . . .11-22 ENGINE . retighten bolts 1 to 6 to 4 Nm (2. tighten bolts in this order and then. . . 10 mm (. . . .B+ CAMSHAFT SPROCKET INSTALLATION Using a wrench at the hexagonal part of the camshaft (to prevent the crankshaft from turning). . (2) Using the special tool. . . . Caution Use care not to damage the camshaft and cylinder head. Black Rear bank . CAMSHAFT SPROCKET REMOVAL Using a wrench at the hexagonal part of the camshaft (to prevent the crankshaft from turning). . . . . . . . Caution Do not hold the camshaft sprocket with a tool. 5 bolt . . . or a damaged sprocket could result. . . I Rear bank 6 011 010 09 I Front bank 6 ZOll 1059 TSB Revision . . . . . . . . . . .) (2) Bolts are color-coded for the front and rear banks as follows: Front bank . . . . Oil seal I 20 1 MOO3 1 +B. 5 bolt in the rear bank differs from other bolts in length. . . . . . . NOTE (1) Only No. .) Except rear bank No. . . . Green (3) When the rocker cover gasket has been replaced. . . . . . . . .39 in.Camshaft Oil Seals REMOVAL SERVICE POINTS +A. Camshaft INSTALLATION SERVICE POINTS . . . 5 bolt . . loosen the camshaft sprocket bolt. Caution Do not hold the camshaft sprocket with a tool. . . . . . . .). . . . (2) Cover the tip of a screwdriver with a cloth and apply it to the cutout in the oil seal to pry off the oil seal. Rear bank No. . .A( CAMSHAFT OIL SEAL INSTALLATION (1) Apply a small amount of engine oil to the oil seal lip. tighten the camshaft sprocket bolt. . . . . 20 mm (. . . insert the oil seal. .CAMSHAFT OIL SEAL REMOVAL (1) Cut out a portion in the camshaft oil seal lip. . . . . . .9 ftlbs. .79 in. . . . or a damaged sprocket could result. . . .

Exhaust Pipe and Main Muffler. . Transaxle stay (rear) cFWD> TSB Revision 5. 43-51 ft. .) Transfer Assembly Removal and Installation cAWD> (Refer to GROUP 22 . fi .l’hs : p-.Aero Parts.) l Front Air Dam Removal and Installation <Active Aero> (Refer to GROUP 51 .Oil Pan and Oil Screen 11-23 OIL PAN AND OIL SCREEN L REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation l Engine Oil Draining and Supplying (Refer to GROUP 00 .lbs.) I I 9 Nm .ENGINE . Transaxle stay (front) 4. .) Sealant: MITSUBISHI GENUINE Part No. 201F0006 00002105 60-70 Nm 43-51 ft.lbs.lbs.Transfer Assembly. Left member 2.lbs. Oil pan .lbs.7 ft.Maintenance Service. Bell housing cover 6. i Removal steps 1. w-.) l Under Cover Removal and installation l l Front Exhaust Pipe Removal and Installation (Refer to GROUP 15 . MD970389 or equivalent 19 Nm 1A. Ihs .ibs. 36 Nm 26 ft. \ -n”. 75 Nm 54 ft. / A fi Iha 6 Nm 9 Nm 7 ft. Oil return pipes connection <Turbo> 7. Starter 3.

.z i.-‘2 / /-i: _I &A _- REMOVAL SERVICE POINT dA.F&g+ _. _ _ . o:“o’~~~:.OIL PAN REMOVAL After removing the bolts. use the special tool and a brass bar to remove the oil pan from the cylinder block.------y 1 ENGINE .11-24 MD998727 .Oil Pan and Oil Screen MD998727 -.Q L Caution Remove the oil pan gradually since the flange of the oil pan is easy to deform. : d L zL0583 j 1 ri. TSB Revision .---- ____ \ -I ._.

. etc. (2) Tap the oil seal into the cylinder block.J G -+Ypy--” :~~s~./.Camshaft Position Sensor and Crankshaft Position Sensor. Crankshaft sensing blade 3.~I~ i ZOlNOOld Eder .ENGINE .Crankshaft Front Oil Seal II-25 CRANKSHAFT FRONT OIL SEAL /’ L. Oil is. Camshaft Caution Be careful not to damage the crankshaft and the oil pump case. R~~~~~~~.7 i Removal steps 1. Crankshaft sprocket 2.~LLATlON ~ Pre-removal and Post-installation Operation l Timing Belt Removal and Installation l Crankshaft Position Sensor Removal and Installation (Refer to GROUP 16 . Crankshaft spacer +A.* 1 /Ah I INSTALLATION SERVICE POINT .A+ CRANKSHAFT FRONT OIL SEAL INSTALLATION (1) Apply a small amount of engine oil to the oil seal lip and then insert. ä A+ g: %kshaft front oil seal REMOVAL SERVICE POINT dAbCRANKSHAFT FRONT OIL SEAL REMOVAL (1) Make a notch in the oil seal lip section with a knife. (2) Cover the end of a (-) screwdriver with a rag and insert into the notched section of the oil seal. and lever out the oil seal to remove it. ~~~~. yp4 .) ZOlN004.

and insert into the notched section of the oil seal. +B. Caution Use only the specified special tools.CRANKSHAFT REAR OIL SEAL REMOVAL (1) Make a notch in the lip section of the oil seal with a knife. TSB Revision d . W-W Removal steps 1.) (A/T: Refer to GROUP 23 . otherwise the crankshaft pulley damper could be damaged.lbs.) l Clutch Cover and Clutch Disc Removal and Installation 73-77 Nm 53-56 ft. Crankshaft rear oil seal REMOVAL SERVICE POINTS +A.Crankshaft Rear Oil Seal CRANKSHAFT REAR OIL SEAL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation l Transaxle Assembly Removal and Installation (M/T Refer to GROUP 22 . (2) Cover the end of (-) screwdriver with a rag. Flywheel 4Bb . etc. FLYWHEEL REMOVAL Stop the crankshaft pulley from turning. Camshaft Caution Be careful not to damage the crankshaft and the oil seal case.Transaxle Assembly. and remove the flywheel.A4 2. and lever out the oil seal to remove it.11-26 ENGINE .Transaxle Assembly.

.03 .A( CRANKSHAFT REAR OIL SEAL INSTALLATION (1) Apply a small amount of engine oil to the oil seal lip and then insert..ENGINE . 1 TSB Revision . (2) Tap the oil seal into the cylinder block.Crankshaft Rear Oil Seal Cylinder blbck side 11-27 ~ INSTALLATION SERVICE POINT . b?ft * P I i//1 Oil s&l ZOlM0031 \ ZOl NO01 1 000021.

Cylinder head assembly . Cylinder head gasket ‘d . Rocker cover (+ .B+ 14. 4 in.Cylinder Head Gasket CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre-removal Operation l Engine Coolant Draining (Refer to GROUP 00 .ltp.) l Engine Coolant Supplying (Refer to GROUP 00 .) l Air Intake Manifold Installation (Refer to GROUP 15 .4 in.Turbocharger.Air Intake Manifold. Water inlet pipe connection (Front bank) +B. Heater hose connection 10. Pipe assembly 2. Radiator hose connection 12. 3 Nm 4 87-94 ft.) l Accelerator Cable Adjustment (Refer to GROUP 13F . Water hoses connection <Turbo> 11.) l Turbocharger Installation <Turbo> (Refer to GROUP 15 . Thermostat housing 13.) 7 0 1 AIUM 7 ZOlLO217 k sealant: 3M ATD Part Jo. Ignition coil TSB Revision 9. iO5-115 N’m Rocker cover 24Nm 17 ft.Exhaust Manifold.Air Intake Manifold.Turbocharger.lbs.ll-31. I j ‘L.lbS.‘Center covet (Front bank) 4. Blow-by hose 3. .) l Timing Belt Removal (Refer to P. ~~5pp.) (. (Non-turbo) 14 .C( 6.) l Air Intake Manifold Removal (Refer to GROUP 15 .lbs.Engine Control.) l Exhaust Manifold Installation (Refer to GROUP 15 .) 10 Nm 7 fi.J 10 Nm 7 ft.A+ 15.g~.) Post-installation Operation l Timing Belt Installation (Refer to P. Removal steps 1.Maintenance Service. Intake camshaft sprocket 7.) l Engine Adjustment (Refer to i?ll-7. Spark plug cable bD+ 5.) l Turbocharger Removal <Turbo> (Refer to GROUP 15 .li-31.Exhaust Manifold. Timing belt rear cover (Center) 8..lbs.Maintenance Service.11-28 ENGINE . 8660 or equivalent 90 Nm 65 ft.) l Exhaust Manifold Removal (Refer to GROUP 15 .

ZOlNOO951 .Cylinder Head Gasket REMOVAL SERVICE POINTS II-29 (A. (2) Lay the cylinder head gasket on the cylinder block with the identification mark at the front top. (2) Using the special tool and a torque wrench. ZOlL1044 L01L0472 ( - g-=~~:~~ Caution Install the head bolt washers with shear droop upward as shown in the illustration. <Turbo> NOTE Use of commercially available cylinder head bolt wrench is recommended.ENGINE . Caution Locking the camshaft sprocket with a tool damages the sprocket. 08 0 7 04 03 01 05 02 06 i Front bank I ZO’L.B+ CYLINDER HEAD ASSEMBLY INSTALLATION (1) Use a scraper to clean the gasket surface of the cylinder head assembly.Cw 00003242 TSB Revision . (2) Remove the camshaft sprockets. tighten the bolts to the specified torque in the order shown in the illustration (in two or three cycles). NOTE Use of commercially available cylinder head bolt wrench is recommended.A4 CYLINDER HEAD GASKET INSTALLATION (1) Make sure that the gasket has the proper identification mark for the engine. Caution Take care that no foreign material gets into the cylinder. CYLINDER HEAD ASSEMBLY REMOVAL Using the special tool. coolant passages or oil passages. (3) Back off the bolts once and tighten them to the specified torque as shown in step (2). hold the camshaft at its hexagon and remove the camshaft sprocket bolt. INSTALLATION SERVICE POINTS dentification nark . remove the cylinder head assembly. dB. INTAKE CAMSHAFT SPROCKET REMOVAL (1) Using a wrench.

. . . . . . . . . . 5 bolt . . . . . . . . .C+ INTAKE CAMSHAFT SPROCKET INSTALLATION Using a wrench. . .) (2) Bolts are color-coded for the front and rear banks as follows: Front bank . ..) Except rear bank No.79 in. . . . . . .&&-$* . . Black Rear bank . . . . . . . . . Green (3) When the rocker cover gasket has been replaced. .. . . . .ENGINE . . .39 in. . . . . .:i . .lbs. Caution Locking the camshaft sprocket with a tool damages the sprocket. .Cylinder Head Gasket . . and then retighten bolts 1 to 6 to 4 Nm (2. . . . 5 bolt .~ . . . 5 bolt in the rear bank differs from other bolts in length.). . . . Rear bank . . . . . . tighten bolts in this order.9 ft. . Front bank 6 . . . . . . .. 20 mm (. 10 mm (. . . . . NOTE (I) Only No. . .’ I s TSB Revision . . . . ..D+ ROCKER COVER INSTALLATION Tighten the rocker cover bolts in the order shown in the illustration. . . Rear bank No. hold the camshaft at its hexagon and tighten the bolt to specification. . . . .

Timing Belt TIMING BELT L i REMOVAL AtiD INSTALLATION Pre-removal Operation l Under Cover (Front L.E+ 10.lbs. A I7 ZOSFOOO3 loo-120 Nm 72-87 ft.) l lo-12 Nm 7-9 ft. 2.f$ . . Timing belt upper cover 8.ey.) l Engine Adjustment (Refer to F!ll-7. Brake fluid level sensor 7. Camshaft position sensor and crankshaft position sensor connector* .) l Under Cover (Front L. l(U-13” 1.9 ft. Engine mount bracket 9.Aero Parts.) Installation l Front Under Cover Panel Installation <Vehicle ‘with Active Aero> l Cruise Control Link Assembly Installation <Vehicle with Cruise Control> (Refer to GROUP 13G .Generator.ll-8. Timing belt lower cover . Auto tensioner NOTE * From 1993 model ‘I Up to 1993 model l 2 From 1994 model TSB Revision .F+ 5.) l Raise and Suspend the Engine to the Extent Force is not Applied to the Engine Mount Post-installation Operation Generator Assembly installation (Refer to GROUP 16 . \ . Crankshaft pulley 6.) Removal l Front Under Cover Panel Removal <Vehicle with Active Aero> (Refer to GROUP 51 . Timing belt .Cruise Control.“nl.z.$T.Cruise Control. 11. .) 4A. 6. %ft. ~~~~. ‘> lo-12 Nm 7-9 ft.H. i L--’ *. .. 3.‘>’ m. 2. Side L.C+ l Tming belt tension adjustment 4C.lbs.D+ 12. 4. ‘@k \&‘p 1 24\ N m l.H.Generator. Side L. ZOlFOO7l 00003248 Removal steps Air hose Air pipe Tensioner assembly Drive belt (power steering) (Refer to P.111 Nm ““--IL” 7:2-87 ft..) l Generator Assembly Removal (Refer to GROUP 16 . Idler pulley (generator/airconditioning) 46.B+ 13.H. .A( 14.H. /%&+-Em IW“ .lbs.lbs.ENGINE .ibs. / 105-115 Nm 76-83fLlbs.lbs. Engine support bracket 1.) l Cruise Control Pump and Link Assembly Removal <Vehicle with Cruise Control> (Refer to GROUP 13G .

or a damaged pulley damper could result. These parts should not be washed. camshaft oil seal and water pump for leaks. CRANKSHAFT PULLEY REMOVAL Using special tools. Replace parts if seriously contaminated. (B. (3) Loosen the center bolt on the tensioner pulley to remove the timing belt. TIMING BELT REMOVAL (1) Align the timing marks. INSTALLATION SERVICE POINTS . slowly remove the bolt (reamer bolt) indicated by the arrow. Caution Use only the specified special tools. sprocket. ZOlLlO3 I TSB Revision . in that position. Spraying lubricant. clamp it in the vise with soft jaws. remove the crankshaft pulley from the crankshaft. 1) Keep the auto tensioner level and. so the removed timing belt.Timing Belt REMOVAL SERVICE POINTS +A. Caution Keep in mind that the reamer bolt is sometimes heat seized on the engine support bracket. and tensioner must be free from oil and water. ENGINE SUPPORT BRACKET REMOVAL Remove the engine support bracket in the numbered sequence shown in the illustration. 2) Push in the rod little by little with the vise until the set hole (A) in the rod is aligned with that (B) in the cylinder. Caution Water or oil on the belt shortens its life drastically. (C. . (2) Make a mark on the back of the timing belt indicating the direction of rotation so it may be reassembled in the same direction if it is to be reused. reset it as follows. If there is oil or water on each part check the front case oil seals.A( AUTO TENSIONER INSTALLATION (1) If the auto tensioner rod is in its fully extended position.II-32 ENGINE .

Og Rocker cover side Exhaust valve side Front bank 1 TSB Revision . the cam lobe on the camshaft lifts the valve through the rocker arm and the camshaft sprocket is apt to rotate by reaction force of the valve spring.Timing Belt 11-33 ZUlL104! Caution Push in the rod slowly to prevent the push rod from being damaged. Caution In range A. 3) Turn the camshaft sprocket for either the intake or exhaust valve to locate the timing mark as shown in the illustration at left. 4) Turn the camshaft sprocket clockwise to align the timing marks.055 in. Therefore.B( TIMING BELT INSTALLATION (1) Align the timing marks on the respective sprockets. 1 cylinder located at TDC on compression stroke may cause the valves to interfere with the piston. Therefore.’ (2) Install the auto tensioner. proceed as follows: 1) Install the crankshaft pulley. If the timing mark is within range A. Shift the timing mark on the crankshaft sprocket by three teeth to lower the piston in No. . 20 1 N~U~I Front bank l : Awrox.4 mm (. turn it counterclockwise to align the timing marks. turn the intake valve camshaft sprocket and the exhaust valve camshaft alternately. 3) Insert a wire [I. In case of the camshaft sprockets in the front bank. Caution Turning the camshaft sprocket with the piston in No. If the camshaft sprocket has been turned excessively. Then turn the other crankshaft to locate the timing mark as shown in the illustration at left.ENGINE .NO. Caution If the intake and exhaust valves of the same cylinder lift simultaneously. be careful not to have the finger pinched between the sprockets. SW Caution Leave the wire installed in the auto tensioner.) in diameter] into the set holes. 35” ZO. 4) Unclamp the auto tensioner from the vise. 2) Make sure that the timing marks on the camshaft sprockets for intake and exhaust valves are not within the range A in the illustration at left. interference with each other may result. turn the camshaft sprocket to move the timing mark to the area closest to the range A. 1 cylinder slightly from the top dead center on compression stroke.

temporarily tighten the center bolt.) [Timing belt tensioning torque] Caution When tightening the center bolt. Be careful. check again that the set pin can be easily removed from. Caution 1. secure them with box wrenches to install the timing belt. make sure that the set pin can be easily removed. Then. (5) Remove the four clips.lbs.C( TIMING BELT TENSION ADJUSTMENT (1) Rotate the crankshaft l/4 turn counterclockwise. 2.Pin hole ‘. ZOlL0948 1 TSB Revision . then rotate it clockwise until the timing marks are aligned. (2) Loosen the center bolt on the tensioner pulley. ZOlN0046 . the camshaft is turned by the reaction of valve spring. at the same time. NOTE Shift the timing mark of the crankshaft sprocket one tooth in counterclockwise direction to facilitate belt installation. and installed to. tighten the center bolt to specification. (3) Turn the tensioner pulley so that its pin holes are located above the center bolt.Center bolt (2) Using bulldog clips. install the timing belt in the following order with care not to allow the belt to slack. make sure that the tensioner pulley is not rotated together.-. at the same time. install it so that the arrow marks made at removal are in the direction of rotation. Timing Belt 5) Align the timing mark of the crankshaft sprocket. (3) Remove the set pin from the auto tensioner. (4) Rotate the crankshaft two turns clockwise and leave it as is for five minutes or more. the auto tensioner. Specified torque: 10 Nm (7 ft. At this time. (4) Check that the timing marks on all sprockets are aligned properly. press the tensioner pulley against the timing belt and.ENGINE -. . apply tensioning torque to the timing belt and. Using the special tool and torque wrench. Then. (1) Exhaust camshaft sprocket (front bank side) -+ (2) Intake camshaft sprocket (front bank side) + (3) Water pump pulley + (4) Intake camshaft sprocket (rear bank side) + (5) Exhaust camshaft sprocket + (6) Idler pulley + (7) Crankshaft sprocket + (8) Tensioner pulley NOTE Since the camshaft sprockets turn easily. If the timing belt is reused.

cl 992 models Thread diameter x length Thread diameter x Lenclth mm (in.06) -\12x71 -39 3 (.5 mm (. .8-4.) If the protrusion is out of specification. attach the crankshaft pulley to the crankshaft.F+ CRANKSHAFT PULLEY INSTALLATION Using the special tool. Caution Use only the specified special tools.Timina Belt 11-35 201L094 NOTE Even if the set pin cannot be easily inserted.ENGINE . Standard value (A): 3.47x 2. (5) Check again that timing marks on all sprockets are aligned properly. repeat steps (1) to (4).2 FE4 ENGINE SUPPORT BRACKET INSTALLATION Since the mounting bolts of engine support bracket are different in size depending on location. insert them in numbered sequence.39x 1. the auto tensioner is normal if its rod protrusion is within specification. insert them with care. otherwise a damaged pulley damper could result.Nm.50) Y0.) Reamer bolt *@aID--+&Jlox3oP(.177 in. Caution When installing the reamer bolt. .149-. - / 1 TSB Revision .Dl TIMING BELT LOWER COVER INSTALLATION Since the mounting bolts of timing cover are different in size depending on location. slowly spraying lubricant on the reamer area. tighten it.

Check the engine oil cooler hoses for cracks. INSPECTION l o l l Check the engine oil cooler fins for bends. Check the eye bolts for clogging or deformation. clogging or deterioration. damage. Engine oil feed hose 3.Engine Oil Cooler REMOVAL AND INSTALLATION l Preremoval and Post-installation Operation Engine Oil Draining and Supplying (Refer to GROUP 00 . Engine oil cooler REMOVAL SERVICE POINTS dAbENGINE OIL FEED HOSE / ENGINE OIL RETURN TUBE REMOVAL Caution Be sure to hold the weld nut of the oil cooler while loosening the eye bolt. Front splash shield extension 2. 5 4W ZOZFOOOl Removal steps 1. Check the gaskets for damage or deformation.) 30-35 N m 9 ft.lbs. Engine oil return tube 5. TSB Revision . Engine oil return hose 4.11-36 ENGINE OIL COOLER ENGINE .Maintenance Service. breaks or plugging.

. . . . . 13c VARIABLE VENTURI TYPE CARBURETOR . ... . . ... . . .. . . . . . . . . . . . . . . .. . . . . . . . .. .. . 13A ELECTRONIC CONTROL TYPE CARBURETOR . . . . . . .. . .. . . 13F CRUISE CONTROL SYSTEM . . .. . . .. . . . . . . . . . . . .. . . . . . ... . . . . . . . . . . . . . 13D DIESEL FUEL .. . . . . . . . . . . . . . . . CONTENTS MULTIPORT FUEL INJECTION (MFI) .. . . . . . . . . . . . 13B . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . .13-1 L. . . . . . . . . . . .. . . . . . t3l-l NOTE Shaded groups in the above list are not included in this manual. . . . . .*. . . . . . . . . . . . . Refer to GROUP 17 TRACTION CONTROL SYSTEful . .. . . . .. . . . . . . . . . . . .. . . . . . . .1 FUEL... . . 13E Li FUEL SUPPLY .. . .. . . CONVENTIONAL TYPE CARBURETOR . . . . . . . . . . . . . . .*. . . . ..

13-2 .

. . .. .. . Ignition Switch-ST and Park/Neutral Position Switch (PNP Switch) . . . . . .. . .. . . . . . . .. . . . .. . . . . . . . . . . . . . . . .. . . 193 Release of Residual Pressure from High Pressure Fuel Hose . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . Ignition Coil and Ignition Power Transistor . . . . . . . .. . . . . . . . . . 241 Power Steering Pressure Switch . . . . . . . . . . . . . . . . .. 235 Power Supply (MFI relay) and Ignition Switch-IG . . . . . . 212 ON-VEHICLE INSPECTION OF MFI COMPONENTS <Up to 1995 Non Turbo models for Federal and up to 1993 models> . .. . . . . . . . . . . . . . . . . . . . . . . . . . 237 Manifold Differential Pressure (MDP) Sensor . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . _ . . . . . . . . .. . . . . . . . . . Closed Throttle Position Switch .. . . Air Conditioning Switch and Compressor Clutch Relay . . . . . . . 271 Variable Induction Control Motor (DC Motor) . . .. . . .. .. . . . .. . .. . . . ... . . ... . . . .. 183 Engine Coolant Temperature Sensor . . . . .. . . . . . . . . . . . .. . . . . . . . . . 71 Engine Control Module (ECM) Terminal Voltages Inspection . _ . . . . . . . . . . . . . . . . . .. . . . Fuel Pump Operation Check . . . . . .. . . . . . . . . . . . . . . . . . . . . . Component Location . .. . 93 Evaporative Emission Purge Solenoid . . . . . EGR Temperature Sensor . . . . . . . . . . . .. Components Inspection Procedure . . . . .. . . . . . . . . . . . . . 162 Fan Motor Relay (Radiator. 107 EGR Solenoid . . . . . . . . . . ON-VEHICLE INSPECTION OF MFI COMPONENTS <From 1994 models except Non Turbo up to 1995 models for Federal> . . . . . . . . . . . . . . . . Evaporative Emission Purge Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump .. . . . . . . . . . . . . 221 Turbocharger Waste Gate Solenoid . . . . . . . 177 Engine Control Module Power Ground . . . Crankshaft Position Sensor .. _ . . . 64 Component Location . . . . . . . . . . . . . . . . . .13A-1 i MULTIPORT FUEL INJECTION CONTENTS GENERAL INFORMATION . . . . . . . . . . . . . . . . .. . .. Engine Coolant Temperature Sensor . . . .. . .. . . . . . . . . . Fan Motor Relay . . . . . . . . . . . 60 Active Exhaust Control Unit . .. . . . . . . . . . . . . .. Barometric Pressure Sensor . . . . . . . . . .. . . . . 286 KNOCK SENSOR . . Idle Air Control Motor (Stepper Motor Type) . . . Fuel Pump Circuit Resistor . . .. . . . . . . .3 INJECTOR . . . . . . . . . . . . . . . . . . . . . . _ . . . . . . . .. .. . . . . . . . . . . . . . . . . . . ... .. . . . . . . . . . .. . . 279 Throttle Position Sensor . . . . .. . . . 123 Anti-lock Braking Signal . . . . ... . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 215 Knock Sensor . . . . . . . . . . . . . . . . . .. . . . .. . . . . . .. .. . .. . .. _ . . . . . . . . . . . . .. . . . . . . . . .... . . . 257 Intake Air Temperature Sensor . . . . . . . . . . . . . . . . . . . . . Ignition Switch-ST. . . . . . . . . . . . .. .. . . . . . . . . 244 Muffler Mode Changeover Switch . 242 Injectors . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . Electrical Load Switch . . . . . . . . .. . . . . .. . . . . . . .. . . . . . . . . 127 Engine and Transaxle Total Control Signal . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . Anti-lock Braking Signal . 103 Closed Throttle Position Switch . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pressure Solenoid . . . . . . . . . . . . . .. . . . . . . . . . 276 Vehicle Speed Sensor (Electrical Speedometer Type) . . . . . . . . . . . . . . . . . EGR Solenoid . . . . . . .. . . 171 Camshaft Position Sensor . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Air Conditioning Switch and Compressor Clutch Relay . . . . . . . . . . . . . .... . . . . . . . . .. . . . Camshaft Position Sensor . . . .. . . . . . . . . . . . . . . . . . . . 91 Boost Meter .. . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . _ . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. . ... ... . . . . Air Conditioning Condenser) . Heated Oxygen Sensor . . . . . . . . . . 3 Multiport Fuel Injection (MFI) System Diagram . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . Fuel Pressure Test. . Active Exhaust Control Unit . . . . . .. . . . .. . . . . . . . . . . .. . . . . . . 176 Barometric Pressure Sensor . Boost Meter . . . . 164 EGR Temperature Sensor . . Engine Control Module (ECM) Terminal Voltages Inspection . .. . . . _ . . . . . . . . . . . . 233 (Mechanical Speedometer Type) . . . . . Engine and Transaxle Total Control Signal .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . .. . . . . . . . ._. . . . . . . . . . . .. . . . . . . . . .. . . . . . 289 188 274 236 277 217 273 225 223 193 188 227 269 246 238 278 199 280 219 268 240 270 279 200 279 211 211 247 263 264 229 230 Induction Control Valve Position Sensor . 101 Components Inspection Procedure . . . . . . . . Fuel Pump Relay II . . 60 Crankshaft Position Sensor . .. . . . . . .. . . . 231 Volume Air Flow Sensor. . . . . . .. . . . . Enoine Control Module Power Ground . . . . . . .. . . . . . . . . . . . . . . . . 135 Electrical Load Switch . . . . . . . . .. . . . . . . .. 129 CONTINUED ON NEXT PAGE LJ . . . . .. . . . . .. . . . . .

. . . . . . . . . . . . . . . . . . . . . 57 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Injectors . . . . 12 THROlTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 (Mechanical Speedometer Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Ignition Switch-ST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 85 ON-VEHICLE SERVICE . . . . . . . . . 15 Check Chart Classified by Problem Symptoms . . . . . . . . . . . . . . . . . . . . . . 125 Muffler Mode Changeover Switch . . . . . 166 Fuel Pressure Test . . . . . . . . 179 Fuel Pump Relay II . . . . . . . . . 117 Volume Air Flow Sensor . . . . . . 57 Curb Idle Speed Check . .. . . . . . . . . 137 Idle Air Control Motor (Stepper Motor Type) . . . . . . . . . . . 12 Service Specifications . . . . . . . . . . . . . 84 Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Release of Residual Pressure from High Pressure Fuel Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13A-2 Lq Fuel Pressure Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Vehicle Speed Sensor (Electrical Speedometer Type) . . . . . . . . . . . . . . . . . . . . 15 On-board Diagnostic . . . . 10 Sealant . . 144 Intake Air Temperature Sensor . 54 Read out of Diagnostic Trouble Code . . . . . . . . . . . . . . 55 Basic Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . 169 Variable Induction Control Motor (DC Motor) . . . . . . . . . . . . . . . . 10 General Specifications . . . . . 112 Induction Control Valve Position Sensor . . . . . . . . . . . . . 121 Power Supply (MFI relay) and Ignition Switch-IG . . . . . . . . . . . . . . . . . . . . . . 88 Knock Sensor . . . . . . . . . . . . . . 72 Fuel Pump Operation Check . . . . . . . . 158 Ignition Switch-ST and Park/Neutral Position Switch (PNP Switch) . . . . . . . . . . . . . . . . . . . . . . . 19 Problem Symptoms Table (For Your Information) . . . . . . . . . . . . . . . . . . . . . . 180 Fuel Pump. . 17 Explanation and Cautions about Harness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SPECIFICATIONS . . . . . . 52 Check Engine/Malfunction Indicator Lamp . Refer to GROUP 11 Fixed SAS Adjustment . . . . . . . . . . . . . . . . . . . . . 179 Throttle Position Sensor . . . . . . . . . 98 Turbocharger Waste Gate Solenoid . . 59 Throttle Body (Throttle Valve Area) Cleaning . . . . . . . . . . . . . 55 Closed Throttle Position Switch and Throttle Position Sensor (TPS) Adjustment . 16 Explanation of Troubleshooting Procedures . . . . . . . . . . 288 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Power Steering Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 I I ~ ! I I L/ ~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Fuel Pump Circuit Resistor . . . . . . . . . . . . . . . . . . . . . . . . 153 Ignition Coil and Ignition Power Transistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MULTIPORT FUEL INJECTION .-w EVAP canister Electric load switch I ‘1~‘2~‘3~‘4k i ‘6 ‘7 ‘8 * I! module 27FU1323 NOTE ‘1: EVAP purge solenoid ‘ 2 : lniector ‘3: ldie air control motor ‘4: Variable induction control motor ‘5: AK compressor clutch relay ‘6: Fuel pump relay ‘7: Ignition coil ‘8: Check engine/malfunction indicator lamp ‘9: Engine/transaxle total control iJ TSB Revision . Intake air temp. .Up to 1995 models> I I 1 I I I I -I TPS tr& posItIon Yh “osed.General Information 13A-3 GENERAL INFORMATION MULTIPORT FUEL INJECTION (MFI) SYSTEM DIAGRAM ci <Federal Non Turbo ... . sensor II c From fuel tank ._-._.

Y Induction control valve position sensor m Throttle position sensor.MULTIPORT FUEL INJECTION . Heated oxygen sensor c Knock sensor Enoine coolant temo.Intake air temp.Up to 1993 models> .General Information <California Non Turbo . sensor m Volume air flow sensor. sensor I.. Closed throttle position switch lntake air temp. Barometric pressure sensor 6 ‘7 ‘t Z7FU1325 NOTE ‘1: EVAP purge solenoid ‘2: Injector ‘3: EGR solenoid ‘4: Idle air control motor ‘5: Variable induction control motor ‘6: AIC compressor clutch relay ‘7: Fuel pump relay ‘8: Ignition coil “9: Check engine/malfunction indicator lamp *lo: Engine/transaxle total control TSB Revision . sensor ) . TPS (with closed throttle position switch) IACmotor / / .

. _ _.General Information <California Non Turbo .u.xe”’ *8: Fuel pump relay 7 Ignition coil : Check engine/malfunction indicator lamp ‘11: tngme/trfLnsaxle total control 4 1 TSB Revision .C. r..*..4 . sen~nr I Fuel tank * I Heated :2i P :: nt I IKr. “‘p~. motor I IAC motor Intake air temp. Closed tnrottle poslkon swatch * Intake arr temp.1994 and 1995 models> 13A-5 V. Engme coolant temp. sense+ lnauctron control valve posrtron sensor * I nrottle positron sensor.rk a.“I. sensor * J Z7FU1462 NOTE ‘1 :.MULTIPORT FUEL INJECTION .“.mIII”IY ‘4: Idle air control motor ‘5: Variable induction control motor ‘6: Heater control ‘7: A/c wpwwxenr “. f%/AP purge solenoid ‘2: Injector ‘3: EGR ~plnnni.I. ldlll.

From 1996 models> I / I 1 1 IA? motor 1 Intake air temperature sensor / . sensor .General Information <Non Turbo . Ignition power transistor ‘IO: Check engine/malfunction indicator lamp ‘11: Engine/transaxle total control TSB Revision .MULTIPORT FUEL INJECTION .From fuel tank module Encine coolant temp. Closed throttle cosition switch NOTE l l : EVAP purge solenoid ‘2: Injector ‘3: EGR solenoid ‘4: Idle air control motor ‘5: Variable induction contorl motor ‘6: Heater control ‘7: A/C compressor clutch relay l 8: Fuel pump relay ‘9: Ignition coil. Induction control valve position sensor _ Throttle position sensor.

1992 models> 13A-7 r II / .General Information <Turbo .MULTIPORT FUEL INJECTION .gcontrol NOTE ‘1: injector ‘2: EGR solenoid ‘3: IAC motor ‘4: Fuel pressure solenoid ‘5: Evaporative emission purge solenoid ‘6: Turbocharger waste gate solenoid ‘7: AC compressor clutch relay “8: Fuel pump relay ‘9: Ignition coil “10: Check engine/malfunction indicator lamp ‘11: Muffler mode control 1 TSB Revision I .\ -7 intake air l!&i.

General Information <Turbo . senso Engine ContrOl nlcd”b 27FU1463 NOTE ‘1: Injector ‘2: EGR solenoid ‘3: Evaporative emission purge solenoid ‘4: IAC motor ‘5: Fuel pressure solenoid ‘6: Turbocharger waste gate solenoid “7: AK compressor clutch relay ‘8: Fuel pump relay ‘9: Ignition coil ‘10: Check engine/malfunction indicator lamp ‘11: Muffler mode control 1 TSB Revision I . !I’[ IAC motet Intake air temp.From 1993 Up to 1995 models> R%er@+ /I /f/j .13A-8 MULTIPORT FUEL INJECTION .

General Information <Turbo .From 1996 models> 13A-9 EGR IAC motor- ii Intake air temperature senso \ . Iqnition cower transistor Check enaine~ Iam Enqineltransaxle total control e 7FUl841 TSB Revision . 1 I 1 1 1 C&shaftposition sensor FlW NC switch _ P/S pressure switch c Vehicle speed sensqr _ T mohle lqnition coil. .MULTIPORT FUEL INJECTION .

13A-10 MULTIPORT FUEL INJECTION .Specifications SPECIFICATIONS GENERAL SPECIFICATIONS California <Non Turbo> emperature sensor c emiconductor type l l: 1992 models l 2: 1993 models 1:: : :E: : 1994 and 1995 models Except 1992 models From 1996 models Up to 1993 models NOTE *7: From 1994 models TSB Revision .

Non Turbo. Turbo> <Federal Non Turbo .From 1996 models> Fuel pressure solenoid <Turbo> Turbocharger waste gate solenoid <Turbo> Fuel pressure regulator Regulated pressure kPa (psi) <Non Turbo> Regulated pressure kPa (psi) <Turbo> Specifications Contact switch type Contact switch type Electromagnetic.Specifications terns Sensors 4ctuators Power steering pressure switch Multiport fuel injection (MFI) relay type Injector type and number Injector identification mark <Non Turbo> Injector identification mark <Turbo> Variable induction control motor <Non Turbo> Evaporative emission purge solenoid EGR solenoid <California .MULTIPORT FUEL INJECTION .6) 300 (43.5) NOTE *I: Up to 1993 models *2: From 1994 models <except 1996 and subsequent M/T models> 1:: 1996 and subsequent M/T models : Up to 1995 models *5: From 1996 models -TSB Revision . 6 BDH21 O*‘? l 3 SDH210” BDL360 Direct current motor type ON/OFF type solenoid valve*4 Duty cycle type solenoid valve*5 Duty cycle type solenoid valve 13A-11 ON/OFF type solenoid valve Duty cycle type solenoid valve 335 (47.

Specifications SERVICE SPECIFICATIONS e speed when air conditi gine coolant temperatu . 4171 or equivalent TSB Revision .13A-12 MULTIPORT FUEL INJECTION .OTE : Up to 1992 models *2: From 1993 models SEALANT Items Engine coolant temperature sensor threaded portion Specified sealant 3M NUT Locking Part No.

MULTIPORT FUEL INJECTION .Special Tools SPECIAL TOOLS l Reading diagnostic trouble code MFI system inspection tester cMUT> Test harness set Basic idle speed adjustment l Inspection by oscilloscop TSB Revision .

Special Tools TSB Revision .13A-14 MULTIPORT FUEL INJECTION .

l After repair. t 1 1. check the MFI system component body harness and repair as necessary. Inspection of engine control module input/output signals c 5. L. Inspection of individual MFI system components l If the body harness is normal but the engine control module input/output signals are abnormal. 5. Inspection of MFI system component harness I t 6. Reading of diagnostic trouble code l Read diagnostic trouble code and if a malfunction code is output. 7. judge the sensor input/ actuator control as normal and proceed to check the input/output signals of the next check item.MULTIPORT FUEL INJECTION . 2. verify the check items and checking order for the trouble symptom. proceed to check the input/output signals of the next check item.) under which it is produced. locate and correct the trouble referring to the DIAGNOSIS CHART.Troubleshooting 13A-15 TROUBLESHOOTING . 3. Verification and prevention of reoccurrence after repair l END 1 1 TSB Revision . Estimation of the causes of trouble and setting of check items 4. Inspection of engine control module input/output signals l Using the scan tool or oscilloscope. re-examine the causes of trouble referring to the troubleshooting hints and the checks and repairs included in other groups. l If the signals are normal. l Remove the true causes of the trouble to prevent its reoccurrence. l After repair or replacement. proceed to check the input/output signals of the next check item. If they are normal. Verification of trouble symptom l Reproduce trouble symptom and verify the characteristics of the trouble and the conditions (engine condition. Re-inspection and repair of trouble symptom l If the harness inspection and individual component inspection results are normal but the engine control module input/output signals are abnormal. Inspection of individual MFI system components Re-inspection and repair of trouble t 8. check the engine control module input/output signals. 6. 4. Inspection of MFI system component harness l If the engine control module input/output signals are abnormal. check the engine control module input/output signals again. Estimation of the causes of trouble and setting of check items l Referring to the Check Chart. Verification and prevention of reoccurrence after repair l Perform tests to see if the same problems occur again and make sure that the same problems will not be repeated. etc. If they are normal. check individual MFI system components and repair or replace as necessary./ L START EXPLANATION OF TROUBLESHOOTING PROCEDURES Effective troubleshooting procedures for MFI system problems are given below. Verification of trouble symptom 1 t 3. 8. check the engine control module input/ output signals again. 1. driving conditions.

If the test probe is forced into the terminal. poor contact may be caused. Test Harness. open one end of the wire and check continuity between the other end and ground. do not insert the test probe if the check terminal is female. When checking the terminal voltage with the connector disconnected. i = 26FU1217 l l When checking short-circuit to ground of a wire. the wire is short-circuited to ground and requires repair. be sure to use the special tool. ZOlL1025 l Jumper wire When checking an open circuit of a wire with its ends physically separated. l l If the appropriate test harness for the particular connector is not available. “B+” used as the standard value in voltage check stands for system voltage. Never insert the test probe from the harness side as thiscauses loss of waterproof characteristics and corrosion may result. use an analog ohmmeter (or circuit tester) as a rule.13A-16 MULTIPORT FUEL INJECTION . ground one end using a jumper wire and check the continuity between the other end and ground. Repair the wire if there is no continuity. the use of the Test Harness Set (MB991348) which can be connected directly between the terminals is recommended. For checking continuity. 26FU126 l When checking a waterproof connector for circuit continuity. There are various test harnesses and the appropriate one for the connector being tested should be used.Troubleshooting EXPLANATION AND CAUTIONS ABOUT HARNESS CHECK l 0 The connector symbol shown is as viewed from the terminal end of the connector inside the vehicle. If there is continuity. 1 TSB Revision .

Turbo> Ignition coil. If the wire is normal. However. the lamp goes out.THE CHECK ENGINE/ MALFUNCTION INDICATOR LAMP <Up to 1995 models> Engine control module Heated oxygen sensor Volume air flow sensor Intake air temoerature sensor Throttle position sensor Engine coolant temperature sensor Crankshaft position sensor Camshaft position sensor Barometric oressure sensor 1 Knock sensor Ignition timing adjustment signal Injector EGR system <California . a check engine/malfunction indicator lamp comes on to notify the driver of the emission control items when an irregurality is detected. when the ignition switch is turned off. ignition power transistor unit . check the wire for an open circuit or short-circuit to ground and repair as necessary. TSB Revision i . when an irregular signal returns to normal and the engine control module judges that it has returned to normal. To check the voltage. use an analog voltmeter for checking the power transistor drive voltage. Even if the ignition switch is turned on again. Moreover. replace the engine control module and check again.] r Check engine/malfunction indicator lamp Z6FU1219 CHECK ENGINE/MALFUNCTION INDICATOR LAMP Among the on-board diagnostic items.MULTIPORT FUEL INJECTION . but this does not show any abnormality. Therefore. [However.Non Turbo. Here. immediately after the ignition switch is turned on. use a digital voltmeter (or circuit tester) as a rule. the check engine/malfunction indicator lamp is lit for 5 seconds to indicate that the check engine/malfunction indicator lamp operates normally. the lamp also comes on when the ignition timing adjustment terminal is grounded to adjust the ignition timing.?66FOOll L Caution The check engine/malfunction indicator lamp comes on when the line of the ignition timing adjustment terminal is shorted to ground. ITEMS INDICATED BY . the check engine/malfunction indicator lamp goes out.Troubleshooting l 13A-17 l If the sensor impressed voltage is abnormal. the lamp does not come on until the irregularity is detected.

Troubleshooting ITEMS INDICATED BY THE CHECK ENGINE/MALFUNCTION INDICATOR LAMP <From 1996 models> 2 sensor circuit malfunctio dle control system ma .13A-18 MULTIPORT FUEL INJECTION . TSB Revision .

memorizes the diagnostic trouble code. it will be switched off under the following conditions. however.) are similar to those when the malfunction was first recorded. the lamp illuminates for about 5 seconds and then goes out. etc. engine coolant temperature. For misfiring or a fuel trim malfunction. the check engine/malfunction indicator lamp illuminates when the engine is next turned on and the same malfunction is re-detected. 2. Moreover. blown fuse and blown bulb. In this case. i ON-BOARD DIAGNOSTIC <Up to 1995 models> The engine control module monitors the input/output signals (some signals at all times and the others under specified conditions) of the engine control module. when driving conditions (engine speed. since memorization of the diagnostic trouble codes is backed up directly by the battery. be erased when the battery terminal or the engine control module connector is disconnected. Caution If the check engine/malfunction indicator lamp illuminates because of a malfunction of the ECM. the diagnostic results are memorized even if the ignition key is turned off. When it is noticed that an irregularity has continued for a specified time or longer from when the irregular signal is initially monitored. passing a certain number. l 13A-19 l When the ECM monitored the powertrain malfunction three times* and detected no malfunction. CHECK ENGINE MALFUNCTION INDICATOR LAMP INSPECTION (1) Check that when the ignition switch is turned on. TSB Revision . including the normal state. However. The diagnostic trouble codes will. the check engine/malfunction indicator lamp illuminates on the first detection of the malfunction.MULTIPORT FUEL INJECTION . There are 23 diagnostic items. for items marked with a ‘I*“. (2) If the lamp does not illuminate. one time indicates from engine start to stop. and the diagnostic results can be read out with a voltmeter or scan tool. transmission between the scan tool and the ECM cannot occur. After the check engine/malfunction indicator lamp illuminates. check for open circuit in harness. *: In this case.Troubleshooting NOTE 1. the engine control module judges that an irregularity has occurred. The diagnostic trouble code can also be erased by turning on the ignition switch and sending the diagnostic trouble code erase signal from the scan tool to the engine control module. After the Engine Control Module (ECM) detects a malfunction. the diagnostic trouble code cannot be read. and outputs the signal to the diagnostic output terminal.

and the diagnostic memory will be erased. Therefore. DIAGNOSTIC CHART (FAULT TREE) Code No. the diagnostic trouble code is also output when the ignition timing adjustment terminal is grounded to adjust the ignition timing. the diagnostic trouble code is memorized. The 23 diagnostic items are provided as follows. TSB Revision . Caution The diagnostic trouble code for the ignition timing adjustment signal is output when the line of the ignition timing adjustment terminal is shorted to ground. Output signal pattern Diagnostic item Engine control module l l l Check item (Remedy) Fuse Harness and connector Ground (Replace ECM if power + ground available) Memory otherthan 1994andlaterCalifomia Harness and connector Heated oxygen sensor Fuel pressure 0 Injectors (Replace if defective ) Intake air leaks l l l l Retained 12 Volume air flow sensor :_J-uuL Intake air temperature sensor l l Harness and connector Retained (If harness and connector are normal.) Harness and connector Retained Intake air temperature sensor l l l Harness and connector Retained Throttle position sensor Closed throttle position switch NOTE Do not replace the ECM until a thorough terminal check reveals there are no short/open circuit. but this does not show any abnormality. and if plural items are activated. In this case. send the diagnostic trouble code erase signal from the scan tool to the engine control module or disconnect the battery terminal (-) for 10 seconds or more. replacevolumeairflow sensor assembly.Troubleshooting Caution If the sensor connector is disconnected with the ignition switch turned on.13A-20 MULTIPORT FUEL INJECTION . they are all indicated sequentially from the smallest code number.

) Camshaft position sensor l 23 24 :m x12.MULTIPORT FUEL INJECTION .) 36 Ignition timing adjustment signal <DOHC> l Harness and connector 39 H L U1 y. 21 Output signal pattern Diagnostic item Enginecoolanttemperaturesensor l l 13A-21 Memory Check item (Remedy) Harness and connector Retained Engine coolant temperature sensor := Z12AO107 Crankshaft position sensor 22 :l-uLnnYl2AO107 l Harness and connector Retained (If harness and connector are normal. Turbo> l EGR thermo-sensor l EGR valve l EGR solenoid l EGR valve control vacuum Retained F- w12Ao105 NOTE Do not replace the ECM until a thorough terminal check reveals there are no short/open circuit.Non Turbo. replace crankshaft position sensor assembly. replace barometric pressure sensor assembly.40107 Harness and connector Retained (If harness and connector are normal.) Vehicle speed sensor l l Harness and connector Vehicle speed sensor Retained 25 H L u I nmn v12Ao107 Barometric pressure sensor l Retained Harness and connector (If harness and connector are normal.2Ao. replace camshaft position sensor.05 Heated oxygen sensor <Federal . replace knocksensor. TSB Revision .Troubleshooting Code No.) Knock sensor 31 :nnrLnZ12Ao466 l Retained Harness and connector (If harness and connector are normal.Turbo> Right bank heated oxygen sensor (front) cl994 and later California model> Injector l l l l l Retained Harness and connector Heated oxygen sensor Fuel pressure Injectors (Replace if defective) Intake air leaks Retained 41 Harness and connector 0 Injector coil resistance l rm x1zA0105 43 l Harness and connector EGR <California .

l-4 cylinder) l Ignition power transistor unit :v12Ao105 ’ ‘d ~ . ignition powertransis. ~ ( 52 Ignition coil.Troubleshooting Output signal pattern Diagnostic item Check item (Remedy) Memory Retained Ignition coil. Ignition power transistor unit (No. 44 MULTIPORT FUEL INJECTION .l Harness and connector tor unit l Ignition coil (No.) l 69 ym P12AOlOS Right bank heated oxygen sensor $!$fornia model from 1994) Harness and connector Retained : ~~?$e%?u”re”” SenSor l Injectors (Replace if defective) l Intake air leaks - tinuous) Normal state ui240104 NOTE Do not reljlace the ECM until a thorough terminal check reveals there are no short/open circuit. connector and induction control valve are normal. 3-6 cylinder) :T12A0105 l l l Harness and connector Ignition coil Ignition power transistor unit Retained 59 :m s12Ao105 / Left bank heated oxygen sensor 1 %%!omia model from 1994> l Harness and connector I Retained I I : $lts&$z!? SenSor l Injectors (Replace if defective) l Intake air leaks l 61 Acablefromtransaxlecontrolmodule. replace air intake plenum assembly. for transmission of torque reduction signal CAKP := R12A0105 Harness and connector Retained (If harness and connector are normal.13A-22 Code No. TSB Revision . Ignition power transistor unit (No. 2-5 cylinder) Y= u12Ao105 l l l Harness and connector Ignition coil Ignition power transistor unit Retained 53 Ignition coil. replace only transaxle control module.) 62 Induction control valve position sensor <Non Turbo> Y- l Q12A0105 Harness and connector Retained (If harness.

the volume air flow sensor outputs a pulse signal which corresponds to the volume of air flow. l Engine control module failed. Range of Check l 3 minutes have passed after engine was started. L Background While the engine is running. Set Conditions The oxygen sensor output voltage does not cross specified voltage for specified seconds. or loose connector.200 r/min. l Intake air temperature is 20-50°C (68-122°F). l l Probable causes Volume air flow sensor failed. Set Conditions Sensor output frequency is 3 Hz or less for 4 seconds. Open or shorted oxygen sensor circuit.Troubleshooting DIAGNOSTIC DETECTION LOGIC 13A-23 L Fault ID 11 Title Heated Oxygen Sensor (front) <Except 1994 and Later California model> / Left Bank Heated Oxygen Sensor (front) cl994 and Later California model> Effect Probable causes l Background The oxygen sensor converts the oxygen density in the exhaust gas to a voltage and outputs it. (b) Fixes the IAC motor in the appointed position so idle air control is not performed. 1. l Engine speed is approx. l Air intake. l Injector failed. l l Range of Check Engine speed is 500 r/min or more. l The engine control module checks the change of an oxygen sensor output voltage (Lean/Rich) in the air/fuel ratio closed loop control. 0 Incorrect fuel pressure. l Engine coolant temperature is approx. l Vehicle is moving at constant speed on a flat. Open or shorted volume air flow sensor circuit.MULTIPORT FUEL INJECTION . l l Fault ID 12 Title Effect Volume Air Flow Sensor Limp-in (a) Uses the throttle position sensor signal and engine signal speed (crankshaft position sensor signal) for basic injector drive time and basic ignition timing from the pre-set mapping. Engine control module failed. i TSB Revision . Limp-in Air/fuel ratio closed loop control is not performed. Oxygen sensor deteriorated. level road surface. l The engine control module checks whether the frequency of this signal output by the volume air flow sensor while the engine is running is at or above the set value. or loose connector.900-2. 80°C (176°F) or more.

or l Sensor output voltage is 0. a specified range. the sensor output voltage is 2 V or more for 4 seconds. Probable causes Range of Check Ignition switch : ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. 0 Open or shorted the intake air temperature sensor circuit. Range of Check Ignition switch : ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. \ ‘d i TSB Revision .6 V or more (corresponding to an intake air temperature of 45% (49°F) or less) for 4 seconds.2 V or less (corresponding to an intake air temperature of 125°C (257’F) or more) for 4 seconds. l Probable causes Background Limp-in 0 The intake air temperature sensor converts the intake air Controls as if the intake temperature to a voltage and outputs it. l Set Conditions l When the closed throttle position switch is ON.13A-24 Fault ID 13 MULTIPORT FUEL INJECTION . or loose connector. l Set Conditions l Sensor output voltage is 4. air temperature is 25°C l The engine control module checks whether the voltage is within (77°F).Troubleshootina Title Effect Intake Air Temperature Sensor Intake air temperature sensor failed. l Engine control module failed.

Range of check Ignition switch : ON l Engine spped is approx. it checks the engine coolant temperature (signal) does not drop while the engine is warming up. 1TSB Revision . Range of Check.6 V or more (correponding to an engine coolant temperature of 40°C (104°F) or less).6 V or less (corresponding to an engine coolant temperature of 40°C (104’F) or more) to 1. Range of Check.1 V or less (correspondinf to an engine coolant temperature of 140°C (284’F) or more for 4 seconds.Troubleshooting Fault ID Title Effect Engine Coolant Temperature Sensor Limp-in Controls as if the engine coolant temperature is 80% (176’F). 50 r/min or more. l The engine control module checks whether the voltage is within a specified range. l The engine control module checks whether the pulse signal is input while the engine is cranking. l After this. Engine control module failed.MULTIPORT FUEL INJECTION . or loose connector. or l Sensor output voltage is 0. or loose connector. the crankshaft position sensor outputs a pulse signal. l . Engine control module failed. Set Conditions Range of check l Ignition switch : ON l Engine is not cranking. l l Li Fault ID 22 l Title Effect Crankshaft Position Sensor No limp-in l l Probable causes Crankshaft position sensor failed. Set conditions l Ohe sensor output voltage increases from 1. Open or shorted crankshaft position sensor circuit.6 V or more (corresponding to an engine coolant temperature of 45% (-49’F) or less for 4 seconds. Set conditions Regular signal patterns for cylinder discrimination from the crankshaft position sensor signal and the camshaft position sensor signal are not input 20 times in a 10 seconds period. Set Conditions Range of check l Ignition switch : ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Set conditions Sensor output voltage does not change for 4 seconds (no pulse signal input). the sensor output voltage is 1. Background When the engine is running. Open or shorted the engine coolant temperature sensor circuit. l l Probable causes Engine coolant temperature sensor failed. l The engine control module checks the pulse signal patterns of the crankshaft position sensor. L 21 l Background The engine coolant temperature sensor converts the engine coolant temperature to a voltage and outputs it. Set conditions l Sensor output voltage is 4. In addition. Range of check Engine is cranking.6 V or more for 5 minutes.

or loose connector. the No. 0 The engine control module checks whether the pulse signal is input.) l l Probable causes Camshaft position sensor failed. Set conditions Regular signal patterns for cylinder discrimination from the crankshaft position sensor signal and the camshaft position sensor signal are not input 20 times in a 10 seconds period.13A-26 Fault ID 23 l MULTIPORT FUEL INJECTION . Set conditions Sensor output voltage does not change for 4 seconds (no pulse signal input). Set Conditions ut voltage does not change for 4 seconds (no pulse TSB Revision . l Closed throttle position switch : OFF l Engine speed is 3. l Driving under high engine load conditions. 0 The engine control module checks the pulse signal patterns of the camshaft position sensor. Engine control module failed.000 r/min or more.Troubleshootina Title Effect Camshaft Position Sensor Limp-in (a) Injects fuel into all cylinders simultaneously. Open or shorted camshaft position sensor circuit. (After the ignition switch is turned to ON.1 cylinder top dead center is not detected at all. Range of Check. the No. l ntrol module failed. Set Conditions Range of check l Ignition switch : ON 0 Engine speed is approx. l l le speed sensor outputs a pulse signal while the vehicle ne control module checks whether the pulse signal Range of Check Ignition switch : ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts.1 cylinder top dead center is not detected at all. 50 r/min or more. (After the ignition switch is turned to ON. Range of check Ignition switch : ON l Engine is not cranking. the camshaft position sensor outputs a pulse signal. Background When the engine is running.) (b) Cuts off the fuel supply 4 seconds after a problem is detected.

the line voltage will become low.5 V or more (corresponding to barometric pressure of 114 kPa (33. Range of Check l Ignition switch : ON l Excluding 60 seconds after the ignition switch is turned ON or immediately after the engine starts. ignition timing for Standard octane fuel. l 1 TSB Revision . or l Sensor output voltage is 0. Engine control module failed. Open or shorted barometric pressure sensor circuit. Range of Check l Ignition switch : ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Set Conditions l The change in the knock sensor output voltage (knock sensor peak voltage at each l/3 revolution of the crankshaft) is less than 0. i LJ l Limp-in Background The knock sensor converts the vibration of the cylinder block Switches the ignition into a voltage and outputs it. Hg) or more) for seconds. If there is a malfunction of the timing from ignition timing for high octane to knock sensor. Set Conditions l Sensor output voltage is 4. Background l If there is a short circuit in the line between the engine control module and the ignition timing adjustment terminal. Open or shorted knock sensor circuit. a specified range. Fault ID 36 Title Effect Ignition Timing Adjusting Signal No limp-in l Probable causes Ignition timing adjusting signal wire circuit is shorted to the ground. l Engine speed is approx. Limp-in Background The barometric pressure sensor outputs a voltage which Controls as if the barometric pressure is 101 corresponds to the barometric pressure. Hg) or less) for seconds. Engine control module failed. the voltage output will not change.Troubleshootina Fault ID 25 ii l 13A-27 Title Effect Barometric Pressure Sensor l l Probable causes Barometric pressure sensor failed. l The engine control module checks whether this occurs. Range of Check Ignition switch : ON Set Conditions The ignition timing adjusting signal wire is shorted to the ground. kPa ( 7 6 0 mmHg)(sea l The engine control module checks whether this voltage is within level).MULTIPORT FUEL INJECTION .33 kPa (1. or loose connector.7 in.57 in.06 V for 200 times in succession. 5. l Battery voltage is 8 V or more. or loose connector.000 r/min or more. a 4 a 4 l Fault ID 31 Knock Sensor Title Effect l l l Probable causes Knock sensor failed. l The engine control module checks whether the voltage changes.2 V or less (corresponding to barometric pressure of 5. Engine control module failed.

l Engine speed is approx.15 V or less.200 r/min. l Engine coolant temperature is approx. l The throttle position sensor output voltage is 1. Range of Check 0 Engine speed is approx. Engine control module failed. l Actuator test by scan tool is not carried out. Injector failed. pen or shorted oxygen l l Incorrect fuel pressure. level road surface. l l tput voltage does not cross specified voltage Probable causes I module failed. i TSB Revision . Set Conditions Surge voltage of injector coil is not detected for 4 seconds. 50-1. 1. l Intake air temperature is 20-50°C (68-122°F).900-2. 80% (176OF) or more.000 r/min. l Vehicle is moving at constant speed on a flat.13A-28 MULTIPORT FUEL INJECTION . Range of Check 3 minutes have passed after engine was started.Troubleshooting oxygen sensor Probable causes xygen sensor deteriorated.

6 in. Turbo> 13A-29 Title Effect EGR System No limp-in EGR valve does not open. this excludes cases where no ignition signal is input from any coils. l EGR solenoid failed. 3. l Intake-air temperature is O-55% (32-131°F). However. 50-4. 1. or imperfect contact of the connector. EGR control vacuum istoo low. l Engine is not cranking. l Engine control module failed.100 r/min. l Engine speed is approx. 0 Ignition power transistor unit failed. Effect Background l Ignition power transistor unit converts ON/OFF variation of the ignition coil to the pulse signal (Ignition signal) and outputs it.900-2. Set Conditions l Sensor output voltage is approx.Troubleshooting Fault ID 43 daliforniaNon Turbo.000 r/min. level road surface. or loose connector. l l Probable causes Ignition coil failed Disconnection or short circuit of the primary ignition circuit. l EGR temperature sensor failed.Hg) or more. l The engine control module detects whether ignition occurs or not by checking this signal while the engine is running. 0 Open or shorted EGR temperature sensor circuit. Range of Check l Engine speed is approx. 6 minutes or more have passed after engine was started. a problem is detected after each operation. l Engine control module failed. 1 1 TSB Revision . l When the range of check operation. Set Conditions The ignition signal from the same coil is not input for 4 seconds.MULTIPORT FUEL INJECTION . l l Probable causes Backaround EGR temperature sensor converts the EGR gas temperature to a voltage and outputs it. Limp-in Cuts fuel of an ignition signal abnormal cylinder. l Barometric pressure is 93. l The above conditions continue for a continuous period of 15 seconds. l Range of Check l Approx.3 kPa (27.5 V (corresponding to an EGR temperature of 70°C (158’F)) or more. l Vehicle is moving at constant speed on a flat. l Engine control module checks whether an output voltage of the EGR temperature sensor is within a specified range. given above which accompany starting of the engine are carried out two times in succession.

1 V or heated oxygen sensor (front) output voltage is 0. 0 Open toop control in operation.Troubleshooting Probable causes nverts the oxygen density in the exhaust odule checks an output voltage of the the oxygen volume in the exhaust gas Range of Check Approx. Set Conditions heated oxygen sensor (rear) output voltage is 0. l Closed throttle position switch : OFF l The throttle position sensor output voltage is 4. 80% (176°F) or more.5 V or ve conditions continue for a continuous period of 5 Probable causes e control module inputs a torque reduction request ) when the transaxle is shifted to the engine control shift completes within the usually specified hours. Set Conditions e control module failed. 3 minutes or more have passed after engine was started. TSB Revision I . l 20 seconds have passed after deceleration finished. 50 r/min or more. l Engine coolant temperature is approx.MULTIPORT FUEL INJECTION . l ntrol module failed. l Engine speed is approx.1 V or more. ntrol module checks whether the input hours of uction request signal (LOW) is within a specified Range of Check l 60 seconds or more have passed immediately after engine was started.

or loose connector. l The above conditions continue for a continuous period of 5 seconds. converter. Open or shorted variable induction control motor circuit. Engine control module failed. l l l l l Fault ID 69 cl994 and Right a t e r Califor.Troubleshooting Fault ID Title Effect Limp-in The induction control valve is driven under condition of the valve full opening. Open or shorted induction control valve position sensor circuit. or loose connector. 8 minutes or more have passed after engine was started. l 20 seconds have passed after deceleration finished. l The engine control module checks an output voltage of the loop control) is peroxygen sensor when the oxygen volume in the exhaust gas formed only by using a signal of the oxygen is little (Air/fuel ratio is rich. or loose connector. sensor (front) which is Range of Check installed on the front l Approx. 50 r/min or more. l Closed throttle position switch : OFF l The throttle position sensor output voltage is 4. 0 Open loop control in operation. Engine controt module failed. Set Conditions l The heated oxygen sensor (rear) output voltage is 0. l The engine control module checks an actual valve position when the intake-air control valve drive motor was driven. a problem is detected after each operation. 80°C (176’F) or more. Open or shorted oxygen sensor circuit. side of the catalytic l Engine coolant temperature is approx.MULTIPORT FUEL INJECTION .1 V or less.5 V or more. 13A-31 L 62 <Non Induction Control Valve Position Turbo> Sensor Background l The induction control valve position sensor outputs a pulse signal according to a change of the valve opening.). l Battery voltage is 10 V or more. l l l Oxygen sensor deteriorated. TSB Revision . l Engine speed is approx. Probable causes tnduction control valve position sensor failed. Variable induction control motor failed.(rear) nia model> Title Bank Heated Oxygen Sensor Effect Probable causes L Limp-in Background l The oxygen sensor converts the oxygen density in the exhaust The air/fuel ratio feedback control (closed gas to a voltage and outputs it. Range of Check l 60 seconds or more have passed immediately after engine was started.1 V or more. l When the range of check operations given above which accompany starting of the engine are carried out four times in succession. Set Conditions l The intake-air control valve does not reach target position even after the intake-air control valve drive motor is operated several times. l The heated oxygen sensor (front) output voltage is 0.

(2) Idle air control motor fixed at predetermined position.) (1) Fuel injected into the cylinders in the order l-2-3-4-5-6 with irregular timing (Provided that no No. and the air-fuel ratio feedback control (closed loop control) is not performed. Trouble item Volume air flow sensor Controls to be provided in the event of trouble (1) Based on throttle position sensor (TPS) signal and engine speed signal (crank angle sensor signal) basic driving time of injectors and basic ignition timing is read from the prese map.1 cylinder top dead center position has been detected since the ignition switch was placed in the ON position) Controls provided on the assumption that barometric pressure is 101 kPa (760 mmHg) (sea level) Ignition timing is changed from that for premium gasoline to that for regular gasoline.Troubleshooiing LIST OF FAIL-SAFE/BACK-UP FUNCTIONS When the failure of a major sensor is detected by the on-board diagnostics. and no idling speed control achievec Controls provided on the assumption that intake air temperature is 25% (77°F) No additional fuel injection provided on the basis of throttle position sensor signal at acceleration Controls provided on the assumption that engine coolant temperature is 80°C (176°F) (Even if the sensor signal returns to normal. this control mode is retained until the ignition switch is set to OFF. TSB Revision .13A-32 MULTIPORT FUEL INJECTION . Fuel cut for cylinders whose ignition signal is abnormal Intake air temperature sensor Throttle position sensor (TPS) Engine coolant temperature sensor Camshaft position sensor Barometric pressure sensor Knock sensor Ignition coil and ignition power transistor unit Communication line with transmission control module c/VT> ieated oxygen sensor (front) <All models> Heated oxygen sensor (rear) cl994 and later California model> No ignition timing retard control (overall engine-transmission control) achieved when transmission speeds are changed No air-fuel ratio closed loop control achieved Only signals of oxygen sensor (front) installed upstream of catalyst are used. the preset control logic provides controls to assure safe operation of the vehicle.1 cylinder top dead center position has been detected since the ignition switch was placed in the ON position) (2) Fuel cut 4 seconds after a failure was detected (Provided that no No.

Unit ~ Engine coolant temperature Engine speed Vehicle speed Long-term fuel compensation (Long-term fuel trim) Short-term fuel compensation (Short-term fuel trim) Fuel control condition “C r/min km/h % % 0 Open loop l Closed loop l Open loop . and can then be used in simulation tests for troubleshooting. The ECM records the diagnostic trouble code and the engine operating conditions at the time the malfunction was detected. the diagnostic trouble code is memorized. and the diagnostic results can be read out with a scan tool. In addition.drive condition l Open loop . The diagnostic trouble codes will. These data are called “freeze frame” data. the diagnostic trouble code can also be erased by turning on the ignition switch to ON and sending the diagnostic trouble code erase signal from the scan tool to the engine control module. and if plural items are activated. This data can be read by using the scan tool. When a malfunction has continued for a specified time or longer since the irregular signal is initially monitored. the engine control module judges that a malfunction has occurred. In this case. however.MULTIPORT FUEL INJECTION . for items marked with a I‘*“. This data indicates the engine operating condition from when nothing at all is detected to the initial detection of malfunction. Moreover. The 50 diagnostic items are provided as follows. since memorization of the diagnostic trouble codes is backed up directly by the battery. a diagnostic trouble code is recorded on the first detection of the malfunction. be erased when the battery terminal or the engine control module connector is disconnected. However. Data 13A-33 Caution If the sensor connector is disconnected with the ignition switch turned on.02 (rear) failed % Calculation load value Diagnostic trouble code during data recording / i TSB Revision 1 . a diagnostic trouble code is recorded when the engine is restarted and the same malfunction is re-detected. Caution The diagnostic trouble code of the ignition timing adjustment signal is output whenever terminal for ignition timing adjustment is grounded.DTC set l Closed loop . After the ECM first detects a malfunction.Troubleshooting ON-BOARD DIAGNOSTICS <From 1996 models> The engine control module monitors the input/output signals (some signals at all times and the others under specified conditions) of the engine control module. Therefore. There are 50 diagnostic items. it is not a malfunction that the code is output when adjusting ignition timing. the diagnostic results are memorized even if the ignition key is turned off. they are all indicated sequentially from the smallest code number. send the diagnostic trouble code erase signal to the engine control module in order to erase the diagnostic memory. Data items are as follows.

(6) Coolant temperature at starting: 10% (50°F) or more (7) Intake air temperature at starting: 40°C (104OF) or more (8) Intake air temperature during driving: 50°C (122”F)or more Drive cycle pattern 0 E F G H I . CKP sensor. Before beginning with the first driving. EVAP purge. overdrive switch ON. For checking the following three systems for illumination of the check engine/malfunction indicator lamp.j. emission control system J: ECT sensor K: TP sensor. Fuel pressure l P: CMP sensor. 111 1 . turn off the ignition switch for more than 10 seconds. Perform test drives under the following conditions: (1) On vehicles with automatic transmission. IAT sensor.13A-34 MULTIPORT FUEL INJECTION . 3.J K L M N 0 P Q H H 1 H H H H H I. (2) Acceleration: Keep the throttle in l/4-3/4 opened conditions. A/C OFF and transmission in neutral. NOTE 1. In case of the systems other than those three mentioned above. perform the driving up to the point B twice successively. VAF sensor Q: Excessive time to enter closed loop fuel control TSB Revision 1 . EGR. turn off the ignition switch for more than 10 seconds.Troubleshooting OBD-II DRIVE CYCLE All kinds of diagnostic trouble code can be monitored by carrying out a short drive in accordance with the following drive cycle pattern. l EGR system l Fuel trim l Evaporative emission control system 2. doing such a drive allows to regenerate any kind of trouble which involves illuminating the check engine/malfunction indicator lamp and to check if the repair procedure has eliminated the trouble (the check engine/malfunction indicator lamp is no more illumir$ed).11 I . set selector lever in D range.H@ I I I HO! ! I / H@ / I ( H. (5) During stopping: Keep the throttle fully closed. (4) During cruising: Keep the throttle opening constant. .000 r/min (without operating brake and clutch). In other words. Before beginning with the first driving. Power/Economy changeover switch in P range. I !!I IIIH 11:I 4-A i-b3 HO HO H H H I ! HQ H 6FU2465 Catalytic converter 02 sensor 02 sensor circuit (open/short) 02 sensor heater circuit (open/short) Misfire EGR system MDP sensor Fuel trim Evapo. I’. (3) Deceleration: Lower the vehicle speed below 15 mph or the engine speed below 1.” I I 1 1 HO! . performing a drive up to the point A twice successively will suffice for determining if the check engine/malfunction indicator lamp illuminates or not. BAR0 sensor L: idle control system M: CTP switch Injector circuit (open) N: 0: Solenoid valve circuit (open) TC waste gate.

<General scan tool mode> PO1 00 DTC No.MULTIPORT FUEL INJECTION .) Harness and connector (If harness and connector are normal. replace volume air flow sensor assembly.) Harness and connector Intake air temperature sensor Harness and connector Engine coolant temperature sensor Harness and connector Throttle position sensor Closed throttle position switch O2 sensor (front) 02 sensor harness and connector Injector Harness and connector (If harness and connector are normal. replace volume air flow sensor assembly. replace Right bank 02 sensor front.) Harness and connector Left bank 02 sensor (front) heater Harness and connector Left bank 02 sensor (rear) Harness and connector Left bank 02 sensor (rear) heater Volume air flow sensor output frequency Injector Fuel pressure Intake air leaks Engine coolant temperature sensor Intake air temperature sensor Barometric pressure sensor O2 sensor Exhaust manifold cracked Retained PO1 05 PO1 05 l Retained PO110 PO115 PO120 PO110 PO115 PO120 l l l l l l l Retained Retained Retained PO125 l l l Retained PO1 30 l Retained PO135 PO136 - O2 Sensor Heater Circuit Malfunction (Bank 1 Sensor 1) O2 Sensor Circuit Malfunction (Bank 1 Sensor 2) O2 Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) l l l l l l l Retained Retained Retained Retained i PO141 PO150 - O2 Sensor Circuit Malfunction (Bank 2 Sensor 1) O2 Sensor Heater Circuit Malfunction (Bank 2 Sensor 1) PO155 PO156 PO161 PO170 - l l l l l l l l l l l Retained Retained Retained Retained O2 Sensor Circuit Malfunction (Bank 2 Sensor 2) O2 Sensor Heater Circuit Malfunction (Bank 2 Sensor 2) Fuel Trim Malfunction (Bank 1) PO173 - Fuel Trim Malfunction (Bank 2) l l l l TSB Revision .) Harness and connector Right bank 02 sensor (front) heater Harness and connector Right bank 02 sensor (rear) Harness and connector Right bank 02 sensor (rear) heater Harness and connector (If harness and connector are normal. replace Left bank 02 sensor front.Troubleshooting DIAGNOSTIC CHART (FAULT TREE) 13/J-35 L DTC No. <Scan tool (MUT-II) mode> PO100 Diagnostic item Volume Air Flow Circuit Malfunction Barometric Pressure Circuit Malfunction Intake Air Temperature Circuit Malfunction Engine Coolant Temperature Circuit Malfunction Throttle Position Circuit Malfunction Excessive Time to Enter Closed Loop Fuel Control’ 02 Sensor Circuit Malfunction (Bank 1 Sensor 1) Check item (Remedy) Memory l Harness and connector (If harness and connector are normal.

1) Retained PO400 - l l l l l Retained PO403 PO421 - Exhaust Gas Recirculation Solenoid Malfunction Warm Up Catalyst Efficiency Below Threshold (Bank 1) Warm Up Catalyst Efficiency Below Threshold (Bank 2) l l l Retained Retained PO431 l Retained PO440 - Evaporative Emission Control -System Malfunction l l l l Retained PO443 - Evaporative Emission Control System Purge Control Valve Circuit Malfunction l l Retained TSB Revision . etc.) Harness and connector EGR valve EGR solenoid EGR valve control vacuum Manifold. etc. replace camshaft position sensor.) Exhaust manifold (Replace the catalytic converter if there is no cracks. differential pressure sensor Harness and connector EGR solenoid Exhaust manifold (Replace the catalytic converter if there is no cracks. replace Harness and connector (If harness and connector are normal.) Harness and connector Evaporative emission purge solenoid Purge control valve Vacuum hoses routing Harness and connector Evaporative emission purge solenoid (No.13A-36 MULTIPORT FUEL INJECTION .Troubleshooting Diagnostic item Check item (Remedy) Injector Circuit Malfunction - position sensor circuit and Circuit Malfunction PO340 PO340 Camshaft Position Sensor Circuit Malfunction Exhaust Gas Recirculation Flow Malfunction l (If harness and connector are normal.

a diagnostic trouble code is recorded when the engine is next started and the same malfunction is re-detected. After the ECM detects a malfunction. 5. However.MULTIPORT FUEL INJECTION . for items marked with a “*“. the diagnostic trouble code is recorded on the first detection of the malfunction. 1 TSB Revision . 02: Heated oxygen sensor 4. 3. Sensor 1: indicates sensors which are mounted closest to the engine. <Scan tool (MUT-II) mode> PO500 PO505 - 13A-37 Memory Retained Retained Retained Retained Diagnostic item Vehicle Speed Sensor Malfunction Idle Control System Malfunction Closed Throttle Position Switch Malfunction Transmission Range Sensor Circuit Malfunction (RPNDL Input) Transmission Fluid Temperature Sensor Circuit Malfunction Turbocharger Waste Gate Actuator Malfunction Check item (Remedy) Harness and connector Vehicle speed sensor Harness and connector Idle air control motor Harness and connector Closed throttle position switch Harness and connector Park/Neutral position switch Harness and connector Transaxle oil temperature sensor Harness and connector Turbocharger waste gate solenoid Turbocharger waste gate actuator Vacuum hoses routing Harness and connector Turbocharger waste gate solenoid Harness and connector Fuel pressure solenoid Harness and connector Harness and connector MDP sensor Harness and connector Pulse generator Harness and connector Converter clutch solenoid Shift control solenoid Pressure control solenoid l l l l l l l l PO710 P1103 l l l l l l Retained Retained P1104 P1105 P1300 P1400 - Turbocharger Waste Gate Solenoid Malfunction Fuel Pressure Solenoid Malfunction l l l l l Retained Retained Retained Retained P1300 Ignition Timing Adjustment Circuit Malfunction Manifold Differential Pressure (MDP) Sensor Circuit Malfunction PG Assy Malfunction Solenoid Assy Malfunction l l P1715 P1750 l l l l l l Retained Retained NOTE 1. Sensor 2: indicates sensors which are mounted next-closest to the engine. <General scan tool mode> PO500 PO505 PO510 PO705 DTC No. Do not replace the engine control module (ECM) until a through terminal check reveals there are no short/open circuits.Troubleshooting DTC No. 2.

or loose connector. Set Conditions Sensor output voltage is 4.6 V or more (corresponding to an intake air temperature of -45°C (-49°F) or less) for 4 seconds. Engine control module failed. Engine control module failed. PO1 05 l Title Probable causes Barometric Pressure Circuit Malfunction l l Background The barometric pressure sensor outputs a voltage which corresponds to the barometric pressure.MULTIPORT FUEL INJECTION . l l Intake air temperature sensor failed. the volume air flow sensor outputs a pulse signal which corresponds to the volume of air flow. Set Conditions Sensor output frequency is 3 Hz or less for 4 seconds.57 in. l The engine control module checks whether the voltage is within a specified range. Open or shorted volume air flow sensor circuit.2 V or less (corresponding to a barometric pressure of 5. PO1 00 l Title Volume Air Flow Circuit Malfunction l l Probable causes Volume air flow sensor failed. Range of Check Engine speed is 500 r/min or more. Engine control module failed.Hg) or less) for 4 seconds. d Probable causes l l DTC No.5 V or more (corresponding to a barometric pressure of 114 kPa (33. J Background While the engine is running. PO110 l Title Intake Air Temperature Circuit Malfunction Background The intake air temperature sensor converts the intake air temperature to a voltage and outputs it.2 V or less (corresponding to an intake air temperature of 125°C (257OF) or more) for 4 seconds. l TSB Revision . l The engine control module checks whether the frequency of this signal output by the volume air flow sensor while the engine is running is at or above the set value.Hg) or more) for 4 seconds. Open or shorted the intake air temperature sensor circuit. l Battery voltage is 8 V or more. or loose connector. or l Sensor output voltage is 0.33 kPa (1. Open or shorted barometric pressure sensor circuit. l DTC No. Range of Check Ignition switch: ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. l Barometric pressure sensor failed. or loose connector. l The engine control module checks whether this voltage is within a specified range. Set Conditions l Sensor output voltage is 4. or l Sensor output voltage is 0. Range of Check l Ignition switch: ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts.Troubleshootinn DIAGNOSTIC DETECTION LOGIC DTC No.7 in.

Range of Check l Ignition switch: ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. ) The engine control module checks whether the voltage is within a specified range. l The engine control module checks whether the voltage is within a specified range. Range of Check l Ignition switch: ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Engine control module failed. or l The sensor output voltage is 0. Engine control module failed. Title 13A-39 Probable causes Engine Coolant Temperature Circuit Malfunction l l L’ PO115 3ackground ) The engine coolant temperature sensor converts the engine coolant temperature to a voltage and outputs it. the sensor output voltage is 2 V or more for 4 seconds. Set conditions l The sensor output voltage increases from 1. i DTC No. l Engine speed is approx. or loose connector. or loose connector.1 V or less (corresponding to an engine coolant temperature of 140°C (284’F) or more for 4 seconds. l After this.6 V or more (corresponding to an engine coolant temperature of -45°C (49OF) or less for 4 seconds. or l Sensor output voltage is 0. Set Conditions When the closed throttle position switch is ON. l l l l Throttle position sensor failed or maladjusted. it checks the engine coolant temperature (signal) does not drop while the engine is warming up. TSB Revision I . In addition.6 V or less (corresponding to an engine coolant temperature of 40°C (104°F) or more) to 1. PO1 20 l Title Probable causes Throttle Position Circuit Malfunction l l Background The throttle position sensor outputs a voltage which corresponds to the throttle valve opening angle. it checks that the voltage output does not become too large while the engine is idling.Troubleshooting DTC No.000 r/min or more. Range of check l Ignition switch: ON l Engine speed is approx. Lange of Check.6 V or more (correponding to an engine coolant temperature of 40°C (104°F) or less). In addition. Intake air temperature is 20°C (68°F) or more when the engine is started. 500-3. Open or shorted throttle position sensor circuit. Closed throttle position switch signal wire shorted. 50 r/min or more. l During low load operations Set Conditions l The sensor output voltage is 4. l l l Engine coolant temperature sensor failed. Set conditions l The engine coolant temperature takes 5 minutes or more to rise to approximately 50°C (122OF) after the engine is started. Closed throttle position switch ON malfunction. the sensor output voltage is 1. Range of check Engine coolant temperature is 20% (68°F) or more when the engine is started. Open or shorted the engine coolant temperature sensor circuit.6 V or more for 10 seconds. Set Conditions Range of check l Ignition switch: ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Set conditions l Sensor output voltage is 4.6 V or more for 5 minutes.MULTIPORT FUEL INJECTION .2 V or less for 4 seconds.

an engine speed of 1. Open circuit in heated oxygen sensor output line. In addition. The engine control module checks the time taken until closed-loop fuel control commences. Engine control module failed. Injector failed. and checks the response speed of oxygen sensor. 1 DTC No. / PO1 35 I Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1) l l l Probable causes Open or shorted oxygen sensor heater circuit. PO1 25 l l MULTIPORT FUEL INJECTION . DTC No.200 r/min. etc..Troubleshootina Title Probable causes Excessive Time to Enter Closed Loop Fuel Control l l l Background The MFI system reduces exhaust emissions by means of closed-loop fuel control. Heated oxygen sensor failed. PO1 36 Title Probable causes Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) l l l Background The engine control module checks for an open circuit in the heatd oxygen sensor output line. Background The engine control module checks whether the heater current is within a specified range when the heater is energized. Range of Check. TSB Revision . an intake air temperature of 20-50°C (68-122’F). when the amount of fuel injected is increased ontrol of the air-fuel ratio. the engine control module also checks for an open circuit in the oxygen sensor e control module failed. Probable causes l l When the oxygen sensor begins to deteriorate. Engine control module failed. Range of Check. Set Conditions Even though the specified length of time (approximately 30 seconds) has passed since the conditions* were met following starting of the engine. Set Conditions The heated oxygen sensor output line is open-circuit. Engine control module failed. *: The conditions are an engine coolant temperature of at least 80% (176OF). Open circuit in oxygen sensor heater. Range of Check.13A-40 DTC No. the MFI system does not enter closed-loop fuel control.900-2. Set Conditions The oxygen sensor heater current is either lower than several dozen milliamperes or higherthan several amperes. the oxygen sensor signal response becomes circuit in oxygen sensor The engine control module forcibly varies the air-fuel mixture to make it leaner and richer. Heated oxygen sensor failed.

Open circuit in heated oxygen sensor output line. / po155 Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 1) l l l Probable causes Open or shorted oxygen sensor heater circuit. Set Conditions The heated oxygen sensor output line is open-circuit. Open circuit in oxygen sensor heater. Engine control module failed. Open circuit in oxygen sensor output line. Background The engine control module checks whether the heater current is within a specified range when the heater is energized. Engine control module failed. Engine control module failed. / L 1 DTC No. Set Conditions The oxygen sensor heater current is either lower than several dozen milliamperes or higherthan several amperes. Range of Check. PO1 41 Title Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) l l l Probable causes Open or shorted oxygen sensor heater circuit. Heated oxygen sensor failed. DTC No. The oxygen sensor output line is open-circuit. PO1 50 l Title Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 1) l l l Probable causes Heated oxygen sensor deteriorated. the oxygen sensor signal response becomes poor. In addition. Engine control module failed. Open circuit in oxygen sensor heater. 1. and checks the response speed of oxygen sensor. Range of Check. . PO1 56 Title Probable causes Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 2) l l l Background The engine control module checks for an open circuit in the heatd oxygen sensor output line. Background When the oxygen sensor begins to deteriorate. Background The engine control module checks whether the heater current is within a specified range when the heater is energized. Set Conditions The oxygen sensor heater current is either lower than several dozen milliamperes or higherthan several amperes. * . Engine control module failed.MULTIPORT FUEL INJECTION . DTC No. Set Conditions The oxygen sensor heater current is either lower than several dozen milliamperes or higher than several amperes. Open circuit in oxygen sensor heater. Range of Check. l The engine control module forcibly varies the air-fuel mixture to make it leaner and richer. Set Conditions The response of the oxygen sensor signal is slow when the amount of fuel injected is increased or decreased by an override during closed-loop control of the air-fuel ratio. Range of Check. the engine control module also checks for an open circuit in the oxygen sensor output line. Background The engine control module checks whether the heater current is within a specified range when the heater is energized. I PO1 61 Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 2) l l l Probable causes Open or shorted oxygen sensor heater circuit. 1 DTC No. I TSB Revision I r .Troubleshooting DTC No.. Range of Check.

Set Conditions Surge voltage of injector coil is not detected for 4 seconds.15 V or less. etc. seals. PO300 Random Misfire Detected Title Probable causes l Background 0 If a misfiring occurs while the engine is running. Open or shorted throttle position sensor circuit. ntake air temperature sensor etric pressure sensor DTC No. l There are multiple cylinders for which the number of misfires for every 200 r/min of the l Low compression pressure. Set Conditions 0 Incorrect air-fuel ratio. l Intake air temperature sensor failed l Barometric pressure sensor failed. 50-1. Range of Check. control of the air-fuel ratio.000 r/min of the engine exceeds the specified number. l Heated oxygen sensor failed. l The engine control module checks for changes in the engine speed. 0 Engine control module failed. 0 The engine control module checks whether the fuel compensation value is within a specified range.Cylinder-6 l- Probable causes Injector failed. Range of Check l Engine speed is approx. Range of Check. PO1 70 l MULTIPORT FUEL INJECTION . 0 Incorrect fuel pressure.13A-42 DTC No. Engine control module failed. l The engine control module checks this surge voltage. engine exceeds the specified number. l Actuator test by scan tool is not carried out. l l l ygen sensor failed. 0 There are multiple cylinders for which the number of misfires for every 1. or too small. the fuel compensation value bacomes too large l Injector failed. Set Conditions l Engine coolant temperature The fuel compensation value exceeds the specified range for 10 seconds during closed-loop sensor failed. If a malfunction occurs in the fuel system. Background A surge voltage is generated when the injectors are driven and the current flowing to the injector coil is shut off.000 r/min. Engine coolant temperature sensor failed. l l l DTC No. Engine control module failed.mtir system related part(s) 0 Poor crankshaft position sensor signal. PO201 PO206 l Title Injector Circuit Malfunction Cylinder-l . l The throttle position sensor output voltage is 1. Probable causes Background If a malfunction occurs in the fuel system. Range of Check. the engine speed suddenly changes. or loose connector.Troubleshooting Title Fuel Trim Malfunction (Bank 1) Probable causes Background l Volume air flow sensor failed. TSB Revision . $. the fuel compensation value bacomes too large or too small. l The engine control module checks whether the fuel compensation value is within a specified l Air drawn in from gaps in gasket range. Set Conditions The fuel compensation value exceeds the specified range for 10 seconds during closed-loop control of the air-fuel ratio. l Engine control module failed.

When the engine is running. Set Conditions The number of misfires for every 200 r/min of the engine exceeds the specified number (single cylinder). Engine control module failed. the engine speed suddenly changes. Set Conditions Sensor output voltage does not change for 4 seconds (no pulse signal input). Open or shorted knock sensor circuit. Range of Check. PO335 l l Title Probable causes Crankshaft Position Sensor Circuit Malfunction l Crankshaft position sensor Background failed. Set Conditions l The changes in the knock sensor output voltage (knock sensor peak voltage at each l/2 revolution of the crankshaft) is less than 0.000 r/min of the engine exceeds the specified number (single cylinder). ” Set Conditions Sensor output voltage does not change for 4 seconds (no pulse signal input). The engine control module checks whether the pulse signal is input while the engine is l Open or shorted crankshaft position sensor circuit. the camshaft position sensor outputs a pulse signal. Range of Check l Ignition switch: ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Knock sensor failed. DTC No. the crankshaft position sensor outputs a pulse signal. Engine is cranking.000 r/min or more. I Title Probable causes l l 1 PO340 /Camshaft Position Sensor Circuit Malfunction Background l When the engine is running.Cylinder-l . DTC No.MULTIPORT FUEL INJECTION . or loose crankina. Range of Check l Ignition switch: ON l Engine speed is approx. l Engine speed is approx. l The engine control module checks for changes in the engine speed. l / i TSB Revision . DTC No. Engine control module failed. or loose connector Engine control module failed. If there is a malfunction of the knock sensor. Camshaft position sensor failed. connector. or loose connector. The number of misfires for every 1. the voltage output will not change. Range of Check l Engine control module failed. PO325 Title Probable causes Knock Sensor 1 Circuit Malfunction l l l Background l The knock sensor converts the vibration of the cylinder block into a voltage and outputs it.Troubleshooting DTC No.06 V for 200 times in succession. l The engine control module checks whether the voltage output changes. Ignition system related part(s) failed. 2. Open or shorted camshaft position sensor circuit. Title Probable causes / l l L PO301 . 50 r/min or more. l The enaine control module checks whether the pulse signal is input.Cylinder-6 Misfire Detected PO306 I Background l If a misfiring occurs while the engine is running.

Open or shorted EGR solenoid circuit. PO421 l Title Probable causes Warm Up Catalyst Efficiency Below Threshold (Bank 1) 0 Catalytic converter deteriorated. l Open or shorted EGR solenoid circuit. l The engine control module checks how the EGR gas flow signal changes. 0 Engine control module failed. flows. Probable causes I I 1 TSB Revision . l EGR solenoid failed. Set Conditions 0 No surge voltage is detected even when the EGR solenoid is turned off. Range of Check. DTC No. Range of Check. l The engine control module checks the outputs of the heated oxygen sensor signals. or loose connector. PO403 Title Probable causes Exhaust Gas Recirculation Solenoid Malfunction l l Background l The engine control module checks current flows in the EGR solenoid drive circuit when the solenoid is ON and OFF. PO400 I MULTIPORT FUEL INJECTION .Troubleshooting Title Probable causes Exhaust Gas Recirculation Flow Malfunction 0 EGR valve does not open. Set Conditions The relation between the signals from the heated oxygen sensors preceding (engine side) and following the catalytic converter meets specified condition. sensor failed. EGR gas l EGR control vacuum is too low. When the catalytic converter has deteriorated. or loose connector. from that which precedes the catalytic converter. Background The signal from the heated oxygen sensor which follows the catalytic converter differs l Engine control module failed. the signal from the heated oxygen sensor which follows the catalytic converter becomes similar to that which precedes the catalytic converter. That is because the catalytic converter purifies exhaust gas.13A-44 DTC No. Set Conditions l Manifold differential pressure The EGR gas flow signal changes little when the EGR solenoid switches from OFF to ON. L DTC No. 0 Engine control module failed. Range of Check. EGR solenoid failed. Background l When the EGR solenoid switches from OFF to ON while the engine is running.

Open or shorted evaporative emission purge solenoid circuit. the difference between the actual engine speed and the target engine speed exceeds the specified value. or loose connector. Engine control module failed. Background The engine control module checks whether current flows in the evaporative emission purge solenoid drive circuit when the solenoid is driven. PO500 l Title Probable causes Vehicle Speed Sensor Malfunction l l Background The vehicle speed sensor outputs a pulse signal while the vehicle is driven. Engine control module failed. Engine control module failed. Set Conditions When the evaporative emission purge solenoid opens and closes while the engine is idling the changes in the fuel compensation value is lower than the specified amounts. Range of Check. PO443 I Title Evaporative Emission Control System Purge Control Valve Circuit Malfunction l l Probable causes Evaporative emission purge solenoid failed. Set Conditions Even though the evaporative emission purge solenoid has switched from OFF to ON. Open or shorted idle air control motor circuit.000 r/min or more. Range of Check. or loose connector. Engine control module failed.Troubleshooting DTC No. l Closed throttle position switch: OFF l Engine speed is 3. 1 TSB Revision . current does not flow to the coil for 4 seconds. Open or shorted evaporative emission purge solenoid circuit. l DTC No. or loose connector. Range of Check. PO440 Title 13A-45 ~ Probable causes Evaporative Emission Control System Malfunction l l Background 0 The evaporative emission purge solenoid opens and closes while the engine is idling. Purge hose connection or routing is defective. or loose connector. PO505 l Title Probable causes Idle Control System Malfunction Idle air control motor failed. the actual engine speed will not be identical l to the target engine speed. l The engine control module checks the difference between the actual engine speed and l the target engine speed. Set Conditions Sensor output voltage does not change for 4 seconds (no pulse signal input). l The engine control module checks whether the pulse signal is output.MULTIPORT FUEL INJECTION . Then the fuel compensation value change according to whether the evaporative emission canister emits purge air or not. Set Conditions After the engine has warmed up. DTC No. DTC No. l The engine control module checks for this changes. Range of Check l Ignition switch: ON l Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. l Driving under high engine load conditions. l Vehicle speed sensor failed. Open or shorted vehicle speed sensor circuit. l Background If there is a malfunction of the IAC system. l l Evaporative emission purge solenoid failed.

Open or shorted park/neutral position switch circuit. PO71 0 l Title Transmission Fluid Temperature Sensor Circuit Malfunction l l Probable causes Oil temperature sensor failed. the transaxle control module outputs a malfunction signal to the engine control module. the vehicle should have been driven at speed on or over 30 km/h at least one time before the vehicle is stopped. Open or shorted closed throttle position switch circuit. or loose connector. l l Park/neutral position switch failed. P1103 l Title Probable causes Turbocharger Waste Gate Actuator Malfunction l l l Background The engine control module always monitors the intake air amount to check if the engine is in overboosted condition. Range of Check. Range of Check. 1 PO705 l Title Transmission Range Sensor Circuit Malfunction (RPNDL Input) I Probable causes l l I Background When a malfunction of the park/neutral position switch is detected. Engine control module failed. Set Conditions A condition where the fuel supply is to be shut off is detected. l Range of Check The vehicle is under stopping. l The engine control module is used for checking the input signal during the engine idling. l The engine speed is approx. “ON” signal can be input from the closed throttle position switch to the engine control module. Boost pressure control system failed. DTC No. Engine control module failed. 1TSB Revision . Range of Check. Set Conditions l “OFF” signal was input from the closed throttle position switch for 2 seconds. l l DTC No. however. l When the engine control module judges that the engine is in an overboosted condition. the transaxle control module outputs a malfunction signal to the engine control module. Set Conditions The park/neutral position switch failure signal is input to the engine control module. or loose connector. 800 r/min or below. Set Conditions The fluid temperature sensor failure signal is input to the engine control module. Engine control module failed.13A-46 DTC No. DTC No. Engine control module failed. Open or shorted temperature sensor circuit. Background When a malfunction of the fluid temperature sensor is detected.Troubleshooting Title Probable causes Closed Throttle Position Switch Malfunction l l Background While the engine is idling without pressing the accelerator pedal. it cuts off the fuel supply to protect the engine. PO51 0 l MULTIPORT FUEL INJECTION . l Turbocharger waste gate actuator failed. l Closed throttle position switch failed. or loose connector.

Set Conditions l After the engine has warmed up. DTC No. Engine control module failed. l Turbocharger waste gate solenoid failed. / P1400 Title Manifold Differential Pressure Sensor Circuit Malfunction l l Probable causes Manifold differential pressure sensor failed. it runs at low or medium load. P1105 Title Probable causes Fuel Pressure Solenoid Malfunction l l Background The engine control module checks current flows in the fuel pressure solenoid drive circuit when the solenoid is ON and OFF. Range of Check. Range of Check.MULTIPORT FUEL INJECTION . DTC No. Background l The manifold differential pressure sensor outputs a voltage which corresponds to the negative pressure in the intake manifold. Engine control module failed. or loose connector. l The engine coolant temperature at the time of starting the engine is 18°C (654°F) or more. l i 1 TSB Revision .2 V or less for 4 seconds. the line voltage will become low.Troubleshooting DTC No. P1300 l Title Probable causes Ignition Timing Adjusting Circuit Malfunction l Background If there is a short circuit in the line between the engine control module and the ignition timing adjustment terminal. Open or shorted turbocharger waste gate solenoid circuit. Title Turbochager Waste Gate Solenoid Malfunction l l 13A-47 i P1104 Background The engine control module checks current flows in the turbocharger waste gate solenoid drive circuit when the solenoid is ON and OFF. ‘Engine control module failed. Set Conditions No surge voltage is detected when the fuel pressure solenoid is turned off. or loose connector Engine control module failed. l Fuel pressure solenoid failed. L Range of Check Ignition switch: ON Set Conditions The ignition timing adjusting signal wire is shorted to the ground. DTC No. or loose connector. Open or shorted manifold differential pressure sensor circuit.5 V or more for 4 seconds. Range of Check. Open or shorted fuel pressure solenoid circuit. l Ignition timing adjusting signal wire circuit is shorted to the ground. Set Conditions No surge voltage is detected when the turbocharger waste gate solenoid is turned off. l The engine control module checks whether this occurs. or the sensor output voltage is 0. l The sensor output voltage is 4. l The engine control module checks whether the voltage output by the manifold differential pressure sensor is within a specified range.

the transaxle control module inputs these failed signals to the engine control module. Engine control module failed. 500 r/min or more.13A-48 DTC No. Pressure control solenoid failed. l Position of selector lever: Except “P” or “N” Set Conditions The failed signals of the torque converter clutch solenoid. l When some one of these solenoids failed.Troubleshooting Title PG Assy Malfunction i l l Probable causes Pulse generator failed. Background The transaxle control module monitors the torque converter clutch solenoid. 1 DTC No. Background The transaxle control module monitors the pulse signals of the pulse generator “A” and “B”. Range of Check l Engine speed is approx. the transaxle control module inputs the pulse generator failed signal to the engine control module. Shift control solenoid failed. 500 r/min or more. L 1 TSB Revision . Engine control module failed. shift control solenoid and pressure control solenoid. l When the pulse generators “A” and “B” are failed. l l Range of Check Engine speed is approx. shift control solenoid or pressure control solenoid were inputted from the transaxle control module to the engine control module. P1715 l MULTIPORT FUEL INJECTION . 1 P1750 l Solenoid Assy Malfunction T l l l l Probable causes Torque converter clutch solenoid failed. Position of selector lever: Except “P” or “N” Set Conditions The pulse generator failed signals were inputted from the transaxle control module to the engine control module.

Troubleshooting LIST OF FAIL-SAFE/BACK-UP FUNCTIONS i 1344-49 When the failure of a major sensor is detected by the on-board diagnostics. Controls to be provided in the event of trouble (1) Based on throttle position sensor (TPS) signal and engine speed signal (crank angle sensor signal).nition switch is set to OFF. basic driving time of injectors and basic ignition timing is read from the preset map. No ignition timing retard control (overall engine-transmission control) achieved when transmission speeds are changed No air-fuel ratio closed loop control achieved Only signals of oxygen sensor (front) installed upstream of catalyst are used. (2) Idle air control motor fixed at predetermined position. The ECM stops supplying fuel to the cylinder with the highest misfiring rate if a misfiring that could damage the catalytic converter is detected. and no idling speed control achieved Controls provided on the assumption that intake air temperature is 25°C (77’F) No additional fuel injection provided on the basis of throttle position sensor signal at acceleration Controls provided on the assumption that engine coolant temperature is 80°C (176°F) (Even if the sensor signal returns to normal.1 cylinder top dead center position has been detected since the ignition switch was placed in the ON position) (2) Fuel cut 4 seconds after a failure was detected (Provided that no No. the preset control logic provides controls to assure safe operation of the vehicle. Fuel cut for cylinders whose ignition signal is abnormal Intake air temperature sensor Throttle position sensor (TPS) Engine coolant temperature sensor Camshaft position sensor Barometric pressure sensor Knock sensor Ignition coil and ignition power transistor unit Induction control valve position sensor <Non Turbo> Communication line with transmission control module <AiT> Heated oxygen sensor (front) Heated oxygen sensor (rear) Misfire detection The induction control valve is driven to full open position. this control mode is retained until the ig.MULTIPORT FUEL INJECTION . i: 1 TSB Revision .) (1) Fuel injected into the cylinders in the order l-2-3-4-5-6 with irregular timing (Provided that no No.1 cylinder top dead center position has been detected since the ignition switch was placed in the ON position) Controls provided on the assumption that barometric pressure is 101 kPa (760 mmHg) (sea level) Ignition timing is changed from that for premium gasoline to that for regular gasoline. Trouble item Volume air flow sensor . and the air-fuel ratio feedback control (closed loop control) is not performed.

(6) Erase the diagnostic trouble code. ABS diagnostic trouble code may be stored and ABS warning lamp turned on. turn it back to ON. referring to the diagnostic chart. If the scan tool is disconnected with the ignition switch placed in the ON position. Be sure to check the battery for voltage and other conditions before starting the test. (3) Be sure to connect or disconnect the scan tool with the ignition switch turned off. 1) Turn the ignition switch to OFF. (5) Erase the diagnostic trouble code by the following procedure. L Ground TSB Revision . NOTE Use adapter harness of MUT-II to connect MUT-II to 1993 and earlier models. WHEN USING THE SCAN TOOL [MULTI-USE TESTER (MUT) <Up to 1993 models> or MUT-II <All models>] (1) Connect the scan tool to the data link connector. (3) Take a reading of the diagnostic output. (2) Turn the ignition switch to ON. 3) Turn the ignition switch to ON and take a reading of the diagnostic output to check if a normal code is output. Do not disconnect the battery before the diagnostic result is completely read. (5) After turning the ignition switch once to OFF.Troubleshooting READ OUT OF DIAGNOSTIC TROUBLE CODE Caution (1) When battery voltage is low. (4) Repair the problem location.13A-50 MULTIPORT FUEL INJECTION . Scan tool /. 2) After removing the battery cable from the battery terminals for 10 seconds or more. (2) Turn the ignition switch to ON. (7) Recheck to be sure that the condition is normal. (4) Repair the problem location. reconnect the cable. idle the engine for approx. 15 minutes. 4) With the engine warmed up. referring to the diagnostic chart. (3) Read the diagnostic output indicated by the deflection of the voltmeter pointer.(MB991502) ZZOFO164 Y 27FUO999 r MFI diagnosis WHEN USING THE VOLTMETER CUP TO 1993 MODELS> (1) Connect an analog voltmeter to the diagnostic output terminal (terminal 1) and ground terminal (terminal 12). no detection of failure is possible. (2) Diagnostic item is erased if the battery or the engine control module connector is disconnected.

(4) Repair the problem location. made while diagnostic trouble code is output In case of diagnostic trouble code No. 15 minutes. (2) Road test the vehicle.0. \ 27FU1468 1 Check engine/malfunction indicator lamp WHEN USING THE CHECK ENGINE/MALFUNCTION INDICATOR LAMP <1994 AND 1995 MODELS> (1) Using the special tool. (2) Turn the ignition switch to ON. 1 26FU2061 7FU1657 L DIAGNOSIS BY DIAGNOSTIC TEST MODE II (INCREASED SENSITIVITY) (1) Using the scan tool. ground the diagnostic test mode control terminal (terminal 1) of the data link connector. Diagnostic Trouble Code Check Harness.5 second .Troubleshooting 13A-51 - . changeover the diagnostic test mode of the engine control module to DIAGNOSTIC TEST MODE II (INCREASED SENSITIVITY). referring to the diagnostic chart. reconnect the cable. (4) Turn off the ignition switch once. TSB Revision . (3) Read the diagnostic output by blinking of the check engine/ malfunction indicator lamp. 1) Turn the ignition switch to OFF. NOTE Turning OFF the ignition switch will cause the engine control module to changeover the diagnostic test module from the diagnostic test mode II to the diagnostic test mode I.5 second Ught comes on Light goes out Light comes on Light go- I I l-n .MULTIPORT FUEL INJECTION . tiagnostic result indication method when check engine/malfunction indicator lamp is used Typical blinking. Then turn it ON again. 3) With the engine warmed up.5 second 0.24 Blinking when condition is normal i I L 1. (5) Erase the diagnostic trouble code by the following procedure. idle the engine for approx. 4) Turn the ignition switch to ON and take a reading of the diagnostic output to check if a normal code is output. 2) After removing the battery cable from the battery terminals for 10 seconds or more. (3) Read the diagnostic trouble code in the same manner as “READ OUT OF DIAGNOSTIC TROUBLE CODE” and repair the malfunctioning part. (5) Erase the diagnostic trouble code.0.5 second L Pause time 1 me n u m b e r 3 seconds of tens segnentation 2 <econds out Z6FU2060 NOTE Other diagnostic items are also output by lamp blinking corresponding to the same code number as when scan tool is used.

200*2 85*‘.] l l: Up to 1995 Federal Non Turbo models and up to 1993 l 2: From 1994 models except Federal Non Turbo Up to 1995 models models 1 TSB Revision . 199*2 72*‘.Non Turbo. 1 93*2 714.From 1996 Variable induction control motor (DC motor) <Non Turbo> Anti-lock braking signal <Turbo> Engine and transaxle total control signal cA!T> Fuel pressure 1 74*3.13A-52 items MULTIPORT FUEL INJECTION .Troubleshooting CHECK CHART CLASSIFIED BY PROBLEM SYMPTOMS Starting Will not start Starting Fires up and dies Hard starting idling stability Idling instability (rough idling) Idling stability Incorrect idle speed idling stability Engine stall Reference page (13A-) Power supply and ignition switch-IG Engine control module power around Fuel pump Volume air flow sensor Intake air temperature sensor 1 (1) 2 (2) 3 (3) 1 (1) 5 1 (1) 13 (11) 65*‘. 21 2*2 aa*‘. [Numbers in ( ) are for cold engine. 277*2 177*‘. 276*2 176*‘. 215’2 gnltion switch-ST and Park/Neutral EGR solenoid <California . Turbo> <Federal Non-Turbo . 278*2 5 (6) 4 ( 4 ) 7 (6) 180 NOTE The numbers in the table indicates the check order for warm engine.

Turbo> <Federal Non-Turbo . 247*2 1 l44*‘. 268*2 j 12 (12) / / 5 (5) 1 6 (6) 4 (4) 5 (5) 4 (4) 164*‘. 27ae2 15(5) 1 I 2 (2) I I I 180 NOTE The numbers in the table indicates the check order for warm engine. 231*2 121*‘.From 1996 models> Fuel pressure solenoid <Turbo> Turbocharger waste gate control solenoid <Turbo> Active exhaust control unit <Turbo> Variable induction control motor (DC motor) <Non Turbo> Anti-lock braking signal <Turbo> Engine and transaxle total control signal cpJT> Fuel pressure I 3 (3) 7 (7) 153*‘. 271 *2 173*‘. 277*2 177*‘. 236*2 I 16(6) I I I / I I I / I I I / It/11 I 1125*‘.264*2 162*‘.Troubleshootina Items Driving Hesitation Sag / / Engine control module power ground Power supply and ignition switch-IG Fuel pump Volume air flow sensor I Driving Poor acceleration I 1 (1) Driving Stumble I Driving Shock Driving Surge Driving Knocking I stopping Run-on (Dieseling) Reference page (13A-) I I I 1 (1) I I 12 (12) I I I I 5 (5) I I I 5 (5) I I I I I I 4 (4) I I I I 1 65*‘. 1 26~3’~ t58”. 23ag2 I 129*‘. 200*2 I 85*‘. 276*2 6 (6) 5 (5) / 8 (8) 7 (7) I I 3 (3) I I 2 (2) I7 /a(6) I I I I / 176*‘. [Numbers in ( ) are for cold engine.] “: Up to 1995 Federal Non Turbo models and up to 1993 models *2: From 1994 models except Federal Non Turbo Up to 1995 models / TSB Revision . 274*2 1 74*3. 257’2 Idle air control motor j (stepper motor type) Ignition coil and ignition powertransistor Evaporative emission purge solenoid EGR solenoid <California . 269*2 166”) 270*2 169*‘.MULTIPORT FUEL INJECTION . 199’2 / 72*‘. 237*2 / 127”. 230*2 6 117*‘. 240*2 133”) 242*2 I I / I I I I1 I / I I 2 (2) / I I I I 2 (2) I 1 (11 I I 1 9 1 (7) 1 (1) I 11(l) I I / I I I 137*‘. 212’2 Ignition switch-ST <MIT> Ignition switch-ST and Park/Neutral position switch CA/T> Vehicle speed sensor Power steering pressure switch Air conditioning switch and compressor clutch relay Knock sensor Electrical load switch I I I I Fan motor relay <From i 994 models> I Induction control valve position senI4(4) sor <Non Turbo> Heated oxygen sensor Injectors 112*‘.Non Turbo. 193*2 I 71”. 235*2 123+‘. 229*2 113*‘.

regardless of whether the vehicle is moving or not.. (Refer to Fig. this is a continued operation of the engine after the ignition switch is turned off. and the vibration transmitted to the steering wheel./’I’ Sag IV Time ZlFUGB3 . Time ZlFUOZ24 TSB Revision . Engine speed doesn’t remain constant. body. but then the engine soon stalls. I’\ . or a temporary drop in vehicle speed (engine rpm) during such acceleration. Serious hesitation is called “sag”. 1 . shift lever. etc. (Refer to Fig. This is slight acceleration and deceleration feel usually occurred in steady. changes at idle. 1) Poor acceleration is inability to obtain an acceleration corresponding to the degree of throttle opening. even though acceleration is smooth.*’ r’. “Hesitation” is the delay in response of the vehicle speed (engine speed) that occurs when the accelerator pedal is depressed in order to accelerate from the speed at which the vehicle is now traveling. and the engine won’t start. Hesitation Fig. 2 . A sharp sound like a hammer striking the cylinder walls during driving and which adversely affects driving. Usually. 2) The feeling of a comparatively large impact or vibration when the engine is accelerated or decelerated.13A-54 MULTIPORT FUEL INJECTION . Engine starts after cranking a while. The engine stalls when the foot is taken from the accelerator pedal. This is called rough idle. The engine doesn’t idle at the usual correct speed. Also called dieseling. Sag Poor acceleration Driving Stumble Shock Surge Knocking Run-on (Dieseling) Stopping Fig. a judgement can be based upon the movement of the tachometer pointer. Engine rpm increase is delayed when the accelerator pedal is initially depressed for acceleration from the stopped condition. light throttle cruise. or the inability to reach maximum speed. d’ Idling stability Incorrect idle speed Engine stall (Die out) Engine stall (Pass out) Hesitation.Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION) Items Won’t star-l (no initial combustion) Starting Fires up and dies Hard starting Hunting Rough idle Symptom The starter is used to crank the engine. Most notable under hight loads. There is combustion within the cylinders. but there is no combustion within the cylinders. The engine stalls when the accelerator pedal is depressed or while it is being used.

accessories: OFF l Transaxle: Neutral (P range on vehicles with automatic transaxle) l Steering wheel: Straightforward position (2) Connect the scan tool to the data link connector (white). ground the diagnostic test mode control terminal (terminal (10)) of the data link connector (white). 1993 model: 3) Using a jumper wire. perform the following step to make adjustment.On-vehicle Service 13A-55 ON-VEHICLE SERVICE BASIC IDLE SPEED ADJUSTMENT NOTE (1) The basic idle speed has been factory-adjusted with the engine speed adjusting screw and does not normally require adjustment. 1 TSB Revision . (1) Before starting the inspection and adjustment procedures. proceed as follows: 1) Insert a paper clip into the l-pin blue connector as shown in the illustration. 2) Connect a primary-voltage-detecting tachometer to the paper clip. injector. NOTE The connection of the scan tool grounds the diagnostic test mode control terminal. (3) If not using the scan tool. and compression pressure are normal.MULTIPORT FUEL INJECTION . (2) If adjustment has been disturbed. electric cooling fan. or if the idle speed is too high or it drops owing to application of air conditioning load to the engine. first check that the ignition plug. (3) If the adjustment is required. set the vehicle in the following conditions: l Engine coolant temperature: 80 to 95°C (176 to 203°F) l Lights. idle air control motor.

(1O)When the scan tool has not been used.MULTIPORT FUEL IbiJECTlON . If it does not seem to have been moved. ground the ignition timing adjusting terminal. 500 km (300 miles) or more]. (ll)Remove the jumper wire from the ignition timing adjusting terminal and replace the connector back again. clean the throttle valve. In such a case. NOTE If the idle speed is higher than the standard value even with engine speed adjusting screw fully tightened. Ignition timing adjusting connect01 (brown1 I I 27FUO93i (6) Start the engine and run at idle.) 3. (5) Using a jumper wire.On-vehicle Service <From 1994 models> \ From 1994 models: 3) Use the special tool (Diagnostic Trouble Code Check Harness) to ground the diagnostic test mode control terminal (terminal (1)) of the data link connector (16-pin). (8) If the basic idle speed is out of specification. it is probably due to deposits on the throttle valve. (Refer to P. 1 TSB Revision I LJ I I I ~ ‘d . The tachometer should read l/3 of the actual engine speed. (9) Turn the ignition switch OFF. If the engine stalls or speed is low despite a sufficient distance driven [approx. (7) Check the basic idle speed. If the closed throttle position switch seems to have been moved. there may be a leak caused by deteriorated fast idle air valve (FIAV). check to see if there is evidence of the closed throttle position switch being moved. adjust it. replace the . 13A-57. This means that the actual engine speed is the tachometer reading multiplied by 3. WFU1466 (4) Remove the waterproof female connector from the ignition timing adjusting connector (brown). 500 km (300 miles) or less]. In this case. Basic idle speed: 700 + 50 rpm NOTE 1. The engine speed may be low by 20 to 100 rpm while the vehicle is new [distance driven approx.throttle body. (12)Star-t the engine again and run at idle for 10 minutes to make sure that the engine runs at proper idle speed. but no adjustment is necessary. 2. remove the jumper wire from the diagnostic test mode control terminal. adjust by turning the engine speed adjusting screw.

(2) Disconnect the air intake hose at the throttle body side. Disconnect the throttle position sensor connector. If the MUT-II is not used. (3) Put a plug in the inlet of bypass passage in the throttle body. (4) Spray cleaning agent from the intake port of the throttle body to the valve and leave as it is for 5 minutes or (5) &rt the engine and race it several times. and stop the engine. b. (8) Install the air intake hose. Then.MULTIPORT FUEL INJECTION .On-vehicle Service 13A-57 THROTTLE BODY (THROTTLE VALVE AREA) CLEANING (1) Start the engine. I 27FUO629 TSB Revision . 13A-55. NOTE If the engine idle speed becomes unstable (and fails in the worst case) after plugging the bypass passage. run the engine with the throttle valve slightly opened. run it idle for approx. one minute. a. (9) Use a scan tool to erase the diagnostic trouble code or disconnect the battery ground cable for more than 10 seconds and then connect it again. (1O)Adjust the basic idle speed (speed adjusting screw). repeat steps (4) and (5). (Refer to P. Caution Never allow cleaning agent to flow into the bypass passage. disconnect the negative cable from the battery terminal for more than 10 seconds and then idle the engine again. connect an ohmmeter across terminal (3) (closed throttle position switch) and terminal (4) (sensor ground) of the throttle position sensor. CLOSED THROTTLE POSITION SWITCH AND THROlTLE POSITION SENSOR (TPS) ADJUSTMENT (1) Connect the MUT-II to the diagnosis tester. carry out the following. warm it up until engine coolant temperature rises to 80°C (176”F).) NOTE If the engine hunts while it is idling after adjustment of the basic idle speed. (6) If the deposit cannot be removed from the throttle valve. (7) Disconnect the plug from the inlet of the bypass passage. Using jumper wires.

(7) If not using the scan tool. tighten the throttle position sensor mounting bolt securely. Engine speed adjusting I I screw (3) If the MUT-II is used.)-thick feeler gauge between the fixed SAS and throttle lever. (lO)Remove the feeler gauge. (ll)Turn the ignition switch OFF. TSB Revision . b. Connect a digital voltmeter between the throttle position sensor terminal (2). check the throttle position sensor and associated harnesses. (8) Check the throttle position sensor output voltage. Turn the ignition switch ON (but do not start the engine). Disconnect the throttle position sensor connectors and connect the special tool. Then. between the disconnected connectors. (5) In this condition. turn the ignition switch to ON position.On-vehicle Service (2) Insert a 0. (6) Slowly turn the throttle position sensor clockwise until the idle switch is turned OFF (continuity between terminals (3) and (4) disappears). Standard value: 400-1. check that the idle switch is ON (continuity exists between terminals (3) and (4)).65-mm (. (Do not start the engine. Test Harness Set.000 mV (9) If the voltage is out of specification. c.025 in. (sensor output) and terminal (4) (sensor ground).) (4) Loosen the throttle position sensor mounting bolts and turn the throttle position sensor body fully counterclockwise.13A-58 MULTIPORT FUEL INJECTION . proceed as follows: a.

From that point.17-4.MULTIPORT FUEL INJECTION . (1) Sufficiently slacken the accelerator cable.On-vehicle Service FIXED SAS ADJUSTMENT 13A-59 NOTE (1) The fixed SAS has been factory-adjusted. (6) Adjust the accelerator cable tension. Never attempt to move it.l3A-55. adjust by following the procedure given below. tighten the lock nut securely. tighten the fixed SAS further 1 1/e turns. (2) Should it be out of proper adjustment.l3A-57. (Refer to P. (Refer to P.) (8) Adjust the closed throttle position switch and throttle position sensor (TPS). (2) Loosen the lock nut on the fixed SAS.) (7) Adjust the basic idle speed. ’ (4) Tighten the fixed SAS slowly to find a point at which it contacts the throttle lever (where the throttle valve starts opening). (Refer to P. (3) Sufficiently loosen the fixed SAS by turning it counterclockwise to fully close the throttle valve.) 1 TSB Revision . (5) Holding the fixed SAS to prevent it from turning.

13A-60 MULTIPORT _ On-Vehicle Inspection of MFI FUEL INJECTION Components ON-VEHICLE INSPECTION OF MFI COMPONENTS <Up to 1995 Non Turbo Models for Federal and Up to 1993 Models> COMPONENT LOCATION Engine control module Engine coolant temperature sensor Evaporative emission purge solenoid s B X Throttle position sensor (with built-in closed throttle I. 1 TSB Revision . position switch) Turbocharger waste gate solenoid <Turbo> Variable induction control motor (DC motor) (with built-in induction control valve position sensor) <Non Turbo> Vehicle speed sensor Volume air flow sensor (with built-in intake air temperature sensor and barometric pressure sensor) C U J Fuel pressure solenoid <Turbo> Heated oxygen sensor Idle air control motor (stepper motor) V E L F A NOTE: The “Name” column is in alphabetical order.

MULTIPORT _ On-Vehicle Inspection of MFI FUEL INJECTION Components 13A-61 Volume air flow sensor (with built-in intake air <Fro& 19% models> <Mechanical Speedometer Type> Vehicle speed sensor (reed switch) I 27FU1004 Y68FOOll 1 TSB Revision .

ComDonents Variable induction control motor fi (DC motor) (with built-in induction Z7FUO802 control valG position sensor) Idle air control Injector / \ .-\ t7FU0803 TSB Revision .13A-62 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .

Components 1349-63 Check engine/malfunction indicator lamp 1 z68FOOH <From 1994 models> and diagnostic test mode control terminal control terminal ZlEFC498 ZlBFO292 TSB Revision .MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

etc. and repair as necessary.<MB991502> 79nCmed I TSB Revision . etc. ‘iii (2) After repair. (4) Disconnect the scan tool.Components Camshaft position sensor COMPONENTS INSPECTION PROCEDURE USING SCAN TOOL (1) Check by the data reading and actuator test function. to make sure that the troubles have been corrected. check the body harness. (3) Erase the diagnostic trouble code in memory. (5) Start the engine and perform running test. If any abnormality is found. I Scan tool /. cornponents. check again with the scan tool to make sure that the input and output signals are now normal.13A-64 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

This turns ON the MFI relay switch and the power is supplied from the battery to the engine control module through the MFI relay switch. etc. the battery voltage is applied from the ignition switch to the engine control module. INSPECTION Using Scan Tool Function Data reading 16 Item No. When the ignition switch is turned on.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .jW4~I OFF lanition switch IIG1 4 Equipment side connector MFI relay I A Equipment side connectc br IT r . which then turns ON the power transistor to energize the MFI relay coil. the injector.Components 13A-65 POWER SUPPLY (MFI relay) AND IGNITION SWITCH-IG <Up to 1993 model& 4 nglne control module 16FO29' P . battery power is supplied to the engine control module. Data display Engine control module power voltage Check condition Ignition switch: ON Standard value Battery voltage 1 TSB Revision I .L x 5 I (4 0 8 108 7FUO927 P Engine control module Engine control module connector Z7FUO950 7FU1571 27FUO653 OPERATION l l While the ignition switch is on. the volume air flow sensor.

13A-66 HARNESS INSPECTION MULTIPORT _ On-Vehicle Inspection of MFI FUEL INJECTION Components Measure the ignition switch terminal input voltage. l MFI relay connector: Disconnected l Engine control module connector: Disconnected Repair the -+ harness. l MFI relay connector: Discon- A Harness side connector Engine control module connector: Disconnected Check for an open-circuit. (Ignition switch .25) 27FUO468 TSB Revision . (A4-12. or a short-circuit to ground between the engine control module and the MFI relay. @ Engine control module connectar: Disconnected 0 Ignition switch: ON Battery voltage module harness side connector 201 Lo227 Repair the harness.62) age of the MFI relay.

the relay could be damaged. (1) Remove the MFI relay. make sure that it is applied to correct terminal. H l 1ZI Jumper wire ZOl LO222 I Connected Disconnected Continuity across terminals 2 and 3 Conductive Nonconductive I (6) Using jumper wires. connect terminal (10) of MFI relay to battery (+) terminal and terminal (8) of MFI relay to battery (-) terminal. measure the voltage at terminal (2) of the MFI relay. check the continuity across terminals (2) and (3) of the MFI relay. i 1 TSB Revision . Otherwise.Components 13A-67 ~ OlL0521 MULTIPORT FUEL INJECTION (MFI) RELAY INSPECTION Caution When applying battery voltage directly. (7) Connecting and disconnecting the jumper wire to battery (-) terminal. Jumper wire Connected Disconnected Voltage at terminal 2 B+ ov (8) Replace the MFI relay if any defect is evident. i2V L-l I Z7FUO469 Jumper wire 1 Connected 1 Disconnected Voltage at terminal 4 / 1 B+ 1 ov / 1 B+ I ov Voltage at terminal 5 I I I i Ij (4) Using jumper wires. 01 LO220 00002531 (2) Using jumper wires.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (3) Connecting and disconnecting the jumper wire to battery (-) terminal. connect terminal (9) of MFI relay to battery (+) terminal and terminal (6) of MFI relay to battery (-) terminal. connect terminal (3) of MFI relay to battery (+) terminal and terminal (7) of MFI relay to battery (-) terminal. measure the voltage across terminals (4) and (5) of the MFI relay. (5) Connecting and disconnecting the jumper wire to battery (-) terminal.

l3A-65.- 7FUO927 * Engine control module connector * 21 FU0807 Z7FUO653 7FUl572 OPERATION Refer to P.13A-68 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . 1 TSB Revision . INSPECTION Refer to P.Components POWER SUPPLY (MFI relay) AND IGNITION SWITCH IG <From 1994 models> Battery Ignition 1 itch [IG] A Equipment side connector 8 Engine control module 16FO292 MFI relay A Harness side connector 4.l3A-65. \/ “2 0 0 A12 A 25 /“\ 108 \/ “3 & 6 1 bv -.

or a short-circuit to ground.Ignition switch: OFF l MFI relay connector: Disconnected Battery voltage 21 FUO808 Engine control module harness side connector connector Check for an open-circuit. l . l MFI relav connector: Disconnetted l Engine control module connector: Disconnected - I Repair the harness. between the engine control module and the MFI relay. (/x&-12. or a short-circuit to ground between the enaine control module and the MFI reTay. l MFI relay connector: Connected l Engine control module connectar: Connected Engine cranking: 8 V or higher Engine racing: Battery voltage Replace the MFI relay or defective engine control module 1 . l Engine control module connector: Disconnected Ignition switch OFF: O-l V Ignition switch ON: Battery voltage Measure the power supply voltaoe of the MFI relav.25) A Harness side connector I 1TSB Revision I IPleasure power voltage to the actuator. (A6-108) 21 FUO809 . l Engine control module connector: Disconnected l MFI relay connector: Disconnected 4 l-l Repair the harness. Engine control module harness side connector A Harness side connector Z6AF0050 Check for an open-circuit.MULTIPORT _ On-Vehicle inspection of MFI FUEL INJECTION Components 13A-69 HARNESS INSPECTION Engine control module harness side connector Measure the ignition switch (IG) terminal input voltage.

connect terminal (7) of MFI relay to battery (+) terminal and terminal (5) of MFI relay to battery (-) terminal. check the continuity across terminals (2) and (4) (or (3) and (4)) of the MFI relay. 1 TSB Revision I . Jumper wire Connected ZPFUOOl9 Continuity across terminals 2 and 4 Conductive (0 Sz) Nonconductive (. (2) Check for continuity between MFI relay terminals.Q) LJ Disconnected (7) Replace the MFI relay if any defect is evident. (6) Connecting and disconnecting the jumper wire to battery (-) terminal. Jumper wire Connected 29FUOOl8 Voltage B+ OV Disconnected (5) Using jumper wires. measure the voltage at terminal (1) of the MFI relay.13A-70 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 29FUOOlO (3) Using jumper wires. connect terminal (8) of MFI relay to battery (+) terminal and terminal (6) of MFI relay to battery (-) terminal. (4) Connecting and disconnecting the jumper wire to battery (-) terminal.Q) Continuity across terminals 3 and 4 Conductive (0 Q) Nonconductive (.Components MFI RELAY INSPECTION (1) Remove the MFI relay. Caution If jumper leads are not connected properly the relay will be damaged.

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components 13A-71 ENGINE CONTROL MODULE POWER GROUND Engine control module 16FO292 Y 13 Engine control module connector 26 7FUl573 / OPERATION Grounds the engine control module TROUBLESHOOTING HINTS If the ground wire of the engine control module is not connected securely to ground. l Engine control module con- _: Engine control module harness side connector 201P0150 :-4!2 26 nector: Disconnected 1 TSB Revision . HARNESS INSPECTION I I 1 I Check for continuity of the ground circuit. the module will not operate correctly.

. current flows from the ignition switch through the MFI relay coil to ground. \.\ Fuel pump B Equipment side connector \/ \/ 1.g 3.) Ignition switch (ST) A Harness side connector ..13A-72 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . MFI r e l a y I t B Equipment side connector /. l While the engine is running. the engine control module keeps the power transistor on and energizes the MFI relay coil so that drive power is supplied to the fuel pump. . 6 7 ” 2“ C F u e l pump 1 check terminal harness side connector 8 Engine control module +I‘. l When the ignition switch is set to START. This turns on the MFI relay switch and drive power is supplied from the battery through the MFI relay switch to the fuel pump. / TSB Revision . Z7FUO952 Engine control module connector 27FUO653 7Fu1574 OPERATION l Drives the fuel pump during cranking and engine operation.Non Turbo> A Equipment side connector Ignition switch (IG.Components FUEL PUMP <Up to 1993 Models .

check terminal r ’ -- Check the fuel pump.F&i’pum/. Drive Fuel pump is driven to circulate fuel l l Check condition Check content Normal state Actuator test 07 Engine cranking Hold return hose with Pulsation is felt Forced drive of fuel fingers to feel pulsation indicating fuel flow pump Check is made for above two conditions Listen to pump operat. (Bl -Cl) Z 7FUO955 [ TSB Revision . l Fuel pump connector: Disconnected &round) B Harness side connector Repair the harness.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Apply battery voltage to the l checking terminal and operate the pump.Operating sound ing sound near fuel tank is heard HARNESS INSPECTION !‘-mu I ‘. 2 -a \‘iil\ I I L- 27FUO953 I Check for continuity between the fuel pump and the checking terminal..Components 1344-73 ~ INSPECTION Using Scan Tool L Function Item No.

(Ignition switch-[IG] . 0 MFI relay connector: Disconnected l Engine control module connectar: Disconnected Engine control L 7 cl Repair the harness. A Harness side Measure the Dower SUDDIV voltage of the MF’I relay.A31 (Ignition switch-[ST] .u. 27FUO474 - @ !$!ir the harness.13A-74 4 J C 1’ z -/ia Z@Q0 0 I2 = MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l MFI relay connector: Disconnected nFUO476 I bround) TSB Revision . or a short-circuit to ground between the MFI relay and the engine control module..Components Check for continuity between the checkina terminal and the MFI relay tetminals. &&-Cl) connectorn.A91 Check for an open-circuit.. ’ ’ * l MFI relay connector: Disconnected l Ignition switch: START (when A9 checked) l Ignition switch: ON (when A3 checked) 8 V or more .. (A7-8) module harness side connector 27FUC475 I 7 A Harness side connector Check for continuity of the ground circuit. ..1 connected Repair the harness. l 0 MFI relay connector: Disconnected Fuel pump connector: Dis.

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . or a short-circuit to ground between the MFI relay and the fuel pump. (A2-Bl) 7FUO5’56 MFI RELAY INSPECTION Refer to P. i TSB Revision . l MFI relay connector: Disconnected l Fuel pump connector: Disconnected I 13A-75 @--A Repair the harness.Components Check for an open-circuit.l3A-67.

Non Turbo> 03FOOO4 A Harness side connector A Equipment side connector B Equipment side connecfor B Equipment side connector Z7FU1360 Engine control module connector i7FU06. This causes the MFI relay switch to turn ON.13A-76 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l When the engine is cranking and while the engine is running. 1 TSB Revision .53 7FU1575 OPERATION l The fuel pump is driven when the engine is cranking and while the engine is running. and current is supplied from the ignition switch via the MFI relay switch to drive the fuel pump. the engine control module turns the power transistor ON to the MFI relay coil.Comraonents FUEL PUMP <From 1994 Model .

l3A-73. \&I 1 1. l Connector: Disconnected % + OK 0 Z 7FUO955 1 A Harness side connector Check for continuity between the fuel pump checking terminal and the MFI relav terminals. l Apply battery voltage to the checking terminal and operate the pump. 0 Fuel pump connector: Disconnected Repair the harness. (Al -Cl) Z9FlJOO24 1 TSB Revision . (82 Ground) Z7FUO954 B Harness side connector u 4 &Y l---L la E@”n !I3 7 C Check for continuity between the fuel pump and the checking terminal. 4 Ll Repair the harness. (Bl -Cl) n - Repair the + harness.Components 13A-77 INSPECTION Refer to P. HARNESS INSPECTION Check the fuel pump. 27FUO953 Check the ground circuit of the fuel pump.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . l MFI relay connector: Disconnected l Fuel pump connector: Disconnected I I.

‘ l MFI relay (for fuel pump) connector: Disconnected l Fuel pump connector: Disconnected T Z7FU1437 iamess side :onnector Repair the harness. Check for an open-circuit. MFI RELAY INSPECTION Refer to P.connector: Connetted l Engine control./ ReDair the connector Z9FUOO23 or check the ignition switch. or a short-circuit to ground. l MFI relay.* MFI relay connector: Daconnetted l Engine control module connector: Disconnected Engine control module harness side connector connector Repair the harness. unit connector: Connected Engine cranking: 8 V or more Engine racing: Battery voltage Z6FU1753 Aud!l c /STOP\ MFI relay or engine control module is defective. the fuel pump. (Al -Bl) A Harness side Measure the power supply voltage of the fuel pump. to ground between the MFI relay and the engine control module. TSB Revision .l3A-70. or a short-circuit.13A-78 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (AS-8) 3 Check for an open-circuit. ’ ’ * l Control relay connector: Disconnected Ignition switch OFF: O-l V Ignition switch ON: Battery voltage . between the MFI relay (for fuel pump) and .Components Measure the power SUDDIV voltage of the MF’I relay.

1 ./’ Fuel pump connector j 1-w 1I i I 203kxl04 TSB &vision ._.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components 13A-79 FUEL PUMP <Turbo> / .

Components i g n i t i o n sw. OFF 4 t l 2 1 M Fuel pump Z5ElAO03 ( I 2 D Fuel pump connector Engine control module ? 1 6~ Y c Fuel pump check terminal pikq Z7FUO959 Engine control module connector ~ 7FUO653 7FU1576 TSB Revision .13A-80 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .itch [IG] ignition sivitch [STji A Equipment side connector A Harness side 7 -P 1 ----3 AL B Equipment side B Harness side connector connector O’I.

Operating sound ing sound near fuel tank is heard <Fuel Pump Relay lb L Function Item No.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . This turns on the MFI relay switch and drive power is supplied from the battery through the MFI relay switch to the fuel pump. the engine control module turns off the power transistor to send drive power directly to the fuel pump without passing through the resistor. t When the ignition switch is set to START. If the amount of inlet air is small (the engine load is low). -- Z7FUO953 Check the ground circuit of the fuel pump. INSPECTION Using Scan Tool <Fuel Pump> Function 1 Item No. 13A-81 Drives the fuel pump during cranking and engine operation. current flows from the ignition switch through the MFI relay coil to ground. (B2 Ground) Z7FUO%4 I TSB Revision . l Fuel Pump Relay II Operation l l Change the fuel pump discharge in two stages by ON-OFF operation of the relay switch for fuel pump relay II.Components OPERATION MFI Relay Operation L. l Fuel pump connector: Disconnected Repair the harness. 1 Operation 1 Fuel pump is driven to circulate fuel l l Check condition Engine cranking Forced drive of fuel pump Check is made for above two conditions Check item Hold return hose with fingers to feel pulsation indicating fuel flow 1 Normal condition 1 Pulsation is felt Actuator test 07 Listen to pump operat. If the amount of inlet air is large (the engine load is high). 1 I Actuator test 13 HARNESS INSPECTION f&l p&p\ check terminal Check the fuel pump. While the engine is running. the engine control module keeps the power transistor on and energizes l the MFI relay coil so that drive power is supplied to the fuel pump. the engine control module turns on the power transistor to energize the coil of fuel pump relay II. sending drive power to the fuel pump through the resistor. Apply battery voltage to the l checking terminal and operate the pump. Operation Turn the fuel pump relay II from OFF to ON Check condition Ignition switch: ON Normal condition Operating sound is heard.

13A-82 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 0 MFI relay connector: Disconnetted l Ignition switch: START (when checking A9) l Ignition switch: ON (when checking A3) 8 V or more - I Repair the harness.Components ------L 11 ia 3$j”n !d 1 lr C 1 Z 7FUO955 Check for continuity between the fuel pump and the checking terminal. Cl -D2) iD2-E2j 5 D Harness side connector @ Engine control module connector: Disconnected Repair the harness. (D4-El) Z7FUO962 A Harness side 800 Ii!/ .A% TSB Revision . l Fuel pump connector: Disconnected Repair the harness (Bl -Cl) E Harness side connector Check for continuity between the checking terminal and the fuel r6 .A31 (Igniiion switch W-l .0 T i Measure the power supply voltage of the MFI relay. beheen the fuel pump relay II and the en- Repair t h e harness. l Fuel pump relay II connector: Disconnected l Resistor (for fuel pump) connector: Disconnected Repair the harness.=d27FUO960 D Harness side connector P Engine control module harness side connector 0 l Resistor (for fuel pump) connector: Disconnected Fuel pump connector: Disconnected I short-circuit to ground. (Ignition switch [IG] . (Dl-21) Z7FUO961 Check for continuity between the fuel oumo relay II and the resistor (for iuel bump).

A Harness side connector -/El $@”0 H * 21 4 27FUO963 I Check for continuity of the ground circuit. or a short-circuit to around. between the fuel pump reiay II and the fuel pump. between the MFI relay and the engine control module.control harness side Repair the harness. l MFI relay connector: Disconnected Repair the harness. l Fuel pump relay II connector: Disconnected l Fuel pump connector: Disconnected &round) D Harness side connector LZ7FUO964 Repair the harness. or a short-circuit to ground. (A2-D3) (A2-D5) Z7FUC47E I Check for an open-circuit.l3A-67.Components Check for an open-circuit.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (Bl -D2) MFI RELAY INSPECTION Refer to P. / TSB Revision . (A7-8) i+ 9 --I D Harness side A Harness side Check for continuity between the MFI relay and the fuel pump relay II l MFI relay connector: Disconnected l Fuel Dumb relav II connector: Disconnected 1 II.l MFI relay connector: Disconnetted l Engine control module connector: Disconnected 1344-83 ~ A Harness side Enon.

(2) Measure the resistance between the terminals.6-0. (2) Use a jumper wire to connect terminal (3) of fuel pump relay II and the positive terminal of the battery and use another jumper wire to connect terminal (1) and the negative terminal of the battery. c J 27FU1043 / TSB Revision . FUEL PUMP CIRCUIT RESISTOR INSPECTION (1) Disconnect the connectors for the fuel pump circuit resistor. Standard value: 0. replace the fuel pump circuit resistor.13A-84 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Comaonents FUEL PUMP RELAY II INSPECTION (1) Remove fuel pump relay II. check the continuity between terminals (2) and (5) of fuel pump relay II and between terminals (4) and (5) of fuel pump relay II. (3) With the jumper wire connected to and disconnected from the negative terminal of the battery. Z7FUlO42 ~1 (4) Replace fuel pump relay II if it is faulty.9 Q (3) If the resistance deviates from the standard value.

etc. If the engine stalls.) (3) Air leaking into the intake manifold through gap of gasket. faulty volume air flow sensor or engine control module is suspected. TROUBLESHOOTING HINTS Hint 1: If the engine stalls occasionally. l The volume air flow sensor power is supplied from the MFI relay to the volume air flow sensor and is grounded in the engine control module. [Examples] (1) Disturbed volume air flow in the air flow sensor (Disconnected air duct. poor contact of the volume air flow sensor connector is suspected. The volume air flow sensor generates a pulse signal as it repeatedly opens and closes between the 5 V voltage supplied from the engine control module and ground.7X6sx4x3x2m ZSEL1803j * 1 Engine control module connector Engine control module L ’ Z7FUO654 162451 7FU1577 L OPERATION l The volume air flow sensor located in the air cleaner converts the engine intake air volume into a pulse signal of frequency proportional to the air volume and inputs it to the engine control module. injector. (4) Loose EGR valve seat TSB Revision . ignition coil. etc.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . troubles are often found in other than the volume air flow sensor itself. which then computes the fuel injection rate. crank the engine and shake the volume air flow sensor harness. Hint 3: If the engine can be run idle even though the volume air flow sensor output frequency is out of specification. etc. incorrect compression pressure. Hint 2: If the volume air flow sensor output frequency is other than 0 when the ignition switch is turned on (but not starting the engine).Components 13A-85 MFI relay VOLUME AIR FLOW SENSOR Volume air flow sensor (with built in intake air temperature sensor and lVolume air flow sensor 7 7 7\Y 7FL10941 A Equipment side connector Output frequency (Hz) A Harness side connector @. based on the input signal. clogged air cleaner element) (2) Poor combustion in the cylinder (Faulty ignition plug.

34 Data display Reset signal 0 condition Check conditions Engine warm up Engine conditions 700 rpm (Idle) 2. the volume air flow sensor output frequency may be about 10% higher.13A-86 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . * I Regular waveform ZO3AO2031 I TSB Revision . and check the waveform.Components INSPECTION Using Scan Tool <Volume Air Flow Sensor> Data display Sensor air volume (frequency) l Check condition Engine state / Standard value 22-48 Hz 50-90 <Non turbo> 68-108 <Turbo>’ Frequency with racing increases I l l l Engine coolant 700 rpm (Idle) temperature: 80 to 95°C (176 to 203” F) 2. (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram. <Volume Air Flow Sensor Reset Signals Function Data list Item No.000 rpm Standard value ON OFF <Volumetric Efficiency> l ry operation: OFF Transaxle: Neutral creases with rac- 1 Using Oscilloscope (1) Run the engine at idle speed.000 rpm Lights and accessories: OFF Transaxle: Neutral (P range for vehicle with A/T) Racing Steering wheel: Neutral NOTE When the vehicle is new [within initial operation of about 500 km (300 miles)].

...q rls$zde har- ml r connector Check for continuity between the volume air flow sensor and the engine control unit.. (A7-19) .Control relay) or check the control relay. Z7FUO745 TSB Revision .MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . L Repair the harness. l Connector: Disconnected l Ignition switch: ON Battery voltage 2 0 Repair the harness (A4 . Connector: Disconnected Ignition switch: ON 3 --l A Harness side connector Check for continuity of the ground :...... 0 Volume air flow sensor connector: Disconnected l Engine control module connectar: Disconnected @--A Repair the harness.. (AS-72) 27FUO657 Engine control A Harness side ...Combonents 13A-87 HARNESS INSPECTION L 1 J A Harness side connector Measure the power supply voltage.

the intake air temperature sensor terminal voltage changes with the intake air temperature. it is grounded in the engine control module. which then corrects the fuel injection rate. The intake air temperature sensor resistor has the characteristic of decreasing its resistance decreases as the intake air temperature rises. based on the input signal. etc.13A-88 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . TROUBLESHOOTING HINTS The intake air temperature sensor senses the intake air temperature in the air cleaner so that it may indicate a temperature different from outside temperature depending on engine operating state. TSB Revision .temperature sensor and barometric pressure sensor) Resistance I c Temperature A Equipment side connector Intake air temperature sensor \/ ” 5 \/ ” 6 Volume air flow sensor connector r---1 Intake air temperature sensor I A Harness side connector L ’ I ! mx3x2Bj ZSELlBOSI 1 A 72 Engine control A 52 module Z7FU0659 5V I 7FU1576 OPERATION l The intake air temperature sensor converts the engine intake air temperature into a voltage and inputs it to the engine control module. Via the sensor which is a kind of resistor. l The 5 V power in the engine control module is supplied via a resistor in the module to the intake air temperature sensor. l The intake air temperature sensor terminal voltage increases or decreases as the sensor resistance increases or decreases.Components INTAKE AIR TEMPERATURE SENSOR Volume air flow sensor (with built in intake air ---. decreasing as the temperature rises. Therefore.

Components INSPECTION Using Scan Tool idFunction Item No. (A5-72) Z7FU0657 Volume air flow sensor side connector SENSOR INSPECTION (1) Disconnect the volume air flow sensor connectors. Temperature [“C(‘F)] 0 (32) 20 (68) 80 (176) Resistance (kD) 6. Check for continuity of the ground -T circuit.4 TSB Revision I . (2) Measure resistance between terminals (5) and (6). l Connector: Disconnected 2 0 Repair the harness. Data display Sensor temperature Check condition Intake air temperature 13A-89 Standard value -20°C 0°C 20°C 40°C 80°C Data reading 13 Ignition switch: ON or At -20°C (-4°F) engine running At 0°C (32°F) At 20°C (68°F) At 40°C (104°F) At 80°C (176°F) HARNESS INSPECTION v *.7 0.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .0 2.

replace the volume air flow sensor assembly.13A-90 MULTIPORT On-Vehicle inspection of MFI FUEL INJECTION . Temperature [“C (OF)] Higher Resistance (kL2) Smaller (4) If resistance does not decrease as heat increases or the resistance remains unchanged.Components (3) Measure resistance while heating the sensor using a hair drier. / TSB Revision .

Through the circuit in the sensor. l The 5 V power in the engine control module is supplied to the barometric pressure sensor. 0 The barometric pressure sensor output voltage which is proportional to the barometric pressure (absolute pressure) is supplied to the engine control module./. it is grounded in the engine contrcjl module.Hg)] 760 (30) EC1551 OPERATION l The barometric pressure sensor converts the barometric pressure into a voltage and inputs it to the engine control module. 6 5 27FUO663 Engine control unit connector Barometric pressure [mmHg (in.Components 13A-91 BAROMETRIC PRESSURE SENSOR A Equipment side connector Barometric pressure sensor I Volume air flow sensor connector A Harness side ’ connector r 1 1 Barometric pressure sensor -de 161 . TSB Revision . rate.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . etc. based on the input signal. which then corrects the fuel injection.

check the air cleaner for clogging. poor driveability is caused at high altitude. Data display Sensor pressure Check condition Ignition switch: ON Altitude At 0 m (0 ft. in particular.13A-92 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .) At 1. (A5-72) Z7FUO657 Measure the power supply voltage of the barometric pressure Repair the harness. INSPECTION Using Scan Tool Function Item No.200 m (3.) At 600 m (1. (Al -61) Engine control module harness side connector P F Z7FUO664 Check for an open-circuit.969 ft. 0 Connector: Disconnected Repair the harness.800 m (5.Components TROUBLESHOOTING HINTS Hint 1: If the barometric pressure sensor is faulty.) At 1. Hint 2: If the pressure indication of the barometric pressure sensor drops significantly during high speed driving.937 ft.) Standard value 101 kPa (760 mmHg) 95 kPa (710 mmHg) 88 kPa (660 mmHg) 81 kPa (610 mmHg) I 1 . I/’ Data reading 25 HARNESS INSPECTION A Harness side Check for continuity of the ground circuit. or a short-circuit to ground between the engine control module and the barometric pressure sensor. (A2-65) 1 TSB Revision . 0 Volume air flow sensor connector: Disconnected l Engine control module connector: Disconnected OK 0 A STOP Repair the harness.906 ft.

the engine coolant temperature sensor terminal voltage changes with the coolant temperature. Through the sensor which is a kind of resistor. TSB Revision 1 . The engine coolant temperature sensor resistor has the characteristic of decreasing its resistance decreases as the coolant temperature rises. l The 5 V power in the engine control module is supplied via a resistor in the module to the engine coolant temperature sensor. decreasing as the temperature rises.Components 13A-93 ENGINE COOLANT TEMPERATURE SENSOR <Up to 1993 models> Resistance Output voltage IL Coolant temperature 152455 I‘\ Coolant temperature 1621008 Engine coolant teniperaturesensor A Equipment side connector 27FUO667 7FUl580 OPERATION l The engine coolant temperature sensor converts the engine coolant temperature into a voltage and inputs it to the engine control module. l The engine coolant temperature sensor terminal voltage increases or decreases as the sensor resistance increases or decreases. the engine coolant temperature sensor is often faulty. Therefore. TROUBLESHOOTING HINTS If the fast idle speed is inadequate or the engine emits dark smoke during engine warm up operation.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . which then controls the fuel injection rate and fast idle speed when the engine is cold based on the input signal. it is grounded in the engine control module.

5-4. (Al -63) 27FlJfM69 TSB Revision .Comraonents Data display Sensor temperature Check condition Coolant temperature Standard value -20°C 0°C 20°C 40°C 80°C Data reading 21 Ignition switch: ON or At -20°C (-4°F) engine operating At 0°C (32°F) At 20°C (68°F) At 40°C (104°F) At 80°C (176°F) HARNESS INSPECTION Check for continuity of the ground circuit.1 3A-94 INSPECTION Using Scan Tool Function Item No. On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . (A2-72) 2 J A Harness side connector 1 4 Repair the harness. l Connector: Disconnected A Harness side 27FlJO668 r Measure the power supply voltage. l Connector: Disconnected 0 Ignition switch: ON 4.9 v Repair the harness.

replace the sensor. Specified sealant: 3M NUT locking Part No.3 40 (104) 80 (176) (3) If the resistance deviates from the standard value greatly.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Temperature “C (OF) 0 (32) 20 (68) Z7Fu0670 Resistance (Wz) 5 .) (3) Fasten harness connectors securely. check resistance.Components 13A795 SENSOR INSPECTION (1) Remove engine coolant temperature sensor from the intake manifold. INSTALLATION (1) Apply sealant to threaded portion.1 0. 4171 or equivalent 27FUO671 -I (2) Install engine coolant temperature sensor and tighten it to specified torque. (2) With temperature sensing portion of engine coolant temperature sensor immersed in hot water.4 1. 6 2. i TSB Revision .lbs. Sensor tightening torque: 30 Nm (22 ft.

l3A-94.13A-96 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . l Engine coolant’ temperature sensor connector: Disconnetted Repair the harness.Components ENGINE COOLANT TEMPERATURE SENSOR <From 1994 models> Resistance output voltage Engine coolant temperature . TROUBLESHOOTING HINTS Refer to P. (A2-72) 29FUO112 TSB Revision .l3A-93. HARNESS INSPECTION 1 - Harness side connector Check for continuity of the ground circuit. INSPECTION Refer to P.l3A-93. sensor Engine coolant temperature d--Y~7Fui638 162460 Engine coolant temperature 1621006 Y\ l/ Engine coolant temperature sensor A Equipment side connector Engine control module ZPFUO106 OPERATION Refer to P.

On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .5-4. Engine coolant temperature sensor connector: Disconnected l Engine control module connectar: Connected l Ignition switch: ON 4. (Al -63) ZPFUO114 INSTALLATION Refer to 13A-95. Repair the harness. i TSB Revision .Components Measure the impressed voltage.9 v l 13A-97 a lz -0 Ii T SENSOR INSPECTION Refer to 13A-95.

the voltage at the throttle position sensor variable resistance terminal also increases. The 5 V power in the engine control module is supplied to the throttle position sensor. . 72 . TSB Revision . which then controls the fuel injection based on the input signal. it is grounded in the engine control module. 61 Terminal voltage (V) I 7 - I t7FU0672 Engine control module connector Minimum Maximum Throttle shaft turning angle 162461 7FUO653 7FlJ1582 OPERATION The throttle position sensor converts the throttle position opening into a voltage and inputs it to the l engine control module. As a result. adjust the fixed SAS. adjust the sensor and check the voltage again. Shifting shock and other troubles will be caused if this sensor is faulty.13A-98 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . If there is an evidence of disturbed fixed SAS setting.Components THROlTLE POSITION SENSOR A Equipment side Throttle position sensor connector A Harness side connector ZSELWOO] Engine control module . TROUBLESHOOTING HINTS Hint 1: The throttle position sensor signal is more important in the control of automatic transaxle than in the engine control. Hint 2: If the output voltage of the throttle position sensor is out of specification. Through l the resistor in the sensor. the resistance between l the variable resistor terminal of the throttle position sensor and the ground terminal increases. As the throttle valve shaft rotates from the idle position to wide open position.

8-5.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .500 mV HARNESS INSPECTION Measure the power supply voltacle of the throttle position sensor. (IV-64) i+ 1 TSB Revision . l Connector: Disconnected 26FU1242 I I Engine control module harness side connector y P Y z6FU1243 Check for an open-circuit. or a short-circuit to ground between the enaine control module and the n thr&tle position sensor.2 V A Harness side 0 2 I * 26FU1241 Repair the harness. l . 14 Data display Sensor voltage Check condition Ignition switch: left ON for 15 seconds or more Open widely 4.500~5.Connector: disconnected l Ignition switch: ON 4.ComDonents INSPECTION 13A-99 Using Scan Tool Function Data reading Item No. l Throttle position sensor connectar: disconnected l Engine control module connector: Disconnected l Connector of any control module which uses TPS output signals like ECM: Disconnected Repair the harness. (Al -61) -I 2 Check for continuity of the ground circuit.

5 ft. replace the throttle position sensor.5-6. Throttle position sensor installation torque: 2. front view) SENSOR INSPECTION (1) Disconnect the throttle position sensor connector.0 Nm (1. refer to P.Components shr&e &k%m’. L/J (2) Measure resistance between terminal (4) (sensor ground) and terminal (1) (sensor power).l3A-57.lbs. TSB Revision . (5) If the resistance is out of specification.13A-100 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .) For the closed throttle position switch and throttle position sensor adjusting procedure.&~ connector (sensor side. or fails to change d smoothly. Standard value: 3.5 kQ 27FUO673 (3) Connect a pointer type ohmmeter between terminal (4) (sensor ground) and terminal (2) (sensor output). (4) Operate the throttle valve slowly from the idle position to the full open position and check that the resistance changes smoothly in proportion with the throttle valve \ opening angle.

the following troubles are suspected. TROUBLESHOOTING HINTS If the closed throttle position switch harness and individual part check results are normal but the closed throttle position switch output is abnormal. This causes the closed throttle position switch terminal voltage to go low from high. converts it into high/low voltage and inputs the voltage to the engine control module. zogl 7FU1583 OPERATION l The closed throttle position switch senses whether the accelerator pedal is depressed or not. which then controls the idle air control motor based on the input signal.. l The voltage in the engine control module is applied to the closed throttle position switch through a resistor. poslrlon 5switch Terminal voltage (V) 4 I XII 3 4 I I z7FUO674 Throttle shaft turning angle o..Components 13~9101 CLOSED THROTTLE POSITION SWITCH J-.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . the closed throttle position switch is turned on to conduct the voltage to ground. (1) Poorly adjusted accelerator cable or auto-cruise control cable (2) Poorly adjusted fixed SAS INSPECTION Using Scan Tool Function Item No.Throttle position sensor (Closed throttle position switch mounted) Engine control module I I 7FUO929 A Harness side connector Closed throttle . When the accelerator pedal is released. Data display Switch state Check condition Ignition switch: ON (check by operating accelerator pedal repeatedIY) Throttle valve At idle position Open a little Normal indication O OFF N Data reading 26 1 TSB Revision .

(A4-72) 26FU1242 I SENSOR INSPECTION (1) With the accelerator pedal released. (3) Check the continuity across the throttle position sensor connector terminal (4) (Sensor ground) and (3) (Closed throttle position switch).l3A-59. check again.l3A-57. refer to P.13A-102 HARNESS INSPECTION A Harness side connector MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 0 Connector: Disconnected Repair the harness. (4) Replace the throttle-position sensor (closed throttle position switch incorporated) if there is a malfunction.Components Measure the power supply voltage of the closed throttle position switch. NOTE If there is no continuity when the accelerator pedal is returned. NOTE If it is not pushed. after turning all the way in the counterclockwise direction. (A3-67) C f7FU0675 Check for continuity of the ground circuit.) di (2) Disconnect the throttle position sensor connector. then. I Accelerator pedal Depressed Released Continuity Non-conductive (.8) Conductive (0 52) 1 \ I I I . NOTE For the closed throttle position switch and throttle position sensor adjusting procedure. adjust the fixed SAS (Refer to P. l Connector: Disconnected l Ignition switch: ON 4 V or more 3 OK 2 cl Repair the harness. loosen the throttle-position sensor installation screw. ~ ! ! ~ \ Z7FUO676 d! TSB ReviSion . check to be sure that the throttle valve lever or the fixed SAS is pushed.

The camshaft position sensor generates a pulse signal as it repeatedly connects and disconnects between 5 V voltage supplied from the engine control module and ground. TSB Revision . correct sequential injection is not made so that the engine may stall. run irregularly at idle or fail to accelerate normally.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .4 Engine control module ) Time Z7FUO677 7FUO493 7Fu155.5 cylinders. converts it into a pulse signal and inputs it to the engine control module. l Power to the camshaft position sensor is supplied from the MFI relay and is grounded to the body. TROUBLESHOOTING HINTS Hint 1: If the camshaft position sensor does not function correctly.1 Output characteristic No. No.3 and No. etc.1.Components 13A-103 CAMSHAFT POSITION SENSOR 4 992 models> MFI relay Crankshaft position sensor (with built-in Equipment side connector WI ‘l-nJLm 0 t No. based on the input signal. a faulty camshaft position sensor or engine control module is suspected. Hint 2: If the sensor outputs a pulse signal when the ignition switch is turned ON (with the engine not running). which then controls the fuel injection sequence.l OPERATION l The camshaft position sensor senses the top dead center on compression stroke of the No.

13A-104 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . HARNESS INSPECTION Connector: Disconnected 0 Ignition: switch ON l l Connector: Disconnected A Harness side connector l l Connector: Disconnected ignition switch: ON TSB Revision .Components %nn-nn Normal waveform INSPECTION Using Oscilloscope (1) Run the engine at an idle speed. and check the waveform. (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram.

run irregularly at idle or fail to accelerate normally. a faulty camshaft position sensor or engine control module is suspected. etc. which then controls the fuel injection sequence.l3A-104. based on the input signal. converts it into l a pulse signal and inputs it to the engine control module.Components 13A-105 CAMSHAFT POSITION SENSOR <From 1993 models> Camshaft position sensor MFI relay A Equipment side connector 27FU1301 Engine control module 68 Z7FUO677 Engine control module connector t6AF0054 7FU1585 7FUO653 OPERATION The camshaft position sensor senses the top dead center on compression stroke. TROUBLESHOOTING HINTS Hint 1: If the camshaft position sensor does not function correctly.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l The camshaft position sensor generates a pulse signal as it repeatedly connects and disconnects between 5 V voltage supplied from the engine control module and ground. /’ ! INSPECTION L Refer to P. Hint 2: If the sensor outputs a pulse signal when the ignition switch is turned ON (with the engine not running). correct sequential injection is not made so that the engine may stall. Power to the camshaft position sensor is supplied from the MFI relay and is grounded to the body. 1 TSB Revision .

l Connector: Disconnected Ground) Z6AF0057 I A Harness side connector Measure the impressed voltage.Components 1 --I A Harness side connector Measure the power supply voltage. (A2-68) Z6AF0059 1 TSB Revision .13A-106 HARNESS INSPECTION On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . l Connector: Disconnected l Ignition switch: ON Battery voltage relay) I 21 J A Harness side connector Check for continuity of the ground circuit.2 V l l Repair the harness.8-5. Connector: Disconnected Ignition switch: ON 4.

which then controls the engine speed and controls the fuel injection timing and ignition timing based on the input signal. converts it into a pulse signal and inputs it to the engine control module. The crankshaft position sensor generates a pulse signal as it repeatedly connects and disconnects between 5 V voltage supplied from the engine control module and ground. poor contact of the sensor connector is suspected. Hint 5: If the engine can be run at idle even though the crankshaft position sensor reading is out of specification. troubles in the ignition circuit and ignition coil or faulty ignition power transistor is suspected. II ~w#Ld Crankshaft position sensor A I A3 1‘ n-' \- . troubles are often in other than the crankshaft position sensor. shake the crankshaft position sensor harness. Therefore.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . the primary current of the ignition coil is not turned on and off.Components 13A-107 CRANKSHAFT POSITION SENSOR 4 992 models> MFI rela / Crankshaft position sensor A Equipmerit side CI”. Hint 2: If the crankshaft position sensor outputs a pulse signal when the ignition switch is turned ON (with the engine not running). Hint 3: If the tachometer reads 0 rpm when the engine that has failed to start is cranked. faulty crankshaft position sensor or broken timing belt is suspected. Hint 4: If the tachometer reads 0 rpm when the engine that has failed to start is cranked. If this causes the engine to stall. a faulty crankshaft position sensor or engine control module is suspected. [Examples] (1) Faulty engine coolant temperature sensor (2) Faulty idle air control motor (3) Poorly adjusted reference idle speed TSB Revision .F"6942 Output characteristic * Time Z7FUO682 7FUO499 7Fuls86 OPERATION l l The crankshaft position sensor senses the crank angle (piston position) of each cylinder. Power to the crankshaft position sensor is supplied from the MFI relay and is grounded to the body. TROUBLESHOOTING HINTS Hint 1: If unexpected shocks are felt during driving or the engine stalls suddenly during idling.

1.250. Function Item No. and check the waveform.1.150 rpm 600-800 rpm Data reading 22 0 gtine: Running at At -20°C (4°F) l Closed throttle posi.300. it indicates actual engine speed. 3 times the tachometer indication is the actual engine speed.13A408 INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components Using Scan Tool Check content I I I current of ignition NOTE (1) The tachometer indicates a third of the actual engine speed.At 0°C (32°F) tion switch: ON At 20°C (68°F) At 40°C (104°F) At 80°C (176°F) L) ~ I Using Oscilloscope 5V 7 I (1) Run the engine at idle speed.500 rpm 1. Data display Idle speed Check condition Coolant temperature Standard value 1.300 rpm 950-1. (2) When the tachometer is set to the 2-cylinder range. (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram.450 rpm l.lOO-1. I ~ ov------Normal waveform I I L&l TSB Revision . Therefore.

L r 1 L r MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (AS-69) Y7FUO496 i TSB Revision . 0 Connector: Disconnected 0 Ignition switch: ON Battery voltage 27FUC496 I Check for continuity of the ground circuit. (A4 Ground) connector b Repair the harness.Components 13A-109 HARNESS INSPECTION t I A Harness side connector Measure the power supply voltage. l Connector Disconnected relay) J A Harness side connector + Z7FUC497 I Check the voltage of the output Repair the harness.

(A3 .13A-110 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION T Components CRANKSHAFT POSITION SENSOR <From 1993 models> MFI relay A Equipment side connector 2 3 lzd A Harness side connector I Output characteristic ZSEL1303 I Engine control module connector Time _ 27FUO682 \ ‘iJ 26AF0060 7FU0653m 7FU1587 OPERATION Refer to P.MFI relay) 27FlJl33L d TSB Revision .l3A-107.i3A-108. l Connector: Disconnected l Ignition switch: OM Battery voltage I Repair the harness. INSPECTION Refer to P.l3A-107. TROUBLESHOOTING HINTS Refer to P. HARNESS INSPECTION ’ Harness 7 I1 tonne side ~ Measure the power supply voltage.

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l Connector: Disconnected 13A-111 A Harness side connector Repair the harness. (Al Ground) Z6AF0062 A Harness side i 1 TSB Revision .ComDonents Check for continuity of the ground circuit.

/ Data display / / Switch state Check condition I I Stop Cranking Engine Normal indication 1 OFF ON I 1 Data reading / 18 1 ignition switch: ON HARNESS INSPECTION Engine control module harness side connector Measure the input voltage to the l l 51 --I= I I engine control module. (51 . INSPECTION Using Scan Tool Function / Item No. which detects that the engine is cranking.258 I Check for continuity of the ground circuit. etc.Components IGNITION SWITCH-ST <M/T> Ignition switch (ST) Engine control module connector Engine control module 27FUO653 OPERATION l l The ignition switch-ST inputs a high signal to the engine control module while the engine is cranking.13A-112 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l tion switch) 2 -J Engine control module harness side connector Engine control module connector: Disconnected &round) z Z6FU1259 I 1 TSB Revision . Engine control module connector: Disconnected Ignition switch: START 8 V or more Repair the + harness. When the ignition switch is set to START.Igni- 26FU1. the battery voltage at cranking is applied through the ignition switch to the engine control module. The engine control module provides fuel injection control.. at engine startup based on this signal.

TROUBLESHOOTING HINTS If the park/neutral position switch harness and individual part checked good but the park/neutral position switch output is abnormal.-l_---- .MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l The park/neutral position switch converts the selector lever position (whether it is at the P/N range or at others) into high/low voltage and inputs it to the engine control module. etc.I -2s. In case the selector lever is in a position other than the P/N range. the battery voltage is not applied to the engine control module.. thereby making the terminal voltage go low. at engine startup based on this signal.1 E n g i n e c o n t r o l m o d u l e / Engine control module connector f7FU0625 7FU1999 OPERATION l The ignition switch-ST inputs a high signal to the engine control module while the engine is cranking. l The battery voltage in the engine control module is applied through a resistor to the park/neutral position switch.Components 13A-113 IGNITION SWITCH-ST AND PARK/NEUTRAL POSITION SWITCH (PNP SWITCH) <An . which detects that the engine is cranking. poorly adjusted control cable is suspected. 1 TSB Revision -< . l When the ignition switch is set to START. the battery voltage at cranking is applied through the ignition switch and park/neutral position switch to the engine control module. which then controls the idle air control motor based on this signal. The engine control module provides fuel injection control. .1992 models> Ignition switch (ST) A Harness side connector I Park/Neutral 1 position A Equipment switch side connector 8 L? P v9 T 0 Starter S Control terminal relay . continuity is produced between the park/neutral position switch terminal of the engine control module and ground through the starter motor. When the selector lever is set to the P/N range.

13A-114 INSPECTION Using Scan Tool IGNITION SWITCH-ST Function Item No. L or R Data reading 29 u I HARNESS INSPECTION I 1 A Harness side connector Measure the power supply voltage of the PNP switch. L or R Normal indication P or N D. 2. 2. (A8-7) Measure the input voltage of engine control module. l Engine control module connector: Disconnected l PNP switch connector: Disconnected l Ignition switch: START Battery voltage ZOlA0206 -y I Measure the PNP switch terminal input voltage. connector Harness side = ZOiA0206 Repair the harness.Components sd i Data display Switch state Check condition Ignition switch: ON stop Cranking Engine Normal indication OFF ON Data reading 18 PARK/NEUTRAL POSITION SWITCH Function Item No._ tor: Disconnected P l PNP switch connector: Connected 0 Select lever: P range l Ignition switch: START 8 V or more YOl LO427 I I A -++ I Replace the engine control module / TSB Revision . l Engine control module connec. l Engine control module connector: Connected l PNP switch connector: Disconnected l Ignition switch: ON Battery voltage Check the power supply circuit. Data display Shift position Check condition Ignition switch: ON Select lever position P or N D. MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

From 1993 models> lqnition switch (ST) A Equipment side connector PNP switch r I 8 - - k I Starter S MFI terminal relay I T7 i 51 .MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . TROUBLESHOOTING HINTS Refer to P.1 71 Engine control module B u Engine control module connector 27FU1320 7FlJO653 7Fu1590 OPERATION Refer to P.. TSB Revision .l3A-113.Components 13A-115 . IGNITION SWITCH-ST AND PARK/NEUTRAL POSITION SWITCH (PNP SWITCH) CAIT.l3A-113.

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . f---Y I l Engine control module con.l3A-114. l Engine control module connector: Connected l PNP switch connector: Disconnected l Ignition switch: ON Battery voltage 1 d Replace the engine control module. ( nectar: Disconnected l PNP switch connector: Dis.n nectar: Disconnected l PNP switch connector: Dis. Check the power supply circuit.13A-116 INSPECTION Refer to P. TSB Revision . Measure the impressed voltage to the PNP switch.. l Engine control module con./ connected NOTE Insert the probes of the circuit tester into both ends of the harness.’ connected 0 Ignition switch: START Battery voltage 1 -J A Harness side connector w-+ P-l I I - &Y 11 [a ‘5l@JO0 R r 131 A Harness side connector ZPFUO268 _r Engine control module harness side ZOFUO269 ZPFUO268 I Check for continuity between the PNP switch and engine control module.Components HARNESS INSPECTION ‘d Measure the power supply voltage. - Repair the harness.

which then provides the idle speed control.Components 13A-117 VEHICLE SPEED SENSOR (Mechanical Speedometer Type) Vehicle speed sensor (reed switch) . Continuity Engine control module harness side connector TSB Revision . etc. HARNESS INSPECTION Check the vehicle speed sensor output circuit for continuity. Speedometer Enginecontrol module I 5v A Equipment side connector F 7 ’ 68FOOll Terminal voltage (V) 1 B Equipment side connector I i I 64 10x470 Vehicle speed sensor 169 (inside speedometer) :-IUU-LrL -t Frequency (Hz) ZTFUllJS Vehiclespeed [km/h (mph)] 162451 7FUO6!53 7FUlS91 OPERATION l The vehicle speed sensor which is located in the speedometer converts the vehicle speed into a pulse signal and inputs it to the engine control module. based on this signal. l Engine control module connector: Disconnected l Move the vehicle. l The vehicle speed sensor generates the vehicle speed signal by repeatedly opening and closing between the voltage of about 5 V applied from the engine control module and ground using a reed switch.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . the engine may stall when the vehicle is decelerated to stop. TROUBLESHOOTING HINTS If there is an open or short circuit in the vehicle speed sensor signal circuit.

Meters and Gauges.13A-118 A Harness side MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components l l Connector: Disconnected Ignition switch: ON 0 Connector: Disconnected SENSOR INSPECTION Refer to GROUP 54 . TSB Revision .

the vehicle speed sensor generates the pulse signal. TROUBLESHOOTING HINTS Refer to P. By turning the power transistor ON and OFF. the engine control module performs idle speed control servo control.Components 13A-119 VEHICLE SPEED SENSOR (Electrical Speedometer Type) Ignition switch [IG] A Equipment side connector Engine control module - ZlZFOO50 Terminal voltage (V) Vehicle speed sensor b I 66 5. 5V is applied from the engine control module to the vehicle speed sensor output terminal. TSB Revision . l A voltage of approx. -I Frequency(Hz) 162178 Z7FUl434 / Engine control module connector k. mounted directly to the speedometer driven gear of the transmission. converts the vehicle speed to the pulse signal to be input to the engine control module. By this signal. Vehicle speed [km/h (mph)] 162451 7FltO653 7FUl592 OPERATION l The vehicle speed sensor.l3A-117.MULTIPORT On-Vehicle Inspection of MFI FIJEL INJECTION .

l Connector: Disconnected l Ignition switch: ON Battery voltage d’ L r ZlFUO969 L tion switch) I ’ Check the vehicle speed sensor output circuit for continuity.Meters and Gauges.. ’ ~ Ij’ Repair the harness. . (A3-66) J ii Z7FUl442 A Harness side connector Check for continuity of the ground circuit..+---.Components A Harness side connector Measure the line voltaae of the vehicle steed sensor. l Engine control module con.13A-120 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .One rotation tinuity I I A Harness side connector age of the vehicle speed sensor.\ ~ I I I C o n t i n u i t y -----r? m m 11 UULJ Nocon. 1 TSB Revision 1 .. l Connector: Disconnected @+A bound) Z7FU1443 I SENSOR INSPECTION Refer to GROUP 54 .f-\ 1 nectar: Disconnected l Ignition switch: ON l Move the vehicle Continuity control harness side connector ZO 1 A0508 L A C .

000 (100-284) 1. which then controls the idle air control motor based on this signal. As a result.500-2.ComDonents 13A-121 POWER STEERING PRESSURE SWITCH Engine control module A Harness side connector Power steering pressure switch r ml ON I-f-----’ Pressure [kPa (psi)] zotwuo 27FUO536 ( 700-2. This causes the power steering pressure terminal voltage to go from high to low. The battery voltage in the engine control module is applied through a resistor to the power steering pressure switch. turning the switch on. Steering operation causes the power steering oil pressure to increase. i TSB Revision J .000 (213-284) 7FU1593 OPERATION l l The power steering pressure switch converts presence/absence of power steering load into low/high voltage and inputs it to the engine control module. continuity is produced between the battery voltage applied and ground.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

107) SENSOR INSPECTION Refer to GROUP 37A . 0 Connector: Disconnected 0 Ignition switch: ON Battery voltage . TSB Revision .I 13A-122 INSPECTION Using Scan Tool _ On-Vehicle Inspection of MFI MULTIPORT Components FUEL INJECTION Checking Oil Pressure Steering wheel Straight forward Turned Oil pump delivery pressure (ref.200 kPa (loo-171 psi) 1.500-2. A Harness side connector I ReDair the hainess.000 kPa (213-284 psi) HARNESS INSPECTION Measure the power supply voltage. value) 700-l . (Al .On-vehicle Service.

l When the air conditioning ON signal is input. As a result.xx.OFF pressor to be running when air conditioning ON switch is ON) OFF ON 1 TSB Revision I .MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .~. Data display Check condition Air conditioning switch 28 Switch state Engine: Idling (air corn. ~fxx.Comtaonents 13A-123 AIR CONDITIONING SWITCH AND COMPRESSOR CLUTCH RELAY dzGq. the air conditioning power relay coil is energized to turn on the relay switch. which activates the air compressor magnetic clutch.z _ Engine control module ~~. the engine control module drives the idle air control motor and turns ON the power transistor. INSPECTION Using Scan Tool AIR CONDIT’ )NING S’ ‘ITCH 8 Normal indication Item No. TROUBLESHOOTING HINTS If the air compressor magnet clutch is not activated when the air conditioning switch is turned on during idling. faulty air conditioning control system is suspected.ing L Engine control module connector Z7FUO966 7FUO653 7FUlS94 OPERATION l The air conditioning switch applies the battery voltage to the engine control module when the air conditioning is turned on.Battery Air conditioning control unit Air conditioning compressor lock controller .

AIR CONDITIONING INSPECTION Refer to GROUP 55 . ‘\ d’ 1 TSB Revision .Components AIR CONDITIONING POWER RELAY Data display Air conditioning relay state Check condition Air conditioning switch Normal indication OFF (compressor I/ clutch non-activation) ON (compressor clutch activation) IL Data reading 49 Engine: Idling after OFF warm-up ON HARNESS INSPECTION II-1 --.On-vehicle Service. ~ l Engine control module harness side connector Z7FUO695 Dual air conditioning switch: ON Battery voltage Check the air conditioning circuit.-120 age of the air conditioning circuit.13A-124 Function Item No. MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

the engine control module provides retard control of the ignition timing.Comnonents 13A-125 KNOCKSENSOR Engine control module I A Equipment side connector I Knock sensor A Harness side I 27FU1075 Engine control module connector 7FUO653 7Fu1595 OPERATION The knock sensor generates a voltage proportional to the magnitude of cylinder block vibration due to knocking and inputs it to the engine control module. TROUBLESHOOTING HINTS When knocking occurs while driving under high-load conditions. (1) Inappropriate ignition plug heat range (2) Inappropriate gasoline (3) Incorrectly adjusted reference ignition timing i 1 TSB Revision . Based on this signal.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . the following problems are suspected in addition to the knock sensor itself.

13A-126 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . d.Components I harness side short-circuit to \j ~ nectar: Disconnected I I I 0 Connector: Disconnected I ~ \. TSB Revision .

to the engine control module. 33 Data display Switch state Check condition Operation of equipment: OFF Equipment state Normal display Data reading Lighting switch only: OFF + ON OFF + ON Rear defogger switch OFF + ON only: OFF + ON Brake pedal only: Depressed + Released ON + OFF : TSB Revision . Based on this signal.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . INSPECTION Using Scan Tool Function Item No. namely. l When the switch of equipment with a large electrical load is turned ON. the engine control module controls the idle air control motor. equipment with a large electrical load.Comoonents 13A-127 ELECTRICAL LOAD SWITCH Engine control module connector Engine control module 7FUO453 I 27FUO688 OPERATION l The electrical load switch inputs ON/OFF state of the switch of equipment that consumes much power during idling. the battery voltage is applied to the engine control module to indicate that the equipment switch is turned ON.

Components '1 61r 6 0 4 Measure the input voltage of en-0 0 ~ Battery voltage P I U Engine control module harness side connector Z7FUO689 ” Measure the input voltage of engine control module. l Engine control module connector: Disconnected l Brake pedal: Depressed (Stop light switch ON) Battery voltage 1 @--A Check circuit -+ related to stoplight relay Engine control module harness side connector TSB Revision . Measure .the input voltage of engine control module.13A-128 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l Engine control module connector: Disconnected l Defogger switch: ON (Defogger relay ON) Battery voltage Check circuit related to tail light relay 1 T Engine control module harness side connector Z7FUO689 Check circuit + related to defogger relay -T 4 I.

Components 13A-129 FAN MOTOR RELAY (RADIATOR. AIR CONDITIONING CONDENSER) <From 1994 models> Ignitionswitch (IG) Air conditioner compressor lock controller To air conditioner compressor Condenser fan motor 27~~1366 Engine control module connector 27FltO653 7Fu1597 1 TSB Revision .MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

the radiator fan motor relay (Hi) and condenser fan motor relay (Hi) will operate to send the driving power supply (for high speed rotation) to the radiator fan motor and condenser fan motor. If the engine control unit turns ON the low speed side power transistor inside the module. INSPECTION Using Scan Tool motor are driven at high speeds. and condenser fan motor rotate at high HARNESS INSPECTION Measure input voltage applied to ECM. If the engine control module turns ON the high speed side power transistor inside the unit. I Check the fan motor relay circuit TSB Revision . The condenser fan motor relay (Lo) will operate to send driving power supply (for low speed rotation) from the battery to the condenser fan motor. the current flows to the condenser fan motor relay (Lo).13A-130 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . the radiator l fan motor relay (Lo) coil operates to send driving power supply (for low speed rotation) from the battery to the radiator fan motor.Components OPERATION The engine control module controls the radiator fan motor and condenser fan motor according to l the engine coolant temperature and vehicle speed via the power transistors (low speed side and Ij high speed side) in the module. l ECM connector: Disconnected l Ignition switch: ON Battery voltage OK 0 A STOP FAN MOTOR RELAY INSPECTION Refer to Radiator Check in GROUP 14 and Power Relay Check in GROUP 55. If the air conditioner compressor lock controller outputs the air conditioner compressor driving power supply.

this is converted to high/low voltage to be sent to the engine control module.Components 13A-131 MUFFLER MODE CHANGEOVER SWITCH <Turbo> Engine control module r----7 103 A Equipment side connector ii I Q 3 ON 2 r Muffler OFF mode changeover switch 27FU1053 7FUlS98 OPERATION l If the operator turns the muffler mode changeover switch to ON or OFF position. Place the muffler mode changeover switch to the ON position. l The output terminal of the muffler mode changeover switch has battery voltage applied to it from the engine control module through the resistor inside the module. and the muffler mode changeover switch circuit will be closed to short the voltage applied to output terminal to the ground. the output voltage of the muffler mode changeover switch changes from high to low. Receiving this signal. the engine control module performs the dual mode (TOUR/SPORT mode) muffler control. Accordingly.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . INSPECTION Using Scan Tool Function Data list 35 Data display Switch condition Check condition Ignition switch: ON Muffler mode changeover switch condition Turn to TOUR mode Turn to SPORT Normal display ON OFF mode / TSB Revision .

Components AH connector Measure the power supply voltage.13A-132 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (A3-108) + 27FU1054 A Harness side l Connector: Disconnected Z7FU105 TSB Revision . l Connector: Disconnected l Ignition switch: ON Battery voltage Repair the harness.

INSPECTION Using Scan Tool Function Item No.000 rpm or more Standard value 0 or 9 steps 9 or 12 steps Data reading 62 Induction control Engine: Warm-up valve position 1 TSB Revision . A voltage of 5V from the engine control module is impressed to the two output terminals of the induction control valve position sensor.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . By opening and closing the circuit between the output terminal and ground. the induction control valve position sensor generates the pulse signal. Data display Check condition Engine state 700 rpm (Idling) 5. l The induction control valve position sensor is supplied with 5V power engine control module and is grounded to the engine control module.Components 13A-133 INDUCTION CONTROL VALVE POSITION SENSOR <Non Turbo> Variable induction control motor (DC motor) 1 Induction control valve A Equipment side connector Variable induction control motor’ (DC motor) (with built-in induction Iz _ control valve position sensor) 27FUO802 Variable induction control motor connector 72 A103 5v / i Z7FUO968 7Fu1599 OPERATION l The induction control valve position sensor detects the induction control valve opening degree and converts it into a pulse signal to be input into the engine control module. which provides valve opening and closing control based on this signal.

13A-134 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (Al -61) A Harness side connector Repair the harness. (A3-72) 27FUO824 A Harness side connector \J Repair the harness.2 V 26FU1241 -f Check for continuity of the ground circuit. l Connector: Disconnected Repair the harness.8-5.Components Measure the power supply voltage of the air intake control valve 4. (A2-111) (A4-103) I 27FlJO82S / I 1 TSB Revision .

The engine control module judges the condition of the EGR by this signal.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . which is a kind of resistor. This power supply further passes through the EGR temperature sensor. the lower the EGR temperature sensor terminal voltage. and is grounded at the engine control module. Engine control module 72 5v output voltage 27FU1239 Temperature 21629008 7FU1600 OPERATION l The EGR temperature sensor converts the temperature of EGR gas downstream from the EGR valve to voltage and inputs it to the engine control module. EGR temperature sensor terminal voltage changes with EGR gas temperature. If there is abnormal condition. The resistance of the EGR temperature sensor is characterized by a decrease in resistance with an increase of EGR temperature due to increase in quantity of EGR. Therefore.Components 13A-135 EGR TEMPERATURE SENSOR <California> A Equipment side connector EGR temperature sensor I I A Harness side connector ‘i 1 hV ’ 7FUlOlO 1 I . The higher the EGR gas temperature. l EGR temperature sensor terminal voltage increases or decreases with EGR temperature sensor resistance. l Five volt power supply in the engine control module is applied to the EGR temperature sensor through the resistance in the module. the check engine/malfunction indicator lamp is turned on to notify the driver. TSB Revision .

13A-136 INSPECTION Using Scan Tool MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Exhaust Gas Recirculation (EGR) System. Engine state 700 rpm (Idle) Standard value 100°C (212°F) or less 3.500 rpm 120°C (248°F) or more HARNESS INSPECTION l Connector: Disconnected Ignition switch: ON A Harness side l Connector: Disconnected SENSOR INSPECTION Refer to GROUP’ 17 . TSB Revision .Components Data display Sensor temperature Check condition Engine: Warmed up Engine is maintained in a constant state for 2 minutes or more Disconnect vacuum hose (green stripe) from EGR solenoid and install blind caps to removed vacuum hose end and solenoid nipple.

Therefore. l The engine control module controls the fuel injection ratio based on this signal so that the air-fuel ratio may be kept at the theoretical ratio. converts it into a voltage and inputs it to the engine control module. l The battery voltage is supplied to the heated oxygen sensor through the MFI relay.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .Comoonents 13A-137 HEATED OXYGEN SENSOR <Non Turbo> Heated oxygen / sensor Heated oxygen sensor A Equipment side connector 7FUO786 Electromotive Theoretical A/F force (V) MFI relay L J Engine control module r\5&72 14 A/F 15 16 ZECl007 DFUO969 Engine control module connector 7FUO653 7FU1601 OPERATION l The heated oxygen sensor senses the oxygen concentration in exhaust gas. l The heated oxygen sensor outputs about 1 V when the air-fuel ratio is richer than the theoretical ratio and outputs about 0 V when the ratio is leaner (higher oxygen concentration in exhaust gas). the sensor element is heated by the heater so that the heated oxygen’ sensor remains responsive even when the exhaust temperature is low. 1 TSB Revision .

[Examples] (1) Faulty injector (2) Air leaking into the intake manifold through gasket gap. barometric pressure sensor. troubles of parts related to air-fuel ratio control system are suspected. ) Data display 11 Sensor voltage I the heated oxygen se sor signal. engine coolant temperature sensor INSPECTION Using Scan Tool L) I Function Data reading Item No.Components TROUBLESHOOTING HINTS Hint 1: Poor cleaning of exhaust gas will result if the heated oxygen sensor fails. and also check the condition of control by the engine control module) TSB Revision . (3) Faulty volume air flow sensor. etc. check the air/ fuel mixture ratio. intake air temperature sensor. Hint 2: If the heated oxygen sensor checked good but the sensor output voltage is out of specification.13A-138 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

l Heated oxygen sensor connector: Disconnected l Engine control module connectar: Disconnected Repair the harness. or a module harness short-circuit to ground between the engine control module and the heated oxygen sensor. (Al -56) A Harness side Check for continuity of the ground circuit. l Connector: Disconnected z ZIFUO829 Repair the #( -+ harness. (A3 .Components HARNESS INSPECTION Measure the power supply voltage of the heated oxygen sensor.MFI relay) .Z7FUO827 Er1gine control Check for an open-circuit.Ground)/ i 1 TSB Revision .On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . l Connector: Disconnected l Ignition switch: ON Battery voltage 13A-139 A Harness side connector Repair the harness. L (A2-72) (A4 .

6-l . (7) Racing the engine repeatedly and measure the output voltage of the heated oxygen sensor. \ d NOTE For removal and installation of the heated oxygen sensor. 27FU1014 (4) Warm up the engine until the engine coolant temperature becomes 80°C (176°F) or higher.Components SENSOR INSPECTION (1) Disconnect the heated oxygen sensor connector. Z7FU1015 (6) Connect a digital voltmeter across terminals (1) and (2). I (2) Check that there is continuity [approx. replace the heated oxygen sensor. the heated oxygen sensor should output a voltage of 0.6-l .O V When the air-fuel mixture becomes richer as a result of repeated racing. TSB Revision .O V. as wrong connections result in a broken heated oxygen sensor.13A-140 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Caution Ensure that the jumper wires are connected correctly. refer to GROUP 15 . Heated oxygen Engine When engine is ra. (5) Using jumper wires. (3) If there is no continuity. 20 fiat 20°C (SS’F)] across terminals (3) and (4) of the heated oxygen sensor LJ connector.Exhaust Manifold. connect terminals (3) and (4) of the heated oxygen sensor connector to battery (+) and (-) terminals respectively.ced sensor output Remarks voltage 0.

Data display Sensor detection voltage Check condition Engine: Warm-up (Make the mixture lean by engine speed reduction.l3A-138. sensor (right) I Heated oxygen A Equipment side sensor (right) t I connector d = Heated oxygen B 1 sensor (left) Equipment side r connector Heated ‘oxygen qc sensor (left) ‘. check the air/fuel mixture ratio.---7 B Harness side connector -7 Engine controi module connector Z7FUO653 TFU1602 OPERATION Refer to P. P\ Electromotive force (V) I Al A2 MFI relay I Theoretical A/F 7FU1004 YY Y I 14 Z7FU1332 A/F l5 16iEC1007 -I A Harness side connector ~. TROUBLESHOOTING Refer to P.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .000 rpm Standard value 200 mV or lower Data reading 11 (right) 39 (lefi) When engine is 600-1.000 mV suddenly raced Engine: Warm-up (Using the heated oxygen sensor signal.000 mV (changes) TSB Revision . and rich by racing) Engine condition When sudden deceleration from 4.l3A-137. INSPECTION Using Scan Tool Function Item No.Components 13A-141 HEATED OXYGEN SENSOR <Turbo> Heated ‘d&en .000 rpm 13A-163 400 mV or lower t) 600. and also check the condition of control by the engine control module) 700 rpm (Idling) 2.1.

l Connector: Disconnected Z6AF0079 (A3.B3 .13/b142 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components Measure the power supply voltage of the heated oxygen sensor. l Heated oxygen sensor connector: Disconnected l Engine control module connector: Disconnected hFi relay) u OK Repair the harness. l Connector: Disconnected l Ignition switch: ON Battery voltage 27FUl333 I Check for an open-circuit. 3 --I AB Harness side Check for continuity of the ground circuit. or a short-circuit to ground. between the engine control module and the heated oxygen sensor.’ Ground) TSB Revision .

defective heated oxygen sensor is suspected. hAD998464 i!lFU0980 J L (8) If the measurements are not as specified. 20 Q at 20% (SSOF)] across terminals (1) and (3) of the heated oxygen sensor connector. (2) Tighten the heated oxygen sensor to specified torque. (7) Race the engine repeatedly and measure the output voltage of the heated oxygen sensor. (3) If there is no continuity. replace the heated oxygen sensor. connect terminals (1) (red clip of the special tool) and (3) (blue clip) of the heated oxygen sensor connector to battery (+) and (-) terminals respectively. INSTALLATION (1) For removal and installation of heated oxygen sensor. (6) Connect a digital voltmeter across terminals (2) (black clip of the special tool) and (4) (white clip). Engine When engine is raced Heated oxygen sensor output voltage 0. \ MD998i64 ZlFUO979 (4) Warm up the engine until the engine coolant temperature becomes 80°C (176°F) or higher. (2) Check that there is continuity [approx. i TSB Revision . the heated oxygen sensor should output a voltage of 0.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Caution Ensure that the jumper wires are connected correctty. refer to GROUP 15 .Components 13A-143 SENSOR INSPECTION (1) Disconnect the heated oxygen sensor connector and connect the special tool.1 .Exhaust Manifold. as wrong connections result in a broken heated oxygen sensor. Test Harness.O V.0 V Remarks When the air-fuel mixture becomes richer as a result of repeated racing. (5) Using jumper wires.6-1. to the heated oxygen sensor connector.6.

which then injects fuel. When the engine control module turns on the power transistor in the module. 27FlKU53 7FUl603 OPERATION l The injector is an injection nozzle with a solenoid valve which injects fuel according to the injection signal coming from the engine control module. l The injector has a fixed nozzle opening area and the fuel pressure against manifold inside pressure is regulated to a fixed level. Therefore.Components INJECTORS <Non Turbo> - I I 7FUO803 Filter Engine control module Engine control module connector 27FUO833 @ injection 7FUO832 . by the time during which the solenoid coil is energized. TSB Revision ’ .13A-144 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . the volume of fuel injected by the injector is determined by the time during which the needle valve is open. the solenoid coil is energized to open the injector valve. l The battery voltage is applied through the MFI relay to this injector. namely.

camshaft position sensor Hint 3: If there is any cylinder whose idle state remains unchanged when the fuel injection of injectors is cut one after another during idling. accessory units: All OFF l Transaxle: Neutral (P range for vehicle! with A/T) 0 Steering wheel: Neutral 2. compression pressure.16.000 rpm 2. faulty ground circuit (2) Faulty MFI relay (3) Faulty crankshaft position sensor. the injector drive time may be about 10% longer.4-50.8 ms <From 1994 models> 9.6 injector shut off Engine: Idling after Idle state to change warm-up further (becoming less stable or stalling) (Shut off the injectors in sequence during idling after engine warm-up.7 ms <Up to 1993 models> 13. ignition coil.) (2) Loose EGR valve seating (3) High engine resistance INSPECTION Using Scan Tool Function Item No.1 ms <Up to 1993 models> 86-l 0. etc. *2: When coolant temperature is lower than 0°C (32”F). Hint 2: If the injector does not operate when the engine that is hard to start is cranked. Data display Data reading 41 Drive time” Check condition Engine: Cranking Coolant temperature 0°C (32”F)*2 20°C (68°F) 80°C (176°F) Standard value 15. (1) Injector and harness check (2) Ignition plug and high tension cable check (3) Compression pressure check Hint 4: If the injector harness and individual part checked good but the injector drive time is out of specification. l 3: When the vehicle is new [within initial operation of about 500 km (300 miles)]. the following as well as the injector itself may be responsible. Function Actuator test 01 02 03 04 05 06 item No.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .6 ms <Up to 1993 models> 40-48.3 injector shut off No.4 injector shut off I Check condition Normal state i’/’ No.5 iniector shut off No. check fuel pressure and check the injector for leaks.3-18. (1) Poor combustion in the cylinder (faulty ignition plug. injection is made by 6 cylinders simultaneously.2 injector shut off No.9-12. the following troubles are suspected. Drive content No.8. make following checks about such cylinder.5 ms u i I Function Item No. check the idling condition) TSB Revision .1 injector shut off No.2 ms When sharp racing is To increase made NOTE *1: The injector drive time refers to when the supply voltage is 11 V and the cranking speed is less than 250 rpm.0-3.3-3. (1) Faulty power supply circuit to the engine control unit. Data display I I Drive time’3 Data 41 reading Check condition l Engine state 700 rpm (Idle) Engine coolant temperature: 80 to 95°C (176 to 203°F) l Lights.Components 13A-145 TROUBLESHOOTING HINTS Hint 1: If the engine is hard to start when hot.8 ms <From 1994 models> 41.6 ms <From 1994 models> Standard value 2. electric cooling fan.

l Injector connector: Disconr&ted 0 Engine control module connector: Disconnected 27FUO805 I Repair the harness. Connector: Disconnected Ignition switch: ON Battery voltage Repair the harness.1 l l HARNESS INSPECTION 1 J Harness side connector Measure the power supply voltage of the front bank injector. and check the waveform d at the drive side of each injector. (A B C2i 23) 1 TSB Revision .i i -i I short-circuit between the front bank iniector and the engine control module.Components Using Oscilloscope (1) Run the engine at idle speed. 41 Ak A: Injector drive time Normal waveform 203A0209 . ’ (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram. (A B Cl MFI relay) 27FUO669 Harness side connector relay) 27FUO970 I Harness side connector I---3318 --.13A-146 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

/ /// . Measurement of Resistance between Rear Bank Terminals (1) Remove the injector connector. i TSB Revision I . (2) Measure the resistance between terminals.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . l Connector: Disconnected l Engine control module connector: Disconnected i41516) 27FUO971 1 ACTUATOR INSPECTION Measurement of Resistance between Front Bank Terminals (1) Remove the injector connector.Components 13A-147 L Harness side connector r Check for an open-circuit.. (2) Measure the resistance between terminals. Standard value: 13-16 Q [at 20°C (68”F)] (3) Install the injector connector. or a short-circuit between the rear bank injector and the engine control module. .’ L. Standard value: 13-16 Q [at 20°C (SS’F)] (3) Install the injector connector.

2 ./\ 6 Rear bank connector Inject0 r.Components MFI relay A Equipment side connector / \ Injector (Front bank connector) 7F.3 \.---_ Inject01 r No... Inject0 5 \/ \I 5 I.13A-148 INJECTORS <Turbo> MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .. Q 1 OSCilla: 1’ bisal3 .. ? 3 rI 5 ‘4 P 3 b 14 K I5 K A -- Engine control module Z7FUO973 Fuel Filter Engine control module connector 7FlKM53 @ Injection 7FUO832 7FU1604 OPERATION Refer to P.... TROUBLESHOOTING HINTS Refer to P. ..l3A-145.l3A-144.Injector No. [ TSB Revision .6 E [ . No...1..0SOR ---6 7 4 .

electric cooling 2*ooo rPm fan. and check the waveform at the drive side of each injector.1 injector shut off No.Components 13A-149 INSPECTION Using Scan Tool b Function Data reading item No.3-7. 41 Data display Drive time*” l Check condition I Engine state 1 Standard value 1 (Rear bank) 47 (Front bank) 1. check the idling condition) Normal state Idle state to change further (becoming less stable or stalling) No. Function Act&or test 01 02 03 04 Item No.1-31.700 rpm (Idle) ature: 80 to 95°C (176 to 203°F) 1.9 m s 6.6 ms 0 Lamps.6-2.3 injector shut off No.4 injector shut off No.5 injector shut off No.8 ms Engine coolant temper.MULTIPORT On-Vehicle Inspection of MFI FIUEL INJECTION . the injector drive time may be about 10% longer.4-2.1-9.6 injector shut off 05 06 Using Oscilloscope (1) Run the engine at idle speed.7 m s (Front bank) I Function Data reading Item No. Drive content No. 41 (Rear bank) 47 Data display Drive time” Check condition Engine: Cranking Coolant temperature 0°C (32”F)** 20°C (68°F) 80°C (176°F) Standard value 8.9 ms 26. accessory units: All OFF When stiarp racing is To increase l Transaxle: Neutral made l Steering wheel: Neutral NOTE *l: The injector drive time refers to when the supply voltage is 11 V and the cranking speed is less than 250 rpm. *2: When coolant temperature iis lower than 0°C (32”F). L -+[A k A: Injector Normal waveform 1 TSB Revision . injection is made by 6 cylinders simultaneously.2 injector shut off Check condition Engine: Idling after warm-up (Shut off the injectors in sequence during idling after engine warm-up. ‘3: When the vehicle is new [within initial operation of about 500 km (300 miles)]. (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram.

l lniector connector: Disconn&ted l Engine control module connector: Disconnected Repair the harness.I 6 --.Components Measure the power supply voltaoe of the resistor.-----------------. + ’ .Resistor connector: Disconnected l Ignition switch: ON Battery voltage _ Repair the harness. l .3EiII 0 'I I L-i Check for an open-circuit.MFI relay) Z7FUO976 1 Measure the power supply voltage of the front bank injector. l Connector: Disconnected l Ignition switch: ON Battery voltage harness (E456MFI relay) Check power supply Check resis- i I . (A4 . (B C D2i 23) 1 27FUO805 TSB Revision . or a short-circuit between the front bank iniector and the engine control module. (B C DlMFI relay) Check power supply Check resistor Rear bank harness side connector _ Measure the power supply voltage of the rear bank injector. l Resistor connector: Connecteu l Injector connector: Disconnetted l Ignition switch: ON Battery voltage 4 27FUO661 Repair the harness.#’ connector r = t7FU0977 t J --.13A-150 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

(2) Measure the resistance between terminals. or a short-circuit between the rear bank injector and the engine control module.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Standard value: 2-3 L2 [at 20°C (68”F)] (3) Reconnect the injector connector. i TSB Revision . Measurement of Resistance between Rear Bank Terminals (1) Disconnect the injector connector. (2) Measure the resistance between terminals. I” 27FUO978 13A-151 ’ ACTUATOR INSPECTION INJECTORS Measurement of Resistance between Front Bank Terminals (1) Disconnect the injector connector.Components -Check for an open-circuit. l Connector: Disconnected l Engine control module connector: Disconnected -. Standard value: 2-3 0 [at 20°C (SS’F)] (3) Reconnect the injector connector.

I 1-4 2-4 Measuring terminals I Resistance VI k!E65c~88”F)1 . (2) Measure the resistance between terminals. replace the resistor.Components RESISTOR Measurement of Resistance between Terminals (1) Disconnect the resistor connector.13A-152 MULTIPORT On-Vehicle inspection of MFI FUEL INJECTION . I 8-4 I (3) If the resistance is out of specification. TSB Revision .

etc.) l i TSB Revision . As the engine control module turns on power transistors in the module one after another. \/ 1 “3 ‘/4 ” 6 IAC motor m sTWat 7~~039 I Z7FUO518 Engine control module connector . l The battery power is supplied to the stepper motor through the MFI relay. TROUBLESHOOTING HINTS Hint 1: If the stepper motor step increases to 100 to 120 steps or decreases to 0 step. ignition coil. injector.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (1) Poorly adjusted reference idle speed (2) Deposit on the throttle valve (3) Air leaking into the intake manifold through gasket gap (4) Loose EGR valve seat (5) Poor combustion in the cylinder (faulty ignition plug.’ iJ 7FUO653 7FU1605 OPERATION The intake air volume during idling is controlled by opening or closing the servo valve provided in the air path that bypasses the throttle valve. the stepper motor coil is energized and the motor rotates in normal or reverse direction.e&or - IDLE AIR CONTROL MOTOR (STEPPER MOTOR TYPE) MFI relay \. 1.Components 13A-153 A Harness side 7---conn. Hint 2: If the idle air controll motor harness and individual part checked good but the stepper motor steps are out of specification. \. \. faulty stepper motor or open circuit in the harness is suspected. low compression pressure. the following faults are suspected. l The servo valve is opened or closed by operating the stepper motor in the speed control servo in normal or reverse direction.

accessory units: All OFF Transaxle: Neutral (P range for vehicle with AlT> Steering wheel: Neutral Idle position switch: ON (compressor clutch to be ON if airconditioning switch is ON) Engine: Idling Load state Air conditioning switch: OFF Standard value 2-25 step l l Air conditioning switch: ON Increase by 1 O-70 step l l l NOTE When the vehicle is new [within initial operation of about 500 km (300 miles)]. Caution When the selector lever is shifted to the “D” range. NOTE Keep in mind that the waveform can be observed only when idle speed control is in operation. the stepper motor steps may be about 30 steps more than standard. electric cooling fan. Check the instantaneous waveform. (2) Start the engine. the brakes must be used to prevent the vehicle from moving forward.13A-154 INSPECTION Using Scan Tool Function Data 45 Item No. (3) When the air conditioning switch is turned on. the idling speed increases to operate the idle speed control. MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 1 ~UYUUV"UUdUL Using Oscilloscope (1) Connect the probe to each oscilloscope pick-up point as shown in the circuit diagram.Components Data display Stepper motor steps l Check condition Engine coolant temperature: 80 to 95°C (176 to 203°F) Lights. TSB Revision .

l Idle air control motor connector: Disconnected l Ignition switch: ON Battery voltage 7 ZOlLO395 13A-155 - I Repair the A Harness side connector (MFI’relay .MlJLTlPORT On-Vehicle Inspection of MFI FUEL INJECTION .motor.$~ / -qp j g F ia-I-. If the circuit is normal. (Al -4) (A3-17) (A4-5) (A6-18) ACTUATOR INSPECTION Checking the Operation Sound (1) Check that the operation sound of the stepper motor can be heard after the ignition is switched ON (but without starting the motor). (2) If the operation sound cannot be heard. TSB Revision . check the stepper motor’s activation circuit. or a short-circuit to around between the engine contr.A ----44 ZOlLO397 Repair the harness.l module andthe idle air control motor.A5) Check for an open-circuit. it is probable that there is a malfunction of the stepper motor or of the engine control module.ComDonents HARNESS INSPECTION Measure the power supply voltaae of idle air control . l Enoine control module connectar: Disconnected l Idle air control motor connector: Disconnected J 2 Engine control A Harness side moduk? harness side connector r:i connector [pq :::.

(2) Remove the stepper motor. TSB Revision . / n Standard value: 28-33 Q at 20°C (68°F) 27FUOOlO Operational Check (1) Remove the throttle body. 6 V) to the white clip and the green clip. (4) Connect the positive (+) terminal of a power supply (approx. Standard value: 28-33 Q at 20°C (68°F) (3) Measure the resistance between terminal (5) (green clip of the special tool) and either terminal (6) (yellow clip) or terminal (4) (black clip) of the connector at the idle air control motor side.13A-156 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components Checking the Coil Resistance (1) Disconnect the idle air control motor connector and con- nect the special tool (test harness). (3) Connect the special tool (test harness) to the idle air control motor connector. (2) Measure the resistance between terminal (2) (white clip of the special tool) and either terminal (1) (red clip) or terminal (3) (blue clip) of the connector at the idle air control motor side.

(6) If. 3) Connect the negative (-) terminal of the power supply to the blue and yellow clip. 6) Repeat the tests in sequence from (5) to (1).Components 13A-157 (5) With the idle air control motor as shown in the illustration. connect the negative (-) terminal of the power supply to each clip as described in the following steps. as a result of these tests. 1) Connect the negative (-) terminal of the power supply to the red and black clip. 5) Connect the negative (-) terminal of the power supply to the red and black clip. 1 TSB Revision . vibration is detected. 4) Connect the negative (-) terminal of the power supply to the red and yellow clip.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 2) Connect the negative (-) terminal of the power supply to the blue and black clip. the stepper motor can be considered to be normal. and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor.

13A-158 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . primary current flows to the ignition coil A. the battery voltage in the module is applied to the ignition power transistor unit to turn it on. TSB Revision I L. 3 and No. In addition. 2 and No.Components IGNITION COIL AND IGNITION POWER TRANSISTOR Battery I--T I. 4 cylinders to spark. l When the engine control module turns off the transistor.23 i. the ignition plugs of No.J . 6 cylinders spark. causing the ignition plugs of No. the ignition plugs of No. 1 and No. when the ignition power transistor unit C is turned off. When the ignition power transistor unit B is turned off. 5 cylinders spark. iransistor [T. in the module. the primary current is shut off and a high voltage is induced in the secondary coil A. Ignition switch ! A Harness side connector connector Eq side I3 Harness side connector 1 qj&j) q-1 1 1 B-l B-2 I Spark Plug II “J II 1. When the engine control module turns on the transistor in the module. the ignition power transistor unit is turned off.ofy Engine control module 101 5V 5v UFU1059 7FU1606 7FU0653 OPERATION l When the ignition power transistor unit A is turned on by the signat from the engine control module. When the ignition power transistor unit A is turned off.

17 Drive Set to ignition timing adiustment mode I I l l Check condition Engine: idling Timing light: set I Normal condition 5”BTDC I I I - I 1 Oscillo 1 Using Oscilloscope I 1.-Normal waveform z.) +:II1. ..’ L/I IDV c-l R Normal waveform YO3AO20. Control signal of ignition power transistor Connect the probe to oscilloscope pick-up point 2 as shown in the circuit diagram... Primary signal of ignition coil (1) Run the engine at an idle speed. I <Ignition Timing Adjustmernt Mode> Function Item No Data display Continuiity present or not present between ignition timing adjustment terminal and ground l I I I I I Data display Ignition advance l l Check condition Engine state Standard value Engine: Warming up 700 rpm (Idle) 7-23”BTDC Timing light: Set (set timing light to check 2. Function Data reading T 44 Item No.Spark Ad. 1 ov-i.OFF ment terminal is disconnected from ground <Standard Ignition Timing> I / I Function Actuator test I Item No..MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .~.02.3. Oscillo 2 2. 1 .ON ment terminal is grounded Ignition timing adjust.000 rpm 30-50”BTDC <Non Turbo> actual ignition timing) 23-43”BTDC <Turbo> Check condition Engine: Idling Terminal condition Standard value ignition timing adjust.. (2) Connect the probe to oscilloscope pick-up point 1 as shown in the circuit diagram. i!. . and check the control signal of the ignition power transistor.. .Components 13A-159 L INSPECTION Using Scan Tool . and check the primary signal of the ignition coil.

l Connector: Disconnected l Ignition switch: ON Battery voltage OK--+0 0 2 ZOl Lo4ll Repair the harness.Ignition switch) 0 Ignition power transistor connector: Disconnected Ignition power transistor connector: Disconnected TSB Revision . (A3 .Components A Harness side co Measure the power supply voltage of the ignition coil.13A-160 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

1 TSB Revision . (Bl-11) Z7FUO701 Measure the voltage of the ignition timing adjustment terminal..MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l Connector: Disconnected e Ignition switch: START 0.Components Checkforcontinuity of the ground circuit.5-4.Ignition System. l Connector: Disconnected 13A-161 B-2 Harness side connector 6 cl bound) 1 B-2 Harness side connector Measure the voltage of the control signal circuit of the ignition power transistor. g.0-5.::.0 v Repair the harness.2 V ACTUATOR INSPECTION Refer to GROUP 16 . l Ignition switch: ON 4.

13A-162 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .1206 OlAO324 7FUO653 7FU1607 OPERATION l The evaporative emission purge solenoid is an ON-OFF type one which controls introduction of purge air from the canister into the intake air plenum. When the engine control module turns ON the power transistor in the module. introducing purge air. o The battery power is supplied to the evaporative emission purge solenoid through the MFI relay. 08 Drive content Solenoid valve from Check condition Ignition switch: ON Normal state Operating sound. INSPECTION Using Scan Tool Function Actuator test Item No. is heard when driven OFF to ON TSB Revision . current flows to the coil.Comtaonents EVAPORATIVE EMISSION PURGE SOLENOID MFI relay A Equipment side connector A Harness side connector Engine control module Sm.

i 1 ‘TSB Revision .% z7FuoJ26 connector ACTUATOR INSPECTION Refer to GROUP 17 .Evaporative Emission Control System.Components 13A-163 HARNESS INSPECTION Measure the power supply voltage.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . or a short-circuit to ground between the evaporative emission purge solenoid and the engine control module. l Connector: Disconnected l Ignition switch: ON Battery voltage connector OK-+ 0 2 Repair the + harness. (MFI relay -Al) Check for an open-circuit. l Engine control module connectar: Disconnected l Evaporative emission purge solenoid connector: Disconnetted L Repair the harness. (A2-9) -I A H a r n e s s s i d e .

It makes control by leaking EGR valve operating negative pressure to the throttle body A port. l Power supply from the battery is sent through the MFI relay to the EGR solenoid. check the EGR valve. 1 TSB Revision . vacuum hose and EGR passage for blocking. TROUBLESHOOTING HINT If the results of EGR solenoid on-vehicle and off-vehicle inspections are normal but the diagnostic trouble code for EGR system failure is displayed.ComDonents EGR SOLENOID <California .13A-164 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . When the engine control module turns off the power transistor inside the module. Turbo> MFI relay A1 EGR solenoid A Equipment side connector Engine control module Engine control module connector 7FUO653 7FU1606 OPERATION l The EGR solenoid is a duty control type solenoid valve.Non Turbo. current no more flows through the coil and EGR valve operating negative pressure leaks.

Components INSPECTION Using Scan tool 13A-165 HARNESS INSPECTION Measure the power supply volt- aae.Connector: Disconnected Ignition switch: ON Battery voltage = ZOlAO524 1 Check for an open-circuit.Exhaust Gas Recirculation (EGR) System.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . (A2-6) T ZOlAO525 ACTUATOR INSPECTION Refer to GROUP 17 . l 0 . or a short-circuit to ground between the EGR solenoa and the engine control module. 0 EGR solenoid connector: Disconnected l Engine control module connector: Disconnected relay) Engine control module harness side connector - I Repair the harness. 1 TSB Revision .

Battery power is supplied to this valve via the MFI relay. the coil is energized to allow barometric pressure to be introduced to the fuel pressure regulator. TSB Revision .1 A Equipment side connector +I El lnf kl - I Engine control module Engine control module connector 7FUO653 7FU1609 OPERATION The fuel pressure solenoid is an ON-OFF type solenoid valve that switches the pressure introduced l to the fuel pressure regulator between either intake manifold pressure or barometric pressure.Components FUEL PRESSURE SOLENOID <Turbo> MFI relay - -d 1 f/ 7FU1008 Fuel pressure solenoid l--&l - . When the engine control module turns l ON the internal power transistor.13A-166 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .

1 09to Drive content Turn solenoid valve from ON Check condition Ignition switch: ON / Click heard when driven Normal state HARNESS INSPECTION Measure the power supply voltage. l Connector: Disconnected A Harness side connector .h: ON Repair the harness.MFI relay) = - ZOlA0524 Engine control module harness side CO Check for an open-circuit.. or a short-circuit to ground..MULTIPORT On-Vehicle Inspection of MFI FUJEL INJECTION . between the fuel pressure solenoid and the engine control module.Components INSPECTION 13A-167 Using Scan Tool Function oFF Actuator test Item No. (Al .att. (A2 -7) YOlA0525 TSB Revision .zt. l Engine control module connector: Disconnected 0 Fuel pressure solenoid connector: Disconnected u OK A STOP Repair the harness..

Components ACTUATOR INSPECTION Operation Check NOTE Before disconnecting the vacuum hose. (1) Remove the vacuum hose (blue stripe on black) from the solenoid valve. d (3) Apply a negative pressure to the nipple to which the black vacuum hose has been connected and check airtightness with and without the battery voltage applied to the solenoid valve terminal. . (2) Disconnect the harness connector. mark it to ensure reconnection at the correct position.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Battery voltage The other nipple of solenoid valve Normal state I n Coil Resistance Check (1) Measure the coil resistance with a circuit tester. Standard value: 36-46 iR [at 20°C (SS’F)] TSB Revision .

the follwing problems are suspected. but poor acceleration or other abnormalities are experienced.Components 13A-169 TURBOCHARGER WASTE GATE SOLENOID <Turbo> 7FLJ1007 A Equipment side connector Engine control module 20110324 Engine control module connector 7FUCkS3 7FU1610 OPERATION l The turbocharger waste gate solenoid is an ON-OFF type solenoid valve that controls the boost pressure that is introduced to the turbocharger waste gate actuator. TROUBLESHOOTING HINTS If the turbocharger waste gate solenoid harness and the unit itself are normal. When the engine control module turns ON the internal power transistor. the coil is energized to release part of the boost pressure applied to the turbocharger waste gate actuator.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . (1) Faulty boost pressure control system (2) Poor connection of intake air hose (3) Faulty turbocharger or turbocharger waste gate actuator (4) Clogged exhaust system TSB Revision . l Battery power is supplied to this valve via the MFI relay.

(A2-105) ^ 7 ACTUATOR INSPECTION Refer to GROUP 15.13A-170 INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components Using Scan Tool Function Actuator test 12 Item No. l Turbocharger waste gate solenoid connector: Disconnected l Engine control module connectar: Disconnected Z7FUO526 connector Repair the Harness. between the turbocharger waste gate solenoid and the engine control module.MFI relay) \ < QCCQ J / r z7Fw525 Check for an open-circuit. TSB Revision . l Measure the power supply voltage. Drive content Turn solenoid valve from OFF to ON Check condition Ignition switch: ON Normal State Click heard when driven :J HARNESS INSPECTION A Harness side connector ’ [-. (Al . l Connector: Disconnected 0 Ignition switch: ON Battery voltage Repair the harness. or a short-circuit to ground.

) I A Equipment side connector Boost meter UFUO985 Engine control module connector 27FlJO653 TSB Revision 1 . Boost ry teiter !I I Ignition switch (IG.Components 13~9171 r-A‘4/--l----l \ I449 2 E-27= lb/&: I@ / BOOST METER <Turbo> ---===fy.MULTIPORT On-Vehicle Inspection of MFI FlJEL INJECTION .

l Boost meter connector: Disconnected l Engine control module connector: Disconnected Repair the + harness. between the engine control module and the boost meter. 1 TSB Revision . (A3-111) 7 Y Z7FUO987 ACTUATOR INSPECTION Refer to GROUP 54.13~9172 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l Connector: Disconnected 0 Ignition switch: ON Battery voltage 1 Repair the harness.Ignition coil [IG]) Z7FUO986 - Engine controt moduts Check for an open-circuit or a short-circuit to ground.Components Measure the power supply voltage. (A2 .

MULTIPORT On-Vehicle Inspection of MFI FlJEL INJECTION . l The DC motor is driven in the normal or reverse direction by changing the direction of power flow by the motor driving IC in the active exhaust control unit. l The valve is opened or closed by turning the DC motor in the normal or reverse direction. 1 TSB Revision . l l I Engine control module connector: Disconnected Ignition switch: ON Repair the ~ Engine control module harness side connector Z7FUO689 I Battery voltage harness (A4-102) i ACTUATOR INSPECTION Refer to GROUP 15. l The active exhaust control module opens and closes the valve when it receives the signal produced by the engine control unit. HARNESS INSPECTION 1 -I 02 Measure the input voltaae of enaine control mddule.ComDonents 13/b173 ACTIVE EXHAUST COIWTROL UNIT <Turbo> DC motor for valve drive Active exhaust control unit 27FUO988 A Equipment side connector Z7FUO989 Engine control module connector z7Fuo653 7FU1612 OPERATION l Muffler noise is controlled1 by opening and closing the valve provided inside the main muffler.

Components VARIABLE INDUCTION CONTROL MOTOR (DC MOTOR) <Non Turbo> Engine control module Variable induction control motor (DC motor) (with built-in induction _ control valve position sensor) y 109 7FUO802 v 110 Close A Equipment side connector Open I I Variable induction control motor r M 44 DC motor ZlFUO646 Engine control module connector 7FUO653 7FU1613 OPERATION As the DC motor is driven clockwise or counterclockwise by the signal from the engine control module. l the variable induction valve opens or closes.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . The DC motor is driven clockwise or counterclockwise as the direction of current flow is changed l by the motor drive IC in the engine control module. tion Drive content Drive the variable induccontrol (MC) motor (Open and close the variable induction valve) Check condition Ignition switch: ON Normal state Turn the variable induction valve shaft (Variable induction valve: FULL CLOSE + FULL OPEN) TSB Revision I I . INSPECTION Using Scan Tool <Variable Induction Control Motor> Function Actuator test 11 Item No.

ue - NOTE *: 1992 model only HARNESS INSPECTION Engine control module Check for an open-circuit or a short-circuit to ground. 700 rpm (Idle) .Components <Variable Induction Control Valve Position> 13A-175 L m Vanable rnductton controLv:. between the engine control module and the variable induction control motor connector.. l Variable induction control motor connector: Disconnected l Engine control module connectar: Disconnected f2& 27FUO841 connector Repair the harness.. i .:. zz.. L TSB Revision .MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .:.:.. (Al-log) (A2-1lOj I ACTUATOR INSPECTION Refer to GROUP 15.:.:.

between the ABS control unit and the engine control module. the ABS control unit turns ON the power transistor. This causes the anti-lock braking signal to go from high to low. l ABS control unit connector: Disconnected l Engine control module connector: Disconnected Z6FU1543 TSB Revision . HARNESS INSPECTION Engine control moduls side connector Check for an open-circuit or a short-circuit to ground.ABSHU 1 114 9 Engine control module connector \ 26FU1542 i 7FUO653 7FU1614 OPERATION l The anti-lock braking signal is input to the engine control module from the anti-lock braking system (ABS) control module as a signal to indicate whether or not the motor relay is activated. l When the motor relay is activated. the engine control module controls the idle air control motor to secure effective anti-lock braking. short-circuiting the terminal to ground.Comnonents ANTI-LOCK BRAKING SIGNAL <Turbo> I ABS ECU A ABS control unit equipment side connector d’ 1 A 28 I Engine control module T--.13A-176 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Based on this signal.

If the transistor fitted inside the engine control module changes from ON to OFF. the transaxle control module also controls the terminal voltage of the engine control module by the ON/OFF operation of the transistor fitted inside the transaxle control module in order to send signal. the terminal having a voltage of 5 V applied to it from the transaxle control module is grounded in the engine control module.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . having applied to it a voltage of 5 V from the transaxle control module and grounded in the engine control module. TSB Revision . the terminal voltage of the transaxle control module is controlled by ON/OFF operation of the transistor inside the engine control module in order to send signal. the terminal. l If the transistor inside the engine control module changes from OFF to ON by the command of the engine control module. In this way. This will change the terminal voltage of the transaxle control module from HIGH to LOW. On the other hand. In this way. is released and the terminal voltage of the transaxle control module changes from LOW to HIGH. the engine and transaxle send control signal to each other.Components 13/b177 ENGINE AND TRANSAXLE TOTAL CONTROL SIGNAL <AK> Transaxle control module TT A A P 0 # module 16FO292 Engine control module A Transaxle control module connector Z7FU0843 Engine control module connector Z7FUO903 7Fuo653 7FlJ1615 OPERATION l Three communication lines are connected between the engine control module and the transaxle control module to send and receive the engine and transaxle total control signal.

l Transaxle control module connector: Disconnected l Engine control module connector: Disconnected Repair the harness.e hamess short-circuit to ground between the transaxle control module and the engine control module. or a short-circuit to ground between the transaxle control module and the engine control module. or a short-circuit to ground between the transaxle control module and the engine control module. l Transaxle control module connector: Disconnected 0 Engine control module connector: Disconnected I d’ Repair the harness.13A-178 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (A7-116) A Transaxle control module harness side connector Engine control Check for an open-circuit. or a modu.ComDonents Engine module control harness A Transaxle control module harness side connector side connector Check for an open-circuit.e hamess A Transaxle control module harness side connector side connector Check for an open-circuit. l Transaxle control module connector: Disconnected l Engine control module connector: Disconnected \ d Repair the 3 harness. (Al 08-7) TSB Revision . (A9-59) Engine control modu.

Remove the fuel tank cap and listen to the operating sound through the filter port. the operating sound of the pump can be heard. (2) Disconnect the fuel pump harness connector. (3) Hold the high pressure fuel hose between your fingers and check that the fuel pressure can be felt. (4) Connect the fuel pump harness connector.Components 13A-179 Fuel gauge cover RELEASE OF RESIDUAL PRESSURE FROM HIGH PRESSURE FUEL HOSE Make the following operations to release the pressure remaining in fuel pipe line so that fuel will not flow out. Specified sealant: 3M ATD Part No.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . turn the ignition switch to OFF.8509 or equivalent (6) Install the fuel gauge cover. (5) Apply the specified sealant to the rear floor pan. FUEL PUMP OPERATION CHECK (1) Set the ignition switch at OFF. NOTE Since the fuel pump is installed in the fuel tank. TSB Revision . (1) Remove the fuel gauge cover in the luggage compartment. (2) Check that when the battery voltage is directly applied to the fuel pump check terminal (black). (3) Start the engine and after it stops by itself. its operating sound cannot be readily heard.

With fuel pressure applied. (5) Connect a jumper wire to the terminal for activation of the fuel pump and to the positive (+) terminal of the battery to activate the fuel pump. Standard value: <Non Turbo>Approx. placing an adequate O-ring or gasket between the gauge and special tool prevent fuel leaks. (2) Disconnect the fuel high pressure hose at the fuel rail side.13A-180 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. (3) Set a fuel pressure gauge on the special tool. 270 kPa (38 psi) at curb idle <Turbo> Approx.Combonents FUEL PRESSURE TEST (1) Reduce the internal pressure of the fuel pipes and hoses. (8) Measure the fuel pressure during idling. (7) Start the engine and let it idle. (4) Attach the special tool set in step (3) to the fuel rail between high pressure hoses. check to be sure that there is no fuel leakage from the fuel pressure gauge and the special tool connection part. (6) Disconnect the jumper wire (from the terminal for activation of the fuel pump) to stop the fuel pump. 235 kPa (34 psi) at curb idle 1 TSB Revision .

(ll)Use a finger to gently press the fuel return hose while repeatedly racing the engine. (12)lf the fuel pressure measured in steps (8) to (11) deviates from the standard value range.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .ComPonents 13A-181 (9) Disconnect the vacuum hose from the fuel pressure regulator. / id TSB Revision . Standard value: <Non Turbo>330-350 kPa (47-50 psi) at-curb idle <Turbo> 295-315 kPa (43-45 psi) at curb idle (1O)Check to be sure that the fuel pressure during idling does not decrease even after the engine is raced a few times. Condition l l Fuel pressure is too low. No change of the fuel pres when the vacuum hose is connected and when not connected. check for the probable cause by referring to the table below. Fuel pressure drops during raco return side caused by spring deteri- L Fuel pressure is too high. and check to be sure that there is fuel pressure in the return hose also. and then make the appropriate repair. NOTE There will be no fuel pressure in the return hose if there is insufficient fuel flow. and then measure the fuel pressure while using a finger to plug the end of the hose.

determine the cause of the problem and make the appropriate repair.0 Nm (3.13A-182 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Caution Because there will ‘be some residual pressure in the fuel pipe line. 1) Apply battery voltage to the terminal for activation of the fuel pump so as to activate the fuel pump. Leakage at the fuel pressure regulator valve seat. If there is a decrease of the indicated value. (16)Replace the O-ring at the end of the fuel high-pressure hose with a new one. Condition After the engine is stopped.) (18)Check to be sure that there is no fuel leakage. use a shop towel to cover so that fuel doesn’t splatter. 1 TSB Revision . Replace the fuel pressure regulator. The condition is normal if there is no decrease of the indicated value within two minutes. Tightening torque: 5. check for leakage of the fuel line. Probable cause Injector leakage.6 ft. (15)Disconnect the fuel pressure gauge and the special tools from the delivery pipe. (17)After connecting the fuel high-pressure hose to the fuel rail. referring to the table below. Replace the fuel pump. There is a sudden sharp drop of the fuel pressure immediately after the engine is stopped.ComDonents (13)Stop the engine and check for a change of the value indicated by the fuel pressure gauge. the fuel pressure drops gradually. monitor the speed of the decrease. (14)Reduce the internal pressure of the fuel pipes and hoses. Remedy Replace the injector. and. The check valve (within the fuel pump) is not closed. tighten the installation bolt at the specified torque. 2) With fuel pressure applied.lbs.

26 terminal (ground terminal). Withdraw the ECM for easier access to the connector terminals. B+ B+ o-3 v B+ o-3 v 4. sensors or ECM.Comuonents 13A-183 ENGINE CONTROL MODULE (ECM) TERMINAL VOLTAGES INSPECTION (1) Connect a very thin wire probe (such as a paper clip) to the probe of the voltmeter. (4) After repair or replacement. recheck with the voltmeter to confirm that the problem has cleared completely. Caution Short-circuiting the positive (+) probe between a connector terminal and ground could cause damage to the vehicle wiring.5-5. while referring to the check chart. or all of them. check the corresponding sensor. (2) Insert the very thin probe from the wire side into contact with each of the terminals of the ECM connector and check the voltage.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 4. NOTE 1. 1 60 12 25 62 108 Check point Back-up power supply Power supply Check conditions (Engine conditions) Ignition switch: OFF Ignition switch: ON Standard value / Remarks 1 B+ B+ Ignition switch IG MFI relay (power supply) MFI relay (fuel pump) Sensor impressed voltage Ignition switch: ON Ignition switch: OFF Ignition switch: ON Ignition switch ON Engine: Idle . TERMINAL VOLTAGE CHECK CHART Engine Control Module Connector Terminal Configuration Z?FUCE3 1 Terminal No. actuator and related electrical wiring. The inspection need not be performed in the order of the chart. Measure the voltage between each terminal and the No. 2. then repair or replace.5 v II 8 61 Ignition switch: ON i /’ 1 TSB Revision I . 3. Use care to prevent it! (3) If the voltmeter shows any deviation from the standard value. Measure a voltage with the ECM connector connected.

13A-184 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Comtaonents Camshaft position sen- 1TSB Revision .

2000 rpm (Digital voltmeter to be used for checking) 1 14 2 15 3 16 No.4 injector No..1 injector No.Components Terminal No.5 injector No.8 V (Changes repeated) Terminal 55 for rear bank of turbocharged engine - 56 55 Heated oxygen sensor Engine: Warm. 66 Check point Vehicle speed sensor l l 13A-185 Standard value Remarks OH5V (Changes repeated) B+ O-3 V - Check conditions (Engine conditions) Ignition switch: ON Move the vehicle slowly forward Steering wheel placed in neutral (straight ahead) position Steering wheel turned half a turn 107 Power steering pres.Engine: sure switch Idle.O-3 V OFF l l Air conditioning switch set B+ to ON Indoor set temperature brought closer to atmospheric temperature B+ or 6 V or more for a moment + O-3 V as A/C clutch cycles B+ o-3 v 1994and later Federal model 22 Air conditioning relay l l Engine: Idle Air conditioning switch: OFF + ON (Air compressor in driven state) 6 Fan motor relay (Lo) Radiator fan not operating (Coolant temperature: below 90°C [194”F]) Radiator fan operating at low speeds (Coolant temperature: 9%105°C [203-221 “F]) 53 Fan motor relay (Hi) Radiator fan not operating (Coolant temperature: below 90°C [194”FJ Radiator fan operating at high speeds (Coolant temperature: above 105°C [221 “F] B+ o-3 v 1994 and later Federal model 24 Electric load switch Engine: Runn i n g at idle Lighting switch set to OFF Lighting switch set to ON o-3 v B+ 0 t) 0.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . and accelerated abruptly by depressing accelerator pedal Falls temporarily a little from 11-14v TSB Revision .6 injector Engine: Running at idle after warmup. warm Air conditioning switch 1 Engine: Idle 115 Air conditioning switch set to O-3 V OFF Air conditioning switch set to ON (Air conditioning compressor in driven state) B+ 20 Airconditioning switch 2 Engine: Running at idle Air conditioning switch set to .2 injector No.3 injector No.

4 17 5 18 10 23 11 9 MULTIPORT OrvVehicle Inspection of MFI FUEL INJECTION . 3.500 rpm B+ 103 Muffler mode change.Ignition over switch switch: ON Changeover switch set to ON CrOW Changeover switch set to OFF (SPORT) Ignition timing adjustment terminal connected to ground Ignition timing adjustment terminal disconnected from ground O-3 V B+ O-l V 4.000 rpm Muffler mode changeover switch: ON Engine: Idle 0.Ignition switch: ment terminal ON 106 Check engine/malfunction indicator lamp Ignition switch: OFF -+ ON - TSB Revision I .000 rpm Fuel pressure solenoid Ignition switch: ON Engine: Warm.0-5.000 rpm 0.000 rpm B+ o-3 v B+ 0-3V+B+ B+ O-3 V 4-13 v Turbo Turbo Turbo Engine speed: 3.Components Check point Stepper motor coil <Al> Stepper motor coil <AZ?> Stepper motor coil <Bl> Stepper motor coil <B2> Ignition power transistor unit A Ignition power transistor unit B Ignition power transistor unit C Evaporative emission Ignition switch: ON purge solenoid Engine: Warm.Turbo rarily from abruptly while the engine is idling o-3 v Engine: 3.5 V o-3v+ 9-13 v (Several seconds later) Turbo 104 Ignition timing adjust.3-3 v Check conditions (Engine conditions) Engine: Warm Check immediately after hot restart Standard value Remarks B+ttO-3V (Changed repeated) - 7 105 Turbocharger gate solenoid waste Ignition switch: ON Engine: Idle (when the premium gasoline is used) Ignition switch: ON 11 Turbo meter Engine: Depress the accelerator pedal Falls temporarily from B+ abruptly while the engine is idling 21 Fuel pump relay 2 Engine: Depress the accelerator pedal Rises tempo.3-3 v o-3 v Turbo 101 102 Engine ignition signal Valve opened or closed indication signal Engine: 4. 3.13A-186 Terminal No.

5-5.5 v O-l V o-1 v l-5.O-l V perature at 50°C (122°F) or lower torque”executionsignal Engine: Idle.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .000 rpm 4 V or more (for a moment) Engine: Slowly decelerated from 5.6mph) 4.5 v + 1.000 rpm 4. warm l-4v .5-5.5 V AIT AnAn- 116 Total control “Reduce Engine: Idle torque” request signal 1 Engine: Running at idle after warmup and changing speeds Total control “Reduce Engine: Idle torque” request signal 2 Engine: Running at idle after warmup and changing speeds 59 7 Total control “Reduce Engine: Running at idle with coolant tern.000 rpm 103 Induction contrc position sensor I Engine: Slowly accelerated from/ idling O-l V or speed to 5. 6 Check poi EGR solenoid 13A-187 53 EGR temperatu sor 111 Induction control valve position sensor No. i 1 TSB Revision . 1 nition switch: ON Engine: Slowly accelerated from idling speed to 5.000 rpm to idling speed Engine: Idle l Non Turbo B+ Turbo l When vehicle is put in motion for the B+ 3 O-3 V first time after the ignition switch was (for a moment) placed in ON position Vehicle speed: 0 + lOkm/h (0 + 0.Components Terminal No.5-4 v (for a moment) 110 109 114 L Induction control valve (Opened) Induction control valve (Closed) Anti-lock braking signal Engine: Slowly accelerated from idling O-l V + speed to 5.

ComDonents ON-VEHICLE INSPECTION OF MFI COMPONENTS <From 1994 Models except Non Turbo up to 1995 Models for Federal> COMPONENT LOCATION L terminal Federal .13A-188 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Non Turbo> Engine coolant temperature sensor Evaporative emission purge solenoid Fuel pressure solenoid <Turbo> Heated oxygen sensor Idle air control motor (stepper motor) B X V E L Variable induction control motor (DC motor) (with built-in induction control valve position sensor) <Non Turbo> Vehicle speed sensor Volume air flow sensor (with built-in intake air temperature sensor and barometric pressure sensor) J F A NOTE: The “Name” column is in alphabetical order 7FU1003 A7FUl842 TSB Revision .

MIULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components Volume airflow sensor (with built-in intake air temperature sensor and barometric pressure sensoc 13A-189 ‘ii I\ -bank heated oxygen -wxor (rear) = 5 cl sensor (fro1 . ‘1 /i‘ 1 TSB Revision . left P\ I Z7FU1004 .Turbo from 1996~ l%&d..ge~ I 1 <Mechanical Speedometer Type> Vehicle speed sensor (reed switch) Y68FWll P <Electrical Speedometer Type> // \.T u r and Federal .nia . 2 y( Heated oxygen sensor.

27FUO803 /\ ~$~~rtrad.dt ode& - R16FOSQO 1 TSB Revision .Components Variable air intake control s (DC motor) (with built-in air intak I Injector \ I-.13A-190 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components 13A-191 piagnostic output terminal and &agnostic test mode control terminal ZlBFO292 <California up to 1995 Imodels. _E_G_~veraturel Iii i Z7FUlOlOI 1 TSB Revision . _ Federal -Turbo up to 1995 models> I \v.

Components <From 1996 models> <Turbo> Manifolddifferential pressure sensor Camshaft position sensor 1 <Non T u r b o > Manifolddifferential pressure sensor TSB Revision .13A-192 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

l3A-65. TSB Revision .IMULTIPORT On-Vehicle Inspection of MFI IFUEL INJECTION .l3A-64.ComDonents 13A-193 COMPONENTS INSPECTION PROCEDURE ‘L USING SCAN TOOL Refer to P. INSPECTlqN Refer to P. POWER SUPPLY (MFI RELAY) AND IGNITION SWITCH .\8 /\ A Harness side connector A r-4 7FUO927 ‘6 82 I 7FU1616 LL 21 FUO807 Engine control module connector z9FUo393 OPERATION Refer to P.l3A-65.IG <Up to 1995 models> Ignition switch [IG] A Equipment side connector En$ine control module 1 16FO292 I MFI relay ~4 /\ .

or a ’ short-circuit to earth between the engine control module and the MFI relay. l Ignition switch: OFF l MFI relay connector: Disconnected Battery voltage Repair the harness. (Battery A4.82) or check the ignition switch Harness A side connector 8 1 \ 0 I : 21 FUO808 Measure the power supply voltage of the MFI relay. (A2-12. l MFI relay connector: Disconnetted l Engine control module connector: Disconnected Z6AF0050 Repair the + harness.Components Engine control module harness side connector Measure the ignition switch (IG) terminal input voltage. l Engine control module connectar: Disconnected l MFI relay connector: Disconnected \ \j Repair the + harness. 25) 1 TSB Revision . between the engine control module and the MFI relay. or a short-circuit to ground.13A-194 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (A6-38) ZlFUO809 Check for an open-circuit. l Engine control module connectar: Disconnected Ignition switch OFF: O-l V Ignition switch ON: Battery voltage d Repair the harness: + (Ignition switch . A8) Engine control module harness side connector Check for an open-circuit.

i3A-70. l MFI relay connector: Connected l Engine control module connector: Connected Engine cranking: 8 V or higher Engine racing: Battery voltage ) 13A-195 A Hamessside r-:=1 connector I MFI RELAY INSPECTION 26AFOO51 I engine control module .MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Refer to P.Components Measure power voltage to the actuator. i 1 TSB Revision .

TSB Revision .Components POWER SUPPLY (MFI RELAY) AND IGNITION SWITCH-IG <From 1996 models> fl=\ .13A-196 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . INSPECTION Refer to P.l3A-65. Battery lcmitionjvitch WI Y ~ & Engi mod A Equipment side connector I MFI relay ED 12 34 r 1 32 7FUl833 Engine control module connector 1 Engine control module 9FUO393 7FUl819 OPERATION Refer to P.l3A-65.

(Ignition switch . ’ ’ ’ 0 Ignition switch: OFF l MFI relay connector: Disconnected Battery voltage harness. l Engine control module connectar: Disconnected l MFI relay connector: Disconnected ‘L-W 1‘7FUl822 z-l R 1 A Harness IEngine control module harries! side connector Repair the harness. l MFI relay connector: Connetted l Engine control module connectar: Connected Engine cranking: 8V or higher Engine racing: Battery voltage Replace the + MFI relay or defective engine control module / TSB Revision .1 V Ignition switch ON: Battery voltage 13~9197 harness. MFI relay connector: Disconnetted l Engine control module connector: Disconnected l OK 0 5 cl Repair the harness. (A2-38) Engine control Check for an open-circuit.Components HARNESS INSPECTION Measure the ignition switch (IG) terminal input voltage. l Engine control module connector: Disconnected Ignition switch OFF: 0. or a module harness short-circuit to ground between side connector the engine control module and the MFI relay. (Al -12.25) side connector 17FU1824 Measure power voltage to the actuator. between the engine control module and the MFI relay.82) or check the ignition switch A Harness side connector 121 r 1 Measure the Dower subolv volt1 age of the MF’I relay. (Battery A3. or a short-circuit to ground. A4) Check for an open-circuit.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

3 while connecting and disconnecting the jumper lead at the battery (-) terminal.Q) I I (5) yeth. replace the MFI relay or fuel pump 1 TSB Revision . ii I Inspection terminals / Continuity I I Continuity (approx.re is a defect. (2) Check for continuity between the relay terminals.13A-198 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Jumper lead 6FU2461 I I Connected Disconnected Continuity across terminals l-3 Continuity (0 Sz) I I No continuity (.Components MULTIPORT FUEL INJECTION (MFI) RELAY AND FUEL PUMP RELAY INSPECTION (1) Remove the relay. (4) Check the continuity between relay terminals 1 . 70 Q) I (3) Use the jumper leads to connect relay terminal 4 to the battery (+) terminal and terminal 2 to the battery (-) terminal.

TSB Revision .Components 13A-199 ENGINE CONTROL MODULE POWER GROUND Engine control module -4 ZOlAOlQl Engine control module connector zpFuo393 7FU1617 OPERATION Refer to 13A-71.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . TROUBLESHOOTING HINTS Refer to 13A-71. LJ HARNESS INSPECTION Refer to 13A-71.

. MFI RELAY INSPECTION Refer to 13A-70. INSPECTION Refer to 13A-73.7 -.. check terminal I B Equipment side connector )I Engine control 8 module I n B Harness side connector .Components FUEL PUMP <Non Turbo . TSB Revision ..Up to 1995 models> I Fuel pump connector 03FOOM J Ignition switch [IG] A Harness side connector A Equipment side connector 7-r MFI relay C Fuel pump .-_ 5EL1603j Z7FU1360 Engine control module connector 7FU1618 OPERATION Refer to 13A-76.13A-200 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .. HARNESS INSPECTION Refer to 13A-77.

NMULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components 13A-201 ' FUEL PUMP <Non Turbo . 1 TSB Revision .tol \ 63 // Fuel pump connector 03FOOO4 Ignition switch [IG] A Equipment side connector 7 Fuel pump C Fuel pump check terminal B Equipment B Harness side connector Engine control module r G” f Engine control module connector 7FUi934 9FUO393 7FUl921 OPERATION Refer to 13A-76. \U* .From 1996 models> ‘i-‘\‘F (q w j Y - Fuel pump check terminal \a b L cm’ . INSPECTION Refer to 13A-73.

Check for continuity between the fuel pump and the checking terminal. MFI relay connector: Disconl netted l Fuel pump connector: Disconnected Repair the harness. Apply battery voltage to the l checking terminal and operate the pump.Components 1 i Y-. d \ - Z7FUO953 Check the ground circuit of the fuel pump. l Fuel pump connector: Disconnected z7Fuo9a I . (Bl -Cl) I) 4 L Harness side connector ! 1 = Repair the harness. (Al -Cl) 1 TSB Revision .rlmF-3 I I Check the fuel pump.13A-202 HARNESS INSPECTION I MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l Connector: Disconnected bround) c P 7 B Harness sic connector Z 7FUO951 r I+ Check for continuity between the fuel pump checking terminal and the MFI relay terminals.1 / ./XT\ L f--ljjy =/---It 0 Ii!! = :-L.

l3A-198.Comwnents Measure the power supply voltaae of the MFI relav.828 1 the MFI relay (for fuel pump) and ~ l Fuel pump connector: Disconnected Repair the harness. MULTIPORT FUEL INJECTION (MFI) RELAY AND FUEL PUMP RELAY INSPECTION Refer to P.1 V Ignition switch ON: Battery voltage WA-203 ’ A Harness side III 7FUl822 A Harness side connector Engine control module harness short-circuit to ground bekeen side connector switch . A4) or check the. l MFI relay connector: Connected l Engine control unit connector: Connected Engine cranking: 8V or more Engine racing: Battery voltage 7FUl825 MFI relay or engine control module is defective. / TSB Revision . 0” Control relay connector: Disconnected Ignition switch OFF: 0. W-8) i’FUl82’i A Harness side connector 7FU. ignition switch.A3. P 21 43 B Harness side A Harness side connector the MFI relay and the engine con- l Engine control module connectar: Disconnected Repair the harness.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (Al -Bl) Measure the power supply voltage of the fuel pump.

E Equipment sidl C Fuel pump check J m terminal Engine control module connector 27FU1363 \ mFlJo393 7FU1619 TSB Revision .Up to 1995 models> Ignition switch [IG] Equipment side connector B Harness side connector 1 Equipment side -~ A Harness side connector -. -.13A-204 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components FUEL PUMP <Turbo .

Components 13A-205 i OPERATION Refer to 13A-81. (B2 Ground) Check for continuity between the fuel pump and the checking terminal.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 0 l Z7FUO960 / i / TSB Revision . HARNESS INSPECTION _---k l-7 ia! -gp B Harness side connector 4 Check the ground circuit of the ~ 7 t C Repair the harness. INSPECTION Refer to 13A-81. (Bl -Cl) 2 7FUO955 Harness side connector Check for continuity between the checking terminal and the fuel l Fuel pump relay II connector: Resistor (for fuel pump) connectar: Disconnected Fuel pump connector: Disconnected Repair the harness. l Fuel pump connector: Disconnected P : I B Harness side connector Repair the harness.

Components Engine control Check for an open-circuit. l Fuel pump relay II connector: Disconnected l Resistor (for fuel pump) connector: Disconnected. l MFI relay connector: Disconnected l Fuel pump relay II connector: Disconnected P t r Z7FU1364 TSB Revision . between 51 D Harness side connector the fuel pump r&ay II and the engine control module. or a short-circuit to around. Repair the harness. (Dl-31) E Harness side connector Check for continuity between the fuel pump relay II and the resistor (for fuel pump). l Fuel pump relay II connector: Disconnected l Engine control module connector: Disconnected Repair the harness. or a short-circuit to ground.13A-206 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . between the MFI relay and the engine control module. (Ignition switch [IG] A7) ZPFUCrO23 Engine control module harness side connector Harness side connector Check for an open-circuit. 0 MFI relay connector: Disconnetted l Engine control module connector: Disconnected - 91 A Harness side connector D Harness side connector 4 -- Check for continuity between the MFI relay and the fuel pump relay II. (D4-El) A Harness side connector Measure the power supply voltage of the MFI relay. l MFI relay connector: Disconnected Ignition switch OFF: 0 V Ignition switch ON: Battery voltage I Repair the harness.

i 1 TSB Revision .Comraonents 13A-207 short-circuit to Fuel pump relay II connector: Disconnected Fuel pump connector: Dis- D Harness side l MFI RELAY INSPECTION Refer to P.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .l3A-70.

-Equipment side connector i’FUl820 Engine control module connector 9FUO393 TSB Revision .13A-208 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .From 1996 models> Fuel pump connector 03FOOO4 Ignition switch [IG] connector A Fuel pump relay II D Equipment side connector / \/ \/ 1” 4”2” Fuel pump circuit resistor B Equipment side connector B Harness side connector r 2 Fuel pump 1 8 Fuel pump El C terminal check E.ComDonents FUEL PUMP <Turbo .

HARNESS INSPECTION l Fuel pump connector: Dis- connector Harness side r Check for continuity between the checking terminal and the fuel pump relay II.l3A-81.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Comuonents OPERATION Refer to P. l Fuel pump relay II connector: Disconnected l Resistor (for fuel pump) connector: Disconnected l Fuel pump connector: Disconnected co Repair the harness. _ 27FUO960 1 TSB Revision .l3A-81. L 13A-209 INSPECTION Refer to P. and between the resistor (for fuel pump).

between side connector the MFI relay and the engine con- Engine control I Measure the power supply voltage of the MFI relay. (A2-8) D f-farncs~ side MFI relay and the fuel pump relay connector II. / Check for continuitv between the --&31211I l MFI relay connector: Discon514 1 netted 0 Fuel pump relay II connector: h’ Y Disconnected I -----I _---l A Harness sic 7FUl854 bid l-id LZJ AJRepair the (Al -05) I TSB Revision . (D4-El) I I ~ I-7 77Flm A Harness side connector IDI 7FUl822 1 A Harness side connector module harness short-circuit to ground. l Fuel pump relay II connector: Disconnected l Engine control module connector: Disconnected ii’ Repair the harness. Repair the harness. or a short-circuit to ground.Components Engine control module harness side connector 5 -I D Harness side connector *-L - r Check for an open-circuit. (Dl-31) I 1 Z7FUO961 Harness side r Check for continuity between the fuel pump relay II and the resistor nectar: Disconnected. l MFI relay connector: Disconnetted l Engine control module connector: Disconnected OK 0 L MC _ _ - \ I-‘7FUl827 I I I 9 0 Repair the harness. l MFI relay connector: Disconnetted Ignition switch OFF: 0 V Ignition switch ON: Battery voltage I I ‘i/’ ’ Check for an open-circuit. between the fuel pump relay II and the engine control module.13A-210 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . or a trol module.

i TSB Revision .Components Check for an open-circuit. l 13A-211 n A 0 Fuel pump relay II connector: Disconnected Fuel pump connector: Disconnected @ j+ LTOA Repair the harness. (Bl -D2) Z7FUO96 MULTIPORT FUEL INJECTION (MFI) RELAY AND FUEL PUMP RELAY INSPECTION Refer to P.l3A-198.l3A-84. .MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . between the fuel pump relay II and the fuel pump. FUEL PUMP CIRCUIT RESISTOR L INSPECTION Refer to P.l3A-84. FUEL PUMP RELAY II INSPECTION Refer to P. or a short-circuit to ground.

2. / Data display 1 Sensor air volume (frequency) Check condition 1 Engine state I Standard value I tral (P range for t l Steering wheel: .13A-212 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .l3A-85. INSPECTION Using Scan Tool <Volume Air Flow Sensors 1 Function 1 Item No.133 Hz <Turbo> 1 Frequency increases with racing 1 NOTE When the vehicle is new [within initial operation of about 500 km (300 miles)]. \ d. the volume air flow sensor output frequency may be about 10% higher. TROUBLESHOOTING HINTS Refer to P.l3A-85.500 rpm 1 --i models> 71-111 Hz <Non Turbo> 93.ComDonents VOLUME AIR FLOW SENSOR :I relay Volume air flow sensor (with built in intake air mperature sensor and Volume air flow sensor A Equipment side connector Output frequency (Hz) il Airflow rate (liters/second) Data reading 12 A Harness side connector Engine control module ‘@&7~6:<5~4~3~2~1] SEL1803 J 7FUO654 Engine control module connector 2162451 \ d ZPFUO393 OPERATION Refer to P. 1 TSB Revision .

.500 rpm Transaxle: Neutral (P range for A/T) Function Data reading <From 1996 models> Check conditions l l Engine state Engine: warm range: Operation idling to maximum output 1 1 700 rpm (Idle) 1 2. and check the waveform.9-7. electric cooling fan. Data display 12 Sensor air volume (Airflow volume) Item No.5 g/s <Non Turbo> 13.n . electric cooling fan and accessory operation: OFF l Transaxle: Neutral (P range for vehicle with A/T) wheel: l Steering Neutral Engine state 700 rpm (Idle) Standard value 1 15-35% ing Using Oscilloscope (1) Run the engine at idle speed. Data display Reset signal condition Check conditions l Engine state l l Engine coolant tem.Idling perature: 80 to 95°C (176 to 203°F) Lights.8 g/s <Turbo> Standard value ~ -I--Item No. 37 Data display Volumetric efficiency B Check condition Engine coolant temperature: 80 to 95°C (176 to 203°F) @ Lights.ComDonents Function Data reading <From 1996 models> 13A-213 Standard value 3.5 g/s <Non Turbo> 3.:lnct.9-19.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 87 Data display Calculation load o . (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram.500 rpm I 15-35% <Non Turbo> lo-30% <Turbo> <Volume Air Flow Sensor Reset Signal> ~ .6-l 6. I Regular waveform I TSB Revision .6-7.tm N Check conditions l Engine conditions 1 Standard value 1 ON I Engine warm up <Volumetric Efficiency> Function Data list Item No.7 g/s CTU rho> 10. accessories: OFF 2.

13A-214 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 0 Volume air flow sensor connector: Disconnected l Engine control module connector: Disconnected 1 TSB Revision .Components l l Connector: Disconnected Ignition switch: ON l Connector: Disconnected volume air flow sensor and the engine control unit.

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components 13A-215 INTAKE AIR TEMPERATURE SENSOR Volume air flow sensor $1.L 5 v I 7FU1621 OPERATION Refer to P..l3A-88.. TROUBLESHOOTING HINTS Refer to P..l3A-88.. TSB Revision .. INSPECTION Refer to P.l3A-89.~ Temperature 2162460 A Equipment side connector Volume air flow sensor connector A Harness side connector \ Temperature 21621CXl8 intake air temperature sensor intake air temperature sensor Z7FUO659 . .g~ed barometric pressure sensor) Output voltage Resistance I t ..

age.13A-216 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .l3A-89.9 v l SENSOR INSPECTION Refer to P. TSB Revision .5-4. the power supply voltMeasure 0 Connector: Disconnected Ignition switch: ON 4. (A592) 2 7FUO657 A Harness side 1 l.Components l Connector: Disconnected Repair the harness.

-~ 5 Barometi pressure - - 5ELl803. Engine conf’ol module 7FUO6631 81 85 Output voltage (V) & i 1 92 I 7FUO664 i Barometricpressure[mmHg(in.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .Components 13A-217 BAROMETRIC PRESSURE SENSOR A EQuiDment side coitriector Barometric pressure sensor Volume air flow sensor connector A Harness side connector .l3A-91.l3A-92. TSB Revision . INSPECTION Refer to P.l3A-92. TROUBLESHOOTING HINTS Refer to P.Hg)] $&KISS 7FU1623 OPERATION Refer to P.--.

0 Volume air flow sensor connector: Disconnected l Engine control module connector: Disconnected Repair the harness. (A2-85) Z7FlKM64 TSB Revision .2 v l--Y - Repair the harness. (AS-92) Z7FUO657 A Harness side connector Measure the power supply voltage of the barometric pressure sensor.Components r A Harness side Check for continuity of the ground l Connector: Disconnected Repair the harness. (Al -81) Z7FUO665 Engine control module harnes side connector Check for an open-circuit. l Connector: Disconnected l Ignition switch: ON 4. or a short-circuit to ground between the engine control module and the barometric pressure sensor.13A-218 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .8-5.

l3A-94. id TSB Revision . INSPECTION Refer to P. TROUBLESHOOTING HINTS Refer to P.l3A-93.Components 13A-219 ENGINE COOLANT TEMPERATURE SENSOR Resistance t I\___: %$~\) sensor \I L/ Coolant temperature lOZ4l8 I Coolant temperature 1621008 Engine coolant temperature sensor A Equipment connector Engine control module connector Engine control module 9FUO393 7FUl829 OPERATION Refer to P.l3A-93.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

Components A Harness side connector Check for continuity of the ground circuit 0 Engine coolant temperature sensor connector: Disconnetted Repair the harness. (Al -83) ZPFUO114 SENSOR INSPECTION Refer to P.13A-220 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Engine coolant temperature sensor connector: Disconnected a Engine control module connector: Connected l Ignition switch: ON 4. (A2-92) Z9FUO112 . TSB Revision . r A Harness side connector i a I q Measure the impressed voltage. INSTALLATION Refer to P.5-4.l3A-95.9 v l Repair the harness.l3A-95.

l3A-99. L-- A Equipment side connector Throttle position sensor I A Harness side connector 2 1 rpJ3jsJYJl I / SE‘l.l3A-98.00~ Engine control module . TROUBLESHOOTING HINTS Refer to P. TSB Revision .Components 13A-221 ~ THROTTLE POSITION SENSOR sensor - .84 I I Terminal voltage (V) % 5V 7FUO672 Engine control module connector Maximum Throttle shaft turning angle 2162461 29Fuo393 7FU1625 Minimum OPERATION Refer to P.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . INSPECTION Refer to P.l3A-98.

13A-222 HARNESS INSPECTION MULTIPORT _ On-Vehicle Inspection of MFI FUEL INJECTION Components A Harness side connector l Connector: Disconnected l Throttle position sensor connector: Disconnected Engine control module connector: Disconnected nals like ECM: Discon- SENSOR INSPECTION Refer to P. TSB Revision .l3A-100.

INSPECTION Refer to P. L TSB Revision .t 4 .Components 13A-223 CLOSED THROTTLE POSITION SWITCH L -__._. si‘\\E:+-< Throttle position sensor (Closed throttle position switch mounted) r Engine control module PLL r r 5V a7 92 A Harness side connector A Equipment side connector Closed throttle position switch I IL 3 \ .On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .l3A-101.l3A-101.\ Terminal voltage (V) -I I m-e-:Ii ‘: OFF 7FUO674 I 1 * 7FU1626 Throttle shaft turning anglezo. .l3A-101.t002 OPERATION Refer to P. TROUBLESHOOTING HINTS Refer to P.

13A-224 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .mk gJ”0 II ciizrgg Check for continuity of the ground Repair the harness. l Connector: Disconnected 0 Ignition switch: ON 4 V or more Repair thl harness.l3A-102. (A4-92) L I ~ 26FU1242 SENSOR INSPECTION Refer to P.Components r I HARNESS INSPECTION A Harness side connector Measure the power supply voltage of the closed throttle position switch. ~ \ d’ 1 TSB Revision . (A3-87) Z7FUO675 ‘J I ~ 2 A Z-.

TSB Revision .MULTIPORT On-Vehicle lixspection of MFI FUEL INJECTION . INSPECTION Refer to P.l3A-104. r IV1 ( Output characteristic No.Components 13A-225 / L CAMSHAFT POSITION SENSOR Camshaft position sensor \ raft position sensor t A Equipment side connector MFI relay I 3 7FU130t Engine control module .l3A-103. TROUBLESHOOTING HINTS Refer to P.4 L No.1 5-v Z7FUO677 6A FOO54 Engine control module connector 7FU1627 / L OPERATION Refer to P.l3A-103.

(A3 .ComDonents Measure the power supply voltage.13A-226 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l Connector: Disconnected 0 Ignition switch: ON Battery voltage Repair the harness.MFI relay) 27FU1330 A Harness side l Connector: Disconnected l Connector: Disconnected Ignition switch: ON 1 TSB Revision .

(2) When the tachometer is set to the 2-cylinder range.l3A-107.. TSB Revision . Therefore. INSPECTION Using Scan Tool Data display Cranking speed Check condition l l Check content Normal state Engine cranking Tachometer connected (check on and off of primary current of ignition coil by tachometer) Compare cranking Indicated speed to speed and scan tool agree reading / NOTE (1) The tachometer indicates a third of the actual engine speed. 3 times the tachometer indication is the actual engine speed..l3A-107.I put characteristic 27 FU9682 7FU1626 OPERATION Refer to P. it indicates actual engine speed. TROUBLESHOOTING HINTS Refer to P.MULTIPORT FUEL INJECTION _ On-Vehicle Inspection of MFI Components 13A-227 :RANKSHAFT POSITION SENSOR CX&haft A Equipment side positioq 7FU130E A Harness side connector .

lOO-1.425 rpm*’ 1. and check the waveform.500 rpm*2 1.h p m (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram.475 rpm*’ 1.050-l . Normal waveform Z7FUO500 HARNESS INSPECTION l Connector: Disconnected Ignition switch: ON l Connector. Disconnected TSB Revision I .300 rpm*l 1. 5v .250 rpm*2 600-800 rpm Check condition l l Data reading 22 Engine: Running at idle At -20°C (4°F) Closed throttle position switch: ON At 0°C (32°F) At 2O”C(68”F) At 4O”C(104”F) At 8O”C(176”F) NOTE *l: Non Turbo. ov------..500 rpm*2 l.225.300-l . MULTIPORT FUEL INJECTION Data display Idle speed _ On-Vehicle Inspection of MFI Components Coolant temperature Standard value 1.300-l .500 rpm*2 950-1.300-l .1.150 rpm*’ 1.275. Turbo Up to 1995 models *2: Turbo From 1996 models [[I Using Oscilloscope (1) Run the engine at idle speed.13A-228 Function Item No.1..

l Engine control module connector: Disconnected Repair the harness. (71 .Ignition switch) Z6FU1256 I 1 Engine control module harness c _ -I side connector /!a Check for continuity of the ground circuit.l3A-112. INSPECTION Refer to P. Disconnected 0 Ignition switch: START 8 V or more Repair the harness.MULTIPORT FUEL INJECTION _ On-Vehicle Inspection of MFI Components 13A-229 0 Connector: Disconnected l Ignition switch: ON IGNITION SWITCH-ST <M/T> Ignition switch (ST) I Engine control module connector 7FUl629 i LJ OPERATION Refer to P. HARNESS INSPECTION \ Engine control Measure the input voltage to the module harness engine control module side connector l Engine control module connectar. (91 Ground) / id Z6FU1259 1 TSB Revision .l3A-112.

HARNESS INSPECTlON A Harness side connector Measure the power supply voltage.l3A-113.13A-230 MULTIPORT FUEL INJECTION _ On-Vehicle Inspection of MFI ComDonents I IGNITION SWITCH-ST AND PARK/NEUTRAL POSITION SWITCH (PNP SWITCH) <AK> Ignition switch (ST) A Equipment side connector l - I Starter S MFI terminal relay A 91 Engine control module 7FU1320 Engine control module connector ji zpFuo393 7FU1630 OPERATION Refer to P.i3A-113. l Engine control module connector: Disconnected l PNP switch connector: Disconnected 0 Ignition switch: START Battery voltage Z9FUO268 Check the power supply circuit.l3A-114. d 1 TSB Revision . INSPECTION Refer to P. TROUBLESHOOTING HINTS Refer to P.

(A8-91) (A7-71) ZOFUO269 131 tA Harness side connector Measure the impressed voltage to the PNP switch. Repair the harness. I ZPFUO268 / VEHICLE SPEED SENSOR (Mechanical Speedometer Type) I i Vehicle speed sensor Engine control module A Equipment side connector I Terminal voltage (V) 68FOOll 5v Lf!il 1 r--L 86 A Vehicle speed sensor 1 og(inside speedometer) B Equipment side connector IJJ-UUL -t Frequency (Hz) 2162478 ZTFU1436 Engine control module connector b Vehicle speed [km/h (mph)] 2162451 Z%Uo393 7FU1631 i 1 TSB Revision .MULTIPORT FUEL INJECTION _ On-Vehicle. l Engine control module connector: Connected l PNP switch connector: Disconnected 0 Ignition switch: ON Bakery voltage OK 0 7 A STOP Replace the engine control module.lnspection ComDonents of MFI 13A-231 I ? A Harness sideI I harness side cOnnectOr Check for continuity between the PNP switch and enaine control module. 8 Engine control module connectar: Disconnected 8 PNP switch connector: Disconnected NOTE Insert the probes of the circuit tester into both ends of the harness.

l3A-117. HARNESS INSPECTION onnector: Disconnected SENSOR INSPECTION Refer to GROUP 54 .l3A-117.Meters and Gauges.13A-232 MULTIPORT FUEL INJECTION _ On-Vehicle Inspection of MFI Components OPERATION Refer to P. 1 TSB Revision . TROUBLESHOOTING HINTS Refer to P.

TROUBLESHOOTING HINTS Refer to P.l3A-119.l3A-117.1 Terminal voltage (V) Vehicle rspeed sensor Frequency (Hz) 2162478 Z?FU1434 Engine control module connector Vehicle speed [km/h (mph)] 2162451 7FUl632 OPERATION Refer to P.MULTIPORT FUEL INJECTION \/EHlCLE _ On-Vehicle Inspection of MFI Components 13A-233 SPEED SENSOR (Electrical Speedometer Type) Ignition switch WI ~A Equipment side connector Engine control module p-j -. TSB Revision .

9 v Repair the harness.Ignition switch) ZlFUO969 Check the vehicle speed sensor output circuit for continuity.5-4. l Engine control module connector: Disconnected l Ignition switch: ON l Move the vehicle Engine control module harness side connector ZOlA0508 Continuity A Harness side connector Measure the power supply voltage of the vehicle speed sensor. (Al . (A3-86) Z7FUl442 0 Connector: Disconnected SENSOR INSPECTION Refer to GROUP 54 .Meters and gauges. l Connector: Disconnected l Ignition switch: ON 4. l Connector: Disconnected 0 Ignition switch: ON Battery voltage 0 OK 2 cl Repair the harness. TSB Revision .13A-234 HARNESS INSPECTION MULTIPORT FUEL INJECTION _ On-Vehicle Inspection of MFI Components A Harness side connector Measure line voltage applied to vehicle speed sensor.

000 Pressure [kPa (psi)] (213-284) 20. (Al -37) Z7FUO505 / I SENSOR INSPECTION / Refer to GROUP 37A . A Harness side connector 0 Connector Disconnected l Ignition switch: ON Battery voltage Repair the harness. TSB Revision . 37 Power steering pressure switch.. 1 /\ A Harness side connector En t 700-2.l3A-122. HARNESS INSPECTION Measure the power supply voltage.Lo~ Z7FUO536 7FU1633 OPERATION Refer to P.500-2. INSPECTION Refer to P.l3A-121.000 (100-284) 1.MULTIPORT FUEL INJECTION _ On-Vehicle Inspection of MFI Components 13A-235 POWER STEERING PRESSURE SWITCH Engine control module L -p-.On-vehicle Service.

HARNESS INSPECTION 1 -I side connector Z7FUO695 Measure the power supply voltage of the conditioning circuit.l3A-123. l Air conditioning switch: ON l Engine control module connector: Disconnected l Ignition switch: ON l Dual air conditioning switch: ON Engine control Battery voltage moduleharness 7 I Check the air conditioning circuit.13A-236 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . NOTE *l: Non Turbo *? Turbo TSB Revision .T Battery T T -1 Air conditioning control unit Air conditioning compressor lock controller -/ \/ 16FOO30 Engine control module r L I Air conditioning compressor Engine control module connector NOTE *l: Non Turbo **: Turbo mFuo393 7FU1634 ‘d 27FUO966 OPERATION Refer to P.l3A-123. TROUBLESHOOTING HINTS Refer to P.l3A-123. INSPECTION Refer to P.Components AIR CONDITIONING SWITCH AND COMPRESSOR CLUTCH RELAY (JLWJ” !L$lioningJ -.

Components AIR CONDITIONING INSPECTION Refer to GROUP 55 .MULTIPORT On-Vehicle Inspection of MFI FUEL ‘INJECTION .On-vehicle Service.l3A-125. Knock sensor connector: Disl connected l Engine control module connector: Disconnected n - Repair the harness. HARNESS INSPECTION Engine control module harness side connector connector + I+ 78 Y r Check for an open-circuit or a short-circuit to ground. 13A-237 I KNOCK SENSOR Engine control module I A Equipment side connector r ‘7 78 Knock sensor = 7FU1075 A Harness side Engine control module connector 29Fuo393 7FU1635 OPERATION Refer to P. between the engine control module and knock sensor. (Al -78) 27FUo906 TSB Revision . TROUBLESHOOTING HINTS Refer to P.l3A-125.

l3A-127. 1 TSB Revision 1 .l3A-127. INSPECTION Refer to P.Comtsonents 2A Check for continuity of the ground STOP I ELECTRICAL LOAD SWITCH bound) Defog ger relay I NOTE *‘: up to 1995 models ‘2: From 1996 models t Engine control module Engine control module connector 27FUO688 7FU1636 OPERATION Refer to P.13A-238 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 58’2 Check circuit related to defogger relay LJ Measure the input voltage of engine control module.Components HARNESS INSPECTION 13A-239 L I I I 24”. l Engine control module connectar: Disconnected l Lighting switch: ON (Tail light relay ON) Battery voltage Check circuit related to tail light relay Engine control module harness side connector Z7FUO689 Measure the input voltage of engine control module. l Engine control module connectar: Disconnected l Brake pedal: Depressed (Stop light switch ON) Battery voltage Check circuit related to stoplight relay . l Engine control module connectar: Disconnected 0 Defogger switch: ON (Defogger relay ON) Battery voltage Engine control module harness side connector 27FUO689 24”.I I ) Engine control module harness side connector Z7FUO609 NOTE 1:: Up to 1995 models : From 1996 models TSB Revision . 58’2 Measure the input voltage of engine control module.

4.13A-240 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . ? 7 1 u-0) I Condenser fan motor 21 /‘ i 27FU1366 b Engine control module connector 7FU1637 TSB Revision .Components FAN MOTOR RELAY (RADIATOR. AIR CONDITIONING CONDENSER) Ignition switch-IG z Battery z ‘EAir conditioning compressor lock controller f ’ I 1(Lo) 1Ir ECM - Radiato r fan mote 3r relay 0w To air conditioning compressor - I\ 7c 4 Ari .

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .l3A-131.l3A-130.Components OPERATION Refer to P. MUFFLER MODE CHANGEOVER SWITCH <Turbo> Engine control module l l: Up to 1995 models *2: From 1996 models A Equipment side connector 7FU1053 7FlJ1638 OPERATION Refer to P.l3A-131. : I -a FAN MOTOR RELAY INSPECTION Refer to Radiator Check in GROUP 14 and Power Relay Check in GROUP 55. id 13A-241 . l ECM connector: Disconnetted l Ignition switch: ON Battery voltage Check the fan motor ECM harness / side connector Z6FU2008 relay circuit. INSPECTION Refer to P. INSPECTION Refer to P. HARNESS INSPECTION Measure input voltage applied to ECM. .TSB Revision I .l3A-130.

13A-242 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l Connector: Disconnected Repair the harness. 61**) 2 J A Harness side connector J 0 NOTE 1:: Up to 1995 models : From 1996 models -Ib!--.Components CI 1 A Harness side connector I 1 Measure the power supply voltage.c /%@ 6 f Z7FU1054 Checkforcontinuity of the ground circuit. (A3-34*‘. l Connector: Disconnected a ignition switch: ON Battery voltage 2 cl Repair the harness. (A2 Ground) Z7FU1055 INDUCTION CONTROL VALVE POSITION SENSOR <Non Turbo> Variable induction control motor (DC motor) induction control valve A Eauioment side 1 I Variable induction control motor r (DC motor) (with built-in induction fi control valve position sensor) 7FUO802 Variable induction control motor connector NOTE l : Up to 1995 models l 2: From 1996 models l Z7FUO968 7FU1639 TSB Revision .

55**) NOTE 1:: Up to 1995 models : From 1996 models 1 TSB Revision . HARNESS INSPECTION Measure the power supply voltage of the air intake control valve A Harness side connector Z6FU1241 A Harness side connector -7 l----L El z@ n 0 H c Check for continuity of the ground circuit. l Connector: Disconnected Repair the harness. (A3-92) 27FUO824 A Harness side fc l l Measure the terminal voltage.~ MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .l3A-133. Connector: Disconnected Ignition switch: ON harness.l3A-133. (A2-41*‘.Components 13A-243 ~ OPERATION Refer to P. Z7FUO825 54*9 (A4-33*‘. INSPCTION Refer to P.

Components MANIFOLD DIFFERENTIAL PRESSURE (MDP) SENSOR <Turbo> Manifold differential pressure sensor <Non Turbo> Manifold differential pressure sensor Manifold differential pressure sensor A Equipment side connector V output voltage Engine control module LL Intake manifold plenum pressure 16z45 l Engine control module connector 9FUO413 I I 9FUO393 7FUl831 OPERATION e Manifold differential pressure switch converts the intake manifold plenum pressure to the voltage and inputs to the engine control module. memorizes the diagnostic trouble code. Engine control module confirms the operation of EGR system from this signal and. l 5 V of power is supplied to the manifold differential pressure sensor from the engine control module. l The manifold differential pressure sensor output voltage is proportioned to the intake manifold plenum pressure and sent to the engine control module. TSB Revision . and the sensor circuit ground is located in the engine control module.13A-244 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . if there is any error in the EGR system.

0 Manifold differential pressure sensor connector: Disconnected l Engine control module connector: Disconnected OK 0 t = 9FUO415 Repair the harness. TSB Revision .5-38.74) I30.92) 9FUO414 Engine control module harness side connector 74 LJ A Harness side connector Check for open-circuit.0-42.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . (A2 .2 V 9FUO416 I Repair the engine control module.Components INSPECTION 13A-245 Using Scan Tool L Function Item No.9 kPa <Non Turbo> kPa 29.a0 J J Measure the impressed voltage to the manifold differential pressure sensor. l Manifold differential pressure sensor connector: Disconnetted a Engine control module connector: Connected l Ignition switch: ON Voltage: 4.4 <Tu rho> Data reading 95 intake manifold Engine: Warm-up plenum pressure HARNESS INSPECTION A Harness side connector Check for continuity of the ground circuit.8-5. or shortcircuit to ground between the engine control module and the manifold differential pressure sensor. (A3 . Data display Check condition Engine state Idling Standard value 25. l Manifold differential pressure sensor connector: Disconnected Repair the harness.

% !.l3A-135.Components EGR TEMPERATURE SENSOR <California Up to 1995 models. HARNESS INSPECTION A Harness side l l Connector: Disconnected Ignition switch: ON TSB Revision ... Federal . I * 7FU1640 Temperature Z~6Z1008 OPERATION Refer to P.l3A-136. INSPECTION Refer to P.13A-246 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .’ ‘2 i .Turbo Up to 1995 models> A Equipment side connector EGR temperature sensor A Harness side 7FUlOlO 5V i ‘.\ .-f' i 7FUlOli 9 27FU1239 t output voltage 1.

---II L I\- ABCD Equipment side connector Right bank heated oxygen sensor (rear) Harness side connector ilectromotive Theoretica.Components Check for continuity of the ground circuit. NF 14 A/F 15 16 ZECIOO: 7FUl431 Engine control module connector z9Fuo3.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . l 13A-247 ~ A Harness side connector Connector: Disconnected @+A Repair the harness. ii +&ii &---& Riaht bank . (Al -92) Z7FU1257 I+ SENSOR INSPECTION Refer to GROUP 17 .Non Turbo Up to 1995 models> 49.93 7FU1641 TSB Revision .Exhaust Gas Recirculation (EGR) System. HEATED OXYGEN SENSOR <California .

1. check the air/fuel mixture ratio. and a so check the condition of control by the engine control module) <Heated Oxygen Sensor (rear)> Function Item No.000 rpm Check condition Transaxle: 2nd gear <M/T> L range <A/T> Drive with wide open throttle Engine state 3. 11 39 Data display Sensor detection voltage Check condition Engine: Warm-up (Make the mixture lean by engine speed reduction.Components <Heated Oxygen Sensor (front)> Function Data reading Item No. TROUBLESHOOTING Refer to P. Data display Heater condition Check condition Engine: Warm-up Engine state 750 rpm (Idle) 5.000 mV 400 mV or lower ts 600.13A-248 OPERATION Refer to P.000 rpm Standard value ON OFF Data reading 48 TSB Revision .l3A-138.500 rpm Standard value 600-l .000 mV Data reading 59 69 <Heated Oxygen Sensor (front.l3A-137.000 mV (changes) 700 rpm (Idling) 2.1.000 rpm When engine is suddenly raced Engine: Warm-up (Using the heated oxygen sensor signal. rear)> Function Item No. Data display 1 Sensor voltage l l Standard value 200 mV or lower 600 . INSPECTION Using Scan Tool MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . and rich by racing) Engine state When sudden deceleration from 4.

Dl MFI relavj UFU1333 I Check for an open-circuit. 642.l3A-143. between side connector the engine control module and the I 74 a 77 Engine control module connector: Disconnected :i 27FUl440 Repair the harness. between the engine control module and the heated oxygen sensor 0 Heated oxygen sensor connectar: Disconnected l Engine control module connectar: Disconnected Engine control module harness side connector I . l Connector: Disconnected l Ignition switch ON Battery voltage Repair the harness.Components HARNESS INSPECTION 13A-249 L. D2-92) I- 27FU1441 L SENSOR INSPECTION Refer to P. C l . (Al. B2. B3-74) (C3. I lJ--TL 27FU1439 / L 3 -J I Harness sit connector Engine control module harness short-circuit to ground. TSB Revision . INSTALLATION Refer to P. D3-77) ABCD Harness side connector Il. C2.l3A-143.- harness. Bl. (A3.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . O-J1 Check for continuity of the ground circuit. l Connector: Disconnected n Repair the harness. i ABCD Harness side connector Measure the power supply voltage of the heated oxygen sensor. or a short-circuit to ground.

Components HEATED OXYGEN SENSOR <Federal .Turbo Up to 1995 models> A Equipment connector Heated oxygen Heated oxygen B Equipment side connector \ i Al Electromotive Engine con T I-. 1 TSB Revision . A Harness side connector I B Harness side Engine control module connector 29Fuo393 I SELl401 6LLl401 7FU1642 OPERATION Refer to P.MFI re’ay = ’ ’ 14 L 27FU1332 16 ZECIOO.l3A-137. TROUBLESHOOTING Refer to P.l3A-138. INSPECTION Refer to P.l3A-141.13A-250 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .

or a short-circuit to ground. (A4-76) (84-75) D ncllltess side connector Check for continuity of the ground circuit.l3A-143. l Connector: Disconnected l Ignition switch: ON Battery voltage Repair the harness.l3A-143. l Connector: Disconnected SENSOR INSPECTION Refer to P. ( A l . i TSB Revision . l Heated oxygen sensor connector: Disconnected l Engine control module connector: Disconnected 0 OK L a@ 0 I 3 Repair the harness. between the enginecontrol module and the heated oxygen sensor. Bl MFI relay) Z7FU1333 A B Harness side Check for an open-circuit.Components 13A-251 HARNESS INSPECTION Measure the power supply voltage of the heated oxygen sensor.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . INSTALLATION Refer to P.

and also check the condition of control by the engine control module) 700 rpm (Idling) 2.l3A-138. 11 39 Data display Sensor detection voltage Check condition Engine Warm-up (Make the mixture lean by engine speed reduction.Turbo Up to 1995 models> MFi relay ABCD Equipment side connector heated oxvaen (front) Harness side connector I Electromotive Theoretical NF force ! (V 92k. and rich by racing) Engine state When sudden deceleration from 4.(60 Im $5 d’6 d’” 14 A/F 15 16 ZEClOO7 / Engine control module connector 27FU1436 7FlJ1643 OPERATION Refer to P.ComDonents HEATED OXYGEN SENSOR <California . TROUBLESHOOTING Refer to P. check the air/ fuel mixture ratio.13A-252 On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .000 rpm [ TSB Revision .l3A-137.000 mV 400 mV or lower t) 600-1. INSPECTION Using Scan Tool <Heated Oxygen Sensor (front)> Function Data reading b item No.000 mV (changes) Engine Warm-up (Using the heated oxygen sensor signal.000 rpm When engine is suddenly raced Standard value 200 mV or lower 600-l .

Data display Sensor voltage l l Check condition Transaxle: 2nd gear Drive with wide open throttle Engine state 3.000 mV <Heated Oxygen Sensor (rear)> Function Item No.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . B2. between the engine control module and the heated oxygen sensor l Heated oxygen sensor connector: Disconnected Engine control module connector: Disconnected Harness side connector Check for continuity of the ground circuit l Connector: Disconnected 3 4 OK -+ 0 Repair the harness (A2.__ l Ignition switch: ON Battery voltage (OK) --++ I 2 I -!Repair the harness. D2-92) \ )* 27FUl441 l Connector: Disconnected i TSB Revision . C2. Dl MFI relay) f---Y - short-circuit to ground. Cl....Components 13A-253 Standard value 600.500 rpm Data reading 59 69 HARNESS INSPECTION ABCD Harness side connector Measure the power supply voltage of the heated oxygen sensor.1. a Connector: Disconnected --. (Al. Bl.

-I^ ^ I 92 73 L I 7 I L f oxygen sensor (rear) 1 A2‘_. MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . Therefore.13A-254 SENSOR INSPECTION Refer to P. TSB Revision J . INSTALLATION Refer to P.Components HEATED OXYGEN SENSOR <From 1996 models> ABCD 7 sensqr (frGtj& ii mm Right bank heated oxygen sensor (rear) Gh3nn /.l3A-143. l The battery voltage is supplied to the heated oxygen sensor through the MFI relay.I I cI F 1I> 1-! I I 0 i Harness side connector 34 I I I I 1 I / SEL140lj - Electromotive orce (U Theoretical A/F m Engine control module connector 7FUl862 ‘)I 7FUl859 OPERATION l The heated oxygen sensor senses the oxygen concentration in exhaust gas.l3A-143. converts it into a voltage and inputs it to the engine control module. the sensor element is heated by the heater so that the heated oxygen sensor remains responsive even when the exhaust temperature is low. l The heated oxygen sensor outputs about 1 V when the air-fuel ratio is richer than the theoretical ratio and outputs about 0 V when the ratio is leaner (higher oxygen concentration in exhaust gas). l The engine control module controls the fuel injection ratio based on this signal so that the air-fuel ratio may be kept at the theoretical ratio.

Hint 2: If the heated oxygen sensor checked good but the sensor output voltage is out of specification. intake air temperature sensor. engine coolant temperature sensor INSPECTION Using Scan Tool <Heated oxygen sensor (front)> Function Data reading item No.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 11 39 Data display Sensor detection voltage Check condition Engine Warm-up (Make the mixture lean by engine speed reduction. Data display Sensor voltage Data reading 59 69 1 1 Check condition l Engine condition 3.000 mV l Transaxle: 2nd gear <M/T>.1.500 rpm ule) Standard value 200 mV or lower 600 . and also check the condition of control by the engine control mod.000 rpm Normal indication ON OFF Data reading 48 / i 1 TSB Revision .000 FXanges) / L <Heated oxygen sensor (rear)> Function Item No.500 rpm Standard value 600. check the air/fuel mixture ratio. rear)> Function Item No. etc. [Examples] (1) Faulty injector (2) Air leaking into the intake manifold through gasket gap. troubles of parts related to air-fuel raito control system are suspected. and rich by racing) Engine state When sudden deceleration from 4.000 rpm When engine is suddenly raced Engine: Warm-up 700 rpm (Using the heated oxygen sensor (Idling) signal.000 mV 400 mV or lower ts 600.t 2. (3) Faulty volume air flow sensor.Components 1349-255 TROUBLESHOOTING HINTS Hint 1: Poor cleaning of exhaust gas will result if the heated oxygen sensor fails.1. barometric pressure sensor. L range <N-r> Drive with wide open throttle <Heated oxygen sensor (front. Data display Heater condition Check condition Engine: Warm-up Engine condition 750 rpm (Idle) 5.1.

TSB Revision . l Heated oxygen sensor connector: Disconnected 0 Engine control module connector: Disconnected 4 cl Repair the harness. between the engine control moduleand the heated oxygen sensor l Heated oxygen sensor connectar: Disconnected l Engine control module connectar: Disconnected i=l.13A-256 HARNESS INSPECTION ABCD Harness side connector MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .l3A-143. ‘d \ ABCD Harness side connector L-J 7FUl816 Check for continuity of the ground circuit. l Connector: Disconnected @---A Z7FUl44 SENSOR INSPECTION Refer to P.Components Measure the power supplv voltage of be heated oxygen’ sensor. or a short-circuit to ground. Check for an open-circuit. D l MFI relay) Engine control module harness side connector 73 75 76 I L-J-33 ABCD Harness sid connector 27FUl439 Engine control Check for an open-circuit.:g. l Connector: Disconnected l Ignition switch: ON Battery voltage dI 27FU1333 . g. between side connector the engine control module and the heated oxygen sensor.l3A-143. INSTALLATION Refer to P. or a module harness short-circuit to ground.

Components 13A-257 INJECTORS <Non Turbo> MFI relay Injector No.: 1 A 2 3 I 15 . i TSB Revision .---_.-.I’3 ~&7*~ ii h 1 Fuel L @ Connector Solenoid coil Plunger 3 71 \\ Filter Engine control module 27FUO833 Engine control module connector Needle valve .l3A-145.l3A-144. 1 2 .4 1 Injector 1 lnjectoi i 1 2 1._____ 7FUO803 1 B 1 4 D Connector for rear bank 2 rear bank \ . TROUBLESHOOTING HINTS Refer to P.6 ’ 2 I- r Injector \ -_.Y Injection @ 7FUO832 7FU1644 OPERATION Refer to P.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . 2 1 No._ 3 :oscillo) NO.

4 ms <From 1996 models Data reading 41 Check condition Engine state Data reading 41 l L NOTE *l: The injector drive time refers to when the supply voltage is 11 V and the cranking speed is less than 250 rpm.5 ms <Up to 1995 models> 2. Data display Drive time*’ Check condition Engine: Cranking Coolant temperature 0°C (32”F)*2 20°C (68°F) 80°C (176°F) Function Item No.1 ms 8.5-3.000 rpm Racing Standard value Closed loop Open loop Data reading 86 TSB Revision .4 ms Standard value 2. electric cooling fan.700 rpm (Idle) perature 80 to 95°C (176 to 203°F) Lights.500 rpm Transaxle Neutral (P range for vehicle with AIT) Steering wheel: Neutral /‘J. sharp racing is To increase <Long-term fuel trim>*4 Function / Item No.2-i 2.3-3. *4: From 1996 models I l l Engine coolant tern.3 ms 36. *2: When coolant temperature is lower than 0°C (32°F) injection is made by 6 cylinders simultaneously.1-54. the injector drive time may about 10% longer.5-12.Components Using Scan Tool Function Item No.2-3.0-3. Data display Drive time*3 l Standard value 12.7 ms <From 1996 models 2..500 rpm Standard value -17-17% Data reading 82 <Fuel control condition>*4 Function Item No. *3: When the vehicle is new [within initial operation of about 500 km (300 miles)].5% Data reading 81 <Short-term fuel trim>*4 Function Item No.2 ms <Up to 1995 models> 2. Data display Specified range Check condition Engine: afterwarming-up (during closed-loop control) Engine state No load 2. accessory units: All OFF 2. Data display Control condition Check condition Engine: after warming-up Engine state 2. 1 Data display 1 Specified range Check condition Engine: after warming-up Idling Engine state 1 Standard value 1 -12.13A-258 INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .9-l 9.

ACTUATOR INSPECTION Refer to P. and check the waveform at the drive side of each injector. 5 injector shut off / No. (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram. check the idling condition) I 13A-259 Normal state Idle state to change further (becoming less stable or stalling) 1 Using Oscilloscope (1) Run the engine at idle speed.Components Function Actuator test 01 02 03 04 05 1 06 Item No. Drive content No.l3A-147.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . 1 injector shut off No. 6 injector shut off Check condition Engine: Idling after warm-up (Shut off the injectors in sequence during idling after engine warm-up. 2 injector shut off No. z A: injector drive time Normal waveform HARNESS INSPECTION Refer to P. TSB Revision .l3A-146. 3 injector shut off No. 4 injector shut off No.

13A-260 INJECTORS <Turbo> MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . TROUBLESHOOTING HINTS Refer to P. . 1.r No.. 3 Engine control module Z7FUO973 Fuel Filter Connector Solenoid coil Plunger q Engine control module connector Needle valv- @ Injection 7FUO832 7FU1645 OPERATION Refer to P. 7FUO803 Resistor ----. 1 TSB Revision .l3A-144.l3A-145. _ --6 lnjectc. 7c inject0 No._.Components MFI relav A Equipment side connector E 4 (Front bank connector) I .

41 (Rear bank) 47 (Front bank) Data display Drive time*’ Check condition Engine: Cranking Coolant temperature 0°C (32”F)** 20°C (68°F) 80°C (176°F) Data display Drive time*3 l Standard value 8.000 rpm Racing Standard value Closed loop / Open loop Data reading 86 i TSB Revision . *3: When the vehicle is new within initial operation of about 500 km (300 miles)].6 ms <Up to 1995 models> 1.6 ms 23. 41 (Rear bank) 47 (Front bank) Item No.9 ms <From 1996 models> 1. *2: When coolant temperature is lower than 0°C (32”F).8 ms <Up to 1995 models> 1. Data display Control condition Check condition Engine: after warming-up Engine state 2.5-2.Comtaonents 13A-261 L INSPECTION Using Scan Tool Function Data reading Item No. *4: From 1996 models <Long-term fuel trim>*4 Function item No.500 rpm Standard value -17-17% Data reading 82 <Fuel control condition>*4 Function Item No.700 rpm (Idle) perature: 80 to 95°C (176 to 203°F) 0 Lamps.4-8.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION . the injector drive time may be about 10% longer.3-34.500 rpm l Transaxle: Neutral l Steering wheel: Neutral L NOTE *l: The injector drive time refers to when the supply voltage is 11 V and the cranking speed is less than 250 rpm.5-l 2.2 ms Standard value 1.7-2. accessory units: All OFF 2.5% Data reading 81 <Short-term fuel trimz-*4 Function Item No. electric cooling fan. Data display Specified range Check condition Engine: after warming-up Idling Engine state Standard value -12.4-l 2. Data display Specified range Check condition Engine: afterwarming-up (during closed-loop control) Engine state No load 2.4-2.6-2.9 ms 5. injection is made by 6 cylinders simultaneously.7 ms <From 1996 models To increase Function Data reading Check condition Engine state Engine coolant tem.

I \ ‘LJ I TSB Revision . 6 injector shut off J -/A&. RESISTOR Refer to P. check the idling condition) 1 Idle state to change further (becoming less stable or stalling) Nor‘maI state ‘d No. 1 injector shut off No.l3A-152.Components Item No. 5 iniector shut off No. 2 injector shut off No. ACTUATOR INSPECTION INJECTORS Refer to P. HARNESS INSPECTION Refer to P.A: injector drive time Normal waveform 203AOX . 3 iniector shut off * No. Drive content No.l3A-150.: 1 Using Oscilloscope (1) Run the engine at idle speed. and check the waveform at the drive side of each injector. (2) Connect the probe to the oscilloscope pick-up point as shown in the circuit diagram.13A-262 Function Actuator test 01 02 03 04 05 06 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .l3A-151. 4 injector shut off I Check condition Engine: Idling after warm-up (Shut off the injectors in sequence during idling after engine warm-up.

INSPECTION Refer to P. TSB Revision . r /\ A 2 /\ .l3A-155.Components 13A-263 A Harness side connector 1 IDLE AIR CONTROL MOTOR (STEPPER MOTOR TYPE) MFI relay I. TROUBLESHOOTING HINTS Refer to P.l3A-154.I On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .l3A-153. ACTUATOR INSPECTION Refer to P.l3A-153.Y 5 1 A Equipment side connector Magnetic rotor Coil i Ball bearing Pintle Throttle body seat /t I ~CJ Y Oscillo Oscillo I I 1 -T\ G 3 A V 4 IAC motor Oscillo Oscillo nI r h17h5 -__ v 0 A V 18 Engine control module Z7FUO518 Engine control module connector ZPFUO393 7FU1646 OPERATION Refer to P. HARNESS INSPECTION Refer to P.l3A-155.

Equipment side connector r B Harness side connector 1 / B-l _.13A-264 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . TSB Revision .d3A-158.Components IGNITION COIL AND IGNITION POWER TRANSISTOR Batterv A Harness side connector Engine speed check control terminal 13 Ignition coil .B-2 iI Ii G r 5v g 5 iransistor ignition timing . adjustment bll connector Spark Plug Tachometer __ Engine control module 7 Engine control module connector 1 ZPFUO393 7FU1059 7FU1647 OPERATION Refer to P.

Control signal of ignition power transistor Connect the probe to oscilloscope pick-up point 2 as shown in the circuit diagram. Primaty signal of ignition coil (1) Run the engine at an idle speed. Data display l I / Engine: Warming up 700 rpm Timing light: Set (set (Idle) timing light to check actual ignition tim. ’ I k--i-Normal waveform Y 03AOa i 1 TSB Revision .500 <From 1996 25-45” BTDC <Turbo> models> Check condition Engine: Idling Terminal condition Standard value Ignition timing adjust.MULTIPORT _ On-Vehicle inspection of MFI FUEL INJECTION Components 13A-265 ~ INSPECTION Using Scan Tool Data display Data reading 44 Ignition tadvance T l l Check condition Engine state Standard value 7-23” BTDC 30-50” BTDC <Non Turbo> 23-43” BTDC <Turbo> i <Ignition Timing Adjustment Mode> Function Data list Item No. and check the control signal of the ignition power transistor.-T-. Drive Set to ignition timing adjustment mode l l Check condition Engine: idling Timing light: set Normal condition 5” BTDC Oscillo 1 1 i/ Using Oscilloscope 1..000 rpm <Up to 1995 iw) models> rpm 32-52” BTDC <Non Turbo> 2. i o v -‘I . I Normal waveform ZO3AO20 7 Oscillo 2 1ov 1 2.ON terminal is ment grounded Ignition timing adjust. / 1ov ov . I--Ll---l . and check the primary signal of the ignition coil.2.OFF ment terminal is disconnected from ground <Standard Ignition Timing> id Function Actuator test 17 Item No. . (2) Connect the probe to oscilloscope pick-up point 1 as shown in the circuit diagram.

Ignition switch) Z7FUO698 i Check for an open-circuit. (B5-58) ‘d B-l Harness side Check for an open-circuit. (B6 . l Ignition coil connector: Disconnetted 0 Ignition power transistor connector: Disconnected UFUO699 (A4-Bll) TSB Revision . or a shottcircuit to ground between the ignition power transistor and the ignition coil. or a shortcircuit to ground between the engine control unit and the ignition power 0 l 31 B-2 Harness side connector Engine control module connecIgnition power transistor connector: Disconnected Repair the harness.Components 1 J A Harness side connector Measure the power supply voltage of the ignition coil. l Connector: Disconnected 0 Ignition switch: ON Battery voltage Repair the harness. (A3 . l Connector: Disconnected l Ignition switch: ON Battery voltage OK : : I : Repair the harness.Ignition switch) ‘L. B-2 Harness side connector Measure the power supply voltage of the ignition coil.13A-266 HARNESS INSPECTION MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .

Components Check for continuity of the ground circuit.0 v Repair the harness. (B3-10) 27FUO701 ACTUATOR INSPECTION Refer to GROUP 16 . l Connector: Disconnected 0 Ignition switch: START 0.ignition System.MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION .5-4. i TSB Revision . 0 Connector: Disconnected 13A-267 B-2 Harness side connector Repair the harness. (B4 Ground) 27FUO700 Measure the voltage of the control signal circuit of the ignition power transistor.

l3A-162. ACTUATOR INSPECTION Refer to GROUP 17 .13A-268 MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION . TSB Revision .Evaporative Emission Control System. HARNESS INSPECTION Refer to P. INSPECTION Refer to P.Components EVAPORATIVE EMISSION PURGE SOLENOID MFI relay j I d EVAP purge solenoid side 7FU1009 Engine control module 7FU1851 Engine control module connector I 9FUO393 7FUl850 d OPERATION Refer to P.l3A-162.l3A-163.

INSPECTION Refer to P. TROUBLESHOOTING HINT Refer to P.. i r Revision TSB .l3A-165.l3A-164.On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION .l3A-164.Components 13A-269 : EGR SOLENOID MFI relay -T- EGR solenoid J 1 / / . HARNESS INSPECTION Refer to P.O. EGR solenoid Engine control module Engine control module connector 7FU1649 OPERATION Refer to P.Cl!.l3A-165.

13A-270

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components

FUEL PRESSURE SOLENOID <Turbo>
MFI relay

l-

l ‘: Up to 1995 models
*2: From 1996 models

Engine control module connector

29Fuo393
7FU1650

OPERATION
Refer to P.l3A-166.

INSPECTION
Refer to P.l3A-167.

HARNESS INSPECTION

1 -.I
A Harness side connector

Measure the power supply voltwe l Connector: Disconnected l Ignition switch: ON Battery voltage

2 cl

=

ZOlA0524

f

Repair the harness. (Al - MFI relay)

TSB Revision

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components
Engine control module harness side connector A Harness side connector

13A-271

Check for an open-circuit, or a short-circuit to ground, between the fuel oressure solenoid and the engine control module. l Engine control module connectar: Disconnected a Fuel pressure solenoid connector: Disconnected

(OK) + /roA
I Repair the harness. (A2-7*‘,
403

n

A

YOlA0525

NOTE *I: Up to 1995 models *2: From 1996 models ACTUATOR INSPECTION Refer to P.l3A-168.

TURBOCHARGER WASTE GATE SOLENOID <Turbo>

MFI relay

A Equipment side connector

ZOO110324

Engine control module connector

7FU1651

TSB Revision

13A-272

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components

OPERATION Refer to P.l3A-169. TROUBLESHOOTING HINTS Refer to P.l3A-169. INSPECTION Refer to P.l3A-170. HARNESS INSPECTION I I
I I - -

Measure the power supply voltage. .- Connector: Disconnected l Ignition switch: ON Battery voltage

I

relay)

1 AFfidepgiiti3 r
Z7FlJOS26

T

Check for an open-circuit, or a short-circuit to ground, between the turbocharger waste gate solen noid and the engine control module. l Turbocharger waste oate so- l e n o i d connector: bisconnetted 0 Engine control module connectar: Disconnected

(OK) -+ /TOA
Repair the harness. (A2-32)

A

ACTUATOR INSPECTION Refer to GROUP 15.

TSB Revision

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components

13A-273

I

BOOST METER <Turbo>

L

----/---I L i
Boost meter _ - - - _--.__--I = = --- - - - - - - - - - y r -==n 1 7FU1022 Engine control module NOTE *‘: Up to 1995 models *2: From 1996 models ignition switch (IG,) A Equipment side connector

7FUO985 / ij
Engine control module connector

29Fuo393 7FU1662

HARNESS INSPECTION
Measure the power supply voltage. 0 Connector: Disconnected l Ignition switch: ON Battery voltage Repair the harness. (A2- Ignition coil [IG])
Z7FUO986

A Harness side connector

1 TSB Revision

13A-274

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components
Engine control module bar ess side connector

A Harness side

short-circuit to ground, between the engine control module and the

l

Engine control module connector: Disconnected

Repair the harness. (A3-41*‘, 39*2)

Z7FUO987

NOTE *I: Up to 1995 models *2: From 1996 models

ACTUATOR INSPECTION
Refer to GROUP 54.

ACTIVE EXHAUST CONTROL UNIT <Turbo>
DC motor for valve drive

A Equipment side
connector Active exhaust control unit

Engine control module connector

7FUO989

TSB Revision

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Comr>onents OPERATION Refer to P.l3A-173. i HARNESS INSPECTION 1

13A-275

1 -I

35” 7”2

)

Measure the input voltage of engine control module. 0 Engine control module connector: Disconnected 0 Ignition switch: ON Battery voltage

@

-

-

A Repair the harness. (A4-35*‘,
7*9

r Engine control
module harness side connector

27FUO689

NOTE *I: Up to 1995 models *2: From 1996 models ACTUATOR INSPECTION Refer to GROUP 15.

1 TSB Revision

13A-276

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components

VARIABLE INDUCTION CONTROL MOTOR (DC MOTOR) <Non Turbo>
Engine control module

Variable induction control motor r (DC motor) (with built-in induction /control valve position sensor) 7FlJflRn7

A Equipment connector

Variable induction control motor

ZlFUO646

ZPFUO393 7FU1654

OPERATION
Refer to P.l3A-174.

INSPECTION
Refer to P.l3A-174.

HARNESS INSPECTION
Enaine control module hasess side connector

Check for an open-circuit or a short-circuit to ground, between the engine control module and the variable induction control motor connector. l Variable induction control motor connector: Disconnected l Engine control module connector: Disconnected

A
STOP

Repair the harness.

27FUO841

ACTUATOR INSPECTION
Refer to GROUP 15.

TSB Revision

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - ComDonents

~

73A-277

ANTI-LOCK BRAKING SIGNAL <Turbo>
ABS ECU

A ABS control unit equipment side connector

28 - ABS HU

Engine control module

5v Engine control module connector

d r:

44

J
Z6FU1542

OPERATION
Refer to P.l3A-176.

HARNESS INSPECTION
Engine control module

Check for an open-circuit or a short-circuit to ground, between the ABS control unit and the engine control module.
l l

@

-

-

A Repair the harness. (A2844

ABS control unit connector: Disconnected Engine control module connectar: Disconnected

26FU1543

TSB r--- Revision

7 314-278

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components

ENGINE AND TRANSAXLE TOTAL CONTROL SIGNAL <A/T>
Transaxle control module

7r :
16FO292

!+

7

9

P
6
! 7

5v

108

NOTE ‘l: Up to 1995 models *2: From 1996 models 46

43”, 60e2

I
Engine control module f

A Transaxle control module connector Engine control module connector

Z7FUO843

I

27 FUO903
7FU1656

OPERATION Refer to P.l3A-177

TSB Revision

I

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components HARNESS INSPECTION

7 344-279

1 Ll

A Transaxle control module harness side connector

Engine control module harness side co”p[RI side corms

Check for an open-circuit, or a short-circuit to ground between the transaxle control module and the engine control module. l Transaxle control module connector: Disconnected l Engine control module connector: Disconnected

Repair the harness. (A7-46)

T

26FU1543

-

4

Engine control module harness

A Transaxle control module harness side

Check for an open-circuit, or a short-circuit to ground between the transaxle control module and the engine control module. l Transaxle control module connector: Disconnected l Engine control module connector: Disconnected

Repair the harness. (A9-43*‘, 60*2)

T

26FU1543

“ I

Q I

Engine control module harness side ‘On””

4 Transaxle control module harness side [El connector
10

Check for an open-circuit, or a short-circuit to around between the transaxle co%rol module and the engine control module. l Transaxle control module connector: Disconnected l Engine control module connector: Disconnected

T T z
26FU1543

Repair the harness. (Al 08-7)

NOTE *I: Up to 1995 models l 2: From 1996 models

RELEASE OF RESIDUAL PRESSURE FROM HIGH PRESSURE FUEL HOSE
Refer to P.l3A-179.

FUEL PUMP OPERATION CHECK
Refer to P.l3A-179.

FUEL PRESSURE TEST
Refer to P.l3A-180.

TSB Revision

13A-280

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components

ENGINE CONTROL MODULE (ECM) TERMINAL VOLTAGE INSPECTION
(1) Connect a very thin wire probe (such as a paper clip) to the probe of the voltmeter. (2) Insert the very thin probe from the wire side into contact with each of the terminals of the ECM connector and check the voltage, while referring to the check chart. NOTE 1. Measure a voltage with the ECM connector connected. 2. Measure the voltage between each terminal and the No. 26 terminal (ground terminal). 3. Withdraw the ECM for easier access to the connector terminals. 4. The inspection need not be performed in the order of the chart. Caution Short-circuiting the positive (+) probe between a connector terminal and ground could cause damage to the vehicle wiring, sensors or ECM, or all of them. Use care to prevent it! (3) If the voltmeter shows any deviation from the standard value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace. (4) After repair or replacement, recheck with the voltmeter to confirm that the problem has cleared completely. TERMINAL VOLTAGE CHECK CHART Engine Control Module Connector Terminal Configuration

Z7FU1264

Z9FUO393

TSB Revision

I On-Vehicle Inspection of MFI MULTIPORT FUEL INJECTION - Components Terminal No. 90 Check point Volume air flow sensor Check conditions (Engine conditions) Engine: Idle Engine: 2,000 rpm 19 Volume air flow sensor reset signal Intake air temperature sensor Engine: Idle Engine: 3,000 rpm ignition switch: ON o-1 v 6-9 V -

13A-281
Standard value Remarks 2.2-3.2 V -

~

72

When intake temperature 3.2-3.8 V is 0°C (32°F) When intake temperature is 20°C (68°F) 2.3-2.9 V

When intake temperature 1.5-2.1 V is 40°C (104°F) When intake temperature is 80°C (176°F) 85 Barometric pressure sensor Ignition switch: ON 0- 10 V

-

When altitude is 0 m (0 ft.) 3.7-4.3 V When altitude is 1,200 m (3,937 ft.) 3.2-3.8 V

-

83

Water temperature sensor

Ignition switch: ON

When water temperature 3.2-3.8 V is 0°C (32°F) When water temperature is 20°C (68°F) 2.3-2.9 V

-

When water temperature 1.3-l .9 V is 40°C (104°F) When water temperature is 80°C (176°F) 84 Throttle position sensor Ignitionswitch: Kept in ON $$:y more seconds 87 Closed throttle position switch Ignition switch: ON Throttle valve placed in O-l V idle position Throttle valve placed in slightly opened position 88 Camshaft position sensor Crankshaft position sensor Ignition Switch - ST Park/Neutral position switch Engine: Cranked Engine: Idle Engine: Cranked Engine: Idle Engine: Cranked Ignition switch: ON Selector lever set to P or N Selector lever set to D, 2, L or R 8 V or more o-3 v 8-14 V 0.2-3.0 V 4 V or more 0.2-3.0 V _ Idle 0.3-0.9 V 0.3-1.0 v

-

-

Wide open throttle

4.5-5.5 v

-

-

89

-

71 91

MiT AIT

1 TSB Revision

I

13A-282
Terminal No. 86

MULTIPORT _ On-Vehicle Inspection of MFI FUEL INJECTION Components Check point Vehicle speed sensor
l

Check conditions (Engine conditions) 0 Ignition switch: ON Move the vehicle slowly forward

Standard value Remarks 0*5v (Changes repeated) -

d

37

Power steering pressure switch

Engine: Idle, warm

Steering wheel placed in B+ neutral (straight ahead) position Steering wheel turned half a turn O-3 V O-3 V B+

45

Air conditioning switch 1

Engine: Idle

Air conditioning switch set to OFF Air conditioning switch set to E conditioning compressor in driven state)

59 <Turbo, Non-Turbo up to 1995 models> 61 <Non-Turbo From 1996 models> 22

Air conditioning switch 2

Engine: Idle

Air conditioning switch set to OFF
l l

O-3 V

Air conditioning switch set B+ to ON Indoor set temperature brought closer to atmospheric temperature

Air conditioning relay

l

0

Engine: Idle B+ or 6 V or Air conditioning switch: OFF -+ ON more for a mo(Air compressor in driven state) ment + O-3 V B+ -

21

Fan motor relay (Lo)

Radiator fan not operating [Coolant temperature: below 90°C (194”F)] Radiator fan operating at low speeds [Coolant temperature: 95-105°C (203-221 “F)]

o-3 v

20

Fan motor relay (Hi)

Radiator fan not operating [Coolant temperature: b e l o w 90°C (194”F)I Radiator fan operating at high speeds [Coolant temperature: above 105% (221

B+

o-3 v

“VI
24 <up to 1995 models> 58 <From 1996 models> 75 76 Electric load switch Engine: Running at idle Lighting switch set to OFF o-3 v

Lighting switch set to ON

B+

Heated oxygen sensor(front)

Engine: Warm, 2,000 rpm (Check using a digital type voltmeter.)

0 e 0.8 V (Changes re- peatedly)

TSB Revision

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Terminal No. Check point
l

13A-283
Standard value Remarks ccalifornia, Federal from 1996 models>

Check conditions (Engine conditions)

L

60 Heated oxygen sensor <Up to 1995 (rear) models> 73,79 <From 1996 models> 1 14 2 15 3 16 4 17 5 18 No. 1 injector No. 2 injector No. 3 injector No. 4 injector No. 5 injector No. 6 injector Stepper motor coil <Al> Stepper motor coil <A2> Stepper motor coil <Bl> Stepper motor coil <B2> Ignition power transistor unit A Ignition power transistor unit B Ignition power transistor unit C

0
l

Transaxle: 2nd gear <M/T>, L range 0.6-l .O V </VT> Drive with wide open throttle Engine 3,500 rpm or more

Engine: Running at idle after warmup, and accelerated abruptly by depressing accelerator pedal

Falls tempo- rarily a little from 11-14 V.

Engine: Warm Check immediately after hot restart.

B+++O-3V (Changed repeated)

-

L

10 23 11 9

Engine speed: 3,000 rpm

0.3-3

v

-

Evaporative emission Ignition switch: ON purge solenoid Engine: Warm, 3,000 rpm Fuel pressure solenoid Ignition switch: ON Engine: From cranking to idling (within approx. 2 minutes) Turbocharger gate solenoid waste Ignition switch: ON Engine: Idle (when the premium gasoline is used)

B+ o-3 v B+ O-3 V + B+ Turbo

7 cup to 1995 models> 40 <From 1996 models> 32

B+ O-3 V 4-13 v

Turbo

41 cup to 1995 models> 39 <From 1996 models>

Turbo meter

Ignition switch: ON

Turbo

Engine: Depress the accelerator pedal Falls abruptly while the engine is idling temporarily from B+

TSB Revision

13A-284

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components

Engine: 4,500 rpm

34 <Up to 1995 models> 61 <From 1996 models> 52

Muffler mode change- Ignition switch: over switch ON

Changeover switch set to ON (TOUR)

O-3 V

Turbo

Changeover switch set to B+ OFF (SPORT) Ignition timing adjust- Ignition switch: ment terminal ON Ignition timing adjustment O-l V terminal connected to ground Ignition timing adjustment 4.0-5.5 V terminal disconnected from ground -

36

Check engine/malfunction indicator lamp

Ignition switch: OFF -+ ON

o-3v+ 9-13 v (Several seconds later) B+

-

6

EGR solenoid

Ignition switch: ON

Engine: Idle Suddenly depress the accelerator pedal

Falls temporarily from B+.

<up to 1995: California Non Turbo, Turbo> <From 1996: All models> California, Fed. eral Turbo <up to 1995: California Non Turbo> <From 1996: All models>

73 EGR temperature sen- Ignition switch: <Up to 1995 sor ON models>

When sensor temperature is 50°C (122°F) When sensor temperature is 100°C (212°F)

3.6-4.4 V 2.2-3.0 V o-3 v

74,77 cup to 1995 models> 34, 35, 42, 43 <From 1996 models>

Oxygen sensor heater

Engine: Idle, warm

Engine: 5,000 rpm

B+

1 TSB Revision

MULTIPORT On-Vehicle Inspection of MFI FUEL INJECTION - Components Terminal No. 41 <Up to 1995 models> 54 <From 1996 models> 33 <Up to 1995 models> 55 <From 1996 models> 40 39 44 Check point Check conditions (Engine conditions)

13A-285
Standard value Remarks O-l V or 4.5-5.5 v Non Turbo

Induction control valve Ignition switch: ON position sensor No. 1

Engine: Slowly accelerated from idling O-l V or speed to 5,000 rpm 4.5-5.5 v + 1.5-4 v (for a moment) Induction control valve Ignition switch: ON position sensor No. 2 O-l V or 4.5-5.5 v NonTurbo

Engine: Slowly accelerated from idling O-l V or speed to 5,000 rpm 4.5-5.5 v + 1.5-4 v (for a moment) Induction control valve Engine: Slowly accelerated from idling ’ O-l V + (Opened) speed to 5,000 rpm 4 V or more (for a moment) Induction control valve Engine: Slowly decelerated from 5,000 rpm (Closed) to idling speed Anti-lock braking signal Engine: idle 0
l

Non Turbo

B+

Turbo

When vehicle is put in motion for the B+ + O-3 V first time after the ignition switch was (for a moment) placed in ON position Vehicle speed: 0 + 10 km/h (0 -+ 0.6 mph) 4.5-5.5 v O-l V o-1 v l-5.5 V An An-

16

Total control “Reduce Engine: Idle torque” request signal 1 Engine: Running at idle after warmup and changing speeds Total control “Reduce Engine: Idle torque” request signal 2 Engine: Running at idle after warmup and changing speeds

43 <Up to 1995 models> 60 <From 1996 models> 7

Total control “Reduce Engine: Running at idle with coolant O-l V torque” execution signal temperature at 50°C (122°F) or lower Engine: idle, warm l-4v

An-

74

Manifold differential Engine: Idle 0.8-2.4 V pressure senosr l Engine: Idle Voltage rises l Suddenly depress the accelerator temporarily pedal. from 0.8-2.4 V

M-T

i

TSB Revision

13A-286 INJECTOR

MULTIPORT FUEL INJECTION - Injector

REMOVAL AND INSTALLATION
(Refer to GROUP 00 - Maintenance Service.) Residual Pressure from High Pressure Hose Release (Refer to GROUP 00 - Maintenance Service.) (Refer to GROUP 15 - Intake Manifold Plenum.)

O-ring 03N0012

4

O-ring
03FOO18

ZO3FOO17
00002423

Engine oil

Removal steps (A, .C+ 1. High pressure fuel hose connection 2. Fuel return hose connection 3. Vacuum hose connection FBI 4. Fuel pressure regulator 5. Control harness connection .C+ 6. Fuel pipe 7. Fuel rail

8. insulator 9. Injector support .A+ 10. Injector 11. Insulator 12. O-ring 13. Grommet

TSB Revision

MULTIPORT FUEL INJECTION - Injector REMOVAL SERVICE POINT
i

13A-287

(A, HIGH PRESSURE FUEL HOSE DISCONNECTION Bleed the residual pressure within the fuel pipe line so as to prevent the flow of fuel. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.

INSTALLATION SERVICE POINTS
,A4 INJECTOR INSTALLATION (1) Apply a small amount of new engine oil to the O-ring. Caution Do not let the engine oil get into the fuel rail. (2) While turning the injector to the left and right, install it to the fuel rail. (3) Check to be sure that the injector turns smoothly. If it does not turn smoothly, the O-ring may be trapped, remove the injector and then reinsert it into the fuel rail and check again. ,BA FUEL PRESSURE REGULATOR INSTALLATION (1) Apply a small amount of new engine oil to a new O-ring and insert it to the fuel rail carefully. Caution Do not let the engine oil get into the fuel rail. (2) If the fuel pressure regulator does not move smoothly, the O-ring may be folded. Then, remove the regulator to check the O-ring for damage. (3) Tighten the regulator to the specified torque. Tightening torque: 9 Nm (7 ftlbs.) ,CdFUEL PIPE / HIGH PRESSURE FUEL HOSE CONNECTION Apply a small amount of new engine oil to the fuel pipe and high pressure fuel hose union, and then insert, being careful not to damage the O-ring. Caution Do not let the engine oil get into the fuel rail.

Grommet

‘/ Fuel rail

A03A0096

O-ring

?B

B03X0037

INSPECTION
INJECTORS CHECK (1) Measure resistance between terminals of injector using a circuit tester. Standard value: 13-16 Q [at 20°C (68”F)] <Non Turbo> 2-3 R [at 20°C (SSOF)] <Turbo> (2) If the resistance is out of specification, replace the injector. TSB Revision

13A-288

MULTIPORT FUEL INJECTION - Throttle Bodv

THROTTLE BODY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation l Engine Coolant Draining and Supplying (Refer to GROUP 00 - Maintenance Service.) <DOHC (Non Turbo) - California> <DOHC (Turbo)>

3

18 Nm 13 ft.lbs. ‘. i

3

ZO : FOOO4

ZOlFOO53 00002424

Removal steps
,Bq
l

Accelerator cable adjustment 1. Accelerator cable connection 2. . Air intake hose connection - . .. 3. vacuum nose connectron 4. TPS connector connection 5. ISC motor connector connection 6. Water hose connection

.A4

7. Vacuum pipe assembly 8. Throttle body 9. Gasket

NOTE The layout of vacuum hoses (No. 3) of the construction drawing is for the DOHC (Non Turbo) - Federal.

INSTALLATION SERVICE POINTS
.A+ GASKET’ INSTALLATION Install the gasket so that the projection is where shown in the illustration. Caution Poor idling etc. may result if the gasket is installed incorrectly. .B( ACCELERATOR CABLE ADJUSTMENT For information concerning adjustment of the accelerator cable, refer to GROUP 17 - Engine Control System. 1 TSB Revision 1

MULTIPORT FUEL INJECTION - Knock Sensor

13A-289

KNOCK SENSOR
L R jMOVAL A N D I N S T A L L A T I O N
Pre-removal and Post-installation Operation l Intake Manifold Plenum Release and Installation (Refer to GROUP 15 - Intake Manifold Plenum.) l Intake Manifold Removal and Installation (Refer to GROUP 15 - Intake Manifold.) 20-25 Nm 14-18 ft.lbs.

203FOO21

+A, .A+ 1. Knock sensor

REMOVAL SERVICE POINT
qA, KNOCK SENSOR REMOVAL Remove the knock sensor with special tool.

INSTALLATION SERVICE POINT
.A4 KNOCK SENSOR INSTALLATION When the knock sensor is installed, be sure to tighten it precisely to the specified torque as its installation affects the engine control.

TSB Revision

NOTES

13F-1

I

i

FUEL SUPPLY
CONTENTS
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 FUEL LINE AND VAPOR LINE . . . . . . . . . . . . . . 8 FUEL PUMP AND FUEL GAUGE UNIT ASSEMBLY AND FUEL TANK PRESSURE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FUEL TANK . . . . . . . . . . . . . . ..e.............. 3 SPECIFICATIONS . . . . . . ..*................. 2
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . 2 Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 2
Fuel Tank and Fuel Line . . . . . . . . . . . . . . . . . . . . . 2

FUEL SUPPLY - SDecifications / Troubleshootinq

SPECIFICATIONS
GENERAL SPECIFICATIONS
1 Items 1 Tank capacity dm3 (gal.) 1Return system
I I

1 Specifications / 75 (19.8) / Equipped
I -I

1 Filter

1 High pressure type

SEALANT
Items Fuel tank hole cover Specified sealant / 3M ATD Part No. 8509 or equivalent

TROUBLESHOOTING
FUEL TANK AND FUEL LINE

Water in fuel filter

functions (When tank cap is removed, pressure releasing noise is heard)

/ TSB Revision

FUEL SUPPLY - Fuel Tank

13F-3

FUEL TANK
‘L, REMOVAL AND INSTALLATION
Pre-removal Operation l Fuel Draining l Residual Pressure from High Pressure Hose Release (Refer to GROUP 13A - On-Vehicle Inspection of MFI Components.)
l

Post-installation Operation Fuel Supplying l Fuel Leakage Checking

3
5-6 Nm .c 3.6-4.3 fLIta.

0

//1

25 Ribs.

L

13 Nm

8 ft.lbs.

.- ..*..

\

v
26 Nm 19 ft.lbs.

203F0007

Removal steps ,Fq 1. Fuel gauge cover 2. Fuel pump and fuel gauge unit assembly connector 3. Fuel tank cap 4. Drain plug 5. Splash shield 6. Fuel tank filler tube protector ,Bd 7. Vapor hose 8. Fuel tank filler tube 9. Fuel filler hose .Bd 10. Vapor hose
/’

.E+ 11. Return hose +A, .D+ 12. High pressure fuel hose .B( 13. Vapor hose 14. Leveling pipe 15. Self-locking nut 16. Fuel tank .C+ 17. Fuel tank pressure control valve .B+ 18. Vapor hose .A+ 19. Fuel pump and fuel gauge unit assembly

i,

TSB Revision

13F-4

FUEL SUPPLY - Fuel Tank REMOVAL SERVICE POINT
(A, HIGH PRESSURE FUEL HOSE DISCONNECTION Disconnect the hose from body main pipe first and then from fuel pump. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line.

INSTALLATION SERVICE POINTS
.A+FUEL PUMP AND FUEL GAUGE UNIT ASSEMBLY INSTALLATION Align the three positioning projections of the packing with the holes in the fuel pump and fuel gauge unit assembly.

ZO3FOO

OJFOO8

.B+ VAPOR HOSE CONNECTION (1) If the pipe has a stepped part, connect the vapor hose to the pipe securely, up to the stepped part, as shown in the illustration. (2) If the pipe does not have a stepped part, connect the vapor hose to the pipe securely, so that it is the standard value. Standard value: 25-30 mm (l-O-1.2 in.)
J

d

Evaporative emission :anister side

.Cd FUEL TANK PRESSURE CONTROL VALVE INSTALLATION Install so that the fuel tank pressure control valve is facing in the direction shown in the illustration.

z003041

Flare nut

.D+ HIGH PRESSURE FUEL HOSE CONNECTION Temporarily tighten the flare nut by hand, and then tighten it to the specified torque, being careful that the high pressure fuel hose does not become twisted. Caution When tightening flare nut, be careful not to bend or twist line to prevent fuel pump from damage.
Sedure side Z03YM3

I iLJ

1TSB Revision

FUEL SUPPLY - Fuel Tank

13F-5

.Ed RETURN HOSE CONNECTION Connect the return hose to the pipe securely, up to the stepped part, as shown in the illustration.

,F( FUEL GAUGE COVER INSTALLATION Before installing the fuel gauge cover, apply the specified sealant to the rear floor pan. Specified sealant: 3M ATD Part No. 8509 or equivalent

INSPECTION
l l l l

Check the hoses and the pipes for crack or damage. Check the fuel tank filler tube cap for malfunction. Check the fuel tank for deformation, corrosion or crack. Check the fuel tank for dust or foreign material. NOTE If the inside of the fuel tank is to be cleaned, use any one of the following: (1) Kerosene (2) Trichloroethylene (3) A neutral emulsion type detergent

Fuel tank pressure control valve

FUEL TANK PRESSURE CONTROL VALVE REPLACEMENT Connect a clean rubber hose to the fuel tank pressure control valve and check for operation.
InsDection Drocedure Lightly blow from the inlet (fuel tank) side Normal condition Air passes through after a slight resistance

Rubber hose

Z03N0078

Lightly blow from the outlet Air passes through (canister) side

TSB Revision

A4 6. High pressure fuel hose connection (body side) . HIGH PRESSURE FUEL HOSE DISCONNECTION (FUEL PUMP SIDE) NOTE Hold the pump side nut with a wrench while turning the nut on the hose side. Fuel pump and fuel gauge unit assembly REMOVAL SERVICE POINTS +A. . High pressure fuel hose connection (fuel pump side) . bB4 4. AsserrlPly and Fuel Tank Pressure Control Valve FUEL PUMP AND FUEL GAUGE UNIT ASSEMBLY AND FUEL TANK PRESSURE CONTROL VALVE REMOVAL AND INSTALLATION Removal steps 2. Fuel pump and fuel gauge unit assembly connector . Fuel tank pressure control valve +A. Fuel gauge cover +B.Bd 5. qB.13F-6 FUEL SUPPLY - r&4=.C+ 3.D41. HIGH PRESSURE FUEL HOSE DISCONNECTION (BODY SIDE) Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. TSB Revision . rWl‘fJ all” ruta uauye “Ill.

.B+ HIGH PRESSURE FUEL HOSE CONNECTION Temporarily tighten the flare nut by hand.. and then tighten it to the specified torque. being careful that the high pressure fuel hose does not become twisted.FUEL SUPPLY . Flare nut . be careful not to bend or twist line to prevent fuel pump from damage.CAFUEL TANK PRESSURE CONTROL VALVE INSTALLATION Install so that the fuel tank pressure control valve is facing in the direction shown in the illustration. apply the specified sealant to the rear floor pan. Secure side Z03rM3 - Evaporative emission . Caution When tightening flare nut. Rubber hose iBN0078 1 TSB Revision I . 8509 or equivalent Fuel tank pressure control valve FUEL TANK PRESSURE CONTROL VALVE REPLACEMENT Connect a clean rubber hose to the overfill limiter and check for operation. Specified sealant: 3M ATD Part No.D+ FUEL G A UGE COVER I N ST A L L A T IO N Before installing the fuel gauge cover.and Fuel Tank Pressure Control Valve L-“=I l-ulrcp all” I-UC. uauye Uilll #hasellluly 13F-7 INSTALLATION SERVICE POINTS bAdFUEL PUMP AND FUEL GAUGE UNIT ASSEMBLY INSTALLATION Align the three positioning projections of the packing with the holes in the fuel pump and fuel gauge unit assembly.

Gasket Engine oil 03NOOV 11. Fuel vapor hose 18. Vapor pipe assembly .A+ 5. Fuel vapor hose 6. Fuel return pipe 21.13F-8 FUEL SUPPLY . Fuel filter 13. Stone protector 19. Purge control valve .w.Jpf . Gasket FBI 15. Fuel rail 6 03FOO20 00002427 16 t Removal steps 1. Fuel vapor pipe 20. Evaporative emission canister 7. s/*L-l .l 14m\ ‘L--B 12 Nm /4 8 ft. _ 35 Nm b I 25 ft. High pressure fuel pipe .’ ciiiz. O-ring .Fuel Line and VaDor Line FUEL LINE AND VAPOR LINE REMOVAL AND INSTALLATION Residual Pressure from High Pressure Hose Release l Air Cleaner and iir Intake Hose Removal (Refer to GROUP 15 . _ dg&.A( 17.lbs. Eye bolt 4Ab 14.Air Cleaner. Fuel main pipe TSB Revision .lbs.) 30 Nm 2 2 ft. Battery 3. Reserve tank 2. @aa / /P a@ Ba // r0 A 1s CT .C( 12. Battery tray with washer tank assembly 4. High pressure fuel hose 16. Eye bolt 4Ab 10.lbs. Fuel return hose 9.A+ 8..

connect the fuel hose to the pipe securely. being careful not to damage the O-ring.CA FUEL -FILTER INSTALLATION (1) When installing the fuel filter. deformation and clogging. Insert the hose.s. be especially sure that there is no fuel leakage in this area. tighten the fuel main pipe’s flare nut and eye bolt at the specified torque. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. then insert the main pipe at the connector part of the high pressure fuel pipe. so that it is the standard value.) . and tighten securely.0-l-2 in. (2) Holding the fuel filter nut. connect the fuel hose to the pipe securely. TSB Revision . up to the stepped part. Check the evaporative emission canister for clogging. EYE BOLT REMOVAL Remove the eye bolt while holding the fuel filter nut securely.FUEL SUPPLY . OJFOO3 05FOO7 . Standard value: 25-30 mm (1. Caution Because there is high pressure applied between the fuel pump and the injection mixer. Z03FOOlr 1 INSTALLATION SERVICE POINTS .1b. as shown in the illustration. first temporarily install the filter to the filter bracket. I i-iare nut &I@ . L m 3 35 Nm 25 ft. INSPECTION l l l Check the hoses and pipes for cracks.Fuel Line and Vapor Line REMOVAL SERVICE POINTS 13F-9 h pressure hose (A.A+FUEL VAPOR HOSE / FUEL RETURN HOSE INSTALLATION (1) If the fuel pipe has a stepped part.B( HIGH PRESSURE FUEL HOSE INSTALLATION Apply small amount of new engine oil to the hose union. Check the fuel filter for clogging and damage. (2) If the fuel pipe does not have a stepped part. Then tighten the filter to the bracket. and manually screw in the main pipe’s flare nut. bend.

A4 8. and manually screw in the main pipe’s flare nut. .A+ FUEL FILTER INSTALLATION (1) When installing the fuel filter. Mounting bolt .13F-10 FUEL FILTER FUEL SUPPLY .?03F0012 6. TSB Revision J . Gasket 5. High pressure fuel pipe 1. Fuel main pipe connection 7. Eye bolt 10. High pressure fuel hose 4Ab Eye bolt REMOVAL SERVICE POINT +A. 25 ft.Fuel Filter REMOVAL AND INSTALLATION 0 Residual Pressure from High Pressure Hose Removal steps Xl f%s ’ . (2) Holding the fuel filter nut. Battery 2. . Gasket 11. tighten the fuel main pipe’s flare nut and eye bolt at the specified torque. then insert the main pipe at the connector part of the high pressure fuel pipe. Eye bolt INSTALLATION SERVICE POINT .lbs. Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line. first temporarily install the filter to the filter bracket. Fuel filter 9. EYE BOLT REMOVAL Remove the eye bolt while holding the fuel filter nut securely. Battery tray with washer tank assenibly 3. Then tighten the filter to the bracket. Eye bolt 4.

. ... . . ENGINE COOLANT TEMPERATURE SENSOR AND AIR CONDITIONING ENGINE COOLANT TEMPERATURE SWITCH . . . .. 4 RADIATOR . . . 2 General Specifications . . . . . . . . . . . . . . * . . .. . . . . . . . . . . . .. . . .. . . . . . . . 9 TROUBLESHOOTING . . . . . . . . 2 Lubricant. WATER PIPE AND WATER HOSE . . 13 ON-VEHICLE SERVICE . . . 3 WATER PUMP. . * . . 2 THERMOSTAT . . . .. . . . . . . . . . . . . ... . .. . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . .. . . . . . . . . . . . . . . . . 5 . . . . .. .. . . . . . . . . . .*. . . . .. . . . . . . . . . . ... ENGINE COOLING CONTENTS ENGINE COOLANT TEMPERATURE GAUGE UNIT. . . . . . . . * . . . . .. . . . . .. . . . . .. . . . .. . . . . . . . . . . . .*. . . . . . . . . . . . . .... . . . . . . . . . . . . 4 Cap Pressure Test . . . .. .. . . . . . . . . . . ... . . .. . . . . . .. . . . . . . .. . . . ... . . . . . . . . . . . . . 4 Engine Coolant Concentration Test .L. .. 4 ~ 4 SPECIFICATIONS . 2 Sealant . . . . . . .. . 3 Service Specifications . . . . . . . . 4 Engine Coolant Leak Check . . . . .. . . .. .. . . ... . . . . .. . . . . . . .. . . . .. 11 / LJ Engine Coolant Replacement . . . . . . . . . . . . . . . . . . .*. . . . . . .

(qts.5) TSB Revision .2) 81-89 (178-192) 77 (171) or less 9 1 .Specifications SPECIFICATIONS GENERAL SPECIFICATIONS Items Cooling method Radiator Radiator fan motor Water pump Thermostat Type Type We Type Identification mark Specifications Water-cooled.Vehicles with air conditioning OFF + ON “C (OF) ON 3 OFF “C (“F) Standard value 30-60 76.5 (170) 90 (194) or more 75-105 (11-15) Limit 65 (9.5 (Stamped on flange) 8 d SERVICE SPECIFICATIONS Items Range of coolant antifreeze concentration % Thermostat Valve opening temperature “C (OF) Full-opening temperature “C (“F) Opening pressure of cap high pressure valve kPa (psi) Therm0 sensor (on radiator) operating temperature <up to 1993 models> For radiator fan OFF + ON “C (“F) ON + OFF “C (“F) For condenser fan . forced circulation with electrical fan Pressurized corrugated fin type Direct current ferrite type Centrifugal impeller type Wax type with jiggle valve 76.ENGINE COOLING . pressurized.9 9 (196-210) 87 (189) or less d LUBRICANT Item Engine coolant lit.0 (8.) Specified lubricant High quality ethylene glycol antifreeze coolant Quantity 8.

heater hose.) Faulty cap valve or setting of spring Cracked thermostat housing Loose water pump mounting bolt or leaking gasket Loose bolt or leaking gasket in water outlet fitting Loose bolt or leaking gasket in water inlet fitting Loose thermostat housing bolts or leaking from gasket Replace Correct or replace Retorque bolts or replace gasket Replace Correct Replace i /L Faulty automatic transaxle oil cooler operation No rise in temperature Faulty thermostat Blocked or collapsed hose and pipe Loose hose and pipe connection TSB Revision .Specifications / Troubleshooting SEALANT Items i Engine coolant temperature gauge unit Engine coolant temperature sensor (Engine control) Engine coolant temperature sensor (Air conditioning) <Up to 1993 models> Specified sealants 3M Nut Locking Part No.ENGINE COOLING . 4171 14-3 TROUBLESHOOTING Symptom Overheat Probable cause Insufficient engine coolant Too high an anti-freeze concentration Damaged or blocked (insufficiently ventilated) radiator fins Faulty thermostat operation Faulty water pump operation Water passage clogged with slime or rust deposit or foreign substance Overheat Clean Replace Remedy Replenish Correct anti-freeze concentration Correct Replace I L Inoperative electric cooling fan Faulty coolant temperature sensor <Up to 1993 models> Engine coolant temperature sensor <From 1994 models> Faulty electrical motor Faulty radiator fan relay Water leaks Damaged radiator core joint Corroded or cracked hoses (radiator hose. etc.

ENGINE COOLANT REPLACEMENT Refer to GROUP 00 . When the tester is removed.2 psi) Standard value: 75-105 kPa (11-15 psi) 3. Caution Be sure to completely clean away any moisture from the places checked. not to deform the water outlet fitting. Limit: 65 kPa (9. 2. NOTE Be sure that the cap is clean before testing. be careful not to spill any engine coolant from it. since rust or other foreign material on the cap seal will cause an improper indication. repair or replace the appropriate part. CAP PRESSURE TEST 1. If there is leakage. Install an adapter and cap adapter to the water outlet fitting and apply 160 kPa (23 psi) pressure. Increase the pressure until the indicator of the gauge stops moving. Hold pressure for two minutes. while checking for leakage from the radiator. hose or connections. Loosen cap. 2. when installing and removing the tester and when testing.Maintenance Service. ENGINE COOLANT CONCENTRATION TEST Refer to GROUP 00 . 4. TSB Revision . Be careful.Selection of Coolant.ENGINE COOLING . Replace the cap if the reading does not remain at or above the limit. Use a cap adapter to attach the cap to the tester. Confirm that the engine coolant level is up to the filler neck.On-vehicle Service ON-VEHICLE SERVICE ENGINE COOLANT LEAK CHECK 1. 3.

lbs. Fan 21. /TF=Y ZO4FOOO2 00002226 18’1. Radiator assembly 17. Radiator fan motor 22. Shroud l : Up to 1993 models NOTE TSB Revision .lbs. 12 Nm ZO4FOO19 16 9ft. Resistor 23. Radiator fan motor assembly 15. Condenser fan motor assembly <Vehicles with air conditioning> Radiator fan motor connector* Therm0 sensor connection* (For radiator fan) 13. Lower insulator 18.Maintenance Service.ENGINE COOLING .) l Checking Automatic Transaxle Fluid Level and Refilling If Necessary I <From 1994 models> 8 ft. Upper insulator 16.) I L l Post-installation Operation Engine Coolant Refilling (Refer to GROUP 00 . Therm0 sensor (For radiator fan)* 19. Therm0 sensor (For condenser fan)* <Vehicles with air conditioningz20.Radiator 14-5 RADIATOR REMOVAL AND INSTALLATION L I l Pre-removal Operation Engine Coolant Draining (Refer to GROUP 00 . Therm0 sensor connection* (For condenser fan) <Vehicles with air conditioning> 14.Maintenance Service. <Vehicles with air conditioning> 10. Radiator removal steps Drain plug Cap Overflow tube Water level sensor connector Reserve tank Radiator upper hose Radiator lower hose Automatic transaxle oil cooler hoses <Vehicles with AIT> Condenser fan motor connector.

Therm0 sensor connection* (For radiator fan) 13. 00002227 ZO4FOOO2 Radiator fan motor assembly removal steps 1. Cap 6.lbs. Radiator upper hose 9. Resistor 23. Shroud NOTE *: Up to 1993 models TSB Revision . Condenser fan motor connector <Vehicles with air conditioning> 10. Therm0 sensor connection* (For condenser fan) <Vehicles with air conditioning> 14. Radiator fan motor connector 12.A4 11. Condenser fan motor assembly <Vehicles with air conditioning> . Radiator fan motor assembly 20. Fan 21.Radiator <From 1994 models> 204FOO19 <Up to 1993 models> 20\4 13 Nm 9 ft. Drain plug 2. Radiator fan motor 22.14-6 ENGINE COOLING .

while motor is turning. RADIATOR FAN MOTOR CHECK (1) Check to be sure that the radiator fan rotates when battery voltage is applied between terminals (as shown in the figure). damage or deterioration. Check the radiator hoses for cracks. (2) Check to see that abnormal noises are not produced. or damage.Radiator REMOVAL SERVICE POINT 14-7 +A. Check the radiator fins for bent. INSTALLATION SERVICE POINT . INSPECTION l l l l i l l Check for foreign material between radiator fins.ENGINE COOLING . do not enter after the hose has been disconnected from the radiator. Then. damage. 204FOO17 TSB Revision . foreign materials. damage or deterioration. dirt. Check the reserve tank for damage. rust or scale. etc. insert into the shroud hole and fix securely. AUTOMATIC TRANSAXLE OIL COOLER HOSES DISCONNECTION Use a plug or otherwise cover the hose and nipple part of the radiator so that dust. Check the automatic transaxle oil cooler hoses for cracking. Check the radiator for corrosion.A+ RADIATOR FAN MOTOR CONNECTOR CONNECTION Connect the radiator fan motor connector to the body harness.

Resistance: 0. (2) The resistor is normal if the resistance is within the following range.35 Q THERM0 SENSOR CHECK <Up to.29-0. Item With continuity For condenser fan 91-99°C (196-210°F) 87°C (189°F) or less For radiator fan 81-89°C (178-192°F) 77°C (171 “F) or less (temperature of point A) Without continuity (temperature of point B) 204A0020 216Y1190 00002228 RADIATOR FAN MOTOR RELAY CHECK (1) Remove radiator fan motor relay from the relay box located at the right side in the engine compartment. 1993 models> (1) Immerse the water temperature switch in hot water as shown.14-8 <UP to 1993 models> E.35 Q d c 04u <From 1994 models> <Up to 1993 models> RESISTOR CHECK (1) Measure the resistance between connector terminals (1) and (3) of the radiator fan motor. ENGINE COOLING .-I1 gp 1 LA!z 2 34 (2) Check for continuity between the terminals when the battery power-supply is applied to terminal (2) and terminal (4) is grounded. If it is as specified below. the switch is functioning correctly. Resistance: 0. \ \ \71C1FfVfil 1-m + . (2) The resistor is normal if the resistance is within the following range.29-0. l I 0 J .Radiator RESISTOR CHECK (1) Measure the resistance between connector terminals (1) and (4) of the radiator fan motor. When current flows When no current flows 00002221 Between terminals l-3 Between terminals l-3 Between terminals 2-4 Continuity No continuity Continuity _\ Y16WO908 ZlliLO312 L/ TSB Revision . (2) Change the water temperature and check continuity with a circuit tester.

Air hose A <Turbo> .B+ 2.ENGINE COOLING .) 17-20 Nm iL Removal steps 1. Air intake hose A <Turbo> 3. Water inlet fitting 6. Thermostat INSTALLATION SERVICE POINTS .Maintenance Service.BdAIR INTAKE HOSE A INSTALLATION Assemble the air intake hose A with its notches (arrow-marked) lined up with the A marks on the air intake hoses B and C. Gasket . Insert the hoses into the air intake hose A until they are bottomed. Air intake hose B ZOSFOO23 TSB Revision .A4 THERMOSTAT INSTALLATION Install the thermostat with its jiggle valve lined up with the mark on the thermostat housing. Radiator lower hose connection 5. Air intake hose <Non-Turbo> 4. .Thermostat 14-9 THERMOSTAT / REMOVAL AND INSTALLATION l Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to GROUP 00 .A( 7.

Stir to raise water temperature and check that thermostat opening valve temperature and the temperature with valve fully open [valve lift-over 8 mm (. Calculate lift by measuring the height when fully open. Valve lift TSB Revision . Check for rust or encrustation on valve.14-10 ENGINE COOLING .Thermostat INSPECTION l l l l ~ ~ \ i ’d Check that valve closes tightly at room temperature. Standard value: Opening valve temperature 76S”C (170°F) Full-open temperature 90°C (194°F) NOTE Measure valve height when fully closed. Immerse thermostat in container of water.)] are at the standard value. Check for defects or damage. Remove if any.31 in.

8 / ’ I 17-20 Nm a. WATER PIPE AND WATER HOSE / REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation l Engine Coolant Draining and Supplying (Refer to GROUP 00 . 6 Removal steps Installation steps 1.) 17-20 Nm 12-14ft.Timing Belt. Air intake hose C <Turbo> 7. Air hose A <Turbo> 4. Air intake hose <Non-Turbo> . Inlet water pipe 22. Water hose connection 14.lbs. Air intake hose A <Turbo> 3. Air intake hose <Non-Turbo> 8. Gasket 3. Gasket 10.B+ 21. Air intake hose A <Turbo> 5. Gasket 21. Water hose connection <Turbo> 10.C+ 4. Harness connection 13. Harness connection 11. Water pump 2.) l Ignition PowerTransistor Unit and Ignition Coil Removal and Installation (Refer to GROUP 16 . Water hose A connection 15. Water hose connection <Turbo> 19. Water hose A connection 13. Thermostat housing 18. Inlet water pipe 20. Radiator lower hose connection 16. Radiator upper hose connection 9. Water hose connection <Turbo> 17.C( 6. Gasket 12.) l Timing Belt Removal and Installation (Refer to GROUP 11 . Water hose connection <Turbo> 15.Maintenance Service.Water Pump.105. Air hose A <Turbo> . Radiator upper hose connection 7. O-ring . O-ring FBI 22. Radiator lower hose connection 18.C( 5. Water pump 2. Water hose connection <Turbo> 17. Heater hose connection 14. Water hose connection <Turbo> 8. Water outlet fitting 11. Water Pipe and Water Hose 14-11 WATER PUMP. Gasket TSB Revision . Water hose connection 16.ENGINE COOLING . Heater hose connection 12. Water outlet fitting 9. Thermostat housing 20. Air intake hose C <Turbo> .Engine Electrical. Air intake hose B cTurboz 6.A( 1.I I 11. Air intake hose B cTurbo> . Gasket 19.

replace the water pump as an assembly.BAO-RING / INLET WATER PIPE INSTALLATION Replace the O-rings at both ends of the water inlet pipe with new ones and apply water to the outside of O-rings to help smooth insertion of the pipe into the water pump. (. TSB Revision . Insert the air intake hoses B and C on the turbocharger side until they are bottomed. Water Pipe and Water Hose INSTALLAilON SERVICE POINTS . (1) Damage or crack on the water pump body (2) Water leakage. a water leakage mark may be observed around hole (A).A+ WATER PUMP INSTALLATION (1) Clean both gasket surfaces of water pump body and cylinder block.C+AIR INTAKE HOSE C / AIR INTAKE HOSE B / AIR INTAKE HOSE A INSTALLATION Assemble the air intake hose A with its notches (arrow-marked) lined up with the A marks on the air intake hoses B and C. (3) Water pump installation bolt size are different and caution must be paid to ensure that they are properly installed.Water Pump. Insert the hoses into the air intake hose A until they are bottomed. thermostat housing. Air intake hose B ZOSFOO23 d’ INSPECTION WATER PUMP CHECK If any of the following irregularities are observed.14-12 ENGINE COOLING .31 x . (2) Install new water pump gasket and water pump assembly and tighten the bolts.98) O-ring I z01L0188 ‘d\ ~ I I . With improper sealing. . Caution Care must be taken not to permit engine oil or other greases to adhere to the O-ring.

ENGINE COOLING . Engine Coolant Temperature and Air Conditioning Engine Coolant Temperature Switch 14-13 ~ L ENGINE COOLANT TEMPERATURE GAUGE UNIT.A+ 2. Engine coolant temperature sensor (Engine control) 7.Jd i ZOlFOO38 ZOlFOO62 00002229 Removal steps 1.) cup to 1993 models> 30 Nm <From 1994 models> 30 Nm 1 . Air intake hose A <Turbo> .s ensor tngme coolant Temperature Gauge Unit. ENGINE COOLANT TEMPERATURE SENSOR AND AIR CONDITIONING ENGINE COOLANT TEMPERATURE SWITCH REMOVAL AND INSTALLATION l Pre-removal and Post-installation operation Engine Coolant Draining and Supplying (Refer to GROUP 00 . Air intake hose B <Turbo> 4. Air conditioning engine coolant temperature switch <Up to 1993 models> 1 TSB Revision . Radiator upper hose connection 5.Maintenance Service. Air hose A <Turbo> .A+ 3. Engine coolant temperature gauge unit 6.

A4 AIR INTAKE HOSE B / AIR INTAKE HOSE A INSTALLATION Assemble the air intake hose A with its notches (arrow-marked) lined up with the A marks on the air intake hoses B and C. Insert the hoses into the air intake hose A until they are bottomed. do not heat more than necessary.Meters and Gauges. 1 TSB Revision I . Engine Coolant Temperature and Air Conditioning Engine Coolant Temperature Switch INSTALLATION SERVICE POINTS . Standard value: 112-118°C (234-244°F) Caution The oil used above should be engine oil and should be stirred well while being heated. 1 ld Air intake hose 6 205FOO23 INSPECTION ENGINE COOLANT TEMPERATURE GAUGE UNIT Refer to GROUP 54 . QOQQQQ Z2OAOlS9 AIR CONDITIONING ENGINE COOLANT TEMPERATURE SWITCH cup to 1993 models> (1) Immerse the A/C engine coolant temperature switch in oil and then heat (by using a gas stove flame or similar method) so as to increase the oil temperature.MFI System Inspection. ENGINE COOLANT TEMPERATURE SENSOR (Engine control) Refer to GROUP 13A . L.s ensor Engme Coolant Temperature Gauge Unit. (2) Check to be sure that the AK engine coolant temperature switch is switched OFF when the oil temperature reaches the standard value.14-l 4 ENGINE COOLING . insert the air intake hose B on the turbocharger side until they are bottomed.

. . ..15-1 INTAKE AND EXHAUST CONTENTS ACTIVE EXHAUST SYSTEM . .. . . . . . . .. . . . . . . . . . . . . . . . . . .*.. ... .. . . . . . . . . . . . . . . . . . . .. .. .. Refer to Group 11 Turbocharger Bypass Valve Check . . .. . . . . .. . . . . . . . . . . * ... . .. . . . . .. . . . .. 11 EXHAUST MANIFOLD <Non Turbo> . . . 3 TROUBLESHOOTING (Active Exhaust System) . . . . * * . . . . .. . 2 SPECIFICATIONS . .. . 23 ON-VEHICLE SERVICE . . .. ... . . 17 INTAKE MANIFOLD PLENUM <Non Turbo> . . . . . . . . . . . . . . . .. .. ... . . . .. . . . . 8 Variable Induction Control System Check . . . .*. . . . . . .. . . . . . . .. . . . . .. . . . . 40 AIR CLEANER . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . .2 0 TURBOCHARGER (REAR) . . . . . 2 INTAKE MANIFOLD . .. . .. . . . . . .. . .. . . . .. . . . . . . . . . 5 SPECIAL TOOL . 26 <Turbo> .. .. . .. . . 8 Turbocharger Supercharging Pressure Check . . . . . .. . . . . . . . 7 Intake Manifold Vacuum Check . 15 TROUBLESHOOTING . .. . . . . . . . .. . . . . . . . .. .. . . ... 28 EXHAUST PIPE. . . 6 Turbocharger Waste Gate Solenoid Check . . .*. . . . . . * . . .. .*. .. . . . .. .. .. . ... . . . .. . . . . . . . .s . . . .. . .. . 2 Service Specifications . . . . . . . . . .. .. .. . . . .. . . . . m . . . . 2 General Specifications . . 30 <Turbo> . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . .. . . . . . . MAIN MUFFLER AND CATALYTIC CONVERTER L’ <Non Turbo> . . . . . 13 <Turbo> . . . . . . . . .. . .. 9 CHARGE AIR COOLER . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. . .. . . . . . 5 i i . . . . .. . . . . . . . . .. . . .. . . .. . . . .. .I. . . . 4 TURBOCHARGER (FRONT). . . . . . . . . . .. . . . . . . . . . . . 33 Intake Charge Pressure Control System Check ..

2 (.) Turbocharger waste gate solenoid terminal resistance [at 20°C (68” F)] !2 Turbocharger Supercharging pressure kPa (psi) SPECIAL TOOL Tool number and name MD998770 Supersession Application Removal/Installation of heated oxygen sensor <Turbo> MB991 348 Test harness set Inspection of variable induction control system TSB Revision . 69 (10) Limit 0.Specifications / Special Tool SPECIFICATIONS GENERAL SPECIFICATIONS xpansron resonance SERVICE SPECIFICATIONS Items Intake manifolds Distortion of cylinder head contacting Standard value Less than 0.15-2 INTAKE AND EXHAUST .15 (0059) 36-44 Approx.008) surface mm (in.

Troubleshooting 15-3 TROUBLESHOOTING Symptom Exhaust gas leakage Probable cause Loose joints Broken pipe or muffler Abnormal noise Broken separator in muffler Broken rubber hangers Interference of pipe or muffler with vehicle body Broken pipe or muffler Remedy Retighten Repair or replace Replace Replace Correct Repair or replace i TSB Revision .INTAKE AND EXHAUST .

i. Faulty power window relay Replace power window relay.J Continuity present between terminals (5) and 4 Actuator assembly No continuity present Check continuity between terminals in between terminals (2) and (5). Faulty actuator assemW Replace actuator assembly.1540. SPORT mode. No continuity present between terminals (5) and (6). (2) Make sure that the connectors of each component are positively connected and that no fuse has blown. ‘d TROUBLESHO. Probable cause Valve sticking Faulty switch Remedy Replace main muffler. Broken or maladjusted cable Replace or adjust cable. 5 Cable Operate active exhaust switch (while idling). With battery voltage applied between terminals (1) and (3) of relay. Replace switch.15-4 INTAKE AND EXHAUST . Motor turns in reverse direction when polarity is reversed. the problem is probably caused by faulty active exhaust control unit and therefore the active exhaust control unit is replaced.Continuity present tween terminals (1) and (3) of relay. Actuator operates and valve operates as well. (4) Check each component with its connectors disconnected. Motor operates. check continuity between terminals (4) and (5) of relay. (3) Have an overall understanding of the substance and procedure of checking by reference to the Troubleshooting Quick-Reference Table and perform check in the proper sequence. Sequence 1 ? Part to be checked Valve Active exhaust switch Power window relay Checking procedure Operate valve manually.Troubleshooting (Active Exhaust System) TROlJBLESHOOTlNG (ACTIVE EXHAUST SYSTEM) cup to 1994 models> TROUBLESHOOTING PROCEDURE (1) Make sure that the valve operating cable is not dislocated. 3 Check continuity be. Apply battery voltage between terminals (1) and (3). TSB Revision 1 . Normal condition Operates freely.Continuity present between terminals while tween terminals (2) and idling in TOUR mode.OTING QUICK-REFERENCE TABLE If no abnormality is found in all parts by the check performed in the following sequence. Check continuity be. Refer to P. (6). (5).

535 n: 20°C (68”F)] (12) Open Close 271 NO105 (3) Make sure that when DC 6V is applied to terminals (11) and (12) of the variable induction control motor connector. TSB Revision .Engine Adjustment. measure the voltage between terminal (3) and terminal (4) in the same way. VARIABLE INDUCTION CONTROL MOTOR CHECK (1) zrnnect the variable induction control motor connec(2) Check the variable induction control motor coil for continuity. (2) Connect the tachometer. the induction control valve shaft turns smoothly. (2) Connect the special tool (test harness set) between the disconnected connectors. (All terminals should be connected. replace the intake manifold plenum assembly.) (3) Make sure that when the engine speed is increased from the idle speed to 5.) (3) Connect a circuit tester between terminal (2) and terminal (3) of the induction control valve position sensor and measure the voltage. <From 1993 models> SYSTEM CHECK (1) Disconnect the induction control valve position sensor connector. In addition. (Refer to GROUP 11 . Caution Be sure to apply a voltage of not higher than DC 6V to the variable induction control motor connector terminals since application of high voltage may lock the servo gears.INTAKE AND EXHAUST . Standard value 26FU1277 Variable induction control servo connectors Measured terminal Between terminals (11) Continuity and Present 1.000 rpm. the induction control valve shaft turns. (4) If deviation from the standard value occurs or the variable induction control valve shaft does not turn smoothly.On-vehicle Service 15-5 ON-VEHICLE SERVICE VARIABLE INDUCTION CONTROL SYSTEM CHECK (Non Turbo) cl 992 models> SYSTEM CHECK (1) Warm up the engine.

0 (momentarily) O-l or 4. VARIABLE INDUCTION CONTROL MOTOR CHECK (1) Disconnect the variable induction control motor connectors.15-6 INTAKE AND EXHAUST . (2) Disconnect the air intake hose from the throttle body. TURBOCHARGER SUPERCHARGING PRESSURE CHECK (Turbo) Caution Perform running inspection with two passengers in the vehicle and where full throttle acceleration can be safely made.000 rpm Voltage [V] O-l or 4.5 1 Z-4. replace the intake manifold plenum assembly. variable induction control motor and the related harnesses. (5) If outside the standard value.000 rpm 5.5-5.5 (4) If the voltages are outside the standard values. or if the variable induction valve does not open and close smoothly. TSB Revision . Caution Be sure to apply a voltage of not higher than DC 6V to the variable induction control motor connector terminals since application of high voltage may lock the servo gears.5-5.On-vehicle Service Standard value Engine condition Idle Engine speed gradually Increases to 5. inspect the induction control valve position sensor. (3) Check the variable induction control motor coil for continuity. The pressure gauge reading is taken by a front seat passenger. Standard value Measured terminal Continuity Between terminals (11) and Present [5-35 Q: 20°C (68”F)] (12) Variable induction control motor connectors J Z6FU1277 Open Close 271 NO105 (4) Make sure that when DC 6V is applied to terminals (11) and (12) of the variable induction control motor connector. the induction control valve opens and closes smoothly.

On-vehicle Service 15-7 (1) Disconnect the hose (black) from the turbocharger waste gate solenoid. When pressure is high: Turbocharger waste gate actuator malfunction When pressure is low: Turbocharger waste gate actuator malfunction Supercharging pressure leaks Faulty turbocharger INTAKE CHARGE PRESSURE CONTROL SYSTEM CHECK (Turbo) (1) After the diagnostic trouble code of MFI system is com- i pletely read.7 psi) Caution If the supercharging pressure deviates from the standard value. (2) Disconnect the hose (black) from the turbocharger waste gate solenoid and connect a three-way joint between the hose and the solenoid. Plug the nipple of the solenoid valve from which the hose (black) has been disconnected. (2) Drive the vehicle with full throttle and accelerate the engine to a speed of more than 3. Engine state stop (Ignition switch: ON) Idling (after I warm-up) Hose (with its end painted red) Opened Closed by finger Closed by finger Normal state Negative pressure leaks. Negative pressure is maintained. I NOTE If this check indicates an abnormal condition. the turbocharger waste gate actuator. turn off the ignition switch.500 rpm at 2nd gear. TSB Revision . (5) Applying a negative pressure with the hand vacuum pump.INTAKE AND EXHAUST . check the following items for possible causes. (4) Disconnect the hose (with its end painted red) from the turbocharger wastegate actuator control boost nipple and plug the nipple.9-8. Standard value: 20-60 kPa (2. Measure the supercharging pressure when the pointer is stabilized. (3) Connect a hand vacuum pump to the three-way joint. check tightness both when the hose end (with its end painted red) is closed and when it is open. and connect the pressure gauge to the hose. turbocharger waste gate solenoid or hose is broken. Negative pressure leaks.

Hg). Standard value: 36-44 Q [at 20°C (SS’F)] Z7lN009f TURBOCHARGER BYPASS VALVE CHECK (Turbo) (1) Remove the turbocharger bypass valve. (2) Connect the hand vacuum pump to the nipple of the turbocharger bypass valve.15-8 INTAKE AND EXHAUST . (3) Apply a negative pressure of approx. connect between the solenoid valve terminal and battery terminal. (3) Connecting and disconnecting the jumper wire at the battery negative terminal to apply a negative pressure. and check operation of the valve. Negative pressure is held.Hg) Valve operation It starts opening TSB Revision . 400 mmHg (16 in. (2) Using a jumper wire.On-vehicle Service TURBOCHARGER WASTE GATE SOLENOID CHECK (Turbo) OPERATION CHECK (1) Connect a hand vacuum pump to the solenoid valve nipple (A) (see the illustration to the left). Jumper wire Connected Disconnected (B) nipple condition Open Close Open Normal condition Negative pressure leaks. Also check that air tightness is maintained. check tightness. I 771NfMW7 Negative pressure About 400 mmHg (16 in. I a-v 7lN0095 COIL RESISTANCE CHECK Measure resistance between solenoid valve terminals. Negative pressure is held.

Resonator Air intake hose removal steps <Turbo> 14. . Air intake hose A / TSB Revision -.A+ 18. Breather hose 17. Air hose A 16. Air by-pass hose 24. turbocharger bypass valve and air by-pass hose 19. Insulator 7. Air cleaner cover and volume airflow sensor assembly 3.A+ 20. Boost hose connection . Breather hose 12. Air duct 6. Air intake hose C 23. Volume air flow sensor assembly Air intake hose removal steps <Non-Turbo> 11. Air intake hose A. Purge hose connection . Boost hose connection 15. Air intake hose B 21. Volume air flow sensor gasket 10. Vacuum hose connection . Turbocharger bypass valve 25. Air cleaner cover 9.INTAKE AND EXHAUST .A( 22.Air Cleaner 15-9 I I AIR CLEANER REMOVAL AND INSTALLATION L ‘P <Non Turbo> <Turbo> 5 OSFOO54 \ 24/y 18 05FOOO1 00000608 Air cleaner removal steps 1. Air intake hose 13. Air cleaner element 4. Air cleaner body 5. Collar 8. Volume airflow sensor connector 2.

remove dust by blowing air from inside of element.Volume Air Flow Sensor Check. contamination or damage. If element is slightly clogged.A4 AIR INTAKE HOSE C / AIR INTAKE HOSE B / AIR INTAKE HOSE A. TURBOCHARGER BY-PASS VALVE AND AIR BY-PASS HOSE INSTALLATION Engaging the notch with the A mark at points indicated by the arrows.INTAKE AND EXHAUST . corrosion or damage. refer to GROUP 13A . cover or packing for deformation. Check the air cleaner element for clogging. 1 TSB Revision . insert air intake hoses B and C until seated.Air Cleaner Jir intalJe hose C INSTALLATION SERVICE POINTS . Insert the turbocharger end of air intake hoses B and C completely. Check the air duct for damage. VOLUME AIR FLOW SENSOR CHECK For inspection of volume airflow sensor. Air intake hose A Air intake hose B ZOSFOO23 INSPECTION l l l Check the air cleaner body.

C+ 1.B+ 5. / Turbocharger O-ring 05FOOO3 10113 Nm 7-9 ft. Air hose D 3. Turbocharger bypass valve / L .A+ 20.A( 19. Air intake hose C 22.C+ 2. Air hose F 13. . Air pipe B 11. Boost hose connection 17.B+ 12.9 ft.B+ 8. Air hose G 6. Air cleaner 23.INTAKE AND EXHAUST . Charge air cooler duct (RH) . Charge air cooler right removal steps . Air hose E 10.B+ 15. Engine oil cooler 14. 2. Heat protector F . Charge air cooler right Charge air cooler left removal steps .‘18 _- lo-13 Nm lo-13 Nm 7 . Air hose A 18.lbs.) .Charge Air Cooler 15-11 CHARGE AIR COOLER i’ L REMOVAL AND INSTALLATION Pre-removal Operation l Front Bumper Removal (Refer to GROUP 51 . L 3 4 lo-13 Nm 7-9 ft. Air intake hose A . Air by-pass hose 24. Air intake hose B .Front Bumper.) (When equipped with charge air cooler left) (Refer to GROUP 51 . Charge air cooler duct (LH) . Air pipe C TSB Revision 4A.lbs.lbs.B+ 9.9 ft. Air hose C . Air hose B .A+ 21.Front Bumper. Volume air flow sensor connector . Air pipe A 7. Charge air cooler left Air intake hose removal steps 16.lbs.C+ 4.

Caution Be careful not to allow any foreign matter to get into the hoses.A4 AIR INTAKE HOSE C / AIR INTAKE HOSE B / AIR INTAKE HOSE A INSTALLATION Engaging the notch with the A mark at points indicated by the arrows. pipes. -6% Air intake hose C INSTALLATION SERVICE POINTS . or the charge air cooler itself. pipes. Insert the turbocharger end of air intake hoses B and C completely. insert securely into the stepped portion of the pipe. U Air intake hose A Air intake hose B 205FOO23 Air Charge air cooler left 205FOO28 l Matchmark AIR HOSE E / AIR HOSE B / AIR HOSE G INSTALLATION Aligning the marks at the points indicated by the arrows..CdCHARGE AIR COOLER RIGHT / AIR HOSE D / AIR HOSE C INSTALLATION Aligning the marks at the points indicated by arrows. or wear.paint Pipe end. insert securely into the stepped portion of the pipe or until seated. TSB Revision . ENGINE OIL COOLER REMOVAL Disconnect the hose from the engine oil cooler and remove the engine oil cooler only. insert air intake hoses B and C until seated... damage. Caution Be careful not to allow any foreign matter to get into the hoses.protrusion .15-12 INTAKE AND EXHAUST . .Charge Air Cooler REMOVAL SERVICE POINT +A. Check the charge air cooler hoses for cracking.B +CHARGE AIR COOLER LEFr / AIR HOSE F / l Matchmark Hose end.. or foreign matter. Air hose D 205~0029 coole? right INSPECTION l l Check the charge air cooler fins for bending. or the charge air cooler itself. damage.

EGR temperature sensor <Up to 1995 model for California> 12. EGR valve gasket <Up to 1995 model for California and from 1996 model> 11. . Accelerator cable connection 3.Intake Manifold Plenum <Non Turbo> 15-13 INTAKE MANIFOLD PLENUM <Non Turbo> REMOVAL AND INSTALLATION id Post-installation operation l Accelerator Cable Adjustment (Refer to GROUP 13F . Throttle body gasket 5. Intake manifold plenum stay connection 15.95 model for California and from 1996 model> 10. Throttle body assembly 4A. Manifold differential pressure sensor <From 1996 model> 13. AOSFOO88 Removal steps 1.) 5 Nm L 60 Nm 43 ft. EGR valve cup to 19. VIC motor connection 8. EGR pipe cup to 1995 model for California and from 1996 model> 9. Brake booster vacuum hose connection 6.lbs. Intake manifold plenum installation bolts 16.Engine Control. Air intake hose connection 2. Intake manifold plenum installation nuts 17.INTAKE AND EXHAUST . Intake manifold plenum 18. 18 Nm 13 ft.A+ 4.lbs. Accelerator cable bracket 14. Intake manifold plenum gasket NOTE 4 Up to 1993 model l2 From 1994 model TSB Revision . Harness connectors 7.

INSPECTION Cheek the following points. Replace if defective or cracked. Caution If installed in an incorrect direction.A4 THROTTLE BODY GASKET INSTALLATION Install with the gasket protrusion positioned as shown. INTAKE MANIFOLD PLENUM CHECK (1) Check intake manifold plenum for defect or cracks. (2) Check load (negative pressure) of drain port. idling failure or other problems may occur. replace the part if a problem is found. Clean if required. 1 TSB Revision . THROTTLE BODY ASSEMBLY REMOVAL Leaving the water hoses and vacuum hoses in their installed positions. remove from the intake manifold plenum. I ~ I ‘d INSTALLATION SERVICE POINT .15-14 INTAKE AND EXHAUST .Intake Manifold Plenum <Non Turbo> REMOVAL SERVICE POINT (A.

EGR valve <Up to 1995 model for California and from 1996 model> 13.Engine Control.A+ 4. THROlTLE BODY ASSEMBLY REMOVAL Leaving the water hoses and vacuum hoses in their installed positions remove from the intake manifold plenum. TSB Revision . 05FOO89 00004150 Removal steps 1. Throttle body gasket 5. Throttle body assembly Mb . Intake manifold plenum installation bolts 18. EGR pipe installation bolts <Up to 1995 model for California and from 1996 model> 15. Air pipe A 6. Vacuum hose connection 7. I Turbocharger O-ring osFooo3 18 Nm lo-13 N m ml IO-.INTAKE AND EXHAUST .3 Nm 7-9 ft. Air hose A connection 2. Brake booster vacuum hose connection 8. Intake manifold plenum 20. Harness connector 9.) 4-6 Nm 3-4 ft. EGR pipe gasket <Up to 1995 model for California and from 1996 model> 16.lbs.Intake Manifold Plenum <Turbo> 15-15 i INTAKE MANIFOLD PLENUM <Turbo> i REMOVAL AND INSTALLATION l L Post-installation Operation Accelerator Cable Adjustment (Refer to GROUP 13F . Intake manifold plenum installation nuts 19. Manifold differential pressure sensor <From 1996 model> 12. Clutch booster vacuum hose connection 10. Accelerator cable connection 3. intake manifold plenum stay connection 17. EGR valve gasket <Up to 1995 model for California and from 1996 model> 14. Intake manifold plenum gasket REMOVAL SERVICE POINT i AA.lbs. EGR temperature sensor <Up to 1995 model for California> 11.

Intake Manifold Plenum <Turbo> I Throttle body Ifi INSTALLATION SERVICE POINT . TSB Revision 2. Replace if defective or cracked. Caution If installed in an incorrect direction. :L/ d $~~mmanifold ZO5FOO57 INSPECTION Check the following points.A+ THROTTLE BODY GASKET INSTALLATION install with the gasket protrusion positioned as shown. . idling failure or other problems may occur. replace the part if a problem is found. Clean if required. (2) Check load (negative pressure) of drain port.15-16 Protrus\ion INTAKE AND EXHAUST . INTAKE MANIFOLD PLENUM CHECK (1) Check intake manifold plenum for defect or cracks.

** 14-17 ft. lo-13 Nm 8-9 ft.lbs. Intake manifold mounting nut*’ .lbs. 15.) l Fuel Leakage Checking 5 Nm 2 4 ft.lbs.Maintenance Service. -High-pressure fuel hose connection ^ . Intake manifold mounting nut*2 11.) Post-installation Operation 0 Intake Manifold Plenum Installation (Refer to P.) l Engine Coolant Filling’ (Refer to GROUP 00 . Vacuum hoses connection 5. i 8 /x&ryLy=--gg \ \ -::-:: 05FOO24 00000612 i Removal steps 1. 1993 models> *4: <From December.C( 9. 1993 models> TSB Revision .) l Intake Manifold Plenum Removal (Refer to P. q 1 3 6 24 Nm 17 ft.lbs. Injector connector 6. Fuel rail (with injectors) 7. Timing belt upper cover . u-nng 3. 15.INTAKE AND EXHAUST .) 0 Accelerator Cable Adjustment (Refer to GROUP 13F . Intake manifold gasket NOTE *l: cl 992 non turbo model> *2: 4992 turbo model and from 1993 model> *3: cl992 turbo model and up to November.Intake Manifold 15-17 INTAKE MANIFOLD REMOVAL AND INSTALLATION L Pre-removal Operation l Residual Pressure Release (Refer to GROUP 13A .Engine Control. 2. Intake manifold .Maintenance Service. Fuel return hose connection 4.On-vehicle Service. Cone disc spring*2 12.) l Engine Coolant Draining (Refer to GROUP 00 .1513. Insulators 8.A+ 13.B+ 10.1513.

).).15-18 INTAKE AND EXHAUST .more time respectively. (4) Repeat steps (2) and (3) one .A( INTAKE MANIFOLD GASKET INSTALLATION Install with gasket protrusions in the position illustrated. (1) Tighten the nuts in the front bank to 5 to 8 Nm (4 to 6 ft.lbs. (3) Tighten the nuts in the front bank to 12 to 15 Nm (9 to 11 ftlbs. ‘d : I ZOlLO857 FRONT A .lbs. Intake manifold Z7lN0090 manifold A mounting stud Cylinder ’ head L OJPO024 FRONT Intake’manifold 71N0090 00003707 A 8/ ?“O 43u uc000>\-@ “=d* 2 l 7 3’ a / .Intake Manifold INSTALLATION SERVICE POINTS .). (3) Tighten the nuts in the front bank to 20 to 23 Nm (14 to 17 ft. (2) Tighten the intake manifold mounting nuts one bank after the other by the following procedure. <From December. model and up to November. (1) Tighten the nuts in the front bank to 3 to 5 Nm (2. (2) Tighten the nuts in the rear bank to 20 to 23 Nm (14 to 17 ft.lbs.2 to 3.).).B( INTAKE MANIFOLD MOUNTING NUT INSTALLATION cl992 turbo. (4) Repeat Steps (2) and (3) one more time respectively.C+ INTAKE MANIFOLD MOUNTING NUT INSTALLATION 4992 non turbo model> Apply lubricant sparingly to the intake manifold mounting nuts. (2) Tighten the nuts in the rear bank to 12 to 15 Nm (9 to 11 ftlbs. 1993 models> (1) Apply engine oil to the intake monifold mounting stud. 205LOO77 TSB Revision .6 ftlbs. 1993 models> Tighten the intake manifold mounting nuts one bank after the other by the following procedure.).

in.008 in.Intake Manifold INSPECTION 15-19 ( . (2) Clogging of the negative pressure (vacuum) outlet port.) TSB Revision .2 mm (.) or less Limit: 0.INTAKE AND EXHAUST . or clogging of the gas passages. INTAKE MANIFOLD CHECK (1) Check for damage or cracking of any part. Check the following points. replace the part if a problem is found.0059. (3) Check deflection of installation surface with straight edge and thickness gauge.15 mm (. Standard value: 0.

‘26 -15 Nm . Gasket (A. 35. . Water pipe A TSB Revision Turbocharger stay Exhaust fitting Gasket Oil return pipe Turbocharger assembly Air conditioning compressor Tension pulley bracket Air conditioning compressor bracket Oil pipe .lbs. ::+ym 7-S ft. 13----bmJF’4\/ Y 31 Nm I( 22 ft.24 N m .ll ft.E( 2. Engine oil level gauge guide 12.C+ 7.A+ 24. 37.15-20 INTAKE AND EXHAUST . 4B. 27.Radiator. Turbocharger & fitting assembly 17. +.l5-33. 26.: JI Nrn 2 4 . 23. Generator assembly GROUP 16 . .Generator. 25. Air hose D 4.Turbocharger (Front) TURBOCHARGER (FRONT) REMOVAL AND INSTALLATION l Pre-removal and Post-installation Operation Radiator Removal and Installation (Refer to GROUP 14 .lbs. Air hose A . 28. Heat protector B 14. Air pipe C 9. .Bd it: !tzed oxygen sensor 20. .) l Transmission Stay (Right) Removal and Installation l Front Exhaust Pipe Removal and Installation (Refer to P.lbs.D+ 1. Drive belt (Refer to GROUP 11 Service Adjustment Procedures. 13. 21. Air hose B 6.lbs. Water pipe B 15. Removal steps 25 05FOO43 00000614 .C( 5. .lbs 55-75 Nm 40-54 ft.) O-ring’) y 1 fj?+--&.‘” / 2\ 7-S ft. Air pipe B .lbs. Air intake hose B . 22.D+ 3.) 11. Air hose C .111 40-47ft.Ll7 ft. Heated oxygen sensor connection 16.li Y.) (Refer to 10.y 9Nm 3---g& I ‘27 “” -v1 1.lbs. Air hose E 8.

INSTALLATION SERVICE POINTS bAdTURBOCHARGER ASSEMBLY INSTALLATION Clean the alignment surfaces shown in the illustration.Bq HEATED OXYGEN SENSOR INSTALLATION Use the special tool to install the heated oxygen sensor. care must be taken so that a piece of the gasket does not enter the oil passage hole.INTAKE AND EXHAUST . etc. insert securely into the stepped portion of the pipe or until seated. . Caution Be careful not to allow any foreign matter to get into the hoses or pipes.Turbocharger (Front) REMOVAL SERVICE POINTS 15-21 dA. Air h . HEATED OXYGEN SENSOR REMOVAL Disconnect the connector of the heated oxygen sensor. AIR CONDITIONING COMPRESSOR DISCONNECTION Disconnect air conditioning compressor with hoses from the bracket. . .C( AIR HOSE E / AIR HOSE B INSTALLATION Aligning the marks at the points indicated by the arrows.) in a position that will not interfere with the removal/installation of the turbocharger assembly. +B. . YO5FOOZ3 b Matchmark Hose end . paint Pipe end . and install the special tool to the heated oxygen sensor. protrusion 1 TSB Revision . Caution When cleaning. NOTE The removed air conditioning compressor should be fastened (by using rope. . Supply clean engine oil through the oil pipe installation hole of the turbocharger assembly.

OIL PIPE AND OIL-RETURN PIPE CHECK Check the oil pipe and oil-return pipe for clogging. bending. protrusion INTAKE AND EXHAUST . . l Check whether the turbine wheel and the compressor wheel can be easily turned by hand. If there is clogging. Caution Be careful not to allow any foreign matter to get into the hoses or pipes. l l Check whether or not the turbocharger waste gate valve remains open. insert until seated.E+ AIR INTAKE HOSE B INSTALLATION Engaging the notches with A marks at the points indicated by the arrows. replace the part after disassembly.@ Matchmark Hose end . Air intake hose B YOSFOO23 INSPECTION TURBOCHARGER ASSEMBLYCHECK l Visually check the turbine wheel and the compressor wheel for cracking or other damage.Turbocharger (Front) .DqAIR HOSE D / AIR HOSE C INSTALLATION Aligning the marks at the points indicated by the arrows. insert securely into the stepped portion of the pipe. Check for oil leakage from the turbocharger assembly. . . clean it. TSB Revision . Insert the turbocharger end of air intake hose 6 completely. . If any problem is found. .15-22 . or other damage. paint Pipe end .

Oil return pipe . Heat protector D 12.Ed FDA . 37. Gasket 25. Exhaust fitting stay TSB Revision . 18' ' / q / 22/l /$=yPq&@J I ’ ‘M”~* 45 Nm 33 ft.-.lbs.INTAKE AND EXHAUST . .lbs.Turbocharger (Rear) 15-23 TURBOCHARGER (REAR) Post-installation ODeration l Front Exhaust Pipe Installation (Refer to P. I UrDOCtIarger & return pipe assembly 22. . Oil Pipe 15.tg . Battery 2.A+ 23.lbs.lbs. Clutch booster vacuum hose 7. 21. Heat protector F 6.lbs. Water pipe A 17.B+ 14. Eye bolt .‘ks. OSFOO41 0 0 0 0 6 1 5 ’ .Maintenance Service. . Accelerator cable connection (engine side) 3. 12-15 Nm 0 9-11 ft. . Air hose A 4. EGR valve 16. 3 8 d-ring OSFOOO3 / -‘ii f .Dd .6 Nm 13 ft. EGR pipe 13. Gasket ^. Turbocharger assembly 24.T&. Water pipe B 18.15-33.Ed . 35. Air intake hose A 9. Heated oxygen sensor 11. ------f l-l 10-13 Nm 7-9 ft. Ring 26.1 (Refer to GROUP 00 . Air pipe A 5.Cd iJ Removal steps 1.l7 q 55-65 Nm 54nf!! 40-47ft. / 75Nm -. Accelerator cable connection (pedal side) 8.y._ .) t t. Air intake hose C 10.dA. Heat protector E 20. Exhaust fitting 19.

15-24 INTAKE AND EXHAUST .E+ AIR PIPE A / AIR HOSE A I. paint Pipe end . .B+ OIL PIPE INSTALLATION Supply clean engine oil through the oil pipe installation hole of the turbocharger assembly. Insert the turbocharger end of air intake hose C completely. d INSTALLATION SERVICE POINTS . bd Air intake hose C . .C+ HEATED OXYGEN SENSOR INSTALLATION Use the special tool to install the heated oxygen sensor. w Air intake hose A Air intake hose B ZO5FOO23 Air hose.A 0 Matchmark Hose end . insert securely into the stepped portion of the pipe. care must be taken so that a piece of the gasket does not enter the oil passage hole. Air hose C L)’ TSB Revision . Caution Be careful not to allow any foreign matter to get into the hoses or pipes.NSTALLATION Aligning the marks at the points indicated by the arrows.Turbocharger (Rear) REMOVAL SERVICE POINT dA. . . Caution When cleaning.A4 TURBOCHARGER ASSEMBLY INSTALLATION Clean the alignment surfaces shown in the Illustration. and install the special tool to the heated oxygen sensor.D+AIR INTAKE HOSE C / AIR INTAKE HOSE A INSTALLATION Engaging the notches with A marks at the points indicated by the arrows insert until seated. . protrusion . . 205FOO19 . HEATED OXYGEN SENSOR REMOVAL Disconnect the connector of the heated oxygen sensor.

l Check for oil leakage from the turbocharger assembly. If any problem is found. l Check whether the turbine wheel and the compressor wheel can be easily turned by hand. .INTAKE AND EXHAUST .Turbocharger (Rear) INSPECTION 15-25 ' L Compressor TURBOCHARGER ASSEMBLY CHECK l Visually check the turbine wheel and the compressor wheel for cracking or other damage. bending. or other damage. i . OIL PIPE AND OIL-RETURN PIPE CHECK Check the oil pipe and oil-return pipe for clogging. replace the part after disassembly. clean it. l Check whether or not the turbocharger waste gate valve remains open. If there is clogging.

Exhaust manifold removal steps (front) 1.lbs.\. Heat protector 9.Exhaust Manifold <Non Turbo> EXHAUST MANIFOLD <Non Turbo> REMOVAL AND INSTALLATION <Vehicles for Federal> Pre-removal and Post-installation Operation l Front Exhaust Pipe Removal and Installation (Refer to P. 3 . . .) Condenser Fan Motor Assembly Removal and Installation <Vehicles with Air Conditioning> (Refer to GROUP 14 . . 6. / 30 Nm 22 ft. stud 8.lbs. Adjustment assembly Generator Procedures. Exhaust manifold (rear) 10.) l 12-15 Nm 9-11 ft. 45 Nm 33 ft.Radiator.) 3.Service 2. Gasket TSB Revision .lbs. 4. Drive belt (Generator) (Refer to GROUP 11 . 5. Oil level gauge guide Heat protector Exhaust manifold (front) Gasket Exhaust manifold removal steps (rear) 7..lbs. 12-15 Nm 9-11 ft.l5-30. 31.15-26 INTAKE AND EXHAUST .

<From 1994 model> <Up to 1993 models> 60 Nm 43 ft. Heat protector 9. 31. Oil level gauge guide 4. replace the part if a problem is found. Exhaust manifold (front) 6. l Check for damage of cracking of any part.) l Condenser Fan Motor Assembly Removal and Installation <Vehicles with Air Conditioning> (Refer to GROUP 14 .Service Adjustment Procedures. Gasket INSPECTION / LJ Check the following points. TSB Revision .1530. Stud 8.Exhaust Manifold <Non Turbo> <Vehicles for California> l 15-27 Pre-removal and Post-installation Operation Catalytic Converter Removal and Installation <Front or Rear> (Refer to P.Radiator. . Exhaust manifold (rear) 11. Drive belt (Generator) (Refer to GROUP 11 . EGR pipe 10. Generator assembly 3.) 2.lbs.lbs. Heat protector 8~ Exhaust manifold removal steps (rear) 7. Gasket 5.) 60 Nm 43 ft.INTAKE AND EXHAUST . 00000617 7 Exhaust manifold removal steps (front) 1.lbs. L 12-15 Nm 33 ft.

lbs. FaFe. ! ( 9-11 ft.t manifold s t a y Exhaust manifold removal steps (rear) 5.t manifold (rear) r TSB Revision . Eaha.Exhaust Manifold <Turbo> EXHAUST MANIFOLD <Turbo> REMOVAL AND INSTALLATION l \ ‘d Pre-removal and Post-installation Operation Turbocharger Assembly Removal and Installation (Refer to P. Heat protector bC+ 2..A+ . Exhaust manifold (front) .1520.lbs. 23.Bq .. Heat protector .) 12-15 Nm 9-11 ft.ii Exhaust manifold removal steps (front) 1.. I I \ 1 .15-28 INTAKE AND EXHAUST .

(2) lIghten nuts (B) to 47-53 Nm (34-38 ftlbs.). NOTE 1. 2. L 205FOOl: I E F 8 63 / Q 0 Q .).) is achieved. (3) Tighten nut (D) to 30 Nm (22 ftlbs. Install the nut. (5) Back off nuts (E) and (F) until torque value of 10 Nm (7 ftlbs. cone disc spring and washer in the order shown in the illustration. (4) Tighten nuts (E) and (F) to 47-53 Nm (34-38 ftlbs. fit it along with the exhaust manifold over the studs. (2) Temporarily tighten the turbocharger to the exhaust manifold. NOTE 1.Cd EXHAUST MANIFOLD INSTALLATION (FRONT) Tighten the nuts in the following order. Fit the cone disc spring with the grooved side facing the nut. (1) Tighten four nuts (C) to 30 Nm (22 ftlbs.). (6) Tighten nuts (E) and (F) to 29-31 Nm (21-22 ftlbs. (3) Back off nuts (B) until torque value of 10 Nm (7 ftlbs. Fit the cone disc spring with the grooved side facing the nut.). c Cone disc spring 8 @P 27lNOll TSB Revision 1 .Exhaust Manifold <Turbo> INSTALLATION SERVICE POINTS 15-29 I L .B( EXHAUST MANIFOLD STAY INSTALLATION With the exhaust manifold stay resting on the exhaust manifold. replace the part if a problem is found.).). B Z7lN0115 Exhaust manifold stay \ . 2. cone disc spring and washer in the order shown in the illustration. (1) Tighten five nuts (A) to 30 Nm (22 ftlbs. l Check for damage of cracking of any part.). (4) Tighten nuts (B) to 29-31 Nm (21-22 ftlbs. INSPECTION Check the following points.) is achieved. Install the nut.A+ EXHAUST MANIFOLD INSTALLATION (REAR) Tighten the nuts in the following order.INTAKE AND EXHAUST .

Rubber hangers 12. Rubber hanker 5.lbs. 27 anm 25lIl/ \ 24 13 Nm 9 ft. w /------- J 13 N m 9 ft.. 13 Nm 9 ft. 27: Rubber hangers Hanger bracket Hanger brackets Rear floor heat protector Catalytic converter and front exhaust pipe installation bolts Catalytic converter Gasket Heated oxygen sensor connection Self-locking nuts Rubber hanger Front exhaust pipe Gasket Hanger bracket Front floor heat protector TSB Revision . MAIN MUFFLER AND CATALYTIC CONVERTER j <Non Turbo> REMOVAL AND INSTALLATION <VEHICLE FOR FEDERAL. 18. Gasket i: 10”: 14. Main muffle. 13 Nm 9 ft. 16.lbs.lbs.lbs. 6. 19.lbs.s. Main muffler and center exhaust pipe installation bolts 2.1b.15-30 INTAKE AND EXHAUST . Center exhaust pipe 13.lbs. E: 2 24: 5:.< Nm 9 ft. Mouldings Hanger brackets Catalytic converter and center exhaust pipe installation bolts Hanger bracket Protector 11. 15.---. ZO5FOO39 Removal steps 1.Up to 1993 models> 50 Nm 36 ft. . A ---------‘--?7 13 Nm ‘12 14 P rw 35 Nm ’ 96 ft Ihr 13 Nm 9 ft. Rubber hanaers 4. CALIFORNIA .<Non rurt~o. 17. Gasket 3. Exhaust Pipe Main Muffler and Catalytic Converter EXHAUST PIPE. 10 V 13 Nm 9 ft..lbs.

45 Nm 33 ftlbs. Exhaust Pipe. 26. 29. 24. Rubber hanger 5.lbs lo-13 Nm 7-9 ftlbs.lbs. A05F0069 :t: 4Ab 1.lbs. 28. Main muffler 6. I Removal steps 13 Nm 9 ft. Gasket Oxygen sensor protector Heated oxygen sensor connection Self-locking nuts Rubber hanger Front exhaust pipe Gasket Self-locking nuts Catalytic converter (front) Gasket Heated oxygen sensor connection Catalytic converter (rear) and exhaust fitting stay installation nut Exhaust fitting stay Heat protector A Heat protector B Exhaust manifold (rear) and catalytic converter (rear) installation nut Catalytic converter (rear) Gasket Hanger bracket Front floor heat protector TSB Revision . 22.INTAKE AND EXHAUST 7 Nm 5 ft. 36. Gasket 14. Mouldings 7. Main Muffler and Catalytic Converter .lbs. 38. 32.lbs. Rubber hanger 12. 33. 31. 37. 13 Nm 9 ft. 30. Rubber hangers 15. Hanger bracket 16. 27. 23. Main muffler and center exhaust pipe installation bolts 2. 21. / 45 1. Catalytic converter 20. 25. 39. Protector 11.From 1994 models> 75 Nm 54 ft. Rear floor heat protector 18. 34. Center exhaust pipe 13. 35.<Non Turbo> 15-31 <VEHICLE FOR CALIFORNIA . Rubber hangers 4. Catalytic converter and front exhaust pipe installation bolts 19. Hanger brackets 8. Gasket 3. \ 34 N m -33 ft. Hanger bracket 10. Catalytic converter and center exhaust pipe installation bolts 9. Hanger brackets 17.

I d INSPECTION l l l Check the mufflers and pipes for corrosion or damage. TSB Revision .<Non T u r b o > REMOVAL SERVICE POINTS dAbRUBBER HANGER / MAIN MUFFLER REMOVAL Support with a transmission jack. Main Muffler and Catalytic Converter INTAKE AND EXHAUST .15-32 Exhaust Pipe. Check the rubber hangers for deterioration or damage. etc. Check for gas leakage from mufflers and pipes.

Removal steps cOSFOO72 1. Main Muffler and Catalytic Converter .9/ e ’ 13Nm 9 ft. MAIN MUFFLER AND CATALYTIC CONVERTER <Turbo> REMOVAL AND INSTALLATION cup to 1993 models> L 36 ftlbs. Hanger bracket 12.. .. Cable assembly connection 4. Mouldings 9. Hanger brackets 17..lbs. Hanger brackets 10. Gasket 8. Ihe.y&$J 4 ft.B( 3. Rubber hangers 6. /I 13 \ 13Nme gftJ=-. . Rubber hangers :i: 5.t..---%hrn -/ .. I I // / J -Nm -. Rubber hangers 13.INTAKE AND EXHAUST Exhaust Pipe.I”.. Main muffler 4w 7.. Center exhaust pipe 14. Protector . 13 Nm 9 ftlbs. Hanger bracket 18. Catalytic converter and center exhaust pipe installation nuts 11.lbs. Rubber hangers 16.<Turbo> 15-33 L EXHAUST PIPE.-------5 !i f. Main muffler and center exhaust pipe installation bolts 2...lbs. Rear floor heat protector TSB Revision . 13 Nm 9 ft. Gasket 15.

Front floor heat protector TSB Revision .15-34 INTAKE AND EXHAUST EXhSUSt Pipe. 19. Left bank warm up three-way catalytic converter 35. Heat protector D 32. Gasket 29. Gasket 37. . Gaskets 26. Front exhaust pipe 25. Gasket 22. Hanger bracket (B. Heated oxygen sensor connection 31. Self-locking nuts 27. Self-locking nuts 23. Heat protector E 36. Catalytic converter and front exhaust pipe installation bolts 20. Right bank warm up threelway catalytic converter 28.A4 30. Main Muffler and catalytic Converter . EGR pipe connection 33. Catalytic converter 21.<Turbo> lo-13 Nm DOSFOO72 . Rubber hanger 24. Gasket 34..

installation bolts 2. 13 Nm 9 ft. Rubber hangers 16.) l Brake Booster VacuumTube Clamp Removal and Installation (Referto GROUP 35 -Master Cylinder and Brake Booster.lbs.’ ------- 3 6 ft. f-i&-rger bracket 12.B( 3. Rubber hangers :t: 4Ab 5. Pre-removal and Post-installation Operation Air Conditioning Low-Pressure Hose and Liquid Pipe B Clamp Removal and Installation (Refer to GROUP 55 . 13 Nm 9 ft. Main Muffler and Catalytic Converter INTAKE AND EXHAUST . Center exhaust pipe 14.Exhaust Pipe.lbs.lbs. Inner Shaft Assembly Removal and Installation (Refer to GROUP 26 . w-otector . Gasket 15.Drive Shaft. Cable assembly connection 4.<Turbo> 15-35 /L cl 994 models> .lbs.Refrigerant Line. 13 13 Nm m 4 n ‘8 \ 5 Nm 4 ft. Catalytic converter and center exhaust pipe installation nuts 11.Clutch Control. 6. Rubber hangers 10. 8.) l l l Clutch Booster Vacuum Pipe Removal and Installation (Refer to GROUP 21 . A05F0012 Removal steps 1.) Drive Shaft (Left Side). Rubber hangers Main muffler Gasket Mouldings 9. Hanger brackets 13. Rear floor heat protector TSB Revision .) 13 Nm 9 ft. Hanger brackets 17. Main muffler and center exhaust pipe . Hanger bracket 18. / i. 7.lbs.

Left bank warm up three-way catalytic converter 37. Gasket 22. Heated oxygen sensor connection 24. Front floor heat protector TSB Revision . Catalytic converter 21.<Turbo> lo-13 Nm 12-15 Nm 6. Main Muffler and Catalytic Converter 15-36 INTAKE AND EXHAUST . Gasket 36. 11 __ . Heat protector E 38.lbs.. Gasket 31. EGR pipe connection 35.A+ 32. I 50 Nm 36 ft. Oxygen sensor protector 23. Heated oxygen sensor connection 33. Self-locking nuts 25. Catalytic converter and front exhaust pipe installation bolts 20. Self-locking nuts 29. Gasket 39. Hanger bracket 4Bb . Gaskets 28. ---------/--------h -% . Rubber hanger 26.lbs.------- B05F0012 19. Right bank warm up three-way catalytic converter 30.Exhaust Pipe._ Nm I3 ft.5 ft. Front exhaust pipe 27. Heat protector D 34.lbs.

Hanger bracket 10.lbs.) .Refrigerant Line.Exhaust Pipe. Removal steps 4Ab / :i: 1. Gasket Mouldings TSB Revision . Gasket Rubber hangers 14. A05F0071 13 Nm 9 ft.<Turbo> <From 1995 models> 15-37 / L Preremoval and Post-installation Operation Air Conditioning Low-Pressure Hose and Liquid Pipe B Clamp Removal and installation (Refer to GROUP 55 . Rubber hangers 11. Hanger brackets I. 13 Nm 9 ft. Hanger brackets 5. Center exhaust pipe 13.) l Brake Booster VacuumTube Clamp Removal and Installation (Referto GROUP 35 -Master Cylinder and Brake Booster. 3. Main Muffler and Catalytic Converter INTAKE AND EXHAUST . Rubber hangers 4. /jf /.~/.Drive Shaft.Clutch Control. 7 A &x./-37 6 l rl . Catalytic converter and center exhaust pipe installation nuts 9. Main muffler and center exhaust pipe installation bolts 2. \ li Nm 9 ft. L -------- J . Main muffler 8.lbs.[ 1 3 13 Nm 9 ft.lbs.lbs. 7.) l l l Clutch Booster Vacuum Pipe Removal and Installation (Refer to GROUP 21 . 12. 2 ’ I \ 4 5 Nm 4 ft. 6. Inner Shaft Assembly Removal and Installation (Refer to GROUP 26 .I.) Drive Shaft (Left Side).lbs.

Heated oxygen sensor connection 22.<Turbo> 18 Nm 13 ft. Rubber hanger 24. \ Exhaust Pipe.lbs. Gasket 34: Left bank warm up three-way catalytic converter Heat protector E Gasket 37: Front floor heat protector 1 TSB Revision . 13 -Nm a *Ike /--- --I.lbs. Oxygen sensor protector 21. Front exhaust pipe 25. Gasket 20. Catalytic converter and front exhaust pipe installation bolts 18. Gaskets 26. Rear floor heat protector 17. - lit-13 Nrn g-11 ft... Catalytic converter 19. ...IS-38 INTAKE AND EXHAUST .lbs. Self-locking nuts 4Bb ä l Z: 2 27.--- D BO5FOO71 15. Hanger bracket 16. 40-47 ft.y. Main Muffler and Catalytic Converter 7-9 ftlbs. Heated oxygen sensor connection Heat protector D EGR pipe connection :23. Right bank warm up three-way catalytic converter Gasket Hanger bracket .-. Self-locking nuts 23.--.

A4 HEATED OXYGEN SENSOR INSTALLATION Use the special tool to install the heated oxygen sensor. etc. . / ZOSFOO21 INSPECTION l l l l Check the mufflers and pipes for corrosion or damage.INTAKE AND EXHAUST . and install the special tool to the heated oxygen. i’ i TSB Revision . Check for gas leakage from mufflers and pipes.<Turbo> Exhaust Pipe. Check the rubber hangers for deterioration or damage. INSTALLATION SERVICE POINTS . Check if the main muffler active exhaust system valve can be moved smoothly by hand.B( CABLE ASSEMBLY INSTALLATION Install with the paint mark facing up and adjust the adjusting nut to obtain the illustrated dimension. +B. Main Muffler and Catalytic Converter 15-39 REMOVAL SERVICE POINTS dAbRUBBER HANGER / MAIN MUFFLER REMOVAL Support with a transmission jack. HEATED OXYGEN SENSOR REMOVAL Disconnect the connector of the heated oxygen sensor.

:.). Protector INSTALLATION SERVICE POINTS .) 7 Nm 5 ft.. Removal steps 1.Active Exhaust Svstem ACTIVE EXHAUST SYSTEM <Up to 1994 models> REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation l Rear Side Trim (LH) Removal and installation (Refer to GROUP 52A . Cable connection (Actuator side) 3. Actuator . adjust the adjusting nuts for an inner cable play of 0 to 1 mm (0 to .04 in.B1 2. Active exhaust system control module . .Bq CABLE INSTALLATION (Actuator Side) After adjusting the cable on the muffler side.lbs.Trims. 205FOO22 TSB Revision ..“I: connection (Muffler side) 4.A+ .15-40 INTAKE AND EXHAUST .A4 CABLE INSTALLATION (Muffler Side) Install with the paint mark facing up and adjust the adjusting nut to obtain the illustrated dimension.

Active Exhaust System INSPECTION 15-41 ACTIVE EXHAUST SWITCH CHECK (1) Remove switch garnish B from the knee protector. 3 n 5 6 O l/4 II I L-J TOUR SPORT 0 c TSB Revision .z ::::: 1 ‘W 1 r$ 1 I (’ i!irJ!l t--t --7-f ^ t-y!!>. ..INTAKE AND EXHAUST . (2) Operate the switch and check the continuity between the terminals. o Ll 205FOO51 Switch position 2 1 Terminal No.

NOTES .

. . . . . . . . . . clock spring and interconnecting wiring. . . . . . . . . . . . . . 28 On-board Diagnostic Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRS warning light. . . . . . . . . . . . . . . Fuel Tank Pressure Control Valve . . . . (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. . . . . . . . . . . . . 24 Preliminary Inspection . . . . . . . . m . . . . . . . . . . . . . . 31 Cruise Control System Check . . . Removal and Installation . . . . . . . can lead to personal injuryordeathtoservicepersonnel(frominadvertentfiringoftheairbag)ortothedriverandpassenger(fromrendering the SRS inoperative). before beginning any service or maintenance of anycomponent of the SRS or any SRS-related component. . . . . . . . . . . . . . . . . . . SRS diagnosis unit. . . . . . . . . . . . . . . . . . <Turbo> . . . . . . . Evaporative Emission Canister . . . . . . 31 Cruise Control Cables Check and Adjustment . . 12 Harness and Component Layout . . air bag module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General Specifications . . . . 57 65 57 65 64 65 65 58 60 64 63 65 SPECIAL TOOLS . . . . . . . . . Purge Port Vacuum Check . . . . . NOTE The SRS includes the following components: impact sensors. . . . . 7 SPECIFICATIONS . . Engine Coolant Temperature Sensor and intake Air Temperature Sensor . . . . . . . . . . . Purge Control Valve <Turbo> . . . . . . . . . 6 l ~ ~ m EMISSION CONTROL SYSTEM . . . . . . . . . . . . 6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Troubleshooting Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . 8 CONTINUED ON NEXT PAGE WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS. . . . . . . . . . . . . . or any SRS-related component. . . . . . . . . 38 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-I I ~ ENGINE AND. . . . . . . . . . . . . . . . Air Conditioning Switch . . . . EMISSION CONTROL CONTENTS CRUISE CONTROL SYSTEM . . . Purge Control System inspection <Non Turbo> . . . . . . . . . . . . . . . . . . . . 71 Inspection . . . . . . . . . . . 32 Individual Parts Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) MITSUBISHI dealer personnel must thoroughly review this manual. . . . . . .Supplemental Restraint System (SRS) and GROUP 00 -Maintenance Service. . . . . . 71 71 CRUISE CONTROL SYSTEM* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*). . Fuel Tank Filler Tube Cap Inspection .41 CATALYTIC CONVERTER . . . . . . . . . . . . Volume Air Flow Sensor. Component Location . . . . . . . . . and especially its GROUP 52B . . . 8 Check Chart . . . . . . . . . . . . . 34 EVAPORATIVE EMISSION CONTROL SYSTEM . . . Evaporative Emission Purge Solenoid . . . . . . . . . 6 Service Specifications . . . . . . . . . . . . . . .

. . . s . . Federal Non Turbo from 1996 model> . . . . . . . . . . . . _ . . Mixture Control (MFI) System . . . . . . . . . . . . . Vacuum Hoses Routing . . . . . . . . . . 56 Crankcase Ventilation System Inspection . . . . . . . . . . . . . . . . 41 VACUUM HOSES . . . . . . . . . . 4 Accelerator Cable Check and Adjustment . . . . . . 3 POSITIVE CRANKCASE VENTILATION SYSTEM . . . . . . . . . . 41 General Specifications . 66 ENGINE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . .Non Turbo. . . . . . . . . . . . . . . . . . . . . . . . 5 ON-VEHICLE SERVICE . 3 TROUBLESHOOTING . . . . . . . . . Federal Turbo 1994 and 1995 models> . . 4 Accelerator Switch Check and Adjustment (1992 models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 I ‘LJ ’ I SPECIFICATIONS . . . . . Federal . . . . . . . . . . . . . . . . . . . . 42 Inspection . . . . . . . EGR Valve <California . . . . . . . . . . . . . . . . . .Non Turbo. . . . . . . . . . Federal . . 3 ENGINE CONTROL . . . . . . . . . . . . . . _ 4 69 70 67 68 68 67 70 69 SPECIFICATIONS . . . . . . . . . . . . .Up to 1995 model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbo . .Non Turbo. . . . . . . . . . . . EGR Solenoid <Turbo> . . . . . . . . . . . . . .Non Turbo from 1996 model> . . . . . 56 Component Location . . . . . Turbo. . . . . . 56 Positive Crankcase Ventilation Valve . . . . 66 Component Location . . . . . . 55 55 47 42 . . . . . . . . . EGR Temperature Sensor <California up to 1995 model. . . . . . . . . . . . . . . . . . . . . 3 Accelerator Cable and Accelerator Pedal . Installation . . . . . . . . . . . . .Non Turbo. . . . . . . : . . Turbo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Circuit Diagram . EGR Solenoid <California . 3 Service Specifications . . . . . . Turbo. . . . . 41 41 TROUBLESHOOTING . . . . . . . . Service Specifications . . EGR Valve Control Vacuum Check <California . . .17-2 EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . Federal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Non Turbo from 1996 model> . . . . . . . . . . . . . . . Vacuum Control Valve <Non Turbo> . . . . . . . . . . . . . . . . . . .Non Turbo from 1996 model> . . . . . . . . . . . . . . EGR System Inspection <California . . . . . . . .

ENGINE AND EMISSION CONTROL .08) I ’ 3-5 (.04-.Engine Control System 17-3 ENGINE CONTROL SYSTEM SPECIFICATIONS SERVICE SPECIFICATIONS Items Accelerator cable play mm (in.20) TROUBLESHOOTING ACCELERATOR CABLE AND ACCELERATOR PEDAL Symptom Throttle valve will not fully open or close ProbabUe cause Misadjusted accelerator cable Misadjusted automatic speed-control cable Broken return spring Throttle lever malfunction Accelerator pedal operation not smooth (over acceleration) Accelerator pedal wrongly tightened Misinstalled accelerator cable Accelerator cable requires lubrication Remedy Adjust Adjust Replace Replace Repair Repair Lubricate or replace TSB Revision .12-.) I Standard value Ml-lI l-2 (.

refer to P. loosen the adjusting bolts. (3) Check to ensure that the inner cable play is within the standard limits.08-.there is no continuity between the terminals of the switch.12-. (2) Check to ensure that the throttle lever is in contact with the engine speed adjusting screw. ACCELERATOR SWITCH CHECK AND ADJUSTMENT (1992 models) Make sure that when the accelerator pedal is free.08 in.) If stroke A is out of specification.20 in.Engine Control System ON-VEHICLE SERVICE ACCELERATOR CABLE CHECK AND ADJUSTMENT For models equipped with the cruise control system.17-31.) Intake manifold (4) If the play is out of the standard limits. d (1) Check the accelerator cable for sharp bends. adjust with adjusting bolt.24 in. .17-4 ENGINE AND EMISSION CONTROL . Standard value: CM/T> l-2 mm (. Standard value: Accelerator switch switching point 2-6 mm (. and then retighten theadjusting bolts. there is continuity between the terminals of the accelerator switch and that when the pedal is pressed until the indicated pedal stroke A reaches the standard value.) <A/T> 3-5 mm (. slide the plate so that the inner cable play will fall within the standard limits. 00002425 1 TSB Revision -1 .04-.

10. / Operation ! 4 ft. Accelerator cable 5. Check the accelerator arm for bending. NOTE Split pin Accelerator arm Return spring Accelerator switch <A/T>* Accelerator arm stopper Bolt <A/T> Stopper l : Equipped on 1992 models only INSPECTION l l l l l l /’ L 1 TSB Revision Check the inner and outer cable for damage. Accelerator pedal 6. Spring 7. Check the connection of bushing to end metal fitting.li’-4. Bushing 4. <A/T> I .1 Accelerator Switch Adjustment ‘<AA> (Refer to f?17-4. i 5 15 07FOO22 00002428 Removal steps 1. 14. 12. 11. - 5 Nm 03K675 \ 10 Nm 7 ft. Accelerator arm bracket 9. Check the accelerator pedal switch for correct ON-OFF switching. Check the cable for smooth movement. 15.1b. Adjusting bolt 2.lbs.ENGINE AND EMISSION CONTROL .Engine Control System 17-5 ENGINE CONTROL REMOVAL AND INSTALLATION L Post-installation l l Accelerator Cable Adiustment (Refer to P. Throttle body side inner cable connection 3.s. Accelerator switch connector connection <AIT>* 8.lbs. 13.) 5 Nm 4 ft. Check the return spring for deterioration.

Cruise Control System CRUISE CONTROL SYSTEM SPECIFICATIONS GENERAL SPECIFICATIONS NOTE *l : Vehicles built up to April 1991.17-6 ENGINE AND EMISSION CONTROL . *2 : Vehicles built from May 1991~ SERVICE SPECIFICATIONS TSB Revision .

Cruise Control System 17-7 SPECIAL TOOLS Up to 1993 models Checking of the diagnostic output Checking of the diagnostic trouble code Checking of the diagnostic trouble code check harness i TSB Revision .ENGINE AND EMISSION CONTROL .

17-25.17-9.? J Basedonthediagnostictroublecode. if any. Or.” (Refer to P.) TSB Revision . ‘Cruise control cannot be set. (3) Check each of the cables for excessive play or tension. i Does the same problem occur again? No a temporary loose contact in the connector Check the diagnostic output. actuator and all cables and vacuum hoses are properly installed and that the cables and vacuum hoses are correctly routed. the cruise control system cannot be set after an automatic cancellation.) Refer to section on trouble symptoms. (Refer to P17-24. (1) Check that the vacuum pump assembly.Cruise Control System TROUBLESHOOTING PRELIMINARY INSPECTION Check the following points and repair defective points. (Refer to l?17-24.ENGINE AND EMISSION CONTROL .) No ---w Is the result of diagnostic output check O.K. Check the diagnostic output.checkthecircuitandindividual parts. TROUBLESHOOTING QUICK REFERENCE CHART Cruise control system is canceled when cancellation not wanted. (2) Check that the link assembly and all cables move smoothly.) Can cruise control be set at t / Set cruise control and perform driving test. before troubleshooting. link assembly. (Refer to P.

code No.17-19 position switch circuit position switch or repair harness.) NOTE This chart contains troubleshooting procedures to perform when a problem cannot be detected by onboard diagnostic. Even when RESUME switch is set to RESUME switch ON Replace control switch OFF.? No Check vacuum pump assembly circuit. 25 is not displayed even when vehicle speed is less than about 40 km/h (25 mph). code No.17-19 or repair harness. either.17-20 position switch or repair harness. Defective control unit Replace control unit. 23 is not. (Refer to P. 21 does not go away. replace the control unit. * (Refer to P. eMiT> Even when select lever is placed in any position other than “N” and “P”. 26 does not go away. Even when clutch pedal is released. Even when vehicle speed is increased to more than about 40 km/h (25 mph). 27 does not go away. Yes 4 Is the result of input check O. 23 does not go away. tion switch. 22 does not go away.17-13 P. Result of check None of the codes appear even if input operations are performed.17-13 switch circuit or repair harness.K.ENGINE AND EMISSION CONTROL . code No.17-12 repair harness.17-17.displayed. Open circuit in control Replace control switch P. code No. 1 17-9 Check input. Even when brake pedal is released. 26 does not go away. code No.17-13 /LJ Even when CANCEL switch is set to CANCEL switch ON Replace control switch.Replace the control P.) NOTE If the results of checks on the vacuum pump assembly circuit and actuator parts (refer to F!17-37. Check and repair vehicle speed sensor circuit. Code No. 25 does not go away. Defective stop switch circuit light Replace stop light switch P.Cruise Control System Cruise control system can not be set. - Even when SET switch is set to OFF. Remedy Reference page Replace main switch or P. 17-23 i TSB Revision . P. cA!T> Code No. Defective park/neutral position switch circuit Defective vehicle speed sensor circuit Replace park/neutral P. 24 is not displayed.) indicate that they are good.l7-26. malfunction P. Probable cause Open circuit in control unit power supply circuit. malfunction Even when brake pedal is depressed.l7-13 code No. Defective clutch pedal Replace clutch pedal P. code No. code No. OFF. SET switch ON malfunc.

Cruise Control System Probable cause Check chart No. speedometer cable or speedometer drive gear <Up to 1993 models (Non turbo)> Vacuum pump assembly No.5 circuit poor contact Malfunction of the vacuum pump assembly (including air leaks from negative pressure passage) Malfunction of the ECU - Repair the actuator systern. Repair the harness or relace the vacuum pump The cruise control system is not Brake switch (for cruise No. (short-circuit) drive circuit short-circuit [It is canceled. disconnected wiring of control switch input circuit Vacuum pump assembly No. or replace the part. Repair the harness or replace the stop light switch. when the xake pedal is depressed. Repair the harness or replace the vacuum pump assembly. speed sensor circuit “Hunting” (repeated alternating the acceleration and deceleration) Malfunction Of occurs after setting is made.4 Remedy Repair the vehicle speed sensor system.) brake pedal is depressed. No. Replace the ECU. however. or replace the part. Trouble symptom l l The set vehicle speed varies Malfunction of the vehicle greatly upward or downward.) SET switch.1740 ENGINE AND EMISSION CONTROL .6 canceled when the brake pedal is control) malfunction depressed. Replace the ECU. NOTE ECU: Electronic control unit 1 TSB Revision I .5 circuit poor contact Malfunction of the vacuurn pump assembly Malfunction of the ECU - Repair the harness or replace the control switch.

<A/T> Repair the harness or replace the part.No. Repair the harness or replace the main switch.2 Malfunction of the ECU - I>ressed.driving. cruise control is not can(:eled (Cruise control. 27 indicates switch control switch a malfunction.No.) Malfunction of circuit reto lated accelerator switch OFF function Malfunction of the ECU No. . - Replace the ECU.5 circuit poor contact Malfunction of the vacuurn pump assembly (including air leaks from negative pressure passage) Malfunction of the ECU IEven when CANCEL switch is 1to ON.4 ! set while traveling at a vehicle hicle-speed sensor circuit !speed of less than 40 km/h (25 the mph). 10 Repair the harness or replace the part. (Zruise control ON indicator light Burned-out indicator light No. however.Malfunction of speedometer cable or the cellation at that speed. or there is no automatic can. 11 No.Cruise Control Svstem Trouble symptom Probable cause Check chart No. bulb (:ruise control is functional. etc. TSB Revision . (:Non-operation of damper clutch. LI / The cruise control system can be Malfunction of the ve. (However. No. Overdrive is not canceled during Malfunction of circuit reIixed speed driving <A/T> lated to overdrive cancellation. is (zanceled when brake pedal is de- control Repair the harness or replace the vacuum pump assembly.) Open or short circuit in harness IMalfunction of control function by (3N/OFF switching of ELC 4 AIT ac(:elerator switch. the control set Open or short circuit in If the input check Replace CANCEL switch circuit in code No.!nd gear hold. control switch Vacuum pump assembly No. the 17-11 L Cannot accelerate or resume Open or shot-t circuit in No. or replace the part. Remedy Replace switch. or malfunction No shift to overdrive during manual of ECU . Repair the harness or replace the light bulb. 2 speed by using the RESUME RESUME switch circuit in switch. The cruise control indicator light of Damaged or discon.3 1the combination meter does not illu.netted bulb of indicator Iminate.3 (joes not come on. speedometer drive gear <Up to 1993 models (Non turbo)> Malfunction of the ECU - Replace the ECU. (But cruise control system light Iis normal) Harness damaged or disconnected Malfunction of the ECU - Replace the ECU.ENGINE AND EMISSION CONTROL .) Replace the ECU Repair the vehicle speed sensor system.

but relay Ryl stays in the OFF state. it automatically returns to the neutral position.----“O. When the ignition switch is set to OFF while relay Ryt in the main switch is ON. Accordingly. the contact of relay Ryl is closed and the power is supplied to the control uhit. When the main switch is released. relay Ryl stays in the OFF state until the main switch is set to ON. 4. the contact of relay Ryl remains closed. current to relay Ryl is interrupted. the current from switch S1 flows through relay Ry.Cruise Control System CHECK CHART 1 inspection of control unit power supply circuit b f$psE IGNITION SWITCH(IG1) I ERUISE ONTKJL MAIN SW ITCH m DHD GND VP 1 . relay Ryl is forced to the OFF state just ‘like when the main switch is set to OFF.17-12 ENGINE AND EMISSION CONTROL . Even if the ignition switch is set to ON again. I . GND a 14 6 m I m I m I DESCRIPTION OF OPERATION The power is supplied through the ignition switch (IG. NOTE The numbers beside each connector correspond to those in the section (P.) and cruise control main switch to the control unit. it automatically returns to the neutral position. in the switch. When the main switch is set to OFF. 2. 1. 3. When the cruise control main switch is set to ON with the ignition switch at ON. This opens the con1 TSB Revision tact of relay Ryt to stop the power supply to the control unit._.17-28) “HARNESS AND COMPONENTS LAYOUT’. Since the current from switch S2 flows to relay Ryl. When the switch is released.

ENGINE AND EMISSION CONTROL .14 16 Control unit ground Control unit back up power supply At all times At all times ov Battery positive voltage I * Inspection of control switch circuit I IGNITION SWITCH(ACC) I CLOCK SPRING CRUISE ~~~~~L %i. to KXJI-AK-Rt501-N 12~From 1 9 9 3 mooels 1 9 9 4 mode!5 TSB Revision . 2 Signal name Control unit power supply Condition Main switch ON and neutral position thereafter Terminal voltage Battery positive voltage Main switch OFF and neutral position 0 V thereafter 8.Cruise Control @stem TROUBLESHOOTING HINTS ECU terminal voltage Terminal No.

the vehicle starts cruising at the speed. RESUME and CANCEL switches are integrated. Therefore. (However. the engine accelerates. different resistance values are used for the individual switches to change the outputs (voltages) to the control unit. 3. If the RESUME switch is kept at ON during cruise operation. *2: Vehicles built from May 1991. the vehicle resumes cruising at the speed set before the cancellation.17-14 ENGINE AND EMISSION CONTROL . the vehicle will not resume cruising at the previously set speed even if the RESUME switch is set to ON. NOTE *l: Vehicles built up to April 1991.Cruise Control System to OFF and when the vehicle speed is reduced to less than 40 km/h (25 mph). Both when the main switch is set TROUBLESHOOTING HINTS Diagnosis No. 15 (Automatically canceled) ECU terminal voltage I I Terminal No. 200 km/h (124 mph)*2. the vehicle coasts. CANCEL switch When the CANCEL switch is set to ON during cruise operation. 18 I Signal name Control switch I . 1. if the SET switch is set to ON while vehicle speed is within a range from about 40 to 145 km/h (25 to 90 mph)*‘. RESUME switch Even if cruise operation is canceled. and starts cruising at the speed reached when the SET switch is set to OFF. 4 of J/B and through the control switch to the control unit. 200 km/h (124 mph)*2. Current flows through fuse No. \ Condition When all switches are OFF When SET switch is ON When RESUME switch is ON When CANCEL switch is ON ov 3v Terminal voltage d 6V Battery positive voltage 1TSB Revision . 2. 40 to 200 km/h (25 to 124 mph)*2. If the SET switch is kept at ON during cruise operation. the vehicle cruises at approximately 145 km/h (90 mph)*‘. the cancel signal is input to the control unit which internally interrupts the power supply to the vacuum pump assembly for cancellation of cruise operation. and the vehicle starts cruising at the speed reached when the RESUME switch was set to OFF. when the vehicle speed is raised to more than 145 km/h (90 mph)*‘. I \ d DESCRIPTION OF OPERATION The control switch is a switch in which the SET. SET switch When the cruise control switch is ON.

23 Signal name Cruise control (CRUISE) indicator light 2. TROUBLESHOOTING HINTS ECU terminal voltage Terminal No. transistor Trl in the control unit is kept in the ON state to keep the indicator light on. it lights as soon as the main switch is set to ON. L 3 Inspection of indicator light circuit $t$ROL IGNI' WITI l&m f$#ATION 1Ii :1’: Ij 0 & -: Trl i8 i L CRUISE ? CONTROL UNIT DESCRIPTION OF OPERATION 1. Cruise control ON (ASC ON) indicator light Located in the combination meter.Cruise Control System 17-15 . Condition When cruise control is active When cruise control is inactive ov Terminal voltage Battery positive voltage 1 TSB Revision .ENGINE AND EMISSION CONTROL . Cruise control (CRUISE) indicator light During cruise control operation.

delivers pulse signals proportional to the rotational speed of the transmission output gear (vehicle speed) to the control unit.17-16 4 ENGINE AND EMISSION CONTROL .). 19 Signal name Vehicle speed sensor <Up to 1993 models (NON-TURBO)> The vehicle speed sensor is a reed switch type and is mounted in the speedometer. (Four pulse signals generated per rotation of the output gear) Since the vehicle speed sensor is of the electronic type.6 V ++ 2 V or more (Flashing) TSB Revision . mounted in the transmission. It sends pulse signals proportional to the rotational speed of the transmission output gear (vehicle speed) to the control unit. (Four pulse signals generated per rotation of the output gear) Condition Slowly drive forward with SELECT lever at “D” or “1 st Speed” Terminal voltage 0 to 0. 12 (Automatically canceled) ECU terminal voltage Terminal No. the power is supplied through the ignition switch (IG.Cruise Control System Inspection of vehicle speed sensor circuit <Up to 1993 models (TURBO) and From 1994 models> IGNITION cup to 1993 models (NON-TURBO)> T 5” El CRUISE %FL Kxs5-AK-R13¶¶ DESCRIPTION OF OPERATION <Up to 1993 models (TURBO) and From 1994 models> The vehicle speed sensor. TROUBLESHOOTING HINTS Diagnosis No.

...... id TSB Revision .Cruise Control System 17-17 I ~ I 5 Inspection of vacuum pump assembly drive circuit LJ Lp s r.13 V 112 V 23 ULW-AI-RlsW-YI NO :&O~“.ENGINE AND EMISSION CONTROL ..48P3d~~~b~~ ...*114 21 ‘I 126 V J.

11 (Automatically canceled) ECU terminal voltage Terminal No. 12 13 r- 26 25 TSB Revision . Accordingly. the power supply to the vacuum pump assembly is cut off. When the brake pedal is depressed during cruise control operation.17-18 ENGINE AND EMISSION CONTROL -‘Cruise Control System DESCRIPTION OF OPERATION The input signal from the control switch causes transistor Trt to be ON. and two solenoid valves (control valve and relief valve) and is controlled by the control unit as shown in the following table. (ON: Current flows) (OFF: No current flows) TROUBLESHOOTING HINTS Diagnosis No. the cruise control relay is placed in the ON state to supply power to the vacuum pump assembly. The vacuum pump assembly consists of a diaphragm type negative pressure pump that is driven by a DC motor.

(Refer to P.Cruise Control System 6 Inspection of stop light switch circuit 17-19 ~ FUSIBLE LINK@ DESCRIPTION OF OPERATION When the brake pedal is depressed during vehicle speed control. As a result. the stoplight (NO) contact is closed.ENGINE AND EMISSION CONTROL . a cancel signal is input to the control unit which internally interrupts the vacuum pump assembly drive circuit. a cancel signal is input to the control unit which internally interrupts the power supply to the vacuum pump assembly drive circuit for cancellation of vehicle speed control. the contact of the clutch pedal position switch is closed. the cruise control (NC) contact of the stop light switch is opened to interrupt the power supply to the vacuum pump assembly for cancellation of vehicle speed control.S-AX-RlSOA-N 7 Inspection of clutch pedal position switch circuit <Mm DESCRIPTION OF OPERATION When the clutch pedal is depressed during vehicle speed control.17-17. TROUBLESHOOTING HINTS ECU terminal voltage Terminal No. 15 Signal name Stop light switch Condition When brake pedal is depressed When brake pedal is not depressed Terminal voltage Battery positive voltage 0V K. TROUBLESHOOTING HINTS ECU terminal voltage Terminal No. As a result. 1 Terminal voltage Clutch pedal When clutch pedal 0 V position is depressed switch When clutch pedal Battery positive is not depressed voltage Signal name / Condition c ItXSN-AR-lllSOT1 2 I 1 TSB Revision .G.) At the same time.

1 Signal name Park/neutral position switch which internally interrupts the power supply to the vacuum pump assembly drive circuit for cancellation of vehicle speed. When the gear selector lever is placed in the “N” position during vehicle speed control. a cancel signal is input to the control unit TROUBLESHOOTING HINTS ECU terminal voltage Terminal No.Cruise Control System Inspection of park/neutral position switch circuit <A/T> STARTER - KX35-AK-R1307 NOTE :I 1993 MODEL :2 1992 MODEL DESCRIPTION OF OPERATION The park/neutral position switch is interlocked with the starter switch.17-20 8 ENGINE AND EMISSION CONTROL . ‘Z”. Condition Park/neutral position switch in “N” or “P” position Park/neutral position switch in “II”. “L” or “R” position 0V Terminal voltage Battery positive voltage TSB Revision .

17 (Not automatically canceled) ECU terminal voltage Terminal No.72 V 4. 1995 MODELS (TURBO. 1995 MODELS (NON TURBO .48 -0. regarding the opening of the accelerator.is depressed When accelerator pedal is not depressed ov Terminal voltage 4. Condition When accelerator pedal . The closed throttle position switch inputs the data to the control unit on whether or not the accelerator pedal is operated.5 v 5 Throttle position sensor During idle When fully opened TSB Revision . The throttle position sensor sends data to the control TROUBLESHOOTING HINTS Diagnosis No.Cruise Control System 17-21 I I ~ ~ I I g Inspection of throttle position sensor circuit CRUlSE CONTROL UNIT i KXJS-AK-RIJOI-N4Y NOTE *I: UP TO 1993 MODELS AND 1994. NON TURBO CALIFORNIA) AND 1996 MODELS DESCRIPTION OF OPERATION The throttle position sensor (with built-in closed throttle position switch) is used for engine control as well as cruise control.0-5.ENGINE AND EMISSION CONTROL .5 v 0.FEDERAL) l 2: 1994.5-5. 4 Signal name Closed throttle position switch unit.

creating the same state as when the accelerator pedal switch is placed in the OFF state.3 I DESCRIPTION OF OPERATION The accelerator pedal switch is used to detect the operating state of the accelerator pedal. Accelerator pedal switch TSB Revision . It is one of the sensors of the ELC-4A/T automatic transmission. Since the accelerator pedal is not operated TROUBLESHOOTING HINTS ECU terminal voltage during vehicle speed control. 0 J f . the cruise control unit forces transistor Tr1 into the OFF state.17-22 10 ENGINE AND EMISSION CONTROL .2 c : 3 9-.Cruise Control System Inspection of circuit associated with accelerator pedal switch OFF function <A/T> (1992 models) IGNITION 'CH (I G2) J/E -TV-c?) 101I CAL "2 : 3 T '3 ? il.

if the actual vehicle speed falls more than about 7 km/h (4 mph) below the set vehicle speed TROUBLESHOOTING HINTS ECU terminal voltage Terminal No.S CRUISE CONTROL UN!. the cruise control unit forces transistor Tr. Signal name Condition When ignition switch is ON When overdrive mode is active I I Terminal voltage Battery positive voltage Battery positive voltage I OD signal control power supply ELC-4AiT control unit When overdrive mode is inactive / OD switch ) When OD switch is ON 1 When OD switch is OFF 0V 1 Battery positive voltage I ov I I TSB Revision .s tO :993 “lOOe. When the vehicle speed control is in the overdrive mode. into the OFF state.Cruise Control System 11 / i Inspection of circuits associated with overdrive cancel <A/T> 17-23 l ~ ELC-GA/T FECY$R"L i .ENGINE AND EMISSION CONTROL .j " 5 3 iKiT5 Xi:‘JD r2:crom 1 9 9 5 mooe. 3 10 I I or the RESUME switch is turned ON. This cancels the overdrive mode because no OD switch ON signal is input to the ELC-4A/T control unit. %X35-A%-R1304-N DESCRIPTION OF OPERATION On a vehicle with cruise control. the OD switch ON signal is input through the cruise control unit to the ELC-4A/T control unit.

use the adapter harness supplied together. 4) Temporarily place the main switch in the OFF position to let the control unit escape from the input check mode. all diagnostic trouble codes are stored and retained. to make sure that the problems encountered in the past can be checked.Cruise Control Svstem ON-BOARD DIAGNOSTIC CHECKING On-board diagnostic checking is performed when there has been an automatic cancellation. 2) With the SET switch in the ON state.0 second thereafter. 1) Place the ignition switch in the ON position. 3) With the SET switch in the ON state again. until the battery cable is disconnected. WHEN USING THE SCAN TOOL [MULTI-USE TESTER (MUT) <Up to 1993 models> OR MUT-II <All models>] (1) Connect the scan tool to the data-link connector to read out the diagnostic trouble codes When connecting the scan tool to a vehicle up to 1993 models.17-24 ENGINE AND EMISSION CONTROL . NOTE Even when the ignition key is placed in the OFF position. without cancel switch operation. Then place the main switch in the ON position again. keep the stop light switch in the ON state for more than 5 seconds. (2) Refer to the diagnostic chart and repair the defective point. set the main switch to ON. set the RESUME switch to ON. When using the MUT <Up to 1993 models> <From 1994 models> Control switch RESUME switch: Oh t 4 ’ 07FOO17 00002430 (3) Clear the diagnostic trouble codes by the following procedure. TSB Revision . Caution Turn off the ignition switch beforehand whenever the scan tool is connected or disconnected. In less than 1. 5) Check the diagnostic trouble code to verify that a normal code is output.

ENGINE AND EMISSION CONTROL . (5) Clear the diagnostic trouble codes in the same way as when a scan tool is used. (3) Read the diagnostic trouble code on the basis of the deflection of the pointer of the voltmeter. Observe the voltmeter pointer deflection to read out the diagnostic trouble codes. <From 1994 models> Connect a voltmeter to the diagnostic output terminal and the ground terminal of the data-link connector using the special tool. (2) Place the ignition switch in the ON position. 5 Vehicle speed signal system out of order 4 Control switch out of order (When SET or RESUME switch is kept in ON state c’ontinuously for more than 60 seconds) 16 Control unit out of order 2 17* n00002434 Throttle position sensor or closed throttle position switch out of order 9 TSB Revision . IA DIAGNOSIS DISPLAY PATTERNS AND CODES Code No.Cruise Control System WHEN USING THE VOLTMETER <Up to 1993 models> 17-25 L. (4) Refer to the diagnostic chart and repair the defective point. 2161'0246 (1) Connect an analog voltmeter across the diagnostic output terminal and ground terminal of the data link connector. 11 i 12 n The same pattern repeatedly displayed Display patterns (output codes) (Use with voltmeter) Probable cause Vacuum pump assembly drive output system out of order Check chart No.-f- \.

When two or more input operations are performed simultaneously. 2. the diagnostic trouble code is displayed as described below. When two or more problems occur simultaneously. 2.17-26 Normal code ENGINE AND EMISSION CONTROL .Cruise Control System NOTE 1. 3. 3. 13). (1) Connect a scan tool or a voltmeter to the data link connector. NOTE 1. Input check can be conducted by set operations. confirm diagnostic trouble code first and conduct input check. In less than 1. 2.17-12. 1) If a scan tool is used: “No abnormality” will be displayed. the cruise control mode will not be canceled. Then the input check results can be displayed. If inspection of on-board diagnostic is necessary. (Refer to the illustration at the left. Perform checks using the following procedures.5 second intervals. I 1 TSB Revision . If no code is output by performing any of the input operations. set the RESUME switch to ON. (2) Calling up a code 1) Set the ignition switch to ON. NOTE Connect a voltmeter using the same procedure as for inspection of diagnostic output. set the main switch to ON. On-board diagnostic terminal outputs display patterns.) INPUT CHECKING Input checks should be made when the cruise control system cannot be set and when it is necessary to check (when a malfunction related to the cruise control system occurs) whether or not the input signals are normal. Id c---- T12A0104 - d 07FOO17 00002431 (3) Reading a code’ 1) Perform the individual input operations according to the input check table and read the codes. Display codes are displayed only if the circuit is normal according to the conditions shown in the table on the next page. Even if the problem represented by the code number marked * occurs during cruise control operation. all the associated code numbers are output in ascending order. the control unit power supply circuit or SET and RESUME switches are probably defective. 2) If a voltmeter is used: Continuous ON/OFF signals will be displayed at 0. d Check the check tables 1 and 2 (P. When the system is normal. 1 NOTE 1. 2) With the SET switch in the ON state.0 second thereafter. the three latest code numbers are displayed in the order of lowest code number first.

5 V or more Throttle position sensor circuit (Accelerator pedal depressed normal more than half the way) Closed throttle position switch Closed throttle position switch OFF (Accelerator pedal de. 40 km/h (25 mph) Stop light switch circuit normal 24 Vehicle speed sensor circuit normal if code Nos.circuit normal pressed) 29 00002432 2) Set main switch to OFF. 24 and 25 are displayed 25 26 M/T Clutch pedal position Clutch pedal position switch switch ON (clutch pedal circuit normal depressed) A/T Park/neutral position Park/neutral position switch switch ON (SELECT le.ENGINE AND EMISSION CONTROL . TSB Revision .circuit normal ver placed in “N” position) CANCEL switch circuit normal i 27 CANCEL switch ON 28 TPS output voltage 1.Cruise Control System INPUT CHECK TABLE 17-27 / L Code No. 40 km/h (25 mph) Vehicle speed less than approx. 21 Display patterns (output codes) (use with voltmeter) n Input operation SET switch ON Check results SET switch circuit normal RESUME switch ON RESUME switch normal 23 Stop light switch ON (brake pedal depressed) Vehicle speed more than approx.

Cruise Control System I HARNESS AND COMPONENT LAYOUT ENGINE COMPARTMENT a n 01 \ \ 16FO256 Engine front view Engine rear view 36FOO60 16FO175 INSTRUMENT PANEL AND FLOOR CONSOLE 01 02 03 04 05 06 07 08 09 Jumper connector Vacuum pump Throttle position sensor Park/neutral position switch <A/T> Vehicle speed sensor Combination meter Combination meter Combination meter Main switch NOTE ‘1 1992 model l 2 From 1993 model 36FOO17 00002433 TSB Revision .17-28 ENGINE AND EMISSION CONTROL .

16. TSB Revision . 11.__ . 13. Front wiring harness and junction block combination 19. Front wiring harness and junction block combination 10. Body wiring harness (LH) and junction block combination 23. Body wiring harness (LH) and junction block combination 22. Adapter wiring harness and junction block combination 21.. 20.Cruise Control System DASH PANEL 17-29 .17 16’ Z36FOO12 00002435 23 36FOOO2 36FOOO3 Clutch pedal position switch <M/T> Stop light switch Clock spring Accelerator pedal switch CA/T>* Cruise control relay Over drive switch CA/T> Cruise control unit Front wiring harness and junction block combination 18..----------.__.-Junction block JUNCTION BLOCK Front side Rear side illf !’ -- . 12._. Body wiring harness (LH) and junction block combination NOTE l : Equipped on 1992 models only. 15. 14.___ -. 17.ENGINE AND EMISSION CONTROL .

-+ f--J Ii c\ I 2=%iFc259 I-/ +--T 1 TSB Revision .Cruise Control System LOCATION OF CONTROL UNIT AND RELAY Engine control module L&264 216FO204 control unit 216FO396 / GROUND POINT A -.17-30 ENGINE AND EMISSION CONTROL .

ENGINE AND EMISSION CONTROL . cruise control cable and throttle cable are routed without sharp bends. lights and other switches to OFF for inspection at no load. 1) Remove the link protector. (7) Check the free travel state of the inner cables of the accelerator cable. cruise control cable and throttle cable. 2) Loosen the adjusting and lock nuts of the throttle lever and intermediate links A. (5) Check that the accelerator cable. (8) If the inner cables are too loose or have no free travel at all. (4) Stop the engine and set the ignition switch to OFF. (6) Depress the accelerator pedal to check that the throttle lever moves smoothly from the fully-closed to fully-opened position.valve Z07N0004 I \\\ I (1) Set the air conditioning.Cruise Control System 17-31 ON-VEHICLE SERVICE 1 L CRUISE CONTROL CABLES CHECK AND ADJUSTMENT Cruise control actuator Adjusting nut A Cruise control assembly Link B Link A Adjusting nut B . I TSB Revision ~~~ 1 . (2) Let the engine warm up until it runs at idle. (3) Check that the idle speed is within the specified range.LA. B and C to place the throttle lever and intermediate links A. rulse control cable Adjusting nut C Throttle cable Accelerator cable -- Throttle. B and C in the free state. check using the following procedure.

/ TSB Revision I . Amount adjusting nut B is to be backed off: About one turn [inner cable free travel l-2 mm (.)] CM> About two turns [inner cable free travel 2-3 mm (. 4) Rotate intermediate link C in the direction shown until it is blocked by the stopper. and back off adjusting nut C the specified number of turns just before intermediate link C begins to move. \ 1 ’i)l Adjusting nut C 207N0019 Link B Link B lever Y07N0019 Adjusting nut A d Link B 207NOOlE CRUISE CONTROL SYSTEM CHECK CRUISE CONTROL MAIN SWITCH CHECK (1) Turn the ignition key to ON.17-32 ENGINE AND EMISSION CONTROL . back off adjusting nut B the specified number of turns.04-. turn down adjusting nut C in the direction that the free travel of the inner cable is reduced. Amount adjusting nut C is to be backed off: <M/T> About l/2 turn [inner cable free travel O-l mm (O-. 8) Secure the adjusting bolt of the intake manifold plenum. 6) Turn down adjusting nut B in the direction that the free travel of the inner cable of the throttle cable is reduced. 9) Turn down adjusting nut A in the direction that the free travel of the inner cable of the cruise control cable is reduced. At the position where the lever of intermediate link A is brought into contact with intermediate link B. At the position where the lever of intermediate link B is brought into contact with intermediate link C. Amount adjusting nut A is to be backed off: About one turn [inner cable free travel l-2 mm (.12 in.08 in. back off adjusting nut A the specified number of turns.)] 5) Secure the accelerator cable with the lock nut. (2) Check to be sure that the CRUfSE CONTROL ON indicator light within the combination meter illuminates when the main switch is switched ON.08 in. check to see that the end of the engine speed adjusting screw is in contact with the stopper of the throttle lever.04-.Cruise Control System 3) Set the ignition switch to ON (do not start the engine).)] 10) Secure the cruise control cable with the lock nut.08-.)] 7) Secure the throttle cable with the lock nut.04 in. 11) After adjustment.

(SET switch: ON) (3) Check to be sure that deceleration continues while the switch is held. *I: Vehicles built up to April 1991 [:I *2: Vehicles built from May 1991 SPEED-INCREASE SElTING CHECK (1) Set to the desired speed. (2) Operate the control switch downward. NOTE When the vehicle speed reaches the low limit [approximately 40 km/h (25 mph)] during deceleration. <A/T> TSB Revision . the cruise control will be cancelled. (2) Drive at the desired speed within the range of approximately 40-145 km/h (25-90 mph)*‘. (SET switch: ON) (4) Check to be sure that the speed is the desired constant speed when the switch is released. (3) Operate the control switch downward. the cruise control will be cancelled. (2) In the cruising condition of the cruise control mode. the normal drive mode is restored and the vehicle coasts smoothly. (CANCEL switch: ON) 2) Depress the brake pedal.cruise control. the set speed (“memo-rized speed”) will become the high limit of the vehicle speed.ENGINE AND EMISSION CONTROL . the vehicle speed reaches or exceeds the high limit. during acceleration. Control switch SET ON Control switch \ CANCEL: ON VO7FOO17 SPEED REDUCTION SETTING CHECK (1) Set to the desired speed. NOTE (1) If the vehicle speed decreases to approximately 15 km/h (9 mph) below the set speed.Cruise Control System -8 17-33 i Control switch \ CRUISE CONTROL SETTING CHECK (1) Switch ON the main switch. however. acceleration will continue. 40-200 km/h (25-124 mph)*2. check that when any of the following operations are performed. 3) Depress the clutch pedal. 1) Move the control switch toward you. and that when it is released the constant speed at the time when it was released becomes the driving speed. (2) Operate the control switch upward. when the switch is released. CM/T> 4) Place the gear selector lever in the N range. because of climbing a hill for example. (RESUME switch: ON) (3) Check to be sure that acceleration continues while the switch is held. CRUISE CONTROL CANCELLATION AND SET SPEED RESUME CHECK (1) Set. and also check to be sure that the CRUISE indicator light (within the combination meter) illuminates. and that when it is released the constant speed at the time when it was released becomes the driving speed. NOTE Even if.

the battery voltage available across terminal (1) and the ground is reduced to 0 V. check that when the control switch is moved upward (RESUME switch: ON).Cruise Control System (3) With the vehicle at a speed of more than about 40 km/h (25 mph). the vehicle resumes cruising at the speed held before cancellation of the cruise control mode. 00002433 TSB Revision . (2) Remove the main switch from the switch garnish.17-34 ENGINE AND EMISSION CONTROL . (4) In the cruise control mode. (3) Operate the main switch and check for continuitv across the individual terminals. the normal drive mode is restored and the vehicle coasts smoothly. XO7FOOl’ INDIVIDUAL PARTS CHECK CRUISE CONTROL MAIN SWITCH CHECK (1) Remove the main switch together with the switch garnish. check that when the main switch is set to OFF. NOTE ILL: Illumination light ZO7FOOlO (4) Connect a positive lead from the battery to terminal (3) and a negative lead from the battery to terminal (4) and check that battery voltage is available across terminal (1) and the ground during the period the ON side of the main switch is pressed and during the period before the OFF side is pressed thereafter. Check that when the OFF side of the main switch is pressed thereafter.

RESUME: ON t &. force the lock outward and pry it with a plain screwdriver as shown at left so that no undue force will be exerted on the connector when it is removed.Cruise Control System 17-35 CRUISE CONTROL SWITCH CHECK (1) Remove the air bag module using the following procedure. 820 Q Approx. 0 52 Approx.4 00002439 1 TSB Revision . r \.ENGINE AND EMISSION CONTROL . 2. If the readings are as shown below. dry.. If an operation is performed during that given period.700 a I SET ON 07FOO12 I When switch is operated toward you (CANCEL switch: ON) When switch is operated upward (RESUME switch: ON) When switch is operated downward 1 (SET switch: ON) - 1 Z07N00. CANCEL: ON 4 (2) Disconnect the connector of the control switch and operate the control switch to measure the resistance between the individual terminals. To remove the clock spring connector (squib connector) from the air bag module. Caution The capacitor in the SRS diagnosis unit retains enough voltage to deploy the air bag for a given period even after disconnection of the battery. unintended deployment of the air bag could result and cause serious injury. Switch operation When switch is not operated Resistance between terminals No continuity Approx. the control switch may be considered good. flat place with the pad side up. 2) Remove the air bag module. 3) The removed air bag module should be stored in a clean. 1) Remove the negative terminal of the battery and wait for more than 60 seconds.

b--+--I I I For brake switch terminal 1 4 For stop light switch terminal 2 3 I I .. ZTFAOlE VEHICLE SPEED SENSOR CHECK cup to 1993 models (Non Turbo)> Use circuit tester to check circuit repeats off/on between terminals when speedometer shaft turned several times.Cruise Control System STOP LIGHT SWITCH/BRAKE SWITCH CHECK (1) Disconnect the connector. (One revolution is four pulses. and that there is no continuity when the pedal is released. (2) Use a voltmeter to check for voltage at terminals (2) and (3) when the pulse generator shaft is turning.1 <Up to 1993 models (Turbo) and From 1994 models> (1) Remove the vehicle’s speed sensor and connect as shown in the illustration. (2) Check that there is continuity between the terminals when the clutch pedal is depressed. (3) From 1993 models. When brake pedal not derxessed. 2141014. Resistance 3-10 kQ Voltmeter Battery Z1aR0213 000024. I --vLJ 1992 model From 1993 model -m.) TSB Revision . (2) On 1992 models. N PARK/NEUTRAL POSITION SWITCH (“N” POSITION) CHECK <A/T> (1) Disconnect the connector. 00002440 CLUTCH PEDAL POSITION SWITCH CHECK <M/T> (1) Disconnect the connector. Measurement conditions When brake pedal depressed. using a 3-10 kS2 resistance.17-36 ENGINE AND EMISSION CONTROL . check to be sure that there is continuity between connector terminals (8) and (9) when the shift lever is moved to the “N” range. (2) Check for continuity between the terminals of the switch. check to be sure that there is continuity between connector terminal (8) and (7) when the shift lever is moved to the “N” range.

refer to GROUP 13A . Inspection of Motor (1) Disconnect the connector of the vacuum pump assembly.ENGINE AND EMISSION CONTROL . (2) Measure the resistance values across terminals (1) and (2) and across terminals (1) and (3).17-31. Retain the negative pressure in that state to check that the holder portion does not change its position. 07AOO51 VACUUM PUMP INSPECTION Inspection of Solenoid Valves (Control and Relief Valves) (1) Disconnect the connector of the vacuum pump assembly. Check for continuity across the terminals. refer to GROUP 13A . the motor operates. (2) Using a vacuum pump. apply a negative pressure to the actuator to check that the holder portion moves more than 35 mm (1.On-Vehicle Inspection of MFI Components. (Refer to P. (2) Check that when the battery voltage is applied across terminals (1) and (4). (3) After the actuator has been mounted.Cruise Control System 17-37 THROTTLE POSITION SENSOR INSPECTION For inspection. replace the vacuum pump assembly.4 in.On-Vehicle Inspection of MFI Components. Standard value: 50-60 Q (3) Check that when the battery voltage is applied across terminals (1) and (2) and across terminals (1) and (3) the operating sounds of the solenoid valves are heard.# 2 is supplied When no power is supplied Across terminals l-3 Across terminals 1-3 Across terminals 2-4 Continuity No continuity Continuity TSB Revision . (2) Apply battery power to terminal (2) and connect terminal (4) to the ground.) 207A005. (4) If the solenoid valves are defective. 2 3 4 207A0050 00002442 ACTUATOR INSPECTION (1) Remove the actuator. !--’ 4 I CRUISE CONTROL RELAY INSPECTION (1) Remove the cruise control relay.). CLOSED THROlTLE POSITION SWITCH INSPECTION For inspection. When power i. check and adjust the cruise control cable.

Vacuum pump connector . Link assembly and vacuum pump 8.) 8 11 07FOO31 00002444 Actuator removal steps 1. Cruise control cable and actuator connection 18.wiorose and vacuum pump 7. Throttle cable and throttle body connection 15.17-38 ENGINE AND EMISSION CONTROL .17-31. Link assembly 11. Link bracket 12. Vacuum pump 9. Cruise control cable and link assembly connection 4.Cruise Control System CRUISE CONTROL SYSTEM REMOVAL AND INSTALLATION Post-installation Operation 0 Cruise Control Cables Adjustment (Refer to R.x. Actuator bracket TSB Revision . Actuator 19. Accelerator cable and link assembly connection 3. Pump bracket 10. Throttle cable and link assembly connection 5. Accelerator cable and accelerator pedal connection 13. $w. Accelerator cable 14. Actuator and actuator bracket 17. Throttle cable 16. Link protector 2.A4 6.

lbs.Cruise Control System 17-39 1. Switch garnish 24. 07FOO27 27 n6FO396 I 07FOO28 00002445 Control switches removal steps 20.2ft. Cowl side trim (R. Air bag module bracket 22. Air bag module (Refer to GROUP 52B .) 21.) 26. Cruise control switch 23.6-2.) 27. Cruise control unit 28. Cruise control relay TSB Revision . Main switch Control unit and relay removal steps 25. Scuff plate (R.ENGINE AND EMISSION CONTROL .H.Air Bag Module and Clock Spring.H.

TSB Revision . Vehicle speed sensor <Non turbo>*2 (Refer to GROUP 54 .Cruise Control System 07FOO20 00002446 Sensors and switches removal steps 29.Meters and Gauges.individual Parts Inspection (P.) 34.17-34).17-40 ENGINE AND EMISSION CONTROL . Accelerator pedal switch*’ 31. Clutch pedal position switch <M/T> 33. INSPECTION OF INDIVIDUAL PARTS Refer to On-vehicle Service .) 35. Vehicle speed sensor*3 (Refer to GROUP 54 . Stop light switch 32. Throttle position sensor 30. Park/neutral position switch <A/T> !pTE Equipped on 1992 models only 1:’ Up to 1993 models : Up to 1993 models (Turbo) and From 1994 models INSTALLATION SERVICE POINT bAdVACUUM HOSE TO VACUUM PUMP CONNECTION Route the vacuum hose over the throttle cable and connect the hose to the vacuum pump so as to prevent the slackened hose from interfering with other parts.Meters and Gauges. Check the cable for smooth movement. Check the link protector for damage. INSPECTION l l l I Check the inner and outer cable for damage.

Non Turbo from 1994 model.Non Turbo.Non Turbo up to 1993 model. California . Federal .Emission Control Svstem 17-41 EMISSION CONTROL SYSTEM L SPECIFICATIONS GENERAL SPECIFICATIONS Items Positive crankcase ventilation system Evaporative emission control system Evaporative emission cEVAP> canister Evaporative emission cEVAP> purge solenoid <Up to 1995 models> Evaporative emission cEVAP> purge solenoid <From 1996 models> EGR valve <California . if there is a problem. Turbo> Exhaust gas recirculation EGR temperature sensor system . check its component parts Check the system.Non turbo UP to 1995 model> Location <Turbo. if there is a problem. Federal . if there is a problem.Non Turbo from 1996 model> I Specifications Closed type with positive crankcase ventilation valve I 1 Evaporative emission canister storage type ( Charcoal type ON/OFF solenoid valve Duty cycle type Vacuum-activated diaphragm type Thermistor type Duty cycle type solenoid valve I 1 Monolith type Under floor Right bank.Non Turbo. Turbo> Catalytic converter Location <California . Federal .ENGINE AND EMISSION CONTROL . check its component parts Check positive crankcase ventilation system Check the system. Left bank and underfloor SERVICE SPECIFICATIONS L Items Evaporative emission purge solenoid coil resistance Q EGR temperature sensor resistance cup to 1995 model> kQ EGR solenoid coil resistance Q Specifications 36-44 [at 20% (68”F)] 60-83 [at 50°C (122”F)] 11-14 [at 100°C (212”F)] 36-44 [at 20°C (68”F)] ‘ROUBLESHOOTING Symptom Engine will not start or hard to start / Probable cause Vacuum hose disconnected or damaged The EGR valve is not closed Malfunction of the evaporative emission purge solenoid Rough idle or engine stalls The EGR valve is not closed Vacuum hose disconnected or damaged Malfunction of the positive crankcase ventilation valve Malfunction of the purge control system Engine hesitates or poor acceleration Malfunction of the exhaust gas recirculation Positive crankcase ventilation line clogged Malfunction of the exhaust gas recirculation svstem / Remedy Repair or replace Repair or replace Repair or replace Repair or replace Repair or replace Replace Check the system. <California. check its component parts / L Excessive oil consumption Poor fuel mileage 1 TSB Revision .Turbo from 1994 model> ’ EGR solenoid <California .

Emission Control System VACUUM HOSES VACUUM HOSES ROUTING <Federal Non Turbo .1992 models> Evaoorativ!emkm purge solenoid AThrottle body L: Light blue R: R6d B: Black Fuel pressure regulator Vehicle front 7EM0131 <Federal Non Turbo .From 1993 up to 1995 models> Evaporative emission purge solenoid Evaporative emission canister Fuel pressure regulator L: Light blue R: Red B: Black / Vehicle front 7EM0285 7EMO 344 1 TSB Revision I .17-42 ENGINE AND EMISSION CONTROL .

- Evaporative emission canister Throttle body A ii Fuel pressure regulator Vehicle front 7EM0286 7EM0 345 G: Green Y: Yellow L: Light blue R: Red B: Black TSB Revision . ..ENGlNE AND EMISSION CONTROL .@ I LliLlIEvaporative v emission purge solenoid / FGR \.Emission Control System <California Non Turbo .1992 models> 17-43 I EGR solenoid / purge solenoid Evaporative emission canister G: Green Y: Yellow L: Light blue R: Red 8: Black Fuel prkssure regulator Vehicle front 7EM0132 <California Non Turbo .al\m b-n. . .a.From 1993 up to 1995 models> L EGR solenoid &$I..

1 TSB Revision .From 1996 models> Evaporative emission purge solenoid EGR solenoid / valve Evaporative emission canister Throttle body G: Green Y Yellow L: Light blue R: Red B: Black W: White Fuel pressure regulator Vehicle front 7F Ul815 .Emission Control System <Non Turbo .17-U ENGINE AND EMISSION CONTROL .

Emission Control System <Turbo .ENGINE AND EMISSION CONTROL .. blue B: Black W: White IfYJYgig.p vIront actuator Turbocharger 27EMOZSA 7EM0346 TSB Revision .From 1993 up to 1995 models> EGR valve 3cElII h/ Turbocharger EGR solenoid u Throttle body Bypass valve Purge valve c G: Green Y: Yellow k L$.Turbocharger Evapc xative emission purge solenoid Bypass valve / Fuel pressure regulator G Green Y: Yellow L: Light blue R: Red B: Black W: White Purge control valve Vehicle front I \ T u r b o c h a r g e r w a s tTurbocharger e ’ gate actuator L <Turbo .1992 models> L Fuel pressure solenoid EGR solenoid Turbocharger waste gate solenoid / Turbocharger waste k.

From 1996 models> EVAP purge solenoid C waste gate solenoid TC waste gate Turbocharger PUI I Ucil IJ’cJ”“U’~ r regulator Check valve G: Green Y: Yellow L: Light blue R: Red B: Black W: White Vehicle front actuator 1 TSB Revision 1 .Emission Control System <Turbo .IT-46 ENGINE AND EMISSION CONTROL .

..ENGINE AND EMISSION CONTROL .....1992 models> 17-47 b .z$\num Y ~ Throes .lntake. (. I To combustion chamber * From air cleaner \ Fuel pressure regulator = EVAP purge solenoid (ON: open) EVAP canister B: Black L: Light blue R: Red Z7EM0248 TSB Revision ....Emission Control System VACUUM CIRCUIT DIAGRAM <Federal Non Turbo ....

17-48 ENGINE AND EMISSION CONTROL .From 1993 up to 1995 models> Intake manifold plenum EVAP canister B: Black L: Light blue R: Red 27EM0287 1 TSB Revision .Emission Control System <Federal Non Turbo .

.ENGINE AND EMISSION CONTROL . : G G A EGR solenoid (ON: close) r EGR valve B: Black G: Green L: Light blue R: Red Y Yellow EVAP canister Z7EM0249 TSB Revision .: .Emission Control System <California Non Turbo .1992 models> Intake manifold plenum Throttle body 17-49 I To combustion chamber \ From air cleaner I (Y Fuel pressure t regulator - P1< .

From 1993 up to 1995 models> Intake.manifold plenum Throttle body \ To combustion chamber i 0 Fuel pressure regulator EVAP purge solenoid (ON: open) d B B: Black G: Green L: Light blue R: Red Y: Yellow EGR solenoid (ON: close) I EGR valve EVAP canister 27EM0288 TSB Revision .Emission Control Svstem <California Non Turbo .17-50 ENGINE AND EMISSION CONTROL .

I ENGINE AND EMISSION CONTROL .-a 1I wm17zi/imii~~~/ From noid e) Fuel pressure regulator EGR valve G: Green Y: Yellow L: Light blue 6: Red B: Black W: White 7EM0377 TSB Revision .From 1996 models> take/manifold plenum Jp .Emission Control System <Non Turbo . -.-I-To combustion chamber Throttle body 17-51 ~ .

1992 models> Throttle body To combustion chamber a Fuel pressure regulator TC waste gate solenoid (ON: open) Turbocharger bypass vah EGR valve Air cleaner EVAP purge solenoid (ON: close) .ao B Air intake hose (ON: close) EGR solenoid EVAP canister Z7EMO250 TSB Revision . 12.17-52 ENGINE AND EMISSION CONTROL .Emission Control System <Turbo .

Emission Control System <Turbo . Air cleaner cd EVAP purge solenoid (ON: close) Air intake hose EVAP canister Z7EM0251 TSB Revision .From 1993 up to 1995 models> Intake manifold plenum 17-53 1 LJ Throttle body ! To combustion chamber : : : Fuel pressure regulator tii? rn-I I e-n valve 1 W Turbocharger bypass valve I .ENGINE AND EMISSION CONTROL .

Emission Control System <Turbo . 1 I --IL Check valve EVAP canister 13 3 Fuel pressure regulator I Air cleaner EGR valve TC waste gate actuator <Front bank> $4==+$ +J 7EM0378 TC waste gate actuator <Rear banlo G: Green Y: Yellow L: Light blue R: Red B: Black W: White TSB Revision .From 1996 models> i .17-54 ENGINE AND EMISSION CONTROL . YTnifold plenum Throttle body \ To combustion chamber F1 m II.

INSTALLATION (1) When connecting a hose. connect the hoses correctly. etc.Emission Control System INSPECTION 17-55 (1) Referring to the VACUUM HOSES ROUTING. (2) Check the hoses for irregularities (disconnection. 1 TSB Revision . firmly press it onto the nipple. (2) Referring to the VACUUM HOSES ROUTING. confirm that the vacuum hoses are properly connected.ENGINE AND EMISSION CONTROL . looseness.) and confirm that there is no breakage or damage.

17-56 ENGINE AND EMISSION CONTROL . INSTALLATION Install the positive crankcase ventilation valve and tighten to specified torque. (3) If the plunger does not move. the positive crankcase ventilation valve is clogged.) Positive crankcase ventilation valve 27EM0109 1 TSB Revision . NOTE At this time. POSITIVE CRANKCASE VENTILATION VALVE INSPECTION (1) Remove the positive crankcase ventilation valve. (2) Insert a thin stick into the positive crankcase ventilation valve from the threaded side to check that the plunger moves. (3) If negative pressure is not felt.2 ft. Clean it or replace. put finger on the opening end of the positive crankcase ventilation valve. clean or replace the positive crankcase ventilation valve.Emission Control System POSITIVE CRANKCiSE VENTILATION SYSTEM COMPONENT LOCATION r- Name Symbol Positive crankcase ventilation valve 7EM0340 CRANKCASE VENTILATION SYSTEM INSPECTION (1) After disconnecting the ventilation hose from the positive crankcase ventilation valve. the plunger in the positive crankcase ventilation valve moves back and forth.lbs. Specified tightening torque: 10 Nm (7. disconnect the positive crankcase ventilation valve from the rocker cover. and check that the negative pressure of the intake manifold is felt with finger. (2) Idle engine. and reconnect the positive crankcase ventilation valve to the ventilation hose.

ENGINE AND EMISSION CONTROL .Emission Control System 17-57 EVAPORATIVE EMISSION CONTROL SYSTEM COMPONENT LOCATION Name Evaporative emission (EVAP) canister Evaporative emission (EVAP) purge solenoid Symbol C A Name Purge control valve <Turbo> Symbol B i TSB Revision .

Emission Control System PURGE CONTROL SYSTEM INSPECTION <Non Turbo . T T <Non Turbo .From 1993 up to 1995 models> Z7EM5289 Barometric pressure sensor intake air temperature sensor Engine coolant temperature sensor Volume air flow sensor Engine control module / Z7Eb.1992 models> body EVAP purge solenoid EVAP canister Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Engine control module Volume air flow sensor .17-58 ENGINE AND EMISSION CONTROL .40290 7EM0354 1 TSB Revision . MFI .

200 ft. .engine coolant temperature: 70°C (158°F) or higher Engine operating condition Idling Applying vacuum 3 7 5 mmHg (14.ENGINE AND EMISSION CONTROL .Hg) Result Vacuum is maintained I When engine is hot .) or higher.8 in.000 rpm after 375 mmHg three minutes have (14. or the intake air temperature is 50°C (122°F) or higher.000 mm Applying vacuum 375 mmHg (14. nected. check by appiying vacuum from a hand vacuum pump. d * MFI relay h s s 3 1 1 Barometric pressure sensor 7EM0379 (1) Disconnect the vacuum hose (red stripes) from the throttle body and connect it to a hand vacuum pump.8 in.Emission Control Svstem /<Non Turbo . after which it will leak*.engine coolant temperature: 60°C (140°F) or less /.Hg) Result Vacuum is maintained I 3. When engine is cold . / TSB Revision .Hg) elapsed after starting engine Vacuum leaks Vacuum will be maintained momentarily. L NOTE * I The vacuum will leak continuously if the altitude is 2.000 rpm within Try applying three minutes after vacuum starting engine 3. (3) Under the engine conditions shown below.8 in.i : 27EM0140] (2) Plug the nipple from which the vacuum hose is discon- I I Engine’operating condition Idling 3.200 m (7.From 1996 models> Throttle body 17-59 i Evaporative emission Engine control module Volume air flow sensor EvaDorative emission purge solenoid !+a.

Then. When engine is cold . and plug the air intake hose.1992 models> EVAP canister ‘d I Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Volume air flow sensor Engine control module ~ (1) Disconnect the purge air hose from the air intake hose.Hg) 3.8 in. / Vacuum is maintained / 375 mmHg Idling (14. or the intake air temperature is 50°C (122°F) or higher.200 m (7.Hg) Vacuum will be maintained momentarily.Vacuum leaks three minutes af. 3.8 in.) or higher.engine coolant temperature: 70% (158°F) or higher Engine operating Applying vacuum condition .000 rpm after 375 mmHg minutes three have elapsed after starting engine (14.Emission Control System PURGE CONTROL SYSTEM INSPECTION <Turbo . connect the hand vacuum pump to the purge air hose. NOTE *: The vacuum will leak continuously if the altitude is 2. check by applying vacuum from a hand vacuum pump. J’ TSB Revision 1 .000 mm Applying vacuum 375 mmHg (14.17-W ENGINE AND EMISSION CONTROL . .8 in.Hg) Result 1 Vacuum is maintained When engine is hot . (2) Under the engine conditions shown below.uum ter starting engine .200 ft. after which it will leak*.engine coolant temperature: 60°C (140°F) or less I \ ‘Lj ~ I I Engine operating condition Idling 3.000 rpm within Try applying vat.

^ 17-61 ‘WAD valve .8 in.rr. (3) Under the engine conditions shown below. When engine is cold .200 ft.ENGINE AND EMISSION CONTROL . i 1 TSB Revision I .Hg) Result Vacuum is maintained When engine is hot .. after which it will leak*..engine coolant temperature: 70°C (158°F) or higher I Engine operating condition Applying vacuum 1Vacuum leaks 3.Hg) three have elapsed after starting engine Vacuum will be maintained momentarily. .000 rpm after 375 mmHg minutes (14. (2) Plug the nipple from which the vacuum hose is disconnected.^I.200 m (7. or the intake air temperature is 50°C (122°F) or higher..000 mm within 1 Try applying three minutes af.vacuum ter starting engine 3.000 rpm Applying vacuum 375 mmHg (14. 0 LXLer Barometric pressure sensor ‘y$yenoid I V P A / I I/I% t t t Intake air temperature sensor 1 Engine coolant temperature sensor Volume air flow sensor t Enginecontrolmodule ZFXM0405 (1) Disconnect the vacuum hos e (red stripes) from the throttle body and connect it to a hana vacuum pump.) or higher.From 1993 up to 1995 models> rb.engine coolant temperature: 60°C (140°F) or less _---L \ Z7EM0140 1 Engine operating condition 3.8 in. NOTE *: The vacuum will leakcontinuously if the altitude is 2. Purge control +.Emission Control System PURGE CONTROL SYSTEM INSPECTION <Turbo . check by applying vacuum from a hand vacuum pump.

Then. connect the hand vacuum pump to the purge air hose. When engine ‘is hot .8 in. (3) Under the engine conditions shown below.engine coolant temperature: 70°C (158°F) or higher Applying vacuum 375 mmHg (14. check by applying vacuum from a hand vacuum pump.) Engine operating condition Idling Sudden racing Result Vacuum is maintained Vacuum leaks LJ PURGE CONTROL SYSTEM INSPECTION <Turbo . (6) Under the engine conditions shown below.Hg. and plug the air intake hose. (5) Disconnect the purge air hose from the air intake hose.From 1996 models> To air intake hose Purge c valve vaporative emission Engine control module Volume air flow sensor Engine coolant temperature sensor Intake air temperature sensor Barometric pressure sensor Throttle body ‘d (1) Disconnect the vacuum hose (red stripes) from the throttle body and connect it to a hand vacuum pump.Emission Control Svstem (4) Connect the vacuum hose (red stripes) removed in (1) above to P nipple of the throttle body as before.17-62 ENGINE AND EMISSION CONTROL . TSB Revision . check by applying vacuum from a hand vacuum pump. (2) Plug the nipple from which the vacuum hose is disconnected.

TSB Revision .Hg) Result Vacuum is maintained When engine is hot .8 in. <Non Turbo up to 1995 models. Engine speed (rpm) ) ZlFU L (2) Start the engine and check to see that. Turbo . NOTE If there is a problem with the change in vacuum.From 1993 up to 1995 models> Vacuum raises proportionately with the rise in engine speed.vacuum ter starting engine Result Vacuum leaks (4) Connect the vacuum hose (red stripes) removed in (1) above to P nipple of the throttle body as before.000 rpm within Try applying three minutes af. and plug the air intake hose. after raising the engine speed by racing the engine. e hose --_-_ . connect the hand vacuum pump to the purge air hose.Emission Control System 17-63 L When engine is cold .engine coolant temperature: 70°C (158°F) or higher Engine operating Applying vacuum condition 3.engine coolant temperature: 60°C (140°F) or less Engine operating condition 3. Then. it is possible that the throttle body purge port may be clogged and require cleaning.000 rpm Applying vacuum 375 mmHg (14.ENGINE AND EMISSION CONTROL . (5) Disconnect the purge air hose from the air intake hose. Vacuum ‘f. and check to see that vacuum leak is caused when performing a sudden racing.L/---I--_ ‘_C- PURGE PORT VACUUM CHECK Check Condition Engine coolant temperature: 80-95°C (176-205°F) (1) Disconnect the vacuum hose from the throttle body purge hose nipple and connect a hand vacuum pump to the nipple. (6) Apply vacuum in hot engine [coolant temperature: 70°C (158°F) or higher].

(1) Disconnect the vacuum hoses (non stripe and red stripe hose) from the solenoid.Hg. (4) Blow in air lightly from the canister side nipple and check conditions as follows. Vacuum I Engine speed (rpm) 3 Z3FU26i PURGE CONTROL VALVE <Turbo> INSPECTION (1) Remove the purge control valve.17-64 ENGINE AND EMISSION CONTROL .) airtightness. the red-striped vacuum hose was connected.From 1996 models.Hg. it is possible that the throttle body purge port may be clogged and require cleaning. mmHg in. Turbo . <Non Turbo> . TSB Revision .1992 and from 1996 models> Vacuum is kept constant regardless of the increased engine speed.. NOTE If there is no vacuum created.. Valve Jll (5) Connect a hand vacuum pump to the positive pressure nipple of the purge control valve. of the purge control valve.I-? IGL INSPECTION NOTE When disconnecting the vacuum hose. make an identification mark on it so that it can be reconnected to the original position. (2) Disconnect the harness connector from solenoid.EvaDorative emission 1 _-- \ 2=q-=y-Ey )!/ Fe-T-.) airtightness. mmHg in..Emission Control Svstem <Non Turbo .

MFI System Components. refer to GROUP 55 . FUEL TANK FILLER TUBE CAP INSPECTION Check the gasket of the fuel tank filler tube cap. for damage or deformation. Battery voltage Non-Turbo.From 1993 models When discontinued I Result Vacuum leaks Vacuum is maintained I ZECl510 Turbo .Air Conditioning Switch. AIR CONDITIONING SWITCH To inspect the air conditioning switch.Fuel Line and Vapor Line.1992 1 When applied models When discontinued 1I Vacuum is maintained Vacuum leaks (5) Measure the resistance between the terminals of the solenoid. 1 TSB Revision 1 . When applied Turbo . refer to GROUP 13F .Fuel Tank. Standard value: 36-44 Q [at 20°C (68”F)] 26EM137 VOLUME AIR FLOW SENSOR. FUEL TANK PRESSURE CONTROL VALVE To inspect the fuel tank pressure control valve. refer to GROUP 13A . refer to GROUP 13F . replace the cap if necessary. EVAPORATIVE EMISSION CANISTER To inspect the evaporative emission canister. and the fuel tank filler’cap itself.Emission Control System 17-65 r (4) Apply a vacuum and check for air tightness when voltage applied directly to the evaporative emission purge solenoid and when the voltage is discontinued.ENGINE AND EMISSION CONTROL . ENGINE COOLANT TEMPERATURE SENSOR AND INTAKE AIR TEMPERATURE SENSOR To inspect these parts.

Turbo. Federal -Turbo 1994 and 1995 model> Symbol S C Name EGR solenoid <California . Turbo. Federal .17-66 ENGINE AND EMISSION CONTROL .Non Turbo.up to 1995.Emission Control System EXHAUST GAS RECIRCULATION (EGR) SYSTEM COMPONENT LOCATION Name EGR valve <California .Non Turbo. Federal .Non Turbo from 1996 model> Symbol A TSB Revision .Non Turbo from 1996 model> EGR temperature sensor <California .

Turbo.ENGINE AND EMISSION CONTROL . and connect a hand vacuum pump through the three-way terminal. 4 Vacuum (2) Start the engine and check to see that. Normal state The negative pressure does not vary.Non Turbo. check the following two points: <Cold condition of engine> Engine operation Race the engine by rapidly press in the accelerator pedal. check that the engine stops or idles unstably. and connect the hand vacuum pump to the EGR valve.9 in. 100 mmHg (3.Non Turbo.Hg) or more.) is applied during idling. (3) Disconnect the three-way terminal.Hg.Non Turbo from 1996 model> (1) Disconnect the vacuum hose (green stripe) from the EGR valve. after raising the engine speed by racing the engine. Turbo. (4) When a negative pressure of 230 mmHg (9. vacuum -- EGR VALVE CONTROL VACUUM CHECK <California . (2) Regarding cold condition [coolant temperature: 20°C (68°F) or less] and warm condition [coolant temperature: 70°C (158°F) or more] of the engine. / / 2 1 FU446 TSB Revision . (Atmospheric pressure) <Warm condition of engine> Engine operation Normal state Race the engine by rapidly The negative pressure rises to press in the accelerator pedal. Federal . Federal .Emission Control System 17-67 EGR SYSTEM INSPECTION <California . cup to 1995 models> Vacuum raises proportionately with the rise in engine speed.1 in.Non Turbo from 1996 model> Check Condition Engine coolant temperature: 80-95°C (176-203°F) (1) Disconnect the vacuum hose from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple.

Hg.) or more Result Air does not blow through Air blows through INSTALLATION Install a new gasket and EGR valve. NOTE If there is a problem with the change in vacuum.Emission Control System <From 1996 models> Vacuum remains fairly constant. (4) Blow in air from one passage of the EGR to check condition as follows.Hg. Federal . Specified tightening torque: 11 Nm (8 ft.) and check air-tightness.) I d TSB Revision .8 in.1 in. etc. deposit of carbon. Specified tightening torque: 22 Nm (16 ft.lbs. Replace the EGR temperature sensor if there is a significant deviation from the standard value.Hg. Turbo. Temperature “C (OF) 50 (122) 1 100 (212) 1 @ 0 L. Federal . and then measure the resistance value between terminals 1 and 2 while increasing the water’s temperature.Turbo 1994 and 1995 model> INSPECTION (1) Remove the EGR temperature sensor.1’7-68 Vacuum ENGINE AND EMISSION CONTROL . Engine speed (rpm) 3FU262 EGR VALVE <California . (2) Connect a hand vacuum pump to the EGR valve.) or less 230 mmHg (9. Applying vacuum 45 mmHg (1. it is possible that the throttle body port may be clogged and require cleaning.Non Turbo. clean with adequate solvent to ensure tight valve seat contact.Non Turbo from 1996 models> INSPECTION (1) Remove the EGR valve and check it for sticking. tighten bolts to specified torque.lbs. (3) Apply a vacuum of 500 mmHg (19. 27EMOOd M// 888888 Resistance k~ 60-83 / 11-14 INSTALLATION Install the EGR temperature sensor tighten to specified torque. If such condition exists.8 in. (2) Place the EGR temperature sensor in water.) ‘d 1i EGR TEMPERATURE SENSOR <California up to 1995 models.

Up to 1995 models.Non Turbo From 1996 models> INSPECTION NOTE When disconnecting the vacuum hose.Non Turbo.! /IV 41 / . Battery voltage When applied When discontinued 26EM0167 / V/R \ \. (3) Start the engine and run at idle. make an identification mark on it so that it can be reconnected to the original position. (3) <Up to 1995 models> Connect a hand vacuum pump to the nipple to which the green-striped vacuum hose was connected. (2) Disconnect the harness connector.Emission Control System Plug 17-69 ~ VACUUM CONTROL VALVE <Non Turbo> INSPECTION (1) Disconnect the vacuum hose (white stripe) from the vacuum control valve and connect the hand vacuum pump to the vacuum control valve. Federal . (1) cup to 1995 models> Disconnect the vacuum hose (yellow and green stripe) from the solenoid.ENGINE AND EMISSION CONTROL .Hg) EGR SOLENOID <California . (4) Apply a vacuum and check for air-tightness when voltage applied directly to the EGR solenoid and when the voltage is discontinued.7 in.?FUIOll I/ // Result Vacuum is maintained Vacuum leaks 1 TSB Revision . Turbo . (2) Put the blind plug to the removed vacuum hose. 170 mmHg (6. (4) Check the vacuum condition. <From 1996 models> Connect a hand vacuum pump to the nipple to which the white-striped vacuum hose was connected. <From 1996 models> Disconnect the vacuum hose (yellow and white stripe) from the solenoid. Engine condition Idling Normal vacuum condition Approx.

place an identification mark on it for proper re-connection. (4) Check air tightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage.On-vehicle Service. For detailed information concerning the illumination pattern of the check engine/malfunction indicator lamp and other aspects of the on-board diagnostic.On-board Diagnostic. (3) Connect a hand vacuum pump to the nipple to which the white-striped vacuum hose was connected. Battery voltage Not applied .17-70 ENGINE AND EMISSION CONTROL . (2) Disconnect the harness connector. (1) Disconnect the vacuum hose (yellow stripe. refer to GROUP 13A . I B Nipple condition Open Open Closed Normal condition Vacuum maintained Vacuum leaks Vacuum maintained 6EMQ435 Applied (5) Measure the resistance between the solenoid valve terminals. green stripe.Emission Control System (5) Measure the resistance between the terminals of the solenoid. refer to GROUP 13A . white stripe) from the solenoid valve. Standard value: 36-44 !2 [at 20°C (68”F)] ZGEMO166 EGR SOLENOID <Turbo> INSPECTION NOTE When disconnecting the vacuum hose. Standard value: 36-44 S2 [at 20°C (68”F)] MIXTURE CONTROL (MFI) SYSTEM l l To inspect the mixture control (MFI) system. 1 TSB Revision .

Exhaust Pipe. Main Muffler and Catalytic Converter. Under this condition the exhaust system will operate at abnormally high temperature. Replace if faulty. including idling. Alteration or deterioration of ignition or fuel system. cracking or deterioration. i 1 TSB Revision .Emission Control Svstem 17-71 CATALYTIC CONVERTER REMOVAL AND INSTALLATION Refer to GROUP 15 . 3. INSPECTION Inspect for damage. 2. Proper maintenance and tune up according to manufacturer’s specifications should be made to correct the conditions as soon as possible. Caution 1.ENGINE AND EMISSION CONTROL . should be avoided if engine misfiring occurs. which may cause damage to the catalyst or underbody parts of the vehicle. or any type of operating condition which results in engine misfiring must be corrected to avoid overheating the catalytic converters. Operation of any type.

NOTES .

.. . .. 14 CLUTCH PEDAL . ... 20 CLUTCH MASTER CYLINDER .. . .. .. . . . . . ....... . 16 CLUTCH VACUUM LINE. ... ....... .. ... . . . . . . . . 2 -I ~ TROUBLESHOOTING ... .... _ . . . 18 General Specifications . .. . . .. . . ..... . . . . . 8 CLUTCH RELEASE CYLINDER . . . . .21-I CLUTCH CONTENTS CLUTCH CONTROL . . .. . .. . . ... . . .. . .. ... .... . .. ... . . .. . ...... .... . . .. . .. .. .. . . . . . .. . . . . . . . . 6 Clutch Pedal Check and Adjustment . .. . . .. . . ... . . .... . .. . . . . . ... .. .. 5 Bleeding ... ... . 10 SPECIFICATIONS .. . . . . . . .. .. . 7 Check Valve Operation Check cAWD> . . .. .. . . . . ... . . 3 Service Specifications . .. .. .. ... . . . .. . .. .. . .. .. . . . . . . 5 .. . .. . . . . .. . . . . . ... . .. . . . . . . .... .... 7 Clutch Booster Operating Check cAWD> .... . .... . . .*. . 2 Lubricants. . . ... . . . VACUUM TANK <AWD> ... . . .. . . . . 3 Sealant . . . .. .. 2 I CLUTCH COVER AND DISC . . . .. .. . .. .. .. ... ... . . 3 id ON-VEHICLE SERVICE ... . . .. . . . . ... . . ..

Specifications 225 x 150 (8.7 [at 110 N (24 Ibs.)] SERVICE SPECIFICATIONS TSB Revision .91) 250 x 160 (9.30) Clutch booster Boosting ratio [Clutch pedal depressing force] - 1.86 x 5.21-2 SPECIFICATIONS GENERAL SPECIFICATIONS CLUTCH .84 x 6.

Specifications / Troubleshooting LUBRICANTS Items Contact surface of release bearilng and fulcrum of clutch release fork Inner surface of clutch release bearing Inner surface of clutch disc spline Contact portion of release fork to release cylinder push rod Clutch fluid Inner surface of clutch release cylinder and outer circumference of piston and cup Inner surface of clutch master cylinder and outer circumference of piston assembly Conforming to DOT3 or DOT4 Specified lubricants 21-3 ~ MITSUBISHI genuine grease Part No. 8663 or equivalent TROUBLESHOOTING Symptom Clutch slips Probable cause Clutch.pedal play too small Excessive wear of clutch disc facing Hardened clutch disc facing or oil on facing Clutch release fork not operating smoothly Settled or damaged diaphragm spring Clogged hydraulic system Poorly adjusted clutch booster push rod cAWD> Gear shifting failure Clutch pedal play too large Large clutch disc distortion or runout Worn clutch cover assembly Worn or corroded clutch disc splines Separated clutch disc facing Worn clutch release bearing Damaged pressure plate or flywheel Leaky or clogged hydraulic system or air trapped in hydraulic system Poorly adjusted clutch booster push rod cAWD> Remedy Adjust Replace Replace Repair or replace Replace Repair or replace Adjust Adjust Replace Replace Replace Replace Replace Replace Repair or replace Adjust . 0101011 or equivalent SEALANT I I Items 1 Thread part fitting 1Specified sealant 13M ATD Part No.CLUTCH .

21-4 CLUTCH .Troubleshooting I LJ Excessive wear of clutch disc facin 1 TSB Revision .

97-7. Clutch pedal position switch ZO8FOOlC 2.lbs. Vehicles with auto-cruise control system. tighten the bolt or clutch pedal position switch to reach the pedal stopper. turn the push rod to adjust the stroke.) <AWD> 183-188 mm (7. and then secure by tightening the lock nut to the specified torque. Take off the carpet at under the clutch pedal. i i 208FOO55 TSB Revision . and then lock with the lock nut. turn and adjust the bolt so that the pedal height is the standard value.17 in. and then turn the push rod to make the adjustment. \ Lock nut ZO8FOO54 00002166 Z14UOO52 3. disconnect the clutch pedal position switch connector and turn the switch for standard clutch pedal height. Specified torque: 13 Nm (9 ft.CLUTCH .) NOTE When the pedal height is lower than the standard value. Standard value: 160 mm (6. Measure the clutch pedal height (from the face of the pedal pad to the firewall).40 in. adjust as follows: For vehicles without auto-cruise control system. adjust it by loosening the lock nut and turning the interlock switch. Return the clutch pedal gradually from its full-stroke position to measure amount of the return made by the pedal until.) If the amount of pedal return deviates from the standard value.) or more If the clutch pedal stroke deviates from the standard value. Measure the clutch pedal stroke.20-7. Standard value: lo-15 mm (. 0 Vehicles wiiho& .A Ve’hicles^ with auto-cruise auto-cruise concontrol system trol system Lock nut Lock nut 7 If the clutch pedal height is not within the standard value range.29 in.On-vehicle Service Clutch pedal height 21-5 ON-VEHICLE SERVICE CLUTCH PEDAL CHECK AND ADJUSTMENT 1. Standard value: cFWD> 177-182 mm (6. After making the adjustment.3g4-Sgl in.) ZO8YO41 L <FWD> d. loosen the bolt or clutch pedal position switch. the interlock switch makes an operating sound. Tighten the lock nut _ to the specified torque.

In the case of AWD vehicles.12 in. 6. If there is no change. bleed the hydraulic system or check the master cylinder. If the pedal depressed fully the first time but gradually becomes higher when depressed succeeding times. the booster is faulty. Measure pedal play. adjust with the push rod. Clutch pedal clevis pin play Standard value: l-3 mm (. (3) With the engine stopped. release cylinder or clutch proper. If the pedal height remains unchanged.04-. the booster is operating properly. Zl4UOO61 When engine is stopped 00002188 Whin engine is started z14uoo59 00002189 z14u0060 TSB Revision . Then step on the clutch pedal and start the engine.) cAWD> 12-20 mm (. Caution Do not push in the master cylinder push rod at this time. In the case of AWD vehicles.) If the clutch pedal clevis pin play is outside the standard value. If the play and/or clearance is out of specification.4g-. Clearance to toe board when clutch disengages: Standard value: 55 mm (2. the booster is faulty.On-vehicle Service 4.) ZO8YOO3 Distance between the clutch pedal and the firewall when the clutch is disengaged -\ Measure the clearance to the toe board (or pedal stopper) when the clutch disengages. depress the pedal 2 or 3 times to eliminate booster negative pressure with the engine stopped and then push the pedal with a finger to measure the play. carry out the following tests. and then stop it. measure with the engine running. Clutch pedal play Standard value: <FWD> 6-13 mm (. If the pedal moves downward slightly. 8. (2) Step on the clutch pedal several times with normal pressure.7g in. (1) Run the engine for one or two minutes. the booster is in good condition.2 in.) or more 7. 5. Return the carpet to the original position.24-51 in. Measure the clutch pedal clevis pin play.21-6 Clutch pedal clevis pin play and clutch pedal free play CLUTCH . ‘d Z08N0010 Good No good CLUTCH BOOSTER OPERATING CHECK <AWD> For simple checking of clutch booster operation. step on the clutch pedal several times with the same foot pressure to make sure that the pedal height will not change.

Avoid using a mixture of the specified fluid and other fluid. keep the check valve fit in the vacuum hose. BLEEDING Whenever the clutch tube. step on the clutch pedal and then stop the engine. replace it as an assembly unit together with the vacuum hose. the booster is in good condition. the check valve. r. Remove the vacuum hose.TSB Revision .On-vehicle Service 21-7 (4) With the engine running. vacuum hose. the clutch hose. CHECK VALVE OPERATION CHECK <AWD> When checking the check valve. and/or the clutch master cylinder have been removed. If the above three tests are okay. the booster performance can be determined as good. If the pedal height does not change. bleed the system. or if the clutch pedal is spongy. Caution The check valve is press-fit inside the vacuum hose and do not remove the check valve from the vacuum hose. If one of the above three tests is not okay at last. 1 Clutch booster side 2. the booster is faulty. Check the operation of the check valve by using a vacuum pump.CLUTCH . manifold side 208FOO31 Caution If the check valve is defective. 1. Hold the pedal depressed for 30 seconds. If the pedal rises. Specified fluid: Conforming to DOT3 or DOT4 Caution Use the specified fluid. or booster will be faulty.

Service Adjustment Procedures. Interlock syitch TSB Revision .lbs. 17. Clutch pedal positiorxwitch <Vehicles with’ auto-cruise control system> 22. 14.Clutch Pedal REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation 0 Steering Column Assembly Removal and Installation (Refer to GROUP 37A .i.) I d 30 Nm 13 Nm 9 ft. 15. Clutch master cylinder connection 3. 13.) 2. pin 9: Turn over spring 10.Steering Wheel and Shaft. Return spring 6.) 1’ l Adjustment Clutch Pedal Adjustment (Refer to F?21-5. 16.21-8 CLUTCH PEDAL CLUTCH . Clevis pin 4. Pedal support bracket . Clutch pedal shaft Clutch pedal Bushing Spacer Clutch pedal pad Brake pedal shaft Brake pedal Stop light switch Bolt <Vehicles without auto-cruise control system> 21.. 19. _ -A 12 Nm 18 208FOO47 00002218 Removal steps 1. 20. 18. Rod B 11.Ie. Clevis pin 5. . Brake booster connection l Brake pedal adjustment (Refer to GROUP 35 . Bush 12.

38. 37. 40. clutch pedal for bend or torsion. Clevis pin 28. Vacuum hose connection 26. (2) Check to be sure that there is continuity between connector terminals 1 and 2. 43. 36.Brake Booster. Brake booster (Refer to GROUP 35. pedal pad for damage or wear.Clutch Pedal 13 Nm . Pedal support bracket 27. Clevis pin 29.23 1 *. 39.I TSB Revision .CLUTCH . Clevis pin 30. Bushing Spacer Clutch pedal pad Bolt Lever assembly Bushing Spacer Support bracket Clutch booster Clutch pedal position switch Interlock switch INSPECTION Ohmmeter n l l l 0 1 2 9 I El &t I I l Check the Check the Check the <FWD> Check the pedal shaft and bushing for wear. Clutch master cylinder connection 25. 41. Clutch pedal 33.. 34. turn over spring for damage or deterioration.) 24. Yoke 31. Clutch pedal shaft 32. 35. .> / I’ @” _ 42 rd n 208FOO25 00002219 Removal steps 23. INTERLOCK SWITCH CHECK (1) Disconnect the connector.c . 42.

4. air intake hose .) 1I <AWDa 15 Nm 4 1 ftlhr 15 Nm 11 ft. . Faren p i p e cAWD> 10.-11 _ 1 -v ZOBFOO46 00002214 208FOO44 <AWD> Clutch master cylinder removal steps 1.E+ 5.) (A.ner cover. Clutch master cylinder bF+ l Piston adjustment to push rod clearance cAWD> 4.Steering Wheel and Shaft. . Battery seat.ner cover. washer tank 11.) 2. Ai4i. ?5 Nm 11 ft.C( g. Brake booster (Refer to GROUP 35.lbs.lbs. Clevis pin &WD> 3. Air hose A <AWD> 6.21-5.D+ 7.21-10 CLUTCH CONTROL CLUTCH .A+ 12. Sealer Clutch tube removal steps 1.Clutch Control REMOVAL AND INSTALLATION l Pre-removal Operation Draining of the Clutch Fluid 0 Clutch Pedal Adjustment (Refer to P.Brake Booster. Clutch tube TSB Revision . . Steering column assembly (Refer to GROUP 37A .Brake Booster.4. Brake booster (Refer to GROUP 35 . air intake hose A .) ..

4.CLUTCH .E+ 5. . tube B. damper removal steps .. Clutch tube A &AID> +D. Nm I 1 push rod zo8wos17 14 19 Nm 13 ft. .B+ 13. washer tank +C. use a flat type short box wrench to remove the clutch release cylinder mounting bolts.A4 14. Air cleaner cover. \ 17 19 13lt.Cd .lbs.lbs. / ZOEFOO45 00002215 13 Clutch release cylinder removal steps . +B.~ cover.4. air intake hose A . Air cleaner cover. Clutch damper <FWD> REMOVAL SERVICE POINTS +A.A+ 15.Clutch Control 21-11 <FWD> 10 15 Nm 11 ft. Clutch release cylinder Clutch hose removal steps . tube C. CLUTCH RELEASE CYLINDER REMOVAL On AWD-vehicles. 15 Nm 11 ft. Air cleaner cover.. air intake hose .D+ 7. Farey p i p e <AWD> 10: Battery seat. washer tank +B. Fare” p i p e <AWD> 10: Battery seat.Cq i. Air hose A cAWD> 6.D( 7.D+ 7. .aner cover. V 15 Nm 11 ft. air intake hose <FWD> . .lbs. Air cleaner.E+ 5. air intake hose A <AWD> . air intake hose <FWD> . Clutch tube B eAWD> 17. TSB Revision . washer tank dD.CLUTCH TUBE REMOVAL (CLUTCH HOSE SIDE) While holding the clutch hose side nut. air intake hose A <AWD> . Air&e. loosen the clutch tube flare nut. Clutch tube C cFWD> 18.A+ 16.lbs.E+ 5. Clutch hose Clutch tube A. Fare7 p i p e cAWD> 10: Battery seat. Air hose A cAWD> 6.C+ . . Air hose A cAWD> 6.lbs.

use a flat type short box wrench to tighten the clutch release cylinder mounting bolts. (2) Remove the clip from the clutch hose to remove clutch hose from bracket. b Air intake hose C . CLUTCH HOSE REMOVAL To disconnect clutch hose from the clutch tube. Caution Be careful not to allow any foreign matter to get into the hoses. proceed as follows: (1) Secure the nut on the clutch hose and loosen the flare nut on the clutch tube. &:_:. as shown in the illustration. loosen the clutch tube flare nut. up to the stepped part. INSTALLATION SERVICE POINTS bAdCLUTCH TUBE B <AWD> / CLUTCH TUBE A <FWD> / CLUTCH HOSE / CLUTCH TUBE INSTALLATION Be careful that the clutch hose does not become twisted. or the intercooler itself. Air hose A Air . .Cd VACUUM PIPE <AWD> INSTALLATION If the vacuum pipe has a stepped part.Bd CLUTCH RELEASE CYLINDER INSTALLATION On AWD-vehicles. Insert air hoses B and C into pipe all the way to its step.E( AIR HOSE A INSTALLATION Connect the air hoses ensuring that alignment marks are aligned with projections.21-12 CLUTCH . AD.CLUTCH TUBE A <FWD> (CLUTCH HOSE SIDE) / CLUTCH TUBE B <AWD> (CLUTCH HOSE SIDE) REMOVAL .While holding the clutch hose side nut. AIR INTAKE HOSE A INSTALLATION Align slots indicated by arrows in air intake hose A with A markings on air intake hoses B and C. WO5FOO28 TSB Revision . connect the vacuum hose to the pipe securely.. insert hoses B and C all the way into air intake hose A. pipes.Clutch Control ’ 208FOO35 +C. then. .D(AIR CLEANER COVER. Insert air intake hoses B and C all the way up to the roots on the turbocharger end.

). Standard value: [A (A = B . subtract the thickness of the square to arrive at (D). z14u0065 00002195 00002196 (3) Measure the dimension (D) between the master cylinder mounting surface on clutch booster and the push rod end. (2) Obtain the dimension (C) between the clutch booster mounting surface on the master cylinder and the end face.7 psi) is applied.0118 in.CLUTCH . (4) Using the measured values obtained in (1) through (3). first take measurement with a square placed on the clutch booster.3 mm (-0039 to .D)] 0. obtain the clearance (A) between the clutch booster push rod and piston. first take measurement with a square placed on the master cylinder end face.21-0. Then.) [Atmospheric pressure] [When the clutch booster negative pressure of 66.] TSB Revision .Clutch Control 21-13 .0082-.0181 in. the clearance (A) becomes 0.1 to 0. NOTE To obtain (B).7 kPa (9. NOTE To obtain (D).C .Fq CLEARANCE BETWEEN CLUTCH BOOSTER PUSH ROD AND PISTON ADJUSTMENTcAWD> Adjust the clearance (A) between the clutch booster push rod and piston as follows: (1) Measure the dimension (B) between the master cylinder end face and piston. Then. subtract the thickness of the square to arrive at (B).46 mm (.

lbs.c- Master cylinder kit 3 Mu ZOBFOO40 <AWD> 6 10 208FOO38 00002216 1-A 7 7 P 208FOO41 1 Brake fluid: Conformina to DOT3 or DOT4 Disassembly steps 1. INSPECTION l Check the clutch hose or tube for cracks or clogging. Reservoir 11. Master cylinder body 1 TSB Revision . Boot <FWD> 4W 7. Piston stop bolt &WDr 2. Push rod cFWD> 6. Piston stop ring cFWD> :i: 4. Reservoir band 10. adjust by changing the push rod length by turning the adjustable end of the push rod.A( 5. Piston assembly 8.< EF i. Snap ring cAWD> . --5iR/g “‘: + 7 g--P Ii a n 13 Nm 9.Clutch Control / Clutch Master Cylinder (5) If the clearance is not within the standard value range.8 i. Gasket cFWD> 3. Caution Insufficient clearance may cause the slippage or seizure of the clutch.21-14 C L U T C H . Reservoir cap 9. CLUTCH MASTER CYLINDER DISASSEMBLY AND REASSEMBLY <FWD> t:: ES.0 ft. ZOXFOO39 &=4 Q.

Check the piston cup for wear or deformation. Do not damage the master cylinder body and piston assembly.C L U T C H . This can facilitate the clutch pedal adjustment. Check the clutch tube connection part for clogging.A( PUSH ROD INSTALLATION NOTE Set the push rod length to the dimension shown in the illustration before installation. n REASSEMBLY SERVICE POINT . TSB Revision . 2.Clutch Master Cvlinder 21-15 i +A.) -I 0820004 I INSPECTION l l l Check the inside cylinder body for rust or scars.80 in. . II 122 mm (4.PlSTON STOP RING 4WD> / SNAP RING <AWD> DISASSEMBLY Remove the piston stop ring or snap ring. while depressing the piston.214LO193 +B. PISTON ASSEMBLY REMOVAL Caution 1. Do not disassemble piston assembly.

Apply compressed air slowly to prevent brake fluid from splashing. PISTON AND CUP DISASSEMBLY (1) Remove the corrosion from the piston-removal port of the release cylinder. Valve plate 2.A+ 5.21-16 CLUTCH . Caution 1 s Cover with rags to prevent the piston from popping out. Piston and cup 6. ’ ” 8. (2) Remove the piston from the release cylinder using compressed air. Conical smina 7.Clutch Release Cylinder CLUTCH RELEASE CYLINDER DISASSEMBLY AND REASSEMBLY 3 d’ 6C LO003 ATFM0576 Lubricant: Conforming to DOT3 or DOT4 ‘d ~ Lubricant: Conforming to DOT3 or DOT4 Disassembly steps 1. Spring 3. 2. Release cylinder DlSASSEMbLY SERVICE POINT dA. Boots 4Ab . 1 TSB Revision I (d . Push rod 4. Bleeder plug 9.

260 0003 TSB Revision 1 . or if there is excessive wear of the lip where indicated in the figure. Specified brake fluid: Conforming to DOT3 or DOT4 ADCLOOb INSPECTION \ *:3 q>ca (1) Check the inner surface of the release cylinder for scratches or irregular wear.C L U T C H .Clutch Release Cylinder REASSEMBLY SERVICE POINT 21-17 .A(FLUlD APPLICATION TO PISTON AND CUP Apply specified brake fluid to the release cylinder inside and outer surface of the piston and piston cup and push the piston cup assembly in the cylinder. (2) Replace if the piston cup outer circumference is scratched or shows signs of fatigue.

Air hose A . Vacuum ‘hose B 4A. Vacuum pipe A Vacuum pipe B.Right Member. air intake hose A 7.B+ 6. Vacuum hose E 14.A+ 3.Clutch Vacuum Line. vacuum hose D removal steps 8. Vacuum hose A . 208FOO21 0000324g . Air cleaner cover.) 12. Vacuum pipe C 1 TSB Revision .A+ 1. vacuum pipe C removal steps 11. Vacuum tank assembly .Brake Booster.Cd 5.A( 10. Vacuum Tank <AWD> CLUTCH VACUUM LINE. .lbs. Vacuum pipe B . Brake booster (Refer to GROUP 35 . VACUUM TANK <AWD> REMOVAL AND INSTALLATION Sealant: 3M ATD Part No. Fitting Vacuum pipe A removal steps . Left Member and Crossmember.21-18 C L U T C H . Vacuum hose D Vacuum tank assembly.A+ 2. 8663 or equivalent 6 \ 214LO216 43-51 ft. vacuum hose E.) 9.A4 13. Vacuum hose C with check valve 4. Right member (Refer to GROUP 32 .

pipes.) . Air hose A . replace the check valve as an assembly unit together with the vacuum hose C if the check valve is defective. WO5FOO2i 3 INSPECTION l l Check the hose and pipes for cracks. insert the hose until the insertion amount reaches the standard value.BdAIR CLEANER COVER.o~FOo. 203FOOO8 YO3FOOO7 00002200 ”T c A i r Air intake hose A i n t a k e hos. Caution Be careful not to allow any foreign matter to get into the hoses.Clutch Vacuum Line. 1 TSB Revision . Check the vacuum tank for deformation or crack.C+AIR HOSE A INSTALLATION Connect the air hoses ensuring that alignment marks are aligned with projections. Vacuum Tank <AWD> REMOVAL SERVICE POINT dAbVACUUM HOSE C WITH CHECK VALVE REMOVAL 21-19 NOTE Since the check valve is fit to the vacuum hose C. bend. insert hoses B and C all the way into air intake hose A.0 in. Insert air intake hoses B and C all the way up to the roots on the turbocharger end. If it is connected to a pipe without any stepped part.. ZO9FO13: 3 I INSTALLATION SERVICE POINTS .AdVACUUM HOSE E / VACUUM HOSE D / VACUUM HOSE C WITH CHECK VALVE / VACUUM HOSE B / VACUUM HOSE A INSTALLATION If a hose is connected to a pipe with a stepped part. AIR INTAKE HOSE A INSTALLATION Align slots indicated by arrows in air intake hose A with A markings on air intake hoses B and C.8-1. deformation and clogging.C L U T C H . Insert air hoses B and C into pipe all the way to its step. insert the hose up to the stepped part. Standard value: 20-25 mm (. then. or the intercooler itself.

) l Post-installation Operation Transaxle Assembly Installation (Refer to GROUP 22 . 4Ab .21-20 CLUTCH . Release fork boot TSB Revision .lbs.C+ 3.Clutch Cover and Disc CLUTCH COVER AND DISC REMOVAL AND INSTALLATION l Pre-removal Operation Transaxle Assembly Removal (Refer to GROUP 22 . Clutch release bearing . Release fork 6. 15-21 Nm ft.Transaxle Assembly.Transaxle Assembly.A4 5.C+ 4Ab .) 30-42 Nm \ \ 2 1 . Fulcrum 7. Return clip .Bq 4.

1 TSB Revision . one or two turns at a time. Back off bolts in succession.Clutch Cover and Disc 21-21 6CLO16 Lubricant: MITSUBISHI genuine grease Part No. to avoid bending cover flange.C L U T C H . 0101011 or eauivalent ATFM0857 REMOVAL SERVICE POINT dAbCLUTCH COVER ASSEMBLY / CLUTCH DISC REMOVAL Diagonally loosen bolts which attach clutch cover to flywheel. Caution DO NOT clean clutch disc or release bearing with cleaning solvent. 0101011 or equivalent 7CLOOO8 Lubricant: MITSUBISHI genuine grease Part No. 0101011 or equivalent L 6CLO33 Lubricant: MITSUBISHI genuine grease Part No.

- BCLOZ TSB Revision .B+ GREASE APPLICATION TO CLUTCH RELEASE BEARING (FWD) Pack the inner surface of the clutch release bearing and the groove with the specified grease. 0101011 or equivalent Caution When installing the clutch. (3) install the clutch cover assembly. finally tightening them to the specified torque. Tighten the bolts a little at a time.A4 GREASE APPLICATION TO RELEASE FORK (1) Apply a coating of the specified grease to the point of contact with the fulcrum and the point of contact with the release bearing.Clutch Cover and Disc INSTALLATION SERVICE POINTS . 0101011 or equivalent (2) Using the universal clutch disc aligner. but be careful not to apply excessive grease.CqGREASE APPLICATION TO CLUTCH DISC / CLUTCH COVER ASSEMBLY (1) Apply a coating of the specified grease to the clutch disc spline. apply grease to each part. 0101011 or equivalent YGCLOi 6 L) J .21-22 CLUTCH . Clutch disc Clutch cove1 assembly . position the clutch disc to the flywheel. 0101011 or equivalent Y6CLCGZ \d\s . working in a diagonal sequence. and then use a brush to rub it in. excessive grease will cause clutch slippage and shudder. Specified grease: MITSUBISHI genuine grease Part No. (2) Apply a coating of the specified grease to the end of the release cylinder’s push rod and to the push rod hole in the release fork. Specified grease: MITSUBISHI genuine grease Part No. Specified grease: MITSUBISHI genuine grease Part No. Specified grease: MITSUBISHI genuine grease Part No.

(AWD only) Check for bearing heat damage. The release bearing is packed with grease. Combine the clutch disc with the input shaft and check sliding condition and check for play in the rotating direction. replace the clutch disc.5 mm (. replace the release fork. If the play is excessive. If there is abnormal wear at the point of contact with l the release fork. cracks and l color change. Measure the rivet sink and replace the clutch disc if it is out of specification. RELEASE FORK CHECK If there is abnormal wear at the point of contact with the bearing. so don’t use cleaning oil.020 in. other damage. abnormal l noise and/or improper rotation. etc.3 mm (. Also check whether or not there is wear at the point of contact with the diaphragm spring.012 in.Clutch Cover and Disc INSPECTION 21-23 Z6cLOO3 J CLUTCH COVER ASSEMBLY CHECK Check the diaphragm spring end for wear and uneven l height. replace the bearing. Limit: 0. uneven contact. 1 TSB Revision . 2. adhesion of oil or grease and replace the clutch disc if defective. check after cleaning and reassembling.C L U T C H . CLUTCH DISC CHECK Check the facing for loose rivets. Do not disassemble the bearing and sleeve of the clutch release bearing.) Check for torsion spring play and damage and if defective. If it does not slide smoothly. replace. replace the clutch disc and/or the input shaft. Replace if wear is evident or height difference exceeds l the limit. deterioration due to seizure.) Check the pressure plate surface for wear. to clean it. Check the strap plate rivets for looseness and replace l the clutch cover assembly if loose. Limit: 0. If disassembled. Sleeve Bearing CLUTCH RELEASE BEARING CHECK Caution 1.

NOTES .

r . .. .. 9 6 3 TRANSAXLE ASSEMBLY .. .. .. . .. 15 Drive Shaft Oil Seals Replacement .. . ... SRS diagnosis unit. . . Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).. . SPECIFICATIONS . . . ... .. .... . .. . . ... . . .. .. SPECIFICATIONS . . .. . ... .. clock spring and interconnecting wiring. . . . .... . 2 Lubricants . . . . 3 2 SHIFT LEVER ASSEMBLY .. . ... . .. ... . . ... 2 Sealants and Adhesives . .. .. : ..... . . . . . . .. .. .. .. . . .... . . . .. . . 4 Transmission Oil Level Check . . . . .. ... 15 MANUAL TRANSAXLE <FWD> . . ... . . . .. .... . (2) Service or maintenance of any SRS component or SK-related component must be performed only at an authorized MITSUBISHI dealer... . ..... .. before beginning any service or maintenance of any component of the SRS or any SRS-related component. . . . . . . . . . . .. .. . .. .. . .. . .. . . . . . 15 Transfer Oil Level Check . . .. . .. .. . . . . .. .. TRANSAXLE CONTROL* .... .. . . .. ... ... . . . . ... . . . 19.. . or any SRS-related component. .. ... . . . .. . .. .. .. 4 SHIFT LEVER ASSEMBLY .. . ... .. . .. .. ... .. .. 5 Speedometer Cable Replacement . NOTE The SRS includes the following components: impact sensors. . 2 General Specifications . . .. .... 8 SPECIAL TOOLS .. .. ... 15 Transfer Oil Seal Replacemeni: . .. . .. . . . . . . . .. .. (3) MITSUBISHI dealer personnel must thoroughly review this manual. . . . ... . ..... .. . . . . . .. . . . .. .. . . . . .. . 22 WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS..... can lead to personal injuryordeathtoservicepersonnel(frominadvertentfiringoftheairbag)ortothedriverandpassenger(fromrendering the SRS inoperative). 13 TRANSAXLE ASSEMBLY .. .. . and especially its GROUP 528 -Supplemental Restraint System (SRS) and GROUP 00 -Maintenance Service. .. .. . . .. .. .. . .. .. .. . . . . . . .. . air bag module. .. . 15 Transmission Oil Replacement . ........ 23 TRANSAXLE CONTROL* . 13 Lubricants .I.. . . . . . . . .2 ON-VEHICLE SERVICE . . .. .. ....... . . . . . . . . . .. . . .. .. ... . . . ... .. . . .. .13 ON-VEHICLE SERVICE . .. 14 13 General Specifications .. . . . . . 4 Drive Shaft Oil Seals Replacement .. . 4 Transmission Oil Replacement .... .. . .... 17 TRANSFER ASSEMBLY . -3.... . . .. . . .... . . . .. . . .. . 16 Transmission Oil Level Check . ... . .. .22-1 MANUAL TRANSAXLE CONTENTS MANUAL TRANSAXLE cAWD> . .. . . .. . . . . . . 15 Transfer Oil Replacement .. . . .. .. .. .. .... .. . . ... . TROUBLESHOOTING . . .. . .. ... . . .. . ... .. .... .. .. .. . .. . . .. . ... SRS warning light.. . ... . 16 ~j SPECIAL TOOLS ... . . . . . ..

sealants and adhesives Mitsubishi genuine part No.clutch housing mating surfaces Transaxle case . SAE 75W-90 or 2.. 8001 or equivalent -7 3M STUD Locking part No.1) 75W-85W conforming to API classification GL-4 As required SEALANTS AND ADHESIVES Items Transaxle case .rear cover mating surfaces Differential drive gear bolts Bearing retainer screw (flush head screw) Reverse brake cone mounting screw bolts Air breather 3M ATD part No.0 (2.Specifications MANUAL TRANSAXLE cFWD> SPECIFICATIONS GENERAL SPECIFICATIONS LUBRICANTS Items Manual transmission oil Drive shaft oil seal lip Specified lubricant Quantity dm3 (qts) Hypoid gear oil. 997740 or equivalent TSB Revision .22-2 MANUAL TRANSAXLE cFWD> . 4170 or equivalent Specrfred -7.

Low oil level f. Worn gear shift fork or broken poppet spring b. Replace control cable b. Replace with specified oil e. noise Probable cause a. Replenish f. Adjust idle speed a. Worn of damaged gears d. oil seal or O-ring a. Replace oil seal or O-ring a.Special Tools / Troubleshooting 22-3 SPECIAL TOOLS Tool Tool number and name ME)991113 Steering linkage puller Supersession MB991113-01 Application 0 Disconnection of the coupling. Use of inadequate grade of oil e. Replace with specified oil a. Use of inadequate grade of oil Jumps out of gear a. Tighten or replace mounts b. Synchronizer hub to sleeve spline clearance too large Remedy a.MANUAL TRANSAXLE <FWD> . Inadequate engine idle speed Oil leakage Hard shift a. Faulty control cable b. Poor contact or wear of synchronizer ring and gear cone c. Weakened synchronizer spring d.of the knuckle and lower arm ball joint l Disconnection of the coupling of the knuckle and tie-rod end ball joint kg98325 Ditierential o i l seal installer MD998325-01 Installation of differential oil seal TROUBLESHOOTING Symptom Vibration. Replace shift fork or poppet spring b. Replace synchronizer hub and Sleeve 1 TSB Revision . Correct or replace c. Loose or damaged transaxle and engine mounts b. Correct end play c. Inadequate shaft end play c. Replace gears d. Replace synchronizer spring d. Broken or damaged.

TSB Revision .Maintenance Service. At the transaxle end of the soeedometer cable. Caution The cable arrangement should be made so that the radius of cable bends is 150 mm (5.9 in. 3. Correctly insert the adapter into the instrument panel.Maintenance Service. TRANSMISSION OIL REPLACEMENT Refer to GROUP 00 .On-vehicle Service ON-VEHICLE SERVICE TRANSMISSION OIL LEVEL CHECK Refer to GROUP 00 . the cable attachment part and the projecting part are horizontal. and fasten the new speedometer cable. it may cause incorrect indication by the speedometer. 209FOO83 2. Install the grommet so that. and the nut should be securely tightened.) or more. Be sure to connect it correctly. the key joint should be inserted into the transaxle.22-4 MANUAL TRANSAXLE cFWD> . Caution If the cable is not correctly and securely connected. SPEEDOMETER CABLE REPLACEMENT <Up to 1993 models> 1. as shown in the illustration. or abnormal noise.

(4) Apply a coating of the transmission oil to the lip of the oil seal.MANUAL TRANSAXLE cFWD> . (Refer to GROUP 26 . remove the oil seal.H. side 22-5 ’ DRIVE SHAFT OIL SEALS REPLACEMENT (1) Disconnect the drive shaft from the transaxle.On-vehicle Service R. tap the drive shaft oil seal into the transaxle. The drive shaft oil seal must be installed in the direction shown.Drive Shaft. Transmission oil: Hypoid gear oil.) (2) Using a flat-tip (-) screwdriver. SAE 75W-90 or 75W-85W conforming to API classification GL-4 MD998325 160024 I) Transaxle side Oil seal lip 2200037 00001754 1 TSB Revision I . (3) Using the special tool.

A( 2.lbs.9 ft.0 Nm 2. Shift lever assembly 1 TSB Revision . Air intake hose . Air cleaner. Air cleaner. Retainer 4. 12 Nm 9 ft.lbs. 5 Transaxle control cable assembly removal steps 1. Air intake hose .Transaxle Control TRANSAXLE CONTROL REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation l Front Console Assembly Removal and Installation (Refer to GROUP 52A .22-6 MANUAL TRANSAXLE <FWD> .Floor Console. Transaxle control cable assembly connection (Shift lever assembly side) 3.A+ 2.) 4. Transaxle control cable assembly ZO9FOO79 Shift lever assembly removal steps 1. Transaxle control ‘cable assembly connection (Shift lever assembly side) 5.

impeded action.A+ TRANSAXLE CONTROL CABLE ASSEMBLY CONNECTION (SHIFT LEVER ASSEMBLY SIDE) (1) Move the transaxle shift lever to the neutral position.ever (4) Turn adjuster on shift cable so that shift cable end is positioned as shown with reference to shift lever on the passenger compartment side.h9. (6) Connect the shift cable. Check each bushing for wear or abrasion. and damage. Neutral position Shift lever Adjuster (2) With the shift lever on the passenger compartment side in the neutral position.MANUAL TRANSAXLE <FWD> .e 22: Shift lever Lever B ooooi53o mLhi. i 1 TSB Revision .Transaxle Control INSTALLATION SERVICE POINTS 22-7 . . then turn adjuster on shift cable so that dimension A equals dimension B. Check the boot for damage. I z/fya. NOTE The select lever will be set to the neutral position when the transaxle shift lever is moved to the neutral position. INSPECTION l l l Check the transaxle control cable assembly for function and for damage. turn adjuster on select cable so that select cable end is positioned as shown with reference to lever B of shift lever.. (7) Move the shift lever to each position and check that the shifting is smooth. sticking. (5) Install the shift cable so that the flange side of the plastic bushing at the end of shift cable is on the split pin side. (3) Install the select cable so that the flange side of the plastic bushing at the end of select cable is on the end face side of lever B.

Pipe Bolt Lever (A) Bushing Bushing Snap ring Washer Lever(B) Bushing Cable bracket Bracket assembly 1 TSB Revision . Plain washer 11. 23. 21. Spring washer 3.22-8 MANUAL TRANSAXLE <FWD> . 14. Plain washer 7.Shift Lever Assembly SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 16 24 Nm 17 ft. 15.lbs. Return spring 12. Bushing 13. Plain washer 4. Nut 2. 19. 22. Spring washer 10. Shift lever 5. Bushing 6. Wave washer 8. 17. 18. Nut 9. 16. \ 24 17 23 ’ - / 8 09FOO17 00001531 09FOO66 Disassembly steps 1. 20.

Battery 3. washer tank 4. Clutch release cylinder connection 4A.MANUAL TRANSAXLE <FWD> . Side under cover 2.22-4.Front Bumper.) l Engine Coolant Filling (Refer to GROUP 14. Speedometer cable <Up to 1993 models> or speedometer connector <From 1994 models> connection 1 TSB Revision . Air cleaner cover.Front Bumper.Service Adjustment Procedures.Transaxle Assembly 22-9 TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION Post-installation Operation l Front Under Cover Installation (Refer to GROUP 51 . air intake hose 5. Battery seat. Clutch tube bracket and clutch damper assembly connection 7.) 19 Nm 209FO112 09FOO99 00001532 Removal steps 1. Transaxle control cable connection 8.) l Transmission Oil Supplying (Refer to P.) l Shift Lever at Each Position Checking Operation l Meters and Gauges Checking Operation (Refer to GROUP 51 . 6.

Right member 16.lbs. Tie rod end connection 4Cb 14. Inner shaft assembly +F. 11 h \ Q 11 A 12 / n-ql./. Transaxle mount connection 10.A+ 18. Drive shaft (Right side) 19. I8 c7 60-72 Nm 43-52 ft. Drive shaft (Left side). Transaxle assembly lower part 4G.B( 11. . 60-70 Nm 43-51 ft. Transaxle stay (Rear bank side) 21.lbs. coupling bolt 22. Lower arm ball joint connection 4D. 17. and then secure at the body side without disconnecting the oil line coupling. Transaxle mount bracket .4 d . ZO9FOO84 9. Transaxle assembly 4Gb 4Eb REMOVAL SERVICE POINTS dAbCLUTCH TUBE BRACKET AND CLUTCH DAMPER ASSEMBLY DISCONNECTION Remove the clutch release cylinder and clutch oil line bracket installation bolt.lbs. Mounting stopper 12. Starter 4B. TSB Revision . 15. Transaxle assembly upper part coupling bolt 13. 26 ftlbs.Transaxle Assembly 70 Nm 51 ft.22-10 MANUAL TRANSAXLE 4WD> . Transaxle stay (Front bank side) 20.

MANUAL TRANSAXLE cNVD> . 2. +E. Caution Support the transaxle assembly with the jack so that no localized force is applied to the assembly. LOWER ARM BALL JOINT DISCONNECTION Using the special tool. NOTE Remove drive shaft and inner shaft assembly as an assembly together with hub. DRIVE SHAFT (LEFT SIDE). 2. and other parts. Caution 1. Caution 1. Be sure to tie the cord of the special tool to the nearby part. AD. (2) Remove drive shaft (left side) and inner shaft assembly from transaxle assembly. +C. disconnect the tie rod end from the knuckle.TIE ROD END DISCONNECTION Using the special tool. disconnect the lower arm ball joint from the knuckle.Transaxle Assembly 22-11 +B. knuckle. Loosen the nut but do not remove it. Be sure to tie the cord of the special tool to the nearby part. (3) Suspend the removed drive shaft (left side) and inner shaft assembly with wire or something similar to prevent it from sharply bending or turning at each joint. Loosen the nut but do not remove it. INNER SHAFT ASSEMBLY REMOVAL (1) Remove the bearing bracket mounting bolts and insert the pry bar between the bearing bracket and the cylinder block.TRANSAXLE MOUNT DISCONNECTION Raise transaxle assembly with a jack up to a level where mount bracket no longer receives its weight and remove transaxle mount insulator bolt. 1 TSB Revision I .

+G. and not bent relative to the transaxle. (2) Suspend the removed drive shaft (right side) with wire or something similar to prevent it from sharply bending or turning at each joint. NOTE Remove drive shaft (right side) as an assembly together with hub. knuckle.Bd MOUNTING STOPPER INSTALLATION Install mounting stopper in the direction shown. Caution Care must be taken to ensure that the oil seal lip part of the transaxle is not damaged by the serrated part of the drive shaft (right side).Transaxle Assemblv +F. DRIVE SHAFT (RIGHT SIDE) REMOVAL (1) To remove drive shaft (right side) from transaxle assembly. jack ZOSFOOO4 INSTALLATION SERVICE POINTS . apply pry bar to the protrusion. . Transaxle mount \ bracket 1 TSB Revision . lower transaxle assembly. and other parts. then.MANUAL TRANSAXLE cFWD> .TRANSAXLE ASSEMBLY LOWER PART COUPLING BOLT / TRANSAXLE ASSEMBLY REMOVAL Support transaxle assembly with a transaxle jack and remove transaxle assembly lower part coupling bolt.A4 DRIVE SHAFT (RIGHT SIDE) INSTALLATION Provisionally install the drive shaft (right side) so that the inboard joint part of the drive shaft (right side) is straight.

Special Tools Tool Tool number and name MD998330 Oil pressure gaugle (30 kg/cm2) MD999563 Oil pressure gauge (10 kg/cm2) MD998332 Adapter MD998332-01 Connection of the oil pressure gauge Supersession MD998330-01 Application Measuring oil pressure 23-13 3 H A: MD99891 5 A MD99891 6-01 MD99891 6-l-01 Adjustment of kickdown servo Kickdown servo wrench adapter B: MD99891 6 Kickdown servo adjust wrench set MD99891 8 Kickdown servo wrench MD99891 6-2-01 MD99891 6-3-01 @ 69 B Q Adjustment of kickdown servo 1 TSB Revision .AUTOMATIC TRANSAXLE .

22-14 MANUAL TRANSAXLE <AWD> .Special Tools SPECIAL TOOLS Oil seal installer TSB Revision .

MANUAL TRANSAXLE <AWD> .Maintenance Service.Maintenance Service. and the shape of each type is different. Dust seal . For R.Maintenance Service.Maintenance Service. TRANSFER OIL LEVEL CHECK Refer to GROUP 00 ..H. (4) Install the oil seals using the following procedure: Using the special tool.H. and the other for L. remove the oil seal.Drive Shaft. For L. TSB Revision 1 .H. one for R. R.H. Note that there are two types of oil seals. side DRIVE SHAFT OIL SEALS REPLACEMENT (1) Disconnect the drive shaft from the transaxle.H. (3) Using a flat-tip (-) screwdriver.) (2) Remove the transfer assembly. as shown.On-vehicle Service 22-15 ON-VEHICLE SERVICE TRANSMISSION OIL LEVEL CHECK Refer to GROUP 00 . TRANSMISSION OIL REPLACEMENT Refer to GROUP 00 . tap the oil seal into the transaxle. TRANSFER OIL REPLACEMENT Refer to GROUP 00 . (Refer to GROUP 26 .

SAE 75W-90 or 75W-85W conforming to API classification GL-4 d R. (Refer to GROUP 25 .Propeller Shaft.. (4) Apply a coating of the transmission oil to the lip of the oil seal. . / (5) Drive shaft oil seal must be installed in the direction shown. tap the drive shaft oil seal into the transfer.) (2) Using a flat-tip (-) screwdriver.H.On-vehicle Service / Shift Lever Assembly L.H. TSB Revision .22-8.22-I 6 MANUAL TRANSAXLE cAWD> . TRANSFER OIL SEAL REPLACEMENT (1) Pull out the propeller shaft from the transfer. (6) Apply a coating of the transmission oil to the lip of the oil seal. Transmission oil: Hypoid gear oil. side -. (3) Using the special tool. Transmission oil: Hypoid gear oil. remove the oil seal. SAE 75W-90 or 75W-85W conforming to API classification GL-4 SHIFT LEVER ASSEMBLY Refer to P. side .

Bd .Transaxle Control 22-17 TRANSAXLE CONTROL REMOVAL AND INSTALLATION I I Pre-removal and Post-installation Operation l Front Console Assembly Removal and Installation (Refer to GROUP 52A .Cd .Dq . Air hose A 2.Cd .l 9 ft. Shift lever assembly TSB Revision . Transaxle control cable assembly connection (Shift lever assembly side) 5. Air cleaner cover. Vacuum pipe 4. Air intake hose A 3.A4 1..) -![i>” 12 Nm \k \ I . Vacuum pipe 4.Dd .lbs. OQFOO80 00001536 Transaxle controll cable assembly removal steps . Transaxle control cable assembly connection (Shift lever assembly side) 7. Retainer 6.Floor Console. Air intake hose A 3.A+ 1.MANUAL TRANSAXLE <AWD> . Air cleaner cover. Air hose A Shift lever assembly removal steps .B( . Transaxle control cable assembly 2.

impeded action. then. pipes.22-18 MANUAL TRANSAXLE <AWD> . WO5FOO28 d INSPECTION l l l Check the transaxle control cable assembly for function and for damage.B( VACUUM PIPE INSTALLATION If the vacuum pipe has a stepped part. or the intercooler itself.C(AIR CLEANER COVER. .Transaxle Control INSTALLATION SERVICE POINTS . or up to the step in hose A. and damage. Check the boot for damage. connect the vacuum hose to the pipe securely.A+ TRANSAXLE CONTROL CABLE ASSEMBLY CONNECTION (SHIFT LEVER ASSEMBLY SIDE) Refer to P.DqAIR HOSE A CONNECTION Connect the hoses ensuring that paint marks are aligned with projections. A Air intake hose B 205FOO23 Air hose C AirhoseA I .22-7. 203FOO8 d’ . sticking. insert hoses B and C all the way into air intake hose A. up to the stepped part. Caution Be careful not to allow any foreign matter to get into the hoses. Insert air hoses B and C into air hose A all the way. 1 TSB Revision . AIR INTAKE HOSE A CONNECTION Align slots indicated by arrows in air intake hose A with markings on air intake hoses B and C. Check each bushing for wear or abrasion. as shown in the figure.

Battery seat. Air cleaner body 7. Air cleaner cover.22-22.Transaxle Assembly 22-19 TRANSAXLE ASSEMBLY / li l l REMOVAL AND INSTALLATION fransmission Oil Draining (Refer to P.22-15. Washer tank 9.) l Shift Lever at Each Position Checking Operation l Meters and Gauges Checking the Operation c Hose clamp 4. Air cleaner element 6. Transaxle control cable connection / i TSB Revision . Battery 8.MANUAL TRANSAXLE <AWLI> .) l l Post-installation Operation Transfer Assembly installation (Refer to P. Side under cover . Air intake hose A .I34 4.D+ 2.22-22.) Transfer Assembly Removal1 (Refer to P.0 Nm 09FOllO 00001537 Removal steps 1. Air hose A bC+ 3. Vacuum pipe 5.) Transmission Oil Supplying (Refer to l?22-15.

60-70 Nm 43-51 ft. OWXW 00001538 10.22-20 MANUAL T R A N S A X L E <AWD> Transaxle Assembly 45 Nm 22 lt.lbs. Drive shaft (Left side).A+ 15. TSB Revision . 6. Transaxle assembly lower part coupling bolt 18. Mounting stopper 16. Clutch tube bracket connection 11. Inner shaft 6.0 Nm 4. Transaxle mount bracket (Body side) . Starter 23. 19. Transaxle mount connection 13.lbs. Transaxle assembly 4C. Transaxle mount bracket (Transaxle side) 17.A+ 24. Transaxle stay connection (Rear bank side) 27. Starter cover 22. 20. Transaxle assembly lower part 4C. coupling bolt 28. Clutch release cylinder connection 12. Transaxle stay connection (Front bank side) 26. Lower arm ball joint connection 4B. Right member 21.lbs. .0 ft. Tie rod end connection 4B. assembly +C. Plug 14. Drive shaft (Right side) 25.

22-11. or the intercooler itself.D+ AIR HOSE A INSTALLATION Connect the air hoses ensuring that alignment marks are aligned with projections. INNER SHAFT ASSEMBLY / DRIVE SHAFT (RIGHT SIDE) / TRANSAXLE ASSEMBLY LOWER COUPLING BOLT / TRANSAXLE ASSEMBLY REMOVAL Refer to P.A i r i n t a k e holIoo23 Air hose B . AIR INTAKE HOSE A INSTALLATION Align slots indicated by arrows in air intake hose A with A markings on air intake hoses B and C. INSTALLATION SERVICE POINTS .A4 DRIVE SHAFT (RIGHT SIDE) / MOUNTING STOPPER INSTALLATION Refer to P. ZO3FOO8 i Air intake hose C . as shown in the figure. REMOVAL SERVICE POINTS 22-21 +A. up to the stepped part. Insert air hoses B and C into pipe all the way to its step.22-il. CLUTCH RELEASE CYLINDER / TRANSAXLE MOUNT CONNECTION Refer to P. connect the vacuum hose to the pipe securely.MANUAL TRANSAXLE cAWD> .22-12. Insert air intake hoses B and C all the way up to the roots on the turbocharger end. WOSFOO28 1 TSB Revision .TIE ROD END / LOWER ARM BALL JOINT CONNECTION Refer to P. @. insert hoses B and C all the way into air intake hose A. +B.B+ VACUUM PIPE INSTALLATION If the vacuum pipe has a stepped part.DRlVE SHAFT (LEFT SIDE). .Transaxle Assembly . +C.22-10. then.C+AIR CLEANER COVER. Caution Be careful not to allow any foreign matter to get into the hoses. pipes.

q& \ Sleeve yoke lOG0001 Gear oil: Hypoid gear oil. Be cautious to avoid damaging the transfer oil seal lip.) - 2m - WI .Front Bumper.. 09FOOO8 09FOOO9 00001540 TSB Revision . 85-90 Nm’lb” 6 1 . Gaskets 3. .6 5 ft. Bolts and nuts 2.22-22 MANUAL TRANSAXLE <AWD> .lbs.a 36 ft.TRANSFER ASSEMBLY REMOVAL Caution 1. Transfer assembly l l: Up to 1993 models l 2: From 1994 models NOTE REMOVAL SERVICE POINT qA.lbs. Cover the transfer opening with the special tool to prevent transaxle oil discharge and the entry of foreign objects.Transfer Assembly TRANSFER ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation l Transfer Oil Draining and Supplying (Refer to !?22-15.Nm 1” . Warm up catalytic converter and front exhaust pipe 4. 25-29 Nm*2 18-22 ft. SAE 75W-90 or 75W-85W conforming to API classifi 09 FOO08 00001539 Removal steps 1.lbs. 2.) l Active Front Venturi Skirt Removal and Installation (Refer to GROUP 51 .

.LOSAO027 TRANSAXLE ASSEMBLY The transaxle cannot be disassembled.MANUAL TRANSAXLE <AWD> .B+ .A4 5.A+DRlVE SHAFT OIL SEAL INSTALLATION Using the special tool. The propeller shaft should be suspended so that it is not sharply bent. Transfer oil seal guide .D+ .Fd 2. Transfer case oil seal . install the drive shaft oil seal. Drive shaft oil seal 8. Drive shaft oil seal INSTALLATION SERVICE POINTS . Input shaft rear seal cap 6. replace the transaxle assembly.Transfer Assembly / Transaxle Assembly 22-23 3. REPLACEMENT PART ZfFM0157 1. If any parts other than describes below are defective. TSB Revision . Transfer mounting bolts .C( . Center shaft oil seal 7.E+ 3. Transfer extension housing oil seal 4.

MD998325 2201029 . install the transfer extension housing oil seal. . .DdlNPUT SHAFT REAR SEAL CAP INSTALLATION Using the special tool.F+ TRANSFER CASE OIL SEAL INSTALLATION Using the special tool.22-24 MANUAL TRANSAXLE <AWD> . \I L I ZTFM0163 / / \ 1 TSB Revision . install the drive shaft oil seal. drive the oil seal until it is flush with the case. install the input shaft rear seal cap.B+DRlVE SHAFT OIL SEAL INSTALLATION Using the special tool. Do not drive the oil seal more than necessary.C+CENTER SHAFT OIL SEAL INSTALLATION Using a pipe shown in the illustration.E+ TRANSFER EXTENSION HOUSING OIL SEAL INSTALLATION Using the special tool.Transaxle Assembly . x1-. 22200081 MD99881 2 . install the transfer case oil seal.

. s . . . . . . . . . . . . . . . . . . 52 Speedometer. . 50 Selector Lever Operation Check . . . . . . . . . . . . . . . . HOSES. . . . . . . . . . . . . . . SRS warning light. . . . : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Drive Shaft Oil Seals Replacement . . . . . . . . . . 14 Reducing Pressure Adjustment . . . 41 Inspection of Control System . . . . . . . . . . . . . . . . . . . SRS diagnosis unit. . .23-1 AUTOMATIC TRANSAXLE CONTENTS GENERAL INFORMATION . . . . . . . . . .. . . . . . . . . . . . . . . . . (3) MITSUBISHI dealer personnel must thoroughly review this manual. . . . . . . . . . . . . . . . . . . . . . . . 25 Inspection of Electronic Control System Components 32 Shift Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . clock spring and interconnecting wiring. . . . . . . . . . . . . 11 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Line Pressure Adjustment . . . . . . . . . . . . . . . and especially its GROUP 528 -Supplemental Restraint System (SRS) and GROUP 00 -Maintenance Service. . . . . . . . . . . . . . . . . 51 Shift Lock Mechanism Check . . . . . . . . . . . . . . . . . . . . . Other SRS-related components (that may have to be removedlinstalled in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (‘). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Element in Use at Each Position of Selector Lever . . . . . . . . . . . . . . . . . . . NOTE The SRS includes the following components: impact sensors. . . . . . . . . . . . . . . . . . . . . . . . 11 General Specifications . . . 64 TRANSAXLE CONTROL* . . . . . . . . . . . . . . . . . . . 27 Troubleshooting Guide . 2 ON-VEHICLE SERVICE . . 29 Transaxle Control Module. . . . . . . . . . . . i . . . . . . . . . . . before beginning any service or maintenance of any component of the SRS or any SRS-related component. . 44 Diagnosis and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Replacement <Up to 1993 models> . . . . . . . . . . . . . . . . . 54 m Safety-lock System Troubleshooting . . . . . . . . . . . . . Park/Neutral Position Switch and Control Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. . . . . . . . . 51 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 47 Transmission Fluid Replacement . . . . . . . . . . . 53 Key Interlock Mechanism Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Transmission Fluid Level Check . can lead to personal injuryordeathtoservicepersonnel (from inadvertentfiringoftheairbag)ortothedriverandpassenger(fromrendering the SRS inoperative). . . . . . . . . . . 12 WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS. . . . 29 Hydraulic Pressure Tests . . . . . . . . . 51 Kickdown Servo Adjustment . . . . 47 SELECTOR LEVER ASSEMBLY . . . . . . . . TUBES . . or any SRS-related component. . . . . . . . . . 59 SPECIAL TOOLS. . . . . . 11 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Accelerator Switch Check and Adjustment (1992 model) . . 62 TROUBLESHOOTING . . . 45 Converter Stall Test . . . . . . . . . . 55 TRANSAXLE OIL COOLER. . . . . . . . . . air bag module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LJ 48 53 TRANSAXLE ASSEMBLY . . . . . . . . . . . . . . .

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Rear clutch exhaust valve 10._. Kickdown servo 7. l-2 shift valve 15. N-R control valve 24. End clutch valve 16. Manuai valve 22.. 2-3/4-3 shift valve 11. Transaxle control module 8. Oil pan 26.. End clutch 6. Torque converter 2.mx. Shift control valve 19. Torque converter clutch valve 9.NeutraD To lubrlcatlon (front) To lutmcatm (rear) . Torque converter control valve 17’.~ ! Pressure control solenoid valve pressure m Torque converter clutch pressure m Torque converter clutch solenoid pressure WA0070 1. Front clutch 3. Line relief valve 28. WG control valve 20. Regulator valve 21. Pressure control solenoid valve .i Oil pump suction pressure iModulated line pressure _-. Reducing valve 13. Rear clutch 4. Line pressure /-J Torque converter and lubrlcatlon pressure a Reducing pressure i. Shift control solenoid valve ‘“13” 18. Oii pump 27. Oil filter 25. Low-reverse brake 5. Pressure control vaive 23. Shift control solenoid valve “A“ 14. Torque converter clutch soieno~d 12.

I di .

Pressure control valve 23.. 2-3/4-3 shift valve 11. Rear clutch exhaust valve 10. End clutch valve 16. Pressure control solenoid valve TSB Revision . Oil pan 26. Shift control solenoid valve “B” 18. N-R control valve 24. Torque converter control valve 2. 1-2 shift valve 17.Parking 6 To lubncation (front) . Shift control solenoid valve “A” 14. Line relief valve 28. Low-reverse brake 5.-E? To lubrication (rear) -= 16 25 _ Line pressure m Torque converter and lubrication pressure m Reducing pressure /-J Oil pump suction pressure j Modulated line pressure i Pressure control solenoid valve pressure I que converter clutch ssure que converter clutch . End clutch 6. Front clutch 3. Torque converter 15. Oil pump 27. Reducing valve 13. N-D control valve 20. Kickdown servo 7.. Rear clutch 4. Oil filter 25. Transaxle control module 8. Regulator valve 21.. Torque converter clutch valve 9. Manual valve 22. Shift control valve 19. Torque converter clutch solenoid 12.anoid pressure TFA0071 1.

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Rear clutch exhaust valve 10. l-2 shift valve End clutch valve Torque converter control valve Shift control solenoid valve “B” Shift control valve N-D control valve Regulator valve Manual valve Pressure control valve N-R control valve Oil filter Oil pan Oil pump Line relief valve Pressure control solenoid valve TSB Revision J .-= To lubrication (rear) -I 25 Ed a 011 pump suction pressure / Modulated line pressure 0 Pressure control solenoid valve pressure 15. 2-3/4-3 shift valve Torque converter clutch solenoid ::: Reducing valve 13 Shift control solenoid valve “A” 14. 18. / Torque converter clutch pressure ( Torque converter clutch solenoid pressure VA0242 Line pressure j Torque converter and lubrrcation pressure II Reducing pressure Torque converter :: Front clutch Rear clutch t Low-reverse brake 5: End clutch Kickdown servo 7. 19. 16. 26. 17. 25. 21. 27. 24. 22. 28.23-4 Drive (Stop) AUTOMATIC TRANSAXLE . 23.General ln~~r~~ti~m 6 El: T To lubrication (front) . Transaxle control module 8: Torque converter clutch valve 9. 20.

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AUTOMATIC TRANSA LE . Transaxle control module 8.General h-d Drive (First) YiFTh &Ah & I* [. End clutch 6. Kickdown servo 7. 16. 19. Torque converter clutch valve 9. 25. Front clutch 3. 26. 2 22: 23. 24. Reducing valve 13. F lb5 ----___ 24 25 E” brque converter clutch lressure brque converter clutch -olenoid pressure Line pressure ye converter and luulication pressure Reducing pressure /-J Oil pump suction pressure j Modulated line pressure j Pressure control solenoid valve pressure 15. Low-reverse brake 5. t 1 TFA0072 1. Shift control solenoid valve “A” 14. 2-3/4-3 shift valve 11. Torque converter 2. Rear clutch exhaust valve 10. . Rear clutch 4. 17. I-2 shift valve End clutch valve Torque converter control valve Shift control solenoid valve “B” Shift control valve N-D control valve Regulator valve Manual valve Pressure control valve N-R control valve Oil filter Oil pan Oil pump Line relief valve Pressure control solenoid valve TSB Revision . 18. -5 1~ IIL i&II ?--FTTY To lubrication (front) -3 To lubrication (rear) C= 16 . Torque converter clutch solenoid 12.

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25. 16. Rear clutch 4. l-2 shift valve End clutch valve Torque converter control valve Shift control solenoid valve ‘33” Shift control valve N-D control valve Regulator valve Manual valve Pressure control valve N-R controi valve Oil fitter Oil pan Oil pump Line relief vaive Pressure control solenoid valve . 26. Front clutch 3. Torque converter clutch solenoid 12. Torque converter 2. Reducing valve 13. Kickdown servo 7. 22.riv Ic2‘%aas-. ] Pressure control solenoid valve pressuie 15. 20.d\ To lubrication (front) To lubrication (rear) -Z 25 Line pressure j Torque converter and lubrlcatlon pressure Reducing pressure m Oil pmp suction pressure . Z&3/4-3 shift valve Il. Low-reverse brake 5. 19. 27. Shift control solenoid valve “A” 14. 7 i__i Torque converter clutch pressure ! Torque. 18. 23. 28. Torque converter clutch valve 9. End clutch 6. 21. 1. 24. 17. Rear clutch exhaust valve 10. Transaxle control module 8. converter clutch solenoid pressure TFA0073 j Modulated ltna pressure 1.

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17. Transaxle control module 8. Rear clutch exhaust valve 10. Front clutch 3. Rear clutch 4.Drive (Third) 6 I. 26. 16. ’ rF!zKxzr‘i-t A==8w ~u To lubrication (fror. 28. 20. End clutch 6. 25. 24. _~_ To lubrication (rear) +Z 16 19 b 28 7 4 m Line pressure j 011 pump suction pressure / Modulated line pressure Lque converter clutch ssure que converter clutch ?noid pressure m Torque converter and lubrication pressure m Reducing pressure j Pressure control solenoid valve pressure TFA0074 1. Low-reverse brake 5. Shift control solenoid valve “A” ‘14. End clutch valve Torque converter control valve Shift control solenoid valve “B” Shift control valve N-D control valve Regulator valve Manual valve Pressure control valve N-R control valve Oil filter Oil pan Oil pump Line relief valve Pressure control solenoid valve . 18. Reducing valve 13. 22... Torque converter clutch valve 9. 21. 23. 27. Torque converter 2. Torque converter clutch solenoid 12. Kickdown servo 7. 2-3/4-3 shift valve 11. l-2 shift valve 15. 19.

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End clutch valve Torque converter control valve Shift control solenoid valve “B” Shift control valve N-D control valve Regulator valve Manual valve Pressure control valve N-R control valve Oil filter Oil pan Oil pump Line relief valve Pressure control solenoid valve 1 TSB Revision .L. 23. 28. To lubric :ation (rear) +I m Line pressure lue converter and . Rear clutch exhaust valve IO.ication pressure m Reducing pressure 0 Oil pump suction pressure 0 Modulated line pressure 0 Pressure control solenoid valve pressure 0 Torque converter clutch pressure m Torque converter clutch solenoid pressure TFA0075 1. 21. Reducing valve 13. Shift control solenoid valve “A” 14. 24. . 22. 19. End clutch 6. 2-3/4-3 shift valve 11. 20. Torque converter clutch solenoid 12. 18. 27. 16. Front clutch 3. 25.23-8 AUTOMATIC TRANSAXLE . 17. Torque converter 2. 26.General Information rive (Fourth) r To lubrrc ation (frc. Kickdown servo 7. Transaxle control module 8. Low-reverse brake 5. Torque converter clutch valve 9. 1-2 shift valve 15. Rear clutch 4.

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ule 8. Reducing valve 13.-=/ To lubrication (rear) -= 18 I tx !Ih 5 m Line pressure 0 Torque converter and lubrication pressure m Reducing pressure I Oil pump suction pressure 1 Modulated line pressure 0 Pressure control solenoid valve pressure 15. 27. 28.AUTOMATIC TRANSAXLE . 25. 2-3/4-3 shift valve 11. 24. 16. Shift control solenoid valve “A” 14. Transaxle control mod. 19. Rear clutch 4. Front clutch 3. 26. Torque converter clutch solenoid 12. Kickdown servo 7. 17. 20. 23.General Information . Torque convertor clutch valve 9. End clutch 6. 17 rque converter clutch 3ssure rque converter clutch Jenoid pressure c TFA0076 1.ock-up (First) 23-9 To lubrrcatron (front) . 21. Rear clutch exhaust valve 10. Torque converter 2. Low-reverse brake 5. 22. l-2 shift v?r\~n End clutch valve Torque converter control valve Shift control solenoid valve “B” Shift control valve N-D control valve Regulator valve Manual valve Pressure control valve N-R control valve Oil filter Oil pan Oil pump Line relief valve Pressure control solenoid valve 1 TSB Revision . 18.

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Line pressure 0 Oil pump suction pressure 0 Modulated line pressure m Reducing pressure / Pressure control solenoid valve pressure r--F. N-D control valve 20. Torque converter 2. 5.General Information Reverse L / iso / I!~!~i’m To lubrication (front) . Shift control valve 19. Shift control solenoid valve “B” 18. Oil filter 25. Pressure control solenoid valve TSB Revision . 7.-Ia Torque converter clutch pressure 0 Torque converter clutch solenoid pressure TFA0077 1. Rear clutch Low-reverse brake End clutch Kickdown servo Transaxle control module 8. Reducing valve 13. Shift control solenoid valve “A” 14. Manual valve 22. Front clutch 3. Regulator valve 21.23-10 AUTOMATIC TRANSAXLE . Torque converter clutch solenoid 12. N-R control valve 24. Line relief valve 28. Torque converter clutch valve L 9. 6.-= To lubrication (rearj +Z 25 . l-2 shift valve End clutch valve Torque converter control valve 17. Oil pan 26. 2-3/4-3 shift valve 11. Rear clutch exhaust valve 10. 4. Pressure control valve 23. Oil pump 27.

I I I LJ \ LJ I L/’ .

9 (.685 2.24) 15. 13 870-890 (124-127) 38 (5) 425+10(60&l) 45 (6) 275 (39) 22 (3) 2-6 (.176 3.SPecifications 23-11 SPECIFICATIONS i L GENERAL SPECIFICATIONS Items Model Specifications F4A33-1 -MNP2 cl 992 model> F4A33-l-MNP8 cl993 model> F4A33-1 -MNQ2 cl 994 model> F4A33-1 -MNQ7 <From 1995 models> Electronically controlled 4-speed full-automatic 3 element with torque converter clutch 2.) TSB Revision .598-.200-3.2-15.625) L Accelerator pedal stroke (accelerator pedal switch ON to OFF) cl992 model> mm (in.079-.958 36129 I I SERVICE SPECIFICATIONS Items Resistance of torque converter clutch solenoid valve coil [at 20°C (68”F)] <Up to 1993 model> Q Resistance of torque converter clutch solenoid valve coil [at 20°C (68”F)] <From 1995 model> Q Line pressure Line pressure kPa (psi) Oil pressure change for each turn of adjustment screw kPa (psi) Reducing pressure (when the scan tool is not used) Reducing pressure (when the scan tool is used) Reducing pressure kPa (psi) Oil pressure change for each turn of adjustment screw kPa (psi) Reducing pressure kPa (psi) Oil pressure change for each turn of adjustment screw kPa (psi) Specifications Approx.200 rpm Type Torque converter Gear ratio First Fourth Reverse Final gear ratio Speedometer gear ratio (Drive/Driven) i l- 0. 3 Approx.) Sleeve and selector lever assembly end play mm (in.AUTOMATIC TRANSAXLE .

) Drive shaft oil seal lip SPECIAL TOOLS l and lower arm ball joint Disconnection of thecoupling of the knuckle and tie-rod end ball joint ecking of the diagnostic trouble code Checking of the diagnostic trouble code stic trouble codes using a check harness oil seal installer 1 TSB Revision .5 (7.23-12 LUBRICANTS Items AUTOMATIC TRANSAXLE .Specifications / Special Tools Specified lubricants DIAMOND ATF SP or equivalent Quantity 7.9) As required Transmission fluid dm3 (qts.

29) <W5MGl> 0.27 (.375 2.) / Transaxle Transfer 3.076 1.071 From 1994 model WGMGl-0-FNBR 6G72-DOHC (Turbo) 1 6-speed transaxle floor shift / 3.) 2.266 I Me Sear ratio 3rd / 4th / 1.4 (2.4 (2.888 0.27 (.5) 1 0.823 / 1.814 27136 2.29) 0.958 28136 2.MANUAL TRANSAXLE cAWD> .103 1 0.Specifications MANUAL TRANSAXLE cAWD> Li SPECIFICATIONS GENERAL SPECIFICATIONS Items Model r\pplicable engine Up to 1993 model W5MGl-0-FNBR 6G72-DOHC (Turbo) 5-speed transaxle floor shift j 1st / 3. SAE 75W-90 or 76W-85W conforming to API classification GL-4 Drive shaft oil seal lip Transfer oil seal lip Specified lubricants Quantity dm3 (qts.63) I LUBRICANTS Items Transmission oil Transfer oil Hypoid gear oil.918 I I 6th Reverse Reduction ratio Primary Front differential Transfer Speedometer gear ratio (driven/drive) Oil quantity dm3 (qts.166 0.6 (.6 (63) <WGMGl> As required TSB Revision .241 / 0.153 1.5) 1 0.222’ 3.5) 0.589 3.4 (2.

and any other relevant information. by using a multi-use tester or voltmeter. or slippage of the clutch or brakes.Troubleshooting TROUB. the situation at the time the problem occurred. all in as much detail as possible. or an abnormalcondition of the transaxle itself. When the abnormal condition is presumed to be in the hydraulic-pressure-control system. The user should also be asked whether or not the problem has occurred more than once. etc. such as the condition of the problem. Subsequently.23-14 AUTOMATIC TRANSAXLE . oil leakage. in order to determine jhe probable location of the problem. check each system at places related to the valve body. as well as the condition of the manual control cables. and under what conditions. + When the result of the oil-pressure test does not satisfy the specified pressure. check the fault code. certain tests should be conducted in a certain order. + When the abnormal system is discovered. as described at the left.) one by one. disassemble and repair the transaxle. I t Checks should be made of fluid levels and the condition of the ATF. check by making an oil-pressure test. abnormal noises. I t Functional malfunctions of the ELC-4A/T can lead to other problems. and make repairs as necessary. it is first essential to methodically question the user concerning the details of the problem. such as those described below: (1) Improper maintenance and/or adjustments (2) Malfunctions of the electronic control functions (3) Malfunctions of mechanical functions (4) Malfunctions of hydraulic control functions (5) Malfunctions of engine performance etc.LESHOOTING Based upon use of the troubleshooting guide. etc. 1 TSB Revision . check each element (sensors. If a presumption has been made that there is an abnormalconditionsomewhere in the electronic-control svstern. the probable location of the problem should be estimated. check the hydraulic-pressure oassaaes for leakaae. adjustments should then be made if found to 1 be necessary. In order to properly determine (“Troubleshoot”) the source of these malfunctions. If the problem is unusually dirty ATF.

other) Malfunction of park/neutral position switch. or improper adjustment of the preload ( Malfunction of parking mechanism Cracked drive plate or loose bolt I 8 X X 63 X X X @ X X I X I I X I 10 / Worn inside diameter of front clutch retainer 11 12 Low fluid level Line pressure too low (seal damaged. or shortcircuit Pulse generator(B) damaged or disconnected wiring.) I I I 63 63 69 I I @ 63 8 8 I I 8 c9 @3 x I I I I 13 Hydraulicpressure system (including friction elements) ] 14 15 16 17 I 18 r’ 1Malfunction of front clutch or piston Malfunction of rear clutch or piston Malfunction of kickdown band or piston lmorooer adiustment of kickdown servo 1 Malfunction of low-reverse brake or piston 0-ring of low-reverse brake circuit between valve body and case notinstalled Malfunction of end clutch or piston (check ball hole. PSCV = Pressure control valve I Abbrevilations: TPS = Throttle position sensor TCC solenoid = Torque converter clutch solenoid I I SCSV = Shirt control solenoid valve OD = Overdrive TSB Revision . or shortcircuit servo switch I I I I I I x X I I / I 19 20 21 22 23 24 I X 25 26 IElectronic(:ontrol system I Malfunction of kickdown I .Troubleshooting TROUBLESHOOTING GUIDE 1 il terns 23-15 Driving impossible or abnormal (before start-off) Starter motor won’t function Forward/ backward movement impossible Forward movement impossible Backward movement impossible Engine 1 Abnormal idling rpm X 2 I Performancemalfunction 3 4 5 Transaxle (power train) / 6 . etc.) Malfunction of valve body (sticking valve. working cavity. or short-circuit or sticking (valve open) Malfunction of ignition signal system 27 1 28 I incorrectly grounded ground strap 29 30 I 31 32 33 34 PCSV damaged or disconnected wiring. or improper adjustment Pulse generator (A) damaged or disconnected wiring. damaged or disconnected wiring.AUTOMATIC TRANSAXLE . leakage. looseness. 1 1 1 SCSV-Aor B damaged or disconnected wiring. or improper adjustment Malfunction of TPS. etc. adjustment. 8 9 Improper adjustmentof manual linkage Malfunction of torque convertor Operation malfunction of oil pump Malfunction of one-way clutch Damagedor worn gear or other rotating pan. or short-circuit PCSV damaged or disconnected wiring (valve open) I TCC solenoid damaged or disconnecting wiring (valve open) TCC solenoid short-circuit or sticking (valve open) Malfunction of overdrive control switch Malfunction of oil-temoerature sensor leadswitch I I I 63 I I “@ I 8 I I I I I 35 I Malfunctlonof I 36 I Poor contact of ignition switch Malfunction of transaxle control module I I x I I I I I I I I I I I s7 I OTE: @ Indicates items of priority inspection.

Troubleshooting Driving impossible or abnormal (before start-off) Engine stalls when N+DorR 1 2 (59 X Clutch slips at D (stall rpm too high) Clutch slips at R (stall rpm too high) Stall rpm too low Vehicle moves at P or N Enginestarts. or vehicle moves.23-16 - AUTOMATIC TRANSAXLE . between N-R or N-D Parking doesn’t hold Abnormal vibration-shock when shift to D-2-L-R X X TSB Revision .

Troubleshooting 23-17 Won’t shift from xcessive creepWon’t shift to 4th . 37 X / X X I X I X I X I X TSB Revision .AUTOMATIC TRANSAXLE .

23-18 AUTOMATIC TRANSAXLE .Troubleshooting Excessive vibrationshock during upshift TSB Revision .

Troubleshooting 23-I 9 L / L /- 1 TSB Revision .AUTOMATIC TRANSAXLE .

fluid oxidation. Also check to be sure the vehicle doesn’t begin to move and the lever doesn’t stop between P-R-N-D. 3. l If there is a “burning” odor. Slowly move the selector lever upward until it clicks as it fits in notch of ‘P” range. When transaxle has too much fluid. 5. air bubbles can cause overheating. then place lever in “N” Neutral position. as described above. If starter motor operates when lever makes a click. Place selector lever to “R” range. Foaming can also result in fluid escaping from transaxle vent where it may be mistaken for a leak. Then take out the dipstick and check the condition of the fluid. Low fluid level can cause a variety of conditions because it allows pump to take in air along with fluid. ZT FA070( I \ ‘d ~ I I TSB Revision . CONTROL CABLE Whether control cable is properly adjusted can be confirmed by checking whether park/neutral position switch is performing well. “N” position is correct. The transaxle should be overhauled under the following conditions. Before removing dipstick. This operation is necessary to be sure that fluid level check is accurate.23-20 AUTOMATIC TRANSAXLE . In either case. Check to see if fluid level is in “HOT” range on dipstick. wipe all dirt from area around dipstick. The control cable is properly adjusted if.Troubleshooting DIAGNOSIS AND TEST FLUID LEVEL AND CONDITION 1. Be sure to examine fluid on dipstick closely. gears churn up foam and cause same conditions which occur with low fluid level. 4. 5. 6. Drive until the fluid temperature reaches the usual temperature [70-80°C (158-176”F)j. clutch. “P” position is correct. If starter motor operates when selector lever fits in ‘IN”. Place vehicle on level floor. 2. 4. Improper filling can also raise fluid level too high. 3. Therefore. add automatic transmission fluid until level reaches “HOT” range. l If the fluid color has become noticeably blacker. resulting in accelerated deterioration of automatic transmission fluid. pressures will be erratic. l If there is a noticeably great amount of metal particles in the fluid. the starter motor starts at both the ‘P” range and the “N” range. Then slowly move selector lever to “N” range by the same procedure as in foregoing paragraph. 1. 6. and servo operation. 7. Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid. Set ignition key to “ST” position. which can interfere with normal valve. Air trapped in hydraulic circuit forms bubbles which make fluid spongy. 2. Apply parking brakes and service brakes securely. If fluid level is low.

6 terminal) and the ground terminal (No. (4) After turning the ignition switch once to OFF. (2) Obtain the diagnostic output by observing the voltmeter pointer deflection. r MFI diagnosis I Ground YZOFO163 When using a Voltmeter <From 1994 model> (1) Connect an analog voltmeter to the diagnostic output terminal (No. 4 or 5 terminal) of the data link connector. (2) Obtain the diagnostic output by observing the voltmeter pointer deflection. referring to’ the diagnostic c h a r t . (1) Connect the scan tool to the data link connector. 1993 model.AUTOMATIC TRANSAXLE . 4 or 5 terminal).Troubleshootina cup to 1993 model> %. 23-21 1 Scan tool (MB991341 or MB991502) \ 2OFOl59 Scan tool /-.(MB991 502) DIAGNOSIS FUNCTION METHOD OF READING THE DIAGNOSTIC TROUBLE CODES When using the scan tool [Multi-use tester (MUT) cl993 model> or MUT-II <All models>] Caution Connection and disconnection of the scan tool should always be made with the ignition switch in the OFF position. TSB Revision . use the adapter harness supplied together. referring to the diagnostic chart. (2) Take a reading of the diagnostic output. turn it back to ON. Caution Be sure to use the special tool (diagnostic trouble code check harness) to connect the voltmeter to the -ground terminal (No. 00002231 2OFO164 When using a voltmeter cl993 model> (1) Connect an analog voltmeter to the diagnostic output terminal (No. NOTE When connecting MUT-II to a vehicle up to. 12 terminal) of the data link connector (white). (3) Repair the problem location. referring to the diagnostic chart. (3) Repair the problem location. (3) Repair the problem location. 6 terminal) and the ground terminal (No.

Troubleshooting Diagnostic result indication by voltmeter r Example of diagnostic trouble code output voltage waveform Waveform for diagnostic trouble code No...A i’ . and read the diagnostic trouble codes to check that a normal code is output. (3) Check to be sure that no diagnostic trouble codes exist.~ ~ TSB Revision .23-22 AUTOMATIC TRANSAXLE . METHOD OF ERASE THE DIAGNOSTIC TROUBLE CODES When using the scan tool [Multi-use tester (MUT) cup to 1993 model> or MUT-II <All models>] (1) Turn the ignition switch to OFF and then back to ON again. 24 . When using the voltmeter (1) Turn the ignition switch to the OFF.L Waveform when normal LJ digit signal delimiter 2 sec. reconnect the cable. I’\.. (2) Erase the diagnostic trouble codes. (3) Turn the ignition switch to the ON. digit signal Z14NO173 Z14N0174 NOTE Other diagnostic items are also indicated by the voltage waveforms corresponding to the code numbers obtainea when the scan tool is used. (2) After disconnecting the battery cable from the battery (-) terminal for 10 seconds or more.

Check solenoid valve connector. Check shift control solenoid valve B on bench. . Adjust throttle position sensor. Check throttle position sensor on bench. Check pressure control solenoid valve on bench.AUTOMATIC TRANSAXLE .Troubleshooting FAULT CODE’ DESCRIPTION 23-23 I L Code No. Open-circuited or improperly adjusted accelerator l Check accelerator switch connector. switch l Adjust accelerator switch. l Check accelerator switch on bench. ~199. Check solenoid valve connector. cl 992 model only> Open-circuited pulse generator A Open-circuited pulse generator B Short-circuited Park/neutral position switch Open-circuited Park/neutral position switch Open-circuited shift control solenoid valve A Short-circuited shift control solenoid valve A Open-circuited shift control solenoid valve B Short-circuited shift control solenoid valve B Open-circuited pressure control solenoid valve Short-circuited pressure control solenoid valve Open-circuited torque converter clutch solenoid Short-circuited torque converter clutch solenoid Defective torque converter clutch system l l l l l l l l l l l l l 31 32 36 37 41 42 43 44 45 46 47 48 49 Check pulse generator A or B on bench. Check shift control solenoid valve A on bench Check solenoid valve connector. 11 12 13 14 15 Item Excessively large throttle position sensor output Excessively small throttle position sensor output Defective or improperly adjusted throttle position sensor Improperly adjusted throttle position sensor l l l l l l Remedial Action Check throttle position sensor connector. Check Park/neutral position switch connector Check Park/neutral position switch on bench Check solenoid valve connector. Check accelerator switch (whether code number 24 is being output). models only> Open-circuited low-oil-temperature sensor cl 992 model> Open-circuited oil temperature sensor <From 1993 model> Short-circuited high-oil-temperature sensor cl992 model only> Short-circuited oil-temperature sensor <From 1996 model> l l Check oil temperature sensor connector. Check kickdown servo switch on bench. Check ignition pulse signal line. Check torque converter clutch solenoid on bench 0 LJ TSB Revision Check torque converter clutch hydraulic circuit Check torque converter clutch solenoid on bench 0 Replace control unit. Check vehicle-speed reed switch (chattering). 16 l l 17 Open-circuited high-oil-temperature sensor or shortcircuited low-oil-temperature sensor cl 992 model only> Open-circuited kickdown servo switch Short-circuited kickdown servo switch Open-circuited ignition pulse pickup cable l l l 21 22 23 ii 24 Check kickdown servo switch connector. Check oil temperature sensor on bench.

46 51. Front clutch slipping Rear clutch slipping Check connectors of pulse generators A and B.L) Fixed at 3rd (D) or 2nd (2. 51 AUTOMATIC TRANSAXLE .Troubleshooting Item 1 st gear incorrect ratio l Remedial Action 0 0 0 l l Check connectors of pulse generators A and B. Check torque reduction request signal line.44 45. L) Fixed at 3rd (D) or 2nd (2. L) Fixed at 3rd Fixed at 3rd Fixed at 3rd (D) or 2nd (2. Check torque reduction execution signal line. di 52 2nd gear incorrect ratio 0 53 3rd gear incorrect ratio l l l l l l l l 54 4th gear incorrect ratio 59 Dccurence of abnormal vibration <From 1994 model> Short-circuited torque reduction request signal line or open-circuited torque reduction execution signal line Open-circuited torque reduction request signal line Short-circuited torque reduction execution signal line l l l l l l l 61 62 63 FAIL-SAFE CODE DESCRIPTION Code No.or short-circuited pressure control solenoid valve Incorrect gear ratio Fail-safe Fixed at 3rd (D) or 2nd (2. Check torque reduction request signal line. 81 82 83 84 85 Item Open-circuited pulse generator A Open-circuited pulse generator B Open. Rear clutch slipping Kickdown brake slipping Check connectors of pulse generators A and B. Replace automatic transmission fluid. Check pulse generators A and B on bench. Rear clutch slipping Check connectors of pulse generators A and B. Check torque reduction execution signal line.54 Related Self-Diagnosis L) TSB Revision . Check pulse generators A and B on bench.or short-circuited shift control solenoid valve B Open. End clutch slipping Kickdown brake slipping Check connector of pulse generator A. Check pulse generators A and B on bench.42 43. Check pulse generators A and B on bench. Check pulse generator A proper.52 53.23-24 Code No.or short-circuited shift control solenoid valve A Open. L) 31 32 41.

21 Ignition signal line B Data list D Item No. Iidle OFF ID I 23-25 Criteria 0. 15 Cold engine (before start) Engine warming up After engine warming up Kickdown servo switch l Data list l Item No. 24 Closed throttle position switch D Data list D Item No.0 v Equivalent to outside temperature Gradually increases 80-110°C ON ON Possible Cause of Trouble (or Remedy) l l l TPS is improperly adjusted if voltage is high when accelerator pedal is fully depressed or released. O/D OFF. idle IL range.400-2. L CONTROL SYSTEM INSPECTION TABLE Check Item Throttle position sensor (TPS) l Data list l Item No. O/D.600 rpm ON OFF ON OFF ON OFF C I Improperly adjusted kickdown servo Defective kickdown servo switch or circuit harness Defective kickdown servo Defective ignition system Defective ignition signal pickup circuit harness Improperly adjusted accelerator pedal switch Defective accelerator pedal switch or circuit harness Improperly adjusted TPS Defective TPS or circuit harness 0 l l 0 0 0 Accelerator pedal slightly air conditioning air conditioning ’ 0 Defective air-conditioning compressor clutch relay ON signal detection circuit harness range.AUTOMATIC TRANSAXLE . 26 Transaxle gear position 1 Data list ) Item No. idle N range.5-5. 2. 11 Condition Accelerator pedal fully released Accelerator pedal slowly depressed Accelerator pedal fully depressed Oil temperature sensor l Data list l Item No.o v Varies with throttle opening degree 4.depressed ID range. Iidle-up ID range. 1st or 3rd speed D range. 2nd speed 1ST 2ND I ID range. 27 L range. 4th speed 3RD / 4TH 0 Defective TCM l Defective accelerator pedal switch circuit a Defective park/neutral position switch circuit l Defective TPS circuit -1 TSB Revision . 25 Air conditioning compressor clutch relay signal ) Data list D Item No. idle D range.500 rpm (tachometer reading) Accelerator pedal fully released Accelerator pedal slightly depressed Accelerator pedal fully released . Defective oil temperature sensor or circuit harness l l 0 0 OFF 650-900 rpm 2. 3rd speed I1 range. TPS or circuit harness is defective if there is no change. 2nd or 4th speed N range.4-l . 23 Accelerator pedal switch cl992 model only> D Data list D Item No. TPS or accelerator pedal cable is defective if change is not smooth. idle 12 range.Troubleshootina INSPECTION OF CONTROL SYSTEM Check the control system by using the scan tool and following the procedure given below.

23-26 AUTOMATIC TRANSAXLE . 47 tachometer readin l l generator B circuit Incorrect transmission fluid pressure Defective T D Item No. 38 l Duty should become 100% when ac- D range.Traubleshnntinn e pulse generator A shieldec rnal noise interference 0 Item No. 32 l External noise interference Overdrive switch Overdrive switch in ON tion switch l l Defective park/neutral position switch or circuit harness Defective manual control cable If selector lever does not move. gear being shifted ive TPS circuit ive accelerator pedal switch ) Data list D Item No. 49 generator B circuit I 1 TSB Revision I . Vehicle-speed reed D Data list D Item No. check shift lock mechanism.

Power source (backup) 11. Park/neutral position switch 57. Park/neutral position switch 52. 14. 104. Diagnostic test mode control terminal 9. Ground 106. Oil temperature sensor (High temperature side) 16. Park/neutral position switch 54. Pulse generator B 59. Ground 2. Park/neutral position switch 53. Ignition pulse 64. Park/neutral position switch 55. 5. Accelerator switch 4. Here are the pin L . Air conditioning compressor clutch relay signal 7. Power source 110. Sensor ground 18.AUTOMATIC TRANSAXLE . Vehicle-speed reed switch 51. Engine communication signal 10. Ground 63. Overdrive switch 58. assignments. Closed throttle position switch 13. Pulse generator A 62. Kickdown servo switch 12. On-board diagnostic output 6. Park/neutral position switch 56. Torque converter clutch solenoid 102. Pulse generator B 60. Power source 105. Oil temperature sensor (Low temperature side) 15. Throttle position sensor 17. Ground 1. Pulse generator A 61. Engine communication signal 109.Troubleshooting TRANSAXLE CONTROL MODULE 23-27 The connector has 42 pins to accommodate the increased number of sensor inputs. Engine communication signal 8. cl 992 models> ZT’FAO360 101. Pressure control solenoid valve 107. Power mode signal (P) (R) (N) (D) (2) (L) TSB Revision . Shift control solenoid valve A 103. 3. Shift control solenoid valve B 108.

Park/neutral position switch 35. Pulse generator B (PG-A) 45. Park/neutral position switch 36. rpcYe. 20. Pulse generator B (PG-B) 43. Engine communication signal 19. Park/neutral position switch 32. Pulse generator B (PG-B) 42. Park/neutral position switch 37.Troubleshooting <From 1993 models> ZTFA0744 1. Throttle position sensor (TPS) 23: Oil temperature sensor 24.e control solenoid valve 15. Power source (backup) 40. Sensor ground 25. Ignition pulse (P) (R) (N) (D) (2) (L) 1 TSB Revision . Power source 26.. Power source 13. Shift control solenoid valve A (SCSV-A) 3. Kickdown servo switch 8. Air conditioning relay signal 9.23-28 AUTOMATIC TRANSAXLE . 4. Engine communication signal 65: 1 7. Park/neutral position switch 34. Torque converter clutch solenoid 2. Pulse generator B (PG-B) output 11. Pulse generator A (PG-A) 44.. Vehicle-speed reed switch 41.. Park/neutral position switch 33. On-board diagnostic output terminal 10. 17. Ground 31. Diagnostic test mode control terminal 12. Shift control solenoid valve B (SCSV-B) 16. Closed throttle position switch . Ground 14. Power mode signal 39. Overdrive switch 38. Ground 46. Engine communication signal 18.

The reason why there is a difference between the shift points for up-shifts and for down-shifts is so that up-shifts and down-shifts will not occur frequently when driving at a speed in the vicinity of the shift point. there is a shift to 2nd gear in order to obtain a suitable “creeping”.000 0.551 1. When the vehicle is stopped. One is the power pattern (for more powerful performance). End clutch Kickdown brake 2:::: Low reverse brake OWC . The solid lines shown in these shift patterns indicate up-shifts.176 Possible - l D ON 1st 2nd 3rd OD 2. .AUTOMATIC TRANSAXLE .551 L - 1st NOTE Cl . Rear clutch C3 .551 2 - 1st 2nd / l l l 1. but when the accelerator pedal is then depressed the vehicle starts off in 1st gear. ! l l D OFF 1st 2nd 3rd 1. . The driver can select and switch to the desired pattern by using the power/economy select switch on the center console. Front clutch i C2 .000 2.551 1. and the broken lines indicate down-shifts.685 2. . One way clutch SHIFT PATTERNS Two shift patterns are prestored in the control unit of this transaxle.488 2. TSB Revision . . lever position P R N Overdrive control switch Shifting gear Neutral Reverse Neutral - Gear ratio Engine start Possible Parking mechanism l l Clutch Cl C2 C3 Brake owe Bl B2 2.Troubleshooting ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER 23-29 L Selector. and the other is the economy pattern (for improved fuel consumption and quieter operation).488 / I l l l l l l l l l l l l l l l l .488 1.

.I .3~ 40 20 I ii I 0 0 1 0 I/ IA /‘+F2W 1000 1 10 I 20 I 30 I 40 I 50 2000 3000 4000 il 5000 I 6000 I I Transferdrivegearspeed(rpm) I I I ! I I ! 1 1 I I I I 60 70 80 90 100 110 120 130 140 150 160 170 180 Vehicle speed (km/h) ZTFAO571 TSB Revision .Troubleshooting 100 80 I I 1 III I / I I II 60 Throttle I K 1 . L1 .~ ir ' ng 4ol ./ 1.23-30 cl 992 model> P range AUTOMATIC TRANSAXLE .'-I -' 1 I I I 5000 3 4Q 20 I 8 J 0 0 If f 1000 44 I I 2 (L) 2000 3000 4000 6000 Transfer drive gearspeed(rpm) I 0 I I I I I I I I 10 20 30 40 50 60 70 80 90 I 100 I 110 I 120 130 140 150 I I I 1 160 170 180 ZTFA0570 I I I I Vehiclespeed(km/h) E range 100 80 60 _- I --i-I 27 ~~~ --I J / I I I I I I Throttle i .3 in 31 I I I /! I 2&3 (2.

0 I 10 L 20 1000 I 30 1 50 2000 40 5000 4000 3000 Transferdrivegearspeed(rpm) 1 I 1 1 1 I 1 1 1 I 60 90 100 110 120 130 140 150 70 80 Vehicle speed (km/h) 6000 1 I 160 170 1 180 I 1 c ZTFA0817 L ‘E range I I / .Troubleshooting <From 1993 models> P range 23-31 / 80 L “0 . TSB Revision . ’ 1 2000 L 4000 3000 Transferdrivegearspeed(rpm) I 1 5000 I 6000 1. Ii 11 I I I 1000 . 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 ZTFAO818 Vehicle speed (km/h) i.AUTOMATIC TRANSAXLE .

d’ 1: Low temperature side 2: Ground 3: High temperature side --+ Vatythethermo-sensitivepartfromlowtempera3.23-32 AUTOMATIC TRANSAXLE . <From 1993 model> Damaged or disconnected wiring 4 Replace the oil-temperature sensor (resistance: -) Changes of the resistance continuous and smooth. 1 Continuity i Normal lmproperconnectionof connectar. 1 Reconnecttheconnector. damaged or disconnected hamessorincorrectwiringconnection. i Normal ZTFA0821 1: Oil temperature sensor 2: Ground d TSB Revision .Troubleshooting INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS Based on the wiring diagram check whether the continuity and grounding of each harness is OK. Oil-temperature ture to high temperature and check the resissensor tance between the terminals 1 and 2. repair or replace the harness.

1. Closed throttle position switch 3. Power Check for changes of the resistance between --+ Changes of the resisterminals 4 and 2 when the throttle valve is opertance are not continuous. output 4. (68°F) 1 1 Resistance: approx.4 kW2O”C 2 with the engine idling after throttle-valve opening warm-up.4 W2O”C (68°F) I 1 Readjust the TPS installation.Troubleshooting Check the resistance between terminals 1 and 4 of the TPS. t imj Z7FUO535 Check the resistance between terminals 4 and --w Resistance: more or less than 0. I Resistance: highorinfinite 23-33 sensor V’S) TPS terminal t 3. ated from the idling position to the fully open position. 0. t / Normal 1 Changes of the resistance continuous and I i i TSB Revision .AUTOMATIC TRANSAXLE .5 kN20”C (68°F) I Damaged or disconnected wiring I t Replace the TPS. Poor contact Replace the TPS. Ground 2.5-6.

Pulse generator ---+ Connect the pulse generator and body harness. 1 Replace the pulse generator. Replace the pulse generator. or replace the pulse gener- Improper grounding of the pulse generator circuits shielded wir1 ins.Troubleshooting Short-circuit. 500 mVp-p or higher 1 1 Noise in thewaveform r 1 Correct the installation condition. Pulse generator terminals 215-275 R/2O”C (68°F) 1-2: pulse generator A 3-4: pulse generator B J Normal 1 6. or malfunction of the pulse generator.r\. check the voltage waveform between terminals 3 and 4.000 rpm.23-34 AUTOMATIC TRANSAXLE . or malfunction of the pulse generator. TFA1328 Normal TSB Revision .ordamagedordisconnected wiring 4 Replace the pulse generator. I tion. 2 or 3 and 4. 1 lncorrectinstallationofthe pulse generator. I TFA1328 I With the selector lever at the “L” position and the engine running at 1. or replace the pulse generator. Very low voltage Oscilloscope waveform age waveform between terminals 1 and 2. mWpr. Improper grounding of the pulse generator circuits shielded wiring. A or B (checking by and connect an oscilloscope. I Incorrectinstallationofthepulse generator. Check with the an oscilloscope) chassis on a dynamo or with the front wheels raised.

ordamagedordisconnected wiring i Replace the PCSV.ordamagedordisconnected wiring + 1 22.3 ? 1.5Q/20°C (68°F) I t Replace the SCSV. and (. I Short-circuit. in. i 2. (stroke: 0.3 mm (.OlO in.012 operation noise. 4 Noise exists.25 mm terminal 3 or 4. + Normal 8.) or less) check the valve stroke. switch ON and OFF and check for (stroke: 0. Pressure-control sot h solenoidvalveconnectorandthetransaxlecase.AUTOMATIC TRANSAXLE . switch ON and OFF and check for operation noise of the solenoid valve.9 f 0. Noise exists. 1 Solenoid valve connector terminals 1: PCS” 2: TCC solenoid 3: SCSV-A 4: SCSV-B 21750338 Foreign material caught between the valve and guide 4 Replace the PCSV.3W2O”C (68°F) i Connect 12 V between the transaxle case and .) or less) e too high 23-35 Short-circuit.Troubleshooting 7. Residue accumulated in valve and core. Shift-control solenoid valve (SCSV) A or B ---+ Check the resistance between terminal 3 or 4 ofthesolenoidvalveconnectorandthetransaxle case.No operation noise. 1 / Normal I TSB Revision . 1 _ c Connect 12V between the transaxle case and --c No operation noise. terminal 1.

and start With the engine idling.23-36 clutch system AUTOMATIC TRANSAXLE . Sticking of the clutch control valve - i Overhaul the valve body. depress the foot brake firmly. I Set the selector lever to ” P” or “N”. I / Normal Replace the torque converter clutch solenoid. Readjust the idling. TSB Revision . Improper adjustment of idling I f Let the engine continue idling.Troubleshooting Pull the parking brake to set it securely. 1 i Sticking (seizure) of the torque converter clutch - / i Replace the torque converter assemblv. c d Poor closure (sticking) of the / torque converter clutch solenoid.

l- 11.Troubleshooting 10. switch ON and OFF and check Check for sticking. (Valve stroke: in. check the resistance between terminals 1 and 2. Accelerator switch cl992 model only the resistance between terminals 1 and 2. 1 solenoid valve connector and the transmission case.ordamagedordisconnected wiring. i Replace the accelerator switch.M?O”C (68°F) <From 1994 models> Replace the TCC solenoid.AUTOMATIC TRANSAXLE . Torque converter clutch solenoid (KC solenoid) Solenoid valve connector terminals 1: PCS” 2: TCC solenoid 3: SCSV-A 4: SCSV-B 21750338 23-37 Short-circuit. 2171096 1 i / Problem not solved. / L No continuity (resistance: -) 1 1 Normal I TSB Revision .1993 models> 13 .adjustifnecessarv. (resistance: -) Continuity exists (resiitance: 0) I With the accelerator pedal depressed slightly (aboutli%). tween the valve and guide for operation noise.) or less) I i Replace the TCC solenoid. Foreign terminal caught beand terminal 2. *Sticking is usually 1 Noise exists. at the release side. i t Standard value: 3 fY2O”C (68°F) <1992. I l i / Normal I Check the installation of the acceleratorswitch. 4 Connect 12 V between the transmission case -+ No operation noise.

or damaged or disconnected wiring. 1 In the “2” range. and terminals 8 and 9. I I Continuity exists In the ‘I” range.23-38 12. check for continuity between Poor contact. and terminals 10 and 11. check for continuity between terminals 2 and 4. 21750339 I I Continuity exists In the “N” range. check for continuity between terminals 4 and 5. i Continuity exists 1 1Normal TSB Revision . 1 1 Continuity exists I In the “R” range. check for continuity between terminals 4 and 7. check for continuity between terminals 1 and 4. check for continuity between terminals 3 and 4. Park/neutral position switch cl992 models AUTOMATIC TRANSAXLE . c No continuity In the “D” range. 4 / ContinuiD/ exists Replace the park/ neutral position switch.Troubleshooting In the “P” range. and terminals 8 and 9.

/ Continuity exists In the “2” range. and terminals 7 and 8. and terminals 5 and 6. check for continuity between terminals 3 and 10. I 4 I Continuity exists 1 Normal TSB Revision . 1 In the “D” range. check for continuity between teninals 2 and 3. and terminals 5 and 6.AUTOMATIC TRANSAXLE . or damaged or disconnected wiring. i Replace the park/neutral position switch. check for continuity between terminals 3 and 4. 23-39 i 1Continuity exists In the “R” range. check for continuity between terminals 3 and 11 Continuity exists 1 In the “L” range. 1 I Continuitv exists ZTFA0802 In the “R” range.Troubleshooting In the “P” range. check for continuity between terminals 2 and 3. check for continuity between terminals 3 and 9. / Continuity exists 1 1 Poor contact.

via an intermediate harness for checking. or damaged or disconnected wiring switch terminal and the transaxle case. wiring. a new TCM to this harness and make a road test. + Consider the original TCM to be normal. Transaxle control module (TCM) No continuity J Normal .Disconnect the harness (both A and B connec. i Same problem (as before TCM exchange) 1occurs. and again check the sensors. i L/ \ 1 Dl ZTFA0389 t Start the engine. set to the “D” range. etc. Then connect.--+ tors) from the vehicle’s TCM. I Install a new TCM. <From 1993 model> 1 0 43 ZTFA0809 15.Troubleshooting I Poor contact. -cl 992 model> Continuity exists + I Replace the K/D servo switch.23-40 servo switch AUTOMATIC TRANSAXLE . and let the engine idle: check for continuity between the kickdown servo switch terminal and the Continuity exists 1Poor contact (sticking) I t Replace the K/D servo switch. TSB Revision 1 .

Measure the hydraulic pressure under various conditions. If the oil pressure is not within the specified range. 4.Troubleshooting HYDRAULIC PRESSURE TESTS 23-41 I pressure(d)Front clutch &t& pressure (h)Torque I\ I converter pressure I _ pressure S Ir “I ZTFA0333 1.6402. 2. Completely warm up the transaxle. STANDARD HYDRAULIC PRESSURE TABLE Conditions No. Connect an engine tachometer and place it in a position where it’s easy to see.wOFF) 5 6 2 L Engine speed wm Idling Idling APP~~X 2.000 verse Re360-480 (51-68) (W IUD brake pressure (application) 100-210 (14-30) 830-900 (118-128) 830-900 (118-128) 830-900 (118-128) 1. (3) SW-OFF: OD switch in OFF position.000 kPa (400 psi) type of gauge should be used.500 Approx 1. . (2) SW-ON: OD switch in ON position.6402. When the reverse position pressure is to be tested. Attach the special oil-pressure gauge (MD998330 or MD999563) and the adaptor (MD998332) to each oil-pressure outlet port. (4) *: Pressure is not standard. 1 TSB Revision .240 (233-319) 1.AUTOMATIC TRANSAXLE .240 (233-319) 1.000 (142) or more 830-900 (118-128) 830-900 (118-128) 830-900 (118-128) 830-900 (118-128) 830-900 (118-128) 730-830 (104-118) 830-900 (118-128) 830-900 (118-128) 300-450 (43-64) 1. 3.500 Approx 2. 5.500 7 R Approx 1.4 psi).500 Approx 2. Select lever position N D PSW-ON.6402. Raise the vehicle by using a jack so that the front wheels can be rotated.000 Approx 2. the 3. and check to be sure that the measured results are within the standard value range shown in the “Standard oil pressure table” below.240 (233-319) 1.000 (142) or more Standard oil pressure kPa (psi) (a) Reducing pressure 360-480 (51-68) 360-480 (51-68) 360-480 (51-68) 360-480 (51-68) 360-480 (51-68) 360-480 (51-68) 360-480 (51-68) CC) WD brake pressure (release) Cd) Front clutch pressure W Rear clutch pressure (9) Low-reverse brake pressure (W Torque converter pressure Gear position 0) End clutch pressure 1 2 3 4 Neutral 2nd 4th 3rd * * 450-650 (64-92) 450-650 (64-92) 450-650 (64-92) * 450-650 (64-92) 450-650 (84-92) 2nd 1st Reverse - i NOTE (1) -: Indicates pressure is below 10 kPa (1.000 (142) or more 1. check and repair as described in the section “Remedial action to take for inadequate hydraulic pressure” on the next page.

Replace valve body assembly. Improper rear clutch pressure Defective D-ring (6) of piston. replace valve body assembly. Remove valve body assembly and check O-ring on top of upper valve body. and center support seal ring. replace if damage or scratches are evident. and piston D-ring. Improper low-reverse brake pressure Damaged O-ring between valve body and transmission Defective valve body assembly Defective D-ring (13) of piston or O-ring (14) of center support. Improper torque converter pressure Sticking torque converter clutch solenoid (TCC solenoid) or torque converter clutch control valve Plugged or leaky oil cooler and pipings Damaged seal ring (15) of input shaft Defective torque converter 1TSB Revision .23-42 Symptom 1. Replace valve body assembly. Check oil pump gear side clearance pump assembly as necessary. Replace torque converter. Replace seal ring or D-ring if damaged or scratched. Improper reducing pressure Plugged reducing pressure circuit filter (L-shaped) Improperly adjusted reducing pressure Defective valve body assembly 3. (0 and (g) shown on the Standard Oil Pressure Table on the preceding page. D-ring. 6. Replace seal ring or D-ring if damaged or scratched. Measure reducing pressure (a) and readjusts as necessary.Troubleshooting REMEDIAL ACTION TO TAKE FOR INADEQUATE HYDRAULIC PRESSURE Possible cause Plugged oil filter Improperly adjusted regulator valve line pressure Defective valve body assembly Valve body left loose Improper oil pump delivery pressure 2. center support seal ring. seal ring (7) of retainer. and replace oil Disassemble valve body assembly to check filter and replace filter if it is plugged. Measure line pressure (b) (K/D brake pressure) and readjust line pressure if it is out of specifications. Replace valve body assembly. Improper K/D brake pressure (release) 5. Replace valve body assembly. Improper K/D brake pressure (application) 4. D-ring (11) and oil seal (12) of end clutch Defective valve body assembly 7. Repair or replace cooler or pipings. Disassemble K/D servo and check seal ring and D-ring for damage. Disassemble transaxle and check front clutch piston and retainer for wear and D-ring and seal ring for damage. Torque valve body clamp bolt and mounting bolt to specification. Disassemble K/D servo and check seal ring and D-ring for damage. Replace valve body assembly. Replace valve body assembly. (4. (e). replace if damage or scratches are evident. NOTE: Line pressures are (WY (cl. All line pressures are low (or high). Or. Disassemble rear clutch and check input shaft D-ring. AUTOMATIC TRANSAXLE . D-ring. Disassemble transaxle and check D-ring and O-ring. Disassemble transaxle and check seal ring. Replace valve body assembly. replace if it is damaaed. replace if damaged or scratched. 3. Improper end clutch pressure 3. Improper front clutch pressure Defective seal ring (1) and D-ring (2) of K/D servo piston and seal ring (3) of sleeve Defective valve body assembly Defective seal ring (1) and D-ring (2) of K/D servo piston and seal ring (3) of sleeve Defective valve body assembly Defective seal ring (1) and D-ring (2) of K/D servo piston and seal ring (3) of sleeve Defective valve body assembly Worn front clutch piston and retainer or defective D-ring (4) or seal ring (5) Remedy Visually check oil filter and replace it if plugged. Disassemble the end clutch and check piston oil seal. and seal ring (8) and D-ring (9) of input shaft Defective valve body assembly Defective seal ring (IO). or seal ring as necessary. replace if damage or scratches are evident Check torque converter clutch system and TCC solenoid for operation. Disassemble K/D servo and check seal ring and D-ring for damage. retainer. Replace seal ring or D-ring if damaged or scratched. Replace valve body assembly. Replace piston.

Troubleshootina -l L I-\ (5) Seal ring \ (7) Seal ring \ (4) D-ring\ (14) O-ring I (12) Oil seal D-ring \ ii \\ (6) D-ring (8) Seal ring / (15) Seal ring / Rear clutch Front clutch (13) O-ring I Low-reverse brake Y End &tch (10) SeaI ring L (1) Seal ring --.(2) Seal ring brake c 1TSB Revision .AUTOMATIC TRANSAXLE .

depress accelerator pedal fully to read engine maximum rpm.23-44 AUTOMATIC TRANSAXLE .200 rpm Stall Speed Above Specification in “D” If stall speed is higher than specification.000 rpm in neutral for 2 minutes to cool transmission fluid between tests. Caution During this test. front clutch of transaxle or low-reverse brake is slipping. and holding ability of transaxle clutches and low-reverse brake. Engine coolant should also be at normal operating temperature [80-90°C (176-194”F)]. and never longer than 5 seconds at a time. Check for engine misfiring. etc. 2. This test checks torque converter stator overrunning clutch operation. Do not hold throttle wide open any longer than is necessary to obtain maximum engine rpm reading. Stall Speed Above Specification in “R” If stall speed is higher than specification. If these are good. ignition timing. Stall Speed Below Specification in “D” and “R” If stall speed is lower than specification. 5. 6. In this case. perform hydraulic test to locate cause of slippage.200-3. valve clearance. operate engine at approximately 1. make sure that no one stand in front of or behind vehicle. In this case. rear clutch or overrunning clutch of transaxle is slipping. 1. Apply parking and service brakes fully. Apply chocks to both rear wheels. TRANSAXLE CONTROL Symptom Selector lever operation is stiff T i Starter motor does not operate with the selector lever in the “N” or ‘F” position Malfunction of starter rela Will not shift to 4-speed TSB Revision . Start engine. insufficient engine output or faulty torque converter is suspected. 7. With selector lever in “D” position. 4. Stall speed: 2. If more than one stall test is required.Troubleshooting CONVERTER STALL TEST Stall test consist of determining maximum engine speed obtained at full throttle in “D” and “R” positions. Attach engine tachometer. Check transmission fluid level. Place selector lever to “R” position and perform stall test by the same procedure as in foregoing item. 3. perform hydraulic test to locate cause of slippage. Fluid should be at normal operating temperature [70-80°C (158-176”F)]. torque converter is faulty.

Selector lever cannot be selected into R from P by depressing brake pedal with ignition key in position other than LOCK. Defective selector lever assembly Sticking shift lock cable. broken inner cable. Check and adjust key interlock 23-58 cable. adjust. Check and replace key interlock cable. key interlock cable. adjust. Check. Selector lever operation from P to R is not smooth. and replace shift lock cable. 23-45 ~ Ref. Check and replace lock cam A.AUTOMATIC TRANSAXLE . and transaxle control cable. and transaxle control cable. Foreign matter wedged in lock cams A and B Improperly adjusted shift lock cable. elongated inner cable Binding lock cams A and B (in rotation) Defective selector lever assembly Binding slide lever inside key cylinder Check and replace slide lever 23-56 and cam lever. Check slide lever and cam lever. adjust or replace the shift lock cable. Check and adjust lock cams A and B. Probable cause Damaged lock cam B Improperly adjusted shift lock cable. page 23-59 2357 Broken or sagging outer cable (shift lock Check and replace shift lock 23-56 cable) return spring cable. loose or off connections Remedy Check and replace lock cam B. Check and adjust slide lever and cam lever. 23-59 23-56 23-56 23-59 23-56 / I/ Selector lever can be selected into R from P when brake pedal is depressed even though the ignition key is in the LOCK position. Damaged lock cam A Broken or disconnected key interlock cable Damaged slide lever and cam lever inside key cylinder Improperly adjusted key interlock cable Improperly adjusted shift lock cable. i TSB Revision . 23-55 Check and replace shift lock 23-55 cable. Check rotating parts of lock cams A and B. Check and replace selector lever assembly.Troubleshooting A/T SAFETY-LOCK SYSTEM TROUBLESHOOTING Symptom Selector lever can be selected into R from P without depressing brake pedal with ignition key in a position other than LOCK. Check. 23-56 23-59 23-55 23-56 . and replace shift lock cable. Check. elongated inner cable Sticking slide lever and cam lever inside key cylinder Check and replace selector lever assembly. key interlock cable.

and replace key 23-56 sticking inner cable interlock cable. Defective park/neutral position switch Improperly adjusted transaxle control cable Check slide lever. AUTOMATIC TRANSAXLE . elongated inner cable Damaged cam lever inside key cylinder Buzzer does not Defective buzzer sound even when selector lever is placed Open-circuited buzzer circuit harness in R position. 23-55 I L. Adjust transaxle control cable. Check or correct harness. Check.23-46 Symptom Selector lever cannot be shifted from R to P. loose connecother than P. Check and retighten cover. Check and replace cam lever.&j I 1 I I d [ TSB Revision . Check and replace lock cam A. Binding slide lever inside key cylinder Ignition key can be Damaged lock cam A turned to LOCK position even with selec. Check and replace lock cams A and B. page 23-55 .Loose key cylinder cover tor lever in position Broken key interlock cable.\j 23-57 23-59 Ignition key cannot be turned to LOCK posi!iiFinwp selector le- Foreign matter wedged in lock cams A and B Improperly adjusted key interlock cable.Troubleshooting Probable cause Defective selector lever assembly Improperly adjusted transaxle control cable Remedy Check and replace selector lever assembly. Check and replace park/neutral position switch. tions. Ref. Check and replace key interlock 23-56 23-59 23-56 23-56 23-56 23-56 - cable. adjust. Check and replace buzzer. Adjust transaxle control cable.

AUTOMATIC TRANSAXLE . back off special tool (Inner Wrench) 2 to 2’14 turns.Maintenance Service.Maintenance Service. dirt. (6) Fit torque wrench to special tool (Inner Wrench) and repeat tightening and loosening cycle two times with a torque of 10 Nm (7. TRANSMISSION FLUID REPLACEMENT Refer to GROUP 00 . (5) Fit special tool (Outer Wrench) over the lock nut. Turn Outer Wrench counterclockwise and turn inner cylinder clockwise to lock the lock nut and special tool (Inner Wrench). (2) Snap off the snap ring and remove K/D servo switch.6 ftlbs.2 ftlbs. KICKDOWN SERVO ADJUSTMENT (1) Remove dust. (3) Fit claw of special tool into cutout in piston to prevent piston from turning and use adapter to fix the piston into position.). Next. Then. Secure adapter only hand-tight to L/R brake pressure take-up port and do not apply excessive torque. torque-to 5 Nm (3. Do not push piston with the special tool.On-vehicle Service 23-47 ON-VEHICLE SERVICE TRANSMISSION FLUID LEVEL CHECK i Refer to GROUP 00 . (4) Loosen lock nut to immediately before V-groove in adjust rod (see illustration on left) and tighten special tool (Inner Wrench) until it contacts lock nut. Caution 1. TSB Revision .). and other contaminants completely from kickdown (K/D) servo cover and surrounding areas. 2.

) Caution Use of socket wrench or torque wrench could result in lock nut being turned with adjust rod.23-48 AUTOMATIC TRANSAXLE . (6) Turn adjusting screw of regulator valve to obtain the specified line pressure (K/D brake pressure). LINE PRESSURE ADJUSTMENT (1) Discharge ATF. tighten to specification. using torque wrench. (9) Remove the special tool to secure the piston and torque plug to specification at UR brake pressure take-up port. Lock nut: 29 Nm (21 ft. (4) Remove oil temperature sensor. (2) Remove oil pan. (3) Remove oil filter. Standard value: 870-890 kPa (124-127 psi) Oil pressure change for each turn of adjustment screw: 38 kPa (5. (8) Tighten lock nut by hand until it contacts piston.lbs.On-vehicle Service -I (7) Fit special tool (Outer Wrench) to lock nut. remove valve body assembly. Turn Outer Wrench clockwise and Inner Wrench counterclockwise to unlock the lock nut from special tool (Inner Wrench). Caution Be sure to apply even torque to the two special tools when unlocking. Caution Do not let manual valve fall. (5) Press solenoid valve harness grommet catch to push in grommet.4 psi) TSB Revision . Then. then.

) Bolt B = Length 25 mm (. (1O)lnstall oil filter. Bolt A = Length 18 mm (. (13)Carry out hydraulic test. (8) Replace O-ring of solenoid valve intermediate grommet with a new one and then fit the O-ring into case. Readjust as necessary. Failure to secure the harness results in its contact with the detent plate or parking rod.AUTOMATIC TRANSAXLE .57 in.On-vehicle Service 23-49 (7) Check that an O-ring is fitted at the location shown on top of valve body. 4992 model> B (9) Install valve body and oil temperature sensor. (11) Install new oil pan gasket and oil pan.98 in. <From 1993 model> TSB Revision . Especially the pressure control solenoid valve (PCSV) harness must be routed and clamped as shown in the illustration since it is separated from other harnesses.71 in.) Bolt C = Length 40 mm (1.) Caution Secure solenoid valve and oil temperature sensor harness at locations shown. (12)Add the specified amount of ATF.

When scan tool is used (1) Use scan tool to measure the K/D brake apply pressure when the pressure control solenoid valve is force-driven at 50% duty. install oil filter and oil pan. There is no need to remove valve body. ( TSB Revision . If the K/D brake apply pressure is not within the specified limit. Turn it counterclockwise to increase the pressure.On-vehicle Service REDUCING PRESSURE ADJUSTMENT When scan tool is not used (1) Following the same steps as those in line pressure adjustment. check that the reducing pressure is in the range 360-480 kPa (51-68 psi). Standard value: 275 kPa (39 psi) Oil pressure change for each turn of adjusting screw: 22 kPa (3 psi) (2) After adjustment has been made. Adjust as necessary.23-50 AUTOMATIC TRANSAXLE . make readjustment by using the reducing pressure adjustment screw. (2) Turn adjusting screw of lower valve body to obtain the specified reducing pressure. The adjustment made with high oil temperature could result in improper adjustment due to a line pressure drop at idle. Standard value: 425 + 10 kPa (60 & 1 psi) Oil pressure change for each turn of adjusting screw: 45 kPa (6 psi) (3) In the same way as in line pressure adjustment. remove parts up to oil filter. (4) Perform hydraulic test. Caution This adjustment should be made with oil temperature 70-80°C (158-176°F).

and moves backward when shifted to R. Start the engine and check if the vehicle moves forward when the selector lever is shifted from N to D. Check to be sure the selector lever can be shifted to each position (by button operation as shown in the illustration).l position to any other position.) If stroke A is out of specification. Completely stop the vehicle and switch OFF the engine before making the check 1. the selector lever cannot be moved from the “P” position to any other position.24 in.On-vehicle Service ACCELERATOR SWITCH CHECK AND ADJUSTMENT (1992 model) 23-51 09FO117 Check that current flows between terminals of accelerator switch when accelerator pedal is in free state and that no current flows when the pedal is depressed and the specified stroke A is obtained. 4. Also check. 2. Ignition key position: “LOCK” or removed Brake pedal: Depressed TSB Revision .AUTOMATIC TRANSAXLE . Check to be sure that. Check for worn shift lever assembly sliding parts. 3. that the button cannot be pressed. adjust with adjusting bolt. Standard value: 2-6 mm (.079-. at the same time. NOTE To move the selector lever from the “p. under the following conditions. 1. first turn the ignition key to any position other than “LOCK” and depress the brake pedal. When the shift lever malfunctions. Check that position indicator is correct.t t + m* Q II Lo zo9Foo61 @J Button pressed (while brake pedal is depressed) c Button not pressed c3 Button pressed Shift selector lever to each range and check that lever moves smoothly and clicks into position. 09FOO19 00001846 SELECTOR LEVER OPERATION CHECK r---Push button my) 4 by) &. KEY INTERLOCK MECHANISM CHECK . adjust control cable and selector lever sleeve.

-2: Push button Brake Check to be sure that. If above are not checked okay. Check to be sure that. the ignition key cannot be turned to the “LOCK” position. Ignition key position: “ACC” Brake pedal: Not depressed 2. 3. j. (5) Lightly pressing lock cam A in the direction of arrow. under the following conditions. Ignition key position: “ACC” Brake pedal: Depressed Button: Pressed Brake 09PO104 00001851 Check to be sure that. 09PO105 00001850 Button: Pressed Check to be sure that. SHIFT LOCK MECHANISM CHECK 1. (6) Reinstall front console assembly. adjust key interlock cable mechanism as follows. 4. Check to be sure that. Press the button a few times and check to be sure that the selector lever moves smoothly. TSB Revision . (4) Loosen nut that secures key interlock cable.23-52 AUTOMATIC TRANSAXLE . Ignition key position: “ACC” Brake pedal: Depressed Button: Pressed 3. the selector lever cannot be moved from the “P” position to any other position. under the following conditions. If a malfunction is discovered when following the above checking procedures. (3) Turn ignition key to the “LOCK” position. the selector lever can be moved smoothly from ‘the “P” position to any other position. Ignition key position: “ACC” Brake pedal: Released Button: Pressed 4. under the following conditions. the selector lever can be moved from the “P” position to any other position. lightly push key interlock cable to take up slack and tighten nut to secure key interlock cable. (1) Remove front console assembly. Check to be sure that the ignition key smoothly turns to the “LOCK” position when the selector lever is then set to the “P” position and the button is released. either adjust or check the shift lock cable mechanism.On-vehicle Service 2. under the following conditions. at all positions of the selector lever (other than “P”). the selector lever can be moved smoothly from the “R” position to the “P” position. (2) Place selector lever into “P position.

4. 2. Loosen transaxle control cable to manual control coupling adjusting nut to set cable and lever free. 1 DRIVE SHAFT OIL SEALS REPLACEMENT (1) Disconnect the drive shaft from the transaxle. and turn park/neutral position switch body so that the end (section A-A in illustration on left) of manual control lever is aligned with the hole in park/neutral position switch body flange. L. and tighten the adjusting nut to the specified torque. Place selector lever in “N” (Neutral) position. Check that the selector lever is in “N” position. loosen the park/neutral position switch body mounting bolt. Tighten the mounting bolts of the park/neutral position switch body to the specified torque.H. remove the oil seal.lbs. For adjustment. .) 7. 8. Specified torque: 13 Nm (9 ft.Drive Shaft. 3. 0’3K567 / \ Front exhaust pipe TSB Revision . 6. Place manual control lever in “N” (Neutral) position.AUTOMATIC TRANSAXLE .On-vehicle Service Manual control lever 23-53 PARK/NEUTRAL POSITION SWITCH AND CONTROL CABLE ADJUSTMENT 1. Be careful at this time that the position of the switch body is not changed.) TFA0359 Mounting bolt Section A-A Hole in end iole in lange Manual control lever Park/neutral position switch body 09COO89 00001852 Lightly pull the transaxle control cable in the arrow direction. side\ . 5.) (2) Using a flat-tip (-) screwdriver. Check that it securely operates and functions on the transaxle side in the range which corresponds to each position of the selector lever. (Refer to GROUP 26 . Specified torque: lo-12 Nm (7-9 klbs.

Install the grommet so that. I Oil seal lip 22200037 SPEEDOMETER CABLE REPLACEMENT <Up to 1993 models> 1. Caution The cable arrangement should be made so that the radius of cable bends is 150 mm (5.3 2. or abnormal noise. tap the drive shaft oil seal into the transaxle. as shown in the illustration. the cable attachment part and the projecting part are horizontal. Caution If the cable is not correctly and securely connected. ‘d TSB Revision . Note in illustration the direction of installation of drive shaft oil seal.On-vehicle Service (3) Using the special tool. At the transaxle end of the speedometer cable. the key joint should be inserted into the transaxle.9 in. Be sure to connect it correctly. Correctly insert the adapter into the instrument panel. and the nut should be securely tightened. and fasten the new speedometer cable.23-54 AUTOMATIC TRANSAXLE .) or more. LJ 209FOO8. I I 3. it may cause incorrect indication by the speedometer. Transmission fluid: DIA QUEEN ATF SP or equivalent Transaxle side I. (4) Apply a coating of the transmission fluid to the lip of the oil seal.

Clamp 7.lbs. Adjuster Selector lever assembly removal steps 1. 209FOO31 Transaxle control cable removal steps 1. Air intake hose .) When re. Transaxle control cable connection (Selector lever assembly side) 8.C+ 4.Floor Console. Shift-lock cable connection (Selector lever assembly side) . 7 ft. Transaxle control cable assembly 6.04 3.C+ 4. Transaxle control cable assembly connection (Select lever assembly side) 5. Air cleaner cover. Air intake hose FE+ 2. Selector lever assembly I id [ TSB Revision .Transaxle Control 23-55 TRANSAXLE CONTROL L/ REMOVAL AND INSTALLATION l Pre-removal and Post-installation Operation Front Console Assembly Removal and Installation (Refer to GROUP 52A .oving and installing the front con shock to the SRS diagnosis unit.AUTOMATIC TRANSAXLE . Air cleaner cover. 8 12 Nm / 9 ft.lbs. Key-interlock cable connection (Selector lever assembly side) .

Clamp Reverse (R) position alarm buzzer removal 20.A4 18.B+ 14. Cable guide 17. Slide lever 16. Key-interlock cable connection (Selector lever assembly side) 9. Shift-lock cable connection (Selector lever assembly side) 9. 17 ’ L) ‘” 9 tt. Transaxle control module connection 10.lbS. Knee protector (Refer to GROUP 52A . Column cover lower 12.B+ 13. Cover . Cam lever .B+ 15. Clamp Shift-lock cable removal steps . Shift-lock cable 19. Key-interlock cable . i IClYNm 7ft.lbs.Transaxle Control 12 Nm 9 ft.lbs.Instrument Panel. 09FOO35 00001854 I Key-interlock cable removal steps .) 11.Ed 2. Transaxle control module connection .23-56 AUTOMATIC TRANSAXLE . Reverse (R) position alarm buzzer I TSB Revision .Dq 3.

16 in. . Caution Do not change the routing of shift lock cable to the selector lever assembly. (1) Place the selector lever in “N” position. (2) Loosen the nut and slightly pull the transaxle control cable in the direction of the arrow. ZO9FOO21 t YO9FOO5 . At this time.DdSHlFT LOCK CABLE CONNECTION (SELECTOR LEVER ASSEMBLY SIDE) (1) Place the selector lever in “P” position.Cd TRANSAXLE CONTROL CABLE CONNECTION (SELECTOR LEVER ASSEMBLY SIDE) Connect the transaxle control cable. (2) Disconnect the key interlock cable from the selector lever assembly side.BdSLlDE LEVER / KEY INTERLOCK CABLE (STEERING LOCK ASSEMBLY SIDE) / CAM LEVER INSTALLATION (1) Place the ignition key at the “LOCK” position or keep it removed. . and cam lever to the steering lock assembly as shown. (6) Pressing the set lever to prevent lock cam B from moving. key interlock cable. (4) Fit the cutout in set lever to the lock pin of lock cam B. which have been fitted to the shift lock cable. Caution Do not change the routing of key interlock cable to the selector lever assembly. (2) Install the slide lever. install the spring and washer. (3) Turn the lock cam B counterclockwise (arrow (1)) to move the set lever upward (arrow (2)). lightly pull the shift lock cable to take up slack and tighten the nut to secure the shift lock cable into position.Transaxle Control INSTALLATION SERVICE POINTS 23-57 bAASHIFT LOCK CABLE CONNECTION (BRAKE PEDAL SIDE) Connect the shift lock cable so that its threads measure about 4 mm (. then make the following adjustment. tighten the nut. 1 TSB Revision . then install the washer and snap pin.). Set lever Fixing pin (5) Connect the shift lock cable to lock cam B and temporarily tighten the nut.AUTOMATIC TRANSAXLE . NOTE Make sure that the shift lock cable end is in contact with the fixing pin of lock cam B as shown. then. as shown.

then install the snap pin. At this time. install the spring and washer. Check the outer cable (key interlock cable. (4) Turn the set lever and fit it onto the fixing pin on lock cam A. which have been fitted to the key interlock cable.) . (Refer to P.cam A in the direction of arrow. (Refer to P. lightly push the key interlock cable to take up slack and tighten the nut to secure the key interlock cable in position.23-51. (10)After the key interlock cable has been connected. shift lock cable) for extension. then install the snap pin. REVERSE (R) POSITION ALARM BUZZER CHECK Check that the buzzer sounds when battery voltage is applied across terminals. At this time. which have been fitted to the key interlock cable. 52. check the key interlock mechanism. lightly push the key interlock cable to take up slack and tighten the nut to secure the key interlock cable in position. (8) Lightly pressing lock.Transaxle Control Lock cam A W (7) Connect the key interlock cable to lock cam A and temporarily tighten the nut. ZO9N0049 Lock cam A Reverse (R) position alarm buzzer INSPECTION Check the control cable for function and for damage. shift lock cable) for damage and spring for breakage and tension. install the spring and washer.23-51. check the shift lock and key interlock mechanism.23-58 m AUTOMATIC TRANSAXLE .Ed KEY INTERLOCK CABLE CONNECTION (SELECTOR LEVER ASSEMBLY SIDE) (1) Place the selector lever into “P” position. 209N0049 I ock cam A (9) Turn the set lever and fit it onto the fixing pin on lock cam A. as shown. (5) After the key interlock cable has been connected. l Check the inner cable (key interlock cable. (3) Lightly pressing lock cam A in the direction of arrow. as shown.) Look cam A Wa . l o i 209P0094 TSB Revision . (2) Connect the key interlock cable to lock cam A and temporarily tighten the nut.

lbs. 24. Indicator panel 10. Slider 12.lbs. Overdrive control switch 6.leve 16: 17.Selector Lever Assembly SELECTOR LEVER ASSEMBLY L DISASSEMBLY AND REASSEMBLY 6 -/7 16 1.6 ft.AUTOMATIC TRANSAXLE . 1 11 0 09FO108 2. 23. Power (PWR)/Economy (ECO)/Hold (HOLD) changeover switch connector 11. Overdrive control switch. 19. Spring 9. Cover 3. / Ld Disassembly steps 1. 26.A+ . position light and Power (PWR)/Economy (ECO)/Hold (HOLD) changeover switch connector 2. Pushbutton 8. Indicator panel lower 13. 25. 22. Lever assembly Bushing Pipe Cotter pin Washer Lock cam B Spring Cotter pin Washer Set lever Lock cam A Bracket assembly 1 TSB Revision I . Overdrive control switch button 5.. Selector knob 4. 20. 09FOO39 00001855 4W 4W 4B.. 27. Socket assembly . 21. .6 i 238 26 d A. 27 12 Nm 9 ft. Pin 7. 18.0 1.

remove the overdrive control switch button.23-60 AUTOMATIC TRANSAXLE .2-15. 09FOO99 09FOlOO 00001857 POWER (PWR)/ECONOMY (ECO)/HOLD (HOLD) SWITCH CHECK Check for continuity between terminals when the switch is OFF and when ON. Screwdriver ZOQR0054 qB. (2) Remove the overdrive control switch mounting screw. Standard value (A): 15.625 in.OVERDRlVE CONTROL SWITCH BUTTON / OVERDRIVE CONTROL SWITCH REMOVAL (1) Using the flat-tip screwdriver.Selector Lever Assembly DISASSEMBLY SERVICE POINTS Terminal +A. Check the spring for damage or deterioration. remove the overdrive control switch.598-. OVERDRIVE CONTROL SWITCH CONNECTOR REMOVAL Disconnect the overdrive control switch connector and then remove the terminal from the overdrive control switch connector.) Sleeve zos*ooo8 INSPECTION l l l 2 (GW 1 (LW / Check the detent plate for wear. (3) Pressing the switch.A( SLEEVE INSTALLATION Place the selector lever in the “N” position. Check the bushing for wear or damage. and then turn the sleeve so that the clearance between the sleeve and the lever assembly end is within the standard value.9 mm (. TSB Revision . Lever assembly i= a / A REASSEMBLY SERVICE POINT .

Selector Lever Assembly OVERDRIVE CONTROL SWITCH CHECK ON 23-61 id OFF* 6 (RW) ’ (Bw) \ i Check for continuity between terminals when the switch is OFF and when ON.AUTOMATIC TRANSAXLE . / I I 1 ON (Overdrive activation) 09FOO99 09FO101 00001858 1 0 I-+-oI OFF (Overdrive non-activation) 0 i TSB Revision . 1 Switch position I . Terminal No.

16 00001859 4Ab :t: 4Ab 1. Air cleaner cover.Maintenance Service. Air intake hose 6.lbs./.) <Vehicles with oil cooler> 4.) l Front Under Cover Removal and Installation (Refer to GROUP 51 . HOSES.Front Bumper. ‘d 4.9 ft.Transaxle Oil Cooler.9 ft.A+ 8 p/ftb?) 9: Tube assembly Transaxle oil cooler removal steps 7. Hoses. Tubes TRANSAXLE OIL COOLER. Feed hose 4.lbs.0 Nm 2.2. 09FO. \ 12 Nm 9 ft. q 30-35 Nm 22-25 ft. Eye bolt 10.23-62 AUTOMATIC TRANSAXLE . Hose 2. Hose assembly Tube assembly removal steps 7.lbs.A( 8. Front splash shield extension +C. Front splash shield extension (right side) +Cb . Transaxle oil cooler 4Bb \ d TSB Revision . .lbs. Tube assembly 3. TUBES REMOVAL AND INSTALLATION l Pre-removal and Post-installation Operation Automatic Transmission Fluid Drainage and Filling (Refer to GROUP 00 . Return hose Hose assembly removal steps 5.0 N m 10 .

(2) Secure the oil cooler connector with a spanner to prevent excessive force from being applied to it. 209FOO95 INSTALLATION SERVICE POINT . ZOSFOO95 INSPECTION l l l Check the hose for crack. EYE BOLT REMOVAL (1) Wipe the connection threads and tightly contacting surfaces clean of dust and dirt. (C. then tighten the eye bolt. Check for rusted or clogged radiator oil cooler. 2. 1 TSB Revision . Hoses. Tubes REMOVAL SERVICE POINTS dA.HOSE / TUBE ASSEMBLY / FEED HOSE / RETURN HOSE REMOVAL 23-63 Caution Be careful not to spill the transmission fluid when removing components.Transaxle Oil Cooler. plug so that foreign materials cannot enter the transaxle. (2) Secure the oil cooler connector with a spanner to prevent excessive force from being applied to it. AB.AUTOMATIC TRANSAXLE .A4 EYE BOLT INSTALLATION (1) Wipe the connection threads and tightly contacting surfaces clean of dust and dirt. and clogged foreign matter. damage and clog. After removing the hose assembly. damage. be careful not to allow the transmission fluid to spill. When removing the hose assembly. HOSE ASSEMBLY REMOVAL Caution 1. then loosen the eye bolt. Check oil cooler fins for bend.

lbs.23-64 AUTOMATIC TRANSAXLE . Transaxle mount bracket connection I . Speedometer cable <Up to 1993 models> or speedometer connector <From 1994 models> connection 13.) l Front Under Cover Removal (Refer to GROUP 51 .Front Bumper. Air cleaner cover. ZOSFO112 OSFOO61 00001860 Removal steps 1. l Transaxle Fluid Draining (Refer to GROUP 00 .Maintenance Service.Transaxle Assembly TRANSAXLE ASSEMBLY REMOVAL AND INSTALLATION I Pre-removal Operation l Place Selector Lever in “N” Position and Stop the Engine.C4 5. Shift control solenoid valve connector 8.) l Transaxle Fluid Supplying (Refer to GROUP 00 . Oil temperature sensor connector 11. Battery 3.) I Post-installation Operation l Front Under Cover Installation (Refer to GROUP 51 . Air intake hose .Front Bumper. Side under cover 2.) l Selector Lever Operation Check 0 Speedometer Operation Check 51 ft. Battery seat. Park/neutral position switch connector TSB Revision l b 12. m 70 Nm 51 ft. Kickdown servo switch connector 4.lbs. Transaxle control cable connection 6. Washer tank 9. Oil cooler hose connection 7. Pulse generator connector 10.Maintenance Service.

Right member 18. Transaxle stay (rear bank side) 23.AUTOMATIC TRANSAXLE . make sure it is supported over a wide area and no local force is being applied. Transaxle assembly upper part coupling bolt 15. Transaxle stay (front bank side) 22. . .Transaxle Assembly 75 Nm !iA ftlhc . Bell housing cover 24. Caution When raising the transaxle assembly. Lower arm ball joint connection 17. 23-65 75 Nm 60. Tie rod end connection 16. 14.lbs. TSB Revision . ZO9FOO88 L ::: 4C. Transaxle assembly REMOVAL SERVICE POINTS +AbTRANSAXLE MOUNT BRACKET DISCONNECTION (1) Raise the transaxle assembly with a jack up to a level where no weight is applied to the mount bracket.A+ 26. Starter 19. Inner shaft assembly ++ . Drive shaft (right side) 21.B+ 20. Drive shaft (left side). 43. 26 ft. 60-70 Nm 43-51 ft. Special bolts ::: 25. Transaxle assembly lower part coupling bolt 4D.lbs.

(4) Remove coupling bolt at the bottom of transaxle assembly and lower the transaxle assembly. . remove the transaxle mount bracket mounting bolt. push the torque converter toward transaxle so that it does not remain on the engine side. then. dC. (3) After removing the special bolts. Therefore.23-66 AUTOMATIC TRANSAXLE .Manual Transaxle. 1 TSB Revision . SPECIAL BOLTS / TRANSAXLE ASSEMBLY LOWER PART COUPLING BOLT / TRANSAXLE ASSEMBLY REMOVAL (1) Support the transaxle assembly with the transaxle jack. (2) Rotating the crankshaft. be sure to first assemble the torque converter on the transaxle side. ~ ‘d ~ bracket installation INSTALLATION SERVICE POINTS .TIE ROD END / LOWER ARM BALL JOINT DISCONNECTION Refer to GROUP 22 .Manual Transaxle.DRlVE SHAFT (LEFT SIDE) AND INNER SHAFT ASSEMBLY / DRIVE SHAFT (RIGHT SIDE) REMOVAL Refer to GROUP 22 . (2) Loosen the nut.A+ TRANSAXLE ASSEMBLY INSTALLATION Attach the torque converter on the transaxle side and mount the transaxle assembly on the engine. Caution If the torque converter is mounted first on the engine. +B.B( DRIVE SHAFT INSTALLATION (RIGHT SIDE) Refer to GROUP 22 . \.Manual Transaxle. the oil seal on the transaxle side may be damaged.Cq TRANSAXLE CONTROL CABLE CONNECTION (1) Connect the transaxle control cable to the manual control lever and tighten the nut temporarily. I I .Transaxle Assemblv (2) Remove the nut and move the bolt so that a spanner can be applied to the transaxle mount bracket mounting bolt. remove the special bolts at four places. pull the transaxle control cable lightly in the arrow direction and retighten the nut. (D.

. . . . . . . . . . . 2 Lubricants. . . . . . . . 3 . . . . . . . 2 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Adhesive . . . . . . . . . . . . . . . . 3 SPECIFICATIONS . . . . . . . . . . . 3 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . .PROPELLER SHAFT CONTENTS PROPELLER SHAFT . . 2 ~ TROUBLESHOOTING . . . . .. . . . . .

5 x 65 (26. SERVICE SPECIFICATIONS Items Propeller shaft runout (Dial indicator reading) mm (in.56) 662.D.024) or less 0.87 x 2.) cup to 1993 models> UNIVERSAL JOINT Items Type No.024) or less 0.56) Type Length x O.) ADHESIVE Item Lobro joint rubber packing Specified adhesive 3M ATD Part No.024) or less LUBRICANTS Items Sleeve yoke surface Lobro joint assembly Outer and inner races ball grooves Lobro joint assembly inner part Specified lubricant Hypoid Gear Oil/API classification GL-4. 2 (center front) No.52 x 2.56) 555.95) 698. 4 (rear) Lubrication Size mm (in.6 (.5 x 65 (26.87 x 2.25-2 SPECIFICATIONS PROPELLER SHAFT . 8155 or equivalent TSB Revision . mm (in. 3 (center rear) [Lobro joint] No.D.6 (.Specifications GENERAL SPECIFICATIONS PROPELLER SHAFT Items Specifications 4 joint propeller shaft Front Center Rear Length x O.5 x 65 (27.94 oz. 1 (front) No.59-l .) <From 1994 models> Front Center Rear 673. Specifications Cross type Cross type Constant velocity type Cross type Pre-packed type 16 (.) Cross type joint journal O.56) 555.) Front Center Rear Limit 0. Constant velocity joint O.08 x 2.50 x 2.5 x 65 (26.5 x 75 (21. SAE 75W-90 or 75W-85W Repair kit grease Repair kit grease Quantity As required As required 45-55 g (1.56) 662.D.6 (.63) 99.08 x 2. mm (in.93) NOTE Propeller shaft length indicates the length between the center points of each joint.5 x 65 (21.73 (3.D.

g. Self-locking nut FBI 2.f& NM i.Propeller Shaft Special tool / Troubleshooting / 25-3 ~ SPECIAL TOOL Tool Tool number and name MB991193 Plug W I Supersession General service tool Application Prevention of entry of foreign objects into the transaxle and transfer TROUBLESHOOTING Symptom Noise at start Probable cause Worn journal bearing Worn sleeve yoke spline Loose propeller shaft installation Noise and vibration at high speed Unbalanced propeller shaft Worn journal bearing Remedy Replace Replace Retighten Replace Replace PROPELLER SHAFT REMOVAL AND INSTALLATION lOGO Gear oil: Hypoid Gear Oil / API classification GL-4. ION0013 00001024 Removal steps 1. Insulator :.PROPELLER SHAFT .lbs.gp shaft TSB Revision . SAE 75W-90 or 75W-85W 22 ft.

+B. (2) Use the special tool provided as a cover to prevent the entry of foreign objects into the transfer. Record the number of spacers used to ensure correct installation. REMOVAL SERVICE POINTS +Ab PROPELLER SHAFT REMOVAL (1) Make mating marks on the differential companion flange and flange yoke. .6b 100 Caution Remove the propeller shaft in a straight and level manner so as to ensure that the boot is not damaged through pinching. right.-. . if a piece of cloth or similar material is inserted in the boot. ProDeller shah LBbro inint . 1 TSB Revision . Lo0ro pm DOOK &&&‘I \ .-. rear. NOTE Damage to the boot can be avoided. and the work will be easier. Caution Tighten installation bolts after removing oil and grease from threads to prevent them from loosening due to lubrication. SPACER REMOVAL The number of spacers necessary may differ from one location to another (front. left)..Propeller Shaft /. INSTALLATION SERVICE POINTS FAA PROPELLER SHAFT INSTALLATION (1) Caution Be cautious to avoid damage to the oil seal lip of the transfer. zL . (2) Install the propeller shaft to the companion flange with the mating marks properly aligned.-.25-4 Mating marks PROPELLER SHAFT .

) or less 0. assemble the same spacers as removed from it (or new spacers of equal thickness). Caution When installing the center bearing.6 mm (. twisting or damage. damage or cracks.024 in. l I/ l l l Measure the propeller shaft runout with a dial indicator.6 mm (. damage or cracks. Limit: Front propeller shaft 0.PROPELLER SHAFT .Propeller Shaft 25-5 . lOW504 lOWSO 00001025 i TSB Revision . Check the center bearing mounting rubber for damage or deterioration. ZlOAOOl2 INSPECTION l l l Check the sleeve yoke.6 mm (.024 in.) or less Rear propeller shaft NOTE Set the V-blocks as much as possible to the end of the shaft. center yoke and flange yoke for wear. Check the propeller shaft for bends.024 in. Check the center bearing for smooth movement.Bq INSULATOR INSTALLATION Install spacers and insulators as indicated in the illustration.) or less Center propeller shaft 0. Check the universal joints for smooth operation in all directions. Measure deflection at the center of the shaft. Check the propeller shaft yokes for wear.

.A+ 13. Center propeller shaft . . 3 / I4 zlOFOOO6 16 Liibro joint assembly Ltibro joint Lijbro joint [outer race) (inner race) 1oxoo1e 10x0040 lONO 06001026 Grease: Repair kit grease [45-55g (1.)] Adhesive: 3M ATD Part No. Rubber packing 4Fb .B+ 10. Companion flange +H. WC+ 8.A+ 15. Companion flange +C. Self-locking nut +G. Self-locking nut +B.F( 3. Lobro joint boot 11.iq 2. Snap ring . .E+ 5.Propeller Shaft DISASSEMBLY AND REASSEMBLY 55 Nm 40 ft. . Washer 12.59-l .A+ 14.25-6 PROPELLER SHAFT . Center propeller shaft assembly 6.94 oz. Center bearing assembly 16. Rear propeller shaft Disassembly steps 1.F+ 4.lbs. Boot band (E. . LZjbro joint assembly 4Ab TSB Revision . Center bearing assembly qD. 8155 or equivalent 9.D( 7. Front propeller shaft assembly .

ZlON0003 +C. +D. COMPANION FLANGE REMOVAL Put mating marks on the companion flange and the center propeller shaft before removing the companion flange. FRONT PROPELLER SHAFT ASSEMBLY REMOVAL Put mating marks on the front propeller shaft flange yoke and the companion flange before removing the front propeller shaft assembly. CENTER PROPELLER SHAFT ASSEMBLY REMOVAL Put mating marks on the center propeller shaft. CENTER BEARING ASSEMBLY REMOVAL First remove the center bearing bracket and then remove the center bearing using a puller (commercially available).Propeller Shaft 25-7 . TSB Revision . L6BRO JOINT ASSEMBLY REMOVAL (1) Remove the Lobro joint boot from the Lobro joint assembly. +E. ZlON0004 Mating marks +B. the Lobro joint assembly and the companion flange before removing the center propeller shaft assembly. L Mating marks DISASSEMBLY SERVICE POINTS +A.PROPELLER SHAFT .

TSB Revision .COMPANlON FLANGE REMOVAL Put mating marks on the companion flange and the rear propeller shaft before removing the companion flange. wipe off the grease and clean the outer and inner races. cage and inner race with a scriber before removing the outer race and balls. (4) If the outer race cannot be removed. NOTE When changing the grease on the Lobro joint assembly.Propeller Shaft (2) Put mating marks on the outer race. I d Cage Inner race (3) Remove the inner race with cage from the center propeller shaft by using a puller (commercially available). +G. Caution Note the positions of balls so that they can be reinstalled in their original positions.25-8 PROPELLER SHAFT . +F. remove the complete Lobro joint assembly from the center propeller shaft by using a puller (commercially available). LijBRO JOINT BOOT REMOVAL Tape the serration of the center propeller shaft and then remove the Lobro joint boot. cage and balls.

(2) Install the center bearing assembly to the rear propeller shaft with its dust seal facing the companion flange side. CENTER BEARING ASSEMBLY REMOVAL First remove the center bearing bracket and then remove the center bearing using a puller (commercially available). Also ensure that the relative positions of the inner and outer races are as shown in the illustration.A( CENTER BEARING ASSEMBLY / COMPANION FLANGE / SELF-LOCKING NUT INSTALLATION (1) Install the bearing in the rubber mount groove of the center bearing bracket. the recessed end (where packing will be fitted) of the outer race. Specified grease: Repair kit grease x10x0018 Mating marks Recessed end of inner race Chamfered end (2) Put the cage on the inner race with the mating marks aligned and install two balls. (3) Install. .B+ LOBRO JOINT BOOT INSTALLATION Tape the serration of the center propeller shaft and then install the Lobro joint boot. Both balls should be placed in the grooves where they were before disassembly.PROPELLER SHAFT . 00001027 Companion flange Dust seal \ Rubber mount REASSEMBLY SERVICE POINTS . lining up the mating marks on the companion flange and the rear propeller shaft. (3) Assemble the inner race and cage in the outer race with their mating marks aligned. and the chamfered end of the cage are all on the same side.Propeller Shaft 25-9 +H. NOTE Make sure that the recessed end (where snap ring will be fitted) of the inner race. TSB Revision . Self-locking nut .Cq L6BRO JOINT ASSEMBLY INSTALLATION Assemble the Lobro joint as follows: (1) Apply a thin coat of the specified grease to the ball grooves of the inner and outer races. (4) While tightening the self-locking nut. one in a groove and the other in the groove opposite to that groove. install the center bearing assembly with the companion flange.

Lijbro joint boot TSB Revision . 8155 or equivalent zwxoo37 (8) Lining up the mating marks on the Lobro joint assembly and the center propeller shaft and applying the socket to the inner race of the Lobro joint assembly.59-1.94 oz.)] Rubber packing (7) Apply quick fix adhesive at three locations illustrated to prevent displacement of the rubber packing and fix it to the Lobro joint assembly temporarily. zloxoo36 Mouyting bolts 1 (9) Using the center propeller shaft bolt. (5) Check that the outer race rotates on the inner race smoothly.PROPELLER SHAFT . (6) Apply specified grease to the Lobro joint assembly.Propeller Shaft I Install these balls first (4) Install the remaining balls in their original positions. Specified grease: Repair kit grease [45-55 g (1. Specified adhesive: 3M ATD Part No. install the Lobro joint assembly to the center propeller shaft. align the bolt holes of the Lobro joint boot and the Lobro joint assembly and install the Lobro joint boot to the Lobro joint assembly.

D+ BOOT BAND INSTALLATION Caution Clamp the boot band by folding down the lever at a position nearly opposite to the vent groove provided in the Liibro-joint boot (at arrow marked position on boot). damage or rust. Be sure to remove grease. Check the ball grooves in inner or outer race for uneven wear.E+ CENTER PROPELLER SHAFT ASSEMBLY INSTALLATION Install. TSB Revision . Check ball surface for rust. (2) Install the center bearing assembly to the center propeller shaft with its dust seal facing the companion flange side. lining up the mating marks on the center propeller shaft. lining up the mating marks on the companion flange and the center propeller shaft. . (4) While tightening the self-locking nut. install the center bearing assembly with the companion flange. 00001030 . nut .PROPELLER SHAFT . if present. INSPECTION l l l l Check the propeller shaft splines for wear or damage.F+ CENTER BEARING ASSEMBLY / COMPANION FLANGE / SELF-LOCKING NUT INSTALLATION (1) Install the bearing in the rubber mount groove of the center bearing bracket. from around the vent groove. Companion flange Du? seal \ Self-locking. (3) Install. wear or other damage. Check the cage for rust or damage. Grease obstructs the ventilation air passage.Propeller Shaft 25-11 ~ (10)Check that the Lobro joint assembly moves smoothly. the Lobro joint assembly and the companion flange.

NOTES .

. . . . . . 5 SPECIAL TOOLS . . . . . . . . 2 Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . 2 General Specifications . . . . . . . . . 3 . . . . . . . . . .. . . . . . . . . . . . . . 12 HUB AND KNUCKLE . . . . . . . . . . . . 6 ON-VEHICLE SERVICE . 2 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 5 SPECIFICATIONS . . . . . . . . . . . . 5 Hub End Play Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FRONT AXLE CONTENTS DRIVE SHAFT . . . . . i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9) or 393 (15.) 1.77) AWD Unit ball bearing d DRIVE SHAFT Items Joint type Outer Inner Length mm (in.) L.12) 85 f 3 (3.H. 419 (16.8 (16) LUBRICANTS TSB Revision .) L.5) 391(15. shaft NOTE *: <Al-r> / FWD B.31 x 1.4) SERVICE SPECIFICATIONS Items Setting of T..Specifications GENERAL SPECIFICATIONS WHEEL BEARING Items Type O.J.4) 405 (15.35 f.J. ( Hub end play mm (in.H.26-2 SPECIFICATIONS FRONT AXLE . T. mm (in.35 i.12) Limit \ R. x I.) FWD Double-row angular-contact ball bearing 84 x 45 (3.) Wheel bearing starting torque (Hub starting torque) Nm (in. shaft R.D.H.lbs.J. .H. T.5)* AWD B.D. 417 (16. boot length mm (in. Standard value 85 + 3 (3.J.J.

FRONT AXLE .SDecial Tools 26-3 SPECIAL TOOLS A: MB990244 Preload socket rement of the lower arm ball joint starting ment of the stabilizer link rotation Press-out of the center bearing Press-fitting of the center bearing Press-fitting of the dust seal outer TSB Revision .

Special Tools Tool number and name MB990890 Rear suspension bushing base MB990883 MB990883-01 Supersession MB990890-01 Application Press-fitting of the dust seal Press-fitting of the wheel bearing.26-4 Tool FRONT AXLE . oil-seal (drive shaft side) / Fate&suspension MB990947 4 ki$%i:bor MB990955 Oil seal installer MB990947-01 Press-fitting of the oil seal (hub side) MB990955-01 1 TSB Revision .

Remove the disc brake caliper and suspend it with a wire. (Refer to GROUP 35 .05 mm (. Attach a dial indicator as shown in the illustration. play or seizure of wheel bearing.On-vehicle Service. damage or abnormal wear of drive shaft Play in drive shaft and hub serration Abnormal wear.) 3. and then measure the axial play while moving the hub back and forth. Jack up. grease leakage Bend. repack grease Replace Replace Replace Replace Retighten Adjust or replace ON-VEHICLE SERVICE HUB END PLAY CHECK 1. 21116285 TSB Revision . play or seizure of wheel bearing Shimmy Improper wheel alignment Malfunction of front suspension or steering Excessive noise Broken boot.Troubleshooting / On-vehicle Service 26-5 TROUBLESHOOTING Symptom Vehicle pulls to one side Probable cause Seizure of drive shaft ball joint Abnormal wear. play or seizure of wheel bearing Malfunction of front suspension or steering Vibration Bend. disassemble and check parts. Limit: 0. play or seizure of center bearing Abnormal wear.FRONT AXLE .) 4.002 in. damage or abnormal wear of drive shaft Play of drive shaft and hub serration Abnormal wear. Loose wheel nut Malfunction of front suspension and steering Remedy Replace Replace Adjust or replace Replace Replace Replace Adjust or replace Adjust or replace Replace. 2. If axial play exceeds the limit. the vehicle and remove the front wheels.

Tie rod end connection 11. Lower arm ball joint connection 4Db 9.Hub and Knuckle HUB AND KNUCKLE REMOVAL AND INSTALLATION I :L) cFWD> cAWD> 12 w-ius Nm 65-76 ftlbs.lbs. \ 9m . Cotter pin TSB Revision 4Eb 4Fb 4.lbs. Callper assembly 5. 10.2 Nm 43-52 ft.’ 1 12 Nm . ilN0029 10 50 Nm . Dust shield 8. 230 Nm 166 ft. Front strut mounting bolt 13. Front speed sensor connection 4Ab <Vehicles with ABS*> . Drive shaft nut 4. Brake disc 6. Front hub unit bearing 7.A( 3. Drive shaft 12. -r llFO026 00000628 Removal steps 1.lbs.9 ft. Hub and knuckle 14. 60-.A( 2.‘+.lbs.26-6 FRONT AXLE . Cotter pin :I& . 230 Nm 166 ft. 36fLlbs. Hub NOTE ‘: Anti-lock braking system ‘d .

disconnect the lower arm ball joint from the knuckle. Be sure to tie the cord of the special tool to the nearby part. CALIPER ASSEMBLY REMOVAL Remove the caliper assembly and suspend it with wires. take care not to damage the rotor for ABS installed to the B. etc. +E. DRIVE SHAFT REMOVAL Use the special tool to push out the drive shaft from the front hub. 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. 2. and then remove the speed sensor. outer race when removing the hub. AD. Loosen the nut but do not remove it. MB990998. Caution Do not apply vehicle load to the wheel bearing loosing the drive shaft nut. Caution 1. FRONT SPEED SENSOR DISCONNECTION Remove the mounting bolts which hold the speed sensor bracket to the knuckle.J. i +F. +C.HUB REMOVAL In the case of AWD-vehicles with ABS. Be sure to tie the cord of the special tool to the nearby part. disconnect the tie rod end from the knuckle. (B. z TSB Revision . If. the nut but do not remove it.Hub and Knuckle Front speed 26-7 REMOVAL SERVICE POINTS +A. +G. Caution 1. Loosen.DRlVE SHAFT NUT REMOVAL Loosen the drive shaft nut while the vehicle is on the floor with the brakes applied. TIE ROD END DISCONNECTION Using the special tool. however. temporarily secure the wheel bearing by using the special tools. vehicle load must be applied to the bearing in moving the vehicle. 2.FRONT AXLE . LOWER ARM BALL JOINT DISCONNECTION Using the special tool.

MEASUREMENT OF FRONT HUB UNIT BEARING ROTATION STARTING TORQUE (1) Set the special tool to the front hub unit bearing. Check the oil seal for damage.) in maximum. do u 711FOO4 I (4) Measure the rotation starting torque of the hub.Hub and Knuckle INSTALLATION SERVICE POINT bAdDRIVE SHAFT NUT / COTTER PIN INSTALLATION (1) Be sure to install the washer and wheel bearing nut in the specified direction. (2) Holding the special tool (bolt). TSB Revision . (3) Turn the hub to cause grease to distribute evenly over the bearing. (4) Install the cotter pin in the first matching holes and bend it securely. (2) After installing the wheel. lower the vehicle to the ground and finally tighten the wheel bearing nut.26-8 FRONT AXLE . (3) If the position of the cotter pin holes does not match.8 Nm (16 in. the bearing must not feel rough when rotated. in addition. replace the bearing or damaged parts. is loose. Limit: 1.lbs. Check the knuckle for cracks. tighten the nut up to 260 Nm (188 ftlbs.). or of the wheel bearing inner race and the hub.) or less (5) The starting torque must be within the limit and. tighten its nut to 200 to 260 Nm (145 to 188 ftlbs. Check for defective bearing. NOTE If the meshing of the wheel bearing outer race and the knuckle. INSPECTION l l l l Check the hub for cracks and spline for wear.

lbs. the bearing will be damaged. Dust shield .A4 8.o*lo .B+ 6. If the hub and knuckle are disassembled by striking them with a hammer. WHEEL BEARING REMOVAL (1) Crush the oil seal in two places to that the tabs of the special tool will be caught on the wheel bearing inner race. 2. Be sure to use the special tools. +B. Snap ring 4B.n. Hub 4. llLO125 Caution 1. Rotor <Vehicles with ABS> 5..D+ 1.N0030 00000630 Disassembly steps . . Hub and rotor (A. 211 A0281 . . (2) Secure the knuckle in a vise. 7 . Oil seal (hub side) 7.FRONT AXLE .Hub and Knuckle DISASSEMBLY AND REASSEMBLY cFWD> 26-9 ’ 4 I (‘9 Nm 7 ft. (3) Tighten the nut of the special tool and remove the hub and rotor from the knuckle.C( l Adjustment of wheel bearing starting torque 3.HUB AND ROTOR REMOVAL (1) Attach the special tools to the knuckle and front hub. Knuckle DISASSEMBLY SERVICE POINTS +A. Wheel bearing 9. Oil seal (drive shaft side) 2.

). MB991355 00000631 or MB991 056 I I REASSEMBLY SERVICE POINTS .C+ WHEEL BEARING STARTING TORQUE ADJUSTMENT (1) Use the special tool to mount the hub assembly onto the knuckle.Hub and Knuckle (2) Remove the wheel bearing inner race from the hub by using the special tool: Caution Be careful that the hub will not fall down as the wheel bearing inner race (outer side) is removed from the hub.B+OIL SEAL (HUB SIDE) INSTALLATION (1) Drive the oil seal (hub side) into the knuckle by using the special tools until it is flush with the knuckle end surface. .26-10 FRONT AXLE . press-in the bearing by using the special tools. MB990932 / (3) Remove the snap ring from the knuckle. (3) Rotate the hub assembly in order to seat the bearing. (4) Install the wheel bearing inner race to the wheel bearing. 212A05 4 MB990947 . MB990998 Turn the nut ZllR004 7 TSB Revision . (3) With the wheel bearing inner race removed. NOTE Removal is easier if the outer side inner race removed from the hub is placed on the bearing and the wheel bearing is then removed. (4) Remove the bearing by using the special tools. (2) Apply multipurpose grease to the lip of the oil seal and to the surfaces of the oil seal which contact the hub.A4 WHEEL BEARING INSTALLATION (1) Fill the wheel bearing with multipurpose grease. (2) Apply a thin coating of multipurpose grease to the knuckle and bearing contact surfaces. (2) Tighten .the nut of the special tool to 200-260 Nm (146-188 fblbs.

lbs. Repeat the disassembly and assembly procedure. . TSB Revision . Limit: 0.) or less NOTE The starting torque must be within the limit and. Check the knuckle inner surface for galling and cracks.D+OIL SEAL (DRIVE SHAFT SIDE) INSTALLATION Drive the oil seal (drive shaft side) into the knuckle until it contacts the snap ring. Check for defective bearing. in addition.FRONT AXLE .Hub and Knuckle MB990998 990326 26-11 (4) Measure the wheel bearing starting torque (hub starting torque) by using the special tools.). hub and/or knuckle have probably not been installed correctly.) (6) If the starting torque and hub end play are not within the limit range while the nut is tightened to 200-260 Nm (145-188 ftlbs. Apply multipurpose grease to the lip of the oil seal. the bearing must not feel rough when rotated.8 Nm (16 in.002 in. ZllKOl2 MB990998 l7h (5) Measure to determine whether the end play of the hub is within the specified limit or not.05 mm (. the bearing. INSPECTION l l l Check the hub and brake disc mounting surfaces for galling and contamination. Limit: 1.

Circlip d Caution In the case of AWD-vehicles with ABS. Drive shaft and inner shaft assembly (L. 230 166 <AWD> 50 Nm 4 y F@=p 230 ‘Nm 166 ft. 6. temporarily secure the wheel bearing by using the special tools. /! p a IL . MB990998. --L. Cotter pin 5. <--7q. Lower arm ball joint connection 4. etc.H.H.*-. If.1 bs I ? 29 Nm 21 ft.26-12 DRIVE SHAFT FRONT AXLE . vehicle load must be applied to the bearing in moving the vehicle. Cotter pin I.. take care not to damage the rotor for ABS installed to the B.) 8.lbs.A( 2.. Tie rod end connection 6.-ii-:.L . Center bearing bracket installation bolt 7.) 9. Drive shaft (R. however.Drive Shaft REMOVAL AND INSTALLATION I l Pre-removal and Post-installation Operation Under Cover Removal and Installation <FWD> 60-72 Nm 43-52 ft.DRlVE SHAFT NUT REMOVAL Loosen the drive shaft nut while the vehicle is on the floor with the brakes applied. REMOVAL SERVICE POINTS +A. 1 TSB Revision I d .J. Drive shaft nut 3. Caution Do not apply vehicle load to the wheel bearing loosing the drive shaft nut. outer race.lbs.’ . 7 ZllN0028 Removal steps 1.

) from the hub._ _c /. Be sure to use a lever..H. Loosen the nut but do not remove it.” (5 J 3 I pw-& ‘.) from the transaxle. Be sure to tie the cord of the special tool to the nearby part. ” ~:. \ ZllAO350 (3) To remove the drive shaft (R.DRlVE SHAFT AND INNER SHAFT .&. +D. push out the drive shaft and inner shaft assembly (L. 2. strike the center bearing bracket lightly with a plastic hammer.) / DRIVE SHAFT (R-H. Loosen the nut but do not remove it.” i \.‘/ .‘ :. disconnect the tie rod end from the knuckle.~~~~~~ i.FRONT AXLE . TIE ROD END DISCONNECTION Using the special tool.! /.- 1 TSB Revision I .\y/: . LOWER ARM BALL JOINT DISCONNECTION Using the special tool.) (1) Using the special tool. . (C. Caution 1.’ .Drive Shaft 26-13 +B.J. Caution 1.H. .‘. Be sure to tie the cord of the special tool to the nearby part.p ~~. ’ . disconnect the lower arm ball joint from the knuckle.----y~ . /q?p: “1 r.H. 2.> !:. pry off the shaft using a lever against’ the protrusion of the drive shaft..) or the drive shaft (R..F Protrusion ‘4 -2 ‘. Caution Pulling the drive shaft can cause damage to the T..H. (2) If the inner shaft is hard to remove from the transaxle..FokllLY (L.

) in maximum. Check the ball joints for wear or operating condition. 1 TSB Revision .Drive Shaft INSTALLATION SERVICE POINT . (3) If the position of the cotter pin holes does not match. Check the spline part for wear or damage. tighten the nut up to 260 Nm (188 ftlbs. lllj J l l l Check the drive shaft boot for damage or deterioration. d INSPECTION L@@ \ m\I. (4) Install the cotter pin in the first matching holes and bend it securely. lower the vehicle to the ground and finally tighten the wheel bearing nut.26-14 FRONT AXLE .A+ DRIVE SHAFT NUT INSTALLATION (1) Be sure to install the washer and wheel bearing nut in the specified direction. (2) After installing the wheel.

I: 14.J. B.J.I . Snap ring . . Boot Repair Kit qq%& ln -. assembly 4Db Caution in the case of AWD-vehicles with ABS.A( 17.FRONT AXLE .& L 00 6 /‘2!8 fh & @ 1 19 ? . case 2: Seal plate 4Ab FE4 F: Inner shaft 4B. Dust shield Bracket assembly Dust seal outer Dust seal inner . . boot band (small) ::: $: T.J. boot band (large) T.J.@ lw.A( 20.J. Boot Repair Kit B. L TSB Revision .J. boot cl992 models> 21. Repair Kit Bearing Dust Seal Rer>air Kit I Bracket Assemblv Reoair---~~---‘ Kit Disassembly steps .Drive Shaft DISASSEMBLY AND REASSEMBLY cl 992 models> 26-15 T. boot 18. case and inner shaft T.*gg ?f .q $p$ 1@ 2 ’ 1110118 :1992 models> T. B. outer race. 4 5 ?FqB 15 ‘6 17 L r.%4 0 :1992 models> . .. TJ. Dust shield cl992 models> 22. Repair Kit 2’820 P&g y-9 -I5$? 9 .J. take care not to damage the rotor installed to the B. boot band (small) cl 992 models> dC.J. Circlip assembly :.J.J. boot band (large) cl 992 models> 19.B( 16.J. B. Center bearing bracket 13. B.0116 llA0315 00000632 B.G4 1.J.J. Dust shield 15. T. Spider assembly +C.c+ 11: Center bearing 12.

) cAWDr 135 g (4.) /Gr:::t ::::::?g.11 oz..) Caution The grease in the repair kit should be divided in half for use.. at the joint and inside the boot.26-16 Lubrication Points FRONT AXLE . at the joint and inside the boot.) Caution The grease in the repair kit should be divided in half for use.76 oz.64 oz.71 oz. respectively.42 oz. <From 1993 models. Do not mix old and new grease or different types of grease. /Grease: Repair kit grease Grease: Repair kit grease cFWDr 145 g (5.49-. Do not mix old and new grease or different types 1 of grease. Special grease is used to lubricate the joint. respectively. Special grease is used to lubricate the joint.) I llNoo33 Grease: Repair kit grease 160 g (5. 1 TSB Revision 1 .Drive Shaft Dust seal inner 14-20 g (.

J. case. ASSEMBLY 4992 models> REMOVAL Wipe off grease from the B.J. NOTE Press the tool directly against the seal plate. The tool under oressure will ouncture and deform the seal plate. and B. and B.J. ADbGREASE FROM B. i +C. boots from the drive shaft. boots are not damaged when they are removed.J. from the T. BOOT / B.J.Drive Shaft DISASSEMBLY SERVICE POINTS 26-17 -- plate ZllN0036 llA0076 +A. TSB Revision . T. CENTER BEARING REMOVAL Use the special tools to remove the center bearing from the center bearing bracket.J.J. 00000634 (2) Use the special tool to remove the inner shaft from the center bearing bracket. BOOT cl992 models> REMOVAL (1) Wrap vinyl tape around the spline on the T. side of the drive shaft so that the T. assembly.J.J. assembly cannot be disassembled.FRONT AXLE . remove the inner shaft assembly. together with the seal plate. INNER SHAFT REMOVAL (1) Using the special tool. (2) Withdraw the T.J. and push out the inner shaft underneath. Caution B. ZllLOllI +B.J.

and B. The boot bands should be tightened with the drive shaft at a 0” joint angle.J. boots.) Caution 1. Take good care to install the correct one. Ij I I .76 oz. 4 992 models> I I (2) Fill the inside of the B. Do not mix old and new grease or different types of grease.J. boot with the specified grease.J. BOOT cl992 models> / T. 2. ZllK033 Caution 1. at the joint and inside the boot. boot band and T. (3) Secure the boot bands. respectively.J. boot band are identified by the identification number stamped on the lever.) cAWD> 135 g (4.J.J.B( SPIDER ASSEMBLY INSTALLATION (1) Pack specified grease amply between the spider shaft and rollers of the spider assembly. Specified grease: Repair kit grease Caution Special grease is used to lubricate the joint. Special grease is used to lubricate the joint. insert the shaft from the chamfered end of the spider. TSB Revision .J. The grease in the repair kit should be divided in half for use. (2) To install the spider assembly to the shaft. Specified grease: Repair kit grease <PWD> 145 g (5. in that order.A4 B.11 oz. llE560 00000635 . 2. Do not mix old and new grease or different types of grease.26-18 FRONT AXLE .J. boots and T. and then install the R. BOOT INSTALLATION (1) Wrap vinyl tape around the splines on the drive shaft.Drive Shaft REASSEMBLY SERVICE POINTS . The B.

71 oz.FRONT AXLE . (2) Use the special tools to press-fit the center bearing into the center bearing bracket.CA CENTER BEARING INSTALLATION (1) Apply multipurpose grease to the center bearing and inside the center bearing bracket.28-. Caution Take care not to damage the rubber part on the periphery of the dust seal. (3) Apply multipurpose grease to the lip of each dust seal. NOTE When applying grease.42 oz.) Dust seal outer: 8-12 g (. i 1 TSB Revision . ZllLOO1O . ZllLOO93 Dust seal outer .Drive Shaft 26-19 i. ZllLOO64 .49-. make sure that it does not adhere to anything outside the lip.DA DUST SEALS INSTALLATION (1) Apply multipurpose grease to the rear surfaces of all dust seals.) Dust seal inner MB990890 (2) Press the oil seal into the center bearing bracket using the special tool. Dust seal inner: 14-20 g (.

boot bands at the specified distance in order to adjust the amount of air inside the T. grease (2) Using the special tool. The drive shaft joint uses special grease. case. boot. bG4T.E( INNER SHAFT INSTALLATION Use the special tool to hold the inner race of the center bearing and force the inner shaft into place.J. CASE AND INNER SHAFT ASSEMBLY INSTALLATION (1) Apply multipurpose grease to the inner shaft spline.J.J.J boot band securely. at the joint and inside the boot. Specified grease: Repair kit grease 160 g (5.) TSB Revision . The grease in the repair kit should be divided in half for use. then press fit it into the T. case ZllN0033 (3) Fill the specified grease furnished in the repair kit to the T.26-20 J FRONT AXLE . Do not mix old and new or different types of grease. BOOT BANDS INSTALLATION Set the T. case. T. respectively.J.J.12 in. press the seal plate into the T. MB991172 Zll LOO94 Inner shaft assembly bF4T.Drive Shaft ‘--‘-I-p inner shaft .35 + .J.64 oz. Standard value (A): 85 + 3 mm (3. 2. and then tighten the T.J. case.) Caution 1.J.

Adjusting bolt 11x0141 / *1x0131 00003420 TSB Revision . NOTE (1) One complete turn of the adjusting bolt will change the width by approx. BOOT (RESIN BOOT) REPLACEMENT (1) Remove the large and small boot. Check the inner shaft for damage.114 in. Check the center bearing for seizure. Check for entry of water and/or foreign material into B. Check the boots for deterioration. <When width is below 2.)> Loosen the adjusting bolt. Check the spider assembly for roller rotation.114 in.J. Check the drive shaft splines for wear or damage.9 mm (. (2) Remove the B.9 mm (. case for wear of corrosion. bending or corrosion. boot. Standard value (W): 2.)> Tighten the adjusting bolt. 1 r / 11X0138 MB991561 Stopper (4) Turn the adjusting bolt of the special tool to obtain a standard value of the opening width (W). Check the inner shaft splines for wear or damage. bending or corrosion.J. NOTE Do not reuse the boot bands. Check the dust cover for damage or deterioration. damage or cracking. discoloration or roughness of rolling surface. Check the groove inside T.FRONT AXLE .). boot by so locating it as to expose only one of the grooves provided on the shaft. (2) Do not give more than one turn to the adjusting bolt.9 mm (.) <When width is above 2.J. wear or corrosion.Drive Shaft INSPECTION l 26-21 L l l l l l l l l l Check the drive shaft for damage.J.114 in. 0.J.028 in. B.7 mm (. bands. (3) Install the small diameter end of the B.

J. (7) Make sure that the amount of boot band crimping (B) is of the standard value.217 in.26-22 FRONT AXLE .Drive Shaft (5) Install the boot band (small) against the projection at the boot end to provide clearance A as shown in the illustration. W = 3.47 oz.)..114 in.126 in. W = 5.2 mm (.4.217 in.091 in. 2. Be sure to compress the boot band until the special tool handle comes in contact with the stopper. W = 2.6 mm (.)] (8) Make sure that the boot band does not protrude from the band mounting area.9 mm (.5 mm (.) .)] <When amount of crimping is below 2.) <When amount of crimping is above 2. pinch positively the portion to be crimped of the band between the tips of the special tool. readjust W given in (4) to the value calculated by the following formula and repeat work described in (5) and (6) by using a new boot band. W = 5.)> Readjust W given in (4) above to the value calculated by the following formula. replace it with a new band and repeat work described in (5) through (7).) 00003422 TSB Revision . crimp the boot band. boot band \ d’ AllSO (6) Using the special tool.102 in. Standard value (B): 2. Specified grease: Grease in repair kit Amount applied: 155 g (5.5 mm (.2.094 in.) . With the drive shaft secured vertically.llO in.4 mm (.094 . B. (9) Pack the boot with specified amount of grease to specification. Caution 1. and repeat work described in (6).8 mm (.3 mm (.B [Example: When B = 2.)> Remove the boot band.).llO in.B [Example: When B = 2.8 mm (. If the band protruds.

)> Remove the boot band.Drive Shaft 26-23 (10)lnstall the boot with a clearance of standard value (C) provided between the large diameter end of the boot and the shoulder of B.llO in.1 .). Standard value (E): 2.5 mm (.228 in.) .110 in. W = 3. readjust W given in (11) to a value calculated by the following formula and repeat work described in (12) and (13) by using a new boot band.)] (15)Make sure that the boot band does not protrude from its mounting area.004 . If the band protrudes.)] <When amount of crimping is below 2.061 in.E [Example: When E = 2.114 in.) L (12)lnstall the boot band (large) against the projection at the boot end to provide clearance D as shown in the illustration.4 mm (.) (ll)Adjust the width of opening in the special tool (W) to standard value in the same manner as described in (4). W = 2.9 mm (114 in.8 mm (. Standard value (C): 0.3 mm (..138 in.. W = 5.8 mm (.094.4-2.).094 in. replace it with a new -band and repeat work described in (12) through (14).55 mm (.8 mm (.8 mm (. (13)Crimp the boot band (large) with the special tool in the same manner as described in (6) above.228 in.E [Example: When E = 2. TSB Revision . housing.1. Standard value (W): 3.FRONT AXLE .126 in.) . W = 5.)> Readjust W given in (11) to a value obtained by the following formula and repeat work described in (13) above.meA 00003424 (14)Make sure that the amount of boot band crimping is within the range of standard value (E).J.9 mm (.) <When amount of crimping is above 2. AllS0169 >.2 mm (.091 in.

NOTES .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sealants and Adhesives . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 16 DIFFERENTIAL CARRIER . . . 14 Gear Oil Level Check . 2 SPECIAL TOOLS . . . 2 General Specifications . . . . . . . . . 6 AXLE SHAFT . . . 7 Service Specifications . . . . . . . . . . . . . . . . . . . . 14 Rear Wheel Bearing End Play Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TROUBLESHOOTING . . . . . . 25 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 8 SPECIFICATIONS . 15 Rear Axle Total Backlash Check . . . . . . . . . . 3 Wheel Bearing End Play Check . 2 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . 6 General Specifications . . . . . . . . . . . . . 40 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . 4 SPECIFICATIONS . . . . . . . . . . . . 6 Lubricants. . . . . . . . . . . . . . 19 LSD CASE ASSEMBLY . . 14 Limited-Slip Differential Check . . . . . . . . . . 12 L. . . . . . . . . . . . . . . 15 REAR AXLE cFWD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I . 14 Rear Wheel Bearing Rotary-Sliding Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear Hub Rotary-Sliding Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . .27-1 REAR AXLE CONTENTS REAR AXLE <AWD> . . . 2 i TROUBLESHOOTING . . . . . . . . . . . 3 REAR AXLE HUB . . . . . . . . . . . . . . . . . . .

) Rear hub rotary-sliding resistance N (Ibs.002) or less 31 (7) or less TROUBLESHOOTING 1 TSB Revision .) Limit 0.27-2 REAR AXLE <FW& .05 (.Specifications / Troubleshooting REAR AXLE <FWD> SPECIFICATIONS GENERAL SPECIFICATIONS Item Wheel bearing Type Specification Unit ball bearing d SERVICE SPECIFICATIONS Items Wheel bearing end play mm (in.

After turning the hub a few times to seat the bearing. Remove the hub cap and then release the parking brake. 4. Remove the caliper assembly and the brake disc. Inspect the play of the bearings while the vehicle is jacked up and resting on floor jack. pulling at a 90” angle from the hub bolt. Remove the caliper assembly and the brake disc. Release the parking brake. Place a dial gauge against the hub surface. the lock nut should be tightened to the specified torque and check the end play again. 2. 5. 4. 2. REAR HUB ROTARY-SLIDING RESISTANCE CHECK Inspect the play of the bearings while the vehicle is jacked up and resting on floor jack. and check the rear hub rotary-sliding resistance again. 1. and. Limit: 0.On-vehicle Service 27-3 ON-VEHICLE SERVICE WHEEL BEARING END PLAY CHECK 1.05 mm (-002 in. then move the hub in the axial direction and check whether or not there is end play. measure to determine whether or not the rotary-sliding resistance of the rear hub is the limit value. 1 TSB Revision .REAR AXLE cFWD> . \ // 712NOOO 5. Replace the rear hub bearing unit if an adjustment cannot be made to within the limit. Check the bearing’s end play. 3. attach a spring balance to the hub bolt. 3.) or less NOTE If the limit value is exceeded. Replace the rear hub unit bearing if an adjustment cannot be made to within the limit. Limit: 31 N (7 Ibs. loosen the nut and then tighten it to the specified torque.) or less NOTE If the limit value is exceeded.

Tongued washer 4CP 7.27-4 REAR AXLE HUB REAR AXLE cFWD> . TSB Revision . Brake disc 4. Caliper assembly 4Bb 3.lbs. Rear hub unit bearing Caution Rear hub unit bearing cannot be disassembled. Rear speed sensor <Vehicles with ABS> 2.A( 5. Wheel bearing nut 6.Rear Axle Hub REMOVAL AND INSTALLATION 50-60 Nm 36-43 ft. Hub cap . Pole pie/cc ZlCN0107 +B. REMOVAL SERVICE POINTS +A. Removal steps l b 1. Rear rotor <Vehicles with ABS> 9. CALIPER ASSEMBLY REMOVAL Remove the caliper assembly and suspend it with a piece of wire. Rear hub assembly 8. REAR SPEED SENSOR REMOVAL <VEHICLES WITH ABS> 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.

align with the spindle’s indentation and crimp. If the rotor’s toothed surface is chipped or the rotor is deformed. and not to drop it. it might not be able to accurately sense the wheel rotation speed and the system as a result might not perform normally.REAR ROTOR REMOVAL <VEHICLES WITH ABS> 27-5 Caution Care must be taken not to scratch or scar the rotor’s toothed surface. Z 13NOO(! idi TSB Revision . INSTALLATION SERVICE POINT .REAR AXLE eFWD> .Rear Axle Hub (C.A( WHEEL BEARING NUT INSTALLATION After tightening the wheel bearing nut.

307 Differential gear type Side gear and configuration Pinion gear Number of teeth Drive gear Straight bevel gear x 2* Straight bevel gear x 4 <Up to 1993 models> 39 <From 1994 models> 43 Drive pinion Side gear Pinion gear 1 O.00 x 1 A-4) NOTE l : Denotes the gear (L.78) 68.19) 1 76.) / Side Front <Up to 1993 models> 11 <From 1994 models> 13 16 10 1I 82.27-6 REAR AXLE cAWD> .) which is in a single body with the viscous coupling. 395x28 (15.69 x 1 .545 <From 1994 models> 3. T.: Bit-field Joint T.Specifications REAR AXLE <AWD> SPECIFICATIONS GENERAL SPECIFICATIONS AXLE SHAFT DRIVE SHAFT items Joint type Outer Inner Length (joint to joint) x diameter mm (in.500 x 45.25 x 1.10) DIFFERENTIAL items Reduction gear type Reduction ratio Specifications Hypoid gear <Up to 1993 models> 3.J.) N O T E B.263 x 30. TSB Revision . mm (in.H.J.163 (2.242 (3.6x 1.J.513 (3.D.: Tripod Joint Specifications B. x I.D.J.200 x 36.

J.15-0.35-0.4 ) (gear oil application) Without oil seal New part (with rust-prevention oil) 0.004-.006) 0.) L New part/reusable part 0.35k.16 (. boot grease 125 g (4. 8663 or equivalent Differential cover Specified sealants and adhesives 3M Stud Locking Part No.031) I LUBRICANTS Items Rear axle gear oil Specified lubricants Hypoid Gear Oil API classification GL-5 or higher Above -23°C (-10°F) SAE 90.7 (4-6) 1 Limit 1 / 12 (2.2 qts.2) I 1 0.45 ( 3 .) 135 g (4.8 (.lbs. 8OW-90 Below -34°C (-30” F) SAE 75W Repair kit grease Quantity 1. 4170 or equivalent 1 TSB Revision .) B.) SEALANTS AND ADHESIVES Items Drive gear threaded hole Vent plug 3M ATD Part No.0012-.41 oz.05 (002) I I With oil seal New part (with rust-prevention oil) N e w parVreusable part 0.25 (l-2) (gear oil application) I - I - I 0.6) 5 (.J. (1.5 (3-4) Rear wheel bearing rotation torque N (Ibs.3-0.11-0.) Drive pinion rotation torque Nm (in. boot grease T.) c 27-7 ~ / Standard value 1 85c3 (3.REAR AXLE <AWD> . boot length mm (in.03-0.0035) 0.) Final drive gear backlash mm (in.Specifications SERVICE SPECIFICATIONS Items Setting of T.) Differential gear backlash (Limited slip differential) mm (in.J.12) 0.8OW-90 From -34°C (-30°F) to -23°C (-10°F) SAE 8OW.85W-90.) Drive gear runout mm (in.) Rear wheel bearing end play mm (in.) Rear axle total backlash mm (in.1 lit.09 (.76 oz.5-0.

Special Tools MB990560 * Bearing remover MB990925 General service tooj Removal of the axle shaft dust shield. outer bearing and rear rotor Press-in the outer wheel bearing and rear rotor MB990925 or General service Bearing and oil tool seal installer set Removal of axle shaft inner bearing Installation of axle shaft inner bearing Installation of drive pinion rear bearing outer race Installation of drive pinion front bearing outer race Installation of differential side oil seal (Use in conjunction with MB991 380) Removal of drive pinion front bearing and drive pinion rear bearing outer race Adjustment of differential final gear tooth contact Press-fitting of axle housing oil seal MB990641 Lower arm bushing installer and remover A TSB Revision .27-8 SPECIAL TOOLS REAR AXLE’ eAWD> .

RFAR AXI F eAWl& . I Is.- Tnnln 27-9 Tool Tool number and name MB990901 Drive pinion setDrive pinion gauge assembly B: MB990552 Cylinder gauge MB991 378 Drive pinion setting gauge set A: MB991 366 Head B: MB991 365 Cylinder gauge MB990802 Bearing installer Supersession MB990901 -01 MIT21 5838 Application Drive pinion height adjustment (Use in conjunction with MB991 366) MB991366-01 MB990802-01 Pressing of drive pinion rear bearing inner race Pressing of side bearing inner race MB990326 Preload socket General tool service Measurement of the drive pinion preload MB990728 Bearing installer MB990802-01 Press-fitting of the side bearing inner race MB991 380 Oil seal installer MB991 380-01 Press-fitting of differential oil seal MB991294 Side gear holding tool MB990799 Ball joint dust shield installer 6 MB990799-01 Inspection of differential gear backlash Press-fitting the axle shaft dust shield TSB Revision ..1-m I..-r Snnttinl -r--m-= .--. .--I .

Special Tools Tool number and name MB991153 Bushing remover & installer arbor MB990831 Bushing remover & installer ring Supersession Application Driving-out and press-fitting of differential support bushing and differential support member bushing MB990847 Bushing remover & installer base MB990909 Working base General service tool Disassembly and reassembly of differential carrier assembly (Use in conjunction with adapter MB991 116) MB991116 Working base adapter General service tool MB991 367 Special spanner MB991367-01 Removal and installation of side bearing nut MB991 385 Pin MB99081 0 Bearing puller P-334 MB990339-01 MB990811 -01 MIT44801 MIT303173 MB990767-01 Removal of companion flange Removal of the side bearing inner race and drive pinion rear bearing inner race MB990850 End yoke holder Removal and installation of companion flange TSB Revision .27-10 REAR AXLE eAWD> .

SDecial Tools Tool number and name MB990339 Taper roller bearing puller Supersession General service tool Application Removal of drive pinion rear bearing inner race MB990648 General service Bearing remover tool @ MB990890 Rear suspension bushing base MB990890-01 Press-fitting of drive gear (for 4WS) i 1 TSB Revision .REAR AXLE cAWD+ .

etc. muffler vibration. broken. TSB Revision . acceleration. constant speed driving. is easily mistaken as being caused by malfunctions in the differential carrier components. broken.. and/or seized drive pinion bearings Damaged. Be extremely careful and attentive when performing the driving test. take all possibilities into consideration and confirm the source of the noise. etc. abnormal noise can also be caused by the universal joint of the propeller shaft. the axle shafts. transaxle. wheel bearings. Test methods to confirm the source of the abnormal noise include: coasting. Before disassembling any parts. Use the method most appropriate to the circumstances.27-12 REAR AXLE eAWD> . play or seizure of ball joint Excessive drive shaft spline looseness Remedy Replace DIFFERENTIAL (LIMITED SLIP DIFFERENTIAL) driving or gear changing* when cornering Damaged. (2) *2: Noise from the engine. the wheel bearings. tires. body. raising the rear wheels on a jack. propeller shaft. and/or seized side bearings Damaged differential case Inferior gear oil lnsuff icient gear oil quantity Replenish N O T E (1) *‘: In addition to a malfunction of the differential carrier components. etc.Troubleshooting TROUBLESHOOTING AXLE SHAFT DRIVE SHAFT Symptom Noise Probable cause Wear. etc.

check the functioning and replace the damaged parts Replace Replenish Adjust Retighten or replace Retighten or apply adhesive Clean or replace Adjust Remedy Replace NOTE (1) l ‘: In the event of seizure. mud. or an improperly installed oil seal Damaged gasket Loose companion flange self-locking nut Loose filler or drain plug Clogged or damaged vent plug Seizure*’ Insufficient final drive gear backlash Excessive drive pinion preload Excessive side bearing preload Insufficient differential gear backlash Excessive clutch plate preload Inferior gear oil Insufficient gear oil quantity Breakdown*2 Incorrect final drive gear backlash Insufficient drive pinion preload Insufficient side bearing preload Excessive differential gear backlash Loose drive gear clamping bolts The limited slip differential does not function (on snow. be sure to check all components for irregularities and repair or replace as necessary. and also be sure to check all components for any irregularities and repair or replace as necessary.Traubleshootina Symptom Gear oil leakage Probable cause Worn or damaged front oil seal. ice. disassemble and replace the parts involved. etc. (2) l ? In addition to disassembling and replacing the failed parts.) The limited slip device is damaged Retighten Disassemble. TSB Revision .REAR AXLE <AWD> .

)] NOTE Above -23°C (-10°F): SAE 90.27-27. (1) Place the gearshift lever in the neutral position. 5. Remove the caliper assembly and brake disc. 2. 8OW-90 Below -34°C (-30°F): SAE 75W REAR WHEEL BEARING END PLAY CHECK 1. Place a dial gauge as shown in the illustration.) If the play exceeds the limit. Limit: 0. apply the parking brake and jack up the vehicle. (3) Manually turn the propeller shaft counterclockwise as far as it will go and measure the movement of the mating marks. Specified gear oil: Hypoid Gear Oil API classification GL-5 or higher [1. Limit: 5 mm (.2 qts. Support the vehicle on axle stands positioned at the specified locations and remove the rear wheel. 85W-90. replace the wheel bearing. Remove the filler plug. The oil level is sufficient if it reaches the filler plug hole. 4. 8OW-90 From -34°C (-30°F) to -23°C (-10°F): SAE 8OW. measure the rear axle total backlash by the following procedures to see if the differential carrier assembly required removal. 1 TSB Revision .2 in.) GEAR OIL LEVEL CHECK 1. remove the differential carrier assembly and adjust the backlash. and check the oil level.) (4) If the backlash exceeds the limit. and then measure the play when the axle shaft is moved in the axial direction.1 liter (1. check the tightening torque of the companion flange of the axle shaft. Separate the parking brake cable from the rear brake. Mating marks / (2) Manually turn the propeller shaft clockwise as far as it will go and make mating marks on the companion flange dust shield and the differential carrier. 3.031 in. if it is correct. 2.27-14 REAR AXLE cAWD> . (Refer to P.On-vehicle S&vice ON-VEHICLE SERVICE REAR AXLE TOTAL BACKLASH CHECK If the vehicle vibrates and produces a booming sound due to an imbalance of the driving system.8 mm (.

Jack up the rear wheels and place a rigid rack at the specified part of the side sill. Remove the drive shaft from the companion flange. 2. pulling the balance at a right angle to the hub bolt. Attach a spring balance to the hub bolt. replace the viscous unit. Block the front wheels and move the shift lever to neutral. If it is normal. Disconnect the coupling of the differential and propeller shaft. then. 3. 4. measure the rotary-sliding resistance to see whether it is within the limit value. replace the bearing. Completely release the parking brake. LIMITED-SLIP DIFFERENTIAL CHECK Correct &ncorrect 1. Remove the brake pad or caliper assembly. check the tightening torque of the axle shaft companion flange.On-vehicle Service 27-15 REAR WHEEL BEARING ROTARY-SLIDING RESISTANCE CHECK 1. When one wheel is slowly rotated. 6.) Z14AO521 4. If the rotary-sliding resistance exceeds the limit value.6 Ibs. 2.REAR AXLE <AWD> . 3. If it turns in the opposite direction. 5. Limit: 12 N (2. i TSB Revision . check whether or not the wheel on the other side turns in the same direction.

. Outer bearing (F.A0263 11 NO021 00001040 Removal steps 4w 1.Axle Shaft REMOVAL AND INSTALLATION 55-65 Nm 40-47 ft. Rear rotor <Vehicles with ABS> 4F.D( 11. d 1 TSB Revision 1 .F+ 9. $++e. 50-60 Nm 36-43 ft.A4 15.lbs. Axle shaft assembly dE. Inner bearing d REMOVAL SERVICE POINTS . Oil seal (G.REAR SPEED SENSOR REMOVAL <VEHICLES WITH ABS> Caution Be cautious to ensure that the tip of the pole piece does not come in contact with other parts when removing the speed sensor. Dust shield .G( . Drive shaft mounting nut +C.C+ 12.B( 14. +A. I ===ib llA0325 . Brake disc 4. Axle shaft 4G.lbs.27-16 AXLE SHAFT REAR AXLE cAWD> . . Dust shield 13. . BRAKE CALIPER ASSEMBLY REMOVAL Remove the brake caliper assembly and suspend it with a piece of wire. Rear speed sensor <Vehicles with ABS> 2. . FE+ 10. . Brake caliper assembly 4Bb 3. +B. 12 Nm 9 ft...king n u t 4W 7: Companion flange 8.lbs.

OUTER BEARING / DUST SHIELD REMOVAL Using the special tool. remove the inner bearing and oil seal from the axle housing. MB99 c>lN0039 qD.REAR AXLE eAWD> .Axle Shaft 27-17 +. remove the outer bearing and dust shield concurrently from the axle shaft. remove the axle shaft from the axle housing. dF. i. MB990560 MB990938 dG. remove the rear rotor from the axle shaft. MB990560 \ +E. secure the axle shaft and remove the companion flange self-locking nut. AXLE SHAFT ASSEMBLY REMOVAL With the special tool. MB990928 nlAQQ3s 1 TSB Revision . SELF-LOCKING NUT REMOVAL With the special tool.OIL SEAL / INNER BEARING REMOVAL With the special tool. REAR ROTOR REMOVAL <VEHICLES WITH ABS> Using the special tool.

LJ 00001041 . and until it contacts the shoulder on the inside of the axle housing.A( INNER BEARING INSTALLATION With the special tool.27-18 REAR AXLE cAWD> . use a plastic hammer to lightly tap the top and circumference of the special tool. NOTE When tapping the oil seal in.D+ DUST SHIELD INSTALLATION With the special tool. .C( DUST SHIELD INSTALLATION Orienting the dust shield as shown in the illustration.Axle Shaft Axle housing / INSTALLATION SERVICE POINTS MB990938 F MB990931 Axle hou ZllNOOlS . ~ 211 A 0 0 3 9 B990641 . use a plastic hammer to lightly tap the top and circumference of the special tool. install the dust shield so that the depression is facing upward. press fit the outer bearing to the axle shaft so that the bearing seal lip surface is facing towards the axle shaft flange. Lj. 00001043 11AO263 ce TSB Revision . use a plastic hammer to lightly tap the top and circumference of the special tool. . (2) Apply multipurpose grease to the oil seal lip. NOTE When tapping the oil seal in. press fitting gradually and evenly. press fit the dust shield until it contacts the axle shaft shoulder. NOTE When tapping the oil seal in.E( OUTER BEARING INSTALLATION (1) Apply multipurpose grease around the entire circumference of the inner side of the outer bearing seal lip. press the oil seal onto the axle housing with the depression in the oil seal facing upward. press fitting gradually and evenly. press fit the inner bearing onto the axle housing. (2) Using the special tool. press fitting gradually and evenly. and using the special tool.B+OIL SEAL INSTALLATION (1) With the special tool.

Check the wheel bearings for burning or discoloration. Oil seal TSB Revision .lbs.Axle Shaft / Drive Shaft 27-19 . press fit the rear rotor to the axle shaft with the rear rotor groove surface toward the axle shaft flange. secure the axle shaft and tighten the companion flange self-locking nut. Circlip . wear or damage. 55-65 Nm 40-47 ft.F( REAR ROTOR INSTALLATION <VEHICLES WITH ABS> Using the special tool.Bd 2.A+ 4. MB9 c” AN0039 INSPECTION l l l iv DRIVE SHAFT REMOVAL AND INSTALLATION l l l Check the companion flange for wear or damage.G+ SELF-LOCKING NUT INSTALLATION With the special tool. . Check the wheel bearing for unsmooth rotation. . llN0020 00001045 Removal steps /’ L 1. Check oil seal for cracking or damage. Bolt I+A. Drive shaft 3 . Check the axle shaft for cracking.REAR AXLE <AWD> . Check the dust shield for deformation or damage.

Check the drive shaft spline for wear or damage. side). grease. The right drive shaft for models equipped with the LSD having a VCU has a two-part serration. DRIVE SHAFT REMOVAL Using a tire lever. (2) Apply the specified grease to the oil seal lip. from the threaded part of the bolt and nut used for installation to the companion flange. TSB Revision . side) identification color Drive shaft (LH) White Drive shaft (RH) Blue Caution Be sure to thoroughly remove any oil or grease. NOTE The left and right drive shafts can also be distinguished from each other by the identification color of boot band (B.J. remove the drive shaft from the differential carrier. etc. INSPECTION l l l Check the drive shaft boots for damage or deterioration. etc. item Boot band (B. etc. Be very careful to install each one on the correct side.J<side) I Two-part serration ZilAO260 Caution 1. because any oil. drive it in by using the special tool. INSTALLATION SERVICE POINTS . Check the ball joints for excessive play or check operation.27-20 REAR AXLE <AWD> .Drive Shaft REMOVAL SERVICE POINT +A. on these parts might cause later loosening even though tightening is at the specified torque.B+ DRIVE SHAFT INSTALLATION Boot band (B. MB991380 ZllFOO12 I .J. Be cautious to ensure that the differential carrier oil seal is not damaged by the drive shaft spline. 2.A( OIL SEAL INSTALLATION (1) If the oil seal is to be replaced because of damage.

J.J. boot band (small) (f3. Spider assembly +B. B.J.J. repair kit llNO024 00001046 B. boot band (large) .A( 8. boot band (large) .J. T. assembly 4C. boot .J. boot repair kit P i 1 2 1 lN0023 fg . boot band (small) 3.A+ 6. . repair kit Disassembly steps . .C( 2. E. B.J. case 4. b o o t 10. 11 .% c T.J. boot repair kit llN0022 llA0108 B.A( 9. T.REAR AXLE <AWD> .J. FBI 5.J.C+ 1.A+ 7. T.J. Circlip 1 TSB Revision .J.Drive Shaft DISASSEMBLY AND REASSEMBLY 27-21 ” 4 6 1 2 Li if) llUOO77 T. Snap ring 4W +A. B. T.

27-22 Lubrication Points REAR AXLE cAWD> . llN0022 00001047 1 TSB Revision .76 oz. Special grease is used for the joint. Do not mix old grease with new or mix different types. Special grease is used for the joint. a half to each as a rule.) Caution Apply all of the grease from the repair kit to the joint and boot.41 oz. . a half to each as a rule. Donot mix old grease with new or mix different types.) Caution Apply all of the grease from the repair kit to the joint and boot.llA0369 Grease: Repair kit grease Quantity to use: 125 g (4.Drive Shaft llA0084 Grease: Repair kit grease Quantity to use: 135 g (4.

Use care in handling the drive shaft.J. BOOT / B. 4BbT. and B.J. side of the drive shaft so that the T.41 oz. Do not disassemble the spider assembly.J.Drive Shaft DISASSEMBLY SERVICE POINTS 27-23 Snap ring +A. Caution 1. boots from the drive shaft. (2) Withdraw the T. YllKOO7 REASSEMBLY SERVICE POINTS bA4B. and B. The drive shaft joint use special grease. boot bands.GREASE FROM B.J. REMOVAL Wipe out the grease from the B.SNAP RING / SPIDER ASSEMBLY REMOVAL (1) Remove the snap ring from the drive shaft with the snap ring pliers. A special type of grease is used on the joint. boots are not damaged when they are removed.J. BOOT / B. of the drive shaft assembly is bent.J. BOOT INSTALLATION (1) Wrap vinyl tape around the drive shaft spline. (2) Take out the spider assembly from the drive shaft. I ZllYO97I +C. 2.J.J. Do not add another type of grease.) Caution The grease in the repair kit should be divided in half for use. (3) Fill the inside of the B.J. boot in that sequence. Caution Do not disassemble the B. respectively.J.J.J. 3. (2) Insert the drive shaft in B. ZllKOO8 1 TSB Revision . T.J. boot with the specified grease. Be cautious to ensure that not other grease is allowed to come in contact with the joint. BOOT BAND (SMALL) / B. If the T.J. the joint may be damaged. BOOT REMOVAL (1) Wrap vinyl tape around the spline part on the T.REAR AXLE cAWD> . at the joint and inside the boot.J. and B.J. (3) Clean the spider assembly.J. Specified grease: Repair kit grease 125 g (4.J. .J. boot. BOOT BAND (LARGE) / T.

boot bands at the specified distance in order to adjust the amount of air inside the T.J. 11560 00001048 . Check the spider assembly for roller rotation.27-24 REAR AXLE <AWD> .Bq SPIDER ASSEMBLY INSTALLATION (1) Apply the specified grease furnished in the repair kit to the spider assembly.J. boot band: 20-74 #BJ95 T. boot band securely. BOOT BANDS INSTALLATION Set the T-J. The B. The boot bands should be tightened with the drive shaft at a 0” joint angle. Check the boots for deterioration. wear or corrosion.Drive Shaft (4) Secure the boot bands. Check the drive shaft spline part for wear or damage. Standard value (A): 85 + 3 mm (3. Caution 1.C+ T. u TSB Revision . Check for entry of water and/or foreign material into B. boot band are identified by the identification number stamped on the lever. boot. 2.35 f -12 in. boot band: 20-75#BJ95 ZllK033 .J. Check the groove inside T.J. case for wear or corrosion. and then tighten the T. boot band and T. damage or cracking. Specified grease: Repair kit grease (2) Install the spider: assembly with the chamfered spline end first. d B.J.J.J. Install correct ones at correct positions.) INSPECTION l l l l l l Check the drive shaft for damage.J.J. bending or corrosion.

. Propeller shaft connection 4. 2.) 6 90 Nm 90 Nm 65 ft.) 24 Nm 17 ft.A( .Exhaust Pipe and Muffler. 90 Nm 65 ft. ~-i%rx-d~al earner i 1 TSB Revision I .lbs. . Differential support assembly 5. L 22-25 ft. Differential support member assembly 6.lbs. Drive shaft +A. Rear wheel oil Pump installation bolt (C. Circlip (BF bB+ 3. \ l Main Muffler Removal and Installation (Refer to Group 15 .Differential Carrier 27-25 DIFFERENTIAL CARRIER Ld REMOVAL AND INSTALLATION l Pre-removal and Post-installation Operation Differential Gear Oil Draining and Filling (Refer to Group 00 .REAR AXLE cAWD> .lbs.Maintenance Service.lbs. Removal steps 1.

remove the drive shaft from the differential carrier. MB990831 ----+ MB990847 ’ rDifferential support member Differential (?g) (yi. PROPELLER SHAFT DISCONNECTION (1) Make mating marks on the differential companion flange and the propeller shaft flange yoke for reference during reassembly. Use care not to allow dirt or foreign matter to fall into the differential carrier. Use care not to damage the rear wheel oil pump gears. Caution Install the bushing with the differential support and differential support member chamfered end first and install until the bushing outer case end face is flush with the support and support member. Mating marks / (B. 2.. ZlOD505 (C. NOTE Be cautious to ensure that the differential carrier oil seal is not damaged by the drive shaft spline.‘&*$ >3 j0 cc llNOOl1 llN0053 00001049 I TSB evision I .27-26 REAR AXLE cAWD> . (3) Support the propeller shaft with wire. DRIVE SHAFT REMOVAL With atire lever.Differential Carrier REMOVAL SERVICE POINTS +A. Install the bushing with its hollow portion facing in the direction shown. Caution 1. DIFFERENTIAL CARRIER REMOVAL Holding the bottom of the differential carrier and removing the rear wheel oil pump through the mounting hole. etc. (2) Remove the differential carrier and propeller shaft connection. DIFFERENTIAL SUPPORT BUSHING AND DIFFERENTIAL SUPPORT MEMBER BUSHING REPLACEMENT Install or remove the bushing using the special tool. remove the differential carrier.

TSB Revision . (1) Apply a thin.OOS in. NOTE Measure at four points or more on the circumference of the drive gear. MB991116 BEFORE DISASSEMBLY CHECK Hold the special tools in a vice. FINAL DRIVE GEAR BACKLASH CHECK With the drive pinion locked in place. and attach the differential carrier to the working base. measure the final drive gear backlash with a dial indicator on the drive gear. Caution Use care not to damage the rear wheel oil pump gears.B+ PROPELLER SHAFT CONNECTION Align the mating marks on the flange yoke and the companion flange to install the propeller shaft.11-0. .004-. Limit: 0.) DRIVE GEAR RUNOUT CHECK Measure the drive gear runout at the shoulder on the reverse side of the drive gear. Standard value: 0.16 mm (.A+ DIFFERENTIAL CARRIER INSTALLATION Install the rear wheel oil pump by inserting it through the mounting hole and install the differential carrier securely.) FINAL DRIVE GEAR TOOTH CONTACT CHECK Check the final drive gear tooth contact by following the steps below.002 in. uniform coat of machine blue to both surfaces of the drive gear teeth.05 mm (.REAR AXLE cAWD> .Differential Carrier INSTALLATION SERVICE POINTS 27-27 .

lbs. and then once in the reverse direction) while applying a load to the drive gear.5-3.27-28 REAR AXLE eAWD> . so that the revolution torque [approximately 2. Caution If the drive gear is rotated too much. and then rotate the companion flange by hand (once in the normal direction.Differential Carrier (2) Insert a brass rod between the differential carrier and the differential case. d 211 GO076 1 TSB Revision . the tooth contact pattern will become unclear and difficult to check. (3) Check the tooth contact condition of the drive gear and drive pinion.)] is applied to the drive pinion.0 Nm (28-33 in.

Also. and position the drive pinion closer to the center of the drive gear.REAR AXLE eAWD> . NOTE (1) Tooth contact pattern is a method for judging the result of the adjustment of drive pinion height and final drive gear backlash. Decrease the thickness of the pinion height adjusting shim. Increase the thickness of the pinion height adjusting shim. Also. i TSB Revision . The adjustment of drive pinion height and final drive gear backlash should be repeated until tooth contact patterns bear a similarity to the standard tooth contact pattern. Tooth contact pattern resulting from insufficient pinion height The drive pinion is positioned too close to the center of the drive gear. position the drive gear closer to the drive pinion. for backlash adjustment. (2) When adjustment is not able to obtain a correct pattern. for backlash adjustment. I.Differential Carrier Standard tooth contact pattern 1 Narrow tooth side 2 Drive-side tooth surface (the side applying power during forward movement) 3 Wide tooth side 4 Coast-side tooth surface (the side applying power during reverse movement) 27-29 I L Problem Tooth contact pattern resulting from excessive pinion height Solution The drive pinion is positioned too far from the center of the drive gear. it may be judged that the drive gear and drive pinion have exceed their usage limits and both gears should be replaced as a set. position the drive gear farther from the drive pinion. and position the drive pinion farther from the center of the drive gear.

TSB Revision .27-27. Drive gear 11. Oil seal 23. Oil seal 4. Drive pinion rear shim (for pinion height adjustment) 21.) 13. Vent plug 3. Spring pin (for 4WS) 12.27-30 DISASSEMBLY REAR AXLE cAWD> . Side bearing inner race 9. Snap ring 5.27-40. Drive pinion rear bearing outer race 25. Drive pinion spacer 19. Companion flange 17. LSD case (Refer to P.Differential Carrier Inspection Before Disassembly l Final Drive Gear Backlash (Refer to P.) l Drive Gear Runout (Refer to P. Drive pinion rear bearing inner race 20.SlDE BEARING NUT REMOVAL Using the special tool. 4. Self-locking nut 14. Drive pinion assembly 16. Drive pinion front shim (for preload adjustment) 18. Washer 4F.) :ig ::: 4W 4Eb Disassembly steps 1.) l Final Drive Gear Tooth Contact (Refer to P. Differential cover assembly 2. Side bearing nut 6. Drive gear (for 4WS) 10.27-27.27-27. Side bearing outer race 7. Drive pinion 22. 15. remove the side bearing nut. Differential case assembly 8. Differential carrier DISASSEMBLY SERVICE POINTS +A. Drive pinion front bearing 24.

30 mm (1.18 in. Caution Use care not to drop the side bearing outer race. TSB Revision . +D. (2) Hook the pawl of the special tool to the side bearing inner race using the two notches on the differential case. NOTE (1) Identify the right-and left-hand side bearing outer races for correct reassembly.) long. NOTE (1) For 4WS. made of copper sheet or the like to prevent damage to the bearing.SlDE BEARING OUTER RACE REMOVAL (1) Using a press.REAR AXLE eAWD> . SELF-LOCKING NUT REMOVAL Use the special tools to hold the companion flange and remove the companion flange self-locking nut. push the differential case until it is pressed against the carrier. DRIVE GEAR REMOVAL (1) Make the mating marks to the differential case and the drive gear. (2) Remove the differential case from the press. approx. remove the side bearing inner race together with the rear wheel oil pump drive gear. remove the outer race. (2) Use a spacer. (2) Loosen the drive gear attaching bolts in diagonal sequence to remove the drive gear.08 in. Using the press again. +E. Insert two spacers in diagonally opposed positions between the side bearing outer race to be removed and the inner race. (C.) high.Differential Carrier 27-31 +B.) wide and 1 to 2 mm (.39 in.04 to .SlDE BEARING INNER RACES / DRIVE GEAR (FOR 4WS) REMOVAL Pull out the side bearing inner races by using the special tools. 10 mm (.

pinion gears and pinion shaft for wear or damage. Check the oil seal for wear or deterioration. drive out the drive pinion rear bearing outer race from the gear carrier. I MB990939 +H. Check the bearings for wear or discoloration. drive out the drive pinion front bearing from the gear carrier. dG.27-32 Mating marks REAR AXLE cAWD> .DRlVE PINION REAR BEARING INNER RACE REMOVAL Pull out the drive pinion rear bearing inner race by using the special tools.OIL SEAL / DRIVE PINION FRONT BEARING REMOVAL Using the special tool. NOTE Mating marks should not be made to the contact surfaces of companion flange and propeller shaft. Check the side gear spline for wear or damage. DRIVE PINION ASSEMBLY REMOVAL (1) Make the mating marks to the drive pinion and companion flange. Check the gear carrier for cracks. INSPECTION l l l l l l l Check the companion flange for wear or damage. DRIVE PINION REAR BEARING OUTER RACE REMOVAL Using the special tool. 4 MB990939 +I. Check the side gears. (2) Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims. TSB Revision .Differential Carrier MB99081 0 G/ +F. Check the drive pinion and drive gear for wear or cracks.

Differential case assembly 22..I+ 24.A4 .REAR AXLE cAWD> . Side bearing inner race 20. Washer 16.G+ 19. Vent plug 26. Snap ring .27-40. Oil seal 25. Differential cover assembly NOTE *: Tightening torque with oil applied.‘o Drive pinion preload adjustment Drive pinion front shim 11: Drive pinion assembly Drive pinion front bearing inner race E Oil seal 14: Companion flange .) .BI p: ä 4 15.F+ 18.Differential Carrier REASSEMBLY 27-33 ! I Aen YllFOO32 Reassembly steps 1. Side bearing nut 23.Drive gear (for 4WS) Differential carrier 2: Drive pinion rear bearing outer race Drive pinion front bearing outer race . Drive gear . Self-locking nut 17. Side bearing outer race bH( l Final drive gear backlash adjustment 21. c TSB Revision . LSD case (Refer to P. Spring pin (for 4WS) .‘ Drive pinion height adjustment Drive pinion 7: Drive pinion rear shim (for drive pinion height adjustment) Drive pinion rear bearing inner race :: Drive pinion spacer FE4 .

The notch on the spring pin should be in the position shown in the illustration. 4170 or equivalent Spring pin Drive gear I REASSEMBLY SERVICE POINTS bAdSPRING PIN INSTALLATION (FOR 4WS) Tap the spring pin into the differential case to the position shown in the illustration before press fitting the rear wheel oil pump drive gear.27-34 REAR AXLE eAWD> . llA0262 llA0261 00001520 . Sealing and Adhesion Points r llK801 llFOOI1 Sealant: 3M ATD Part No.Differential Carrier I- Lubrication. 8663 or equivalent I zllFOO32 llFO019 113364 -00001519 Adhesive: 3M Stud Locking Part No.

(2) Check to ensure that the drive gear and the spring pin are flush.C+DRlVE PINION REAR BEARING OUTER RACE / DRIVE PINION FRONT BEARING OUTER RACE INSTALLATION Press-fit the drive pinion rear and front bearing outer races into the gear carrier by using the special tools. Standard value NOTE (1) Gradually tighten the nut of the special tool while checking the drive pinion rotation torque. (2) Tighten the special tool until the standard value of drive pinion rotation torque is obtained. (2) Because the special tool cannot be turned one turn. then. MB!390938 . Caution Be careful not to press in the outer race at an angle. . TSB Revision .Differential Carrier 27-35 Beveled (law) pati llA0318 . turn it several times within the range that it can be turned.D+ DRIVE PINION HEIGHT ADJUSTMENT Adjust the drive pinion height by the following procedures: (1) Install special tools and drive pinion front and rear bearing inner races on the gear carrier in the sequence shown in the illustration.REAR AXLE eAWD> . NOTE Apply a thin coat of multipurpose grease to the mating face of the washer of the special tool. (3) Measure the drive pinion rotation torque (without the oil seal). measure the rotation torque.B+DRlVE GEAR PRESS-IN (FOR 4WS) (1) With the beveled (large) part of the rear wheel oil pump drive gear at the inner side. press in the drive gear (by using the special tool) until the drive gear contacts the end surface of the differential case. after fitting to the bearing.

(5) Fit the selected drive pinion rear shim(s) to the drive pinion. keep the number of shims to a minimum. Standard value Bearing classification New New/reused Bearing Rotation torque lubrication Nm (in. When selecting the drive pinion rear shims. and then select a drive pinion rear shim of a thickness which corresponds to the gap between the special tools.) None (with 0. (2) Tighten the companion flange to the specified torque by using the special tools.15-0.27-36 REAR AXLE <AWD> . and press-fit the drive pinion rear bearing inner race by using the special tool. . reduce the number of shims to a minimum by selecting the drive pinion spacers. NOTE Clean the side bearing seat thoroughly.5 rust-prevention oil) (3-4) Gear oil 0.lbs. NOTE When selecting the drive pinion front shims.3-0. (3) Measure the drive pinion rotation torque (without the oil seal) by using the special tools. TSB Revision . adjust the rotation torque by replacing the drive pinion front shim(s) or the drive pinion spacer.E( DRIVE PINION PRELOAD ADJUSTblENT Adjust the drive pinion rotation torque by using the following procedures: (1) Fit the drive pinion front shim(s) between the drive pinion spacer and the drive pinion front bearing inner race.25 application (l-2) (4) If the drive pinion rotation torque is not within the range of the standard value.Differential Carrier (4) Position the special tool in the side bearing seat of the gear carrier. if the number of shims is large. NOTE Do not install the oil seal.

Differential Carrier 27-37 (5) Remove the companion flange and drive pinion once again. Standard value Bearing classification New New/reused Bearing Rotation torque Nm (in. or incorrect fitting of the oil seal. [ TSB Revision .45 aoolication (3-4) If there is a deviation from the standard value.7 rust-prevention oil) (4-6) Gear oil 0.REAR AXLE cAWD> . (6) Apply a thin coat of multipurpose grease to the companion flange contacting surface of the washer before installing drive pinion assembly.35-0. .Fd DRIVE GEAR INSTALLATION (1) Clean the drive gear attaching bolts. (2) Use an Ml 0 x 1. Drive the oil seal into the gear carrier front lip by using the special tool. (6) fvleasure the drive pinion rotation torque (with oil seal) to verify that the drive pinion rotation torque complies with the standard value.5-0. check whether or not there is incorrect tightening torque of the companion flange tightening self-locking nut. Apply multipurpose grease to the oil seal lip. U ZllD55r (7) Install the drive pinion assembly and companion flange with mating marks properly aligned.) lubrication None (with 0. and then clean the threaded holes by applying compressed air. and tighten the companion flange self-locking nut to the specified torque by using the special tools.lbs.25 tap to remove the adhesive adhering to the threaded holes of the drive gear.

) NOTE Measure at four or more points around the drive gear circumference. NOTE First turn the side bearing nut for loosening.27-38 REAR AXLE eAWD> . (2) Measure the final drive gear backlash.11-0.16 mm (. temporarily tighten the side bearing nut until it is in the state just before preloading of the side bearing. and then turn (by the same amount) the side bearing nut for tightening. 1 When backlash is ] excessive 2110267 TSB Revision . Specified adhesive: 3M Stud Locking Part No. Standard value: 0.004-. 4170 or equivalent (4) Install the drive gear onto the differential case with the mating marks properly aligned. 3 IContactlk &%%I . When backlash i (3) Using the special tool (MB991 367 and MB991 385).G+SIDE BEARING INNER RACE PRESS-FITTING Press-fit the side bearing inner races to the differential case by using the special tool. adjust the backlash to standard value by moving the side bearing nut as shown.H+ FINAL DRIVE GEAR BACKLASH ADJUSTMENT (1) Using the special tool. Tighten the bolts to the specified torque in a diagonal sequence. ~~ ZllGO121 .Differential Carrier (3) Apply multipurpose adhesive to the threaded holes of the drive gear.006 in.

REAR AXLE cAWD> . install the oil seal flush with the gear carrier end face.05 mm (. ZllFOO20 .) llFOOO9 llFOOl0 00001524 (7) Measure the drive gear runout at the shoulder on the reverse side of the drive gear. If poor contact is evident. turn down both right and left side bearing nuts on half the distance between centers of two neighboring holes. (Refer to P-27-29. to apply the preload. (2) Apply a thin coat of Multi-purpose grease to the oil seal lip. . reinstall by changing the phase of the drive gear and differential case. and remeasure.) (8) If the drive gear runout exceeds the limit. Limit: 0.Differential Carrier MB991 367 27-39 (4) Using the special tool. (6) Check the drive gear and drive pinion for tooth contact. I Snap ring 00001523 (5) Fit the snap ring at either position shown to lock the side bearing nut. TSB Revision .002 in. make adjustment.I+ OIL SEAL INSTALLATION (1) Using the special tool.

Cd 3. be sure not to hold the differential case assembly too tightly. Viscous unit ’ ’ 7. Differential case B .) feeler gauge at two places (diagonally) between differential case B and the thrust washer (right). Caution When securing the vise.H.) +A. Thrust washer (L.A4 10. ZllFOO31 Diffkential side gear (right) Thnk w&her (right) YllFM)37 TSB Revision .03 mm (. (2) Insert a 0.27-40 REAR AXLE <AWD> .H. Differential pinion shaft 8.) 9.H.B+ 5.Bd 6. .) . Thrust washer (R.LSD Case Assembly LSD CASE ASSEMBLY DISASSEMBLY AND REASSEMBLY ZllFOO33 Disassembly steps 4Ab . Differential side gear (R. Pinion mate washer .A+ 2. Screw 4. Differential pinion mate BEFORE DISASSEMBLY CHECK DIFFERENTIAL GEAR BACKLASH CHECKING (1) Secure the differential case assembly in a vise so that the differential side gear (right) is facing upward. Differential case A 1.0012 in. Caution Do not insert a feeler gauge in the oil groove of differential case B.

(6) If the clearance in the thrust direction of the side gear is not within the standard value range. the backlash of the differential gear is normal.09 mm (.03 mm (.LSD Case Assembly I”. ZllPO134 TSB Revision . I\ I k?llFOO30 Pinion mate 1 .0035 in.) gauge. (5) insert the special tool at the spline part of the differential side gear (right) and check to be sure the side gear (right) does not rotate.09 mm (.REAR AXLE <AWD> .) feeler gauge to replace a 0. eeler gauge r f 27-41 =eeler gauge (3) insert the special tool at the spline part of differential case B (right) and check to be sure the side gear (right) rotates.A+DlFFERENTlAL CASE B / DIFFERENTIAL CASE A INSTALLATION Align the mating marks of differential cases B and A. and assemble the cases. and so should be discriminated in some way for reference. remove differential case A and make the adjustment by adjusting the thickness of the thrust washer (left). Differential gear backlash Standard value (clearance in thrust direction of side gear): 0. .0035 in.0012-.) NOTE if the clearance in the thrust direction of the side gear is within the standard value range. and then install to differential case B.’ L a Differential case B REASSEMBLY SERVICE POINTS . (4) Then insert a 0. install to the differential pinion shaft.B+DlFFERENTlAL PINION MATE / PINION MATE WASHER INSTALLATION With the washer in the position shown in the illustration. during installation. 00001525 DISASSEMBLY SERVICE POINTS dAbTHRUST WASHER (LEFT) / THRUST WASHER (RIGHT) REMOVAL The thrust washers (left and right) are of different thickness.0012 in.03-0.

27-42

I

REAR AXLE <AWD> - LSD Case Assemblv
.Cd THRUST WASHER (LEFT) SELECTION If the differential side gear and pinion mate gear have been replaced, select the thrust washer (left) by following the steps below. (1) Wash the differential side gear and pinion mate gear in unleaded gasoline to remove all oil, grease, etc. (2) Install the previously used thrust washers (being careful the left and right ones are used at the correct side), together with the gears, viscous unit, pinion mate washer and pinion shaft, to differential cases A and B, and then, using screws, secure them temporarily. (3) Secure the differential case assembly in a vise so that the differential side gear (right) is facing upward. Caution When securing in the vise, be sure not to hold the differential case assembly too tightly. (4) Insert a 0.03 mm (.0012 in.) feeler gauge at two places (diagonally) between differential case B and the thrust washer (right). Caution Do not insert a feeler gauge in the oil groove of differential cace B.

ij~

/

I

Differential gear (r&V)

Thrust washer (@W

llFO937 00001526

-Feeler gauge , P-

r-3==-

=

Feeler gauge ’ MB991 \ H---- ----294

(5) Insert the special tool at the spline part of differential side gear (right) and check to be sure the side gear (right) rotates. (6) Then insert a 0.09 mm (.0035 in.) feeler gauge to replace a 0.03 mm (-0012 in.) gauge. (7) Insert the special tool at the spline part of the differential side gear (right) and check to be sure the side gear (right) ) /-,J does not rotate. Differential gear backlash Standard value (clearance in thrust direction of side gear): 0.03-0.09 mm (.0012-.0035 in.) NOTE If the clearance in the thrust direction of the side gear is within the standard value range, the backlash of the differential side gear is normat. (8) If the clearance in the thrust direction of the side gear is not within the standard value range, remove differential case A and make the adjustment by adjusting the thickness of the thrust washer (left).

~

11 FOO36 00001525

TSB Revision

REAR AXLE <AWD> - LSD Case Assemblv
Thrust washer (left) Part No. Thickness mm (in.) 0.8 (.031) 0.9 (.035) 1 .o (.039) 1.1 (.043) 1.15 (.045) MB83746 1 1.2 (.047) 1.25 (.049) 1.3 (.051) 1.35 (.053) 1.4 (.055) 1.5 (.059)

1 Thrust washer (right) (reference) Part No. M B837522 Thickness mm (in.) 0.8 (.031)

NOTE Select one thrust washer (left) from the eleven types in the kit.

Differential side

Differential

INSPECTION
(1) Check the gears and differential pinion shaft for unusual wear or damage. (2) Check the spline part of the differential side gear (right) for stepped wear or damage.

Differential pinion mate
HlP0128

Thrust washer mate ‘r c @ 3 Q1 od I ‘( 69 n fi TV
7HP012l

(3) Check the thrust washer and pinion mate washer for unusual wear of contact surfaces, heat damage or other damage.

i

PinioiZnate washer

TSB Revision

1

27-44
Differential case B

REAR AXLE cAWD> - LSD Case Assembly
Differential

(4) Check differential cases A and B for unusual wear of contact surfaces, heat damage or other damage. 1: Contact surface with the viscous unit 2: Contact surface with the pinion mate washer 3 and 4: Contact surfaces with thrust washer

ZllFOO35

Contact surface with differential

(5) Check the spline part of the viscous unit for stepped wear or damage, and check the contact surface with differential case B. (6) Check the side gear (left) of the viscous unit for unusual wear or damage.

1 TSB Revision

I

31-1

WHEEL AND TIRE
CONTENTS
ON-VEHICLE SERVICE . . . . m . . . . . . . . . . . . . . . . 4
Tire Inflation Pressure Check . . . . . . . . . . . . . . . . . 4 Tire Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel Runout Check . . . . . . . . . . . . . . . . . . . . . . . . . 4

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 3
Bald Spots Cracked Treads Feathered Edge Rapid Wear at Center Rapid Wear at Shoulders Scalloped Wear Wear on One Side

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Specifications . . . . . . I . . . . . . . . . . . . . . . . . 2 Service Specifications . . . . . . ~ . . . . . . . . . _ . . . . . . . 2

WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . 4

31-2 SPECIFICATIONS

WHEEL AND TIRE - Specifications

GENERAL SPECIFICATIONS
Items

except spare wheel)

except spare tire)

Size Amount of wheel offset mm (in.) Pitch circle diameter (P.C.D.). mm (in.) Spare tire Size

16 x 4T 14 (55) 114.3 (4.50) T125/90D16

16 x 4T*‘, 17 x 4T*2 14 (.55)*’ 14 * 1 .o (.55 + .04)‘2 114.3 (4.50) T125/90016*‘, T135/8ODl 7*2

17 x 4-r 14 III 1 .o (55 zk .04) 114.3 (4.50) T135/80D17

l l: Up to 1993 models
*2: From 1994 models *3: From 1995 models <Option>

NOTE

SERVICE SPECIFICATIONS

1 TSB Revision

WHEEL AND TIRE - Troubleshooting

31-3

TROUBLESHOOTING

L

Symptom Rapid wear at shoulders

Probable cause Under-inflation or lack of rotation

Remedy Adjust the tire pressure.

Rapid wear at center

Over-inflation or lack of rotation

llXO110 Cracked treads Under-inflation

11x0117

Adjust the tire pressure.

L

Wear on one side

Excessive camber

Inspect the camber.

Feathered edge

Incorrect toe-in

Adjust the toe-in.

Bald spots

Unbalanced wheel

Adjust the unbalanced wheels.

1,X0114

llXO120

Scalloped wear

Lack of rotation of tires or worn or out-of-alignment suspension

Rotate the tires. Inspect the front suspension alignment.

TSB Revision

31-4

WHEEL AND TIRE - On-vehicle Service / Wheel and Tire
1

ON-VEHICLE SERVICE
TIRE INFLATION PRESSURE CHECK
Check the inflation pressure of the tires. If it is not within the standard value, make the necessary adjustment. L)

I

TIRE WEAR CHECK
Wear indicator

Measure the tread depth of tires. Limit: 1.6 mm (.06 in.) If the remaining tread depth is less than the limit, replace the tire. NOTE When the tread depth of tire is reduced to 1.6 mm (.06 in.) or less, wear indicator will appear.

/,/ / /I’1:, / I/ --&!I(?= Tia’ 4 w@ -/ Lateral

253Y510 -I

WHEEL RUNOUT CHECK
Jack up the vehicle so that the wheels are clear of the floor. While slowly turning the wheel, measure wheel runout with a dial indicator. Limit: Radial 1.0 mm or less (.04 in. or less) Lateral 1.0 mm or less (.04 in. or less) If wheel runout exceeds the limit, replace the wheel.

ZllFOO13

WHEEL AND TIRE
SERVICE POINTS OF INSTALLATION
Tighten the wheel nut to the specified torque. Tightening torque: 120-140 Nm (87-101 ft.lbs.)

TSB Revision

32-1

L

POWER PLANT MOUNT
CONTENTS
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE ROLL STOPPER . . . . . . . . . . . . . . . . . . 6 RIGHT MEMBER, LEFT MEMBER AND CROSSMEMBER* . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS .......................... 2
2 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . .

TRANSAXLE MOUNTING . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 2 I

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component;can lead to personal injuryordeath toservicepersonnel(from inadvertentfiringoftheairbag)ortothedriverandpassenger(fromrendering the SRS inoperative). (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 528 -Supplemental Restraint System (SRS) and GROUP 00- Maintenance Service, before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: impact sensors, SRS diagnosis unit, SRS warning light, air bag module, clock spring and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

, LJ

32-2

POWER PLANT MOUNT - Troubleshootincl

3pwIIbamni3 I qaxdal IuUlIi I

SPECIFICATIONS
SERVICE SPECIFICATIONS
Items No. 1 crossmember Crossmember Bushing (B) projection mm (in.) Bushing (A) projection mm (in.) Bushing (B) projection mm (in.) Standard value 7.5-10.5 (.30-.41) 7.2-10.2 (.28-.40) 6.5-9.5 (.26-.37)

SPECIAL TOOLS
Tool

TROUBLESHOOTING
Symptom Excessive engine wobble or vibration (with engine in normal condition) Abnormal noise Probable cause Cracked rubber parts of insulator Insufficiently tightened parts lnsuff iciently tightened parts Remedy Replace Retighten Retighten

TSB Revision

POWER PLANT MOUNT - Engine Mounting

32-3

ENGINE MOUNTING

l

Raise and Suspend the Engine to the Extent Force is not Applied to the Engine Mount

<Up to 1993 models>
100-120 NIT .1 72-87 ft.lbs. /12 Nm 7 9 ft.lbs.

<From 1994 models>
loo-120 Nm . 72-87 ft.lbs. h31 1 c

35 Nm R 25 ft.lbs.,-&//,i ‘I

Removal steps

4A,

1. Air hose G connection <Turbo> 2. Cruise control pump and link assembly <Vehicles with Cruise Control> 3. Engine mount bracket and body connection bolt

4. Engine mount bracket

,A4 5. Mounting stopper 6. Dynamic damper <Up to 1993 models>

REMOVAL SERVICE POINT
(A,CRUlSE CONTROL PUMP AND LINK ASSEMBLY REMOVAL Remove the actuator mounting nuts and place the actuator where it will not interfere with the work.

32-4

POWER PLANT MOUNT - Engine Mounting INSTALLATION SERVICE POINT
.A4 MOUNTING STOPPER INSTALLATION Attach the engine mounting bracket so that the arrow mark on the mounting stopper is in the direction as shown in the illustration. d

:From 1994 models>

Engine mount bracket

INSPECTION
l l

Check each insulator for cracks or damage. Check each bracket for deformation or damage.

TSB r---- Revision

POWER PLANT MOUNT - Transaxle Mountina

32-5

TRANSAXLE MOUNTING

(Refer to GROUP 15 - Air Cleaner.) 45 Nm / 33 ft.lbs.

mount

201 Fow4

i

Removal steps 1. Transaxle mount bracket and transaxle connection bolt 2. Cap Transaxle mount bracket \ Engine

3. Transaxle mount bracket installation bolt 4. Transaxle mount bracket .A+ 5. Mounting stopper

INSTALLATION SERVICE POINT
.A+ MOUNTING STOPPER INSTALLATION Attach the transaxle mounting bracket so that the arrow mark on the mounting stopper is in the direction as shown in the illustration.

Arrow mark

INSPECTION
l l

Check each insulator for cracks or damage. Check each bracket for deformation or damage.

i

TSB Revision

I

32-6

POWER PLANT MOUNT - Engine Roll Stopper

ENGINE ROLL STOPPER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation Condenser Fan Motor Assembly Removal and Installation <Turbo> (Refer to GROUP 55 - Condenser and Condenser Fan Motor.) l Left Bank Warm Up Three-Way Catalytic Converter Removal and Installation <Turbo> (Refer to GROUP 15 - Turbocharger <Rear>.)
l

5

P”--,” ,“I,,

43-51 ft.lbs.

4

.50-60 Nm 36-43 ft.lbs.

d
ZOlFOO30

Front stopper bracket removal steps 1. Front roil stopper bracket and engine connection bolt 2. Front roll stopper bracket installation bolt Front roll stopper bracket 43: Heat protector <Turbo>

Rear roll stopper bracket removal steps Air hose A <Turbo> :: Air intake hose C <Turbo> .B4 7. Rear roll stopper bracket and engine connection bolt 8. Rear roll stopper bracket installation bolt 4Ab .A4 ,;. Rear roll stopper bracket Heat protector <Turbo>

REMOVAL SERVICE POINT
+A,REAR ROLL STOPPER BRACKET REMOVAL
(1) Slightly raise the rear roll stopper bracket. (2) Turn the rear roll stopper bracket in the direction shown in the illustration and lift upward to remove.

sropper orawe

TSB Revision

POWER PLANT MOUNT - Engine Roll Stopper INSTALLATION SERVICE POINTS

32-7

,A+ REAR ROLL STOPPER BRACKET INSTALLATION Install the rear roll stopper bracket as shown in the illustration. ,B+REAR ROLL STOPPER BRACKET AND ENGINE CONNECTION BOLT INSTALLATION Install the bolt as shown in the illustration.

INSPECTION
l l

Check each insulator for cracks or damage. Check each bracket for deformation or damage.

i

TSB Revision

32-8

POWER PLANT MOUNT - Crossmember

nlgrrr ivtr311u~r, L~IL nfIt3rIuer arlu

RIGHT MEMBER, LEFT- MEMBER AND CROSSMEMBER
REMOVAL AND INSTALLATION
Pre-removal Operation
l

I
Post-installation Operation
l l

;/,

Under Cover Removal (Refer to GROUP 51 - Front Bumper.)

CAUTION: SRS Before removal of steering gear box, refer to GROUP 528 - SRS, center front wheels and remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative, risking serious driver injury.

l

l

Under Cover Installation (Refer to GROUP 51 - Front Bumper.) Power-steering Fluid Air Bleeding (Refer to GROUP 37A - Service Adjustment Procedures.) Front Wheel Alignment Adjustment (Refer to GROUP 33A - Service Adjustment Procedures.) Transfer Oil Supplying <AWD> (Refer to GROUP 00 - Maintenance Service.)

No. 1 crossmember, Left member, Right member
60-70 Nm

11

90 Nm / 65 Klbs.

43-51 ft.lbs.

60-70 Nm 43-51 ft.lbs.
ZOlFOO47

60-70 Nm 43-51 ft.lbs.

No. 1 crossmember, left member, right member removal steps 1. Cover installation screw 2. Left member 3. Clutch vacuum hose connection <Turbo> 4. Vacuum tank installation bolt <Turbo>
5. Right member

6. Vacuum tank <Turbo>

7. Front roll stopper installation bolt 8. No. 1 crossmember installation nut 9. Lower plate 10. No. 1 crossmember 11. Stopper(B) 12. Bushing (B)

TSB Revision

POWER PLANT MOUNT - Crossmember
Crossmember

mgni wemuer, Leli wlemaer anu

L

r--L

45 Nm 33 ft.lbs.

/

24

f

26

90 Nm / 65 ft.lbs.

78 ft.lbs.*

28 23

16

40 Nm 29 ft.lbs.

i

Crossmember removal steps
l

l l

Front exhaust pipe (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Convener.) Transfer cAWD> (Refer to GROUP 22 - Transfer.) Stabilizer bar #?$r to GROUP 33A - Stabilizer Steering gear box (Refer to GROUP 37A - Power Steering Gear Box.) Self-locking nut Clamp installal:ion bolt (short) Clamp installal:ion bolt (long) Clamp Lower arm mounting bolt

l

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

Stopper Rear roll stopper bracket mounting bolt Self-locking nut Lower plate Self-locking nut Lower plate Crossmember Stopper B Stopper A Bushing B Bushing A

13. 14. 15. 16. 17.

Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.

TSB Revision

32-10

POWER PLANT MOUNT - Crossmember

nlyllr

I~I~III~~I,

LCIL

IvI~lIILJcI

QIIU

INSPECTION Check the crossmember for cracks or deformation. l Check the bushings for cracks or deterioration. l Check the right member for cracks or deformation. l Check the left member for cracks or deformation. l

Press out

Press fit
Nut Base

BUSHING A AND B REPLACEMENT
Use the special tool to remove and press in bushings A and B.

Washer Bolt
10120

Front

Press in bushings A and B so that the arrows on their bottom surfaces may be directed in the crosswise direction (except those on No. 1 crossmember of FWD vehicles). Caution Shifting of the arrow in the direction of rotation shall be within +5” of the crosswise direction.

Rear

ZOlFOO52

Bushing A

Bushing B

Inner sleeve
12RO128 12R0129 00002122

Press in bushings A and B so that the projecting amount of the inner sleeve agrees with the standard value. Standard value: No. 1 crossmember Bushing B 7.5-10.5 mm (.30-.41 in.) Crossmember Bushing A 7.2-10.2 mm (.28-.40 in.) Bushing B 6.5-9.5 mm (.26-.37 in.) Caution When pressing in, apply a solution of soap and water to the slidina Dart of the bushings, and then press them in without s%pping one after tile other. If there is a pause during the pressing operation, the frictional resistance will prevent installation.

TSB Revision

33-1

L

FRONT SUSPENSION ~
CONTENTS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33A ELECTRONIC CONTROL SUSPENSION (ECS)* . . . . . . . . . . . . . . . . . . . . 33B ELECTRONIC CONTROL SUSPENSION (ACTIVE PREVIEW ECS) . . . 33C

NOTE (1) Shaded groups in the above list are not included in this manual. (2) *: Up to 1995 models

i:

33-2
NOTES

33A-1

FRONT SUSPENSION
CONTENTS
LOWER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6
Front Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . 6 Wheel Bearing Adjustment . . . . . . . . . . . . . . . . . . . . 6

SPECIFICATIONS . . . . . . ..s................. 2
General SpecificationS . . . . . . . . . . . . . . . . . . . . . . . . 2 Service Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3

STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . 12 STRUT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 7 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

33A-2 SPECIFICATIONS

FRONT SUSPENSION - Specifications

GENERAL SPECIFICATIONS
SUSPENSION SYSTEM
Items Suspension type Specification McPherson strut with coil spring and compression rod type

COIL SPRING (Hatchback) <Up to 1993 models>
Items Wire dia. x O.D. x free length mm (in.) FWD M/T: 14.8 x 170 x 322.5 (.58x 6.69 x 12.70) Wr, M/T*: 15.0 x 1,70 x 331 .O (.59 x 6.69 x 13.03) Coil spring identification color M/TI Orange x 1 A/T Orange x 2 Spring constant N/mm (Ibs./in.) 30 (168) Blue x 1 AWD 15.7x170x301.5 (.62 x 6.69 x 11.87)

<From 1994 models>
Items Wire dia. x O.D. x free length mm (in.) FWD MTT: 14.4 x 170 x 322.7 (.56x 6.69 x 12.4) NT, M/T*: 14.5 x 170 x 329.3 (.57 x 6.69 x 12.96) Coil spring identification color M/T Green x 1 AfE Green x 2 Spring constant N/mm (Ibs./in.) 29 (162) 38 (212) Brown x 1 AWD 15.2x170x301.6 (.60 x 6.69 x 11.87)

CZOIL SPRING (Convertible)
Items Wire dia. x O.D. x free length mm (in.) Coil spring identification color Spring constant N/mm (Ibs./in.) NOTE *: Option FWD 14.7 x 170 x 338.0 (.58x 6.69 x 13.31) Orange x 1 30 (168) AWD 15.4x170x308.5 (.61 x 6.69 x 12.15) Gray x 1 39 (218)

1 TSB Revision

FRONT SUSPENSION - Specifications
SHOCK ABSORBER
Items Vehicles without ECS Vehicles with ECS (up to 1995 models)

33A-3

Maximum length mm (in.) Compressed length mm (in.) Stroke mm (in.) Damping force [at 0.3 m/set. (0.984 ft./ sec.)] Expansion 1,080 (238)

I 150 (5.91)
Hard: 2,530 (558) Medium: 1,580 (348) Soft: 620 (137) Hard: 1 ,190 (262) Medium: 1,120 (247) Soft: 970 (214)

Contraction

540 (119)

SERVICE SPECIFICATIONS
Items Camber Caster Toe-in mm (in.) Lower arm ball joint breakaway torque Nm (in.lbs.) Stabilizer link ball joint breakaway torque Nm (in.lbs.) Steering angle Inner wheel Cuter wheel Standard value 0” +30 3”55’ Lk 30 O&3(0&.12) lo-22 (86-191) 1.7-3.2 (15-28) 33”45 1 28”21’

TSB Revision

3344-4 SPECIAL TOOLS
Tool

FRONT SUSPENSION - Special Tools

A: MB991 237 B: MB991 238

Compression of the front coil spring

MB990326

General service

Measurement of the ball joint and stabilizer link ball joint starting torque

@ @ ’ P r e l o a d s o c k e t too’

1 TSB Revision

FRONT SUSPENSION - Troubleshooting

33A-5

TROUBLESHOOTIIWG
Symptom i Steering wheel is heavy, vibrates or pulls to one side Suspension malfunction Ball joint Coil spring Wheel alignment Unbalanced or worn tires Excessive vehicle rolling Poor riding Broken or deteriorated stabilizer Shock absorber malfunction Improper tire inflation pressure Broken or deteriorated coil spring Shock absorber malfunction Inclination of vehicle Noise Broken or deteriorated coil spring Lack of lubrication Looseness and wear of each part Broken coil spring Shock absorber malfunction Replace Lubricate Retighten or replace Replace Adjust Replace Replace Adjust or replace Probable cause Remedy

-TSB Revision

33A-6

FRONT SUSPENSION - On-vehicle Service

ON-VEHICLE SERVICE
FRONT WHEEL ALIGNMENT
TOE-IN Standard value: 0 + 3 mm (0 f .12 in.) 1. Adjust the toe-in by undoing the clips and turning the left and right tie rod turnbuckles by the same amount (in opposite directions). 2. After making the adjustments, use a turning radius gauge to confirm that the steering wheel turning angle is within the standard value range. (Refer to GROUP 37A - On-vehicle Service.) Standard value: inner wheel Outer wheel 33”45’ 28”21’

Strut lower mounting bolt (upper)

CAMBER AND CASTER Standard value: Camber 0” f 30’ Caster 3”55’ * 30’ Install the special tool by tightening it to the same torque as that applied to the drive shaft nut. To adjust camber, turn the strut lower mounting bolt (upper). One graduation is equivalent to about 20’ in camber. Caster has been factory-adjusted to the standard value and requires no adjustment. Caution 1. One camber graduation changes toe by about 0.5 mm (.02 in.). Be sure to adjust toe after camber has been adjusted. 2. The difference in camber between right and left should be within O”30’.

- camber

+ camber
Z12FOO31

WHEEL BEARING ADJUSTMENT
Bearing preload is preset to the specified value by design and therefore can not be adjusted.

TSB Revision

FRONT SUSPENSION - Strut Assemblv

33A-7

STRUT ASSEMBLY

l

Wheel Alignment Adjustment (Refer to P.33A-6.)

Removal steps 1. Brake hose tube clamp mounting bolt 2. Brake hose tube clamp 3. Front speed sensor clamp mounting nut <ABS> 4. Front speed sensor clamp <ABS> i

5. Strut lower mounting bolt 6. Strut upper mounting bolt 7. ECS connector <EC&8. Cap <EC&- or dust cover 9. Strut assembly

1 TSB Revision

3344-8 FRONT SUSPENSION . take care that grease does not adhere to the insulator’s rubber part. Dust shield 8. . Strut assembly \ -I ‘U ~ I DISASSEMBLY SERVICE POINT +A. and then remove the self-locking nut. 1 TSB Revision . I ~ MB991238 I (2) Using the special tools. Strut insulator assembly . Self-locking nut 3. compress the coil spring. 3 4 5 12FC024 00000616 Caution When applying the grease.Bd 2.lbs. (2) Do not use an air tool to tighten the bolt of the special tool and to remove the self-locking nut. t 12FOO30 Disassembly steps 1. Spring upper seat assembly’ 5. and so that the maximum length will be attained within the installation range. Front coil spring 9. loosen the self-locking nut. Upper spring pad 6. Caution (1) Install the special tools evenly. Bump rubber 7. SELF-LOCKING NUT REMOVAL (1) Holding the spring upper seat with the special tool.Strut Assembly DISASSEMBLY AND REASSEMBLY 78 Nm 56 ft. Dust shield dA.A4 4. Caution The self-locking nut should be loosened only not removed.

tighten the strut insulator at the specified torque. Caution Do not use an air tool. fitting the notch in the rod to the shaped hole in spring seat. line up the holes in the strut assembly spring lower seat with the hole in the spring upper seat.A+ SPRING UPPER SEAT ASSEMBLY INSTALLATION (1) Assemble the spring upper seat to the piston. Caution Do not use an air tool to tighten the bolt of the special tool.)].rod.3 in. NOTE The job is easily accomplished with a pipe [Q 8 mm x 300 mm (+ . (3) Using the special tool. 212FOO2~ TSB Revision .B+ SELF-LOCKING NUT INSTALLATION (1) With the coil spring held compressed by the special tools (MB991 237 and MB991 238). (2) Using a pipe. x 11. provisionally tighten the self-locking nut. (2) Correctly align both ends of the coil spring with the grooves in the spring seat.8 in.Strut Assemblv REASSEMBLY SERVICE POINTS 33A-9 . .FRONT SUSPENSION . and then loosen the special tools (MB991237 and MB991238).

and then fully tightened with the vehicle on the ground in the unladen condition. Stabilizer link mounting nut (lower arm side) 3.A4 10. Logw. Lower arm mounting nut 6. Lower arm mounting bolt 7. Clamp mounting bolt (small) 9. 12.) / 5 shield 00000619 IPNOO17 Removal steps 1. / TSB Revision . Lower arm mounting clamp Lower arm Stopper Dust shield Rod bushing - NOTE *: Indicates parts which should be temporarily tightened. Clamp mounting self-locking nut 8. Stabilizer link 4.33A-10 LOWER ARM FRONT SUSPENSION .:rarm clamp mounting self-lock11. 15. Self-locking nut connecting lower arm ball joint to knuckle 5. 14.Adjustment (Refer to P. 13.33A-6. Stabilizer link mounting nut (stabilizer bar side) 2.Lower Arm REMOVAL AND INSTALLATION Post-installation Operation l Wheel Alignment. Clamp mounting bolt (large) .

l Check all bolts for condition and straightness. INSTALLATION SERVICE POINT . Check the lower arm for bend or breakage.A+LOWER A R M C L A M P MOUNTING SELF-LOCKING NUT INSTALLATION Place the lower arm bushing bracket so that its mounting surface tilts 6” + 1” with respect to the bottom surface of the lower arm. disconnect the knuckle from the lower arm ball joint. Caution 1. INSPECTION ’ Check the bushing for wear and deterioration. Be sure to tie the cord of the special tool to a nearby pa& 2. (2) Apply multipurpose grease to the lip and inside of the dust shield.Lower Arm REMOVAL SERVICE POINT 33A-11 +A. l Check the ball joint dust shield for cracks.) l l 212UOO18 BALL JOINT DUST SHIELD REPLACEMENT Dust shield (1) Remove the dust shield. then.LOWER ARM BALL JOINT REMOVAL Using the special tool. CHECKING BALL JOINT FOR BREAKAWAY TORQUE Using the special tool. mount the self-locking nut.FRONT SUSPENSION . measure the ball joint breakaway torque. l Check the clamp for deterioration or damage. Y12RO487 (3) &izedn the dust shield with special tool until it is fully MS990799 Dust shield Snap ring 1 TSB Revision .lbs. Loosen the nut but do not remove it. Standard value: lo-22 Nm (86-191 in.

Bushing 7.Transfer.) 6 36 Nm 26 ft. Transfer (AWD) (Refer to GROUP 22 .33A-12 STABILIZER BAR FRONT SUSPENSION . Transmission stay B cAWD vehicles with automatic transaxle> 2. Stabilizer bar INSTALLATION SERVICE POINT .) 3. 1210011 00000627 I I Removal steps 1.lbs.Exhaust Pipe and Main Muffler. mount the stabilizer bar bracket (RH) and temporarily tighten it. (3) Temporarily fix the both ends of the stabilizer bar to the link and tighten the stabilizer bar bracket mounting bolts to specification. Stabilizer bar bracket mounting bolt .A+ 5.Stabilizer Bar REMOVAL AND INSTALLATION l Pre-removal and Post-installation Operation Front Exhaust Pipe Removal and installation (Refer to GROUP 15 .A+ STABILIZER BAR BRACKET POSITIONING (1) Align the bushing (LH) with the stabilizer bar marking end and temporarily tighten the stabilizer bar bracket (LH). 40 Nm 29 ft. (2) In this condition. 1 TSB Revision . Stabilizer bar bracket 6. Stabilizer link 4.) l Under Cover Removal and Installation l Left Member and Right Member Removal and Installation (Refer to GROUP 32 . Left Member and Crossmember.Right Member.lbs.

(4) Secure the dust shield by the clip link. make sure that the clip ring ends are located at a point 90” + 20” with reference to the link axis. ere I j 9042or.) BALL JOINT DUST SHIELD REPLACEMENT (1) Remove the clip ring and the dust shield.2 Nm (15-28 in. Clipiing (2) Apply multipurpose grease to the lip and inside of the dust shield. and then install the dust shield to the stabilizer link.7-3. the stabilizer link ball joint dust cover for cracks. Standard value: 1. Then use the special tool to measure the ball joint breakaway. the stabilizer bar for deterioration or damage. 1 TSB Revision .07~~~~~ ~0156 opposite side) (3) Use vinyl tape to tape the stabilizer link where shown in the illustration. torque.Stabilizer Bar INSPECTION l l l l 33A-13 Check Check Check Check the bushing for wear and deterioration.lbs. Clip ring ends (Could beon 1 80”. all bolts for condition and straightness. CHECKING STABILIZER LINK BALL JOINT BREAKAWAY TORQUE Install the nut to each stud. At this time.FRONT SUSPENSION .

NOTES .

. . ... . 2 4 STEERING ANGULAR VELOCITY SENSOR* . . 19 ECS CONTROL UNIT . . . . . . . . . . . . 11 On-Vehicle Inspection . .. . . . . . . . . . . . . . . . . . . . . .. . ... . . . . .. . . . . . . . . . . . . . . . .*. (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. . . . . . 11 SPECIAL TOOLS . . .33B-1 L ELECTRONIC CONTROL SUSPENSION 0 CONTENTS DAMPING FORCE CHANGEOVER ACTUATOR . . .. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (‘). . . . 20 ECS INDICATOR LIGHT . . . . . . . . .. . . . . 5 VEHICLE SPEED. . .. . . . .. . . . and especially its GROUP 528 -Supplemental Restraint System (SRS) and GROUP 00 -Maintenance Service.. . .. .. .. . . . . . . . 19 THROlTLE POSITION SENSOR . . . SENSOR . . . . . . . . . .. . . . . . . . 19 SERVICE ADJUSTMENT PROCEDURES. . . . . . . 18 STOP LIGHT SWITCH . . SRS diagnosis unit. . . . . . . . . . . . .. .. air bag module. . . . . . . . . . Service Specifications . . . . .. . . . . . . . . . . . . . . . . . . 18 SPECIFICATIONS . . . . . clock spring and interconnecting wiring. . . . . . . . before beginning any service or maintenance of any component of the SRS or any SRS-related component. . can lead to personal injuryordeathtoservicepersonnel(from inadvertentfiringoftheairbag)ortothedriverandpassenger(from rendering the SRS inoperative). . . . NOTE The SRS includes the following components: impact sensors. . .. . . . . . 18 POSITION DETECTION SWIITCH . . . . . . . . . . _ _ . .*. . . . . . 19 TROUBLESHOOTING . . . 19 ECS SWITCH . . . . . . . . . . . . . . . . . . . . . .. . . . 4 WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS. . . .. . . (3) MITSUBISHI dealer personnel must thoroughly review this manual.. . or any SRS-related component. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . _ . . . . . . . . . . . . . . 18 ~ c ’ G SENSOR . . . 2 General Specifications . . . . . . . . . . . . . . . . . . . . . SRS warning light. . . . . . . . . . . . . . . . . . . . . .

69 x 12.) Stroke mm (in.9) 2.530 (558) 1.69 x 12.580 (348) 620 (137) 1 1.. x free length mm (in.D.4 x 170 x 322.57 x 6.190 (262) I 1.96) Green x 2 29 (162) AWD 15. x O.70) Green x 1 29 (162) FWD-A/T 14.) Min.5 x 170 x 329. (.62 x 6.120 (247) 1 970 (214) TSB Revision .) Coil spring identification color Spring (Ibs.7 x 170 x 338.) FWD 14.60 x 6.69 x 12./in.57 x 6. x center dia.) Expansion Hard Medium soft Contraction 1 Hard 1 Medium L Specifications Hydraulic.) Coil spring identification color Spring constant N/mm (Ibs. length mm (in.5 (.N (Ibs.4 x 170 x 308.87) Brown x 1 38 (212) I COIL SPRING (Convertible) Items Wire dia. x free length mm (in.7 (.) Damping force at 0.2 x 170 x 301.)/sec.69 x 11.9 ft.15) Gray x 1 39 (218) SHOCK ABSORBER Items Type Max.2) I 150 (5.69 x 13.87 <From 1994 models> Items Wire dia.M/l 14.) N/mm constant FWD .Specifications / Specification McPherson strut type COIL SPRING (Hatchback) <Up to 1993 models> 58 x 6.0 (58 x 6./in.6 (. cylindrical double-acting type 485 (19.69 x 12.3 (.1) 335 (13.33B-2 SPECIFICATIONS GENERAL SPECIFICATIONS FRONT SUSPENSION item Suspension system ECS .31) Orange x 1 30 (168) AWD 15.69 x13.3 m/set.69 x 11.03 .61 x 6. length mm (in.70 .59 x 6.

) / FWD 11. N (Ibs. mm (in.2 (.5x105x379.0) Damping force at 0.3 (.010 (223) 880 (194) 48) 670 (.13 x 14.) Coil spring identification color Spring constant N/mm (Ibs.78) Green x 1 34 (190) / AWD 11. x free length mm (in.160 (256) 560 (123) 1.86) TiiiD 7 Pillow ball type 23 t. x center dia. x center dia.) Coil spring identification color Spring constant N/mm (Ibs.13 x 14.46 x 4. (.0 x 105 x 366./in.6 x 105 x 350.3 m/set.2 x 105 x 379.) Expansion Hard Medium soft I.) 1 FWD 12.2 x 105 x 350.78) Orange x 1 35 (196) AWD 12.9 ft. x center dia.43) Blue x 1 35 (196) / AWD 11.13 x 15.47 x 4.93) Blue x 2 28 (157) COIL SPRING (Convertible) Items Wire dia.0 (./in. cylindrical double-acting type 515 (20.0 (.48 x 4.56) Gray x 1 28 (157) 1 I SHOCK ABSORBER Items FWD AWD We Hydraulic.13 x 13.48 x 4.93) Brown x 1 28 (157) FWD 12.71 0 (377) 1. x free length mm (in.)/sec. x free length mm (in.8x105x395.91) REAR SUSPENSION Items Suspension system FWD Multi-link type AWD Double-wishbone type COIL SPRING (Hatchback) <Up to 1993 models> Items Wire dia.3) 610 (24.160 (256) 560 (123) 1.710 (377) 1.13 x 13.45 x 4.3 (.ECS . 1 TSB Revision .) <From 1994 models> Items Wire dia.13 x 14.5 (.Sl>ecifications STABILIZER BAR Items Mounting method Outside dia.) 1 FWD Pillow ball type 22 i.46 x 4.

02+.12) Rear suspension .FWD 0” t 30’ At-2.02f .5 (.AWD -0”10’~30’ SPECIAL TOOLS Tool ectronic control suspension l l Reading service data Actuator test Reading and erasing diagnostic trouble l l Reading service data Actuator test Electronic control system inspection using a check harness TSB Revision .) FWD Pillow ball type 10 (.5+ 2.l) Rear suspension.5 1.ECS . mm (in.86) SERVICE SPECIFICATIONS Items Standard value Camber Caster Toe-in mm (in.1j .SDecifications / SDecial Tools STABILIZER BAR Items Mounting method Outside dia.37) AWD Pillow ball type 22 (.) Front suspension 0” + 30’ 3”55’ ri: 30’ Ozk3(Ok.

the check engine/malfunction indicator lamp in the combination meter will light. The sensor is also used for control of the engine and automatic transaxle. therefore. anti-squat) and steering stability controls (anti-roll. 14 will be output. a short-circuited sensor output line or open-circuited sensor power line is suspected. therefore.33B-9 Anti-squat control only stops. etc. If all these controls stop. bouncing and rough road). and engine diagnostic trouble code No.33B-10 TROUBLESHOOTING HINTS *I. 21 is not on display. ECS control unit Anti-roll control only stops. trouble in the sensor is suspected. The vehicle speed sensor is also in use for operation of the speedometer and for the other electronics controlled systems for the engine. In a situation where anti-roll control only stops. however. defective wiring is suspected between the ECS control unit and throttle position sensor. A self diagnostic decision on the steering angular velocity sensor is made by the ECS control unit which internally detects the voltages of the two sensor output lines connected to the ECS control unit to detect an open circuit in the signal line. In a situation where anti-squat control only stops. high speed sensitive controls). The G sensor is a sensor associated with ride control (detecting pitching. therefore. it cannot be detected.ECS . if the check engine/malfunction indicator lamp does not light. *2 When diagnostic trouble code N ECS indicator light does not switch is operated. The sensor associated with anti-squat control is the throttle position sensor. therefore. 21 is output. automatic transaxle. *3. *2 Steering angular velocity sensor *2 ECS control unit P. TSB Revision .Troubleshooting 33B-5 TROUBLESHOOTING WICK REFERENCE CHART FOR TROUBLESHOOTING Symptoms When diagnostic trouble code No.33B-6 i / Anti-dive control only stops. *2. Stop light switch ECS control unit P. The vehicle speed sensor is a sensor associated with attitude controls (anti-dive. If it fails. If the sensor fails. When diagnostic trouble code No. *4. *4 Throttle position sensor *4 ECS control unit P. if diagnostic trouble code No. When the signal line is short-circuited or when the power line is open-circuited. ride control stops.

or when anti-roll control only stops.2.) Good? /Good/ / Replace ECS control unit.33B-17. 21 is output. Replace ECS control unit. 1 terminal of steering angular velocity sensor and No. 56 terminal Between No. Check by entering simulated vehicle speed from scan tool to simulate pitching and bouncing controls. 3 terminal and No. (Refer to P. 3 terminal and ground up to specification? (Sensor power supply and ground) Is continuity provided across the following areas? Between G sensor and ECS control unit Between No. (Refer to P. With ignition switch at ON. 61 terminal of ECS control unit? Yes Is trouble cleared by replaced G sensor? Yes 1 End Correct harness. Withignition switch at ON. 54 terminal Yes Correct harness. Check by entering simulated vehicle speed to simulate anti-roil controls. 1 terminal voltage and continuity between No. No. check sensor. 11 is output Using scan tool.3and4terminalvoltagesuptospecification? / Standard: 5 V N o -/ Is continuity provided across the following areas? Between steering angular velocity sensor Between No. 1 terminal and No. 57 terminal of ECS control unit? Is trouble cleared by replacing steering angular End 1 TSB Revision . 55 terminal Is continuity provided between No.33B-6 1 ECS . 2 terminal of G sensor and No. When diagnostic trouble code No. 2 terminal and No. check harness connector.) Good? Disconnect steering angular velocity sensor con- ‘1. No Continuity provided between No. check harnessconnecNo. Good? No Disconnect G sensor connector.33B-15.Troubleshootina When diagnostic trouble code No.

ECS . p Correct harness (between No. of combination meter and No. 53 terminal of ECS control unit? Yes + No Check vehicle speed sensor. I 1 Replace ECS control unit. (Refer to P. Good? I No 1 Disconnect vehicle speed sensor check harness connector. check service data on vehicle p Check by entering simulated vehicle speed from scan tool to simulate high speed-sensitive control.33B-16. (Refer to P.) Good? t No Is continuity provided between No.) _____t Replace vehicle speed sensor.) Good? speed sensor. (Sensor power supply and ground) $ 1 1 Is continuity provided between No.Troubleshootina . (Refer to P. 1 No No. 3 terminal of vehicle speed sensor and No. 24 is output L. I No 1 Replace ECS control unit. check service data No Check by entering simulated vehicle speed from scan tool to simulate high speed-sensitive control. 2 terminal of vehicle speed sensor 2 terminal and ground up to specification? and ground).33B-16. Good? 4 <Non-Turbo> Yes 1 Reolace ECS control unit. I Using scan tool.Correct harness. 53 terminal of ECS control unit? +YeS No Is continuity provided between No. 109 _____c Correct harness. <Turbo> Yes Using scan tool. 1 terminal voltage and continuity between No. 1 terminal of vehicle speed sensor and battery and between No.33B-18.3 When diagnostic trouble code No. i 1 TSB Revision 1 . 64 terminal . of combination meter and ground? 1 Replace vehicle speed sensor.

3 and the body ground. 5 and the body ground.INO + Correct harness. No.33B-15. 1 sec. 1 RR No. No. No. check actuator. 1 RL No. 3 ECS control unit terminal No. 2 and 4 terminals and ground? Correct harness (between No.? Shock absorber terminal FR No. Is terminal voltage up to specification? Standard: 9 V during forced drive of actuator (for approx.Troubleshooting When diagnostic trouble code Nos. for the continuity between terminal No. Using scan tool. 3 RL No. ! 1 Yes . 1 t Is continuity provided between No. (Refer to P. 3 FL No. for the continuity between terminal No. No Yes Correct harness. No.Replace ECS control unit. 1 FL No.) 0 V except during forced drive Yes I-- No c r Is continuity provided across the following areas of shock absorber associated with diagnostic trouble code No. 1 Yes While measuring No. No Replace ECS control unit. Yes Correct harness. No. End . 1 FR No.) Good? with diagnostic trouble code No. 61. I Check the shock absorber which corresponds to the displayed diagnosis code No.33B-8 4 ECS .. 1 TSB Revision . 5 terminal voltage. 7 6 10 9 13 12 16 15 Check the shock absorber which corresponds to the displayed diagnosis code No.? P N o Is trouble corrected by replacing shock absorber (includingdamping force changeover actuator and positiondetectionswitch)associatedwithdiagnostic trouble code No. 62. No. and Standard: 5 V Y Is continuity provided across the following areas of shock absorber associated with diagnostic trouble code No. disconnect connector directly connected to shock absorber. 2 and 4 terminals of shock absorber and ground).? Yes Yes No + Correct harness. No. 63 and 64 are output. 3 RR No. forcedrive actuator by scan tool. 1 and the body ground and terminal No.

No. 11 terminal and ground up to specification? Is continuity provided between No. 58 terminal of ECS control unit? 1 Yes i Replace ECS control unit. 11 terminal of ECS switch and ground? t 1 Replace ECS control unit. lYes ( End I I Anti-dive control only stops. (Refer to P.) Good? I i Yes Replace ECS control unit. control unit Is continuity provided between No. Replace stop light switch. Yes Does ECS indicator light flash? No i Disconnect ECS switch connector and check harness connector with ignition switch at ON. Good? Replace ECS indicator light bulb. 2 terminal of stop light switch and battery) Standard* Battery postwe voltage Check stop light switch. (Refer to P. 3 terminal of stop light switch and No. 1 Replace EC.ECS . Correct harness.Troubleshootina 5 ECS indicator light does not switch when ECS switch is operated. - I T S B Revision * . 2 terminal voltage up to specification? (Between No.) C--W Replace ECS switch. Yes Removecombination meter and check cator light for burnt filament.33B-15. 2 terminal of ]Ee. 1 No. /JL*i Correct harness. 1 terminal of ECS control unit and between No. combination meter and ground? I Yes 1 Istroubleclearedbyreplacing combinationmwL* Replace ECS control unit. + Check ECS switch. 11 and 3 terminals J Yes / 1 1 Is continuity provided between No. I / LBetween No. 10 terminal voltage and continuity between No. No Correct harness. + Read diagnostic trouble code and check area associated with diagnostic trouble code. 10 terminal of ECS switch and No.33B-18. 1 1 Correct harness.) Good? I 6 I Good Does stop light illuminate when brake depressed? No + Disconnectstop light switch connector and check harness connector. Check by entering simulated vehicle speed from scan tool to simulate anti-dive control. (Refer to F!33B-19.

Troubleshooting Check by entering simulated vehicle speed from scan tool to simulate anti-squat control. Correct harness. 2 terminal of throttle position sensor and No.33B-10 7 Anti-squat control only stops. ’ No Check throttle position sensor. 59 terminal of ECS control unit? 1 Yes Correct harness. 1No 7 Replace throttle position sensor. 4 terminal Continuity provided / Yes N o Replace E&control unit. 4 terminal and ground up to specification? (Sensor power supply and ground) Standards: No. -f No.) Good? Yes Disconnectthrottle position sensor connector and check harness connector with ignition switch at ON. 1 terminal voltage and continuity between No. 4 and 72 terminals Yes No L t Defective engine control unit.33B-19.33B-16. c Is continuity provided across the following areas? Between throttle position sensor and engine’ control unit Between No.) Good? Does check engine/malfunction indicator lamp illuminate? Is continuity provided between No. 1 terminal 5 V No. TSB Revision . t 1 Replace throttle position sensor. (Refer to P. (Refer to P. ECS . 1 and 61 terminals Between No.

(3) After the defective portion has been repaired. .-.Service Adjustment Procedures 33B-11 SERVICE ADJUSTMENT PROCEDURES ON-VEHICLE INSPECTION 1. (2) Check the diagnostic trouble code. When connecting the scan tool (MUT-II) to a vehicle up to 1993 model. . WARNING INDICATION BY ECS INDICATOR LIGHT If a problem associated with the following items occurs. use the adapter harness supplied together with the scan tool. f’--__ -1 wnen usmg tne MUT-II cup to 1993 models> \ZlZFOO57 2. Warning Indication Items l G sensor 0 Steering angular velocity sensor l Vehicle speed sensor l Damping force changeover actuator (including position detection switch) 1Zl2FOOO61 When using the MUT I .) (4) Perform on-board diagnostic output check again and check that the diagnostic trouble code is good. erase the diagnostic trouble code. At the same time.5 sec. the ECS indicator light (Tour Sport) in the combination light flashes at intervals of 0. Caution Turn off the ignition switch beforehand whenever the scan tool is connected or disconnected. ( ’ . .. (If the defective portion is not completely repaired.<From 1994 models> / ZZOFO164 0~0001022 TSB Revision . it may be impossible to erase the diagnostic trouble code by the scan tool. ON-BOARD DIAGNOSTIC OUTPUT CHECK When using the scan tool [multi-use tester (MUT) <Up to 1993 models> or MUT-II call models>] (1) Connect scan tool to the data link connector. the diagnostic trouble code associated with the problem is output to the data link connector.ECS .

perform on-board diagnostic check again. and check that the diagnostic trouble code is good. <. Observe the pointer deflection to read out the diagnostic trouble code. (7) Disconnect the battery cables from the battery terminals and reconnect them more than 10 seconds thereafter. (3) Set the ignition switch to ON. 3 terminal of the data link connector beside the junction d block and connect the negative (-) terminal of the voltmeter to the No. (2) Connect the positive (+) terminal of the voltmeter to the No.33B-12 ECS .I 1 \(A 1121. 12 terminal. (6) Set the ignition switch to OFF.) <From 1994 models> Connect a voltmeter to the diagnostic output terminal and ground terminal of the data link connector using the special tool. .Service Adjustment Procedures -I 5c @+ When using the voltmeter <Up to 1993 models> (1) Set the ignition switch to OFF. (4) Read the diagnostic trouble code on the basis of the deflection of the pointer of the voltmeter. (5) Based on the diagnostic trouble code. repair the associated defective portion. TSB Revision .3\4151617!8 4 Ground term. (8) Set the ignition switch to ON.

In addition.. it is automatically cleared if the ON/OFF control of the ignition switch is repeated 60 times after the diagnostic trouble code has been output. When any of the problems marked * occurs. damping EEiPlZZL I R.Ln F. R. when the problem is transient). (2) Even if control stop. TSB Revision 1 ..Service Adjustment Procedures Fail Safe and Diagnosis List 33B-13 i L output Code No.zrr actuator f NOTE (1) Control stop. bad road detection control) stop.. : nnnnnn Vehicle speed sensor * .KS. high speed sensitive controls) and attitude controls (anti-dive. if no subsequent problem occurs (for example. normal operation will be restored even if the ignition switch is not set to OFF. 0 Output Code indication Pattern Diagnostic Item [Good] [Good] Fail Safe llm 11 G sensor defective* l Ride controls (pinching and bouncing control. Shock absorber damping force fixed at MEDIUM All ECS controls stop.. Steering angular J-j-Jg~!$:$$g.-. warning indication and fixed damping force return to normal when the ignition switch is set to OFF. (3) The diagnostic trouble code can be force-cleared by use of the scan tool or by stopping the power supply to the ECS control unit. . open-crrcurted * l l Steering stability controls (anti-roil. damping force nr~ cdf7gncever actuator I63 ]-flJljlj-[lJljljL R. the diagnostic trouble code is stored in the memory in the ECS control unit.-.iver actuator l l LJ-Y 62 F. L. R. damping force cj$. f51 . provided that no new diagnostic trouble code is output during the period. Normal shock absorber damping force fixed at HARD.-.. L. warning indication and fixed damping force return to normal as described above. damping force . anti-squat) stop.: n l Anti-roll control stops.ha.-.

500-5.33B-14 Code No. actuator R. 11 decreases from 2. check the service data.5 or less or 4.5 V) or more lasts for more than 60 seconds with the ignition switch at ON and if there is no input from the vehicle speed sensor during the period. sensor 26 61 62 F. SERVICE DATA OUTPUT CHECK’ Using the scan tool.R. it is regarded as a problem.L. it is regarded as a problem.5 V 14 sensor Throttle fully opened 21 sensor 4.5 V or more lasts for more than 10 seconds.Service Adjustment Procedures On-board Diagnostic Determination Conditions What is Defective G sensor defective Steering angular velocity sensor open-circuited Vehicle speed sensor defective On-board Diagnostic Determination Conditions When sensor input of 0.500 mV 24 ication coincide. When throttle opening of 30% (1. actuator Tour mode with vehicle stationary Sport mode with vehicle stationary Tour mode with vehicle stationary Sport mode with vehicle stationary Tour mode with vehicle stationarv Sport mode with vehicle stationary I SOFT HARD ~~ ---r&r HARD SOFT HARD I 63 64 TSB Revision . actuator R. If no damping force changeover is made in a second afteractuatordrive signal has been output (position detection switch output pattern does not change to that of target damping force). Service Data Inspection List Item No. Open circuit detected on the basis of difference in voltage level of sensor signal. 61-64 Damping force changeover actuator defective 3. 11 21 24 ECS .L.

ACTUATOR CHECK (1) Using the scan tool. (7) Using the scan tool. NOTE l All of the four actuators in the shock absorbers are simultaneously changed over by forced drive. l The damping force changed over and fixed by forced drive is cleared by the following three conditions. CONTROL FUNCTION SIMULATION CHECK 110004356 Using the scan tool. (2) Enter a simulated vehicle speed of 100 km/h (62 mph) from the scan tool. Scan tool disconnected Actuator Check List Item No. check that the indications of service data items No. Ignition switch OFF 2. 5-1. (2) Place the steering wheel in straight ahead position. Steering turning speed I I Scan tool indication MEDIUM HARD I Approx. 5-2. Anti-Dive Control Function Check (1) Select the Tour mode by the ECS switch. 61 through 64) to verify that the actuator has been force-driven. 61-64 Indicated SOFT MEDiUM HARD L 5.2 seconds for 90” rotation (8) Check that the original damping force indication (SOFT) is restored a second later. (2) Check service data (Item No. 1. 61 through 64. check the indications of service data items No.9 mph) or more 3. (3) Using the scan tool. check all control functions during operation with the vehicle in stationary condition. i Scan tool indication: SOFT TSB Revision . (4) Enter a simulated vehicle speed of 100 km/h (62 mph) from the scan tool. 01 03 04 Check Point Damping force SOFT Damping force MEDIUM Damping force HARD Check Condition Vehicle in stationary condition Scan Tool Service Data Item No. Scan tool indication: SOFT (6) Turn the steering wheel clockwise or counterclockwise from the straight ahead position. (3) Select the Tour mode by the ECS switch. 61 through 64 change over. Anti-Roll Control Function Check (1) Raise the front wheels on a jack and have them supported by rigid racks. 0. Vehicle speed 3 km/h (1. force-drive the actuator and fix the damping force changeover. check the indications of service data items No. (5) Using the scan tool.ECS . 0.Service Adjustment Procedures 33B-15 4. 61 through 64.3 seconds for 90” rotation Approx.

(2) Enter a simulated vehicle speed of 30 km/h (19 mph) from the scan tool. 5-3. check that the indications of service data items No. Entered simulated Accelerator operating condition vehicle speed Quickly A second later with km/h (mph) depress oedal deoressed 1 HARD t MEDIUM I I 30 (19) 1 MEDIUM I / MEDIUM 1 60 (37) -1 1 MEDIUM I SOFT 1 90 (56) (6) Check that when the accelerator pedal is released. Anti-Squat Control Function Check (1) Select the Tour mode by the ECS switch. the original damping force (SOFT) is restored in less than a second. 61 through 64 change over. 61 through 64. 5-4. however. Scan tool indication: SOFT (4) Check that when the accelerator pedal is operated.Service Adjustment Procedures (4) Depress the brake pedal and simultaneously change the entered simulated vehicle speed by the scan tool.I 33B-16 ECS . the indications of service data items No.4 seconds after depressing the brake pedal. 61 through 64 on the scan tool change as shown in the following table. (2) Check that when the entered simulated vehicle speed is changed by the scan tool. similarly operate the accelerator pedal and check that the scan tool indications change over. the indications of service data items No. Changing entered simulated vehicle soeed 1 100 km/h (62 mph) to 80 km/h (50 mph) 212FOO64 I a Scan tool indication 1 HARD (6) Check that the original damping force indication (SOFT) is restored a second later. (3) Using the scan tool. the indications of service data items No.) Scan tool Changing entered simulated vehicle speed I indication Acceleration 129 km/h (80 mph) to 130 km/h 1 SOFT + MEDIUM I (81 mph) MEDIUM + SOFT Deceleration 120 km/h (75 mph) to 119 km/h (74 mob) \ ‘d I ~ TSB Revision . check the indications of service data items No.) (5) Using the scan tool. (If the simulated vehicle speed is continuously changed by the fixed function keys of the scan tool. 61 through 64 change. (Change the speed in 0. High Speed Sensitive Control Function Check (1) Select the Tour mode by the ECS switch. (5) With the simulated vehicle speed at 60 km/h (37 mph) and 90 km/h (56 mph). 61 through 64 do not change during the period the fixed function key is pressed.

slowly shake it up and down through a space of about 5 cm (1. remove the trim cover at the top of the shock absorber before bringing your ear near the shock absorber. 6.Service Adjustment Procedures 33B-17 5-5. NOTE In the case of the rear shock absorbers. and check that the indications of service data items No. damping force SOFT) (2) Check the damping force SOFT state by shaking the top mounting points of the front shock absorbers or the top of the rear end panels of the rear shock absorbers up and down. 12FOO65 12FOO66 00001023 (Front) (Rear) 212FOO67 i 1 TSB Revision .9 in.) with the connector connected. (3) Check that the operating sound of the actuator in the shock absorber can be heard each time the control modes are changed by pressing the ECS switch. 6-2. check the indications of service data items No. 61 through 64. (2) Bring your ear near the top of the shock absorber. (ECS indicator Sport ON. (2) Using the scan tool. (ECS indicator Tour ON.ECS . I Scan tool indication HARD I I (4) Check that when the G sensor is held stationary. 61 through 64 change. the original damping force indication (SOFT) is restored. Pitching and Bouncing Control Function Check (1) Select the Tour mode by the ECS switch. (3) Press the ECS switch to change the control mode to sport. Actuator Operating Sound Check (1) Set the ignition switch to ON. ACTUATOR OPERATION CHECK 6-1. . Damping Force Check (1) Set the ignition switch to ON. damping force HARD) (4) Shake the vehicle up and down to check that the damping force is harder than in the SOFT state. Scan tool indication: SOFT (3) Remove the G sensor. G sensor status Shake up and down at a speed of a round trb in a second.

Column Switch.H. Switch position 3 ECS switch ON OFF 14 Terminal No. refer to GROUP 54 . Remove the meter bezel before mounting or removing the ECS switch. 212FOO68 INSPECTION Operate the switch to check for continuity between the individual terminals.Front Seat. Remove the Steering wheel and clock spring before mounting or removing the sensor. INSPECTION Refer to GROUP 54 . / ~.Meters and Gauges.Meters and Gauges. 1 10 1 11 0 0 0 0 0 0 STEERING ANGULAR VELOCITY SENSOR To mount or remove the steering angular velocity sensor./:. Remove the front seat (L.i & af1.33B-18 ECS . refer to GROUP 52A . refer to GROUP 54 ._-I 3 pi 1 w+\j \\ 212FOO72 \ / 212FOO96 G SENSOR To mount or remove the G sensor.i+--JL .Service Precautions and Air Bag Module and Clock Spring. refer to GROUP 54 .G Sensor / Vehicle Speed Sensor rb3 3wmn 1 3Ieermg nngular velocuy 3ensor I ECS SWITCH To mount or remove the ECS switch. VEHICLE SPEED SENSOR To mount or remove the vehicle speed sensor.$.) before removing or mounting the sensor. a/-y/. TSB Revision . refer to GROUP 528 . CAUTION: SRS Before removal of air bag module.Meters and Gauges.

refer to GROUP 54 . Caution The position detection switch and damping force changeover actuator are built into the shock absorber assemblies of front and rear suspensions. STOP LIGHT SWITCH To remove or mount the stoplight switch. remove or mount them in the form of a strut assembly or shock absorber assembly.Shock Absorber Assembly. / i TSB Revision .Brake Pedal.Damping Force Changeover Actuator / ECS Indicator Light Throttle Position Sensor I Stop Light Switch / Position Detection Switch / 338-l 9 THROTTLE POSITION SENSOR Li INSPECTION AND ADJUSTMENT Refer to GROUP 13A .ECS . ECS INDICATOR LIGHT To remove or mount the ECS indicator lights.Strut Assembly and GROUP 34 . refer to GROUP 35 .Fuel System. refer to GROUP 33A .Meters and Gauges. Since they are of the non& disassembly type. POSITION DETECTION SWITCH and DAMPING FORCE CHANGEOVER ACTUATOR L To remove or mount the position detection switch and damping force changeover actuator. INSPECTION Refer to GROUP 35 .Brake Pedal.

ECS control unit 1 TSB Revision . Lid 3.ECS Control Unit REMOVAL AND INSTALLATION Z12FOO98 Removal steps 1.33B-20 ECS CONTROL UNIT ECS .) 2.H. Cargo floor box (R.

. . . . . 21 REAR AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wheel Bearing End Play Check . . 22 SPECIFICATIONS . 25 REAR SUSPENSION cFWD> ON-VEHICLE SERVICE . . . . . . . . . . . . . 3 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 UPPER ARM. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 25 Rear Wheel Alignment Check . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 24 UPPER AND LOWER ARM . . . . . . 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34-1 REAR SUSPENSION CONTENTS REAR SUSPENSION <AWD> ASSIST LINK . . . . . . . . . 26 SHOCK ABSORBER ASSEMBLY. . . . . . . . . . . . . . . . . . . .. . . . . 20 Service Specifications . . . . . . . 3 SPECIFICATIONS . . . . 6 REAR SUSPENSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 rn~ Service Specifications . . . . . . . . ... . . . 16 TRAILING ARM . . . . . . . . . . . . 38 TRAILING ARM . . . . . . . . . . . . . . . LOWER ARM AND ASSIST LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 General Specifications . . . . 5 Rear Hub Rotary-sliding Resistance Check . . . . . . .*. . . . . . . . . . . . . . . . . . . . . . . 29 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . 7 SHOCK ABSORBER ASSEMBLY . . . 36 SPECIAL TOOLS . . . . . 11 TROUBLESHOOTING . . . . . . . . . . . . 2 General Specifications . . . . . . . . . . . . . . . . . . . . 6 Rear Wheel Alignment Check . . . . . 18 REAR SUSPENSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 35 ON-VEHICLE SERVICE . . . . 13 SPECIAL TOOLS .

x O.D.34-2 REAR SUSPENSION <FWD> .78) Pink x 2 34 (190) Vehicles with ECS 11.74 x 13.010 (223) Medium: 880 (194) Soft: 670 (148) I We Max.) Stroke mm (in.44 x 3.000 (220) 1Vehicles with ECS Hydraulic cylindrical double-acting type 515 (20.3x95x350 (. length mm (in.13 x 13.74 x 14.0) / 159 (6.) Min.) Contraction 550 (121) TSB Revision .2) / 356 (14.0) / 159 (6./in.Specifications REAR SUSPENSION <FWD> SPECIFICATIONS GENERAL SPECIFICATIONS SUSPENSION SYSTEM Item Suspension system Specification Multi-link COIL SPRING (Hatchback) <Up to 1993 models> Items Wire dia./set. x O. x free length mm (in. x free length mm (in.43) Blue x 2 34 (190) Specifications 12. length mm (in.) Specifications 11.78) Orange x 1 35 (196) COIL SPRING (Convertible) cl 995 model> Items Wire dia. x free length mm (in.47 x 3.160 (256) Soft: 560 (123) Hard: 1 .710 (377) Medium: 1 .7 x 95 x 366.3) 1.D.5 (.74 x 13.6~105~350 (.78) Green x 1 34 (190) Vehicles without ECS 12X95X350 (.9 ft.)] N (Ibs.3) Hard: 1.) Coil spring identification color Spring constant N/mm (IbsAn.13 x 14.2) j 356 (14./in.48x 4.46 x 3.43) Blue x 1 35 (196) SHOCK ABSORBER Items 1Vehicles without ECS Hydraulic cylindrical double-acting type 515 (20.13 x 13.5 (.D. (.D. x O.) Coil spring identification color Spring constant N/mm (Ibs.) Coil spring identification color Spring constant N/mm (Ibs. x free’ length mm (in.2~105~350 (.78) Pink x 1 35 (196) Vehicles with ECS 12.) Damping force [at 0.) Coil spring identification color Spring constant N/mm (IbsAn.46x 4.47 x4.3 m/set. x O.) Vehicles without ECS 11.) <From 1994 models> Items Wire dia.0 x 105 x 366.) cl 996 model> Items Wire dia.

) Ball joint rotation breakaway torque Nm (in.197-.Ol + .) Crossmember bushing projection mm (in.5 (.5 (.7-3.Specifications / Special Tools WHEEL BEARING I Item 34-3 I Soecification I . lower arm.002) or less 31 (7) or less Limit / ! - SPECIAL TOOLS Tool TOOI number and Supersession name MB991113 Steering linkage puller MB991 113-01 Application Removal of the ball joint i MB990326 Preload socket 0 El Y-l 0 MB990800 MB990800-01 Installation of the dust cover General service tool Measurement of the ball joint break away torque 0 8 Ball joint remover and installer MB991 071 Bushing remover and installer A: MB991 073 Base B: MB991 072 Arbor Removal and installation of bushing from/to upper arm.09) 0” f 30’ 1.) Camber Stabilizer link ball joint breakaway torque Nm (inlbs.) 11 Wheel bearing end play mm (in.) Stabilizer link protrusion mm (in.276) 8. Unit ball bearing SERVICE SPECIFICATIONS Items Toe-in (Left-right difference) mm (in.lbs.33-.05 (.REAR SUSPENSION <FWD> .2 (15-28) 2-9 (17-78) 5-7 (.) Rear hub rotary-sliding resistance N (Ibs. and assist link TSB Revision .5-9.5 + 2.37) 0.) Standard value 0.

Special Tools / Troubleshootina Tool Tool number and name A: MB991 237 Spring compressor body B: MB991 239 Arm set Supersession MIT62220 Application Compression of the coil spring MB991 045 Bushing remover and installer Removal and installation of the crossmember bushing MB990880 MB991 005-01 .’-t \ :’‘. Y 0 Removal and installation of trailing arm bushing Arbor MB990847 Base MB991389-01 - TROUBLESHOOTING pper arms and/or lower arms a TSB Revision .‘\:.REAR SUSPENSION <FWD> .

TOE-IN Standard value: 0. and. (2) Left wheel: Clockwise (toe-in) Right wheel: Clockwise (toe-out) One graduation changes toe by about 4. Adjust the eccentric bolt within 90” from the central position. NOTE (1) The difference between right and left wheels should be 3 mm (.12 in.) To adjust toe.5 & 2. NOTE (1) Make the adjustment with the assist link mounting bolt (crossmember side) loosened.REAR SUSPENSION <FWD> . Adjust camber and toe.8 mm (-19 in. turn the assist link mounting bolts (on crossmember side) on both sides the same amount. I Z12FOO251 TSB Revision .) <equivalent to toe angle 27’ on one side>.Ol + .) or less. (3) Left wheel: Clockwise ((-) camber) Right wheel: Clockwise ((+) camber) One graduation changes camber by about 15’.On-vehicle Service 34-5 ON-VEHICLE SERVICE REAR WHEEL ALIGNMENT CHECK CAMBER Standard value: 0” f 30’ To adjust camber.09 in.5 mm (. (2) The difference between the right and left wheels should be 30’ or less. if camber is adjusted. 2. Caution 1. in that order. be sure to adjust toe also. turn the lower arm mounting bolt (crossmember side).

TSB Revision . 2. 1. 3. After turning the hub a few times to seat the bearing.002 in. Limit: 31 N (7 Ibs. Place a dial gauge against the hub surface. pulling at a 90” angle from the hub bolt. Remove the hub cap and then release the parking brake. 5. attach a spring balance to the hub bolt. 4. 2.) or less NOTE If the limit value is exceeded. 4. and. Remove the caliper assembly and the brake disc. the lock nut should be tightened to the specified torque and check the end play again. the lock nut should be tightened to the specified torque and check the end play again. Release the parking brake.34-6 REAR SUSPENSION <FWD> . Remove the caliper assembly and the brake disc.On-vehicle Service WHEEL BEARING END PLAY CHECK 1. Inspect the play of the bearings while the vehicle is jacked up and resting on floor jack. then move the hub in the axial direction and check whether or not there is end play. Replace the rear hub bearing unit if an adjustment cannot be made to within the limit. 5. 3.) or less NOTE If the limit value is exceeded. Replace the rear hub unit bearing if an adjustment cannot be made to within the limit. Limit: 0. REAR HUB ROTARY-SLIDING RESISTANCE CHECK inspect the play of the bearings while the vehicle is jacked up and resting on floor jack. measure to determine whether or not the rotary-sliding resistance of the rear hub is the limit value. Check the bearing’s end play.05 mm (.

Parking brake cable end (Referto GROUP 36. ABS speed sensor CABS> 12.On-vehicle Service.) l Absorber Lid to Rear Side Trim Installation (Refer to GROUP 52A . and then fully tightened with the vehicle on the ground In the unladen condition. Brake caliper mounting bolt 6. Trailing arm mounting bolt and nut 13. Crossmember mounting nut 14. Rear speed sensor clamp bolt CABS> 11. Brake caliper assembly 7.) 0 Main Muffler Removal (RefeitoGROUP 15-Exhaust Pipe and Main Muffler.Trims.Rear Suspension Assembly 34-7 REAR SUSPENSION ASSEMBLY cd RI MOVAL AND INSTALLATION Pre-removal Operation l Absorber Lid Removal from Rear Side Trim (Refer to GROUP 52A .) Post-installation Operation Main Muffler Installation (Refer to GROUP 15 . Shock absorber mounting nuts (upper) 2.) 0 Wheel Alignment Check (Refer to P.) l Parking Brake Lever Stroke Check (Refer to GROUP 36 . ECS connector <EC% 3. Parking brake cable clamp bolt 9. Brake disc 8.) 10.Exhaust Pipe and Main Muffler.Trims. Brake tube clannp bolt 5. TSB Revision . Cap 4.REAR SUSPENSION <FWD> .Parking Brake. Rear suspension assembly NOTE *: i indicates parts which should be temporarily tightened.34-5.) l Z12FOllO Removal steps 1.

CROSSMEMBER MOUNTING NUT I REAR SUSPENSION ASSEMBLY REMOVAL Support the crossmember with a transmission jack.5-9. remove and press-fit the bushing.33-.Rear Suspension Assembly I REMOVAL SERVICE POINT +A.) TSB Revision . Check the bushings for cracks or deterioration.34-8 \\\ REAR SUSPENSION eFWD> . Standard value (A) : 8. (2) When press-fitting the bushing. Z12FOO78 Inner sleeve (3) Make sure that the protrusion (dimension A) of the inner sleeve is up to specification.37 in. then remove the crossmember mounting nut and rear suspension assembly. i ‘cJ INSPECTION l l Check the crossmember for cracks or deformation.5 mm (. Press out Press fit CROSSMEMBER BUSHING REPLACEMENT (1) Using the special tool. apply soapsuds to it and position the arrows as shown.

Self-locking nut 3. 00001032 Upper arm removal steps Assist link removal steps 4Ab 1. 12FO10. Caution 1. I 212A0091 1 TSB Revision I . Upper arm 4Ab 8.) 1 4 Nm ft. Brake tube clamp bolt 2. 2.REAR SUSPENSION <FWD> upper nrm. Lower nrm ano .) l Shock Absorber Installation (Refer to P. Assist link Lower arm removal steps 4Ab 5. and then fully tightened with the vehicle on the ground in the unladen condition. Upper arm mounting bolt and nut 4. lower arm. Be sure to tie the cord of the special tool to a nearby part.34-13. Lower ami nut l . SELF-LOCKING NUT REMOVAL Using the special tool.* \ l Shock Absorber Removal (Refer to P.34-13. and assist link. disconnect the knuckle from the upper arm. Self-locking nut 7. Loosen the nut but do not remove it. Assist link mounting bolt and nut 9.lbs.) 140-160 Nm* lOl-116ft. NOTE . REMOVAL SERVICE POINT +A.Assist Link 34-9 UPPER ARM. Indicates parts which should be temporarily tightened.34-5. Self-locking nut 10. Lower arm mounting bolt and 6. LOWER ARM AND ASSIST LINK Post-installation Operation l Wheel Alignment Check (Refer to P.lbs.

(3) LVFedn the dust cover with special tool until it is fully ‘L) . Check the upper. Standard value: 2-9 Nm (17-78 in.Assist Link INSPECTION l l l l Check the bushing for wear and deterioration. l?NOIOl 1 TSB Revision .REAR SUSPENSION cFWD> upper Arm.) z12u001. Check the ball joint dust cover for cracks. measure the ball joint breakaway torque. ASSIST LINK BUSHING REPLACEMENT Use the special tool to remove and press-fit the bushing.lbs.3 m-u MB990800 Dust cover Snap ring BALL JOINT DUST COVER REPLACEMENT (1) Remove the dust cover. Lower Hrm anu . . lower arm or assist link for bend or breakage. di BALL JOINT BREAKAWAY TORQUE CHECKING Using the special tool. Check all bolts for condition and straightness. (2) Apply multipurpose grease to the lip and inside of the dust cover. UPPER ARM. 212R0119 J Removal Pressure fitting LOWER ARM.

Self-locking nut 17. Rear brake disc 2.116 ft.On-vehicle Service.) 54-64fLlbs. Self-locking nut Trailing arm mounting bolt and nut Trailing arm assembly :* Brake caliper Hub cap 3: Brake tube clamp bolt 4. TSB Revision .lbs.REAR SUSPENSION cFWD> .) 10.) Rear Brake Disc Run-out Check (Refer to GROUP 35 . Rear speed sensor clamp bolt CABS> ABS speed sensor CABS> ::: Backing plate NOTE Indicates parts which should be temporarily tightened. and “1 then fully tightened with the vehicle on the ground in the unladen condition.lbs.* 8- q 13< 36-43 ft.lbs.160 Nm* 2 101. Stabilizer link mounting nut 4Bb Self-locking nut 2 Shock absorber mounting bolt (upper) 16.Trailing Arm 34-11 TRAILING ARM l l Parking Brake Lever Stroke Check (Refer to GROUP 36 . Z12FOlll Removal steps Brake caliper mounting bolt bAd. Wheel bearing nut 7: Rear hub assembly Parking brake cable clamp bolt i: Parking brake cable end (Refer to GROUP 36 . 5-89 Nm l/T% 83 Nm 60 ft. / c 18 140.Parking Brake.On-vehicle Service.13.

If the removed rear hub assembly is reinstalled with the inner race attached on the spindle. upper arm. it can be caused that the oil seal lip is pushed in the reverse direction. SELF-LOCKING NUT REMOVAL Using the special tool. 2.) J 212AOlOO INSPECTION l l Check trailing arm for cracks and deformation. REAR HUB ASSEMBLY REMOVAL Caution Replace the rear hub assembly with a new one if the bearing inner race is left on the spindle when removing the rear hub assembly.A+ STABILIZER LINK MOUNTING NUT INSTALLATION Holding the stabilizer link with a wrench. tighten the self-locking nut so that the protrusion of the stabilizer link (dimension A indicated in illustration) is within the standard value. deterioration and wear. Be sure to tie the cord of the special tool to a nearby part. Caution 1. +B. remove the knuckle from the lower arm. Check bushing for cracks. ~ INSTALLATION SERVICE POINT wrench . and assist link. resulting in oil leaks or loose mounting.34-12 REAR SUSPENSION cFWD> . 1 TSB Revision .276 in. Press-fit I I Removal TRAILING ARM BUSHING REPLACEMENT Use the special tool to remove and press-fit the bushing.197-. Standard value (A) : 5-7 mm (. Loosen the nut but do not remove it.Trailing Arm REMOVAL SERVICE POINTS AA.

Brake tube clamp bolt 5.Shock Absorber Assembly 34-13 SHOCK ABSORBER ASSEMBLY 212F0087 Removal steps L. n 1.REAR SUSPENSION cFWD> . Shock absorber upper mounting nut 3 L”” nnnnnrtnr “CCC. and then fully tightened with the vehicle on the ground in the unladen condition. biqJ n-- 4. l=clc ““IIIIU”L”I . 1 TSB Revision . Shock absorber lower mounting bolt 6. Shock absorber ‘I NOTE Indicates parts which should be temporarily tightened.L”“/ J.

Upper spring pad 6. Washer 3.Shock Absorber Assembly DISASSEMBLY AND REASSEMBLY 11 .PlSTON ROD TIGHTENING NUT REMOVAL (1) Before removing the piston rod tightening nut. 8. C 3 12 Z12A0328 Disassembly steps +A. Bracket assembly 5. Collar Cup assembly Dust cover Bump rubber Coil spring Shock absorber DISASSEMBLY SERVICE POINT +A. Upper bushing (A) . Piston rod tightening nut 2. 12.B( 4. remove the piston rod tightening nut.A.34-14 REAR SUSPENSION <FWD> . (2) While holding the piston rod.. . 10. compress the coil spring using the special tool. 1 TSB Revision . l-q 4 --A --Y. -!3 3 [iI .A( 11. Upper bushing (B) 7. . 9..B+ 1.

tighten the tightening nut to the specified torque. (2) Install the coil spring so that the lower edge fits into the spring seat groove and the upper edge fits into the spring pad groove. (2) Align the edge of the coil spring to the position of the shock absorber spring seat as shown.Shock Absorber Assembly REASSEMBLY SERVICE POINTS 34-15 . Coil sprin 212A004 c FBdBRACKET ASSEMBLY t PISTON ROD TIGHTENING NUT INSTALLATION (1) With the position of the bracket assembly as shown in the figure.A( COIL SPRING INSTALLATION (1) Use the special tool (MB991237 and MB991239) to compress the coil spring and insert it in the shock absorber. damage or deterioration. Lower bushing inner pipe zlZFOO77 INSPECTION l l Check the rubber parts for damage.REAR SUSPENSION <FWD> . then remove the special tool (MB991237 and MB991 239). Check the coil springs for crack. ~ 1 TSB Revision .

Joint (B) . Stabilizer link 10. Bushing . (2) Holding the stabilizer link with a wrench. Stabilizer bar CUD INSTALLATION SERVICE POINTS Hold with wrench .Bd 2. Stabilizer rubber 7.A+ 8. Self-locking nut 5.276 in. Stabilizer rubber 12.) TSB Revision .34-16 REAR SUSPENSION cFWD> .Stabilizer Bar STABILIZER BAR REMOVAL AND INSTALLATION Removal steps 1.A+ 4. Standard value: 5-7 mm (. tighten the self-locking nut (B) so that the protrusion of the stabilizer link is within the standard value. Stabilizer bar bracket 3. Self-locking nut . Joint cup (A) 11.AdSTABlLlZER LINK / SELF-LOCKING NUT / SELF-LOCKING NUT INSTALLATION (1) Hold the stabilizer link ball studs with a wrench and install the self-locking nut (A).197-. Joint cup (A) 6. Stabilizer bracket mountina bolt .A+ 9.

TSB Revision . (4) Secure the dust cover by the clip ring.7-3.) l l 212L0241 BALL JOINT DUST COVER REPLACEMENT (1) Remove the clip ring and the dust cover.) with the stabilizer bar marking end and temporarily tighten the stabilizer bar bracket (L. measure the ball joint breakaway torque. (3) Temporarily fix the both ends of the stabilizer bar to the link and tighten the stabilizer bar bracket mounting bolts to specification.2 Nm (15-28 in.) and temporarily tighten it. ZlZL024E (2) Apply multipurpose grease to the lip and inside of the dust cover.H. l Check all bolts for condition and straightness. ZlZFOO76 INSPECTION Check the bushing for wear and deterioration. Standard value: 1. and then install the dust cover to the stabilizer link. STABILIZER LINK BALL JOINT BREAKAWAY TORQUE CHECKING Using the special tool.B+ STABILIZER BAR BRACKET INSTALLATION (1) Align the bushing (L.Stabilizer Bar 34-17 . l Check the stabilizer link ball joint dust cover for cracks. mount the stabilizer bar bracket (R.H. (2) In this condition. (3) Use vinyl tape to tape the stabilizer link where shown in the illustration.H.).REAR SUSPENSION <FWD> .lbs. Check the stabilizer bar for deterioration or damage.

7. Caliper assembly 3.lbs. Rear rotor CABS> 9. Rear speed sensor CABS> 2. CALIPER ASSEMBLY REMOVAL Remove the caliper assembly and suspend it with a piece of wire. Wheel bearing nut 6. 8. Brake disc 4. Removal steps 1.REAR SPEED SENSOR REMOVAL <ABS> 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. Tongued washer 4. TSB Revision . Hub cap . REMOVAL SERVICE POINTS dA.34-18 REAR SUSPENSION <FWD> . Pole piece 214N0107 (B.Rear Axle Hub REAR AXLE HUB REMOVAL AND INSTALLATION 50-60 Nm 36-43 ft. Rear hub assembly 4D.A+ 5. Rear hub unit bearing Caution Rear hub unit bearing cannot be disassembled.

214NO00 r 1 TSB Revision . align with the spindle’s indentation and crimp. REAR HUB ASSEMBLY REMOVAL 34-19 L Caution Replace the rear hub assembly with a new one if the bearing inner race is left on the spindle when removing the rear hub assembly.Rear Axle Hub +C. +D.’ . it might not be able to accurately sense the wheel rotation speed and the system as a result might not perform normally. and not to drop it. Spindle I L .A4 WHEEL BEARING NUT INSTALLATION After tightening the wheel bearing nut. If the rotor’s toothed surface is chipped or the rotor is deformed.REAR SUSPENSION <FWD> . If the removed rear hub assembly is reinstalled with the inner race attached on the spindle.REAR ROTOR REMOVAL CABS> Caution Care must be taken not to scratch or scar the rotor’s toothed surface. INSTALLATION SERVICE POINT . resulting in oil leaks or loose mounting. it can be caused that the oil seal lip is pushed in the reverse direction.

13 x 14.0 (157) d 1 TSB Revision .) I Coil spring identification color Spring constant N/mm (IbeAn.46x4.93) Blue x 2 28.0 (157) COIL SPRING (Convertible) cl 995 model> Items Wire dia.2 (. x free length mm (in. x free length mm (in.0 (157) cl 996 model> Items Wire dia. x O. x O.l x 95 x 372 (44 x 3. x O.13x 15. x free length mm (in.) \d\ cl 996 models> Items Wire dia.D.) Specifications 11 .45 x 3.) Specifications 11.) Specifications 11.D.5x 105x379.65) Light blue x 1 28. x O.3 (.0 (157) I I I Wire dia.74 x 15.D.13x14.) Coil spring identification color Spring constant N/mm (Ibs.74 x 14. x O./in.REAR SUSPENSION cAWD> .) Coil spring identification color Spring constant N/mm (IbsAn.56) Grayx2 28.D.0 (157) cl994 and 1995 models> I items Specifications 11.48x 4.2 x 105 x 379. x free length mm (in.3 (.56) Gray x 1 28.) Specifications 12.8x 105x395.2 (.45x4. x free length mm (in.5 x 95 x 395.93) 1Light brown x 2 28.) Coil spring identification color Spring constant N/mm (IbsAn.) Coil spring identification color L Spring constant N/mm (IbsAn.Specifications REAR SUSPENSION <AWD> SPECIFICATIONS GENERAL SPECIFICATIONS SUSPENSION SYSTEM ‘d ) Specification 1 Double wishbone suspension type I I I I Item Suspension system I COIL SPRING (Hatchback) cup to 1993 models> Items Wire dia.D.

08-.) Expansion Specifications Hydraulic.0) 1.) Camber Protruding length of stabilizer bar mounting bolt mm (in.3 (.276) ’ 2.0) 203 (8. length mm (in. cylindrical.7-7.09) -0”10’+30 5-7 (.Ol zk .) / Upper part Lower part 15.)] N (Ibs.29) I Differential support bushing projection mm (in.REAR SUSPENSION <AWD> .) Damping force [at 0.lbs.160 (256) Soft: 560 (123) Hard: 1 .Specifications SHOCK ABSORBER <Up to 1995 models> Items Type Max.) Min. cylindrical.7-3./set.) Expansion Contraction Specifications Hydraulic.9 ft. double-acting type 610 (24.5 (.0) 203 (8. length mm (in.1-3.710 (377) Medium: 1 . double-acting type 610 (24. (0.9 ft.5 (59) 2.) Min.2 (15-28) .15) 6.010 (223) Medium: 880 (194) Soft: 670 (148) Contraction ’ cl 996 models> Items Type Max.26-. length mm (in.0-9.)] N (Ibs.0 (17-78) 1.0) 407 (16.400 (309) I / 500 (110) SERVICE SPECIFICATIONS Items Toe-in mm (in. I I Crossmember support bushing projection mm (in.3 m/set.0) 407 (16. (0.) Lower arm ball joint breakaway itorque Nm (in.) Stroke mm (in.197-.) Stroke mm (in.lbs.7 (.) Stabilizer link ball joint break away torque Nm (in.5 + 2.) Standard value 0.3 m/set. length mm (in.) Damping force [at 0./set.0) Hard: 1.) 1 TSB Revision .

and assist link B Q@ MB990767 End yoke holder MB990767-01 To stop axle shaft turning 1 TSB Revision . lower arm.Special Tools SPECIAL TOOLS Tool Tool numberand name A: MB991 387 Arbor B: MB991 388 Base C: MB990890 Base B Supersession Application Removal and installation of the crossmember bushing @ f!? 6 A C MB990958 Arbor 8 MB991113 Steering linkage puller MB990958-01 Removal and installation of crossmember bushings MB991113-01 Disconnection of the ball joint MB990326 Preload socket 0 J Em General service tool Measurement of the ball joint break away torque 0 8 MB990800 Ball joint remover and installer MB991 071 Bushing remover and installer A: MB991 073 Base B: MB991 072 Arbor Installation of the dust cover A / Removal and installation of bushing from/to upper arm.34-22 REAR SUSPENSION <AWD> .

REAR SUSPENSION <AWD> .Special Tools 34-23 B: lMB990244 i TSB Revision .

Troubleshooting TROUBLESHOOTING TSB Revision .34-24 REAR SUSPENSION <AWD> .

if camber is adjusted.) or less. One graduation changes toe by about 2 mm (. One graduation changes camber by about 12’. Adjust the eccentric cam bolt within 90” from the central position.) To adjust toe. disconnect the assist links from the trailing arms before adjustment. 4. in that order. Left wheel: Clockwise ((-) camber) Right wheel: Clockwise ((+) camber) The difference between the right and left wheels should be 30’ or less.).5 mm (. turn the lower arm mounting bolt on the crossmember side. and.12 in.Ol + -09 in. Make the adjustments with the 4WS tie rod end disconnected from the trailing arm. Adjust camber and toe. 2. turn the trailing arm mounting bolts on the crossmember side on both sides the same amount. / i TSB Revision .On-vehicle Service 34-25 ON-VEHICLE SERVICE REAR WHEEL ALIGNMENT CHECK Standard value: -0”lO’ + 30’ To adjust camber. /1 T r a i l i n g yzf+lM8j TOE-IN Standard value: 0.08 in. Caution 1. 3. be sure to adjust toe also.5 + 2. On vehicles without 4WS.REAR SUSPENSION <AWD> . NOTE Left wheel: Clockwise (toe-out) Right wheel: Clockwise (toe-in) The difference between right and left wheels should be 3 mm (.

5 . NOTE Parts marked with * are symmetrical.) 4WS System Bleeding and Operation Inspection (Refer to GROUP 378 . Feed pipe assembly to suction hose connection <4WS> 10. )bx Removal steps 1.) 5. ECS connector cECS>* 3. Brake disc* 7.Trims. Brake tube to brake hose connection* (Refer to GROUP 35 .34-26 REAR SUSPENSION <AWD> .Exhaust Pipe and Main Muffler.Exhaust Pipe and Main Muffler.lbs. 1 TSB Revision . Crossmember mounting nut (on differential side)* 19.On-vehicle Service. Power cylinder tie rod coupling nut <4WS>* or assist link coupling nut <except 4WS>* 12. Parking brake cable and ABS sensor fixing bolt CABS>* 16.) Center Exhaust Pipe and Main Muffler Removal (Refer to GROUP 15 . Cap* 4. Brake caliper* 6. /6 \ L) 80-94 ft.Ibs. Crossmember bracket* 18. Center bearing mounting nut 14. 4 .) l Power Steering System Refilling and Bleeding (Refer to GROUP 37A .Brake Line.) I Post-installation Operation Center Exhaust Pipe and Main Muffler Installation (Refer to GROUP 15 .) 8. Pressure tube assembly to pipe assembly connection <4WS> 9.) Parking Brake Lever Stroke Checking (Refer to GROUP 36 .lbs. Harness connector CABS>* 15. Differential carrier to propeller shaft coupling bolt and nut 13. Shock absorber mounting nuts bweO* 2.34-25.On-vehicle Service.Trims. Parking brake cable end* (Refer to GROUP 36 . 2 _12 30-35 Nm \ /%Bi 50-60 N m 36-43 ft.On-vehicle Service.Parking Brake.) l Rear Side Trim Absorber Lid Installation (Refer to GROUP 52A . Cable band* 17. Return pipe assembly to rubber hose connection c4WS> 11. Rear suspension assembly :t: 4A.) 3 1 45 Nm 3 ft.Rear Suspension Assembly REAR SUSPENSION ASSEMBLY REMOVAL AND INSTALLATION Pre-removal Operation l I \ I Id 1 l Rear Side Trim Absorber Lid Removal (Refer to GROUP 52A .) l l l l Wheel Alignment Checking (Refer to P.lbs. d.

support the differential case with the transmission jack. make sure that the hollow portions are positioned as shown.REAR SUSU’ENSION cAWD> . NOTE Ensure that the shift in rotating direction is within So. (2) Remove the crossmember mounting bolt and nut.) (3) Apply a wood block to the ball joint of the lower arm to prevent the dust shield from being deformed. as the rear suspension assembly is very heavy. \ 212A022: Press out MB991 387 INSPECTION l l Check the crossmember for cracks or deformation. CROSSMEMBER SUPPORT BUSHING (FRONT) REPLACEMENT MB991 388 212N008f 5 (1) Using the special tool. u " 212FOO79 TSB Revision . (Assign one person to the differential and one each to the left and right lower arm. remove and press-fit the crossmember support bushing.Rear Suspension Assembly REMOVAL SERVICE POINTS 34-27 dA. CROSSMEMBER BRACKET / CROSSMEMBER MOUNTING NUT (ON DIFFERENTIAL SIDE) / REAR SUSPENSION ASSEMBLY REMOVAL (1) Before removing the crossmember bracket. NOTE Lowering the rear suspension assembly down from the transmission jack requires three persons. Check the bushings for cracks or deterioration. 212NOOB 1 (2) When press-fitting the bushing.

Rear Suspension Assembly (3) Make sure that the protrusion of the inner sleeve (dimension A and B) are up to specifications.5 mm (59 in. NOTE Ensure that the shift in rotating direction is within +5”. 212N0088 212N0081 (2) When press-fitting.) Dimension B: 2.7-7. position the bushing as shown. Standard value (A) : 6.26-.7 mm (.3 mm (.REAR SUSPENSION <AWD> . Standard value Dimension A: 15.29 in. remove and press-fit the bushing.) Y12FW7! Press out CROSSMEMBER BUSHING (REAR) REPLACEMENT (1) Using the special tool.) Wl2FOO79 1 TSB Revision I .08-.1-3. L X12FOO79 (3) Make sure that the protrusion of the inner sleeve (dimension A) is up to specification.15 in.

fzbilizer link to lower arm coupling 8. and then fully tightened with the vehicle on the ground in the unladen condition. Caution 1. Self-locking nut 2.34-25. Upper arm mounting nut 3. Nm EL/ i 2 R0487 140-160 Nm* 1 0 1 .A4 7. Lower arm NOTE *: Indicates parts which should be temporarily tightened. Loosen the nut but do not remove it.Upper and Lower Arm 34-29 UPPER AND LOWER ARM REMOVAL AND INSTALLATION iI Post-installation Operation 0 Wheel Alignment Check (Refer to P. Lower arm mounting nut 6.REAR SUSPENSION cAWD> .* g E L7Bl 12FOO93 00001036 Upper arm removal steps 1.lbs. Upper arm mounting bolt 4. Be sure to tie the cord of the special tool to a nearby part. TSB Revision .1 1 6 ft. Upper arm 4Bb Lower arm removal steps 5.lbs. disconnect the upper arm ball joint from the knuckle.) I 140-160 Nm 1 0 1 . SELF-LOCKING NUT REMOVAL Using the special tool. Self-locking nut 9. Lower arm mounting bolt .1 1 6 ft.lbs. Dust cover 4 r g!-Wd 3:::: ft. 2. REMOVAL SERVICE POINTS (A.

install the special tool and disconnect the lower arm ball joint from the knuckle. tighten the self-locking nut so that the protrusion of the stabilizer link (dimension A indicated in illustration) is within the standard value. Standard value: 2-9 Nm (17-78 in. I 212A009d INSTALLATION SERVICE POINT . Check the ball joint dust cover for cracks. Caution 1.lbs. (2) Apply multipurpose grease to the lip and inside of the dust cover. Check the upper arm or lower arm for bend or breakage. Check all bolts for condition and straightness. 2. (3) Drive in the dust cover with special tool until it is fully seated. Then. measure the ball joint breakaway torque.AQSTABlLlZER LINK TO LOWER ARM COUPLING NUT INSTALLATION Holding the stabilizer link with a wrench.276 in.) I zl2UOO18 BALL JOINT DUST COVER REPLACEMENT MB990800 . Snap ring 212R019 9 TSB Revision . Loosen the nut but do not remove it. Standard value (A) : 5-7 mm (. Be sure to tie the cord of the special tool to a nearby part.) ZlZAOlOt I INSPECTION l l l l Check the bushing for wear and deterioration. SELF-LOCKING NUT REMOVAL Lower down the lower arm on the crossmember side.Upper and Lower Arm (B. Dust cover (1) Remove the dust cover. BALL JOINT BREAKAWAY TORQUE CHECKING Using the special tool.197-.REAR SUSPENSION cAWD> .

MB991 073 YlZNOlOl Press-fit (2) Press-fit the lower arm bushing until the bushing outer pipe edge flush with the lower arm pipe edge.REAR SUSPENSION cAWD> . i Pipe (lower am) OLer pipe (bushing) 12A003! TSB Revision .Upper and Lower Ark 34-31 .’ L Removal MI3991 072 LQWER ARM BUSHING REPLACEMENT (1) Use the special tool to remove and press-fit the bushing.

Trailina Arm REMOVAL AND INSTALLATION l Wheel Alignment Check (Refer to P. Self-locking nut (upper arm) 4Cb 13.On-vehicle Service. Trailing arm l: NOTE Indicates parts which should be temporarily tightened.On-vehicle Service. Rear brake disc 3. Parking brake cable clamp bolt 9. Self-locking nut (lower arm) 14. Drive shaft to companion flange mounting bolt and nut 4. Companion flange 6.* Al2FO134 58 Am 42 ft.34-32 TRAILING ARM REAR SUSPENSION cAWD> . Stopper (18 in. Assist link or tie rod end mounting nut 15.) Post-installation Operation Lj l Rear Brake Disc Run-out Check (Refer to GROUP 35 . Rear speed sensor cable and parking brake cable bands CABS> 11. Trailing arm ‘mounting bolt and nut 16. Dust shield 12.lbs. Rear shock absorber mounting bolt 18.) * Parking Brake Lever Stroke Check (Refer to GROUP 36 .34-25. and then fully tightened with the vehicle on the ground in the unladen condition. ‘ 8 Removal steps 1. Rear speed sensor CABS> 10. 9 \ 55-6 40-4 200-240 Nm* 145-174 ft.lbs. 260-300 Nm 188-217 ft. Self-locking nut 5.lbs. Parking brake cable end 8.-wheel equipped vehicles) 17. TSB Revision . Rear brake caliper assembly 2.) 50-60 Nm 36-43 ft. Rear axle shaft 7.lbs.

+B.REAR AXLE SHAFT REMOVAL With the special tool. then remove the self-locking nut. remove the rear axle shaft. Be sure to tie the cord of the special tool to a nearby part.SELF-LOCKING NUT (UPPER ARM) / SELF-LOCKING NUT (LOWER ARM) REMOVAL Using the special tool.Trailing Arm REMOVAL SERVICE POINTS 34-33 +A. Trailina arm bushina 2i2A0298 I~ TSB Revision . Caution 1. Check bushing for cracks. Press-fit Removal INSPECTION l l Check trailing arm for cracks and deformation. +C. CONNECTING ROD REPLACEMENT Replace the connecting rod using the following procedure: (1) Remove the trailing arm bushing. (2) Remove the bolt and nut.REAR SUSPENSION <AWD> . TRAILING ARM BUSHING REPLACEMENT Use the special tool to remove and press-fit the bushing. Loosen the nut but do not remove it. secure the rear axle shaft. 2. deterioration and wear. disconnect the ball joint from the knuckle. SELF-LOCKING NUT REMOVAL With the special tool.

NOTE (1) Apply lubricant to the sliding portion of the special tool (at the arrow marked “A” in the illustration).) TSB Revision . (Refer to P.) (lO)Press-fit the trailing arm bushing.i’ I (6) “.34-34 REAR SUSPENSION cAWD> .lbs. to turn the portion marked “C” in the illustration to remove the connecting rod.\ -A MB991254 (3) Set the special tool onto the trailing arm as shown in the illustration.pdp’y soapy water to the rubber portion of the connecting (7) Reverse the removal procedures to press-fit. (5) Installation of the body (special tool) should be performed with the screw shaft and guide shaft center lines oriented as shown in the illustration. etc. \. at the point shown in the figure. (9) Tighten the bolts and nuts to the specified torque.34-33. (4) Use a spanner. (2) Install bolt B to the trailing arm.Trailina Arm Bolt B ‘ i i . Tightening torque : 98 Nm (71 ft.. (8) Remove the special tool after aligning the holes in the special tool and trailing arm.

loosen the lock nuts and turn the adjusting bolt to adjust the length of the assist link.REAR SUSPENSION cAWD> . INSTALLATION SERVICE POINT Bolt . Lock nut A12FO125 i TSB Revision .A+ 1.A+ ASSIST LINK INSTALLATION If the ball studs of the assist link does not align with their mounting holes. side shown. i. 58 Nm 42 ft.lbs.Assist Link 34-35 ASSIST LINK cup to 1994 models> l Wheel Alignment Check (Refer to P.H. Assist link A12F0126 NOTE L.lbs.) 40 Nm 29 ft. .34-25.

34-36 REAR SUSPENSION <AWD> . ECS connector <EC&3. Shock absorber assembly 1 TSB Revision .) ZlZFOO86 Removal steps 1.Shock Absorber Assembly SHOCK ABSORBER ASSEMBLY REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation 0 Rear Side Trim Absorber Lid Removal and Installation (Refer to GROUP 52A . Shock absorber lower mounting bolt 5.Trims. Cap 4. Shock absorber upper mounting nut 2.

Washer 4.) 13.34-15. Cap 2. Shock absorber INSPECTION l l Check the rubber parts for damage. damage or deterioration. Coil spring (Refer to P.34-14. Upper bushing (A) 5. Piston rod tightening nut (Refer to P. Bracket assembly (Refer to P.34-15.Shock Absorber Assembly DISASSEMBLY AND REASSEMBLY 20-25 14-18 34-37 Z12AO360 i Disassembly steps 1. i TSB Revision . &&‘. Bump rubber 12.) 6. bushing (B) 9: Cup assembly 10.. Spring pad .REAR SUSPENSION <AWD> . Dust cover 11.) 3. Check the coil springs for crack.

Stabilizer link 7.A. 12FO109 2 9 f t .1 49& . Crossmember mounting nut* 16. Joint cup A* 4.Ibs. Tie rod end mounting nut* 10.A+ 1. Joint cup B* 6. Rear shock absorber mounting bolt 13. Self-locking nut* 3. 4WS piping fixing bolt <4WS> 12. Power cylinder mounting bolt <4WS> 14. l b s .Stabilizer Bar STABILIZER BAR REMOVAL AND INSTALLATION Nm . s -) -.34-38 REAR SUSPENSION cAWD> . Stabilizer bracket* 17. Self-locking nut* .A+ 2. -+?!a $Q -3 2P L 12LO217 00001037 11. Stabilizer rubber* 5. Joint cup A* 8. Parking brake cable bracket mounting bolt* :t: 4Bb 11. Stabilizer rubber* 9. Bushing* 18. n4. TSB Revision . Stabilizer bar NOTE Parts marked with * are symmetrical. Removal steps . Crossmember bracket* 15.

I i-_--I 3 -------I -&I$ -A -1. (2) Remove the stabilizer bar.Stabilizer Bar REMOVAL SERVICE POINTS 34-39 L/ +A. Standard value (A) : 5-7 mm (.A+STABlLlZER LINK / SELF-LOCKING NUT / SELF-LOCKING NUT INSTALLATION (1) Secure the stabilizer link ball stud with a wrench and mount the self-locking nut. CROSSMEMBER BRACKET / CROSSMEMBER MOUNTING NUT REMOVAL (1) Support the rear suspension assembly with the transmission jack.) with wrench c 12AO099 TSB Revision .REAR SUSPENSION cAWD> . Air7 b-- I I Zl2AOlO$ +B. STABILIZER BAR REMOVAL (1) Lower the transmission jack a little to obtain a gap between the rear suspension and body. (2) Remove the crossmember bracket and crossmember mounting nut. L /Z. then mount the self-locking nut.276 in.197-. I. INSTALLATION SERVICE POINTS .2A‘ wyny j I (2) Hold the stabilizer link with a wrench so that its protrusion on the lower arm side (dimension A) is up to specification. -\ L-.

At this time. all bolts for condition and straightness. TSB Revision .7-3. (2) Apply multipurpose grease to the lip and inside of the dust cover. (3) Wind tape around the threads of the stabilizer link stud and install the dust cover. (4) Secure the dust cover with the clip ring.) BALL JOINT DUST COVER REPLACEMENT (1) Remove the clip ring and the dust cover. measure the ball joint breakaway torque. make sure that the clip ring ends are located at a point 90” + 20” with reference to the link axis.Stabilizer Bar INSPECTION l l l l Check Check Check Check the bushing for wear and deterioration. the stabilizer link ball joint dust cover for cracks. the stabilizer bar for deterioration or damage.lbs. STABILIZER LINK BALL JOINT BREAKAWAY TORQUE CHECKING Using the special tool.34-40 REAR SUSPENSION <AWD> . Standard value: 1.2 Nm (15-28 in.

. . 83 Wheel Speed Sensor Output Voltage Measurement . . . . . . . .. . 76 Power Relay Check . . 73 Rear Brake Disc Run-out Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 SPECIAL TOOLS . . . 65 Rear Brake Disc Run-out Check . . 82 Valve Relay and Motor Relay Check CABS> . . . . . . ... . . . . . . . Service Specifications .. 73 Rear Disc Brake Pad Check and Replacement . . . .. . 82 Proportioning Valve Function Test . . . . . . .. . . . . .. . . . . . RELAY <ABS> . . ... . .. . . . . . . . . . . . . . . . . . . . . .. .. 66 Brake Booster Operating Check . . 87 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . .. . . . . (3) MITSUBISHI dealer personnel must thoroughly review this manual. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 74 Brake Pedal Check and Adjustment . . . . . ... . . . . . . . . . .. . NOTE The SRS includes the following components: impact sensors. . . . . . . . . . . . . . . ... . . . 113 I WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS. . Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*). . . . . clock spring and interconnecting wiring. . . . . .. . . .. . . 63 Check Valve Operation Check . . . . . . .. . . . . . . . . . . . . . . 75 REAR DISC BRAKE . . . ... . . . . .PNS . . . . . . . . . . . . . 65 Front Brake Disc Run-out Check .. . . . . . . . 74 Brake Fluid Level Sensor Check . ... . . . . . . . . . . . . . . . .. . air bag module. . . . . . . . . . . . . . ... . . 63 Bleeding . . . 4 SPECIFICATI. . . . . . . . . . . . . . . . 74 Brake Lining Thickness Check . . . .. .. .. . . . .. . . . .. . . . . . . . .. . 64 Brake Drum Inside Diameter Check . . . .3 TROUBLESHOOTING . . .. . . . . . . . . . . . . . . . . . . . . . .. . . 7 BRAKE LINE . . . .. .. . . . . . . .. . .. . . . . . .. .. . . . . . . 73 Rear Brake Disc Thickness Check . . .. . . . . . . . 119 FRONT DISC BRAKE . . . . . . . . . . . . . . 4 Sealants . .. . . .. . . .. . . . . . . . . . . . . 70 Front Brake Disc Run-out Correction . . . . .. .. . . . . or any SRS-related component. . .. . . . . can lead to personal injuryordeathtoservicepersonnel(frominadvertentfiringoftheairbag)ortothedriverandpassenger(fromrendering the SRS inoperative).. . . . . . . . . . . 91 BRAKE PEDAL . . . . . . . . . . . . . .. . SRS warning light. . . before beginning any service or maintenance of any component of the SRS or any SRS-related component. . 110 MASTER CYLINDER AND BRAKE BOOSTER . . . . . . . . . . .. . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Lubricants . . . . . .. . . . . . . . . .. . . . . 64 Brake Lining and Brake Drum Connection Check . . . . . . . . . . . . . . . . . . . . . . . 70 Front Disc Brake Pad Check and Replacement . . .. . . . . . . 117 HYDRAULIC UNIT (HU). . . . . . 84 ELECTRONIC CONTROL UNIT (ABS-ECU) <ABS> .. 5 WHEEL SPEED SENSOR <ABS> ... . . . . . . SRS diagnosis unit. . . . . .35-1 i id SERVICE BRAKES CONTENTS ANTI-LOCK BRAKING SYSTEM TROUBLESHOOTING . . . . . . . . 93 G SENSOR <AWD-ABS>* . . 70 Front Brake Disc Thickness Check . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . .. . . . . .. 2 General Specifications . . . . . . . . . . . . 71 Remedy for a Discharged Battery . . . . . . . . . . . . . . 66 Hydraulic Unit (HU) Check . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . ... . . and especially its GROUP 528 -Supplemental Restraint System (SRS) and GROUP 00 -Maintenance Service. . . . . . . (2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer.. . . . . . . . . . .. . .. . .

(MR58V) 237 (9.25 (533-604) 0.s) AWD Tandem type (with level sensor) 26. mm (in.9 (1 s/*.79) 1 15 (.0) + 205 (8. Automatic AWD AWD <From 1994 models> CUD to 1993 models> Floating caliper.60) 38.61) 34.s) FWD with ABS Tandem type (with level sensor) 26.0) + 230 (9.0) 7.79) / 15.43 Hatchback 3.75-4.45 (704-775) 0.4 (1) or 26.0) + 230 (9.9 (1 ‘/.0) 18 (.96 FRONT BRAKES REAR BRAKES ’ Items FWD Floating caliper.) Pad thickness mm (in.5 (. 1 -piston.)] FWD with ABS Vacuum type. tandem 180 (7.%)] PROPORTIONING VALVE Items Split point MPa (psi) Decompression ratio Convertible 4.D. 1 -pis. tandem 203 (8.9 (1 ‘/. 8 ) Type Disc effective dia.61) 38.) Disc thickness m m (in.1 (1 ‘12) Automatic ( 9 .9 (1 1/.95-5.6) GENERAL SPECIFICATIONS MASTER CYLINDER Items Type I. 2-piston.35-2 SPECIFICATIONS SERVICE BRAKES .D.0) 7.1 (1 ‘12) Automatic 2 5 0 20 (.) Wheel cylinder I.Specifications i FWD without ABS Tandem type (with level sensor) 25.0 [at 261 N (58 lb.0) or 203 (8. mm (in.) Boosting ratio [Brake pedal depressing force] FWD without ABS Vacuum type.0 [at 261 N (58 Ibs.71) / 15.0) + 230 (9. tandem 203 (8.5 (. ventilated disc ventilated disc (MR68X) ton.4) 20 l. mm (in.Rigid caliper.)] AWD Vacuum type.) Clearance adiustment WHEEL SPEED SENSOR <ABS> Items Rotor teeth Speed sensor Front wheel side Rear wheel side Specifications 47 47 Magnet coil type TSB Revision .0 [at 247 N (54 Ibs.) BRAKE BOOSTER Items Type Effective dia. of power cylinder mm (in. ventilated disc (MR45V) 228 (9.0) 6.

(in.) Speed sensor’s internal resistance CABS> kQ Solenoid valve (HU) resistance R <Up to 1995 models> Hydraulic unit solenoid valve inte nal resistance R G-sensor output voltage V clearance cAWD> m m (in.SERVICE BRAKES .) Rear disc thickness mm.) Clearance between the speed pal iece and the toothed rotor 4WD> Left/right proportioning valve out difference MPa (psi) Front disc run-out mm (in.) to master cylinder c Disc brake drag force (tangenti mounting bolts) N (Ibs. \ id .Specifications SERVICE SPECIFICATIONS Items Front disc thickness mm (in.) .

08 (.35-4 Items SERVICE BRAKES .002) 0.o (. or inside of inner shim A. inner shim B. NLGI No.) LUBRICANTS Items Brake fluid Inside of shim A and shim B. and outer shim Guide pin and lock pin sliding part Piston boot inner surface Pin boot inner surface Specified lubricant Conforming to DOT3 or DOT4 Brake grease SAE J310.002) 0.0031) or less FWD AWD 0.) Front hub end play mm (in.031) I Rear brake lining thickness mm (in.04) 1 169. 1 Repair kit grease SEALANTS Items Specified sealant 3M ATD Part No.8 (.7) 0.ll) 1 168.05 (.) 1 Rear drum inside diameter mm (in.) Rear hub end play mm (in.05 (.TSB Revision .Specifications / Special Tools Standard value 2.8 (. 8663 or equivalent I Thread part fitting SPECIAL TOOLS Tool Tool number and name MB990964 Brake tool set 4: MB990520 Disc brake piston expander MB991 356 4BS check harless MB991341C MB991 356 Supersession General tool \ d’ I I Application Compressing disc brake piston I service For checking of ABS MB991 341 Scan tool (Multi-Use Tester <MUT>) Up to 1993 models For checking of ABS I.0 (6.) Rear disc run-out mm (in.0 (6.6) Limit 1 .

Special Tools / Troubleshootincl refer to GROUP For checking of ABS check harness TROUBLESHOOTING Symptom Vehicle pulls to one side when brakes are applied Probable cause Grease or oil on pad or lining surface Inadequate contact of pad Auto ad.SERVICE BRAKES .juster malfunction Insufficient braking Dower Low or deteriorated brake fluid Air in brake system Overheated brake rotor due to dragging of pad Grease or oil on pad surface Inadequate contact of pad Brake booster malfunction Auto adjuster malfunction Remedy Replace Correct Adjust Add or refill Bleed air from system Correct Replace Correct Correct Adjust Correct Replace c/ Clogged brake line 1 Proportioning valve malfunction TSB Revision .

SERVICE BRAKES - Troubleshootina

Insufficient parking brake function Excessive parking brake lever stroke

the parking brake lever stroke ck the parking brake cable rout-

Scraping or grinding noise when brakes are applied

when brakes are ap-

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SERVICE BRAKES
Symptom Squealing noise when brakes are not applied

- Troubleshooting / Anti-lock Braking System Troubleshooting

35-7

Probable cause Disc brakes - rusted, stuck Loose or extra brake parts Improper positioning of pads in caliper

Remedy Lubricate or replace Retighten

Correct Correct Replace

Improper installation of support mounting to caliper body Poor return of brake booster or master cylinder

Incorrect adjustment of brake pedal or booster Adjust push-rod setting Groaning, clicking or rattling noise when brakes are not applied Stones or foreign material trapped inside wheel covers Loose wheel nuts Disc brakes -failure of anti-rattle shim Disc brakes - loose installation bolt Remove stones, etc. Retighten Replace Retighten

Incorrect adjustment of brake pedal or booster Adjust push-rod setting.

ANTI-LOCK BRAKING SYSTEM TROUBLESHOOTING
<Up to 1995 models> PARTICULAR PHENOMENA OF THE ANTI-LOCK BRAKING SYSTEM
Models equipped with the anti-lock braking system (ABS) may exhibit one or more of the following phenomena from time to time, but none of these are abnormal.’ (1) A pulsing feeling in the brake pedal, or vibration of the body or the steering wheel, when the anti-lock braking system is activated by sudden braking or by braking on a slippery road surface. Actually, this phenomenon is an indication that the anti-lock braking system is functioning normally. (2) When the vehicle speed reaches approximately 6 km/h (4 mph) after the engine is started and the vehicle starts off (for the first time), a whining motor noise may be heard from the engine compartment if the vehicle is traveling in a quiet place, but this noise is simply the result of a self-check being made of the anti-lock braking system operation. For problems in the electrical system, the on-board diagnostic is built into the electronic control unit (ECU) causing the ABS warning light to illuminate as a warning to the driver. In this instance, checks can be made by using the multi-use tester and oscilloscope. Problems in the hydraulic system (poor, braking, etc.) can be located in the same way as for ordinary brakes. There is, however, the necessity to check to determine whether the problem is related to ordinary brake components or to the components related to the ABS. To make this check, use the scan tool.

HOW TO USE THE TROUBLESHOOTING FLOW CHART
(1) Using the flow chart, check the ABS warning light light-up sequence. Read the diagnosis codes and check the condition of braking operation. (2) Following the check chart listed in the remedy column, perform the checks. There are [Explanation] and [Hint] in each check chart. Refer to them when troubleshooting. NOTE ECU: Electronic control unit HU: Hydraulic unit /

TROUBLESHOOTING METHODS
I‘ L Problems related to the anti-lock braking system (ABS) can be classified into two general categories: problems in the electrical system and those in the j hydraulic system. TSB Revision

35-8

SERVICE BRAKES - Anti-lock Braking System Troubleshooting (ABS-FWD)
(2) With the ignition key in the “START” position, power to the ABS ECU is interrupted and the ABS warning light remains lit because the valve relay is OFF. (3) When the ignition key is returned from the “START’ position to the “ON” position, the ABS warning light flashes twice in about one second (during which the valve relay self check is made again) and then goes out.
1 sec. ABS warning light ONI‘ OFF ignition key
00002166

TROUBLESHOOTING

Confirm condition in the following way and diagnosis accordingly. Does the ABS warning light illuminate as described below up to the time the engine starts? (1) When the ignition key is turned to the “ON” position, the ABS ECU causes the ABS warning light to flash twice in about one second (during which the valve relay self check is made) and then causes it to go out. -

1 sec. / I 1 I c

- CONTINUED ON NEXT PAGE 1

Yes

No

warntng light drive cir-

1 TSB Revision

I

SERVICE BRAKES - Anti-lock Braking Svstem Troubleshooting
No. 4 Trouble condition After the ignition key is turned to the “ON” position, it blinks once and then illuminates when it is turned to the “START’ position. When the key is returned to the “ON” position, the light blinks again. (Blinking with the ignition key in the “ON” position is synchronized with operation noise of the valve relay.)
ABS light

Remedy Major causes Break in harness for ECU warning light Check, using flow drive circuit chart D (Refer to Malfunction of ECU p.3519.j

warning
ST Ignition ON key ACC, LOCK J-214AO593

1 CONTINUED FROM PREVIOUS=/

when starting to drive the car?

Trouble with the motor relay, solenoid valve [due to self test at start-up or malfunction of wheel speed sensor]

Is there one-sided braking, insufficient braking force or malfunction of ABS operation? Yes i Trouble condition One-sided braking lnsuff icient braking force Decline in ABS function

CONTINUED ON NEXT PAGE

Major causes
l l l l

Remedy Check HU operation and, if necessary, replace HU. If HU is normal, check structural parts for normal braking.

Hydraulic line in HU is clogged. Mechanical lock of HU solenoid valve Hydraulic line in HU is clogged. Malfunction in HU solenoid valve operation Insufficient wheel speed sensor output voltage (sensor malfunction, too large a gap between sensor rotor, missing rotor teeth). Malfunction of ABS ECU

ABS sometimes functions even when there is no sudden braking. (ABS operation vibration is transmitted.)

l

l

Check wheel speed sensor (Refer to P.3575.) and, if necessary, replace sensor, adjust gap or replace rotor. If tests indicate that there are no mechanical or electrical failures, replace the ECU.

TSB Revision

35-10

SERVICE BRAKES - Anti-lock Braking System Troubleshooting

/ CONTINUED FROM PREVIOUS PAGE /

After a test drive*, use on-board diagnostic to check (Refer to P.3520.). / No diagnostic trouble codes output and normal codes are displayed? I Yes

J

I
NOTE l : Drive at 19 mph or higher for more than 30 seconds. .

d

on-board diagnostic output terminals and the diagnosis check

intermittent or other trouble.

/ If trouble does not reappear 1 watch vehicle movements until it reappears. (Refer to P.35-11.)

1 All ABS functions are normal. (Nor are there stored memory of past diagnostic trouble code.)

I

d
Caution 1. When carrying out inspection of the ABS-ECU terminal voltage and resistance, the special tool (MB991356)
should be used.

Connector terminal No. layout for troubleshooting

2.
Terminal No. layout shown on the special tool connector

Because the ABS-ECU connector terminal No. layout for troubleshooting is different from the terminal No. layout shown on the special tool connector, when using the special tool for inspecting, take the readings from the special tool terminal Nos.
Example

00002535

r~ ~
18

ABS-ECU connector terminal No. for troubleshooting

Terminal No. shown on the special tool connector 1 I

1TSB Revision

SERVICE BRAKES - Anti-lock Braking System Troubleshooting METHOD OF CLEARING DIAGNOSTIC TROlJtiLE CODE MEMORY
Caution ii l When servicing is finished, clear the diagnostic trouble code memory. Trouble codes cannot be cleared from memory when the ABS ECU system is in fail safe. Proceed to diagnosis and repair. (1) Clear memory using scan tool. (No. 7 “DIAG. ERASE” in the actuator test is selected to erase the diagnostic trouble code.) (2) After clearing, recheck the diagnostic trouble codes, and check that memory is cleared.

35-11

ACTUATOR TEST FUNCTION
The actuator can be forcibly driven in the following way by using the scan tool. NOTE l The actuator test cannot be carried out when the ABS ECU System is in fail safe. l When using forced drive using the scan tool, the vehicle must be stopped. l During forced drive using the scan tool, forced drive operation is stopped when any wheel speed reaches 10 km/h (6 mph).

Actuator test specifications

I I
No.
02 03

Scan tool display FR VALVE A FL VALVE A REAR VALVE A FR VALVE M

Drive solenoid valve and motor Not used

Drive pattern

/ LJ

04

05

FL VALVE M

Soleinoid valve and pump motor for each HU car- zz/;responding than- va,ve nel. <Manual pattern> Pump motor Start of forced drive End of forced drive Z14A0508

06

REAR VALVE M

i

TSB Revision

35-12
A

SERVICE BRAKES - Anti-lock Braking System Troubleshooting

ABS warning light does not light at all.

[Explanation] When it does not light up at all, there is a strong possibility that there is trouble with ABS warning light or with power to the light.

[Hint] If other warning lights do not light up either, fuse is probably blown.
IGNITION SWITCH(IG2) 00 d 2 -____-________ J/B 0 IGNIT 3N SWITC (!Gl) 3 ::

ABS POWER RELAY (~gwTls1994)

I

$;$gCU

5g IN
.
29

= SUPPLY (1995 MODELS)

G-R

COMBINATiON

.0_- _-_- __-- -1 ylTT%aq 1 2; -7 SOLE NO11 VALV E

Ll

f . I
> w A .> k! s
.127 .

I

G-R

! = 3 ‘3

41 FL 1
1 cs 1 iI 7 ?+
1 9

* %

ABS ECU [ 11213/415 161718 /9~10~11~:2~13~14~15~16137l~E~ ~'9~al21~2~31~125~6~~2~~Q~30~1~2~3~~~35~

KXI-kKK-R35Rl-I1

1 TSB Revision

SERVICE BRAKES - Anti-lock Braking System Troubleshooting
With the ignition key in the “ON” position, No do other warning lights (except door-ajar warning light, seat belt warning light) illu- I---minate? / Yes Remove the combination meter, and check with the ignition key “ON”. i No Does voltage between harness connector terminal No. 14 and ground indicate battery positive voltage? I Check fuse No. 11. If it is blown, correct the cause of the blown fuse and then replace the fuse.

35-13

l

Yes

I--

1
is broken. Turn the ignition switch OFF and check.1 I Is the ABS warning light normal? for burned bulb.)
+

* ABS warning light bulb burned.

/

Is there continuity between combiination meter No. 58 and No. 59 terminals? Yes

/ No

-- * 1 Faulty combination meter

I

I

1

c Repair or replace combination meter.

r

I

Connect connectors firmly. (Check for pins pulled out or bent, and repair as needed.)

drive circuits. Check both circuits.

1 TSB Revision

I

35-14

SERVICE BRAKES - Anti-lock Braking System Troubleshooting

/ Remove the ECU connector and check. /

Repair harness. connector terminal No. 25 and ground the ignition key is in the “ON” position?

ABS ECU malfun

Replace ABS ECU.

I

[ Check valve relay.

Remove valve relay and check.

Replace valve relay.

Install the valve relay, remove the HU connector and check.

I

Yes

Does positive .voltage between the HU K-**i;;E3]4 Repair harness. harness connector termrnal No. 8 and ground rndrcate battery positive voltage while the ignition key is in the “ON” posiYes t Is there continuity between HU harness connector terminal No. 9 and ground? Broken harness wire between HU and ground Repair harness.

Replace HU. connector terminals No. 8 and No. 9? Yes .I Connector not connected securely. Replace connector.

1 Revision TSB

I

SERVICE BRAKES - Anti-lock Braking System Troubleshooting
B ABS warning light stays on when the ignition key is in the “ON” position.

35-I 5

[Explanation] This is the symptom when the ABS ECU does not power up due to broken ECU power circuit, etc., when the fail safe function operates and isolates the system or when the warning light drive circuit is short circuited.

[Hint] Check the on-board diagnostic output and if there is no output voltage or if the scan tool and ABS ECU cannot communicate, there is a good possibility that power is not flowing to the ECU. Caution l If the diagnostic trouble code is output, the system can be in the fail safe mode. In such a case, erase the diagnostic trouble code and then restart the engine to check if the system is currently in a fault condition.

EYWPbE

IGNiTlOW SWITCti(IG1)

~ No Is there on-board diagnostic

output? (Is there communication with scan tool?) Yes

On vehicles produced up to Oct. 1994, refer to P.35-16. On vehicles produced from Nov. 1994, refer to P.35-17. * Check, using the diagnostic trouble code check chart (Refer to P.3521.).

No

Yes

t No Does the ABS warning light re- - Short in ECU transistor main illuminated even with the ECU connector disconnected? I I Yes

86 ,,87 t --I ,,30

I

Does the ABS warning light remain illuminated even with the HU connector disconnected? Yes

1 85 87a'lALVE RELAY

lNo

No

~n~oflZ!h!ZZrr~~o~~ I

j

+,

t

tween HU or ECU and ABS
warning light

* Repair harness or replace combination meter.

KX35-AK-R3513-K

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35-16

SERVICE BRAKES - Anti-lock Braking System Troubleshooting

<Models produced up to Oct. 1994>
CONTINUED FROM PREVIOUS PAGE
:GNI:‘ION SWITCH (lG2)

Can other electronic control systems communicate with scan tool?

No

c Scan tool related malfunction. Repair and recheck.

* Correct cause of blown Yes
ABS POWFR RELAY

Disconnect ECU connector and check harness connector
ABS ECU I 18

Is there continuity between body harness terminals No. 9 and No. 34, and ground? Yes

No

-7

x2 RI!’ 1-1 -1 z2 EZ pg$q r;‘
KX35-RK-R3514-W

NOTE x::1994 -0061.5. :2:ur, to 1993 rn30815.

Is there continuity between body harness connector terminals No. 23 and No. 24, and diagnosis inspection terminals No.4&No.lOorNo.7&No. 8?

I

Repair harness. Harness wire between diagnosis inspection terminal and ABS ECU is broken.

Malfunction of ABS ECU

1

Yes

1

1 Repair harness. Replace ABS ECU.

1 TSB Revision

I

SERVICE BRAKES - Anti-lock Braking System Troubleshooting
<Models produced from Nov. 1994>
CONTINUED FROM PREVIOUS PAGE
IGNITION SWITCH (IG2) I

35-17

i

m d

2

J’B @ IOA

Can other electronic control systems communicate with scan tool?

No

* Scan tool related malfunction. Repair and recheck.

_I
B

2

Correct cause of blown fuse and replace fuse. Disconnect ECU connector and check harness connector

. . . . ‘: No pizfy ~~~~
ABS ECU

Yes Is there continuity between body harness terminals No. 9

1 bodv harness connector termi1 ry7rNT;d No 24-and diagnosis inspection terminals Yes i 1 Repair harness. t ) Malfunction of ABS ECU
KK35-AK-R3315-N

Replace ABS ECU.

TSB Revision

35-18
C

SERVICE BRAKES - Anti-lock Braking System Troubleshooting

ABS warning light does not illuminate when the ignition key is in the “START” position.

[Explanation]

The ABS ECU uses the IGz power source which is turned off in the “START” position. The ABS warning light uses the IG, power source which is not turned off even in the “START” position. Con-

sequently, in the “START” position power is off and the ECU turns the valve relay OFF. If the warning light does not illuminate at this time, there is trouble in the warning light circuit on the valve relay side.

;yWx;B E !a

IGNiTlON SWITCH(IG1)

Remove the No. 3 fuse from the junction box to turn off power to the ABS-ECU. Disconnect the hydraulic unit connector (A-64) and the ABS valve relay connector (A-65). Inspect the harness side of both connectors for damage to the terminal pins. Repair terminal pins as needed.

- No With the ignition key in the “ON” position, does voltage between body connector terminal No. 8 and ground indicate the battery positive voltage? Yes t Is there continuity between body connector terminal No. 9 and ground? , Yes i
86 B? T ,\30 _ --I 85 4, B7a;gw;p 1

- Harness wire between HU and warning light is broken.

No

+ Broken line between HU and body ground

1; I

A

Is there continuity between HU connector terminal No. 8 and terminal No. 9? Yes

$

No

- Valve relay malfunction or break in HU harness wire

1 I

t Remove the valve relay. Is there continuity between terminal No. 87a and No. 30? Yes t HU harness malfunction

1

Replace HU.

KXB-AK-R35134

NOTE When performing the check marked *, note polarity of the diode (refer to the circuit diagram).

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SERVICE BRAKES - Anti-lock Braking System Troubleshooting

35-19

When power flows, the ABS ECU turns on the warning light for approximately 1 sec. while it performs a valve relay test. If there is a break in the

harness between the ECU and the warning light, the light illuminates only when the valve relay is off in the valve relay test, etc.

IGNITION SWITCH(lG1) j: w -TJ/B

Disconnect the hydraulic unit connector (A-64) and the ABSECU connector (E-12). Inspect the harness’ side of both connectors for damage to individual terminal pins. Repair terminal pins as needed.

In the ignition key “ON” position, does voltage between terminal No. 25 and ground indicate battery positive voltage? Yes

No
i

t [Malfunction of ABS ECU

Replace ABS ECU.

ABS-ECU

TSB Revision I-- ~~~

35-20

SERVICE BRAKES - Anti-lock Braking System Troubleshooting CHECK USING ON-BOARD DIAGNOSTIC When using the scan tool [Multi-use tester (MUT) <Up
to 1993 models> or MUT-II <All models>] (1) With the ignition switch OFF, connect the scan tool. When connecting the scan tool (MUT-II) to a 1993 model vehicle, use the adapter harness supplied together. Caution Turn off the ignition switch beforehand whenever the scan tool is connected or disconnected. Turn the ignition ON and select the ABS system. (The ABS warning light lights up, it goes into the scan tool mode. In the scan tool mode, ABS does not function.) If it does not go into the scan tool mode, check the ECU power circuit and the harness between the ECU and diagnostic output terminals. (2) Read the on-board diagnostic output codes from the ECU memory. (3) Clear the diagnostic trouble codes once from memory. (Refer to P.3511.) If the memory cannot be cleared, the ECU is currently detecting the trouble and the ABS ECU is in fail safe. If it can be cleared, the trouble is either temporary or appears only when driving. (4) When the diagnostic trouble codes cannot be cleared, or when the ABS ECU goes into fail safe during another test drive and diagnostic trouble codes are output, check according to diagnostic trouble code check charts (E-l -E-6).

When using the MUT

khb using th/e MUTill

\Z12FOO57

<From 1994 models>

i2OFO159

I
Z2OFOl64 00002160

DIAGNOSTIC TROUBLE CODE CHART

/ VEH. SPD. SNSR. STOP LAMP SW

E-2 E-3

1 P.3521 P.3523

1 52 55

MOTOR RELAY CONT. UNIT

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SERVICE BRAKES - Anti-lock Braking System Troubleshooting

35-21
I

i

I
I

E-l

When the following diagnostic trouble codes are displayed “11 FL SNSR. OPEN” “12 FR SNSR. OPEN” “13 RL SNSR. OPEN” “14 RR SNSR. OPEN” [Hint]

I

Ld

[Explanation]

The ABS ECU detects breaks in the wheel speed sensor wire. This trouble code is output if the wheel speed sensor signal is not input (or short circuited) or if its output is low when starting to drive or while driving.

In addition to a broken wire/short circuit in the wheel speed sensor, also check whether the sensor gap is too large, sensor harness wire is broken, or sensor harness and body connector are not properly connetted.

1 E-2

When diagnostic trouble code “15 VEH. SPD. SNSR.” is displayed

I

[Explanation]

This trouble code is output when there is an abnormality (other than broken wire or short circuit) in any of the wheel speed sensor output signals while driving.
[Hint]

The following can be considered as the cause of the wheel speed sensor output abnormality. l Distortion of rotor, teeth missing Low frequency noise interference when sensor l harness wire is broken l Noise interference in sensor signal Sensor output signal is below the standard vall ue or amplitude modulation is over the standard / value. Using an oscilloscope to measure the L; wave shape of the wheel speed sensor output signal is very effective. l Broken sensor harness 0 Poor connection of connector

NOTE (1) If contact is poor, check the sensor cable by bending and lightly stretching it. (2) Except for the case where a fault condition exists in the system, but the inspection results are normal; if an abnormality cannot be found in the sensor circuit displayed as abnormal, erase the diagnostic trouble code and turn the ignition switch to OFF once, and then test-drive* again. If the same diagnostic trouble code is output, replace the ABS ECU. If the trouble does not occur anymore, the problem is likely to be with the ABS ECU. (If the trouble is in the speed sensor circuit, but is difficult to recreate, it will recur even after the ABS ECU has been replaced.) (3) *: Drive at 19 mph or higher for more than 30 seconds.

SPEED SENSOR

ASS ECU

1

/ Ld

DATA LlNK CONNECTOR

TSB Revision

35-22

SERVICE BRAKES - Anti-lock Braking System Troubleshooting
NOTE When checking with an oscilloscope, first measure voltage variations in the wheel speed sensor output. (Refer to P.35-75.) sensor * Replace wheel speed sensor

Check flow connected with wheel speed sensor

sr
Is the resistance value of the wheel speed Yes

No Is the resistance value with the ECU con- ----+ Harness wire for wheel speed nectar normal? sensor circuit is broken Standard value: Front 0.8-1.2 Wz Rear 0.6-0.8 kQ Yes

Repair harness.

1

Is the standard value for the gap between the wheel speed sensor and rotor within the range? Standard value: Front 0.3-0.9 mm (.012-.035 in.) Rear 0.2-0.7 mm (.008-.028 in.) Yes t Is the wheel speed sensor rotor normal, with no missing or damaged teeth? Yes Check the output of each wheel speed sensor with an oscilloscope, including the waveform. (Refer to measurement of wheel speed sensor output voltage variations on P.3575.) Is the output voltage for each wheel speed sensor over the standard value and is the waveform normal? Yes t If the above checks are normal, there is a malfunction of ABS ECU when this diagnostic trouble code re-occurs often. No

- Adjust the gap between the

* Replace rotor that has missing or damaged teeth.

No

Recheck if below the standard value or if the sensor has a poor waveform. Replace sensor or rotor.

- Replace the ABS ECU and check that the trouble code does not reoccur.

1 TSB Revision

SERVICE BRAKES - Anti-lock Braking System Troubleshooting
E-3 L When diagnostic trouble code “22 STOP LAMP SW” is displayed [Hint]

35-23

[Explanation]

The ABS ECU outputs this diagnostic trouble code in the following cases. l Stop light switch may remain on for more than 15 minutes without ABS operation. l The harness wire for the stop light switch may be open.
Do the stop lights light up and go out normally?

If the stop light operates normal, the harness for the stop light switch input circuit is broken or there is a malfunction in the ABS ECU.

/ Disconnect the ABS ECU con- / nectar and inspect at the harness side connector.

Repair harness.

I

Malfunction of ABS ECU /

I

Yes Replace ABS ECU. 1

I/

<HatchtIack>

<ConventiDle>

STOP LIGHT

ABS ECU

NOTE
Kx33-u-*soc-I

w
WITH AUTO-CRUISE CONTRO SYSTEH >ROL SYSTEM Y,THO"T AUTO-CRUISE CO NC Kx3s-u-!asIo-” 00002529

xI:“EHICLES

t2:YEHlCLES

/ TSB Revision

35-24
E-4

SERVICE BRAKES - Anti-lock Braking System Troubleshooting
When diagnostic trouble codes “41 FL SOL. VALVE“, “42 FR SOL. VALVE” or “43 REAR SOL. V.” are displayed.

[Explanation]

The ABS ECU normally monitors the solenoid valve drive circuit. If no current flows in the solenoid even if the ECU turns the solenoid ON or if it continues to flow even

when turned OFF, the ECU determines the solenoid coil wire is broken/short-circuited or the harness is broken/short-circuited, and then these diagnostic trouble codes are output.

IGR:ITION SWiTCy(IG1)

+ Is the resistance solenoid valve within the ranae of the standard values? Standard value: 1.0-l .3 Q

Replace HU.

+I
I

Is the solenoid valve resistance value within the range of the standard values when measured at the ECU connector? Standard value: 1.0-l .3Q Yes
, G-R $l G-R ]

No

c

The harness wire for the solenoid valve circuit whose resistance value is outside the range of the standard value is broken or short circuited.

SOLENOID

I I

/ Malfunction of ABS ECU

7 Replace ABS ECU.

ABS ECU

Ll 121 3 14 15 1617 (6 19 jlO~l1~12~13/i4/15~16~17~16~ ~19~20~1e2~23~426i26~7~6~~30~1~2l~~~~5~ Iu(35-AK-R3512-2

TSB Revision

SERVICE BRAKES - Anti-lock Braking System Troubleshooting
E-5 When diagnostic trouble code “51 VALVE RELAY” is displayed

35-25

[Explanation]
When the ignition switch is turned ON, the ABS ECU switches the valve relay OFF and ON for an initial check, compares the voltage of the signal to the valve relay and valve power monitor line voltage to check whether the valve relay operation is normal. In addition, normally it monitors whether
SE L!L IGNITION

or not there is power in the valve power monitor line since the valve relay is normally ON. Then, if the supply of power to the valve power monitor line is interrupted, this diagnostic trouble code will be output.

Remove and check the valve
SWITOH(IG1)

relay.

:.I 0 d 5l ;’ oi cjl 0 2--?. B3 3 Dz c:1 1227 52 P

8- 8f: 4

t When the valve relay is checked, are the following conditions found? No. 85-No. 86: Resistance value 60-120 Q No. 30-No. 87a: Continuity No. 30-No. 87: No continuity When battery positive voltage is applied between terminals No. 86 and No. 85. No. 30-No. 87: Continuity No. 30-No. 87a: No continuity Yes i Install the valve relay and remove the HU connector. I i No 1With the ignition -“ON”,

+/ HU power harness wire is 1

Is there continuity between HU No. 8 and No. 7 terminals?
3 e -I ‘-L 5 8 7a II I8 1 -__-_---- ----------- (‘+ ----- 1# I p!iiazq$: __________________--. T1

1 Yes

Faulty harness in HU I

Yes Connect the HU harness and remove the ECU connector.

P

i

P.

i1
B 22 .;
I

Yes t No Is there continuitv between 1 harness side connector terminal No. 22 and ground? Yes

Repair harness. -+I Malfunction of harness 1 !betxtn H U ; ABS!

ABS

ECU

ABS ECU malfunction

I

Repair harness. Replace ABS ECU.

I

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35-26
E-6

SERVICE. BRAKES - Anti-lock Braking System Troubleshooting
When diagnostic trouble code “52 MOTOR RELAY” is displayed
l

[Explanation]
The ABS ECU outputs this diagnostic trouble code for the motor relay and motor in the following cases. l When the motor relay does not function l When there is trouble with the motor itself and it does not revolve l When the motor ground line is disconnected and the motor does not revolve
FUGIBLE LINK @ I

When the motor continues to revolve

[Hint]
If there is motor operation noise during scan tool forced drive mode, there is a broken or short circuited motor monitor wire.

Does the motor make a noise
during scan tool forced drive mode? No + Remove the motor relay.

Yes

/I

i - No Remove the motor relay and -----+ Motor relay malfunction check resistance values. No. 8%No. 86: Resistance I value 72-88 Q Replace motor relay. No. 30-No. 87: No continuity Battery positive voltage is applied between terminals No. 85

and No. 86.
No. 30-No. 87: Continuitv Is pump motor ground connetted normally? Yes Install motor relay and remove HU connector. I Connect ground wire.

Connect the HU connector and remove the ECU connector Is resistance between body .%-..connector terminal No. 2 and No. 26: 72-88 Q?

1

i Yes 1 ABS ECU malfunction

4 Replace ABS ECU.

TSB Revision

SERVICE BRAKES - Anti-lock Braking Svstem Troubleshootina TROUBLESHOOTING (ABS-AWD)
Confirm condition in the following way and diagnosis accordingly. Ioes the ABS warning light illuminate as described lelow up to the time the engine starts? :l) When the ignition key is turned to the “ON” position, the ABS ECU causes the ABS warning light to flash four times in about one second (during which the valve relay self check is made) and then causes it to go out.

35-27

(2) With the ignition key in the “START” position, power to the ABS ECU is interrupted and the ABS warning light remains lit because the valve relay is OFF. (3) When the ignition key is returned from the “START” position to the “ON” position, the ABS warning light flashes four times in about one second (during which the valve relay self check is made again) and then goes out.

214AO594 00002165

7

No. Trouble condition 1 ABS warning light does not light up at all. ABS warning
light

Major causes
l l

Remedy

ON
OFF -

ABS warning light bulb is burnt out. Check, using flow Open in ABS warning light electrical chart A (Refer to circuit (check for blown fuse) P.3531.)

Ignition key
214A0690

2

When the ignition key is turned to the “ON” position, it remains lighted.
ABS ON

l l l

Fail safe is functioning due to ECU Check, using flow self diagnosis. chat-l B (Refer to

Short in ECU warning light drive cir- P.35-34.) cuit
Malfunction of ECU

warning light Ignition key 3

OFF -I-

214A0597

Does not illuminate when ignition key is in
“START’ position. ABS warning ON light OFF
Ignition W ACC, LO:: --k5

l l l

Check, using flow Malfunction of valve relay Break in harness between ABS chart C (Refer to

warning light and HU
Break in harness between HU and body ground

P.35-37.)

1 TSB Revision

35-28
No.
4

SERVICE BRAKES - Anti-lock Braking System Troubleshooting
Major causes
l l

Trouble condition After the ignition key is turned to the “ON” position, it blinks once and then illuminates when it is turned to the “START’ position. When the key is returned to the “ON” position, the light blinks again. (Blinking with the ignition key in the “ON” position is synchronized with operation noise of the valve relay.) ABS warning
light

Remedy Check, using flow chart D (Refer to P.3538.) .i

Break in harness for ECU warning light drive circuit Malfunction of ECU

Ignition key ACC, LO?L14A0693

j CONTINUED FROM PREVIOUS PAGE Does the ABS warni when starting to drive * Trouble with the motor relay, solenoid valve [due to self test at start-up or malfunction of wheel speed sensor] /No 1 + 4 No Is there one-sided braking, insufficient CONTINUED ON NEXT PAGE braking force or malfunction of ABS operation? Yes

!
Trouble condition

Yes Major causes
l

Remedy Check HU operation and, if necessary, replace HU. If HU is normal, check structural parts for normal braking.

d

One-sided braking lnsuff icient braking force Decline in ABS function

0
l l

Hydraulic line in HU is clogged. Mechanical lock of HU solenoid valve Hydraulic line in HU is clogged. Malfunction in HU solenoid valve operation

ABS sometimes functions even when there is no sudden braking. (ABS operation vibration is transmitted.)

l

l

Insufficient wheel speed sensor out- Check wheel speed sensor put voltage (sensor malfunction, too (Refer to P.35-60.) and, if neclarge a gap between sensor rotor, essary, replace sensor, adjust missing rotor teeth) gap or replace rotor. Malfunction of ABS ECU If tests indicate that there are no mechanical or electrical failures, replace the ECU.

TSB Revision

SERVICE BRAKES - Anti-lock Braking System Troubleshooting
1 CONTINUED FROM PREVIOUS=]

35-29

/ LA

After a test drive, use on-board tic to check (Refer to P.35-39.). 1 t No diagnostic trouble codes out normal codes are displayed? Yes No No No on-board diagnostic output + Check and repair the harness Diagnostic trouble codes are OUtpUt bebeen the ABS ECU serial/ 1 on-board diagnostic output terminals and the diagnosis check connector. Referring to the diagnostic trouble code check chart E-l-E-7, make the diagnostic trouble code reoccur to discover the main cause of intermittent or other trouble.

I

1
t 1 All ABS functions are normal. (Nor are there stored memory of past diagnostic trouble code.) If trouble does not reappear, watch vehicle movements until it reappears. (Refer to P.35-30.)

Connector terminal No. layout for troubleshooting

1

Terminal No. layout shown on the special tool connector

Caution 1. When carrying out inspection of the ABS-ECU terminal voltage and resistance, the special tool (MBgg1356) should be used. 2. Because the ABS-ECU connector terminal No. layout for troubleshooting is different from the terminal No. layout shown on the special tool connector, when using the special tool for inspecting, take the readings
from the special tool terminal Nos.

1 OO(802535

Example
ABS-ECU connector terminal No. for troubleshooting 18 Terminal No. shown on the special tool connector 1

TSB Revision

35-30

SERVICE BRAKES - Anti-lock Braking System Troubleshooting ACTUATOR TEST FUNCTION
The actuator can be forcibly driven in the following way by using the scan tool. NOTE l The actuator test cannot be carried out when the ABS ECU system is in fail safe mode. l When using forced drive using the scan tool, the vehicle must be stopped. l During forced drive using the scan tool, forced drive operation is stopped when any wheel speed reaches 10 km/h (6 mph).

METHOD OF CLEARING DIAGNOSTIC TROUBLE CODE MEMORY
Caution When servicing is finished, clear the diagl nostic trouble code memory Diagnostic trouble codes cannot be cleared from memory when the ABS-ECU system is in fail safe mode. Proceed to diagnosis and repair. (1) Clear memory using scan tool. (No. 7 “DIAG. ERASE” in the actuator test is selected to erase the diagnostic trouble code.) (2) After clearing, recheck the diagnostic trouble codes, and check that memory is cleared. Actuator test specifications No.
01
02 04

Scan tool display FR VALVE A FL VALVE A FR VALVE M

Drive solenoid valve and motor Not used

Drive pattern

valve Solenoid and pump motor for each HU carresponding channel. <Manual pattern>

valve solenoid Lfg3J +/-d e c r e a s e I44 ’ rmsf Pump motor

I
3s : 3s IrnS I

05

FL VALVE M

O N
OFF

I Start of forced drive

End of forced drive
214AO588

TSB Revision

SERVICE BRAKES - Anti-lock Braking System Troubleshooting

35-31

A

ABS warning light does not light at all.

[Explanation]
When it does not light up at all, there is a strong possibility that there is trouble with ABS warning light or with power to the light. If other. warning lights do not light up either, fuse is probably blown.
IGNITION SWITCH(IG2) FUSIBLE LINK0 IGNI' TIO. N SWITi 3 ( IGl) 3

I

I

J/B

r

t3 2 --_---__- ____. 7 [ 0 - i - - G i i 6
: 2 c5 I I 6 : E2 5 c
0

m d

1234 5678 BE!

i%Efi"" %R RELAY RELAY (KoEgg4) (B%E5LS)

G-R

L

HU I

w 1_5_?----------~2 I I

II: “8 E Fp;om EL f

: n ,,E 19 -x- COMBINATION METER c9 AL 51 3 : 9

P

x 5--Y 3_____:

3 ‘7

1

I 1

I I I I

I

J

~ I "
2 i-4 -- ~~ 6--1:11 paq ': :: G
12 3s 17 (1: A 2‘5 * F GND v GND v I J

______.___

> :I

::m I 1

-1

,;;I& [ / Ill

-PP
i
ABS ECU

Y Y

i

I L 1(x35-AK-R350*-*

TSB Revision

Faulty combination meter Repair or replace combination meter. seat belt warning light) illuminate? Yes * The harness between the -1 1 Repair harness. 59 terminals? c ABS warning light bulb burned. 58 and No.Anti-lock Braking System Troubleshooting door-ajar warning light.) i Yes Is there continuity between combination meter No. Repair or replace combination meter 1 Yes Are instrument panel wiring harness and body wiring harness connected properly? drive circuits.35-32 SERVICE BRAKES . No (Check for burned bulb. TSB Revision . * Replace ABS warning light bulb. I t Turn the ignition switch OFF and check. Check both circuits.

connector terminals No. L.SERVICE BRAKES .[ I R e p lI a c e H U . i No [ Is valve relay normal? (Refer to P. 8 and ground indicate battery positive voltage while the ignition kev is in the “ON” position? Yes w 1 Broken harness wire between r 1 Repair harness. 1 Check valve relav. 9 and ground? Yes 1 1 Is there continuitv between HU harness % I1 H U m a l f u n c t i o n .No Does the voltage between ECU harness connector terminal No. I . Does voltage between the HU harness 1 No connector terminal No. 8 and No.3583.Anti-lock Brakina Svstem Troubleshooting Check ABS ECU. 9? L Connector not connected se. ABS warning light and HU 1 Repair harness.) I-* 1 Valve relay malfunction 1 Yes Install the valve relay: remove the HU conReplace valve relay. t Remove valve relay and check. 35-33 1 . 25 and ground indicate battery positive voltage while the ianition kev is in the “ON” oosition? ABS ECU malfunction Replace ABS ECU. t Broken wire between ABS warning light and ECU Repair harness. 1 1 I 1 TSB Revision . i Remove the ECU connector and check.r 1 Replace connector. +-. Is there continuity between HU harness connector terminal No. curely.

Caution l [Explanation] This is the symptom when the ABS ECU does not power up due to broken ECU power circuit..Anti-lock Braking System Troubleshooting ABS warning light stays on when the ignition key is in the “ON” position. erase the diagnostic trouble code and then restart the engine to check if the system is currently in a fault condition. iYWR"8 IGNIT!OPd SWITCti(IG1) Is there diagnosis output? (Is there communication with scan tool?) --------------O Yes I Does diagnostic trouble code output display normal codes? iNo Yes @WIW.NAT’ON 159 bpl 1 No Does the ABS warning light re. the system can be in the fail safe mode. there is a good possibility that power is not flowing to the ECU. __. when the fail safe function operates and isolates the system or when the warning light drive circuit is short circuited.I I e5 .. In such a case. etc. If the diagnostic trouble code is output. [Hint] Check the on-board diagnostic output and if there is no output voltage or if the scan tool and ABS ECU cannot communicate.main illuminated even with the yiizyzz HU connector disconnected? Yes /I 1 or ECU and ABS warning light I 87aVALVE RELAY I ___ -_ _____----------1 10 4m9 25 - I I KX35-AK-R35¶3-R TSB Revision .30 / 1 Does the ABS warning light re.------+ Short in ECU transistor main illuminated even with the ECU connector disconnected? 1 Yes Replace ECU.35-34 B SERVICE BRAKES .

and ground? Yes t 1213141 5/6~7(*~8/~0/Hj12113~14~15i16117/18 x1 RF ylgg@lgv Is there continuity between body harness connector terminals No.Anti-lock Braking System Troubleshooting <Models produced up to Oct. . Disconnect ECU connector / and check harness connector 1 ABS-ECU :B With the ignition key in the “ON” position.) Yes I I Replace power relay. 8? Yes Repair harness. 23 and No. 7 & No.2 nwae15 . NOTE r1:1994 moDel5.SERVICE BRAKES . 24. 10 or No. 1 Repair harness.Power relay malfunction (Refer to P. 9 and No.t Malfunction of ABS ECU i TSB Revision . does voltage between ECU connector terminal No. tm GND v v 23 24 a 12a 9 E R 34 i -21 ~~&CToR 4:2 lo:2 *:1 7:' u = t Is there continuity between body harness terminals No.3565. 3 normal? Yes -TN0 t No Is power relay normal? . 18 and ground indicate the battery positive voltage? Yes Harness wire between power relay and ECU is broken I / L Ti lx L lx i2 a I Repair harness. 1994> 35-35 KR”1” IGNITION SWITCH(iG21 Can other electronic control systems communicate with scan tool? c Yes is fuse No.Replace ABS ECU. 34. t2:LJo to 199. and diagnosis inspection terminals No. 4 & No.

and ground? Is there continuity between body harness connector terminals No. 1994> IGNITION SWiTCH(IG2) I J’B @ r-T-l 2 a . 23 and No. t Malfunction of ABS ECU 1-b Replace ABS ECU. T @I Ls: ABS ECU V DIODE Disconnect ECU connector and check harness connector 18 I Is there continuity between body harness terminals No. KX35-AR-R3516-N TSB Revision . 9 and No. 24.234 5678 El Can other electronic control systems communicate with scan tool? tion.L 9 1234 d Im 2 5678 . and diagnosis inspection terminals No. 7 & No. Repair and recheck.Anti-lock Braking System Troubleshooting <Models produced from Nov. 34.35-36 SERVICE BRAKES . 8? Yes Repair harness.

8 and terminal No. 3 fuse from the junction box to turn off power to the ABS-ECU. The ABS warning light uses the lG1 power source which is not turned off even in the “START” position. Replace HU. note polarity of the diode (refer to the circuit diagram). If the warning light does not illuminate at this time.Anti-lock Braking System -Troubleshooting 35-37 I / i Explanation] LJThe ABS ECU uses the IG2 power source which ( C ABS warning light does not illuminate when the ignition key is in the “START” position. L1: u I connector terminal No. in the “START” position. Repair terminal pins as needed. Inspect the harness side of both connectors for damage to the terminal pins. 17 30 7 G-R 11 G-R I--+-8-----1 I 1.SERVICE BRAKES . Disconnect the hydraulic unit connector (A-64) and the ABS valve relay connector (A-65). power is off and the ECU turns the valve relay OFF. is turned off in the “START” position. FUS LIN - IGNIT swm . Yes i HU harness malfunction 1 1 Replace valve relay.- IN 1Gl) - Remove the No. Consequently. 9? ii ______--_______. ABS ECU KK35-AK-R3513-N NOTE When performing the check marked *. TSB Revision . L and ground? SmJ -L 12. there is trouble in the warning light circuit on the valve relay side.

In the ignition key “ON” position. It illuminates in the “START” position and blinks once again when turned to the “ON” position. while it performs a valve relay test. If there is a break in the harness between the ECU and the warning light. [Explanation] When power flows. . Inspect the harness side of both connectors for damage to individual terminal pins. Repair terminal pins as needed. I A&3-ECU I 25 TSB Revision .35-38 D SERVICE BRAKES . etc. 25 and ground indicate battery positive voltage? fX&NAT’ON Malfunction of A& ECU I Yes Repair harness. IGNITION SWITCH(IG1) I J/B Disconnect the hydraulic unit connector (A-64) and the ABSECU connector (E-l 2).Anti-lock Braking System Troubleshooting ABS warning light blinks once after the ignition key is turned to the “ON” position. does voltage between terminal No. Replace ABS ECU. the ABS ECU turns on the warning light for approximately 1 sec. the light illuminates only when the valve relay is off in the valve relay test.

(3) Clear the diagnostic trouble codes once from memory. the trouble is either temporary or appears only when driving. ABS does not function. (4) When the diagnostic trouble codes cannot be cleared. check the ECU power circuit and the harness between the ECU and diagnostic output terminals.3512. use the adapter harness supplied together.SERVICE BRAKES . When connecting the scan tool (MUT-II) to a 1993 model vehicle. connect the scan tool. (The ABS warning light lights up. Caution Turn off the ignition switch beforehand whenever the scan tool is connected or disconnected. or when the ABS ECU goes into fail safe during another test drive and diagnostic trouble codes are output. the ECU is currently detecting the trouble and the ABS ECU is in fail safe.) If the memory cannot be cleared. If it can be cleared. Turn the ignition ON and select the ABS system. it goes into the scan tool mode. In the scan tool mode. (2) Read the on-board diagnostic output codes from the ECU memory.Anti-lock Braking System Troubleshooting When using the MUT 35-39 CHECK USING ON-BOARD DIAGNOSTIC When using the scan tool [Multi-use tester (MUT) <Up to 1993 models> or MUT-II <All models> (1) With the ignition switch OFF. check accordinn to diaanostic trouble code check charts (E-l -E-i). ‘Whk using t/he MUT-II harness / \ Z2OFO159 DIAGNOSTIC TROUBLE CODE CHART TSB Revision . (Refer to P.) If it does not go into the scan tool mode.

” is displayed I. but is difficult to recreate. 0 Poor connection of connector NOTE (1) If contact is poor. 1 E-2 I When diagnostic trouble code “15 VEH. [Hint] The following can be considered as the cause of the wheel speed sensor output abnormality. i I [Explanation] This diagnostic trouble code is output when there is an abnormality (other than broken wire or short circuit) in any of the wheel speed sensor output signals while driving. check the sensor cable by bending and lightly stretching it. OPEN” “12 FR SNSR. Using an oscilloscope to measure the wave shape of the wheel speed sensor output signal is very effective. l Distortion of rotor. or sensor harness and body connector are not properly connetted. :2:uo t o 1 9 9 3 modles 1 TSB Revision .I 35-40 E-l SERVICE BRAKES . (If the trouble is in the speed sensor circuit. In addition to a broken wire/short circuit in the wheel speed sensor. replace the ABS ECU. sensor harness wire is broken. also check whether the sensor gap is too large. and then test-drive again. SNSR. erase the diagnostic trouble code and turn the ignition switch to OFF once. OPEN” [Hint] #L) I I [Explanation] The ABS ECU detects breaks in the wheel speed sensor wire.) SPEED SENSOR REAR (LH) REAR (RH) -\ 12 gcg 12 &?g NOTE tl:From 1 9 9 4 moWIs. if an abnormality cannot be found in the sensor circuit displayed as abnormal. teeth missing l Low frequency noise interference when sensor harness wire is broken l Noise interference in sensor signal l Sensor output signal is below the standard value or amplitude modulation is overthe standard value. the problem is likely to be with the ABS ECU.Anti-lock Braking System Troubleshooting When the following diagnostic trouble codes are displayed “11 FL SNSR. If the trouble does not occur anymore. SPD. OPEN” “14 RR SNSR. but the inspection results are normal. it will recur even after the ABS ECU has been replaced. If the same diagnostic trouble code is output. OPEN” “13 RL SNSR. l Broken sensor harness FRONT CLH) FRONT (RH. This diagnostic trouble code is output if the wheel speed sensor signal is not input (or short circuited) or if its output is low when starting to drive or while driving. (2) Except for the case where a fault condition exists in the system.

9 mm (.Anti-lock Braking System Troubleshooting Check flow connected with speed sensor NOTE Check speed sensor harness and connector connection and then observe with oscilloscope.45 mm (1.“Owl mal? Standard value: 0. (Refer to P.) Is the output voltage for each wheel speed sensor over the standard value and is the waveform normal? Yes t 4 mal.8-1.) 35-41 L Is the resistance value of the sensor part normal? Standard value: 0.3-0.2 k~2 Yes Is the resistance value at the ECU tor normal? Standard value: 0.11-1.035 in.12 in.) Yes 214NOlW I Yes Check the output of each wheel speed sensor with an oscilloscope.SERVICE BRAKES .8-1.15-28. Replace the ABS ECU and I Yes 1 TSB Revision . (Refer to P.2 kL2 1 Yes Malfunction of wheel speed Harness wire for wheel speed sensor circuit is broken Repair harness. including the waveform.) Yes L Is the rear speed sensor surface-to-rotor mounting tooth flank (all around) distance normal? Standard value: 28. i Is the front wheel speed sensor-to-rotor clearance nor. there is a malfunction of ABS ECU when this diagnostic trouble code reoccurs often.3575.3575.012-.

Anti-lock Braking System Troubleshooting When diagnostic trouble code “21 G SNSR.) Yes Replace G sensor.” is displayed I [Explanation] The ABS-ECU outputs this diagnostic trouble code in the following cases.35117. I I -1 ~~~~1~ Yes Repair harness.) When there is a broken wire or short circuit in the harness for the G sensor system.35-42 E-3 SERVICE BRAKES . LJ ( iws’gg” ) xi”bE -IT-- (1995 MODELS) IGNITION SWITCH (:S2) - Is G sensor normal? (Refer to P. I I ‘iJ NOTE fl:FROM 1 9 9 4 M O D E L S Z2:UP T O 1 9 9 3 M O D E L S TSB Revision . v ABS-ECU malfunction Replace ABS-ECU. l G sensor OFF trouble (It is judged that the G sensor continues to be OFF for more than approximately 13 seconds except when the l vehicle is stopped or when there is stop light switch input.

8% 1 RESISTOR rfk3 i c) f: 8iiT x7 Am-EC” P 42?A cm cxo ‘i o_-0 0 34 m.THOu? NJro-CRUIS CONTR I. % B J : ‘8” 1 . L 5 Y.2 If = ABS ECU ABS ECU B d 0. ~1995 models> Hatchback cl 995 models> Convertible eriy%f W 1 --m-o ..:YEH.* m” g3 gj L T %d i?T% G .7-~ xX55-AX-RWOO-N 00002538 TSB Revision . l The harness wire for the stop light switch may be open.Anti-lock Braking System Troubleshooting E-4 When diagnostic trouble code “22 STOP LAMP SW” is displayed 35-43 ( [Explanation] id The ABS-ECU outputs this diagnostic trouble code in the following cases.TH AUTO-CRUISE CjNTROL gYSTEM *B:“EH. SYSTEM KXW-AK-R5?)00 XX30-AK-R38‘. cup to 1994 models> F”SiSLE LINKQ [Hint] If the stop light operates normal.:.7 cam 29 z n = NOTE S. the harness for the stop light switch input circuit is broken or there is a malfunction in the ABS-ECU. l Stop light switch remains on for more than 15 minutes while the ABS is not functioning.~L~ w.SERVICE BRAKES .

Anti-lock Braking System Troubleshooting Do the stop lights light up and go out normally? Yes ’ Disconnect the ABS-ECU con- 1 When the brake pedal is No py-------*I Repair harness. Is there continuity 2 terminal and ground? I Yes I Yes No ) Open circuit in harness between resistor and ground. Repair harness. [ Malfunction of ABS-ECU Replace ABS-ECU. TSB Revision .35-44 SERVICE BRAKES . 1 Zjrr!$$o~~ZtKYZ$~ I ~ pjii%zq-bl Repair harness. Yes I Is resistor resistance 780 to 860 !a? Replace resistor.

VALVE” or “43 VALVE DRIFT” The ABS-ECU normally monitors the solenoid valve drive circuit. f x1xi _ _ I _- I -_-__I Malfunction of ABS-ECU Replace ABS-ECU. I I ym.7 > -f--J1 pLii$q $ ’ g i*-+ & ABS ECU c TSB Revision . If no current flows in the solenoid even if the ECU turns the solenoid ON or if it continues to flow even when turned OFF. the ECU determines the solenoid coil wire is broken/short-circuiited or the harness iGNiTlON SWITCH(IG1) is broken/short-circuited.oHI Repair harness. “42 FR SOL.3 Q Yes I c1 * I Reolace HU.NAT’ON m 59 I ‘-= 56 P tance value within the range of the standard values when measured at the ECU connector? Standard value: 1. and then these diagnostic trouble codes are output.8 __-_---__. + . In the No solenoid valve within the range / of the standard values? Standard value: 1. 1 iLJ E A HU * \ !LM.0-1.0-1.SERVICE BRAKES . VALVE “. >7 5 3 ’ u :: ’ g OJ % .__-. ABS-ECU controls the solenoid valve current and if the current value of the solenoid valves differs from each other in the same mode..3 Q Yes The harness wire for the solenoid valve circuit whose resistance value is outside the range of the standard value is broken or short circuited.Anti-lock Braking System Troubleshooting 35-45 JcrLT [Explanation] When diagnostic trouble codes “41 FL SOL. solenoid valve drift error is produced and the ABS-ECU goes into the failsafe mode.

1 Yes Connect the HU harness and remove the ECU connector. Remove and check the valve relay. normally it monitors whether IGNITION SWITCH (IGil or not there is power in the valve power monitor line since the valve relay is normally ON. 30-No. No. With the ignition key “ON”. does the v&age betv\. 87a: Continuity No. 86 and No. 30-No. 85. harness side connector termlYes t ABS ECU malfunction + Repair harness.35-46 E-6 SERVICE BRAKES . 87: Continuity No. No. 87a: No continuity Yes i Install the valve relay and remove the HU connector. 30-No. 7 terminals? 1 Repair harness.een the connector terminal No. 8 and No. this diagnostic trouble code will be output. 1-b Replace ABS ECU.Anti-lock Braking System Troubleshooting When diagnostic trouble code “51 VALVE RELAY” is displayed [Explanation] When the ignition switch is turned ON. compares the voltage of the signal to the valve relay and valve power monitor line voltage to check whether the valve relay operation is normal.Faulty harness in HU Vo. If the supply of power to the valve power monitor line is interrupted. In addition. TSB Revision . 30-No. No Is there continuity between HU . 87: No continuity When battery voltage is applied between terminals No. the ABS ECU switches the valve relay OFF and ON for an initial check. 52 and around indicate battery positive voltage? Yes t Repair harness.

38-No. 4 p L Replace ABS ECU. No.Anti-lock Braking System Troubleshooting E-7 / iI [Explanation] The ABS ECU outputs this diagnostic trouble code for the motor relay and motor in the following cases. there is a broken or short circuited motor monitor wire. l When the motor relay does not function l When there is trouble with the motor itself and it does not revolve l l 35-47 When diagnostic trouble code “52 MOTOR RELAY” is displayed When the motor ground is disconnected and the motor does not revolve When the motor continues to revolve [Hint] If there is motor operation noise durino scan tool forced drive mode. 86.2 10 Z 1 10 --------. 5 and around 0.SERVICE BRAKES .O d ABS-ECU . I Does the motor make a noise -yes during scan tool forced drive mode? !No 1 B$ ii _Ft:: IM . 10 72-88 Q? i I Is resistance between body connector terminal No. 86: Resistance value 72-88 SLZ Replace motor relay. 26 72-88 !2? Yes 1 Is resistance between body connector terminal No.j ~ 4. pFizdqs. I I Yes Is resistance between HU con-t H a r n e s s i n H U faulty No nectar terminals No.’ 1 No. No. 1 and No. 30-No.~~~~ tween HU and ECU Repair harneis. 2 and No.1-0. r Remove the motor relay. 87: No continuity Battery voltage is applied between terminals No. 85 and No.3 Q? iYes ABS ECU malfunction TSB Revision I-~-. . 85-No. 2 e connector terminal 11 and ground indicate battery positive voltaae? I Broken wire in pump motor power circuit Repair harness. 87: Continuity Yes r Is pump motor ground cont netted normally? Connect ground wire. Remove the motor relav and No Pw Motor relay malfunction check resistance values.-----.

) No diagnostic trouble code or can’t communicate with scan tool / Is the basic brake system functioning / normally? Does not reoccur Check diagnostic trouble cod (Refer to P. This is considered normal. Accordingly.51. When checking to see if the trouble symptom reoccurs after the diagnostic trouble code has been erased.Anti-lock Braking System Troubleshooting <From 1996 models> DIAGNOSTIC TROUBLESHOOTING FLOW Gather information from customer Verify complaint Reoccurs Check diagnostic trouble code (Refer to P.) 1 lnspectionchartfordiagnosttctroubie codes (Refer to P. Diagnosis detection condition can vary depending on the diagnostic trouble code. a thudding sound can sometimes be heard coming from inside the engine compartment.35. TSB Revision . Condition System check sound Explanation of condition When starting the engine.OO-10. squeak: tires) ABS operation sound For road surfaces such as snow-covered roads and gravel roads.3551) and the memorize conditions recorded in the “Comments” column of the inspection procedure chart for diagnostic trouble codes in order to carry out testing under driving conditions which satisfy each of the given conditions.) I I f - Intermittent malfunction (Refer to INTRODUCTION AND MASTER TROUBLESHOOTING P. check the memorize timing column in the inspection chart for diagnostic trouble codes (refer to P.3551. 1.35-48 SERVICE BRAKES .) Diagnostic trouble code displayed Diagnostic trouble code displayed Nodiagnostic trouble code I 1 Recheck diagnostic trouble code(s) then erase (Refer to P.35-51. 3. (Thump: suspension.35-51. but this is because the system operation check is being performed.35-58. 2.) NOTES WITH REGARD TO DIAGNOSIS The condition listed in the following table are considered normal. advise the customer to drive safely on such roads by lowering the vehicle speed and not being overconfident. sound is generated from the vehicle chassis due to repeated brake application and release.) ‘es t Recheck trouble symptom Check diagnostic trouble codes Diagnostic trouble t No diagnostic trouble code N lnspectionchartfortroublesymptoms (Refer to P. the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles. I ABS operation (Long braking distance) Sound of the motor inside the ABS hydraulic unit (HU) operating (whine) Sound is generated along with vibration of the brake pedal (scraping) When ABS operates.

TSB Revision .5 second: 1.seconds lluminated Switch OFF 1 Pause One-digit Ten-digit Digit time: signal signal section: 3 seconds 2 seconds 14N0173 No diagnostic trouble code is output I I Diagnostic trouble code No. 24 is output Al4FOl66 0. NOTE Diagnostic trouble code No.5 0.5 seconds-~-j-f. (2) Take a reading of the diagnostic trouble code from the flashing of the ABS warning light. 16 can be output when the ABS system fails because of a battery surge. Caution Always turn the ignition switch to connect or disconnect the scan tool.SERVICE BRAKES .5 seconds 14NO174 NOTE (1) Other diagnostic trouble codes also are output as the same code numbers as when using the scan tool. With 3he ABS Warning Light (1) Use the special tool (diagnostic trouble code check harness) to ground the terminal (1) of the data link connector. 16 can be output when the ABS system fails because of a battery surge. 0.Anti-lock Braking System Troubleshooting DIAGNOSTIC FUNCTION 35-49 ytoo’ 22OFO164 1 DIAGNOSTIC TROUBLE CODES CHECK With the Scan Tool Connect the scan tool to the data link connector. then check diagnostic trouble codes. (2) Diagnostic trouble code No.

the stop light switch will operate 10 times in succession according to the timing given below. (2) When the generator L terminal voltage increased (HI state). With the ABS Warning Light When the ignition switch is turned on while the stop light switch is on.35-50 SERVICE BRAKES . (1) When the stop light switch is not turned on and off according to the table below. Caution The memory cannot be erased under the following conditions. Ignition switch ON OFF I I I ’ ’ I I I I I Warning light ON OFF 1 second ABS-ECU memory I Eliminated 14x0229 Generator HI L terminal LOW voltage ON Within 3seconds Within Within Within lsecond 1 second 1 second Within 1 second Stop light switch OFF ----j 1st 2nd 3rd A-p-~----~ -I 4th 9th 10th I I 1 TSB Revision 1 .Anti-lock Braking System Troubleshooting ERASING DIAGNOSTIC TROUBLE CODES With the Scan Tool Connect the scan tool to the data link connector (l&pin). then erase the diagnostic trouble codes.

L.R.R. wheel speed sensor system (shorted) F. solenoid valve IN system F. wheel speed sensor system (shorted) R.L. solenoid valve IN system R. solenoid valve IN system R. solenoid valve IN system F. solenoid valve OUT system ABS valve relay system HU pump motor or ABS motor relay system ABS-ECU system ’ 35-51 Reference Page 35-52 35-52 35-52 35-52 35-52 35-53 35-53 35-53 35-53 35-53 35-54 35-54 35-55 35-55 35-55 35-55 35-55 35-55 35-55 35-55 35-56 35-57 ABS-ECU replacement i 1 TSB Revision .L.Anti-lock Braking System Troubleshooting INSPECTION CHART FOR DIAGNOSTIC TROUBLE CODES Code No.SERVICE BRAKES .L. wheel speed sensor system (open-circuited) F.R. wheel speed sensor system (open-circuited) Wheel speed sensor system (output signal abnormal) ABS-ECU power supply system (voltage abnormally low or high) F. solenoid valve OUT system R.R.L.L.L.R. 11 12 13 14 15 16 21 22 23 24 26 38 41 42 43 44 45 46 47 48 51 53 63 Diagnostic Item F. wheel speed sensor system (open-circuited) R. wheel speed sensor system (open-circuited) RR. solenoid valve OUT system F.R. solenoid valve OUT system R. wheel speed sensor system (shorted) G-sensor system (open.L. wheel speed sensor system (shorted) R.or short-circuited or signal provided abnormally) Stop light switch system (open-circuited or ON trouble) F.R.

Check wheel speed sensor.35-52 SERVICE BRAKES . l Resistance between 74-75. Disconnect connectors and make measurements on harness side.. NG + Replace ABS-ECU. A-12. I Check wheel bearing. 13. 14 Wheel speed sensor system (open-circuited) . loK ILeI Replace rotor. 12.Anti-lock Brakina Svstem Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODES Code Nos. OK Replace ABS-ECU.1. (Improper number of rotor teeth or the like) Probable cause Wheel speed sensor installation defective Wheel speed sensor defective o Harness and connector defective l Rotor defective l Wheel bearing defective l ABS-ECU defective l l NG OK c Repair 1 Check trouble syrir:oCms.and open-circuits). Probable cauSe l l l Wheel speed sensor defective Harness and connector defective ABS-ECU defective * Repair tion. Check harness between each wheel 1 TSB Revision . Code No. Output is provided when signal is not input due to breakage of the (+) or (-) wire of one or more of the four wheel speed sensors. IOK Replace wheel speed sensor. 71-72. 11. ol t 1 / Check trouble symptoms.2 kR l /A-29. E-i 2. wheel speed sensor and ABS-ECU. 69-70. Check the following connector +y Repair 1 C h e c k r o t o r . Check trouble symptoms. 73-46 OK: 0. E-l! Check wheel speed sensor output voltage. 15 Wheel speed sensor system (output signal abnormal) Output is provided when output signal produced by any of wheel speed sensors is abnormal (excluding short.8 .

/ TSB Revision . NG Check harness betweeneach wheel . Measure voltage between terminal No. making it impossible to perform correct trouble diagnosis. l Start engine. be sure to check the battery for conditions and charge it if necessary.e cauSe (shorted) Output is provided in the following case. Replace rotor. Replace wheel speed sensor.Check wheel speed sensor.22.SERVICE BRAKES . 16 ABS-ECU power supply system (voltage Probab. Replace ABS-ECU. Before carrying out the following check. this code is output as an existing trouble. Check wheel bearing. 21. OK: Batterv voltaae Repair Check battery. I is received by one or more of the four wheel speed sensors at a vehicle speed of 10 km/h (6 mph) or more. I IOK ------+ Repair ~~-~--’ Repair Check the following connectors.23 and 24 Wheel speed sensor system ’ Probab. lnu Check harness between ignition Code Nos. l l l l l l Wheel speed sensor defective Harness and connectors defective Rotor defective Excessive clearance between sensor and rotor ABS-ECU defective Wheel bearing defective I -1 NG Check wheel speed sensor installation.Anti-lock Braking System Troubleshooting Code No. 83 and body ground.e cauSe abnormally low or high) Output is provided when ABS-ECU power supply voltage drops below or rises above if power supply voltage returns to normal l l 35-53 Harness and connector defective ABS-ECU defective Caution If battery voltage drops or rises while making this check.

36 and body ground OK: Battery voltage l iOK 1 Check the following connector. 26 G-sensor system (open-. Probab.3 .35-54 SERVICE BRAKES .7 V OK Replace G-sensor. Check the following 1OK r Check trouble symptoms. E-12. D-27 OK / Check trouble svmptoms. l l Stop light switch system harness is broken and no signal is input to ABS-ECU. l Disconnect connectors and make measurements on harness side. Replace stop light switch. 38 Stop light switch system (open-circuited or ON trouble) .W or rises above 4. Stop light switch is in trouble and remains in ON state for more than 15 minutes.Repair Replace ABS-ECU. l Stop light switch ON l Voltage between terminal No.Anti-lock Braking System Troubleshooting Probab.e cauSe l l l Code No. Disconnect connectors and make measurements on harness side. Replace ABS-ECU. --t Check the following connector. TSB Revision .35117.2.e cauSe l l l Stop light switch defective Harness and connector defective ABS-ECU defective c Repair or distinguish stop light.W l G-sensor svstem harness is broken or shorted G-sensor defective Harness and connector defective ABS-ECU defective Check G-sensor. OK -1NG Check stop light switch installation. NG * Repair Code No.) OK t . NG NG + Repair 1 Check harness between G-sensor and ABS-ECU. and repair if necessarv. (Refer to P. E-12 OK Check trouble symptoms. 1 lOK Check stop light switch.NG Measure at ABS-ECU connector E-12. l Ignition switch: ON l Voltage between No. NG B. l G-sensor output drops below 0. 62 and 45 OK: 2. short-circuited or signal abnormal) Output is provided in the following cases. Output is provided in the following cases.

Check solenoid valve.42. Replace ABS-ECU.SERVICE BRAKES . : 2 6 - 30 58 79 51 OK NG * Repair Check the following connector. Replace HU. E-12 lOK 1 Check trouble symptoms.) IOK -I UG vleasure at HU connector A-64 and p Check th A-64. and repair if necessary. solenoid coil is judged to be openor short-circuited or harness is judged to be broken or shorted and output is provided.43.45. ) Disconnect connectors and IOK make measurements on hart ness side ) Continuitybetween the following terminals OK: Continuity ABS-ECU side HU side 78 3 50 7 31 4 59 8 t NG * Repair NG * Check harness between HU and ABS-ECU.Anti-lock Braking System Troubleshooting Code Nos. E-12. i i 1 TSB Revision 1 . connector defective * ABS-ECU defective l l L ABS-ECU monitors solenoid valve drive circuit at all times.e cauSe HU defective Harness. 41.44. C-32 jBS-ECU connector E-l 2.46.35-112. When solenoid is not energized with solenoid valve turned ON by ABS-ECU or when it is kept energized with solenoid valve turned OFF by ABS-ECU.47 and 48 Solenoid valve systems Probab. (Refer to P.

Check trouble symptoms. (Refer to P. and repair if necessary.Anti-lock Braking System Troubleshooting Probable cause l l l l Code No. -7-i A-64. l Voltage between terminal No. 51 ABS valve relay system ABS-ECU monitors solenoid valve drive circuit at all times. (Refer to P.) Replace ABS valve relay.S OK: Continuity provided HU side ABS valve relay side ) 1 2 . and repair if necessary. ABS valve relay defective Harness. Measure at HU connector A-64 and Check the following connectors. l Resistance between 82-47 * Repair L Check harness between ABS valve Check solenoid valve. r Measure at ABS valve relay connector A-80. Er] NG 1 Disconnect connectors and make measurements on harness side.35-56 SERVICE BRAKES . l Continuitybetween thefollowing &^-:^^I^ . . iBS-ECU connector E-l 2.) AOK Replace HU.Ollllllld. [ c-94.35-112. connector defective HU defective ABS-ECU defective Check ABS valve relay. 5 and body ground OK: Battery voltage AOK Check harness between ABS valve NG Measure at ABS-ECU connector Ii NG E-12.35-83. When 5 or more solenoids are not energized with solenoid valve turned ON by ABS-ECU or when 5 or more solenoids are kept energized with solenoid valve turned OFF by ABS-ECU.1 ness side. l Disconnect connectors and /AK make measurements on har. A-80 ABS valve relay connector A-80. 1 Continuity between the following termina