Mitsibushi Galant 96 02 Workshop Manual

00109000812
General . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .
00 11 12 13 14 15 16 17 21 22 23 26 27 31 32 33 34 35 36 37 42 51 52 54 55
WORKSHOP MANUAL
FOREWORD
This Workshop Manual contains procedures for service mechanics, including removal, disassembly, inspection, adjustment, reassembly and installation. Use the following manuals in combination with this manual as required. TECHNICAL INFORMATION MANUAL PYDE9604 WORKSHOP MANUAL ENGINE GROUP PWEEjjjj (Looseleaf edition) ELECTRICAL WIRING PHDE9608 BODY REPAIR MANUAL PBDE9609 PARTS CATALOGUE Sedan B608S107Aj Wagon B608T507Aj
Engine Cooling . . . . . . . . . . . . . . . . . Intake and Exhaust ............
Engine Electrical . . . . . . . . . . . . . . . Engine and Emission Control . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transmission . . . . . . . . . . . Automatic Transmission . . . . . . . . Front Axle . . . . . . . . . . . . . . . . . . . . . . Rear Axle . . . . . . . . . . . . . . . . . . . . . . Wheel and Tyre . . . . . . . . . . . . . . . . . Power Plant Mount . . . . . . . . . . . . . . Front Suspension . . . . . . . . . . . . . . . Rear Suspension . . . . . . . . . . . . . . .
All information, illustrations and product descriptions contained in this manual are current as at the time of publication. We, however, reserve the right to make changes at any time without prior notice or obligation.
Service Brakes . . . . . . . . . . . . . . . . . Parking Brakes . . . . . . . . . . . . . . . . . Steering . . . . . . . . . . . . . . . . . . . . . . . . Body . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior . . . . . . . . . . . . . . . . . . . . . . . . Interior and Supplemental Restraint System (SRS) . . . . . . . . . Chassis Electrical . . . . . . . . . . . . . . Heater, Air Conditioner and Ventilation . . . . . . . . . . . . . . . . . . . . . .
E Mitsubishi Motors Corporation
Dec. 1996
WARNING! (1) Improper service or maintenance of any component of the SRS and seat belt with pre-tensioner, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag and seat belt with pre-tensioner) or to the driver and passenger (from rendering the SRS inoperative). (2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module (drivers side and front passengers side), clock spring, side impact sensor, front seat assembly (side air bag module) and seat belt with pre-tensioner before drying or baking the vehicle after painting. SRS-ECU, air bag module, clock spring and side impact sensor: 93_C or more Seat belt with pre-tensioner: 90_C or more (3) Service or maintenance of any SRS component and seat belt with pre-tensioner or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS and seat belt with pre-tensioner or any SRS-related component. NOTE Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
00-1
GENERAL
CONTENTS
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . 2
Scope of Maintenance, Repair and Servicing Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Indication of Tightening Torque . . . . . . . . . . . . . . . . 2 Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Explanation of Manual Contents . . . . . . . . . . . . . . . 4
00109000829
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Model Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine Model Number . . . . . . . . . . . . . . . . . . . . . . . 17
MAJOR SPECIFICATIONS . . . . . . . . . . . . . . . . 18 PRECAUTIONS BEFORE SERVICE . . . . . . . 20 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEAT BELT WITH PRE-TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . 24 SUPPORT LOCATIONS FOR LIFTING AND JACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Support Positions for a Garage Jack and Axle Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Support Positions for a Single-Post Lift or Double-Post Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Support Positions and Support Method for an H-Bar Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Troubleshooting Contents . . . . . . . . . . . . . . . . . . . . . 6 Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 How to Use the Inspection Procedures . . . . . . . . 9 Connector Measurement Service Points . . . . . . . 10 Connector Inspection . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspection Service Points for a Blown Fuse . . . 12 Points to Note for Intermittent Malfunctions . . . . 12
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . 13
Vehicle Information Code Plate . . . . . . . . . . . . . . . 13
STANDARD PART/TIGHTENING-TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
00-2
GENERAL - How to Use This Manual

00100010302
HOW TO USE THIS MANUAL

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS
This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Note, however, that for engine and transmission-related component parts, this manual covers only on-vehicle inspections, adjustments, and the removal and installation procedures for major components. For detailed information concerning the inspection, checking, adjustment, disassembly and reassembly of the engine, transmission and major components after they have been removed from the vehicle, please refer to separate manuals covering the engine and the transmission. ON-VEHICLE SERVICE On-vehicle Service is procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspection (for looseness, play, cracking, damage, etc.) must also be performed. INSPECTION Under this title are presented inspection and checking procedures to be performed by using special tools and measuring instruments and by feeling, but, for actual maintenance and servicing procedures, visual inspections should always be performed as well.
DEFINITION OF TERMS
STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection 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 10% except the following cases when the upper and lower limits of tightening torque are given. (1) The tolerance of the basic value is within 10%. (2) Special bolts or the like are in use. (3) Special tightening methods are used.
GENERAL - How to Use This Manual MODEL INDICATIONS

The following abbreviations are used in this manual for classification of model types.
00-3
2000: Indicates models equipped with the 2,000 mL <4G63> petrol engine. 2500: Indicates models equipped with the 2,500 mL <6A13> petrol engine. 2000D: Indicates models equipped with the 2,000 mL <4D68> diesel engine. MPI: Indicates the multi-point injection, or engine equipped with the multi-point injection. SOHC: Indicates an engine with the single overhead camshaft, or models equipped with such an engine. M/T: Indicates the manual transmission, or models equipped with the manual transmission. A/T: Indicates the automatic transmission, or models equipped with the automatic transmission. A/C: Indicates the air conditioner.
00-4
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. Component Diagram A diagram of the component parts is provided near the front of each section in order to give a 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. D Removal steps: The part designation number corresponds to the number in the illustration to indicate removal steps. D Disassembly steps: The part designation number corresponds to the number in the illustration to indicate disassembly steps.
D 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. D Reassembly steps: Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted if reassemby is possible in reverse order of disassembly steps.
Classifications of Major Maintenance/Service Points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.), these are arranged together as major maintenance and service points and explained in detail. AA" "AA : Indicates that there are essential points for removal or disassembly. : Indicates that there are essential points for installation or reassembly.
Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts or on the page following the component parts page, and explained. : Grease (multipurpose grease unless there is a brand or type specified) : Sealant or adhesive : Brake fluid or automatic transmission fluid : Engine oil, gear oil or air conditioner compressor oil : Adhesive tape or butyl rubber tape

Indicates the group title. Indicates the section title. Indicates the group number. Indicates the page number.
00-5
Denotes able part.
non-reus-
Denotes tightening torque. For bolts and nuts which do not have a tightening torque listed, refer to the Standard Partstightening-torque Table. Repair kit or set parts are shown. (Only very frequently used parts are shown.)
Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described.
indicates that there is a continuity between the terminals. 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 lubrication and sealing procedures.
00-6
GENERAL - How to Use Troubleshooting/Inspection Service Points
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00100020152
Troubleshooting of electronic control systems for which the MUT-II can be used follows the basic outline described below. Furthermore, even in systems for which the MUT-II cannot be used, part of these systems still follow this outline.
TROUBLESHOOTING CONTENTS
1. STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING The troubleshooting sections follow the basic diagnosis flow which is given below. If the diagnosis flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed. Diagnosis method
Gathering information from the customer.
Check trouble symptom. Reoccurs Does not reoccur.
Read the diagnosis code No diagnosis code or communication with MUT-II not possible Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS (Refer to applicable group.) Diagnosis code displayed.
Read the diagnosis code Diagnosis code displayed. No diagnosis code
After taking note of the malfunction code, erase the diagnosis code memory
Recheck trouble symptom.
Read the diagnosis codes. Diagnosis code displayed. No diagnosis code
Refer to the INSPECTION CHART FOR DIAGNOSIS CODES (Refer to applicable group.)
INTERMITTENT MALFUNCTIONS (Refer to P.00-12.)
2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the trouble symptoms is difficult, procedures for checking operation and verifying trouble symptoms are shown. 3. DIAGNOSIS FUNCTION Details which are different from those in the Diagnosis Function section on the next page are listed.

4. INSPECTION CHART FOR DIAGNOSIS CODES
00-7
5. INSPECTION PROCEDURE FOR DIAGNOSIS CODES Indicates the inspection procedures corresponding to each diagnosis code. (Refer to P.00-9 for how to read the inspection procedures.) 6. INSPECTION CHART FOR TROUBLE SYMPTOMS If there are trouble symptoms even though the results of inspection using the MUT-II show that all diagnosis codes are normal, inspection procedures for each trouble symptom will be found by means of this chart. 7. INSPECTION PROCEDURE FOR TROUBLE SYMPTOM Indicates the inspection procedures corresponding to each trouble symptoms classified in the Inspection Chart for Trouble Symptoms. (Refer to P.00-9 for how to read the inspection procedures.) 8. SERVICE DATA REFERENCE TABLE Inspection items and normal judgement values have been provided in this chart as reference information. 9. CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items and standard values have been provided in this chart as reference information. 10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are listed here.
DIAGNOSIS FUNCTION
METHOD OF READING DIAGNOSIS CODES WHEN USING THE MUT-II Connect the MUT-II to the diagnosis connector and take a reading of the diagnosis codes. Caution Turn off the ignition switch before connecting or disconnecting the MUT-II.
MUT-II
00-8

WHEN USING THE WARNING LAMP 1. Use the special tool to earth No.1 terminal (diagnosis control terminal) of the diagnosis connector. 2. To check ABS system, remove the valve relay.
MB991529
Diagnosis connector
NOTE That is because the valve relay is off and the warning lamp remains illuminated if there is a fault in the ABS system. 3. Turn off the ignition switch. 4. Read out a diagnosis code by observing how the warning lamp flashes. Applicable systems
System name MPI A/T ABS TCL Warning lamp name Engine warning lamp Neutral position indicator lamp ABS warning lamp TCL-OFF indicator lamp
Indication of diagnosis code by warning lamp

When the diagnosis code No.24 is output
1.5 secs. 0.5 sec. 0.5 sec.
When no diagnosis code is output*

0.5 sec. <MPI, A/T> 0.25 sec. <ABS> On Off
On Off
Pause time 3 secs.
Tens signal
Place division 2 secs.
Units signal
NOTE *: Even if the ABS system is normal, removing the valve relay causes the diagnosis code No.52 to be output. METHOD OF ERASING DIAGNOSIS CODES WHEN USING THE MUT-II Connect the MUT-II to the diagnosis connector and erase the diagnosis code. Caution Turn off the ignition switch before connecting or disconnecting the MUT-II. WHEN NOT USING THE MUT-II (1) Turn the ignition switch to OFF. (2) After disconnecting the battery cable from the battery ( - ) terminal for 10 seconds or more, reconnect the cable. (3) After the engine has warmed up, run it at idle for about 15 minutes.
GENERAL - How to Use Troubleshooting/Inspection Service Points HOW TO USE THE INSPECTION PROCEDURES
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.
1. Comments on the diagnosis code or trouble symptom above.
CHECKING PROCEDURE 4
D Indicator does not turn on or off even if control mode switch is pressed. D Indicator switch should not be illuminated is illuminated.
In the above cases, the ECS switch circuit is defective or the indicator circuit is defective.
Probable cause
2. Indicates inspection carried out using the MUT-II. Indicates the operation and inspection procedures. Indicates the OK judgement conditions. Detailed inspection procedures (methods) such as component inspection and circuit inspection are listed on a separate page, and are given here for reference.
3. OK
MUT-II Data list 17 Control mode selection switch OK: Voltage changes between approx. 0V approx. 2.5V approx. 5V when the switch is operated.
4. Indicates voltage and resistance to be measured at a particular NG connector. (Refer to Connector Measurement Service Points.) OK The connector position can be located in the wiring diagram in the OK electrical wiring manual by means of this symbol. Measure at switch connector A-44 Indicates operation and inspection procedures, inspection terminals D Disconnect the connector, and measure at the harness and inspection conditions. side. Indicates the OK judgement conditions. D Voltage between terminal 6 - earth and terminal 8 ECU switch component inspection (Refer to P.3-44.) earth OK: Approx. 5V
NG
OK
Check the following connector. A-44
NG 5.
Repair
OK
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 the electrical wiring manual by means of this symbol. Caution After carrying out connector inspection, always be sure to reconnect the connector as it was before.
6.
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 seems that trouble symptoms still remain, proceed to the next page of instructions.
7.
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.
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 the electrical wiring 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. MEASURES TO TAKE AFTER REPLACING THE ECU If the trouble symptoms have not disappeared even after replacing the ECU, repeat the inspection procedure from the beginning.
00-10
GENERAL - How to Use Troubleshooting/Inspection Service Points CONNECTOR MEASUREMENT SERVICE POINTS
Turn the ignition switch to OFF when connecting disconnecting the connectors, and turn the ignition switch to ON when measuring if there are no instructions to be contrary.
Harness connector
IF INSPECTING WITH THE CONNECTOR CONNECTED (WITH CIRCUIT IN A CONDITION OF CONTINUITY) Waterproof Connectors Be sure to use the special tool (harness connector). Never insert a test bar from the harness side, because to do so will reduce the waterproof performance and result in corrosion.
Extra-thin probe
Test bar Connector
Ordinary (non-waterproof) Connectors Check by inserting the test bar from the harness side. Note that if the connector (control unit, etc.) is too small to permit insertion of the test bar, it should not be forced; use a special tool (the extra-thin probe in the harness set for checking for this purpose.
Inspection harness for connector pin contact pressure
IF INSPECTING WITH THE CONNECTOR DISCONNECTED <When Inspecting a Female Pin> Use the special tool (inspection harness for connector pin contact pressure in the harness set for inspection). The inspection harness for connector pin contact pressure should be used. the test bar should never be forcibly inserted, as it may cause a defective contact.
<When Inspecting a Male Pin> Touch the pin directly with the test bar. Caution At this time, be careful not to short the connector pins with the test bars. To do so may damage the circuits inside the ECU.

Connector disconnected or improperly connected
00-11
CONNECTOR INSPECTION
VISUAL INSPECTION D Connector is disconnected or improperly connected D Connector pins are pulled out D Due to harness tension at terminal section D Low contact pressure between male and female terminals D Low connection pressure due to rusted terminals or foreign matter lodged in terminals
Defective connector contact
Harness wire breakage at terminal section Low contact pressure
CONNECTOR PIN INSPECTION If the connector pin stopper is damaged, the terminal connections (male and female pins) will not be perfect even if the connector body is connected, and the pins may pull out of the reverse side of the connector. Therefore, gently pull the harnesses one by one to make sure that no pins pull out of the connector.
MB991219
CONNECTOR ENGAGEMENT INSPECTION Use the special tool (connector pin connection pressure inspection harness of the inspection harness set) to inspect the engagement of the male pins and females pins. (Pin drawing force : 1 N or more)
00-12
GENERAL - How to Use Troubleshooting/Inspection Service Points INSPECTION SERVICE POINTS FOR A BLOWN FUSE
0W
Battery
Remove the fuse and measure the resistance between the load side of the fuse and the earth. Set the switches of all circuits which are connected to this fuse to a condition of continuity. If the resistance is almost 0 W at this time, there is a short somewhere between these switches and the load. If the resistance is not 0 W, there is no short at the present time, but a momentary short has probably caused the fuse to blow. The main causes of a short circuit are the following. D Harness being clamped by the vehicle body D Damage to the outer casing of the harness due to wear or heat D Water getting into the connector or circuitry D Human error (mistakenly shorting a circuit, etc.)
Fuse Connector inspection
Load switch Load
POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONS

Intermittent malfunctions often occur under certain conditions, and if these conditions can be ascertained, determining the cause becomes simple. In order to ascertain the conditions under which an intermittent malfunction occurs, first ask the customer for details about the driving conditions, weather conditions, frequency of occurrence and trouble symptoms, and then try to recreate the trouble symptoms. Next, ascertain whether the reason why the trouble symptom occurred under these conditions is due to vibration, temperature or some other factor. If vibration is thought to be the cause, carry out the following checks with the connectors and components to confirm whether the trouble symptom occurs. The objects to be checked are connectors and components which are indicated by inspection procedures or given as probable causes (which generates diagnosis codes or trouble symptoms.) D Gently shake the connector up, down and to the left and right. D Gently shake the wiring harness up, down and to the left and right. D Gently rock each sensor and relay, etc. by hand. D Gently shake the wiring harness at suspensions and other moving parts. NOTE If determining the cause is difficult, the flight recorder function of the MUT-II can also be used.
GENERAL - Vehicle Identification
00-13
00100540085
VEHICLE IDENTIFICATION
VEHICLE INFORMATION CODE PLATE
LOCATION Vehicle information code plate is riveted on the toeboard inside the engine compartment.
1 2 3 4 5
CODE PLATE DESCRIPTION The plate shows model code, engine model, transmission model, and body colour code.
No. 1 Item MODEL Contents EA2A SNHEQL6 4G63 B60B F5M42 B60 41H 03V EA2A: Vehicle model SNHEQL6: Model series Engine model Exterior code Transmission code B60: Body colour code 41H: Interior code 03V: Equipment code
2 3 4 5
ENGINE EXT TRANS AXLE COLOR INT OPT
For monotone colour vehicles, the body colour code shall be indicated. For two-tone or three-way two-tone colour vehicles, each colour code only shall be indicated in series.
MODELS
<SEDAN>
Model code EA2A SNJEQL6 SNHEQL6 SRHEQL6 EA5A SNGEQL6 SRGEQL6 EA6A SNHFQL6 4D68-SOHC (1,998 mL) 6A13-SOHC (2,497 mL) F4A42 (2WD-4A/T) F5M42 (2WD-5M/T) F4A42 (2WD-4A/T) F5M42 (2WD-5M/T) MPI Engine model 4G63-SOHC (1,997 mL) Transmission model F5M42 (2WD-5M/T)
00100030223
Fuel supply system MPI
Electronically controlled injection pump MPI
EA2A
SNJEQL6C SNHEQL6C SRHEQL6C
4G63-SOHC (1,997 mL)
F5M42 (2WD-5M/T)
F4A42 (2WD-4A/T)
00-14
Model code EA5A

Engine model SNGEQL6C SRGEQL6C 6A13-SOHC (2,497 mL) Transmission model F5M42 (2WD-5M/T) F4A42 (2WD-4A/T) 4D68-SOHC (1,998 mL) F5M42 (2WD-5M/T) Electronically controlled injection pump MPI Fuel supply system MPI
EA6A
SNHFQL6C
EA2A
SNHEQR6 SRHEQR6
4G63-SOHC (1,997 mL)
F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)
EA5A
SNGEQR6 SRGEQR6
6A13-SOHC (2,497 mL)
F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)
MPI
EA6A
SNHFQR6
4D68-SOHC (1,998 mL)
F5M42 (2WD-5M/T)
Electronically controlled injection pump
<WAGON>
Model code EA2W LNJEQL6 LNHEQL6 LRHEQL6 EA5W LNGEQL6 LRGEQL6 EA6W LNHFQL6 4D68-SOHC (1,998 mL) 6A13-SOHC (2,497 mL) F4A42 (2WD-4A/T) F5M42 (2WD-5M/T) F4A42 (2WD-4A/T) F5M42 (2WD-5M/T) Electronically controlled injection pump MPI MPI Engine model 4G63-SOHC (1,997 mL) Transmission model F5M42 (2WD-5M/T) Fuel supply system MPI
EA2W
LNJEQL6C LNHEQL6C LRHEQL6C
4G63-SOHC (1,997 mL)
F5M42 (2WD-5M/T)
F4A42 (2WD-4A/T) 6A13-SOHC (2,497 mL) F5M42 (2WD-5M/T) F4A42 (2WD-4A/T) 4D68-SOHC (1,998 mL) F5M42 (2WD-5M/T) Electronically controlled injection pump MPI MPI
EA5W
LNGEQL6C LRGEQL6C
EA6W
LNHFQL6C
EA2W
LNHEQR6 LRHEQR6
4G63-SOHC (1,997 mL)
F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)
EA5W
LNGEQR6 LRGEQR6
6A13-SOHC (2,497 mL)
F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)
MPI
EA6W
LNHFQR6
4D68-SOHC (1,998 mL)
F5M42 (2WD-5M/T)
Electronically controlled injection pump
GENERAL - Vehicle Identification MODEL CODE

No. 1 Items Development Engine type Contents
00-15
00100040257
EA: MITSUBISHI GALANT 2: 2,000 mL petrol engine 5: 2,500 mL petrol engine 6: 2,000 mL diesel engine A: Passenger car W: Wagon S: 4-door sedan L: 4-door station wagon N: 5-speed manual transmission R: 4-speed automatic transmission J: GLX H: GLS G: V6-24 E: MPI-SOHC F: Turbocharger with intercooler Q: With catalytic converter None: Without catalytic converter L: Left hand R: Right hand 6: For Europe C: Central Europe
1 2 3 4 5 6 7 8 9 10
3 4 5
Sort Body style Transmission type
Trim level
Specification engine feature Exhaust system specification Steering wheel location Destination
9 10
00-16
GENERAL - Vehicle Identification CHASSIS NUMBER

00100560104
The chassis number is stamped on the toeboard inside the engine compartment.
10
11
No. 1 2 3
Items Fixed figure Distribution channel Destination J M A B
Contents Asia Japan channel For Europe, right hand drive For Europe, left hand drive 4-door sedan 4-door station wagon 5-speed manual transmission 4-speed automatic transmission GALANT 4G63: 1,997 mL petrol engine 6A13: 2,498 mL petrol engine 4D68: 1,998 mL diesel engine Passenger car 1997 Okazaki Motor Vehicle Works -
Body style
S L
Transmission type
N R
6 7
Development order Engine
EA 2 5 6
8 9 10 11
Sort Model year Plant Serial number
A V Z -

<4G63>
00-17
00100570107
ENGINE MODEL NUMBER
1. The engine model number is stamped at the cylinder block as shown in the following.
Engine model 4G63 6A13 4D68 Engine displacement mL 1,997 2,498 1,998
Front of vehicle
2. The engine serial number is stamped near the engine model number.
Engine serial number AA0201 to YY9999
<6A13>
Front of vehicle
<4D68>
Front of vehicle
00-18
GENERAL - Major Specifications

00100080143
MAJOR SPECIFICATIONS
<Sedan>
9 5 2 7 4 1 8 6
Items
EA2AS NJEQL6, NJEQL6C
EA2AS NHEQL6, NHEQL6C, NHEQR6
EA2AS RHEQL6, RHEQL6C, RHEQR6
EA5AS NGEQL6, NGEQL6C, NGEQR6
EA5AS RGEQL6, RGEQL6C, RGEQR6
EA6AS NHFQL6, NHFQL6C, NHFQR6
Vehicle dimensions mm
Overall length Overall width Overall height (unladen) Wheelbase Track-front Track-rear Overhang-front Overhang-rear Ground clearance (unladen)
1 4,630 2 1,740 3 1,415 4 2,635 5 1,510 6 1,505 7 930 8 1,065 9 150 1,260 1,775 925 850 5 4G63 1,997 F5M42
4,630 1,740 1,415 2,635 1,510 1,505 930 1,065 150
4,630 1,740 1,415 2,635 1,510 1,505 930 1,065 150 1,280
4,630 1,740 1,415 2,635 1,510 1,505 930 1,065 150 1,290 1,805 955 850
4,630 1,740 1,415 2,635 1,510 1,505 930 1,065 150 1,310
4,630 1,740 1,415 2,635 1,510 1,505 930 1,065 150 1,300 1,795 955 840
Vehicle weight kg
Kerb weight Max. gross vehicle weight Max. axle weight rating-front Max. axle weight rating-rear
Seating capacity Engine Model No. Total displacement mL Transmission Fuel system Model No. Type Fuel supply system
6A13 2,498 F4A42 4-speed automatic F5M42 5-speed manual F4A42 4-speed automatic
4D68 1,998 F5M42 5-speed manual Electronically controlled fuel injection
5-speed manual
Electronically controlled multi-point injection
GENERAL - Major Specifications

<Wagon>
00-19
5 2
4 1
Items
EA2WL NJEQL6, NJEQL6C
EA2WL NHEQL6, NHEQL6C, NHEQR6
EA2WL RHEQL6, RHEQL6C, RHEQR6
EA5WL NGEQL6, NGEQL6C, NGEQR6
EA5WL RGEQL6, RGEQL6C, RGEQR6
EA6WL NHFQL6, NHFQL6C, NHFQR6
Vehicle dimensions mm
Overall length Overall width Overall height (unladen) Wheelbase Track-front Track-rear Overhang-front Overhang-rear Ground clearance (unladen)
1 4,680 2 1,740 3 1,495 4 2,635 5 1,510 6 1,505 7 930 8 1,115 9 150 1,310 1,830 920 910 5 4G63 1,997 F5M42
4,680 1,740 1,495 2,635 1,510 1,505 930 1,115 150 1,310
4,680 1,740 1,495 2,635 1,510 1,505 930 1,115 150 1,330
4,680 1,740 1,495 2,635 1,510 1,505 930 1,115 150 1,340 1,860 950 910
4,680 1,740 1,495 2,635 1,510 1,505 930 1,115 150 1,360
4,680 1,740 1,495 2,635 1,510 1,505 930 1,115 150 1,350 1,850
Vehicle weight kg
Kerb weight Max. gross vehicle weight Max. axle weight rating-front Max. axle weight rating-rear
900
Seating capacity Engine Model No. Total displacement mL Transmission Fuel system Model No. Type Fuel supply system
6A13 2,498 F4A42 4-speed automatic F5M42 5-speed manual F4A42 4-speed automatic
4D68 1,998 F5M42 5-speed manual Electronically controlled fuel injection
5-speed manual
Electronically controlled multi-point injection
00-20
GENERAL - Precautions Before Service

00100050229
PRECAUTIONS BEFORE SERVICE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS), SEAT BELT WITH PRE-TENSIONER

1. Items to follow when servicing SRS (1) Be sure to read GROUP 52B - Supplemental Restraint System (SRS). For safe operations, please follow the directions and heed all warnings. (2) 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. (3) Warning labels must be heeded when servicing or handling SRS components and seat belt with pre-tensioner. Warning labels are located in the following locations. D Sun visor D Glove box D SRS air bag control unit D Steering wheel D Steering gear and linkage D Air bag module (drivers side and front passengers side) D Clock spring D Seat belt with pre-tensioner D Side air bag module D Side impact sensor (4) Always use the designated special tools and test equipment. (5) Store components removed from the SRS and seat belt with pre-tensioner in a clean and dry place. The air bag module and seat belt with pre-tensioner should be stored on a flat surface and placed so that the pad surface is facing upward. Do not place anything on top of it. (6) Never attempt to disassemble or repair the SRS components (SRS air bag control unit, air bag module, clock spring and side impact sensor) and seat belt with pre-tensioner. (7) Whenever you finish servicing the SRS and seat belt with pre-tensioner, check the SRS warning lamp operation to make sure that the system functions properly. (8) Be sure to deploy the air bag and seat belt with pre-tensioner before disposing of the air bag module and seat belt with pre-tensioner or disposing of a vehicle equipped with an air bag and seat belt with pre-tensioner. (Refer to GROUP 52B - Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures.) 2. Observe the following when carrying out operations on places where SRS components and seat belt with pre-tensioner are installed, including operations not directly related to the SRS air bag and seat belt with pre-tensioner. (1) When removing or installing parts do not allow any impact or shock to the SRS components and seat belt with pre-tensioner. (2) SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS components and seat belt with pre-tensioner before drying or baking the vehicle after painting. D SRS air bag control unit, air bag module, clock spring and side impact sensor: 93_C or more D Seat belt with pre-tensioner 90_C or more After re-installing them, check the SRS warning lamp operation to make sure that the system functions properly.
GENERAL - Precautions Before Service SERVICING THE ELECTRICAL SYSTEM
00-21
Before replacing a component related to the electrical system and before undertaking any repair procedures involving the electrical system, be sure to first disconnect the negative ( - ) cable from the battery in order to avoid damage caused by short-circuiting. Caution 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.)
APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS

If oil or grease gets onto the oxygen sensor, it will cause a drop in the performance of the sensor. Cover the oxygen sensor with a protective cover when applying anti-corrosion agents and undercoats.
PRE-INSPECTION CONDITION
Pre-inspection condition refers to the condition that the vehicle must be in before proper engine inspection can be carried out. If you see the words Set the vehicle to the pre-inspection condition. in this manual, it means to set the vehicle to the following condition. D Engine coolant temperature: 80 - 90_C D Lamps, electric cooling fan and all accessories: OFF D M/T: Neutral D A/T: P range
VEHICLE WASHING
Approx. 40 cm
If high-pressure car-washing equipment or steam car-washing equipment is used to wash the vehicle, be sure to note the following information in order to avoid damage to plastic components, etc. D Spray nozzle distance: Approx. 40 cm or more D Spray pressure: 3,900 kPa or less D Spray temperature: 82_C or less D Time of concentrated spray to one point: within 30 sec.
00-22
MUT-II sub-assembly
GENERAL - Precautions Before Service MUT-II

Refer to the MUT-II INSTRUCTION MANUAL for instructions on handling the MUT-II.
ROM pack
Connect the MUT-II to the diagnosis connector as shown in the illustration.

MUT-II
Caution Connection and disconnection of the MUT-II should always be made with the ignition switch in the OFF position.
IN ORDER TO PREVENT VEHICLES FROM FIRE

Improper installation of electrical or fuel related parts could cause a fire. In order to retain the high quality and safety of the vehicle, it is important that any accessories that may be fitted or modifications/repairs that may be carried out which involve the electrical or fuel systems, MUST be carried out in accordance with MMCs information/Instructions.
ENGINE OILS Health Warning

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitits. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them.
GENERAL - Precautions Before Service
00-23
Other precautions: D Avoid prolonged and repeated contact with oils, particularly used engine oils. D Wear protective clothing, including impervious gloves where practicable. D Avoid contaminating clothes, particularly underpants, with oil. D Do not put oily rags in pockets, the use of overalls without pockets will avoid this. D Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separately from personal clothing. D Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. D Obtain First Aid treatment immediately for open cuts and wounds. D Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised. D Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. D Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work. D If skin disorders develop, obtain medical advice without delay.
00-24
GENERAL -
Supplemental Restraint System (SRS) and Seatbelts with Pre-tensioner
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AND SEATBELTS 00100590073 WITH PRE-TENSIONER

To improve safety, the SRS and seat belts with pre-tensioner are available as optional parts. These systems enhance collision safety by restraining the front passengers in case of an accident. The SRS works with the pre-tensioner simultaneously when a collision is detected. The SRS consists of four air bag modules, SRS air bag control unit (SRS-ECU), side impact sensor, SRS warning lamp and clock spring. The air bags are located in the centre of the steering wheel, above the glove box, and built into the front seat back assemblies. Each air bag has a folded air bag and an inflator unit. The SRS-ECU under the floor console monitors the system and has a safing G sensor and an analog G sensor. The side impact sensor inside the center pillar monitors any shocks coming from the side of the vehicle. The warning lamp on the instrument panel indicates the operational status of the SRS. The clock spring is installed in the steering column. The SRS side air bag deploys if an impact received at the side of the vehicle is stronger than a certain set value, in order to protect the upper bodies of front seat passengers in the event of a collision. The seat belt pre-tensioner is built into the front seat belt retractor. Only authorized service personnel should do work on or around the SRS components and seat belt with pre-tensioner. Those service personnel should read this manual carefully before starting any such work. Extreme care must be used when servicing the SRS to avoid injury to the service personnel (by inadvertent deployment of the air bags or inadvertent operation of the seat belt with pre-tensioner) or the driver (by rendering the SRS or the seat belt with pre-tensioner inoperative).
Side impact sensor Side air bag module Clock spring Air bag module (Drivers side)
Air bag module (Front passengers side)
Diagnosis connector
SRS-ECU Seat belt with pre-tensioner SRS warning lamp
GENERAL -
00-25
SEAT BELT WITH PRE-TENSIONER The seat belt with pre-tensioner has a pre-tensioner operating mechanism and a G-sensor which detects the force from an impact built into the seat belt retractor. The G-sensor is a mechanical-type sensor which includes components such as a weight which moves as a result of the impact from a collision, and a spike which strikes a charge and causes it to detonate. Thus the pre-tensioner is equipped with a safety mechanism to prevent mis-operation during maintenance operations such as removal and installation of the seat belt.
The safety mechanism operates automatically when the retractor top mounting screw is removed during removal of the seat belt. When the retractor top mounting screw is removed, the force of the spring plate causes the tab at the lower edge of plate (A) to push in the pin of the G-sensor, which prevents the weight inside the G-sensor from moving. At the same time, the retractor bracket and the top of plate (A) become separated. A stopper is inserted into the gap thus formed by the force from a spring to prevent the tab from being removed from the pin if an outside force is applied to plate (A).
Plate (A) Spring Stopper Retractor bracket Plate (A) (when safety mechanism is disengaged) Plate (A) (when safety mechanism is engaged) Stopper
Spring plate
Tab
Tab
G-sensor structure Charge
Spike
Pin Pin (when safety mechanism is engaged)
Tab
Sensor weight
00-26
GENERAL -

00100600073
SRS SERVICE PRECAUTIONS

1. In order to avoid injury to yourself or others from accidental deployment of the air bag and accidental operation of the seat belt with pre-tensioner during servicing, read and carefully follow all the precautions and procedures described in this manual. 2. Do not use any electrical test equipment on or near SRS components, except those specified on GROUP 52B. 3. Never Attempt to Repair the Following Components: D SRS air bag control unit (SRS-ECU) D Clock Spring D Air bag module (Drivers side or front passengers side) D Side air bag module D Side impact sensor D Seat belt with Pre-tensioner
NOTE If any of these components are diagnosed as faulty, they should only be replaced, in accordance with the INDIVIDUAL COMPONENTS SERVICE procedures in this manual, starting at page GROUP 52B.
Insulating tape
Battery
4. After disconnecting the battery cable, wait 60 seconds or more before proceeding with the following work. The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected.
SRS-ECU connector <Vehicles without SRS side air bag>
5. Do not attempt to repair the wiring harness connectors of the SRS. If any of the connectors are diagnosed as faulty, replace the wiring harness. If the wires are diagnosed as faulty, replace or repair the wiring harness according to the following table.
<Vehicles with SRS side air bag>
GENERAL <Vehicles without SRS side air bag>

SRS-ECU Terminal No. 1 to 4 5, 6 7, 8 9, 10 11 12 13 14 15 16 to 19 20, 21 Destination of harness -
00-27
Corrective action Correct or replace the dash wiring harness. Replace the clock spring. Correct or replace the dash wiring harness.
Dash wiring harness Clock spring Air bag module (Drivers side) Dash wiring harness Air bag module (Front passengers side) Dash wiring harness Diagnosis connector Dash wiring harness Junction block (fuse No.4) Dash wiring harness Junction block (fuse No.13) Dash wiring harness Instrument panel wiring harness SRS warning lamp Dash wiring harness Earth
Correct or replace each wiring harness. Correct or replace the dash wring harness.

SRS-ECU Terminal No. 1, 2 3 4 5, 6 7, 8 9 10, 11 12 13 14, 15 16 17 to 20 21, 22 23, 24 Destination of harness Dash wiring harness Earth Dash wiring harness Instrument panel wiring harness SRS warning lamp Dash wiring harness Air bag module (Front Passengers side) Dash wiring harness Clock spring Air bag module (Drivers side) Dash wiring harness Junction block (fuse No.4) Dash wiring harness Junction block (fuse No.13) Dash wiring harness Earth Dash wiring harness Diagnosis connector Dash wiring harness Side air bag module (LH) Dash wiring harness Side air bag module (RH) Corrective action Correct or replace the dash wiring harness Correct or replace each wiring harness. Correct or replace the dash wiring harness. Correct or replace the dash wiring harness. Replace the clock spring. Correct or replace the dash wiring harness.
00-28
SRS-ECU Terminal No. 25 to 33 34, 35, 36 37 to 39 40, 41, 42
GENERAL Destination of harness -
Supplemental Restraint System (SRS) and Seatbelts with Pre-tensioner Corrective action Correct or replace the dash wiring harness. Correct or replace each wiring harness
Dash wiring harness Floor wiring harness Side impact sensor (LH) Dash wiring harness Floor wiring harness Side impact sensor (RH)
6. Inspection of the SRS-ECU harness connector <vehicles with SRS side air bag> should be carried out by the following procedure. Insert the special tool (narrow probe in the harness set) into connector from harness side (rear side), and connect the tester to this probe. If any to other than the special tool is used, it may cause damage to the harness and other components. Furthermore, measurement should not be carried out by touching the probe directly against the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are touched directly by the probe, the plating may break, which will cause drops in reliability.
MB991222 SRS-ECU harness connector SRS-ECU harness connector (rear side)
7. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module (drivers side and front passengers side), clock spring, side impact sensor, front seat assembly (side air bag module), and seat belt with pre-tensioner before drying or baking the vehicle after painting. D SRS-ECU, air bag module, clock spring, side impact sensor: 93_C or more D Seat belt with pre-tensioner: 90_C or more 8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system functions properly. (Refer to GROUP 52B.) 9. Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected. 10. If you have any questions about the SRS, please contact your local distributor. NOTE SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.
GENERAL - Support Locations for Lifting and Jacking
00-29
00100070065
SUPPORT LOCATIONS FOR LIFTING AND JACKING
Caution Do not support the vehicles at locations other than specified supporting points. If do so, this will cause damage, etc.
SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS

GARAGE JACK Caution Never support any point other than the specified one, or it will be deformed.
Caution Never support the rear floor crossmember.
AXLE STANDS
Notch Notch
Rubber
Rubber
00-30

Caution When service procedures require removing rear suspension, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes.
SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT
DOUBLE-POST LIFT Notch Notch
SINGLE-POST LIFT

H-bar lift H-bar lift
00-31
SUPPORT POSITIONS AND SUPPORT METHOD FOR AN H-BAR LIFT

Caution When service procedures require removing rear suspension, fuel tank, spare tyre and rear bumper, place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes. When H-bar lift is used to lift up vehicles, use of metallic attachment attached to the H-bar lift may cause damage to the suspension arm etc. Therefore, lift up the vehicle by the following procedure.
Chassis-support position (side sill) Attachment
1. Place the vehicle on the H-bar lift (same direction). 2. Place attachments on the H-bar lift at the designated chassis-support positions. When making the attachments, refer to the section concerning making them.
Section A-A Side sill
H-bar lift Attachment
Caution If support is at any location other than the designated positions, the body or suspension might be deformed or otherwise damaged, so care should be taken to support only at the correct (designated) positions. 3. Raise the H-bar lift to the height at which the vehicle is slightly raised and check to be sure that the vehicle is correctly and sufficiently secured; then raise the vehicle.
H-bar lift
00-32
Block (A) 1,800 90 95 Block (B) 15 40 60 40 20

mm
PREPARATION OF ATTACHMENTS 1. Prepare the blocks (wooden) and nails as shown in the figure.
Item Block (A) Block (B) Block (C) Dimensions mm 90 95 1,800 60 100 95 140 40 95 70 or more Quantity 2 4 8 32
Block (C) 15 40 40
Nail
20
Caution The wood selected for the blocks must be hard. 2. For the (B) blocks and (C) blocks, use a saw and chisel or similar tool to make grooves of the dimensions shown in the figure. 3. Make four ATTACHMENTS such as shown in the figure nailing (B) and (C) blocks so that each (B) blocks is sandwiches between (C) blocks.
140 100 40
Block (C) 100 Block (C) 140 Nail
Block (B) Finished attachment
Movable according to vehicle width
GENERAL - Standard Part/Tightening-Torque Table
00-33
00100110033
STANDARD PART/TIGHTENING-TORQUE TABLE

Each torque value in the table is a standard value for tightening under the following conditions. (1) Bolts, nuts and washers are all made of steel and plated with zinc. (2) The threads and bearing surface of bolts and nuts are all in dry condition. Standard bolt and nut tightening torque
Thread size Bolt nominal diameter (mm) M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 Pitch (mm) 0.8 1.0 1.25 1.25 1.25 1.5 1.5 1.5 1.5 1.5 1.5 Torque Nm Head mark 4 2.5 4.9 12 24 41 72 111 167 226 304 392 Head mark 7 4.9 8.8 22 44 81 137 206 304 412 559 735
The values in the table are not applicable: (1) If toothed washers are inserted. (2) If plastic parts are fastened. (3) If bolts are tightened to plastic or die-cast inserted nuts. (4) If self-tapping screws or self-locking nuts are used.
Head mark 8 5.9 9.8 25 52 96 157 235 343 481 647 853
Flange bolt and nut tightening torque

Thread size Bolt nominal diameter (mm) M6 M8 M10 M10 M12 M12 Pitch (mm) 1.0 1.25 1.25 1.5 1.25 1.75 Torque Nm Head mark 4 4.9 13 26 24 46 42 Head mark 7 9.8 24 49 44 93 81 Head mark 8 12 28 57 54 103 96
NOTES
11A-1
ENGINE
CONTENTS
11109000276
ENGINE <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A ENGINE <6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11B ENGINE <4D6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11C
11A-2
ENGINE <4G6>
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6
Drive Belt Tension Check and Adjustment . . . . . . 6 Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . 7 Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Compression Pressure Check . . . . . . . . . . . . . . . . . 9 Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . 10
11109000603
Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 11
CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 15 CAMSHAFT AND CAMSHAFT OIL SEAL . . . 16 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 20 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 22 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE <4G6> - General Information/Service Specifications
11A-3
11100010469
GENERAL INFORMATION
Items Total displacement mL Bore Stroke mm Compression ratio Combustion chamber Camshaft arrangement Number of valve Intake Exhaust Intake Valve timing Exhaust Fuel system Rocker arm Auto-lash adjuster Opening Closing Opening Closing 4G63 1,997 85.0 88.0 10.0 Pentroof type SOHC 8 8 BTDC 11_ ABDC 53_ BBDC 63_ ATDC 21_
Electronically controlled multipoint fuel injection Roller type Equipped

11100030489
SERVICE SPECIFICATIONS
Items When checked Tension N Alternator drive belt tension When a used belt is installed When a new belt is installed Deflection (Reference value) mm When checked When a used belt is installed When a new belt is installed When checked Power steering oil pump and A/C compressor drive belt tension Tension N When a used belt is installed When a new belt is installed When checked Deflection mm When a used belt is installed When a new belt is installed Basic ignition timing Ignition timing Standard value 294 - 490 343 - 441 490 - 686 7.7 - 12.3 8.4 - 10.6 5.9 - 7.7 392 - 588 441 - 539 637 - 833 11.7 - 15.3 12.5 - 14.3 8.8 - 11.0 5_ BTDC2_ Approx. 10_BTDC Limit -
11A-4
Items
ENGINE <4G6> - Service Specifications/Sealants/Special Tools

Standard value 750 100 0.5 or less 100 or less 1,400 Within 1 3.5 3.8 - 4.5 5-7 Limit Min. 1,060 Max. 100 Min. 69 99.4 11100050201
Idle speed r/min CO contents % HC contents ppm Compression pressure (250 - 400 r/min) kPa Compression pressure difference of all cylinder kPa Intake manifold vacuum kPa Cylinder head bolt shank length mm Auto-tensioner push rod movement mm Timing belt tension torque Nm (Reference value) Auto-tensioner rod protrusion amount mm Timing belt B tension mm
SEALANTS
Items Rocker cover and cylinder head Semi-circular packing Oil pan Thermostat case Flywheel bolt Specified sealants 3M ATD Part No.8660 or equivalent MITSUBISHI GENUINE MD970389 or equivalent PART Remarks Semi-drying sealant -
3M Stud Locking 4170 or equivalent
SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub assembly Use D D Checking the idle speed Erasing diagnosis code
11100060457
MB990767
End yoke holder
D D
Holding the camshaft sprocket Holding the crankshaft sprocket
MD998719 MD998754
or
Crankshaft pulley holder pin
D D
Holding the camshaft sprocket Holding the crankshaft sprocket
ENGINE <4G6> - Special Tools

Tool Number MD998713 Name Camshaft oil seal installer Use Press-in of the camshaft oil seal
11A-5
MD998443
Auto-lash adjuster holder
Supporting of auto-lash adjuster
MD998727
Oil pan remover
Removal of oil pan
MD998781
Flywheel stopper
Securing the flywheel
MD998776
Crankshaft rear oil seal installer
Press-in of the crankshaft rear oil seal
MB990938
Handle
MD998767
Tension pulley socket wrench
Timing belt tension adjustment
GENERAL SERVICE TOOL MZ203827
Engine lifter
Supporting the engine assembly during removal and installation of the transmission
MB991453
Engine hanger assembly
11A-6
Alternator pulley
ENGINE <4G6> - On-vehicle Service

Water pump pulley
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK AND ADJUSTMENT
11100090432
Crankshaft pulley
ALTERNATOR DRIVE BELT TENSION CHECK Use a belt tension gauge to check that the belt tension is at the standard value at a point half-way between the two pulleys as shown in the illustration. In addition, press this section with a force of 98 N and check that the amount of belt deflection is at the standard value. Standard value:
Tension N Deflection (Reference value) mm 294 - 490 7.7 - 12.3
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen the nut of the alternator pivot bolt. 2. Loosen the lock bolt. 3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. Standard value:
Adjusting bolt Lock bolt
Items Tension N
When a used belt is installed 343 - 441
When a new belt is installed 490 - 686 5.9 - 7.7
Deflection (Reference 8.4 - 10.6 value) mm
4. Tighten the nut of the alternator pivot bolt. Tightening torque: 44 Nm 5. Tighten the lock bolt. Tightening torque: 22 Nm 6. Tighten the adjusting bolt. Tightening torque: 10 Nm

<Vehicles without A/C> Oil pump pulley 98 N A Crankshaft pulley Tensioner pulley B
11A-7
POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT 11100130127 1. Use a belt tension gauge to check that the belt tension is at the standard value at a point half-way between the two pulleys (indicated by an arrow in the illustration). In addition, press this section with a force of 98 N and check that the amount of belt deflection is at the standard value. Standard value:
Items When checked 392 - 588 11.7 - 15.3 When a used belt is installed 441 - 539 12.5 - 14.3 When a new belt is installed 637 - 833 8.8 - 11.0
<Vehicles with A/C> Oil pump pulley 98 N Crankshaft pulley A Tensioner pulley B A/C compressor pulley
Tension N Deflection (Reference value) mm
2. If the tension or deflection is outside the standard value, adjust by the following procedure. (1) Loosen tensioner pulley fixing nut A. (2) Adjust the amount of belt deflection using adjusting bolt B. (3) Tighten fixing nut A. Tightening torque: 25 Nm (4) Check the belt deflection amount and tension, and readjust if necessary. Caution Check after turning the crankshaft once or more clockwise (right turn).
IGNITION TIMING CHECK
11100170297
1. Before inspection, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector. 3. Set up a timing light. 4. Start the engine and run at idle. 5. Check that engine idle speed is within the standard value. Standard value: 750 100 r/min 6. Select No.17 of the MUT-II Actuator test.
11A-8

7. Check that basic ignition timing is within the standard value. Standard value: 5_ BTDC2_ 8. If the basic ignition timing is outside the standard value, inspect the MPI system while referring to GROUP 13A - Troubleshooting. 9. Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test. Caution If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine. 10. Check that ignition timing is at the standard value. Standard value: approx. 10_BTDC NOTE 1. Ignition timing is variable within about 7_, even under normal operating. 2. And it is automatically further advanced by about 5_ from standard value at higher altitudes.
IDLE SPEED CHECK
11100350066
1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to OFF and connect the MUT-II to the diagnosis connector. 3. Check the basic ignition timing. Standard value: 5_ BTDC2_ 4. Run the engine at idle for 2 minutes. 5. Check the idle speed. Select item No. 22 and take a reading of the idle speed. Standard value: 750 100 r/min NOTE The idle speed is controlled automatically by the idle speed control (ISC) system. 6. If the idle speed is outside the standard value, inspect the MPI components by referring to GROUP 13A Troubleshooting.
IDLE MIXTURE CHECK
11100210418
1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to OFF and connect the MUT-II to the diagnosis connector. 3. Check that the basic ignition timing is within the standard value. Standard value: 5_ BTDC2_ 4. Run the engine at 2,500 r/min for 2 minutes.
11A-9
5. Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. Standard value CO contents: 0.5% or less HC contents: 100 ppm or less 7. If there is a deviation from the standard value, check the following items: D Diagnosis output D Closed-loop control (When the closed-loop control is normal, the output signal of the oxygen sensor changes between 0 - 400 mV and 600 - 1,000 mV at idle.) D Fuel pressure D Injector D Ignition coil, spark plug cable, spark plug D Leak in the EGR system and in the EGR valve D Evaporative emission control system D Compression pressure NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.
COMPRESSION PRESSURE CHECK
11100260499
1. Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition. 2. Disconnect the spark plug cables. 3. Remove all of the spark plugs. 4. Disconnect the crank angle sensor connector. NOTE Doing this will prevent the engine-ECU from carrying out ignition and fuel injection. 5. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. Caution 1. Keep away from the spark plug hole when cranking. 2. If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.
11A-10

6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure.
Compression gauge
Standard value (at engine speed of 250 - 400 r/min): 1,400 kPa Limit (at engine speed of 250 - 400 r/min): Min. 1,060 kPa 8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 100 kPa 9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 7 and 8. (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 10. Connect the crank angle sensor connector. 11. Install the spark plugs and spark plug cables. 12. Use the MUT-II to erase the diagnosis codes. NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.
MANIFOLD VACUUM CHECK

Vacuum gage
11100270409
1. Start the engine and allow it to warm up until the temperature of the engine coolant reaches 80 to 95_C. 2. Connect a tachometer. 3. Attach a three-way union to the vacuum hose between the fuel pressure regulator and the air intake plenum, and connect a vacuum gauge. 4. Start the engine and check that idle speed is within standard value. Then read off the vacuum gauge. Limit: Min. 69 kPa
ENGINE <4G6> - On-vehicle Service LASH ADJUSTER CHECK
11A-11
11100290344
If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE (1) The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load. Because of this, if the noise does not occur immediately after the engine is started, if it does not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters. (2) If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick. 1. Start the engine. 2. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. If the noise does not occur immediately after the engine is started, or if it does not change in accordance with the engine speed, the problem is not being caused y the lash adjusters, so check for some other cause of the problem. Moreover, if the noise does not change in accordance with the engine speed, the cause of the problem is probably not with the engine. (In these cases, the lash adjusters are normal.) 3. While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N D). If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings. (In such cases, the lash adjusters are normal.) 4. After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or has disappeared, the cause of the noise was probably that oil sludge had caused the lash adjusters to become stuck. If this happens, carry out the following check. If the noise level does not change, go to step 5. (1) Let the engine cool down sufficiently. (2) Turn the crankshaft two full revolutions.
11A-12

(3) Carry out lash adjuster simple check. (Refer to P.11A-13.) D If any of the rocker arms can be pushed down easily during the lash adjuster simple check, replace the corresponding lash adjusters. D If the lash adjuster simple check has been carried out but all lash adjusters are normal (if none of the rocker arms could be pushed down easily), check for some other cause of the problem. NOTE You can check whether the lash adjusters are normal or not by carrying out a leak-down test. (Refer to the Engine Workshop Manual.) Caution Make sure that the air has been fully bled before installation of a new lash adjuster. (Refer to the Engine Workshop Manual.) 5. Bleed the air from the lash adjusters. (Refer to P.11A-13.) 6. If the noise does not disappear even after the air has been bled from the lash adjusters, carry out the following check. Carry out lash adjuster simple check. (Refer to P.11A-13.) D If one of the rocker arms can be pushed down easily during the lash adjuster simple check, replace the corresponding lash adjuster. D If two or more of the rocker arms can be pushed down easily during the lash adjuster simple check, the cause may be that the oil passage to the cylinder head is blocked. Check for blockages in the oil passage, and clear the blockages if any are found. If there are no blockages, replace the lash adjusters. D If the lash adjuster simple check has been carried out but all lash adjusters are normal (if none of the rocker arms could be pushed down easily), check for some other cause of the problem. NOTE You can check whether the lash adjusters are normal or not by carrying out a leak-down test. (Refer to the Engine Workshop Manual.) Caution Make sure that the air has been fully bled before installation of a new lash adjuster. (Refer to the Engine Workshop Manual.) 7. Start the engine and check that the abnormal noise has disappeared. If necessary, bleed the air from the lash adjusters. (Refer to P.11A-13.)
11A-13
<LASH ADJUSTER SIMPLE CHECK> 1. Stop the engine. 2. Remove the rocker cover. 3. Set the No.1 cylinder to the compression top dead centre position. 4. Check the rocker arms indicated by white arrows in the illustration by the procedures given below. <Checking an intake-side rocker arm> Check whether the rocker arm moves downwards when the part of the rocker arm which touches the top of the lash adjuster is pushed. D If the rocker arm moves down easily when it is pushed, make a note of which is the corresponding lash adjuster. D If the rocker arm feels extremely stiff when it is pushed and does not move down, the lash adjuster is normal, so check for some other cause of the problem. <Checking an exhaust-side rocker arm> NOTE It will not be possible to depress the Y-shaped rocker arm at the exhaust valve side if one lash adjuster is defective but the other one is normal. In such cases, carry out the following procedure using a thickness gauge. (1) Check that a thickness gauge with a thickness of 0.1 - 0.2 mm can be inserted easily between the valve and the lash adjuster. (2) If the thickness gauge can be inserted easily, make a note of which is the corresponding lash adjuster. (3) If the thickness gauge cannot be inserted easily, the lash adjuster is normal, so check for some other cause of the problem. 5. Slowly turn the crankshaft 360_ in the clockwise direction. 6. Check the rocker arms indicated by black arrows in the illustration in the same way as explained in step 4. <LASH ADJUSTER AIR BLEEDING> NOTE (1) If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine. (2) After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber. (3) If either of the above situations occur, the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters.
11A-14

1. Check the engine oil and replenish or replace the oil if necessary. NOTE (1) If there is a only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage. (2) If the amount of oil is greater than normal, then the oil will being mixed by the crankshaft and a large amount of air may get mixed into the oil. (3) If the oil is degenerated, air and oil will not separate easily in oil, and the amount of air mixed into the oil will increase.
Good
High pressure chamber
(4) If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve closes. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal. 2. Run the engine at idle for 1 - 3 minutes to let it warm up. 3. With no load on the engine, repeat the drive pattern shown in the illustration at left and check if the abnormal noise disappears. (The noise should normally disappear after 10 - 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably not due to air inside the lash adjusters.) 4. After the noise has disappeared, repeat the drive pattern shown in the illustration at left a further 5 times. 5. Run the engine at idle for 1 - 3 minutes and check that the noise has disappeared.
Drive pattern for air bleeding Gradually open the Close the throttle throttle valve. valve. Approx. 3,000 r/min. Idle speed
15 seconds 15 seconds
Once
ENGINE <4G6> - Crankshaft Pulley
11A-15
11200160303
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
Pre-removal Operation D Under Cover Removal
Post-installation Operation D Drive Belt Tension Adjustment (Refer to P.11A-6.) D Under Cover Installation
2 3
25 Nm
Removal steps 1. Drive belt (Power steering and A/C)
2. Drive belt (Alternator) 3. Crankshaft pulley
11A-16
ENGINE <4G6> - Camshaft and Camshaft Oil Seal

11200190418
CAMSHAFT AND CAMSHAFT OIL SEAL

Pre-removal and Post-installation Operation D Air Cleaner Removal and Installation D Timing Belt Removal and Installation (Refer to P.11A-26.) D Relay Box Removal and Installation
10 Nm
1 2
(f 3 1 mm)
4
14 Nm 3.4 Nm
3
22 Nm
Sealant: MITSUBISHI GENUINE PART MD970389 or equivalent
5
28 - 34 Nm
8
Lip section
9 5 6 12 10
11
88 Nm
Cam section and journal section
12 8 7
Engine oil
Removal steps 1. Control harness connection 2. Spark plug cable 3. PCV hose connection 4. Rocker cover 5. Camshaft position sensor support 6. Camshaft position sensing cylinder AA" "CA 7. Camshaft sprocket
"BA 8. Camshaft oil seal 9. Spark plug guide oil seal AB" "AA 10. Rocker arm and shaft assembly (intake side) AB" "AA 11. Rocker arm and shaft assembly (exhaust side) 12. Camshaft
ENGINE <4G6> - Camshaft and Camshaft Oil Seal REMOVAL SERVICE POINTS
MB990767
11A-17
AA" CAMSHAFT SPROCKET REMOVAL
MD998719 or MD998754
MD998443
AB" ROCKER ARM AND SHAFT ASSEMBLY REMOVAL Before removing the rocker arm and shaft assembly, install the special tools as shown in the illustration so that the lash adjusters will not fall out.
INSTALLATION SERVICE POINTS

"AA ROCKER ARM AND SHAFT ASSEMBLY
INSTALLATION 1. Temporarily tighten the rocker shaft with the bolt so that all rocker arms on the inlet valve side do not push the valves. 2. Fit the rocker shaft spring from the above and position it so that it is right angles to the plug guide. NOTE Install the rocker shaft spring before installing the rocker arm and rocker arm shaft on the exhaust side. 3. Remove the special tool for fixing the lash adjuster.
4. Confirm that the rocker shaft notch is in the direction shown in the diagram.
11A-18
ENGINE <4G6> - Camshaft and Camshaft Oil Seal

"BA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the camshaft oil seal lip. 2. Use the special tool to press-fit the camshaft oil seal.
MD998713
"CA CAMSHAFT SPROCKET INSTALLATION Use the special tool to stop the camshaft sprocket from turning in the same way as was done during removal, and then tighten the bolts to the specified torque.
ENGINE <4G6> - Oil Pan
11A-19
11200280207
OIL PAN
Pre-removal and Post-installation Operation D Engine Oil Draining and Supplying (Refer to GROUP 12 - On-vehicle Service.) D Oil Level Gauge Removal and Installation D
Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.)
5
f 4 1 mm Groove Bolt hole
3
Sealant: MITSUBISHI GENUINE MD970389 or equivalent PART
7 Nm 9 Nm
2 1
9 Nm
Removal steps 1. Drain plug "AA 2. Drain plug gasket 3. Bell housing cover
MD998727 MD998727
AA"
4. Oil level sensor 5. Oil pan
REMOVAL SERVICE POINT

AA" OIL PAN REMOVAL After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar. Caution Perform this slowly to avoid deformation of the oil pan flange.
INSTALLATION SERVICE POINT

Oil pan side Drain plug gasket
"AA DRAIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces as shown in the illustration.
11A-20
ENGINE <4G6> - Crankshaft Oil Seal

11200310135
CRANKSHAFT OIL SEAL

127 - 137 Nm
7 8
<M/T>
9 11 12
127 - 137 Nm <A/T>
6 2 8 10 1
<M/T> <A/T> Crankshaft Crankshaft
(Engine oil: bolt washer surface)
12
9 10
Lip section
Lip section
Sealant: 3M Stud locking 4170 or equivalent
Engine oil
Crankshaft front oil seal removal steps D Timing belt (Refer to P.11A-26.) D Crank angle sensor (Refer to GROUP 16.) 1. Crankshaft sprocket 2. Flange 3. Crankshaft sprocket B 4. Key "CA 5. Crankshaft front oil seal
AA" AB" AB" AB" AB" AB" "BA "BA "BA "BA "BA "AA
Crankshaft rear oil seal removal steps D Oil pan (Refer to P.11A-19.) D Transmission assembly D Clutch cover and disc <M/T> 6. Crankshaft bushing 7. Plate <M/T> 8. Adapter plate 9. Flywheel <M/T> 10. Drive plate <A/T> 11. Adapter plate <M/T> 12. Crankshaft rear oil seal
ENGINE <4G6> - Crankshaft Oil Seal

<M/T>
11A-21
REMOVAL SERVICE POINTS

AA" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to GROUP 22. Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become out of balance and damaged. <A/T>: Refer to GROUP 23. AB" PLATE <M/T>/ADAPTER PLATE/FLYWHEEL <M/T>/DRIVE PLATE <A/T> REMOVAL Use the special tool to secure the flywheel or drive plate, and remove the bolts.
Flywheel Bolt
MD998781
Crankshaft rear oil seal MD990938

Crankshaft
"AA CRANKSHAFT REAR OIL SEAL INSTALLATION 1. Apply a small mount of engine oil to the entire circumference of the oil seal lip. 2. Install the oil seal by tapping it as far as the chamfered position of the oil seal case as shown in the illustration.
MD998776
"BA DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER PLATE/PLATE <M/T> INSTALLATION 1. Clean off all sealant, oil and other substances which are adhering to the threaded bolts, crankshaft thread holes and the flywheel or drive plate. 2. Apply oil to the bearing surface of the flywheel or drive plate bolts. 3. Apply oil to the crankshaft thread holes. 4. Apply sealant to the threaded mounting holes. Specified sealant: 3M Stud locking 4170 or equivalent 5. Use the special tool to hold the flywheel or drive plate in the same manner as removal, and install the bolt. "CA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1. Apply a small amount of engine oil to the entire circumference of the oil seal lip. 2. Press-fit the oil seal unit it is flush with the oil seal case.
11A-22
ENGINE <4G6> - Cylinder Head Gasket

11200400542
CYLINDER HEAD GASKET

Pre-removal Operation D Fuel Discharge Prevention (Refer to GROUP 13A - On-vehicle Service.) D Engine Oil Draining (Refer to GROUP 12 On-vehicle Service.) D Thermostat Case Assembly Removal (Refer to GROUP 14 - Water Hose and Water Pipe.)
Post-installation Operation D Thermostat Case Assembly Installation (Refer to GROUP 14 - Water Hose and Water Pipe.) D Engine Oil Supplying (Refer to GROUP 12 On-vehicle Service.) D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)
Delivery pipe
O-ring
1 9 10 10
7 5 2
Engine oil
8 6 4
3 11
Removal steps 1. Accelerator cable connection 2. Vacuum hose connection 3. Brake booster vacuum hose connection 4. Vacuum hose connection 5. Throttle position sensor connector 6. Idle speed control connector
7. Injector connector 8. Purge control solenoid valve connector 9. EGR solenoid valve connector "CA 10. High-pressure fuel hose connection 11. Fuel return hose connection

10 Nm
11A-23
15 <Cold engine> 78 Nm 0 Nm 20 Nm + 90_ + 90_ 16 27

(Engine oil) 3.4 Nm
14
12 26
17
19 28 13
22 20 21
29 18
49 Nm
24
24 Nm 44 Nm
25 23
31 Nm 34 Nm
12. 13. 14. 15. 16. 17.
Radiator upper hose connection PCV hose Ignition coil connector Ignition coil assembly Breather hose Engine coolant temperature sensor connector 18. Engine coolant temperature gauge unit connector 19. Camshaft position sensor 20. Water hose connection
AA"
21. 22. 23. 24.
25. 26. D AB" "BA 27. 28. "AA 29.
Heater hose connection Thermostat case assembly Water hose connection Power steering oil pump and bracket assembly Front exhaust pipe connection Rocker cover Timing belt (Refer to P.11A-26.) Cylinder head bolt Cylinder head assembly Cylinder head gasket
11A-24
ENGINE <4G6> - Cylinder Head Gasket REMOVAL SERVICE POINTS

AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the cylinder head assembly, and tie it with a cord. AB" CYLINDER HEAD BOLT REMOVAL Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove the cylinder head assembly. Caution Because the plug guides cannot be replaced by themselves, be careful not to damage or deform the plug guides when removing the cylinder head bolts.
Intake side
Front of engine
10
Exhaust side

"AA CYLINDER HEAD GASKET INSTALLATION 1. Wipe off all oil and grease from the gasket mounting surface. 2. Install so that the shapes of the cylinder head holes match the shapes of the respective cylinder head gasket holes.
Burred side Head bolt washer Cylinder head
Head bolt (Engine oil)
"BA CYLINDER HEAD BOLT INSTALLATION 1. When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts. Limit (A): 99.4 mm 2. The head bolt washer should be installed with the burred side caused by tapping out facing upwards. 3. Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt.

Intake side Front of engine
11A-25
Remarks Carry out in the order shown in the illustration. Carry out in the reverse order of that shown in the illustration. Carry out in the order shown in the illustration. In the order shown in the illustration. Mark the head of the cylinder head bolt and cylinder head by paint. In the order shown in the illustration. Check that the painted mark of the head bolt is lined up with that of the cylinder head.
4. Tighten the bolts by the following procedure.

Step 1
9
Operation Tighten to 78 Nm. Fully loosen.
2
10 4 2 5 7
3
Exhaust side
Tighten to 20 Nm. Tighten 90_ of a turn.
4
Step 4 90_ Step 5 90_
Tighten 90_ of a turn.
Painted mark
Painted mark
Caution 1. Always make a tightening angle just 90_. If it is less than 90_, the head bolt will be loosened. 2. If it is more than 90_, remove the head bolt and repeat the procedure from step 1.
"CA HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a small amount of new engine oil to the O-ring. Caution Do not let any engine oil get into the delivery pipe. 2. While turning the high-pressure fuel hose to the right and left, install the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the high-pressure fuel hose and check the O-ring for damage. After this, re-insert the delivery pipe and check that the hose turns smoothly.
11A-26 TIMING BELT
ENGINE <4G6> - Timing Belt

11200430473

Pre-removal and Post-installation Operation D Crankshaft Pulley Removal and Installation (Refer to P.11A-15.) D Engine Mount Bracket Removal and Installation (Refer to GROUP 32 - Engine Mounting.)
1
10 - 12 Nm
48 Nm
4
24 Nm
9 Nm
Removal steps 1. Timing belt upper cover 2. Timing belt lower cover "CA D Timing belt tension adjustment AA" "BA 3. Timing belt 4. Tension pulley "AA 5. Auto tensioner

Timing mark (Top of cylinder head) Timing mark Camshaft sprocket
11A-27

AA" TIMING BELT REMOVAL 1. Turn the crankshaft clockwise (right turn) to align each timing mark and to set the No. 1 cylinder at compression top dead centre. Caution The crankshaft should always be turned only clockwise.
Timing mark Timing mark Crankshaft sprocket
Timing mark Oil pump sprocket
2. Loosen the tension pulley centre bolt. 3. Move the tension pulley to the water pump side, and then remove the timing belt.
Centre bolt
Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.

98N - 196N
Movement Push rod
"AA AUTO TENSIONER INSTALLATION 1. Apply 98 - 196 N force to the auto tensioner by pressing it against a metal (cylinder block, etc.), and measure the movement of the push rod. Standard value: Within 1 mm A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement 2. If it is out of the standard value, replace the auto tensioner.
Auto tensioner
3. Use a press or vice to gently compress the auto tensioner push rod until pin hole A of the push rod and pin hole B of the tensioner cylinder are aligned. Caution If the compression speed is too fast, the rod may become damaged, so be sure to carry out this operation slowly.
11A-28
Set pin

4. Once the holes are aligned, insert the set pin. NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner. 5. Install the auto tensioner to the engine.
Timing mark (Top of cylinder head)
Timing mark Camshaft sprocket
"BA TIMING BELT INSTALLATION 1. Align the timing marks on the camshaft sprocket, crankshaft sprocket and oil pump sprocket.
Timing mark Timing mark Crankshaft sprocket
Timing mark Oil pump sprocket
Plug
60 mm or more
8 mm
Screwdriver Counterbalance shaft
Cylinder block
2. After aligning the timing mark on the oil pump sprocket, remove the cylinder block plug and insert a Phillips screwdriver with a diameter of 8 mm, and check to be sure that the screwdriver goes in 60 mm or more. If the screwdriver will only go in 20 - 25 mm before striking the counterbalance shaft, turn the sprocket once, realign the timing mark and check that the screwdriver goes in 60 mm or more. The screwdriver should not be taken out until the timing belt is installed.
3. Install the belt to the crankshaft sprocket, oil pump sprocket and camshaft sprocket in that order, so that there is no slackness in the belt tension.
Fixing bolt Pin hole Belt tension side
Caution If the timing belt is re-used, install so that the arrow marked on it at time of removal is pointing in the clockwise direction. 4. Set the tension pulley so that the pin holes are at the top, press the tension pulley lightly against the timing belt, and then provisionally tighten the fixing bolt. 5. Adjust the timing belt tension.
Belt tension side

50 Nm
11A-29
MD998767
Tension direction
"CA TIMING BELT TENSION ADJUSTMENT 1. After turning the crankshaft 1/4 of a revolution in the anticlockwise direction, turn it in the clockwise direction until the timing marks are aligned. 2. Loosen the tension pulley fixing bolt, and then use the special tool and a torque wrench to tighten the fixing bolt to the specified torque while applying tension to the timing belt. Standard value: 3.5 Nm <Timing belt tension torque> Caution When tightening the fixing bolt, make sure that the tension pulley does not turn with the bolt.
3. Turn the crankshaft two revolutions in the clockwise direction so that the timing marks are aligned. After leaving it for 15 minutes, measure the amount of protrusion of the auto tensioner. Standard value (A): 3.8 - 4.5 mm 4. If the amount of protrusion is outside the standard value, repeat the operation in steps (1) to (3). 5. Check again to be sure that the timing marks of each sprocket are aligned.
Auto tensioner
11A-30 TIMING BELT B
ENGINE <4G6> - Timing Belt B

11200460106
5 1
19 Nm
3 2
108 - 127 Nm
Removal steps 1. Timing belt (Refer to P.11A-26.) AA" "CA 2. Crankshaft sprocket "BA 3. Flange
4. Timing belt B tensioner AB" "AA 5. Timing belt B
Crankshaft sprocket
MD998719 or MD998754

AA" CRANKSHAFT SPROCKET REMOVAL
MB990767
AB" TIMING BELT B REMOVAL Caution If timing belt B is to be re-used, use chalk to mark it with an arrow on its flat side indicating the turning direction (to the right).

Counterbalance shaft sprocket Belt tension side
11A-31

"AA TIMING BELT B INSTALLATION, ADJUSTMENT 1. Install timing belt B by the following procedure. (1) Ensure that crankshaft sprocket B timing mark and the counterbalance shaft sprocket timing mark are aligned. (2) Fit timing belt B over crankshaft sprocket B and the counterbalance shaft sprocket. Ensure that there is no slack in the belt. 2. Adjust the tension of timing belt B by the following procedure. (1) Temporarily fix the timing belt B tensioner such that the centre of the tensioner pulley is to the left and above the centre of the installation bolt, and temporarily attach the tensioner pulley so that the flange is toward the front of the engine.
Timing marks Crankshaft sprocket B
Timing marks
Centre of tensioner pulley
Centre of installation bolt
Shaft
(2) Holding the timing belt B tensioner up with your finger in the direction of the arrow, place pressure on the timing belt so that the tension side of the belt is taut. Now tighten the bolt to fix the tensioner. Caution When tightening the bolt, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension on the belt.
3. To ensure that the tension is correct, depress the belt (point A) with a finger. If not, adjust. Standard value: 5 - 7 mm
Centre of tensioner pulley Centre of installation bolt
"BA FLANGE INSTALLATION When installing, make sure the direction is correct. See figure.
Crankshaft
Crankshaft sprocket Flange
Crankshaft sprocket B
11A-32
Crankshaft sprocket

MD998719 or MD998754
"CA CRANKSHAFT SPROCKET INSTALLATION NOTE Apply the minimum amount of engine oil to the bearing surface and thread of the crankshaft bolt.
MB990767
ENGINE <4G6> - Engine Assembly
11A-33
11200090015
ENGINE ASSEMBLY
Pre-removal Operation D Fuel Discharge Prevention (Refer to GROUP 13A - On-vehicle Service.) D Engine Coolant Draining D Thermostat Case Assembly Removal (Refer to GROUP 14 - Water Hose and Water Pipe.) D Front Exhaust Pipe Removal (Refer to GROUP 15.) D Hood Removal (Refer to GROUP 42.) D Under Cover Removal D Radiator Assembly Removal (Refer to GROUP 14.) D Air Cleaner Removal
Post-installation Operation D Thermostat Case Assembly Installation (Refer to GROUP 14 - Water Hose and Water Pipe.) D Engine Coolant Supplying D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.) D Front Exhaust Pipe Installation (Refer to GROUP 15.) D Hood Installation (Refer to GROUP 42.) D Under Cover Installation D Radiator Assembly Installation (Refer to GROUP 14.) D Air Cleaner Installation
1 10 9
Delivery pipe
O-ring
10
7 5 8 2 12 6 4
Engine oil
3 11
Removal steps 1. Accelerator cable connection 2. Vacuum hose connection 3. Brake booster vacuum hose connection 4. Vacuum hose connection 5. Throttle position sensor connector 6. Idle speed control connector
7. Injector connector 8. Purge control solenoid valve connector 9. EGR solenoid valve connector "DA 10. High-pressure fuel hose connection 11. Fuel return hose connection 12. PCV hose connection
11A-34
20 22 23
ENGINE <4G6> - Engine Assembly

15
26
49 Nm
21
19
17 18
16
14 13
57 Nm*
24 25
25
98 Nm
AA" AB"
13. Drive belt (Alternator) 14. Drive belt (Power steering and A/C) 15. Power steering oil pump and bracket assembly 16. A/C compressor 17. Alternator connector 18. Oil pressure switch connector 19. Heater hose connection 20. Engine coolant temperature gauge unit connector 21. Engine coolant temperature sensor connector
22. 23. AC" D AD" "CA 24. "BA 25. AE" "AA 26.
Camshaft position sensor connector Detonation sensor connector Transmission assembly Engine mount bracket Engine mount stopper Engine assembly
Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.
ENGINE <4G6> - Engine Assembly REMOVAL SERVICE POINTS
11A-35
AA" POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL Remove the power steering oil pump and bracket assembly from the engine with the hose attached. NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord. AB" A/C COMPRESSOR REMOVAL Disconnect the A/C compressor connector and remove the compressor from the compressor bracket with the hose still attached. NOTE Place the removed A/C compressor where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord.
<M/T>
AC" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to GROUP 22.

Flywheel
Bolt
Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become out of balance and damaged. <A/T>: Refer to GROUP 23. AD" ENGINE MOUNT BRACKET REMOVAL 1. Support the engine with a garage jack. 2. Remove the special tool which was attached when the transmission assembly was removed. 3. Hold the engine assembly with a chain block or similar tool. 4. Place a garage jack against the engine oil pan with a piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket. AE" ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.
MZ203827
MB991453
11A-36
ENGINE <4G6> - Engine Assembly INSTALLATION SERVICE POINTS

"AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped.
Engine side Dynamic damper Arrow
"BA ENGINE MOUNT STOPPER INSTALLATION Clamp the engine mount stopper so that the arrow points in the direction as shown in the diagram.
Engine mount stopper Engine mount bracket
"CA ENGINE MOUNT BRACKET INSTALLATION 1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine. 2. Support the engine with the garage jack. 3. Remove the chain block and support the engine assembly with the special tool.
"DA HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a small amount of new engine oil to the O-ring. Caution Do not let any engine oil get into the delivery pipe. 2. While turning the high-pressure fuel hose to the right and left, install it to the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the high-pressure fuel hose and check the O-ring for damage. After this, re-insert the delivery pipe and check that the hose turns smoothly.
11B-1
ENGINE <6A1>
CONTENTS
Drive Belt Tension Check and Adjustment . . . . . . 5 Ignition Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . 6 Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Idle Mixture Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Compression Pressure Check . . . . . . . . . . . . . . . . . 8 Manifold Vacuum Check . . . . . . . . . . . . . . . . . . . . . . 9 Lash Adjuster Check . . . . . . . . . . . . . . . . . . . . . . . . 10
11109000610
CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 14 CAMSHAFT AND CAMSHAFT OIL SEAL . . . 15 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 21 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 24 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 30
11B-2
ENGINE <6A1> - General Information/Service Specifications

11100010452
GENERAL INFORMATION
Items Total displacement mL Bore Stroke mm Compression ratio Combustion chamber Camshaft arrangement Number of valve Intake Exhaust Intake Valve timing Exhaust Fuel system Rocker arm Auto-lash adjuster Opening Closing Opening Closing 6A13 2,498 81.0 80.8 9.5 Pentroof type SOHC 12 12 BTDC 15_ ABDC 53_ BBDC 53_ ATDC 15_
Electronically controlled multipoint fuel injection Roller type Equipped

11100030496
Items When checked Tension N Alternator drive belt tension When a used belt is installed When a new belt is installed Deflection (Reference value) mm When checked When a used belt is installed When a new belt is installed When checked Power steering oil pump and A/C compressor drive belt tension Tension N When a used belt is installed When a new belt is installed Deflection (Reference value) mm When checked When a used belt is installed When a new belt is installed Standard value 294 - 490 343 - 441 490 - 686 9.0 - 13.0 10.0 - 12.0 6.8 - 8.0 490 - 686 539 - 637 784 - 980 11.0 - 15.0 12.0 - 14.0 8.0 - 12.0 5_ BTDC3_ Approx. 7 BTDC Limit -
Basic ignition timing Ignition timing
ENGINE <6A1> - Service Specifications/Sealants/Special Tools

Items Idle speed r/min CO contents % HC contents ppm Compression pressure (250 - 400 r/min) kPa Compression pressure difference of all cylinder kPa Intake manifold vacuum kPa Cylinder head bolt shank length mm Auto-tensioner push rod movement mm Timing belt tension torque Nm Auto-tensioner rod protrusion amount mm Standard value 650 100 0.2 or less 100 or less 1177 Within 1 3 3.8 - 4.5 Limit Min. 875 Max. 98 Min. 60 96.4 -
11B-3
SEALANTS
Items Oil pan Flywheel bolt or drive plate bolt Specified sealants MITSUBISHI GENUINE MD970389 or equivalent PART Remarks Semi-drying sealant -
11100050379
3M Stud Locking 4170 or equivalent
SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub assembly Use Engine idle speed check Erasing diagnosis code
11100060464
MB990767
End yoke holder
D D
Holding the camshaft sprocket Holding the crankshaft pulley
MD998719
MD998715
11B-4
Tool
ENGINE <6A1> - Special Tools

Number MD998443 Name Auto-lash adjuster holder Use Supporting of auto-lash adjuster
MD998713
Camshaft oil seal installer
Press-in of the camshaft oil seal
MD998776
MB990938
Handle
MD998767
Tension pulley socket wrench
Timing belt tension adjustment
MD998717
Crankshaft front oil seal installer
Press-in of the crankshaft front oil seal
MD998727
Oil pan remover
Removal of oil pan
MD998781
Flywheel stopper
Securing the flywheel <M/T> or drive plate <A/T>
Engine lifter
ENGINE <6A1> - Special Tools/On-vehicle Service

Tool Number MB991453 Name Engine hanger assembly Use
11B-5
Alternator pulley
Tension pulley
ON-VEHICLE SERVICE
11100090425
Crankshaft pulley
Tension N Deflection (Reference value) mm 294 - 490 9.0 - 13.0
Adjusting bolt
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen the tension pulley fixing nut. 2. Use the adjusting bolt to adjust the belt tension or deflection to the standard value. Standard value:
Items Tension N When a used belt is installed 343 - 441 When a new belt is installed 490 - 686 6.8 - 8.0
Fixing nut
Deflection (Reference 10.0 - 12.0 value) mm
3. Tighten the fixing nut. Tightening torque: 49 Nm Caution Turn the crankshaft one full rotation or more clockwise before this check.
11B-6
ENGINE <6A1> - On-vehicle Service

Power steering oil pump pulley
A
Crankshaft pulley
A/C compressor pulley
POWER STEERING OIL PUMP AND AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT 11100130134 1. Use a belt tension gauge to check that the belt tension is at the standard value at a point half-way between the two pulleys (indicated by an arrow in the illustration). In addition, press this section with a force of 98 N and check that the amount of belt deflection is at the standard value. Standard value:
2. If the tension or deflection is outside the standard value, adjust by the following procedure. (1) Loosen tensioner pulley fixing nut A. (2) Adjust the amount of belt deflection using adjusting bolt B. (3) Tighten fixing nut A. Tightening torque: 49 Nm (4) Check the belt deflection amount and tension, and readjust if necessary. Caution Check after turning the crankshaft once or more clockwise (right turn).
IGNITION TIMING CHECK
11100170280
1. Before inspection, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector. 3. Set up a timing light. 4. Start the engine and run at idle. 5. Check that engine idle speed is within the standard value. Standard value: 650 100 r/min 6. Select No.17 of the MUT-II Actuator test. 7. Check that basic ignition timing is within the standard value. Standard value: 5_ BTDC3_ 8. If the basic ignition timing is outside the standard value, inspect the MPI system while referring to GROUP 13A - Troubleshooting.
11B-7
9. Press the MUT-II clear key (Select a forced driving cancel mode) to release the Actuator test. Caution If the test is not cancelled, a forced driving will continue for 27 minutes. Driving under this condition may damage the engine. 10. Check that ignition timing is at the standard value. Standard value: approx. 7_BTDC NOTE 1. Ignition timing is variable within about 7_, even under normal operating. 2. And it is automatically further advanced by about 5_ from standard value at higher altitudes.
IDLE SPEED CHECK
11100350059
1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to OFF and connect the MUT-II to the diagnosis connector. 3. Check the basic ignition timing. Adjust if necessary. Standard value: 5_ BTDC3_ 4. Run the engine at idle for 2 minutes. 5. Check the idle speed. Select item No. 22 and take a reading of the idle speed. Curb idle speed: 650 100 r/min NOTE The idle speed is controlled automatically by the idle speed control (ISC) system. 6. If the idle speed is outside the standard value, check the MPI components by referring to GROUP 13A Troubleshooting.
IDLE MIXTURE CHECK
1110020401
1. Before inspection, set the vehicle to the pre-inspection condition. 2. Turn the ignition switch to OFF and connect the MUT-II to the diagnosis connector. 3. Check that the basic ignition timing is within the standard value. Standard value: 5_ BTDC3_ 4. Run the engine at 2,500 r/min for 2 minutes.
11B-8

5. Set the CO, HC tester. 6. Check the CO contents and the HC contents at idle. Standard value CO contents: 0.2% or less HC contents: 100 ppm or less 7. If there is a deviation from the standard value, check the following items: D Diagnosis output D Closed-loop control (When the closed-loop control is normal, the output signal of the oxygen sensor changes between 0 - 400 mV and 600 - 1,000 mV at idle.) D Fuel pressure D Injector D Ignition coil, spark plug cable, spark plug D Leak in the EGR system and in the EGR valve D Evaporative emission control system D Compression pressure NOTE Replace the three way catalyst when the CO and HC contents are not within the standard value, even though the result of the inspection is normal on all items.
11100260482
1. Before inspection, check that the engine oil, starter and battery are normal. In addition, set the vehicle to the pre-inspection condition. 2. Disconnect the spark plug cables. 3. Remove all of the spark plugs.
Crank angle sensor connector
4. Disconnect the crank angle sensor connector. NOTE Doing this will prevent the engine-ECU from carrying out ignition and fuel injection. 5. Cover the spark plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. Caution 1. Keep away from the spark plug hole when cranking. 2. If compression is measured with water, oil, fuel, etc., that has come from cracks inside the cylinder, these materials will become heated and will gush out from the spark plug hole, which is dangerous.

Compression gauge
11B-9
6. Set compression gauge to one of the spark plug holes. 7. Crank the engine with the throttle valve fully open and measure the compression pressure. Standard value (at engine speed of 250 - 400 r/min): 1,177 kPa Limit (at engine speed of 250 - 400 r/min): Min. 875 kPa 8. Measure the compression pressure for all the cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 98 kPa 9. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the spark plug hole, and repeat the operations in steps 7 and 8. (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 10. Connect the crank angle sensor connector. 11. Install the spark plugs and spark plug cables. 12. Use the MUT-II to erase the diagnosis codes. NOTE This will erase the diagnosis code resulting from the crank angle sensor connector being disconnected.
MANIFOLD VACUUM CHECK

Vacuum gauge Fuel pressure regulator
11100270393
1. Start the engine and allow it to warm up until the temperature of the engine coolant reaches 80 to 95_C. 2. Connect a tachometer. 3. Attach a three-way union to the vacuum hose between the fuel pressure regulator and the air intake plenum, and connect a vacuum gauge. 4. Start the engine and check that idle speed is within the standard value. Then read off the vacuum gauge. Limit: Min. 60 kPa
11B-10
ENGINE <6A1> - On-vehicle Service LASH ADJUSTER CHECK

11100290337
If an abnormal noise (knocking) that seems to be coming from the lash adjuster is heard after starting the engine and does not stop, carry out the following check. NOTE (1) The abnormal noise which is caused by a problem with the lash adjusters is generated after the engine is started, and will vary according to the engine speed. However, this noise is not related to the actual engine load. Because of this, if the noise does not occur immediately after the engine is started, if it does not change in accordance with the engine speed, or if it changes in accordance with the engine load, the source of the noise is not the lash adjusters. (2) If there is a problem with the lash adjusters, the noise will almost never disappear, even if the engine has been run at idle to let it warm up. The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick. 1. Start the engine. 2. Check that the noise occurs immediately after the engine is started, and that the noise changes in accordance with changes in the engine speed. If the noise does not occur immediately after the engine is started, or if it does not change in accordance with the engine speed, the problem is not being caused y the lash adjusters, so check for some other cause of the problem. Moreover, if the noise does not change in accordance with the engine speed, the cause of the problem is probably not with the engine. (In these cases, the lash adjusters are normal.) 3. While the engine is idling, check that the noise level does not change when the engine load is varied (for example, by shifting from N D). If the noise level changes, the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings. (In such cases, the lash adjusters are normal.) 4. After the engine has warmed up, run it at idle and check if any noise can be heard. If the noise has become smaller or has disappeared, the cause of the noise was probably that oil sludge had caused the lash adjusters to become stuck. If this happens, carry out the following check. If the noise level does not change, go to step 5. (1) Let the engine cool down sufficiently. (2) Turn the crankshaft two full revolutions.
11B-11
(3) Carry out lash adjuster simple check. (Refer to P.11B-12.) D If any of the rocker arms can be pushed down easily during the lash adjuster simple check, replace the corresponding lash adjusters. D If the lash adjuster simple check has been carried out but all lash adjusters are normal (if none of the rocker arms could be pushed down easily), check for some other cause of the problem. NOTE You can check whether the lash adjusters are normal or not by carrying out a leak-down test. (Refer to the Engine Workshop Manual.) Caution Make sure that the air has been fully bled before installation of a new lash adjuster. (Refer to the Engine Workshop Manual.) 5. Bleed the air from the lash adjusters. (Refer to P.11B-12.) 6. If the noise does not disappear even after the air has been bled from the lash adjusters, carry out the following check. Carry out lash adjuster simple check. (Refer to P.11B-12.) D If one of the rocker arms can be pushed down easily during the lash adjuster simple check, replace the corresponding lash adjuster. D If two or more of the rocker arms can be pushed down easily during the lash adjuster simple check, the cause may be that the oil passage to the cylinder head is blocked. Check for blockages in the oil passage, and clear the blockages if any are found. If there are no blockages, replace the lash adjusters. D If the lash adjuster simple check has been carried out but all lash adjusters are normal (if none of the rocker arms could be pushed down easily), check for some other cause of the problem. NOTE You can check whether the lash adjusters are normal or not by carrying out a leak-down test. (Refer to the Engine Workshop Manual.) Caution Make sure that the air has been fully bled before installation of a new lash adjuster. (Refer to the Engine Workshop Manual.) 7. Start the engine and check that the abnormal noise has disappeared. If necessary, bleed the air from the lash adjusters. (Refer to P.11B-12.)
11B-12

<LASH ADJUSTER SIMPLE CHECK> 1. Stop the engine. 2. Remove the rocker cover. 3. Set the No.1 cylinder to the compression top dead centre position. 4. Check the rocker arms indicated by white arrows in the illustration by the procedures given below. <Checking an intake-side rocker arm> Check whether the rocker arm moves downwards when the part of the rocker arm which touches the top of the lash adjuster is pushed. D If the rocker arm moves down easily when it is pushed, make a note of which is the corresponding lash adjuster. D If the rocker arm feels extremely stiff when it is pushed and does not move down, the lash adjuster is normal, so check for some other cause of the problem. <Checking an exhaust-side rocker arm> NOTE It will not be possible to depress the Y-shaped rocker arm at the exhaust valve side if one lash adjuster is defective but the other one is normal. In such cases, carry out the following procedure using a thickness gauge. (1) Check that a thickness gauge with a thickness of 0.1 - 0.2 mm can be inserted easily between the valve and the lash adjuster. (2) If the thickness gauge can be inserted easily, make a note of which is the corresponding lash adjuster. (3) If the thickness gauge cannot be inserted easily, the lash adjuster is normal, so check for some other cause of the problem. 5. Slowly turn the crankshaft 360_ in the clockwise direction. 6. Check the rocker arms indicated by black arrows in the illustration in the same way as explained in step 4. <LASH ADJUSTER AIR BLEEDING> NOTE (1) If the vehicle is parked on a slope for a long period of time, the amount of oil inside the lash adjuster will decrease, and air may get into the high pressure chamber when starting the engine. (2) After parking the vehicle for long periods, the oil drains out of the oil passage, and it takes time for the oil to be supplied to the lash adjuster, so air can get into the high pressure chamber. (3) If either of the above situations occur, the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters.
Timing belt side
11B-13
1. Check the engine oil and replenish or replace the oil if necessary. NOTE (1) If there is a only small amount of oil, air will be drawn in through the oil screen and will get into the oil passage. (2) If the amount of oil is greater than normal, then the oil will being mixed by the crankshaft and a large amount of air may get mixed into the oil. (3) If the oil is degenerated, air and oil will not separate easily in oil, and the amount of air mixed into the oil will increase.
Good
High pressure chamber
(4) If the air which has been mixed in with the oil due to any of the above reasons gets into the high pressure chamber of the lash adjuster, the air inside the high pressure chamber will be compressed when the valve is open and the lash adjuster will over-compress, resulting in abnormal noise when the valve closes. This is the same effect as if the valve clearance is adjusted to be too large by mistake. If the air inside the lash adjusters is then released, the operation of the lash adjusters will return to normal. 2. Run the engine at idle for 1 - 3 minutes to let it warm up. 3. With no load on the engine, repeat the drive pattern shown in the illustration at left and check if the abnormal noise disappears. (The noise should normally disappear after 10 - 30 repetitions, but if there is no change in the noise level after 30 repetitions or more, the problem is probably not due to air inside the lash adjusters.) 4. After the noise has disappeared, repeat the drive pattern shown in the illustration at left a further 5 times. 5. Run the engine at idle for 1 - 3 minutes and check that the noise has disappeared.
Drive pattern for air bleeding Gradually open the Close the throttle throttle valve. valve. Approx. 3,000 r/min. Idle speed
15 seconds 15 seconds
Once
11B-14
ENGINE <6A1> - Crankshaft Pulley

11200160310
CRANKSHAFT PULLEY
Post-installation Operation D Drive Belt Tension Adjustment (Refer to P.11B-5.) D Under Cover Installation
(Engine oil)
3 1 4
177 - 186 Nm
2
Removal steps 1. Drive belt (Power steering oil pump, or A/C compressor and power steering oil pump) 2. Drive belt (Alternator) AA" "AA 3. Crankshaft bolt 4. Washer 5. Crankshaft pulley

AA" CRANKSHAFT BOLT REMOVAL
MD998719
MB990767

"AA CRANKSHAFT BOLT INSTALLATION When installing the crankshaft bolt, apply the minimum amount of engine oil to the bearing surface and thread of the bolt.
ENGINE <6A1> - Camshaft and Camshaft Oil Seal
11B-15
11200220124

<Front bank>
Pre-removal and Post-installation Operation D Engine Coolant Draining and Refilling (Refer to GROUP 14 - On-vehicle Service.) D Air Intake Hose Assembly Removal and Installation D D
Timing Belt Removal and Installation (Refer to P.11B-26.) Drive Belt Tension Adjustment (Refer to P.11B-5.)
Apply engine oil to all sliding parts when installing.
6 3 4
3.4 Nm
5 2 7
28 - 34 Nm
10
22 Nm
(Engine oil)
12 5 11
24 Nm
9 8
88 Nm
13
Removal steps AA" "DA 1. Radiator upper hose connection AA" "DA 2. Radiator lower hose connection 3. Blow-by hose connection 4. PCV hose connection 5. Vacuum hose connection 6. Spark plug cable 7. Rocker cover
AB" "CA 8. Camshaft sprocket "BA 9. Camshaft oil seal 10. Engine hanger 11. Thrust case 12. Rocker arm and shaft assembly AC" "AA 13. Camshaft
11B-16
<Rear bank>
Pre-removal and Post-installation Operation D Air Intake Plenum Removal and Installation (Refer to GROUP 15.) D Timing Belt Removal and Installation (Refer to P.11B-26.)
D D
Distributor Removal and Installation (Refer to GROUP 16.) Drive Belt Tension Adjustment (Refer to P.11B-5.)
6 1
Apply engine oil to all sliding parts when installing.
7
3.4 Nm
2
28 - 34 Nm
12 8 9 13
88 Nm
Removal steps 1. Breather hose connection 2. Blow-by hose connection 6. Spark plug cable 7. Rocker cover
AB" "CA "BA AC" "AA
8. 9. 12. 13.
Camshaft sprocket Camshaft oil seal Rocker arm and shaft assembly Camshaft

AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose.

AB" CAMSHAFT SPROCKET REMOVAL
MB990767
11B-17
MD998715
AC" ROCKER ARM AND SHAFT ASSEMBLY REMOVAL 1. Install the special tools as shown in the illustration so that the lash adjusters will not fall out.
MD998443
2. Loosen the rocker arm and shaft assembly mounting bolt, and then remove the rocker arm and shaft assembly with the bolt still attached. Caution Never disassemble the rocker arm assembly. and shaft
<Front bank side>
<Rear bank side>

"AA CAMSHAFT INSTALLATION Set the camshaft dowel pins so that they are in the position shown in the illustration.
Approx. 35_ Dowel pin
Approx. 35_ Dowel pin
Caution Do not mistake the camshafts for the front bank and the rear bank. The camshaft for the rear bank has a slit with a width of approximately 4 mm on its rear end.
<Front bank side>
<Rear bank side>
"BA CAMSHAFT OIL SEAL INSTALLATION 1. Apply engine oil to the camshaft oil seal lip. 2. Use the special tool to press-fit the camshaft oil seal.
MD998713 MD991559
MD998713
11B-18

"CA CAMSHAFT SPROCKET INSTALLATION Use the special tool to stop the camshaft sprocket from turning in the same way as was done during removal, and then tighten the bolts to the specified torque. Tightening torque: 88 Nm
"DA RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION 1. Insert each hose as far as the projection of the water inlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose. Caution Be sure to install the clamp as far as the old clamp position.
ENGINE <6A1> - Oil Pan
11B-19
11200280214
OIL PAN
Pre-removal and Post-installation Operation D Engine Oil Draining and Supplying (Refer to GROUP 12 - On-vehicle Service.) D Oil Level Gauge Removal and Installation D Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) D D Under Cover Removal and Installation Starter Motor Removal and Installation
Groove
Bolt hole
7 Nm
39 Nm
2
7 Nm
4 3
44 Nm 7 Nm 44 Nm
7 Nm
Removal steps 1. Drain plug "AA 2. Drain plug gasket AA" 3. Lower oil pan
AA"
4. Cover 5. Upper oil pan
11B-20
MD998727 MD998727
ENGINE <6A1> - Oil Pan REMOVAL SERVICE POINT

AA" LOWER OIL PAN/UPPER OIL PAN REMOVAL After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar. Caution Perform this slowly to avoid deformation of the oil pan flange.

ENGINE <6A1> - Crankshaft Oil Seal
11B-21
11200310142
CRANKSHAFT OIL SEAL

<M/T>
Crankshaft
5 4 3 1 2
<A/T> Crankshaft
10 7 6
<M/T>
9
Sealant: 3M Stud Locking 4170 or equivalent
11
<A/T> 93 - 103 Nm
Lip section
11 10 7
Engine oil
Lip section
Crankshaft front oil seal removal steps D Timing belt (Refer to P.11B-26.) D Crank angle sensor (Refer to GROUP 16.) 1. Crankshaft sprocket 2. Crankshaft sensing blade 3. Crankshaft spacer 4. Key "CA 5. Crankshaft front oil seal
AA" AB" AB" AB" AB" AB" "BA "BA "BA "BA "BA "AA
Crankshaft rear oil seal removal steps D Transmission assembly D Clutch cover and disc <M/T> 6. Plate <M/T> 7. Adapter plate 8. Flywheel <M/T> 9. Adapter plate <M/T> 10. Drive plate <A/T> 11. Crankshaft rear oil seal
11B-22
<M/T>
ENGINE <6A1> - Crankshaft Oil Seal REMOVAL SERVICE POINTS

AA" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to GROUP 22. Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become out of balance and damaged. <A/T>: Refer to GROUP 23. AB" PLATE <M/T>/ADAPTER PLATE/FLYWHEEL <M/T>/DRIVE PLATE <A/T> REMOVAL Use the special tool to secure the flywheel or drive plate, and remove the bolts.
Flywheel
Bolt
MD998781

Crankshaft
MD998776
"BA DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER PLATE/PLATE <M/T> INSTALLATION 1. Clean off all sealant, oil and other substances which are adhering to the threaded bolts, crankshaft thread holes and the flywheel or drive plate. 2. Apply oil to the bearing surface of the flywheel or drive plate bolts. 3. Apply oil to the crankshaft thread holes. 4. Apply sealant to the threaded mounting holes. Specified sealant: 3M Stud locking 4170 or equivalent 5. Use the special tool to hold the flywheel or drive plate in the same manner as removal, and install the bolt.
ENGINE <6A1> - Crankshaft Oil Seal
11B-23
Crankshaft MD998717
"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1. Apply a small amount of engine oil to the entire circumference of the oil seal lip. 2. Tap the oil seal unit it is flush with the oil seal case.
MD998717 Oil seal
11B-24
ENGINE <6A1> - Cylinder Head Gasket

11200400559

Pre-removal and Post-installation Operation D Engine Coolant Draining and Refilling (Refer to GROUP 14 - On-vehicle Service.) D Air Intake Hose Assembly Removal and Installation D Radiator Assembly Removal and Installation (Refer to GROUP 14 - Radiator.) D Air Intake Plenum and Intake Manifold Removal and Installation (Refer to GROUP 15 - Air Intake Plenum.) D Engine Cover Removal and Installation D Drive Belt Tension Adjustment (Refer to P.11B-5.) D Timing Belt Removal and Installation (Refer to P.11B-26.) D D D D
Fuel Discharge Prevention (Refer to GROUP 13A - On-vehicle Service.) Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) Thermostat Case Assembly Removal and Installation (Refer to GROUP 14 - Water Hoses and Pipes.) Water Inlet Pipe Removal and Installation (Refer to GROUP 14 - Water Hoses and Pipes.)
5 3 6
3.4 Nm
5 1 2
2
(Engine oil)
3.4 Nm
20 Nm + 120_ + 120_
10
20 Nm + 120_ + 120_
(Engine oil)
11
10 - 12 Nm
11
35 Nm
Removal steps 1. PCV hose connection 2. Blow-by hose connection 3. Breather hose connection 4. Vacuum hose connection 5. Spark plug cable 6. Rocker cover
7. 8. AA" "BA 9. 10. "AA 11.
Idler pulley Timing belt rear centre cover Cylinder head bolt Cylinder head assembly Cylinder head gasket
ENGINE <6A1> - Cylinder Head Gasket

<Front bank side> Exhaust side
11B-25

AA" CYLINDER HEAD BOLT REMOVAL Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove the cylinder head assembly.
<Rear bank side> Intake side
Front of engine
Exhaust side Identification mark

"AA CYLINDER HEAD GASKET INSTALLATION 1. Wipe off all oil and grease from the gasket mounting surface. 2. Install the gasket to the cylinder block with the identification mark facing upwards.
<Front bank side>
Exhaust side
<Rear bank side> Intake side
Front of engine
4. Install the bolts by the following procedure. (1) Tighten the bolts to 20 Nm in the sequence shown in the illustration. (2) From the position in (1) above, turn each bolt a further 120_ in the same sequence. (3) Turn each bolt a further 120_ in the same sequence. Caution 1) If the tightening angle is less than 120_, that bolt will not be sufficiently tight. 2) If a bolt is tightened by more than the specified angle, loosen the bolts and repeat the procedure from step (1).
Exhaust side
11B-26 TIMING BELT
ENGINE <6A1> - Timing Belt

11200430480

Pre-removal and Post-installation Operation D Under Cover Removal and Installation D Crankshaft Pulley Removal and Installation D Alternator Removal and Installation (Refer to GROUP 16.) D Drive Belt Tension Adjustment (Refer to P.11B-5.)
3 Nm
1
44 Nm
9
12 Nm
3 7 6 4
24 Nm 35 Nm 24 Nm 10 - 12 Nm
10 8
10 - 12 Nm
22 Nm
11 2 14
10 - 12 Nm
13 12
Removal steps 1. Engine cover 2. Engine mount stay 3. Power steering hose clamp bolt 4. Crank angle sensor mounting bolt 5. Oil level gauge assembly 6. Engine hanger 7. Tension pulley bracket assembly 8. Tensioner bracket
9. Timing belt cover (front, upper right) 10. Timing belt cover (front, upper left) 11. Timing belt cover (front, lower) 12. Flange "CA D Timing belt tension adjustment AA" "BA 13. Timing belt "AA 14. Auto tensioner
ENGINE <6A1> - Timing Belt REMOVAL SERVICE POINT

AA" TIMING BELT REMOVAL 1. Align each of the timing marks.
Tensioner pulley Timing marks
11B-27
2. Loosen the centre bolt of the tension pulley and remove the timing belt.
Timing belt
Caution (1) If the timing belt is to be reused, use chalk to mark it with an arrow on its flat side indicating the turning direction. (2) If the timing belt is to be re-used, be careful not to damage the teeth of the timing belt against the edges of the camshaft sprocket when removing the timing belt.

98 N - 196 N
Movement Push rod
"AA AUTO TENSIONER INSTALLATION 1. Apply 98 - 196 N force to the auto tensioner by pressing it against a metal (cylinder block, etc.), and measure the movement of the push rod. Standard value: Within 1 mm A: Length when it is free (not pressed) B: Length when it is pressed A - B: Movement 2. If it is out of the standard value, replace the auto tensioner. 3. Use a press or vice to gently compress the auto tensioner push rod until pin hole A of the push rod and pin hole B of the tensioner cylinder are aligned. Caution If the compression speed is too fast, the rod may become damaged, so be sure to carry out this operation slowly.
Auto tensioner
Set pin
4. Once the holes are aligned, insert the set pin. NOTE When replacing the auto tensioner with a new part, the pin will be in the auto tensioner. 5. Install the auto tensioner to the engine.
11B-28
Rocker cover

Rocker cover
"BA TIMING BELT INSTALLATION 1. Check that the timing marks of the both camshaft sprockets and the crankshaft sprocket are aligned. NOTE In this condition, the No.1 cylinder will be in the compression top dead centre position.
Camshaft sprocket Camshaft sprocket Crankshaft sprocket

Tension side A Tension side B
Timing marks
2. Install the timing belt so that there is no slackness on the tension sides of the belt (A, B, C and D). Caution Be careful not to damage the teeth of the timing belt against the edges of the camshaft sprocket when installing the timing belt. NOTE If reusing the old timing belt, install it so that the arrow made on the belt during removal is pointing in the direction of rotation (clockwise). 3. Set the tensioner pulley so that the pin holes are at the bottom, press the tensioner pulley lightly against the timing belt, and then provisionally tighten the fixing bolt.
Rear bank side camshaft sprocket
Tension side C Tension side D
Pin holes
Fixing bolt
4. Apply force to the rear bank side camshaft sprocket in the direction of the arrow to apply tension to the tension sides (A, B, C and D), and check that all of the timing marks are aligned at this time.

MD998767 Tension direction
11B-29
Tensioner pulley 48 Nm
"CA TIMING BELT TENSION ADJUSTMENT 1. After turning the crankshaft 1/4 of a revolution in the anticlockwise direction, turn it in the clockwise direction until the timing marks are aligned. 2. Loosen the tensioner pulley fixing bolt, and then use the special tool and a torque wrench to tighten the fixing bolt to the specified torque while applying tension to the timing belt. Standard value: 3 Nm <Timing belt tension torque> Caution When tightening the fixing bolt, make sure that the tensioner pulley does not turn with the bolt.
3. Turn the crankshaft two revolutions in the clockwise direction, and after leaving it for 5 minutes or more, check if the set pin of the auto tensioner can be removed and inserted easily. A NOTE If the set pin cannot be inserted easily, the auto tensioner is good. Check if the amount of protrusion of the auto tensioner rod is within the standard value. Standard value (A): 3.8 - 4.5 mm If the amount of protrusion is outside the standard value, repeat the procedure in steps 1 to 3 4. Check to be sure that the timing marks of each sprocket are aligned.
11B-30
ENGINE <6A1> - Engine Assembly

11200100558
ENGINE ASSEMBLY
Pre-removal Operation D Fuel Discharge Prevention (Refer to GROUP 13A - On-vehicle Service.) D Under Cover Removal D Hood Removal (Refer to GROUP 42.) D Air Cleaner Removal D Radiator Removal (Refer to GROUP 14.) D Front Exhaust Pipe Removal (Refer to GROUP 15.) D Engine Cover Removal D Battery Removal D Engine Coolant Draining
Post-installation Operation D Front Exhaust Pipe Installation (Refer to GROUP 15.) D Radiator Installation (Refer to GROUP 14.) D Air Cleaner Installation D Hood Installation (Refer to GROUP 42.) D Under Cover Installation D Drive Belt Tension Adjustment (Refer to P.11B-5.) D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.) D Engine Cover Installation D Battery Installation D Engine Coolant Supplying
1
18 Nm
3 17 23 24 16 2
5 6
8 9 10
18
19 11 22 20 21
9
O-ring
12
19 14
Engine oil Removal steps 1. Accelerator cable connection 2. Capacitor connector 3. Vacuum hose connection 4. TPS connector 5. Accelerator pedal position sensor connector <TCL> 6. ISC connector 7. Control harness connector 8. Distributor connector 9. Vacuum hose connection 10. Engine coolant temperature sensor connector 11. Engine coolant temperature gauge unit connector 12. Injector connector
13
15
13. Power steering oil pressure switch connector 14. Oil pressure harness connector 15. Thermo switch connector 16. Crank angle sensor connector 17. Brake booster vacuum hose connection 18. Fuel return hose connection "DA 19. High-pressure fuel hose connection 20. Earth cable connection 21. Control harness connector 22. Front harness connector 23. Purge control solenoid valve connector 24. EGR solenoid valve connector
ENGINE <6A1> - Engine Assembly

30
12 Nm
11B-31
28 27
27
12 Nm
27
39 Nm
25 26 34 29
35 Nm
31
67 Nm
32 33
57 Nm
33
98 - 118 Nm*
AA" AB" AC"
25. Drive belt (Alternator) 26. Drive belt (Power steering and A/C) 27. Clamp bolt (Power steering hose and pipe) 28. Power steering oil pump assembly 29. A/C compressor 30. Heater hose connection D Transmission assembly 31. Engine mount stay
AD" "CA 32. Engine mount bracket "BA 33. Engine mount stopper AE" "AA 34. Engine assembly Caution Mounting locations marked by * should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.
11B-32
ENGINE <6A1> - Engine Assembly REMOVAL SERVICE POINTS

<M/T>
AC" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to GROUP 22. Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become out of balance and damaged. <A/T>: Refer to GROUP 23. AD" ENGINE MOUNT BRACKET REMOVAL 1. Support the engine with a garage jack. 2. Remove the special tool which was attached when the transmission assembly was removed. 3. Hold the engine assembly with a chain block or similar tool. 4. Place a garage jack against the engine oil pan with a piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket. AE" ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.
Flywheel
Bolt
MZ203827
MB991453
ENGINE <6A1> - Engine Assembly INSTALLATION SERVICE POINTS
11B-33
Engine side Dynamic damper Arrow Engine mount stopper Engine mount bracket
"DA HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a small amount of new engine oil to the O-ring. Caution Do not let any engine oil get into the delivery pipe. 2. While turning the high-pressure fuel hose to the right and left, install it to the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the high-pressure fuel hose and check the O-ring for damage. After this, re-insert the delivery pipe and check that the hose turns smoothly.
NOTES
11C-1
ENGINE <4D6>
CONTENTS
Drive Belt Tension Check and Adjustment . . . . . . 6 Valve Clearance Check and Adjustment . . . . . . . . 8 Injection Timing Check and Adjustment . . . . . . . . 10 Idle Speed Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Compression Pressure Check . . . . . . . . . . . . . . . . 12 Timing Belt Tension Adjustment . . . . . . . . . . . . . . . 13
11109000627
CRANKSHAFT PULLEY . . . . . . . . . . . . . . . . . . . 15 CAMSHAFT AND CAMSHAFT OIL SEAL . . . 16 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CRANKSHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 20 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . 23 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 TIMING BELT B . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 33
11C-2
ENGINE <4D6> - General Information/Service Specifications

11100010476
GENERAL INFORMATION
Items Total displacement mL Bore Stroke mm Compression ratio Combustion chamber Camshaft arrangement Number of valve Intake Exhaust Valve timing Intake Opening Closing Exhaust Opening Closing Fuel system Rocker arm Adjusting screw 4D68 1,998 82.7 93.0 22.4 Vortex chamber type SOHC 4 4 BTDC 20_ ABDC 48_ BBDC 54_ ATDC 22_ Distribution type injection pump Roller type Elephant foot type
Items Alternator drive belt tension Tension N When checked When a used belt is installed When a new belt is installed Deflection (Reference value) mm Centre of belt between alternator pulley and water pump pulley When checked When a used belt is installed When a new belt is installed Centre of belt between crankshaft pulley and alternator pulley When checked When a used belt is installed When a new belt is installed Standard value 343 - 490 392 - 490 490 - 588 8.0 - 10.0 8.0 - 9.4 7.0 - 8.0 7.9 - 9.9 7.9 - 9.2 6.8 - 7.9 Limit -
11100030502
ENGINE <4D6> - Service Specifications/Sealants

Items Power steering oil pump drive belt tension Tension N When checked When a used belt is installed When a new belt is installed Deflection mm When checked When a used belt is installed When a new belt is installed A/C compressor drive belt tension Tension N When checked When a used belt is installed When a new belt is installed Deflection mm When checked When a used belt is installed When a new belt is installed Valve clearance (at hot) mm Intake valve Exhaust valve Standard value 294 - 490 343 - 441 490 - 686 12.6 - 16.3 13.4 - 15.3 10.0 - 12.6 392 - 588 441 - 539 637 - 833 9.2 - 12.0 9.8 - 11.2 7.0 - 8.6 0.35 0.45 1 0.03 (10_ATDC) 800 30 3,500 4-5 5-7 Limit -
11C-3
Injection timing (Dial gauge display value mm) Idle speed r/min Compression pressure kPa Compression pressure difference of all cylinder (at engine speed of 280 r/min) kPa Cylinder head bolt shank length mm Timing belt deflection mm Timing belt B deflection mm
Min. 2,560 Max. 300 99.4 11100050362
SEALANTS
Items Oil pan Semi-circular packing and rocker cover seal, and cylinder head seal Flywheel bolt or adapter plate bolt Specified sealants MITSUBISHI GENUINE PART MD970389 or equivalent 3M ATD Part No.8660 or equivalent 3M Stud Locking 4170 or equivalent Remarks Semi-drying sealant
11C-4 SPECIAL TOOLS

Tool
ENGINE <4D6> - Special Tools

11100060471
Number MB991502
Name MUT-II sub assembly
Use Idle speed check
MB998720
Prestroke measuring adapter
Adjustment of the injection timing
MB990767
End yoke holder
Holding the camshaft sprocket
MD998719
MD998754
MD998364
Camshaft oil seal installer
Installing the camshaft oil seal
MD998727
Oil pan remover
Removal of oil pan
MD998776
MB990938
Handle
ENGINE <4D6> - Special Tools

Tool Number MD998382 Name Crankshaft front oil seal installer Use Installing the crankshaft front oil seal
11C-5
MD998383
Crankshaft front oil seal guide
MD998781
Flywheel stopper
Securing the flywheel <M/T> or drive plate <A/T>
Engine lifter
MB991453
11C-6
ENGINE <4D6> - On-vehicle Service
ON-VEHICLE SERVICE
Alternator pulley
11100090449
Water pump pulley
Tension N 343 - 490 Portion A Portion B 8.0 - 10.0 7.9 - 9.9
B
Crankshaft pulley
Deflection (Reference value) mm
Adjusting bolt
Lock bolt
ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1. Loosen the nut of the alternator pivot bolt. 2. Loosen the lock bolt. 3. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. Standard value:
Items When a used belt is installed 392 - 490 Portion A Portion B 8.0 - 9.4 7.9 - 9.2 When a new belt is installed 490 - 588 7.0 - 8.0 6.8 - 7.9
Pivot bolt
4. Tighten the lock bolt. Tightening torque: 23 Nm 5. Tighten the nut of the alternator pivot bolt. Tightening torque: 44 Nm 6. Tighten the adjusting bolt. Tightening torque: 10 Nm Caution Check after turning the crankshaft once or more clockwise (right turn).

Power steering oil pump pulley
11C-7
POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK AND ADJUSTMENT 11100110183 1. Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 98 N as shown in the figure. Measure drive belt deflection amount. Standard value:
Water pump pulley
Oil pump
2. If the tension is outside the standard value, adjust by the following procedure. (1) Loosen oil pump fixing bolts A and B. Check that the slide bushing at the place where bolt B was installed is touching the A/C bracket and that there is no looseness in the oil pump mounting. (2) While holding a bar or similar tool against the oil pump body, apply a suitable amount of force to the belt with your hand to adjust the tension of the belt. (3) Tighten oil pump fixing bolts A and B in that order. Tightening torque: 39 Nm (4) Check the belt tension, and readjust if necessary. Caution Check after turning the crankshaft once or more clockwise (right turn).
11C-8
A

A/C compressor pulley
COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT 11100100203 1. Check the tension by pulling or pushing at the centre of the belt between pulleys with a force of 98 N as shown in the figure. Measure drive belt deflection amount. Standard value:
Crankshaft pulley
B
2. If the tension is outside the standard value, adjust by the following procedure. (1) Loosen tensioner pulley fixing nut A. (2) Adjust the belt tension using adjusting bolt B. (3) Tighten fixing nut A. Tightening torque: 25 Nm (4) Check the belt frequency, tension or deflection, and readjust if necessary. Caution Check after turning the crankshaft once or more clockwise (right turn).
VALVE CLEARANCE CHECK AND ADJUSTMENT
11100150130
1. Start the engine and allow it to warm up until the engine coolant temperature reaches 80 to 95 _C. 2. Remove the timing belt upper cover. 3. Remove the rocker cover. 4. Remove the glow plug plate and all of the glow plugs.
Camshaft sprocket
Timing marks Timing marks
5. Turn the crankshaft clockwise to align the crankshaft pulley timing mark and to set the No.1 cylinder or No.4 cylinder to the compression top dead centre position. NOTE Aligning the camshaft sprocket timing mark will set the No.1 cylinder to the compression top dead centre position. If the crankshaft is turned one more full revolution from this position, the No.4 cylinder will be set to the compression top dead centre position.
Crankshaft pulley
11C-9
Timing belt side
6. Measure the valve clearance in the places indicated by arrows in the illustration. Arrow A: When the No.1 cylinder is at compression top dead centre Arrow B: When the No.4 cylinder is at compression top dead centre Standard value: A B
When warm Intake Exhaust 0.35 mm 0.45 mm When cold (NOTE) 0.25 mm 0.35 mm
Adjusting screw Pad
NOTE (1) When inserting the thickness gauge, press the pad from the opposite side using a flat-tipped screwdriver or similar tool to make a gap for the thickness gauge to be inserted.
Flat-tipped screwdriver
Thickness gauge
Pad
Thickness gauge
(2) If you attempt to insert the thickness gauge without using a flat-tipped screwdriver to make a gap, the pad will become tilted as shown in the illustration, and it will not be possible to insert the thickness gauge.
Thickness gauge
7. If the clearance is outside the standard value, loosen the lock nut and turn the adjusting screw while using a thickness gauge to adjust the clearance.
11C-10

8. Tighten the lock nut while holding the adjusting screw with a screwdriver so that it doesnt turn. 9. Turn the crankshaft one full revolution to align the crankshaft pulley timing mark. 10. Adjust the remaining valves by the same procedure as in steps 7. - 9. above. 11. Install the glow plugs and the glow plug plate. 12. Install the rocker cover. 13. Install the timing belt upper cover.
INJECTION TIMING CHECK AND ADJUSTMENT

1. Remove all of the glow plugs. 2. Remove the timing belt upper cover.
11100180054
Camshaft sprocket
Timing marks Timing marks
3. Align the timing marks of the camshaft sprocket and set the No.1 cylinder to the top dead centre position.
Crankshaft pulley
4. Remove the timing check plug at the rear of the injection pump.
Timing check plug
Dial gauge MD998720
5. Install the special tool to the timing check plug hole at the rear of the injection pump. 6. Connect the dial gauge to the special tool.
11C-11
Set to 0
7. Turn the crankshaft clockwise to move the No.1 cylinder approximately 30_ before compression top dead centre. 8. Set the needle of the dial gauge to 0. 9. Check that the needle doesnt move even if the crankshaft is turned slightly (2 - 3_) in both clockwise and anti-clockwise direction. NOTE If the needle moves, the notch is not positioned properly, so once again move the No.1 cylinder approximately 30_ before compression top dead centre. 10. Turn the crankshaft clockwise to align the No.1 cylinder to 10_ ATDC. 11. Check that the value indicated on the dial gauge is at the standard value. Standard value: 1 0.03 mm
Approx. 30_
Timing mark
Set to 10_ ATDC
1 0.03 mm
12. If the value is outside the standard value, adjust the injection timing by the following procedure. (1) Loosen the injection pipe union nuts (4 places) on the injection pump. (Do not remove the union nuts.)
Bolts
Caution When loosening the nuts, hold the delivery valve holders with a spanner so that they dont turn at the same time. (2) Loosen the upper mounting nuts and the lower mounting bolts of the injection pump. (Do not remove the nut and bolt.) (3) Tilt the injection pump to the left or right and adjust the needle on the dial gauge so that the display value is uniform. (4) Provisionally tighten the mounting nuts and bolts of the injection pump. (5) Repeat steps 7 - 12 to check if the adjustment has been made correctly. (6) Tighten the mounting nuts and bolts securely. (7) Tighten the injection pump union nuts securely. Caution When tightening the nuts, hold the delivery valve holders with a spanner so that they dont turn at the same time. 13. Remove the special tool. 14. Install a new gasket to the timing check plug. 15. Tighten the timing check plug securely.
Nuts When the value is 1 0.03 mm or more
When the value is 1 0.03 mm or less
11C-12
ENGINE <4D6> - On-vehicle Service IDLE SPEED CHECK

11100350073
NOTE Check that the injection timing is normal, and then perform this check. 1. Before inspection, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector. 3. Start the engine and check that the idle speed is at the standard value. Standard value: 800 30 r/min 4. If the idle speed is not at the standard value, refer to GROUP 13E - Troubleshooting.
11100260505
1. Before inspection, check that the engine oil, starter motor and battery are normal. In addition, set the vehicle to the pre-inspection condition. 2. Remove the glow plug plate and all of the glow plugs.
3. Disconnect the fuel cut solenoid valve connector. NOTE Doing this will prevent carrying out fuel injection.
Fuel cut solenoid valve connector
4. Cover the glow plug hole with a shop towel etc., and after the engine has been cranked, check that no foreign material is adhering to the shop towel. Caution 1. Keep away from the glow plug hole when cranking. 2. If compression is measured with water, oil, fuel, etc,. that has come from cracks inside the cylinder, these materials will become heated and will gush out from glow plug hole, which is dangerous.
11C-13
Compression gauge
5. Set compression gauge to one of the glow plug holes. 6. Crank the engine and measure the compression pressure. Standard value: 3,500 kPa (at engine speed of 280 r/min) Limit: Min. 2,560 kPa (at engine speed of 280 r/min) 7. Measure the compression pressure for all cylinders, and check that the pressure differences of the cylinders are below the limit. Limit: Max. 300 kPa 8. If there is a cylinder with compression or a compression difference that is outside the limit, pour a small amount of engine oil through the glow plug hole, and repeat the operations in steps 6 and 7. (1) If the compression increases after oil is added, the cause of the malfunction is a worn or damaged piston ring and/or cylinder inner surface. (2) If the compression does not rise after oil is added, the cause is a burnt or defective valve seat, or pressure is leaking from the gasket. 9. Connect the fuel cut solenoid valve connector. 10. Install the glow plugs and the glow plug plate.
Adapter
TIMING BELT TENSION ADJUSTMENT
11100280174
There are two timing belts: one is the timing belt for the valve timing, and the other is the timing belt B for driving the right-side counterbalance shaft. 1. Remove the timing belt upper cover. 2. Remove the glow plug plate and all of the glow plugs.
Timing marks
3. Turn the crankshaft clockwise and check that there is nothing wrong with the timing belt. Replace the belt if necessary. 4. Turn the crankshaft clockwise to set the No.1 cylinder to the compression top dead centre position.
11C-14

5. Turn the crankshaft anti-clockwise by 1/2 the width of a camshaft sprocket tooth in order to take up the slack in the idler pulley belt (the side where the belt is slack).
1/2 the width of a tooth Timing mark
Timing mark
6. Loosen the timing belt tensioner mounting bolt by 1/4 - 1/3 a turn, and use the force of the tensioner spring to apply tension to the belt.
7. Turn the crankshaft anti-clockwise again by the width of three camshaft sprocket teeth.
Timing mark Width of 2-1/2 teeth
Timing mark
1/2 the width of a tooth
Deflection
Camshaft sprocket Injection pump sprocket
8. Securely tighten the timing belt tensioner mounting bolt. 9. Turn the crankshaft clockwise to align the timing mark. 10. Press the belt at the point between the camshaft sprocket and the injection pump sprocket with your index finger to check the belt deflection. Standard value: 4.0 - 5.0 mm 11. Install the timing belt upper cover. 12. Install the glow plugs and the glow plug plate.
ENGINE <4D6> - Crankshaft Pulley
11C-15
11200160327
CRANKSHAFT PULLEY
Post-installation Operation D Drive Belt Tension Adjustment (Refer to P.11C-6.) D Under Cover Installation
4 3
25 Nm
Removal steps 1. Drive belt (Power steering) 2. Drive belt (A/C)
3. Drive belt (Alternator) 4. Crankshaft pulley
11C-16
ENGINE <4D6> - Camshaft and Camshaft Oil Seal

11200190425

Pre-removal and Post-installation Operation D Timing Belt Removal and Installation (Refer to P.11C-26.) D Air Pipe A Removal and Installation D Vacuum Pump Removal and Installation (Refer to GROUP 14.)
6 Nm Lip section
1 5 3
19 - 21 Nm 27 - 31 Nm 27 - 31 Nm
19 - 21 Nm
7
Cam section and journal section
6
19 - 21 Nm
7 5 4 8
Engine oil
88 Nm
Removal steps 1. Breather hose connection 2. Control harness 3. Rocker cover AA" "DA 4. Camshaft sprocket
"CA 5. Camshaft oil seal "BA 6. Rocker arm and shaft assembly "AA 7. Camshaft bearing cap 8. Camshaft
ENGINE <4D6> - Camshaft and Camshaft Oil Seal

MB990767
11C-17

AA" CAMSHAFT SPROCKET REMOVAL
MD998719 or MD998754
Camshaft sproket side

"AA CAMSHAFT BEARING CAP INSTALLATION The cap numbers are embossed on the top surface of the bearing caps, so install in the order of the numbers. However, no numbers are embossed on bearing caps 1 and 5.
Cap No.
Indent Bearing cap
"BA ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION 1. Install the rocker arm and shaft assembly to the bearing caps. 2. Set the rocker arm springs into the bearing cap indents. 3. Check the valve clearance and adjust if necessary. (Refer to P.11C-8.)
Oil seal Camshaft
"CA CAMSHAFT OIL SEAL INSTALLATION 1. Apply a small amount of engine oil to the entire circumference of the oil seal lip and camshaft. 2. Use the special tool to tap in the oil seal. NOTE The oil seal should be tapped in until the distance from the end of the camshaft to the end of the oil seal is as shown in the illustration.
MD998364 5.5 mm
"DA CAMSHAFT SPROCKET INSTALLATION Use the special tool to stop the camshaft sprocket from turning in the same way as was done during removal, and then tighten the bolts to the specified torque. Tightening torque: 88 Nm
11C-18 OIL PAN
ENGINE <4D6> - Oil Pan

11200280221

Pre-removal and Post-installation Operation D Under Cover Removal and Installation D Front Exhaust Pipe Removal and Installation (Refer to GROUP 15.) D D Engine Oil Level Gauge Removal and Insertion Engine Oil Draining and Refilling (Refer to GROUP 12 - On-vehicle Service.)
BOLT IDENTIFICATION
7 A
7 B
f4 1 mm
Groove
Bolt hole
B B B
A: 6 8 mm B: 6 10 mm
29 - 34 Nm
9 Nm
4 3
2 7
39 Nm Washer assembled bolt 9 Nm Flange bolt 10 Nm
7 Nm
Removal steps 1. Drain plug "AA 2. Drain plug gasket 3. Oil filter 4. Engine oil cooler pipe connection
AA"
5. Bell housing cover 6. Oil level sensor 7. Oil pan
ENGINE <4D6> - Oil Pan

MD998727 MD998727
11C-19

AA" OIL PAN REMOVAL After removing the oil pan mounting bolts, remove the oil pan with the special tool and a brass bar. Caution Perform this slowly to avoid deformation of the oil pan flange.

11C-20
ENGINE <4D6> - Crankshaft Oil Seal

11200310159
CRANKSHAFT OIL SEAL

<M/T>
9 10 6 11 7
127 - 137 Nm
5 4 2 1 3
<A/T> 127 - 137 Nm
6 10
(Engine oil)
108 - 127 Nm Crankshaft Crankshaft
11
Lip section
Lip section
Engine oil
Sealant: 3M Stud Locking 4170 or equivalent
Crankshaft front oil seal removal steps D Timing belt (Refer to P.11C-26.) D Crank angle sensor (Refer to GROUP 16.) 1. Crankshaft sprocket 2. Flange 3. Crankshaft sprocket B 4. Key "CA 5. Crankshaft front oil seal
AA" AB" AB" AB" AB" "BA "BA "BA "BA "AA
Crankshaft rear oil seal removal steps D Transmission assembly D Clutch cover and disc <M/T> 6. Adapter plate 7. Flywheel <M/T> 8. Drive plate <A/T> 9. Adapter plate <M/T> 10. Crankshaft bushing 11. Crankshaft rear oil seal

<M/T>
11C-21

AA" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to GROUP 22. Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become out of balance and damaged. <A/T>: Refer to GROUP 23. AB" ADAPTER PLATE/FLYWHEEL <M/T>/DRIVE PLATE <A/T> REMOVAL Use the special tool to secure the flywheel or drive plate, and remove the bolts.
Flywheel Bolt
MD998781

Crankshaft
MD998776
"BA DRIVE PLATE <A/T>/FLYWHEEL <M/T>/ADAPTER PLATE INSTALLATION 1. Clean off all sealant, oil and other substances which are adhering to the threaded bolts, crankshaft thread holes and the flywheel or drive plate. 2. Apply oil to the bearing surface of the flywheel or drive plate bolts. 3. Apply oil to the crankshaft thread holes. 4. Apply sealant to the threaded mounting holes. Specified sealant: 3M Stud locking 4170 or equivalent 5. Use the special tool to hold the flywheel or drive plate in the same manner as removal, and install the bolt.
11C-22
Crankshaft

Oil seal Front lower case
"CA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1. Apply a small amount of engine oil to the entire circumference of the oil seal lip. 2. Tap the oil seal unit it is flush with the oil seal case.
MD998382
MD998383
ENGINE <4D6> - Cylinder Head Gasket
11C-23
11200400566

Pre-removal and Post-installation Operation D Engine Coolant Draining and Refilling (Refer to GROUP 14 - On-vehicle Service.) D Air Pipe A Removal and Installation (Refer to GROUP 15 - Intercooler.) D Vacuum Pump Removal and Installation (Refer to GROUP 14.) 6 Nm D D
Timing Belt Removal and Installation (Refer to P.11C-26.) Thermostat Case Assembly Removal and Installation (Refer to GROUP 14 - Water Hoses and Pipes.)
3 16
1 2
27 - 31 Nm
O-ring 27 - 31 Nm 19 - 21 Nm 27 - 31 Nm
Engine oil
12 - 15 Nm
7 5
13 Nm
16 9 18
88 Nm 0 Nm 39 Nm + 90_ + 90_
10 11 19 8
12
15 14
44 Nm 9 Nm
4
29 Nm
20
17 13
24 Nm 10 - 12 Nm
Removal steps 1. Breather hose connection 2. Control harness 3. Rocker cover AA" "DA 4. Fuel injection pipe 5. Camshaft bearing cap 6. Glow plug plate "CA 7. Rocker arm and shaft assembly 8. Fuel return hose connection 9. Water temperature sensor connector 10. Vacuum air temperature sensor connector 11. Engine coolant temperature gauge unit connector
12. Brake booster vacuum hose connection 13. Timing belt rear centre cover 14. Front exhaust pipe connection 15. Oil return pipe connection 16. Oil level gauge guide assembly 17. Alternator brace AB" "BA 18. Cylinder head bolt 19. Cylinder head assembly "AA 20. Cylinder head gasket
11C-24
AA" FUEL INJECTION PIPE REMOVAL When loosening nuts at injection pipe ends, hold the nut at other side (delivery holder nut for pump side, nozzle holder nut at nozzle side) with wrench. Caution After disconnecting the injection pipe, plug the opening so that no foreign particles get inside the pump or into the injection nozzle.
Intake side
Front of engine
10
AB" CYLINDER HEAD BOLT REMOVAL Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustration, and remove the cylinder head assembly.
Exhaust side

"AA CYLINDER HEAD GASKET INSTALLATION 1. Wipe off all oil and grease from the gasket mounting surface.
Identification mark
2. Check the number of identification holes on the cylinder head gasket that was removed, and select a cylinder head gasket with the same number of identification holes. 3. Place the cylinder head gasket on top of the cylinder block so that the identification mark is facing upwards as shown in the illustration.
Identification holes
ENGINE <4D6> - Cylinder Head Gasket

Intake side Front of engine
11C-25
Remarks Carry out in the order shown in the illustration. Carry out in the reverse order of that shown in the illustration. Carry out in the order shown in the illustration. In the order shown in the illustration. Mark the head of the cylinder head bolt and cylinder head by paint. In the order shown in the illustration. Check that the painted mark of the head bolt is lined up with that of the cylinder head.
4. Tighten the bolts by the following procedure.

Step 1
9
Operation Tighten to 88 Nm. Fully loosen.
2
10 4 2 5 7
3
Exhaust side
Tighten to 39 Nm. Tighten 90_ of a turn.
4
Step 4 90_ Step 5 90_
Tighten 90_ of a turn.
Painted mark
Painted mark
Caution (1) Always make a tightening angle just 90_. If it is less than 90_, the head bolt will be loosened. (2) If it is more than 90_, remove the head bolt and repeat the procedure from step 1.
Indent Bearing cap
"CA ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION 1. Install the rocker arm and shaft assembly to the bearing caps. 2. Set the rocker arm springs into the bearing cap indents. 3. Check the valve clearance and adjust if necessary. (Refer to P.11C-8.)
Fuel injection pipe Nut Nozzle holder
"DA FUEL INJECTION PIPE INSTALLATION When tightening the nuts at both ends of the fuel injection pipe, hold the delivery holder (for pump side) and the fuel injection nozzle assembly (for nozzle side) with a wrench, and tighten the nuts to the specified torque.
11C-26 TIMING BELT
ENGINE <4D6> - Timing Belt

11200430497

Pre-removal and Post-installation Operation D Crankshaft Pulley Removal and Installation (Refer to P.11C-15.) D Engine Mount Bracket Removal and Installation (Refer to GROUP 32.)
10 - 12 Nm
3 7
9 Nm
10 - 12 Nm
1
19 Nm 25 Nm 10 - 12 Nm
4
10 - 12 Nm
2 5
9 Nm 23 Nm 10 - 12 Nm
AA"
Removal steps 1. Water pump pulley 2. A/C tension pulley assembly 3. Timing belt front upper cover 4. Timing belt front centre cover
5. 6. "BA D AB" "AA 7.
Timing belt front lower cover Injection pump bracket stay Timing belt tension adjustment Timing belt
ENGINE <4D6> - Timing Belt REMOVAL SERVICE POINTS
11C-27
AA" TIMING BELT FRONT UPPER COVER INSTALLATION Attach protective tape to the engine mount bracket, and then remove the timing belt front upper cover.
Protective tape
Timing marks
AB" TIMING BELT REMOVAL 1. Align the timing marks.
2. Loosen the installation bolt of the timing belt tensioner.
3. Move the timing belt tensioner downward and loosely tighten the bolt so that the tensioner doesnt return; then remove the timing belt. Caution If the timing belt is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.
Thread diameter length pitch (mm)
Move to the bottom of the slot.
11C-28
Timing marks
ENGINE <4D6> - Timing Belt INSTALLATION SERVICE POINTS

Injection pump sprocket
Camshaft sprocket Timing mark Crankshaft sprocket Timing mark Oil pump sprocket
"AA TIMING BELT INSTALLATION 1. Ensure that the timing marks of the camshaft sprocket, the injection pump sprocket, the crankshaft sprocket, and the oil pump sprocket are all aligned.
Move to the bottom of the slot.
2. Move the timing belt tensioner downward and loosely tighten the bolt so that the tensioner doesnt return. 3. Install the timing belt onto the crankshaft sprocket, the timing belt idler, the camshaft sprocket, the injection pump sprocket, and the oil pump sprocket in that order. Caution If the timing belt is reused, install so that the arrow marked on it at the time of removal is pointing in the clockwise direction.
"BA TIMING BELT TENSION ADJUSTMENT 1. Turn the crankshaft anti-clockwise by a distance equivalent to 1/2 tooth of the camshaft sprocket in order to correct looseness at the timing belt idler side.
1/2 tooth Timing mark
Timing mark
2. Loosen (by 90_ to 120_ turn) the tensioner installation bolt previously secured provisionally, taking advantage of the force of the tensioner spring to provide tension to the belt.
Timing mark 2-1/2 teeth
3. In addition, turn the crankshaft anti-clockwise by a distance equivalent to 2-1/2 teeth. 4. Tighten the timing belt tensioner to the specified torque. Tightening torque: 48 Nm 5. Turn the crankshaft clockwise and align the timing mark.
Timing mark
ENGINE <4D6> - Timing Belt
11C-29
6. Using the index finger, press between the camshaft sprocket and the injection pump sprocket, and check whether or not the amount of flexion is within the standard value range.
Camshaft sprocket Injection pump sprocket
Standard value: 4 - 5 mm
11C-30 TIMING BELT B
ENGINE <4D6> - Timing Belt B

11200460113

Pre-removal and Post-installation Operation D Crankshaft Pulley Removal and Installation (Refer to P.11C-15.) D Engine Mount Bracket Removal and Installation (Refer to GROUP 32.) D Timing Belt Removal and Installation (Refer to P.11C-26.)
1
48 Nm
4
19 Nm 108 - 127 Nm
5 3 2
(Engine oil)
Removal steps 1. Idler pulley AA" "BA 2. Crankshaft sprocket 3. Flange
4. Timing belt tensioner AB" "AA 5. Timing belt B
Crankshaft sprocket

MB991385
AA" CRANKSHAFT SPROCKET REMOVAL
MB991367

AB" TIMING BELT B REMOVAL
11C-31
Caution If the timing belt B is to be re-used, use chalk to mark (on its flat side) an arrow indicating the clockwise direction.
Counter balance shaft sprocket Belt tension side Crankshaft sprocket B

"AA TIMING BELT B INSTALLATION 1. Install the timing belt B by the following procedure. (1) Ensure that crankshaft sprocket B timing mark and the counterbalance shaft sprocket timing mark are aligned. (2) Fit timing belt B over crankshaft sprocket B and the counterbalance shaft sprocket. Ensure that there is no slack in the belt. 2. Adjust timing belt B by the following procedure, (1) Temporarily fix the timing belt B tensioner such that the centre of the tensioner pulley is to the left and above the centre of the installation bolt, and temporarily attach the tensioner pulley so that the flange is toward the front of the engine.
Timing mark
Centre of tensioner pulley
(2) Holding the timing belt B tensioner up with your finger in the direction of the arrow, place pressure on the timing belt so that the tension side of the belt is taut. Now tighten the bolt to fix the tensioner. Caution When tightening the bolt, ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension of the belt.
Shaft
Centre of pulley
(3) Check to ensure that when centre of span on tension side is depressed with index finger in direction of arrow, tension of belt is up to specification. Standard value: 5 - 7 mm
11C-32

"BA CRANKSHAFT SPROCKET INSTALLATION 1. Apply as little engine oil as possible to the seat and the thread of the crankshaft bolt. 2. Secure the crankshaft sprocket in the same way as during removal, and then tighten the bolt to the specified torque. Tightening torque: 108 - 127 Nm
ENGINE <4D6> - Engine Assembly
11C-33
11200100565
ENGINE ASSEMBLY
Pre-removal Operation D Hood Removal (Refer to GROUP 42.) D Air Cleaner Assembly Removal D Engine Coolant Draining D Radiator Assembly Removal (Refer to GROUP 14.) D Under Cover Removal D Front Exhaust Pipe Removal (Refer to GROUP 15.)
Post-installation Operation D Front Exhaust Pipe Installation (Refer to GROUP 15.) D Under Cover Installation D Radiator Assembly Installation (Refer to GROUP 14.) D Engine Coolant Supplying D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.) D Air Cleaner Assembly Installation D Hood Installation (Refer to GROUP 42.)
2 3
1 7
12 10 11
13
4 5 17
14 6 16 15
Removal steps 1. Vacuum hose connection 2. Vacuum air temperature sensor connector 3. Brake booster vacuum hose connection 4. Alternator connector 5. Oil pressure switch connector 6. Engine oil level sensor connector 7. Glow plug connector 8. Engine coolant temperature sensor connector 9. Engine coolant temperature gauge unit connector
10. 11. 12. 13. 14.
Pump revolution sensor connector Timing control valve connector Solenoid-type spill valve connector Fuel cut solenoid valve connector Injection rate correction resistor connector 15. Injection timing correction resistor connector 16. Crank angle sensor connector 17. Fuel temperature sensor connector
11C-34
ENGINE <4D6> - Engine Assembly
25 29
18
19
22 Nm
21
20
39 Nm
29 - 34 Nm
22
24
12 Nm
23
26
57 Nm*
27 28
28
98 Nm
AA" AB"
18. 19. 20. 21. 22. 23. 24. 25. 26.
Heater hose connection Drive belt (Power steering) Drive belt (A/C) Oil pump brace Power steering oil pump and bracket assembly A/C compressor Engine oil cooler pipe connection Fuel hose connection Clamp bolt (Power steering hose and pipe)
AC" AD" "CA "BA AE" "AA
D 27. 28. 29.
Transmission assembly Engine mount bracket Engine mount stopper Engine assembly
ENGINE <4D6> - Engine Assembly REMOVAL SERVICE POINTS
11C-35
<M/T>
AC" TRANSMISSION ASSEMBLY REMOVAL <M/T>: Refer to GROUP 22. Caution Do not remove the flywheel mounting bolt shown by the arrow. If this bolt Is removed, the flywheel will become out of balance and damaged. <A/T>: Refer to GROUP 23. AD" ENGINE MOUNT BRACKET REMOVAL 1. Support the engine with a garage jack. 2. Remove the special tool which was attached when the transmission assembly was removed. 3. Hold the engine assembly with a chain block or similar tool. 4. Place a garage jack against the engine oil pan with a piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket. AE" ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and harness connectors, etc., are disconnected from the engine, lift the chain block slowly to remove the engine assembly upward from the engine compartment.
Flywheel Bolt
MZ203827
MB991453
11C-36
ENGINE <4D6> - Engine Assembly INSTALLATION SERVICE POINTS

Engine side Dynamic damper Arrow
Engine mount stopper Engine mount bracket
12-1
ENGINE LUBRICATION
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3
Engine Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12109000129
Engine Oil Replacement . . . . . . . . . . . . . . . . . . . . . . 3 Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil Level Warning System Check . . . . . . . . . . . . . . 5
ENGINE OIL COOLER <6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 <4D6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
12-2
ENGINE LUBRICATION - General Information

12100010114
GENERAL INFORMATION
The lubrication method is a fully force-fed, full-flow filtration type. The oil pump for 6A1 engines is a trochoid type which is directly mounted to the crankshaft, and the one for 4G6 and 4D6 engines is a gear type which is driven by the crankshaft
via the timing belt. Furthermore, the oil level sensor is located in the oil pan, and a system is equipped whereby an indicator gives a warning when the oil level drops.
ENGINE OILS Health Warning

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Adequate means of skin protection and washing facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working practices which prevent, as far as practicable, the risk of skin contact with mineral oils, for example by using enclosed systems for handling used engine oil and by degreasing components, where practicable, before handling them. Other precautions: D Avoid prolonged and repeated contact with oils, particularly used engine oils. D Wear protective clothing, including impervious gloves where practicable. D Avoid contaminating clothes, particularly underpants, with oil. D Do not put oily rags in pockets, the use of overalls without pockets will avoid this. D Do not wear heavily soiled clothing and oil-impregnated foot-wear. Overalls must be cleaned regularly and kept separate from personal clothing. D Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Obtain First Aid treatment immediately for open cuts and wounds. Wash regularly with soap and water to ensure all oil is removed, especially before meals (skin cleansers and nail brushes will help). After cleaning, the application of preparations containing lanolin to replace the natural skin oils is advised. Do not use petrol, kerosine, diesel fuel, gas oil, thinners or solvents for cleaning skin. Use barrier creams, applying them before each work period, to help the removal of oil from the skin after work. If skin disorders develop, obtain medical advice without delay.
D D
D D D
ENGINE LUBRICATION - Lubricants/Special Tools/On-vehicle Service
12-3
12100040151
LUBRICANTS
Items Engine oil (API classification) Engine oil quantity L Oil filter Oil cooler Total 4G6 SG or higher 0.3 4.3 6A1 SG or higher 0.3 0.1 4.3 4D6 CD or higher 0.8 0.3 5.1
SPECIAL TOOLS
Tool Number MB991396 Name Oil filter wrench Use
12100060119
Removal and installation of engine oil filter (When using the oil filter of MD135737) <4G6>
MB991610
Oil filter wrench
Removal and installation of engine oil filter (When using the oil filter of MD136466) <6A1>
ON-VEHICLE SERVICE
ENGINE OIL CHECK
12100090095
1. Pull out the level gauge slowly and check that the oil level is in the illustrated range. 2. Check that the oil is not excessively dirty, that there is no coolant or gasoline mixed in, and that it has sufficient viscosity.
ENGINE OIL REPLACEMENT
12100100163
1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80_C to 90_C. 2. Remove the engine oil filler cap. 3. Remove the drain plug to drain oil. Caution Use care as oil could be hot.
Drain plug gasket Oil pan side 39 Nm
4. Install a new drain plug gasket so that it faces in the direction shown in the illustration, and then tighten the drain plug to the specified torque. NOTE Install the drain plug gasket so it faces in the direction shown in the illustration.
Drain plug
12-4
ENGINE LUBRICATION - On-vehicle Service

5. Refill with specified quantity of oil. Specified Engine Oil (API classification): <4G6, 6A1> SG or higher <4D6> CD or higher Total quantity (Includes volume inside oil filter and oil cooler): <4G6, 6A1> 4.3 L <4D6> 5.1 L 6. Install the engine oil filler cap. 7. Check oil level.
<Petrol-powered vehicles> Barometric temperature
<Diesel-powered vehicles> Barometric temperature
OIL FILTER REPLACEMENT

MB991396, MB991610 or commercially-available tool
12100110159
1. Start the engine and allow it to warm up until the temperature of the coolant reaches 80_C to 90_C. 2. Remove the engine oil filler cap. 3. Remove the drain plug to drain oil. Caution Use care as oil could be hot. 4. Use the respective tool in the following table to remove the engine oil filter. Caution For vehicles with 6A1 engine, the oil which is still inside the oil filter may overflow from the oil guide groove and get onto the starter motor. To prevent this, the oil inside the filter should be gradually removed while removing the oil filter. 5. Clean the filter bracket side mounting surface.
O-ring
6. Apply a small amount of engine oil to the O-ring of the new oil filter. 7. Once the O-ring of the oil filter is touching the flange, use the respective tool in the following table to tighten to the specified torque. 8. Install the drain plug and refill engine oil. (Refer to Engine Oil Replacement on P.12-3.) 9. Race the engine 2 - 3 times, and check to be sure that no engine oil leaks from installation section of the oil filter.

Number MD135737 MD136466 MD336080 Engine 4G6 6A1 4D6 Tool MB991396 or equivalent tool MB991610 or equivalent tool Commercially-available tool Tightening torque Approx. 1 turn (14 Nm) Approx. 3/4 turn (17 Nm)
12-5
Approx. 1-1/8 turns (20 Nm)
Engine oil level relay
OIL LEVEL WARNING SYSTEM CHECK
12100200047
1. Check that the proper amount of oil has been filled. 2. When the ignition switch is turned to ON (do not start the engine), check that the oil level warning lamp illuminates. NOTE If the oil level warning lamp does not illuminate, the cause is probably a blown lamp, or a malfunction in the relay.
Engine oil level sensor connector (Harness side)
3. When the engine is started, check that the oil level warning lamp turns off. If the oil level warning lamp will not go out, disconnect the connector of the oil level relay and measure the voltage of the No.1 terminal on the harness side of the connector while idling the engine in order to confirm that it is the same as the battery voltage. NOTE (1) If the voltage at the connector is the same as the battery voltage, the problem is probably a malfunction of either the oil level relay or the oil level sensor. (2) If the voltage at the connector is lower than the battery voltage, the problem is probably a malfunction of either the alternator or the wiring harness. 4. Disconnect the oil level sensor connector. Check that the oil level warning lamp illuminates after approximately 40 seconds. If the oil level warning lamp does not illuminate, replace the oil level relay.
12-6
Engine oil level sensor connector (Equipment side)

5. Check the continuity between the oil level sensor terminals.
Engine oil temperature At 50_C or lower Oil level Normal (proper volume) Low (drained) At 60_C or higher Normal (proper volume) Low (drained) Continuity Continuity Continuity Continuity No continuity
6. If there is a defect, replace the oil level sensor.
9 Nm
Engine oil level sensor Oil pan
ENGINE LUBRICATION - Engine Oil Cooler <6A1>
12-7
12100130155
ENGINE OIL COOLER <6A1>

Pre-removal and Post-installation Operation Engine Coolant Draining and Supplying (Refer to GROUP 14 - On-vehicle Service.)
2 4
64 - 69 Nm
3 2
Removal steps 1. Oil filter (Refer to P.12-4.) 2. Water hose connection 3. Oil cooler bolt
"AA
4. Engine oil cooler 5. O-ring

"AA ENGINE OIL COOLER INSTALLATION Insert the engine oil cooler positioning tab into the cylinder block rib, and tighten it with the oil cooler bolt.
INSPECTION
D D
12100140110
Check the water hoses for crack, damage, clogging or deterioration. Check the oil cooler bolt for clogging or deformation.
12-8
ENGINE LUBRICATION - Engine Oil Cooler <4D6>

12100130162
ENGINE OIL COOLER <4D6>

Pre-removal and Post-installation Operation D Engine Oil Draining and Supplying (Refer to P.12-3.) D Front Bumper Removal and Installation (Refer to GROUP 51.) D Air Guide Panel Removal and Installation
2
29 - 34 Nm 39 - 44 Nm
3
12 Nm
5 Nm 39 - 44 Nm 5 Nm
5 Nm
4
39 - 44 Nm
Removal steps 1. Hose assembly and joint connection 2. Engine oil cooler 3. Joint
"AA
4. 5. 6. 7.
Return hose assembly Feed hose assembly Return tube assembly Feed tube assembly

Eye joint pin
"AA RETURN TUBE ASSEMBLY INSTALLATION Insert the eye joint pin into the oil filter bracket hole and install the return tube assembly.
ENGINE LUBRICATION - Engine Oil Cooler <4D6> INSPECTION

D D D D
12-9
12100140127
Check for foreign material between oil cooler fins. Check the oil cooler fins for bend or damage. Check the oil cooler hoses for crack, damage, clogging or deterioration. Check the eye bolts for clogging or deformation.
NOTES
13A-1
FUEL
CONTENTS
13109000195
MULTIPOINT FUEL INJECTION (MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A ELECTRONIC CONTROL TYPE CARBURETTOR . . . . . . . . . . . . . . . . . . . 13B CONVENTIONAL TYPE CARBURETTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 13C VARIABLE VENTURI TYPE CARBURETTOR . . . . . . . . . . . . . . . . . . . . . . . 13D DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13E FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13F AUTO-CRUISE CONTROL SYSTEM . . . . . . . . . . . . . . . . . Refer to GROUP 17 TRACTION CONTROL SYSTEM (TCL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13H NOTE THE GROUPS MARKED BY ARE NOT IN THIS MANUAL
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MULTIPOINT FUEL INJECTION (MPI)

CONTENTS MULTIPOINT FUEL INJECTION <4G6>
GENERAL INFORMATION . . . . . . . . . . . . . . . . 4 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 7 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 9 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 81
Throttle Body (Throttle Valve Area) Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Idle Position Switch and Throttle Position Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . 81 Fixed SAS Adjustment . . . . . . . . . . . . . . . . . . . . 83 Basic Idle Speed Adjustment . . . . . . . . . . . . . . 83 Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . . 85 Fuel Pump Connector Disconnection (How to Reduce the Fuel Pressure) . . . . . . . . . . . . . . . 88 Fuel Pump Operation Check . . . . . . . . . . . . . . 88 Component Location . . . . . . . . . . . . . . . . . . . . . . 89 Control Relay and Fuel Pump Relay Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Intake Air Temperature Sensor Check . . . . . . 90 Engine Coolant Temperature Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Throttle Position Sensor Check . . . . . . . . . . . . 91 Idle Position Switch Check . . . . . . . . . . . . . . . . 91 Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . . 92 Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
13109000409
Idle Speed Control (ISC) Servo (Stepper Motor) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Purge Control Solenoid Valve Check . . . . . . . 95 EGR Control Solenoid Valve Check . . . . . . . . 95
INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . 98
MULTIPOINT FUEL INJECTION <6A1>

GENERAL INFORMATION . . . . . . . . . . . . . 102 SERVICE SPECIFICATIONS . . . . . . . . . . . 106 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . 107 TROUBLESHOOTING . . . . . . . . . . . . . . . . . 108 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 184
Throttle Body (Throttle Valve Area) Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Idle Position Switch and Throttle Position Sensor Adjustment <Vehicles without TCL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Throttle Position Sensor Adjustment <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 186 Idle Position Switch and Accelerator Pedal Position Sensor Adjustment <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 186 Fixed SAS Adjustment . . . . . . . . . . . . . . . . . . . 187 Basic Idle Speed Adjustment . . . . . . . . . . . . . 188 CONTINUED ON NEXT PAGE
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Fuel Pressure Test . . . . . . . . . . . . . . . . . . . . . . 189 Fuel Pump Connector Disconnection (How to Reduce the Fuel Pressure) . . . . . . . . . . . . . . 191 Fuel Pump Operation Check . . . . . . . . . . . . . 191 Component Location . . . . . . . . . . . . . . . . . . . . . 192 Control Relay and Fuel Pump Relay Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Intake Air Temperature Sensor Check . . . . . 193 Engine Coolant Temperature Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Throttle Position Sensor Check . . . . . . . . . . . 194 Accelerator Pedal Position Sensor Check <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 194 Idle Position Switch Check <Vehicles without TCL> . . . . . . . . . . . . . . . . . . 195 Idle Position Switch Check <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 195 Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . 196 Injector Check . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Idle Speed Control (ISC) Servo (Stepper Motor) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Purge Control Solenoid Valve Check . . . . . . 200 EGR Control Solenoid Valve Check . . . . . . . 200 Ventilation Control Solenoid Valve Check <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 201 Vacuum Control Solenoid Valve Check <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 201 Vacuum Tank Check <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 202 Vacuum Actuator Check <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 202 Throttle Valve Operation Check <Vehicles with TCL> . . . . . . . . . . . . . . . . . . . . 202 Negative Pressure Check during Traction Control Operation <Vehicles with TCL> . . . 203 Power Steering Air Control Valve Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 THROTTLE BODY . . . . . . . . . . . . . . . . . . . . 207
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MPI <4G6> - General Information

13100010449
MULTIPOINT FUEL INJECTION (MPI) <4G6>

GENERAL INFORMATION
The Multipoint Fuel Injection System consists of sensors which detect the engine conditions, the engine-ECU which controls the system based on signals from these sensors, and actuators which operate under the control of the engine-ECU. The engine-ECU carries out FUEL INJECTION CONTROL The injector drive times and injector timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continually-changing engine operation conditions. A single injector is mounted at the intake port of each cylinder. Fuel is sent under pressure from the fuel tank by the fuel pump, with the pressure being regulated by the fuel pressure regulator. The fuel thus regulated is distributed to each of the injectors. Fuel injection is normally carried out once for each cylinder for every two rotations of the crankshaft. The firing order is 1-3-4-2. This is called sequential fuel injection. IDLE AIR CONTROL The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in accordance with changes in idling conditions and engine load during idling. The engine-ECU drives the idle speed control (ISC) motor to keep the engine running at the pre-set idle target speed in accordance with the engine coolant temperature and air IGNITION TIMING CONTROL The power transistor located in the ignition primary circuit turns ON and OFF to control the primary current flow to the ignition coil. This controls the ignition timing in order to provide the optimum ignition timing with respect to the SELF-DIAGNOSIS FUNCTION D When an abnormality is detected in one of the sensors or actuators related to emission control, the engine warning lamp (check engine lamp) illuminates as a warning to the driver. D When an abnormality is detected in one of the sensors or actuators, a diagnosis
activities such as fuel injection control, idle speed control and ignition timing control. In addition, the engine-ECU is equipped with several diagnosis modes which simplify troubleshooting when a problem develops.
The engine-ECU provides a richer air/fuel mixture by carrying out open-loop control when the engine is cold or operating under high load conditions in order to maintain engine performance. In addition, when the engine is warm or operating under normal conditions, the engine-ECU controls the air/fuel mixture by using the oxygen sensor signal to carry out closed-loop control in order to obtain the theoretical air/fuel mixture ratio that provides the maximum cleaning performance from the three way catalyst.
conditioner load. In addition, when the air conditioner switch is turned off and on while the engine is idling, the ISC motor operates to adjust the throttle valve bypass air amount in accordance with the engine load conditions in order to avoid fluctuations in the engine speed.
engine operating conditions. The ignition timing is determined by the engine-ECU from the engine speed, intake air volume, engine coolant temperature and atmospheric pressure.
code corresponding to the abnormality is output. The RAM data inside the engine-ECU that is related to the sensors and actuators can be read by means of the MUT-II. In addition, the actuators can be force-driven under certain circumstances.

OTHER CONTROL FUNCTIONS 1. Fuel Pump Control Turns the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running. 2. A/C Relay Control Turns the compressor clutch of the A/C ON and OFF. 3. Fan Relay Control The revolutions of the radiator fan and
13A-5
condenser fan are controlled in response to the engine coolant temperature and vehicle speed. 4. Purge Control Solenoid Valve Control Refer to GROUP 17. 5. EGR Control Solenoid Valve Control Refer to GROUP 17.
GENERAL SPECIFICATIONS
Items Throttle body Throttle bore mm Throttle position sensor Idle speed control servo Specifications 54 Variable resistor type Stepper motor type (Stepper motor type by-pass air control system with the air volume limiter) Rotary contact type, within throttle position sensor E2T67673 Karman vortex type Semiconductor type Thermistor type Thermistor type Zirconia type Magnetic resistive element type Contact switch type Hall element type Hall element type Piezoelectric type Contact switch type Contact switch type Contact switch type Electromagnetic type, 4 CDH275 Duty cycle type solenoid valve ON/OFF type solenoid valve 329
Idle position switch Engine-ECU Sensors Identification model No. Air flow sensor Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Oxygen sensor Vehicle speed sensor Inhibitor switch Camshaft position sensor Crank angle sensor Detonation sensor Power steering fluid pressure switch Actuators Control relay type Fuel pump relay type Injector type and number Injector identification mark EGR control solenoid valve Purge control solenoid valve Fuel pressure Regulator pressure kPa regulator
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*1 *2 *3 *4 *5 *6 *7 *8 *9 *10 *11 D D D D D D D D D
MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM

Oxygen sensor (front) Air flow sensor Intake air temperature sensor Throttle position sensor Idle position switch Camshaft position sensor Crank angle sensor Barometric pressure sensor Engine coolant temperature sensor Detonation sensor Oxygen sensor (rear) Power supply voltage Vehicle speed sensor A/C switch 1, 2 Inhibitor switch Power steering fluid pressure switch Ignition switch - ST Ignition switch - IG Alternator FR terminal A/T-ECU
Engine-ECU
z1 z2 z3 z4 D D D D D D D D D
Injector Purge control solenoid valve Idle speed control servo EGR control solenoid valve Fuel pump relay Control relay A/C power relay Engine warning lamp Diagnosis signal Ignition coil, power transistor Fan controller Alternator G terminal A/T-ECU
z3 Idle speed control servo *6 Camshaft position sensor Fuel pressure regulator From fuel pump EGR valve *4, *5
*3 Intake air temperature sensor Air flow sensor (with barometric pressure sensor) Air cleaner Air
*8 *2 EGR control solenoid valve Throttle position sensor (with idle position switch) Canister z2 Purge control solenoid valve
To fuel tank PCV valve
z1 Injector
*9 Engine coolant z4 temperature sensor *10 Detonation sensor *1 Oxygen sensor
Catalytic converter *7 Crank angle sensor
MPI <4G6> - Service Specifications/Sealant
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13100030339
Items Basic idle speed r/min Throttle position sensor adjusting voltage mV Throttle position sensor resistance kW Idle speed control servo coil resistance W Intake air temperature sensor resistance kW Engine coolant temperature sensor resistance kW 20_C 80_C 20_C 80_C Specifications 75050 400 - 1,000 3.5 - 6.5 28 - 33 (at 20_C) 2.3 - 3.0 0.30 - 0.42 2.1 - 2.7 0.26 - 0.36 0.6 - 1.0 324 - 343 at kerb idle Approx. 265 at kerb idle 13 - 16 (at 20_C)
Oxygen sensor output voltage V Fuel pressure kPa Vacuum hose disconnection Vacuum hose connection Injector coil resistance W
SEALANT
Item Engine coolant temperature sensor threaded portion Specified sealant 3M Nut Locking Part No. 4171 or equivalent Remark
13100050199
Drying sealant
13A-8 SPECIAL TOOLS

Tool
A
MPI <4G6> - Special Tools

13100060338
Number MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222
Name Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe
Use D A: B: C: D: Fuel gauge simple inspection Connector pin contact pressure inspection Power circuit inspection Power circuit inspection Commercial tester connection
MB991502
MUT-II sub assembly
D D
Reading diagnosis code MPI system inspection
MB991348
Test harness set
D D
Measurement of voltage during troubleshooting Inspection using an analyzer
MB991709
Test harness
MB991519
Alternator harness connector
Measurement of voltage during troubleshooting
MD998463
Test harness (6-pin, square)
D D
Inspection of idle speed control servo Inspection using an analyzer
MD998478
Test harness (3-pin, triangle)
D D
MPI <4G6> - Special Tools/Troubleshooting

Tool Number MD998709 Name Adaptor hose Use Measurement of fuel pressure
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MD998742
Hose adaptor
MD998706
Injector test set
Checking the spray condition of injectors
MB991607
Injector test harness
MD998741
Injector test adaptor
MB991608
Clip
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
13100850256
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
DIAGNOSIS FUNCTION
13100860358
ENGINE WARNING LAMP (CHECK ENGINE LAMP) If an abnormality occurs in any of the following items related to the Multipoint Fuel Injection (MPI) system, the engine warning lamp will illuminate. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.
Engine warning lamp (check engine lamp)
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MPI <4G6> - Troubleshooting

Engine warning lamp inspection items
Engine-ECU Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor Engine coolant temperature sensor Crank angle sensor Camshaft position sensor Barometric pressure sensor Detonation sensor Injector Ignition coil, power transister Immobilizer system
METHOD OF READING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points. INSPECTION USING MUT-II DATA LIST AND ACTUATOR TESTING 1. Carry out inspection by means of the data list and the actuator test function. If there is an abnormality, check and repair the chassis harnesses and components. 2. After repairing, re-check using the MUT-II and check that the abnormal input and output have returned to normal as a result of the repairs. 3. Erase the diagnosis code memory. 4. Remove the MUT-II. 5. Start the engine again and carry out a road test to confirm that the problem has disappeared.
MPI <4G6> - Troubleshooting FAIL-SAFE FUNCTION REFERENCE TABLE
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13100910299
When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving.
Malfunctioning item Air flow sensor Control contents during malfunction 1. 2. Intake air temperature sensor Throttle position sensor (TPS) Engine coolant temperature sensor Camshaft position sensor Barometric pressure sensor Detonation sensor Ignition coil, transistor Oxygen sensor Communication wire with transmission control unit <A/T> Alternator FR terminal power Uses the throttle position sensor signal and engine speed signal (crank angle sensor signal) to take reading of the basic injector drive time and basic ignition timing from the pre-set mapping. Fixes the ISC servo in the appointed position so idle control is not performed.
Controls as if the intake air temperature is 25_C. No increase in fuel injection amount during acceleration due to the throttle position sensor signal. Controls as if the engine coolant temperature is 80_C. Injects fuel to all cylinders simultaneously. (However, after the ignition switch is turned to ON, the No. 1 cylinder top dead centre is not detected at all.) Controls as if the barometric pressure is 101 kPa. Switches the ignition timing from ignition timing for super petrol to ignition timing for standard petrol. Cuts off the fuel supply to cylinders with an abnormal ignition. Air/fuel ratio feedback control (closed loop control) is not performed. Ignition timing is not retarded during transmission gear shifting (overall engine and transmission control). Does not control the output of the alternator according to an electrical load. (works as a normal alternator)
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Code No. 11 12 13 14 21 22 23 24 25 31 41 44 54 59 61 64 Diagnosis item

13100870375
INSPECTION CHART FOR DIAGNOSIS CODES

Oxygen sensor (front) system Air flow sensor system Intake air temperature sensor system Throttle position sensor system Engine coolant temperature sensor system Crank angle sensor system Camshaft position sensor Vehicle speed sensor system Barometric pressure sensor system Detonation sensor system Injector system Ignition coil system Immobilizer system Oxygen sensor (rear) system Communication wire with A/T-ECU system <A/T> Alternator FR terminal system 13A-13 13A-14 13A-14 13A-15 13A-16 13A-17 13A-18 13A-19 13A-20 13A-21 13A-21 13A-22 13A-23 13A-24 13A-25 13A-25
Reference page
MPI <4G6> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code No. 11 Oxygen sensor (front) system
Range of Check D 3 minutes have passed after engine was started. D Engine coolant temperature is approx. 80_C or more. D Intake air temperature is 20 - 50_C. D Engine speed is approx. 2,000 - 3,000 r/min D Vehicle is moving at constant speed on a flat, level road surface Set conditions D The oxygen sensor (front) output voltage is around 0.6 V for 30 seconds (does not cross 0.6 V for 30 seconds). D When the range of check operations given above which accompany starting of the engine are carried out four time in succession, a problem is detected after each operation. NG
13A-13
Probable cause
D D D Malfunction of the oxygen sensor (front) Improper connector contact, open circuit short-circuited harness wire Malfunction of the engine-ECU or
Check the oxygen sensor (front). (Refer to P.13A-92.) OK
Replace
1. NG Measure at the oxygen sensor (front) connector C-46. D Disconnect the connector, and measure at the harness side. 1. Voltage between 3 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Continuity between 2 and earth OK: Continuity OK
Check the harness wire between the oxygen sensor (front) and the control relay connector, and repair if necessary. Check the following connector: C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor (front) connector. OK Replace the engine-ECU. Check the following connector: C-46 OK Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor (front) connector, and repair if necessary. NG Repair NG NG Repair
Repair
Measure at the engine-ECU connector C-38. D Disconnect the connector, and measure at the NG harness side. D Voltage between 60 and earth (Ignition switch: ON) OK: System voltage OK Check the following connectors: C-46, C-38 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor (front) connector. OK Replace the engine-ECU. NG NG
Repair
13A-14

Probable cause
D D D Malfunction of the air flow sensor Improper connector contact, open circuit or short-circuited harness wire of the air flow sensor Malfunction of the engine-ECU
Code No. 12 Air flow sensor system

Range of Check D Engine speed is 500 r/min or more. Set conditions D Sensor output frequency is 3 Hz or less for 4 seconds. 1. NG Measure at the air flow sensor conCheck the air flow sensor circuit. nector B-12. (Refer to P.13A-59, INSPECTION D Connect the connector. (Use PROCEDURE 48.) the test harness: MB991709) 1. Voltage between 3 and earth NG 2. NG (Engine: Idling) Measure at the engine-ECU conOK: 2.2 - 3.2 V nector C-34. 2. Voltage between 7 and earth D Connect the connector. OK: 0 - 1 V (Engine: idling) D Voltage between 19 and earth 6 - 9 V (2,000 r/min) (Ignition switch: ON) OK: 6 - 9 V OK Replace the engine-ECU. OK Check the following connector: C-34 OK Check trouble symptom. NG Replace the engine-ECU. NG
Check the following connector: B-12 OK Check trouble symptom. NG Repair Replace the air flow sensor.
NG
Repair
Code No. 13 Intake air temperature sensor system

Range of Check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Set conditions D Sensor output voltage is 4.6 V or more (corresponding to an intake air temperature of - 45_C or less) for 4 seconds. or D Sensor output voltage is 0.2V or less (corresponding to an intake air temperature of 125_C or more) for 4 seconds. NG
Probable cause
D D D Malfunction of the intake air temperature sensor Improper connector contact, open circuit or short-circuited harness wire of the intake air temperature sensor circuit Malfunction of the engine-ECU
Check the intake air temperature sensor. (Refer to P.13A-90.) OK Measure at the air flow sensor connector B-12. D Disconnect the connector, and measure at the harness side. D Voltage between 6 and earth (Ignition switch: ON) OK: 4.5 - 4.9 V D Continuity between 5 and earth OK: Continuity OK Check the following connector: B-12 OK Check trouble symptom.
Replace
NG
Check the following connector: C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the intake air temperature sensor connector. Repair OK Replace the engine-ECU.
NG
Repair
NG
Repair
NG
NG
Replace the engine-ECU.

Code No. 14 Throttle position sensor system
Range of Check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Set conditions D When the idle position switch is ON, the sensor output voltage is 2 V or more for 4 seconds. or D The sensor output voltage is 0.2 V or less for 4 seconds. NG
13A-15
Probable cause
D D D D D Malfunction of the throttle position sensor or maladjustment Improper connector contact, open circuit or short-circuited harness wire of the throttle position sensor circuit Improper ON state of idle position switch Short circuit of the idle position switch signal line Malfunction of the engine-ECU
MUT-II Data list 26 Idle position switch system OK: With the throttle valve at the idle position: ON With the throttle valve slightly open: OFF OK Check the throttle position sensor. (Refer to P.13A-91.) OK Measure at the throttle position sensor connector B-07. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 4 and earth OK: Continuity OK Check the throttle position sensor output circuit. (Refer to P.13A-60, INSPECTION PROCEDURE 49.)
Check the idle position switch system. (Refer to P.13A-46, INSPECTION PROCEDURE 28.)
NG
Replace
NG
Check the following connector: C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the throttle position sensor connector. OK Replace the engine-ECU.
NG
Repair
NG
Repair
13A-16

Probable cause
D D D Malfunction of the engine coolant temperature sensor Improper connector contact, open circuit or short-circuited harness wire of the engine coolant temperature sensor circuit Malfunction of the engine-ECU
Code No. 21 Engine coolant temperature sensor system

Range of Check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Set conditions D Sensor output voltage is 4.6 V or more (corresponding to an engine coolant temperature of - 45_C or less) for 4 seconds. or D Sensor output voltage is 0.1 V or less (corresponding to an engine coolant temperature of 140_C or more) for 4 seconds. Range of Check D Ignition switch: ON D Engine speed is approx. 50 r/min or more Set conditions D The sensor output voltage increases from 1.6 V or less (corresponding to an engine coolant temperature of 40_C or more) to 1.6 V or more (corresponding to an engine coolant temperature of 40_C or less). D After this, the sensor output voltage is 1.6 V or more for 5 minutes. NG
Check the engine coolant temperature sensor. (Refer to P.13A-90.) OK Measure at the engine coolant temperature sensor connector B-33. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.5 - 4.9 V D Continuity between 2 and earth OK: Continuity OK
Replace
NG
Check the following connector: C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the engine coolant temperature sensor connector. OK Replace the engine-ECU.
NG
Repair
NG
Repair
Check the following connector: B-33 NG Repair
OK
Check trouble symptom. NG Replace the engine-ECU.

Code No. 22 Crank angle sensor system
Range of Check D Engine is cranking. Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal input.) OK
13A-17
Probable cause
D D D Malfunction of the crank angle sensor Improper connector contact, open circuit or short-circuited harness wire of the crank angle sensor Malfunction of the engine-ECU
Measure at the crank angle sensor connector B-77. D Connect the connector. (Use the test harness: MD998478.) D Voltage between 2 and earth (Engine: cranking) OK: 0.4 - 4.0 V D Voltage between 2 and earth (Engine: idling) OK: 1.5 - 2.5 V NG
1. NG Measure at the crank angle sensor connector B-77. D Disconnect the connector, and measure at the harness side. 1. Voltage between 3 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Voltage between 2 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V 3. NG 3. Continuity between 1 and earth OK: Continuity OK Check the following connector: B-77 OK Check trouble symptom. NG Replace the crank angle sensor. NG
Check the harness wire between the crank angle sensor and the control relay connector, and repair if necessary. Check the following connector: C-40 OK Check trouble symptom. NG NG NG Repair
Repair
Check the harness wire between the engine-ECU and the crank angle sensor connector. OK Replace the engine-ECU.
Repair
Check the harness wire between the crank angle sensor and the earth, and repair if necessary.
13A-18

Probable cause
D D D Malfunction of the camshaft position sensor Improper connector contact, open circuit or short-circuited harness wire of the camshaft position sensor circuit Malfunction of the engine-ECU
Code No. 23 Camshaft position sensor system

Range of Check D Ignition switch: ON D Engine speed is approx. 50 r/min or more. Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal input.) OK
Measure at the camshaft position sensor connector B-64. D Connect the connector. (Use the test harness: MB991223 and jumper wire.) D Voltage between 2 and earth (Engine: cranking) OK: 0.4 - 3.0 V D Voltage between 2 and earth (Engine: idling) OK: 1.5 - 2.0 V NG
1. NG Measure at the camshaft position sensor connector B-64. D Disconnect the connector, and measure at the harness side. 1. Voltage between 3 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Voltage between 2 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V 3. NG 3. Continuity between 1 and earth OK: Continuity OK Check the following connector: B-64 OK Check trouble symptom. NG Replace the camshaft position sensor. NG
Check the harness wire between the camshaft position sensor and the control relay connector, and repair if necessary. Check the following connector: C-40 OK Check trouble symptom. NG NG NG Repair
Repair
Check the harness wire between the engine-ECU and the camshaft position sensor connector. OK Replace the engine-ECU.
Repair
Check the harness wire between the camshaft position sensor and the earth, and repair if necessary.

Code No. 24 Vehicles speed sensor system
Range of check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. D Idle position switch: OFF D Engine speed is 3,000 r/min or more. D Driving under high engine load conditions. Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal input). NG
13A-19
Probable cause
D D D Malfunction of the vehicle speed sensor Improper connector contact, open circuit or short-circuited harness wire of the vehicle speed sensor circuit Malfunction of the engine-ECU
Check the vehicle speed sensor. (Refer to GROUP 54 - Combination Meters.) OK Measure at the vehicle speed sensor connector B-66 <M/T>, B-67 <A/T>. D Disconnect the connector, and measure at the harness side. 1. Voltage between 1 and earth (Ignition switch: ON) OK: System voltage 2. Voltage between 3 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V 3. Continuity between 2 and earth OK: Continuity OK Check the following connectors: B-66 <M/T>, B-67 <A/T>, C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the vehicle speed sensor connector. OK Replace the engine-ECU. NG NG Repair
Replace
1. NG
2. NG
Check the following connectors: B-65 <M/T>, C-90, C-135, C-131 OK Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and ignition switch connector. OK
NG
Repair
3. NG
NG
Repair
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.) Check the following connectors: B-65 <M/T>, C-48, C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the vehicle speed sensor connector. OK Replace the engine-ECU. Check the following connector: B-65 <M/T> OK Check trouble symptom. OK Check the harness wire between the vehicle speed sensor and the earth, and repair if necessary. NG Repair NG NG Repair
Repair
Repair
13A-20

Probable cause
D D D Malfunction of the barometric pressure sensor Improper connector contact, open circuit or short-circuited harness wire of the barometric pressure sensor circuit Malfunction of the engine-ECU
Code No. 25 Barometric pressure sensor system

Range of Check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. D Battery voltage is 8 V or more. Set conditions D Sensor output voltage is 4.5 V or more (corresponding to a barometric pressure of 114 kPa or more) for 4 seconds. or D Sensor output voltage is 0.2 V or less (corresponding to a barometric pressure of 5.33 kPa or less) for 4 seconds. NG NG
Measure at the air flow sensor connector B-12. D Connect the connector. (Use the test harness: MB991709) D Voltage between 2 and earth (Ignition switch: ON) OK: 3.7 - 4.3 V (Altitude: 0 m) 3.2 - 3.8 V (Altitude: 1,200 m) OK
Measure at the air flow sensor connector B-12. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 5 and earth OK: Continuity OK Check the following connector: B-12 OK Check trouble symptom. NG
Check the following connector: C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the barometric pressure sensor connector.
NG
Repair
NG
Repair
NG
Repair
OK
NG Check the harness wire between the engine-ECU and the baromet- OK ric pressure sensor connector. Measure at the engine-ECU connector C-40. D Connect the connector. D Voltage between 85 and earth (Ignition switch: ON) OK: 3.7 - 4.3 V (Altitude: 0 m) 3.2 - 3.8 V (Altitude: 1,200 m) OK Check the following connector: C-40 OK Check trouble symptom. NG Replace the engine-ECU. NG Repair NG Check the harness wire between the engine-ECU and the barometric pressure sensor connector, and repair if necessary.
Repair Replace the air flow sensor.

Code No. 31 Detonation sensor system
Range of Check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. D Engine speed is approx. 5,000 r/min or more Set conditions The change in the detonation sensor output voltage (detonation sensor peak voltage at each 1/2 revolution of the crankshaft) is less than 0.06 V for 200 times in succession. OK
13A-21
Probable cause
D D D Malfunction of the detonation sensor Improper connector contact, open circuit or short-circuited harness wire of the detonation sensor circuit Malfunction of the engine-ECU
Measure at the detonation sensor connector B-34. D Disconnect the connector and measure at the harness side. D Continuity between 2 and earth OK: Continuity NG Check the harness wire between the detonation sensor and earth, and repair if necessary.
Check the following connectors: B-34, C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the detonation sensor connector. NG Repair
NG
Repair
OK
Replace the detonation sensor. Check trouble symptom. NG Replace the engine-ECU.
Code No. 41 Injector system

Range of Check D Engine speed is approx. 50 - 1,000 r/min D The throttle position sensor output voltage is 1.15 V or less. D Actuator test by MUT-II is not carried out. Set conditions D Surge voltage of injector coil is not detected for 4 seconds. NG NG
Probable cause
D D D Malfunction of the injector Improper connector contact, open circuit or short-circuited harness wire of the injector circuit Malfunction of the engine-ECU
Check the injector. (Refer to P.13A-93.) OK Measure at the injector connectors B-02, B-03, B-05, B-36. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Check the injector control circuit. (Refer to P.13A-60, INSPECTION PROCEDURE 50.)
Replace NG
Check the following connectors: B-02, B-03, B-05, B-36 OK Check trouble symptom.
Repair
NG
Check the harness wire between the control relay and the injector connector, and repair if necessary.
13A-22

Probable cause
D D D D D Malfunction of the ignition coil Improper connector contact, open circuit or short-circuited harness wire of the ignition primary circuit Malfunction of the spark plug and spark plug cable Improper compression pressure Malfunction of the engine-ECU OK
Code No. 44 Ignition coil system

Range of Check D Engine speed is approx. 50 - 4,000 r/min D Excluding deceleration driving and sudden acceleration or deceleration driving Set conditions D Misfire occurs in No.1 and No.4 cylinders or No.2 and No.3 cylinders more than predeterminated times per 1,000 r/min.
1. NG Measure at the ignition coil connectors B-01, B-11 D Disconnect the connector, and measure at the harness. 1. Voltage between 1 and earth (Ignition switch: ON) OK: System voltage 2. Voltage between 3 and earth 2. NG (Engine: Cranking) OK: 0.5 - 4.0 V 3. Continuity between the 2 and earth 3. NG OK: Continuity OK
Check the following connectors: C-92, C-131 NG Repair
Check trouble symptom. NG Check the harness wire between the ignition coil and ignition switch connector, and repair if necessary.
Check the following connector: C-34 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and ignition coil connector. NG Repair Check the harness wire between the ignition coil connector and earth, and repair if necessary.
NG
Repair
OK
Check the following connectors: B-01, B-11 Check trouble symptom. NG Check the following items. D Check the spark plugs, spark plug cables. D Check the compression pressure. OK Replace the ignition coil. Check trouble symptom. NG Replace the engine-ECU.
NG
Repair
NG
Repair or replace

Code No.54 Immobilizer system
Range of Check D Ignition switch: ON Set Conditions D Improper communication between the engine-ECU and immobilizer-ECU
13A-23
Probable cause
D D D D D Radio interference of ID codes Incorrect ID code Malfunction of harness or connector Malfunction of immobilizer-ECU Malfunction of engine-ECU
NOTE (1) If the ignition switches are close each other when starting the engine, radio interference may cause this code to be displayed. (2) This code may be displayed when registering the key ID code.
Is there another ignition key near the ignition key that is inserted in the ignition switch? Yes Remove the extra ignition key. NG No Is a diagnosis code output from the immobilizer-ECU? No Check the following connectors: C-38, C-81, C-68 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the immobilizer-ECU. NG Repair Replace the engine-ECU. OK Replace the immobilizer-ECU. NG Check trouble symptom. NG NG Yes Check trouble symptom. Check the immobilizer system. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) Repair
13A-24

Probable cause
D D D Malfunction of the oxygen sensor (rear) Improper connector contact, open circuit short-circuited harness wire Malfunction of the engine-ECU or
Code No. 59 Oxygen sensor (rear) system

Range of Check D 3 minutes have passed after engine was started. D Engine coolant temperature is approx. 80_C or more. D Idle position switch: OFF D The throttle position sensor output voltage is 4.1 V or more. D Open loop control in operation D 20 seconds have passed after deceleration finished. Set conditions D The oxygen sensor (rear) output voltage is 0.1 V or less. D The difference in the maximum and minimum values for the oxygen sensor (rear) output voltage is 0.08 V or less. D The oxygen sensor (rear) output voltage is 0.5 V or more. D The above conditions continue for a continuous period of 5 seconds. NG
Check the oxygen sensor (rear). (Refer to P.13A-93.) OK
Replace
1. NG Measure at the oxygen sensor (rear) connector C-85. D Disconnect the connector, and measure at the harness side. 1. Voltage between 3 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Continuity between 2 and earth OK: Continuity 3. Continuity between 4 and earth 3. NG OK: Continuity OK
Check the harness wire between the oxygen sensor (rear) and the control relay connector, and repair if necessary. Check the following connector: C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor (rear) connector. OK Replace the engine-ECU. Check the harness wire between the oxygen sensor (rear) and the earth, and repair if necessary. NG NG Repair
Repair
Check the following connectors: C-85, C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor (rear) connector. OK Replace the oxygen sensor (rear). Check trouble symptom. NG Replace the engine-ECU.
NG
Repair
NG
Repair

Code No. 61 Communication wire with A/T-ECU system <A/T>
Range of Check D 60 seconds or more have passed immediately after engine was started. D Engine speed is approx. 50 r/min or more Set conditions The voltage of the torque reduction request signal from the A/T-ECU is LOW for 1.5 seconds or more. NG
13A-25
Probable cause
D D D Malfunction of the harness wire and the connector Malfunction of the engine-ECU Malfunction of the A/T-ECU
Check the following connectors: C-34, C-38, C-30 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the A/T-ECU connector. NG Repair
Repair
OK
Check trouble symptom. NG Replace the A/T-ECU.
Code No. 64 Alternator FR Terminal System

Range of Check, Set Conditions D The alternator FR terminal signal voltage remains high for approximately 20 seconds while the engine is running. OK
Probable cause
D D Open circuit in alternator FR terminal circuit Malfunction of the engine-ECU
Measure at the alternator connector B-38. D Connect the connector. D Voltage between 4 and earth (Engine: Idling) (Radiator fan: Stopped) (Headlamp: OFF ON) OK: 1.8 - 2.4 1.0 - 1.6 V NG Measure at the alternator connector B-38. D Disconnect the connector, and measure at the harness side. D Voltage between 4 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V OK Check the following connector: B-38 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the alternator connector. OK Replace the alternator.
NG
Check the following connectors: B-31, C-36 OK Check trouble symptom. NG Repair Check the harness wire between the engine-ECU and the alternator connector.
NG
Repair
NG
NG
Repair
NG
Repair
OK
13A-26
Trouble symptom

13100880354
INSPECTION CHART FOR TROUBLE SYMPTOMS

Inspection procedure No. Communication with all systems is not possible. Communication with engine-ECU only is not possible. The engine warning lamp does not illuminate right after the ignition switch is turned to the ON position. The engine warning lamp remains illuminating and never goes out. No initial combustion (starting impossible) Initial combustion but no complete combustion (starting impossible) Long time to start (improper starting) Idling stability (Improper idling) Unstable idling (Rough idling, hunting) Idling speed is high. (Improper idling speed) Idling speed is low. (Improper idling speed) Idling stability (Engine stalls) When the engine is cold, it stalls at idling. (Die out) When the engine becomes hot, it stalls at idling. (Die out) The engine stalls when starting the car. (Pass out) The engine stalls when decelerating. Driving Hesitation, sag or stumble The feeling of impact or vibration when accelerating The feeling of impact or vibration when decelerating Poor acceleration Surge Knocking Dieseling Too high CO and HC concentration when idling Low alternator output voltage (approx. 12.3 V) Idling speed is improper when A/C is operating Fans (radiator fan, A/C condensor fan) are inoperative 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Reference page
Communication with MUT-II is II impossible. Engine warning lamp and related parts
13A-28 13A-29 13A-30 13A-30 13A-31 13A-32 13A-33 13A-34 13A-35 13A-36 13A-37 13A-38 13A-39 13A-39 13A-40 13A-40 13A-41 13A-41 13A-42 13A-42 13A-42 13A-43 13A-44 13A-44 13A-45
Starting
MPI <4G6> - Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)

Items Starting Wont start Fires up and dies Hard starting Idling stability Hunting Rough idle Symptom
13A-27
The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine wont start. There is combustion within the cylinders, but then the engine soon stalls. Engine starts after cranking a while. Engine speed doesnt remain constant; changes at idle. Usually, a judgement can be based upon the movement of the tachometer pointer, and the vibration transmitted to the steering wheel, shift lever, body, etc. This is called rough idle.
Incorrect idle speed The engine doesnt idle at the usual correct speed. Engine stall (Die out) Engine stall (Pass out) Driving Hesitation Sag The engine stalls when the foot is taken from the accelerator pedal, regardless of whether the vehicles is moving or not. The engine stalls when the accelerator pedal is depressed or while it is being used. Hesitation is the delay in response of the vehicle speed (engine speed) that occurs when the accelerator is depressed in order to accelerate from the speed at which the vehicle is now traveling, or a temporary drop in vehicle speed (engine speed) during such acceleration. Serious hesitation is called sag.
Hesitation Normal Vehicle Initial acspeed celerator pedal depression Sag
Time
Poor acceleration
Poor acceleration is inability to obtain an acceleration corresponding to the degree of throttle opening, even though acceleration is smooth, or the inability to reach maximum speed. Engine speed increase is delayed when the accelerator pedal is initially depressed for acceleration.
Stumble
Vehicle speed
Normal Initial accelerator pedal depression Idling Time Stumble
13A-28
Items Driving Shock Surge Knocking Stopping Run on (Dieseling)

Symptom The feeling of a comparatively large impact or vibration when the engine is accelerated or decelerated. This is repeated surging ahead during constant speed travel or during variable speed travel. A sharp sound like a hammer striking the cylinder walls during driving and which adversely affects driving. The condition in which the engine continues to run after the ignition switch is turned to OFF. Also called Dieseling.
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. (Communication with all systems is not possible.)
The cause is probably a defect in the power supply system (including earth) for the diagnosis line. NG
Probable cause
D D Malfunction of the connector Malfunction of the harness wire NG
Measure at the diagnostic connector (16-pin) C-20. D Voltage between 16 and earth OK: Battery voltage OK
Check the following connectors: C-66, (C-63, C-132, C-141) <L.H.>, (C-62, C-14) <R.H.> OK Check trouble symptom.
Repair
NG
Check the harness wire between the power supply and diagnostic connector (16 pin), and repair if necessary.
Measure at the diagnostic connector (16-pin) C-20. D Continuity between 4 and earth D Continuity between 5 and earth OK: Continuity OK Replace the MUT-II.
NG
Check the harness wire between the diagnostic connector (16-pin) and earth, and repair if necessary.

INSPECTION PROCEDURE 2 MUT-II communication with engine-ECU is impossible.
One of the following causes may be suspected. D No power supply to engine-ECU. D Defective earth circuit of engine-ECU. D Defective engine-ECU. D Improper communication line between engine-ECU and MUT-II
13A-29
Probable cause
D D D D D Malfunction of engine-ECU power supply circuit Malfunction of engine-ECU Malfunction of immobilizer-ECU Open circuit between immobilizer-ECU and diagnosis connector Open circuit between engine-ECU and immobilizerECU
Is communication possible between the MUT-II and the immobilizerECU? Yes Check the following connectors: C-20, C-66, C-68, C-83, C-81, C-38 OK Check trouble symptom. NG Check the harness wire between engine-ECU and diagnosis connector. OK Check the harness wire between engine-ECU and immobilizerECU. NG Repair
No
Check the diagnosis line between the immobilizer-ECU and the MUT-II, and repair if necessary. (Refer to GROUP 54 - Ignition Key and Immobilizer.) Repair
NG
NG
Repair
OK
Check the harness wire between engine-ECU and earth. OK
NG
Repair
Check the power supply and ignition switch-IG system. (Refer to P.13A-45, INSPECTION PROCEDURE 26.)
13A-30
INSPECTION PROCEDURE 3
The engine warning lamp does not illuminate right after the ignition switch is turned to the ON position.
Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp to illuminate for five seconds immediately after the ignition switch is turned to ON. If the engine warning lamp does not illuminate immediately after the ignition switch is turned to ON, one of the malfunctions listed at right has probably occurred. NG
Probable cause
D D D Burnt-out bulb Defective warning lamp circuit Malfunction of the engine-ECU
MUT-II Data list 16 engine-ECU power supply voltage (Refer to P.13A-62.) OK Measure at the engine-ECU connector C-36. D Disconnect the connector, and measure at the harness side. D Earth the terminal No. 36. OK: The engine warning lamp illuminates. NG Check a burnt-out bulb. OK Measure at the combination meter connector D-03. D Disconnect the connector, and measure at the harness side. D Voltage between 4 and earth (Ignition switch: ON) OK: System voltage OK Check the following connectors: D-03, C-90, C-36 OK Check trouble symptom. NG
Check the engine-ECU power supply and earth circuit. (Refer to P.13A-58, INSPECTION PROCEDURE 45.) NG
OK
Check the following connector: C-36. OK Check trouble symptom. NG Replace the engine-ECU.
Repair
Replace NG
Check the engine warning lamp power supply circuit, and repair if necessary.
NG
Repair
NG
Check the harness wire between combination meter and engineECU, and repair if necessary.
INSPECTION PROCEDURE 4 The engine warning lamp remains illuminating and never goes out.
In cases such as the above, the cause is probably that the engine-ECU is detecting a problem in a sensor or actuator, or that one of the malfunctions listed at right has occurred. Yes No Measure at the combination meter connector D-03. D Disconnect the connector, and measure at the harness side. D Disconnect the engine-ECU connector D Continuity between 16 and earth OK: No continuity OK Replace the engine-ECU.
Probable cause
D D Short-circuit between the engine warning lamp and engine-ECU Malfunction of the engine-ECU
MUT-II Self-Diag code Are diagnosis codes displayed?
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES Check the harness wire between combination meter and engineECU connector, and repair if necessary.
NG

INSPECTION PROCEDURE 5 No initial combustion (starting impossible)
In cases such as the above, the cause is probably that a spark plug is defective, or that the supply of fuel to the combustion chamber is defective. In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel.
13A-31
Probable cause
D D D D D D Malfunction of the ignition system Malfunction of the fuel pump system Malfunction of the injectors Malfunction of the engine-ECU Malfunction of the immobilizer system Foreign materials in fuel
Check battery voltage when cranking. OK: 8 V or higher OK Is immobilizer-ECU diagnosis code displayed? No MUT-II: Inspection of no initial combustion. (Refer to P.13A-52, INSPECTION PROCEDURE 37.) OK Can any sound be heard from the injectors when cranking? OK Ignition system: Inspection of no initial combustion. (Refer to P.13A-52, INSPECTION PROCEDURE 38.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check if the injectors are clogged. D Check if foreign materials (water, alcohol, etc.) got into fuel. D Check the compression pressure. D Check the immobilizer system.
NG
Check the battery. (Refer to GROUP 54 - Battery.)
Yes
Check the immobilizer. (Refer to GROUP 54 - Ignition Key and Immobilizer.)
NG
Check the injector system. (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.)
13A-32
Initial combustion but no complete combustion (starting impossible)

In such cases as the above, the cause is probably that the spark plugs are generating sparks but the sparks are weak, or the initial mixture for starting is not appropriate.
Probable cause
D D D D D Malfunction of the ignition system Malfunction of the injector system Foreign materials in fuel Poor compression Malfunction of the engine-ECU
Check battery voltage when cranking. OK: 8 V or higher OK MUT-II: Check if uncompleted combustion occurs. (Refer to P.13A-53, INSPECTION PROCEDURE 39.) OK Can any sound be heard from the injectors when cranking? OK Is starting good if the engine is cranked with the accelerator pedal slightly depressed? No
NG
NG
Check the injector system, (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.) Check ISC servo for operation sound. (Refer to P.13A-95.) OK D D NG Check the ISC servo system. (Refer to P.13A-50, INSPECTION PROCEDURE 34.)
Yes
Clean the throttle valve area. (Refer to P.13A-81.) Check and adjust the fixed SAS. (Refer to P.13A-83.)
Check the ignition timing when cranking. OK: Approx. 5_BTDC OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check if the injectors are clogged. D Check the compression pressure. D Check fuel lines for clogging. D Check if foreign materials (water, alcohol, etc.) got into fuel.
NG
Check that the crank angle sensor is installed properly.

INSPECTION PROCEDURE 7 It takes too long time to start. (Incorrect starting)
In cases such as the above, the cause is probably that the spark is weak and ignition is difficult, the initial mixture for starting is not appropriate, or sufficient compression pressure is not being obtained.
13A-33
Probable cause
D D D D Malfunction of the ignition system Malfunction of the injector system Inappropriate gasoline use Poor compression
Check battery voltage when cranking OK: 8 V or higher OK MUT-II: Check if uncomplete combustion occurs. (Refer to P.13A-53, INSPECTION PROCEDURE 39.) OK Can any sound be heard from the injectors when cranking? OK Check the ignition timing when cranking. OK: Approx. 5_BTDC OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check if the injectors are clogged. D Check the compression pressure. D Check if foreign materials (water, alcohol, etc.) got into fuel.
NG
NG NG
Check the injector system. (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.) Check that the crank angle sensor is installed properly.
13A-34
Unstable idling (Rough idling, hunting)

In cases as the above, the cause is probably that the ignition system, air/fuel mixture, idle speed control (ISC) or compression pressure is defective. Because the range of possible causes is broad, inspection is narrowed down to simple items.
Probable cause
D D D D D D D Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the ISC system Malfunction of the purge control solenoid valve system Malfunction of the EGR solenoid valve system Poor compression Drawing air into exhaust system
Were the battery terminals disconnected? No MUT-II Self-Diag code Are diagnosis codes displayed? No Does idling speed fluctuate excessively? No Check the ISC servo for operation sound. (Refer to P.13A-95.) OK Check the injector for operation sound. OK MUT-II: Check if idling speed is unstable. (Refer to P.13A-54, INSPECTION PROCEDURE 41.) OK Check the ignition timing. (Refer to GROUP 11A - On-vehicle Service.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check the purge control system. D Check the EGR control system. D Check the compression pressure. D Check if foreign materials (water, alcohol, etc.) got into fuel.
Yes Yes
After warming-up, let the engine run at idling for 10 minutes. Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check if hunting occurs. (Refer to P.13A-53, INSPECTION PROCEDURE 40.) Check the ISC servo system. (Refer to P.13A-50, INSPECTION PROCEDURE 34.) Check the injector system. (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.)
Yes NG NG
NG

INSPECTION PROCEDURE 9 Idling speed is high. (Improper idling speed)
In such cases as the above, the cause is probably that the intake air volume during idling is too great. Yes No Check the ISC servo for operation sound. (Refer to P.13A-95.) OK MUT-II Data list 26 Idle position switch (Refer to P.13A-63.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-62.) OK MUT-II Data list 28 A/C switch (Refer to P.13A-63.) OK Basic idle adjustment (Refer to P.13A-83.) Check trouble symptom. NG Clean the throttle valve area. (Refer to P.13A-81.) NG
13A-35
Probable cause
D D Malfunction of the ISC servo system Malfunction of the throttle body
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check the ISC servo system. (Refer to P.13A-50, INSPECTION PROCEDURE 34.) Check the idle position switch system. (Refer to P.13A-46, INSPECTION PROCEDURE 28.)
NG NG
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the A/C switch and A/C relay system. (Refer to P.13A-49, INSPECTION PROCEDURE 32.)
Check and adjust the fixed SAS. (Refer to P.13A-83.)
13A-36
Idling speed is low. (Improper idling speed)

In cases such as the above, the cause is probably that the intake air volume during idling is too small. Yes No Check the ISC servo for operation sound. (Refer to P.13A-95.) OK MUT-II Data list 26 Idle position switch (Refer to P.13A-63.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-62.) OK MUT-II Data list 29 Inhibitor switch (Refer to P.13A-63.) OK Basic idle adjustment (Refer to P.13A-83.) Check trouble symptom. NG NG
Probable cause
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check the ISC servo system. (Refer to P.13A-50, INSPECTION PROCEDURE 34.) Check the idle position switch system. (Refer to P.13A-46, INSPECTION PROCEDURE 28.)
NG NG
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the ignition switch ST and inhibitor switch system <A/T>. (Refer to P.13A-48, INSPECTION PROCEDURE 30.)

INSPECTION PROCEDURE 11 When the engine is cold, it stalls at idling. (Die out)
In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate when the engine is cold, or that the intake air volume is insufficient.
13A-37
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the ISC servo system throttle body injector system ignition system
Were the battery terminals disconnected? No MUT-II Self-Diag code Are diagnosis codes displayed? No Does the engine stall right after the accelerator pedal is released? No
Yes Yes
After warming-up, let the engine run at idling for 10 minutes. Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES.
Yes
Clean the throttle valve area. (Refer to P.13A-81.)
Is engine-idling stable after the warming-up? Yes Check the ISC servo for operation sound. (Refer to P.13A-95.) OK Check the injector for operation sound. OK MUT-II Data list 26 Idle position switch (Refer to P.13A-63.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-62.) OK MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-65.) OK Check the fuel pressure. (Refer to P.13A-85.) OK Check the ignition timing. (Refer to GROUP 11A - On-vehicle Service.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check the compression pressure. D Check the engine oil viscosity.
No
Check if the unstable idling (Rough idling, hunting). (Refer to P.13A-34, INSPECTION PROCEDURE 8.) Check the ISC servo system. (Refer to P.13A-50, INSPECTION PROCEDURE 34.) Check the injector system. (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.) Check the idle position switch system. (Refer to P.13A-46, INSPECTION PROCEDURE 28.)
NG
NG
NG
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the EGR control solenoid valve system. (Refer to P.13A-51, INSPECTION PROCEDURE 36.)
NG
NG
13A-38
When the engine is hot, it stalls at idling. (Die out)

In such cases as the above, the cause is probably that ignition system, air/fuel mixture, idle speed control (ISC) or compression pressure is defective. In addition, if the engine suddenly stalls, the cause may also be a defective connector contact.
Probable cause
D D D D D Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the ISC system Drawing air into intake system Improper connector contact
Were the battery terminals disconnected? No MUT-II Self-Diag code Are diagnosis codes displayed? No Check the ISC servo for operation sound. (Refer to P.13A-95.) OK Check the injector for operation sound. OK Does the engine stall right after the accelerator pedal is released? No
Yes Yes
After warming-up, let the engine run at idling for 10 minutes. Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check the ISC servo system. (Refer to P.13A-50, INSPECTION PROCEDURE 34.) Check the injector system. (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.) Clean the throttle valve area. (Refer to P.13A-81.) Check and adjust the fixed SAS. (Refer to P.13A-83.)
NG
NG
Yes
Does the engine stall easily again? Yes MUT-II: Engine stalling inspection when the engine is warm and idling. (Refer to P.13A-55, INSPECTION PROCEDURE 42.) OK
No
While carrying out an intermittent malfunction simulation test (Refer to GROUP 00 - Points to Note for Intermittent Malfunctions.), check for sudden changes in the signals shown below. D Crank angle sensor signal D Primary and secondary D Air flow sensor signal ignition signal D Injector drive signal D Fuel pump drive signal D Engine-ECU power supply voltage
Check the ignition timing. (Refer to GROUP 11A - On-vehicle Service.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check if the injectors are clogged. D Check the compression pressure. D Check if foreign materials (water, alcohol, etc.) got into fuel.
NG

INSPECTION PROCEDURE 13 The engine stalls when starting the car. (Pass out)
In cases such as the above, the cause is probably misfiring due to a weak spark, or an inappropriate air/fuel mixture when the accelerator pedal is depressed. Yes No MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-65.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check if air was drawn into the intake system. Broken intake manifold gasket Broken or disconnected vacuum hose Improper operation of the PCV valve Broken air intake hose
13A-39
Probable cause
D D Drawing air into intake system Malfunction of the ignition system
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check the EGR control solenoid valve system. (Refer to P.13A-51, INSPECTION PROCEDURE 36.)
NG
INSPECTION PROCEDURE 14 The engine stalls when decelerating.

In cases such as the above, the cause is probably that the intake air volume is insufficient due to a defective idle speed control (ISC) servo system. Yes Yes
Probable cause
D Malfunction of the ISC system
Were the battery terminals disconnected? No MUT-II Self-Diag code Are diagnosis codes displayed? No MUT-II Data list 26 Idle position switch (Refer to P.13A-69.) P.13A-63.) OK MUT-II Data list 14 Throttle position sensor (Refer to P.13A-62.) OK MUT-II Data list 45 ISC servo position D Is the idle speed control (ISC) servo position drops to 0 - 2 steps when decelerating (engine r/min less than 1,000)? No MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-65.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Clean the throttle valve area. D Check and adjust the fixed SAS.
After warming-up, let the engine run at idling for 10 minutes. Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check the idle position switch system. (Refer to P.13A-49, INSPECTION PROCEDURE 26.) P.13A-46, 28.) Check the throttle position sensor system. (Refer to P.13A-15, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.) Check the vehicle speed sensor system. (Refer to P.13A-19, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 24.)
NG
NG
Yes
NG
Check the EGR control solenoid valve system. (Refer to P.13A-51, INSPECTION PROCEDURE 36.)
13A-40
INSPECTION PROCEDURE 15 Hesitation, sag or stumble
Probable cause
D D D D D Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the fuel supply system Malfunction of the EGR control solenoid valve system Poor compression
In cases such as the above, the cause is probably that ignition system, air/fuel mixture or compression pressure is defective.
MUT-II Self-Diag code Are diagnosis codes displayed? No Check the injectors for operation sound. OK Check the ignition timing. (Refer to GROUP 11A - On-vehicle Service.) OK MUT-II: Check if hesitation, sag, stumble or poor acceleration occur. (Refer to P.13A-56, INSPECTION PROCEDURE 43.) OK Check the fuel pressure. (Refer to P.13A-85.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check the EGR control system. D Check the compression pressure. D Check the fuel filter or fuel line for clogging.
Yes
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check the injector system. (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.) Check that the crank angle sensor is installed properly.
NG
NG
INSPECTION PROCEDURE 16 The feeling of impact or vibration when accelerating

In cases such as the above, the cause is probably that there is an ignition leak accompanying the increase in the spark plug demand voltage during acceleration. Yes No Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check for occurrence of ignition leak.
Probable cause
D Malfunction of the ignition system
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES.

INSPECTION PROCEDURE 17 The feeling of impact or vibration when decelerating.
Malfunction of the ISC system is suspected. Yes No Check the ISC servo for operation sound. (Refer to P.13A-95.) OK MUT-II Data list 14 Throttle position sensor (Refer to P.13A-62.) OK MUT-II Data list 26 Idle position switch (Refer to P.13A-63.) OK Clean the throttle valve area. (Refer to P.13A-81.) NG
13A-41
Probable cause
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check the ISC servo system. (Refer to P.13A-50, INSPECTION PROCEDURE 34.) Check the throttle position sensor system. (Refer to P.13A-15, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
NG NG
INSPECTION PROCEDURE 18 Poor acceleration

Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc. are suspected.
Probable cause
D D D D D Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the fuel supply system Poor compression pressure Clogged exhaust system
MUT-II Self-Diag code Are diagnosis codes displayed? No Check the injectors for operation sound. OK Check the ignition timing. (Refer to GROUP 11A - On-vehicle Service.) OK MUT-II: Check if hesitation, sag, stumble or poor acceleration occur. (Refer to P.13A-56, INSPECTION PROCEDURE 43.) OK Check the fuel pressure. (Refer to P.13A-85.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check the compression pressure. D Check the fuel filter or fuel line for clogging. D Broken air intake hose D Clogged air cleaner
Yes
NG
NG
13A-42
INSPECTION PROCEDURE 19 Surge
Probable cause
D D D Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the EGR control solenoid valve system
Defective ignition system, abnormal air-fuel ratio, etc. are suspected.
MUT-II Self-Diag code Are diagnosis codes displayed? No Check the injectors for operation sound. OK Check the ignition timing. (Refer to GROUP 11A - On-vehicle Service.) OK MUT-II: Check if surge occurs. (Refer to P.13-57, INSPECTION PROCEDURE 44.) OK Check the fuel pressure. (Refer to P.13A-85.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check the EGR control system.
Yes
NG
NG
INSPECTION PROCEDURE 20 Knocking

In cases as the above, the cause is probably that the detonation control is defective or the heat value of the spark plug is inappropriate. Yes No Does knocking occur when driving with the sensor disconnected? At this time, use the MUT-II to check if the timing is retarded compared to when the detonation sensor connector is connected. Yes Check the following items. D Spark plugs D Check if foreign materials (water, alcohol, etc.) got into fuel.
Probable cause
D D Defective detonation sensor Inappropriate heat value of the spark plug
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check the detonation sensor system. (Refer to P.13A-21, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 31.)
No
INSPECTION PROCEDURE 21 Dieseling

Fuel leakage from injectors is suspected. Check the injectors for fuel leakage.
Probable cause
D Fuel leakage from injectors

INSPECTION PROCEDURE 22 Too high CO and HC concentration when idling
Abnormal air-fuel ratio is suspected.
13A-43
Probable cause
D D Malfunction of the air-fuel ratio control system Deteriorated catalyst
MUT-II Self-Diag code Are diagnosis codes displayed? No Check the ignition timing. (Refer to GROUP 11A - On-vehicle Service.) OK MUT-II Data list 21 Engine coolant temperature sensor. (Refer to P.13A-62.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-62.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-63.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-65.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor OK: 600 - 1,000 mV when racing suddenly (Refer to P.13A-61.) OK MUT-II Data list 11 Oxygen sensor OK: Repeat 0 - 400 mV and 600 - 1,000 mV alternately when idling. (Refer to P.13A-61.) NG Check the fuel pressure. (Refer to P.13A-85.) OK Check the following items. D Check the injectors for operation sound. D Check the injectors for fuel leakage. D Check the ignition coil, spark plugs, spark plug cables. D Check the compression pressure. D Check the positive crankcase ventilation system. D Check the purge control system. D Check the EGR control system.
Yes
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check that the crank angle sensor is installed properly.
NG
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the intake air temperature sensor system. (Refer to P.13A-14, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
NG
NG
Check the barometric pressure sensor system. (Refer to P.13A-20, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.) Check the oxygen sensor (rear) system. (Refer to P.13A-24, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)
NG
NG
Check the oxygen sensor system. (Refer to P.13A-13, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 11.)
OK
Replace the oxygen sensor. Check trouble symptom. NG
Check the trouble symptom. NG Replace the catalytic converter.
13A-44
Low alternator output voltage (approx. 12.3 V)

The alternator may be defective, or malfunctions, which are listed in the right column, may be suspected.
Probable cause
D D D Malfunction of charging system Short circuit in harness between alternator G terminal and engine-ECU Malfunction of engine-ECU NG
Measure at the alternator connector side. B-38 D Connect the connector. (Test harness: MB991519) D Voltage between 1 (black clip) and earth Engine: at idle Radiator fan: does not run Headlamp: OFF ON Brake lamp: OFF ON Rear defogger switch: OFF ON OK: Voltages rises by 0.2 - 3.5 V. OK Check the alternator. (Refer to GROUP 16 - Charging System.)
NG
Measure at the alternator connector. B-38 D Disconnect the connector, and measure at the harness side. D Disconnect the engine-ECU connector. D Continuity between 1 and earth OK: No continuity OK Check the harness wire between the alternator and the engine-ECU connector. OK Replace the engine-ECU.
Check the harness wire between the alternator and the engine-ECU connector, and repair if necessary.
NG
Repair
INSPECTION PROCEDURE 24 Idling speed is improper when A/C is operating

If the engine-ECU detects that the air conditioner is on, it activates the idle speed control (ISC) servo to control idle-up operation. The A/C-ECU judges if the load caused by air conditioner operation is high or low, and converts it to voltage signal (high or low voltage) and inputs the signal to the engine-ECU. Based on this voltage signal, the engine-ECU controls the idle-up speed (for high or low load). OK
Probable cause
D D D Malfunction of the A/C control system Improper connector contact, open circuit or short-circuited harness wire Malfunction of the engine-ECU
Measure at the engine-ECU connector C-34. D Connect the connector. D Voltage between 24 and earth (Engine: at idle, outside air temperature: 25_C or more) OK: 0 - 3 V [When A/C is MAX. COOL condition (when the load by A/C is high)] System voltage [When A/C is MAX. HOT condition (when the load by A/C is low)] NG Check the A/C system. (Refer to GROUP 55 - On-vehicle Service.)
Check the following connector: C-34 OK NG Repair Check trouble symptom. NG Replace the engine-ECU.

INSPECTION PROCEDURE 25 Fans (radiator fan, A/C condenser fan) are inoperative
The engine-ECU outputs a duty signal to the fan controller depending on the engine coolant temperature, vehicle speed, and air conditioner switch condition. Based on this signal, the fan controller controls the radiator fan and condenser fan speeds (The more the average voltage at the terminal approaches 5 V, the higher the fan speed become.)
13A-45
Probable cause
D D D D D Malfunction of the fan motor relay Malfunction of the fan motor Malfunction of the fan controller Improper connector contact, open circuit or short-circuited harness wire Malfunction of the engine-ECU NG
Measure at the engine-ECU connector C-34. D Disconnect the connector, and measure at the harness side. D Voltage between 21 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V (Fan rotates at high speed.) D Connect a jumper cable between 21 and earth (Ignition switch: ON) OK: Fan stops OK Check the following connector: C-34 OK Check trouble symptom. NG Replace the engine-ECU. NG
NG
Check the harness wire between the engine-ECU and the fan controller connector. OK Check the radiator fan and condenser fan circuit. (Refer to GROUP 14 Troubleshooting.)
Repair
Repair
INSPECTION PROCEDURE 26 Power supply system and ignition switch-IG system

When an ignition switch ON signal is input to the engine-ECU, the engine-ECU turns the control relay ON. This causes battery voltage to be supplied to the engine-ECU, injectors and air flow sensor.
Probable cause
D D D D D Malfunction of the ignition switch Malfunction of the control relay Improper connector contact, open short-circuited harness wire Disconnected engine-ECU earth wire Malfunction of the engine-ECU circuit or
Check the control relay. (Refer to P.13A-90.) OK Measure at the control relay connector C-31. D Disconnect the connector, and measure at the harness side. D Voltage between 3, 4 and earth OK: System voltage OK Check the engine-ECU power supply and earth circuit. (Refer to P.13A-58, INSPECTION PROCEDURE 45.)
NG NG
Replace NG
Check the following connector: B-30 OK Check trouble symptom. NG
Repair
Check the harness wire between battery and control relay connector, and repair if necessary.
13A-46
INSPECTION PROCEDURE 27 Fuel pump system
Probable cause
D D D D NG Malfunction of the fuel pump relay Malfunction of the fuel pump Improper connector contact, open short-circuited harness wire Malfunction of the engine-ECU circuit or
The engine-ECU turns the control relay ON when the engine is cranking or running, and this supplies power to drive the fuel pump.
Check the fuel pump operation. (Refer to P.13A-88.) OK Check the fuel pump relay. (Refer to P.13A-90.) OK Measure at the fuel pump relay connector C-32. D Connect the connector. D Voltage between 1 and earth D MUT-II Actuator test: Fuel pump drive OK: System voltage OK Check the harness wire between fuel pump relay connector and fuel pump drive terminal, and repair if necessary.
Check the fuel pump circuit. (Refer to P.13A-58, INSPECTION PROCEDURE 46.)
NG NG
Replace
Check the fuel pump drive control circuit. (Refer to P.13A-59, INSPECTION PROCEDURE 47.)
INSPECTION PROCEDURE 28 Idle position switch system

The idle position switch inputs the condition of the accelerator pedal, i.e. whether it is depressed or released (HIGH/LOW), to the engine-ECU. The engine-ECU controls the idle speed control servo based on this input.
Probable cause
D D D D D NG Maladjustment of the accelerator pedal Maladjustment of the fixed SAS Maladjustment of the idle position switch and throttle position sensor Improper connector contact, open circuit or short-circuited harness wire Malfunction of the engine-ECU
Check the idle position switch. (Refer to P.13A-91.) OK Measure at the throttle position sensor connector B-07. D Disconnect the connector, and measure at the harness side. D Voltage between 3 and earth (Ignition switch: ON) OK: 4 V or higher D Continuity between 4 and earth OK: Continuity OK Check the following connector: B-07 OK Check trouble symptom. NG Replace the engine-ECU. NG
Replace the throttle position sensor. NG
NG
Check the following connector: C-40 OK Check trouble symptom. NG
Repair
Repair
Check the harness wire between engine-ECU and throttle position sensor connector. OK Replace the engine-ECU. NG Repair

INSPECTION PROCEDURE 29 Ignition switch-ST system <M/T>
The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine is cranking. The engine-ECU controls fuel injection, etc. during starting based on this input.
13A-47
Probable cause
D D D Malfunction of ignition switch Improper connector contact, short-circuited harness wire Malfunction of the engine-ECU NG open circuit or
1. NG Measure at the engine-ECU connector C-40. D Disconnect the connector, and measure at the harness side. 2. NG 1. Voltage between 71 and earth (Ignition switch: START) OK: 8V or more 2. Continuity between 91 and earth OK: Continuity OK Check the following connector: C-40 OK Check trouble symptom. NG Replace the engine-ECU. NG
Check the following connector: C-92 OK Check trouble symptom. NG Check harness wire between the engine-ECU and ignition switch connector. OK
Repair
NG
Repair
Repair
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch and Immobilizer system.) Check the harness wire between engine-ECU connector (terminal No. 91) and earth, and repair if necessary.
13A-48
Ignition switch-ST and inhibitor switch system <A/T>

D D The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine is cranking. The engine-ECU controls fuel injection, etc. during starting based on this input. The inhibitor switch inputs the condition of the select lever, i.e. whether it is in P or N range or in some other range, to the engine-ECU. The engine-ECU controls the idle speed control (ISC) servo based on this input. NG
Probable cause
D D D D Malfunction of ignition switch Malfunction of inhibitor switch Improper connector contact, short-circuited harness wire Malfunction of the engine-ECU. open circuit or
Check the inhibitor switch. (Refer to GROUP 23A - On-vehicle Service.) OK
Replace
1. NG Measure at the inhibitor switch connector B-72. D Disconnect the connector, and measure at the harness side. 1. Voltage between 10 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Continuity between 9 and earth OK: Continuity 3. Voltage between 10 and earth D Ignition switch: START D Disconnect engine-ECU connector. 3. NG OK: System voltage OK Check the following connector: B-72 OK Check trouble symptom. NG Check harness wire between engine-ECU and inhibitor switch connector. OK Replace the engine-ECU. NG NG
Check harness wire between engine-ECU and inhibitor switch connector. OK Replace the engine-ECU.
NG
Repair
Check harness wire between inhibitor switch connector and starter S terminal, and repair if necessary. NG
Repair
Check the connector: C-92
following
Repair
OK Check trouble symptom. Repair NG Check harness wire between inhibitor switch and ignition switch connector. OK Check the ignition switch. (Refer to GROUP 54 - Ignition Switch and Immobilizer system.) NG
Repair

INSPECTION PROCEDURE 31 Power steering fluid pressure switch system
The presence or absence of power steering load is input to the engine-ECU. The engine-ECU controls the idle speed control (ISC) servo based on this input.
13A-49
Probable cause
D D D Malfunction of power steering fluid pressure switch Improper connector contact, open circuit or short-circuited harness wire Malfunction of the engine-ECU
Check the power steering fluid pressure switch. (Refer to GROUP 37A - On-vehicle Service.) OK Measure at the power steering fluid pressure switch connector B-76. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: B-76 OK Check trouble symptom. NG Replace the engine-ECU. NG
NG
Replace
NG
Check the following connector: C-36 OK Check trouble symptom. NG Check harness wire between engine-ECU and power steering fluid pressure switch connector. OK Replace the engine-ECU.
NG
Repair
Repair
NG
Repair
INSPECTION PROCEDURE 32 A/C switch and A/C relay system

When an A/C ON signal is input to the engine-ECU, the engine-ECU carries out control of the idle speed control (ISC) servo, and also operates the A/C compressor magnetic clutch.
Probable cause
D D D D NG Malfunction of A/C control system Malfunction of A/C switch Improper connector contact, open short-circuited harness wire Malfunction of the engine-ECU circuit or
Check the A/C compressor relay. (Refer to GROUP 55 - On-vehicle Service.) OK
Replace
NG Measure at the engine-ECU connectors C-34, C-36. D Disconnect the connector, and measure at the harness side. D Voltage between 8 and earth, and 45 and earth (Ignition switch: ON) OK: 0 - 3 V (A/C switch: OFF) OK System voltage (A/C switch: ON) D Short circuit between 8 and earth (Ignition switch: ON, A/C switch: ON) OK: A/C compressor clutch turns on.
Check the A/C system. (Refer to GROUP 55 - Troubleshooting.)
Check the following connectors: C-34, C-36 OK Check trouble symptom. NG Replace the engine-ECU.
NG
Replace
13A-50
INSPECTION PROCEDURE 33 Ignition circuit system
Probable cause
D D D Malfunction of ignition switch. Improper connector contact, short-circuited harness wire Malfunction of the engine-ECU NG open circuit or
The engine-ECU interrupts the ignition coil primary current by turning the power transistor inside the engine-ECU ON and OFF.
1. NG Measure at the ignition coil connectors B-01, B-11. D Disconnect the connector and measure at the harness side. 1. Voltage between 1 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Continuity between 2 and earth OK: Continuity OK
Check the following connectors: C-92, C-131 OK Check trouble symptom. NG Check the harness wire between ignition coil and ignition switch connector. OK
Repair
NG
Repair
Check the following connectors: B-01, B-11 OK
NG
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) Repair Check the harness wire between power transistor unit connector and earth, and repair if necessary. NG Check ignition coil and power transistor unit system. (Refer to P.13A-22, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 44.)
Check trouble symptom.
INSPECTION PROCEDURE 34 Idle speed control (ISC) servo (Stepper motor) system
The engine-ECU controls the intake air volume during idling by opening and closing the servo valve located in the bypass air passage.
Probable cause
D D D Malfunction of ISC servo Improper connector contact, short-circuited harness wire Malfunction of the engine-ECU open circuit or
Check the ISC servo (Refer to P.13A-95.) OK
NG
Replace
Measure at the ISC servo connector B-10. D Disconnect the connector and measure at the harness side. D Voltage between 2 and earth, and 5 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-34. D Disconnect the connector, measure at the harness side. D Voltage between each of 4, 5, 17, 18 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-34 OK Check trouble symptom. NG
NG
Check the harness wire between control relay and ISC servo connector, and repair if necessary.
NG
NG
Repair
Repair
Check harness wire between engine-ECU and ISC servo connector, and repair if necessary. NG Replace the engine-ECU.

INSPECTION PROCEDURE 35 Purge control solenoid valve system
The purge control solenoid valve controls the purging of air from the canister located inside the intake manifold.
13A-51
Probable cause
D D D NG Malfunction of solenoid valve Improper connector contact, short-circuited harness wire. Malfunction of the engine-ECU open circuit or
Check the purge control solenoid valve. (Refer to GROUP 17 - Emission Control System.) OK Measure at the purge control solenoid valve connector B-04. D Disconnect the connector and measure at the harness side. D Voltage between 2 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-34. D Disconnect the connector and measure at the harness side. D Voltage between 9 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-34 OK Check trouble symptom. NG Replace the engine-ECU. NG
Replace
NG
Check the harness wire between control relay and solenoid valve connector, and repair if necessary.
NG
NG
Repair
Repair
Check the harness wire between engine-ECU and solenoid valve connector, and repair if necessary.
INSPECTION PROCEDURE 36 EGR control solenoid valve system

The EGR control solenoid valve is controlled by the negative pressure resulting from EGR operation leaking to port A of the throttle body.
Probable cause
Check the EGR control solenoid valve. (Refer to GROUP 17 - Emission Control System.) OK Measure at the EGR control solenoid valve connector B-06. D Disconnect the connector and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-34. D Disconnect the connector and measure at the harness side. D Voltage between 6 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-34 OK Check trouble symptom. NG Replace the engine-ECU. NG Repair
Replace
NG
NG
Check the connector: B-06
following
NG
Repair
OK Check trouble symptom. NG Check the harness wire between engine-ECU and solenoid valve connector, and repair if necessary.
13A-52
MUT-II: Inspection of no initial combustion

MUT-II Data list 16 Power supply voltage (Refer to P.13A-62.) OK Does the camshaft rotate at the engine cranking? (When oil filler cap is removed.) Yes MUT-II Self-Diag code Are diagnosis codes displayed? No MUT-II Data list 22 Crank angle sensor OK: Cranking speed is displayed. OK MUT-II Actuator test 07 Fuel pump (Refer to P.13A-65.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-62.) NG Check the power supply and ignition switch-IG system. (Refer to P.13A-45, INSPECTION PROCEDURE 26.) Check timing belt for breakage.
No
Yes
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODES. Check the crank angle sensor system. (Refer to P.13A-17, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 22.)
No
NG
Check the fuel pump system. (Refer to P.13A-46, INSPECTION PROCEDURE 27.) Check the engine coolant temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)
NG
INSPECTION PROCEDURE 38 Ignition system: Inspection of no initial combustion.

Check ignition circuit system. (Refer to P.13A-50, INSPECTION PROCEDURE 33.) OK NG
Check the ignition timing when cranking. OK: Approx. 5_BTDC

INSPECTION PROCEDURE 39 MUT-II: Check if uncomplete combustion occurs.
MUT-II Self-Diag code Are diagnosis codes displayed? No MUT-II Actuator test 07 Fuel pump (Refer to P.13A-65.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-62.) OK MUT-II Data list 18 Ignition switch-ST (Refer to P.13A-62.) NG Yes
13A-53
Refer to P.13A-12, INSPECTION CHART FOR DIAGNOSIS CODE
NG
Check the fuel pump system. (Refer to P.13A-46, INSPECTION PROCEDURE 27.) Check the engine coolant temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURES FOR DIAGNOSIS CODE 21.) Check (Refer Check (Refer the ignition switch-ST system <M/T>. to P.13A-47, INSPECTION PROCEDURE 29.) the ignition switch-ST and inhibitor switch system <A/T>. to P.13A-48, INSPECTION PROCEDURE 30.)
NG
INSPECTION PROCEDURE 40 Check if hunting occurs.

Clean the throttle body. (Refer to P.13A-81.)
Check trouble symptom. NG Inspect the intake of air into the air intake system D Broken intake manifold gasket D Broken air intake hose D Broken vacuum hose D Positive crankcase ventilation valve does not operate.
13A-54
MUT-II: Check if idling speed is unstable.

MUT-II Data list 26 Idle position switch (Refer to P.13A-63.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-62.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-63.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-62.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13A-65.) OK MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-65.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-65.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor OK: 600 - 1,000 mV during sudden racing OK MUT-II Data list 11 Oxygen sensor OK: Changes between 0 - 400 mV and 600 - 1,000 mV during idling OK MUT-II Data list 27 Power steering fluid pressure switch (Refer to P.13A-63.) OK NG Check the fuel pressure. (Refer to P.13A-85.) OK 1. Inspect the intake of air into the air intake system. D Broken intake manifold gasket D Broken vacuum hose D PCV valve does not operate. D Broken air intake hose 2. Check the injector for clog. NG NG Check the engine coolant temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the purge control solenoid valve system (Refer to P.13A-51, INSPECTION PROCEDURE 35.) NG Check the barometric pressure sensor system. (Refer to P.13A-20, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.) NG Check the intake air temperature sensor system. (Refer to P.13A-14, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.) NG Check the idle position switch system. (Refer to P.13A-46, INSPECTION PROCEDURE 28.)
NG
Check the EGR control solenoid valve system. (Refer to P.13A-51, INSPECTION PROCEDURE 36.) Check the oxygen sensor (rear) system. (Refer to P.13A-24, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)
NG
NG
Check the oxygen sensor (front) system. (Refer to P.13A-13, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 11.)
NG
Check the power steering fluid pressure switch system. (Refer to P.13A-49, INSPECTION PROCEDURE 31.)
MUT-II Data list 28 A/C switch (Refer to P.13A-63.) OK MUT-II Data list 29 Inhibitor switch (Refer to P.13A-63.) OK MUT-II Data list 45 ISC Servo position (Refer to P.13A-64.)
NG
Check the A/C switch and A/C relay system. (Refer to P.13A-49. INSPECTION PROCEDURE 32.) Check the ignition switch-ST and inhibitor switch system. <A/T> (Refer to P.13A-48, INSPECTION PROCEDURE 30.) Adjust the basic idle speed. (Refer to P.13A-83.)
NG
NG

INSPECTION PROCEDURE 42 MUT-II: Engine stalling inspection when the engine is warmed up and idling.
MUT-II Data list 26 Idle position switch (Refer to P.13A-63.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-62.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-63.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-62.) OK MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-65.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-65.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor OK: Changes between 600 - 1,000 mV during sudden racing OK MUT-II Data list 11 Oxygen sensor OK: Changes between 0 - 400 mV and 600 - 1,000 mV during idling OK MUT-II Data list 27 Power steering fluid pressure switch (Refer to P.13A-63.) OK NG Check the fuel pressure. (Refer to P.13A-85.) OK NG NG NG NG NG
13A-55
Check the intake air sensor system. (Refer to P.13A-14, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
Check the barometric pressure sensor system. (Refer to P.13A-20, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)
Check the engine coolant temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the EGR control solenoid valve system. (Refer to P.13A-51, INSPECTION PROCEDURE 36.) Check the oxygen sensor (rear) system. (Refer to P.13A-24, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)
NG
NG
NG
1. Inspect the intake of air into the air intake system D Broken intake manifold gasket D Broken vacuum hose D PCV valve does not operate. D Broken air intake hose 2. Check the injector for clog.
MUT-II Data list 28 A/C switch (Refer to P.13A-63.) OK MUT-II Data list 29 Inhibitor switch (Refer to P.13A-63.) OK MUT-II Data list 45 ISC servo position (Refer to P.13A-64.)
NG
Check the A/C switch and A/C relay system. (Refer to P.13A-49, INSPECTION PROCEDURE 32.) Check the ignition switch-ST and inhibitor switch system. <A/T> (Refer to P.13A-48, INSPECTION PROCEDURE 30.) Adjust the basic idle speed. (Refer to P.13A-83.)
NG
NG
13A-56
MUT-II: Check if hesitation, sug, stumble or poor acceleration occurs.

MUT-II Data list 26 Idle position switch (Refer to P.13A-63.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-62.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-63.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-62.) OK MUT-II Data list 14 Throttle position sensor (Refer to P.13A-62.) OK MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-65.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-65.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor OK: Changes between 600 - 1,000 mV during sudden racing OK MUT-II Data list 11 Oxygen sensor OK: Changes between 0 - 400 mV and 600 - 1,000 mV during idling NG Check the fuel pressure. (Refer to P.13A-85.) OK 1. Inspect the intake of air into the air intake system D Broken intake manifold gasket D Broken vacuum hose D PCV valve does not operate. D Broken air intake hose 2. Check the injector for clog. NG Check the EGR control solenoid valve system. (Refer to P.13A-51, INSPECTION PROCEDURE 36.) NG NG Check the engine coolant temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSTIC CODE 21.) Check the throttle position sensor system. (Refer to P.13A-15, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.) NG Check the barometric pressure sensor system. (Refer to P.13A-20, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.) NG Check the intake air sensor system. (Refer to P.13A-14, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.) NG Check the idle position switch system. (Refer to P.13A-46, INSPECTION PROCEDURE 28.)
NG
Check the oxygen sensor (rear) system. (Refer to P.13A-24, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)
NG

INSPECTION PROCEDURE 44 MUT-II: Check if surge occurs.
MUT-II Data list 26 Idle position switch (Refer to P.13A-63.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-62.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-63.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-62.) OK MUT-II Data list 14 Throttle position sensor (Refer to P.13A-62.) OK MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-65.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-65.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor OK: Changes between 600 - 1,000 mV during sudden racing OK MUT-II Data list 11 Oxygen sensor OK: Changes between 0 - 400 mV and 600 - 1,000 mV during idling NG Check the fuel pressure. (Refer to P.13A-85.) OK NG NG NG NG NG NG
13A-57
Check the intake air sensor system. (Refer to P.13A-14, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
Check the engine coolant temperature sensor system. (Refer to P.13A-16, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the throttle position sensor system. (Refer to P.13A-15, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
NG
NG
13A-58
Check the engine-ECU power supply and earth circuit.

Measure the engine-ECU connectors, C-34, C-36, C-40. D Disconnect the connector and measure at the harness side 1. Voltage between 82 and earth (Ignition switch: ON) OK: System voltage 2. Voltage between 38 and earth OK: System voltage 3. Voltage between 12, 25 and earth (Ignition switch: ON) OK: System voltage (when the terminal 38 is earthed) 4. Continuity between 13, 26 and earth OK: Continuity 5. Voltage between 80 and earth OK: System voltage OK Check the following connectors: C-34, C-36, C-40 OK Check trouble symptom. NG Replace the engine-ECU. Check the following connectors: C-47, C-83, C-66, (C-63, C-132, C-141) <L.H.>, (C-62, C-14) <R.H.> OK Check trouble symptom NG Check the harness wire between engine-ECU and battery, and repair if necessary. NG Repair Check the harness wire between engine-ECU and control relay connector, and repair if necessary. Check the harness wire between engine-ECU and earth, and repair if necessary. NG 1. NG Check the following connectors: C-92, C-131 OK Check trouble symptom. OK Check the harness wire between engine-ECU and ignition switch connector. OK Check the ignition switch. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) NG NG Repair
2, 3. NG 4. NG 5. NG
Repair
Repair
INSPECTION PROCEDURE 46 Check fuel pump circuit.

NG NG
Measure at the fuel pump connector E-16. D Disconnect the connector and measure at the harness side. D Continuity between 2 and earth OK: Continuity OK Check the following connectors: E-16, E-11, C-123, C-92, B-09 OK Check trouble symptom. NG Check the harness wire between terminal for fuel pump drive and fuel pump connector. OK Replace the fuel pump.
Check the following connector: E-11 OK Check trouble symptom NG
Repair
NG
Check the harness wire between fuel pump and earth, and repair if necessary. Repair
NG
Repair

INSPECTION PROCEDURE 47 Check the fuel pump drive control circuit.
Measure at the fuel pump relay connector C-32. D Disconnect the connector and measure at the harness side. D Voltage between 3, 4 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-34. D Disconnect the connector and measure at the harness side. D Voltage between 22 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-34 OK NG Repair Check trouble symptom. NG Replace the engine-ECU. NG NG Check the following connectors: C-92, C-131 OK Check trouble symptom. NG Check the harness wire between fuel pump relay and ignition switch connector. OK NG NG Repair
13A-59
Repair
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) Check the harness wire between engine-ECU and fuel pump relay connector, and repair if necessary.
INSPECTION PROCEDURE 48 Check air flow sensor (AFS) control circuit.

1. NG Measure at the air flow sensor connector B-12. D Disconnect the connector and measure at the harness side. 1. Voltage between 4 and earth (Ignition switch: ON) OK: System voltage 2, 3. NG 2. Voltage between 3 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V 3. Continuity between 5 and earth OK: Continuity OK Check the following connector: B-12 OK NG Repair Check trouble symptom. NG Replace the air flow sensor. Check the harness wire between the air flow sensor and control relay connector, and repair if necessary. NG
Check the following connector: C-40 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and air flow sensor connector. OK Replace the engine-ECU.
Repair
NG
Repair
13A-60
Check throttle position sensor (TPS) output circuit.

Measure at the engine-ECU connector C-40. D Connect the connector. D Voltage between 84 and earth (Ignition switch: ON) OK: 0.3 - 1.0 V (Throttle valve at idle position) 4.5 - 5.5 V (Throttle valve fully open) NG Check the harness wire between engine-ECU and throttle position sensor connector, and repair if necessary. OK Check the following connector: C-40 OK Check trouble symptom. NG Replace the engine-ECU. NG Repair
INSPECTION PROCEDURE 50 Check injector control circuit

Measure at the engine-ECU connector C-34. D Disconnect the connector and measure at the harness side. D Voltage between 1, 2, 14, 15 and earth (Ignition switch: ON) OK: System voltage OK NG Check the following connectors: B-02, B-03, B-05, B-36 OK Check trouble symptom. NG Check the harness between engine-ECU and injector connector, and repair if necessary. Check the following connector: C-34 OK Check trouble symptom. NG Replace the engine-ECU. NG Repair NG Repair
MPI <4G6> - Troubleshooting DATA LIST REFERENCE TABLE
13A-61
13100890289
Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE *1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes 10% higher than the standard frequency. *2. The idle position switch normally turns off when the voltage of the throttle position sensor is 50 100 mV higher than the voltage at the idle position. If the throttle position switch turns back on after the throttle position sensor voltage has risen by 100 mV and the throttle valve has opened, the idle position switch and the throttle position sensor need to be adjusted. *3. The injector drive time represents the time when the cranking speed is at 250 r/min or below when the power supply voltage is 11 V. *4. In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer than the standard time. *5. In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes 30 steps greater than the standard value.
Item No. 11 Inspection item Oxygen sensor (front) Inspection contents Normal condition Inspection procedure No. Code No. 11 Reference page 13A-13
Engine:After having warmed up Air/fuel mixture is made leaner when decelerating, and is made richer when racing. Engine:After having warmed up The oxygen sensor signal is used to check the air/fuel mixture ratio, and control condition is also checked by the ECU.
When at 4,000 r/min, engine is suddenly decelerated When engine is suddenly raced Engine is idling
200 mV or less
600 - 1,000 mV 400 mV or less (Changes)
2,500 r/min
600 - 1,000 mV
12
Air flow sensor*1
D D D
Engine coolant Engine is idling temperature: 80 95_C 2,500 r/min Lamps, electric cooling fan and all accessories: OFF Engine is raced Transmission: Neutral (A/T: P range) When intake air temperature is - 20_C When intake air temperature is 0_C When intake air temperature is 20_C When intake air temperature is 40_C When intake air temperature is 80_C
17 - 43 Hz 70 - 110 Hz Frequency increases in response to racing - 20_C 0_C 20_C 40_C 80_C
13
Intake air temperature sensor
Ignition switch: ON or with engine running
Code No. 13
13A-14
13A-62
Item No. 14 Inspection item Throttle position sensor Inspection contents Normal condition Inspection procedure No. Code No. 14 Reference page 13A-15
Ignition switch: ON
Set to idle position Gradually open
300 - 1,000 mV Increases in proportion to throttle opening angle 4,500 - 5,500 mV System voltage
Open fully 16 Power supply voltage Cranking signal (ignition switch-ST) Ignition switch: ON
Procedure No. 26 Procedure No. 29 <M/T> Procedure No. 30 <A/T> Code No. 21
13A-45
18
Ignition switch: ON
Engine: Stopped
OFF
Engine: Cranking
ON
13A-47 <M/T> 13A-48 <M/T>
21
Engine coolant temperature sensor
When engine coolant temperature is - 20_C When engine coolant temperature is 0_C When engine coolant temperature is 20_C When engine coolant temperature is 40_C When engine coolant temperature is 80_C
- 20_C
13A-16
0_C
20_C
40_C
80_C

Item No. 22 Inspection item Crank angle sensor Inspection contents Normal condition Inspection procedure No. Code No. 22
13A-63
Reference page 13A-17
D D
Engine: Cranking Tachometer: Connected Engine: Idling Idle position switch: ON
Compare the engine speed readings on the tachometer and the MUT-II. When engine coolant temperature is - 20_C When engine coolant temperature is 0_C When engine coolant temperature is 20_C When engine coolant temperature is 40_C When engine coolant temperature is 80_C
Accord
D D
1,275 - 1,475 rpm
1,225 - 1,425 rpm
1,100 - 1,300 rpm
950 - 1,150 rpm
650 - 850 rpm
25
Barometric pressure sensor
Ignition switch: ON
At altitude of 0 m At altitude of 600 m At altitude of 1,200 m At altitude of 1,800 m
101 kPa 95 kPa 88 kPa 81 kPa ON OFF*2 OFF ON OFF ON P or N D, 2, L or R
Code No. 25
13A-20
26
Idle position switch
Ignition switch: ON Check by operating accelerator pedal repeatedly
Throttle valve: Set to idle position Throttle valve: Slightly open Steering wheel stationary Steering wheel turning A/C switch: OFF A/C switch: ON P or N D, 2, L or R
Procedure No. 28
13A-46
27
Power Engine: Idling steering fluid pressure switch A/C switch Engine: Idling (when A/C switch is ON, A/C compressor should be operating.) Ignition switch: ON
Procedure No. 31
13A-49
28
Procedure No. 32
13A-49
29
Inhibitor switch <A/T>
Procedure No. 30
13A-48
13A-64
Item No. 41 Inspection item Injectors *3

Inspection contents Normal condition Inspection procedure No. Reference page -
Engine: Cranking
When engine coolant temperature is 0_C (injection is carried out for all cylinders simultaneously) When engine coolant temperature is 20_C When engine coolant temperature is 80_C
12 - 19 ms
26 - 40 ms
6.0 - 9.1 ms
Injectors*4
D D D
Engine coolant temperature: 8095_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T : P range)
Engine is idling 2,500 r/min When engine is suddenly raced
1.6 - 2.8 ms 1.4 - 2.6 ms Increases
44
Ignition coils and power transistors
D D
Engine: After Engine is idling having warmed up Timing lamp is set. (The timing lamp is set in order to 2,500 r/min check actual ignition timing.) Engine coolant temperature: 80 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T : P range) Idle position switch: ON Engine: Idling When A/C switch is ON, A/C compressor should be operating A/C switch: OFF
2 - 18_BTDC
18 - 38_BTDC
45
ISC (stepper) motor position *5
D D D D D D
2 - 25 STEP
A/C switch: OFF ON
Increases by 10 - 70 steps
D D
A/C switch: OFF Select lever: N range D range
49
A/C relay
Engine: After having warmed up/Engine is idling
A/C switch: OFF
OFF (Compressor clutch is not operating) ON (Compressor clutch is operating)
Procedure No. 32
13A-49
A/C switch: ON

Item No. 59 Inspection item Oxygen sensor (rear) Inspection contents Normal condition Inspection procedure No. Code No. 59
13A-65
D D
Transmission: 2nd gear <M/T>, L range <A/T> Drive with throttle widely open
3,500 r/min
600 - 1,000 mV
ACTUATOR TEST REFERENCE TABLE

Item No. 01 02 03 04 07 Fuel pump Inspection item Injectors Drive contents Inspection contents Normal condition Inspection procedure No. Code No. 41
13100900357
Cut fuel to No. 1 injector Cut fuel to No. 2 injector Cut fuel to No. 3 injector Cut fuel to No. 4 injector Fuel pump operates and fuel is recirculated.
Engine: After having warmed up/Engine is idling (Cut the fuel supply to each injector in turn and check cylinders which dont affect idling.)
Idling condition becomes different (becomes unstable).
D D
Engine: Cranking Fuel pump: Forced driving Inspect according to both the above conditions.
Pinch the return hose with fingers to feel the pulse of the fuel being recirculated. Listen near the fuel tank for the sound of fuel pump operation.
Pulse is felt.
Procedure No. 27
13A-46
Sound of operation is heard.
08
Purge control solenoid valve EGR control solenoid valve Basic ignition timing Fan controller
Solenoid valve turns from OFF to ON. Solenoid valve turns from OFF to ON. Set to ignition timing adjustment mode Drive the fan motor
Ignition switch: ON
Sound of operation can be heard when solenoid valve is driven. Sound of operation can be heard when solenoid valve is driven. 5_BTDC
Procedure No. 35
13A-51
10
Ignition switch: ON
Procedure No. 36
13A-51
17
Engine: Idling Timing light is set Ignition switch: ON
21
Radiator fan and condenser fan operate at high speed
Procedure No. 25
13A-45
13A-66
Needle-nosed wire probe
MPI <4G6> - Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS

13100920285
TERMINAL VOLTAGE CHECK CHART 1. Connect a needle-nosed wire probe (test harness: MB991223 or paper clip) to a voltmeter probe. 2. Insert the needle-nosed wire probe into each of the engine-ECU connector terminals from the wire side, and measure the voltage while referring to the check chart. NOTE (1) Make the voltage measurement with the engine-ECU connectors connected. (2) You may find it convenient to pull out the engine-ECU to make it easier to reach the connector terminals. (3) The checks can be carried out off the order given in the chart. Caution Short-circuiting the positive (+) probe between a connector terminal and earth could damage the vehicle wiring, the sensor, engine-ECU or all of them. Be careful to prevent this! 3. If voltmeter shows any division from 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 repair has corrected the problem.

Engine-ECU Connector Terminal Arrangement
13A-67
Terminal No. Check item 1 14 2 15 4 17 5 18 6 No. 1 injector No. 2 injector No. 3 injector No. 4 injector Stepper motor coil <A1> Stepper motor coil <A2> Stepper motor coil <B1> Stepper motor coil <B2> EGR control solenoid valve
Check condition (Engine condition) While engine is idling after having warmed up, suddenly depress the accelerator pedal.
Normal condition From 11 - 14 V, momentarily drops slightly
Engine: Soon after the warmed up engine is started
System voltage 0 V (Changes repeatedly)
Ignition switch: ON While engine is idling, suddenly depress the accelerator pedal. D D Engine: Idle speed A/C switch: OFF ON (A/C compressor is operating)
System Voltage From system voltage, momentarily drops System voltage or momentarily 6V or more 0 - 3V System voltage 0 - 3V 0.3 - 3.0V
A/C relay
Purge control solenoid valve
Ignition switch: ON Running at 3,000r/min while engine is warming up after having been started. Engine r/min: 3,000 r/min
10 23 12 25 19
Ignition coil - No. 1, No. 4 (power transistor) Ignition coil - No. 2, No. 3 (power transistor) Power supply
Ignition switch: ON
System voltage
Air flow sensor reset signal Fan controller
Engine: Idle speed Engine r/min: 3,000 r/min Radiator fan and condenser fan are not operating Radiator fan and condenser fan are operating
0 - 1V 6 - 9V 0 - 0.3 V 0.7 V or more
21
13A-68
Terminal No. Check item 22 Fuel pump relay

Check condition (Engine condition) Ignition switch: ON Engine: Idle speed Normal condition System voltage 0 - 3V When A/C is MAX. COOL condition (when the load by A/C is high) (When A/C is MAX. HOT condition (when the load by A/C is low) 0 - 3V
24
A/C switch 2
D D
Engine: Idling Outside air temperature: 25_C or more
System voltage
33
Alternator G terminal
D D D D
Engine: Warm, idle (radiator fan: OFF) Headlamp: OFF to ON Rear defogger switch: OFF to ON Brake lamp: ON Engine: Warm, idle (radiator fan: OFF) Headlamp: OFF to ON Rear defogger switch: OFF to ON Brake lamp: ON
Voltage rises by 0.2 - 3.5 V.
41
Alternator FR terminal
D D D D
Voltage drops by 0.2 - 3.5 V.
36
Engine warning lamp
Ignition switch: OFF ON
0 - 3V 9 - 13V (After several seconds have elapsed) System voltage 0 - 3V System voltage 0 - 3V
37
Power steering fluid pressure switch
Engine: Idling after warming up
When steering wheel is stationary When steering wheel is turned
38
Control relay (Power supply) A/C switch 1
Ignition switch: OFF Ignition switch: ON Engine: Idle speed Turn the A/C switch OFF Turn the A/C switch ON (A/C compressor is operating)
45
0 - 3V System voltage
58 60
Tachometer signal Oxygen sensor heater
Engine r/min: 3,000 r/min Engine: Idling after warming up Engine r/min: 5,000r/min.
0.3 - 3.0V 0 - 3V System voltage 8V or more
71
Ignition switch - ST
Engine: Cranking

Terminal No. Check item 72 Intake air temperature sensor Check condition (Engine condition) Ignition switch: ON When intake air temperature is 0_C When intake air temperature is 20_C When intake air temperature is 40_C When intake air temperature is 80_C 75 Oxygen sensor (rear) D D D 76 Oxygen sensor (front) Transmission: 2nd gear <M/T>, L range <A/T> Engine r/min: 3,500 r/min or more Driving with the throttle valve widely open Normal condition 3.2 - 3.8V
13A-69
2.3 - 2.9V
1.5 - 2.1V
0.4 - 1.0V
0.6 - 1.0 V
Engine: Running at 2,500 r/min after warmed up (Check using a digital type voltmeter) Ignition switch: OFF Ignition switch: ON Ignition switch: ON Ignition switch: ON When engine coolant temperature is 0_C When engine coolant temperature is 20_C When engine coolant temperature is 40_C When engine coolant temperature is 80_C
0 0.8V (Changes repeatedly) System voltage 4.5 - 5.5V System voltage 3.2 - 3.8V
80 81 82 83
Backup power supply Sensor impressed voltage Ignition switch - IG Engine coolant temperature sensor
2.3 - 2.9V
1.3 - 1.9V
0.3 - 0.9V
84
Throttle position sensor
Ignition switch: ON
Set throttle valve to idle position Fully open throttle valve
0.3 - 1.0V 4.5 - 5.5V 3.7 - 4.3V 3.2 - 3.8V 0 5V (Changes repeatedly)
85
Ignition switch: ON
When altitude is 0m When altitude is 1,200m
86
Vehicle speed sensor
D D
Ignition switch: ON Move the vehicle slowly forward
13A-70
Terminal No. Check item 87 Idle position switch

Check condition (Engine condition) Ignition switch: ON Set throttle valve to idle position Slightly open throttle valve Normal condition 0 - 1V 4V or more 0.4 - 3.0V 0.5 - 2.0V 0.4 - 4.0V 1.5 - 2.5V 2.2 - 3.2V
88
Camshaft position sensor Crank angle sensor
Engine: Cranking Engine: Idle speed Engine: Cranking Engine: Idle speed
89
90
Air flow sensor
Engine: Idle speed Engine r/min: 2,500r/min
91
Ignition switch: ON
Set selector lever to P or N Set selector lever to Other than P or N
0 - 3V 8 - 14V
CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to OFF. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart. NOTE (1) When measuring resistance and checking continuity, a harness for checking contact pin pressure should be used instead of inserting a test probe. (2) Checking need not be carried out in the order given in the chart. Caution If the terminals that should be checked are mistaken, or if connector terminals are not correctly shorted to earth, damage may be caused to the vehicle wiring, sensors, engine-ECU and/or ohmmeter. Be careful to prevent this! 4. If the ohmmeter shows any deviation from the standard value, check the corresponding sensor, actuator and related electrical wiring, and then repair or replace. 5. After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement has corrected the problem.

Engine-ECU Harness Side Connector Terminal Arrangement
13A-71
Terminal No. 1 - 12 14 - 12 2 - 12 15 - 12 4 - 12 17 - 12 5 - 12 18 - 12 6 - 12 9 - 12 13 - Body earth 26 - Body earth 60 - 12 72 - 92
Inspection item No. 1 injector No. 2 injector No. 3 injector No. 4 injector Stepper motor coil (A1) Stepper motor coil (A2) Stepper motor coil (B1) Stepper motor coil (B2) EGR control solenoid valve Purge control solenoid valve Engine-ECU earth Engine-ECU earth Oxygen sensor heater Intake air temperature sensor
Normal condition (Check condition) 13 - 16 W (At 20_C)
28 - 33 W (At 20_C)
36 - 44 W (At 20_C) 36 - 44 W (At 20_C) Continuity (0W)
11 - 18 W (At 20_C) 5.3 - 6.7 kW (When intake air temperature is 0_C) 2.3 - 3.0 kW (When intake air temperature is 20_C) 1.0 - 1.5 kW (When intake air temperature is 40_C) 0.30 - 0.42 kW (When intake air temperature is 80_C)
83 - 92
5.1 - 6.5 kW (When coolant temperature is 0_C) 2.1 - 2.7 kW (When coolant temperature is 20_C) 0.9 - 1.3 kW (When coolant temperature is 40_C) 0.26 - 0.36 kW (When coolant temperature is 80_C)
87 - 92
Continuity (when throttle valve is at idle position) No continuity (when throttle valve is slightly open)
91 - Body earth
Continuity (when select lever is at P or N) No continuity (when select lever is at D, 2, L or R)
13A-72

Analyzer
INSPECTION PROCEDURE USING AN ANALYZER

13100930219
Special patterns pickup
AIR FLOW SENSOR (AFS) Measurement Method 1. Disconnect the air flow sensor connector, and connect the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to air flow sensor connector terminal 3. Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 90. Standard Wave Pattern Observation conditions
Function Pattern height Pattern selector Engine r/min Special patterns Low Display Idle speed
Standard wave pattern

(V) 10 T1 T T2 The time (cycle time) T is reduced when the amount of intake air increases. Times T1 and T2 are equal.
Time
Observation conditions (from conditions above engine speed is increased by racing.)

(V) 10 T
Time
Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased.

Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics
13A-73
Rectangular wave pattern is output even when the engine is not started. D Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency. However, when an ignition leak occurs during acceleration, the wave pattern will be distorted temporarily, even if the air flow sensor is normal.
Camshaft connector
position
sensor
Analyzer
Special patterns pick-up
CAMSHAFT POSITION SENSOR AND CRANK ANGLE SENSOR Measurement Method 1. Disconnect the camshaft position sensor connector and connect the special tool (test harness: MB991223) and jumper wire in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to camshaft position sensor terminal 2. 3. Disconnect the crank angle sensor connector and connect the special tool (test harness: MD998478) in between. 4. Connect the analyzer special patterns pickup to crank angle sensor terminal 2. Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 88. (When checking the camshaft position sensor signal wave pattern.) 2. Connect the analyzer special patterns pickup to engine-ECU terminal 89. (When checking the crank angle sensor signal wave pattern.)
Standard Wave Pattern Observation conditions

13A-74
(V) 75_BTDC
2 engine revolutions (1 camshaft revolution) 5_BTDC
The time (cycle time) T is reduced when the engine speed increases
Crank angle sensor output wave pattern
0 131 Camshaft position sensor output wave pattern 49 56 34
0 No. 1 TDC TDC: Top dead centre No. 3 TDC No. 4 TDC No. 2 TDC
Time
Wave Pattern Observation Points Check that cycle time T becomes shorter when the engine speed increases.
Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started.
Example 2 Cause of problem Loose timing belt Abnormality in sensor disk Wave pattern characteristics Wave pattern is displaced to the left or right.

Analyzer
13A-75
INJECTOR Measurement Method 1. Disconnect the injector connector, and then connect the special tool (test harness: MB991348) in between. (Both the power supply side and engine-ECU side should be connected.) 2. Connect the analyzer special patterns pickup to terminal 2 of the injector connector.
Alternate Method (Test harness not available) 1. Connect the analyzer engine-ECU terminal 1. cylinder.) 2. Connect the analyzer engine-ECU terminal 14. cylinder.) 3. Connect the analyzer engine-ECU terminal 2. cylinder.) 4. Connect the analyzer engine-ECU terminal 15. cylinder.) special patterns pickup to (When checking the No. 1 special patterns pickup to (When checking the No. 2 special patterns pickup to (When checking the No. 3 special patterns pickup to (When checking the No. 4
13A-76
Function Pattern height Variable knob Pattern selector Engine r/min
Special patterns Variable Adjust while viewing the wave pattern Display Idle speed

(V) Point A
50 Solenoid back electromotive force (Approx. 710 V) Point B Injector drive time Power voltage 0 Drive signal: ON Drive signal: OFF Time
Wave Pattern Observation Points Point A: Height of solenoid back electromotive force
Contrast with standard wave pattern Solenoid coil back electromotive force is low or doesnt appear at all. Probable cause Short in the injector solenoid
Point B: Injector drive time
D D
The injector drive time will be synchronized with the MUT-II tester display. When the engine is suddenly raced, the drive time will be greatly extended at first, but the drive time will soon match the engine speed.
--- When idling - - When racing

Analyzer
13A-77
STEPPER MOTOR Measurement Method 1. Disconnect the stepper motor connector, and connect the special tool (test harness: MD998463) in between. 2. Connect the analyzer special patterns pickup to the stepper motor-side connector terminal 1 (red clip of special tool), terminal 3 (blue clip), terminal 4 (black clip) and terminal 6 (yellow clip) respectively.
Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 4, connection terminal 5, connection terminal 17, and connection terminal 18 respectively. Standard Wave Pattern Observation conditions
Function Pattern height Pattern selector Engine condition Special patterns High Display When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF to ON (without starting the engine). While the engine is idling, turn the A/C switch to ON. Immediately after starting the warm engine
(V) 30 20 10
The wave pattern appears for an instant, but soon disappears.
Point B Coil reverse electromotive force (Approx. 3 10V)
Point A Induced electromotive force from the motor turning
Stepper motor control signal wave pattern
Time
13A-78
Wave Pattern Observation Points Check that the standard wave pattern appears when the stepper motor is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.)
Contrast with standard wave pattern Induced electromotive force does not appear or is extremely small. Probable cause Motor is malfunctioning
Point B: Height of coil reverse electromotive force

Contrast with standard wave pattern Coil reverse electromotive force does not appear or is extremely small. Probable cause Short in the coil
Examples of Abnormal Wave Pattern D Example 1 Cause of problem Motor is malfunctioning. (Motor is not operating.) Wave pattern characteristics Induced electromotive force from the motor turning does not appear.
Open circuit side
Example 2 Cause of problem Open circuit in the line between the stepper motor and the engine-ECU. Wave pattern characteristics Current is not supplied to the motor coil on the open circuit side. (Voltage does not drop to 0 V.) Furthermore, the induced electromotive force waveform at the normal side is slightly different from the normal waveform.
Normal side

Analyzer
13A-79
IGNITION COIL AND POWER TRANSISTOR Power transistor control signal Measurement Method 1. Disconnect the ignition coil connector, and connect the special tool (test harness: MB991348) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to terminal 3 of each ignition coil connector in turn. Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 10 (No. 1 - No. 4), terminal 23 (No. 2 - No. 3) respectively.
Standard Wave Pattern Observation condition

Function Pattern height Pattern selector Engine r/min Special patterns Low Display Approx. 1,200 r/min

(V) 6 4 Crank angle sensor output wave pattern 2 0 4 Power transistor control signal 2 wave pattern 0 T1 q Ignition period q: Spark advance angle OFF ON Time 75_BTDC T T: Revolution time corresponding to a crank angle of 180_ 5_BTDC Compression top dead center
Dwell section T1: Time computed by the engine-ECU
13A-80
Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.)
Condition of wave pattern build-up section and maximum voltage Rises from approx. 2V to approx. 4.5V at the top-right 2V rectangular wave Rectangular wave at power voltage Probable cause Normal Open-circuit in ignition primary circuit Power transistor malfunction
--- Normal wave pattern
Examples of Abnormal Wave Patterns D Example 1 Wave pattern during engine cranking Cause of problem
2V
Open-circuit in ignition primary circuit Wave pattern characteristics Top-right part of the build-up section cannot be seen, and voltage value is approximately 2V too low.
--- Normal wave pattern VB
Example 2 Wave pattern during engine cranking Cause of problem Malfunction in power transistor Wave pattern characteristics Power voltage results when the power transistor is ON.
MPI <4G6> - On-vehicle Service
13A-81
13100100306
ON-VEHICLE SERVICE
THROTTLE BODY (THROTTLE VALVE AREA) CLEANING

1. Start the engine and warm it up until the coolant is heated to 80_C or higher and then stop the engine. 2. Remove the air intake hose from the throttle body.
3. Plug the bypass passage inlet of the throttle body. Caution Do not allow cleaning solvent to enter the bypass passage. 4. Spray cleaning solvent into the valve through the throttle body intake port and leave it for about 5 minutes.
5. Start the engine, race it several times and idle it for about 1 minute. If the idling speed becomes unstable (or if the engine stalls) due to the bypass passage being plugged, slightly open the throttle valve to keep the engine running. 6. If the throttle valve deposits are not removed, repeat steps 4 and 5. 7. Unplug the bypass passage inlet. 8. Attach the air intake hose. 9. Use the MUT-II to erase the self-diagnosis code. 10. Adjust the basic idle speed. (Refer to P.13A-83.) NOTE If the engine hunts while idling after adjustment of the basic idle speed, disconnect the () cable from the battery for 10 seconds or more, and then reconnect it and run the engine at idle for about 10 minutes.
Throttle position sensor (with built-in idle position switch)
IDLE POSITION SWITCH AND THROTTLE 13100130268 POSITION SENSOR ADJUSTMENT

1. Connect the MUT-II to the diagnosis connector.
13A-82
Throttle lever

2. Insert a thickness gauge as follows: <Vehicles without auto-cruise control system> Insert a thickness gauge with a thickness of 0.45 mm between the fixed SAS and the throttle lever.
<Vehicles without auto-cruise control system>
Fixed SAS
Thickness gauge
Fixed SAS
<Vehicles with auto-cruise control system> Throttle lever
<Vehicles with auto-cruise control system> Insert a 1.4-mm thick thickness gauge up to approx. 3 mm between the levers shown in the figure. NOTE Do not insert the thickness gauge 3 mm or more. If doing that, the throttle lever opening angle becomes larger than the predetermined angle, causing maladjustment.
Free lever
Thickness gauge
3. Turn the ignition switch to ON (but do not start the engine).
4. Loosen the throttle position sensor mounting bolt, and then turn the throttle position sensor anti-clockwise as far as it will go. 5. Check that the idle position switch is ON at this position. 6. Slowly turn the throttle position sensor clockwise and find the point where the idle position switch turns off. Securely tighten the throttle position sensor mounting bolt at this point.
7. Check the throttle position sensor output voltage. Standard value: 400 - 1,000 mV 8. If there is a deviation from the standard value, check the throttle position sensor and the related harness. 9. Remove the thickness gauge. 10. Turn the ignition switch to OFF. 11. Disconnect the MUT-II.
MPI <4G6> - On-vehicle Service FIXED SAS ADJUSTMENT
13A-83
13100150301
NOTE (1) The fixed SAS should not be moved unnecessarily; it has been precisely adjusted by the manufacturer. (2) If the adjustment is disturbed for any reason, readjust as follows.
Fixed SAS
1. Loosen the tension of the accelerator cable sufficiently. 2. Back out the fixed SAS lock nut. 3. Turn the fixed SAS counterclockwise until it is sufficiently backed out, and fully close the throttle valve. 4. Tighten the fixed SAS until the point where the throttle lever is touched (i.e., the point at which the throttle valve begins to open) is found. From that point, tighten the fixed SAS 1-1/4 turn. 5. While holding the fixed SAS so that it doesnt move, tighten the lock nut securely. 6. Adjust the tension of the accelerator cable. 7. Adjust the basic idling speed. 8. Adjust the idle position switch and the throttle position sensor (P.13A-81).
BASIC IDLE SPEED ADJUSTMENT
13100180348
NOTE (1) The standard idling speed has been adjusted by the speed adjusting screw (SAS) by the manufacturer, and there should usually be no need for readjustment. (2) If the adjustment has been changed by mistake, the idle speed may become too high or the idle speed may drop too low when loads from components such as the A/C are placed on the engine. If this occurs, adjust by the following procedure. (3) The adjustment, if made, should be made after first confirming that the spark plugs, the injectors, the idle speed control servo, the compression pressure, etc., are all normal. 1. Before inspection and adjustment, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector (16-pin). NOTE When the MUT-II is connected, the diagnosis control terminal should be earthed. 3. Start the engine and run at idle.
13A-84

4. Select the item No.30 of the MUT-II Actuator test. NOTE This holds the ISC servo at the basic step to adjust the basic idle speed. 5. Check the idle speed. Standard value: 750 50 r/min NOTE (1) The engine speed may be 20 to 100 r/min lower than indicated above for a new vehicle [driven approximately 500 km or less], but no adjustment is necessary. (2) If the engine stalls or the engine speed is low even though the vehicle has been driven approximately 500 km or more, it is probable that deposits are adhered to the throttle valve, so clean it. (Refer to P.13A-81.)
6. If not within the standard value range, turn the speed adjusting screw (SAS) to make the necessary adjustment. NOTE If the idling speed is higher than the standard value range even when the SAS is fully closed, check whether or not there is any indication that the fixed SAS has been moved. If there is an indication that it has been moved, adjust the fixed SAS. 7. Press the MUT-II clear key, and release the ISC servo from the Actuator test mode. NOTE Unless the ISC servo is released, the Actuator test mode will continue 27 minutes. 8. Switch OFF the ignition switch. 9. Disconnect the MUT-II. 10. Start the engine again and let it run at idle speed for about 10 minutes; check that the idling condition is normal.
MPI <4G6> - On-vehicle Service FUEL PRESSURE TEST

Delivery pipe Fuel high pressure hose
13A-85
13100190303
1. Release residual pressure from the fuel pipe line to prevent fuel gush out. (Refer to P.13A-88.) 2. Disconnect the fuel high pressure hose at the delivery pipe 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. 3. Remove the union joint and bolt from the special tool (adapter hose MD998709) and instead attach the special tool (hose adapter MD998742) to the adapter hose. 4. Install a fuel pressure gauge on the adapter hose that was set up in step 3. Use a suitable O-ring or gasket between the fuel pressure gauge and the special tool so as to seal in order to prevent fuel leakage at this time.
High pressure hose
Fuel pressure gauge O-ring or gasket MD998709 MD998742
Delivery pipe
5. Install the special tool, which was set in place in steps 3 and 4 between the delivery pipe and the high pressure hose.
6. Connect the No. 2 terminal of 3 pin connector (fuel pump drive terminal) shown in the figure at left to the battery (+) terminal using a jumper wire and drive the fuel pump. Under fuel pressure, check the fuel pressure gauge and special tool connections for leaks.
Fuel pump drive connector
7. Disconnect the jumper wire from the fuel pump drive terminal to stop the fuel pump. 8. Start the engine and run at idle. 9. Measure fuel pressure while the engine is running at idle. Standard value: Approx. 265 kPa at kerb idle
13A-86

10. Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed by a finger. Standard value: 324 - 343 kPa at kerb idle 11. Check to see that fuel pressure at idle does not drop even after the engine has been raced several times.
12. Racing the engine repeatedly, hold the fuel return hose lightly with fingers to feel that fuel pressure is present in the return hose. NOTE If the fuel flow rate is low, there will be no fuel pressure in the return hose. 13. If any of fuel pressure measured in steps 9 to 12 is out of specification, troubleshoot and repair according to the table below.
Symptom D D D Fuel pressure too low Fuel pressure drops after racing No fuel pressure in fuel return hose Probable cause Clogged fuel filter Fuel leaking to return side due to poor fuel regulator valve seating or settled spring Low fuel pump delivery pressure Fuel pressure too high Binding valve in fuel pressure regulator Clogged fuel return hose or pipe Same fuel pressure when vacuum hose is connected and when disconnected Damaged vacuum hose or clogged nipple Remedy Replace fuel filter Replace fuel pressure regulator
Replace fuel pump Replace fuel pressure regulator Clean or replace hose or pipe Replace vacuum hose or clean nipple
13A-87
14. Stop the engine and check change of fuel pressure gauge reading. Normal if the reading does not drop within 2 minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below.
Symptom Fuel pressure drops gradually after engine is stopped Fuel pressure drops sharply immediately after engine is stopped Probable cause Leaky injector Leaky fuel regulator valve seat Check valve in fuel pump is held open Remedy Replace injector Replace fuel pressure regulator Replace fuel pump
15. Release residual pressure from the fuel pipe line. (Refer to P.13A-88.) 16. Remove the fuel pressure gauge and special tool from the delivery pipe. 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. 17. Replace the O-ring at the end of the fuel high pressure hose with a new one. Furthermore, apply engine oil to the new O-ring before replacement. 18. Fit the fuel high pressure hose over the delivery pipe and tighten the bolt to specified torque. Tightening torque: 5 Nm 19. Check for fuel leaks. (1) Apply the battery voltage to the fuel pump drive terminal to drive the fuel pump. (2) Under fuel pressure, check the fuel line for leaks.
13A-88
MPI <4G6> - On-vehicle Service FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE)
13100090252
When removing the fuel pipe, hose, etc., since fuel pressure in the fuel pipe line is high, do the following operation so as to release fuel pressure in the line and prevent fuel from running out. 1. Raise the rear seat cushion. 2. Disconnect the floor wiring harness and fuel wiring harness under the floor carpet. 3. After starting the engine and letting it run until it stops naturally, turn the ignition switch to OFF. 4. Connect the fuel wiring harness and floor wiring harness. 5. Install the rear seat cushion.
FUEL PUMP OPERATION CHECK
13100200105
1. Check the operation of the fuel pump by using the MUT-II to force-drive the fuel pump. 2. If the fuel pump will not operate, check by using the following procedure, and if it is normal, check the drive circuit. (1) Turn the ignition switch to OFF. (2) When the fuel pump drive connector (black) is attached directly to the battery, check if the sound of the fuel pump operation can be heard. NOTE As the fuel pump is an in-tank type, the fuel pump sound is hard to hear, so remove the fuel filler cap and check from the tank inlet. (3) Check the fuel pressure by pinching the fuel hose with the fingertips.
MPI <4G6> - On-vehicle Service COMPONENT LOCATION

Name A/C relay A/C switch Air flow sensor (with intake air temperature sensor and barometric pressure sensor) Camshaft position sensor Control relay and fuel pump relay Crank angle sensor Detonation sensor Diagnosis connector EGR control solenoid valve Engine coolant temperature sensor Engine-ECU Symbol G R F Name Engine warning lamp (check engine lamp) Fuel pump check terminal Idle speed control servo Ignition coil K P I B O A L Q Inhibitor switch <A/T> Injectors Oxygen sensor (front) Oxygen sensor (rear) Power steering fluid pressure switch Purge control solenoid valve Throttle position sensor (with idle position switch) Vehicle speed sensor
13A-89
13100210368
Symbol N E C J M J S T H A C D
13A-90
Equipment side connector
MPI <4G6> - On-vehicle Service CONTROL RELAY AND FUEL PUMP RELAY 13100990170 CONTINUITY CHECK
Battery voltage
Fuel pump relay and control relay
Terminal No. 1 2 3 4
Not supplied Supplied
INTAKE AIR TEMPERATURE SENSOR CHECK

Air flow sensor
13100280239
1. Disconnect the air flow sensor connector. 2. Measure resistance between terminals 5 and 6. Standard value: 2.3 - 3.0 kW (at 20_C) 0.30 - 0.42 kW (at 80_C)
3. Measure resistance while heating the sensor using a hair drier. Normal condition:
Temperature (_C) Higher Resistance (kW) Smaller
4. If the value deviates from the standard value or the resistance remains unchanged, replace the air flow sensor assembly.
ENGINE COOLANT TEMPERATURE SENSOR 13100310242 CHECK

Caution Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Remove the engine coolant temperature sensor.
2. With temperature sensing portion of engine coolant temperature sensor immersed in hot water, check resistance. Standard value: 2.1 - 2.7 kW (at 20_C) 0.26 - 0.36 kW (at 80_C) 3. If the resistance deviates from the standard value greatly, replace the sensor.

4. Apply sealant to threaded portion.
13A-91
Specified sealant: 3M NUT Locking Part No.4171 or equivalent 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 Nm
THROTTLE POSITION SENSOR CHECK
13100320276
1. Disconnect the throttle position sensor connector. 2. Measure the resistance between the throttle position sensor side connector terminal 1 and terminal 4. Standard value: 3.5 - 6.5 kW 3. Measure the resistance between the throttle position sensor side connector terminal 2 and terminal 4. Normal condition:
Throttle valve slowly open until fully open from the idle position Changes smoothly in proportion to the opening angle of the throttle valve
4. If the resistance is outside the standard value, or if it doesnt change smoothly, replace the throttle position sensor. NOTE For the throttle position sensor adjustment procedure, refer to P.13A-81.
Throttle position sensor TPS equipment side connector
IDLE POSITION SWITCH CHECK
13100330262
1. Disconnect the throttle position sensor connector. 2. Check the continuity between the throttle position sensor connector side terminal 3 and terminal 4. Normal condition:
Accelerator pedal Depressed Released Continuity Non-conductive Conductive (0 W)
3. If out of specification, replace the throttle position sensor. NOTE After replacement, the idle position switch and throttle position sensor should be adjusted. (Refer to P.13A-81.)
13A-92

Oxygen sensor (front)
OXYGEN SENSOR CHECK
13100510161
<Oxygen sensor (front)> 1. Disconnect the oxygen sensor connector and connect the special tool (test harness) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 - 18 W at 20_C) between terminal 3 and terminal 4 on the oxygen sensor connector.
3. If there is no continuity, replace the oxygen sensor. 4. Warm up the engine until engine coolant is 80_C or higher.
MB991223
5. Use the jumper wire to connect terminal 3 of the oxygen sensor connector to the battery (+) terminal and terminal 4 to the battery ( - ) terminal. Caution Be very careful when connecting the jumper wire; incorrect connection can damage the oxygen sensor. 6. Connect a digital voltage meter between terminal 1 and terminal 2. 7. While repeatedly racing the engine, measure the oxygen sensor output voltage. Standard value:
Engine When racing the engine Oxygen sensor output voltage 0.6 - 1.0 V Remarks If you make the air/fuel ratio rich by racing the engine repeatedly, a normal oxygen sensor will output a voltage of 0.6 - 1.0 V.
MB991223
8. If the sensor is defective, replace the oxygen sensor. NOTE For removal and installation of the oxygen sensor, refer to GROUP 15 - Exhaust Pipe and Main Muffler.

Equipment side connector Oxygen sensor (rear)
13A-93
<Oxygen sensor (rear)> 1. Disconnect the oxygen sensor connector and connect the special tool (test harness set) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 - 18 W at 20_C) between terminal 3 and terminal 4 on the oxygen sensor connector. 3. If there is no continuity, replace the oxygen sensor. NOTE (1) If the MUT-II does not display the standard value although no abnormality is found by the above mentioned continuity test and harness check, replace the oxygen sensor (rear). (2) For removal and installation of the oxygen sensor, refer to GROUP 15 - Exhaust Pipe and Main Muffler.
MB991223
INJECTOR CHECK
Measurement of Resistance between Terminals 1. Remove the injector connector. 2. Measure the resistance between terminals. Standard value: 13 - 16 W (at 20_C) 3. Install the injector connector.
Injector
13100520287
Checking the Injection Condition 1. Following the steps below, bleed out the residual pressure within the fuel pipe line to prevent flow of the fuel. (Refer to P.13-88.) 2. Remove the injector.
13A-94

3. Arrange the special tool (injector test set), adaptor, fuel pressure regulator and clips as shown in the illustration below.
High-pressure fuel hose MD998741 Return hose MB991607
Pressure regulator (MD116395) Injector MD998706
Battery
Clip (MB991608)
4. Apply battery voltage to the No. 2 terminal of 3 pin connector (fuel pump drive connector) shown in the figure at left and drive the fuel pump.
Main hose
Return hose
5. Activate the injector and check the atomized spray condition of the fuel. The condition can be considered satisfactory unless it is extremely poor.
Injector
Battery
6. Stop the actuation of the injector, and check for leakage from the injectors nozzle. Standard value: 1 drop or less per minute 7. Activate the injector without activating the fuel pump; then, when the spray emission of fuel from the injector stops, disconnect the special tool and restore it to its original condition.

Idle speed control servo
13A-95
13100540238
IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) CHECK
Checking the Operation Sound 1. Check that the engine coolant temperature is 20_C or below. NOTE Disconnecting the engine coolant temperature sensor connector and connecting the harness-side of the connector to another engine coolant temperature sensor that is at 20_C or below is also okay. 2. Check that the operation sound of the stepper motor can be heard after the ignition is switched ON. (but without starting the motor.) 3. If the operation sound cannot be heard, check the stepper motors activation circuit. If the circuit is normal, it is probable that there is a malfunction of the stepper motor or of the engine control unit. Checking the Coil Resistance 1. Disconnect the idle speed control servo connector and connect the special tool (test harness). 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 speed control servo side. Standard value: 28 - 33 W (at 20_C) 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 speed control servo side. Standard value: 28 - 33 W (at 20_C)
PURGE CONTROL SOLENOID VALVE CHECK

13100560241
Refer to GROUP 17 - Emission Control System.
EGR CONTROL SOLENOID VALVE CHECK

13100570206
13A-96 INJECTOR
MPI <4G6> - Injector

13100710332

Pre-removal Operation D Fuel Discharge Prevention (Refer to P.13A-88.)
8 12
11 10 5, 7
6 7
9 Nm 10 - 13 Nm
9 4 3 2
O-ring
11
12
Engine oil
O-ring
Removal steps 1. PCV hose connection 2. Injector connector 3. Purge control solenoid valve connector 4. EGR solenoid valve connector "AA 5. High-pressure fuel hose connection 6. Fuel return hose connection
"AA 7. 8. 9. 10. AA" "AA 11. 12. AA"
Fuel pressure regulator Delivery pipe Insulator Insulator Injector Grommet
MPI <4G6> - Injector REMOVAL SERVICE POINT
13A-97
AA" DELIVERY PIPE/INJECTOR REMOVAL Remove the delivery pipe (with the injectors attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector.

"AA INJECTOR/FUEL PRESSURE REGULATOR/ HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a drop of new engine oil to the O-ring. Caution Be sure not to let engine oil in the delivery pipe. 2. While turning the injector, high-pressure fuel hose and fuel pressure regulator to the right and left, install the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly. 3. If it does not turn smoothly, the O-ring may be trapped, remove the fuel pressure regulator and then re-insert it into the delivery pipe and check once again. 4. Tighten the high-pressure fuel hose to the standard torque, and tighten the fuel pressure regulator to the specified torque. Tightening torque: 9 Nm (Fuel pressure regulator)
13A-98 THROTTLE BODY
MPI <4G6> - Throttle Body

13100770132

Pre-removal Operation D Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service.) D Air Cleaner Removal Post-installation Operation D Air Cleaner Installation D Engine Coolant Supplying (Refer to GROUP 14 - On-vehicle Service.) D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)
2
19 Nm
3 6
Removal steps 1. Accelerator cable connection 2. Throttle position sensor connector 3. Idle speed control servo connector 4. Vacuum hose connection
5. Water hose connection 6. Throttle body "AA 7. Throttle body gasket
Up

"AA THROTTLE BODY GASKET INSTALLATION Place the gasket so that the projecting part is positioned as shown in the illustration, and then install it between the intake manifold and the throttle body.
Towards front of vehicle

DISASSEMBLY AND REASSEMBLY <Vehicles without auto-cruise control system>
13A-99
13100970280
6 1 7 5
Disassembly steps "AA 1. Throttle position sensor 2. Idle speed control body assembly 3. O-ring 4. Throttle body 5. Fixed SAS 6. Speed adjusting screw 7. O-ring
NOTE 1. The fixed SAS and the speed adjusting screw are correctly adjusted at the factory and should not be removed. 2. If the fixed SAS should happen to have been removed, carry out fixed SAS adjustment. (Refer to page 13A-83.) 3. If the speed adjusting screw should happen to have been removed, carry out speed adjusting screw adjustment. (Refer to 13A-83.)
13A-100
<Vehicles with auto-cruise control system>
7 8 6 1 2 5
Disassembly steps "AA 1. Throttle position sensor 2. Lever assembly 3. Idle speed control body assembly 4. O-ring 5. Throttle body 6. Fixed SAS 7. Speed adjusting screw 8. O-ring
CLEANING THROTTLE BODY PARTS

1. Clean all throttle body parts. Do not use solvent to clean the following parts: D Throttle position sensor D Accelerator pedal position sensor D Idle speed control body assembly If these parts are immersed in solvent, their insulation will deteriorate. Wipe them with cloth only. 2. Check if the vacuum port or passage is clogged. Use compressed air to clean the vacuum passage.
MPI <4G6> - Throttle Body REASSEMBLY SERVICE POINT
13A-101
TPS output TPS power supply Earth
"AA THROTTLE POSITION SENSOR (TPS) INSTALLATION 1. Install the TPS so that it faces as shown in the illustration, and then tighten it with the screw. 2. Connect a multimeter between terminal (1) (TPS power supply) and terminal (2) (TPS output) of the TPS connector, and check that the resistance increases gradually as the throttle valve is opened slowly to the fully-open position. 3. For vehicles without TCL, check the continuity between terminal (3) (idle position switch) and terminal (4) (earth) of the TPS connector when the throttle valve is fully closed and fully open. Normal condition:
Throttle valve condition Fully closed Fully open Continuity Continuity No continuity
If there is no continuity when the throttle valve is fully closed, turn the TPS body anti-clockwise and then check again. 4. If there is an abnormality, replace the TPS.
13A-102
MPI <6A1> - General Information

13100010456
MULTIPOINT FUEL INJECTION (MPI) <6A1>

GENERAL INFORMATION
The Multipoint Fuel Injection System consists of sensors which detect the engine conditions, the engine-ECU which controls the system based on signals from these sensors, and actuators which operate under the control of the engine-ECU. The engine-ECU carries out FUEL INJECTION CONTROL The injector drive times and injector timing are controlled so that the optimum air/fuel mixture is supplied to the engine to correspond to the continually-changing engine operation conditions. A single injector is mounted at the intake port of each cylinder. Fuel is sent under pressure from the fuel tank by the fuel pump, with the pressure being regulated by the fuel pressure regulator. The fuel thus regulated is distributed to each of the injectors. Fuel injection is normally carried out once for each cylinder for every two rotations of the crankshaft. The firing order is 1-2-3-4-5-6. This is called sequential fuel injection. IDLE AIR CONTROL The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in accordance with changes in idling conditions and engine load during idling. The engine-ECU drives the idle speed control (ISC) motor to keep the engine running at the pre-set idle target speed in accordance with the engine coolant temperature and air IGNITION TIMING CONTROL The power transistor located in the ignition primary circuit turns ON and OFF to control the primary current flow to the ignition coil. This controls the ignition timing in order to provide the optimum ignition timing with respect to the SELF-DIAGNOSIS FUNCTION D When an abnormality is detected in one of the sensors or actuators related to emission control, the engine warning lamp (check engine lamp) illuminates as a warning to the driver. D When an abnormality is detected in one of the sensors or actuators, a diagnosis
activities such as fuel injection control, idle speed control and ignition timing control. In addition, the engine-ECU is equipped with several diagnosis modes which simplify troubleshooting when a problem develops.
The engine-ECU provides a richer air/fuel mixture by carrying out open-loop control when the engine is cold or operating under high load conditions in order to maintain engine performance. In addition, when the engine is warm or operating under normal conditions, the engine-ECU controls the air/fuel mixture by using the oxygen sensor signal to carry out closed-loop control in order to obtain the theoretical air/fuel mixture ratio that provides the maximum cleaning performance from the three way catalyst.
conditioner load. In addition, when the air conditioner switch is turned off and on while the engine is idling, the ISC motor operates to adjust the throttle valve bypass air amount in accordance with the engine load conditions in order to avoid fluctuations in the engine speed.
engine operating conditions. The ignition timing is determined by the engine-ECU from the engine speed, intake air volume, engine coolant temperature and atmospheric pressure.
code corresponding to the abnormality is output. The RAM data inside the engine-ECU that is related to the sensors and actuators can be read by means of the MUT-II. In addition, the actuators can be force-driven under certain circumstances.

OTHER CONTROL FUNCTIONS 1. Fuel Pump Control Turn the fuel pump relay ON so that current is supplied to the fuel pump while the engine is cranking or running. 2. A/C Relay Control Turn the compressor clutch of the A/C ON and OFF. 3. Fan Relay Control The revolutions of the radiator fan and condenser fan are controlled in response to the engine coolant temperature and vehicle speed.
13A-103
4. Traction Control Engine output torque is reduced based on signals from the TCL-ECU in response to the conditions under which slipping of the driven wheels and turning of the vehicle occur. Furthermore, reduction of output torque is performed by closing the throttle valve and retarding the ignition timing. 5. Purge Control Solenoid Valve Control Refer to GROUP 17. 6. EGR Control Solenoid Valve Control Refer to GROUP 17.
GENERAL SPECIFICATIONS
Items Throttle body Throttle bore mm Throttle position sensor Accelerator pedal position sensor Idle speed control servo Specifications 60 Variable resistor type Variable resistor type Stepper motor type (Stepper motor type by-pass air control system with the air volume limiter) Rotary contact type, within throttle position sensor Rotary contact type, within accelerator pedal position sensor E2T66876 <Vehicles without TCL> E2T66877 <Vehicles with TCL> Karman vortex type Semiconductor type Thermistor type Thermistor type Zirconia type Magnetic resistive element type Contact switch type Hall element type Hall element type Piezoelectric type Contact switch type
Idle position switch <Vehicles without TCL> Idle position switch <Vehicles with TCL> Engine-ECU Sensors Identification model No. Air flow sensor Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Oxygen sensor Vehicle speed sensor Inhibitor switch Top dead centre sensor Crank angle sensor Detonation sensor Power steering fluid pressure switch
13A-104
Items Actuators Control relay type

Specifications Contact switch type Contact switch type Electromagnetic type, 6 CDH210 Duty cycle type solenoid valve ON/OFF type solenoid valve Duty cycle type solenoid valve Duty cycle type solenoid valve 329
Fuel pump relay type Injector type and number Injector identification mark EGR control solenoid valve Purge control solenoid valve Ventilation control solenoid valve Vacuum control solenoid valve Fuel pressure Regulator pressure kPa regulator
MPI <6A1> - General Information MULTIPOINT FUEL INJECTION SYSTEM DIAGRAM

*1 *2 *3 *4 *5 *6 *7 *8 *9 *10 D D D D D D D D D D Oxygen sensor (front) Air flow sensor Intake air temperature sensor Throttle position sensor Idle position switch Top dead centre sensor Crank angle sensor Engine coolant temperature sensor Barometric pressure sensor Oxygen sensor (rear) Power supply voltage Vehicle speed sensor A/C switch 1, 2 Inhibitor switch Power steering fluid pressure switch Ignition switch - ST Ignition switch - IG Alternator FR terminal A/T-ECU TCL-ECU <TCL> EngineECU z1 z2 z3 z4 z5
13A-105
Injector Purge control solenoid valve Idle speed control servo EGR control solenoid valve Ventilation control solenoid valve <TCL> z6 Vacuum control solenoid valve <TCL> D D D D D D D D D D Fuel pump relay Control relay A/C power relay Engine warning lamp Diagnosis signal Ignition coil, power transistor Fan controller Alternator G terminal A/T-ECU TCL-ECU <TCL>
z6 Vacuum control solenoid valve <TCL> z5 Ventiration control solenoid valve <TCL> Vacuum tank Vacuum actuator <TCL> Fuel pressure regulator PCV valve *4, *5 EGR valve z1 Injector z4 From fuel pump EGR control solenoid valve z2 Purge control solenoid valve *10 Oxygen sensor (rear) *6 Top dead centre sensor Throttle position sensor (with idle position switch) Canister *3 Intake air temperature sensor Air flow sensor (with barometric z3 Idle speed pressure sensor) control servo Air cleaner Air
*9
*2
To fuel tank
*8 Engine coolant temperature sensor
*1 Oxygen sensor (front)
Distributor Catalytic converter *7 Crank angle sensor
13A-106
MPI <6A1> - Service Specifications/Sealant

13100030346
Items Basic idle speed r/min Throttle position sensor adjusting voltage mV Vehicles without TCL Vehicles with TCL Specifications 65050 400 - 1,000 580 - 690 400 - 1,000 3.5 - 6.5 3.5 - 6.5 28 - 33 (at 20_C) 2.3 - 3.0 0.30 - 0.42 2.1 - 2.7 0.26 - 0.36 0.6 - 1.0 324 - 343 at kerb idle Approx. 265 at kerb idle 13 - 16 (at 20_C) 36 - 44 (at 20_C) 36 - 44 (at 20_C)
Accelerator pedal position sensor adjusting voltage mV Throttle position sensor resistance kW Accelerator pedal position sensor resistance kW Idle speed control servo coil resistance W Intake air temperature sensor resistance kW Engine coolant temperature sensor resistance kW 20_C 80_C 20_C 80_C
Oxygen sensor output voltage V Fuel pressure kPa Vacuum hose disconnection Vacuum hose connection Injector coil resistance W Ventilation control solenoid valve coil resistance W Vacuum control solenoid valve coil resistance W
SEALANT
13100050205
Drying sealant
MPI <6A1> - Special Tools
13A-107
13100060345
SPECIAL TOOLS
Tool
A
Use D A: B: C: D: Fuel gauge simple inspection Connector pin contact pressure inspection Power circuit inspection Power circuit inspection Commercial tester connection
MB991502
MUT-II sub assembly
D D
Reading diagnosis code MPI system inspection
MB991348
Test harness set
D D
MB991709
Test harness
MB991519
Alternator harness connector
Measurement of voltage during troubleshooting
MD998463
Test harness (6-pin, square)
D D
Inspection of idle speed control servo Inspection using an analyzer
MD998478
Test harness (3-pin, triangle)
D D
13A-108
Tool
MPI <6A1> - Special Tools/Troubleshooting

Number MD998709 Name Adaptor hose Use Measurement of fuel pressure
MD998742
Hose adaptor
MD998706
Injector test set
Checking the spray condition of injectors
MB991607
Injector test harness
MD998741
Injector test adaptor
MB991608
Clip
TROUBLESHOOTING
13100850256
DIAGNOSIS FUNCTION
13100860365
ENGINE WARNING LAMP (CHECK ENGINE LAMP) If an abnormality occurs in any of the following items related to the Multipoint Fuel Injection (MPI) system, the engine warning lamp will illuminate. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.
Engine warning lamp (check engine lamp)
MPI <6A1> - Troubleshooting

Engine-ECU Oxygen sensor Air flow sensor Intake air temperature sensor Throttle position sensor Engine coolant temperature sensor Crank angle sensor Top dead centre sensor Barometric pressure sensor Detonation sensor Injector Vacuum control solenoid valve <TCL> Ventilation control solenoid valve <TCL> Immobilizer system
13A-109
13A-110

13100910305
FAIL-SAFE FUNCTION REFERENCE TABLE
Malfunctioning item Air flow sensor Control contents during malfunction 1. 2. Intake air temperature sensor Throttle position sensor (TPS) Engine coolant temperature sensor Top dead centre sensor Barometric pressure sensor Detonation sensor Oxygen sensor Communication wire with transmission control unit <A/T> Alternator FR terminal Uses the throttle position sensor signal and engine speed signal (crank angle sensor signal) to take reading of the basic injector drive time and basic ignition timing from the pre-set mapping. Fixes the ISC servo in the appointed position so idle control is not performed.
Controls as if the intake air temperature is 25_C. No increase in fuel injection amount during acceleration due to the throttle position sensor signal. Controls as if the engine coolant temperature is 80_C. Injects fuel to all cylinders simultaneously. (However, after the ignition switch is turned to ON, the No. 1 cylinder top dead centre is not detected at all.) Controls as if the barometric pressure is 101 kPa. Switches the ignition timing from ignition timing for super petrol to ignition timing for standard petrol. Air/fuel ratio feedback control (closed loop control) is not performed. Ignition timing is not retarded during transmission gear shifting (overall engine and transmission control). Does not control the output of the alternator according to an electrical load. (works as a normal alternator)
NOTE When a problem is detected in the vacuum control solenoid valve, ventilation control solenoid valve, crank angle sensor or any of the above items, traction control is not performed <Vehicles with TCL>.
MPI <6A1> - Troubleshooting INSPECTION CHART FOR DIAGNOSIS CODES

Code No. 11 12 13 14 21 22 23 24 25 31 41 54 59 61 64 71 72 Diagnosis item Oxygen sensor (front) system Air flow sensor system Intake air temperature sensor system Throttle position sensor system Engine coolant temperature sensor system Crank angle sensor system Top dead centre sensor Vehicle speed sensor system Barometric pressure sensor system Detonation sensor system Injector system Immobilizer system Oxygen sensor (rear) system Communication wire with A/T-ECU system <A/T> Alternator FR terminal system Vacuum control solenoid valve system <Vehicles with TCL> Ventilation control solenoid valve system <Vehicles with TCL>
13A-111
13100870382
Reference page 13A-112 13A-113 13A-113 13A-114 13A-115 13A-116 13A-117 13A-118 13A-119 13A-120 13A-120 13A-121 13A-122 13A-123 13A-123 13A-124 13A-125
13A-112
INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code No. 11 Oxygen sensor (front) system
Range of Check D 3 minutes have passed after engine was started. D Engine coolant temperature is approx. 80_C or more. D Intake air temperature is 20 - 50_C. D Engine speed is approx. 2,000 - 3,000 r/min D Vehicle is moving at constant speed on a flat, level road surface Set conditions D The oxygen sensor (front) output voltage is around 0.6 V for 30 seconds (does not cross 0.6 V for 30 seconds). D When the range of check operations given above which accompany starting of the engine are carried out four time in succession, a problem is detected after each operation. NG
Probable cause
D D D Malfunction of the oxygen sensor (front) Improper connector contact, open circuit short-circuited harness wire Malfunction of the engine-ECU or
Check the oxygen sensor (front). (Refer to P.13A-196.) OK
Replace
1. NG Measure at the oxygen sensor (front) connector C-46. D Disconnect the connector, and measure at the harness side. 1. Voltage between 3 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Continuity between 2 and earth OK: Continuity 3. Continuity between 4 and earth 3. NG OK: Continuity OK NG Check the following connectors: C-46, C-39 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor (front) connector. OK Replace the engine-ECU. NG
Check the harness wire between the oxygen sensor (front) and the control relay connector, and repair if necessary. Check the following connector: C-39 OK Check trouble symptom. Repair NG Check the harness wire between the engine-ECU and the oxygen sensor (front) connector. OK Replace the engine-ECU. Repair NG NG Repair
Repair
Check the harness wire between the oxygen sensor (front) and the earth, and repair if necessary.

Code No. 12 Air flow sensor system
Range of Check D Engine speed is 500 r/min or more. Set conditions D Sensor output frequency is 3 Hz or less for 4 seconds. 1. NG Measure at the air flow sensor conCheck the air flow sensor circuit. nector B-12. (Refer to P.13A-159, INSPECD Connect the connector. (Use TION PROCEDURE 49.) the test harness: MB991709) 1. Voltage between 3 and earth NG 2. NG (Engine: Idling) Measure at the engine-ECU conOK: 2.2 - 3.2 V nector C-33. 2. Voltage between 7 and earth D Connect the connector. OK: 0 - 1 V (Engine: idling) D Voltage between 19 and earth 6 - 9 V (2,000 r/min) (Ignition switch: ON) OK: 6 - 9 V OK Replace the engine-ECU. OK Check the following connector: C-33 OK Check trouble symptom. NG Replace the engine-ECU. NG
13A-113
Probable cause
D D D Malfunction of the air flow sensor Improper connector contact, open circuit or short-circuited harness wire of the air flow sensor Malfunction of the engine-ECU
Check the following connector: B-12 OK Check trouble symptom. NG Repair Replace the air flow sensor.
NG
Repair
Code No. 13 Intake air temperature sensor system

Range of Check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Set conditions D Sensor output voltage is 4.6 V or more (corresponding to an intake air temperature of - 45_C or less) for 4 seconds. or D Sensor output voltage is 0.2V or less (corresponding to an intake air temperature of 125_C or more) for 4 seconds. NG
Probable cause
D D D Malfunction of the intake air temperature sensor Improper connector contact, open circuit or short-circuited harness wire of the intake air temperature sensor circuit Malfunction of the engine-ECU
Check the intake air temperature sensor. (Refer to P.13A-193.) OK Measure at the air flow sensor connector B-12. D Disconnect the connector, and measure at the harness side. D Voltage between 6 and earth (Ignition switch: ON) OK: 4.5 - 4.9 V D Continuity between 5 and earth OK: Continuity OK Check the following connector: B-12 OK Check trouble symptom.
Replace
NG
Check the following connector: C-39 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the intake air temperature sensor connector. Repair OK Replace the engine-ECU.
NG
Repair
NG
Repair
NG
NG
13A-114

Probable cause
D D D D D Malfunction of the throttle position sensor or maladjustment Improper connector contact, open circuit or short-circuited harness wire of the throttle position sensor circuit Improper ON state of idle position switch Short circuit of the idle position switch signal line Malfunction of the engine-ECU
Code No. 14 Throttle position sensor system

Range of Check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Set conditions D When the idle position switch is ON, the sensor output voltage is 2 V or more for 4 seconds. or D The sensor output voltage is 0.2 V or less for 4 seconds. NG
MUT-II Data list 26 Idle position switch system OK: With the throttle valve at the idle position: ON With the throttle valve slightly open: OFF OK Check the throttle position sensor. (Refer to P.13A-194.) OK Measure at the throttle position sensor connector B-07. D Disconnect the connector, and measure at the harness side. D Voltage between 4 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 1 and earth OK: Continuity OK Check the throttle position sensor output circuit. (Refer to P.13A-160, INSPECTION PROCEDURE 50.)
Check the idle position switch system. (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles without TCL> (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles with TCL> Replace
NG
NG
Check the following connector: C-39 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the throttle position sensor connector. OK Replace the engine-ECU.
NG
Repair
NG
Repair

Code No. 21 Engine coolant temperature sensor system
Range of Check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. Set conditions D Sensor output voltage is 4.6 V or more (corresponding to an engine coolant temperature of - 45_C or less) for 4 seconds. or D Sensor output voltage is 0.1 V or less (corresponding to an engine coolant temperature of 140_C or more) for 4 seconds. Range of Check D Ignition switch: ON D Engine speed is approx. 50 r/min or more Set conditions D The sensor output voltage increases from 1.6 V or less (corresponding to an engine coolant temperature of 40_C or more) to 1.6 V or more (corresponding to an engine coolant temperature of 40_C or less). D After this, the sensor output voltage is 1.6 V or more for 5 minutes. NG
13A-115
Probable cause
D D D Malfunction of the engine coolant temperature sensor Improper connector contact, open circuit or short-circuited harness wire of the engine coolant temperature sensor circuit Malfunction of the engine-ECU
Check the engine coolant temperature sensor. (Refer to P.13A-193.) OK Measure at the engine coolant temperature sensor connector B-33. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.5 - 4.9 V D Continuity between 2 and earth OK: Continuity OK
Replace
NG
Check the following connector: C-39 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the engine coolant temperature sensor connector. OK Replace the engine-ECU.
NG
Repair
NG
Repair
Check the following connector: B-33 NG Repair
OK
13A-116

Probable cause
D D D Malfunction of the crank angle sensor Improper connector contact, open circuit or short-circuited harness wire of the crank angle sensor Malfunction of the engine-ECU

Range of Check D Engine is cranking. Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal input.) OK
Measure at the crank angle sensor connector B-77. D Connect the connector. (Use the test harness: MD998478.) D Voltage between 2 and earth (Engine: cranking) OK: 0.4 - 4.0 V D Voltage between 2 and earth (Engine: idling) OK: 1.5 - 2.5 V NG
1. NG Measure at the crank angle sensor connector B-77. D Disconnect the connector, and measure at the harness side. 1. Voltage between 3 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Voltage between 2 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V 3. NG 3. Continuity between 1 and earth OK: Continuity OK Check the following connector: B-77 OK Check trouble symptom. NG Replace the crank angle sensor. NG
Check the harness wire between the crank angle sensor and the control relay connector, and repair if necessary. Check the following connector: C-39 OK Check trouble symptom. NG NG NG Repair
Repair
Check the harness wire between the engine-ECU and the crank angle sensor connector. OK Replace the engine-ECU.
Repair

Code No.23 Top dead centre sensor system
Range of Check D Ignition switch: ON D Engine speed is approx. 50 r/min or more. Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal input.) OK
13A-117
Probable cause
D D D Malfunction of the top dead centre sensor Improper connector contact, open circuit or short-circuited harness wire of the top dead centre sensor circuit Malfunction of the engine-ECU
Measure at the distributor connector B-42. D Connect the connector. (Use the test harness: MB991348 and jumper wire.) D Voltage between 5 and earth (Engine: cranking) OK: 0.4 - 3.0 V D Voltage between 5 and earth (Engine: idling) OK: 1.5 - 2.0 V NG
1. NG Measure at the distributor connector B-42. D Disconnect the connector, and measure at the harness side. 1. Voltage between 6 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Voltage between 5 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V 3. NG 3. Continuity between 7 and earth OK: Continuity OK Check the following connector: B-42 OK Check trouble symptom. NG Replace the distributor NG
Check the harness wire between the top dead centre sensor and the control relay connector, and repair if necessary. Check the following connector: C-39 OK Check trouble symptom. NG NG NG Repair
Repair
Check the harness wire between the engine-ECU and the top dead centre sensor connector. OK Replace the engine-ECU.
Repair
Check the harness wire between the top dead centre sensor and the earth, and repair if necessary.
13A-118

Probable cause
D D D Malfunction of the vehicle speed sensor Improper connector contact, open circuit or short-circuited harness wire of the vehicle speed sensor circuit Malfunction of the engine-ECU
Code No. 24 Vehicles speed sensor system

Range of check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. D Idle position switch: OFF D Engine speed is 3,000 r/min or more. D Driving under high engine load conditions. Set conditions D Sensor output voltage does not change for 4 seconds (no pulse signal input). NG
Check the vehicle speed sensor. (Refer to GROUP 54 - Combination Meters.) OK
Replace
1. NG Measure at the vehicle speed sensor connector B-66 <M/T>, B-67 <A/T>. D Disconnect the connector, and measure at the harness side. 2. NG 1. Voltage between 1 and earth (Ignition switch: ON) OK: System voltage 2. Voltage between 3 and earth (Ignition switch: ON) 3. NG OK: 4.8 - 5.2 V 3. Continuity between 2 and earth OK: Continuity OK Check the following connectors: B-66 <M/T>, B-67 <A/T> OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the vehicle speed sensor connector. OK Replace the engine-ECU. NG NG Repair
Check the following connectors: B-65 <M/T>, C-90, C-135, C-131 OK Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and ignition switch connector. OK
NG
Repair
NG
Repair
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.) Check the following connectors: B-65 <M/T>, C-48, C-39 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the vehicle speed sensor connector. OK Replace the engine-ECU. Check the following connector: B-65 <M/T> OK Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and the earth, and repair if necessary. NG Repair NG NG Repair
Repair
Repair

Code No. 25 Barometric pressure sensor system
Range of Check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. D Battery voltage is 8 V or more. Set conditions D Sensor output voltage is 4.5 V or more (corresponding to a barometric pressure of 114 kPa or more) for 4 seconds. or D Sensor output voltage is 0.2 V or less (corresponding to a barometric pressure of 5.33 kPa or less) for 4 seconds. NG NG
13A-119
Probable cause
D D D Malfunction of the barometric pressure sensor Improper connector contact, open circuit or short-circuited harness wire of the barometric pressure sensor circuit Malfunction of the engine-ECU
Measure at the air flow sensor connector B-12. D Connect the connector. (Use the test harness: MB991709) D Voltage between 2 and earth (Ignition switch: ON) OK: 3.7 - 4.3 V (Altitude: 0 m) 3.2 - 3.8 V (Altitude: 1,200 m) OK
Measure at the air flow sensor connector B-12. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 5 and earth OK: Continuity OK Check the following connector: B-12 OK Check trouble symptom. NG
Check the following connector: C-39 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the barometric pressure sensor connector.
NG
Repair
NG
Repair
NG
Repair
OK
NG Check the harness wire between the engine-ECU and the baromet- OK ric pressure sensor connector. Measure at the engine-ECU connector C-39. D Connect the connector. D Voltage between 85 and earth (Ignition switch: ON) OK: 3.7 - 4.3 V (Altitude: 0 m) 3.2 - 3.8 V (Altitude: 1,200 m) OK Check the following connector: C-39 OK Check trouble symptom. NG Replace the engine-ECU. NG Repair NG Check the harness wire between the engine-ECU and the barometric pressure sensor connector, and repair if necessary.
Repair Replace the air flow sensor.
13A-120

Probable cause
D D D Malfunction of the detonation sensor Improper connector contact, open circuit or short-circuited harness wire of the detonation sensor circuit Malfunction of the engine-ECU
Code No. 31 Detonation sensor system

Range of Check D Ignition switch: ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts. D Engine speed is approx. 5,000 r/min or more Set conditions The change in the detonation sensor output voltage (detonation sensor peak voltage at each 1/2 revolution of the crankshaft) is less than 0.06 V for 200 times in succession. OK
Measure at the detonation sensor connector B-34. D Disconnect the connector and measure at the harness side. D Continuity between 2 and earth OK: Continuity NG Check the harness wire between the detonation sensor and earth, and repair if necessary.
Check the following connectors: B-34, C-39 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the detonation sensor connector. NG Repair
NG
Repair
OK
Replace the detonation sensor. Check trouble symptom. NG Replace the engine-ECU.
Code No. 41 Injector system

Range of Check D Engine speed is approx. 50 - 1,000 r/min D The throttle position sensor output voltage is 1.15 V or less. D Actuator test by MUT-II is not carried out. Set conditions D Surge voltage of injector coil is not detected for 4 seconds. NG NG
Probable cause
D D D Malfunction of the injector Improper connector contact, open circuit or short-circuited harness wire of the injector circuit Malfunction of the engine-ECU
Check the injector. (Refer to P.13A-197.) OK Measure at the injector connectors B-02, B-03, B-05, B-36, B-40, B-44. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Check the injector control circuit. (Refer to P.13A-159, INSPECTION PROCEDURE 51.)
Replace NG
Check the following connectors: B-02, B-03, B-05, B-36, B-40, B-44. OK Check trouble symptom.
Repair
NG
Check the harness wire between the engine-ECU and the injector connector, and repair if necessary.

Range of Check D Ignition switch: ON Set Conditions D Improper communication between the engine-ECU and immobilizer-ECU
13A-121
Probable cause
D D D D D Radio interference of ID codes Incorrect ID code Malfunction of harness or connector Malfunction of immobilizer-ECU Malfunction of engine-ECU
NOTE (1) If the ignition switches are close each other when starting the engine, radio interference may cause this code to be displayed. (2) This code may be displayed when registering the key ID code.
Is there another ignition key near the ignition key that is inserted in the ignition switch? Yes Remove the extra ignition key. NG No Is a diagnosis code output from the immobilizer-ECU? No Check the following connectors: C-37, C-81, C-68 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the immobilizer-ECU. NG Repair Replace the engine-ECU. OK Replace the immobilizer-ECU. NG Check trouble symptom. NG NG Yes Check trouble symptom. Check the immobilizer system. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) Repair
13A-122

Probable cause
D D D Malfunction of the oxygen sensor (rear) Improper connector contact, open circuit short-circuited harness wire Malfunction of the engine-ECU or
Code No. 59 Oxygen sensor (rear) system

Range of Check D 3 minutes have passed after engine was started. D Engine coolant temperature is approx. 80_C or more. D Idle position switch: OFF D The throttle position sensor output voltage is 4.1 V or more. D Open loop control in operation D 20 seconds have passed after deceleration finished. Set conditions D The oxygen sensor (rear) output voltage is 0.1 V or less. D The difference in the maximum and minimum values for the oxygen sensor (rear) output voltage is 0.08 V or less. D The oxygen sensor (rear) output voltage is 0.5 V or more. D The above conditions continue for a continuous period of 5 seconds. NG
Check the oxygen sensor (rear). (Refer to P.13A-197.) OK
Replace
1. NG Measure at the oxygen sensor (rear) connector C-85. D Disconnect the connector, and measure at the harness side. 1. Voltage between 3 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Continuity between 2 and earth OK: Continuity 3. Continuity between 4 and earth 3. NG OK: Continuity OK
Check the harness wire between the oxygen sensor (rear) and the control relay connector, and repair if necessary. Check the following connector: C-39 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor (rear) connector. OK Replace the engine-ECU. Check the harness wire between the oxygen sensor (rear) and the earth, and repair if necessary. NG NG Repair
Repair
Check the following connectors: C-85, C-39 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the oxygen sensor (rear) connector. OK Replace the oxygen sensor (rear). Check trouble symptom. NG Replace the engine-ECU.
NG
Repair
NG
Repair

Code No. 61 Communication wire with A/T-ECU system <A/T>
Range of Check D 60 seconds or more have passed immediately after engine was started. D Engine speed is approx. 50 r/min or more Set conditions The voltage of the torque reduction request signal from the A/T-ECU is LOW for 1.5 seconds or more. NG
13A-123
Probable cause
D D D Malfunction of the harness wire and the connector Malfunction of the engine-ECU Malfunction of the A/T-ECU
Check the following connectors. (C-30, C-37) <Vehicles without TCL>, (C-28, C-35) <Vehicles with TCL> OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the A/T-ECU connector. NG Repair
Repair
OK
Check trouble symptom. NG Replace the A/T-ECU.
Code No. 64 Alternator FR Terminal System

Range of Check, Set Conditions D The alternator FR terminal signal voltage remains high for approximately 20 seconds while the engine is running. OK
Probable cause
D D Open circuit in alternator FR terminal circuit Malfunction of the engine-ECU
Measure at the alternator connector B-38. D Connect the connector. D Voltage between 4 and earth (Engine: Idling) (Radiator fan: Stopped) (Headlamp: OFF ON) OK: 1.8 - 2.4 1.0 - 1.6 V NG Measure at the alternator connector B-38. D Disconnect the connector, and measure at the harness side. D Voltage between 4 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V OK Check the following connector: B-38 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the alternator connector. OK Replace the alternator.
NG
Check the following connectors: B-31, C-37 OK Check trouble symptom. NG Repair Check the harness wire between the engine-ECU and the alternator connector.
NG
Repair
NG
NG
Repair
NG
Repair
OK
13A-124

Probable cause
D D D Malfunction of the vacuum control solenoid valve Improper connector contact, open circuit or short-circuited harness wire of the vacuum control solenoid valve Malfunction of the engine-ECU
Code No. 71 Vacuum control solenoid valve system <Vehicles with TCL>
Range of Check D Ignition switch: ON D Excluding 60 seconds immediately after the engine starts. D Battery voltage is 10 V or more. D Forced actuation by means of MUT-II is not being carried out. Set condition Solenoid valve drive or non-drive instruction and energized condition of solenoid coil are different. NG
Check the vacuum control solenoid valve. (Refer to P.13A-201.) OK Measure at the vacuum control solenoid valve connector B-78. D Disconnect the connector and measure at the harness side. D Voltage between 2 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-35. D Disconnect the connector and measure at the harness side. D Voltage between 32 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-35 OK Check trouble symptom.
Replace
NG
Check the harness wire between the vacuum control solenoid valve connector and the control relay connector, and repair if necessary.
NG
Check the following connector: B-78 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the vacuum control solenoid valve connector, and repair if necessary.
NG
Repair
NG
Repair
NG

Code No. 72 Ventilation control solenoid valve system <Vehicles with TCL>
Range of Check D Ignition switch: ON D Excluding 60 seconds immediately after the engine starts. D Battery voltage is 10 V or more. D Forced actuation by means of MUT-II is not being carried out. Set condition Solenoid valve drive or non-drive instruction and energized condition of solenoid coil are different. NG
13A-125
Probable cause
D D D Malfunction of the ventilation control solenoid valve Improper connector contact, open circuit or short-circuited harness wire of the ventilation control solenoid valve Malfunction of the engine-ECU
Check the ventilation control solenoid valve. (Refer to P.13A-201.) OK Measure at the ventilation control solenoid valve connector B-79. D Disconnect the connector and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-35. D Disconnect the connector and measure at the harness side. D Voltage between 31 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-35 OK Check trouble symptom.
Replace
NG
Check the harness wire between the control relay and the ventilation control solenoid valve connector, and repair if necessary.
NG
Check the following connector: B-79 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the ventilation control solenoid valve connector, and repair if necessary.
NG
Repair
NG
Repair
NG
13A-126
Trouble symptom

13100880361

Inspection procedure No. Communication with all systems is not possible. Communication with engine-ECU only is not possible. The engine warning lamp does not illuminate right after the ignition switch is turned to the ON position. The engine warning lamp remains illuminating and never goes out. No initial combustion (starting impossible) Initial combustion but no complete combustion (starting impossible) Long time to start (improper starting) Idling stability (Improper idling) Unstable idling (Rough idling, hunting) Idling speed is high. (Improper idling speed) Idling speed is low. (Improper idling speed) Idling stability (Engine stalls) When the engine is cold, it stalls at idling. (Die out) When the engine becomes hot, it stalls at idling. (Die out) The engine stalls when starting the car. (Pass out) The engine stalls when decelerating. Driving Hesitation, sag or stumble The feeling of impact or vibration when accelerating The feeling of impact or vibration when decelerating Poor acceleration Surge Knocking Dieseling Too high CO and HC concentration when idling Low alternator output voltage (approx. 12.3 V) Idling speed is improper when A/C is operating Fans (radiator fan, A/C condensor fan) are inoperative 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Reference page
Communication with MUT-II is II impossible. Engine warning lamp and related parts
13A-128 13A-129 13A-130 13A-130 13A-131 13A-132 13A-133 13A-134 13A-135 13A-136 13A-137 13A-138 13A-139 13A-139 13A-140 13A-140 13A-141 13A-141 13A-142 13A-142 13A-142 13A-143 13A-144 13A-144 13A-145
Starting
MPI <6A1> - Troubleshooting PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)

Items Starting Wont start Fires up and dies Hard starting Idling stability Hunting Rough idle Symptom
13A-127
The starter is used to crank the engine, but there is no combustion within the cylinders, and the engine wont start. There is combustion within the cylinders, but then the engine soon stalls. Engine starts after cranking a while. Engine speed doesnt remain constant; changes at idle. Usually, a judgement can be based upon the movement of the tachometer pointer, and the vibration transmitted to the steering wheel, shift lever, body, etc. This is called rough idle.
Incorrect idle speed The engine doesnt idle at the usual correct speed. Engine stall (Die out) Engine stall (Pass out) Driving Hesitation Sag The engine stalls when the foot is taken from the accelerator pedal, regardless of whether the vehicles is moving or not. The engine stalls when the accelerator pedal is depressed or while it is being used. Hesitation is the delay in response of the vehicle speed (engine speed) that occurs when the accelerator is depressed in order to accelerate from the speed at which the vehicle is now traveling, or a temporary drop in vehicle speed (engine speed) during such acceleration. Serious hesitation is called sag.
Hesitation Normal Vehicle Initial acspeed celerator pedal depression Sag
Time
Poor acceleration
Poor acceleration is inability to obtain an acceleration corresponding to the degree of throttle opening, even though acceleration is smooth, or the inability to reach maximum speed. Engine speed increase is delayed when the accelerator pedal is initially depressed for acceleration.
Stumble
Vehicle speed
Normal Initial accelerator pedal depression Idling Time Stumble
13A-128
Items Driving Shock Surge Knocking Stopping Run on (Dieseling)

Symptom The feeling of a comparatively large impact or vibration when the engine is accelerated or decelerated. This is repeated surging ahead during constant speed travel or during variable speed travel. A sharp sound like a hammer striking the cylinder walls during driving and which adversely affects driving. The condition in which the engine continues to run after the ignition switch is turned to OFF. Also called Dieseling.

Probable cause
Measure at the diagnostic connector (16-pin) C-20. D Voltage between 16 and earth OK: Battery voltage OK
Check the following connectors: C-66, (C-63, C-132, C-141) <L.H.>, (C-62, C-14) <R.H.> OK Check trouble symptom.
Repair
NG
Check the harness wire between the power supply and diagnostic connector (16 pin), and repair if necessary.
Measure at the diagnostic connector (16-pin) C-20. D Continuity between 4 and earth D Continuity between 5 and earth OK: Continuity OK Replace the MUT-II.
NG
Check the harness wire between the diagnostic connector (16-pin) and earth, and repair if necessary.

INSPECTION PROCEDURE 2 MUT-II communication with engine-ECU is impossible.
One of the following causes may be suspected. D No power supply to engine-ECU. D Defective earth circuit of engine-ECU. D Defective engine-ECU. D Improper communication line between engine-ECU and MUT-II
13A-129
Probable cause
D D D D D Malfunction of engine-ECU power supply circuit Malfunction of engine-ECU Malfunction of immobilizer-ECU Open circuit between immobilizer-ECU and diagnosis connector Open circuit between engine-ECU and immobilizerECU
Is communication possible between the MUT-II and the immobilizerECU? Yes Check the following connectors: C-37, C-81, C-68 OK Check trouble symptom. NG Check the harness wire between engine-ECU and diagnosis connector. OK Check the harness wire between engine-ECU and immobilizerECU. NG Repair
No
Check the diagnosis line between the immobilizer-ECU and the MUT-II, and repair if necessary. (Refer to GROUP 54 - Ignition Key and Immobilizer.) Repair
NG
NG
Repair
OK
Check the harness wire between engine-ECU and earth. OK
NG
Repair
Check the power supply and ignition switch-IG system. (Refer to P.13A-145, INSPECTION PROCEDURE 26.)
13A-130
The engine warning lamp does not illuminate right after the ignition switch is turned to the ON position.
Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp to illuminate for five seconds immediately after the ignition switch is turned to ON. If the engine warning lamp does not illuminate immediately after the ignition switch is turned to ON, one of the malfunctions listed at right has probably occurred. NG
Probable cause
D D D Burnt-out bulb Defective warning lamp circuit Malfunction of the engine-ECU
MUT-II Data list 16 Engine-ECU power supply voltage (Refer to P.13A-163.) OK Measure at the engine-ECU connector C-35. D Disconnect the connector, and measure at the harness side. D Earth the terminal No. 36. OK: The engine warning lamp illuminates. NG Check a burnt-out bulb. OK Measure at the combination meter connector D-03. D Disconnect the connector, and measure at the harness side. D Voltage between 4 and earth (Ignition switch: ON) OK: System voltage OK Check the following connectors: D-03, C-90, C-35 OK Check trouble symptom. NG
Check the engine-ECU power supply and earth circuit. (Refer to P.13A-158, INSPECTION PROCEDURE 46.) NG
OK
Check the following connector: C-35. OK Check trouble symptom. NG Replace the engine-ECU.
Repair
Replace NG
Check the engine warning lamp power supply circuit, and repair if necessary.
NG
Repair
NG
Check the harness wire between combination meter and engineECU, and repair if necessary.
In cases such as the above, the cause is probably that the engine-ECU is detecting a problem in a sensor or actuator, or that one of the malfunctions listed at right has occurred. Yes No Measure at the combination meter connector D-03. D Disconnect the connector, and measure at the harness side. D Disconnect the engine-ECU connector D Continuity between 16 and earth OK: No continuity OK Replace the engine-ECU.
Probable cause
D D Short-circuit between the engine warning lamp and engine-ECU Malfunction of the engine-ECU
Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES Check the harness wire between combination meter and engineECU connector, and repair if necessary.
NG

INSPECTION PROCEDURE 5 No initial combustion (starting impossible)
In cases such as the above, the cause is probably that a spark plug is defective, or that the supply of fuel to the combustion chamber is defective. In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel.
13A-131
Probable cause
D D D D D D Malfunction of the ignition system Malfunction of the fuel pump system Malfunction of the injectors Malfunction of the engine-ECU Malfunction of the immobilizer system Foreign materials in fuel
Check battery voltage when cranking. OK: 8 V or higher OK Is immobilizer-ECU diagnosis code displayed? No MUT-II: Inspection of no initial combustion. (Refer to P.13A-152, INSPECTION PROCEDURE 38.) OK Can any sound be heard from the injectors when cranking? OK Ignition system: Inspection of no initial combustion. (Refer to P.13A-153, INSPECTION PROCEDURE 39.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check if the injectors are clogged. D Check if foreign materials (water, alcohol, etc.) got into fuel. D Check the compression pressure. D Check the immobilizer system.
NG
Yes
Check the immobilizer. (Refer to GROUP 54 - Ignition Key and Immobilizer.)
NG
Check the injector system. (Refer to P.13A-120, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.)
13A-132
Initial combustion but no complete combustion (starting impossible)

In such cases as the above, the cause is probably that the spark plugs are generating sparks but the sparks are weak, or the initial mixture for starting is not appropriate.
Probable cause
D D D D D Malfunction of the ignition system Malfunction of the injector system Foreign materials in fuel Poor compression Malfunction of the engine-ECU
Check battery voltage when cranking. OK: 8 V or higher OK MUT-II: Check if uncompleted combustion occurs. (Refer to P.13A-153, INSPECTION PROCEDURE 40.) OK Can any sound be heard from the injectors when cranking? OK Is starting good if the engine is cranked with the accelerator pedal slightly depressed? No
NG
NG
Check the injector system, (Refer to P.13A-120, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.) Check ISC servo for operation sound. (Refer to P.13A-199.) OK D D NG Check the ISC servo system. (Refer to P.13A-151, INSPECTION PROCEDURE 35.)
Yes
Check the ignition timing when cranking. OK: Approx. 5_BTDC OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check if the injectors are clogged. D Check the compression pressure. D Check fuel lines for clogging. D Check if foreign materials (water, alcohol, etc.) got into fuel.
NG

INSPECTION PROCEDURE 7 In takes too long time to start. (Incorrect starting)
In cases such as the above, the cause is probably that the spark is weak and ignition is difficult, the initial mixture for starting is not appropriate, or sufficient compression pressure is not being obtained.
13A-133
Probable cause
D D D D Malfunction of the ignition system Malfunction of the injector system Inappropriate gasoline use Poor compression
Check battery voltage when cranking OK: 8 V or higher OK MUT-II: Check if uncomplete combustion occurs. (Refer to P.13A-153, INSPECTION PROCEDURE 40.) OK Can any sound be heard from the injectors when cranking? OK Check the ignition timing when cranking. OK: Approx. 5_BTDC OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check if the injectors are clogged. D Check the compression pressure. D Check if foreign materials (water, alcohol, etc.) got into fuel.
NG
NG NG
Check the injector system. (Refer to P.13A-120, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.) Check that the crank angle sensor is installed properly.
13A-134
Unstable idling (Rough idling, hunting)

In cases as the above, the cause is probably that the ignition system, air/fuel mixture, idle speed control (ISC) or compression pressure is defective. Because the range of possible causes is broad, inspection is narrowed down to simple items.
Probable cause
D D D D D D D Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the ISC system Malfunction of the purge control solenoid valve system Malfunction of the EGR solenoid valve system Poor compression Drawing air into exhaust system
Were the battery terminals disconnected? No MUT-II Self-Diag code Are diagnosis codes displayed? No Does idling speed fluctuate excessively? No Check the ISC servo for operation sound. (Refer to P.13A-199.) OK Check the injector for operation sound. OK MUT-II: Check if idling speed is unstable. (Refer to P.13A-153, INSPECTION PROCEDURE 41.) OK Check the ignition timing. (Refer to GROUP 11B - On-vehicle Service.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check the purge control system. D Check the EGR control system. D Check the compression pressure. D Check if foreign materials (water, alcohol, etc.) got into fuel. D Check the operation of the power steering control valve.
Yes Yes
After warming-up, let the engine run at idling for 10 minutes. Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES. Check if hunting occurs. (Refer to P.13A-153, INSPECTION PROCEDURE 41.) Check the ISC servo system. (Refer to P.13A-151, INSPECTION PROCEDURE 35.) Check the injector system. (Refer to P.13A-120, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.)
Yes NG NG
NG

INSPECTION PROCEDURE 9 Idling speed is high. (Improper idling speed)
In such cases as the above, the cause is probably that the intake air volume during idling is too great. Yes No Check the ISC servo for operation sound. (Refer to P.13A-199.) OK MUT-II Data list 26 Idle position switch (Refer to P.13A-164.) OK
13A-135
Probable cause
Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES. Check the ISC servo system. (Refer to P.13A-151, INSPECTION PROCEDURE 35.) Check the idle position switch system. (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles without TCL> (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles with TCL>
NG NG
MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-163.) OK MUT-II Data list 28 A/C switch (Refer to P.13A-164.) OK Basic idle adjustment (Refer to P.13A-188.) Check trouble symptom.
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the A/C switch and A/C relay system. (Refer to P.13A-149, INSPECTION PROCEDURE 33.)
NG
NG
13A-136
Idling speed is low. (Improper idling speed)

In cases such as the above, the cause is probably that the intake air volume during idling is too small. Yes No Check the ISC servo for operation sound. (Refer to P.13A-199.) OK MUT-II Data list 26 Idle position switch (Refer to P.13A-164.) OK
Probable cause
Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES. Check the ISC servo system. (Refer to P.13A-151, INSPECTION PROCEDURE 35.) Check the idle position switch system. (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles without TCL> (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles with TCL>
NG NG
MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-163.) OK MUT-II Data list 29 Inhibitor switch (Refer to P.13A-164.) OK Basic idle adjustment (Refer to P.13A-188.) Check trouble symptom.
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the ignition switch ST and inhibitor switch system <A/T>. (Refer to P.13A-148, INSPECTION PROCEDURE 31.)
NG
NG

INSPECTION PROCEDURE 11 When the engine is cold, it stalls at idling. (Die out)
In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate when the engine is cold, or that the intake air volume is insufficient.
13A-137
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the ISC servo system throttle body injector system ignition system
Were the battery terminals disconnected? No MUT-II Self-Diag code Are diagnosis codes displayed? No Does the engine stall right after the accelerator pedal is released? No
Yes Yes
After warming-up, let the engine run at idling for 10 minutes. Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES.
Yes
Clean the throttle valve area. (Refer to P.13A-184.)
Is engine-idling stable after the warming-up? Yes Check the ISC servo for operation sound. (Refer to P.13A-199.) OK Check the injector for operation sound. OK MUT-II Data list 26 Idle position switch (Refer to P.13A-164.) OK
No
Check if the unstable idling (Rough idling, hunting). (Refer to P.13A-134, INSPECTION PROCEDURE 8.) Check the ISC servo system. (Refer to P.13A-151, INSPECTION PROCEDURE 35.) Check the injector system. (Refer to P.13A-120, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.) Check the idle position switch system. (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles without TCL> (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles with TCL>
NG
NG
NG
MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-163.) OK MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-167.) OK Check the fuel pressure. (Refer to P.13A-189.) OK Check the ignition timing. (Refer to GROUP 11B - On-vehicle Service.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check the compression pressure. D Check the engine oil viscosity.
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the EGR control solenoid valve system. (Refer to P.13A-152, INSPECTION PROCEDURE 37.)
NG
NG
13A-138
When the engine is hot, it stalls at idling. (Die out)

In such cases as the above, the cause is probably that ignition system, air/fuel mixture, idle speed control (ISC) or compression pressure is defective. In addition, if the engine suddenly stalls, the cause may also be a defective connector contact.
Probable cause
D D D D D Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the ISC system Drawing air into intake system Improper connector contact
Were the battery terminals disconnected? No MUT-II Self-Diag code Are diagnosis codes displayed? No Check the ISC servo for operation sound. (Refer to P.13A-199.) OK Check the injector for operation sound. OK Does the engine stall right after the accelerator pedal is released? No
Yes Yes
After warming-up, let the engine run at idling for 10 minutes. Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES. Check the ISC servo system. (Refer to P.13A-151, INSPECTION PROCEDURE 35.) Check the injector system. (Refer to P.13A-120, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 41.) Clean the throttle valve area. (Refer to P.13A-184.) Check and adjust the fixed SAS. (Refer to P.13A-187.)
NG
NG
Yes
Does the engine stall easily again? Yes MUT-II: Engine stalling inspection when the engine is warm and idling. (Refer to P.13A-155, INSPECTION PROCEDURE 43.) OK
No
While carrying out an intermittent malfunction simulation test (Refer to GROUP 00 - Points to Note for Intermittent Malfunctions.), check for sudden changes in the signals shown below. D Crank angle sensor signal D Primary and secondary D Air flow sensor signal ignition signal D Injector drive signal D Fuel pump drive signal D Engine-ECU power supply voltage
Check the ignition timing. (Refer to GROUP 11B - On-vehicle Service.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check if the injectors are clogged. D Check the compression pressure. D Check if foreign materials (water, alcohol, etc.) got into fuel.
NG

INSPECTION PROCEDURE 13 The engine stalls when starting the car. (Pass out)
In cases such as the above, the cause is probably misfiring due to a weak spark, or an inappropriate air/fuel mixture when the accelerator pedal is depressed. Yes No MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-167.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check if air was drawn into the intake system. Broken intake manifold gasket Broken or disconnected vacuum hose Improper operation of the PCV valve Broken air intake hose
13A-139
Probable cause
D D Drawing air into intake system Malfunction of the ignition system
Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES. Check the EGR control solenoid valve system. (Refer to P.13A-152, INSPECTION PROCEDURE 37.)
NG
INSPECTION PROCEDURE 14 The engine stalls when decelerating.

In cases such as the above, the cause is probably that the intake air volume is insufficient due to a defective idle speed control (ISC) servo system. Yes Yes
Probable cause
Were the battery terminals disconnected? No MUT-II Self-Diag code Are diagnosis codes displayed? No MUT-II Data list 26 Idle position switch (Refer to P.13A-164.) OK
After warming-up, let the engine run at idling for 10 minutes. Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES. Check the idle position switch system. (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles without TCL> (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles with TCL> Check the throttle position sensor system. (Refer to P.13A-114, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.) Check the vehicle speed sensor system. (Refer to P.13A-119, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)
NG
MUT-II Data list 14 Throttle position sensor (Refer to P.13A-163.) OK MUT-II Data list 45 ISC servo position D Is the idle speed control (ISC) servo position drops to 0 - 2 steps when decelerating (engine r/min less than 1,000)? No MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-167.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Clean the throttle valve area. D Check and adjust the fixed SAS.
NG
Yes
NG
13A-140
INSPECTION PROCEDURE 15 Hesitation, sag or stumble
Probable cause
D D D D D Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the fuel supply system Malfunction of the EGR control solenoid valve system Poor compression
In cases such as the above, the cause is probably that ignition system, air/fuel mixture or compression pressure is defective.
MUT-II Self-Diag code Are diagnosis codes displayed? No Check the injectors for operation sound. OK Check the ignition timing. (Refer to GROUP 11B - On-vehicle Service.) OK MUT-II: Check if hesitation, sag, stumble or poor acceleration occur. (Refer to P.13A-156, INSPECTION PROCEDURE 44.) OK Check the fuel pressure. (Refer to P.13A-189.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check the injector operating sound at the rear bank. D Check the operation vacuum of the traction control (TCL). D Check the operation of the throttle valve. D Check the vacuum tank and vacuum actuator. D Check the EGR control system. D Check the compression pressure. D Check the fuel filter or fuel line for clogging.
Yes
NG
NG
INSPECTION PROCEDURE 16 The feeling of impact or vibration when accelerating

In cases such as the above, the cause is probably that there is an ignition leak accompanying the increase in the spark plug demand voltage during acceleration. Yes No Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check for occurrence of ignition leak.
Probable cause
D Malfunction of the ignition system
Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES.

INSPECTION PROCEDURE 17 The feeling of impact or vibration when decelerating.
Malfunction of the ISC system is suspected. Yes No Check the ISC servo for operation sound. (Refer to P.13A-199.) OK MUT-II Data list 14 Throttle position sensor (Refer to P.13A-163.) OK MUT-II Data list 26 Idle position switch (Refer to P.13A-164.) OK Clean the throttle valve area. (Refer to P.13A-184.) NG
13A-141
Probable cause
Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES. Check the ISC servo system. (Refer to P.13A-151, INSPECTION PROCEDURE 35.) Check the throttle position sensor system. (Refer to P.13A-114, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
NG NG
Check the idle position switch system. (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles without TCL> (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles with TCL>

Defective ignition system, abnormal air-fuel ratio, poor compression pressure, etc. are suspected.
Probable cause
D D D D D Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the fuel supply system Poor compression pressure Clogged exhaust system
MUT-II Self-Diag code Are diagnosis codes displayed? No Check the injectors for operation sound. OK Check the ignition timing. (Refer to GROUP 11B - On-vehicle Service.) OK MUT-II: Check if hesitation, sag, stumble or poor acceleration occur. (Refer to P.13A-156, INSPECTION PROCEDURE 44.) OK Check the fuel pressure. (Refer to P.13A-189.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check the injector operating sound at the rear bank. D Check the operation vacuum of the traction control (TCL). D Check the operation of the throttle valve. D Check the vacuum tank and vacuum actuator. D Check the compression pressure. D Check the fuel filter or fuel line for clogging. D Broken air intake hose D Clogged air cleaner
Yes
NG
NG
13A-142
INSPECTION PROCEDURE 19 Surge
Probable cause
D D D Malfunction of the ignition system Malfunction of air-fuel ratio control system Malfunction of the EGR control solenoid valve system
Defective ignition system, abnormal air-fuel ratio, etc. are suspected.
MUT-II Self-Diag code Are diagnosis codes displayed? No Check the injectors for operation sound. OK Check the ignition timing. (Refer to GROUP 11B - On-vehicle Service.) OK MUT-II: Check if surge occurs. (Refer to P.13-157, INSPECTION PROCEDURE 45.) OK Check the fuel pressure. (Refer to P.13A-189.) OK Check the following items. D Check the ignition coil, spark plugs, spark plug cables. D Check the injector operation sound at the rear bank. D Check the EGR control system.
Yes
NG
NG
INSPECTION PROCEDURE 20 Knocking

In cases as the above, the cause is probably that the detonation control is defective or the heat value of the spark plug is inappropriate. Yes No Does knocking occur when driving with the sensor disconnected? At this time, use the MUT-II to check if the timing is retarded compared to when the detonation sensor connector is connected. Yes Check the following items. D Spark plugs D Check if foreign materials (water, alcohol, etc.) got into fuel.
Probable cause
D D Defective detonation sensor Inappropriate heat value of the spark plug
Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES. Check the detonation sensor system. (Refer to P.13A-120, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 31.)
No
INSPECTION PROCEDURE 21 Dieseling

Fuel leakage from injectors is suspected. Check the injectors for fuel leakage.
Probable cause
D Fuel leakage from injectors

INSPECTION PROCEDURE 22 Too high CO and HC concentration when idling
Abnormal air-fuel ratio is suspected.
13A-143
Probable cause
D D Malfunction of the air-fuel ratio control system Deteriorated catalyst
MUT-II Self-Diag code Are diagnosis codes displayed? No Check the ignition timing. (Refer to GROUP 11B - On-vehicle Service.) OK MUT-II Data list 21 Engine coolant temperature sensor. (Refer to P.13A-163.) OK MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-163.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-164.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-166.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor (front) OK: 600 - 1,000 mV when racing suddenly (Refer to P.13A-162.) OK MUT-II Data list 11 Oxygen sensor (front) OK: Repeat 0 - 400 mV and 600 - 1,000 mV alternately when idling. (Refer to P.13A-162.) NG Check the fuel pressure. (Refer to P.13A-189.) OK Check the following items. D Check the injectors for operation sound. D Check the injectors for fuel leakage. D Check the ignition coil, spark plugs, spark plug cables. D Check the compression pressure. D Check the positive crankcase ventilation system. D Check the purge control system. D Check the EGR control system.
Yes
Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES. Check that the crank angle sensor is installed properly.
NG
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the intake air temperature sensor system. (Refer to P.13A-113, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.) Check the barometric pressure sensor system. (Refer to P.13A-119, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.) Check the oxygen sensor (rear) system. (Refer to P.13A-122, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)
NG
NG
NG
NG
OK
Replace the oxygen sensor (front). Check trouble symptom. NG
Check the trouble symptom. NG Replace the catalytic converter.
13A-144
Low alternator output voltage (approx. 12.3 V)

The alternator may be defective, or malfunctions, which are listed in the right column, may be suspected.
Probable cause
D D D Malfunction of charging system Short circuit in harness between alternator G terminal and engine-ECU Malfunction of engine-ECU NG
Measure at the alternator connector side. B-38 D Connect the connector. (Test harness: MB991519) D Voltage between 1 (black clip) and earth Engine: at idle Radiator fan: does not run Headlamp: OFF ON Brake lamp: OFF ON Rear defogger switch: OFF ON OK: Voltage rises by 0.2 - 3.5 V. OK Check the alternator. (Refer to GROUP 16 - Charging System.)
NG
Measure at the alternator connector. B-38 D Disconnect the connector, and measure at the harness side. D Disconnect the engine-ECU connector. D Continuity between 1 and earth OK: No continuity OK Check the harness wire between the alternator and the engine-ECU connector. OK Replace the engine-ECU.
Check the harness wire between the alternator and the engine-ECU connector, and repair if necessary.
NG
Repair

If the engine-ECU detects that the air conditioner is on, it activates the idle speed control (ISC) servo to control idle-up operation. The A/C-ECU judges if the load caused by air conditioner operation is high or low, and converts it to voltage signal (high or low voltage) and inputs the signal to the engine-ECU. Based on this voltage signal, the engine-ECU controls the idle-up speed (for high or low load). OK
Probable cause
D D D Malfunction of the A/C control system Improper connector contact, open circuit or short-circuited harness wire Malfunction of the engine-ECU
Measure at the engine-ECU connector C-37. D Connect the connector. D Voltage between 57 and earth (Engine: at idle, outside air temperature: 25_C or more) OK: 0 - 3 V [When A/C is MAX. COOL condition (when the load by A/C is high)] System voltage [When A/C is MAX. HOT condition (when the load by A/C is low)] NG Check the A/C system. (Refer to GROUP 55 - On-vehicle Service.)

INSPECTION PROCEDURE 25 Fans (radiator fan, A/C condenser fan) are inoperative
The engine-ECU outputs a duty signal to the fan controller depending on the engine coolant temperature, vehicle speed, and air conditioner switch condition. Based on this signal, the fan controller controls the radiator fan and condenser fan speeds (The more the average voltage at the terminal approaches 5 V, the higher the fan speed become.)
13A-145
Probable cause
D D D D D Malfunction of the fan motor relay Malfunction of the fan motor Malfunction of the fan controller Improper connector contact, open circuit or short-circuited harness wire Malfunction of the engine-ECU NG
Measure at the engine-ECU connector C-33. D Disconnect the connector, and measure at the harness side. D Voltage between 21 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V (Fan rotates at high speed.) D Connect a jumper cable between 21 and earth (Ignition switch: ON) OK: Fan stops OK Check the following connector: C-33 OK Check trouble symptom. NG Replace the engine-ECU. NG
NG
Check the harness wire between the engine-ECU and the fan controller connector. OK Check the radiator fan and condenser fan circuit. (Refer to GROUP 14 Troubleshooting.)
Repair
Repair
INSPECTION PROCEDURE 26 Power supply system and ignition switch-IG system

When an ignition switch ON signal is input to the engine-ECU, the engine-ECU turns the control relay ON. This causes battery voltage to be supplied to the engine-ECU, injectors and air flow sensor.
Probable cause
D D D D D Malfunction of the ignition switch Malfunction of the control relay Improper connector contact, open short-circuited harness wire Disconnected engine-ECU earth wire Malfunction of the engine-ECU circuit or
Check the control relay. (Refer to P.13A-193.) OK Measure at the control relay connector C-31. D Disconnect the connector, and measure at the harness side. D Voltage between 3, 4 and earth OK: System voltage OK Check the engine-ECU power supply and earth circuit. (Refer to P.13A-158, INSPECTION PROCEDURE 46.)
NG NG
Replace NG
Repair
Check the harness wire between battery and control relay connector, and repair if necessary.
13A-146
INSPECTION PROCEDURE 27 Fuel pump system
Probable cause
D D D D NG Malfunction of the fuel pump relay Malfunction of the fuel pump Improper connector contact, open short-circuited harness wire Malfunction of the engine-ECU circuit or
The engine-ECU turns the control relay ON when the engine is cranking or running, and this supplies power to drive the fuel pump.
Check the fuel pump operation. (Refer to P.13A-191.) OK Check the fuel pump relay. (Refer to P.13A-193.) OK Measure at the fuel pump relay connector C-32. D Connect the connector. D Voltage between 1 and earth D MUT-II Actuator test: Fuel pump drive OK: System voltage OK Check the harness wire between fuel pump relay connector and fuel pump drive terminal, and repair if necessary.
Check the fuel pump circuit. (Refer to P.13A-158, INSPECTION PROCEDURE 47.)
NG NG
Replace
Check the fuel pump drive control circuit. (Refer to P.13A-159, INSPECTION PROCEDURE 48.)
INSPECTION PROCEDURE 28 Idle position switch system <Vehicles without TCL>

Probable cause
D D D D D Maladjustment of the accelerator pedal Maladjustment of the fixed SAS Maladjustment of the idle position switch and throttle position sensor Improper connector contact, open circuit or short-circuited harness wire Malfunction of the engine-ECU
Check the idle position switch. (Refer to P.13A-195.) OK Measure at the throttle position sensor connector B-07. D Disconnect the connector, and measure at the harness side. D Voltage between 2 and earth (Ignition switch: ON) OK: 4 V or higher D Continuity between 1 and earth OK: Continuity OK Check the following connector: B-07 OK Check trouble symptom. NG Replace the engine-ECU. NG
NG
Replace the throttle position sensor. NG
NG
Repair
Repair
Check the harness wire between engine-ECU and throttle position sensor connector. OK Replace the engine-ECU. NG Repair

INSPECTION PROCEDURE 29 Idle position switch system <Vehicles with TCL>
13A-147
Probable cause
D D D D D Maladjustment of the accelerator pedal Maladjustment of the fixed SAS Maladjustment of the idle position switch and accelerator pedal position sensor Improper connector contact, open circuit or short-circuited harness wire Malfunction of the engine-ECU
Check the idle position switch. (Refer to P.13A-195.) OK Measure at the accelerator pedal position sensor connector B-41. D Disconnect the connector, and measure at the harness side. D Voltage between 3 and earth (Ignition switch: ON) OK: 4 V or higher D Continuity between 4 and earth OK: Continuity OK Check the following connector: B-41 OK Check trouble symptom. NG Replace the engine-ECU. NG
NG
Replace the accelerator pedal position sensor. NG
NG
Repair
Repair
Check the harness wire between engine-ECU and accelerator pedal position sensor connector. OK Replace the engine-ECU. NG Repair
INSPECTION PROCEDURE 30 Ignition switch-ST system <M/T>

The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine is cranking. The engine-ECU controls fuel injection, etc. during starting based on this input.
Probable cause
D D D Malfunction of ignition switch Improper connector contact, short-circuited harness wire Malfunction of the engine-ECU NG open circuit or
1. NG Measure at the engine-ECU connector C-39. D Disconnect the connector, and measure at the harness side. 2. NG 1. Voltage between 71 and earth (Ignition switch: START) OK: 8V or more 2. Continuity between 91 and earth OK: Continuity OK Check the following connector: C-39 OK Check trouble symptom. NG Replace the engine-ECU. NG
Check the following connector: C-92 OK Check trouble symptom. NG Check harness wire between the engine-ECU and ignition switch connector. OK
Repair
NG
Repair
Repair
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch and Immobilizer system.) Check the harness wire between engine-ECU connector (terminal No. 91) and earth, and repair if necessary.
13A-148
Ignition switch-ST and inhibitor switch system <A/T>

D D The ignition switch-ST inputs a HIGH signal to the engine-ECU while the engine is cranking. The engine-ECU controls fuel injection, etc. during starting based on this input. The inhibitor switch inputs the condition of the select lever, i.e. whether it is in P or N range or in some other range, to the engine-ECU. The engine-ECU controls the idle speed control (ISC) servo based on this input. NG
Probable cause
D D D D Malfunction of ignition switch Malfunction of inhibitor switch Improper connector contact, short-circuited harness wire Malfunction of the engine-ECU. open circuit or
Check the inhibitor switch. (Refer to GROUP 23A - On-vehicle Service.) OK
Replace
1. NG Measure at the inhibitor switch connector B-72. D Disconnect the connector, and measure at the harness side. 1. Voltage between 10 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Continuity between 9 and earth OK: Continuity 3. Voltage between 10 and earth D Ignition switch: START D Disconnect engine-ECU connector. 3. NG OK: System voltage OK Check the following connector: B-72 OK Check trouble symptom. NG Check harness wire between engine-ECU and inhibitor switch connector. OK Replace the engine-ECU. NG NG
Check harness wire between engine-ECU and inhibitor switch connector. OK Replace the engine-ECU.
NG
Repair
Check harness wire between inhibitor switch connector and starter S terminal, and repair if necessary. NG
Repair
following
Repair
OK Check trouble symptom. Repair NG Check harness wire between inhibitor switch and ignition switch connector. OK Check the ignition switch. (Refer to GROUP 54 - Ignition Switch and Immobilizer system.) NG
Repair

INSPECTION PROCEDURE 32 Power steering fluid pressure switch system
The presence or absence of power steering load is input to the engine-ECU. The engine-ECU controls the idle speed control (ISC) servo based on this input.
13A-149
Probable cause
D D D Malfunction of power steering fluid pressure switch Improper connector contact, open circuit or short-circuited harness wire Malfunction of the engine-ECU
Check the power steering fluid pressure switch. (Refer to GROUP 37A - On-vehicle Service.) OK Measure at the power steering fluid pressure switch connector B-76. D Disconnect the connector, and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: B-76 OK Check trouble symptom. NG Replace the engine-ECU. NG
NG
Replace
NG
Check the following connector: C-35 OK Check trouble symptom. NG Check harness wire between engine-ECU and power steering fluid pressure switch connector. OK Replace the engine-ECU.
NG
Repair
Repair
NG
Repair
INSPECTION PROCEDURE 33 A/C switch and A/C relay system

When an A/C ON signal is input to the engine-ECU, the engine-ECU carries out control of the idle speed control (ISC) servo, and also operates the A/C compressor magnetic clutch.
Probable cause
D D D D NG Malfunction of A/C control system Malfunction of A/C switch Improper connector contact, open short-circuited harness wire Malfunction of the engine-ECU circuit or
Check the A/C compressor relay. (Refer to GROUP 55 - On-vehicle Service.) OK
Replace
NG Measure at the engine-ECU connectors C-33, C-35. D Disconnect the connector, and measure at the harness side. D Voltage between 8 and earth, and 45 and earth (Ignition switch: ON) OK: 0 - 3 V (A/C switch: OFF) OK System voltage (A/C switch: ON) D Short circuit between 8 and earth (Ignition switch: ON, A/C switch: ON) OK: A/C compressor clutch turns on.
Check the following connectors: C-33, C-35 OK Check trouble symptom. NG Replace the engine-ECU.
NG
Replace
13A-150
INSPECTION PROCEDURE 34 Ignition circuit system
Probable cause
D D D D Malfunction of ignition switch. Malfunction of power transistor Improper connector contact, short-circuited harness wire Malfunction of the engine-ECU NG open circuit or
The engine-ECU interrupts the ignition coil primary current by turning the power transistor inside the engine-ECU ON and OFF.
1. NG Measure at the distributor connector B-42. D Disconnect the connector and measure at the harness side. 1. Voltage between 1 and earth (Ignition switch: ON) 2. NG OK: System voltage 2. Continuity between 4 and earth OK: Continuity OK Check ignition coil and power transistor unit circuit. (Refer to P.13A-161, INSPECTION PROCEDURE 52.)
Check the following connectors: C-92, C-131 OK Check trouble symptom. NG Check the harness wire between distributor and ignition switch connector. OK
Repair
NG
Repair
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) Check the harness wire between distributor connector and earth, and repair if necessary.

INSPECTION PROCEDURE 35 Idle speed control (ISC) servo (Stepper motor) system
The engine-ECU controls the intake air volume during idling by opening and closing the servo valve located in the bypass air passage.
13A-151
Probable cause
D D D Malfunction of ISC servo Improper connector contact, short-circuited harness wire Malfunction of the engine-ECU open circuit or
Check the ISC servo (Refer to P.13A-199.) OK
NG
Replace
Measure at the ISC servo connector B-10. D Disconnect the connector and measure at the harness side. D Voltage between 2 and earth, and 5 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-33. D Disconnect the connector, measure at the harness side. D Voltage between each of 4, 5, 17, 18 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-33 OK Check trouble symptom. NG
NG
Check the harness wire between control relay and ISC servo connector, and repair if necessary.
NG
NG
Repair
Repair
Check harness wire between engine-ECU and ISC servo connector, and repair if necessary. NG Replace the engine-ECU.
INSPECTION PROCEDURE 36 Purge control solenoid valve system

The purge control solenoid valve controls the purging of air from the canister located inside the intake manifold.
Probable cause
Check the purge control solenoid valve. (Refer to GROUP 17 - Emission Control System.) OK Measure at the purge control solenoid valve connector B-04. D Disconnect the connector and measure at the harness side. D Voltage between 2 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-33. D Disconnect the connector and measure at the harness side. D Voltage between 24 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-33 OK Check trouble symptom. NG Replace the engine-ECU. NG
Replace
NG
NG
NG
Repair
Repair
13A-152
EGR control solenoid valve system

The EGR control solenoid valve is controlled by the negative pressure resulting from EGR operation leaking to port A of the throttle body.
Probable cause
Check the EGR control solenoid valve. (Refer to GROUP 17 - Emission Control System.) OK Measure at the EGR control solenoid valve connector B-06. D Disconnect the connector and measure at the harness side. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-33. D Disconnect the connector and measure at the harness side. D Voltage between 6 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-33 OK Check trouble symptom. NG Replace the engine-ECU. NG Repair
Replace
NG
NG
NG
Repair
INSPECTION PROCEDURE 38 MUT-II: Inspection of no initial combustion

MUT-II Data list 16 Voltage of engine-ECU power source (Refer to P.13A-163.) OK Does the camshaft rotate at the engine cranking? (When oil filler cap is removed.) Yes MUT-II Self-Diag code Are diagnosis codes displayed? No MUT-II Data list 22 Crank angle sensor OK: Cranking speed is displayed. OK MUT-II Actuator test 07 Fuel pump (Refer to P.13A-167.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-163.) NG Check the power supply and ignition switch-IG system. (Refer to P.13A-145, INSPECTION PROCEDURE 26.) Check timing belt for breakage.
No
Yes
Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODES. Check the crank angle sensor system. (Refer to P.13A-116, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 22.) Check the fuel pump system. (Refer to P.13A-146, INSPECTION PROCEDURE 27.) Check the engine coolant temperature sensor system. (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.)
No
NG
NG

INSPECTION PROCEDURE 39 Ignition system: Inspection of no initial combustion.
Does the engine tachometer display the cranking speed? D Set the tachometer of primary voltage detection type. OK Check the ignition timing when cranking. OK: Approx. 5_BTDC NG
13A-153
Check the ignition circuit system (Refer to P.13A-150, INSPECTION PROCEDURE 34.) Check the installation condition of crank angle sensor and timing belt cover.
NG
INSPECTION PROCEDURE 40 MUT-II: Check if uncomplete combustion occurs.

MUT-II Self-Diag code Are diagnosis codes displayed? No MUT-II Actuator test 07 Fuel pump (Refer to P.13A-167.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-163.) OK MUT-II Data list 18 Ignition switch-ST (Refer to P.13A-163.) NG Yes Refer to P.13A-111, INSPECTION CHART FOR DIAGNOSIS CODE Check the fuel pump system. (Refer to P.13A-146, INSPECTION PROCEDURE 27.) Check the engine coolant temperature sensor system. (Refer to P.13A-115, INSPECTION PROCEDURES FOR DIAGNOSIS CODE 21.) Check (Refer Check (Refer the ignition switch-ST system <M/T>. to P.13A-147, INSPECTION PROCEDURE 30.) the ignition switch-ST and inhibitor switch system <A/T>. to P.13A-148, INSPECTION PROCEDURE 31.)
NG
NG
INSPECTION PROCEDURE 41 Check if hunting occurs.

Clean the throttle body. (Refer to P.13A-184.)
Check trouble symptom. NG Inspect the intake of air into the air intake system D Broken intake manifold gasket D Broken air intake hose D Broken vacuum hose D Positive crankcase ventilation valve does not operate.
13A-154
MUT-II: Check if idling speed is unstable.

MUT-II Data list 26 Idle position switch (Refer to P.13A-164.) OK NG Check the idle position switch system. (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles without TCL> (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles with TCL> Check the intake air temperature sensor system. (Refer to P.13A-113, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.) Check the barometric pressure sensor system. (Refer to P.13A-119, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 25.)
MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-163.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-164.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-163.) OK MUT-II Actuator test 08 Purge control solenoid valve (Refer to P.13A-167.) OK MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-167.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-166.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor (front) OK: 600 - 1,000 mV during sudden racing OK MUT-II Data list 11 Oxygen sensor (front) OK: Changes between 0 - 400 mV and 600 - 1,000 mV during idling OK MUT-II Data list 27 Power steering fluid pressure switch (Refer to P.13A-164.) OK
NG
NG
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the purge control solenoid valve system (Refer to P.13A-151, INSPECTION PROCEDURE 36.)
NG
NG
NG
NG
NG
Check the fuel pressure. (Refer to P.13A-189.)
OK
NG
1. Inspect the intake of air into the air intake system. D Broken intake manifold gasket D Broken vacuum hose D PCV valve does not operate. D Broken air intake hose 2. Check the injector for clog.
MUT-II Data list 28 A/C switch (Refer to P.13A-164.) OK MUT-II Data list 29 Inhibitor switch (Refer to P.13A-164.) OK MUT-II Data list 45 ISC Servo position (Refer to P.13A-166.)
NG
Check the A/C switch and A/C relay system. (Refer to P.13A-149. INSPECTION PROCEDURE 33.) Check the ignition switch-ST and inhibitor switch system. <A/T> (Refer to P.13A-148, INSPECTION PROCEDURE 31.) Adjust the basic idle speed. (Refer to P.13A-188.)
NG
NG

INSPECTION PROCEDURE 43 MUT-II: Engine stalling inspection when the engine is warmed up and idling.
MUT-II Data list 26 Idle position switch (Refer to P.13A-164.) OK NG
13A-155
Check the idle position switch system. (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles without TCL> (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles with TCL> Check the intake air sensor system. (Refer to P.13A-113, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-163.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-164.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-163.) OK MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-167.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-166.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor (front) OK: Changes between 600 - 1,000 mV during sudden racing OK MUT-II Data list 11 Oxygen sensor (front) OK: Changes between 0 - 400 mV and 600 - 1,000 mV during idling OK MUT-II Data list 27 Power steering fluid pressure switch (Refer to P.13A-164.) OK
NG
NG
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the EGR control solenoid valve system. (Refer to P.13A-152, INSPECTION PROCEDURE 37.) Check the oxygen sensor (rear) system. (Refer to P.13A-122, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)
NG
NG
NG
NG
OK
NG
MUT-II Data list 28 A/C switch (Refer to P.13A-164.) OK MUT-II Data list 29 Inhibitor switch (Refer to P.13A-164.) OK MUT-II Data list 34 Air flow sensor reset signal (Refer to P.13A-165.) OK MUT-II Data list 45 ISC servo position (Refer to P.13A-166.)
NG
Check the A/C switch and A/C relay system. (Refer to P.13A-149, INSPECTION PROCEDURE 33.) Check the ignition switch-ST and inhibitor switch system. <A/T> (Refer to P.13A-148, INSPECTION PROCEDURE 31.) Check the air flow sensor system. (Refer to P.13A-113, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 12.) Adjust the basic idle speed. (Refer to P.13A-188.)
NG
NG
NG
13A-156
MUT-II: Check if hesitation, sug, stumble or poor acceleration occurs.

MUT-II Data list 26 Idle position switch (Refer to P.13A-164.) OK NG Check the idle position switch system. (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles without TCL> (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles with TCL> Check the intake air sensor system. (Refer to P.13A-113, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-163.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-164.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-163.) OK MUT-II Data list 14 Throttle position sensor (Refer to P.13A-163.) OK MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-167.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-166.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor (front) OK: Changes between 600 - 1,000 mV during sudden racing OK MUT-II Data list 11 Oxygen sensor (front) OK: Changes between 0 - 400 mV and 600 - 1,000 mV during idling OK
NG
NG
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSTIC CODE 21.) Check the throttle position sensor system. (Refer to P.13A-114, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
NG
NG
NG
Check the oxygen sensor (rear) system. (Refer to P.13A-122, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 59.)
NG
NG
OK
MUT-II Actuator test 15 Vacuum control solenoid valve <Vehicles with TCL> (Refer to P.13A-167.) OK MUT-II Actuator test 16 Ventilation control solenoid valve <Vehicles with TCL> (Refer to P.13A-167.)
NG
Check the vacuum control solenoid valve system. (Refer to P.13A-124, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 71.) Check the ventilation control solenoid valve system. (Refer to P.13A-125, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 72.)
NG

INSPECTION PROCEDURE 45 MUT-II: Check if surge occurs.
MUT-II Data list 26 Idle position switch (Refer to P.13A-164.) OK NG
13A-157
Check the idle position switch system. (Refer to P.13A-146, INSPECTION PROCEDURE 28.) <Vehicles without TCL> (Refer to P.13A-147, INSPECTION PROCEDURE 29.) <Vehicles with TCL> Check the intake air sensor system. (Refer to P.13A-113, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 13.)
MUT-II Data list 13 Intake air temperature sensor (Refer to P.13A-163.) OK MUT-II Data list 25 Barometric pressure sensor (Refer to P.13A-164.) OK MUT-II Data list 21 Engine coolant temperature sensor (Refer to P.13A-163.) OK MUT-II Data list 14 Throttle position sensor (Refer to P.13A-163.) OK MUT-II Actuator test 10 EGR control solenoid valve (Refer to P.13A-167.) OK MUT-II Data list 59 Oxygen sensor (rear) (Refer to P.13A-166.) D Transmission: 2nd gear <M/T>, L range <A/T> D Driving with throttle widely open OK: 600 - 1,000 mV OK MUT-II Data list 11 Oxygen sensor (front) OK: Changes between 600 - 1,000 mV during sudden racing OK MUT-II Data list 11 Oxygen sensor (front) OK: Changes between 0 - 400 mV and 600 - 1,000 mV during idling
NG
NG
NG
Check the engine coolant temperature sensor system. (Refer to P.13A-115, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 21.) Check the throttle position sensor system. (Refer to P.13A-114, INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14.)
NG
NG
NG
NG
NG
OK
13A-158
Check the engine-ECU power supply and earth circuit.

Measure the engine-ECU connectors, C-33, C-35, C-39. D Disconnect the connector and measure at the harness side 1. Voltage between 82 and earth (Ignition switch: ON) OK: System voltage 2. Voltage between 38 and earth OK: System voltage 3. Voltage between 12, 25 and earth (Ignition switch: ON) OK: System voltage (when the terminal 38 is earthed) 4. Continuity between 13, 26 and earth OK: Continuity 5. Voltage between 80 and earth OK: System voltage OK Check the following connectors: C-33, C-35, C-39 OK Check trouble symptom. NG Replace the engine-ECU. Check the following connectors: C-47, C-83, C-66, (C-63, C-132, C-141) <L.H.>, (C-62, C-14) <R.H.> OK Check trouble symptom NG Check the harness wire between engine-ECU and battery, and repair if necessary. NG Repair Check the harness wire between engine-ECU and control relay connector, and repair if necessary. Check the harness wire between engine-ECU and earth, and repair if necessary. NG 1. NG Check the following connectors: C-92, C-131 OK Check trouble symptom. OK Check the harness wire between engine-ECU and ignition switch connector. OK Check the ignition switch. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) NG NG Repair
2, 3. NG 4. NG 5. NG
Repair
Repair
INSPECTION PROCEDURE 47 Check fuel pump circuit.

NG NG
Measure at the fuel pump connector E-16. D Disconnect the connector and measure at the harness side. D Continuity between 2 and earth OK: Continuity OK Check the following connectors: E-16, E-11, C-123, C-92, B-09 OK Check trouble symptom. NG Check the harness wire between terminal for fuel pump drive and fuel pump connector. OK Replace the fuel pump.
Check the following connectors: E-11 OK Check trouble symptom NG
Repair
NG
Check the harness wire between fuel pump and earth, and repair if necessary. Repair
NG
Repair

INSPECTION PROCEDURE 48 Check the fuel pump drive control circuit.
Measure at the fuel pump relay connector C-32. D Disconnect the connector and measure at the harness side. D Voltage between 3, 4 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-33. D Disconnect the connector and measure at the harness side. D Voltage between 22 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-33 OK NG Repair Check trouble symptom. NG Replace the engine-ECU. Check the following connector: C-32 OK Check trouble symptom. NG NG Repair NG NG Check the following connectors: C-92, C-131 OK Check trouble symptom. NG Check the harness wire between fuel pump relay and ignition switch connector. OK NG NG Repair
13A-159
Repair
Check the ignition switch. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.)
Check the harness wire between engine-ECU and fuel pump relay connector, and repair if necessary.
INSPECTION PROCEDURE 49 Check air flow sensor (AFS) control circuit.

1. NG Measure at the air flow sensor connector B-12. D Disconnect the connector and measure at the harness side. 1. Voltage between 4 and earth (Ignition switch: ON) OK: System voltage 2, 3. NG 2. Voltage between 3 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V 3. Continuity between 5 and earth OK: Continuity OK Check the following connector: B-12 OK NG Repair Check trouble symptom. NG Replace the air flow sensor. Check the harness wire between the air flow sensor and control relay connector, and repair if necessary. NG
Check the following connector: C-39 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and air flow sensor connector. OK Replace the engine-ECU.
Repair
NG
Repair
13A-160
Check throttle position sensor (TPS) output circuit.

Measure at the engine-ECU connector C-39. D Connect the connector. D Voltage between 84 and earth (Ignition switch: ON) OK: 0.3 - 1.0 V (Throttle valve at idle position) 4.5 - 5.5 V (Throttle valve fully open) NG NG OK Check the following connector: C-39 OK Check trouble symptom. NG Replace the engine-ECU. Check the following connector: B-07 OK Check trouble symptom. NG Check the harness wire between engine-ECU and throttle position sensor connector, and repair if necessary. Repair NG Repair
INSPECTION PROCEDURE 51 Check injector control circuit

Measure at the engine-ECU connector C-33. D Disconnect the connector and measure at the harness side. D Voltage between 1, 2, 3, 14, 15, 16 and earth (Ignition switch: ON) OK: System voltage OK NG Check the following connectors: B-02, B-03, B-05, B-36, B-40, B-44 OK Check trouble symptom. NG Check the harness between engine-ECU and injector connector, and repair if necessary. Check the following connector: C-33 OK Check trouble symptom. NG Replace the engine-ECU. NG Repair NG Repair

INSPECTION PROCEDURE 52 Check ignition coil and power transistor unit circuit.
Check the ignition coil. (Refer to GROUP 16 Ignition System.) OK Check the power transistor unit. (Refer to GROUP 16 Ignition System.) OK 1. NG Measure at the distributor connector B-42. D Disconnect the connector and measure at the harness side. 1. Voltage between 3 and earth (Ignition switch: START) OK: 2 - 7 V 2. NG 2. Continuity between 2 and earth OK: No continuity OK Check the following connectors, and repair if necessary. B-42 Check the following connector: C-33 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the distributor connector. OK Replace the engine-ECU. NG NG Repair NG Replace NG Replace
13A-161
Repair
As short circuit occurs between distributor and combination meter (tachometer), check the harness wire, and repair if necessary.
13A-162

13100890296
DATA LIST REFERENCE TABLE
Caution When shifting the select lever to D range, the brakes should be applied so that the vehicle does not move forward. NOTE *1. In a new vehicle [driven approximately 500 km or less], the air flow sensor output frequency is sometimes 10% higher than the standard frequency. *2. The idle position switch normally turns off when the voltage of the throttle position sensor is 50 100 mV higher than the voltage at the idle position. If the throttle position switch turns back on after the throttle position sensor voltage has risen by 100 mV and the throttle valve has opened, the idle position switch and the throttle position sensor need to be adjusted. *3. The injector drive time represents the time when the cranking speed is at 250 r/min or below when the power supply voltage is 11 V. *4. In a new vehicle [driven approximately 500 km or less], the injector drive time is sometimes 10% longer than the standard time. *5. In a new vehicle [driven approximately 500 km or less], the step of the stepper motor is sometimes 30 steps greater than the standard value.
Item No. 11 Inspection item Oxygen sensor (front) Inspection contents Normal condition Inspection procedure No. Code No. 11 Reference page 13A-112
Engine:After having warmed up Air/fuel mixture is made leaner when decelerating, and is made richer when racing. Engine:After having warmed up The oxygen sensor signal is used to check the air/fuel mixture ratio, and control condition is also checked by the ECU.
When at 4,000 r/min, engine is suddenly decelerated When engine is suddenly raced Engine is idling
200 mV or less
600 - 1,000 mV
400 mV or less (Changes) 600 - 1,000 mV
2,500 r/min
12
Air flow sensor*1
D D
Engine coolant temperature: 80 - 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T: P range)
Engine is idling 2,500 r/min Engine is raced
14 - 40 Hz 42 - 82 Hz Frequency increases in response to racing

Item No. 13 Inspection item Intake air temperature sensor Inspection contents Normal condition Inspection procedure No. Code No. 13
13A-163
When intake air temperature is - 20_C When intake air temperature is 0_C When intake air temperature is 20_C When intake air temperature is 40_C When intake air temperature is 80_C
- 20_C
0_C 20_C 40_C 80_C 300 - 1,000 mV Increases in proportion to throttle opening angle 4,500 - 5,500 mV System voltage Procedure No. 25 Procedure No. 30 <M/T> Procedure No. 31 <A/T> Code No. 21 13A-145 Code No. 14 13A-114
14
Ignition switch: ON
Set to idle position Gradually open
Open fully 16 Power supply voltage Cranking signal (ignition switch-ST) Ignition switch: ON
18
Ignition switch: ON
Engine: Stopped
OFF
Engine: Cranking
ON
13A-147 <M/T> 13A-148 <M/T>
21
When engine coolant temperature is - 20_C When engine coolant temperature is 0_C When engine coolant temperature is 20_C When engine coolant temperature is 40_C When engine coolant temperature is 80_C
- 20_C
13A-115
0_C
20_C
40_C
80_C
13A-164
Item No. 22 Inspection item Crank angle sensor

Inspection contents Normal condition Inspection procedure No. Code No. 22 Reference page 13A-116
D D D D
Engine: Cranking Tachometer: Connected Engine: Idling Idle position switch: ON
Compare the engine speed readings on the tachometer and the MUT-II. When engine coolant temperature is - 20_C When engine coolant temperature is 0_C When engine coolant temperature is 20_C When engine coolant temperature is 40_C When engine coolant temperature is 80_C
Accord
1,300 - 1,500 rpm
1,300 - 1,500 rpm
1,300 - 1,500 rpm
1,100 - 1,300 rpm
550 - 750 rpm
25
Ignition switch: ON
At altitude of 0 m At altitude of 600 m At altitude of 1,200 m At altitude of 1,800 m
101 kPa 95 kPa 88 kPa 81 kPa ON
Code No. 25
13A-119
26
Ignition switch: ON Check by operating accelerator pedal repeatedly
Throttle valve: Set to idle position
Throttle valve: Slightly open
OFF*2
Procedure No.28 <Vehicles without TCL> Procedure No.29 <Vehicles with TCL> Procedure No. 32
13A-146 <Vehicles without TCL> 13A-147 <Vehicles with TCL>
27
Power steering fluid pressure switch A/C switch
Engine: Idling
Steering wheel stationary Steering wheel turning
OFF ON OFF ON P or N D, 2, L or R
13A-149
28
Engine: Idling (when A/C switch is ON, A/C compressor should be operating.) Ignition switch: ON
A/C switch: OFF A/C switch: ON P or N D, 2, L or R
Procedure No. 33
13A-149
29
Procedure No. 31
13A-148

Item No. 34 Inspection item Air flow sensor reset signal Volumetric efficiency Inspection contents Normal condition Inspection procedure No. Code No.12
13A-165
Engine: After having warmed up
Engine is idling 2,000 r/min
ON OFF 15 - 35 % 15 - 35 % Volumetric efficiency increases in response to racing Engine speeds displayed on the MUT-II and tachometer are identical. 23 - 80 ms
37
D D
Engine coolant temperature: 80 - 95 _C Lights, power cooling fan and all accessories: OFF Transmission: Neutral (A/T: P range)
Engine is idling 2,000 r/min Engine is suddenly raced
38
Crank angle sensor
D D
Engine: Cranking [reading is possible at 2,000 r/min or less] Tachometer: Connected
41
Injectors *3
Engine: Cranking
When engine coolant temperature is 0_C (injection is carried out for all cylinders simultaneously) When engine coolant temperature is 20_C When engine coolant temperature is 80_C
12 - 40 ms
2.0 - 8.0 ms
Injectors*4
D D
Engine coolant temperature: 8095_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T : P range) Engine: After having warmed up Timing lamp is set. (The timing lamp is set in order to check actual ignition timing.)
Engine is idling 2,500 r/min When engine is suddenly raced Engine is idling
2.6 - 3.8 ms 1.8 - 3.0 ms Increases
44
Ignition coils and power transistors
D D
1 - 15_BTDC
2,500 r/min
23 - 43_BTDC
13A-166
Item No. 45 Inspection item ISC (stepper) motor position *5

Inspection contents Normal condition Inspection procedure No. Reference page -
D D
D D D D
Engine coolant temperature: 80 - 95_C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral (A/T : P range) Idle position switch: ON Engine: Idling When A/C switch is ON, A/C compressor should be operating
A/C switch: OFF
2 - 25 STEP
A/C switch: OFF ON
D D
A/C switch: OFF Select lever: N range D range
49
A/C relay
Engine: After having warmed up/Engine is idling
A/C switch: OFF
OFF (Compressor clutch is not operating) ON (Compressor clutch is operating) 600 - 1,000 mV
Procedure No. 33
13A-149
A/C switch: ON
59
Oxygen sensor (rear)
D D
Transmission: 2nd gear <M/T>, L range <A/T> Drive with throttle widely open
3,500 r/min
Code No. 59
13A-122

Item No. 01 02 03 04 05 06 Inspection item Injectors Drive contents Inspection contents Normal condition Inspection procedure No. Code No. 41
13100900364
Cut fuel to No. 1 injector Cut fuel to No. 2 injector Cut fuel to No. 3 injector Cut fuel to No. 4 injector Cut fuel to No. 5 injector Cut fuel to No. 6 injector
Engine: After having warmed up/ Engine is idling (Cut the fuel supply to each injector in turn and check cylinders which dont affect idling.)
Idling condition becomes different (becomes unstable).

Item No. 07 Inspection item Fuel pump Drive contents Inspection contents Normal condition Inspection procedure No. Procedure No. 27
13A-167
Fuel pump operates and fuel is recirculated.
D D
Engine: Cranking Fuel pump: Forced driving Inspect according to both the above conditions.
Pinch the return hose with fingers to feel the pulse of the fuel being recirculated. Listen near the fuel tank for the sound of fuel pump operation.
Pulse is felt.
Sound of operation is heard.
08
Purge control solenoid valve EGR control solenoid valve Vacuum control solenoid valve <Vehicles with TCL> Ventilation control solenoid valve <Vehicles with TCL> Basic ignition timing Fan controller
Solenoid valve turns from OFF to ON.
Ignition switch: ON
Sound of operation can be heard when solenoid valve is driven. Sound of operation can be heard when solenoid valve is driven. Sound of operation can be heard when solenoid valve is driven.
Procedure No. 36
13A-151
10
Ignition switch: ON
Procedure No. 37
13A-152
15
Ignition switch: ON
Code No. 71
13A-124
16
Ignition switch: ON
Sound of operation can be heard when solenoid valve is driven.
Code No. 72
13A-125
17
Set to ignition timing adjustment mode Drive the fan motor
Engine: Idling Timing light is set D Ignition switch: ON
5_BTDC
21
Radiator fan and condenser fan rotate at high speed
Procedure No. 25
13A-145
13A-168
MPI <6A1> - Troubleshooting CHECK AT THE ENGINE-ECU TERMINALS

13100920292
TERMINAL VOLTAGE CHECK CHART 1. Connect a needle-nosed wire probe (test harness: MB991223 or paper clip) to a voltmeter probe. 2. Insert the needle-nosed wire probe into each of the engine-ECU connector terminals from the wire side, and measure the voltage while referring to the check chart. NOTE 1. Make the voltage measurement with the engine-ECU connectors connected. 2. You may find it convenient to pull out the engine-ECU to make it easier to reach the connector terminals. 3. The checks can be carried out off the order given in the chart. Caution Short-circuiting the positive (+) probe between a connector terminal and earth could damage the vehicle wiring, the sensor, engine-ECU or all of them. Be careful to prevent this! 3. If voltmeter shows any division from 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 repair has corrected the problem.

13A-169
Terminal No. Check item 1 14 2 15 3 16 4 17 5 18 6 No. 1 injector No. 2 injector No. 3 injector No. 4 injector No. 5 injector No. 6 injector Stepper motor coil <A1> Stepper motor coil <A2> Stepper motor coil <B1> Stepper motor coil <B2> EGR control solenoid valve
Check condition (Engine condition) While engine is idling after having warmed up, suddenly depress the accelerator pedal.
Normal condition From 11 - 14 V, momentarily drops slightly
Engine: Soon after the warmed up engine is started
System voltage 0 V (Changes repeatedly)
Ignition switch: ON While engine is idling, suddenly depress the accelerator pedal. D D Engine: Idle speed A/C switch: OFF ON (A/C compressor is operating)
System Voltage From system voltage, momentarily drops System voltage or momentarily 6V or more 0 - 3V 0.3 - 3.0V System voltage
A/C relay
10 12 25 19
Power transistor unit Power supply
Engine r/min: 3,000 r/min Ignition switch: ON
Air flow sensor reset signal Fan controller
Engine: Idle speed Engine r/min: 3,000 r/min When the radiator fan and condenser fan are not operating When the radiator fan and condenser fan are operating
0 - 1V 6 - 9V 0 - 0.3 V 0.7 V or more System voltage 0 - 3V
21
22
Fuel pump relay
Ignition switch: ON Engine: Idle speed
13A-170
Terminal No. Check item 24

Check condition (Engine condition) Ignition switch: ON Running at 3,000 r/min while engine is warming up after having been started. Ignition switch: ON Normal condition System voltage 0 - 3V System voltage
31
Ventilation control solenoid valve <Vehicles with TCL> Vacuum control solenoid valve <Vehicles with TCL> Engine warning lamp
32
Ignition switch: ON
System voltage
36
0 - 3V 9 - 13V (After several seconds have elapsed) System voltage 0 - 3V System voltage 0 - 3V
37
Power steering fluid pressure switch
Engine: Idling after warming up
When steering wheel is stationary When steering wheel is turned
38
Control relay (Power supply) A/C switch 1
Ignition switch: OFF Ignition switch: ON Engine: Idle speed Turn the A/C switch OFF Turn the A/C switch ON (A/C compressor is operating)
45
0 - 3V System voltage
54
Alternator G terminal
D D D D
Engine: Warm, idle (radiator fan: OFF) Headlamp: OFF to ON Rear defogger switch: OFF to ON Brake lamp: ON Engine: Warm, idle (radiator fan: OFF) Headlamp: OFF to ON Rear defogger switch: OFF to ON Brake lamp: ON Engine: Idling Outside air temperature: 25_C or more When A/C is MAX. COOL condition (when the load by A/C is high) When A/C is MAX. HOT condition (When the load by A/C is low)
Voltage rises by 0.2 - 3.5 V.
55
Alternator FR terminal
D D D D
Voltage drops by 0.2 - 3.5 V.
57
A/C switch 2
D D
0 - 3V
System voltage
71
Ignition switch - ST
Engine: Cranking
8V or more

Terminal No. Check item 72 Intake air temperature sensor Check condition (Engine condition) Ignition switch: ON When intake air temperature is 0_C When intake air temperature is 20_C When intake air temperature is 40_C When intake air temperature is 80_C 75 Oxygen sensor (rear) D D D 76 Oxygen sensor (front) Transmission: 2nd gear <M/T>, L range <A/T> Engine r/min: 3,500 r/min or more Driving with the throttle valve widely open
13A-171
Normal condition 3.2 - 3.8V
2.3 - 2.9V
1.5 - 2.1V
0.4 - 1.0V
0.6 - 1.0 V
Engine: Running at 2,500 r/min after warmed up (Check using a digital type voltmeter) Ignition switch: OFF Ignition switch: ON Ignition switch: ON Ignition switch: ON When engine coolant temperature is 0_C When engine coolant temperature is 20_C When engine coolant temperature is 40_C When engine coolant temperature is 80_C
0 0.8V (Changes repeatedly) System voltage 4.5 - 5.5V System voltage 3.2 - 3.8V
80 81 82 83
Backup power supply Sensor impressed voltage Ignition switch - IG Engine coolant temperature sensor
2.3 - 2.9V
1.3 - 1.9V
0.3 - 0.9V
84
Ignition switch: ON
Set throttle valve to idle position Fully open throttle valve
0.3 - 1.0V 4.5 - 5.5V 3.7 - 4.3V 3.2 - 3.8V 0 5V (Changes repeatedly)
85
Ignition switch: ON
When altitude is 0m When altitude is 1,200m
86
D D
Ignition switch: ON Move the vehicle slowly forward
13A-172
Terminal No. Check item 87 Idle position switch

Check condition (Engine condition) Ignition switch: ON Set throttle valve to idle position Slightly open throttle valve Normal condition 0 - 1V 4V or more 0.4 - 3.0V 0.5 - 2.0V 0.4 - 4.0V 1.5 - 2.5V 2.2 - 3.2V
88
Top dead centre sensor
Engine: Cranking Engine: Idle speed
89
Crank angle sensor
Engine: Cranking Engine: Idle speed
90
Air flow sensor
Engine: Idle speed Engine r/min: 2,500r/min
91
Ignition switch: ON
Set selector lever to P or N Set selector lever to Other than P or N
0 - 3V 8 - 14V
13A-173
CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to OFF. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart. NOTE 1. When measuring resistance and checking continuity, a harness for checking contact pin pressure should be used instead of inserting a test probe. 2. Checking need not be carried out in the order given in the chart. Caution If the terminals that should be checked are mistaken, or if connector terminals are not correctly shorted to earth, damage may be caused to the vehicle wiring, sensors, engine-ECU and/or ohmmeter. Be careful to prevent this! 4. If the ohmmeter shows any deviation from the standard value, check the corresponding sensor, actuator and related electrical wiring, and then repair or replace. 5. After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement has corrected the problem. Engine-ECU Harness Side Connector Terminal Arrangement
Terminal No. 1 - 12 14 - 12 2 - 12 15 - 12 3 - 12 16 - 12
Inspection item No. 1 injector No. 2 injector No. 3 injector No. 4 injector No. 5 injector No. 6 injector
13A-174
Terminal No. 4 - 12 17 - 12 5 - 12 18 - 12 6 - 12 24 - 12 13 - Body earth 26 - Body earth 31 - 12 32 - 12 72 - 92 Inspection item

Stepper motor coil (A1) Stepper motor coil (A2) Stepper motor coil (B1) Stepper motor coil (B2) EGR control solenoid valve Purge control solenoid valve Engine-ECU earth Engine-ECU earth Ventilation control solenoid valve <Vehicles with TCL> Vacuum control solenoid valve <Vehicles with TCL> Intake air temperature sensor
36 - 44 W (At 20_C) 36 - 44 W (At 20_C) Continuity (0 W)
36 - 44 W (At 20 _C) 36 - 44 W (At 20 _C) 5.3 - 6.7 kW (When intake air temperature is 0_C) 2.3 - 3.0 kW (When intake air temperature is 20_C) 1.0 - 1.5 kW (When intake air temperature is 40_C) 0.30 - 0.42 kW (When intake air temperature is 80_C)
83 - 92
5.1 - 6.5 kW (When coolant temperature is 0_C) 2.1 - 2.7 kW (When coolant temperature is 20_C) 0.9 - 1.3 kW (When coolant temperature is 40_C) 0.26 - 0.36 kW (When coolant temperature is 80_C)
87 - 92
Continuity (when throttle valve is at idle position) No continuity (when throttle valve is slightly open)
91 - Body earth
Continuity (when select lever is at P or N) No continuity (when select lever is at D, 2, L or R)

Analyzer
13A-175
13100930226

AIR FLOW SENSOR (AFS) Measurement Method 1. Disconnect the air flow sensor connector, and connect the special tool (test harness: MB991709) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to air flow sensor connector terminal 3. Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 90. Standard Wave Pattern Observation conditions

(V) 10 T1 T T2 The time (cycle time) T is reduced when the amount of intake air increases. Times T1 and T2 are equal.
Time
Observation conditions (from conditions above engine speed is increased by racing.)

(V) 10 T
Time
13A-176

Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started. D Example 2 Cause of problem Damaged rectifier or vortex generation column Wave pattern characteristics Unstable wave pattern with non-uniform frequency. However, when an ignition leak occurs during acceleration, the wave pattern will be distorted temporarily, even if the air flow sensor is normal.
Distributor connector
Analyzer
TOP DEAD CENTER SENSOR AND CRANK ANGLE SENSOR Measurement Method 1. Disconnect the distributor connector and connect the special tool (test harness: MB991348) and jumper wire in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to distributor terminal 5 (top dead centre sensor). 3. Disconnect the crank angle sensor connector and connect the special tool (test harness: MD998478) in between. 4. Connect the analyzer special patterns pickup to crank angle sensor terminal 2. Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 88. (When checking the top dead centre sensor signal wave pattern.) 2. Connect the analyzer special patterns pickup to engine-ECU terminal 89. (When checking the crank angle sensor signal wave pattern.)
Special patterns pick-up


13A-177
2 engine revolutions (1 camshaft revolution) Crank angle sensor output wave pattern 75_BTDC 5_BTDC T The time (cycle time) T is reduced when the amount of intake air increases.
35 TDC sensor output wave pattern
85
Time No.1 TDC TDC: Top dead centre No.2 TDC No.3 TDC No.4 TDC No.5 TDC No.6 TDC
13A-178

Analyzer
INJECTOR Measurement Method Measurement at the front bank (No.2, No.4, or No.6 cylinder) 1. Disconnect the injector connector, and then connect the special tool (test harness: MB991348) in between. (Both the power supply side and engine-ECU side should be connected.) 2. Connect the analyzer special patterns pickup to terminal 2 of the injector connector. Measurement at the rear bank (No.1, No.3, or No.5 cylinder) 1. Disconnect the injector intermediate harness connector, and connect the special tool (test harness: MD998464) in between. 2. Connect the probe of the oscilloscope to the following terminal: terminal 2 (the black clip of the special tool) when observing at the No.1 cylinder; terminal 3 (the blue clip) when observing at the No.3 cylinder; terminal 4 (the white clip) when observing at the No.5 cylinder
Analyzer
Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 1. (When checking the No. 1 cylinder.) 2. Connect the analyzer special patterns pickup to engine-ECU terminal 14. (When checking the No. 2 cylinder.) 3. Connect the analyzer special patterns pickup to engine-ECU terminal 2. (When checking the No. 3 cylinder.) 4. Connect the analyzer special patterns pickup to engine-ECU terminal 15. (When checking the No. 4 cylinder.) 5. Connect the analyzer special patterns pickup to engine-ECU terminal 3. (When checking the No. 5 cylinder.) 6. Connect the analyzer special patterns pickup to engine-ECU terminal 16. (When checking the No. 6 cylinder.)

Function Pattern height Variable knob Pattern selector Engine r/min Special patterns Variable Adjust while viewing the wave pattern Display Idle speed
13A-179

(V) Point A
50 Solenoid back electromotive force (Approx. 710 V) Point B Injector drive time Power voltage 0 Drive signal: ON Drive signal: OFF Time
Point B: Injector drive time
D D
The injector drive time will be synchronized with the MUT-II tester display. When the engine is suddenly raced, the drive time will be greatly extended at first, but the drive time will soon match the engine speed.
--- When idling - - When racing
13A-180
Analyzer

STEPPER MOTOR Measurement Method 1. Disconnect the stepper motor connector, and connect the special tool (test harness: MD998463) in between. 2. Connect the analyzer special patterns pickup to the stepper motor-side connector terminal 1 (red clip of special tool), terminal 3 (blue clip), terminal 4 (black clip) and terminal 6 (yellow clip) respectively.
Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 4, connection terminal 5, connection terminal 17, and connection terminal 18 respectively. Standard Wave Pattern Observation conditions
Function Pattern height Pattern selector Engine condition Special patterns High Display When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF to ON (without starting the engine). While the engine is idling, turn the A/C switch to ON. Immediately after starting the warm engine
(V) 30 20 10
The wave pattern appears for an instant, but soon disappears.
Point B Coil reverse electromotive force (Approx. 3 10V)
Point A Induced electromotive force from the motor turning
Stepper motor control signal wave pattern
Time
13A-181
Wave Pattern Observation Points Check that the standard wave pattern appears when the stepper motor is operating. Point A: Presence or absence of induced electromotive force from the motor turning. (Refer to the abnormal wave pattern.)
Contrast with standard wave pattern Induced electromotive force does not appear or is extremely small. Probable cause Motor is malfunctioning
Point B: Height of coil reverse electromotive force

Contrast with standard wave pattern Coil reverse electromotive force does not appear or is extremely small. Probable cause Short in the coil
Examples of Abnormal Wave Pattern D Example 1 Cause of problem Motor is malfunctioning. (Motor is not operating.) Wave pattern characteristics Induced electromotive force from the motor turning does not appear.
Open circuit side
Example 2 Cause of problem Open circuit in the line between the stepper motor and the engine-ECU. Wave pattern characteristics Current is not supplied to the motor coil on the open circuit side. (Voltage does not drop to 0 V.) Furthermore, the induced electromotive force waveform at the normal side is slightly different from the normal waveform.
Normal side
13A-182

Analyzer
IGNITION COIL AND POWER TRANSISTOR D Ignition coil primary signal Refer to GROUP 16 - Ignition System. D Power transistor control signal Measurement Method 1. Disconnect the distributor connector, and connect the special tool (test harness: MB991348) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to distributor connector terminal 3. Alternate Method (Test harness not available) 1. Connect the analyzer special patterns pickup to engine-ECU terminal 10.
Standard Wave Pattern Observation condition

Function Pattern height Pattern selector Engine r/min Special patterns Low Display Approx. 1,200 r/min
(V) Crank angle sensor output wave pattern Compression top dead centre
T: Revolution time corresponding to a crank angle of 180_
6 4 2 0
Power transistor 6 control signal wave pattern 4 2
Point Wave build-up section
q: Spark advance angle
OFF
ON
Dwell section
Time
13A-183
Wave Pattern Observation Points Point: Condition of wave pattern build-up section and maximum voltage (Refer to abnormal wave pattern examples 1 and 2.)
Condition of wave pattern build-up section and maximum voltage Rises from approx. 2V to approx. 4.5V at the top-right 2V rectangular wave Rectangular wave at power voltage Probable cause Normal Open-circuit in ignition primary circuit Power transistor malfunction
--- Normal wave pattern
Examples of Abnormal Wave Patterns D Example 1 Wave pattern during engine cranking Cause of problem
2V
Open-circuit in ignition primary circuit Wave pattern characteristics Top-right part of the build-up section cannot be seen, and voltage value is approximately 2 V too low.
--- Normal wave pattern VB
Example 2 Wave pattern during engine cranking Cause of problem Malfunction in power transistor Wave pattern characteristics Power voltage results when the power transistor is ON.
13A-184
MPI <6A1> - On-vehicle Service
ON-VEHICLE SERVICE
13100100313
THROTTLE BODY (THROTTLE VALVE AREA) CLEANING

1. Start the engine and warm it up until the coolant is heated to 80_C or higher and then stop the engine. 2. Remove the air intake hose from the throttle body.
3. Plug the bypass passage inlet of the throttle body. Caution Do not allow cleaning solvent to enter the bypass passage. 4. Spray cleaning solvent into the valve through the throttle body intake port and leave it for about 5 minutes.
5. Start the engine, race it several times and idle it for about 1 minute. If the idling speed becomes unstable (or if the engine stalls) due to the bypass passage being plugged, slightly open the throttle valve to keep the engine running. 6. If the throttle valve deposits are not removed, repeat steps 4 and 5. 7. Unplug the bypass passage inlet. 8. Attach the air intake hose. 9. Use the MUT-II to erase the self-diagnosis code. 10. Adjust the basic idle speed. (Refer to P.13A-188.) NOTE If the engine hunts while idling after adjustment of the basic idle speed, disconnect the () cable from the battery for 10 seconds or more, and then reconnect it and run the engine at idle for about 10 minutes.
IDLE POSITION SWITCH AND THROTTLE POSITION SENSOR ADJUSTMENT (Vehicles 13100130275 without TCL>
Throttle position sensor (with built-in idle position switch)

<Vehicles without auto-cruise control system> Throttle lever Fixed SAS
13A-185
2. Insert a thickness gauge as follows: <Vehicles without auto-cruise control system> Insert a thickness gauge with a thickness of 0.65 mm between the fixed SAS and the throttle lever.
Thickness gauge Fixed SAS
<Vehicles with auto-cruise control system> Insert a 1.4-mm thick thickness gauge up to approx. 3 mm between the levers shown in the figure. NOTE Do not insert the thickness gauge 3 mm or more. If doing that, the throttle lever opening angle becomes larger than the predetermined angle, causing maladjustment.
Thickness gauge
Free lever
3. Turn the ignition switch to ON (but do not start the engine).
4. Loosen the throttle position sensor mounting bolt, and then turn the throttle position sensor clockwise as far as it will go. 5. Check that the idle position switch is ON at this position. 6. Slowly turn the throttle position sensor counterclockwise and find the point where the idle position switch turns off. Securely tighten the throttle position sensor mounting bolt at this point.
7. Check the throttle position sensor output voltage. Standard value: 400 - 1,000 mV 8. If there is a deviation from the standard value, check the throttle position sensor and the related harness. 9. Remove the thickness gauge. 10. Turn the ignition switch to OFF. 11. Disconnect the MUT-II. When the MUT-II is not used, remove the special tool, and connect the throttle position sensor.
13A-186
MPI <6A1> - On-vehicle Service THROTTLE POSITION SENSOR ADJUSTMENT 13100110040 <Vehicles with TCL>
1. Connect the MUT-II to the diagnosis connector. 2. Turn the ignition switch to ON (but do not start the engine). 3. Check the throttle position sensor output voltage. Standard value: 580 - 690 mV
4. If the voltage is outside the standard value, adjust by loosening the throttle position sensor mounting bolts and turning the throttle position sensor body. After adjusting, tighten the bolts securely. 5. Turn the ignition switch to OFF. 6. If a diagnosis code is output while adjusting the throttle position sensor, use the MUT-II to erase the diagnosis code.
Accelerator pedal position sensor (with built-in idle position switch)
IDLE POSITION SWITCH AND ACCELERATOR PEDAL POSITION SENSOR ADJUSTMENT 13100140049 <Vehicles with TCL>
<Vehicles without auto-cruise control system> Accelerator lever
2. Insert a thickness gauge with a thickness of 0.5 mm in between the accelerator lever and throttle lever to a depth of approximately 3 mm. NOTE If the thickness gauge is inserted more than 3 mm, the accelerator lever opening angle will become greater than the set opening angle, which will result in defective adjustment. 3. Turn the ignition switch to ON (but do not start the engine).
Throttle lever
Thickness gauge
Throttle lever Thickness gauge

Accelerator pedal position sensor (with built-in idle position switch)
13A-187
4. Loosen the accelerator pedal position sensor mounting bolt, and then turn the accelerator pedal position sensor counterclockwise as far as it will go. 5. Check that the idle position switch is ON at this position. 6. Slowly turn the accelerator pedal position sensor clockwise and find the point where the idle position switch turns off. Securely tighten the accelerator pedal position sensor mounting bolt at this point.
7. Select Traction Control System on the MUT-II. 8. Check the accelerator pedal position sensor output voltage. Standard value: 400 - 1,000 mV 9. If the voltage is outside the standard value, check the accelerator pedal position sensor and related harnesses. 10. Remove the thickness gauge. 11. Turn the ignition switch to OFF. 12. Disconnect the MUT-II.
FIXED SAS ADJUSTMENT
13100150318
Fixed SAS
NOTE 1. The fixed SAS should not be moved unnecessarily; it has been precisely adjusted by the manufacturer. 2. If the adjustment is disturbed for any reason, readjust as follows. 1. Loosen the tension of the accelerator cable sufficiently. 2. Back out the fixed SAS lock nut. 3. Turn the fixed SAS counterclockwise until it is sufficiently backed out, and fully close the throttle valve. 4. Tighten the fixed SAS until the point where the throttle lever is touched (i.e., the point at which the throttle valve begins to open) is found. From that point, tighten the fixed SAS 1 turn. 5. While holding the fixed SAS so that it doesnt move, tighten the lock nut securely. 6. Adjust the tension of the accelerator cable. 7. Adjust the basic idling speed. 8. Adjust the idle position switch and throttle position sensor <vehicles without TCL> (P.13A-184), throttle position sensor <vehicles with TCL> (P.13A-186), idle position switch and accelerator pedal position sensor <vehicles with TCL> (P.13A-186).
13A-188
MPI <6A1> - On-vehicle Service BASIC IDLE SPEED ADJUSTMENT

13100180355
NOTE (1) The standard idling speed has been adjusted, by the speed adjusting screw (SAS), by the manufacturer, and there should usually be no need for readjustment. (2) If the adjustment has been changed by mistake, the idle speed may become too high or the idle speed may drop too low when loads from components such as the A/C are placed on the engine. If this occurs, adjust by the following procedure. (3) The adjustment, if made, should be made after first confirming that the spark plugs, the injectors, the idle speed control servo, the compression pressure, etc., are all normal. 1. Before inspection and adjustment, set the vehicle to the pre-inspection condition. 2. Connect the MUT-II to the diagnosis connector (16-pin). NOTE When the MUT-II is connected, the diagnosis control terminal should be earthed. 3. Start the engine and run at idle. 4. Select the item No.30 of the MUT-II Actuator test. NOTE This holds the ISC servo at the basic step to adjust the basic idle speed. 5. Check the idle speed. Standard value: 650 50 r/min NOTE (1) The engine speed may be 20 to 100 r/min lower than indicated above for a new vehicle [driven approximately 500 km or less], but no adjustment is necessary. (2) If the engine stalls or the engine speed is low even though the vehicle has been driven approximately 500 km or more, it is probable that deposits are adhered to the throttle valve, so clean it. (Refer to P.13A-184.)
6. If not within the standard value range, turn the speed adjusting screw (SAS) to make the necessary adjustment. NOTE If the idling speed is higher than the standard value range even when the SAS is fully closed, check whether or not there is any indication that the fixed SAS has been moved. If there is an indication that it has been moved, adjust the fixed SAS.
13A-189
7. Press the MUT-II clear key, and release the ISC servo from the Actuator test mode. NOTE Unless the ISC servo is released, the Actuator test mode will continue 27 minutes. 8. Switch OFF the ignition switch. 9. Disconnect the MUT-II. 10. Start the engine again and let it run at idle speed for about 10 minutes; check that the idling condition is normal.
FUEL PRESSURE TEST
13100190310
1. Release residual pressure from the fuel pipe line to prevent fuel gush out. (Refer to P.13A-191.) 2. Disconnect the fuel high pressure hose at the delivery pipe 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. 3. Remove the union joint and bolt from the special tool (adapter hose MD998709) and instead attach the special tool (hose adapter MD998742) to the adapter hose. 4. Install a fuel pressure gauge on the adapter hose that was set up in step 3. Use a suitable O-ring or gasket between the fuel pressure gauge and the special tool so as to seal in order to prevent fuel leakage at this time. 5. Install the special tool, which was set in place in steps 3 and 4 between the delivery pipe and the high pressure hose. 6. Use a jumper wire to connect the terminal No.2 (fuel pump drive terminal) of the 3-pin connector shown in the illustration to the battery (+) terminal in order to activate the fuel pump. Under fuel pressure, check the fuel pressure gauge and special tool connections for leaks. 7. Disconnect the jumper wire from the fuel pump drive terminal to stop the fuel pump. 8. Start the engine and run at idle. 9. Measure fuel pressure while the engine is running at idle. Standard value: Approx. 265 kPa at kerb idle
High pressure hose
Fuel pressure gauge O-ring or gasket MD998709 MD998742
Delivery pipe
13A-190

10. Disconnect the vacuum hose from the fuel pressure regulator and measure fuel pressure with the hose end closed by a finger. Standard value: 324 - 343 kPa at kerb idle 11. Check to see that fuel pressure at idle does not drop even after the engine has been raced several times. 12. Racing the engine repeatedly, hold the fuel return hose lightly with fingers to feel that fuel pressure is present in the return hose. NOTE If the fuel flow rate is low, there will be no fuel pressure in the return hose. 13. If any of fuel pressure measured in steps 9 to 12 is out of specification, troubleshoot and repair according to the table below.
Symptom D D D Fuel pressure too low Fuel pressure drops after racing No fuel pressure in fuel return hose
Probable cause Clogged fuel filter Fuel leaking to return side due to poor fuel regulator valve seating or settled spring Low fuel pump delivery pressure
Remedy Replace fuel filter Replace fuel pressure regulator
Replace fuel pump Replace fuel pressure regulator Clean or replace hose or pipe Replace vacuum hose or clean nipple
Fuel pressure too high
Binding valve in fuel pressure regulator Clogged fuel return hose or pipe
Same fuel pressure when vacuum hose is connected and when disconnected
Damaged vacuum hose or clogged nipple
13A-191
14. Stop the engine and check change of fuel pressure gauge reading. Normal if the reading does not drop within 2 minutes. If it does, observe the rate of drop and troubleshoot and repair according to the table below.
Symptom Fuel pressure drops gradually after engine is stopped Fuel pressure drops sharply immediately after engine is stopped Probable cause Leaky injector Leaky fuel regulator valve seat Check valve in fuel pump is held open Remedy Replace injector Replace fuel pressure regulator Replace fuel pump
15. Release residual pressure from the fuel pipe line. (Refer to P.13A-191.) 16. Remove the fuel pressure gauge and special tool from the delivery pipe. 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. 17. Replace the O-ring at the end of the fuel high pressure hose with a new one. Furthermore, apply engine oil to the new O-ring before replacement. 18. Fit the fuel high pressure hose over the delivery pipe and tighten the bolt to specified torque. 19. Check for fuel leaks. (1) Apply the battery voltage to the fuel pump drive terminal to drive the fuel pump. (2) Under fuel pressure, check the fuel line for leaks.
FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE THE FUEL PRESSURE)

13100090269
Refer to P.13A-88.
FUEL PUMP OPERATION CHECK

Refer to P.13A-88.
13100200242
13A-192
COMPONENT LOCATION
Name A/C relay

13100210375
Symbol H R C G P A J O L B K Q N
Name Fuel pump check terminal Idle speed control servo Inhibitor switch <A/T> Injectors Oxygen sensor (front) Oxygen sensor (rear) Power steering fluid pressure switch Purge control solenoid valve Throttle position sensor <Vehicles with TCL> Throttle position sensor (with idle position switch) <Vehicles without TCL> Vacuum control solenoid valve <Vehicles with TCL> Vehicle speed sensor Ventilation control solenoid valve <Vehicles with TCL>
Symbol F C M J S T I B C C D E D
A/C switch Accelerator pedal position sensor (with idle position switch) <Vehicles with TCL> Air flow sensor (with intake air temperature sensor and barometric pressure sensor) Control relay and fuel pump relay Crank angle sensor Detonation sensor <Vehicles for Hong Kong and Singapore> Diagnosis connector Distributor (with top dead centre sensor and ignition coil) EGR control solenoid valve Engine coolant temperature sensor Engine-ECU Engine warning lamp (check engine lamp)
13A-193
CONTROL RELAY AND FUEL PUMP RELAY 13100990187 CONTINUITY CHECK

Battery voltage Not supplied Supplied
Fuel pump relay and control relay
Air flow sensor (with intake air temperature sensor) Equipment side connector

13100280246
1. Disconnect the air flow sensor connector. 2. Measure resistance between terminals 5 and 6. Standard value: 2.3 - 3.0 kW (at 20_C) 0.30 - 0.42 kW (at 80_C)
4. If the value deviates from the standard value or the resistance remains unchanged, replace the air flow sensor assembly.

Caution Be careful not to touch the connector (resin section) with the tool when removing and installing.
1. Remove the engine coolant temperature sensor.
13A-194

4. Apply sealant to threaded portion. Specified sealant: 3M Nut Locking Part No.4171 or equivalent 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 Nm
<Vehicles without TCL> Equipment side connector
THROTTLE POSITION SENSOR CHECK
13100320283
1. Disconnect the throttle position sensor connector. 2. Measure the resistance between the throttle position sensor side connector terminal 1 and terminal 4. Standard value: 3.5 - 6.5 kW 3. Measure the resistance between the throttle position sensor side connector terminal 3 and terminal 4. Normal condition:
<Vehicles with TCL> Throttle position sensor Equipment side connector
4. If the resistance is outside the standard value, or if it doesnt change smoothly, replace the throttle position sensor. NOTE For the throttle position sensor adjustment procedure, refer to P.13A-184 <Vehicles without TCL>, P.13A-186 <Vehicles with TCL>.
Accelerator pedal position sensor
ACCELERATOR PEDAL POSITION SENSOR 13100340012 CHECK <Vehicles with TCL>

1. Disconnect the accelerator pedal position sensor connector. 2. Measure the resistance between the accelerator pedal position sensor side connector terminal 1 and terminal 4. Standard value: 3.5 - 6.5 kW 3. Measure the resistance between the accelerator pedal position sensor side connector terminal 1 and terminal 2. Normal condition:
13A-195
4. If the resistance is outside the standard value, or if it doesnt change smoothly, replace the accelerator pedal position sensor. NOTE For the accelerator pedal position sensor adjustment procedure, refer to P.13A-186.
IDLE POSITION SWITCH CHECK <Vehicles 13100330279 without TCL>

1. Disconnect the throttle position sensor connector. 2. Check the continuity between the throttle position sensor connector side terminal 1 and terminal 2. Normal condition:
Accelerator pedal Depressed Released
Continuity Non-conductive Conductive (0 W)
3. If out of specification, replace the throttle position sensor. NOTE After replacement, the idle position switch and throttle position sensor should be adjusted. (Refer to P.13A-184.)
IDLE POSITION SWITCH CHECK <Vehicles with TCL>
13100330286
1. Disconnect the accelerator pedal position sensor connector. 2. Check the continuity between the accelerator pedal position sensor connector side terminal 3 and terminal 4. Normal condition:
Accelerator pedal Depressed Released Continuity Non-conductive ( W) Conductive (0 W)
3. If out of specification, replace the accelerator pedal position sensor. NOTE After replacement, the idle position switch and accelerator pedal position sensor should be adjusted. (Refer to P.13A-186.)
13A-196
MPI <6A1> - On-vehicle Service OXYGEN SENSOR CHECK

Oxygen sensor (front)
13100510178
<Oxygen sensor (front)> 1. Disconnect the oxygen sensor connector and connect the special tool (test harness) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 - 18 W at 20_C) between terminal 3 and terminal 4 on the oxygen sensor connector.
3. If there is no continuity, replace the oxygen sensor. 4. Warm up the engine until engine coolant is 80_C or higher.
MB991223
5. Use the jumper wire to connect terminal 3 of the oxygen sensor connector to the battery (+) terminal and terminal 4 to the battery ( - ) terminal. Caution Be very careful when connecting the jumper wire; incorrect connection can damage the oxygen sensor. 6. Connect a digital voltage meter between terminal 1 and terminal 2. 7. While repeatedly racing the engine, measure the oxygen sensor output voltage. Standard value:
Engine When racing the engine Oxygen sensor output voltage 0.6 - 1.0 V Remarks If you make the air/fuel ratio rich by racing the engine repeatedly, a normal oxygen sensor will output a voltage of 0.6 - 1.0 V.
MB991223
8. If the sensor is defective, replace the oxygen sensor. NOTE For removal and installation of the oxygen sensor, refer to GROUP 15 - Exhaust Pipe and Main Muffler.
13A-197
Oxygen sensor (rear) Equipment side connector
<Oxygen sensor (rear)> 1. Disconnect the oxygen sensor connector and connect the special tool (test harness set) to the connector on the oxygen sensor side. 2. Make sure that there is continuity (11 - 18 W at 20_C) between terminal 3 and terminal 4 on the oxygen sensor connector. 3. If there is no continuity, replace the oxygen sensor. NOTE (1) If the MUT-II does not display the standard value although no abnormality is found by the above mentioned continuity test and harness check, replace the oxygen sensor (rear). (2) For removal and installation of the oxygen sensor, refer to GROUP 15 - Exhaust Pipe and Main Muffler.
MB991223
INJECTOR CHECK
Measurement of Resistance between Terminals D Front bank side (No.2, No.4, No.6 cylinders) 1. Remove the injector connector. 2. Measure the resistance between terminals. Standard value: 13 - 16 W (at 20_C)
13100520294
Intermediate harness side connector Injector intermediate harness connector
D Rear bank side (No.1, No.3, No.5 cylinders) 1. Disconnect the injector intermediate harness connectors. 2. Measure the resistance between terminals. Standard value: 13 - 16 W (at 20_C)
Injector No.1 cylinder No.3 cylinder No.5 cylinder Measurement probe 1- 2 1- 3 1- 4
13A-198

Checking the Injection Condition 1. Following the steps below, bleed out the residual pressure within the fuel pipe line to prevent flow of the fuel. (Refer to P.13-191.) 2. Remove the injector.
3. Arrange the special tool (injector test set), adaptor, fuel pressure regulator and clips as shown in the illustration below.
High-pressure fuel hose MD998741 Return hose MB991607
Pressure regulator (MD116395) Injector MD998706
Battery
Clip (MB991608)
4. Apply battery voltage to terminal 2 (fuel pump drive terminal) of the 3-pin connector shown in the illustration, and activate the fuel pump
Main hose
Return hose
5. Activate the injector and check the atomized spray condition of the fuel. The condition can be considered satisfactory unless it is extremely poor.
Injector
Battery
13A-199
6. Stop the actuation of the injector, and check for leakage from the injectors nozzle. Standard value: 1 drop or less per minute 7. Activate the injector without activating the fuel pump; then, when the spray emission of fuel from the injector stops, disconnect the special tool and restore it to its original condition.
IDLE SPEED CONTROL (ISC) SERVO (STEPPER MOTOR) CHECK
13100540245
Checking the Operation Sound 1. Check that the engine coolant temperature is 20_C or below. NOTE Disconnecting the engine coolant temperature sensor connector and connecting the harness-side of the connector to another engine coolant temperature sensor that is at 20_C or below is also okay. 2. Check that the operation sound of the stepper motor can be heard after the ignition is switched ON. (but without starting the motor.) 3. If the operation sound cannot be heard, check the stepper motors activation circuit. If the circuit is normal, it is probable that there is a malfunction of the stepper motor or of the engine control unit.
Checking the Coil Resistance 1. Disconnect the idle speed control servo connector and connect the special tool (test harness). 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 speed control servo side. Standard value: 28 - 33 W (at 20_C) 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 speed control servo side. Standard value: 28 - 33 W (at 20_C)
13A-200

Operation Check 1. Remove the throttle body. 2. Remove the stepper motor.
White
Green
MD998463
3. Connect the special tool (test harness) to the idle speed control servo connector. 4. Connect the positive (+) terminal of a power supply (approx. 6 V) to the white clip and the green clip. 5. With the idle speed control servo as shown in the illustration, connect the negative ( - ) terminal of the power supply to each clip as described in the following steps, and check whether or not a vibrating feeling (a feeling of very slight vibration of the stepper motor) is generated as a result of the activation of the stepper motor. (1) Connect the negative ( - ) terminal of the power supply to the red and black clip. (2) Connect the negative ( - ) terminal of the power supply to the blue and black clip. (3) Connect the negative ( - ) terminal of the power supply to the blue and yellow clip. (4) Connect the negative ( - ) terminal of the power supply to the red and yellow clip. (5) Connect the negative ( - ) terminal of the power supply to the red and black clip. (6) Repeat the tests in sequence from (5) to (1). 6. If, as a result of these tests, vibration is detected, the stepper motor can be considered to be normal.

13100560241
EGR CONTROL SOLENOID VALVE CHECK

13100570206

Vacuum control solenoid valve
13A-201
Ventilation control solenoid valve
VENTILATION CONTROL SOLENOID VALVE 13100630041 CHECK <Vehicles with TCL>

NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (green stripe) from the solenoid valve. 2. Disconnect the harness connector.
3. Connect a hand vacuum pump to the nipple. 4. Check air-tightness by applying a vacuum with voltage applied directly from the battery to the solenoid valve and without applying voltage. Normal condition:
Battery voltage Applied
Battery
Normal condition Vacuum maintained Vacuum leaks
Not applied
5. Measure the resistance between the terminals of the solenoid valve. Standard value: 36 - 44 W (at 20_C)
Ventilation control solenoid valve
Vacuum control solenoid valve
VACUUM CONTROL SOLENOID VALVE CHECK 13100620048 <Vehicles with TCL>

NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (blue stripe, green stripe) from the solenoid valve. 2. Disconnect the harness connector.
13A-202

3. Connect a hand vacuum pump to the nipple to which the blue-striped vacuum hose was connected. 4. Check air-tightness by applying a vacuum with voltage applied directly from the battery to the solenoid valve and without applying voltage.
Battery voltage Applied
Battery
Normal condition Vacuum leaks Vacuum maintained
Not applied
VACUUM TANK CHECK
13100810049
A B
<Vehicles with TCL> 1. Connect a hand vacuum pump to vacuum tank A nipple, apply 67 kPa of vacuum and check that the vacuum is held. 2. Connect a hand vacuum pump to vacuum tank B nipple. 3. First, close A nipple with your finger and apply 67 kPa of vacuum. Then, check that the vacuum leaks immediately when you remove the finger blocking the nipple.
Vacuum actuator
VACUUM ACTUATOR CHECK
13100820042
Rod
<Vehicles with TCL> 1. Remove the vacuum hose (green stripe) from the vacuum actuator and connect a hand vacuum pump to the vacuum actuator. 2. With the accelerator pedal depressed, check that the rod is pulled up and that vacuum is held when 27 kPa of vacuum is applied.
Accelerator lever
THROTTLE VALVE OPERATION CHECK
13100830052
Throttle lever
Throttle valve
<Vehicles with TCL> 1. Check that the throttle valve opens and closes smoothly (throttle lever moves) according to the opening and closing of the accelerator lever. 2. If the throttle valve does not open and close smoothly, there might be a deposit on the throttle valve, so clean the throttle body. (Refer to P.13A-184.)

Vacuum actuator
13A-203
13100840055
NEGATIVE PRESSURE CHECK DURING TRACTION CONTROL OPERATION
T-joint
Green stripe
<Vehicles with TCL> 1. Disconnect the vacuum hose (green stripe) from the vacuum actuator, connect a hand vacuum pump between the actuator nipple and the vacuum hose via a T-joint. Set the hand vacuum pump near the drivers seat so that the negative pressure check can be carried out at the drivers seat. 2. Check the negative pressure during traction control operation. Inspection service points are the same as for the traction control operation inspection. (Refer to GROUP 13H or 23 - On-vehicle Service.) Normal condition:
Vehicle condition Normal negative pressure when accelerator pedal is depressed 20 kPa or more No change
Vehicle is lifted up Driving on a dry, sealed road surface
NOTE The traction control system function will stop 20 seconds after the accelerator pedal has been depressed, and negative pressure will gradually drop.
Power steering air control valve
POWER STEERING AIR CONTROL VALVE 13101180019 OPERATION CHECK

1. Disconnect the vacuum hose (connected to air intake hose) from the power steering air control valve, and plug the vacuum hose. 2. Connect a vacuum gauge to the power steering air control valve nipple from which the vacuum hose has been disconnected. 3. Start the engine and run at idle. 4. Check that the value of the vacuum gauge changes from 0 kPa (barometric pressure) to 60 kPa or more when turning the steering wheel.
13A-204 INJECTOR
MPI <6A1> - Injector

13100710349

<Front bank>
Pre-removal Operation D Fuel Discharge Prevention (Refer to P.13A-88.)
18 Nm
8, 9
10 4 4
3 Nm
O-ring
13
3
O-ring
2
9 Nm
1
Engine oil
14
6 8
12 Nm
10 7 14 13 12
11 9
9 Nm
Removal steps 1. Engine cover 2. Crank angle sensor connector 3. Injector connector 4. Vacuum hose connection 5. Air pipe assembly mounting bolt 6. Vacuum hose connection 7. Fuel return hose connection
"AA 8. Fuel pressure regulator "AA 9. Fuel pipe assembly AA" 10. Delivery pipe 11. Insulator 12. Insulator AA" "AA 13. Injector 14. Grommets
MPI <6A1> - Injector

<Rear bank>
Pre-removal Operation D Fuel Discharge Prevention (Refer to P.13A-88.) D Air Cleaner Removal
13A-205
Post-installation operation D Air Cleaner Installation D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle service.)
18 Nm
4 8
4 9
3 Nm
3 12 6
1 2
18 Nm
7
12 Nm
13 11
18 Nm
16 15 18 21 20
9 Nm
17
10
14 20 15, 16
19
21
Engine oil
O-ring
17
O-ring
Removal steps 1. Engine cover 2. Crank angle sensor connector 3. Injector connector 4. Vacuum hose 5. Air pipe assembly mounting bolt 6. Brake booster vacuum hose connection 7. Connector bracket mounting bolt 8. Connector bracket mounting bolt 9. Noise condenser mounting bolt 10. EGR solenoid valve connector 11. Purge control solenoid valve connector
12. 13. 14. "AA 15. "AA 16. AA" 17. 18. 19. AA" "AA 20. 21.
Air intake plenum Air intake plenum gasket Injector connector High pressure fuel hose connection Fuel pipe assembly Delivery pipe Insulator Insulator Injector Grommets
13A-206
MPI <6A1> - Injector REMOVAL SERVICE POINT

AA" DELIVERY PIPE/INJECTOR REMOVAL Remove the delivery pipe (with the injectors attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector.

"AA INJECTOR/FUEL PIPE ASSEMBLY/FUEL PRESSURE REGULATOR/HIGH-PRESSURE FUEL HOSE INSTALLATION 1. Apply a drop of new engine oil to the O-ring. Caution Be sure not to let engine oil in the delivery pipe. 2. While turning the injector, fuel pipe assembly, high-pressure fuel hose and fuel pressure regulator to the right and left, install the delivery pipe, while being careful not to damage the O-ring. 3. If it does not turn smoothly, the O-ring may be trapped, remove the fuel pressure regulator and then re-insert it into the delivery pipe and check once again. 4. Tighten the high-pressure fuel hose to the standard torque, and tighten the fuel pressure regulator and fuel pipe assembly to the specified torque. Tightening torque: 9 Nm (Fuel pressure regulator)
MPI <6A1> - Throttle Body
13A-207
13100770293
THROTTLE BODY
Pre-removal Operation D Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service.) D Air Cleaner Removal Post-installation Operation D Air Cleaner Installation D Engine Coolant Supplying (Refer to GROUP 14 - On-vehicle Service.) D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)
<Vehicles without traction control system> 6 2
10 - 13 Nm
4 8 4 3
18 Nm
Removal steps 1. Accelerator cable connection 2. Throttle position sensor connector 3. Idle speed control servo connector 4. Vacuum hose connection
5. 6. 7. "AA 8.
Water hose connection Vacuum pipe assembly Throttle body Throttle body gasket
13A-208
<Vehicles with TCL and <Vehicles with TCL> auto-cruise control system>
10 - 13 Nm
7 4
10 - 13 Nm
2 8 9
7 3
2 5 9 6
4 8
18 Nm
Removal steps 1. Accelerator cable connection 2. Throttle position sensor connector 3. Idle speed control servo connector 4. Accelerator pedal position sensor connector
5. 6. 7. 8. "AA 9.
Vacuum hose connection Water hose connection Vacuum pipe assembly Throttle body Throttle body gasket
Up

"AA THROTTLE BODY GASKET INSTALLATION Place the gasket so that the projecting part is positioned as shown in the illustration, and then install it between the intake manifold and the throttle body.
Towards front of vehicle
MPI <6A1> - Throttle Body DISASSEMBLY AND REASSEMBLY

<Vehicles without TCL and auto-cruise control system> 7 8 9 1 5 4 2 3
13A-209
13100970297
Disassembly steps "BA 1. Throttle position sensor 2. Idle speed control servo (Stepper motor) 3. O-ring 4. Fast idle air valve 5. O-ring 6. Throttle body 7. Fixed SAS 8. Speed adjusting screw 9. O-ring
13A-210
<Vehicles with auto-cruise control system>
10 7 5 3 4 1
Disassembly steps "BA 1. Throttle position sensor 2. Idle speed control servo (Stepper motor) 3. O-ring 4. Fast idle air valve 5. O-ring 6. Lever assembly 7. Throttle body 8. Fixed SAS 9. Speed adjusting screw 10. O-ring

<Vehicles with TCL> 3 11 12
13A-211
8 11
10
9 1 7
4 5 6
Disassembly steps 1. Water hose "BA 2. Throttle position sensor "AA 3. Accelerator pedal position sensor 4. Idle speed control servo (Stepper motor) 5. O-ring 6. Fast idle air valve 7. O-ring 8. Throttle lever 9. Throttle body 10. Fixed SAS 11. Speed adjusting screw 12. O-ring
NOTE 1. The fixed SAS and the speed adjusting screw are correctly adjusted at the factory and should not be removed. 2. If the fixed SAS should happen to have been removed, carry out fixed SAS adjustment. (Refer to 13A-187.) 3. If the speed adjusting screw should happen to have been removed, carry out speed adjusting screw adjustment. (Refer to 13A-188.)
13A-212
<Vehicles with TCL and auto-cruise control system> 3 11 12
10
9 7
4 5 6
Disassembly steps 1. Water hose "BA 2. Throttle position sensor "AA 3. Accelerator pedal position sensor 4. Idle speed control servo (Stepper motor) 5. O-ring 6. Fast idle air valve 7. O-ring 8. Throttle lever 9. Throttle body 10. Fixed SAS 11. Speed adjusting screw 12. O-ring
NOTE 1. The fixed SAS and the speed adjusting screw are correctly adjusted at the factory and should not be removed. 2. If the fixed SAS should happen to have been removed, carry out fixed SAS adjustment. (Refer to 13A-187.) 3. If the speed adjusting screw should happen to have been removed, carry out speed adjusting screw adjustment. (Refer to 13A-188.)
MPI <6A1> - Throttle Body CLEANING THROTTLE BODY PARTS
13A-213
1. Clean all throttle body parts. Do not use solvent to clean the following parts: D Throttle position sensor D Accelerator pedal position sensor D Idle speed control body assembly If these parts are immersed in solvent, their insulation will deteriorate. Wipe them with cloth only. 2. Check if the vacuum port or passage is clogged. Use compressed air to clean the vacuum passage.
REASSEMBLY SERVICE POINTS

"AA ACCELERATOR PEDAL POSITION SENSOR (APS) INSTALLATION 1. Install the APS so that it faces as shown in the illustration, and then tighten it with the screw. 2. Connect a multimeter between terminal (3) (APS output) and terminal (4) (APS power supply) of the APS connector, and check that the resistance increases gradually as the throttle valve is opened slowly to the fully-open position. 3. Check the continuity between terminal (2) (idle position switch) and terminal (1) (earth) of the APS connector when the throttle valve is fully closed and fully open. Normal condition:
APS power supply
Idle position switch Earth
Throttle valve condition Fully closed Fully open
Continuity Continuity No continuity
APS output
If there is no continuity when the throttle valve is fully closed, turn the APS body clockwise and then check again. 4. If there is an abnormality, replace the APS.
13A-214

"BA THROTTLE POSITION SENSOR (TPS) INSTALLATION 1. Install the TPS so that it faces as shown in the illustration, and then tighten it with the screw. 2. Connect a multimeter between terminal (1) (TPS power supply) and terminal (2) (TPS output) of the TPS connector, and check that the resistance increases gradually as the throttle valve is opened slowly to the fully-open position. 3. For vehicles without TCL, check the continuity between terminal (3) (idle position switch) and terminal (4) (earth) of the TPS connector when the throttle valve is fully closed and fully open. Normal condition:
Earth
TPS output TPS power supply
Throttle valve condition Fully closed Fully open
Continuity Continuity No continuity
Idle position switch (Vehicles without TCL only)
If there is no continuity when the throttle valve is fully closed, turn the TPS body anti-clockwise and then check again. 4. If there is an abnormality, replace the TPS.
13E-1
DIESEL FUEL
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 53
Evacuation of Water from Fuel Filter . . . . . . . . . 53 Evacuation of Air from Fuel Line . . . . . . . . . . . . . 53 Fuel Filter Cartridge Replacement . . . . . . . . . . . . 53 Accelerator Pedal Position Sensor and Idle Position Switch 1 Adjustment . . . . . . . . . . . . . . . . 53 Idle Position Switch 2 Adjustment . . . . . . . . . . . . 54 Component Location . . . . . . . . . . . . . . . . . . . . . . . . . 55 Control Relay and Solenoid-type Spill Valve Relay Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Intake Air Temperature Sensor Check . . . . . . . . 56
13309000047
Engine Coolant Temperature Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Accelerator Pedal Position Sensor Check . . . . . 57 Idle Position Switch 1 Check . . . . . . . . . . . . . . . . . 58 Idle Position Switch 2 Check . . . . . . . . . . . . . . . . . 58 Solenoid-type Spill Valve Check . . . . . . . . . . . . . . 59 Timing Control Solenoid Valve Check . . . . . . . . . 59 Diesel Fuel Temperature Sensor Check . . . . . . . 59 Pump Operation Sensor Check . . . . . . . . . . . . . . . 60 Injection Timing Correction Resistor Check . . . . 60 Injection Rate Correction Resistor Check . . . . . . 60 Fuel Cut Solenoid Valve Check . . . . . . . . . . . . . . 60 Throttle Solenoid Valve Check . . . . . . . . . . . . . . . 60 Throttle Actuator Check . . . . . . . . . . . . . . . . . . . . . 61 Injection Nozzle Check and Adjustment . . . . . . . 61
INJECTION PUMP AND NOZZLE . . . . . . . . . 63 THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 68
13E-2
DIESEL FUEL - General Information

13300010063
GENERAL INFORMATION
The electronically-controlled fuel injection system consists of sensors which detect the condition of the diesel engine, an engine-ECU which controls the system based on signals from these sensors, and actuators which operate according to control commands from the engine-ECU. The engine-ECU carries out operations such as fuel injection rate control, fuel injection timing control and idle up control. In addition, the engine-ECU is equipped with several self-diagnosis functions which make troubleshooting easier in the event that a problem develops. FUEL INJECTION RATE CONTROL The fuel injection completion timing is controlled by means of a solenoid-type spill valve to ensure that the optimum amount of fuel is supplied to the engine in accordance with gradual changes in the engine running condition. Before fuel injection starts, the solenoid-type spill valve is on (energized), so that the valve is closed. As the plunger turns and rises, fuel is sent out under pressure, and when the fuel flow rate reaches the target value for fuel injection, the solenoid-type spill valve turns off. When the solenoid-type spill valve turns off, the fuel under high pressure inside the plunger is leaked out into the pump chamber and fuel injection is completed. FUEL INJECTION TIMING CONTROL The position of the injection pump timer piston is controlled so that fuel injection is carried out at the optimum timing in accordance with the engine running condition. The timer piston position is determined by duty control of the timing control solenoid valve which is located in the line between the high-pressure chamber and the low-pressure chamber of the timer piston. The fuel injection timing is advanced by increasing the control duty of the timing control solenoid valve. IDLE SPEED CONTROL Controlling the fuel injection rate in accordance with the engine running condition maintains the idle speed at the optimum condition. SELF-DIAGNOSIS FUNCTION D When an abnormality is detected in any of the sensors or actuators, the engine warning lamp illuminates to warn the driver. D When an abnormality is detected in any of the sensors or actuators, a diagnosis code number corresponding to the problem which occurred is output. D The RAM data relating to the sensors and actuators which is stored in the engine-ECU can be read using the MUT-II. In addition, the actuators can be force-driven under certain conditions. OTHER CONTROL FUNCTIONS 1. Power Supply Control When the ignition switch is turned to ON, the relay turns on and power is supplied to components such as the timing control solenoid valve. 2. Intake Air Throttle Control When the engine is idling after having warmed up, the throttle valve is half opened to restrict the amount of intake air in order to reduce vibration and noise. 3. A/C Relay Control Turns the compressor clutch of the A/C ON and OFF 4. Fan motor relay control The radiator fan and condenser fan operating speeds are controlled in accordance with the engine coolant temperature and the vehicle speed. 5. Glow Control Refer to GROUP 16. 6. EGR Control Refer to GROUP 17.
DIESEL FUEL - General Information DIESEL FUEL SYSTEM DIAGRAM

*1 *2 *3 *4 *5 *6 D D D D D D D D D D Pump operation sensor Crank angle sensor Engine coolant temperature sensor Boost sensor Diesel fuel temperature sensor Intake air temperature sensor Accelerator pedal position sensor Idle position switch 1 Idle position switch 2 Power supply voltage Ignition switch-IG Ignition switch-ST Vehicle speed sensor A/C switch Injection timing correction resistor Injection rate correction resistor Engine-ECU z1 Solenoid-type spill valve z2 Timing control solenoid valve z3 EGR solenoid valve z4 Throttle solenoid valve D D D D D D D D Control relay Solenoid-type spill valve relay Glow plug relay A/C power relay Fan motor relay Engine warning lamp Glow indicator lamp Diagnosis signal
13E-3
z4 Throttle solenoid valve z3 EGR solenoid valve Vacuum pump Air cleaner Throttle actuator z1 Solenoid-type spill valve *4 Boost sensor *5 Diesel fuel temperature sensor *1 Pump operation sensor Injection pump Alternator
*6 Intake air temperature sensor
Throttle valve EGR valve Turbocharger
Waste gate actuator Oxidation catalyst
z2 Timing control solenoid valve *3 Engine coolant temperature sensor *2 Crank angle sensor
13E-4
DIESEL FUEL - Service Specifications/Sealant

13300030069
Items Accelerator pedal position sensor adjusting voltage mV Idle position switch 1 check voltage mV Intake air temperature sensor resistance kW Engine coolant temperature sensor resistance kW At 20 _C At 80 _C At 20 _C At 80 _C Specifications 530 - 570 875 - 925 2.3 - 3.0 0.30 - 0.42 2.1 - 2.7 0.26 - 0.36 3.5 - 6.5 1 - 2 (at 20 _C) 8 - 12 (at 20 _C) 2.2 - 2.7 (at 20 _C) 215 - 245 (at 20 _C) 0.1 - 2.5 (at 20 _C) 0.1 - 2.5 (at 20 _C) 8 - 10 36 - 44 (at 20 _C)
Resistance between accelerator pedal position sensor terminals (1) and (4) kW Solenoid-type spill valve resistance W Timing control solenoid valve resistance W Diesel fuel temperature sensor resistance kW Pump operation sensor resistance W Injection timing correction resistor resistance kW Injection rate correction resistor resistance kW Fuel cut solenoid valve resistance W Throttle solenoid valve resistance W
SEALANT
13300050010
Drying sealant
DIESEL FUEL - Special Tools
13E-5
13300060068
SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub assembly Use D D
Reading diagnosis code Checking the electronicallycontrolled fuel injection system
MB991348
Test harness set
Inspection using an analyzer
MD998478
Test harness (3 pin, triangle)
Inspection using an analyzer
MB990767
End yoke holder
Fuel injection pump sprocket holding
MD998719
MD998388
Sprocket puller
Fuel injection pump sprocket removal
13E-6
DIESEL FUEL - Troubleshooting

13300370024
TROUBLESHOOTING
DIAGNOSIS FUNCTION
13300380027
ENGINE WARNING LAMP (CHECK ENGINE LAMP) If an abnormality occurs in any of the following items which are related to the electronically-controlled fuel injection system, the engine warning lamp will illuminate. If the lamp remains illuminated or if the lamp illuminates while the engine is running, check the diagnosis code output.
Engine warning lamp

Accelerator pedal position sensor Boost sensor Barometric pressure sensor Diesel fuel temperature sensor Engine coolant temperature sensor Intake air temperature sensor Pump operation sensor Crank angle sensor Idle position switch 1 Idle position switch 2 Throttle solenoid valve system Timing control solenoid valve system Solenoid-type spill valve system Immobilizer system Engine-ECU
13E-7
FAIL-SAFE/BACKUP FUNCTION TABLE
13300390020
Malfunctioning item Accelerator pedal position sensor Boost sensor Diesel fuel temperature sensor Engine coolant temperature sensor Intake air temperature sensor Vehicle speed sensor Pump operation sensor Crank angle sensor Ignition switch-ST Timing control solenoid valve Solenoid-type spill valve Correction resistors (injection timing and injection rate) Control contents during malfunction Carries out control as if the accelerator opening angle is at a specified angle (0 %/approx. 10%) on the basis of idle position switch inputs (ON/OFF). Carries out control as if the intake air pressure is at a specified value (101 kPa). Carries out control as if the fuel temperature is 50 _C. Carries out control as if the engine coolant temperature is at a specified value (80_C). Carries out control as if the intake air temperature is at a specified value (25_C). Carries out control as if the vehicle is moving. Controls the injection rate according to the speed reported by the crank angle sensor. D D Reduces the fuel injection rate. Fixes the injection timing at a specified value.
Carries out control as if ignition switch ST is OFF. Reduces the fuel injection rate. Solenoid-type spill valve relay is turned off (engine stops). Carries out control as if the correction resistance are at specified values.
13E-8

13300400044
Caution Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
Code No. 11 12 13 14 15 16 17 18 19 21 22 23 24 41 43 44 45 46 47 Diagnosis item Accelerator pedal position sensor system Boost sensor system Barometric pressure sensor system Diesel fuel temperature sensor system Engine coolant temperature sensor system Intake air temperature sensor system Vehicle speed sensor system Pump operation sensor system (open circuit) Pump operation sensor system (intermittent fault) Crank angle sensor system Ignition switch-ST signal system Idle position switch 1 system Idle position switch 2 system Throttle solenoid valve system Timing control solenoid valve system Solenoid-type spill valve system Injection timing correction resistor system Injection rare correction resistor system Immobilizer system Reference page 13E-9 13E-10 13E-11 13E-11 13E-12 13E-12 13E-13 13E-14 13E-14 13E-15 13E-16 13E-16 13E-17 13E-18 13E-19 13E-20 13E-21 13E-21 13E-22
DIESEL FUEL - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code No.11 Accelerator pedal position sensor system
Range of Check, Set Conditions D Open or short circuit is detected in accelerator pedal position sensor circuit. or D Mechanical problem is detected in accelerator pedal position sensor. Range of Check D Idle position switch 1: ON D Idle position switch 2: ON Set Conditions D Accelerator pedal position sensor signal output is 1.2 V or higher NG NG
13E-9
Probable cause
D D D Malfunction of the accelerator pedal position sensor Open or short circuit in accelerator pedal position sensor circuit or poor connector contact Malfunction of the engine-ECU
Check the accelerator pedal position sensor. (Refer to P.13E-57.) OK Measure at the accelerator pedal position sensor connector B-41. D Disconnect the connector and measure at the harness side connector. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.5 - 5.5 V D Continuity between 4 and earth OK: Continuity OK Check the following connector: B-41 OK NG Repair Check trouble symptom. NG Replace the engine-ECU.
Replace
Check the following connector: C-54 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the accelerator pedal position sensor connector. OK NG Repair Repair the engine-ECU.
13E-10

Probable cause
D D D NG Malfunction of the boost sensor Open or short circuit in boost sensor circuit or poor connector contact Malfunction of the engine-ECU NG
Code No.12 Boost sensor system

Range of Check, Set Conditions D Open or short circuit is detected in boost sensor circuit for 1 second.
Measure at the boost sensor connector B-50. D Connect the connector. (Use the test harness: MB991348) D Voltage between 1 and earth (Ignition switch: ON) OK: 2.0 - 2.6 V (Altitude: 0 m) 1.7 - 2.3 V (Altitude: 1200 m) OK
Measure at the boost sensor connector B-50. D Disconnect the connector and measure at the harness side connector. D Voltage between 3 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V D Continuity between 2 and earth OK: Continuity OK
Check the following connector: C-54 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the boost sensor connector. OK NG Repair Replace the engine-ECU.
Check the following connector: B-50 OK NG Repair Check trouble symptom. Measure at the engine-ECU connector C-54. D Connect the connector. D Voltage between 37 and earth (Ignition switch: ON) OK: 2.0 - 2.6 V (Altitude: 0 m) 1.7 - 2.3 V (Altitude: 1200 m) OK Check the following connectors: B-50, C-54 OK NG Repair Check trouble symptom. NG Replace the engine-ECU. NG Check the harness wire between the engine-ECU and the boost sensor connector, and repair if necessary. NG
Check the harness wire between the engine-ECU and the boost sensor connector. OK NG Repair Check the vacuum hose between the boost sensor and the intake manifold. OK NG Repair Replace the boost sensor.

Code No.13 Barometric pressure sensor system
Range of Check, Set Conditions D An abnormal signal being output from the barometric pressure sensor is detected for 3 seconds. OK NG Replace the engine-ECU.
13E-11
Probable cause
D Malfunction of the engine-ECU
MUT-II Data list 03 Barometric pressure sensor
INTERMITTENT MALFUNCTIONS
Code No.14 Diesel fuel temperature sensor system

Range of Check D Open or short circuit is detected in diesel fuel temperature sensor circuit for 4 seconds.
Probable cause
D D D Malfunction of the diesel fuel temperature sensor Open or short circuit in diesel fuel temperature sensor circuit or poor connector contact Malfunction of the engine-ECU
Check the diesel fuel temperature sensor. (Refer to P.13E-59.) OK Measure at the diesel fuel temperature sensor connector B-62. D Disconnect the connector and measure at the harness side connector. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.5 - 5.5 V D Continuity between 2 and earth OK: Continuity OK Check the following connector: B-62 OK NG Repair Check trouble symptom. NG Replace the engine-ECU.
NG
Replace the injection pump.
NG
Check the following connector: C-54 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the diesel fuel temperature sensor connector. OK NG Repair Replace the engine-ECU.
13E-12

Probable cause
D D D Malfunction of the engine coolant temperature sensor Open or short circuit in engine coolant temperature sensor circuit or poor connector contact Malfunction of engine-ECU
Code No.15 Engine coolant temperature sensor system

Range of Check, Set Conditions D Open or short circuit is detected in engine coolant temperature sensor circuit for 1 second.
Check the engine coolant temperature sensor. (Refer to P.13E-57.) OK Measure at the engine coolant temperature sensor connector B-33. D Disconnect the connector and measure at the harness side connector. D Voltage between 2 and earth (Ignition switch: ON) OK: 4.5 - 5.5 V D Continuity between 1 and earth OK: Continuity OK Check the following connector: B-33 OK NG Repair Check trouble symptom. NG Replace the engine-ECU.
NG NG
Replace
Check the following connector: C-54 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the engine coolant temperature sensor connector. OK NG Repair Replace the engine-ECU.
Code No.16 Intake air temperature sensor system

Range of Check, Set Conditions D Open or short circuit is detected in intake air temperature sensor circuit for 3 seconds.
Probable cause
D D D Malfunction of the intake air temperature sensor Open or short circuit in intake air temperature sensor circuit or poor connector contact Malfunction of the engine-ECU
Check the intake air temperature sensor. (Refer to P.13E-56.) OK Measure at the intake air temperature sensor connector B-45. D Disconnect the connector and measure at the harness side connector. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.5 - 5.5 V D Continuity between 2 and earth OK: Continuity OK Check the following connector: B-45 OK NG Repair Check trouble symptom. NG Replace the engine-ECU.
NG NG
Replace
Check the following connector: C-54 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the intake air temperature sensor connector. OK NG Repair Replace the engine-ECU.

Code No.17 Vehicle speed sensor system
Range of Check D Engine speed: 2,400 r/min or more D Accelerator pedal opening amount: 50 % or more D Engine coolant temperature: 60 _C or higher Set Conditions D Vehicle speed signal is 0 km/h for 10 seconds or more. NG
13E-13
Probable cause
D D D Malfunction of the vehicle speed sensor Open or short circuit in vehicle speed sensor circuit or poor connector contact Malfunction of the engine-ECU
Check the vehicle speed sensor. (Refer to GROUP 54 - Combination Meters.) OK Measure at the vehicle speed sensor connector B-66. D Disconnect the connector, and measure at the harness side. 1. Voltage between 1 and earth (Ignition switch: ON) OK: System voltage 2. Voltage between 3 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V 3. Continuity between 2 and earth OK: Continuity OK Check the following connectors: B-66, C-53 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the vehicle speed sensor connector. OK NG Repair Replace the engine-ECU.
Replace
1. NG
Check the following connectors: B-65, C-90, C-135, C-131 OK NG Repair
2. NG
3. NG
Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and ignition switch connector. OK NG Repair Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.) Check the following connectors: B-65, C-56, C-53 OK
NG Repair
Check trouble symptom. NG Check the harness wire between the engine-ECU and the vehicle speed sensor connector. OK NG Repair Replace the engine-ECU. Check the following connector: B-65 OK NG Repair Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and the earth, and repair if necessary.
13E-14

Probable cause
D D D Malfunction of the pump operation sensor Open or short circuit in pump operation sensor circuit or poor connector contact Malfunction of the engine-ECU
Code No.18 Pump operation sensor system (open circuit)

Range of Check D The injection pump operation speed computed from the crank angle sensor signal is 80 r/min or more. Set Conditions D No injection pump operation signal (pump operation sensor signal) is not during six successive crank angle sensor pulse signal inputs. NG
Check the pump operation sensor. (Refer to P.13E-60.) OK Measure at the engine-ECU connector C-53. D Connect the connector. D Voltage between 10 and 23 (AC range) OK: 0.2 - 1.0 V (Engine: idling) 1.2 - 2.2 V (Engine: 2500 r/min) OK Replace the engine-ECU.
NG
Check the following connectors: C-53, B-63 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the pomp operation sensor connector, and repair if necessary.
Code No.19 Pump operation sensor system (intermittent fault)

Range of Check D No open circuit in pump operation sensor D Injection pump speed: 650 r/min or more D Ignition switch-ST signal: OFF Set Conditions D Abnormal number of pump operation sensor signal pulses counted during two full engine rotations. D Pulse count abnormality occurs 10 times or more. NG
Probable cause
D D D D Malfunction of the pump operation sensor Poor contact in pump operation sensor connector or malfunction of circuit Malfunction of pump operation sensor circuit shielding Malfunction of the engine-ECU
Check the following connectors: C-53, B-63 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the pump operation sensor connector. OK Replace the engine-ECU.
Repair
NG
Repair

Code No.21 Crank angle sensor system
Range of Check D Injection pump speed: 500 r/min or more Set Conditions D No crank angle sensor signal pulses input during two full engine rotations.
13E-15
Probable cause
D D D Malfunction of the crank angle sensor Open or short circuit in crank angle sensor circuit or poor connector contact Malfunction of the engine-ECU
Measure at the crank angle sensor connector B-77. D Connect the connector. (Use the test harness: MD998478) D Voltage between 2 and earth (Engine: cranking) OK: 0.4 - 4.0 V D Voltage between 2 and earth (Engine: idling) OK: 2.5 - 4.5 V NG
OK
1.NG Measure at the crank angle sensor connector B-77. D Disconnect the connector and measure at the harness side connector. 1. Voltage between 3 and earth (Ignition switch: ON) 2.NG OK: System voltage 2. Voltage between 2 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V 3.NG 3. Continuity between 1 and earth OK: Continuity OK Check the following connector: B-77 OK NG Repair Check trouble symptom. NG Replace the crank angle sensor.
Check the harness wire between the crank angle sensor and the control relay connector, and repair if necessary. Check the following connector: C-53 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the crank angle sensor connector. OK NG Repair Replace the engine-ECU.
13E-16

Probable cause
D D D Malfunction of the starter relay Malfunction of starter relay-related circuit Malfunction of the engine-ECU
Code No.22 Ignition switch-ST signal system

Range of Check D Ignition switch: ON D Injection pump speed: 1,200 r/min or more Set Conditions D Ignition switch-ST signal (high) is input for 10 seconds or more.
Measure at the engine-ECU connector C-55. D Disconnect the connector and measure at the harness side connector. D Voltage between 51 and earth (Ignition switch: ST) OK: 8 V or higher OK Check the following connector: C-55 OK NG Repair Check trouble symptom. NG Replace the engine-ECU.
NG
Check the following connectors: B-30, A-10 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the starter relay connector. OK NG Repair Replace the starter relay.
Code No.23 Idle position switch 1 system

Range of Check D Accelerator pedal position sensor signal output is 1.2 V or higher. D Idle position switch 2: OFF Set Conditions D Idle position switch 1 on signal is input for 1 second or more. Range of Check D Accelerator pedal position sensor signal output is 0.58 V or lower. D Idle position switch 2: ON Set Conditions D Idle position switch 1 off signal is input for 1 second or more. NG
Probable cause
D D D Malfunction of the idle position switch 1 Open or short circuit in idle position switch 1 circuit or poor connector contact Malfunction of the engine-ECU
Check the idle position switch 1. (Refer to P.13E-58.) OK Measure at the accelerator pedal position sensor connector B-41. D Disconnect the connector and measure at the harness side connector. D Voltage between 3 and earth (Ignition switch: ON) OK: 4 V or higher D Continuity between 4 and earth OK: Continuity OK Check the following connector: B-41 OK NG Repair Check trouble symptom. NG Replace the engine-ECU.
Replace the accelerator pedal position sensor.
NG
Check the following connector: C-54 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the accelerator pedal position sensor connector. OK NG Repair Replace the engine-ECU.

Code No.24 Idle position switch 2 system
Range of Check D Accelerator pedal position sensor signal output is 1.2 V or higher. D Idle position switch 1: OFF Set Conditions D Idle position switch 2 on signal is input for 1 second or more. Range of Check D Accelerator pedal position sensor signal output is 0.48 V or lower. D Idle position switch 1: ON Set Conditions D Idle position switch 2 off signal is input for 1 second or more. NG NG
13E-17
Probable cause
D D D Malfunction of the idle position switch 2 Open or short circuit in idle position switch 2 circuit or poor connector contact Malfunction of the engine-ECU
Check the idle position switch 2. (Refer to P.13E-58.) OK Measure at the idle position switch 2 connector B-47 <L.H. drive vehicles>, B-48 <R.H. drive vehicles>. D Disconnect the connector and measure at the harness side connector. D Voltage between 1 and earth (Ignition switch: ON) OK: 4 V or higher OK Check the following connector: B-47 OK NG Repair Check trouble symptom. NG Replace the engine-ECU.
Replace
Check the following connector: C-53 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the idle position switch 2 connector. OK NG Repair Replace the engine-ECU.
13E-18

Probable cause
D D D D Malfunction of the throttle solenoid valve Open or short circuit in throttle solenoid valve circuit or poor connector contact Incorrect vacuum hose routing Malfunction of the throttle actuator
Code No.41 Throttle solenoid valve system

Range of Check From the following condition, the ignition switch is turned to OFF. D 2.2 seconds or more have passed since idle position switch turned on and ignition switch-ST turned off D Accelerator pedal opening amount: Approx. 0 % D Vehicle speed: 0 km/h D Injection pump speed: Between 700 r/min and 1,500 r/min Set Conditions D The difference between the boost sensor signal output before and after the engine stops is 50 mmHg or less for 10 times in succession (ignition switch transition to off counted as one time). NG NG NG
Check the throttle solenoid valve. (Refer to P.13E-60.) OK Check the throttle actuator. (Refer to P.13E-61.) OK Measure at the throttle solenoid valve connector B-49. D Disconnect the connector and measure at the harness side connector. D Voltage between 2 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-53. D Disconnect the connector and measure at the harness side connector. D Voltage between 4 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-53 OK NG Repair Check the vacuum hose routing. NG Check the vacuum hose routing. OK NG Repair Replace the engine-ECU.
Replace
Replace
Check the harness wire between the control relay and the throttle solenoid valve connector, and repair if necessary.
NG
Check the following connector: B-49 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the throttle solenoid valve connector, and repair if necessary.

Code No.43 Timing control solenoid valve system
Range of Check D Ignition switch-ST: OFF D Engine speed: 400 r/min or more D Engine coolant temperature: 60 _C or higher Set Conditions D Target advance value differs from actual advance value by 7_ or more for a continuous period of 10 seconds or more. NG
13E-19
Probable cause
D D D D D Malfunction of the timing control solenoid valve Open or short circuit in timing control solenoid valve circuit or poor connector contact Incorrect ignition timing adjustment Malfunction of the injection pomp Malfunction of the engine-ECU
Check the timing control solenoid valve. (Refer to P.13E-59.) OK Measure at the timing control solenoid valve connector B-56 <L.H. drive vehicles>, B-57 <R.H. drive vehicles>. D Disconnect the connector and measure at the harness side connector D Voltage between 2 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-53. D Disconnect the connector and measure at the harness side connector. D Voltage between 2 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-53 OK NG Repair Check trouble symptom. NG MUT-II Actuator test 11 Timing control solenoid valve OK: Sound of operation can be heard. OK Replace the engine-ECU.
Replace the injection pump. Check the harness wire between the control relay and the timing control solenoid valve connector, and repair if necessary.
NG
NG
Check the following connector: B-56 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the timing control solenoid valve connector, and repair if necessary.
NG
13E-20

Probable cause
D D D D Malfunction of the solenoid-type spill valve Open or short circuit in solenoid-type spill valve circuit or poor connector contact Malfunction of the injection pump Malfunction of the engine-ECU
Code No.44 Solenoid-type spill valve system

Range of Check D Ignition switch-ST: OFF D Injection pump speed: 750 r/min or more D Solenoid-type spill valve relay: ON Set Conditions D Solenoid-type spill valve does not turn off. Range of Check, Set Conditions D Injection pump speed is 5,400 r/min or more for a continuous period of 2 seconds or more. NG
Check the solenoid-type spill valve. (Refer to P.13E-59.) OK Measure at the solenoid-type spill valve connector B-61. D Disconnect the connector and measure at the harness side connector. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-53. D Disconnect the connector and measure at the harness side connector. D Voltage between 3 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-53 OK NG Repair Check trouble symptom. NG MUT-II Actuator test 01 Solenoid-type spill valve OK: Sound of operation can be heard. OK Replace the engine-ECU.
Replace the injection pump. Check the harness wire between the solenoid-type spill valve relay and the solenoid-type spill valve connector, and repair if necessary.
NG
NG
Check the following connector: B-61 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the solenoidtype spill valve connector, and repair if necessary.
NG

Code No.45 Injection timing correction resistor system
Range of Check, Set Conditions D Open or short circuit is detected in injection timing correction resistor circuit.
13E-21
Probable cause
D D D Malfunction of the injection timing correction resistor Open or short circuit in injection timing correction resistor circuit of poor connector contact Malfunction of the engine-ECU
Check the injection timing correction resistor. (Refer to P.13E-60.) OK Measure at the injection timing correction resistor connector B-60. D Disconnect the connector and measure at the harness side connector. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.5 - 5.5 V D Continuity between 2 and earth OK: Continuity OK Check the following connector: B-60 OK NG Repair
NG
NG
Check the following connector: C-54 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the injection timing correction resistor connector. OK NG Repair
Code No.46 Injection rate correction resistor system

Range of Check, Set Conditions D Open or short circuit is detected in injection rate correction resistor circuit.
Probable cause
D D D Malfunction of the injection rate correction resistor Open or short circuit in injection rate correction resistor circuit or poor connector contact Malfunction of the engine-ECU
Check the injection rate correction resistor. (Refer to P.13E-60.) OK Measure at the injection rate correction resistor connector B-58 <L.H. drive vehicles>, B-59 <R.H. drive vehicles>. D Disconnect the connector and measure at the harness side connector. D Voltage between 1 and earth (Ignition switch: ON) OK: 4.5 - 5.5 V D Continuity between 2 and earth OK: Continuity OK Check the following connector: B-58 <L.H. drive vehicles>, B-59 <R.H. drive vehicles> OK NG Repair Check trouble symptom. NG Replace the engine-ECU.
NG
NG
Check the following connector: C-54 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine-ECU and the injection rate correction resistor connector. OK NG Repair Replace the engine-ECU.
13E-22

Probable cause
D D D D D Radio interference of ID codes Incorrect ID code Malfunction of harness or connector Malfunction of the immobilizer-ECU Malfunction of the engine-ECU

Range of Check D Ignition switch: ON Set Conditions D Communication problem between the engine-ECU and the immobilizer-ECU. NOTE If the engine is started while several ignition keys are present nearly, signal mixing may occur, which will cause this diagnosis code to be generated. This code may also be generated when registering the key ID codes. Yes
Is there another ignition key near the ignition key that is inserted in the ignition switch? No
Remove the extra ignition key. NG
Check trouble symptom. Check the immobilizer system. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) Repair
Is a diagnosis code output from the immobilizer-ECU. No Check the following connectors: C-54, C-81, C-66 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the immobilizer-ECU. NG Repair
Yes
NG
OK
Replace the immobilizer-ECU. NG Check trouble symptom. NG Replace the engine-ECU.
DIESEL FUEL - Troubleshooting INSPECTION CHART FOR TROUBLE SYMPTOM
13E-23
13300410023
Caution Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
Trouble symptoms Communication with MUT-II is II impossible. Engine warning lamp and related parts MUT-II communication with all systems is impossible. MUT-II communication with engine-ECU only is impossible. The engine warning lamp does not illuminate right after the ignition switch is turned to the ON position. The engine warning lamp remains illuminating and never goes out. No initial combustion (Starting not possible) Poor startability when engine is cold (Poor starting) Poor startability when engine is cold or warm (Poor starting) Idling stability (Improper idling) Idling speed is low when engine is cold (Improper idling speed) Idling speed is high (Improper idling speed) Idling speed is low (Improper idling speed) Idling speed is unstable (Rough idling, hunting) Idling stability (Engine stalls) Driving Engine stops soon after starting Engine stops during idling Engine output is too low Abnormal engine knocking occurs Abnormally black smoke Abnormally white smoke Hunting occurs while driving Idling speed is improper when A/C is operating Fans (radiator fan and A/C condenser fan) are imoperative Inspection procedure No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Reference page 13E-24 13E-24 13E-25 13E-25 13E-26 13E-26 13E-27 13E-27 13E-28 13E-28 13E-29 13E-29 13E-30 13E-30 13E-31 13E-31 13E-32 13E-32 13E-33 13E-33
Starting
13E-24

Communication with MUT-II is impossible. (MUT-II communication with all systems is impossible.)
Probable cause
Measure at the diagnosis connector C-20. D Voltage between 16 and earth OK: System voltage OK
Check the following connectors: C-66, C-63, (C-132, C-141) <L.H. drive vehicles>, (C-62, C-14) <R.H. drive vehicles> OK Check trouble symptom.
Repair
NG
Measure at the diagnosis connector C-20. D Continuity between 4 and earth D Continuity between 5 and earth OK: Continuity OK Replace the MUT-II.
NG
Check the harness wire between the power supply and the diagnosis connector, and repair if necessary.
Check the harness wire between the diagnosis connector and the earth, and repair if necessary.
INSPECTION PROCEDURE 2 MUT-II communication with engine-ECU only is impossible.

One of the following causes may be suspected. D No power supply to engine-ECU D Defective earth circuit of engine-ECU D Defective engine-ECU D Improper communication line between engine-ECU and MUT-II
Probable cause
D D D D D Malfunction of the engine-ECU power supply circuit Malfunction of the engine-ECU Malfunction of the immobilizer-ECU Open circuit between immobilizer-ECU and diagnosis connector Open circuit between engine-ECU and immobilizerECU
Is communication possible between the MUT-II and the immobilizer-ECU. Yes Check the following connectors: C-54, C-81, C-68, C-66, C-56 <R.H. drive vehicles>, C-83, C-20 OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the diagnosis connector. OK Check the harness wire between the engine-ECU and the immobilizer-ECU. NG Repair
No
Check the diagnosis line between the immobilizer-ECU and the MUT-II, and repair if necessary. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) Repair
NG
NG
Repair
OK
Check the harness wire between the engine-ECU and the earth OK NG Repair Check the engine-ECU power supply and earth circuit. (Refer to P.13E-34, INSPECTION PROCEDURE 21.)

INSPECTION PROCEDURE 3 The engine warning lamp does not illuminate right after the ignition switch is turned to the ON position.
Because there is a burn-out bulb, the engine-ECU causes the engine warning lamp to illuminate for five seconds immediately after the ignition switch is turned to ON. If the engine warning lamp does not illuminate immediately after the ignition switch is turned to ON, one of the malfunctions listed at right has probably occurred. NG
13E-25
Probable cause
D D D Burn-out bulb Defective warning lamp circuit Malfunction of the engine-ECU
MUT-II Data list 11 Battery voltage (Refer to 13E-39.) OK Measure at the engine-ECU connector C-55. D Disconnect the connector and measure at the harness side connector. D Earth the terminal No.57. OK: The engine warning lamp illuminates. NG Check a burn-out bulb. OK NG Replace Measure at the combination meter connector D-03. D Disconnect the connector and measure at the harness side connector. D Voltage between 4 and earth (Ignition switch: ON) OK: System voltage OK Check the following connectors: D-03, C-90 OK NG Repair Check trouble symptom.
Check the engine-ECU power supply and earth circuit. (Refer to P.13E-34, INSPECTION PROCEDURE 21.)
OK
NG
Check the following connectors: C-135, C-131 OK NG Repair Check trouble symptom. NG Check the harness wire between the engine warning lamp and the ignition switch connector, and repair if necessary.
NG
Check the harness wire between the combination meter and the engine-ECU connector, and repair if necessary.
In case such as the above, the cause is probably that the engine-ECU is detecting a problem in a sensor or actuator, or that one of the malfunctions listed at right has occurred. Yes
Probable cause
D D Short-circuit between the engine warning lamp and the engine-ECU Malfunction of the engine-ECU
MUT-II Self-Diagnosis code Are diagnosis codes output? No Measure at the combination meter connector D-03. D Disconnect the connector and measure at the harness side connector. D Continuity between 16 and earth OK: No continuity OK Replace the engine-ECU.
Refer to P.13E-8, INSPECTION CHART FOR DIAGNOSIS CODES. Check the harness wire between the combination meter and the engine-ECU connector, and repair if necessary.
NG
13E-26
No initial combustion (Starting not possible)

The cause is probably a malfunction of the control system, injection nozzles, injection pump, glow system or power supply.
Probable cause
D D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of of the the the the the the control system injection nozzles injection pump glow system immobilizer system engine-ECU
Is immobilizer-ECU diagnosis code output? No MUT-II Self-Diagnosis code Are diagnosis codes output? Yes Refer to P.13E-8, INSPECTION CHART FOR DIAGNOSIS CODES.
Yes
Check the immobilizer system. (Refer to GROUP 54 - Ignition Switch and Immobilizer System.) Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Glow plug, glow plug relay D Battery D Fuel cut solenoid valve D Injection nozzle D Compression pressure D Injection pump D Contamination (water, kerosene, etc.) in fuel D Immobilizer system
No
INSPECTION PROCEDURE 6 Poor startability when engine is cold (Poor starting)

The cause is probably a malfunction of the control system, injection pump, fuel system, air intake system or glow system.
Probable cause
D D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of of the the the the the the control system injection pump fuel system air intake system glow system engine-ECU
MUT-II Self-Diagnosis code Are diagnosis codes output? Yes Refer to P.13E-8, INSPECTION CHART FOR DIAGNOSIS CODES.
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Glow plug, glow plug relay D Injection nozzle, fuel filter D Throttle body assembly D Starter switch input signal D Engine oil viscosity D Injection pump D Contamination (water, kerosene, etc.) in fuel

INSPECTION PROCEDURE 7 Poor startability when engine is cold or warm (Poor starting)
The cause is probably a malfunction of the control system, injection pump, fuel system or air intake system.
13E-27
Probable cause
D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of the the the the the control system injection pump fuel system air intake system engine-ECU
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Injection nozzle, fuel filter D Throttle body assembly D Compression pressure D Injection pump D Contamination (water, kerosene, etc.) in fuel
INSPECTION PROCEDURES 8 Idling speed is low when engine is cold (Improper idling speed)
The cause is probably a malfunction of the control system, injection pump or fuel system.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the control system injection pump fuel system engine-ECU
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Injection nozzle D Injection pump D Fuel filter
13E-28
Idling speed is high (Improper idling speed)

The cause is probably a malfunction of the control system, injection nozzles or injection pump.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the control system injection nozzles injection pump engine-ECU
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Injection nozzle D Injection pump D Starter switch input signal
INSPECTION PROCEDURE 10 Idling speed is low (Improper idling speed)

Probable cause
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Injection pump D Injection nozzle

INSPECTION PROCEDURE 11 Idling speed is unstable (Rough idling, hunting)
The cause is probably a malfunction of the control system, injection pump, fuel system, air intake system or glow system.
13E-29
Probable cause
D D D D D D D Malfunction Malfunction Malfunction Malfunction malfunction Malfunction Malfunction of of of of of of of the the the the the the the control system injection pump fuel system air intake system glow system EGR system engine-ECU
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Glow plug, glow plug relay D EGR system D Injection nozzle D Compression pressure D Valve clearance D Throttle body assembly D Injection timing D Air in fuel line D Injection pump
INSPECTION PROCEDURE 12 Engine stops soon after starting

The cause is probably a malfunction of the control system, injection pump, fuel system or air intake system.
Probable cause
D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of the the the the the control system injection pump fuel system air intake system engine-ECU
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Throttle body assembly D Injection nozzle, fuel filter D Injection pump
13E-30
Engine stops during idling
INSPECTION PROCEDURE 13 Probable cause

D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of the the the the the control system injection pump EGR system air intake system engine-ECU The cause is probably a malfunction of the control system, injection pump, air intake system or power supply system.
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Power supply system D Throttle body assembly D EGR system D Injection pump
INSPECTION PROCEDURE 14 Engine output is too low

The cause is probably a malfunction of the control system, injection pump, fuel system, air intake system or EGR system.
Probable cause
D D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of of the the the the the the control system injection pump fuel system air intake system EGR system engine-ECU
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Injection nozzle, fuel filter D Throttle body assembly D EGR system D Turbocharger D Compression pressure D Injection timing D Injection pump D Contamination (water, kerosene, etc.) in fuel

INSPECTION PROCEDURE 15 Abnormal engine knocking occurs
13E-31
Probable cause
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42) OK NG Repair Check the following items: D Injection nozzle D Injection timing D Injection pump
INSPECTION PROCEDURE 16 Abnormally black smoke

The cause is probably a malfunction of the control system, injection pump, fuel system, air intake system or EGR system.
Probable cause
D D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of of the the the the the the control system injection pump fuel system air intake system EGR system engine-ECU
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Air cleaner D Injection nozzle D Throttle body assembly D EGR system D Turbocharger D Injection pump D Injection timing
13E-32
Abnormally white smoke

D D D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of of of the the the the the the the control system injection pump fuel system air intake system EGR system glow system engine-ECU The cause is probably a malfunction of the control system, injection pump, fuel system, air intake system, EGR system or glow system.
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Glow plug, glow plug relay D Injection nozzle D Throttle body assembly D EGR system D Turbocharger D Injection pump D Injection timing
INSPECTION PROCEDURE 18 Hunting occurs while driving

The cause is probably a malfunction of the control system, injection pump, fuel system or EGR system.
Probable cause
D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of the the the the the control system injection pump fuel system EGR system engine-ECU
No
Carry out MUT-II Data list check and Actuator test. (Refer to P.13E-38, 42.) OK NG Repair Check the following items: D Injection nozzle, fuel filter D EGR system D Injection pump

OK
13E-33
Measure at the engine-ECU connector C-54. D Connect the connector. D Voltage between 39 and earth (Engine: Idling, Outside air temperature: 25 _C or higher) OK: 0 - 3 V [When A/C is MAX. COOL condition (when the load by A/C is high)] System voltage [(When A/C is MAX. HOT condition (When the load by A/C is low)] NG Check the A/C system. (Refer to GROUP 55 - On-vehicle Service.)
INSPECTION PROCEDURE 20 Fans (radiator fan and A/C condenser fan) are imoperative
NG
Measure at the engine-ECU connector C-53. D Disconnect the connector and measure at the harness side connector. D Voltage between 18 and earth (Ignition switch: ON) OK: 4.8 - 5.2 V (Fan rotates at high speed.) D Short circuit between 18 and earth (Ignition switch: ON) OK: Fan stops. OK Check the following connector: C-53 OK NG Repair Check trouble symptoms. NG Replace the engine-ECU.
Check the harness wire between the engine-ECU and the fan controller connector. OK NG Repair Check the radiator fan and the condenser fan circuit. (Refer to GROUP 14 - Troubleshooting.)
13E-34
INSPECTION PROCEDURE 21 Check the engine-ECU power supply and earth circuit
Check the control relay. (Refer to P.13E-56.) OK Measure at the control relay connector C-31. D Disconnect the connector and measure at the harness side connector. 1. Voltage between 2, 3 and earth OK: System voltage OK Check trouble symptoms. NG Check the harness wire between the battery and control relay connector, and repair if necessary. 1.NG Measure at the engine-ECU connector C-53, C-55. D Disconnect the connector and measure at the harness side connector. 2,3 NG 1. Voltage between 25 and earth (Ignition switch: ON) OK: System voltage 2. Voltage between 59 and earth 4.NG OK: System voltage 3. Voltage between 72 and earth OK: System voltage (When the terminal 59 is earthed) 4. Continuity between 1, 14, 26 and earth 5.NG OK: Continuity 5. Voltage between 61 and earth OK: System voltage OK Check the following connectors: C-53, C-55 OK NG Repair Check trouble symptoms. NG Replace the engine-ECU. NG NG Replace
Check the following connector: B-30 OK NG Repair
Check the following connector: C-92, C-131 OK NG Repair Check trouble symptoms. NG Check the harness wire between the engine-ECU and ignition switch connector. OK NG Repair Check the ignition switch. (Refer to GROUP 54 - Ignition Switch.) Check the harness wire between the engine-ECU and control relay connector, and repair if necessary. Check the harness wire between the engine-ECU and earth, and repair if necessary.
Check the following connectors: C-83, C-66, (C-63, C-132, C-141) <L.H. drive vehicles>, (C-62, C-14) <R.H. drive vehicles> OK NG Repair Check trouble symptoms. NG Check the harness wire between the battery and engine-ECU connector, and repair if necessary.

INSPECTION PROCEDURE 22 Check the solenoid-type spill valve relay circuit.
NG NG
13E-35
Check the solenoid-type spill valve relay. (Refer to P.13E-56.) OK Measure at solenoid-type spill valve relay connector C-52. D Disconnect the connector and measure at the harness side connector. D Voltage between 2, 3 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-55. D Disconnect the connector and measure at the harness side connector. D Voltage between 71 and earth OK: System voltage (When the terminal 3 is earthed) OK Check the following connector: C-55 OK NG Repair Check trouble symptoms. NG Replace the engine-ECU.
Replace
Check the harness wire between the control relay and solenoid-type spill valve relay connectors, and repair if necessary.
NG
Check the following connector: C-52 OK NG Repair Check trouble symptoms. NG Check the harness wire between the solenoid-type spill valve relay and engine-ECU connectors, and repair if necessary.
13E-36
INSPECTION PROCEDURE 23 Check the fuel cut solenoid valve circuit.

NG NG
Check the fuel cut solenoid valve. (Refer to P.13E-60.) OK Measure at the fuel cut solenoid valve connector B-55. D Disconnect the connector and measure at the harness side connector. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Check the connector B-55, and repair if necessary.
Replace
Check the following connector: C-52 OK NG Repair Check trouble symptoms. NG Check the harness wire between the fuel cut solenoid valve and solenoid-type spill valve relay connectors, and repair if necessary.
INSPECTION PROCEDURE 24 Check the EGR solenoid valve circuit.

NG
Check the EGR solenoid valve. (Refer to GROUP 17 - Emission Control System.) OK Measure at the EGR solenoid valve connector B-06. D Disconnect the connector and measure at the harness side connector. D Voltage between 1 and earth (Ignition switch: ON) OK: System voltage OK Measure at the engine-ECU connector C-53. D Disconnect the connector and measure at the harness side connector. D Voltage between 16 and earth (Ignition switch: ON) OK: System voltage OK Check the following connector: C-53 OK NG Repair Check trouble symptoms.
Replace
NG
Check the harness wire between the control relay and EGR solenoid valve connector, and repair if necessary.
NG
Check the following connector: B-06 OK NG Repair Check trouble symptoms. NG Check the harness wire between the engine-ECU and EGR solenoid valve connector, and repair if necessary.
NG

INSPECTION PROCEDURE 25 Check the glow plug relay circuit
NG NG
13E-37
Check the glow plug relay. (Refer to GROUP 16 - Glow System.) OK Measure at the glow plug relay connector B-52. D Disconnect the connector and measure at the harness side connector. D Voltage between 1 and earth (Ignition switch: ON)(Engine coolant temperature: 40 _C or lower) OK: System voltage (Between approx. 4 - 8 seconds) OK Check the following connector, and repair if necessary. B-52
Replace
Check the following connector: C-55 OK NG Repair Check trouble symptoms. NG Check the harness wire between the engine-ECU and glow plug relay connector. OK NG Repair Check the glow control system. (Refer to GROUP 16 - Glow System.) OK NG Repair Replace the engine-ECU.
INSPECTION PROCEDURE 26 Check the A/C switch and A/C relay circuit
NG
Check the A/C compressor relay. (Refer to GROUP 55 - On-vehicle Service.) OK Check the A/C variable capacity relay. (Refer to GROUP 55 - On-vehicle Service.) OK
Replace
NG
Replace
NG Measure at the engine-ECU connector C-55. D Disconnect the connector and measure at the harness side connector. D Voltage between 52 and earth, and between 53 and earth (Ignition switch: ON) OK: 0 - 3 V (A/C switch: OFF) OK System voltage (A/C switch: ON) D Short circuit between 53 and earth (Ignition switch: ON, A/C switch: ON) OK: A/C compressor clutch turns on.
Check the following connector: C-55 OK NG Repair Check trouble symptoms. NG Replace the engine-ECU.
13E-38

13300420026

Caution Driving tests always need another personnel.
Item No. Inspection item Intake air temperature sensor Inspection contents Normal condition Intake air temperature is - 20 _C Intake air temperature is 0 _C Intake air temperature is 20 _C Intake air temperature is 40 _C Intake air temperature is 80 _C 02 Engine coolant temperature sensor Ignition switch: ON or with engine running Engine coolant temperature is - 20 _C Engine coolant temperature is 0 _C Engine coolant temperature is 20 _C Engine coolant temperature is 40 _C Engine coolant temperature is 80 _C 03 Barometric pressure sensor Ignition switch: ON At altitude of 0 m At altitude of 600 m At altitude of 1,200 m At altitude of 1,800 m 04 Boost sensor D D Engine coolant temperature: 80 - 95 _C Lamps, electric cooling fan and all accessories: OFF Transmission: Neutral Ignition switch: ON At altitude of 0 m At altitude of 600 m At altitude of 1,200 m At altitude of 1,800 m When the engine is suddenly raced - 20 _C 0 _C 20 _C 40 _C 80 _C - 20 _C 0 _C 20 _C 40 _C 80 _C 101 kPa 95 kPa 88 kPa 81 kPa 101 kPa 95 kPa 88 kPa 81 kPa Increases Code No.12 Code No.13 Code No.15 Inspection procedure No. Code No.16
Reference page 13E-12
01
13E-12
13E-11
13E-10
D D

Item No. Inspection item Diesel fuel temperature sensor Inspection contents Normal condition Fuel temperature is - 20 _C Fuel temperature is 0 _C Fuel temperature is 20 _C Fuel temperature is 40 _C Fuel temperature is 80 _C 06 Vehicle speed sensor Pump operation sensor (high speed) Pump operation sensor (low speed) Accelerator pedal position sensor When vehicle is moving Compare the speeds displayed on the speedometer and the MUT-II. Compare the engine speeds displayed on the tachometer and MUT-II. Compare the engine speeds displayed on the tachometer and the MUT-II. Accelerator pedal is released Accelerator pedal is fully depressed Ignition switch: ON Throttle lever: Idle position Throttle lever: Fully open position Ignition switch: ON Engine: After having warmed up Engine: Idling A/C switch OFF ON Engine: After having warmed up When engine is suddenly decelerated from 3,000 r/min. - 20 _C 0 _C 20 _C 40 _C 80 _C Identical Code No.17 Inspection procedure No. Code No.14
13E-39
05
13E-13
07
Engine: Idling
The same engine speed is displayed. The same engine speed is displayed. 480 - 570 mV 4000 4690 mV 0% 100 % System voltage 51.5 66.5 deg Advances slightly Momentarily increases slightly
Code No.18, 19
13E-14
08
Engine: Idling
Code No.18, 19
13E-14
09
Ignition switch: ON
Code No.11
13E-9
10
Accelerator pedal position sensor (Accelerator opening angle) Battery voltage Solenoidtype spill valve
Code No.11
13E-9
11 12
Code No.44
13E-20
13
Timing control solenoid valve duty ratio
Code No.43
13E-19
13E-40
Item No. Inspection item EGR command value

Inspection contents Normal condition 44.8 % When engine is suddenly raced 0% 0.2 - 4.5 V Inspection procedure No. Procedure No.24 Reference page 13E-36
14
Engine: Idle Engine: After having warmed up Ignition switch: ON
15
Injection rate correction resistance value Injection timing correction resistance value Fuel injection rate command value Actual injection timing
Code No.46
13E-21
16
Ignition switch: ON
0.2 - 4.5 V
Code No.45
13E-21
17
Engine: Idling A/C switch: OFF ON
3.5 - 12.5 m3/st Increases slightly The same value as the injection timing command value is displayed. 12.6 14.6 deg Advances slightly 0%
18
Code No.43
13E-19
19
Injection timing command value
Engine: Idling Engine: Racing to 3500 r/min or more
20
Radiator fan, A/C condenser fan duty ratio
Engine: Idling
When radiator fan and condenser fan are not operating When radiator fan and condenser fan are operating
Procedure No.26
13E-20
5 % or more (varies in accordance with fan operating speed)

Item No. Inspection item Idle position switch 1 (Built into accelerator pedal position sensor) Idle position switch 2 Inspection contents Normal condition Accelerator pedal is released Accelerator pedal is slightly depressed Ignition switch: ON Accelerator pedal is released Accelerator pedal is slightly depressed 43 A/C switch Engine: Idling (When the A/C switch is on, the A/C compressor should be driven.) Ignition switch: ON A/C switch: ON A/C switch: OFF Engine: Stopped Engine: Cranking Ignition switch: ON Ignition switch: ON Engine: Idling after having warmed up Ignition switch: ON A/C switch: ON A/C switch: OFF ON OFF ON OFF ON OFF OFF ON ON ON ON OFF ON Code No.22 Procedure No.21 Procedure No.26 Code No.44 Procedure No.25 Code No.41 Procedure No.26 Code No.24 Inspection procedure No. Code No.23
13E-41
41
Ignition switch: ON
42
13E-17
13E-37
44
Ignition switch: ST Ignition switch-IG Control relay A/C relay
13E-16
45 46 47
13E-34 13E-37
49
Solenoidtype spill valve relay Glow plug relay Throttle solenoid valve Engine warning lamp Glow indicator lamp
13E-20
52
MUT-II Actuator test: Glow plug relay (item No.2) is driven Engine: After having warmed up Engine: Idling Gently racing
ON (for approx. 6 seconds) ON OFF ON (For approx. 6 seconds) ON (for approx. 6 seconds)
13E-37
53
13E-18
55
MUT-II Actuator test: Engine warning lamp (item No.16) is driven MUT-II Actuator test: Glow indicator lamp (item No.15) is driven
56
13E-42
Item No. 01 Inspection item Solenoid-type spill valve relay Glow plug relay

13300440022

Drive contents Turns relay from OFF to ON and from ON to OFF Turns relay from OFF to ON and from ON to OFF. Inspection contents Ignition switch: ON Normal condition Operation sound can be heard. Battery voltage is applied to glow plug when glow plug relay is ON. A/C compressor clutch operation sound can be heard. Throttle valve opens half way. Throttle valve opens fully. Operation sound can be heard. Operation sound can be heard. Inspection procedure No. -
Reference page -
02
Ignition switch: ON
Procedure No.25
13E-37
03
A/C compressor relay
Turns relay from OFF to ON and from ON to OFF. Turns throttle solenoid valve ON. Turns throttle solenoid valve OFF.
D D
Ignition switch: ON A/C switch: ON
Procedure No.26
13E-37
08
Throttle solenoid valve
Engine: 1500 r/min Engine: Idling
Code No.41
13E-18
09
Code No.41
13E-18
11
Timing control solenoid valve
Drives timing control solenoid valve at 94 % duty. Turns solenoid-type spill valve from OFF to ON and from ON to OFF. Turns EGR solenoid valve OFF. Turns glow indicator lamp ON and OFF. Turns engine warning lamp ON and OFF.
Ignition switch: ON
Code No.43
13E-19
13
Solenoid-type spill valve
Ignition switch: ON
Code No.44
13E-20
14
EGR solenoid valve Glow indicator lamp
Engine: Idling
EGR valve closes. Glow indicator lamp illuminates and switches OFF. Engine warning lamp illuminates and switches OFF.
Procedure No.24 -
13E-36
15
Ignition switch: ON
16
Engine warning lamp
Ignition switch: ON

Item No. 17 Inspection item Radiator fan, A/C condenser fan Drive contents Drives radiator fan and A/C condenser fan at 0 % duty Drives radiator fan and A/C condenser fan at 50 % duty Drives radiator fan and A/C condenser fan at 100 % duty Inspection contents Ignition switch: ON Normal condition Fans stop. Inspection procedure No. Procedure No.20
13E-43
18
Ignition switch: ON
Fans operate at medium speed. Fans operate at high speed.
19
Ignition switch: ON
CHECK AT THE ENGINE-ECU TERMINALS

13300450025
TERMINAL VOLTAGE CHECK CHART 1. Connect a needle-nosed wire probe (test harness: MB991223 or paper clip) to a voltmeter probe. 2. Insert the needle-nosed wire probe into each of the engine-ECU connector terminals from the wire side, and measure the voltage while referring to the check chart. NOTE (1) Make the voltage measurement with the engine-ECU connectors connected. (2) You may find it convenient to pull out the engine-ECU to make it easier to reach the connector terminals. (3) The checks can be carried out off the order given in the chart. Caution Short-circuiting the positive (+) probe between a connector terminal and earth could damage the vehicle wiring, the sensor, engine-ECU or all of them. Be careful to prevent this! 3. If voltmeter shows any division from 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 repair has corrected the problem.
13E-44
Terminal No. 2
Check item Timing control solenoid valve
Check condition (Engine condition) Ignition switch: ON Engine: Idling Engine: 2,500 r/min
Normal condition 11 - 13 V 3.5 - 7.5 V 5 - 9V 11 - 13 V 0 12.5 V (varies repeatedly) and momentarily increases 0 - 3V
Ignition switch: ON When engine is suddenly decelerated from 3000 r/min
Ignition switch: ON Engine: Idling Engine coolant temperature is 40 _C or lower Engine coolant temperature is 80 _C or higher
12 - 15 V 0 - 3V 0.4 - 4.0 V 2.5 - 4.5 V 0.2 - 1.0 V (AC range) 1.2 - 2.2 V (AC range) 11 - 13 V Momentarily increases 0 - 0.3 V 0.7 V or more 0 - 1V 4 V or higher
Crank angle sensor
Engine: Cranking Engine: Idling
Between terminals 10 and 23
Pump operation sensor
Engine: Idling Engine: 2,500 r/min
16
EGR solenoid valve
Ignition switch: OFF ON When idling after having warmed up, engine is suddenly raced.
18
Fan controller
When radiator fan and A/C condenser fan are not operating When radiator fan and A/C condenser fan are operating
19
Idle position switch 2
Ignition switch: ON
Accelerator pedal is released Accelerator pedal is slightly depressed

Terminal No. 21 25 31 Check item Vehicle speed sensor Ignition switch-IG A/C switch 2 Check condition (Engine condition) D D Ignition switch: ON Vehicle is moving forward slowly
13E-45
Normal condition 05V (Varies repeatedly) 11 - 13 V 0 - 3V
Ignition switch: ON D D Engine: Idling When A/C is MAX. COOL Outside air tem- condition (When the load perature: 25 _C by A/C is high) or more When A/C is MAX. HOT condition (When the load by A/C is low)
System voltage
33 34 35
Fuel injection rate correction resistor Diesel fuel temperature sensor Engine coolant temperature sensor
Ignition switch: ON Ignition switch: ON (when cranking at cold engine) Ignition switch: ON Engine coolant temperature is 0 _C Engine coolant temperature is 20 _C Engine coolant temperature is 40 _C Engine coolant temperature is 80 _C
0.2 - 4.5 V 0.5 - 3.4 V 3.2 - 3.8 V 2.3 - 2.9 V 1.3 - 1.9 V 0.3 - 0.9 V 3.2 - 3.8 V 2.3 - 2.9 V 1.5 - 2.1 V 0.4 - 1.0 V 2.0 - 2.6 V 1.7 - 2.3 V 4.5 - 5.5 V 0.2 - 4.5 V Accelerator pedal is released Accelerator pedal is depressed 0 - 1V 4 V or higher
36
Ignition switch: ON
Intake air temperature is 0 _C Intake air temperature is 20 _C Intake air temperature is 40 _C Intake air temperature is 80 _C
37
Boost sensor
Ignition switch: ON
Altitude is 0 m Altitude is 1,200 m
38 41 43
Sensor applied voltage Fuel injection timing correction resistor Idle position switch 1
Ignition switch: ON Ignition switch: ON Ignition switch: ON
13E-46
Terminal No. 44 Check item Accelerator pedal position sensor

Check condition (Engine condition) Ignition switch: ON Accelerator pedal is released Accelerator pedal is fully depressed Normal condition 0.3 - 0.8 V 4.2 - 4.5 V 8 V or higher A/C switch is off A/C switch is on (A/C compressor is operating) 0 - 3V 13 - 15 V 13 - 15 V or momentarily 6 V or more 0 - 3V
51 52
Ignition switch-ST A/C switch 1
Engine: Cranking Engine: Idling
53
A/C relay
D D D D
Engine: Idling A/C switch: OFF ON (A/C compressor is operating)
55
Glow indicator lamp
Ignition switch: OFF ON 0 - 1 V; after approx. Engine coolant temperature is 40 _C or less 1 second 11 - 13 V (at engine coolant temperature of 20 _C) 0 - 3 V (after several seconds) 9 - 13 V 11 - 13 V 0 - 3V
57
Engine warning lamp
59
Control relay
Ignition switch: OFF Ignition switch: ON
60
Glow plug relay (pre-heat time control)
D D
Ignition switch: OFF ON 9 - 12 V; after Engine coolant temperature is 40 _C or less approx. 8 seconds (Pre-glow function check) 0 - 0.5 V (at engine coolant temperature of 20 _C) 11 - 13 V Engine coolant temperature is 5 _C or less Engine coolant temperature is 5 _C or more 0 - 3V 13 - 15 V 0.39 V (after approx. 3 seconds) 0V 11 - 13 V
61 66
Backup power supply A/C variable capacity relay
Ignition switch: OFF D D Engine: Idling A/C switch: ON
71
Solenoid-type spill valve Power supply
Ignition switch: ON OFF
72
Ignition switch: ON
13E-47
CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1. Turn the ignition switch to OFF. 2. Disconnect the engine-ECU connector. 3. Measure the resistance and check for continuity between the terminals of the engine-ECU harness-side connector while referring to the check chart. NOTE (1) When measuring resistance and checking continuity, a harness for checking contact pin pressure should be used instead of inserting a test probe. (2) Checking need not be carried out in the order given in the chart. Caution If the terminals that should be checked are mistaken, or if connector terminals are not correctly shorted to earth, damage may be caused to the vehicle wiring, sensors, engine-ECU and/or ohmmeter. Be careful to prevent this! 4. If the ohmmeter shows any deviation from the standard value, check the corresponding sensor, actuator and related electrical wiring, and then repair or replace. 5. After repair or replacement, recheck with the ohmmeter to confirm that the repair or replacement has corrected the problem.
Terminal No. 2 - 72 4 - 72 10 - 23 16 - 72 19 - Body earth
Check item Timing control valve Throttle solenoid valve Pump operation sensor EGR solenoid valve Idle position switch 2
Normal condition (Check condition) 8 - 12 W (At 20 _C) 36 - 44 W (At 20 _C) 215 - 245 W (At 20 _C) 11 - 14 W (At 20 _C) Continuity (When accelerator lever is at idle position) No continuity (When accelerator lever is at slightly open)
13E-48
Terminal No. 26 - Body earth 33 - 46 34 - 46 35 - 46 Check item

Normal condition (Check condition) Continuity (0 W) 0.1 - 2.5 kW (At 20 _C) 2.2 - 2.7 kW 5.1 - 6.5 kW (When engine coolant temperature is 0 _C) 2.1 - 2.7 kW (When engine coolant temperature is 20 _C) 0.9 - 1.3 kW (When engine coolant temperature is 40 _C) 0.26 - 0.36 kW (When engine coolant temperature is 80 _C)
Engine-ECU earth Injection rate correction resistor Diesel fuel temperature sensor Engine coolant temperature sensor
36 - 46
5.3 - 6.7 kW (When intake air temperature is 0 _C) 2.3 - 3.0 kW (When intake air temperature is 20 _C) 1.0 - 1.5 kW (When intake air temperature is 40 _C) 0.30 - 0.42 kW (When intake air temperature is 80 _C)
41 - 46 43 - 46
Injection timing correction resistor Idle position switch 1
0.1 - 2.5 kW (At 20 _C) Continuity (When accelerator lever is at idle position) No continuity (When accelerator lever is at slightly open)
Analyzer
13300460028
CRANK ANGLE SENSOR Measurement Method 1. Disconnect the crank angle sensor connector and connect the special tool (test harness: MD998478) in between. 2. Connect the analyzer special patterns pickup to crank angle sensor connector terminal (2) (black clip of special tool). Alternate Method (Test harness not available) Connect the analyzer special patterns pickup to engine-ECU terminal 9.

Standard Wave pattern Observation conditions
13E-49
2 engine revolutions (1 camshaft revolution) (V) 15 _BTDC 75 _ATDC The time (cycle time) T is reduced when the engine speed increase
0 No.1 TDC TDC: Top dead centre No.3 TDC No.4 TDC No.2 TDC
Time
13E-50

Analyzer
PUMP OPERATION SENSOR Measurement Method 1. Disconnect the pump operation sensor connector and connect the special tool (test harness: MB991348) in between. (All terminals should be connected.) 2. Connect the analyzer special patterns pickup to pump operation sensor connector terminal (1). Alternate Method (Test harness not available) Connect the analyzer special patterns pickup to engine-ECU terminal 10.


13E-51
2 engine revolutions (1 camshaft revolution) (V) The time (cycle time) T is reduced when the engine speed increases Time
Time
Examples of Abnormal Wave Patterns D Example Cause of problem Loose timing belt Incorrect installation of injection pump or pump operation sensor Wave pattern characteristics Wave pattern is displaced to the left or right.
Analyzer
SOLENOID-TYPE SPILL VALVE Measurement Method 1. Disconnect the solenoid-type spill valve connector and connect the special tool (test harness: MB991348) in between. (Both the power supply side and the engine-ECU side should be connected.) 2. Connect the analyzer special patterns pickup to solenoid-type spill valve connector terminal (2).
13E-52

Alternate Method (Test harness not available) Connect the analyzer special patterns pickup to engine-ECU terminal 3.

Function Pattern height Variable knob Pattern selector Engine r/min Special patterns Variable Adjust while viewing the wave pattern Display Idle speed
(V)
Point B Point A
10
Solenoid back electromotive force
Time
Point B: Solenoid-type spill valve drive cycle Check that cycle time T becomes shorter when the engine speed increases.
DIESEL FUEL - On-vehicle Service
13E-53
13300120056
ON-VEHICLE SERVICE
EVACUATION OF WATER FROM FUEL FILTER

Water is in the filter when fuel filter warning lamp lights. Evacuate water by the following procedures. 1. Loosen the water level sensor. 2. Operate the hand pump to drain the water, and then tighten the water level sensor to the specified torque. Tightening torque: 13 Nm
Water level sensor
EVACUATION OF AIR FROM FUEL LINE

13300130059
Hand pump
Air plug
Bleed the air from the fuel line after refilling the fuel. D When fuel is drained for service. D When fuel filter is replaced. D When main fuel line is removed. 1. Loosen fuel filter air plug. 2. Place rags around air plug hole. Operate hand pump repeatedly until no bubbles come from plug hole. Tighten air plug. 3. Repeat until hand pump operation becomes stiff.
FUEL FILTER CARTRIDGE REPLACEMENT

13300320036
Refer to GROUP 13F.
ACCELERATOR PEDAL POSITION SENSOR AND IDLE POSITION SWITCH 1 ADJUSTMENT

13300600017
Accelerator pedal position sensor (with built-in idle position switch 1)
1. Connect the MUT-II to the diagnosis connector. 2. Turn the ignition switch to ON. (but do not start the engine.) 3. Check the accelerator pedal position sensor output voltage. Standard value: 530 - 570 mV 4. If the output voltage is outside the standard value range, loosen the accelerator pedal position sensor mounting bolt and turn the accelerator pedal position sensor body to adjust. After adjusting, securely tighten the mounting bolt. 5. Check the voltage at the point where idle position switch 1 turns from on to off. Standard value: 650 - 1,150 mV 6. If the voltage is outside the standard value range, replace the accelerator pedal position sensor assembly.
13E-54

7. Check the accelerator pedal position sensor output voltage when the accelerator pedal is fully depressed. Standard value: 4,000 - 4,690 mV NOTE If the voltage is outside the standard value range, check whether there are any marks which show that idle position switch 2 has been moved. If such marks can be found, adjust the idle position switch 2. If no such marks can be found, re-adjust the output voltage of the accelerator pedal position sensor. 8. Turn the ignition switch to OFF. 9. Disconnect the MUT-II.
IDLE POSITION SWITCH 2 ADJUSTMENT

13300610010
NOTE (1) The idle position switch 2 should not be moved unnecessarily; it has been precisely adjusted by the manufacturer. (2) If the adjustment is disturbed for any reason, re-adjust as follows. 1. 2. 3. 4. Loosen the tension of the accelerator cable sufficiently. Connect the MUT-II to the diagnosis connector. Turn the ignition switch to ON. (but do not start the engine.) Check the accelerator pedal position sensor output voltage when the accelerator pedal is fully depressed. Standard value: 4,000 - 4,690 mV 5. If the output voltage is outside the standard value range, loosen the accelerator pedal position sensor mounting bolt and turn the accelerator pedal position sensor body to adjust. Standard value: 4,350 mV 6. Tighten securely the accelerator pedal position sensor mounting bolt. 7. Back out the idle position switch 2 lock nut. 8. Adjust the idle position switch 2 so that the accelerator pedal position sensor output voltage is within the standard value range when the accelerator pedal is released. Standard value: 530 - 570 mV 9. While holding the idle position switch 2 so that it doesnt move, tighten the lock nut securely. 10. Turn the ignition switch to OFF. 11. Disconnect the MUT-II. 12. Adjust the tension of the accelerator cable.
DIESEL FUEL - On-vehicle Service COMPONENT LOCATION

Name A/C relay A/C switch Accelerator pedal position sensor (with built-in idle position switch 1) Boost sensor Control relay Crank angle sensor Diagnosis connector Diesel fuel temperature sensor EGR solenoid valve Solenoid-type spill valve Solenoid-type spill valve relay Symbol G N C D L A K H D H L Name Engine coolant temperature sensor Engine-ECU Engine warning lamp (check engine lamp) Glow indicator lamp Glow plug relay Idle position switch 2 Intake air temperature sensor Pump operation sensor Throttle solenoid valve Timing control solenoid valve Vehicle speed sensor
13E-55
13300470021
Symbol I M J J F C B H D H E
13E-56
DIESEL FUEL - On-vehicle Service CONTROL RELAY AND SOLENOID-TYPE SPILL VALVE RELAY CONTINUITY CHECK
13300620013
Control relay and solenoidtype spill valve relay
Battery voltage

13300490027
1. Disconnect the intake air temperature sensor connector. 2. Measure resistance between terminals 1 and 2. Standard value: 2.3 - 3.0 kW (at 20_C) 0.30 - 0.42 kW (at 80_C) 3. Remove the intake air temperature sensor.
5. If the value deviates from the standard value or the resistance remains unchanged, replace the intake air temperature sensor. 6. Install the intake air temperature sensor and tighten it to the specified torque. Tightening torque: 12 - 15 Nm
13E-57

Caution Be careful not to touch the connector (resin section) with the tool when removing and installing. 1. Remove the engine coolant temperature sensor.
4. Apply sealant to threaded portion. Specified sealant: 3M NUT Locking Part No.4171 or equivalent 5. Install the engine coolant temperature sensor and tighten it to the specified torque. Tightening torque: 29 Nm
Equipment side connector Accelerator pedal position sensor
ACCELERATOR PEDAL POSITION SENSOR 13300630016 CHECK

1. Disconnect the accelerator pedal position sensor connector. 2. Measure the resistance between the accelerator pedal position sensor side connector terminal 1 and terminal 4. Standard value: 3.5 - 6.5 kW 3. Measure the resistance between the accelerator pedal position sensor side connector terminal 2 and terminal 4. Normal condition:
Depress the accelerator pedal slowly until fully depressed position from the idle position. Changes smoothly in proportion to the opening angle of the throttle valve.
13E-58

4. If the resistance is outside the standard value, or if it doesnt change smoothly, replace the accelerator pedal position sensor. NOTE For the accelerator pedal position sensor adjustment procedure, refer to P.13E-53.
APS equipment side connector Accelerator pedal position sensor
IDLE POSITION SWITCH 1 CHECK
13300640019
1. Disconnect the accelerator pedal position sensor connector. 2. Check the continuity between the accelerator pedal position sensor connector side terminal 3 and terminal 4. Normal condition:
3. If out of specification, replace the idle position switch 1. NOTE After replacement, the accelerator pedal position sensor should be adjusted. (Refer to P.13E-53.)
IDLE POSITION SWITCH 2 CHECK

13300650012
1. Disconnect the idle position switch 2 connector. 2. Check the continuity between the idle position switch 2 terminal and body earth. Normal condition:
3. If out of specification, replace the idle position switch 2.

NOTE After replacement, the accelerator pedal position sensor should be adjusted. (Refer to P.13E-53.)
DIESEL FUEL - On-vehicle Service SOLENOID-TYPE SPILL VALVE CHECK

13E-59
13300660015
1. Disconnect the solenoid-type spill valve connector. 2. Measure the resistance between terminals 1 and 2. Standard value: 1 - 2 W (at 20_C)
3. Check that the sound of the solenoid valve operating can be heard when battery voltage is applied momentarily (for 2 - 3 seconds) between the solenoid-type spill valve terminals. Caution Because the solenoid-type spill valve is current-controlled, it should not be left for a long time with the voltage applied.
TIMING CONTROL SOLENOID VALVE CHECK

13300560025
Timing control solenoid valve
1. Disconnect the timing control solenoid valve connector. 2. Measure the resistance between terminals 1 and 2. Standard value: 8 - 12 W (at 20_C)
3. Check that the sound of the solenoid valve operating can be heard when battery voltage is applied between the timing control solenoid valve terminals.
Diesel fuel temperature sensor
DIESEL FUEL TEMPERATURE SENSOR CHECK
13300680011
1. Disconnect the diesel fuel temperature sensor connector. 2. Measure the resistance between terminals 1 and 2. Standard value: 2.2 - 2.7 kW (at 20_C)
13E-60
Pump operation sensor
DIESEL FUEL - On-vehicle Service PUMP OPERATION SENSOR CHECK

Standard value: 215 - 245 W (at 20_C)
13300690014
1. Disconnect the pump operation sensor connector. 2. Measure the resistance between terminals 1 and 2.
Injection timing correction resistor
INJECTION TIMING CORRECTION RESISTOR 13300700014 CHECK

1. Disconnect the injection timing correction resistor connector. 2. Measure the resistance between terminals 1 and 2. Standard value: 0.1 - 2.5 kW (at 20_C)
Injection rate correction resistor
INJECTION RATE CORRECTION RESISTOR 13300710017 CHECK

1. Disconnect the injection rate correction resistor connector. 2. Measure the resistance between terminals 1 and 2. Standard value: 0.1 - 2.5 kW (at 20_C)
FUEL CUT SOLENOID VALVE CHECK

Fuel cut solenoid valve
13300720010
1. When a sound scope is held against the fuel cut solenoid valve and the ignition switch is turned to ON, check that the sound of the valve operating can be heard. 2. Disconnect the fuel cut solenoid valve connector. 3. Measure the resistance between fuel cut solenoid valve terminal and the injection pump body. Standard value: 8 - 10 W
THROTTLE SOLENOID VALVE CHECK

13300730013
NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (green stripe, yellow stripe) from the solenoid valve. 2. Disconnect the harness connector.

B A
13E-61
3. Connect a hand vacuum pump to nipple B of the solenoid valve. 4. Use jumper wires to connect the terminals of the solenoid valve and the battery. 5. Check the air-tightness when negative pressure is applied while the jumper wire is connected to the battery ( - ) terminal and while it is disconnected. Normal condition:
Battery
Jumper wire Connected
Nipple A condition Open Closed
Normal condition Negative pressure leaks Negative pressure is maintained Negative pressure leaks
Disconnected
Open
Throttle actuator
THROTTLE ACTUATOR CHECK
13300740016
1. Remove the vacuum hose (red stripe) from the throttle actuator and connect a hand vacuum pump to the throttle actuator nipple. 2. Check that the actuator rod moves smoothly when applying vacuum gradually. Also, check that the vacuum is maintained when applying 53 kPa of vacuum.
INJECTION NOZZLE CHECK AND ADJUSTMENT
13300170020
Caution Never touch the injection spray that is injected from the nozzle. FUEL INJECTION INITIAL PRESSURE CHECK 1. Install the injection nozzle to a nozzle tester. 2. Move the lever of the nozzle tester 2 - 3 times to inject fuel and to bleed the air. 3. Gently press down the lever of the nozzle tester, and take a reading of the indication value on the pressure gauge at the point where the needle slowly rises and then suddenly drops. Standard value: 14,710 - 15,690 kPa
13E-62

4. If the fuel injection initial pressure is outside the standard value, disassemble the nozzle holder to clean it, and then change the thickness of the shim to adjust the fuel injection initial pressure. NOTE (1) For disassembly, reassembly and adjustment of the nozzle holder, refer to P.13E-66. (2) There are 10 shims for adjustment, with thicknesses in the range of 0.10 - 0.80 mm. (3) When the shim thickness is increased by 0.1 mm, the fuel injection initial pressure increases by 2,350 kPa.
13300180023 INJECTION SPRAY CONDITION CHECK 1. Move the lever of the nozzle tester rapidly (4 - 6 times per second) to eject the fuel continuously. Check to be sure that the injection spray comes out evenly in a cone shape (injection spray angle is 10_). The injection spray patterns shown in the illustration at left are wrong. A. Injection angle is too large B. Bias C. Intermittent fuel injection
2. Check to be sure that no fuel drips after injection is completed. 3. If there are any drips, disassemble the nozzle, clean it and re-inspect, or replace the nozzle.
13300190026 NOZZLE FUEL-TIGHT CHECK 1. Gently raise the lever of the nozzle tester until the pressure inside the nozzle (value displayed on pressure gauge) becomes 12,750 - 13,730 kPa, and after holding this pressure for approximately 10 seconds, check to be sure that there are no fuel leaks from the nozzle. 2. If there are any leaks, disassemble the nozzle, clean it and re-inspect, or replace the nozzle.
DIESEL FUEL - Injection Pump and Nozzle
13E-63
13300210036
INJECTION PUMP AND NOZZLE

Pre-removal and Post-installation Operation D Glow Plug Removal and Installation (Refer to GROUP 16.) D Timing Belt Removal and Installation (Refer to GROUP 11C.)
9 Nm
29 Nm 9 Nm
49 - 59 Nm
29 Nm
12 2
29 Nm
15 17 16
78 - 88 Nm
14
3 13 8
7 6
9 Nm
1 4
9
24 Nm 19 Nm
10 11
12 - 15 Nm 19 Nm 35 Nm
Fuel injection pump removal steps 1. Fuel return hose connection 2. Fuel return hose connection 3. Fuel main hose connection 4. Control wiring harness connection AA" "DA 5. Fuel injection pipe 6. Flange AB" 7. Fuel injection pump sprocket AB" 8. Fuel injection pump 9. Key 10. Injection pump stay 11. Injection pump bracket stay
AA" "DA AC" "CA AC" "CA AD" "BA "AA "AA
Fuel injection nozzle removal steps 1. Fuel return hose connection 5. Fuel injection pipe 12. Nut 13. Fuel return pipe 14. Fuel return pipe gasket 15. Fuel injection nozzle and holder assembly 16. Holder gasket 17. Nozzle gasket
13E-64
Fuel injection pipe Nut Delivery holder or nozzle holder
DIESEL FUEL - Injection Pump and Nozzle REMOVAL SERVICE POINTS

AA" FUEL INJECTION PIPE REMOVAL When loosening nuts at both ends of injection pipe, hold the delivery holder (for pump side) an the injection nozzle holder (for nozzle side) with wrench and loosen nut. Caution After disconnecting the injection pipe, be sure to use a plug so that foreign material, etc. does not get into the pump. AB" FUEL INJECTION PUMP SPROCKET/ FUEL INJECTION PUMP REMOVAL 1. Use the special tool to hold the injection pump sprocket, and then remove the injection pump sprocket fixing nut.
MB990767
MD998719
2. After removing the nut, install the special tool to the injection pump sprocket. 3. Pull the injection pump sprocket off from the pump drive shaft.
MD998388
Caution (1) When removing the sprocket, care must be taken not to subject the pump drive shaft to an impact. (2) After removal, the crankshaft should not be turned. 4. Remove the fuel injection pump. AC" NUT/FUEL RETURN PIPE REMOVAL 1. While using a spanner or similar tool to hold the hexagonal nut of the fuel return pipe, remove the nut.
Nut
Fuel return pipe
Caution If an attempt is made to loosen the nut without first holding the fuel return pipe, the pipe may be broken or otherwise damaged. 2. Disconnect the fuel return pipe.
Deep socket wrench
AD" FUEL INJECTION NOZZLE AND HOLDER ASSEMBLY REMOVAL Using a deep socket wrench, remove the fuel injection nozzle and holder assembly. Caution (1) Make a mark on the removed injection nozzle assembly (the cylinder No.). (2) Use a cap to prevent foreign material, etc. from entering the injection nozzle hole.
DIESEL FUEL - Injection Pump and Nozzle INSTALLATION SERVICE POINTS

Holder gasket Nozzle gasket
13E-65
"AA NOZZLE GASKET/HOLDER GASKET INSTALLATION Clean the cylinder heads injection nozzle hole, and insert a new gasket.
"BA FUEL INJECTION NOZZLE AND HOLDER ASSEMBLY INSTALLATION Use a deep socket wrench in the same way as during removal to tighten to the specified torque. Tightening torque: 49 - 59 Nm
"CA FUEL RETURN PIPE/NUT INSTALLATION While holding the hexagonal nut on the fuel return pipe with a spanner in the same way as during removal, tighten the nut to the specified torque. Tightening torque: 29 Nm Caution If an attempt is made to tighten the nut without first holding the fuel return pipe, the pipe may be broken or otherwise damaged. "DA FUEL INJECTION PIPE INSTALLATION When tightening the nuts at both ends of the fuel injection pipe, hold the delivery holder (for pump side) an the injection nozzle holder (for nozzle side) with wrench in the same way as during removal, and then tighten the nuts to the specified torque. Tightening torque: 29 Nm
13E-66
DIESEL FUEL - Injection Pump and Nozzle

13300350035
DISASSEMBLY AND REASSEMBLY
2 6 5 1
39 Nm
Disassembly steps AA" "AA 1. Retaining nut 2. Nozzle tip 3. Distance piece 4. Retaining pin
5. Pressure spring 6. Shim 7. Nozzle holder body
DISASSEMBLY SERVICE POINT

Deep socket
AA" RETAINING NUT REMOVAL 1. Lightly clamp the retaining nut in a vise with soft jaws. 2. Hold the retaining nut with a box wrench, and loosen the nozzle holder body using a deep socket.
REASSEMBLY SERVICE POINT

"AA RETAINING NUT INSTALLATION 1. Finger-tighten the nozzle holder body. 2. Lightly clamp the retaining nut in a vise with soft jaws. 3. While holding the retaining nut with a box wrench in the same way as during removal, use a deep socket wrench to tighten the nozzle holder body to the specified torque.
DIESEL FUEL - Injection Pump and Nozzle INSPECTION
13E-67
13300360038
Plunger Nozzle tip
NOZZLE TIP 1. Check the nozzle tip for carbon deposits. Scape off carbon deposits with a piece of wood and clean each part with petrol. After cleaning, keep parts submerged in diesel fuel. Take particular care to protect the nozzle tip needle valve from damage. 2. While the nozzle tip is submerged in diesel fuel, check that the needle valve slides smoothly. If the needle valve does not slide smoothly, replace the nozzle tip. When replacing the nozzle tip, completely wash off the anticorrosive oil from the new nozzle tip with clean diesel fuel before using it. 3. Check plunger tip A for deformation and breakage. If A is damaged or broken, replace it. DISTANCE PIECE Check the surface in contact with the nozzle holder body by using minium. PRESSURE SPRING Check spring for weakness and breakage.
13E-68 THROTTLE BODY
DIESEL FUEL - Throttle Body

13300760012
1
18 Nm
6 Nm
2 5 3 6
Removal steps 1. Air hose connection 2. Intake air temperature sensor connector 3. Vacuum hose connection
4. 5. 6. 7.
Air intake fitting Intake fitting gasket Throttle body assembly Intake fitting gasket
13F-1
FUEL SUPPLY
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
13509000197
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
13F-2
D
FUEL SUPPLY - General Information/Special Tool

13500010120
GENERAL INFORMATION
The steel fuel tank is located under the floor of the rear seats to provide increased safety and increase the amount of luggage compartment space. The fuel tank has been equipped with a valve assembly which incorporates a fuel cut-off valve to prevent fuel from leaking out in the event of a collision and a two-way valve for adjusting the pressure inside the fuel tank. D
A plastic snap-fitting hose (high-pressure fuel hose) has been adopted between the fuel pump assembly and the fuel filter assembly in petrol-powered vehicles in order to improve ease of maintenance.
SPECIAL TOOL
Tool Number MB991610 Name Oil filter wrench Use Fuel filter cartridge replacement <Diesel-powered vehicles>
13500060088
FUEL SUPPLY - Fuel Tank
13F-3
13500190244
FUEL TANK
Pre-removal Operation D Draining Fuel D Reduce the Inner Pressure of Fuel Line and Hose <Petrol-powered Vehicles> (Refer to GROUP 13A - On-vehicle Service.) Post-installation Operation D Refilling Fuel. D Checking for Fuel Leaks
4
<Petrol-powered vehicles>
<Diesel-powered vehicles>
7 6 15 8 14 11 17 16
<Petrol-powered ve<Diesel-powered hicles> vehicles>
13
12
10
9
25 Nm
1 <Diesel-powered
vehicles>
Removal steps 1. Drain plug 2. Fuel filler cap 3. Fuel filler neck assembly 4. Packing D Parking brake cable connection (Refer to GROUP 36) D Rear seat cushion (Refer to GROUP 52A) 5. Return hose "AA 6. High-pressure fuel hose 7. Main hose
8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Vapour hose Fuel tank assembly Fuel wiring harness Filler hose Vapour hose Vapour cap Valve assembly Fuel pump assembly Fuel pipe assembly Fuel gauge unit assembly
13F-4
FUEL SUPPLY - Fuel tank INSTALLATION SERVICE POINT

"AA HIGH-PRESSURE FUEL HOSE INSTALLATION Caution After connecting the high-pressure fuel hose, pull it gently in the direction of removal to check that the hose is firmly connected.
INSPECTION
13500300104
VALVE CHECK If the sound of the float valve moving (knocking sound) can be heard when the valve assembly is gently shaken up and down, then the valve is okay.
FUEL GAUGE UNIT CHECK Refer to GROUP 54 - Combination Meter.
FUEL GAUGE UNIT REPLACEMENT
13500140065
1. Remove the rear seat cushion. (Refer to GROUP 52A.) 2. Remove the protector, and then disconnect the connector from the fuel gauge unit. 3. Remove the mounting nut, and then remove the fuel gauge unit. 4. Install the new fuel gauge unit, align the projections on the packing (indicated by arrows in the illustration) with the holes in the fuel gauge unit, and then tighten the mounting nut to the standard torque. 5. Connect the connector, and then install the protector. 6. Install the rear seat cushion. (Refer to GROUP 52A.)
FUEL SUPPLY - Fuel Filter
13F-5
13500280101
FUEL FILTER
Pre-removal Operation D Reduce the Inner Pressure of Fuel Line and Hose <Petrol-powered Vehicles> (Refer to GROUP 13A - On-vehicle Service.) <Diesel-powered vehicles> <Petrol-powered vehicles> Post-installation Operation D Checking for Fuel Leaks
8 7 3 4 3 6
12 - 14 Nm
2 1 9 4
5
3 Nm
Removal steps AA" "BA 1. High-pressure fuel hose connection 2. Main pipe connection "AA 3. Main hose connection 4. Fuel filter assembly 5. Water level sensor
6. 7. 8. 9.
Fuel filter cartridge Breather screw Fuel filter pump body Fuel filter bracket

AA" HIGH-PRESSURE FUEL HOSE DISCONNECTION Caution As there will be some pressure remaining in the fuel pipe line, cover it with a rag to prevent fuel from spraying out.

"AA MAIN HOSE CONNECTION Insert the main hose as far as the stepped section of the pipe.
13F-6

"BA HIGH-PRESSURE FUEL HOSE CONNECTION Caution After connecting the high-pressure fuel hose, pull it gently in the direction of removal to check that the hose is firmly connected.
Float
INSPECTION
13500290043
WATER LEVEL SENSOR CHECK <DIESEL-POWERED VEHICLES> 1. Connect the circuit tester to the water level sensor connector. 2. The water level sensor is operating correctly if there is continuity when the float is raised, and no continuity when it is lowered.
FUEL FILTER CARTRIDGE REPLACEMENT

MB991610
13500130147
<DIESEL-POWERED VEHICLES>
1. Remove the fuel tank cap to release the pressure inside the fuel tank. 2. Disconnect the connector and the main hose, and then remove the fuel filter assembly from the bracket. 3. Remove the water level sensor. 4. Use an oil filter wrench to remove the fuel filler cartridge from the fuel filter pump body. Caution Cover the cartridge with a rag to prevent fuel from spraying out. 5. Install a new filter, and bleed the air from fuel line. (Refer to GROUP 13E - On-vehicle Service.) 6. Start the engine, and check that there are no fuel leakage.
Fuel filter assembly Main pipe
FUEL FILTER ASSEMBLY REPLACEMENT 13500130130 <PETROL-POWERED VEHICLES>

1. Bleed the residual pressure from inside the fuel line. (Refer to GROUP 13A - On-vehicle Service.) 2. Remove the parking brake cable clamp. 3. Disconnect the high-pressure fuel hose. Caution As there will be some pressure remaining in the fuel pipe line, cover it with a rag to prevent fuel from spraying out.
36 Nm
High-pressure fuel hose
13F-7
4. Hold the fuel filter with a spanner and loosen the flare nut. Then disconnect the main pipe connection. 5. Remove the fuel filter. 6. After installing the new fuel filter, tighten the main pipe flare nut to the specified torque. 7. Connect the high-pressure fuel hose. Caution After connecting the high-pressure fuel hose, pull it gently in the direction of removal to check that the hose is firmly connected. 8. After installation, check that there are no fuel leaks. (1) Apply battery voltage to the fuel pump drive terminal to operate the fuel pump. (Refer to GROUP 13A On-vehicle Service.) (2) Check for leaks when fuel pressure is applied.
NOTES
13H-1
TRACTION CONTROL SYSTEM (TCL)

CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 25
System Check Using the TCL Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 TCL Operation Check . . . . . . . . . . . . . . . . . . . . . . . 25 Stop Lamp Switch Check . . . . . . . . . . . . . . . . . . . . 27
13609000039
Wheel Speed Sensor Check . . . . . . . . . . . . . . . . . 27 Vacuum Solenoid Valve Check . . . . . . . . . . . . . . . 27 Ventilation Solenoid Valve Check . . . . . . . . . . . . . 27 Vacuum Tank Check . . . . . . . . . . . . . . . . . . . . . . . . 27 Vacuum Actuator Check . . . . . . . . . . . . . . . . . . . . . 27 Accelerator Pedal Position Sensor (APS) Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TCL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 STEERING WHEEL SENSOR* . . . . . . . . . . . . 29 TCL-ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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 and passenger (from rendering 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 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensor 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 (*)
13H-2
TCL - General Information

13600010031
GENERAL INFORMATION
For vehicles with 6A13 engine, the TCL system (slip control and trace control) is available as an option. This system facilitates starting, accelerating, and cornering on slippery roads such as snowy
roads. In addition, this system improves driveability while cornering on normal roads and contributes to easier driving.
Ventilation solenoid valve Vacuum solenoid valve Steering wheel sensor Engine-ECU Vacuum actuator TCL-ECU ABS-ECU
Vacuum tank Accelerator pedal position sensor (APS) A/T-ECU Stop lamp switch TCL switch Indicator
TCL - Service Specification/Special Tools/Troubleshooting
13H-3
13600030013
SERVICE SPECIFICATION
Item Accelerator pedal position sensor resistance kW Standard value 3.5 - 6.5
SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub assembly Use
13600060029
For checking of TCL (Diagnosis code display when using the MUT-II)
MB991529
Diagnosis code check harness
For checking of TCL (Diagnosis code display when using the TCL-OFF warning lamp)
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
13600070039
NOTE Before carrying out trouble diagnosis, check to be sure that all of the following items are normal. D Is the standard steering wheel being used, and has it been correctly installed to the straight-ahead position on the steering shaft? D Are the size, specifications, air pressure, balance and wear conditions of the tyres and wheels normal? D Is the wheel alignment normal? D Have any other modifications been made to the engine or suspension which could conceivably have an effect on the TCL system?
DIAGNOSTIC FUNCTION
METHOD OF READING THE DIAGNOSIS CODES Use the MUT-II or the warning lamp to read the diagnosis codes. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) NOTE Connect the MUT-II to the diagnosis connector (16 pin) under the instrument under cover. METHOD OF ERASING THE DIAGNOSIS CODES Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
13H-4
TCL - Troubleshooting
13600330014

Code No. 11 12 13 23 24 26 27 31 32 33 34 35 36 41 42 43 44 45 71 72 73 74 76 A/T-ECU communication circuit system ABS circuit system Diagnosis item APS circuit system APS or TPS circuit system TPS circuit system Stop lamp switch circuit system TCL switch circuit system Ignition switch (IG2) circuit system TCL-ECU power supply voltage circuit (engine control relay circuit) system Front right wheel speed sensor circuit system Front left wheel speed sensor circuit system Rear right wheel speed sensor circuit system Rear left wheel speed sensor circuit system Rear wheel speed sensor circuit system (1) Rear wheel speed sensor circuit system (2) Steering wheel sensor (ST-1) circuit system (open circuit) Steering wheel sensor (ST-2) circuit system (open circuit) Steering wheel sensor (ST-N) circuit system (open circuit) Steering wheel sensor circuit system (short circuit) Steering wheel sensor (ST-N) circuit system (short circuit) Engine-ECU communication circuit system Engine-ECU circuit system
Reference page 13H-5 13H-6 13H-7 13H-7 13H-8 13H-8 13H-9 13H-10 13H-10 13H-10 13H-10 13H-11 13H-11 13H-12 13H-12 13H-12 13H-13 13H-13 13H-14 GROUP 13A Troubleshooting 13H-14 13H-15
TCL - Troubleshooting INSPECTION PROCEDURES FOR DIAGNOSIS CODES

Code No. 11 APS circuit system
This diagnosis code is output if the APS output voltage is less than 0.2 V due to an open circuit or other malfunction in the APS circuit. The APS power supply and earth are supplied from the engine-ECU, and the output signal is used by the A/T-ECU and auto-cruise control-ECU as well as by the TCL-ECU. NG NG
13H-5
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of APS TCL-ECU engine-ECU harness or connector NG
MUT-II Data list 11 APS output Open and close the throttle lever. OK: Changes smoothly between 300 mV - 5,500 mV OK
Measure the voltage at APS connector B-41. D Ignition switch: ON D Disconnect the APS connector and measure at harness side. D Measure at the harness side. D Between terminal (1) and body earth OK: 4.8 - 5.2 V Repair OK Check the APS. (Refer to P.13H-27.) OK Measure the voltage at TCLECU connector C-10. D Ignition switch: ON D Disconnect the TCL-ECU connector and measure at the harness side. D Between terminal (19) and body earth OK: 0.3 V or more OK
Check the following connectors: B-41, C-39 OK Check trouble symptom. NG Check the harness between the APS and the engine-ECU, and repair if necessary. OK
Repair
NG
Repair
Check the following connectors: C-10, B-41, C-39 OK Check trouble symptom. NG Replace the TCL-ECU.
NG
NG
Replace Replace the engine-ECU.
NG
Check the following connectors: C-10, C-51, B-41 OK Check trouble symptom. NG Check the harness between the APS and the TCL-ECU, and repair if necessary.
NG
Repair
Check the following connector: C-10 OK Check trouble symptom. NG Replace the TCL-ECU.
NG
Repair
13H-6
Probable cause
D D D D D D Malfunciton Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of of APS TPS TCL-ECU engine-ECU harness or connector vacuum actuator NG
Code No. 12 APS or TPS circuit system

This diagnosis code is output if the APS opening angle is 20_ or greater than the TPS opening angle because of a short in the APS, an open circuit in the TPS or sticking of the vacuum actuator. As this detection condition can be applicable during throttle control, trouble diagnosis is invalid at this time.
MUT-II Data list 13 TPS output Open and close the throttle lever. OK: Changes smoothly between 300 mV - 5,500 mV NG Vacuum actuator operation inspection (Refer to GROUP 13A - On-vehicle Service.) OK
OK
Check the APS. (Refer to P.13H-27.) NG Replace
OK
Check the following connectors: C-10, C-51, B-41 OK Check trouble symptom. NG
Repair
NG
Replace
Check the harness between the APS and the TCL-ECU, and repair if necessary. OK Replace the TCL-ECU NG
NG
Repair
Measure the voltage at TPS connector B-07. D Ignition switch: ON D Disconnect the TPS NG connector and measure at the harness side. D Between terminal (4) and body earth OK: 4.8 - 5.2 V OK Check the TPS. (Refer to GROUP 13A - Onvehicle Service.) OK Measure the voltage at engine-ECU connector C-39. D Ignition switch: ON D Connect the engine-ECU NG connector. D Between terminal (84) and body earth. Move the accelerator lever OK: 0.3 - 1.0 V (Set to idle position) 4.5 - 5.5 V (Fully open) OK Check the following connector: C-39 OK Check trouble symptom. NG NG
Check the following connectors: B-07, C-39 OK Check trouble symptom. Replace
Repair
NG
Check the harness between the TPS and the engine-ECU, and repair if necessary. OK Replace the engine-ECU.
NG
Repair
Check the following connectors: B-07, C-39 OK Check trouble symptom.
NG
Repair
NG
Check the harness between the TPS and the engine-ECU, and repair if necessary.
Repair
NG
Code No.13 TPS circuit system
This diagnosis code is output if the TPS opening angle is 20_ or greater than the APS opening angle because of a short in the TPS or an open circuit in the APS. If there is an open circuit in the APS, diagnosis code No. 11 is output at the same time. Accordingly, if only diagnosis code No. 11 is output, the cause is probably an abnormality in the TPS circuit system. Yes
13H-7
of of of of APS TPS harness or connector engine-ECU
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction
MUT-II Self-Diag code Is TCL diagnosis code No. 11 output? No Check the TPS. (Refer to GROUP 13A - On-vehicle Service.) OK Measure the voltage at engine-ECU connector C-39. D Ignition switch: ON D Connect the engine-ECU connector. D Between terminals (84) and body earth D Move the accelerator lever. OK: 0.3 - 1.0 V (Set to idle position) 4.5 - 5.5 V (Fully open) OK
Code No. 11 APS circuit system (Refer to P.13H-5.)
NG
Replace
NG
Check the following connectors: B-07, C-39 OK Check trouble symptom. NG Check the harness between the TPS and the engine-ECU, and repair if necessary.
NG
Repair
Check the following connector: C-39 NG Repair
OK
Code No. 23 Stop lamp switch circuit system

This diagnosis code is output if the stop lamp switch remains ON for a continuous period of 15 minutes or more, or for a continuous period of 1 minute or more when driving at a speed of 10 km/h or more, because of a short circuit or defective adjustment of the stop lamp switch. This diagnosis code No. may also occur while driving in traffic jams or if the foot is resting on the brake pedal with driving. OK
Probable cause
D D D Malfunction of stop lamp switch Malfunction of harness or connector Malfunction of TCL-ECU
Measure the continuity at the stop lamp switch connector C-02. D Disconnect the connector and measure at the switch side. D Between terminals (1) - (2) OK: Continuity when the brake pedal is depressed No continuity when the brake pedal is released NG
Check the following connectors: C-02, C-65, C-75, C-11 OK Check trouble symptom. NG Inspect the harness between stop lamp switch and the TCL-ECU. OK Replace the TCL-ECU.
NG
Repair
NG
Repair
Stop lamp switch installation check (Refer to GROUP 35A - On-vehicle Service.) NG Stop lamp switch adjustment (Refer to GROUP 35A - On-vehicle Service.)
OK
Replace the stop lamp switch.
13H-8
Probable cause
D D D Malfunction of the TCL switch Malfunction of harness or connector Malfunction of TCL-ECU
Code No. 24 TCL switch circuit system

This diagnosis code is output if signals are input simultaneously from both the TCL-OFF and TCL-ON positions because of a short circuit in the TCL switch circuit.
Measure the continuity at TCL switch connector C-98. D Disconnect the connector and measure at the switch side. D Between terminals (2) - (3) and (3) - (6) OK: No continuity OK Check the following connectors: C-98, C-75, C-11 OK Check trouble symptom. NG Inspect the harness between the TCL switch and the TCL-ECU. OK Replace the TCL-ECU.
NG
Replace the TCL switch.
NG
Repair
NG
Repair
Code No. 26 Ignition switch (IG2) circuit system

This diagnosis code is output if the IG2 power supply is not distributed, even though the engine speed is 450 r/min or more. OK
Probable cause
D D Malfunction of harness or connector Malfunction of TCL-ECU NG
Measure the voltage at TCL-ECU connector C-11. D Ignition switch : ON D Disconnect the TCL-ECU connector and measure at the harness side. D Between terminal (35) and body earth OK: System voltage NG
following
Repair
OK Check trouble symptom. NG Replace the TCL-ECU.
Check the following connectors: C-131, C-134, C-66, C-75, C-11 OK Check trouble symptom. NG Check the harness between the ignition switch and the TCL-ECU, and repair if necessary.
NG
Repair
Code No. 27 TCL-ECU power supply voltage circuit (engine control relay circuit) system
This diagnosis code is output if the TCL-ECU power supply voltage (engine control relay supply voltage) is lower than the specified value. If the voltage returns to the specified value or greater, the diagnosis code is erased. OK
13H-9
Probable cause
D D D Malfunction of control relay Malfunction of harness or connector Malfunction of TCL-ECU
Measure the voltage at TCL-ECU connector C-10. D Engine: idling D Disconnect the TCL-ECU connector and measure at the harness side. D Between terminal (25) and body earth OK: 10 V or more NG
Check the following connector: C-10 OK Check trouble symptom. NG Replace the TCL-ECU.
Check the following connectors: C-31, C-47, C-51, C-10 OK Check trouble symptom. NG Inspect the harness between the control relay and the TCL-ECU. OK Engine control relay inspection (Refer to GROUP 13A - On-vehicle Service.)
NG
Repair
NG
Repair
13H-10
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of front wheel speed sensor harness or connector TCL-ECU ABS-ECU
Code No. 31 Front right wheel speed sensor circuit system Code No. 32 Front left wheel speed sensor circuit system
These diagnosis codes are output if a pulse (from the front wheels) indicates that the difference between the front wheels and the rear wheels is 8km/h or more because of an open or short circuit in a wheel speed sensor or a malfunction of sensor.
NOTE When these diagnosis codes are output, erase the diagnosis code memory after carrying out repairs, and then carry out a road test at 20 km/h or more and check to be sure that the diagnosis codes are not output again.
Is the ABS warning lamp illuminated, or is an ABS diagnosis code output? No Measure at ABS-ECU connector A-04. D Ignition switch: ON D Measure at the ECU side with the connector connected. D Voltage between terminal (17) and body earth D Voltage between terminal (21) and body earth OK: 4.8 - 5.2 V OK Check the following connectors: A-04, C-10 OK Check trouble symptom. NG Check the harness connectors between the ABS-ECU and the TCL-ECU, and repair if necessary. NG Repair Yes Carry out ABS troubleshooting (Refer to GROUP 35B - Troubleshooting.) Replace the TCL-ECU.
NG
Code No. 33 Rear right wheel speed sensor circuit system Code No. 34 Rear left wheel speed sensor circuit system
These diagnosis codes are output if a pulse (from the wheels on one side of rear) indicates that the difference between the left wheel and the right wheel is 8km/h or more because of an open or short circuit in a wheel speed sensor or a defective sensor.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of rear wheel speed sensor harness or connector TCL-ECU ABS-ECU
NOTE When these diagnosis codes are output, erase the diagnosis code memory after carrying out repairs, and then carry out a road test at 20 km/h or more and check to be sure that the diagnosis codes are not output again.
Is the ABS warning lamp illuminated, or is an ABS diagnosis code output? No Measure at ABS-ECU connector A-04. D Ignition switch : ON D Measure at the ECU side with the connector connected. D Voltage between terminal (3) and body earth D Voltage between terminal (10) and body earth OK: 4.8 - 5.2 V OK Check the following connectors: A-04, C-10 OK Check trouble symptom. NG Repair Yes Carry out ABS troubleshooting (Refer to GROUP 35B - Troubleshooting.) Replace the TCL-ECU.
NG
NG
Check the harness connectors between the ABS-ECU and the TCL-ECU, and repair if necessary.
Code No. 35 Rear wheel speed sensor circuit system (1) Code No. 36 Rear wheel speed sensor circuit system (2)
Diagnosis code No. 35 is output if the pulse signal from a rear wheel sensor is momentarily interrupted (0.02 sec.) because of a transient open circuit in a rear wheel speed sensor. Diagnosis code No. 36 is output if a rear wheel speed sensor abnormality is judged when the turning speed of both rear wheels is 0 km/h for 20 seconds or more while TCL is operating. D D D D Malfunction Malfunction Malfunction Malfunction of of of of
13H-11
Probable cause
rear wheel speed sensor harness or connector ABS-ECU TCL-ECU
NOTE (1) If the front wheels only are turning while the rear wheels are stationary (wheel slip), the TCL-OFF indicator will start flashing after 20 seconds, and the system will be isolated. (2) When these diagnosis codes are output, erase the diagnosis code memory after carrying out repairs, and then carry out a road test at 20 km/h or more and check to be sure that the diagnosis codes are not output again.
Is a diagnosis code output from the ABS-ECU? No MUT-II Data list 33, 34 Wheel speed sensor Accelerate from a stationary position. OK: Vehicle speeds displayed on the speedometer and MUT-II are identical. NG Check the following connectors: A-04, C-10 NG Check trouble symptom. OK Repair Yes OK Carry out ABS troubleshooting (Refer to GROUP 35B - Troubleshooting.) Replace the TCL-ECU.
NG
Check the harness connectors between the ABS-ECU and the TCL-ECU, and repair if necessary.
13H-12
Probable cause
Code No. 41 Steering wheel sensor (ST-1) circuit system (open circuit) Code No. 42 Steering wheel sensor (ST-2) circuit system (open circuit) Code No. 43 Steering wheel sensor (ST-N) circuit system (open circuit)
These diagnosis codes are output if there is an open circuit in the output wire of the steering wheel sensor circuit.
D D D
Malfunction of harness or connector Malfunction of steering wheel sensor Malfunction of TCL-ECU
NG OK Check the following Measure at TCL-ECU connector C-11. connectors: D Ignition switch: ON C-11, C-75, C-106 D Connector connected D Voltage between terminals (32), (40) and (41) and the body NG: Stays at OK earth 0V without OK: Changes between approx. 3 V and approx. 0.5 V when changing Check trouble symptom. the steering wheel is turned NG: Changes between 4 V or more and approx. 0.5 V NG: Stays at 4 V or more without changing NG Replace the TCL-ECU. Check the connectors: C-106, C-62 following NG
Repair
NG
Measure at steering wheel sensor connector C-106. D Disconnect the connector and measure at the harness side. D Continuity between terminal (3) and body earth OK: Continuity OK
Repair
OK Check trouble symptom. NG Check the harness between the steering wheel sensor and the body earth, and repair if necessary.
Check the following connectors: C-106, C-75, C-11 OK Check trouble symptom. NG Inspect the harness between the steering wheel sensor and the TCL-ECU. OK Replace the steering wheel sensor.
NG
Repair
NG
Repair
Code No. 44 Steering wheel sensor circuit system (short circuit)
This diagnosis code is output when no steering angle signal is output because there is a short-circuit in either steering wheel sensor ST-1 or steering wheel sensor ST-2 when the speed averages output by the left and right rear wheel speed sensors are 15 km/h or more. OK
13H-13
Probable cause
D D D Malfunction of harness or connector Malfunction of steering wheel sensor Malfunction of TCL-ECU
Measure at TCL-ECU connector C-11. D Ignition switch: ON D Connector connected D Voltage between terminals (40) and (41) and the body earth OK: Changes between approx. 3 V and approx. 0.5 V when the steering wheel is turned NG Check the following connectors: C-11, C-75, C-106 OK Inspect the harness between the steering wheel sensor and the TCL-ECU. OK Measure at steering wheel sensor connector C-106. D Ignition switch: ON D Disconnect the connector and measure at the harness side. D Continuity between terminal (2) and body earth OK: System voltage OK
following
NG
Repair
OK Check trouble symptom. NG NG Repair Replace the TCL-ECU. NG Repair
NG
Check the following connectors: C-131, C-132, C-61, C-106 OK Check trouble symptom.
NG
Repair
NG Check the harness between the steering wheel sensor and the ignition switch, and repair if necessary. Repair
Check the following connector: C-106 OK Replace the steering wheel sensor.
NG
Code No. 45 Steering wheel sensor (ST-N) circuit system (short circuit)
This diagnosis code is output if it is considered that there is an abnormality in the steering wheel sensor (ST-N) circuit system when the straight-ahead position is continuously detected even though the steering wheel is turned 20_ or more. OK
Probable cause
D D D Malfunction of steering wheel sensor Malfunction of harness or connector Malfunction of TCL-ECU NG
Measure at TCL-ECU connector C-11. D Connector connected D Voltage between terminals (32) and the body earth OK: Changes between approx. 3V and approx. 0.5 V when the steering wheel is turned NG
following
Repair
OK Check trouble symptom. NG Replace the TCL-ECU. NG
Check the following connectors: C-11, C-75, C-106 OK Inspect the harness between the steering wheel sensor and the TCL-ECU. OK Replace the steering wheel sensor.
Repair
NG
Repair
13H-14
Probable cause
D D D Malfunction of harness or connector Malfunction of TCL-ECU Malfunction of engine-ECU
Code No. 71 Engine-ECU communication circuit system

This diagnosis code is output if an error is detected in the communication contents because of an open or short circuit in the serial communication circuit between the TCL-ECU and the engine-ECU, a malfunction of ECU and a defective shielding of the shield wire. NG
Check the following connectors: C-10, C-51, C-37 OK Check trouble symptom. NG Inspect the harness between the TCL-ECU and the engine-ECU. OK Is a diagnosis code output from the engine-ECU? No Replace the TCL-ECU. Check trouble symptom.
Repair
NG Yes
Repair
Carry out engine-ECU troubleshooting (Refer to GROUP 13A - Troubleshooting.)
NG
Code No. 74 A/T-ECU communication circuit system

This diagnosis code is output if an error is detected in the communication contents because of an open or short circuit in the serial communication circuit between the TCL-ECU and the A/T-ECU, a malfunction of ECU and a defective shielding of the shield wire. NG
Probable cause
D D D Malfunction of harness or connector Malfunction of TCL-ECU Malfunction of A/T-ECU
Check the following connectors: C- 10, C-51, C-49, C-29, C-30 OK Check trouble symptom. NG Inspect the harness between the TCL-ECU and the A/T-ECU. OK Is a diagnosis code output from the A/T-ECU? No Replace the TCL-ECU. Check trouble symptom.
Repair
NG Yes
Repair
Carry out A/T-ECU troubleshooting (Refer to GROUP 23 - Troubleshooting.)
NG
Replace the A/T-ECU.
Code No. 76 ABS circuit system
This diagnosis code is output if the ABS-ECU detects the system abnormality (when ABS warning lamp illumination is controlled).
13H-15
Probable cause
D D D Malfunction of harness or connector Malfunction of TCL-ECU Malfunction of ABS-ECU
Is the ABS warning lamp illuminated, or is an ABS diagnosis code output? No Check the following connectors: A-04, C-10 OK Check trouble symptom. NG Inspect the harness between the ABS-ECU and the TCL-ECU. OK Replace the TCL-ECU. Check trouble symptom.
Yes
Carry out ABS troubleshooting. (Refer to GROUP 35B - Troubleshooting.)
NG
Repair
NG
Repair
NG
Replace the ABS-ECU.

Trouble symptom Communication II with the MUT-II is not possible. Malfunction of TCL indicator lamp display Communication with all systems is not possible. Communication with TCL-ECU only is not possible. None of the TCL indicator lamps (TCL OFF, TCL) illuminate when the ignition switch is ON. One of the TCL indicator lamps does not illuminate when the ignition switch is ON (Another lamp does illuminate). TCL OFF indicator lamp remains illuminated even after the engine is started. TCL OFF indicator lamp flashes after the engine is started. TCL remains illuminated even after the engine is started. TCL OFF indicator lamp does not illuminate even if the TCL switch is continuously pressed to the OFF side while the engine is idling. Malfunction of TCL operation Poor starting Poor acceleration TCL illuminates in the TCL operation range, but torque is not reduced. Engine output is reduced in the TCL non-operation range (TCL indicator lamp does not illuminate) and starting and acceleration performance is poor. 6 7 13H-19 13H-20 Inspection procedure No. 1 2 3 4 5 Reference page 13H-16 13H-17 13H-18 13H-18 13H-19
13H-20
13H-16
INSPECTION PROCEDURES FOR EACH TROUBLE SYMPTOM Inspection Procedure 1 Communication with the MUT-II is not possible. (Communication with all systems is not possible.)
The cause is probably a defective power supply system (including earth) for the diagnosis line. NG
Probable cause
D D Malfunction of connector Malfunction of harness NG
Measure at the diagnosis connector C-20. Voltage between terminal (16) and body earth OK: System voltage OK
Check the following connectors: C-141, C-132, C-63, C-66, C-20 <L.H. drive vehicles> C-14, C-62, C-66, C-20 <R.H.drive vehicles> OK Check trouble symptom.
Repair
NG NG
Measure at the diagnosis connector C-20. Continuity between terminal (4), (5) and body earth OK: Continuity OK Check trouble symptom.
NG
Check the harness between the fusible link No. 2 and diagnosis connector, and repair if necessary. Repair
Check the following connector: C-20 OK Check trouble symptom.
NG
Check the harness between the diagnosis connector and the earth, and repair if necessary.
NG
Replace the MUT-II.
Inspection Procedure 2 Communication with the MUT-II is not possible. (Communication with TCL-ECU only is not possible.)
If the MUT-II cannot communicate with the TCL-ECU only, the cause is probably an abnormality in the TCL diagnosis line or in the TCL-ECU power supply line or earth line. NG
13H-17
Probable cause
D D D Malfunction of harness or connector Malfunction of engine control relay Malfunction of TCL-ECU NG
Measure at diagnosis connector C-20 and TCL-ECU connector C-10. D Disconnect the connector and measure at the harness side. D Continuity between the following terminals OK: Continuity TCL-ECU side 1 14 | | Diagnosis connector side 1 7 OK Measure at TCL-ECU connector C-10. D Disconnect the connector and measure at the harness side. D Engine: idling D Voltage between 25 - body earth OK: 10 V or more OK
Check the following connectors: C-20, C-66, C-83, C-49, C-51, C-10 OK Check trouble symptoms.
Repair
NG
Check the harness between the TCLECU and diagnosis connector, and repair if necessary.
NG
Check the following connectors: C-31, C-47, C-51, C-10 OK Check trouble symptoms. NG Check the harness between the engine control relay and TCL-ECU. NG Repair
NG
Repair
OK
Check the engine control relay. (Refer to GROUP 13A - On-vehicle Service.)
Measure at TCL-ECU connectors C-10 and C-11. D Disconnect the connector and measure at the harness side. D Continuity between 13, 26 (C-10), 31 (C-11) - body earth OK: Continuity OK Check the following connectors: C-10, C-11 OK Check trouble symptoms.
NG
Check the harness between the TCLECU and the earth, and repair if necessary.
NG
Repair
NG
Replace the TCL-ECU.
13H-18
Inspection Procedure 3
None of the TCL indicator lamps (TCL OFF, TCL) illuminate when the ignition switch is ON.
The main cause is an open circuit in the indicator circuit because of a burnt-out indicator lamp bulb.
Probable cause
D D D Malfunction of harness or connector Malfunction of TCL-ECU Malfunction of indicator lamp bulb OK
Do other warning lamps illuminate when the ignition switch is at ON position? Yes
No
Check the following connectors: C-131, C-135, D-03 NG Repair
Check trouble symptom. NG Check the harness between the combination meter and the junction block, and repair if necessary.
MUT-II Self-Diag code Is code No.27 output? No Check the following connectors: D-03, C-50, C-11 OK Check trouble symptom. NG Inspect the harness between the combination meter and the TCL-ECU. OK Check if a TCL indicator lamp bulb is burnt out. OK Replace the TCL-ECU.
Yes
Code No.27 TCL-ECU power supply voltage circuit system (Refer to P.13H-9.) Repair
NG
NG
Repair
NG
Replace the lamp bulb.
Inspection Procedure 4 One of the TCL indicator lamps does not illuminate when the ignition switch is ON.
Because the TCL indicators utilise shared power supply circuits, if one of the indicator lamps is illuminated, the power supply circuit can be judged to be normal. No
Probable cause
D D Open circuit in indicator lamp power supply circuit. Burnt-out indicator lamp bulb
Is the bulb of the non-illuminated indicator lamp normal? Yes Measure at the TCL-ECU connector C-11. D Disconnect the connector and measure at the harness side. D Voltage between terminal (45) and body earth D Voltage between terminal (46) and body earth OK: System voltage NG Check the following connectors: D-03, C-50, C-11
Replace the lamp bulb.
OK
OK
Check trouble symptom
NG
Check the harness between the combination meter and the TCL-ECU, and repair if necessary.
Inspection Procedure 5 D D TCL OFF indicator lamp remains illuminated even after the engine is started. TCL OFF indicator lamp flashes after the engine is started. Probable cause
13H-19
The TCL-OFF indicator is also used as a system warning indicator. If there is a system abnormality, this indicator will illuminate or flash. No
D D
Other system related to the TCL Malfunction of harness or connector
Is the diagnosis code normal? (Is communication with the MUT-II possible?) Yes Does the TCL OFF indicator lamp switch off when TCL-ECU connector C-11 is disconnected? No Check the following connectors: D-03, C-50, C-11 NG Repair
To trouble symptom inspection procedure 1 (Refer to P.13H-16.) Replace the TCL-ECU.
Yes
OK
NG
Inspection Procedure 6 TCL indicator lamp remains illuminated even after the engine is started.
The TCL indicator lamp only illuminates while the engine is running if the TCL is operating.
Probable cause
D D D Malfunction of TCL indicator power supply circuit Malfunction of TCL-ECU Malfunction of harness or connector
Does the TCL indicator remain illuminated when TCL-ECU connector C-11 is disconnected and the ignition switch is turned to ON? Yes Check the following connectors: D-03, C-50, C-11 NG Repair
No
OK
NG
13H-20
TCL OFF indicator lamp does not illuminate even if the TCL switch is continuously pressed to the OFF side while the engine is idling.
If the indicator lamp does not illuminate when the switch is operated, there is a malfunction in the switch, switch circuit or in the TCL-ECU.
Probable cause
D D D
Malfunction of harness or connector Malfunction of TCL switch Malfunction of TCL-ECU
MUT-II Data list D 25 TCL OFF switch D Press the TCL switch continuously to the OFF side while the engine is idling. OK: ON is displayed NG Check the following connectors: C-11, C-75, C-98 OK Check trouble symptom
OK
NG
Repair
NG
Inspect the harnesses between the TCL-ECU and the TCL switch, and between the TCL switch and the body earth. OK TCL switch component inspection (Refer to P.13H-28.)
OK
Repair
Inspection Procedure 8 D D TCL illuminates in the TCL operation range, but torque is not reduced. Engine output is reduced in the TCL non-operation range (TCL indicator lamp does not illuminate) and starting and acceleration performance is poor. Probable cause
In cases such as the above, the electrical system is normal, and the cause is probably an abnormality in the mechanical system (vacuum actuator).
D D D D D D D
Malfunction of vacuum solenoid valve Malfunction of ventilation solenoid valve Malfunction of vacuum actuator Incorrect vacuum hose connector Malfunction of throttle link Malfunction of vacuum tank Blocked air cleaner element
As the cause is probably a malfunction of the vacuum actuator system, carry out inspection of the following items in order. D Vacuum solenoid valve operation inspection (Refer to GROUP 13A - On-vehicle Service.) D Ventilation solenoid valve operation inspection (Refer to GROUP 13A - On-vehicle Service.) D Disconnected or mis-connected vacuum hose inspection (Refer to GROUP 13A - On-vehicle Service.) D Throttle link operation inspection (Refer to GROUP 13A - On-vehicle Service.) D Vacuum tank inspection (Refer to GROUP 13A - On-vehicle Service.) D Air cleaner element blockage inspection
TCL - Troubleshooting DATA LIST REFERENCE TABLE

No. 11 Check item APS Check condition Accelerator pedal position Engine stop Selector lever position: P Fully closed Depressed Fully open 13 TPS Accelerator pedal position Engine stop Selector lever position: P Fully closed Depressed Fully open 15*1 Inhibitor switch Ignition switch: ON Engine stop Selector lever: P position Selector lever: R position Selector lever: N position Selector lever: D position Selector lever: 3 position Selector lever: 2 position Selector lever: L position 16*1 Shift position Shift lever position: D Driving at constant speed of 10 km/h in 1 range Driving at constant speed of 30 km/h in 2 range Driving at constant speed of 50 km/h in 3 range Driving at constant speed of 70 km/h in 4 range 21 22 23 24 25 Idle switch Ignition switch Stop lamp switch TCL ON switch TCL OFF switch Accelerator pedal position Ignition switch: ON Ignition switch: ON Ignition switch: OFF Brake pedal position Ignition switch: ON TCL ON switch operation Ignition switch : ON TCL OFF switch operation Ignition switch: ON Depressed Released Pressed Released Pressed Released Depressed Released
13H-21
Normal condition 300 - 1,000 mV Gradually rises from the above value 4,500 - 5,500 mV 300 - 1,000 mV Gradually rises from the above value 4,500 - 5,500 mV P R N D 3 2 L 1st 2nd 3rd 4th OFF ON ON OFF ON OFF ON OFF ON OFF
13H-22
No. 27 31 32 33 34 40 Check item ECU power supply voltage Front right wheel speed sensor Front left wheel speed sensor Rear right wheel speed sensor Rear left wheel speed sensor Engine speed
Check condition Ignition switch: ON Engine running Selector lever position: D Engine running Selector lever position: D Engine running Selector lever position: D Engine running Selector lever position: D Ignition switch: ON Vehicle stopped Driving at 40 km/h Vehicle stopped Driving at 40 km/h Vehicle stopped Driving at 40 km/h Vehicle stopped Driving at 40 km/h Engine: idling Normal condition System voltage 0 km/h 40 km/h 0 km/h 40 km/h 0 km/h 40 km/h 0 km/h 40 km/h Engine speeds displayed on the MUT-II and tachometer are identical. R 88 deg or R 92 deg L 88 deg or L 92 deg OFF ON ON OFF ON OFF LOW HIGH HIGH and LOW display alternately HIGH and LOW display alternately 6A13 SOHC N/A NORMAL EUR*2
44 45
Steering angle Steering straightahead point learning Slip control
Steering wheel position Ignition switch: ON Steering wheel position Ignition switch: ON
Turned 90_ to the right Turned 90_ to the left Immediately after ignition switch is ON Immediately after city driving
51
TCL switch: ON Driving on low frictional resistance road TCL switch: ON Driving on winding road
TCL indicator lamp illuminated TCL indicator lamp switched off TCL indicator lamp illuminated TCL indicator lamp switched off
52
Trace control
74
Steering wheel sensor (ST-N) Steering wheel sensor (ST-1) Steering wheel sensor (ST-2) Engine model Valve type Aspiration type Engine classification Destination
Steering wheel position Engine idling Steering wheel position Ignition switch: ON Steering wheel position Ignition switch: ON Ignition switch: ON Ignition switch: ON Ignition switch: ON Ignition switch: ON Ignition switch: ON
Neutral position Steering wheel turned 90_ from neutral position Steering wheel turned slowly to left Steering wheel turned slowly to right
75 76 81 82 83 84 85
NOTE *1: A/T *2: For Europe
TCL - Troubleshooting CHECK AT ECU TERMINALS
13H-23
Terminal No. 1
Check item Diagnosis control
Measurement condition When MUT-II is not connected When MUT-II is connected
Normal condition Approx. 5 V 0V 0V Serial communication with MUT-II 1 V or less Other than 0 V
13 14
Earth Diagnosis data input
Ignition switch: ON When MUT-II is connected When MUT-II is not connected
15 16 17 18 19
A/T-ECU data communication
Engine: Idling
Engine-ECU data communication
Engine: Idling
Other than 0 V
APS output
Ignition switch: ON Accelerator pedal fully depressed Ignition switch: ON Accelerator pedal released
4.5 - 5.5 V 0.4 - 1.0 V Flashes between 0 V and approx. 5 V Flashes between 0 V and approx. 5 V Flashes between 0 V and approx. 5 V Flashes between 0 V and approx. 5 V Battery voltage 0V 0V
20 21 22 23 25 26 31
Wheel speed sensor input (rear left wheel) Wheel speed sensor input (front right wheel) Wheel speed sensor input (front left wheel) Wheel speed sensor input (rear right wheel) ECU power supply Earth Earth
Engine: Idling, Vehicle slowly moving forward Engine: Idling, Vehicle slowly moving forward Engine: Idling, Vehicle slowly moving forward Engine: Idling, Vehicle slowly moving forward Ignition switch: ON Ignition switch: ON Ignition switch: ON
13H-24
Terminal No. 32 Check item
Measurement condition Engine: Idling Steering wheel in straight-ahead position Engine: Idling Steering wheel turned 90_ from straight-ahead position Normal condition 0.5 V or less 2.5 - 3.5 V
Steering wheel sensor (ST-N) input
34
TCL ON switch
Ignition switch: ON TCL switch: Pressed to ON side Ignition switch: ON TCL switch: Released
0 - 2V Battery voltage Battery voltage Battery voltage Flashes between 0 V and approx. 3 V Flashes between 0 V and approx. 3 V 0 - 2V Battery voltage Battery voltage 0 - 2V 0 - 2V Battery voltage Battery voltage 0 - 2V 0 - 2V Battery voltage
35 39 40 41 42
Ignition switch IG2 ECU back-up power supply Steering wheel sensor (ST-1) input Steering wheel sensor (ST-2) input TCL OFF switch
Ignition switch: ON Ignition switch: OFF Ignition switch: ON Steering wheel turned slowly Ignition switch: ON Steering wheel turned slowly. Ignition switch: ON TCL switch: Pressed to OFF side Ignition switch: ON TCL switch: Released
43
Stop lamp switch input
Ignition switch: ON Brake pedal depressed Ignition switch: ON Brake pedal released
44
ABS fail signal
During ABS fail When ABS is normal
45
TCL-OFF indicator
Ignition switch: ON Indicator: Extinguished Ignition switch: ON Indicator: Illuminated
46
TCL indicator
Ignition switch: ON Indicator: Illuminated Ignition switch: ON Indicator: Extinguished
TCL - On-Vehicle Service
13H-25
13600090035
ON-VEHICLE SERVICE
SYSTEM CHECK USING THE TCL INDICATOR LAMPS

Press the TCL switch and check if each TCL indicator lamp illuminates or switches off.
TCL switch mode Switch does not operate TCL OFF mode TCL ON mode
Inspection conditions Turn the ignition switch to the ON position. Start the engine. Engine is idling. Drive the vehicle at 30 km/h for 2 minutes or more.
TCL OFF indicator (A) TCL indicator (B) f f No illumination f -
NOTE O: illuminated, X: extinguished, - : not relevant Caution If a different result is obtained when checking, refer to the Troubleshooting section for remedy.
TCL OPERATION CHECK
13600110038
<When using the MUT-II> 1. Connect the MUT-II to the diagnosis connector. 2. Move the selector lever to P range <A/T>, or move the shift lever to the neutral position <M/T>. 3. Start the engine. 4. Turn the TCL switch to ON. 5. Operate the MUT-II to start the actuator test (item No. 05) and fully depress the accelerator pedal at the same time. Check that the engine speed is kept down to 3,000 r/min at this time. Caution The actuator test should only be carried out for 3 seconds. Because the engine speed will increase once the actuator test is stopped, the accelerator pedal should be released quickly after it has been depressed. NOTE The TCL-ECU will output a request torque: 0 signal to the engine-ECU for 3 seconds while the actuator test is being carried out, and the TCL OFF indicator will illuminate during this time.
13H-26
TCL - On-vehicle Service

<When not using the MUT-II> 1. Turn the TCL switch to ON. 2. Place the front wheels onto a speedometer tester or a chassis dynamo and start the engine. (The front wheels may also be jacked up.) 3. Move the shift lever to 1st position <M/T> or the selector lever to D range <A/T>. 4. Check to be sure that the engine speed is restrained when the accelerator pedal is depressed.
NOTE If the following symptoms occur when the accelerator pedal is depressed, refer to Troubleshooting. (1) If the TCL indicator lamp does not illuminate. (2) If the TCL indicator lamp illuminates but the engine is not restrained. Caution (1) Inspection should be completed within 20 seconds after the accelerator pedal was depressed. If it takes longer than 20 seconds, the TCL system function will stop and the engine speed will gradually increase. (2) Because the TCL OFF indicator will flash when the TCL system operation is stopped, the diagnosis codes should be erased if you notice that the indicator is flashing. (Refer to P.13H-3.)
TCL - On-vehicle Service STOP LAMP SWITCH CHECK

Refer to GROUP 35A - On-vehicle Service.
13H-27
13600120024
WHEEL SPEED SENSOR CHECK

Refer to GROUP 35B - On-vehicle Service.
13600130027
VACUUM SOLENOID VALVE CHECK

13600390012
VENTILATION SOLENOID VALVE CHECK

13600400012
VACUUM TANK CHECK

13600410015
VACUUM ACTUATOR CHECK

13600420018
APS connector
APS
ACCELERATOR PEDAL POSITION SENSOR 13600430028 (APS) CHECK

1. Disconnect the APS connector. 2. Measure the resistance between terminals (1) and (4) of the APS connector. Standard value: 3.5 - 6.5 kW 3. When the accelerator pedal is gradually depressed, check that the resistance between terminals (1) and (2) of the APS connector changes smoothly in proportion to the pedal opening amount. 4. If the resistance is outside the standard value, or if the resistance does not change smoothly, replace the APS. Adjust the APS after it has been replaced. (Refer to GROUP 13A - On-vehicle Service.)
Throttle body
13H-28 TCL SWITCH

TCL - TCL Switch

13600160033
1
Removal steps 1. Switch bezel 2. TCL switch
INSPECTION
TCL SWITCH CONTINUITY CHECK
ON Neutral OFF
13600170036
Switch position ON Neutral OFF
Terminal No. 1 2 3 6 4 5
TCL - Steering Wheel Sensor
13H-29
13600220014
STEERING WHEEL SENSOR

CAUTION: SRS Before removal of air bag module and clock spring, refer to GROUP 52B - Service Precautions and Air Bag Module and Clock Spring.
AA"
Removal steps D Steering wheel and column cover (Refer to GROUP 37A - Steering Wheel and Shaft.) 1. Steering wheel sensor
Slit plate

AA" STEERING WHEEL SENSOR REMOVAL Caution 1. Do not adhere any dust or grease, etc. to the steering wheel sensor, which has a photo coupler in it. 2. Do not bend the slit plate of the column switch nor adhere any grease etc. to it.
Steering wheel sensor
INSPECTION
STEERING WHEEL SENSOR CHECK Refer to P.13H-22.
13600230017
13H-30 TCL-ECU
TCL - TCL-ECU
13600280036
Pre-removal and Post-installation Operation Grove Box, Grove Box Frame, Side Cover and Corner Panel Removal and Installation (Refer to GROUP 52A - Instrument panel.)
5 Nm
3 2
5 Nm
5 Nm
AA"
Removal steps 1. Instrument panel lower passenger side bracket 2. Upper bracket 3. TCL-ECU 4. Lower bracket

AA" UPPER BRACKET REMOVAL Loosen the dash wiring harness mounting nut. Lower the dash wiring harness to the position where the upper bracket can be removed, and the remove the upper bracket.
Dash wiring harness
INSPECTION
TCL-ECU CHECK Refer to P.13H-23.
13600290015
14-1
ENGINE COOLING
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9
Engine Coolant Leak Checking . . . . . . . . . . . . . . . . 9 Radiator Cap Opening Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
14109000208
Engine Coolant Replacement . . . . . . . . . . . . . . . . . 10 Concentration Measurement . . . . . . . . . . . . . . . . . . 11 Fan Controller Check . . . . . . . . . . . . . . . . . . . . . . . . 12 Fan Control Relay Continuity Check . . . . . . . . . . 12
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 WATER PUMP <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 <6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 <4D6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 WATER HOSE AND WATER PIPE . . . . . . . . 19 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
14-2
ENGINE COOLING -
General Information/ Service Specifications/Lubricant/Sealants

14100010217
GENERAL INFORMATION
The cooling system is designed to keep every part of the engine at appropriate temperature in whatever condition the engine may be operated. The cooling method is of the water-cooled, pressure forced circulation type in which the water pump pressurizes coolant and circulates it throughout the engine. If the coolant temperature exceeds the prescribed temperature, the thermostat opens to circulate the coolant through the radiator as well so that the heat absorbed by the coolant may be radiated into the air.
Items Radiator Performance kJ/h 4G6 6A1 4D6 A/T oil cooler Performance kJ/h 4G6 6A1, 4D6
The water pump is of the centrifugal type and is driven by the timing belt or drive belt from the crankshaft. The radiator is the corrugated fin, down flow type and is cooled by the electrical radiator fan. The cooling fans are controlled by a fan controller and the engine-ECU depending on driving conditions.
Specifications 175,800 200,900 213,500 5,700 7,100

14100030091
Items Radiator cap opening pressure kPa Range of coolant antifreeze concentration of radiator % Thermostat Valve opening temperature of thermostat _C Full-opening temperature of thermostat _C Valve lift (at 95_C) mm Standard value 74 - 103 30 - 60 82 1.5 95 8.5 or more Limit 64 -
LUBRICANT
Items HIGH QUALITY ETHYLENE GLYCOL ANTIFREEZE COOLANT 4G6, 6A1 4D6 Quantity L 6 8
14100040148
SEALANTS
Items Cylinder block drain plug Water pump <6A1>, Thermostat case assembly <4G6, 4D6>, Water outlet fitting <4D6> Specified sealant 3M Nut Locking Part No. 4171 or equivalent Mitsubishi Genuine Parts No. MD970389 or equivalent Remarks
14100050172
Drying sealant Semi-drying sealant
ENGINE COOLING - Special Tool/Troubleshooting
14-3
14100060038
SPECIAL TOOL
Tool
A
Name Harness set A: Test harness B: LED harness C: LED harness adapter D: probe
Use Measurement of terminal voltage A: Connector pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection
TROUBLESHOOTING
Trouble symptoms Radiator fan and condenser fan do not operate. <Vehicles with A/C> Radiator fan does not operate. <Vehicles without A/C> Radiator fan and condenser fan do not change speed or stop. <Vehicles with A/C> Radiator fan does not change speed or stop. <Vehicles without A/C> Radiator fan does not operate. <Vehicles with A/C> Condenser fan does not operate. <Vehicles with A/C> Inspection procedure No. 1 2
14100560019
Reference page 14-3 14-6
3 4
14-8 14-8

Inspection Procedure 1 Radiator fan and condenser fan do not operate. <Vehicles with A/C> Radiator fan does not operate. <Vehicles without A/C>
The cause could be a malfunction of the fan controller power supply or earth circuit. The cause could also be a malfunction of the fan controller or the engine-ECU.
Probable cause
D D D D D
Malfunction Malfunction Malfunction Malfunction Malfunction
of of of of of
fusible link fan control relay fan controller engine-ECU wiring harness or connector
14-4
<Vehicles with A/C>
D D
ENGINE COOLING - Troubleshooting
Fusible links (4) and (7) check Fan control relay check (Refer to P.14-12.) OK
NG
Replace
1. NG Measure at the fan control relay connector B-20X. D Remove the relay, and measure at the harness side connector. 1. Voltage between 4 and body earth 2. NG OK: Battery voltage 2. Voltage between 3 and body earth (Ignition switch: ON) OK: Battery voltage 3. NG 3. Continuity between 1 and body earth OK: Continuity 1. NG Measure at the fan controller connector A-22. D Disconnect the connector, and measure at the harness side connector. 2. NG 1. Voltage between 3 and body earth (Ignition switch: ON) OK: Battery voltage 2. Continuity between 1 and body earth OK: Continuity OK Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3. D Connect the connector. <Except 4D6> D Voltage between 21 and body earth (Engine: idling, A/C switch: ON) OK: 0.7 V or more (When A/C compressor is operating) <4D6> D Voltage between 18 and body earth (Engine: idling, A/C switch: ON) OK: 0.7 V or more (When A/C compressor is operating) OK NG OK
Check the harness wire between fan control relay and fusible link (4), and repair if necessary. Check the harness wire between fan control relay and fusible link (7), and repair if necessary. Check the harness wire between fan control relay and body earth, and repair if necessary. Check the harness wire between fan controller and fan control relay, and repair if necessary. Check the harness wire between fan controller and body earth, and repair if necessary.
Check the harness wire between fan controller and engine-ECU. OK NG Repair Engine-ECU terminal voltage check (Refer to GROUP 13A - Troubleshooting.) OK NG Replace Check the automatic compressor-ECU <manual air conditioner> or A/C-ECU <automatic air conditioner>, and repair if necessary. (Refer to GROUP 55 - Troubleshooting.)
Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3. D Connect the connector. <Except 4D6> D Pull out the terminal No.21 to disconnect it (Ignition switch: ON) OK: The radiator fan motor and condenser fan motor operate. <4D6> D Pull out the terminal No.18 to disconnect it (Ignition switch: ON) OK: The radiator fan motor and condenser fan motor operate. YES Engine-ECU terminal voltage check (Refer to GROUP 13A - Troubleshooting.) NO Replace the radiator fan motor and fan controller assembly.
NOTE *1: 4G6 *2: 6A1 *3: 4D6

<Vehicles without A/C>
D D Fusible links (4) and (7) check Fan control relay check (Refer to P.14-12.) OK NG Replace
14-5
1. NG Measure at the fan control relay connector B-20X. D Remove the relay, and measure at the harness side connector. 1. Voltage between 4 and body earth 2. NG OK: Battery voltage 2. Voltage between 3 and body earth (Ignition switch: ON) OK: Battery voltage 3. NG 3. Continuity between 1 and body earth OK: Continuity 1. NG Measure at the fan controller connector A-22. D Disconnect the connector, and measure at the harness side connector. 2. NG 1. Voltage between 3 and body earth (Ignition switch: ON) OK: Battery voltage 2. Continuity between 1 and body earth OK: Continuity OK Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3. D Connect the connector. <Except 4D6> D Voltage between 21 and body earth (Engine: idling) OK: 0.7 V or more (When radiator fan is operating) <4D6> D Voltage between 18 and body earth (Engine: idling) OK: 0.7 V or more (When radiator fan is operating) OK Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3. D Connect the connector. <Except 4D6> D Pull out the terminal No.21 to disconnect it (Ignition switch: ON) OK: The radiator fan motor operates. <4D6> D Pull out the terminal No.18 to disconnect it (Ignition switch: ON) OK: The radiator fan motor operates. YES Engine-ECU terminal voltage check (Refer to GROUP 13A - Troubleshooting.) NG OK
Check the harness wire between fan control relay and fusible link (4), and repair if necessary. Check the harness wire between fan control relay and fusible link (7), and repair if necessary. Check the harness wire between fan control relay and body earth, and repair if necessary. Check the harness wire between fan controller and fan control relay, and repair if necessary. Check the harness wire between fan controller and body earth, and repair if necessary.
Check the harness wire between fan controller and engine-ECU. OK NG Repair Engine-ECU terminal voltage check (Refer to GROUP 13A - Troubleshooting.)
NO Replace the radiator fan motor and fan controller assembly.
NOTE *1: 4G6 *2: 6A1 *3: 4D6
14-6
Radiator fan and condenser fan do not change speed or stop. <Vehicles with A/C> Radiator fan does not change speed or stop. <Vehicles without A/C>
The fan controller carries out step-free control of the radiator fan motor and the condenser fan motor speeds using signals transmitted from the engine-ECU.
Probable cause
D D D D
Malfunction Malfunction Malfunction Malfunction
of of of of
fan control relay fan controller engine-ECU wiring harness or connector
<Vehicles with A/C>

Fan control relay check (Refer to P.14-12.) OK D D D Check the harness wire between fan control relay and fusible link (7). Check the harness wire between fan control relay and body earth. Check the harness wire between fan control relay and fan controller. OK Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3. D Connect the connector. <Except 4D6> D Voltage between 21 and body earth (Engine: idling, engine coolant temperature: 80_C or less) OK: 0 - 0.3 V (Engine: idling, A/C switch: ON) OK: 0.7 V or more (When A/C compressor is operating) <4D6> D Voltage between 18 and body earth (Engine: idling, engine coolant temperature: 80_C or less) OK: 0 - 0.3 V (Engine: idling, A/C switch: ON) OK: 0.7 V or more (When A/C compressor is operating) OK NG Repair NG Replace
NG
Check the harness wire between fan controller and engine-ECU. NG OK Repair
Engine-ECU terminal voltage check (Refer to GROUP 13A - Troubleshooting.) NG OK Replace
Check the automatic compressor-ECU <manual air conditioner> or A/C-ECU <automatic air conditioner>, and repair if necessary. (Refer to GROUP 55 - Troubleshooting.) NG Replace the radiator fan motor and fan controller assembly.
Fan controller check (Refer to P.14-12.) OK
Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3. D Connect the connector. <Except 4D6> D Pull out the terminal No.21 to disconnect it (Ignition switch: ON) OK: The radiator fan motor and condenser fan motor operate. D Connect the terminal No.21 to the body earth (Ignition switch: ON) OK: The radiator fan motor and condenser fan motor stop. <4D6> D Pull out the terminal No.18 to disconnect it (Ignition switch: ON) OK: The radiator fan motor and condenser fan motor operate. D Connect the terminal No.18 to the body earth (Ignition switch: ON) OK: The radiator fan motor and condenser fan motor stop. YES Engine-ECU terminal voltage check (Refer to GROUP 13A - Troubleshooting.) NO Replace the radiator fan motor and fan controller assembly.
NOTE *1: 4G6 *2: 6A1 *3: 4D6

<Vehicles without A/C>
Fan control relay check (Refer to P.14-12.) OK D D D Check the harness wire between fan control relay and fusible link (7). Check the harness wire between fan control relay and body earth. Check the harness wire between fan control relay and fan controller. OK Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3. D Connect the connector. <Except 4D6> D Voltage between 21 and body earth (Engine: idling, engine coolant temperature: 80_C or less) OK: 0 - 0.3 V (Engine: idling) OK: 0.7 V or more (When radiator fan is operating) <4D6> D Voltage between 18 and body earth (Engine: idling, engine coolant temperature: 80_C or less) OK: 0 - 0.3 V (Engine: idling) OK: 0.7 V or more (When radiator fan is operating) OK Fan controller check (Refer to P.14-12.) OK Measure at the engine-ECU connectors C-34*1, C-33*2, C-53*3. D Connect the connector. <Except 4D6> D Pull out the terminal No.21 to disconnect it (Ignition switch: ON) OK: The radiator fan motor operates. D Connect the terminal No.21 to the body earth (Ignition switch: ON) OK: The radiator fan motor stops. <4D6> D Pull out the terminal No.18 to disconnect it (Ignition switch: ON) OK: The radiator fan motor operates. D Connect the terminal No.18 to the body earth (Ignition switch: ON) OK: The radiator fan motor stops. YES Engine-ECU terminal voltage check (Refer to GROUP 13A - Troubleshooting.) NO NG Repair NG Replace
14-7
NG
Check the harness wire between fan controller and engine-ECU. OK NG Repair Engine-ECU terminal voltage check (Refer to GROUP 13A - Troubleshooting.)
NG
Replace the radiator fan motor and fan controller assembly.
NOTE *1: 4G6 *2: 6A1 *3: 4D6
14-8
Radiator fan does not operate. <Vehicles with A/C>

The cause could be a malfunction of the radiator fan motor or an open circuit between the fan controller and the radiator fan motor.
Probable cause
D D Malfunction of radiator fan motor Open circuit between fan controller and radiator fan motor
Inspection Procedure 4 Condenser fan does not operate. <Vehicles with A/C>
The cause could be a malfunction of the condenser fan motor or of the fan controller.
Probable cause
D D D Malfunction of condenser fan motor Malfunction of fan controller Malfunction of wiring harness or connector NG NG
Condenser fan motor check (Refer to GROUP 55.) OK Replace the radiator fan motor and fan controller assembly.
NG
Condenser fan motor connector OK Check the trouble symptom.
Repair
Replace the condenser fan motor.
ENGINE COOLING - On-vehicle Service
14-9
14100100136
ON-VEHICLE SERVICE
Cap adapter Adapter
ENGINE COOLANT LEAK CHECKING

1. Confirm that the coolant level is up to the filler neck. Install a radiator cap tester and apply 160 kPa pressure, and then check for leakage from the radiator hose or connections. Caution (1) Be sure to completely clean away any moisture from the places checked. (2) When the tester is taken out, be careful not to spill any coolant from it. (3) Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator. 2. If there is leakage, repair or replace the appropriate part.
RADIATOR CAP OPENING PRESSURE CHECK

14100130159
Cap adapter
1. Use a cap adapter to attach the cap to the tester. 2. Increase the pressure until the indicator of the gauge stops moving. Limit: 64 kPa Standard value: 74 - 103 kPa 3. Replace the radiator cap if the reading does not remain at or above the limit. NOTE Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an improper indication.
14-10
ENGINE COOLING - On-vehicle Service ENGINE COOLANT REPLACEMENT

14100120231
1. Drain the engine coolant by removing the drain plug and then the radiator cap. 2. Remove the drain plug from the cylinder block to drain the engine coolant. Cylinder block drain plug
<4G6> <4D6>
<6A1> Front bank <6A1> Rear bank
3. Remove the reserve tank to drain the engine coolant. 4. When the engine coolant has drained, pour in water from the radiator cap to clean the engine coolant line.
<6A1>
<4G6, 4D6>
5. Coat the thread of the cylinder block drain plug with the specified sealant and tighten to the specified torque. Specified sealant: 3M Nut Locking Part No. 4171 or equivalent 6. Securely tighten the radiator drain plug. 7. Install the reserve tank.
39 Nm
44 Nm
ENGINE COOLING - On-vehicle Service

<6A1> Water outlet fitting Air bleed bolt 12 - 15 Nm
14-11
8. Remove the air bleed bolt and replace the seal washer. 9. Fill the radiator until the engine coolant flows from the air bleed bolt section, and then close the air bleed bolt.
Seal washer
10. Slowly pour the engine coolant into the mouth of the radiator until the radiator is full, and pour also into the reserve tank up to the FULL line. Recommended antifreeze: HIGH QUALITY ETHYLENE GLYCOL ANTIFREEZE COOLANT Quantity: <4G6, 6A1> 6 L <4D6> 8 L NOTE For Norway, the non-amine type of antifreeze should be used. 11. Install the radiator cap securely. 12. Start the engine and warm the engine until the thermostat opens. (Touch the radiator hose with your hand to check that warm water is flowing.) 13. After the thermostat opens, race the engine several times, and then stop the engine. 14. Cool down the engine, and then pour engine coolant into the reserve tank until the level reaches the FULL line. If the level is low, repeat the operation from step 11.
CONCENTRATION MEASUREMENT
14100110146
Measure the temperature and specific gravity of the engine coolant to check the antifreeze concentration. Standard value: 30 - 60 % (allowable concentration range) RECOMMENDED ANTIFREEZE
Antifreeze HIGH QUALITY ETHYLENE GLYCOL ANTIFREEZE COOLANT Allowable concentration 30 - 60 %
Caution If the concentration of the antifreeze is below 30 %, the anti-corrosion property will be adversely affected. In addition, if the concentration is above 60 %, both the anti-freezing and engine cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range.
14-12
Fan controller
ENGINE COOLING - On-vehicle Service FAN CONTROLLER CHECK

14100610011
1. Remove the fan controller mounting bolt, and then disconnect the condenser fan motor connector. 2. Start the engine and run it at idle. 3. Turn the A/C switch to ON and maintain the coolant temperature at 80_C or less. 4. When measuring the voltage between the fan controller-side connector terminals, check that the value changes repeatedly as indicated by (1) - (3) below. (1) 0 V (2) <4G6> 8.2 2.6 V <Except 4G6> 6.8 2.6 V (3) Battery voltage 2.6 V 5. If the voltage does not repeatedly change as indicated, replace the radiator fan motor and the fan controller assembly.
FAN CONTROL RELAY CONTINUITY CHECK

14100620014
Fan control relay
Battery voltage
When current is not supplied When current supplied is
ENGINE COOLING - Thermostat
14-13
14100240265
THERMOSTAT
Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to P.14-10.) D Air Cleaner and Air Intake Hose Assembly Removal and Installation D
Air Hose and Air Pipe Assembly Removal and Installation <4D6> (Refer to P.14-21.)
<4G6>
4 6 7 3
<6A1>
13 Nm
4
17 - 20 Nm
6 7 3
<4D6>
12 - 15 Nm
5
13 Nm
7 6 1
4
12 - 15 Nm
Removal steps 1. Heater hose connection <4D6> 2. Water hose connection <4D6> AA" "BA 3. Radiator lower hose connection 4. Control wiring harness mounting bolt
5. Fuel pipe mounting bolt <4D6> 6. Water inlet fitting "AA 7. Thermostat
14-14
ENGINE COOLING - Thermostat REMOVAL SERVICE POINT

AA" RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose.

Jiggle valve
"AA THERMOSTAT INSTALLATION Install the thermostat so that the jiggle valve is facing straight up. Caution Make absolutely sure that no oil is adhering to the rubber ring of the thermostat. In addition, be careful not to fold over or scratch the rubber ring when inserting. If the rubber ring is damaged, replace the thermostat. "BA RADIATOR LOWER HOSE CONNECTION 1. Insert each hose as far as the projection of the water inlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.
Rubber ring
INSPECTION
14100250275
THERMOSTAT CHECK 1. Immerse the thermostat in water, and heat the water while stirring. Check the thermostat valve opening temperature. Standard value: Valve opening temperature: 821.5_C
2. Check that the amount of valve lift is at the standard value when the water is at the full-opening temperature. Standard value: Full-opening temperature: 95_C Amount of valve lift: 8.5 mm or more
Valve lift
NOTE Measure the valve height when the thermostat is fully closed, and use this measurement to calculate the valve height when the thermostat is fully open.
ENGINE COOLING - Water Pump <4G6>
14-15
14100270363
WATER PUMP <4G6>

Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to P.14-10.) D Timing Belt Tensioner Pulley Removal Installation (Refer to GROUP 11.)
and
Bolt specifications 8 60 8 22
1
8 14 8 25
3
20 - 25 Nm
2
8 22 Screw diameter length mm
2
24 Nm 12 - 15 Nm
Removal steps 1. Alternator brace 2. Water pump 3. Water pump gasket "AA 4. O-ring

Water pump
O-ring
"AA O-RING INSTALLATION Insert the O-ring to the water inlet pipe assembly, and coat the outer circumference of the O-ring with water or engine coolant. Caution Do not allow engine oil or other greases to adhere to the O-ring
Water inlet pipe assembly
14-16
ENGINE COOLING - Water Pump <6A1>

14100270370
WATER PUMP <6A1>

Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to P.14-10.) D Power Steering Fluid Draining and Supplying (Refer to GROUP 37A - On-vehicle Service.) D Radiator Removal and Installation (Refer to P.14-24.) D A/C Compressor Removal and Installation (Refer to GROUP 55.) D D
Timing Belt Removal and Installation (Refer to GROUP 11.) Engine Mount Bracket Removal and Installation (Refer to GROUP 32.)
Bolt specifications 8 30
5
8 20 39 Nm 24 Nm
8 25 8 25
4 5
49 Nm 8 30 8 25
8 30 Screw diameter length mm
1 3
12 Nm
2
39 Nm
f3mm
18 Nm
Sealant: Mitsubishi Genuine Part MD970389 or equivalent Removal steps 1. Pressure tube connection 2. Power steering oil pump assembly 3. Power steering oil pump bracket
No.
AA"
4. Engine support bracket "AA 5. Water pump
ENGINE COOLING - Water Pump <6A1> REMOVAL SERVICE POINT
14-17
AA" POWER STEERING OIL PUMP ASSEMBLY REMOVAL Remove the power steering oil pump assembly with the hoses still attached. NOTE Secure the removed oil pump with rope, etc. in a place where it will not be in the way when removing and installing the power steering oil pump bracket.

"AA WATER PUMP INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there is not too much sealant and no places without sealant. Specified Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent
14-18
ENGINE COOLING - Water Pump <4D6>

14100270387
WATER PUMP <4D6>

Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to P.14-10.) D Timing Belt Idler Pulley Removal and Installation (Refer to GROUP 11.)
4
24 Nm Bolt specifications
8 25
8 22
2
24 Nm 12 - 15 Nm
3
8 65 8 20 8 22 Screw diameter length mm
Removal steps 1. Alternator brace 2. Water pump 3. Water pump gasket "AA 4. O-ring
Water pump

"AA O-RING INSTALLATION Insert the O-ring to the water inlet pipe assembly, and coat the outer circumference of the O-ring with water or engine coolant. Caution Do not allow engine oil or other greases to adhere to the O-ring
O-ring
Water inlet pipe assembly
ENGINE COOLING - Water Hose and Water Pipe
14-19
14100330306
WATER HOSE AND WATER PIPE

<4G6>
Pre-removal and Post-installation Operation D Engine Coolant Draining and Suppling (Refer to P.14-10.) D Air Cleaner and Air Intake Hose Assembly Removal and Installation
4 2
13 Nm
24 Nm
5 7 10
13 Nm
1 6 8
7 12 11
9
f3mm
Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent
Removal steps AA" "CA 1. Radiator lower hose connection 2. Control wiring harness mounting bolt 3. Water inlet fitting 4. Engine coolant temperature gauge unit connector 5. Water hose
6. Heater hose connection "BA 7. Thermostat case assembly "AA 8. O-ring 9. Heater hose connection 10. Water hose 11. Water inlet pipe assembly "AA 12. O-ring
14-20
<6A1>
Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying (Refer to P.14-10.) D Air Cleaner and Air Intake Hose Assembly Removal and Installation
Distributor Removal and Installation (Refer to GROUP 16.)
10 - 12 Nm 22 - 25 Nm
2 1 7 6 5
10
13
11 4
12 - 15 Nm
16 15
14
22 - 25 Nm
12
12 - 15 Nm 22 Nm
19
39 Nm
18
27 - 33 Nm
17
Removal steps 1. Control wiring harness mounting bolt 2. Spark plug cable clamp mounting bolt AA" "CA 3. Radiator upper hose connection AA" "CA 4. Radiator lower hose connection 5. Engine coolant temperature sensor connector 6. Engine coolant temperature gauge unit connector 7. Water hose 8. Water hose
9. 10. "AA 11. 12. 13. "AA 14. 15. "AA 16. 17. 18. 19.
Heater hose connection Heater pipe assembly O-ring Water hose Thermostat case assembly O-ring Water inlet pipe assembly O-ring Water hose Water pipe assembly Water pipe joint

<4D6>
Pre-removal operation D Engine Coolant Draining (Refer to P.14-10.) D Air Cleaner and Air Intake Hose Assembly Removal
14-21
Post-installation Operation D Engine Coolant Supplying (Refer to P.14-10.) D Engine Oil Supplying and Checking (Refer to GROUP 11 - On-vehicle Service.) D Air Cleaner and Air Intake hose Assembly Installation
11 7 10 9
17 Nm
20 - 25 Nm
17 Nm
45 Nm
6 Nm
10 - 12 Nm
2
6 Nm 10 - 13 Nm
9 Nm
12 - 15 Nm
5 4
12 - 15 Nm
12 13
12 - 15 Nm
12 - 15 Nm
10 - 12 Nm
Removal steps 1. Air hose and air pipe assembly AA" "CA 2. Radiator upper hose connection AA" "CA 3. Radiator lower hose connection 4. Heater hose connection 5. Turbocharger heat protector 6. Oil return hose and pipe assembly 7. Vacuum hose connection
8. 9. 10. 11. 12.
Air pipe bracket stay Oil pipe assembly Oil pipe assembly Vacuum pump assembly Control wiring harness mounting bolt 13. Fuel pipe mounting bolt
14-22
24 Nm
18 16
10 Nm
14
27 - 33 Nm
17 15 23
27 - 33 Nm 24 Nm
24
13 Nm
19 21 20 22
10 Nm
13 Nm
18
17
f3mm f3mm
Sealant: Mitsubishi Genuine Part No. MD970389 or equivalent 14. 15. 16. "BA 17. "BA 18. "AA 19. Water pipe assembly (A) Water hose Water inlet fitting Thermostat case assembly Water outlet fitting O-ring 20. 21. 22. 23. "AA 24. Heater hose connection Water hose Water pipe assembly (B) Water inlet pipe assembly O-ring
ENGINE COOLING - Water Hose and Water Pipe REMOVAL SERVICE POINT
14-23
AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose.
Thermostat case assembly, water pump or cylinder block

"AA O-RING INSTALLATION Insert the O-ring to the water inlet pipe assembly or the heater pipe assembly and coat the outer circumference of the O-ring with water or engine coolant. Caution Do not allow engine oil or other greases to adhere to the O-ring
O-ring
Water inlet pipe assembly or heater pipe assembly
"BA WATER OUTLET FITTING/THERMOSTAT CASE ASSEMBLY INSTALLATION Squeeze out the sealant from the tube evenly and apply it so that there is not too much sealant and no places without sealant. Specified Sealant: Mitsubishi Genuine Parts No. MD970389 or equivalent
"CA RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION 1. Insert each hose as far as the projection of the water inlet fitting or water outlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.
INSPECTION
14100340118
WATER PIPE AND HOSE CHECK Check the water pipe and hose for cracks, damage, clog and replace them if necessary.
14-24 RADIATOR
ENGINE COOLING - Radiator

14100150285

Pre-removal operation D Engine Coolant Draining (Refer to P.14-10.) D Air Cleaner and Air Intake Hose Assembly Removal Post-installation Operation D Engine Coolant Supplying (Refer to P.14-10.) D A/T Fluid Supplying and Checking (Refer to GROUP 23 - On-vehicle Service.) D Air Cleaner and Air Intake Hose Assembly Installation
12 Nm 12 Nm
11 2 3
18 20
17 19
11
12
6 1
4
5 Nm
12 Nm
9 5 8 16 10 14
5 Nm
15
5 Nm
13
13
Radiator removal steps 1. Drain plug 2. Radiator cap 3. Overflow hose 4. Reserve tank 5. Reserve tank bracket AA" "AA 6. Radiator upper hose AA" "AA 7. Radiator lower hose 8. Clamp <6A1 - A/T> AB" 9. Transmission fluid cooler hose connection <A/T> 10. Engine oil cooler hose mounting bolt <4D6> 11. Upper insulator 12. Radiator assembly 13. Lower insulator 14. Bolt <A/T>
AB"
15. Transmission fluid cooler hose and pipe assembly <A/T> 16. Condenser fan motor assembly <Vehicle with A/C> 17. Radiator fan motor assembly Radiator fan motor and fan controller assembly removal steps AA" "AA 6. Radiator upper hose 8. Clamp <6A1 - A/T> 14. Bolt <A/T> 17. Radiator fan motor assembly 18. Fan 19. Radiator fan motor and fan controller assembly 20. Shroud
ENGINE COOLING - Radiator REMOVAL SERVICE POINTS
14-25
AA" RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose. AB" TRANSMISSION FLUID COOLER HOSE AND PIPE ASSEMBLY REMOVAL After disconnecting the hoses from the radiator and the transmission, plug all of the pipes and hoses to prevent dirt and other foreign objects from getting inside.

"AA RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION 1. Insert each hose as far as the projection of the water inlet fitting. 2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.
NOTES
15-1
INTAKE AND EXHAUST

CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATION . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3
Turbocharger Supercharging Check . . . . . . . . . . . . 3 Waste Gate Actuator Check . . . . . . . . . . . . . . . . . . 3
15109000250
AIR INTAKE PLENUM . . . . . . . . . . . . . . . . . . . . . . 6 INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 8 EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 13 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . 16 EXHAUST PIPE AND MAIN MUFFLER . . . . 22
INTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
15-2
INTAKE AND EXHAUST -
General Information/ Service Specifications/Special Tool

15100010061
GENERAL INFORMATION
The intake manifold is made of an aluminium alloy, and the shape provides an increased intake inertia effect and has a good volumetric efficiency.
The exhaust manifold is made of stainless steel. The exhaust pipe is divided into three parts; the front pipe, the centre pipe, and the main muffler.
15100030197
Items Manifold distortion of the installation surface mm Waste gate actuator activation pressure kPa Air temperature switch _C <Vehicles with intercooler turbocharger> OFF ON ON OFF Standard value 0.15 or less Approx. 75 57 or more 45 or less Limit 0.20 -
SPECIAL TOOL
Tool Number MD998770 Name Oxygen sensor wrench Use
15100060066
Removal/Installation of oxygen sensor
INTAKE AND EXHAUST - On-vehicle Service
15-3
15100100072
ON-VEHICLE SERVICE
TURBOCHARGER SUPERCHARGING CHECK <4D6>

Caution Conduct the driving test in a location where driving at full acceleration can be done with safety. Two persons should be in the vehicle when the test is conducted; the person in the passenger seat should read the indications shown by the pressure meter. 1. Connect the pressure gauge to the hose between the turbochager and the waste gate actuator. 2. Drive at full-throttle acceleration in second gear and then measure the supercharging when the engine speed in about 3,000 r/min. 3. When the indicated supercharging does not become positive pressure, check the following items. D Malfunction of the waste gate actuator. D Leakage of supercharging pressure. D Malfunction of the turbocharger. 4. When the indicated supercharging is 76 kPa or more, supercharging control may be faulty, therefore check the followings. D Disconnection or cracks of the waste gate actuator rubber hose. D Malfunction of the waste gate actuator. D Malfunction of the waste gate valve.
WASTE GATE ACTUATOR CHECK <4D6>

15100120054
1. Connect a manual pump (pressure-application type) to nipple A. 2. While gradually applying pressure, check the pressure that begins to activate (approx. 1 mm stroke) the waste gate actuator rod. Standard value: Approx. 75 kPa Caution In order to avoid damage to the diaphragm, do not apply a pressure of 109 kPa or higher. 3. If there is a significant deviation from the standard value, check the actuator or the waste gate valve: replace if necessary.
15-4 INTERCOOLER
INTAKE AND EXHAUST - Intercooler

15100420055
Hose clamp tightening torque 6 Nm
Pipe installation bolt tightening torque 10 - 13 Nm
3 5 4
1 2
9 7
10 - 13 Nm
10 - 13 Nm
6 11
10
"AA "AA "BA "AA "AA "AA
Air hose and air pipe removal steps 1. Air hose E 2. Air hose B 3. Air hose F 4. Air hose A 5. Air pipe A 6. Air hose C 7. Air hose C 8. Air pipe B 9. Air pipe C
Intercooler assembly removal steps "AA 6. Air hose C "AA 7. Air hose C 10. Intercooler duct 11. Intercooler assembly
INTAKE AND EXHAUST - Intercooler INSTALLATION SERVICE POINTS
15-5
"AA AIR HOSE C/AIR HOSE A/AIR HOSE B/AIR HOSE E INSTALLATION Align the alignment mark (white paint) on each hose with the protrusion on each pipe. "BA AIR HOSE F INSTALLATION Install the hose with its marking (white paint) upward.
15-6
INTAKE AND EXHAUST - Air Intake Plenum

15100270124
AIR INTAKE PLENUM

Pre-removal Operation D Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service.) D Air Cleaner Removal D Throttle Body Removal (Refer to GROUP 13A.)
Post-installation Operation D Engine Coolant Supplying (Refer to GROUP 14 - On-vehicle Service.) D Throttle Body Installation (Refer to GROUP 13A.) D Air Cleaner Installation D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)
3 Nm
4 8 9
14 Nm
2
18 Nm
12
10 - 12 Nm
13
14
15
11
9 Nm
10
19 Nm
9 Nm 18 Nm
15
Removal steps 1. Engine cover 2. Crankshaft position sensor connector 3. Injector connector 4. Vacuum hose connection 5. Air pipe assembly mounting bolt 6. Brake booster vacuum hose connection 7. Connector bracket mounting bolt
8. 9. 10. 11. 12. 13. "AA 14. 15.
Connector bracket mounting bolt Noise condenser mounting bolt EGR valve Solenoid valve assembly Vacuum pipe assembly Air intake plenum Air intake plenum gasket Air intake plenum stay
INTAKE AND EXHAUST - Air Intake Plenum INSTALLATION SERVICE POINT

Protrusion Front
15-7
"AA AIR INTAKE PLENUM GASKET INSTALLATION Install with gasket protrusions in the position illustrated.
15-8
INTAKE AND EXHAUST - Intake Manifold

15100300441
INTAKE MANIFOLD
<4G6>
Pre-removal Operation D Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service.) D Air Cleaner Removal D Throttle Body Removal (Refer to GROUP 13A.)
Post-installation Operation D Throttle Body Installation (Refer to GROUP 13A.) D Air Cleaner Installation D Engine Coolant Supplying (Refer to GROUP 14 - On-vehicle Service.) D Accelerator Cable Ajdustment (Refer to GROUP 17 - On-vehicle Service.)
1 4
5 2
Removal steps 1. Accelerator cable 2. Brake booster vacuum hose connection 3. Injector connector 4. EGR solenoid valve connector 5. Purge control solenoid valve connector

10 - 13 Nm
15-9
10 9
10 - 12 Nm
8
9 Nm
20 Nm
20 Nm
11
6 13 14
20 Nm 31 Nm
12
AA"
6. 7. 8. 9.
EGR valve PCV hose Fuel return hose connection Delivery pipe, injector and pressure regulator
10. 11. 12. 13. 14.
Vacuum pipe assembly Solenoid valve assembly Intake manifold Intake manifold gasket Intake manifold stay
15-10
<6A1>
Pre-removal Operation D Fuel Discharge Prevention (Refer to GROUP 13A - On-vehicle Service.) D Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service.) D Air Cleaner Removal D Air Intake Plenum Removal (Refer to P.15-6.)
Post-Installation Operation D Air Intake Plenum Installation (Refer to P.15-6.) D Air Cleaner Installation D Engine Coolant Supplying (Refer to GROUP 14 - On-vehicle Service.) D Accelerator Cable Adjustment (Refer to GROUP 17 - On-vehicle Service.)
2 3 5
12 Nm
5
Engine oil
O-ring
4
18 Nm
6 7
35 Nm
8 9
18 Nm
Removal steps 1. Engine mount stay 2. Fuel return hose connection "BA 3. Fuel high-pressure hose connection 4. Injector connector AA" 5. Delivery pipe, injector and pressure regulator
6. 7. 8. "AA 9.
PCV hose connection Vacuum hose connection Intake manifold Intake manifold gasket

<4D6>
Pre-removal and Post-installation Operation D Air Cleaner Removal and Installation D Air Pipe A Removal and Installation (Refer to P.15-4.)
15-11
10 - 12 Nm
18 Nm
12 - 15 Nm
1 2
25 Nm
3 6 5 4 8
18 Nm
9
18 Nm
18 Nm
10
12 - 15 Nm
Removal steps 1. Air inlet fitting 2. Brake booster vacuum hose 3. Vacuum hose 4. Throttle body assembly 5. EGR valve and pipe assembly 6. Turbocharger heat protector
7. 8. 9. D 10.
Rear heat protector Vacuum hose Intake manifold Turbocharger (Refer to P.15-6.) Intake and exhaust manifold gasket
15-12
INTAKE AND EXHAUST - Intake Manifold REMOVAL SERVICE POINT

AA" DELIVERY PIPE, INJECTOR AND PRESSURE REGULATOR REMOVAL Remove the delivery pipe (with the injectors and pressure regulator attached to it). Caution Care must be taken, when removing the delivery pipe, not to drop the injector.
Front
Protrusion

"AA INTAKE MANIFOLD GASKET INSTALLATION Install gasket with its protrusion in the position illustrated.
Protrusion
Delivery pipe
"BA HIGH-PRESSURE FUEL HOSE INSTALLATION 1. When connecting the high-pressure fuel hose to the delivery pipe, apply a small amount of new engine oil to the O-ring and then insert the high-pressure fuel hose, being careful not to damage the O-ring. Caution Be careful not to let any engine oil get into the delivery pipe. 2. While turning the high-pressure fuel hose to the left and right, install it to the delivery pipe. 3. Check to be sure that the injector turns smoothly. If it does not turn smoothly, the O-ring may be trapped, remove the high-pressure fuel hose and then re-insert it into the delivery pipe and check once again.
O-ring High-pressure fuel hose
INSPECTION
15100310161
Check the following points; replace the part if a problem is found. INTAKE MANIFOLD CHECK 1. Check for damage or cracking of any part. 2. Check for obstruction of the negative pressure (vacuum) outlet port, and for obstruction of the water passage or gas passage. 3. Using a straight edge and thickness gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less Limit: 0.20 mm
INTAKE AND EXHAUST - Exhaust Manifold
15-13
15100330440
EXHAUST MANIFOLD
Pre-removal and Post-installation Operation D Front Exhaust Pipe Removal and Installation (Refer to P.15-22.)
<4G6> 3
29 Nm 49 Nm
12 - 15 Nm
49 Nm
Removal steps 1. Exhaust manifold cover 2. Exhaust manifold 3. Exhaust manifold gasket
15-14
<6A1>
12 - 15 Nm
12 - 15 Nm
4 3
49 Nm
12 - 15 Nm
49 Nm
2
34 Nm
2
44 Nm
Removal steps 1. Heat protector 2. Exhaust manifold stay 3. Exhaust manifold 4. Exhaust manifold gasket

<4D6>
15-15
29 Nm 14 Nm 29 Nm
2 3
Removal steps 1. Front heat protector 2. Engine hanger 3. Exhaust manifold D Turbocharger (Refer to P.15-16.) 4. Intake and exhaust manifold gasket
INSPECTION
15100340061
EXHAUST MANIFOLD CHECK 1. Check for damage or cracking of any part. 2. Using a straight edge and thickness gauge, check for distortion of the cylinder head installation surface. Standard value: 0.15 mm or less Limit: 0.20 mm
15-16 TURBOCHARGER
INTAKE AND EXHAUST - Turbocharger

15100450047

Pre-removal and Post-installation Operation D Engine Coolant Draining and Supplying D Engine Oil Draining and Supplying D Air Cleaner Removal and Installation D Intake Manifold Removal and Installation (Refer to P.15-8.) D Front Exhaust Pipe and Front Heat Protector Removal and Installation (Refer to P.15-15, 23.)
25 Nm
18 Nm 10 - 12 Nm 12 - 15 Nm
17 Nm
2 4 6
10 Nm
5 1
6 Nm
3
27 - 33 Nm
11 13
12 - 15 Nm
14 7
12 - 15 Nm
12
59 Nm
15
59 Nm 12 - 15 Nm
10 Nm
8
59 Nm 9 Nm
27 - 33 Nm
10
Removal steps 1. Air hose A 2. EGR valve and pipe assembly 3. Turbocharger heat protector 4. Oil pipe assembly A 5. Oil pipe assembly B 6. Water pipe assembly A 7. Water pipe assembly B 8. Oil return pipe
AA" AA" AA"
9. 10. 11. 12. 13. "AA 14. 15.
Rear heat protector Exhaust fitting heat protector Turbocharger assembly Exhaust fitting assembly Exhaust fitting gasket Turbocharger Turbocharger gasket
INTAKE AND EXHAUST - Turbocharger REMOVAL SERVICE POINT
15-17
AA" OIL PIPE ASSEMBLY A/OIL PIPE ASSEMBLY B/OIL RETURN PIPE REMOVAL Caution After disconnecting the oil pipe, take care that foreign material does not enter the oil passage hole of the turbocharger assembly.

"AA TURBOCHARGER INSTALLATION 1. Clean the alignment surfaces shown in the illustration. Caution When cleaning, take care that no foreign material gets into the engine coolant or oil passages hole. 2. Supply clean engine oil through the oil pipe installation hole of the turbocharger.
INSPECTION
15100460057
Compressor wheel
TURBOCHARGER ASSEMBLY CHECK D Visually check the turbine wheel and the compressor wheel for cracking or other damage. D Check whether the turbine wheel and the compressor wheel can be easily turned by hand. D Check for oil leakage from the turbocharger assembly. D Check whether or not the waste gate valve remains open. If any problem is found, replace the part after disassembly. OIL PIPE ASSEMBLY AND OIL-RETURN PIPE CHECK Check the oil pipe assembly and oil-return for clogging, bending, or other damage. If there is clogging, clean it.
15-18

2
9 10 8 7 5 6 1
3
Disassembly steps 1. Hose clip 2. Hose 3. Snap ring (E-ring) "FA 4. Turbocharger waste gate actuator "EA 5. Coupling "DA 6. AA" "CA 7. AB" "BA 8. 9. "AA 10. Turbine housing Snap ring Turbine wheel assembly Compressor cover O-ring
DISASSEMBLY SERVICE POINTS

AA" SNAP RING REMOVAL Lay the unit with the compressor cover side facing down and using snap ring pliers, remove the compressor cover attaching snap ring. Caution When removing the snap ring, hold it with fingers to prevent it from springing away.
Snap ring
15-19
AB" TURBINE WHEEL ASSEMBLY REMOVAL Remove the turbine wheel assembly, striking the circumference of the compressor cover with a plastic hammer. The turbine wheel assembly may be a little hard to remove due to an O-ring put on the outer circumference.
Turbine wheel assembly
CLEANING 1. Use a clean cleaning oil commercially available. Do not use corrosive cleaning oils as they could damage to some parts. 2. Use a plastic scraper or hard brush to clean aluminum parts.

"AA O-RING INSTALLATION Apply a light coat of engine oil to a new O-ring and fit in the turbine wheel assembly groove.
O-ring
Caution When installing the O-ring, use care not to damage it. A damaged O-ring causes oil leaks.
Dowel pin hole Dowel pin
"BA TURBINE WHEEL ASSEMBLY 1. Apply a light coat of engine oil to the periphery of the O-ring. 2. Install the turbine wheel assembly to the compressor cover while aligning the dowel pin with the hole. Caution Use care not to damage the blades of turbine wheel and compressor wheel.
Snap ring
Chamfered edge
"CA SNAP RING INSTALLATION Lay the assembly with the compressor cover facing down and fit the snap ring. Caution Fit the snap ring with its chamfered side facing up.
Turbine wheel assembly Compressor cover
15-20

"DA TURBINE HOUSING INSTALLATION Install the turbine housing while aligning the dowel pin with the hole.
Dower pin
Caution Use care not to damage the blades of turbine wheel.
Dower pin hole
"EA COUPLING INSTALLATION Install the coupling and tighten to the specified torque.
Coupling
"FA TURBOCHARGER WASTE GATE ACTUATOR OPERATION INSPECTION Using a tester, apply pressure to the actuator and check the pressure when the rod starts moving (moves approx. 1 mm). Standard value: Approx. 75 kPa Caution Do not apply a pressure of more than 109 kPa to the actuator. Otherwise, diaphragm may be damaged. Never attempt to adjust the turbocharger waste gate valve.
Traces of contact
INSPECTION
15100610025
TURBINE HOUSING 1. Check the housing for traces of contact with the turbine wheel, cracks due to overheating, pitching, deformation and other damage. Replace with a new turbine housing if cracked. 2. Operate the waste gate valve lever manually to check that the gate can be operated and closed smoothly.

Oil passage Turbine wheel
15-21
COMPRESSOR COVER Check the compressor cover for traces of contact with the compressor wheel and other damage. TURBINE WHEEL ASSEMBLY 1. Check the turbine and compressor wheel blades for bend, burr, damage, corrosion and traces of contact on the back side and replace if defective. 2. Check the oil passage of the turbine wheel assembly for deposit and clogging. 3. Check also the water passage for deposit and clogging. 4. Check the turbine wheel and compressor wheel for light and smooth turning. OIL PIPE/OIL RETURN PIPE Correct or replace the oil pipe and oil return pipe if clogged, collapsed, deformed or otherwise damaged.
Compressor wheel
Water passage
15-22
INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler

15100540355
EXHAUST PIPE AND MAIN MUFFLER

Pre-removal and Post-installation Operation D Under Cover Removal and Installation
<4G6>
Hanger installation bolt tightening torque
3, 10, 17 6
13 Nm 13 Nm
4
13 Nm 34 Nm 49 Nm 34 Nm 49 - 59 Nm 49 - 59 Nm 49 Nm
5 3
11
16
18 14
13
13 Nm
1 3 2 8 10 10
34 Nm
15
44 Nm
12 17
Main muffler removal steps 1. Main muffler assembly 2. Gasket 3. Hanger 4. Tail hanger 5. Rear hanger 6. Rear floor heat protector panel Center exhaust pipe removal steps AA" "AA 7. Oxygen sensor 8. Center exhaust pipe 9. Gasket 10. Hanger 11. Center hanger
Catalytic converter removal steps 12. Catalytic converter 13. Gasket Front exhaust pipe removal steps AA" "AA 14. Oxygen sensor 15. Front exhaust pipe 16. Gasket 17. Hanger 18. Front exhaust pipe bracket
INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler

Hanger installation bolt tightening torque
15-23
6
13 Nm
3, 10, 17 3
13 Nm 13 Nm 34 Nm
11 <6A1> 16 16
49 Nm 49 Nm 49 - 59 Nm
49 - 59 Nm 13 Nm
14 3 12
49 Nm
1 8 10 10 6
49 Nm
15 17
13
13 Nm
3
13 Nm
<4D6> 16
49 Nm 49 Nm
3 11
13 Nm 34 Nm
13 1 3 2 8 9 10 10
15
49 Nm
12 17
Main muffler removal steps 1. Main muffler assembly 2. Gasket 3. Hanger 4. Tail hanger 5. Rear hanger 6. Rear floor heat protector panel Center exhaust pipe removal steps AA" "AA 7. Oxygen sensor 8. Center exhaust pipe 9. Gasket 10. Hanger 11. Center hanger
Catalytic converter removal steps 12. Catalytic converter 13. Gasket Front exhaust pipe removal steps AA" "AA 14. Oxygen sensor 15. Front exhaust pipe 16. Gasket 17. Hanger
15-24
INTAKE AND EXHAUST - Exhaust Pipe and Main Muffler REMOVAL SERVICE POINT
AA" OXYGEN SENSOR REMOVAL

"AA OXYGEN SENSOR INSTALLATION
MD998770
16-1
ENGINE ELECTRICAL
CONTENTS CHARGING SYSTEM . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 5 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 6
Alternator Output Line Voltage Drop Test . . . . 6 Output Current Test . . . . . . . . . . . . . . . . . . . . . . . 8 Regulated Voltage Test . . . . . . . . . . . . . . . . . . . 10 Waveform Check Using An Analyzer . . . . . . . 12 Alternator Relay Continuity Check . . . . . . . . . 13
16109000233
IGNITION SYSTEM <4G6, 6A1> . . . . . 35

GENERAL INFORMATION . . . . . . . . . . . . . . 35 SERVICE SPECIFICATIONS . . . . . . . . . . . . 37 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 37 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 38
Power Transistor Continuity Check <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Ignition Coil Check <6A1> . . . . . . . . . . . . . . . . 38 Power Transistor Continuity Check <6A1> . . 39 Resistive Cord Check . . . . . . . . . . . . . . . . . . . . . 39 Spark Plug Check and Cleaning <4G6> . . . . 39 Spark Plug Check <6A1> . . . . . . . . . . . . . . . . . 40 Camshaft Position Sensor Check <4G6> . . . 40 Top Dead Center Sensor Check <6A1> . . . . 40 Crank Angle Center Sensor Check . . . . . . . . 40 Detonation Sensor Check . . . . . . . . . . . . . . . . . 41 Waveform Check Using An Analyzer . . . . . . . 41
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . 14
STARTING SYSTEM . . . . . . . . . . . . . . . . 23
GENERAL INFORMATION . . . . . . . . . . . . . . 23 SERVICE SPECIFICATIONS . . . . . . . . . . . . 23 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 24
Starter Relay Continuity Check <4D6> . . . . . 24
CONTINUED ON NEXT PAGE
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . 24
16-2
DISTRIBUTOR <6A1> . . . . . . . . . . . . . . . . . . 52 IGNITION COIL <4G6> . . . . . . . . . . . . . . . . . 54 CAMSHAFT POSITION SENSOR <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 CRANK ANGLE SENSOR . . . . . . . . . . . . . . 55 DETONATION SENSOR . . . . . . . . . . . . . . . . 56
Self-regulating Glow System Check . . . . . . . . 58 Check at the Engine-ECU Terminals . . . . . . . 59 Glow Plug Relay Check . . . . . . . . . . . . . . . . . . 60 Glow Plug Check . . . . . . . . . . . . . . . . . . . . . . . . 60 Engine Coolant Temperature Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
GLOW PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . 61
GLOW SYSTEM <4D6> . . . . . . . . . . . . . 57

GENERAL INFORMATION . . . . . . . . . . . . . . 57
INJECTION SYSTEM <4D6> . . . . . . . . 62

GENERAL INFORMATION . . . . . . . . . . . . . . 62 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 62
SERVICE SPECIFICATIONS . . . . . . . . . . . . 58 CRANK ANGLE SENSOR . . . . . . . . . . . . . . 62 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 58
ENGINE ELECTRICAL - Charging System
16-3
16100010341
CHARGING SYSTEM
GENERAL INFORMATION
The charging system uses the alternator output to keep the battery charged at a constant level under various electrical loads.
Voltage
OPERATION
Rotation of the excited field coil generates AC voltage in the stator. This alternating current is rectified through diodes to DC voltage having a waveform shown in the illustration at left. The average output voltage fluctuates slightly with the alternator load condition.
Approx. 14.4 V
Time
When the ignition switch is turned on, current flows in the field coil and initial excitation of the field coil occurs. When the stator coil begins to generate power after the engine is started, the field coil is excited by the output current of the stator coil. The alternator output voltage rises as the field current increases and it falls as the field current decreases. When the battery voltage (alternator S terminal voltage) reaches a regulated voltage
of approx. 14.4 V, the field current is cut off. When the battery voltage drops below the regulated voltage, the voltage regulator regulates the output voltage to a constant level by controlling the field current. In addition, when the field current is constant, the alternator output voltage rises as the engine speed increases.
16-4
SYSTEM DIAGRAM
<4G6, 6A1>
B Stator coil Engine-ECU
Field coil Voltage regulator
G S L FR Charging warning lamp
+
Ignition switch Battery
<4D6>
Stator coil
Charging warning lamp
Ignition switch
Field coil Voltage regulator
+
Battery
ENGINE ELECTRICAL - Charging System ALTERNATOR SPECIFICATIONS

Items Type Rated output V/A Voltage regulator 4G6 Battery voltage sensing 12/90 Electronic built-in type 6A1 Battery voltage sensing 12/85 <M/T>, 12/100 <A/T> Electronic built-in type 4D6 Battery voltage sensing
16-5
12/100 <Except cold climate zone>, 12/120 <Cold climate zone> Electronic built-in type
16100030231
Items Alternator output line voltage drop (at 30A) V Regulated voltage ambient temp. at voltage regulator V - 20_C 20_C 60_C 80_C Output current Standard value 14.2 - 15.4 13.9 - 14.9 13.4 - 14.6 13.1 - 14.5 Limit max. 0.3 -
70% of normal output current

16100060117
SPECIAL TOOLS
Tool Number MB991519 Name Alternator test harness Use
Checking the alternator (S terminal voltage) <4G6, 6A1>
MB991450
Alternator test harness
Checking the alternator (S terminal voltage) <4D6>
16-6

16100090314
ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST
+
Alternator Voltmeter
Ammeter
Terminal B
Battery
This test determines whether the wiring from the alternator B terminal to the battery (+) terminal (including the fusible line) is in a good condition or not. (1) Always be sure to check the following before the test. D Alternator installation D Alternator drive belt tension D Fusible link D Abnormal noise from the alternator while the engine is running (2) Turn the ignition switch off. (3) Disconnect the negative battery cable. (4) Disconnect the alternator output wire from the alternator B terminal and connect a DC test ammeter with a range of 0 - 100 A in series between the B terminal and the disconnected
output wire. (Connect the (+) lead of the ammeter to the B terminal, and then connect the ( - ) lead of the ammeter to the disconnected output wire.) NOTE An inductive-type ammeter which enables measurements to be taken without disconnecting the alternator output wire should be recommended. Using this equipment will lessen the possibility of a voltage drop caused by a loose B terminal connection. (5) Connect a digital-type voltmeter between the alternator B terminal and the battery (+) terminal. (Connect the (+) lead of the voltmeter to the B terminal and the connect the ( - ) lead of the voltmeter to the battery (+) cable.)

(6) Reconnect the negative battery cable. (7) Connect a tachometer or the MUT-II. (8) Leave the hood open. (9) Start the engine. (10)With the engine running at 2,500 r/min, turn the headlamps and other lamps on and off to adjust the alternator load so that the value displayed on the ammeter is slightly above 30 A. Adjust the engine speed by gradually decreasing it until the value displayed on the ammeter is 30 A. Take a reading of the value displayed on the voltmeter at this time. Limit: max. 0.3 V NOTE When the alternator output is high and the value displayed on the ammeter does not decrease until 30 A, set the value to 40 A. Read the value displayed on the voltmeter at this time. When the value range is 40 A, the limit is max. 0.4 V.
16-7
(11)If the value displayed on the voltmeter is above the limit value, there is probably a malfunction in the alternator output wire, so check the wiring between the alternator B terminal and the battery (+) terminal (including fusible link). If a terminal is not sufficiently tight or if the harness has become discolored due to overheating, repair and then test again. (12)After the test, run the engine at idle. (13)Turn off all lamps and the ignition switch. (14)Remove the tachometer or the MUT-II. (15)Disconnect the negative battery cable. (16)Disconnect the ammeter and voltmeter. (17)Connect the alternator output wire to the alternator B terminal. (18)Connect the negative battery cable.
16-8
<4G6, 6A1>

16100100314
OUTPUT CURRENT TEST
Load Voltmeter Ammeter Charging warning lamp Ignition switch Alternator relay
B FR L S G
Battery Engine -ECU
Alternator
<4D6>
Charging warning lamp Ignition switch Alternator relay S Alternator Load
Voltmeter Ammeter
Battery

This test determines whether the alternator output current is normal. (1) Before the test, always be sure to check the following. D Alternator installation D Battery NOTE The battery should be slightly discharged. The load needed by a fully-charged battery is insufficient for an accurate test. D Alternator drive belt tension D Fusible link D Abnormal noise from the alternator while the engine is running. (2) Turn the ignition switch off. (3) Disconnect the negative battery cable. (4) Disconnect the alternator output wire from the alternator B terminal. Connect a DC test ammeter with a range of 0 - 100 A in series between the B terminal and the disconnected output wire. (Connect the (+) lead of the ammeter to the B terminal. Connect the ( - ) lead of the ammeter to the disconnected output wire.) Caution Never use clips but tighten bolts and nuts to connect the line. Otherwise loose connections (e.g. using clips) will lead to a serious accident because of high current. NOTE An inductive-type ammeter which enables measurements to be taken without disconnecting the alternator output wire should be recommended. (5) Connect a voltmeter with a range of 0 - 20 V between the alternator B terminal and the earth. (Connect the (+) lead of the voltmeter to the B terminal, and then connect the ( - ) lead of the voltmeter to the earth.) (6) Connect the negative battery cable. (7) Connect a tachometer or the MUT-II. (8) Leave the hood open. (9) Check that the reading on the voltmeter is equal to the battery voltage. NOTE If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the alternator B terminal and the battery (+) terminal.
16-9
(10)Turn the light switch on to turn on headlamps and then start the engine. (11)Immediately after setting the headlamps to high beam and turning the heater blower switch to the high revolution position, increase the engine speed to 2,500 r/min and read the maximum current output value displayed on the ammeter. Limit: 70% of normal current output NOTE D For the nominal current output, refer to the Alternator Specifications. D Because the current from the battery will soon drop after the engine is started, the above step should be carried out as quickly as possible in order to obtain the maximum current output value. D The current output value will depend on the electrical load and the temperature of the alternator body. D If the electrical load is small while testing, the specified level of current may not be output even though the alternator is normal. In such cases, increase the electrical load by leaving the headlamps turned on for some time to discharge the battery or by using the lighting system in another vehicle, and then test again. D The specified level of current also may not be output if the temperature of the alternator body or the ambient temperature is too high. In such cases, cool the alternator and then test again. (12)The reading on the ammeter should be above the limit value. If the reading is below the limit value and the alternator output wire is normal, remove the alternator from the engine and check the alternator. (13)Run the engine at idle after the test. (14)Turn the ignition switch off. (15)Remove the tachometer or the MUT-II. (16)Disconnect the negative battery cable. (17)Disconnect the ammeter and voltmeter. (18)Connect the alternator output wire to the alternator B terminal. (19)Connect the negative battery cable.
16-10
<4G6, 6A1>

16100110317
REGULATED VOLTAGE TEST
Ignition switch
Charging warning lamp
Load MB991519 Alternator FR L S G
Alternator relay
EngineECU Voltmeter
Yellow Ammeter
Battery
<4D6>
Ignition switch Charging warning lamp Load MB991450 Alternator L Alternator relay Voltmeter S B Ammeter
Battery
+ +
Yellow

This test determines whether the voltage regulator is correctly controlling the alternator output voltage. (1) Always be sure to check the following before the test. D Alternator installation D Check that the battery installed in the vehicle is fully charged. D Alternator drive belt tension D Fusible link D Abnormal noise from the alternator while the engine is running (2) Turn the ignition switch to the OFF position. (3) Disconnect the negative battery cable. (4) Use the special tool (Alternator test harness: MB991519, MB991450) to connect a digital voltmeter between the alternator S terminal and earth. (Connect the (+) lead of the voltmeter to the S terminal, and then connect the (-) lead of the voltmeter to a secure earth or to the battery (-) terminal.) (5) Disconnect the alternator output wire from the alternator B terminal. (6) Connect a DC test ammeter with a range of 0 - 100 A in series between the B terminal and the disconnected output wire. (Connect the (+) lead of the ammeter to the B terminal. Connect the ( - ) lead of the ammeter to the disconnected output wire.) (7) Reconnect the negative battery cable. (8) Connect a tachometer or the MUT-II. (9) Turn the ignition switch to the ON position and check that the reading on the voltmeter is equal to the battery voltage. Voltage Regulation Table Standard value:
Inspection terminal Terminal S Voltage regulator ambient temperature _C - 20 20 60 80 Voltage V 14.2 - 15.4 13.9 - 14.9 13.4 - 14.6 13.1 - 14.5
16-11
NOTE If the voltage is 0 V, the cause is probably an open circuit in the wire or fusible link between the alternator S terminal and the battery (+) terminal. (10)Turn all lamps and accessories off. (11)Start the engine. (12)Increase the engine speed to 2,500 r/min. (13)Read the value displayed on the voltmeter when the alternator output current alternator becomes 10 A or less. (14)If the voltage reading conforms to the value in the voltage regulation, then the voltage regulator is operating normally. If the voltage is not within the standard value, there is a malfunction of the voltage regulator or of the alternator. (15)After the test, lower the engine speed to the idle speed. (16)Turn the ignition switch off. (17)Remove the tachometer or the MUT-II. (18)Disconnect the negative battery cable. (19)Disconnect the ammeter and voltmeter. (20)Connect the alternator output wire to the alternator B terminal. (21)Remove the special tool, and return the connector to the original condition. (22)Connect the negative battery cable.
16-12
Alternator Special patterns pickup

Analyzer
WAVEFORM CHECK USING AN ANALYZER

16100120211
MEASUREMENT METHOD Connect the analyzer special patterns pick-up to the alternator B terminal.
B terminal
STANDARD WAVEFORM Observation Conditions

FUNCTION PATTERN HEIGHT VARIABLE knob PATTERN SELECTOR Engine speed SPECIAL PATTERNS VARIABLE Adjust while viewing the waveform. RASTER Curb idle speed
0.4 0.2 Voltage at alternator B terminal 0 - 0.2 - 0.4
Time
NOTE The voltage waveform of the alternator B terminal can undulate as shown at left. This waveform is produced when the regulator operates according to fluctuations in the alternator load (current), and is normal for the alternator. In addition, when the voltage waveform reaches an excessively high value (approx. 2 V or higher at idle), it often indicates an open circuit due to a brown fuse between alternator B terminal and battery, but not a defective alternator.

EXAMPLES OF ABNORMAL WAVEFORMS
16-13
NOTE 1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the analyzer. 2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not operating). (Waveforms can be observed when the headlamps are illuminated.) 3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging system totally.
Abnormal waveforms Example 1 Problem cause D Open diode Abnormal waveforms Example 4 Problem cause D Short in stator coil
Example 2
Short in diode
Example 5
Open supplementary diode
Example 3
Broken wire in stator coil
At this time, the charging warning lamp is illuminated.
ALTERNATOR RELAY CONTINUITY CHECK

Alternator relay
16100190045
1. Remove the alternator relay from the relay box inside the engine compartment. 2. Set the analogue-type circuit tester to the W range and check that there is continuity when the (+) terminal of the tester is connected to terminal 2 of the alternator relay and the ( - ) terminal is connected to terminal 4. 3. Next, check that there is no continuity when the (+) terminal is connected to terminal 4 and the ( - ) terminal is connected to terminal 2. 4. If the continuity checks in steps 2 and 3 show a defect, replace the alternator relay.
16-14 ALTERNATOR

16100140286

<4G6>
Pre-removal Operation D Under Cover Removal (R.H. side) D Engine Mount Bracket Removal (Refer to GROUP 32.) Post-installation Operation D Engine Mount Bracket Installation (Refer to GROUP 32.) D Under Cover Installation (R.H. side) D Drive Belt Tension Adjustment (Refer to GROUP 11A - On-vehicle Service.)
12 Nm
1 2
12 Nm
12 Nm
1 6
9 Nm 20 - 25 Nm
4 8
24 Nm 44 Nm
3
Removal steps 1. Oil pressure hose and tube assembly clamp bolt 2. Oil return tube assembly clamp bolt 3. Drive belt (Power steering, A/C) 4. Drive belt (Alternator) 5. 6. 7. 8. Water pump pulley Alternator connector Alternator Alternator brace
AA"

<6A1>
Pre-removal Operation Solenoid Valve Assembly Removal (Refer to GROUP 15 - Air Intake Plenum.)
16-15
Post-installation Operation D Solenoid Valve Assembly Installation (Refer to GROUP 15 - Air Intake Plenum.) D Drive Belt Tension Adjustment (Refer to GROUP 11B - On-vehicle Service.)
12 Nm
4 5
18 Nm 22 Nm
6
44 Nm 24 Nm
Removal steps 1. Oil pressure hose and tube assembly clamp bolt 2. Drive belt (Alternator) 3. Alternator connector
4. Air intake plenum stay 5. Alternator brace 6. Alternator
16-16
<4D6>
Pre-removal Operation D Under Cover Removal (R.H. side) D Engine Mount Bracket Removal (Refer to GROUP 32.)
Post-installation Operation D Engine Mount Bracket Installation (Refer to GROUP 32.) D Under Cover Installation (R.H. side) D Drive Belt Tension Adjustment (Refer to GROUP 11C On-vehicle Service.)
12 - 15 Nm
1
24 Nm
7 1
29 Nm
12 Nm
11 10
44 Nm
8
24 Nm
9 5
9 Nm
AB" AC"
Removal steps 1. Oil pressure hose and tube assembly clamp bolt 2. Oil level gauge guide assembly mounting bolt 3. Drive belt (Power steering) 4. Drive belt (A/C) 5. Drive belt (Alternator)
6. 7. 8. 9. 10. 11.
Water pump pulley Alternator connector Alternator Alternator brace Engine hanger Alternator brace stay
ENGINE ELECTRICAL - Charging System REMOVAL SERVICE POINTS

B A
16-17
AA" DRIVE BELT (POWER STEERING, A/C) REMOVAL 1. Loosen nut A for holding the tension pulley. 2. Loosen bolt B for adjustment. 3. Remove the drive belt.
Power steering oil pump
AB" DRIVE BELT (POWER STEERING) REMOVAL Loosen the power steering oil pump fixing bolt, and then remove the drive belt.
AC" DRIVE BELT (A/C) REMOVAL 1. Loosen tension pulley fixing nut A. 2. Loosen adjusting nut B, and then remove the drive belt.
16-18

16100160213
2 9
12
14
8 11 10
13
Disassembly steps AA" 1. Front bracket assembly AB" 2. Alternator pulley "BA 3. Rotor 4. Rear bearing 5. Bearing retainer 6. Front bearing 7. Front bracket
AC"
8. 9. AC" "AA 10. 11. 12. 13. 14.
Stator Plate Regulator assembly Brush Slinger Rectifier Rear bracket
ENGINE ELECTRICAL - Charging System DISASSEMBLY SERVICE POINTS
16-19
AA" FRONT BRACKET ASSEMBLY REMOVAL Insert a flat tip screwdriver, etc., in the clearance between the front bracket assembly and stator core, to pry open and separate the stator and front bracket. Caution The stator coil could be damaged so do not insert the screwdriver too far.
AB" ALTERNATOR PULLEY REMOVAL Face the pulley side upward, fix the rotor with a work bench and remove the pulley. Caution Use care so that the rotor is not damaged.
Soldered
AC" STATOR/REGULATOR ASSEMBLY REMOVAL (1) When removing the stator, remove the stator lead wire soldered onto the main diode of the rectifier. (2) When removing the rectifier from the regulator assembly, remove the soldered sections of the rectifier. Caution 1. Use care to make sure that the heat of the soldering iron is not transmitted to the diodes for a long period. 2. Use care that no undue force is exerted to the lead wires of the diodes.
16-20
ENGINE ELECTRICAL - Charging System REASSEMBLY SERVICE POINTS

Wire
"AA REGULATOR ASSEMBLY INSTALLATION After installing the regulator assembly, insert a wire into the hole provided on the rear bracket while pressing in the brush to fix the brush. NOTE The brush is fixed when a wire is inserted, making rotor installation easier.
Rear bracket Brush Wire
Wire
"BA ROTOR INSTALLATION After installing the rotor, remove the wire used to fix the brush.
INSPECTION
16100170216
ROTOR CHECK 1. Check the continuity between the rotor coil slip rings, and replace the rotor if the resistance value is not at the standard value. Standard value: 3 - 5 W
2. Check the continuity between the slip ring and core, and if there is continuity, replace the rotor.
16-21
STATOR CHECK 1. Check the continuity between the coil leads, and if there is continuity, replace the stator.
2. Check the continuity between the coil and core, and if there is continuity, replace the stator.
RECTIFIER CHECK 1. Inspect the (+) heat sink by checking the continuity between the (+) heat sink and stator coil lead wire connection terminal using a tester probe. If there is a continuity at both, the diode is short circuited, so replace the rectifier.
2. Inspect the ( - ) heat sink by checking the continuity between the ( - ) heat sink and stator coil lead wire connection terminal using a tester probe. If there is a continuity at both, the diode is short circuited, so replace the rectifier.
3. Check the diode trio by connecting an ohmmeter to both ends of each diode and check the continuity of the three diodes. If there is a continuity at both ends, or if there is no continuity, the diode is damaged so replace the rectifier.
16-22

BRUSH CHECK 1. Measure the length of the brush protrusion shown in the illustration, and replace the brush if the measured value is below the limit value.
Protrusion length
Limit: 2 mm or less
Soldered
2. The brush can be removed if the solder of the brush lead wire is removed. 3. When installing a new brush, insert the brush into the holder as shown in the illustration, and then solder the lead wires.
ENGINE ELECTRICAL - Starting System
16-23
16200010290
STARTING SYSTEM
GENERAL INFORMATION
If the ignition switch is turned to the START position, current flows in the pull-in and holding coils provided inside magnetic switch, attracting the plunger. When the plunger is attracted, the lever connected to the plunger is actuated to engage the starter clutch. On the other hand, attracting the plunger will turn on the magnetic switch, allowing the B terminal SYSTEM DIAGRAM
Pull-in coil Holding coil Plunger Lever Over-running clutch Pinion shaft Ignition switch Armature Battery
and M terminal to conduct. Thus, current flows to engage the starter motor. When the ignition switch is returned to the ON position after starting the engine, the starter clutch is disengaged from the ring gear. An overrunning clutch is provided between the pinion and the armature shaft, to prevent damage to the starter.
Brush
Yoke
STARTER MOTOR SPECIFICATIONS

Items Type Rated output kW/V No. of pinion teeth 4G6-M/T <Except 4G6-M/T <Models for cold models for cold climate> climate>, 4G6-A/T, 6A1 Direct drive 0.9/12 8 Reduction drive with planetary gear 1.2/12 8 4D6 <Except models for cold climate> 4D6 <Models for cold climate>
Reduction drive with Reduction drive planetary gear with planetary gear 2.0/12 10 2.2/12 12
16200030173
Items Pinion gap mm Commutator outer diameter Standard value mm Limit Commutator runout mm Commutator undercut mm Standard value Limit Standard value Limit 4G6 <Models for cold climate>, 6A1 0.5 - 2.0 29.4 28.4 0.05 0.1 0.5 0.2 0.5 - 2.0 32.0 31.0 0.05 0.1 0.5 0.2
4G6 <Except models cold climate>, 4D6
16-24
ON-VEHICLE SERVICE
STARTER RELAY CONTINUITY CHECK <4D6>
Battery voltage
Starter relay
16200140074
<4G6>
Switch
STARTER MOTOR
INSPECTION
S
16200110242
Battery
Field coil wire
PINION GAP ADJUSTMENT 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between S-terminal and M-terminal. 3. Set switch to ON, and pinion will move out. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning.
<6A1>
Switch
B Battery S M
Field coil wire
<4D6>
Switch
B Battery M S
Field coil wire
16-25
4. Check pinion to stopper clearance (pinion gap) with a thickness gauge. Pinion gap: 0.5 - 2.0 mm
Stopper Pinion gap Pinion
5. If pinion gap is out of specification, adjust by adding or removing gaskets between magnetic switch and front bracket.
<4G6>
S Battery M
MAGNETIC SWITCH PULL-IN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between S-terminal and M-terminal. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning. 3. If pinion moves out, then pull-in coil is good. If it doesnt, replace magnetic switch.
Field coil wire
<6A1>
Battery
S M Field coil wire
<4D6>
Battery M
Field coil wire
16-26
<4G6>

MAGNETIC SWITCH HOLD-IN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between S-terminal and body. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning. 3. Manually pull out the pinion as far as the pinion stopper position. 4. If pinion remains out, everything is in order. If pinion moves in, hold-in circuit is open. Replace magnetic switch.
S Battery
Field coil wire
<6A1>
Battery
Field coil wire
<4D6>
Battery
Field coil wire
<4G6> S M B
Carbon-pile rheostat Ammeter Battery Voltmeter
Starter motor
<6A1> B S M
Carbon-pile rheostat Ammeter Battery Voltmeter
FREE RUNNING TEST 1. Place starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor as follows: 2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series with battery positive post and starter motor terminal. 3. Connect a voltmeter (15-volt scale) across starter motor. 4. Rotate carbon pile to full-resistance position. 5. Connect battery cable from battery negative post to starter motor body. 6. Adjust the rheostat until the battery voltage shown by the voltmeter is 11 V. 7. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Current: max. 60 Amps

<4D6> B S M Voltmeter Carbon-pile rheostat Ammeter Battery
16-27
<4G6>
MAGNETIC SWITCH RETURN TEST 1. Disconnect field coil wire from M-terminal of magnetic switch. 2. Connect a 12V battery between M-terminal and body.
M
Battery
Field coil wire
Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning. 3. Pull pinion out and release. If pinion quickly returns to its original position, everything is in order. If it doesnt, replace magnetic switch. Caution Be careful not to get your fingers caught when pulling out the pinion.
<6A1>
Battery M Field coil wire
<4D6>
Battery M
Field coil wire
16-28
<DIRECT DRIVE TYPE>

16200120269
13
3 6 4
16 18 14 15 17
12
10 11
AA"
Disassembly steps 1. Screw 2. Magnetic switch 3. Packing 4. Plate 5. Screw 6. Through bolt 7. Rear bracket 8. Rear bearing
9. 10. 11. 12. 13. 14. AC" "AA 15. AC" "AA 16. 17. 18.
Brush holder Yoke assembly Brush Armature Lever Washer Snap ring Stop ring Overrunning clutch Front bracket

<PLANETARY GEAR REDUCTION DRIVE TYPE FOR PETROL ENGINE> 2 13 23 1 17 15 14 10
16-29
12 20 18 21 19 8 4 7 9 6 22 11 16
AA"
AB" AB"
Disassembly steps 1. Screw 2. Magnetic switch 3. Starter cover 4. Screw 5. Through bolt 6. Rear bracket 7. Brush holder 8. Brush 9. Rear bearing 10. Armature 11. Yoke assembly 12. Ball
13. 14. 15. 16. 17. AC" "AA 18. AC" "AA 19. 20. 21. 22. 23.
Packing A Packing B Plate Planetary gear Lever Snap ring Stop ring Overrunning clutch Internal gear Planetary gear holder Front bracket
16-30
<PLANETARY GEAR REDUCTION DRIVE TYPE FOR DIESEL ENGINE> 2
11 13 16 21 23 1 17 20 18 19 7 5 14 12
15 4
22
9 10
AA"
AB"
Disassembly steps 1. Screw 2. Magnetic switch 3. Screw 4. Through bolt 5. Rear bracket 6. Brush holder 7. Yoke assembly 8. Brush 9. Armature 10. Bearing 11. Packing A 12. Packing A
13. 14. 15. 16. AC" "AA 17. AC" "AA 18. 19. 20. 21. 22. 23. AB"
Plate Ball Planetary gear Lever Snap ring Stop ring Overrunning clutch Internal gear Washer Planetary gear holder Front bracket

Magnetic switch S terminal M terminal Field coil wire
16-31

AA" MAGNETIC SWITCH REMOVAL Disconnect the field coil wire from terminal M of the magnetic switch.
AB" ARMATURE AND BALL REMOVAL When removing the armature, do not lose the ball placed at the end as a bearing.
Socket
AC" SNAP RING/STOP RING REMOVAL 1. Using an appropriate wrench socket, push the stop ring toward the overrunning clutch.
Stop ring
Pinion gear Overrunning clutch
Armature
Snap ring Pinion gear Overrunning clutch Snap ring pliers
2. Remove the snap ring with snap ring pliers and then remove the stop ring and overrunning clutch.
Armature
STARTER MOTOR PARTS CLEANING

1. Do not immerse the parts in cleaning solvent. Immersing the yoke and field coil assembly and/or armature will damage insulation. Wipe these parts with a cloth only. 2. Do not immerse the drive unit in cleaning solvent. The overrunning clutch is pre-lubricated at the factory and solvent will wash lubrication from clutch. 3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.
16-32
ENGINE ELECTRICAL - Starting System REASSEMBLY SERVICE POINTS

"AA STOP RING/SNAP RING INSTALLATION Using an appropriate tool, pull the stop ring over the snap ring.
Stop ring Overrunning clutch Snap ring
Stop ring
INSPECTION
16200130255
COMMUTATOR 1. Place the armature in a pair of V blocks and check the runout with a dial indicator. Standard value: 0.05 mm Limit: 0.1 mm
2. Measure the commutator outer diameter. Direct drive type and planetary gear reduction drive type (for diesel engine) Standard value: 32.0 mm Limit: 31.0 mm Planetary gear reduction drive type (for petrol engine) Standard value: 29.4 mm Limit: 28.4 mm
3. Check the undercut depth between segments.

Undercut Segment Mica
Standard value: 0.5 mm Limit: 0.2 mm
FIELD COIL OPEN-CIRCUIT TEST - Except planetary gear reduction drive type (for petrol engine) Check the continuity between field brushes. If there is continuity, the field coil is in order.
Yoke
16-33
Field brush
FIELD COIL GROUND TEST - Except planetary gear reduction drive type (for petrol engine) Check the continuity between field coil brush and yoke. If there is no continuity, the field coil is free from earth.
Yoke
Brush holder
BRUSH HOLDER Check the continuity between brush holder plate and brush holder. If there is no continuity, the brush holder is in order.
Free Lock
OVERRUNING CLUTCH 1. Check that the pinion locks when it is turned counterclockwise and moves smoothly when it is turned clockwise. 2. Check the pinion for wear or damage.
BRUSH 1. Check the brush for roughness of the surface that contacts the commutator and check the brush length. Limit: Wear limit line 2. In case the contacting surface has been corrected or the brush has been replaced, correct the contacting surface by winding sandpaper around the commutator.
Wear limit line
New brush Pigtail
Soldered (Make sure that there is no excess solder on blush surface) Mark
3. When removing a worn brush by breaking with pliers, use care to prevent damage to the pigtail. 4. Polish the pigtail end for secure soldering. 5. Insert the pigtail into the hole of a new brush and solder. Make sure that there is no excess solder on the brush surface.
16-34

Growler
ARMATURE COIL SHORT-CIRCUIT TEST 1. Place armature in a growler. 2. Hold a thin steel blade parallel and just above while rotating armature slowly in growler. A shorted armature will cause blade to vibrate and be attracted to the core. Replace shorted armature. Caution Clean the checking. armature surface thoroughly before
3. Check the insulation between each commutator segment and armature coil core. If there is no continuity, the insulation is in order.
ARMATURE COIL OPEN-CIRCUIT INSPECTION Check the continuity between segments. If there is continuity, the coil is in order.
ENGINE ELECTRICAL - Ignition System <4G6, 6A1>
16-35
16300010316
IGNITION SYSTEM <4G6, 6A1>

GENERAL INFORMATION
<4G6> This system is equipped with two ignition coils (A and B) with built-in power transistors for the No. 1 and No. 4 cylinders and the No. 2 and No. 3 cylinders respectively. Interruption of the primary current flowing in the primary side of ignition coil A generates a high voltage in the secondary side of ignition coil A. The high voltage thus generated is applied to the spark plugs of No. 1 and No. 4 cylinders to generate sparks. At the time that the sparks are generated at both spark plugs, if one cylinder is at the compression stroke, the other cylinder is at the exhaust stroke, so that ignition of the compressed air/fuel mixture occurs only for the cylinder which is at the compression stroke. In the same way, when the primary current flowing in ignition coil B is interrupted, the high voltage thus generated is applied to the spark plugs of No. 2 and No. 3 cylinders. The engine-ECU turns the two power transistors SYSTEM DIAGRAM
Air flow sensor Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Idle position switch Camshaft position sensor Crank angle sensor Ignition switch - ST Detonation sensor Vehicle speed sensor Inhibitor switch <A/T> Spark plugs A/T-ECU To tachometer Cylinder No. 3 2 1 4 Engine-ECU Ignition coil B Ignition coil A
inside the ignition coils alternately on and off. This causes the primary currents in the ignition coils to be alternately interrupted and allowed to flow to fire the cylinders in the order 1 - 3 - 4 - 2. The engine-ECU determines which ignition coil should be controlled by means of the signals from the camshaft position sensor which is incorporated in the camshaft and from the crank angle sensor which is incorporated in the crankshaft. It also detects the crankshaft position in order to provide ignition at the most appropriate timing in response to the engine operation conditions. It also detects the crankshaft position in order to provide ignition at the most appropriate timing in response to the engine operation conditions. When the engine is cold or operated at high altitudes, the ignition timing is slightly advanced to provide optimum performance. Furthermore, if knocking occurs, the ignition timing is gradually retarded until knocking ceases.
Ignition switch
Battery
16-36

by the crank angle sensor incorporated in the distributor to provide ignition at the most appropriate timing for the engine operating condition. When the engine is cold or operated at a high altitude, the ignition timing is slightly advanced to provide optimum performance to the operating condition. Furthermore, if knocking occurs, the ignition timing is gradually retarded until knocking ceases. When the automatic transmission shifts gears, the ignition timing is also retarded in order to reduce output torque, thereby alleviating shifting shocks.
<6A1> Interruption of the primary current flowing in the primary side of the ignition coil generates high voltage in the secondary side of the ignition coil. The high voltage thus generated is directed by the distributor to the applicable spark plug. The engine firing order is 1 - 2 - 3 - 4 - 5 - 6 cylinders. On application of high voltage, the spark plug generates a spark to ignite the compressed air fuel mixture in the combustion chamber. The engine-ECU makes and breaks the primary current of the ignition coil to regulate the ignition timing. The engine-ECU detects the crankshaft position SYSTEM DIAGRAM
Air flow sensor Barometric pressure sensor Intake air temperature sensor Engine coolant temperature sensor Idle position switch Crank angle sensor Vehicle speed sensor Detonation sensor Ignition switch - ST Inhibitor switch <A/T> Power transistor
Engine-ECU
Top dead centre sensor Spark plug
Distributor
A/T-ECU
ENGINE ELECTRICAL - Ignition System <4G6, 6A1> DISTRIBUTOR SPECIFICATIONS

Items Type Advance mechanism Firing order 6A1 Contact pointless Electronic 1- 2- 3- 4- 5- 6
16-37
IGNITION COIL SPECIFICATIONS

Items Type 4G6 Molded 2-coil 6A1 Molded single-coil with a built-in distributor
SPARK PLUG SPECIFICATIONS

Items NGK DENSO 4G6 BKR6E-11 K20PR-U11 6A1 PFR6G-11 PK20PR11
16300030282
IGNITION COIL
Items Primary coil resistance W Secondary coil resistance kW 6A1 6A1 Standard value 0.5 - 0.7 9 - 13
SPARK PLUG
Items Spark plug gap mm 4G6, 6A1 Standard value 1.0 - 1.1
RESISTIVE CORD
Items Resistance kW 4G6, 6A1 Limit max. 22
16300060250
SPECIAL TOOLS
Tool Number MB991348 Name Test harness set Use
Inspection of ignition primary voltage (power transistor connection)
16-38
Tool

Number MD998773 Name Detonation sensor wrench Use Detonation sensor removal and installation
ON-VEHICLE SERVICE
16300130234
POWER TRANSISTOR CONTINUITY CHECK <4G6>

NOTE 1. An analogue-type circuit tester should be used. 2. Connect the negative ( - ) prove of the circuit tester to terminal 1. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning and power transistor from breakage.
Voltage: 1.5V When current is flowing When current is not flowing Terminal No. 1 2 3
Ignition coil
Replace the power transistor if there is a malfunction.
IGNITION COIL CHECK <6A1>
16300120323
1. Measurement of the primary coil resistance Measure the resistance between connector terminal 1 and 2 of the distributor. Standard value: 0.5 - 0.7 W
High-voltage terminal
2. Measurement of secondary coil resistance Measure the resistance between the high-voltage terminals and connector terminals 1. Standard value: 9 - 13 kW
16-39
POWER TRANSISTOR CONTINUITY CHECK 16300130241 <6A1>

+ +
1.5V
NOTE 1. An analogue-type circuit tester should be used. 2. Connect the negative ( - ) prove of the circuit tester to terminal 2. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning and power transistor from breakage.
Voltage: 1.5V When current is flowing When current is not flowing Terminal No. 2 3 4
Distributor connector
Replace the power transistor if there is a malfunction.
RESISTIVE CORD CHECK
16300140107
Measure the resistance of the all spark plug cables. 1. Check cap and coating for cracks. 2. Measure resistance. Limit: Max. 22 kW
SPARK PLUG CHECK AND CLEANING <4G6>

1. Remove the spark plug cables.
16300150315
Caution When pulling off the spark plug cable from the plug always hold the cable cap, not the cable. 2. Remove the spark plugs. 3. Check for burned out electrode or damaged insulator. Check for even burning. 4. Remove carbon deposits with wire brush or plug cleaner. Remove sand from plug screw with compressed air.
16-40

Plug gap gauge
5. Use a plug gap gauge to check that the plug gap is within the standard value range. Standard value: 1.0 - 1.1 mm If the plug gap is not within the standard value range, adjust by bending the earth electrode. 6. Clean the engine plug holes. Caution Be careful not to allow foreign matter in cylinders. 7. Install the spark plugs.
Measurement direction
SPARK PLUG CHECK <6A1>

1. Remove the air intake plenum. 2. Remove the spark plug cables.
16300150322
Caution When pulling off the spark plug cable from the plug always hold the cable cap, not the cable. 3. Remove the spark plugs.
4. Check the plug gap and replace if the limit is exceeded. Standard value: 1.0 - 1.1 mm Limit: 1.3 mm Caution 1. Do not attempt to adjust the gap of the platinum plug. 2. Always use a plug cleaner and finish cleaning within 20 seconds. Do not use wire brushes. Otherwise, the platinum tip may be damaged. 5. Clean the engine plug holes. Caution Be careful not to allow foreign matter in cylinders. 6. Install the spark plugs.
Platinum tips
CAMSHAFT POSITION SENSOR CHECK <4G6>

16300260438
Refer to GROUP 13A - Troubleshooting.
TOP DEAD CENTER SENSOR CHECK <6A1>

16300380011
CRANK ANGLE SENSOR CHECK

16300260445
ENGINE ELECTRICAL - Ignition System <4G6, 6A1> DETONATION SENSOR CHECK
16-41
16300180086
Check the detonation sensor circuit if self-diagnosis code, No. 31 is shown. NOTE For information concerning the self-diagnosis codes, refer to GROUP 13A - Troubleshooting.
WAVEFORM CHECK USING AN ANALYZER

16300170427
Ignition Secondary Voltage Waveform Check

<4G6> MEASUREMENT METHOD 1. Clamp the secondary pickup around the spark plug cable. NOTE (1) The peak ignition voltage will be reversed when the spark cables No. 2 and No. 4, or No. 1 and No. 3 cylinders are clamped. (2) Because of the two-cylinder simultaneous ignition system, the waveforms for two cylinders in each group appear during waveform observation (No. 1 cylinder - No. 4 cylinder, No. 2 cylinder - No. 3 cylinder). However, waveform observation is only applicable for the cylinder with the spark plug cable clamped by the secondary pickup. (3) Identifying which cylinder waveform is displayed can be difficult. For reference, remember that the waveform of the cylinder attached to the secondary pickup will be displayed as stable. 2. Clamp the spark plug cable with the trigger pickup. NOTE Clamp the trigger pickup to the same spark plug cable clamped by the secondary pickup.
16-42
STANDARD WAVEFORM Observation Conditions

Function Pattern height Pattern selector Engine revolutions
kV Ignition voltage (point D)
Secondary High (or Low) Raster Curb idle speed

Spark line (point A)
Secondary ignition voltage waveform
Dwell section
Wave damping reduction section (point B)
Point C Time
Observation Condition (The only change from above condition is the pattern selector.)
Pattern selector
kV
Display
No. 4 cylinder No. 2 cylinder ignition noise Secondary ignition voltage waveform
No. 1 cylinder
No. 3 cylinder ignition noise
Time 0 2 Neutral section
16-43
WAVEFORM OBSERVATION POINTS Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal waveform examples, 1, 2, 3 and 4).
Spark line Length Long Short Height High Low Slope Plug gap Small Large Large Small Large Condition of electrode Normal Large wear Large wear Normal Plug is fouled Compression force Low High High Low Concentration of air mixture Rich Lean Lean Rich Ignition timing Advanced Retarded Retarded Advanced Spark plug cable Leak High resistance High resistance Leak -
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations Three or more Except above Coil and condenser Normal Abnormal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations 5 - 6 or higher Except above Coil Normal Abnormal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition voltage High Low Plug gap Large Small Condition of electrode Large wear Normal Compression force High Low Concentration of air mixture Lean Rich Ignition timing Retarded Advanced Spark plug cable High resistance Leak
16-44

Abnormal waveform Example 1 Wave characteristics Spark line is high and short. Cause of problem Spark plug gap is too large.
01P0215
Example 2
Spark line is low and long, and is sloping. Also, the second half of the spark line is distorted. This could be a result of misfiring.
Spark plug gap is too small.
Example 3
Spark line is low and long, and is sloping. However, there is almost no spark line distortion.
Spark plug gap is fouled.
Example 4
Spark line is high and short. Difficult to distinguish between this and abnormal waveform example 1.
Spark plug cable is nearly falling off. (Causing a dual ignition)
Example 5
No waves in wave damping section.
Layer short in ignition coil
16-45
Ignition Secondary Voltage Waveform Check

<6A1> MEASUREMENT METHOD 1. Clamp the spark plug cable of the No. 1 cylinder with the secondary pickup and check the waveform. 2. Connect the secondary pickup to the other cylinders in turn and check the waveforms for each cylinder. STANDARD WAVEFORM Observation Conditions
FUNCTION PATTERN HEIGHT PATTERN SELECTOR Engine Speed
kV Ignition voltage (Point D)
SECONDARY HIGH (or LOW) RASTER Curb idle speed

Spark line (Point A)
Vibration damping section (Point B) Dwell section
Ignition secondary voltage waveform
(Point C) Time
16-46
WAVEFORM OBSERVATION POINTS Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal waveform examples, 1, 2, 3 and 4).
Spark line Length Long Short Height High Low Slope Plug gap Small Large Large Small Large Condition of electrode Normal Large wear Large wear Normal Plug is fouled Compression force Low High High Low Concentration of air mixture Rich Lean Lean Rich Ignition timing Advanced Retarded Retarded Advanced Spark plug cable Leak High resistance High resistance Leak -
Number of vibrations Three or more Except above Coil and condenser Normal Abnormal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations 5 - 6 or higher Except above Coil Normal Abnormal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition voltage High Low Plug gap Large Small Condition of electrode Large wear Normal Compression force High Low Concentration of air mixture Lean Rich Ignition timing Retarded Advanced Spark plug cable High resistance Leak

16-47
01P0215
Example 2
Example 3
Example 4
Spark line is high and short. Difficult to distinguish between this and abnormal waveform example 1.
Example 5
No waves in wave damping section.
16-48
ENGINE ELECTRICAL - Ignition System <4G6, 6A1> Ignition Primary Voltage Waveform Check <6A1>
MEASUREMENT METHOD 1. Disconnect the distributor connector and connect the special tool (test harness: MB991348) in between. (All of the terminals should be connected.)
Analyzer
2. Connect the analyzer primary pickup to the distributor connector terminal 2. 3. Connect the primary pickup earth terminal. 4. Clamp the spark plug cable with the trigger pickup. NOTE The waveform of the cylinder clamped to the trigger pickup will appear at the left edge of the screen.
Primary pickup Earth

STANDARD WAVEFORM Observation conditions
FUNCTION PATTERN HEIGHT PATTERN SELECTOR Engine Speed
(V) Zener voltage (Point C)
16-49
SECONDARY HIGH (or LOW) RASTER Curb idle speed
100
(Approx. 4010V)
Spark line (Point A)
Vibration damping section (Point B) Dwell section Ignition primary voltage 0 waveform Time
Observation conditions (Only the pattern selector shown below changes from the previous conditions)
PATTERN SELECTOR DISPLAY
(V)
100
Centre section Ignition primary voltage waveform
Time
16-50
WAVEFORM OBSERVATION POINTS Point A: The height, length and slope of the spark line (refer to abnormal waveform examples 1, 2, 3 and 4) show the following trends.
Spark line Length Long Short Height High Low Slope Plug gap Small Large Large Small Large Condition of electrode Normal Large wear Large wear Normal Plug is fouled Compression force Low High High Low Concentration of air mixture Rich Lean Lean Rich Ignition timing Advanced Retarded Retarded Advanced High tension cable Leak High resistance High resistance Leak -
Number of vibrations 3 or higher Except above Coil, condenser Normal Abnormal
Point C: Height of Zener voltage

Height of Zener voltage High Low Probable cause Problem in Zener diode Abnormal resistance in primary coil circuit

16-51
Example 2
Example 3
Example 4
Spark line is high and short.
Example 5
No waves in wave damping section
16-52

16300200188
DISTRIBUTOR <6A1>
Pre-removal Operation Air Cleaner, Air Intake Hose Removal
Post-installation Operation D Air Cleaner, Air Intake Hose Installation D Ignition timing Check and Adjustment (Refer to GROUP 11B - On-vehicle service.)
22 - 25 Nm
3 5 4
10 - 12 Nm
6
25 Nm
1 5
6
25 Nm
Removal steps 1. Distributor connector 2. Spark plug cable connection 3. Water guard "AA 4. Distributor
D Air intake plenum (Refer to GROUP 15.) 5. Spark plug cable 6. Spark plug

"AA DISTRIBUTOR INSTALLATION 1. Set the No. 1 cylinder to top dead compression centre. 2. Align the mating marks on the distributor housing and coupling, and then install the distributor to the engine. 3. Check that the ignition timing is at the standard value. (Refer to GROUP 11B - On-vehicle service.)
Mating marks
ENGINE ELECTRICAL - Ignition System <4G6, 6A1> DISASSEMBLY AND REASSEMBLY

5
16-53
16300220207
Disassembly steps 1. Distributor cap 2. Packing 3. Rotor 4. O-ring 5. Distributor housing
INSPECTION
16300230125
Check the following points; repair or replace if a problem is found. CAP, ROTOR 1. There must be no cracking in the cap. 2. There must be no damage to the caps electrode or the rotors electrode. 3. Clean away any dirt from the cap and rotor.
16-54

16300320174
IGNITION COIL <4G6>

10 Nm 10 Nm
1 2 3
25 Nm
Removal steps 1. Spark plug cable 2. Ignition coil assembly 3. Spark plug
CAMSHAFT POSITION SENSOR <4G6>

9 Nm
16300340026
Camshaft position sensor
16-55
16300350036
CRANK ANGLE SENSOR

Pre-removal and Post-installation Operation D Timing Belt Removal and Installation <4G6> (Refer to GROUP 11A.) D Timing Belt Cover Removal and Installation <6A1> (Refer to GROUP 11B.)
<4G6> <6A1> 1
12 Nm 10 - 13 Nm
1
10 - 12 Nm 28 Nm 28 Nm 9 Nm
4
49 Nm
4
49 Nm
9 Nm
AA"
Removal steps 1. Pressure hose and tube assembly connection 2. Power steering oil pump assembly
3. Power steering oil pump bracket 4. Crank angle sensor

AA" POWER STEERING OIL PUMP ASSEMBLY REMOVAL Remove the power steering oil pump assembly with the hoses still attached. NOTE Secure the removed oil pump with rope, etc. in a place where it will not be in the way when removing and installing the power steering oil pump bracket.
16-56

16300280144
DETONATION SENSOR
Pre-removal and Post-installation Operation Intake Manifold Removal and Installation <6A1> (Refer to GROUP 15.)
<4G6>
<6A1>
20 - 25 Nm
1
20 - 25 Nm
AA" "AA 1. Detonation sensor
Caution Do not subject the detonation sensor to any shocks.
<4G6>

AA" DETONATION SENSOR REMOVAL
MD998773

"AA DETONATION SENSOR INSTALLATION
<6A1>
MD998773
ENGINE ELECTRICAL - Glow System <4D6>
16-57
16400010043
GLOW SYSTEM <4D6>

GENERAL INFORMATION
SELF-REGULATING GLOW SYSTEM
The self-regulating glow system reduces the time required for starting at low temperatures to provide a degree of starting and operation that is identical to petrol-engine vehicles by preheating the glow plugs at super-quick speed. The engine-ECU controls both the time during which current is supplied to the glow plugs after the ignition switch is turned to the ON position and also the glow indicator lamp illumination time in accordance with the engine coolant temperature.
The resistances of the heating coils which are built into the glow plugs increase as the glow plug temperatures become higher. As a result of this, the flow of current gradually decreases, thus stabilizing the glow plug temperature at the specified temperature.
Glow plug relay Engine-ECU
Pre-heat indicator lamp
Engine coolant temperature sensor Glow plugs
Charge lamp ON ST Ignition switch
Alternator
Starter motor Battery
16-58
ENGINE ELECTRICAL - Glow System

16400030056
Item Resistance between glow plug plate and glow plug body (parallel resistance for 4 glow plugs) (at 20 _C) W Voltage between glow plug plate and glow plug body V Immediately after ignition switch is turned to ON (without starting the engine) While engine is cranking While engine is warming up Standard value 0.10 - 0.15
9 - 11 (Drops to 0 V after 4 - 8 seconds have passed)
6 or more 12 - 15 (Drops to 0 V when the engine coolant temperature increases to 60 _C or more or if 30 seconds have passed since the engine was started) 0.6 - 1.0
Glow plug resistance (at 20 _C) W
ON-VEHICLE SERVICE
16400100047
SELF-REGULATING GLOW SYSTEM CHECK

1. Check that the battery voltage is 11 - 13 V. 2. Check that the engine coolant temperature is 40 _C or less. NOTE If the engine coolant temperature is too high, disconnect the engine coolant temperature sensor connector. 3. Measure the resistance between the glow plug plate and the glow plug body (earth). Standard value: 0.10 - 0.15 W (at 20 _C) NOTE The resistance value is the parallel resistance value for the four glow plugs.
(- )
(+)
4. Connect a voltmeter between the glow plug plate and the glow plug body (earth). 5. Measure the voltage immediately after the ignition switch is turned to ON (without starting the engine). Standard value: 9 - 11 V (Drops to 0 V after 4 - 8 seconds have passed) In addition, check to be sure that the glow indicator lamp (red) illuminates immediately after the ignition switch is turned to ON. NOTE The time during which the voltage appears (energizing time) will depend on the engine coolant temperature.
16-59
6. Measure the voltage while the engine is cranking. Standard value: 6 V or more 7. Start the engine and measure the voltage while the engine is warming up. However, if the engine coolant temperature rises above 60 _C or when 180 seconds have passed since the engine was started, the voltage will always return to 0 V. (Refer to the Glow Plug Energization Timing Chart.) Standard value: 12 - 15 V <Reference> Glow Plug Energization Timing Chart
START Ignition switch Glow indicator lamp Glow plug relay ON OFF ON OFF ON OFF H L T2 T3 T1
Alternator L terminal
T1: Glow indicator lamp T2: Glow plug relay drive time after ignition switch is turned ON T3: Glow plug relay drive time after engine starts (after glow)
NOTE After glow time T3 becomes longer as the engine coolant temperature drops.

Refer to GROUP 13E - Troubleshooting.
16400360025
16-60
Glow plug relay
ENGINE ELECTRICAL - Glow System <4D6> GLOW PLUG RELAY CHECK

16400330026
G terminal B terminal
1. Check to be sure that there is continuity (approx. 3 W) between glow plug relay terminal C and the terminal E. 2. Use jumper cables to connect terminal C of the glow plug relay to the battery (+) terminal and the terminal E to the battery ( - ) terminal Caution (1) Always be sure to disconnect the harnesses connected to glow plug relay terminals B and G before using the jumper cables. (2) The terminals of the disconnected harnesses must not be shorted to earth. (3) When connecting the jumper cables, be very careful not to make a mistake in connecting the terminals, as this will cause damage to the relay. 3. Check the continuity between glow plug relay terminals B and G while disconnecting and connecting the jumper cable at the battery (+) terminal
Jumper cable at battery (+) terminal Connected Disconnected Continuity between terminals B- G Continuity (0.01 W or less) No continuity (infinite resistance)
GLOW PLUG CHECK

(+)
16400340029
1. Remove the glow plug plate. 2. Measure the resistance between the glow plug terminals and the body. Standard value: 0.6 - 1.0 W (at 20 _C)
(- )

Refer to GROUP 13E - On-vehicle Service.
16-61
16400180058
GLOW PLUG
1.8 Nm
1 2 3
18 Nm
AA"
Removal steps 1. Control wiring harness connection 2. Glow plug plate 3. Glow plug

AA" GLOW PLUG REMOVAL Remove glow plug by hand after loosening with tool as its ceramic part is fragile.
INSPECTION
D D Check for rust on glow plug plate. Check glow plug for damage.
16400190044
Caution Do not use a plug that has been dropped from a height of 10 cm or more.
16-62
ENGINE ELECTRICAL - Injection System <4D6>

16500010015
INJECTION SYSTEM <4D6>

GENERAL INFORMATION
For the injection system, refer to GROUP 13E - General Information.
ON-VEHICLE SERVICE
CRANK ANGLE SENSOR CHECK Refer to GROUP 13E - Troubleshooting.
16500130018
CRANK ANGLE SENSOR

Pre-removal and Post-installation Operation Timing Belt Removal and Installation (Refer to GROUP 11C.)
16500120015
10 - 12 Nm
9 Nm
2 1
Removal steps 1. Harness support 2. Crank angle sensor
17-1
ENGINE AND EMISSION CONTROL

CONTENTS ENGINE CONTROL SYSTEM . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 3
Accelerator Cable Check and Adjustment . . . . 3 Accelerator Pedal Position Sensor Check . . . . 4
17109000193
ACCELERATOR PEDAL POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AUTO-CRUISE CONTROL SYSTEM ..................................... 8

GENERAL INFORMATION . . . . . . . . . . . . . . . . 8 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 8 CONTINUED ON NEXT PAGE
ACCELERATOR CABLE AND PEDAL . . . . 5
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 and passenger (from rendering 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 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors 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 (*).
17-2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 9 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 27
Auto-cruise Control Main Switch Check . . . . 27 Auto-cruise Control Switch Check . . . . . . . . . . 27 Auto-cruise Control Component Check . . . . . 28
EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

General Information . . . . . . . . . . . . . . . . . . . . . . 42 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 42 Component Location . . . . . . . . . . . . . . . . . . . . . . 43 Exhaust Gas Recirculation (EGR) Control system Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 EGR Valve Check . . . . . . . . . . . . . . . . . . . . . . . . 44 EGR Port Vacuum Check <4G6> . . . . . . . . . . 44 EGR Port Vacuum Check <6A1> . . . . . . . . . . 45 EGR Control Solenoid Valve Check <4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 EGR Control Solenoid Valve Check <6A1> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
AUTO-CRUISE CONTROL* . . . . . . . . . . . . . 30
EMISSION CONTROL SYSTEM (MPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

GENERAL INFORMATION . . . . . . . . . . . . . . 33
Emission Control Device Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SERVICE SPECIFICATIONS . . . . . . . . . . . . 34 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 34 VACUUM HOSE . . . . . . . . . . . . . . . . . . . . . . . 34

Vacuum Hose Piping Diagram . . . . . . . . . . . . . 34 Vacuum Circuit Diagram . . . . . . . . . . . . . . . . . . 35 Vacuum Hose Check . . . . . . . . . . . . . . . . . . . . . 36 Vacuum Hose Installation . . . . . . . . . . . . . . . . . 36
CATALYTIC CONVERTER . . . . . . . . . . . . . . 47
General Information . . . . . . . . . . . . . . . . . . . . . . 47
CANISTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
EMISSION CONTROL SYSTEM <DIESEL> . . . . . . . . . . . . . . . . . . . . . . . . . 49

GENERAL INFORMATION . . . . . . . . . . . . . . . . 49 SERVICE SPECIFICATION . . . . . . . . . . . . . . . . 49 EXHAUST GAS RECIRCULATION SYSTEM (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 49
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 EGR Solenoid Valve Check . . . . . . . . . . . . . . . . . . 50 Accelerator Pedal Position Sensor Check . . . . . 50 Pump Operation Sensor Check . . . . . . . . . . . . . . . 50 Engine Coolant Temperature Sensor Check . . . 50 Intake Air Temperature Sensor Check . . . . . . . . 51 Barometric Pressure Sensor Check . . . . . . . . . . . 51 A/C Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Check at the Engine-ECU Terminals . . . . . . . . . . 51
CRANKCASE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

General Information . . . . . . . . . . . . . . . . . . . . . . 37 System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 37 Component Location . . . . . . . . . . . . . . . . . . . . . . 37 Positive Crankcase Ventilation System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 PCV Valve Check . . . . . . . . . . . . . . . . . . . . . . . . 38
EVAPORATIVE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

General Information . . . . . . . . . . . . . . . . . . . . . . 39 System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 39 Component Location . . . . . . . . . . . . . . . . . . . . . . 39 Purge Control System Check . . . . . . . . . . . . . . 40 Purge Port Vacuum Check . . . . . . . . . . . . . . . . 40 Purge Control Solenoid Valve Check . . . . . . . 41
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . 51
General Information . . . . . . . . . . . . . . . . . . . . . . . . . 51
ENGINE AND EMISSION CONTROL - Engine Control System
17-3
17100010102
ENGINE CONTROL SYSTEM

GENERAL INFORMATION
A cable-type accelerator mechanism and a suspended-type pedal have been adopted.
Accelerator pedal position sensor is used for vehicles with 4D6 engine which is equipped with the electronically-controlled fuel injection system.
17100030139
Items Accelerator cable play mm Engine idle speed r/min 4G6 6A1 4D6 Standard value 1-2 75050 65050 80030
ON-VEHICLE SERVICE
ACCELERATOR CABLE CHECK AND ADJUSTMENT
1. Turn A/C and lamps OFF. Inspect and adjust at no load. 2. Warm engine until stabilized at idle. 3. Confirm idle speed is at prescribed value. Standard value: <4G6> 75050 r/min <6A1> 65050 r/min <4D6> 80030 r/min
17100090243
4. Stop engine (ignition switch OFF). 5. Confirm there are no sharp bends in accelerator cable. 6. Check inner cable for correct slack. Standard value: 1 - 2 mm
17-4
<Except 4D6>

7. If there is too much slack or no slack, adjust play by the following procedures. <Except 4D6> (1) Loosen the adjusting bolt to release the cable. (2) Move the plate until the inner cable play is at the standard value, and then tighten the adjusting bolt. (3) After adjusting, check that the throttle lever is touching the stopper. <4D6> (1) Loosen the adjusting nut, and then move the lever to throttle fully-closed position. (2) Tighten the adjusting nut until the lever start to move, turn back one turn, and then tighten the lock nut to the specified torque.
Adjusting bolts
<4D6>
Plate
Adjusting nut
Lever
Lock nut
10 Nm

Refer to GROUP 13E - On-vehicle Service.
17-5
17100120256
ACCELERATOR CABLE AND PEDAL

Post-installation Operation Adjusting the Accelerator Cable (Refer to P.17-3.)
<L.H. drive vehicles>
<4G6, 6A1>
1 5
<4D6>
2 5 4
<4G6, 4D6> 10 Nm
4 8 11
10 11
<6A1>
5 6 12
14
12 Nm
13
<A/T>
15
<M/T>
15
Removal steps 1. Adjusting bolt 2. Adjusting nut 3. Inner cable connection 4. Inner cable connection 5. Accelerator cable 6. Snap ring 7. Accelerator arm assembly 8. Spring
9. 10. 11. 12. 13. 14. 15.
Pedal pad Accelerator pedal bracket Bushing Stopper Accelerator pedal stopper <M/T> Wide open throttle switch <A/T> Bracket
17-6

1 5
<4G6, 6A1>
<R.H. drive vehicles>
3 5
<4D6>
2 3
12 Nm 10 Nm
4 10
<4G6, 4D6>
5 6 8 7 11
<6A1>
7 11 12 13
14
Removal steps 1. Adjusting bolt 2. Adjusting nut 3. Inner cable connection 4. Inner cable connection 5. Accelerator cable 6. Snap ring 7. Accelerator arm assembly
8. 9. 10. 11. 12. 13. 14.
Spring Pedal pad Accelerator pedal bracket Bushing Stopper Accelerator pedal stopper <M/T> Wide open throttle switch <A/T>
17-7
17100180018
ACCELERATOR PEDAL POSITION SENSOR

Post-installation Operation Adjusting the Accelerator Cable (Refer to P.17-3.)

10 - 13 Nm
4 5 6 2 <R.H. drive vehicles> 1

10 Nm
1
10 Nm
3
10 - 13 Nm
10 - 13 Nm 10 - 13 Nm
4 5 6
10 - 13 Nm
Removal steps 1. Adjusting nut 2. Inner cable connection 3. Idle position switch connector 4. Accelerator pedal position sensor connector
5. Accelerator pedal position sensor assembly 6. Accelerator pedal position sensor bracket
17-8
ENGINE AND EMISSION CONTROL - Auto-cruise Control System

17200010143
AUTO-CRUISE CONTROL SYSTEM

GENERAL INFORMATION
By using the auto-cruise control, the driver can drive at the speed he/she likes (in a range of
approximately 40 - 200 km/h) without depressing the accelerator pedal.

Stop lamp switch Clutch switch
Auto-cruise control main switch
Vacuum actuator Accelerator pedal position sensor Auto-cruise vacuum pump assembly Auto-cruise control main switch
Auto-cruise control switch
Inhibitor switch Vehicle speed sensor Auto-cruise control-ECU Auto-cruise control indicator lamp
SPECIAL TOOL
Tool Number MB991502 Name MUT-II sub assembly Use D D
17200060179
Reading diagnosis codes Auto-cruise control system check
17-9
17200200236
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSIS TROUBLESHOOTING
NOTE Check that the vacuum hose is connected correctly and is not damaged, and then carry out the diagnosis.
DIAGNOSIS FUNCTION
17200210161
METHOD OF READING THE DIAGNOSIS CODES 1. Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) 2. With the ignition switch in the ON position, turn the auto-cruise control main switch to ON and take a reading of the diagnosis codes. METHOD OF ERASING THE DIAGNOSIS CODES The diagnosis codes can erased by disconnecting the ( - ) cable from the battery for 10 seconds or more and then re-connecting it, or by the following procedure. 1. Turn the ignition switch to ON. 2. After pushing the auto-cruise control switch in the direction of arrow (B) in the illustration, press the cruise control main switch to the ON position, and within 1 second after doing this, push the cruise control switch back in the direction of arrow (A). 3. After pushing the auto-cruise control switch once more in the direction of arrow (A) in the illustration and keeping it in this position, press the stop lamp switch to the ON position for 5 seconds or more. INPUT SWITCH CODE CHECK METHOD 1. Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover. 2. Turn the ignition switch to ON. 3. After pushing the auto-cruise control switch in the direction of arrow (B) in the illustration, press the cruise control main switch to the ON position, and within 1 second after doing this, push the cruise control switch back in the direction of arrow (A). 4. Operate each switch listed in the input check table and take a reading of the input switch codes with the MUT-II.
(A)
Auto-cruise control switch
(B)
17-10
Code No. 21 22 23 24
Input Check Table

Input operation SET switch ON RESUME switch ON Stop lamp switch (ON when brake pedal depressed) Operation judgement Auto-cruise control-ECU judges that SET switch is ON Auto-cruise control-ECU judges that RESUME switch is ON Auto-cruise control-ECU judges that stop lamp switch is ON Auto-cruise control-ECU judges that vehicle speed is 40 km/h or higher Auto-cruise control-ECU judges that vehicle speed is lower than 40 km/h Auto-cruise control-ECU judges that clutch switch <M/T> or inhibitor switch <A/T> is ON Auto-cruise control-ECU judges that CANCEL switch is ON Auto-cruise control-ECU judges that throttle position sensor (accelerator pedal position sensor*) voltage is 1.5 V or more Auto-cruise control-ECU judges that idle switch is OFF
Vehicle speed signal 25 D 26 27 28 29 D Clutch switch <M/T> (ON when clutch pedal depressed) Inhibitor switch <A/T> (ON when select lever in N range)
CANCEL switch ON Throttle position sensor (accelerator pedal position sensor*) signal Idle switch
NOTE * : Vehicles with TCL

Code No. 11 12 14 15 16 17 Diagnosis item Auto-cruise vacuum pump drive system Vehicle speed signal system Auto-cruise vacuum pump power supply system Auto-cruise control switch Auto-cruise control-ECU Throttle position sensor system <Vehicles without TCL> or accelerator pedal position sensor system <Vehicles with TCL>
17200220249
Reference page 17-11 17-11 17-12 17-12 17-12 17-13
ENGINE AND EMISSION CONTROL - Auto-cruise Control System INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code No. 11 Auto-cruise vacuum pump drive system
This diagnosis code is output if the release valve, control valve or motor drive signals from the auto-cruise vacuum pump are not input to the auto-cruise control-ECU.
17-11
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the auto-cruise vacuum pump connector harness auto-cruise control-ECU
Check the auto-cruise vacuum pump. (Refer to P.17-29.) OK Check the following connectors: C-74 <L.H.> or C-113 <R.H.>, A-02 and C-82 OK Check trouble symptom.
NG
Replace
NG
Repair
NG
Check the harness between the auto-cruise vacuum pump and auto-cruise control-ECU. OK NG Repair Replace the auto-cruise control-ECU.
Code No. 12 Vehicle speed signal system

This diagnosis code is output if the vehicle speed signals from the vehicle speed sensor are not input to the auto-cruise control-ECU when the vehicle speed is 40 km/h or more.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the vehicle speed sensor connector harness auto-cruise control-ECU
Is the speedometer operating normally? Yes Disconnect the vehicle speed sensor connector B-66 <M/T> or B-67 <A/T>. Measure at auto-cruise control-ECU connector C-82. D Disconnect the connector and measure at the harness side. D Ignition switch: ON D Voltage between terminal (11) and earth OK: 4.5 V or more NG Check the harness between the vehicle speed sensor and autocruise control-ECU, and repair if necessary.
No
Vehicle speed sensor circuit inspection (Refer to GROUP 54 - Combination Meter.)
OK
Check the following connector: C-82 OK NG Repair Check trouble symptom. NG Replace the auto-cruise control-ECU.
17-12

Probable cause
D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of the the the the the stop lamp switch connector harness auto-cruise control-ECU auto-cruise vacuum pump
Code No. 14 Auto-cruise vacuum pump power supply system

This diagnosis code is output when none of the drive signals from the release valve, control valve and motor of the auto-cruise vacuum pump are input to the auto-cruise control-ECU.
Measure at the auto-cruise vacuum pump connector A-02. D Disconnect the connector and measure at the harness side. D Ignition switch and main switch: ON D Stop lamp switch: OFF (When brake pedal is not depressed.) D Voltage between terminal (1) and earth OK: System voltage NG Check the stop lamp switch (Refer to P.17-28.) OK NG Replace Check the following connectors: C-74 <L.H.> or C-113 <R.H.>, A-02, C-02 and C-82 OK Check trouble symptom. NG Check the harness between the auto-cruise vacuum pump and auto-cruise control-ECU. OK NG Repair Replace the auto-cruise control-ECU.
OK
Check the auto-cruise vacuum pump. (Refer to P.17-29.) OK NG Replace Check the following connectors: C-74 <L.H.> or C-113 <R.H.>, A-02 and C-82 OK NG Repair Check trouble symptom. NG Replace the auto-cruise control-ECU.
Code No. 15 Auto-cruise control switch

This diagnosis code is output if the cruise control RESUME switch or SET switch remains ON. Replace the auto-cruise control switch.
Probable cause
D Malfunction of the auto-cruise control switch
Code No. 16 Auto-cruise control-ECU

This diagnosis code is output if there is an abnormality in the CANCEL hold circuit or the microprocessor monitor circuit in the auto-cruise control-ECU. Replace the auto-cruise control-ECU.
Probable cause
D Malfunction of the auto-cruise control-ECU

Code No. 17 Throttle position sensor system <Vehicles without TCL> or accelerator pedal position sensor system <Vehicles with TCL>
This diagnosis code is output if a voltage of 2.5 V or more when the idle switch is ON or 0.2 V or less when the idle switch is OFF is output for a continuous period of 4 seconds or more.
17-13
Probable cause
D D D D D
Malfunction of the throttle position sensor <Vehicles without TCL> Malfunction of the accelerator pedal position sensor <Vehicles with TCL> Malfunction of the connector Malfunction of the harness Malfunction of the auto-cruise control-ECU
MUT-II SELF DIAG CODE Is diagnosis code No.14 output from the engine-ECU? <Vehicles without TCL> Is diagnosis code No.11 output from the TCL-ECU? <Vehicles with TCL> No Check the following connectors: B-07 <Vehicles without TCL> or B-41 <Vehicles with TCL>, C-48, C-49, C-83 and C-82 OK Check trouble symptom.
Yes
D D
Throttle position sensor check <Vehicles without TCL> (Refer to GROUP 13A - Troubleshooting.) Accelerator pedal position sensor check <Vehicles with TCL> (Refer to GROUP 13A - Troubleshooting.)
NG
Repair
NG
D D
Check the harness between the throttle position sensor and auto-cruise control-ECU <Vehicles without TCL> Check the harness between the accelerator pedal position sensor and auto-cruise control-ECU <Vehicles with TCL> OK NG Repair
Replace the auto-cruise control-ECU.

Trouble symptom Communication with II MUT-II is not possible. Communication with all systems is not possible. Communication with auto-cruise control-ECU only is not possible. Inspection procedure No. 1 2 3
17200230228
Reference page 17-14 17-15 17-16
Input switch inspection using the MUT-II is not possible. (However, diagnosis inspection is possible.)
17-14

Inspection procedure No. Even if brake pedal is depressed Even if clutch pedal is depressed <M/T> Even if select lever is set to N range <A/T> Even if CANCEL switch is set to ON 4 5 6 7 8 9 10 11 12 13 Reference page 17-17 17-18 17-18 17-19 17-19 17-20 17-21 17-21 17-22 17-22
Trouble symptom Auto-cruise control is not cancelled.
The diagnosis result displayed on the MUT-II is normal even though auto-cruise control cannot be set. Auto-cruise control cannot be set. Hunting (repeated acceleration and deceleration) occurs at the set vehicle speed. Even though auto-cruise control main switch is ON, switch indicator lamp does not illuminate. (However, auto-cruise control is normal.) Auto-cruise control main switch illumination lamp does not illuminate. Auto-cruise control indicator lamp (CRUISE MAIN, CRUISE SET) inside combination meter does not illuminate. (However, auto-cruise control is normal.)

Inspection Procedure 1 Communication with MUT-II is not possible. (Communication with all system is not possible.)
The reason is probably a defect in the power supply system (including earth) for the diagnosis line. NG
Probable cause
D D Malfunction of the connector Malfunction of the harness NG
Measure at the diagnosis connector C-20. D Voltage between 16 and earth OK: Battery voltage OK
Check the following connectors: <L.H.> C-20, C-66, C-63, C-132, C-141 <R.H.> C-20, C-66, C-62, C-14 OK Check trouble symptom.
Repair
NG
Check the harness wire between the power supply and diagnosis connector, and repair if necessary.
Measure at the diagnosis connector C-20. D Continuity between 4 and earth D Continuity between 5 and earth OK: Continuity OK Replace the MUT-II.
NG
Check the following connector: C-20 OK Check trouble symptom.
NG
Repair
NG
Check the harness wire between the diagnosis connector and earth, and repair if necessary.

Inspection Procedure 2 Communication with MUT-II is not possible. (Communication with auto-cruise control-ECU only is not possible.)
The cause is probably a malfunction of auto-cruise control main switch circuit or a malfunction of auto-cruise control-ECU earth circuit.
17-15
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the auto-cruise control main switch connector harness auto-cruise control-ECU
Auto-cruise control main switch check (Refer to P.17-32.) OK Measure at auto-cruise control main switch connector C-22. D Disconnect the connector and measure at the harness side. D Ignition switch: ON D Voltage between the terminal (1) and earth OK: System voltage OK
NG NG
Replace Check the following connectors: C-22, C-134 OK NG Repair Check trouble symptom. NG Check the harness between the auto-cruise control main switch and power supply, and repair if necessary.
Check the following connectors: <L.H.> C-22, C-62, C-82 <R.H.> C-22, C-63, C-64, C-82 OK Check trouble symptom. OK Check the harnesses between the auto-cruise control main switch and earth or between the auto-cruise control main switch and autocruise control-ECU. OK Measure at auto-cruise control-ECU connector C-82. D Disconnect the connector and measure at the harness side. D Continuity between terminal (9) and earth, terminal (13) and earth. OK: Continuity NG Check the harness between the auto-cruise control-ECU and earth, and repair if necessary.
NG
Repair
NG
Repair
OK
Check the following connectors: C-82, C-20 OK NG Repair Check trouble symptom. NG Check the harness between the auto-cruise control-ECU and diagnosis connector OK NG Repair Replace the auto-cruise control-ECU.
17-16
Inspection Procedure 3 Input switch inspection using the MUT-II is not possible. (However, diagnosis inspection is possible.)
The cause is probably a malfunction of auto-cruise control switch circuit system.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the auto-cruise control switch clock spring connector harness
Auto-cruise control main switch check (Refer to P.17-32.) OK Clock spring check (Refer to GROUP 52B - Air Bag Modules and Clock Spring.) OK Measure at the clock spring connector C-107. D Disconnect the connector and measure at the harness side. D Ignition switch: ON D Voltage between the terminal (2) and earth OK: System voltage OK
NG
Replace
NG
Replace
NG
Check the following connectors: C-107, C-61, C-134, C-63 <R.H.> OK NG Repair Check trouble symptom.
Check the following connectors: C-107, C-82 OK Check trouble symptom. NG Check the harness between the clock spring and auto-cruise controlECU, and repair if necessary.
NG
NG Repair Check the harness between the clock spring and power supply, and repair if necessary.

Inspection Procedure 4 Even if brake pedal is depressed, auto-cruise control is not cancelled.
The cause is probably a malfunction of stop lamp switch or a malfunction of stop lamp circuit.
17-17
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the stop lamp switch connector harness auto-cruise control-ECU
Does stop lamp illuminate? No Stop lamp switch check (Refer to P.17-28.) OK NG Replace
Yes
Check the following connectors: C-65, C-82 OK NG Repair Check trouble symptom. NG Check the harness between the stop lamp switch and auto-cruise control-ECU. OK NG Repair Replace the auto-cruise control-ECU.
Measure at stop lamp switch connector C-02. D Disconnect the connector and measure at the harness side. D Voltage between terminal (1) and earth OK: System voltage OK
NG
Check the following connectors: C-02, C-134 OK NG Repair Check trouble symptom. NG Check the harness between the stop lamp switch and power supply, and repair if necessary.
Check the following connectors: C-02, C-65, C-82 OK Check trouble symptom.
NG
Repair
NG
Check the harness between the stop lamp switch and auto-cruise control-ECU, and repair if necessary.
17-18
Inspection Procedure 5 Even if clutch pedal is depressed, auto-cruise control is not cancelled. <M/T>
The cause is probably a malfunction of clutch switch or clutch circuit.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the clutch switch connector harness auto-cruise control-ECU
Clutch switch check (Refer to P.17-29.) OK Measure at clutch switch connector C-01. D Disconnect the connector and measure at the harness side. D Ignition switch: ON D Voltage between terminal (1) and earth OK: 5 V OK Check the following connectors: <L.H.> C-01, C-62 <R.H.> C-01, C-63, C-64 OK Check trouble symptom. NG Check the harness between the clutch switch and earth. NG Repair
NG NG
Replace
Check the following connectors: C-01, C-82 OK NG Repair Check trouble symptom.
NG
NG Repair Check the harness between the clutch switch and auto-cruise control-ECU, and repair if necessary.
OK
Replace the auto-cruise control-ECU.
Inspection Procedure 6 Even if select lever is set to N range, auto-cruise control is not cancelled. <A/T>
The cause is probably an open-circuit in the output signal circuit in N range.
Probable cause
D D D Malfunction of the connector Malfunction of the harness Malfunction of the auto-cruise control-ECU
Inhibitor switch check (N range) (Refer to P.17-29.) OK Check the following connectors: C-48, C-83, C-82
NG OK
Replace Check trouble symptom. NG Check the harness between the inhibitor switch and auto-cruise control-ECU. OK NG Repair Replace the auto-cruise control-ECU.

Inspection Procedure 7 Even if auto-cruise control CANCEL switch is set to ON, auto-cruise control is not cancelled.
The cause is probably an open-circuit in the circuit inside the CANCEL switch. Replace the auto-cruise control switch.
17-19
Probable cause
D Malfunction of the auto-cruise control-ECU
Inspection Procedure 8 The diagnosis result displayed on the MUT-II is normal even though auto-cruise control cannot be set.
Because of an open-circuit in the battery backup circuit system, the fail-safe function prevents diagnosis codes from being memorised and displayed even though auto-cruise control is cancelled. NG
Probable cause
D D D Malfunction of the connector Malfunction of the harness Malfunction of the auto-cruise control-ECU
Measure at auto-cruise control-ECU connector C-82. D Disconnect the connector and measure at the harness side. D Voltage between terminal (6) and earth OK: System voltage OK Check the following connector: C-82 OK NG Repair Check trouble symptom. NG Replace the auto-cruise control-ECU.
Check the following connectors: C-66 <L.H.> or C-62 <R.H.> and C-82 OK NG Repair Check trouble symptom. NG Check the harness between the auto-cruise control-ECU and power supply, and repair if necessary.
17-20
Inspection Procedure 9 Auto-cruise control cannot be set.

The cause is probably that the fail-safe function is cancelling auto-cruise control. In this case, the MUT-II can be used to check the trouble symptoms in each system by inspecting the diagnosis codes. The MUT-II can also be used to check if the circuits of each input switch are normal or not by inspecting the input switch codes.
Probable cause
D D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of of the the the the the the auto-cruise control main switch auto-cruise control switch clock spring harnesses or connectors clutch switch <M/T> auto-cruise control-ECU
Can the auto-cruise control communicate with the MUT-II? Yes Is the diagnosis system diagnosis displayed on the MUT-II normal? No Are any of MUT-II diagnosis code Nos. 11, 12, 14, 15, 16 or 17 output? No
No
Check for each trouble symptom. (Refer to inspection procedure No. 2 on P.17-15.) Check for each trouble symptom. (Refer to inspection procedure No. 8 on P.17-19.) Check for each diagnosis code. (CODE No.11: Refer to P.17-11.) (CODE No.12: Refer to P.17-11.) (CODE No.14: Refer to P.17-12.) (CODE No.15: Refer to P.17-12.) (CODE No.16: Refer to P.17-12.) (CODE No.17: Refer to P.17-13.) Check for each trouble symptom. (Refer to inspection procedure No. 3 on P.17-16.) D D Stop lamp switch input circuit system [code No. 23] inspection (Refer to inspection procedure No. 14 on P.17-24.) Clutch switch <M/T> or inhibitor switch <A/T> input circuit system [code No. 26] inspection (Refer to inspection procedure No. 15 on P.17-24.)
Yes
Yes
Is input switch inspection possible with the MUT-II? Yes Are either of MUT-II diagnosis code Nos. 23 or 26 output? No Replace the auto-cruise control-ECU.
No
Yes

Inspection Procedure 10 Hunting (repeated acceleration and deceleration) occurs at the set vehicle speed.
The cause is probably a malfunction of vehicle speed sensor or incorrect vacuum in the auto-cruise vacuum pump or vacuum actuator.
17-21
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the the the the vehicle speed sensor auto-cruise vacuum pump vacuum actuator auto-cruise control-ECU
Vehicle speed sensor check (Refer to GROUP 54 - Combination Meter.) OK Auto-cruise vacuum pump check (Refer to P.17-29.) OK Vacuum actuator check (Refer to P.17-29.) OK Replace the auto-cruise control-ECU.
NG
Replace
NG
Replace
NG
Replace
Inspection Procedure 11 Even though auto-cruise control main switch is ON, switch indicator lamp does not illuminate. (However, auto-cruise control is normal.)
Blown bulb in auto-cruise control main switch
Probable cause
Malfunction of the auto-cruise control main switch
Replace the auto-cruise control main switch.
17-22
Inspection Procedure 12 Auto-cruise control main switch illumination lamp does not illuminate.
The cause is probably a malfunction of auto-cruise control main switch or a malfunction of harness or connector.
Probable cause
D D D Malfunction of the auto-cruise control main switch Malfunction of the connector Malfunction of the harness
Auto-cruise control main switch check (Refer to P.17-32.) OK Measure at auto-cruise control main switch connector C-22. D Disconnect the connector and measure at the harness side. D Lighting switch: TAIL D Voltage between terminal (2) and earth OK: System voltage OK Check the following connectors: <L.H.> C-22, C-64, C-25 <R.H.> C-22, C-61, C-62, C-25 OK NG Repair Check trouble symptom.
NG NG
Replace
Check the following connectors: <L.H.> C-22, C-64, C-67, C-116 <R.H.> C-22, C-61, C-62, C-14 OK NG Repair Check trouble symptom. NG Check the harness between the auto-cruise control main switch and power supply, and repair if necessary.
NG
Check the harness between the auto-cruise control main switch and rheostat, and repair if necessary.
Inspection Procedure 13 Auto-cruise control indicator lamp (CRUISE MAIN, CRUISE SET) inside combination meter does not illuminate. (However, auto-cruise control is normal.)
The cause is probably a malfunction of bulb or a malfunction of connector or harness.
Probable cause
D D D D
of of of of
the the the the
bulb harness connector auto-cruise control-ECU
<CRUISE MAIN indicator lamp>

CRUISE MAIN indicator lamp bulb check OK Combination meter check OK Measure at the combination meter connector D-01. D Disconnect the connector and measure at the harness side. D Ignition switch and main switch: ON D Voltage between terminal (56) and earth OK: System voltage OK Check the following connectors: C-135, C-131 OK NG Repair Check trouble symptom. NG Check the harness between the combination meter and earth, and repair if necessary. NG NG Repair NG Replace
Check the following connectors: D-01, C-26 OK NG Repair Check trouble symptom. NG Check the harness between the combination meter and auto-cruise control main switch, and repair if necessary.

<CRUISE SET indicator lamp>
CRUISE SET indicator lamp bulb check OK Combination meter check OK Measure at the combination meter connector D-03. D Disconnect the connector and measure at the harness side. D Ignition switch: ON D Voltage between terminal (4) and earth OK: System voltage OK NG NG Repair NG Replace
17-23
Check the following connectors: D-03, C-135 OK NG Repair Check trouble symptom. NG Check the harness between the combination meter and power supply, and repair if necessary.
Measure at auto-cruise control-ECU connector C-82. D Disconnect the connector and measure at the harness side. D Ignition switch: ON D Voltage between terminal (17) and earth OK: System voltage OK Replace the and auto-cruise control-ECU.
NG
Check the following connectors: C-82, C-25 OK NG Repair Check trouble symptom. NG Check the harness between the combination meter and auto-cruise control-ECU, and repair if necessary.
17-24
Inspection Procedure 14 Stop lamp switch input circuit system inspection (Code No. 23)
Stop lamp switch check (Refer to P.17-28.) OK Check the following connectors: C-82, C-65, C-02, C-134, C-142, C-12 <R.H.> OK Check trouble symptom. NG NG Replace
Repair
NG
Check the harness between fusible link No. 1 and auto-cruise control-ECU, and repair if necessary.
Inspection Procedure 15 Clutch switch <M/T> or inhibitor switch <A/T> input circuit system inspection (Code No. 26) <M/T>
Clutch switch check (Refer to P.17-29.) OK Check the following connectors: <L.H.> C-82, C-01, C-62 <R.H.> C-82, C-01, C-63, C-64 OK Check trouble symptom. NG NG Replace
Repair
NG
Check the harness between auto-cruise control-ECU and earth, and repair if necessary.
<A/T>
Inhibitor switch check (Refer to P.17-29.) OK Check the following connectors: B-72, C-48, C-83, C-82 OK Check trouble symptom. NG NG Replace
Repair
NG
Check the harness between the auto-cruise control-ECU and inhibitor switch, and repair if necessary.
ENGINE AND EMISSION CONTROL - Auto-cruise Control System CHECK AT THE ECU TERMINALS
17-25
17200270121
Terminal No. 1
Check item Throttle position sensor (accelerator pedal position sensor*) input Idle switch output
Check conditions When accelerator pedal is fully depressed When accelerator pedal is released When accelerator pedal is depressed When accelerator pedal is not depressed When idle switch is OFF When idle switch is ON
Normal condition 4.5 - 5.5V 0.3 - 1.0V 4.5 - 5.5V 0V System voltage System voltage 0V 4V or more System voltage Release valve closed Control valve open/closed Release valve open Control valve open 0V System voltage/0V System voltage System voltage Continuity System voltage 0V
3 4
ACC power supply Stop lamp switch input
When ignition switch is in ACC position When brake pedal is depressed When brake pedal is not depressed When ignition switch is ON At any time When decelerating with the SET switch while driving at constant speed When cancelling constant speed driving with the CANCEL switch At any time No OD-OFF request OD-OFF request When stop lamp switch is ON When stop lamp switch is OFF
5 6 7 8 7 8 9 10
Diagnosis control input ECU backup power supply Auto-cruise vacuum pump release valve and control valve input Earth A/T control output
NOTE *: Vehicles with TCL
17-26
Terminal No. 11

Check item Vehicle speed sensor input Auto-cruise control switch input Check conditions When vehicle is moved forwards and backwards, sensor turns ON and OFF repeatedly When input switch has not been operated When input switch is pushed down When input switch is pushed up When input switch is pulled forward When sensor is ON When sensor is OFF When all switches are OFF When SET switch is ON When RESUME switch is ON When CANCEL switch is ON Normal condition 0V 4.5V or more 0V Approx. 3V Approx. 6V System voltage Continuity When clutch switch is OFF When clutch switch is ON When inhibitor switch is OFF When inhibitor switch is ON 5V 0V 5V 0V System voltage
12
13 14
Earth Clutch switch input <M/T> Inhibitor switch input <A/T>
At any time When pedal is not depressed When pedal is depressed When select lever is in a position other than N range When select lever is in N range Ignition switch : ON Main switch : ON Stop lamp switch : OFF Ignition switch : ON Main switch : ON When driving at constant speed When constant-speed driving is cancelled When driving at constant speed using the SET switch When accelerating with the RESUME switch while driving at constant speed When decelerating with the SET switch while driving at constant speed When cancelling constant speed driving with the CANCEL switch When indicator lamp is illuminated When indicator switched off lamp is
15
Pump power supply ECU power supply Indicator lamp input (inside combination meter) Auto-cruise vacuum pump motor input
16 17
System voltage 0V System voltage System voltage/0V System voltage/0V
18
Motor stopped/running Motor stopped/running
Motor stopped
System voltage
Motor stopped
System voltage

17-27
17200110133
ON-VEHICLE SERVICE
AUTO-CRUISE CONTROL MAIN SWITCH CHECK

1. Turn the ignition key to ON. 2. Check to be sure that the indicator lamp within the switch illuminates when the main switch is switched ON.
AUTO-CRUISE CONTROL SWITCH CHECK

(A)
17200120143
(C)
(B)
AUTO-CRUISE CONTROL SETTING 1. Switch ON the main switch. 2. Drive at the desired speed within the range of approximately 40 - 200 km/h. 3. Push the auto-cruise control switch in the direction of arrow (B). 4. Check to be sure that when the switch is released the speed is the desired constant speed. NOTE If the vehicles speed decreases to approximately 15 km/h below the set speed because of climbing a hill for example, the auto-cruise control will be cancelled. SPEED-INCREASE SETTING 1. Set to the desired speed. 2. Push the auto-cruise control switch in the direction of arrow (A). 3. Check to be sure that acceleration continues while the switch is hold, and that when it is released the constant speed at the time when it was released becomes the driving speed. NOTE Acceleration can be continued even if the vehicle speed has passed the high-speed limit (approx. 200 km/h). But the speed when the auto-cruise control switch is released will be recorded as the high-speed limit.
17-28

SPEED-REDUCTION SETTING 1. Set to the desired speed. 2. Push the auto-cruise control switch in the direction of arrow (B). 3. Check to be sure that deceleration continues while the switch is pressed, and that when it is released the constant speed at the time when it was released becomes the driving speed. NOTE When the vehicle speed reaches the low limit (approximately 40 km/h) during deceleration, the auto-cruise control will be cancelled. RETURN TO THE SET SPEED BEFORE CANCELLATION AND AUTO-CRUISE CONTROL CANCELLATION 1. Set the auto-cruise speed control. 2. When any of the following operations are performed while at constant speed during auto-cruise control, check if normal driving is resumed and deceleration occurs. a. The auto-cruise control switch is pushed in the direction of arrow (C). b. The brake pedal is depressed. c. The clutch pedal is depressed. <M/T> d. The selector lever is moved to the N range. <A/T> 3. When the auto-cruise control switch is pushed in the direction of arrow (A) at a vehicle speed of 40 km/h or higher, check if the vehicle speed returns to the speed before auto-cruise control driving was cancelled, and constant speed driving occurs. 4. When the main switch is turned to OFF while driving at constant speed, check if normal driving is resumed and deceleration occurs.
AUTO-CRUISE CONTROL COMPONENT CHECK

17200170223
STOP LAMP SWITCH 1. Disconnect the connector. 2. Check for continuity between the terminals of the switch.
Measurement conditions When brake pedal is depressed. (for stop lamp circuit) When brake pedal is not depressed. (for auto-cruise control circuit) Terminal No. 1 2 3 4
17-29
CLUTCH SWITCH 1. Disconnect the connector. 2. Check for continuity between the terminals of the switch.
Measurement conditions When clutch pedal is depressed. When clutch pedal is not depressed. Terminal No. 1 2
INHIBITOR SWITCH (N POSITION) Refer to GROUP 23 - On-vehicle Service. THROTTLE POSITION SENSOR Refer to GROUP 13A - On-vehicle Service. ACCELERATOR PEDAL POSITION SENSOR <Vehicles with TCL> Refer to GROUP 13A - On-vehicle Service. AUTO-CRUISE VACUUM PUMP 1. Disconnect the vacuum hose from the auto-cruise vacuum pump and connect a vacuum gauge to the vacuum pump. 2. Disconnect the vacuum pump connector. 3. Check that the reading on the vacuum gauge matches the values in the table below when the battery is connected to each connector terminal.
Terminal No. 1
1
Vacuum gauge
Valve condition Release valve closed Control valve closed Release valve open Control valve open
Vacuum gauge kPa 53 or more 20 or less
Release valve 2 3
Control valve 4
VACUUM ACTUATOR 1. Disconnect the vacuum hose from the vacuum actuator, and connect a hand vacuum pump to the actuator. 2. Check that the throttle lever operates when applying vacuum, and the vacuum is kept.
Vacuum actuator
17-30

17200140224
AUTO-CRUISE CONTROL
3 2
Auto-cruise vacuum pump removal steps 1. Vacuum hose 2. Auto-cruise vacuum pump and pump bracket assembly 3. Auto-cruise vacuum pump assembly 4. Pump bracket 5. Body pump bracket
Auto-cruise control main switch removal steps D Meter bezel assembly <L.H. drive vehicles> (Refer to GROUP 52A.) D Bezel switch <R.H. drive vehicles> (Refer to GROUP 52A.) 6. Auto-cruise control main switch
17-31
CAUTION: SRS Before removal of air bag module, refer to GROUP 52B - SRS Service Precautions and Air Bag Modules and Clock Spring.
9 Nm
10
11
8 12
14
13
Auto-cruise control switch removal steps D Steering wheel (Refer to GROUP 37A.) 7. Auto-cruise control switch Auto-cruise control-ECU removal steps D Radio and tape player (Refer to GROUP 54.) 8. Auto-cruise control-ECU
Sensor removal 9. Throttle position sensor 10. Accelerator pedal position sensor <Vehicles with TCL> 11. Stop lamp switch 12. Clutch switch <M/T> 13. Vehicle speed sensor 14. Inhibitor switch <A/T>
17-32
ENGINE AND EMISSION CONTROL - Auto-cruise Control System INSPECTION

17200110140
<L.H. drive vehicles> <R.H. drive vehicles>
AUTO-CRUISE CONTROL MAIN SWITCH CHECK 1. Connect the terminal 1 to the battery (+) side and connect the terminal 4 to the battery ( - ) side, and then turn the main switch to ON. Check that the voltage between the terminal 5 and earth is battery voltage. Also, check that the indicator lamp illuminates. 2. When the main switch is turned to OFF, check that the voltage between the terminal 5 and earth becomes 0 V. 3. Check the continuity between terminals 2 and 7.
OFF
ON ON OFF N N IND
ILL
17200120150 AUTO-CRUISE CONTROL SWITCH CHECK Measure the resistance between the terminals when each of the SET, RESUME and CANCEL switches is pressed. If the values measured at this time correspond to those in the table below, then there is no problem.
Switch position Switch OFF CANCEL switch ON RESUME switch ON

2 OFF OFF SET ON
Resistance between terminals No continuity Approx. 0 W Approx. 820 W Approx. 2,700 W

17200300042
SET switch ON
VEHICLE SPEED SENSOR CHECK Refer to GROUP 54 - Combination Meters.

ON
RESUME CANCEL
ON
OFF 1
ENGINE AND EMISSION CONTROL -
Emission Control System <MPI>
17-33
17300010252
EMISSION CONTROL SYSTEM <MPI>

GENERAL INFORMATION
The emission control system consists of the following subsystems: D Crankcase emission control system D Evaporative emission control system D Exhaust emission control system
Items Crankcase emission control system Evaporative emission control system Exhaust emission control system Name Positive crankcase ventilation (PCV) valve Canister Purge control solenoid valve Air-fuel ratio control device- MPI system Exhaust gas recirculation system D EGR valve D EGR control solenoid valve Catalytic converter Specification Variable flow type (Purpose: HC reduction) Equipped ON/OFF type solenoid valve (Purpose: HC reduction)
Oxygen sensor feedback type (Purpose: CO, HC, NOx reduction) Equipped Single type Duty cycle type solenoid valve (Purpose: NOx reduction) Monolith type (Purpose: CO, HC, NOx reduction)
EMISSION CONTROL DEVICE REFERENCE TABLE

Related parts Crankcase emission control system Evaporative emission control system Air/fuel ratio control system Catalytic converter Exhaust gas recirculation system Reference page
PCV valve Purge control solenoid valve MPI system component Catalytic converter EGR valve EGR control solenoid valve
17-38 17-41 GROUP 13A 17-47 17-44 17-45
17-34

17300030265
Items Purge control solenoid valve coil resistance (at 20_C) W EGR control solenoid valve coil resistance (at 20_C) W Standard value 36 - 44 36 - 44
SPECIAL TOOL
Tool Number MD998770 Name Oxygen wrench sensor Use
17300060073
Removal/Installation of oxygen sensor
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
<4G6>
17300090317
Air cleaner
Air
Fuel pressure regulator PCV valve EGR valve
OFF OFF ON
Canister
ON
EGR control solenoid valve Oxygen sensor (front) Oxygen sensor (rear)
Three-way catalytic converter
ENGINE AND EMISSION CONTROL <6A1>
17-35
Vacuum cotrol solenoid valve <TCL>

OFF ON ON
Vacuum tank <TCL>
OFF
Ventilation control solenoid valve <TCL> Air cleaner
Air
PCV valve
Fuel pressure regulator
EGR valve EGR control solenoid valve
OFF
ON
Canister Purge control solenoid valve Oxygen sensor Oxygen sensor (front) (rear)
Three-way catalytic converter
VACUUM CIRCUIT DIAGRAM

<4G6>
Intake manifold To combustion chamber Throttle body
From air cleaner
EGR control solenoid valve (ON: OPEN)
Vacuum hose colour B: Black G: Green L: Light blue R: Red W: White Y: Yellow
EGR valve Purge control solenoid valve (ON: OPEN)
Canister
17-36
<6A1>
Intake manifold
To combustion chamber
Throttle body From air cleaner
Purge control solenoid valve (ON: OPEN)
EGR control solenoid valve (ON: CLOSE)
Vacuum tank <TCL>
EGR valve Canister Ventilation control solenoid valve <TCL> (ON: CLOSE) Vacuum control solenoid valve <TCL> (ON: OPEN) Vacuum hose colour B: Black G: Green L: Light blue R: Red Y: Yellow
Vacuum actuator <TCL>
VACUUM HOSE CHECK

1. Using the piping diagram as a guide, check to be sure that the vacuum hoses are correctly connected. 2. Check the connection condition of the vacuum hoses, (removed, loose, etc.) and check to be sure that there are no bends or damage.
VACUUM HOSE INSTALLATION

1. When connecting the vacuum hoses, they should be securely inserted onto the nipples. 2. Connect the hoses correctly, using the vacuum hose piping diagram as a guide.
17-37
17300500247
CRANKCASE EMISSION CONTROL SYSTEM

GENERAL INFORMATION
The crankcase emission control system prevents blow-by gases from escaping inside the crankcase into the atmosphere. Fresh air is sent from the air cleaner into the crankcase through the breather hose. The air becomes mixed with the blow-by gases inside the crankcase. The blow-by gas inside the crankcase is drawn into the intake manifold through the positive crankcase ventilation (PCV) valve.
The PCV valve lifts the plunger according to the intake manifold vacuum so as to regulate the flow of blow-by gas properly. In other words, the blow-by gas flow is regulated during low load engine operation to maintain engine stability, while the flow is increased during high load operation to improve the ventilation performance.
SYSTEM DIAGRAM
Ventilation hose
PCV valve
Breather hose
NOTE The illustration shows the system for 4G63 engine.
COMPONENT LOCATION
PCV valve <4G6> PCV valve <6A1>
17-38
POSITIVE CRANKCASE VENTILATION SYSTEM 17300110136 CHECK

1. 2. 3. 4. Remove the ventilation hose from the PCV valve. Remove the PCV valve from the rocker cover. Reinstall the PCV valve at the ventilation hose. Start the engine and run at idle.
PCV valve
5. Place a finger at the opening of the PCV valve and check that vacuum of the intake manifold is felt. NOTE At this moment, the plunger in the PCV valve moves back and forth. 6. If vacuum is not felt, clean the PCV valve or replace it.
PCV VALVE CHECK

PCV valve
17300120122
1. Insert a thin rod into the PCV valve from the side shown in the illustration (rocker cover installation side), and move the rod back and forth to check that the plunger moves. 2. If the plunger does not move, there is clogging in the PCV valve. In this case, clean or replace the PCV valve.
17-39
17300510363
EVAPORATIVE EMISSION CONTROL SYSTEM

GENERAL INFORMATION
The evaporative emission control system prevents fuel vapours generated in the fuel tank from escaping into the atmosphere. Fuel vapours from the fuel tank flow through the fuel tank pressure control valve and vapour pipe/hose to be stored temporarily in the canister. When driving the vehicle, fuel vapours stored in the canister flow through the purge solenoid and purge port and go into the intake manifold to be
sent to the combustion chamber. When the engine coolant temperature is low or when the intake air quantity is small (when the engine is at idle, for example), the engine control unit turns the purge solenoid off to shut off the fuel vapour flow to the intake manifold. This does not only insure the driveability when the engine is cold or running under low load but also stabilize the emission level.
SYSTEM DIAGRAM
Throttle body From fuel tank Canister OFF ON Purge control solenoid valve
Engine-ECU Air flow sensor Engine coolant temperature sensor Intake air temperature sensor Control relay Barometric pressure sensor
COMPONENT LOCATION
<4G6>

<6A1>
17-40
<4G6>

17300140357
PURGE CONTROL SYSTEM CHECK

Plug
Red stripe
1. Disconnect the vacuum hose (red stripe) from the throttle body and connect it to a hand vacuum pump. 2. Plug the nipple from which the vacuum hose was removed. 3. When the engine is cold or hot, apply a vacuum while the engine is idling, and check the condition of the engine and the vacuum. When engine is cold (Engine coolant temperature: 40_C or less)
Vacuum Engine condition 3,000 r/min Normal condition Vacuum is maintained 53 kPa
<6A1> Red stripe
When engine is hot (Engine coolant temperature: 80_C or higher)

Vacuum 53 kPa Engine condition At idle 3,000 r/min Normal condition Vacuum is maintained Vacuum will leak for approximately 3 minutes after the engine is started. After 3 minutes have passed, the vacuum will be maintained momentarily, after which it will again leak.*
Plug
NOTE *: The vacuum will leak continuously if the atmospheric pressure is approximately 77 kPa or less, or the temperature of the intake air is approximately 50_C or higher.
<4G6> Purge port vacuum nipple
PURGE PORT VACUUM CHECK
17300150282
1. Disconnect the vacuum hose (red stripe) from the throttle body purge vacuum nipple and connect a hand vacuum pump to the nipple.
ENGINE AND EMISSION CONTROL <6A1>
17-41
Purge port vacuum nipple
Vacuum
2. Start the engine and check that, after raising the engine speed by racing the engine, purge vacuum raises according to engine speed. NOTE If there is a problem with the change in vacuum, the throttle body purge port may be clogged and require cleaning.
Engine speed (r/min)

17300170127
Battery
NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (black stripe, red stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to nipple (A) of the solenoid valve (refer to the illustration at left). 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying voltage.
Battery voltage Applied Not applied Normal condition Vacuum leaks Vacuum maintained
17-42

17300520274
EXHAUST GAS RECIRCULATION (EGR) SYSTEM

GENERAL INFORMATION
The exhaust gas recirculation (EGR) system lowers the nitrogen oxide (NOx) emission level. When the air/fuel mixture combustion temperature is high, a large quantity of nitrogen oxides (NOx) is generated in the combustion chamber. Therefore, this system recirculates part of emission gas from
the exhaust port of the cylinder head to the combustion chamber through the intake manifold to decrease the air/fuel mixture combustion temperature, resulting in reduction of NOx. The EGR flow rate is controlled by the EGR valve so as not to decrease the driveability. D D D The engine coolant temperature is low. The engine is at idle. The throttle valve is widely opened.
OPERATION
The EGR valve is being closed and does not recirculate exhaust gases under one of the following conditions. Otherwise, the EGR valve is opened and recirculates exhaust gases.
SYSTEM DIAGRAM
<4G6>
A
EGR control solenoid valve OFF
Air flow sensor

EGR valve ON Control relay Engine-ECU Battery
Crank angle sensor
<6A1>
EGR valve EGR control solenoid valve

OFF ON
Air flow sensor Engine coolant temperature sensor Crank angle sensor Control relay
Engine-ECU
Battery
ENGINE AND EMISSION CONTROL COMPONENT LOCATION

EGR control solenoid valve
<4G6>
17-43
EGR control solenoid valve

<6A1>
AGR valve E
<4G6>
BGR valve E
<6A1>
<4G6> Green stripe
EXHAUST GAS RECIRCULATION (EGR) CONTROL SYSTEM CHECK
17300260282
Three-way terminal
1. Disconnect the vacuum hose (green stripe) from the EGR valve, and then connect a hand vacuum pump via the three-way terminal. 2. When the engine is hot or cold, check the condition of vacuum by racing the engine. When engine is cold (Engine coolant temperature: 20_C or less)
Throttle valve Normal vacuum condition No vacuum will generate (the same as barometric pressure.) Open quickly
EGR valve
<6A1>
Green stripe
When engine is hot (Engine coolant temperature: 80_C or higher)

Three-way terminal EGR valve
Throttle valve Open quickly
Normal vacuum condition It will momentarily rise over 13 kPa
17-44
<4G6>
Green stripe
Plug
3. Disconnect the three-way terminal. 4. Connect the hand vacuum pump to the EGR valve. 5. Check whether the engine stalls or the idling is unstable when a vacuum of 30 kPa or higher is applied during idling.
EGR valve
<6A1>
Green stripe
Plug EGR valve
EGR VALVE CHECK
17300280196
1. Remove the EGR valve and inspect for sticking, carbon deposits, etc. If found, clean with a suitable solvent so that the valve seats correctly. 2. Connect a hand vacuum pump to the EGR valve. 3. Apply 67 kPa of vacuum, and check that the vacuum is maintained. 4. Apply a vacuum and check the passage of air by blowing through one side of the EGR passage.
Vacuum 3.3 kPa or less 28 kPa or more Passage of air Air is not blown out Air is blown out
5. Replace the gasket, and tighten to the specified torque. Specified torque: 22 Nm
EGR PORT VACUUM CHECK <4G6>

EGR vacuum nipple
17300290199
1. Disconnect the vacuum hose (white stripe) from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple.
ENGINE AND EMISSION CONTROL Vacuum
17-45
2. Start the engine and check that the vacuum remains fairly constant after racing the engine. NOTE If vacuum changes, it is possible that the throttle body EGR port may be clogged and require cleaning.
EGR PORT VACUUM CHECK <6A1>

EGR port vacuum nipple
17300290205
1. Disconnect the vacuum hose (green stripe) from the throttle body EGR vacuum nipple and connect a hand vacuum pump to the nipple.
Vacuum
2. Start the engine and check to see that, after raising the engine speed by racing the engine, EGR vacuum raises proportionately with the rise in engine speed. NOTE If there is a problem with the change in vacuum, it is possible that the throttle body EGR port may be clogged and require cleaning.
EGR CONTROL SOLENOID VALVE CHECK 17300310222 <4G6>

NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (yellow stripe, white stripe, green stripe) from the solenoid valve. 2. Disconnect the harness connector.
3. Connect a hand vacuum pump to the nipple to which the white-striped vacuum hose was connected. 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage.
Battery voltage Not applied
Battery
B nipple condition Open Open Closed
Normal condition Vacuum maintained Vacuum leaks Vacuum maintained
Applied
17-46
EGR CONTROL SOLENOID VALVE CHECK 17300310239 <6A1>

NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (yellow stripe, green stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to the nipple to which the green-striped vacuum hose was connected. 4. Check airtightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage.
Battery voltage Not applied Applied Normal condition Vacuum leaks Vacuum maintained
Battery
17-47
17300530055
CATALYTIC CONVERTER
GENERAL INFORMATION
The three-way catalytic converter, together with the closed loop air-fuel ratio control based on the oxygen sensor signal, oxidizes carbon monoxides (CO) and hydrocarbons (HC) and reduces nitrogen oxides (NOx).
When the mixture is controlled at stoichiometric air-fuel ratio, the three-way catalytic converter provides the highest purification against the three constituents, namely, CO, HC and NOx.
17300390233

Pre-removal and Post-installation Operation Under Cover Removal and Installation
<4G6>
49 - 59 Nm 34 Nm 44 Nm
49 Nm
4 3
49 Nm
<6A1>
13 Nm 49 Nm 49 Nm 44 Nm 49 Nm
2 4 3
49 Nm 13 Nm
1
7 Nm
Removal steps 1. Heat protector AA" "AA 2. Oxygen sensor
3. Front exhaust pipe 4. Catalytic converter
17-48

AA" OXYGEN SENSOR REMOVAL

"AA OXYGEN SENSOR INSTALLATION
MD998770
CANISTER
17300420055
4 3
Removal steps 1. Vapor hose connection 2. Vent hose 3. Hose clamp 4. Canister 5. Canister bracket
Emission Control System <Diesel>
17-49
17500010036
EMISSION CONTROL SYSTEM <DIESEL>

GENERAL INFORMATION
Item Exhaust emission control system Name Exhaust gas recirculation system D EGR valve D EGR solenoid valve Specification
Equipped Single type Duty cycle type solenoid valve

17500030032
Item EGR solenoid valve coil resistance W Specification 11 - 14 (at 20_C)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM

SYSTEM CHECK
Vacuum pump
17500010030
EGR solenoid valve Accelerator pedal position sensor A/C switch Pump operation sensor EGR valve Engine-ECU Engine coolant temperature sensor Intake air temperature sensor Barometric pressure sensor (built into engine-ECU)
1. Start the engine and let it warm up until the engine coolant temperature is 80_C or above. 2. Check that the diaphragm of the EGR valve moves towards the EGR valve closing direction when the engine is raced by suddenly depressing the accelerator pedal.
Diaphragm
17-50 ENGINE AND EMISSION CONTROL EGR solenoid valve
Emission Control System <Diesel>

17500290027
EGR SOLENOID VALVE CHECK
NOTE When disconnecting the vacuum hose, always make a mark so that it can be reconnected at original position. 1. Disconnect the vacuum hose (yellow stripes green stripe) from the solenoid valve. 2. Disconnect the harness connector. 3. Connect a hand vacuum pump to the nipple to which the yellow-striped vacuum hose was connected. 4. Check that the needle reading rises by 47 kPa or more when negative pressure is applied. NOTE There is no problem if the needle reading rises by 47 kPa or more, even though there is a leak. 5. Apply a voltage of 6 V between the terminals, and check that the pressure leaks at this time even when negative pressure applied.
6. Measure the resistance between the terminals. Standard value: 11 - 14W (at 20_C)

PUMP OPERATION SENSOR CHECK

17500350015

ENGINE AND EMISSION CONTROL - Emission Control System <Diesel>
17-51
17500360018

BAROMETRIC PRESSURE SENSOR CHECK

17500370011
A/C SWITCH CHECK

17500380014

17500300010
CATALYTIC CONVERTER
GENERAL INFORMATION
A monolith-type oxidation catalytic converter is located between the front exhaust pipe and the center exhaust pipe. This catalytic converter
17500270021
reduces the amounts of carbon monoxide (CO) and hydrocarbons (HC) in the exhaust gas.

Pre-removal and Post-installation Operation Under Cover Removal and Installation
17500210030
49 Nm 49 Nm
49 Nm 2
1
13 Nm
Removal steps 1. Front exhaust pipe 2. Catalytic converter
NOTES
21-1
CLUTCH
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 2
Clutch Pedal Inspection and Adjustment . . . . . . . 2 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
21109000190
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CLUTCH CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 5

Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 7
21-2
CLUTCH -
General Information/Service Specifications/Lubricants/On-vehicle Service

21100010093
GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type; hydraulic pressure is used for the clutch control.
Items Clutch pedal height mm Clutch pedal clevis pin play mm Clutch pedal free play mm Distance between the clutch pedal and the toeboard when the clutch is disengaged mm Standard value 163 - 166 1- 3 6 - 13 80 or more
21100030150
LUBRICANTS
Items Clutch fluid Push rod assembly Boot Release cylinder push rod MITSUBISHI genuine grease Part No. 0101011 Specified lubricants Brake fluid DOT3 or DOT4 Rubber grease Quantity As required
21100040078
Clutch pedal height
ON-VEHICLE SERVICE
CLUTCH PEDAL INSPECTION AND ADJUSTMENT
21100090158
1. Turn up the carpet, etc. under the clutch pedal. 2. Measure the clutch pedal height.
A
Standard value (A): 163 - 166 mm
Lock nut
Adjusting bolt or clutch switch
3. If the height of the clutch pedal is outside the standard value, loosen the lock nut and adjust the pedal height to the standard value using the push rod, adjusting bolt <vehicles without auto cruise control system> or clutch switch <vehicles with auto cruise control system>.
Lock nut 13 Nm 13 Nm Push rod
CLUTCH - On-vehicle Service

Clutch pedal clevis pin play
21-3
4. Measure the clutch pedal play. Standard value (B): 1 - 3 mm 5. If the clutch pedal play is not within the standard value, loosen the lock nut and move the push rod to adjust. Caution Do not push in the master cylinder push rod at this time.
Clutch pedal free play
6. After completing the adjustments, confirm that the clutch pedal free play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the toeboard when the clutch is disengaged are within the standard value ranges.
C
Standard value (C): 6 - 13 mm Standard value (D): 80 mm or more 7. If the clutch pedal free play and the distance between the clutch pedal and the toeboard when the clutch is disengaged do not agree with the standard values, it is probably the result of either air in the hydraulic system or a faulty master cylinder or clutch. Bleed the air, or disassemble and inspect the master cylinder or clutch. 8. Turn back the carpet, etc.
Distance between the clutch pedal and the toeboard when the clutch is disengaged
BLEEDING
Specified fluid: Brake fluid DOT 3 or DOT 4
21100140143
Caution Use the specified brake fluid. Avoid using a mixture of the specified fluid and other fluid.
21-4 CLUTCH PEDAL
CLUTCH - Clutch Pedal

21100160224

Post-installtion Operation Clutch Pedal Adjustment (Refer to P.21-2)
13 Nm
22 3
29 Nm
10
4 21 5 19 13 11
12 Nm
20
18
13 Nm
12
7 12 1 2 17 9 15 16 14
Removal steps 1. Clevis pin assembly 2. Bushing 3. Nut 4. Bolt 5. Clevis pin <6A1> 6. Rod A <6A1> 7. Turnover spring <6A1> 8. Rod B <6A1> 9. Bushing <6A1> 10. Bolt 11. Clutch return spring 12. Clutch pedal bushing 13. Pipe
14. 15. 16. 17. 18. 19. 20. 21. 22.
Stopper <R.H. drive vehicles> Clutch pedal Pedal pad Stopper Adjusting bolt <Vehicles without auto cruise control system> Lock nut <Vehicles without auto cruise control system> Clutch switch <Vehicles with auto cruise control system> Clip <Vehicles with auto cruise control system> Master cylinder member assembly
CLUTCH - Clutch Control
21-5
21100190216
CLUTCH CONTROL
REMOVAL AND INSTALLTION
Pre-removal Operation Clutch Fluid Draining Post-installation Operation D Clutch Fluid Supplying D Clutch Line Bleeding (Refer to P.21-3) D Clutch Pedal Adjustment (Refer to P.21-2)

<4G6>
8 10 8
<4D6, 6A1>
8 6 1 9
10 - 12 Nm
3
13 Nm
19 Nm
Release cylinder push rod 15 Nm
Release fork
Specified grease: MITSUBISHI genuine grease Part No. 0101011
Clutch master cylinder removal steps 1. Clevis pin assembly 2. Clutch pipe connection 3. Clutch master cylinder Clutch release cylinder removal steps 4. Clutch pipe connection 5. Clutch release cylinder
Clutch fluid line damper removal steps <4D6, 6A1> 6. Clutch pipe connection 7. Clutch fluid line damper Clutch line removal steps 8. Clutch pipe 9. Bracket 10. Clutch hose
21-6
CLUTCH - Clutch Control
13 Nm
3
<4G6>
2 4 8 10
<4D6, 6A1>
8 6
5
10 - 12 Nm
19 Nm
Release cylinder push rod
Release fork
15 Nm
Specified grease: MITSUBISHI genuine grease Part No. 0101011
Clutch master cylinder removal steps 1. Clevis pin assembly 2. Clutch pipe connection 3. Clutch master cylinder Clutch release cylinder removal steps 4. Clutch pipe connection 5. Clutch release cylinder
Clutch fluid line damper removal steps <4D6, 6A1> 6. Clutch pipe connection 7. Clutch fluid line damper Clutch line removal steps 8. Clutch pipe 9. Bracket 10. Clutch hose
CLUTCH - Clutch Control DISASSEMBLY AND REASSEMBLY

CLUTCH MASTER CYLINDER 5 4 3 <4G6, 4D6>
21-7
21100210172
7 6 2
13 Nm
8 1
3 <6A1>
3
Piston repair kit Clutch fluid: Brake fluid DOT3 or DOT4 Grease: Rubber grease
Dsassembly steps 1. Piston stopper ring 2. Piston assembly "AA 3. Push rod assembly 4. Boot 5. Reservoir cap 6. Spring pin
7. Reservoir tank 8. Clutch master cylinder assembly Caution Do not disassemble piston assembly.

"AA PUSH ROD ASSEMBLY INSTALLATION Set the length of the push rod assembly to the shown dimension to make the adjustment of clutch pedal easier.
121 mm
NOTES
22-1
MANUAL TRANSMISSION
CONTENTS
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3
Transmission Oil Check . . . . . . . . . . . . . . . . . . . . . . . 3
22109000319
Transmission Oil Replacement . . . . . . . . . . . . . . . . 3
TRANSMISSION CONTROL* . . . . . . . . . . . . . . . . 4 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . 6
WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICULES 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 driver and passenger (from rendering 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 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors 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 (*).
22-2 LUBRICANT
Item Transmission oil
MANUAL TRANSMISSION - Lubricant/Special Tools

22100040242
Specified lubricant Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4
Quantity L 2.2
SPECIAL TOOLS
Tool Number MB990635 or MB991113 Name Steering linkage puller Use Ball joint disconnection
22100060187
Engine lifter
MB991453
Engine hanger
MANUAL TRANSMISSION - On-vehicle Service
22-3
22100090124
ON-VEHICLE SERVICE
TRANSMISSION OIL CHECK
Transmission oil Filler plug hole
(1) Remove the oil filler plug. (2) Oil level should be at the lower portion of the filler plug hole. (3) Check that the transmission oil is not noticeably dirty, and that it has a suitable viscosity. (4) Tighten the filler plug to the specified torque. Tightening torque: 32 Nm
TRANSMISSION OIL REPLACEMENT

Filler plug
22100100247
(1) Remove the drain plug to drain oil. (2) Tighten the drain plug to the specified torque. (3) Remove the filler plug and fill with specified oil till the level comes to the lower portion of filler plug hole. Transmission oil Specified oil: Hypoid gear oil SAE 75W - 90 or 75W - 85W conforming to API GL-4 Quantity: 2.2 L (4) Tighten the filler plug to the specified torque.
32 Nm
Drain plug
22-4
MANUAL TRANSMISSION - Transmission Control

22100380238
TRANSMISSION CONTROL
Pre-removal and Post-installation Operation D Air Cleaner Assembly Removal and Installation D Battery and Battery Tray Removal and Installation
Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the shift cable and select cable assembly.
8
12 Nm
9 8 10 11 5 6
1 2 3
12 Nm
12
14 13
"BA "BA "BA
"AA "AA "AA
Shift cable and select cable assembly removal steps D Lower cover and side cover (Refer to GROUP 52A - Instrument Panel.) 1. Shift knob 2. Spring washer 3. Nut D Floor console box (Refer to GROUP 52A.) 4. Snap pin 5. Select cable connection (Shift lever side) 6. Clip 7. Shift cable connection (Shift lever side) 8. Snap pin 9. Select cable connection (Transmission side) 10. Shift cable connection (Transmission side) 11. Shift cable and select cable assembly
Shift lever assembly removal steps "BA 1. Shift knob "BA 2. Spring washer "BA 3. Nut D Floor console box (Refer to GROUP 52A.) 4. Snap pin 5. Select cable connection (Shift lever side) 6. Clip 7. Shift cable connection (Shift lever side) 12. Shift lever assembly 13. Distance piece 14. Bushing
MANUAL TRANSMISSION - Transmission Control INSTALLATION SERVICE POINTS

Shift lever
22-5
"AA SHIFT CABLE AND SELECT CABLE ASSEMBLY/ SHIFT CABLE CONNECTION/SELECT CABLE CONNECTION (1) Set the transmission side shift lever and the passenger compartment side shift lever to the neutral position.
Neutral position
(2) For the transmission side, the white and yellow paint marks on the shift and select cable ends should face the snap pins. (3) Move the shift lever to all positions and check that the operation is smooth.
"BA NUT/SPRING WASHER/SHIFT KNOB INSTALLATION (1) Screw in the nut all the way by hand, turn back half a turn, and then insert the spring washer. (2) Screw in the shift knob until it touches the spring washer, and make one more turn. Then turn more to adjust the shift pattern on the shift knob. (3) If the above steps are impossible, you can turn back the shift knob by one turn at most after screwing in all the way to adjust the shift pattern.
22-6
MANUAL TRANSMISSION - Transmission Control

22100400101
SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY
5 Nm
9 6
6 Nm
7 3
3 1 5 2 4 10
Disassembly steps 1. Bolt 2. Select lever 3. Bushing 4. Return spring 5. Collar
6. 7. 8. 9. 10.
Cap Spacer Shift lever Shift lever bushing Lever bracket
MANUAL TRANSMISSION - Transmission Assembly
22-7
22100270290
TRANSMISSION ASSEMBLY
Pre-removal Operation D Transmission Oil Draining (Refer to P.22-3.) D Under Cover Removal D Battery and Battery Tray Removal D Air Cleaner Assembly Removal
Post-installation Operation D Air Cleaner Assembly Installation D Battery and Battery Tray Installation D Under Cover Installation D Transmission Oil Supplying (Refer to P.22-3.) D Check the Dust Cover for Cracks or Damage by Pushing it with Finger. D Shift Lever Operation Check D Speedometer Operation Check D Wheel Alignment Adjustment (Refer to GROUP 33A - On-vehicle Service.)
19 Nm
5 <4G6>
19 Nm
5 <4D6, 6A1>
103 Nm 19 Nm 44 Nm
9
88 Nm*1
3 4
10 8
98 - 118 Nm*1
15
15
10 - 12 Nm 81 Nm
12 11
24 - 33 Nm 81 Nm 67 - 78 Nm 30 Nm 30 Nm
14
13
88 Nm
98 - 118 Nm
AA"
Removal steps 1. Select cable connection 2. Shift cable connection 3. Backup lamp switch connector 4. Vehicle speed sensor connector 5. Clutch release cylinder connection 6. Clutch fluid line damper connection 7. Starter motor <6A1> 8. Tie rod end connection 9. Stabilizer link connection 10. Damper fork
AB" AC"
11. 12. 13. 14. 15.
No.2 stay Lateral lower arm connection No.3 stay Compression lower arm connection Drive shaft
Caution *1: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
22-8
57 Nm
18
81 Nm*2 49 Nm 30 Nm
16
19 17 19 25
24
10 - 12 Nm
24 49 Nm
49 Nm 57 Nm*2
22
25 Nm
23
44 Nm
7 Nm
20
21
69 Nm
10Nm <Flange bolts> 9Nm <Washer assembled bolts>
93 Nm
69 - 78 Nm
16. Starter motor <4G6, 4D6> 17. Transmission assembly upper part coupling bolts AD" 18. Transmission mount bracket "AA 19. Transmission mount stopper AE" D Engine and transmission assembly supporting 20. Centermember assembly 21. Rear roll stopper 22. Bell housing cover <4G6, 4D6>
AF" AF"
23. Cover <6A1> 24. Transmission assembly lower part coupling bolts 25. Transmission assembly
Caution Mounting locations marked by *2 should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.

Cord Ball joint MB990635 or MB991113
22-9

AA" TIE ROD END DISCONNECTION Caution 1. Use the special tool to loosen the tie rod end mounting nut. Only loosen the nut; do not remove it from the ball joint. 2. Support the special tool with a cord, etc. not to let it come off.
Nut
AB" NO.3 STAY REMOVAL No.3 stay is tightened together with the crossmember. Therefore, after removing No.3 stay, install the nut and bolt to the crossmember provisionally.
No.3 stay
Crossmember
Transmission side
AC" DRIVE SHAFT DISCONNECTION (1) Insert a pry bar between the transmission case and the drive shaft as shown to remove the drive shaft. NOTE Do not remove the hub and knuckle from the drive shaft. Caution Always use a pry bar, or the TJ will be damaged. (2) Suspend the removed drive shaft with a wire so that there are no sharp bends in any of the joints. (3) Use a shop towel to cover the transmission case not to let foreign material get into it.
Pry bar
AD" TRANSMISSION MOUNT BRACKET REMOVAL Jack up the transmission assembly gently with a garage jack, and then remove the transmission mount bracket.
22-10

MZ203827
AE" ENGINE AND TRANSMISSION ASSEMBLY SUPPORTING Set the special tool to the vehicle to support the engine and transmission assembly.
MB991453
Flywheel
Bolt
AF" TRANSMISSION ASSEMBLY LOWER PART COUPLING BOLTS/TRANSMISSION ASSEMBLY REMOVAL 1. Support the transmission assembly with a transmission jack. 2. Remove the transmission assembly lower part coupling bolts, and lower the transmission assembly to remove. Caution Do not remove the flywheel mounting bolt shown in the illustration. If this bolt is removed, the flywheel will become out of balance and damaged.
Engine side Arrow

"AA TRANSMISSION MOUNT STOPPER INSTALLATION Install the transmission mount stopper so that the arrow points as shown in the illustration.
Transmission mount stopper
Transmission mount bracket
23-1
AUTOMATIC TRANSMISSION
CONTENTS
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 4 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 46
Essential Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 A/T Control Component Location . . . . . . . . . . . . . 51
23109000347
A/T Control Component Check . . . . . . . . . . . . . . . 52 Torque Converter Stall Test . . . . . . . . . . . . . . . . . . 54 Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . . 56 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Line Pressure Adjustment . . . . . . . . . . . . . . . . . . . . 62 Selector Lever Operation Check . . . . . . . . . . . . . . 62
TRANSMISSION CONTROL* . . . . . . . . . . . . . . 63 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . 66
WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICULES 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 driver and passenger (from rendering 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 52B - Supplemental Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors 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 (*).
23-2
Items
AUTOMATIC TRANSMISSION -
Service Specifications/ Lubricants/Special Tools

23100030222
Oil temperature sensor kW at 0_C at 100_C Resistance of damper clutch control solenoid valve coil (at 20_C) W Resistance of Low-Reverse solenoid valve coil (at 20_C) W Resistance of second solenoid valve coil (at 20_C) W Resistance of underdrive solenoid valve coil (at 20_C) W Resistance of overdrive solenoid valve coil (at 20_C) W Stall speed r/min 16.5 - 20.5 0.57 - 0.69 2.7 - 3.4 2.7 - 3.4 2.7 - 3.4 2.7 - 3.4 2.7 - 3.4 2,100 - 2,600
Standard value
LUBRICANTS
Items Transmission fluid Specified lubricant DIA QUEEN ATF SPII or equivalent Quantity L 7.8
23100040034
SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub assembly Use Checking of the diagnosis code
23100060214
MD998330 (including MD998331)
Oil pressure gauge (2,942 kPa)
Measurement of oil pressure
MD998332
Adapter
MD998900
Adapter
AUTOMATIC TRANSMISSION - Special Tools

Tool Number MB990635 or MB991113 Name Steering linkage puller Use Ball joint disconnection
23-3
MB991610
Oil filter wrench
Removal and installation of automatic transmission oil filter
Engine lifter
MB991453
23-4
AUTOMATIC TRANSMISSION - Troubleshooting

23100760275
TROUBLESHOOTING
Gathering information from customer.
Check trouble symptoms. Communication with MUT-II not possible
Read the diagnosis code (GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) Diagnosis code displayed Erase the diagnosis code (GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)
Inspection procedure No. 1 in Inspection Chart For Trouble Symptoms (Refer to P.23-27.)
No diagnosis code displayed
Carry out the essential service (Refer to P.23-46.) Abnormality exists (no diagnosis code) No abnormality Recheck diagnosis codes which were read before the road test. Diagnosis code displayed To INSPECTION CHART DIAGNOSIS CODES (Refer to P.23-14.) FOR To INSPECTION CHART TROUBLE SYMPTOMS (Refer to P.23-26.) No diagnosis code displayed FOR
Road test (Refer to P.23-6.) Abnormality exists (diagnosis code present)
Search for cause. Found Repair NG Not found INTERMITTENT MALFUNCTION (GROUP 00 - Points to Note for Intermittent Malfunctions.) OK Completed
NG
Confirmation test (road test)
OK
AUTOMATIC TRANSMISSION - Troubleshooting DIAGNOSIS FUNCTION

1. N range lamp The N range lamp flashes at a frequency 1 Hz if there is an abnormality in any of table below which are related to the A/T the diagnosis code output if the N range at a frequency of approximately 1 Hz. N range lamp flashing items
Crank angle sensor Input shaft speed sensor Output shaft speed sensor Each solenoid valve Out of phase at each shift point
23-5
23100770186
of approximately the items in the system. Check lamp is flashing
Caution If the N range lamp is flashing at a frequency of approximately 2 Hz (faster than at 1 Hz), it means that the automatic transmission fluid temperature is too high. Stop the vehicle in a safe place and wait until the N range lamp switches off. 2. Method of reading the diagnosis code Use the MUT-II or the N range lamp to take a reading of the diagnosis codes. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)
23-6
ROAD TEST

23100780271
Check by the following procedure.

No. State prior to test and operation Ignition switch: OFF Ignition switch: ON Engine: Stopped Selector lever position: P Test and operation Judgement value Check item Diagnosis code No. 54 Inspection procedure page if there is an abnormality A/T Control relay system (23-25) Inhibitor switch system (23-36)
Ignition switch (1) ON Selector lever position (1) P, (2) R, (3) N, (4) D, (5) 3, (6) 2, (7) L
Data list No. 54 Battery voltage [V] Data list No. 61 (1) P, (2) R, (3)N, (4) D, (5) 3, (6) 2, (7) L
Control relay
Inhibitor switch
Data list No. 11 Accelerator pedal (1) 400 - 1,000 mV (1) Released (2) Half depressed (2) Gradually rises from (1) (3) Depressed (3) 4,500 - 5,000 mV
Throttle position sensor <Vehicles without TCL> Accelerator pedal position sensor <Vehicles with TCL> Wide open throttle switch Stop lamp switch Starting possible or impossible Oil temperature sensor
11 12 14
Throttle position sensor system (23-15) Accelerator pedal position sensor system (23-15)
Data list No. 25 (1) OFF (2) ON Brake pedal (1) Depressed (2) Released 3 Ignition switch: ST Engine: Stopped Warming up Starting test with lever P or N range Drive for 15 minutes or more so that the automatic fluid temperature becomes 70 90_C. Data list No. 26 (1) ON (2) OFF Starting should be possible Data list No. 15 Gradually rises to 70 - 90_C
25
Wide open throttle switch system (23-17) Stop lamp switch system (23-18) Starting impossible (23-28) Oil temperature sensor system (23-15)
26
15

No. State prior to test and operation Test and operation Judgement value Check item Diagnosis code No. 26
23-7
Inspection procedure page if there is an abnormality Stop lamp switch system (23-18)
Engine: Idling Selector lever position: N
Brake pedal (Retest) (1) Depressed (2) Released A/C switch (1) ON (2) OFF
Data list No. 26 (1) ON (2) OFF Data list No. 65 (1) ON (2) OFF
Stop lamp switch
Dual pressure switch Idle position switch
Dual pressure switch system (23-37) Idle position switch system (23-37) Crank angle sensor system (23-16) Serial communication system (23-25)
Data list No. 64 Accelerator pedal (1) ON (1) Released (2) Half depressed (2) OFF
Data list No. 21 Crank angle (1) 550 - 850 rpm sensor Gradually rises from (1) Data list No. 57 (2) Data changes Communication with engineECU <Vehicles without TCL> Communication with TCL-ECU <Vehicles with TCL> Malfunction when starting
21
51
Selector lever position (1) N D (2) N R
Should be no abnormal shifting shocks Time lag should be within 2 seconds
Engine stalling during shifting (23-30) Shocks when changing from N to D and large time lag (23-30) Shocks when changing from N to R and large time lag (23-31) Shocks when changing from N to D,N to R and large time lag (23-32) Does not move forward (23-28) Does not reverse (23-29) Does not move (forward or reverse) (23-29)
Driving impossible
23-8
No.

State prior to test and operation Test and operation Judgement value Check item Diagnosis code No. Inspection procedure page if there is an abnormality -
Selector lever position: N (Carry out on a flat and straight road.)
Selector lever position and vehicle speed (1) Idling in L range (Vehicle stopped) (2) Driving at constant speed of 10 km/h in L position (3) Driving at constant speed of 30 km/h in 2 position (4) Driving at 50 km/h in 3 position with accelerator fully closed (5) Driving at constant speed of 50 km/h in D position (Each condition should be maintained for 10 seconds or more.) Selector lever position and vehicle speed (1) Release the accelerator pedal fully while driving at 50 km/h in 3rd gear. (2) Driving at constant speed of 50 km/h in 3rd gear.
Data list No. 63 (2) 1st, (4) 3rd, (3) 2nd, (5) 4th Data list No. 31 (2) 0 %, (4) 100 %, (3) 100 %, (5) 100 % Data list No. 32 (2) 0 %, (4) 0 %, (3) 0 %, (5) 100 % Data list No. 33 (2)100 %, (4) 100 %, (3) 0 %, (5) 0 % Data list No. 34 (2) 100 %, (4) 0 %, (3) 100 %, (5) 0 % Data list No. 29 (1) 0 km/h (4) 50 km/h
Shift condition
Low and reverse 31 solenoid valve
Low and reverse solenoid valve system (23-18) Underdrive solenoid valve system (23-18) Second solenoid valve system (23-18) Overdrive solenoid valve system (23-18) Vehicle speed sensor system (23-38) Input shaft speed sensor system (23-16) Output shaft speed sensor system (23-17) Damper clutch control solenoid valve system (23-19)
Underdrive solenoid valve Second solenoid valve Overdrive solenoid valve
32
33
34
Data list No. 22 Input shaft (4) 1,800 - 2,100 speed sensor rpm Data list No. 23 Output shaft (4) 1,800 - 2,100 speed sensor rpm Data list No. 36 Damper clutch control solenoid (1) 0 % (2) Approx. 70 - 90 valve % Data list No. 52 (1) Approx. 100 - 300 rpm (2) Approx. 0 - 10 rpm
22
23
Selector lever position: 3 (Carry out on a flat and straight road.)
36 52

No. State prior to test and operation Test and operation Judgement value Check item Diagnosis code No. -
23-9
Inspection procedure page if there is an abnormality Shocks and running up (23-32) All points (23-33) Some points (23-34) No diagnosis code (23-34) Input shaft speed sensor system (23-16) Output shaft speed sensor system (23-17) Low and reverse solenoid valve system (23-18) Second solenoid valve system (23-18) 1st gear ratio is not specified (23-20) 2nd gear ratio is not specified (23-21) Second solenoid valve system (23-18) Overdrive solenoid valve system (23-18) 2nd gear ratio is not specified (23-21) 3rd gear ratio is not specified (23-22) Underdrive solenoid valve system (23-18) Second solenoid valve system (23-18) 3rd gear ratio is not specified (23-22) 4th gear ratio is not specified (23-23)
Use the MUT-II to stop the INVECSII function. Selector lever position: D (Carry out on a flat and straight road.)
Monitor data list No. 11, 23, and 63 with the MUT-II. (1) Accelerate to 4th gear at a throttle position sensor output of 1.5V (accelerator opening angle of 30 %). (2) Gently decelerate to a standstill. (3) Accelerate to 4th gear at a throttle position sensor output of 2.5 V (accelerator opening angle of 50%). (4) While driving at 60 km/h in 4th gear, shift down to 3 range. (5) While driving at 40 km/h in 3rd gear, shift down to 2 range. (6) While driving at 20 km/h in 2nd gear, shift down to L range.
For (1), (2) and (3), the reading should be the same as the specified output shaft speed and no abnormal shocks should occur. For (4), (5) and (6), downshifting should occur immediately after the shifting operation is made.
Malfunction when shifting Displaced shifting points Does not shift
22
23
Does not shift from 1 to 2 or 2 to 1
31
33
41
42
33
34
42
43
32
33
43
44
23-10
No.

Test and operation Judgement value Check item Diagnosis code No. 22 Inspection procedure page if there is an abnormality Input shaft speed sensor system (23-16) Output shaft speed sensor system (23-17) Reverse gear ratio is not specified (23-24)
State prior to test and operation
Selector lever position: N (Carry out on a flat and straight road.)
Monitor data list No. 22 and No. 23 with the MUT-II. II (1) Move selector lever to R range, drive at constant speed of 10 km/h.
The ratio between data list No. 22 and No. 23 should be the same as the gear ratio when reversing.
Does not shift
23
46
SHIFT PATTERN
<4G63 engine> UPSHIFT PATTERN
Throttle opening % 100 1 2 2 3 3 4
Thick line: Standard shift pattern
50 23 movement range 34 movement range 4,000 5,000 6,000 7,000
1,000
2,000
3,000
Output shaft speed r/min 0 50 100 Vehicle speed km/h 150 200

DOWNSHIFT PATTERN
23-11
Throttle opening % 100 1 2 2 3 3
Thick line: Standard shift pattern 4
1 50 23 movement range 0
2 (L)
3 (L,2)
4 (L,2,3)
34 movement range
0 0
1,000
2,000 50
3,000 4,000 5,000 Output shaft speed r/min 100 Vehicle speed km/h 150
6,000
7,000 200
HOLD MODE PATTERN
Throttle opening % 100 2 3
Thick line: Standard shift pattern 3 4
3 50 1 2
2,000
4,000 Output shaft speed r/min 100 Vehicle speed km/h 150
6,000
8,000
50
200
23-12
<6A13 engine> UPSHIFT PATTERN
Throttle opening % 100 1 2 2 3
50
23 movement range
34 movement range 5,000 6,000 7,000
1,000
2,000
3,000 4,000 Output shaft speed r/min 100 Vehicle speed km/h
50
150
200
DOWNSHIFT PATTERN
Throttle opening % 100 1 2 2 3 3
Thick line: Standard shift pattern 4
1 50 23 movement range
2 (L)
3 (L,2)
4 (L,2,3)
34 movement range
1,000
2,000
3,000 4,000 Output shaft speed r/min 100 Vehicle speed km/h
5,000
6,000
7,000
50
150
200

HOLD MODE PATTERN
23-13
Throttle opening % 100 2 3
3 50 1 2
2,000
4,000 Output shaft speed r/min 100 Vehicle speed km/h 150
6,000
8,000
50
200
23-14
Code 11 12 14 15 21 22 23 25 26 31 32 33 34 36 41 42 43 44 46 51 52 54 56 71

23100790243
INSPECTION CHART FOR DIAGNOSIS CODE

Diagnosis item Throttle position sensor system <Vehicles without TCL> Accelerator pedal position sensor system <Vehicles with TCL> Oil temperature sensor system Crank angle sensor system Input shaft speed sensor system Output shaft speed sensor system Wide open throttle switch system Stop lamp switch system Low and reverse solenoid valve system Underdrive solenoid valve system Second solenoid valve system Overdrive solenoid valve system Damper control clutch solenoid valve system 1st gear ratio does not meet the specification 2st gear ratio does not meet the specification 3rd gear ratio does not meet the specification 4th gear ratio does not meet the specification Reverse gear ratio does not meet the specification Abnormal communication with engine-ECU <Vehicles without TCL> Abnormal communication with TCL-ECU <Vehicles with TCL> Damper control clutch solenoid valve system A/T Control relay system N range lamp system Malfunction of A/T-ECU Defective system Short circuit to earth/ open circuit Short circuit to earth Short circuit Open circuit Sensor maladjustment Open circuit Open circuit Short circuit/open circuit Short circuit/open circuit Short circuit Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit Short circuit/open circuit 23-15 23-15 23-15 23-15 23-16 23-16 23-17 23-17 23-18 23-18 23-18 23-18 23-18 23-19 23-20 23-21 23-22 23-23 23-24 23-25 23-19 23-25 23-26 23-26
Reference page
AUTOMATIC TRANSMISSION - Troubleshooting INSPECTION PROCEDURES FOR DIAGNOSIS CODES

Code No. 11, 12, 14 Throttle position sensor system <Vehicles without TCL>, accelerator pedal position sensor <Vehicles with TCL>
If the TPS or APS output voltage is 4.8 V or higher when the engine is idling, the output is judged to be too high and diagnosis code No. 11 is output. Code No. 11 is also output if there is a problem with the APS and an APS fail-safe signal is received from the TCL-ECU. If the TPS or APS output voltage is 0.2 V or lower at times other than when the engine is idling, the output is judged to be too low and diagnosis code No. 12 is output. If the TPS or APS output voltage is 0.2 V or lower or if it is 1.2 V or higher when the engine is idling, the TPS or APS adjustment is judged to be incorrect and diagnosis code No. 14 is output. NG
23-15
Probable cause
D D D D
Malfunction of the throttle position sensor <Vehicles without TCL> Malfunction of the accelerator pedal position sensor <Vehicles with TCL> Malfunction of connector Malfunction of the A/T-ECU
Throttle position sensor check <Vehicles without TCL> (Refer to GROUP 13A - On-vehicle Service.) Accelerator pedal position sensor check<Vehicles with TCL> (Refer to GROUP 13H - On-vehicle Service.) OK Check the following connectors: B-07 <Vehicles without TCL>, B-41 <Vehicles with TCL>, C-29 OK Harness check D Between throttle position sensor and A/T-ECU <Vehicles without TCL> D Between accelerator pedal position sensor and A/T-ECU <Vehicles with TCL> OK Check the trouble symptoms.
Replace
NG
Repair
NG
Repair
NG
Code No. 15 Oil temperature sensor system

If the oil temperature sensor output voltage is 2.6 V or more even after driving for 10 minutes or more (if the oil temperature does not increase), it is judged that there is an open circuit in the oil temperature sensor and diagnosis code No. 15 is output. NG
Probale cause
D D D Malfunction of the oil temperature sensor Malfunction of connector Malfunction of the A/T-ECU
Oil temperature sensor check (Refer to P.23-52.) OK Check the follwing connectors: B-70, C-29 OK Harness check D Between oil temperature sensor and A/T-ECU OK Check the trouble symptoms.
Replace
NG
Repair
NG
Repair
NG
23-16

Probable cause
D D D Malfunction of the crank angle sensor Malfunction of connector Malfunction of the A/T-ECU

If no output pulse is detected from the crank angle sensor for 5 seconds or more while driving at 25 km/h or more, it is judged that there is an open circuit in the crank angle sensor and diagnosis code No. 21 is output. NG
Check the follwing connectors: B-77, C-29 OK Harness check D Between crank angle sensor and A/T-ECU OK Crank angle sensor system check (Refer to GROUP 13A - Troubleshooting.) OK Check the trouble symptoms.
Repair
NG
Repair
NG
Code No. 22 Input shaft speed sensor system

If no output pulse is detected from the input shaft speed sensor for 1 second or more while driving in 3rd or 4th gear at a speed of 30 km/h or more, there is judged to be an open circuit or short-circuit in the input shaft speed sensor and diagnosis code No. 22 is output. If diagnosis code No. 22 is output four times, the transmission is locked into 3rd gear (D range) or 2nd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the input shaft speed sensor the underdrive clutch retainer connector A/T-ECU
L: Refer to the Transmission Workshop Manual.

Measure at the input shaft speed sensor connector B-71. D Disconnect the connector and measure at the harness side. (1) Voltage between 3 and earth (Ignition switch: ON) OK: Battery voltage (2) Voltage between 2 and earth (Ignition switch: ON) OK approx. 5 V (3) Continuity between 1 and earth OK: Continuity OK Measure output waveform of the input shaft speed sensor. (using an oscilloscope) D Engine: 2,000 r/min (approx. 50 km/h) D Transmission: 3rd gear (Voltage) OK: Conforms to the waveform shown at page 23-45 (Inspection procedure using an oscilloscope). There is no noise in the output waveform. OK Check the trouble symptoms. NG NG Check the following connectors: B-71, C-29 OK Check the following harness: D Between the input shaft speed sensor and the ignition switch D Between the input shaft speed sensor and A/T-ECU OK Check the trouble symptoms. Replace the input shaft speed sensor. NG A/T overhaul K D Replace the retainer. NG Repair
NG
Repair
NG
Check the trouble symptoms.
underdrive
clutch
Check the trouble symptoms. NG NG Replace the A/T-ECU. Eliminate the cause of the noise.

Code No. 23 Output shaft speed sensor system
If the output from the output shaft speed sensor is continuously 50% lower than the vehicle speed for 1 second or more while driving in 3rd or 4th gear at a speed of 30 km/h or more, there is judged to be an open circuit or short-circuit in the output shaft speed sensor and diagnosis code No. 23 is output. If diagnosis code No. 23 is output four times, the transmission is locked into 3rd gear (D range) or 2nd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.
23-17
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the output shaft speed sensor the transfer drive gear or driven gear connector the A/T-ECU

Measure at the output shaft speed sensor connector B-68. D Disconnect the connector and measure at the harness side. (1) Voltage between 3 and earth (Ignition switch: ON) OK: Battery voltage (2) Voltage between 2 and earth (Ignition switch: ON) OK: approx. 5 V (3) Continuity between 1 and earth OK: Continuity OK Measure output waveform of the output shaft speed sensor. (using an oscilloscope) D Engine: 2,000 r/min (approx. 50 km/h) D Transmission: 3rd gear (Voltage) OK: Conforms to the waveform shown at page 23-45 (Inspection procedure using an oscilloscope). There is no noise in the output waveform. OK Check the trouble symptoms. NG NG Check the following connectors: B-68, C-29 OK Check the following harness: D Between the output shaft speed sensor and the ignition switch D Between the output shaft speed sensor and A/T-ECU OK Check the trouble symptoms. Replace the output shaft speed sensor. Check the trouble symptoms. NG A/T overhaul L D Replace the transfer drive gear and driven gear. Check the trouble symptoms. NG Eliminate the cause of the noise. NG Replace the A/T-ECU. NG Repair
NG
Repair
NG
Code No. 25 Wide open throttle switch system

If the wide open throttle switch is on for 1 second or more with the throttle valve opening angle at 70% or less, it is judged that there is a short circuit in the wide open throttle switch and diagnosis code No. 25 is output.
Probable cause
D D D Malfunction of the wide open throttle switch Malfunction of connector Malfunction of A/T-ECU
Wide open throttle switch check (Refer to P.23-64). OK Check the following connectors: C-18, C-30, C-83 OK Harness check D Between the wide open throttle switch and the A/T-ECU. OK Check the trouble symptoms.
NG
Replace
NG NG
Repair
Repair
NG
23-18

Probable cause
D D D Malfunction of the stop lamp switch Malfunction of connector Malfunction of the A/T-ECU
Code No. 26 Stop lamp switch system

If the stop lamp switch is on for 5 minutes or more while driving, it is judged that there is a short circuit in the stop lamp switch and diagnosis code No. 26 is output.
Stop lamp switch check (Refer to GROUP 35 - Brake Pedal.) OK Check the following connectors: C-02, C-30, C-65, C-83 OK Harness check D Between stop lamp switch and A/T-ECU OK Check the trouble symptoms.
NG
Replace
NG
Repair
NG
Repair
NG
Code No. 31 Low and reverse solenoid valve system Code No. 32 Underdrive solenoid valve system Code No. 33 Second solenoid valve system Code No. 34 Overdrive solenoid valve system
If the resistance value for a solenoid valve is too large or too small, it is judged that there is a short-circuit or an open circuit in the solenoid valve and the respective diagnosis code is output. The transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz. NG
Probable cause
D D D
Malfunction of solenoid valve Malfunction of connector Malfunction of the A/T-ECU
Solenoid valve check (Refer to P.23-54.) OK Check the following connectors: B-70, C-28, C-30, C-41 OK Harness check D Between solenoid valve and A/T-ECU OK Replace the solenoid valve.
Replace
NG
Repair
NG
Repair
Check the trouble symptoms.
NG

Code No. 36, 52 Damper clutch control solenoid valve system
If the resistance value for the damper clutch control solenoid valve is too large or too small, it is judged that there is a short-circuit or an open circuit in the damper clutch control solenoid valve and diagnosis code No. 36 is output. If the drive duty rate for the damper clutch control solenoid valve is 100 % for a continuous period of 4 seconds or more, it is judged that there is an abnormality in the damper clutch control system and diagnosis code No. 52 is output. When diagnosis code No. 36 is output, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz. NG
23-19
Probable cause
D D D Malfunction of the damper clutch control solenoid valve Malfunction of connector Malfunction of the A/T-ECU
Damper clutch control solenoid valve check (Refer to P.23-54.) OK Check the following connectors: B-70, C-28, C-41 OK Harness check D Between damper clutch control solenoid valve and A/T-ECU OK Replace the damper clutch control solenoid valve. Check the trouble symptoms.
Replace
NG
Repair
NG
Repair
NG
23-20

Probable cause
D D D D D D D Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear low and reverse brake system underdrive clutch system
Code No. 41 1st gear ratio does not meet the specification
If the output from the output shaft speed sensor multiplied by the 1st gear ratio is not the same as the output from the input shaft speed sensor after shifting to 1st gear has been completed, diagnosis code No. 41 is output. If diagnosis code No. 41 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

MUT-II Self-Diag code Is the diagnosis code No. 22 output? No MUT-II Self-Diag code Is the diagnosis code No. 23 output? No Measure output waveform from the input shaft speed sensor. (using an oscilloscope) D Connect the connector B-71 and measure voltage between 31 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-45 (Inspection Procedure Using an Oscilloscope) is output (flalshing between 0 5V) and there is no noise appearing in the waveform. OK Yes Code No. 22 Input shaft speed sensor system check (Refer to P.23-16.) Code No. 23 Output shaft speed sensor system check (Refer to P.23-17.) Replace the input shaft speed sensor.
Yes
NG
Check the trouble symptoms. NG A/T overhaul L D Replace the underdrive clutch retainer. Check the trouble symptoms. NG Eliminate the cause of the noise.
Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector B-68 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-45 (Inspection Procedure Using an Oscilloscope) is output (flalshing between 0 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Underdrive clutch system check (No. 42, No. 43, or no diagnosis code is output). D Low and reverse brake system check (No. 46 or no diagnosis code is output).
NG
Replace the output shaft speed sensor.
Check the trouble symptoms. NG A/T overhaul L D Replace the transfer drive gear and driven gear. Check the trouble symptoms. NG Eliminate the cause of the noise.

Code No. 42 2nd gear ratio does not meet the specification
If the output from the output shaft speed sensor multiplied by the 2nd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 2nd gear has been completed, diagnosis code No. 42 is output. If diagnosis code No. 42 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.
23-21
Probable cause
D D D D D D D Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear second brake system underdrive clutch system

Yes
NG
Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector B-68 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-45 (Inspection Procedure Using an Oscilloscope) is output (flalshing between 0 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Underdrive clutch system check (No. 41, No. 43, or no diagnosis code is output). D Second brake system check (No. 44 or no diagnosis code is output).
NG
23-22

Probable cause
D D D D D D D Malfunction of the Malfunction of the Malfunction of the Malfunciton of the Malfunction of the Malfunction of the Noise generated input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear underdrive clutch system overdrive clutch system
Code No. 43 3rd gear ratio does not meet the specification
If the output from the output shaft speed sensor multiplied by the 3rd gear ratio is not the same as the output from the input shaft speed sensor after shifting to 3rd gear has been completed, diagnosis code No. 43 is output. If diagnosis code No. 43 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

Yes
NG
Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector B-68 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-45 (Inspection Procedure Using an Oscilloscope) is output (flalshing between 0 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Underdrive clutch system check (No. 41, No. 42, or no diagnosis code is output). D Overdrive clutch system check (No. 44 or no diagnosis code is output).
NG

Code No. 44 4th gear ratio does not meet the specification
If the output from the output shaft speed sensor multiplied by the 4th gear ratio is not the same as the output from the input shaft speed sensor after shifting to 4th gear has been completed, diagnosis code No. 44 is output. If diagnosis code No. 44 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.
23-23
Probable cause
D D D D D D D Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Malfunction of the Noise generated input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear second brake system overdrive clutch system

MUT-II Self-Diag code Is the diagnosis code No. 22 output? No MUT-II Self-Diag code Is the diagnosis code No. 23 output? No Measure output waveform from the input shaft speed sensor. (using an oscilloscope) D Connect the connector B-71 and measure voltage between 31 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-45 (Inspection Procedure Using an Oscilloscope) is output (flashing between 0 5V) and there is no noise appearing in the waveform. OK Yes Code No. 22 Input shaft speed sensor system check (Refer to P.23-16.) Code No. 23 Output shaft speed sensor system check (Refer to P.23-17.) Replace the input shaft speed sensor.
Yes
NG
Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector B-68 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-45 (Inspection Procedure Using an Oscilloscope) is output (flalshing between 0 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Second brake system check (No. 42 or no diagnosis code is output). D Overdrive clutch system check (No. 43 or no diagnosis code is output).
NG
23-24

does not meet the Probable cause
D D D D D D D Malfunction of the Malfunction of the Malfunction of the Malfunciton of the Malfunction of the Malfunction of the Noise generated input shaft speed sensor output shaft speed sensor underdrive clutch retainer transfer drive gear or driven gear low and reverse brake system reverse clutch system
Code No. 46 Reverse gear ratio specification
If the output from the output shaft speed sensor multiplied by the reverse gear ratio is not the same as the output from the input shaft speed sensor after shifting to reverse gear has been completed, diagnosis code No. 46 is output. If diagnosis code No. 46 is output four times, the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz.

Yes
NG
Measure output waveform from the output shaft speed sensor. (using an oscilloscope) D Connect the connector B-68 and measure voltage between 32 and 43 at the A/T-ECU. D Engine: 2,000 r/min (approx. 50 km/h) D Selector lever position: 3 (Voltage) OK: A waveform such as the one shown on P.23-45 (Inspection Procedure Using an Oscilloscope) is output (flalshing between 0 5V) and there is no noise appearing in the waveform. OK A/T overhaul L D Low and reverse brake system check (No. 41 or no diagnosis code is output). D Reverse clutch system check (No diagnosis code is output).
NG

Code No. 51 Abnormal communication with engine-ECU <Vehicles without TCL> Abnormal communication with TCL-ECU <Vehicles with TCL>
If normal communication is not possible for a continuous period of 1 second or more when the ignition switch is at the ON position, the battery voltage is 10 V or more and the engine speed is 450 r/min or more, diagnosis code No. 51 is output. Diagnosis code No. 51 is also output if the data being received is abnormal for a continuous period of 4 seconds under the same conditions. NG
23-25
Probable cause
D D D D
Malfunction of connector Malfunction of the engine-ECU <Vehicles without TCL> Malfunction of the TCL-ECU <Vehicles with TCL> Malfunction of the A/T-ECU
Check the following connectors: D C-30, C-34, C-38 <4G6-vehicles without TCL> D C-30, C-37 <6A1-vehicles without TCL> D C-10, C-30, C-51 <Vehicles with TCL> OK Harness check D Between engine-ECU and A/T-ECU <Vehicles without TCL> D Between TCL-ECU and A/T-ECU <Vehicles with TCL> OK Check the trouble symptoms. NG Replace the engine-ECU. <Vehicles without TCL> Replace the TCL-ECU. <Vehicles with TCL> Check the trouble symptoms.
Repair
NG
Repair
NG
Code No. 54 A/T control relay system

If the A/T control relay voltage is less than 7 V after the ignition switch has been turned ON, it is judged that there is an open circuit or a short-circuit in the A/T control relay earth and diagnosis code No. 54 is output. Then the transmission is locked into 3rd gear as a fail-safe measure, and the N range lamp flashes at a frequency of 1 Hz. NG
Probable cause
D D D Malfunction of the A/T control relay Malfunction of connector Malfunction of the A/T-ECU
Check the A/T control relay. (Refer to P.23-53.) OK Check the following connectors: B-30, C-28, C-30, C-41, C-45 OK Harness check D Between control relay and body earth D Between control relay and battery D Between control relay and A/T-ECU OK Check the trouble symptoms.
Replace
NG
Repair
NG
Repair
NG
23-26

Probable cause
D D D Malfunction of the N range lamp bulb Malfunction of connector Malfunction of the A/T-ECU
Code No. 56 N range lamp system

If the N range signal is off after an N range lamp illumination instruction (ON instruction) has been given, it is judged that there is a short-circuit in the N range lamp earth and diagnosis code No. 56 is output. NG
Check the N range lamp bulb (Refer to GROUP 52A - Instrument Panel.) OK Check the following connectors: C-30, C-90, D-02 OK Harness check D Between N range lamp bulb and A/T-ECU OK Check the trouble symptoms.
Replace
NG
Repair
NG
Repair
NG
Code No. 71 Malfunction of A/T-ECU

There is an abnormality in the A/T-ECU. The transmission is locked into 3rd gear as a fail-safe measure. Replace the A/T-ECU.
Probale cause
D Malfunction of the A/T-ECU

Trouble symptom Communication with MUT-II is not possible Driving impossible Starting impossible Does not move forward Does not reverse Does not move (forward or reverse) Malfunction when starting Engine stalling when shifting Shocks when changing from N to D and large time lag Shocks when changing from N to R and large time lag Shocks when changing from N to D, N to R and large time lag Malfunction when shifting Shocks and running up Inspection procedure No. 1 2 3 4 5 6 7 8 9 10
23100800267
Reference page 23-27 23-28 23-28 23-29 23-29 23-30 23-30 23-31 23-32 23-32

Trouble symptom Displaced shifting points All points Some points Does not shift Malfunction while driving No diagnosis codes Poor acceleration Vibration Inhibitor switch system Mode control switch system Idle position switch system Dual pressure switch system Vehicle speed sensor system Auto-cruse-ECU signal system Inspection procedure No. 11 12 13 14 15 16 17 18 19 20 21
23-27
Reference page 23-33 23-34 23-34 23-35 23-35 23-36 23-36 23-37 23-37 23-38 23-38

INSPECTION PROCEDURE 1 Communication with MUT-II is not possible
If communication with the MUT-II is not possible, the cause is probably a defective diagnosis line or the A/T-ECU is not functioning.
Probable cause
D D D Malfunction of diagnosis line Malfunction of connector Malfunction of the A/T-ECU
Is communication with other systems possible using the MUT-II? Yes Check the continuity and voltage of the A/T-ECU connector. D Disconnect the connector C-28 and check at harness side. D Voltage between terminals No. 11, 24 and earth OK: Battery voltage D Voltage between C-28 terminals Nos.12, 13, 25, 26, C-30 terminal No. 72 and earth OK: Continuity OK Check the following connectors: C-20, C-28, C-30, C-49, C-66, C-83 OK Harness check D Between diagnosis connector and A/T-ECU OK Check the trouble symptoms.
No
Check the diagnosis line with MUT-II, and repair if necessary. NG
NG
Check the following connectors: C-28, C-30, C-45, C-83, C-131, C-134 OK Harness check power supply and D Between A/T-ECU D Between earth and A/T-ECU OK Check the trouble symptoms. NG Repair Repalce the A/T-ECU.
Repair
NG
Repair
NG
NG
Repair
NG
23-28
Starting impossible

D D D Malfunction of the engine system Malfunction of the torque converter Malfunction of the oil pump Starting is not possible when the selector lever is in P or N range.In such cases, the cause is probably a defective engine system, torque converter or oil pump.

Check the engine system. D Control system, ignition system, fuel system, main engine system OK Torque converter check D Check for incorrect installation (inserted at an angle, etc.) and for damaged splines. OK Repalce the oil pump assembly. L (The oil pump cannot be disassembled.) NG Repair, replace
NG
Repair if possible. If the splines are damaged and repairs are not possible, replace the torque converter assembly.
INSPECTION PROCEDURE 3 Does not move (forward)

If the vehicle does not move forward when the selector lever is shifted from N to D, 3, 2 or L range while the engine is idling, the cause is probably abnormal line pressure or a malfunction of the underdrive clutch or valve body.
Probable cause
D D D D Abnormal line Malfunction of Malfunction of Malfunction of pressure the underdrive solenoid valve the underdrive clutch the valve body

MUT-II Actuator test D No. 2 Underdrive solenoid valve OK: Sound of operation can be heard. OK Hydraulic pressure test (Refer to P.23-56.) D Measure the hydraulic pressure for each element when in L range. Standard value: Refer to P.23-57. OK OK Underdrive clutch system check L D Remove the transmission assembly, valve body cover and valve body. NG D Pistons should operate and pressure should be maintained when air is blown through the underdrive clutch oil hole in the transmission case. NG Replace the solenoid valve. L
NG
Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.
Underdrive clutch check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.

INSPECTION PROCEDURE 4 Does not reverse
If the vehicle does not reverse when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal pressure in the reverse clutch or low and reverse brake or a malfunction of the reverse clutch, low and reverse brake or valve body.
23-29
Probable cause
D D D D D D Abnormal reverse clutch pressure Abnormal low and reverse brake pressure Malfunction of the low and reverse solenoid valve Malfunction of the reverse clutch Malfunction of the low and reverse brake Malfunction of the valve body

MUT-II Actuator test D No. 1 Low and reverse solenoid valve OK: Sound of operation can be heard. OK Hydraulic pressure check (Refer to P.23-56.) D Measure the reverse clutch pressure in R range. Standard value: Refer to P.23-57. OK Hydraulic pressure check (Refer to P.23-56.) D Measure the low and reverse brake pressure in R range. Standard value: Refer to P.23-57. OK Reverse clutch system and low and reverse brake system check OK L D Remove the transmission assembly, valve body cover and valve body. D Pistons should operate and pressure should be maintained NG when air is blown through the reverse clutch oil hole and the low reverse brake oil hole in the transmission case. NG Replace the low and reverse solenoid valve. L
NG
NG
Reverse clutch and low and reverse brake check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.
INSPECTION PROCEDURE 5 Does not move (forward or reverse)

If the vehicle does not move forward or reverse when the selector lever is shifted to any position while the engine is idling, the cause is probably abnormal line pressure, or a malfunction of the power train, oil pump or valve body.
Probable cause
D D D D Abnormal line Malfunction of Malfunction of Malfunction of pressure power train the oil pump the valve body

Hydraulic pressure check (Refer to P.23-56.) D Measure the hydraulic pressure for each element when moving forward and back. Standard value: Refer to P.23-57. NG Replace the oil pump assembly. L (The oil pump cannot be disassembled.) OK Power train check L D Disassemble the transmission, check the condition of the planetary carrier, output shaft and differential, etc.
NG
23-30
INSPECTION PROCEDURE 6 Engine stalling when shifting

If the engine stalls when the selector lever is shifted from N to D or R range while the engine is idling, the cause is probably a malfunction of the engine system, damper clutch solenoid valve, valve body or torque converter (damper clutch malfunction).
Probable cause
D D D D Malfunction of the engine system Malfunction of the damper clutch control solenoid valve Malfunction of the valve body Malfunction of the torque converter (Malfuction of the damper clutch)

Engine system check D Check the control system, ignition system, fuel system and main system. OK Replace the damper clutch control solenoid valve. Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly. NG Repalce the torque converter. NG Repair, replace
INSPECTION PROCEDURE 7 Shocks when changing from N to D and large time lag
If abnormal shocks or a time lag of 2 seconds or more occur when the selector lever is shifted from N to D range while the engine is idling, the cause is probably abnormal underdrive clutch pressure or a malfunction of the underdrive clutch, valve body or idle position switch.
Probable cause
D D D D D Abnormal underdrive clutch pressure Malfunction of the underdrive solenoid valve Malfunction of the underdrive clutch Malfunction of the valve body Malfunction of the idle position switch

MUT-II Actuator test D No. 2 Underdrive solenoid valve OK: Sound of operation can be heard. OK When does the shock occur? When shifting Hydraulic pressure test (Refer to P.23-56.) D Measure the underdrive clutch pressure when shifting from N to D. Standard value: Refer to P.23-57. OK Underdrive clutch system check L D Remove the transmission assembly, valve body cover and valve body. D Pistons should operate and pressure should be maintained when air is blown through the underdrive clutch oil hole in the transmission case. NG Underdrive clutch check L D Check for burning of the facing, defective piston seal rings and interference at the retainer. OK NG NG Replace the underdrive solenoid valve. L
When starting Shocks sometimes occur No Yes
MUT-II Data list D No. 64 Idle position switch OK: Turns from on to off when the accelerator pedal is slightly depressed from the fully closed position. OK NG Idle position switch check D INSPECTION PROCEDURE 18 - Idle position switch system check (Refer to P.23-37.)

INSPECTION PROCEDURE 8 Shocks when changing from N to R and large time lag
If abnormal shocks or a time lag of 2 seconds or more occurs when the selector lever is shifted from N to R range while the engine is idling, the cause is probably abnormal reverse clutch pressure or low and reverse brake pressure, or a malfunction of the reverse clutch, low and reverse brake, valve body or idle position switch.
23-31
Probable cause
D D D D D D D Abnormal reverse clutch pressure Abnormal low and reverse brake pressure Malfunction of the low and reverse solenoid valve Malfunction of the reverse clutch Malfunction of the low and reverse brake Malfunction of the valve body Malfunction of the idle position switch

MUT-II Actuator test D No. 1 Low and reverse solenoid valve OK: Sound of operation can be heard. OK When does the shock occur? When shifting Hydraulic pressure test (Refer to P.23-56.) D Measure the reverse clutch pressure in R range. Standard value: Refer to P.23-57. OK NG NG NG Replace the low and reverse solenoid valve. L
When starting Shocks sometimes occur No Yes
MUT-II Data list D No. 64 Idle position switch OK: Turns from on to off when the accelerator pedal is slightly depressed from the fully closed position. OK NG Idle position switch check D INSPECTION PROCEDURE 18 - Idle position switch system check (Refer to P.23-37.) Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.
Hydraulic pressure test (Refer to P.23-56.) D Measure the low and reverse brake pressure in R range. Standard value: Refer to P.23-57. OK Reverse clutch system and low reverse brake system check L D Remove the transmission assembly, valve body cover and valve body. D Pistons should operate and pressure should be maintained when air is blown through the reverse clutch oil hole and low and reverse brake oil hole in the transmission case. NG Reverse clutch and low reverse brake check L D Check for burning of the facing, defective piston seal rings and interference at the retainer.
OK
23-32
INSPECTION PROCEDURE 9 Shocks when changing from N to D, N to R and large time lag
If abnormal shocks or a time lag of 2 seconds or more occur when the selector lever is shifted from N to D range and from N to R range while the engine is idling, the cause is probably abnormal line pressure or a malfunction of the oil pump or valve body.
Probable cause
D D D Abnormal line pressure Malfunction of the oil pump Malfunction of the valve body

Hydraulic pressure test (Refer to P.23-56.) D Measure the hydraulic pressure for each element when in D range and R range. Standard value: Refer to P.23-57. OK When does the shock occur? When shifting Replace the oil pump assembly. L (The oil pump cannot be disassembled.) NG Adjust the line pressure. (Refer to P.23-62.) NG When starting
INSPECTION PROCEDURE 10 Shocks and running up

If shocks occur when driving due to upshifting or downshifting and the transmission speed becomes higher than the engine speed, the cause is probably abnormal line pressure or a malfunction of a solenoid valve, oil pump, valve body or of a brake or clutch.
Probable cause
D D D D D Abnormal line Malfunction of Malfunction of Malfunction of Malfunction of pressure each solenoid valve the oil pump the valve body each brake or each clutch

MUT-II Actuator test D No. 1 Low and reverse solenoid valve D No. 2 Underdrive solenoid valve D No. 3 Second solenoid valve D No. 4 Overdrive solenoid valve OK: Sound of operation can be heard. OK Adjust the line pressure. (Refer to P.23-62.) OK Clutch and brake check L D Check for burning of the facing, defective piston seal rings and interference at the retainer. NG Replace the solenoid valve.
NG
Replace the oil pump assembly. L (The oil pump cannot be disassembled.) NG Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.

INSPECTION PROCEDURE 11 All points (Displaced shifting points)
If all shift points are displaced while driving, the cause is probably a malfunction of the output shaft speed sensor, TPS or of a solenoid valve.
23-33
Probable cause
D D D D D D Malfunction of Malfunction of Malfunction of Abnormal line Malfunction of Malfunction of the output shaft speed sensor the throttle position sensor each solenoid valve pressure the valve body the A/T-ECU

MUT-II Data list D No. 23 Output shaft speed sensor OK: Increases in proportion to vehicle speed. OK MUT-II Data list D No. 11 TPS/APS OK: Increases in proportion to accelerator pedal opening angle OK MUT-II Data list D No. 31 Low and reverse solenoid valve duty % D No. 32 Underdrive solenoid valve duty % D No. 33 Second solenoid valve duty % D No. 34 Overdrive solenoid valve duty % OK: Refer to the table below. OK Adjust the line pressure. (Refer to P.23-62.) NG Code No. 23 - Output shaft speed sensor system (Refer to P.23-17.)
NG
Code No. 11, 12, 14 TPS/APS system check (Refer to P.23-15.)
NG
Replace the solenoid valve. L NG Repalce the A/T-ECU.
NG
No. 31 Driving at constant speed in 1st gear Driving at constant speed in 2nd gear Driving at constant speed in 3rd gear Driving at constant speed in 4th gear 0% 100 % 100 % 100 %
No. 32 0% 0% 0% 100 %
No. 33 100 % 0% 100 % 0%
No. 34 100 % 100 % 0% 0%
23-34
INSPECTION PROCEDURE 12 Some points (Displaced shifting points)

If some of the shift points are displaced while driving, the cause is probably a malfunction of the valve body, or it is related to control and is not an abnormality.
Probable cause
D Malfunction of the valve body

INVECS-II CANCEL COMMAND D Use the MUT-II to stop the INVECS-II function. Does standard shifting occur normally? Yes No Does the problem occur only when the automatictransmissionfluidtemperature is - 29_C or lower or 125_C or higher? Yes It is related to control and is not an abnormality. No Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.
INSPECTION PROCEDURE 13 No diagnosis codes (Does not shift)

If shifting does not occur while driving and no diagnosis codes are output, the cause is probably a malfunction of the inhibitor switch, or A/T-ECU. No
Probable cause
D D Malfunction of the inhibitor switch Malfunction of the A/T-ECU NG
Does the transmission remain in 3rd gear with selector lever in position D ? Yes Is backup power being supplied to the A/T-ECU? No Yes Is power being supplied to the A/T-ECU? No Power supply circuit check D Pay particular attention to open circuits in the harnesses, poor connector connections and open circuits in fuses. D If there is a blown fuse, investigate why a short-circuit has occurred and then replace the fuse.
MUT-II Data list D No. 61 Inhibitor switch OK: A/T-ECU input signal and selector lever position should match. OK MUT-II Data list D No. 62 Hold mode signal OK: The signal should change when the mode control switch position is changed. OK Replace the A/T-ECU.
Inhibitor switch check D INSPECTION PROCEDURE 16 Inhibitor switch system check. (Refer to P.23-36.)
NG
Yes
Mode control switch check D INSPECTION PROCEDURE 17 Mode control switch system check (Refer to P.23-36.)

If acceleration is poor even if downshifting occurs while driving, the cause is probably a malfunction of the engine system or of a brake or clutch.
23-35
Probable cause
D D Malfunction of the engine system Malfunction of the brake or clutch

Engine system check D Check the control system, ignition system, fuel system and main system. OK Brake or clutch check L D Check for burning of the facing, defective piston seal rings and interference at the retainer. NG Replace, repair
INSPECTION PROCEDURE 15 Vibration

If vibration occurs when driving at constant speed or when accelerating and deceleration in top range, the cause is probably abnormal damper clutch pressure or a malfunction of the engine system, damper clutch control solenoid valve, torque converter or valve body.
Probable cause
D D D D D Abnormal damper clutch pressure Malfunction of the engine system Malfunction of the damper clutch control solenoid valve Malfunction of the torque converter Malfunction of the valve body

MUT-II Actuator test D No. 6 Damper clutch control solenoid valve OK: Sound of operation can be heard. OK Does the problem occur even when the oil temperature sensor connector is disconnected? No Hydraulic pressure test (Refer to P.23-56.) D Measure the damper clutch pressure. Standard value: Refer to P.23-57. OK Replace the torque converter assembly. NG NG Replace the damper clutch control solenoid valve. L
Yes
Engine system check D Check the control system, ignition system, fuel system and main system. Valve body disassembly, cleaning and reassembly L D Pay particular attention to loosening of bolts, and to damage and slippage of O-rings, valves and valve bodies. D If the damage cannot be repaired, replace the valve body assembly.
23-36
INSPECTION PROCEDURE 16 Inhibitor switch system

The cause is probably a malfunction of the inhibitor switch circuit, ignition switch circuit or a defective A/T-ECU.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the inhibitor switch the ignition switch connector the A/T-ECU
Inhibitor switch check (Refer to P.23-49.) OK Check the voltage of the inhibitor switch connector B-72. D Disconnect the connector and measure at the harness side. D Voltage between terminal No. 8 and earth OK: Battery voltage OK Check the following connectors: B-72, C-30, C-47, C-48 OK Harness check D Between inhibitor A/T-ECU connector OK Check the trouble symptoms. switch and
NG NG
Replace NG
Check the following connectors: C-49, C-83, C-131, C-134 OK Harness check D Between inhibitor switch and ignition switch
Repair
NG
Repair
NG
OK Repair Check the trouble symptoms. NG Ignition switch check (Refer to GROUP54 - Ignition Switch.)
NG
Repair
NG
Repalce the A/T-ECU.
INSPECTION PROCEDURE 17 Mode control switch system

The cause is probably a defective mode control switch circuit or a defective A/T-ECU.
Probable cause
D D D Malfunction of the mode control switch Malfunction of connector Malfunction of the A/T-ECU
Mode control switch check (Refer to P.23A-65.) OK Check the voltage of the A/T-ECU connector C-30. D Disconnect the connector and check at the harness side. D Ignition switch: ON D Select the HOLD mode. D Voltage between terminal No. 70 and earth OK: Battery voltage OK
NG
Replace
NG
Check the following connectors: C-49, C-83, C-89, C-131, C-134 OK Harness check. D Between mode control switch and A/T-ECU OK Harness check D Between mode control switch and ignition switch OK Check the trouble symptoms. NG
NG
Repair
NG
Repair
NG
Repair
Check the following the connector: C-30 OK Check the trouble symptoms. NG
Ignition switch check (Refer to GROUP 54 - Ignition Switch.) Replace the A/T-ECU.

INSPECTION PROCEDURE 18 Idle position switch system
The cause is probably a defective idle position switch circuit or a defective A/T-ECU.
23-37
Probable cause
D D D Malfunction of the idle position switch Malfunction of connector Malfunction of the A/T-ECU
Idle position switch check (Refer to GROUP 13A - On-vehicle Service.) OK Check the following connectors: B-07 <Vehicles without TCL>, B-41 <Vehicles with TCL>, C-29 OK Harness check D Between idle position switch and A/T-ECU OK Check the trouble symptoms.
NG
Replace the throttle position sensor.
NG
Repair
NG
Repair
NG
INSPECTION PROCEDURE 19 Dual pressure switch system

The cause is probably a defective dual pressure switch circuit or a defective A/T-ECU.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the dual pressure switch connector A/C system the A/T-ECU
Dual pressure switch check (Refer to GROUP 55 - On-vehicle service.) OK Check the voltage of the A/T-ECU connector C-28. D Disconnect the connector and check at the harness side. D Ignition switch: ON D A/C switch: ON D Voltage between terminal No. 10 and earth OK: Battery voltage NG A/C system check (Refer to GROUP 55 - Troubleshooting.)
NG
Replace
OK
Check the following connectors: B-30, C-28 OK Check the trouble symptoms. NG Check the A/C system. (Refer to GROUP 55 - Troubleshooting.) OK Replace the A/T-ECU.
NG
Repair
NG
Repair
23-38
INSPECTION PROCEDURE 20 Vehicle speed sensor system

The cause is probably a defective vehicle speed sensor circuit or a defective A/T-ECU.
Probable cause
D D D Malfunction of the vehicle speed sensor Malfunction of connector Malfunction of the A/T-ECU
Check the vehicle speed sensor. (Refer to GROUP 54 - Combination Meters.) OK
NG
Replace
1. NG Measure at the vehicle speed sensor connector B-67. D Disconnect the connector, and measure at the harness side. 2. NG 1. Voltage between 1 and earth (Ignition switch: ON) OK: Battery voltage 2. Voltage between 3 and earth (Ignition switch: ON) 3. NG OK: 4.8 - 5.2 V 3. Continuity between 2 and earth OK: Continuity OK Check the connector: B-67 following NG Repair
Check the following connectors: C-90, C-131, C-135 OK Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and ignition switch connector. OK
NG
Repair
NG
Repair
OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the vehicle speed sensor connector. OK Replace the engine-ECU. NG
Check the ignition switch. (Refer to GROUP 54 - Ignition switch.) NG
Repair
Check the connectors: C-30, C-48
following
Repair
OK Check trouble symptom. NG Check the harness wire between the engine-ECU and the vehicle speed sensor connector. OK Replace the engine-ECU. Check the harness wire between the vehicle speed sensor and the earth, and repair if necessary. NG
Repair
INSPECTION PROCEDURE 21 Auto-cruise-ECU signal system

The cause is probably a defective auto-cruise signal line circuit or a defective A/T-ECU.
Probable cause
D D D Malfunction of connector Malfunction of the A/T-ECU Malfunction of the auto-cruise-ECU
Auto-cruise system check (Refer to GROUP 17 - Troubleshooting.) OK Check the following connectors: C-28, C-82, C-83 OK Harness check D Between auto-cruise-ECU and A/T-ECU NG Repair
NG
Repair
NG OK
Repair
AUTOMATIC TRANSMISSION - Troubleshooting DATA LIST REFERENCE TABLE

Item No. Check item 11 Throttle position sensor <Vehicles without TCL> Accelerator pedal position sensor <Vehicles with TCL> Check requirement Engine: Stopped Selector lever position: P Accelerator pedal: Released Accelerator pedal: Halfly depressed Accelerator pedal: Depressed 15 Oil temperature sensor Warming up Drive for 15 minutes or more so that the automatic transmission fluid temperature becomes 70 - 90 _C. Accelerator pedal: Released Accelerator pedal: Halfly depressed Driving at constant speed of 50 km/h in 3rd gear Driving at constant speed of 50 km/h in 3rd gear Released Depressed Brake pedal: Depressed Brake pedal: Released Idling with 1st gear (Vehicle stopped) Driving at constant speed of 50 km/h in 3rd gear 31 Low and reverse solenoid valve duty % Underdrive solenoid valve duty % Second solenoid valve duty % Overdrive solenoid valve duty % Selector lever position: L, 2, 3, D 10 km/h in 1st gear Normal value 400 - 1,000 mV
23-39
23100810208
Gradually rises from the above value 4,500 - 5,000 mV Gradually rises to 70 - 90 _C
21
Crank angle sensor
Engine: Idling Selector lever position: P
550 - 900 rpm Gradually rises from the above value 1,800 - 2,100 rpm 1,800 - 2,100 rpm OFF ON ON OFF 0 km/h 50 km/h No. 31: 0 %, No. 32: 0 %, No. 33: 100 %, No. 34: 100% No. 31: 100 %, No. 32: 0 %, No. 33: 0 %, No. 34: 100% No. 31: 100 %, No. 32: 0 %, No. 33: 100 %, No. 34: 0% No. 31: 100 %, No. 32: 100 %, No. 33: 0 %, No. 34: 0%
22 23 25
Input shaft speed sensor Output shaft speed sensor Wide open throttle switch Stop lamp switch
Selector lever position: 3 Selector lever position: 3 Accelerator pedal position Ignition switch: ON Engine: Stopped Selector lever position: 3
26
29
32
30 km/h in 2nd gear
33
50 km/h in 3rd gear
34
70 km/h in 4th gear
23-40
Item No. Check item 36

Check requirement Selector lever position: 3 Driving at 50 km/h in 3rd gear with accelerator released Driving at constant speed of 70 km/h in 3rd gear Normal value 0%
Damper clutch control solenoid valve duty %
Approx. 70 - 90 % Approx. 100 - 300 rpm*
52
Amount of damper clutch slippage
Selector lever position: 3
Driving at 50 km/h in 3rd gear with accelerator fully closed Driving at constant speed of 70 km/h in 3rd gear
Approx. 0 - 10 rpm Battery voltage (mV) 0 mV Data changes
54 57
Control relay output voltage Engine volumetric efficiency Inhibitor switch
Ignition switch : OFF Selector lever position: N Ignition switch: ON Engine: Stopped
Ignition switch: ON OFF N range with accelerator pedal released depressed. Selector lever position: P Selector lever position: R Selector lever position: N Selector lever position: D Selector lever position: 3 Selector lever position: 2 Selector lever position: L
61
P R N D 3 2 L ON OFF 1st 2nd 3rd 4th ON OFF ON OFF
62
HOLD mode signal
Mode control switch position Selector lever position: L, 2, 3, D
HOLD AUTO Driving at constant speed of 10 km/h in 1st gear Driving at constant speed of 30 km/h in 2nd gear Driving at constant speed of 50 km/h in 3rd gear Driving at constant speed of 70 km/h in 4th gear
63
Shift position
64
Accelerator pedal: Released Accelerator pedal: Halfly depressed A/C switch: ON A/C switch: OFF
65
Dual pressure switch

Item No. Check item 66 Auto-cruse-ECU signal Check requirement While auto-cruise operating Plain road Sloping road Normal value OFF ON
23-41
NOTE *: The damper clutch is released when the accelerator is fully closed (Idle position switch: ON).
ACTUATOR TEST JUDGEMENT VALUE

Item No. 1 2 3 4 6 12 Check item Low reverse solenoid valve Underdrive solenoid valve Second solenoid valve Overdrive solenoid valve Damper clutch control solenoid valve A/T control relay Control relay is OFF for 3 seconds. Test content Drive the solenoid valve specified by the MUT-II at 50 % duty for 5 seconds. No other solenoid valve should be energised. Check requirement Ignition switch: ON Selector lever position: P Engine: 0 r/min Vehicle speed: 0 km/h (Vehicle stopped) Throttle (Accelerator) opening voltage: Less than 0 V Idle switch: ON Normal value
23100820065
The operation sound should be audible when the solenoid valve is driven.
Data list No. 54 (1) During test: 0 mV (2) Normal: Battery voltage [mV]
23100950023
INVECS-II CANCEL COMMAND

Item No. 14 Item INVECS-II Content Stop the INVECS-II control and change gears according to the standard shift pattern. Remarks
Use this function when carrying out procedure 8 in the road tests.
23-42

23100840207
CHECK AT A/T-ECU TERMINALS
Terminal No. 1
Check item Underdrive solenoid valve
Check requirement Selector lever position: D (1st gear) Selector lever position: P
Standard value Battery voltage Approx.7 - 9 V 0V Battery voltage 0V Battery voltage Battery voltage 0V 0V Battery voltage 0V Battery voltage 0V 0V Battery voltage Approx. 7 - 9 V Battery voltage Other than battery voltage Battery voltage Approx. 7 - 9 V 4 - 5V
Solenoid valve power supply
Solenoid valve power supply
Auto-cruse control unit
No OD-OFF request OD-OFF request
10
A/C compressor load signal
A/C switch: OFF A/C switch: ON
11
Power supply
12 13 14
Earth Earth Overdrive solenoid valve
Always Always Selector lever position: D (3rd gear) Selector lever position: P
15
Damper clutch control solenoid valve
Selector lever position: L (1st gear) Selector lever position: 3 (50 km/h in 3rd gear) Selector lever position: 2 (2nd gear) Selector lever position: P
16
Second solenoid valve
21
Engine-ECU torque reduction request signal <Vehicles with TCL>
Ignition switch: ON (except during shifting)

Terminal No. 23 24 Check item Diagnosis control Power supply Check requirement Ignition switch: OFF Ignition switch: ON 25 26 31 Earth Earth Input shaft speed sensor Always Always Measure between terminal No. 31 and No. 43 by an oscilloscope. Engine: 2,000 r/min Selector lever position: 3 Measure between terminal No. 32 and No. 43 by an oscilloscope. Engine: 2,000 r/min Selector lever position: 3 Engine: Idling Engine: Idling Engine: Other than idling 38 43 44 Back up power suuply Sensor earth Oil temperature sensor Ignition switch: OFF Always ATF temperature: 25 _C ATF temperature: 80 _C 45 Throttle position sensor (TPS) <Vehicles without TCL> Accelerator pedal position sensor (APS) <Vehicles with TCL> Communication with engine-ECU <Vehicles without TCL> Communication with TCL-ECU <Vehicles with TCL> Communication with engine-ECU <Vehicles without TCL> Communication with TCL-ECU <Vehicles with TCL> Inhibitor switch P Accelerator pedal: Released (Engine stopped) Accelerator pedal: Depressed (Engine stopped) Engine: Idling Selector lever position: D
23-43
Standard value 0V Battery voltage 0V 0V Refer to P.23-45, Oscilloscope inspection procedure. Refer to P.23-45, Oscilloscope inspection procedure. 2.0 - 2.4 V 0V 5V Battery voltage 0V 3.8 - 4.0 V 2.3 - 2.5 V 0.5 - 1.0 V 4.5 - 5.0 V Other than 0 V
32
Output shaft speed sensor
33 36
Crank angle sensor Idle position switch
53
54
Engine: Idling Selector lever position: D
Other than 0 V
55
Selector lever position: P Selector lever position: Other than above
Battery voltage 0V Battery voltage 0V Battery voltage 0V
56
Inhibitor switch N
Selector lever position: N Selector lever position: Other than above
57
Inhibitor switch 3
Selector lever position: 3 Selector lever position: Other than above
23-44
Terminal No. 58 Check item

Check requirement Selector lever position: L Selector lever position: Other than above Standard value Battery voltage 0V Battery voltage 0V Battery voltage Approx. 7 - 9 V 0 5 V flashing 4.5 - 5.5 V Less than 0.4 V Battery voltage 0V Battery voltage 0V Battery voltage 0V 0V 0 5 V flashing Battery voltage 0V 0V Battery voltage 0V
Inhibitor switch L
59
Stop lamp switch
Brake pedal: Depressed Brake pedal: Released
62
Low and reverse solenoid valve
Selector lever position: D (1st gear) Selector lever position: D (2nd gear)
63 65
Diagnosis output Wide open throttle switch
Normal (No diagnosis code output) Accelerator pedal: Released Accelerator pedal: Depressed
66
Inhibitor switch R
Selector lever position: R Selector lever position: Other than above
67
Inhibitor switch D
Selector lever position: D Selector lever position: Other than above
68
Inhibitor switch 2
Selector lever position: 2 Selector lever position: Other than above
69
When stopped Move forward slowly
70
Mode control switch
Select HOLD mode Select AUTO mode
71
A/T control relay
72
Earth
Ignition switch: ON
AUTOMATIC TRANSMISSION - Troubleshooting OSCILLOSCOPE INSPECTION PROCEDURE

Check item Crank angle sensor Input shaft speed sensor Output shaft speed sensor Vehicle speed sensor Low reverse solenoid valve Underdrive solenoid valve Second solenoid valve Overdrive solenoid valve Damper clutch control solenoid valve Ignition switch: ON Selector lever position: P Engine: 0 r/min Vehicle speed: 0 km/h (Vehicle stopped) Throttle (Accelerator) opening angle: Less than 1 V Idle switch: ON Force drive each solenoid valve (Actuator test) Check requirement Selector lever position: N Selector lever position: 3 Idling (Vehicle stopped) Driving at constant speed of 50 km/h in 3rd gear (Engine: 1,800 - 2,100 r/min)
23-45
23100850064
Normal condition (Waveform sample) Waveform A Waveform B
Waveform C
Waveform sample
Waveform A (V) 5 Waveform B (V) 5 Waveform C (V) 60 40 20 0 (ms) 0 (ms) 0 (ms)
23-46
AUTOMATIC TRANSMISSION - On-vehicle Service
ON-VEHICLE SERVICE
ESSENTIAL SERVICE
23100090237
AUTOMATIC TRANSMISSION FLUID CHECK 1. Drive the vehicle until the fluid temperature rises to the normal temperature (70 - 80_C). 2. Park the vehicle on a level surface. 3. Move the selector lever through all positions to fill the torque converter and the hydraulic circuits with fluid, and then move the selector lever to the N position. 4. After wiping off any dirt around the oil level gauge, remove the oil level gauge and check the condition of the fluid. NOTE If the fluid smells as if it is burning, it means that the fluid has been contaminated by the particles from the bushes and friction materials, a transmission overhaul and flushing the cooler line may be necessary. 5. Check that the fluid level is at the HOT mark on the oil level gauge. If the fluid level is lower than this, pour in more fluid until the level reaches the HOT mark. Automatic transmission fluid: Dia Queen ATF SP II or equivalent NOTE If the fluid level is low, the oil pump will draw in air along with the fluid, which will cause bubbles to form inside the hydraulic circuit. This will in turn cause the hydraulic pressure to drop, which will result in late shifting and slipping of the clutches and brakes. If there is too much fluid, the gears can churn it up into foam and cause the same conditions that can occur with low fluid levels. In either case, air bubbles can cause overheating and oxidation of the fluid which can interfere with normal valve, clutch, and brake operation. Foaming can also result in fluid escaping from the transmission vent, in which case it may be mistaken for a leak. 6. Securely insert the oil level gauge. 7. The fluid and oil filters should always be replaced in the following conditions: When troubleshooting the transmission When overhauling the transmission When the oil is noticeably dirty or deteriorates (driving under the severe condition) Furthermore, the oil filters are special filters which are only to be used for the automatic transmission.
23-47
23100100251
AUTOMATIC TRANSMISSION FLUID REPLACEMENT If you have a fluid changer, use this changer to replace the fluid. If you do not have a fluid changer, replace the fluid by the following procedure. 1. Disconnect the hose shown in the illustration which connects the transmission and the oil cooler (inside the radiator). 2. Start the engine and let the fluid drain out. Running conditions: N range with engine idling Caution The engine should be stopped within one minute after it is started. If the fluid has all drained out before then, the engine should be stopped at that point. Discharge volume: Approx. 3.5 L
3. Remove the drain plug from the bottom of the transmission case to drain the fluid. Discharge volume: Approx. 2.0 L 4. Replace the oil filters. (Refer to P.23-48.) 5. Install the drain plug via a new gasket, and tighten it to the specified torque. Tightening torque: 32 Nm 6. Pour the new fluid in through the oil filler tube. Adding volume: Approx. 5.5 L Caution Stop pouring if the full volume of fluid cannot be poured in. 7. Repeat the procedure in step 2. NOTE Drain the fluid from the cooler hose 7 L at least. Then drain the fluid a little and check the fluid for dirt. If it has been contaminated, repeat the steps 6 and 7. 8. Pour the new fluid in through the oil filler tube. Adding volume: Approx. 3.5 L
23-48

9. Reconnect the hose which was disconnected in step 1 above, and firmly replace the oil level gauge. 10. Start the engine and run it at idle for 1 - 2 minutes. 11. Move the selector lever through all positions, and then move it to the N position.
12. Check that the fluid level is at the COLD mark on the oil level gauge. If the level is lower than this, pour in more fluid. 13. Drive the vehicle until the fluid temperature rises to the normal temperature (70 - 80_C), and then check the fluid level again. The fluid level must be at the HOT mark. NOTE The COLD level is for reference only; the HOT level should be regarded as the standard level. 14. Firmly insert the oil level gauge into the oil filler tube. 23101050067 OIL FILTER REPLACEMENT 1. Use the special tool (MB991610) to remove the automatic transmission oil filter. 2. Clean the filter bracket side mounting surface. 3. Apply a small amount of automatic transmission fluid to the O-ring of the new oil filter. 4. Use the special tool (MB991610) to install the automatic transmission oil filter. NOTE Tightening torque: 12 Nm 5. Check the quantity of the automatic transmission fluid. (Refer to P.23-46.) THROTTLE POSITION SENSOR ADJUSTMENT <Vehicles without TCL> Refer to GROUP 13A - On-vehicle Service. ACCELERATOR PEDAL POSITION SENSOR ADJUSTMENT <Vehicles with TCL> Refer to GROUP 13A - On-vehicle Service.
23100190142
Apply ATF to O-ring
23100250048

INHIBITOR SWITCH CONTINUITY CHECK
Items P R N
Inhibitor switch
23-49
23100140345
Terminal No. 1 2 3 4 5 6 7 8 9 10
D 3 2 L
P R N D 3 2 L
Transmission control cable Manual control lever
Adjusting nut
INHIBITOR SWITCH AND CONTROL CABLE 23100150096 ADJUSTMENT 1. Set the selector lever to the N position. 2. Loosen the control cable to manual control lever coupling nut to free the cable and lever. 3. Set the manual control lever to the neutral position.
23-50

10 - 12 Nm Mounting bolts
A A Manual control lever Section A-A Hole in end Hole in flange Manual control lever Inhibitor switch body
4. Loosen the inhibitor switch body mounting bolts and the turn the inhibitor switch body so the hole in the end of the manual control lever and the hole (cross section A-A in the figure on the left) in the flange of the inhibitor switch body flange are aligned. 5. Tighten the inhibitor switch body mounting bolts to the specified torque. Be careful at this time that the position of the switch body is not changed.
12 Nm
Adjusting nut
6. Gently pull the transmission control cable in the direction of the arrow, and then tighten the adjusting nut. 7. Check that the selector lever is in the N position. 8. Check that each range on the transmission side operates and functions correctly for each position of the selector lever.
Manual control lever
AUTOMATIC TRANSMISSION - On-vehicle Service A/T CONTROL COMPONENT LOCATION

Name Accelerator position sensor (with idle position switch) <Vehicles with TCL> A/T control relay A/T-ECU Crank angle sensor Diagnosis connector Dual pressure switch Engine ECU Inhibitor switch Input shaft speed sensor Symbol C M K B O A K F H Name Mode control switch Oil temperature sensor Output shaft speed sensor Shift indicator lamp Solenoid valve Stop lamp switch TCL-ECU Throttle position sensor (with idle position switch) <Vehicles without TCL> Vehicle speed sensor Wide open throttle switch
23-51
23100860234
Symbol L G E I G P J C D N
C B
A F
G I H
P O N M L K J
23-52
AUTOMATIC TRANSMISSION - On-vehicle Service A/T CONTROL COMPONENT CHECK

CRANK ANGLE SENSOR CHECK Refer to GROUP 13A - Troubleshooting. THROTTLE POSITION SENSOR CHECK <Vehicles without TCL> Refer to GROUP 13A - On-vehicle Service.
23100390030 23100900011
ACCELERATOR PEDAL POSITION SENSOR CHECK 23100420029 <Vehicles with TCL> Refer to GROUP 13H - On-vehicle Service.
OIL TEMPERATURE SENSOR CHECK 1. Remove the oil temperature sensor.
23100450035
Oil temperature sensor
2. Measure the resistance between terminals No. 1 and No. 2 of the oil temperature sensor connector. Standard value:
Oil temperature (_C) 0
ATF
Resistance (kW) 16.7- 20.5 0.57- 0.69
100
INHIBITOR SWITCH CHECK Refer to P.23A-49. STOP LAMP SWITCH CHECK Refer to GROUP 35 - Brake Pedal. VEHICLE SPEED SENSOR CHECK Refer to GROUP 54 - On-vehicle Service.
23100140352
23100910014
23100460038

DUAL POSITION PRESSURE SWITCH CHECK
23-53
23100470031
Refer to GROUP 55 - On-vehicle Service. IDLE POSITION SWITCH CHECK Refer to GROUP 13A - On-vehicle Service. MODE CONTROL SWITCH CHECK Refer to P.23-65. WIDE OPEN THROTTLE SWITCH CHECK Refer to P.23-64.
23100410033
23100920048
23100890080
A/T CONTROL RELAY CHECK 1. Remove the A/T control relay.
23100930065
2. Use jumper wires to connect A/T control relay terminal 2 to the battery ( - ) terminal and terminal 4 to the battery (+) terminal. 3. Check the continuity between terminal 1 and terminal 3 of the A/T control relay when the jumper wires are connected to and disconnected from the battery.
Jumper wire Connected Disconnected Continuity between terminals No. 1 and No. 3 Continuity No continuity
4. If there is a problem, replace the A/T control relay.
23-54
Overdrive solenoid valve

Underdrive solenoid valve Second solenoid valve
23100940013 SOLENOID VALVE CHECK 1. Remove the valve body cover. 2. Disconnect the connectors of each solenoid valve.
Low and reverse solenoid valve
Damper clutch solenoid valve
3. Measure the resistance between terminals 1 and 2 of each solenoid valve. Standard value:
Name Damper clutch solenoid valve Low and reverse solenoid valve Second solenoid valve Underdrive solenoid valve Overdrive solenoid valve Resistance 2.7 - 3.4 W (at 20_C)
4. If the resistance is outside the standard value, replace the solenoid valve.
TORQUE CONVERTER STALL TEST

Reverse clutch Torque converter Low-reverse Underdrive brake clutch
23100540206
This test measures the maximum engine speed when the selector lever is at the D or R position and the torque converter stalls to test the operation of the torque converter, starter motor and one-way clutch operation and the holding performance of the clutches and brakes in the transmission. Caution Do not let anybody stand in front of or behind the vehicle while this test is being carried out. 1. Check the automatic transmission fluid level and temperature and the engine coolant temperature. D Fluid level: At the HOT mark on the oil level gauge D Fluid temperature: 80 - 100_C D Engine coolant temperature: 80 - 100_C
23-55
2. Check both rear wheels (left and right). 3. Pull the parking brake lever on, with the brake pedal fully depressed. 4. Start the engine. 5. Move the selector lever to the D position, fully depress the accelerator pedal and take a reading of the maximum engine speed at this time. Caution 1. The throttle should not be left fully open for any more than eight seconds. 2. If carrying out the stall test two or more times, move the selector lever to the N position and run the engine at 1,000 r/min to let the automatic transmission fluid cool down before carrying out subsequent tests. Standard value Stall speed: 2,100 - 2,600 r/min 6. Move the selector lever to the R position and carry out the same test again. Standard value Stall speed: 2,100 - 2,600 r/min TORQUE CONVERTER STALL TEST JUDGEMENT RESULTS a. Stall speed is too high in both D and R ranges D Low line pressure D Low & reverse brake slippage b. Stall speed is too high in D range only D Underdrive clutch slippage c. Stall speed is too high in R range only D Reverse clutch slippage d. Stall speed too low in both D and R ranges D Malfunction of torque converter D Insufficient engine output
23-56
AUTOMATIC TRANSMISSION - On-vehicle Service HYDRAULIC PRESSURE TEST

23100550216
1. Warm up the engine until the automatic transmission fluid temperature is 80 - 100_C. 2. Jack up the vehicle so that the wheels are free to turn. 3. Connect the special tools (2,942 kPa oil pressure gauge [MD998330] and joints [MD998332, MD998900]) to each pressure discharge port. 4. Measure the hydraulic pressure at each port under the conditions given in the standard hydraulic pressure table, and check that the measured values are within the standard value ranges. 5. If a value is outside the standard range, correct the problem while referring to the hydraulic pressure test diagnosis table.

STANDARD HYDRAULIC PRESSURE TEST <4G63>
Measurement condition Selector lever position P R N D Shift position Engine speed (r/min) 2,500 2,500 2,500 2,500 2,500 2,500 2,500 Standard hydraulic pressure kPa Underdrive clutch pressure 1,010 1,050 1,010 1,050 590 - 690 Reverse clutch pressure 1,320 1,720 Overdrive clutch pressure 590 - 690 590 - 690 Low and reverse brake pressure 310 - 390 1,320 1,720 310 - 390 1,010 1,050 Second brake pressure 1,010 1,050 590 - 690
23-57
Torque converter pressure 310 - 390 500 - 700 310 - 390 500 - 700 500 - 700 450 - 650 450 - 650
Reverse 1st gear 2nd gear 3rd gear 4th gear
<6A13>
Measurement condition Selector lever position P R N D Shift position Engine speed (r/min) 2,500 2,500 2,500 2,500 2,500 2,500 2,500 Standard hydraulic pressure kPa Underdrive clutch pressure 1,010 1,050 1,010 1,050 780 - 880 Reverse clutch pressure 1,320 1,720 Overdrive clutch pressure 780 - 880 780 - 880 Low and reverse brake pressure 260 - 340 1,320 1,720 260 - 340 1,010 1,050 Second brake pressure 1,010 1,050 780 - 880 Torque converter pressure 260 - 340 500 - 700 260 - 340 500 - 700 500 - 700 450 - 650 450 - 650
Reverse 1st gear 2nd gear 3rd gear 4th gear
23-58
Trouble symptom
HYDRAULIC PRESSURE TEST DIAGNOSIS TABLE

Probable cause Incorrect transmission control cable adjustment Malfunction of the regulator valve All hydraulic pressures are low. Incorrect transmission control cable adjustment Malfunction of the oil pump Clogged internal oil filter Clogged external oil filter Clogged oil cooler Malfunction of the regulator valve Malfunction of the relief valve Incorrect valve body installation Hydraulic pressure is abnormal in R range only. Malfunction of the regulator valve Clogged orifice Incorrect valve body installation Hydraulic pressure is abnormal in 3 or 4 range only. Malfunction of the overdrive solenoid valve Malfunction of the overdrive pressure control valve Malfunction of the regulator valve Malfunction of the switch valve Clogged orifice Incorrect valve body installation Only underdrive hydraulic pressure is abnormal. Malfunction of the oil seal K Malfunction of the oil seal L Malfunction of the oil seal M Malfunction of the underdrive solenoid valve Malfunction of the underdrive pressure control valve Malfunction of check ball Clogged orifice Incorrect valve body installation Only reverse clutch hydraulic pressure is abnormal. Malfunction of the oil seal A Malfunction of the oil seal B Malfunction of the oil seal C Clogged orifice Incorrect valve body installation
All hydraulic pressures are high.

Trouble symptom Only overdrive hydraulic pressure is abnormal. Probable cause Malfunction of the oil seal D Malfunction of the oil seal E Malfunction of the oil seal F Malfunction of the overdrive solenoid valve Malfunction of the overdrive pressure control valve Malfunction check ball Clogged orifice Incorrect valve body installation Only low and reverse hydraulic pressure is abnormal. Malfunction of the oil seal I Malfunction of the oil seal J Malfunction of the low and reverse solenoid valve Malfunction of the low and reverse pressure control valve Malfunction of the switch valve Malfunction of the fail safe valve A Malfunction of check ball Clogged orifice Incorrect valve body installation Only second hydraulic pressure is abnormal. Malfunction of the oil seal G Malfunction of the oil seal H Malfunction of the oil seal O Malfunction of the second solenoid valve Malfunction of the second pressure control valve Malfunction of the fail safe valve B Clogged orifice Incorrect valve body installation Only torque converter pressure is abnormal. Malfunction of the oil cooler Malfunction of the oil seal N Malfunction of the damper clutch control solenoid valve Malfunction of the damper clutch control valve Malfunction of the torque converter pressure control valve Clogged orifice Incorrect valve body installation Pressure applied to non operating element. Incorrect transmission control cable adjustment Malfunction of the manual valve Malfunction of check ball Incorrect valve body installation
23-59
23-60
OIL SEAL LAYOUT
F G
D C B A
AUTOMATIC TRANSMISSION - On-vehicle Service HYDRAULIC CIRCUIT

PARKING AND NEUTRAL
23-61
23100880070
1 6 8
2 6
3 6
4 6
5 7
10
11 12 13
14 19
15
16 20
17 21
18 22
23
24
25 26
R ND P3 2 L
27 29 31
28 30 32
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Reverse clutch Low-reverse brake Second brake Underdrive clutch Overdrive clutch Accumulator Check ball Damper clutch Fail safe valve A Fail safe valve B Damper clutch control valve Switch valve Automatic transmission fluid cooler Lubrication Low-reverse pressure control valve Second pressure control valve Underdrive pressure control valve
18. Overdrive pressure control valve 19. Damper clutch control solenoid valve 20. Low-reverse solenoid valve 21. Second solenoid valve 22. Underdrive solenoid valve 23. Overdrive solenoid valve 24. Torque converter pressure control valve 25. Regulator valve 26. Manual valve 27. Oil filter 28. Oil pump 29. Oil strainer 30. Oil filter (Built in type) 31. Relief valve 32. Oil pan
23-62
AUTOMATIC TRANSMISSION - On-vehicle Service LINE PRESSURE ADJUSTMENT

23100170122
Adjusting screw
1. Discharge the automatic transmission fluid, and then remove the valve body cover. 2. Turn the adjusting screw shown in the illustration at left to adjust the underdrive pressure to the standard value. The pressure increases when the screw is turned to the left. NOTE When adjusting the underdrive pressure, adjust to the middle of the standard value range. Standard value: 1,010 - 1,050 kPa Change in pressure for each turn of the adjusting screw: 35 kPa 3. Install the valve body cover, and pour in the standard volume of automatic transmission fluid. 4. Carry out a hydraulic pressure test. (Refer to P.23-56.) Readjust the line pressure if necessary.
SELECTOR LEVER OPERATION CHECK

23100130090
Push button
1. Shift selector lever to each range and check that lever moves smoothly and is controlled. Check that position indicator is correct. 2. Check the selector lever can be moved to each position (by button operation as shown in the illustration). 3. Start the engine and check if the vehicle moves forward when the selector lever is moved from N or D, and moves backward when moved to R. 4. When the shift lever malfunctions, adjust control cable and selector lever sleeve. Check for worm shift lever assembly sliding parts.
Button not pressed Button pressed
AUTOMATIC TRANSMISSION - Transmission Control
23-63
23100660247
TRANSMISSION CONTROL
Pre-removal and Post-installation Operation D Air Cleaner Assembly Removal and Installation D Battery and Battery Tray Removal and Installation D Lower Cover and Side Cover Removal and Installation (Refer to GROUP 52A - Instrument Panel.) D Floor Console Box Removal and Installation (Refer to GROUP 52A.)
Caution: SRS Be careful not to subject the SRS-ECU to any shocks during removal and installation of the transmission control cable and selector lever assembly.
9 1
12 Nm
3 4 6
12 Nm
8 7
12 Nm
Transmission control cable removal steps 1. Foot rest <R.H. drive vehicles> 2. Engine-ECU, A/T-ECU and A/T control relay assembly "AA 3. Nut 4. Adjuster 5. Transmission control cable connection 6. Transmission control cable assembly
Selector lever assembly removal steps 5. Transmission control cable connection 7. Wiring harness connector 8. Selector lever assembly A/T-ECU removal steps 1. Foot rest <R.H. drive vehicles> 2. Engine-ECU, A/T-ECU and A/T control relay assembly Wide open throttle switch removal step 9. Wide open throttle switch
23-64
AUTOMATIC TRANSMISSION - Transmission Control INSTALLATION SERVICE POINT

Nut
Manual control lever
"AA NUT INSTALLATION 1. Put the selector lever in the N position. 2. Loosen the adjusting nut, gently pull the transmission control cable in the direction of the arrow and tighten the nut.
INSPECTION
WIDE OPEN THROTTLE SWITCH CHECK
OFF ON
23100890097
Switch position OFF ON
Terminal No. 1 2
AUTOMATIC TRANSMISSION - Transmission Control SELECTOR LEVER ASSEMBLY

23-65
23100680168
1 2 3 4
2 Nm
8 7
10
2 Nm
12 11 11 15
13 Nm
14
13 9
Disassembly steps 1. Push button 2. Spring 3. Bumper 4. Adjuster 5. Shift knob 6. Indicator panel assembly 7. Switch holder 8. A/T mode changeover switch
9. 10. 11. 12. 13. 14. 15.
Bolt Shift lever assembly Bushing Detent spring Pipe Position indicator lamp assembly Bracket assembly
INSPECTION
A/T MODE CHANGEOVER SWITCH CHECK
Switch position Terminal No. 1 OFF ON 2 4 3
23100670059
23-66
AUTOMATIC TRANSMISSION - Transmission Assembly

23100570274
TRANSMISSION ASSEMBLY
Pre-removal Operation D Carry out the essential service for the troubleshooting (Refer to P.23-46.) D Transmission Fluid Draining (Refer to P.23-47.) D Under Cover Removal D Battery and Battery Tray Removal D Air Cleaner Assembly Removal
Post-installation Operation D Air Cleaner Assembly Installation D Battery and Battery Tray Installation D Under Cover Installation D Transmission Fluid Supplying <Supplying should be done before starting the engine> (Refer to P.23-47.) D Check the Dust Cover for Cracks or Damage by Pushing it with Finger. D Selector Lever Operation Check D Speedometer Operation Check D Wheel Alignment Adjustment (Refer to GROUP 33A - On-vehicle Service.)
12 Nm 103 Nm
4 8 2
11
44 Nm
7 12
5 17
88 Nm*1
98 - 118 Nm*1
10 17
81 Nm
10 - 12 Nm
13
24 - 33 Nm 67 - 78 Nm 81 Nm
14
30 Nm
30 Nm
16
98 - 118 Nm
15
88 Nm
Removal steps 1. Transmission control cable connection 2. Transmission fluid cooler hoses connection 3. Bolt 4. Input shaft speed sensor connector 5. Output shaft speed sensor connector 6. Inhibitor switch connector 7. A/T control solenoid valve assembly connector 8. Vehicle speed sensor connector 9. Starter motor <6A1>
AA"
AB"
AC" Caution *1: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
10. 11. 12. 13. 14. 15. 16. 17.
Tie rod end connection Stabilizer link connection Damper fork No. 2 stay Lateral lower arm connection No. 3 stay Compression lower arm connection Drive shaft
23-67
57 Nm
20
81 Nm*2
49 Nm 30 Nm
18
10 - 12 Nm
21 19 21 27
26
45 - 52 Nm
26
49 Nm 57 Nm*2
49 Nm
24
25 Nm
25
44 Nm 7 Nm
10 Nm <Flange bolts> 9 Nm <Washer assembled bolts>
22
93 Nm 69 - 78 Nm
23
69 Nm
18. Starter motor <4G6> 19. Transmission assembly upper part coupling bolts AD" 20. Transmission mount bracket "BA 21. Transmission mount stopper AE" D Engine and transmission assembly supporting 22. Centermember assembly 23. Rear roll stopper 24. Bell housing cover <4G6>
25. Cover <6A1> 26. Transmission assembly lower part coupling bolts AF" "AA 27. Transmission assembly AF" Caution Mounting locations marked by *2 should be provisionally tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.
23-68

Cord

AA" TIE ROD END DISCONNECTION Caution 1. Use the special tool to loosen the tie rod end mounting nut. Only loosen the nut; do not remove it from the ball joint. 2. Support the special tool with a cord, etc. not to let it come off.
Ball joint MB990635 or MB991113
Nut
AB" NO.3 STAY REMOVAL No.3 stay is tightened together with the crossmember. Therefore, after removing No.3 stay, install the nut and bolt to the crossmember provisionally.
No.3 stay
Crossmember
Transmission side
AC" DRIVE SHAFT DISCONNECTION 1. Insert a pry bar between the transmission case and the drive shaft as shown to remove the drive shaft. NOTE Do not remove the hub and knuckle from the drive shaft. Caution Always use a pry bar, or the TJ will be damaged. 2. Suspend the removed drive shaft with a wire so that there are no sharp bends in any of the joints. 3. Use a shop towel to cover the transmission case not to let foreign material get into it.
Pry bar
AD" TRANSMISSION MOUNT BRACKET REMOVAL Jack up the transmission assembly gently with a garage jack, and then remove the transmission mount bracket.

MZ203827
23-69
AE" ENGINE AND TRANSMISSION ASSEMBLY SUPPORTING Set the special tool to the vehicle to support the engine and transmission assembly.
MB991453
Drive plate bolts
AF" TRANSMISSION ASSEMBLY LOWER PART COUPLING BOLTS/TRANSMISSION ASSEMBLY REMOVAL 1. Support the transmission assembly by using a transmission jack. 2. Remove the drive plate bolts while turning the crank shaft. 3. Press in the torque converter to the transmission side so that the torque converter does not remain on the engine side. 4. Remove the transmission assembly lower bolts and lower the transmission assembly.

"AA TRANSMISSION ASSEMBLY INSTALLATION After securely inserting the torque converter into the transmission side so that the value shown in the illustration becomes the reference value, install the transmission assembly to the engine. Reference value (A): Approx. 12.2 mm
Engine side Arrow
"BA TRANSMISSION MOUNT STOPPER INSTALLATION Install the transmission mount stopper so that the arrow points as shown in the illustration.
Transmission mount stopper
NOTES
26-1
FRONT AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
26109000157
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4
Wheel Bearing Axial Play Check . . . . . . . . . . . . . . 4 Hub Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . 5 KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
26-2
FRONT AXLE - General Information/Service Specifications/Lubricants

26100010173
GENERAL INFORMATION
The front axle consists of a knuckle, front hub, unit bearing and drive shaft. The unit bearing is press-fitted to the front hub and bolted to the knuckle. Also, the unit bearing utilizes a double
row angular contact ball bearing. The drive shaft has a tripod joint (T.J.) on the transmission side and a birfield joint (B.J.) or rzeppa joint (R.J.) on the wheel side.
Knuckle
Dynamic damper
Front hub Drive shaft
T.J.
B.J. (or R.J.) Unit bearing
Items Wheel bearing axial play mm Wheel bearing rotation starting torque Nm Setting of T.J. boot length mm 2000 - petrol-powered vehicles 2000 - diesel-powered vehicles, 2500 Opening dimension of the special tool (MB991561) mm When the B.J. (or R.J.) boot band (small) is crimped When the B.J. (or R.J.) boot band (large) is crimped Crimped width of the B.J. (or R.J.) boot band mm Clearance between the B.J. (or R.J.) boot (large diameter side) and the stepped phase of the B.J. (or R.J.) housing mm Standard value 82 81 2.9 3.2 2.4 - 2.8 0.1 - 1.5 Limit 0.05
26100030179
1.0 or less -
LUBRICANTS
Items T.J. 2000 - petrol-powered vehicles 2000 - diesel-powered vehicles, 2500 Specified lubricant Repair kit grease Repair kit grease Quantity g 120 150
26100040202
FRONT AXLE - Lubricants/Special Tools

Items B.J. (or R.J.) 2000 2500 Specified lubricant Repair kit grease Repair kit grease Quantity g 120 135
26-3
SPECIAL TOOLS
Tool Number MB990767 Name End yoke holder Use Fixing of the hub
26100060185
MB991618
Hub bolt remover
Hub bolt removal
MB991406, MB990635 or MB991113
Steering linkage puller
Ball joint disconnection
B A
MB990241 A: MB990242 B: MB990244
Axle shaft puller A: Puller shaft B: Puller bar
D D
Front hub assembly removal Drive shaft removal
MB990998
Front hub remover and installer
D D
Removal of or pressing-in the hub Provisional holding of the wheel bearing
MB990326
Preload socket
Wheel bearing rotation starting torque measurement
MB991461
Plug
Preventing of entry of foreign objects into the transmission case
MB991561
Boot band crimping tool
B.J. (or R.J.) boot band installation
26-4
FRONT AXLE - On-vehicle Service
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK
26100110088
1. Remove the disc brake caliper and suspend it with a wire. 2. Remove the brake disc from the front hub. 3. Attach a dial gauge as shown in the illustration, and then measure the axial play while moving the hub in the axial direction. Limit: 0.05 mm 4. If axial play exceeds the limit, replace the front hub assembly.
HUB BOLT REPLACEMENT

MB991618 MB990767
26100100085
1. Remove the caliper assembly and secure it with wire so that it does not fall. 2. Remove the brake disc. 3. Use the special tools to remove the hub bolts.
4. Install the plain washer to the new hub bolt, and install the bolt with a nut.
MB990767 Plane washer
FRONT AXLE - Front Hub Assembly
26-5
26100170154
FRONT HUB ASSEMBLY

Post-installation Operation Check the Dust Cover for Cracks or Damage by Pushing it with Finger.
28 Nm 88 Nm
100 Nm
196 - 255 Nm
Removal steps 1. Front wheel speed sensor <Vehicles with ABS> (Refer to GROUP 35B.) AA" 2. Caliper assembly 3. Brake disc AB" "AA 4. Drive shaft nut AC" 5. Upper arm ball joint and knuckle connection AD" 6. Front hub assembly
Caution The front hub assembly should not be disassembled. When removing the front hub assembly, the wheel bearing inner race may be left at the spindle side. In this case, always replace the front hub assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play.

AA" CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, so that it does not fall. AB" DRIVE SHAFT NUT REMOVAL
MB990767
Caution Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut.
26-6
MB991406, MB990635 or MB991113 Ball joint
FRONT AXLE - Front Hub Assembly

AC" UPPER ARM BALL JOINT AND KNUCKLE DISCONNECTION Caution 1. Use the special tool to loosen the nut only; do not remove it from the ball joint. 2. Tie the special tool with a cord not to let it fall off.
Cord
Nut
AD" FRONT HUB ASSEMBLY REMOVAL (1) Use the special tool to push out the drive shafts from the hub.
MB990767
MB990241
(2) Shift the knuckle to the outside in order to maintain the clearance between the front hub assembly mounting bolts and the drive shaft. Caution 1. Do not damage the ball joint boot. 2. Be careful not to damage the rotor.
Washer

"AA DRIVE SHAFT NUT INSTALLATION (1) Install the drive shaft washer in the specified direction. (2) Using the special tool, tighten the drive shaft nut. Caution Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings.
196 - 255 Nm MB990767
(3) If the position of the split pin holes does not match, tighten the nut up to 255 Nm in maximum. (4) Install the split pin in the first matching holes and bend it securely.
FRONT AXLE - Front Hub Assembly INSPECTION

MB990998 MB990326
26-7
26100180119
196 - 255 Nm
WHEEL BEARING ROTATION STARTING TORQUE CHECK (1) Install the special tool to the front hub assembly and tighten the nut to the specified torque 196 - 255 Nm. (2) Use the special tool to measure the wheel bearing starting torque. Limit: 1.0 Nm or less (3) The wheel bearing starting torque should be within the limit value range, and there should be no engagement or feeling of roughness.
26100110095 WHEEL BEARING AXIAL PLAY CHECK (1) Install the special tool to the front hub assembly and tighten the nut to the specified torque 196 - 255 Nm. (2) Measure the play in the hub axial direction.
Limit: 0.05 mm
MB990998
(3) If the limit value of hub axial play cannot be obtained, replace the front hub assembly.
26-8 KNUCKLE
FRONT AXLE - Knuckle

26100240138

Pre-removal Operation Front Hub Assembly Removal (Refer to P.26-5.) Post-installation Operation D Check the Dust Cover for Cracks or Damage by Pushing it with Finger. D Front Hub Assembly Installation (Refer to P.26-5.)
2
59 - 71 Nm
6 3
88 Nm*
5
24 - 33 Nm 9 Nm
1 4
AA"
AA" AA"
Removal steps 1. Dust shield 2. Tie rod end and knuckle connection 3. Damper fork and lateral lower arm connection 4. Lateral lower arm and knuckle connection 5. Compression lower arm and knuckle connection
6. Knuckle Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.

MB991406, MB990635 or MB991113 Ball joint Cord
AA" TIE ROD END AND KNUCKLE/LATERAL LOWER ARM AND KNUCKLE/COMPRESSION LOWER ARM AND KNUCKLE DISCONNECTION Caution 1. Use the special tool to loosen the nut only; do not remove it from the ball joint. 2. Tie the special tool with a cord not to let it fall off.
Nut
FRONT AXLE - Drive Shaft
26-9
26100350213
DRIVE SHAFT
Post-installation Operation D Check the Dust Cover for Cracks or Damage by Pushing it with Finger. D Wheel Alignment Check and Adjustment (Refer to GROUP 33A - On-vehicle Service.)
103 Nm
4 5
44 Nm 88 Nm*
3
98 - 118 Nm* 81 Nm
7 9 6 2
24 - 33 Nm 196 - 255 Nm 81 Nm
1 8
69 - 78 Nm
Removal steps 1. Front wheel speed sensor <Vehicles with ABS> (Refer to GROUP 35B.) AA" "AA 2. Drive shaft nut AB" 3. Tie rod end and knuckle connection 4. Stabilizer link and damper fork connection 5. Damper fork 6. No.2 stay 7. Lateral lower arm connection
AC" AD"
8. Compression lower arm connection 9. Drive shaft
Caution 1. *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. 2. For vehicles with ABS, be careful not to damage the rotors installed to the B.J. (or R.J.) outer race during removal and installation of the drive shaft.
26-10
FRONT AXLE - Drive Shaft REMOVAL SERVICE POINTS

AA" DRIVE SHAFT NUT REMOVAL Caution Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut.
MB990767
AB" TIE ROD END AND KNUCKLE DISCONNECTION

Caution 1. Use the special tool to loosen the nut only; do not remove it from the ball joint. 2. Tie the special tool with a cord not to let it fall off.
Nut
Compression lower arm No.3 stay Crossmember
AC" COMPRESSION LOWER ARM DISCONNECTION To remove the compression lower arm from the crossmember, No.3 stay must not be removed as it is tightened together with the crossmember.
MB990767
AD" DRIVE SHAFT REMOVAL (1) Use the special tools to push out the drive shafts from the hub.
MB990241
(2) While pulling out the lower side of the rotor toward you, rotate it toward the rear side of the vehicle 90_ to remove the drive shaft from the hub.
26-11
Oil seal
(3) Insert a pry bar between the transmission case and the drive shaft, and then pry the drive shaft from the transmission. Caution 1. Always use a lever as pulling out the drive shaft from B.J. (or R.J.) assembly may damage the T.J. assembly. 2. Do not insert the pry bar so deep as to damage the oil seal.
Drive shaft Pry bar Transmission
(4) Use the special tool as a cover not to let foreign objects get into the transmission case.
MB991460
MB990998
Caution Do not apply the vehicle weight to the wheel bearing while loosening the drive shaft nut. If, however, the vehicle weight must be applied to the bearing (because of moving the vehicle), temporarily secure the wheel bearing by using the special tool.
Washer

"AA DRIVE SHAFT NUT INSTALLATION (1) Be sure to install the drive shaft washer in the specified direction. (2) Using the special tool, tighten the drive shaft nut. Caution Before securely tightening the drive shaft nuts, make sure there is no load on the wheel bearings. (3) If the position of the split pin holes does not match, tighten the nut up to 255 Nm in maximum. (4) Install the split pin in the first matching holes and bend it securely.
196 - 255 Nm MB990767
26-12

26100370233
3 5 6 7 1 2
9 8
10
4 3
4 5 5 6 7 1 2
4 5 1 2
8 11 12
13
T.J. repair kit
T.J. boot repair kit
B.J. (or R.J.) boot repair kit
Disassembly steps "CA 1. T.J. boot band (large) "CA 2. T.J. boot band (small) AA" "BA 3. T.J. case 4. Circlip 5. Snap ring AA" "BA 6. Spider assembly AB" "AA 7. T.J. boot "AA 8. Damper band "AA 9. Dynamic damper
Caution 1. Never disassemble the B.J. (or R.J.) assembly except when replacing the B.J. (or R.J.) boot. 2. On vehicles with ABS, be sure not to damage the rotor attached to the B.J. (or R.J.) outer race.
10. 11. 12. 13.
B.J. B.J. B.J. B.J.
(or (or (or (or
R.J.) R.J.) R.J.) R.J.)
assembly boot band (small) boot band (large) boot
FRONT AXLE - Drive Shaft DISASSEMBLY SERVICE POINTS
26-13
AA" T.J. CASE/SPIDER ASSEMBLY REMOVAL (1) Wipe off grease from the spider assembly and the inside of the T.J. case. (2) Always clean the spider assembly when the grease contains water or foreign material. Caution 1. Do not disassemble the spider assembly. 2. Use care in handling so as not to damage the drive shaft. AB" T.J. BOOT REMOVAL (1) Wipe off grease from the shaft spline. (2) When reusing the T.J. boot, wrap plastic tape around the shaft spline to avoid damaging the boot.

LH: 229 mm RH: 278 mm
"AA DYNAMIC DAMPER/DAMPER BAND/T.J. BOOT INSTALLATION (1) Straighten the B.J. (or R.J.) assembly, and secure the dynamic damper with the damper band as shown in the figure. Caution There should be no grease adhered to the rubber part of the dynamic damper. NOTE The damper band and the T.J. boot band (small) are the same parts. (2) Wrap plastic tape around the shaft spline, and then install the T.J. boot band (small) and T.J. boot.
Bevelled section
"BA SPIDER ASSEMBLY/T.J. CASE INSTALLATION (1) Apply the specified grease furnished in the repair kit to the spider assembly between the spider axle and the roller. Specified grease: Repair kit grease Caution 1. The drive shaft joint uses special grease. Do not mix old and new or different types of grease. 2. If the spider assembly has been cleaned, take special care to apply the specified grease.
26-14

(2) Install the spider assembly to the shaft from the direction of the spline bevelled section. (3) After applying the specified grease to the T.J. case, insert the drive shaft and apply grease one more time. Specified grease: Repair kit grease Amount to use: <2000 - petrol-powered vehicles> 120 g <2000 - diesel-powered vehicles, 2500> 150 g NOTE The grease in the repair kit should be divided in half for use, respectively, at the joint and inside the boot. Caution The drive shaft joint uses special grease. Do not mix old and new or different types of grease.
"CA T.J. BOOT BAND (SMALL)/T.J. BOOT BAND (LARGE) INSTALLATION Set the T.J. boot bands at the specified distance in order to adjust the amount of air inside the T.J. boot, and then tighten the T.J. boot bands securely. Standard value (A): <2000 - petrol-powered vehicles> 82 mm <2000 - diesel-powered vehicles, 2500> 81 mm
INSPECTION
D D D D D D
26100380120
Check the drive shaft for damage, bending or corrosion. Check the drive shaft spline part for wear or damage. Check the spider assembly for roller rotation, wear or corrosion. Check the groove inside T.J. case for wear or corrosion. Check the dynamic damper for damage or cracking. Check the boots for deterioration, damage or cracking.
B.J. (or R.J.) BOOT (RESIN BOOT) REPLACEMENT
26100520089
(1) Remove the B.J. (or R.J.) boot bands (large and small). NOTE The B.J. (or R.J.) boot bands cannot be re-used. (2) Remove the B.J. (or R.J.) boot. (3) Wrap a plastic tape around the shaft spline, and assemble the B.J. (or R.J.) boot band and B.J. (or R.J.) boot.
26-15
(4) Install the B.J. (or R.J.) boot with the part with the smallest diameter in a position such that the shaft groove can be seen.
MB991561 Stopper
(5) Turn the adjusting bolt on the special tool so that the size of the opening (W) is at the standard value. Standard value (W): 2.9 mm <If it is larger than 2.9 mm> Tighten the adjusting bolt. <If it is smaller than 2.9 mm> Loosen the adjusting bolt.
W Adjusting bolt
NOTE (1) The value of W will change by approximately 0.7 mm for each turn of the adjusting bolt. (2) The adjusting bolt should not be turned more than once.
B.J. (or R.J.) boot
(6) Place the B.J. (or R.J.) boot band (small) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (A) in the illustration.
B.J. (or R.J.) boot band (small) Projection
(7) Use the special tool to crimp the B.J. (or R.J.) boot band (small). Caution 1. Secure the drive shaft in an upright position and clamp the part of the B.J. (or R.J.) boot band to be crimped securely in the jaws of the special tool. 2. Crimp the B.J. (or R.J.) boot band until the special tool touches the stopper.
MB991561
26-16

(8) Check that the crimping amount (B) of the B.J. (or R.J.) boot band is at the standard value.
B
Standard value (B): 2.4 - 2.8 mm <If the crimping amount is larger than 2.8 mm> Readjust the value of (W) in step (5) according to the following formula, and then repeat the operation in step (7). W = 5.5 mm - B Example: If B = 2.9 mm, then W = 2.6 mm. <If the crimping amount is smaller than 2.4 mm> Remove the B.J. (or R.J.) boot band, readjust the value of (W) in step (5) according to the following formula, and then repeat the operations in steps (6) and (7) using a new B.J. (or R.J.) boot band. W = 5.5 mm - B Example: If B = 2.3 mm, then W = 3.2 mm. (9) Check that the B.J. (or R.J.) boot band is not sticking out past the place where it has been installed. If the B.J. (or R.J.) boot band is sticking out, remove it and then repeat the operations in steps (6) to (8) using a new B.J. (or R.J.) boot band. (10)Fill the inside of the B.J. (or R.J.) boot with the specified amount of the specified grease. Specified grease: Repair kit grease Amount to use: <2000> 120 g, <2500> 135 g Caution The drive shaft joint uses special grease. Do not mix old and new or different types of grease.
(11)Install the B.J. (or R.J.) boot band (large) so that there is the clearance (C) between it and the B.J. (or R.J.) housing is at the standard value. Standard value (C): 0.1 - 1.5 mm (12)Follow the same procedure as in step (5) to adjust the size of the opening (W) on the special tool so that it is at the standard value. Standard value (W): 3.2 mm
B.J. (or R.J.) boot
Projection B.J. (or R.J.) boot band (large) D
(13)Place the B.J. (or R.J.) boot band (large) against the projection at the edge of the boot, and then secure it so that there is a clearance left as shown by (D) in the illustration. (14)Use the special tool to crimp the B.J. (or R.J.) boot band (large) in the same way as in step (7).
26-17
(15)Check that the crimping amount (E) of the B.J. (or R.J.) boot band is at the standard value. Standard value (e): 2.4 - 2.8 mm <If the crimping amount is larger than 2.8 mm> Readjust the value of (W) in step (12) according to the following formula, and then repeat the operation in step (14). W = 5.8 mm - E Example: If E = 2.9 mm, then W = 2.9 mm.
E
<If the crimping amount is smaller than 2.4 mm> Remove the B.J. (or R.J.) boot band, readjust the value of (W) in step (12) according to the following formula, and then repeat the operations in steps (13) and (14) using a new B.J. (or R.J.) boot band. W = 5.8 mm - E Example: If E = 2.3 mm, then W = 3.5 mm. (16)Check that the B.J. (or R.J.) boot band is not sticking out past the place where it has been installed. If the B.J. (or R.J.) boot band is sticking out, remove it and then repeat the operations in steps (13) to (15) using a new B.J. (or R.J.) boot band.
NOTES
27-1
REAR AXLE
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
27109000161
Wheel Bearing Axial Play Check . . . . . . . . . . . . . . 3 Wheel Bearing Rotary-Sliding Resistance Check ............................................. 3 Hub Bolt Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR AXLE HUB . . . . . . . . . . . . . . . . . . . . . . . . . . 5 KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
27-2
REAR AXLE -
General Information/Service Specifications/ Special Tools

27100010156
GENERAL INFORMATION
The rear axle consists of a knuckle, rear hub, unit bearing and axle shaft. The unit bearing is press-fitted to the rear axle shaft and bolted to the knuckle. Also, the unit bearing utilizes the same
type of double row angular contact ball bearing as does the front axle. A rotor for detecting the vehicle speed is located on the rear axle shaft, and a speed sensor is located on the knuckle.
Oil seal
Knuckle
Rear axle shaft Cap Oil seal Unit bearing Rotor <Vehicles with ABS>
Items Wheel bearing axial play mm Wheel bearing rotary-sliding resistance N Limit 0.05 18 or less
27100030183
SPECIAL TOOLS
Tool Number MB990767 Name End yoke holder Use Fixing of the hub
27100060175
MB991618
Hub bolt remover
Removal of the hub bolt
MB991248
Inner shaft remover
Rotor removal
REAR AXLE - Special Tools/On-vehicle Service

Tool Number MB991406 MB990635 or MB991113 Name Steering linkage puller Use Ball joint disconnection
27-3
ON-VEHICLE SERVICE
WHEEL BEARING AXIAL PLAY CHECK
27100090136
1. For vehicles with rear disc brake, remove the caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brake, remove the brake drum. 3. Check the bearings axial play. Place a dial gauge against the hub surface; then move the hub in the axial direction and check whether or not there is axial play. Limit: 0.05 mm 4. If the play exceeds the limit value, replace the rear hub assembly.
WHEEL BEARING ROTARY-SLIDING RESISTANCE CHECK
27100110153
1. For vehicles with rear disc brake, remove the caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brake, remove the brake drum. 3. After turning the hub a few times to seat the bearing, wind a rope around the hub bolt and turn the hub by pulling at a 90_ angle with a spring balance. Measure to determine whether or not the rotary-sliding resistance of the rear hub is at the limit value. Limit: 18 N or less 4. If the rotary-sliding resistance exceeds the limit value, replace the rear hub assembly.
27-4
REAR AXLE - On-vehicle Service HUB BOLT REPLACEMENT

27100100112
MB991618
MB990767
1. For vehicles with rear disc brake, remove the caliper assembly, suspend the caliper assembly with a wire and remove the brake disc. 2. For vehicles with rear drum brake, remove the brake drum. 3. Pull the hub bolt out using the special tool. NOTE For vehicles with drum brakes, the hub bolts should be removed near the retainer spring installation position in order to maintain enough clearance for removal. 4. Install the plain washer to the new hub bolt, and install the bolt with a nut.
MB990767 Plane washer
REAR AXLE - Rear Axle Hub
27-5
27100200188
REAR AXLE HUB

<Vehicles with drum brake>
5
74 - 88 Nm
3 8 7 6
<Vehicles with disc brake>

74 - 88 Nm
1
100 Nm
7 6
Removal steps 1. Rear wheel-speed sensor <Vehicles with ABS> (Refer to GROUP 35B.) AA" 2. Caliper assembly 3. Brake drum 4. Brake disc 5. Brake hose installation bracket 6. Rear hub assembly AB" "AA 7. Rotor <Vehicles with ABS> AC" 8. Backing plate
Caution The rear hub unit bearing should not be dismantled. When removing the rear hub assembly, the wheel bearing inner race may be left at the spindle side. In this case, always replace the rear hub assembly, otherwise the hub will damage the oil seal, causing oil leaks or excessive play.
27-6
REAR AXLE - Rear Axle Hub REMOVAL SERVICE POINTS

Socket MB991248
AA" CALIPER ASSEMBLY REMOVAL Remove the caliper assembly and suspend it. AB" ROTOR REMOVAL AC" BACKING PLATE REMOVAL Remove the backing plate and suspend it.
Socket

"AA ROTOR INSTALLATION
REAR AXLE - Knuckle
27-7
27100300123
KNUCKLE
Pre-removal Operation Rear Hub Assembly Removal (Refer to P.27-5.)
Post-installation Operation D Check the Dust Cover for Cracks or Damage by Pushing It with Finger. D Rear Hub Assembly Installation (Refer to P.27-5.)
5
98 Nm*
7
98 Nm 28 Nm
4 6
118 - 137 Nm*
98 Nm*
AA"
Removal steps 1. Trailing arm connection 2. Lower arm connection 3. Toe control arm connection 4. Shock absorber connection 5. Upper arm connection 6. Hub cap
7. Knuckle Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
MB990635, MB991113 or MB991406 Nut Cord

AA" TOE CONTROL ARM DISCONNECTION Caution 1. Use the special tool to loosen the nut only; do not remove it from the ball joint. 2. Tie the special tool with a cord not to let it fall off.
Ball joint
NOTES
31-1
WHEEL AND TYRE

CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 5
31109000120
Tyre Inflation Pressure Check . . . . . . . . . . . . . . . . . 6 Tyre Wear Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wheel Runout Check . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL AND TYRE . . . . . . . . . . . . . . . . . . . . . . . . 6
31-2
WHEEL AND TYRE - General Information

31100010221
GENERAL INFORMATION
Both steel type and aluminium type wheels have been adopted. The type of wheel used depends on the vehicle model.
Items EA2ASNJEQL6, WLNJEQL6
A compact spare tyre has been adopted as the spare tyre in some models.
EA2ASNHEQL6, ASRHEQL6, WLNHEQL6, WLRHEQL6 Steel type Aluminium type* 14 5 1/2 JJ 15 6 JJ* 46 114.3 195/65R14 89 V 195/60R15 88 V* Steel type 15 x 4.0T 14 x 5 1/2 JJ* 15 x 6 JJ* 46 114.3 T125/70D15 (High pressure) 195/65R14 89V* 195/60R15 88V* EA5ASNGEQL6, ASRGEQL6, WLNGEQL6, WLRGEQL6 Aluminium type 15 6 JJ 46 114.3 195/60R15 88 V 205/60R15 91 V* Steel type 15 x 4.0T 15 x 6 JJ* 46 114.3 T125/70D15 (High pressure) 195/60R15 88V* 205/60R15 91 V*
Wheel
Type Size Amount of wheel offset mm Pitch circle diameter (P.C.D.) mm
Steel type Aluminium type* 14 5 1/2 JJ 46 114.3 195/65R14 89 V Steel type 15 x 4.0T 14 x 5 1/2 JJ* 46 114.3 T125/70D15 (High pressure) 195/65R14 89V*
Tyre Spare wheel
Size Type Size
Amount of wheel offset mm Pitch circle diameter (P.C.D) mm Spare tyre Size
NOTE *: Optional items
WHEEL AND TYRE - General Information

Items EA6ASNHFQL6, WLNHFQL6 EA2ASNJEQL6C, WLNJEQL6C
31-3
EA2ASNHEQL6C, ASRHEQL6C, ASNHEQR6, ASRHEQR6, WLNHEQL6C, WLRHEQL6C, WLNHEQR6, WLRHEQR6 Steel type Aluminium type* 14 5 1/2 JJ 15 6 JJ* 46 114.3 195/65R14 89 V 195/60R15 88 V* Steel type Aluminium type* 14 5 1/2 JJ 15 6 JJ* 46 114.3 195/65R14 89 V 195/60R15 88 V*
Wheel
Type Size Amount of wheel offset mm Pitch circle diameter (P.C.D.) mm
Steel type Aluminium type* 14 5 1/2 JJ 15 6 JJ* 46 114.3 185/70R14 88H 195/60R15 88 V* Steel type 15 x 4.0T 14 x 5 1/2 JJ* 15 6 JJ* 46 114.3 T125/70D15 (High pressure) 185/70R14 88H* 195/60R15 88 V*
Steel type Aluminium type* 14 5 1/2 JJ 46 114.3 195/65R14 89 V Steel type Aluminium type* 14 5 1/2 JJ
Tyre Spare wheel
Size Type Size
Amount of wheel offset mm Pitch circle diameter (P.C.D.) mm Spare tyre Size
46 114.3 195/65R14 89 V
31-4
Items
WHEEL AND TYRE - General Information/Service Specifications

EA5ASNGEQL6C, ASRGEQL6C, WLNGEQL6C, WLRGEQL6C Type Size Amount of wheel offset mm Pitch circle diameter (P.C.D.) mm Aluminium type 15 6 JJ 46 114.3 205/60R15 91 V Steel type 15 6 JJ 46 114.3 205/60R15 91 V EA6ASNHFQL6C, ASNHFQR6, WLNHFQL6C, WLNHFQR6 Steel type Aluminium type* 14 5 1/2 JJ 15 6 JJ* 46 114.3 185/70R14 88 H 195/60R15 88 V* Steel type Aluminium type* 14 5 1/2 JJ 15 6 JJ* 46 114.3 185/70R14 88 H 195/60R15 88 V EA5ASNGEQR6, ASRGEQR6, WLNGEQR6, WLRGEQR6 Aluminium type 15 6 JJ 46 114.3 195/60R15 88 V 205/60R15 91 V* Aluminium type 15 6 JJ 46 114.3 195/60R15 88 V 205/60R15 91 V*
Wheel
Tyre Spare wheel
Size Type Size Amount of wheel offset mm Pitch circle diameter (P.C.D.) mm
Spare tyre
Size
Items Tread depth of tyre mm Wheel runout (Radial runout) mm Steel wheel Aluminium wheel Wheel runout (Lateral runout) mm Steel wheel Aluminium wheel Limit 1.6 1.2 or less 1.0 or less 1.2 or less 1.0 or less
31100030135
WHEEL AND TYRE - Troubleshooting
31-5
31100070083
TROUBLESHOOTING
Symptom Rapid wear at shoulders Probable cause Under-inflation or lack of rotation Remedy Adjust the tyre pressure. 31-6.
Reference page
Rapid wear at centre
Over-inflation or lack of rotation
Cracked treads
Under-inflation
Adjust the tyre pressure.
31-6.
Wear side
on
one
Excessive camber
Inspect the camber.
Feathered edge
Incorrect toe-in
Adjust the toe-in.
Bald spots
Unbalanced wheel
Adjust the imbalanced wheels.
Scalloped wear
Lack of rotation of tyres or worn or out-of-alignment suspension
Rotate the tyres and check the front suspension alignment.
31-6
WHEEL AND TYRE - On-vehicle Servic/Wheel and Tyre
ON-VEHICLE SERVICE
TYRE INFLATION PRESSURE CHECK
31100090089
NOTE For information on tyre inflation pressure, refer to the label attached at the drivers side to the centre pillar.
TYRE WEAR CHECK

Measure the tread depth of tyres. Limit: 1.6 mm
31100100034
If the remaining tread depth is less than the limit, replace the tyre. NOTE When the tread depth of tyres is reduced to 1.6 mm or less, wear indicators will appear.
WHEEL RUNOUT CHECK

Radial
31100110037
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:
Item Radial runout mm Steel wheel 1.2 1.2 Aluminium wheel 1.0 1.0
Lateral
Lateral runout mm
If wheel runout exceeds the limit, replace the wheel.
WHEEL AND TYRE

Tighten the wheel nut to the specified torque. Tightening torque: 98 Nm
31100130071
32-1
POWER PLANT MOUNT

CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . 4
32109000165
TRANSMISSION MOUNTING . . . . . . . . . . . . . . . . 5 ENGINE ROLL STOPPER, CENTERMEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 6
32-2
POWER PLANT MOUNT - General Information/Service Specifications

32100010150
GENERAL INFORMATION
The engine-transmission mount is of an inertial axis supporting type whose excellent features have already been proven in many Mitsubishi vehicles. The inertial axis supporting type mount supports
the front upper part of the engine at the front and the rear upper part of the transmission at the rear. This arrangement effectively supresses the engine vibration.
Dynamic damper Engine mount Crossmember
Dynamic damper Engine mount
Transmission mount
Centermember Front
Rear roll stopper
Front roll stopper Front roll stopper Transmission mount Rear roll stopper Centermember Crossmember Dynamic damper
Items Crossmember Bushing (A) projection mm Bushing (B) projection mm Bushing (C) projection mm Standard value 9.0 1.0 4.0 1.0 4.0 0.5
32100030095
POWER PLANT MOUNT - Special Tools
32-3
32100060148
SPECIAL TOOLS
Tool Number MB991453 Name Engine hanger Use
To support the engine assembly during removal and installation of the transmission mount
Engine lifter
MB991045
Bushing remover and installer
Driving out and press-fitting of crossmember bushings A and B
MB990828
Bushing remover and installer
Driving out and press-fitting of crossmember bushing C
32-4
POWER PLANT MOUNT - Engine Mounting

32100110263
ENGINE MOUNTING
Pre-removal and Post-installation Operation D Jack Up the Engine and Transmission Assembly Until There is no Weight on the Engine Mount Bracket Insulator. D D Reserve Tank Removal and Installation (Refer to GROUP 14) Engine Cover Removal and Installation <6A1>
<6A1> 35 Nm <4D6> 12 Nm
1
5 Nm
2
67 Nm
6 4 5
57 Nm
98 - 118 Nm*
Removal steps 1. Engine mount stay <6A1> 2. Power steering hose bracket <4D6> 3. Engine mount insulator mounting bolt 4. Engine mount bracket "AA 5. Engine mount stopper 6. Dynamic damper
Engine side Dynamic damper Arrow Engine mount stopper Engine mount bracket

"AA ENGINE MOUNT STOPPER INSTALLATION Clamp the engine mount stopper so that the arrow points in the direction as shown in the diagram.
POWER PLANT MOUNT - Transmission Mounting
32-5
32100140170
TRANSMISSION MOUNTING
Pre-removal and Post-installation Operation D Air Cleaner Assembly Removal and Installation (Refer to GROUP 14.) D Battery and Battery Tray Removal and Installation D Centermember Removal and Installation D D
Transmission and Rear Roll Stopper Connecting Bolt Removal and Installation (Refer to P.32-6.) Rear Roll Stopper Bracket Removal and Installation (Refer to GROUP 22, 23 - Transmission Assembly)
81 Nm*
57 Nm
2 1
Removal steps AA" 1. Transmission mount bracket "AA 2. Transmission mount stopper
MZ203827

AA" TRANSMISSION MOUNT BRACKET REMOVAL (1) Install the special tool to the vehicle body to support the engine and transmission assembly. (2) Remove the centermember and rear roll stopper bracket. (3) Remove the bolt and nut of the transmission mount bracket. (4) After lowering the engine and transmission assembly, remove the transmission mount bracket.
MB991453
Engine side Arrow Transmission mount stopper

"AA TRANSMISSION MOUNT STOPPER INSTALLATION Clamp the transmission mount stopper so that the arrow points in the direction as shown in the diagram.
32-6
POWER PLANT MOUNT - Engine Roll Stopper, Centermember

32100200144
ENGINE ROLL STOPPER, CENTERMEMBER

44 Nm 44 Nm*
11 10
44 Nm 57 Nm*
5 8
1 2
69 - 78 Nm
7 6 3 2
93 Nm
4 2
25 Nm 69 - 78 Nm
Front roll stopper, centermember removal steps 1. Transmission and front roll stopper connecting bolt 2. Centermember mounting bolts 3. Stopper 4. Centermember "AA 5. Front roll stopper 6. Collar 7. Bushing (lower) 8. Bushing (upper) 9. Dynamic damper <4G6, 4D6>
Rear roll stopper removal steps 10. Transmission and rear roll stopper connecting bolt 11. Rear roll stopper

Hole
"AA FRONT ROLL STOPPER INSTALLATION Install so that the hole in the front roll stopper is facing towards the front of the vehicle.
Front of vehicle
POWER PLANT MOUNT - Crossmember
32-7
32100320178
CROSSMEMBER
CAUTION: SRS For vehicles with SRS, before removal of steering gear box, refer to GROUP 52B, centre front wheels and remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative, risking serious driver injury.
Pre-removal Operation D Power Steering Fluid Draining (Refer to GROUP 37A - On-vehicle Service.) D Centermember Removal (Refer to P.32-6.) D Front Exhaust Pipe Removal (Refer to GROUP 15.) D Stabilizer Bar Removal (Refer to GROUP 33A.) D Rear Roll Stopper Removal (Refer to P.32-6.)
Post-installation Operation D Rear Roll Stopper Installation (Refer to P.32-6.) D Stabilizer Bar Installation (Refer to GROUP 33A.) D Front Exhaust Pipe Installation (Refer to GROUP 15.) D Centermember Installation (Refer to P.32-6.) D Power Steering Fluid Supplying and Bleeding (Refer to GROUP 37A - On-vehicle Service.) D Steering Wheel Straight Ahead Position Checking D Wheel Alignment Check and Adjustment (Refer to GROUP 33A - On-vehicle Service.)
11 10
98 - 118 Nm*
6 7 3
81 Nm
14 8
88 Nm
13
12
81 Nm
1
69 - 78 Nm 88 Nm*
5 2
4
88 Nm 98 - 118 Nm
AA"
Removal steps 1. No. 2 stay 2. Lateral lower arm and damper fork connection 3. Lateral lower arm and crossmember connection 4. No. 3 stay 5. Compression lower arm mounting bolts 6. No. 1 stay D Power steering gear box (Refer to GROUP 37A.) 7. Crossmember mounting nut
Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
8. 9. 10. 11. 12. 13. 14.
Lower plate Crossmember Stopper A Stopper B Bushing C Bushing A Bushing B
32-8
POWER PLANT MOUNT - Crossmember REMOVAL SERVICE POINT

AA" NO.3 STAY REMOVAL Hold the crossmember with a transmission jack, and remove No.3 stay.
Crossmember
Transmission jack
Removal
Bolt Washer
Press-fitting Nut Base
CROSSMEMBER BUSHING REPLACEMENT

32100090062
Base Nut
CROSSMEMBER BUSHINGS A AND B (1) Apply soapy water to the contact surface of the bushing when press-fitted the bushing.
Washer Bolt
MB991045
Bushing A Inner pipe
Bushing B Inner pipe
(2) The bushing should be press-fitted so that the inner pipe projection is at the standard length. Standard values Bushing A: 9.0 1.0 mm Bushing B: 4.0 1.0 mm
Removal
Press-fitting
CROSSMEMBER BUSHING C (1) Use the special tool to drive out and press-fit the crossmember bushing C.
MB990828
(2) The bushing should be press-fitted so that the inner pipe projection is at the standard length. Standard value (A): 4.0 0.5 mm
A Inner pipe
33A-1
FRONT SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4
Wheel Alignment Check and Adjustment . . . . . . . 4 Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . . 5
33209000158
UPPER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . 6 SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . 9 COMPRESSION LOWER ARM AND LATERAL LOWER ARM ASSEMBLIES . . . . . . . . . . . . . . 12 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 15
33A-2
FRONT SUSPENSION - General Information

33200010181
GENERAL INFORMATION
The front suspension is of a multi-link construction with two lower arms which create the ideal virtual kingpin axis for the suspension system. In addition,
by mounting the upper arm in a higher position than the tyres, excellent steering stability and ride comfort are obtained.
COIL SPRING
Items Sedan (2000 - petrol-powered vehicles - M/T), Wagon (2000 - petrol-powered vehicles) 12 70 - 110 366 Sedan (except 2000 petrol-powered vehicles - M/T), Wagon (except 2000 petrol-powered vehicles) 12 70 - 110 374
Wire diameter average diameter free length mm
CONSTRUCTION DIAGRAM
Shock absorber Crossmember Stabilizer bar
Upper arm
Knuckle
Compression lower arm
Centermember
Lateral lower arm
FRONT SUSPENSION - Service Specifications/Special Tools
33A-3
33200030125
Items Toe-in At the centre of tyre tread mm Toe-angle (per wheel) Toe-out angle on turns (inner wheel when outer wheel at 20_) Camber Caster Kingpin inclination Upper arm ball joint rotation starting torque Nm Compression lower arm ball joint rotation starting torque Nm Lateral lower arm ball joint rotation starting torque Nm Stabilizer link ball joint turning torque Nm Standard value 03 0_00 09 22_
0_00 30 (difference between right and left wheel: less than 30) 4_20 1_30 (difference between right and left wheel: less than 30) 7_20 1_30 0.3 - 1.5 0.5 - 2.5 1.5 or less 0.5 - 1.5
33200060117
SPECIAL TOOLS
Tools Number MB991004 Name Wheel alignment gauge attachment Use
Wheel alignment measurement <Vehicles with aluminium type wheels>
A: MB991237
A B
A: B:
B: MB991238
Spring com- Coil spring compression pressor body Arm set
MB991406, MB990635 MB991113
or
Steering linkage puller
Ball joint disconnection
MB990326
Preload socket
Ball joint rotation starting torque and turning torque measurement
MB990800
Ball joint remover and installer
Ball joint dust cover installation
33A-4
FRONT SUSPENSION - On-vehicle Service
ON-VEHICLE SERVICE
WHEEL ALIGNMENT CHECK AND ADJUSTMENT
33100090175
Measure the wheel alignment with the vehicle parked on a level surface. The front suspension, steering system, and wheels should be serviced to normal condition prior to measurement of wheel alignment. TOE-IN Standard value: At the centre of tyre tread 03 mm Toe angle (per wheel) 0_0009
Clip
(1) If the toe-in is not within the standard value, adjust the toe-in by undoing the clips and turning the left and right tie rod turnbuckles by the same amount (in opposite directions). NOTE The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle. (2) Use a turning radius gauge to check that the steering angle is at the standard value. (Refer to GROUP 37A - On-vehicle Service.) TOE-OUT ANGLE ON TURNS To check the steering linkage, especially after the vehicle has been involved in an accident or if an accident is presumed, it is advisable to check the toe-out angle on turns in addition to the wheel alignment. Conduct this test on the left turn as well as on the right turn. Standard value: 22_ (inner wheel when outer wheel at 20_)
FRONT SUSPENSION - On-vehicle Service
33A-5
CAMBER, CASTER AND KINGPIN INCLINATION

MB991004
Standard value: Camber 0_00 30 (difference between right and left wheel: less than 30) Caster 4_20 1_30 (difference between right and left wheel: less than 30) Kingpin inclination 7_20 1_30 NOTE 1. Camber and caster are preset at the factory and cannot be adjusted. 2. If camber is not within the standard value, check and replace bent or damaged parts. 3. For vehicles with aluminium type wheels, attach the camber/caster/kingpin gauge to the drive shaft by using the special tool. Tighten the special tool to the same torque 196 - 255 Nm as the drive shaft nut. Caution Never subject the wheel bearings to the vehicle load when the drive shaft nuts are loosened.
BALL JOINT DUST COVER CHECK
33200860021
(1) Check the dust cover for cracks or damage by pushing it with finger. (2) If the dust cover is cracked or damaged, replace the upper arm assembly, compression lower arm assembly, lateral lower arm assembly or stabilizer link. NOTE Cracks or damage of the dust cover may cause damage of the ball joint.
33A-6
FRONT SUSPENSION - Upper Arm Assembly

33200430079
UPPER ARM ASSEMBLY

Post-installation Operation D Check the Dust Cover for Cracks or Damage by Pushing it with Finger. D Wheel Alignment Check and Adjustment (Refer to P.33A-4.)
2
86 Nm
57 Nm
57 Nm
28 Nm
AA"
Removal steps 1. Upper arm and knuckle connection 2. Upper arm mounting nut
"AA 3. Upper arm shaft assembly 4. Upper arm assembly

AA" UPPER ARM AND KNUCKLE DISCONNECTION Caution 1. Use the special tool to loosen the nut only; do not remove it from the ball joint. 2. Tie the special tool with a cord not to let it fall off.
Nut

Upper arm shaft assembly
33A-7

"AA UPPER ARM SHAFT ASSEMBLY INSTALLATION Install the upper arm shaft assembly at the angle shown in the illustration. NOTE If the upper arm shaft is installed at the above-mentioned angle, the reference dimension is determine as follows;
Upper arm
85_ 1_
A: 300.1 mm B: 234.3 mm
B
Ball joint case V groove
INSPECTION
MB990326
33200440072
UPPER ARM BALL JOINT ROTATION STARTING TORQUE CHECK (1) After shaking the ball joint stud several times, install the nut to the stud and use the special tool to measure the rotation starting torque of the ball joint. Standard value: 0.3 - 1.5 Nm (2) When the measured value exceeds the standard value, replace the upper arm assembly. (3) When the measured value is lower than the standard value, check that the ball joint turns smoothly without excessive play. If so, it is possible to use that ball joint.
33A-8

UPPER ARM BALL JOINT DUST COVER CHECK
33200870017
(1) Check the dust cover for cracks or damage by pushing it with finger. (2) If the dust cover is cracked or damaged, replace the upper arm assembly. NOTE Cracks or damage of the dust cover may cause damage of the ball joint. When it is damaged during service work, replace the dust cover.
MB990800 Dust cover
UPPER ARM BALL JOINT DUST COVER 33200770065 REPLACEMENT

Snap ring
Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: (1) Remove the dust cover. (2) Apply multipurpose grease to the lip and inside of the dust cover. (3) Drive in the dust cover with special tool until it is fully seated. (4) Check the dust cover for cracks or damage by pushing it with finger.
FRONT SUSPENSION - Shock Absorber Assembly
33A-9
33200460078
SHOCK ABSORBER ASSEMBLY

Post-installation Operation D Wheel Alignment Check and Adjustment (Refer to P.33A-4.)
2
44 Nm
1
44 Nm
4
103 Nm
88 Nm*
Removal steps 1. Stabilizer link 2. Shock absorber mounting nuts 3. Damper fork and lateral lower arm connection 4. Damper fork and shock absorber connection
"AA 5. Damper fork 6. Shock absorber assembly Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
Damper fork positioning projection

"AA DAMPER FORK INSTALLATION The damper fork must face against the damper fork positioning projection of the shock absorber assembly as shown in the figure.
Inside of the body
Damper fork mounting bolt
33A-10
FRONT SUSPENSION - Shock Absorber Assembly

33200480050
23 Nm
9 2 3 4 5 11 12 6 7 8
10
Disassembly steps AA" "CA 1. Self-locking nut 2. Washer 3. Upper bushing A "BA 4. Upper bracket assembly 5. Upper spring pad 6. Collar
7. 8. 9. 10. "AA 11. 12.
Upper bushing B Cup assembly Bump rubber Dust cover Coil spring Shock absorber assembly

MB991237
AA" SELF-LOCKING NUT REMOVAL (1) Use the special tools to compress the coil spring. Caution 1. Install the special tools evenly, and so that the maximum length will be attained within the installation range. 2. Do not use an impact wrench to tighten the special tool bolt. (2) While holding the piston rod, remove the self-locking nut. Caution Do not use an impact wrench.
MB991238
FRONT SUSPENSION - Shock Absorber Assembly REASSEMBLY SERVICE POINTS
33A-11
"AA COIL SPRING INSTALLATION (1) Install the special tool in the same manner as for removal, and compress the coil spring to install to the shock absorber. Caution Do not use an impact wrench to tighten the bolt of the special tool.
(2) Align the upper side of the coil spring with the upper spring pad stepped portion and the lower side with the spring seat stepped portion, respectively.
Spring seat
End of coil spring
Damper fork positioning projection
"BA UPPER BRACKET ASSEMBLY INSTALLATION The upper bracket assembly must face against the damper fork positioning projection of the shock absorber as shown in the figure.
"CA SELF-LOCKING NUT INSTALLATION (1) Temporarily tighten the self-locking nut. (2) Remove the special tools (MB991237, MB991238), and tighten the self-locking nut to the specified torque. Caution Do not use an impact wrench.
33A-12
FRONT SUSPENSION -
Compression Lower Arm and Lateral Lower Arm Assemblies
COMPRESSION LOWER ARM AND LATERAL LOWER ARM ASSEMBLIES

Post-installation Operation D Check the Dust Cover for Cracks or Damage by Pushing it with Finger. D Wheel Alignment Check and Adjustment (Refer to P.33A-4.)
33200510100
8 4
98 - 118 Nm*
6
88 Nm* 59 - 71 Nm 81 Nm
3 2
7
81 Nm
5 9
69 - 78 Nm
1 10
LATERAL LOWER ARM 88 Nm
4, 10
98 - 118 Nm
AA" AB"
Compression lower arm assembly removal steps 1. No.3 stay 2. Compression lower arm and knuckle connection 3. Compression lower arm mounting bolts 4. Compression lower arm assembly
AB"
Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
Lateral lower arm assembly removal steps 5. No.2 stay 6. Lateral lower arm and damper fork connection 7. Lateral lower arm and knuckle connection 8. Lateral lower arm mounting bolt 9. Stopper 10. Lateral lower arm assembly
FRONT SUSPENSION -
33A-13

AA" NO.3 STAY REMOVAL No.3 stay is tightened together with the crossmember. Therefore, after removing No.3 stay, install the nut and bolt to the crossmember provisionally.
No.3 stay
Crossmember
Nut
MB991406, MB990635 or MB991113 Cord
AB" COMPRESSION LOWER ARM AND KNUCKLE/LATERAL LOWER ARM AND KNUCKLE DISCONNECTION Caution 1. Use the special tool to loosen the nut only; do not remove it from the ball joint. 2. Tie the special tool with a cord not to let it fall off.
Ball joint
INSPECTION
MB990326
33200520066
LOWER ARM BALL JOINT ROTATION STARTING TORQUE CHECK (1) After shaking the ball joint stud several times, install the nut to the stud and use the special tool to measure the rotation starting torque of the ball joint. Compression lower arm ball joint Standard value: 0.5 - 2.5 Nm Lateral lower arm ball joint Standard value: 1.5 Nm or less (2) When the measured value exceeds the standard value, replace the lower arm assembly. (3) When the measured value is lower than the standard value, check that the ball joint turns smoothly without excessive play. If so, it is possible to use that ball joint.
LOWER ARM BALL JOINT DUST COVER CHECK

33200880010
(1) Check the dust cover for cracks or damage by pushing it with finger. (2) If the dust cover is cracked or damaged, replace the lower arm assembly. NOTE Cracks or damage of the dust cover may cause damage of the ball joint. When it is damaged during service work, replace the dust cover.
33A-14
FRONT SUSPENSION LATERAL LOWER ARM Tapered portion
LOWER ARM BALL JOINT DUST COVER 33200780051 REPLACEMENT

Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: (1) Remove the dust cover. (2) Apply multipurpose grease to the inside of the dust cover. (3) Apply multipurpose grease to the shown portion on the top of the lateral lower arm assembly dust cover. Caution Be careful not to let multipurpose grease touch the ball joint thread and the knuckle joint (tapered portion). If it touches, wipe away it.
MB990800 Dust cover
(4) Drive in the dust cover with special tool until it is fully seated. (5) Check the dust cover for cracks or damage by pushing it with finger.
FRONT SUSPENSION - Stabilizer Bar
33A-15
33200540079
STABILIZER BAR
Pre-removal Operation D Left Side of No.1 and No.2 Stays Disconnection <L.H. Drive Vehicles> (Refer to GROUP 32 Crossmember.) D Right Side of No.1 and No.2 Stays Disconnection <R.H. Drive Vehicles> (Refer to GROUP 32 Crossmember.)
Post-installation Operation D Check the Dust Cover for Cracks or Damage by Pushing it with Finger. D Right Side of No.1 and No.2 Stays Connection <R.H. Drive Vehicles> (Refer to GROUP 32 Crossmember.) D Left Side of No.1 and No.2 Stays Connection <L.H. Drive Vehicles> (Refer to GROUP 32 Crossmember.)
5
44 Nm
1 1
44 Nm
Removal steps 1. Stabilizer link mounting nut 2. Stabilizer link "AA 3. Stabilizer bar bracket
"AA 4. Bushing "AA 5. Stabilizer bar
Approx. 20 mm

"AA STABILIZER BAR/BUSHING/STABILIZER BAR BRACKET INSTALLATION Position the stabilizer bar so that left side identification mark is at the shown position, and tighten the stabilizer bar bracket mounting bolt.
Inside of the body
33A-16
FRONT SUSPENSION - Stabilizer Bar INSPECTION

33200550072
STABILIZER LINK BALL JOINT TURNING TORQUE CHECK (1) After shaking the ball joint stud several times, install the nut to the stud and use the special tool to measure the turning torque of the ball joint. Standard value: 0.5 - 1.5 Nm (2) When the measured value exceeds the standard value, replace the stabilizer link. (3) When the measured value is lower than the standard value, check that the ball joint turns smoothly without excessive play. If so, it is possible to use that ball joint.
STABILIZER LINK BALL JOINT DUST COVER CHECK

33200890013
(1) Check the dust cover for cracks or damage by pushing it with finger. (2) If the dust cover is cracked or damaged, replace the stabilizer link. NOTE Cracks or damage of the dust cover may cause damage of the ball joint. When it is damaged during service work, replace the dust cover.
STABILIZER LINK BALL JOINT DUST COVER 33200790078 REPLACEMENT

Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: (1) Remove the clip ring and the dust cover. (2) Apply multipurpose grease to the inside of the dust cover.
Clip ring
Plastic tape
Approx. 90_ Clip ring ends (180_ on opposite side also possible)
(3) Use plastic tape on the stabilizer link threads as shown in the illustration, and then install the dust cover to the stabilizer link. (4) Secure the dust cover by the clip ring. When installing the clip ring, align the ends at a 90_ angle from the axis of the stabilizer link. (5) Check the dust cover for cracks or damage by pushing it with finger.
34-1
REAR SUSPENSION
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 4
Wheel Alignment Check and Adjustment . . . . . . . 4 Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . . 4
34109000145
UPPER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . 7 TRAILING ARM ASSEMBLY . . . . . . . . . . . . . . . . 9 LOWER ARM AND TOE CONTROL ARM ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SHOCK ABSORBER ASSEMBLY . . . . . . . . . 13 STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 16
REAR SUSPENSION ASSEMBLY . . . . . . . . . . . 5
34-2
REAR SUSPENSION - General Information

34100010192
GENERAL INFORMATION
The rear suspension is a multi-link suspension, which has been used for the previous models. The layout of each arm and the rigidity balance of each
bushing have been rationalized to provide both excellent steering stability and riding comfort.
COIL SPRING
Items Wire diameter average diameter free length mm NOTE *1: Self-leveling shock absorber *2: Heavy-duty suspension Sedan 9 62 - 102 397, 9 94 - 102 330*1, 9 - 10 63 - 103 386*2 Wagon 9 - 10 63 - 103 405, 10 95 - 103 321*1, 10 - 11 64 - 104 383*2
Shock absorber
Upper arm Knuckle
Crossmember Toe control arm
Lower arm
Trailing arm
REAR SUSPENSION - Service Specifications/Special Tools
34-3
34100030174
Items Toe-in At the centre of tyre tread mm Toe-angle (per wheel) Camber Dimension for positioning upper arm bracket mm Toe control arm ball joint turning torque Nm Stabilizer link ball joint turning torque Nm Specifications 33 0_09 09 - 1_00 30 37.2 2 1.0 - 2.6 0.5 - 1.5
SPECIAL TOOLS
Tool Number MB990635, MB991113 or MB991406 Name Steering linkage puller Use
34100060159
Ball joint and knuckle disconnection
MB990326
Preload socket
Ball joint continuous rotating check
MB990800
Ball joint remover and installer
Ball joint dust cover installation
A B
A: MB991237 B: MB991239
A: B:
Spring compressor body Arm set
Coil spring compression
34-4
REAR SUSPENSION - On-vehicle Service
ON-VEHICLE SERVICE
Crossmember
33100100106
WHEEL ALIGNMENT CHECK AND ADJUSTMENT

TOE-IN Standard value: At the centre of tyre tread 3 3 mm Toe angle (per wheel) 0_09 09 Turn the toe control arm mounting bolts of the left and right toe control arms by equal amounts to adjust. LH: Clockwise viewed from the rear Toe-out RH: Clockwise viewed from the rear Toe-in Furthermore, toe adjustment can be mode at graduations of approximately 2.5 mm CAMBER Standard value: - 1_00 30 NOTE 1. Camber is preset at the factory and can not be adjusted. 2. If camber is not within the standard value, check and replace bent or damaged parts.
34101280011
1. Check the dust cover for cracks or damage by pushing it with finger. 2. If the dust cover is cracked or damaged, replace the toe control arm assembly or stabilizer link. NOTE Cracks or damage of the dust cover may cause damage of the ball joint.
REAR SUSPENSION - Rear Suspension Assembly
34-5
34100330113
REAR SUSPENSION ASSEMBLY

Pre-removal Operation D Brake Fluid Draining <Vehicles with drum brake> D Rear Seat Removal <Sedan> (Refer to GROUP 52A.) D Retractor Trim Removal <Wagon> (Refer to GROUP 52A.) D Center Exhaust Pipe Removal (Refer to GROUP 15.)
Post-installation Operation D Center Exhaust Pipe Installation (Refer to GROUP 15.) D Retractor Trim Installation <Wagon> (Refer to GROUP 52A.) D Rear Seat Installation <Sedan> (Refer to GROUP 52A.) D Parking Brake Lever Stroke Check (Refer to GROUP 36 - On-vehicle Service.) D Brake Line bleeding <Vehicles with drum brake> (Refer to GROUP 35A - On-vehicle Service.) D Wheel Alignment Check and Adjustment (Refer to P.34-4.)
1 2
44 Nm
8
39 Nm
12 13 11
88 Nm
137 - 157 Nm*
100 Nm
5 4
7
15 Nm
10 9
AA"
Removal steps 1. Cap 2. Shock absorber mounting nuts 3. Brake caliper assembly 4. Brake disc or brake dram 5. Shoe and lining assembly (Refer to GROUP 36 - Parking Brake Drum.) 6. Parking brake cable connection (Refer to GROUP 36.) 7. Brake hose connection <Vehicles with drum brake> 8. Upper arm mounting bolts
AB"
9. 10. 11. 12.
Grommet Trailing arm mounting bolt Crossmember mounting nuts Rear wheel speed sensor connector connection <Vehicles with ABS> 13. Rear suspension assembly
Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicles on the ground in the unladen condition.
34-6
REAR SUSPENSION - Rear Suspension Assembly REMOVAL SERVICE POINT

AA" BRAKE CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire, so that it does not fall.
AB" CROSSMEMBER MOUNTING NUT REMOVAL Hold the crossmember with a garage jack or transmission jack to remove a crossmember mounting nut.
REAR SUSPENSION - Upper Arm Assembly
34-7
34100360082
UPPER ARM ASSEMBLY

Post-installation Operation Wheel Alignment Check and Adjustment (Refer to P.34-4.)
39 Nm
2 3
98 Nm*
1 4
57 Nm
57 Nm
Removal 1. Upper bolt 2. Upper bolts 3. Upper "AA 4. Upper
steps arm and knuckle connecting arm assembly mounting arm assembly arm bracket
5. Upper arm Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicles on the ground in the unladen condition.
34-8
Upper arm
REAR SUSPENSION - Upper Arm Assembly INSTALLATION SERVICE POINT

"AA UPPER ARM BRACKET INSTALLATION Install the upper arm bracket that the dimension shown in the illustration is at the standard value. Standard value (A): 37.2 2 mm
Upper arm bracket
NOTE Refer to distances B and C shown in the illustration to check the installation angle of the upper arm bracket.
B: 220.1 mm C: 274.4 mm
REAR SUSPENSION - Trailing Arm Assembly
34-9
34100420162
TRAILING ARM ASSEMBLY

Post-installation Operation Wheel Alignment Check and Adjustment (Refer to P.34-4.)
137 - 157 Nm*
118 - 137 Nm*
3 2
Removal steps 1. Knuckle and trailing arm assembly connecting bolt 2. Grommet 3. Trailing arm assembly mounting bolt 4. Stopper
5. Trailing arm assembly Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicles on the ground in the unladen condition.
34-10 REAR SUSPENSION -
Lower Arm and Toe Control Arm Assemblies

34100450086
LOWER ARM AND TOE CONTROL ARM ASSEMBLIES

Post-installation Operation D Check the Dust Cover for Cracks or Damage by Pushing it with Finger D Wheel Alignment Check and Adjustment (Refer to P.34-4.)
67 - 98 Nm*
4 8
98 Nm*
6
28 Nm
2 5 3
98 Nm*
39 Nm
Lower arm assembly removal steps 1. Stabilizer link connection 2. Wheel speed sensor mounting bolts 3. Lower arm assembly and knuckle connecting bolt 4. Lower arm assembly mounting bolt 5. Lower arm assembly
AA" AB"
Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicles on the ground in the unladen condition.
Toe control arm assembly removal steps 6. Toe control arm and knuckle connection 7. Toe control arm assembly mounting bolt 8. Toe control arm assembly
REAR SUSPENSION - Lower Arm and Toe Control Arm Assemblies

MB990635, MB991113 or MB991406
34-11

AA" TOE CONTROL ARM AND KNUCKLE DISCONNECTION
Cord
Nut
Caution 1. Use the special tool to loosen the nut only; do not removal it from the ball joint. 2. Tie the special tool with a cord not to let it fall off.
Ball joint
Plate
AB" TOE CONTROL ARM ASSEMBLY MOUNTING BOLT REMOVAL Place mating marks on the crossmember and the plate before removing the bolt.
Mating marks
INSPECTION
MB990326
34100460096
TOE CONTROL ARM BALL JOINT TURNING TORQUE CHECK 1. After shaking the ball joint stud several times, install the nut to the stud and use the special tool to measure the turning torque of the ball joint. Standard value: 1.0 - 2.6 Nm 2. When the measured value exceeds the standard value, replace the toe control arm assembly. 3. When the measured value is lower than the standard value, check that the ball joint turns smoothly without excessive play. If so, it is possible to use that ball joint.
MB990800 Dust cover Snap ring
TOE CONTROL ARM BALL JOINT DUST 34101290014 COVER CHECK

1. Check the dust cover for cracks or damage by pushing it with finger. 2. If the dust cover is cracked or damaged, replace the toe control arm assembly. NOTE Cracks or damage of the dust cover may cause damaged of the ball joint. When it is damaged during service work, replace the dust cover.
34-12 REAR SUSPENSION -
Lower Arm and Toe Control Arm Assemblies
TOE CONTROL ARM BALL JOINT DUST 34101080062 COVER REPLACEMENT

Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Remove the dust cover. 2. Apply multipurpose grease to inside and lip of the dust cover. 3. Using the special tool, press the dust cover until it contacts the snap ring. 4. Check the dust cover for cracks or damage by pushing it with finger.
REAR SUSPENSION - Shock Absorber Assembly
34-13
34100510159
SHOCK ABSORBER ASSEMBLY

Pre-removal and Post-installation Operation D Rear Seat Removal and Installation <Sedan> (Refer to GROUP 52A.) D Retractor Trim Removal and Installation <Wagon> (Refer to GROUP 52A.)
1 2
44 Nm
3
98 Nm
Removal steps 1. Cap 2. Shock absorber mounting nuts 3. Bolt "AA 4. Shock absorber assembly

Outside of the body Lower bushing inner pipe
"AA SHOCK ABSORBER ASSEMBLY INSTALLATION Install the shock absorber so that the larger diameter side of the lower bushing inner pipe faces toward the outside of the vehicle.
34-14
REAR SUSPENSION - Shock Absorber Assembly

34100530117
23 Nm
1 8 11 9 2 3 4 5 6 12 7
10
Disassembly steps AA" "CA 1. Self-locking nut 2. Washer 3. Upper bushing A "BA 4. Upper bracket assembly 5. Upper spring pad 6. Collar
7. 8. 9. 10. "AA 11. 12.
Upper bushing B Cup assembly Bump rubber Dust cover Coil spring Shock absorber assembly

MB991237
MB991239
AA" SELF-LOCKING NUT REMOVAL 1. Use the special tools to compress the coil spring. Caution (1) Install the special tools evenly, and so that the maximum length will be attained within the installation range. (2) Do not use an impact wrench to tighten the special tool bolt. 2. While holding the piston rod, remove the self-locking nut. Caution Do not use an impact wrench.
REAR SUSPENSION - Shock Absorber Assembly REASSEMBLY SERVICE POINTS
34-15
"AA COIL SPRING INSTALLATION 1. Install the special tool in the same manner as for removal, and compress the coil spring to install the shock absorber. Caution Do not use an impact wrench to tighten the special tool bolt.
Coil spring edge Spring seat
2. Align the edge of the coil spring to the stepped part of the shock absorber spring seat. "BA UPPER BRACKET ASSEMBLY INSTALLATION Install the upper bracket assembly so that the lower bushing inner pipe of the shock absorber is at the shown position.
Lower bushing inner pipe
"CA SELF-LOCKING NUT INSTALLATION 1. Temporarily tighten the self-locking nut. 2. Remove the special tools (MB991237, MB991239), and tighten the self-locking nut to the specified torque. Caution Do not use an impact wrench.
34-16 STABILIZER BAR
REAR SUSPENSION - Stabilizer Bar

34100560109

Post-installation Operation Check the Dust Cover for Cracks or Damage by Pushing it with Finger.
44 Nm
1
39 Nm
39 Nm
Removal steps 1. Stabilizer link mounting nuts 2. Stabilizer link "AA 3. Stabilizer bar bracket
"AA 4. Bushing "AA 5. Stabilizer bar
Approx. 20 mm

"AA STABILIZER BAR/BUSHING/STABILIZER BAR BRACKET INSTALLATION Position the stabilizer bar identification mark to the left side. Adjust the identification mark position as shown in the figure, and tighten the stabilizer bar bracket mounting bolt.
Outside of the body
REAR SUSPENSION - Stabilizer Bar INSPECTION

MB990326
34-17
34100570119
STABILIZER LINK BALL JOINT TURNING TORQUE CHECK 1. After shaking the ball joint stud several times, install the nut to the stud and use the special tool to measure the turning torque of the ball joint. Standard value: 0.5 - 1.5 Nm 2. When the measured value exceeds the standard value, replace the stabilizer link. 3. When the measured value is lower than the standard value, check that the ball joint turns smoothly without excessive play. If so, it is possible to use that ball joint.
STABILIZER LINK BALL JOINT DUST COVER CHECK

34101300014
1. Check the dust cover for cracks or damage by pushing it with finger. 2. If the dust cover is cracked or damaged, replace the stabilizer link. NOTE Cracks or damage of the dust cover may cause damage of the ball joint. When it is damaged during service work, replace the dust cover.
STABILIZER LINK BALL JOINT DUST COVER 34101090089 REPLACEMENT

Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Remove the clip ring and the dust cover. 2. Apply multipurpose grease to the lip and inside of the dust cover.
Clip ring
Plastic tape Approx. 90_ Clip ring ends (180_ on opposite side also possible)
3. Use plastic tape on the stabilizer link threads as shown in the illustration, and then install the dust cover to the stabilizer link. 4. Secure the dust cover with the clip ring. When installing the clip ring, align the ends at a 90_ angle from the axis of the stabilizer link. 5. Check the dust cover for cracks or damage by pushing it with finger.
NOTES
35A-1
SERVICE BRAKES
CONTENTS
35109000159
BASIC BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35A ANTI-SKID BRAKING SYSTEM (ABS) <2WD> . . . . . . . . . . . . . . . . . . . . . . 35B ANTI-SKID BRAKING SYSTEM (ABS) <4WD> . . . . . . . . . . . . . . . . . . . . . . 35C NOTE THE GROUPS MARKED BY ARE NOT IN THIS MANUAL
35A-2
BASIC BRAKE SYSTEM

CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 4 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6
Brake Pedal Check and Adjustment . . . . . . . . . . . 6 Stop Lamp Switch Check . . . . . . . . . . . . . . . . . . . . . 7 Brake Booster Operating Test . . . . . . . . . . . . . . . . . 7 Check Valve Operation Check . . . . . . . . . . . . . . . . . 8 Proportioning Valve Function Test . . . . . . . . . . . . . 9 Brake Fluid Level Sensor Check . . . . . . . . . . . . . . 9 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
35109000302
Disc Brake Pad Check and Replacement . . . . . 10 Disc Brake Rotor Check . . . . . . . . . . . . . . . . . . . . . 12 Brake Lining Thickness Check . . . . . . . . . . . . . . . 14 Brake Drum Inside Diameter Check . . . . . . . . . . 14 Brake Lining and Brake Drum Connection Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 15 MASTER CYLINDER AND BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DISC BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . 24

Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . 28
BASIC BRAKE SYSTEM - General Information
35A-3
35100010182
GENERAL INFORMATION
The brake system offers high dependability and durability along with improved braking performance and brake sensitivity.
Items Master cylinder Type I.D. mm Brake booster Type Effective dia. of power cylinder mm Boosting ratio Proportioning valve Type Decompression ratio Front brakes Type Disc effective dia. thickness mm Wheel cylinder I.D. mm Pad thickness mm Clearance adjustment Rear disc brakes Type Disc effective dia. thickness mm Wheel cylinder I.D. mm Pad thickness mm Clearance adjustment Rear drum brakes Type Drum I.D. mm Wheel cylinder I.D. mm Lining thickness mm Clearance adjustment Brake fluid Specifications Tandem type (with level sensor) 23.8 Vacuum type, single 230 6.0 Dual type 0.25 Floating caliper, 1-piston, ventilated disc 256 24 60.3 10.0 Automatic Floating caliper, 1-piston, solid disc 262 24 34.9 10.0 Automatic Leading trailing 203 20.6 4.4 Automatic DOT3 or DOT4
35A-4
BASIC BRAKE SYSTEM -
General Information/ Service Specifications
Brake booster Master cylinder
Rear brake Proportioning valve Front brake Brake pedal
Items Brake pedal height mm Brake pedal free play mm Brake pedal to floor board clearance mm Proportioning valve Split point MPa Sedan Wagon Output fluid pressure (Input fluid pressure) MPa Sedan Wagon Standard value 162.8 - 165.8 3-8 90 or more 2.94 0.25 3.43 0.25 4.66 0.39 (9.81) 5.80 0.39 (9.81) 9.65 - 9.90 10.0 24.0 69 or less Limit 0.39 2.0 22.4 0.06 -
35100030201
Output fluid pressure difference between left and right MPa Brake booster push rod protruding length mm Front disc brake Pad thickness mm Disc thickness mm Disc runout mm Drag force (tangential force of wheel mounting bolts) N
BASIC BRAKE SYSTEM Items Rear disc brake Pad thickness mm Disc thickness mm Disc runout mm
Service Specifications/Lubricants/ Sealants/Special Tools Standard value 10.0 10.0 69 or less 4.4 203 Limit 2.0 8.4 0.08 1.0 205
35A-5
Drag force (tangential force of wheel mounting bolts) N Rear drum brake Lining thickness mm Drum inside diameter mm
LUBRICANTS
Items Brake fluid Brake piston seal Slide pin boot and slide pin bush inner surfaces Brake piston boot inner surfaces Piston boot mounting grooves Rear brake shoe and backing plate contact surfaces Shoe assembly and auto adjuster assembly contact surfaces Shoe and lever assembly and auto adjuster assembly contact surfaces Brake grease SAE J310, NLGI No.1 Specified Lubricant DOT3 or DOT4 Repair kit grease (orange)
35100040082
SEALANTS
Items Thread part fitting Vacuum switch Specified sealant 3M ATD Part No. 8661 or equivalent Remarks Semi-drying sealant
35100050153
SPECIAL TOOLS
Tool Number MB990964 MB990520 MB990619 Name Brake tool set Use D D
35100060071
Pushing-in of the disc brake piston Installation of drum brake wheel cylinder piston cup
MB990998
Front hub remover and installer
Provisional holding of the wheel bearing
35A-6
BASIC BRAKE SYSTEM - On-vehicle Service
ON-VEHICLE SERVICE
Operating rod Operating rod lock nut Stop lamp switch
35100090186
BRAKE PEDAL CHECK AND ADJUSTMENT

BRAKE PEDAL HEIGHT 1. Turn up the carpet, etc under the brake pedal. 2. Measure the brake pedal height as illustrated. If the brake pedal height is not within the standard value, follow the procedure below. Standard value: 162.8 - 165.8 mm (1) Disconnect the stop lamp switch connector. (2) Adjust the brake pedal height by turning the operating rod with pliers (with the operating rod lock nut loosened), until the correct brake pedal height is obtained. (3) Secure by tightening the lock nut of the operating rod.
Pedal down
Pedal up Lock nut
Lock nut Outer case 0.5 - 1.0 mm
(4) Push the stop lamp switch in the direction of the pedal stroke until it stops. (The switch will slide if it is pushed firmly.) (5) Lift up the pedal until the operating rod is fully extended, and then slide the stop lamp switch back to the required position. Adjust the position of the switch by turning it until the distance shown in the illustration is correct. (6) Connect the connector of the stop lamp switch. (7) Check that the stop lamp is not illuminated with the brake pedal unpressed. 3. Return the carpet etc.
BRAKE PEDAL FREE PLAY With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (the free play) is within the standard value range.

Standard value: 38 mm
35A-7
If the free play exceeds the standard value, it is probably due to excessive play between the retaining ring bolt and brake pedal arm. Check for excessive clearance and replace faulty parts as required.
CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR BOARD 1. Turn back the carpet etc. under the brake pedal. 2. Start the engine, depress the brake pedal with approximately 490 N of force, and measure the clearance between the brake pedal and the floorboard. Standard value: 90 mm or more 3. If the clearance is outside the standard value, check for air trapped in the brake line, clearance between the lining and the drum and dragging in the parking brake. Adjust and replace defective parts as required. 4. Return the carpet etc.
STOP LAMP SWITCH CHECK
35100890120
No continuity
Continuity
Connect a circuit tester to the stop lamp switch, and check whether or not there is continuity when the plunger of the stop lamp switch is pushed in and when it is released. The stop lamp switch is in good condition if there is no continuity when the plunger is pushed in to a depth of within 4 mm from the outer case edge surface, and if there is continuity when it is released.
4 mm
Good
No good
BRAKE BOOSTER OPERATING TEST
35100100117
For simple checking of the brake booster operation, carry out the following tests: 1. Run the engine for one or two minutes, and then stop it. If the pedal depresses fully the first time but gradually becomes higher when depressed succeeding times, the booster is operating properly, if the pedal height remains unchanged, the booster is defective.
35A-8
When engine is stopped

When engine is started
2. With the engine stopped, step on the brake pedal several times. Then step on the brake pedal and start the engine. If the pedal moves downward slightly, the booster is in good condition. If there is no change, the booster is defective. 3. With the engine running, step on the brake pedal and then stop the engine. Hold the pedal depressed for 30 seconds. If the pedal height does not change, the booster is in good condition, if the pedal rises, the booster is defective. If the above three tests are okay, the booster performance can be determined as good. If one of the above three tests is not okay at last, the check valve, vacuum hose, or booster will be defective.
CHECK VALVE OPERATION CHECK
35100900151
1. Remove the vacuum hose. (Refer to P.35A-16.) Caution The check valve should not be removed from the vacuum hose.
Valve A Booster side
Spring B Intake manifold side
2. Check the operation of the check valve by using a vacuum pump.

Vacuum pump connection Connection at the brake booster side (A) Connection at the intake manifold side (B) Accept/reject criteria A negative pressure (vacuum) is created and held. A negative pressure (vacuum) is not created.
Caution If the check valve is defective, replace it as an assembly unit together with the vacuum hose.

Pressure gauge
35A-9
35100110172
PROPORTIONING VALVE FUNCTION TEST

1. Connect two pressure gauges, one each to the input side and output side of the proportioning valve, as shown. 2. Bleed the air in the brake line and the pressure gauge. 3. While gradually depressing the brake pedal, make the following measurements and check to be sure that the measured values are within the allowable range.
Proportioning valve
(1) Output pressure begins to drop relative to input pressure (split point).
Split point Output pressure
Standard value:
Sedan 2.94 0.25 Wagon 3.43 0.25
MPa
Input pressure
(2) Check to be sure that the output fluid pressure is at the standard value when the pedal depression force is increased so that the input fluid pressure is at the values shown in the table below. Standard value:
Sedan Output fluid pressure (Input fluid pressure) 4.66 0.39 (9.81) Wagon 5.80 0.39 (9.81)
MPa
(3) Output pressure difference between left and right brake lines. Limit: 0.39 MPa 4. If the measured pressures are not within the permissible ranges, replace the proportioning valve.
BRAKE FLUID LEVEL SENSOR CHECK

35100910123
The brake fluid level sensor is in good condition if there is no continuity when the float surface is above MIN and if there is continuity when the float surface is below MIN.
35A-10
BASIC BRAKE SYSTEM - On-vehicle Service BLEEDING

35100140089
Caution Use the specified brake fluid. Avoid using a mixture of the specified brake fluid and other fluid. Specified brake fluid: DOT3 or DOT4
MASTER CYLINDER BLEEDING The master cylinder used has no check valve, so if bleeding is carried out by the following procedure, bleeding of air from the brake pipeline will become easier. (When brake fluid is not contained in the master cylinder.) (1) Fill the reserve tank with brake fluid. (2) Keep the brake pedal depressed. (3) Have another person cover the master cylinder outlet with a finger. (4) With the outlet still closed, release the brake pedal. (5) Repeat steps (2) - (4) three or four times to fill the inside of the master cylinder with brake fluid.
4 (2)
1 (3)
BRAKE PIPE LINE BLEEDING Bleed the air in the sequence shown in the figure.
2 (4)
( ): R.H. drive vehicles
3 (1)
When new Pad
When worn
DISC BRAKE PAD CHECK AND REPLACEMENT
35100230014
NOTE The left side outer brake pad has a wear indicator. The wear indicator contacts the brake disc when the brake pad thickness becomes 2 mm and emit a squealing sound to warn the driver.
Brake disc
Wear indicator
35A-11
1. Check brake pad thickness through caliper body check port. Standard value: 10 mm Limit: 2.0 mm Caution 1. When the limit is exceeded, replace the pads at both sides, and also the brake pads for the wheels on the opposite side at the same time. 2. If there is a significant difference in the thickness of the pads on the left and right sides, check the sliding condition of the piston and guide pin. 2. Remove the guide pin. Lift caliper assembly and retain with wires. Caution Do not wipe off the special grease that is on the guide pin or allow it to contaminate the guide pin.
3 2
3. Remove the following parts from caliper support. (1) Pad and wear indicator assembly <L.H.>, and pad assembly <R.H.> (2) Pad assembly (3) Pad liner (4) Outer shim 4
1 3
4. In order to measure the brake drag force after pad installation, measure the rotary-sliding resistance of the hub with the pads removed. (Refer to P.35A-19.) 5. Install the pads and the caliper assembly, and then check the brake drag force. (Refer to P.35A-19.)
35A-12

35100290012
DISC BRAKE ROTOR CHECK
Caution When servicing disc brakes, it is necessary to exercise caution to keep the disc brakes within the allowable service values in order to maintain normal brake operation. Before re-finishing or re-processing the brake disc surface, the following conditions should be checked.
Inspection items Scratches, rust, saturated lining materials and wear Remarks D D If the vehicle is not driven for a certain period, the sections of the discs that are not in contact with lining will become rusty, causing noise and shuddering. If grooves resulting from excessive disc wear and scratches are not removed prior to installing a new pad assembly, there will momentarily be inappropriate contact between the disc and the lining (pad).
Run-out or drift Change in thickness (parallelism) Inset or warping (flatness)
Excessive run-out or drift of the discs will increase the pedal depression resistance due to piston knock-back. If the thickness of the disc changes, this will cause pedal pulsation, shuddering and surging. Overheating and improper handling while servicing will cause inset or warping.
35100240017 THICKNESS CHECK 1. Using a micrometer, measure disc thickness at eight positions, approximately 45_ apart and 10 mm in from the outer edge of the disc.
Brake disc thickness Standard value: 24.0 mm <Front>, 10.0 mm <Rear> Limit: 22.4 mm <Front>, 8.4 mm <Rear> Thickness variation (at least 8 positions) The difference between any thickness measurements should not be more than 0.015 mm. 2. If the disc is beyond the limits for thickness, remove it and install a new one. If thickness variation exceeds the specification, replace the brake disc or turn rotor with on the car type brake lathe (MAD, DL-8700PF or equivalent).
35A-13
35100250010 RUN-OUT CHECK 1. Remove the caliper support; then raise the caliper assembly upward and secure by using wire. 2. Inspect the disc surface for grooves, cracks and rust. Clean the disc thoroughly and remove all rust.
3. Place a dial gauge approximately 5 mm from the outer circumference of the brake disc, and measure the run-out of the disc. Limit: 0.06 mm or less <Front> 0.08 mm or less <Rear> NOTE Tighten the nuts in order to secure the disc to the hub.
35100180081 RUN-OUT CORRECTION 1. If the run-out of the brake disc is equivalent to or exceeds the limit specification, change the phase of the disc and hub, and then measure the run-out again. (1) Before removing the brake disc, chalk both sides of the wheel stud on the side at which run-out is greatest.
Chalk mark
(2) Remove the brake disc, and then place a dial gauge as shown in the illustration; then move the hub in the axial direction and measure the play. Limit: 0.05 mm If the play is equivalent to or exceeds the limit, disassemble the hub knuckle and check each part.
(3) If the play does not exceed the limit specification, install the brake disc at a position 180_ away from the chalk mark, and then check the run-out of the brake disc once again. 2. If the run-out cannot be corrected by changing the phase of the brake disc, replace the disc or turn rotor with on the car type brake lathe (MAD, DL-8700PF or equivalent).
35A-14
BASIC BRAKE SYSTEM - On-vehicle Service BRAKE LINING THICKNESS CHECK

35100300166
1. Remove the brake drum. 2. Measure the wear of the brake lining at the place worn the most. Standard value: 4.4 mm Limit: 1.0 mm Replace the shoe and lining assembly if brake lining thickness is less than the limit or if it is not worn evenly. For information concerning the procedures for installation of the shoe and lining assembly, refer to P.35A-24. Caution 1. Whenever the shoe and lining assembly is replaced, replace both R.H. and L.H. assemblies as a set to prevent car from pulling to one side when braking. 2. If there is a significant difference in the thickness of the shoe and lining assemblies on the left and right sides, check the sliding condition of the piston.
BRAKE DRUM INSIDE DIAMETER CHECK

35100320148
1. Remove the brake drum. 2. Measure the inside diameter of the brake drum at two or more locations. Standard value: 203 mm Limit: 205 mm 3. Replace brake drums, shoe and lining assembly when wear exceeds the limit value or is badly imbalanced.
BRAKE LINING AND BRAKE DRUM CONNECTION CHECK
35100310169
1. Remove the brake drum. 2. Remove the shoe and lining assembly. (Refer to P.35A-24.) 3. Chalk inner surface of brake drum and rub with shoe and lining assembly. 4. Replace shoe and lining assembly or brake drums if there are any irregular contact area. NOTE Clean off chalk after check.
BASIC BRAKE SYSTEM - Brake Pedal
35A-15
35100340243
BRAKE PEDAL
Post-installation Operation Brake Pedal Adjustment (Refer to P.35A-6.)
14 Nm
5 11
12 Nm 13 Nm
29 Nm
9 8 4 10 3 6 7 8
Removal steps 1. Stop lamp switch connector 2. Stop lamp switch 3. Snap pin 4. Pin assembly 5. Brake pedal shaft bolt 6. Brake pedal
7. 8. 9. 10. 11.
Brake pedal pad Brake pedal return spring Bushing Pipe Pedal support member
35A-16
BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster

35100370242
MASTER CYLINDER AND BRAKE BOOSTER

Pre-removal Operation Brake Fluid Draining Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to P.35A-10.) D Brake Pedal Adjustment (Refer to P.35A-6.)
6 3
11 12
20 - 25 Nm
14 9
15 Nm
22 Nm 10 Nm
10
14 Nm
1 15 Nm
13
<L.H. drive vehicles - 4D6> <R.H. drive vehicles - 4G6, 6A1>
<L.H. drive vehicles - 4G6, 6A1>
6 7 15 Nm 6 4 7
15 Nm
<R.H. drive vehicles - 4D6>
4 7 12 5
Sealant: 3M ATD Part No.8661 or equivalent

Removal steps 1. Brake pipe connection 2. Brake fluid level sensor connector 3. Master cylinder assembly "BA D Push rod protruding length check and adjustment 4. Vacuum hose <4D6> 5. Vacuum pipe <4D6> "AA 6. Vacuum hose (with built-in check valve) 7. 8. 9. 10. 11. 12. 13. 14.
35A-17
Fitting Snap pin Pin assembly Clevis Vacuum switch connector <4D6> Vacuum switch <4D6> Brake booster Sealer

"AA VACUUM HOSE CONNECTION Insert securely and completely until the vacuum hose at the engine side contacts the edge of the hexagonal part of the fitting, and then secure by using the hose clip.
"BA PUSH ROD PROTRUDING LENGTH CHECK AND ADJUSTMENT 1. Measure dimension A. Standard value: 9.65 - 9.90 mm
A
Measuring dimension A
Block gauge
2. If the protruding length is not within the standard value range, adjust by changing the push rod length by turning the end of the push rod.
35A-18

35100420145
MASTER CYLINDER DISASSEMBLY AND REASSEMBLY
2 3
1 9 10
5 9 7 4
Master cylinder kit
11
12 8 10 11 10
11
12
Brake fluid: DOT3 or DOT4
Disassembly steps 1. Reservoir cap assembly 2. Reservoir cap 3. Diaphragm 4. Brake fluid level indicator assembly 5. Float 6. Spring pin
7. 8. 9. 10. 11. 12.
Reservoir tank Reservoir seal Piston retainer Primary piston assembly Secondary piston assembly Master cylinder body
BASIC BRAKE SYSTEM - Disc Brake
35A-19
35100800017
DISC BRAKE
Pre-removal Operation Brake Fluid Draining Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to P.35A-10.)
<Front>
4
90 - 110 Nm
29 Nm
2 3
<Rear>
29 Nm
2
55 - 65 Nm
Removal steps 1. Brake hose connection 2. Gasket
"AA 3. Disc brake assembly 4. Brake disc
MB990998
INSTALLATION SERVICE POIINT

"AA DISC BRAKE ASSEMBLY INSTALLATION 1. In order to measure the brake drag torque after pad installtion, measure the rotary-sliding resistance of the hub by the following procedure with the pads removed.
Bolt
Tighten the nut with the bolt secured.
<Front> (1) Remove the drive shaft. (Refer to GROUP 26 - Front Axle.)
35A-20

(2) Attach the special tool to the front hub assembly as shown in the illustration, and tighten it to the specified torque. Tightening torque: 196 - 255 Nm
(3) Use a spring balance to measure the rotary-sliding resistance of the hub in the forward direction. <Rear> Use a spring balance to measure the rotary-sliding resistance of the hub in the forward direction.
2. After installing the caliper support to the knuckle, install the pad clips and the pads to the caliper support. Caution Do not let any oil, grease or other contamination get onto the friction surfaces of the pads and brake discs.
3. Clean piston and insert into cylinder with special tool. 4. Be careful that the piston boot does not become caught when lowering the caliper assembly, and tighten the guide pin to the specified torque. Tightening torque: 74 Nm
MB990520
5. Start the engine and then depress the brake pedal 2 - 3 times. 6. Stop engine. 7. Turn brake disc forward 10 times. 8. Use a spring balance to measure the rotation sliding resistance of the hub in the forward direction. 9. Calculate the drag force of the disc brake (difference between of values measured in item 8 and item 1.) Standard value: 69 N or less 10. If the drag force of the disc brake exceeds the standard value, disassemble piston and clean piston. Check for corrosion or worn piston seal, and check the sliding condition of the lock pin and guide pin.
BASIC BRAKE SYSTEM - Disc Brake DISASSEMBLY AND REASSEMBLY
35A-21
35100820013
14 2 3 5
74 Nm
12 11 13
8 Nm
14
1
74 Nm
10 9 5 8 7 6 14 9 8 6 7 13 4
Grease
3 2
14 9 3 5
13 10 5 12 11 14 11 12 14
Seal and boots repair kit
Brake caliper kit
Pad repair kit
Caliper assembly disassembly steps "AA 1. Guide pin "AA 2. Lock pin 3. Bushing 4. Caliper support (pad, clip, shim) 5. Boot 6. Boot ring AA" 7. Piston boot AA" 8. Piston AB" 9. Piston seal 10. Caliper body
Pad assembly disassembly steps "AA 1. Guide pin "AA 2. Lock pin 3. Bushing 4. Caliper support (pad, clip, shim) 11. Pad and wear indicator assembly 12. Pad assembly 13. Outer shim (coated with rubber) 14. Clip
35A-22
LUBRICATION POINTS
Piston seal
Grease: Repair kit grease
Caution The piston seal inside the seal and boot kit is coated with special grease, so do not wipe this grease off.

When disassembling the disc brakes, disassemble both sides (left and right) as a set.
35A-23
AA" PISTON BOOT/PISTON REMOVAL Protect caliper body with cloth. Blow compressed air through brake hose to remove piston boot and piston. Caution Blow compressed air gently.
AB" PISTON SEAL REMOVAL 1. Remove piston seal with finger tip. Caution Do not use a flat-tipped screwdriver or other tool to prevent damage to inner cylinder. 2. Clean piston surface and inner cylinder with trichloroethylene, alcohol or specified brake fluid. Specified brake fluid: DOT3 or DOT4
Lock pin L Front

"AA LOCK PIN/GUIDE PIN INSTALLATION Install the guide pin and lock pin as illustrated that each head mark of the guide pin and the lock pin matches the indication mark (G or L) located on the caliper body.
Guide pin G
INSPECTION
D D D D
35100630081
Check cylinder for wear, damage or rust. Check piston surface for wear, damage or rust. Check caliper body or sleeve for wear. Check pad for damage or adhesion of grease, check backing metal for damage.
35A-24
BASIC BRAKE SYSTEM - Rear Drum Brake

35100750145
REAR DRUM BRAKE

Pre-removal Operation D Loosening the Parking Brake Cable Adjusting Nut. D Brake Fluid Draining Post-installation Operation D Brake Line Bleeding (Refer to P.35A-10.) D Parking Brake Lever Stroke Adjustment (Refer to GROUP 36 On-vehicle Service.)
15 Nm 74 - 88 Nm
17 16 20 16 11 12 3 13 14 15 5 4 19 9 1
18
10
8 7 2
5 10 4 5 20
15
Specified grease: Brake grease SAE J310, NLGI No.1 Removal steps 1. Brake drum 2. Lever return spring 3. Shoe-to-lever spring 4. Adjuster lever 5. Auto adjuster assembly 6. Retainer spring 7. Shoe hold-down cup 8. Shoe hold-down spring 9. Shoe-to-shoe spring 10. Shoe and lining assembly
11. Shoe and lever assembly AA" "BA 12. Retainer "AA 13. Wave washer 14. Parking lever 15. Shoe and lining assembly 16. Shoe hold-down pin 17. Brake pipe connection 18. Snap ring 19. Rear hub assembly 20. Backing plate

Pin of shoe assembly
35A-25

AA" RETAINER REMOVAL Use a flat-tipped screwdriver or the like to open up the retainer joint, and remove retainer.
Retainer

Washer Shoe assembly
"AA WAVE WASHER INSTALLATION Install the washer in the direction shown in the illustration.
Pin
Parking lever
Pin of shoe assembly
"BA RETAINER INSTALLATION Use pliers or the like to install the retainer or the pin positively.
Retainer
35A-26

35100930082
WHEEL CYLINDER REMOVAL AND INSTALLATION

Pre-removal Operation Brake Fluid draining Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to P.35A-10.)
3
15 Nm 10 Nm
8 Nm
7 5 6 1
Removal steps 1. Brake drum 2. Shoe-to-lever spring 3. Shoe-to-shoe spring 4. Auto adjuster assembly
5. Brake pipe connection 6. Wheel cylinder 7. Bleeder screw
BASIC BRAKE SYSTEM - Rear Drum Brake DISASSEMBLY AND REASSEMBLY
35A-27
35100770097
6 3 6 3
Grease: Repair kit grease Brake fluid: DOT3 or DOT4
2 6 1 5 4 3
3 2
Grease
Wheel cylinder repair kit Disassembly steps 1. Boots 2. Piston assembly "AA 3. Pistons
"AA 4. Piston cups 5. Spring 6. Wheel cylinder body

MB990619
"AA PISTON CUP/PISTON REASSEMBLY 1. Use alcohol or specified brake fluid to clean the wheel cylinder and the piston. 2. Apply the specified brake fluid to the piston cups and the special tool. Specified brake fluid: DOT3 or DOT4 3. Set the piston cup on the special tool with the lip of the cup facing up, fit the cup onto the special tool, and then slide it down the outside of the tool into the piston groove. Caution In order to keep the piston cup from becoming twisted or slanted, slide the piston cup down the tool slowly and carefully, without stopping.
Piston
Have the lip facing upwards.
35A-28 BASIC BRAKE SYSTEM -
Rear Drum Brake/Proportioning Valve

35100780038
INSPECTION
Check the piston and wheel cylinder walls for rust or damage, and if there is any abnormality, replace the entire wheel cylinder assembly.
PROPORTIONING VALVE
Pre-removal Operation Brake Fluid Draining Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to P.35A-10.)
35100570154
Flared brake line nuts
2 1
15 Nm
Removal steps "AA 1. Brake pipe 2. Proportioning valve

1 3 2 4 "AA BRAKE PIPE CONNECTION Connect the pipes to the hydraulic unit as shown in the illustration. 1. Proportioning valve Rear brake (L.H.) 2. Proportioning valve Rear brake (R.H.) 3. Proportioning valve Front brake (R.H.) 4. Proportioning valve Front brake (L.H.) 5. Proportioning valve Master cylinder (secondary) 6. Proportioning valve Master cylinder (primary)
35B-1
ANTI-SKID BRAKING SYSTEM (ABS) <2WD>

CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 5 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 6 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 19
Brake Pedal Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Stop Lamp Switch Check . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Brake Booster Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Check Valve Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Proportioning Valve Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Brake Fluid Level Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
35209000206
Bleeding . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Disc Brake Pad Check and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Disc Brake Rotor Check . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Brake Lining Thickness Check . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Brake Drum Inside Diameter Check . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Brake Lining and Brake Drum Connection Check . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A Wheel Speed Sensor Output Voltage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ABS Warning Lamp Relay Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hydraulic Unit Check . . . . . . . . . . . . . . . . . . . . . . . . 22 Remedy for a Flat Battery . . . . . . . . . . . . . . . . . . . 23
35B-2
BRAKE PEDAL . . . . . . . . Refer to GROUP 35A MASTER CYLINDER AND BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Wheel Cylinder . . . . . . . . . . . Refer to GROUP 35A
PROPORTIONING VALVE . . . . . . . . . . . . . . . . . 25 HYDRAULIC UNIT . . . . . . . . . . . . . . . . . . . . . . . . 26 WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . 28
DISC BRAKE . . . . . . . . . . Refer to GROUP 35A REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . . . . Refer to GROUP 35A
ABS <2WD> - General Information
35B-3
35200010222
GENERAL INFORMATION
The ABS consists of components such as the wheel speed sensors, stop lamp switch, hydraulic unit assembly, ABS control unit (ABS-ECU) and the ABS warning lamp. If a problem occurs in the system, the malfunctioning components can be
Items Master cylinder Type I.D. mm Brake booster Type Effective dia. of power cylinder mm Boosting ratio Proportioning valve Type Decompression ratio Front brakes Type Disc effective dia. thickness mm Wheel cylinder I.D. mm Pad thickness mm Clearance adjustment Rear drum brakes Type Drum I.D. mm Wheel cylinder I.D. mm Lining thickness mm Clearance adjustment Brake fluid ABS type Speed sensor Front ABS rotor teeth Rear ABS rotor teeth
identified and the trouble symptoms will be memorized by the diagnosis function. In addition, reading of diagnosis codes and service data and actuator testing are possible by using the MUT-II.
Specifications Tandem type (with level sensor) 25.4 Vacuum type, tandem 180 + 205 6.5 Dual type 0.25 Floating caliper, 1-piston, ventilated disc 256 24 60.3 10.0 Automatic Leading trailing 203 20.6 4.4 Automatic DOT3 or DOT4 4-sensor, 3-channel method Magnet coil type on 4 wheels 43 43
35B-4
ABS <2WD> - General Information
2 7 6 8 1
3 4 5
<R.H. drive vehicles> 3 2 7
5 6
1 8
1. 2. 3. 4.
ABS ABS Stop ABS
relay warning lamp lamp switch rotor
5. 6. 7. 8.
Wheel-speed sensor ABS-ECU Diagnosis connector Hydraulic unit
ABS <2WD> - Service Specifications/Lubricants/Special Tools
35B-5
35200030242
Items Wheel speed sensor internal resistance kW Clearance between the wheel speed sensor mounting surface and the ABS toothed rotor mm Wheel speed sensor insulation resistance kW Standard value 1.0 - 1.5 28.2 - 28.5 100 or more
LUBRICANTS
Items Brake fluid Specified lubricant DOT3 or DOT4
35200040054
SPECIAL TOOLS
35200060210
For checking of ABS (Diagnosis code display when using the MUT-II)
MB991529
For checking of ABS (Diagnosis code display when using the ABS warning lamp)
35B-6 TROUBLESHOOTING
ABS <2WD> - Troubleshooting

35201110129

NOTES WITH REGARD TO DIAGNOSIS

The phenomena listed in the following table are not abnormal.
Phenomenon System check sound Explanation of phenomenon When starting the engine, a thudding sound can sometimes be heard coming from inside the engine compartment, but this is because the system operation check is being performed, and is not an abnormality. 1. 2. 3. Sound of the motor inside the ABS hydraulic unit operation. (whine) Sound is the generated along with vibration of the brake pedal. (scraping) When ABS operates, sound is generated from the vehicle chassis due to repeated brake application and release. (Thump: suspension; squeak: tyres)
ABS operation sound
ABS operation (Long braking distance)
For road surfaces such as snow-covered roads and gravel roads, the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles. Accordingly, advise the customer to drive safely on such roads by lowering the vehicle speed and not being too overconfident.
Diagnosis detection condition can vary depending on the diagnosis code. Make sure that checking requirements listed in the Comment are satisfied when checking the trouble symptom again.
DIAGNOSIS FUNCTION
35201120221
DIAGNOSIS CODES CHECK Read a diagnosis code by the MUT-II or ABS warning lamp. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)
ERASING DIAGNOSIS CODES With the MUT-II Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
35B-7
With the ABS Warning Lamp 1. Use the special tool to earth terminal (1) (diagnosis control terminal) of the diagnosis connector. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) 2. Stop the engine. 3. Turn on the stop lamp switch. (Depress the brake.) 4. After carrying out steps 1. to 3., turn the ignition switch to ON. Within 3 seconds after turning the ignition switch to ON, turn off the stop lamp switch (release the brake). Then, turn the stop lamp switch on and off a total of 10 times. NOTE If the ABS-ECU function has been stopped because of fail-safe operation, it will not be possible to erase the diagnosis codes.
Ignition switch
ON OFF ON OFF ON OFF
Stop lamp switch
ABS warning lamp
ABS-ECU memory
Within 3 seconds
Within Within Within Within Within Within Within Within Within Within 1 1 1 1 1 1 1 1 1 1 second second second second second second second second second second
1 second
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th
Erasing of ABS-ECU diagnosis codes complete.
35B-8

35201130323

Inspect according to the inspection chart that is appropriate for the malfunction code.
Diagnosis code No. 11 12 13 14 15 16 21 22 23 24 33 41 42 43 44 51 52 53 54 55 63 Inspection item Front right wheel speed sensor Front left wheel speed sensor Rear right wheel speed sensor Rear left wheel speed sensor Wheel speed sensor Power supply system Front right wheel speed sensor Front left wheel speed sensor Rear right wheel speed sensor Rear left wheel speed sensor Stop lamp switch system Front right solenoid valve Front left solenoid valve Rear right solenoid valve Rear left solenoid valve Valve relay problem (stays on) Valve relay problem (stays off) Motor relay problem (stays off) Motor relay problem (stays on) Motor system (seized pump motor) ABS-ECU 35B-11 Short circuit Abnormal output signal 35B-10 35B-10 35B-9 Diagnosis content Open circuit
Reference page 35B-9
35B-26 (Replace the hydraulic unit.)
ABS <2WD> - Troubleshooting INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code Nos.11, 12, 13 and 14 Wheel speed sensor (open circuit or short circuit) Code Nos.21, 22, 23 and 24 Wheel speed sensor
Code Nos 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit or short-circuit in the (+) wire or (- ) wire in any one of the four wheel speed sensors. Code Nos.21, 22, 23 and 24 are output in the following cases. D When there is no input from any one of the four wheel speed sensors when travelling at several km/h or more, even though open circuit can not be verified. D When a chipped or blocked-up ABS rotor is detected and if the anti-lock system operates continuously because a malfunctioning sensor or a warped ABS rotor is causing sensor output to drop. NG NG D D D D D D D D D
35B-9
Probable cause
Malfunction of wheel speed sensor Malfunction of wiring harness or connector Malfunction of hydraulic unit Malfunction of wheel speed sensor Malfunction of wiring harness or connector Malfunction of ABS rotor Too much gap between the sensor and the rotor Malfunction of hydraulic unit Malfunction of wheel bearing
Wheel speed sensor installation check OK Measure at the ABS-ECU connector A-04. D Disconnect the connector, and measure at the harness side connector. D Resistances between 20 and 19, 2 and 1, 22 and 23, 6 and 5 OK: 1.0 - 1.5 kW OK Wheel speed sensor output voltage check (Refer to P.35B-19.) OK NG Wheel speed sensor check (Refer to P.35B-29.) OK ABS rotor check (Refer to P.35B-29.) OK Wheel bearing check (Refer to GROUP 26 and GROUP 27 - On-vehicle Service.) NG
Repair Wheel speed sensor check (Refer to P.35B-29.) OK NG Replace Check the following connectors: <L.H. drive vehicles> A-09, C-115, C-75, A-39, C-74, E-14, E-13, E-11, C-123, E-12 NG <R.H. drive vehicles> A-09, A-41, A-39, C-115, C-75, E-14, E-13, E-11, C-121, E-12 Repair
Replace
OK
Check the trouble symptom. NG NG Replace Check the harness wire, and repair if necessary. D Between each wheel speed sensor and ABS-ECU
Check the following connector: A-04 OK Check the trouble symptom. NG Replace the hydraulic unit.
NG Repair
35B-10

Probable cause
D D D D D D D The four vehicle tires are of different sizes Improper installation of wheel speed sensor Malfunction of wheel speed sensor Malfunction of wiring harness or connector Malfunction of ABS rotor Malfunction of wheel bearing Malfunction of hydraulic unit
Code No.15 Wheel speed sensor (abnormal output signal)

This code is output when there is an abnormality in the output signal from any one of the four wheel speed sensors while driving (except for an open circuit or short circuit).
Are the sizes of all four tires identical? YES Check the trouble symptom. NG Wheel speed sensor installation check OK Wheel speed sensor output voltage check (Refer to P.35B-19.) OK Check the following connector: A-04 OK Check the trouble symptom. NG Replace the hydraulic unit. NG Repair
NO
Equip the vehicle with tires of identical sizes.
NG NG
Repair Wheel speed sensor check (Refer to P.35B-29.) OK NG Replace ABS rotor check (Refer to P.35B-29.) OK NG Replace Wheel bearing check (Refer to GROUP 26 and GROUP 27 On-vehicle Service.) NG Check the harness wire, and repair if necessary. D Between each wheel speed sensor and ABS-ECU
Code No.16 ABS-ECU power supply system (abnormal voltage drop or rise)
This code is output if the ABS-ECU power supply voltage drops below or rises above the rated values. Furthermore, if the voltage returns to normal, this code is no longer output.
Probable cause
D D D Malfunction of battery Malfunction of wiring harness or connector Malfunction of hydraulic unit
Caution If battery voltage drops or rises during inspection, this code will be output as well. If the voltage returns to standard value, this code is no longer output. Before carrying out the following inspection, check the battery level, and refill it if necessary.
Measure at the ABS-ECU connector A-04. D Disconnect the connector, and measure at the harness side connector. D Start the engine. Voltage between 4 and body earth OK: Battery voltage OK Check the following connector: A-04 OK Check the trouble symptom. NG Replace the hydraulic unit. NG Repair Check the trouble symptom. NG Check the harness wire, and repair if necessary. D Between ignition switch and ABS-ECU NG Check the following connectors: A-04, C-75, C-66 <L.H. drive vehicles>, C-134, C-131 OK NG Repair OK Check the battery.

Code No.33 Stop lamp switch system (open circuit or stop lamp stays ON)
This code is output in the following cases. D If the stop lamp switch is continuously on for 15 minutes or more even though the ABS system is not operating. D If there is an open circuit in the stop lamp switch input circuit harness. NO
35B-11
Probable cause
D D D Malfunction of stop lamp switch Malfunction of wiring harness or connector Malfunction of hydraulic unit
Does the stop lamp turn on and off normally? YES Measure at the ABS-ECU connector A-04. D Disconnect the connector, and measure at the harness side connector. D Stop lamp switch: ON D Voltage between 18 and body earth OK: Battery voltage OK Check the following connector: A-04 OK NG Repair Repair Check the trouble symptom. NG Replace unit. the hydraulic Check the trouble symptom. NG Check the harness wire, and repair if necessary. D Between stop lamp switch and ABS-ECU NG Check the following connectors: A-04, C-75, C-65 OK NG
Stop lamp switch installation check OK NG Repair Stop lamp switch check (Refer to GROUP 35A - Brake Pedal.) OK NG Replace Check the following connectors: C-12 <R.H. drive vehicles>, C-142, C-134, C-02, C-65, C-75, A-04 OK NG Check the trouble symptom. NG Check the harness wire, and repair if necessary. D Between fusible link No.1 and ABS-ECU Repair
ABS WARNING LAMP INSPECTION
35201200123
ABS warning lamp Approx. 3 s Illuminated ABS warning Not lamp illuminated START Ignition ON switch ACC, LOCK Approx. 3 s
Check that the ABS warning lamp illuminates as follows. 1. When the ignition key is turned to ON, the ABS warning lamp illuminates for approximately 3 seconds and then switches off. 2. When the ignition key is turned to START, the ABS warning lamp remains illuminated. 3. When the ignition key is turned from START back to ON, the ABS warning lamp illuminates for approximately 3 seconds and then switches off. NOTE The ABS warning lamp may remain on until the vehicle reaches a speed of several km/h. This is limited to cases where diagnosis code Nos.21 - 24 and 55 have been recorded because of a previous problem occurring. In this case, the ABS-ECU keeps the warning lamp illuminated until the problem corresponding to that diagnosis code can be detected. 4. If the illumination is other than the above, check the diagnosis codes.
35B-12

35201140289

Trouble symptoms Communication between the MUT-II and the whole system is not possible. Communication between the MUT-II and the ABS-ECU is not possible. When the ignition key is turned to ON (engine stopped), the ABS warning lamp does not illuminate. Even after the engine is started, the ABS warning lamp remains illuminated. Faulty ABS operation Inspection procedure No. 1 2 3 4 5
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Reference page 35B-12 35B-13 35B-14 35B-15 35B-16
Caution 1. If steering movements are made when driving at high speed, or when driving on road surfaces with low frictional resistance, or when passing over bumps, the ABS may operate even though sudden braking is not being applied. Because of this, when getting information from the customer, check if the problem occurred while driving under such conditions as these. 2. During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent the wheels from locking and is not an abnormality.

Inspection Procedure 1 Communication between the MUT-II and the whole system is not possible.
The cause may be a malfunction of the power supply circuit or the earth circuit of the diagnosis connector. NG
Probable cause
D D Malfunction of diagnosis connector Malfunction of wiring harness or connector
Measure at the diagnosis connector C-20. D Voltage between 16 and body earth OK: Battery voltage OK
Check the following connectors: <L.H. drive vehicles> C-20, C-66, C-63, C-132, C-141 <R.H. drive vehicles> C-20, C-66, C-62, C-14 OK Check the trouble symptom. NG Check the harness wire, and repair if necessary. D Between power supply and diagnosis connector NG Repair
Measure at the diagnosis connector C-20. D Continuity between 4 and body earth, and between 5 and body earth OK: Continuity OK Check the trouble symptom. NG Replace the MUT-II.
NG
Check the following connector: C-20 OK Check the trouble symptom. NG Check the harness wire, and repair if necessary. D Between diagnosis connector and earth NG Repair

Inspection Procedure 2 Communication between MUT-II and the ABS-ECU is not possible.
The cause may be an open circuit in the ABS-ECU power supply circuit or an open circuit in the diagnosis output circuit.
35B-13
Probable cause
D D D Blown fuse Malfunction of wiring harness or connector Malfunction of hydraulic unit
Measure at the diagnosis connector C-20 and the ABS-ECU connector A-04. D Disconnect the connector, and measure at the harness side connector. D Continuity between the following terminals ABS-ECU side - Diagnosis connector side 14 - 1 7 - 7 OK: Continuity OK
NG
Check the following connectors: <PETROL-POWERED VEHICLES> C-51, C-49, C-83, C-66, C-20 <DIESEL-POWERED VEHICLES> C-51, C-56, C-83, C-66, C-20 OK Check the trouble symptom. NG Check the harness wire, and repair if necessary. D Between ABS-ECU and diagnosis connector NG Repair
Measure at the ABS-ECU connector A-04. D Disconnect the connector, and measure at the harness side connector. D Ignition switch: ON D Voltage between 4 and body earth OK: Battery voltage OK
NG
Check the following connectors: A-04, C-75, C-66 <L.H. drive vehicles>, C-134, C-131 OK NG Check the trouble symptom. NG Repair
Check the harness wire, and repair if necessary. D Between ignition switch and ABS-ECU Measure at the ABS-ECU connector A-04. D Disconnect the connector, and measure at the harness side connector. D Continuity between 8 and body earth, between 11 and body earth and between 24 and body earth OK: Continuity OK Check the following connector: A-04 OK Check the trouble symptom. NG Replace the hydraulic unit. NG Repair NG Check the following connector: A-04 OK Check the trouble symptom. NG NG Repair
Check the harness wire, and repair if necessary. D Between ABS-ECU and earth
35B-14
When the ignition key is turned to ON (engine stopped), the ABS warning lamp does not illuminate.
The cause may be an open circuit in the lamp power supply circuit, a blown lamp, a malfunction of the ABS warning lamp relay or an open circuit between the ABS warning lamp and the earth.
Probable cause
D D D D D Blown fuse Burn out ABS Malfunction of Malfunction of Malfunction of warning lamp bulb ABS warning lamp relay wiring harness or connector hydraulic unit
Fuse check Multi-purpose fuse No.13 OK Measure at the connector C-50. D Disconnect the connector, and measure at the combination meter side connector. D Ignition switch: ON D ABS warning lamp condition when terminal 2 <LHD> or terminal 7 <RHD> is earthed. OK: Illuminates OK ABS warning lamp relay check (Refer to P.35B-21.) OK NG Replace the ABS warning lamp relay.
NG
Refer to GROUP 00 - Inspection Service Points for Blown Fuse.
NG
Check whether the ABS warning lamp bulb is burnt out. OK NG Replace the ABS warning lamp bulb. Check the following connectors: D-01, D-03, C-135, C-131 OK Check the trouble symptom. NG Replace the combination meter. NG Repair
Disconnect the ABS warning lamp relay connector A-05X and ABSECU connector A-04, and measure at the harness side connector of ABS warning lamp relay. D Ignition switch: ON D Voltage between 5 and body earth OK: Battery voltage OK Replace the hydraulic unit.
NG
Check the following connector: A-05X OK Check the trouble symptom. NG Check the harness wire, and repair if necessary. D Between ABS warning lamp and ABS warning lamp relay D Between ABS warning lamp relay and earth NG Repair

Inspection Procedure 4 Even after the engine is started, the ABS warning lamp remains illuminated.
The cause is probably a short-circuit in the ABS warning lamp illumination circuit.
35B-15
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of combination meter ABS warning lamp relay wiring harness (short circuit) hydraulic unit
NOTE This trouble symptom is limited to cases where communication with the MUT-II is possible (ABS-ECU power supply is normal) and the diagnosis code is a normal diagnosis code.
Does the ABS warning lamp stay illuminated when the connector C-50 is disconnected and the ignition switch is turned to ON? NO ABS warning lamp relay check (Refer to P.35B-21.) OK Disconnect the ABS warning lamp relay connector A-05X and ABSECU connector A-04, and measure at the harness side connector of ABS warning lamp relay. D Ignition switch: ON D Voltage between 2 and body earth OK: Battery voltage OK Replace the hydraulic unit. YES Replace the combination meter.
NG NG
Replace the ABS warning lamp relay. Check the following connectors: A-05X, A-04 OK Check the trouble symptom. NG Check the harness wire, and repair if necessary. D Between ABS warning lamp and ABS warning lamp relay D Between ABS warning lamp relay and ABS-ECU NG Repair
35B-16
Inspection Procedure 5 Faulty ABS operation
Probable cause
D D D D D D D Improper installation of wheel speed sensor Malfunction of wiring harness or connector Malfunction of wheel speed sensor Malfunction of ABS rotor Foreign material adhering to wheel speed sensor Malfunction of wheel bearing Malfunction of hydraulic unit
This varies depending on the driving conditions and the road surface conditions, so problem diagnosis is difficult. However, if a normal diagnosis code is displayed, carry out the following inspection.
Wheel speed sensor installation check OK Wheel speed sensor output voltage check (Refer to P.35B-19.) NG Wheel speed sensor check (Refer to P.35B-29.) OK ABS rotor check (Refer to P.35B-29.) OK Wheel bearing check (Refer to GROUP 26 and GROUP 27 On-vehicle Service.) OK Check the following connectors: <L.H. drive vehicles> A-09, C-115, C-75, A-39, C-74, E-14, E-13, E-11, C-123, E-12 <R.H. drive vehicles> A-09, A-41, A-39, C-115, C-75, E-14, E-13, E-11, C-121, E-12 OK Check the trouble symptom. NG Measure at the ABS-ECU connector A-04. D Disconnect the connector, and measure at the harness side connector. D Resistances between 20 and 19, 2 and 1, 22 and 23, 6 and 5 OK: 1.0 - 1.5 kW (The sensor harness and connector should be moved while these inspections are carried out.) OK Check the following connector: A-04 OK Check the trouble symptom. NG Replace the hydraulic unit.
NG OK NG
Repair Hydraulic unit check (Refer to P.35B-22.) Replace the wheel speed sensor.
NG NG
Repair
Repair
NG
Repair
NG
Repair
ABS <2WD> - Troubleshooting DATA LIST REFERENCE TABLE

The following items can be read by the MUT-II from the ABS-ECU input data. 1. When the system is normal
Item No. 11 12 13 14 16 33 Check item Front-right wheel speed sensor Front-left wheel speed sensor Rear-right wheel speed sensor Rear-left wheel speed sensor ABS-ECU power supply voltage Stop lamp switch Ignition switch power supply voltage and valve monitor voltage Depress the brake pedal. Release the brake pedal. Checking requirements Perform a test run
35B-17
35201150206
Normal value Vehicle speeds displayed on the speedometer II and MUT-II are identical.
9.2 - 17.5 V ON OFF
2. When the ABS-ECU shut off ABS operation. When the diagnosis system stops the ABS-ECU, the MUT-II display data will be unreliable.

The MUT-II activates the following actuators for testing.
35201160025
NOTE 1. If the ABS-ECU runs down, actuator testing cannot be carried out. 2. Actuator testing is only possible when the vehicle is stationary. If the vehicle speed during actuator testing exceeds 10 km/h, forced actuation will be canceled. 3. During the actuator test, the ABS warning lamp will illuminate and the anti-skid control will be cancelled.
ACTUATOR TEST SPECIFICATIONS

Activation pattern Start of forced action 1s End of forced action
No. 01 02
Item Solenoid valve for front-left wheel Solenoid valve for front-right wheel Solenoid valve for rear-left wheel Solenoid valve for rear-right wheel Solenoid valves and pump motors in the hydraulic unit (simple inspection mode)
Solenoid B valve C 48 ms Pump motor ON OFF
2s
8 ms
03 04
NOTE
A: Hydraulic pressure increase B: Hydraulic pressure holds C: Hydraulic pressure decrease
35B-18
CHECK AT ABS-ECU

35201180229
TERMINAL VOLTAGE CHECK CHART 1. Measure the voltage between each terminal and earth. 2. The terminal layout is shown in the illustration below.
Terminal No. 4
Check item ABS-ECU power supply MUT-II
Checking requirements Ignition switch: ON Ignition switch: START When the MUT-II is connected When the MUT-II is not connected
Normal condition Battery voltage 0V Serial communication with MUT-II 1 V or less Battery voltage 0V Approx. 12 V is is 2 V or less Battery voltage Battery voltage 1 V or less Battery voltage
9 14
Solenoid valve power supply Diagnosis changeover input ABS valve transistor output
Always When the MUT-II is connected When the MUT-II is not connected Ignition switch: ON When the lamp switched off When the illuminated lamp
16
18
Stop lamp switch input
Ignition switch: ON
Stop lamp switch: ON Stop lamp switch: OFF
25
Motor power supply
Always
RESISTANCE AND CONTINUITY BETWEEN HARNESS-SIDE CONNECTOR TERMINALS 1. Turn the ignition switch off and disconnect the ABS-ECU connectors before checking resistance and continuity. 2. Check them between the terminals indicated in the table below. 3. The terminal layouts are shown in the illustrations below.
Terminal No. 1- 2 5- 6 19 - 20
Signal Wheel speed sensor (front left) Wheel speed sensor (rear left) Wheel speed sensor (front right)
Normal condition 1.0 - 1.5 kW 1.0 - 1.5 kW 1.0 - 1.5 kW
ABS <2WD> - Troubleshooting/On-vehicle Service

Terminal No. 23 - 22 8 - Body earth 24 - Body earth Signal Wheel speed sensor (rear right) Solenoid valve earth Motor earth
35B-19
Normal condition 1.0 - 1.5 kW Continuity
ABS-ECU connector (harness side)
ON-VEHICLE SERVICE
35200160224
WHEEL SPEED SENSOR OUTPUT VOLTAGE CHECK

1. Lift up the vehicle and release the parking brake. 2. Disconnect the ABS-ECU connector, and then use the special tool (inspection harness for connector pin contact pressure) to measure the output voltage at the harness-side connector. 3. Rotate the wheel to be measured at approximately 1/2 - 1 rotation per second, and check the output voltage using a circuit tester or an oscilloscope.
Wheel speed sensor Terminal No. Front left Front right 19 20 Rear left Rear right 23 22
1 2
5 6
Output voltage When measuring with a circuit tester: 42 mV or more When measuring with an oscilloscope: 120 mV p-p or more 4. If the output voltage is lower than the above values, the reason could be as follow: D Faulty wheel speed sensor. So replace the wheel speed sensor.
35B-20
ABS <2WD> - On-vehicle Service

Inspecting Waveforms With An Oscilloscope Use the following method to observe the output voltage waveform from each wheel sensor with an oscilloscope. D Start the engine, and rotate the front wheels by engaging 1st gear (vehicles with manual transmission) or D range (vehicles with automatic transmission). Turn the rear wheels manually so that they rotate at a constant speed. NOTE 1. Check the connection of the sensor harness and connector before using the oscilloscope. 2. The waveform measurements can also be taken while the vehicle is actually moving. 3. The output voltage will be small when the wheel speed is low, and similarly it will be large when the wheel speed is high.
When turning by hand
When idling (5 - 6 km/h), 1st gear (manual transmission) or D range (automatic transmission)
10.0 ms/DIV 1 V/DIV
Points In Waveform Measurement

Symptom Too small or zero waveform amplitude Waveform amplitude fluctuates excessively (this is no problem if the minimum amplitude is 100 mV or more) Noisy or disturbed waveform Probable causes Faulty wheel speed sensor Axle hub eccentric or with large runout Remedy Replace sensor Replace hub
Open circuit in sensor Open circuit in harness Incorrectly mounted wheel speed sensor Rotor with missing or damaged teeth
Replace sensor Correct harness Mount correctly Replace rotor
Caution Because the wheel speed sensor cables move together with the front and rear suspension, they vibrate greatly when driving over poor road surfaces. As a result, the sensor harnesses should also be shaken when monitoring of output waveforms of the wheel speed sensors in order to simulate conditions such as driving over poor road surfaces.

35B-21
ABS WARNING LAMP RELAY CONTINUITY 35200930023 CHECK

Battery voltage Terminal No. 1 Power is not supplied Power is supplied 2 3 5
35B-22

35200170227
HYDRAULIC UNIT CHECK

Caution Turn the ignition switch off before connecting or disconnecting the MUT-II.
1. Jack up the vehicle and support the vehicle with rigid racks placed at the specified jack-up points or place the wheels which are checked on the rollers of the braking force tester. Caution 1. The roller of the braking force tester and the tyre should be dry during testing. 2. When testing the front brakes, apply the parking brake, and when testing the rear brakes, stop the front wheels by chocking them. 2. Release the parking brake, and feel the drag force (drag torque) on each road wheel. When using the braking force tester, take a reading of the brake drag force. 3. Turn the ignition key to the OFF position and set the MUT-II. 4. After checking that the shift lever <M/T> or the selector lever <A/T> is in neutral, start the engine. 5. Use the MUT-II to force-drive the actuator. NOTE 1. During the actuator test, the ABS warning lamp will illuminate and the anti-skid control will be cancelled. 2. When the ABS has been interrupted by the fail-safe function, the MUT-II actuator testing cannot be used. 6. Turn the wheel by hand and check the change in braking force when the brake pedal is depressed. When using the braking force tester, depress the brake pedal until the braking force is at the following values, and check that the braking force decreases when the actuator is force-driven.
Front wheel Rear wheel 785 - 981 N 588 - 784 N
The result should be as shown in the following diagram.

Depressed Pedal operation Released Increase in pressure Steady pressure Reduction in pressure (when not working) Checking the brake force Lock Drag force when the pedal is free 3 seconds MUT-II actuator test (Item No. 01, 02, 03, 04) start 2 seconds 1 seconds
Solenoid valve position
7. If the result of inspection is abnormal, correct according to the Diagnosis Table (Refer to P.35B-23). 8. After inspection, disconnect the MUT-II immediately after turning the ignition switch to OFF.

Diagnosis Table
No. 01 Operation (1) Depress brake pedal to lock wheel. (2) Using the MUT-II, select the wheel to be checked and force the actuator to operate. (3) Turn the selected wheel manually to check the change of brake force. Judgement - Normal Brake force released for 3 seconds after locking. Judgement - Abnormal Wheel does not lock when brake pedal is depressed. Probable cause Clogged brake line other than hydraulic unit Clogged hydraulic circuit in hydraulic unit Incorrect hydraulic unit brake tube connection Hydraulic unit solenoid valve not functioning correctly
35B-23
Remedy Check and clean brake line Replace hydraulic unit assembly Connect correctly Replace hydraulic unit assembly
02
03
Brake force is not released
04
REMEDY FOR A FLAT BATTERY

Fusible link
35200350188
When booster cables are used to start the engine when the battery is completely flat and then the vehicle is immediately driven without waiting for the battery to recharge itself to some extent, the engine may misfire, and driving might not be possible. This happens because ABS consumes a great amount of current for its self-check function; the remedy is to either allow the battery to recharge sufficiently, or to remove the fusible link for ABS circuit, thus disabling the anti-skid brake system. The ABS warning lamp will illuminate when the fusible link (for ABS) is removed. After the battery has sufficiently recharged, install the fusible link (for ABS) and restart the engine; then check to be sure the ABS warning lamp is not illuminated.
35B-24
ABS <2WD> - Master Cylinder and Brake Booster

35200400142
MASTER CYLINDER AND BRAKE BOOSTER

Refer to GROUP 35A.
MASTER CYLINDER DISASSEMBLY AND REASSEMBLY
35200450147
9 2 1 3 4 5
Master cylinder kit
10 13
11 12
8 6 9 12 7 10 13 13 14 12
14
11
Disassembly steps 1. Reservoir cap assembly 2. Reservoir cap 3. Diaphragm 4. Filter 5. Brake fluid level indicator assembly 6. Float 7. Spring pin
8. 9. 10. 11. 12. 13. 14.
Reservoir tank Reservoir seal Pin Piston retainer Primary piston assembly Secondary piston assembly Master cylinder body
35200460027
INSPECTION
D D D
Check the inner surface of master cylinder body for rust or pitting. Check the primary and secondary pistons for rust, scoring, wear, damage or wear. Check the diaphragm for cracks and wear.
ABS <2WD> - Proportioning Valve
35B-25
35200570126
PROPORTIONING VALVE
Pre-removal Operation Brake Fluid Draining
Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to GROUP 35A On-vehicle Service.)
Flared brake line nuts

15 Nm
2 1
Removal steps "AA 1. Brake pipe 2. Proportioning valve

1 3 2 4 "AA BRAKE PIPE CONNECTION Connect the pipes to the hydraulic unit as shown in the illustration. 1. Proportioning valve Rear brake (L.H.) 2. Proportioning valve Rear brake (R.H.) 3. Proportioning valve Hydraulic unit 4. Proportioning valve Hydraulic unit
35B-26 HYDRAULIC UNIT
ABS <2WD> - Hydraulic Unit

35200860261

Pre-removal Operation Brake Fluid Draining Post-installation Operation D Brake Fluid Supplying D Brake Line Bleeding (Refer to GROUP 35A - On-vehicle Service.) D Brake Pedal Adjustment (Refer to GROUP 35A - On-vehicle Service.)
15 Nm
2 2
3 1 3
9 Nm
9 Nm 22 Nm 22 Nm
Removal steps AA" 1. Harness connector "AA 2. Brake pipe connection AB" 3. Hydraulic unit and ABS-ECU 4. Hydraulic unit bracket assembly
ABS <2WD> - Hydraulic Unit REMOVAL SERVICE POINT

Locking lever
35B-27
AA" HARNESS CONNECTOR REMOVAL Raise the locking lever as shown in the illustration, and then disconnect the harness connector.
AB" HYDRAULIC UNIT ASSEMBLY REMOVAL Caution 1. The hydraulic unit assembly is heavy, and so care should be taken when removing it. 2. The hydraulic unit assembly is not to be disassembled; its nuts and bolts should absolutely not be loosened. 3. The hydraulic unit assembly must not be dropped or otherwise subjected to impact shocks. 4. The hydraulic unit assembly must not be turned upside down or laid on its side. 6 2 1 5 4 3

"AA BRAKE PIPE CONNECTION Connect the pipes to the hydraulic unit assembly as shown in the illustration. 1. To the proportioning valve (RH) 2. To the proportioning valve (LH) 3. From the master cylinder (Primary) 4. From the master cylinder (Secondary) 5. To the front brake (RH) 6. To the front brake (LH)
35B-28
ABS <2WD> - Wheel Speed Sensor

35200830279
WHEEL SPEED SENSOR

Post-installation Operation Wheel Speed Sensor Output Voltage Check (Refer to P.35B-19.) <Front> <Rear>
4 2
Front speed sensor removal steps D Splash Shield Removal (Refer to GROUP 42 - Fender.) AA" "AA 1. Front speed sensor 2. Front ABS rotor (Refer to GROUP 26 - Drive Shaft.) Rear speed sensor removal steps AA" "AA 3. Rear speed sensor 4. Rear ABS rotor (Refer to GROUP 27 - Rear Axle Hub.)
NOTE The front rotor is integrated with the drive shaft and is not disassembled.

AA" FRONT SPEED SENSOR/REAR SPEED SENSOR REMOVAL Caution Be careful when handling the pole piece at the tip of the speed sensor and the toothed edge of the rotor so as not to damage them by striking against other parts.

Front Rear
35B-29

"AA FRONT SPEED SENSOR/REAR SPEED SENSOR INSTALLATION The clearance between the wheel speed sensor and the ABS rotors toothed surface is not adjustable, but measure the distance between the sensor installation surface and the ABS rotors toothed surface. Standard value: 28.2 - 28.5 mm
ABS rotors toothed surface Front Rear
ABS rotors toothed surface
INSPECTION
35200840227
SPEED SENSOR 1. Check whether any metallic foreign material has adhered to the pole piece at the speed sensor tip, and if so, remove it. Also check whether the pole piece is damaged, and if so, replace it with a new one. NOTE The pole piece can become magnetized because of the magnet but into the speed sensor, with the result that metallic foreign material easily adheres to it. Moreover, the pole piece may not be able to function to correctly sense the wheel rotation speed if it is damaged. 2. Measure the resistance between the speed sensor terminals. Standard value: 1.0 - 1.5 kW If the internal resistance of the speed sensor is not within the standard value, replace with a new speed sensor. 3. Check the speed sensor cable for breakage, damage or disconnection; replace with a new one if a problem is found. NOTE When checking for cable damage, remove the cable clamp part from the body and then bend and pull the cable near the clamp to check whether or not temporary disconnection occurs.
35B-30

SPEED SENSOR INSULATION INSPECTION 1. Remove all connections from the speed sensor, and then measure the resistance between terminals 1 and 2 and the body of the speed sensor. Standard value: 100 kW or more 2. If the speed sensor insulation resistance is outside the standard value range, replace with a new speed sensor.
ABS TOOTHED ROTOR Check whether ABS rotor teeth are broken or deformed, and, if so, replace the ABS rotor.
36-1
PARKING BRAKES
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 3
Parking Brake Lever Stroke Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parking Brake Switch Check . . . . . . . . . . . . . . . . . . 4
36109000187
Lining Running-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . 5 PARKING BRAKE CABLE <DRUM BRAKE> . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PARKING BRAKE CABLE <DRUM-IN-DISC BRAKE> . . . . . . . . . . . . . . . . . . . 7 PARKING BRAKE DRUM . . . . . . . . . . . . . . . . . . . 9
36-2
PARKING BRAKES -
General Information/ Service Specifications/Lubricants

36100010158
GENERAL INFORMATION
The parking brake is of a mechanical control type acting on the rear wheels. A lever is used to apply the parking brake. The operation method utilizes
a parking brake lever which is in an offset position at the passengers side.
Parking brake lever
Parking brake cable
Parking brake switch
Items Parking brake lever stroke Rear brake lining thickness mm Rear drum inside diameter mm Standard value 5 - 7 notches*1, 3 - 5 notches*2 2.8 168.0 Limit 1.0 169.0
36100030147
NOTE *1: Vehicles with drum brake *2: Vehicles with drum-in-disc brake
LUBRICANTS
Items Backing plate Shoe and lining assembly Adjuster Specified lubricant Multipurpose grease
36100040126
PARKING BRAKES - Special Tool/On-Vehicle Service
36-3
36100060047
SPECIAL TOOL
Tool Number MB990998 Name Front hub remover and installer Use Fixing of the rear hub
Adjusting nut
ON-VEHICLE SERVICE
36100090145
PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT

1. Pull the parking brake lever with a force of approx. 196 N and count the number of notches.
Cable rod
Standard value: 5 - 7 notches <Vehicles with drum brake> 3 - 5 notches <Vehicles with drum in disc brake> 2. If the parking brake lever stroke is not the standard value, adjust as described below. Remove the floor console cup holder, loosen the adjusting nut as far as the end of the cable rod to release the cable, and then adjust by the following procedure: <Vehicles with drum brake> Depress the brake pedal repeatedly until the stroke no longer changes. NOTE Depressing the brake pedal repeatedly will automatically adjust the shoe clearance to the normal setting. <Vehicles with drum-in-disc brake> (1) Attach the special tool to the hub as shown in the illustration.
MB990998
Bolt
Hold the bolt in place when tightening
Adjuster
(2) Remove the adjustment hole plug, and then use a flat-tip ( - ) screwdriver to turn the adjuster in the direction of the arrow (the direction which expands the shoe) so that the disc will not rotate. Return the adjuster five notches in the direction opposite to the direction of the arrow.
36-4
PARKING BRAKES - On-Vehicle Service

Adjusting nut
Nut holder Pin
(3) Turn the adjusting nut to adjust the parking brake lever stroke to the standard value. After adjusting, check that there is no space between the adjusting nut and the parking brake lever. Caution If the parking brake lever stroke is below the standard value and the braking is too firm, the rear brakes may drag. (4) After adjusting the parking brake lever stroke, jack up the rear of the vehicle. Release the parking brake and turn the rear wheels to check that the rear brakes are not dragging.
PARKING BRAKE SWITCH CHECK
36100330124
1. Remove the floor console. (Refer to GROUP 52A.) 2. Check for continuity between the parking brake switch terminal and the switch mounting bolt.
When parking brake lever is pulled When parking brake lever is released Continuity No continuity
Pull
LINING RUNNING-IN
Spring balance
36100110087
Carry out running-in by the following procedure when replacing the parking brake linings or the rear brake disc rotors, or when brake performance is insufficient. Caution Carry out running-in in a place with good visibility, and pay careful attention to safety. 1. Adjust the parking brake stroke to the specified value. Standard value [Operation force: Approx. 196 N] 5 - 7 notches <Vehicles with drum brake> 3 - 5 notches <Vehicles with drum in disc brake> 2. Hook a spring balance onto the centre of the parking brake lever grip and pull it with a force of 98 - 147 N in a direction perpendicular to the handle. 3. Drive the vehicle at a constant speed of 35 - 50 km/h for 100 metres. 4. Release the parking brake and let the brakes cool for 5 - 10 minutes. 5. Repeat the procedure in steps 2. to 4. 4 - 5 times.
Approx. 40 mm
PARKING BRAKES - Parking Brake Lever
36-5
36100130168
PARKING BRAKE LEVER

Pre-removal Operation D Floor Console Removal (Refer to GROUP 52A.)
Post-installation Operation D Parking Brake Lever Stroke Check and Adjustment (Refer to P.36-3.) D Floor Console Installation (Refer to GROUP 52A.)
5 3 4 1 2
Ratchet plate Section A - A Section B - B
B 5
Ratchet pawl
Removal steps 1. Adjusting nut 2. Parking brake stay 3. Bushing
4. Parking brake switch 5. Parking brake lever
36-6
PARKING BRAKES - Parking Brake Cable <Drum brake>

36100190197
PARKING BRAKE CABLE <DRUM BRAKE>

Pre-removal Operation D Floor Console and Rear Seat Removal (Refer to GROUP 52A.)
Post-installation Operation D Parking Brake Lever Stroke Check and Adjustment (Refer to P.36-3.) D Floor Console and Rear Seat Installation (Refer to GROUP 52A.)
10
10 11
4 8
9 3
2 5 7 6
Removal steps 1. Rear brake drum 2. Shoe-to-lever spring 3. Auto adjuster assembly 4. Shoe-to-shoe spring 5. Retainer spring 6. Shoe hold-down cup 7. 8. 9. 10. 11. Shoe hold-down spring Shoe hold-down pin Shoe and lining assembly Clip Parking brake cable
PARKING BRAKES - Parking Brake Cable <Drum-in-disc brake>
36-7
36100190203
PARKING BRAKE CABLE <DRUM-IN-DISC BRAKE>

Pre-removal Operation D Floor Console and Rear Seat Removal (Refer to GROUP 52A.)
Post-installation Operation D Parking Brake Lever Stroke Check and Adjustment (Refer to P.36-3.) D Floor Console and Rear Seat Installation (Refer to GROUP 52A.)
12
90 - 110 Nm
12 13 2
10
11
3 6
7 4 5 9 8
AA"
Removal steps 1. Rear brake caliper assembly 2. Rear brake disc "BA 3. Shoe-to-anchor spring 4. Adjusting screw spring "AA 5. Adjuster 6. Strut 7. Strut return spring
AB"
8. 9. 10. 11. 12. 13.
Shoe hold-down cup Shoe hold-down spring Shoe hold-down pin Shoe and lining assembly Clip Parking brake cable
36-8
PARKING BRAKES - Parking Brake Cable <Drum-in-disc brake> REMOVAL SERVICE POINTS
AA" REAR BRAKE CALIPER ASSEMBLY REMOVAL Remove the rear brake caliper assembly and support it with wire or similar.
Shoe hold-down cup
AB" SHOE HOLD-DOWN CUP REMOVAL Extend the shoe and lining assembly, and remove the shoe hold-down cup.

"AA ADJUSTER INSTALLATION Install the adjuster so that the shoe adjusting bolt of left hand wheel is attached towards the front of the vehicle, and the shoe adjusting bolt of right hand wheel is towards the rear of the vehicle.
Shoe adjusting bolt
"BA SHOE-TO-ANCHOR SPRING INSTALLATION Install the shoe-to-anchor springs in the order shown in the illustration. Caution The load on the respective shoe-to-anchor springs is different, so the spring in the figure has been painted.
Rear 1 2 (Painted)
NOTE The figure shows the left wheel; for the right wheel, the position is symmetrical.
PARKING BRAKES - Parking Brake Drum
36-9
36100250109
PARKING BRAKE DRUM

Post-installation Operation D Parking Brake Lever Stroke Check and Adjustment (Refer to P.36-3.)
74 - 88 Nm
14
90 - 110 Nm
15 3 3
13 12
10 11 9 8
11 9 8
15 11
11
Brake grease: Multipurpose grease
Removal steps 1. Rear brake caliper (Refer to P.36-8) 2. Rear brake disc 3. Shoe-to-anchor spring (Refer to P.36-8) 4. Adjusting screw spring 5. Adjuster (Refer to P.36-8) 6. Strut 7. Strut return spring 8. Shoe hold-down cup (Refer to P.36-8)
9. 10. 11. 12. 13. 14.
Shoe hold-down spring Shoe hold-down pin Shoe and lining assembly Clip Parking brake cable Rear hub assembly (Refer to GROUP 27.) 15. Backing plate
36-10
PARKING BRAKES - Parking Brake Drum INSPECTION

36100260096
BRAKE LINING AND BRAKE DRUM CHECK 1. Measure the thickness of the brake lining at several places. Standard value: 2.8 mm Limit: 1.0 mm 2. If the thickness of the brake lining has worn down to the limit value or more, replace the shoe and lining assemblies on both sides of the vehicle. 3. Measure the inside diameter of the brake disc in two places or more. Standard value: 168.0 mm Limit: 169.0 mm 4. If the inside of the brake disc has worn down to the limit value or more, or if it is excessively worn on one side, replace the brake disc.
37A-1
STEERING
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 6
Steering Wheel Free Play Check . . . . . . . . . . . . . . 6 Steering Angle Check . . . . . . . . . . . . . . . . . . . . . . . . 7 Tie Rod End Ball Joint Starting Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Stationary Steering Effort Check . . . . . . . . . . . . . . . 8 Checking Steering Wheel Return to Centre . . . . . 8
37209000217
Drive Belt Tension Check . . . . . . . . . . . . . . . . . . . . . 8 Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fluid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Oil Pump Pressure Test . . . . . . . . . . . . . . . . . . . . . 11 Power Steering Oil Pressure Switch Check . . . . 12 Ball Joint Dust Cover Check . . . . . . . . . . . . . . . . . 12
STEERING WHEEL AND SHAFT* . . . . . . . . . 13 POWER STEERING GEAR BOX* . . . . . . . . . 16 POWER STEERING OIL PUMP . . . . . . . . . . . 29 POWER STEERING HOSES . . . . . . . . . . . . . . 34
37A-2
STEERING - General Information

37200010172
GENERAL INFORMATION
The steering wheel is 4-spoke type. The steering wheel including the air bag is a 3-spoke type. The steering column is equipped with both shock absorbing and tilt steering mechanisms. The power steering is an integral rack and pinion
Items Steering gear and linkage Type Gear type Oil pump Type Displacement mL Relief set pressure MPa
type that combines the steering gear and linkage into one light-weight and compact assembly. The steering system uses a vane oil pump with a fluid flow control system, so that steering effort varies with engine speed.
Specifications Integral type Rack and pinion Vane type 9.6 11.8
Steering wheel Oil reservoir
Steering column assembly
Oil pump Tilt lever
Steering gear and linkage
STEERING - Service Specifications/Lubricants/Sealant
37A-3
37200030192
Items Steering wheel free play mm Steering angle with engine stopped when hydraulic operation Inner wheel Standard value 10 or less 38_00 2_ <Except 6A1 - R.H. drive vehicles> 39_00 2_ <6A1 - R.H. drive vehicles> 30_30 0.5 - 2.5 30 or less (5.9 or less) 11.8 0.8 - 1.0 11.8 1.8 - 2.4 0.8 - 2.4 0.7 - 1.4 8 - 27 (1.5 - 4.9) 2.9 2.4 - 2.8 30 -
Limit
Outer wheel Tie rod end ball joint starting torque Nm Stationary steering effort N (Fluctuation allowance) Oil pump pressure MPa Oil pump relief pressure Pressure under no-load conditions Steering gear retention hydraulic pressure Oil pressure switch operating pressure MPa OFFON ONOFF Total pinion torque Nm (Change in torque: 0.4 Nm) Tie rod joint swing resistance N (Tie rod joint swing torque Nm) Opening dimension of special tool (MB991561) mm Band crimped width mm
37200040140
LUBRICANTS
Items Power steering fluid Bellows Pinion and valve assembly Rack assembly Oil seal, pinion and valve assembly, ball bearing, needle roller bearing, special tool (MB991213) Flow control valve, friction surface of rotor, vanes, cam ring, pump cover, O-ring Automatic transmission fluid DEXRON or DEXRON II As required Specified lubricant Automatic transmission fluid DEXRON or DEXRON II Silicone grease Repair kit grease Quantity As required As required As required
SEALANT
Items End plug screw Power steering rack support cover screw Dust cover lip for tie rod end ball joint Specified sealant 3M ATD Part No. 8661 or equivalent Remarks Semi-drying sealant
37200050136
37A-4 SPECIAL TOOLS

Tool Number
STEERING - Special Tools

37200060177
Name Steering linkage puller
Use Disconnection of tie rod end
MB990635, MB991113 or MB991406
MB990685
Torque wrench
D D
Measurement of the ball joint starting torque Measurement of the total pinion torque
MB991006
Preload socket
Measurement of the total pinion torque
MB990326
Preload socket
Measurement of the ball joint starting torque
MB990993
Power steering oil pressure gauge adapter (pump side)
MB990994
Power steering oil pressure gauge adapter (hose side)
MB990662
Oil pressure gauge assembly
MB991204
Torque wrench socket
D D
Adjustment of rack support Removal of rack support cover
MB990803
Steering wheel puller
Disconnection of the steering wheel
STEERING - Special Tools

Tool Number MB991202 Name Oil seal and bearing installer Use Press fitting of rack housing bearing
37A-5
MB991197
Bar (long type)
To press in the oil seal for the rack
MB991199
Oil seal installer
To press in the oil seal for the rack
MB991213
Rack installer
Rack installation
MB990925
Bearing and oil seal installer set
Installation of the oil seal and bearing
MB991120
Needle bearing puller
Removal of rack housing needle bearing
MB991203
Oil seal and bearing installer
To press in the valve housing oil seal and bearing
MB991317
Seal ring installer
Compression of the seal rings after replacement of the pinion seal rings
MB990941
Torque tube bearing installer
Installation of valve housing oil seal
37A-6
Tool
STEERING - Special Tools/On-vehicle Service

Number MB991561 Name Boot band crimping tool Use Installation of bellows band
MB990776
Front axle base
Installation of dust cover for tie rod end ball joint
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK
37200100138
1. With engine running (hydraulic operation), set front wheels straight ahead.
2. Measure the play on steering wheel circumference before wheels start to move when slightly moving steering wheel in both directions. Limit: 30 mm 3. When play exceeds the limit, check for play on steering shaft connection and steering linkage. Correct or replace. 4. If the free play still exceeds the limit value, set steering wheel straight ahead with engine stopped. Load 5 N towards steering wheel circumference and check play. Standard value (steering wheel play with engine stopped): 10 mm or less If the play exceeds the standard value, remove steering gear box and check total pinion torque.
STEERING - On-vehicle Service STEERING ANGLE CHECK
37A-7
37200110179
1. Locate front wheels on turning radius gauge and measure steering angle. Standard value: Inner wheel 38_00 2_ <Except 6A1-R.H. drive vehicles> 39_00 2_ <6A1-R.H. drive vehicles> Outer wheel 30_30 2. When the angle is not within the standard value, the toe is probably incorrect. Adjust toe (Refer to GROUP 33A - On-vehicle Service) and recheck steering angle.
Cord Ball joint
TIE ROD END BALL JOINT STARTING TORQUE 37200150140 CHECK

1. Disconnect tie rod and knuckle with special tool.
MB990635, MB991113 or MB991406
Nut
Caution 1. Using the special tool, loosen the tie rod end mounting nut. Only loosen the nut; do not remove it from the ball joint. 2. Support the special tool with a cord, etc. to prevent it from coming off. 2. Move ball joint stud several times and install nut on stud. Measure ball joint starting torque with special tools.
MB990685
MB990326
Standard value: 0.5 - 2.5 Nm 3. When the starting torque exceeds the standard value, replace tie rod end. 4. When the starting torque is under the standard value, check ball joint for end play or ratcheting. If none of these, the joint is still serviceable.
37A-8
STEERING - On-vehicle Service STATIONARY STEERING EFFORT CHECK

37200170160
1. With the vehicle stopped on a flat, paved surface, turn the steering wheel to the straight ahead position. 2. Start the engine and set it to 1,000100 r/min. Caution After checking the engine r/min must return to the standard idling r/min. 3. Attach a spring balance to the outer circumference of the steering wheel and measure the steering force required to turn the steering wheel from the straight ahead position to the left and right (within a range of 1.5 turns). Also check to be sure that there is no significant fluctuation of the required steering force. Standard value: Steering effort: 30N or less Fluctuation allowance: 5.9N or less
CHECKING STEERING WHEEL RETURN TO 37200180156 CENTRE

70_ 70_
To make this test, conduct a road test and check as follows. 1. Make both gradual and sudden turns and check the steering feeling to be sure that there is not difference in the steering force required and the wheel return between left and right turns. 2. At a speed of 35 km/h, turn the steering wheel 90_ and release the steering wheel after 1 or 2 seconds. If the steering wheel then returns 70_ or more, the return can be judged to be satisfactory. NOTE There will be a momentary feeling or heaviness when the wheel is turned quickly, but this is not abnormal. (This is because the oil pump discharge amount is especially apt to be insufficient during idling.)
DRIVE BELT TENSION CHECK

Refer to GROUP 11 - On-vehicle Service.
37200190050
STEERING - On-vehicle Service

Fluid level change: Within 5 mm
37A-9
37200200043
FLUID LEVEL CHECK
While engine running
While engine stopped
1. Park the vehicle on a flat, level surface, start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50 - 60_C. 2. With the engine running, turn the wheel all the way to the left and right several times. 3. Check the fluid in the oil reservoir for foaming or milkiness. Check the difference of the fluid level when the engine is stopped, and while it is running. If the change of the fluid level is 5 mm or more, air bleeding should be done.
FLUID REPLACEMENT
37200210046
Return hose
Vinyl hose
1. Raise the front wheels on a jack, and then support them with rigid racks. 2. Disconnect the return hose connection. 3. Connect a vinyl hose to the return hose, and drain the oil into a container. 4. Disconnect the high tension cable. Caution Be careful not to position the high-tension cable near the delivery pipe. 5. While operating the starting motor intermittently, turn the steering wheel all the way to the left and right several times to drain all of the fluid. 6. Connect the return hoses securely, and then secure it with the clip. 7. Fill the oil reservoir with the specified fluid up to the lower position of the filter, and then bleed the air. Specified fluid: Automatic transmission fluid DEXRON or DEXRON II
37A-10
STEERING - On-vehicle Service BLEEDING

37200220155
1. Jack up the front wheels and support them by using a rigid rack. 2. Manually turn the oil pump pulley a few times. 3. Turn the steering wheel all the way to the left and to the right five or six times. 4. On vehicles with a petrol engine, disconnect the high-tension cable. On vehicles with a diesel engine, remove the fuel cut valve connector attached to the injection pump. Caution Be careful not to position the high-tension cable near the delivery pipe. 5. While operating the starting motor intermittently, turn the steering wheel all the way to the left and right five or six times (for 15 to 20 seconds). Caution 1. During air bleeding, refill the fluid so that the level never falls below the lower position of the filter. 2. If air bleeding is done while engine is running, the air will be broken up and absorbed into the fluid; be sure to do the bleeding only while cranking. 6. On vehicles with a petrol engine, connect the high-tension cable. On vehicles with a diesel engine, connect the fuel cut valve connector attached to the injection pump. Start the engine (idling). 7. Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir. 8. Confirm that the fluid is not milky, and that the level is up to the specified position on the level gauge. 9. Confirm that there is very little change in the fluid level when the steering wheel is turned left and right.
Fluid level change: Within 5 mm
10. Check whether or not the change in the fluid level is within 5 mm when the engine is stopped and when it is running. 11. If the change of the fluid level is 5 mm or more, the air has not been completely bled from the system, and thus must be bled completely. Caution 1. If the fluid level rises suddenly after the engine is stopped, the air has not been completely bled. 2. If air bleeding is not complete, there will be abnormal noises from the pump and the flow-control valve, and this condition could cause a lessening of the life of the pump, etc.
While engine running
While engine stopped

Pressure gauge (MB990662) Shut-off valve Temperature gauge Oil pump relief pressure Adapter (MB990993)
37A-11
37200230189
OIL PUMP PRESSURE TEST
1. Disconnect the pressure hose from the oil pump, and then connect the special tools. 2. Bleed the air, and then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60_C. 3. Start the engine and idle it at 1,000100 r/min. 4. Fully close the shut-off valve of the pressure gauge and measure the oil pump relief pressure to confirm that it is within the standard value range. Standard value: 11.8 MPa Caution Pressure gauge shut off valve must not remain closed for more than 10 seconds. 5. If it is not within the standard value, replace the oil pump. 6. Check whether or not the hydraulic pressure is the standard value when no-load conditions are created by fully opening the shut-off valve of the pressure gauge. Standard value: 0.8 - 1.0 MPa 7. If it is not within the standard value, the probable cause is a malfunction of the oil line or steering gear box, so check these parts and repair as necessary. 8. Fully open the shut-off valve of the pressure gauge. 9. Turn the steering wheel all the way to the left or right; then check whether or not the retention hydraulic pressure is the standard value. Standard value: 11.8 MPa 10. When not within the standard value, replace the power steering gear box. Remeasure fluid pressure. 11. Remove the special tools, and then tighten the pressure hose to the specified torque. Tightening torque: 18 Nm 12. Bleed the system.
Oil pump Reservoir Pressure hose Adapter (MB990994)
37A-12
Adapter (MB990993) Pressure gauge (MB990662) Temperature gauge

Shut-off valve
POWER STEERING OIL PRESSURE SWITCH 37200720150 CHECK

1. Disconnect the pressure hose from the oil pump, and then connect the special tools. 2. Bleed the air, and then turn the steering wheel several times while the vehicle is not moving so that the temperature of the fluid rises to approximately 50 - 60_C. 3. The engine should be idling. 4. Disconnect the connection of the connector for the oil pressure switch, and place an ohmmeter in position. 5. Gradually close the shut-off valve of the pressure gauge and increase the hydraulic pressure, then check whether or not the hydraulic pressure that activates the switch is the standard value.
Oil pump Reservoir Adapter (MB990994)
Standard value: 1.8 - 2.4 MPa 6. Gradually open the shut-off valve and reduce the hydraulic pressure; then check whether or not the hydraulic pressure that deactivates the switch is the standard value. Standard value: 0.8 - 2.4 MPa 7. Remove the special tools, and then tighten the pressure hose to the specified torque. Tightening torque: 18 Nm 8. Bleed the system.
37200860012
1. Check the dust cover for cracks or damage by pushing it with finger. 2. If the dust cover is cracked or damaged, replace the tie rod end. NOTE Cracks or damage of the dust cover may cause damage of the ball joint.
STEERING - Steering Wheel and Shaft
37A-13
37200260218
STEERING WHEEL AND SHAFT

CAUTION: SRS For vehicles with SRS, before removal of air bag module, refer to GROUP 52B - Service Precautions and Air Bag Module and Clock Spring.
Pre-removal Operation Instrument Lower Panel Assembly Removal (Refer to GROUP 52A - Instrument Panel.)
Post-installation Operation D Instrument Lower Panel Assembly Installation (Refer to GROUP 52A - Instrument Panel.) D Checking Steering Wheel Position with Wheels Straight Ahead
41 Nm 25 Nm
2 6
Standard bolt
Earth bolt
12 Nm
7
18 Nm
3
12 Nm 22 Nm
5 Nm
Removal steps 1. Air bag module (Refer to GROUP 52B - Air Bag Module and Clock Spring.) AA" 2. Steering wheel 3. Lower column cover 4. Upper column cover "AA 5. Clock spring and column switch (Refer to GROUP 52B - Air Bag Module and Clock Spring.)
6. Steering shaft assembly 7. Steering cover assembly Caution One of the steering shaft assembly mounting bolts must be the earth bolt. The earth bolt has a E mark on its head.
37A-14
MB990803
STEERING - Steering Wheel and Shaft REMOVAL SERVICE POINT

AA" STEERING WHEEL REMOVAL

"AA CLOCK SPRING AND COLUMN SWITCH/COLUMN SWITCH INSTALLATION Tighten the screws in an alphabetical order.
A

1 2 4 5 9 5 3 6
37200280153
8 7
Disassembly steps AA" "AA 1. Special bolt "AA 2. Steering lock bracket "AA 3. Steering lock cylinder 4. Snap ring 5. Stopper
6. 7. 8. 9.
Spacer Steering shaft assembly Snap ring Steering column assembly
STEERING - Steering Wheel and Shaft

Steering lock bracket
37A-15

AA" STEERING LOCK BRACKET/STEERING LOCK CYLINDER REMOVAL If it is necessary to remove the steering lock cylinder, use a hacksaw to cut the special bolts at the steering lock bracket side.
Steering lock cylinder

"AA STEERING LOCK CYLINDER/STEERING LOCK BRACKET/SPECIAL BOLT INSTALLATION 1. When installing the steering lock cylinder and steering lock bracket to the column tube, temporarily install the steering lock in alignment with the column boss.
2. After checking that the lock works properly, tighten the special bolts until the head twists off. Caution The steering lock bracket and bolts must be replaced with new ones when the steering lock is installed.
37A-16
STEERING - Power Steering Gear Box

37200390207
POWER STEERING GEAR BOX

CAUTION: SRS For vehicles with SRS, before removal of steering gear box, refer to GROUP 52B, centre front wheels and remove ignition key. Failure to do so may damage SRS clock spring and render SRS system inoperative, risking serious driver injury.
Pre-removal Operation D Power Steering Fluid Draining (Refer to P.37A-9.) D Center Member Removal (Refer to GROUP 32.) D Front Exhaust Pipe Removal (Refer to GROUP 15.) D Stabilizer Bar Removal (Refer to GROUP 33A.)
Post-installation Operation D Check the Dust Cover for Cracks or Damage by Pushing it with Finger. D Stabilizer Bar Installation (Refer to GROUP 33A.) D Front Exhaust Pipe Installation (Refer to GROUP 15.) D Center Member Installation (Refer to GROUP 32.) D Power Steering Fluid Supplying (Refer to P.37A-9.) D Power Steering Fluid Line Bleeding (Refer to P.37A-10.) D Checking Steering Wheel Position with Wheels Straight Ahead D Front Wheel Alignment Adjustment (Refer to GROUP 33A.)
6
15 Nm
18 Nm
8 5
2
81 Nm
24 - 33 Nm 69 Nm
69 - 78 Nm
AA"
Removal steps 1. Steering shaft assembly and gear box connecting bolt 2. No.2 stay 3. No.3 stay 4. Split pin
AB"
AC"
5. 6. 7. 8. 9.
Tie rod end and knuckle connection Pressure tube connection Return tube connection Cylinder clamp Gear box assembly
STEERING - Power Steering Gear Box REMOVAL SERVICE POINTS
37A-17
AA" NO.3 STAY REMOVAL Hold the crossmember with a transmission jack, and remove the No.3 stay.
Crossmember
Transmission jack
Cord Ball joint MB990635 or MB991113
AB" TIE ROD END DISCONNECTION Caution 1. Using the special tool, loosen the tie rod end mounting nut. Only loosen the nut; do not remove it from the ball joint. 2. Support the special tool with a cord, etc. to prevent it from coming off.
Nut
AC" GEAR BOX ASSEMBLY REMOVAL Caution Be careful not to damage the bellows and the tie rod end dust cover when removing the gear box assembly.
INSPECTION
D
37200400139
Check the rubber parts for cracks and breakage.
37A-18

MB991006
GEAR BOX TOTAL PINION TORQUE Using the special tools, rotate the pinion gear at the rate of one rotation in approximately 4 to 6 seconds to check the total pinion torque. Standard value: 0.7 - 1.4 Nm [Change in torque: 0.4 Nm] Caution When holding the steering gear box assembly in a vice, secure its mounting positions. If it is secured in any other places, the gear housing may become deformed or damaged. NOTE When measuring, remove the bellows from the rack housing. Measure the pinion torque through the whole stroke of the rack. If the measured value is not within the standard range, first adjust the rack support cover, and then check the total pinion starting torque again. If the total pinion starting torque cannot be adjusted to within the standard range by adjusting the rack support cover, check the rack support cover, rack support spring, rack support and replace any parts if necessary. CHECK THE TIE ROD FOR SWING RESISTANCE 1. Give 10 hard swings to the tie rod. 2. Measure the tie rod swing resistance with a spring balance. Standard value: 8 - 27 N [1.5 - 4.9 Nm] 3. If the measured value exceeds the standard value, replace tie rod. 4. Even if the measured value is below the standard value, the tie rod which swings smoothly without excessive play may be used.
TIE ROD END BALL JOINT DUST COVER CHECK

1. Check the dust cover for cracks or damage by pushing it with finger. 2. If the dust cover is cracked or damaged, replace the tie rod end. (Refer to P.37A-19.) NOTE Cracks or damage of the dust cover may cause damage of the ball joint. When it is damaged during service work, replace the dust cover.
STEERING - Power Steering Gear Box DISASSEMBLY AND REASSEMBLY

Steering gear seal kit
37A-19
37200410132
22 Nm
2 26 17 1 19 34 33
25 Nm
21 19 2
22 21 20 18 17 32 6 16 2 29 30 9
15
27 33 9
31 15
Flare nut
14
49 - 54 Nm
59 Nm
3 8
13 12 11 9
59 Nm
10
15 Nm - 30
13 Nm
26 7 6
22 Nm
25 28
23 24 27 30 29
Disassembly steps 1. Feed pipe 2. O-ring "NA 3. Tie rod end locking nut "NA 4. Tie rod end 5. Bellows clip "MA 6. Bellows band 7. Bellows "LA 8. Tie rod "LA 9. Tab washer "KA D Total pinion torque adjustment "JA 10. Locking nut AA" "JA 11. Rack support cover 12. Rack support spring 13. Rack support "IA 14. End plug 15. Self-locking nut 16. Valve housing assembly AB" "HA 17. Oil seal
AB" 18. Pinion and valve assembly AC" "GA 19. Seal ring AD" "FA 20. Ball bearing AD" "FA 21. Oil seal 22. Valve housing AE" "EA 23. Circlip AF" 24. Rack stopper AF" "DA 25. Rack bushing AG" "DA 26. Oil seal 27. O-ring AF" "CA 28. Rack AC" 29. Seal ring 30. O-ring AH" "BA 31. Ball bearing AI" "BA 32. Needle roller bearing AJ" "AA 33. Oil seal 34. Rack housing
37A-20
Lubrication and Sealing Points
Fluid: Automatic transmission fluid DEXRON or DEXRON II
Sealant: 3M ATD Part No. 8661 or equivalent Grease: Repair kit grease
Sealant: 3M ATD Part No. 8661 or equivalent
Grease: Silicone grease
Fluid: Automatic transmission fluid DEXRON or DEXRON II Grease: Repair kit grease
STEERING - Power Steering Gear Box DISASSEMBLY SERVICE POINTS

MB991204
37A-21
AA" RACK SUPPORT COVER REMOVAL Use the special tool to remove the rack support cover from the gear box.
AB" OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL Using a plastic hammer, gently tap the pinion to remove it.
AC" SEAL RING REMOVAL Cut the seal ring and remove it from the pinion and valve assembly and the rack. Caution When cutting the seal ring, be careful not to damage the pinion and valve assembly or the rack.
AD" BALL BEARING/OIL SEAL REMOVAL Use a socket, remove the oil seal and the ball bearing from the valve housing assembly simultaneously.
Socket
Rack stopper
AE" CIRCLIP REMOVAL 1. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing. 2. Turn the rack stopper anticlockwise to remove the circlip. Caution Note that if the rack stopper is first turned anticlockwise, the circlip will get caught in the slot in the housing and the rack stopper will not turn.
Circlip
37A-22

AF" RACK STOPPER/RACK BUSHING/RACK REMOVAL Pull out the rack assembly gently, and remove the rack stopper and rack bushing together.
AG" OIL SEAL REMOVAL Partially bend the oil seal to remove from the rack bushing.
Rack bushing
Caution Do not damage the oil seal press fitting surface of the rack bushing.
MB990925 (MB990939) or brass bar
AH" BALL BEARING REMOVAL Use a brass bar or the special tool to remove the ball bearing from the gear housing.
Ball bearing
MB991120
AI" NEEDLE ROLLER BEARING REMOVAL Use the special tool to remove the needle roller bearing from the rack housing. Caution Do not open the special tool excessively to prevent damaging housing interior.
Needle roller bearing
Gear housing Pipe or similar tool
AJ" OIL SEAL REMOVAL Use a piece of pipe or similar tool to remove the oil seal from the gear housing. Caution Be careful not to damage the inner surface of the rack cylinder of the gear housing.
Oil seal
STEERING - Power Steering Gear Box REASSEMBLY SERVICE POINTS

Gear housing MB991199 MB991197
37A-23
"AA OIL SEAL INSTALLATION
Oil seal
MB990925 (MB990938) MB991202
Needle roller bearing
MB990925 (MB990938) MB991202 Ball bearing
"BA NEEDLE ROLLER BEARING/BALL BEARING INSTALLATION
Vent hole
"CA RACK INSTALLATION 1. Apply a coating of repair kit grease to the rack tooth face. Caution Do not close the vent hole in the rack with grease.
Seal ring, O-ring
Oil seal
2. Cover rack serrations with special tool. 3. Apply the specified fluid on the special tool. Specified fluid: Automatic transmission fluid DEXRON or DEXRON II 4. Match the oil seal centre with rack to prevent retainer spring from slipping and slowly insert rack from power cylinder side.
MB991213
MB990925 (MB990927) Oil seal O-ring Rack bushing
"DA OIL SEAL/RACK BUSHING INSTALLATION 1. Apply the specified fluid to the outer surface of the oil seal. Press-fit the oil seal using the special tool until it is flush with the bushing end face. Specified fluid: Automatic transmission fluid DEXRON or DEXRON II
37A-24
Rack

2. Apply the specified fluid to the oil seal inner surface and the O-ring. Specified fluid: Automatic transmission fluid DEXRON or DEXRON II
Plastic tape
3. Wrap the rack end with plastic tape, and push the rack bushing onto the rack.
Rack bushing
Circlip
Circlip
"EA CIRCLIP INSTALLATION Insert the circlip to the rack stopper hole through the cylinder hole. Turn the rack stopper clockwise and insert the circlip firmly. Caution Insert the circlip to the rack stopper hole while turning the rack stopper clockwise.
Slot
Slot
MB990938
"FA OIL SEAL/BALL BEARING INSTALLATION 1. Apply a coating of the specified fluid to the outside of the oil seal. Using the special tools, press the oil seal into the valve housing. Specified fluid: Automatic transmission fluid DEXRON or DEXRON II
Oil seal
MB991203
MB990938
2. Apply a coating of the specified fluid to the outside of the ball bearing. Using the special tools, press the ball bearing into the valve housing. Specified fluid: Automatic transmission fluid DEXRON or DEXRON II
Ball bearing
MB991203
MB991317
Tapered side
"GA SEAL RING INSTALLATION 1. Kneed the seal ring to soften it. 2. Apply the specified fluid to the seal ring, and install to the rack groove. Specified fluid: Automatic transmission fluid DEXRON or DEXRON II
Pinion gear
37A-25
3. Insert the tapered side of the special tool from the pinion gear side, and compress the seal ring.
MB990941
"HA OIL SEAL INSTALLATION Use the special tool to press the oil seal into the valve housing. The upper surface of the oil seal should project outwards approx. 1 mm from the housing edge surface. Caution If the oil seal is flush with or lower than the housing edge, it will cause oil leaks and require reassembly.
Approx. 1 mm
End plug
End plug
"IA END PLUG INSTALLATION 1. Apply the specified sealant to the threaded part of the end plug. Specified sealant: 3M ATD Part No.8661 or equivalent 2. Secure the threaded portion of the end plug at two places by using a punch.
Sealant
"JA RACK SUPPORT COVER/LOCKING NUT INSTALLATION 1. Use the special tool to tighten the rack support cover to 15 Nm. 2. Return the rack support cover 30_. 3. Use the special tool to hold the rack support cover and tighten the locking nut to the specified torque.
MB991204
MB991006
"KA TOTAL PINION TORQUE ADJUSTMENT 1. Using the special tool, rotate the pinion shaft at the rate of one rotation in 4 to 6 seconds to check the total pinion torque and the change in torque. Standard value: Total pinion torque: 0.7 - 1.4 Nm Change in torque: 0.4 Nm or less
37A-26

2. If the total pinion torque or the change in torque is outside the standard value, return the rack support cover within 0 to 30_, and adjust again. Caution (1) When adjusting, set the standard value at its highest value. (2) Assure no ratcheting or catching when operating the rack towards the shaft direction. (3) Measure the total pinion torque through the whole stroke of the rack. NOTE If the total pinion toque cannot be adjusted to the standard value within the specified return angle, check the rack support cover components and replace any parts if necessary.
"LA TAB WASHER/TIE ROD INSTALLATION After installing the tie rod to the rack, fold the tab washer end (2 locations) to the tie rod notch.
MB991561 Stopper W
"MABELLOWS BAND INSTALLATION 1. Turn the adjusting bolt of the special tool to adjust the opening dimension (W) to the standard value. Standard value (W): 2.9 mm <When more than 2.9 mm> Screw in the adjusting bolt. <When less than 2.9 mm> Loosen the adjusting bolt. NOTE (1) The dimension (W) is adjusted by approx. 0.7 mm per one turn. (2) Do not turn the adjusting bolt more than one turn. 2. Use the special tool to crimp the bellows band. Caution (1) Hold the rack housing, and use the special tool to crimp the bellows band securely. (2) Crimp the bellows band until the special tool touches the stopper.
Adjusting bolt
MB991561
37A-27
3. Check that the crimped width (A) is within the standard value.
A
Standard value (A): 2.4 - 2.8 mm <When more than 2.8 mm> Readjust the dimension (W) of step (1) to the value calculated by the following equation, and repeat step (2). W = 5.5 mm - A [Example: If (A) is 2.9 mm, (W) is 2.6 mm.] <When less than 2.4 mm> Remove the bellows band, readjust the dimension (W) of step (1) to the value calculated by the following equation, and use a new bellows band to repeat steps (2) to (3). W = 5.5 mm - A [Example: If (A) is 2.3 mm, (W) is 3.2 mm.]
Edge of bellows assembly groove
Lock nut
"NA TIE ROD END/TIE ROD END LOCKING NUT INSTALLATION Screw in the tie rod end to have its right and left length as illustrated. Lock with lock nut.
104 mm
INSPECTION
37200440131
RACK CHECK D Check the rack tooth surfaces for damage or wear. D Check the oil seal contact surfaces for uneven wear. D Check the rack for bends. PINION AND VALVE ASSEMBLY CHECK D Check the pinion gear tooth surfaces for damage or wear. D Check for worn or defective seal ring. BEARING CHECK D Check for roughness or abnormal noise during bearing operation. D Check the bearing for play. D Check the needle roller bearing for roller slip-off.
37A-28

OTHER CHECK D Check the cylinder inner surface of the rack housing for damage. D Check the boots for damage, cracking or deterioration. D Check the rack support for uneven wear or dents. D Check the rack bushing for uneven wear or damage.
TIE ROD END BALL JOINT DUST COVER REPLACEMENT

Only when the dust cover is damaged accidentally during service work, replace the dust cover as follows: 1. Apply grease to the inside of the dust cover. 2. Apply the specified sealant to the mounting surface of the dust cover. Specified sealant: 3M ATD Part No.8661 or equivalent 3. Drive in the dust cover with special tool until it is fully seated. 4. Check the dust cover for cracks or damage by pushing it with finger.
MB990776
STEERING - Power Steering Oil Pump
37A-29
37200520262
POWER STEERING OIL PUMP

Pre-removal Operation D Power Steering Fluid Draining (Refer to P.37A-9.) D Condenser Fan Motor Assembly Removal (Refer to GROUP 14.) <6A1>
Post-installation Operation D Condenser Fan Motor Assembly Installation (Refer to GROUP 14.) <6A1> D Power Steering Fluid Supplying (Refer to P.37A-9.) D Drive Belt Tension Adjusting (Refer to GROUP 11 - On-vehicle Service.) D Power Steering Fluid Line Bleeding (Refer to P.37A-10.) D Oil Pump Pressure Check (Refer to P.37A-11.)
<4G6>
12 Nm
12 Nm 49 Nm
3 8
10
28 Nm
7
10 - 12 Nm
5 6 4
18 Nm
49 Nm 28 Nm
1 <4D6>
3 8 9
22 Nm
5 1
18 Nm
39 Nm
Removal steps 1. Drive belt 2. Pressure switch connector 3. Suction hose 4. Pressure hose 5. O-ring
6. 7. 8. 9. 10.
Bolt Bolt Oil pump Oil pump brace Oil pump bracket
37A-30
<6A1>
36 Nm
5 4 10 3
39 Nm
9 8
12 Nm
18 Nm
39 Nm
7 1
Removal steps 1. Drive belt 2. Pressure switch connector 3. Suction hose 4. Air control valve 5. Pressure hose
6. 7. 8. 9. 10.
O-ring Bolt Bolts Oil pump Oil pump bracket
INSPECTION
D D
37200530036
Check the drive belt for cracks. Check the pulley assembly for uneven rotation.
STEERING - Power Steering Oil Pump DISASSEMBLY AND REASSEMBLY
37A-31
37200540220
24 7
2 5 9 3
13 21
Oil pump seal kit
4
Oil pump cartridge kit
7.9 Nm
1 2 4 3 6 7 24 25 11 10 9
59 Nm
20 Nm
23
8 16 15 14 13 18 20 21 22
29 Nm
12
20 19 17
"EA "DA "CA "AA "AA
"AA "BA
Disassembly steps 1. Pump cover 2. O-ring 3. Vanes 4. Rotor 5. Cam ring 6. Side plate 7. O-ring 8. Connector 9. O-ring 10. Flow control valve 11. Flow control spring 12. Terminal assembly 13. O-ring 14. Spring 15. Plunger
16. 17. 18. 19. 20. "AA 21. 22. 23. "AA 24. 25.
Piston rod Snap ring Terminal Washer Insulator O-ring Plug Suction connector O-ring Oil pump body and pulley assembly
Caution Do not disassemble the flow control valve.
37A-32
Connector 1 2 3 6 4 Side plate
STEERING - Power Steering Oil Pump REASSEMBLY SERVICE POINTS

"AA O-RINGS INSTALLATION Apply the specified fluid on O-rings to install.
No. 1 2
Suction connector mounting portion of oil pump body
I.D. Width mm 11 1.9 13 1.9 17.8 2.4 13.5 1.5 3.8 1.9 16.8 2.4 17.8 2.4 13.0 1.9
3 4 5 6 7 8
Terminal assembly 8 5
"BA SPRING INSTALLATION Fit the spring to the oil pump body with the larger diameter end at the terminal assembly side.
"CA SIDE PLATE INSTALLATION Install the side plate so that the screw hole in the oil pump body and the knock pin holes in the side plate are all in a straight line.
Screw hole Knock pin hole (round hole) Side plate Knock pin hole (oval hole) Screw hole
"DA CAM RING INSTALLATION Install the cam ring with the punch mark facing the side plate.
Punch mark
37A-33
Direct round edge to the cam ring.
"EA VANE INSTALLATION Install the vanes on the rotor, paying close attention to the installation direction.
Rotor
Vane
Cam ring
INSPECTION
D D D D D
37200550087
Check the flow control valve for clogging. Check the pulley assembly for wear or damage. Check the groove of rotor and vanes for stepped wear. Check the contact surface of cam ring and vanes for stepped wear. Check the vanes for damage.
37A-34
STEERING - Power Steering Hoses

37200570267
POWER STEERING HOSES

Pre-removal Operation D Power Steering Fluid Draining (Refer to P.37A-9.) D Front Bumper Removal (Refer to GROUP 51.)
Post-installation Operation D Front Bumper Installation (Refer to GROUP 51.) D Power Steering Fluid Supplying (Refer to P.37A-9.) D Power Steering Fluid Line Bleeding (Refer to P.37A-10.)
<4G6> 12
<L.H. drive vehicles> 12 Nm
8 7
11
12 Nm
10
7 5
15 Nm
13
12 Nm
12 Nm
15 Nm
6
12 Nm
12 Nm 12 Nm
1
2
18 Nm
12 Nm 34 Nm
3
12 Nm
4
15 Nm 34 Nm
15 Nm
"AA 1. 2. 3. 4. 5. 6. 7.
Pressure hose O-ring Pressure tube O-ring Return tube O-ring Return hose
8. 9. 10. 11. 12. 13.
Return tube Return hose Suction hose Return hose Oil reservoir Cooler tube

<4D6>
37A-35
12
11
12 Nm
7 10 9
7 5
15 Nm
13
12 Nm
12 Nm
5
15 Nm
6
12 Nm 12 Nm
1
<L.H. drive vehicles> 12 Nm 34 Nm
2
12 Nm
3 4
18 Nm
15 Nm 34 Nm <R.H. drive vehicles>
15 Nm
"AA 1. 2. 3. 4. 5. 6. 7.
Pressure hose O-ring Pressure tube O-ring Return tube O-ring Return hose
8. 9. 10. 11. 12. 13.
Return tube Return hose Suction hose Return hose Oil reservoir Cooler tube
37A-36
<6A1> 13

12 11
12 Nm
10
<R.H. drive vehicles> 12 Nm
8 6
15 Nm
9 6
15 Nm
14
12 Nm
12 Nm
12 Nm
1
36 Nm 12 Nm
2 3
12 Nm 34 Nm
4
18 Nm 12 Nm
5
15 Nm 34 Nm <R.H. drive vehicles>
4
8. 9. 10. 11. 12. 13. 14.
15 Nm
1. "AA 2. 3. 4. 5. 6. 7.
Air control valve Pressure hose O-ring Pressure tube O-ring Return tube O-ring
Return hose Return tube Return hose Suction hose Return hose Oil reservoir Cooler tube

"AA PRESSURE HOSE INSTALLATION Align the marks on the pressure hose and pressure tube, and install the pressure hose.
Mating mark
42-1
BODY
CONTENTS HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TRUNK LID <Sedan> . . . . . . . . . . . . . . . . 4
TRUNK LID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
42109000201
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SERVICE SPECIFICATIONS . . . . . . . . . . . . 19 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 19 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 20 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 28
Door Fit Adjustment . . . . . . . . . . . . . . . . . . . . . . 28 Door Window Glass Adjustment . . . . . . . . . . . Adjustment and Replacement When There is a Malfunction of the Power Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Window Safety Mechanism Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Outside Handle Play Check . . . . . . . . . . Power Window Operation Current Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Breaker (Incorporated in the Power Window Motor) Inspection . . . . . . . . . . . . . . . . . 28 29 29 30 30 30
FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL FILLER DOOR . . . . . . . . . . . . . . . . 7 WINDOW GLASS . . . . . . . . . . . . . . . . . . . 8

ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 8 WINDOW REPAIR . . . . . . . . . . . . . . . . . . . . . . . 8 WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 QUARTER WINDOW GLASS <Wagon> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 TAILGATE WINDOW GLASS <Wagon> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 REAR WINDOW GLASS <Sedan> . . . . . . 17
Door Inside Handle Play Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 31 DOOR TRIM AND WATERPROOF FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
42-2
DOOR GLASS AND REGULATOR . . . . . . 36 DOOR HANDLE AND LATCH . . . . . . . . . . 41 WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP . . . . . 44
KEYLESS ENTRY SYSTEM . . . . . . . . . 51

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 51 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 51 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 55
How to Replace a Battery of the Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Secret Code Registration Method . . . . . . . . . . 56
TAILGATE <Wagon> . . . . . . . . . . . . . . . 45
SERVICE SPECIFICATION . . . . . . . . . . . . . 45 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 45 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 46 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 46
Tailgate Fit Adjustment . . . . . . . . . . . . . . . . . . . 46 Tailgate Handle Play Check . . . . . . . . . . . . . . . 46
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . 57
SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . 57
SERVICE SPECIFICATION . . . . . . . . . . . . . 57 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 57 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 58 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 62
Water Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Sunroof Fit Adjustment . . . . . . . . . . . . . . . . . . . 62
TAILGATE ASSEMBLY . . . . . . . . . . . . . . . . . 47 TAILGATE TRIM AND WATERPROOF FILM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 TAILGATE HANDLE AND LATCH . . . . . . . 50
SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
BODY - Hood
42-3
42100160229
HOOD
3 4 11 1
10 6 5
12 Nm 5 Nm
2
22 Nm
12 9 1
9 Nm
9 7
12
5, 6
9
Adjustment of hood step and hood striker linkage Adjustment of clearance and height around hood 8. Hood lock release cable Hood latch removal steps D Radiator grille (Refer to GROUP 51.) 9. Hood latch Hood and hood hinge removal steps 10. Washer hose connection 11. Hood 12. Hood hinge
1. Hood lock release handle 2. Hood weatherstrip 3. Front hood weatherstrip 4. Hood insulator "AA 5. Bumper A "AA 6. Bumper B 7. Hood support rod Hood lock release cable removal steps D Splash shield <Drivers side> (Refer to P.42-6.)
42-4
Bumper A 16.0 0.5 mm Bumper B
BODY - Hood/Trunk Lid <Sedan> INSTALLATION SERVICE POINT

"AA BUMPER B/BUMPER A INSTALLATION Install the bumpers A and B as shown in the illustration.
18.8 0.5 mm
TRUNK LID <Sedan>

42100220132
10
7 6
9 Nm
4 3
7 9
11 8
12 5 2 1
9 Nm
8
Adjustment of clearance around trunk lid and trunk lid striker linkage
Trunk lid panel removal steps "BA 1. Bumper A "BA 2. Bumper B D Licence plate lamp 3. Licence plate lamp garnish 4. Trunk lid lock cylinder 5. Trunk lid latch D Spring cover (Refer to GROUP 52A - Trims.) 6. Trunk lid hinge spring 7. Trunk lid panel Trunk lid hinge removal steps D Rear shelf trim (Refer to GROUP 52A - Trims.) 7. Trunk lid panel assembly 8. Trunk lid hinge Trunk lid latch removal 5. Trunk lid latch
Trunk lid striker removal steps D Rear end trim (Refer to GROUP 52A - Trims.) 9. Trunk lid striker Trunk lid release handle and cable removal steps D Front seat (drivers side) (Refer to GROUP 52A.) D Rear seat (Refer to GROUP 52A.) D Front scuff plate (drivers side) (Refer to GROUP 52A.) D Rear scuff plate (drivers side) (Refer to GROUP 52A.) D Trunk room side trim (drivers side) (Refer to GROUP 52A.) 5. Trunk lid latch 10. Trunk lid release handle 11. Trunk lid release cable Trunk lid weatherstrip removal "AA 12. Trunk lid weatherstrip removal
BODY - Trunk Lid <Sedan>/Fender INSTALLATION SERVICE POINTS
42-5
"AA TRUNK LID WEATHER STRIP INSTALLATION Install the trunk lid weatherstrip so that the marking and the joint are aligned with the body centre line.
Bumper A
Bumper B
"BA BUMPER B/BUMPER A INSTALLATION Install the bumpers A and B as shown in the illustration.
15 mm 14 mm
ON OFF
INSPECTION
TRUNK LID LATCH CONTINUITY CHECK
Switch position ON (Latch open) OFF (Latch shut) Terminal No.1 Body earth
42100410034
FENDER
SEALANT
Item Splash shield Fender Specified sealant 3M ATD Part No. 8625 or equivalent Remark Ribbon sealer
42100050137
42-6
BODY - Fender
42100190204
FENDER
Pre-removal and Post-installation Operation D Front Bumper Removal and Installation (Refer to GROUP 51.) D Front Turn-signal Lamp Removal and Installation (Refer to GROUP 54.) D
Side Sill Cover Removal and Installation (Refer to GROUP 51 - Aero Parts.)
2 3
Sealant: 3M ATD Part No. 8625 or equivalent
Sealant: 3M ATD Part No. 8625 or equivalent Removal steps 1. Splash shield "AA 2. Side turn signal lamp
3. Fender

Hook
"AA SIDE TURN-SIGNAL LAMP INSTALLATION Insert the hook into the fender panel, and then install the side turn signal lamp.
Front of vehicle
Fender panel
BODY - Fuel Filler Door
42-7
42100250254
FUEL FILLER DOOR

Pre-removal and Post-installation Operation D Front Seat (drivers side), Rear Seat Removal and Installation (Refer to GROUP 52A.) D Front Scuff Plate (drivers side), Rear Scuff Plate (drivers side), Center Pillar Lower Trim (drivers side),
Trunk Side Trim (drivers side) <Sedan>, Quarter Lower Trim (drivers side) <Wagon> Removal and Installation (Refer to GROUP 52A.)
1 3
2 3
1 2
Fuel filler door height and clearance adjustment
Removal steps 1. Fuel filler door pannel assembly 2. Fuel filler door hook assembly 3. Lid lock release handle 4. Fuel filler door lock release cable
42-8
BODY - Window Glass

42200050123
WINDOW GLASS
ADHESIVES
Items Windshield Quarter window glass Tailgate window glass Rear window glass Specified adhesives
3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealants or equivalent
SPECIAL TOOLS
Tool Number MB990480 Name Glass holder Use D D D
42200060126
Removal and installation of windshield Removal and installation of tailgate window glass Removal and installation of rear window glass
MB990449
Window moulding remover
Removal of roof drip moulding
WINDOW REPAIR
42200560084
The following glass sections are installed by means of a liquid urethane adhesive method. D Windshield D Quarter window glass D Tailgate window glass D Rear window glass
BODY - Window Glass ITEMS NEEDED

Name Adhesive Primer Spacers Anti-rust solvent (or Tectyl 506T...Valvoline Oil Company) Isopropyl alcohol Steel piano wire Adhesive gun Remarks
42-9
3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent Available as service part For rust prevention For grease removal from bonded surface Dia. length...0.6mm 1m For cutting adhesive For pressing-out adhesive
NOTE The TEROSON 127.37V auto window sealer kit can also be used. If using the TEROSON 127.37V auto window sealer kit, follow the instructions in the manual included with the kit.
HANDLING OF AUTO WINDOW SEALER Keep the sealant in a cool place, not exposed to the direct rays of the sun. Do not place any heavy article on the sealant nor press it, otherwise it will become deformed. Avoid storing the sealant for more than 6 months, because it will lose its sealing effect. BODY PINCH-WELD FLANGE SERVICING. Before servicing the body pinch-weld flange, remove old adhesive completely. If the flange requires painting, bake it after painting is completed.
42-10
WORKING PROCESS
BODY - Window Glass
Window glass installation procedure
Body side
Window glass side
Reusing the glass
Replacing the glass
Cleaning of adhesion surface Cut off the residual adhesive until the thickness is less than 2 mm. Clean the adhesion surface with isopropyl alcohol, and let dry for 3 minutes or more.
Cleaning of adhesion surface Competely cut off all of the residual adhesive. Clean the adhesion surface with isopropyl alcohol, and let dry for 3 minutes or more.
Cleaning of adhesion surface Clean off any dirt adhering to the adhesion surface with isopropyl alcohol, and let dry for 3 minutes or more.
Attaching of clip Attach the clip to set the positions for the glass to be installed.
Gluing of window spacer and glass stoppers Glue the window spacer along the standard position on the glass outer circumference. Install the glass stoppers to the specified positions.
Application of primer Apply to the adhesion surface of the body and let dry for 3 minutes or more.
Application of primer Apply sufficient primer evenly to the adhesion surface so that there is no patchiness. After application, let dry for 3 to 30 minutes.
Application of adhesive Within 30 minutes after applying the primer, apply the adhesive evenly all the way around the inside edge of the glass.
Installing the glass After applying the adhesive, lightly press the glass evenly so that it adheres completely.
Cleaning After removing any adhesive that is sticking out or adhering to the body or glass with a spatula, ect., clean off with isopropyl alcohol.
Checking for water leaks Carry out a shower test to check that no water will leak through.
BODY - Window Glass
42-11
42200100255
WINDSHIELD
Pre-removal and Post-installation Operation D Front Pillar Trim Removal and Installation (Refer to GROUP 52A.) D Headlining Removal and Installation
Section A-A A
Section B-B
mm
36 A C C 22 Primer 16 Section C-C B B 7.5 2 (Entire circumference) Primer
Primer
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
5 2 3
6 7
1 8
Removal steps AA" 1. Roof drip moulding D Front deck garnish (Refer to GROUP 51 - Windshield Wiper and Washer.) AB" "AA 2. Windshield "AA 3. Glass stopper
"AA 4. Window spacer "AA 5. Windshield upper moulding 6. Drip moulding clip A 7. Drip moulding clip B 8. Drip moulding clip C
42-12
MB990449
BODY - Window Glass REMOVAL SERVICE POINTS

AA" ROOF DRIP MOULDING REMOVAL Use the special tool to lever out the moulding. Caution If the moulding has become warped, it should not be reused.
AB" WINDSHIELD REMOVAL 1. In order to protect the body (paint surface), apply cloth tape to all body areas around the installed windshield. 2. Using a sharp-point drill, make hole in the windshield adhesive. 3. Pass the piano wire from the inside of the vehicle through the hole. 4. Pull the piano wire alternately from the inside and outside along the windshield to cut the adhesive. Caution Do not let the piano wire touch the edge of the windshield. 5. Make mating marks on the windshield and body.
MB990480
6. Use the special tool to remove the windshield.
7. Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm around the entire circumference of the body flange.
BODY - Window Glass
42-13
8. Finish the flange surfaces so that they are smooth. Caution (1) Be careful not to remove more adhesive than is necessary. (2) Be careful also not to damage the paintwork on the body surface with the knife. If the paintwork is damaged, repair the damaged area with repair paint or anti-rust agent. 9. When reusing the windshield, remove the adhesive still adhering to the windshield, and clean with isopropyl alcohol. 10. Clean the body side in the same way. Caution Let the cleaned places stand for 3 minutes or more, and carry out the next procedures after they have dried. Also, do not touch any surface that has been cleaned.

"AA WINDSHIELD UPPER MOULDING/WINDOW SPACER/GLASS STOPPER/WINDSHIELD INSTALLATION 1. When replacing the windshield, temporarily set the windshield against the body, and place a mating mark on the windshield and body. 2. Use isopropyl alcohol to degrease the inside and outside of the windshield and the body flanges. 3. Soak a sponge in the primer, and apply evenly to the windshield and the body in the specified places. 4. Apply the primer, and then let it dry for 3 to 30 minutes. Caution (1) The primer strengthens the adhesive, so be sure to apply it evenly around the entire circumference. However, a too thick application will weaken the adhesive. (2) Do not touch the coated surface. 5. Install the windshield upper moulding to the windshield. 6. Place the window spacer to the windshield so that it inclines toward the windshield and its right and left clearances are equal. Then install the spacer firmly so that it is not adrift.
42-14
A 300 mm Centre 300 mm
BODY - Window Glass

7. Install the glass stopper to the shown dimension.
A Glass stopper
Section A - A 20 mm
Glass stopper
8. Fill a sealant gun with adhesive. Then apply the adhesive evenly around the windshield within 30 minutes after applying the primer. NOTE Cut the tip of the sealant gun nozzle into a V shape to simplify adhesive application.
15 mm
10 mm
9. After applying the adhesive, align the mating marks on the windshield and the body, and then press the windshield gently to seat it. 10. Use a spatula or the like to remove any excessive adhesive. Then clean the surface with isopropyl alcohol. Install the roof drip moulding before the adhesive hardens. 11. Try not to move the vehicle until the adhesive sets. Wait 30 minutes or more, and then test for water leakage. Caution (1) Do not move the vehicle unless absolutely necessary. (2) When testing for water leakage, do not pinch the end of the hose to spray the water.
BODY - Window Glass
42-15
42200250127
QUARTER WINDOW GLASS <Wagon>

Pre-removal and Post-installation Operation D Quarter Upper Trim, Retractor Trim and Belt Line Trim Removal and Installation (Refer to GROUP 52A.) D Headlining Removal and Installation
Section A - A
Section B - B
mm
Primer B B A A D D Primer C C Section C - C 5 5.5 9.5 5.5 22 7.5 Section D - D 5.5 5 Primer Primer
3 3 2
Removal steps AA" "AA 1. Quarter window glass 2. Packing 3. Clip

AA" QUARTER WINDOW GLASS REMOVAL Remove the quarter window glass in the same manner as for the windshield, except the clips (Refer to P.42-11.)

"AA QUARTER WINDOW GLASS INSTALLATION Install the quarter window glass in the same manner as for the windshield, except the clips (Refer to P.42-11.)
42-16
BODY - Window Glass

42200370144
TAILGATE WINDOW GLASS

Pre-removal and Post-installation Operation D Side Tailgate Trim, Lower Tailgate Trim and Cover Removal and Installation (Refer to P.42-49.) D Rear Wiper Removal and Installation (Refer to GROUP 51.)
Section A - A
Section B - B
mm
Primer A A B B C C D D 5 15 Section C - C Primer 81.5 5 56.5 5 Primer 5 15 Section D - D Primer
3 2
3
Removal steps 1. Harness connector AA" "AA 2. Tailgate window glass 3. Glass stopper

AA" TAILGATE WINDOW GLASS REMOVAL Remove the tailgate window glass in the same manner as for the windshield, except the glass stopper (Refer to P.42-11).

"AA TAILGATE WINDOW GLASS INSTALLATION Install the tailgate window glass in the same manner as for the windshield, except the glass stopper (Refer to P.42-11).
BODY - Window Glass
42-17
42200160123
REAR WINDOW GLASS <Sedan>

Pre-removal and Post-installation Operation D Rear Wiper Motor Removal and Installation (Refer to GROUP 51.) D High Mounted Stop Lamp Removal and Installation (Refer to GROUP 54.) D D Rear Pillar Trim Removal and Installation (Refer to GROUP 52A.) Headlining Removal and Installation
Section A - A
Section B - B 6.7
mm
A 14 B A B Primer
8.5 Primer
Section C - C
7
11 7
Primer
6 1 5 7 8
2 1 10 4 9 3
Adhesive tape: double-sided tape [6 mm width and 0.125 mm thickness]
Removal steps 1. Harness connector AA" 2. Roof drip moulding AA" 3. Rear window lower moulding 4. Rear window moulding clip AB" "AA 5. Rear window glass
"AA 6. Glass stopper "AA 7. Window spacer "AA 8. Rear window upper moulding 9. Clip grommet A 10. Rear drip moulding clip
42-18
BODY - Window Glass REMOVAL SERVICE POINTS

MB990449
AA" ROOF DRIP MOULDING/ REAR WINDOW LOWER MOULDING REMOVAL Use the special tool to lever out the moulding. Caution If the moulding has become warped, it should not be reused.
AB" REAR WINDOW GLASS REMOVAL Remove the rear window glass by the same procedure as for the windshield. (Refer to P.42-11.)

"AA REAR WINDOW UPPER MOULDING/WINDOW SPACER/GLASS STOPPER/REAR WINDOW GLASS INSTALLATION Install the rear window glass in the same manner as for the windshield (Refer to P.42-11).
BODY - Door
42-19
42300030137
DOOR
Items Door outside handle play mm Front Rear Power window operating current A Door inside handle play mm Standard value 3.7 or more 2.4 or more 5 1 (for 14 - 15 V power supply at 25_C) 5.3 or more
SEALANT
Item Waterproof film Specified sealant 3M ATD Part No. 8625 or equivalent Remark
42300050065
Ribbon sealer
42300060105
SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub assembly Use ETACS-ECU input signal checking
MB990784
Ornament remover
Removal of door trim
MB990900 or MB991164
Door adjusting wrench
Adjustment of door fit
42-20
Tool
A
BODY - Door
Number MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222 Name Harness set A: Test harness B: LED harness C: LED harness adapter D: probe Use Measurement of terminal voltage A: Connector pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection
TROUBLESHOOTING
DIAGNOSIS FUNCTION
MUT-II
42300070160
INPUT SIGNAL INSPECTION POINTS <VEHICLES WITH ETACS-ECU> 1. Connect the MUT-II to the diagnosis connector. 2. If buzzer of the MUT-II sounds once when door lock actuator switch is operated (LOCK/UNLOCK), the ETACS-ECU input signal for that switch circuit system is normal.
BODY - Door INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom Power windows The power windows cannot be operated by any of the power window switches. Drivers side power window cannot be operated by the power window main switch. Passengers side and rear power windows cannot be operated by the power window main switch. (However, they can be operated by the power window sub-switches.) When the glass is raised, it then lowers automatically. The glass is not lowered when something is jammed in the window. When the glass is fully raised, it then lowers automatically. Door locking mechanism None of the door lock functions operate. None of the doors lock or unlock when the drivers side inside door locking knob is operated (including by means of the door key). Some doors do not lock or unlock. Inspection procedure 1 2 3
42-21
42300700021
4 5 6 7 8 9
42-25 42-25 42-26 42-26 42-27 42-27
42-22
BODY - Door

The power windows cannot be operated by any of the power window switches. <Vehicles without ETACS>
The cause may be a malfunction of the power window relay and of the power window relay drive circuit. NG
Probable cause
D D Malfunction of power window relay Malfunction of wiring harness or connector
Check power window relay continuity. (Refer to P.42-40.) OK Measure at the power window relay connector B-15X. D Disconnect the connector and measure at the harness side. D Voltage between 1 and body earth D Voltage between 5 and body earth OK: System voltage OK Measure at the power window relay connector B-15X. D Disconnect the connector and measure at the harness side. D Continuity between 3 and body earth OK: Continuity OK Measure at the power window main switch connector F-19. D Disconnect the connector and measure at the harness side. D Voltage between 6 and body earth OK: System voltage OK Measure at the power window main switch connector F-19. D Disconnect the connector and measure at the harness side. D Continuity between 9 and body earth OK: Continuity OK Replace the power window switch.
Replace
NG
Check the following connectors: C-131, C-141 OK Check trouble symptoms.
NG
Repair
NG
Check the harness wire between ignition switch (IG2) and power window relay, between fusible link No. 3 and power window relay, and repair if necessary. Check the harness wire between power window relay and the earth, and repair if necessary.
NG
Check trouble symptoms.
NG
NG
Check the following connectors: F-19, C-120, C-114, B-15X OK Check trouble symptoms.
NG
Repair
NG
NG
Check the following connectors: C-120, F-19 OK Check trouble symptoms.
NG
Check the harness wire between power window main switch and power window relay, and repair if necessary. Repair
NG
Check the harness wire between power window main switch and earth, and repair if necessary.
BODY - Door
The power windows cannot be operated by any of the power window switches. <Vehicles with ETACS>
The cause may be a malfunction of the power window relay, power window relay drive circuit and of the ETACS-ECU.
42-23
Probable cause
D D D Malfunction of power window relay Malfunction of ETACS-ECU Malfunction of wiring harness or connector
Check the power window relay continuity. (Refer to P.42-40.) OK Measure at the power window main switch connector F-19. D Disconnect the connector and measure at the harness side. D Ignition switch: ON and OFF D Voltage between 6 and body earth OK: System voltage (ON) 0 V (OFF) OK Measure at the ETACS-ECU connector C-138. D Disconnect the connector and measure at the harness side. D Voltage between 26 and body earth OK: System voltage OK Replace the ETACS-ECU.
NG
Replace NG
NG
Check the following connectors: F-19, C-120, C-114, B-15X OK Check trouble symptoms.
Repair
NG
Check the harness wire between fusible link No.3 and power window relay, and repair if necessary.
NG
Check the following connectors: C-138, C-116, B-15X OK Check trouble symptoms.
NG
Repair
NG
Check the harness wire between power window relay and ETACS-ECU, and repair if necessary.
42-24
BODY - Door
Drivers side power window cannot be operated by the power window main switch.
The cause may be a malfunction of power window main switch, power window motor-ECU, or open circuit or short circuit in the communication line between power window main switch and power window motor-ECU.
Probable cause
D D D Malfunction of power window main switch Malfunction of power window motor-ECU Malfunction of wiring harness or connector
Measure at the power window main switch connector F-19. D Disconnect the connector and measure at the harness side. D Ignition switch: ON and OFF D Voltage between 6 and body earth OK: System voltage (ON) 0 V (OFF) D Continuity between 9 and body earth OK: Continuity OK Measure at the power window motorECU connector F-21. D Disconnect the connector and measure at the harness side. D Ignition switch: ON and OFF D Voltage between 2 and body earth OK: System voltage (ON) 0 V (OFF) D Continuity between 1 and body earth OK: Continuity OK Measure at the power window main switch connector F-19 and the power window motor-ECU connector F-21. D Disconnect the connector and measure at the harness side. D Continuity between 2 (power window main switch side) and 4 (power window motor-ECU side) OK: Continuity OK Replace the power window main switch.
NG
Check the following connectors: F-19, C-120, C-114, B-15X OK Check trouble symptoms. OK Replace the power window main switch.
NG
Repair
NG
Check the harness wire between power window relay and power window main switch, between power window main switch and earth, and repair if necessary.
NG
Check the following connectors: F-21, C-120 OK Check trouble symptoms.
NG
Repair
NG
Check the harness wire between power window relay and power window motorECU, and between power window motor-ECU and earth.
NG
Check the harness wire between power window main switch and power window motor-ECU, and repair if necessary.
NG
Replace the power window motor-ECU.
BODY - Door
Inspection Procedure 3 Passengers side and rear power windows cannot be operated by the power window main switch. (However, they can be operated by the power window sub-switches.)
The cause may be open circuit or short circuit in the communication line between power window main switch, passengers side power window motor-ECU and rear power window motor-ECU. NG
42-25
Probable cause
Malfunction of wiring harness or connector
Check the following connectors: F-10, F-15, F-04 or F-21 OK Check the harness wire between power window main switch F-19 and joint connector (1 or 5). OK Check the following connectors: Passengers side: <LHD> C-61, C-124 <RHD> C-65, C-120 Rear <LH>: <LHD> C-61, C-119, E-17 <RHD> C-65, C-119, E-17 Rear <RH>: <LHD> C-61, C-123, E-10 <RHD> C-65, C-123, E-10 OK Check trouble symptoms.
Repair
NG
Repair
NG
Repair
NG
Check the harness wire between joint connector and power window motor-ECU.
Inspection Procedure 4 When the glass is raised, it then lowers automatically.

If the sliding resistance is too large when the glass is being raised, it is judged that something is jammed in the window, and the window is lowered by approximately 150 mm. YES
Probable cause
D D Incorrect window glass adjustment Glass slider is incorrectly installed or warped
Does the glass move in the opposite direction when the power window drive current is above the following value? (Refer to P.42-30.) Drive current: 5 1 A NO Replace the power window motor-ECU.
Adjust the window glass. (Refer to P.42-28.) Check trouble symptoms. NG Replace the window regulator assembly.
Inspection Procedure 5 The glass is not lowered when something is jammed in the window.
The cause may be a malfunction of the revolution detection sensor in the power window motor-ECU. Replace the power window motor-ECU.
Probable cause
D Malfunction of power window motor-ECU
42-26
Inspection Procedure 6 When the glass automatically. is fully raised,
BODY - Door
it
then lowers
Probable cause
D Malfunction of the power window motor-ECU
When the window is within 15 mm of being fully closed, the limit switch turns off to prevent the window from being lowered. However, the above problem can occur if there is a malfunction of the limit switch in the power window motor-ECU.
Limit switch operation position adjustment (Refer to P.42-40.) Check trouble symptoms. NG Replace the power window motor-ECU.
Inspection Procedure 7 None of the door lock functions operate.

The cause may be a malfunction of the ETACS-ECU power supply circuit system or of the earth circuit system.
Probable cause
D D Malfunction of ETACS-ECU Malfunction of wiring harness or connector
Measure at the junction block connector C-142. D Remove the ETACS-ECU and measure at the junction block side. D Voltage between 16 and body earth OK: System voltage OK Check the following connectors: C-142, C-144 OK Check trouble symptoms.
NG
NG
Repair
NG
Check the harness wire between fusible link No.1 and junction block, and repair if necessary.
NG
Repair
NG
Check the harness wire between ETACS-ECU and body earth. OK Replace the ETACS-ECU.
NG
Repair
BODY - Door
Inspection Procedure 8 None of the doors lock or unlock when the drivers-side inside door locking knob is operated (including by means of the door key).
The cause may be a malfunction of the door lock actuator switch, the ETACS-ECU or of a wiring harness or connector.
42-27
Probable cause
D D D
Malfunction of front door lock actuator (drivers side) Malfunction of ETACS-ECU Malfunction of wiring harness or connector NG
MUT-II Pulse check Front door lock actuator switch (driversside) input signal OK: The MUT-II buzzer sounds once when the front door lock actuator moves from the locked to the unlocked position, or from the unlocked to the locked position. OK Replace the ETACS-ECU.
NG
Check the front door lock actuator (drivers side). (Refer to P.42-42.) OK Check the following connectors: F-17, C-120, C-138 OK Check trouble symptoms.
Replace
NG
Repair
NG
Check the harness wire between the front door lock actuator (drivers side) and ETACS-ECU, between front door lock actuator and the earth, and repair if necessary.
Inspection Procedure 9 Some doors do not lock or unlock.

The cause may be a malfunction of the door lock actuator or tailgate lock actuator or of a wiring harness or connector.
Probable cause
D D D Malfunction of door lock actuator Malfunction of tailgate lock actuator Malfunction of wiring harness or connector
Check the door lock actuator of the door that does not operate. OK Check the following connectors: <Front L.H.> F-17, C-120, C-138 <Front R.H.> F-08, C-124, C-138 <Rear L.H.> F-14, E-17, C-119, C-138 <Rear R.H.> F-12, E-10, C-123, C-138 <Tailgate> G-30, G-29, C-138 OK Check trouble symptoms.
NG NG
Replace
Repair
NG
Check the harness between the ETACS-ECU and the door lock actuator of the door that does not operate, and repair if necessary.
42-28
BODY - Door
ON-VEHICLE SERVICE
MB990900 or MB991164
42300090128
DOOR FIT ADJUSTMENT

1. If the clearance between the door and the vehicle body is uneven, affix protective tape to the fender around the hinge and to the edge of the door. Then use the special tool to loosen the door hinge mounting bolts on the body, and adjust the clearance around the door so that it becomes even. 2. If the door and the body are not flush with each other, use the special tool to loosen the door hinge mounting bolts. Then align the door. Caution Do not load more than 98 Nm on the special tool (MB991164).
Striker
Shim
3. If the door opening and closing is heavy, adjust the meshing of the striker and the door latch (in the longitudinal direction) by adding shims to the striker and by moving the striker up and down or to the left and right.
Front
Rear
DOOR WINDOW GLASS ADJUSTMENT
42300100227
Adjusting hole
Adjusting hole
Check that the door glass moves securely along the door glass runchannel when the window glass is fully raised and fully lowered. If the glass does not move correctly, adjust by the following procedure. 1. Remove the door trim and the waterproof film. (Refer to P.42-33.) 2. Loosen the mounting screw through the adjusting hole with the door window glass fully closed, and lower the door window glass slightly. 3. Close the door window glass fully again, and tighten the door glass mounting screw securely through the adjusting hole.
BODY - Door
Runchannel
42-29
Door sash
ADJUSTMENT AND REPLACEMENT WHEN THERE IS A MALFUNCTION OF THE POWER 42900190062 WINDOWS
If the window glass automatically starts moving downwards at the wrong time while it is being raised, carry out the following adjustment or replacement procedures. 1. Remove the door trim and waterproof film. (Refer to P.42-33.) 2. Remove the window regulator assembly from the door window glass, and then raise and lower the door window glass by hand to check the operation force. NOTE Insert a cushion or similar object to prevent damage to the glass if it should happen to fall down. 3. If the door window glass does not move up and down smoothly, check or repair the following points. D Check the installation condition of the runchannel. D Repair the twisting in the door sash. D Check the installation condition of the lower sash or the center sash. NOTE The lower sash cannot normally be adjusted, but it may be possible to adjust the sash span slightly within the range allowed by manufacturing tolerances by pushing the lower sash outwards while re-installing it. 4. If repair or adjustment is not possible, replace the door assembly.
Lower sash
POWER WINDOW SAFETY MECHANISM 42900100065 CHECK

1. Place a wooden board with a thickness of approximately 10 mm as shown in the illustration, and then raise the window glass. 2. Check that the window lowers by a distance of approximately 150 mm when the window clamps the wooden board. If this doesnt happen, refer to Troubleshooting (P.42-25).
42-30
Section A - A A
BODY - Door DOOR OUTSIDE HANDLE PLAY CHECK

42300160126
1. Check that the door outside handle play is within the standard value range. Standard value (B): Front door: 3.7 mm or more Rear door: 2.4 mm or more
A B
2. If the door outside handle play is not within the standard value range, check the door outside handle or the door latch assembly. Replace, if necessary.
POWER WINDOW OPERATION CURRENT 42900110051 INSPECTION

1. Remove the power window fuse and connect a circuit analyser as shown in the illustration. 2. When the power window switch is pressed to the UP position, a large amount of current flows at the time the window starts to close and when it is fully closed, so measure the operation current in the interval between these two points. Standard value: 5 1 A (for 14 - 15 V power supply voltage at 25_C) 3. If the operation current is outside the standard value, refer to Troubleshooting (P.42-25).
CIRCUIT BREAKER (INCORPORATED IN THE POWER WINDOW MOTOR) INSPECTION 42900170080

1. Press the power window switch to the UP position to fully close the window glass, and keep pressing the switch for a further 10 seconds. 2. Release the power window switch from the UP position and immediately press it to the DOWN position. The condition of the circuit breaker is good if the power window glass starts to move downwards within 60 seconds.
DOOR INSIDE HANDLE PLAY CHECK AND 42300150208 ADJUSTMENT

1. Check that the door inside handle play is within the standard value range. Standard value (A): 5.3 mm or more
A
2. If the door inside handle play is outside the standard value range, remove the door trim. (Refer to P.42-33.) 3. Loosen the inside handle mounting screws, and then move the inside handle back and forth to adjust the play.
BODY - Door
42-31
42300220237
DOOR ASSEMBLY
Post-installation Operation Door Adjustment (Refer to P.42-28.)
Front door
4, 5
22 Nm 26 Nm
6 7
12 Nm
4
26 Nm
5
22 Nm
Rear door
26 Nm
12 Nm
6
22 Nm
26 Nm
8 9
22 Nm
Door assembly removal steps 1. Harness connector 2. Spring pin 3. Door assembly "AA 4. Door upper hinge "AA 5. Door lower hinge
Striker removal steps 6. Striker 7. Striker shim Door switch removal steps 8. Door switch cap 9. Door switch
42-32
Front (upper, lower) Rear (upper) Rear (lower)
BODY - Door INSTALLATION SERVICE POINT

"AA DOOR LOWER HINGE/DOOR UPPER HINGE INSTALLATION The door hinges differ according to where they are used, so check the identification marks before installation.
Identification mark
Applicable location Front left side door Front right side door Rear left side door Rear right side door Upper hinge Lower hinge Upper hinge Lower hinge Upper hinge Lower hinge Upper hinge Lower hinge
Identification mark
Identification mark V U U V M2 O2 N2 P2
INSPECTION
DOOR SWITCH CONTINUITY CHECK
2 1 ON OFF Stroke
42300600093
Switch position Open (ON) Depressed (OFF)
Terminal No. 1 2
BODY - Door
42-33
42300430210
DOOR TRIM AND WATERPROOF FILM

Front door
7 2 5 8 3 12 11 10
12
NOTE : Resin clip position
Sealant: 3M ATD Part. No. 8625 or equivalent Removal steps 1. Power window switch panel 2. Power window switch 3. Inside handle cover 4. Inner delta cover or tweeter cover 5. Door trim 6. Cover
7. 8. 9. 10. 11. 12.
Pull handle bracket A Pull handle bracket B Door inside handle Speaker Speaker cover Waterproof film
42-34
Rear door
BODY - Door
11
9 4 6
14 10
1 7 13 12 3 2 5 8
NOTE : Resin clip position
14
Sealant: 3M ATD Part. No. 8625 or equivalent
Removal steps AA" "AA 1. Clip <Vehicles without power windows> "AA 2. Regulator handle <Vehicles without power windows> "AA 3. Escutcheon <Vehicles without power windows> 4. Power window switch panel <Vehicles with power windows> 5. Power window switch <Vehicles with power windows>
6. 7. 8. 9. 10. 11. 12. 13. 14.
Pull handle box Inside handle cover Door trim Pull handle bracket A Pull handle bracket B Door inside handle Speaker Speaker cover Waterproof film
BODY - Door REMOVAL SERVICE POINT
42-35
AA" CLIP REMOVAL Remove the clip by using a rag, and then remove the regulator handle.

Horizontal line
30_
"AA ESCUTCHEON/REGULATOR HANDLE/CLIP INSTALLATION 1. Install the escutcheon and the clip to the regulator handle. 2. Fully close the front door glass, and install the regulator handle so that it faces as shown in the illustration.
Front of vehicle
42-36
BODY - Door
42900130231
DOOR GLASS AND REGULATOR

Pre-removal Operation D Door Trim and Waterproof Film Removal (Refer to P.42-33.) D Door Beltline Inner Weatherstrip Removal (Refer to P.42-44.)
Post-installation Operation D Door Window Glass Adjustment (Refer to P.42-28.) D Door Beltline Inner Weatherstrip Installation (Refer to P.42-44.) D Door Trim and Waterproof Film Installation (Refer to P.42-33.)
Front door
Rear door 5 1 7 6 8
1 2 2
4 3 3 4
<Vehicles without power windows>
3
<Vehicles with power windows>
Front window regulator assembly removal steps "BA 1. Door window glass 2. Door window glass holder "AA 3. Window regulator assembly AA" "AA 4. Power window motor Rear window regulator assembly removal steps D Window glass runchannel (Refer to P.42-44.) "BA 1. Door window glass 2. Door window glass holder "AA 3. Window regulator assembly AA" "AA 4. Power window motor
AB"
Stationary window glass removal steps D Window glass runchannel (Refer to P.42-44.) 1. Door window glass 5. Door center sash 6. Stationary window glass and weatherstrip assembly 7. Stationary window glass 8. Stationary window weatherstrip
BODY - Door REMOVAL SERVICE POINTS

AA" POWER WINDOW MOTOR ASSEMBLY
42-37
Caution Be careful when handling the power window motor assembly, as the force of the spring may cause the wires to pull out of the drum.
AB" DOOR CENTER SASH REMOVAL 1. Remove the door outer opening weatherstrip from the door center sash only. 2. Remove the door center sash mounting screws, and then remove the door center sash from the door panel.
Door outer opening weatherstrip Door center sash
Opening

"AA POWER WINDOW MOTOR ASSEMBLY/WINDOW REGULATOR ASSEMBLY POWER WINDOW MOTOR ASSEMBLY AND WINDOW REGULATOR ASSEMBLY INSTALLATION PROCEDURE 1. Align the power window motor drive shaft and the square hole in the drum while using the guide and the opening in the motor housing as a reference for the installation position. NOTE (1) Align the square hole with the drive shaft by sliding the glass bracket (glass mounting section) or by turning the drum using a ratchet wrench (with a socket diameter of 12.7 mm). (2) Support the drum and the guide with your hand while turning the drum, otherwise the wires may pull out of the drum. (3) If the wires pull out of the drum, re-insert them by following the drum and regulator wire installation procedure. 2. Align the guide and the opening of the motor housing, and slide the guide into the motor housing while holding the guide and drum.
Drive shaft Square hole
Drum Guide
Rachet wrench
Glass bracket
42-38
Mounting screw
BODY - Door
3. Install the metal cover securely to the housing. Caution Make sure that the metal cover is installed securely and does not move, in order to stop the drum from vibrating. If the drum vibrates, the glass may not slide up and down smoothly, or it may fall down.
Metal cover
4. Apply battery voltage to the power window motor, and check that the glass bracket moves smoothly.
Guide Drum
Square hole
Spring A Lifting wire

Spring B
Slit
Lowering wire
DRUM AND REGULATOR WIRE INSTALLATION PROCEDURE 1. Place the drum, guide and regulator on a work bench as shown in the illustration. (1) Place the drum so that the square hole is facing upward. (2) Place the guide so that the slits are facing upward. (3) Place the regulator so that the glass bracket is facing downward. Position the glass bracket so that glass is in the fully-open position. 2. Pass the springs over the wires, and then install the lowering wire to the guide first, followed by the lifting wire. (The lifting wire should be on top of the lowering wire.)
Lowering wire Slit Lifting wire Guide
Spring
BODY - Door
42-39
3. Use some narrow-gauge wire (approx. 0.5 mm diameter) to compress the springs.
Narrowgauge wire
NOTE Tie the narrow-gauge wires to the slits in the guide.
Lowering wire
4. Insert the end of the lowering wire into the wire hole at the bottom of the drum, and then wrap the wire securely around the groove of the drum from the bottom so that there is no slackness in the wire.
Lifting wire
5. Install the lifting wire to the drum as follows: (1) Insert the end of the lifting wire into the wire hole at the top of the drum.
(2) Raise the front of the drum until the drum is vertical, and then position the lifting wire in the groove of the drum.
42-40
BODY - Door
(3) Return the drum to its original position while holding the wires to make sure that they do not pull out. 6. After installing the power window motor assembly to the window regulator assembly, cut and remove the wires which are compressing the springs.
"BA DOOR WINDOW GRASS INSTALLATION 1. Provisionally secure the door window glass to the window regulator assembly. 2. After raising the door window glass as far as it will go, fully secure the door window glass to the window regulator assembly. NOTE Fully raising the door window glass will set the door limit switch to the correct position.
INSPECTION
POWER WINDOW RELAY CONTINUITY CHECK
System voltage Not applied Applied
Power window relay
42900180106
BODY - Door
42-41
42300460219
DOOR HANDLE AND LATCH

Pre-removal Operation D Door Trim Removal (Refer to P.42-33.)
Post-installation Operation D Door Inside Handle Play Check (Refer to P.42-30.) D Door Outside Handle Play Check (Refer to P.42-30.) D Door Trim Installation (Refer to P.42-33.)
Front door
Rear door
3 1
6 Nm
7 5 1 8
6 Nm
8 5 9 9 4 6
Front door handle and door latch assembly removal steps 1. Door inside handle D Waterproof film (Refer to P.42-33.) 2. Door outside handle 3. Door lock key cylinder 4. Rear lower sash 5. Door latch assembly Rear door handle and door latch assembly removal steps 1. Door inside handle D Waterproof film (Refer to P.42-33.) D Door center sash (Refer to P.42-36.) 5. Door latch assembly 6. Door lock actuator 7. Door outside handle
Door check removal steps 1. Door inside handle D Waterproof film (Refer to P.42-33.) 8. Spring pin 9. Door check
42-42
<L.H.> View A Lock Unlock
BODY - Door INSPECTION

FRONT DOOR LOCK ACTUATOR CHECK L.H. drive vehicles <Drivers side>
Rod position LOCK
A
42300610102
Terminal No. 1 2 3 4 6
Rod operation LOCK position UNLOCK position UNLOCK position LOCK position
<R.H.> View B Unlock Lock
UNLOCK LOCK UNLOCK
<Passengers side>
Rod position LOCK
B
Terminal No. 4 6
UNLOCK
R.H. drive vehicles <Drivers side>

Rod position LOCK UNLOCK LOCK UNLOCK Terminal No. 1 2 3 4 6 LOCK position UNLOCK position UNLOCK position LOCK position Rod operation
<Passengers side>
Rod position LOCK UNLOCK Terminal No. 4 6 LOCK position UNLOCK position UNLOCK position LOCK position Rod operation
BODY - Door
<L.H.> View A
42-43
42300620082
REAR DOOR LOCK ACTUATOR CHECK <L.H.>

Rod position
Lock Unlock A
Terminal No. 2 3
LOCK UNLOCK
<R.H.> View B
<R.H.>
Rod position LOCK
Lock Unlock B
Terminal No. 2 3
UNLOCK
DOOR LOCK KEY CYLINDER SWITCH CHECK

Switch position Terminal No. 1 LOCK NEUTRAL (OFF)
Neutral 21_ Unlock 21_
42300630122
UNLOCK
Lock
42-44
BODY - Door
WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP

Front door Rear door
42300310187
6 6 3 2 5 5 3 2 1
Door inner opening weatherstrip removal steps D Scuff plate (Refer to GROUP 52A.) D Cowl side trim <Front door> (Refer to GROUP 52A.) D Center pillar lower trim (Refer to GROUP 52A.) 1. Door inner opening weatherstrip Door outer opening weatherstrip removal AA" "AA 2. Door outer opening weatherstrip
Door window glass runchannel removal steps 3. Door window glass runchannel 4. Door window glass lower runchannel <Rear door> Door beltline inner weatherstrip removal steps D Door trim (Refer to P.42-33.) 5. Door beltline inner weatherstrip Door beltline moulding removal steps D Door mirror (Refer to GROUP 51.) 6. Door beltline moulding

15 mm 4 mm 8 mm
Thickness 1mm
AA" DOOR OUTER OPENING WEATHERSTRIP REMOVAL Make a tool as shown in the illustration to remove the door opening weatherstrip.
BODY - Door/Tailgate <Wagon> INSTALLATION SERVICE POINT
42-45
"AA DOOR OUTER OPENING WEATHERSTRIP INSTALLATION The clip colour identifies the left and right weatherstrips, so be sure to use the colours so as to install correctly.
Item Front door Left Right Rear door Left Right Identification colour White Brown Yellow Blue
42400030017
TAILGATE <Wagon>
Item Tailgate handle free play mm Standard value 1.5 - 5.5
SEALANT
Item Waterproof film Specified sealant 3M ATD Part No.8625 or equivalent Remark Ribbon sealer
42400050044
SPECIAL TOOLS
Tool Number MB990784 Name Ornament remover Use Removal of the tailgate trim
42400060030
MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222
Harness set A: Test harness B: LED harness C: LED harness adapter D: probe
Measurement of terminal voltage A: Connector pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection
42-46 TROUBLESHOOTING
BODY - Tailgate <Wagon>

42400070088

Trouble symptom Door lock mechanism does operate. Reference page 42-26.
ON-VEHICLE SERVICE
TAILGATE FIT ADJUSTMENT
42400090039
1. If the striker and the latch do not mesh properly, move the striker forward or back or to the left or right to adjust.
2. If the clearance all the way around the tailgate is not uniform when the tailgate is closed, adjust by moving the tailgate hinges forward or back or to the left or right until the clearance is uniform.
3. Check the contact between the upper tailgate damper and the lower tailgate damper when the tailgate is closed. If they do not contact properly, adjust by moving the upper tailgate damper in the direction of the arrows.
Upper tailgate dumper
Section A - A Holder Tailgate handle
TAILGATE HANDLE PLAY CHECK

1. Check that the tailgate handle play is within the standard value range. Standard value (B): 1.5 - 5.5 mm 2. If the play is outside the standard value range, open the tailgate handle holder and adjust the contact condition between the tailgate latch rod and the tailgate handle.
Rod
42-47
42400110124
TAILGATE ASSEMBLY
Post-installation Operation <Tailgate assembly> D Tailgate fit adjustment (Refer to P.42-46.)
7 1
9 5
12 Nm
Adjustment of clearance around tailgate
3 9 2
9 Nm
11 4
Adjustment of tailgate step and tailgate striker linkage

14 Nm
12
10 11 8 9
AA"
Tailgate assembly removal steps D High-mounted stop lamp (Refer to GROUP 54.) 1. Bumper 2. Washer hose 3. Harness connector 4. Tailgate gas spring 5. Tailgate side weatherstrip 6. Tailgate assembly 7. Upper tailgate dumper 8. Lower tailgate dumper Tailgate striker removal steps 10. Rear end trim 11. Tailgate striker
Tailgate opening weatherstrip removal steps 10. Rear end trim "AA 12. Tailgate opening weatherstrip Tailgate hinge removal steps 2. Washer hose 3. Harness connector AA" 4. Tailgate gas spring 6. Tailgate assembly D Headlining 9. Tailgate hinge
42-48
BODY - Tailgate <Wagon> REMOVAL SERVICE POINT

AA" TAILGATE GAS SPRING REMOVAL Caution 1. Never try to disassemble the tailgate gas spring or burn it. 2. Always bore a hole in the tailgate gas spring to release the interior gas before the gas spring is discarded.

"AA TAILGATE OPENING WEATHERSTRIP INSTALLATION Install the tailgate opening weatherstrip so that the marked part is at the centre of the body.
42-49
42400140048
TAILGATE TRIM AND WATERPROOF FILM

5 4
5 3 2
7 1
NOTE : Resin clip position : Sheet metal clip position
Sealant: 3M ATD Part No.8625 or equivalent
Removal steps 1. Tailgate grip 2. Lower tailgate trim 3. Tailgate clip 4. Cover
5. 6. 7. 8.
Side tailgate trim Rear roof rail trim Tailgate trim bracket Waterproof film
42-50

42400170054
TAILGATE HANDLE AND LATCH

Post-installation Operation D Tailgate Handle Free Play Check (Refer to P.42-46.)
3 1 2
4 5
6 6
9 Nm
Tail handle and lock key cylinder removal steps D Tailgate trim and waterproof film (Refer to P.42-49.) D Tailgate garnish 1. Tailgate handle 2. Cylinder lock retainer 3. Tailgate lock key cylinder
Tailgate latch removal steps D Tailgate trim and waterproof film (Refer to P.42-49.) D Tailgate garnish 4. Tailgate lock actuator 5. Holder 6. Tailgate latch assembly
INSPECTION
TAILGATE LOCK ACTUATOR CHECK
A View A UNLOCK LOCK
42400180033
Rod position
Terminal No. 2 3
Rod operation
LOCK UNLOCK
LOCK position UNLOCK position UNLOCK position
BODY - Keyless Entry System
42-51
42800060032
KEYLESS ENTRY SYSTEM

SPECIAL TOOL
Recording secret codes
TROUBLESHOOTING
Trouble symptom None of the doors can be locked or unlocked using the transmitter. All of the doors can be locked and unlocked using the transmitter, but the room lamp does not flash or illuminate. (However, the room lamp operates normally when the doors are opened and closed.) Secret codes cannot be registered. Inspection procedure No. 1 2
42800180035
42-53

INSPECTION PROCEDURE 1 None of the doors can be locked or unlocked using the transmitter.
The cause may be a malfunction of the transmitter, a malfunction of the receiver or the lock and unlock signals are not being input to the ETACS-ECU.
Probable cause
D D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of of transmitter receiver ETACS-ECU wiring harness or connector key reminder switch door switch
Can the doors be locked and unlocked by the drivers-side door key cylinder and lock knob? Yes Has the secret code been registered properly? * OK Replace the transmitter battery. (Refer to P.42-55.) NG To next page
No
Check the centre door lock system.
NG
Re-register the secret code. (Refer to P.42-56.)
NOTE *: This should be done if a transmitter or receiver has been replaced, and if a secret code has not been registered properly.
42-52
From previous page
Measure at the receiver connector C-80. D Disconnect the connector, and measure at the harness side. D Voltage between 10 and body earth D Voltage between 9 and body earth OK: Battery voltage OK
NG
Check the following connectors: C-80, C-63, C-132, C-141, C-61, C-134, C-131 OK Check trouble symptoms. NG Check the harness wire, and repair if necessary. D Between ignition switch (ACC) and receiver D Between fusible link No.2 and receiver NG Repair
Measure at the receiver connector C-80. D Disconnect the connector, and measure at the harness side. D Continuity between 20 and body earth OK: Continuity OK
NG
Check the following connectors: C-80, C-62 OK Check trouble symptoms. NG Check the harness wire, and repair if necessary. D Between receiver and earth NG Repair
Measure at the receiver connector C-80. D Disconnect the connector, and measure at harness side. D Voltage between 12 and body earth D Voltage between 14 and body earth D Voltage between 16 and body earth OK: Battery voltage OK
NG
Check the connectors: C-80, C-138 OK Check trouble symptoms. NG Check the harness wire. D Between ETACS-ECU and receiver OK Replace ECU. the ETACSNG Repair NG Repair
Door switch continuity check (Refer to P.42-32.) OK Check the following connectors: E-19, E-08, G-16, G-09, G-32, G-28, C-65, C-143 OK Check trouble symptoms. NG Check the harness wire. D Between ETACS-ECU and door switch OK Key reminder switch continuity check (Refer to GROUP 54 - Ignition Switch.) OK Check the following connectors: C-109, C-65, C-80 OK Check trouble symptoms. NG Check the harness wire. D Between key reminder switch and receiver D Between key reminder switch and ETACS-ECU D Between key reminder switch and earth OK Replace the transmitter.
NG NG
Replace
Repair
NG
Repair
NG
Replace
NG
Repair
NG
Repair
NG
Replace the receiver.

INSPECTION PROCEDURE 2 All of the doors can be locked and unlocked using the transmitter, but the room lamp does not flash or illuminate. (However, the room lamp operates normally when the doors are opened and closed.)
If the room lamp operates normally when the doors are opened and closed, the cause of the problem may be a malfunction of the ETACS-ECU or a malfunction of the drivers-side door lock actuator. NG
42-53
Probable cause
D D D
Malfunction of ETACS-ECU Malfunction of drivers door lock actuator Malfunction of connector or wiring harness
Drivers door lock actuator check (Refer to P.42-42.) OK Replace the ETACS-ECU.
Replace
INSPECTION PROCEDURE 3 Secret codes cannot be registered.

The cause may be a malfunction of the diagnosis connector, a malfunction of the power supply or earth circuit of the receiver, a malfunction of the ETACS-ECU or a malfunction of the diagnosis output circuit.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of receiver MUT-II connector or wiring harness ETACS-ECU
Measure at the diagnosis connector C-20 and the receiver connector C-80. D Disconnect the connector, and measure at harness side. D Continuity between following terminals: OK: Continuity 7 <Receiver side> - 1 <Diagnosis connector side> OK Can the MUT-II communicate with other systems? Yes No Measure at the diagnosis connector C-20. D Voltage between 16 and body earth OK: Battery voltage OK
NG
Check the following connectors: C-20, C-66, C-80 OK Check trouble symptoms. NG Check the harness wire, and repair if necessary. D Between receiver and diagnosis connector NG Repair
NG
Check the following connectors: C-20, C-66, C-63, C-132, C-141 OK Check trouble symptoms. NG
NG Repair
Check the harness wire, and repair if necessary. D Between fusible link No.2 and diagnosis connector Measure at the diagnosis connector C-14. D Continuity between 4 and body earth D Continuity between 5 and body earth OK: Continuity NG Check the connector: C-20 following OK Replace MUT-II.
NG
Repair
OK Check trouble symptoms. To next page
NG
Check the harness wire, and repair if necessary. D Between diagnosis connector and earth
42-54
From previous page
Measure at the receiver connector C-80. D Disconnect the connector, and measure at the harness side. D Voltage between 10 and body earth D Voltage between 9 and body earth OK: Battery voltage OK
NG
Check the following connectors: C-80, C-63, C-132, C-141, C-61, C-134, C-131 OK Check trouble symptoms. NG Check the harness wire, and repair if necessary. D Between fusible link No.2 and receiver D Between ignition switch and receiver NG Repair
Measure at the receiver connector C-80. D Disconnect the connector, and measure at the harness side. D Between 20 and body earth OK: Continuity OK Replace the receiver.
NG
Check the following connectors: C-80, C-62 OK Check trouble symptoms. NG
NG Repair
Check the harness wire, and repair if necessary. D Between receiver and earth
INSPECTION OF RECEIVER TERMINAL VOLTAGE
Terminal 2
Signal name Door switch
Conditions Room lamp switch: OFF or ON One or more doors are open (Door switch: ON) All doors are closed (Door switch: OFF) Room lamp switch: DOOR One or more doors are open (Door switch: ON) All doors are closed (Door switch: OFF)
Terminal voltage 0V 5 V and pulse output* 0V Battery voltage 5 V and pulse output* 0V 0V 5 V and pulse output* 5 V and pulse output* 0V Battery voltage 0V
Door lock actuator switch (drivers side) Diagnosis changeover input
LOCK UNLOCK When MUT-II is connected When MUT-II is disconnected (Ignition switch: ACC or OFF) OFF (When ignition key is inserted) ON (When ignition key is removed)
Key reminder switch
Ignition switch
Ignition switch: ACC or ON Ignition switch: OFF

Terminal 10 11 Signal name Receiver power supply Room lamp output Conditions At all times All doors are closed (Door switch: OFF) Room lamp switch: OFF or ON Room DOOR 12 Door lock output lamp switch:
42-55
Terminal voltage Battery voltage 0V Battery voltage 0V Battery voltage 0V Battery voltage 5 V and pulse output (fluctuation pulse) 5 V and pulse output (constant pulse) 0V
When door lock control unit outputs signal, or door lock switch: LOCK Other than above
14
Door unlock output
When door lock control unit outputs signal, or door lock switch or door lock key cylinder: UNLOCK Other than above
16
Driver identification signal output (Vehicles with theft-alarm system)
When keyless entry system is operating (When transmitter switch is pressed) When keyless entry system is not operating (When transmitter switch is not pressed) At all times
20
Earth
NOTE Values marked with * should be measured using an oscilloscope. (The value will alternate between 0 V and 0.03 V if a circuit tester is used.)
Battery Open Claw
ON-VEHICLE SERVICE
42800090079
HOW TO REPLACE A BATTERY OF THE TRANSMITTER

1. Remove the set screw to remove the battery from the transmitter. 2. Install a battery with its (+) side face-down.
Screw O-ring
Battery required for replacement: Coin type battery CR2032 3. Insert the claw first, and with care not to displace the O-ring, assemble the transmitter. 4. Check to see if the keyless entry system operates. NOTE (1) Do not let water or dust stick to the inside of the transmitter when it is open. Also, do not touch the precision electronic device. (2) If the O-ring is displaced during the assembly of the transmitter, water or dust penetrates in it causing trouble.
42-56

42800100109
SECRET CODE REGISTRATION METHOD

Each individual secret code is registered inside the transmitter, and so it is necessary to register these codes with the EEPROM inside the receiver in the following cases. D When either the transmitter or receiver is replaced; D If a second transmitter is to be used; D If it appears that a problem is occurring because of faulty registration of a code. A maximum of two different codes can be stored in the memory area of the EEPROM (two different transmitters can be used). When the code for the first transmitter is registered, the previously-registered codes for two transmitters are cleared. Therefore, if you are using two transmitters or are adding a second transmitter, the codes for both transmitters must be registered at the same time. 1. Check that the doors lock normally when the key is used. 2. Connect the MUT-II to the diagnosis connector. NOTE This will connect terminal (1) of the diagnosis connector to earth, and the system will be in secret code registration standby mode. Caution Always turn the ignition switch to OFF before connecting and disconnecting the MUT-II. 3. Within 10 seconds after connecting the MUT-II, turn the ignition switch to ACC ON for 1 second and then to OFF for 1 second; repeat this procedure three times.
NOTE The doors will lock and unlock once at this time and the system will switch to registration mode. 4. Press the transmitter switch, and then press it two times within 10 seconds of the first press. This will register the code. 5. After registration is completed, the doors will be automatically locked and unlocked once. 6. If you are using two transmitters or have added a second transmitter, the same registration procedure should be carried out for the second transmitter, and it should be carried out within one minute after registration of the code for the first transmitter has been completed. After the second registration is completed, the doors will be automatically locked and unlocked once. 7. Registration mode will be cancelled under the following conditions. D When the secret codes for two transmitters have been registered; D When 1 minute has passed after registration mode started; D If the MUT-II is disconnected (the earth connection is broken); D If the ignition switch is turned to ON; D If any of the doors are opened;
BODY - Keyless Entry System/Sunroof
42-57
42800130153
KEYLESS ENTRY SYSTEM

Pre-removal and Post-installation Operation D Side Cover Removal and Installation (Refer to GROUP 52A - Instrument Panel.)
ETACS-ECU Keyless entry receiver
SUNROOF
Items Roof lid glass operating current A Standard value 7 or less (at 20_C)
42600030068
SPECIAL TOOL
Tool
A
42600060043
Use Measurement of terminal voltage A: Connector pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection
42-58 TROUBLESHOOTING
BODY - Sunroof
42600200070

Trouble symptom The sunroof does not operate when the ignition switch is turned to ON. The motor does not reverse its direction when a load of 140 N or more is applied while the sunroof is closing. The timer does not operate for 30 seconds after the ignition switch is turned to OFF. Opening or closing of the sunroof is possible immediately after turning the ignition switch to OFF, but the timer function does not operate continuously for another 30 seconds if the drivers side door is opened within 30 seconds. Inspection procedure 1 2 3 4 Reference page 42-58 42-60 42-60 42-60

Inspection Procedure 1 The sunroof does not operate when the ignition switch is turned to ON.
One of the following items may be defective. D Sunroof switch D Sunroof motor D Sunroof-ECU D Power supply circuit D Earth circuit
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of sunroof switch sunroof motor sunroof-ECU wiring harness or connector
BODY - Sunroof
Measure at the sunroof-ECU connector E-07. D Disconnect the connector and measure at the harness side. D Ignition switch: ON (1) Voltage between 6 and body earth (2) Voltage between 7 and body earth OK: System voltage (3) Continuity between 17 and body earth OK: Continuity OK (3) NG (1) NG Check the following connectors: E-07, C-27, C-134, C-131 OK Check trouble symptoms. NG Check the harness wire between ignition switch (IG2) and sunroof-ECU, and repair if necessary. Check the following connectors: E-07, C-27, C-114 Check the following connectors: E-07, C-133, C-131 OK Check trouble symptoms. NG Check the harness wire between sunroof-ECU and the earth, and repair if necessary. NG NG NG OK Repair Check trouble symptoms. NG Check the harness wire between fusible link No. 3 and sunroof-ECU, and repair if necessary. NG NG
42-59
Repair
(2) NG
Repair
Check sunroof switch continuity (Refer to P.42-66.) OK Measure at the sunroof-ECU connector E-07. D Disconnect the connector and measure at the harness side. D Continuity between 4 and body earth OK: Continuity present when UP sunroof switch is on D Continuity between 12 and body earth OK: Continuity present when CLOSE/DOWN sunroof switch is on D Continuity between 3 and body earth OK: Continuity present when OPEN sunroof switch is on OK
Repair NG
Check the following connectors: E-07, E-04, C-133, C-131 OK Check trouble symptoms. NG Check the harness wire between sunroof-ECU and sunroof switch, between sunroof switch and the earth, and repair if necessary.
Repair
Check the sunroof motor. (Refer to P.42-66.) Check limit switch continuity. (Refer to P.42-66.) OK Measure at the sunroof motor connector E-03. D Disconnect the connector and measure at the harness side. D Continuity between 5 and body earth OK: Continuity OK
NG
Replace
NG
Check the following connectors: E-03, C-133, C-131 OK Check trouble symptoms. NG Check the harness wire between sunroof motor and the earth, and repair if necessary.
NG
Repair
Check the following connectors: E-03, E-07 OK Check trouble symptoms.
NG
Repair
NG
Check the harness wire between sunroof-ECU and sunroof motor. OK Replace the sunroof-ECU.
NG
Repair
42-60
BODY - Sunroof
The motor does not reverse its direction when a load of 140 N or more is applied while the sunroof is closing.
The sunroof-ECU monitors the load conditions from the amount of current flowing to the motor. If more than the constant amount of current is flowing, the direction of motor operation is reversed to prevent jamming. If the motor does not reverse direction even when an excessive load is being applied, the cause may be a malfunction of the sunroof-ECU. Replace the sunroof-ECU.
Probable cause
D Malfunction of sunroof-ECU
Inspection Procedure 3 The timer does not operate for 30 seconds after the ignition switch is turned to OFF.
The sunroof-ECU has a timer function which operates for 30 seconds after the ignition switch is turned to OFF. If the timer does not operate, the cause may be a malfunction of the sunroof-ECU or of the wiring harness or connector. NG
Probable cause
D D Malfunction of sunroof-ECU Malfunction of wiring harness or connector
Measure at the sunroof-ECU connector E-07. D Disconnect the connector and measure at the harness side. D Voltage between 7 and body earth OK: System voltage OK Replace the sunroof-ECU.
NG
Repair
NG
Check the harness wire between fusible link No.3 and sunroof-ECU, and repair if necessary.
Inspection Procedure 4 Opening or closing of the sunroof is possible immediately after turning the ignition switch to OFF, but the timer function does not operate continuously for another 30 seconds if the drivers side door is opened within 30 seconds.
The operation period for the sunroof timer is extended when an on signal is output from the drivers-side door switch. Because of this, if the timer operation period is not extended, the cause may be a malfunction of the door switch input circuit. NG
Probable cause
D D D
Malfunction of the front door switch (drivers side) Malfunction of sunroof-ECU Malfunction of wiring harness or connector
Check front door switch (drivers side) continuity. (Refer to P.42-32.) OK Check the following connectors: E-19 or E-08, C-143, C-134, C-65, C-27, E-07 OK Check trouble symptoms.
Replace
NG
Repair
NG
Check the harness wire between front door switch (drivers side) and sunroofECU. OK Replace the sunroof-ECU.
NG
Repair
BODY - Sunroof TERMINAL VOLTAGE CHART
42-61
Terminal No. 1 2 3
Check Item Sensor power supply Sensor 1 Sunroof switch (open input) Sunroof switch (up input)
Check Condition Ignition switch: ON When motor is operating Sunroof switch (open position) Sunroof switch (up position) Ignition switch: ON Always While sunroof is closing or moving up Other than the above ON OFF ON OFF
Normal Condition Battery voltage Battery voltage (pulse) 0V Battery voltage 0V Battery voltage Battery voltage Battery voltage Battery voltage 0V 0V Battery voltage (pulse) ON OFF 0V Battery voltage Battery voltage 0V 0V Battery voltage 0V Battery voltage 0V
6 7 8
Timer operation power supply ECU power supply Motor output
9 10 12
Sensor earth Sensor 2 Sunroof switch (close or down) input Limit switch input
Always When motor is operating Sunroof switch (close position or down position)
14
From tilt up condition to fully-closed condition From fully-closed condition to fully-open condition
16
Door switch input
Drivers door switch
ON OFF
17 18
Earth Motor output
Always While sunroof is opening or moving down Other than the above
42-62
Hose Apporox. 30cm
BODY - Sunroof
ON-VEHICLE SERVICE
WATER TEST
42600090127
Check if there are any leaks in the sunroof by the following procedure. 1. Fully close the roof lid glass. 2. Adjust the water pressure so that water comes out of the hose to a height of approximately 50 cm when the hose is held vertically facing upwards. 3. Hold the end of the hose approximatery 30 cm above the roof and let the water run onto the weatherstrip for 5 minutes or more. 4. While doing this, check if any water leaks through into the passenger compartment from around the roof lid glass.
SUNROOF FIT ADJUSTMENT
42600100110
1. Fully close the roof lid glass. 2. Fully open the sunshade. 3. Loosen the roof lid glass assembly mounting screws (four for sedans or six for wagons), and then slide the roof lid glass assembly along the slot in the drive cable assembly to adjust the height of the roof lid glass. 4. After adjustment, check to be sure that the sunroof operates smoothly.
BODY - Sunroof
42-63
42600120239
SUNROOF
Post-installation Operation <Roof lid glass assembly, Sunroof assembly> (1) Sunroof Water Test (Refer to P.42-62.) (2) Sunroof Fit Adjustment (Refer to P.42-62.)
<Sedan> 1
7 13
7 10 9 11 3 4 6
1. Roof lid glass assembly 2. Roof wind deflector panel Sunroof switch removal steps 3. Sunroof switch cover 4. Sunroof switch Drain hose removal steps D Splash shield (Front drain hose) 6. Headlining AA" "BA 7. Drain hose
Sunroof-ECU removal steps 6. Headlining 8. Sunroof-ECU Sunroof motor removal steps 6. Headlining AB" "AA 9. Sunroof motor Sunroof assembly removal steps 6. Headlining 7. Drain hose connection 10. Room lamp bracket 11. Sunroof switch bracket 13. Sunroof assembly
42-64
<Wagon>
BODY - Sunroof
5 1
13 8
12 10 11 7 6 9
NOTE : indicates the sheet metal clip position.
1. Roof lid glass assembly Sunroof switch removal steps 3. Sunroof switch cover 4. Sunroof switch Drain hose removal steps D Splash shield (Front drain hose) 5. Rear roof rail trim 6. Headlining AA" "BA 7. Drain hose
Sunroof-ECU removal steps 5. Rear roof rail trim 6. Headlining 8. Sunroof-ECU Sunroof motor removal steps 5. Rear roof rail trim 6. Headlining AB" "AA 9. Sunroof motor Sunroof assembly removal steps 5. Rear roof rail trim 6. Headlining 7. Drain hose connection 10. Room lamp bracket 11. Sunroof switch bracket 12. Set bracket 13. Sunroof assembly
BODY - Sunroof
Drain hose
42-65

AA" DRAIN HOSE REMOVAL Tie a cord to the end of the drain hose, and wind tape around the tie until it is smooth. Then pull the drain hose out from the passenger compartment.
Cord
AB" SUNROOF MOTOR REMOVAL Caution Always close the roof lid glass fully before removing the sunroof motor. If the fully-closed positions of the roof lid glass and the sunroof motor are not the same, the sunroof will not operate properly.

"AA SUNROOF MOTOR INSTALLATION If the fully-closed position of the sunroof motor is incorrect, set the motor to the fully-closed position by the procedure given below before installing the motor. 1. Connect a circuit analyser between terminals (5) and (6) of the motor connector. 2. Operate the motor until the position is reached at which continuity switches from on to off or from off to on, and then install the motor.
Cord
"BA DRAIN HOSE INSTALLATION 1. Tie the cord that was used during removal to the end of the drain hose, and wind tape around it so that there is no unevenness. 2. Pull the cord to pull through the drain hose
Drain hose
Grommet 20 - 30 mm
3. Make the protrusion from the drain hose grommet as shown in the illustration.
42-66
BODY - Sunroof INSPECTION

42600130119
ROOF LID GLASS OPERATION CURRENT CHECK 1. Remove the sunroof fuse and connect a circuit analyser as shown in the illustration. 2. Press the sunroof switch to the ON position, and then measure the operation current in the intervals between the points when the sunroof starts to operate, when it is fully open, when it is fully closed and when it is fully tilted up. Standard value: 7 A or less (at 20_C) 3. If the operation current is outside the standard value, check the following points. D Installation condition, warping or jamming of sunroof assembly D Sticking of drive cable D Tilt of roof lid glass
Drive gear Left rotation Right rotation
SUNROOF MOTOR CHECK Check the direction of rotation of the drive gear when the battery is connected to the connector.
Battery connection terminal 1 4 Drive gear rotation direction Right Left
LIMIT SWITCH CONTINUITY CHECK Remove the limit switch from the sunroof motor, and then check the operation of the limit switch.
Switch
ON OFF
Terminal No. 5 6
Limit switch
ON OFF
SUNROOF SWITCH CONTINUITY CHECK

Switch position Slide open Off Tilt up Slide close, Tilt down Terminal No. 3 4 5 6
BODY - Sunroof DISASSEMBLY AND REASSEMBLY

<Sedan>
42-67
42600140105
13 11 1
2 6
5 9 4 10
12 3 11 13
Disassembly steps 1. Roof lid glass assembly 2. Weatherstrip 3. Sunroof motor 4. Roof wind deflector panel 5. Guide block 6. Roof drip channel 7. Panel stopper
8. 9. 10. 11. 12. 13.
Sunshade assembly Guide rail stopper Rail sub assembly Housing sub assembly Side deflector Drive cable assembly
42-68
<Wagon>
BODY - Sunroof
11 15
5 1
2 7
6 8
4 10
12 14 9 15 3 13 11
Disassembly steps 1. Roof lid glass assembly 2. Weatherstrip 3. Sunroof motor 4. Roof wind deflector panel 5. Roof drip channel 6. Panel stopper 7. Sunshade assembly 8. Guide rail stopper
9. 10. 11. 12. 13. 14. 15.
Cable guide casing Side deflector Drive cable assembly Seal Seal Clamp Guide rail sub assembly
51-1
EXTERIOR
CONTENTS
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 2 SEALANT AND ADHESIVE . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 RADIATOR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . 7 ROOF RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
51109000210
MOULDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 AERO PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 WINDSHIELD WIPER AND WASHER . . . . . . 12 REAR WIPER AND WASHER . . . . . . . . . . . . . 15 HEADLAMP WASHER . . . . . . . . . . . . . . . . . . . . 18 MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DOOR MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . 22
51-2
EXTERIOR - Service Specifications/Sealant and Adhesive/Special Tools

51100030195
Items Windshield wiper blade installation position mm Drivers side Passengers side Rear wiper blade installation position mm Standard value 35 5 205 155
SEALANT AND ADHESIVE

Items Side protect moulding to body panel Side sill cover to body panel Specified sealant and adhesive
51100050177
Adhesive tape: double-sided tape <(10 mm width and 0.8 mm thickness>) Adhesive tape: double-sided tape (5 mm width and 0.8 mm thickness)
51100060071
SPECIAL TOOLS
Tool Number MB990784 Name Ornament remover Use
Removal of bumper mounting clips (front and rear) and door mirror control switch
MB990449
Window moulding remover
Removal of roof drip moulding, etc.
EXTERIOR - Front Bumper
51-3
51100140201
FRONT BUMPER
Pre-removal and Post-installation Operation D Splash Shield Removal and Installation (Refer to GROUP 42 - Fender.) D Radiator Grile Removal and Installation (Refer to P.51-7.)
3 3
2
Removal Steps 1. Fog lamp bezel 2. Fog lamp 3. Clip 4. Front bumper assembly 5. Front bumper reinforcement assembly
AA"
MB990784 MB990784

AA" CLIP REMOVAL (1) Use the special tool to pull up the centre pin in the clip. (2) Remove the clip.
Pin
Clip
51-4
EXTERIOR - Front Bumper

51100160238
1 4 5 3 6
Disassembly steps 1. Dynamic damper assembly <except vehicles with 6A1 engine> 2. Fog lamp hole cover 3. Licence plate bracket
AA"
4. Clip 5. Front bumper upper reinforcement 6. Front bumper face
MB990784 MB990784

Pin
Clip
EXTERIOR - Rear Bumper
51-5
51100190220
REAR BUMPER
Pre-removal and Post-installation Operation D Trunk Rear Trim (side, centre), Side Tray Removal and Installation <Sedan> (Refer to GROUP 52A - Trims.) D Quarter Lower Trim Removal and Installation <Wagon> (Refer to GROUP 52A - Trims.) D Lower Tailgate Damper Removal and Installation <Wagon> (Refer to GROUP 42 - Tailgate.)
<Sedan>
Rear bumper assembly
<Wagon>
Rear bumper assembly
51-6
EXTERIOR - Rear Bumper

51100210186

<Sedan> 1 2 1 1 3 7
4 <Wagon>
1 1 3 1 7 2 1
5 6 4
Disassembly steps 1. Clip 2. Side upper bracket 3. Rear bumper reinforcement 4. Side retainer
AA"
5. Rear bumper lower plate 6. Muffler cutter cover 7. Rear bumper face
MB990784 MB990784

Pin
Clip
EXTERIOR - Radiator Grille/Roof Rail
51-7
51100280026
RADIATOR GRILLE
RADIATOR GRILLE REMOVAL Remove the radiator grille by pushing the tab of the radiator grille clips in the direction of the arrows with a flat-tipped screwdriver, while lightly pulling the radiator grille towards you.
ROOF RAIL
Pre-removal and Post-installation Operation D Headlining Removal and Installation
51101660010
Roof rail
51-8 MOULDINGS
EXTERIOR - Mouldings
51100470157

<Sedan> 1
4 2 5
6 <Wagon>
6
AA" "AA 1. Roof drip moulding 2. Windshield upper moulding (Refer to GROUP 42 - Windshield.) 3. Belt line moulding (Refer to GROUP 42.) 4. Rear window moulding, upper (Refer to GROUP 42 - Rear Window Glass.) 5. Rear window moulding, lower (Refer to GROUP 42 - Rear Window Glass.) AB" "BA 6. Side protect moulding
51-9
73 mm 35 mm f 10 40 mm
71 mm
f 10
Adhesive tape: double-sided tape <A (10 mm width and 0.8 mm thickness) B, C (0.8 mm thickness)>

AA" ROOF DRIP MOULDING REMOVAL Use the special tool to lever out the moulding. Caution If the moulding has become warped, it should not be reused.
MB990449
Protection tape
AB" SIDE PROTECT MOULDING REMOVAL 1. Attach protection tape all the way along the edges of the double-sided tape which is still adhering to the body.
Double-sided tape
51-10
Double-sided tape
2. Use a resin spatula to scrape off the double-sided tape. 3. Peel off the protection tape. 4. Wipe the body surface and clean it with a rag moistened with isopropyl alcohol.

"BA SIDE PROTECT MOULDING INSTALLATION Double-sided tape affixing to the side protect moulding (when reusing) 1. Scrape off the double-sided tape with a resin spatula or gasket scraper.
2. Wipe off the side protect moulding adhesion surface and clean it with a shop towel moistened with isopropyl alcohol. 3. Affix the specified double sided tape to the side protect moulding. Specified adhesive tape: Double-sided tape A: 10 mm width and 0.8 mm thickness B, C: 0.8 mm thickness
4. Remove strip paper double-sided tape.
from the
pressure sensitive
NOTE Affix double-sided tape to the end of strip paper for ease of strip paper removal. 5. Install the side protect moulding. NOTE If it is hard to affix the double-sided tape in winter, heat the application surfaces at both the vehicle body and the side protect moulding. Body 40 - 60_C Side protect moulding 20 - 30 _C Apply pressure fully to the side protect moulding.
EXTERIOR - Mouldings/Aero Parts
51-11
"AA ROOF DRIP MOULDING INSTALLATION Install the clip to the roof drip moulding before installing the moulding to the vehicle body.
AERO PARTS
51100500184
Adhesive tape: double-sided tape (5 mm width and 0.8 mm thickness)
AA" "AA 1. Side sill cover

AA" SIDE SILL COVER REMOVAL Remove the side sill cover in the same manner as for the side protect moulding (Refer to P.51-8).

"AA SIDE SILL COVER INSTALLATION Install the side sill cover in the same manner as for the side protect moulding (Refer to P.51-8).
51-12
EXTERIOR - Windshield Wiper and Washer

51100760261
WINDSHIELD WIPER AND WASHER

3 2
13 Nm
A 9 Nm A
5
5 Nm
6 9
11 8 8 10 12
Section A - A
1
Clip
1. Column switch assembly (Refer to GROUP 37A.) 2. Washer hose 3. Washer nozzle assembly Wiper motor and linkage removal steps "AA 4. Wiper arm and blade assembly 5. Front deck garnish AA" 6. Wiper motor 7. Linkage
Washer tank removal steps D Draining washer fluid D Front bumper (Refer to P.51-3.) 8. Washer hose 9. Washer tank 10. Washer motor (front) 11. Washer motor (rear) 12. Washer motor <vehicles with headlamp washer>

Linkage
51-13

AA" WIPER MOTOR REMOVAL Loosen the wiper motor assembly mounting bolts, and then remove the wiper motor assembly. Disconnect the linkage and the motor assembly, and then remove the linkage.
Crank arm
Wiper motor
Caution Because the installation angle of the crank arm and the motor has been set, do not remove them unless it is necessary to do so. If they must be removed, remove them only after marking their mounting positions.

"AA WIPER ARM AND BLADE ASSEMBLY INSTALLATION Install the wiper blade in the specified position (standard value) as shown in the illustration. Standard value (A): <Drivers side> 35 5 mm <Passengers side> 20 5 mm
Front deck garnish end
INSPECTION
COLUMN SWITCH CHECK Wiper and Washer Switch <L.H. drive vehicles>
Switch position Wiper switch OFF INT 1 (LO) 2 (HI) Washer switch ON Terminal No. 6 7 8 9
51101450044
10
51-14

Switch position Wiper switch OFF INT 1 (LO) 2 (HI) Washer switch ON Terminal No. 8 9 10 11 12
Intermittent Wiper Relay (Intermittent Operation Inspection) 1. Connect the column switch connector. 2. Turn the ignition switch to ACC. 3. Inspect the intermittent operation time when the wiper switch is turned to INT. Vehicles with variable intermittent control FAST: Approx. 2 seconds SLOW: Approx. 15 seconds
51101260104 WIPER MOTOR CHECK Check the wiper motor after disconnecting the wiring harness connector, and with the wiper motor remaining installed to the body.
Wiper Motor at Low Speed and High Speed Operation Connect a battery to the wiper motor as shown in the illustration and inspect motor operation at low speed and high speed. Wiper Motor at Stop Position Operation
Inspection while operating
Battery Low speed High speed Inspection while stopped
1. Run the wiper motor at low speed, disconnect the battery, and stop the motor. 2. Reconnect the battery as shown in the illustration, and confirm that after the motor starts turning at low speed, it stops at the automatic stop position.
Battery Low speed Automatic stop
51101270107 WASHER MOTOR CHECK 1. With the washer motor installed to the washer tank, fill the washer tank with water. 2. Check that the water squirts out strongly when battery voltage is applied to terminals (1) and (2).
EXTERIOR - Rear Wiper and Washer
51-15
51100850159
REAR WIPER AND WASHER

<Sedan> 2 3
9.8 Nm
1
7.4 Nm
11
5 9
12 8
7.4 Nm
1 4
<Wagon>
10 11
9.8 Nm
6 8
<Wagon>
7 8 12
Wiper motor assembly removal steps 1. Cover 2. Wiper arm and blade assembly 3. Shield cap 4. Cover 5. Nozzle collar assembly 6. Packing and washer <Wagon> 7. Tailgate trim (Refer to group 42.) 8. Wiper motor and bracket assembly 9. Packing and washer <Sedan>
Rear washer hose removal steps D Scuff plate, quarter trim, quarter upper trim, beltline trim (Refer to GROUP 52A.) D Front seat, rear seat (Refer to GROUP 52A.) 10. Washer nozzle 11. Washer hose Rear intermittent wiper relay removal 7. Tailgate trim (Refer to GROUP 42.) 12. Rear intermittent wiper relay NOTE 1. *: For washer tank (Refer to P.51-12.) 2. For removal and installation of the column switch assembly (windshield wiper and washer switch), refer to GROUP 37A - Steering Wheel and Shaft.}
51-16
<Sedan>
EXTERIOR - Rear Wiper and Washer INSTALLATION SERVICE POINT

"AA WIPER ARM AND BLADE ASSEMBLY INSTALLATION <Sedan> Install the wiper arm to the pivot shaft so that the wiper blades stop position is the position (standard value) shown in the illustration.
Glass end line
Standard value (A): 15 5 mm <Wagon> Install the wiper arm by aligning the blade with the marking position.
<Wagon> Marking position
INSPECTION
51101290080
WIPER MOTOR CHECK Check the wiper motor after first disconnecting the wiring harness connector, and with the wiper motor remaining installed to the body. Wiper Motor Operation Connect a battery to the wiper motor as shown in the illustration and inspect the motor operation. Wiper Motor at Stop Position Operation 1. Run the wiper motor, disconnect the battery, and stop the motor. 2. Reconnect the battery as shown in the illustration, and confirm that after the motor starts turning, it stops at the automatic stop position.
Operation check
Battery
Stop position check
Battery
EXTERIOR - Rear Wiper and Washer
51-17
51101300066
REAR INTERMITTENT WIPER RELAY CHECK

1. Apply battery voltage to terminal 4, and earth the terminal 7. 2. Measure voltage according to the table below.
Measurement requirement
Rear intermittent wiper relay
Terminal number 2
Apply battery voltage to terminal 6. Battery voltage Apply battery voltage to terminal 5. Battery voltage generates every approx. eight seconds. Apply battery voltage to terminal 8. Battery voltage generates after approx. one second.
3. Check that there is continuity between terminals 1 and 2.
COLUMN SWITCH (WIPER AND WASHER) 51100950057 CHECK

Switch position Wiper switch Washer switch INT ON ON NOTE *: R.H. drive vehicles Terminal No. 2 3 4 10, 8*
WASHER MOTOR CHECK
51101310083
1. With the washer motor installed to the washer tank, fill the washer tank with water. 2. Check that washer fluid sprays strongly when battery voltage is applied to terminal 2 and terminal 1 is earthed.
51-18
EXTERIOR - Headlamp Washer

51100970107
HEADLAMP WASHER
3 1 4 4 4 2
4.9 Nm
4 4
4.9 Nm
5 6 6
1. Headlamp washer relay Nozzle, check valve and joint removal steps D Draining of washer fluid D Front bumper (Refer to P.51-3.) 2. Check valve 3. Joint 4. Washer hose assembly 5. Collar 6. Nozzle
NOTE 1. For removal and installation of the column switch assembly (built-in headlamp washer switch), refer to GROUP 37A - Steering Wheel and Shaft. 2. For removal and installation of the washer tank, refer to P.51-12.
INSPECTION
Headlamp washer relay
51101320055
HEADLAMP WASHER RELAY CHECK 1. Connect battery and test lamp to the relay as illustrated.
STEP 1
Test lamp
EXTERIOR - Headlamp Washer

STEP 2 Test lamp
51-19
2. The relay is normal if the lamp lights for approximately 0.5 second upon connection of terminal (2) to battery ( - ).
Connector A
Connector B
COLUMN SWITCH (HEADLAMP WASHER SWITCH) 51100980063 CHECK Check the continuity between terminal 2 of connector A and terminal 1 of connector B with headlamp washer switch in ON position.
51101330058 CHECK VALVE CHECK Apply pressure to the inlet of the check valve to check its opening pressure.
Opening pressure: 78 kPa
51101340051 HEADLAMP WASHER MOTOR CHECK 1. With the washer motor installed to the washer tank, fill the washer tank with water. 2. Connect battery (+) and ( - ) cables to terminals (1) and (2) respectively to see that the washer motor runs and water is injected.
51-20 MARKS
<Sedan>
EXTERIOR - Marks
51101180110
<Wagon>
2 2 1 1
"AA 1. Mitsubishi mark "AA 2. Grade mark

"AA INSTALLATION OF MARKS 1. APPLICATION POSITION MITSUBISHI mark <Sedan> <Wagon>
12 mm 7 mm
30 mm
7 mm
24 mm
26.6 mm
35 mm
Trunk lid end line
Trunk lid press line
Tailgate end line
EXTERIOR - Marks Grade mark

<Sedan>
GLS (also applicable to GLX and V6-24) GLS TD
51-21
15 mm
28 mm
24 mm
21 mm
26.9 mm
24 mm
21 mm
Trunk lid end line
Trunk lid end line
<Wagon>
GLS (also applicable to GLX and V6-24) 35 mm GLS TD 35 mm
35 mm
35 mm
15 mm
Tailgate end line
Tailgate end line
2. INSTALLATION PROCEDURE (1) Clean the mark installation surfaces on the body with unleaded petrol. (2) Peel off the backing paper from the reverse side of the marks, and then attach the marks to the vehicle body so that they fit properly into position. Caution When attaching the marks, the surrounding temperature should be 20 - 38_C and the air should be completely free from dust. If the surrounding temperature is lower than 20_C, the marks and the places on the body where the marks are to be attached should be heated to 20 - 38_C.
51-22 DOOR MIRROR
EXTERIOR - Door Mirror

51100640121

5 6
3 1 7
AA"
1. Door mirror control switch Door mirror removal steps 2. Door trim attaching screw 3. Delta cover inner 4. Boot 5. Door mirror 6. Delta cover base 7. Mirror
Spring

AA" MIRROR REMOVAL Let the mirror face up, insert a flat-tipped screwdriver wound with masking tape, and remove the mirror by releasing the spring from the hook.
Hook
EXTERIOR - Door Mirror INSPECTION
51-23
51100650100
REMOTE CONTROL MIRROR ASSEMBLY CHECK 1. Check to be sure that the mirror moves as described in the table when each terminal is connected to the battery. 2. For printed heater, check the continuity between terminals 1 and 4.
Battery connection terminal 5 6 7 1 4 UP Printed heating wire DOWN RIGHT LEFT Direction of operation
DOOR MIRROR CONTROL SWITCH CONTINUITY CHECK

51101350061
Switch position Left side UP DOWN LEFT RIGHT Right side UP DOWN LEFT RIGHT
Terminal No. 2 3 4 6 7 8 9
SWITCH AND RELAY OF DOOR MIRROR 51101360019 PRINTED HEATING WIRE CHECK
The printed heating wire of the door mirror operates in conjunction with the rear window defogger. The switch and relay are used for the rear window defogger also, so refer to GROUP 54 for inspection service points.
NOTES
52A-1
INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

CONTENTS
52109000187
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . . . . . . . . . . 52B
52A-2
INTERIOR
CONTENTS
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . 3 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 INSTRUMENT PANEL* . . . . . . . . . . . . . . . . . . . . . . 3 FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . 7 TRIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
52109000385
INSIDE REAR VIEW MIRROR . . . . . . . . . . . . . . 11 FRONT SEAT* . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 FRONT SEAT BELT . . . . . . . . . . . . . . . . . . . . . . 19 REAR SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . 20
INTERIOR - Service Specifications/Special Tool/Instrument Panal
52A-3
52100030055
Items Seatback heater resistance (between terminals) W Seat cushion heater resistance (between terminals) W Between terminals 2 and 3 Between terminals 1 and 2 Standard value Approx. 8 Approx. 8 0
SPECIAL TOOL
Tool Number MB990784 Name Ornament remover Use Removal of switch, trim, etc.
52100060191
INSTRUMENT PANEL
52100170252
For installation of the instrument panel, the bolts and screws described below are used. They are indicated by symbols in the illustration.
Name Tapping screw Symbol A B C D E F Washer-assembled screw G H Washer-assembled bolt I J D = Thread diameter L = Effective thread length Size mm (D L) 512 514 516 425 512 520 516 520 616 620 Colour Black Shape
52A-4
INTERIOR - Instrument Panel
CAUTION: SRS For the passenger side air bag module removal/installation, always observe the service
procedures of GROUP 52B - Air Bag Module and Clock Spring.
12 10 C 9 8 C 16 7 D 2 6 F F 17 3 4 5 C H 1 A 16 15 B 23 18
<Automatic air conditioner>
11 13 19
21 20
14
<Manual air conditioner>
22
NOTE : metal clip position
AA"
Removal steps 1. Hood lock release handle 2. Switch bezel 3. TCL switch or auto-cruise control main switch 4. TCL switch or plug 5. Headlamp leveling switch 6. Lower cover 7. Column cover 8. Meter bezel 9. Combination meter 10. Door mirror control switch 11. Fog lamp switch 12. Side air outlet assembly (L.H.) 13. Center air outlet assembly 14. Side air outlet assembly (R.H.)
15. Ashtray D Floor console panel (Refer to P.52A-7.) 16. Centre console panel 17. Sunglasses box 18. Radio and tape player 19. Heater control assembly (Refer to GROUP 55 - Manual air conditioner.) 20. Rear window defogger switch 21. A/C switch 22. Inside/Outside air changeover switch 23. Air conditioner control panel and ECU assembly
52A-5
24 30 I 25 A I I
32 I J G G C C 28 G J H
NOTE : metal clip position
29
12 Nm
29
Earth bolt
I I 31
Standard bolt
12 Nm
22 Nm
27 26
24. 25. 26. D 27. 28. 29. 30.
Centre display bezel Clock Glove box Under cover (Refer to GROUP 55 Ventilators.) Side cover Glove box frame Steering mounting bolts Front passengers side air bag module (Refer to GROUP 52B.)
D Floor console box (Refer to P.52A-7.) 31. Corner panel 32. Instrument panel assembly Caution One of the steering shaft assembly mounting bolts must be the earth bolt. The earth bolt has a E mark on its head.

AA" CENTER AIR OUTLET ASSEMBLY REMOVAL Refer to GROUP 54 - Hazard warning lamp switch.
52A-6

52100190210
1 2 E E I 4 7 I I I I 5 I I 8 9 I I I
Disassembly steps D Heater ducts (Refer to GROUP 55.) 1. Photo sensor (Refer to GROUP 55.) 2. Defroster garnish 3. Instrument panel wiring harness 4. Instrument panel lower drivers side bracket 5. Center reinforcement
6. Console bracket 7. Instrument panel lower passengers side bracket 8. Passengers side air bag rear bracket 9. Air bag reinforcement assembly
INTERIOR - Floor Console
52A-7
52100220193
FLOOR CONSOLE
<Vehicles without heated seat> <Vehicles with heated seat>
3 2 2
6 5 8
7
NOTE : metal clip position Removal steps 1. Floor console panel 2. Cup holder assembly 3. Heated seat switch 4. Floor console box
5. 6. 7. 8.
Floor console Ashtray Console bracket B Console bracket A
52A-8 TRIMS
<Sedan> 4 C B B C
INTERIOR - Trims
52100110292
C C D D
C 5
44 Nm
2 1 A A 3 8
NOTE : metal clip position : resin clip position For door trim, refer to GROUP 42.
Section A - A Scuff plate
Section B - B
Section C - C Trim Clip
Section D - D
Front pillar trim
Clip
Trim Clip
1. 2. 3. 4. 5.
Front scuff plate Rear scuff plate Cowl side trim Front pillar trim Center pillar lower trim
6. 7. 8. 9.
Center pillar upper trim Rear pillar trim Rear shelf trim Shelf front cover
INTERIOR - Trims
<Sedan>
52A-9
17 12 10 E E 13
14 12 11
15 16
NOTE : metal clip position : resin clip position
Section E - E
Rear end trim cover
Clip
10. 11. 12. 13.
Trunk side trim Corner plate Trunk rear side trim Rear end trim cover
14. 15. 16. 17.
Trunk rear center trim Side tray Under tray Trunk lid trim
52A-10
<Wagon> 6 4 C B B 4 5 1 A C
INTERIOR - Trims
7 C C 16 C 8 2 A 10 H H 11 C C H H 11 I I 13 C C 12 C F 9 F G G
44 Nm
3 15 14
NOTE : metal clip position : resin clip position For door trim, refer to GROUP 42.
13 H H 10
Section A - A Scuff plate
Section B - B
Section C - C Trim
Section F - F Trim Clip
Section G - G Trim
Front pillar trim
Clip
Clip Clip
Section H - H
Section I - I Clip
Trim, Lid Clip
Trim
1. 2. 3. 4. 5. 6. 7. 8.
Front scuff plate Rear scuff plate Cowl side trim Front pillar trim Center pillar lower trim Center pillar upper trim Quarter upper trim Retractor trim
9. 10. 11. 12. 13. 14. 15. 16.
Belt line trim Quarter lower trim Maintenance lid Rear end trim Luggage under floor side trim Luggage under floor centre box Utility box lid Shelf holder
INTERIOR - Inside Rear View Mirror/Front Seat

Button
52A-11
52100270105
INSIDE REAR VIEW MIRROR

Remove by pushing in the direction of the arrow in the illustration.

Spring
NOTE 1. The mirror spring fits firmly in the groove of the button that is attached to the glass. 2. The mirror breaking load is within 450 N.
FRONT SEAT
Caution: SRS Before removal of the seat equipped with the side air bag module, refer to GROUP 52B - SRS Service Precautions and Air Bag Module.
52200130222
3
44 Nm
2 3 1
4 3
44 Nm
4
44 Nm
3
29 Nm 44 Nm
3
29 Nm
D Cup holder assembly <Vehicles with heated seat> (Refer to P.52A-7.) 1. Heated seat switch <vehicles with heated seat> 2. Headrestraint Front seat assembly removal steps D Harness connector 3. Seat anchor cover 4. Front seat assembly
NOTE After provisionally tightening the seat assembly mounting nuts and bolts in every installation location, fully tighten them to the specified torque.
52A-12
INTERIOR - Front Seat INSPECTION

HEATED SEAT SWITCH CONTINUITY CHECK
Switch position Terminal No. 1 Drivers seat switch HI 3 4 5 8 9 2 6
52200390033
LO
Passengers seat switch
HI
LO
NOTE To inspect the diode, match the polarity of the circuit tester with the (+) (- ) polarities in the table.
SEATBACK HEATER CHECK Measure the resistance between terminals. Standard value: Approx. 8 W
SEAT CUSHION HEATER CHECK Measure the resistance between terminals. Standard value: Between terminals 2 and 3: Approx. 8 W Between terminals 1 and 2: 0 W
INTERIOR - Front Seat DISASSEMBLY AND REASSEMBLY

Caution Do not disassemble the front seatback assembly with built-in side air bag module.
52A-13
52200150297
<Normal seat> 17 16 18 12 13
Seat with height adjuster 14 44 Nm 20 9
10 11 15 14
14 13 Nm 6 3 8
21 Nm 44 Nm
19
21 Seat without height adjuster 2 1 5
14 44 Nm 20
13 Nm
14
44 Nm
8 21
21 Nm
Disassembly steps 1. Reclining adjuster knob 2. Slide adjuster knob 3. Clip 4. Height adjuster knob 5. Front seat side shield cover 6. Front seat hinge cover 7. Inner seat belt 8. Bolt 9. Front seat cushion assembly 10. Front seat cushion cover 11. Front seat cushion frame
AA"
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Front seatback panel Front seatback assembly Cap Lumbar support lever Headrestraint guide Front seatback cover Front seatback frame Seat heater harness Seat adjuster assembly Wire
52A-14
<Power seat>
INTERIOR - Front Seat
14 18 17 19 20
13
6 7
8 9 16 15 22
21 Nm
10 5 11 12
21
21 Nm
3
44 Nm
4
21 Nm
23 24
Disassembly steps 1. Front seat side shield cover 2. Front seat hinge cover 3. Inner seat belt 4. Bolt 5. Front seat cushion assembly 6. Front seat reclining adjuster lever 7. Front seat slide adjuster lever 8. Garnish 9. Power seat switch 10. Front seat cushion cover 11. Front seat cushion pad 12. Front seat cushion frame
AA"
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Front seatback panel Front seatback assembly Cap Lumbar support lever Headrestraint guide Front seatback cover Front seatback pad Front seatback frame Reclining adjuster lower cover Seat heater harness Power seat harness Power seat adjuster assembly
INTERIOR - Front Seat DISASSEMBLY SERVICE POINT

Clip
52A-15
AA" FRONT SEATBACK PANEL DISASSEMBLY 1. Using a screwdriver or similar tool, push inward the clip of the front seatback panel lower portion to remove it. 2. Pull down the front seatback panel to remove it.
Front seatback panel
Reclining switch
INSPECTION
POWER SEAT SWITCH CONTINUITY CHECK
52200160122
Slide and height switch
Switch position
Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Reclining switch
Forward*1/ Backward*2 Backward*1/ Forward*2
Slide switch
Forward*1/ Backward*2 Backward*1/ Forward*2
Front height switch*1/ Rear height switch*2
Up Down
Rear height switch*1/ Front height switch*2
Up Down
NOTE *1: Power seat switch (R.H.) *2: Power seat switch (L.H.)
52A-16
Rear height motor connector
INTERIOR - Front Seat

POWER SEAT MOTOR OPERATION CHECK Inspect the operation of each motor according to the following procedures. 1. Disconnect the connector for each motor. 2. When the battery is connected directly to the motor terminals, check if the motors run smoothly, and check if each setting mechanism runs in the direction shown in the table below for each motor. 3. If there is an abnormality, replace the power seat adjuster assembly.
Name of motor Front/Rear height Direction of operation Down Up Backward Forward Reclining Backward Forward Terminal No. 1 2 3 4 Stop at operating range limit. Stop position
Slide motor connector
Reclining motor connector
Slide
Front height motor connector
INTERIOR - Rear Seat
52A-17
52200180258
REAR SEAT
2 4 3
22 Nm
5 7
29 Nm
22 Nm
AA" "CA "BA "BA "AA "AA
Removal steps 1. Seat cushion 2. Seatback (R.H.) 3. Seatback (L.H.) 4. Side seatback (R.H.) 5. Side seatback (L.H.) 6. Headrestraint 7. Armrest
Rear seat stopper

AA" SEAT CUSHION REMOVAL While keeping the rear seat stopper pulled, lift up the seat cushion to remove it.
Side seatback

"AA SIDE SEATBACK (L.H.)/SIDE SEATBACK (R.H.) INSTALLATION Push the side seatback in the direction indicated in the illustration; then securely attach the attachment wire to the body side hook and install the side seatback.
Attachment wire
Hook
52A-18
Seatback (R.H.) hinge bracket
INTERIOR - Rear Seat

"BA SEATBACK (L.H.)/SEATBACK (R.H.) INSTALLATION Put the seatback (R.H.) hinge bracket upon the seatback (L.H.) hinge bracket.
Seatback (L.H.) hinge bracket
Attachment wire Lock plate
"CA SEAT CUSHION INSTALLATION 1. Pull the rear seat belt on top of the seat cushion. 2. Insert the seat cushion attachment wire securely below the seatback. 3. Insert the seat cushion lock plate securely into the floor holes.
Rear seat belt

7 5 8 9 4 3 7 8 9 3 6 10 11
52200200077
11 10
Disassembly steps 1. Seat cushion cover 2. Seat cushion pad* 3. Seatback panel 4. Headrestraint guide 5. Unlock knob 6. Armrest 7. Seatback cover
8. 9. 10. 11.
Seatback pad* Seatback frame Side seatback cover Side seatback pad*
NOTE *: Vehicles with front power seat
INTERIOR - Front Seat Belt
52A-19
52300130225
FRONT SEAT BELT

3 2
44 Nm
44 Nm
44 Nm
Outer seat belt removal steps 1. Outer seat belt (seat belt with pre tensioner) (Refer to GROUP 52B.) 2. Center pillar trim upper 3. Adjustable seat belt anchor
Inner seat belt removal steps D Front seat assembly (Refer to P.52A-11.) D Front seat hinge cover (Refer to P.52A-13, 14.) 4. Inner seat belt
52A-20 REAR SEAT BELT
INTERIOR - Rear Seat Belt

52300160194

44 Nm
44 Nm 44 Nm
2 2 1
Removal steps D Rear seat (Refer to P.52A-17.) 1. Rear center seat belt assembly 2. Rear seat belt assembly (inner) D Rear shelf trim <Sedan> (Refer to P.52A-8.) D Retractor trim <Wagon> (Refer to P.52A-10.) 3. Rear seat belt assembly (outer)
52B-1
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 2 SRS SERVICE PRECAUTIONS . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 8 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 8 SRS MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 21 POST-COLLISION DIAGNOSIS . . . . . . . . . . . . 25 INDIVIDUAL COMPONENT SERVICE . . . . . . 28 WARNING/CAUTION LABELS . . . . . . . . . . . . . 29 AIR BAG MODULES AND CLOCK SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SIDE IMPACT SENSOR . . . . . . . . . . . . . . . . . . 38 SEAT BELT WITH PRE-TENSIONER . . . . . . 40 AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Undeployed Air Bag Module and Seat Belt Pre-tensioner Disposal . . . . . . . . . . . . . . . . . . . . . . . 42 Deployed Air Bag Module or Operated Seat Belt Pre-tensioner Disposal Procedures . . . . . . . . . . . . 49
52409000193
SRS AIR BAG CONTROL UNIT (SRS-ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CAUTION D D D D Carefully read and observe the information in the SERVICE PRECAUTIONS (P.52B-4.) prior to any service. For information concerning troubleshooting or maintenance, always observe the procedures in the Troubleshooting (P.52B-8.) section. If any SRS components are removed or replaced in connection with any service procedures, be sure to follow the procedures in the INDIVIDUAL COMPONENT SERVICE section (P.52B-28.) for the components involved. If you have any questions about the SRS, please contact your local distributor.
52B-2
SRS - General Information

52400010232
GENERAL INFORMATION
To improve safety, the SRS and seat belts with pre-tensioner are available as optional parts. These systems enhance collision safety by restraining the front passengers in case of an accident. The SRS works with the pre-tensioner simultaneously when a collision is detected. The SRS consists of four air bag modules, SRS air bag control unit (SRS-ECU), side impact sensors, SRS warning lamp and clock spring. The air bags are located in the centre of the steering wheel, above the glove box, and built into the front seat back assemblies. Each air bag has a folded air bag and an inflator unit. The SRS-ECU under the floor console monitors the system and has a safing G sensor and an analog G sensor. The side impact sensor inside the center pillar monitors any shocks coming from the side of the vehicle. The warning lamp on the instrument panel indicates
the operational status of the SRS. The clock spring is installed in the steering column. The SRS side air bag deploys if an impact received at the side of the vehicle is stronger than a certain set value, in order to protect the upper bodies of front seat passengers in the event of a collision. The seat belt pre-tensioner is built into the front seat belt retractor. Only authorized service personnel should do work on or around the SRS components and seat belt with pre-tensioner. Those service personnel should read this manual carefully before starting any such work. Extreme care must be used when servicing the SRS to avoid injury to the service personnel (by inadvertent deployment of the air bags or inadvertent operation of the seat belt with pre-tensioner) or the driver (by rendering the SRS or the seat belt with pre-tensioner inoperative).
Side impact sensor Side air bag module Clock spring Air bag module (Drivers side)
Air bag module (Front passengers side)
Diagnosis connector
SRS-ECU Seat belt with pre-tensioner SRS warning lamp
SRS - General Information

SEAT BELT WITH PRE-TENSIONER The seat belt with pre-tensioner has a pre-tensioner operating mechanism and a G-sensor which detects the force from an impact built into the seat belt retractor. The G-sensor is a mechanical-type sensor which includes components such as a weight which moves as a result of the impact from a collision, and a spike which strikes a charge and causes it to detonate. Thus the pre-tensioner is equipped with a safety mechanism to prevent mis-operation during maintenance operations such as removal and installation of the seat belt.
52B-3
The safety mechanism operates automatically when the retractor top mounting screw is removed during removal of the seat belt. When the retractor top mounting screw is removed, the force of the spring plate causes the tab at the lower edge of plate (A) to push in the pin of the G-sensor, which prevents the weight inside the G-sensor from moving. At the same time, the retractor bracket and the top of plate (A) become separated. A stopper is inserted into the gap thus formed by the force from a spring to prevent the tab from being removed from the pin if an outside force is applied to plate (A).
Plate (A) Spring Stopper Retractor bracket Plate (A) (when safety mechanism is disengaged) Plate (A) (when safety mechanism is engaged) Stopper
Spring plate
Tab
Tab
G-sensor structure Charge
Spike
Pin Pin (when safety mechanism is engaged)
Tab
Sensor weight
52B-4
SRS - SRS Service Precautions

52400030238
SRS SERVICE PRECAUTIONS

1. In order to avoid injury to yourself or others from accidental deployment of the air bag and accidental operation of the seat belt with pre-tensioner during servicing, read and carefully follow all the precautions and procedures described in this manual. 2. Do not use any electrical test equipment on or near SRS components, except those specified on P.52B-7. 3. Never Attempt to Repair the Following Components: D SRS air bag control unit (SRS-ECU) D Clock spring D Front air bag module (Drivers side or front passengers side) D Side air bag module D Side impact sensor D Seat belt with pre-tensioner
NOTE If any of these components are diagnosed as faulty, they should only be replaced, in accordance with the INDIVIDUAL COMPONENTS SERVICE procedures in this manual, starting at page 52B-28.
Insulating tape
Battery
4. After disconnecting the battery cable, wait 60 seconds or more before proceeding with the following work. The SRS system is designed to retain enough voltage to deploy the air bag for a short time even after the battery has been disconnected, so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected.
SRS-ECU connector <Vehicles without SRS side air bag>
5. Do not attempt to repair the wiring harness connectors of the SRS. If any of the connectors are diagnosed as faulty, replace the wiring harness. If the wires are diagnosed as faulty, replace or repair the wiring harness according to the following table.

<Vehicles without SRS side air bag>
SRS-ECU Terminal No. 1 to 4 5, 6 7, 8 9, 10 11 12 13 14 15 16 to 19 20, 21 Destination of harness Dash wiring harness Clock spring Air bag module (Drivers side) Dash wiring harness Air bag module (Front passengers side) Dash wiring harness Diagnosis connector Dash wiring harness Junction block (fuse No.4) Dash wiring harness Junction block (fuse No.13) Dash wiring harness Instrument panel wiring harness SRS warning lamp Dash wiring harness Earth Corrective action -
52B-5
Correct or replace the dash wiring harness. Replace the clock spring. Correct or replace the dash wiring harness.
Correct or replace each wiring harness. Correct or replace the dash wiring harness.

SRS-ECU Terminal No. 1, 2 3 4 5, 6 7, 8 9 10, 11 12 13 14, 15 16 17 to 20 21, 22 23, 24 Destination of harness Dash wiring harness Earth Dash wiring harness Instrument panel wiring harness SRS warning lamp Dash wiring harness Air bag module (Front Passengers side) Dash wiring harness Clock spring Air bag module (Drivers side) Dash wiring harness Junction block (fuse No.4) Dash wiring harness Junction block (fuse No.13) Dash wiring harness Earth Dash wiring harness Diagnosis connector Dash wiring harness Side air bag module (L.H.) Dash wiring harness Side air bag module (R.H.) Corrective action Correct or replace the dash wiring harness. Correct or replace each wiring harness. Correct or replace the dash wiring harness. Correct or replace the dash wiring harness. Replace the clock spring. Correct or replace the dash wiring harness.
52B-6
SRS-ECU Terminal No. 25 to 33 34, 35, 36 37 to 39 40, 41, 42

Destination of harness Dash wiring harness Floor wiring harness Side impact sensor (L.H.) Dash wiring harness Floor wiring harness Side impact sensor (R.H.) Corrective action Correct or replace each wiring harness.
6. Inspection of the SRS-ECU harness connector <vehicles with SRS side air bag> should be carried out by the following procedure. Insert the special tool (narrow probe in the harness set) into connector from harness side (rear side), and connect the tester to this probe. If any to other than the special tool is used, it may cause damage to the harness and other components. Furthermore, measurement should not be carried out by touching the probe directly against the terminals from the front of the connector. The terminals are plated to increase their conductivity, so that if they are touched directly by the probe, the plating may break, which will cause drops in reliability.
MB991222 SRS-ECU harness connector SRS-ECU harness connector (rear side)
7. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag module (drivers side and front passengers side), clock spring, side impact sensors, front seat assemblies (side air bag module), and seat belts with pre-tensioner before drying or baking the vehicle after painting. D SRS-ECU, air bag module, clock spring, side impact sensor: 93_C or more D Seat belt with pre-tensioner: 90_C or more 8. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the system functions properly. (Refer to P.52B-19.) 9. Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected. 10. If you have any questions about the SRS, please contact your local distributor. NOTE SERIOUS INJURY CAN RESULT FROM UNINTENDED AIR BAG DEPLOYMENT, SO USE ONLY THE PROCEDURES AND EQUIPMENT SPECIFIED IN THIS MANUAL.
SRS - Special Tools
52B-7
52400070209
SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub assembly Use D D D D Reading diagnosis codes Erasing diagnosis code Reading trouble period Reading erase times
MB991613
SRS check harness
Checking the SRS electrical circuitry
MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222
Harness set Checking the continuity and measuring the A: Check harness voltage at the SRS-ECU harness connector <vehicles with SRS side air bag> B: LED harness C: LED harness adapter D: Probe
MB990803
Steering wheel puller
Steering wheel removal
MB686560
SRS air bag adapter harness A
D D
Deployment of air bag modules inside the vehicle Deployment of air bag module (front passengers side) and side air bag module outside the vehicle
MR203491 or MB628919
SRS air bag adapter harness B
Deployment of air bag module (drivers side) outside the vehicle
52B-8
SRS - Test Equipment/Troubleshooting

52400080035
TEST EQUIPMENT
Tool Name Digital multi-meter Use
Checking the SRS electrical circuitry Use a multi-meter for which the maximum test current is 2 mA or less at the minimum range of resistance measurement
TROUBLESHOOTING
52400310097
DIAGNOSIS FUNCTION
52400320083
DIAGNOSIS CODES CHECK Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check diagnosis codes. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) ERASING DIAGNOSIS CODES Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.

Inspect according to the inspection chart that is appropriate for the malfunction code.
Code No. 14 15, 16 17 21, 22, 61, 62 24, 25, 64, 65 31, 32 34* 35 41* 42* 43 Diagnosis Item Analog G-sensor system in the SRS-ECU Front impact safing G sensor system inside SRS-ECU Side impact safing G sensor system inside SRS-ECU Drivers side air bag module (squib) system Front passengers side air bag module (squib) system SRS-ECU capacitor system Connector lock system SRS-ECU (deployed air bag) system IG1 (A) power circuit system IG1 (B) power circuit system SRS warning lamp drive circuit system SRS warning lamp drive circuit system Internal circuit system of non-volatile memory (EEPROM) inside SRS-ECU Lamp does not illuminate.* Lamp does not switch off.
52400330222
Reference page 52B-9 52B-9 52B-10 52B-10 52B-11 52B-11 52B-12 52B-12 52B-12 52B-13 52B-14 52B-15 52B-15 52B-15
44* 45
SRS - Troubleshooting
Code No. 51, 52 54, 55 71, 72, 75, 76 73, 74 79, 93 81, 82, 85, 86 83, 84 89, 96 91* 92 94* 95 Diagnosis Item Drivers side air bag module (squib ignition drive circuit) system Front passengers side air bag module (squib ignition drive circuit) system Side air bag module (R.H) (squib) system Side air bag module (R.H.) (squib) ignition drive circuit system Side impact sensor (L.H.) communication system Side air bag module (L.H.) (squib) system Side air bag module (L.H.) (squib) ignition drive circuit system Side impact sensor (R.H.) communication system Side impact sensor (L.H.) power supply circuit system Side impact sensor (L.H.) system Side impact sensor (R.H.) power supply circuit system Side impact sensor (R.H.) system
52B-9
Reference page 52B-15 52B-15 52B-16 52B-16 52B-16 52B-17 52B-17 52B-17 52B-18 52B-18 52B-18 52B-18
NOTE (1) *: If the vehicle condition returns to normal, the diagnosis code will be automatically erased, and the SRS warning lamp will return to normal. (2) If the vehicle has a discharged battery it will store the fault codes 41 or 42. When these diagnosis codes are displayed, check the battery.
INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE

Code No.14 Analog G-sensor system in the SRS-ECU
The SRS-ECU monitors the output of the analog G-sensor inside the SRS-ECU. It outputs this code when any of the following are detected. D When the analog G-sensor is not operating D When the characteristics of the analog G-sensor are abnormal D When the output from the analog G-sensor is abnormal Replace the SRS-ECU.
Probable cause
D Malfunction of SRS-ECU
Code No.15 or 16 Front impact safing G sensor system inside SRS-ECU

These diagnosis codes are output if there is a short or open circuit between the terminals of the safing G-sensor inside the SRS-ECU. The trouble causes for each diagnosis code No. are as follows.
Probable cause
Code No. 15 16
Replace the SRS-ECU.
Trouble cause Short circuit in the safing G-sensor Open circuit in the safing G-sensor
52B-10
Probable cause
Malfunction of SRS-ECU
Code No.17 Side impact safing G sensor system inside SRS-ECU

This code is output if the following are detected from the side impact safing G sensor output. D Safing G sensor is not operating D Safing G sensor characteristics are abnormal D Safing G sensor output is abnormal Replace the SRS-ECU.
Code No.21, 22, 61 or 62 Drivers side air bag module (squib) system
These diagnosis codes are output if there is abnormal resistance between the input terminals of the drivers side air bag module (squib). The trouble causes for each diagnosis code No. are as follows.
Probable cause
D D D D D Malfunction of clock spring Partial disconnection due to incorrect clock spring neutral position Malfunction of wiring harnesses or connectors Malfunction of drivers side air bag module (squib) Malfunction of SRS-ECU
Code No. 21 22
Trouble cause D D D D D D D D D Short in drivers side air bag module (squib) or harness short Short in clock spring Open circuit in drivers side air bag module (squib) or open harness Open circuit in clock spring Disconnected drivers side air bag module (squib) connector Partial disconnection due to incorrect clock spring neutral position Malfunction of connector contact Short in drivers side air bag module (squib) harness leading to the power supply Short in drivers side air bag module (squib) harness leading to the earth
NG YES
61 62
Check the clock spring (Refer to P.52B-37.) OK
Replace
SRS check harness (MB991613)
Dash wiring harness
MUT-II Self-diag code D Disconnect clock spring connector C-108, and connect the harness side connector to SRS check harness connector 1. D Erase diagnosis code memory. Are code Nos.21, 22, 61 or 62 output?
Check the following connectors: <Vehicles with SRS side air bag> C-108, C-43 <Vehicles without SRS side air bag> C-108, C-44 OK Check trouble symptoms. NG Check the harness wire between the clock spring and SRS-ECU. OK Replace the SRS-ECU. NG Repair NG Repair
NO
Check the following connector: C-110 OK Check trouble symptoms. NG Replace the drivers side air bag module (squib). NG Repair
Clock spring
Code No.24, 25, 64 or 65 Front passengers side air bag module (squib) system
These diagnosis codes are output if there is abnormal resistance between the input terminals of the front passengers side air bag module (squib). The trouble causes for each diagnosis code No. are as follows.
52B-11
Probable cause
D D D Malfunction of wiring harnesses or connectors Malfunction of front passengers side air bag module (squib) Malfunction of SRS-ECU
Code No. 24 25 64 65
Trouble cause D D D D D Short in front passengers side air bag module (squib) or harness short Open circuit in front passengers side air bag module (squib) or open harness Malfunction of connector contact Short in front passengers side air bag module (squib) harness leading to the power supply Short in front passengers side air bag module (squib) harness leading to the earth
MUT-II Self-diag code D Disconnect front passengers side air bag module connector C-71, and connect the harness side connector to SRS check harness connector 1. D Erase diagnosis code memory. Are code Nos.24, 25, 64 or 65 output? YES Check the following connectors: <Vehicles with SRS side air bag> C-71, C-43 <Vehicles without SRS side air bag> C-71, C-44 OK Check trouble symptoms. NG Check the harness wire between the front passengers side air bag module (squib) and SRS-ECU. OK Replace the SRS-ECU. NG Repair NG Repair
Dash wiring harness

NO Replace the front passengers side air bag module (squib).
Code No.31 or 32 SRS-ECU capacitor system

These diagnosis codes are output if the voltage at the SRS-ECU capacitor terminals is higher (No.31) or lower (No.32) than the specified value for 5 seconds or more. However, if diagnosis code Nos.41 and 42 are being output due to a drop in battery voltage, code No.32 will not be detected. Replace the SRS-ECU.
Probable cause
52B-12
Probable cause
D D Malfunction of connectors Malfunction of SRS-ECU
Code No.34 Connector lock system

This diagnosis code is output if a poor connection of the SRS-ECU is detected. However, if the vehicle condition returns to normal, diagnosis code No.34 will be automatically erased, and the SRS warning lamp will switch off. Check the following connector: <Vehicles with SRS side air bag> C-42, C-43 <Vehicles without SRS side air bag> C-44 OK Replace the SRS-ECU. NG Repair
Code No.35 SRS-ECU (deployed air bag) system

This diagnosis code is output after the air bag deploys. If this code is output before the air bag has deployed, the cause is probably a malfunction inside the SRS-ECU. Replace the SRS-ECU.
Probable cause
Code No.41 IG1 (A) power circuit system

This diagnosis code is output if the voltage between the IG1 (A) terminal and the earth is lower than the specified value for a continuous period of 5 seconds or more. However, if the vehicle condition returns to normal, diagnosis code No.41 will be automatically erased, and the SRS warning lamp will switch off.
Probable cause
D D Malfunction of wiring harnesses or connectors Malfunction of SRS-ECU

Measure at SRS-ECU connector C-43. D Disconnect the connector, and measure at the harness side connector. D Connect the battery (- ) terminal. D Ignition switch: ON D Voltage between terminal 12 and body earth OK: 9 V or more OK Replace the SRS-ECU.
NG
Check the following connectors: C-43, C-134 OK Check trouble symptoms. NG Check the harness wire between the SRS-ECU and ignition switch IG1, and repair if necessary. NG Repair
<Vehicles without SRS side air bag> SRS check harness (MB991613)
Measure at SRS check harness connector 5. D Disconnect SRS-ECU connector C-44. D Connect SRS check harness connector 3 to SRS-ECU connector. D Connect the battery (- ) terminal. D Ignition switch: ON D Voltage between terminal 14 and body earth OK: 9 V or more NG Check the following connectors: C-44, C-134 OK Check trouble symptoms. NG Check the harness wire between the SRS-ECU and ignition switch IG1, and repair if necessary. NG Repair
OK Replace the SRS-ECU.
Code No.42 IG1 (B) power circuit system
This diagnosis code is output if the voltage between the IG1 (B) terminal and the earth is lower than the specified value for a continuous period of 5 seconds or more. However, if the vehicle condition returns to normal, diagnosis code No.42 will be automatically erased, and the SRS warning lamp will switch off.
52B-13
Probable cause

Measure at SRS-ECU connector C-43. D Disconnect the connector, and measure at the harness side connector. D Connect the battery (- ) terminal. D Ignition switch: ON D Voltage between terminal 9 and body earth OK: 9 V or more OK Replace the SRS-ECU. NG Check the following connectors: C-43, C-134 OK Check trouble symptoms. NG Check the harness wire between the SRS-ECU and ignition switch IG1, and repair if necessary. NG Repair
Measure at SRS check harness connector 5. D Disconnect SRS-ECU connector C-44. D Connect SRS check harness connector 3 to SRS-ECU connector. D Connect the battery (- ) terminal. D Ignition switch: ON D Voltage between terminal 13 and body earth OK: 9 V or more NG Check the following connectors: C-44, C-134 OK Check trouble symptoms. NG Check the harness wire between the SRS-ECU and ignition switch IG1, and repair if necessary. NG Repair
52B-14
Probable cause
D D D D Malfunction of wiring harnesses or connectors Blown bulb Malfunction of SRS-ECU Malfunction of combination meter
Code No.43 SRS warning lamp drive circuit system (Lamp does not illuminate.)
This diagnosis code is output when an open circuit occurs for a continuous period of 5 seconds while the SRS-ECU in monitoring the SRS warning lamp and the lamp is OFF (transistor OFF). However, if this code is output due to an open circuit, if the vehicle condition returns to normal, this diagnosis code No.43 will be automatically erased, and the SRS warning lamp will return to normal.

Measure at SRS-ECU connector C-43. D Disconnect the connector, and measure at the harness side connector. D Connect the battery (- ) terminal. D Ignition switch: ON D Connect terminal 4 to the body earth. OK: Lamp illuminates OK Replace the SRS-ECU. NG Blown bulb inspection OK NG Repair Check the following connectors: C-43, C-25, D-01, D-03 OK Check trouble symptoms. NG Check the harness wire between the SRS-ECU, combination meter and ignition switch IG1. OK Replace the combination meter. NG Repair NG Repair
Measure at SRS check harness connector 5. D Disconnect SRS-ECU connector C-44. D Connect SRS check harness connector 3 to SRS-ECU connector. D Connect the battery (- ) terminal. D Ignition switch: ON D Connect terminal 15 to the body earth. OK: Lamp illuminates NG Blown bulb inspection OK NG Repair Check the following connectors: C-44, C-25, D-01, D-03 OK Check trouble symptoms. NG Check the harness wire between the SRS-ECU, combination meter and ignition switch IG1. OK Replace the combination meter. NG Repair NG Repair
Code No.43 SRS warning lamp drive circuit system (Lamp does not switch off.)
This diagnosis code is output when a short to earth occurs in the harness between the lamp and the SRS-ECU while SRS-ECU is monitoring the SRS warning lamp and the lamp is ON. NO
52B-15
Probable cause
D D D Malfunction of wiring harnesses or connectors Malfunction of SRS-ECU Malfunction of combination meter NG
SRS warning lamp inspection D Connect the battery (- ) terminal. D Ignition switch: ON D Does lamp switch off when SRS-ECU connector C-43 <vehicles with SRS side air bag> or C-44 <vehicles without SRS side air bag> is disconnected? YES Replace the SRS-ECU.
Check the following connectors: <Vehicles with SRS side air bag> C-43, C-25, D-01 <Vehicles without SRS side air bag> C-44, C-25, D-01 OK Check trouble symptoms.
Repair
NG
Check the harness wire between the SRS-ECU and combination meter. OK NG Repair Replace the combination meter.
Code No.44 SRS warning lamp drive circuit system

This diagnosis code is output when a short occurs in the lamp drive circuit or a malfunction of the output transistor inside the SRS-ECU is detected while the SRS-ECU is monitoring the SRS warning lamp drive circuit. However, if the vehicle condition returns to normal, diagnosis code No.44 will be automatically erased, and the SRS warning lamp will switch off. OK
Probable cause
Check the SRS warning lamp drive circuit system. (Refer to P.52B-14.)
Replace the SRS-ECU.
Code No.45 Internal circuit system of non-volatile memory (EEPROM) inside SRS-ECU
This diagnosis code is output if there is an internal problem with the non-volatile memory (EEPROM) ,etc. inside the SRS-ECU. Replace the SRS-ECU.
Probable cause
Code No.51 or 52 Drivers side air bag module (squib ignition drive circuit) system
This diagnosis code is output if a short (No.51) or an open circuit (No.52) is detected in the circuit for the drivers seat. Replace the SRS-ECU.
Probable cause
Code No.54 or 55 Front passengers side air bag module (squib ignition drive circuit) system
This diagnosis code is output if a short (No.54) or an open circuit (No.55) is detected in the circuit for the passengers seat. Replace the SRS-ECU.
Probable cause
52B-16
Probable cause
D D D Malfunction of wiring harnesses or connectors Malfunction of side air bag module (R.H.) (squib) Malfunction of SRS-ECU
Code No.71, 72, 75 or 76 Side air bag module (R.H.) (squib) system
These diagnosis codes are output if the resistance value between the side air bag module (R.H.) (squib) input terminals of the SRS-ECU is abnormal. The problems which cause these codes to be output are as follows.
Code No. 71 72 75 76
Trouble cause Short in side air bag module (R.H.) (squib) or harness short D D Open circuit in side air bag module (R.H.) (squib) or open harness Malfunction of connector contact
Short in side air bag module (R.H.) (squib) harness leading to the power supply Short in side air bag module (R.H.) (squib) harness leading to the earth
MUT-II Self-diag code D Disconnect side air bag module (squib) connector C-16, and connect the harness side connector to SRS check harness connector 1. D Erase diagnosis code memory. Are code Nos.71, 72, 75 or 76 output? NO YES Check the following connectors: C-16, C-42 OK Check trouble symptoms. NG Check the harness wire between the side air bag module (R.H.) (squib) and SRS-ECU. OK Replace the SRS-ECU. NG Repair NG Repair
Replace the seat back assembly of the front seat (R.H.).
Code No.73 or 74 Side air bag module (R.H.) (squib) ignition drive circuit system
These diagnosis codes are output if there is a short-circuit (code No.73) or an open circuit (code No.74) in the squib ignition drive circuit. Replace the SRS-ECU.
Probable cause
Code No.79 or 93 Side impact sensor (L.H.) communication system

These diagnosis codes are output if communication between the side impact sensor (L.H.) and the SRS-ECU is not possible (code No.79) or abnormal (code No.93).
Probable cause
D D D Malfunction of wiring harnesses or connectors Malfunction of side impact sensor (L.H.) Malfunction of SRS-ECU
MUT-II Self-diag code D Switch over the right side impact sensor (R.H.) and the side impact sensor (L.H.). D Erase diagnosis code memory. Are code Nos.79 and 93 erased and code Nos.89 and 96 output? YES Replace the side impact sensor (L.H.).
NO
Check the following connectors: C-42, C-117, E-18 OK Check trouble symptoms. NG Check the harness wire between the side impact sensor (L.H.) and SRS-ECU. OK Replace the SRS-ECU. NG Repair NG Repair
Code No.81, 82, 85 or 86 Side air bag module (L.H.) (squib) system
These diagnosis codes are output if the resistance value between the side air bag module (L.H.) (squib) input terminals of the SRS-ECU is abnormal. The problems which cause these codes to be output are as follows.
52B-17
Probable cause
D D D Malfunction of wiring harnesses or connectors Malfunction of side air bag module (L.H.) (squib) Malfunction of SRS-ECU
Code No. 81 82 85 86
Trouble cause Short in side air bag module (L.H.) (squib) or harness short D D Open circuit in side air bag module (L.H.) (squib) or open harness Malfunction of connector contact
Short in side air bag module (L.H.) (squib) harness leading to the power supply Short in side air bag module (L.H.) (squib) harness leading to the earth
MUT-II Self-diag code D Disconnect side air bag module (L.H.) (squib) connector C-21, and connect the harness side connector to SRS check harness connector 1. D Erase diagnosis code memory. Are code Nos.81, 82, 85 or 86 output? NO YES Check the following connectors: C-21, C-42 OK Check trouble symptoms. NG Check the harness wire between the side air bag module (L.H.) (squib) and SRS-ECU. OK Replace the SRS-ECU. NG Repair NG Repair
Replace the seat back assembly of the front seat (L.H.).
Code No.83 or 84 Side air bag module (L.H.) (squib) ignition drive circuit system
These diagnosis codes are output if there is a short-circuit (code No.83) or an open circuit (code No.84) in the squib ignition drive circuit. Replace the SRS-ECU.
Probable cause
Code No.89 or 96 Side impact sensor (R.H.) communication system

These diagnosis codes are output if communication between the side impact sensor (R.H.) and the SRS-ECU is not possible (code No.89) or abnormal (code No.96).
Probable cause
D D D Malfunction of wiring harnesses or connectors Malfunction of side impact sensor (R.H.) Malfunction of SRS-ECU
MUT-II Self-diag code D Switch over the side impact sensor (R.H.) and the side impact sensor (L.H.). D Erase diagnosis code memory. Are code Nos.89 and 96 erased and code Nos.79 and 93 output? YES Replace the side impact sensor (R.H.).
NO
52B-18
Probable cause
D D D Malfunction of wiring harnesses or connectors Malfunction of side impact sensor (L.H.) Malfunction of SRS-ECU
Code No.91 Side impact sensor (L.H.) power supply circuit system
This diagnosis code is output if the power supply voltage of the side impact sensor (L.H.) drops below the rated value for a continuous period of 5 seconds or more. However, code No.91 will be automatically cleared and the SRS warning lamp will switch off if the condition returns to normal. NG
Measure at side impact sensor (L.H.) connector E-18. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal 1 and body earth OK: 9 V or more Continuity between terminal 3 and body earth OK Replace the side impact sensor (L.H.).
Code No.92 Side impact sensor (L.H.) system

This diagnosis code is output if the following are detected from the analog G-sensor output. D Analog G-sensor is not operating. D Analog G-sensor characteristics are abnormal. D Analog G-sensor output is abnormal. Replace the side impact sensor (L.H.).
Probable cause
D Malfunction of side impact sensor (L.H.)
Code No.94 Side impact sensor (R.H.) power supply circuit system
This diagnosis code is output if the power supply voltage of the side impact sensor (R.H.) drops below the rated value for a continuous period of 5 seconds or more. However, code No.94 will be automatically cleared and the SRS warning lamp will switch off if the condition returns to normal. NG
Probable cause
D D D Malfunction of wiring harnesses or connectors Malfunction of side impact sensor (R.H.) Malfunction of SRS-ECU
Measure at side impact sensor (R.H.) connector E-09. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal 1 and body earth OK: 9 V or more Continuity between terminal 3 and body earth OK Replace the side impact sensor (R.H.).
Check the following connectors: C-42, C-121, E-09 OK Check trouble symptoms. NG Check the harness wire between the side impact sensor (R.H.) and SRS-ECU. OK Replace the SRS-ECU. NG Repair NG Repair
Code No.95 Side impact sensor (R.H.) system

This diagnosis code is output if the following are detected from the analog G-sensor output. D Analog G-sensor is not operating. D Analog G-sensor characteristics are abnormal. D Analog G-sensor output is abnormal. Replace the side impact sensor (R.H.).
Probable cause
D Malfunction of side impact sensor (R.H.)
SRS - Troubleshooting SRS WARNING LAMP INSPECTION
52B-19
52400430052
1. Check to be sure that the SRS warning lamp illuminates when the ignition switch is in the ON position. 2. Check to be sure that it illuminates for approximately 7 seconds and then switches off. 3. If the above is not the cause, inspect the diagnosis codes.

Trouble symptom Communication with MUT-II is not possible. Communication with all systems is not possible. Communication is not possible with SRS only. When the ignition key is turned to ON (engine stopped), the SRS warning lamp does not illuminate. After the ignition switch is turned to ON, the SRS warning lamp is still on after approximately 7 seconds have passed. Inspection procedure No. 1 2 Refer to diagnosis code No.43. Refer to diagnosis code No.43, 44.
52400340201
Get an understanding of the trouble symptoms and check according to the inspection procedure chart.
Reference page 52B-19 52B-20 52B-14 52B-15

Inspection Procedure 1 Communication with MUT-II is not possible. (Communication with all systems is not possible.)
The cause is probably a power supply system (including earth circuit) of the diagnosis line. Refer to GROUP 13A - Troubleshooting.
Probable cause
D D Malfunction of connectors Malfunction of wiring harness
52B-20
Communication with MUT-II is not possible. (Communication is not possible with SRS only.)
If communication is not possible with the SRS only, the cause is probably an open circuit in the diagnosis output circuit of the SRS or in the power circuit (including earth circuit).
Probable cause

(1) NG Measure at SRS-ECU connector C-43. D Disconnect the connector, and measure at the harness side connector. (1) Continuity between terminal 14 and body earth, and between (2) NG terminal 15 and body earth OK: Continuity (2) Voltage between terminal 9 and body earth, and between terminal 12 and body earth OK: 9 V or more OK Check the connectors: C-43, C-20 following NG Check the following connector: C-43 OK Check trouble symptoms. NG Check the harness wire between the SRS-ECU and earth, and repair if necessary. Check the following connectors: C-43, C-134, C-131 OK Check trouble symptoms. NG Check the harness wire between the SRS-ECU and ignition switch IG1, and repair if necessary. NG Repair NG Repair
Repair
OK Check trouble symptoms. NG Check the harness wire between the SRS-ECU and diagnosis connector. OK Replace the SRS-ECU. NG Repair
(1) NG Measure at SRS check harness Check the following connector: connector 5. C-44 D Disconnect SRS-ECU conOK NG nector C-44. D Connect SRS check harCheck trouble symptoms. Repair ness connector 3 to SRS-ECU connector. NG (1) Continuity between terminal Check the harness wire between the SRS-ECU and earth, and 20 and body earth, and repair if necessary. between terminal 21 and body earth (2), (3) NG Check the following connectors: OK: Continuity C-44, C-134, C-131 (2) Voltage between terminal 13 and body earth OK NG OK: 9 V or more (3) Voltage between terminal 14 Check trouble symptoms. Repair and body earth NG OK: 9 V or more Check the harness wire between the SRS-ECU and ignition switch IG1, and repair if necessary. NG Repair
OK Check the following connectors: C-44, C-20 OK Check trouble symptoms. NG Check the harness wire between the SRS-ECU and diagnosis connector. OK Replace the SRS-ECU. NG
Repair
SRS - SRS Maintenance
52B-21
52400390176
SRS MAINTENANCE
The SRS must be inspected by an authorized dealer 10 years after the date of vehicle registration.
SRS WARNING LAMP CHECK

Turn the ignition key to the ON position. Does the SRS warning lamp illuminate for about 7 seconds, turn off and then remain extinguished for at least 5 seconds? If yes, SRS system is functioning properly. If no, consult page 52B-8.
Insulating tape
SRS COMPONENT VISUAL CHECK

Battery
Turn the ignition key to the LOCK position, disconnect the negative battery cable and tape the terminal. Caution Wait at least 60 seconds after disconnecting the battery cable before doing any further work. (Refer to P.52B-4.)
Battery (- ) cable
SRS-ECU
SRS AIR BAG CONTROL UNIT (SRS-ECU) 1. Check SRS-ECU case and brackets for dents, cracks, deformation or rust. Caution The SRS may not activate if the SRS-ECU is not installed properly, which could result in serious injury or death to the vehicles driver or front passenger. 2. Check connector for damage, and terminals deformation or rust. Replace SRS-ECU if it fails visual check. (Refer to P.52B-30.) for
52B-22
<Drivers side> Connector

AIR BAG MODULES, STEERING WHEEL AND CLOCK SPRING 1. Remove the air bag modules, steering wheel and clock spring. (Refer to P.52B-32, 33.) Caution The removed air bag modules should be stored in a clean, dry place with the air bag deployment side face up. 2. Check pad cover for dents, cracks or deformation. 3. Check connector for damage, terminals deformities, and harness for binds. 4. Check air bag inflator case for dents, cracks or deformities. 5. Check harness and connectors for damage, and terminals for deformation.
Inflator case <Front passengers side>
Connector Inflator case
Protective tube
Case
6. Check clock spring connectors and protective tube for damage, and terminals for deformation. 7. Visually check the clock spring case for damage. 8. Align the mating marks of the clock spring and, after turning the vehicles front wheels to straight-ahead position, install the clock spring to the column switch. Mating Mark Alignment Turn the clock spring clockwise fully, and then turn back it approx. 3 4/5 turns counterclockwise to align the mating marks. Caution If the clock springs mating mark is not properly aligned, the steering wheel may not be completely rotational during a turn, or the flat cable within the clock spring may be severed, obstructing normal operation of the SRS and possibly leading to serious injury to the vehicles driver or front passenger. 9. Install the steering column covers, steering wheel and the air bag module. 10. Check steering wheel for noise, binds of difficult operation. 11. Check steering wheel for excessive free play. REPLACE ANY VISUALLY INSPECTED PART IF IT FAILS THAT INSPECTION. (Refer to P.52B-32, 33.) Caution The SRS may not activate if any of the above components is not installed properly, which could result in serious injury or death to the vehicles driver or front passenger.
Protective tube Mating marks
52B-23
Air bag module deployment section
FRONT SEAT BACK ASSEMBLY (SIDE AIR BAG MODULE) 1. Check that there is no abnormality in the seat air bag module deployment section. 2. Check that there is no connector damage, bent terminals or clamping of the harness.
Center pillar
Side impact sensor
Front of vehicle
SIDE IMPACT SENSORS 1. Check that there is no bending or corrosion in the center pillar. 2. Check that there is no denting, breakage, bending or corrosion of the side impact sensor. 3. Check that there is no clamping of the harness, connector damage or bent terminals. NOTE The illustration at left shows the side impact sensor (L.H.). The position of the side impact sensor (R.H.) is symmetrical to this. Caution The SRS may not activate if the side impact sensors are not installed properly, which could result in serious injury or death to the vehicles driver or front passenger.
52B-24
Dash wiring harness
DASH WIRING HARNESS/FLOOR WIRING HARNESS
Floor wiring harness
Dash wiring harness
1. Check connector for poor connection. 2. Check harnesses for binds, connectors for damage, and terminals for deformation. REPLACE ANY CONNECTORS OR HARNESSES THAT FAIL THE VISUAL INSPECTION. (Refer to P.52B-5.) Caution The SRS may not activate if SRS harnesses or connectors are damaged or improperly connected, which could result in serious injury or death to the vehicles driver or front passenger.
POST-INSTALLATION INSPECTION
Reconnect the negative battery terminal. Turn the ignition key to the ON position. Does the SRS warning lamp illuminate for about 7 seconds, turn off and then remain extinguished for at least 5 seconds? If yes, SRS system is functioning properly. If no, consult page 52B-8.
SRS warning lamp
SRS - Post-collision Diagnosis
52B-25
52400110239
POST-COLLISION DIAGNOSIS
To inspect and service the SRS after a collision (whether or not the air bags have deployed), perform the following steps.
SRS-ECU MEMORY CHECK

1. Connect the MUT-II to the diagnosis connector (16-pin). Caution Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected. 2. Read (and write down) all displayed diagnosis codes. (Refer to P.52B-8.) NOTE If the battery power supply has been disconnected or disrupted by the collision, the MUT-II cannot communicate with the SRS-ECU. Inspect and, if necessary, repair the dash wiring harness before proceeding further. 3. Read the data list (fault duration and how many times memories are erased) using the MUT-II. Data list
No 92 93 Service Data Item Number indicating how often the memory is cleared How long a problem has lasted (How long it takes from the occurrence of the problem till the firest igniting signal) How long a problem has lasted (How long it takes from the first igniting signal till now) Applicability Maximum time to be stored: 250 Maximum time to be stored: 9999 minutes (approximately 7 days)
94
4. Erase the diagnosis codes and after waiting 45 seconds or more read (and write down) all displayed diagnosis codes. (Refer to P.52B-8.)
52B-26
SRS - Post-collision Diagnosis REPAIR PROCEDURE

WHEN AIR BAGS (DRIVERS SIDE AND FRONT PASSENGERS SIDE) DEPLOY OR SEAT BELT PRE-TENSIONER OPERATES IN A COLLISION. 1. Replace the following parts with new ones. D SRS-ECU (Refer to P.52B-30.) D Drivers side air bag module (Refer to P.52B-32.) D Front passengers side air bag module (Refer to P.52B-33.) D Seat belt with pre-tensioner (Refer to P.52B-40.) D Instrument pad assembly (Refer to GROUP 52A Instrument Panel.) 2. Check the following parts and replace if there are any malfunctions. D Clock spring (Refer to P.52B-32.) D Steering wheel, steering column and intermediate joint (1) Check wiring harness (built into steering wheel) and connectors for damage, and terminals for deformation. (2) Install air bag module to check fit or alignment with steering wheel. (3) Check steering wheel for noise, binds or difficult operation and excessive free play. 3. Check harnesses for binding, connectors for damage, poor connections, and terminals for deformation. (Refer to P.52B-24.)
WHEN SRS SIDE AIR BAG DEPLOYS OR SEAT BELT PRE-TENSIONER OPERATES IN A COLLISION 1. Replace the following parts with new ones. D SRS-ECU (Refer to P.52B-30.) D Side impact sensor (Refer to P.52B-38.) D Front seat back assembly (Refer to GROUP 52A Seat.) D Seat belt with pre-tensioner (Refer to P.52B-40.) 2. Check harnesses for binding, connectors for damage, poor connections, and terminals for deformation. (Refer to P.52B-24.) WHEN AIR BAG OR SEAT BELT PRE-TENSIONER DOES NOT DEPLOY IN LOW-SPEED COLLISION. Check the SRS components and seat belt with pre-tensioner. If the SRS components and seat belt with pre-tensioner are showing any visible damage such as dents, cracks, or deformation, replace them with new ones. Concerning parts removed for inspection, replacement with new parts and cautionary points for working, refer to appropriate INDIVIDUAL COMPONENT SERVICE, P. 52B-28.
SRS - Post-collision Diagnosis

SRS-ECU
52B-27
SRS-ECU 1. Check SRS-ECU case and brackets for dents, cracks or deformation. 2. Check connector for damage, and terminals for deformation.
<Drivers side>
Connector
Air bag modules 1. Check pad cover for dents, cracks or deformation. 2. Check connector for damage, terminals deformities, and harness for binds. 3. Check air bag inflator case for dents, cracks or deformities. 4. Install air bag module to steering wheel to check fit or alignment with the wheel.
Connector
Inflator case
Front seat back assembly (Side air bag module) 1. Check that there is no abnormality in the seat air bag module deployment section. 2. Check that there is no connector damage, bent terminals or clamping of the harness.
Protective tube
Case
Clock spring 1. Check clock spring connectors and protective tube for damage, and terminals for deformation. 2. Visually check the case for damage.
Protective tube
52B-28
SRS - Post-collision Diagnosis/Individual Component Service

Steering wheel, steering column and intermediate joint 1. Check wiring harness (built into steering wheel) and connectors for damage, and terminals for deformation. 2. Install air bag module to check fit or alignment with steering wheel. 3. Check steering wheel for noise, binds or difficult operation and excessive free play.
Center pillar
Side impact sensor
Front of vehicle
Side impact sensor 1. Check that there is no bending or corrosion in the center pillar. 2. Check that there is no denting, breakage or bending of the side impact sensor. 3. Check that there is no clamping of the harness, connector damage or bent terminals. NOTE The illustration at left shows the side impact sensor(L.H.). The position of the side impact sensor (R.H.) is symmetrical to this. Harness connector (dash wiring harness and floor wiring harness) Check harnesses for binding, connectors for damage, poor connection, and terminals for deformation. (Refer to P.52B-24.) Seat belt with pre-tensioner 1. Check the seat belt for damage or deformation. 2. Check the pre-tensioner for cracks or deformation. 3. Check that the unit is installed correctly to the vehicle body.
INDIVIDUAL COMPONENT SERVICE
52400290223
If the SRS components and seat belt with pre-tensioner are to be removed or replaced as a result of maintenance, troubleshooting, etc., follow each procedure (P.52B-24 - P.52B-33). Caution 1. SRS components and seat belt with pre-tensioner should not be subjected to heat, so remove the SRS-ECU, air bag modules (drivers side and front passengers side), front seat assemblies (side air bag module), clock spring, side impact sensors and seat belts with pre-tensioner before drying or baking the vehicle after painting. D SRS-ECU, air bag module, clock spring, side impact sensor: 93_C or more D Seat belt with pre-tensioner: 90_C or more Recheck SRS system operability after re-installing them. 2. If the SRS components and seat belts with pre-tensioner are removed for the purpose of check, sheet metal repair, painting, etc., they should be stored in a clean, dry place until they are reinstalled.
SRS - Warning/Caution Labels
52B-29
52400300070
WARNING/CAUTION LABELS
A number of caution labels relating to the SRS and seat belt with pre-tensioner are found in the vehicle, as shown in the following illustration. Follow
Steering wheel
label instructions when servicing SRS and seat belt pre-tensioner. If labels are dirty or damaged, replace them with new ones.
Clock spring
Air bag module (drivers side)
Sun visor
SRS-ECU
Glove box
Air bag module (front passengers side)
Steering gear box
Seat belt pre-tensioner
Side air bag module (drivers seat and front passengers seat)
Side impact sensor
Center pillar
NOTE *: Vehicles with front passengers air bag
52B-30
SRS - SRS-ECU
52400210168
SRS AIR BAG CONTROL UNIT (SRS-ECU)

Caution 1. Disconnect the battery ( - ) terminal and wait for 60 seconds or more before starting work. Furthermore, the disconnected battery terminal should be covered with tape to insulate it. (Refer to P.52B-4.) 2. Never attempt to disassemble or repair the SRS-ECU. If faulty, replace it.
3. Do not drop or subject the SRS-ECU to impact or vibration. If denting, cracking, deformation, or rust are discovered in the SRS-ECU, replace it with a new SRS-ECU. Discard the old one. 4. After deployment of an air bag, replace the SRS-ECU with a new one. 5. Never use an ohmmeter on or near the SRS-ECU, and use only the special test equipment described on P.52B-7.

Pre-removal Operation Turn the ignition key to the LOCK position.
4.9 Nm
Removal steps "BA D Post-installation inspection D Negative (- ) battery cable connection D Lower cover, side cover (Refer to GROUP 52A - Instrument Panel.) 1. Engine-ECU, A/T-ECU, and A/T control relay
"AA 2. SRS-ECU
SRS - SRS-ECU INSTALLATION SERVICE POINTS
52B-31
"AA SRS-ECU INSTALLATION Caution The SRS may not activate if SRS-ECU is not installed properly, which could result in serious injury or death to the vehicles driver or front passenger.
"BA POST-INSTALLATION INSPECTION 1. Reconnect the negative battery terminal. 2. Turn the ignition key to the ON position. 3. Does the SRS warning lamp illuminate for about 7 seconds, and then remain extinguished for at least 5 seconds after turning OFF? 4. If yes, SRS system is functioning properly. If no, consult page 52B-8.
SRS warning lamp
INSPECTION
D D
52400220147
Check the SRS-ECU and brackets for dents, cracks or deformation. Check connector for damage, and terminals for deformation. Caution If a dent, crack, deformation or rust is discovered, replace the SRS-ECU with a new one. NOTE For checking of the SRS-ECU other than described above, refer to the section concerning troubleshooting. (Refer to P.52B-8.)
52B-32
SRS - Air Bag Modules and Clock Spring

52400240211
AIR BAG MODULES AND CLOCK SPRING

Caution 1. Disconnect the battery ( - ) terminal and wait for 60 seconds or more before starting work. Furthermore, the disconnected battery terminal should be covered with tape to insulate it. (Refer to P.52B-4.) 2. Never attempt to disassemble or repair the air bag modules or clock spring. If faulty, replace it. 3. Do not drop the air bag modules or clock spring or allow contact with water, grease or oil. Replace it if a dent, crack, deformation or rust is detected. 4. The air bag modules should be stored on a flat surface and placed so that the air bag deployment surfaces are facing upward.
5. Do not expose the air bag modules to temperatures over 93_C. 6. When the drivers-side and passengersside air bags have been deployed, the air bag modules (drivers-side and passengers-side) should be replaced with new modules. When a side air bag has been deployed, the front seat back assembly (drivers seat or passengers seat) should be replaced with a new assembly. 7. Wear gloves and safety glasses when handling air bags that have already deployed. 8. An undeployed air bag module should only be disposed of in accordance with the procedures (Refer to P.52B-42.)

<Side air bag module> For removal and installation of the front seat back assembly with side air bag module, refer to GROUP 52A - Seat. <Air bag module (drivers side), clock spring>
Pre-removal Operation After setting the steering wheel and the front wheels to the straight ahead position, remove the ignition key.
3 2
0.69 Nm
1 1
9 Nm
Air bag module removal steps "DA D Post-installation inspection D Negative (- ) battery cable connection 1. Air bag module mounting screw (Torx screw) AA" 2. Air bag module "AA D Pre-installation inspection
Clock spring removal steps "DA D Post-installation inspection D Negative (- ) battery cable connection 1. Air bag module mounting screw (Torx screw) AA" 2. Air bag module AB" "CA 3. Steering wheel D Lower cover, column cover (Refer to GROUP 52A - Instrument Panel.) AC" "BA 4. Clock spring "AA D Pre-installation inspection

<Air bag module (front passengers side)>
52B-33
Air bag module removal steps "DA D Post-installation inspection D Negative (- ) battery cable connection D Glove box (Refer to GROUP 52A Instrument Panel.)
AD"
1. Bolt 2. Air bag module "AA D Pre-installation inspection

AA" AIR BAG MODULE REMOVAL (DRIVERS SIDE) When disconnecting the connector of the clock spring from the air bag module, press the air bags lock towards the outer side to spread it open. Use a flat-tipped screwdriver, as shown in the figure at the left, to pry so as to remove the connector gently. Caution 1. When disconnect the air bag module-clock spring connector, take care not to apply excessive force to it. 2. The removed air bag module should be stored in a clean, dry place with the pad cover face up.
Lock Connector Flat-tipped screwdriver Lock
52B-34
MB990803

AB" STEERING WHEEL REMOVAL Caution Do not hammer on the steering wheel. Doing so may damage the collapsible column mechanism. AC" CLOCK SPRING REMOVAL Caution The removed clock spring should be stored in a clean, dry place. AD" AIR BAG MODULE REMOVAL (FRONT PASSENGERS SIDE) Caution The removed air bag module should be stored in a clean, dry place with the air bag deployment side face up.

"AA PRE-INSTALLATION INSPECTION 1. When installing the new air bag modules and clock spring, refer to INSPECTION, P.52B-36. Caution Dispose of air bag modules only according to the specified procedure. (Refer to P.52B-42.) 2. Connect the battery ( - ) terminal. 3. Connect the MUT-II to the diagnosis connector. Caution Make certain that the ignition switch is OFF when the MUT-II is connected or disconnected. 4. Turn the ignition key to the ON position. 5. Conduct self-diagnosis using the MUT-II to ensure entire SRS operates properly, except open circuit of air bag modules. 6. Turn the ignition key to the LOCK position, disconnect the negative battery cable and tape the terminal. Caution Wait at least 60 seconds after disconnecting the battery cable before doing any further work. (Refer to P.52B-4.)

Mating marks
52B-35
"BA CLOCK SPRING INSTALLATION Align the mating marks of the clock spring and, after turning the front wheels to the straight-ahead position, install the clock spring to the column switch.
Mating Mark Alignment Turn the clock spring clockwise fully, and then turn back it approx. 3 4/5 turns counterclockwise to align the mating marks. Caution If the clock springs mating marks are not properly aligned, the steering wheel may not be completely rotational during a turn, or the flat cable within the clock spring may be severed, obstructing normal operation of the SRS and possibly leading to serious injury to the vehicles driver. "CA STEERING WHEEL INSTALLATION 1. Before installation the steering wheel, be sure to first turn the vehicles front wheels to the straight-ahead position and align the mating marks of the clock spring. Caution Be sure when installing the steering wheel, that the harness of the clock spring does not become caught or tangled. 2. After clamping, turn the steering wheel all the way in both directions to confirm that steering is normal. "DA POST-INSTALLATION INSPECTION 1. Reconnect the negative battery terminal. 2. Turn the ignition key to the ON position. 3. Does the SRS warning lamp illuminate for about 7 seconds, and then remain extinguished for at least 5 seconds after turning OFF? 4. If yes, SRS system is functioning properly. If no, consult page 52B-8.
SRS warning lamp
52B-36
<Drivers side>

Connector
INSPECTION
52400250238
AIR BAG MODULE CHECK If any improper part is found during the following inspection, replace the air bag modules with a new one. Dispose the old one according to the specified procedure. (Refer to P.52B-42.)
Caution Never attempt to measure the circuit resistance of the air bag modules (squib) even if you are using the specified tester. If the circuit resistance is measured with a tester, accidental air bags deployment will result in serious personal injury. 1. Check pad cover for dents, cracks or deformation. 2. Check connectors for damage, terminals for deformation, and harness for binds. 3. Check air bag inflator case for dents, cracks or deformation. 4. Install the air bag module to steering wheel to check fit or alignment with the wheel. Caution If dents, cracks, deformation, or rust are discovered in the air bag module, replace it with a new one. Dispose of the old one according to the specified procedure. (Refer to P.52B-42.)
Connector Inflator case
FRONT SEAT BACK ASSEMBLY WITH SIDE AIR BAG MODULE CHECK If any improper part is found during the following inspection, replace the front seat back assembly with a new one. Dispose the old one according to the specified procedure. (Refer to P.52B-42.) Caution Never attempt to measure the circuit resistance of the air bag module (squib) even if you are using the specified tester. If the circuit resistance is measured with a tester, accidental air bag deployment will result in serious personal injury. 1. Check the air bag module deployment section for dents or deformation. 2. Check connector for damage, terminals for deformation, and harness for binds.

Protective tube Case
52B-37
CLOCK SPRING CHECK If, as result of following checks, even one abnormal point is discovered, replace the clock spring with a new one. 1. Check connectors and protective tube for damage, and terminals for deformation. 2. Visually check the case for damage.
Protective tube
3. Check continuity between the No.1 connector of the clock spring and connectors No.3 and 4.
No.1 connector No.3 connector No.4 connector Terminal 1 Terminal 2
5 2 3
Terminal 1
Terminal 2
Terminal 3
1 4
To autocruise control unit
To ACC power
To horn relay
To horn switch
To auto-cruise control switch
Paint mark SRS check harness (MB991613)
Notch
4. Align the paint mark of the SRS check harness connector No.4 with the notch in clock spring connector No.2 to connect the connectors Nos.2 and 4. 5. Check continuity between the terminals 22 and 23 of the SRS check harness connector No.5.
5
View A
Clock spring connector 2
52B-38
SRS - Side Impact Sensor

52400460013
SIDE IMPACT SENSOR

Caution 1. Disconnect the battery ( - ) terminal and wait for 60 seconds or more before starting work. Furthermore, the disconnected battery terminal should be covered with tape to insulate it. (Refer to P.52B-4.) 2. Never attempt to disassemble or repair the side impact sensor. If faulty, replace it.
3. Do not drop or subject the side impact sensor to impact or vibration. If denting, cracking, deformation, or rust are discovered in the side impact sensor, replace it with a new side impact sensor. Discard the old one. 4. After deployment of an air bag, replace the side impact sensor with a new one.

Pre-removal Operation Turn the ignition key to the LOCK position.
5 Nm
Center pillar
2 4
Front of vehicle
5 Nm
Removal steps "CA D Post-installation inspection D Negative (- ) battery cable connection D Center pillar lower trim (Refer to GROUP 52A.) D Seat belt with pre-tensioner (Refer to P.52B-40.) 1. Water proof cover 2. Side impact sensor and bracket
3. Bracket "BA 4. Side impact sensor "AA D Pre-installation inspection NOTE The illustration above shows the side impact sensor (L.H.). The position of the side impact sensor (R.H.) is symmetrical to this.
SRS - Side Impact Sensor INSTALLATION SERVICE POINTS
52B-39
"AA PRE-INSTALLATION INSPECTION Check the side impact sensor for dents, breakage and bending and measure the resistance between the terminals, even when installing a new side impact sensor.
Center pillar
"BA SIDE IMPACT SENSOR INSTALLATION Securely connect the connector. Caution If the side impact sensor is not installed securely and correctly, the side air bag may not operate normally.
"CA POST-INSTALLATION INSPECTION 1. Reconnect the negative battery terminal. 2. Turn the ignition key to the ON position. 3. Does the SRS warning lamp illuminate for about 7 seconds, and then remain extinguished for at least 5 seconds after turning the ignition key to OFF position? 4. If yes, SRS system is functioning properly. If no, consult page 52B-8.
SRS warning lamp
INSPECTION
D D
52400470016
Check the side impact sensor and bracket for dents, cracks or deformation. Check connector for damage, and terminals for deformation. Caution If a dent, crack, deformation or rust is discovered, replace the side impact sensor with a new one. NOTE For checking of the side impact sensor other than described above, refer to the section concerning troubleshooting. (Refer to P.52B-8.) Check that there is no bending or corrosion in the center pillar.
52B-40
SRS - Seat Belt with Pre-tensioner

52400410056
SEAT BELT WITH PRE-TENSIONER

Caution 1. Never attempt to disassemble or repair the seat belt with pre-tensioner. If faulty, replace it. 2. Be extremely careful when handling the seat belt with pre-tensioner. Do not subject it to shocks, drop it, bring it close to strong magnets or allow contact with water, grease or oil. Always replace it with a new part if any dents, cracks or deformation is found. 3. Do not place anything on top of the seat belt pre-tensioner.
4. Do not expose the seat belt with pre-tensioner to temperatures over 90_C. 5. After operating the seat belt pre-tensioner, replace the seat belt pre-tensioner with a new part. 6. Gloves and protective goggles should be worn when handling a pre-tensioner once it has been used. 7. If disposing of a seat belt with pre-tensioner which has not yet been used, its pre-tensioner should be operated first before disposal. (Refer to P.52B-42.)

Pre-removal and Post-installation Operation Center Pillar Lower Trim Removal and Installation (Refer to GROUP 52A.)
3
44 Nm
2 4 1
44 Nm
Removal steps AA" "BA 1. Retractor top mounting screw (for engaging and disengaging safety mechanism) 2. Sash guide cover 3. Sash guide 4. Seat belt with pre-tensioner "AA D Pre-installation inspection
SRS - Seat Belt with Pre-tensioner

When safety mechanism is engaged
52B-41

AA" RETRACTOR TOP MOUNTING SCREW REMOVAL (SAFETY MECHANISM ENGAGEMENT) The safety mechanism which is equipped in the seat belt pre-tensioner will engage automatically when the retractor top mounting screw is removed. Caution All of the following operations should be carried out while the safety mechanism is engaged to prevent mis-operation of the seat belt pre-tensioner. Furthermore, the safety mechanism should not be disengaged while the seat belt pre-tensioner is removed from the vehicle.

"AA PRE-INSTALLATION INSPECTION When installing a new seat belt with pre-tensioner refer to INSPECTION, P.52B-42. Caution Disposal of the pre-tensioner must be carried out as stated in the procedure. (Refer to P.52B-42.)
"BA RETRACTOR TOP MOUNTING SCREW

Retractor bracket Plate (A) Stopper
INSTALLATION (SAFETY MECHANISM DISENGAGEMENT) 1. Lift up the stopper and then bring the retractor bracket and plate (A) together so that the stopper tab goes into the hole in the retractor bracket. 2. Screw the retractor bracket and plate (A) together with the retractor top mounting screw. 3. Check that the seat belt can be pulled out smoothly. If it does not move smoothly, the safety mechanism may not have been properly disengaged, so remove the retractor top mounting screw and repeat the installation procedure.
52B-42
SRS -
Seat Belt with Pre-tensioner/Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures
INSPECTION
52400420059
SEAT BELT WITH PRE-TENSIONER CHECK If any part is found to be faulty during the inspection. It must be replaced with a new one. Dispose of the old one according to the specified procedure described below. D Check seat belt pre-tensioner for dents, cracks or deformation.
AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL 52400120225 PROCEDURES
Before disposing of a vehicle which is equipped with air bags or seat belts with pre-tensioner, or when disposing of the air bags or seat belt pre-tensioner themselves, the following procedures must be used to deploy the air bags or operate the seat belt pre-tensioners before disposal.
UNDEPLOYED AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL

Caution 1. If the vehicle is to be scrapped or otherwise disposed of, deploy the air bags inside the vehicle, and operate the seat belt pre-tensioners outside the vehicle. If the vehicle will continue to be operated and only the air bag modules and seat belt pre-tensioner are to be disposed of, deploy the air bags and operate the seat belt pre-tensioners outside the vehicle. 2. Since a large amount of smoke is produced when the air bag are deployed or the seat belt pre-tensioner is operated, avoid residential areas whenever possible. 3. Since there is a loud noise when the air bags are deployed and when the seat belt pre-tensioners are operated, avoid residential areas whenever possible. If anyone is nearby, give warning of the impending noise. 4. Suitable ear protection should be worn by personnel performing these procedures or by people in the immediate area. AIR BAG MODULE DEPLOYMENT Deployment Inside The Vehicle (when disposing of a vehicle) 1. Move the vehicle to an isolated spot. 2. Disconnect the negative ( - ) and positive (+) battery cables from the battery terminals, and then remove the battery from the vehicle. Caution Wait at least 60 seconds after disconnecting the battery cables before doing any further work. (Refer to P.52B-4.)
SRS Dash wiring harness connector (2-pin)
Air Bag Module and Seat Belt Pre-tensioner Disposal Procedures
52B-43
3. To deploy the air bag module (drivers side): (1) Remove the lower cover and the steering column lower cover. (2) Remove the connection between the clock spring 2-pin connector (red) and the dash wiring harness connector. NOTE If the clock spring connector is disconnected from the dash wiring harness, both electrodes of the clock spring connector will be automatically shorted to prevent unintended deployment of the air bag due to static electricity, etc.
Clock spring 2-pin connector (red)
Dash wiring harness connector (2-pin)
4. To deploy the air bag module (front passengers side): (1) Remove the glove box. (2) Remove the connection between the air bag module (front passengers side) connector (red 2-pin) and the dash wiring harness connector. NOTE If the air bag module connector is disconnected from the dash wiring harness, both electrodes of the air bag module connector will be automatically shorted to prevent unintended deployment of the air bag due to static electricity, etc. 5. To deploy the side air bag module: Remove the connection between the side air bag module connector (red 2-pin) and the dash wiring harness connector.
Air bag module 2-pin connector (red)
Dash wiring harness connector (2-pin) Side air bag module 2-pin connector (red)
Caution The side air bag modules for both the drivers-side and passengers-side should be deployed. NOTE If the side air bag module connector is disconnected from the dash wiring harness, both electrodes of the side air bag module connector will be automatically shorted to prevent unintended deployment of the side air bag due to static electricity, etc.
52B-44
Connection Insulation SRS air bag tape adapter harness A MB686560
SRS -
6 m or longer Two wires
6. Connect two wires, each six meters or longer, to the two leads of SRS air bag adapter harness A and cover the connections with insulation tape. The other ends of the two wires should be connected to each other (short-circuited), to prevent sudden unexpected deployment of the air bag.
SRS air bag adapter harness A MB686560
7. Connect the clock spring, air bag module (front passengers side), or side air bag module 2-pin connector (red) to SRS air bag adapter harness A and pass the deployment wires out of the vehicles.
2-pin connector (red) Deployment wires
Cover
8. Fully close all door windows, close the doors and place a cover over the vehicle to minimize the amount of noise. Caution If the glass is damaged, it may break, so the car must be covered. 9. At a location as far away from the vehicle as possible, disconnect the two connected wires from each other, and connect them to the two terminals of the battery (which has been removed from the vehicle) to deploy the air bag. Caution 1. Before deploying the air bag in this manner, first check to be sure that there is no one in or near the vehicle. Wear safety glasses. 2. The inflator will be quite hot immediately following the deployment, so wait at least 30 minutes to allow it to cool before attempting to handle it. Although not poisonous, do not inhale gas from air bag deployment. See Deployed Air Bag Module or Operated Seat Belt Pre-tensioner Disposal Procedures (P.52B-49.) for post-deployment handling instructions. 3. If the air bag module fails to deploy when the procedures above are followed, do not go near the module. Contact your local distributor. 10. After deployment, dispose of air bag module according to the Deployed Air Bag Module or Operated Seat Belt Pre-tensioner Disposal Procedures. (Refer to P.52B-49.)
Wires 6 m or longer
SRS -
52B-45
Deployment Outside The Vehicle Caution 1. This should be carried out in a wide, flat area at least 6 m away from obstacles and other people. 2. Do not perform deployment outside, if a strong wind is blowing, and if there is even a slight breeze, the air bag module should be placed and deployed downwind from the battery. 1. Disconnect the negative ( - ) and positive (+) battery cables from the battery terminals, and then remove the battery from the vehicle. Caution Wait at least 60 seconds after disconnecting the battery cables before doing any further work. (Refer to P.52B-4.) 2. Remove the air bag modules (drivers-side and front passengers-side) (Refer to P.52B-32, 33.) and the front seat back assemblies with built-in side air bag module from the vehicle. (Refer to GROUP 52A - Front Seat.) Caution The air bag modules should be stored on flat surface and placed so that the air bag deployment surfaces are facing upward. Do not place anything on top of them.
<Air bag module (drivers side)> Two wires SRS air bag adapter harness B MR203491 or MB628919
Connection
6m long or more
3. Connect two wires, each six meters or longer, to the two leads of SRS air bag adapter harness B <air bag module (drivers side)> or SRS air bag adapter harness A <air bag module (front passengers side) and side air bag module>, and cover the connections with insulation tape. The other ends of the two wires should be connected to each other (short-circuited), to prevent sudden unexpected deployment of the air bag module.
Insulation tape <Air bag module (front passengers side) and side air bag module> Two wires SRS air bag adapter harness A MB686560 Insulation tape Connection
6m long or more
52B-46
SRS Air bag module
4. Set the air bag modules as follows: <Air bag module (drivers side)> (1) Take the SRS air bag adapter harness B that is connected to the wires, pass it beneath the old tyre wheel assembly, and connect it to the air bag module. (2) Pass the thick wire through the air bag module mounting hole, and then secure the air bag module to an old tyre with a wheel in it so that the pad on the module is facing upwards. Caution Leave some space below the wheel for the adaptor harness. If there is no space, the reaction when the air bag deploys could damage the adaptor harness.
Wires
Tyres without wheels
(3) Place three old tyres with no wheels on top of the tyre secured to the air bag module.
Wires
Air bag module
<Air bag module (front passengers side)> (1) Connect the deployment wires to the SRS air bag adaptor harness A, pass it beneath the tyre, and wheel assembly, and connect it to the air bag module. (2) Pass thick wires into the hole of the air bag module bracket, and secure them to the wheel of the old tyre with wheel (4 locations) with the air bag deployment surface facing upwards.
Deployment wire
Caution 1. Leave some space below the wheel for the deployment wires. If there is no space, the reaction of the air bag deployment could result in damage of the adaptor harness. 2. While deployment takes place, do not have the connector of the SRS air bag adaptor harness A inserted between the tyres.
SRS -
52B-47
Tyres without wheels
(3) Place four old tyres, without wheels, on top of the tyre secured to the air bag module, and secure all tyres with ropes (4 locations).
Deployment wire
Seat back assembly
<Side air bag module> (1) Place the seat back assembly so that the rear of the assembly is lying on the ground. (2) Connect SRS air bag adapter harness A (which is connected to the deployment harness) to the side air bag module connector.
SRS air bag adapter harness A MB686560
5. At a location as far away from the air bag module as possible, and from a shielded position, disconnect the two connected wires from each other, and connect them to the two terminals of the battery (which has been removed from the vehicle) to deploy the air bag. Caution 1. Before deployment, check carefully to be sure that no one is nearby. 2. The inflator will be quite hot immediately following deployment, so wait at least 30 minutes to allow it to cool before attempting to handle it. Although the gas resulting from air bag deployment is not poisonous, it should not be inhaled. Refer to the Deployed Air Bag Module or Operated Seat Belt Pre-tensioner Disposal Procedures (P.52B-49) for post-deployment handling instructions. 3. If the air bag fails to deploy when the procedures above are followed, do not go near the module. Contact your local distributor. 6. After deployment, dispose of air bag module according to the Deployed Air Bag Module or Operated Seat Belt Pre-tensioner Disposal Procedures. (Refer to P.52B-49.) SEAT BELT PRE-TENSIONER OPERATION Operate the seat belt pre-tensioner by the following procedure after it has been removed from the vehicle. Caution Operation of the seat belt pre-tensioner should be carried out in a clear, open space at least 5 meters away from people and other objects.
52B-48
6 m or more
SRS -
1. Remove the seat belt with pre-tensioner. (Refer to P.52B-40.) Caution The pre-tensioner safety mechanism should be engaged to prevent accidental operation of the pre-tensioner. 2. Tie a rope which is 6 meters or more in length to the seat belt pre-tensioner so that the pre-tensioner is level and the sensor side (the side with the white cover) is at the bottom when the pre-tensioner is suspended. 3. Disengage the pre-tensioner safety mechanism by the following procedure. Caution After disengaging the safety mechanism, the pre-tensioner can operate even if it is dropped by a distance of as little as 5 cm, so be extremely careful when handling the pre-tensioner in this condition.
Approx. 0.4 m
Sensor side (white cover side)
Retractor bracket Plate (A) Stopper
(1) Lift up the stopper and then bring the retractor bracket and plate (A) together so that the stopper tab goes into the hole in the retractor bracket. This will disengage the safety mechanism. (2) Use a bulldog clip to secure the retractor bracket and plate (A) so that they do not become separated.
Old tyre with wheel attached
Old tyres without wheels
4. Place the pre-tensioner down gently onto a solid base such as a concrete floor, and stack four tyres without wheels around it. Then place one more tyre with the wheel still attached on top, and pass the rope through the hole in the middle of the wheel. 5. Tie the tyres together with rope so that they do not slip apart.
5 m or more
6. From a distance of 5 meters away, pull the rope to raise the seat belt pre-tensioner off the ground by 20 cm or more.
20 cm or more
SRS -
52B-49
7. Release the rope so that the pre-tensioner drops down and operates from the force of the impact. Caution 1. Check that nobody is near the tyres before operating the pre-tensioner. 2. The seat belt pre-tensioner will be hot after it has operated, so leave it for 30 minutes or more to wait for it to cool down before handling it further. 3. If the safety mechanism has not been properly disengaged or if the cylinder is not at the bottom when the pre-tensioner is dropped, the pre-tensioner may not operate. In such cases, repeat the procedure from the beginning, while being careful to avoid applying shocks to the pre-tensioner. 8. After the seat belt pre-tensioner has operated, dispose of it according to the proper disposal procedures discribed below.
DEPLOYED AIR BAG MODULE OR OPERATED SEAT BELT PRE-TENSIONER DISPOSAL PROCEDURES
After deployment or operation, the air bag module and the seat belt pre-tensioner should be disposed of in the same manner as any other scrap parts, adhering to local laws and/or legislation that may be in force except that the following points should be carefully noted during disposal. 1. The inflator will be quite hot immediately following deployment, so wait at least 30 minutes to allow it cool before attempting to handle it. 2. Do not put water or oil on the air bag after deployment or on the seat belt pre-tensioner after operation. 3. There may be, adhered to the deployed air bag module or the operated seat belt pre-tensioner, material that could irritate the eye and/or skin, so wear gloves and safety glasses when handling a deployed air bag module or a operated seat belt pre-tensioner. IF AFTER FOLLOWING THESE PRECAUTIONS, ANY MATERIAL DOES GET INTO THE EYES OR ON THE SKIN, IMMEDIATELY RINSE THE AFFECTED AREA WITH A LARGE AMOUNT OF CLEAN WATER. IF ANY IRRITATION DEVELOPS, SEEK MEDICAL ATTENTION.
Strong vinyl bag
4. Tightly seal the air bag module and seat belt pre-tensioner in a strong vinyl bag for disposal.
Air bag module and seat belt pre-tensioner
NOTE The side air bag module does not contain any toxic sodium azides, so that the seat back assembly with built-in side air bag module can be disposed of in the same way as a seat without a side air bag. 5. Be sure to always wash your hands after completing this operation.
NOTES
54-1
CHASSIS ELECTRICAL
CONTENTS BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE SPECIFICATION . . . . . . . . . . . . . . . 4 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 4
Fluid Level and Specific Gravity Check . . . . . 4 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Battery Testing Procedure . . . . . . . . . . . . . . . . . . 6
54109000211
COMBINATION METERS . . . . . . . . . . . . 20
SERVICE SPECIFICATIONS . . . . . . . . . . . . 20 SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 21 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 22 CONTINUED ON NEXT PAGE
IGNITION SWITCH, ETACS-ECU AND IMMOBILIZER SYSTEM* . . . . . . . . . . . . . 7

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 7 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 7 IGNITION SWITCH, ETACS-ECU AND IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . 17
54-2
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 24
Speedometer Check . . . . . . . . . . . . . . . . . . . . . . 24 Tachometer Check . . . . . . . . . . . . . . . . . . . . . . . 24 Fuel Gauge Simple Check . . . . . . . . . . . . . . . . 25 Fuel Gauge Unit Check . . . . . . . . . . . . . . . . . . . 25 Engine Coolant Temperature Gauge Simple Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Engine Coolant Temperature Gauge Unit Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FRONT FOG LAMP . . . . . . . . . . . . . . . . 45

SERVICE SPECIFICATIONS . . . . . . . . . . . . 45 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 45 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 45
Front Fog Lamp Aiming . . . . . . . . . . . . . . . . . . 45 Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . 46
FRONT FOG LAMP . . . . . . . . . . . . . . . . . . . . 47 COMBINATION METERS . . . . . . . . . . . . . . . 28
HEADLAMP AND FRONT TURN-SIGNAL LAMP* . . . . . . . . . . . . . . 30

SERVICE SPECIFICATIONS . . . . . . . . . . . . 30 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 30 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 31 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 37
Headlamp Aiming . . . . . . . . . . . . . . . . . . . . . . . . 37 Intensity Measurement . . . . . . . . . . . . . . . . . . . . 38 Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . 39
REAR COMBINATION LAMP . . . . . . . . 48

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 48 REAR COMBINATION LAMP . . . . . . . . . . . 49
HIGH MOUNTED STOP LAMP . . . . . . 51 RHEOSTAT . . . . . . . . . . . . . . . . . . . . . . . . 52 HAZARD WARNING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 CIGARETTE LIGHTER . . . . . . . . . . . . . . 54 CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
HEADLAMP AND FRONT TURN-SIGNAL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SIDE TURN-SIGNAL LAMP . . . . . . . . . 44

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 55 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 44 CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 CONTINUED ON NEXT PAGE
54-3
RADIO AND TAPE PLAYER . . . . . . . . 56
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 56 RADIO AND TAPE PLAYER . . . . . . . . . . . . 72
SERVICE BRAKES (ABS) . . . . . . . . . . . . . . . . . Refer to GROUP 35B DOOR GLASS AND REGULATOR (POWER WINDOWS) . . . . . . . . . . . . . . . . . . . Refer to GROUP 42 DOOR HANDLE AND LATCH (DOOR LOCKING) . . . . . . . . . . . . . . . . . . . Refer to GROUP 42 KEYLESS ENTRY SYSTEM . . . . . . . . . . . . . . . . . . . Refer to GROUP 42 SUNROOF . . . . . . . . Refer to GROUP 42 WINDSHIELD WIPER AND WASHER . . . . . . . . . . . . . . . . . . . Refer to GROUP 51 REAR WIPER AND WASHER . . . . . . . . . . . . . . . . . . . Refer to GROUP 51 DOOR MIRROR (ELECTRONIC CONTROLLED DOOR MIRROR) . . . . . . . . . . . . . . . . . . . Refer to GROUP 51 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . . . . . . . . . . . Refer to GROUP 52B HEATER . . . . . . . . . . Refer to GROUP 55 AIR CONDITIONER . . . . . . . . . . . . . . . . . . . Refer to GROUP 55
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . 73 ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . 74 REAR WINDOW DEFOGGER . . . . . . . 77

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 77 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 77
Printed-heater Line Check . . . . . . . . . . . . . . . . . 77 Rear Window Defogger Relay Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
REAR WINDOW DEFOGGER SWITCH <VEHICLES WITH MANUAL A/C> . . . . . . 78
THEFT-ALARM SYSTEM . . . . . . . . . . . . 79
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 79 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 79
TRACTION CONTROL (TCL) . . . . . . . . . . . . . . . . . . . Refer to GROUP 13 RADIATOR FAN MOTOR . . . . . . . . . . . . . . . . . . . Refer to GROUP 14 AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . Refer to GROUP 23
54-4
CHASSIS ELECTRICAL - Battery

54100030028
BATTERY
Item Specific gravity of the battery fluid Specification 1.220 - 1.290 [20_C]
ON-VEHICLE SERVICE
Thermo meter Good Hydrometer
54100090026
FLUID LEVEL AND SPECIFIC GRAVITY CHECK

1. Inspect whether or not the battery fluid is between the UPPER LEVEL and LOWER LEVEL marks. 2. Use a hydrometer and thermometer to check the specific gravity of the battery fluid. Standard value: 1.220 - 1.290 [20_C] The specific gravity of the battery fluid varies with the temperature, so use the following formula to calculate the specific gravity for 20_C. Use the calculated value to determine whether or not the specific gravity is satisfactory. D20=Dt+0.0007 (t - 20) D20: Specific gravity of the battery fluid calculated for 20_C. Dt: Actually measured specific gravity t: Actually measured temperature
CHASSIS ELECTRICAL - Battery CHARGING
54-5
54100110029
1. When charging a battery while still installed in the vehicle, disconnect the battery cables to prevent damage to electrical parts. 2. The current normally used for charging a battery should be approximately 1/10th of the battery capacity. 3. When performing a quick-charging due to lack of time, etc., the charging current should never exceed the battery capacity as indicated in amperes. 4. Determining if charging is completed. (1) If the specific gravity of the battery fluid reaches 1.250 - 1.290 and remains constant for at least one hour. (2) If the voltage of each cell reaches 2.5 - 2.8 V and remains constant for at least one hour. Caution 1. Be careful since the battery fluid level may rise during charging. 2. Keep all sources of fire away while charging because there is a danger of explosion. 3. Be careful not to do anything that could generate sparks while charging. 4. When charging is completed, replace the battery caps, pour clean water over the battery to remove any sulfuric acid and dry.
54-6
TEST STEP
CHASSIS ELECTRICAL - Battery

54100120176
BATTERY TESTING PROCEDURE

(1) Turn headlamps on for 15 seconds. (2) Turn headlamps off for 2 minutes to allow battery voltage to stabilize. (3) Disconnect cables. OK Read open circuit voltage. OK: Open circuit voltage is more than 12.4 V (specific gravity: 1.240) OK NG
Charge battery at 5 amps. (see LOAD TEST RATE CHART)
Retest
(1) Connect a load tester to the battery. (2) Load the battery at the recommended discharge rate (see LOAD TEST RATE CHART) for 15 seconds. (3) Read voltage after 15 seconds, then remove load. (4) Compare the measured value with the minimum voltage (see LOAD TEST CHART). OK: Higher than minimum voltage OK Normal
NG
Replace battery
LOAD TEST RATE CHART

Battery type Charging time when fully discharged h [5-amp rated current charging] Load test (Amps) 75D26L 11 260 95D31L 14 310
LOAD TEST CHART

Temperature _C Minimum voltage V 21 and above 9.6 16 9.5 10 9.4 4 9.3 -1 9.1 -7 8.9 - 12 8.7 - 18 8.5
CHASSIS ELECTRICAL -
Ignition Switch, ETACS-ECU and Immobilizer System
54-7
IGNITION SWITCH, ETACS-ECU AND IMMOBILIZER SYSTEM

SPECIAL TOOL
Tool Number MB991502 Name MUT-II sub assembly Use D D D
54300060092
Immobilizer system check (Diagnosis display using the MUT-II) Registration of the ID code ETACS-ECU input signal checking
TROUBLESHOOTING
MUT-II
54300070477
IGNITION SWITCH DIAGNOSIS FUNCTION

INPUT SIGNAL INSPECTION POINTS <VEHICLES WITH ETACS-ECU> 1. Connect the MUT-II to the diagnosis connector. 2. If buzzer of the MUT-II sounds once when a switch is operated (ON/OFF), the ETACS-ECU input signal for that switch circuit system is normal.

Trouble symptom Communication with MUT-II is not possible. Communication with all systems is not possible. Communication with the one-shot pulse input signal only is not possible. While key hole illumination lamp is illuminated, ignition key is turned to the ON position but key hole illumination lamp does not switch off. (However, it switch off after 10 seconds.) Key hole illumination lamp remains illuminated. Even if drivers side door is opened, key hole illumination lamp does not illuminate. Inspection procedure No. 1 2 3 Reference page 54-8 54-8 54-8
4 5
54-9 54-9
54-8

The cause is probably a defect in the power supply system (including earth) for the diagnosis line. Refer to GROUP 13A - Troubleshooting.
Probable cause
D D Malfunction of connector Malfunction of harness wire
INSPECTION PROCEDURE 2 Communication with MUT-II is not possible. (Communication with the one-shot pulse input signal only is not possible.)
The cause is probably a defective one-shot pulse input signal circuit system of the diagnosis line.
Probable cause
D D D
Malfunction of connector Malfunction of harness wire Malfunction of ECU NG
Check the harness between the diagnosis connector and junction block. NG Repair
OK
Check the following connectors: C-20, C-134 and C-144 OK Check trouble symptom.
Repair
NG
Replace the ECU.
INSPECTION PROCEDURE 3 While key hole illumination lamp is illuminated, ignition key is turned to the ON position but key hole illumination lamp does not switch off. (However, it switch off after 10 seconds.)
The cause is probably a defective ignition switch input circuit or a defective ECU.
Probable cause
D D D
Malfunction of connector Malfunction of harness wire Malfunction of ECU
MUT-II Input Signal Inspection Ignition switch input signal OK: The MUT-II buzzer sounds once OK when the ignition key is turned to the ON or OFF position. NG Disconnect the junction block connector C-131, and measure at the harness side. D Voltage between the terminal (6) and earth OK: System voltage NG Check the harness wire between the ignition switch (IG1) and junction block, and repair if necessary. OK
Replace the ECU.
Check the following connectors: C-144 and C-131 OK Check trouble symptom.
NG
Repair
NG
Replace the ECU.
CHASSIS ELECTRICAL INSPECTION PROCEDURE 4 Key hole illumination lamp remains illuminated.
The cause is probably a harness short or a defective ECU.
54-9
Probable cause
D D Malfunction of harness wire Malfunction of ECU
When the connector C-134 of the junction block (1) is disconnected, does the lamp switch off? YES Replace the ECU.
NO
Check the harness wire between the key reminder switch and junction block, and repair if necessary.
INSPECTION PROCEDURE 5 Even if drivers side door is opened, key hole illumination lamp does not illuminate.
The cause is probably a defective key hole illumination lamp circuit system or a defective drivers side door switch input circuit system.
Probable cause
D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of drivers side door switch bulb connector harness wire ECU
MUT-II Input Signal Inspection Drivers side door switch input signal OK: The MUT-II buzzer sounds once NG when the drivers side door switch is ON. OK Key hole illumination lamp inspection OK Disconnect the key reminder switch connector C-109, and measure at the harness side. D Voltage between the terminal (2) and earth OK: System voltage OK Check the following connectors: C-109, C-134 and C-144 OK Check trouble symptom. NG Check the harness wire between the key reminder switch and junction block, and repair if necessary. NG NG
Drivers side door switch input circuit system inspection (Refer to Inspection Procedure 6 on P.54-10.)
Replace NG
Check the following connectors: L.H. drive vehicles: C-66, C-63, C-132, C-141 R.H. drive vehicles: C-62, C-14 OK Check trouble symptom.
Repair
NG
Repair
NG
Check the harness wire between the key reminder switch and junction block, and repair if necessary. OK Replace the ECU.
NG
Repair
54-10
INSPECTION PROCEDURE 6 Drivers side door switch input circuit system inspection
Door switch inspection (Refer GROUP 42 - Door Assembly.) OK Door switch earth inspection OK Disconnect the door switch connector E-09 <L.H. drive vehicles>, E-08 <R.H. drive vehicles>, and measure at the harness side. D Voltage between the terminal (2) and earth OK: System voltage OK Check trouble symptom. NG Check the following connectors: C-144 and C-143 OK Check trouble symptom. to NG Replace
NG
Repair NG
Repair
NG
Check the harness wire between the door switch and junction block, and repair if necessary.
NG
Replace the ECU.
IMMOBILIZER SYSTEM
Caution The ID code should always be re-registered when replacing the immobilizer-ECU.

Refer to GROUP 00 - How To Use Troubleshooting/Inspection Service Points.
DIAGNOSIS FUNCTION
DIAGNOSIS CODES CHECK Refer to GROUP 00 - How To Use Troubleshooting/Inspection Service Points. ERASING DIAGNOSIS CODES Refer to GROUP 00 - How To Use Troubleshooting/Inspection Service Points. Caution The diagnosis codes which result from disconnecting the battery cables cannot be erased.

Diagnosis code No. 11* 12* 21 31 32 33* Inspection items Transponder communication system ID code are not the same or are not registered Communication system between immobilizer-ECU and engine-ECU EEPROM abnormality inside immobilizer-ECU Ignition switch IG signal circuit system Starting prevention system activated due to incorrect operation.
54300710065
Reference page 54-11 54-11 54-12 54-12 54-12 54-13
NOTE *: Diagnosis code No. 11, No. 12 and No.33 are not recorded.
54-11
INSPECTION PROCEDURE FOR DIAGNOSIS CODES

Code No. 11 Transponder communication system
The ID code of the transponder is not sent to the immobilizer-ECU immediately after the ignition switch is turned to the ON position. If the engine is started while several ignition keys are in the vicinity, then interference between the different keys may occur, which will cause this code to be generated.
Probable cause
D D D D D Radio interference of ID codes Malfunction of the transponder Malfunction of the ignition key ring antenna Malfunction of harness or connector Malfunction of the immobilizer-ECU
Are there any other ignition keys in the vicinity of the ignition key being used for starting? No
Yes
Move other keys well away from the key being used. Check the trouble symptoms. NG
Does the engine start using the spare ignition key which has had the ID code registered? NG Diagnosis codes check
OK
Replace the ignition key that does not work.
Re-register the ID code. (Refer to P.54-19.)
Code No. 12 occurs To INSPECTION PROCEDURE FOR DIAGNOSIS CODE No. 12 (Refer to P.54-11.)
Code No. 11 occurs NG Check the continuity of the ignition key ring antenna. (Refer to P.54-18.) OK Check the following connectors: C-68, C-104 OK Check trouble symptoms. NG NG
Replace
Repair
Check the harness wire between immobilizer-ECU and key ring antenna. OK Replace the immobilizer-ECU.
NG
Repair
Code No. 12 ID code are not the same or are not registered
The ID code which is sent from the transponder is not the same as the ID code which is registered in the immobilizer-ECU.
Probable cause
D D The ID code in the ignition key being used has not been properly registered. Malfunction of the immobilizer-ECU NG
Replace the immobilizer-ECU.
54-12
Code No.21 Communication system between immobilizer-ECU and engine-ECU

After the ignition switch is turned to the ON position, the confirmation code is not received from the engine-ECU within the allowable time, or an abnormal code is received.
Probable cause
D D D Malfunction of harness or connector Malfunction of the engine-ECU Malfunction of the immobilizer-ECU
Is diagnosis code No. 54 being generated by the engine-ECU? YES
NO
Check the engine-ECU power source and the earth circuit. (Refer to GROUP 13A - Troubleshooting.)
Check the following connectors: C-68, C-81, C-38 <4G6> C-37, <6A1>, C-54 <4D6> OK Check trouble symptoms.
NG
Repair
NG
Check the harness wire between engine-ECU and immobilizer-ECU. OK Check trouble symptoms. NG Replace the immobilizer-ECU. OK Check trouble symptoms.
NG
Repair
NG
Code No. 31 EEPROM abnormality inside immobilizerECU

No data has been written to the EEPROM inside the immobilizer-ECU. NG
Probable cause
D Malfunction of the immobilizer-ECU
Code No.32 Ignition switch IG signal circuit system

The ignition switch signsl is not being input to the immobilizer-ECU.
Probable cause
D D D Malfunction of harness or connector Malfunction of the ignition switch Malfunction of the immobilizer-ECU NG
Check the input of the ignition switch IG signal. Measure at the immobilizer-ECU connector C-68. D Disconnect the connector, and measure at the harness side. D Voltage between 2 and body earth (Ignition switch: ON position) OK System voltage OK Replace the immobilizer-ECU.
NG
Check the following connectors: C-68, C-134, C-131 OK Check trouble symptoms. NG Check the fuse and the harness wire between ignition switch (IG) and immobilizer-ECU. OK Check trouble symptoms
Repair
NG
Repair
NG
Check the ignition switch. (Refer to 54-18.)
54-13
Code No.33 Starting prevention system activated due to incorrect operation

If the transponder ID code mismatches five times in succession, this code will be output. This code can be canceled by turning the ignition switch ON, and then turning it OFF after 16 minutes have passed. Turn the ignition switch ON and then turn it OFF after 16 minutes have passed. Re-register the ID code. (Refer to P.54-19.) Check trouble symptoms. NG Replace the ignition key. Check trouble symptoms. NG
Probable cause
D D Malfunction of the immobilizer-ECU Malfunction of the transponder
Replace the immobilizer-ECU

Trouble symptom Communication with MUT-II is impossible. Diagnosis code No. 54 has been generated by the engine-ECU. ID code cannot be registered using the MUT-II. Engine does not start (Cranking but no initial combustion). Malfunction of the immobilizer-ECU power source and earth circuit Inspection procedure No. 1 2 3 4 5 Reference page 54-14 54-14 54-15 54-15 54-16
54-14

Inspection Procedure 1 Communication with MUT-II is impossible.
The cause is probably that a malfunction of the diagnosis line or the immobilizer-ECU is not functioning.
Probable cause
D D D Malfunction of the diagnosis line Malfunction of harness or connector Malfunction of the immobilizer NG
Can the MUT-II communicate with the engine-ECU? YES
NO
Repair
Disconnect the immobilizer-ECU connector C-68 and check at the harness side. (Short-circuited harness wire between terminal No. 13 and No. 14) OK Check trouble symptoms. NG Replace the immobilizer-ECU.
NG
Repair
NG NG Repair
Check the harness wire between immobilizer-ECU and diagnosis connector. OK Check the immobilizer-ECU power supply and earth circuit. (Refer to INSPECTION PROCEDURE 5.) OK Check trouble symptoms.
NG
Inspection Procedure 2 Diagnosis code No. 54 has been generated by the engine-ECU.
There is a problem with communication between the engine-ECU and the immobilizer-ECU.
Probable cause
D D D Malfunction of harness or connector Malfunction of the immobilizer-ECU Malfunction of the engine-ECU
Check the following connectors: C-68, C-81, C-38 <4G6>, C-37 <6A1>, C-54 <4D6> OK Check trouble symptoms. NG Check the harness wire between engine-ECU and immobilizer-ECU. OK Is diagnosis code No. 21 being generated by the immobilizer-ECU? NO Check the immobilizer-ECU power supply and earth circuit. (Refer to INSPECTION PROCEDURE 5.)
NG
Repair
NG
Repair
YES
OK
Check trouble symptoms. NG Replace the immobilizer-ECU. NG Check trouble symptoms. NG Replace the engine-ECU.
CHASSIS ELECTRICAL Inspection Procedure 3 ID code cannot be registered using the MUT-II.
54-15
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the transponder the ignition key ring antenna harness or connector the immobilizer-ECU
The cause is probably that there is no ID code registered in the immobilizer-ECU, or there is a malfunction of the immobilizer-ECU.
No ignition key can be registered. YES Is a normal diagnosis code output? YES Check the immobilizer-ECU power source and earth circuit. (Refer to INSPECTION PROCEDURE 5.)
NO
Replace the ignition key that cannot be registered. To INSPECTION CHART FOR DIAGNOSIS CODE (Refer to P.54-10.) Check trouble symptoms. NG
NO
OK
Inspection Procedure 4 Engine does not start (cranking but no initial combustion).
If the fuel injectors are not operating, there might be a problem with the MPI system in addition to a malfunction of the immobilizer system. It is normal for this to occur if an attempt is made to start the engine using a key that has not been properly registered. NG
Probable cause
D D Malfunction of the MPI system Malfunction of the immobilizer-ECU
Check the system voltage during cranking OK: 8V or more OK Is the diagnosis code ouutput? No Check the fuel system (Refer to GROUP 13E - On-vehicle Service.) OK Check the power supply and earth circuit of the immobilizer (Refer to INSPECTION PROCEDURE 5) NG Repair
Check the battery. (Refer to P 54-4.)
Yes NG
To INSPECTION CHART FOR DIAGNOSIS CODE (Refer to P.54-10.) Repair
OK
Check trouble symptoms. NG Replace the immobilizer-EUC. Check trouble symptoms. NG Replace the Injection pump assembly.
54-16
Inspection Procedure 5 Malfunction of the immobilizer-ECU power supply and earth circuit
1. NG Measure at the immobilizer-ECU connector. D Disconnect the connector and measure at the harness side. 1. Voltage between 1 and earth and between 9 and earth <Petrol-powered vehicles> OK: System voltage 2 Continuity between 8 and earth OK: Continuity 2, 3. NG 3 Continuity between 16 and body earth OK: Continuity Check the following connectors: C-81, C-47 OK Check trouble symptoms. NG Repair
NG
Check the harness wire between immobilizer-ECU and engine control relay and repair if necessary.
Check the following connectors: L.H. drive vehicles: C-62. R.H. drive vehicles: C-63, C-64. OK Check trouble symptoms. NG Check the harness wire between immobilizer-ECU and body earth and repair if necessary.
NG
Repair
CHECK AT IMMOBILIZER-ECU
TERMINAL VOLTAGE CHECK CHART
Terminal No. 1 2
Signal Immobilizer-ECU power supply Ignition switch-IG
Checking requirements Ignition switch: ON Ignition switch: OFF Ignition switch: ON
Terminal voltage System voltage 0V System voltage 0V System voltage 0V
8 9 16
Immobilizer-ECU earth Immobilizer-ECU power supply Immobilizer-ECU earth
Always Ignition switch: ON Always
CHASSIS ELECTICAL -
Ignition Switch, ETACS-ECU and Immobolizer System
54-17
IGNITION SWITCH, ETACS-ECU AND IMMOBILIZER SYSTEM 54300210220

Caution: SRS Before removal of air bag module and clock spring, refer to GROUP 52B - Service Precautions and Air Bag Module and Clock Spring.
6 9
10 12 11 1
8 3 2
: metal clip position
ETACS-ECU removal steps 1. Junction block 2. ETACS-ECU Immobilizer-ECU removal steps 3. Hood lock release handle 4. Instrument under cover (Refer to GROUP 52A - Instrument Panel.) 5. Immobilizer-ECU
AA"
Ignition switch and ignition key ring antenna removal steps 3. Hood lock release handle 4. Instrument under cover (Refer to GROUP 52A - Instrument Panel.) 6. Steering wheel (Refer to GROUP 37A.) 7. Column cover, upper 8. Column cover, lower 9. Column switch (Refer to GROUP 37A - Steering Wheel and Shaft.) 10. Ignition key ring antenna 11. Steering lock cylinder 12. Ignition switch
54-18
CHASSIS ELECTICAL -

AA" STEERING LOCK CYLINDER REMOVAL 1. Insert the key in the steering lock cylinder and turn it to the ACC position. 2. Using a cross-tip (+) screwdriver (small) or a similar tool, push the lock pin of the steering lock cylinder inward and then pull the steering lock cylinder toward you.
Cross-tip (+) screwdriver
INSPECTION
54300220032
IGNITION SWITCH CONTINUITY CHECK 1. Remove the column cover lower and upper. 2. Disconnect the wiring connector from the ignition switch. 3. Operate the switch, and check the continuity between the terminals.
Ignition key position LOCK ACC ON START Terminal No. 1 2 3 4 5 6
IGNITION KEY RING ANTENNA CONTINUITY CHECK Use a circuit tester to check the continuity between the terminals.
CHASSIS ELECTICAL -
54-19
54300810062
ID CODE REGISTRATION METHOD
If using an ignition key that has just been newly purchased, or if the immobilizer-ECU has been replaced, you will need to register the ID codes for each ignition key being used into the immobilizer-ECU. (A maximum of eight different ID codes can be registered.) Moreover, when the immobilizer-ECU has been replaced, you will need to use the MUT-II to register the ID number that the user specifies into the immobilizer-ECU. (Refer to the MUT-II instruction manual for instructions on using the MUT-II.) Caution If registering of the ID codes is carried out all previously-registered codes will be erased. Accordingly, you should have ready all of the ignition keys that have already been registered.
1. Connect the MUT-II to the diagnosis connector. Caution Connection and disconnection of the MUT-II should always be carried out with the ignition switch in the OFF position. 2. Use the ignition key that is to be registered to turn the ignition switch to the ON position. 3. Use the MUT-II to register the ID code. If you are registering two or more codes, use the next key to be registered to turn the ignition switch to the ON position without disconnecting the MUT-II. 4. Disconnect the MUT-II. This completes the registration operation.
MUT-II
54-20
CHASSIS ELECTRICAL - Combination Meters

54300030215
COMBINATION METERS
Items Speedometer indication error km/h(mph) 40 (20) 80 (40) 120 (60) 160 (80) - (100) Tachometer indication error r/min 700 3,000 5,000 6,000 Fuel gauge unit resistance W Float point F Float point E Fuel gauge unit float height mm A (Float point F) B (Float point E) Fuel gauge resistance W Power supply and earth Power supply and fuel gauge Fuel gauge and earth Engine coolant temperature gauge resistance W Power supply and earth Power supply and engine coolant temperature gauge Engine coolant temperature gauge and earth Engine coolant temperature gauge unit resistance (at 70_C) W Standard value 40 - 48 (20 - 25) 80 - 92 (40 - 47) 120 - 136 (60 - 69) 160 - 180 (80 - 91) - (100 - 114) 100 150 250 300 42 112 7 28.6 159.9 111.5 98.2 101.0 111.5 53.6 165.0 10413.5
SEALANT
Items Engine coolant temperature gauge unit threaded portion Specified sealant 3M Adhesive nut locking No. 4171 or equivalent Remark Drying sealant
54300050037
54-21
54300060429
SPECIAL TOOLS
Tool Number MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222 Name Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe Use
Making voltage and resistance measurements during troubleshooting A: Connector pin contact pressure check B: Power circuit check C: Power circuit check D: Commercial tester connection
C D
54-22

5430070471
TROUBLESHOOTING
Trouble symptom Speedometer does not work. Tachometer does not work. Inspection procedure 1 2

Inspection Procedure 1 Speedometer does not work.
The cause may be a defective vehicle speed sensor circuit system or a defective speedometer. Vehicle speed sensor is also used by the engine-ECU and A/T-ECU.
Probable cause
D D D Malfunction of vehicle speed sensor Malfunction of speedometer Malfunction of harness or connector
1. NG Disconnect the combination meter connectors D-01, D-02 and D-03 and measure at the harness sides. 1. Measure the voltage between terminal No.25 and body earth when the vehicle is moved forwards and 2. NG backwards. OK: 4.7 V or more 2. Voltage between the terminal No.4 and body earth OK: System voltage (Ignition switch: ON) 3. Continuity between the terminal No.46 and body earth OK: Continuity OK 3. NG
Vehicle speed sensor circuit system inspection (Refer to Inspection Procedure 3 on P.54-23.) NG
Check the following connectors: D-03, C-135, C-131 OK Check trouble symptom.
Repair
NG
Check the harness wire between the power supply and combination meter, and repair if necessary.
Check the following connectors: C-25, D-01 OK Check trouble symptom. Replace the speedometer.
NG
Repair
NG
Check the harness wire between the body earth and combination meter, and repair if necessary.

Inspection Procedure 2 Tachometer does not work.
The ignition signal may not be input from the engine, or there may be a malfunction in the power supply or ground circuit.
54-23
Probable cause
D D Malfunction of tachometer Malfunction of harness or connector
1. NG Disconnect the combination meter connector D-03 and measure at the harness sides. 1. Measure the voltage between terminal No.8 and body earth. OK: 5 V 2. Continuity between the terminal No.7 and body earth OK: Continuity 3. Voltage between the terminal No.4 and body earth 2. NG OK: System voltage OK 3. NG
Check the following connectors: C-90, D-03 OK Check trouble symptom.
NG
Repair
NG
Check the harness wire between the distributor assembly <6A1> or engineECU <4G6, 4D6> and combination meter, and repair if necessary.
Check the following connectors: C-45, C-90, D-03 OK Check trouble symptom.
NG
Repair
NG
Check the harness wire between the combination meter and the body earth, and repair if necessary.
Check the following connectors: C-131, C-135, D-03 Replace the tachometer. OK Check trouble symptom.
NG
Repair
NG
Check the harness wire between the power supply and combination meter, and repair if necessary.
Inspection Procedure 3 Vehicle speed sensor circuit system inspection

Vehicle speed sensor inspection (Refer to P.54-29.) OK Disconnect the vehicle speed sensor connector B-67 <A/T> or B-66 <M/T> and measure at the harness side. 1. Voltage between the terminal No.3 and body earth OK: 4.5 V or more 2. Continuity between terminal No.2 and body earth OK: Continuity 3. Voltage between the terminal No.1 and body earth OK: System voltage (Ignition switch: ON) OK 3. NG Check the following connectors: B-65<M/T>, C-90, C-135, C-131 OK Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and power supply, and repair if necessary. NG 1. NG Check the following connectors: D-02, C-25, C-66, C-83, B-67 <A/T>, B-66 <M/T>, B-65 <M/T> NG Check trouble symptom. NG Check the harness wire between the vehicle speed sensor and combination meter, and repair if necessary. NG NG Repair NG Replace
2. NG Repair
Check the following connector: B-65 <M/T>, B-67 <A/T>, B-66 <M/T> OK Check trouble symptom. NG
Repair
Replace the speedometer.
Check the harness wire between the vehicle speed sensor and body earth, and repair if necessary.
54-24
ON-VEHICLE SERVICE
SPEEDOMETER CHECK
54300090176
Wheel chocks
1. Adjust tire pressure to the specified level. (Refer to GROUP 31 Service Specifications.) 2. Set the vehicle onto a speedometer tester and use wheel chocks to hold the rear wheels.
Tension bar
Front Anchor plate
3. To prevent the front wheel from moving from side to side, attach tension bars to the tie-down hook, and secure both ends to anchor plates. 4. To prevent the vehicle from launching, attach a chain or wire to the rear retraction hook, and make sure the end of the chain or wire is secured firmly. 5. Check if the speedometer indicator range is within the standard values. Caution Do not operate the clutch suddenly. Do not increase/decrease speed rapidly while testing. Standard values:
Standard (mph) 40 (20) 80 (40) 120 (60) 160 (80) - (100) indication km/h Allowable range km/h (mph) 40 - 48 (20 - 25) 80 - 92 (40 - 47) 120 - 136 (60 - 69) 160 - 180 (80 - 91) - (100 - 114)
Engine speed detection connector Tachometer
TACHOMETER CHECK
54300100176
1. Insert a paper clip in the engine speed detection connector from the harness side, and attach an external high quality tachometer. NOTE For tachometer check, use an external high quality inductive tachometer. 2. Compare the readings of the vehicle tachometer and the external tachometer at every engine speed, and check if the variations are within the standard values. Standard values: 700 r/min : 100 r/min 3,000 r/min : 150 r/min 5,000 r/min : 250 r/min 6,000 r/min : 300 r/min
Paper clip
CHASSIS ELECTRICAL - Combination Meters FUEL GAUGE SIMPLE CHECK

Remove the fuel gauge unit connector. Use the special tool to connect a test lamp (12 V - 3.4 W) to the harness connector.
54-25
54300110179
Fuel gauge Test lamp (12 V - 3.4 W) Earth MB991219
When the ignition switch is turned to ON, the test lamp illuminates. NG Repair the harness.
OK
The needle of the fuel gauge moves. NG Replace the fuel gauge.
OK
Replace the fuel gauge unit.
FUEL GAUGE UNIT CHECK

Remove the fuel gauge unit from the fuel tank. (Refer to GROUP 13F.)
54300120240
Fuel gauge unit Earth
FUEL GAUGE UNIT RESISTANCE 1. Check that resistance value between the fuel gauge terminal and ground terminal is at standard value when fuel gauge unit float is at point F (highest) and point E (lowest). Standard value: Point F: 4 2 W Point E: 112 7 W 2. Check that resistance value changes smoothly when float moves slowly between point F (highest) and point E (lowest).
54-26

FUEL GAUGE UNIT FLOAT HEIGHT Move float and measure the height A at point F (highest) and B at point E (lowest) with float arm touching stopper.
Point E B (lowest)
A Point F (highest)
Standard value: A: 28.6 mm B: 159.9 mm
Thermistor
Earth Thermistor Illuminated Not illuminated
THERMISTOR 1. Connect fuel gauge unit (thermistor) to battery via test lamp (12 V - 3.4 W). Immerse in water. 2. Condition is good if lamp goes off when the thermistor is immersed in water and comes on when it is taken out of water. Caution After finishing this test, wipe the unit dry and install it in the fuel tank.
CHASSIS ELECTRICAL - Combination Meters ENGINE COOLANT TEMPERATURE GAUGE SIMPLE CHECK
Remove the engine coolant gauge unit connector.
54-27
54300140215
Connect a test lamp (12 V - 3.4 W) between the harness side connector and the earth.
<4G6>
Earth
<6A1> Earth
Test lamp (12 V - 3.4 W)
Test lamp (12 V - 3.4 W)
Connector
Connector
<4D6> Test lamp (12 V - 3.4 W) MB991219
Earth
When the ignition switch is turned to ON, the test lamp illuminates. NG Repair the harness.
OK
The needle of the engine coolant temperature gauge moves. OK Replace the engine coolant temperature gauge unit.
NG
Replace the engine coolant temperature gauge.
54-28
CHASSIS ELECTRICAL - Combination Meters ENGINE COOLANT TEMPERATURE GAUGE UNIT 54300150041 CHECK
1. Bleed the engine coolant. (Refer to GROUP 00 Maintenance Service.) 2. Remove the engine coolant temperature gauge unit. 3. Immerse the unit in 70_C water to measure the resistance. Standard value: 104 13.5 W
4. After checking, apply the specified adhesive around the thread of engine coolant temperature gauge unit. Specified sealant: 3M Adhesive Nut Locking No. 4171 or equivalent 5. Add engine coolant. (Refer to GROUP 14 On-vehicle Service.)
11 Nm
COMBINATION METERS
54300290200
2
Combination meter removal steps 2. Meter bezel 3. Combination meter
Vehicle speed sensor removal steps D Air cleaner assembly 1. Vehicle speed sensor

Turn Shaft
54-29
5430060135
INSPECTION
Resistance 3 - 10 kW Ohmmeter
VEHICLE SPEED SENSOR CHECK 1. Remove the vehicle speed sensor and connect a 3 10 kW resistance as shown in the illustration. 2. Turn the shaft of the vehicle speed sensor and check that there is voltage between terminals 2 - 3. (1 turn = 4 pulses)
Power supply Fuel gauge
54300300132 FUEL GAUGE RESISTANCE CHECK 1. Remove the power supply tightening screw. 2. Use an ohmmeter to measure the resistance value between the terminals.
Earth
Standard value: Power supply - Earth: 111.5 W Power supply - Fuel gauge: 98.2 W Fuel gauge - Ground: 101.0 W Caution When inserting the testing probe into the power supply terminal, be careful not to touch the printed board.
Engine coolant temperature gauge
ENGINE COOLANT TEMPERATURE GAUGE RESISTANCE CHECK 1. Remove the power supply tightening screw. 2. Use an ohmmeter to measure the resistance value between the terminals. Standard value: Power supply - Earth: 111.5 W Power supply - Engine coolant temperature gauge: 53.6 W Engine coolant temperature gauge - Earth: 165.0 W Caution When inserting the testing probe into the power supply terminal, be careful not to touch the printed board.
Earth
Power supply
54-30
CHASSIS ELECTRICAL - Headlamp and Front Turn-Signal Lamp

54200300199
HEADLAMP AND FRONT TURN-SIGNAL LAMP

Items Headlight airming for low beam Vertical direction Horizontal direction Vertical direction Horizontal direction Standard value 60 mm below horizontal (H) Position where the 15 sloping section intersects the vertical line (V) 22 mm below horizontal (H) Parallel to direction of vehicle travel Limit -
Headlamp aiming for high beam Headlamp intensity cd
30,000 or more
54200060457
SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub assenbly Use ETACS-ECU input signal checking
MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222
Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe
Making voltage and resistance measurements during troubleshooting A: Connector pin contact pressure check B: Power circuit check C: Power circuit check D: Commercial tester connection
54-31
54200900063
TROUBLESHOOTING
The special tool (MB991223) should always be used to measure voltages and resistance when carrying out troubleshooting.
DIAGNOSTIC FUNCTION
INPUT SIGNAL INSPECTION POINTS <VEHICLES WITH ETACS-ECU> 1. Connect the MUT-II to the diagnosis connector. 2. If a buzzer of the MUT-II sounds once when a switch is operated (ON/OFF), the ETACS-ECU input signal for that switch circuit system is normal.
MUT-II

Trouble symptoms Communication with MUT-II is impossible. <Vehicles with ETACS-ECU> Trouble symptoms Communication with all systems impossible. is Inspection procedure 1 2 3
54200910103
Communication with one-shot pulse input signal only is impossible. The lighting monitor buzzer doesnt sound under the following conditions while tail lamps or headlamps illuminate. D When the ignition switch is turned to OFF and the drivers side door is open. Headlamp leveling does not occur when the headlamp leveling switch is operated. The headlamps do not illuminate when the vehicle is in the following condition and the ignition switch is at the ON position. However, the headlamps illuminate when the lighting switch is moved to the HEAD position. <Vehicles with daytime running lamp system> D Lighting switch: OFF D Passing switch: OFF The headlamps do not switch off when the vehicle is in the following condition and the lighting switch is moved to the TAIL position. <Vehicles with daytime running lamp system> D Ignition switch: OFF D Passing switch: OFF
5 6
54-34 54-35
54-36
54-32

Inspection Procedure 1 Communication with MUT-II is impossible. (Communication with all systems is impossible.)
The cause is probably a defective power supply system (including ground) for the diagnosis line. Refer to GROUP 13A - Troubleshooting.
Probable cause
Inspection Procedure 2 Communication with the MUT-II is impossible. (Communication with the one-shot pulse input signal only is impossible.)
The cause is probably a defective one-shot pulse input circuit system of the diagnosis line.
Probable cause
D D D
Malfunction of connector Malfunction of harness wire Malfunction of ETACS-ECU
Check the harness wire between the diagnosis connector and junction block. NG Repair
OK
Check the following connectors: C-20, C-134 OK Check trouble symptom.
NG
Repair
NG
Replace the ETACS-ECU.
Inspection Procedure 3 The ignition switch is turned to the OFF position and the drivers side door is opened while the tail lamps or headlamps are operating, but the lighting monitor buzzer does not sound.
The cause is probably a defective lighting switch input circuit system or a defective drivers side door switch input circuit system.
Probable cause
D D D
Malfunction of drivers side door switch Malfunction of harness or connector Malfunction of BUZZER-ECU or ETACS-ECU
Drivers side door switch input circuit system inspection (Refer to Inspection Procedure 4.) OK Check the following connectors: C-20, C-134 OK Check trouble symptom. NG
Repair
NG
Check the harness wire between the junction block and column switch. NG Repair
OK
Replace the BUZZER-ECU or ETACS-ECU.

Inspection Procedure 4 Drivers side door switch input circuit system inspection
Door switch inspection (Refer to GROUP 42 Door Assembly.) OK Door switch earth inspection OK Disconnect the door switch connector E-19 <L.H. drive vehicles>, E-08 <R.H. drive vehicles> and measure at the harness side. D Voltage between the terminal No. 2 and body earth OK: 5 V OK Check trouble symptom. NG Replace the BUZZER-ECU or ETACS-ECU. NG Check the following connectors: L.H. drive vehicles: E-19, C-144, C-145 R.H. drive vehicles: E-08, C-144, C-145 OK Check trouble symptom. NG Replace
54-33
NG
Repair NG
Repair
NG
Check the harness wire between the door switch and junction block, and repair if necessary.
54-34
Inspection procedure 5 Headlamp leveling does not occur when the headlamp leveling switch is operated.
The cause is probably a malfunction of the headlamp leveling switch circuit system or a malfunction of the headlamp leveling unit circuit system. If there is a blown fuse, there may also be a short-circuit in a harness.
Probable cause
D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of fuse the headlamp leveling switch connector harness the headlamp leveling unit
Headlamp leveling switch check (Refer to P.54-42.) OK Disconnect the headlamp leveling switch connector C-94 and measure at the harness side. D Continuity between terminal No.3 - earth OK: Continuity OK
NG
Replace
NG
Check the following connectors: C-94, A-33 OK Check trouble symptoms.
NG
Repair
NG
Check the harness between the headlamp leveling switch and body earth. Repair, if necessary.
1. Disconnect the headlamp leveling unit connectors A-12, A-33 and measure at the harness side. Both the left and right connectors of the headlamp leveling unit should be checked. 1 Voltage between terminal No.1 earth OK: System voltage 2 Continuity between terminal No.2 earth 2. OK: Continuity
NG
Check the following connectors: A-12, A-33, C-74, C-115 OK Check trouble symptoms.
NG
Repair
NG
Check the harness between the headlamp relay and the headlamp leveling unit Repair, if necessary. Repair
NG
Check the following connectors: A-12, A-33 OK Check trouble symptoms.
NG
OK
NG
Check the harness between the body earth and the headlamp leveling unit. Repair, if necessary. Repair
Disconnect the headlamp leveling unit (LH), headlamp leveling unit (RH) and headlamp leveling switch connectors A-12, A-33, C-94 and measure at the harness side. D Continuity between terminal No. 3 of the headlamp leveling unit (both) and terminal No. 4 of the headlamp leveling switch. OK: Continuity OK Malfunction of the headlamp leveling unit.
NG
Check the following connectors: A-12, A-33, C-115, C-74, C-94 OK Check trouble symptoms.
NG
NG
Check the harness between the headlamp leveling switch and the headlamp leveling unit (both). Repair, if necessary.
Replace

Inspection procedure 6 The headlamps do not illuminate when the vehicle is in the following condition and the ignition switch is moved to the ON position. However, they illuminate when the lighting switch is moved to the HEAD position. <Vehicles with daytime running lamp> D Lighting switch: OFF D Passing switch: OFF
The cause is probably a malfunction of the daytime running lamp control unit (DRL-ECU) circuit system. If there is a blown fuse, there may also be a short-circuit in a harness.
54-35
Probable cause
D D D D
of of of of
fuse connector harness the DRL-ECU
Headlamp P.54-42.)
relay
check OK
(Refer
to
NG
Replace
1. NG Disconnect the DRL-ECU connector A-37 and measure at the harness side. D Ignition switch: ON 1. Voltage between terminal (No.1) and earth OK: System voltage 2. Voltage between terminal (No.9) and earth 2. NG OK: System voltage 3. Continuity between terminal (No.2) and earth OK: Continuity OK 3. NG
Check the following connectors: A-37, C-14, C-63, C-132, C-131 OK Check trouble symptoms.
NG
Repair
NG
Check the harness between the DRLECU and the ignition switch. Repair, if necessary.
Check the following connectors: A-37, C-14, C-116, B-18X OK Check trouble symptoms. NG Check the harness between the DRLECU and the headlamp relay. Repair, if necessary.
Check the following connectors: A-37, C-14 OK Check trouble symptoms. NG
Check the harness between the DRLECU and the body earth. Repair, if necessary.
Malfunction of the DRL-ECU.
Replace
54-36
Inspection procedure 7 The headlamps do not switch off when the vehicle is in the following condition and the lighting switch is moved to the TAIL position. <Vehicles with daytime running lamp> D Ignition switch: OFF D Passing switch: OFF
The cause is probably a malfunction of the daytime running lamp control unit (DRL-ECU) circuit system. If there is a blown fuse, there may also be a short-circuit in a harness.
Probable cause
D D D D D
Malfunction Malfunction Malfunction Malfunction Malfunction
of of of of of
fuse connector harness the tail lamp relay the DRL-ECU
Lighting switch check (Refer to P.54-41.) OK Disconnect DRL-ECU connector A-37 and measure at the harness side. D Continuity between terminal (2) earth OK: Continuity OK Tail lamp relay check (Refer to P.54-40.) OK Disconnect the DRL-ECU connector A-37 and measure at the harness side. D Continuity between terminal (5) earth OK: System voltage OK Malfunction of the DRL-ECU
NG
Replace
NG
Check the following connectors: A-37, C-14 OK Check trouble symptoms.
NG
Repair
NG
Check the harness between the DRLECU and body earth. Repair, if necessary.
Replace NG NG
Check the following connectors: A-37, C-14, C-116, B-14X OK Check trouble symptoms.
Repair
NG
{{36#1}}
Replace
54-37
54200090173
ON-VEHICLE SERVICE
HEADLAMP AIMING
<USING A BEAMSETTING EQUIPMENT> 1. The headlamps should be aimed with the proper beamsetting equipment, and in accordance with the equipment manufactures instructions. NOTE If there are any regulations pertinent to the aiming of headlamps in the area where the vehicle is to be used, adjust so as to meet those requirements. 2. Alternately turn the adjusting screw to adjust the headlamp aiming. (Refer to P.54-38.) 3. With the engine running at 2,000 r/min. aim the headlamp.
<USING A SCREEN> 1. Inflate the tyres to the specified pressures and there should be no other load in the vehicles other than driver or substituted weight of approximately 75 kg placed in drivers position. 2. Set the distance between the screen and the centre marks of the headlamps as shown in the illustration.
Screen
5m
(V) Distance of vertical direction (H) Lamp centre 15 High intensity zone
3. Check if the beam shining onto the screen is at the standard value. Standard value: <For lower beam adjustment> (Vertical direction) 60 mm below horizontal (H) (Horizontal direction) Position where the 15_ sloping section intersects the vertical line (V)
54-38

Standard value: <For upper beam adjustment>
(V) Lamp centre
(H)
(Vertical direction) 22 mm below horizontal (H) (Horizontal direction) Parallel to direction of vehicle travel
Centre of high intensity zone
Distance High intensity of vertical zone direction
Caution 1. When making the aiming adjustment, be sure to mask those lamps which are not being adjusted. 2. When it is difficult, because of outside light, to distinguish the light/dark dividing line, use a curtain, screen or similar material to reduce the effects of the outside light.
4. Alternately turn the adjusting screw to adjust the headlamp aiming.

Horizontal direction adjustment (Lower beam)
Caution Be sure to adjust the aiming adjustment screw in the tightening direction.
INTENSITY MEASUREMENT
Horizontal direction adjustment (Upper beam) Vertical direction adjustment (Upper beam)
54200100135
Using a photometer, and following its manufactures instruction manual, measure the headlamp intensity and check to be sure that the limit value is satisfied. Limit: 30,000 cd or more NOTE 1. When measuring the intensity, maintain an engine speed of 2,000 r/min, with the battery in the charging condition. 2. There may be special local regulations pertaining to headlamp intensity, be sure to make any adjustments necessary to satisfy such regulations. 3. If an illuminometer is used to make the measurements, convert its values to photometer values by using the following formula. I = Er2 Where: I = intensity (cd) E = illumination (lux) r = distance (m) from headlamps to illuminometer
CHASSIS ELECTRICAL - Headlamp and Front Turn-Signal Lamp BULB REPLACEMENT

<Headlamp Bulb> 1. Disconnect the connector. 2. Remove the socket cover.
54-39
54200130189
Socket cover Spring Spring
3. Unhook the spring which secures the bulb, and then remove the bulb. Caution Do not touch the surface of the bulb with hands or dirty gloves. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing.
<Position Lamp Bulb> 1. Disconnect the connector, and then remove the socket cover of headlamp lower beam. 2. Pinch the spring and pull out the position lamp bulb.
Spring
<Turn-signal Lamp Bulb> 1. Disconnect the connector. 2. Turn the bulb socket counterclockwise together with the bulb, and remove the bulb. Caution If the bulb socket is not securely installed, the lens will moisten, or water will get inside the lamp unit, so the bulb socket should be securely installed.
54-40

54200240141
HEADLAMP AND FRONT TURN-SIGNAL LAMP

CAUTION: SRS Before removal of air bag module and clock spring, refer to GROUP 52B - Service Precautions and Air Bag Module and Clock Spring.
5 Nm
5 Nm
4 6
5 Nm
1. Column switch <Lighting switch and dimmer/passing switch> (Refer to GROUP 37A - Steering Wheel and Shaft.) Headlamp leveling switch removal steps 2. Switch bezel 3. Headlamp leveling switch
AA"
Headlamp removal steps 4. Radiator grille 5. Front turn-signal lamp 6. Headlamp
CHASSIS ELECTRICAL - Headlamp and Front Turn-Signal Lamp REMOVAL SERVICE POINT
54-41
AA" RADIATOR GRILLE REMOVAL Remove the radiator grille by pushing the tab of the radiator grille clips in the direction of the arrows with a flat-tipped screwdriver, while lightly pulling the radiator grille towards you.
Connector A
INSPECTION
54200250045
LIGHTING SWITCH, DIMMER/PASSING SWITCH AND TURN-SIGNAL LAMP SWITCH CHECK

Switch position Connector Aterminal No. 1 LIGHTING SWITCH OFF TAIL HEAD DIMMER/ PASSING SWITCH LOWER UPPER PASSING TURNSIGNAL LAMP SWITCH RH OFF LH
*1 *2
Connector Bterminal No. 6 3 5 6 7 8 9
Connector B
NOTE 1. *1 indicates continuity when the dimmer switch is in the lower position. 2. *2 indicates continuity when the dimmer switch is in the upper position.
54-42

HEADLAMP RELAY AND TAIL LAMP RELAY CHECK
Headlamp relay
Battery voltage Supplied Not supplied
Tail lamp relay
HEADLAMP LEVELING SWITCH CHECK Check the resistance between the terminals when the headlamp leveling switch is operated. Standard value:
Resistance measurement terminal No. Between 3 and 4 W Between 4 and 6 W Between 3 and 6 W Switch position 0 1,235 548 1,003 1 1,114 669 2 977 806 3 862 921 4 747 1,036

DAYTIME RUNNING LAMP RELAY CHECK
Battery voltage
Daytime running lamp relay
54-43
Supplied Not supplied
54-44
CHASSIS ELECTRICAL - Side Turn-signal Lamp

54200060105
SIDE TURN-SIGNAL LAMP

SPECIAL TOOL
Tool Number MB990784 Name Ornament remover Use Removal of side turn-signal lamp
MB990784
54200330091
AA" SIDE TURN-SIGNAL LAMP REMOVAL Use a special tool to remove the lock from the fender panel, and then remove the side turn-signal lamp.
Fender panel

Hook
"AA SIDE TURN-SIGNAL LAMP INSTALLATION 1. Fit the lock into the fender panel. 2. Push the side turn-signal lamp into the fender, and secure it with the hook.
Fender panel
CHASSIS ELECTRICAL - Front Fog Lamp
54-45
54200030069
FRONT FOG LAMP

Items Front fog lamp aiming Vertical direction Horizontal direction Standard value 100 mm below horizontal (H) Parallel to direction of vehicle travel
SPECIAL TOOL
Tool Number MB990784 Name Ornament remover Use Removal of switch garnish
54200060464
Parabola type Lamp centre
Unit: mm
ON-VEHICLE SERVICE
FRONT FOG LAMP AIMING
54200110138
76
1. Measure the centre of the fog lamps, as shown in the illustration.
28
Projector type
37
Lamp centre
49
Screen
2. Set the distance between the screen and the centre of the fog lamps as shown in the illustration. 3. Inflate the tyres to the specified pressures and there should be no other load in the vehicles other than driver or substituted weight of approximately 75 kg placed in the drivers position. 4. With the engine running at 2,000 r/min, aim the fog lamp.
5m
54-46
Lamp centre

5
Distance of vertical direction
Check if the beam shining onto the screen is at the standard value. Standard value: (Vertical direction) 100 mm below horizontal (H) (Horizontal direction) Parallel to direction of vehicle travel
Centre of high intensity zone
High intensity zone
Parabola type Adjusting screw
NOTE The horizontal direction is non-adjustable. If the deviation of the light beam axis exceeds the standard value, check to be sure that the mounting location or some other point is not defective. Caution When making the aiming adjustment, be sure to mask those lamps which are not being adjusted.
Projector type Adjusting screw
BULB REPLACEMENT
1. Remove the fog lamp bezel. 2. Remove the fog lamp unit.
54200130196
Fog lamp rear cover
Fog lamp rear cover
3. Undo the fog lamp rear cover. 4. Unhook the spring which secures the bulb and then remove the bulb. Caution Do not touch the surface of the bulb with hands or dirty gloves. If the surface does become dirty, clean it with alcohol or thinner, and let it dry thoroughly before installing.
Spring
54-47
54200150161
FRONT FOG LAMP

5 4
5 4
Front fog lamp switch removal steps 1. Side air outlet 2. Front fog lamp switch
Front fog lamp removal steps 3. Fog lamp bezel 4. Fog lamp D Front bumper (Refer to GROUP 51.) 5. Fog lamp bracket
54-48
CHASSIS ELECTRICAL - Rear Combination Lamp

54200060471
REAR COMBINATION LAMP

SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub assembly Use ETACS-ECU input signal checking
MB990784
Ornament remover
Removal of side air outlet (L.H.)
CHASSIS ELECTRICAL - Rear Combination Lamp
54-49
54200450094
REAR COMBINATION LAMP

Caution: SRS Before removal of air bag module and clock spring, refer to GROUP 52B - SRS Service Precautions and Air Bag Module and Clock Spring.
3 2 1 <Sedan>
5 Nm
4 <Wagon> 5 6
5 Nm
5 Nm
7 9
1. Column switch <Lighting switch and turn-signal lamp switch> (Refer to GROUP 37A - Steering Wheel and Shaft.) Rear fog lamp switch removal steps 2. Side air outlet 3. Rear fog lamp switch Rear combination lamp removal steps <Sedan>
AA"
D Rear end side trim (L.H.) D Side box (L.H.) 4. Rear combination lamp Rear combination lamp removal steps <Wagon> 5. Maintenance lid 6. Tailgate lamp lid 7. Rear combination lamp D Tail gate waterproof film (Refer to GROUP 42.) 8. Tailgate lamp 9. Packing
54-50
CHASSIS ELECTRICAL - Rear Combination Lamp REMOVAL SERVICE POINT

AA" REAR COMBINATION LAMP REMOVAL <SEDAN> 1. Turn up the trunk room rear side trim as shown in the figure, and remove the mounting nut and disconnect the connector. 2. Remove the rear combination lamp.
Trunk room rear side trim
INSPECTION
54200460035
LIGHTING SWITCH AND TURN-SIGNAL LAMP SWITCH CHECK Refer to P.54-41. TAIL LAMP RELAY CHECK <Vehicles with Daytime Running Lamp System> Refer to P.54-42.
CHASSIS ELECTRICAL - High Mounted Stop Lamp
54-51
54200510204
HIGH MOUNTED STOP LAMP

<Sedan> 3 <Wagon>
2 1 1
3 2
Removal steps <Sedan> 1. Socket assembly 2. Bulb 3. High mounted stop lamp
Removal steps <Wagon> 1. Cover 2. Lamp unit 3. Bulb 4. Socket assembly
54-52
CHASSIS ELECTRICAL - Rheostat

54200600093
RHEOSTAT
2
Removal steps 1. Meter bezel assembly 2. Rheostat
40W
INSPECTION
54200610034
1. Connect the battery and the test bulb (40W) as shown in the illustration. 2. Operate the rheostat, and if the brightness changes smoothly without switching off, then the rheostat function is normal.
CHASSIS ELECTRICAL - Hazard Warning Lamp Switch
54-53
54200660121
HAZARD WARNING LAMP SWITCH

AA"
Removal steps D Center console panel (Refer to GROUP 52A.) D A/C-ECU or heater control panel (Refer to GROUP 55.) 1. Center outlet assembly 2. Hazard warning lamp switch

AA" CENTER OUTLET ASSEMBLY REMOVAL Press the tabs indicated in the illustration, and pull the center outlet assembly to remove it.
INSPECTION
Switch position OFF ON Terminal No. 1 2 3 4 5 6 7 9
54200670155
ILL ILL
10
54-54
CHASSIS ELECTRICAL - Horn/Cigarette Lighter
HORN
Horn relay Theft-alarm horn relay
54300800038
INSPECTION
Switch position Terminal No. 1 Power is not supplied Power is supplied 3 4 5
CIGARETTE LIGHTER
Element Spot
54300570083
INSPECTION
D D Take out the plug, and check for a worn edge on the element spot connection, and for shreds of tobacco or other material on the element. Using a circuit tester, check the continuity of the element.
CHASSIS ELECTRICAL - Clock
54-55
54300060436
CLOCK
SPECIAL TOOL
Tool Number MB990784 Name Ornament remover Use Removal of center display bezel
CLOCK
1 2
54300590072
AA" AA"
Removal steps 1. Center display bezel 2. Clock

AA" CENTER DISPLAY BEZEL/CLOCK REMOVAL Use the special tool (MB990784) to pry up the tabs indicated in the illustration, and remove the center display bezel and the clock.
54-56
CHASSIS ELECTRICAL - Radio and Tape Player

54400070227
RADIO AND TAPE PLAYER

TROUBLESHOOTING
QUICK-REFERENCE TROUBLESHOOTING CHART
Items Noise Problem symptom Noise appears at certain places when travelling (AM). Noise appears at certain places when travelling (FM). Mixed with noise, only at night (AM). Broadcasts can be heard but both AM and FM have a lot of noise. There is more noise either on AM or on FM. There is noise when starting the engine. Some noise appears when there is vibration or shocks during travelling. Noise sometimes appears on FM during travelling. Ever-present noise. Radio When switch is set to ON, no power is available. No sound from one speaker. There is noise but no reception for both AM and FM or no sound from AM, or no sound from FM. Insufficient sensitivity. Distortion on AM or on both AM and FM. Distortion on FM only. Too few automatic select stations. Insufficient memory (preset stations are erased). NOTE Refer to problem symptoms of AM radio for MW radio.
Relevant chart A- 1 A- 2 A- 3 A- 4 A- 5 A- 6 A- 7 A- 8 A- 9 B- 1 B- 2 B- 3 B- 4 B- 5 B- 6 B- 7 B- 8

Items Tape player Problem symptom Cassette tape will not be inserted. No sound. No sound from one speaker. Sound quality is poor, or sound is weak. Cassette tape will not be ejected. Uneven revolution. Tape speed is fast or slow. Faulty auto reverse. Tape gets caught in mechanism. Motor antenna Motor antenna wont extend or retract. Motor antenna extends and retracts but does not receive.
54-57
Relevant chart C- 1 C- 2 C- 3 C- 4 C- 5 C- 6 C- 7 C- 8 D- 1 D- 2
CHART
A. NOISE A - 1 Noise appears at certain places when travelling (AM).
Is there a particular structure? Yes Find out the following information from the user: 1. Place 2. Locality conditions (valley, mountain, etc.) 3. Name and frequency of stations affected by noise No Do the following measures eliminate the noise? 1. Change to a different station with a strong signal to boost resistance to interference. 2. Suppress high tones to reduce noise. 3. Extend antenna completely. No Yes OK
If due to vehicle noise: It may not be possible to prevent noise if the signal is weak.
If due to external noise: In almost all cases, prevention on the receiver side is impossible. Weak signals especially are susceptible to interference.
If there is more noise than other radios, find out the noise conditions and the name and frequency of the receiving stations from the user, and consult with the service centre.
54-58
A - 2 Noise appears at certain places when travelling (FM).

Do the following measures eliminate the noise? D D D Change to a different station with a strong signal to boost resistance to interference. Suppress high tones to reduce noise. Extend antenna completely. No If there is more noise than other radios, find out the noise conditions and the name and frequency of the receiving stations from the user, and consult with the service centre. Yes OK
NOTE About FM waves: FM waves have the same properties as light, and can be deflected and blocked. Wave reception is not possible in the shadow of obstructions such as buildings or mountains. 1. The signal becomes weak as the distance from the stations transmission antenna increases. Although this may vary according to the signal strength of the transmitting station and intervening geographical formation or buildings, the area of good reception is approx. 20 - 25 km for stereo reception, and 30 - 40 km for monaural reception. 2. The signal becomes weak when an area of shadow from the transmitting antenna (places where there are obstructions such as mountains or buildings between the antenna and the car), and noise will appear. <This is called first fading, and gives a steady buzzing noise.>
FM Broadcast Good Reception Areas
3. If a direct signal hits the antenna at the same time as a signal reflected by obstructions such as mountains or buildings, interference of the two signals will generate noise. During travelling, noise will appear each time the vehicles antenna passes through this kind of obstructed area. The strength and interval of the noise varies according to the signal strength and the conditions of deflection. <This is called multipath noise, and is a repetitious buzzing.> 4. Since FM stereo transmission and reception has a weaker field than monaural, it is often accompanied by a hissing noise.
FM Signal Characteristics and Signal Interference First fading interference
10 kW output FM broadcast
For stereo: 20 - 25 km For monaural: 30 - 40 km For home stereos: 80 - 90 km
Multipath interference

A - 3 Mixed with noise, only at night (AM). The following factors can be considered as possible causes of noise appearing at night. 1. Factors due to signal conditions: Due to the fact that long-distance signals are more easily received at night, even stations that are received without problem during the day may experience interference in a general worsening of reception conditions. The weaker a station is the more susceptible it is to interference,
Is the noise still obvious even with the lamps OFF? Yes Do the following measures eliminate the noise? D D Tune to a station with a strong signal. Tune to a station with a strong signal without completely extending the antenna. No No
54-59
and a change to a different station or the appearance of a beating sound* may occur. Beat sound*: Two signals close in frequency interfere with each other, creating a repetitious high-pitched sound. This sound is generated not only by sound signals but by electrical waves as well. 2. Factors due to vehicle noise: Alternator noise may be a cause.
Yes
OK
Does the noise fade away when the vehicle harness is moved away from the radio chassis? (if the harness is not in the proper position.) No
Yes
OK
If there is more noise than other radios, consult a service centre.
54-60
A-4 Broadcasts can be heard but both AM and FM have a lot of noise.
(1)
Noise occurs when the engine is stopped. Yes Do the following measures eliminate the noise? D D D Tune to a station with a strong signal. Extend the antenna completely. Adjust the sound quality to suppress high tones. No Is the radio body earth mounted securely? Yes Is the antenna plug properly connected to the radio? Yes Is the antenna itself in good condition or is it properly mounted? Yes Yes OK Inspect the vehicles noise suppressor. (Refer to A-6.)
(2)
Noise occurs when the engine in running.
No
Securely tighten the nuts for the body earth. Correctly attach the antenna plug.
No
No
Clean the antenna plug and earth wire mounting area. Mount the antenna securely.
Is the noise eliminated? No
Yes
OK
If there is more noise than other radios, consult a service centre.
NOTE About noise encountered during FM reception only. Due to differences in FM and AM systems, FM is not as susceptible as AM to interference from engines, power lines, lightning, etc. On the other hand, there are cases due to the characteristics
of FM waves of noise or distortion generated by typical noise interference (first fading and multipath). (Refer to A - 2.) <Noise (hissing) occurs in weak signal areas such as mountainous regions, but this is not due to a problem with the radio.>

A - 5 There is more noise either on AM or on FM. 1. There is much noise only on AM. Due to differences in AM and FM systems, AM is more susceptible to noise interference.
Were conditions such as the following present when noise was received? D D D D D D Yes Lightning was flashing. A motorcycle was passing. A vehicle passed close by, but it appeared to be a vehicle generating a particularly large amount of noise radiation. Passed beneath a power line. Passed under a bridge. Passed beneath a telephone line. Passed close by a signal generator. Passed close by some other source of electrical noise. No Continue to check for static; when static is detected, check for the conditions listed above. No If the problem is particularly worse than other radios, consult a service centre. Yes
54-61
Noise prevention on the radio side is difficult. If the problem is particularly worse than other radios, consult a service centre.
2. There is much noise only on FM. Due to differences in FM and AM systems, FM is not as susceptible as AM to interference from engines, power lines, lightning, etc. On the other hand, there are cases due to the characteristics of FM waves of noise or
distortion generated by typical noise interference (first fading and multipath). (Refer to A - 2) <Noise (hissing) occurs in weak signal areas such as mountainous regions, but this is not due to a problem with the radio.>
54-62
A - 6 There is noise when starting the engine.

Noise type Sounds are in parentheses ( ). AM, FM: Ignition noise (Popping, snapping, cracking, buzzing) Conditions D Cause Remedy Check or replace the earth cable.
Increasing the en- D gine speed causing the popping D sound to speed up, and volume decreases. Disappears when the ignition switch is turned to ACC.
Mainly due to the D spark plugs. Due to the engine noise.
Earth cable
D Other electrical components Static electricity (Cracking, crinkling) Noise may appear as electrical components become older. Disappears when the vehicle is completely stopped. Severe when the clutch is engaged. Various noises are produced depending on the body part of the vehicle. Occurs when parts or wiring move for some reason and contact metal parts of the body. Due to detachment from the body of the front hood, bumpers, exhaust pipe and muffler, suspension, etc.
Check or replace the noise capacitor.
Repair or replace electrical components.
Return parts or wiring to their proper position.
D D
Tighten the mounting bolts securely. Cases where the problem is not eliminated by a single response to one area are common, due to several body parts being imperfectly earthed.
Caution 1. Connecting a high tension cable to the noise filter may destroy the noise filter and should never be done. 2. Check that there is no external noise. Since failure caused by this may result in misdiagnosis due to inability to identify the noise source, this operation must be performed. 3. Noise prevention should be performed by suppressing strong sources of noise step by step. NOTE 1. Capacitor The capacitor does not pass D.C. current, but as the number of waves increases when it
passes A.C. current, impedance (resistance against A.C.) decreases, and current flow is facilitated. A noise suppressing condenser which takes advantage of this property is inserted between the power line for the noise source and the earth. This suppresses noise by earthing the noise component (A.C. or pulse signal) to the body of the vehicle. 2. Coil The coil passes D.C. current, but impedance rises as the number of waves increases relative to the A.C. current. A noise suppressing coil which takes advantage of this property is inserted into the power line for the noise source, and works by preventing the noise component from flowing or radiating out of the line.

A - 7 Some noise appears when there is vibration or shocks during travelling.
Are connectors properly connected? Yes Does noise appear when the radio switch is turned on while the vehicle is stopped and the radio is struck while tuned away from a station? Yes No No Ensure proper connection.
54-63
Static electricity noise: Body static electric from the shock absorber rubber bushings used to prevent vibration, tyres, etc. occurs because of separation from the earth, causing a buzzing noise. Since no measures can be taken on the radio side, other steps should be taken to discharge the static electricity of the vehicle body. Tighten the screw securely.
Is the radio correctly earthed? (Is the mounting screw tightened securely?) Yes Is the antenna correctly earthed? (If noise appears when the antenna is moved, this means the earth is not securely connected.) Yes Repair or replace radio.
No
No
If rust is present at the antenna earth screw, clean and tighten the earth securely.
A - 8 Noise sometimes appears on FM during travelling.

Does the problem clear up when returned? No Does the problem appear only in certain locations and only with certain stations? No Are connectors properly connected? Yes Does noise appear when the radio switch is turned on while the vehicle is stopped and the radio is struck while tuned away from a station? Yes Yes Yes OK Due to electrical field conditions. (Multipath noise*, fading noise*).
No No
Check connector connections. Static electricity noise: Body static electric from the shock absorber rubber bushings used to prevent vibration, tyres, etc. occurs because of separation from the earth, causing a buzzing noise. Since no measures can be taken on the radio side, other steps should be taken to discharge the static electricity of the vehicle body.
Is the radio body correctly earthed? (Is the mounting screw tightened securely?) Yes Is the antenna correctly earthed? (If noise appears when the antenna is moved, this means the earth is not securely connected.) Yes Repair or replace radio.
No
Tighten the screw securely.
No
If rust is present at the antenna earth screw, clean and tighten the earth securely.
About multipath noise and fading noise Because the frequency of FM waves is extremely high, it is highly susceptible to effects from geological formations and buildings. These effects disrupt the broadcast signal and obstruct reception in several ways. D Multipath noise This describes the echo that occurs when the broadcast signal is reflected by a large
obstruction and enters the receiver with a slight time delay relative to the direct signal (repetitious buzzing). Fading noise This is a buzzing noise that occurs when the broadcast beam is disrupted by obstructing objects and the signal strength fluctuates intricately within a narrow range.
54-64
A - 9 Ever-present noise. Noise is often created by the following factors, and often the radio is OK when it is checked individually. D Travelling conditions of the vehicle D Terrain of area travelled through D Surrounding buildings D Signal conditions D Time period B. RADIO B - 1 No power is supplied when the switch is set to ON.
Is dedicated fuse No. 6 blown or is the circuit open? No Is the connector at the back of the radio connected properly? Yes Disconnect and check the connector at the rear of the radio. Is the ACC power (12 V) being supplied to the radio? Yes Repair or replace radio. Yes Replace fuse or repair harness. Connect connector securely. Repair harness.
For this reason, if there are still problems with noise even after the measures described in steps A - 1 to A - 8 have been taken, get information on the factors listed above as well as determining whether the problem occurs with AM or FM, the station names, frequencies, etc., and contact a service centre.
No No
B - 2 No sound from one speaker.

Check to see if there is any sound when attached to another radio. No Remove the connector on the back of the radio and check the speaker harness for conductance. No Check the speaker for conductance. No Repair or replace speaker. Yes Repair or replace radio.
Yes
It conducts electricity but is shorted out.
Repair speaker harness.
Yes
Repair speaker harness and ensure proper connection of relay connectors.
54-65
B - 3 There is noise but no reception for both AM and FM or no sound from AM, or no sound from FM.
Is the check being conducted under special electrical field conditions? No Yes
Example: In an underground garage or inside a building.
Is proper performance obtained when the vehicle is moved? No Does tuning solve the problem? No Are the antenna plug and radio unit properly connected? Yes Does the problem disappear if connected to another radio? No Replace the antenna. Yes No Yes
Yes
OK
OK
Reconnect
Repair or replace radio.
B - 4 Insufficient sensitivity.
Example: In an underground garage or inside a building.
Is proper performance obtained when the vehicle is moved? No Does tuning solve the problem? No Is the problem limited to the reception of a specific radio station from a specific position? No Is the antenna plug properly connected to the unit? Yes Does the problem disappear when a different radio is connected? No Replace the antenna. Yes No Yes Yes
Yes
OK
OK
Electrical field condition related* (multipath noise or fading noise)
Ensure proper connection.
For multipath noise and fading noise problems, refer to P. 54-63.
54-66
B - 5 Distortion on AM or on both AM and FM.

How much distortion is there? Constant Occasional Distortion in the vicinity of the radio station No Yes Yes Yes Excessive antenna input
Are the speaker cords in contact with the cone paper? No Remove the speakers and check for torn cone paper or foreign objects. No Check for deformation with speaker installed. No Repair or replace radio.
Remove cords away from cone paper. Repair or replace speakers.
Yes
Install speaker securely.
B - 6 Distortion on FM only
Does the distortion persist when the radio is tuned to another station? Yes Does distortion increase or decrease when the vehicle is moved? No Repair or replace radio. No Yes Due to weak electrical field of radio station Due to multipath noise
B - 7 Too few automatic select stations.

Example: In an underground garage or inside a building
Is proper performance obtained when the vehicle is moved? No Is the antenna plug properly connected to the equipment? Yes Does the equipment work properly if the radio is changed? No Replace the antenna. Yes No
Yes
OK
Ensure proper connection.

B - 8 Insufficient memory (preset stations are erased).
Is dedicated fuse No. 5 blown or is the circuit open? No Disconnect and check the connector at the rear of the radio. Is the memory backup (battery) power being supplied? Yes Repair or replace radio. Yes No Replace fuse or repair harness. Repair harness.
54-67
C. TAPE PLAYER C - 1 Cassette tape will not be inserted.

Are there any foreign objects in the tape player? No Yes Remove the object(s)*1 *1 Attempting to force a foreign object (e.g., a coin or clip, etc.) out of the tape player may damage the mechanism. The player should be taken to a service dealer for repair. Yes Replace tape*2 *2 Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. Also, tape of C-120 or greater length often get caught in the mechanism and should not be used.
Does the tape player work if another tape is inserted? No Repair or replace tape player.
C - 2 No sound (even after a tape has been inserted).

Is dedicated fuse No. 6 blown or is the circuit open? No Is connector at rear of radio connected tightly? Yes Disconnect connector at rear of radio. Is ACC power being supplied to the radio? No Repair harness. Yes No Yes Replace fuse or repair harness. Connect connector firmly. Repair or replace tape player.
54-68
C - 3 No sound from one speaker.

Clean the tape player head and check again. No Replace the tape player and check again. No Remove the connector on the back of the radio and check the speaker harness for conductance. No Check the speaker for conductance. No Repair or replace speaker. Yes OK
Yes Yes
Repair or replace tape player. It conducts electricity but is shorted out. Repair harness. Repair harness.
Yes
C - 4 Sound quality is poor, or sound is weak.

Does the player play properly when another tape* is inserted? No Yes OK
*: D Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. D Tapes of C-120 or greater length often get caught in the mechanism and should not be used. Yes Yes OK Repair or replace tape player.
Does the player play properly when the tape player head is cleaned? No Is proper operation obtained when the tape player is replaced? No Repair or replace speaker.
C - 5 Cassette tape will not be ejected. The problems covered here are all the result of the use of a bad tape (deformed or not properly tightened) or of a malfunction of the tape player itself. Malfunctions involving the tape becoming caught in the mechanism and ruining the case are also possible, and attempting to force the tape out of the player can cause damage to the mechanism. The player should be taken to a service dealer for repair.

C - 6 Uneven revolution. Tape speed is fast or slow.
Does the player play OK if the tape*1 is changed? No Yes OK
54-69
*1 Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. Also, tape of C-120 or greater length often get caught in the mechanism and should not be used. Yes Remove foreign object(s).
Are there any foreign objects *2 inside the tape player? No
*2 Attempting to force a foreign object (e.g., a coin or clip, etc.) out of the tape player may damage the mechanism. The player should be taken to a service dealer for repair. Yes
Is the head or capstan roller diry?
Clean.
Pinch roller
Head
Capstan roller
No Repair or replace tape player.
C - 7 Faulty auto reverse.

Does the player play OK if the tape* is changed? No Yes OK
*: D Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. D Tapes of C-120 or greater length often get caught in the mechanism and should not be used. No No Repair or replace tape player. Ensure tape player installation.
Does the problem only occur while the vehicle is being driven? Yes Is the tape player properly installed to the vehicle? Yes Repair or replace tape player.
54-70
C - 8 Tape gets caught in mechanism*1.

*1 When the tape is caught in the mechanism, the case may not eject. When this occurs, do not try to force the tape out as this may damage the tape player mechanism. Take the cassette to a service dealer for repair. Does the player play OK if the tape*2 is changed? No *2 Ensure that the tape label is not loose, that the tape itself is not deformed and that the tape is tightly wound. Also, tapes of C-120 or greater length often get caught in the mechanism and should not be used. Repair or replace tape player. Yes Tape used is bad.
D. MOTOR ANTENNA D-1 Motor antenna wont extend or retract. Clean and polish the surface of the antenna rod.
Is the radio power switch ON? Yes Is voltage (approx. 12 V) emitted to the radios motor antenna terminal? Yes Is the antenna bent? No Is the antenna relay OK? Yes Is the motor OK? Yes Repair the harness. No Switch it ON. Repair or replace the radio. Repair the bend, or replace the antenna mast. Replace the antenna relay. Replace the motor.
No Yes
No No

D-2 Motor antenna extends and retracts but does not receive.
Is the antenna itself OK?
54-71
A B C D E
Ohmmeter measurement locations Circuits from F to A, B, C, D and E Circuit between G and H Result Continuity Continuity No continuity No
G F
Circuits from H to A, B, C, D and E
Repair or replace it.
Fender
H
Yes Is operation normal when a new antenna assembly is directly installed to the radio? Yes Replace the feeder cable. No Refer to B Radio troubleshooting.
54-72

54400140126
RADIO AND TAPE PLAYER

Pre-removal and Post-installation Operation Ashtray and Sunglasses Pocket Removal and Installation
4 2 3 4
NOTE : Metal clip position
Removal steps 1. Floor console panel 2. Centre console panel assembly 3. Radio and tape player 4. Radio bracket 5. Box
CHASSIS ELECTRICAL - Speaker
54-73
54400260266
SPEAKER
<Sedan, Wagon> 1
2 5
<Sedan>
<Wagon> 9 3 7 8
10 11
Speaker (front door) removal steps 1. Tweeter cover <Vehicles with 6 speakers> 2. Tweeter <Vehicles with 6 speakers> 3. Front door trim (Refer to GROUP 42.) 4. Speaker 5. Speaker cover
Speaker (rear door) removal steps 6. Rear door trim (Refer to GROUP 42.) 7. Speaker 8. Speaker cover Speaker (rear shelf) removal steps 9. Speaker garnish 10. Speaker 11. Speaker bracket
54-74
CHASSIS ELECTRICAL - Antenna

54400290180
ANTENNA
<Sedan - Vehicles with motor antenna> 1 2
3 4
<Sedan - Vehicles with pole antenna>
3 4
Antenna feeder cable removal steps 1. Radio and tape player D Instrument panel (Refer to GROUP 52A.) D Front pillar trim (Refer to GROUP 52A.) D Centre pillar trim (Refer to GROUP 52A.) D Rear pillar trim (Refer to GROUP 52A.) D Headlining 2. Antenna feeder cable
Motor antenna or pole antenna removal steps D Trunk side trim (L.H.) (Refer to GROUP 52A.) 3. Ring nut 4. Base 5. Motor antenna 6. Pole antenna
CHASSIS ELECTRICAL - Antenna

<Wagon>
54-75
3 4 5
2 1
Antenna feeder cable removal steps 1. Radio and tape player D Instrument panel D Front pillar trim (Refer to GROUP 52A.) D Centre pillar trim (Refer to GROUP 52A.) D Quarter upper trim (Refer to GROUP 52A.) D Headlining 2. Antenna feeder cable
Antenna (rear roof) removal steps 3. Rod assembly D Headlining 4. Cover 5. Packing
54-76
CHASSIS ELECTRICAL - Antenna INSPECTION

54400360072
MOTOR ANTENNA ASSEMBLY CHECK 1. Connect the circuit as indicated by the solid lines in the illustration. 2. Check that the motor antenna extends when the connection indicated by the broken line is made. 3. Check that the motor antenna retracts fully when the connection indicated by the broken line is removed.
ANTENNA POLE REPLACEMENT
54400090032
Antenna pole
1. Remove the ring nut. 2. After turning the ignition switch to ACC or ON, turn the radio switch to ON to raise the antenna pole, and remove it, together with the rack cable.
Rack cable
Rack cable teeth Luggage compartment side
3. Draw out the antenna pole to the maximum extension. NOTE If there is a bend in the motor end of the rack cable, remove the bend. 4. Insert the rack cable into the motor assembly with the rack cable teeth facing the luggage compartment side.
Rack cable
Rack cable teeth
Rear of the vehicle
5. Turn the rack cable teeth towards the rear of the vehicle (right 90_) so that the rack cable meshes with the motor gear. 6. If the rack cable pulls out with no resistance when it is lightly pulled, then the cable is not meshed with the motor gear, so check that there are no bends in the end of the rack cable, and then repeat steps 4 and 5 above. 7. Set the antenna pole vertically and turn the radio switch OFF to wind up the rack cable. Insert the antenna to the motor antenna side to align it with the wound-up rack cable. 8. After tightening the ring nut, check the movement of the antenna by turning the radio switch ON and OFF.
CHASSIS ELECTRICAL - Rear Window Defogger
54-77
54300720488
REAR WINDOW DEFOGGER

TROUBLESHOOTING
INSPECTION CHART FOR TROUBLE SYMPTOM
Trouble symptom Rear window defogger does not operate. <Vehicles with automatic A/C> Reference page Refer to GROUP 55.
Normal characteristic curve Voltage A (Centre point) approx. 6 V
ON-VEHICLE SERVICE
PRINTED-HEATER LINE CHECK
54300180033
Positive terminal
Printed heater line
Negative terminal
Abnormal characteristic curve Voltage Open-circuit point
1. Run engine at 2,000 r/min. Check heater element with battery at full. 2. Turn ON rear window defogger switch. Measure heater element voltage with circuit tester at rear window glass centre A. Condition is good if it indicates about 6V. 3. If 12 V is indicated at A, there is a break in the negative terminals from A. Move test bar slowly to negative terminal to detect where voltage changes suddenly (0V). 4. If 0 V is indicated at A, there is a break in the positive terminals from A. Detect where the voltage changes suddenly (12 V) in the same method described above.
Positive terminal
Printed heater line
Negative terminal
REAR WINDOW DEFOGGER RELAY CONTINUITY CHECK

Defogger relay
54300680168
Battery voltage Power is not supplied Power is supplied

Junction block
54-78
CHASSIS ELECTRICAL - Rear Window Defogger
REAR WINDOW DEFOGGER SWITCH <VEHICLES WITH MANUAL A/C>

54300620115

Refer to GROUP 55 - Heater Control Assembly, A/C Switch and Inside/Outside Air Changeover Switch.
OFF
INSPECTION
DEFOGGER SWITCH CONTINUITY CHECK
Switch position OFF ON Terminal No. 1 ILL ILL 3 2 4
54300670097
ON
IND
CHASSIS ELECTRICAL - Theft-alarm System
54-79
54700060070
THEFT-ALARM SYSTEM
SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub assenbly Use ETACS-ECU input signal checking
MB991223 A: MB991219 B: MB991220 C: MB991221 D: MB991222
Harness set A: Test harness B: LED harness C: LED harness adapter D: Probe
Making voltage and resistance measurements during troubleshooting A: Connector pin contact pressure inspection B: Power circuit inspection C: Power circuit inspection D: Commercial tester connection
TROUBLESHOOTING
5420070066
The special tool (MB991223) should always be used to measure voltages and resistance when carrying out troubleshooting.
DIAGNOSTIC FUNCTION
54700130030
MUT-II
INPUT SIGNAL INSPECTION POINTS <VEHICLES WITH ETACS-ECU> 1. Connect the MUT-II to the diagnosis connector. 2. If a buzzer of the MUT-II sounds once when a switch is operated (ON/OFF), the ETACS-ECU input signal for that switch circuit system is normal.
54-80
Trouble symptom

54700150074

Inspection procedure No. Communication with all system is not possible. Communication with one-shot pulse input signal only is not possible. The system is not armed. (The security indicator lamp does not illuminate, and the alarm does not function.) The arming procedures are followed, but the security indicator lamp does not illuminate. (There is an alarm, however, when an alarm test is conducted after about 20 seconds have passed.) The alarm sounds in error when, the system is armed, a door or the tailgate is unlocked by using the key. 1 2 3
Communication with MUT-II is not possible. <Vehicles with ETACS-ECU> Arming/disarming relationship
54-82
54-83

INSPECTION PROCEDURE 1 Communication with MUT-II is not possible. (Communication with all system is not possible.)
The cause is probably a defect in the power supply system (including earth) for the diagnosis line.
Probable cause
Refer to GROUP 13A - Troubleshooting
INSPECTION PROCEDURE 2 Communication with MUT-II is not possible. (Communication with one-shot pulse input signal only is not possible.)
The cause is probably a defective one-shot pulse input signal circuit system of the diagnosis line.
Probable cause
D D D Malfunction of connector Malfunction of harness wire Malfunction of ECU NG
Check the harness wire between the diagnosis connector and junction block. NG Repair
OK
Check the following connectors: C-20, C-134, C-144 OK Check trouble symptom.
Repair
NG
Replace the ETACS-ECU.

54-81
The system is not armed. (The security indicator lamp does not illuminate, and the alarm does not function.)
Check the dedicated fuse No.14. OK Check the fusible link No.2. OK Disconnect the ETACS-ECU connector C-43 and measure at the harness side connector. D Voltage between the terminal (2) and earth OK: System voltage OK Check trouble symptom. NG Check the harness wire between the fusible link No.2 and ETACSECU. Repair, if necessary. NG Replace the fuse. Replace the fusible link.
NG NG
Check the following connectors: L.H. drive vehicles: C-144, C-141 R.H. drive vehicles: C-144, C-141, C-62, C-14 OK NG Repair
Measure at the harness side connector. D Continuity between the terminal (1) and body earth OK: Continuity OK Replace the ETACS-ECU.
NG
Check the following connectors: C-131 and C-144 OK NG Repair Check trouble symptom. NG Check the harness wire between the ETACS-ECU and body earth. Repair, if necessary.
54-82
INSPECTION PROCEDURE 4 The arming procedures are followed, but the security indicator lamp does not illuminate. (There is an alarm, however, when an alarm test is conducted after about 20 seconds have passed.)
Remove the combination meter and check if the security indicator lamp bulb is burnt out. OK Disconnect the combination meter connector D-03, and measure at the combination meter side. D Continuity between terminals (10) and (11) OK: Continuity OK Measure at the harness side of the same connector. D Voltage between the terminal (11) and earth OK: System voltage OK Check trouble symptoms. NG Check the harness wire between the combination meter and fusible link (2). Repair, if necessary. Disconnect the ETACS-ECU connector C-139, and measure at the harness side. D Earth the terminal (49) and check if the security indicator lamp illuminates. OK: Illuminates OK Replace the ETACS-ECU. NG Check the following connectors: C-139, C-25, D-03 NG Replace
NG
Replace the combination meter.
NG
Check the following connectors: L.H. drive vehicles: D-03, C-135, C-144, C-141 R.H. drive vehicles: D-03, C-135, C-144, C-141, C-62, C-141 OK

MEASUREMENT AT ECU TERMINALS
54-83
Terminal No. 1 2 7
Item Earth ECU power supply Ignition switch (ACC)
Check condition At all times ON OFF
Normal value System voltage System voltage 0V System voltage 0V 0V 5V ON (Removed) OFF (Inserted) 0V 5V 0V 5V 0V System voltage 5V 0V 0V 5V 5V 0V 0V 5V 5V 0V 0V 5V 0V 5V
11
Ignition switch (IG1)
ON OFF
13,19
Front door switch (L.H.)
Door open Door closed
17
Key reminder switch
Ignition switch
28
Keyless entry receiver-ECU Theft-alarm horn relay
Receiver output signal
ON OFF
29
ON OFF
33
Front door lock actuator switch (R.H.)
Lock Unlock Lock Unlock
34
35
Front door lock actuator switch (L.H.)
36
41
Rear door lock actuator switch (R.H.)
42
43
Trunk lid latch switch <Sedan>
ON OFF
54-84
Terminal No. 44 Item

Check condition ON OFF Lock Unlock Lock Unlock Normal value 0V 5V 5V 0V 0V 5V 0V 5V 0V 5V 0V System voltage 0V 5V 0V 5V
Trunk lid lock key cylinder switch <Sedan> Tailgate lock <Wagon> actuator
45
46
47
Door lock key cylinder switch
Unlock Neutral Lock Neutral
48
49
Combination meter (Security indicator lamp) Front door switch (R.H.)
ON OFF ON OFF
50
51
Hood switch
ON OFF
55-1
HEATER, AIR CONDITIONER AND VENTILATION

CONTENTS MANUAL AIR CONDITIONER . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . 3
55109000119
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . 5 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 7

Sight Glass Refrigerant Level Test . . . . . . . . . . 7 Magnetic Clutch Test . . . . . . . . . . . . . . . . . . . . . . 7 Receiver Drier Test . . . . . . . . . . . . . . . . . . . . . . . . 7 Dual Pressure Switch Check . . . . . . . . . . . . . . . 8
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 4 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . 5
55-2
Compressor Drive Belt Adjustment . . . . . . . . . . 8 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Performance Test . . . . . . . . . . . . . . . . . . . . . . . . 14 Refrigerant Leak Repair . . . . . . . . . . . . . . . . . . . 15 Compressor Noise . . . . . . . . . . . . . . . . . . . . . . . . 16 Power Relay Check . . . . . . . . . . . . . . . . . . . . . . 16 Idle-up Operation Check . . . . . . . . . . . . . . . . . . 18
AUTOMATIC AIR CONDITIONER . . . . 35

GENERAL INFORMATION . . . . . . . . . . . . . . 35 SERVICE SPECIFICATIONS . . . . . . . . . . . . 35 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . 36 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 36 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 36 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . 56 AIR CONDITIONER CONTROL PANEL AND ECU ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 57 DAMPER MOTOR ASSEMBLY AND POWER TRANSISTOR . . . . . . . . . . . . . . . . . 58 COMPRESSOR AND TENSION PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 PHOTO SENSOR . . . . . . . . . . . . . . . . . . . . . . 67 OUTSIDE AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 HEATER WATER TEMPERATURE SENSOR* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 OTHER MAINTENANCE SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
HEATER CONTROL ASSEMBLY, A/C SWITCH AND INSIDE/OUTSIDE AIR CHANGEOVER SWITCH . . . . . . . . . . . . . . . 19 HEATER UNIT*, HEATER CORE AND BLOWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 22 RESISTOR, BLOWER FAN AND MOTOR AND INSIDE/OUTSIDE AIR CHANGEOVER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . 25 AIR PURIFIER ASSEMBLY . . . . . . . . . . . . . 27 COMPRESSOR AND TENSION PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 REFRIGERANT LINE . . . . . . . . . . . . . . . . . . 28 CONDENSER AND CONDENSER FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 VENTILATORS . . . . . . . . . . . . . . . . . . . . . . . . 33
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - General Information
55-3
55200010190
MANUAL AIR CONDITIONER

GENERAL INFORMATION
The heater system uses a two-way-flow full-air-mix system that features high performance and low operating noise, and includes an independent face air blowing function. The A/C system is basically the same as the conventional system, but a new
Items Heater unit Type
refrigerant system has been adopted as a response to restrictions on the use of chlorofluorocarbons. In addition, an air purifier which carries out fine A/C control has been included.
Specifications Two-way-flow full-air-mix system Dial type Scroll type <MSC90> ON OFF: 2,942, OFF ON: 2,353 ON OFF: 196, OFF ON: 221 R-134a (HFC-134a), Approx. 670 - 710
Heater control assembly Compressor Dual pressure switch kPa Model High-pressure switch Low-pressure switch
Refrigerant and quantity g
SAFETY PRECAUTIONS Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer. Refrigerant R-134a is transparent and colourless in both the liquid and vapour state. Since it has a boiling point of - 29.8_C, at atmospheric pressure, it will be a vapour at all normal temperatures and pressures. The vapour is heavier than air, non-flammable, and nonexplosive. The following precautions must be observed when handling R-134a.
Caution Wear safety goggles when servicing the refrigeration system. R-134a evaporates so rapidly at normal atmospheric pressures and temperatures that it tends to freeze anything it contacts. For this reason, extreme care must be taken to prevent any liquid refrigerant from contacting the skin and especially the eyes. Always wear safety goggles when servicing the refrigeration part of the A/C system. Keep a bottle of sterile mineral oil handy when working on the refrigeration system. Should any liquid refrigerant get into the eyes, use a few drops of mineral oil to wash them out. R-134a is rapidly absorbed by the oil. Next splash the eyes with plenty of cold water. Call your doctor immediately even though irritation has ceased after treatment.
55-4
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER>
General Information/ Service Specifications/Lubricants
Caution Do not heat R-134a above 40_C In most instances, moderate heat is required to bring the pressure of the refrigerant in its container above the pressure of the system when charging or adding refrigerant. A bucket or large pan of hot water not over 40_C is all the heat required for this purpose. Do not heat the refrigerant container with a blow torch or any other means that would raise temperature and pressure above this temperature. Do not weld or steam clean on or near the system components or refrigerant lines. Caution Keep R-134a containers upright when charging the system.
When metering R-134a into the refrigeration system keep the supply tank or cans in an upright position. If the refrigerant container is on its side or upside down, liquid refrigerant will enter the system and damage the compressor. Caution 1. The leak detector for R-134a should be used to check for refrigerant gas leaks. 2. Do not allow liquid refrigerant to touch bright metal. Refrigerant will tarnish bright metal and chrome surfaces, and in combination with moisture can severely corrode all metal surfaces.
Items Idle speed r/min 4G6 6A1 4D6 Idle-up speed r/min When load by A/C is low 4G6 6A1 4D6 When load by A/C is high 4G6 6A1 4D6 Resistor (for blower motor) W Air gap (Magnetic clutch) mm Standard value 750 50 650 50 800 30 750 50 650 50 850 50 850 50 900 50 850 50 LO: 2.30, ML: 1.10, MH: 0.40 0.40 - 0.65
55200030219
LUBRICANTS
Items Each connection of refrigerant line Compressor refrigerant unit lubricant mL Specified lubricants SUN PAG 56 SUN PAG 56 Quantity As required 120
55200040199
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Special Tools/Troubleshooting
55-5
55200060133
SPECIAL TOOLS
Tool Number MB991367 Name Special spanner Use
Removal and installation of armature mounting nut of compressor
MB991386
Pin
TROUBLESHOOTING
TROUBLESHOOTING PROCEDURES
Trouble symptom When the ignition switch is ON, the A/C does not operate. Problem cause A/C compressor relay is defective Magnetic clutch is defective Refrigerant leak or overfilling of refrigerant Remedy Replace the A/C compressor relay Replace the armature plate, rotor or clutch coil Replenish the refrigerant, repair the leak or take out some of the refrigerant Replace the dual pressure switch Replace the A/C switch Replace the blower switch Replace the refrigerant temperature switch Replace the automatic compressor-ECU Replace the engine-ECU Replenish the refrigerant and repair the leak Replace the dual pressure switch Replace the refrigerant temperature switch Replace the automatic compressor-ECU Replace the engine-ECU
55200070242
Dual pressure switch is defective A/C switch is defective Blower switch is defective Refrigerant temperature switch is defective Automatic compressor-ECU is defective Engine-ECU is defective When the A/C is operating, temperature inside the passenger compartment doesnt decrease (cool air is not emitted). Refrigerant leak Dual pressure switch is defective Refrigerant temperature switch is defective Automatic compressor ECU is defective Engine-ECU is defective
55-28, 29 55-19 55-21 55-65 55-26 55-15 55-28, 29 55-65 55-26 -
55-6
Trouble symptom Blower fan and motor doesnt turn
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Troubleshooting Problem cause Blower relay is defective Blower fan and motor is defective Resistor (for blower motor) is defective Blower switch is defective Remedy Replace the blower relay Replace the blower fan and motor Replace the resistor Replace the blower switch Repair the harness Replace the blower switch Replace the blower relay Replace the condenser fan motor Replace the radiator fan motor Replace the fan control relay Replace the engine-ECU Reference page 55-16 55-23 55-23 55-21 55-21 55-16 55-31 55-17 55201030041
Blower fan and motor doesnt stop turning.
Short circuit of the harness between the blower fan and motor and the blower switch Blower switch is defective Blower relay is defective Condenser fan motor is defective Radiator fan motor is defective Fan control relay is defective Engine-ECU is defective
When the A/C is operating condenser fan or radiator fan does not run
INSPECTION AT THE AUTOMATIC COMPRESSOR-ECU TERMINAL
Terminal No. 1
Check item Input from A/C switch to ECU
Checking requirements A/C switch: OFF A/C switch: ON
Normal condition 0V Battery voltage Battery voltage 0V Battery voltage 0V 0V
Output from ECU to A/C compressor relay Output from ECU to engine-ECU
A/C compressor relay: OFF A/C compressor relay: ON Air thermo sensor detection temperature: 5_C or less Air thermo sensor detection temperature: 8_C or more
Earth
Always
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - On-vehicle Service
55-7
55200840133
ON-VEHICLE SERVICE
SIGHT GLASS REFRIGERANT LEVEL TEST

The sight glass is a refrigerant level indicator. To check the refrigerant level, clean the sight glass and start the vehicle engine. Push the A/C button to operate the compressor, place the blower switch to high and move the temperature control lever to max cool. After operating for a few minutes in this manner, check the sight glass. 1. If the sight glass is clear, the magnetic clutch is engaged, the compressor discharge line is warm and the compressor inlet line is cool; the system has a full charge. 2. If the sight glass is clear, the magnetic clutch is engaged and there is no significant temperature difference between compressor inlet and discharge lines; the system has lost some refrigerant. 3. If the sight glass shows foam or bubbles, the system could be low on charge. The system has to be recharged with refrigerant.
Sight glass
MAGNETIC CLUTCH TEST
55200850174
1. Disconnect the connector (1-pin) to the magnetic clutch. 2. Connect battery (+) voltage directly to the connector for the magnetic clutch. 3. If the magnetic clutch is normal, there will be click. If the pulley and armature do not make contact (click), there is a malfunction.
Magnetic clutch connector
RECEIVER DRIER TEST
55200860115
Operate the unit and check the piping temperature by touching the receiver drier outlet and inlet. If there is a difference in the temperatures, the receiver drier is restricted. Replace the receiver drier.
55-8
High/Low pressure side
DUAL PRESSURE SWITCH CHECK
55201040167
1. Remove the dual pressure switch connector and connect the high/low pressure side terminals located on the harness side as shown in the illustration. 2. Install a gauge manifold to the high-pressure side service valve of the refrigerant line. (Refer to Performance Test.) 3. When the high/low pressure sides of the dual pressure switch are at operation pressure (ON) and there is continuity between the respective terminals, then the condition is normal. If there is no continuity, replace the switch.
Items Low-pressure side kPa High-pressure side kPa Switch position OFF ON 221 2,353 ON OFF 196 2,942
LOW-PRESSURE SIDE ON OFF
HIGH-PRESSURE SIDE ON OFF
COMPRESSOR DRIVE BELT ADJUSTMENT

55200100101
Refer to GROUP 11 - On-vehicle Service.
55-9
55200120176
CHARGING
Low-pressure valve High-pressure valve
Gauge manifold Adapter valve Charging hose (blue) Switch R-12 connection port Vacuum pump Quick joint (for adaptor low pressure) Charging hose (yellow)
1. With the handles turned back all the way (valve closed), install the adaptor valve to the low-pressure side of the gauge manifold. 2. Connect the charging hose (blue) to the adaptor valve. 3. Connect the quick joint (for low pressure) to the charging hose (blue). 4. Connect the quick joint (for low pressure) to the low pressure service valve. NOTE The low-pressure service valve should be connected to the suction flexible hose. Caution (1) Use tools that are suited to R-134a. (2) To install the quick joint, press section A firmly against the service valve until a click is heard. When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose. 5. Close the high and low-pressure valves of the gauge manifold. 6. Install the vacuum pump adaptor to the vacuum pump. 7. Connect the vacuum pump plug to the vacuum pump adaptor. 8. Connect the charging hose (yellow) to the R-134a connection port of the vacuum pump adaptor. 9. Tighten the adaptor valve handle (valve open). 10. Open the low-pressure valve of the gauge manifold. 11. Turn the power switch of the vacuum pump to the ON position. NOTE Even if the vacuum pump power switch is turned ON, the vacuum pump will not operate because of the power supply connection in step (7).
R-134a connection port
Vacuum pump Switch
Power supply plug
Low-pressure service valve A Sleeve
55-10
12. Turn the vacuum pump adaptor switch to the R-134a side to start the vacuum pump. Caution Do not operate the compressor for evacuation. 13. Evacuate to a vacuum reading of 100 kPa or higher (takes approx. 10 minutes). 14. Turn the vacuum pump adaptor switch OFF and allow to stand it for 5 minutes. Caution Do not operate the compressor in the vacuum condition; damage may occur. 15. Carry out a leak test. (Good if the negative pressure does not drop.) Caution If the negative pressure drops, increase the tightness of the connections, and then repeat the evacuation procedure from step (12).
Vacuum pump
Low-pressure service valve
Valve open Valve close Charging valve Adaptor valve Service can
16. With the handle turned back all the way (valve open), install the charging valve to the service can. 17. Turn the handle of the adaptor valve back all the way (valve closed), remove it from the gauge manifold and install the service can. 18. Tighten the handle of the charging valve (valve closed) to puncture the service can.
55-11
Charging valve
19. Turn the handle of the charging valve back (valve open) and tighten the handle of the adaptor valve (valve open) to charge the system with refrigerant. Caution If the service can is inverted, liquid refrigerant may be drawn into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is charged in gas state.
Service can (Refrigerant container)
20. If the refrigerant is not drawn in, turn the handle of the adaptor valve back all the way (valve closed). 21. Check for gas leaks using a leak detector. If a gas leak is detected, re-tighten the connections, and then repeat the charging procedure from evacuation in step (12).
Caution The leak detector for R-134a should be used. 22. Start the engine. 23. Operate the A/C and set to the lowest temperature (MAX. COOL). 24. Fix the engine speed at 1,500 r/min. 25. Tighten the handle of the adaptor valve (valve open) to charge the required volume of refrigerant. Caution If the service can is inverted, liquid refrigerant may be drawn into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is charged in gas state. 26. After charging with refrigerant, turn the handle of the adaptor valve back all the way (valve closed). 27. Tighten the charging valve handle (valve closed). Remove the quick joint (for low pressure) from the low-pressure service valve. NOTE If the service can is not emptied completely, keep the handles of the charging valve and adaptor valve closed for the next charging.
55-12
Valve open
Charging valve Valve close Adaptor valve
Charging hose (blue) Service can (Refrigerant container) Quick joint (for low pressure)
CORRECTING LOW REFRIGERANT LEVEL IN CASE THE SERVICE CAN IS USED. 1. Install the charging valve with the handle turned all the way back (valve open) to the service can. 2. Install the adaptor valve with the handle turned all the way back (valve close) to the charging valve. 3. Connect the charging hose (blue) to the adaptor valve. 4. Connect the charging hose (blue) to the quick joint (for low pressure). 5. Tighten the handle of the charging valve (valve close), and pierce the service can. 6. Turn the handle of the adaptor valve to bleed the air.
7. Install the quick joint (for low pressure) to the low-pressure service valve.
Quick joint (for low pressure)
NOTE The low-pressure service valve should be connected to the suction flexible hose.
Charging valve
8. Start the engine. 9. Operate the air conditioner and set at the lowest temperature (MAX. COOL). 10. Fix the engine speed at 1,500 r/min. 11. Tighten the handle of the adaptor valve (valve open), and replenish refrigerant while checking the quantity through the sight glass. Caution If the service can is inverted, liquid refrigerant may be draw into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is changed in gas state. 12. After replenishing is completed, turn the handle of the adaptor valve all the way back (valve close), and remove the quick joint.
Service can (Refrigerant container)
NOTE When there is remainder of refrigerant in the service can, keep it for next use with the charge value and the valve of the adaptor valve being closed.
55-13
DISCHARGING SYSTEM 1. Run the engine at an engine speed of 1,200 - 1,500 r/min for approximately 5 minutes with the A/C operating to return to the oil.
A
NOTE Returning the oil will be more effective if it is done while driving. 2. Stop the engine. 3. Connect the charging hose (blue) to the adaptor valve with its handle turned back all the way (valve closed). 4. Connect the quick joint to the charging hose (blue). 5. Install the quick joint to the low-pressure service valve. NOTE The low-pressure service valve should be connected to the suction flexible hose. Caution To connect the quick joint, press section A firmly against the service valve until a click is heard. When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose. 6. Place the adaptor valve inside the container and discharge the refrigerant by opening the handle gradually so that oil does not gush out.
Sleeve
Charging hose (blue)
Quick joint
Adaptor valve Oil
NOTE Any oil remaining in the container should be returned to the A/C system.
REFILLING OF OIL IN THE A/C SYSTEM Too little oil will provide inadequate compressor lubrication and cause a compressor failure. Too much oil will increase discharge air temperature. When a compressor is installed at the factory, it contains 120 mL of refrigerant oil. While the A/C system is in operation, the oil is carried through the entire system by the refrigerant. Some of this oil will be trapped and retained in various parts of the system. When the following system components are changed, it is necessary to add oil to the system to replace the oil being removed with the component. Compressor oil: SUN PAG 56 Quantity Condenser: 15 mL Evaporator: 60 mL Suction hose: 10 mL Receiver: 10 mL
55-14
Low-pressure valve
PERFORMANCE TEST
High-pressure valve
55200140189
Gauge manifold Charging hose (red) Charging hose (blue) A Adaptor valve (for low pressure) Sleeve Adaptor valve (for high pressure) Highpressure service valve
1. The vehicles to be tested should be in a place that is not in direct sunlight. 2. Close the high and low-pressure valve of the gauge manifold. 3. Connect the charging hose (blue) to the low-pressure valve and connect the charging hose (red) to the high-pressure valve of the gauge manifold. 4. Install the quick joint (for low pressure) to the charging hose (blue), and connect the quick joint (for high pressure) to the charging hose (red). 5. Connect the quick joint (for low pressure) to the low-pressure service valve and connect the quick joint (for high pressure) to the high-pressure service valve. NOTE The high-pressure service valve is on liquid pipe B and the low-pressure service valve is on the suction flexible hose. Caution To connect the quick joint, press section A firmly against the service valve until a click is heard. When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose. 6. Start the engine. 7. Set the controls to the A/C as follows: A/C switch: A/C - ON position Mode selection: Face position Temperature control: Max. cooling position Air selection: Recirculation position Blower switch: HI (Fast) position 8. Adjust engine speed to 1,000 r/min with A/C clutch engaged. 9. Engine should be warmed up with doors and windows closed. 10. Insert a thermometer in the left center A/C outlet and operate the engine for 20 minutes. 11. Note the discharge air temperature. NOTE If the clutch cycles, take the reading before the clutch disengages.
Lowpressure service valve
Thermometer
55-15
40 6.5 - 9.0 1,570 - 1,765 155 - 255
Performance Temperature Chart

Garage ambient temperature _C Discharge air temperature _C Compressor high pressure kPa Compressor low pressure kPa 20 2.5 - 4.5 765 - 960 40 - 135
55200150045
25 2.5 - 4.5 765 - 960 40 - 135
35 4.0 - 6.5 1,325 - 1,420 80 - 175
REFRIGERANT LEAK REPAIR
LOST CHARGE If the system has lost all charge due to a leak: 1. Evacuate the system. (See procedure.) 2. Charge the system with approximately one pound of refrigerant. 3. Check for leaks. 4. Discharge the system. 5. Repair leaks. 6. Replace receiver drier. Caution Replacement filter-drier units must be sealed while in storage. The drier used in these units will saturate water quickly upon exposure to the atmosphere. When installing a drier, have all tools and supplies ready for quick reassembly to avoid keeping the system open any longer than necessary. 7. Evacuate and charge system. LOW CHARGE If the system has not lost all of its refrigerant charge; locate and repair all leaks. If it is necessary to increase the system pressure to find the leak (because of an especially low charge) add refrigerant. If it is possible to repair the leak without discharging the refrigerant system, use the procedure for correcting low refrigerant level.
HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The following precautions must be observed. The system must be completely discharged before opening any fitting of connection in the refrigeration system. Open fittings with caution even after the system has been discharged. If any pressure is noticed as a fitting is loosened, allow trapped pressure to bleed off very slowly. Never attempt to rebend formed lines to fit. Use the correct line for the installation you are servicing. A good rule for the flexible hose lines is keep the radius of all bends at least 10 times the diameter of the hose. Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so that they are at least 80 mm from the exhaust manifold. It is good practice to inspect all flexible hose lines at least once a year to make sure they are in good condition and properly routed. Unified plumbing connections with O-rings, these O-rings are not reusable.
55-16
55200870033
COMPRESSOR NOISE
You must first know the conditions when the noise occurs. These conditions are: weather, vehicle speed, in gear or neutral, engine temperature or any other special conditions. Noises that develop during A/C operation can often be misleading. For example: what sounds like a failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a loose clutch assembly. Verify accessory drive belt tension (power steering or alternator). Improper accessory drive belt tension can cause a misleading noise when the compressor is engaged and little or no noise when the compressor is disengaged. Drive belts are speed-sensitive. That is, at different engine speeds, and depending upon belt tension, belts can develop unusual noises that are often mistaken for mechanical problems within the compressor.
ADJUSTMENT 1. Select a quiet area for testing. Duplicate conditions as much as possible. Switch compressor on and off several times to clearly identify compressor noise. To duplicate high ambient conditions (high head pressure), restrict air flow through condenser. Install manifold gauge set to make sure discharge pressure doesnt exceed 2,070 kPa. 2. Tighten all compressor mounting bolts, clutch mounting bolt, and compressor drive belt. Check to assure clutch coil is tight (no rotation or wobble). 3. Check refrigerant hoses for rubbing or interference that can cause unusual noises. 4. Check refrigerant charge. (See Charging System.) 5. Recheck compressor noise as in Step 1. 6. If noise still exists, loosen compressor mounting bolts and retorque. Repeat Step 1. 7. If noise continues, replace compressor and repeat Step 1.
55200880210
POWER RELAY CHECK

BLOWER RELAY
Battery voltage
Blower relay
Power is not supplied Power is supplied
55-17
A/C COMPRESSOR RELAY

A/C compressor relay
Battery voltage Power is not supplied Power is supplied
FAN CONTROL RELAY Refer to GROUP 14 - Radiator.
55-18
IDLE-UP OPERATION CHECK
55200160208
1. Before inspection and adjustment, set vehicle in the following condition: D Engine coolant temperature: 80 - 90_C D Lights, electric cooling fan and accessories: Set to OFF D Transmission: Neutral (N or P for vehicles with A/T) D Steering wheel: Straightforward 2. Check whether or not the idle speed is the standard value. Standard value: <4G6> 750 50 r/min <6A1> 650 50 r/min <4D6> 800 30 r/min 3. When the A/C is running after turning the A/C switch to ON, and the blower switch to the MH or HI position, check to be sure that the idle speed is at the standard value. Standard value:
Engine Idle speed r/min When load by A/C is low 4G6 6A1 4D6 750 50 650 50 850 50 When load by A/C is high 850 50 900 50 850 50
NOTE (1) The engine-ECU determine whether the load by A/C is low or high according to the output signal from the automatic compressor-ECU <manual A/C> or the A/C-ECU <automatic A/C>. (2) There is no necessity to make an adjustment, because the idle speed is automatically adjusted by the ISC system. If, however, there occurs a deviation from the standard value for some reason, check the ISC system. (Refer to GROUP 13A - On-vehicle Service.)
Heater Control Assembly, A/C Switch and Inside/Outside Air Changeover Switch
55-19
55201240017
HEATER CONTROL ASSEMBLY, A/C SWITCH AND INSIDE/OUTSIDE AIR CHANGEOVER SWITCH
Pre-removal and Post-installation Operation D Center Console Panel, Side Cover Removal and Installation (Refer to GROUP 52A - Instrument Panel.) D
Radio, Tape Player Removal and Installation (Refer to GROUP 54.)
6 3 4
5 2 1
Removal steps "BA 1. Air mix damper cable connection "AA 2. Air outlet changeover damper cable connection 3. Rear window defogger switch
4. A/C switch 5. Inside/outside air changeover switch 6. Heater control assembly

"AA AIR OUTLET CHANGEOVER DAMPER CABLE
Air outlet changeover damper lever
CONNECTION 1. Set the air outlet changeover control knob on the heater control assembly to the DEF position. 2. Set the air outlet changeover damper lever of the heater unit to the DEF position (turn clockwise the damper lever until it stops), and then connect the to cable to the lever.
DEF position
"BA AIR MIX DAMPER CABLE CONNECTION
Air mix damper lever
1. Set the temperature control knob on the heater control assembly to the MAX HOT position. 2. Set the air mix damper lever of the heater unit to the MAX HOT position (turn clockwise the damper lever until it stops), and then connect the cable to the lever.
MAX HOT position
55-20
55201250010
INSPECTION
BLOWER SWITCH CONTINUITY CHECK
Switch position OFF D (LO) Terminal No. 1 2 3 4 5 6
D (ML)
(MH)
D (HI)
FRESH position
INSIDE/OUTSIDE AIR CHANGEOVER SWITCH CONTINUITY CHECK

Switch position RECIRC FRESH Terminal No. 1 ILL 2 3 IND 4 5 6
RECIRC position
OFF position
A/C SWITCH CONTINUITY CHECK

Switch position Terminal No. 1 ILL 2 IND 4 5 7
ON position
OFF ON
55-21
55100130077
HEATER CONTROL ASSEMBLY

6 4 3
AA" AA"
Disassembly steps 1. Knob assembly 2. Bulb harness 3. Air outlet changeover damper cable 4. Air mix damper cable
5. 6. 7. 8.
Heater control panel Nut Blower switch Control base assembly

Flat-tipped screwdriver
AA" AIR OUTLET CHANGEOVER DAMPER CABLE/AIR MIX DAMPER CABLE REMOVAL Insert a flat-tipped screwdriver into the control base clip from inner side, and then remove the cable by lifting the claw part of the clip.
Claw part
55-22
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Heater Unit, Heater Core, and Blower Unit
55201270016
HEATER UNIT, HEATER CORE, AND BLOWER UNIT

Pre-removal and Post-installation Operation D Under Cover Removal and Installation (Refer to P.55-33.) D Instrument Panel removal and Installation (Refer to GROUP 52A.)
Caution: SRS When removing and installing the heater unit from vehicles equipped with SRS, do not let it bump against the SRS-ECU or the components.
1
Vehicles with automatic A/C
2 5
3 4
2 6
AA"
Heater unit and heater core removal steps D Center reinforcement (Refer to GROUP 52A - Instrument panel.) D Center duct assembly and foot distribution duct (Refer to P.55-33.) D Draining and refilling engine coolant (Refer to GROUP 14 - On-vehicle service.) 1. Heater hose connection 2. Evaporator mounting bolt and nut 3. Heater unit 4. Heater core
Blower unit removal steps 2. Evaporator mounting bolt and nut 5. Clip 6. Blower unit

AA" HEATER UNIT REMOVAL After sliding the cooling unit towards you slightly, remove the heater unit.
Heater unit
Resistor, Blower Fan and Motor, and Inside/Outside Air Changeover Damper Motor
55-23
RESISTOR, BLOWER FAN AND MOTOR, AND INSIDE/OUTSIDE 55100500014 AIR CHANGEOVER DAMPER MOTOR
Pre-removal and Post-installation Operation Glove Box Removal and Installation (Refer to GROUP 52A - Instrument Panel.)
Resistor removal steps D Under cover (Refer to P.55-33.) 1. Resistor Blower fan and motor removal steps D Under cover (Refer to P.55-33.) 2. Blower fan and motor
Inside/outside air changeover damper motor removal 3. Inside/outside air changeover damper motor
INSPECTION
55100510017
BLOWER FAN AND MOTOR CHECK When battery voltage is applied between the terminals, check that the motor operates. Also, check that there is no abnormal noise.
55-24
Resistor, Blower Fan and Motor, and Inside/Outside Air Changeover Damper Motor
RESISTOR CHECK Use a circuit tester to measure the resistance between the terminals as indicated below. Check that the measured value is at the standard value. Standard value:
Measurement terminal Between terminals 3 and 2 (LO) Between terminals 3 and 4 (ML) Between terminals 3 and 1 (MH) Standard value W 2.30 1.10 0.40
INSIDE/OUTSIDE CHANGEOVER DAMPER MOTOR CHECK

Battery connection terminal 1 2 Moves to the outside air position Moves to the inside air position Lever operation
Caution Cut off the battery voltage when the damper is in the inside air position or outside air position.
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Evaporator
55-25
55200360165
EVAPORATOR
Pre-removal and Post-installation Operation D Discharging and Charging of Refrigerant (Refer to P.55-9.) D Glove Box, Side Cover and Glove Box Frame Removal and Installation (Refer to GROUP 52A - Instrument Panel.) D
Under Cover Removal and Installation (Refer to P.55-33.)
Piping connection
3
4 Compressor oil: SUN PAG 56
AA" AA"
Removal steps 1. Suction hose connection 2. Discharge pipe connection 3. O-ring
4. Drain hose 5. Plate "AA 6. Evaporator

AA" SUCTION HOSE, DISCHARGE PIPE DISCONNECTION Plug the disconnected hose and the evaporator nipple not to let foreign matter get into them. Caution Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily.

"AA EVAPORATOR INSTALLATION When replacing the evaporator, refill it with a specified amount of compressor oil and install it (to the vehicle). Compressor oil: SUN PAG 56 Quantity: 60 mL
55-26
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Evaporator

55200380154

3 2 7 6 1 8 7
Compressor oil: SUN PAG 56
6 5
AA"
Disassembly steps 1. Clip 2. Evaporator case (upper) 3. Automatic compressor-ECU <Manual A/C> 4. Air thermo sensor <Automatic A/C>
5. 6. 7. 8.
Evaporator case (lower) Expansion valve O-ring Evaporator

AA" CLIP REMOVAL Remove the clips with a flat-tipped screwdriver covered with a shop towel to prevent damage to case surfaces.
Clip
Evaporator/Air Purifier Assembly/ Compressor and Tension Pulley
55-27
55200390058
INSPECTION
Resistance kW 20 15 10 5 0 - 10
AIR THERMO SENSOR When the resistance value between the sensor terminals is measured under two or more temperature conditions, the resistance value should be close to the values shown in the graph.
0 10 20 30 40
Temperature _C
NOTE The temperature conditions when testing should not exceed the range of the characteristic curve in the graph.
AIR PURIFIER ASSEMBLY

Pre-removal and Post-installation Operation D Glove Box, Side Cover and Glove Box Frame Removal and Installation (Refer to GROUP 52A - Instrument Panel.) D
55500100032
Under Cover Removal and Installation (Refer to P.55-33.)
Air purifier assembly
COMPRESSOR AND TENSION PULLEY

Refer to P.55-61.
55200410266
55-28
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Refrigerant Line
55200640269
REFRIGERANT LINE
<L.H. DRIVE VEHICLES>
Pre-removal and Post-installation Operation D Discharging and Changing of Refrigerant (Refer to P.55-9.) D Reserve Tank Removal and Installation (Refer to GROUP 14 - Radiator.) D
Oil Reservoir Removal and Installation (Refer to GROUP 37A - Power Steering Hoses.)
1
Piping connection
2 10
10
10
10 6 10 5 3
10 8
10
AA" AA" AA" AA"
Removal steps 1. Suction pipe 2. Clamp and bracket 3. Suction flexible hose 4. Liquid pipe A 5. Liquid pipe B
6. 7. AA" "AA 8. 9. AA" 10.
Dual pressure switch Receiver bracket assembly Receiver assembly Discharge flexible hose O-ring
55-29
<R.H. DRIVE VEHICLES>

Pre-removal and Post-installation Operation D Discharging and Changing of Refrigerant (Refer to P.55-9.) D Canister Removal and Installation (Refer to GROUP 17.) D D Reserve Tank Removal and Installation (Refer to GROUP 14 - Radiator.) Oil Reservoir Removal and Installation (Refer to GROUP 37A - Power Steering Hoses.)
Piping connection
1 5 11 11
11 7 6 11
11 3 4 11 11
10 8
AA" AA" AA" AA"
Removal steps 1. Clamp 2. Suction pipe 3. Clamp and bracket 4. Suction flexible hose 5. Liquid pipe B 6. Liquid pipe A
7. 8. AA" "AA 9. AA" 10. 11.
Dual pressure switch Receiver bracket assembly Receiver assembly Discharge flexible hose O-ring
55-30

AA" HOSE/PIPE/RECEIVER ASSEMBLY DISCONNECTION Plug the disconnected hose, the receiver, the evaporator and the compressor nipple not to let foreign matter get into them. Caution Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily.

"AA SUCTION HOSE/RECEIVER ASSEMBLY INSTALLATION When replacing the suction hose or receiver assembly, refill them with a specified amount of compressor oil, and then install them. Compressor oil: SUN PAG 56 Quantity: Suction hose: 10 mL Receiver assembly: 10 mL
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Condenser and Condenser Fan Motor
55-31
55200670244
CONDENSER AND CONDENSER FAN MOTOR

Piping connection
O-ring
6 2 4 1 3
Condenser fan motor removal steps 1. Condenser fan motor and shroud assembly 2. Condenser fan 3. Shroud 4. Condenser fan motor
Condenser removal steps D Discharging and charging of refrigerant (Refer to P.55-9.) D Air cleaner D Engine coolant draining and supplying (Refer to GROUP 14 - On-vehicle service.) D Radiator (Refer to GROUP 14.) AA" 5. Discharge flexible hose and liquid pipe A connection "AA 6. Condenser

AA" DISCHARGE FLEXIBLE HOSE AND LIQUID PIPE A CONNECTION Plug the disconnected pipe, hose and the condenser nipple not to let foreign matter get into them. Caution Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily.
55-32
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Condenser and Condenser Fan Motor

"AA CONDENSER INSTALLATION When replacing the condenser, refill it with a specified amount of compressor oil and install it. (to the vehicle). Compressor oil: SUN PAG 56 Quantity: 15 mL
INSPECTION
55200680148
CONDENSER FAN MOTOR CHECK Check to be sure that the condenser fan motor operates when battery voltage is applied to terminal 1 and terminal 2 earthed.
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Ventilators
55-33
55300160119
VENTILATORS
<Automatic A/C>
5 3 2
2 4 6 9 1
7 8
Under cover removal 1. Under cover Defroster nozzle and distribution duct removal steps D Floor console assembly (Refer to GROUP 52A.) D Instrument panel (Refer to GROUP 52A.) 2. Side defroster duct 3. Defroster nozzle assembly 4. Distribution duct assembly 5. Defroster garnish and photo sensor 6. Center duct assembly
Rear heater duct and foot distribution duct removal steps D Front seat (Refer to GROUP 52A.) D Floor console assembly (Refer to GROUP 52A.) D Instrument panel and center reinforcement (Refer to GROUP 52A.) 7. Rear heater duct (R.H.) 8. Rear heater duct (L.H.) 9. Foot distribution duct
NOTE For the center air outlet assembly and the side air outlet assembly, refer to GROUP 52A - Instrument panel.
55-34
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Ventilators
<Wagon> <Sedan>
10
Rear ventilation duct assembly removal steps D Rear bumper (Refer to GROUP 51.) 10. Rear ventilation duct assembly
NOTE For the front deck garnish, refer to GROUP 51 - Windshield wiper and washer.
HEATER, AIR CONDITIONER AND VENTILATION <AUTOMATIC AIR CONDITIONER>
General Information/ Service Specifications
55-35
55400010080
AUTOMATIC AIR CONDITIONER

GENERAL INFORMATION
The heater system uses a two-way-flow full-air-mix system that features high performance and low operating noise, and includes an independent face-directed air flow function. An air purifier which carries out fine A/C control has been included.
Items Heater unit Heater control assembly Compressor Dual pressure switch kPa Model High-pressure switch Low-pressure switch Type
The A/C system is basically the same as the manual air conditioner in which a new refrigerant system has been adopted. However, an A/C control panel with a reduced number of buttons and more compact arrangement of necessary functions owing to more functions being assigned to each button has been adopted.
Specifications Two-way-flow full-air-mix system Push button type Scroll type <MSC 90> ON OFF: 2,942, OFF ON: 2,353 ON OFF: 196, OFF ON: 221 R-134a (HFC-134a), Approx. 670 - 710
55400030086
Refrigerant and quantity g
Items Idle speed r/min 4G6 6A1 4D6 Idle-up speed r/min When load by A/C is low 4G6 6A1 4D6 When load by A/C is high 4G6 6A1 4D6 Air mix damper motor potentiometer resistance kW Outlet air changeover damper motor potentiometer resistance kW Air gap (Magnetic clutch) mm MAX. HOT position MAX. COOL position DEF position FACE position Standard value 750 50 650 50 800 30 750 50 650 50 850 50 850 50 900 50 850 50 Approx. 4.8 Approx. 0.2 Approx. 4.8 Approx. 0.2 0.40 - 0.65
55-36
Lubricants/Special Tools/ Troubleshooting

55400040072
LUBRICANTS
Items Each connection of refrigerant line Compressor refrigerant unit lubricant mL Specified lubricants SUN PAG 56 SUN PAG 56 Quantity As required 120
SPECIAL TOOLS
Tool Number MB991502 Name MUT-II sub-assembly Use
55400060061
Inspection of automatic air conditioner
MB991529
Inspection of automatic air conditioner using a voltmeter
NOTE Other special tools are the same as for the manual A/C.
TROUBLESHOOTING
55400470055
DIAGNOSIS FUNCTION
55400480072
DIAGNOSIS CODES CHECK Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check diagnosis codes. (Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.) ERASING DIAGNOSIS CODES Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
HEATER, AIR CONDITIONER AND VENTILA- Troubleshootimg TION <AUTOMATIC AIR CONDITIONER>
55-37
55400490051

Code No. 11 12 13 14 15 16 21 22 31 32 41 42 Diagnosis item Inside air temperature sensor system (open circuit) Inside air temperature sensor system (short circuit) Outside air temperature sensor system (open circuit) Outside air temperature sensor system (short circuit) Heater water temperature sensor system (open circuit) Heater water temperature sensor system (short circuit) Air thermo sensor system (open circuit) Air thermo sensor system (short circuit) Potentiometer system of air mix damper motor assembly Potentiometer system of air outlet changeover damper motor assembly Drive system of air mix damper motor assembly Drive system of air outlet changeover damper motor assembly
Reference page 55-37 55-37 55-38 55-38 55-39 55-39 55-40 55-40 55-41 55-42 55-43 55-43
INSPECTION PROCEDURES FOR DIAGNOSIS CODES Code No.11 or 12 Inside air temperature sensor system
This diagnosis code is output if the inside air temperature sensor inside the A/C-ECU is defective. Replace the A/C-ECU.
Probable cause
D Malfunction of the A/C-ECU
55-38
Code No.13 Outside air temperature sensor system (open circuit)

This diagnosis code is output if there is a defective connector connection, or if there is an open circuit in the harness.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of connector harness the outside air temperature sensor the A/C-ECU
Outside air temperature sensor check (Refer to P.55-68.) OK Measure at the outside air temperature sensor connector A-21. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (1) and body earth OK: 5 V OK
NG NG
Replace
Check the following connectors: C-05, C-64 <L.H. drive vehicles>, C-116 <L.H. drive vehicles>, C-99 <R.H. drive vehicles> OK NG Repair Check the trouble symptom. NG Check the harness between the outside air temperature sensor and the A/C-ECU. OK NG Repair Replace the A/C-ECU.
Measure at the A/C-ECU connector C-05. D Connect the connector. D Voltage between terminal (7) and body earth OK: 2.3 - 2.9 V OK
NG
Check the following connectors: C-05, C-116 <L.H. drive vehicles>, C-99 <R.H. drive vehicles> OK NG Repair Check the trouble symptom. NG Check the harness between the outside air temperature sensor and the A/C-ECU, and repair if necessary.
Check the following connector: C-05 OK Check the trouble symptom.
NG NG
Repair
Replace the A/C-ECU.
Code No.14 Outside air temperature sensor system (short circuit)

This diagnosis code is output if there is a short circuit in the outside air temperature sensor input circuit.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of harness connector the outside air temperature sensor the A/C-ECU
Outside air temperature sensor check (Refer to P.55-68.) OK Measure at the A/C-ECU connector C-05. D Connect the connector. D Voltage between terminal (7) and body earth OK: 2.3 - 2.9 V OK Replace the A/C-ECU.
NG NG
Replace Check the harness between the outside air temperature sensor and the A/C-ECU, and repair if necessary.
55-39
Code No.15 Heater water temperature sensor system (open circuit)

Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of connector harness the heater water temperature sensor the A/C-ECU
Heater water temperature sensor check (Refer to P.55-70.) OK Measure at the heater water temperature sensor connector C-70. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (1) and body earth OK: 5 V OK
NG NG
Replace
Check the following connectors: C-05, C-64 <L.H. drive vehicles> OK NG Repair Check the trouble symptom. NG Check the harness between the heater water temperature sensor and the A/C-ECU. OK NG Repair Replace the A/C-ECU.
NG
Check the following connector: C-70 OK NG Repair Check the trouble symptom. NG Check the harness between the heater water temperature sensor and the A/C-ECU, and repair if necessary.
NG NG
Repair
Code No.16 Heater water temperature sensor system (short circuit)

This diagnosis code is output if there is a short circuit in the heater water temperature sensor input circuit.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of harness connector the heater water temperature sensor the A/C-ECU
Heater water temperature sensor check (Refer to P.55-70.) OK Measure at the A/C-ECU connector C-05. D Connect the connector. D Voltage between terminal (4) and body earth OK: 2.3 - 2.9 V OK Replace the A/C-ECU.
NG NG
Replace Check the harness between the heater water temperature sensor and the A/C-ECU, and repair if necessary.
55-40
Code No.21 Air thermo sensor system (open circuit)

Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of connector harness the air thermo sensor the A/C-ECU
Air thermo sensor check (Refer to P.55-26.) OK Measure at the air thermo sensor connector C-73. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (2) and body earth OK: 5 V OK
NG NG
Replace
Check the following connectors: C-05, C-64 <L.H. drive vehicles> OK NG Repair Check the trouble symptom. NG Check the harness between the air thermo sensor and the A/C-ECU. OK NG Repair Replace the A/C-ECU.
NG
Check the following connector: C-73 OK NG Repair Check the trouble symptom. NG Check the harness between the air thermo sensor and the A/C-ECU, and repair if necessary.
NG NG
Repair
Code No.22 Air thermo sensor system (short circuit)

This diagnosis code is output if there is a short circuit in the air thermo sensor input circuit.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of harness connector the air thermo sensor the A/C-ECU
Air thermo sensor check (Refer to P.55-26.) OK Measure at the A/C-ECU connector C-05. D Connect the connector. D Voltage between terminal (8) and body earth OK: 2.3 - 2.9 V OK Replace the A/C-ECU.
NG NG
Replace Check the harness between the air thermo sensor and the A/C-ECU, and repair if necessary.
55-41
Code No.31 Potentiometer system of air mix damper motor assembly

This diagnosis code is output if there is an open or short circuit in the potentiometer input circuit, or if there is an open circuit in the power circuit or earth circuit.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the air mix damper motor assembly connector harness the A/C-ECU
Air mix damper motor potentiometer check (Refer to P.55-59.) OK Measure at the air mix damper motor potentiometer connector C-79. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (6) and body earth OK: 5 V OK
NG NG
Replace
Check the following connectors: C-05, C-64 <L.H. drive vehicles> OK NG Repair Check the trouble symptom. NG Check the harness between the air mix damper motor potentiometer and the A/C-ECU. OK NG Repair Replace the A/C-ECU.
Measure at the A/C-ECU connector C-05. D Connect the connector. D Air mix damper position: MAX.HOT D Voltage between terminal (5) and body earth OK: 4.7 - 5.0 V OK
NG
Check the following connector: C-79 OK NG Repair Check the trouble symptom. NG Check the harness between the air mix damper motor potentiometer and the A/C-ECU, and repair if necessary.
NG NG
Repair
55-42
Code No.32 Potentiometer system of air outlet changeover damper motor assembly
This diagnosis code is output if there is an open or short circuit in the potentiometer input circuit, or if there is an open circuit in the power circuit or earth circuit.
Probable cause
D D D D Malfunction of the air outlet changeover damper motor assembly Malfunction of connector Malfunction of the A/C-ECU Malfunction of harness
Air outlet changeover damper motor potentiometer check (Refer to P.55-60.) OK Measure at the air outlet changeover damper motor potentiometer connector C-17. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (2) and body earth OK: 5 V OK
NG
Replace
NG
Check the following connectors: C-05, C-64 <L.H. drive vehicles> OK NG Repair Check the trouble symptom. NG Check the harness between the air outlet changeover damper motor potentiometer and the A/C-ECU. OK NG Repair Replace the A/C-ECU.
Measure at the A/C-ECU connector C-05. D Connect the connector. D Air outlet changeover damper position: DEF D Voltage between terminal (6) and body earth OK: 4.8 - 5.2 V OK
NG
Check the following connector: C-17 OK NG Repair Check the trouble symptom. NG Check the harness between the air outlet changeover damper motor potentiometer and the A/C-ECU, and repair if necessary.
NG NG
Repair
55-43
Code No.41 Drive system of air mix damper motor assembly

This diagnosis code is output if the motor drive circuit is defective.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of the air mix damper motor assembly connector harness the A/C-ECU
Air mix damper motor check (Refer to P.55-59.) OK Check the following connectors: C-07, C-79 OK Check the trouble symptom.
NG
Replace
NG
Repair
NG
Check the harness between the air mix damper motor and the A/C-ECU. OK NG Repair Replace the A/C-ECU.
Code No.42 Drive system of air outlet changeover damper motor assembly
This diagnosis code is output if the motor drive circuit is defective.
Probable cause
D D D D Malfunction of the air outlet changeover damper motor assembly Malfunction of connector Malfunction of harness Malfunction of the A/C-ECU
Air outlet changeover damper motor check (Refer to P.55-60.) OK Check the following connectors: C-17, C-07 OK Check the trouble symptom.
NG
Replace
NG
Repair
NG
Check the harness between the air outlet changeover damper motor and the A/C-ECU. OK NG Repair Replace the A/C-ECU.
55-44
Trouble symptom
55400500068

Inspection procedure No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Reference page 55-45 55-46 55-47 55-47 55-47 55-47 55-48 55-49 55-49 55-50 55-51 55-51 55-52 55-53 Refer to GROUP 14 - Troubleshooting.
Communication with the MUT-II is not possible. Air conditioner does not operate. A/C graphic display on control panel is blank. Temperature cannot be set. A/C outlet air temperature does not increase. A/C outlet air temperature does not decrease. Blower does not operate. Blower air amount cannot be changed. Air outlet port cannot be changed. Inside/outside air changeover is not possible. Defroster function does not operate. Rear defogger does not operate. A/C-ECU power supply circuit check A/C compressor control circuit check Radiator fan does not operate. Condenser fan does not operate.
55-45
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS Inspection procedure 1

Communication with the MUT-II is not possible.
If communication with all other systems is not possible, there is a high possibility that there is a malfunction of the diagnosis line. If communication with only the A/C is not possible, the cause is probably a malfunction of the diagnosis line or of the A/C-ECU power supply system (earth). NO
Probable cause
D D Malfunction of connector or harness Malfunction of A/C-ECU
Is communication between MUT-II and other system is possible? YES Measure at the diagnosis connector C-20. D Voltage between terminal (11) and body earth OK: Indication fluctuates between 0 V and 12 V. NG
Check the MUT-II diagnosis line, and repair if necessary. Measure at the A/C-ECU connector C-05. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (18) and body earth OK: Battery voltage - 2 V OK Check the following connector: C-05 OK NG Repair Check the trouble symptom. NG Replace the A/C-ECU. NG
OK
Check the following connector: C-05 OK NG Repair Check the trouble symptom. NG Check the harness between the diagnosis connector and the A/C-ECU, and repair if necessary.
Measure at the A/C-ECU connector C-05. D Connect the connector. D Voltage between terminal (17) and body earth OK: Indication fluctuates between 0 V and 12 V. OK
NG
Check the harness between the diagnosis connector and the A/C-ECU. NG Check the following connectors: C-05, C-20 OK Check the trouble symptom. NG Measure at the A/C-ECU connector C-07. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (28) and body earth OK: Battery voltage OK Measure at the A/C-ECU connector C-07. D Disconnect the connector, and measure at the harness side connector. D Continuity between terminales (27), (35) and body earth OK: Continuity OK Replace the A/C-ECU.
NG
Repair
NG
Repair
NG
Check the following connectors: C-132, C-63 <L.H. drive vehicles>, C-61 <R.H. drive vehicles> OK Check the trouble symptom.
NG
Repair
NG
Check the harness between the junction block and the A/C-ECU, and repair if necessary. Repair
NG
Check the following connectors: C-07, C-62 <L.H. drive vehicles> OK Check the trouble symptom.
NG
NG
Check the harness between the A/C-ECU and the body earth, and repair if necessary.
55-46
Inspection procedure 2 Air conditioner does not operate.

If the A/C does not operate when the A/C switch is on and the temperature setting is at 17_C, the cause is probably insufficient refrigerant, or a malfunction of the blower or of the magnet clutch power supply.
Probable cause
D D D D D D D D D D Malfunction of blower Insufficient refrigerant Malfunction of magnetic clutch Malfunction of air thermo sensor Malfunction of A/C compressor relay Malfunction of refrigerant temperature switch Malfunction of dual pressure switch Malfunction of connector or harness Malfunction of engine-ECU Malfunction of A/C-ECU
Does the blower operate? YES A/C system refrigerant pressure check (Refer to P.55-14.) OK MUT-II DIAGNOSIS CODE Is any of the codes 11, 21 and 22 output? NO D D D D Magnetic clutch check (Refer to P.55-7.) A/C compressor relay check (Refer to P.55-17.) Refrigerant temperature switch check (Refer to P.55-65.) Dual pressure switch check (Refer to P.55-8.) OK Measure at the A/C compressor relay connector B-28X. D Disconnect the connector, and measure at the harness side connector. (1) Continuity between terminal (4) and body earth OK: Continuity (2) Voltage between terminal (5) and body earth OK: Battery voltage (1) NG Check the following connectors: B-28X, B-30, B-75 OK Check the trouble symptom. NG Check the harness between the magnetic clutch and the A/C compressor relay, and repair if necessary.
NO
Inspection procedure 7 (Refer to P.55-48.) Refill the specified amount of refrigerant. (Refer to P.55-9.) INSPECTION CHART FOR DIAGNOSIS CODES (Refer to P.55-37.)
NG YES
NG
Replace
OK
Inspection procedure 14 (Refer to P.55-53.)
(2) NG
Check the following connector: B-28X OK NG Repair Repair Check the trouble symptom. NG Check the harness between the fusible link and the A/C compressor relay, and repair if necessary.
NG
55-47
Inspection procedure 3 A/C graphic display on control panel is blank.

The cause is probably a malfunction of the A/C-ECU power supply system (earth). NO YES Replace the A/C-ECU.
Probable cause
Does the A/C operate?
Inspection procedure 4 Temperature cannot be set.

The cause is probably a malfunction of the temperature setting signal input system or output system. Inspection procedure 13 (Refer to P.55-52.)
Probable cause
Inspection procedure 5 A/C outlet air temperature does not increase.

If the outlet air temperature does not increase when the temperature setting is increased, the cause is probably a sensor malfunction or a problem with operation of the air mix damper. The MUT-II can be used to check the diagnosis codes in order to check the cause of the problem for each separate system.
Probable cause
D D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of of air mix damper motor potentiometer air mix damper motor air mix damper connector or harness thermostat A/C-ECU
MUT-II DIAGNOSIS CODE Is any of the codes 11, 12, 31 and 41 output? NO Thermostat check (Refer to GROUP 14 - On-vehicle Service.) OK Replace the A/C-ECU.
YES
INSPECTION CHART FOR DIAGNOSIS CODES (Refer to P.55-37.)
NG
Replace
Inspection procedure 6 A/C outlet air temperature does not decrease.

If the outlet air temperature does not decrease when the temperature setting is decreased, the cause is probably a problem in A/C system operation due to a sensor error, or a problem with operation of the air mix damper. The MUT-II can be used to check the diagnosis codes in order to check the cause of the problem for each separate system.
Probable cause
D D D D D D D Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction Malfunction of of of of of of of outside air temperature sensor air mix damper motor potentiometer air mix damper motor air thermo sensor connector or harness air mix damper A/C-ECU
Does the A/C operate? YES MUT-II DIAGNOSIS CODE Is any of the codes 11, 12, 13, 14, 21, 22, 31 and 41 output? NO Replace the A/C-ECU.
NO
YES
55-48
Inspection procedure 7 Blower does not operate.

If no air comes out of the blower even though the blower switch is on, the cause is probably a malfunction of the blower motor relay circuit.
Probable cause
D D D D Malfunction Malfunction Malfunction Malfunction of of of of blower motor relay blower motor connector or harness A/C-ECU
Can an operating sound be heard when the blower speed changeover switch is operated? YES D D Blower relay check (Refer to P.55-16.) Blower motor check (Refer to P.55-23.) OK Measure at the blower relay connector C-140. D Disconnect the connector, and measure at the harness side connector. (1) Continuity between terminal (1) and body earth OK: Continuity (2) Voltage between terminal (3) and body earth (Ignition switch: ON) OK: Battery voltage (3) Voltage between terminal (2) and body earth OK: Battery voltage OK Measure at the blower motor connector C-09. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (1) and body earth (Ignition switch: ON) OK: Battery voltage OK
NO
NG
Replace
(1) NG (2) NG (3) NG
Check the harness between the blower relay and the body earth, and repair if necessary. Check the harness between the blower relay and the ignition switch, and repair if necessary. Check the harness between the blower relay and the fusible link No.1, and repair if necessary.
NG
Check the following connector: C-131 OK NG Repair Check the trouble symptom. NG Check the harness between the blower relay and the blower motor, and repair if necessary.
NG
Repair
NG
Check the harness between the blower motor and the A/C-ECU, and repair if necessary.
55-49
Inspection procedure 8 Blower air amount cannot be changed.

If the blower does not operate in any mode other than HI setting, the cause is probably a malfunction of the power transistor system.
Probable cause
D D D Malfunction of power transistor Malfunction of connector or harness Malfunction of A/C-ECU
Measure at the power transistor connector C-77. D Blower switch position: LO D Connect the connector. (1) Continuity between terminal (1) and body earth OK: Continuity (2) Voltage between terminal (3) and body earth (Ignition switch: ON) OK: Battery voltage - 2 V (3) Voltage between terminal (4) and body earth (Ignition switch: ON) OK: Approx. 1.3 V
OK
Check the following connector: C-77 OK NG Repair Check the trouble symptom. NG Replace the power transistor.
(1) NG (2) NG (3) NG Measure at the A/C-ECU connector C-05. D Blower switch position: LO D Connect the connector. (1) Voltage between terminal (1) and body earth (Ignition switch: ON) OK: Approx. 7 V (2) Voltage between terminal (2) and body earth (Ignition switch: ON) OK: Approx. 1.3 V OK Check the harness between the power transistor and the A/C-ECU. OK Replace the power transistor. NG NG
Check the harness between the power transistor and the body earth, and repair if necessary. Check the harness between the power transistor and the blower motor, and repair if necessary.
Check the following connector: C-05 OK NG Repair Check the trouble symptom. NG Replace the A/C-ECU. Repair
Inspection procedure 9 Air outlet port cannot be changed.

The cause is probably a malfunction of the air outlet port changeover signal input system or output system. The MUT-II can be used to check the diagnosis codes in order to check the cause of the problem for each separate system.
Probable cause
D D D D D Malfunction of potentiometer Malfunction of Malfunction of Malfunction of Malfunction of air outlet changeover damper motor air outlet changeover damper motor air outlet changeover damper connector or harness A/C-ECU
Can an operating sound be heard when the air outlet port changeover switch is operated? YES MUT-II DIAGNOSIS CODE Is either code 32 or code 42 output? NO Air outlet changeover damper check OK Replace the A/C-ECU.
NO
YES
NG
Repair
55-50
Inspection procedure 10 Inside/outside air changeover is not possible.

If inside/outside air changeover is not possible even when the inside/outside air changeover switch is on, the cause is probably a malfunction of the inside/outside air changeover damper motor.
Probable cause
D D D D Malfunction of damper motor Malfunction of damper Malfunction of Malfunction of inside/outside air changeover inside/outside air changeover connector or harness A/C-ECU
Can an operating sound be heard when the inside/outside air changeover switch is operated? YES Inside/outside air changeover damper motor check (Refer to P.55-24.) OK Measure at the inside/outside air changeover damper motor connector C-78. D Disconnect the connector, and measure at the harness side connector. D Outside air select button: ON D Voltage between terminal (1) and body earth OK: 10 V D Inside air select button: ON D Voltage between terminal (2) and body earth OK: 10 V OK Check the following connector: C-78 OK Check the trouble symptom. NG Inside/outside air changeover damper check OK Replace the A/C-ECU.
NO
NG
Replace
NG
Check the following connector: C-07 OK NG Repair Check the trouble symptom. NG Check the harness between the inside/outside air changeover damper motor and the A/C-ECU, and repair if necessary. Repair OK NG Repair Replace the A/C-ECU.
NG
NG
Repair
55-51
Inspection procedure 11 Defroster function does not operate.

If the defroster function does not operate when the defroster switch is turned on, the cause is probably a malfunction of the A/C or of the air outlet port changeover circuit.
Probable cause
D D D D Malfunction Malfunction system Malfunction Malfunction of air conditioner drive system of air outlet changeover damper drive of connector or harness of A/C-ECU
Can an operating sound be heard when the defroster switch is operated? YES Does the A/C operate? YES Can the air outlet port be changed over? YES Air outlet changeover damper (for defroster) check OK Replace the A/C-ECU.
NO
NO NO
Inspection procedure 2 (Refer to P.55-46.) Inspection procedure 9 (Refer to P.55-49.)
NG
Repair
Inspection procedure 12 Rear defogger does not operate.

If the rear defogger does not operate when the rear defogger switch is turned on (timer operates for 20 minutes), the cause is probably a malfunction of the A/C-ECU power supply system (earth). NO
Probable cause
Can an operating sound be heard when the rear defogger switch is operated? YES Replace the A/C-ECU.
55-52
Inspection procedure 13 A/C-ECU power supply circuit check

Measure at the A/C-ECU connector C-05. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (3) and body earth OK: Battery voltage OK Check the trouble symptom. NG Check the harness between the A/C-ECU and the fusible link No.2, and repair if necessary. Measure at the A/C-ECU connector C-07. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (28) and body earth (Ignition switch: ON) OK: Battery voltage OK NG Check the following connectors: C-63 <L.H. drive vehicles>, C-61 <R.H. drive vehicles>, C-132 OK NG Repair Check the trouble symptom. NG Check the harness between the A/C-ECU and the junction block, and repair if necessary. Measure at the A/C-ECU connector C-07. D Disconnect the connector, and measure at the harness side connector. D Continuity between terminal (27) and body earth OK: Continuity D Continuity between terminal (35) and body earth OK: Continuity OK Check the following connector: C-07 OK Check the trouble symptom. NG Repair NG Check the harness between the A/C-ECU and the body earth, and repair if necessary. NG Check the following connectors: C-63, C-132, C-141 <L.H. drive vehicles>, C-62, C-14 <R.H. drive vehicles> OK NG Repair
NG
55-53
Inspection procedure 14 A/C compressor control circuit check

Measure at the A/C-ECU connector C-07. D Blower switch and A/C switch: ON D Setting temperature: 17_C D Connect the connector. D Voltage between terminal (34) and body earth (Ignition switch: ON) OK: Battery voltage OK Replace the A/C-ECU. Measure at the A/C compressor relay connector B-28X. D Blower switch and A/C switch: ON D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (3) and body earth OK: Battery voltage OK NG NG Check the following connector: C-07 OK NG Repair Check the trouble symptom. NG
Check the following connectors: C-116, C-67, C-14, C-64, C-07 <L.H. drive vehicles> C-14, C-66, C-115, C-07 <L.H. drive vehicles> OK NG Repair Check the trouble symptom. NG Check the harness between the A/C-ECU and the A/C compressor relay, and repair if necessary.
Measure at the engine-ECU connector C-55 <4D6>, C-34 <4G6>, C-33 <6A1>. D Disconnect the connector, and measure at the harness side connector. D Voltage between terminal (53) and body earth <4D6> D Voltage between terminal (8) and body earth <4G6, 6A1> OK: Battery voltage OK Replace the engine-ECU.
NG
Check the following connectors: B-30, B-28X OK NG Repair Check the trouble symptom. NG Check the harness between the A/C compressor relay and the engine-ECU, and repair if necessary.
55-54
Item No. 11
55400510078

Check item Inside air temperature sensor Outside air temperature sensor Heater water temperature sensor Air thermo sensor Check condition Ignition switch: ON Normal condition
Inside air temperature and temperature displayed on the MUT-II are identical. Outside air temperature and temperature displayed on the MUT-II are identical. Heater core surface temperature and temperature displayed on the MUT-II are identical. Evaporator surface temperature and temperature displayed on the MUT-II are identical. Amount of incident light is proportional to voltage displayed on the MUT-II. Damper position MAX. HOT MAX. COOL Opening degree (%) Approx. 100 Approx. 0 Opening degree (%) Approx. 0 Approx. 50 Approx. 75 Approx. 100
55400540077
13
Ignition switch: ON
15
Ignition switch: ON
21
Ignition switch: ON
25
Photo sensor
Ignition switch: ON
31
Air mix damper motor potentiometer
Ignition switch: ON
32
Air outlet changeover damper motor potentiometer
Ignition switch: ON
Damper position FACE FOOT FOOT/DEF. DEF.
CHECK AT THE A/C-ECU TERMINALS
Terminal No. 1
Check item Power MOS FET drain output
Check condition When blower switch is at OFF When blower switch is at LO When blower switch is at HI
Normal condition System voltage Approx. 9 V Almost no voltage (0 V)
HEATER, AIR CONDITIONER AND VENTILA- Troubleshootimg TION <AUTOMATIC AIR CONDITIONER> Terminal No. 2 Check item Power MOS FET gate output Check condition When blower switch is at OFF When blower switch is at LO When blower switch is at HI 3 4 5 6 7 8 9 A/C-ECU backup power supply Heater water temperature sensor input Air mix damper motor potentiometer input Air outlet changeover damper motor potentiometer input Outside air temperature sensor input Air thermo sensor input Photo sensor (- ) At all times When sensor section temperature is 25_C (4 kW) When damper is moved to MAX. HOT position When damper is moved to DEF. position When sensor section temperature is 25_C (4 kW) When sensor section temperature is 25_C (4 kW) At luminous intensity of 100,000 lux or more At luminous intensity of 0 lux 10 16 Sensor power supply Rear defogger input At all times When rear defogger switch is ON When rear defogger switch is OFF 17 18 19 20 Diagnosis date output Diagnosis control input Photo sensor (+) Air mix damper motor and air outlet changeover damper motor potentiometers Air outlet changeover damper motor (+) When ignition switch is ON When ignition switch is ON At all times At all times
55-55
Normal condition 0V Approx. 1.3 V Approx. 2.5 V System voltage 2.3 - 2.9 V 4.7 - 5.0 V 4.8 - 5.2 V 2.3 - 2.9 V 2.3 - 2.9 V - 0.1 - 0.2 V 0V 4.8 - 5.2 V 1.5 V or less System voltage 0 V System voltage Battery voltage - 2 V 0V 0V
21
Set to FACE position (OFF after 40 seconds of output) Set to DEF. position (OFF after 40 seconds of output)
10 V 0.5 V 10 V
22
Air mix damper motor (- )
Set the setting temperature to 17_C and set to MAX. COOL position (OFF after 40 seconds of output) Set the setting temperature to 32_C and set to MAX. HOT position (OFF after 40 seconds of output)
0.5 V
55-56
Terminal No. 23
HEATER, AIR CONDITIONER AND VENTILATION <AUTOMATIC AIR CONDITIONER> Check item Inside/outside air changeover damper motor (- ) Check condition
Troubleshooting/ On-vehicle Service Normal condition 0.5 V 10 V 0.5 V 10 V 0.5 V
Set to inside air position (OFF after 40 seconds of output) Set to outside air position (OFF after 40 seconds of output)
24
Air outlet changeover damper motor (- )
Set to FACE position (OFF after 40 seconds of output) Set to DEF. position (OFF after 40 seconds of output)
25
Air mix damper motor (+)
Set the setting temperature to 17_C and set to MAX. COOL position (OFF after 40 seconds of output) Set the setting temperature to 32_C and set to MAX. HOT position (OFF after 40 seconds of output)
10 V
26
Inside/outside air changeover damper motor (+)
Set to inside air position (OFF after 40 seconds of output) Set to outside air position (OFF after 40 seconds of output)
10 V 0.5 V Continuity System voltage Continuity System voltage 0V System voltage 0V System voltage Continuity
55400080029
27 28 29 30 33
Earth A/C-ECU power supply ILL earth (rheostat) ILL power supply Engine-ECU output
At all times When ignition switch is ON At all times When lighting switch is at ON When air mix damper is at MAX. COOL position When air mix damper is at MAX. HOT position
34
A/C output
When A/C is OFF When A/C is ON
35
Earth
At all times
ON-VEHICLE SERVICE
The service procedures are the same as for the manual air conditioner. (Refer to P.55-7.)
Air Conditioner Control Panel and ECU Assembly
55-57
55400100084
AIR CONDITIONER CONTROL PANEL AND ECU ASSEMBLY

Pre-removal and Post-installation Operation D Floor Console Panel Removal and Installation (Refer to GROUP 52A - Floor Console Box.)
1 2 3
Removal steps 1. Center console panel and air conditioner control panel assembly 2. Center console panel 3. Air conditioner control panel and ECU assembly
55-58
Damper Motor Assembly and Power Transistor

55400580024
DAMPER MOTOR ASSEMBLY AND POWER TRANSISTOR

Inside/outside air changeover damper motor assembly removal steps D Glove box (Refer to GROUP 52A Instrument Panel.) 1. Inside/outside air changeover damper motor assembly Outlet air changeover damper motor assembly removal steps D Lower cover (Refer to GROUP 52A - Instrument Panel.) 2. Outlet air changeover damper motor assembly
Air mix damper motor assembly removal steps D Glove box, side cover, glove box frame, radio, tape player (Refer to GROUP 52A - Instrument Panel.) D Under cover (Refer to P.55-33.) 3. Control relay bracket assembly 4. Air mix damper motor assembly Power transistor removal steps D Glove box (Refer to GROUP 52A Instrument Panel.) D Under cover (Refer to P.55-33.) 5. Power transistor
INSPECTION
55400590027
INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR ASSEMBLY CHECK For inspection service points, refer to P.55-24 for heater and manual A/C.
55-59
Lever
AIR MIX DAMPER MOTOR ASSEMBLY CHECK Motor Check that the lever moves when battery voltage is applied across terminals 1 and 3 of the motor assembly connector. Check also that the lever moves in the backward direction when polarity is changed. Caution 1. Cut off the voltage when the damper is in the MAX. HOT or MAX. COOL position. 2. Cut off the voltage if the motor does not turn when battery voltage is applied. Potentiometer Connect a circuit tester across terminals 2 and 5 of the motor assembly connector and check that resistance gradually changes as the damper is moved from MAX. HOT to MAX. COOL position. Standard value: MAX. HOT position: Approx. 4.8 kW MAX. COOL position: Approx. 0.2 kW
MOTOR
POTENTIOMETER
55-60
Lever
AIR OUTLET CHANGEOVER DAMPER MOTOR ASSEMBLY CHECK Motor Check that the lever moves when battery voltage is applied across terminals 1 and 3 of the motor assembly connector. Check also that the lever moves in the backward direction when polarity is changed. Caution 1. Cut off the voltage when the damper is in the DEF or FACE position. 2. Cut off the voltage if the motor does not turn when battery voltage is applied. Potentiometer Connect a circuit tester across terminals 5 and 6 of the motor assembly connector and check that resistance gradually changes as the damper is moved from DEF. to FACE position. Standard value: DEF. position: Approx. 4.8 kW FACE position: Approx. 0.2 kW
MOTOR
POTENTIOMETER
HEATER, AIR CONDITIONER AND VENTILA- Compressor and Tension Pulley TION <AUTOMATIC AIR CONDITIONER>
55-61
55200410273
COMPRESSOR AND TENSION PULLEY

Pre-removal Operation D Discharging of Refrigerant (Refer to P.55-13.) Post-installation Operation D Drive Belt Tension Adjustment (Refer to GROUP 11 - On-vehicle Service.) D Charging of Refrigerant (Refer to P.55-9.)
Piping connection
<4G6>
2
O-ring
25 Nm
5 6 6 5
<6A1>
3 2
49 Nm
4 1
AA"
Removal steps D Under cover D Condenser fan motor (Refer to P.55-31.) D Drive belt (for alternator) <6A1> (Refer to GROUP 11 - Crankshaft Pulley.) 1. Drive belt
AB"
2. Tension pulley 3. Hose connections 4. Power steering oil pressure switch harness <6A1> AC" "AA 5. Compressor 6. Compressor bracket
55-62
<4D6> 39 Nm Piping connection
O-ring
6 8 3 5
25 Nm
20 - 25 Nm
4 1
AA"
Removal steps D Under cover D Condenser fan motor (Refer P.55-31.) 1. Drive belt (for compressor) 2. Tension pulley 3. Tension pulley bracket
to
AB" 4. Hose connections AC" "AA 5. Compressor 6. Drive belt (for power steering oil pump) 7. Power steering oil pump 8. Compressor bracket
<4G6>
55-63

AA" DRIVE BELT REMOVAL 1. Loosen the nut A for holding. 2. Loosen the bolt B <4G6 and 6A1> or nut B <4D6> for adjustment. 3. Remove the drive belt.
Bolt B
Nut A
<6A1>
Nut A Bolt B <4D6> Nut A
Nut B
AB" HOSE DISCONNECTION Plug the disconnected hose and the compressor nipple not to let foreign matter get into them. Caution Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily.
AC" COMPRESSOR REMOVAL When doing this work, be careful not to spill the compressor oil.
55-64

"AA COMPRESSOR INSTALLATION If a new compressor is installed, first adjust the amount of oil according to the procedures described below, and then install the compressor. 1. Measure the amount (X mL) of oil within the removed compressor. 2. Drain (from the new compressor) the amount of oil calculated according to the following formula, and then install the new compressor. New compressor oil amount 120 mL - X mL = Y mL NOTE (1) Y mL indicates the amount of oil in the refrigerant line, the condenser, the evaporator etc. (2) When replacing the following parts at the same times as the compressor, subtract the rated oil amount of the each part from Y mL and discharge from the new compressor. Quantity Evaporator: 60 mL Condenser: 15 mL Suction hose: 10 mL Receiver: 10 mL
55-65
55200930083
INSPECTION
Refrigerant temperature switch
REFRIGERANT TEMPERATURE SWITCH SIMPLE CHECK When the A/C is off, check that there is continuity between the refrigerant temperature switch terminals. If no, replace the refrigerant temperature switch.
COMPRESSOR MAGNETIC CLUTCH OPERATION 55200850181 CHECK Connect the battery (+) terminal to the compressor side terminal, and earth the battery ( - ) terminal to the body of the compressor. The condition is normal if the sound of the magnetic clutch (click) can be heard.
MAGNETIC CLUTCH AND REFRIGERANT TEMPERATURE SWITCH

55200460216
9 7 1 2 4 6 8
10
<4G6>
5 3
<6A1, 4D6>
9 8 6 3 4 7
"EA AA" "DA "CA "BA
Magnetic clutch disassembly steps 1. Bolt <4G6> 2. Pulley <4G6> D Air gap adjustment 3. Nut 4. Armature plate 5. Shims 6. Snap ring
7. Rotor 8. Snap ring "AA 9. Clutch coil Refrigerant temperature switch removal 10. Refrigerant temperature switch
55-66

MB991386
AA" NUT REMOVAL
MB991367
Clutch coil projection

"AA CLUTCH COIL INSTALLATION When installing the clutch coil to the A/C compressor body, install so that the pin hole of the A/C compressor body and the clutch coil projection are aligned.
Compressor body pin hole
Snap ring
Rotor
Clutch coil
"BA SNAP RING INSTALLATION Install the snap ring so that the tapered surface is at the outer side.
Tapered part
Armature plate Serration notch
"CA ARMATURE PLATE INSTALLATION Align the mating mark of the crankshaft spline and the mating mark of the armature plate, and then fit them together. "DA NUT INSTALLATION Use the special tool to hold the magnet clutch, and tighten the nut in the same manner as removal.
Matching mark
Crankshaft
Thickness gauge
"EA AIR GAP ADJUSTMENT Check whether or not the air gap of the clutch is within the standard value. Standard value: 0.40 - 0.65 mm NOTE If there is a deviation of the air gap from the standard value, make the necessary adjustment by adjusting the number of shims.
- Photo Sensor
55-67
55400310067
PHOTO SENSOR
1
AA"
Removal step 1. Photo sensor

AA" PHOTO SENSOR REMOVAL Use a flat-tipped screwdriver (width: 3 mm or less) to remove the photo sensor.
Flat-tipped screwdriver Photo sensor
INSPECTION
55400320046
If the blower speed drops when the receiver section of the photo sensor is covered with your hand, then the photo sensor is normal. If the speed does not drop, replace the photo sensor.
55-68
HEATER, AIR CONDITIONER AND VENTILA- Outside Air Temperature Sensor TION <AUTOMATIC AIR CONDITIONER>
55400340042
OUTSIDE AIR TEMPERATURE SENSOR

Pre-removal and Post-installation Operation D Front Bumper Removal and Installation (Refer to GROUP 51.)
Outside air temperature sensor
INSPECTION
Resistance kW 20 15 10 5 0 - 10
55400350021
When the resistance value between the sensor terminals is measured under two or more temperature conditions, the resistance value should be close to the values shown in the graph. NOTE The temperature conditions when testing should not exceed the range of the characteristic curve in the graph.
0 10 20 30 40 Temperature _C
HEATER, AIR CONDITIONER AND VENTILA- Heater Water Temperature Sensor TION <AUTOMATIC AIR CONDITIONER>
55-69
55400450080
HEATER WATER TEMPERATURE SENSOR

Pre-removal and Post-installation Operation D Lower Cover and Side Cover Removal and Installation (Refer to GROUP 52A - Instrument Panel.) D Engine-ECU, A/T-ECU and A/T Control Relay Removal and Installation (Refer to GROUP 52B - SRS-ECU.)
Caution: SRS When removing and installing the engine-ECU, A/T-ECU, A/T control relay and clip from vehicles equipped with SRS, do not let them bump against the SRS-ECU.
Removal steps AA" "AA 1. Heater water temperature sensor clip AA" "AA 2. Heater water temperature sensor

Foot distribution duct Heater unit
Heater water temperature sensor clip
AA" HEATER WATER TEMPERATURE SENSOR CLIP AND HEATER WATER TEMPERATURE SENSOR REMOVAL Pull out the heater water temperature sensor clip which is at the bottom of the heater unit, and then remove the heater water temperature sensor from the heater unit.

"AA HEATER WATER TEMPERATURE SENSOR AND HEATER WATER TEMPERATURE SENSOR CLIP INSTALLATION Insert the heater water temperature sensor into its mounting hole at the bottom of the heater unit, and then fix it by inserting the heater water temperature sensor clip.
55-70
Heater Water Temperature Sensor/ Other Maintenance Service Points

55400460021
INSPECTION
Resistance kW 20 15 10 5 0 - 10
When the resistance value between the sensor terminals is measured under two or more temperature conditions, the resistance value should be close to the values shown in the graph. NOTE The temperature conditions when testing should not exceed the range of the characteristic curve in the graph.
0 10 20 30 40 Temperature _C
OTHER MAINTENANCE SERVICE POINTS

The following maintenance service points are the same as for the manual A/C.
Items GENERAL INFORMATIONS ON-VEHICLE SERVICE Safety Precautions Sight Glass Refrigerant Level Test Magnetic Clutch Test Receiver Drier Test Dual Pressure Switch Check Compressor Drive Belt Adjustment Charging Performance Test Refrigerant Leak Repair Compressor Noise Power Relay Check Idle-up Operation Check HEATER UNIT, HEATER CORE, AND BLOWER UNIT BLOWER FAN AND MOTOR EVAPORATOR AIR PURIFIER ASSEMBLY REFRIGERANT LINE CONDENSER AND CONDENSER FAN MOTOR VENTILATORS
55400400078
Reference page 55-3 55-7 55-7 55-7 55-8 55-8 55-9 55-14 55-15 55-16 55-16 55-18 55-22 55-23 55-25 55-27 55-28 55-31 55-33
RJST612005 - 1218

Mitsibushi Galant 96 02 Workshop Manual

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General . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling . . . . . . . . . . . . . . . . . Intake and Exhaust ............

E Mitsubishi Motors Corporation

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

STANDARD PART/TIGHTENING-TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

GENERAL - How to Use This Manual

HOW TO USE THIS MANUAL

INDICATION OF TIGHTENING TORQUE

GENERAL - How to Use This Manual MODEL INDICATIONS

GENERAL - How to Use This Manual

EXPLANATION OF MANUAL CONTENTS

GENERAL - How to Use This Manual

Denotes able part.

GENERAL - How to Use Troubleshooting/Inspection Service Points

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

Check trouble symptom. Reoccurs Does not reoccur.

Read the diagnosis code Diagnosis code displayed. No diagnosis code

Recheck trouble symptom.

Read the diagnosis codes. Diagnosis code displayed. No diagnosis code

INTERMITTENT MALFUNCTIONS (Refer to P.00-12.)

GENERAL - How to Use Troubleshooting/Inspection Service Points

GENERAL - How to Use Troubleshooting/Inspection Service Points

Indication of diagnosis code by warning lamp

When no diagnosis code is output*

Pause time 3 secs.

Place division 2 secs.

Test bar Connector

Inspection harness for connector pin contact pressure

GENERAL - How to Use Troubleshooting/Inspection Service Points

Defective connector contact

Harness wire breakage at terminal section Low contact pressure

Fuse Connector inspection

Load switch Load

POINTS TO NOTE FOR INTERMITTENT MALFUNCTIONS

GENERAL - Vehicle Identification

ENGINE EXT TRANS AXLE COLOR INT OPT

Fuel supply system MPI

Electronically controlled injection pump MPI

SNJEQL6C SNHEQL6C SRHEQL6C

4G63-SOHC (1,997 mL)

GENERAL - Vehicle Identification

4G63-SOHC (1,997 mL)

F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)

6A13-SOHC (2,497 mL)

F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)

4D68-SOHC (1,998 mL)

Electronically controlled injection pump

LNJEQL6C LNHEQL6C LRHEQL6C

4G63-SOHC (1,997 mL)

4G63-SOHC (1,997 mL)

F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)

6A13-SOHC (2,497 mL)

F5M42 (2WD-5M/T) F4A42 (2WD-4A/T)

4D68-SOHC (1,998 mL)

Electronically controlled injection pump

GENERAL - Vehicle Identification MODEL CODE

Sort Body style Transmission type

GENERAL - Vehicle Identification CHASSIS NUMBER

Items Fixed figure Distribution channel Destination J M A B

Development order Engine

Sort Model year Plant Serial number

GENERAL - Vehicle Identification