Professional Documents
Culture Documents
00
Engine . . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Lubrication . . . . . . . . . . . . . 12
WORKSHOP Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MANUAL Engine Cooling . . . . . . . . . . . . . . . . . 14
Intake and Exhaust ............ 15
FOREWORD Engine Electrical . . . . . . . . . . . . . . . 16
This Workshop Manual contains procedures Engine and Emission Control . . . . 17
for service mechanics, including removal,
disassembly, inspection, adjustment, Clutch . . . . . . . . . . . . . . . . . . . . . . . . . 21
reassembly and installation. Use the
following manuals in combination with this Manual Transmission . . . . . . . . . . . 22
manual as required.
Automatic Transmission . . . . . . . . 23
TECHNICAL INFORMATION MANUAL
PYJE0001 Propeller Shaft . . . . . . . . . . . . . . . . . 25
WORKSHOP MANUAL
ENGINE GROUP PWEE____ Front Axle . . . . . . . . . . . . . . . . . . . . . .
(Looseleaf edition)
26
CHASSIS GROUP PWJE0001 Rear Axle . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL WIRING PHJE0001
27
BODY REPAIR MANUAL PBJE0001 Wheel and Tyre . . . . . . . . . . . . . . . . .
PARTS CATALOGUE B603H601Aj 31
Power Plant Mount . . . . . . . . . . . . . . 32
Front Suspension . . . . . . . . . . . . . . . 33
All information, illustrations and product
descriptions contained in this manual are Rear Suspension . . . . . . . . . . . . . . . 34
current as at the time of publication. We,
however, reserve the right to make changes Service Brakes . . . . . . . . . . . . . . . . . 35
at any time without prior notice or obligation.
Parking Brakes . . . . . . . . . . . . . . . . . 36
Steering . . . . . . . . . . . . . . . . . . . . . . . . 37
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Exterior . . . . . . . . . . . . . . . . . . . . . . . . 51
Interior and Supplemental
Restraint System (SRS) . . . . . . . . . 52
Chassis Electrical . . . . . . . . . . . . . . 54
Heater, Air Conditioner and
Ventilation . . . . . . . . . . . . . . . . . . . . . . 55
GDI is a trade mark of Mitsubishi Motors Corpo-
ration.
E Mitsubishi Motors Corporation February 2000
WARNING!
(1) Improper service or maintenance of any component of the SRS and 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) SRS components 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 and front seat
assembly (side air bag module) before drying or baking the vehicle after painting.
SRS-ECU, air bag module, clock spring and side impact sensor: 93_C or more
(3) Service or maintenance of any SRS component and 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 any SRS-related component.
NOTE
Section titles with asterisks (*) in the table of contents in each group indicate operations requiring warnings.
11A-1
ENGINE
CONTENTS
FUEL
CONTENTS
SERVICE BRAKES
CONTENTS
INTERIOR AND
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS
INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52A
CHASSIS
ELECTRICAL
CONTENTS
HEATER, AIR
CONDITIONER AND
VENTILATION
CONTENTS
GENERAL
CONTENTS
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
Component Diagram
A diagram of the component parts is
provided near the front of each section
in order to give a reader a better under-
standing of the installed condition of
component parts.
denotes non-re-
usable part.
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.
No diagnosis code
or communication Diagnosis code Diagnosis code No diagnosis
with MUT-II not displayed. displayed. code
possible
Refer to the INSPECTION CHART FOR DIAGNOSIS INTERMITTENT MALFUNCTIONS (Refer to P.00-13.)
CODES (Refer to applicable group.)
3. DIAGNOSIS FUNCTION
Details which are different from those in the Diagnosis Function section on the next page are listed.
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 the ignition switch to LOCK(OFF) position before
connecting or disconnecting the MUT-II.
0.5 sec.
0.5 sec. <SS4 II, A/T>
1.5 secs. 0.5 sec. 0.25 sec. <ABS, HBB>
On
Off On
Pause Tens Place Units Off
time 3 signal division signal
secs. 2 secs.
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 the ignition switch to LOCK (OFF) position before connecting or disconnecting the MUT-II.
WHEN NOT USING THE MUT-II
1. Turn the ignition switch to LOCK(OFF) position.
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.
MB991529
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.
Purchased from www.WorkshopManuals.co.uk
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GENERAL - How to Use Troubleshooting/Inspection Service Points 00-11
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.
Connector
Good
Bad
Load
Transfer
Filler plug
Filler plug
Filler plug
VEHICLE IDENTIFICATION
VEHICLE INFORMATION CODE PLATE
LOCATION
Vehicle information code plate is riveted on the toeboard
inside the engine compartment.
MNHFR6
MNXFL6
MNXFR6
MNXFR6
MYXFR6
MNHCR6
MYHCR6
MNXCR6
MYXCR6
<Long wheelbase>
Model code Engine model Transmission model Fuel supply system
LNXFL6
LNHFR6
LYHFR6
LNXFR6
LYXFR6
LNHCR6
LYHCR6
LNXCR6
LYXCR6
MODEL CODE
4 Sort W: Wagon
7 Trim level D: GL
H: GLX
X: GLS
1 2 3 4 5 6 7 8 9 10 11
L 5-door
10 Plant J Nagoya-3
11 Serial number - -
<4D56>
ENGINE MODEL NUMBER
1. The engine model number is stamped at the cylinder
block as shown in the following.
Engine model Engine displacement mL
4D56 2,477
4M41 3,200
6G74 3,496
2. The engine serial number is stamped near the engine
model number.
Engine serial number AA0201 to YY9999
<4M41>
<6G74>
A
B
A
B
The illustration indicates left outer side. Right side is The illustration indicates left outer side. Right side is
symmetrically opposite. symmetrically opposite.
A
A
B
B
The illustration indicates right outer side. The illustration indicates right outer side.
Left side is symmetrically opposite. Left side is symmetrically opposite.
TARGET AREA (A: FOR ORIGINAL EQUIPMENT PARTS, B: FOR REPLACEMENT PARTS)
A B
NOTE:
*1: Vehicles with roof rails
*2: Vehicles with 235/80R16 Tyre
*3: Vehicles with 265/70R16 Tyre
Purchased from www.WorkshopManuals.co.uk
00-24 www.WorkshopManuals.co.uk
GENERAL - Major Specifications
NOTE:
*1: Vehicles with roof rails
*2: Vehicles with 235/80R16 Tyre
*3: Vehicles with 265/70R16 Tyre
NOTE:
*1: Vehicles with roof rails
*2: Vehicles with 235/80R16 Tyre
*3: Vehicles with 265/70R16 Tyre
<Long wheelbase>
NOTE:
*1: Vehicles with roof rails
*2: Vehicles with 235/80R16 Tyre
*3: Vehicles with 265/70R16 Tyre
NOTE:
*1: Vehicles with roof rails
*2: Vehicles with 235/80R16 Tyre
*3: Vehicles with 265/70R16 Tyre
Items V75W
LNXCL6, LYXCL6,
LNXCR6 LYXCR6
Vehicle Overall length 1 4,795
dimensions
Overall width 2 1,875
mm
Overall height (unladen) 3 1,855,1,885*1
Wheelbase 4 2,780
Track-front 5 1,560
Track-rear 6 1,560
Overhang-front 7 710
Overhang-rear 8 1,285*2, 1,305*3
Ground clearance 9 235
(unladen)
Angle of approach 10 42*
degree
Angle of departure 11 24*
degree)
Vehicle Kerb weight 2,095
weight kg
Max. gross vehicle weight 2,760
Max. axle weight rating-front 1,110
Max. axle weight rating-rear 1,650
Seating capacity 7
Engine Model No. 6G74GDI
Total displacement mL 3,496
Transmis- Model No. V5M31 V5A51
sion
Type 5-speed 5-speed
manual automatic
Fuel system Fuel supply system GDI
NOTE:
*1: Vehicles with roof rails
*2: Vehicles with 235/80R16 Tyre
*3: Vehicles with 265/70R16 Tyre
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
If high-pressure car-washing equipment or steam car-washing
Approx. equipment is used to wash the vehicle, be sure to note the
40 cm 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.
MUT-II
MUT-II
sub-assembly Refer to the MUT-II REFERENCE MANUAL or MUT-II
OPERATING INSTRUCTIONS for instructions on handling
the MUT-II.
ROM pack
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
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.
Diagnosis connector
NOTE
*: Indicates the parts equipped on the right and left sides.
1, 2, 3, 4 Instrument panel wiring harness Front wiring harness Front Repair or replace each wiring
impact sensor harness
11, 12 Instrument panel wiring harness Clock spring Drivers air bag Repair or replace the Instrument
module) panel wiring harness. Replace
clock spring.
13 Instrument panel wiring harness Junction block (fuse No.8) Repair or replace Instrument
panel wiring harness.
16 Instrument panel wiring harness Junction block (fuse No.6)
21, 22 Side air bag wiring harness Side air bag module (L.H.) Repair or replace side air bag
wiring harness.
23, 24 Side air bag wiring harness Side air bag module (R.H.)
34, 35, 36 Side air bag wiring harness Floor wiring harness Side impact Repair or each wiring harness.
sensor (L.H.)
40, 41, 42 Side air bag wiring harness Floor wiring harness Side impact
sensor (R.H.)
6. Inspection of the SRS-ECU harness connector should be carried out by the following procedure.
Insert the special tool (probe, MB991222, in the harness set) into the connector from harness side
(rear side), and connect the tester to this probe. If any tool than specified is used, damage to the
harness and other components will result. 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
MB991222
7. SRS components should not be subjected to temperature over 93_C, so remove the SRS-ECU, drivers
and front passengers air bag modules, clock spring, side impact sensors and front seat assemblies (side
air bag modules) before drying or baking the vehicle after painting.
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 LOCK (OFF) position 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.
Bolts
Side sill rear end
Rubber
Rubber
SINGLE-POST
LIFT OR DOUBLE-
POST LIFT
Attachment Attachment
Bolt nominal Pitch (mm) Head mark 4 Head mark 7 Head mark 8
diameter (mm)
Bolt nominal Pitch (mm) Head mark 4 Head mark 7 Head mark 8
diameter (mm)
NOTE
1. Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
2. Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the
greater the bolt strength.
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
INFORMATION INTERNATIONAL
CAR
ADMINISTRATION T. MASAKI - MANAGER
T
OFFICE TECHNICAL SERVICE PLANNING
1. Description:
On the 2001 PAJERO/MONTERO, the 4M41 engine equipped models have been added.
2. Applicable Manuals:
3. Effective Date:
From the 2001 model.
MSB-00E00-009 1
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
GENERAL - Outline of Changes/Vehicle Identification 00-1
GROUP 00
GENERAL
OUTLINE OF CHANGES
The following models have been added for England that are equipped with the 4M41 engine.
VEHICLE IDENTIFICATION
MODELS
<Short wheelbase>
Model code Engine model Transmission model Fuel supply system
V68W MNHFR6 4M41-DOHC V5M31 <5M/T> Electronically-controlled
Intercooler high pressure fuel
MNHFR6 Turbo (3,200 mL) V5A51 <5A/T> distribution
MSB-00E00-009 3
Items V68W
MNHFR6 MYHFR6
Vehicle Overall length 1 4,260
dimensions
mm Overall width 2 1,845
Overall height (unladen) 3 1,845, 1,875*1
Wheelbase 4 2,545
Track-front 5 1,560
Track-rear 6 1,560
Overhang-front 7 710
Overhang-rear 8 1,000*2, 1,025*3
Ground clearance 9 225
(unladen)
Angle of approach degrees 10 42
Angle of departure degrees 11 33.5
Vehicle Kerb weight 1,980
weight kg
Max. gross vehicle weight 2,510
Max. axel weight rating-front 1,165
Max. axel weight rating-rear 1,345
Seating capacity 5
Engine Model No. 4M41-DOHC Intercooler Turbo
Total displacement mL 3,200
Transmission Model No. V5M31 V5A51
Type 5-speed manual 5-speed automatic
Fuel system Fuel supply system Electronically-controlled high pressure fuel
distribution
NOTE
*1: Vehicles with roof rails
*2: Vehicles with 235/80R16 Tyre
*3: Vehicles with 265/70R16 Tyre
MSB-00E00-009 4
1. Description:
On the GDI engine equipped cars, an idle learning function that will be required after replacement
of the ECU (for engine control) or after resetting of the battery* has been established.
*: Disconnection of ECU (for engine control) battery backup power supply (disconnection of battery
terminals or ECU connectors)
2. Applicable Manuals:
MSB-00E00-505 1
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
3. Details:
Contents of Attachment are to be added to GROUP 00 (GENERAL).
MSB-00E00-505 3
GROUP 00
GENERAL
OUTLINE OF CHANGES
The following models are equipped with Mitsubishi Stability Control (MITSUBISHI SC) system.
VEHICLE IDENTIFICATION
MODELS
<Short wheelbase>
Model code Engine model Transmission model Fuel supply system
MNHFR6
MYHFR6
MNXFR6
MYXFR6
MNHCR6
MYHCR6
MNXCR6
MYXCR6
LNHFR6
LYHFR6
LNXFR6
LYXFR6
LNHCR6
LYHCR6
LNXCR6
LYXCR6
VEHICLE IDENTIFICATION
MODELS
<Short wheelbase>
Model code Engine model Transmission model Fuel supply system
MNHFR6
MNXFL6
MNXFR6
MNHFR6
MYHFR6
MNXFR6
MYXFR6
MYHCR6
MYXCR6
LNXFL6
LNHFR6
LYHFR6
LNXFR6
LYXFR6
LYHCR6
LYXCR6
1 2 3 4 5 6 7 8 9 10 11
L 5-door
11 Serial number - -
NOTE
*: Indicates changes.
<Short wheelbase>
Items V64W
MNDFL6 MNHFL6, MNXFL6,
MNHFR6 MNXFR6
Vehicle Kerb weight 1,875 1,910 1,930
weight
i ht kg
k
Max. gross vehicle weight 2,510
Max. axle weight rating-front 1,200
Max. axle weight rating-rear 1,600
<Long wheelbase>
Items V74W
LNDFL6 LNHFL6 LNXFL6
Vehicle Kerb weight 2,025 2,065 2,100
weight
i ht kg
k
Max. gross vehicle weight 2,760
Max. axle weight rating-front 1,200
Max. axle weight rating-rear 1,650
Items V78W
LNDFL6 LNHFL6, LYHFL6, LNXFL6, LYXFL6,
LNHFR6 LYHFR6 LNXFR6 LYXFR6
Vehicle Max. gross vehicle weight 2,810
weight
i ht kg
k
Max. axle weight rating-front 1,200
Max. axle weight rating-rear 1,650
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ENGINE <6G7>
Click on the applicable bookmark to selected the required model year.
ENGINE <6G7>
CONTENTS
SERVICE SPECIFICATIONS
Items Standard value Limit
NOTE
*1: Indicates the value measured within 4 minutes since the engine was started.
*2: Indicates the value when more than 4 minutes have passed since the engine was started.
SEALANT
Items Specified sealants Remarks
SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub D Checking the ignition timing
assembly D Checking the idle speed
D Erasing diagnosis code
MB991802 Pin B
MD998718 Crankshaft rear oil Press-fitting the crankshaft rear oil seal
seal installer
ON-VEHICLE SERVICE
DRIVE BELT TENSION CHECK AND
A ADJUSTMENT
Caution
Perform the check after rotating the engine to the normal
direction (one revolution and over).
Indicator mark
1. Check that the indicator mark of the auto-tensioner is
located within the scope shown as A on the tensioner
bracket.
2. If the mark is located out of the scope A, replace the
drive belt.
NOTE
Since the auto-tensioner is used, it is not necessary to
adjust the tension of the belt.
AUTO-TENSIONER CHECK
1. Run the engine at idling speed and then stop it to check
whether the drive belt is forced out from the width of
the auto-tensioner pulley.
2. Remove the drive belt. (Refer P.11A-17.)
3. Move the auto-tensioner right and left by using a 12.7
mm spinner handle and the like to check whether there
is no catch.
4. If some abnormality is found during the above mentioned
check (1) and (3), replace the auto-tensioner.
5. Install the drive belt. (Refer P.11A-18.)
IGNITION TIMING CHECK
1. Before inspection, set the vehicle to the pre-inspection
condition.
2. Turn the ignition switch to the LOCK (OFF) position, and
then connect the MUT-II to the diagnosis connector.
MUT-II
Ignition coil 3. Set a timing light to the ignition coil power supply line
intermediate (intermediate connector No. 7 terminal) of the ignition coil
connector intermediate connector engine-side harness.
4. Start the engine and let it run at idle.
5. Use the MUT-II to measure engine idle speed and check
that it is within the standard value.
Standard value: 600 100 (700 100)*
NOTE
*: Indicates the values when more than 4 minutes have
passed since the idling condition was started.
PCV valve
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
High-pressure chamber to normal.
Drive pattern for air bleeding 2. Run the engine at idle for 1 - 3 minutes to let it warm
Gradually open the Close the throttle up.
throttle valve. valve. 3. With no load on the engine, repeat the drive pattern shown
Approx. in the illustration at left and check if the abnormal noise
3,000 r/min disappears. (The noise should normally disappear after
10 - 30 repetitions, but if there is no change in the noise
Idle speed level after 30 repetitions or more, the problem is probably
15 15 not due to air inside the lash adjusters.)
seconds seconds
4. After the noise has disappeared, repeat the drive pattern
Once 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.
f4.0 mm
6 44 8 Nm
10
14 1 Nm
9 24 4 Nm
5
36 5 Nm
19 3 Nm
7 8 O-ring
5.0 10 Nm
5.9 0.9 Nm
4.0 0.5 Nm
4
5.9 0.9 Nm
36 5 Nm 6
1
O-ring
60 10 Nm
69 9 Nm Engine oil
3 2
Removal steps
1. Drive shaft <R.H.> 6. Engine dipstick assembly
2. Drive shaft <L.H.> "BA 7. Gasket
3. Front differential, No.2 crossmember AA" "AA 8. Oil pan
4. Cover 9. Oil screen
5. A/T oil dipstick assembly 10. Gasket
(A)
REMOVAL SERVICE POINT
AA" OIL PAN REMOVAL
1. Remove the oil pan installation bolts.
Caution
The use of an oil pan remover (MD998727) can damage
the oil pan (aluminum made).
2. Screw the bolts (M10) securing the oil pan to the
(A) transmission assembly in the illustrated bolt holes, then
remove the oil pan.
Transmis-
sion side
Oil pan
13,14 (Installation bolt)
3.0 0.4 Nm
1
24 4 Nm
41 8 Nm 11
5
24 4 Nm
6 7
11 1 Nm
44 10 Nm
22 4
Nm 74 9 Nm 8
12 9
4
41 8 Nm 41 8 Nm
3 44 10 Nm
Removal steps
"FA 1. Cover AB" 7. Power steering oil pump assembly
2. Drive belt AB" 8. A/C compressor assembly
3. Cooling fan and fan clutch assembly 9. Compressor bracket
4. Cooling fan pulley 10. Cooling fan bracket
AA" "EA 5. Drive belt auto-tensioner "DA 11. Accessory mount assembly
6. Engine hanger <R.H.> 12. Power steering oil pump bracket
D Alternator (Refer to Group16.)
13
11 1 Nm
14
18
23 3 Nm
44 10 Nm
48 6 Nm
11 1 Nm 11 1 Nm
20 17
19
15
16
11 1 Nm
182 4 Nm
Removal steps
13. Timing belt upper cover assembly 16. Timing belt lower cover assembly
<R.H.> AD" "BA 17. Timing belt
14. Timing belt upper cover assembly "AA 18. Auto-tensioner
<L.H.> 19. Tension pulley
AC" "CA 15. Crankshaft pulley 20. Tensioner arm assembly
Clockwise
REMOVAL SERVICE POINTS
AA" DRIVE BELT AUTO-TENSIONER REMOVAL
Hole B
Hole A The following operations will be needed due to the introduction
of the serpentine drive system with the drive belt auto
tensioner.
1. Insert a 12.7 mm spinner handle into the square hole
on the drive belt auto tensioner, and rotate it clockwise
Square
until the tensioner touches the stopper.
hole 2. Align hole B with hole A, and insert a 5.0 mm Allen
wrench to hold the tensioner. Then loosen the drive
belt, and then remove the drive belt auto tensioner.
Allen wrench
MB991802
Tension Timing
pulley mark
Crankshaft
sprocket
MD998769
Timing mark 2. Align the timing marks on the right bank side crankshaft
sprocket.
Timing mark
Timing mark 3. Align the timing marks on the left bank side crankshaft
Timing mark sprocket, and then hold the sprocket with a wrench as
shown.
Caution
(1) The left bank side camshaft sprockets will turn
readily because of the spring force being applied,
so be careful not to get your fingers caught.
Clip
Timing mark 8. Check that the timing marks of the right bank side exhaust
camshaft sprocket is aligned, and clamp the timing belt
with a clip.
9. Set the timing belt onto the tension pulley.
Clip
10. Turn the right bank side camsahft sprocket (exhaust side)
<Right bank> <Left bank> anticlockwise unitl the tension side of the timing belt is
firmaly stretched. Check all timing marks again.
Timing mark Timing mark
Centre
bolt
Timing
Tension mark
pulley
MD998767
MD998769
Pin holes 14. Loosen the centre bolt of the tensioner pulley. Use special
tool and a torque wrench to apply the standard torque
Centre to the timing belt as shown in the illustration. Then tighten
bolt the centre bolt to the specified torque.
Standard value: 4.4 Nm
48 6 Nm <Timing belt tension torque>
Caution
Tension torque When tightening the centre bolt, be careful that the
MD998767 Tension 4.4 Nm tensioner pulley does not turn with the bolt.
pulley
15. Remove the setting pin that has been inserted into the
auto-tensioner.
16. Turn the crankshaft two turns clockwise to align the timing
marks.
Setting pin
17. Wait for at least five minutes, and then check that the
A auto-tensioner pushrod extends within the standard value.
Standard value (A): 3.8 - 5.0 mm
18. If no, repeat the operation in steps (13) to (17) above.
19. Check again that the timing marks of each sprocket are
aligned.
MB991802
4
1
Spring
Auto-tensioner
6 12
Lip portion
<M/T>
9
Lip portion
74 4 Nm
Engine oil
7
12
<A/T> 74 4 Nm
1 8
5
4
11 10
8.5 0.5 Nm
6
2 3
Removal steps
1. Crank angle sensor AA" "BA 7. Bolt
"DA 2. Crankshaft sprocket 8. Adaptor plate
"DA 3. Crankshaft sensing blade 9. Flywheel
"DA 4. Crankshaft spacer 10. Drive plate
5. Key 11. Crankshaft adaptor
"CA 6. Crankshaft front oil seal "AA 12. Crankshaft rear oil seal
MD998781
MD998717
Oil seal
MD998781
2
Lip portion
2
1
Engine oil
2
88 10 Nm
Removal steps
AA" "BA 1. Camshaft sprocket
AB" "AA 2. Camshaft oil seal
MD998719
MD998761
MD998761
MD998719
14 1 Nm
3.4 0.5 Nm 4 <Cold engine>
108 5 Nm 2
19 1 Nm 3
19 1 Nm
1 7
5.0 1.0 Nm <Cold engine>
108 5 Nm
12 3
8 3.4 0.5 Nm
19
9
13 16
14 1 Nm 18 14 1 Nm
14 19
17
15
23 2 Nm 4
6
20 20 44 8 Nm
10
28 2 Nm
88 10 Nm 11 5
(Automatic
transmission
24 4 Nm fluid)
14 1 Nm
(Engine oil)
Removal steps
1. Water hose 12. Water hose connection
2. Water outlet pipe assembly 13. Heater hose connection
"CA 3. O-ring 14. Water pipe assembly
4. Rocker cover "CA 15. O-ring
5. Oil dipstick assembly <when 16. Camshaft position sensor connector
removing left bank only> <when removing left bank only>
6. A/T Fluid dipstick assembly <when 17. Camshaft sprocket (Intake side)
removing left bank only> <when removing right bank only>
7. Heater hose connection 18. Timing belt rear cover
"EA 8. Water passage assembly <when removing right bank only>
"EA 9. Gasket AB" "BA 19. Cylinder head assembly
AA" "DA 10. Detonation sensor "AA 20. Cylinder head gasket
11. Detonation sensor bracket
<Left bank>
Exhaust side
Right
bank
Left
bank
Exhaust side
O-ring
Pipe assembly
Gasket
Tabs
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Caution
*: Indicates parts which should be initially tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
1 3.0 0.4 Nm
4
8
Removal steps
"BA 1. Engine cover 5. Freewheel engage switch connector
2. Drive belt AA" 6. Power steering oil pump assembly
3. Alternator connector AA" 7. A/C compressure assembly
4. Starter motor connector 8. Heater hose connection
11 1 Nm
11 13
10 12
9
21 14
16 23
15 17
20
19 18
26 4 Nm* 22
24
25
26 4 Nm*
24
25
44 10 Nm*
26
44 10 Nm*
4
1
ENGINE <4D5>
Click on the applicable bookmark to selected the required model year.
ENGINE <4D5>
CONTENTS
GENERAL INFORMATION
Items 4D56
Compression ratio 21
Exhaust 4
SEALANTS
Items Specified sealant Remarks
SPECIAL TOOLS
Tools Number Name Use
MB991502 MUT-II Drive belt tension measurements
sub-assembly
MB991802 Pin B
MD998382 Crankshaft front oil Installing the crankshaft front oil seal
seal installer
MD998051 Cylinder head bolt Removal and installation of the cylinder head
wrench bolt
ON-VEHICLE SERVICE
A
DRIVE BELT TENSION CHECK AND
ADJUSTMENT
Indicator mark ALTERNATOR AND POWER STEERING OIL PUMP
DRIVE BELT TENSION CHECK
Caution
Perform the check after rotating the engine to the normal
direction (one revolution and over).
1. Check that the indicator mark of the auto-tensioner is
located within the scope shown as A on the tensioner
bracket.
2. If the mark is located out of the scope A, replace the
drive belt.
NOTE
Since the auto-tensioner is used, it is not necessary to
adjust the tension of the belt.
Deflec-
tion
AUTO-TENSIONER CHECK
1. Run the engine at idling speed and then stop it to check
whether the drive belt is forced out from the width of
the auto-tensioner pulley.
2. Remove the alternator and power steering oil pump drive
belt. (Refer P.11B-19.)
3. Locate a ring spanner onto the auto-tensioner pulley
mounting bolt, and move the tensioner back and forth
to confirm there is no stiffness.
4. If some abnormality is found during the above mentioned
check (1) and (3), replace the auto-tensioner.
5. Install the alternator and power steering oil pump drive
belt. (Refer P.11B-19.)
NOTE
Insert the thickness gauge from the centre of the cylinder
Adjusting head towards the outside so that it doesnt touch the
screw
pad.
Pad
Thickness gauge
10 mm
Timing marks Timing marks 4. Align the timing marks of the camshaft sprocket and set
the No. 1 cylinder to the top dead centre position.
Camshaft Crankshaft
sprocket pulley
10 mm
MD998384
Set to 9_ ATDC
1 0.03 mm or more (3) Tilt the injection pump to the left and right and adjust
the needle on the dial gauge so that the display value
is uniform.
(4) Provisionally tighten the mounting nut and bolt of
the injection pump.
(5) Repeat steps 9 - 13 to check if the adjustment has
been made correctly.
1 0.03 mm of less
Front
view
Injection pipe (6) Tighten the mounting nuts and bolts to the specified
union nuts torque.
(30 6 Nm) (7) Tighten the injection pump union nuts to the specified
torque.
Caution
When tightening the nuts, hold the delivery valve
Nuts holders with a spanner so that they dont turn
(19 3 Nm) Bolts
(23 3 Nm) at the same time.
Timing
check plug
(17 2Nm)
Locking
nut
Idle speed ad-
justing screw
Vehicles with immobilizer 3. Disconnect the fuel cut solenoid valve connector.
<Vehicles without immobilizer> Disconnect the fuel cut
Fuel cut valve valve controller connector. <Vehicles with immobilizer>
controller
NOTE
Doing this will prevent carrying out fuel injection.
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.
Compression gauge 5. Set compression gauge to one of the glow plug holes.
6. Crank the engine and measure the compression pressure.
Standard value (at engine speed of 280 r/min):
3,040 kPa
Limit (at engine speed of 280 r/min): min. 2,256 kPa
7. Measure the compression pressure for all the cylinders,
and check that the pressure differences of the cylinders
are below the limit.
Limit: max 294 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 or fuel
cut valve controller connector.
10. Install the glow plugs.
Tightening torque: 18 2 Nm
Bolt B
Bolt B
Access cover
Access cover 7. Install the access cover while sliding the front lower cover
Guide down along the two guides.
8. Install the timing belt upper cover.
1
10
12 1 Nm
11
19 3 Nm
19 3 Nm
8.8 1.0 Nm
5 6
(Engine oil)
4
9
3
7.0 1.0 Nm
2
39 5 Nm
8.8 1.0 Nm 7
35 6 Nm
Removal steps
1. Engine oil level gauge and guide 6. Oil level sensor
assembly 7. Space rubber
2. Drain plug 8. Bell housing cover
"BA 3. Drain plug gasket AA" "AA 9. Oil pan
4. Alternator vacuum pump oil return 10. Oil screen
hose connection 11. Oil screen gasket
5. Oil level sensor connector
INSPECTION
D Check oil pan for cracks.
D Check oil pan sealant-coated surface for damage and
deformation.
D Check oil screen for cracked, clogged or damaged wire
net and pipe.
8
6 7
44 10 Nm
5 11
11 1 Nm
11 1 Nm
(Engine oil)
11 1 Nm
11 1 Nm
10
177 9 Nm
4
3
2
1
Removal steps
D Radiator upper shroud D Cooling fan (Refer to GROUP 14.)
(Refer to GROUP 14.) AC" 5. Alternator and power steering oil
AA" 1. A/C compressor drive belt pump drive belt
<Vehicles with A/C> 6. Auto-tensioner
2. A/C compressor connector 7. Fan Clutch
<Vehicles with A/C> 8. Water pump pulley
AB" 3. A/C compressor <Vehicles with A/C> "CA 9. Timing belt front upper cover
4. Tension pulley and tension pulley AD" 10. Crankshaft pulley
bracket assembly <Vehicles with A/C> "CA 11. Timing belt front lower cover
15
12 26 3 Nm
14
13
26 3 Nm
23
22
20
21
26 3 Nm
26 3 Nm
19
18
17
16
MB991802
Belt deflection
Crankshaft
sprocket B
Tension
side
Amount of belt 9. Press on the center of the bolt with an index finger to check
deflection the amount of deflection.
Standard value: 4 - 5 mm
C B 650
C 660
d=Nominal diameter
l=Nominal length
A
A
B
A A
5 6
3
7
8
10
9
1 (Engine oil)
2
(Engine oil)
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
D Timing belt and timing belt B removal D Transmission assembly
and installation (Refer to P.11B-19.) (Refer to GROUP 22.)
1. Crankshaft sprocket B 3. Adapter plate
"DA 2. Crankshaft front oil seal AA" "CA 4. Flywheel assembly
5. Crankshaft adaptor
6. Ball bearing
7. Oil seal case
8. Gasket
"BA 9. Oil separator
"AA 10. Crankshaft rear oil seal
MD998781
MD998376
MD998382 MD998383
(Apply oil to outer
surface)
6 5.9 0.9 Nm
Apply engine oil to all moving
parts during installation. 1
1
8
3
10 mm 10 mm
5
7 37 2 Nm
7
8
Sealant: 4
11 20 1 Nm
3M ATD Part No. 8660 or
equivalent 37 2 Nm 12 12
20 1 Nm
12
13
12
10
9
69 5 Nm
11 1 Nm
Cable tie wrap 2. Tie the camshaft sprocket and timing belt together with
a cable tie wrap so that timing mark is not maladjusted.
Timing belt
Camshaft
sprocket
MD998719
Front of engine
C 660
d=Nominal diameter
l=Nominal length
4.9 1.0 Nm
4.9 1.0 Nm 30 6 Nm
30 6 Nm
5
4
(During cold engine)
118 5 Nm 3
4.9 1.0 Nm
11
22 4 Nm 8
30 6 Nm
22 4 Nm
9
7
10
13 6
24 4 Nm 2
12 12 1 Nm
14 1
(Engine oil)
Removal steps
1. Oil level gauge guide and oil level 7. Earth cable connection
gauge assembly AB" "CA 8. Fuel injection pipe
AA" "DA 2. Radiator upper hose 9. Heater hose connection
D Rocker cover (Refer to P.11B-27.) 10. Fuel hose connection
3. Engine coolant temperature switch D Water pipe assembly C
connector (for A/C compressor (Refer to GROUP 14.)
control.) AC" 11. Power steering oil pump assembly
4. Engine coolant temperature switch 12. Power steering oil pump bracket
connector (for condenser fan con- bolt
trol.) AD" "BA 13. Cylinder head assembly
5. Glow plug connector "AA 14. Cylinder head gasket
6. Engine coolant temperature gauge
unit and sensor connector
6 14 16 8
2 10 18 12 4
1 5 13 17 15 11 7
9 3
Front of engine
Identification code
INSTALLATION SERVICE POINTS
"AA CYLINDER HEAD GASKET INSTALLATION
To replace the cylinder head gasket only, select a gasket
of correct specification according to the table below.
Identification holes Identification code Part number
specification specification
C (Thickness after tightening 145 MD302891
the bolts 1.45 mm)
Identification holes
D (Thickness after tightening 150 MD302892
the bolts 1.50 mm)
E (Thickness after tightening 155 MD302893
Detail of the Identification holes
the bolts 1.55 mm)
Caution
The thickness of the original cylinder head gasket is
selected according to the protrusion amount of the piston.
Therefore, if the piston or the connecting rod is replaced,
the protrusion amount may be changed. Always select
a correct gasket by measuring the protrusion amount.
(For details, refer to the Engine Workshop Manual.)
Cylinder head
bolt washer
MD998051
17 13 9 5 1 3 7 11 15
14 10 6 4 12
18 2 8 16
Front of engine
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Hood Removal and Installation (Refer to GROUP 42.) D Accelerator Cable Adjustment
D Under Cover and Skid Plate Removal and Installation (Refer to GROUP 17 - On-vehicle Service.)
D Engine Oil Draining and Refilling <Post-installation operation>
(Refer to GROUP 12 - On-vehicle Service.) D Fuel Line Air-bleeding
D Battery and Battery Tray Removal and Installation (Refer to GROUP 13B - On-vehicle Service.)
D Air Cleaner Removal and Installation <Post-installation operation>
(Refer to GROUP 15.) D Drive Belt Tension Check and Adjustment
D Radiator Removal and Installation <Vehicles with A/C> (Refer to P.11B-6.)
(Refer to GROUP 14.) <Post-installation operation>
5.0 1.0 Nm
2
3
5
11 1 Nm 4
12
13 6
14 3 Nm 11
12
7
8
10
9
Removal steps
1. Earth cable connection 8. Oil pressure switch connector
2. Glow plug connector 9. Engine oil level sensor connector
3. Engine coolant temperature switch 10. Free-wheeling hub engage switch
connector (for A/C compressor 11. A/C compressor connector
control) <Vehicles with A/C>
4. Engine coolant temperature switch 12. Starter connector
connector (for condenser fan control) D A/C compressor assembly <Vehicles
5. Fuel cut solenoid valve connector with A/C> (Refer to P.11B-19.)
6. Injection pump connector 13. Earth cable connection
7. Alternator connector
18
18
15 22 4 Nm
19
17
22 4 Nm 12 2 Nm
20
16 21
44 5 Nm
18
23
22
44 10 Nm*
14
ENGINE <4D5>
CONTENTS
GENERAL INFORMATION
Items 4D56
Compression ratio 21
Exhaust 4
SERVICE SPECIFICATIONS
Items Standard value
Idle speed r/min 750 30
Timing belt tension mm 4-5
Timing belt B tension mm 4-5
SEALANT
Items Specified sealant Remarks
MB991802 Pin B
MD998051 Cylinder head bolt Removal and installation of the cylinder head
wrench bolt
Tachometer
Injection
nozzle
12 1 Nm
12
19 3 Nm
19 3 Nm
9.0 1.0 Nm
11
5
(Engine oil)
6
4
9
8
2 3
7.0 1.0 Nm
39 5 Nm
7
10
35 6 Nm
9.0 1.0 Nm
9.0 1.0 Nm
Removal steps
1. Engine oil level gauge and guide 6. Oil level sensor
assembly 7. Space rubber
2. Drain plug 8. Bell housing cover
"BA 3. Drain plug gasket AA" "AA 9. Oil pan
4. Alternator vacuum pump oil return 10. Oil pan cover
hose connection 11. Oil screen
5. Oil level sensor connector 12. Oil screen gasket
INSPECTION
D Check oil pan for cracks.
D Check oil pan sealant-coated surface for damage and
deformation.
D Check oil screen for cracked, clogged or damaged wire
net and pipe.
6 7
44 10 Nm
5 11
11 1 Nm
11 1 Nm
(Engine oil)
11 1 Nm
11 1 Nm
10
177 9 Nm
4
3
2
1
Removal steps
D Radiator upper shroud AC" 5. Alternator and power steering oil
AA" 1. A/C compressor drive belt pump drive belt
<Vehicles with A/C> 6. Auto-tensioner
2. A/C compressor connector 7. Fan Clutch
<Vehicles with A/C> 8. Water pump pulley
AB" 3. A/C compressor <Vehicles with A/C> "CA 9. Timing belt front upper cover
4. Tension pulley and tension pulley AD" 10. Crankshaft pulley
bracket assembly <Vehicles with A/C> "CA 11. Timing belt front lower cover
D Cooling fan
26 3 Nm
24
23
21
22 26 3 Nm
19
18
17
26 3 Nm
20
16
9.0 1.0 Nm
MB991802
Belt deflection
Crankshaft
sprocket B
Tension
side
C B 650
C 660
d=Nominal diameter
l=Nominal length
A
A
B
A
A
4.9 1.0 Nm
4.9 1.0 Nm 30 6 Nm
5
29 2 Nm +120 4
(During cold engine)
3
(Engine oil) 4.9 1.0 Nm
6
9
22 4 Nm 30 6 Nm
22 4 Nm
7
8
24 4 Nm
11 2
12 1 Nm
10
1
12
(Engine oil)
Removal steps
1. Oil level gauge guide and oil level AB" "CA 6. Fuel injection pipe
gauge assembly 7. Heater hose connection
AA" "DA 2. Radiator upper hose 8. Fuel hose connection
D Rocker cover D Water pipe assembly C
3. Engine coolant temperature switch (Refer to GROUP 14.)
connector (for A/C compressor AC" 9. Power steering oil pump assembly
control) 10. Power steering oil pump bracket
4. Engine coolant temperature switch bolt
connector (for condenser fan con- AD" "BA 11. Cylinder head assembly
trol) "AA 12. Cylinder head gasket
5. Glow plug connector
6 14 16 8
2 10 18 12 4
1 5 9 13 17 15 11 7 3
Front of engine
B Caution
The thickness of the original cylinder head gasket is
selected according to the protrusion amount of the piston.
C Therefore, if the piston or the connecting rod is replaced,
the protrusion amount may be changed. Always select
a correct gasket by measuring the protrusion amount.
(For details, refer to the Engine Workshop Manual.)
MD998051
17 13 9 5 1 3 7 11 15
14 10 6 4 12
18 2 8 16
Front of engine
14 10 6 4 12
18 2 8 16
Front of engine
ENGINE <4M4>
Click on the applicable bookmark to selected the required model year.
ENGINE <4M4>
CONTENTS
GENERAL INFORMATION
Items 4M41
Total displacement mL 3,200
Bore Stroke mm 98.5 105.0
Compression ratio 17.0
Camshaft arrangement DOHC
Number of valve Intake 8
Exhaust 8
Valve timing Intake Opening BTDC 13_
Closing ABDC 31_
Exhaust Opening BBDC 55_
Closing ATDC 17_
Fuel system Distribution type injection pump
Rocker arm Roller type
SERVICE SPECIFICATIONS
Items Standard value Limit
Alternator drive belt Vibration frequency Hz 122 - 161
(When inspection)
Tension N 207 - 363
Deflection mm <Reference> 8 - 11
Alternator drive belt Vibration frequency Hz 122 - 136
(When adjustment) Tension N 207 - 259
Deflection mm <Reference> 10 - 11
Alternator drive belt Vibration frequency Hz 149 - 161
(When replacement)
Tension N 311 - 363
Deflection mm <Reference> 8- 9
A/C compressor drive belt Vibration frequency Hz A 177 - 191
(When inspection) B 145 - 156
Tension N C 343 - 392
Deflection mm C 7.5 - 8.5
<Reference>
A/C compressor drive belt Vibration frequency Hz A 177 - 191
(When adjustment)
B 145 - 156
Tension N C 343 - 392
Deflection mm C 7.5 - 8.5
<Reference>
A/C compressor drive belt Vibration frequency Hz A 177 - 191
(When replacement) B 145 - 156
Tension N C 490 - 539
Deflection mm C 6.0 - 6.5
<Reference>
NOTE
A: Between crankshaft pulley and tension pulley
B: Between crankshaft pulley and A/C compressor pulley
C: Between A/C compressor pulley and tension pulley
SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II D Drive belt tension measurement
sub-assembly D Fuel injection timing check and adjustment
D Idle speed check
MB991802 Pin B
Crankshaft
pulley
Alternator
pulley
Deflection
Timing gear
VALVE CLEARANCE CHECK AND ADJUSTMENT
case
NOTE
Crankshaft The valve clearance check and adjustment should be done
pulley
when the engine is cold.
0
MD998754
1. Remove the rocker cover.
2. Remove all the glow plugs.
3. Use the special tool to turn the crankshaft clockwise,
Notch and align the notch on the crankshaft pulley with timing
MB990767
mark 0 to set the No.1 cylinder or No.4 cylinder to the
top dead centre of its compression stroke.
Caution
Never turn the crankshaft anticlockwise, or the
tensioner for adjusting the timing chain tension at
Projection
the timing gear can be damaged.
If it is turned anticlockwise, once remove the tensioner
and reinstall.
NOTE
If the projection on the camshaft faces up, the No.1
cylinder is on the top dead centre of its compression
stroke .When the crankshaft is turned just one more turn,
the No.4 cylinder is at top dead centre.
Delivery
valve(without
CPV)
MB991502
8. Turn the ignition switch to LOCK(OFF), and connect
the diagnosis connector to the MUT-II.
9. Turn the ignition switch ON.
10. Carry out the actuator test (No.34) on MUT-II.
11. Supply the fuel by operating the fuel filer hand pump,and
turn the engine clockwise while allowing the fuel to flow
Injection pipe through the injection pipe.
MH063494
5. Install the special tool to the glow plug mounting holes,
and install the compression gauge.
6. Measure the compression pressure while cranking the
engine.
Standard value: 2844 kPa 240 r/min
Compression Limit value: 2256 kPa 240 r/min
gauge 7. Measure the compression pressure for all the cylinders
and check that the pressure differences of the cylinders
are below the limit.
Limit: 294 kPa in maximum
OIL PAN
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Skid Plate and Under Cover Removal and Installation D Front Differential and No.2 Crossmember Assembly
D Engine Oil Draining and Refilling Removal and Installation
(Refer to GROUP 12 - On-vehicle Service.) (Refer to GROUP 11A - Oil Pan.)
D Differential Gear Oil Draining and Refilling
(Refer to GROUP 26 - On-vehicle Service.)
1
15
48 6 Nm
13
(Engine oil)
6
13
5 7 (Engine oil)
10
(3M ATD Part
No. 8121)
4
11
12
14
9
3 2
39 3 Nm 10 5
8
6
7
5 10
7
6
Removal steps
1. Engine oil level gauge and guide 8. Oil pan rubber
assembly 9. Rubber
2. Drain plug 10. Oil pan cover
"BA 3. Drain plug gasket 11. Engine oil level sensor
4. Engine oil level sensor connector 12. Dust cover
5. Oil pan cover assembly 13. Stiffener
6. Insulator collar AA" "AA 14. Oil pan
7. Insulator 15. Oil screen
f4 mm
3. Apply a continuous bead of the specified sealant to the
the oil pan mating surface as shown.
Specified sealant:
MITSUBISHI GENUINE PART MD970389 or
equivalent
4. After applying the sealant, install the oil pan within 15
minutes.
Caution
(1) When installing the oil pan, be careful not to
disturb the sealant.
(2) Whenever the oil pan mounting bolts are loosened
or tightened again after the oil pan installation,
Oil pan side
always apply the sealant again.
(3) After the oil pan is installed, wait for at least one
hour, and then start the engine.
"BA DRAIN PLUG GASKET INSTALLATION
Always replace the gasket with a new one so that it faces
the direction shown.
INSPECTION
D Check oil pan for cracks.
D Check oil pan sealant-coated surface for damage and
deformation.
D Check oil screen for cracked, clogged or damaged wire
net and pipe.
VACUUM PUMP
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Cover Removal and Installation D Engine Oil Check and Refill
(Refer to P.11C-23.) (Refer to GROUP 12 - On-vehicle Service.)
D Battery and Battery Tray Removal and Installation <Post-installation operation>
20 2 Nm 8
20 2 Nm
3
7
23 4 Nm
4 8 5 6
(Engine
oil)
9
(Engine oil)
Removal steps
1. Power steering oil pressure switch 5. Vacuum hose connection
connector 6. Brake booster vacuum hose
AA" 2. Power steering oil pump assembly connection
3. Vacuum hose <L.H. drive vehicles without ABS>
<Except R.H. drive vehicles without 7. Vacuum pump oil pipe
ABS> 8. Vacuum pump oil pipe gasket
4. Vacuum hose 9. Vacuum pump assembly
<R.H. drive vehicles without ABS>
17
16
(Engine oil)
2
23 2 Nm 13
12
(Engine oil) 14
8 11
10
9 15
7
3
323 32 Nm
6 4
1 5
Removal steps
AA" 1. A/C compressor drive belt 7. Timing gear case cover assembly
<Vehicles with A/C> 8. Insulator collar
AB" 2. Alternator drive belt 9. Insulator
AC" 3. Crankshaft pulley 10. Timing gear case cover
D Alternator(Refer to GROUP 16.) "BA 11. Bearing block assembly
D Water pump(Refer to GROUP 14.) 12. Drain plug
D Cylinder Head Assembly 13. Drain plug gasket
(Refer to P.11C-27.) 14. Bearing block bushing
4. A/C compressor connector 15. Bearing block
<Vehicles with A/C> "BA 16. Timing gear case
5. A/C compressor 17. Lower guide plate
<Vehicles with A/C>
6. A/C compressor bracket and tension
pulley assembly<Vehicles with A/C>
20
33 3 Nm 19
18
23
24
(Engine oil)
40 4 Nm
MB991802
Mating
mark 1
Mating mark
Mark ring
plate
Crankshaft gear
G H
B
C
E
I A
A
B
F
I D*
F
F D*
I
F D*
D=Nominal diameter
L=Nominal length
*: Vehicles without A/C
<M/T>
123 14 Nm
3
1 8 2
(Lip) (Lip)
Engine oil
8
135 5 Nm
4
<A/T>
7 6
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps
D Crankshaft pulley <M/T>
(Refer to P.11C-17.)
1. Crankshaft front oil seal D Transmission assembly
(Refer to GROUP 22.)
AA" 2. Flywheel bolt
3. Flywheel
8. Crankshaft rear oil seal
<A/T>
D Transmission assembly
(Refer to GROUP 23.)
AA" 4. Drive plate bolt
"AA 5. Adapter plate
"AA 6. Drive plate
"AA 7. Crankshaft adapter
8. Crankshaft rear oil seal
MD998781
Drive Adapter
INSTALLATION SERVICE POINT
plate plate "AA CRANKSHAFT ADAPTER/DRIVE PLATE/ADAPTER
PLATE INSTALLATION
Assemble the crankshaft adapter and the adapter plate to
the drive plate as shown, and then install the drive plate
Front of Front of assembly into the crankshaft.
engine engine
Crankshaft adapter
1
3
Removal steps
1. Engine cover assembly D Air cleaner (Refer to GROUP 15.)
2. Insulator collar D EGR valve and EGR pipe assembly
3. Insulator (Refer to GROUP 17 - EGR Valve.)
4. Engine cover bracket
5. Engine cover bracket
11
13 2 Nm 10
11
20 1 Nm
16
17
18
19
14
15
(Engine oil)
12
88 8 Nm
13
Front of engine
Hook NOTE
If the crankshaft is turned clockwise after the chain
Plunger tensioner is installed, the plunger is automatically
unhooked. Then its internal ratchet mechanism adjusts
the timing chain tension.
98 10 Nm 0 Nm
49 5 Nm +90 +90
20 18 (During cold engine)
19
(Engine oil)
57 5 Nm
21
(Engine oil)
7 15
5.0 1.0 Nm
1
3
6
2
8
4
10
12 22
11 9
5
17
13
14
16
Removal steps
1. Glow plug connector 12. Timing gear case cover
2. Engine coolant temperature gauge D Alternator brace
unit connector (Refer to GROUP 16.)
3. Engine coolant temperature sensor "CA 13. Heater return pipe connection
connector "CA 14. Bypass pipe, thermostat case and
D Drive belt (Refer to P.11C-17.) cover assembly
AA" "DA 4. Radiator upper hose connection 15. Heater hose connection
AA" "DA 5. Radiator lower hose connection 16. Fuel return pipe connection
6. Free-wheeling hub solenoid valve 17. Fuel return pipe gasket
vacuum hose connection 18. Engine hanger
7. Brake booster vacuum hose 19. Short rocker, adjusting screw and lock
connection nut assembly
<R.H. drive vehicles without ABS> 20. Long rocker, adjusting screw and lock
8. Vacuum pipe nut assembly
9. Timing gear case cover assembly AB" "BA 21. Cylinder head assembly
10. Insulator collar "AA 22. Cylinder head gasket
11. Insulator
Front of engine
Front of engine
5
1
14 3 Nm 2 6
22 4 Nm
1 5.0 1.0 Nm
7
8
9 11
3
10
4
Removal steps
D Intercooler air pipe 6. Glow plug connector
(Refer to GROUP 15 - Intercooler.) 7. Boost air temperature sensor
1. Alternator connector connector
2. Oil pressure switch connector 8. Engine coolant temperature gauge
3. Engine oil level sensor connector unit connector
4. Free-wheeling hub engage switch 9. Power steering oil pressure switch
connector connector
5. Earth cable connection 10. A/C compressor connector
D EGR valve and EGR pipe assembly <Vehicles with A/C>
(Refer to GROUP 17 - EGR Valve.) 11. Injection pump connector
Caution
*: indicates parts which should be temporarily tightened, and then fully tightened with the engine
weight applied on the vehicle body.
15
21 19
12 (Engine oil)
16
19
13
14
23 4 Nm
17
20
44 9 Nm*
18
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
INFORMATION INTERNATIONAL
CAR
ADMINISTRATION T. MASAKI - MANAGER
T
OFFICE TECHNICAL SERVICE PLANNING
1. Description:
This Service Bulletin informs you of the timing chain replacement procedures for 4M40 and 4M41
engines, the relevant special tools and the timing chain replacement kits available.
MH063566: Timing chain tool set
ME190551: Timing chain kit (for 4M40 single chain) ME190549: Timing chain kit (for 4M40 double chain)
ME190552: Timing chain kit (for 4M41)
2. Applicable Manuals:
MSB-00E11-002 1
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
2001 PAJERO Workshop Manual Chassis
MSB-00E11-002 16
MSB-00E11-002 17
MSB-00E11-002 18
MSB-00E11-002 19
MSB-00E11-002 20
MSB-00E11-002 21
MSB-00E11-002 22
MSB-00E11-002 23
MSB-00E11-002 24
CORRECTION INTERNATIONAL
CAR
ADMINISTRATION T.NITTA - PROJECT LEADER
OFFICE AFTER SALES SERVICE & CS PROMOTION
1. Description:
On the 4M40 or 4M41 engine equipped vehicles, correction has been made to A/C compressor
drive belt tension check and adjustment.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)
2001 PAJERO PWJE0001 (1/2) (English) 11C-2, 3, 7
Workshop Manual Chassis VOL.1
2001 MONTERO PWJE0001 (1/2) (Spanish)
Workshop Manual Chassis VOL.1
GENERAL INFORMATION
Items 4M41
Total displacement m 3,200
Bore x Stroke mm 98.5 x 105.0
Compression ratio 17.0
Camshaft arrangement DOHC
Number of valve Intake 8
Exhaust 8
Valve timing Intake Opening BTDC 13
Closing ABDC 31
Exhaust Opening BBDC 55
Closing ATDC 17
Fuel system Distribution type injection pump
Rocker arm Roller type
SERVICE SPECIFICATIONS
Items Standard value Limit
Alternator drive belt Vibration frequentcy Hz 122 161 -
(When inspection) Tension N 207 363 -
Deflection mm <Reference> 8 11 -
Alternator drive belt Vibration frequentcy Hz 122 136 -
(When adjustment) Tension N 207 259 -
Deflection mm <Reference> 10 11 -
Alternator drive belt Vibration frequentcy Hz 149 161 -
(When replacement) Tension N 311 363 -
Deflection mm <Reference> 89 -
A/C compressor drive belt Vibration frequentcy A 177 191 -
(When inspection) Hz B 145 156 -
Tension N C 343 392 -
Deflection mm C 7.5 8.5 - A 169 189
<Reference> B 111 124
A/C compressor drive belt Vibration frequentcy A 177 191 - A 285 355
(When adjustment) Hz B 145 156 - A 7.0 8.0
Tension N C 343 392 - A 169 189
Deflection mm C 7.5 8.5 - B 111 124
<Reference> A 285 355
A/C compressor drive belt Vibration frequentcy A 177 191 - A 7.0 8.0
(When replacement) Hz B 145 156 - A 207 223
Tension N C 490 539 - B 135 146
Deflection mm C 6.0 6.5 - A 425 500
<Reference> A 6.0 6.5
<Incorrect> <Correct>
NOTE
A: Between crankshaft pulley and tension pulley
B: Between crankshaft pulley and A/C compressor pulley <Incorrect>
C: Between A/C compressor pulley and tension pulley
SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II Drive belt tension measurement
Sub-assembly Fuel infection timing check and
adjustment
Idle speed check
B991502
MB991668 Belt tension meter Drive belt tension measurements (Use with
set MUT-II)
B991668
CORRECTION INTERNATIONAL
CAR
ADMINISTRATION T.MASAKI-MANAGER
OFFICE TECHNICAL SERVICE PLANNING
1. Description:
On the vehicle equipped with the 4M41 engine, corrections have been made to the
REMOVAL/INSTALLATION procedure for the bearing block.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)
2001 PAJERO PWJE0001 (1/2) (English) 11C-4, 17,
Workshop Manual VOL.1 19, 20
2001 MONTERO PWJS0002 (1/2) (Spanish)
Workshop Manual VOL.1
2001 PAJERO/MONTERO PWJT0008R (English)
Workshop Manual CD-ROM PWJT0008R (Spanish)
PWJT0008R (French)
PWJT0008R (German)
MH063494
B991800
MB991802 Pin B
B991802
<Added>
MH063497 Bearing installer Bearing block installation
H063497
2
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
ENGINE <4M4> - Timing Chain 11C-17
TIMING CHAIN
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation Camshaft Removal and Installation
Engine Coolant Drain and Refill (Refer to P.11C-23.)
(Refer to GROUP 14 On-vehicle Service.) Cooling Fan and Fan Clutch Assembly Removal
Under Cover and Skid Plate Removal and Installation and Installation (Refer to GROUP 14.)
Engine Oil Draining and Refilling. Vacuum Pump Removal and Installation
(Refer to GROUP 12 On-vehicle Service.) (Refer to P.11C-16.)
Fuel Line Air-bleeding Oil Pan Removal and Installation
(Refer to GROUP 13C On-vehicle Service.) (Refer to P.11C-14.)
<Post-installation operation>
Drive Belt Tension Check and Adjustment
(Refer to P.11C-5.) <Post-installation operation>
<Incorrect>
(Engine oil)
23 2 N.m
(Engine oil)
323 32 N.m
AX1639CA
Removal steps
A 1. A/C compressor drive belt 7. Timing gear case cover assembly
<Vehicles with A/C> 8. Insulator collar
B 2. Alternator drive belt 9. Insulator
3. Crankshaft pulley <Incorrect> 10. Timing gear case cover
C Alternator (Refer to GROUP 16.) B 11. Bearing block assembly
Water pump (Refer to GROUP 14.) 12. Drain plug
Cylinder Head Assembly 13. Drain plug gasket
(Refer to P.11C-27.) 14. Bearing block bushing
4. A/C compressor connector 15. Bearing block
<Vehicles with A/C> B 16. Timing gear case
5. A/C compressor 17. Lower guide plate
<Vehicles with A/C> <Correct>
6. A/C compressor bracket and tension 11. Drain plug
pulley assembly<Vehicles with A/C> 12. Drain plug gasket
13. Timing gear case stay
See next page. Injection pump
(Refer to GROUP 13C.)
14. Timing gear case stiffener 3
C 15. Bearing block
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
<Correct>
23 2 N.m
(Engine oil)
(Engine oil)
323 32 N.m
AY0400CA
4
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
ENGINE <4M4> - Timing Chain 11C-19
MB991802
AX0849CA
Mark ring plates Timing chain Mark ring plates INSTALLATION SERVICE POINTS
A TIMING CHAIN/CAMSHAFT SPROCKET/IDLER
WASHER/SPRING PIN/OIL JET INSTALLATION
1. Check that the mating mark on the idler gear and sprocket
assembly is aligned with mating mark 1 on the crankshaft
Mating marks gear.
2. Align the mating mark on the idler gear and sprocket
Camshaft assembly with the dark blue mark ring plate on the timing
sprocket chain.
AX1131CA
Caution
Note that the timing chain has one mark ring plate for
Timing chain the idler gear and sprocket assembly side, and two
mark ring plates for each camshaft sprocket.
3. Align the mark ring plates with the camshaft sprocket
Idler gear and
sprocket mating marks.
assembly Idler washer 4. Tie up the timing chain and the camshaft sprocket with a
front mark F
cord to prevent the mating mark misalignment.
5. Install the idler washer front mark F must face toward the
front of the engine.
Mating mark 1 <Incorrect>
Mating marks
Crankshaft gear
AX1132CA
AY0401CA
<Incorrect>
B TIMING GEAR CASE/BEARING BLOCK ASSEMBLY
INSTALLATION
1. Clean the timing gear case and the front plate mating
surfaces with a scraper or a wire brush.
2. Apply a continuous bead of the specified sealant to the
timing gear case-mating surface as shown.
Specified sealant:
MITSUBISHI GENUINE PART MD970389 or
equivalent
AX1679CA
5
Purchased from www.WorkshopManuals.co.uk
11C-20 www.WorkshopManuals.co.uk
ENGINE <4M4> - Timing Chain
BX1667CA
BX1666CA
D= Nominal diameter
L= Nominal length
*: Vehicles without A/C
6
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
<Correct>
4. Install the mounting nuts and bolts to the timing gear case at
the shown positions.
Name Symbol Quantity Size mm (D x L)
Flange A* 2 8 x 60
bolt B 1 8 x 75
C 3 8 x 85
D 1 8 x 90
Cap nut E 3 -
BY0402CA
D= Nominal diameter
L= Nominal length
*: Vehicles without A/C
Section A - A AY0404CA
Bearing
block
AY0405CA
7
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
CORRECTION INTERNATIONAL
CAR
ADMINISTRATION T. MASAKI - MANAGER
T
OFFICE TECHNICAL SERVICE PLANNING
1. Description:
For the valve clearance inspection and adjustment of the 4M41 engine, the standard values of
valve clearance when the engine is hot (cooling water temperature at 80 to 95C) have been
established.
2. Applicable Manuals:
3. Details:
Standard values of valve clearance when the engine is hot (cooling water temperature at 80 to
95C):
Intake valve: 0.15 mm
Exhaust valve: 0.20 mm
* The valve clearance inspection and adjustment procedures are the same as the conventional
ones except those procedures to be followed when the engine is hot (cooling water temperature
at 80 to 95C).
MSB-00E11-506 1
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
ENGINE LUBRICATION
Click on the applicable bookmark to selected the required model year.
ENGINE
LUBRICATION
CONTENTS
GENERAL INFORMATION
The lubrication method is a fully force-fed, full-flow An oil cooler with high cooling performance and
filtration type. which is built into the crankcase has been adopted.
<4M4>
Oil pump type Trochoid type External gear type External gear type
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil harmful contaminants which may cause skin cancer.
will result in the removal of natural fats from the Adequate means of skin protection and washing
skin, leading to dryness, irritation and dermatitis. facilities must be provided.
In addition, used engine oil contains potentially
Recommended Precautions
The most effective precaution is to adapt working D Where there is a risk of eye contact, eye
practices which prevent, as far as practicable, the protection should be worn, for example,
risk of skin contact with mineral oils, for example chemical goggles or face shields; in addition
by using enclosed systems for handling used engine an eye wash facility should be provided.
oil and by degreasing components, where D Obtain First Aid treatment immediately for open
practicable, before handling them. cuts and wounds.
Other precautions: D Wash regularly with soap and water to ensure
D Avoid prolonged and repeated contact with oils, all oil is removed, especially before meals (skin
particularly used engine oils. cleansers and nail brushes will help). After
D Wear protective clothing, including impervious cleaning, the application of preparations
gloves where practicable. containing lanolin to replace the natural skin
D Avoid contaminating clothes, particularly oils is advised.
underpants, with oil. D Do not use petrol, kerosine, diesel fuel, gas
D Do not put oily rags in pockets, the use of oil, thinners or solvents for cleaning skin.
overalls without pockets will avoid this. D Use barrier creams, applying them before each
D Do not wear heavily soiled clothing and work period, to help the removal of oil from
oil-impregnated foot-wear. Overalls must be the skin after work.
cleaned regularly and kept separate from D If skin disorders develop, obtain medical advice
personal clothing. without delay.
SEALANT
Item Specified sealant Remark
LUBRICANTS
Items 6G7 4D5 4M4
SPECIAL TOOLS
Tool Number Name Use
MB991610 Oil filter wrench Removal and installation of engine oil filter
(When using the oil filter of MD352626)
MH061590 Oil filter wrench Removal and installation of engine oil filter
(When using the oil filter of MD069782 or
MD326489 or ME013307)
MD998054 Oil pressure switch Removal and installation of oil pressure switch
<6G7, 4D5> wrench
MD998012
<4M4>
ON-VEHICLE SERVICE
ENGINE OIL CHECK
1. Pull out the level gauge slowly and check that the oil
level is in the illustrated range.
2. Check that the oil is not excessively dirty, that there is
no coolant or petrol mixed in, and that it has sufficient
viscosity.
395 Nm
Drain plug gasket
<4M4>
395 Nm
O-ring
10. Race the engine 2-3 times, and check to be sure that
no engine oil leaks from installation section of the oil
filter.
<6G7>
OIL PRESSURE CHECK
Oil pressure <6G7, 4D5>
switch
1. Check engine oil quantity.
2. Remove the oil pressure switch terminal.
Oil filter
<4D5>
12 2 Nm
4
48 7 Nm
3
2
5.0 1.0 Nm
1 5.0 1.0 Nm
5.0 1.0 Nm
6
43 2 Nm
1
Removal steps
1. Oil cooler hose connection at 4. Eye bolts
cooler side 5. Oil cooler return hose
2. Oil cooler assembly 6. Oil cooler feed hose
3. Bracket
<4D5>
4 44 5 Nm
5.0 1.0 Nm
6
43 2 Nm
5 7
44 5 Nm
12 2 Nm
1
Removal steps
D Radiator grille (Refer to GROUP 51.) 4. Oil cooler return tube
1. Oil cooler assembly 5. Oil cooler feed tube
2. Bracket 6. Oil cooler return hose
D Headlamp (Refer to GROUP 54A.) 7. Oil cooler feed hose
3. Bracket
D Intercooler air pipe (Refer to GROUP
15.)
4
Engine oil
6
7 37 7 Nm
9
20 4 Nm
5
8
3 13
12
44 5 Nm
11
10
10 12 13
11
9
44 5 Nm
37 7 Nm
2
1
Removal steps
1. Oil filter (Refer to P.12-5.) 7. Oil cooler element
2. Water drain plug 8. Gasket
"AA 3. Oil cooler assembly 9. Plug
4. Gasket 10. Plug
5. O ring 11. Gasket
6. Water separator 12. Spring
D Engine oil draining 13. Valve
(Refer to P.12-4.)
1
2
1
3
LUBRICANT
Items 4D5
Engine oil quantity L Oil filter 0.8
Total 7.5
GASOLINE DIRECT
INJECTION (GDI)
Click on the applicable bookmark to selected the required model year.
GASOLINE DIRECT
INJECTION (GDI)
CONTENTS
SELF-DIAGNOSIS FUNCTION
D When an abnormality is detected in one frame data.
of the sensors or actuators related to This data can be read by using the MUT-II,
emission control, the engine warning lamp and can then be used in simulation tests
(check engine lamp) illuminates or flashes for troubleshooting. <Only vehicles with
as a warning to the driver. M/T>
D When an abnormality is detected in one D The RAM data inside the engine-ECU
of the sensors or actuators, a diagnosis <M/T> or engine-A/T-ECU <A/T> that is
code corresponding to the abnormality is related to the sensors and actuators can
output. be read by means of the MUT-II. In addition,
D The engine-ECU records the engine the actuators can be force-driven under
operating condition when the diagnosis certain circumstances.
code is set. This data is called freeze
GENERAL SPECIFICATIONS
Items Specifications
Items Specifications
Accelerator pedal position switch Rotary contact type, within accelerator pedal position
sensor (1st channel)
z2 EGR
valve
Canister
L10 Fuel pressure
sensor
z3 Purge control solenoid valve
L6 Camshaft position sensor
L1 Oxygen sensor (front)
L9 Engine coolant tempera-
ture sensor L2 Oxygen sensor (rear) <M/T>
SEALANT
Item Specified sealant Remark
Engine coolant temperature sensor 3M Nut Locking Part No.4171 or Drying sealant
equivalent
SPECIAL TOOLS
Tools Number Name Use
MB991502 MUT-II sub as- D GDI system check
sembly D Take a reading of the diagnosis codes
MB991709
- Engine-ECU
NOTE
1. If the engine warning lamp illuminates because of a malfunction of the engine-ECU, communication
between MUT-II and the engine-ECU is impossible. In this case, the diagnosis code cannot be read.
2. After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the
engine is next turned on and the same malfunction is re-detected. However, for items marked with
a L in the diagnosis code number column, the engine warning lamp illuminates only on the first
detection of the malfunction.
If diagnosis code P0120, P0220, P0225 or P1225 is set, the engine warning lamp will flash. If the
1st and 2nd channels of the throttle postion sensor or the acccelerator pedal position sensor fail
at the same time, the engine warning lamp will also flash.
3. After the engine warning lamp illuminates, it will be switched off under the following conditions.
(1) When the engine-ECU monitored the power train malfunction three times* and met set condition
requirements, it detected no malfunction.
*: In this case, one time indicates from engine start to stop.
(2) For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature,
etc.) are similar to those when the malfunction was first recorded.
NOTE
If malfunctions have been detected in multiple systems, store
one malfunction only, which has been detected first.
READINESS TEST STATUS
The engine-ECU monitors the following main diagnosis items,
judges if these items are in good condition or not, and the
stores its history. This history can be read out by using MUT-II.
(If the ECU has judged a item before, the MUT-II displays
Complete.)
In addition, if diagnosis codes are erased or the battery
cable is disconnected, this history will also be erased (the
memory will be reset).
D Catalyst: P0420
D Oxygen sensor: P0130
D Oxygen sensor heater: P0135, P0141
Intake air temperature sensor Controls as if the intake air temperature is 25_C.
Engine coolant temperature Controls as if the engine coolant temperature is 80_C. (Moreover, the control system
sensor is working until the ignition switch is turned OFF if the sensor signal returns to normal.)
Camshaft position sensor Cuts the fuel supply once a malfunction is detected. (Only when there has been
no occasion of detecting No.1 cylinder top dead centre after the ignition switch
is turned ON.)
Vehicle speed sensor 1. Suspends lean burn operation. However, the control is cancelled as a certain
time passes by with the engine speed of 1,500 r/min or more.
2. Suspends lean burn operation during the engine idling.
Detonation sensor Fixes the ignition timing as that for standard petrol.
Alternator FR terminal Refrains from controlling to suppress the alternator output to electrical load.
(Operated as a normal alternator)
Throttle valve position feed- 1. Suspends the electronic controlled throttle valve system.
back 2. Suspends lean burn operation.
3. Suspends the engine speed feedback control.
However, if the throttle valve opening angle is significantly wide, this system carries
out the following controls.
1. Always cuts the fuel supply to three cylinders.
2. Cuts the fuel supply when the engine speed reaches 3,000 r/min or more.
Communication line between 1. Communication error between the throttle valve controller and the engine-ECU:
the throttle valve controller and D Suspends lean burn operation.
the ECU D Cuts the fuel supply when the engine speed reaches 3,000 r/min or
more.
D Suspends the cruise-control.
2. Communication error between the throttle valve controller and the engine-ECU:
D Suspends lean burn operation.
D Cuts the fuel supply when the engine speed reaches 3,000 r/min or
more.
D Suspends the cruise-control.
D The throttle valve controller controls the throttle valve opening angle by
using signals from accelerator pedal position sensor (2nd channel).
NOTE
If the electronic-controlled throttle valve system is suspended, the engine warning lamp will illuminate.
NOTE
1. Do not replace the engine-ECU until a through terminal check reveals there are no short/open circuit.
2. Check that the engine-ECU earth circuit is normal before checking for the cause of the problem.
3. After the engine-ECU has detected a malfunction, a diagnosis code is recorded the next time the
engine is started and the same malfunction is re-detected. However, for items marked with a L,
the diagnosis code is recorded on the first detection of the malfunction.
4. Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates
the sensor mounted at the position second closest to the engine.
OK
MUT-II Data list Transient malfunction
12 Air flow sensor (Refer to (Refer to GROUP 00 - Points to
P.13A-105, DATA LIST Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
NG
NG
Check the following connector: Repair
B-120
OK
(1) NG OK
Measure at air flow sensor connector Measure at engine-ECU connector Check the following connector:
B-120. D-117. D-117
D Disconnect the connector and D Measure the voltage at the
OK NG
measure at the harness side. engine-ECU terminal. Repair
(1) Voltage between terminal 3 and D Ignition switch: ON
earth (Ignition switch: ON) D Voltage between terminal 61 and
OK: 4.8 - 5.2 V earth Check the harness between the air
(2) Voltage between terminal 4 and OK: 4.8 - 5.2 V flow sensor and the engine-ECU,
earth (Ignition switch: ON) and repair if necessary.
OK: System voltage NG
(3) Resistance between terminal 5 NG
and earth Check the following connector: Repair
OK: 2 W or less D-117
OK
NG NG
Measure at air flow sensor connector Check the following connector: Repair
B-120. D-118
D Use test harness (MB991709) to OK
connect the connector, and
measure at the pick-up harness. NG
Check the harness between the air Repair
D Ignition switch: ON
flow sensor and the engine-ECU.
D Voltage between terminal 7 and
earth OK
OK: 7 - 8 V
Replace the air flow sensor.
OK
OK
NG
Measure the output wave form at air Replace the air flow sensor.
flow sensor connector B-120 (by
using an analyzer).
D Use test harness (MB991709) to Check the trouble symptoms.
connect the connector, and
measure at the pick-up harness. NG
D Engine: Idling NG
D Voltage between terminal 3 and Check the following connectors: Repair
earth B-25X, D-117, D-118
OK
OK: Waveforms should be dis- OK
played on P.13A-118 (In-
spection Procedure Using
Check the harnesses between the
an Analyzer) and noise
air flow sensor and the engine-ECU
should not be displayed in
and between the air flow sensor and
the waveform.
the engine control relay, and repair if
OK necessary.
OK
MUT-II Data list Transient malfunction
25 Barometric pressure sensor (Refer to GROUP 00 - Points to
(Refer to P.13A-105, DATA LIST Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
NG
Check the following connector: NG
B-120 Repair
OK
(1) NG
Measure at air flow sensor connector Measure at engine-ECU connector OK Check the following connector:
B-120. D-117. D-117
D Disconnect the connector and D Measure the voltage at the OK NG
measure at the harness side. engine-ECU terminal. Repair
(1) Voltage between terminal 1 and D Ignition switch: ON
earth (Ignition switch: ON) D Voltage between terminal 41 and Check the harness between the air
OK: 4.8 - 5.2 V earth flow sensor and the engine-ECU,
(2) Resistance between terminal 5 OK: 4.8 - 5.2 V and repair if necessary.
and earth
OK: 2 W or less NG
Check the following connector: NG
Repair
D-117
OK
Check the harness between the air NG
Repair
flow sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
(2) NG NG
Check the following connector: Repair
D-117
OK
Check the harness between the air NG Repair
flow sensor and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
OK
(1) NG NG
Measure at air flow sensor connector Check the following connector: Repair
B-120. (3) NG D-117
D Connect connector terminals
No.1, No.2 and No.5 only by OK
using test harness (MB991709), Check the harness between the air
and measure at the pick-up flow sensor and the engine-ECU,
harness. and repair if necessary.
D Ignition switch: ON (2) NG
(1) Voltage between terminal 1 and Replace the air flow sensor.
earth
OK: 4.8 - 5.2 V
(2) Voltage between terminal 2 and
earth Check the trouble symptoms.
OK: Altitude 0 m: 3.7 - 4.3 V NG
Altitude 1200 m:
3.2 - 3.8 V NG
Check the following connector: Repair
(3) Voltage between terminal 5 and
D-117
earth
OK: 0.5 V or less OK
OK Check the harness between the air
flow sensor and the engine-ECU,
To the next page and repair if necessary.
OK
MUT-II Data list Transient malfunction
13 Intake air temperature sensor (Refer to GROUP 00 - Points to
OK: Roughly the same as ambi- Note for Intermittent Malfunctions.)
ent temperature.
NG
NG
Check the intake air temperature Repair
sensor itself.
(Refer to P.13A-1227.)
OK
NG
Check following connector: B-120 Repair
OK
(1) NG NG
Measure at air flow sensor connector Check the following connector: Repair
B-120. D-118
D Disconnect the connector and OK
measure at the harness side.
Check the harness between the air NG
(1) Resistance between terminal 5 Repair
and earth flow sensor and the engine-ECU.
OK: 2 W or less OK
(2) Voltage between terminal 6 and NG
earth Check the trouble symptoms. Replace the engine-ECU.
(Ignition switch: ON)
OK: 4.8 - 5.2 V
(2) NG OK
Measure at engine-ECU connector Check the following connector:
D-117. D-117
D Measure the voltage at the
OK NG
engine-ECU terminal. Repair
D Disconnect connector B-120.
D Ignition switch: ON
D Voltage between terminal 62 and Check the harness between the air
earth flow sensor and the engine-ECU,
OK: 4.8 - 5.2 V and repair if necessary.
NG
OK
NG
Check the harness between the air Repair
flow sensor and the engine-ECU.
OK OK
NG
To the next page Check the trouble symptoms. Replace the engine-ECU.
OK
(1) NG OK
Measure at engine coolant Measure at engine-ECU connector Check the following connector:
temperature sensor connector B-56. D-117. D-117
D Disconnect the connector and D Measure the voltage at the
measure at the harness side. engine-ECU terminal. OK NG
D Disconnect connector B-56. Repair
(1) Voltage between terminal 1 and
earth D Ignition switch: ON
(Ignition switch: ON) D Voltage between terminal 44 and Check the harness wire between the
OK: 4.8 - 5.2 V earth engine coolant temperature sensor
(2) Resistance between terminal 2 OK: 4.8 - 5.2 V and the engine-ECU, and repair if
and earth necesary.
NG
OK: 2 W or less
Check the following connector: NG
Repair
D-117
OK
Check the harness wire between the
engine coolant temperature sensor NG
Repair
and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
(2) NG NG
Check the following connector: Repair
D-118
OK
OK Check the harness wire between the NG
engine coolant temperature sensor Repair
To the next page and the engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
OK
MUT-II Data list Transient malfunction
79 Throttle position sensor (1st (Refer to GROUP 00 - Points to
channel) (Refer to P.13A-105, Note for Intermittent Malfunctions.)
DATA LIST REFERENCE
TABLE.)
NG
NG
Check the throttle position sensor. Replace
(Refer to P.13A-228.)
OK
NG
Check the following connector: Repair
B-102
OK
(1) NG OK
Measure at throttle position sensor Measure at throttle valve controller Check the following connector:
connector B-102. connector D-11. D-11
D Disconnect the connector and D Measure voltage at the throttle
OK NG
measure at the harness side. valve controller connector Repair
(1) Voltage between terminal 1 and terminals.
earth D Ignition switch: ON
(Ignition switch: ON) D Voltage between terminal 6 and Check the harness wire between the
OK: 4.8 - 5.2 V earth the throttle position sensor and the
(2) Resistance between terminal 3 OK: 4.8 - 5.2 V throttle valve controller, and repair if
and earth necessary.
NG
OK: 2 W or less
NG
Check the following connector: Repair
D-11
OK
NG
Check the harness wire between the Repair
the throttle position sensor and the
throttle valve controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.
(2) NG NG
Check the following connector: Repair
D-11
OK
NG
OK Check the harness wire between the Repair
the throttle position sensor and the
To the next page throttle valve controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.
NG
Check the following connector: Repair
C-19
OK
NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector C-19. D-118, E-116
D Disconnect the connector and OK
measure at the harness side. NG
D Resistance between terminal 2 Check the harness wire between Repair
and earth between the oxygen sensor (front)
OK: 2 W or less and the engine-ECU.
OK OK
Check the trouble symptoms.
NG
(1) NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector C-19. D-118, E-116
D Use the test harness
OK
(MD998464) to connect the
connector, and measure at the
pick-up harness side. Check the harness wire between the
D Engine: 2,500r/min (after warming oxygen sensor (front) and the
up) engine-ECU, and repair if necessary.
(1) Voltage between terminal 2 and (2) NG NG
earth Check the oxygen sensor (front). Replace
OK: 0.5 V or less (Refer to P.13A-230.)
(2) Voltage between terminal 4 and OK
earth NG
OK: 0 V and 0.8 V alternate. Check the following connectors: Repair
D-118, E-116
OK
OK
(1) NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector C-19. D-118, E-116
D Use the test harness
OK
(MD998464) to connect the
connector, and measure at the
pick-up harness side. Check the harness wire between the
D Engine: 2,500r/min (after warming oxygen sensor (front) and the
up) engine-ECU, and repair if necessary.
(1) Voltage between terminal 2 and (2) NG NG
earth Check the oxygen sensor (front). Replace
OK: 0.5 V or less (Refer to P.13A-230.)
(2) Voltage between terminal 4 and OK
earth NG
OK: 0 V and 0.8 V alternate. Check the following connectors: Repair
D-118, E-116
OK
OK
NG
Measure at oxygen sensor (front) Replace
connector C-19.
D Disconnect the connector and
measure at the harness side.
D Resistance between terminals 1
and 3
OK: 4.5 - 8.0 W
OK
NG
Check the following connector: Repair
C-19
OK
NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector C-19. B-25X, D-128, E-113
D Disconnect the connector and OK
measure at the harness side.
D Ignition switch: ON Check the harness wires between
D Voltage between terminal 1 and the oxygen sensor (front) and the
earth engine control relay, and repair if
OK: System voltage necessary.
OK
NG NG
Measure at engine-ECU connector Check the following connectors: Repair
D-118. D-118, E-113
D Measure the voltage at the
OK
engine-ECU terminal.
D Ignition switch: ON
D Voltage between terminal 89 and Check the harness wire between the
earth oxygen sensor (front) and the
OK: System voltage engine-ECU, and repair if necessary.
OK
NG
Check the following connector: Repair
D-118
OK
NG
Check the harness wires between Repair
the oxygen sensor (front) and the
engine-ECU and between the oxygen
sensor (front) and the engine control
relay.
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 - Points to
NG Note for Intermittent Malfunctions.)
NG
Check the following connector: Repair
C-10
OK
NG NG
Measure at oxygen sensor (rear) Check the following connectors: Repair
connector C-10. D-118, E-116
D Disconnect the connector and OK
measure at the harness side. NG
D Resistance between terminal 2 Check the harness wire between Repair
and earth between the oxygen sensor (rear)
OK: 2 W or less and the engine-ECU.
OK OK
Check the trouble symptoms.
NG
(1) NG NG
Measure at oxygen sensor (rear) Check the following connectors: Repair
connector C-10. D-118, E-116
D Use the test harness
OK
(MD998464) to connect the
connector, and measure at the
pick-up harness side. Check the harness wire between the
D Engine: 2,500r/min (after warming oxygen sensor (rear) and the
up) engine-ECU, and repair if necessary.
(1) Voltage between terminal 2 and (2) NG NG
earth Check the oxygen sensor (rear). Replace
OK: 0.5 V or less (Refer to P.13A-230.)
(2) Voltage between terminal (4) and OK
earth NG
OK: 0 V and 0.8 V alternate. Check the following connectors: Repair
D-117, E-116
OK
OK
NG
Measure at oxygen sensor (rear) Replace
connector C-10.
D Disconnect the connector and
measure at the harness side.
D Resistance between terminals 1
and 3
OK: 4.5 - 8.0 W
OK
NG
Check the following connector: Repair
C-10
OK
NG NG
Measure at oxygen sensor (rear) Check the following connectors: Repair
connector C-10. B-25X, D-128, E-113
D Disconnect the connector and OK
measure at the harness side.
D Ignition switch: ON Check the harness wires between
D Voltage between terminal 1 and the oxygen sensor (rear) and the
earth engine control relay, and repair if
OK: System voltage necessary.
OK
NG NG
Measure at engine-ECU connector Check the following connectors: Repair
D-118. D-118, E-113
D Measure the voltage at the
OK
engine-ECU terminal.
D Ignition switch: ON
D Voltage between terminal 90 and Check the harness wire between the
earth oxygen sensor (rear) and the
OK: System voltage engine-ECU, and repair if necessary.
OK
NG
Check the following connector: Repair
D-118
OK
NG
Check the harness wires between Repair
the oxygen sensor (rear) and the
engine-ECU and between the oxygen
sensor (rear) and the engine control
relay.
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 - Points to
NG Note for Intermittent Malfunctions.)
YES
MUT-II Self-Diag Code Refer to P.13A-15, INSPECTION
Is any diagnosis code other than CHART FOR DIAGNOSIS CODES.
No.P0170 output?
NO
NG
Check the air intake from the intake Repair
hose and intake manifold.
OK
NG
Check the exhaust gas leaks from Repair
the exhaust manifold.
OK
NG
Check the throttle body (around the Cleaning
throttle valve), and clean if
necessary. (Refer to P.13A-220).
OK
NG NG
MUT-II Data list Check fuel leakage around the fuel Repair
74 Fuel pressure sensor (Refer to pump (high-pressure) line.
13A-105, DATA LIST
REFERENCE TABLE.) OK
NG
MUT-II Data list Refer to the Inspection procedure for
11 Oxygen sensor (front) the sensor, which is indicated by the
12 Air flow sensor abnormal service data.
13 Intake air temperature sensor (Refer to P.13A-15, INSPECTION
21 Engine coolant temperature CHART FOR DIAGNOSIS CODES.)
sensor
25 Barometric pressure sensor
(Refer to 13A-105, DATA LIST
REFERENCE TABLE.)
Reference
If all the service data is normal, go
to OK.
If any abnormal service is found, go
to NG.
OK
NG
Check the oxygen sensor (front) Replace
(Refer to P.13A-230.)
OK
NG
Check the purge control solenoid Replace
valve (Refer to GROUP 17 -
Emission Control).
OK
NG
Check the fuel pressure between the Repair
fuel pump (low-pressure) and the
fuel pump (high-pressure) (Refer to
P.13A-222).
OK
NG
Check the fuel lines for fuel leaks. Repair
OK
NG
Check the injectors for clogging or Repair
leaks.
OK
OK
Check the trouble symptoms. Transient malfunction
NG (Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions.)
Replace the engine-ECU.
OK
MUT-II Data list Transient malfunction
74 Fuel pressure sensor (Refer to (Refer to GROUP 00 - Points to
13A-105, DATA LIST Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
NG
NG
Check the following connector: Repair
B-110
OK
(1) NG OK
Measure at intermediate connector Measure at engine-ECU connector Check the following connector:
B-110. D-117. D-117
D Disconnect the connector, and D Measure the voltage at the OK NG
measure at the engine-ECU engine-ECU terminal. Repair
harness side. D Ignition switch: ON
(1) Voltage between terminal 4 and D Voltage between terminal 41 and Check the harness wire between the
earth (Ignition switch: ON) earth intermediate connector and the
OK: 4.8 - 5.2 V OK: 4.8 - 5.2 V engine-ECU, and repair if necessary.
(2) Resistance between terminal 6
and earth NG
NG
OK: 2 W or less Check the following connector: Repair
D-117
OK NG
Repair
Check the harness wire between the
intermediate connector and the
engine-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
(2) NG NG
Check the following connector: Repair
D-118
OK
NG
Check the harness wire between the Repair
intermediate connector and the
engine-ECU.
OK
OK
To the next page NG
Check the trouble symptoms. Replace the engine-ECU.
NG
(2) NG Check the following connector: Repair
B-111
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
D-118. D-118
D Measure the voltage at the
engine-ECU terminal. OK
D Engine: Idling Check the harness wire between the
D Voltage between terminal 92 and intermediate connector and the
earth engine-ECU, and repair if necessary.
OK: 0.3 - 4.7 V
OK NG
Check the following connector: Repair
D-118
OK
Check the trouble symptoms.
OK
OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
01 No.1 injector (Refer to GROUP 00 - Points to
NG
OK: The idling condition should Note for Intermittent Malfunctions.)
change.
Replace the injector driver.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Check the following connector: Repair
B-105
OK
NG NG
Measure at intermediate connector Check the following connector: Repair
B-105. B-117
D Disconnect the connector and
OK
measure at the harness side. NG
D Resistance between terminals 11 Check the harness wire between Repair
and 12 No.1 injector and the intermediate
OK: 0.9 - 1.1 W connector.
OK OK
Replace the No.1 injector.
NG
Check the following connector: Repair
B-121
OK
NG
Check the harness wire between the Repair
injector driver and the intermediate
connector.
OK
NG
Check the following connector: Repair
D-116
OK
NG
Check the harness wire between the Repair
injector driver and the engine-ECU.
OK
NG NG
Use an analyzer to measure the Check the following connector: Repair
signal waveform at engine-ECU B-117
connectors D-116 and D-118.
D Engine: Idling OK
D Voltage between terminal 1 and NG
Check the harness wire between the Repair
earth
No.1 injector and the intermediate
OK: A normal waveform should
connector.
be displayed as described
on P.13A-121 (INSPEC- OK
TION PROCEDURE US-
ING AN ANALYZER). Replace the engine-ECU.
OK
NG
Check the following connector: Repair
B-117
OK
OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
02 No.2 injector (Refer to GROUP 00 - Points to
NG
OK: The idling condition should Note for Intermittent Malfunctions.)
change.
Replace the injector driver.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Check the following connector: Repair
B-105
OK
NG NG
Measure at intermediate connector Check the following connector: Repair
B-105. B-114
D Disconnect the connector and
OK
measure at the harness side. NG
D Resistance between terminals 5 Check the harness wire between Repair
and 6 No.2 injector and the intermediate
OK: 0.9 - 1.1 W connector.
OK OK
Replace the No.2 injector.
NG
Check the following connector: Repair
B-121
OK
NG
Check the harness wire between the Repair
injector driver and the intermediate
connector.
OK
NG
Check the following connector: Repair
D-116
OK
NG
Check the harness wire between the Repair
injector driver and the engine-ECU.
OK
NG NG
Use an analyzer to measure the Check the following connector: Repair
signal waveform at engine-ECU B-114
connectors D-116 and D-118.
D Engine: Idling OK
D Voltage between terminal 9 and NG
Check the harness wire between the Repair
earth
No.2 injector and the intermediate
OK: A normal waveform should
connector.
be displayed as described
on P.13A-121 (INSPEC- OK
TION PROCEDURE US-
ING AN ANALYZER). Replace the engine-ECU.
OK
NG
Check the following connector: Repair
B-114
OK
NG
Check the trouble symptoms. Replace the injector driver.
OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
03 No.3 injector (Refer to GROUP 00 - Points to
NG
OK: The idling condition should Note for Intermittent Malfunctions.)
change.
Replace the injector driver.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Check the following connector: Repair
B-105
OK
NG NG
Measure at intermediate connector Check the following connector: Repair
B-105. B-118
D Disconnect the connector and
OK
measure at the harness side. NG
D Resistance between terminals 9 Check the harness wire between Repair
and 10 No.3 injector and the intermediate
OK: 0.9 - 1.1 W connector.
OK OK
Replace the No.3 injector.
NG
Check the following connector: Repair
B-121
OK
NG
Check the harness wire between the Repair
injector driver and the intermediate
connector.
OK
NG
Check the following connector: Repair
D-116
OK
NG
Check the harness wire between the Repair
injector driver and the engine-ECU.
OK
NG NG
Use an analyzer to measure the Check the following connector: Repair
signal waveform at engine-ECU B-118
connectors D-116 and D-118.
D Engine: Idling OK
D Voltage between terminal 24 and NG
Check the harness wire between the Repair
earth
No.3 injector and the intermediate
OK: A normal waveform should
connector.
be displayed as described
on P.13A-121 (INSPEC- OK
TION PROCEDURE US-
ING AN ANALYZER). Replace the engine-ECU.
OK
NG
Check the following connector: Repair
B-118
OK
NG
Check the trouble symptoms. Replace the injector driver.
OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
04 No.4 injector (Refer to GROUP 00 - Points to
NG
OK: The idling condition should Note for Intermittent Malfunctions.)
change.
Replace the injector driver.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Check the following connector: Repair
B-105
OK
NG NG
Measure at intermediate connector Check the following connector: Repair
B-105. B-115
D Disconnect the connector and
OK
measure at the harness side. NG
D Resistance between terminals 3 Check the harness wire between Repair
and 4 No.4 injector and the intermediate
OK: 0.9 - 1.1 W connector.
OK OK
Replace the No.4 injector.
NG
Check the following connector: Repair
B-121
OK
NG
Check the harness wire between the Repair
injector driver and the intermediate
connector.
OK
NG
Check the following connector: Repair
D-116
OK
NG
Check the harness wire between the Repair
injector driver and the engine-ECU.
OK
NG NG
Use an analyzer to measure the Check the following connector: Repair
signal waveform at engine-ECU B-115
connectors D-116 and D-118.
D Engine: Idling OK
D Voltage between terminal 2 and NG
Check the harness wire between the Repair
earth
No.4 injector and the intermediate
OK: A normal waveform should
connector.
be displayed as described
on P.13A-121 (INSPEC- OK
TION PROCEDURE US-
ING AN ANALYZER). Replace the engine-ECU.
OK
NG
Check the following connector: Repair
B-115
OK
NG
Check the trouble symptoms. Replace the injector driver.
OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
05 No.5 injector (Refer to GROUP 00 - Points to
NG
OK: The idling condition should Note for Intermittent Malfunctions.)
change.
Replace the injector driver.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Check the following connector: Repair
B-105
OK
NG NG
Measure at intermediate connector Check the following connector: Repair
B-105. B-103
D Disconnect the connector and
OK
measure at the harness side. NG
D Resistance between terminals 7 Check the harness wire between Repair
and 8 No.5 injector and the intermediate
OK: 0.9 - 1.1 W connector.
OK OK
Replace the No.5 injector.
NG
Check the following connector: Repair
B-121
OK
NG
Check the harness wire between the Repair
injector driver and the intermediate
connector.
OK
NG
Check the following connector: Repair
D-116
OK
NG
Check the harness wire between the Repair
injector driver and the engine-ECU.
OK
NG NG
Use an analyzer to measure the Check the following connector: Repair
signal waveform at engine-ECU B-103
connectors D-116 and D-118.
D Engine: Idling OK
D Voltage between terminal 10 and NG
Check the harness wire between the Repair
earth
No.5 injector and the intermediate
OK: A normal waveform should
connector.
be displayed as described
on P.13A-121 (INSPEC- OK
TION PROCEDURE US-
ING AN ANALYZER). Replace the engine-ECU.
OK
NG
Check the following connector: Repair
B-103
OK
NG
Check the trouble symptoms. Replace the injector driver.
OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
06 No.6 injector (Refer to GROUP 00 - Points to
NG
OK: The idling condition should Note for Intermittent Malfunctions.)
change.
Replace the injector driver.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Check the following connector: Repair
B-105
OK
NG NG
Measure at intermediate connector Check the following connector: Repair
B-105. B-104
D Disconnect the connector and
OK
measure at the harness side. NG
D Resistance between terminals 1 Check the harness wire between Repair
and 2 No.6 injector and the intermediate
OK: 0.9 - 1.1 W connector.
OK OK
Replace the No.6 injector.
NG
Check the following connector: Repair
B-121
OK
NG
Check the harness wire between the Repair
injector driver and the intermediate
connector.
OK
NG
Check the following connector: Repair
D-116
OK
NG
Check the harness wire between the Repair
injector driver and the engine-ECU.
OK
NG NG
Use an analyzer to measure the Check the following connector: Repair
signal waveform at engine-ECU B-104
connectors D-116 and D-118.
D Engine: Idling OK
D Voltage between terminal 25 and NG
Check the harness wire between the Repair
earth
No.6 injector and the intermediate
OK: A normal waveform should
connector.
be displayed as described
on P.13A-121 (INSPEC- OK
TION PROCEDURE US-
ING AN ANALYZER). Replace the engine-ECU.
OK
NG
Check the following connector: Repair
B-104
OK
NG
Check the trouble symptoms. Replace the injector driver.
OK
MUT-II Data list Intermittent malfunction
14 Throttle position sensor (2nd (Refer to GROUP 00 - Points to
channel) Note for Intermittent Malfunctions.)
OK: Refer to P.13A-105, DATA
LIST REFERENCE TABLE.
NG
NG
Check throttle position sensor (2nd Replace
channel). (Refer to P.13A-228).
OK
NG
Check the following connector: Repair
B-102
OK
(1) NG OK
Measure at throttle position sensor Measure at throttle valve controller Check the following connector:
connector B-102. connector D-11. D-11
D Disconnect the connector and D Measure the voltage at the
OK NG
measure at the harness side. throttle valve controller connector Repair
(1) The voltage between terminal 1 terminals.
and earth D Ignition switch: ON
(Ignition switch: ON) D The voltage between terminal 6 Check the harness wire between the
OK: 4.8 - 5.2 V and earth throttle position sensor and the
(2) Resistance between terminal 3 OK: 4.8 - 5.2 V throttle valve controller, and repair if
and earth necessary.
NG
OK: 2 W or less
NG
Check the following connector: Repair
D-11
OK
NG
Check the harness wire between the Repair
throttle position sensor and the
throttle valve controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.
(2) NG NG
Check the following connector: Repair
OK D-11
OK
To the next page NG
Check the harness wire between the Repair
throttle position sensor and the
throttle valve controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.
(1) NG
MUT-II Actuator Test Check the following connectors: Repair
01 No.1 injector B-107 and the ignition coil
02 No.2 injector connectors, which correspond to
03 No.3 injector defective cylinders (B-101, B-108,
04 No.4 injector B-112, B-113, B-116, B-119).
05 No.5 injector OK
06 No.6 injector
NG
OK: The idling condition should Check the harness wire between the Repair
change. ignition coil connector for a defective
Reference cylinder and the intermediate
When the cylinder (defective connector.
cylinder) where idling condition does
not change is detected after OK
suspending the injector, go to (1) NG
and inspect the spark plug, the Check the spark plug and the Replace
ignition coil, the connector, and the ignition coil for a defective cylinder.
harness of the defective cylinder. (Refer to GROUP 16 - Ignition
(When more than one cylinder are System.)
detected, inspect all of them.)
OK
When all the cylinders are OK, go to
NG
(2).
Check the following connector: Repair
(2) D-116
OK
NG
Check the harness wire between the Repair
engine-ECU and the intermediate
connector.
OK
OK
Check the ignition coil (Refer to Check the harness wire between the
GROUP 16 - Ignition System.) ignition coil and the earth, and repair
if necessary.
NG
Check the following connector: B-05 Repair
OK
NG
Measure at the detonation sensor connector B-05. Check the harness wire between the detonation sensor and
D Disconnect the connector and measure at the harness earth, and repair if necessary.
side.
D The resistance between terminal 2 and earth
OK: 2 W or less
OK
NG
Check the following connector: D-118 Repair
OK
NG
Check the harness wire between the detonation sensor and Repair
the engine-ECU.
OK
OK
Check the trouble symptoms. Intermittent malfunction
(Refer to GROUP 00 - Points to Note for Intermittent
NG Malfunctions.)
Replace the detonation sensor.
OK
Check the trouble symptoms. Intermittent malfunction
NG (Refer to GROUP 00 - Points to Note for Intermittent Malfunctions.)
NG
Measure at EGR valve connector B-60 Replace
D Disconnect the connector, and
measure at the EGR valve side.
D The resistance between terminals 1
and 2
D The resistance between terminals 2
and 3
D The resistance between terminals 4
and 5
D The resistance between terminals 5
and 6
OK: 15 - 20 W
OK
NG
Check the following connector: B-60 Repair
OK
NG NG
Measure at EGR valve connector Check the following connector: B-25X Repair
B-60
OK
D Disconnect the connector and
measure at the harness side. Check the harness wire between the
D Ignition switch: ON EGR valve and the engine control relay,
D The voltage between terminal 2 and repair if necessary.
and earth
D The voltage between terminal 5
and earth
OK: System voltage
OK
NG NG
Measure at engine-ECU connector Check the following connector: D-116 Repair
D-116. OK
D Measure the voltage at the
NG
engine-ECU terminal. Check the harness wire between the Repair
D The voltage between terminal 5 EGR valve and the engine-ECU.
and earth.
D The voltage between terminal 6 OK
and earth.
D The voltage between terminal 32 Replace the engine-ECU.
and earth.
D The voltage between terminal 34
and earth.
OK: The voltage changes as follows
for three seconds when the igni-
tion switch is turned ON.
(When using a circuit tester)
5 V and 8 V alternates
(When using an analyzer)
1 V or less and system voltage
alternates
OK
NG
Check the following connector: Repair
D-116
OK
NG
Check the harness wires between the Repair
EGR valve and the engine control
relay, and between the EGR valve
and the engine-ECU.
OK
OK Intermittent malfunction
Check the trouble symptoms.
(Refer to GROUP 00 - Points to
NG Note for Intermittent Malfunctions.)
NG
Check the exhaust manifold. (Are there any cracks?) Repair
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system <sensor 2>
59 Oxygen sensor (rear) (Refer to P.13A-31, INSPECTION PROCEDURE FOR
D Transmission: 2nd DIAGNOSTIC TROUBLE CODE P0136.)
D Drive with wide open throttle
OK: 600 - 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system <sensor 1>
11 Oxygen sensor (front) (Refer to P.13A-28, INSPECTION PROCEDURE FOR
OK: 600 - 1,000 mV when racing suddenly DIAGNOSTIC TROUBLE CODE P0130.)
OK
NG
MUT-II Data list Replace the oxygen sensor (front).
11 Oxygen sensor (front)
D Transmission: 2nd
OK: Changeover between 0 - 400 mV and 600 - 1,000
mV occur 15 times in 10 seconds.
OK
OK
MUT-II Actuator Test Intermittent malfunction
08 Purge control solenoid valve (Refer to GROUP 00 - Points to
OK: Operating sound can be Note for Intermittent Malfunctions.)
heard and the valve vibrates.
NG
NG
Measure at the purge control Replace
solenoid valve connector B-106.
D Disconnect the connector, and
measure at the solenoid valve
side.
D The resistance between terminals
1 and 2
OK: 28 - 36 W (at 20_C)
OK
NG
Check the following connector: Repair
B-106
OK
NG
Check the following connector: NG
Measure at the purge control Repair
solenoid valve connector B-106. B-25X
D Disconnect the connector and NG
measure at the harness side.
D Ignition switch: ON Check the harness wire between the
D The voltage between terminal 2 purge control solenoid valve and the
and earth engine control relay, and repair if
OK: System voltage necessary.
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
D-116. D-119
D Measure the voltage at the
OK
engine-ECU terminal.
D Ignition switch: ON Check the harness wire between the NG
Repair
D The voltage between terminal 16 purge control solenoid valve and the
and earth engine-ECU.
OK: System voltage
OK
OK
Replace the engine-ECU.
NG
Check the following connector: Repair
D-116
OK
NG
Check the harness wires between Repair
the purge control solenoid valve and
the engine control relay, and
between the purge control solenoid
valve and the engine-ECU.
OK
NO
Does the speedometer operate normally? Check the vehicle speed sensor
YES (Refer to GROUP 54 - Combination Meter.)
NG
Use an analyzer to measure the output waveform of the Check the following connectors: D-118, E-13
vehicle speed sensor at engine-ECU connector D-118. OK NG
D Driving the vehicle
D The voltage between terminal 80 and earth Repair
OK: A normal waveform should be displayed as described
in OSCILLOSCOPE INSPECTION PROCEDURE, Check the harness wire between intermediate connector E-13
and noise should not be displayed in the waveform. and the engine-ECU, and repair if necessary.
(Refer to GROUP 23 - Troubleshooting)
OK
NG
Check the following connector: C-09 Repair
OK
NG
Check the following connectors: B-121, D-118 Repair
OK
NG
Check the harness wire between the injector driver and the Repair
engine-ECU.
OK
NG
Use an analyzer to measure the signal waveform at Replace the injector driver.
engine-ECU connectors D-116, D-118.
D Engine: Idling
D The voltage between terminal 96 and earth, terminal 1 and
earth
OK: A normal waveform should be displayed as described
on P.13A-121 (INSPECTION PROCEDURE USING
AN ANALYZER).
OK
OK
Check the trouble symptoms. Intermittent malfunction
(Refer to GROUP 00 - Points to Note for Intermittent
NG Malfunctions.)
Replace the engine-ECU.
NG
Check the following connectors: D-11, D-118 Repair
OK
NG
Check the harness wire between the throttle valve controller Repair
and the engine-ECU.
OK
YES
MUT-II Self-Diag Code Refer to Code No.P0120, Throttle position sensor (1st
Is code No.P0120 set? channel) system (Refer to P.13A-25).
NO
YES
MUT-II Self-Diag Code Refer to Code No.P1222, Throttle valvr control servo system
Is Code No.P1222 set? (Refer to P.13A-66.)
NO
OK
Check the operation of the throttle Transient malfunction
valve control servo. (Refer to GROUP 00 - Points to
OK: The throttle valve opens or Note for Intermittent Malfunctions.)
closes when the accelerator
pedal is depressed or released.
NG
NG
Check the throttle valve control Replace the throttle body assembly
servo (Refer to P.13A-232.)
OK
NG
Check the following connector: Repair
B-122
OK
NG NG
Measure at the throttle valve control Check the following connector: Repair
servo connector B-122 D-11
D Use test harness (MB991658) to OK
connect the connector, and NG
measure at the pick-up harness. Check the harness wire between the Repair
D Ignition switch: ON throttle valve control servo and the
D The voltage between terminal 1 throttle valve controller.
and earth
D The voltage between terminal 2 OK
and earth
Check the trouble symptoms.
D The Voltage between terminal 3
and earth NG
OK: Voltage changes between 5
- 7 V when the accelerator Replace the throttle valve controller.
pedal is operated.
NOTE: Erase the diagnosis code
before the measurement
since a diagnosis code is
recorded when the harness
is disconnected.
OK
Check the trouble symptoms.
NG
YES
MUT-II Self-Diag Code Refer to Code No.P1220,
Is Code No.P1220 output? Electronic-controlled throttle valve system
NO (Refer to P13A-64.)
NG
Check the following connector: Repair
D-11
OK
NG
(1) NG
Measure at throttle valve controller Check the following connectors: B-25X, Repair
connector D-11. D-128
D Measure voltage at the throttle OK
valve controller connector
terminals. Check the harness wire between the
D Ignition switch: ON throttle valve controller and the engine
(1) The voltage between terminal 5 control relay, and repair if necessary.
and earth
OK: System voltage (2) NG NG
Check the following connectors: D-208, Repair
(2) The voltage between terminal 22 D-223, E-13
and earth
OK: System voltage OK
(3) The voltage between terminal 3
and earth Check the harness wire between the
The voltage between terminal 4 throttle valve controller and the ignition
and earth switch, and repair if necessary.
The voltage between terminal 16
and earth (3) NG NG
OK: 0.5 V or less Check the following connector: D-14 Repair
OK
OK
NG
Check the following connector: Repair
D-118
OK
NG
Replace the throttle valve controller.
OK
MUT-II Data list Intermittent malfunction
77 Accelerator pedal position sensor (Refer to GROUP 00 - Points to
(2nd channel) (Refer to P. Note for Intermittent Malfunctions.)
13A-105, DATA LIST
REFERENCE TABLE.)
NG
NG
Check the accelerator pedal position Replace
sensor (Refer to P.13A-229.)
OK
NG
Check the following connector: Repair
D-135
OK
(1) NG NG
Measure at accelerator pedal position Check the following connector: Repair
sensor connector D-135 D-11
D Disconnect the connector and
measure at the harness side. OK
(1) The resistance between terminal NG
Check the harness wire between Repair
7 and earth accelerator pedal position sensor
OK: 2 W or less (2nd channel) and the throttle valve
(2) The voltage between terminal 8 controller.
and earth
(Ignition switch: ON) OK
OK: 4.8 - 5.2 V NG
Check the trouble symptoms. Replace the throttle valve controller.
(2) NG OK
Measure at throttle valve controller Check the following connector:
connector D-11. D-11
D Measure voltage at the throttle NG
OK
valve controller connector Repair
terminals.
D Ignition switch: ON
Check the harness wire between
D The voltage between terminal 6
accelerator pedal position sensor
and earth
(2nd channel) and the throttle valve
OK: 4.8 - 5.2 V
controller, and repair if necessary.
NG
NG
Check the following connector: Repair
D-11
OK
OK
NG
To the next page Check the harness wire between Repair
accelerator pedal position sensor
(2nd channel) and the throttle valve
controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.
NG
Check the following connector: Repair
B-41
OK
NG NG
Measure at intermediate connector Measure at engine-ECU connector Check the following connector:
B-41. D-117. D-117
D Use test harness (MB991658) to D Measure the voltage at the
connect the connector, and engine-ECU terminal. OK NG
measure at the pick-up harness. D Ignition switch: ON Repair
D Ignition switch: ON D The voltage between terminal 52
D The voltage between terminal 2 and earth Check the harness wire between the
and earth OK: 9 - 10 V intermediate connector and the
OK: 9 - 10 V engine-ECU, and repair if necessary.
NG
NG
Check the following connector: Repair
D-117
OK
NG
Check the harness wire between the Repair
intermediate connector and the
OK engine-ECU.
OK
Measure at intermediate connector NG
Check the trouble symptoms. Replace the engine-ECU.
B-41.
D Use test harness (MB991658) to NG NG
connect the connector, and Check the following connector: Repair
measure at the pick-up harness. B-59
D Engine:idling (After warming up) OK
D Radiator fan: Not operating
D The voltage between terminal 2 Check the harness wire between the NG
alternator and the intermediate Repair
and earth
OK: The voltage drops when connector.
the headlamps are turned OK
on.
Check the following connector: NG
D-117 Replace
OK
NOTE
(1) If the registered ignition keys 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 encrypted code.
NG
Check the following connectors: Repair
D-118, D-202, E-13
OK
NG
Check the harness wire between the Replace
immobilizer-ECU and the
engine-ECU.
OK
Engine warning The engine warning lamp does not illuminate right after the 3 13A-76
lamp and ignition switch is turned to the ON position.
related parts
The engine warning lamp remains illuminating and never goes 4 13A-76
out.
Idling stability When the engine is cold, it stalls at idling. (Die out) 9 13A-84
(Engine stalls)
When the engine is hot, it stalls at idling. (Die out) 10 13A-85
The engine stalls when starting the car. (Pass out) 11 13A-87
Poor acceleration
Surge
Knocking 16 13A-91
Dieseling 17 13A-91
GDI ECO indi- GDI ECO indicator lamp does not illuminate. 23 13A-96
cator lamp sys-
tem GDI ECO indicator lamp remains illuminated and does not go off. 24 13A-97
Starting Wont start The starter is used to crank the engine, but there is no combustion within the
cylinders, and the engine wont start.
Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Incorrect idle speed The engine doesnt idle at the usual correct speed.
Engine stall The engine stalls when the foot is taken from the accelerator pedal, regardless
(Die out) of whether the vehicles is moving or not.
Engine stall The engine stalls when the accelerator pedal is depressed or while it is being
(Pass out) used.
Time
Idling Stumble
Time
Items Symptom
Driving Shock The feeling of a comparatively large impact or vibration when the engine is
accelerated or decelerated.
Surge This is repeated surging ahead during constant speed travel or during variable
speed travel.
Knocking A sharp sound like a hammer striking the cylinder walls during driving and which
adversely affects driving.
Stopping Run on The condition in which the engine continues to run after the ignition switch is
(Dieseling) turned to OFF. Also called Dieseling.
NG NG
Measure at the diagnostic connector Check the following connectors: Repair
(16-pin) D-23. D-27, D-210, D-211
D Voltage between 16 and earth
OK
OK: System voltage
NG
OK Check trouble symptom. Check the harness wire between the
power supply and diagnostic connector
(16 pin), and repair if necessary.
NG
Measure at the diagnostic connector Check the harness wire between the
(16-pin) D-23. diagnostic connector (16-pin) and earth,
D Continuity between 4 and earth and repair if necessary.
D Continuity between 5 and earth
OK: Continuity
OK
NG
Check the following connectors: Repair
D-06, D-23, D-33, D-118, D-128, D-222, E-13
OK
NOTE
On vehicles with center display, if a malfunction cannot be resolved after the procedure above, check the center
display and replace if necessary. (Refer to GROUP 54 - Center display.)
Inspection procedure 3
The engine warning lamp does not illuminate right after Probable cause
the ignition switch is turned to the ON position.
Because there is a burnt-out bulb, the engine-ECU causes the engine warning lamp D Burnt-out bulb
to illuminate for five seconds immediately after the ignition switch is turned to ON. D Defective warning lamp circuit
If the engine warning lamp does not illuminate immediately after the ignition switch D Malfunction of the engine-ECU
is turned to ON, one of the malfunctions listed at right has probably occurred.
NG
MUT-II Data list Check the engine-ECU power supply and earth circuit system.
16 engine-ECU power supply voltage (Refer to P.13A-105.) (Refer to P.13A-98, Inspection procedure 25.)
OK
OK NG
Measure at the engine-ECU connector D-116. Check the following Repair
D Disconnect the connector, and measure at the harness side. connector: D-116
D Earth the terminal No. 31.
OK
OK: The engine warning lamp illuminates.
NG Check trouble symptom.
NG
NG
Check a burnt-out bulb. Replace Replace the engine-ECU.
OK
NG
Measure at the combination meter connector D-01. Check the engine warning lamp power supply circuit, and repair
D Disconnect the connector, and measure at the harness side. if necessary.
D Voltage between 62 and earth (Ignition switch: ON)
OK: System voltage
OK
NG
Check the following connectors: Repair
D-02, D-116, E-13
OK
NG
Check trouble symptom. Check the harness wire between combination meter and engine-
ECU, and repair if necessary.
Inspection procedure 4
The engine warning lamp remains illuminating and never Probable cause
goes out.
In cases such as the above, the cause is probably that the engine-ECU is detecting D Short-circuit between the engine warning lamp and
a problem in a sensor or actuator, or that one of the malfunctions listed at right has engine-ECU
occurred. D Malfunction of the engine-ECU
Yes
MUT-II Self-Diag code Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES
No
NG
Measure at the combination meter connector D-02. Check the harness wire between combination meter and engine-
D Disconnect the connector, and measure at the harness side. ECU connector, and repair if necessary.
D Disconnect the engine-ECU connector
D Continuity between 38 and earth
OK: No continuity
OK
NG
Check system voltage while the engine is cranking. Check the battery. (Refer to GROUP 55 - Battery.)
OK: 8 V or more
OK
Yes
MUT-II Self-Diag code Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Data list Check the engine control relay and ignition switch-IG system. (Refer
16 System voltage (Refer to P.13A-105.) to P.13A-99, Inspection procedure 26.)
OK
No
Does the camshaft rotate when the engine is cranking? Check if the timing belt is broken or damaged.
Yes
NG
MUT-II Actuator test Check the fuel pump (low pressure) system. (Refer to P.13A-101,
07 Fuel pump (low pressure) (Refer to P.13A-110.) Inspection procedure 29.)
OK
NG
MUT-II Data list Check the crank angle sensor system. (Refer to P.13A-56, code
22 Crank angle sensor (Refer to P.13A-105.) No. P0335.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system. (Refer to
21 Engine coolant temperature sensor (Refer to P.13A-105.) P.13A-22, code No. P0115.)
OK
NG
MUT-II Data list Check the throttle position sensor (1st channel) system. (Refer
79 Throttle position sensor (1st channel) (Refer to P.13A-105.) to P.13A-25, code No. P0120.)
OK
OK
Inspect engine start ability by cranking the engine while the accelera- Clean around the throttle valve. (Refer to P.13A-220.)
tor pedal is slightly depressed.
NG
NG
Measure at injector driver connector B-121. Check the injector driver system. (Refer to P.13A-104, Inspection
D Disconnect the connector, and measure at the connector side. procedure 34.)
D Voltage between each of terminals 4, 12, 21 and earth
(Ignition switch: ON)
OK: System voltage
OK
NG
Check fuel leakage. (Refer to P.13A-225.) Repair
OK
NG
Measure low fuel pressure between the fuel pump (low pressure) Repair
and fuel pump (high pressure). (Refer to P.13A-222.)
OK
NG
Measure at ignition coil connectors B-101, B-108, B-112, B-113, Check the ignition coil (incorporating power transitor) system. (Refer
B-116, B-119. to P.13A-53, code No. P0300.)
D Connect the connector.
D Connect a timing light to the No.1 terminal of each connector
in turn.
(Engine cranking)
OK: The timing light flashes.
OK
NG
Check ignition timing while the engine is cranking. Check that the crank angle sensor and timing belt cover are properly
OK: Approx. 5_ BTDC installed.
OK
NG
Check system voltage while the engine is cranking. Check the battery. (Refer to GROUP 55 - Battery.)
OK: 8 V or more
OK
Yes
MUT-II Self-Diag code Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Actuator test Check the fuel pump (low pressure) system. (Refer to P.13A-101,
07 Fuel pump (low pressure) (Refer to P.13A-110.) Inspection procedure 29.)
OK
NG
MUT-II Data list Check the engine coolant temperature system. (Refer to P.13A-22,
21 Engine coolant temperature sensor (Refer to P.13A-105.) code No. P0115.)
OK
NG
MUT-II Data list Check the ignition switch-ST system. (Refer to P.13A-99, Inspection
18 Cranking signal (Refer to P.13A-105.) procedure 27.)
OK
NG
MUT-II Data list Check an abnormal fuel pressure system. (Refer to P.13A-36, code
74 Fuel pressure sensor (Refer to P.13A-105.) No. P0190.)
OK
NG
Check fuel leakage. (Refer to P.13A-225.) Repair
OK
Yes
Is the engine started normally when it is cranked with the accelerator Clean around the throttle valve. (Refer to P.13A-220.)
pedal depressed slightly?
No
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-105.) P.13A-65, code No. P1221.)
OK
NG
Check ignition timing when the engine is cranked. Check that the crank angle sensor and timing belt cover are properly
OK: approx. 5_ BTDC installed.
OK
OK
NG
Check trouble symptom. Replace the injector.
Yes
Has the battery been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
minutes.
No
Yes
MUT-II Self-Diag code Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
Yes
Does the engine idle speed fluctuates excessively (excessive hunt- Clean around the throttle valve. (Refer to P.13A-220.)
ing)?
No
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-105.) P.13A-65, code No. P1221.)
OK
NG
MUT-II Data list Check the accelerator pedal position switch system. (Refer to
26 Accelerator pedal position switch (Refer to P.13A-110.) P.13A-100, Inspection procedure 28.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system. (Refer to P.13A-21,
13 Intake air temperature sensor (Refer to P.13A-105.) code No. P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system. (Refer to P.13A-19,
25 Barometric pressure sensor (Refer to P.13A-105.) code No. P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-22,
21 Engine coolant temperature sensor (Refer to P.13A-105.) code No. P0115.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve system. (Refer to P.13A-62,
08 Purge control solenoid valve (Refer to P.13A-110.) code No. P0443.)
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13A-31, code
59 Oxygen sensor (rear) No. P0136.)
D Transmission: 2nd gear
D Driving with throttle widely open
OK: 600 - 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13A-28, code
11 Oxygen sensor (front) No. P0130.)
OK: 600 - 1,000 mV when the engine is suddenly raced
OK
NG
MUT-II Data list Check the power steering fluid pressure switch system. (Refer
27 Power steering fluid pressure switch (Refer to P.13A-105.) to P.13A-102, Inspection procedure 30.)
OK
MUT-II Data list NG Check the A/C switch and A/C relay system. (Refer to P.13A-102,
28 A/C switch (Refer to P.13A-105.) Inspection procedure 31.)
OK
NG Check the stop lamp switch. (Refer to P.13A-103, Inspection proce-
MUT-II Data list
67 Stop lamp switch (Refer to P.13A-105.) dure 32.)
OK
MUT-II Data list NG Check the small lamp switch system. (Refer to P.13A-104, Inspec-
31 Small lamp switch (Refer to P.13A-105.) tion procedure 33.)
OK
NG
MUT-II Data list Check the EGR valve. (Refer to P.13A-60, code No. P0403.)
68 EGR valve (Refer to P.13A-105.)
OK
NG
Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.) Check that the crank angle sensor and timing belt cover are properly
OK installed.
Yes
MUT-II Self-Diag code (Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-105.) P.13A-65, code No.S P1221.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve. (Refer to P.13A-62, code
08 Purge control solenoid valve (Refer to P.13A-110.) No. P0443.)
OK
NG
MUT-II Data list Check the accelerator pedal position switch system. (Refer to
26 Accelerator pedal position switch (Refer to P.13A-105.) P.13A-100, Inspection procedure 28.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-22,
21 Engine coolant temperature sensor (Refer to P.13A-105.) code No. P0115.)
OK
NG
MUT-II Data list Check the A/C switch and A/C relay system. (Refer to P.13A-102,
28 A/C switch (Refer to P.13A-105.) Inspection procedure 31.)
OK
NG
MUT-II Data list Check the stop lamp switch system. (Refer to P.13A-103, Inspection
67 Stop lamp switch (Refer to P.13A-105.) procedure 32.)
OK
Inspection procedure 9
When the engine is cold, it stalls at idling. (Die out) Probable cause
The cause is probably an incorrect air/fuel ratio or poor intake air amount when the D Malfunction of the electronic-control throttle valve
engine is cold. system
D Malfunction of the throttle body
Yes
Have the battery terminals been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
No minutes.
Yes
MUT-II Self-Diag code (Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
Yes
Is the engine idling correct after the engine has been warmed up? Refer to Unstable idling (rough idle, hunting). (Refer to P.13A-81,
Inspection procedure 7.)
No
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
22 Crank angle sensor (Refer to P.13A-105.) P.13A-65, code No. P1221.)
Check idling speed when the engine is cold.
OK
NG
MUT-II Data list Check the accelerator position switch. (Refer to P.13A-100, Inspec-
26 Accelerator pedal position switch (Refer to P.13A-105.) tion procedure 28.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-22,
21 Engine coolant temperature sensor (Refer to P.13A-105.) code No. P0115.)
OK
NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-60, code No. P0403.)
68 EGR valve (Refer to P.13A-105.)
OK
Yes
Does the engine stall immediately after the accelerator pedal is Clean around the throttle valve. (Refer to P.13A-220.)
released?
No
Measure fuel high pressure between the fuel pump (high pressure) NG
and injector. (Refer to P.13A-224.) Repair
OK
NG
Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.) Check that the crank angle sensor and timing belt cover are properly
installed.
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK
OK
Check all the following items: Check trouble symptom.
D Spark plugs
D Compression pressure NG
D Engine oil viscosity
Replace the injector.
Yes
Have the battery terminals been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
No minutes.
Yes
MUT-II Self-Diag code Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
No
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-105.) P.13A-65, code No. P1221.)
OK
No
Is it easy to reproduce the engine stall? While carrying out an intermittent malfunction simulation test. (Refer
to GROUP 00 - Points to Note for Intermittent Malfunction.), check
Yes for sudden changes in the following signals.
D Crank angle sensor signal
D Injector drive signal
D Fuel pump (low pressure) drive signal
D Air flow sensor
D Primary ignition signal
D Power supply to the engine-ECU
NG
MUT-II Data list Check the accelerator pedal position switch. (Refer to P.13A-100,
26 Accelerator pedal position switch (Refer to P.13A-105.) Inspection procedure 28.)
OK
NG
MUT-II Data list Check the intake air temperature sensor. (Refer to P.13A-21, code
13 Intake air temperature sensor (Refer to P.13A-105.) No. P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor. (Refer to P.13A-19, code
25 Barometric pressure sensor (Refer to P.13A-105.) No. P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-22,
21 Engine coolant temperature sensor (Refer to P.13A-105.) code No. P0115.)
OK
MUT-II Data list NG Check the oxygen sensor (rear) system. (Refer to P.13A-31, code
59 Oxygen sensor (rear) No. P0136.)
D Transmission: 2nd gear
D Driving with throttle widely open
OK: 600 - 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13A-28, code
11 Oxygen sensor (front) No. P0130.)
OK: 600 - 1,000 mV when the engine is suddenly raced
OK
NG
MUT-II Data list Measure fuel high-pressure between the fuel pump (high pressure)
11 Oxygen sensor (front) and injector. (Refer to P.13A-224.)
OK: 0 - 400 mV and 600 - 1,000 mV alternates when the NG
OK
engine is idling (wait for four minutes after the engine
started). Repair
OK Check that air is sucked in the air intake system.
D Broken intake manifold gasket
To the next page D Damaged vacuum hose
D Damaged air intake hose
Yes
MUT-II Self-Diag code (Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the EGR valve. (Refer to P.13A-60, code No. P0403.)
68 EGR valve (Refer to P.13A-105.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve system. (Refer to P.13A-62,
08 Purge control solenoid valve (Refer to P.13A-110.) code No. P0443.)
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK
Inspection procedure 12
The engine stalls when decelerating. Probable cause
The cause is probably an improper air/fuel ratio due to a faulty EGR system, or poor D Malfunction of the electronic-controlled throttle valve
intake air volume due to a faulty electronic-controlled throttle valve system. system
D Malfunction of the EGR valve
Yes
Have the battery terminals been disconnected recently? Warm up the engine, and then let it run at idle for approx. ten
No minutes.
Yes
MUT-II Self-Diag code (Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the accelerator pedal position switch. (Refer to P.13A-100,
26 Accelerator pedal position switch (Refer to P.13A-105.) Inspection procedure 28.)
OK
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-105.) P.13A-65, code No. P1221.)
OK
NG
MUT-II Data list Check the EGR valve system. (Refer to P.13A-69, code No. P0403.)
68 EGR valve (Refer to P.13A-105.)
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
OK
Yes
MUT-II Self-Diag code (Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
OK
NG
Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.) Check that the crank angle sensor and timing belt cover are properly
OK installed.
NG
MUT-II Data list Check the accelerator pedal position switch. (Refer to P.13A-100,
26 Accelerator pedal position switch (Refer to P.13A-105.) Inspection procedure 28.)
OK
NG
MUT-II Data list Check the intake air temperature sensor. (Refer to P.13A-21, code
13 Intake air temperature sensor (Refer to P.13A-105.) No. P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor. (Refer to P.13A-19, code
25 Barometric pressure sensor (Refer to P.13A-105.) No. P0105.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-22,
21 Engine coolant temperature sensor (Refer to P.13A-105.) code No. P0115.)
OK
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-105.) P.13A-65, code No. P1221.)
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13A-31, code
59 Oxygen sensor (rear) (Refer to P.13A-78.) No. P0136.)
D Transmission: 2nd gear
D Driving with throttle widely open
OK: 600 - 1,000 mV
OK
NG
MUT-II Data list Check the oxygen sensor (front) system. (Refer to P.13A-28, code
11 Oxygen sensor (front) No. P0130.)
OK: 600 - 1,000 mV when the engine is suddenly raced
OK
NG
MUT-II Data list Measure fuel high-pressure between the fuel pump (high pressure)
11 Oxygen sensor (front) and injector. (Refer to P.13A-224.)
OK: 0 - 400 mV and 600 - 1,000 mV alternates when the
OK
engine is idling (wait for four minutes after the engine
started).
Check that air is sucked in the air intake system.
OK D Broken intake manifold gasket
D Damaged vacuum hose
D Damaged air intake hose
NG
MUT-II Data list Check the EGR valve. (Refer to P.13A-60, code No. P0403.)
68 EGR valve (Refer to P.13A-105.)
OK
NG
MUT-II Actuator test Check the purge control solenoid valve. (Refer to P.13A-62, code
08 Purge control solenoid valve (Refer to P.13A-110.) No. P0443.)
OK
Inspection procedure 14
The feeling of impact when accelerating Probable cause
The cause is probably an ignition leak being generated in line with an increase in D Malfunction of the ignition system
the spark plug request voltage during acceleration.
Yes
MUT-II Self-Diag code (Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-105.) P.13A-65, code No. P1221.)
OK
OK
Check ignition coil spark for each cylinder. Check all the following items:
(1) Remove the ignition coil. D Spark plug
(2) Install a new spark plug to the removed ignition coil. D Ignition current leak
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured. NG
(4) Earth the spark plug electrode securely. Replace the ignition coil.
(5) Check that the spark plug ignites when the engine is cranked.
Yes
MUT-II Self-Diag code (Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
MUT-II Data list Check the throttle valve position feedback system. (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-105.) P.13A-65, code No. P1221.)
OK
NG
MUT-II Data list Check the accelerator pedal position switch system. (Refer to
26 Accelerator pedal position switch (Refer to P.13A-105.) P.13A-100, Inspection procedure 28.)
OK
Inspection procedure 16
Knocking Probable cause
The cause is probably incorrect detonation control or improper heat range of the D Malfunction of the detonation sensor
spark plugs. D Improper heat range of the spark plugs
Yes
MUT-II Self-Diag code (Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
No
Does knocking occur when the vehicle is driven with the detonation Check the detonation sensor system. (Refer to P.13A-56, code
sensor disconnected? No. P0325.)
(At this time, use the MUT-II to check whether the ignition timing
is retarded from when the detonation sensor connector is con-
nected.)
Yes
Inspection procedure 17
Run-on (dieseling) Probable cause
The cause is probably fuel leak from injector(s) D Malfunction of the injector
Inspection procedure 18
Too high CO and HC concentration when idling Probable cause
The cause is probably an incorrect air/fuel ratio D Malfunction of air/fuel ratio control system
D Deterioration of the catalyst
Yes
MUT-II Self-Diag code (Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.)
No
NG
Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.) Check that the crank angle sensor and timing belt cover are properly
OK installed.
NG
MUT-II Data list Check the engine coolant temperature sensor. (Refer to P.13A-22,
21 Engine coolant temperature sensor (Refer to P.13A-105.) code No. P0115.)
OK
NG
MUT-II Data list Check the intake air temperature sensor. (Refer to P.13A-21, code
13 Intake air temperature sensor (Refer to P.13A-105.) No. P0110.)
OK
NG
MUT-II Data list Check the barometric pressure sensor. (Refer to P.13A-19, code
25 Barometric pressure sensor (Refer to P.13A-105.) No. P0105.)
OK
NG
MUT-II Data list Check the oxygen sensor (rear) system. (Refer to P.13A-31, code
59 Oxygen sensor (rear) (Refer to P.13A-78.) No. P0136.)
D Transmission: 2nd gear
D Driving with throttle widely open
OK: 600 - 1,000 mV
OK
Inspection procedure 19
Low alternator output voltage (approx. 12.3 V) Probable cause
The cause is probably a malfunction of the alternator or one of the problems D Malfunction of the charging system
listed at right. D Open circuit between the alternator G terminal and
the engine-ECU
D Malfunction of the engine-ECU
NG NG
Measure at the alternator connector Measure at the alternator connector Check the harness wire between the
B-59. B-59. alternator and the engine-ECU, and
D Connect the connector. (Use the D Disconnect the connector, and repair if necessary.
test harness MB991519) measure at the harness side.
D Voltage between 1 (black clip) D Disconnect the engine-ECU
and earth connector.
(Engine: Idling) D Continuity between 1 and earth
(Radiator fan: Not operating) OK: No continuity
(Headlamp: OFF ON) OK
(Stop lamp: OFF ON)
(Rear defogger switch: OFF
NG
ON) Check the following connectors: Repair
OK: Voltage increased by B-41, B-59, D-119
0.2 - 3.5 V. OK
OK
Inspection procedure 20
Idling speed is improper when A/C is operating Probable cause
If the engine-ECU detects that the air conditioner is on, it activates the throttle control D Malfunction of the A/C control system
servo to control idle-up operation. D Improper connector contact, open circuit or
The A/C-ECU judges if the load caused by air conditioner operation is high or low, short-circuited harness wire
and converts it to voltage signal (high or low voltage) and inputs the signal to the D Malfunction of the engine-ECU
engine-ECU.
Based on this voltage signal, the engine-ECU controls the idle-up speed (for high
or low load).
OK
Measure at the engine-ECU connector D-117. Check the following connector:
D Connect the connector. D-117
D Voltage between 65 and earth (Engine: at idle, outside air OK NG
temperature: 25_C or more)
OK: 0 - 3 V [When A/C is MAX. COOL condition (when the Repair
load by A/C is high)]
System voltage [When A/C is MAX. HOT condition (when
the load by A/C is low)] Check trouble symptom.
NG NG
Check the A/C system. (Refer to GROUP 55 - On-vehicle Service.) Replace the engine-ECU.
NG
Measure at the engine-ECU connector D-116. Check the condenser fan circuit. (Refer to ELECTRICAL WIRING)
D Disconnect the connector, and measure at the harness side.
D Check condition of the condenser fan.
(Ignition switch: ON)
OK: Fan stops.
D The voltage between 18 and earth
(Ignition switch: ON)
OK: System voltage
D Connect a jumper cable between 18 and earth.
(Ignition switch: ON)
OK: A/C condenser fan rotates.
OK
NG
Check the following connector: D-116 Repair
OK
Inspection procedure 22
Clutch switch system malfunction Probable cause
The clutch pedal switch sends a signal indicating clutch pedal depression to the D Malfunction of the clutch switch
engine-ECU. The engine-ECU controls the fuel injection properly according to this D Open circuit or short-circuited harness wire in the clutch
signal, thus prevents the fluctuation of the engine speed during shift change. switch circuit
D Malfunction of the engine-ECU
Repair
NG
Inspection procedure 23
GDI ECO indicator lamp does not illuminate. Probable cause
If the GDI ECO indicator lamp does not illuminate after turning switch, the causes D Burned-out GDI ECO indicator lamp bulb
listed in the right column are suspected. D Open circuit or short-circuited harness wire in the GDI
ECO indicator lamp circuit
D Malfunction of the engine-ECU
D Malfunction of the GDI ECO indicator lamp-ECU
OK
Measure at the engine-ECU connector D-116. Check the following connector: D-116
D Disconnect the connector, and measure at the harness side.
D Earth terminal 14 (Ignition switch: ON) OK NG
OK: The GDI ECO indicator lamp illuminates.
Repair
NG
Check trouble symptom.
Check the following connectors: E-13, E-112
NG
OK NG
Replace the engine-ECU.
Repair
NG
Measure at GDI ECO indicator lamp-ECU connector E-112. Check the harness wire between the GDI ECO indicator
D Disconnect the connector, and measure at the harness side. lamp-ECU and engine-ECU, and repair if necessary.
D Disconnect the engine-ECU connector.
D Continuity between terminal 3 and earth
OK: No continuity
OK
Inspection procedure 25
Engine-ECU power supply and earth circuit system Probable cause
The cause is probably a malfunction of the engine-ECU or one of the problems D Open circuit or short-circuited harness wire in the
listed at right. engine-ECU power supply circuit
D Open circuit or short-circuited harness wire in the
engine-ECU earth circuit
D Malfunction of the engine-ECU
(1) NG NG
Measure at the engine-ECU connectors Check the following connector: Repair
D-117, D-118. D-208, D-223, E-13
D Disconnect the connector, and
OK
measure at the harness side.
(1) Voltage between 99 and earth NG
Check the trouble symptoms. Check the harness wire between the
(Ignition switch: ON) engine-ECU and ignition switch, and re-
OK: System voltage pair if necessary.
(2) Voltage between 57 and earth (2), (3) NG
OK: System voltage Check the harness wire between the OK NG
(3) Voltage between 47, 59 and engine-ECU and engine control relay,
earth (Ignition switch: ON) and repair if necessary. Repair
OK: System voltage (When ter-
minal 57 is shorted to Check the ignition switch. (Refer to
earth) GROUP 54.)
(4) Continuity between 46, 58 and
(4) NG NG
earth
Check the following connector: Repair
OK: Continuity
(5) Voltage between 60 and earth D-14
OK: System voltage OK
(5) NG NG
Check the following connectors: Repair
D-27, D-31 <LHD>, E-13
OK
OK
Check the following connectors: NG
D-117, D-118 Check the trouble symptoms. Check the harness wire between the
engine-ECU and the battery, and repair
OK NG if necessary.
Repair
NG
Check the engine control relay. (Refer Replace
to P.13A-227.)
OK
NG NG
Measure at the engine control relay con- Check the following connector: Repair
nector B-25X. D-143
D Disconnect the connector, and OK
measure at the harness side.
D Voltage between 2, 3 and earth NG
Check the trouble symptoms. Check the harness wire between the
OK: System voltage battery and the engine control relay, and
OK repair if necessary.
Inspection procedure 27
Ignition switch-ST system Probable cause
The ignition switch-ST outputs a HIGH signal to the engine-ECU while the D Malfunction of the ignition switch
engine is cranking. D Open circuit or short-circuited harness wire of the
The engine-ECU uses this signal to carry out functions such as fuel injection ignition switch circuit
control during starting. D Malfunction of the engine-ECU
NG NG
Measure at the engine-ECU connector Check the following connectors: Repair
D-117. C-01, E-113, E-114
D Disconnect the connector, and OK
measure at the harness side.
D Voltage between 68 and earth NG
Check the trouble symptoms. Check the harness wire between the
(Ignition switch: START) engine-ECU and the ignition switch.
OK: 8 V or more
OK NG
OK
NG Repair
Check the following connector: Repair
D-117
Check the ignition switch. (Refer to
OK GROUP 54.)
Check the trouble symptoms.
NG
Inspection procedure 28
Accelerator pedal position switch system Probable cause
The accelerator pedal position switch detects that the accelerator pedal is fully closed, D Maladjustment of the accelerator cable
and sends a signal to the engine-ECU. The engine-ECU controls idle speed, based D Maladjustment of the accelerator pedal position switch
on this signal. D Open circuit or short-circuited harness wire in the
accelerator pedal position switch system, or poor
connector contact
D Malfunction of the engine-ECU
NG
Check the accelerator pedal position switch. (Refer to P.13A-230.) Replace the accelerator pedal position sensor assembly.
OK
NG
Measure at accelerator pedal position sensor connector D-135. Check the following connector: D-118
D Disconnect the connector, and measure at the harness side. NG
OK
D Voltage between terminal 4 and earth
(Ignition switch: ON) Repair
OK: 4 V or more
D Continuity between terminal 5 and earth
OK: Continuity
Check trouble symptom.
OK
NG
OK
MUT-II Actuator test Normal
07 Fuel pump (Refer to P.13A-110.)
NG
NG
Check the fuel pump relay. (Refer to Replace
P.13A-227.)
OK
NG NG
Measure at fuel pump relay connector Check the following connectors: Repair
B-27X. D-208, D-213, E-10
D Disconnect the connector, and
OK
measure at the harness side.
D Voltage between terminals 3, 4 and NG
Check trouble symptom. Check the harness wire between the
earth
fuel pump relay and ignition switch.
(Ignition switch: ON)
OK: System voltage OK NG
OK Repair
NG
Measure at engine-ECU connector Check the following connector:
D-116. B-27X Check the ignition switch. (Refer to
D Disconnect the connector, and GROUP 54 - Ignition Switch.)
OK NG
measure at the harness side.
D Voltage between terminal 21 and Repair
earth (Ignition switch: ON)
OK: System voltage NG
Check trouble symptom. Check the harness wire between the
OK fuel pump relay and engine-ECU, and
repair if necessary.
OK NG
Measure at engine-ECU connector Check the following connector: Repair
D-116. D-116
D Disconnect the connector, and
OK
measure at the harness side.
D Short circuit between terminal 21 NG
Check trouble symptom. Replace the engine-ECU.
and earth (Ignition switch: ON)
OK: The fuel pump operates (its
operation sound can be
heard).
NG
(1) NG NG
Measure at fuel pump (low pressure) Check the following connectors: Repair
connector G-12. B-27X, D-124, E-13, F-11
D Disconnect the connector, and OK
measure at the harness side.
(1) Voltage between terminal 5 and NG
Check trouble symptom. Check the harness wire between the
earth fuel pump relay and fuel pump (low
(Ignition switch: ON) pressure), and repair if necessary.
OK: System voltage
(2) Continuity between 4 and earth (2) NG
OK: Continuity Check the following connector:
F-11
OK
OK NG
Repair
NG
Check trouble symptom. Check the harness wire between the
NG fuel pump (low pressure) and earth, and
Check the following connector: Repair repair if necessary.
G-12
OK
Inspection procedure 30
Power steering fluid pressure switch system Probable cause
The power steering fluid pressure switch sends a signal to the engine-ECU according D Malfunction of the power steering fluid pressure switch
to power steering load. D Open circuit or short-circuited harness wire in the power
Based on this signal, the engine-ECU controls the throttle control servo so that idle steering fluid pressure switch circuit, or poor connector
speed increases when the power steering is in operation. contact
D Malfunction of the engine-ECU
NG
Check the power steering fluid pressure switch. (Refer to GROUP Replace
37A - On-vehicle Service.)
OK
NG
Measure at power steering fluid pressure switch connector B-51. Check the following connector: D-117
D Disconnect the connector, and measure at the harness side. OK NG
D Voltage between terminal 1 and earth
(Ignition switch: ON) Repair
OK: System voltage
OK
Check trouble symptom.
Check the following connector: B-51
NG
OK NG
Check the harness wire between the engine-ECU and power steer-
Repair ing fluid pressure switch.
OK NG
Repair
NG
Check trouble symptom. Replace the engine-ECU.
Inspection procedure 31
A/C switch and A/C relay system Probable cause
If the engine-ECU receives a A/C on signal, it operates the throttle control servo D Malfunction of the A/C control system
and A/C compressor magnetic clutch so that idle speed increases. D Malfunction of the A/C switch
D Open circuit or short-circuited harness wire in the A/C
switch circuit, or poor connector contact
D Malfunction of the engine-ECU
NG
Service the A/C compressor relay. (Refer to GROUP 55 - On-ve- Replace
hicle Service.)
OK
OK
Measure at engine-ECU connectors D-116, D-118. Check the following connectors: D-116, D-118
D Disconnect the connector, and measure at the harness side. NG
OK
D Voltage between terminals 20, 83 and earth
(Ignition switch: ON) Repair
OK: 0 - 3 V
(A/C switch: OFF)
System voltage
Check trouble symptom.
(A/C switch: ON)
D Connect terminal 20 to earth. NG
(Ignition switch: ON, A/C switch: ON)
OK: A/C compressor clutch turns on. Replace the engine-ECU.
NG
NG
Check the stop lamp switch. (Refer to GROUP 35 - Brake Pedal.) Replace
OK
NG
Measure at stop lamp switch connector D-136. Check the following connectors: D-26 <LHD>, D-27, D-124
D Disconnect the connector, and measure at the harness side. <RHD>
D Voltage between terminal 2 and earth
OK NG
OK: System voltage
OK Repair
Check trouble symptom.
NG
Check the harness wire between the battery and stop lamp switch.
NG
Measure at engine-ECU connector D-117. Check the following connectors: D-26 <LHD>, D-124 <RHD>,
D Disconnect the connector, and measure at the harness side. D-128, E-13
D Voltage between terminal 63 and earth
(Ignition switch: ON) OK NG
OK: 0 - 3 V (when the brake pedal is not depressed)
System voltage (when the brake pedal is depressed) Repair
OK Check trouble symptom.
NG
Check the harness wire between the engine-ECU and stop lamp,
and repair if necessary.
NG
Check the following connector: D-117 Repair
OK
Inspection procedure 33
Small lamp switch system Probable cause
The engine-ECU determines whether the small lamp switch is on or off. D Improper connector contact, open circuit or
According to that information, the engine-ECU controls short-circuited harness wire in the taillamp circuit
alternator output current when the vehicle is started. D Malfunction of the engine-ECU
NG
Measure at the engine-ECU connector D-118. Check the taillamp circuit. (Refer to ELECTRICAL WIRING.)
D Disconnect the connector, and measure at the harness
side.
D Voltage between 88 and earth
(Lighting switch: ON)
OK: System voltage
OK
NG
Check the following connector: D-118 Repair
OK
Inspection procedure 34
Injector driver system Probable cause
The engine-ECU drives the injector by the drive signal. D Malfunction of the injector driver
D Improper connector contact, open circuit or
short-circuited harness wire
D Malfunction of the engine-ECU
NG
Check the following connectors: B-121, D-116 Repair
OK
NG
Check the harness wire between the injector driver and engine-ECU. Repair
OK
NG
Use a analyzer to measure the signal waveform at the engine-ECU Replace the injector driver.
connectors D-116 and D-118.
D Engine: idling
D Voltage between 96 and earth, and between 1 and earth
OK: A normal waveform should be displayed as described
on P.13A-118 (INSPECTION PROCEDURE USING
AN ANALYZER).
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 - Points to Note for Intermittent
NG Malfunctions.)
Replace the engine-ECU.
11 Oxygen sen- Engine: After Idling 200 mV or lessK1 Code No. 13A-28
sor warm-up P0130
(front) Sudden racing 600 - 1,000 mV
13 Intake air tem- Ignition switch: ON Intake air tempera- - 20_C Code No. 13A-21
perature sen- ture: - 20_C P0110
sor
Intake air tempera- 0_C
ture: 0_C
14 Throttle posi- D Engine coolant Release the accel- 4,000 mV or more Code No. 13A-52
tion sensor temperature: erator pedal. P0225
(2nd channel) 80 - 95_C
D Ignition switch: Depress the accel- Voltage decreases
ON (Engine erator pedal gradu- in response to the
stopped) ally. pedal depression.
21 Engine coolant Ignition switch: ON Engine coolant - 20_C Code No. 13A-22
temperature temperature: P0115
sensor - 20_C
22 Crank angle D Engine: crank- Compare the engine Accord Code No. 13A-56
sensor ing speed readings on P0335
D Tachometer: the tachometer and
Connected the MUT-II.
27 Power steer- Engine: Idling Steering wheel sta- OFF Procedure 13A-102
ing fluid pres- tionary No.30
sure switch
Steering wheel ON
turning
28 A/C switch Engine: Idling (The A/C switch: OFF OFF Procedure 13A-100
A/C compressor is No.31
running when the
A/C switch: ON ON
A/C switch is on.)
Lighting switch: ON ON
34 Air flow sensor Engine: After hav- Engine is idling ON Code No. 13A-17
reset signal ing warmed up P0100
3,000 r/min OFF
49 A/C relay Engine: After A/C switch: OFF OFF (compressor Procedure 13A-102
warm-up, idling clutch is not oper- No.31
ating)
59 Oxygen sen- D Transmission: 3,500 r/min 600 - 1,000 mV Code No. 13A-31
sor (rear) 2nd gear P0136
D Drive with
throttle widely
open
67 Stop lamp Ignition switch: ON Brake pedal: De- OFF Procedure 13A-103
switch pressed No.32
74 Fuel pressure D Engine coolant Engine: Idling 4 - 6.9 MPa Code No. 13A-36
sensor temperature: P0190
80 - 95_C
D Lamps, electric
cooling fan and
all accessories:
OFF
D Transmission:
Neutral
77 Accelerator Ignition switch: ON Release the accel- 985 - 1085 mV Code 13A-68
pedal position erator pedal. No.P1225
sensor (2nd
channel) Depress the accel- Increases in re-
erator pedal gradu- sponse to the ped-
ally. al depression
stroke.
78 Accelerator Ignition switch: ON Release the accel- 985 - 1085 mV Code 13A-50
pedal position erator pedal. No.P0220
sensor (1st
channel) *3 Depress the accel- Increases in re-
erator pedal gradu- sponse to pedal
ally. depression stroke.
79 Throttle posi- D Engine coolant Release the accel- 400 - 800 mV Code 13A-25
tion sensor temperature: erator pedal. No.0120
(1st channel) 80 - 95_C
D Ignition switch: Depress the accel- Increases in re-
ON (Engine erator pedal gradu- sponse to pedal
stopped) ally. depression stroke.
99 Fuel injection Engine: After warm Idling (after four Lean compression - -
mode up minutes or more
have passed since
engine start)
01 Injectors Cut fuel to No. 1 Engine: Idling condition Code No. 13A-38
injector After having becomes different P0201
warmed up/Engine (becomes unsta-
02 Cut fuel to No. 2 is idling ble). Code No. 13A-40
injector (Cut the fuel supply P0202
to each injector in
03 Cut fuel to No. 3 turn and check Code No. 13A-42
injector cylinders which P0203
dont affect idling.)
04 Cut fuel to No. 4 Code No. 13A-44
injector P0204
07 Fuel pump Fuel pump Ignition switch: ON Sound of opera- Procedure 13A-101
(low pressure) operates and tion is heard. No. 29
fuel is recirculated.
08 Purge Solenoid valve Ignition switch: ON Sound of opera- Code No. 13A-62
control turns from OFF to tion can be heard P0443
solenoid valve ON. when solenoid
valve is
driven.
21 Condenser fan Drive the fan motor Ignition switch: ON The fan motor Procedure 13A-95
operates No.21
34 Electronic- Stop the throttle Ignition switch: ON Throttle valve is Code No. 13A-64
controlled control servo. opened slightly. P1220
throttle valve
system
1 No.1 injector Engine: Warm up, and then depress Decreases slightly for short
the accelerator pedal suddenly from time from 9 - 13 V.
9 No.2 injector the idle speed.
24 No.3 injector
2 No.4 injector
10 No.5 injector
25 No.6 injector
8 Alternator G terminal D Engine: Warm up, and then idling Voltage increases by
D Radiator fan: not operating 0.2 - 3.5 V
D Headlamp: OFF ON
D Stop lamp: OFF ON
D Rear defogger switch: OFF ON
16 Purge control solenoid valve D Engine cool- Engine: stopped System voltage
ant tempera-
ture: Engine: Start the Voltage decreases.
80 - 95_C engine, and then
D Ignition increase engine
switch: ON speed up to 3,500
r/min.
59
52 Alternator FR terminal D Engine: Warm up, and then idling Voltage decreases
D Radiator fan: not operating
D Headlamp: OFF ON
D Stop lamp: OFF ON
D Rear defogger: OFF ON
62 Intake air temperature Ignition switch: Intake air temper- 3.2 - 3.8 V
sensor ON ature: 0_C
65 A/C switch (2nd channel) Refer to GROUP 55 - Troubleshooting Check at the A/C-ECU
terminal, engine-ECU output terminals.
71 Oxygen sensor (front) Engine: Warm up, and then hold the 0 0.8 V alternates.
engine speed at 2,500r/min (Use a
digital voltmeter).
94 Accelerator pedal position Ignition switch: Release the acceler- 0.3 - 1.0 V*1
sensor (1st channel) ON ator pedal.
96 Injector open circuit check Engine: Increase engine speed from Decreases slightly (approx.
signal idle speed to 4,000 r/min. 0.7V) from 4.5 V - 5.0 V.
NOTE
Check if the difference in output between *1 and *2 is 4 V or more.
Terminal No. Check item Standard value, normal condition (check require-
ments)
44 - 72 Engine coolant temperature sensor 5.1 - 6.5 kW (when engine coolant temperature is
0_C)
58 - Body earth
62 - 72 Intake air temperature sensor 5.3 - 6.7 kW (when intake air temperature is 0_C)
79 - 49 Accelerator pedal position switch Continuity (when the accelerator pedal is released)
7 Throttle position sensor Ignition switch: ON Release the accelerator 0.4 - 0.8 V
(1st channel) pedal.
20 Accelerator pedal position Ignition switch: ON Release the accelerator 0.985 - 1.085 V
sensor (2nd channel) pedal.
Time
0
(V)
10
T
Time
0
2 engine revolutions
(1 camshaft revolution)
(V)
75_BTDC T
Crank 5_BTDC
angle
sensor
output
wave 4
pattern
Cam- 0
shaft
position
sensor
output
wave 4
pattern
Time
0
No. 1 TDC No. 2 TDC No. 3 TDC No. 4 TDC No. 5 TDC No. 6 TDC
NOTE
1. TDC: Top dead centre
2. The time (cycle time) T is reduced when the engine speed increases
D Example 2
Cause of problem
Loose timing belt
Abnormality in sensor disk
Wave pattern characteristics
Wave pattern is displaced to the left or right.
(V)
4
Injector
open circuit
check signal
0
Injector
drive signal
4
0
Time
(V) T
Ignition period
Power 6 T1 q
transis-
tor con-
trol sig- 4
nal
wave
pattern 2
0
OFF ON
Dwell section Time
Condition of wave pattern build-up section and maximum voltage Probable cause
D Example 2
--- Normal wave pattern
Wave pattern during engine cranking
VB
Cause of problem
Malfunction in power transistor
Wave pattern characteristics
Power voltage results when the power transistor is ON.
Engine condition When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF
to ON (without starting the engine).
(V)
The wave pattern
appears for an Point B Point A
instant, but soon Coil reverse electromotive Induced electromotive force
30 disappears. force (Approx. 3 10V) from the motor turning
20
EGR 10
valve
control
signal
wave
pattern
Time
Induced electromotive force does not appear or is extremely small. Motor is malfunctioning
Coil reverse electromotive force does not appear or is extremely small. Short in the coil
D Example 2
Open
circuit Cause of problem
side
Open circuit in the line between the EGR valve 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.)
Normal Furthermore, the induced electromotive force waveform
side at the normal side is slightly different from the normal
waveform.
TROUBLESHOOTING <A/T>
STANDARD FLOW OF DIAGNOSTIC
TROUBLESHOOTING
Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.
NOTE
When replacing the engine-A/T-ECU, replace immobilizer-
ECU as well at the same time.
Caution
If a malfunction occurred inside the engine-A/T-ECU, the engine warning lamp will remain illuminated.
NOTE
The engine warning lamp will flash when the electronic-controlled throttle valve system is suspended
by the fail-safe function.
Intake air temperature sensor Controls as if the intake air temperature is 25_C.
Engine coolant temperature Controls as if the engine coolant temperature is 80_C. (Moreover, the control system
sensor is working until the ignition switch is turned OFF if the sensor signal returns to normal.)
Camshaft position sensor Cuts the fuel supply once a malfunction is detected. (Only when there has been
no occasion of detecting No.1 cylinder top dead centre after the ignition switch
is turned ON.)
Vehicle speed sensor 1. Suspends lean burn operation. However, the control is cancelled as a certain
time passes by with the engine speed of 1,500 r/min or more.
2. Suspends lean burn operation during the engine idling.
Detonation sensor Fixes the ignition timing as that for regular gasoline.
Alternator FR terminal Refrains from controlling to suppress the alternator output to electrical load.
(Operated as a normal alternator)
Throttle valve position feed- 1. Suspends the electronic controlled throttle valve system.
back 2. Suspends lean burn operation.
3. Suspends the engine speed feedback control.
However, if the throttle valve opening angle is significantly wide, this system carries
out the following controls.
1. Always cuts the fuel supply to three cylinders.
2. Cuts the fuel supply when the engine speed reaches 3,000 r/min or more.
Communication line between 1. Communication error between the throttle valve controller and the
the throttle valve controller and engine-A/T-ECU:
the ECU D Suspends lean burn operation.
D Cuts the fuel supply when the engine speed reaches 3,000 r/min or
more.
D Suspends the cruise-control.
2. Communication error between the throttle valve controller and the
engine-A/T-ECU:
D Suspends lean burn operation.
D Cuts the fuel supply when the engine speed reaches 3,000 r/min or
more.
D Suspends the cruise-control.
D The throttle valve controller controls the throttle valve opening angle by
using signals from accelerator pedal position sensor (2nd channel).
NOTE
If the electronic-controlled throttle valve system is suspended, the engine warning lamp will illuminate.
44 Ignition coil (incorporating power transistor) system (for No. 1 and No. 4 cylinders) 13A-148
52 Ignition coil (incorporating power transistor) system (for No. 2 and No. 5 cylinders) 13A-148
53 Ignition coil (incorporating power transistor) system (for No. 3 and No. 6 cylinders) 13A-148
NOTE
Code No. 56 may be also output when air is sucked in high-pressure fuel line due to no fuel supply.
NG
Check the following connector: Repair
C-20
OK
NG NG
Measure at oxygen sensor (front) Check the following connectors: Repair
connector C-20. D-121, E-116
D Disconnect the connector and OK
measure at the harness side. NG
D Resistance between terminal 2 Check the harness wire between Repair
and earth between the oxygen sensor and the
OK: 2 W or less engine-A/T-ECU.
OK OK
Check the trouble symptoms.
NG
(1) NG NG
Measure at oxygen sensor connector Check the following connectors: Repair
C-20. D-121, E-116
D Use the test harness
OK
(MD998464) to connect the
connector, and measure at the
pick-up harness side. Check the harness wire between the
D Engine: 2,500r/min (after warming oxygen sensor and the
up) engine-A/T-ECU, and repair if
D Selector lever position: P necessary.
(1) Voltage between terminal 2 and (2) NG NG
earth Check the oxygen sensor. (Refer to Replace
OK: 0.5 V or less P.13A-230.)
(2) Voltage between terminal 4 and OK
earth
OK: 0 V and 0.8 V alternate. NG
Check the following connectors: Repair
OK D-121, E-116
OK
NG NG
Measure at engine-A/T-ECU Check the following connectors: Repair
connector D-121. D-121, E-116
D Measure the voltage at the OK
engine-A/T-ECU terminal.
D Engine: 2,500r/min (after warming
Check the harness wire between the
up)
oxygen sensor and the
D Selector lever position: P
engine-A/T-ECU, and repair if
D Voltage between terminal 72 and
necessary.
earth
OK: 0V and 0.8 V alternate.
OK
NG
Check the following connectors: Repair
D-121, E-116
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 - Points to
NG Note for Intermittent Malfunctions.)
Replace the engine-ECU.
OK
MUT-II Data list Transient malfunction
12 Air flow sensor (Refer to (Refer to GROUP 00 - Points to
13A-198, DATA LIST Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
NG
NG
Check the following connector: Repair
B-120
OK
(1) NG OK
Measure at air flow sensor connector Measure at engine-A/T-ECU Check the following connector:
B-120. connector D-120. D-120
D Disconnect the connector and D Measure the voltage at the
OK NG
measure at the harness side. engine-A/T-ECU terminal. Repair
(1) Voltage between terminal 3 and D Ignition switch: ON
earth (Ignition switch: ON) D Voltage between terminal 65 and
earth Check the harness between the air
OK: 4.8 - 5.2 V
OK: 4.8 - 5.2 V flow sensor and the engine-A/T-ECU,
(2) Voltage between terminal 4 and
and repair if necessary.
earth (Ignition switch: ON) NG
OK: System voltage
(3) Resistance between terminal 5 NG
and earth Check the following connector: Repair
OK: 2 W or less D-120
OK
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
(2) NG NG
Check the following connector: Repair
B-25X
OK
Check the harness between the air
flow sensor and the engine control
relay, and repair if necessary.
(3) NG NG
Check the following connector: Repair
D-121
OK OK NG
Check the harness between the air Repair
flow sensor and the engine-A/T-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
NG NG
Measure at air flow sensor connector Check the following connector: Repair
B-120. D-119
D Use test harness (MB991709) to
OK
connect the connector, and
measure at the pick-up harness. NG
Check the harness between the air Repair
D Ignition switch: ON
D Voltage between terminal 7 and flow sensor and the engine-A/T-ECU.
earth OK
OK: 7 - 8 V
Replace the air flow sensor.
OK
NG
Measure the output waveform from Replace the air flow sensor.
at air flow sensor connector B-120
(by using an analyzer).
D Use test harness (MB991709) to Check the trouble symptoms.
connect the connector, and
measure at the pick-up harness. NG
D Engine: Idling NG
Check the following connectors: Repair
D Selector lever position: P
D Voltage between terminal 3 and D-120, D-121, B-25X
OK
earth OK
OK: Waveform should be dis-
played on P.13A- 211 (In- Check the harnesses between the
spection Procedure Using air flow sensor and the
an Analyzer) and noise engine-A/T-ECU and between the air
should not be displayed in flow sensor and the engine control
the waveform relay, and repair if necessary.
OK
OK
MUT-II Data list Transient malfunction
13 Intake air temperature sensor (Refer to GROUP 00 - Points to
OK: Roughly the same as ambi- Note for Intermittent Malfunctions.)
ent temperature.
NG
NG
Check the intake air temperature Repair
sensor itself. (Refer to P.13A-227.)
OK
NG
Check following connector: B-67 Repair
OK
(1) NG NG
Measure at air flow sensor connector Check the following connector: Repair
B-120. D-121
D Disconnect the connector and OK
measure at the harness side.
Check the harness between the air NG
(1) Resistance between terminal 5 Repair
and earth flow sensor and the engine-A/T-ECU.
OK: 2 W or less OK
(2) Voltage between terminal 6 and NG
earth (Ignition switch: ON) Check the trouble symptoms. Replace the engine-A/T-ECU.
OK: 4.8 - 5.2 V
(2) NG OK
Measure at engine-A/T-ECU Check the following connector:
connector D-120. D-120
D Measure the voltage at the
OK NG
engine-A/T-ECU terminal. Repair
D Disconnect connector B-120.
D Ignition switch: ON
D Voltage between terminal 64 and Check the harness between the air
earth flow sensor and the engine-A/T-ECU,
OK: 4.8 - 5.2 V and repair if necessary.
NG
NG
Check the following connector: Repair
D-120
OK
NG
Check the harness between the air Repair
flow sensor and the engine-A/T-ECU.
OK OK
NG
To the next page Check the trouble symptoms. Replace the engine-A/T-ECU.
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
OK
MUT-II Data list Transient malfunction
14 Throttle position sensor (2nd (Refer to GROUP 00 - Points to
channel) (Refer to P.13A-198, Note for Intermittent Malfunctions.)
DATA LIST REFERENCE
TABLE.)
NG
NG
Check the throttle position sensor Replace
(2nd channel). (Refer to P.13A-228.)
NG
Check the following connector: NG
B-102 Repair
OK
(1) NG OK
Measure at throttle position sensor Measure at throttle valve controller Check the following connector:
connector B-102. connector D-11. D-11
D Disconnect the connector and D Measure voltage at the throttle
OK NG
measure at the harness side. valve controller connector Repair
(1) Voltage between terminal 1 and terminals.
earth (Ignition switch: ON) D Ignition switch: ON
OK: 4.8 - 5.2 V D Voltage between terminal 6 and Check the harness wire between the
(2) Resistance between terminal 3 earth the throttle position sensor and the
and earth OK: 4.8 - 5.2 V throttle valve controller, and repair if
OK: 2 W or less necessary.
NG
(2) NG NG
Check the following connector: Repair
D-11
OK
OK
(1) NG OK
Measure at engine coolant Measure at engine-ECU connector Check the following connector:
temperature sensor connector B-56. D-120. D-120
D Disconnect the connector and D Measure the voltage at the
measure at the harness side. engine-A/T-ECU terminal. OK NG
D Disconnect connector B-56. Repair
(1) Voltage between terminal 1 and
earth D Ignition switch: ON
(Ignition switch: ON) D Voltage between terminal 44 and Check the harness wire between the
OK: 4.8 - 5.2 V earth engine coolant temperature sensor
(2) Resistance between terminal 2 OK: 4.8 - 5.2 V and the engine-A/T-ECU.
and earth
NG
OK: 2 W or less
Check the following connector: NG
Repair
D-120
OK
Check the harness wire between the
engine coolant temperature sensor NG
Repair
and the engine-A/T-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
(2) NG NG
Check the following connector: Repair
D-121
OK
OK Check the harness wire between the NG
engine coolant temperature sensor Repair
To the next page and the engine-A/T-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
OK
Check the trouble symptoms. Intermittent malfunction
NG (Refer to GROUP 00 - Points to Note for Intermittent Malfunctions.)
NO
Does the speedometer operate normally? Check the vehicle speed sensor
YES (Refer to GROUP 54 - Combination Meter.)
NG
Use an analyzer to measure the output waveform of the Check the following connectors: C-09, E-13
vehicle speed sensor at engine-A/T-ECU connector C-09. OK NG
D Driving the vehicle
D Selector lever position: P Repair
D The voltage between terminal 80 and earth
OK: A normal waveform should be displayed as described Check the harness wire between intermediate connector E-13
in OSCILLOSCOPE INSPECTION PROCEDURE, and the engine-A/T-ECU, and repair if necessary.
and noise should not be displayed in the waveform.
(Refer to GROUP 23 - Troubleshooting.)
OK
NG
Check the following connector: C-09 Repair
OK
OK
MUT-II Data list Transient malfunction
25 Barometric pressure sensor (Refer to GROUP 00 - Points to
(Refer to P.13A-198, DATA LIST Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
NG
Check the following connector: NG
B-120 Repair
OK
(1) NG
Measure at air flow sensor connector Measure at engine-A/T-ECU OK Check the following connector:
B-120. connector D-121. D-121
D Disconnect the connector and D Measure the voltage at the OK NG
measure at the harness side. engine-A/T-ECU terminal. Repair
(1) Voltage between terminal 1 and D Ignition switch: ON
earth (Ignition switch: ON) D Voltage between terminal 87 and Check the harness between the air
OK: 4.8 - 5.2 V earth flow sensor and the engine-A/T-ECU,
(2) Resistance between terminal 5 OK: 4.8 - 5.2 V and repair if necessary.
and earth
OK: 2 W or less NG
Check the following connector: NG
Repair
D-121
OK
Check the harness between the air NG
Repair
flow sensor and the engine-A/T-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
(2) NG NG
Check the following connector: Repair
D-121
OK
Check the harness between the air NG Repair
flow sensor and the engine-A/T-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
OK
(1) NG NG
Measure at air flow sensor connector Check the following connector: Repair
B-120. (3) NG D-121
D Connect connector terminals
No.1, No.2 and No.5 only by OK
using test harness (MB991709), Check the harness between the air
and measure at the pick - up flow sensor and the engine-A/T-ECU,
harness. and repair if necessary.
D Ignition switch: ON (2) NG
(1) Voltage between terminal 1 and Replace the air flow sensor.
earth
OK: 4.8 - 5.2 V
(2) Voltage between terminal 2 and
earth Check the trouble symptoms.
OK: Altitude 0 m: 3.7 - 4.3 V NG
Altitude 1200 m:
3.2 - 3.8 V NG
Check the following connector: Repair
(3) Voltage between terminal 5 and
D-120
earth
OK: 0.5 V or less OK
OK Check the harness between the air
flow sensor and the engine-A/T-ECU,
To the next page and repair if necessary.
NG
Check the following connector: B-05 Repair
OK
NG
Measure at the detonation sensor connector B-05. Check the harness wire between the detonation sensor and
D Disconnect the connector and measure at the harness earth, and repair if necessary.
side.
D The resistance between terminal 2 and earth
OK: 2 W or less
OK
NG
Check the following connector: D-121 Repair
OK
NG
Check the harness wire between the detonation sensor and Repair
the engine-A/T-ECU.
OK
OK
Check the trouble symptoms. Intermittent malfunction
(Refer to GROUP 00 - Points to Note for Intermittent
NG Malfunctions.)
Replace the detonation sensor.
OK OK
MUT-II Actuator Test Check the trouble symptoms. Transient malfunction
01 No.1 injector (Refer to GROUP 00 - Points to
NG
02 No.2 injector Note for Intermittent Malfunctions.)
03 No.3 injector Replace the injector driver.
04 No.4 injector
05 No.5 injector
06 No.6 injector NG
OK: The idling condition should Check the trouble symptoms. Replace the engine-A/T-ECU.
change.
NG
NG
Check the following connector: Repair
B-105
OK
NG NG
Measure at intermediate connector Check the following connectors: Repair
B-105. B-117 <No.1 injector>, B-114 <No.2
D Disconnect the connector and injector>, B-118 <No.3 injector>,
measure at the harness side. B-115 <No.4 injector>, B-103 <No.5
D Resistance between terminals 11 injector>, B-104 <No.6 injector>
and 12 <No.1 injector> OK
Resistance between terminals 5 NG
and 6 <No.2 injector> Check the harness wire between Repair
Resistance between terminals 9 injector and the intermediate
and 10 <No.3 injector> connector.
Resistance between terminals 3
and 4 <No.4 injector> OK
Resistance between terminals 7 Replace the injector.
and 8 <No.5 injector>
Resistance between terminals 1
and 2 <No.6 injector>
OK: 0.9 - 1.1 W
OK
NG
Check the following connector: Repair
B-121
OK
NG
Check the harness wire between the Repair
injector driver and the intermediate
connector.
OK
NG
Check the following connector: Repair
D-119
OK
NG
Check the harness wire between the Repair
injector driver and the
engine-A/T-ECU.
OK
NG
Check the following connectors: Repair
B-117 <No.1 injector>, B-114 <No.2
injector>, B-118 <No.3 injector>,
B-115 <No.4 injector>, B-103 <No.5
injector>, B-104 <No.6 injector>
OK
NG
Check the harness wire between Repair
injector and the intermediate
connector.
OK
Replace the injector.
NG
Check the trouble symptoms. Replace the injector driver.
Check the harness wire between the engine-A/T-ECU and the igni-
tion coil.
OK NG
Repair
Replace the engine-A/T-ECU.
Check and repair the harness wire between the ignition coil and
earth.
(1) NG
Measure at the ignition failure sensor connector B-04. There is short circuit or open circuit in the ignition signal output
D Disconnect the connector, and measure at the harness harness of the ignition failure sensor. Check and repair the harness.
side. (2) NG
(1) Voltage between 2 and earth (Ignition switch: ON) Check and repair the harness wire between the ignition failure
OK: 4 V or more sensor and earth.
(2) Continuity between 1 and earth
OK: Continuity
OK
NG
Measure at the engine-A/T-ECU connector D-120. Check the following connectors: B-04, D-120
D Connect the connector.
OK NG
D Voltage between 45 and earth (Engine: 3,000 r/min)
OK: 0.3 - 3.0 V Repair
OK Check the harness wire between the engine-A/T-ECU and the igni-
tion failure sensor.
Replace the engine-A/T-ECU. OK NG
Repair
NOTE
(1) If the registered ignition keys 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 encrypted code.
NG
Check the following connectors: Repair
D-122, D-202, E-13
OK
NG
Check the harness wire between the Replace
immobilizer-ECU and the
engine-A/T-ECU, and repair if
necessary.
OK
OK
MUT-II Data list Transient malfunction
74 Fuel pressure sensor (Refer to (Refer to GROUP 00 - Points to
13A-198, DATA LIST Note for Intermittent Malfunctions.)
REFERENCE TABLE.)
NG
NG
Check the following connector: Repair
B-35
OK
(1) NG OK
Measure at intermediate connector Measure at engine-A/T-ECU Check the following connector:
B-110. connector D-121. D-121
D Disconnect the connector, and D Measure the voltage at the OK NG
measure at the engine-A/T-ECU engine-A/T-ECU terminal. Repair
harness side. D Ignition switch: ON
(1) Voltage between terminal 4 and D Voltage between terminal 87 and Check the harness wire between the
earth (Ignition switch: ON) earth intermediate connector and the
OK: 4.8 - 5.2 V OK: 4.8 - 5.2 V engine-A/T-ECU, and repair if
(2) Resistance between terminal 6 necessary.
and earth NG
NG
OK: 2 W or less Check the following connector: Repair
D-121
OK NG
Repair
Check the harness wire between the
intermediate connector and the
engine-A/T-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
(2) NG NG
Check the following connector: Repair
D-121
OK
NG
Check the harness wire between the Repair
intermediate connector and the
engine-A/T-ECU, and repair if
OK necessary.
To the next page OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
NG
(2) NG Check the following connector: Repair
B-111
OK
NG NG
Measure at engine-A/T-ECU Check the following connector: Repair
connector D-121. D-121
D Measure the voltage at the
engine-A/T-ECU terminal. OK
D Engine: Idling Check the harness wire between the
D Selector lever position: P intermediate connector and the
D Voltage between terminal 93 and engine-A/T-ECU, and repair if
earth necessary.
OK: 0.3 - 4.7 V
OK NG
Check the following connector: Repair
D-121
OK
Check the trouble symptoms.
OK
NG
Check the following connector: Repair
B-41
OK
NG NG
Measure at intermediate connector Measure at engine-A/T-ECU Check the following connector:
B-41. connector D-120. D-120
D Use test harness (MB991658) to D Measure the voltage at the
connect the connector, and engine-A/T-ECU terminal. OK NG
measure at the pick-up harness. D Ignition switch: ON Repair
D Ignition switch: ON D The voltage between terminal 54
Check the harness wire between the
D The voltage between terminal 2 and earth
intermediate connector and the
and earth OK: 9 - 10 V
engine-A/T-ECU, and repair if
OK: 9 - 10 V
NG necessary.
NG
Check the following connector: Repair
D-120
OK
NG
Check the harness wire between the Repair
intermediate connector and the
OK engine-A/T-ECU.
OK
Measure at intermediate connector NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
B-41.
D Use test harness (MB991658) to NG NG
connect the connector, and Check the following connector: Repair
measure at the pick-up harness. B-59
D Engine:idling (After warming up) OK
D Selector lever position: P
D Radiator fan: Not operating Check the harness wire between the NG
alternator and the intermediate Repair
D The voltage between terminal 2
and earth connector.
OK: The voltage drops when OK
the Headlamp are turned
on. Check the following connector: NG
D-120 Replace
OK
OK
MUT-II Data list Intermittent malfunction
77 Accelerator pedal position sensor (Refer to GROUP 00 - Points to
(2nd channel) (Refer to P. Note for Intermittent Malfunctions.)
13A-198, DATA LIST
REFERENCE TABLE.)
NG
NG
Check the accelerator pedal position Replace
sensor (Refer to P.13A-229.)
OK
NG
Check the following connector: Repair
D-45
OK
(1) NG NG
Measure at accelerator pedal position Check the following connector: Repair
sensor connector D-135 D-11
D Disconnect the connector and
measure at the harness side. OK
(1) The resistance between terminal NG
Check the harness wire between Repair
7 and earth accelerator pedal position sensor
OK: 2 W or less (2nd channel) and the throttle valve
(2) The voltage between terminal 8 controller.
and earth
(Ignition switch: ON) OK
OK: 4.8 - 5.2 V NG
Check the trouble symptoms. Replace the throttle valve controller.
(2) NG OK
Measure at throttle valve controller Check the following connector:
connector D-11. D-11
D Measure voltage at the throttle NG
OK
valve controller connector Repair
terminals.
D Ignition switch: ON
Check the harness wire between
D The voltage between terminal 6
accelerator pedal position sensor
and earth
(2nd channel) and the throttle valve
OK: 4.8 - 5.2 V
controller, and repair if necessary.
NG
NG
Check the following connector: Repair
D-11
OK
OK
NG
To the next page Check the harness wire between Repair
accelerator pedal position sensor
(2nd channel) and the throttle valve
controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.
Measure at accelerator pedal position (1) NG Adjust the accelerator pedal position
sensor (2nd channel) connector sensor (2nd channel). (Refer to
D-135. P.13A-221.)
D Use test harness (MB991658) to NG
connect terminals No.6, No.7,
No.8 only, and measure at the NG
Check the following connector: D-11 Repair
pick-up harness side.
D Ignition switch: ON OK
(1) The voltage between terminal 6
and earth Check the harness wire between
OK: Accelerator pedal fully re- accelerator pedal position sensor (2nd
leased: 0.985 - 1.085 V channel) and the throttle valve controller.
Accelerator pedal fully de- (2), (3) NG NG
pressed: 4.0 V or higher Check the following connector: D-11 Repair
(2) The voltage between terminal 7
and earth OK
OK: 0.5 V or more
(3) The voltage between terminal 8 Check the harness wire between
and earth accelerator pedal position sensor (2nd
OK: 4.8 - 5.2 V channel) and the throttle valve controller.
OK
NG NG
Measure at throttle valve controller Check the following connector: D-11 Repair
connector D-11. OK
D Measure voltage at the throttle
valve controller connector Check the harness wire between
terminals. accelerator pedal position sensor (2nd
D Ignition switch: ON channel) and the throttle valve controller.
D The resistance between 20 and
earth OK NG
OK: Accelerator pedal fully re- Check the following connector: D-11 Repair
leased: 0.985 - 1.085 V
Accelerator pedal fully de- OK
pressed: 4.0 V or higher
Check the trouble symptoms.
NG
NG
MUT-II Data list Check the accelerator pedal position
26 Accelerator pedal position switch switch system. (Refer to P.13A-192,
(Refer to 13A-198, DATA LIST Inspection Procedure 28).
REFERENCE TABLE.)
OK
OK
MUT-II Data list Transient malfunction
78 Accelerator pedal position sensor (Refer to GROUP 00 - Points to
(1st channel) (Refer to 13A-198, Note for Intermittent Malfunctions.)
DATA LIST REFERENCE
TABLE.)
NG
NG
Check Accelerator pedal position Replace
sensor (1st channel) (Refer to
P.13A-229).
OK
NG
Check the following connector: Repair
D-45
OK
(1) NG NG
Measure at accelerator pedal position Check the following connector: Repair
sensor connector D-135. D-120
D Disconnect the connector and
OK NG
measure at the harness side.
(1) Resistance between terminal 1 Check the harness wire between Repair
and earth accelerator pedal position sensor
OK: 2 W or less (1st channel) and the engine-
(2) Voltage between terminal 2 and A/T-ECU.
earth OK
(Ignition switch: ON) NG
OK: 4.8 - 5.2 V Check the trouble symptoms. Replace the engine-A/T-ECU.
(2) NG
Measure at engine-A/T-ECU OK
connector D-120. Check the following connector:
D Measure the voltage at the D-120 OK
engine-A/T-ECU terminal. NG Repair
D Ignition switch: ON
D Voltage between terminal 46 and
earth Check the harness wire between
OK: 4.8 - 5.2 V accelerator pedal position sensor
(1st channel) and the engine-
NG A/T-ECU, and repair if necessary.
Check the following connector: NG
D-117 Repair
OK
OK
Check the harness wire between
accelerator pedal position sensor NG
To the next page Repair
(1st channel) and the engine-
A/T-ECU.
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
OK
MUT-II Data list Transient malfunction
79 Throttle position sensor (1st (Refer to GROUP 00 - Points to
channel) (Refer to P.13A-198, Note for Intermittent Malfunctions.)
DATA LIST REFERENCE
TABLE.)
NG
NG
Check the throttle position sensor. Replace
(Refer to P.13A-228.)
NG NG
Check the following connector: Repair
B-102
OK
(1) NG OK
Measure at throttle position sensor Measure at throttle valve controller Check the following connector:
connector B-102. connector D-11. D-11
D Disconnect the connector and D Measure voltage at the throttle
OK NG
measure at the harness side. valve controller connector Repair
(1) Voltage between terminal 1 and terminals.
earth D Ignition switch: ON
(Ignition switch: ON) D Voltage between terminal 6 and Check the harness wire between the
OK: 4.8 - 5.2 V earth the throttle position sensor and the
(2) Resistance between terminal 3 OK: 4.8 - 5.2 V throttle valve controller, and repair if
and earth necessary.
NG
OK: 2 W or less
NG
Check the following connector: Repair
D-11
OK
NG
Check the harness wire between the Repair
the throttle position sensor and the
throttle valve controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.
(2) NG NG
Check the following connector: Repair
D-11
OK
NG
OK Check the harness wire between the Repair
the throttle position sensor and the
To the next page throttle valve controller.
OK
NG
Check the trouble symptoms. Replace the throttle valve controller.
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION
Is any diagnosis code other than CHART FOR DIAGNOSIS CODES.
No.89 output?
NO
NG
Check the air intake from the intake Repair
hose and right bank intake manifold.
OK
NG
Check the exhaust gas leaks from Cleaning
the right bank exhaust manifold.
OK
NG
Check the throttle body (around the Cleaning
throttle valve), and clean if
necessary. (Refer to P.13A-220).
OK
NG NG
MUT-II Data list Check fuel leakage around the fuel Repair
74 Fuel pressure sensor (Refer to pump (high-pressure) line.
13A-198, DATA LIST
REFERENCE TABLE.) OK
NG
MUT-II Data list Refer to the Inspection procedure for
11 Oxygen sensor the sensor, which is indicated by the
12 Air flow sensor abnormal service data.
13 Intake air temperature sensor (Refer to P.13A-130, INSPECTION
21 Engine coolant temperature CHART FOR DIAGNOSIS CODES.)
sensor
25 Barometric pressure sensor
(Refer to 13A-198, DATA LIST
REFERENCE TABLE.)
Reference
If all the service data is normal, go
to OK.
If any abnormal service is found, go
to NG.
OK
NG
Check the oxygen sensor (Refer to Replace
P.13A-230.)
NG
Check the purge control solenoid Replace
valve (Refer to GROUP 17 -
Emission Control).
OK
NG
Check the following connectors: D-11, D-119, D-122 Repair
OK
NG
Check the harness wire between the throttle valve controller Repair
and the engine-A/T-ECU.
OK
YES
MUT-II Self-Diag Code Refer to Code No.79, Throttle position sensor (1st channel)
Is code No.79 set? system. (Refer to P.13A-158.)
NO
YES
MUT-II Self-Diag Code Refer to Code No.93, Throttle valve control servo system
Is Code No.93 set? (Refer to P.13A-163.)
NO
OK
Check the operation of the throttle Transient malfunction
valve control servo. (Refer to GROUP 00 - Points to
OK: The throttle valve opens or Note for Intermittent Malfunctions.)
closes when the accelerator
pedal is depressed or released.
NG
NG
Check the throttle valve control Replace the throttle body assembly
servo. (Refer to P.13A-232.)
OK
NG
Check the following connector: Repair
B-122
OK
NG NG
Measure at the throttle valve control Check the following connector: Repair
servo connector B-122 D-11
D Use test harness (MB991658) to OK
connect the connector, and NG
measure at the pick-up harness. Check the harness wire between the Repair
D Ignition switch: ON throttle valve control servo and the
D The voltage between terminal 1 throttle valve controller.
and earth
D The voltage between terminal 2 OK
and earth
Check the trouble symptoms.
D The Voltage between terminal 3
and earth NG
OK: Voltage changes between 5
- 7 V when the accelerator Replace the throttle valve controller.
pedal is operated.
NOTE: Erase the diagnosis code
before the measurement
since a diagnosis code is
recorded when the harness
is disconnected.
OK
Check the trouble symptoms.
NG
Replace the throttle valve controller.
NG
Replace the engine-A/T-ECU.
Code No.94 Communication line system with the throttle Probable cause
valve controller
Range of Check D Short in communication line
D Ignition switch: ON D Malfunction of engine-A/T-ECU
D Battery voltage: 8 V or more. D Malfunction of throttle valve controller
D Engine: not cranking
Set Conditions
D System detects an error in communication line between the engine-A/T-ECU
and the throttle valve controller, and between the throttle valve controller and
the engine-A/T-ECU.
YES
MUT-II Self-Diag Code Refer to Code No.91, Electronic-con-
Is Code No.91 output? trolled throttle valve system (Refer to
NO P13A-161.)
NG
Check the following connector: Repair
D-11
OK
NG
(1) NG
Measure at throttle valve controller Check the following connectors: B-25X, Repair
connector D-11. D-128
D Measure voltage at the throttle OK
valve controller connector
terminals. Check the harness wire between the
D Ignition switch: ON throttle valve controller and the engine
(1) The voltage between terminal 5 control relay, and repair if necessary.
and earth
OK: System voltage (2) NG NG
Check the following connectors: D-208, Repair
(2) The voltage between terminal 22 D-223, E-13
and earth
OK: System voltage OK
(3) The voltage between terminal 3
and earth Check the harness wire between the
The voltage between terminal 4 throttle valve controller and the ignition
and earth switch, and repair if necessary.
The voltage between terminal 16
and earth (3) NG NG
OK: 0.5 V or less Check the following connector: D-14 Repair
OK
OK
NG
Check the following connectors: Repair
D-119, D-122
OK
NG
Replace the throttle valve controller.
Engine warning The engine warning lamp does not illuminate right after the 3 13A-170
lamp and ignition switch is turned to the ON position.
related parts
The engine warning lamp remains illuminating and never goes 4 13A-170
out.
Idling stability When the engine is cold, it stalls at idling. (Die out) 9 13A-177
(Engine stalls)
When the engine is hot, it stalls at idling. (Die out) 10 13A-178
The engine stalls when starting the car. (Pass out) 11 13A-180
Poor acceleration
Surge
Knocking 16 13A-184
Dieseling 17 13A-184
Engine idle speed is incorrect while the A/C is on (A/C switch 2 signal). 20 13A-187
GDI ECO indi- GDI ECO indicator lamp does not illuminate. 22 13A-188
cator lamp sys-
tem GDI ECO indicator lamp remains illuminated and does not go off. 23 13A-188
Starting Wont start The starter is used to crank the engine, but there is no combustion within the
cylinders, and the engine wont start.
Fires up and dies There is combustion within the cylinders, but then the engine soon stalls.
Incorrect idle speed The engine doesnt idle at the usual correct speed.
Engine stall The engine stalls when the foot is taken from the accelerator pedal, regardless
(Die out) of whether the vehicles is moving or not.
Engine stall The engine stalls when the accelerator pedal is depressed or while it is being
(Pass out) used.
Time
Idling Stumble
Time
Items Symptom
Driving Shock The feeling of a comparatively large impact or vibration when the engine is
accelerated or decelerated.
Surge This is repeated surging ahead during constant speed travel or during variable
speed travel.
Knocking A sharp sound like a hammer striking the cylinder walls during driving and which
adversely affects driving.
Stopping Run on The condition in which the engine continues to run after the ignition switch is
(Dieseling) turned to OFF. Also called Dieseling.
(1) NG NG
Measure at the diagnosis connecter Check the following connectors: Repair
D-23. D-27, D-210, D-211
(1) The voltage between terminal 16 OK
and earth
OK: Battery voltage (2) NG
(2) Continuity between 4 and earth Check the trouble symptoms.
Continuity between 5 and earth NG
OK: Continuity
OK Check the harness wire between the
power supply and diagnosis
Check the harness wire between connector, and repair if necessary.
diagnosis connector and the
engine-A/T-ECU. Check the earth line, and repair if
OK NG necessary.
Repair
Inspection procedure 2
Communication with engine-A/T-ECU is not possible. Probable cause
The cause is probably a defect in the engine-A/T-ECU power supply circuit D Open circuit or short-circuited harness wire in the
(including earth). engine-A/T-ECU power supply circuit.
D Open circuit between engine-A/T-ECU and
diagnosis connector
D Malfunction of the engine-A/T-ECU
NG
Check the following connectors: D-06, D-23, D-122, D- 128, Repair
D-222, E-13
OK
Check the trouble symptoms.
NG
OK
Check the harness wire between engine-A/T-ECU and Check the engine-A/T-ECU power supply and earth circuit.
diagnosis connector. (Refer to P. 13A-189, Inspection procedure 24.)
NOTE
On vehicles with multi communication system (MMCS) or RV meter, if a malfunction cannot be resolved
after the procedure above, check the multi center display unit or RV meter and replace if necessary.
(Refer to GROUP 54 - Clock, multi center display and RV meter.)
Inspection procedure 3
The engine warning lamp does not illuminate right after Probable cause
the ignition switch is turned to the ON position.
Because there is a burnt-out bulb, the engine-A/T-ECU causes the engine D Burnt-out bulb
warning lamp to illuminate for five seconds immediately after the ignition switch D Open circuit or short-circuit between the engine
is turned to ON. warning lamp and engine-A/T-ECU.
If the engine warning lamp does not illuminate immediately after the ignition D Malfunction of the engine-A/T-ECU
switch is turned to ON, one of the malfunction listed at right has probably
occurred.
NG
MUT-II Data list Check the engine-A/T-ECU power
16 Engine-A/T-ECU power supply supply and earth circuit (Refer to
voltage P.13A-189, Inspection procedure 24.)
(Refer to P.13A-198.)
OK
Inspection procedure 4
The engine warning lamp remains illuminating and Probable cause
never goes out.
In cases such as the above, the cause is probably that the engine-A/T-ECU is D Short-circuit between the engine warning lamp and
detecting a problem in a sensor or actuator, or that one of the malfunctions engine-A/T-ECU
listed at right has occurred. D Malfunction of the engine-A/T-ECU
MUT-II Self-Diag Code YES Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code set? CODES.
NO
Measure at the combination connector D-02. NG Check the harness wire between combination meter and
D Disconnect the connector, and measure at the harness engine-A/T-ECU connector, and repair if necessary.
side.
D Disconnect the engine-A/T-ECU connector
D Continuity between 38 and earth
OK: No continuity
OK
NG
Check battery voltage when cranking. Check the battery.
OK: 8 V or higher
OK
MUT-II Self-Diag Code YES Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code set? CODES
NO
MUT-II Data list NG Check the engine control relay and ignition switch-IG system
16 Battery voltage (Refer to P.13A-198.) (Refer to P.13A-190, Inspection procedure 25.)
OK
NO
Does the camshaft rotate when the engine is cranking? Check if the timing belt is broken or damaged.
YES
MUT-II Actuator Test NG Check fuel pump (low pressure) system
07 Fuel pump (low pressure) (Refer to P.13A-203.) (Refer to P.13A-193, Inspection procedure 29.)
OK
MUT-II Data list NG Check the engine coolant temperature sensor system
21 Engine coolant temperature sensor (Refer to P.13A-198.) (Refer to P.13A-138, code No.21.)
OK
MUT-II Data list NG Check the throttle position sensor (1st channel) system
79 Throttle position sensor (1st channel) (Refer to P.13A-198.) (Refer to P.13A-158, code No.79.)
OK
Is starting good if the engine is cranked with the accelerator YES D Clean the throttle valve area. (Refer to P.13A-220.)
pedal slightly depressed? D Check and adjust the throttle position sensor (Refer to
P.13A-220.)
NO
NG
Check fuel leakage (Refer to P.13A-225.) Repair
OK
NG
Measure low fuel pressure between the fuel pump (low Repair
pressure) and fuel pump (high pressure) (Refer to P.13A-222.)
OK
Inspection procedure 6
Initial combustion but no complete combustion (starting Probable cause
impossible), long time to start (hard starting)
In such cases as the above, the cause is probably that the spark plugs are D Malfunction of fuel supply system
generating sparks by the spark are weak, or the initial mixture is not appropriate. D Malfunction of of fuel pressure control solenoid
valve
D Malfunction of the ignition system
D Malfunction of the electronic-controlled throttle
valve system
D Malfunction of the engine-A/T-ECU
NG
Check the battery voltage when cranking. Check the battery.
OK: 8 V or higher
OK
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code set? CODES.
NO
NG
MUT-II Actuator Test Check fuel pump system (low-pressure)
07 Fuel pump (low pressure) (Refer to P.13A-203.) (Refer to P.13A-193, Inspection procedure 29.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system (Refer
21 Engine coolant temperature sensor (Refer to P.13A-198.) to P.13A-138, code No.21.)
OK
NG
Check the ignition timing when cranking. Check that the crank angle sensor and timing belt cover are
OK: Approx. 5 _BTDC installed properly.
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
1. Remove the ignition coil.
2. Install a new spark plug to the removed ignition coil.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
3. Disconnect the injector intermediate connector.
4. Earth the spark plug electrode securely.
5. Check that the spark plug ignites when the engine is
cranked.
OK
NG
Check the trouble symptoms. Replace the injector.
Inspection procedure 7
Unstable idling (Rough idling, hunting) Probable cause
The cause is probably a malfunction of the ignition system, air/fuel ratio control D Malfunction of the ignition system
system, electronic controlled throttle valve system, compression pressure, etc. As D Malfunction of the air/fuel ratio control system
many causes can be suspected, diagnose from easier items. D Malfunction of the electronic-controlled throttle
valve system
D Poor compression
D Air sucking into the air intake system
YES
Has the battery been disconnected recently? After warming-up, let the engine run at idling for 10 minutes.
NO
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code set? CODES.
NO
NG
MUT-II Data list Check the throttle valve position feedback system
79 Throttle position sensor (1st channel) (Refer to P.13A-198.) (Refer to P.13A-162, code No.92.)
OK
YES
Does the idling speed fluctuate excessively? D Clean around the throttle valve. (Refer to P.13A-220)
D Adjust the throttle position sensor (Refer to P.13A-220.)
NO
NG
MUT-II Data list Check the accelerator pedal position switch system (Refer to
26 Accelerator pedal position switch (Refer to P.13A-198.) P.13A-192, Inspection procedure 28.)
OK
MUT-II Data list NG Check the intake air temperature sensor system (Refer to
13 Intake air temperature sensor (Refer to P.13A-198.) P.13A-135, code No.13.)
OK
MUT-II Data list NG Check the barometric pressure sensor system (Refer to
25 Barometric pressure sensor (Refer to P.13A-198.) P.13A-145, code No.25.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system (Refer
21 Engine coolant temperature sensor (Refer to P.13A-198.) to P.13A-138, code No.21.)
OK
NG
MUT-II Actuator Test Check the purge control solenoid valve system
08 Purge control solenoid valve (Refer to P.13A-203.) (Refer to P.13A-197, Inspection procedure 36.)
OK
NG
MUT-II Data list 11 Oxygen sensor system check
11 Oxygen sensor (Refer to P.13A-198.) (Refer to P. 13A-131, code No.11.)
OK: 600 - 1,000 mV when the engine is suddenly raced
OK
NG
MUT-II Data list Measure fuel high-pressure between the fuel pump (high
11 Oxygen sensor (Refer to P.13A-198.) pressure) and injector. (Refer to P.13A-222.)
OK: 0 - 400 mV and 600 - 1,000 mV alternates when OK
the engine is idling (wait for 2 minutes after the en-
gine is started).
Check that air is sucked in the air intake system.
OK D Broken intake manifold gasket
D Damaged vacuum hose
To the next page D Damaged air intake hose
OK
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
1. Remove the ignition coil.
2. Install a new spark plug to the removed ignition coil.
3. Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
4. Earth the spark plug electrode securely.
5. Check that the spark plug ignites when the engine is
cranked.
OK
Check the following items in that order. Check the trouble symptoms.
D Check the spark plug
D Check the exhaust gas emission control system NG
D Check the EGR control system
D Check the compression pressure Air is sucked in the air intake system, or EGR gas leaks.
D Check if foreign materials (water, kerosine,etc.) got into D Broken intake manifold gasket
fuel. D Damaged air intake hose
D Damaged vacuum hose
D Faulty EGR valve seat
Inspection procedure 8
Idling speed is high or low (Improper idling speed) Probable cause
The cause is probably that the intake air amount during idling is too great or too D Malfunction of the electronic-controlled throttle
small. valve system
D Malfunction of the throttle body
YES
Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
MUT-II Self-Diag Code
CODES.
Is a diagnosis code set?
NO
NG
MUT-II Data list Check the throttle valve position feedback system
79 Throttle position sensor (1st channel) (Refer to P.13A-198.) (Refer to P.13A-162, code No.92.)
OK
NG
MUT-II Actuator Test Check the purge control solenoid valve system
08 Purge control solenoid valve (Refer to P.13A-203.) (Refer to P.13A-197, Inspection procedure 36.)
OK
NG
MUT-II Data list Check the accelerator pedal position switch system
26 Accelerator pedal position switch (Refer to P.13A-198.) (Refer to P.13A-192, Inspection procedure 28.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system (Refer
21 Engine coolant temperature sensor (Refer to P.13A-198.) to P.13A-138, code No.21.)
OK
NG
MUT-II Data list Check the A/C switch and A/C relay system
28 A/C switch (Refer to P.13A-198.) (Refer to P.13A-194, Inspection procedure 31.)
OK
NG
MUT-II Data list Check the stop lamp switch system
67 Stop lamp switch (Refer to P.13A-198.) (Refer to P.13A-195, Inspection procedure 32.)
OK
YES
Has the battery been disconnected recently? After warming-up, let the engine run at idling for 10 minutes.
NO
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code set? CODES.
NO
YES
Is engine-idling stable after the warming-up? Check the unstable idling (rough, hunting).
NO (Refer to P.13A-174, Inspection procedure 7.)
NG
MUT-II Data list Check the throttle valve position feedback system.
14 Throttle position sensor (2nd channel) (Refer to P.13A-198.) (Refer to P.13A-162, code No.92.)
OK
NG
MUT-II Data list Check the accelerator pedal position switch system.
26 Accelerator pedal position switch (Refer to P.13A-192, Inspection procedure 28.)
(Refer to P.13A-198.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system.
21 Engine coolant temperature sensor (Refer to P.13A-198.) (Refer to P.13A-138, code No.21.)
OK
NG
MUT-II Data list Check the EGR valve system.
68 EGR valve (Refer to P.13A-198.) (Refer to P.13A-196, Inspection procedure 35.)
OK
YES
Does the engine stall right after the accelerator pedal is D Clean around the throttle valve. (Refer to P.13A-220.)
released? D Adjust the throttle position sensor. (Refer to P.13A-220.)
NO
Inspection procedure 10
When the engine becomes hot, it stalls at idling. (Die Probable cause
out)
In such cases as the above, the cause is probably that ignition system, air/fuel D Malfunction of the ignition system
mixture, electronic-controlled throttle valve system, compression pressure is D Malfunction of the air/fuel ratio control system
defective. In addition, if the engine suddenly stalls, the cause may also be a D Malfunction of the electronic-controlled throttle
defective connector contact. valve system
D Malfunction of the throttle body
D Improper connector contact
D Drawing air into intake system
YES
Has the battery been disconnected recently? After warming-up, let the engine run at idling for 10 minutes.
NO
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code set? CODES.
NO
NG
MUT-II Data list Check the throttle valve position feedback system.
79 Throttle position sensor (1st channel) (Refer to P.13A-198.) (Refer to P.13A-162, code No.92.)
OK
NO
Does the engine stall easily again? While carrying out an intermittent malfunction simulation test
(Refer to GROUP 00 - Points to Note for Intermittent
YES Malfunctions.), check for sudden changes in the signals shown
below.
D Crank angle sensor signal
D Injector activating signal
D Low pressure fuel pump drive signal
D Air flow sensor
D Primary ignition signal
D Engine-A/T-ECU power supply voltage
NG
MUT-II Data list Check the accelerator pedal position switch system.
26 Accelerator pedal position switch (Refer to P.13A-192, Inspection procedure 28.)
(Refer to P.13A-198.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system.
13 Intake air temperature sensor (Refer to P.13A-198.) (Refer to P.13A-135, code No.13.)
OK
MUT-II Data list NG Measure fuel high-pressure between the fuel pump (high
11 Oxygen sensor (Refer to P.13A-198.) pressure) and injector. (Refer to P.13A-222.)
OK 0 - 400 mV and 600 - 1,000 mV alternates when
the engine is idling (wait for 2 minutes after the en- OK
gine is started).
Check that air is sucked in the air intake system.
OK
D Broken intake manifold gasket
D Damaged vacuum hose
To the next page
D Damaged air intake hose
MUT-II Data list NG D Clean around the throttle valve. (Refer to P.13A-220)
14 Throttle position sensor (2nd channel) D Adjust the throttle position sensor (Refer to P.13A-220.)
After warming-up, let the engine run at idling with no load.
OK: 3,900 - 4,800 mV
OK
NG
MUT-II Data list Check the EGR valve system (Refer to P.13A-196, Inspection
68 EGR valve (Refer to P.13A-198.) procedure 35.)
OK
YES
Does the engine stall right after the accelerator pedal is Clean around the throttle valve. (Refer to P.13A-220.)
released?
NO
OK
Check the ignition timing. (Refer to GROUP 11A - Engine Check that the crank angle sensor and timing belt cover are
Adjustment.) properly installed.
NG
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
1. Remove the ignition coil.
2. Install a new spark plug to the removed ignition coil.
3. Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
4. Earth the spark plug electrode securely.
5. Check that the spark plug ignites when the engine is
cranked.
OK
Inspection procedure 11
The engine stalls when starting the car. (Pass out) Probable cause
In cases such as the above, the cause is probably misfiring due to a weak D Malfunction of the ignition system
spark, or an inappropriate air/fuel mixture when the accelerator pedal is D Malfunction of the EGR valve
depressed. D Air stuck in the air intake system
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code set? CODES.
NO
NG
MUT-II Data list Check the EGR valve system (Refer to P.13A-196, Inspection
68 EGR valve (Refer to P.13A-198) procedure 35.)
OK
NG
MUT-II Actuator Test Check the purge control solenoid valve system
08 Purge control solenoid valve (Refer to P.13A-203.) (Refer to P.13A-197, Inspection procedure 36.)
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
1. Remove the ignition coil.
2. Install a new spark plug to the removed ignition coil.
3. Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 mV is
applied to the injector, or you are seriously injured.
4. Earth the spark plug electrode securely.
5. Check that the spark plug ignites when the engine is
cranked.
OK
YES
Has the battery been disconnected recently? After warming-up, let the engine run at idling for 10 minutes.
NO
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code set? CODES.
NO
NG
MUT-II Data list Check the accelerator pedal position switch system.
26 Accelerator pedal position switch (Refer to P.13A-198.) (Refer to P.13A-192, Inspection procedure 28)
OK
NG
MUT-II Data list Check the throttle valve position feedback system
79 Throttle position sensor (1st channel) (Refer to P.13A-198.) (Refer to P.13A-162, code No.P92)
OK
NG
Check the vehicle speed sensor system Repair
(Refer to P.13A-144, code No.24.)
NO
NG
MUT-II Data list Check the EGR valve system (Refer to P.13A-196, Inspection
68 EGR valve (Refer to P.13A-198.) procedure 35.)
OK
NG
Check ignition coil spark for each cylinder. Replace the ignition coil.
1. Remove the ignition coil.
2. Install a new spark plug to the removed ignition coil.
3. Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
4. Earth the spark plug electrode securely.
5. Check that the spark plug ignites when the engine is
cranked.
OK
Inspection procedure 13
Hesitation, sag, stumble, poor acceleration or surge Probable cause
The cause is probably a malfunction of the ignition system, air/fuel ratio control D Malfunction of the ignition system
system, electronic controlled throttle valve system, compression pressure, etc. D Malfunction of the air/fuel ratio control system
D Malfunction of the electronic-controlled throttle
valve system
D Improper compression pressure
D Air stuck in the air intake system
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
NO
NG
Check the ignition timing. (Refer to GROUP11A - Engine Check that the crank angle sensor and timing belt cover are
Adjustment) properly installed.
OK
NG
MUT-II Data list Check the accelerator pedal position switch system.
26 Accelerator pedal position switch (Refer to P.13A-192, Inspection procedure 28.)
(Refer to P.13A-198.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system (Refer to
13 Intake air temperature sensor (Refer to P.13A-198.) P.13A-135, code No.13.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system (Refer to
25 Barometric pressure sensor (Refer to P.13A-198.) P.13A-145, code No.25.)
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system (Refer
21 Engine coolant temperature sensor (Refer to P.13A-198.) to P.13A-138, code No.21.)
OK
NG
MUT-II Data list Check the throttle valve position feedback system (Refer to
79 Throttle position sensor (1st channel) (Refer to P.13A-198.) P.13A-162, code No.92.)
OK
NG
MUT-II Data list Check the oxygen sensor system. (Refer to P.13A-131, code
11 Oxygen sensor (Refer to P.13A-198.) No.11.)
OK: 600 - 1,000 mV when the engine is suddenly raced
OK
NG
MUT-II Data list Measure fuel high-pressure between the fuel pump (high
11 Oxygen sensor (Refer to P.13A-198.) pressure) and injector. (Refer to P.13A-222.)
OK: 0 - 400 mV and 600 - 1,000 mV alternates when OK
the engine is idling (wait for 2 minutes after the en-
gine is started). Check that air is sucked in the air intake system.
OK D Broken intake manifold gasket
D Damaged vacuum hose
D Damaged air intake hose
NG
MUT-II Data list Check the EGR valve system (Refer to P.13A-196, Inspection
68 EGR valve (Refer to P.13A-198.) procedure 35.)
OK
NG
Check the trouble symptoms. Replace the injector.
Inspection procedure 14
The feeling of impact or vibration when accelerating Probable cause
In cases such as the above, the cause is probably that there is an ignition leak D Malfunction of the ignition system
accompanying the increase in the spark plug demand voltage during
acceleration.
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code displayed? CODES.
NO
NG
MUT-II Data list Check the throttle valve position feedback system
79 Throttle position sensor (1st channel) (Refer to P.13A-198.) (Refer to P.13A-162, code No.92.)
OK
NG
Check the spark plug Replace
OK
Inspection procedure 15
The feeling of impact or vibration when decelerating Probable cause
The cause is probably insufficient intake air due to a faulty electronic-controlled D Malfunction of the electronic- controlled throttle
throttle valve system. valve system
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
NO
NG
MUT-II Data list Check the throttle valve position feedback system
79 Throttle position sensor (1st channel) (Refer to P.13A-198.) (Refer to P.13A-162, code No.92.)
OK
NG
MUT-II Data list Check the accelerator pedal position switch system (Refer to
26 Accelerator pedal position switch P.13A-192, Inspection procedure 28.)
(Refer to P.13A-198.)
OK
Inspection procedure 16
Knocking Probable cause
In case as the above, the cause is probably that the heat value of the spark D Malfunction of the detonation sensor
plug is inappropriate. D Improper heat range of the spark plugs.
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Is a diagnosis code set? CODES.
NO
NO
Does knocking occur when the vehicle is driven with the Check the detonation sensor system. (Refer to P.13A-146,
detonation sensor disconnected? code No.31.)
(At this time, use the MUT-II to check whether the ignition
timing is retarded from when the detonation sensor connector
is connected.)
YES
Inspection procedure 17
Run-on (Dieseling) Probable cause
Fuel leakage from injectors is suspected. D Malfunction of the injector
YES
MUT-II Self-Diag Code Refer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
Are diagnosis codes displayed? CODES.
NO
NG
Check the ignition timing. (Refer to GROUP 11A - Engine Check that the crank angle sensor and timing belt cover are
Adjustment.) properly installed.
OK
NG
MUT-II Data list Check the engine coolant temperature sensor system (Refer
21 Engine coolant temperature sensor (Refer to P.13A-198.) to P.13A-138, code No.21.)
OK
NG
MUT-II Data list Check the intake air temperature sensor system (Refer to
13 Intake air temperature sensor (Refer to P.13A-198.) P.13A-135, code No.13.)
OK
NG
MUT-II Data list Check the barometric pressure sensor system (Refer to
25 Barometric pressure sensor (Refer to P.13A-198.) P.13A-145, code No.25.)
OK
NG
MUT-II Data list Check the EGR valve system (Refer to P.13A-196, Inspection
68 EGR valve (Refer to P.13A-198.) procedure 35.)
OK
NG
MUT-II Actuator Test Check the purge control solenoid valve system
08 Purge control solenoid valve (Refer to P.13A-197, Inspection procedure 36.)
(Refer to P.13A-203.)
OK
NG
MUT-II Data list Check the oxygen sensor system. (Refer to P.13A-131, code
11 Oxygen sensor (Refer to P.13A-198.) No.11.)
OK: 600 - 1,000 mV when the engine is suddenly raced
OK
OK
MUT-II Data list Replace the oxygen sensor.
11 Oxygen sensor (Refer to P.13A-198.)
OK: Repeat 0 - 400 mV and 600 - 1,000 mV alternately
during idling (wait for at least 2 minutes after the Check the trouble symptoms.
engine started to run at idle).
NG
NG
NG
Check the trouble symptoms. Replace the injector.
Inspection procedure 19
Low alternator output voltage (approx. 12.3 V) Probable cause
The cause is probably a malfunction of the alternator or one of the problems D Malfunction of the charging system
listed at right. D Open circuit between the alternator G terminal and
the engine-A/T-ECU
D Malfunction of the engine-A/T-ECU
NG NG
Measure at alternator connector B-59 Measure at alternator connector B-59 Check the harness wire between the
D Connect the connector. D Disconnect the connector, and alternator and the engine-A/T-ECU,
(Use test harness: MB991519) measure at the harness side. and repair if necessary.
D The voltage between terminal 1 D Disconnect the engine-A/T-ECU
(black clip) and earth connector
(Engine: Idling) D The continuity between terminal 1
(Headlamp: OFF to ON) and earth
(Stop lamp: OFF to ON) OK: No continuity
(Rear defogger switch: OFF to OK
ON) NG
OK: The voltage increases by Check the following connectors: Repair
0.2 - 3.5 V B-41, D-119
OK OK
Check the alternator Check the trouble symptoms.
(Refer to GROUP16 - Charging
System.) NG
NG
Check the harness wire between the Repair
alternator and the engine-A/T-ECU.
OK
NG
Check the following connectors: D-120, D-131, E-13 Repair
OK
Inspection procedure 21
A/C condenser fan is inoperative Probable cause
The fan motor relay is controlled by turning on and off the power transistor in D Malfunction of the A/C condenser fan relay.
the engine-A/T-ECU. D Malfunction of the A/C condenser fan motor.
D Open or short circuit, or loose connector contact
D Malfunction of the engine-A/T-ECU
NG
Measure at the engine-A/T-ECU connector D-119. Check the condenser fan circuit. (Refer to ELECTRICAL
D Disconnect the connector, and measure at the harness WIRING.)
side.
D Check condition of the condenser fan.
(Ignition switch: ON)
OK: Fan stops. OK
Check the following connector: D-119
D The voltage between terminal 18 and earth
(Ignition switch: ON) OK NG
OK: System voltage Repair
D Connect terminal 18 to earth.
(Ignition switch: ON) Check the trouble symptoms.
OK: A/C condenser fan rotates.
NG
Inspection procedure 22
GDI ECO indicator lamp does not illuminate. Probable cause
If the GDI ECO indicator lamp does not illuminate after turning switch, the causes D Burned-out GDI ECO indicator lamp bulb
listed in the right column are suspected. D Open circuit or short-circuited harness wire in the GDI
ECO indicator lamp circuit
D Malfunction of the engine-A/T-ECU
D Malfunction of the GDI ECO indicator lamp ECU
OK
Measure at the engine-A/T-ECU connector D-119. Check the following connector: D-119
D Disconnect the connector, and measure at the harness side.
D Earth terminal 14 (Ignition switch: ON) OK NG
OK: The GDI ECO indicator lamp illuminates.
Repair
NG
Check trouble symptom.
Check the following connectors: E-13, E-112
NG
OK NG
Replace the engine-A/T-ECU.
Repair
Inspection procedure 23
GDI ECO indicator lamp remains illuminated and does Probable cause
not go off.
If the GDI ECO indicator lamp does not go off during high load operation, the causes D Short circuit between the GDI ECO indicator lamp and
listed in the right column are suspected. engine-A/T-ECU
D Malfunction of the engine-A/T-ECU
D Malfunction of the GDI ECO indicator lamp ECU
NG
Measure at GDI ECO indicator lamp ECU connector E-112. Check the harness wire between the GDI ECO indicator lamp
D Disconnect the connector, and measure at the harness side. ECU and engine-A/T-ECU, and repair if necessary.
D Disconnect the engine-A/T-ECU connector.
D Continuity between terminal 3 and earth
OK: No continuity
OK
(1) NG NG
Measure at engine-A/T-ECU Check the following connectors: Repair
connectors D-120, D-121. D-208, D-223 <LHD>, E-13
D Disconnect the connector, and
OK
measure at the harness side.
(1) The voltage between terminal 98 Check the trouble symptoms.
and earth.
(Ignition switch: ON) NG
OK: System voltage NG
(2) The voltage between terminal 49 (2), (3) NG Check the harness wire between the Repair
and earth. engine-A/T-ECU and the ignition
OK: System voltage switch.
(3) The voltage between terminals 41 OK
and 47 and earth.
(Ignition switch: ON) Ignition switch check
OK: System voltage (Refer to GROUP 54 - Ignition
(When terminal 49 was Switch.)
connected to earth)
(4) The continuity between terminals (4) NG
42 and 48 and earth. NG
OK: Continuity Check the following connector: Repair
(5) The voltage between terminal 66 D-128
and earth (5) NG OK
OK: System voltage
OK Check the trouble symptoms.
NG
Check the following connectors:
D-120, D-121 Check the harness wire between the
OK NG engine-A/T-ECU and the engine
control relay, and repair if necessary.
Repair
Check the trouble symptoms. NG
Check the following connector: Repair
NG D-14
Replace the engine-A/T-ECU. OK
NG
Check the following connectors: Repair
D-27, D-31 <LHD>, D-223 <LHD>,
E-13
OK
NG
Check the trouble symptoms. Check the harness wire between the
engine-A/T-ECU and the battery, and
repair if necessary.
Inspection procedure 25
Engine control relay, ignition switch-IG system Probable cause
When an ignition switch ON signal is input to the engine-A/T-ECU, the D Malfunction of the ignition switch
engine-A/T-ECU turns the control relay ON. D Malfunction of the control relay.
This causes system voltage to be supplied to the engine-A/T-ECU, sensors, and D Open circuit or short-circuited harness wire in the
actuators. engine control relay circuit.
D Malfunction of the engine-A/T-ECU
NG
Check the control relay. Replace
(Refer to P.13A-227.)
OK
NG
Measure at control relay connector Check the harness wire between the
B-25X. battery and the engine control relay,
D Disconnect the connector, and and repair if necessary.
measure at the harness side. OK
D The voltage between 2, 3 and Check the engine-A/T-ECU power
earth supply and earth circuit. (Refer to
OK: System voltage P.13A-189, Inspection procedure 24.)
Inspection procedure 26
Injector driver relay system Probable cause
When an ignition switch ON signal is input to the engine-A/T-ECU, the D Malfunction of the injector driver relay.
engine-A/T-ECU turns the injector driver relay ON. D Open or short circuit, or loose connector contact
This causes system voltage to be supplied to the injector driver. D Malfunction of the engine-A/T-ECU
NG
Check the injector driver relay (Refer to P.13A-227.) Replace
OK
(1) NG
Measure at the injector driver relay connector B-28X. Check the harness wire between the injector driver relay and
D Disconnect the connector, and measure at the harness the battery, and repair if necessary.
side.
(1) The voltage between terminal 3 and earth (2)NG
OK: System voltage Check the following connectors: D-208, D-223 <LHD>, E-13
(2) The voltage between terminal 4 and earth (Ignition switch:
ON) OK NG
Repair
OK: System voltage
OK Check the trouble symptoms.
NG
Check the harness wire between the injector driver relay and
the ignition switch, and repair if necessary.
NG
Measure at engine-A/T-ECU connector D-119. Check the following connector: B-28X
D Disconnect the connector, and measure at the harness OK NG
side. Repair
D The voltage between terminal 6 and earth (Ignition switch:
ON)
Check the trouble symptoms.
OK: System voltage
NG
OK
Check the harness wire between the injector driver relay and
Check the following connector: D-119
the engine-A/T-ECU, and repair if necessary.
OK NG
Repair
NG
MUT-II Data list Check the inhibitor switch system.
Confirm the data list concerning the A/T system. (Refer to GROUP 23 - Troubleshooting.)
61 Inhibitor switch
(Refer to GROUP 23 - Troubleshooting.)
OK
NG
Check the inhibitor switch. Replace
D The continuity between terminals 9 and 10 (Refer to
GROUP 23 - On-vehicle Service.)
OK
NG
Measure at inhibitor switch connector C-05. Check the following connector: E-114
D Disconnect the connector, and measure at the harness NG
side. OK
D The voltage between terminal 10 and earth (Ignition switch: Repair
ON)
OK: System voltage
Check the trouble symptoms.
OK
NG
Repair
NG
Measure at engine-A/T-ECU connector D-120. Check the following connector: C-05
D Disconnect the connector, and measure at the harness
OK NG
side.
D The voltage between terminal 58 and earth Repair
(Selector lever position: P or N)
(Ignition switch: START)
Check the trouble symptoms.
OK: System voltage
NG
OK NG
Repair Check the harness wire between the inhibitor switch and the
engine-A/T-ECU, and repair if necessary.
Check the following connector: D-120
OK
Inspection procedure 28
Accelerator pedal position switch system Probable cause
The accelerator pedal position switch detects that the accelerator pedal is fully D Maladjustment of the accelerator pedal position
closed, and sends a signal to the engine-A/T-ECU. The engine-A/T-ECU uses switch and the accelerator pedal position sensor.
this signal to carry out idle speed control. D Open circuit or short-circuited harness wire in the
accelerator pedal position switch system, or poor
connector contact
D Malfunction of the engine-A/T-ECU
NG
Check the accelerator pedal position Replace the accelerator pedal
switch. (Refer to P.13A-230.) position sensor.
OK
NG NG
Measure at accelerator pedal position Check the following connector: Repair
sensor connector D-135. D-121
D Disconnect the connector, and
OK
measure at the harness side.
D The voltage between terminal 4 Check the trouble symptoms.
and earth
(Ignition switch: ON) NG
OK: 4 V or more NG
D The continuity between terminal 5 Check the harness wire between the Repair
and earth engine-A/T-ECU and the accelerator
OK: Continuity pedal position sensor.
OK OK
NG
Check the following connector: Repair
D-135
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
OK
MUT-II Actuator Test Normal
07 Fuel pump
(Refer to P.13A-203.)
OK
NG
Check the fuel pump relay (Refer to Replace
P.13A-227.)
OK
NG NG
Measure at the fuel pump relay Check the following connectors: Repair
connector B-27X. D-208, D-213, E-10
D Disconnect the connector, and
measure at the harness side. OK
D The voltage between terminal 3, NG
Check the trouble symptoms. Check the harness wire between the
4 and earth
fuel pump relay and the ignition
(Ignition switch: ON)
switch.
OK: System voltage
OK NG
OK Repair
NG
Measure at the engine-A/T-ECU Check the harness wire between the
connector D-119. Check the ignition switch (Refer to
fuel pump relay and the
D Disconnect the connector, and GROUP54 - Ignition Switch.)
engine-A/T-ECU, and repair if
measure at the harness side. necessary.
D The voltage between terminal 21
and earth
(Ignition switch: ON)
OK: System voltage
OK
OK NG
Measure at the engine-A/T-ECU Check the following connector: Repair
connector D-119. D-119
D Disconnect the connector, and
OK
measure at the harness side.
D Short circuit between terminal 21
and earth Check the trouble symptoms.
(Ignition switch: ON) NG
OK: The fuel pump operates.
(Its operation sound can be Replace the engine-A/T-ECU.
heard.)
NG
(1) NG NG
Measure at fuel pump (low pressure) Check the following connectors: Repair
connector G-12. B-27X, D-124, E-17, F-11
D Disconnect the connector, and
measure at the harness side. OK
(1) The voltage between terminal 5 NG
and earth Check the trouble symptoms. Check the harness wire between the
(Ignition switch: ON) fuel pump relay and the fuel pump
OK: System voltage (low pressure).
(2) NG
(2) The continuity between terminal 4 Check the following connector:
and earth F-11
OK: Continuity
OK NG
OK Repair
NG
Check the trouble symptoms. Check the harness wire between the
fuel pump (low pressure) and earth,
and repair if necessary.
NG
Check the following connector: Repair
G-12
OK
NG
Check the trouble symptoms. Replace the fuel pump (low
pressure).
Inspection procedure 30
Power steering fluid pressure switch system Probable cause
The presence or absence of power steering load is input to the engine-A/T-ECU. D Malfunction of the power steering fluid pressure
Based on this signal, the engine-A/T-ECU controls the throttle control servo so switch.
that idle speed increases when the power steering is in operation. D Improper connector contact, open circuit or
short-circuited harness wire
D Malfunction of the engine-A/T-ECU
NG
Check the power steering fluid Replace
pressure switch (Refer to GROUP
37A - On-vehicle Service.)
OK
NG NG
Measure at power steering fluid Check the following connector: Repair
pressure switch connector B-51. D-120
D Disconnect the connector, and
OK
measure at the harness side.
D The voltage between terminal 1 Check the trouble symptoms.
and earth
(Ignition switch: ON) NG
OK: System voltage
Check the harness wire between the
OK engine-A/T-ECU and the power
steering fluid pressure switch, and
repair if necessary.
NG
Check the following connector: Repair
B-51
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
Inspection procedure 31
A/C switch and A/C relay system Probable cause
When an A/C ON signal is input to the engine-A/T-ECU, the engine-A/T-ECU D Malfunction of the A/C control system
controls the throttle control servo so that idle speed increases, and also operates D Malfunction of the A/C switch
the A/C compressor magnetic clutch. D Improper connector contact, open circuit or
short-circuited harness wire
D Malfunction of the engine-A/T-ECU
NG
Service the A/C compressor relay. Replace
(Refer to GROUP 55 - On-vehicle
Service.)
OK
OK NG
Measure at engine-A/T-ECU Check the following connectors: Repair
connectors D-119, D-121. D-119, D-121
D Disconnect the connector, and
measure at the harness side. OK
D The voltage between terminal 20,
Check the trouble symptoms.
83 and earth
(Ignition switch: ON) NG
OK: 0 - 3 V
(A/C switch: OFF) Replace the engine-A/T-ECU.
System voltage
(A/C switch: ON)
D Connect terminal 20 to earth.
(Ignition switch: ON, A/C switch:
ON)
OK: A/C compressor clutch
turns on.
NG
NG
Stop lamp switch check (Refer to Replace
GROUP 35 - Brake Pedal.)
OK
OK NG
Measure at stop lamp switch Measure at the engine-A/T-ECU Check the following connectors:
connector D-136. connector D-122. D-26 <LHD>, D-33, D-128, D-136,
D Disconnect the connector, and D Disconnect the connector, and D-124 <RHD>, E-13
measure at the harness side. measure at the harness side. OK NG
D The voltage between terminal 2 D The voltage between terminal 123
and earth and earth Repair
OK System voltage (Ignition switch: ON)
Check the trouble symptoms.
OK 0 - 3 V (when the brake
NG
pedal is not depressed) NG
System voltage (when the
brake pedal is depressed) Check the harness wire between the
NG engine-A/T-ECU and the stop lamp
Check the following connectors: OK
Repair switch, and repair if necessary.
D-26 <LHD>, D-27, D-124 <RHD> NG
Check the following connector: Repair
OK D-122
Check the trouble symptoms. OK
NG NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
Check the harness wire between the
battery and the stop lamp switch,
and repair if necessary.
Inspection procedure 33
Small lamp switch system Probable cause
The engine-A/T-ECU determines whether the small lamp switch is on or off. D Improper connector contact, open circuit or
According to that information, the engine-A/T-ECU controls alternator output short-circuited harness wire in the taillamp relay
current when the vehicle is started. circuit.
D Malfunction of the engine-A/T-ECU
NG
Measure at engine-A/T-ECU connector D-121. Check the taillamp circuit. (Refer to ELECTRICAL WIRING.)
D Disconnect the connector, and measure at the harness
side.
D The voltage between terminal 86 and earth (Lighting
switch: ON)
OK: System voltage
OK
NG
Check the following connector: D-121 Replace
OK
Inspection procedure 34
Injector driver Probable cause
The engine-A/T-ECU drives the injector by the drive signal. D Malfunction of the injector driver
D Improper connector contact, open circuit or
short-circuited harness wire
D Malfunction of the engine-A/T-ECU
NG
Check the following connectors: B-121, D-119 Repair
OK
NG
Check the harness wire between the injector driver and engine- Repair
A/T-ECU.
OK
NG
Use a analyzer to measure the signal waveform at the engine- Replace the injector driver.
A/T-ECU connectors D-119 and D-120.
D Engine: idling
D Selector lever position: P
D Voltage between 96 and earth, and between 1 and earth
OK: A normal waveform should be displayed as described
on P.13A-214 (INSPECTION PROCEDURE USING
AN ANALYZER).
OK
OK
Check the trouble symptoms. Transient malfunction
(Refer to GROUP 00 - Points to Note for Intermittent
NG Malfunctions.)
Replace the engine-A/T-ECU.
Inspection procedure 35
EGR valve (stepper motor) system Probable cause
The engine-A/T-ECU controls the EGR valve (stepper motor) in order to control D Malfunction of the EGR valve
the amount of exhaust gas mixed in the intake air. D Open circuit or short-circuited harness wire in the
EGR valve circuit
D Malfunction of the engine-A/T-ECU
NG
Check the EGR valve. (Refer to GROUP Replace
17 - Emission Control System.)
OK
NG NG
Measure at the EGR valve connector Check the following connector: Repair
B-60. B-25X
D Disconnect the connector, and OK
measure at the harness side.
D Voltage between 2, 5 and earth NG
Check the trouble symptoms. Check the harness wire between the
(Ignition switch: ON) engine control relay and the EGR valve,
OK: System voltage and repair if necessary.
OK
NG NG
Measure at the engine-A/T-ECU con- Check the following connector: Repair
nector D-120. B-60
D Disconnect the connector, and OK
measure at the harness side.
D Voltage between 51, 53, 60, 62 NG
Check the trouble symptoms. Check the harness wire between the
and earth (Ignition switch: ON) engine-A/T-ECU and EGR valve, and
OK: System voltage repair if necessary.
OK
NG
Check the following connector: Repair
D-120
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
NG
Check the purge control solenoid valve. Replace
(Refer to GROUP 17 - On-vehicle Ser-
vice.)
OK
NG
Measure at the purge control solenoid Check the harness wire between the
valve connector B-106. engine control relay and the purge
D Disconnect the connector, and control solenoid valve, and repair if
measure at the harness side. necessary.
D Voltage between 2 and earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at the engine-A/T-ECU con- Check the following connector: Repair
nector D-120. B-106
D Disconnect the connector, and OK
measure at the harness side.
D Voltage between 5 and earth NG
Check the trouble symptoms. Check the harness wire between the
(Ignition switch: ON) engine-A/T-ECU and the purge control
OK: System voltage solenoid valve, and repair if necessary.
OK
NG
Check the following connector: Repair
D-120
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU.
11 Oxygen Engine: After having When at 4,000 r/min, 200 mV or less Code No. 13A-131
sensor warmed up engine is deceler- 11
(Air/fuel mixture is ated
made leaner when
decelerating, and is
Race the engine sud- 600 - 1,000 mV
made richer when
denly.
racing.)
13 Intake air Ignition switch: ON or When intake air tem- - 20_C Code No. 13A-135
temperature with engine running perature is - 20_C 13
sensor
When intake air tem- 0_C
perature is 0_C
14 Throttle D Engine: After hav- Release the acceler- 4,000 mV or more Code No. 13A-137
position ing warmed up ator pedal. 14
sensor (2nd D Ignition switch: ON
channel) (Engine: Stopped) Depress the acceler- Voltage
ator pedal gradually. decreases in
response to the
pedal depression.
21 Engine cool- Ignition switch: ON or When engine coolant - 20_C Code No. 13A-138
ant temper- with engine running temperature is 21
ature sensor - 20_C
22 Crank angle D Engine: Cranking Compare the Identical Code No. 13A-140
sensor D Tachometer: Con- tachometer with the 22
nected MUT-II reading.
28 A/C switch Engine: Idling A/C switch: OFF OFF Procedure 13A-194
(The A/C compres- No.31
sor is running when
A/C switch: ON ON
the A/C switch is on.)
31 Small lamp Engine: Idling Lighting switch: OFF OFF Procedure 13A-195
switch No.33
Lighting switch: ON ON
34 Air flow sen- Engine: After having Idling ON Code No. 13A-133
sor reset warmed up 12
signal 3,000 r/min OFF
41 Injector D Engine: Cranking When engine coolant 120 - 160 ms Code No. 13A-147
drive time*1 temperature is 0_C 41
44 Ignition ad- D Engine: After hav- Idling 12 - 28_ BTDC Code No. 13A-148
vance value ing warmed up 44
D Timing lamp is set.
(The timing lamp is
set in order to
check actual igni-
tion timing.) 2,500 r/min 15 - 35_ BTDC
D Within six minutes
after engine start-
ing
49 A/C relay Engine: After having A/C switch: OFF OFF (compressor Procedure 13A-194
warmed up, idling clutch is not oper- No.31
ating)
67 Stop lamp Ignition switch: ON Brake pedal: De- OFF Procedure 13A-195
switch pressed No.32
74 Fuel pres- D Engine coolant Engine: Cranking 2 MPa or more Code No. 13A-151
sure sensor temperature: 85 - 56
95_C
D Lamps and all
accessories: OFF Engine: Idling 4.0 - 6.9 MPa
D Transmission: P
range
77 Accelerator Ignition switch: ON Release the acceler- 985 - 1,085 mV Code No. 13A-154
pedal posi- ator pedal. 77
tion sensor
(2nd chan- Depress the acceler- Increases in re-
nel) ator pedal gradually. sponse to the
pedal depression
stroke.
78 Accelerator Ignition switch: ON Release the acceler- 985 - 1085 mV Code No. 13A-156
pedal posi- ator pedal. 78
tion sensor
(1st chan- Depress the acceler- Increases in re-
nel) ator pedal gradually. sponse to the
pedal depression
stroke.
79 Throttle D Engine: After hav- Release the acceler- 400 - 800 mV Code No. 13A-158
position ing warmed up ator pedal. 79
sensor (1st D Ignition switch: ON
channel) (Engine stopped) Depress the acceler- Increases in re-
ator pedal gradually. sponse to the
pedal depression
stroke.
Transmission: P to D Increases by 0 -
range 200 mV.
07 Fuel pump Operates the Ignition Pinch the return Pulse is felt. Proce- 13A-193
(low-pres- fuel pump (low- switch: hose with fin- dure
sure) pressure) to cir- ON gers to feel the No.29
culate fuel. pulse of the fuel
being circulated.
08 Purge con- Solenoid valve Ignition switch: ON Sound of opera- Proce- 13A-197
trol solenoid turns from OFF tion can be dure
valve to ON. heard when so- No.36
lenoid valve is
driven.
21 Condenser Drive the fan D Ignition switch: ON Fan motor runs Proce- 13A-187
fan motor D A/C switch: ON dure
No.21
34 Electronic- Stop the throttle Ignition switch: ON The throttle Code 13A-161
controlled control servo valve opens No. 91
throttle valve slightly
system
1 No.1 injector While engine is idling after having warmed up, From 9 - 13 V, momen-
suddenly depress the accelerator pedal. tarily drops slightly
9 No.2 injector
24 No.3 injector
2 No.4 injector
10 No.5 injector
25 No.6 injector
Engine: Idling 0 - 3V
47
44 Engine coolant tem- Ignition switch: ON When engine coolant tem- 3.2 - 3.8 V
perature sensor perature is 0_C
52 Power steering fluid Engine: Idling after When steering wheel is System voltage
pressure switch warming-up stationary
63 Injector open circuit Engine: Increases from idling up to 4,000 r/min The voltage decreases
check signal slightly (approx. 0.7 V)
from 4.5 - 5.0 V.
64 Intake air temperature Ignition switch: ON When intake air tempera- 3.2 - 3.8 V
sensor ture is 0_C
71 Oxygen sensor Engine: Running at 2,500 r/min after warming-up Voltages of 0 V and 0.8
(Check by using a digital voltmeter.) V alternate
78 Throttle position sen- Ignition switch: ON Release the accelerator 4.0 V or higher
sor (2nd channel) pedal.
95 Accelerator pedal posi- Ignition switch: ON Release the accelerator 0.985 - 1.085 V
tion sensor (1st chan- pedal.
nel)
Depress the accelerator 4.0 V or higher
pedal fully.
123 Stop lamp switch Depress the brake pedal. System voltage
Terminal No. Check item Standard value, normal condition (check conditions)
44- 81 Engine coolant temperature sensor 5.1 - 6.5 kW (When coolant temperature is 0_C)
64- 81 Intake air temperature sensor 5.3 - 6.7 kW (When intake air temperature is 0_C)
79- 81 Accelerator pedal position switch Continuity (when the accelerator pedal is released)
7 Throttle position sensor (1st Ignition switch: ON Release the accel- 0.4 - 0.8 V
channel) erator pedal.
20 Accelerator pedal position Ignition switch: ON Release the accel- 0.985 - 1.085 V
sensor (2nd channel) erator pedal.
Time
0
(V)
10
T
Time
0
Crank angle
sensor output
wave pattern 4
Camshaft
position sensor
output wave 4
pattern
(ms)
0
No.1 TDC No.2 TDC No.3 TDC No.4 TDC No.5 TDC No.6 TDC
D Example 2
Cause of problem
Loose timing belt
Abnormality in sensor disk
Wave pattern characteristics
Wave pattern is displaced to the left or right.
(V)
4
Injector
open circuit
check signal
0
Injector
drive signal
4
0
(ms)
Power transistor 2
control signal wave
pattern 0 (ms)
OFF
ON
Dowel division
Condition of wave pattern build-up section and maximum voltage Probable cause
D Example 2
--- Normal wave pattern
Wave pattern during engine cranking
VB
Cause of problem
Malfunction in power transistor
Wave pattern characteristics
Power voltage results when the power transistor is ON.
Engine condition When the engine coolant temperature is 20_C or below, turn the ignition switch from OFF
to ON (without starting the engine).
(V)
The wave pattern
appears for an Point B Point A
instant, but soon Coil reverse electromotive Induced electromotive force
30 disappears. force (Approx. 3 10V) from the motor turning
20
EGR 10
valve
control
signal
wave
pattern
Time
Induced electromotive force does not appear or is extremely small. Motor is malfunctioning
Coil reverse electromotive force does not appear or is extremely small. Short in the coil
D Example 2
Open
circuit Cause of problem
side
Open circuit in the line between the EGR valve and the
engine-A/T-ECU
Wave pattern characteristics
Current is not supplied to the motor coil on the open
circuit side. (Voltage does not drop to 0 V.)
Normal Furthermore, the induced electromotive force waveform
side at the normal side is slightly different from the normal
waveform.
3. Remove the union joint and bolt from the special tool
MB991637 (adapter hose) and instead attach the special tool (hose
adapter) to the adapter hose.
Gasket 4. Install the special tool (for measuring the fuel pressure)
Fuel
pump MD998709 that was set up in step 3.
(high
pressure) <When using the fuel pressure gauge set (special tool)>
MD998742 (1) Install the special tool (for measuring the fuel pressure)
High-pressure between the high-pressure fuel hose and the fuel
fuel hose pump (high pressure).
D Fuel pressure too low Clogged fuel filter Replace fuel filter
D Fuel pressure drops after racing
Fuel leaking to return side due to poor Replace fuel pressure regulator
fuel pressure regulator (low pressure) (low pressure)
valve seating or settled spring
Low fuel pump (low pressure) Replace the fuel pump (low pressure)
delivery pressure
Fuel pressure too high Binding valve in fuel pressure Replace fuel pressure regulator
regulator (low pressure) (low pressure)
13. 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.
Fuel pressure drops gradually after Leaky fuel pressure regulator (low Replace fuel pressure regulator
engine is stopped pressure) valve seat (low pressure)
Fuel pressure drops sharply Check valve in fuel pump (low Replace the fuel pump (low pressure)
immediately after engine is stopped pressure) is held open
14. Release residual pressure from the fuel pipe line. (Refer
to P.13A-225.)
15. Remove the fuel pressure gauge and special tools from the
fuel pump (high pressure).
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.
16. Replace the O-ring at the end of the high-pressure fuel
hose with a new one. Furthermore, apply engine oil to
the new O-ring before replacement.
17. Fit the high-pressure fuel hose to the fuel pump (high
pressure) and tighten the mounting bolt to specified
torque.
18. Check for any fuel leaks by following the procedure in
step 7.
19. Disconnect the MUT-II.
D Fuel pressure too low Fuel leaking to return side due to poor Replace fuel pressure regulator
D Fuel pressure drops after racing fuel pressure regulator (high pres- (high pressure)
sure) valve seating or settled spring
Fuel pressure too high Binding valve in fuel pressure Replace fuel pressure regulator
regulator (high pressure) (high pressure)
14. Stop the engine and turn the ignition switch to OFF.
15. Disconnect the MUT-II.
COMPONENT LOCATION
Name Symbol Name Symbol
A/C relay O Fuel pump relay H
A/C switch R Ignition coil F
A B C D E F G H
I J y
K L M N O
P Q R V W
S T U X Y
Engine coolant
temperature sensor
MD998464
MD9998464
MD998464
Injector intermediate
INJECTOR CHECK
Injector side connector harness
1. Disconnect the injector intermediate harness connector.
2. Measure the resistance between each of the terminals.
Standard value: 0.9 - 1.1 W (at 20_C)
No.1 cylinder 11 - 12
No.2 cylinder 5- 6
No.3 cylinder 9 - 10
No.4 cylinder 3- 4
No.5 cylinder 7- 8
No.6 cylinder 1- 2
1- 3
2- 3
INJECTOR
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Fuel Line Pressure Reduction <before removal only> D Intake Manifold Removal and Installation
(Refer to P.13A-219.) (Refer to GROUP 15 - Intake Manifold.)
D Engine Cover Removal and Installation D Fuel Leak Check <after installation only> (Refer to
D Air Intake Hose Removal and Installation (Refer to P.13A-225.)
GROUP 15 - Air Cleaner.)
193 Nm O-ring
3
2
6
121 Nm 5 8
1
232 Nm
4
7
8 O-ring
10
9
121 Nm
16
232 Nm
21 O-ring
14
3 11
4
12 13
5 18
19 3
6 16
20
193 Nm 17 Engine oil
15
Removal steps
"FA D Air bleeding from high-pressure fuel "BA 11. Injector washer
line "BA 12. Injector holder
1. Fuel pressure sensor connector AC" "BA 13. Delivery pipe assembly and Fuel injec-
AA" 2. Injector harness tor assembly
"EA 3. Fuel feed pipe "BA 14. Insulator
"EA 4. Back-up ring A "BA 15. Injector gasket
"EA 5. O-ring 16. Fuel injector assembly
"EA 6. Back-up ring B "AA 17. Corrugated washer
AB" "DA 7. Flange "AA 18. Back-up ring A
"DA 8. Fuel pressure sensor "AA 19. O-ring
"CA 9. O-ring "AA 20. Back-up ring B
"CA 10. Back-up ring 21. Delivery pipe
NOTE
When removing the fuel pump (high pressure), air may
get into the fuel pump (high pressure). If air gets into
the fuel pump (high pressure), diagnosis code No.56 for
abnormal fuel pressure will be output.
2. Use the MUT-II to check the diagnosis code. If the
diagnosis code No.56 for fuel pressure sensor system
defect is output, erase it.
193 Nm
4
7
1 5.01.0 Nm
6
2
5
6 3
5.0 Nm to 172 Nm
4
Engine oil
Removal steps
"DA 1. Fuel return hose connection "BA 6. O-ring
"CA 2. Fuel pressure hose connection "BA 7. Back-up ring B
"CA 3. O-ring "AA 8. Fuel pump (high pressure)
"BA 4. Fuel feed pipe 9. O-ring
"BA 5. Back-up ring A
4 2
THROTTLE BODY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying D Air Cleaner Removal and Installation
(Refer to GROUP 14 - On-vehicle Service.) (Refer to GROUP 15.)
D Engine Cover Removal and Installation
6
3
5
121 Nm
5.01.0 Nm
182 Nm
141 Nm
2
4
5.01.0 Nm 1
182 Nm
Removal steps
1. Throttle body stay 4. Water hose connection
2. Throttle control servo connector con- "BA 5. Throttle body assembly
nection "AA 6. Throttle body gasket
3. Throttle position sensor connector
connection
Disassembly steps
"AA 1. Throttle position sensor
2. Throttle body
214 Nm
214 Nm 5.01.0 Nm
Removal steps
AA" 1. Injector driver
2. Bracket
5.0 1.0 Nm
10
7
9
5.0 1.0 Nm
4 5
3 2
6
8
9.0 2.0 Nm
Removal steps
1. Cowl side trim 7. Engine-ECU <M/T>, Engine A/T-
2. Instrument panel harness and front ECU <A/T>
door harness connection 8. Throttle valve controller connector
3. Instrument panel harness and front "AA 9. Throttle valve controller
floor harness connection Instrument panel (Refer to GROUP
4. A/T control relay connector <A/T> 52A.)
5. A/T control relay <A/T> 10. Bracket
6. Engine-ECU <M/T>, Engine A/T-
ECU <A/T> connector
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
DRIVE CYCLE
Performing the running test of the car using the following five drive cycle patterns makes it possible to
monitor all the diagnosis codes that are required for operation of the car in order to determine if the
applicable system is operating properly or not.
In other words, doing such a drive allows to regenerate any kind of trouble which involves illuminating the
Engine Warning Lamp (Check Engine Lamp) and to verify the repair procedure has eliminated the trouble
[the Engine Warning Lamp (Check Engine Lamp) is no longer illuminated].
Caution
Two technicians should always be in the vehicle when carrying out a test drive.
NOTE
Check that the diagnosis code is not output before traveling in the Drive cycle pattern. Erase the diagnosis
code if it has been output.
NOTE
The vehicle speed sensor (P0500) and the power steering fluid pressure switch (P0551) are used to
determine if the system is operating properly or not through use of the Data List function of the MUT-II.
15
PROCEDURE 1
monitor item CATALYTIC CONVERTER MONITOR (P0420)
OXYGEN SENSOR <FRONT> MONITOR (P0130)
Drive cycle One trip monitor [from start to ignition switch to LOCK (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 10 minutes or more.
5 minutes or more
60 80 km/h
Vehicle
speed
Time
16
PROCEDURE 2
monitor item FUEL TRIM MONITOR (P0170)
Drive cycle One trip monitor [from start to ignition switch to LOCK (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 15 minutes or more.
15 minutes or more
80 110 km/h
Vehicle
speed
Stopping and
braking permitted
Time
17
PROCEDURE 3
monitor item FEED BACKK MONITOR (P0125)
Drive cycle One trip monitor [from start to ignition switch to LOCK (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 5 minutes or more.
5 minutes or more
Vehicle
speed
Stopping and
braking permitted
Time
18
PROCEDURE 4
monitor item OTHER MONITOR
Diagnosis P0136, P0201, P0202, P0203, P0204, P0205, P0206, P0300, P0301, P0302, P0303, P0304,
code No. P0305, P0306, P0325
Drive cycle One trip monitor [from start to ignition switch to LOCK (OFF) position] will be completed while
pattern traveling with the following drive cycle pattern. It will take 6 minutes or more.
5 minutes or more
60 km/h or more
Vehicle
speed 30 seconds or more
Engine: Idling
Transmission: Neutral
Time
Engine start
Ignition switch LOCK
(OFF) position
Y6009BY
Inspection Engine coolant temperature : 85 C or more
conditions Atmospheric temperature : -10 C or more
Condition of A/T :Selector lever D range, overdrive switch ON position
Test 1. Engine : start
procedure 2. Accelerate until the vehicle speed is 60 km/h.
3. While keeping the accelerator pedal opening degree constant, keep the vehicle speed at 60
km/h or more and travel for 5 minutes or more.
4. Return the vehicle to the shop
5. After stopping the vehicle, continue idling for 30 seconds, and then turn the ignition switch to
LOCK (OFF) position.
A/C switch : OFF
Light and all accessories: OFF
Transmission : Neutral
19
GASOLINE DIRECT
INJECTION (GDI)
CONTENTS
GASOLINE DIRECT
INJECTION (GDI)
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 3
Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3 Oxygen Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION
GENERAL SPECIFICATIONS
Items Specifications
TROUBLESHOOTING
DIAGNOSIS FUNCTION
ENGINE WARNING LAMP (CHECK ENGINE LAMP)
The following item has been added as diagnosis code P1603 has been added. The other items are
the same as before.
22 Crank angle D Engine: Cranking Compare the engine Accord Code 13A-56*
sensor D Tachometer: speed readings on No.
Connected the tachometer and P0335
the MUT-II.
A1L Oxygen Engine: After having When at 4,000 200 mV or less Code 13A-28*
sensor warmed up. (Air/fuel r/min, engine is No.
mixture is made decelerated P0130
leaner when deceler-
deceler
ating, and is made Rev the engine. 600 - 1000 mV
richer when racing.)
Engine: After having Engine is idling Voltage should
warmed up (The (more than 4 alternate between
oxygen sensor signal minutes later after 400 mV or less
is used to check the engine has started) and 600 - 1,200
air/fuel mixture ratio, mV (more than 4
and control condition minutes after the
is also check by the engine has
engine-ECU <M/T> 2,500 r/min started).
or engine-A/T-ECU
<A/T>.)
81L Learned Engine: Warm, 2,500 r/min without any load - 10 - 10 % Code 13A-34*
value (during closed loop lambda control) No.
P0170
82L Closed loop Engine: Warm, 2,500 r/min without any load - 25 - 25 % Code 13A-34*
control (during closed loop lambda control) No.
P0170
2,500 r/min 10 - 30 %
NOTE
L: will not displayed if service data is selected on the check mode.
*: Refer to the 2001 PAJERO Workshop Manual (Pub.No. PWJE0001)
71 Oxygen sensor (front) Engine: Warmed up, and then hold the engine 0 and 0.8 V alternate.
speed at 2,500 r/min (Use a digital voltmeter)
ON-VEHICLE SERVICE
OXYGEN SENSOR CHECK
On A/T, a dual oxygen sensor has been adopted. Its service
procedure is the same as for the previous M/T.
DIESEL FUEL
<4D5>
CONTENTS
GENERAL INFORMATION
The fuel is drawn out of the fuel tank by means Engine speed (fuel injection amount) control is
of the feed pump which is built into the fuel injection carried out by means of a centrifugal-type governor
pump. It then passes through the fuel filter and using a flyweight.
is fed to the injection pump. Fuel injection timing control is carried out by a
The fuel is pressurized by the feed pump, and this hydraulic timer. The hydraulic timer operates by
fuel pressure is controlled by the regulating valve the fuel pressure inside the pump chamber. This
which is built into the pump. Then, the fuel is pressure is controlled by the regulating valve.
compressed by the plunger and injected from the
nozzles at high pressure in accordance with the
injection sequence.
SERVICE SPECIFICATIONS
Items Standard value
SPECIAL TOOL
Tool Number Name Use
MD998388 Injection pump sprocket Fuel injection pump sprocket
puller removal
ON-VEHICLE SERVICE
FUEL INJECTION TIMING CHECK AND
ADJUSTMENT
Refer to GROUP 11B - On-vehicle Service.
ENGINE IDLE SPEED CHECK AND
ADJUSTMENT
Refer to GROUP 11B - On-vehicle Service.
Drain plug
INJECTION NOZZLE
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Battery and Battery Tray Removal D Air Pipe Installation (Refer to GROUP 15.)
D Air Pipe Removal (Refer to GROUP 15.) D Battery and Battery Tray Installation
D Accelerator Cable Adjustment
(Refer to GROUP 17 - On-vehicle Service.)
4.9 1.0 Nm
1
12 2 Nm
27 2 Nm
5 2
6
7
8 4.9 1.0 Nm
2
2
4
9
10 54 5 Nm
30 6 Nm
Removal steps
1. Accelerator cable connection AB" 6. Fuel return pipe
2. Injection pipe clamp 7. Fuel return pipe gasket
AA" 3. Injection pipe AC" 8. Injection nozzle assembly
4. Fuel return hose "AA 9. Holder gasket
AB" 5. Nut "AA 10. Nozzle gasket
Nut
Delivery holder
7
3
2
6
5 38 2 Nm
1
4
Disassembly steps
AA" "AA 1. Retaining nut
2. Nozzle tip
3. Distance piece
4. Retaining pin
5. Pressure ring
6. Shim
7. Nozzle holder body
INJECTION PUMP
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
D Engine Coolant Draining D Air Pipe Installation (Refer to GROUP 15.)
(Refer to GROUP 14 - On-vehicle Service.) D Timing Belt Installation (Refer to GROUP 11B.)
D Battery and Battery Tray Removal D Battery and Battery Tray Installation
D Timing Belt Removal (Refer to GROUP 11B.) D Engine Coolant Supplying
D Air Pipe Removal (Refer to GROUP 15.) (Refer to GROUP 14 - On-vehicle Service.)
D Injection Timing Adjustment
(Refer to GROUP 11B - On-vehicle Service.)
D Accelerator Cable Adjustment
(Refer to GROUP 17 - On-vehicle Service.)
4.9 1.0 Nm
30 6 Nm
30 6 Nm 6
4
4.9 1.0 Nm 12 2 Nm 3
2
5
30 6 Nm
23 3 Nm
1
83 5 Nm 8 19 3 Nm
7
Removal steps
1. Fuel injection pump wiring harness 5. Boost hose connection
2. Water hoses connection AA" 6. Fuel injection pipe
3. Fuel hoses connection AB" 7. Fuel injection pump sprocket
4. Accelerator cable connection 8. Fuel injection pump
Nut
Delivery holder
DIESEL FUEL
<4M4>
CONTENTS
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.
SEALANT
Item Specified sealant
Engine coolant temperature sensor 3M Nut Locking Part No.4171 or equivalent
SPECIAL TOOLS
Tools Number Name Application
MB991502 MUT-II sub Electronically controlled fuel injection system
assembly check
DIAGNOSIS FUNCTION
Engine warning lamp
(check engine lamp) ENGINE WARNING LAMP (CHECK ENGINE LAMP)
Engine warning lamp is lit when any abnormality takes place
in the item related to electronically controlled fuel injection
system shown in the following table.
If the malfunction indicator lamp has been on and/or is lit
when the engine is in operation, check the diagnosis output.
Engine warning lamp check items
Caution
If the the above-mentioned diagnosis code number with the asterisks can be displayed along with
another code number in parentheses simultaneously, check the other code number before replacing
the engine-ECU.
12 (41, 49), 26 (48), 25 (43), 41 (12, 49), 48 (26), 49 (12, 41)
NG
Accelerator pedal position sensor check Replace
(Refer to P.13C-37.)
OK
NG NG
Measure at D-135 accelerator pedal position Check the following connector: D-113 Repair
sensor connector OK
D Disconnect the connector and measure
at the harness side. Check the trouble symptoms.
D Voltage between 2 and earth NG
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V Check the harness between the Repair
D Continuity between 1 and earth engine-ECU and the accelerator pedal
OK: Continuity position sensor connector.
OK
OK
Replace the engine-ECU.
NG NG
Measure at D-113 engine-ECU connector Check the following connectors: Repair
D Connect the connector. D-113, D-135
D Voltage between 84 and the earth OK
(Ignition switch: ON)
OK: 0.9 - 1.1 V Check the trouble symptoms.
(Throttle lever idling position) NG
4.1 V or higher
Replace the engine-ECU.
(Throttle lever fully opened position)
OK
NG
Check the following connector: D-113 Repair
OK
NG NG
Measure at B-08 boost pressure Measure at B-08 boost pressure Check the harness between the
sensor connector sensor connector engine-ECU and the boost pressure
D Connect the connector. D Disconnect the connector and sensor connector.
(Test harness: MB991348 used) measure at the harness side.
OK NG
D Voltage between 1 and the earth D Voltage between 3 and the earth Repair
(Engine: Idling) (Ignition switch: ON)
OK: 1.2 - 1.6 V OK: 4.5 - 5.5 V Replace the engine-ECU.
D Voltage between 1 and the earth D Continuity between 2 and the
OK: When the accelerator pedal earth
is suddenly pressed from OK: Continuity
the idling condition, the OK
voltage temporarily in-
creases from 1.2 V to 1.6
V. Check the following connector: NG
A-120 Repair
OK
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Fuel temperature sensor check (Refer to Replace the injection pump.
P.13C-47.)
OK
NG NG
Measure at B-38 fuel temperature sensor Check the following connectors: Repair
connector D-112, D-113
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 11 and the earth Check the trouble symptoms.
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
Check the harness between the
D Continuity between 7 and the earth Repair
engine-ECU and the fuel temperature
OK: Continuity
sensor connector.
OK
OK
Check the following connector: B-38 Replace the engine-ECU.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Engine coolant temperature sensor check Replace
(Refer to P.13C-38.)
OK
NG NG
Measure at B-36-3 engine coolant sensor Check the following connectors: Repair
connector B-36, D-112, D-113
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
Check the harness between the Repair
D Continuity between 2 and the earth
OK: Continuity engine-ECU and the engine coolant
temperature sensor connector.
OK
OK
Check the following connector: B-36-3 Replace the engine-ECU.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
Code No. 16 Boost air temperature sensor (intake air Probable cause
sensor) system
Range of Check D Boost air temperature sensor inoperative
D Ignition switch:ON, except for during engine cranking D Boost air temperature sensor open circuit, short
Set Conditions circuit, or connector contact inoperative
D The sensor output voltage for 3 seconds is 4.6V or higher (the coolant D Engine-ECU inoperative
temperature is approximately 45 _C or lower).
or
D The sensor output voltage for 3 seconds is 0.3V or lower (the coolant
temperature is approximately 110 _C or higher).
NG
Boost air temperature sensor check Replace
(Refer to P.13C-44.)
OK
NG NG
Measure at B-49 boost air temperature Check the following connectors: Repair
connector D-112, D-113
D Disconnect the connector and measure at
OK
the harness side.
D Voltage between 1 and the earth
Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.0 - 5.3 V NG
D Continuity between 2 and the earth
OK: Continuity NG
Check the harness between the Repair
OK engine-ECU and the boost air temperature
sensor connector.
OK
NO
Is the speed meter working properly? Vehicle speed sensor circuit check
YES
OK NG
Measure at D-113 engine-ECU connector Check the following connector: D-113 Repair
D Connect the connector. OK
D Voltage between 86 and the earth
(Ignition switch: ON) Check the trouble symptoms.
OK: When the vehicle is pushed to NG
move, the cycle change of 0.5 V is
repeated. Replace the engine-ECU.
NG
NG (1) NG
Measure at B-36-2 engine speed Measure at B-36-2 engine speed Check the following connector:
sensor connector sensor connector B-36
D Connect the connector. D Disconnect the connector and
OK NG
(Test harness: MB998348 used) measure at the harness side.
Repair
D Voltage between 2 and the earth (1) Voltage between 3 and the earth
(Engine: cranking) (Ignition switch: ON) (2) NG Check the trouble symptoms.
OK: 0.4 - 4.0 V OK: System voltage
D Voltage between 2 and the earth (2) Voltage between 2 and the earth NG
(Engine: Idling) (Ignition switch: ON)
OK: 1.5 - 2.5 V OK: 4.8 - 5.2V Check and repair the harness
(3) Continuity between 1 and the between the engine speed sensor
OK earth and the control relay connector.
OK: Continuity
Check the following connectors:
B-36, D-112
Replace the engine-ECU.
OK NG
Repair
NG (1) NG
Measure at B-36-1 engine speed Measure at B-36-1 engine speed Check the following connector:
sensor connector sensor connector B-36 OK
D Connect the connector. D Disconnect the connector and
NG
(Test harness: MB998348 used) measure at the harness side.
D Voltage between 2 and the earth (1) Voltage between 3 and the earth Repair
(Engine: cranking) (Ignition switch: ON) Check the trouble symptoms.
OK: 0.4 - 4.0 V OK: System voltage
D Voltage between 2 and the earth (2) Voltage between 2 and the earth NG
(Engine: idling) (Ignition switch: ON)
OK: 1.5 - 2.5 V OK: 4.8 - 5.2V (2) NG Check and repair the harness
(3) Continuity between 1 and the between the engine speed sensor
OK and the control relay connector.
earth
OK: Continuity
NG
Accelerator pedal position sensor check Replace
(Refer to P.13C-43.)
OK
NG NG
Measure at D-135 accelerator pedal position Check the following connectors: Repair
sensor connector D-111, D-112
D Disconnect the connector and measure at
the harness side. OK
D Voltage between 4 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.5 - 5.5 V NG
D Continuity between 5 and the earth NG
OK: Continuity Check the harness between the Repair
engine-ECU and the accelerator pedal
OK position sensor connector.
Check the following connector: D-135 OK
OK NG Replace the engine-ECU.
Repair
Check the trouble symptoms.
NG
NOTE:
*1: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
*2: This voltage is shown as a square wave with a cycle of 66 mircosec (High: 2.5V, Low: 1.25V).
2.5 V
12.5 V
66 microsec
NG
Timer piston position sensor check (Refer to Replace injection pump assembly.
P.13C-47.)
OK
NG NG
Measure at B-39 timer piston position sensor Check the following connector: D-113 Repair
connector OK
D Disconnect the connector and measure at
the harness with an analogue voltmeter. Check the trouble symptoms.
D Voltage between 3 and the earth
(Ignition switch: ON) NG
NG
OK: 2.5 V fixed voltage Repair
D Voltage between 1 and the earth*2 Check the harness between the
(Ignition switch: ON) engine-ECU and the timer piston sensor
OK: Approx. 1.4 - 2.3 V connector.
D Voltage between 2 and the earth*2 OK
OK: Approx. 1.4 - 2.3 V
OK Replace the engine-ECU.
NG
Check the following connector: B-12 Repair
OK
2.5 V
12.5 V
66 microsec
NOTE:
*1: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
*2: This voltage is shown as a square wave with a cycle of 16.7 microsec (High: 2.5V, Low: 1.25V.)
NG
Control sleeve position sensor check (Refer Replace injection pump assembly.
to P.13C-47.)
OK
NG NG
Measure at B-38 injection pump assembly Check the following connector: D-113 Repair
connector OK
D Disconnect the connector and measure at
the harness with an analogue voltmeter. Check the trouble symptoms.
D Voltage between 8 and the earth
(Ignition switch: ON) NG
NG
OK: 2.5 V fixed voltage Repair
D Voltage between 4 and the earth*2 Check the harness between the
(Ignition switch: ON) engine-ECU and the injection pump
OK: Approx. 1.4 - 2.3 V assembly connector.
D Voltage between 12 and the earth*2 OK
OK: Approx. 1.4 - 2.3 V
Replace the engine-ECU.
OK
NG
Check the following connector: B-38 Repair
OK
NG
Accelerator pedal position sensor check Replace
(Refer to P.13C-43.)
OK
NG NG
Measure at D-135 accelerator pedal position Check the following connector: D-112 Repair
sensor connector
D Disconnect the connector and measure at OK
the harness side. Check the trouble symptoms.
D Voltage between 8 and the earth
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
Check the harness between the Repair
D Continuity between 7 and the earth
OK: Continuity engine-ECU and the accelerator pedal
position sensor connector.
OK OK
NG
Check the following connector: D-135 Repair
OK
Check the trouble symptoms.
NG
NG
Main throttle solenoid valve check (Refer to Replace
P.13C-48.)
OK
NG NG
Measure at B-45-2 main throttle solenoid Check the following connector: B-45 Repair
valve connector OK
D Disconnect the connector and measure at
the harness side. Check the trouble symptoms.
D Voltage between 1 and the earth
(Ignition switch: ON) NG
OK: System voltage
Check and repair the harness between the
OK control relay and the solenoid valve
connector.
NG NG
Measure at D-110 engine-ECU connector Check the following connectors: Repair
D Disconnect the connector and measure at B-45, B-45-2
the harness side.
D Voltage between 14 and the earth OK
(Ignition switch: ON)
OK: System voltage Check the trouble symptoms.
OK NG
Check and repair the harness between the
control relay and the solenoid valve
connector.
NG
Check the following connector: D-110 Repair
OK
NG
Timing control valve check (Refer to Replace injection pump assembly.
P.13C-40.)
OK
NG
Measure at B-38 injection pump assembly Check and repair the harness between the
connector. control relay and the injection pump
D Disconnect the connector and measure at assembly connector.
the harness side.
D Voltage between 5 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at D-110 engine-ECU connector. Check the following connector: B-38 Repair
D Disconnect the connector and measure at
the harness side. OK
D Voltage between 3 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK Check and repair the harness between the
engine-ECU and the injection pump
assembly connector.
NG
Check the following connector: D-110 Repair
OK
NG NG
Measure at B-37 injection correction ROM Check the following connectors: Repair
connector. D-112, D-113
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 3 and the earth Check the trouble symptoms.
(Ignition switch: ON)
NG
OK: 4.5 - 5.5 V
D Continuity between 2 and the earth NG
Check and repair the harness between the Repair
OK: Continuity
engine-ECU and the injection correction
OK ROM connector.
OK
NG
Check the following connector: B-37 Repair
OK
Code No. 48 GE actuator (in the middle of control sleeve Probable cause
position sensor inoperative) system
Range of Check D Control sleeve position sensor inoperative
D Ignition switch: ON D GE actuator inoperative
Set Conditions D Control sleeve position sensor open circuit, short
D Target value minus actual value is 1 V or more. circuit, or connector contact inoperative
D Engine-ECU inoperative
NG
GE actuator check (Refer to P.13C-46.) Replace injection pump assembly.
OK
NG NG
Measure at D-110 engine-ECU connector Check the following connector: B-38 Repair
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK Check and repair the harness between the
control relay and the injection pump
assembly connector.
NG
Check the following connector: D-110 Repair
OK
NG
Turbocharger waste gate check (Refer to GROUP 15 - On-vehicle Replace
Service.)
OK
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 encrypted code.
Yes
Is there another ignition key near the ignition key that is inserted Remove the extra ignition key
in the ignition switch?
No
NG
Check the trouble symptoms.
Yes
Is a diagnosis code output from the immobilizer-ECU? Check the immobilizer system. (Refer to GROUP 54 - Ignition
Switch and Immobilizer System.)
No
OK
Check the harness between the engine-ECU and immobilizer-ECU. Replace the engine-ECU and immobilizer-ECU.
NG
Repair
NG NG
Measure at D-23 diagnosis Check the following connector: Repair
connector. D-27, D-210, D-211
D Voltage between 16 and the
earth OK
OK: System voltage
Check the trouble symptoms.
OK NG
NG
Measure at D-23 diagnosis Check and repair the earth line.
connector.
D Continuity between 4 and the
earth
D Continuity between 5 and the
earth
OK: Continuity
OK
Replace MUT-II.
Inspection procedure 2
No communication can be established between MUT-II Probable cause
and the engine-ECU.
Probable causes are shown in the following: D The power supply circuit of the engine-ECU
D The power is not supplied to the engine-ECU. inoperative
D The earth circuit of the engine-ECU inoperative D Engine-ECU inoperative
D The engine-ECU inoperative D Open circuit at the harness between the
D Communication between the engine-ECU and MUT-II inoperative engine-ECU and the diagnosis connector
NG
Check the following connector: D-23, D-33, D-112, E-13, Repair
D-06<Vehicle with the RV multi-meter>
OK
NOTE
If the trouble symptoms persist even after implementing the above-mentioned inspection procedure to
the vehicle with center display, check the center display and replace it if necessary. (Refer to GROUP
54A - Clock or Center display.)
NG
MUT-II Data list The engine-ECU power supply and
11 Engine-ECU power supply voltage the earth circuit check (Refer to
(Refer to P.13C-33.) P.13C-31, Inspection procedure 19.)
OK
OK NG
Measure at D-110 engine-ECU Check the following connector: Repair
connector. D-110
D Disconnect the connector and
measure at the harness side. OK
D Short circuit between 8 and the Check the trouble symptoms.
earth (Ignition switch:ON)
OK: The engine warning lamp turns NG
on.
Replace the engine-ECU.
NG
Inspection procedure 4
The engine warning lamp keeps on and does not turn Probable cause
off.
The probable causes can be found in either the engine-ECU detecting the D Short circuit at the harness between the engine
malfunction in the sensor and/or the actuator, or the problem shown in the right warning lamp and the engine-ECU
takes place. D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
NG
Measure at D-02 combination meter connector. Check and repair the harness between the combination meter
D Disconnect the connector and measure at the harness and the engine-ECU connector.
side.
D Disconnect the engine-ECU connector.
D Continuity between 38 and the earth
OK: No continuity
OK
NG
Check the following connector: E-28 Repair
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
Inspection procedure 5
No initial combustion (unable to start) Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
glow system, and power supply system. D Injection pump inoperative
D Glow system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Check the following items in order:
to P.13C-30, 37.) D Glow plug, glow plug relay
D Battery
NG D Injection nozzle
D Injection pump
Repair D Compression pressure
D Existence of mixing foreign objects (water, kerosene) with
the fuel
Inspection procedure 6
Starting performance is bad when the engine is cold Probable cause
(unable to start)
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, and glow system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Glow system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37) D Glow plug, glow plug relay
D Injection nozzle, fuel filter
NG D Throttle body assembly
D Existence of starter switch signal input
Repair D Engine oil
D Injection pump
D Existence of mixing foreign objects (water, kerosene) with
the fuel
Inspection procedure 7
Starting performance is bad regardless of whether the Probable cause
engine is hot or cold (unable to start)
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, and intake system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Injection nozzle, fuel filter
D Throttle body
NG D Compression pressure
D Injection pump
Repair D Existence of mixing foreign objects (water, kerosene) with
the fuel
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Injection pump
D Fuel filter
NG
Repair
Inspection procedure 9
High idling speed (improper idling speed) Probable cause
Probable causes can be found in troubles with control system and injection D Control system inoperative
pump. D Injection pump inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Injection pump
D Starter switch signal
NG
Repair
Inspection procedure 10
Low idling speed (improper idling speed) Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
and fuel. D Injection pump inoperative
D Fuel system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Injection nozzle
D Injection pump
NG
Repair
Inspection procedure 11
Idling instable (rough idling, hunting) Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, glow system, intake system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Glow system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Glow plug, glow plug relay
D EGR system
NG D Injection nozzle
D Compression pressure
Repair D Valve clearance
D Throttle body assembly
D Injection timing
D Fuel line bleeding
D Injection pump
Inspection procedure 12
The engine stalls after running for a while. Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, and intake system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Throttle body assembly
D Fuel filter
NG D Injection pump
Repair
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Power supply system
D Throttle body assembly
NG D EGR system
D Injection pump
Repair
Inspection procedure 14
Lack of output power Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Injection nozzle, fuel filter
D Throttle body assembly
NG D EGR system
D Turbocharger
Repair D Compression pressure
D Injection timing
D Injection pump
D Existence of mixing foreign objects (water, kerosene) with
the fuel
Inspection procedure 15
Occurrence of abnormal knocking Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Injection nozzle
D Injection timing
NG D EGR system
D Injection pump
Repair
Inspection procedure 16
Abnormal black smoke Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Air cleaner
D Injection nozzle
NG D Throttle body assembly
D EGR system
Repair D Turbocharger
D Injection pump
Inspection procedure 17
Abnormal white smoke Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, EGR system, and glow system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D EGR system inoperative
D Glow system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Glow plug, glow plug relay
D Injection nozzle
NG D Throttle body assembly
D EGR system
Repair D Turbocharger
D Injection pump
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13C-7.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. (Refer Inspect the following items in order:
to P.13C-32, 37.) D Injection nozzle
D Injection pump
NG
Repair
Inspection procedure 19
Engine-ECU power supply and earth circuit check
(1) NG NG
Measure at D-110, D-111, D-112 Check the following connector: Repair
engine-ECU connectors. D-208, D-223, E-13
D Disconnect the connector and
(2), (3) NG OK
measure at the harness side.
(1) Voltage between 82 and the
earth (Ignition switch: ON) Check the trouble symptoms.
OK: System voltage
NG
(2) Voltage between 46 and the NG
earth Check the harness between the Repair
OK: System voltage engine-ECU and the ignition switch.
(3) Voltage between 12, 25 and the
earth (Ignition switch: ON) (4) NG OK
OK: System voltage
(When terminal 62 is short Ignition switch check
circuited to the earth)
(4) Continuity between 13, 26 and (5) NG NG
the earth Check the following connector: Repair
OK: Continuity D-21
(5) Voltage 80 and the earth OK
OK: System voltage NG
Check the trouble symptoms. Check and repair the harness
between the engine-ECU and the
control relay connector.
NOTE
*1: The opening degree of the timing control valve is converted into percentage. (0%: timer non-advanced angle,
100%: timer maximum advanced angle)
*2: The opening degree of the EGR solenoid valve is converted into percentage.
Item Check item Drive Con- Inspection Value to be determined Code No. Reference
No. tents conditions as normal or inspec- page
tion proce-
dure No.
25 GE actuator Turn the GE D Ignition Makes an audible Code 13C-21
actuator to switch: ON sound No.48
ON D Engine
speed:
0 r/min or
26 Turn the GE lower
actuator to D Control
OFF sleeve posi-
tion sensor:
Normal
27 Fuel cut solenoid Turn the D Ignition Makes an audible
valve solenoid switch: ON sound
valve to ON D Vehicle
speed:
0 km/h
28 EGR solenoid Turn the D Ignition Makes an audible
valve No.1 solenoid switch: ON sound
valve to ON D Vehicle
speed:
29 Turn the
0 km/h
solenoid
valve to ON
30 EGR solenoid Turn the D Ignition Makes an audible
valve No.2 solenoid switch: ON sound
valve from D Vehicle
OFF to ON or speed:
from ON to 0 km/h
OFF
33 PTC heater Switch the D Ignition Voltage on the ECU
PTC heater switch: ON terminal No.9: 0 - 1V
relay ON/
OFF.
34 Middle position Hold the D Ignition When the crankshaft Code 13C-21
of GE actuator injection switch: ON is turned clockwise No.48
governor in during the adjustment
its middle of the injection timing,
position. the injection pipes
spray out fuel.
ON-VEHICLE SERVICE
INJECTION TIMING CHECK AND
ADJUSTMENT
Refer to GROUP 11C - Engine Adjustment.
IDLE SPEED CHECK AND ADJUSTMENT
Refer to GROUP 11C - Engine Adjustment.
Accelerator
pedal arm
Accelerator
pedal
Normal condition:
Accelerator pedal Continuity
Step on None
Release Yes
3. Replace APS if it is inoperative.
NOTE
Make an adjustment on APS after replacement.(Refer
to P.13C-42.)
Connector at the
equipment
Fuel cut solenoid Coil resistance check
valve
1. Disconnect the injection pump connector (12 pin).
2. Measure the resistance between terminal No.1 (fuel cut
solenoid valve) and the injection pump body.
Standard value: 6.8 - 9.2 W
Connector at Engine speed sensor (main) Engine speed sensor (main) check
the equipment
1. Disconnect the engine speed sensor connector.
2. Measure the resistance between terminal No.2 and
terminal No.3.
Standard value: 2.15 kW
INJECTION NOZZLE
REMOVAL AND INSTALLATION
Pre-removal Operations Post-installation Operations
D Engine Cover Removal D Skid Plate and Under Cover Installation
(Refer to GROUP 11C - Camshaft.) D Fuel Filter Installation
D Battery and Battery Tray Removal (Refer to GROUP 13D.)
D Fuel filter removal D Battery and Battery Tray Installation
(Refer to GROUP 13D.) D Fuel Line Bleeding (Refer to P.13C-45.)
D Skid Plate and Under Cover Removal D Engine Cover Installation
(Refer to GROUP 11C - Camshaft.)
10 11
13 2 Nm
21 2 Nm 9
8
11
(Engine oil)
6
3
14
7
12
31 1 Nm
13
(Engine oil) 5
3
31 1 Nm
3
4
(Transmission fluid)
1
2
(Engine oil) 22 4 Nm
44 8 Nm
Removal steps
1. Engine oil level gauge and guide 9. Fuel return pipe gasket
2. A/T oil level gauge and guide D Rocker cover
3. Clamp (Refer to GROUP 11C - Camshaft.)
4. Injection pipe stay 10. Fuel leak off pipe
AA" "CA 5. Injection pipe 11. Fuel leak off pipe gasket
"CA 6. Injection pipe seal AB" 12. Injection nozzle assembly
"BA 7. Fuel return hose "AA 13. Nozzle gasket
8. Fuel return pipe "AA 14. Injection nozzle
Nut
Delivery holder
15 mm
15 10
8
14 7
6
13
3 5
12
11 4
2
345 Nm
Disassembly steps
AA" "AA 1. Retaining nut 9. Second spring
2. Nozzle 10. Push rod
3. Needle valve 11. Collar
4. Pin 12. Spring seat
5. Spacer 13. First spring
6. Lift piece 14. Shim
7. Spring seat 15. Nozzle holder
8. Shim
Push rod
DISASSEMBLY SERVICE POINT
157992 - 2820 AA" RETAINING NUT REMOVAL
Use the special tool to remove the retaining nut.
Caution
A 1. Never touch the A part of the needle valve.
Needle valve
2. Always handle the needle valve and the nozzle as
a set per cylinder.
Push rod
REASSEMBLY SERVICE POINT
157992 - 2820 "AA RETAINING NUT INSTALLATION
Use the special tool to install the retaining nut.
Caution
A 1. Never touch the A part of the needle valve.
Needle valve
2. Always handle the needle valve and the nozzle as
a set per cylinder.
INJECTION PUMP
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
D Removal and Installation Of Engine Cover D Removal and Installation of Intercooler Hose
(Refer to GROUP 11C - Camshaft.) (Refer to GROUP 15.)
D Removal and Installation of Battery and Battery Tray D Removal and Installation of Glow Plug Relay and
D Removal and Installation of Injection Pipe Solenoid Valve Assembly
(Refer to P.13C-50.) D Removal and Installation of Vacuum Pump
D Removal and Installation of Air Cleaner (Refer to (Refer to GROUP 11C.)
GROUP 15.)
7
18 2 Nm
5.0 1.0 Nm
10 9
4
3
8
15
1
2
(Engine oil)
1
6 5.0 1.0 Nm
14
13
11 12
Removal steps
1. Injection pump connector "BA 9. Fuel main hose
2. Engine speed sensor connector 10. Injection pump stay
3. Engine speed sensor 1 connector 11. Injection pump cover assembly
4. Engine speed sensor 1 12. Insulator collar
5. Engine speed sensor 2 connector 13. Insulator
6. Engine speed sensor 2 14. Injection pump cover
"CA 7. Fuel return hose AA" "AA 15. Injection pump assembly
"BA 8. Fuel return hose
25 - 32 mm
15 mm
(Engine oil)
1.5 0.5 Nm
38 2 Nm
180 10 Nm
3
2
Disassembly steps
AA" 1. Injection pump gear assembly 4. Key
2. Sensor plate 5. Injection pump
3. Flange plate
ENGINE-ECU
REMOVAL AND INSTALLATION
1
5.0 1.0 Nm
10
5.0 1.0 Nm
7 5
4
9
5.0 1.0 Nm
6 3
2
5.0 1.0 Nm
Removal steps
1. Cowl side trim (LH) 6. A/T-ECU connector
2. Joint of the instrument panel harness 7. A/T-ECU
and front door harness (LH) 8. Engine-ECU connector
3. Joint of the instrument panel harness 9. Engine-ECU
and floor harness (LH) D Instrument panel
4. A/T control relay connector (Refer to GROUP 52A.)
5. A/T control relay 10. ECU bracket
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
CORRECTION INTERNATIONAL
CAR
ADMINISTRATION T.NITTA - PROJECT LEADER
OFFICE AFTER SALES SERVICE & CS PROMOTION
1. Description:
On the 4M41 engine equipped vehicles, incorrect description of the injection pump installation
given under INSTALLATION SERVICE POINTS has been corrected.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)
2001 PAJERO PWJE0001 (1/2) (English) 13C-56, 57
Workshop Manual VOL1
2001 MONTERO PWJS0002 (1/2) (Spanish)
Workshop Manual VOL1
INJECTION PUMP
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Removal and installation Of Engine Cover Removal and Installation of Intercooler Hose
(Refer to GROUP 11C - Camshaft.) (Refer to GROUP 15.)
Removal and Installation of Battery and Battery Tray Removal and Installation of Glow Plug Relay and
Removal and Installation of Injection Pipe Solenoid Valve Assembly <Incorrect>
(Refer to P. 13C 50.) Removal and Installation of Vacuum Pump
Removal and Installation of Air Cleaner (Refer to (Refer to GROUP 11C.)
GROUP 15.) <Incorrect>
11C Vacuum Pump Power Steering Oil
<Correct> <Correct>
(Engine oil)
Removal steps
1. Injection pump connector B 9. Fuel main hose
2. Engine speed sensor connector 10. Injection pump stay
3. Engine speed sensor 1 connector 11. Injection pump cover assembly
4. Engine speed sensor 1 12. Insulator collar
5. Engine speed sensor 2 connector 13. Insulator
6. Engine speed sensor 2 14. Injection pump cover
C 7. Fuel return hose A A 15. Injection pump assembly
B 8. Fuel return hose
<Correct>
4. Remove the drain plug.
<Incorrect
5. Remove the bolt, which has been installed in
Step 1, from the drain plug mounting hole.
6. Install the drain plug.
YO148CA
<Correct>
X1202CA
Drain plug
AY0372CA
DIESEL FUEL
<4M4>
CONTENTS
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE SPECIFICATIONS
Item Standard value
at 50 - 100_C 12 - 23
TROUBLESHOOTING
FAIL-SAFE, BACKUP FUNCTIONS
When abnormalities in the major sensors are detected by diagnosis functions, pre-set control logic operates
to maintain a safe driving condition for the vehicle.
Accelerator pedal position sensor D Accelerator pedal released (idle switch ON)
Acceleration opening degree = 0 %
D Accelerator pedal applied (idle switch OFF)
Engine controlled at low speed
Acceleration opening degree = 40 % <M/T>, 28 % <A/T>
D Void cruise control
Boost air temperature sensor Maintain the intake air temperature at 50_C
Engine coolant temperature sensor Maintain the engine coolant temperature at 80_C (engine running), 0_C
(engine stopped or just started)
Control sleeve position sensor D With accelerator pedal released (when idle switch is on)
Engine speed = 800 r/min
D With accelerator pedal depressed (when idle switch is off)
Engine speed = 2,000 r/min
D Void cruise control
Barometric pressure sensor (ECU built-in) Keep the barometric pressure at 101 kPa
Boost pressure sensor D Keep the boost pressure as barometric pressure (101 kPa)
D Void cruise control
Injection correction ROM D When backup data is normal: Correction calculation using backup
data
D When backup data is corrupted: Fixed at correction value 0 %
48 GE actuator (in the middle of control sleeve position sensor inoperative) system 13C-7
Code No. 23 Idle switch (accelerator pedal position sensor Probable cause
built-in) system
Range of Check D Accelerator pedal position sensor inoperative
Ignition switch: ON, accelerator pedal position sensor (main, sub) operative, D Accelerator pedal position sensor open circuit,
except for during engine cranking short circuit, or connector contact inoperative
Set Conditions D Idle switch ON inoperative
D Idle switch (built-in): ON, accelerator pedal position sensor (main, sub) output D Idle switch signal line short circuit
voltage for 0.8 second 1.875 V or higher D Engine-ECU inoperative
D Idle switch (built-in): OFF, accelerator pedal position sensor (main, sub)
opening degrees less than 1 %
NG
Throttle body assembly check (P.13C-12.) Repair
OK
NG NG
Measure at throttle body assembly connector Check the following connector: B-25X Repair
B-65.
OK
D Ignition switch: ON
D Disconnect the connector and measure at Check the trouble symptoms.
the harness side.
D Voltage between (2), (5) and earth NG
OK: System voltage
Check and repair the harness between the
OK control relay and the throttle body assembly
connector.
NG NG
Measure at engine-ECU connector D-110. Check the following connector: B-65 Repair
D Ignition switch: ON OK
D Disconnect the connector and measure at
the harness side. Check the trouble symptoms.
D Voltage between (14), (18), (19), (20) and
earth NG
OK: 9 V or more
Check and repair the harness between the
OK engine-ECU and the throttle body assembly
connector.
NG
Check the following connector: D-110 Repair
OK
NG
GE actuator check (Refer to Replace injection pump assembly.
P.13C-46.*)
OK
NG
Measure at B-38 injection pump Check and repair the harness
assembly connector. between the control relay and the
D Disconnect the connector and injection pump assembly connector.
measure at the harness side.
D Voltage between 6 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG
Check the following connector: Repair
D-110
OK
NOTE:
*: Refer to the 2001 PAJERO Workshop Manual (Pub. No. PWJE0001).
OK
MUT-II data list Transient malfunction (Refer to
31 EGR sensor (Target value) GROUP 00 - Point to Note for
32 EGR sensor (Output value) Intermittent Malfunctions.)
NG
NG NG
Measure at EGR valve assembly Check the following connector: Repair
connector B-64. D-112
D Disconnect the connector and
OK
measure at the harness side.
OK
D Voltage between (3) and earth
Check the trouble symptoms. Transient malfunction (Refer to
OK: 4.5 - 5.5 V
(Ignition switch: ON) NG GROUP 00 - Point to Note for
D Continuity between (2) and earth Intermittent Malfunctions.)
OK: Continuity Check and repair the harness
between the engine-ECU and the
OK EGR valve assembly connector.
NG NG
Measure at engine-ECU connector Check the following connector: Repair
D-113. D-113
D Connector connected
OK
D Ignition switch: ON
OK
D Voltage between (90) and earth
Check the trouble symptoms. Transient malfunction (Refer to
OK: 0.5 - 4.5 V
NG GROUP 00 - Point to Note for
OK Intermittent Malfunctions.)
Check and repair the harness
between the engine-ECU and the
EGR valve assembly connector.
NG NG
Measure at EGR valve assembly Check the following connector: Repair
connector B-64. B-25X
D Ignition switch: ON
OK
D Disconnect the connector and
OK
measure at the harness side.
Check the trouble symptoms. Transient malfunction (Refer to
D Voltage between (6) and earth
OK: System voltage NG GROUP 00 - Point to Note for
Intermittent Malfunctions.)
OK Check and repair the harness
between the control relay and the
To the next page EGR valve assembly connector.
NG
Check the following connector: Repair
D-113
OK
OK
Check the trouble symptoms. Transient malfunction (Refer to
NG GROUP 00 - Point to Note for
Intermittent Malfunctions.)
Replace the EGR valve assembly.
OK
Check the trouble symptoms. End
NG
Yes
MUT-II diagnosis code Diagnosis code classification chart (Refer to P.13C-3.)
Is a diagnosis code output?
No
OK
Carry out MUT-II service data inspection and actuator test. (Refer Check for seizure of throttle body assembly (stuck open)
to P.13C-10.) (Refer to P.13C-42*.)
NG
Repair
NOTE:
*: Refer to the 2001 PAJERO Workshop Manual (Pub. No. PWJE0001).
31 EGR sensor Engine: Racing Changes between 0.5 Code No. 51 13C-8
(Target value) V and 4.5 V
33 A/C load signal Engine: Idle During weak cooling or System voltage
A/C switch: ON heating
41 Select switch <M/T> Ignition switch: Move shift lever to 4st or System voltage
ON (Engine stops) R
42 1st - 2nd switch <M/T> Ignition switch: Move shift lever to 1st or System voltage
ON (Engine stops) 2nd
43 3rd - 4th switch <M/T> Ignition switch: Move shift lever to 3rd or System voltage
ON (Engine stops) 4th
4-5
5-6
7
18 2 Nm
5.0 1.0 Nm
10 9
3 16 11
4 8
(Engine oil)
1 2
1
6
5
5.0 1.0 Nm
15
14
12 13
Removal steps
1. Injection pump connector "BA 9. Fuel main hose
2. Engine speed sensor connector 10. Injection pump stay
3. Engine speed sensor 1 connector 11. Intake manifold cover
4. Engine speed sensor 1 12. Injection pump cover assembly
5. Engine speed sensor 2 connector 13. Insulator collar
6. Engine speed sensor 2 14. Insulator
"CA 7. Fuel return hose 15. Injection pump cover
"BA 8. Fuel return hose AA" "AA 16. Injection pump assembly
Drain plug
25 - 32 mm
15 mm
FUEL SUPPLY
Click on the applicable bookmark to selected the required model year.
FUEL SUPPLY
CONTENTS
GENERAL INFORMATION
The fuel tank is located under the floor below the The high-pressure fuel hose is of an one-touch
rear seats. joint type.
The fuel pump module contains a fuel pump
(low-pressure), fuel filter and fuel pressure regulator
(low-pressure).
The valve assembly contains a cut-off valve, which
prevents fuel to flow out, and a two-way valve,
which regulates the fuel pressure inside the fuel
tank.
9 10
2
6 11
8
7
4
5
26 4 Nm
26 4 Nm
26 4 Nm
Removal steps 7. Fuel tank band, front
1. Fuel tank under protector 8. Fuel tank band, rear
2. Fuel filler hose connection 9. Fuel tank breather hose connection
3. Fuel return hose connection AA" 10. Fuel tank harness connector con-
4. Fuel vapor hose connection nection
5. Fuel return hose connection AA" 11. Fuel tank assembly
"AA 6. Fuel high-pressure hose connection
27
26
28 2.5 0.4 Nm
2.5 0.4 Nm
12 22 25
13
34
22 4 Nm
21
33
14
35
38
36
37
42
40
41
43
39
<LONG WHEELBASE>
1. Tumble the second seat.
Fuel gauge unit 2. Remove the service hole cover (upper side) and the
packing located under the second seat.
3. Remove the second seat, the rear scuff plate, the anchor
bolts for the outer seat belt (second) and mounting screws
Harness connector of the lower quarter trim. Tear off the carpet. (Refer to
GROUP 52A.)
4. Remove the service hole cover and the packing located
between the front seat and the second seat.
5. Disconnect the harness connector.
6. Unscrew the mounting nut to remove the fuel gauge unit.
7. Assemble the fuel gauge unit and tighten the mounting
nut to the specified torque.
Tightening torque : 2.5 0.4 Nm
8. Connect the harness connector.
9. Attach the service hole cover and the packing located
between the front seat and the second seat.
10. Restore the carpet; attach the second seat, the rear scuff
plate, anchor bolts for the outer seat belt (second) and
mounting screws of the lower quarter trim.
(Refer to GROUP 52A.)
11. Attach the service hole cover located under the second
seat and the packing.
12. Restore the second seat.
11
5
8
10
4
9
3
10
9
2 8
4
11
6
5
3
26 4 Nm
26 4 Nm
26 4 Nm
20 19 2.5 0.4 Nm
23
21
2.5 0.4 Nm 22
24
16
2.5 0.4 Nm
17
18 15
14
2.5 0.4 Nm
15
12
25
26
13 22 4 Nm
27
41
28 30
40
39
36
29
38 33
37
34
35
32
42
31
<LONG WHEELBASE>
1. Tumble the second seat.
Fuel gauge unit 2. Remove the service hole cover (upper side) and the
packing located under the second seat.
3. Remove the second seat, the rear scuff plate, the anchor
bolts for the outer seat belt (second) and mounting screws
Harness connector of the lower quarter trim. Tear off the carpet. (Refer to
GROUP 52A.)
4. Remove the service hole cover and the packing located
between the front seat and the second seat.
5. Disconnect the harness connector.
6. Unscrew the mounting nut to remove the fuel gauge unit.
7. Assemble the fuel gauge unit and tighten the mounting
nut to the specified torque.
Tightening torque : 2.5 0.4 Nm
8. Connect the harness connector.
9. Attach the service hole cover and the packing located
between the front seat and the second seat.
10. Restore the carpet; attach the second seat, the rear scuff
plate, anchor bolts for the outer seat belt (second) and
mounting screws of the lower quarter trim.
(Refer to GROUP 52A.)
11. Attach the service hole cover located under the second
seat and the packing.
12. Restore the second seat.
<4D5>
6.0 1.0 Nm
6
7
14 1 Nm
2 3
5
2.5 0.5 Nm
1 4
<4M4>
3
2
1
11
5
12
6.0 1.0 Nm
9
10
14 1 Nm
4 6
8
2.5 0.5 Nm
1 7
ON
OFF
- 31 5 - 18 5 (kPa)
DIESEL FUEL
<4D5-STEP III>
Click on the applicable bookmark to selected the required model year.
DIESEL FUEL
<4D5-STEP III>
CONTENTS
Vacuum pump
l5 Throttle solenoid valve
l3 l7
EGR control Variable geometry Alternator
solenoid valve No. 1 solenoid valve
Throttle
actuator
To variable
geometry actuator L7 Control
Boost air sleeve
L6 l4 EGR control L4 Boost pressure
temperature sensor solenoid position L5 Fuel
sensor
valve No. 2 sensor temperature
L3 Engine coolant sensor
temperature sensor
L9 EGR L1 Pump speed
valve position l6 Fuel cut sensor
sensor solenoid
valve
EGR valve
Variable geometry
turbocharger
l1 GE actuator
L10 Variable geometry control
pressure sensor L8 Timer piston
To variable geome- l2 Timing control position
Variable try solenoid valve valve sensor
L2 Crank angle
geometry sensor
actuator
Catalytic converter
SEALANT
Item Specified sealant
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent
MB990767 End yoke holder Holding the fuel injection pump sprocket
Caution
If the above-mentioned diagnosis code number with the asterisks can be displayed along with another
code number in parentheses simultaneously, check the other code number before replacing the
engine-ECU.
12 (41, 49), 26 (48), 25 (43), 41 (12, 49), 48 (26), 49 (12, 41)
NG
Accelerator pedal position sensor check Replace
(Refer to P.13E-57.)
OK
NG NG
Measure at D-135 accelerator pedal position Check the following connector: D-113 Repair
sensor connector OK
D Disconnect the connector and measure
at the harness side. Check the trouble symptoms.
D Voltage between 2 and earth NG
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V Check the harness between the Repair
D Continuity between 1 and earth engine-ECU and the accelerator pedal
OK: Continuity position sensor connector.
OK
OK
Replace the engine-ECU.
NG NG
Measure at D-113 engine-ECU connector Check the following connectors: Repair
D Connect the connector. D-113, D-135
D Voltage between 84 and the earth OK
(Ignition switch: ON)
OK: 0.9 - 1.1 V Check the trouble symptoms.
(Throttle lever idling position) NG
4.1 V or higher
(Throttle lever fully opened position) Replace the engine-ECU.
OK
NG
Check the following connector: D-113 Repair
OK
NG
Check the harness between the Repair
engine-ECU and the accelerator pedal
position sensor connector.
OK
NG NG
Measure at B-08 boost pressure Measure at B-08 boost pressure Check the following connector:
sensor connector sensor connector D- 112
D Connect the connector. D Disconnect the connector and
(Test harness: MB991348 used) measure at the harness side. OK NG
D Voltage between 1 and the earth D Voltage between 3 and the earth Repair
(Engine: Idling) (Ignition switch: ON)
Check the trouble symptoms.
OK: 1.3 - 1.7 V OK: 4.5 - 5.5 V
D Voltage between 1 and the earth D Continuity between 2 and the NG
OK: When the accelerator pedal earth
is suddenly pressed from OK: Continuity
the idling condition, the Check
Replacethetheharness between the
engine-ECU.
OK
voltage temporarily in- engine-ECU and the boost pressure
creases from 1.3 V to 1.7 sensor connector.
V. Check the following connector: NG NG
B-08 Repair OK Repair
OK
OK
Replace the engine-ECU.
Check the trouble symptoms.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Fuel temperature sensor check (Refer to Replace the injection pump.
P.13E-61.)
OK
NG NG
Measure at B-38 fuel temperature sensor Check the following connectors: Repair
connector D-112, D-113
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 11 and the earth Check the trouble symptoms.
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
Check the harness between the
D Continuity between 7 and the earth Repair
engine-ECU and the fuel temperature
OK: Continuity
sensor connector.
OK
OK
Check the following connector: B-38 Replace the engine-ECU.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Engine coolant temperature sensor check Replace
(Refer to P.13E-59.)
OK
NG NG
Measure at B-56 engine coolant temperature Check the following connectors: Repair
sensor connector D-112, D-113
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON) NG
OK: 4.1 - 4.9 V NG
D Continuity between 2 and the earth Check the harness between the Repair
OK: Continuity engine-ECU and the engine coolant
temperature sensor connector.
OK
OK
Check the following connector: B-56 Replace the engine-ECU.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
Code No. 16 Boost air temperature sensor (intake air Probable cause
sensor) system
Range of Check D Boost air temperature sensor inoperative
D Ignition switch: ON, except for during engine cranking D Boost air temperature sensor open circuit, short
Set Conditions circuit, or connector contact inoperative
D The sensor output voltage for 3 seconds is 4.6 V or higher (the intake air D Engine-ECU inoperative
temperature is approximately - 45_C or lower).
or
D The sensor output voltage for 3 seconds is 0.3 V or lower (the intake air
temperature is approximately 110_C or higher).
NG
Boost air temperature sensor check Replace
(Refer to P.13E-58.)
OK
NG NG
Measure at B-49 boost air temperature Check the following connectors: Repair
connector D-112, D-113
D Disconnect the connector and measure at
OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.0 - 5.3 V NG
D Continuity between 2 and the earth
OK: Continuity NG
Check the harness between the Repair
OK engine-ECU and the boost air temperature
sensor connector.
OK
NO
Is the speedometer working properly? Check the vehicle speed sensor circuit.
YES
OK NG
Measure at engine-ECU connector D-113. Check the following Repair
D Disconnect the connector. connector:
D Voltage between terminal 86 and earth (Ignition switch: ON) D- 113
OK: When the vehicle is pushed to move, the cycle change OK
of 0.5 V is repeated.
Check trouble symptoms.
NG
NG
NG
Check the following connectors: Repair Replace the engine-ECU.
C-09, D-113, E-113
OK
NG
Check trouble symptom. Check the harness wire between the engine-ECU and the vehicle
speed sensor connector, and repair if necessary.
NG
Pump speed sensor check (Refer to Replace the injection pump.
P.13E-62.)
OK
NG NG
Measure at engine-ECU connector D-112. Check the following connector: Repair
D Connect the connector. B-36, D-112
D Voltage between 51 - 61. OK
(Engine: idling and then raced)
OK: Voltage increases from the voltage Check the trouble symptoms.
when engine is idling
NG
OK
Check the harness between the
Check the following connector: D-112 engine-ECU and the pump speed sensor
OK NG connector, and repair if necessary.
Repair
Check trouble symptoms.
NG
NG (1) NG
Measure at crank angle sensor Measure at crank angle sensor Check the harness between the
connector B-52. connector B-52. crank angle sensor and the engine
D Connect the connector. D Disconnect the connector and control relay, and repair if necessary.
(Test harness: MB998478 used) measure at the harness side.
D Voltage between 2 (black clip) (1) Voltage between 3 and the earth (2) NG
Check the following connector:
and the earth (Ignition switch: ON)
D-113
OK: 0.4 - 4.0 V OK: System voltage
(Engine: cranking) (2) Continuity between 2 and the OK NG
1.5 - 2.5 V earth (Ignition switch: ON) Repair
(Engine: idling) OK: 4.6 - 5.4 V
(3) Continuity between 1 and the Check the trouble symptoms.
OK earth NG
OK: Continuity
Check the harness between the
Replace the engine-ECU. (3) NG engine-ECU and the crank angle
sensor.
OK OK NG
Repair
Check the following connector:
B-52 Replace the engine-ECU.
OK NG
Repair
Check the harness between the
Check the trouble symptoms. crank angle sensor and the earth,
and repair if necessary.
NG
Replace the crank angle sensor.
NG
Idle switch check (Refer to P.13E-58.) Replace
OK
NG NG
Measure at D-135 accelerator pedal position Check the following connectors: Repair
sensor connector D-111, D-112
D Disconnect the connector and measure at
the harness side. OK
D Voltage between 4 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.5 - 5.5 V NG
D Continuity between 5 and the earth NG
OK: Continuity Check the harness between the Repair
engine-ECU and the accelerator pedal
OK position sensor connector.
Check the following connector: D-135 OK
OK NG Replace the engine-ECU.
Repair
Check the trouble symptoms.
NG
NOTE:
*: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
NG
Timer piston position sensor check Replace injection pump assembly.
(Refer to P.13E-62.)
OK
NG NG
Check the following connector: B-39 Check the following connector: D-113 Repair
OK OK
NG
MUT-II Data list Replace the engine-ECU.
19 Injection timing (command value)
(Refer to P.13E-41.)
OK
OK
MUT-II Data list Replace the engine-ECU.
18 Actual injection timing (Refer to
P.13E-41.)
NG Check the trouble symptoms.
NG
NOTE:
*: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
NG
Control sleeve position sensor check (Refer Replace injection pump assembly.
to P.13E-62.)
OK
NG NG
Check the following connector: B-38 Check the following connector: D-113 Repair
OK OK
NG
Accelerator pedal position sensor check Replace
(Refer to P.13E-57.)
OK
NG NG
Measure at D-135 accelerator pedal position Check the following connector: Repair
sensor connector D-112
D Disconnect the connector and measure at
the harness side. OK
D Voltage between 8 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.5 - 5.5 V NG
D Continuity between 7 and the earth NG
Check the harness between the Repair
OK: Continuity
engine-ECU and the accelerator pedal
OK position sensor connector.
OK
NG
Check the following connector: D-135 Repair
OK
Check the trouble symptoms.
NG
NG
Throttle solenoid valve check Replace
(Refer to P.13E-62.)
OK
NG
Throttle actuator check Replace
(Refer to P.13E-63.)
OK
NG
Measure at B-62 throttle solenoid valve Check and repair the harness between the
connector control relay and the solenoid valve
D Disconnect the connector and measure at connector.
the harness side.
D Voltage between 2 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at D-110 engine-ECU connector Check the following connector: Repair
D Disconnect the connector and measure at B-62
the harness side.
D Voltage between 14 and the earth OK
(Ignition switch: ON)
OK: System voltage Check the trouble symptoms.
OK NG
NG
Timing control valve check Replace injection pump assembly.
(Refer to P.13E-61.)
OK
NG
Measure at B-38 injection pump assembly Check and repair the harness between the
connector. control relay and the injection pump
D Disconnect the connector and measure at assembly connector.
the harness side.
D Voltage between 5 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at D-110 engine-ECU connector. Check the following connector: B-38 Repair
D Disconnect the connector and measure at
OK
the harness side.
D Voltage between 3 and the earth
Check the trouble symptoms.
(Ignition switch: ON)
OK: 11 V or higher NG
OK
Check and repair the harness between the
engine-ECU and the injection pump
assembly connector.
NG
Check the following connector: D-110 Repair
OK
NG
Fuel system blockage check Replace
D Fuel filter blocked
D Fuel hose blocked or bent
D Fuel tank filter blocked
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
NG NG
Measure at B-37 injection volume adjusting Check the following connector: D-112 Repair
ROM connector.
OK
D Disconnect the connector and measure at
the harness side.
Check the trouble symptoms.
D Voltage between 3 and the earth
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
D Continuity between 4 and the earth Check the harness between the Repair
OK: Continuity engine-ECU and the injection volume
adjusting ROM connector.
OK
OK
NG
GE actuator check (Refer to P.13E-61.) Replace injection pump assembly.
OK
NG
Measure at B-38 injection pump assembly Check and repair the harness between the
connector. control relay and the injection pump
D Disconnect the connector and measure at assembly connector.
the harness side.
D Voltage between 6 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at D-110 engine-ECU connector Check the following connector: B-38 Repair
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 9 V or higher NG
OK Check and repair the harness between the
control relay and the injection pump
assembly connector.
NG
Check the following connector: D-110 Repair
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Variable geometry actuator check (Refer to Replace
GROUP 15 - On-vehicle Service.)
OK
NG
Variable geometry solenoid valve check Replace
(Refer to GROUP 15 - On-vehicle Service.)
OK
NG
Measure at B-61 variable geometry solenoid Check and repair the harness between the
valve connector control relay and the solenoid valve
D Disconnect the connector and measure at connector.
the harness side.
D Voltage between 2 and earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at D-110 engine-ECU connector Check the following connector: B-61 Repair
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 17 and earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK Check and repair the harness between the
engine-ECU and the solenoid valve
connector.
NG
Check the following connector: D-110 Repair
OK
YES
Connect a boost gauge to the boost Replace the turbocharger assembly.
pressure sensor hose. When the vehicle is
driven at 1st gear with full throttle, does
boost pressure exceed 133 kPa
momentarily?
NO
NG
NG
EGR valve position sensor check Replace
(Refer to P.13E-60.)
OK
NG NG
Measure at B-66 EGR valve position sensor Check the following connector: D-112 Repair
connector.
OK
D Disconnect the connector and measure at
the harness side.
Check the trouble symptoms.
D Voltage between 2 and earth
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
D Continuity between 3 and earth Check the harness between the Repair
OK: Continuity engine-ECU and the EGR valve position
sensor connector.
OK
OK
NG NG
Measure at B-63 variable geometry Measure at B-63 variable geometry Check the following connector:
control pressure sensor connector. control pressure sensor connector D-112
D Connect the connector. D Disconnect the connector, and OK NG
(Use the test harness: measure at the harness side. Repair
MB991348) D Voltage between 3 and earth Check the trouble symptoms.
D Voltage between 1 and earth (Ignition switch: ON)
(Ignition switch: ON) OK: 4.8 - 5.2 V NG
OK: Altitude 0 m: 3.7 - 4.3 V D Continuity between 2 and earth
Check the harness between the
Altitude 1,200 m: 3.2 - 3.8 OK: Continuity
engine-ECU and the variable
V
OK geometry control pressure sensor
OK: 0.5 - 1.2 V when 80 kPa
connector.
of negative pressure is ap-
plied to the sensor OK NG
Repair
OK
Replace the engine-ECU.
NG
Check the following connector: Repair
B-63
OK
NG
Check the trouble symptoms. Check the harness between the
engine-ECU and the variable
NG geometry control pressure sensor
Measure at D-111 engine-ECU Check the following connector: connector.
connector B-63
D Connect the connector. OK NG
OK NG Repair
D Voltage between 45 and earth.
Repair
(Ignition switch: ON) Check the vacuum hose and pipe
OK: Altitude 0 m: 3.7 - 4.3 V Check the trouble symptoms. between the variable geometry
Altitude 1,200 m: 3.2 - 3.8 control pressure sensor and
NG
V alternator.
OK: 0.5 - 1.2 V when 80 kPa Check the harness between the OK NG
of negative pressure is ap- engine-ECU and the variable Repair
plied to the sensor geometry control pressure sensor Replace the variable geometry
OK connector, if necessary. control pressure sensor.
NG
Check the following connector:
Repair
D-111
OK
NG
Check the trouble symptoms. Replace the 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 encrypted code.
Yes
Is there another ignition key near the ignition key that is inserted Remove the extra ignition key
in the ignition switch?
No NG
Check the trouble symptoms.
OK
Check the harness between the engine-ECU and immobilizer-ECU. Replace the engine-ECU and immobilizer-ECU.
NG
Repair
Engine warning lamp Immediately after the ignition switch is ON, the engine 3 13E-30
related warning lamp does not turn on.
The engine warning lamp keeps on and does not turn off. 4 13E-30
Idling stability Low idling speed when the engine is cold (improper idling 8 13E-32
(idling inoperative) speed)
Idling stability The engine halts after running for a while. 12 13E-33
(idling sustainment in-
in
operative) The engine halts during idling. 13 13E-34
NG NG
Measure at D-23 diagnosis Check the following connectors: Repair
connector. D-27, D-211, D-210
D Voltage between 16 and the
earth OK
OK: System voltage
Check the trouble symptoms.
OK NG
NG
Measure at D-23 diagnosis Check and repair the earth line.
connector.
D Continuity between 4 and the
earth
D Continuity between 5 and the
earth
OK: Continuity
OK
Replace MUT-II.
INSPECTION PROCEDURE 2
No communication can be established between MUT-II Probable cause
and the engine-ECU.
Probable causes are shown in the following: D The power supply circuit of the engine-ECU
D The power is not supplied to the engine-ECU. inoperative
D The earth circuit of the engine-ECU inoperative D Engine-ECU inoperative
D The engine-ECU inoperative D Open circuit at the harness between the
D Communication between the engine-ECU and MUT-II inoperative engine-ECU and the diagnosis connector
NOTE
If the trouble symptoms persist even after implementing the above - mentioned inspection procedure
to the vehicle with center display, check the center display or the RV meter and replace it if necessary.
(Refer to GROUP 54A - Clock or Center display.)
NG
MUT-II Data list The engine-ECU power supply and
11 Engine-ECU power supply voltage the earth circuit check (Refer to
(Refer to P.13E-41.) P.13E-37, Inspection procedure 20.)
OK
OK NG
Measure at D-110 engine-ECU Check the following connector: Repair
connector. D-110
D Disconnect the connector and OK
measure at the harness side.
D Short circuit between 8 and the Check the trouble symptoms.
earth (Ignition switch: ON)
OK: The engine warning lamp turns NG
on.
NG Replace the engine-ECU.
INSPECTION PROCEDURE 4
The engine warning lamp keeps on and does not turn Probable cause
off.
The probable causes can be found in either the engine-ECU detecting the D Short circuit at the harness between the engine
malfunction in the sensor and/or the actuator, or the problem shown in the right warning lamp and the engine-ECU
takes place. D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
NG
Measure at D-02 combination meter connector. Check and repair the harness between the combination meter
D Disconnect the connector and measure at the harness and the engine-ECU connector.
side.
D Disconnect the engine-ECU connector D-110.
D Continuity between 38 and the earth
OK: No continuity
OK
NG
Check the following connector: E-13 Repair
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Check the following items in order:
(Refer to P.13E-40, 44.) D Glow plug, glow plug relay
D Battery
NG D Injection nozzle
D Throttle body assembly
Repair D Injection pump
D Compression pressure
D Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 6
Starting performance is bad when the engine is cold Probable cause
(unable to start)
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, and glow system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Glow system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Glow plug, glow plug relay
D Injection nozzle, fuel filter
NG D Throttle body assembly
D Existence of starter switch signal input
Repair D Engine oil
D Injection pump
D Existence of mixing foreign objects (water, kerosene) with
the fuel
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection nozzle, fuel filter
D Throttle body assembly
NG D Compression pressure
D Injection pump
Repair D Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 8
Low idling speed when the engine is cold (improper Probable cause
idling speed)
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
and fuel system. D Injection pump inoperative
D Fuel system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection pump
D Fuel filter
NG
Repair
INSPECTION PROCEDURE 9
High idling speed (improper idling speed) Probable cause
Probable causes can be found in troubles with control system and injection D Control system inoperative
pump. D Injection pump inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection pump
D Starter switch signal
NG
Repair
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection nozzle
D Injection pump
NG
Repair
INSPECTION PROCEDURE 11
Idling instable (rough idling, hunting) Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, glow system, intake system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Glow system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Glow plug, glow plug relay
D EGR system
NG D Injection nozzle
D Compression pressure
Repair D Valve clearance
D Throttle body assembly
D Injection timing
D Fuel line bleeding
D Injection pump
INSPECTION PROCEDURE 12
The engine stalls after running for a while. Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, and intake system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Throttle body assembly
D Fuel filter
NG D Injection pump
Repair
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Power supply system
D Throttle body assembly
NG D EGR system
D Injection pump
Repair
INSPECTION PROCEDURE 14
Lack of output power Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection nozzle, fuel filter
D Throttle body assembly
NG D EGR system
D Turbocharger
Repair D Compression pressure
D Injection timing
D Injection pump
D Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 15
Occurrence of abnormal knocking Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection nozzle
D Injection timing
NG
D EGR system
D Injection pump
Repair
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Air cleaner
D Injection nozzle
NG D Throttle body assembly
D EGR system
Repair D Turbocharger
D Injection pump
INSPECTION PROCEDURE 17
Abnormal white smoke Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, EGR system, and glow system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D EGR system inoperative
D Glow system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Glow plug, glow plug relay
D Injection nozzle
NG D Throttle body assembly
D EGR system
Repair D Turbocharger
D Injection pump
INSPECTION PROCEDURE 18
Hunting during driving Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
and fuel system. D Injection pump inoperative
D Fuel system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection nozzle
D Injection pump
NG
Repair
NG
Measure at engine-ECU connector D-110. A/C condenser fan motor circuit check
D Disconnect the connector and measure at the harness (Refer to the wiring harness configuration diagram.)
side.
D Check the A/C condenser fan condition.
(Ignition switch: ON)
OK: Fan stopped
D Voltage between 7 and the earth
(Ignition switch: ON)
OK: System voltage
D Short out 7 and the earth
(Ignition switch: ON)
OK: A/C condenser fan turns
OK
NG
Check the following connector: D-110 Repair
OK
(1) NG NG
Measure at D-110, D-111, D-113 Check the following connectors: Repair
engine-ECU connectors. D-208, D-223, E-13
D Disconnect the connector and
(2), (3) NG OK
measure at the harness side.
(1) Voltage between 82 and the
earth (Ignition switch: ON) Check the trouble symptoms.
OK: System voltage NG
(2) Voltage between 46 and the NG
earth Check the harness between the Repair
OK: System voltage engine-ECU and the ignition switch.
(3) Voltage between 12, 25 and the (4) NG
OK
earth (Ignition switch: ON)
OK: System voltage
Ignition switch check
(When terminal 38 is short
circuited to the earth) (5) NG
(4) Continuity between 13, 26 and NG
Check the following connectors: Repair
the earth
B-25X, D-128
OK: Continuity
(5) Voltage 80 and the earth OK
OK: System voltage NG
OK Check the trouble symptoms. Check and repair the harness
between the engine-ECU and the
control relay connector.
Check the following connectors:
Check and repair the harness
D-110, D-111, D-113
between the engine-ECU and the
OK NG earth.
Repair
INSPECTION PROCEDURE 21
Fuel cut solenoid valve circuit inspection
NG
Fuel cut solenoid valve check Replace the injection pump.
(Refer to P.13E-61.)
OK
OK NG
Measure at fuel injection pump Check the following connector: Repair
assembly connector B-38. D-110
D Disconnect the connector and OK
measure at the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK NG
Check the harness between the Repair
engine-ECU and the fuel cut
Check the fuel injection pump solenoid valve connector.
assembly connector B-38, and repair OK
if necessary.
Replace the engine-ECU.
NG
EGR control solenoid valve No. 1 Replace
check (Refer to GROUP 17 -
Service Adjustment Procedures.)
OK
NG
Measure at EGR control solenoid Check the harness between the
valve No. 1 connector B-35. control relay and the EGR control
D Disconnect the connector and solenoid valve No. 1 connector, and
measure at the harness side. repair if necessary.
D Voltage between 1 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
D-110. B-35
D Disconnect the connector and OK
measure at the harness side.
D Voltage between 9 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK
Check the harness between the
Check the following connector: engine-ECU and the EGR control
D-110 solenoid valve No. 1 connector, and
repair if necessary.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
INSPECTION PROCEDURE 23
EGR control solenoid valve No. 2 circuit inspection
NG
EGR control solenoid valve No. 2 Replace
check (Refer to GROUP 17 -
Service Adjustment Procedures.)
OK
NG
Measure at EGR control solenoid Check the harness between the
valve No. 2 connector B-34. control relay and the EGR control
D Disconnect the connector and solenoid valve No. 2 connector, and
measure at the harness side. repair if necessary.
D Voltage between 1 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
D-110. B-34
D Disconnect the connector and OK
measure at the harness side.
D Voltage between 5 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK
Check the harness between the
Check the following connector: engine-ECU and the EGR control
D-110 solenoid valve No. 2 connector, and
repair if necessary.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Glow plug relay check. (Refer to Replace
GROUP 16 - Glow System.)
OK
NG NG
Measure at glow plug relay Check the following connector: Repair
connector B-42. D-110
D Disconnect the connector and
OK
measure at the harness side.
D Voltage between 1 and the earth
Check the trouble symptoms.
(Ignition switch: ON)
(Engine coolant temperature: NG
40_C or lower) NG
OK: System voltage (for 1 - 8 sec- Check the harness between the Repair
onds after ignition switch is engine-ECU and the glow plug relay
turned to ON) connector.
OK OK
Check glow plug relay connector Replace the engine-ECU.
B-42, and repair if necessary.
INSPECTION PROCEDURE 25
A/C switch and A/C relay inspection
OK NG
Measure at engine-ECU connector Check the following connectors: Repair
D-110 or D-111. D-110, D-111
D Disconnect the connector and
OK
measure at the harness side.
D Voltage between 21 and 32 and
Check the trouble symptoms.
the earth (Ignition switch: ON)
OK: 0 - 3 V (A/C switch: OFF) OK
System voltage (A/C
switch: ON) Replace the engine-ECU.
D Short out 21 and the earth
(Ignition switch: ON)
(A/C switch: ON)
OK: A/C compressor clutch
turns on
NG
31 EGR valve Engine: After warming Idling under no load 2.3 - 3.3 V Code No. 13E-25
position up the engine 51
sensor (tar- Engine is suddenly Momentarily
get value) raced decreases
(0.3 - 0.7 V)
32 EGR valve Engine: After warming Idling under no load 2.3 - 3.3 V Code No. 13E-25
position up the engine 51
sensor (ac- Engine is suddenly Momentarily
tual value) raced decreases
(0.3 - 0.7 V)
NOTE
*1: The opening degree of the timing control valve is converted into percentage. (0 %: timer non-advanced angle,
100 %: timer maximum advanced angle)
*2: The opening degree of the EGR solenoid valve is converted into percentage.
02 Glow plug relay Turning the Ignition switch: Battery charge is Procedure 13E-39
relay from ON energized to the glow No 24
No.
OFF to ON or plug when the glow
from ON to plug relay is ON.
ON
OFF
03 A/C compressor Turning the Ignition switch: The A/C compressor Procedure 13E-39
relay relay from ON clutch makes an No 25
No.
OFF to ON or audible sound.
from ON to
OFF
11 Timing control Turn the D Ignition Makes an audible Code No. 13E-21
valve timing control switch: ON sound 43
valve to ON D Engine:
Idling
12 Turn the D Timer piston
timing control position
valve to OFF sensor:
Normal
15 Glow lamp Turn the glow Ignition switch: The glow lamp turns
lamp on or off ON on.
16 Warning lamp Turn the Ignition switch: The warning lamp Procedure 13E-30
warning lamp ON turns on. No. 3, 4
on or off
22 Condenser fan Turning the Ignition switch: The condenser fan Procedure 13E-36
relay relay from ON rotates. No. 19
OFF to ON or
from ON to
OFF
23 Throttle solenoid Turn the D Ignition Makes an audible Code No. 13E-20
valve solenoid switch: ON sound 41
valve from D Vehicle
OFF to ON or speed:
from ON to 0 km/h
OFF D Engine
speed:
1,000 r/min
or lower
25 GE actuator Turn the GE D Ignition Measure the wave Code No. 13E-23
actuator to switch: ON pattern between 48
ON D Engine engine-ECU connec-
speed: tor terminals No. 1
0 r/min or and No. 15 using an
lower analyzer and check
26 Turn the GE
D Control the change in the duty
actuator to
sleeve posi- ratio.
OFF
tion sensor:
Normal
34 Middle position Hold the D Ignition When the crankshaft Code No. 13E-23
of GE actuator injection switch: ON is turned clockwise 48
governor in during the adjustment
its middle of the injection timing,
position. the injection pipes
spray out fuel.
35 Variable Turn the Ignition switch: Makes an audible Code No. 13E-24
geometry solenoid ON sound 49
solenoid valve valve to ON
37 EGR control Turn the Ignition switch: Makes an audible Procedure 13E-38
solenoid valve solenoid ON sound No. 22
No. 1 valve from
OFF to ON
from ON to
OFF
38 EGR control Turn the Ignition switch: Makes an audible Procedure 13E-38
solenoid valve solenoid ON sound No. 23
No. 2 valve from
OFF to ON
from ON to
OFF
26 - Body earth
73 - 75 5.6 - 6.2
74 - 75 11.2 - 12.4
76 - 77 80 - 84
76 - 78 80 - 84
83 - 61 Engine coolant temperature sensor 5.1 - 6.5 k (when the engine coolant temperature is
0_C)
87 - 61 Fuel temperature sensor 5.1 - 6.5 k (when the fuel temperature is 0_C)
88 - 61 Boost air temperature sensor 5.3 - 6.7 k (when the intake air temperature is 0_C)
Measurement Method
Analyzer
1. Disconnect the crank angle sensor connector and connect
the special tool (test harness: MD998478) in between.
CHI 2. Connect the analyzer probe to terminal No. 2 of the crank
angle sensor connector (black clip of special tool).
NOTE
When measuring at the engine-ECU connector, connect
the analyzer probe to terminal No. 89.
TIME/DIV. 10 ms
VOLTS/DIV. 2V
AC - GND - DC DC
Other -
1 engine revolution
(V)
T
Crank angle
sensor output ATDC BTDC9_
wave pattern 90_ BTDC35_ ATDC
12_
5
TDC TDC
D Example 2
Cause of problem
Abnormality in sensor disk
Wave pattern characteristics
Wave pattern is displaced to the left or right.
Measurement Method
Analyzer
1. Disconnect the pump speed sensor connector and
Sensor side connector
connect the special tool (test harness: MD991658) in
between. (All terminals should be connected.)
2. Connect the analyzer probe to terminal No. 1 of the pump
speed sensor connector (black clip of special tool).
NOTE
When measuring at the engine-ECU connector, connect
the analyzer probe to terminal No. 51.
AC - GND - DC DC
(V)
0.85
- 0.85 T
1 cranking
D Example 2
Cause of problem
Incorrect gap between sensor and sensing gear plate
Wave pattern characteristics
No signal is output even when engine is started, or signal
amplitude is small.
Accelerator
pedal arm
Connector at the
CONTROL RELAY CONTINUITY CHECK
control replay
Terminals to be Battery voltage Normal
connected conation
2-4 Not applied Continuity
1-3 Not applied No continuity
Control relay
Connect a positive battery Continuity
cable to No.2 terminal and a
negative battery cable to No.4
terminal, respectively.
Connector at the
Coil resistance check
Fuel cut solenoid
equipment (12 pin) valve 1. Disconnect the injection pump connector (12 pin).
2. Measure the resistance between terminal No. 1 (fuel cut
solenoid valve) and the injection pump body.
Standard value: 6.8 - 9.2
Throttle solenoid
valve
Battery
30 7 Nm
5.0 1.0 Nm
5.0 1.0 Nm
3
30 7 Nm 12 1 Nm
7
2
4
10 2 Nm
1 (Engine oil)
5
6 23 3 Nm
19 3 Nm
83 5 Nm
Removal steps
1. Fuel injection pump connector AB" 5. Fuel injection pump sprocket
2. Fuel hoses connection 6. Flange
AA" 3. Fuel injection pipe 7. Fuel injection pump
4. Engine oil level gauge guide and
oil level gauge assembly
Nut
Delivery holder
MD998719
Crankshaft
position sensor
9.0 1.0 Nm
ENGINE-ECU
REMOVAL AND INSTALLATION
Removal and installation is the same as for 6G7 engine or 4M4 engine. Refer to GROUP 13A or 13C
of the 2001 PAJERO Workshop Manual {Pub. No. PWJE0001 (1/2)}
MITSUBISHI STABILITY
CONTROL
(MITSUBISHI SC)
Click on the applicable bookmark to selected the required model year.
MITSUBISHI STABILITY
CONTROL
(MITSUBISHI SC)
CONTENTS
GENERAL INFORMATION
The MITSUBISHI Stability Control (MITSUBISHI Then the system will control the engine output,
SC) system, which compensates for an unsafe based on the vehicle speed and the throttle opening
driving by controlling the engine output (i.e., traction angle.
control), has been introduced. In addition, if the system fails, the SC warning lamp
The MITSUBISHI SC judges that the vehicle is inside the combination meter will illuminate or flash
unstable via the lateral gravity sensor. to warn the driver.
System Diagram
ABS-ECU
SC-ECU
Diagnosis
Engine-ECU connector
<M/T, 4M4-A/T>
or Engine-
Wheel speed sensor (FR) A/T-ECU
<6G7-A/T>
A/T-ECU <4M4-A/T>
Multi-purpose
fuse
Engine control
relay G sensor
Combination meter
Engine-ECU
<M/T, 4M4-A/T> or SC-ECU
Engine-A/T-ECU
<6G7-A/T>
Diagnosis connector
Wheel speed
sensor (FR)
ABS-ECU
SC-ECU Receives signals from various sensors, and transmits an engine output control signal
to the engine-ECU or engine-A/T-ECU, based on the information.
Engine-ECU Transmits the engine information (such as APS signal and engine speed), which is
<M/T, 4M4-A/T> required for control the Mitsubishi SC, to the SC-ECU.
Compensate for the engine output according to the current engine condition on
request from the SC-ECU.
Engine-A/T-ECU <6G7-A/T> D Transmits the engine information (such as APS signal and engine speed),
which is required for controlling the Mitsubishi SC, to the SC-ECU.
D Transmits the transmission information (such as shift position), which is required
for controlling the Mitsubishi SC, to the SC-ECU.
Compensate for the engine output according to the current engine condition on
request from the SC-ECU.
A/T-ECU <4M4-A/T> Transmits the transmission information (such as shift position), which is required for
controlling the Mitsubishi SC, to the SC-ECU.
ABS-ECU Transmits the wheel speed sensor (FR) signal to the SC-ECU.
G sensor Measures the vehicle lateral gravity, and transmit the information to the SC-ECU as
a voltage signal.
Vehicle speed sensor Transmits the vehicle speed (transmission output gear speed) signal to the SC-ECU.
SC warning lamp Illuminates or flashes when the SC-ECU transmits a signal indicating the system error.
Diagnosis connector When a diagnosis code is set, the MUT-II communicates with the system via this
connector.
SERVICE SPECIFICATIONS
Items Standard value
SPECIAL TOOLS
Tools No. Name Application
MB991502 MUT-II sub as- Checking the MITSUBISHI SC
sembly (Diagnosis display using the MUT-II)
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 the ignition switch to LOCK (OFF) position before
connecting or disconnecting the MUT-II.
NOTE
*1: Code No.27 and 81 are erased from the memory if the condition returns to normal.
*2: For code Nos.51, 53, 55 and 74, a diagnosis code will be set in ten seconds after a failure is detected.
Caution
If the system voltage drops during inspection, this code will be output to indicate a current problem.
And correct problem diagnosis will not be possible. Before carrying out the following procedure,
check the battery and recharge it if necessary.
(1)NG
Measure at SC-ECU connectors E-120, E-121. Check the following connectors: B-25X, D-128, E-122,
D Disconnect the connector and measure at the harness E-121
side. NG
(1) Voltage between terminal 25 and body earth OK
(2)NG
(Ignition switch: ON) Check the trouble symptoms.
Repair
OK: System voltage NG
(2) Voltage between terminal 39 and body earth
OK: System voltage
Check the harness wire between the engine control relay and
OK the SC-ECU, and repair if necessary.
Check the harness wire between the battery and the SC-ECU,
and repair if necessary.
(1)NG
Measure at SC-ECU connector E-120, E-121. Check the following connectors: E-120, E-122
D Disconnect the connector and measure at the harness
side. OK NG
(2), (3)NG
(1) Continuity between 31 and body earth
OK: Continuity Check the trouble symptoms. Repair
(2) Continuity between 13 and body earth NG
OK: Continuity
(3) Continuity between 26 and body earth
OK: Continuity Check the harness wire between the SC-ECU and the body
earth, and repair if necessary.
OK
Check the trouble symptoms. Check the following connector: E-121, E-122
NG OK NG
NO
Does the speedometer operate normally? Check the vehicle speed sensor system (Refer to Basic
Manual GROUP 54A - Combination Meter).
YES
NO
Does the ABS system operate normally? Check the ABS system (Refer to Basic Manual GROUP 35B
- ABS).
YES
Code No. 52 Vehicle speed sensor system (open circuit Probable cause
or short-circuit)
This diagnosis code will be set when the vehicle speed sensor does not send D Malfunction of vehicle speed sensor
vehicle speed signal to the SC-ECU. D Malfunction of harness or connector
D Malfunction of the SC-ECU
NO
Does the speedometer operate normally? Check the vehicle speed sensor system
(Refer to Basic Manual GROUP 54A - Combination Meter).
YES
NG
Check the following connectors: D-222, E-13, E-122, E-121 Repair
OK
Code No. 53 Wheel speed sensor system (open circuit Probable cause
or short-circuit)
This code is output when the open circuit or short-circuit detection carried out by D Malfunction of wheel speed sensor
the ABS-ECU hardware circuit detects that there is an open circuit or D Malfunction of harness or connector
short-circuit in the (+) or (- ) wire in one of the four wheel speed sensors and D Malfunction of the ABS-ECU
signals are consequently not being input.
NO
Does the ABS system operate normally? Check the ABS system (Refer to Basic Manual GROUP 35B -
ABS.)
YES
NG
Measure at ABS-ECU connectors E-106. Check the following connectors: E-106, E-122, E-120
D Disconnect the connector and measure at the harness
OK NG
side.
D Ignition switch: ON
Check the trouble symptoms. Repair
D Voltage between terminal 11 and body earth
OK: 4.8 - 5.2 V NG
OK Check the harness wire between the SC-ECU and the
ABS-ECU
Check the trouble symptoms.
NG OK NG
Replace
NG the SC-ECU
(1)NG
Measure at G sensor connector E-123. Check the following connectors: D-208, D-213, D-32, E-115,
D Disconnect the connector and measure at the harness E-123 NG
side. NG
(1) Voltage between terminal 1 and body earth OK
(Ignition switch: ON) (2)NG Check the trouble symptoms. Repair
OK: System voltage
NG
(2) Continuity between terminal 3 and body earth
OK: Continuity Check the harness wire, and repair if necessary.
OK D Between ignition switch and G sensor
E-123
Harness - side
connector
OK
NG
Check the following connectors: E-123, E-113, E-122, E-121 Repair
OK
Check the trouble symptoms.
NG
NG
Check the harness wire between the G sensor and SC-ECU Repair
OK
NG
Check the following connectors: D-118 <6G7-M/T>, D-119 Repair
<6G7-A/T>, D- 112 <4M4>, E - 122, E-121
OK
NG
Check the trouble symptoms. Replace the engine-ECU or engine-A/T-ECU
NG
Check the following connectors: D-109, E - 122, E-121 Repair
OK
NG
Check the trouble symptoms. Replace the A/T-ECU
Code No. 81 The SC-ECU is controlling the system too Probable cause
long
This diagnosis code will be set when the SC-ECU is controlling the system for D Malfunction of G sensor
20 seconds or more. D Malfunction of SC-ECU
NG
Replace the G sensor.
Label
Label
MB991348
E-123
Harness - side
connector
OK
Measure at diagnosis connecter D-23. NG Check the following connectors: D-27, D-211, D-210, D-23
D Voltage between 16 and body earth OK NG
OK: System voltage
OK Check the trouble symptoms. Repair
NG
NG
Measure at diagnosis connecter D-23. Check the following connector: D-23
D Continuity between terminals 4, 5 and body earth OK NG
OK: Continuity
OK Check the trouble symptoms. Repair
NG
Check the trouble symptoms.
NG Check the harness wire between diagnosis connector and
earth, and repair if necessary.
Replace the MUT-II.
NG
Measure at SC-ECU connector E-121 and diagnosis connector Check the following connectors: E-121, E-122, D-128, E-13,
D-23. D-33, D-222, D-23
D Disconnect the connectors and measure at the harness
OK NG
side.
D Continuity between the following terminals:
Between terminals 1 (SC-ECU side) and 1 (diagnosis Repair
Check the trouble symptoms.
connector side)
NG
Between terminals 14 (SC-ECU side) and 7 (diagnosis
connector side) Check the harness wire between SC-ECU and diagnosis
Between terminals 23 (SC-ECU side) and 14 (diagnosis connector, and repair if necessary.
connector side)
OK: Continuity
OK
(1)NG
Measure at SC-ECU connectors E-120, E-121. Check the following connectors: B-25X, D-128, E-122,
D Disconnect the connector and measure at the harness E-121
side. NG
(1) Voltage between terminal 25 and body earth OK
(2)NG
(Ignition switch: ON) Check the trouble symptoms.
Repair
OK: System voltage NG
(2) Voltage between terminal 39 and body earth
OK: System voltage
Check the harness wire between the engine control relay and
OK the SC-ECU, and repair if necessary.
Check the harness wire between the battery and the SC-ECU,
and repair if necessary.
(1)NG
Measure at SC-ECU connector E-120, E-121. Check the following connectors: E-120, E-122
D Disconnect the connector and measure at the harness
side. OK NG
(2), (3)NG
(1) Continuity between 31 and body earth
OK: Continuity Check the trouble symptoms. Repair
(2) Continuity between 13 and body earth NG
OK: Continuity
(3) Continuity between 26 and body earth
OK: Continuity Check the harness wire between the SC-ECU and the body
earth, and repair if necessary.
OK
Check the trouble symptoms. Check the following connector: E-121, E-122
NG OK NG
Inspection procedure 3
The SC warning lamp does not illuminate when the Probable cause
ignition key is turned to ON (engine stopped).
When the ignition switch is turned on, the SC-ECU starts to communicate with D Blown fuse
the engine-ECU or engine-A/T-ECU. Then the SC-ECU will illuminate the SC D Blown SC warning lamp bulb
warning lamp if the engine speed is 350 rpm or less. If the SC warning lamp D Malfunction of harness or connector
does not illuminate, the case is probably an open circuit in the SC warning lamp D Malfunction of combination meter
power supply circuit, a blow lamp bulb or an open circuit between the SC D Malfunction of the SC-ECU
warning lamp and the SC-ECU.
NG
Multi - purpose fuse No. 6 check Refer to Basic Manual GROUP 00 Inspection service Points
OK for Blown Fuse.
NG NG
Measure at the SC-ECU connector E-120. Check for a blown bulb. Replace the SC
D Disconnect the connector and measure at the harness warning lamp bulb.
OK
side.
D Ignition switch: ON
D Warning lamp condition when terminal 45 is shorted to Check the following connectors: D-208, D-210 <L.H.D.>,
body earth D-213 <R.H.D.>, D-01, E-10, E-122, E-120
OK: Illuminates OK NG
OK Check the trouble symptoms. Repair
NG
Check the following connector: E-107
OK NG Check the harness wire.
D Between the ignition switch and the combination meter
Repair D Between the combination meter and the SC-ECU
Check the trouble symptoms.
OK NG
NG
Repair
Replace the SC-ECU
Replace the combination meter.
Inspection procedure 4
The SC warning lamp remains illuminated after the Probable cause
engine has started.
The cause is probably a short-circuit in the SC warning lamp illumination circuit. D Malfunction of combination meter
D Malfunction of harness (short-circuit)
D Malfunction of the SC-ECU
NOTE
This trouble symptom is limited to cases where communication with the MUT-II is possible(SC-ECU power
supply is normal) and the diagnosis code is a normal diagnosis code.
YES
When the SC-ECU connector E-120 are disconnected and the Check the harness wire between the combination meter and
ignition switch is turned to the ON position, does the SC the SC-ECU
warning lamp remain illuminated? OK NG
NO
Repair
SC-ECU
Harness-side connector
ON-VEHICLE SERVICE
OPERATION TEST OF MITSUBISHI SC
1. Connect the MUT-II to the 16-pin diagnosis connector.
Caution
Turn the ignition switch to the LOCK (OFF) position
when connecting and disconnecting the MUT-II.
2. Move the shift lever to the neutral <M/T>, or the selector
lever to the P range.
3. Start the engine.
4. Use the MUT-II to activate the Actuator Test (item No.05)
while depressing the accelerator pedal fully. Check that
the engine speed should decrease gradually.
Caution
Activate the Actuator Test for three seconds.
Release the accelerator pedal immediately after the
Actuator Test is complete, or the engine speed will
rise.
NOTE
During the Actuator Test, the SC-ECU transmits the signal,
which requests no torque and wide open throttle, to the
engine-ECU or engine-A/T-ECU for three seconds.
Heater unit
Accelerator
pedal
5 1 Nm
SC-ECU
5 1 Nm
G SENSOR
REMOVAL AND INSTALLATION
Caution
Do not drop the G sensor or subject it to any shocks.
5 1 Nm
5 1 Nm
1
4
5 2
3
5 1 Nm
5 1 Nm
Earth bolt
Removal steps
1. G sensor (for SC) connector and 4. G sensor (for ABS)
harness clamp 5. Harness clamp <L.H.D>
2. G sensor (for SC) 6. G sensor bracket
3. G sensor (for ABS) connector
ENGINE COOLING
Click on the applicable bookmark to selected the required model year.
ENGINE COOLING
CONTENTS
GENERAL INFORMATION
The cooling system is designed to keep every part The water pump is of the centrifugal type and is
of the engine at appropriate temperature in driven by the drive belt from the crankshaft.
whatever condition the engine may be operated. The radiator is the corrugated fin, down flow type.
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 Specifications
Radiator Performance kJ/h 6G7 203,023
4D5, 4M4 232,326
SERVICE SPECIFICATIONS
Items Standard value Limit
High pressure valve opening pressure of radiator cap kPa 74 - 103 64
Range of coolant antifreeze concentration of radiator % 30 - 60 -
Thermostat Valve opening temper- 6G7 88 2.0 -
ature of thermostat _C
4D5 82 1.5 -
4M4 76.5 2.0 -
Full-opening tempera- 6G7 100 -
ture of thermostat _C
4D5 95 -
4M4 90 -
Valve lift mm 6G7 10 or more -
4D5, 4M4 8.5 or more -
LUBRICANT
Item Applicable model Amount (including
condense tank) L
MITSUBISHI GENUINE COOLANT or equivalent Vehicles without rear heater 9.0
Vehicles with rear heater 10.5
SEALANT
Items Specified sealant Remarks
Cylinder block drain plug 3M Nut Locking Part No. 4171 or equivalent Drying sealant
<6G7> 2. Remove the cylinder block drain plug from the cylinder
Left bank Right bank block to drain the engine coolant.
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.
<4D5>
<4M4>
Oil filter
5. Coat the thread of the cylinder block drain plug with the
specified sealant and tighten to the specified torque.
39 5 Nm
Specified sealant:
3M Nut Locking Part No. 4171 or equivalent
6. Securely tighten the radiator drain plug.
7. Install the reserve tank.
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.
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 anti-freeze:
MITSUBISHI GENUINE COOLANT or equivalent
Quantity:
<Vehicles without rear heater> 9.0 L
<Vehicles with rear heater> 10.5 L
CONCENTRATION MEASUREMENT
Measure the temperature and specific gravity of the engine
coolant to check the antifreeze concentration.
Standard value: 30 - 60 % (allowable concentration range)
RECOMMENDED ANTI-FREEZE
Caution
If the concentration of the anti-freeze 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.
COOLING FAN
REMOVAL AND INSTALLATION
<6G7>
4
2
3
1
5 6
11 1 Nm
11 1 Nm
<4D5>
1
3 2 4
5 6
11 1 Nm
11 1 Nm
1 3
5 6
Removal steps
1. Radiator upper shroud 4. Pulley
2. Drive belts 5. Cooling fan
3. Cooling fan and fan clutch 6. Fan clutch
INSPECTION
COOLING FAN CHECK
D Check blades for damage and cracks.
D Check for cracks and damage around bolt holes in fan
hub.
D If any portion of fan is damaged or cracked, replace cooling
fan.
FAN CLUTCH CHECK
D Check to ensure that fluid in fan clutch is not leaking
at case joint and seals. If fluid quantity decreases due
to leakage, fan speed will decrease and engine
overheating might result.
D When a fan attached to an engine is turned by hand,
it should give a sense of some resistance. If fan turns
lightly, it is faulty.
D Check bimetal strip for damage.
THERMOSTAT
REMOVAL AND INSTALLATION
<6G7> <4D5>
3 2 3
1 2
1
14 1 Nm
12 1 Nm
<4M4>
Removal steps
AA" "BA 1. Radiator lower hose connection
2. Water inlet fitting
"AA 3. Thermostat
<4D5>
90_
Thermostat
housing
Jiggle valve
Thermostat
Rubber ring
INSPECTION
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:
<6G7> 88 2.0_C
<4D5> 82 1.5_C
<4M4> 76.5 2.0_C
Full-opening 100 95 90
Valve lift temperature _C
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.
5 7 12 1 Nm
12 1 Nm
3
9 1 Nm
2
Thread diameter length mm
30 9 Nm
4 6
8
12
1 13
14 15
11
24 3 Nm 10
9
Removal steps
AA" "CA 1. Radiator upper hose connection 9. Water pump
2. Water hose 10. Gasket
3. Water hose "AA 11. O-ring
4. Water temperature sensor 12. Fitting
5. Water outlet fitting bracket 13. Gasket
6. Water outlet fitting 14. Thermostat case
"AA 7. O-ring 15. Gasket
8. Gasket
<4D5>
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying D Thermostat Removal and Installation
(Refer to P. 14-3.) (Refer to P.14-7.)
D Timing Belt Removal and Installation
(Refer to GROUP 11B.)
885 840
825
5
3
2 1 840
1
2 Thread diameter length mm
13 2 Nm
4
3
24 3 Nm
13 2 Nm
Removal steps
D Air intake hose 2. Gasket
(Refer to GROUP 15 - Air Cleaner.) 3. Water pump assembly
D Power steering oil pump 4. Gasket
(Refer to GROUP 37A.) "AA 5. O-ring
1. Plate
3
1
2
Removal steps
1. Drive belt 4. Water pump
2. Coupling plate "BA 5. O-ring
3. Fan pulley
14 1 Nm
3 2
19 3 Nm 3
5.0 1.0 Nm
25 1 13
24 5.0 1.0 Nm
23 11 5.0 1.0 Nm
29
12 1 Nm 28
9 1 Nm 10
8 14 1 Nm
12
23 2 Nm 19 1 Nm
22
18 9
19
28 2 Nm
21 14
20
17 15
16
6
19 3 Nm 5 7
26
27 4
Removal steps
1. Water hose AB" "AA 16. Radiator upper hose connection
2. Water outlet pipe 17. Water hose
"BA 3. O-ring 18. Water hose
4. Heater hose and water passage as- 19. Fitting
sembly 20. Gasket
5. Water passage assembly 21. Water outlet fitting and thermostat
"DA 6. Gasket case
7. Heater hose 22. Gasket
AA" "CA 8. Detonation sensor 23. Water hose
9. Detonation sensor bracket 24. Water pipe
10. Heater hose connection 25. Water hose
11. Water hose 26. Left fitting
12. Water pipe 27. Gasket
13. Water hose 28. Right fitting
14. Water pipe assembly 29. Gasket
"BA 15. O-ring
<4D5>
Pre-removal and Post-installation Operation
D Engine Coolant Draining and Supplying
(Refer to P.14-3.)
D Injection Pipe Removal and Installation
(Refer to GROUP 13E - Injection Nozzle.)
D Intake, Exhaust Manifold Removal and Installation
(Refer to GROUP 15.)
14 1 Nm
9 10
14 1 Nm
11 1 Nm
42 7 Nm 6
2
6 11
5
5 12
42 7 Nm
1
7
8 4
11 1 Nm
13
4
4
Removal steps
1. Heater hose connection 8. Water hose
2. Vacuum pipe installation bolt 9. Water pipe assembly B
3. Cable ban 10. Water hose
4. Water hose 11. Water pipe assembly C
5. Eye bolt 12. Water pipe assembly
6. Gasket "BA 13. O-ring
7. Water pipe assembly A
4 25 2 Nm
5
25 2 Nm 14
13
6
8 16 10
9 15
11
17
12
1 2
3
Removal steps
AB" "AA 1. Radiator upper hose connection 10. Water hose
2. Water outlet pipe 11. EGR water inlet pipe
3. Gasket "BA 12. O-ring
4. Water hose 13. Tuebocharger water outlet pipe
5. EGR water outlet pipe 14. Tuebocharger water inlet pipe
"BA 6. O-ring 15. Heater hose connection
7. Bypass pipe 16. Heater return pipe
"BA 8. O-ring "BA 17. O-ring
9. Thermostat case
Pipe
Tab (four
"DAGASKET INSTALLATION <6G7>
pieces) Water passage Engage the gasket tabs with recesses on the water passage.
assembly
Gasket
INSPECTION
WATER PIPE AND HOSE CHECK
Check the water pipe and hose for cracks, damage, clog
and replace them if necessary.
RADIATOR
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Engine Coolant Draining (Refer to P. 14-3.) D Engine Coolant Supplying (Refer to P. 14-3.)
D A/T Fluid Supplying and Checking
(Refer to GROUP 23 - On-vehicle Service.)
<6G7> 12 2 Nm
9
4
5
7
5.0 1.0 Nm
1
8
11
10 3
2
<4D5>
12 2 Nm
9 5
5.0 1.0 Nm
11
8
1
10
4
5.0 1.0 Nm
11
1
8
4
3
10
Removal steps
AA" "BA 1. Radiator shroud upper cover 6. Shroud
AA" "BA 2. Radiator shroud lower cover 7. Rubber hose
AB" 3. Transmission fluid cooler hose con- 8. Reserve tank assembly
nection <A/T> 9. Upper insulator
AC" "AA 4. Radiator upper hose 10. Radiator
AC" "AA 5. Radiator lower hose 11. Lower insulator
ENGINE COOLING
CONTENTS
14 1 Nm 13
22 4 Nm
11
11 1 Nm
7 14 1 Nm
12
4
9
3 1
5
15 14
8
10 14 1 Nm
42 7 Nm
2
6
11 1 Nm
Removal steps
1. Heater hose connection D Turbocharger heat protector (Refer to
2. Water hose GROUP 15 - Intake and exhaust
D Air cleaner assembly manifold, turbocharger.)
3. Water pipe and hose assembly 8. Water hose
"AA 4. Water hose 9. Water pipe A
5. Water pipe E 10. Gasket
"BA 6. O-ring 11. Water pipe B
"AA 7. Water hose 12. Gasket
D EGR valve, EGR cooler 13. Water hose
(Refer to GROUP 17.) 14. Water pipe C
15. Water pipe D
4 25 2 Nm
6
25 2 Nm 15
12
7
10
16
13
14 11 5
18
17
19
1 2
3
Removal steps
AA" "BA 1. Radiator upper hose connection "AA 11. O-ring
2. Water outlet pipe D Turbocharger heat cover upper
3. Gasket (Refer to GROUP 15.)
4. Water hose 12. Turbocharger water outlet pipe
5. Water hose 13. Gasket
D Air cleaner assembly 14. Thermostat case
D Thermostat 15. Turbocharger water inlet pipe
D EGR valve, EGR cooler 16. Gasket
(Refer to GROUP 17.) D Exhaust manifold
6. EGR water outlet pipe (Refer to GROUP 15.)
"AA 7. O-ring 17. Heater hose connection
8. EGR water inlet pipe 18. Heater return pipe
"AA 9. O-ring "AA 19. O-ring
10. Bypass pipe
INTAKE AND
EXHAUST
CONTENTS
SERVICE SPECIFICATIONS
Items Standard value Limit
SEALANT
Item Specified sealant Remarks
Thread of the intake manifold mounting 3M Stud Locking No.4170 or equivalent Anaerobic sealant
bolts
SPECIAL TOOL
Tool Number Name Use
MD998770 Oxygen sensor Removal/Installation of oxygen sensor <6G7>
wrench
ON-VEHICLE SERVICE
INTAKE MANIFOLD VACUUM CHECK <6G7>
Refer to GROUP 11A - On-vehicle Service
AIR CLEANER
REMOVAL AND INSTALLATION
Caution
Parts marked by * are made of recycled-paper mixed plastic material, so observe the following
precautions.
1. Avoid any shock or load to these parts when removing and installing them.
2. Engage the case hinges securely when assembling these parts.
NOTE
Parts marked by * are made of recycled-paper mixed plastic material, so can be disposed of by incineration.
<6G7> <4D5, 4M4>
6
7* 3.9 1.0 Nm
7*
4
3.9 1.0 Nm
5 3.9 1.0 Nm
8
8
9.0 1.0 Nm
9.0 1.0 Nm
5.0 1.0 Nm
2 3
5.0 1.0 Nm
9*
9*
11
9.0 1.0 Nm 9.0 1.0 Nm 1
1 11
10 12
10
Removal steps
1. Air duct (A) 7. Air cleaner cover
2. Air duct (B) <6G7> 8. Air cleaner element
3. Pre-cleaner assembly <4D5, 4M4> 9. Air cleaner body
4. Air intake hose 10. Air cleaner bracket
5. Resonator <6G7> 11. Unloader valve
6. Air flow sensor assembly <6G7> 12. Unloader valve <4D5, 4M4>
1
6.0 1.0 Nm
9.0 2.0 Nm
6 6.0 1.0 Nm
6.0 1.0 Nm
5 2
12 2 Nm
6.0 1.0 Nm
12 2 Nm
4
Removal steps
1. Intercooler air hose 4. Intercooler assembly
2. Intercooler air hose 5. Deflector plate
3. Intercooler air hose 6. Intercooler air pipe
INSPECTION
D Check the intercooler fins for bending damage or foreign
matter.
D Check the intercooler hoses for cracking, damage or wear.
3 5
4 11 1 Nm
2
11 1
17
6
10
9
8 7
5.0 1.0 Nm
16
20
15
11 1 Nm 22 21 9.0 1.0 Nm 12
14
23 13
19 11 1 Nm
14 1 Nm
24
18
25
INSPECTION
Check the following points; replace the part if a problem is
found.
3.0 0.3 Nm
19
10 6
9
21
11 18 20
17
12
22 4 Nm
5 16
15 8
13
44 8 Nm
4
31 1 Nm
(Engine oil)
13 7 (Transmission fluid)
31 1 Nm
2
3
6.0 1.0 Nm 13 (Engine oil)
14
Nut
Delivery
holder
INSPECTION
INTAKE MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Clogging of the negative pressure (vacuum) outlet port,
or clogging of the gas passages.
3. Check distortion of installation surface with straight edge
and thickness gauge.
Standard value: 0.15 mm or less
Limit: 0.20 mm
18 2 Nm 5.0 1.0 Nm
5.0 1.0 Nm 3
14 1 Nm
18 2 Nm
2
1
59 10 Nm 18 2 Nm
14 1 Nm
14 1 Nm
14 1 Nm
8
4
10
6
49 5 Nm 5
9
49 5 Nm
14 1 Nm
(Engine oil)
Removal steps
1. EGR pipe 6. Exhaust manifold gasket
2. EGR pipe gasket 7. Engine oil level gauge and guide
3. Throttle body stay 8. Heat protector
4. Heat protector 9. Exhaust manifold
5. Exhaust manifold 10. Exhaust manifold gasket
INSPECTION
Check the following points; replace the part if a problem is
found.
EXHAUST MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Using a straight edge and a thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
Purchased from www.WorkshopManuals.co.uk
Intake and Exhaust Manifold,
15-12 www.WorkshopManuals.co.uk
INTAKE AND EXHAUST - Turbocharger <4D5>
2.5 0.3 Nm
2
2.5 0.3 Nm
25 4 Nm 18 2 Nm
12 1
21
8.8 1.0 Nm 6 1 Nm
4 18 2 Nm
17 2 Nm
59 10 Nm 18 2 Nm
7
11
20
6 6 1 Nm
3
18 2 Nm
14 1 Nm
19
12 1 Nm 11 1 Nm
42 7 Nm 14 8
13
17
5
18 16
3 18 2 Nm
59 10 Nm
42 7 Nm
15
8.8 1.0 Nm
10 22
9
8.8 1.0 Nm
Removal steps
1. Air pipe 13. Exhaust manifold and turbocharger
2. Air intake hose assembly
3. Vacuum hose connection 14. Exhaust fitting heat protector
4. Turbocharger heat protector 15. Exhaust manifold heat protector
5. Water pipe (B) connection 16. Exhaust manifold
6. Waste gate actuator "AA 17. Turbocharger assembly
7. Oil pipe 18. Turbocharger gasket
8. Water pipe (A) 19. Exhaust fitting assembly
9. Oil return hose 20. Exhaust fitting gasket
10. Oil return pipe 21. Intake manifold
11. EGR pipe 22. Intake and exhaust manifold gasket
12. EGR valve
INSPECTION
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.
13 1 Nm
30 3 Nm
16
9
1
20 2 Nm
25 2 Nm 5 17
25 2 Nm
20 2 Nm
13 1 Nm
13 1 Nm
49 4 Nm
3 2 13 1 Nm
25 2 Nm 4
3
13 1 Nm
6.0 1.0 Nm
14
13
49 4 Nm
15
8 10
12
11
7
4.9 0.4 Nm
6 13 1 Nm
Removal steps
1. EGR valve and pipe assembly 10. Turbocharger and exhaust fitting
2. Turbocharger cover assembly
3. Water pipe 11. Turbocharger cover
4. Turbocharger cover 12. Waste gate actuator
5. Oil pipe 13. Turbocharger cover
6. Oil return hose 14. Exhaust fitting
7. Oil return pipe "AA 15. Turbocharger assembly
8. Oil return pipe gasket 16. Exhaust manifold
9. Heat protector 17. Exhaust manifold gasket
INSPECTION
Check the following points; replace the part if a problem is
found.
EXHAUST MANIFOLD CHECK
1. Check for damage or cracking of any part.
2. Using a straight edge and a thickness gauge, check for
distortion of the cylinder head installation surface.
Standard value: 0.15 mm or less
Limit: 0.20 mm
TURBOCHARGER <4D5>
DISASSEMBLY AND REASSEMBLY
5
6
5 Nm
Disassembly steps
"EA 1. Coupling
"DA 2. Turbine housing
AA" "CA 3. Snap ring
AB" "BA 4. Turbine wheel assembly
5. Compressor cover
"AA 6. O-ring
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.
Coupling
COMPRESSOR COVER
Oil passage
Check the compressor cover for traces of contact with the
Turbine wheel 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.
Water passage 2. Check the oil passage of the turbine wheel assembly
Compressor
wheel for deposit and clogging.
3. In the case of water cooled type, check also the water
passage for deposit and clogging.
4. Check the turbine wheel and compressor wheel for light
and smooth turning.
3
8.3 Nm
5
6 8
7
4
*1
1
*2
Disassembly steps
1. Hose "AA 7. O-ring
2. Actuator 8. Cartridge assembly
3. Coupling
AA" 4. Turbine housing *1: Turbine wheel
"BA 5. Snap ring *2: Compressor wheel
AB" 6. Compressor cover
Compressor cover
CLEANING
TURBINE HOUSING/COMPRESSOR COVER
1. Prior to cleaning, visually check the disassembled parts
for evidences of burns, abrasions or other flaws because
they may become unrecognizable after washing. Replace
A
B if necessary.
C
2. Immerse the disassembled parts in the nonflammable
solvent A (DAI-CLEANER T-30 from Daido Chemical
Industry Co., Ltd.). Remove them from the solvent and
blow compressed air B against them.
Scrape off foreign matters, if any, using a plastic scraper
C before the immersion.
12
13 2 Nm
9
7 7 8
49 10 Nm
14 1
13 2 Nm
<Short wheelbase>
19
14 4 13 2 Nm
49 10 Nm
15
44 5 Nm 13 2 Nm
6
17 14
49 10 Nm
16
25 4 Nm
20
49 10 Nm 3
44 5 Nm
18
49 4 Nm 7
13 11
2
49 10 Nm
<Long wheelbase>
14
13 2 Nm
19
14 5
13 2 Nm 10
49 10 Nm 15 7
13 2 Nm
44 5 Nm
13 2 Nm
6 17
14
16 49 5 Nm
25 4 Nm
49 10 Nm 20 3
44 5 Nm
18
49 4 Nm
13 2 Nm 11
8
6 6
7
49 10 Nm
<Short wheelbase> 13 1 13 2 Nm
18
3 13 2 Nm
49 10 Nm
14
16
17 13 13 2 Nm
15
13
49 10 Nm
5
49 4 Nm
19
25 4 Nm
6
10
12
2
<Long wheelbase> 49 10 Nm
13
13 2 Nm
18 4
16 9
13
13 2 Nm
6
14 13 2 Nm
17
49 10 Nm 13 2 Nm
13
15 49 10 Nm
5
19 49 4 Nm
25 4 Nm
Exhaust main muffler and rear Exhaust main muffler removal steps
floor heat protector removal steps <Long wheelbase>
<Short wheelbase> 4. Exhaust main muffler
1. Exhaust main muffler 13. Hanger
6. Hanger 14. Hanger bracket
7. Hanger bracket Front exhaust pipe and dash heat
8. Hanger bracket protector removal steps
11. Rear floor heat protector
D Under cover
Tail exhaust pipe and rear floor 5. Front exhaust pipe
heat protector removal steps 15. Exhaust support bracket
<Long wheelbase> 16. Dash heat protector
2. Tail exhaust pipe Pre-muffler and front floor heat
7. Hanger protector removal steps
9. Hanger bracket
10. Hanger bracket 17. Pre-muffler
12. Rear floor heat protector 18. Front floor heat protector
19. Seal ring
Center exhaust pipe removal steps
<Short wheelbase>
3. Center exhaust pipe
13. Hanger
14. Hanger bracket
11
13 2 Nm
8
6
6 7
49 10 Nm
13
<Short wheelbase> 1 13 2 Nm
18
13 13 2 Nm
49 10 Nm 3
16 14
15 13 2 Nm
5 13
49 10 Nm
17
25 4 Nm 19
6 10
49 4 Nm
2 12
49 10 Nm
<Long wheelbase>
13
13 2 Nm
16 18
49 10 Nm 13 4
13 2 Nm 9
14 6
13 2 Nm
15
13 2 Nm
49 10 Nm
13
5 17
25 4 Nm 19
49 4 Nm
Exhaust main muffler and rear Exhaust main muffler removal steps
floor heat protector removal steps <Long wheelbase>
<Short wheelbase> 4. Exhaust main muffler
1. Exhaust main muffler 13. Hanger
6. Hanger 14. Hanger bracket
7. Hanger bracket Front exhaust pipe and dash heat
8. Hanger bracket protector removal steps
11. Rear floor heat protector
D Under cover
Tail exhaust pipe and rear floor 5. Front exhaust pipe
heat protector removal steps 15. Exhaust support bracket
<Long wheelbase> 16. Dash heat protector
2. Tail exhaust pipe Front floor heat protector removal
7. Hanger steps
9. Hanger bracket
10. Hanger bracket 17. Catalytic converter
12. Rear floor heat protector 18. Front floor heat protector
19. Seal ring
Center exhaust pipe removal steps
<Short wheelbase>
3. Center exhaust pipe
13. Hanger
14. Hanger bracket
INTAKE AND
EXHAUST
CONTENTS
SERVICE SPECIFICATIONS
Items Standard value
SEALANT
Item Specified sealant Remarks
Thread of the intake manifold mounting 3M Stud Locking No.4170 or equivalent Anaerobic sealant
bolts
ON Approximately 80 Approximately 3
kPa kPa
NOTE
(1) If the variable geometry actuator vacuum is not in a normal
condition, the variable geometry actuator, variable
geometry solenoid valve, variable geometry control
pressure sensor, vacuum pump or hose may be faulty.
(2) If the variable geometry actuator vacuum is in a normal
condition but the supercharging pressure is not in a normal
condition, the variable geometry turbocharger nozzle,
boost pressure sensor, or hose may be faulty.
Caution
Be careful not to forcibly activate the variable geometry
solenoid valve to the fullest degree when running at a
high speed. Too much supercharging pressure could
damage the engine or the turbocharger.
3.0 0.3 Nm
20
10
21
22
29 18
19
28
17 16
18 2 Nm (Transmission fluid)
9
8 22 4 Nm
27
15
7 5
26 13
6 15 1 Nm
23 14
4 11
3 44 8 Nm
1 12
2 3.0 0.3 Nm
(Engine oil)
13 1 Nm 25
(Engine oil)
23 1 Nm 23 3.0 0.3 Nm
29 1 Nm
23
24
Nut
Delivery
holder
18 2 Nm
24 4 Nm
2.5 0.3 Nm
12
7 3 2.5 0.3 Nm
11 13
10
14 1 Nm
8
8
6
5 9
14 14 1 Nm 2
8 18 2 Nm
15 18 22 4 Nm
16 17
14 1 Nm 6.0 1.0 Nm
22
17 2 9.0 1.0 Nm
4 Nm
20 4 Nm
20 19 11 1
Nm
18 2
Nm 25
1
24
6.0 1.0 Nm 21 26 42 7 Nm
31
33 14 1
Nm 34
14 1 Nm
23 32
28 30
27
12 1 Nm
35 42 7
Nm
29
14 1 Nm
Removal steps
1. Dash panel heat protector 20. Gasket
2. Air pipe 21. Vacuum hose connection
3. Air intake hose 22. Intake manifold
4. Intercooler air hose 23. Exhaust manifold heat protector
5. Air temperature sensor connector 24. Water pipe A and water hose
6. Throttle solenoid valve connector assembly
7. VGT solenoid valve connector 25. Gasket
8. Vacuum hose connection 26. Water pipe B connection
9. Solenoid valve assembly 27. Gasket
10. Air temperature sensor 28. VG actuator
11. Gasket 29. Exhaust fitting heat protector
12. Earth cable connection 30. Front exhaust pipe connection
13. Air intake fitting 31. Gasket
14. Gasket 32. Oil return hose connection
15. Throttle body assembly 33. Exhaust manifold and turbocharger
16. Gasket assembly
17. Engine hanger 34. Intake and exhaust manifold gasket
18. Turbocharger upper heat protector 35. Oil return hose
19. Oil pipe assembly
40
38
39
59 10 Nm
37
36
9.0 1.0 Nm
13 1 Nm
30 3 Nm
15
8
20 2 Nm
25 2 Nm 4 16
25 2 Nm
20 2 Nm
13 1 Nm
13 1 Nm
49 4 Nm
2 1 13 1 Nm
25 2 Nm
3
2
13 1 Nm
6.0 1.0 Nm
13
12
49 4 Nm
14
7 9
11
10
6
4.9 0.4 Nm
5 13 1 Nm
Removal steps
1. Turbocharger cover 10. Turbocharger cover
2. Water pipe 11. Waste gate actuator
3. Turbocharger cover 12. Turbocharger cover
4. Oil pipe 13. Exhaust fitting
5. Oil return hose "AA 14. Turbocharger assembly
6. Oil return pipe 15. Exhaust manifold
7. Oil return pipe gasket 16. Exhaust manifold gasket
8. Heat protector
9. Turbocharger and exhaust fitting
assembly
11
13 2 Nm
8
6
6 7
49 10 Nm
13 13 2 Nm
<Short wheelbase> 1
18
49 10 Nm 13 2 Nm
3
16 14
13
13 2 Nm
15 13
5 49 10 Nm
17
19
25 4 Nm
6
49 4 Nm 10
12
2
49 10 Nm
<Long wheelbase>
13
13 2 Nm
4
18
16 49 10 Nm 13 2 Nm 9
13
6
14
13 2 Nm
13 2 Nm
15
13
49 10 Nm
5
17
25 4 Nm 19
49 4 Nm
ENGINE ELECTRICAL
Click on the applicable bookmark to selected the required model year.
ENGINE
ELECTRICAL
CONTENTS
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.
Approx. 14.4 V The average output voltage fluctuates slightly with the
alternator load condition.
Time
When the ignition switch is turned on, current flows of approximately 14.4 V, the field current is cut
in the field coil and initial excitation of the field off. When the battery voltage drops below the
coil occurs. regulated voltage, the voltage regulator regulates
When the stator coil begins to generate power after the output voltage to a constant level by controlling
the engine is started, the field coil is excited by the field current.
the output current of the stator coil. In addition, when the field current is constant, the
The alternator output voltage rises as the field alternator output voltage rises as the engine speed
current increases and it falls as the field current increases.
decreases. When the battery voltage (alternator
S terminal voltage) reaches a regulated voltage
SYSTEM DIAGRAM
<6G7>
Stator coil B
Engine-ECU
Field coil
G
S +
Voltage L
regulator Ignition
FR Battery
Charging switch
warning lamp
-
Stator coil
Charging
warning lamp
Ignition
Field coil switch
L
Voltage
regulator
S Battery
ALTERNATOR SPECIFICATIONS
Items 6G7, 4M4 4D5
SERVICE SPECIFICATIONS
Items Standard value Limit
4M4 - 5
SPECIAL TOOL
Tool Number Name Use
MD998467 Alternator test Checking the alternator (S terminal voltage)
harness <4D5, 4M4>
Ammeter
+ -
Alternator
Voltmeter
+ - Battery
B-terminal
This test determines whether the wiring from the output wire. (Connect the (+) lead of the
alternator B terminal to the battery (+) terminal ammeter to the B terminal, and then connect
(including the fusible line) is in a good condition the ( - ) lead of the ammeter to the disconnected
or not. output wire.)
1. Always be sure to check the following before NOTE
the test. An inductive-type ammeter which enables
D Alternator installation measurements to be taken without
D Alternator drive belt tension disconnecting the alternator output wire should
D Fusible link be recommended. Using this equipment will
D Abnormal noise from the alternator while lessen the possibility of a voltage drop caused
the engine is running by a loose B terminal connection.
2. Turn the ignition switch off.
3. Disconnect the negative battery cable. 5. Connect a digital-type voltmeter between the
4. Disconnect the alternator output wire from the alternator B terminal and the battery (+)
alternator B terminal and connect a DC test terminal. (Connect the (+) lead of the voltmeter
ammeter with a range of 0 - 150 A in series to the B terminal and the connect the ( - ) lead
between the B terminal and the disconnected of the voltmeter to the battery (+) cable.)
6. Reconnect the negative battery cable. 11. If the value displayed on the voltmeter is above
7. Connect a tachometer or the MUT-II. the limit value, there is probably a malfunction
8. Leave the hood open. in the alternator output wire, so check the wiring
9. Start the engine. between the alternator B terminal and the
10. With the engine running at 2,500 r/min, turn battery (+) terminal (including fusible link).
the headlamps and other lamps on and off If a terminal is not sufficiently tight or if the
to adjust the alternator load so that the value harness has become discolored due to
displayed on the ammeter is slightly above 30 overheating, repair and then test again.
A. 12. After the test, run the engine at idle.
Adjust the engine speed by gradually 13. Turn off all lamps and the ignition switch.
decreasing it until the value displayed on the 14. Remove the tachometer or the MUT-II.
ammeter is 30 A. Take a reading of the value 15. Disconnect the negative battery cable.
displayed on the voltmeter at this time. 16. Disconnect the ammeter and voltmeter.
Limit: max. 0.3 V 17. Connect the alternator output wire to the
alternator B terminal.
NOTE 18. Connect the negative battery cable.
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.
Voltmeter
Ammeter
Charging warning lamp
Ignition switch
Alternator relay
- + + -
B
FR
L
S
G
Battery
Engine-ECU<M/T> Alternator
or Engine-A/T ECU
<A/T>
Ignition
switch L
B
Alternator relay
S
Voltmeter
Ammeter
Battery
+ -
10. Turn the light switch on to turn on headlamps D The specified level of current also may not
and then start the engine. be output if the temperature of the alternator
11. Immediately after setting the headlamps to high body or the ambient temperature is too
beam and turning the heater blower switch to high. In such cases, cool the alternator and
the high revolution position, increase the engine then test again.
speed to 2,500 r/min and read the maximum 12. The reading on the ammeter should be above
current output value displayed on the ammeter. the limit value. If the reading is below the limit
Limit: 70% of normal current output value and the alternator output wire is normal,
remove the alternator from the engine and
NOTE check the alternator.
D For the nominal current output, refer to the 13. Run the engine at idle after the test.
Alternator Specifications. 14. Turn the ignition switch off.
D Because the current from the battery will 15. Remove the tachometer or the MUT-II.
soon drop after the engine is started, the 16. Disconnect the negative battery cable.
above step should be carried out as quickly 17. Disconnect the ammeter and voltmeter.
as possible in order to obtain the maximum 18. Connect the alternator output wire to the
current output value. alternator B terminal.
D The current output value will depend on 19. Connect the negative battery cable.
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.
Ammeter
Voltmeter
Battery
- +
+ -
Load
Ignition Charging warning
switch lamp MD998467 Alternator
L
Alternator relay
S B
Ammeter
Voltmeter
Red
Battery + -
Blue
This test determines whether the voltage regulator 6. Connect a DC test ammeter with a range of
is correctly controlling the alternator output voltage. 0 - 100 A in series between the B terminal
1. Always be sure to check the following before and the disconnected output wire. (Connect
the test. the (+) lead of the ammeter to the B terminal.
D Alternator installation Connect the ( - ) lead of the ammeter to the
D Check that the battery installed in the disconnected output wire.)
vehicle is fully charged. 7. Reconnect the negative battery cable.
D Alternator drive belt tension 8. Connect a tachometer or the MUT-II.
D Fusible link 9. Turn the ignition switch to the ON position and
D Abnormal noise from the alternator while check that the reading on the voltmeter is equal
the engine is running to the battery voltage.
2. Turn the ignition switch off. NOTE
3. Disconnect the negative battery cable. If the voltage is 0 V, the cause is probably
4. Use the special tool (Alternator test harness: an open circuit in the wire or fusible link between
MD998467 or MB991519) to connect a digital the alternator S terminal and the battery (+)
voltmeter between the alternator S terminal and terminal.
earth. (Connect the (+) lead of the voltmeter
to the S terminal, and then connect the ( - ) 10. Turn all lamps and accessories off.
lead of the voltmeter to a secure earth or to 11. Start the engine.
the battery ( - ) terminal.) 12. Increase the engine speed to 2,500 r/min.
5. Disconnect the alternator output wire from the 13. Read the value displayed on the voltmeter when
alternator B terminal. the alternator output current alternator
becomes 10 A or less.
14. If the voltage reading conforms to the value 17. Remove the tachometer or the MUT-II.
in the voltage regulation, then the voltage 18. Disconnect the negative battery cable.
regulator is operating normally. 19. Disconnect the ammeter and voltmeter.
If the voltage is not within the standard value, 20. Connect the alternator output wire to the
there is a malfunction of the voltage regulator alternator B terminal.
or of the alternator. 21. Remove the special tool, and return the
15. After the test, lower the engine speed to the connector to the original condition.
idle speed. 22. Connect the negative battery cable.
16. Turn the ignition switch off.
20 13.9 - 14.9
60 13.4 - 14.6
80 13.1 - 14.5
B terminal
STANDARD WAVEFORM
Observation Conditions
FUNCTION SPECIAL PATTERNS
0.4
0.2
Voltage at
alternator 0
B terminal
- 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.
NOTE
At this time, the charging warning lamp
is illuminated.
44 10 Nm
22 4 Nm 1
Disassembly steps
1. Alternator connector
2. Alternator
<4D5>
Pre-removal Operation Post-installation Operation
Under Cover Removal D Drive Belt Tension Adjustment (Refer to GROUP
11B On-vehicle Service.)
D Under Cover Installation
5
22 4 Nm
44 10 Nm
2
3
1
17 2 Nm
Disassembly steps
1. Drive belt 4. Vacuum hose connection
2. Oil pipe connection 5. Alternator
3. Oil return hose connection
1
3
2
Disassembly steps
1. Alternator connector
2. Adjusting plate
3. Alternator
3 4
1
5
6
7
12
10
9
14
8
13
11
Disassembly steps
AA" 1. Front bracket assembly AC" 8. Stator
AB" 2. Pulley 9. Plate
"BA 3. Rotor AC" "AA 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Slinger
6. Front bearing 13. Rectifier assembly
7. Front bracket 14. Rear bracket
12
9
11
13
15 14
10
22
16
21 1
20
2
18
17 19 3
4
5
6
7
Disassembly steps
1. Check valve 12. Rear bearing
2. Nipple 13. Bearing retainer
3. Vacuum pump housing 14. Front bearing
4. O-ring 15. Front bracket
"CA 5. Vane AC" 16. Stator
"CA 6. Rotor 17. Plate
7. Vacuum pump plate AC" "AA 18. Regulator assembly
8. O-ring 19. Brush
AA" 9. Front bracket assembly 20. Slinger
AB" 10. Pulley 21. Rectifier assembly
"BA 11. Rotor 22. Rear bracket
1 4
3
5
7 6
14
13
12
10
9
8
11
Disassembly steps
AA" 1. Front bracket assembly AC" 8. Stator
AB" 2. Pulley 9. Plate
"BA 3. Rotor AC" "AA 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Slinger
6. Front bearing 13. Rectifier assembly
7. Front bracket 14. Rear bracket
Rear bracket
Brush
Wire
Wire
STATOR
1. Make continuity test on stator coil. Check that there is
continuity between coil leads. If there is no continuity,
replace stator assembly.
RECTIFIERS
1. Check for continuity between positive rectifier and stator
coil lead connection terminal with an ohmmeter. If there
is continuity in both directions, diode is shorted. Replace
rectifier assembly.
BRUSH
1. Replace the brush if its protrusion length is less than
the limit.
Protrusion Limit: min. 2 mm <6G7, 4D5>
length min. 5 mm <4M4>
Vane
O-ring
GENERAL INFORMATION
If the ignition switch is turned to the START and M terminal to conduct. Thus, current flows to
position, current flows in the pull-in and holding engage the starter motor.
provided inside magnetic switch, attracting the When the ignition switch is returned to the ON
plunger. When the plunger is attracted, the lever position after starting the engine, the starter clutch
connected to the plunger is actuated to engage is disengaged from the ring gear.
the starter clutch. An overrunning clutch is provided between the
On the other hand, attracting the plunger will turn pinion and the armature shaft, to prevent damage
on the magnetic switch, allowing the B terminal to the starter.
SYSTEM DIAGRAM
Holding coil Plunger
Pull-in coil Lever
Pinion shaft
Overrunning clutch
Ignition
switch
Armature
Battery
Brush
Yoke
SERVICE SPECIFICATIONS
Items Standard value Limit
Pinion gap mm 0.5 - 2.0 -
Commutator outer diameter mm 6G7 29.4 28.8
4D5, 4M4 32 31.4
Commutator runout mm 0.05 0.1
Commutator undercut mm 0.5 0.2
S
INSPECTION
M PINION GAP ADJUSTMENT
B
Battery 1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12V battery between S-terminal and
Field coil wire 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.
4. Check pinion to stopper clearance (pinion gap) with a
thickness gauge.
Standard value: 0.5 - 2.0 mm
Stopper
Pinion gap
Pinion
<6G7> <4D5>
30 3 Nm
30 3 Nm
1
11 1 Nm
1
11 1 Nm
<4M4>
11 1 Nm 1
Disassembly steps
1. Starter motor assembly
2. Starter cover
12
13
14
16
11
15
1
21
20
19
18 4
17 3
22
8 5
10
Disassembly steps
1. Screw 12. Packing A
AA" 2. Magnetic switch 13. Packing B
3. Screw 14. Plate
4. Screw 15. Planetary gear
5. Rear bracket 16. Lever
6. Brush holder AC" "AA 17. Snap ring
7. Brush AC" "AA 18. Stop ring
8. Rear bearing 19. Overrunning clutch
AB" 9. Armature 20. Internal gear
10. Yoke assembly 21. Planetary gear holder
AB" 11. Ball 22. Front bracket
<4D5>
14
12
13
16
11
15 4
1
22
3
21 8
20
19
18
17
23
5
6
10 7
Disassembly steps
1. Screw 13. Plate
AA" 2. Magnetic switch AB" 14. Ball
3. Screw 15. Planetary gear
4. Screw 16. Lever
5. Rear bracket AC" "AA 17. Snap ring
6. Brush holder AC" "AA 18. Stop ring
7. Yoke assembly 19. Overrunning clutch
8. Brush 20. Internal gear
AB" 9. Armature 21. Washer
10. Bearing 22. Planetary gear holder
11. Packing A 23. Front bracket
12. Packing B
15
18 17 23
16
20
19
21
24
5 22
25
26
8
3 7
1
27
12
4
2
9
14
10
13
11
Disassembly steps
1. Stopper ring 15. Cover
2. Pinion stopper 16. Rubber packing A
AD" "BA 3. Pinion 17. Rubber packing B
4. Spring 18. Plate
5. Screw AB" 19. Ball
6. Magnetic switch 20. Planetary gear
7. Screw 21. Lever
8. Screw 22. Washer
9. Rear bracket 23. Washer
10. Brush holder assembly 24. Gear shaft
AE" 11. Yoke assembly 25. Internal gear
12. Brush 26. Overrunning clutch
AB" 13. Armature 27. Front bracket
14. Rear bearing
M terminal
Field coil wire
Stop ring
Pinion gear
Overrunning
clutch
Snap ring
2. Remove snap ring with snap ring pliers and then remove
Snap ring pliers stop ring and overrunning clutch.
Pinion gear
Over-
running
clutch
Snap ring
Pinion stopper
INSPECTION 16200130286
COMMUTATOR CHECK
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
Yoke
<4D5>
1. Brushes that are worn beyond wear limit line, or are
oil-soaked, should be replaced.
2. When replacing field coil brushes, crush worn brush with
pliers, taking care not to damage pigtail.
IGNITION SYSTEM
GENERAL INFORMATION
This system is equipped with four ignition coils with The engine-ECU <M/T> or engine-A/T-ECU <A/T>
built-in power transistors for each of the cylinders. determines which ignition coil should be controlled
Interruption of the primary current flowing in the by means of the signals from the camshaft position
primary side of an ignition coil generates a high sensor and the crank angle sensor. It also detects
voltage in the secondary side of the ignition coil. the crankshaft position, in order to provide ignition
The high voltage thus generated is applied to the at the most appropriate timing in response to the
spark plugs to generate sparks. engine operation conditions.
The engine-ECU <M/T> or engine-A/T-ECU <A/T> When the engine is cold or running at high altitudes,
turns the power transistors inside the ignition coils the ignition timing is slightly advanced to provide
alternately on and off. This causes the primary optimum performance. Furthermore, if knocking
currents in the ignition coils to be alternately occurs, the ignition timing is gradually retarded until
interrupted and allowed to flow to fire the cylinders knocking ceases.
in the order 1 - 2 - 3 - 4 - 5 - 6.
SYSTEM DIAGRAM
Ignition coill A
To tachometer
Ignitoin coil F
Spark plug
Cylinder No. 1 2 3 4 5 6
NGK IZFR5B
SERVICE SPECIFICATIONS
SPARK PLUG
Items Standard value Limit
SPECIAL TOOL
Tool Number Name Use
MD998773 Detonation sensor Detonation sensor removal and installation
wrench
ON-VEHICLE SERVICE
1.5 V
+ - IGNITION COIL (WITH BUILT-IN POWER
TRANSISTOR) CHECK
PRIMARY COIL AND POWER TRANSISTOR
- + CONTINUITY CHECK
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.
When current is
not flowing
3.0 0.4 Nm
3.0 0.4 Nm
10 2 Nm 1
10 2 Nm
2
6
25 5 Nm 3
25 5 Nm
11 1 Nm
11 1 Nm
23 2 Nm
GENERAL INFORMATION
SELF-REGULATING GLOW SYSTEM
The self-regulating glow system reduces the time also the glow indicator lamp illumination time in
required for starting at low temperatures to provide accordance with the engine coolant temperature.
a degree of starting and operation that is identical The resistances of the heating coils which are built
to petrol-engine vehicles by preheating the glow into the glow plugs increase as the glow plug
plugs at super-quick speed. temperatures become higher. As a result of this,
The glow control unit controls both the time during the flow of current gradually decreases, thus
which current is supplied to the glow plugs after stabilizing the glow plug temperature at the
the ignition switch is turned to the ON position and specified temperature.
Glow plugs ON
ST
Ignition switch
Starter motor
Alternator
Battery
Resistance between glow plug plate and glow plug body 4D5 0.15 - 0.25
(parallel resistance for 4 glow plugs) (at 20 _C) W
4M4 0.05 - 0.07
Voltage between glow plug plate and Immediately after igni- 4D5 9 - 11 (Drops to 0 V after 4 - 8 seconds
glow plug body V tion switch is turned to have passed)
ON (without starting
the engine) 4M4 9 - 11 (Drops to 0 V after approx. 8
seconds have passed)
START
Ignition ON
switch
OFF
Glow ON
indicator lamp
OFF
Glow plug ON
relay OFF
Alternator H
L terminal L
NOTE
After glow time T3 becomes longer as the engine coolant temperature drops.
Glow plug relay Jumper cable at battery (+) Continuity between terminals
terminal (2) - (3)
Connected Continuity (0.01 W or less)
Disconnected No continuity (infinite
Battery resistance)
Glow plug
relay Bracket
(earth)
GLOW PLUG
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
EGR Pipe Removal and Installation (Refer to GROUP
17.)
<4M4> <4D5>
1.8 0.2 Nm
2
3
3
18 2 Nm 2
Removal steps
1. Connector connection
2. Glow plug plate
AA" 3. Glow plug
ENGINE AND
EMISSION CONTROL
Click on the applicable bookmark to selected the required model year.
ENGINE AND
EMISSION
CONTROL
CONTENTS
SERVICE SPECIFICATIONS
Items Standard value
ON-VEHICLE SERVICE
ACCELERATOR CABLE CHECK AND
ADJUSTMENT <4D5>
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: 750 100 r/min
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
8
2.0 0.5 Nm
10
1 2
9
3.5 1.0 Nm
12 2 Nm
6
5
7
4
4
3
11
Removal steps
1. Accelerator pedal position sensor 7. Accelerator pedal pad
2. Accelerator pedal assembly 8. Adjusting screw
3. Push-on spring nut 9. Stopper
4. Bushing 10. Accelerator pedal bracket
5. Return spring 11. Stopper <R.H. drive vehicles-M/T>
6. Accelerator pedal
5.0 1.0 Nm
12 2 Nm
7
2 10
8 4
6
8 11 5
12 2 Nm
11
7
9
12
Removal steps
1. Inner cable connection 6. Push-on spring nut
(Throttle body side) 7. Accelerator arm
2. Inner cable connection 8. Bushing
(Accelerator pedal side) 9. Spring
3. Accelerator cable 10. Stopper
4. Accelerator pedal assembly 11. Accelerator pedal bracket
5. Accelerator pedal pad 12. Accelerator pedal stopper
5.0 1.0 Nm
1 12 2 Nm
12 2 Nm
7
8
10
6 5
4
8
12 2 Nm
11 9
11
12
7
9
Removal steps
1. Inner cable connection 6. Push-on spring nut
(Throttle body side) 7. Accelerator arm
2. Inner cable connection 8. Bushing
(Accelerator pedal side) 9. Spring
3. Accelerator cable 10. Stopper
4. Accelerator pedal assembly 11. Accelerator pedal bracket
5. Accelerator pedal pad 12. Accelerator pedal stopper
Auto-cruise
control switch
Vehicle speed
Stop lamp switch sensor
Clutch switch
Main switch
Throttle valve
control servo
Auto-cruise control
indicator lamp
Engine-ECU<M/T> or
Engine-A/T-ECU<A/T>
Throttle valve
Inhibitor switch controller
Diagnosis
connector
<4M4>
Auto-cruise
control switch
GE actuator
(electronic governor)
Auto-cruise control
indicator lamp
Engine-ECU
Inhibitor switch
A/T-ECU
Diagnosis
connector
SPECIAL TOOL
Tool Number Name Use
MB991502 MUT-II sub D Reading diagnosis codes
assembly D Auto-cruise control system check
0.5 s 0.5 s
1.5 s 0.5 s
12V 12 V
0V
0V
Pause Tens signal Place Units
time: 3 s division: signal Continuous ON and OFF
2s signals at intervals of 0.5 s
NOTE
Other on-board diagnostic items are also output as voltage waveforms corresponding to diagnosis code
numbers.
NG
Check the auto-cruise control switch. (Refer to P.17-29.) Replace
OK
NG
Check the following connectors: Repair
D-205-3, D-205-2, D-205, E-10, D-11
OK
NG
Check trouble symptom. Check the harness between the auto-cruise control switch and
throttle valve controller.
OK NG
Repair
NG
Check the following connectors: Repair
D-118<M/T>, D-122<A/T>, D-11
OK
Check the harness between the throttle valve controller and engine- NG
ECU <M/T> or engine-A/T-ECU <A/T>. Repair
OK
NG
Check trouble symptom. Replace the engine-ECU <M/T> or engine-A/T-ECU <A/T>
NO
Do the stop lamps illuminate normally? Check the stop lamp circuit.
YES
(1)NG
Measure at the throttle valve controller connector D-11. Check the following connectors:
D Disconnect the connector and measure at the harness side. D-136, D-26, D-33, E-13, D-128, D-11 <L.H. drive vehicles>
(1) Voltage between terminal 25 and body earth D-136, D-124, E-13, D-128, D-11 <R.H. drive vehicles>
OK: 0V (When brake pedal is not depressed.)
System voltage (When brake pedal is depressed.) OK NG
(2) Continuity between terminal 26 and body earth (2)NG Check trouble symptom. Repair
OK: Continuity (When brake pedal is not depressed.) NG
No continuity (When brake pedal is depressed.)
OK Check the harness between the stop lamp switch and throttle valve
controller, and repair if necessary.
To the next page. Check the harness between the throttle valve connector and stop
lamp switch, and body earth, and repair if necessary.
Diagnosis
code output
MUT-II Self-Diag code Carry out the troubleshooting regarding the GDI system.
Confirm diagnosis code regarding the GDI system. (Refer to GROUP 13A.)
No diagnosis code output
NG
Check the auto-cruise control switch. (Refer to P.17-29.) Replace
OK
NG
Check the following connectors: Repair
D-205-3, D-205-2, D-205, E-10, D-111
OK
NG
Check trouble symptom. Check the harness between the auto-cruise control switch and
engine-ECU.
OK NG
Repair
NO
Do the stop lamps illuminate normally? Check the stop lamp circuit.
YES
(1)NG
Measure at the engine-ECU connector D-111. Check the following connectors:
D Disconnect the connector and measure at the harness side. D-136, D-26, D-33, E-13, D-128, D-111 <L.H. drive vehicles>
(1) Voltage between terminal 39 and body earth D-136, D-124, E-13, D-128, D-111 <R.H. drive vehicles>
OK: 0V (When brake pedal is not depressed.)
System voltage (When brake pedal is depressed.) OK NG
(2) Continuity between terminal 40 and body earth (2)NG Check trouble symptom. Repair
OK: Continuity (When brake pedal is not depressed.) NG
No continuity (When brake pedal is depressed.)
OK Check the harness between the stop lamp switch and engine-ECU,
and repair if necessary.
Check trouble symptom.
NG Check the following connectors:
D-136, D-26, E-10, D-111 <L.H. drive vehicles>
Replace the engine-ECU. D-136, D-124, E-10, D-111 <R.H. drive vehicles>
OK NG
Check trouble symptom. Repair
NG
Check the harness between the engine-ECU and stop lamp switch,
and body earth, and repair if necessary.
Diagnosis
code output
MUT-II Self-Diag code Carry out the troubleshooting regarding the diesel fuel system.
Confirm diagnosis code regarding the diesel fuel system. (Refer to GROUP 13C.)
No diagnosis code output
Hunting (repeated acceleration and deceleration) occurs at the set vehicle speed. 7 17-18
When the MAIN switch of the auto-cruise control switch is turned ON, the 8 17-18
auto-cruise control indicator lamp does not illuminate. (However, the auto-cruise
control system is normal.)
NO
Can the MUT-II communicate with the other systems (except the Refer to GROUP 13A - Troubleshooting (Inspection procedure 1).
GDI system)?
YES
NO
Can the MUT-II communicate with the GDI system? Refer to GROUP 13A - Troubleshooting (Inspection procedure 2).
YES
Inspection Procedure 2
Even if brake pedal is depressed, auto-cruise control is Probable cause
not cancelled.
The cause is probably a malfunction of stop lamp switch or a malfunction of stop D Malfunction of the stop lamp switch
lamp circuit. D Malfunction of the connector
D Malfunction of the harness
D Malfunction of the throttle valve controller
NO
Is the stop lamp switch installed correctly? Repair
YES
Inspection Procedure 3
Even if clutch pedal is depressed, auto-cruise control is Probable cause
not cancelled. <M/T>
The cause is probably a malfunction of clutch switch or clutch switch circuit. D Malfunction of the clutch switch
D Malfunction of the connector
D Malfunction of the harness
D Malfunction of the throttle valve controller
NG
Clutch switch check (Refer to GROUP 21.) Replace
OK
NG
Measure at clutch switch connector D-137. Check the following connector: D-137
D Disconnect the connector and measure at the harness side. NG
OK
D Continuity between terminal 1 and body earth
OK: Continuity Repair
OK Check trouble symptom.
NG NG
Check the following connectors: Repair
D-11, E-10, D-26, D-137 <L.H. drive vehicles>
D-11, E-10, D-124, D-137 <R.H. drive vehicles> Check the harness between the clutch switch and body earth,
and repair if necessary.
OK
NG
Check the following connector: D-11, E-113, C-05 Repair
OK
Inspection Procedure 5
Even if auto-cruise control CANCEL switch is set to ON, Probable cause
auto-cruise control is not cancelled.
The cause is probably an open-circuit in the circuit inside the CANCEL switch. D Malfunction of the auto-cruise control switch
Inspection Procedure 6
Auto-cruise control cannot be set. Probable cause
The cause is probably that the fail-safe function is cancelling auto-cruise control. D Malfunction of the auto-cruise control switch
In this case, the MUT-II can be used to check the trouble symptoms in each system D Malfunction of the harnesses
by inspecting the diagnosis codes. D Malfunction of the connectors
The MUT-II can also be used to check if the circuits of each input switch are normal D Malfunction of the throttle valve controller
or not by inspecting the data list. D Malfunction of the engine-ECU <M/T>
D Malfunction of the engine-A/T-ECU <A/T>
NO
Can the auto-cruise control system communicate with the MUT-II? Follow inspection procedure for trouble symptom No.1.
(Refer to P.17-15.)
YES
(1) YES
MUT-II Self-Diag code INSPECTION CHART FOR DIAGNOSIS CODES (Refer to
(1) Is a diagnosis code regarding the auto-cruise control P.17-10.)
system output? (2) YES
(2) Is a diagnosis code regarding the GDI system output? Carry out the troubleshooting regarding the GDI system. (Refer
to GROUP 13A.)
NO
NG
MUT-II Data list Check the control switch input system. (Inspection procedure 9,
02 SET switch P.17-19.)
OK
NG
MUT-II Data list Follow inspection procedures for trouble symptom Nos. 3 or 4.
07 Clutch switch <M/T> or inhibitor switch <A/T> (Refer to P.17-16, 17.)
NO
Replace the throttle valve controller.
NG
Check trouble symptoms. Replace the engine-ECU <M/T> or engine-A/T-ECU <A/T>
Inspection Procedure 7
Hunting (repeated acceleration and deceleration) occurs Probable cause
at the set vehicle speed.
The cause is probably a malfunction of vehicle speed sensor or throttle control servo. D Malfunction of the vehicle speed sensor
In either case, a diagnosis code regarding the GDI system must be confirmed. D Malfunction of the throttle control servo
D Malfunction of the throttle valve controller
D Malfunction of the engine-ECU <M/T>
D Malfunction of the engine-A/T-ECU <A/T>
YES
MUT-II Self-Diag code Follow the troubleshooting regarding the GDI system. (Refer to
Is a diagnosis code regarding the GDI system output? GROUP 13A.)
NO
NG
Check trouble symptoms. Replace the engine-ECU <M/T> or engine-A/T-ECU <A/T>
Inspection Procedure 8
When the MAIN switch of the auto-cruise control switch is Probable cause
turned on, the auto-cruise control indicator lamp does not
illuminate. (However, the auto-cruise control in normal.)
There may be a burnt-out bulb or a malfunction of the auto-cruise control indicator D Burnt-out bulb
lamp circuit. D Malfunction of the harness
D Malfunction of the connector
D Malfunction of the engine-ECU <M/T>
D Malfunction of the engine-A/T-ECU <A/T>
NG
Auto-cruise control indicator lamp bulb check Replace
OK
NG
Measure at the combination meter connector D-01. Check the following connector: D-01
D Disconnect the connector and measure at the harness side.
OK NG
D Ignition switch and MAIN switch: ON
D Voltage between terminal 62 and earth Repair
OK: System voltage
OK Check trouble symptom.
NG
Check the harness between the J/B and the combination meter,
and repair if necessary.
NG
Measure at the engine-ECU connector D-116 <M/T> or engine- Check the following connectors:
A/T-ECU connector D-119 <A/T>. D-02, E-10, D-116 <M/T>
D Disconnect the connector and measure at the harness side. D-02, E-10, D-119 <A/T>
D Ignition switch and auto-cruise control MAIN switch: ON OK NG
D Voltage between terminal 28 and earth <M/T> or
voltage between terminal 15 and earth <A/T> Repair
OK: System voltage
OK Check trouble symptom.
NG
Check trouble symptom.
NG Check the harness between the combination meter and the engine-
ECU <M/T> or engine-A/T-ECU <A/T>, and repair if necessary.
Replace the engine-ECU <M/T> or engine-A/T-ECU <A/T>
NG
Auto-cruise control switch check (Refer to P.17-29.) Replace
OK
NG
Clock spring check (Refer to GROUP 52B.) Repair
OK
NG
Measure at the auto-cruise control switch connector D-205-3. Check the following connectors:
D Disconnect the connector and measure at the harness side. D-210, D-31, D-205, D-205-2, D-205-3
D Ignition switch: ON
OK NG
D Voltage between terminal 1 and earth
OK: System voltage Repair
OK
Check trouble symptom.
NG
Check the harness between the J/B and the auto-cruise control
switch, and repair if necessary.
NG
Measure at the throttle valve controller connector D-11. Check the following connectors:
D Disconnect the connector and measure at the harness side. D-205-3, D-205-2, D-205, E-10, D-11
D Ignition switch and auto-cruise control MAIN switch: ON OK NG
D Voltage between terminal 12 and earth
OK: System voltage Repair
OK
Check trouble symptom.
NG
Hunting (repeated acceleration and deceleration) occurs at the set vehicle speed. 7 17-23
When the MAIN switch of the auto-cruise control switch is turned ON, the 8 17-23
auto-cruise control indicator lamp does not illuminate. (However, the auto-cruise
control system is normal.)
NO
Can the MUT-II communicate with the other systems (except the Refer to GROUP 13C - Troubleshooting (Inspection procedure 1).
diesel fuel system)?
YES
NO
Can the MUT-II communicate with the diesel fuel system? Refer to GROUP 13C - Troubleshooting (Inspection procedure 2).
YES
NO
Is the stop lamp switch installed correctly? Repair
YES
Inspection Procedure 3
Even if clutch pedal is depressed, auto-cruise control is Probable cause
not cancelled. <M/T>
The cause is probably a malfunction of clutch switch or clutch switch circuit. D Malfunction of the clutch switch
D Malfunction of the connector
D Malfunction of the harness
D Malfunction of the engine-ECU
NG
Clutch switch check (Refer to GROUP 21.) Replace
OK
NG
Measure at clutch switch connector D-137. Check the following connector: D-137
D Disconnect the connector and measure at the harness side. NG
OK
D Continuity between terminal 1 and body earth
OK: Continuity Repair
OK Check trouble symptom.
NG NG
Check the following connectors: Repair
D-111, E-10, D-26, D-137 <L.H. drive vehicles>
D-111, E-10, D-124, D-137 <R.H. drive vehicles> Check the harness between the clutch switch and body earth,
and repair if necessary.
OK
Inspection Procedure 4
Even if select lever is set to N range, auto-cruise control Probable cause
is not cancelled. <A/T>
The cause is probably a defective inhibitor switch circuit. D Malfunction of the connector
D Malfunction of the harness
D Malfunction of the engine-ECU
NG
Check the following connectors: D-113, E-113, C-05 Repair
OK
Inspection Procedure 5
Even if auto-cruise control CANCEL switch is set to ON, Probable cause
auto-cruise control is not cancelled.
The cause is probably an open-circuit in the circuit inside the CANCEL switch. D Malfunction of the auto-cruise control switch
Inspection Procedure 6
Auto-cruise control cannot be set. Probable cause
The cause is probably that the fail-safe function is cancelling auto-cruise control. D Malfunction of the auto-cruise control switch
In this case, the MUT-II can be used to check the trouble symptoms in each system D Malfunction of the harnesses
by inspecting the diagnosis codes. D Malfunction of the connectors
The MUT-II can also be used to check if the circuits of each input switch are normal D Malfunction of the engine-ECU
or not by inspecting the data list.
NO
Can the auto-cruise control system communicate with the MUT-II? Follow inspection procedure for trouble symptom No.1.
(Refer to P.17-20.)
YES
(1) YES
MUT-II Self-Diag code INSPECTION CHART FOR DIAGNOSIS CODES (Refer to
(1) Is a diagnosis code regarding the auto-cruise control P.17-13.)
system output? (2) YES
(2) Is a diagnosis code regarding the diesel fuel system Carry out the troubleshooting regarding the diesel fuel system.
output? (Refer to GROUP 13C.)
NO
NG
MUT-II Data list Check the control switch input system. (Inspection procedure 9,
02 SET switch P.17-24.)
OK
NG
MUT-II Data list Follow inspection procedures for trouble symptom Nos. 3 or 4.
07 Clutch switch <M/T> or inhibitor switch <A/T> (Refer to P.17-21, 22.)
NO
NG
Check trouble symptoms. Replace the engine-ECU.
YES
MUT-II Self-Diag code Follow the troubleshooting regarding the diesel fuel system. (Refer
Is a diagnosis code regarding the diesel fuel system output? to GROUP 13C.)
NO
NG
Check trouble symptoms. Replace the engine-ECU.
Inspection Procedure 8
When the MAIN switch of the auto-cruise control switch is Probable cause
turned on, the auto-cruise control indicator lamp does not
illuminate. (However, the auto-cruise control in normal.)
There may be a burnt-out bulb or a malfunction of the auto-cruise control indicator D Burnt-out bulb
lamp circuit. D Malfunction of the harness
D Malfunction of the connector
D Malfunction of the engine-ECU
NG
Auto-cruise control indicator lamp bulb check Replace
OK
NG
Measure at the combination meter connector D-01. Check the following connector: D-01
D Disconnect the connector and measure at the harness side.
OK NG
D Ignition switch and MAIN switch: ON
D Voltage between terminal 62 and earth Repair
OK: System voltage
OK Check trouble symptom.
NG
Check the harness between the J/B and the combination meter,
and repair if necessary.
NG
Measure at the engine-ECU connector D-110. Check the following connectors:
D Disconnect the connector and measure at the harness side. D-02, E-10, D-110
D Ignition switch and auto-cruise control MAIN switch: ON OK NG
D Voltage between terminal 22 and earth
OK: System voltage Repair
OK
Check trouble symptom.
Check trouble symptom. NG
NG
Check the harness between the combination meter and the engine-
Replace the engine-ECU. ECU, and repair if necessary.
Inspection Procedure 9
Auto-cruise control switch input system check
NG
Auto-cruise control switch check (Refer to P.17-29.) Replace
OK
NG
Clock spring check (Refer to GROUP 52B.) Repair
OK
NG
Measure at the auto-cruise control switch connector D-205-3. Check the following connectors:
D Disconnect the connector and measure at the harness side. D-210, D-31, D-205, D-205-2, D-205-3
D Ignition switch: ON
OK NG
D Voltage between terminal 1 and earth
OK: System voltage Repair
OK
Check trouble symptom.
NG
Check the harness between the J/B and the auto-cruise control
switch, and repair if necessary.
NG
Measure at the engine-ECU connector D-111. Check the following connectors:
D Disconnect the connector and measure at the harness side. D-205-3, D-205-2, D-205, E-10, D-111
D Ignition switch and auto-cruise control MAIN switch: ON OK NG
D Voltage between terminal 45 and earth
OK: System voltage Repair
OK
Check trouble symptom.
NG
<4M4>
Terminal Check item Check conditions Normal condition
No.
01 Auto-cruise MAIN MAIN switch: ON ON
control
switch MAIN switch: OFF OFF
02 SET MAIN switch: SET switch: ON ON
(COAST) ON
SET switch: OFF OFF
03 RESUME RESUME switch: ON ON
(ACCEL)
RESUME switch: OFF OFF
04 CANCEL CANCEL switch: ON ON
10 Vehicle speed sensor Road test the vehicle The speedometer and
the MUT-II display the
same value.
11 Acclelerator pedal Accelerator pedal: Fully depressed 0.9 - 1.1 V
position sensor
Accelerator pedal: Release 4.1 V or more
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
combination meter illuminates when the MAIN switch is
switched ON.
Auto-cruise control
indicator lamp
1 2 3 4
CAUTION: SRS
Before removal of air bag module, refer to
GROUP 52B - SRS Service Precautions and Air
Bag Modules and Clock Spring.
Crankcase emission Positive crankcase ventilation (PCV) valve Variable flow type
control system (Purpose: HC reduction)
Exhaust emission Air-fuel ratio control device - GDI system Oxygen sensor feedback type
control system (Purpose: CO, HC, NOx reduction)
SERVICE SPECIFICATIONS
Items Standard value
SPECIAL TOOL
Tool Number Name Use
MB991658 Test harness set Inspection of EGR valve
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
EGR valve
(stepper
motor)
Canister
Fuel pump
(high-pressure) Purge control
solenoid valve
Oxygen sensor (front)
Oxygen sensor (rear) <M/T only>
Catalytic converter
To
combustion From air
chamber cleaner
B Canister
Purge control
solenoid valve
Vacuum hose colour (ON: OPEN)
B: Black
SYSTEM DIAGRAM
Ventilation hose
PCV
valve
Breather hose
COMPONENT LOCATION
PCV valve
Left bank
rocker cover
SYSTEM DIAGRAM
Throttle body
Engine-ECU
Purge control
Canister solenoid valve
(ON: Open) Air flow sensor
Battery
COMPONENT LOCATION
Purge control solenoid valve
Vacuum 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
purge port may be clogged and require cleaning.
OPERATION
The EGR valve is being closed and does not D The engine coolant temperature is low.
recirculate exhaust gases under one of the following D The engine is at idle.
conditions. Otherwise, the EGR valve is opened D The throttle valve is widely opened.
and recirculate exhaust gases.
SYSTEM DIAGRAM
Throttle body
Engine-ECU
COMPONENT LOCATION
EGR valve
Battery
MB991658
EGR VALVE
REMOVAL AND INSTALLATION
Pre-removal Operation
D Engine Coolant Draining and Refilling D Air Cleaner Assembly Removal and Installation
(Refer to GROUP 14 - On-vehicle Service.) (Refer to GROUP 15)
D Engine Cover Removal and Installation
(Refer to GROUP 11A - Timing Belt.)
14 1 Nm
4
18 2 Nm
3
59 10 Nm
22 4 Nm
1
5
2
Removal steps
1. Water hose connection 4. EGR pipe gasket
2. EGR valve connector 5. EGR valve
3. EGR pipe "AA 6. EGR valve gasket
Projection
INSTALLATION SERVICE POINT
"AA EGR VALVE GASKET INSTALLATION
Install the gasket so that its projection faces towards the
direction shown.
7
4
1
2
3
Removal steps
1. Hose clip 5. Purge hose connection
2. Vapor hose 6. Canister
3. Breather valve 7. Canister bracket
4. Vapor hose connection
CATALYTIC CONVERTER
GENERAL INFORMATION
The three-way catalytic converter, together with When the mixture is controlled at stoichiometric
the closed loop air-fuel ratio control based on the air-fuel ratio, the three-way catalytic converter
oxygen sensor signal, oxidizes carbon monoxides provides the highest purification against the three
(CO) and hydrocarbons (HC) and reduces nitrogen constituents, namely, CO, HC and NOx.
oxides (NOx).
49 10 Nm
49 4 Nm
Removal steps
1. Catalytic converter
2. Seal ring
SERVICE SPECIFICATIONS
Items Standard value
SEALANT
Item Specified sealant Remark
Engine coolant temperature gauge unit 3M Nut Locking Part No. 4171 or equivalent Drying sealant
threaded portion
SPECIAL TOOL
Tool Number Name Use
MD998464 Test harness Inspection of lever position sensor
(4P, square)
SYSTEM DIAGRAM
OFF ON
Orifice
EGR solenoid
Alternator valve No.1
(duty control)
Vacuum pump
OFF ON
EGR valve Glow & EGR
Engine coolant
temperature switch control unit
Rotation sensor
Lever position sensor
Engine coolant
temperature sensor
COMPONENT LOCATION
EGR solenoid valve No.1 EGR solenoid valve No.2
Rocker cover
FUNCTION CHECK
1. Start the engine and warm it up until the engine coolant
temperature reaches 65_C or above.
2. Race the engine by suddenly depressing the accelerator
pedal, then check that the EGR valve diaphragm lifts.
Diaphragm
Blue
Standard value:
White
Red Lever condition Voltage V
0 7.7 - 9.5
20 2.9 - 3.6
40 1.3 - 1.7
80 0.26 - 0.35
6 Lever position Ignition switch: ON Set throttle lever to idle position 0.8 - 1.0 V
sensor
Fully open throttle lever 3.7 - 4.9 V
5 - Body earth Engine coolant temperature sensor 7.7 - 9.5 kW (Coolant temperature at 0_C)
SERVICE SPECIFICATIONS
Items Standard value
SYSTEM DIAGRAM
EGR solenoid
valve No.1 (duty
control)
Vacuum pump
A/C switch
Inhibitor switch
COMPONENT LOCATION
EGR solenoid valve No.1 EGR solenoid valve No.2
FUNCTION CHECK
1. Start the engine and warm it up until the engine coolant
temperature reaches 65_C or above.
2. Turn the A/C switch OFF.
3. Place the selector lever in P range.
Diaphragm
CATALYTIC CONVERTER
GENERAL INFORMATION
The three-way catalytic converter, together with When the mixture is controlled at stoichiometric
the closed loop air-fuel ratio control based on the air-fuel ratio, the three-way catalytic converter
oxygen sensor signal, oxidizes carbon monoxides provides the highest purification against the three
(CO) and hydrocarbons (HC) and reduces nitrogen constituents, namely, CO, HC and NOx.
oxides (NOx).
49 10 Nm
2
49 4 Nm
Removal steps
1. Catalytic converter
2. Seal ring
ENGINE AND
EMISSION
CONTROL
CONTENTS
GENERAL INFORMATION
The electronically-controlled EGR system reduces
the level of exhaust gases (NOx).
SERVICE SPECIFICATIONS
Items Standard value
SYSTEM DIAGRAM
Vacuum pump
COMPONENT LOCATION
EGR solenoid valve No.1 EGR solenoid valve No.2
EGR valve
position
sensor
FUNCTION CHECK
1. Start the engine and warm it up until the engine coolant
temperature reaches 65_C or above.
2. Race the engine by suddenly depressing the accelerator
pedal, then check that the EGR valve diaphragm lifts.
Diaphragm
17 2 Nm
17 2 Nm 6
7
5
22 4 Nm
22 4 Nm
10
3
22 4 Nm
1
14
8
2
12
15 13
11
9 17 2 Nm
Removal steps
1. EGR valve connector "BA 9. O-ring
2. Vacuum hose connection 10. Water hose connection
3. EGR valve 11. EGR cooler and EGR lower pipe
4. EGR gasket assembly
5. EGR pipe gasket "AA 12. EGR pipe gasket
6. EGR upper pipe 13. EGR lower pipe
"AA 7. EGR pipe gasket "AA 14. EGR pipe gasket
"CA 8. Water pipe and hose assembly 15. EGR cooler
EGR cooler or
cylinder block
49 10 Nm
2
49 4 Nm
Removal steps
1. Catalytic converter
2. Seal ring
3. Gasket
SERVICE SPECIFICATION
Items Standard value
2
B
D
9
A C
6 3
7
H H
G
4
F
5 16C012CA
COMPONENT LOCATION
EGR valve assembly
8
9
2
9 10
1
10
11 2
6
3
12
4 5
Removal steps
1. EGR pipe B 7. EGR pipe insulator
2. EGR pipe gasket 8. EGR pipe A
3. Engine cover bracket 9. EGR pipe gasket
4. EGR valve connector 10. Water hose connection
5. EGR valve 11. EGR cooler assembly
6. EGR valve gasket 12. EGR cooler bracket
D Air cleaner assembly
CLUTCH
Click on the applicable bookmark to selected the required model year.
CLUTCH
CONTENTS
GENERAL INFORMATION
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
SERVICE SPECIFICATIONS
Items Standard value
Clutch pedal height mm 202 - 205 <L.H. drive vehicles>
197 - 200 <R.H. drive vehicles>
Clutch pedal clevis pin play mm 1- 3
Clutch pedal free play mm 6 - 13
Distance between the clutch pedal and the toeboard 75 or more <L.H. drive vehicles>
when the clutch is disengaged mm 70 or more <R.H. drive vehicles>
LUBRICANTS
Items Specified lubricants Quantity
Clutch fluid Brake fluid DOT3 or DOT4 As required
Push rod assembly Rubber grease
Release cylinder push rod MITSUBISHI genuine grease Part No. 0101011
Clutch pedal 3. If the height of the clutch pedal is outside the standard
position switch value, loosen the setting nut or clutch pedal position switch
lock nut <vehicles with auto-cruise control> to adjust the
Setting nut pedal height to the standard value.
Lock nut
12 3 Nm
Clutch pedal free Distance between the 6. After completing the adjustments, confirm that the clutch
play clutch pedal and the pedal free play (measured at the face of the pedal pad)
toeboard when the
clutch is disengaged 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.
Standard value (C): 6 - 13 mm
Standard value (D):
C D 75 mm or more <L.H. drive vehicles>
70 mm or more <R.H. drive vehicles>
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, release cylinder or clutch.
Bleed the air, or disassemble and inspect the master
cylinder, release cylinder or clutch.
8. Turn back the carpet, etc.
BLEEDING
Specified fluid: Brake fluid DOT 3 or DOT 4
Caution
Use the specified brake fluid. Avoid using a mixture of
the specified fluid and other fluid.
CLUTCH PEDAL
REMOVAL AND INSTALLATION
Post-installation Operation
Clutch Pedal Adjustment (Refer to P.21-2)
12 2 Nm
5
4 1
13 2 Nm 3 2
7
6
12 2 Nm
5
2 1
Removal steps
D Stay A (Refer to GROUP 52A - 3. Clevis pin
Instrument Panel) 4. Clutch master cylinder mounting nut
1. Clutch pedal position switch 5. Master cylinder member mounting bolt
<vehicles with auto-cruise control> 6. Pedal pad
2. Snap pin 7. Clutch pedal assembly
<6G74>
<R.H. drive vehicles>
2 1
3
4 <L.H. drive vehicles>
3 1
13 2 Nm
7
13 2 Nm
18 2 Nm
7
9 8
7
22 4 Nm
Release fork
Release cylinder 5 23 2 Nm
push rod
6
Specified grease:
MITSUBISHI genuine
grease Part No. 0101011 6
<4D56>
<R.H. drive vehicles>
1
2
3
<L.H. drive vehicles>
4
3 1
13 2 Nm
13 2 Nm
7 2
7
18 2 Nm
35 6 Nm
23 2 Nm
7
8
Release fork
Release cylinder
push rod
6 5
6
Specified grease:
MITSUBISHI genuine
grease Part No. 0101011
3 1
13 2 Nm
10 13 2 Nm
2
11 10
48 6 Nm
9 19 3 Nm
12
8
22 2 Nm
23 2 Nm
7
25 5 Nm
5
6
Release fork
Release cylinder
push rod
15 1 Nm 18 2 Nm
6
Specified grease:
MITSUBISHI genuine 11 10
grease Part No. 0101011
13 2 Nm
7
8
3
4
6
1
6 2
9
4 2
1
2
3
4
Clutch fluid:
Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease
Disassembly steps
1. Piston stopper ring 6. Spring pin
2. Piston assembly 7. Reservoir tank
"AA 3. Push rod assembly 8. Seal
4. Boot 9. Master cylinder body
5. Reservoir cap
121 1 mm
MANUAL
TRANSMISSION
Click on the applicable bookmark to selected the required model year.
MANUAL
TRANSMISSION
CONTENTS
GENERAL INFORMATION
Items Specifications
4th 1.000
LUBRICANTS
Items Specified lubricants Quantity L
Transmission oil Hypoid gear oil SAE 75W-90 or 75W-85W conforming to 3.2
API GL-4
Transfer oil Hypoid gear oil SAE 75W-90 or 75W-85W conforming to 2.5
API GL-4
SEALANTS
Items Specified sealant Remarks
Oil filler plug 3M ATD Part No. 8660 or equivalent Semi-drying sealant
Oil drain plug 3M ATD Part No. 8660 or equivalent Semi-drying sealant
SPECIAL TOOL
Tool Number Name Use
MD998464 Test harness Inspection of lever position sensor
(4P, square)
OK Intermittent malfunction
MUT-II Data list
D No.1 LPS (Refer to GROUP 00 - Points to
OK: Refer to P.23-5, DATA LIST Note for Transient Malfunctions.)
REFERENCE TABLE.
OK
ON-VEHICLE SERVICE
TRANSMISSION OIL CHECK
Filler plug hole
Transmission oil 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 2 Nm
Transfer
<V5M31>
OilOil filler
filler plug
plug
OilOil
drain plug
drain plug
1 2
2H
4H
1 2
4H
4L
4H-4L
5
1
3
2
3
2 5.0 1.0 Nm
1
3 7
4
11 2 Nm
4HLc 4H
INSPECTION
4LLc 2H TRANSFER SELECT SWITCH CONTINUITY CHECK
Switch posi- Terminal number
tion 1 2 3 5 6
2H
4H
4HLc
4LLc
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Caution
The rear propeller shaft is made of fiber-reinforced plastic tube, so always refer to GROUP 25
prior to its removal.
11
10
6
48 6 Nm
35 6 Nm
53 5 Nm
24 5 Nm
23 3 Nm
35 6 Nm
44 10 Nm
48 6 Nm
8
4
3 35 6 Nm
44 10 Nm
2
35 6 Nmm
1 7
44 10 Nm
26 4 Nm
35 6 Nm
9.0 2.0 Nm
44 10 Nm
24 5 Nm
9 35 6 Nm 5
11
10
6
35 6 Nm
53 5 Nm
48 6 Nm
24 5 Nm
23 3 Nm
44 10 Nm
8
35 6 Nm
48 6 Nm
44 10 Nm
4
3
35 6 Nm
2 35 6 Nm
1 7
44 10 Nm
26 4 Nm
35 6 Nm 44 10 Nm
9.0 2.0 Nm
Removal steps
1. Clutch release cylinder 7. Transmission mount center member
2. Space rubber assembly
3. Bell housing cover 8. Transmission mount insulator assem-
4. Starter motor bly
5. Dynamic damper assembly AA" 9. Transmission wiring harness connec-
6. Tension wire bracket tor connection
D Support the transmission with a "AA 10. Transmission assembly
transmission jack 11. Tension wire
24 5 Nm 35 6 Nm 9
13
15
10
7 14 35 6 Nm
53 5 Nm
24 5 Nm
48 6 Nm
8
44 10 Nm
11 1 Nm
48 6 Nm
12
44 10 Nm
6
1
3
5 11
44 10 Nm
26 4 Nm
48 6 Nm
4 2
44 10 Nm
Removal steps
1. Clutch release cylinder 4. Battery cable connection
(Refer to GROUP15) 5. Spacing rubber
2. Clutch dumper assembly 6. Dust cover
(Refer to GROUP15) 7. Heater hose connection
3. Exhaust support bracket 8. Starter motor
12
24 5 Nm
35 6 Nm 8
14
9
13
35 6 Nm
53 5 Nm
7
74 10 Nm
24 5 Nm
30 3 Nm
5
4
44 10 Nm
11
1
44 10 Nm
89 9 Nm
5.9 0.9 Nm 10
44 10 Nm
11 1 Nm 6 11 1 Nm
36 5 Nm 26 4 Nm
44 10 Nm
<6G7> A A C 10 x 50
A
<6G7>
A
Starter
motor Bolt Diameter (D) x Length (L) mm
B
B
A 12 x 40
B 12 x 55
4WD indicator-ECU
Bracket
4.9 1.0 Nm
Transfer-ECU
4.9 1.0 Nm
INSPECTION
4WD INDICATOR-ECU
1. Measure the voltage with the control unit and harness
View A still connected.
2. Earth terminal (8) and then measure terminal voltage.
Terminal No. Inspection item Inspection condition Inspection condition Terminal voltage
1: Ignition switch 2: Transfer lever position
ON - System voltage
2H, 4H, 4L 0V
NOTE
*1: When vehicle has been moved once.
*2: Shift the lever from 4H to 2H, and then turn the ignition switch to OFF and then back to ON.
TRANSFER-ECU
Measure the terminal voltage (Refer to P.22-3).
OK Transient malfunction
MUT-II Data List
D No. 1 APS (Refer to GROUP 00 - Points to
OK: Refer to P.22-2 (Data List Note for Transient Malfunctions.)
Reference Table).
NG
NG
APS check Replace
OK
OK
NG NG
Measure at transfer-ECU connector Check the following connectors: Repair
E-105 E-105, E-113
D Measure at ECU terminals.
D Ignition switch: ON OK
D Voltage between terminal 5 and Check the harness between the APS
earth and the transfer-ECU, and repair if
OK: Fully close the accelerator necessary.
985 - 1,085 mV
fully open the accelerator OK
4,000 mV or more NG
Checkthefollowingconnector:E-105 Repair
OK
AUTOMATIC
TRANSMISSION
Click on the applicable bookmark to selected the required model year.
AUTOMATIC
TRANSMISSION
CONTENTS
SERVICE SPECIFICATIONS
Item Standard value
A/T fluid temperature sen- At 0C 16.7 - 20.5
sor resistance kW At 20C 7.3 - 8.9
At 40C 3.4 - 4.2
At 60C 1.9 - 2.2
At 80C 1.0 - 1.2
At 100C 0.57 - 0.69
Damper clutch control (DCC) solenoid valve coil resistance (at 20C) W 2.7 - 3.4
Low & reverse (LR) solenoid valve coil resistance (at 20C) W 2.7 - 3.4
Second (2ND) solenoid valve coil resistance (at 20C) W 2.7 - 3.4
Underdrive solenoid valve (UD solenoid valve) coil resistance (at 20C) W 2.7 - 3.4
Overdrive solenoid valve (OD solenoid valve) coil resistance (at 20C) W 2.7 - 3.4
Resistance of reduction (RED) solenoid valve coil at (20C) W 2.7 - 3.4
Stall speed r/min 6G7 2,200 - 2,700
4M4 2,400 - 2,900
Line pressure adjustment value kPa 1,010 - 1,050
LUBRICANTS
Item Brand Quantity L
Transmission fluid DIA QUEEN ATF SP II M, ATF SP III or equivalent 9.3
Transfer oil Hypoid gear oil SAE 75W-90 or 75W-85W conforming to API 2.8
GL-4
SPECIAL TOOLS
Tools No. Name Application
MB991502 MUT-II Sub Diagnosis code checking
assembly
MD998900 Adapter
TROUBLESHOOTING <A/T>
BASIC FLOW OF PROBLEM DIAGNOSIS
Ask about trouble symptoms.
NG
Check the A/T fluid. Replace the A/T fluid.
OK
NG
Inhibitor switch and APS check Repair
(Refer to P.23-97.)
OK
END
DIAGNOSIS FUNCTION
N RANGE LAMP
If there is a problem with any of the following items which
are related to the A/T system, the N range lamp will flash
at a rate of approximately 1 Hz.
If the N range lamp is flashing at a rate of approximately
1 Hz, check the diagnosis output.
D N range lamp flashing item
Input shaft speed sensor system
Output shaft sensor system
Solenoid valve system
Non-synchronization at various shift ranges
A/T control relay system
No. Pre-test/opera- Test/operation Judgment value Check item Diag- Inspection pro-
tion conditions nosis cedure if there is
code an abnormality
No.
3 Ignition switch: Starting test at P or N Starting should be Starting pos- - Starting not
START position possible sible/not possible
Engine: Stopped possible
4 Driving after en- Drive for 15 minutes Data list No.15 A/T fluid tem- 15 A/T fluid temper-
gine has warmed or more until the A/T Gradually rises to 70 perature ature sensor sys-
up fluid temperature - 80_C sensor tem
rises to 70 - 80_C.
5 Engine: Idling Brake pedal (re-test) Data List No. 26 Stop lamp 26 Stop lamp switch
Selector lever (1) Depressed (1) ON switch system
position: N (2) Released (2) OFF
A/C switch Data List No. 65 Dual pres- - Dual pressure
(1) ON (1) ON sure switch switch system
(2) OFF (2) OFF
Accelerator pedal Data List No. 21 Crank angle 21 Crank angle sen-
(1) Fully closed (1) The engine sensor sor system
(2) Apply speed displayed <6G7> <6G7>
on the tachome- Engine speed
ter is identical to Engine sensor system
the engine speed sen- <4M4>
speed displayed sor
on MUT-II. <4M4>
(2) Gradually in-
creases from (1)
Data List Communica- 51 Serial commu-
No.73 <6G7> tion with en- nication system
No.76 <4M4> gine-ECU
(2) Data changes.
Selector lever posi- No abnormal shock Malfunction - Engine stalls dur-
tion during shifting when start- ing shifting
(1) N to D Within 2 seconds of ing off - N-to-D shocks,
(2) N to R time lag large time lag
- N-to-R shocks,
large time lag
- N-to-D, N-to-R
shocks, large
time lag
Driving not - Does not move
possible forward
- Does not reverse
- Does not move
(forward or re-
verse)
No. Pre-test/opera- Test/operation Judgment value Check item Diag- Inspection pro-
tion conditions nosis cedure if there is
code an abnormality
No.
7 Suspends the Use the MUT-II to For (1), (2) and (3), Problem dur- - Shocks, engine
INVECS-II func- monitor data list Nos. the output shaft ing shifting racing
tion using MUT-II 11, 23 and 63. speed (vehicle - All points
Incorrect
Selector level (1) Accelerate to 5th speed) should be
shift points - Some points
position:D gear at an APS identical, and there
(Must be done on output of 1.5 V should be no abnor- - No diagnosis
No shifting
a level and (opening angle mal shocks. For (4), codes
straight road.) 30%). (5) and (6), down-
(2) Slowly deceler- shifting should occur 22 Input shaft speed
ate and stop. immediately after sensor system
(3) Accelerate to 5th the operation is car- 23 Output shaft sen-
gear at an APS ried out. sor system
output of 2.5 V
(opening angle No shifting 31 LR solenoid
50%). from 1st to valve system
(4) At 60 km/h in 5th, 2nd, or no 33 2nd solenoid
select Sports shifting from valve system
mode and shift 2nd to 1st
down to 4th. 41 1st without
(5) At 40 km/h in 4th, completion of
select Sports shifting
mode and shift 42 2nd without
down to 3rd. completion of
(6) At 20 km/h in 3rd, shifting
shift down to 2nd.
(7) At 20 km/h in No shifting 33 2nd solenoid
2nd, shift down from 2nd to valve system
to 1st. 3rd, or no 34 OD solenoid
shifting from valve system
3rd to 2nd
42 2nd without
completion of
shifting
43 3rd without
completion of
shifting
No shifting 31 LR solenoid
from 3rd to valve system
4th, or no 35 RED solenoid
shifting from valve system
4th to 3rd
43 3rd without
completion of
shifting
44 4th without
completion of
shifting
No shifting 32 UD solenoid
from 4th to valve system
5th, or no 33 2nd solenoid
shifting from valve system
5th to 4th
44 4th without
completion of
shifting
45 5th without
completion of
shifting
SHIFT PATTERN
<4M4>
Upshift pattern
Throttle opening % Thick line: Standard shift pattern
100
1 2 2 3 3 4 4 5
23 34
move- move-
ment ment
50 range 45
range move-
ment
range
Downshift pattern
Throttle opening % Thick line: Standard shift pattern
100
34 move-
1 2 ment range
4 5
3 4
4 5
50 2 3 (Sports
mode)
23 2 3
move- (Sports 3 4
ment 1 2 mode) (Sports
range (Sports mode) mode)
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
Output shaft speed r/min
<6G7>
Upshift pattern
Throttle opening % Thick line: Standard shift pattern
100
1 2 2 3 3 4 4 5
23 move- 34 move-
ment range ment range
50 45 move-
ment range
OK
MUT-II Data List Transient malfunction
D No.11 APS (Refer to GROUP 00 - Points to
OK: Refer to P.23-61 (Data List Note for Transient Malfunctions.)
Chart).
NG
OK
(1)NG NG
Measure at APS connector D-135 Check the following connectors: Repair
D Disconnect the connector and <6G7> D-120, <4M4> D-112
measure at the harness side. OK
(1) <6G7> Resistance between NG
terminal 1 and earth D Check the harness between the
Repair
<4M4> Resistance between APS and the engine-A/T-ECU.
terminal 7 and earth <6G7>
OK: 2 W or less D Check the harness between the
(2) <6G7> Voltage between terminal APS and the engine-ECU. <4M4>
2 and earth
OK
<4M4> Voltage between terminal
8 and earth NG
(Ignition switch: ON) Check the trouble symptoms. Replace the engine-A/T-ECU or
OK: 4.8 - 5.2 V NG engine-ECU.
(2)NG OK
Check the following connectors: D Check the harness between the
<6G7> D-120, <4M4> D-112 APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
OK NG D Check the harness between the
APS and the engine-ECU, and
Repair repair if necessary. <4M4>
NG
Measure at engine-A/T-ECU APS adjustment
connector D-121 <6G7>, or at (Refer to GROUP 13 - On-vehicle
A/T-ECU connector D-107 <4M4>. Service.)
D Measure at the ECU terminals
D Ignition switch: ON
D <6G7> Voltage between terminal
95 and earth OK
Check the following connectors: D Check the harness between the
D <4M4> Voltage between terminal <6G7> D-121, <4M4> D-108 APS and the engine-A/T-ECU,
45 and earth and repair if necessary. <6G7>
OK: Fully close the accelerator NG
D Check the harness between the
985 - 1,085 mV APS and the A/T-ECU, and
fully open the accelerator Repair repair if necessary. <6G7>
4,000 mV or more
OK NG
Check the following connectors: Repair
<6G7> D-121, <4M4> D-108
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU or
A/T-ECU.
OK
NG OK
Measure at APS connector D-135 Measure at engine-A/T-ECU Check the following connectors:
D Disconnect the connector and connector D-120 <6G7>, or at <6G7> D-120, <4M4> D-112
measure at the harness side. engine-ECU connector D-112 <4M4>.
D <6G7>Voltage between terminal D Measure at the ECU terminals OK NG
2 and earth D Ignition switch: ON
D <4M4>Voltage between terminal D <6G7> Voltage between terminal Repair
8 and earth 46 and earth
D Check the harness between the
OK: 4.8 - 5.2 V D <4M4> Voltage between terminal
APS and the engine-A/T-ECU,
60 and earth
OK and repair if necessary. <6G7>
OK: 4.8 - 5.2 V
D Check the harness between the
NG APS and the engine-ECU, and
repair if necessary. <4M4>
NG
D Check the harness between the
Repair
APS and the engine-A/T-ECU.
<6G7>
D Check the harness between the
APS and the engine-ECU. <4M4>
OK
Measure at APS connector D-135.
D Use the test harness NG
Check the trouble symptoms. Replace the engine-A/T-ECU or
(MB991658) to connect only
engine-ECU.
terminals 1, 2 and 3 <6G7>, or
only terminals 6, 7 and 8 <4M4>, (1)NG Check the following connectors: NG
and then measure at the pickup <6G7> D-120, <4M4> D-112 Repair
harness.
D Ignition switch: ON OK
(1) <6G7> Voltage between terminal
2 and earth D Check the harness between the
<4M4> Voltage between terminal
APS and the engine-A/T-ECU,
8 and earth and repair if necessary. <6G7>
OK: 4.8 - 5.2 V D Check the harness between the
(2) <6G7> Voltage between terminal APS and the engine-ECU, and
3 and earth repair if necessary. <4M4>
<4M4> Voltage between terminal
6 and earth (2)NG
OK: Fully close the accelerator APS adjustment (Refer to GROUP
985 - 1,085 mV 13 - On-vehicle Service.)
fully open the accelerator D Check the harness between the
4,000 mV or more APS and the engine-A/T-ECU,
and repair if necessary. <6G7>
Check the following connectors: OK D Check the harness between the
OK <6G7> D-121, <4M4> D-108 APS and the engine-ECU, and
repair if necessary. <4M4>
NG
To the next page Repair
OK Transient malfunction
MUT-II Data List
D No.11 APS (Refer to GROUP 00 - Points to
OK: Refer to P.23-61 (Data List Note for Transient Malfunctions.)
Chart).
NG
NG
Check the following connector: Repair
D-135
OK
NG
Check the following connectors: Repair
<6G7> D-120, <4M4> D-112
OK
D Check the harness between the NG
APS and the engine-A/T-ECU. Repair
<6G7>
D Check the harness between the
APS and the engine-ECU. <4M4>
OK
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU or
engine-ECU.
(1)NG OK
Measure at APS connector D-135. Check the following connectors: D Check the harness between the
D Use the test harness <6G7> D-120, <4M4> D-112 APS and the engine-A/T-ECU,
(MB991658) to connect only (2)NG and repair if necessary. <6G7>
terminals 1, 2 and 3 <6G7>, or D Check the harness between the
only terminals 6, 7 and 8 <4M4>, NG
APS and the engine-ECU, and
and then measure at the pickup repair if necessary. <4M4>
harness.
D Ignition switch: ON Repair
(1) <6G7> Voltage between terminal
1 and earth
<4M4> Voltage between terminal (3)NG
7 and earth APS adjustment
OK: 0.5 V or less (Refer to GROUP 13 - On-vehicle
(2) <6G7> Voltage between terminal Service.)
2 and earth
<4M4> Voltage between terminal
8 and earth OK D Check the harness between the
Check the following connectors:
(Ignition switch: ON) <6G7> D-121, <4M4> D-108 APS and the engine-A/T-ECU,
OK: 4.8 - 5.2 V and repair if necessary. <6G7>
(3) <6G7> Voltage between terminal NG D Check the harness between the
3 and earth APS and the A/T-ECU, and
<4M4> Voltage between terminal Repair repair if necessary. <4M4>
6 and earth
OK: Fully close the accelerator
985 - 1,085 mV
fully open the accelerator
4,000 mV or more
OK
NG OK
Measure at engine-A/T-ECU Check the following connectors: D Check the harness between the
connector D-121 <6G7>, or at <6G7> D-121, <4M4> D-108 APS and the engine-A/T-ECU,
A/T-ECU connector D-107 <4M4>. and repair if necessary. <6G7>
NG D Check the harness between the
D Measure at the ECU terminals.
D Ignition switch: ON APS and the A/T-ECU, and
Repair repair if necessary. <4M4>
D <6G7> Voltage between terminal
95 and earth
D <4M4> Voltage between terminal
45 and earth OK NG
OK: Fully close the accelerator Check the following connectors:
<6G7> C-121, <4M4> C-108 Repair
985 - 1,085 mV
fully open the accelerator OK
4,000 mV or more Replace the engine-A/T-ECU or
NG
Check the trouble symptoms. A/T-ECU.
NG
Measure at engine-A/T-ECU connector D-121 <6G7>, or at Check the following connectors: <6G7> D-121, <4M4> D-108
A/T-ECU connector D-107 <4M4>. NG
D Measure at the ECU terminals OK
D Ignition switch: ON
Repair
D <6G7> Voltage between terminal 81 and earth
D <4M4> Voltage between terminal 43 and earth Check the trouble symptoms.
OK: 0.5 V or less
NG
OK
Replace the engine-A/T-ECU or A/T-ECU.
NG
Measure at engine-A/T-ECU connector D-122 <6G7>, or at Check the following connectors: <6G7> D-122, <4M4> D-108
A/T-ECU connector D-108 <4M4>.
OK NG
D Measure at the ECU terminals
D Ignition switch: ON
D <6G7> Voltage between terminal 124 and earth Revision
D <4M4> Voltage between terminal 44 and earth
OK: A/T fluid temperature Check the trouble symptoms.
3.8 - 4.0 V at 20_C NG
3.2 - 3.4 V at 40_C
1.7 - 1.9 V at 80_C Replace the engine-A/T-ECU or A/T-ECU.
OK
NG
Check the following connectors: <6G7> C-04, D-122, Repair
D-121,<4M4> D-108, C-04
OK
NG
Measure at solenoid valve assembly connector C-04. Replace the A/T fluid temperature sensor. L
D Disconnect the connector and measure at the sensor side.
D Resistance between terminals 1 and 2
OK: A/T fluid temperature
16.7 - 20.5 kW at 0_C
7.3 - 8.9 kW at 20_C
3.4 - 4.2 kW at 40_C
1.9 - 2.2 kW at 60_C
1.0 - 1.2 kW at 80_C
0.57 - 0.69 kW at 100_C
OK
Code No. 21 Crank angle sensor <6G7> or engine speed Probable cause
sensor <4M4> system
If no output pulse from the crank angle sensor or engine speed sensor is D Malfunction of crankshaft sensing blade <6G7>
detected for 5 seconds or more when the vehicle speed is 25 km/h or more, it D Malfunction of crank angle sensor <6G7>
is judged that there is an open circuit in the crank angle sensor or an open D Malfunction of engine speed sensor <4M4>
circuit in the engine speed sensor, and code No. 21 is output. D Malfunction of harness or connector
D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
OK
Measure at crank angle sensor (1)NG Check the following connectors: OK D Check the harness between the
connector B-52 <6G7>, or at <6G7> B-52, <4M4> B-36 crank angle sensor and body
injection pump assembly connector earth, and repair if necessary.
B-36 <4M4>. NG <6G7>
D Disconnect the connector and D Check the harness between the
measure at the harness side. Repair injection pump assembly and
(1) <6G7> Resistance between body earth, and repair if
terminal 1 and earth necessary. <4M4>
<4M4> Resistance between
terminal 4 and earth (2)NG Measure at engine-A/T-ECU OK Check the following connectors:
OK: 2 W or less connector D-120 <6G7>, or at <6G7> D-120,<4M4> D-113, D-108
(2) Voltage between terminal 2 and A/T-ECU connector D-107 <4M4>.
earth D Measure at the ECU terminals OK NG
(Ignition switch: ON) D Disconnect connector B-52
OK: 4.8 - 5.2 V <6G7>, or connector B-36 Repair
(3) Voltage between terminal 3 and <4M4>. D Check the harness between the
earth D Ignition switch: ON
(Ignition switch: ON) crank angle sensor and the
D <6G7> Voltage between terminal engine-A/T-ECU, and repair if
OK: System voltage 45 and earth necessary. <6G7>
D <4M4> Voltage between terminals D Check the harness between the
33 and earth injection pump assembly and the
OK: 4.8 - 5.2 V A/T-ECU, and repair if necessary.
NG <4M4>
NG
Check the following connectors: Repair
<6G7> D-120, <4M4> D-113, D-108
OK
OK
D Check the harness between the Check the trouble symptoms.
crank angle sensor and the NG
engine-A/T-ECU. <6G7>
D Check the harness between the
Replace the engine-A/T-ECU or
injection pump assembly and the
A/T-ECU.
A/T-ECU. <4M4> NG
Repair
(3)NG
OK
Check the following connector: D Check the harness between the
B-25X crank angle sensor and the
engine control relay, and repair if
OK NG necessary. <6G7>
D Check the harness between the
Repair injection pump assembly and the
NG engine control relay, and repair if
Measure the output wave pattern at Check the following connectors: necessary. <4M4>
crank angle sensor connector <6G7> B-52, D-120, B-25X NG
B-52 <6G7>, or at injection pump <4M4> D-108, D-113, B-36, B-25X Repair
assembly connector B-36 <4M4>
(using an oscilloscope). OK
D Use the test harness (MD998478)
to connect the terminals, and NG
then measure at the pickup D Check the harness between the Repair
harness. crank angle sensor and the
D Engine: Idling engine-A/T-ECU, and repair if
D Selector lever position: P necessary. <6G7>
D Voltage between terminal 2 and D Check the harness between the
earth engine speed sensor and the
OK: A wave pattern such as the A/T-ECU, and repair if necessary.
one shown on P.23-69 <4M4>
(Check Procedure Using an D Check the harness between the
Oscilloscope) should be crank angle sensor and the
output, and the maximum engine control relay, and repair if
value should be 4.8 V or necessary. <6G7> OK
D Check the harness between the Check the trouble symptoms.
more and the minimum val-
ue should be 0.6 V or less. engine speed sensor and the NG
There should be no noise engine control relay, and repair if
in the output wave pattern. necessary. <4M4> Replace the crank angle sensor
D Check the harness between the <6G7> or the engine speed sensor
OK crank angle sensor and body <4M4>.
earth, and repair if necessary.
Check the trouble symptoms. <6G7>
D Check the harness between the
NG engine speed sensor and body Replace the crankshaft sensing
earth, and repair if necessary. blade. <6G7>
Replace the engine-A/T-ECU or
A/T-ECU. <4M4>
OK
MUT-II Data List Transient malfunction
D No. 22 Input shaft speed sensor (Refer to GROUP 00 - Points to
OK: Refer to P.23-61 (Data List Note for Transient Malfunctions.)
Chart).
NG
NG NG
Measure at engine-A/T-ECU Check the following connectors: Repair
connector D-121 <6G7>, or at <6G7> D-121, <4M4> D-108
A/T-ECU connector D-107 <4M4>. OK
D Measure at the ECU terminals
D Ignition switch: ON NG
D <6G7> Voltage between terminal Check the trouble symptoms. Replace the engine-A/T-ECU or
81 and earth A/T-ECU.
D <4M4> Voltage between terminal
43 and earth
OK: 0.5 V or less
OK
NG NG
Measure at engine-A/T-ECU Check the following connectors: Repair
connector D-122 <6G7>, or at <6G7> D-122, <4M4> D-108
A/T-ECU connector D-108 <4M4>.
D Measure at the ECU terminals OK
D Disconnect C-23 NG
D Ignition switch: ON Check the trouble symptoms. Replace the engine-A/T-ECU or
D <6G7> Voltage between terminal A/T-ECU.
103 and earth
D <4M4> Voltage between terminal
31 and earth
OK: 4.8 - 5.2 V
OK
NG NG
Measure the output wave pattern of Check the following connectors: Repair
the input shaft speed sensor at <6G7> D-121, D-122, <4M4> D-108
engine-A/T-ECU connectors D-121
and D-122 <6G7>, or at A/T-ECU OK
connector D-108 <4M4> (using an NG
oscilloscope). Check the trouble symptoms. Replace the engine-A/T-ECU or
D Vehicle speed: approx. 50 km/h A/T-ECU.
D Shift range: 4th
D <6G7> Voltage between terminal
81 of D-121 and terminal 103 of
D-122
D <4M4> Voltage between terminal
31 of D-108 and terminal 43 of
D-108
OK: A wave pattern such as the
one shown on P.23-69
(Check Procedure Using an
Oscilloscope) should be
output, and the maximum
value should be 4.8 V or
more and the minimum val-
ue should be 0.8 V or less.
There should be no noise
in the output wave pattern.
OK
NG
NG
Check the following connectors: Repair
D-208, D-213, D-32, E-115, E-113
OK
NG
D Check the harness between the Repair
input shaft speed sensor and the
engine-A/T-ECU (earth line).
<6G7>
D Check the harness between the
input shaft speed sensor and the
A/T-ECU (earth line). <4M4>
D Check the harness between the
input shaft speed sensor and the
ignition switch.
OK
OK NG
MUT-II Data List Transient malfunction Repair
D No. 23 Output shaft speed (Refer to GROUP 00 - Points to
sensor system Note for Transient Malfunctions.)
OK: Refer to P.23-61 (Data List
Chart).
NG
NG NG
Measure at engine-A/T-ECU Check the following connectors: Repair
connector D-121 <6G7>, or at <6G7> D-122, <4M4> D-108
A/T-ECU connector D-107 <4M4>. OK
D Measure at the ECU terminals NG
D Ignition switch: ON Check the trouble symptoms. Replace the engine-A/T-ECU or
D <6G7>Voltage between terminals
A/T-ECU.
81 and earth
D <4M4> Voltage between terminal
43 and earth
OK: 0.5 V or less
OK
NG NG
Measure at engine-A/T-ECU Check the following connectors: Repair
connector D-122 <6G7>, or at <6G7> D-122, <4M4> D-108
A/T-ECU connector D-108 <4M4>. OK
D Measure at the ECU terminals
D Disconnect C-02 NG
D Ignition switch: ON Check the trouble symptoms. Replace the engine-A/T-ECU or
D <6G7>Voltage between terminals A/T-ECU.
104 and earth
D <4M4> Voltage between terminal
32 and earth
OK: 4.8 - 5.2 V
OK
OK NG
Measure the output wave pattern of Check the following connectors: Repair
the output shaft speed sensor at <6G7> D-121, D-122, <4M4> D-108
engine-A/T-ECU connectors D-121
and D-122 <6G7>, or at A/T-ECU OK
connector D-108 <4M4> (using an NG
oscilloscope). Check the trouble symptoms. Replace the engine-A/T-ECU or
D Vehicle speed: approx. 50 km/h A/T-ECU.
D Shift range: 4th
D <6G7> Voltage between terminal
81 of D-121 and terminal 104 of
D-122
D <4M4> Voltage between terminal
32 of D-108 and terminal 43 of
D-108
OK: A wave pattern such as the
one shown on P.23-69
(Check Procedure Using an
Oscilloscope) should be
output, and the maximum
value should be 4.8 V or
more and the minimum val-
ue should be 0.8 V or less.
There should be no noise
in the output wave pattern.
NG
Measure at output shaft speed (1)NG OK D Check the harness between the
sensor connector C-23. Check the following connector: E-113 output shaft speed sensor and
D Disconnect the connector and the engine-A/T-ECU (earth line),
NG
measure at the harness side. and repair if necessary. <6G7>
(1) Resistance between terminal 1 D Check the harness between the
and earth output shaft speed sensor and
OK: 2 W or less Repair the A/T-ECU (earth line), and
(2) Voltage between terminal 2 and repair if necessary. <4M4>
earth
(Ignition switch: ON) (2)NG OK
OK: 4.8 - 5.2 V Check the following connector: E-113 D Check the harness between the
(3) Voltage between terminal 3 and output shaft speed sensor and
earth NG the engine-A/T-ECU (earth line),
(Ignition switch: ON) and repair if necessary. <6G7>
OK: System voltage Repair D Check the harness between the
output shaft speed sensor and
the A/T-ECU (sensor line), and
repair if necessary. <4M4>
(3)NG
OK Check the harness between the
Check the following connectors:
D-208, D-213, D-32, E-115 output shaft speed sensor and the
ignition switch, and repair if
NG
OK necessary.
Repair
Replace the output shaft speed
sensor. L
NG
D Check the harness between the Repair
output shaft speed sensor and
the engine-A/T-ECU. <6G7>
D Check the harness between the
output shaft speed sensor and
the A/T-ECU. <4M4>
D Check the harness between the
output shaft speed sensor and
the ignition switch.
OK
OK
MUT-II Data list Transient malfunction
D No.25 Wide open throttle switch (Refer to GROUP 00 - Points to Note for Transient
OK: The switch turns ON when fully open the accelerator Malfunctions.)
the switch turns OFF when fully close the accelera-
tor.
NG
NG
Wide open throttle switch single part check Replace
OK
NG
Measure at Wide open throttle switch connector D-134 Check the following connectors: <6G7-L.H. drive vehicles>
D Disconnect the connector and measure at the harness D-122, D-134, <6G7-R.H. drive vehicles> D-122, E-11, D-124,
side. D-134, <4M4-L.H. drive vehicles> D-109, D-134, <4M4-R.H. drive
D Ignition switch: ON vehicles> D-109, E-11, D-124, D-134
D Voltage between terminal 1 and earth
OK NG
OK: System voltage
OK
Repair
Check the following connector: <L.H. drive vehicles> D-14 D Check the harness between the Wide open throttle switch
NG and the engine-A/T-ECU, and repair if necessary. <6G7>
OK D Check the harness between the Wide open throttle switch
Repair and the A/T-ECU, and repair if necessary. <4M4>
NG
OK Transient malfunction
MUT-II Data List
D No. 26 Stop lamp switch system (Refer to GROUP 00 - Points to
OK: The switch turns ON when Note for Transient Malfunctions.)
brake pedal is depressed
the switch turns OFF when
the brake pedal is released.
NG
NG
Stop lamp switch check Replace
(Refer to GROUP 35A - On-vehicle
Service.)
OK
NG
Check the following connector: Repair
D-136
OK
NG OK
Measure at stop lamp switch Check the following connectors: Check the harness between the stop
connector D-136. <L.H. drive vehicles> D-26, D-27 lamp switch and the battery, and
D Disconnect the connector and <R.H. drive vehicles> D-124, D-27 repair if necessary.
measure at the harness side. NG
D Voltage between terminals 2 and
earth
OK: System voltage Repair
OK
NG OK
Measure at engine-A/T-ECU Check the following connectors: D Check the harness between the
connector D-122 <6G7>, A/T-ECU <6G7-L.H. drive vehicles> D-27, D-26, stop lamp switch and the
connector D-109 <4M4>. D-33, E-13, D-128, D-122, engine-A/T-ECU, and repair if
D Measure at the ECU terminals <6G7-R.H. drive vehicles> D-27, D-124, necessary. <6G7>
D <6G7> Voltage between terminals E-13, D-128, D-122, D Check the harness between the
123 and earth <4M4-L.H. drive vehicles> D-27, D-26, stop lamp switch and the
D <4M4> Voltage between terminal D-33, E-13, D-128, D-109 A/T-ECU, and repair if necessary.
59 and earth <4M4-R.H. drive vehicles> D-27, D-124, <4M4>
OK: System voltage when brake E-13, D-128, D-109 D Check the harness between the
pedal is depressed stop lamp switch and the battery,
1 V or less when the brake NG and repair if necessary.
pedal is released
Repair
OK
OK NG
Check the following connectors: Check the trouble symptoms. Replace the engine-A/T-ECU or
<6G7> D-122, <4M4> D-109 A/T-ECU.
NG
Repair
NG
Check the following connector: C-04 Repair
OK
NG
Measure at solenoid valve assembly connector C-04. Replace the LR solenoid valve L
D Disconnect the connector and measure at the solenoid
valve side.
D Resistance between terminals 6 and 10
OK: 2.7 - 3.4 W
OK
NG
Measure at solenoid valve assembly connector C-04. Check the following connectors: E-113, D-12
D Disconnect the connector and measure at the harness
OK NG
side.
D Ignition switch: ON
D Voltage between terminal 10 and earth Repair
OK: System voltage
Check the harness between the solenoid valve assembly and
OK the A/T control relay, and repair if necessary.
NG
Check the following connectors: <6G7> D-122, E-113, D-12 Repair
<4M4> D-109, E-113, D-12
OK
MUT-II Self-Diag Code YES Code No. 54 - A/T control relay system check
D Is code No. 54 output? (Refer to P.23-103.)
NO
NG
Measure at solenoid valve assembly connector C-04. Check the following connectors: E-113, D-12
D Disconnect the connector and measure at the harness
OK NG
side.
D Ignition switch: ON Repair
D Voltage between terminals 9 and earth
OK: System voltage
OK Check the harness between the solenoid valve assembly and
the A/T control relay, and repair if necessary.
NG
Check the following connectors: <6G7> D-122, E-113, D-12, Repair
<4M4> D-107, E-113, D-12
OK
MUT-II Self-Diag Code YES Code No. 54 - A/T control relay system check
D Is code No. 54 output? (Refer to P.23-103.)
NO
NG
Measure at engine-A/T-ECU connector D-122 <6G7>, or at Check the following connectors: <6G7> D-122, <4M4> D-107
A/T-ECU connector D-107 <4M4>. OK NG
D Measure at the ECU terminals
D Ignition switch: ON Repair
D <6G7> Voltage between terminal 106 and earth
D <4M4> Voltage between terminal 16 and earth Check the trouble symptoms.
OK: System voltage
NG
OK
Replace the engine-A/T-ECU or A/T-ECU.
NG
Check the following connector: C-04 Repair
OK
NG
Measure at solenoid valve assembly connector C-04. Replace the 2nd solenoid valve. L
D Disconnect the connector and measure at the solenoid
valve side.
D Resistance between terminals 4 and 9
OK: 2.7 - 3.4 W
OK
NG
Measure at solenoid valve assembly connector C-04. Check the following connectors: E-113, D-12
D Disconnect the connector and measure at the harness
OK NG
side.
D Ignition switch: ON Repair
D Voltage between terminals 9 and earth
OK: System voltage
OK Check the harness between the solenoid valve assembly and
the A/T control relay, and repair if necessary.
NG
Check the following connectors: <6G7> D-122, E-113, D-12, Repair
<4M4> D-107, E-113, D-12
OK
MUT-II Self-Diag Code YES Code No. 54 - A/T control relay system check
D Is code No. 54 output? (Refer to P.23-103.)
NO
NG
Measure at solenoid valve assembly connector C-04. Check the following connectors: E-113, D-12
D Disconnect the connector and measure at the harness
OK NG
side.
D Ignition switch: ON Repair
D Voltage between terminals 9 and earth
OK: System voltage
NG
Check the following connectors: <6G7> D-122, E-113, D-12, Repair
<4M4> D-107, E-113, D-12
OK
MUT-II Self-Diag Code YES Code No. 54 - A/T control relay system check
D Is code No. 54 output? (Refer to P.23-103.)
NO
NG
Measure at solenoid valve assembly connector C-04. Check the following connectors: E-113, D-12
D Disconnect the connector and measure at the harness
OK NG
side.
D Ignition switch: ON Repair
D Voltage between terminal 10 and earth
OK: System voltage
OK Check the harness between the solenoid valve assembly and
the A/T control relay, and repair if necessary.
NG
Check the following connectors: <6G7> D-122, E-113, D-12, Repair
<4M4> D-109, E-113, D-12
OK
MUT-II Self-Diag Code YES Code No. 54 - A/T control relay system check
D Is code No. 54 output? (Refer to P.23-103.)
NO
NG
Measure at engine-A/T-ECU connector D-122 <6G7>, or at Check the following connectors: <6G7> D-122, <4M4> D-107
A/T-ECU connector D-107 <4M4>. OK NG
D Measure at the ECU terminals.
D Ignition switch: ON Repair
D <6G7> Voltage between terminal 107 and earth
D <4M4> Voltage between terminal 15 and earth
OK: System voltage Check the trouble symptoms.
OK NG
NG
Check the following connector: C-04 Repair
OK
NG
Measure at solenoid valve assembly connector C-04. Replace the DCC solenoid valve. L
D Disconnect the connector and measure at the solenoid
valve side.
D <4M4> Resistance between terminal 7 and 10
OK: 2.7 - 3.4 W
OK
NG
Measure at solenoid valve assembly connector C-04. Check the following connectors: E-113, D-12
D Disconnect the connector and measure at the harness
OK NG
side.
D Ignition switch: ON Repair
D Voltage between terminal 10 and earth
OK: System voltage
OK Check the harness between the solenoid valve assembly and
the A/T control relay, and repair if necessary.
NG
Check the following connectors: <6G7> D-122, E-113, D-12, Repair
<4M4> D-107, E-113, D-12
OK
MUT-II Self-Diag Code YES Code No. 22 Input shaft speed sensor system check
D Is code No. 22 output? (Refer to P.23-20.)
NO
MUT-II Actuator Test YES Code No. 23 Input shaft speed sensor system check
D Is code No. 23 output? (Refer to P.23-22.)
NO
NG
MUT-II Actuator Test Replace the appropriate solenoid valve. L
D No.1 LR solenoid valve
D No.2 UD solenoid valve
D No.3 2ND solenoid valve
D No.4 OD solenoid valve
D No.5 RED solenoid valve
OK: The sound of operation should be heard.
OK
NG
Measure the output wave pattern of the input shaft speed D Check the harness between the input shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the input shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h OK NG
D Shift range: 4th
<6G7> Voltage between No.81 (D-121) and No.103 (D-122)
<4M4> Voltage between No.31 (D-108) and No.43 (D-108) Repair
OK: A wave pattern such as the one shown on P.23-69 Replace the input shaft speed sensor. L
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There
Check the trouble symptoms.
should be no noise in the output wave pattern.
NG
OK
Overhaul the A/T. L
D Replace the reverse clutch retainer.
Measure the output wave pattern of the output shaft speed NG D Check the harness between the output shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the output shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h OK NG
D Shift range: 4th
<6G7> Voltage between No.81 (D-121) and No.104 (D-122) Repair
<4M4> Voltage between No.32 (D-108) and No.43 (D-108)
OK: A wave pattern such as the one shown on P.23-69 Replace the output shaft speed sensor. L
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There Check the trouble symptoms.
should be no noise in the output wave pattern.
NG
OK
Overhaul the A/T. L
D Replace the direct planetary carrier.
Replace the valve body assembly. L
MUT-II Self-Diag Code YES Code No. 22 Input shaft speed sensor system check
D Is code No. 22 output? (Refer to P.23-20.)
NO
MUT-II Actuator Test YES Code No. 23 Output shaft speed sensor system check
D Is code No. 23 output? (Refer to P.23-22.)
NO
NG
MUT-II Actuator Test Replace the appropriate solenoid valve. L
D No.1 LR solenoid valve
D No.2 UD solenoid valve
D No.3 2ND solenoid valve
D No.4 OD solenoid valve
D No.5 RED solenoid valve
OK: The sound of operation should be heard.
OK
NG
Measure the output wave pattern of the input shaft speed D Check the harness between the input shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the input shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h
OK NG
D Shift range: 4th
<6G7> Voltage between No.81 (D-121) and No.103 (D-122)
<4M4> Voltage between No.31 (D-108) and No.43 (D-108) Repair
OK: A wave pattern such as the one shown on P.23-69
(Check Procedure Using an Oscilloscope) should be Replace the input shaft speed sensor. L
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There
should be no noise in the output wave pattern. Check the trouble symptoms.
OK NG
Overhaul the A/T. L
D Replace the reverse clutch retainer.
Measure the output wave pattern of the output shaft speed NG D Check the harness between the output shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the output shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h OK NG
D Shift range: 4th
<6G7> Voltage between No.81 (D-121) and No.104 (D-122) Repair
<4M4> Voltage between No.32 (D-108) and No.43 (D-108) Replace the output shaft speed sensor. L
OK: A wave pattern such as the one shown on P.23-69
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There Check the trouble symptoms.
should be no noise in the output wave pattern.
NG
OK
Overhaul the A/T. L
Replace the valve body assembly. L D Replace the direct planetary carrier.
MUT-II Self-Diag Code YES Code No. 22 Input shaft speed sensor system check
D Is code No. 22 output? (Refer to P.23-20.)
NO
MUT-II Actuator Test YES Code No. 23 Output shaft speed sensor system check
D Is code No. 23 output? (Refer to P.23-22.)
NO
NG
MUT-II Actuator Test Replace the appropriate solenoid valve. L
D No.1 LR solenoid valve
D No.2 UD solenoid valve
D No.3 2ND solenoid valve
D No.4 OD solenoid valve
D No.5 RED solenoid valve
OK: The sound of operation should be heard.
OK
NG
Measure the output wave pattern of the input shaft speed D Check the harness between the input shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the input shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h NG
OK
D Shift range: 4th
<6G7> Voltage between No.81 (D-121) and No.103 (D-122) Repair
<4M4> Voltage between No.31 (D-108) and No.43 (D-108)
OK: A wave pattern such as the one shown on P.23-69 Replace the input shaft speed sensor. L
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There Check the trouble symptoms.
should be no noise in the output wave pattern.
NG
OK
Overhaul the A/T. L
D Replace the reverse clutch retainer.
MUT-II Self-Diag Code YES Code No. 22 Input shaft speed sensor system check
D Is code No. 22 output? (Refer to P.23-20.)
NO
MUT-II Actuator Test YES Code No. 23 Output shaft speed sensor system check
D Is code No. 23 output? (Refer to P.23-22.)
NO
NG
MUT-II Actuator Test Replace the appropriate solenoid valve. L
D No.1 LR solenoid valve
D No.2 UD solenoid valve
D No.3 2ND solenoid valve
D No.4 OD solenoid valve
D No.5 RED solenoid valve
OK: The sound of operation should be heard.
OK
NG
Measure the output wave pattern of the input shaft speed D Check the harness between the input shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the input shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h
D Shift range: 4th OK NG
<6G7> Voltage between No.81 (D-121) and No.103 (D-122) Repair
<4M4> Voltage between No.31 (D-108) and No.43 (D-108)
OK: A wave pattern such as the one shown on P.23-69 Replace the input shaft speed sensor. L
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There
Check the trouble symptoms.
should be no noise in the output wave pattern.
OK NG
Overhaul the A/T. L
D Replace the reverse clutch retainer.
Measure the output wave pattern of the output shaft speed NG D Check the harness between the output shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the output shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h OK NG
D Shift range: 4th
<6G7> Voltage between No.81 (D-121) and No.104 (D-122) Repair
<4M4> Voltage between No.32 (D-108) and No.43 (D-108) Replace the output shaft speed sensor. L
OK: A wave pattern such as the one shown on P.23-69
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There Check the trouble symptoms.
should be no noise in the output wave pattern.
NG
OK
Overhaul the A/T. L
Replace the valve body assembly. L D Replace the direct planetary carrier.
MUT-II Self-Diag Code YES Code No. 22 Input shaft speed sensor system check
D Is code No. 22 output? (Refer to P.23-20.)
NO
MUT-II Actuator Test YES Code No. 23 Output shaft speed sensor system check
D Is code No. 23 output? (Refer to P.23-22.)
NO
NG
MUT-II Actuator Test Replace the appropriate solenoid valve. L
D No.1 LR solenoid valve
D No.2 UD solenoid valve
D No.3 2ND solenoid valve
D No.4 OD solenoid valve
D No.5 RED solenoid valve
OK: The sound of operation should be heard.
OK
NG
Measure the output wave pattern of the input shaft speed D Check the harness between the input shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the input shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h NG
OK
D Shift range: 4th
<6G7> Voltage between No.81 (D-121) and No.103 (D-122) Repair
<4M4> Voltage between No.31 (D-108) and No.43 (D-108)
OK: A wave pattern such as the one shown on P.23-69 Replace the input shaft speed sensor. L
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There
should be no noise in the output wave pattern. Check the trouble symptoms.
NG
OK
Overhaul the A/T. L
D Replace the reverse clutch retainer.
Measure the output wave pattern of the output shaft speed NG D Check the harness between the output shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the output shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h OK NG
D Shift range: 4th
<6G7> Voltage between No.81 (D-121) and No.104 (D-122) Repair
<4M4> Voltage between No.32 (D-108) and No.43 (D-108)
OK: A wave pattern such as the one shown on P.23-69 Replace the output shaft speed sensor. L
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There Check the trouble symptoms.
should be no noise in the output wave pattern.
NG
OK
Overhaul the A/T. L
Replace the valve body assembly. L D Replace the direct planetary carrier.
MUT-II Self-Diag Code YES Code No. 22 Input shaft speed sensor system check
D Is code No. 22 output? (Refer to P.23-20.)
NO
MUT-II Actuator Test YES Code No. 23 Output shaft speed sensor system check
D Is code No. 23 output? (Refer to P.23-22.)
NO
NG
MUT-II Actuator Test Replace the appropriate solenoid valve. L
D No.1 LR solenoid valve
D No.2 UD solenoid valve
D No.3 2ND solenoid valve
D No.4 OD solenoid valve
D No.5 RED solenoid valve
OK: The sound of operation should be heard.
OK
NG
Measure the output wave pattern of the input shaft speed D Check the harness between the input shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the input shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h OK NG
D Shift range: 4th
<6G7> Voltage between No.81 (D-121) and No.103 (D-122)
Repair
<4M4> Voltage between No.31 (D-108) and No.43 (D-108)
OK: A wave pattern such as the one shown on P.23-69 Replace the input shaft speed sensor. L
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There Check the trouble symptoms.
should be no noise in the output wave pattern.
NG
OK
Overhaul the A/T. L
D Replace the reverse clutch retainer.
Measure the output wave pattern of the output shaft speed NG D Check the harness between the output shaft speed sensor
sensor at engine-A/T-ECU connectors D-121 and D-122 and the engine-A/T-ECU. <6G7>
<6G7>, or at A/T-ECU connector D-108 <4M4> (using an D Check the harness between the output shaft speed sensor
oscilloscope). and the A/T-ECU. <4M4>
D Vehicle speed: approx. 50 km/h
OK NG
D Shift range: 4th
<6G7> Voltage between No.81 (D-121) and No.104 (D-122) Repair
<4M4> Voltage between No.32 (D-108) and No.43 (D-108)
Replace the output shaft speed sensor. L
OK: A wave pattern such as the one shown on P.23-69
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or more
and the minimum value should be 0.8 V or less. There Check the trouble symptoms.
should be no noise in the output wave pattern.
NG
OK
Overhaul the A/T. L
Replace the valve body assembly. L D Replace the reverse clutch.
<6G7>
Malfunction of engine-A/T-ECU
<4M4>
NG
Check the following connectors: D-112, D-109 Repair
OK
NG
Check the harness between the engine-ECU and the Repair
A/T-ECU.
OK
Malfunction of A/T-ECU
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
A/T control relay check Replace
(Refer to P.23-103.)
OK
NG
Check the following connector: D-12 Replace
OK
(1)NG NG
Measure at A/T control relay Check the following connector: <L.H. Repair
connector D-12. drive vehicles> A-04, <R.H. drive
D Disconnect the relay and vehicles> D-145
measure at the connector side.
(1) Voltage between terminal 1 and OK
earth Check the harness between the A/T
OK: System voltage control relay and the battery.
(2) Resistance between terminal 2
and earth (2)NG NG
OK: 2 W or less Check the following connector: D-14 Repair
(3) Voltage between terminal 4 and OK
earth
(Ignition switch: ON) Check the harness between the A/T
OK: System voltage control relay and body earth.
(3)NG OK
Measure at engine-A/T-ECU Check the following connectors:
connector D-120 <6G7>, or at <6G7> D-120, <4M4> D-109
A/T-ECU connector D-109 <4M4>. OK NG
OK D Measure at the ECU terminals.
D <6G7> Voltage between terminal
50 and earth Repair
D <4M4> Voltage between terminal
71 and earth D Check the harness between the
OK: System voltage A/T control relay and the
engine-A/T-ECU. <6G7>
NG D Check the harness between the
A/T control relay and the
Measure at engine-A/T-ECU D Check the harness between the A/T-ECU, and repair if necessary.
connector D-121 <6G7>, or at A/T control relay and the <4M4>
A/T-ECU connector D-107 <4M4>. engine-A/T-ECU. <6G7>
D Measure at the ECU terminals. D Check the harness between the
D Ignition switch: ON A/T control relay and the
D <6G7> Voltage between terminals A/T-ECU. <4M4>
77, 89 and earth
D <4M4> Voltage between terminals OK NG
2, 3 and earth
Repair
OK: System voltage OK NG
Check the trouble symptoms. Replace the engine-A/T-ECU or
A/T-ECU.
NG
OK
Check the following connectors: D Check the harness between the
<6G7> D-121, <4M4> D-107 A/T control relay and the battery.
D Check the harness between the
NG A/T control relay and the
engine-A/T-ECU. <6G7>
Repair D Check the harness between the
A/T control relay and the
A/T-ECU, and repair if necessary.
<4M4>
NG
Check the following connectors: Repair
D-01, D-03
OK
NG NG
Measure at combination meter Check the following connector: D-30 Repair
connector D-01. OK
D Disconnect the connector and
measure at the harness side. Check the harness between the
D Resistance between terminal 57 combination meter and earth, and
and earth repair if necessary.
OK: 2 W or less
OK
NG NG
Measure at combination meter Check the following connectors: Repair
connector D-03. <6G7> D-122, E-11, <4M4> E-11,
D Disconnect the connector and E-113, D-109
measure at the harness side. OK
D Resistance between terminal 3
and earth
D Check the harness between the
OK: No continuity
combination meter and the
OK engine-A/T-ECU, and repair if
necessary. <6G7>
D Check the harness between the
combination meter and the
A/T-ECU, and repair if necessary.
<4M4>
Check the following connectors:
<6G7> D-30, D-122, E-11, <4M4> NG
D-30, E-11, D-109, E-113 Repair
OK
NG
D Check the harness between the Repair
combination meter and earth.
D Check the harness between the
combination meter and the
engine-A/T-ECU. <6G7>
D Check the harness between the
combination meter and the
A/T-ECU. <4M4>
OK
NO
Is communication with other systems possible Check the MUT-II diagnosis line, and repair if
using the MUT-II? necessary.
YES
OK
Measure at engine-A/T-ECU connector D-120, Check the following connectors: <6G7> D-120, NG Repair
D-121 <6G7>, or at A/T-ECU connectors D-107 D-121, <4M4> D-107, D-109
and D-109 <4M4>.
D Disconnect the connector and measure at the OK
harness side.
Check the trouble symptoms.
D Ignition switch: ON
<6G7> Voltage between terminals 41, 47 and NG
earth
<4M4> Voltage between terminals 11, 24 and Replace the engine-A/T-ECU or A/T-ECU.
earth
OK System voltage
<6G7> Continuity between terminals 76, 97,
88 and earth
<4M4> Continuity between terminals 13, 25,
26, 12, 72 and earth
OK Continuity
NG
NG
Check the following connectors: <6G7> A-04, Repair
B-25X, D-128, D-120, D-121, D-14, <4M4> D-208,
D-213, D-32, E-13, D-107, D-109, D-14
OK
NG
Check the trouble symptoms. D Check the harness between the
engine-A/T-ECU and the ignition switch, and
repair if necessary. <6G7>
D Check the harness between the A/T-ECU and
the ignition switch, and repair if necessary.
<4M4>
D Check the harness between the
engine-A/T-ECU and earth, and repair if
necessary. <6G7>
D Check the harness between the A/T-ECU and
earth, and repair if necessary. <4M4>
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU or A/T-ECU.
Inspection procedure 3
Does not move forward Probable cause
If the vehicle does not move forward when the engine is idling and the selector D Abnormal line pressure
lever is moved from N to D, 3, 2 or L, or if it is shifted to 1st or 2nd in Sports D Malfunction of UD solenoid valve
mode, the cause is probably a problem with line pressure, or a malfunction of D Malfunction of UD clutch system
the UD clutch or valve body. D Malfunction of valve body
D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
NG
MUT-II Actuator Test Replace the solenoid valve. L
D No.2 UD solenoid valve
OK: Sound of operation can be heard
OK
Fluid pressure test (Refer to P.23-106.) NG Disassemble, clean and re-assemble the valve body. L
D Measure the fluid pressure at each element in 1st in D Make sure that the mounting bolts are not loose and that
Sports mode the O-ring and valve body are not damaged or positioned
Standard value: Refer to P.23-106. incorrectly.
D If the extent of the damage looks too bad for repairs to be
OK
carried out, replace the valve body assembly.
NG
UD clutch check L Check the trouble symptoms.
D Check for a problem such as burnt facing, poor piston
sealing or interference with the retainer. NG
Replace the engine-A/T-ECU or A/T-ECU.
Inspection procedure 4
Does not reverse Probable cause
If the vehicle does not reverse when the engine is idling and the selector lever D Abnormal reverse clutch pressure
is moved from N to R, the cause is probably a problem with reverse clutch D Abnormal LR brake pressure
pressure or LR brake pressure, or a malfunction of the reverse clutch, LD clutch D Malfunction of LR solenoid valve
or valve body. D Malfunction of reverse clutch
D Malfunction of LR brake
D Malfunction of valve body
D Replacement of engine-A/T-ECU <6G7>
D Replacement of A/T-ECU. <4M4>
Check the reverse clutch and LR brake. L Check the trouble symptoms.
D Check for a problem such as burnt facing, poor piston
sealing or interference with the retainer. NG
Replace the engine-A/T-ECU or A/T-ECU.
Disassemble, clean and re-assemble the valve body. L Check the trouble symptoms.
D Make sure that the mounting bolts are not loose and that
the O-ring and valve body are not damaged or positioned NG
incorrectly.
Replace the engine-A/T-ECU or A/T-ECU.
D If the extent of the damage looks too bad for repairs to be
carried out, replace the valve body assembly.
Inspection procedure 6
Engine stalls during shifting Probable cause
If the engine stalls when the selector lever is moved from N to D or R while the D Malfunction of engine system
engine is idling, the cause is probably a malfunction of the engine system, DCC D Malfunction of DCC solenoid valve
solenoid valve, valve body, or torque converter (damper clutch). D Malfunction of valve body
D Malfunction of torque converter (malfunction of
damper clutch)
D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
OK
NG
Disassemble, clean and re-assemble the valve body. L Replace the torque converter assembly.
D Make sure that the mounting bolts are not loose and that
the O-ring and valve body are not damaged or positioned
incorrectly. Check the trouble symptoms.
D If the extent of the damage looks too bad for repairs to be
carried out, replace the valve body assembly. NG
Replace the engine-A/T-ECU or A/T-ECU.
Inspection procedure 7
N-to-D shocks, large time lag Probable cause
If abnormal shocks or a time lag of 2 seconds or more occurs when the D Abnormal UD clutch pressure
selector lever is moved from N to D while the engine is idling, the cause is D Malfunction of UD solenoid valve
probably abnormal UD clutch pressure, or a malfunction of the UD clutch, valve D Malfunction of UD clutch system
body or APS. D Malfunction of valve body
D Malfunction of APS
D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
NG
MUT-II Actuator Test Replace the solenoid valve. L
D No.2 UD solenoid valve
OK: Sound of operation can be heard
OK
When starting off
When are shocks generated? Shocks are sometimes generated.
During shifting NO YES
OK
UD clutch system check L Code No. 11, 12, 14 APS system check (Refer to P.23-13, 14
D Remove the transmission assembly, the valve body cover and 15.)
and the valve body.
D Blow air through the UD clutch oil hole in the transmission
case, and check that the piston operates to maintain
pressure. Disassemble, clean and re-assemble the valve body. L
D Make sure that the mounting bolts are not loose and that
the O-ring and valve body are not damaged or positioned
NG incorrectly.
D If the extent of the damage looks too bad for repairs to be
carried out, replace the valve body assembly.
Check the reverse clutch and LR brake. L Check the trouble symptoms.
D Check for a problem such as burnt facing, poor piston
NG
sealing or interference with the retainer.
Replace the engine-A/T-ECU or A/T-ECU.
Inspection procedure 9
N-to-D and N-to-R shocks, large time lag Probable cause
If abnormal shocks or a time lag of 2 seconds or more occurs when the D Abnormal line pressure
selector lever is moved from N to both D and R while the engine is idling, the D Malfunction of oil pump
cause is probably abnormal line pressure, or a malfunction of the oil pump or D Malfunction of valve body
valve body. D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
Inspection procedure 10
Shocks, engine racing Probable cause
If shocks occur when driving due to upshifting or downshifting, or the D Abnormal line pressure
transmission speed becomes higher than the engine speed, the cause is D Malfunction of solenoid valve
probably abnormal line pressure or a malfunction of a solenoid valve, oil pump, D Malfunction of oil pump
valve body or of a brake or clutch. D Malfunction of valve body
D Malfunction of brake or clutch
D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
NG
Adjust the line pressure. (Refer to P.23-111.) Replace the oil pump assembly. L
(The oil pump cannot be disassembled.)
OK
NG
Disassemble, clean and re-assemble the valve body. L Check the trouble symptoms.
D Make sure that the mounting bolts are not loose and that NG
the O-ring and valve body are not damaged or positioned
incorrectly.
D If the extent of the damage looks too bad for repairs to be Replace the engine-A/T-ECU or A/T-ECU.
carried out, replace the valve body assembly.
Inspection procedure 12
Some points (incorrect shift points) Probable cause
If some of the shift points are incorrect while driving, the cause is probably a D Malfunction of valve body
malfunction of the valve body, or it is a characteristic of control and is not a D Malfunction of engine-A/T-ECU <6G7>
malfunction. D Malfunction of A/T-ECU <4M4>
NO NO
Is standard shifting normal? Does the problem occur when the Disassemble, clean and re-assemble
ATF temperature is less than 35C the valve body. L
YES or higher than 120C? D Make sure that the mounting
bolts are not loose and that the
YES O-ring and valve body are not
Problem is a characteristic of control damaged or positioned incorrectly.
and is not a malfunction. D If the extent of the damage looks
too bad for repairs to be carried
out, replace the valve body
assembly.
Inspection procedure 13
No diagnosis code (no shifting) Probable cause
No shifting during driving D Malfunction of Inhibitor switch
However, if a diagnosis code is not output, the cause is probably malfunction of D Malfunction of shift switch assembly system
the inhibitor switch system, the shift switch assembly, the engine A/T-ECU or D Malfunction of engine-A/T-ECU <6G7>
the A/T-ECU. D Malfunction of A/T-ECU <4M4>
NO NG
Does the transmission stay at 3rd in MUT-II Data List Inspection Procedure 16: Inhibitor
D range? D No. 61 Inhibitor switch switch system check (Refer to
OK: The ECU input signal and P.23-58.)
YES the selector lever position
should correspond.
Is the backup power supply being
supplied to the A/T-ECU or to the OK
engine-A/T-ECU?
NG
NO YES MUT-II Data List Inspection Procedure 17: Shift switch
YES D No.67 Select switch assembly system check (Refer to
Is power being supplied to the D No.68 Shift switch (UP) P.23-58.)
A/T-ECU or to the D No.69 Shift switch (DOWN)
engine-A/T-ECU? OK: The ECU input signal and
NO the selector lever position
should correspond.
Inspection procedure 15
Vibration Probable cause
If vibration occurs when accelerating or decelerating while driving at a constant D Abnormal damper clutch pressure
speed or driving in top range, the cause is probably abnormal damper clutch D Malfunction of engine system
pressure, or a malfunction of the engine system, DCC solenoid valve, torque D Malfunction of DCC solenoid valve
converter or valve body. D Malfunction of torque converter
D Malfunction of valve body
D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
Fluid pressure test (Refer to P.23-106.) NG Disassemble, clean and re-assemble the valve body. L
D Measure the damper clutch fluid pressure. D Make sure that the mounting bolts are not loose and that
Standard value: Refer to P.23-106. the O-ring and valve body are not damaged or positioned
incorrectly.
OK D If the extent of the damage looks too bad for repairs to be
carried out, replace the valve body assembly.
Inspection procedure 16
Inhibitor switch system Probable cause
The cause is probably a malfunction of the inhibitor switch circuit or the ignition D Malfunction of Inhibitor switch
switch circuit. D Malfunction of ignition switch
D Malfunction of harness or connector
D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
NG
Inhibitor switch check (Refer to P.23-98.) Replace
OK
NG NG
Inhibitor switch connector C-05 voltage check Check the following connectors: D-208, D-213, Repair
D Disconnect the connector and measure at the D-32, E-115, C-05
harness side.
D Voltage between terminal 7 and earth OK
(Ignition switch: ON) NG
Check the harness between the inhibitor switch Repair
OK: System voltage
and the ignition switch.
OK
OK
Inspection procedure 17
Shift switch assembly system Probable cause
The cause is probably a malfunction of the inhibitor switch circuit, shift switch D Malfunction of inhibitor switch
assembly circuit, or of the engine-A/T-ECU or A/T-ECU. D Malfunction of select switch
D Malfunction of shift switch (UP)
D Malfunction of shift switch (DOWN)
D Malfunction of harness or connector
D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
NG
Inhibitor switch check (Refer to P.23-98.) Inhibitor switch check
D Inspection Procedure 16: Inhibitor switch system check
OK
(Refer to P.23-58.)
NG
Shift switch assembly check (Refer to P.23-117.) Replace
OK
NG
Check the following connectors: <6G7> E-117, E-113, Repair
D-122, <4M4> E-117, E-113, D-109
OK
NG
D Check the harness between the shift switch assembly and Repair
the engine-A/T-ECU. <6G7>
D Check the harness between the shift switch assembly and
the A/T-ECU. <4M4>
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU or A/T-ECU.
NG
Dual pressure switch check Replace
(Refer to GROUP 55 On-Vehicle Service.)
OK
NG NG
Measure at engine-A/T-ECU connector D-121 Check the following connectors: <6G7> D-121, Repair
<6G7> or at A/T-ECU connector D-107 <4M4>. A-04, <4M4> D-107, A-04
D Disconnect the connector and measure at the
harness side.
D Ignition switch: ON
D A/C switch: ON Check the trouble symptoms.
D <6G7> Voltage between terminal 83 and earth NG
<4M4> Voltage between terminal 10 and
earth A/C system check (Refer to GROUP 55 -
OK: System voltage Troubleshooting.)
OK
Replace the engine-A/T-ECU or A/T-ECU.
Inspection procedure 19
Vehicle speed sensor system Probable cause
The cause is probably a malfunction of the vehicle speed sensor circuit, or of D Malfunction of vehicle speed sensor
the A/T-ECU or the engine-A/T-ECU. D Malfunction of connector
D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
NO
Is the speedometer correct? Speedometer check
(Refer to GROUP 54A - Combination Meter.)
YES
OK
MUT-II Data List Transient malfunction (Refer to GROUP 00 - Points to Note
D No.29 Vehicle speed sensor for Transient Malfunctions.)
OK: Refer to P.23-61 (Data List Chart).
NG
NG
Check the following connectors: <6G7> C-09, E-113, E-13, Repair
D-121 <4M4> C-09, E-113, E-13, D-109
OK
NG
D Check the harness between the engine-A/T-ECU and the Repair
vehicle speed sensor. <6G7>
D Check the harness between the A/T-ECU and the vehicle
speed sensor. <4M4>
OK
Inspection procedure 20
4LLc switch system Probable cause
The cause is probably a malfunction of the 4LLc switch circuit, or of the D Malfunction of 4LLc switch
engine-A/T-ECU or A/T-ECU. D Malfunction of harness or connector
D Malfunction of engine-A/T-ECU <6G7>
D Malfunction of A/T-ECU <4M4>
NG
4LLc switch check (Refer to P.23-99.) Replace
OK
NG NG
4LLc switch connector C-06 voltage check Check the following connectors: <6G7> C-06, Repair
D Disconnect the connector and measure at the E-113, D-122, <4M4> C-06, E-113, D-107
harness side.
D Ignition switch: ON OK
D Voltage between terminal 1 and earth
OKF System voltage D Check the harness between 4LLc switch and
the engine-A/T-ECU, and repair if necessary.
OK <6G7>
D Check the harness between 4LLc switch and
the A/T-ECU, and repair if necessary. <4M4>
NG Repair
Check the following connector: C-06
OK
NG
Check the trouble symptoms. Replace the engine-A/T-ECU or A/T-ECU.
<4M4>
1 2 3 4 5 6 7 8 9 10 11 12 13 31 32 33 34 35 36 37 38 51 52 53 54 55 56 57 58 59 60 61
14 15 16 17 18 19 20 21 22 23 24 25 26 39 40 41 42 43 44 45 46 62 63 64 65 66 67 68 69 70 71 72
(ms) (ms)
(ms)
OK
MUT-II Data List Transient malfunction (Refer to GROUP 00 - Points to Note
D No. 9 Ignition voltage for Transient Malfunctions.)
OK: Refer to P.23-87 (Data List Chart).
NG
NG
Ignition switch single part check Replace
(Refer to GROUP 54 - Ignition Switch.)
OK
NG
Measure at transfer-ECU connector E-105 Check the following connectors: <L.H. drive vehicles> D-208,
D Measure at ECU terminals. D-210, D-32, E-115, E-105, <R.H. drive vehicles> D-208, D-210,
D Ignition switch: ON E-115, E-105
D Voltage between terminal 13 and earth OK NG
OK: System voltage
Repair
OK
Check the harness between the ignition switch and the
transfer-ECU, and repair if necessary.
NG
Check the following connector: E-105 Repair
OK
NG
Check the trouble symptoms. Replace the transfer-ECU.
OK Transient malfunction
MUT-II Data List
D No. 1 APS (Refer to GROUP 00 - Points to
OK: Refer to P.23-87 (Data List Note for Transient Malfunctions.)
Chart).
NG
Measure at APS connector D-135 NG Measure at throttle valve controller OK Check the following connectors:
D Disconnect the connector and connector D-11 <6G7>, or at <6G7> D-11, <4M4> D-112
measure at the harness side. engine-ECU connector D-112 <4M4>.
D Voltage between terminal 8 and D Measure at ECU terminals. OK NG
earth D Ignition switch: ON
(Ignition switch: ON) Repair
D <6G7> Voltage between terminal
OK: 4.8 - 5.2 V 6 and earth D Check the harness between the
D <4M4> Voltage between terminal APS and the throttle valve
60 and earth controller, and repair if necessary.
OK: 4.8 - 5.2 V <6G7>
D Check the harness between the
NG
NG APS and the engine-ECU, and
repair if necessary. <4M4>
Repair
OK
NG
Check the trouble symptoms. Replace the throttle valve controller
or the engine-ECU.
OK
MUT-II Data List Transient malfunction (Refer to GROUP 00 - Points to Note
D No. 2 Front propeller shaft speed sensor for Transient Malfunctions.)
OK: Refer to P.23-87 (Data List Chart).
NG
NG
Measure at transfer-ECU connector E-105 Check the following connector: E-105
D Measure at ECU terminals. OK NG
D Ignition switch: ON
D Voltage between terminals 18 and earth Repair
OK: 0.5 V or less Check the trouble symptoms.
NG
OK
Replace the transfer-ECU.
NG
Measure at transfer-ECU connector E-105 Check the following connector: C-17
D Measure at ECU terminals.
OK NG
D Disconnect front propeller shaft speed sensor connector
C-17. Repair
D Ignition switch: ON Check the harness between the front propeller shaft speed
D Voltage between terminals 7 and earth sensor and the transfer-ECU.
OK: 4.8 - 5.2 V
OK NG
Repair
Check the trouble symptoms.
OK NG
Replace the transfer-ECU.
OK
Measure the front propeller shaft speed sensor output wave Check the following connector: E-105
pattern at transfer-ECU connector E-105 (using an
OK NG
oscilloscope).
D Vehicle speed: approx. 50 km/h Repair
D Shift range: 3rd
D Voltage between terminals 7 - 18 Check the trouble symptoms.
OK: A wave pattern such as the one shown on P.23-69 NG
(Check Procedure Using an Oscilloscope<Wave pat-
tern B>) should be output, and the maximum value Replace the transfer-ECU.
should be 4.8 V or more and the minimum value
should be 0.8 V or less.
There should be no noise in the output wave pattern.
OK
NG
Check the following connectors: C-17, E-105 Repair
OK
OK
MUT-II Data List Transient malfunction (Refer to GROUP 00 - Points to Note
D No. 3 Rear propeller shaft speed sensor for Transient Malfunctions.)
OK: Refer to P.23-87 (Data List Chart).
NG
NG
Measure at transfer-ECU connector E-105 Check the following connector: E-105
D Measure at ECU terminals. OK NG
D Ignition switch: ON
D Voltage between terminals 18 and earth Repair
OK: 0.5 V or less Check the trouble symptoms.
NG
OK Replace the transfer-ECU.
NG
Measure at transfer-ECU connector E-105 Check the following connector: C-08
D Measure at ECU terminals. OK NG
D Disconnect rear propeller shaft speed sensor connector
C-08. Repair
D Ignition switch: ON Check the harness between the rear propeller shaft speed
D Voltage between terminals 9 and earth sensor and the transfer-ECU.
OK: 4.8 - 5.2 V
OK NG
Repair
Check the trouble symptoms.
OK
NG
Replace the transfer-ECU.
OK
Measure the rear propeller shaft speed sensor output wave Check the following connector: E-108
pattern at transfer-ECU connector E-105 (using an OK NG
oscilloscope).
D Vehicle speed: approx. 50 km/h Repair
D Shift range: 3rd
Check the trouble symptoms.
D Voltage between terminals 9 - 18
OK: A wave pattern such as the one shown on P.23-69 NG
(Check Procedure Using an Oscilloscope) should be
output, and the maximum value should be 4.8 V or Replace the transfer-ECU.
more and the minimum value should be 0.8 V or
less.
There should be no noise in the output wave pattern.
OK
NG
Check the following connectors: C-08, E-108 Repair
OK
NG
Stop lamp switch check Replace
(Refer to GROUP 35 - Brake Pedal.)
OK
NG
Check the following connector: D-136 Repair
OK
NG
Measure at stop lamp switch connector D-136. Check the following connectors: <L.H. drive vehicles> D-27,
D Disconnect the connector and measure at the harness D-26, <R.H. drive vehicles> D-27, D-124
side.
D Voltage between terminals 2 and earth OK NG
OK: System voltage Repair
Check the harness between the stop lamp switch and the
OK battery, and repair if necessary.
NG
Measure at transfer-ECU connector E-108 Check the following connectors: <L.H. drive vehicles> D-27,
D Measure at ECU terminals. D-26, D-33, E-105, E-108, <R.H. drive vehicles> D-124, E-115,
D Voltage between terminals 34 and earth E-108, D-27
OK: System voltage when brake pedal is depressed OK NG
1 V or less when brake pedal is released
Repair
D Check the harness between the stop lamp switch and the
transfer-ECU, and repair if necessary.
OK D Check the harness between the stop lamp switch and the
battery, and repair if necessary.
NG
Check the following connector: E-108 Repair
OK
NG
Check the trouble symptoms. Replace the transfer-ECU.
NG
NG
Transfer lever switch check (Refer to P.23-117.) Replace
OK
NG
Check the following connector: E-19 Repair
OK
NG
Measure at transfer lever switch connector E-19. Check the following connectors: D-208, D-213, D-32, E-115
D Disconnect the connector and measure at the harness OK NG
side.
D Ignition switch: ON Repair
D Voltage between terminal (1) and earth
OK: System voltage Check the harness between the transfer lever switch and the
ignition switch, and repair if necessary.
OK
NG
Measure at transfer-ECU connector E-105 Check the following connectors: D-208, D-213, D-32, E-115,
D Measure at ECU terminals. E-105
D Ignition switch: ON
OK NG
(1) Transfer lever position: 2H> Voltage between terminal 20
and earth Repair
(2) Transfer lever position: 4H> Voltage between terminal 21
and earth D Check the harness between the transfer lever switch and
(3) Transfer lever position: 4H> Voltage between terminal 22 the transfer-ECU, and repair if necessary.
and earth D Check the harness between the transfer lever switch and
(4) Transfer lever position: 4H> Voltage between terminal 23 the ignition switch, and repair if necessary.
and earth
OK: System voltage
OK
NG
Check the following connector: E-105 Repair
OK
NG
Check the trouble symptoms. Replace the transfer-ECU.
OK
MUT-II Data List Transient malfunction (Refer to GROUP 00 - Points to Note
D No. 7 Transfer position for Transient Malfunctions.)
OK: Refer to P.23-87 (Data List Chart).
NG
NG
Transfer lever switch check (Refer to P.23-117.) Replace
OK
NG
Measure at transfer-ECU connector E-108 Check the following connector: E-108
D Measure at ECU terminals. NG
OK
D Ignition switch: ON
D Voltage between terminals 43, 44, 45, 46, 47 and earth Repair
OK: System voltage
Check the trouble symptoms.
OK NG
NG
Freewheel engage solenoid valve check Replace
(Refer to GROUP 26 - On-Vehicle Service.)
OK
NG
Check the following connectors: A-40, A-41 Repair
OK
NG
Measure at freewheel engage solenoid valve connectors A-40 Check the following connectors: D-208, D-210, D-27, A-15
and A-41.
OK NG
D Disconnect the connector and measure at the harness
side. Repair
D Ignition switch: ON
D Voltage between terminal 1 and earth Check the harness between the freewheel engage solenoid
OK: System voltage valve and the ignition switch, and repair if necessary.
OK
Measure at transfer-ECU connector E-108 Check the following connectors: <L.H. drive vehicles> D-208,
D Measure at ECU terminals. D-210, D-27, A-15, A-16, A-04, E-113, E-108, <R.H. drive vehicles>
D Transfer: 4WD D-208, D-210, D-27, A-15, A-16, D-143, E-113, E-108,
D Ignition switch: ON OK NG
D Voltage between terminals 41 and earth
OK: System voltage
Repair
D Check the harness between the freewheel engage solenoid
valve and the transfer-ECU, and repair if necessary.
OK D Check the harness between the freewheel engage solenoid
valve and the ignition switch, and repair if necessary.
NG
Check the following connector: E-108 Repair
OK
NG
Check the trouble symptoms. Replace the transfer-ECU.
MUT-II Self-Diag Code YES Code No. 34 Freewheel engage solenoid valve system check
D Is code No. 34 output? (Refer to P.23-82.)
NO
OK
MUT-II Data List Transient malfunction (Refer to GROUP 00 - Points to Note
D No. 38 Freewheel engage switch for Transient Malfunctions.)
OK: Refer to P.23-87 (Data List Chart).
NG
NG
Freewheel engage switch check (Refer to GROUP 26 - Replace
Freewheel Clutch.)
OK
NG
Check the following connector: B-54 Repair
OK
(1)NG
Measure at freewheel engage switch connector B-54. Check the following connector: B-40
D Disconnect the connector and measure at the harness OK NG
side.
(1) Resistance between terminal 1 and earth Repair
OK: 2 W or less Check the harness between the freewheel engage switch and
(2) Voltage between terminal 2 and earth
earth, and repair if necessary.
(Ignition switch: ON)
OK: System voltage
(2)NG
Check the following connectors: E-108, E-113, B-40
OK OK NG
Repair
Check the harness between the freewheel engage switch and
the transfer-ECU, and repair if necessary.
NG
Check the following connector: B-54 Repair
OK
NG
Check the trouble symptoms. Replace the transfer-ECU.
NG
NG
Measure at transfer-ECU connector E-105 Check the following connector: E-105
D Measure at ECU terminals. OK NG
D Drive the shift actuator in accordance with MUT-II actuator
test No. 2. Repair
D Voltage between terminal 1 and earth
Replace the transfer-ECU.
OK: System voltage
D Drive the shift actuator in accordance with MUT-II actuator
test No. 3.
D Voltage between terminals 3 and earth
OK: System voltage
OK
NG
Measure at shift actuator connector C-11. Check the following connectors: C-11, E-105
D Disconnect the connector and measure at the harness OK NG
side.
D Drive the shift actuator in accordance with MUT-II actuator Repair
test No. 2.
Check the harness between the shift actuator and the
D Voltage between terminals 2 and earth
transfer-ECU, and repair if necessary.
OK: System voltage
D Drive the shift actuator in accordance with MUT-II actuator
test No. 3.
D Voltage between terminal 1 and earth
OK: System voltage
OK
NG
Check the following connector: C-11 Repair
OK
NG
Check the trouble symptoms. Replace the shift actuator. L
NG
NG
Measure at transfer-ECU connector E-105 Check the following connector: E-105
D Measure at ECU terminals. OK NG
D Drive the shift actuator in accordance with MUT-II actuator
test No. 2. Repair
D Voltage between terminal 1 and earth
OK: System voltage Replace the transfer-ECU.
D Drive the shift actuator in accordance with MUT-II actuator
test No. 3.
D Voltage between terminals 3 and earth
OK: System voltage
OK
NG
Measure at shift actuator connector C-11. Check the following connectors: C-11, E-105
D Disconnect the connector and measure at the harness NG
OK
side.
D Drive the shift actuator in accordance with MUT-II actuator Repair
test No. 2.
D Voltage between terminals 2 and earth Check the harness between the shift actuator and the
OK: System voltage transfer-ECU, and repair if necessary.
D Drive the shift actuator in accordance with MUT-II actuator
test No. 3.
D Voltage between terminal 1 and earth
OK: System voltage
OK
NG
Check the following connector: C-11 Repair
OK
NG
Check the trouble symptoms. Replace the shift actuator. L
OK
MUT-II Data List Transient malfunction (Refer to GROUP 00 - Points to Note
D No. 12 Shift actuator voltage for Transient Malfunctions.)
OK: Refer to P.23-87 (Data List Chart).
NG
NG
Measure at transfer-ECU connector E-105 Check the following connector: E-105
D Measure at ECU terminals. OK NG
D Drive the shift actuator in accordance with MUT-II actuator
test No. 2. Repair
D Voltage between terminal 1 and earth Replace the transfer-ECU.
OK: System voltage
D Drive the shift actuator in accordance with MUT-II actuator
test No. 3.
D Voltage between terminals 3 and earth
OK: System voltage
OK
NG
Measure at shift actuator connector C-11. Check the following connectors: C-11, E-105
D Disconnect the connector and measure at the harness OK NG
side.
D Drive the shift actuator in accordance with MUT-II actuator Repair
test No. 2. Check the harness between the shift actuator and the
D Voltage between terminals 2 and earth transfer-ECU, and repair if necessary.
OK: System voltage
D Drive the shift actuator in accordance with MUT-II actuator
test No. 3.
D Voltage between terminal 1 and earth
OK: System voltage
OK
NG
Check the following connector: C-11 Repair
NG
Tyre Check Replace
OK
NG
Check the trouble symptoms. Replace the transfer-ECU.
ABS-
Transfer-ECU ECU
Transfer-ECU connector
Inspection procedure 2
When the ignition switch is at a position other than the Probable cause
LOCK position, the selector lever cannot be moved from
the P to the R position even though the brake pedal is
being depressed.
The cause is probably a malfunction of the selector lever assembly, transmission D Malfunction of selector lever assembly
control cable, shift lock cable unit or the ignition key cylinder lock bar. D Malfunction of transmission control cable
D Malfunction of shift lock cable unit
D Malfunction of lock bar
Inspection procedure 4
The selector lever cannot be easily moved from the P to Probable cause
the R position.
The cause is probably a malfunction of the selector lever assembly, transmission D Malfunction of selector lever assembly
control cable, shift lock cable unit or the ignition key cylinder lock bar. D Malfunction of transmission control cable
D Malfunction of shift lock cable unit
D Malfunction of lock bar
Inspection procedure 5
The selector lever cannot be moved from the R to the P Probable cause
position.
The cause is probably a malfunction of the selector lever assembly or of the D Malfunction of selector lever assembly
transmission control cable. D Malfunction of transmission control cable
Inspection procedure 6
The ignition key cannot be turned to the LOCK position Probable cause
when the selector lever is at the P position.
The cause is probably a malfunction of the selector lever assembly, shift lock D Malfunction of selector lever assembly
cable unit or the ignition key cylinder lock bar. D Malfunction of shift lock cable unit
D Malfunction of lock bar
Inspection procedure 7
The ignition key can be turned to the LOCK position even Probable cause
when the selector lever is at a position other than the P
position.
The cause is probably a malfunction of the shift lock cable unit or of the ignition D Malfunction of shift lock cable unit
key cylinder lock bar. D Malfunction of lock bar
ON-VEHICLE SERVICE
BASIC ADJUSTMENT PROCEDURES
AUTOMATIC TRANSMISSION FLUID (ATF) CHECK
NOTE
When replacing the transmission with a new one, overhauling
the existing transmission, or driving in a harsh condition, the
ATF cooler line should always be flushed out and ATF should
be replaced with a new one.
11. Check that the ATF level on the oil level gauge is at the
COLD mark. If it is not up to this mark, add more ATF.
12. Drive the vehicle until the ATF temperature reaches the
20 normal temperature (70 - 80C), and then re-check the
Oil
10 ATF level.
level
0 The ATF level must be between the HOT marks.
- 10 NOTE
- 20 (1) The COLD mark is for reference only; the HOT
- 30 marks should be used as the standard for judgment.
Oil (2) Measure ATF temperature using MUT-II.
- 40
(mm) 40 60 80 level (3) Check the oil level referring to the characteristics chart
gauge
Temperature (C) shown at left if it takes some time until reaching the
normal operation temperature of ATF (70 - 80C.)
13. Securely insert the oil level gauge into the oil filler tube.
NOTE
The inhibitor switch has 7 positions, but only four positions
(P, R, N and D) are used.
P
R
N
D
3
2
L
Specified lubricant:
Hypoid gear oil SAE 75W-90 or 75W-85W
conforming to API GL-4
Oil level: 2.8 L
4. Install the oil filler plug, and tighten it to the specified
torque.
Tightening torque: 32 2 Nm
<6G7> <4M4>
A B C A D C
E N O P Q R S T
L M
F G H I J K U V W
Torque converter
Low &
Underdrive clutch
TORQUE CONVERTER STALL TEST
reverse
Reverse clutch brake
Reduction brake The purpose of this test is to measure the maximum engine
speed when the torque converter stalls in D or R ranges
in order to check the torque converter operation and the
holding performance of the clutches and brakes which are
built into the transmission.
NOTE
For safety, the front and rear of the vehicle should be kept
clear of other people while this test is being carried out.
One-way clutch
1. Check the ATF level, the ATF temperature and the engine
coolant temperature.
D ATF level: HOT position on oil level gauge
D ATF temperature: 70 - 80C
D Engine coolant temperature: 80 - 100C
2. Place wheel locks on both the left and right front wheels.
3. Pull the parking brake lever to apply the parking brake
and depress the brake pedal fully.
4. Start the engine.
5. Move the selector lever to the D position, fully depress
the accelerator pedal and quickly take a reading of the
maximum engine speed at this time.
Caution
(1) Do not keep the throttle fully open for any longer
than 8 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 a speed of 1000 r/min to let the
ATF cool down before the next test is carried out.
Standard value - Stalling speed:
2,200 - 2,700 r/min <6G7>
2,400 - 2,900 r/min <4M4>
6. Move the selector lever to the R position and repeat the
test described above.
Standard value - Stalling speed:
2,200 - 2,700 r/min <6G7>
2,400 - 2,900 r/min <4M4>
Torque converter stall test judgment
1. High stalling speed in both D and R ranges
D Low line pressure
D Low & reverse brake slipping
2. High stalling speed in D range only
D Underdrive clutch slipping
3. High stalling speed in D range only
D Reverse clutch slipping
D Reduction brake slipping
4. High stalling speed in both D and R ranges
D Malfunction of torque converter
D Poor engine output
Selector Shift En- Underdrive Reverse Overdrive Direct Low & brake Second Reduction Torque
lever range gine clutch pres- clutch pres- clutch clutch pressure brake pres- brake pres- converter
position position speed sure sure pressure pressure [LR pressure] sure sure pressure
r/min [UD pres- [RC pres- [OD pres- port [2ND pres- [RB pres- [DR pres-
sure] sure] sure] [DIR pres- sure] sure] sure]
sure]
R Reverse 2,500 - 1,270 - 1,770 - - 1,270 - 1,770 - 1,270 - 1,770 500 - 700
Sports 1st 2,500 1,010 - 1,050 - - - 1,010 - 1,050 - 1,010 - 1,050 500 - 700
mode
2nd 2,500 1,010 - 1,050 - - - - 1,010 - 1,050 1,010 - 1,050 500 - 700
3rd 2,500 784 - 882 - 784 - 882 - - - 784 - 882 450 - 650
5th 2,500 784 - 882 - 784 - 882 784 - 882 - 784 - 882 - -
N A B C D E F G H I J K L M T S R Q
HYDRAULIC CIRCUIT
Parking & Neutral
1 2 3 4 5 6 7
8 8 8 8 9 8 8
10
13
11 12
14
15
16
17 18 19 20 21
Lubrica-
tion
22 23 24 25 26 27
28
29 30
31 32
33 34
35
Transfer-ECU
Indicator panel
TRANSMISSION CONTROL
REMOVAL AND INSTALLATION
NOTE
When removing and installing the transmission control cable and shift lock cable unit, be careful not
to hit them against the SRS-ECU.
5.0 1.0 Nm 6
12 2 Nm
5.0 1.0 Nm
12 2 Nm
3
5
7
8 1
9
Selector lever assembly and AA" "AA 6. Transmission control cable assembly
transmission control cable
assembly removal steps Transfer shift lever removal steps
D Front floor console (Refer to GROUP D Indicator panel (Refer to GROUP 52A
52A.) - Floor Console.)
1. Transfer shift lever and bracket as- 7. Transfer shift lever
sembly 8. Bracket
"BA 2. Shift lock cable unit connection
3. Transmission control harness connec-
tion Wide open throttle switch removal
4. Transmission control cable connection step
5. Selector lever assembly 9. Wide open throttle switch
D Front exhaust pipe (Refer to GROUP
15.)
4HLc 4H
INSPECTION
4LLc 2H TRANSFER SHIFT LEVER SWITCH CONTINUITY
CHECK
3 5
14
15 13 2 Nm
2.5 0.4 Nm
13
12
11
17 18
6 4.9 1.0 Nm
19
8
10 20
9
10
16
21 7
Disassembly steps
1. Knob cover B 12. Bolt
2. Knob cover A 13. Universal joint
3. Shift knob 14. Lever assembly
4. Sleeve 15. Stay cover
5. Pushbutton 16. Shift switch assembly
6. Detent spring 17. Snap ring
7. Snap ring 18. Malfunction of lock cam
8. Shaft 19. Detent plate assembly
9. Arm assembly 20. Collar
10. Bushing 21. Base bracket
11. Arm cover
4
:Tab position
3
2 5
5.0 1.0 Nm
Removal steps
D Front floor console (Refer to GROUP AA" 2. Key interlock cable connection
52A.) 3. Cover
D Switch panel and lower column cover 4. Lock bar
(Refer to GROUP 52A - Instrument 5. Shift lock cable connection
Panel.) 6. Shift lock cable unit
"AA 1. Shift lock cable unit connection
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
NOTE
The rear propeller shaft incorporates a carbon fibre-reinforced plastic tube, so be sure to refer to GROUP
25 during removal.
<6G7>
Pre-removal and Post-installation Operations
D Skid Plate And Under Cover Removal and Installation D Front Exhaust Pipe Removal and Installation
D Transmission Fluid and Transfer Oil Draining and (Refer to GROUP 15.)
Filling (Refer to P.23-95 and P.23-99.) D Radiator Shroud Lower Cover Removal and
D Front and Rear Propeller Shaft Removal and Installation (Refer to GROUP 14.)
Installation (Refer to GROUP 25.)
24 4 Nm
44 8 Nm
9
30 3 Nm
49 3 Nm
3
2
11 1 Nm 6
11 1 Nm
36 5 Nm 8 11 1 Nm
Removal steps
1. Oil level gauge assembly 6. Starter motor
2. Transmission control cable connection 7. Starter cover
AA" 3. Drive plate connection bolts 8. Oil pan connection bolts
4. Heater hose connection 9. Battery cable connection
5. Cover
24 5 Nm 36 6 Nm
15
17 11
12
35 6 Nm
42 2 Nm 53 5 Nm
24 5 Nm
5.0 1.0 Nm 74 10 Nm
44 10 Nm
10 14
44 10 Nm
16
13
89 9 Nm 44 10 Nm
26 4 Nm
44 10 Nm
<4M4>
Pre-removal and Post-installation Operations
D Skid Plate and Under Cover Removal and Installation D Radiator Shroud Lower Cover Removal and
D Transmission Fluid and Transfer Oil Draining and Installation (Refer to GROUP 14.)
Filling (Refer to P.23-95 and P.23-99.) D Intercooler Assembly Removal and Installation
D Front and Rear Propeller Shaft Removal and (Refer to GROUP 15.)
Installation (Refer to GROUP 25.)
D Front Exhaust Pipe and Catalytic Converter Removal
and Installation (Refer to GROUP 15.)
22 4 Nm
44 8 Nm
49 3 Nm
7 2
6
11 1 Nm
5 49 6 Nm
Removal steps
1. Oil level gauge assembly 6. Dust cover
2. Transmission control cable connection AA" 7. Drive plate connection bolts
3. Exhaust support bracket 8. Heater hose connection
4. Battery cable connection 9. Starter motor
5. Spacing rubber
24 5 Nm 35 6 Nm
15 11
17
12
35 6 Nm
42 2 Nm
53 5 Nm
24 5 Nm
5.0 1.0 Nm
49 6 Nm
44 10 Nm
10
14
44 10 Nm
16 13
44 10 Nm
26 4 Nm
44 10 Nm
D B
C C
<6G7>
7
12 2 Nm 8
6
9
10
11
5
12
12 2 Nm
1
2
3
4
5.0 1.0 Nm
5.0 1.0 Nm
19
5.0 1.0 Nm
17 42 2 Nm
14
15 13
20
21
16
18
14
<4M4>
12 2 Nm 7
8
6
9
10
11
5
12
12 2 Nm
1
2
3
4 5.0 1.0 Nm
5.0 1.0 Nm
19
5.0 1.0 Nm 42 2 Nm
14 13
17
15 16
20 21
18
14
Return hose
Front of vehicle Feed hose
A/T-ECU
REMOVAL AND INSTALLATION
<6G7> Refer to GROUP 13A - Engine-A/T-ECU; <4M4>Refer to GROUP 13C - Engine-ECU.
INSPECTION
ECU TERMINAL VOLTAGE MEASUREMENT
<6G7>Refer to P.23-64; <4M4>Refer to P.23-66.
TRANSFER-ECU
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
Indicator Panel and Floor Console Front Panel Removal
and Installation (Refer to GROUP 52A - Floor Console.)
Transfer-ECU
4.9 1.0 Nm
INSPECTION
ECU TERMINAL VOLTAGE MEASUREMENT
Refer to P.23-89.
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
1. Description:
On the 6G7 engine equipped vehicle, correction has been made to the transmission removal steps.
2. Applicable Manuals:
MSB-01E23-501 1
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
3. Details:
<Correct>
5
<Incorrect>
<Incorrect>
3
<Correct>
<Deleted>
<Incorrect>
A <Incorrect>
<Added> Cover <Correct>
MSB-01E23-501 2
SPECIAL TOOL
Tool No. Name Application
MD998727 Oil pan remover Oil pan removal
1 44 8 Nm
24 4 Nm
44 10 Nm
3
11 1 Nm 26 4 Nm
44 10 Nm
Removal steps
1. Oil level gauge assembly 2. Transmission mount center member
D Support the transmission with a assembly
transmission jack AA" "AA 3. Oil pan
PROPELLER SHAFT
Click on the applicable bookmark to selected the required model year.
PROPELLER
SHAFT
CONTENTS
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
A two-joint propeller shaft was used for both the front and rear.
Rear propeller shaft is equipped with a carbon-fiber reinforced plastic (CFRP) tube.
SERVICE SPECIFICATIONS
Items Standard value Limit
Propeller shaft runout mm - 0.5
Clearance between rear propeller shaft tube end and shaft mm 0.2 - 0.5 -
Clearance of snap ring groove mm 0 - 0.06 -
LUBRICANT
Items Specified lubricant Quantity
Propeller shaft sleeve yoke Hypoid gear oil SAE 75W- 90 or 75W- 85W or 80W As required
conforming to API GL- 4
SPECIAL TOOL
Tool Number Name Use
MB990840 Universal joint re- Disassembly and reassembly of the universal
mover and installer joint
PROPELLER SHAFT
Caution
Observe the following precautions, as the rear propeller shaft uses a carbon fiber-reinforced plastic
(CFRP) tube.
1. If a scratch is found on the propeller shaft tube, check that the tube is damaged by using
a dye penetrant method.
2. If the tube is cracked, chipped or bent, replace the propeller shaft.
3. Be careful not to impact or damage the tube.
4. If the propeller shaft has been dropped accidentally, replace it.
6010 Nm
Joint boot 4. Wrap a rag around the joint boot, and then remove the
front propeller shaft assembly.
Caution
When removing the propeller shaft, be careful not
to damage the joint boot by pinching it.
5. Cover the transfer to prevent the entrance of foreign
material.
Rag
Propeller shaft
Joint assembly (BJ)
Rag
Propeller
shaft Joint assembly
(BJ)
Oil seal
INSPECTION
FRONT PROPELLER SHAFT RUNOUT
Limit: 0.5 mm
Sealed
Sealed REAR PROPELLER SHAFT
part
part 1. Replace the propeller shaft if cracks or peelings are found
at the sealed part.
2. Check the tube for cracks, chips or bends and replace
CFRP tube the propeller shaft if damage is found. If defective, check
for damage by a dye penetrant method.
4
3
1
6
4
5
2 1
3
2
4
3
Disassembly steps
1. Grease fitting 4. Journal
AA" "BA 2. Snap ring 5. Flange yoke
AB" "AA 3. Journal bearing 6. Propeller shaft
Mating marks
MB990840
MB990840
MB990840
4. If the standard value(s) are not met, use other snap rings
to adjust the clearance.
Snap ring thickness mm Identification
colour
1.28 -
1.31 Yellow
1.34 Blue
1.37 Purple
FRONT AXLE
Click on the applicable bookmark to selected the required model year.
FRONT AXLE
CONTENTS
GENERAL INFORMATION
The front axle consists of the front hubs, knuckles, NOTE
drive shaft, wheel bearings, ball joints, front U.J. is an abbreviation of Under cut Joint.
differential, and freewheel clutch. D A vacuum-type freewheel clutch has been
The features are: adopted in the freewheel mechanism. Its
D The structural method of press fitting unit solenoid valve and actuator switch powertrain
bearing into the front hub is applied. between 2WD and 4WD.
D The wheel bearing uses a taper roller unit D The differential support method is a four-point
bearing. For vehicles with ABS, a rotor for elastic support method which reduces vibration
detecting the wheel speed is press-fitted to and noise.
the U.J. outer wheel.
D Drive shafts incorporate U.J.-B.J.-type constant
velocity ball joint has high power transmission
efficiency and reduces vibration and noise.
Item Specification
Wheel Wheel bearing type Taper roller type unit bearing
bearings
Bearing (outside diameter inside diameter) 88 50
mm
Drive Joint type Outside U.J.
shaft
Inside D.O.J.
Shaft length*1 Shaft diam- Right 353 28*2, 361.5 26*3
eter mm
Left 323 28*2, 330 26*3
Inner Shaft length Shaft diameter mm 389.2 31.5
shaft
Bearing (outside diameter inside diameter) 62 35
mm
NOTE
*1: The shaft length indicates the length between the center points of each joint.
*2: 4M41-M/T
*3: 4D56, 4M41-A/T, 6G74 GDI
FRONT DIFFERENTIAL
Item Specification
Reduction gear type Hypoid gear
Reduction ratio 4.900*1, 3.917*2, 4.100*3, 4.300*4
Side gear 14
Pinion gear 10
NOTE
*1: 4D56
*2: 4M41-A/T
*3: 4M41-M/T
*4: 6G74 GDI
STRUCTURAL DIAGRAM
Front differential
Freewheel clutch
DRIVE SHAFT
(L.H.) Knuckle
Differential side Wheel side
D.O.J. type U.J. type
Hub
Unit bearing
SERVICE SPECIFICATIONS
Item Standard value Limit
Opening dimension of the spe- When the B.J. boot band 2.9 -
cial tool (MB991561) mm (small) is crimped.
LUBRICANTS
Items Specified lubricants Quantity
Front differential gear oil Hypoid gear oil API classification GL-5 or higher, SAE 1.2 L
viscosity No. 90, 80W
Contact surface of differential cover and 3M ATD Part No. 8661 or equivalent Semi-drying sealant
differential carrier
Vent plug
Drive gear threaded hole 3M Stud Locking 4170 or equivalent Anaerobic sealant
SPECIAL TOOLS
Tool Number Name Use
MB990925 Bearing and oil D Press-fitting of housing tube dust seal
seal installer set D Press-fitting of oil seal
D Removal and installation of drive pinion
front & rear bearing outer race
D Checking of drive gear tooth contact
MB990906 Drive shaft attach- Removal and installation of inner shaft (Used
ment together with MB990211)
MB990339 Bearing puller Removal of drive pinion front bearing inner race
MB990031 Drive pinion oil seal Press-fitting of drive pinion oil seal
or installer
MB990699
MB990947 Lower arm bush Press fitting of front differential mount insulator
arbor <Front, rear L.H.>
MB991318 Lower arm bush Press fitting of front differential mount insulator
arbor <Rear R.H.>
MB990925
Tool box
C Brass bar
B
A Bar (snap-in type)
Installer adapter
MB990930 54 MB990937 79
A MB990931 57 B MB990938 -
A MB990932 61 C MB990939 -
ON-VEHICLE SERVICE
WHEEL BEARING BACKLASH CHECK
1. Remove the caliper assembly and hold it with wires to
prevent it from falling.
2. Remove the brake disk from hub.
Remove the filler plug, and check the gear oil level. Check
that gear oil level is not 8 mm below the bottom of filler plug
8 mm hole.
Upper limit Specified gear oil:
Hypoid gear oil API classification GL-5 or higher, SAE
viscosity No. 90, 80W [Quantity: 1.2 L]
Lower limit
MB990934 MB990938
Solenoid valve A
Solenoid valve A
Vacuum
hose
Solenoid valve B
Solenoid valve B
10
113 10 Nm
4 74 14 Nm
6
39 4 Nm
13
12
5
9
255 29 Nm
2
147 29 Nm
8 1
8.9 1.9 Nm
11
3
7
5.0 1.0 Nm
MB990767
Cord Caution
1. Do not remove nut from ball joint but loosen it and
use special tools instead to avoid possible damage
to ball joint threads.
2. Hang special tools with ropes to prevent them from
Ball joint falling.
255 29 Nm
INSPECTION
MB990998 INSPECTION OF HUB ROTATION STARTING TORQUE
1. Tighten special tools in hub and knuckle assembly to
Bolt the specified torque.
255 29 Nm
Secure bolt and
tighten nut.
MB990326
88 10 Nm
Disassembly steps
1. Knuckle
2. Front hub assembly
DRIVE SHAFT
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
D Removal and Installation of Under Cover and Skid D Removal and Installation of Front Brake Assembly
Plate (Refer to GROUP 42.) (Refer to GROUP 35A.)
D Connection and Disconnection of Shock Absorber D Connection and Disconnection of Knuckle and Tie
and Stabilizer Link in the Lower Arm Side (Refer to Rod End (Refer to GROUP 37 - Steering Gear
GROUP 33 - Lower Arm.) Linkage.)
60 10 Nm
<R.H.> 7
25 4 Nm
<L.H.> 7
4
3
1
2
5 255 29 Nm
Removal steps
1. Hub cap 6. Upper arm and upper arm ball joint
AA" "BA 2. Castle nut connection
"BA 3. Washer AB" "AA 7. Drive shaft
4. Brake hose and vehicle speed sensor 8. Circlip <L.H.>
clamp bracket
5. Wheel speed sensor <vehicles with
ABS>
MB990767
255 29 Nm
INSPECTION
D Check the boot for damage or deterioration.
D Check the ball joint for operating condition and excessive
looseness.
D Check the splines for wear or damage.
D Check the differential carrier oil seal (L.H.) for damage.
4 <R.H.>
11
2
1
12 3 5 4 3
2 5
1 12 3 5 6
7 7 2
2 13 12
1 1
8
9
10
U.J. boot repair kit D.O.J. boot repair kit D.O.J. repair kit
D.O.J. U.J.
4
11
Caution
Do not mix old and new or different types of grease, as a special grease is used in the joint.
3. Install the small part on the plastic boot aligning the groove
of the shaft.
6. Use the special tool to crimp the U.J. boot band (small).
Caution
(1) Secure the drive shaft in an upright position and
clamp the part of the U.J. boot band to be crimped
securely in the jaws of the special tool.
(2) Crimp the U.J. boot band until the special tool
touches the stopper.
MB991561
10. Install the large diameter part on the plastic boot alighning
the groove of the shaft.
11. Follow the same procedure as in step (4) 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
12. Install the U.J. boot band (large) to the U.J. boot.
13. Use the special tool to crimp the U.J. boot band (large)
in the same way as in step (6).
14. Check that the crimping amount (B) of the U.J. boot band
is at the standard value and that the crimping amount
(C) of the U.J. boot band is at the limited value
Standard value (B): 2.4 - 2.8 mm
Limit (C): 9.5 mm
C
12 2 Nm
69 9 Nm*
2
1 8 9
12 2 Nm
6 90 10 Nm
25 5 Nm
69 9 Nm* 10
89 9 Nm
5
17 3 Nm 4
3
Removal steps
AA" "BA 1. Inner shaft AB" "AA D Loosening and tightening of differential
2. Clip mounting insulator bolt
3. Collar D Support the differential by a
4. Pin transmission jack.
5. Actuator assembly 8. Differential mounting bracket <R.H.>
6. Vacuum tank assembly 9. Breather pipe
7. Engage switch assembly 12. Housing tube
MB990211
3
5
3 5
2
4
Disassembly steps
1. Inner shaft 4. Housing tube
AA" "CA 2. Bearing "AA 5. Dust seal
"BA 3. Dust cover
MB990560
MB990560
MB990560
4
69 9 Nm*
90 10 Nm
8 1
4 60 10 Nm59 9 Nm
25 5 Nm
7
2
6 11
69 9 Nm* 5
9
2
89 9 Nm
69 9 Nm* 10
128 9 Nm
Sealant:
3M ATD Part No. 8661 or 12
equivalent
3
Removal steps
AA" "BA 1. Front propeller shaft connection 7. Freewheel engage switch assembly
2. Front frame and differential bracket "AA 8. Differential mounting bracket <R.H.>
connection and housing tube assembly
3. Front frame and No.2 crossmember 9. Freewheel clutch assembly
assembly connection "AA 10. Differential mounting bracket <L.H.>
4. Vacuum hose 11. Differential carrier
5. Collar 12. No.2 crossmember assembly
AB" 6. Pin
Caution
Joint boot
1. Be careful not to damage joint boot by cramping with
the bent propeller shaft joint.
2. Hang propeller shaft with wires to prevent it from
falling.
Cloth
Propeller
shaft Joint assembly
(BJ)
Pin
INSPECTION
FREEWHEEL ENGAGE SWITCH
12 11
12
10
10
4
13
7
3
2
9 9
5
6
8
Disassembly steps
AA" 1. Main shaft 8. Shift rod
2. Clutch sleeve "CA 9. Oil seal
3. Spacer AB" "BA 10. Clutch gear
AA" "EA 4. Bearing AB" "BA 11. Bearing
"DA 5. Spring pin "AA 12. Oil seal
6. Snap ring 13. Clutch housing
7. Shift fork
A
DISASSEMBLY SERVICE POINTS
MB990560 AA" MAINSHAFT/BEARING REMOVAL
1. After the special tool has been installed as shown, tighten
the nut of the special tool until the portion A of the
special tool touches the bearing outer race.
Bearing
Clutch gear
Oil seal
MB990926
Clutch
housing
0 - 1 mm Chamfer
DIFFERENTIAL CARRIER
DISASSEMBLY
7
16 10 8
21 17
18
9
12
11
13
15 14
20
19
1 29
30
6
25
24 23 26
28 2 22
27
5 4 3
Disassembly steps
AA" D Inspection before disassembly 15. Drive pinion
1. Cover AH" 16. Oil seal
AB" 2. Differential case assembly AH" 17. Drive pinion rear bearing inner race
3. Side bearing spacer AH" 18. Drive pinion rear bearing outer race
4. Side bearing outer race AI" 19. Drive pinion front bearing outer race
AC" 5. Side bearing inner race 20. Oil seal
AD" 6. Drive gear 21. Differential carrier
AE" 7. Self-locking nut AJ" 22. Lock pin
8. Washer 23. Pinion shaft
AF" 9. Drive pinion assembly 24. Pinion gear
10. Companion flange 25. Pinion washer
11. Drive pinion spacer 26. Side gear
12. Drive pinion rear shim (for turning 27. Side gear spacer
torque adjustment) 28. Filler plug
AG" 13. Drive pinion front bearing inner race 29. Drain plug
14. Drive pinion front shim (for pinion 30. Differential case
height adjustment)
3 3
2 1 4 Increase the thickness of the drive
The drive pinion is positioned too far
pinion rear shim, and position the
from the centre of the drive gear.
drive pinion closer to the centre of the
drive gear. Also, for backlash adjust-
3 ment, position the drive gear farther
from the drive pinion.
2 1 2 1
4 4
3 3
Decrease the thickness of the drive
The drive pinion is positioned too
pinion rear shim, and position the
close to the centre of the drive gear.
drive pinion farther from the centre of
the drive gear. Also, for backlash
adjustment, position the drive gear
closer to the drive pinion.
NOTE
Checking the tooth contact pattern is the way to If, even after adjustments have been made, the
confirm that the adjustments of the pinion height correct tooth contact pattern cannot be obtained,
and backlash have been done properly. Continue it means that the drive gear and the drive pinion
to adjust the pinion height and backlash until the have become worn beyond the allowable limit.
tooth contact pattern resembles the standard Replace the gear set.
pattern.
MB990850
MB990339
AG" DRIVE PINION FRONT BEARING INNER RACE
REMOVAL
MB990648
Punch
REASSEMBLY
20
23
18 15
17 17
18 5
20
3
28 65 5 Nm 29
18 3 Nm
16
23
19
20 21
17
22
30 50 10 Nm 27 18 24
25 26
Reassembly steps
1. Differential carrier "FA D Differential gear backlash adjustment
"AA 2. Oil seal 17. Side gear spacer
"BA 3. Drive pinion front bearing outer race 18. Side gear
"CA 4. Drive pinion rear bearing outer race 19. Pinion washer
"DA D Pinion height adjustment 20. Pinion gear
5. Drive pinion 21. Pinion shaft
6. Drive pinion front shim (for pinion "GA 22. Lock pin
height adjustment) "HA 23. Drive gear
7. Drive pinion front bearing inner race "IA 24. Side bearing inner race
8. Drive pinion spacer 25. Side bearing outer race
"EA D Drive pinion turning torque adjustment "JA D Drive gear backlash adjustment
9. Drive pinion rear shim (for turning 26. Side bearing spacer
torque adjustment) 27. Differential case assembly
10. Drive pinion assembly 28. Cover
11. Drive pinion rear bearing inner race 29. Drain plug
12. Oil seal 30. Filler plug
13. Companion flange
14. Washer NOTE
15. Self-locking nut Specified torque with astarisks means that it is
16. Differential case covered with oil.
(Apply
tocircum-
ference of
oil seal
lip)
f 2 - 3 mm
(Apply to
circumference
of oil seal lip)
Sealant: Adhesive:
3M ATD Part No. 8663 3M Stud Locking 4170 or
orequivalent equivalent
MB990934
Oil seal
MB990936
11. Fit the selected drive pinion front shim(s) to the drive
pinion, and press-fit the drive pinion front bearing inner
Drive MB990802
pinion race by using the special tool.
front
shim
MB990802
MB990850
NOTE
Apply gear oil around the circumference of companion
flange (and the mating surface of oil seal) when press
fitting oil seal into companion flange.
7. Measure the drive pinion turning torque (with the oil seal)
MB990685 MB990326
by using the special tools.
Standard value:
(With oil seal)
Bearing division Bearing lubrication Turning torque
New None (With 0.93 - 1.28 Nm
anti-rust agent)
Gear oil applied 0.97 - 1.32 Nm
8. If the drive pinion turning torque is not within the standard
value, check the tightening torque of the companion flange
self-locking nut and the oil seal.
Attachment
3. Insert a wedge between the side gear and the pinion
Wedge shaft to lock the side gear.
4. Measure the differential gear backlash with a dial indicator
on the pinion gear.
Standard value: 0 - 0.076 mm
Side gear
Limit: 0.2 mm
thrust spacer 5. If the differential gear backlash exceeds the limit, adjust
Side gear thrust the backlash by installing thicker side gear spacers.
spacer
MB990813
MB990802
MB990802
Clearance/2 0.05 mm
= Thickness of the spacer on one
side
MB990939
6. Align the mating marks on the gear carrier and the bearing
cap, and then tighten the bearing cap.
If backlash is too small 8. Change the side bearing adjusting spacers as illustrated,
Thinner Thicker
and then adjust the drive gear backlash between the
spacer spacer drive gear and the drive pinion.
NOTE
When increasing the number of side bearing adjusting
spacers, use the same number for each, and as few
as possible.
Thicker Thinner
spacer spacer
If backlash is too large
9. Check the drive gear and drive pinion for tooth contact. If
poor contact is evident, make adjustment. (Refer to P.
26-39.)
10. Measure the drive gear runout at the shoulder on the
reverse side of the drive gear.
Limit: 0.05 mm
11. If the drive gear runout exceeds the limit, reinstall by
changing the phase of the drive gear and differential case,
and remeasure.
12. If adjustment is not possible, replace the differential case
or replace the drive gear and drive pinion as a set.
7
11
<6G7>
2 6
12
9.0 1.0 Nm
3 1 12 2 Nm
8
10
9 10 7
10 9
<4M4>
2 6 5
9.0 1.0 Nm 1
3
8
12 2 Nm 4
10 12 2 Nm
14
<4D5> 11
7
1 18
10
2 6 19
9.0 1.0 Nm
15 17
13
3 12 2 Nm
8 1
10 16
9
10 21
17 3 Nm
10
20
Pin
59 9 Nm
69 9 Nm*
128 9 Nm
1 4
23 4 Nm
5
69 9 Nm*
128 9 Nm
89 9 Nm
89 9 Nm
69 9 Nm*
2
MD999547
DIFFERENTIAL MOUNTING INSULATOR
REPLACEMENT
DIFFERENTIAL MOUNTING BRACKET
<L.H., R.H.-FRONT, REAR>
1. Remove insulator with special tools.
MB990947 L.H., R.H. - Front 2. By using special tools along with a hydraulic press, press
MB990847 fit each insulator to adjust until the hollow part faces as
shown and the difference between dimensions A, B should
MB990981 be within 0.7 mm.
A
Rear
REAR AXLE
Click on the applicable bookmark to selected the required model year.
REAR AXLE
CONTENTS
SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 KNUCKLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GENERAL INFORMATION
The rear axle has the following features.
D D.O.J.-type on the differential side and B.J.-type on the hub side constant velocity joints are featured
in the drive shaft.
D Large capacity and high rigidity taper-roller type unit bearing in the wheel bearing is featured.
D The hybrid LSD and differential lock with LSD which benefit driving on muddy and rough roads are
featured as an option.
D ABS rotor to detect wheel speed is press-fitted in the drive shaft.
NOTE
The structure of normal differential and hybrid LSD is basically the same as featured in existing models.
SPECIFICATIONS
Item Normal Differential Hybrid LSD Differential Lock
with LSD
Differential gear type (Type Side gear Straight bevel gear Helical gear 2 Helical gear 2
number of gears) 2
Number Drive gear 49*1, 47*2, 41*3, 49*1, 47*2, 41*3, 49*1, 47*2, 41*3,
of teeth 43*4 43*4 43*4
Drive pinion 10*1, *3, *4, 12*2 10*1, *3, *4, 12*2 10*1, *3, *4, 12*2
Side gear 18 22 22
Pinion gear 10 7 7
Bearings (Outside diameter Side 90.0 55.0 90.0 55.0 90.0 55.0
Inside diameter) mm
Front 68.3 30.2 68.3 30.2 68.3 30.2
NOTE
*1: 4D56
*2: 4M41-A/T
*3: 4M41-M/T
*4: 6G74 GDI
Knuckle
Differential carrier
Rear hub
B.J.
Unit bearing
Drive shaft
D.O.J.
SERVICE SPECIFICATIONS
Item Standard value Limit
LUBRICANTS
Item Specified lubricants Quantity
SEALANTS
Items Specified sealants Remarks
Drive gear and differential case mounting part 3M Stud Locking 4170 or equivalent Anaerobic sealant
MB990810 Side bearing puller D Removal of the side bearing inner race
D Removal of the companion flange
MB991445 Bush remover and Installation of drive pinion rear bearing outer
installer base race
MB990727 Drive pinion oil seal Press-fitting of the drive pinion oil seal
installer
ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK
1. Park the vehicle on a flat, level surface.
2. Move the transmission control lever to the neutral position.
Move the transfer control lever to the neutral position.
Apply the parking brake. Raise the vehicle on a jack.
Lower
limit
Post-installation Operation
Parking Brake Lever Stroke Adjustment (Refer to
GROUP 36 On-vehicle Service.)
6 113 14 Nm
10
4
88 10 Nm 3
9
255 29 Nm
2
81 6 Nm
5
152 25 Nm
11
7
Removal steps
1. Hub cap 6. Companion shaft and drive shaft
AA" "BA 2. Drive shaft nut connection
AB" 3. Rear brake caliper AC" "AA 7. Lower arm and knuckle connection
4. Rear brake disc 8. Rear drive shaft assembly
5. Parking brake shoe & lining assembly 9. ABS rotor protector
(Refer to GROUP 36 - Parking Brake 10. Rear hub assembly
Drum.) 11. Backing plate
MB990767
Wooden
block
Wooden
block
Wooden
block
4
150 30 Nm
67 7 Nm
2
1
231 34 Nm
Removal steps
1. Vehicle speed sensor 3. Knuckle and trailing arm connection
AA" 2. Knuckle and toe-control arm AA" 4. Knuckle and upper arm connection
connection 5. Knuckle assembly
MB991113 or
REMOVAL SERVICE POINT
MB990635 AA" KNUCKLE AND CONTROL ARM/UPPER ARM
Nut DISCONNECTION
Caution
Cord 1. Use special tools to loosen the nut from the ball joint
instead of removing it.
2. Hang special tools with ropes to prevent them from
falling.
Ball joint
DRIVE SHAFT
REMOVAL AND INSTALLATION
113 14 Nm
255 29 Nm
2 1
152 25 Nm
Removal steps
1. Cap AB" "AA 4. Knuckle and lower arm connection
AA" "BA 2. Drive shaft nut 5. Rear drive shaft assembly
3. Companion shaft and drive shaft
connection
MB990767
Wooden
block
Wooden
block
10
13
12
11
10
12
7 2
9
1 6
8
11 5
2 7
1 3 3
4
B.J. boot repair kit
9
13 5 1
7 7
3 3
4
2
9
1 2
6
8
2 3
1 7
B.J. repair kit D.O.J. repair kit D.O.J. boot repair kit
D.O.J. B.J
.
1 2
4.9 1.0 Nm
6 36 6 Nm
4 7 8
3
12 2 Nm
ON
1 Rear differential OFF side Ignition switch: ON When in neutral System voltage
lock switch
2 Vehicle speed reed switch Select D or 1 (1st gear) and drive forward 5V
slowly
4 Rear differential lock air pump Ignition switch: ON When filling or holding System voltage
When releasing 0V
Battery (- )
REAR DIFFERENTIAL LOCK AIR PUMP CHECK
1. Install air hose to the differential.
Battery (+) 2. Connect a pressure gauge to the air pump discharge
T - joint outlet nozzle, via the air hose and T-joint.
To 3. Apply battery voltage to the air pump connector.
differential 4. Measure the time when the pump starts and stops
operating, and if stops within five seconds, the pressure
switch inside the pump is normal.
Air hose (as Pressure 5. Measure the pressure 10 - 20 seconds after the pump
short as gauge
possible) has stopped.
Standard value: 25 - 40 kPa
If the pressure is within the standard value, the release
Release valve valve inside the pump is normal.
6. Check that the pump does not begin operating for five
minutes after it has stopped.
7. If the inspection for 4 - 6 is normal, then the pump is
fully operational.
Motor
Pressure
switch To differential
9
1
152 25 Nm
5 3 8
4
3 113 14 Nm
46 8 Nm
46 8 Nm
7
113 14 Nm
6
8
152 25 Nm
3 2
10
1
83 12 Nm
Removal steps
D Propeller shaft 7. Hose connection <Vehicles with
(Refer to GROUP 25.) rear differential lock>
1. Drive shaft connection AB" 8. Differential carrier assembly
AA" "AA 2. Knuckle and lower arm connection D Fuel tank
3. Companion shaft (Refer to GROUP 13B - Fuel Supply.)
4. Toe control tower bar 9. Rear differential mount member
5. Breather hose connection 10. Dynamic damper
6. Harness connection <Vehicles with
rear differential lock>
Wooden
block
Wooden
block
<Conventional differential>
7 8 6 4
9
16 15
13
11
12
14
13 15 17 3
16 10
14
8
5 9
33 7
26 27
29 30 31
25
28 24
22 23
21 <Limited slip differential>
20
19
32 7
8
9
10
18
2 8
9
1 7
Disassembly steps
AA" D Inspection before disassembly AF" 19. Self-locking nut
1. Filler plug 20. Washer
2. Drain plug AG" 21. Drive pinion assembly
3. Differential cover AG" 22. Companion flange
4. Vent plug 23. Drive pinion front shim (For adjusting
5. Bearing cap preload of drive pinion)
AB" 6. Differential case assembly 24. Drive pinion spacer
AB" 7. Differential side shim AH" 25. Drive pinion rear bearing inner race
AB" 8. Side bearing outer race 26. Drive pinion rear shim (For adjusting
AC" 9. Side bearing inner race drive pinion height)
AD" 10. Drive gear 27. Drive pinion
AE" 11. Lock pin AI" 28. Oil seal
12. Pinion shaft AI" 29. Drive pinion front bearing inner race
13. Pinion gear AI" 30. Drive pinion front bearing outer race
14. Pinion washer AJ" 31. Drive pinion rear bearing outer race
15. Side gear 32. Oil seal
16. Side gear thrust spacer 33. Differential carrier
17. Differential case
18. Limited slip differential case assembly*
8 11
14
9 3
7
12
16
13
15 14
30
32 33 5 15
26
25
29 34 24 17
23 13
27 22
21 20
19
18 31
1
28
2
Disassembly steps
AA" D Inspection before disassembly 19. Washer
1. Filler plug AG" 20. Drive pinion assembly
2. Drain plug AG" 21. Companion flange
3. Differential cover 22. Drive pinion front shim (For adjusting
4. Vent plug preload of drive pinion)
5. Bearing cap 23. Drive pinion spacer
6. Hose AH" 24. Drive pinion rear bearing inner race
7. Air pipe assembly (A) 25. Drive pinion rear shim (For adjusting
8. Eye bolt drive pinion height)
9. Air pipe assembly (B) 26. Drive pinion
10. Gasket AI" 27. Oil seal
11. Actuator assembly AI" 28. Drive pinion front bearing inner race
12. Pressure plate AI" 29. Drive pinion front bearing outer race
AB" 13. Differential side shim AJ" 30. Drive pinion rear bearing outer race
AB" 14. Side bearing outer race 31. Oil seal
AC" 15. Side bearing inner race 32. Rear differential lock position switch
AD" 16. Drive gear 33. Gasket
17. Limited slip differential case assembly* 34. Differential carrier
AF" 18. Self-locking nut
MB990850
MB990810
AG" DRIVE PINION ASSEMBLY/COMPANION FLANGE
REMOVAL
1. Make the mating marks to the drive pinion and companion
flange.
Caution
Do not make mating marks on the contact surfaces
Companion of the companion flange and propeller shaft.
flange
2. Use special tools to pull out the companion flange.
REASSEMBLY
<Conventional differential>
28 30
27 26
25 19 35 5 Nm
18 21 23
22 20
21 19 24
74 5 Nm 18 16
20 25 31
29 26
1 6 5 27
4 3
11 7
14 13 8
9 84 5 Nm <4D5>
10 152 15 Nm <4M4, 6G7>
216 29 Nm
24 21 19
5 18
15 84 5 Nm <4D5>
152 15 Nm <4M4, 6G7>
18
19 21
Reassembly steps
1. Differential carrier 17. Limited slip differential case assembly
"AA 2. Oil seal "FA D Differential gear backlash adjustment
"BA 3. Drive pinion rear bearing outer race 18. Side gear thrust spacer
"CA 4. Drive pinion front bearing outer race 19. Side gear
"CA D Drive pinion height adjustment 20. Pinion washer
5. Drive pinion 21. Pinion gear
6. Drive pinion rear shim (For adjusting 22. Pinion shaft
drive pinion height) "GA 23. Lock pin
7. Drive pinion rear bearing inner race "HA 24. Drive gear
8. Drive pinion spacer "IA 25. Side bearing inner race
"EA D Drive pinion turning torque adjustment 26. Side bearing outer race
9. Drive pinion front shim (For adjusting 27. Side bearing shim
drive pinion preload) 28. Differential case assembly
10. Drive pinion assembly "JA 29. Bearing cap
11. Drive pinion front bearing inner race 30. Vent plug
"EA 12. Oil seal 31. Differential cover
13. Companion flange 32. Drain plug
14. Washer 33. Filler plug
15. Self-locking nut "JA D Final drive gear backlash adjustment
16. Differential case
Reassembly steps
1. Differential carrier 17. Self-locking nut
2. Gasket 18. Gasket
3. Rear differential lock position switch 19. Air pipe assembly (B)
"AA 4. Oil seal 20. Eye bolt
"BA 5. Drive pinion rear bearing outer race 21. Air pipe assembly (A)
"CA 6. Drive pinion front bearing outer race 22. Hose
"DA D Drive pinion height adjustment 23. Limited slip differential case assembly
7. Drive pinion "HA 24. Drive gear
8. Drive pinion rear shim (For adjusting 25. Pressure plate
drive pinion height) 26. Actuator assembly
9. Drive pinion rear bearing inner race "IA 27. Side bearing inner race
10. Drive pinion spacer 28. Side bearing outer race
"EA D Drive pinion turning torque adjustment 29. Side bearing shim
11. Drive pinion front shim (For adjusting "JA 30. Bearing cap
drive pinion preload) 31. Vent plug
12. Drive pinion assembly 32. Differential cover
13. Drive pinion front bearing inner race 33. Drain plug
"EA 14. Oil seal 34. Filler plug
15. Companion flange "JA D Final drive gear backlash adjustment
16. Washer
2 - 3mm
(bead diameter)
Oil seal
MB990685
MB990326
MB990819
MB991169
Thickness
gauge
11. Fit the selected drive pinion rear shim(s) to the drive
pinion, and press-fit the drive pinion rear bearing inner
Drive pinion
race by using special tool.
rear shim
MB990802
MB990326
3. Measure the drive pinion turning torque (without the oil
MB990685 seal).
Standard value:
Bearing division Turning torque
New 1.94 - 2.25 Nm
52.50 Yellow
52.84 Red
MB990326
7. Measure the drive pinion turning torque (with oil seal)
MB990685 to verify that the drive pinion turning torque complies
with the standard value.
Standard value:
MB990813
3. Select two pairs of the side bearing spacer with the thickness
derived from the sum of the clearance and a half of pre-load,
0.05 mm.
MB990810
4. Remove the side bearing with special tools.
NOTE
Hook the claws of the special tool with the side bearing
MB991407 inner race by using the notches (two areas) of the differential
case side.
5. Assemble the selected side bearing spacers to each side.
Drive MB990802 6. Use special tools to press-fit the side bearing inner case
pinion into the differential case. After installing the outer race,
rear assemble the differential case to the gear carrier.
shim 7. Align the mating marks of differential carrier and the bearing
cap with each other to tighten to the specified torque.
Tightening torque: 74 5 Nm
MB990802
When the backlash is small 9. If the backlash is not within the standard value, move the
side bearing spacer as shown in the illustration to adjust
De- In-
creased the backlash.
creased
NOTE
The increment of side bearing spacer must be coincided
with the decreased amount.
10. Inspect the tooth condition at the final drive gear and make
In- De- an adjustment if required. (Refer to GROUP 26 Pre-removal
creased creased
Inspection.)
When the backlash is large
GENERAL INFORMATION
The wheels and tyres of the following specifications
have been established.
SPECIFICATIONS
Items 4D5, 4M4 6G7
GL, GLX GLS
Wheel Type Steel type Aluminium type Aluminium type
Aluminium type*
Size 16 6JJ 16 7JJ 16 7JJ
16 7JJ*
Amount of wheel offset mm 46 46 46
Pitch circle diameter (P.C.D.) mm 139.7 139.7 139.7
Tyre Size 235/80R16 109S 265/70R16 112S 265/70R16 112H
265/70R16 112S*
NOTE
*: Optional items
SERVICE SPECIFICATIONS
Items Limit
Scalloped wear Lack of rotation of tyres or worn or Rotate the tyres Refer to GROUP
out-of-alignment suspension and check the 33A - On-ve-
front suspension hicle Service.
alignment.
PROCEDURE
Balancing Tips
1. Confirm that the balancers cone and the wheel 3. Install a wheel mounting cone. The appropriate
mounting cone are undamaged and free of size cone for this vehicle is 67.0 mm.
dirt and rust. 4. Before balancing the wheel, remove any wheel
2. On this vehicle the wheels center hole on the weights from both sides. Also check both sides
hub side has a chamfered edge. Use a for any damage.
back-mounting cone on your wheel balancer 5. When installing wheel weights, hammer them
to center the wheel on the balancer shaft. at a straight (not diagonal) angle.
Wing nut
Spring plate
Wheel mounting
cone
Standard passenger
car wheel
Balance wheel.
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
INFORMATION/ INTERNATIONAL
CAR
CORRECTION ADMINISTRATIO T.NITTA - PROJECT LEADER
OFFICE AFTER SALES SERVICE & CS PROMOTION
1. Description:
There have been cases where the troubles failed to be removed completely because of incorrect
balancer machine handling or use of an inaccurately calibrated balancer machine. This Service
Bulletin informs you of the cautions to be taken when handling a balancer machine and the
balance check procedures to prevent such a case from recurring in a dealer.
2. Details:
To solve the problems caused by steering or body vibrations, it is essential to balance the wheels
and tires accurately. For this, the wheel and tire must be accurately centered with respect to the
balancer shaft, and the balancer must also be calibrated accurately.
SPRING PLATE
STANDARD WHEEL
RIM X0043BY
5. Loosen the wing nut, rotate the wheel half a turn (180) and tighten the nut again. Then, perform the
measurement again to confirm that the wheel is in balance. If not in balance, check if the balancer is
correctly calibrated. Go to Step 11.
SPRING PLATE
7. Loosen the wing nut, rotate the wheel half a turn (180) and tighten the wing nut carefully again. Then,
perform the measurement again.
8. Repeat the measurement three times in the same manner, and take either of the following measures
according to the measurement again.
Caution: Be sure to drive the weight straight in the wheel.
a. If the results are the same in all measurements, attach a weight according to the indication on th
machine.
b. If the weight difference among the three measurements is less than 0.5 oz and the thre indicated
points are all within a range of less than 8 inch (30), attach a weight having the average weight at
the mean position.
c. If the weight difference among the three measurements is 0.5 oz or more or if the indicate
positions are not within a range of less than 8 inch (30), check if th balancer is correctly calibrated.
Go to step 11.
9. Reinstall the tire to the vehicle, and perform a driving WHEEL
test. If the tire still generates vibration, perform the Ste
10. MB991820
10. Attach the adapter (MB991820) on the back side of th
wheel, and install the wheel onto the machine using the
back-mounted cone. Then, perform the balance
adjustment again. For the procedure, refer to Steps 4
and 5
Caution Check to ensure that the contactin
portions of the adapter, wheel and
balancer are free from any dirt, corrosion HUB/SHAFT
and damage. ASSEMBLY
WHEEL
CLAMPING
MOUNTING
CUP
CONE X0045BY
Balance Wheel
Rebalance wheel
Rotate wheel turn
YES NO
YES NO
POWER PLANT
MOUNT
CONTENTS
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
For vehicles with A/T, the engine and transmission D The transmission mount supports the
assembly is supported at three points, where transmission and the transmission mount
insulators are used. (Two points for the engine, center member elastically (dual anti-vibration
one point for the transmission.) method) in order to reduce vibration, which
For vehicles with M/T, the engine and transmission is transmitted to the vehicle body.
assembly is supported at four points, where D For the transmission mount insulator, a
insulators are used. (Two points for the engine, shear-type insulator has been introduced.
two points for the transmission.)
D For the engine mount, a liquid-charged mount
has been introduced in order to improve driving
comfort and reduce vibration and noise during
idling.
CONSTRUCTION DIAGRAM
Transmission
<M/T> mounting
<A/T>
Transmission mounting
center member
ENGINE MOUNTING
REMOVAL AND INSTALLATION
Caution
*: Indicates parts which should be initially tightened, and then fully tightened after placing the
vehicle horizontally and loading the full weight of the engine on the vehicle body.
Pre-removal and Post-installation Operation
D Under Cover and Skid Plate Removal and Installation D Radiator Removal and Installation
D Battery Removal and Installation (Refer to GROUP 14.)
D Air Cleaner Removal and Installation D Glow Plug Relay and Solenoid Valve Assembly
(Refer to GROUP 15.) Removal and Installation <4M4>
D Engine Cover Removal and Installation D Intercooler Removal and Installation<4M4>
(Refer to GROUP 11A,11B,11C.) (Refer to GROUP 15.)
26 4 Nm*
2
2
4
3 4
3
44 10 Nm*
1
1
44 10 Nm*
Removal steps
D brake hose clip (Refer to GROUP 33A D Vacuum hose (Refer to GROUP 26
- Upper Arm Assembly.) - Free Wheel Assembly, Differential
D Connecting bolt between steering gear Carrier.)
and joint (Refer to GROUP 37A AA" 1. Engine mounting bolt
- Power Steering Gear and Linkage.) AA" 2. Engine mounting nut
D Power steering pressure hose AB" 3. Engine mounting bracket
mounting bolt (Refer to GROUP 37A 4. Engine mounting stopper
- Power Steering Gear and Linkage.)
D A/T oil cooler tube mounting bolt
(Refer to GROUP 23 - Transmission
Oil Cooler.)
MB991453
Transmission jack
INSPECTION
D Check the engine mounting bracket for cracks, separation
or deformation.
D Check the engine mounting stoppers for deformation.
TRANSMISSION MOUNTING
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Raise the engine and transmission assembly until its
weight is not applied to the insulator, and support it
securely.
44 10 Nm
<A/T> <M/T>
4 4
44 10 Nm
44 10 Nm
2
2
2
26 4 Nm 2
44 10 Nm
3
44 10 Nm
Removal steps
1. Transmission mounting center 3. Collar
member assembly 4. Transmission mounting insulator as-
2. Transmission mounting bush sembly
INSPECTION
D Check the transmission mounting insulator for cracks,
separation or deformation.
D Check the transmission mounting center member for
cracks or damage.
1
5
26 4 Nm*
6
1
44 10 Nm*
2 255 19 Nm
58 7 Nm
69 10 Nm
69 10 Nm
4
Removal steps
AA" 1. Engine mounting nuts 4. Power steering gear and linkage
2. Front reinforcement bar 5. Engine mounting stopper
AB" 3. No.1 crossmember assembly 6. Engine mounting
MB991453
Transmission jack
INSPECTION
D Check the No.1 crossmember for cracks and damage.
FRONT SUSPENSION
Click on the applicable bookmark to selected the required model year.
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATION
A coil spring-type double wishbone independent- very little variation in roll centre height and
type suspension has been adopted as the front provides excellent riding comfort, making it ideal
suspension. This type of suspension is rigid, has for cross-country vehicles.
COIL SPRING
Item Short wheelbase-2500,3500, Short wheelbase-3200,
Long wheelbase Long wheelbase
-2500 (GL, GLX),3500 (GLX) -2500 (GLS),3200,3500 (GLS)
CONSTRUCTION DIAGRAM
Coil spring
Strut assembly
(shock absorber)
No.2 crossmember
Upper arm
Front frame
Stabilizer bar
Lower arm
NOTE
*: difference between right and left wheels: less than 30
SPECIAL TOOLS
Tools Number Name Use
MB990635, Steering linkage Ball joint and knuckle disconnection
MB991113 or puller
MB991406
MB990968 Torque wrench Upper arm ball joint, lower arm ball joint and
stabilizer link ball joint rotation starting torque
measurement
ON-VEHICLE SERVICE
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
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 2.5 2.5 mm
Toe angle (per wheel) 0_05 05
1. Adjust the toe-in by undoing the clip and turning the left
and right tie rod turnbuckles by the same amount (in
opposite directions).
Bellows NOTE
clip 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 (inner wheel when outer wheel
at 20_): 21_48
D i re c ti o n A
Rear adjusting
cam graduation
(S ta n d a rd v a l u e )
SIDE SLIP
Measure the side slip with a side slip tester.
Standard value: 0 3 mm
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.)
147 10 Nm*
5
7
30 4 Nm
147 10 Nm*
3
74 14 Nm
2
4
Removal steps
1. Front wheel speed sensor bracket 5. Upper arm assembly and front frame
mounting bolt <Vehicles with ABS> connection
2. Clip 6. Upper arm assembly
3. Brake hose 7. Upper arm ball joint assembly
AA" 4. Upper arm assembly and knuckle con-
nection
INSPECTION
UPPER ARM BALL JOINT ROTATION TORQUE CHECK
MB990326
1. After shaking the upper arm ball joint stud several times,
use the special tool to measure the rotation torque of
the upper arm ball joint.
Standard value: 0.4 - 2.5 Nm
MB990968 2. When the measured value exceeds the standard value,
replace the upper arm ball joint assembly.
3. When the measured value is lower than the standard
value, check that the upper arm ball joint turns smoothly
without excessive play. If there is no excessive play, the
ball joint can be reused.
2
44 5 Nm
162 14 Nm*
Removal steps
1. Cap
2. Shock absorber mounting nut
3. Shock absorber assembly
5
9
11 6
10
7
Disassembly steps
AA" "CA 1. Self-locking nut 7. Cup assembly
2. Seat 8. Helper rubber
3. Collar "AA 9. Coil spring
4. Upper bush "AA 10. Spring lower pad
"BA 5. Spring bracket assembly 11. Shock absorber assembly
6. Spring upper pad
C o i l s p ri n g e n d
S h o c k a b s o rb e r
S p ri n g u p p e r
b ra c k e t
assembly
Vi e w A
123 14 Nm*
5
8
7
123 14 Nm*
4
10
25 4 Nm
11
1
162 14 Nm* 39 4 6
Nm
9
3
108 10 Nm
5
9 5 11 N m
2
1
147 29 Nm
Removal steps
1. Split pin 7. Shock absorber and lower arm assem-
2. Lower arm ball joint and knuckle as- bly connection
sembly connection 8. Bump stopper
AA" 3. Tie rod end and knuckle connection 9. Lower arm assembly and stabilizer
4. Upper arm and upper arm ball joint link connection
connection AB" 10. Lower arm mounting bolt
AA" 5. Lower arm ball joint 11. Lower arm assembly
6. Hub and knuckle assembly
INSPECTION
LOWER ARM BALL JOINT ROTATION STARTING
MB990326 TORQUE CHECK
1. After shaking the ball joint stud several times, use the
special tools to measure the rotation starting torque of
the lower ball joint.
MB990968 Standard value: 0.3 - 4.5 Nm
2. When the measured value exceeds the standard value,
replace the lower arm ball joint assembly.
3. When the measured value is lower than the standard
value, check that the lower arm ball joint turns smoothly
without excessive play. If there is no excessive play, the
ball joint can be reused.
STABILIZER BAR
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Under Cover Removal D Check the Dust Cover for Cracks or Damage by
Pushing it with Finger.
D Under Cover Installation
108 10 Nm
44 10 Nm
3
108 10 Nm
2 1
Removal steps
1. Stabilizer link "AA 3. Stabilizer bush
"BA 2. Stabilizer clamp 4. Stabilizer bar
Slit
MB990968 INSPECTION
MB990326 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 tools to measure
the turning torque of the ball joint.
Standard value: 0.5 - 2.0 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 reuse that ball joint.
REAR SUSPENSION
Click on the applicable bookmark to selected the required model year.
REAR
SUSPENSION
CONTENTS
GENERAL INFORMATION
A multi-link type double wishbone independent
suspension has been adopted as the rear
suspension. Because the left and right wheels move
independently with almost no change in tyre
posture, the tyres contact the ground firmly,
providing excellent steering stability as well as
offering improved riding comfort.
COIL SPRING
Items Short wheelbase- Except short wheelbase- Long wheelbase
2500(GL) 2500(GL)
CONSTRUCTION DIAGRAM
Shock absorber
Coil spring
Upper arm
Rear frame
Trailing arm
Camber 0_ 30*
Thrust angle 0_ 9
NOTE
*: difference between right and left wheels: less than 30
SPECIAL TOOLS
Tool Number Name Use
MB990635, Steering linkage Ball joint and knuckle disconnection
MB991113 or puller
MB991406
MB990968 Torque wrench Upper arm ball joint, lower arm ball joint and
stabilizer link ball joint rotation starting torque
measurement
MD998236 Output shaft bear- Trailing arm bushing removal and press-fitting
ing installer
MB990799 Ball joint remover Upper arm ball joint dust cover press-in
and installer
ON-VEHICLE SERVICE
WHEEL ALIGNMENT CHECK AND
ADJUSTMENT
1. The rear suspension, wheels and tyres should be serviced
to normal condition prior to measurement of wheel
alignment.
2. Measure the wheel alignment with the vehicle parked
on a level surface.
TOE-IN
Toe control arm
Standard value:
At the centre of tyre tread 3 3 mm
Toe angle (per wheel) 1_06 1_06
If toe-in is not within the standard value, adjust by following
procedures.
(1) Be sure to adjust the camber before making toe
adjustment.
Toe adjusting bolt (2) Carry out adjustment by turning the toe adjusting bolt
(toe control arm mounting bolt which faces the inside
of the body).
Left wheel: Turning clockwise ( - ) toe-in
Right wheel: Turning clockwise (+) toe-in
CAMBER
Use the compensator to measure camber.
Compensator Standard value:
Camber 0_ 30 (difference between right and left
wheel: less than 30)
Lower arm
15 2 Nm 8
167 10 Nm 10
1 104 14 Nm
2
5
10
2
98 12 Nm
167 10 Nm
8
7
6
3 150 30 Nm
Removal steps
1. Brake pipe connection 6. Split pin
2. Clip AA" 7. Upper arm ball joint and knuckle con-
3. Rear wheel speed sensor and upper nection
arm assembly connection <vehicles AB" "AA 8. Upper arm assembly and rear frame
with ABS> connection
4. Bump stopper 9. Upper arm
5. Stabilizer link and upper arm assembly 10. Upper arm ball joint
connection.
Companion
shaft assembly
Companion shaft
113 14 Nm assembly
INSPECTION
MB990326 UPPER ARM BALL JOINT ROTATION TORQUE CHECK
1. After shaking the upper arm ball joint stud several times,
use the special tool to measure the rotation torque of
the upper arm ball joint.
Standard value: 0.5 3.0 Nm
MB990968
2. When the measured value exceeds the standard value,
replace the upper arm ball joint assembly.
3. When the measured value is lower than the standard
value, check that the upper arm ball joint turns smoothly
without excessive play. If there is no excessive play, the
ball joint can be reused.
5. Using the special tool, drive the dust cover into the position
MB990799 shown in the illustration.
Caution
Dust cover
To prevent the grease to be applied on the ball joint
connection (taper) with knuckle, do not compress the
dust cover before installation.
6. Press the dust cover with your finger to check that there
are no cracks or damage in the dust cover.
Post-installation Operation
Wheel Alignment Check And Adjustment
(P.34-4.)
44 10 Nm*
5
1
123 15 Nm*
152 25 Nm*
8
7
9
152 25 Nm*
Lower arm
BUSHING REPLACEMENT
MB990881
Use the special tool to drive out and press fit the lower arm
bushing.
Lower arm
assembly
104 14 Nm
4
3 1
104 14 Nm
44 10 Nm 2
Removal steps
1. Stabilizer link assembly
2. Stabilizer clamp
"AA 3. Bushing
4. Stabilizer bar
Bushing
Bushing
INSPECTION
MB990326
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 tools to measure
the turning torque of the ball joint.
Standard value: 0.5 - 2.0 Nm
MB990968 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 reuse that ball joint.
Post-installation Operations
D Press the dust cover with your finger to check that
there are no cracks or damage in the dust cover.
D Wheel alignment check and adjustment
(Refer to P.34-4.)
4 6 8 N m
3
4
1 2 3 1 5 N m * 5 6 7 7 N m
Removal steps
1. Parking brake cable mounting bolt AB" 4. Bolt assembly (for toe adjustment)
2. Toe control tower bar 5. Toe control arm assembly
AA" 3. Toe control arm ball joint and knuckle
connection
Boot Caution
Cord 1. To prevent the ball joint thread from damage, only
loosen but do not remove the nut securing the toe
control arm to the knuckle from the ball joint and
use the special tool.
Nut
Toe adjusting
bolt
INSPECTION
MB990326
TOE CONTROL ARM BALL JOINT TURNING TORQUE
CHECK
1. After shaking the toe control arm ball joint stud several
times, use the special tool to measure the turning torque
of the toe control arm ball joint.
Standard value: 1.0 - 2.5 Nm
MB990968
2. When the measured value exceeds the standard value,
replace the toe control arm ball joint assembly.
3. When the measured value is lower than the standard
value, check that the toe control arm ball joint turns
smoothly without excessive play. If there is no excessive
play, the ball joint can be reused.
5. Using the special tool, drive the dust cover into the position
MB990800 shown in the illustration.
Caution
Dust cover
To prevent the grease to be applied on the ball joint
connection (taper) with knuckle, do not compress the
dust cover before installation.
6. Press the dust cover with your finger to check that there
are no cracks or damage in the dust cover.
Post-installation Operations
Wheel Alignment Check and Adjustment (Refer to
P.34-4.)
2
231 34 Nm*
1
231 34 Nm
3 4
Removal steps
1. Trailing arm and knuckle connecting 3. Stopper
bolt 4. Trailing arm
2. Trailing arm and rear frame connecting
nut
BUSHING REPLACEMENT
Trailing arm 1. Use the special tool to drive out and press fit the trailing
arm bushing.
MD998236
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
CORRECTION INTERNATIONAL
CAR
ADMINISTRATION T. MASAKI - MANAGER
T
OFFICE TECHNICAL SERVICE PLANNING
1. Description:
The rear suspension toe angle has been corrected.
2. Applicable Manuals:
MSB-00E34-501 1
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
2001 PAJERO Workshop Manual chassis VOL2
<Incorrect>
MSB-00E34-501 3
<Incorrect>
MSB-00E34-501 4
BASIC BRAKE
SYSTEM
CONTENTS
Items Specifications
Hydraulic brake booster Master cylinder type Single type (with center valve)
(HBB) <Vehicles with ABS>
Master cylinder I.D. mm 22.22
Boosting ratio 5.4 <Pedal depressing force: 274 N>
Master cylinder Type Tandem type
<Vehicles without ABS>
I.D. mm 23.81
Brake booster Type Vacuum type, tandem
<Vehicles without ABS>
Effective dia. of power cylinder mm 216 + 217
Boosting ratio 6.5 <Pedal depressing force: 240 N>
Rear wheel hydraulic pressure control type <Vehicles with ABS> Electronic brake-force distribution (EBD)
Load sensing proportioning Decompression ratio 0.3
valve<Vehicles without ABS>
Front brakes Type Floating caliper, 2 piston, ventilated disc
Disc effective dia. thickness mm 241 26
Wheel cylinder I.D. mm 45.4
Pad thickness mm 10.0
Clearance adjustment Automatic
Rear brakes Type Floating caliper, 1 piston, ventilated disc
Disc effective dia. thickness mm 256 22
Wheel cylinder I.D. mm 44.5
Pad thickness mm 10.0
Clearance adjustment Automatic
Brake fluid DOT3 or DOT4
CONSTRUCTION DIAGRAM
Hydraulic brake
booster (HBB)
Brake booster
Load sensing
Master cylinder proportioning
valve*
NOTE
For short wheelbase, only the position indicated by the * is symmetrical.
Brake pedal to floorboard clearance when the brake pedal is depressed mm 90 or more -
Hydraulic brake Pump motor When power supply system brake fluid 20 - 80 -
booster (HBB) operation time pressure is not applied
<Vehicles with ABS> second
When power supply system brake fluid 2 - 11 -
pressure is applied
Clearance between brake booster push rod and primary piston 6G7 0.5 - 0.9 -
mm <Vehicles without ABS>
4D5, 4M4 0.8 - 1.2 -
Load sensing propor- When load sensing spring length is 133 Short wheelbase 4.9 - 5.9 (9.8) -
tioning valve output mm (when unladen)
fluid pressure (Input Long wheelbase 5.9 - 6.9 (9.8) -
fluid pressure) MPa
<Vehicles without When load sensing spring length is 149 Short wheelbase 7.5 - 8.5 (9.8) -
ABS> mm (when laden)
9.0 - 11.0 -
(16.7)
11.4 - 13.4 -
(16.7)
Load sensing spring length <Distance between spring ends> mm 135 - 139 -
<Vehicles without ABS>
Drag force N 55 -
Drag force N 55 -
LUBRICANTS
Items Specified Lubricant Quantity
SPECIAL TOOLS
Tool Number Name Use
MB991502 MUT-II sub D Hydraulic brake booster (HBB) check
assembly (Reading diagnosis code by using
MUT-II)
D Air bleeding of hydraulic brake booster
(HBB) ABS system
DIAGNOSIS FUNCTION
READING DIAGNOSIS CODES
Read a diagnosis code by the MUT-II or brake warning lamp.
(Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.)
NOTE
Connect the MUT-II to the diagnosis connector (16-pin).
ERASING DIAGNOSIS CODES
When using the MUT-II
Connect the MUT-II to the diagnosis connector (16-pin) and
erase the diagnosis code.
Caution
Turn the ignition key to the LOCK (OFF) position before
connecting or disconnecting the MUT-II.
When not using the MUT-II
1. Stop the engine.
1 second
ON
ABS warning lamp
OFF
ABS-ECU memory
Erasing of
Within 3 Within Within Within Within Within Within Within Within Within Within
1 1 1 1 1 1 ABS-ECU
1 1 1 1
seconds second second second second second second second second second second
diagnosis
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th codes
complete.
NOTE
*: Code No. 16 is erased by turning the ignition switch OFF.
Caution
If the battery voltage is decreased or increased during the test, code No. 16 is output as a present
malfunction, disabling a correct diagnosis. Check the battery and fully charge it if necessary before
carrying out the following tests.
NG
Measure at the ABS-ECU connector E-107. Check the following connectors: E-13, E-107
D Disconnect the connector, and measure at the harness side. NG
OK
D Start the engine and then measure the voltage between terminal
31 and the body earth. Repair
OK: System voltage Check trouble symptom.
OK NG
Measure at the ABS-ECU connector E-106. Check the harness wire, and repair if necessary.
D Disconnect the connector, and measure at the harness side. D Between the ignition switch and the ABS-ECU
D Start the engine and then measure the voltage between terminal
13 and the body earth. NG Check the following connectors: D-32 <R.H. drive vehicles>,
OK: System voltage D-128, D-208, D-210 <R.H. drive vehicles>, D-213 <L.H.drive
OK vehicles>, E-08 <Diesel-powered vehicles>, E-13, E-106
OK NG
Check the following connectors: E-106, E-107
OK NG Check trouble symptom. Repair
NG
Check trouble symptom. Repair
NG Check the harness wire, and repair if necessary.
D Between the ignition switch and the ABS-ECU
Replace the ABS-ECU. (Refer to GROUP 35B.)
Code No.53 Motor relay system (open circuit, short circuit Probable cause
or a defective motor relay coil)
This code is output if the motor relay circuit is short or open, ABS-ECU internal circuit D Malfunction of connector or harness
is defective, or the hydraulic brake booster (HBB) master cylinder and hydraulic unit D Malfunction of the motor relay
assembly is defective. D Malfunction of the ABS-ECU
D Malfunction of the HBB (master cylinder and
hydraulic unit assembly)
NG
Check the motor relay. (Refer to P.35A-24.) Replace
OK
OK
Check trouble symptom.
NG
NG
Visually check the accumulator Replace
OK
Check the continuity and resistance of the pump motor. (Refer NG
to P.35A-23.) Replace
OK
NG
Check the motor relay. (Refer to P.35A-24.) Replace
OK
NG
Check the pressure switch. (Refer to P.35A-23.) Replace the master cylinder and hydraulic unit assembly.
OK
Inspection procedure 1
The brake warning lamp does not illuminate when the Probable cause
ignition switch is turned ON (engine stopped).
The cause may be an open circuit in the lamp power supply circuit, a blown lamp, D Blown fuse
a malfunction of the lamp drive transistor inside the ABS-ECU, an open circuit between D Burn out brake warning lamp bulb
the ignition switch and brake warning lamp or an short circuit between the brake D Malfunction of combination meter
warning lamp and the ABS-ECU. D Malfunction of connector or harness
D Malfunction of ABS-ECU (lamp drive transistor)
NG
Check multi-purpose fuse No.6. Refer to GROUP 00 Inspection Procedure when a Fuse is blown.
OK
NG
Check for blown bulb. Replace the brake warning lamp bulb.
OK
Check the following connectors: D-01, D-208, D-210 <L.H. NG
Repair
drive vehicles>, D-213 <R.H.drive vehicles>
OK
Check trouble symptom.
NG
OK
YES
Disconnect the ABS-ECU connector E-107. Does the brake warning Replace the ABS-ECU. (Refer to GROUP 35B.)
lamp illuminate when the ignition switch is turned ON?
NO
NG
Check the harness wire:
Repair
D Between the combination meter and the ABS-ECU
OK
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.
YES
Disconnect the ABS-ECU connector E-107. Does the brake warning Replace the ABS-ECU. (Refer to GROUP 35B.)
lamp go out when the ignition switch is turned ON and No.39 terminal
is connected to the body earth.
NO
NG
Check the following connectors: D-01, E-13, E-107 Repair
OK
OK
Inspection procedure 3
The HBB buzzer does not sound when the hydraulic brake Probable cause
booster (HBB) is defective. (However, the brake warning
lamp is illuminated.)
The cause is probably an open circuit in the buzzer power supply circuit, a defective D Blown fuse
buzzer, a malfunction of the buzzer drive transistor inside the ABS-ECU or an open D Malfunction of the HBB buzzer
circuit from the ignition switch through the HBB buzzer to the ABS-ECU. D Malfunction of connector or harness
D Malfunction of ABS-ECU (buzzer drive transistor)
NG
Check multipurpose fuse No.5. Refer to GROUP 00 Inspection Service Points for Blown Fuse.
OK
NG
Check the HBB buzzer. (Refer to P.35A-40.) Replace
OK
Inspection procedure 4
The HBB buzzer does not stop sounding. Probable cause
The HBB buzzer circuit may be short. D Malfunction of the HBB buzzer
D Malfunction of the harness
D Malfunction of ABS-ECU (buzzer drive transistor)
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.
NO
Disconnect the ABS-ECU connector E-107. Does the HBB buzzer Replace the ABS-ECU. (Refer to GROUP 35B.)
remain sounding when the ignition switch is turned ON?
YES
NG
Check the following connectors: E-107, E-108 Repair
OK
Standard value:
Pedal effort N Fluid pressure at Fluid pressure at
front wheels MPa rear wheels MPa
100 0.6 or more 0
500 4.5 or more 0
Good No good
BRAKE BOOSTER OPERATING TEST
<Vehicles without ABS>
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.
Good No good 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 least, the check
valve, vacuum hose, or booster will be defective.
Caution
If the check valve is defective, always replace it as
an assembly unit together with the vacuum hose.
2. With the lever pressed all the way to the load sensing
Spring support proportioning valve side, check whether or not the length
(shown in the figure) of the spring (the length between
A
its ends) is the standard value.
Standard value (A): 135 - 139 mm
3. If the spring length is not within the standard value, loosen
Lever
the bolt attaching the support and adjust the distance
Load sensing spring by moving the support.
Pressure gauge
LOAD SENSING PROPORTIONING VALVE
FUNCTION TEST <Vehicles without ABS>
1. Connect pressure gauges to the input and output ports
of the load sensing proportioning valve.
2. Bleed the system. (Refer to P.35A-29.)
3. Disconnect the spring at the support side.
Load sensing
proportioning valve
Load sensing 4. Place the spring so that it is in parallel with the load
proportioning valve sensing proportioning valve, and then pull in the direction
indicated by arrow A so that its length H shown in the
Load sensing spring
figure (the length between its ends) is as noted below.
Parallel A
NOTE
At this time the lever is pressed all the way to the load
sensing proportioning valve side.
Lever
H
NOTE
*1 and *2 indicate the applicable lengths for unladen and
laden vehicles respectively.
6. After making the check, install the spring. Disconnect
the pressure gauges from the load sensing proportioning
valve and bleed air.
2 (4) 3 (1)
( ): R.H. drive vehicles
MIN
MAX
MIN
FRONT REAR 1. Check the brake pad thickness through the caliper body
check port.
Standard value: 10.0 mm
Limit: 2.0 mm
2. When the thickness is less than the limit, always replace
the pads at an axle set.
14Z0017
3. Remove the guide lock pin bolt. Pivot the caliper assembly
and hold it with wires.
REAR
2
3 1
4
Scratches, rust, saturated lining materials D If the vehicle is not driven for a certain period, the sections of
and wear the discs that are not in contact with lining will become rusty, causing
noise and shuddering.
D 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 Excessive run-out or drift of the discs will increase the pedal depression
resistance due to piston knock-back.
Change in thickness (parallelism) If the thickness of the disc changes, this will cause pedal pulsation,
shuddering and surging.
Inset or warping (flatness) Overheating and improper handling while servicing will cause inset or
warping.
BRAKE PEDAL
REMOVAL AND INSTALLATION
Post-installation Operaion
Brake Pedal Adjustment (Refer to P.35A-19.)
14 3 Nm
11
9 5
4
12
12 2 Nm 6
8
7
10
3
2
Removal steps
D Instrument panel lower panel (Refer 7. Pedal stopper
to GROUP 52A.) 8. Snap pin
1. Return spring 9. Pin assembly
2. Split pin <A/T> 10. Pedal pad
3. Shift lock cable connection <A/T> 11. Brake booster mounting nuts
4. Harness connector "AA 12. Brake pedal and pedal support mem-
5. Stop lamp switch ber
6. Adjuster
No continuity Continuity
4 mm
4 8
2 7
15 2 Nm
14 3 Nm
3 9 5
7
2
6
Removal steps
D Battery <L.H. drive vehicles> 4. Pin assembly
D Air intake hose, and air cleaner 5. HBB mounting nuts
<R.H. drive vehicles> AA" "AA 6. HBB
(Refer to GROUP 15.) 7. Seal
1. Harness connector 8. Insulator <4M4>
2. Brake pipe connection 9. Spacer
3. Snap pin
1 1.7 0.3 Nm
2
1.7 0.3 Nm 25.5 5.1 Nm
21
22
3 19
4 53.9 2.9 Nm 23
20
6 11.8 2.3 Nm
24
15
7 11
13 12
7.8 1.5 Nm 14
8 18
17
9 16
15.2 3 Nm
10
3.0 0.5 Nm
1.7 0.1 Nm
7.8 1.5 Nm
Disassembly steps
1. Filler cap 14. Pin
2. Reservoir assembly 15. Bracket
3. Grommet 16. Bracket
4. Accumulator 17. Bushing
5. O - ring 18. Pump motor
6. Spring 19. Clevis
7. Silencer tube 20. Boot
8. Hose AA" D Holding the HBB
9. Tube AB" 21. Snap ring
10. Lead wire AB" 22. Power piston assembly
11. Washer AB" 23. Master cylinder piston assembly
12. Bushing 24. Master cylinder and hydraulic unit
13. Collar assembly
MB991620
10 - 20 mm
ACCUMULATOR DISPOSAL
Use a saw to punch hole around (A) range of the accumulator,
and discharge the gas.
A
Caution
1. Cover the saw with a rag as metal particles may fly
out.
2. Slowly and steadily carry out the work.
NOTE
The gas is an odorless, colorless and harmless (nitrogen
gas).
5.0 1.0 Nm
5.0 1.0 Nm
1
Removal steps
1. Bracket
2. HBB buzzer
INSPECTION
HBB BUZZER CHECK
The buzzer should sound when the battery is connected as
shown.
8
11
13
6
4
5 7
5
1 15 14 3 Nm
1 13 14
10
15 2 Nm 1
1
3 15 2 Nm 12
10 2 Nm 2
8 9 8
22 2 Nm 8 8
9
22 2 Nm
Block gauge
Angle-nose pliers
MB991568
Purchased from www.WorkshopManuals.co.uk
www.WorkshopManuals.co.uk
BASIC BRAKE SYSTEM - Master Cylinder and Brake Booster 35A-43
MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY
4 8 6
9
5
7
10
5 11
12
12
10
11 10
6
9 8 7
11
12 Brake fluid: DOT3 or DOT4
Master cylinder kit
Disassembly steps
1. Reservoir cap 7. Piston guide
2. Pin 8. Cylinder cup
3. Reservoir tank 9. Plate
4. Brake fluid level sensor 10. Primary piston assembly
5. Reservoir seal 11. Secondary piston assembly
AA" 6. Stopper ring 12. Master cylinder body
1
30 4 Nm 2
113 9 Nm
2
Removal steps
1. Brake hose connection
2. Gasket
"AA 3. Disc brake assembly
4. Brake disc
13 13
88 5 Nm 13
2 11
7.4 1.4 Nm
10 13 13
88 5 Nm Clip kit
1
13
12
4
9 3
8
7
6
2 10
12 8
4
4
1 3
9 6
8 5
7
6
5 11
Brake caliper kit Pad set Shim kit Seal and boot kit
Disassembly steps
1. Guide pin lock bolt AA" 7. Piston
2. Guide pin AB" 8. Piston seal
3. Caliper support (including pad, clip and 9. Caliper body
shim) 10. Pad and wear indicator assembly
4. Boot 11. Pad assembly
5. Bushing 12. Shim
AA" 6. Piston boot 13. Clip
Piston seal
Caution
The piston seal inside the
seal and boot kit is coated
with special grease, so do
not wipe this grease off.
INSPECTION
D Check the cylinder for wear, damage or rust.
D Check the piston surface for wear, damage or rust.
D Check the caliper body or sleeve for wear.
D Check pad for damage or adhesion of grease, check
the backing metal for damage.
30 4 Nm
1
88 10 Nm
3
2
Removal steps
1. Brake hose connection
2. Gasket
"AA 3. Disc brake assembly
4. Brake disc
Caution
Do not contaminate the friction surfaces of the pads
and brake discs by any oil or grease.
3. Clean the piston and insert it into the cylinder with the
special tool.
4. Be careful that the piston boot does not become caught,
when lowering the caliper assembly and install the guide
pin to the caliper.
5. Start the engine, and then depress the brake pedal two
or three times strongly. Then stop the engine.
6. Turn the brake disc forward 10 times.
MB990520
15 10
5 5
14 12 10
14 3 3
7 12 11
8 9
8
10 13 4 4 10
11
Brake caliper kit Pad set Shim set Seal and boots kit
Disassembly steps
"AA 1. Guide pin 9. Caliper support
2. Pad and clip assembly, shim 10. Pin boot
3. Shim 11. Boot ring
4. Pad and clip assembly AA" 12. Piston boot
5. Pad assembly AA" 13. Piston
6. Pad clip AB" 14. Piston seal
"AA 7. Lock pin 15. Caliper body
8. Bushing
LUBRICATION POINTS
Piston
seal
Caution
The piston seal inside the
seal and boot kit is coated
with special grease, so do
not wipe this grease off.
Lock pin
INSPECTION
D Check the cylinder for wear, damage or rust.
D Check the piston surface for wear, damage or rust.
D Check the caliper body or sleeve for wear.
D Check pad for damage or adhesion of grease, check
the backing metal for damage.
15 2 Nm 15 2 Nm
3 3
3
5
4
3
3
1 15 2 Nm
Removal steps
"AA 1. Spring support 4. Load sensing proportioning valve
2. Load sensing spring 5. Bracket assembly
3. Brake pipe connection
ANTI-SKID BRAKING
SYSTEM (ABS) <4WD>
Click on the applicable bookmark to selected the required model year.
ANTI-SKID
BRAKING SYSTEM
(ABS) <4WD>
CONTENTS
GENERAL INFORMATION
ABS has been adopted as standard equipment D The hydraulic unit function has been integrated
in all vehicles to maintain directional stability and with the hydraulic brake booster (HBB).
steering performance during sudden braking. D Select solenoid valves (two valves for FL and
The ABS control method used is a 4-sensor, FR) have been adopted in order to reduce the
4-channel method (previous models: 4-sensor, pedal kickback and improve the operation
3 - channel method) which allows the brake feeling when the ABS is operating.
pressures for all four wheels to be controlled D Independent 4-wheel control is carried out wile
independently of each other. The system has the the vehicle is turning in order to increase the
following features. braking force.
D EBD* (Electronic Brake force Distribution NOTE
system) control has been added to provide the *EBD: Electronic Brake-force Distribution
ideal braking force for the rear wheels.
EBD CONTROL
In ABS, electronic control method is used whereby D Because the duty placed on the front brakes
the rear wheel brake hydraulic pressure during has been reduced, the increases in pad
braking is regulated by rear wheel control solenoid temperature can be controlled during front
valves in accordance with the vehicles rate of brakes applying to improve the wear resistance
deceleration and the front and rear wheel slippage characteristics of the pad.
which are calculated from the signals received from D Control valves such as the proportioning valve
the various wheel sensors. EBD control is a control are no longer required.
system which provides a high level of control for
both vehicle braking force and vehicle stability. The
system has the following features.
D Because the system provides the optimum rear
wheel braking force regardless of the vehicle
laden condition and the condition of the road
surface, the system reduces the required pedal
depression force, particularly when the vehicle
is heavily laden or driving on road surfaces
with high frictional coefficients.
SPECIFICATIONS
Item Specifications
ABS control method 4-sensor, 4-channel
No. of ABS rotor teeth Front 50
Rear 50
ABS speed sensor Type Magnet coil type
Gap between sensor and rotor mm 0.9 (non-adjustable type)
ABS-ECU
Valve relay
SERVICE SPECIFICATIONS
Item Standard value
Control solenoid valve resistance W IN 4.75 - 5.25
OUT 2.0 - 2.4
Select solenoid valve resistance W 3.5 - 3.9
Wheel speed sensor terminal resistance kW 1.0 - 1.5
Wheel speed sensor insulation resistance kW 100 or more
SPECIAL TOOLS
Tools No. Name Application
MB991502 MUT-II sub as- Checking the ABS
sembly (Diagnosis display using the MUT-II)
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
PRECAUTIONS WHEN CARRYING OUT DIAGNOSIS
(1) The ABS is a system which controls the brake pressure by means of the operation of the ECU.
Accordingly, the following symptoms may occur at times, but these are a sign of normal ABS operation,
and do not indicate a malfunction.
Symptom Explanation of symptom
When the engine starts, a knocking sound can be heard coming from This sound occurs as a result of system
the engine compartment. operation checking, and is not a
malfunction.
1. The brake pedal feeling changes and noise is generated.(Rattling) This is the sound of normal system
2. When the ABS is operating, noise is generated by parts of the operation, and is not a malfunction.
vehicle chassis as control turns on and off. (Thump: suspension;
squeak: tyres)
Shocks are felt if the brake pedal is depressed when driving at low This is due to system operation
speed. checking (starting- of check when the
vehicle speed reaches a certain
number of km/h) and is not a
malfunction.
DIAGNOSIS FUNCTION
READING DIAGNOSIS CODES
Use the MUT-II or the ABS 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 16-pin diagnosis connector.
ON
Ignition switch
LOCK (OFF)
ON
Stop lamp switch
OFF
1s
ON
ABS warning
lamp
OFF
NOTE
*: Code No.16 is erased from the memory if the condition returns to normal.
NG
Wheel speed sensor installation check Repair
OK
NG
Measure at ABS-ECU connector E-106. Wheel speed sensor check (Refer to P.35B-34.)
D Disconnect the connector and measure at the harness OK NG
side.
D Front: resistance between 10 23, 7 20 Replace
Rear: resistance between 8 21, 9 22
OK: 1.0 - 1.5 kW
Check the following connectors: A-04 <L.H.D.>, A-23, A-39,
OK D-124, D-143 <R.H.D.>, E-10, E-106, F-17, G-11, G-15
Wheel speed sensor output voltage check (Refer to P.35B-27.) OK NG
OK NG
Check the trouble Repair
Wheel speed sensor check symptoms.
(Refer to P.35B-34.)
NG
OK NG
Check the harness wire, and repair if necessary.
Replace D Between each wheel speed sensor and ABS-ECU
ABS rotor check
(Refer to P.35B-33.)
OK NG
Replace
NO
Are the tyres on all four wheels of identical size? Fit tyres which are of identical size.
YES
Check the trouble Repair Check the ABS rotor (Refer to P.35B-33).
symptoms. OK NG
NG
Replace
Replace the ABS- ECU.
Wheel bearing check
(Refer to GROUP 26, 27 - On-vehicles Service.
NG
Caution
If the system voltage drops or rises during inspection, this code will be output to indicate a current
problem. And correct problem diagnosis will not be possible. Before carrying out the following
procedure, check the battery and recharge it if necessary.
(1)NG
Measure at E-106, E-107 ABS-ECU connectors. Check the following connectors: D-32 <R.H.D.>, D-128,
D Disconnect the connector and measure at the harness D-208, D-210 <R.H.D.>, D-213 <L.H.D.>, E-08 <Diesel>, E-13,
side. E-106
D Ignition switch: ON (2)NG NG
OK
(1) Voltage between terminal 13 and body earth
OK: System voltage Check the trouble symptoms.
Repair
(2) Voltage between terminal 31 and body earth NG
OK: System voltage
OK Check the harness wire, and repair if necessary.
D Between the ignition switch and the ABS-ECU
NG
Check the ABS valve relay (Refer to P.35B-28). Replace the ABS valve relay.
OK
(1)NG
Measure at ABS valve relay connector B-21X. Check the following connectors: B-21X, D-32 <R.H.D.>,
D Disconnect the connector and measure at the harness D-128, D-208, D-210 <R.H.D.>, D-213 <L.H.D.>, E-13
side. OK NG
D Ignition switch: ON
(1) Voltage between 1 and body earth Check the trouble symptoms.
(2)NG Repair
OK: System voltage NG
(2) Voltage between terminal 5 and body earth
OK: System voltage
Check the harness wire, and repair if necessary.
OK D Between ignition switch and ABS valve relay
NG
Measure at ABS-ECU connector E-107. Check the following connector: D-32, D-124, D-208, D-210,
D Disconnect the connector and measure at the harness E-13, E-107, F-17
side. NG
OK
D Ignition switch: ON
D Voltage between terminal 33 and body earth Repair
OK: System voltage Check the trouble symptoms.
OK NG
Check the following connector: E-107 Check the harness wire, and repair if necessary.
D Between the ignition switch and the ABS-ECU
OK NG
YES
Do the both of the center differential lock indicator lamp and the Measure at the ABS-ECU connector E-107.
rear differential lock indicator lamp illuminate normally? D Disconnect the connector, and measure at the harness side
NO connector.
D Ignition switch: ON
Does the center differential lock indicator lamp illuminate normally?
D Voltage between 33 and body earth
YES NO
OK: System voltage
Replace the center differ- OK NG
ential lock detection
switch. Check the following Check the following
connector: E-107 connectors:
D-32<R.H.D.>,
Rear differential lock detection switch check OK NG
D-124<L.H.D.>, E-13,
(Refer to GROUP 27) E-107
Repair
OK NG OK NG
Check the trouble symp-
Replace the rear differen-
tom Repair
tial lock detection switch.
NG Check the trouble symp-
Check the following connectors: tom
Check the following
D-26, D-32<R.H.D.>, D-124, F-17, G-01, G-13 connectors: NG
OK NG C-16, E-107, E-113
Check the harness wire,
OK NG
Check the trouble symptom Repair and repair if necessary.
D Between ABS-ECU
NG Repair
and rear differential
Check the trouble symp-
lock-ECU
Check the harness wire. tom
D Between rear differential lock-ECU and rear differential lock NG
detection switch
Check the harness wire.
OK NG
D Between ABS-ECU and center differential lock detection switch
Check the trouble symptom Repair OK NG
NG Check the trouble symp- Repair
tom
Replace the rear differential lock-ECU. NG
(1)NG
Measure at G sensor connector E-01. Check the following connectors: D-32<L.H.D.>, D-208,
D Disconnect the connector and measure at the harness D-210, E-01, E-115 NG
side. NG
(1) Voltage between terminal 1 and body earth (Ignition switch: OK
ON) (2)NG Check the trouble symptoms. Repair
OK: System voltage
NG
(2) Continuity between terminal 3 and body earth
OK: Continuity Check the harness wire, and repair if necessary.
OK D Between ignition switch and G sensor
E-01 OK NG
Harness - side Replace the ABS-ECU. Repair
connector
OK
NG
Check the following connectors: E-01, E-106, E-113 Repair
OK
OK
Code No. 33 Stop lamp switch system (open circuit or Probable cause
ON problem)
This code is output at the following cases: D Malfunction of stop lamp switch
D If the stop lamp switch is continuously on for 15 minutes or more while D Malfunction of harness or connector
driving D Malfunction of ABS-ECU
D If there is an open circuit in the stop lamp switch input circuit harness
NO
Does the stop lamp turn on and off normally? Stop lamp switch installation check
YES (Refer to 35A - On-vehicle Service.)
OK NG
Measure at ABS-ECU connector E-107.
D Disconnect the connector and measure at the harness Repair
side.
D Stop lamp switch: ON Stop lamp switch check
D Voltage between terminal 34 and body earth (Refer to GROUP 35A - Brake Pedal.)
OK: System voltage
OK NG
OK NG
Replace
Check the following Check the following
Check the following connectors: D-26 <L.H.D.>, D-27,
OK E-107
connector: connectors: D-26
D-124 <R.H.D.>, D-136
NG <L.H.D.>, D-33 <L.H.D.>,
OK
D-124 <R.H.D.>, D-128, OK NG
Repair D-136, E-13, E-107
NG Check the trouble symptoms. Repair
OK
Check the trouble NG
symptoms. Repair
Check the trouble Check the harness wire, and repair if necessary.
NG
symptoms. D Between fusible link No.2 and stop lamp switch
Replace the ABS-ECU. NG
Check the harness wire,
and repair if necessary.
D Between stop lamp
switch and ABS-ECU
NG
Measure at HBB connectors B-16, B-17, B-18. Replace the HBBs master cylinder and hydraulic unit
D Disconnect the connectors and measure at the HBB side. assembly.
D Control solenoid valve IN: Resistance between terminals 34
- 19 (FR), 34 - 21 (FL), 34 - 13 (RL) and 34 - 15 (RR)
OK: 4.75 - 5.25 W
D Control solenoid valve OUT: Resistance between terminals
34 - 20 (FR), 34 - 22 (FL), 34 - 14 (RL) and 34 - 16
(RR)
OK: 2.0 - 2.4 W
D Select solenoid valves: Resistance between terminals 34 -
18 (FR) and 34 - 17 (FL)
OK: 3.5 - 3.9 W
D Valve relay monitor: Continuity between terminals 34 - 3
OK: Continuity (approx. 33 W)
OK
NG
Check the following connectors: B-16, B-17, E-106, E-107 Repair
OK
NG
Check the ABS valve relay (Refer to P.35B-28). Replace the ABS valve relay.
OK
NG
Measure at ABS-ECU connector E-107. Check the following connectors: E-107, B-21X
D Disconnect the connector and measure at the harness OK NG
side.
D Ignition switch: ON Check the trouble Repair
D Voltage between terminal 37 and body earth symptoms.
OK: System voltage
NG
OK
Check the harness, and repair if necessary.
Check the harness, and repair if necessary. D Between ABS valve relay and ABS-ECU
D Between ABS valve relay and HBB and ABS-ECU terminal NG
No.48 Repair
D Between ABS valve relay and body earth
OK
NOTE
When reading the diagnosis codes using the ABS warning lamp (Refer to P.35B-5.), the valve relay
connector is disconnected during inspection, with the result that this problem code will be output in addition
to any other problem codes.
After the problem locations indicated by the problem diagnosis codes have been checked and repaired
but the ABS warning lamp remains illuminated and no diagnosis codes other than code No. 52 are displayed,
there is probably a malfunction of the valve relay system. In this case, carry out the following inspection.
NG
Check the ABS valve relay (Refer to P.35B-28). Replace the ABS valve relay.
OK
(1)NG
Measure at ABS valve relay connector B-21X. Check the following connectors: B-21X, D-32 <R.H.D.>,
D Disconnect the connector and measure at the harness D-128, D-208, D- 210 <R.H.D.>, D-213 <L.H.D.>, E- 13
side. OK NG
D Ignition switch: ON
(1) Voltage between 1 and body earth Check the trouble symptoms.
(2)NG Repair
OK: System voltage
(2) Voltage between terminal 5 and body earth NG
OK: System voltage
Check the harness wire, and repair if necessary.
OK D Between ignition switch and ABS valve relay
Measure at ABS-ECU connector E-107. Check the harness wire, and repair if necessary.
D Disconnect the connector and measure at the harness D Between fusible link No. 8 and the ABS valve relay
side.
D Ignition switch: ON NG
D Voltage between terminal 37 and body earth Check the following connectors: E-107, B-21X
OK: System voltage OK NG
OK
Check the trouble symptoms. Repair
NG
Check the following connectors: B-17, B-18, B-21X, E-107
OK Check the harness wire, and repair if necessary.
NG
D Between ABS-ECU and ABS valve relay
Check the trouble symptoms. Repair
OK
Caution
(1) Because the ABS may also operate at times when sudden braking is not being carried out,
such as when driving on low frictional coefficient roads, when turning at high speed or during
high - speed overtaking, check with the customer that the problems are not occurring when
driving under conditions such as these.
(2) When the ABS is operating, changes in the brake pedal feel (vibration and difficulty depressing
the pedal) may occur. This happens because the hydraulic pressure inside the brake line is
continually changing in order to stop the wheels from locking up, and is not a malfunction.
Measure at diagnosis connecter D-23. NG Check the following connectors: D-23, D-27, D-210, D-211
D Voltage between 16 and body earth OK NG
OK: System voltage
OK Check the trouble symptoms. Repair
NG
NG
Measure at diagnosis connector D-23 and ABS-ECU connector Check the following connectors: D-23, D-33, D-128, D-222,
E-107. E-13, E-107
D Disconnect the connectors and measure at the harness
OK NG
side.
D Continuity between the following terminals:
Between terminals 47 (ABS-ECU side) and 1 (diagnosis Repair
Check the trouble symptoms.
connector side)
NG
Between terminals 36 (ABS-ECU side) and 7 (diagnosis
connector side) Check the harness wire, and repair if necessary.
OK: Continuity D Between ABS-ECU and diagnosis connector
OK
(1)NG
Measure at ABS-ECU connectors E-106, E-107. Check the following connectors: D-32 <R.H.D.>, D-128,
D Disconnect the connectors and measure at the harness D-208, D-210 <R.H.D.>, D-213 <L.H.D.>, E-08 <Diesel>, E-13,
side. E-106
D Ignition switch: ON (2)NG
OK
(1) Voltage between terminal 13 and body earth NG
OK: System voltage Check the trouble symptoms.
Repair
(2) Voltage between terminal 31 and body earth NG
OK: System voltage OK
Check the harness wire, and repair if necessary.
OK D Between the ignition switch and the ABS-ECU
Inspection procedure 3
The ABS warning lamp does not illuminate when the Probable cause
ignition key is turned to ON (engine stopped).
When power is first supplied to the ABS-ECU, the ABS-ECU turns the ABS-ECU D Blown fuse
valve relay from off to on, off and back to on again as part of its initial check. D Blown ABS warning lamp bulb
Accordingly, if the ABS warning lamp does not illuminate, the cause is probably D Malfunction of ABS valve relay
an open circuit in the ABS warning lamp power supply circuit, a blown lamp bulb D Malfunction of harness or connector
or an open circuit between the ABS warning lamp and the ABS-ECU. D Malfunction of combination meter
D Malfunction of the ABS-ECU
NG
Multi- purpose fuse No. 6 check Refer to GROUP 00 Inspection service Points for Blown
OK Fuse.
NG NG
Measure at the ABS-ECU connector E-107. Check for a blown bulb. Replace the ABS
D Disconnect the connector and measure at the harness warning lamp bulb.
OK
side.
D Ignition switch: ON
D Warning lamp condition when terminal 50 is shorted to Check the following connectors: D-01, D-208, D-210
body earth <L.H.D.>, D-213 <R.H.D.>, E-10, E-107
OK: Illuminates OK NG
OK Check the trouble symptoms. Repair
NG
Check the following connector: E-107
OK NG Check the harness wire.
D Between ignition switch and combination meter
Repair D Between the combination meter and the ABS-ECU
Check the trouble symptoms.
OK NG
NG
Repair
After replacing the ABS-ECU, carry out the following check.
D Check the harness wire between the ABS warning lamp,
ABS valve relay and earth.
Replace the combination meter.
Inspection procedure 4
The ABS warning lamp remains illuminated after the Probable cause
engine has started.
The cause is probably a short-circuit in the ABS warning lamp illumination circuit. D Malfunction of combination meter
D Malfunction of harness (short-circuit)
D Malfunction of the ABS-ECU
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.
YES
When the ABS valve relay connector B-21X and the Check the harness wire.
ABS-ECU connector E-107 are disconnected and the ignition D Between the ABS warning lamp, the ABS-ECU and the
switch is turned to the ON position, does the ABS warning ABS valve relay
lamp remain illuminated? OK NG
NO
Repair
Replace the ABS-ECU.
Replace the combination meter.
NG
Wheel speed sensor installation check Repair
OK
OK
Wheel speed sensor output voltage check (Refer to P.35B-27.) Check the hydraulic unit inside the hydraulic brake booster
(HBB). (Refer to P.35B-29.)
NG
NG
Check the wheel speed sensor (Refer to P.35B-34.) Replace
OK
NG
Check the ABS rotor (Refer to P.35B-33). Replace
OK
NG
Wheel bearing check Replace
(Refer to GROUP 26, 27 - On-vehicle Service.)
OK
NG
Check the following connectors: A-04 <L.H.D.>, A-23, A-39, Repair
D-124, D-143 <R.H.D.>, E-10, E-106, F-17, G-11, G-15
OK
Measure at ABS-ECU connector E-106. NG Check the harness, and repair if necessary.
D Disconnect the connector and measure at the harness D Between each wheel speed sensor and ABS-ECU
side.
D Front: resistance between 10 23, 7 20
Rear: resistance between 8 21, 9 22
OK: 1.0 - 1.5 kW
(Move the sensor harness and connector while checking at
this time.)
OK
NG
Check the following connector: E-106 Repair
OK
Control solenoid ON
valve IN
OFF
Control solenoid ON
valve OUT
OFF
Select solenoid ON
valve (FR)
OFF
Select solenoid ON
valve (FL)
OFF
Brake fluid Increase Decrease Hold Increase
pressure of
corresponding
wheel
Item No. 27, 28 drive
pattern 0.8 s 0.8 s 2.5 s 0.8 s 2.5 s 0.8 s 0.8 s
ON
Control solenoid
valve OUT (R.H.)* OFF
Control solenoid ON
valve OUT (L.H.)*
OFF
ON
Select solenoid
valve (FL) OFF
NOTE
*: When carrying out item No. 27, the front wheels are driven, and when carrying
out item No. 28, the rear wheels are driven.
Output voltage:
42 mV or higher when measured using a
multimeter
120 mVP - P or more when measured using an
oscilloscope
(4) If the output voltage is lower than that given above, the
cause may be the following, so check or replace the
wheel speed sensor if necessary.
D Excessive clearance between pole piece of wheel
speed sensor and ABS rotor
D Malfunction of wheel speed sensor
Caution
The wheel speed sensor cables move together with the movement of the front and rear
suspension. Accordingly, you should shake the sensor harnesses while observing the wheel
speed sensor output voltage wave patterns.
Petrol-powered vehicles
ABS VALVE RELAY CONTINUITY CHECK
Battery volt- Terminal No.
Valve relay
age 1 2 3 4 5
When no
current is
supplied
When cur-
rent is sup-
plied
Diesel-powered vehicles
Valve relay
(5) Rotate the wheel by hand and check that the brake force changes when the brake pedal is depressed.
If using a brake force tester, depress the brake pedal until the brake force reaches the following value,
and then cheek that the brake force changes when the actuator test is carried out.
Front wheels 785 - 981 N
Rear wheels 785 - 981 N
Caution
The solenoid valves should be driven one wheel at a time, and the brake pedal should be
released each time a wheel is checked.
The following illustration shows this in graphical form.
Depress
Pedal operation
Release
MUT-II actuator test (Item No. 01, 02, 03, 04) start
Increase
1s
Decrease
(6) If the results of checking show an abnormality, fix the problem by following the Judgment Table below.
Judgment Table
No. MUT-II Operation Judgment Cause Remedy
display Normal Problem
01 FR valve (1) Depress the brake Brake Wheel does Blocked brake line oth- Check and
pedal to lock the force not lock er than HBB line clean the
wheels. less- when brake brake line.
(2) Use the MUT-II to ens for pedal is de-
02 FL valve select the wheel to 3 sec- pressed. Blocked hydraulic cir- Replace the
be checked, and onds cuit inside HBB HBB.
then force-drive the after
03 RR valve actuator. lock- Brake force HBB brake tubes con- Connect the
(3) Check the brake ing. does not nected incorrectly tubes correct-
force for the selected lessen. ly.
wheel using a brake
04 RL valve force tester or by Malfunction of HBB Replace the
rotating the wheel by solenoid valve HBB.
hand.
(7) After checking, turn the ignition switch to the LOCK (OFF) position and then disconnect the MUT-II.
ABS-ECU
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
Indicator panel and front panel removal and installation
(Refer to GROUP 52A - Floor Console.)
5 1 Nm
5 1 Nm
2
1
5 1 Nm
Removal steps
1. Buzzer bracket
2. Buzzer
3. ABS-ECU
Front Rear
4
3
6
Front wheel speed sensor removal Rear wheel speed sensor removal
steps steps
AA" 1. Front wheel speed sensors AB" 4. Rear wheel speed sensor
2. Front ABS rotor protector 5. Rear ABS rotor protector
3. Front ABS rotor 6. Rear ABS rotor
(Refer to GROUP 26 - Drive Shaft.) (Refer to GROUP 27 - Drive Shaft.)
NOTE
The front and rear ABS rotors are integrated with
the drive shaft and cannot be disassembled.
INSPECTION
WHEEL SPEED SENSOR TERMINAL RESISTANCE
CHECK
Caution
The wheel speed sensors have magnets built into the
sensors which magnetize the pole pieces. Because of
this, care should be taken not to let metallic foreign
particles get onto the pole pieces. In addition, if the poles
become damaged, the sensors may not be able to detect
the wheel speed correctly.
G SENSOR
REMOVAL AND INSTALLATION
Caution
Do not drop the G sensor or subject it to any shocks.
5 1 Nm
Earth bolt
1
5 1 Nm
5 1 Nm
Removal steps
1. G sensor
2. G sensor bracket
PARKING BRAKES
Click on the applicable bookmark to selected the required model year.
PARKING BRAKES
CONTENTS
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.
CONSTRUCTION DIAGRAM
SERVICE SPECIFICATIONS
Items Standard value Limit
LUBRICANTS
Items Specified lubricants
Adjuster
Shoe hold-down pin 3M ATD Part No. 8513 or equivalent Drying sealant
ON-VEHICLE SERVICE
Cable rod
PARKING BRAKE LEVER STROKE CHECK
AND ADJUSTMENT
1. Pull the parking brake lever with a force of approx. 200
N and count the number of notches.
Standard value: 5 - 7 notches
2. If the parking brake lever stroke is not the standard value,
Adjusting nut
adjust as described below.
(1) Remove the cup holder, and then loosen the adjusting
nut to move it to the cable rod end so that the cable
will be free.
(2) Remove the rear wheels.
4.9 1.0 Nm
1
6
7
2 4
5
3
8
7
B
Ratchet
pawl
B
Removal steps
1. G sensor bracket 5. Parking brake stay
2. Floor console bracket 6. Bushing
3. Adjusting nut 7. Parking brake lever assembly
4. Parking brake cable assembly con- 8. Parking brake switch
nection
Removal steps
D Shoe and lining assembly
(Refer to P.36-7.)
D Parking brake cable assembly
connection (Refer to P.36-5.)
1. Parking brake cable
11 1
14 3
6
10
7
13 11
8
4 5 2
9
8
11 14
11
5
Sealant:
3M ATD Part No. 8513 or
Brake grease: Multipurpose grease equivalent
Removal steps
AA" 1. Rear brake caliper assembly 9. Shoe hold-down spring
2. Rear brake disc 10. Clip
"BA 3. Shoe-to-anchor spring 11. Shoe and lining assembly
4. Adjusting wheel spring 12. Rear hub assembly
"AA 5. Adjuster assembly (Refer to GROUP 27.)
6. Strut 13. Backing plate
7. Strut-to-shoe spring 14. Shoe hold-down pin
8. Shoe hold-down cup
INSPECTION
BRAKE LINING AND BRAKE DRUM CHECK
1. Measure the thickness of the brake lining at several places.
Standard value: 3.0 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.
STEERING
Click on the applicable bookmark to selected the required model year.
STEERING
CONTENTS
GENERAL INFORMATION
A 4-spoke type steering wheel has been mounted. into one light-weight and compact assembly.
All models have been equipped with the SRS as The steering system uses a vane oil pump with
standard. a fluid flow control system, so that steering effort
The power steering is an integral rack and pinion varies with engine speed.
type that combines the steering gear and linkage
Item Specifications
Steering gear and linkage Type Integral type
Gear type Rack and pinion
Oil pump Type Vane type
Displacement ml/rev. 10.0
Relief set pressure MPa 8.8
CONSTRUCTION DIAGRAM
<L.H. drive vehicles6G7, 4M4>
Steering wheel
Suction hose
Pressure hose
Return hose
Oil pump
Return hose
Steering wheel
Oil pump
Oil reservoir
Pressure hose
Return hose
Steering wheel
Suction hose
Return hose
Pressure hose
Oil pump
Return hose
Suction hose
Return hose
LUBRICANTS
Item Specified lubricant Quantity
Power steering Automatic transmission fluid DEXRON II About 0.6 l
Tie rod bellows Silicone grease As required
Pinion and valve assembly Repair kit grease As required
Rack assembly Repair kit grease As required
SPECIAL TOOLS
Tool Number Name Use
MB990635, Steering linkage Tie rod end disconnection
MB991113 or puller
MB991406
MB990925 Bearing and oil Oil seal and bearing press fitting
seal installer set (Refer to GROUP 26 - Special Tools.)
MB991199 Oil seal installer Gear housing oil seal press fitting
MB991202 Oil seal and Valve housing needle bearing and lower
bearing installer bearing press fitting
MB991203 Oil seal and Valve housing oil seal and bearing press
bearing installer fitting
MB990941 Torque tube Valve housing lower oil seal press fitting
bearing installer
ON-VEHICLE SERVICE
STEERING WHEEL FREE PLAY CHECK
1. With the engine running (hydraulic pressure operating),
put the front wheels in straight-ahead position.
2. Lightly turn the steering wheel left and right to measure
circumferential play on the steering wheel before the
wheels start to move.
Limit: 30 mm or less
MB990326
2. After swinging the ball joint stud several times, install
the nut on the stud. Then, measure ball joint turning torque
with the special tool.
Standard value: 0.49 2.45 Nm
3. When the torque is over the standard value, replace the
tie rod end.
4. When the torque is below the standard value, check the
ball joint for looseness or ratcheting. If none of these
found, the ball joint is still serviceable.
Shut-off valve
POWER STEERING OIL PRESSURE SWITCH
Adapter CHECK <6G7, 4M4>
(MB991548) Pressure
gauge 1. Disconnect the pressure hose from the oil pump and
Temperature (MB990662) connect the special tools.
gauge 2. Bleed air. Without the vehicle moving, turn the steering
wheel several times to raise the fluid temperature to 50
to 60_C.
3. Idle the engine.
4. Disconnect the oil pressure switch connector and set
an ohmmeter in position.
5. Gradually close the shut-off valve in the pressure gauge
to increase hydraulic pressure. Check that the hydraulic
Oil pressure activating the switch meets the standard value.
pump
Standard value: 1.5 - 2.0 MPa
Reservoir Adapter 6. Gradually open the shut-off valve and reduce the hydraulic
(MB991549) pressure. Check that the hydraulic pressure deactivating
the switch meets the standard value.
Standard value: 1.5 - 2.0 MPa
7. Remove the special tools and tighten the pressure hose
to the specified torque.
Tightening torque: 57 7 Nm
8. Bleed the system.
Cross-section A A
2 Claw
2
1
A
Cross-section B B
50 5 Nm B Claw
4 B
A 1
1 2
D
C
D C 6 Cross-section C C
5.0 1.0 Nm 4
3
9
Claw
13 2 Nm 3
Cross-section D D
22 4 Nm 7 4
8
Claw
3
5
18 2 Nm
Removal steps
AA" 1. Cover D Brake pedal return spring <Refer to
AB" 2. Steering wheel and air bag module GROUP 35A Brake Pedal.>
assembly 9. Steering column shaft assembly
3. Lower column cover
4. Upper column cover
5. Protector NOTE
6. Clock spring and column switch When the air bag module assembly must be
assembly <Refer to GROUP 52B.> removed, refer to GROUP 52B Air Bag Modules
7. Cover <A/T> and Clock Spring.
8. Key interlock cable <A/T>
MB990784
REMOVAL SERVICE POINTS
AA" COVER REMOVAL
Insert the special tool from the indicated position to remove
the cover.
NOTE
The special tool can be inserted through the notch behind
the position shown.
1 5
13 2 Nm 13 2 Nm
7
6
18 2 Nm
Disassembly steps
1. Steering dynamic damper lower "AA 5. Steering lock cylinder assembly
plate 6. Steering column shaft
2. Steering dynamic damper 7. Shaft support bracket B
AA" "AA 3. Special bolt 8. Shaft support bracket A
"AA 4. Steering lock bracket 9. Joint assembly
12 2 Nm <6G7, 4M4>
4 2
12 2 Nm 3
<4D5>
2
3
15 3 Nm
69 9 Nm
7 18 2 Nm
6
69 9 Nm
39 5 Nm
1
8 5
71 7 Nm
3 15 3 Nm
15 3 Nm
<4D5>
2
12 2 Nm
2 12 2 Nm
18 2 Nm 4
39 5 Nm 6 <6G7, 4M4>
1 15 3 Nm
2
12 2 Nm
5 4
3
69 9 Nm
69 9 Nm
71 7 Nm
7
Nut Caution
1. In order not to damage the ball joint thread, the tie
rod end mounting nut must be only loosened but not
removed from the ball joint. Be sure to use the special
tool.
2. Tie the special tool with a cord so as not to fall off.
Ball joint
<R.H. drive vehicles> 2. Remove the bolts securing the differential mount bracket
assembly (RH) to the front frame assembly and the bolts
securing the differential mount bracket assembly (RH)
to the No.2 crossmember <R.H. drive vehicles>.
<R.H. drive vehicles> 2. Pull the rack to the left as far as it will go, and lower
the steering gear and linkage through the space of the
front frame by manipulating it <R.H. drive vehicles>.
Caution
Be careful not to damage the boot when removing
the steering gear and linkage.
(1)
(2)
INSPECTION
GEAR BOX PINION TOTAL ROTATION TORQUE CHECK
MB991006 1. Using the special tool, turn the pinion gear at a speed
of one rotation per 4 to 6 seconds to measure total rotation
torque.
Standard values:
Total rotation torque: 0.6 1.7 Nm
Torque fluctuation: 0.4 Nm or less
NOTE
(1) Remove the bellows from the rack housing before
measuring.
(2) Measure the total rotation torque by turning the special
tool left and right 180_ from the neutral position.
2. If the standard values are not met, adjust the pinion total
rotation torque. (Refer to P.37-27.)
3. In case the adjustment is impossible, disassemble and
check the components, and repair if necessary.
Caution
Secure the steering gear box and linkage in their
mounting positions only. Otherwise, deformation or
damage could result.
TIE ROD SWING RESISTANCE CHECK
1. Swing the tie rod 10 times hardly.
2. With the tie rod end downwards as shown, use a spring
scale to measure swing resistance (swing torque).
Standard value: 11 - 35 N (1.4 - 4.9 Nm)
3. If the measured value is above the standard value, replace
the tie rod.
4. If below, check the ball joint for looseness or ratcheting.
The tie rod is still serviceable when the ball joint swings
smoothly.
8 11
27
10 28
88 10 Nm 12
26
29
30
32
33
31
Disassembly steps
"OA 1. Gear mounting rubber cushion 19. Valve housing assembly
2. Gear housing mounting bushing AB" "HA 20. Lower oil seal
3. Feed pipe AB" 21. Pinion and valve assembly
4. O-ring AC" "GA 22. Seal ring
"NA 5. Lock nut AD" "FA 23. Upper bearing
"NA 6. Tie rod end AD" "FA 24. Upper oil seal
7. Clip 25. Valve housing
"MA 8. Band AE" "EA 26. Circlip
9. Bellows AF" 27. Rack stopper
"LA 10. Tie rod AF" "DA 28. Rack bushing
"LA 11. Tab washer AF" "DA 29. Oil seal
12. Coil spring AF" 30. O-ring
"KA D Total pinion rotating torque adjustment AF" "CA 31. Rack assembly
"JA 13. Lock nut AC" 32. Seal ring
AA" "JA 14. Rack support cover 33. O-ring
15. Support spring AG" "BA 34. Lower bearing
16. Rack support AH" "BA 35. Needle bearing
"IA 17. End plug AI" "AA 36. Oil seal
18. Lock nut 37. Gear housing
25
15 3 Nm 3
3
24
19 23
21
22 4
20 35
4 24 Repair kit grease
2 22
1
12 2 Nm - 10_ 20
37 4
11 8
59 10 Nm 1415
16 34 36
31
13 18 8
25 4 Nm 1136
18
17 32 33 30 29
59 10 Nm
Disassembly steps
"OA 1. Gear mounting rubber cushion 19. Valve housing assembly
2. Gear housing mounting bushing AB" "HA 20. Lower oil seal
3. Feed pipe AB" 21. Pinion and valve assembly
4. O-ring AC" "GA 22. Seal ring
"NA 5. Lock nut AD" "FA 23. Upper bearing
"NA 6. Tie rod end AD" "FA 24. Upper oil seal
7. Clip 25. Valve housing
"MA 8. Band AE" "EA 26. Circlip
9. Bellows AF" 27. Rack stopper
"LA 10. Tie rod AF" "DA 28. Rack bushing
"LA 11. Tab washer AF" "DA 29. Oil seal
12. Coil spring AF" 30. O-ring
"KA D Total pinion rotating torque adjustment AF" "CA 31. Rack assembly
"JA 13. Lock nut AC" 32. Seal ring
AA" "JA 14. Rack support cover 33. O-ring
15. Support spring AG" "BA 34. Lower bearing
16. Rack support AH" "BA 35. Needle bearing
"IA 17. End plug AI" "AA 36. Oil seal
18. Lock nut 37. Gear housing
Fluid:
Automatic transmission
fluid DEXRON II
Fluid:
Automatic transmission
fluid DEXRON II
Fluid:
Automatic transmission
fluid DEXRON II
Socket
2. Partially bend the oil seal to remove from the rack bushing.
Caution
Use care not to damage the oil seal press-fitting
Rack bushing surface of the rack bushing.
Lower
bearing
Oil seal
Oil seal
MB991202 MB991202
Lower
bearing
2. Apply the specified fluid to the oil seal inner surface and
the O-ring.
Rack
Specified fluid:
Automatic transmission fluid DEXRON II
Caution
Do not use ATF-SP II M and ATF-SP III.
Plastic tape 3. Wrap the rack end with plastic tape, and push the rack
Rack bushing bushing onto the rack.
Slot Slot
MB991203
MB991203
Upper Bearing
oil seal
MB991561
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.
3. See that the crimped width (A) meets the standard value.
Standard value (A): 2.4 - 2.8 mm
A <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.]
<6G7> <4M4>
22 4 Nm 22 4 Nm 57 7 Nm
3 3
23 4 Nm
2
1 2
1 4 57 7 Nm
<4D5>
4
3
22 4 Nm
57 7 Nm
1
22 4 Nm
Removal steps
<6G7, 4D5> <4M4>
1. Drive belt D Engine cover (Refer to GROUP 11C.)
(Refer to GROUP 11A, 11B.) 1. Pressure hose
2. Suction hose 2. Return hose B
3. Pressure tube 3. O-ring
4. Oil pump assembly 4. Oil pump assembly
19 21
37 2 Nm 22
1
5 20
28 2 Nm
13
4
14 24 2 Nm
6
17 11
3
35 4 Nm
8
18 9
7
2
10
44 5 Nm
16 15
12
NOTE
20 22 7 6
14 11 5
4
18 16
9 6
6
12 3
2
10 8
Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit
Disassembly steps
1. Pump cover "BA 12. Oil seal
2. O-ring 13. Terminal assembly <6G7>
3. Adapter ring "AA 14. O-ring <6G7>
"EA 4. Vanes 15. Inner plug A
"DA 5. Cam ring "AA 16. O-ring
6. Snap ring 17. Inner plug B
7. Pulley and shaft "AA 18. O-ring
"CA 8. Rotor 19. Inner plug C
9. Side plate "AA 20. O-ring
"AA 10. O-ring 21. Suction connector
"AA 11. O-ring "AA 22. O-ring
<4M4>
Caution
Never disassemble the terminal assembly unable to be reassembled.
5 13
1 12
7 11
8
6
22 1 Nm
17 10
9 44 5 Nm
18
3
24 2 Nm
4
16
19
37 2 Nm
35 4 Nm
22 14
21
28 2 Nm 15 20
NOTE
3 7
18 8
14 6
13
5 9
12
11
16 20
22
Disassembly steps
1. Tank assembly 12. Side plate
2. Cap assembly "AA 13. O-ring
"AA 3. O-ring "AA 14. O-ring
4. Pump cover 15. Terminal assembly
5. O-ring "AA 16. O-ring
6. Adapter ring 17. Inner plug A
"DA 7. Vanes "AA 18. O-ring
"CA 8. Cam ring 19. Inner plug B
9. Snap ring "AA 20. O-ring
10. Oil pump gear 21. Inner plug C
"BA 11. Rotor "AA 22. O-ring
8 7
MB990938
"BA OIL SEAL INSTALLATION <6G7, 4D5>
MB991203
Vane
4
Oil pump assembly 57 7 Nm
2
<4M4>
3
12 2 Nm
3
12 2 Nm
12 2 Nm 5
4 9 15 3 Nm
7
57 7 Nm
7
15 3 Nm
8
8 9 12 2 Nm
12 2 Nm 15 3 Nm
15 3 Nm 5
Removal steps
1. Oil reservoir <6G7> "AA 6. Pressure tube <6G7>
"DA 2. Suction hose <6G7> "BA 7. Cooler tube
"CA 3. Return hose B "BA 8. Return hose A
4. Eye bolt "AA 9. Return tube
"AA 5. Pressure hose assembly
12 2 Nm
2
57 7 Nm
12 2 Nm 5
6 7 12 2 Nm
15 3 Nm
8 9
12 2 Nm
15 3 Nm
Removal steps
1. Oil reservoir 6. Pressure hose assembly
"DA 2. Suction hose "BA 7. Cooler tube
"CA 3. Return hose B "BA 8. Return hose A
4. Tube clip "AA 9. Return tube
5. Eye bolt
22 4 Nm
1
<6G7> 2
12 2 Nm
57 7 Nm
6 5 <4M4>
7 Oil pump assembly
12 2 Nm
15 3 Nm 10
9
3
8
4
15 3 Nm
Oil pump
12 2 Nm
assembly
57 7 Nm
3 5
6
15 3 Nm
15 3 Nm
10
12 2 Nm
12 2 Nm
9
8
Removal steps
1. Oil reservoir <6G7> "AA 6. Pressure hose assembly
"DA 2. Suction hose <6G7> "BA 7. Pressure tube <6G7>
"CA 3. Return hose B "BA 8. Cooler tube
4. Tube clip "BA 9. Return hose A
5. Eye bolt "AA 10. Return tube
12 2 Nm
2
Oil pump assembly
57 7 Nm
12 2 Nm
5
15 3 Nm
9
15 3 Nm
12 2 Nm
4
12 2 Nm 8
Removal steps
1. Oil reservoir 6. Pressure hose assembly
"DA 2. Suction hose "BA 7. Cooler tube
"CA 3. Return hose B "BA 8. Return hose A
4. Tube clip "AA 9. Return tube
5. Eye bolt
Mating marks
Front Rear
<L.H. drive vehicles 6G7, 4M4> "BA RETURN HOSE A/COOLER TUBE INSTALLATION
Install so that the mating marks are facing upwards.
Mating mark
A
View A
Mating marks
Mating marks
Mating marks
Mating marks
Mating mark
Front Rear
<4D5> 3. Install so that the mating marks are facing towards the
rear <4D5>.
Mating mark
Mating mark
Rear Front
Mating marks
Front Rear
Mating mark
Mating mark
BODY
Click on the applicable bookmark to selected the required model year.
BODY
CONTENTS
SERVICE SPECIFICATION . . . . . . . . . . . . . 39
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . 39
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 39
HOOD
REMOVAL AND INSTALLATION
7
7 22 4 Nm 2
7
9
5
3
1
9.0 2.0 Nm
8 5.0 1.0 Nm
2 1
B
B
A
A
Adjustment of hood step
and hood striker linkage
Section A - A Section B - B
6 6
15 0.5 mm
20 0.5mm
W0382AL
7 7
A
6
Clip
4
: Clip positions
6
FENDER
REMOVAL AND INSTALLATION
Caution: SRS
Do not strike the front impact sensor when removing or installing the fender.
Pre-removal and Post-installation Operation
D Front Bumper Removal and Installation D Overfender Removal and Installation
(Refer to GROUP 51.) (Refer to GROUP 51.)
D Front Mud Guard Removal and Installation
(Refer to GROUP 51.)
2
3 Section A A
A
1
Clip
1 A
Removal steps
1. Splash shield
AA" "AA 2. Side turn signal lamp
3. Fender
Front of vehicle
Front of vehicle
1 2
Removal steps
AA" "AA 1. Rivet D AC inverter (Long wheelbase)
2. Fuel filler door panel assembly (Refer to GROUP 54.)
3. Fuel filler door lock hook assembly 5. Fuel filler door lock release cable
4. Lid lock release handle
D Heater deck cross assembly
(Refer to GROUP 55.)
3 Riveter
Flange surface
4
Rivet
WINDOW GLASS
ADHESIVE
Items Specified adhesive
Windshield 3M ATD Part No. 8609 Super Fast Urethane Auto Glass
Sealant or equivalent
Quarter window glass
Quarter window garnish 3M ATD Part No. 8513 Grommeted Windshield Sealant
or equivalent
SPECIAL TOOL
Tool Number Name Use
MB990480 Window glass Removal and installation of windshield
holder
WINDOW REPAIR
The following glass parts are installed with a liquid urethane
adhesive method:
D Windshield
D Quarter window glass
D Back door window glass
ITEMS NEEDED
Name Remarks
Adhesive 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or
equivalent
Primer 3M ATD Part No. 8608 Super Fast Urethane Primer or equivalent
Application of primer
Application of primer Apply sufficient primer evenly to the adhesion surface so that there is no patchiness. After
Apply to the adhesion surface of the application, let dry for 3 to 30 minutes.
body and let dry for 3 minutes or more.
Application of adhesive
Within 30 minutes after applying the primer, apply the adhesive evenly all the way around
the inside edge of the glass.
Cleaning
After removing any adhesive that is sticking out or adhering to the body or
glass with a spatula, etc., clean off with isopropyl alcohol.
WINDSHIELD
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
D Deck Garnish Removal and Installation D Front Pillar Trim Removal and Installation
(Refer to GROUP 51A.) (Refer to GROUP 52A Trim.)
D Headlining Removal and Installation
B B 2
C Primer
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
13.2mm
Align the glass
stopper end with
the ceramic
notch.
Ceramic line
Windshield
Glass end line
Ceramic line
21.5mm
22.5mm
Windshield spacer
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) Never touch the primer-applied surface.
Windshield moulding 6. Align the marking on the windshield moulding with the
Marking windshield notch, and then install the windshield moulding.
Windshield
Notch
Ceramic line
3
A 8
7 9
Section A A
Clip
Body panel
Primer
8
9
5
Adhesive: 3M ATD Part No. 8513 Grommeted
Windshield Sealant or equivalent
Removal steps
1. Lever 6. Quarter window weatherstrip
2. Quarter window link 7. Quarter window hinge
3. Rubber and nut AA" "AA 8. Quarter window moulding
4. Quarter window glass 9. Quarter window garnish
AA" 5. Quarter window glass
8.5 mm
15 mm
5 A
A
D
1
3
B B C D
4
1
Section A A Section B B 12.5 Section C C Section D D Unit: mm
Primer
Primer
12.5
24.5
18
Primer
13 12.5
Primer
Adhesive: 3M ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
Removal steps
1. Harness connector "AA 4. Glass stopper
AA" "AA 2. Back door glass "AA 5. Window dam
"AA 3. Dual lock fastener
A
Align the back door Window dam
glass end with the
A window dam end.
A Align with
edge of glass
Glass stopper
installation holes
DOORS
SERVICE SPECIFICATIONS
Items Standard value
Power window operating current A 5.0 2 (power supply 14.5 0.3 V at 23_C)
SEALANT
Items Specified sealant Remark
SPECIAL TOOLS
Tool Number Name Use
MB990784 Ornament remover Door trim removal
ON-VEHICLE SERVICE
DOOR FIT ADJUSTMENT
MB990900 or
MB991164 1. If clearance between the door and 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 body are not flush with each other, use
the special tool to loosen the door hinge mounting bolts
on the door. Then align the door.
Caution
Do not load more than 98 Nm on the special tool.
Front Rear 2. With the door window glass fully closed, loosen the door
glass mounting screws through the adjusting holes, and
then lower the door window glass slightly.
3. Fully close the door window glass again, and then fully
tighten the door glass mounting screws through the
Adjusting adjusting holes.
hole
Adjusting
hole
DOOR ASSEMBLY
REMOVAL AND INSTALLATION
Post-installation Operation
Door Fit Adjustment (Refer to P.42-19.)
FRONT DOOR
4, 5
6
3 7
4
26 4 Nm
11 2 Nm
1
21 4 Nm
9
8
5 2
4, 5
4
7
26 4 Nm
11 2 Nm
1
2
21 4 Nm 8
9
5 3
INSPECTION
DOOR SWITCH CONTINUITY CHECK
22
4
16
22 Sealant:
3M ATD Part No. 8625 or equivalent
18
2
21 1
3 12
13
9
10
11
20 15
19
17
4.91.0 Nm
6
7 5
8
14
Removal steps
AA" 1. Power window switch and power 10. Door belt line moulding assembly
window switch panel assembly 11. Door trim
2. Power window switch panel 12. Front arm restraint cover
3. Power window switch AC" 13. Door inside handle cover
4. Delta cover, inner 14. Door grip
5. Door lamp assembly 15. Grip bracket
AB" "BA 6. Clip <Vehicles without power win- 16. Door grip upper retainer
dows> 17. Door grip lower bracket
"BA 7. Escutcheon <Vehicles without pow- 18. Arm restraint bracket
er windows> 19. Speaker
"BA 8. Regulator handle <Vehicles without 20. Power window switch bracket
power windows> 21. Door inside handle
9. Door inside handle cover and door "AA 22. Waterproof film
trim assembly
21
Sealant:
3M ATD Part No. 8625 or equivalent
2
1
3
20 11
15 13
17 8
9
16
10
19
14
21
12
18
5
6
4.91.0 Nm 7 4
Removal steps
AA" 1. Power window switch and power 10. Door trim
window switch panel assembly AC" 11. Door inside handle cover
2. Power window switch panel 12. Door grip
3. Power window switch 13. Rear arm restraint cover
4. Door lamp assembly 14. Door grip bracket
AB" "BA 5. Clip <Vehicles without power win- 15. Door grip upper retainer
dows> 16. Door grip lower bracket
"BA 6. Escutcheon <Vehicles without pow- 17. Arm restraint bracket
er windows> 18. Speaker
"BA 7. Regulator handle <Vehicles without 19. Power window switch bracket
power windows> 20. Door inside handle
8. Door inside handle cover "AA 21. Waterproof film
9. Door belt line moulding assembly
A
A
<Short wheelbase> A
<Long wheelbase>
View B B
B
View C
View A B
View A
View A View B View C
Door lamp lens
C
Power window switch panel assembly Power window switch panel assembly
C E
E
D D
D D E
E
D D
D D
Door lamp
Clip lens cover
Door trim
Clip
Section D - D Section E - E
Clip
Claw
Door trim
NOTE
: Clips positions
: Claws positions
View B
B
View A
C E
D D
E
Door trim
Clip
Clip
Clip Door lamp
lens cover
Claw
Door trim
NOTE
: Clips positions
: Claws positions
MB990784
Inside handle
Section A - A
cover
Claw
Inside Inside
handle handle
cover
Claw
Front of vehicle
INSPECTION
POWER WINDOW SUB SWITCH CONTINUITY CHECK
Switch position Terminal No.
1 4 6
UP
DOWN
NOTE
W0755AU
Power window main switch uses SWS system, for the power
window main switch check, refer to GROUP 54B - SWS.
2
3
1
4 7
5
6
7
5.40.5 Nm
5.40.5 Nm
<Vehicles without power windows>
Door window glass removal steps Power window regulator and motor
1. Door belt line moulding assembly assembly removal steps
2. Door window glass runchannel 5. Power window regulator and motor
"BA D Check operation assembly
3. Door window glass "AA 6. Power window motor assembly
4. Glass holder "AA 7. Power window regulator assembly
10
9
1 3
8
6
4 5
7
2
8 5.40.5 Nm
<Vehicles with power windows>
5.40.5 Nm
<Vehicles without power windows>
Removal steps
1. Door belt line moulding assembly 6. Power window regulator and motor
2. Door window glass runchannel assembly
AA" "CA 3. Center sash "AA 7. Power window motor assembly
"BA D Check operation "AA 8. Power window regulator assembly
4. Rear door window glass 9. Stationary window glass
5. Glass holder 10. Stationary window weatherstrip
INSPECTION
POWER WINDOW RELAY CONTINUITY CHECK
2 2
3
5.91.0 Nm
5.91.0 Nm
1
5
1
7 6
4
7
6
5
<Right side>
LOCK*
UNLOCK*
View B Unlock Lock
NOTE :
*: drivers side only
<Right side>
Rod position Terminal No. Rod operation
1 2 3 4 6 Rod operation
B LOCK LOCK to UNLOCK
UNLOCK UNLOCK to LOCK
LOCK*
UNLOCK*
NOTE :
*: drivers side only
Unlock
<Right side>
A Rod position Rod operation
<Right side> Terminal No.
2 3
Lock LOCK LOCK to UNLOCK
UNLOCK UNLOCK to LOCK
View B
Unlock
B
Long wheelbase
2
Short wheelbase
Sectional view of Sectional view of
clip position clip position
Clip Clip
3 3
6
5 3
1
7
4 Adhesive tape:
Double-sided tape [23 mm width and
0.8 mm thickness], dry adhesive
2
Sectional view of Sectional view of clip position Sectional view of clip position
clip position
Clip Clip
Clip
Clip Clip 4 4
4
3 3
FRONT DOOR
B
A
A: 87 mm
B: 106 mm (Long wheelbase)
B: 98 mm (Short wheelbase)
75 mm
BACK DOOR
SERVICE SPECIFICATION
Item Standard value
SEALANT
Item Specified sealant Remark
SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Back door trim removal
TROUBLESHOOTING
NOTE
Power window main switch uses SWS system, for the power window main switch check, refer to
GROUP 54B - SWS.
ON-VEHICLE SERVICE
BACK DOOR FIT ADJUSTMENT
1. If the striker and latch mesh badly, move the striker forward
and backward or right and left to adjust.
2. If uneven clearance is present between back door and
body, reposition the hinge and striker and/or change the
thickness of shim (change the number of shim) to adjust
the clearance.
214 Nm
3
4
2
214 Nm 1
5
6
9 112 Nm
7
214 Nm
1
10
11 8
12
3, 5
8
1.5 mm
Striker
Latch
INSPECTION
DOOR SWITCH CONTINUITY CHECK
Switch position Terminal No.
1 2 3
Released (ON)
Pressed (OFF)
3
Clip
A 5
2
7
5
A
A
9 7
8 6
Sealant:
3M ATD Part No. 8625 or equivalent
10
4
: Clip positions
Removal steps
1. High-mounted stop lamp cover 5. Back door lower trim
D High-mounted stop lamp 6. Toolbox bracket, lower
(Refer to GROUP 54A.) 7. Waterproof film
"AA 2. Door pull handle 8. Back door lid
3. Back door upper trim 9. Washer tank lid
4. Toolbox assembly 10. Toolbox bracket, upper
5.91.0 Nm
3
2
Back door handle and lock key Back door latch removal steps
cylinder removal steps D Back door trim and waterproof film
D Back door trim and waterproof film (Refer to P.42-43.)
(Refer to P.42-43.) 3. Back door latch assembly
D Back door garnish
(Refer to GROUP 51.)
1. Back door handle
2. Back door lock key cylinder
INSPECTION
BACK DOOR LOCK ACTUATOR CHECK
View A Lock
Rod position Terminal No. Rod operation
2 3
LOCK LOCK to UNLOCK
UNLOCK UNLOCK to LOCK
Unlock
A
NOTE
This sets the system in encrypted code registration
standby mode. If MUT-II is not used, connect terminal
No.1 of the diagnosis connector to earth.
Caution
Always turn the ignition switch to LOCK (OFF) position
before connecting and disconnecting the MUT-II or
earth.
SUNROOF
SERVICE SPECIFICATION
Items Standard value
TROUBLESHOOTING
The sunroof is controlled by the SWS (Smart Wiring System). For troubleshooting procedures, refer to
GROUP 54B - SWS Diagnosis.
ON-VEHICLE SERVICE
WATER TEST
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.
SUNROOF
REMOVAL AND INSTALLATION
Post-installation Operation
D Sunroof Water Test (Refer to P.42-47.)
D Sunroof Fit Adjustment (Refer to P.42-47.)
8 5
5 <Long wheelbase>
<Short wheelbase>
2 6
4
3
20 - 30 mm
16
Sealant:
3M ATD Part No. 8531 or 8646 Auto
Sealant or equivalent
4
5
<Long wheelbase>
A
16
11 12 A <Short wheelbase>
10
7
13
8
14
9
3
15
Disassembly steps
1. Roof lid glass assembly AA" 9. Drive cable
2. Weatherstrip AB" 10. Roof window deflector panel assembly
3. Sunroof motor AC" 11. Deflector
4. Roof drip channel AC" 12. Deflector link
5. Rear drip assembly 13. Set plate
6. Sun shade assembly 14. Front cover
7. Drive cable assembly 15. Cable guide casing
AA" "AA 8. Shaft 16. Guide rail sub-assembly
Shaft
Drive cable assembly
Roof window
deflector panel
assembly
Section A - A
Flat-tipped
screwdriver
Roof window
deflector panel
assembly
Section A - A
Flat-tipped
screwdriver
Deflector
Deflector link
Section A - A
Shaft
Hollow in shaft
Shaft
Front side
of vehicle
Shaft
insertion
direction Raised section of drive
cable assembly
EXTERIOR
Click on the applicable bookmark to selected the required model year.
EXTERIOR
CONTENTS
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 23
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 28
ADHESIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 31
MARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FRONT BUMPER
ADHESIVE
Items Specified sealant and adhesive
Front bumper side extension Double-sided tape [5 mm wide and 1.2 mm thick]
SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Front bumper reinforcement assembly
removal
FRONT BUMPER
REMOVAL AND INSTALLATION
Section A A Section B B Section C C
1 2
Clip
2
Clip 6
Clip
A
1
2 A
4
B
B
5
C
4
C
3
6
Removal steps
1. Radiator cover 5. Front bumper lower stay
AA" 2. Radiator grille D Fog lamp connector connection
3. Skid plate 6. Front bumper face assembly
4. Splash shield mounting clip
A
Radiator
grille
Clip
1 9 Clip 2
3
A 5
A
B
4
B C
C
7 View A
D
E D
A
E
8
2
6
Disassembly steps
D Headlamp washer 5. Air duct <LH side in vehicles without
AA" 1. Front bumper reinforcement assembly fog lamps>
2. Fog lamp cover AB" "AA 6. Front bumper side extension
3. Fog lamp 7. Licence plate garnish
4. Air blower garnish <Vehicles without 8. Licence plate bracket
fog lamps> 9. Front bumper face
Pin Clip
REAR BUMPER
REMOVAL AND INSTALLATION
Section A A Section B B Section C C Section D D
Clip Clip 5
5 3 5
Clip
Clip 1
3
3
C
A
C
4 A D
D 3
1
B
B
2
3
8
4
7
1
Rear bumper side face assembly Rear bumper center face assembly
disassembly steps disassembly steps
AA" "AA 1. Rear mudguard reinforcement 6. Rear bumper step plate
AA" "AA 2. Rear bumper side retainer 7. Rear bumper center face stay
(Short wheelbase) 8. Rear bumper center face
AA" "AA 3. Rear bumper side retainer
(Long wheelbase)
AA" "AA 4. Rear bumper corner bracket
D Rear lamp and rear lamp bracket
(Refer to GROUP 54A.)
5. Rear bumper side face
3 Recommended
tool
Flange
Rivet
ROOF RAIL
ROOF RAIL
REMOVAL AND INSTALLATION
1
4
5
3
5
2
5
Removal steps
D Head lining 2. Roof rail front seal
D Set bracket (Refer to GROUP 42 - 3. Roof rail center seal
Sunroof.) 4. Roof rail rear seal
1. Roof rail assembly 5. Roof rail seal
MOULDING
ADHESIVE
Items Specified sealant and adhesive
Wheel cut moulding and door moulding Double-sided tape [ 4 mm width and 1.2 mm thickness, 12
mm width and 1.2 mm thickness, 5 mm width and 1.2 mm
thicknes.]
SPECIAL TOOL
Tools No. Name Application
MB990449 Window moulding Roof drip moulding removal
remover
MOULDING
REMOVAL AND INSTALLATION
<Vehicles with roof rail> Section A A Section B B
A
A
A 8,9 Clip 1,3, Clip
A 4,5
<Vehicles without roof rail>
A
A
A
A
9 <Long wheelbase>
7
4
2 <Short wheelbase>
6
1
B
5 4
B
1 2
B
B B
B
3
B
B
2 B
B
AA" "AA 1. Front door moulding Roof drip moulding removal steps
Front wheel cut moulding removal D Roof rail assembly
steps AC" 8. Roof drip moulding <Short wheel-
AB" "BA 2. Rivet A base>
AA" "AA 3. Front wheel cut moulding AC" 9. Roof drip moulding <Long wheelbase>
Rear wheel cut moulding removal
steps
AB" "BA 2. Rivet A
AA" "AA 4. Rear wheel cut moulding
Rear door moulding removal steps
AB" "BA 2. Rivet A
AA" "AA 5. Rear door moulding
AB" "CA 6. Rivet B
AA" "AA 7. Rear door moulding bracket
A
A
C
Front door moulding
(Short wheelbase)
Adhesive tape: Double-side tape [A: 4 mm width and 1.2 mm thickness, B: 12 mm width and 1.2
mm thickness, C: 5 mm width and 1.2 mm thickness.]
Double-sided tape
Rivet
Moulding
Drill
3 Recommended
tool
Flange
4
Rivet
GARNISH
ADHESIVE
Items Specified sealant and adhesive
Section A A
1,2, Clip
3,4
2 2
A
A 1
1
A
A
A
A
Side sill garnish removal steps Licence plate garnish removal steps
D Side step D Toolbox bracket, upper (Refer to
D Front mudguard GROUP 42 - Back door trim and
AA" "AA 1. Side sill garnish <Short wheelbase> waterproof film.)
AA" "AA 2. Side sill garnish <Long wheelbase> D Licence lamp (Refer to GROUP 54A.)
3. Licence plate garnish
MUDGUARD
ADHESIVE
Items Specified sealant and adhesive
MUDGUARD
REMOVAL AND INSTALLATION
C 7
A 7
A
4
B
A 5 6
A
3 3
2
1
REAR DEFLECTOR
SPECIAL TOOL
Tools Number Name Use
MB990784 Ornament remover Rear deflector cover removal
REAR DEFLECTOR
REMOVAL AND INSTALLATION
Section A A
2
3
Tab
5.0 1.0 Nm
A
A
3
2
5.0 1.0 Nm
1
5.0 1.0 Nm
SIDE STEP
SIDE STEP
REMOVAL AND INSTALLATION
Section A A
4
1
Tab
12.0 2.0 Nm
4
A
2
A A
A
Side step removal steps AA" "AA 3. Non-slip cover <Long wheelbase>
AA" "AA 1. Side step cover 4. Side step assembly
AA" "AA 2. Non-slip cover <Short wheelbase>
TROUBLESHOOTING
The windshield wiper and washer is controlled by the SWS (Smart Wiring System). For troubleshooting
procedures, refer to GROUP 54B - SWS Diagnosis.
Tab
C Section C C
4.91.0 Nm C
C 5
7
C 4
6
4 Tab
8.91.9 Nm
1 2
8
11 4.90.7 Nm
12 10
4.90.7 Nm
9
INSPECTION
WINDSHIELD WIPER MOTOR ASSEMBLY CHECK
The windshield wiper motor assembly should be installed
to the vehicle body and the harness connector should be
disconnected when checking the wiper motor.
D Low Speed and High Speed Wiper Motor Operation
Check
Connect the battery to the wiper motor as shown in the
illustration, and then check the operation of the wiper
Check operation
motor at low speed and at high speed.
D Windshield Wiper Motor Assembly Stop Position
Check
1. Connect the battery to the wiper motor as shown
Low speed High speed in illustration (A), and then run the wiper motor at
Stop position check low speed. Then, while the motor is operating,
disconnect the battery to make the wiper motor stop.
2. Connect the terminals and the battery as shown in
illustration (B), and then check whether the wiper
motor automatically stops in the correct stop position
(A)Low speed (B)Automatic stop after it has been running at low speed.
50
105 95 90 100
380
200 295
220
<R.H.drive vehicles>
WINDSHIELD INTERMITTENT WIPER INTERVAL
ADJUSTING KNOB
Measure the resistance value at terminal numbers 4 and
6. The resistance value should rise smoothly from
approximately 0 W (FAST position) to apporoximately 1 kW
(SLOW position).
NOTE:
Windshield washer and wiper switch is integrated with the
column-ECU, and can not be checked. However, its operation
can be checked by the input signal check. (Refer to GROUP
54B Troubleshooting.)
TROUBLESHOOTING
The rear wiper and washer is controlled by the SWS (Smart Wiring System). For troubleshooting procedures,
refer to GROUP 54B - SWS Diagnosis.
8.01.2 Nm
4.90.7 Nm
3 2 6
7
4.90.7 Nm
4
4.90.7 Nm
Mating marks
Notch
INSPECTION
REAR WIPER MOTOR ASSEMBLY CHECK
The rear wiper motor assembly should be installed to the
vehicle body and the harness connector should be
disconnected when checking the wiper motor.
D Wiper Motor Operation Check
Connect the battery to the wiper motor as shown in the
illustration, and then check the operation of the wiper
motor.
Check operation D Wiper Motor Stop Position Check
1. Operate the wiper motor by the same method as
Battery described in the check procedure above. Then, while
the motor is operating, disconnect the battery to make
the wiper motor stop.
2. Reconnect the battery as shown in the illustration,
Stop position check
and then check whether the wiper motor automatically
stops in the correct stop position after it has been
running.
Battery
95
85
Centre of vehicle
HEADLAMP WASHER
TROUBLESHOOTING
The headlamp washer is controlled by the Smart Wiring System (SWS). For troublesshooting, refer to
GROUP 54B - Troubleshooting.
HEADLAMP WASHER
REMOVAL AND INSTALLATION
3
1
4.9 0.7 Nm
2
1 3
4.9 0.7 Nm
INSPECTION
CHECK VALVE CHECK
Apply pressure to the inlet of the check valve to check its
opening pressure.
Opening pressure: 78 kPa
<L.H.drive vehicles>
Headlamp washer switch is integrated in the column-ECU,
and can not be checked. However, its operation can be
checked by the input signal check. (Refer to GROUP 54B
Troubleshooting.)
WIPER DEICER
SPECIAL TOOL
Tools No. Name Application
MB990784 Ornament remover Wiper deicer switch removal
1
2
INSPECTION
WIPER DEICER SWITCH CONTINUITY CHECK
Switch Terminal No.
position 1 - 2 3 4 5 - 6
OFF ILL
ON
IND
MARKS
MARKS
REMOVAL AND INSTALLATION
1
2 3
32 mm
90 mm
110 mm 50 mm
45 mm
Caution
1) Carry out this work in a location which has an
ambient temperature of 20 - 38_C and which is
free from dust.
2) If the ambient temperature is lower than 20_C,
heat the mark and the vehicle body (application
location) to 20 - 30_C.
TROUBLESHOOTING
The outside mirrors are controlled by the SWS (Smart Wiring System). For troubleshooting procedures,
refer to GROUP 54B - SWS Diagnosis.
Clip
5
A
B A
B
6
A A
A A
Protective
tape
Notch
A A
A A
INSPECTION
MIRROR ASSEMBLY OPERATION CHECK
Left
Right
Illumination
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
INFORMATION INTERNATIONAL
CAR
ADMINISTRATION T.MASAKI-MANAGER
OFFICE TECHNICAL SERVICE PLANNING
1. Description:
The mounting bolts, nuts, and tightening torque values of the side step assembly have been
changed.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)
2001 PAJERO PWJE0001(2/2) (English) 51-22
Workshop Manual Chassis
2001 MONTERO PWJS0002(2/2) (Spanish)
Workshop Manual Chassis
2001 PAJERO/MONTERO PWJT0008R (English)
Workshop Manual Chassis CD-ROM PWJT0008R (Spanish)
PWJT0008R (French)
PWJT0008R (German)
3. Effective date:
From August 2, 2000
SIDE STEP
SIDE STEP
REMOVAL AND INSTALLATION
Section A-A
Tab
AX1070CA
AX0776CA
AY0455CA
TROUBLESHOOTING
TROUBLE SYMPTOM CHART
Trouble symptom Inspection Reference
procedure page
Both of the electric retractable door mirrors do not work at all. 1 51-2
Either of the electric retractable mirrors does not work. 2 51-3
NG
Check the remote control mirror switch (Refer to 51-4). Replace
OK
NG
Check the mirror assembly (retraction operation) (Refer to Replace
51- 4).
OK
(1) NG
Measure at the Mirror control unit connector D-147. Check the following connectors: D-147, D-209 (RHD),
D Disconnect the connector and test on the harness side. D-223, D-27, D- 31 (LHD)
D Ignition switch (ACC)
(1) Voltage between terminal 5 and the body earth. OK NG
OK : Battery voltage
(2) Continuity between terminal 6 and the body earth. (2) NG Check the trouble
symptoms. Repair
OK : Continuity confirmed.
NG
OK
Check the harness between the Mirror control unit and the
battery, and repair if necessary.
Check the harness between the Mirror control unit and the
battery, and repair if necessary.
NG
NG
Check the harness wire, and repair if necessary.
D Between the Remote controlled mirror switch and earth
Inspection Procedure 2
Either of the electric retractable mirrors does not work. Probable cause
The Mirror control unit controls the electric retractable mirror based on input D Mirror assembly fault
signals from the following switches. D Mirror control unit fault
D Ignition switch (ACC) D Harness or connector fault
D Remote control mirror switch (for retracting and returning the mirror)
If the electric retractable mirror does not operate normally, one of the above
input circuit systems, the mirror assembly, or the Mirror control unit may be
defective.
NG
Check the mirror assembly (retraction operation) (Refer to Replace
51- 4).
OK
Measure at the mirror control unit connector D-147 and remote NG Check the following connectors: D-147, D-15, D-25
controlled mirror connector H-07(LH) or H- 13(RH).
D Continuity between the following terminals: OK NG
Between terminals 1 (Mirror control unit side) and 2
(Remote controlled mirror side) Check the trouble Repair
Between terminals 2 (Mirror control unit side) and 1 symptoms.
(Remote controlled mirror side)
OK : Continuity NG
Down
Left
Right
5.0 1.0 Nm
2
1
Removal steps
1. Glove box assembly 3. Mirror control unit
2. Corner lower panel (Passengers side)
INTERIOR
Click on the applicable bookmark to selected the required model year.
INTERIOR
CONTENTS
SUNVISOR HOLDER . . . . . . . . . . . . . . . . . . . . . . 17
Seat cushion heater resistance W Between terminals 1 and 3 6.410% 5.0 10%
(at cabin temperature of 20_C)
Between terminals 2 and 3 6.010% 5.4 10%
SPECIAL TOOL
Tool Number Name Use
MB990784 Ornament remover Removal of switch, trim, etc.
Tapping screw A 5 x 10 -
B 5 x 12 -
C 5 x 16 -
D 5 x 16 -
E 5 x 16 Black
F 5 x 20 -
G 5 x 20 Black
H 5 x 16 -
K 6 x 16 -
L 6 x 16 Black
M 6 x 20 -
D = Thread diameter
L = Effective thread length
CAUTION: SRS
When removing and installing the instrument
panel (vehicles equipped with SRS), do not let it
bump against the SRS-ECU.
27 26
15 L 8
17 14
18 C
L
L
L 15
E C 22 K
20
16
M 10 L
11 16
9
21 E
25 C I H
1 13
F E
19 C 2 12
5
25
C
24 G 3
J 5
20 4
M
7 6
23
B
23
Removal steps
D Rear floor console assembly (Refer 15. Instrument panel side cover
to P.52A-12.) 16. Air outlet assembly
D CD player unit (Refer to GROUP 54A.) 17. Meter bezel
D Front floor console 18. Combination meter assembly
(Refer to P.52A-12.) D Hood opener lever
1. Center panel assembly (Refer to GROUP 42.)
2. Center display D Fuel lid opener lever
3. Radio and tape player (Refer to GROUP 42.)
4. Manual air conditioner assembly 19. Lower panel
5. Glove box stopper 20. Switch panel
6. Glove box assembly 21. Column cover
7. Glove box lock 22. Stay A
8. Glove box lamp switch harness D Assist grip (Refer to P.52A-13,15.)
connector D Front pillar trim (Refer to P.52A-13,15.)
9. Glove box lamp switch 23. Under cover assembly
10. Glove box lamp 24. Stay B
11. Upper glove box striker 25. Corner lower panel
12. Upper glove box assembly 26. Photo sensor harness connector
13. Upper glove box lid lock D Steering shaft assembly bolt
14. Front passengers side air bag (Refer to GROUP 37A.)
module harness connector 27. Instrument panel assembly
Purchased from www.WorkshopManuals.co.uk
52A-6 www.WorkshopManuals.co.uk
INTERIOR - Instrument Panel <L.H. Drive Vehicles>
E
B
E
F
A
C B B
C F
A
B
C C
NOTE
: Clip position
: Claw position
Instrument panel
Instrument panel
Center panel assembly and upper
Instrument panel glove box assembly and lower
panel Air outlet assembly
Section E - E Section F - F
Column
cover
Column cover
Claw Claw
2
B B
B
B
2
3
B
B
A
4 B
10 A 1
B
D
9
Section A - A
D
Defroster garnish 7 6
E
D 5
Instrument panel
8
Clip K
Disassembly steps
1. Distribution duct 6. Air bag side plate
2. Side defroster duct 7. Glove box striker
3. Center defroster duct 8. Instrument panel center reinforce-
4. Photo sensor ment
5. Front passengers side air bag 9. Defroster garnish
module 10. Instrument panel
Tapping screw a 5 x 10 -
b 5 x 12 -
c 5 x 16 -
d 5 x 16 -
e 5 x 16 Black
f 5 x 20 -
g 5 x 20 Black
h 5 x 16 -
k 6 x 16 -
l 6 x 16 Black
m 6 x 20 -
D = Thread diameter
L = Effective thread length
CAUTION: SRS
When removing and installing the instrument
panel (vehicles equipped with SRS), do not let it
bump against the SRS-ECU.
26
8 27
14 L 15 17
C 18
L
L
L
C E
15 K
10
L M 16
16 11 9 22
E 21
1 I C
H 25
13 F
E
2 C
25 12 19
5
C
G
3
5 J
4 24
7 20
6 M
23
B
23
Removal steps
D Rear floor console assembly (Refer 15. Instrument panel side cover
to P.52A-12.) 16. Air outlet assembly
D CD player unit (Refer to GROUP 54A.) 17. Meter bezel
D Front floor console 18. Combination meter assembly
(Refer to P.52A-12.) D Hood opener lever
1. Center panel assembly (Refer to GROUP 42.)
2. Center display D Fuel lid opener lever
3. Radio and tape player (Refer to GROUP 42.)
4. Manual air conditioner assembly 19. Lower panel
5. Glove box stopper 20. Switch panel
6. Glove box assembly 21. Column cover
7. Glove box lock 22. Stay A
8. Glove box lamp switch harness D Assist grip (Refer to P.52A-13,15.)
connector D Front pillar trim (Refer to P.52A-13,15.)
9. Glove box lamp switch 23. Under cover assembly
10. Glove box lamp 24. Stay B
11. Upper glove box striker 25. Corner lower panel
12. Upper glove box assembly 26. Photo sensor harness connector
13. Upper glove box lid lock D Steering shaft assembly bolt
14. Front passengers side air bag (Refer to GROUP 37A.)
module harness connector 27. Instrument panel assembly
E
B E
F
B A
B C
F C
A
B
C C
NOTE
: Clip position
: Claw position
Meter bezel
Column Column
cover Claw cover
Claw
2
B B
B
2 B
3
B B
A
B
4
1 A 10
B
9 D
6 7
E
D Section A - A
5
Defroster garnish
8
K
Instrument panel
Clip
Disassembly steps
1. Distribution duct 6. Air bag side plate
2. Side defroster duct 7. Glove box striker
3. Center defroster duct 8. Instrument panel center reinforce-
4. Photo sensor ment
5. Front passengers side air bag 9. Defroster garnish
module 10. Instrument panel
FLOOR CONSOLE
REMOVAL AND INSTALLATION
<M/T> <A/T> 4
3
4 3 7 7
1
8 8
2
22 5
26 5
6
10
24
23
25
21
9 19
11
20 12
13 27
14
15
16
18
17
28
Removal steps
1. Parking brake lever cover 15. Rear heater duct nozzle
2. Cup holder 16. Rear floor console ashtray
3. Transfer shift knob 17. Rear floor console box
4. Selector lever knob 18. Rear floor console bracket
5. Indicator panel 19. Rear floor console upper cover
6. Shift lever cover 20. Rear floor console hinge cover
7. Switch panel 21. Hinge bracket
8. Lower center panel 22. Lock A
D Parking brake lever mounting bolt 23. Lock B
9. Rear floor console assembly 24. Lid bracket
10. Front floor console 25. Lid box
11. Rear heater duct A 26. Lid assembly
12. Console bracket A 27. Rear floor console
13. Rear control assembly 28. Console bracket B
14. Rear heater duct B
4410 Nm
13
11
10
4410 Nm
4 12
8
7
9
16
4410 Nm
15
2 1 15
14
4410 Nm 6
NOTE
For door trims, refer to GROUP 42.
E E
A
B
A
B E
E
D
D
D
D
NOTE
: Clip position
: Claw position
Section A - A Section B - B Section C - C
Clip
Clip Front pillar trim
Instrument panel
Front pillar trim
Claw
Claw
Clip
Quarter trim, upper,
Quarter trim, lower
<Long Wheelbase>
20
19 4410 Nm
12 15 18
6 4410 Nm
11 1
10
21
5
2
9
7 16 13
16
14
4 3 17
8
4410 Nm
NOTE
For door trims, refer to GROUP 42.
F
F
E E
A
B
A
B *
*
* * E E
C E
E
C D
D
D D
NOTE
: Clip position (* mark shows L.H. side only)
: Claw position
Section A - A Section B - B Section C - C
Clip
Clip Front pillar trim
Instrument panel
Front pillar trim
Claw
Claw
Clip Quarter trim, upper,
Quarter trim, lower,
Center pillar trim
FRONT SEAT
REMOVAL AND INSTALLATION
2
3 A 5
A
4410 Nm
Section A - A
3
305 Nm 3 A 3
AA
A 5
5
A 4
A
Claw
3 A 4410 Nm
A 3A
A
3 A
305 Nm A 4
3 4410 Nm
A
A
3 1
NOTE:
marks show claw positions.
17
20 19*
21* 18
22 23
6 8
4410 Nm
9
10
5
214 Nm 24
2 11
1 16
3 4410 Nm
4
14
15
13
12 25
NOTE
*: For the sport seat, the seat cover and pad are
non-separable.
Disassembly steps
1. Reclining adjuster knob 14. Seat slide adjuster side cover
2. Slide adjuster knob 15. Seat slide adjuster inner side cover
3. Power seat switch garnish 16. Inner seat belt
4. Power seat switch 17. Front seat back assembly
5. Harness clamp AA" 18. Headrestraint guide
6. Front seat cushion assembly 19. Front seatback cover
7. Front seat cushion cover 20. Front seatback heater
8. Front seat cushion heater 21. Front seatback pad
9. Front seat cushion pad 22. Front seatback frame
10. Front seat cushion frame <Vehicles without side air bag>
11. Side shield cover 23. Front seatback board
12. Front rail cover 24. Reclining adjuster lower cover
13. Hinge cover 25. Seat slide adjuster
20 19*
21* 18
22 23
3 10 13
24
6
51 Nm
5 7
2 1 16
8 4410 Nm 25 12
9 14
26 27 15
4410 Nm
4
214 Nm 11
4410 Nm
<Suspension seat> 10 24 <Normal seat> 24
3 12 16
13
51 Nm
24 25 51 Nm
1 16 14
2 10
25
15
14 4410 Nm
26 13
27
11 27 12
NOTE 26 15 14
*: For the sport seat, the seat cover and pad 11 3
are non-separable.
Disassembly steps
1. Clip<Vehicles with Suspension seat 14. Seat slide adjuster side cover
and dual height adjuster seat> 15. Seat slide adjuster inner side cover
2. Height adjuster knob<Vehicles with 16. Inner seat belt
Suspension seat and dual height 17. Front seat back assembly
adjuster seat> AA" 18. Headrestraint guide
3. Reclining adjuster lever 19. Front seatback cover
4. Harness clamp 20. Front seatback heater
5. Front seat cushion assembly 21. Front seatback pad
6. Front seat cushion cover 22. Front seatback frame
7. Front seat cushion heater <Vehicles without side air bag>
8. Front seat cushion pad 23. Front seat back board
9. Front seat cushion frame 24. Reclining adjuster lower cover
10. Side shield cover 25. Front seat frame
11. Front rail cover 26. Seat slide adjuster
12. Hinge cover 27. Seat slide adjuster lever
13. Rear rail cover
Seat slide
Clip adjuster
Front rail
D cover
D
Claw Claw
C Front rail cover
Seat slide
adjuster
C
Claw
Hinge cover
E Seat slide
adjuster
Reclining adjuster
lower cover Claw
Reclining adjuster
G lower cover
Seat slide
Side shield cover, Hinge adjuster
cover
Claw
F
NOTE
: Clip position
: Claw position
INSPECTION
POWER SEAT MANUAL SWITCH CONTINUITY CHECK
B A
G
E
H
F
D C
Rear D
Front height Up E
switch
Down F
Rear height Up G
switch
Down H
Switch 1 3 4 5 IND 8 9 2 6
position
Drivers side HI
OFF
LO
Passengers HI
ILL
side
OFF
LO
1 1
1
3 1
1 1
2 2
44 10 Nm 44 10 Nm
4 5
2
2
44 10 Nm
44 10 Nm
CLAW POSITION
<Seat anchor cover> Section A - A Section B - B
B
Seat anchor
cover
Seat anchor
B cover
A
A
Claw
Claw
Rear second seat
assembly
A
A
Rear second
seat assembly
Claw Claw
Claw Seat side back
D assembly
NOTE
: Claw position
12
17 16 15 14
11
20
21
12 2 Nm
8
18 22
3 52 7 Nm
13 2 Nm
30 2
31 9
19
29
7 1
44 10 Nm
5
44 10 Nm 27
28
24
23
25 44 10 Nm
24
26
32
44 10 Nm
44 10 Nm 25
26
34
33
12 2 Nm
32
33
Disassembly steps
1. Lower reclining adjuster cover 18. Shaft
2. Center reclining adjuster cover 19. Reclining adjuster back cover
3. Free hinge cover 20. Rod
4. Gas damper connection 21. Spring
5. Rear seat cushion under cover 22. Reclining adjuster
6. Catch cable A, B connection 23. Gas damper
7. Catch cable A 24. Rear seat catch assembly
8. Hinge bracket 25. Upper foot cover
9. Catch cable B 26. Lower foot cover
10. Rear seat back assembly 27. Inner seat belt
11. Folding lever knob 28. Rear seat cushion frame
12. Folding knob garnish 29. Rear seat cushion pad
AA" 13. Headrestraint guide 30. Support pad
14. Rear seat back board 31. Rear seat cushion cover
15. Rear seat back frame 32. Striker cover
16. Rear seat back pad 33. Striker
17. Rear seat back cover 34. Plug
10
9
12 21
16 15 14 22
13
17
11
7 52 7 Nm
23
20
3
19
44 10 Nm
32 7
31
1
29 44 10 Nm
18 30
6
5
6
28
4
44 10 Nm
2
25
24
25 44 10 Nm
26 44 10 Nm
27
26
44 10 Nm
33 27
44 10 Nm
35
34
33
44 10 Nm
34
Disassembly steps
1. Lower reclining adjuster cover 19. Shaft
2. Inner seat belt 20. Reclining adjuster back cover
3. Center reclining adjuster cover 21. Rod
4. Gas damper connection 22. Spring
5. Rear seat cushion under cover 23. Reclining adjuster
6. Catch cable A connection 24. Gas damper
7. Catch cable A 25. Rear seat catch assembly
8. Rear seat back assembly 26. Upper foot cover
9. Folding lever knob 27. Lower foot cover
10. Folding knob garnish 28. Inner seat belt
11. Rear seat back board 29. Center seat belt
AA" 12. Headrestraint guide 30. Rear seat cushion frame
13. Sash anchor garnish 31. Rear seat cushion pad
14. Rear seat back frame 32. Rear seat cushion cover
15. Rear seat back pad 33. Striker cover
16. Rear seat back cover 34. Striker
17. Seat belt protector 35. Plug
18. Center seat belt connection
4
2
13 2 Nm
7
6
Disassembly steps
1. Hinge bracket 5. Rod
2. Cup holder 6. Bushing
3. Knob 7. Rear seat side back
4. Knob guide
11
15
19 18 17 16 13
12
22
23
12 2 Nm 14
34 20 52 7 Nm
3
13 2 Nm
35 9 2
33 10
21
5 8
24 1
44 10 Nm
44 10 Nm 30
31
32 6
7
26
4
27
25
28 44 10 Nm
29 27
36 28 44 10 Nm
44 10
Nm 29
38
37 36
12 2 Nm
37
Disassembly steps
1. Lower reclining adjuster cover 20. Shaft
2. Center reclining adjuster cover 21. Reclining adjuster back cover
3. Free hinge cover 22. Rod
4. Gas damper connection 23. Spring
5. Rear seat cushion under cover 24. Reclining adjuster
6. Reclining cable connection 25. Gas damper
7. Catch cable A, B connection 26. Reclining cable
8. Catch cable A 27. Second seat catch assembly
9. Hinge bracket 28. Upper foot cover
10. Catch cable B 29. Lower foot cover
11. Second seat back assembly 30. Reclining knob
12. Folding lever knob 31. Inner seat belt
13. Folding knob garnish 32. Second seat cushion frame
14. Second seat side back assembly 33. Second seat cushion pad
AA" 15. Headrestraint guide 34. Support pad
16. Second seat back board 35. Second seat cushion cover
17. Second seat back frame 36. Striker cover
18. Second seat back pad 37. Striker
19. Second seat back cover 38. Plug
11
10
16 25
12 26
18
20 19 17
21
13
14
15
22 4 Nm 27
24 52 7 Nm
7
33 3
23
7
44 10 Nm 38
37 1
44 10 Nm
8 29 35
22 36
5
6
34
6
44 10 Nm 4
2
30
28
30 44 10 Nm
31 44 10 Nm
32
31 44 10 Nm
39
44 10 Nm 32
41
40
39
44 10 Nm
40
Disassembly steps
1. Lower reclining adjuster cover 22. Center seat belt connection
2. Inner seat belt 23. Shaft
3. Center reclining adjuster cover 24. Reclining adjuster back cover
4. Gas damper connection 25. Rod
5. Rear seat cushion under cover 26. Spring
6. Catch cable A connection 27. Reclining adjuster
7. Catch cable A 28. Gas damper
8. Reclining cable connection 29. Reclining cable
9. Second seat back assembly 30. Second seat catch assembly
10. Folding lever knob 31. Upper foot cover
11. Folding knob garnish 32. Lower foot cover
12. Second seat side back assembly 33. Reclining knob
13. Second seat back board 34. Inner seat belt
14. Armrest 35. Center seat belt
15. Cup holder 36. Second seat cushion frame
AA" 16. Headrestraint guide 37. Second seat cushion pad
17. Sash anchor garnish 38. Second seat cushion cover
18. Second seat back frame 39. Striker cover
19. Second seat back pad 40. Striker
20. Second seat back cover 41. Plug
21. Seat belt protector
CLAW POSITION
A
Claw
Lower reclining adjuster cover
Reclining adjuster
Claw Claw
B Folding knob garnish
NOTE
: Claw position
THIRD SEAT
DISASSEMBLY AND REASSEMBLY
7
15
17 16 14
13
12
11
10
18 19
2
3
8
26 21
22 9
25
52 7 Nm
24
23
20
29 44 10 Nm 6
44 10
Nm
30 1
27 31
44 10 Nm
29
28 44 10 Nm
44 10 Nm
5
4 4 32
33
44 10 Nm
34
Purchased from www.WorkshopManuals.co.uk
52A-36 www.WorkshopManuals.co.uk
INTERIOR - Third Seat
Disassembly steps
1. Outer reclining adjuster cover 18. Rod
2. Catch release knob 19. Spring
3. Catch release knob garnish 20. Reclining adjuster
4. Latch cover 21. Inner reclining adjuster cover
5. Catch cable connection 22. Shaft
6. Inner reclining adjuster cover 23. Inner seat belt
7. Third seat back assembly 24. Third seat cushion frame
8. Reclining knob 25. Third seat cushion pad
9. Reclining adjuster cover 26. Third seat cushion cover
10. Damper 27. Catch cable
11. Folding lever knob 28. Third seat latch
12. Folding knob garnish 29. Arm cover
13. Third seat back board 30. Cam
AA" 14. Headrestraint guide 31. Third seat leg frame assembly
15. Third seat back frame 32. Catch assembly
16. Third seat back pad 33. Striker cover
17. Third seat back cover 34. Striker
A Claw
Outer reclining adjuster cover
Reclining adjuster
Claw
Reclining adjuster cover
B
Arm cover
NOTE
: Claw position
44 10 Nm
2
5
1
44 10 Nm
3
4
44 10 Nm
7
2
44 10 Nm
44 10 Nm
Outer seat belt removal steps Inner seat belt removal steps
1. Sash guide cover D Front seat assembly
2. Outer seat belt connection (Refer to P.52A-18.)
D Lower quarter trim <Short wheelbase> 6. Seat belt switch harness connector
(Refer to P.52A-13.) 7. Inner seat belt
D Center pillar trim <Long wheelbase>
(Refer to P.52A-15.)
3. Outer seat belt
4. Front noise protector
5. Shoulder anchor adjuster
Sleeve
44 10 Nm
2
1
6
3
4
44 10 Nm
2 44 10 Nm
5
44 10 Nm
44 10 Nm
Outer seat belt removal steps Inner seat belt and center seat belt
D Rear seat assembly removal steps
(Refer to P.52A-25.) D Rear seat assembly
D Upper quarter trim (Refer to P.52A-25.)
(Refer to P.52A-13.) 5. Inner seat belt
1. Sash guide cover (Refer to P.52A-27,29.)
2. Outer seat belt connection 6. Center seat belt
3. Outer seat belt (Refer to P.52A-29.)
4. ELR cover
6
44 10 Nm 44 10 Nm
5
1 7
2 8
44 10 Nm
6 44 10 Nm
44 10 Nm
1
3 44 10 Nm 9
4 4
44 10 Nm
5
44 10 Nm
Second seat belt removal steps Inner seat belt removal steps
D Lower quarter trim D Lower quarter trim
(Refer to P.52A-15.) (Refer to P.52A-15.)
1. Outer seat belt connection D Pillar duct (R.H.)
2. Outer seat belt (Refer to GROUP 55A)
3. ELR cover D Rear blower assembly (R.H.)
4. Inner seat belt (Refer to GROUP 55A)
(Refer to P.52A-31,33.) D TV tuner (L.H.)(Refer to GROUP 54)
5. Center seat belt 6. Outer seat belt connection
(Refer to P.52A-33.) 7. Outer seat belt
8. ELR cover
9. Inner seat belt
(Refer to P.52A-35.)
TRIMS
REMOVAL AND INSTALLATION
<Long Wheelbase>
19
21
4410 Nm
6 12 20 18
4410 Nm 15
11 1
10
22
5
9 2
13
7 16
16
3 17 14
4 8
4410 Nm
NOTE
For door trims, refer to GROUP 42.
SUPPLEMENTAL
RESTRAINT SYSTEM
(SRS)
Click on the applicable bookmark to selected the required model year.
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS
CAUTION
D Carefully read and observe the information in the SERVICE PRECAUTIONS (P.52B-3.) prior to any service.
D For information concerning troubleshooting or maintenance, always observe the procedures in the Troubleshooting
(P.52B-7.) section.
D 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-26.) for the components involved.
D If you have any questions about the SRS, please contact your local distributor.
GENERAL INFORMATION
To improve safety, the SRS are available as optional wheelbase> inner, monitors any shocks coming
parts. These systems enhance collision safety by from the side of the vehicle. The warning lamp
restraining the front passengers in case of an on the instrument panel indicates the operational
accident. status of the SRS. The clock spring is installed
The SRS consists of four air bag modules, SRS in the steering column.
air bag control unit (SRS-ECU), front impact The SRS side air bag deploys if an impact received
sensors, side impact sensors, SRS warning lamp at the side of the vehicle is stronger than a certain
and clock spring. The air bags are located in the set value, in order to protect the upper bodies of
centre of the steering wheel, above the glove box, front seat passengers in the event of a collision.
and built into the front seat back assemblies. Each Only authorized service personnel should do work
air bag has a folded air bag and an inflator unit. on or around the SRS components. Those service
The SRS-ECU under the floor console monitors personnel should read this manual carefully before
the system and has a safing G sensor and an starting any such work. Extreme care must be used
analog G sensor. The front impact sensors are when servicing the SRS to avoid injury to the service
installed on the headlamp support panel. The side personnel (by inadvertent deployment of the air
impact sensor, which is located inside the quarter bags) or the driver (by rendering the SRS
panels <short wheelbase> or center pillar <long inoperative).
SRS-ECU
Diagnosis
connector
NOTE
*: Indicates the parts equipped on the right and left sides.
34, 35, Side air bag wiring harness Floor wiring harness Side impact Repair or replace each wiring
36 sensor (L.H.) harness.
40, 41, Side air bag wiring harness Floor wiring harness Side impact
42 sensor (R.H.)
6. SRS components should not be subjected to heat over 93_C, so remove the SRS-ECU, front
impact sensor, drivers air bag module, clock spring, passengers air bag module, front seat
assembly(side air bag module) and side impact sensor before drying or baking the vehicle
after painting.
7. Whenever you finish servicing the SRS, always erase the diagnosis code and check warning
lamp operation to make sure that the system functions properly. (Refer to P.52B-7)
MB991222
MB991222
SPECIAL TOOLS
Tools No. Name Application
MB991502 MUT-II sub assem- D Reading and erasing diagnosis code
bly D Reading trouble period
D Reading erase times
MR372530 SRS air bag adapt- Deploying drivers air bag module inside
er harness vehicle
MB686560 SRS air bag adapt- Deploying front passengers air bag module
er harness and side air bag modules inside or outside
vehicle
TEST EQUIPMENT
Tool Name Application
Digital multi-meter Checking SRS electrical circuitry (Use multi-
meter for which the maximum test current is 2
mA or less at minimum range of resistance
measurement
NOTE
1. *1: If the trouble(s) are extinguished, the SRS warning lamp will go out with diagnosis code history
automatically erased.
2. *2: If the vehicle condition return to normal, the diagnosis code will be automatically erased, and
the SRS warning lamp will return to normal.
3. 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.
Table 1
Code No. Trouble Symptom
11 D Short circuit in front impact sensor or harness
D Short circuit in front impact sensor harness leading to the vehicle body ground
D Short circuit in front impact sensor harness leading to the power supply
12 D Open circuit in either left or right front impact sensor or harness
D Short circuit in front impact sensor harness leading to the power supply
13 D Open circuit in both left and right front impact sensor or harness
D Short circuit in front impact sensor harness leading to the power supply
Code No.14, 15, 16, 17, 31, 32, 45, 51, 52, 54, 55, 73, 74, 83, Probable cause
84 System inside SRS-ECU
These diagnosis trouble codes are output when a fault is detected in the Malfunction of SRS-ECU
SRS-ECU.
The trouble causes for each diagnosis code No. are as follows.
Table 2
Code No. Defective part Trouble Symptom
14 Front impact analog G-sensor 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
15 Front impact safing G-sensor Short circuit in the safing G-sensor
16 Open circuit in the safing G-sensor
17 Side impact safing G-sensor D When the safing G-sensor is not operating
D When the characteristics of the safing G-sensor are abnormal
D When the output from the safing G-sensor is abnormal
31 DC-DC converter Voltage at the DC-DC converter terminal is higher than the
specified value for five seconds or more.
32 Voltage at the DC-DC converter terminal is lower than the
specified value for five seconds or more(this is not detected if
diagnosis code No.41 or 42 indicating battery voltage drop has
been output.)
45 Non- volatile memory (EEPROM) When the non-volatile memory (EEPROM) is abnormal
51 Drivers side air bag module Short circuit in the squib ignition drive circuit
52 (squib) Open circuit in the squib ignition drive circuit
54 Passengers air bag module Short circuit in the squib ignition drive circuit
55 (squib) Open circuit in the squib ignition drive circuit
73 Side air bag module (R.H.) (squib) Short circuit in the squib ignition drive circuit
74 Open circuit in the squib ignition drive circuit
83 Side air bag module (L.H.) (squib) Short circuit in the squib ignition drive circuit
84 Open circuit in the squib ignition drive circuit
Code No.21, 22, 61, 62 Drivers side air bag module (squib) Probable cause
system
These diagnosis codes are output if there is an abnormal resistance between the D Malfunction of clock spring
input terminals of the drivers side air bag module (squib) inside the SRS-ECU. D Partially open as clock spring is not in neutral
The trouble causes for each diagnosis code No. are as follow. position
However, as for code Nos.21 and 22, if the vehicles condition return to normal, D Malfunction of harness or connector
SRS warning lamp will go out. (Diagnosis code will remain stored) D Malfunction of drivers air bag module (squib)
D Malfunction of SRS-ECU
Table 3
Code No. Trouble Symptom
21 D Short circuit in drivers air bag module (squib) or harness short
D Short circuit in clock spring
D Poor connector contact*
22 D Open circuit in drivers air bag module (squib) or open harness
D Open circuit in clock spring
D Disconnected drivers air bag module (squib) connector
D Partially open as clock spring is not in neutral position
D Poor connector contact
61 Short circuit in drivers air bag module (squib) harness leading to the power supply
62 Short circuit in drivers air bag module (squib) harness leading to the earth
NOTE
*: The shorting bars, which short positive (+) and negative ( - ) wires to prevent the air bags from accidental
deployment during the disconnection of the connector, are set in the squib circuit connectors. In
a defective connector, the short-bar may be still working even after the connection of the connecter.
Probe
(MB991222)
1
Instrument panel
Check harness
wiring harness
connector (2-pin)
2
YES NO
Check the following connector: D-206, E-111 Replace drivers air bag module (squib).
OK NG
Check the trouble symptoms. Repair
NG
Code No.24, 25, 64, 65 Passengers air bag module (squib) Probable cause
system
These diagnosis codes are output if there is an abnormal resistance between the D Malfunction of harness or connector
input terminals of the passengers air bag module (squib) inside the SRS-ECU. D Malfunction of passengers air bag module (squib)
The trouble causes for each diagnosis code No. are as follow. D Malfunction of SRS-ECU
However, as for code Nos.24, 25, if the vehicles condition return to normal,
SRS warning lamp will go out. (Diagnosis code will remain stored).
Table 4
Code No. Trouble Symptom
24 D Short in passengers air bag module (squib) or harness short
D Poor connector contact*
25 D Open circuit in passengers air bag module (squib) or open harness
D Poor connector contact
64 Short in passengers air bag module (squib) harness leading to the power supply
65 Short in passengers air bag module (squib) harness leading to the earth
NOTE
*: The shorting bars, which short positive (+) and negative ( - ) wires to prevent the air bags from accidental
deployment during the disconnection of the connector, are set in the squib circuit connectors. In
a defective connector, the short-bar may be still working even after the connection of the connector.
YES Check the following connectors: D-10, E-111
SRS check harness
(MB991606 or MB991613) OK NG
YES
Are SRS-ECU connectors E-111, E-110 <vehicles with side air Check the following connectors: E-111,E-110 <vehicles with
bags> connected properly. side air bags>
NO OK NG
Code No.41 Power circuit system (fuse No.6 circuit) Probable cause
Code No.42 Power circuit system (fuse No.8 circuit)
Code No.41 is displayed if voltage between IG1 terminal (SRS-ECU, terminal 16) D Malfunction of harness or connector
and earth is lower than specified for five successive seconds or more. D Malfunction of SRS-ECU
Code No.42 is displayed if voltage between IG1 terminal (SRS-ECU, terminal 13)
and earth is lower than specified for five successive seconds or more.
However, when vehicle condition returns to normal, these codes will be
automatically erased, and the SRS warning lamp will go out. If codes No.41 and
42 are displayed together, check the battery first as vehicle may have
discharged battery.
NG
Measure at SRS-ECU connector E-111. Check the following connectors: D-208, D-209, D-210, E-111
D Disconnect the connector and measure at the harness OK NG
side.
D Connect the negative (- ) battery terminal. Check the trouble symptoms. Repair
D Ignition switch: ON
D Voltage between terminal 16 and body earth (in case of NG
code No. 41)
OK: 9 V or more Check the harness wire between the SRS-ECU and the
D Voltage between terminal 13 and body earth (code No.42) ignition switch IG1, and repair if necessary.
OK: 9 V or more
OK
Code No.43 SRS warning lamp drive circuit system (Lamp Probable cause
does not come on.)
This diagnosis code is output when a open circuit is present for5 successive D Malfunction of harness or connector
seconds or more in SRS warning lamp drive circuit. However, the vehicle D Blown bulb
condition return to normal condition, this code, if displayed due to open circuit, D Malfunction of SRS-ECU
will be automatically erased. D Malfunction of combination meter
NG
SRS warning lamp check Check a burnt-out bulb.
D Connect the negative (- ) battery terminal. NG
D Ignition switch: ON OK
D Does lamp come on when SRS-ECU connector E-111 is Repair
disconnected?
OK: Lamp illuminates
Check the following connectors:
OK L.H. drive vehicles: D-210, D-01, D-02, E-111
R.H. drive vehicles: D-213, D-01, D-02, E-111
Replace the SRS-ECU.
OK NG
OK NG
Code No.43 SRS warning lamp drive circuit system (Lamp Probable cause
does not go out.)
This diagnosis code is output when a short to earth occurs in the harness D Malfunction of harness or connector
between the SRS warning lamp and the SRS-ECU. However, the vehicle D Malfunction of SRS-ECU
condition returns to normal condition, this code will be automatically erased, and D Malfunction of combination meter
SRS warning lamp will go out.
Code No.44 SRS warning lamp drive circuit system Probable cause
This diagnosis code is output when a short occurs in the lamp drive circuit or a D Malfunction of harness or connector
malfunction of the output transistor inside the SRS-ECU is detected while the D Malfunction of SRS-ECU
SRS-ECU is monitoring the SRS warning lamp drive circuit.
However, when vehicle condition returns to normal, these codes will be
automatically erased, and the SRS warning lamp will go out.
Table 5
Code No. Trouble Symptom
71 Short in side air bag module (R.H.) (squib) or harness short
72 D Open in side air bag module (R.H.) (squib) or open harness
D Poor connector contact
75 Short in side air bag module (R.H.) (squib) harness leading to the power supply
76 Short in side air bag module (R.H.) (squib) harness leading to the earth
YES
Check the following connectors: F-28, E-110
SRS check harness
(MB991606 or MB991613) OK NG
NO
Side air bag module Replace the drivers front seat back assembly.
connector (R.H.)
NO
MUT-II Self-Diag Code Check the following connectors: F-19, E-21, E-110
D Switch over the right side impact sensor (R.H.) and the
OK NG
side impact sensor (L.H.).
D Connect the negative (- ) battery terminal. Check the trouble symptoms. Repair
D Erase diagnosis code memory.
Are code Nos.79 and 93 erased and code Nos.89 and 96 NG
output?
Check the harness wire between the left side impact sensor
YES and the SRS-ECU.
Code No.81, 82, 85, 86 Side air bag module (L.H.) (squib) Probable cause
system
These diagnosis codes are output if there is an abnormal resistance between the D Malfunction of harness or connector
input terminals of the side air bag module (L.H.) (squib) inside the SRS-ECU. D Malfunction of side air bag module (L.H.) (squib)
The trouble causes for each diagnosis code No. are as follow. D Malfunction of SRS-ECU
However, as for code No.81, 82, if the vehicle condition returns to normal, the
SRS warning lamp will go out. (Diagnosis code will remain stored)
Table 6
Code No. Trouble Symptom
81 Short in side air bag module (L.H.) (squib) or harness short
82 D Open circuit in side air bag module (L.H.) (squib) or open harness
D Poor connector contact
85 Short in side air bag module (L.H.) (squib) harness leading to the power supply harness
86 Short in side air bag module (L.H.) (squib) harness leading to the earth
YES
SRS check harness Check the following connectors: F-21, E-110
(MB991606 or MB991613) OK NG
NO
Replace the passengers front seat back assembly
Side air bag module (L.H.)
connector
NO
MUT-II Self-Diag Code Check the following connectors: F-01, E-20, E-110
D Switch over the right side impact sensor (R.H.) and the
OK NG
side impact sensor (L.H.).
D Connect the negative (- ) battery terminal. Check the trouble symptoms. Repair
D Erase diagnosis code memory.
Are code Nos.89 and 96 erased and code Nos.79 and 93 NG
output?
Check the harness wire between the side impact sensor
YES (R.H.) and SRS-ECU.
Code No.91 Side impact sensor (L.H.) power supply circuit Probable cause
system
Power supply voltage of side impact sensor (L.H.) is lower than specified for five D Malfunction of harness or connector
successive seconds or more. D Malfunction of side impact sensor (L.H.)
However, when vehicle condition returns to normal, this code will be D Malfunction of SRS-ECU
automatically erased, and the SRS warning lamp will go out.
NG
Measure at side impact sensor connector F-19. Check the following connectors: F-19, E-21, E-110
D Disconnect the connector and measure at the harness
OK NG
side.
D Connect the negative (- ) battery terminal. Check the trouble symptoms. Repair
D Ignition switch: ON
D Voltage between terminal 1 and body earth NG
OK: 9 V or more
Check the harness wire between the left side impact sensor
OK and the SRS-ECU.
Replace side impact sensor (L.H.). OK NG
Table 7
Code No. Defective part Trouble Symptom
92 Side impact analog G-sensor D Not working
D Having abnormal characteristics
95 D Having abnormal output
D Replace the side impact sensor (L.H.) (in case of code No.92)
D Replace the side impact sensor (R.H.) (in case of code No.95)
Code No.94 Side impact sensor (R.H) power supply circuit Probable cause
system
Power supply voltage of side impact sensor (R.H.) is lower than specified for D Malfunction of harness or connector
consecutive five seconds or more. D Malfunction of side impact sensor (R.H.)
However, when vehicle condition returns to normal, this code will be D Malfunction of SRS-ECU
automatically erased, and the SRS warning lamp will go out.
NG
Measure at side impact sensor (R.H.) connector F-01. Check the following connectors: F-01, E-20, E-110
D Disconnect the connector and measure at the harness NG
OK
side.
D Connect the negative (- ) battery terminal. Check the trouble symptoms. Repair
D Ignition switch: ON
D Voltage between terminal 1 and body earth NG
OK: 9 V or more
Check the harness wire between the side impact sensor
OK (R.H.) and SRS-ECU.
Replace side impact sensor (R.H.). OK NG
NO
Is communication between MUT-II and other system is Check the MUT-II diagnosis circuit, and repair if necessary.
possible?
YES
(1)NG
Measure at SRS-ECU connector E-111. Check the following connector: E-111
D Disconnect the connector and measure at the harness OK NG
side.
(1) Continuity between terminal 7 and body earth Check the trouble Repair
OK: Continuity symptoms.
D Connect the negative (- ) battery terminal.
D Ignition switch: ON NG
(2) Voltage between terminal 13 and body earth Check the harness wire between SRS-ECU and earth, and
OK: 9 V or more repair if necessary.
(3) Voltage between (16) and body earth (2), (3)
OK: 9 V or more NG
Check the following connectors:
OK D-208, D-209, D-210, E-111
OK NG
Check the following connectors: D-23, D-33, E-111
OK NG Check the trouble Repair
symptoms.
Check the trouble Repair
symptoms. NG
Battery (- ) cable
SRS-ECU
SRS 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 for
deformation or rust.
Replace SRS-ECU if it fails visual check.
(Refer to P.52B-30.)
FRONT IMPACT SENSORS
1. Check the headlamp support panel for deformation or
Front impact sensor
rust.
2. Check the front impact sensor for dents, cracks,
deformation or rust.
3. Check the sensor harnesses for binding, the connectors
for damage, and the terminals for deformation.
Inflator
92 Number indication how often the memory is cleared. Maximum time to be stored: 250
93 How long problem have lasted (How long it takes Maximum time to be stored: 9999 minutes
from the occurrence of the problem till the first air bag (approximately 7 days)
squib igniting signal)
REPAIR PROCEDURE
DEPLOYED DRIVERS AND FRONT PASSENGERS AIR
BAGS
1. Replace the following parts with new ones.
D SRS-ECU (Refer to P.52B-30.)
D Drivers air bag module (Refer to P.52B-32.)
D Front passengers air bag module (Refer to P.52B-32.)
2. Check the following parts and replace if malfunction is
found:
D Clock spring (Refer to P.52B-32.)
D Steering wheel, steering column and intermediate
joint
(1) Check the wiring harness (built into steering
wheel) and connectors for damage, and terminals
for deformation.
(2) Check the drivers air bag module for proper
installation to the steering wheel.
SRS-ECU
SRS-ECU
1. Check the SRS-ECU case and bracket for dents, cracks
or deformation.
2. Check connectors for damage, and terminals for
deformation.
3. Check the SRS-ECU and bracket for installation condition.
Connector
Passengers side
Connector
Inflator
Clock spring
Case 1. Check the connectors and protective tubes for damage
and terminals for deformation.
2. Visually check the case for damage.
Protective
tubes
Centre pillar
Harness connectors (Instrument panel wiring harness,
Front
side air bag wiring harness, floor wiring harness)
Side impact sensor
side of Check harnesses for binding, connectors for damage and
vehicle terminals for deformation.(Refer toP.52B-4.)
4.9 1.0 Nm
INSPECTION
1. Check the front impact sensor for dents, cracks,
deformation or rust.
Caution
If a dent, crack, deformation or rust is found, replace
the sensor with a new one.
2. Check short or open circuit between the terminals of the
front impact sensor.
Short circuit: 1 W or less
Open circuit: 1 MW or more
Caution
Always replace the sensor with a new one if the
resistance shows a short or open circuit.
3. Check the continuity between the terminal and bracket.
If there is a continuity, the insulation is malfunctioned,
and replace the sensor with a new one.
4. Check the headlamp support panel for deformation and
rust.
4.9 1.0 Nm
3 4.9 1.0 Nm
4.9 1.0 Nm
INSPECTION
1. Check the SRS-ECU case for dents, cracks or
deformation.
2. Check connector for damage, and terminals for
deformation.
Caution
If any problems are found, replace the SRS-ECU.
NOTE
For the checks other than the items above, refer to
Troubleshooting.(Refer to P.52B-7.)
Pre-removal Operations
D After setting the steering wheel and the front wheels to the straight ahead position, remove the ignition key.
D Disconnect the negative battery (- ) terminal.
5 D
5 D
Section A A Section B B
Claw
B A Claw
1
1 BA
3.9 0.4 Nm 3
1
3
Section C C Section D D
Claw Claw
NOTE
: indicates tab.
50 5 Nm
Drivers air bag module removal Drivers air bag module installation
steps steps
AA" 1. Cover "AA D Pre-installation inspection
AB" 2. Steering wheel and air bag module 4. Drivers air bag module
assembly 3. Steering wheel
3. Steering wheel "CA 2. Steering wheel and air bag module
AC" 4. Drivers air bag module assembly
1. Cover
D Connect the negative (- ) battery
terminal.
"DA D Post-installation inspection
NOTE
The arrow in the illustration shows the notch for the special
tool.
Protective
tubes
2 4
Probe
(MB991222)
Clock spring
2
Circuit tester
Caution
Never measure circuit resistance in the side air bag
modules (squib) even with the specified tester.
Measuring the circuit resistance with a tester causes
accidental air bag deployment due to current that
flows or static, resulting in serious personal injury.
1. Check the side air bag module deployment section
for dents and deformation.
2. Check the harness and connector for damage and
the terminals for deformation.
4.9 1.0 Nm
4.9 1.0 Nm
INSPECTION
1. Check the side impact sensor for dents, cracks,
deformation and rust.
2. Check connector for damage, and terminals for
deformation.
3. Check the center pillar or quarter panel, inner for
deformation and rust.
Caution
If a dent, crack, deformation or rust is found, replace
the sensor with a new one.
NOTE
For other inspections than described above, go to
Troubleshooting. (Refer to P.52B-7.)
NOTE
Once disconnected from the instrument panel wiring
harness, both electrodes of the clock spring connector
short automatically. This prevents the drivers air bag
from accidental deployment caused by static, etc.
Insulating
tape
Deployment
harness
(5) Close all the doors with the windows fully closed and
Car cover put a cover over the vehicle to minimize report.
Caution
The cover is required as the glass, if already
damaged, may break.
(6) Separate the deployment harnesses as far from the
Deployment
harness vehicle as possible and connect to the terminals of
the battery removed from the vehicle. Then deploy
the passengers air bag module.
Caution
1) Before deploying the air bag, see that no one
is in and near the vehicle.
2) The deployment makes the inflator of the
drivers air bag very hot. Before handling the
inflator, wait more than 30 minutes for cooling.
3) If the air bag module fails to deploy although
the procedure is respected, do not go near
the module. Contact your distributor.
(7) After deployment of the air bag module, discard as
specified in the procedure. (Refer to P.52B-52)
Passengers air
bag module 2-pin
connector (red)
Deployment
harness
(5) Close all the doors with the windows fully closed and
Car cover put a cover over the vehicle to minimize report.
Caution
The cover is required as the glass, if already
damaged, may break.
(6) Separate the deployment harnesses as far from the
Deployment vehicle as possible and connect to the terminals of
harness
the battery removed from the vehicle. Then deploy
the passengers air bag module.
Caution
1) Before deploying the air bag, see that no one
is in and near the vehicle.
2) The deployment makes the inflator of the
passengers air bag very hot. Before handling
the inflator, wait more than 30 minutes for
cooling.
3) If the air bag module fails to deploy although
the procedure is respected, do not go near
the module. Contact your local distributor.
(7) After deployment of the air bag module, discard as
specified in the procedure. (Refer to P.52B-52)
(4) Close all the doors with the windows fully closed and
Car cover put a cover over the vehicle to minimize report.
Caution
The cover is required as the glass, if already
damaged, may break.
(5) Separate the deployment harnesses as far from the
Deployment
harness vehicle as possible and connect to the terminals of
the battery removed from the vehicle. Then deploy
the side air bag module.
Caution
Never fail to do Step (3) in order to prevent
accidental deployment caused by static.
Drivers air bag Deployment harness (4) Using pliers, cut the drivers air bag module connector
module from the harnesses. Connect the deployment
harnesses to each harness that has been cut and
insulate the connections with plastic tape.
Shorted
Insulating tape
(5) Install a nut to the bolt behind the drivers air bag
Drivers air bag module
module and tie thick wire for securing to the wheel.
Deployment harness
Deployment harness
Deployment
harness
(3) Place the front seat back assembly with its back facing
Front seat-
back assem- the ground.
bly (4) Connect the SRS air bag adapter harness which
connected with the deployment harness to the side
air bag module connector.
SUPPLEMENTAL
RESTRAINT
SYSTEM (SRS)
CONTENTS
CAUTION
D Carefully read and observe the information in the SRS SERVICE PRECAUTIONS (P.52B-3.) prior to any service.
D For information concerning troubleshooting or maintenance, always observe the procedures in the Troubleshooting
(P.52B-6.) section.
D 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-11.) for the components involved.
D If you have any questions about the SRS, please contact your local distributor.
Webbing
Clutch sleeve Clutch sleeve
Constant
voltage
circuit
Microcomputer
Interface Interface
circuit Power supply and circuit Microcomputer
communication
lines
Analog G - sensor
27, 28 Floor wiring harness Seat belt with pre-tensioner (Front Correct or replace each wiring
passengers side) harness.
29, 30 Floor wiring harness Seat belt with pre-tensioner (Drivers side)
6. 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
7. Whenever you finish servicing the SRS, check warning lamp operation to make sure that the
system functions properly.
SPECIAL TOOLS
The items other than below are the same as before.
Tools No. Name Application
MB991865 Dummy resistor SRS air bag circuit check
28*, 29*, 68, 69 Front passengers side pre-tensioner (squib) system 52B-8
56, 57 Drivers side pre-tensioner (squib ignition drive circuit) system 52B-9
58, 59 Front passengers side pre-tensioner (squib ignition drive circuit) system 52B-9
NOTE
*: If the system returns to normal, the SRS warning lamp will go out, but the relevant diagnosis code
will be retained in memory.
66 D Short in drivers side pre-tensioner (squib) harness leading to the power supply
YES NO
Check the following connectors: E-110, E-21, F-34 <L.H. Replace the drivers side seat belt with pre-tensioner.
drive vehicles>, E-20, F-31 <R.H. drive vehicles>
OK NG
Check trouble symptoms. Repair
NG
Check wiring harness between the drivers side pre-tensioner and
SRS-ECU.
OK NG
68 D Short in front passengers side pre-tensioner (squib) harness leading to the power
supply
69 D Short in front passengers side pre-tensioner (squib) harness leading to the earth
YES NO
Check the following connectors: E-110, E-20, F-31 <L.H. drive Replace the front passengers side pre-tensioner.
vehicles>, E-21, F-34 <R.H. drive vehicles>
OK NG
Check trouble symptoms. Repair
NG
Check wiring harness between the front passengers side
pre-tensioner and SRS-ECU.
OK NG
56 Drivers side pre-tensioner D Short circuit in the squib ignition drive circuit
(squib ignition drive circuit)
57 D Open circuit in the squib ignition drive circuit
58 Front passengers side pre- D Short circuit in the squib ignition drive circuit
tensioner (squib ignition drive
59 circuit) D Open circuit in the squib ignition drive circuit
REPAIR PROCEDURE
WHEN PRE-TENSIONER OPERATES IN A COLLISION.
1. Replace the following parts with new ones.
D SRS-ECU
D Front impact sensor
D Seat belt with pre-tensioner (Refer to P.52B-12.)
2. Check harnesses for binding, connectors for damage,
poor connections, and terminals for deformation.
44 10 Nm
2
1
44 10 Nm
2
44 10 Nm
INSPECTION
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.
(Refer to P.52B-14.)
D Check pre-tensioner for dents, cracks or deformation.
pre-tensioner
2-pin connector
(red)
Operation
harness
(5) Close all the doors with the windows fully closed and
Car cover put a cover over the vehicle to minimize report.
Caution
The cover is required as the glass, if already
damaged, may break.
(6) Separate the operation harness as far from the vehicle
Operation as possible and connect to the terminals of the battery
harness
removed from the vehicle. Then operate the
pre-tensioner.
Seat belt with (3) Feed a thick wire through the bracket of the seat
pre-tensioner belt with pre-tensioner, and connect it to a old tyre
with a wheel.
(4) Connect the operation harness to the pre-tensioner.
(5) Pull out the seat belt outside the tyre.
Operation harnesses
(6) Place an old tyre (without a wheel) on the tyre, which the
Tyre without seat belt with pre-tensioner is secured on.
wheels
Caution
Be careful not to trap the SRS air bag adapter
harness connector between tyres.
CHASSIS ELECTRICAL
Click on the applicable bookmark to selected the required model year.
CHASSIS
ELECTRICAL
CONTENTS
BATTERY
SERVICE SPECIFICATIONS
Item Standard value
Battery electrolyte specific gravity 1.220 - 1.290 (electrolyte temperature 20C )
ON-VEHICLE SERVICE
ELECTROLYTE LEVEL AND SPECIFIC
OK GRAVITY CHECK
NG
Measure the battery discharge voltage. Charge the battery at 5 A (constant current charging). (Refer
OK: 12.4 V or more (specific gravity 1.240) to Table 1.)
OK
(Table 2)
Outside air tem- 21 or 16 - 20 10 - 15 4- 9 1 - 3 1 - 1 12 - 1 18
perature (C) more - 13
Minimum volt- 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
age (V)
TROUBLESHOOTING
IGNITION SWITCH
The ignition switch is controlled by the Smart Wiring System (SWS), For troubleshooting procedures,
refer to GROUP 54B.
IMMOBILIZER
BASIC FLOW OF PROBLEM DIAGNOSIS
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
DIAGNOSIS FUNCTION
READING DIAGNOSIS CODES
The diagnosis codes can be read using the MUT-II or by using the Simple Check Diagnosis mode.
(Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points)
NOTE
Connect the MUT-II to the 16-pin diagnosis connector (black).
YES
Can other keys which have been registered be used to start Replace the ignition key which cannot start the engine.
the engine?
NO
Register the ignition key.
If code No. 12 is
output
Check the diagnosis codes. To inspection procedure 12 classified by diagnosis code
(Refer to P.54A-7.)
If code No. 11 is
output
Replace the immobilizer-ECU.
NG
Check the following connectors: D-202-1, D-202, E-13, Repair
D-122<6G74-A/T>, D-118<6G74-M/T>, D-112<4M41>
OK
NO
Can none of the ignition keys be registered? Replace the ignition key that cannot be registered.
YES
Register the ignition key.
YES
Is a normal diagnosis code output? To Chart Classified by Diagnosis Codes (Refer to P.54A-7.)
NO
Immobilizer-ECU power supply and earth circuit system check OK Check the trouble symptoms.
(Refer to Inspection Procedure 4.) NG
Inspection procedure 3
The engine does not start. Probable cause
(The engine cranks but does not fire.)
If the fuel injection does not operate, the cause is probably a problem D Malfunction of GDI system or Diesel
with the immobilizer-ECU, or it could also be a problem with the GDI fuel system
system or the DIESEL system. If an attempt has been made to start D Malfunction of immobilizer-ECU
the engine with a key that has not been properly registered, the
above symptom is a sign of normal operation.
NG
Voltage check during cranking Battery check (P.54A-4)
OK: 8V or higher
OK
YES
Is a normal diagnosis code output by the engine-A/T-ECU Refer to GROUP 13B, 13C - Troubleshooting.
<6G74-A/T> or by the engine-ECU <6G74-M/T, 4M41>?
NO
YES
Is a normal diagnosis code output from the immobilizer-ECU? To Chart Classified by Diagnosis Codes (Refer to P.54A-7.)
NO
Inspection procedure 4
Immobilizer-ECU power supply and earth circuit system check
(1)NG
Measure at immobilizer-ECU connector D-60-1. Check the following connectors: D-128, D-202, D-202-1
D Ignition switch: ON OK NG
D Disconnect the connector and measure at the harness
side. Repair
(1) Voltage between terminal (1) and body earth
OK: System voltage Check the trouble symptoms.
(2) Voltage between terminal (4) and body earth
OK: Continuity NG
(2)NG
Check the harness between the engine control relay and the
Check the following connectors: D-202-1, D-202, D-30 immobilizer-ECU, and repair if necessary.
OK NG
Repair
Check the trouble symptoms.
NG
IMMOBILIZER-ECU CHECK
TERMINAL VOLTAGE CHECK TABLE
7
6
2 9
Removal steps
1. Steering wheel 4. Upper column cover (Refer to GROUP
(Refer to GROUP 37A.) 52A - Instrument Panel.)
2. Instrument panel under cover 5. Column Switch
(Refer to GROUP 52A - Instrument AA" 6. Steering lock cylinder
Panel.) 7. Ignition switch
3. Lower column cover (Refer to GROUP 8. Key Reminder Switch
52A - Instrument Panel.) 9. Immobilizer-ECU
INSPECTION
IGNITION SWITCH CONTINUITY CHECK
With the ignition switch installed to the vehicle, disconnect
and check the ignition switch connector.
Ignition switch Terminal No.
position 1 2 4 5 6
LOCK
ACC
ON
START
NOTE
* : If the engine-ECU is replaced, the ignition key ring antenna
and immobilizer-ECU and ignition key should be replaced
together with it.
Each engine-ECU has an individual information for
immobilizer-ECU, and the individual information is registered
in the immobilizer-ECU.
TROUBLESHOOTING
IGNITION SWITCH
The ignition switch is controlled by the Smart Wiring System (SWS), for troubleshooting procedures,
refer to GROUP 54B.
IMMOBILIZER
BASIC FLOW OF PROBLEM DIAGNOSIS
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
DIAGNOSIS FUNCTION
READING DIAGNOSIS CODES
The diagnosis codes can be read using the MUT-II or by using the Simple Check Diagnosis mode.
(Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)
NOTE
Connect the MUT-II to the 16-pin diagnosis connector (black).
DIAGNOSIS CODE MEMORY ERASING PROCEDURE
Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
INSPECTION USING SIMPLE CHECK DIAGNOSIS MODE
1. Change to Simple Check Diagnosis mode and activate switch diagnosis mode.
(Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.
2. In this condition, the input signals for the following switches can be checked.
YES
Can other keys which have been registered be used to start Replace the ignition key which cannot start the engine.
the engine?
NO
Register the ignition key.
If code No. 12 is
output
Check the diagnosis codes. To inspection procedure 12 classified by diagnosis code
(Refer to P.54A-15.)
If code No. 11 is
output
NG
Check the following connectors: D-133, D-201 Repair
OK
OK
NO
Can none of the ignition keys be registered? Replace the ignition key that cannot be registered.
YES
Register the ignition key.
YES
Is a normal diagnosis code output? To Chart Classified by Diagnosis Codes (Refer to P.54A-14.)
NO
OK
Immobilizer-ECU power supply and earth circuit system check Check the trouble symptoms.
(Refer to Inspection Procedure 3.) NG
Check the following connectors: D-133, D-33, D-222, D-28
OK NG
Check the trouble symptoms. Repair
NG
Check the harness between the immobilizer-ECU and the
diagnosis connector.
OK NG
Check the trouble symptoms. Repair
NG
Replace the immobilizer-ECU.
NG
Voltage check during cranking Battery check (P.54A-4)
OK: 8V or higher
OK
YES
Is a normal diagnosis code output from the immobilizer-ECU? To Chart Classified by Diagnosis Codes (Refer to P.54A-14.)
NO
To inspection procedures if the engine does not fire
(Refer to GROUP 13B, 13C - Troubleshooting.)
NG
Check the trouble symptoms.
NG
OK
Immobilizer-ECU power supply and earth circuit system check Check the trouble symptoms.
(Refer to Inspection Procedure 4.) NG
Check the following connectors: D-133, D-13, B-03
OK
Check the trouble symptoms. Repair
NG
Check the harness between the immobilizer-ECU and the fuel
cut valve controller.
OK
Check the trouble symptoms. Repair
NG
Replace the immobilizer-ECU.
Inspection procedure 3
Immobilizer-ECU power supply and earth circuit system check
(1)NG
Measure at immobilizer-ECU connector D-60-1. Check the following connectors: D-27, D-223, D-31, D-133
D Ignition switch: ON OK NG
D Disconnect the connector and measure at the harness
side. Repair
(1) Voltage between terminal 7 and body earth Check the trouble symptoms.
OK: System voltage NG
(2) Voltage between terminal 6 and body earth
OK: System voltage Check the harness between fusible link No. 1 and the
(3) Voltage between terminal 3 and body earth immobilizer-ECU, and repair if necessary.
OK: Continuity
(2)NG
Check the following connectors: D-210, D-31, D-133
OK NG
(3)NG
Check the trouble symptoms. Repair
Check the following connectors: D-133, D-30
OK NG NG
Repair Check the harness between the ignition switch (IG1) and the
Check the trouble symptoms. immobilizer-ECU, and repair if necessary.
NG
IMMOBILIZER-ECU CHECK
TERMINAL VOLTAGE CHECK TABLE
Diagnosis connector
4
7
6
Removal steps
1. Steering wheel 4. Upper column cover (Refer to GROUP
(Refer to GROUP 37A.) 52A - Instrument Panel.)
2. Instrument panel under cover 5. Column Switch
(Refer to GROUP 52A - Instrument AA" 6. Steering lock cylinder
Panel.) 7. Ignition switch
3. Lower column cover (Refer to GROUP 8. Key Reminder Switch
52A - Instrument Panel.) 9. Immobilizer-ECU
INSPECTION
IGNITION SWITCH CONTINUITY CHECK
With the ignition switch installed to the vehicle, disconnect
and check the ignition switch connector.
Ignition Terminal No.
switch posi-
tion 1 2 4 5 6
LOCK
ACC
ON
START
NOTE
* : If the engine-ECU is replaced, the ignition key ring antenna
and immobilizer-ECU and ignition key should be replaced
together with it.
Each engine-ECU has an individual information for
immobilizer-ECU, and the individual information is registered
in the immobilizer-ECU.
ENCRYPTED 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 encrypted codes for each ignition key being
used into the immobilizer-ECU. (A maximum of eight different
encrypted codes can be registered.)
Moreover, when the immobilizer-ECU has been replaced, you
will need to use the MUT-II to register the password that
the user specifies into the immobilizer-ECU. (Refer to the
MUT-II instruction manual for instructions on using the MUT-II.)
Caution
Because registering of the encrypted codes is carried
out after all previously-registered codes have been
erased, you should have ready all of the ignition keys
that have already been registered.
COMBINATION METER
SERVICE SPECIFICATIONS
Item Standard value Limit
Speedometer indication range At 20 km/h 18 - 23
km/h
At 40 km/h 37 - 45
At 80 km/h 75 - 88
At 120 km/h 113 - 132
At 160 km/h 150 - 176
Speedometer needle swing km/h (when driving at 35 km/h or higher) 3
Tachometer indication error When engine speed is 700 r/min 120
r/min
When engine speed is 2,000 r/min Petrol - 175+225
Diesel 175
When engine speed is 3,000 r/min Petrol - 175+300
Diesel 225
When engine speed is 4,000 r/min Petrol - 225+375
Diesel 300
When engine speed is 4,750 r/min <Diesel vehicles> 260
When engine speed is 5,000 r/min <Petrol vehicles> - 225+425
When engine speed is 6,000 r/min <Petrol vehicles> - 225+475
Fuel gauge unit standard F position 3
resistance value W E position 110
Fuel gauge unit float height F position 11.9
mm
E position 195.2
Engine coolant temperature gauge unit standard resistance value W 104 13.5
Combination meter internal 62 - 11 (IG power supply - earth) 1MW or more
resistance value W 62 - 25 (IG power supply - earth) 1MW or more
(Measured at connector D-38
and connector D-40) 62 - 63 (IG power supply - fuel gauge) 1MW or more
62 - 64 (IG power supply - engine coolant 1MW or more
temperature gauge)
63 - 11 (fuel gauge - earth) 180
63 - 25 (fuel gauge - earth) 180
64 - 11 (engine coolant temperature gauge - earth) 210
64 - 25 (engine coolant temperature gauge - earth) 210
67 - 11 (battery power supply - earth) 1MW or more
67 - 25 (battery power supply - earth) 1MW or more
67 - 63 (battery power supply - fuel gauge) 1MW or more
67 - 64 (battery power supply - engine coolant 1MW or more
temperature gauge)
SEALANTS
Usage location Brand
Engine coolant temperature gauge unit Semi-drying sealant:
Threebond 1104 [0110207], Threebond 1141E
(Manufactured by Threebond)
NOTE
Numbers in [ ] indicate genuine parts numbers.
SPECIAL TOOLS
Tools No. Name Application
A MB991223 Harness set Fuel gauge simple checking
A: MB991219 A: Check harness Engine coolant temperature gauge simple
B: MB991220 B: LED harness checking
C: MB991221 C: LED harness A: For checking contact pin contact pressure
D: MB991222 adapter B: For checking the power supply
D: Probe C: For checking the power supply
B
D: For checking the power supply circuit
TROUBLESHOOTING
DIAGNOSIS FUNCTION
Input signal check procedure
1. Connect the MUT-II or a voltage meter to the diagnosis connector, and check the input. (Refer to
GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)
2. The vehicle speed sensor input signal can be checked.
NOTE
If the vehicle speed sensor input signal cannot be checked using the MUT-II, the cause is probably
a malfunction of the diagnosis circuit system.
YES
MUT-II Self-Diag Code Vehicle speed sensor circuit check (Refer to inspection
Is MPI, GDI or DIESEL diagnosis code No. 24 output? procedure 6 on P.54A-29.)
NO
NG Repair
Check the following connectors: D-01, D-222, E-13, E-113,
C-09
OK
Check the trouble symptoms.
NG
Replace the speedometer.
Inspection procedure 2
Tachometer does not operate.(Other meters and gauges Probable cause
operate.)
The cause is probably that the ignition signal is not being input from D Malfunction of tachometer
the engine, or that there is a malfunction of the meter power supply D Malfunction of harness or connector
or earth circuit. D Malfunction of printed circuit board
YES
MUT-II Self-Diag Code Code No. 44 Ignition coil and power transistor unit system
Is MPI, GDI or DIESEL diagnosis code No. 44 output? (Refer to GROUP 13A - Troubleshooting.)
NO
NG
Check the following connectors: Repair
<6G74-A/T>D-01, D-33, E-13, B-04, D-120,
<6G74-M/T>D-01, D-33, E-13, B-04, D-117,
<4M41>D-01, D-33, E-13, D-112,
<4D56>D-01, D-33, E-13, B-07, B-07-1
OK
(2)NG Check the harness between the combination meter and the
fuel gauge, and repair if necessary.
Combination meter fuel gauge terminal continuity check (Refer NG Replace the fuel gauge and engine coolant temperature
to P.54A-31.) assembly.
OK
Fig. 1
Test lamp
(12 V/3.4 W)
Inspection procedure 4
Engine coolant temperature gauge does not operate. Probable cause
(Other meters and gauges operate.)
If the speedometer and tachometer are normal, the harness from D Malfunction of engine coolant tempera-
the power supply to the combination meter is normal. ture gauge unit
D Malfunction of fuel gauge and engine
coolant temperature assembly
D Malfunction of harness or connector
D Malfunction of printed circuit board
Engine coolant temperature gauge circuit check OK Replace the engine coolant temperature gauge unit.
D Disconnect engine coolant temperature gauge unit
connector <other than 4D56>B-50, <4D56>B-07-2.
D Connect a test lamp (12V - 4W) to the harness-side (1)NG
connector. (Refer to Figure 2, 3 and Figure 5.) Check the following connectors: <other than 4D56> D-01,
D Ignition switch: ON E-13, B-50
(1) Does the test lamp illuminate? <4D56> D-01, E-13, B-07, B-07-2
OK: Illuminated OK NG
(2) Does the engine coolant temperature gauge needle swing
about half-way? Check the trouble symptoms. Repair
OK: Swings NG
(2)NG
Check the harness between the combination meter and the
engine coolant temperature gauge, and repair if necessary.
Engine coolant temperature gauge check (P.54A-32.) NG Replace the fuel gauge and engine coolant temperature
assembly.
Earth
Test lamp (12 V
- 3.4 W)
Connector Connector
Figure 4 <4M41>
Test lamp (12 V
- 3.4 W)
Earth
Connector
NG
Check the following connectors: D-27, D-233, D-218, D-01, Repair
D-03
OK
Check the harness between fusible link No. 2 and the NG Repair
combination meter.
OK
Inspection procedure 6
Vehicle speed sensor check
The vehicle speed sensor is used by the speedometer, engine-ECU and A/T-ECU.
NG
Vehicle speed sensor check (Refer to P.54A-33.) Replace
OK
(1)NG
Measure at vehicle speed sensor connector C-09. Check the following connectors: D-01, D-222, E-13, E-113,
D Disconnect the connector and measure at the harness C-09 OK NG
side.
(1) Voltage between terminal 3 and earth
OK: 4.5 V or higher
Check the trouble symptoms. Repair
(2) Continuity between terminal 2 and earth (2)NG
OK: Continuity NG
(3) Voltage between terminal 1 and earth
OK: System voltage Check the harness between the vehicle speed sensor and the
combination meter, and repair if necessary.
(3)NG
Check the following connectors: D-213, E-115, C-09 Check the following connectors: C-09
OK NG OK NG
Check the trouble symptoms. Repair Check the trouble symptoms. Repair
NG NG
Check the harness between the vehicle speed sensor and Check the harness between the vehicle speed sensor and
multipurpose fuse No. 13, and repair if necessary. body earth, and repair if necessary.
NOTE
If the trouble symptoms cannot be eliminated by the above checks, there is probably a short-circuit at
the vehicle speed sensor output side (harness, speedometer, engine-ECU or A/T-ECU), and so this should
be checked.
ON-VEHICLE SERVICE
SPEEDOMETER CHECK
1. Check that the tyre inflation pressure is at the value
indicated on the tyre pressure labels.
2. Place the vehicle onto a speedometer tester.
3. Place wheel locks on front wheels.
NOTE
Wheel chocks Set the vehicle to 2WD.
4. Install a puller to the towing hook and tie-down hook
a the front of the vehicle to stop the front wheels from
moving sideways, and secure both ends of the puller
Puller to anchor plates.
5. Connect a chain or wire cable to the rear towing hook
and secure the other end to a strong, rigid support, to
stop the vehicle from moving.
6. Check that the speedometer display range is within the
Front
standard value, and that the needle swing is within the
Anchor plate limit value.
Standard value:
Speed km/h 20 40 80 120 160
Speedometer 18 - 37 - 75 - 113 - 150 -
display range 23 45 88 132 176
km/h
TACHOMETER CHECK
Paper clip
1. Insert a paper clip into the harness-side engine speed
Engine tachometer detection terminal and connect an engine tachometer.
2. Compare the engine tachometer display and the vehicle
tachometer display at various engine speeds, and check
that the display errors are within the standard value
ranges.
Engine speed
detection terminal
Multimeter
ENGINE COOLANT TEMPERATURE GAUGE
UNIT CHECK
1. Drain the engine coolant. (Refer to GROUP 14 -
Thermometer On-vehicle Service.)
2. Remove the engine coolant temperature gauge unit.
3. Immerse the engine coolant temperature gauge unit in
water at a temperature of 70C and check that the basic
resistance is at within the standard value range.
Standard value: 104 13.5 W
11 1 Nm
Instrument panel
1 Clip
2
A
A A
INSPECTION
Vehicle VEHICLE SPEED SENSOR CHECK
Terminal No. speed 1. Jack up the vehicle.
sensor
2. Remove the vehicle speed sensor, and then connect a
3 - 10 kW resistance as shown in the illustration at left.
Resistance
3 - 10 kW 3. Use a multimeter to check the change in voltage between
terminals (2) and (3) when the propeller shaft is rotated
Multimeter (4 pulses per rotation).
Battery
5 4
10 8
7
9
11 6
2
1
Disassembly steps
1. Glass 9. Indicator lens
2. Window plate 10. Instrument panel printed circuit board
3. Speedometer 11. Replace the combination meter case
4. Tachometer 12. Indicator case
5. Fuel gauge and engine coolant 13. Combination plate A
temperature assembly 14. Combination plate B
6. Trip meter knob 15. Combination plate C
7. Indicator plate
8. Indicator prism
HEADLAMP ASSEMBLY
SERVICE SPECIFICATIONS
Item Standard value Limit
Headlamp emitter adjustment Low- Vertical 0.57 (10 mm) down from horizontal
[Cut-off line (light/dark boundary beam direction line H
line) position] Horizontal Position where 15 rising portion
direction intersects vertical line V
Headlamp illumination measurement cd 6,400 or higher
(Corresponding to road surface 40 m in front at low beam) for each lamp
SPECIAL TOOLS
Tools No. Name Application
MB991502 MUT-II sub as- Checking the ETACS-ECU input signals
sembly
TROUBLESHOOTING
The headlamps are controlled by the Smart Wiring System (SWS). For troubleshooting procedures, refer
to GROUP 54B.
ON-VEHICLE SERVICE
HEADLAMP AIMING ADJUSTMENT
After setting the vehicle to the following condition, adjust the
headlamp aiming.
D Check that the tyre inflation pressure is at the value
indicated on the tyre pressure labels.
D Set the vehicle to the unladen condition and park it on
a level surface.
D Have a single person (approximately 55 kg) sit in the
drivers seat.
Focusing-type
tester: 1 m
Centre of lamp
Horizontal direction 3. Turn the adjusting screws to adjust so that the deviation in
Vertical direction the centre of the high-luminance zone (main optical axis)
is at the standard value.
Standard value:
Vertical 0.57 _ (10 mm) down from horizontal line H
direction
Horizontal Position where 15 _ rising portion intersects
direction vertical line V
AX0699CA
Caution
(1) For the headlamp which is not being measured,
V disconnect that headlamps connector if possible
Centre of lamp
so that it does not illuminate while carrying out
the adjustment. Furthermore, make sure that the
light axis does not get shifted when re-connecting
H
the connector.
Vertical 15_ (2) The headlamps have outer lenses which are made
direction
of plastic, so if covering the lens surface with
High-lumi-
an object which does not let light pass through,
nance zone the headlamp should not be turned on for any
more than 3 minutes. In addition, do not mask
the outer lens surface by attaching tape or similar.
(3) The adjustment should always be completed by
turning the adjusting screws in the tightening
direction.
LUMINANCE MEASUREMENT
1. Place the tester receiver so that it is directly opposite
Focusing-type tester: 1 m the headlamp at the distance shown in the illustration.
2. Run the engine at a speed of 2000 r/min to fully charge
the battery.
3. Align with the centre of the lamp.
NOTE
Check that the light/dark separation line on the adjustment
screen and the low-beam cut-off line are aligned at this
time.
4. With the headlamps set to low beam, check that the
luminance satisfies the limit value.
Limit: 6,400 cd or higher for each lamp
HEADLAMP ASSEMBLY
REMOVAL AND INSTALLATION
2
3
4.9 0.7 Nm
4.9 0.7 Nm
4.9 0.7 Nm
1 AX0743CA
FOG LAMPS
SERVICE SPECIFICATIONS
Item Standard value
Fog lamp light axis check Illuminates to within 40 metres
SPECIAL TOOLS
Tools No. Name Application
MB991502 MUT-II sub Checking the ETACS-ECU input signals
assembly
TROUBLESHOOTING
The fog lamp are controlled by the Smart Wiring System (SWS). For troubleshooting procedures, refer
to GROUP 54B.
ON-VEHICLE SERVICE
FOG LAMP AIMING CHECK
After setting the vehicle to the following condition, adjust the
headlamp aiming.
D Check that the tyre inflation pressure is at the value
indicated on the tyre pressure labels.
D Set the vehicle to the unladen condition and park it on
a level surface.
D Have a single person (approximately 55 kg) sit in the
drivers seat.
Screen
3m
High-lumi-
nance zone
FOG LAMPS
REMOVAL AND INSTALLATION
5
4.9 0.7 Nm
INSPECTION
FOG LAMP SWITCH CONTINUITY CHECK
REAR
OFF
Front of
vehicle
ROOM LAMP
TROUBLESHOOTING
The room lamps are controlled by the Smart Wiring System (SWS). For troubleshooting procedures,
refer to GROUP 54B.
ON-VEHICLE SERVICE
ROOM LAMP DELAY-OFF TIME ADJUSTMENT PROCEDURE
The-room lamps are controlled by the Smart Wiring System (SWS). For room lamp delay-off time adjustment
procedures, refer to GROUP 54B.
TROUBLESHOOTING
Rear combination lamps are controlled by the Smart Wiring System (SWS). For troubleshooting procedures,
refer to GROUP 54B.
REAR COMBINATION LAMPS
REMOVAL AND INSTALLATION
10
11
11
9
3
9
3 5
2 6
8 4
3
1 6
7
Rear combination lamp removal Licence plate lamp removal steps
steps 9. Licence plate lamp
1. Rear combination lamp 10. Socket assembly
2. Socket assembly 11. Bulb
3. Bulb
Rear lamp removal steps
4. Rear lamp
5. Socket assembly
6. Bulb
7. Rear lamp bracket
8. Clip
4 4
2 2
Removal steps
1. High-mounted stop lamp cover 3. Socket assembly
2. High-mounted stop lamp body 4. Bulb
COLUMN SWITCH
SPECIAL TOOL
Tools No. Name Application
MB990784 Ornament remover Column cover removal
4 A
Section A - A Section B - B
2
3 2
Tab Tab
1
B 1
B
1
Removal steps
1. Lower column cover (Refer to GROUP 3. Wiper and washer switch
52A - Instrument Panel.) 4. Lighting switch
2. Upper column cover (Refer to GROUP
52A - Instrument Panel.)
2
3
Removal steps
1. Center panel (Refer to GROUP 52A - Instrument Panel.)
2. Bracket
3. Hazard Warning Lamp Switch
ON
HORN
INSPECTION
HORN RELAY CONTINUITY CHECK
04Z0001
CIGARETTE LIGHTER
Spot
INSPECTION
Element
D Remove the plug and check the spot for wear.
D Check that there are no tobacco stains or foreign particles
on the element.
D Use a multimeter to check the continuity of the element.
ACCESSORY SOCKET
INSPECTION
ACCESSORY SOCKET RELAY CONTINUITY CHECK
04Z0001
RHEOSTAT
INSPECTION
1. Connect a test lamp (40 W) to the battery as shown
in the illustration.
2. Operate the rheostat. If the luminance of the lamp changes
steadily with no flashing, the rheostat is functioning
normally.
DU-435-1
DU-435-2
Petrol-powered vehicles
A button
Diesel-powered vehicles
A button
Clock set on display Current time Retains data for approx. 1 hour
Vehicle model set Short (3-door models)/long (5-door Retains data for approx. 1 hour
models)
Brightness set for display Position set on display Retains data for approx. 1 hour
Unit set for trip computer km or mile, L/100km or mpg or km/L Retains data for approx. 1 hour
Average vehicle speed after reset
Average vehicle speed on display Average vehicle speed after reset Retains data for approx. 1 hour
Average fuel consumption on display Average fuel consumption after reset Retains data for approx. 1 hour
Cruising range on display Cruising range, fuel economy Retains data for approx. 1 hour
Outside temperature on display Outside temperature after the ignition Retains data for approx. 1 hour
switch is turned to the OFF(LOCK) * The outside temperature sensor
position. is located near the engine.
Therefore, incorrectly high
temperature may be displayed
when the battery cable is
reconnected within one hour.
1. Check of vehicle information The vehicle, short (3-door models)/long (5-door models) set
2. Check of LCD segments The LCD segments for display available to light on or not
3. Check of sensors Outside temperature, voltage of fuel gauge unit, system voltage, fuel amount
remains, fuel economy calculated after supply of fuel
When the SET button is pushed on this screen, the unit proceeds to the next service mode, Check
of LCD segments.
2. Check of LCD segments
This service mode consists of 6 display screens; the screen where all segments are illuminated,
the screen where all segments are extinguished, and four kind of screens where 1/4 of segments
are illuminated. Each screen can be changed sequentially when pushing on the SET button.
When the SET button is pushed on this screen six times, the unit proceeds to the next service
mode, Check of Sensors.
Petrol-powered vehicles
80 - 0.3
70 - 0.7
60 0.4 0.9
50 0.8 1.2
40 1.2 1.5
30 1.6 1.9
20 2.0 2.3
10 2.5 2.7
5 2.8 2.9
0 3.0 3.1
The remained fuel amount, which is displayed on the screen, is less than the actual amount. This will
give the vehicle an extra amount of 5-Litre fuel in case of shortage of gasoline. Moreover, the fuel remaining
under the fuel gauge unit (pump) cannot be sucked. Therefore, there is more than 5 Litre difference
between the actual remaining fuel amount and the displayed amount of fuel.
When the SET button is pushed on this screen, the unit proceeds to the next service mode, Check
of Unit connected Sensors.
When the SET button is pushed on this screen, the unit returns to the first screen, Check of Vehicle
Information.
Terminal Input/ Signal symbol Terminal Wiring harness Trouble symptom caused by wiring
No. Output voltage (V) problem harness problem
Open Short
circuit circuit
1-4 - - - - -
5 Input ISOK Hi: System Exists Exists MUT-II cannot be used to check the
voltage engine-ECU.
Lo: 0-1
6 - - - - -
7 Input/ M-DATA Hi: 4-5 Exists Exists Audio display does not appear. Panel
Output (AUDIO) Lo: 0-1 switch cannot be operated for audio unit.
Nighttime illumination does not appear for
audio unit.
8 Input/ M-CLOCK Hi: 4-5 Exists Exists Audio display does not appear. Panel
Output (AUDIO) Lo: 0-1 switch cannot be operated for audio unit.
Nighttime illumination does not appear for
audio unit.
9 Input/ M-DATA Hi: 4-5 Exists Exists A/C display does not appear.
Output (A/C) Lo: 0-1 Outside air temperature does not appear
10 Input/ M-CLOCK Hi: 4-5 Exists Exists A/C display does not appear.
Output (AUDIO) Lo: 0-1 Outside air temperature does not appear
11-14 - - - - - -
Terminal Input/ Signal symbol Terminal Wiring harness Trouble symptom caused by wiring
No. Output voltage (V) problem harness problem
Open Short
circuit circuit
15 Input/ K Hi: System Exists Exists Values on trip information screen (average
Output voltage vehicle speed, fuel consumption and
Lo: 0-1 cruising distance) are abnormal. Commu-
nication is impossible between the
engine-ECU and the MUT-II.
16 - - - - - -
17 Input/ M-BUSY Hi: 4-5 Exists Exists Audio display does not appear. Panel
Output (AUDIO) Lo: 0-1 switch cannot be operated for audio unit.
Nighttime illumination does not appear for
audio unit.
18 - SHIELD-GND - - - -
19 Input/ M-BUSY Hi: 4-5 Exists Exists A/C display does not appear.
Output (A/C) Lo: 0-1 Outside air temperature does not appear
20 - SHIELD-GND - - - -
21, 22 - - - - - -
23 Input EX-TEMP Exists Exists Outside air temperature does not appear.
24 Input ILL+ Hi: System Exists - Nighttime illumination does not appear for
voltage audio units.
Lo: 0-1
- Exists Blown multipurpose fuse.
25 Input ACC (ACC System volt- Exists - Screen display does not appear.
power supply) age
- Exists Blown multipurpose fuse.
27 Input VSS Hi: System Exists Exists Abnormal outside air temperature ap-
voltage pears.
Lo: 0-1 (only diesel-powered vehicles)
29, 30 - - - - - -
32 Input ILL- Exists Exists The display screen can not be dimmed.
34, 35 - - - - - -
Malfunction of center No display appears after the ignition key is turned to the 1 54A-62
display, related sen- ACC position.
sors, and wiring har-
nesses Outside air temperature does not appear or abnormal 2 54A-62
outside air temperature appears.
INSPECTION PROCEDURE 1
No display appears after the ignition key is turn to the ACC position.
NG
Check the following connector: D-03 Repair
OK
NG
Measure voltages between D-03 display connector terminal (25), Repair the fuse and wiring harness.
(26) voltage and earth.
D Ignition switch: ACC
OK: System voltage
OK
NG
Measure resistance between D-03 display connector terminal (28) Repair the wiring harness.
and earth.
OK: approx. 0 W
OK
INSPECTION PROCEDURE 2
Outside air temperature does not appear or abnormal outside air temperature appears.
<Vehicles without automatic air conditioner system>
NG
Check the following connector: D-03 Repair.
OK
YES YES
Is a correct outside air temperature dis- Is a correct vehicle speed displayed in End (no abnormality).
played in the service mode? the service mode?
NO NO
Go to inspection procedure 3.
OK OK
Check the wiring harness between the Replace the center display unit. End
Center Display and the outside air tem- NG
perature sensor.
NG Replace the outside air temperature
sensor.
Check the wiring harness between the
center display unit and the outside air
temperature sensor, and replace if nec-
essary.
NOTE: It is necessary to drive for a while and get accurate temperature in display if you pass a area
in which temperature is much different. It might show high temperature on display in case it is high
around sensor due to high temperature of engine after battery is exchanged, or a display unit is reinstalled.
NG
Measure at center display unit connec- Check the wiring harness between the
tor D-03. center display unit and the junction
D Disconnect the connector. block, and repair if necessary.
D Voltage between terminal 36 and
body earth.
OK: (Ignition switch: ON)
System voltage.
(Ignition switch: OFF)
0 - 1V
OK
OK
Check the connections between the Replace the center display unit.
center display unit and the engine-ECU.
NG
<Diesel-powered vehicles>
NG
Measure at center display unit connector D-03. Check the wiring harness between the center display unit and
D Disconnect the connector. the junction block, and repair if necessary.
D Voltage between terminal 36 and body earth.
OK: (Ignition switch: ON) System voltage.
(Ignition switch: OFF) 0 - 1 V
OK
NG
Measure at center display unit connector D-03 . Check the wiring harness between the center display unit and
D Disconnect the connector. the vehicle speed sensor, and repair if necessary.
D Voltage between terminal 27 and body earth.
OK: HI: System voltage.
Lo: 0 - 1V
OK
INSPECTION PROCEDURE 4
Abnormal driving data are displayed:
D Abnormal average fuel consumption (momentary fuel consumption) and average vehicle speed
D Abnormal cruising distance
NO
Are the average fuel consumption and average vehicle speed dis- Go to inspection procedure 3.1.
play correctly?
YES
NO
Does the vehicle information on displayed on the screen meet Replace the center display unit.
with the actual vehicle?
Is the vehicle type (long or short body) recognized correctly?
(Select Check of units connected into the center display and
Check of vehicle information on the service mode.)
YES
YES
Is remained fuel amount displayed correctly on service mode? End (no abnormality).
NO
NG
Measure at center display unit connector D-03. Check the wiring harness between center display unit and the
D Disconnect the connector. fuel gauge unit, and repair if necessary. (relevant units: Combination
D Voltage between terminal 33 and body earth. meter, fuel gauge unit)
OK: 0.1 - 3 V
OK
NOTE
(1) If the remained fuel amount is so small that the fuel gauge unit can not detect a correct amount,
incorrect cruising range may be displayed.
(2) Fuel consumption is updated each time fuel is supplied. Furthermore, the cruising range depends
on road and driving conditions.
INSPECTION PROCEDURE 5
Clock runs fast or slow.
NG
Measure at center display unit connec- Repair the fuse and wiring harness.
tor D-03.
D Ignition switch: OFF
D Voltage between terminal 26 and
body earth.
OK: System voltage
OK
YES YES
Is the symbol CT displayed? Does it receive a radio station on differ- Turn off the CT function.
NO ent region where has time lag?
NO
INSPECTION PROCEDURE 7
Air conditioning display is not available.
NG
Measure at center display unit connec- Check the wiring harness between the
tor D-03. center display unit and the junction
D Disconnect the connector. block, and repair if necessary.
D Voltage between terminal 36 and
body earth.
OK: System voltage (Ignition
switch: ON)
0 - 1 V (Ignition switch:
OFF)
OK
NO OK
Select Check of units connected into Check the reoccurrence of symptom. Check the audio unit.
the center display on the service mode. NG
Does the symbol AU appear?
YES
NG
Check the the wiring harnesses: Repair wiring harness.
D Between the center display and
A/C-ECU D-04, D-49
D Between the center display and
AUDIO D-04, D-49
OK
OK
Measure at center display unit connec- Replace the center display unit.
tor D-04.
D Disconnect the connector.
D Voltage between terminal 9 and
body earth.
D Voltage between terminal 10 and
body earth.
D Voltage between terminal 19 and
body earth.
OK: Hi : 4 5V
Lo : 0 1V
NG
NO
MUT-II Self-Diag code Replace the A/C-ECU.
Is the diagnosis code for A/C set?
YES
OK
Refer to GROUP 55 - A/C troubleshoot- Check the reoccurrence of symptom. END
ing. NG
3 4
Removal steps
1. Center panel
(Refer to GROUP 52A - Instrument Panel.)
2. Clock
3. Center display
4. Bracket
RADIO/TAPE PLAYER
TROUBLESHOOTING
QUICK-REFERENCE TROUBLESHOOTING CHART
Items Problem symptom Relevant chart
No sound. C-2
NO YES
Is there a particular structure? Do the following measures eliminate OK
the noise?
YES
1. Change to a different station with
a strong signal to boost
Find out the following information resistance to interference.
2. Suppress high tones to reduce
from the user:
noise.
1. Place 3. Extend antenna completely.
2. Locality conditions (valley,
mountain, etc.) NO
3. Name and frequency of stations
affected by noise
The following factors can be considered as possible and a change to a different station or the
causes of noise appearing at night. appearance of a beating sound* may occur.
1. Factors due to signal conditions: Due to the Beat sound*: Two signals close in frequency
fact that long-distance signals are more easily interfere with each other, creating a repetitious
received at night, even stations that are high-pitched sound. This sound is generated
received without problem during the day may not only by sound signals but by electrical
experience interference in a general worsening waves as well.
of reception conditions. The weaker a station 2. Factors due to vehicle noise: Alternator noise
is the more susceptible it is to interference, may be a cause.
NO
Is the noise still obvious even with
the lamps OFF?
YES
YES
Do the following measures eliminate OK
the noise?
D Tune to a station with a strong
signal.
D Tune to a station with a strong YES
signal without completely Does the noise fade away when the OK
extending the antenna. vehicle harness is moved away from
the radio chassis? (if the harness is
NO not in the proper position.)
NO
(1) (2)
Noise occurs when the engine is stopped. Noise occurs when the engine in running.
YES
Do the following measures eliminate the noise? Inspect the vehicles noise suppressor. (Refer to A-4.)
D Tune to a station with a strong signal. YES
D Extend the antenna completely. OK
D Adjust the sound quality to suppress high tones.
NO
NO
Is the radio body earth mounted securely? Securely tighten the nuts for the
body earth.
YES
NO
Is the antenna plug properly connected to the radio? Correctly attach the antenna plug.
YES
NO
Is the antenna itself in good condition or is it properly Clean the antenna plug and earth
mounted? wire mounting area. Mount the anten-
na securely.
YES
YES
Is the noise eliminated? OK
NO
UKW/MW/LW: D Increasing the engine speed D Mainly due to the spark D Check or replace the
Ignition noise causing the popping sound to plugs. earth cable. (Refer to
(Popping, snap- speed up, and volume D Due to the engine noise. Fig. 1, 2, 3 and 4 on
ping, cracking, decreases. P.54-58 and 54-59.)
buzzing) D Disappears when the ignition D Check or replace the
switch is turned to ACC. noise capacitor.
Static electricity D Disappears when the vehicle Occurs when parts or wiring Return parts or wiring to
(Cracking, crin- is completely stopped. move for some reason and their proper position.
kling) D Severe when the clutch is contact metal parts of the
engaged. body.
D Various noises are produced Due to detachment from the Tighten the mounting bolts
depending on the body part of body of the front hood, securely. Cases where the
the vehicle. bumpers, exhaust pipe and problem is not eliminated by
muffler, suspension, etc. a single response to one
area are common, due to
several body parts being
imperfectly earthed.
Earth cable
Earth cable
Earth cable
Earth cable
A-5 Some noise appears when there is vibration or shocks during travelling.
NO
Are connectors properly connected? Ensure proper connection.
YES
NO
Does noise appear when the radio switch is turned on while Static electricity noise:
the vehicle is stopped and the radio is struck while tuned Body static electric from the shock absorber rubber bushings
away from a station? used to prevent vibration, tyres, etc. occurs because of sepa-
ration from the earth, causing a buzzing noise. Since no mea-
YES sures can be taken on the radio side, other steps should be
taken to discharge the static electricity of the vehicle body.
NO
Is the radio correctly earthed? (Is the mounting screw tight- Tighten the screw securely.
ened securely?)
YES
NO
Is the antenna correctly earthed? (If noise appears when the If rust is present at the antenna earth screw, clean and tighten
antenna is moved, this means the earth is not securely con- the earth securely.
nected.)
YES
Noise is often created by the following factors, and For this reason, if there are still problems with noise
often the radio is OK when it is checked individually. even after the measures described in steps A-1
D Travelling conditions of the vehicle to A-8 have been taken, get information on the
D Terrain of area travelled through factors listed above as well as determining whether
D Surrounding buildings the problem occurs with UKW/MW/LW, the station
D Signal conditions names, frequencies, etc., and contact a service
D Time period centre.
B. RADIO
B-1 No power is supplied when the switch is set to ON.
YES
Is dedicated fuse No. 6 blown or is the circuit open? Replace fuse or repair harness.
NO
NO
Is the connector at the back of the radio connected properly? Connect connector securely.
YES
NO
Disconnect and check the connector at the rear of the radio. Repair harness.
Is the ACC power (12 V) being supplied to the radio?
YES
YES
Check to see if there is any sound Repair or replace radio.
when attached to another radio.
NO
YES
Remove the connector on the back It conducts electricity but is shorted Repair speaker harness.
of the radio and check the speaker out.
harness for conductance.
NO
YES
Check the speaker for conductance. Repair speaker harness and ensure
proper connection of relay connec-
NO
tors.
Repair or replace speaker.
YES
Is the check being conducted under
special electrical field conditions?
NO Example: In an under-
ground garage or inside a
building.
YES
Is proper performance obtained when OK
the vehicle is moved?
NO
YES
Does tuning solve the problem? OK
NO
NO
Are the antenna plug and radio unit properly con- Reconnect
nected?
YES
YES
Does the problem disappear if connected to another Repair or replace radio.
radio?
NO
YES
Is the check being conducted under
special electrical field conditions?
NO Example: In an under-
ground garage or inside a
building.
YES
Is proper performance obtained when OK
the vehicle is moved?
NO
YES
Does tuning solve the problem? OK
NO
YES
Is the problem limited to the reception of a specific Electrical field condition related
radio station from a specific position?
NO
NO
Is the antenna plug properly connected to the unit? Ensure proper connection.
YES
YES
Does the problem disappear when a different radio is Repair or replace radio.
connected?
NO
Occasional YES
How much distortion is there? Distortion in the vicinity of the radio Excessive antenna input
station
Constant
NO
YES
Are the speaker cords in contact with the cone paper? Remove cords away from cone paper.
NO
YES
Remove the speakers and check for torn cone paper or for- Repair or replace speakers.
eign objects.
NO
YES
Check for deformation with speaker installed. Install speaker securely.
NO
YES
Is the check being conducted under
special electrical field conditions?
NO Example: In an under-
ground garage or inside a
building
YES
Is proper performance obtained when OK
the vehicle is moved?
NO
NO
Is the antenna plug properly connected to the equip- Ensure proper connection.
ment?
YES
YES
Does the equipment work properly if the radio is Repair or replace radio.
changed?
NO
YES
Is dedicated fuse No. 5 blown or is the circuit open? Replace fuse or repair harness.
NO
NO
Disconnect and check the connector at the rear of the radio. Repair harness.
Is the memory backup (battery) power being supplied?
YES
C. TAPE PLAYER
C-1 Cassette tape will not be inserted.
YES
Are there any foreign objects in the tape player? Remove the object(s)*1 .
NO
*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
Does the tape player work if another tape is inserted? Replace tape*2 .
NO
*2
Repair or replace tape player. 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
Is dedicated fuse No. 6 blown or is the circuit open? Replace fuse or repair harness.
NO
NO
Is connector at rear of radio connected tightly? Connect connector firmly.
YES
YES
Disconnect connector at rear of radio. Is ACC power being Repair or replace tape player.
supplied to the radio?
NO
Repair harness.
YES
Clean the tape player head and check again. OK
NO
YES
Replace the tape player and check again. Repair or replace tape player.
NO
YES
Remove the connector on the back of the radio and It conducts electricity but is Repair harness.
check the speaker harness for conductance. shorted out.
NO
YES
Check the speaker for conductance. Repair harness.
NO
YES
Does the player play properly when another tape* is inserted? OK
NO *:
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
Does the player play properly when the tape player head is cleaned? OK
NO
YES
Is proper operation obtained when the tape player is replaced? Repair or replace tape player.
NO
Repair or replace speaker.
The problems covered here are all the result of also possible, and attempting to force the tape out
the use of a bad tape (deformed or not properly of the player can cause damage to the mechanism.
tightened) or of a malfunction of the tape player The player should be taken to a service dealer
itself. Malfunctions involving the tape becoming for repair.
caught in the mechanism and ruining the case are
YES
Does the player play OK if the tape*1 is changed? OK
NO
*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
Are there any foreign objects *2 inside the tape player? Remove foreign object(s).
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 dirty? (Refer to the illustration below.) Clean.
NO
Repair or replace tape player.
YES
Does the player play OK if the tape* is changed? OK
NO *:
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
Does the problem only occur while the vehicle is being driven? Repair or replace tape player.
YES
NO
Is the tape player properly installed to the vehicle? Ensure tape player installation.
YES
Repair or replace tape player.
*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.
YES
Does the player play OK if the tape*2 is changed? Tape used is bad.
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.
2
3
FRONT SPEAKERS
REMOVAL AND INSTALLATION
2
1
4 3
REAR SPEAKERS
REMOVAL AND INSTALLATION
<Short wheelbase> <Long wheelbase>
3
1 4 3
Removal steps
1. Lower quarter trim (Refer to GROUP
52A - Instrument Panel.)
2. Rear door trim (Refer to GROUP 52A
- Instrument Panel.)
3. Rear speakers
4. Rear speaker bracket
ANTENNA
REMOVAL AND INSTALLATION
<VEHICLES WITH MAST ANTENNA> <VEHICLES WITH MOTOR ANTENNA>
4
5 7
6 8
1 1
2
2
Caution
Ensure that the cord is wrapped tightly to prevent
it from coming off.
4. Pull out the base antenna assembly slowly to remove.
Cord
INSPECTION
MOTOR ANTENNA CHECK
Check the antenna for extension if the connector of the motor
antenna-ECU is disconnected, the (+) terminal of the battery
is connected to terminal No.1, and the ( - ) terminal of the
battery is connected to terminal No. 2. Check the antenna
for retraction if the connection is reversed.
Ring nut
Rack cable
Rack cable
DEFOGGER
TROUBLESHOOTING <VEHICLE WITH
AUTOMATIC AIR CONDITIONER>
Refer to GROUP 55B.
04Z0001
00009068
INSPECTION
DEFOGGER SWITCH CONTINUITY CHECK
Check the battery voltage between terminal 3 and 10 while
being energized.
Switch position Terminal No.
3 10 - 11 12
OFF IND
Battery ON IND
NOTE
Defogger switch After turning the defogger switch to the ON position, check
the continuity between terminal 3 and 12 for 9 to 13 minutes.
Afterwards, the switch is turned to the OFF position.
Service Bulletins
Click on the applicable bookmark to select the Service Bulletin.
CORRECTION INTERNATIONAL
CAR
ADMINISTRATION T.NITTA - PROJECT LEADER
OFFICE AFTER SALES SERVICE & CS PROMOTION
1. Description:
This Service Bulletin informs you that correction has been made of errors in the illustration for
headlamp aiming adjustment.
2. Applicable Manuals:
Manual Pub. No. Language Page(s)
2001 PAJERO PWJE0001 (2/2) (English) 54A-38
Workshop Manual VOL.2
2001 MONTERO PWJS0002 (2/2) (Spanish)
Workshop Manual VOL.2
Standard value:
Vertical 0.57 (10 mm) sown from horizontal
direction line H
Horizontal Position where 15 rising portion
AX0699CA direction intersects vertical line V
Caution
Centre of lamp (1) For the headlamp which is not being measured,
disconnect that headlamps connector if possible
so that it does not illuminate while carrying out
Vertical the adjustment. Furthermore, make sure that the
direction
light axis does not get shifted when re-
High-luminance connecting the connector.
zone (2) The headlamp have outer lenses which are made
A16WO257 of plastic, so if covering the lens surface with the
headlamp should not be turned on for any more
than 3 minutes. In addition, do not mask the outer
lens surface by attaching tape or similar.
(3) The adjustment should always be completed by
turning the adjustment screws in the tightening
direction.
Vertical Horizontal
direction direction
<Correct> <Correct>
LUMINANCE MEASUREMENT
Focusing-type tester: 1m
1. Place the tester receiver so that it is directly opposite the
headlamp at the distance shown in the illustration.
2. Run the engine at a speed of 2000 r/min to fully charge
the battery.
3. Align with the centre of the lamp.
NOTE
16Z0015
Check that the light/dark separation line on the
adjustment screen and the low-beam cut-off line are
aligned at this time
4. With the headlamps set to low beam, check that the
luminance satisfies the limit value.
Limit: 6,400 cd or higher for each lamp
CHASSIS
ELECTRICAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Outline of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
RV METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Construction Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 3
RV meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . . . . 5
GLASS ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . 24
COMBINATION METER . . . . . . . . . . . . . . . . . . . . . 5 Antenna feeder cable . . . . . . . . . . . . . . . . . . . . . . . . 24
GENERAL INFORMATION
The RV meter, which displays various vehicle information has been used for some models.
By operating each function switch, including ADJ and DISP switches, driving information screen,
A/C information screen, environment information screen, clock information screen, and audio screen
can be called up.
RV meter RV meter
Geomagnetic Barometric air
sensor pressure sensor
Display screen
120mm x 36mm
Function
switch 1 DISP
The driving information screen displays the average The screen displays set temperature, fan air mass,
vehicle speed, average fuel efficiency, and possible rear defogger operation, compressor operation,
travel distance based on the information derived front defroster operation, and inside and outside
from the engine-ECU and the fuel gauge unit. air mode.
The environment information screen displays Digitally displayed clock and date are featured.
ambient temperature, direction, altitude, and When the function switch 3 on the clock display
barometric air pressure. If the ambient temperature screen is pressed for 3 seconds or longer, the time
is 3_C or lower when starting the vehicle, a frozen adjustment screen can be called up.
marking blinks and an alarm sound warns a driver.
AUDIO INFORMATION
CONSTRUCTION DIAGRAM
This system:
1. receives A/C information, such as ambient temperature sensor from the A/C-ECU and audio information
from the audio system through M-BUS.
2. receives information regarding buzzer sound and ignition switch position recognition from the RV
meter through SWS communication.
3. receives the vehicle speed data from the engine-ECU to calculate the average vehicle speed. Moreover,
this system receives the fuel injection amount data to calculate the average fuel efficiency and possible
travel distance.
4. calculates the direction of a vehicle by using the geomagnetic sensor.
5 calculates the outside air temperature by using the ambient temperature sensor.
6. measures the ambient pressure by using the barometric air pressure sensor to calculate the altitude
based on the information.
7. obtains information on remaining fuel amount required for calculating the possible travel distance
by using the fuel gauge unit.
1
Diagnosis connector
COMBINATION METER
TROUBLESHOOTING
INSPECTION PROCEDURES FOR TROUBLE SYMPTOM
Speedometer inoperative (other meters are operated) Probable cause
Failure may occur on vehicle speed sensor, harnesses, connectors, meter D Malfunction of vehicle speed sensor
assembly. D Malfunction of vehicle harness or connector
D Malfunction of combination meter
YES
MUT-II Self-Diag. Code Vehicle speed sensor circuit check
Is diagnostic code P0500 for MPI output?
NO
NG
Repair
NOTE
When vehicle speed signal is checked with MUT-II in the ETACS-ECU input signal test, drive the vehicle
with MUT-II connected to diagnostic connector. When the buzzer sounds, this test is evaluated OK.
Function
switch 1 DISP
Function
switch 2 Function switch 3 ADJ
AUTOMATIC MODE
1. When function switch 1 (AUTO) is pressed at the 1st menu
of the service mode screen, the mode is switched to
automatic checking mode.
At this time, a display will appear to prompt you to turn the
ignition switch to the ON position.
2. When the ignition switch is turned to the ON position,
communication and wiring check is carried out.
NOTE
For diesel vehicles, E2 is normally displayed for
Engine-ECU. (meaning that it is not connected)
DIAGNOSIS MODE
1. From the 1st menu of the service mode screen, press
function switch 2 (DIAG) to display diagnosis mode.
2. The following displays appear when the various function
switches are pressed.
NOTE
For diesel vehicles, E2 is normally displayed for
Engine-ECU. (meaning that it is not connected)
Termi- Input/out-
p Signal
g sym-
y Terminal Harness problem Trouble symptoms
y p when there is a
nal No. putt b l
bol voltage
lt Open short-cir- h
harness problem
bl
(V)
circuit cuit
4-1
5 Input ISOK (MUT- Hi:System Exists Exists Communication between the
II data sig- voltage MUT-II and the engine-ECU
nal) Lo:0 - 1 <Diesel vehicles> or engine-
A/T-ECU <petrol vehicles> is not
possible.
6 Input/out- DATA Hi:System Exists Exists D Switch operating sound (buzzer)
put (ETACS voltage does not sound.
SWS data Lo:0 - 1 D Daytime/nighttime mode does
signal) not change in conjunction with
the tail gate lamps.
D Indicators (buttons, illumination
panel) do not illuminate.
7 Input/out- M-DATA(AU- Hi:4 - 5 Exists Exists D Audio information does not
put DIO) Lo:0 - 1 appear on the screen.
(M-BUS data
signal)
8 Input/out- M- Hi:4 - 5 Exists Exists D Audio information does not
put CLOCK(AU- Lo:0 - 1 appear on the screen.
DIO)
M-BUS (C
(
lock signal)
9 Input/out- M- Hi:4 - 5 Exists Exists D Air conditioner information does
put DATA(A/C) Lo:0 - 1 not appear on the screen.
(M-BUS data D Ambient temperature is not
signal) displayed.
10 Input/out- M- Hi:4 - 5 Exists Exists D Air conditioner information does
put CLOCK(A/C) Lo:0 - 1 not appear on the screen.
M-BUS (C
( D Ambient temperature is not
lock signal) displayed.
NG
Check the following connectors: Repair
<L.H.drive vehicles> D-27, D-223, D-31, D-39
<R.H.drive vehicles> D- 27, D- 33, D- 39
OK
NG
Check the trouble symptoms. Replace the RV meter.
Inspection procedure 2
System voltage abnormality screen appears.
NO
Does the voltage abnormality screen appear immediately End
after the ignition switch is turned to the ACC position?
YES
OK
Measure at RV meter connector D-39. Malfunction of RV meter voltage judgment circuit
D Connector disconnected
D Voltage between terminal (25) and body earth
OK: System voltage
Replace the RV meter.
NG
Carry out a service function wiring NG Check the harness between the RV
check. meter and the ETACS-ECU, and repair if
Is the SWS signal normal? necessary.
OK
NG
Measure at RV meter connector D-39. Replace the RV meter.
D Connector disconnected
D Voltage between terminal (27) and
body earth
OK: Hi: System voltage
Lo: 0 - 1 V
OK
OK
Carry out a geomagnetic sensor End (NO abnormality)
mode check in service mode.
NG
NO YES
Does the location have stable Is operation normal when the vehicle End (NO abnormality)
geomagnetism? is moved to a location with stable
geomagnetism?
YES
NO
YES YES
Is a carrier antenna with a magnet Does operation return to normal End (NO abnormality)
installed to the vehicle, or is there a when the magnet or metal is
magnet or other metal near the RV removed?
meter?
NG
NO OK
Carry out a geomagnetic sensor End (NO abnormality)
mode check in service mode. Does
operation return to normal if
degaussing or calibration is carried
out?
NO
Replace the RV meter.
Carry out an altitude calibration mode check in service OK End (No abnormality)
mode.
NG
Inspection procedure 6
Air conditioner information does not display normally.
Carry out a service function (1) Measure the wave pattern at RV meter OK Replace the RV meter.
communication and wiring check. One connector D-40.
of the following M-BUS outputs will D Connector disconnected
appear. D Voltage between terminal (9) and
(1) E1 (Communication error) body earth
(2) E2 (Open circuit or short-circuit) D Voltage between terminal (10) and
(3) OK body earth
D Voltage between terminal (19) and
(3) (2) body earth
OK: Hi: 4 - 5 V
Lo: 0 - 1 V
NG
Check the following
connectors: D-40, D-131 NG
Measure the wave pattern at A/C-ECU Malfunction of A/C-ECU
NG connector D-131.
OK D Connector disconnected
D Voltage between terminal (6) and
Repair body earth
D Voltage between terminal (16) and
body earth
Check the harness between D Voltage between terminal (17) and
the RV meter and the body earth
A/C-ECU, and repair if OK: Hi: 4 - 5 V
necessary. Lo: 0 - 1 V
OK
NO
MUT-II Self-diag code Replace the RV meter.
Is A/C diagnosis code output?
YES
Carry out a service function (1) Measure the wave pattern at RV meter OK
Replace the RV meter.
communication and wiring check. One connector D-40.
of the following M-BUS outputs will D Connector disconnected
appear. D Voltage between terminal (7) and
(1) E1 (Communication error) body earth
(2) E2 (Open circuit or short-circuit) D Voltage between terminal (8) and
(3) OK body earth
D Voltage between terminal (17) and
(3) (2) body earth
OK: Hi: 4 - 5 V
Lo: 0 - 1 V
NG
NOTE:
The contents of error messages shown in the audio display screen are as follows:
Error message Location and cause of malfunction
EJECT A magazine for CD changer is not inserted.
NO DISC CD is not inserted.
ERROR 001 Program error in audio
ERROR 002 Error in CD disk
ERROR 003 Mechanical error in audio system
ERROR 004 Communication error in audio system and RV meter, power supply error in audio
system, and other errors
ERROR HOT Heat protection for audio system
3
2
Removal steps
1. Center panel
(Refer to GROUP 52A - Instrument Panel.)
2. RV meter
3. Bracket
Removal steps
D Cowl side trim, front pillar, center pillar
trim, quarter trim (Refer to GROUP 1. Antenna feeder cable
52A.) D Instrument Panel
D Head lining (Refer to GROUP 52A)
2. Cable band
SMART WIRING
SYSTEM (SWS)
Click on the applicable bookmark to selected the required model year.
SMART WIRING
SYSTEM (SWS)
CONTENTS
GENERAL INFORMATION
COMMUNICATION LINE
Data lines for multiplex communication are connected between the front-ECU, ETACS-ECU, column switch
assembly, sunroof motor assembly, center display, power window main switch, and power window motors
as illustrated below.
ETACS-ECU MUT-II
NOTE
: Uni-directional communication line
: Bi-directional communication line
*1: Vehicles with center display
*2: Vehicles with sunroof
OPERATION
BUZZER
Light Reminder Warning Buzzer Function function. In addition, the ignition key reminder
When the drivers door is opened with lighting switch warning buzzer function has a priority over this
in the ON (tail lamp switch or headlamp switch) function.
position and ignition switch in the LOCK (OFF) or Center Display Operation Annunciation
ACC position, the buzzer will sound continuously to Function <Vehicles with Center Display>
remind the driver that the lamps (tail lamps or On vehicles with center display, the buzzer (peeps)
headlamps) are ON. sounds when the operation switch of the audio
This function does not work if the lighting switched and navigation system is pressed.
off through the headlamp automatic shutdown
CENTRAL DOOR LOCKING SYSTEM <Vehicles with Central Door Locking System>
Central Door Locking System Operation Forgotten Key Prevention Function
When the lock switch is turned ON after the unlock If, with the key reminder switch OFF and the drivers
switch on the drivers door lock actuator switch door switch ON, the drivers door lock switch is
is OFF, the ETACS-ECU gives a lock output for turned ON after the door unlock switch in the front
0.5 second. When the unlock switch is turned ON door lock actuator is turned OFF, the ETACS-ECU
after the lock switch on the drivers door lock waits 0.3 second then give an unlock relay output
actuator switch is OFF, the ETACS-ECU gives an for 0.5 second, there by preventing the doors from
unlock output for 0.5 second. being locked. This operation prevents the ignition
When the front passengers door key or back door key from being locked inside the vehicle. This
key is operated, the ETACS-ECU gives a lock or function takes precedence over the central door
unlock output for 0.5 second. locking control function.
REAR WIPER AND WASHER <Vehicles with Rear Wiper and Washer>
Rear Wiper Operation Rear Washer Operation
If the rear wiper switch is turned to the ON position If the rear washer switch is turned to the ON position
with the ignition switch at ACC or ON position, with the ignition switch at ACC or ON position,
the ETACS-ECU turns ON the rear wiper drive signal the rear washer ON signal is sent to the
for three seconds (approx. two operations). 7.4 ETACS-ECU, causing the rear wiper signal to turn
seconds later, the wiper begins the intermittent on after 0.3 seconds. After the rear washer switch
operation with 8 seconds cycle. signal turns off, the rear wiper signal turns off in
If the shift lever <M/T> or selector lever <A/T> is three seconds.
moved to the R position when the rear wiper switch If the rear wiper is in intermittent operation when
is turned to the ON position and the ignition switch the rear washer switch is turned ON, the rear wiper
at ACC or ON position, back-up lamp switch <M/T> again continues the intermittent operation with 8
or inhibitor switch R <A/T> turns ON. One second seconds cycle from 7.4 seconds later since the
later, the ETACS-ECU turns ON the rear wiper drive rear drive signal is turned OFF.
signal for three seconds (approx. two operations)
to clear the rear field of view. 7.4 seconds later,
the wiper returns to the intermittent operation with
8 seconds cycle.
FLASHER TIMER
Turn-signal Lamp Hazard Warning Lamp
When the ignition switch is turned to ON position The system detects a change from ON to OFF
and turn-signal lamp switch is placed in the ON of the hazard lamp input signal and activates the
position for right or left turn signaling, the system hazard lamps if they are not in operation or
generates turn-signal lamp drive signals (flashing deactivates the lamps if they are operating (reversal
signals). of state between activation and deactivation).
The system also notifies of a blown turn-signal lamp
bulb by shortening the flashing intervals of the
corresponding indicator lamp.
A
MB991223 Harness set Measurement of terminal voltage at ECUs
A: MB991219 A: Test harness A: Connector pin contact pressure inspec-
B: MB991220 B: LED harness tion
C: MB991221 B: Power circuit inspection
D: MB991222 C: LED harness
adapter C: Power circuit inspection
B
D: Probe D: Commercial tester connection
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING
Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points.
DIAGNOSTIC FUNCTION
DIAGNOSIS CODES CHECK
Use the MUT-II to check a diagnosis code.
(Refer to GROUP 00 How to Use Troubleshooting/Inspection Service Points.)
NOTE
Connect the MUT-II to the 16-pin diagnosis connector (black).
Key reminder switch <Vehicles with keyless entry system> Ignition key removed from ignition key cylinder
(from inserted position)
Back-up lamp switch <M/T, vehicles with rear wiper and washer> Shift lever moved to R position
Inhibitor switch (reverse) <A/T, vehicles with rear wiper and Selector lever moved to R position
washer>
Rear wiper motor auto-stop signal <Vehicles with rear wiper and Rear wiper begins to operate (The input signal
washer> is sent before the rear wiper begins to operate)
Front passengers or back door lock key cylinder switch <Vehicles Turn the key to the locked or unlock
with central door locking system>
Drivers door lock actuator switch <Vehicles with central door Drivers door lock knob moved from lock
locking system> position to unlock position or vice versa
Column switch Tail lamp switch Turned the lighting switch from OFF to tail lamp
position
Headlamp switch Turn the lighting switch from tail lamp position to
headlamp position
Passing switch
Windshield intermittent wiper interval adjusting Rotate the windshield intermittent wiper interval
knob adjusting knob from FAST to SLOW when the
ignition switch is in ON position (The
ETACS-ECU sends a signal around the medium
knob position)
Power window Any switch <Vehicles with power window> Turned from OFF to ON
main switch
Transmitter Any switch <Vehicles with keyless entry Turned from OFF to ON
system>
Sunroof switch Any switch <Vehicles with sunroof> Turned from OFF to ON
Center display Any switch <Vehicles with center display> Turned from OFF to ON
12 Failure concerning the column switch or improper connecting with the ETACS-ECU 54B-10
Yes NG
Is diagnosis code No. 12 output Measure at column switch connector Check the following connectors:
when the ignition switch is at the D-203. D-203, D-223, D-27
ON position? D Disconnect connector and NG
OK
measure at harness side.
No D Voltage between terminal 1 and Repair
body earth.
OK: System voltage
OK Check trouble symptoms
OK NG
Measure at column switch connector Check the following connectors:
D-203. D-203, D-226 Check the harness wire between col-
D Disconnect connector and NG umn switch and fusible link (2).
OK
measure at harness side.
D Continuity between terminal 4 Repair
and body earth.
OK: Continuity
NG
NG Check trouble symptoms Check the harness wire between col-
umn switch and ETACS-ECU.
NG NG
Check the following connector: Replace
D-203 Replace the column switch.
OK
NG
Check trouble symptoms Check the harness wire between column Check trouble symptoms.
switch and body earth. NG
Yes NG
Is diagnosis code No. 12 output Measure at front-ECU connector A-07X. Check the following connector:
when the ignition switch is at the D Disconnect connector and A-07X
ON position? measure at harness side. OK NG
D Voltage between terminal 7 and
No
body earth Repair
OK: System voltage
OK
Check trouble symptoms.
Replace the front-ECU.
NG
Check the harness wire between front-
ECU and fusible link (2).
OK NG
Measure at front-ECU connector A-08X. Check the following connectors: Repair
D Disconnect connector and A-08X, D-27, D-31, D-226
measure at harness side.
OK
D Continuity between terminal 31
and body earth. NG
Check trouble symptoms. Replace the front-ECU.
OK: Continuity
NG
NG Check trouble symptoms.
Check the following connector: Repair
A-08X NG
OK Replace the ETACS-ECU.
NG
Check the trouble symptoms. Check the harness wire between front-
ECU and body earth.
NG
Check the following connectors: Repair
A-08X, D-06, D-25, D-27, D-29, D-31, D-203, D-226, F-02, F-06,
H-05
OK
Buzzer Light reminder warning buzzer function does not work B-1 54B-17
normally.
Center display operation annunciation function does not work B-2 54B-18
normally.
Central door lock- Central door locking system does not work normally. C-1 54B-18
ing system
Some doors does not lock or unlock. C-2 54B-19
Power window Power window does not work at all. D-1 54B-20
Power window main switch can not operate drivers window. D-2 54B-21
Power window sub switch can not operate front passengers or D-3 54B-22
rear window.
Power window main switch can not operate front passengers D-4 54B-23
or rear window.
Power window timer function does not work normally. D-5 54B-23
The glass is not lowered when something is jammed in the D-7 54B-24
window.
When the glass is fully raised, it then lowers automatically. D-8 54B-24
Keyless entry sys- Keyless entry system does not operate. E-1 54B-24
tem
The room lamp and hazard warning lamps do not operate E-2 54B-25
through the answerback function.
Rear wiper and Rear wiper does not work at all. H-1 54B-31
washer
Rear wiper does not stop at the predetermined park position. H-2 54B-31
When the shift lever <M/T> or selector lever <A/T> is moved H-3 54B-32
to R position during the rear wiper operation, the rear wiper
does not operate at the continuous mode.
Ignition key hole Ignition key hole illumination lamp does not work normally. J-1 54B-34
illumination lamp
The headlamp automatic shutdown function does not work K-5 54B-36
normally.
Headlamp dimmer switch automatic reset function does not K-6 54B-37
work normally.
Daytime running lamp (DRL) function does not work. K-7 54B-37
Flasher timer Turn-signal lamp do not flash when the turn-signal lamp switch L-1 54B-37
is turned on.
Hazard warning lamps do not flash when the hazard warning L-2 54B-38
lamp switch is turned on.
Front fog lamp Front fog lamps do not illuminate when the front fog lamp M-1 54B-39
switch is turned on.
Front fog lamp do not go out when the tail lamps are turned off M-2 54B-39
while the front fog lamps are on.
Rear fog lamp Rear fog lamp do not illuminate when the rear fog lamp switch N-1 54B-40
is turned on.
Rear fog lamp do not go out when the headlamps and front fog N-2 54B-40
lamps are turned off while the rear fog lamp is on.
Room lamp dimming function does not work normally. O-2 54B-41
Center display Center display does not work normally. GROUP 54A
Center Dis-
play.
Ignition switch (ACC) signal is not sent to the ETACS-ECU. P-1 54B-42
Ignition switch (IG1) signal is not sent to the ETACS-ECU. P-2 54B-42
Key reminder switch signal is not sent to the ETACS-ECU. P-3 54B-43
Hazard warning lamp switch signal is not sent to the ETACS-ECU. P-4 54B-43
Front fog lamp switch signal is not sent to the ETACS-ECU. P-5 54B-44
Rear fog lamp switch signal is not sent to the ETACS-ECU. P-6 54B-45
Back-up lamp switch signal is not sent to the ETACS-ECU. <M/T> P-7 54B-45
Inhibitor switch (reverse) signal is not sent to the ETACS-ECU. <A/T> P-8 54B-46
Rear wiper motor auto-stop signal is not sent to the ETACS-ECU. P-9 54B-46
Drivers door switch signal is not sent to the ETACS-ECU. P-10 54B-47
Front passengers or back door lock key cylinder switch signal is not sent to the P-11 54B-48
ETACS-ECU.
Drivers door lock actuator switch signal is not sent to the ETACS-ECU. P-12 54B-48
Column switch Tail lamp switch signal is not sent to the ETACS-ECU. P-13 54B-49
Windshield mist wiper switch signal is not sent to the P-14 54B-50
ETACS-ECU.
Headlamp washer switch signal is not sent to the ETACS-ECU. P-13 54B-49
Power window Any switch signal is not sent to the ETACS-ECU. P-16 54B-51
main switch
Transmitter Any switch signal is not sent to the ETACS-ECU. P-17 54B-52
Sunroof switch Any switch signal is not sent to the ETACS-ECU. P-18 54B-52
Center display Any switch signal is not sent to the ETACS-ECU. P-19 54B-53
No
Can MUT-II communicate with other system? Check and repair the self-diagnosis system with the MUT-II.
Yes
Yes
Is communication with the MUT-II possible when the ignition Check the ETACS-ECU battery circuit. (Refer to P.54B-53, Inspec-
switch is at the ON position? tion Procedure Q-1.)
No
NG
Measure at ETACS-ECU connector D-224. Check following connectors:
D Disconnect connector and measure at J/B side. D-224, D-209
D Continuity between terminal 20 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check following connectors:
D-226, D-222, D-23 Check the harness wire between ETACS-ECU and body earth.
OK NG
No
Do all of the following functions operate when the ignition key Check the ETACS-ECU battery circuit. (Refer to P.54B-53, Inspec-
is at the LOCK (OFF) position? tion Procedure Q-1.)
D Hazard warning lamp
D Room lamp
Yes
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Ignition switch (IG1) by Input Signal Check.)
D Drivers door switch
D Tail lamp switch
D Headlamp switch
OK
No
Is the center display operating normally? Carry out troubleshooting for the center display. (Refer to
Yes GROUP 54A Center Display.)
NG
MUT-II input signal check Check the center display input circuit. (Refer to P.54B-53, Inspection
D Center display Procedure P-19.)
OK
NG
Measure at ETACS-ECU connector D-223. Check the following connectors:
D Disconnect connector and measure at J/B side. D-224, D-211, D-27
D Voltage between terminal 12 and body earth. OK NG
OK: System voltage
OK Check trouble symptoms. Repair
NG
Check the following connectors:
D-224, D-209, D-218 <L.H. drive vehicles>, D-219 <R.H. drive Check the harness wire between ETACS-ECU and fusible link
vehicles> (1).
OK NG
NG
Check the defective door lock actuator. (Refer to GROUP 42 Replace the defective door lock actuator.
Door or GROUP 42 - Back Door.)
OK
NG
Check the following connectors <L.H. drive vehicles>: Repair
Front L.H. door: D-224, D-209, D-25, H-03
Front R.H. door: D-224, D-209, D-15, H-18
Rear L.H. door: D-224, D-218, D-26, F-18, H-12
Rear R.H. door:D-224, D-218, D-124, F-04, H-21
Back door: D-224, D-218, D-124, G-06, I-06
Check the following connectors <R.H. drive vehicles>:
Front L.H. door: D-224, D-209, D-31, D-15, H-03
Front R.H. door: D-224, D-209, D-31, D-25, H-18
Rear L.H. door: D-224, D-209, D-31, D-26, F-18, H-12
Rear R.H. door: D-223, D-219, F-04, H-21
Back door: D-224, D-219, G-06, I-06
OK
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Front passengers or back door lock key cylinder switch by Input Signal Check.)
D Drivers door lock actuator switch
OK
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Key reminder switch by Input Signal Check.)
D Drivers door switch
D Drivers door lock actuator switch
OK
NG
Check the power window relay. (Refer to GROUP 42 Door.) Replace
OK
NG
Measure at power window relay connector D-221. Check the following connectors:
D Disconnect connector and measure at J/B side. D-221 D-223, D-27
D Voltage between terminal 5 and body earth. OK NG
OK: System voltage
D Voltage between terminal 3 and body earth. Check trouble symptoms. Repair
OK: System voltage
NG
OK
Check the harness wire between power window relay and fusible
Check the following connectors: link (4).
D-221, D-208, D-25, H-05, D-224
OK NG
NG
MUT-II input signal check Check the power window main switch input circuit. (P.54B-51, In-
D Power window main switch spection Procedure P-16.)
OK
(1) NG
Measure at drivers power window motor connector H-04 <L.H. Check the following connectors:
drive vehicles> or H-16 <R.H. drive vehicles>. H-04 <L.H. drive vehicles>, H-16 <R.H. drive vehicles>, D-25,
D Disconnect connector and measure at harness side. D-208, D-221
D Turn the ignition switch to ON position. OK NG
(1) Voltage between terminal 3 and body earth.
OK: System voltage Check trouble symptoms. Repair
(2) Continuity between terminal 1 and body earth. (2) NG
OK: Continuity NG
OK Check the harness wire between drivers power window motor
and power window relay.
Check the following connectors:
H-04 <L.H. drive vehicles>, H-16 <R.H. drive vehicles>, H-05
OK NG Check the following connectors:
H-04 <L.H. drive vehicles>, H-16 <R.H. drive vehicles>, D-25
Check trouble symptoms. Repair OK NG
NG
Check trouble symptoms. Repair
Check the harness wire between drivers power window motor NG
and power window main switch.
OK NG Check the harness wire between drivers power window motor
and body earth.
Replace the drivers pow- Repair
er window motor or power
window main switch.
NG
Check the power window sub switch. (Refer to GROUP 42 - Door.) Replace
OK
NG
Measure at power window sub switch connector H-26 <Front L.H. Check the following connectors:
door>, H-15 <Front R.H. door>, H-02 <Rear L.H. door> or H-19 Front L.H. door: H-26, D-15
<Rear R.H. door>. Front R.H. door: H-15, D-15
D Disconnect connector and measure at harness side. Rear L.H. door: H-02, F-18
D Continuity between terminal 4 and body earth. Rear R.H. door: H-19, F-04
OK: Continuity OK NG
NG
Check trouble symptoms. Repair
NG
Check the harness wire between power window sub switch and
body earth.
(1) NG
Measure at power window motor connector H-04 <Front L.H. door>, Check the following connectors:
H-16 <Front R.H. door>, H-10 <Rear L.H. door> or H-23 <Rear Front L.H. door: H-04, D-15, D-208, D-221
R.H. door>. Front R.H. door: H-16, D-15, D-208, D-221
D Disconnect connector and measure at harness side. Rear L.H. door: H-10, F-18, D-26, D-208, D-221
D Turn the ignition switch to ON position. Rear R.H. door: H-23, F-04, D-124, D-208, D-221
(1) Voltage between terminal 3 and body earth. OK NG
OK: System voltage
(2) Continuity between terminal 1 and body earth. (2) NG
Check trouble symptom Repair
OK: Continuity
NG
OK
Check the harness wire between power window motor and power
Check the following connectors: window relay.
Front L.H. door: H-04, H-26
Front R.H. door: H-16, H-15
Rear L.H. door: H-10, H-02
Rear R.H. door: H-23, H-19 Check the following connectors:
Front L.H. door: H-04, D-15
OK NG Front R.H. door: H-16, D-15
Rear L.H. door: H-10, F-18
Check trouble symptoms. Repair Rear R.H. door: H-23, F-04
NG OK NG
Check the harness wire between power window sub switch and Check trouble symptom Repair
passengers power window motor.
NG
OK NG
Check the harness wire between power window motor and body
Replace the power win- Repair earth.
dow motor.
No
Can the passengers side power window be operated by the Check the power window sub switch circuit. (Refer to P.54B-22,
power window sub switch? Inspection Procedure D-3.)
Yes
NG
MUT-II input signal check Check the power window main switch input circuit. (P.54B-51, In-
D Power window main switch spection Procedure P-16.)
OK
NG
Check the following connectors: Repair
Front L.H. door: H-05, D-25, D-31, D-15, H-04
Front R.H. door: H-05, D-25, D-31, D-15, H-16
Rear L.H. door: H-05, D-25, D-31, D-26, F-18, H-10
Rear R.H. door: H-05, D-25, D-31, D-124 F-04, H-23
OK
Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis Code
OFF (LOCK) position? Chart on P.54B-9.
No
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Ignition switch (IG1) by input Signal Check.)
D Drivers door switch
D Power window main switch
OK
NG
Check the power window operating currant. (Refer to GROUP Adjust the window glass. (Refer to GROUP 42 Door.)
42 Door.)
OK
Check trouble symptoms.
Replace the power window motor. NG
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Key reminder switch by input Signal Check.)
D Door switches
D Drivers door lock actuator switch
D Transmitter
OK
Yes
Is encrypted code register mode set? Check the transmitter battery. (Refer to GROUP 42 - Keyless
Entry System.)
No
OK NG
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Key reminder switch by input Signal Check.)
D Hazard warning lamp switch
OK
(1) NG
Measure at sunroof motor assembly connector F-16. Check the following connectors:
D Disconnect connector and measure at harness side. F-06, F-02, D-29, D-27
D Turn the ignition switch to ON position. OK NG
(1) Voltage between terminal 1 and body earth.
OK: System voltage Check trouble symptoms. Repair
(2) Voltage between terminal 2 and body earth.
OK: System voltage NG
(3) Voltage between terminal 3 and body earth. (2) NG Check the harness wire between sunroof motor assembly and
OK: System voltage
(4) Continuity between terminal 5 and body earth. fusible link (4).
OK: Continuity
OK (4) NG (3) NG
Check the following connectors:
F-06, F-02, D-29, D-32, D-210, D-208
OK NG
Check the sunroof switch. (Refer to GROUP 42 Sunroof.) Check trouble symptoms. Repair
OK NG NG
Repair Check the harness wire between sunroof motor assembly and
body earth.
NG
Measure at sunroof switch connector F-05. Check the following connectors:
D Disconnect connector and measure at harness side. <L.H. drive vehicles> F-05, F-02, D-29
D Continuity between terminal 4 and body earth. <R.H. drive vehicles> F-05, F-02, D-29, D-207, D-209
OK: Continuity OK NG
OK
Check trouble symptoms. Repair
Check the following connectors: NG
F-05, F-06
OK NG Check the harness wire between sunroof switch and body earth.
Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis Code
OFF (LOCK) position? Chart on P.54B-9.
No
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Ignition switch (IG1) by input Signal Check.)
D Drivers door switch
D Sunroof switch
OK
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Windshield mist wiper switch by Input Signal Check.)
D Windshield intermittent wiper switch
D Windshield low-speed wiper switch
D Windshield high-speed wiper switch
OK
NG
Check the windshield wiper motor. (Refer to GROUP 51 Wind- Replace
shield Wiper and Washer.)
OK
NG
Measure at windshield wiper motor connector B-12. Check the following connector:
D Disconnect connector and measure at harness side. B-12
D Continuity between terminal 5 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the harness wire between windshield wiper motor and body
earth.
NG
Measure at front-ECU connector A-08X. Check the following connectors:
D Disconnect connector and measure at relay box side. A-08X, D-27, D-223, D-208
D Turn the ignition switch to ACC position. OK NG
D Voltage between terminal 24 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Check the following connectors: Check the harness wire between front-ECU and ignition switch
B-12, A-05, A-08X (ACC).
OK NG
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Windshield mist wiper switch by Input Signal Check.)
D Windshield intermittent wiper switch
D Windshield low-speed wiper switch
D Windshield high-speed wiper switch
OK
NG
Check the windshield wiper motor. (Refer to GROUP 51 Wind- Replace
shield Wiper and Washer.)
OK
NG
Check the following connectors: Repair
B-12, A-05, A-08X
OK
NG
Check the windshield wiper motor. (Refer to GROUP 51 Wind- Replace
shield Wiper and Washer.)
OK
NG
Measure at windshield wiper motor connector B-12. Check the following connectors:
D Disconnect connector and measure at harness side. B-12, A-05, D-27, D-223, D-208
D Turn the ignition switch to ACC position. OK NG
D Voltage between terminal 2 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Check the following connectors: Check the harness wire between windshield wiper motor and ignition
B-12, A-05, A-08X switch (ACC).
OK NG
NG
MUT-II input signal check Check the windshield intermittent wiper interval adjusting knob sig-
D Windshield intermittent wiper interval adjusting knob nal input circuit. (Refer to P.54B-50, Inspection Procedure P-15.)
OK
No
Is the windshield wiper operated normally? Check the windshield wiper. (Refer to P.54B-13, Trouble Symptom
Yes Chart.)
NG
MUT-II input signal check Check the windshield washer switch circuit. (Refer to P.54B-50,
D Windshield washer switch Inspection Procedure P-14.)
OK
NG
Check the windshield washer motor. (Refer to GROUP 51 Wind- Replace
shield Wiper and Washer.)
OK
NG
Measure at windshield washer motor connector A-35. Check the following connector:
D Disconnect connector and measure at harness side. A-35
D Continuity between terminal 2 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
A-35, A-08X Check the harness wire between windshield washer motor and
OK NG body earth.
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Ignition switch (ACC) by Input Signal Check.)
D Rear wiper switch
OK
NG
Check the rear wiper motor. (Refer to GROUP 51 Rear Wiper Replace
and Washer.)
OK
NG
Measure at rear wiper motor connector I-07 Check the following connector:
D Disconnect connector and measure at harness side. I-08
D Continuity between terminal 1 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
<L.H. drive vehicles> I-07, G-06, D-124, D-218, D-224 Check the harness wire between rear wiper motor and body earth.
<R.H. drive vehicles> I-07, G-06, D-219, D-224
OK NG
NG
MUT-II input signal check Check the rear wiper auto-stop signal input circuit. (Refer to
D Rear wiper motor auto-stop signal P.54B-46, Inspection Procedure P-9.)
OK
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Back-up lamp switch <M/T> by Input Signal Check.)
D Inhibitor switch (reverse) <A/T>
OK
No
Is the rear wiper operated normally? Check the rear wiper. (Refer to P.54B-13, Trouble Symptom Chart.)
Yes
NG
MUT-II input signal check Check the rear washer switch circuit. (Refer to P.54B-50, Inspection
D Rear washer switch Procedure P-14.)
OK
NG
Check the rear washer motor. (Refer to GROUP 51 Rear Wiper Replace
and Washer.)
OK
NG
Measure at rear washer motor connector I-08. Check the following connector:
D Disconnect connector and measure at harness side. I-08
D Continuity between terminal 1 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
I-08, G-06, D-124, D-223, D-224 Check the harness wire between windshield washer motor and
OK NG body earth.
No
Is the windshield wiper and headlamp operated normally? Check the defective operation. (Refer to P.54B-13, Trouble Symp-
Yes tom Chart.)
NG
MUT-II input signal check Check the headlamp washer switch circuit. (Refer to P.54B-49,
D Headlamp washer switch Inspection Procedure P-13.)
OK
NG
Check the headlamp washer motor. (Refer to GROUP 51 Head- Replace
lamp Washer.)
OK
NG
Measure at headlamp washer motor connector A-36. Check the following connector:
D Disconnect connector and measure at harness side. A-36
D Continuity between terminal 2 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
NG
Measure at front-ECU connector A-07X. Check the following connector:
D Disconnect connector and measure at relay box side. A-07X
D Voltage between terminal 9 and body earth. OK NG
OK: System voltage
OK Check trouble symptoms. Repair
NG
Check the following connectors:
A-36, A-07X Check the harness wire between front-ECU and fusible link (4).
OK NG
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Ignition switch (IG1) by Input Signal Check.)
D Key reminder switch <Vehicles with keyless entry system>
D Drivers door switch
OK
NG
Measure at ETACS-ECU connector D-226. Check the ignition key hole illumination lamp bulb.
D Disconnect connector and measure at harness side. OK NG
D Connect between terminal 36 and body earth.
OK: Ignition key hole illumination lamp illuminate Check trouble symptoms. Repair
OK NG
Check the following connectors: Check the following connectors:
D-202, D-226 D-202, D-223 <L.H. drive vehicles>, D-27
OK NG OK NG
Check trouble symptoms. Repair Check trouble symptoms. Repair
NG NG
Check the harness wire between key reminder switch and ETACS- Check the harness wire between key reminder switch and fusible
ECU. link (2).
OK NG
Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis Code
OFF (LOCK) position? Chart on P.54B-9.
No
NG
MUT-II input signal check Check the tail lamp switch input circuit. (Refer to P.54B-49, Inspec-
D Tail lamp switch tion Procedure P-13.)
OK
NG
Measure at front-ECU connector A-07X. Check the following connector:
D Disconnect connector and measure at relay box side. A-07X
D Voltage between terminal 5 and body earth. OK NG
OK: System voltage
OK Check trouble symptoms. Repair
NG
Replace the front-ECU.
Check the harness wire between front-ECU and battery.
NOTE
If only one lamp does not illuminate, the harness wire between the lamp and front-ECU may be defective
or the light bulb may be burned out. In this case, check the tail lamp circuit
Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis Code
OFF (LOCK) position? Chart on P.54B-9.
No
NG
MUT-II input signal check Check the headlamp switch input circuit. (Refer to P.54B-49, Inspec-
D Headlamp switch tion Procedure P-13.)
OK
NG
Measure at front-ECU connector A-07X. Check the following connector:
D Disconnect connector and measure at relay box side. A-07X
D Voltage between terminal 3 and body earth. OK NG
OK: System voltage
D Voltage between terminal 4 and body earth. Check trouble symptoms. Repair
OK: System voltage
NG
OK
Check the harness wire between front-ECU and battery.
Replace the front-ECU.
NOTE
If only one of the headlamps (low-beam) does not illuminate, the harness wire between the headlamp
and front-ECU may be defective or the headlamp bulb may be burned out. In this case, check the headlamp
circuit.
No
Is the headlamps (low-beam) operated normally? Check the headlamp (low-beam) circuit. (Refer to P.54B-35, Inspec-
Yes tion Procedure K-2.)
NG
MUT-II input signal check Check the dimmer switch input circuit. (Refer to P.54B-49, Inspection
D Dimmer switch Procedure P-13.)
OK
NOTE
If only one of the headlamps (high-beam) does not illuminate, the harness wire between the headlamp
and front-ECU may be defective or the headlamp bulb may be burned out. In this case, check the headlamp
circuit.
No
Is the headlamps (low-beam and high-beam) operated normally? Check the defective circuit. (Refer to P.54B-13, Trouble Symptom
Yes Chart.)
NG
MUT-II input signal check Check the passing switch input circuit. (Refer to P.54B-49, Inspec-
D Passing switch tion Procedure P-13.)
OK
Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis Code
OFF (LOCK) position? Chart on P.54B-9.
No
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Ignition switch (IG1) by Input Signal Check.)
D Drivers door
D Headlamp switch
OK
No
Are the tail lamp and headlamps operated normally? Check the defective device. (Refer to P.54B-13, Trouble Symptom
Yes Chart.)
NG
Measure at ETACS-ECU connector D-226. Check the following connectors:
D Disconnect connector and measure at harness side. D-226, D-27
D Continuity between terminal 29 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Replace the ETACS-ECU or front-ECU.
Check the harness wire between ETACS-ECU and body earth.
Yes
Is the hazard warning lamp operated normally? MUT-II input signal check
No D Ignition switch (IG1)
D Turn-signal lamp switch
OK NG
NG
Measure at ETACS-ECU connector D-224. Check the following connectors:
D Disconnect connector and measure at J/B side. D-224, D-223, D-27
D Voltage between terminal 11 and body earth. OK NG
OK: System voltage.
OK Check trouble symptoms. Repair
NG
Check the following connectors:
D-224, D-213, D-210, D-218 <L.H. drive vehicles>, D-219 <R.H. Check the harness wire between ETACS-ECU and battery.
drive vehicles>
OK NG
NOTE
If only one of the turn-signal lamp does not flash, the harness wire between the lamp and ETACS-ECU
may be defective or the lamp bulb may be burned out. In this case, check the turn-signal lamp and
hazard warning lamp circuit.
No
Is the turn-signal lamp operated normally? Check the turn-signal lamp circuit. (Refer to P.54B-37, Inspection
Yes Procedure L-1.)
NG
Do all of the following functions operate when the ignition key Check the ETACS-ECU battery circuit. (Refer to P.54B-53, Inspec-
is at the LOCK (OFF) position? tion Procedure Q-1.)
D Light reminder warning function
D Room lamp
OK
NG
MUT-II input signal check Check the hazard warning lamp switch input circuit. (Refer to
D Hazard warning lamp switch P.54B-43, Inspection Procedure P-4.)
OK
NG
Is the tail lamps and headlamps operated normally? Check the defective circuit. (Refer to P.54B-13, Trouble Symptom
OK Chart.)
NG
MUT-II input signal check Check the front fog lamp switch input circuit. (Refer to P.54B-44,
D Front fog lamp switch Inspection Procedure P-5.)
OK
NG
Check the front fog lamp relay. (Refer to GROUP 54A Fog Lamp.) Replace
OK
NG
Measure at front fog lamp relay connector A-09X. Check the following connector:
D Disconnect connector and measure at relay box side. A-09X
D Voltage between terminal 3 and body earth. OK NG
OK: System voltage
D Voltage between terminal 4 and body earth. Check trouble symptoms. Repair
OK: System voltage
NG
OK
Check the harness wire between front fog lamp relay and battery.
Check the following connectors:
A-09X, A-07X, A-15, A-26, A-22, A-33
OK NG
NOTE
If only one of the front fog lamp or front fog lamp indicator lamp does not illuminate, the harness wire
between the lamp and front fog lamp relay may be defective or the lamp bulb may be burned out. In
this case, check the front fog lamp circuit.
No
Are the headlamps and front fog lamps operated normally? Check the defective device. (Refer to P.54B-13, Trouble Symptom
Yes Chart.)
NG
MUT-II input signal check Check the Rear fog lamp switch input circuit. (Refer to P.54B-45,
D Rear fog lamp switch Inspection Procedure P-6.)
OK
NG
Check the rear fog lamp relay. (Refer to GROUP 54A Fog Lamp.) Replace
OK
NG
Measure at rear fog lamp relay connector D-212. Check the following connectors:
D Disconnect connector and measure at relay box side. D-212, D-210, D-211, D-27
D Voltage between terminal 3 and body earth. OK NG
OK: System voltage
D Voltage between terminal 5 and body earth. Check trouble symptoms. Repair
OK: System voltage
NG
OK
Check the harness wire between rear lamp relay and fusible link
Check the following connectors: (1).
D-212, D-226, D-26, D-124, G-02, G-07
OK NG
NOTE
If only one of the rear fog lamp or rear fog lamp indicator lamp does not illuminate, the harness wire
between the lamp and rear fog lamp relay may be defective or the lamp bulb may be burned out. In
this case, check the rear fog lamp circuit.
Yes
Does the room lamp turn on when the room lamp switch is Check the following connectors:
set to the ON position? F-07, D-29, D-207, D-224
No OK NG
NG
Measure at room lamp connector F-07. Check the following connectors:
D Disconnect connector and measure at harness side. F-07, D-29, D-207, D-223, D-27
D Voltage between terminal 1 and body earth. OK NG
OK: System voltage
OK Check trouble symptoms. Repair
NG
Replace the room lamp.
Check the harness wire between room lamp and fusible link (2).
NG
Do all of the following functions operate when the ignition key Check the ETACS-ECU battery circuit. (Refer to P.54B-53, Inspec-
is at the LOCK (OFF) position? tion Procedure Q-1.)
D Light reminder warning function
D Central door locking system
D Hazard warning lamp
OK
NG
MUT-II input signal check Check the defective input circuit. (Refer to P.54B-15, Defects Found
D Ignition switch (IG1) by Input Signal Check.)
D Key reminder switch
D Door switches
D Drivers door lock actuator switch
OK
NG
Measure at ETACS-ECU connector D-224. Check the following connectors:
D Disconnect connector and measure at J/B side. D-224, D-208
D Turn the ignition switch to ACC position. OK NG
D Voltage between terminal 2 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Replace the ETACS-ECU. Check the harness wire between ETACS-ECU and ignition switch
(ACC).
NG
Measure at ETACS-ECU connector D-224. Check the following connectors:
D Disconnect connector and measure at J/B side. D-224, D-208
D Turn the ignition switch to ON position. OK NG
D Voltage between terminal 16 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Replace the ETACS-ECU. Check the harness wire between ETACS-ECU and ignition switch
(IG1).
NG
Check the key reminder switch. (Refer to GROUP 54A Ignition Replace
Switch and Immobilizer System.)
OK
NG
Measure at key reminder switch connector D-202. Check the following connectors:
D Disconnect connector and measure at harness side. D-202, D-30 <L.H. drive vehicles>
D Continuity between terminal 4 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
D-202, D-226 Check the harness wire between key reminder switch and body
OK NG earth.
NG
Check the hazard warning lamp switch. (Refer to GROUP 54A Replace
Hazard Warning Lamp Switch.)
OK
NG
Measure at hazard warning lamp switch connector D-104. Check the following connector:
D Disconnect connector and measure at harness side. D-104
D Continuity between terminal 2 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
D-104, D-226 Check the harness wire between hazard warning lamp switch and
OK NG body earth.
NG
Check the front fog lamp switch. (Refer to GROUP 54A Fog Replace
Lamp.)
OK
NG
Measure at fog lamp switch connector D-141. Check the following connectors:
D Disconnect connector and measure at harness side. D-141, D-30
D Continuity between terminal 2 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
D-141, D-226 Check the harness wire between fog lamp switch and body earth.
OK NG
NG
Check the rear fog lamp switch. (Refer to GROUP 54A Fog Replace
Lamp.)
OK
NG
Measure at fog lamp switch connector D-141. Check the following connectors:
D Disconnect connector and measure at harness side. D-141, D-30
D Continuity between terminal 6 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
D-141, D-226 Check the harness wire between fog lamp switch and body earth.
OK NG
NG
Check the back-up lamp switch. Replace
OK
NG
Measure at back-up lamp switch connector C-18. Check the following connectors:
D Disconnect connector and measure at harness side. C-18, E-115, D-32, D-213, D-208
D Turn the ignition switch to ON position. OK NG
D Voltage between terminal 2 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Check the following connectors: Check the harness wire between back-up lamp switch and ignition
C-18, E-113, D-128 <Petrol engine vehicles>, E-13, D-33 <L.H. switch (IG1).
drive vehicles>, D-226
OK NG
NG
Check the inhibitor switch. (Refer to GROUP 23 On-vehicle Ser- Replace
vice.)
OK
NG
Measure at inhibitor switch connector C-05. Check the following connectors:
D Disconnect connector and measure at harness side. C-05, E-115, D-32, D-213, D-208
D Turn the ignition switch to ON position. OK NG
D Voltage between terminal 7 and body earth.
OK: System voltage Check trouble symptoms. Repair
OK NG
Check the following connectors: Check the harness wire between inhibitor switch and ignition switch
C-05, E-113, D-128 <Petrol engine vehicles>, E-13, D-33 <L.H. (IG1).
drive vehicles>, D-226
OK NG
NG
Check the rear wiper motor. (Refer to GROUP 51 Rear Wiper Replace
and Washer.)
OK
NG
Measure at rear wiper motor connector I-07. Check the following connectors:
D Disconnect connector and measure at harness side. L.H. drive vehicles: I-07, G-06, D-124, D-218, D-208
D Turn the ignition switch to ACC position. R.H. drive vehicles: I-07, G-06, D-219, D-208
D Voltage between terminal 4 and ground. OK NG
OK: System voltage
OK Check trouble symptoms. Repair
NG
Check the following connectors:
L.H. drive vehicles: I-07, G-06, D-124, D-218, D-224 Check the harness wire between rear wiper motor and ignition
R.H. drive vehicles: I-07, G-06, D-219, D-224 switch (ACC).
OK NG
NG
Check the door switch. (Refer to GROUP 42 Door or GROUP Replace
42 - Back Door.)
OK
NG
Check the installation of the door switch to the vehicle body. Repair
OK
NG
Check the following connectors <L.H. drive vehicles>: Repair
Front L.H. door: F-20, D-26, D-218, D-224
Front R.H. door: F-03, D-124, D-209, D-224
Rear L.H. door: F-14, D-26, D-218, D-224 OK
Check trouble symptoms.
Rear R.H. door: F-10, D-124, D-209, D-224
Back door: G-03, D-26, D-218, D-224 NG
Check the following connectors <R.H. drive vehicles>: Check the harness wire between door switch and ETACS-ECU.
Front L.H. door: F-20, D-26, D-209, D-224
Front R.H. door: F-03, D-219, D-224 OK NG
Rear L.H. door: F-14, D-26, D-209, D-224
Rear R.H. door: F-10, D-219, D-224 Replace the ETACS- Repair
Back door: G-03, D-26, D-209, D-224 ECU.
NG
Check the door lock key cylinder switch. (Refer to GROUP 42 Replace
Door or GROUP 42 - Back Door.)
OK
NG
Measure at door lock key cylinder switch connector H-17 <Front Check the following connectors:
passengers door> or I-05 <Back door>. Front passengers door: H-17, D-15
D Disconnect connector and measure at harness side Back door: I-05
D Continuity between terminal 2 and body earth. OK NG
OK: Continuity
OK Check trouble symptoms. Repair
NG
Check the following connectors:
Front passengers door: H-17, D-15, D-225 Check the harness wire between door lock key cylinder switch
Back door: I-05, G-05, D-124, D-225 and body earth.
OK NG
NG
Check the door lock actuator switch. (Refer to GROUP 42 Door Replace
or Back Door.)
OK
NG
Measure at door lock actuator connector H-03 <L.H. drive vehicles> Check the following connectors:
or H-18 <R.H. drive vehicles>. H-03 <L.H. drive vehicles>, H-18 <R.H. drive vehicles>, D-25
D Disconnect connector and measure at harness side OK NG
D Continuity between terminal 1 <L.H. drive vehicles> or 3
<R.H. drive vehicles> Check trouble symptoms. Repair
OK: Continuity
NG
OK
Check the harness wire between drivers door lock actuator and
Check the following connectors: body earth.
H-03 <L.H. drive vehicles>, H-18 <R.H. drive vehicles>, D-25, D-225
OK NG
Check trouble symptoms. Repair
NG
NG
Check the harness wire between drivers door lock actuator and Repair
ETACS-ECU.
OK
Replace the ETACS-ECU.
Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis Code
OFF (LOCK) position? Chart on P.54B-9.
No <R.H. drive vehicles> No <L.H. drive vehicles>
NG
Check the column switch (lighting switch and switch body). (Refer Replace
to GROUP 54A - Column Switch.)
OK
Replace the column switch (wiper and washer switch). Replace the column switch (lighting switch).
Yes
Is a diagnosis code output when the ignition switch is at the Carry out troubleshooting while referring to the Diagnosis Code
OFF (LOCK) position? Chart on P.54B-9.
No <L.H. drive vehicles> No <R.H. drive vehicles>
NG
Check the column switch (wiper and washer switch and switch Replace
body). (Refer to GROUP 51 - Windshield Wiper and Washer and
GROUP 54A - Column Switch.)
OK
Replace the column switch (lighting switch). Replace the column switch (wiper and washer switch).
NG
Check the windshield intermittent wiper interval adjusting knob. Replace
(Refer to GROUP 51 - Windshield Wiper and Washer.)
OK
NG
Check the following connectors: Repair
D-203, D-226
OK
Yes
Can the drivers side power window be operated by the power Check the following connectors:
window main switch? H-05, D-25, D-31, D-226
No OK NG
Check the harness wire between power window main switch and
ETACS-ECU.
OK NG
NG
Check trouble symptoms. Replace the ETACS-
ECU.
(1) NG
Measure at power window main switch connector H-05. Check the following connectors:
D Disconnect connector and measure at harness side. H-05, H-25, D-208, D-221
D Turn the ignition switch to ON position. OK NG
(1) Voltage between terminal 1 <Short wheelbase models> or
5 <Long wheelbase models> and body earth. Check trouble symptoms. Repair
OK: System voltage
(2) Continuity between terminal 5 <Short wheelbase models> NG
or 3 <Long wheelbase models> and body earth. (2) NG
Check the harness wire between power window main switch and
OK: Continuity
power window relay.
OK
Check the harness wire between power window main switch and
body earth.
No
Has the encrypted code been registered properly? Re-register the encrypted code. (Refer to GROUP 42 Keyless
Entry System.)
Yes
NG
Check the transmitter battery. (Refer to GROUP 42 Keyless Replace
Entry System.)
OK
NG
Use an other transmitter to register the secret code. (Refer to Replace the ETACS-ECU.
GROUP 42 Keyless Entry System.)
OK
No
Is the sunroof operated normally? Check the sunroof. (Refer to P.54B-13, Trouble Symptom
Yes Chart.)
NG
Check the following connectors: Repair
F-06, F-02, D-29, D-31, D-226
OK
No
Is the center display operated normally? Carry out troubleshooting for the center display. (Refer to
Yes GROUP 54A Center Display.)
NG
Check the following connectors: Repair
D-06, D-31, D-226
OK
NG
Measure at ETACS-ECU connector D-224. Check the following connectors:
D Disconnect connector and measure at J/B side. D-224, D-223, D-27
D Voltage between terminal 6 and body earth. OK NG
OK: System voltage
OK Check trouble symptoms. Repair
NG
Replace the ETACS-ECU.
Check the harness wire between ETACS-ECU and fusible link
(2).
NOTE
*: Since the ETACS-ECU is directly mounted on the junction block and the measurement for connector
of terminals No.1 to 20 is impossible, the values concerning these terminals are shown for reference
only.
Terminal Check items Checking requirements Normal condition
No.
2 Ignition switch (ACC) power supply Ignition switch: ACC System voltage
4 Door lock output When the door lock actuators are System voltage
working to lock
5 Rear wiper auto-stop signal input When rear wiper is operated System voltage
8 Power window relay output When power window can be operated 2 V or less
9 Drivers door switch signal input Drivers door switch: ON (Drivers door 0V
open)
14 Turn-signal lamp (R.H.) output When turn-signal lamp (L.H.) is lighted System voltage
15 Turn-signal lamp (L.H.) output When turn-signal lamp (R.H.) is lighted System voltage
17 Door unlock output When door lock actuators are working System voltage
to unlock
24 Front fog lamp switch signal input Front fog lamp switch: ON 0V
25 Rear fog lamp switch signal input Rear fog lamp switch: ON 0V
26 Key reminder switch signal input Key reminder switch: ON (Ignition key 0V
removed)
35 Back-up lamp switch signal input Ignition switch: ON, System voltage
<M/T> Shift lever: R
Inhibitor switch (reverse) signal input Ignition switch: ON, System voltage
<A/T> Selector lever: R
36 Ignition key hole illumination lamp When ignition key hole illumination 2 V or less
output lamp is lighted
37 Diagnosis code or input signal check When diagnosis code is output 0 - 12 V (pulse
output signal)
40 Rear fog lamp relay output When rear fog lamp is lighted 2 V or less
53 Front passengers and back door lock Front passengers or back door lock key 0V
key cylinder switch (LOCK) signal input cylinder switch: LOCK
54 Front passengers and back door lock Front passengers or back door lock 0V
key cylinder switch (UNLOCK) signal switch: UNLOCK
input
55 Drivers door lock actuator switch Drivers door lock actuator switch: 0V
(LOCK) signal input LOCK
56 Drivers door lock actuator switch Drivers door lock actuator switch: 0V
(UNLOCK) signal input UNLCOK
2. COLUMN SWITCH
4 Ground Always 0V
3. FRONT-ECU
NOTE
Since the front-ECU is directly mounted on the relay box and measurement is impossible, these values
are shown for reference.
Terminal Check items Checking requirements Normal condition
No.
1 Front fog lamp relay output When front fog lamp is lighted 2 V or less
23 Windshield wiper auto-stop signal input When windshield wiper is operated System voltage
24 Ignition switch (ACC) power supply Ignition switch: ACC System voltage
27 Windshield wiper (low-speed) output When windshield wiper is operated (at System voltage
low-speed)
28 Windshield wiper (high-speed) output When windshield wiper is operated (at System voltage
high-speed)
31 Ground Always 0V
5 Ground Always 0V
3 Ground Always 0V
1 Ground Always 0V
2 Power window sub switch (DOWN) Power window sub switch: DOWN 0V
signal input <Except drivers door>
4 Power window sub switch (UP) signal Power window sub switch: UP 0V
input <Except drivers door>
5 Ground Always 0V
7. CENTER DISPLAY
Refer to GROUP 54A - Center Display.
ON-VEHICLE SERVICE
ADJUSTMENT PROCEDURES OF SWS FUNCTION
Through special operation of input switches, it is possible to disable and enable the functions listed below.
Settings are retained even if the battery is disconnected.
D Keyless entry hazard answerback function
D Initialization of above mentioned functions
Configuration Mode Entry Conditions
1. Set each switch at the following condition.
D Hazard warning lamp switch: OFF
D Diagnosis control: ON (MUT-II connected or terminal 1 of diagnosis connector connected to earth)
D Key reminder switch: OFF (ignition key inserted)
D Ignition switch: LOCK (OFF)
D Drivers door switch: OFF (drivers door closed)
2. When the windshield washer switch is continuously turned ON for more than 10 seconds, the buzzer
integrated in the ETACS-ECU sounds once and the mode is switched to the configuration mode.
Configuration Mode Cancellation Conditions
The ETACS-ECU cancels the configuration mode when any of the conditions listed below is satisfied.
D Diagnosis control: OFF (MUT-II disconnected or terminal 1 of diagnosis connector disconnected from
earth)
D Key reminder switch: ON (ignition key removed)
D Ignition switch: any position other than LOCK (OFF)
D Drivers door switch: ON (drivers door open)
D No configuration performed within three minutes of entry to configuration mode (If configuration is
performed within first three minutes, monitoring continues for three minutes from that point.)
Configuration of Functions
Function Configuration procedure
Keyless entry hazard If the transmitters LOCK switch is turned ON twice within two seconds, the lock answerback
answerback functions enabled/disabled status is inverted.
D When function is enabled, buzzer sounds once (initial status).
D When function is disabled, buzzer sounds twice.
If the transmitters UNLOCK switch is turned ON twice within two seconds, the unlock
answerback functions enabled/disabled status is inverted.
D When function is enabled, buzzer sounds once (initial status).
D When function is disabled, buzzer sounds twice.
Initialization of above If the windshield washer switch is turned ON for more than 20 seconds, the buzzer sounds
mentioned functions twice and all functions are initialized. (The configuration mode entry buzzer sounds after 10
seconds, but the switch must be kept ON for 20 seconds to achieve initialization.)
IF the windshield washer switch ins kept ON for more than 20 seconds without prior entry
of the configuration mode, the configuration mode is entered after 10 seconds and
initialization does not take place.
HEATER, AIR
CONDITIONER AND
VENTILATION
<MANUAL A/C>
Click on the applicable bookmark to selected the required model year.
HEATER, AIR
CONDITIONER AND
VENTILATION
<MANUAL A/C>
CONTENTS
LUBRICANTS
Item Specified lubricants Quantity
Compressor oil mL Except for vehicles with rear cooler DENSO OIL 8 120 20
Vehicles with rear cooler DENSO OIL 8 140 20
Pipe connections DENSO OIL 8 As required
Refrigerant g Except for vehicles with rear cooler R134a (HFC-134a) 500 20
Vehicles with rear cooler R134a (HFC-134a) 780 20
ON
OFF
kPa
12. Turn the vacuum pump adaptor switch to the R134a 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).
Low-pressure
service valve Vacuum pump
16. With the handle turned back all the way (valve open),
Valve open
install the charging valve to the service can.
17. Turn the handle of the adaptor valve back all the way
Valve close (valve closed), remove it from the gauge manifold and
install the service can.
Charging 18. Tighten the handle of the charging valve (valve closed)
valve to puncture the service can.
Adaptor valve
Service can
19. Turn the handle of the charging valve back (valve open)
Charging valve 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.
20. If the refrigerant is not drawn in, turn the handle of the
adaptor valve back all the way (valve closed).
Service can
(Refrigerant 21. Check for gas leaks using a leak detector.
container) If a gas leak is detected, re-tighten the connections, and
then repeat the charging procedure from evacuation in
step (12).
Caution
Low-pressure The leak detector for R134a should be used.
service valve
22. Start the engine.
23. Operate the A/C and set to the lowest temperature (MAX.
COOL).
Low-pressure
service valve
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.
Sleeve 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.
Charging hose (blue)
NOTE
The low-pressure service valve should be connected to
Quick joint the suction 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
Low-pressure pressing to ensure that there are no bends in the
service valve 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.
NOTE
Any oil remaining in the container should be returned
Adaptor valve to the A/C system.
Oil
PERFORMANCE TEST
Low-pressure valve High-pressure 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
Gauge manifold high-pressure valve of the gauge manifold.
Charging 4. Install the quick joint (for low-pressure) to the charging
hose (red) hose (blue), and connect the quick joint (for high-pressure)
Charging to the charging hose (red).
hose (blue) 5. Connect the quick joint (for low-pressure) to the
A low-pressure service valve and connect the quick joint
Adaptor
valve (for (for high-pressure) to the high-pressure service valve.
low pres- Sleeve
sure)
NOTE
Adaptor valve The high-pressure service valve is on liquid pipe A and
(for high pressure)
the low-pressure service valve is on the suction hose.
Low-pres- High-
sure ser- pressure
vice valve service
Caution
valve 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.
Discharge air temperature _C 3.5 - 5.5 3.5 - 5.5 4.5 - 6.5 5.5 - 7.5
Compressor high-pressure kPa 1,050 - 1,250 1,050 - 1,250 1,400 - 1,600 1,650 - 1,850
Compressor low-pressure kPa 120 - 140 120 - 140 130 - 150 160 - 180
Discharge air temperature _C 5.5 - 7.5 5.5 - 7.5 6.5 - 8.5 7.5 - 9.5
Compressor high-pressure kPa 1,150 - 1,350 1,150 - 1,350 1,500 - 1,700 1,750 - 1,950
Compressor low-pressure kPa 130 - 150 130 - 150 140 - 160 180 - 200
NOTE
The PTC heater is located at the heater core.
Fuel-injection lever
5. If there is a deviation of the idling speed from the standard
Adjusting value, adjust the idling speed by the following the
A screw
B
procedures.<4D56>
(1) Loosen nuts (A) and (B).
(2) Adjust, by using the adjuster, so that the end of the
vacuum actuators rod is at the position indicated
Cap
in the illustration.
Rod Adjuster (3) Securely tighten nuts (A) and (B).
Holding nut
(4) After activating the vacuum actuator, check to be
Approx. 1 mm
sure that the rod and the lever do not contact when
the activation is cancelled.
(5) Remove the cap and loosen the nut for holding.
(6) Adjust to the specified r/min by turning the adjusting
screw.
(7) Securely tighten the holding nut, and then attach the
cap.
Caution
Be careful, when connecting the vacuum hose not
to damage it.
Vacuum hose
IDLE-UP SOLENOID VALVE CHECK
Idle-up sole-
noid valve (white stripes) <Diesel-powered vehicles>
1. Disconnect the vacuum hoses (white stripes, yellow
stripes) from the solenoid valve.
2. Disconnect the harness connector.
Vacuum hose
(yellow stripes)
Nipple B
NOTE
In case of mark *1, a vacuum can be felt but in case
of mark *2, a vacuum can not be felt.
AX0971CA
2 1
4
Removal steps
D Front floor console 1. Center panel (Refer to GROUP 52A -
(Refer to GROUP 52A.) Instrument Panel.)
D Lower panel (Refer to GROUP 52A "BA 2. Air mix damper cable connection
- Instrument Panel.) "AA 3. Air outlet changeover damper cable
D Foot duct C connection
D Foot duct D 4. Heater control assembly
FACE position
INSPECTION
BLOWER SWITCH CONTINUITY CHECK
2 (ML)
3 (MH)
4 (HI)
1
3 5
Disassembly steps
1. Knob assembly AA" 4. Air mix damper cable
2. Bulb 5. Heater control panel
AA" 3. Air outlet changeover damper cable 6. Blower switch assembly
1
3
12 2 Nm 11 2
9.8 2.0 Nm
4
9
10
8
7
6 22 4 Nm
5
Removal steps
1. Drain hose 7. Foot duct
2. Heater hose connection 8. Front crossmember assembly
AA" 3. Suction flexible hose connection 9. Flange bracket
AA" 4. Liquid pipe A connection 10. Blower assembly
5. Connectors 11. Heater unit
6. Foot duct B
9 1
14
8
2
7
13
12
10 5
11 6
Disassembly steps
1. Foot duct A 8. Joint duct
2. Foot duct C 9. Air duct sub-assembly
3. Air thermo sensor clip 10. Heater core
4. Automatic compressor-ECU and air 11. Front pipe assembly
thermo sensor assembly 12. Expansion valve
5. Aspirator hose 13. Pipe
6. Blower linear controller 14. Evaporator
7. Rear A/C control unit 15. Case
<Vehicles with dual A/C>
INSPECTION
PTC HEATER CHECK <4M41>
Continuity should be present between the terminals.
Disassembly steps
1. Blower motor 3. Inside/outside air changeover damper
2. Clean air filter <Vehicles with clean motor
air filter> 4. Case
2
1
ACX01452
1. Blower motor
2. Resistor
INSPECTION
BLOWER MOTOR INSPECTION
The motor should run when battery voltage is applied between
the terminals. In addition, any abnormal sound should not
be heard from the motor.
RESISTOR CHECK
Standard value:
Terminal to be measured Standard value W
Between terminals No.3 and 2 2.79 7 %
Between terminals No.1 and 2 1.49 7 %
Between terminals No.2 and 4 0.39 7 %
ACX01448
1
Removal steps
D Glove box (Refer to GROUP 52A Instrument Panel.)
1. Inside/outside air changeover damper
motor
INSPECTION
Inside air INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR
CHECK
Battery terminal voltage Lever operation
1 2 3
Rotate to the inside air
recirculation position.
Rotate to the outside air
Outside air
induction position.
Caution
If the lever reaches the stop position, disconnect the
battery voltage.
Removal steps
D Under cover (Refer to GROUP 52A Instrument Panel.)
1. Air thermo sensor clip
2. Automatic compressor-ECU and air thermo sensor assembly
Resist- INSPECTION
ance
(k W) 8 AIR THERMO SENSOR CHECK
6 Measure the resistance between the sensor terminals under
at least two temperatures. The resistance values should meet
4 the left graph.
2 NOTE
0
The temperature should be within the shown range.
10 0 10 20 30 40
Temperature (_C)
INSPECTION
CONTINUITY CHECK OF THE REAR A/C SWITCH
Air Volume Adjusting Switch Check
ON position
ON position
Removal steps
D Front floor console
(Refer to GROUP 52A.)
1. Upper bracket
2. Rear heater unit
8
2 4
5
5
8
7
Disassembly steps
1. Rear inlet duct 5. Heater case
2. Harness assembly 6. Heater core
3. Relay 7. Blower fan
4. Resistor 8. Blower motor
INSPECTION
BLOWER MOTOR INSPECTION
The motor should run when battery voltage is applied between
the terminals. In addition, any abnormal sound should not
be heard from the motor.
RESISTOR CHECK
Standard value:
Terminal to be measured Standard value W
Between terminals No.1 and 6 4.9 7 %
Between terminals No.1 and 3 1.25 7 %
Pipe connections
4
3 5
14 0.5 Nm
2
2, 3 O-ring
33 1 Nm
1 A/C compressor oil:
DENSO OIL 8
Y0312CA
Rear heater unit removal steps Rear blower assembly removal steps
D Refrigerant discharge and refilling D Upper quarter trim (RH), lower quarter
(Refer to P.55A-9.) trim (RH)
D Engine coolant draining and refilling (Refer to GROUP 52A Trim.)
(Refer to GROUP 14 - On-vehicle D Rear quarter duct, rear floor duct A
Service.) mounting bolt, pillar duct mounting bolt
D Rear mud guard (Refer to GROUP (Refer to P.55A-55.)
51.) 6. Rear blower assembly
1. Heater cover
AA" 2. Suction pipe C connection
AA" 3. Liquid pipe D connection
4. Heater hose connection
5. Rear heater unit
4
3
8 9
6
10
9
2
1 5 7
Disassembly steps
1. Tube accessory assembly 7. Connector tube
2. Heater cover <Vehicles with rear cooler>
3. Harness assembly 8. Expansion valve
4. Electric motor for the air mix damper <Vehicles with rear cooler>
<Vehicles with rear heater> 9. Heater case
5. Air thermo sensor 10. Evaporator
<Vehicles with rear cooler> <Vehicles with rear cooler>
6. Heater core
<Vehicles with rear heater>
Caution
If the lever reaches the stop position, disconnect the
battery voltage.
Potentiometer Check
When the resistances between terminals 3 and 5 as well
as terminals 3 and 7 are measured at the previous check,
the resistance value should change gradually within the
standard value.
Standard value: 1.2 - 4.8 kW
3
4
Disassembly steps
1. Harness assembly 3. Blower motor assembly
2. Resistor 4. Case
INSPECTION
BLOWER MOTOR CHECK
The motor should run when battery voltage is applied between
the terminals. In addition, any abnormal sound should not
be heard from the motor.
RESISTOR CHECK
Standard value:
Terminal to be measured Standard value W
Between terminals No.1 and 6 4.9 7%
Between terminals No.1 and 3 1.25 7%
ON position
AX0707CA
<4D56>
9.8 2.0 Nm
6
3
4 <4M41>
9.8 2.0 Nm
5 6
1 2
44 4 Nm 3
Pipe connections
2, 3 O-ring
1
A/C compressor oil:
DENSO OIL 8
Removal steps
AA" 1. Drive belt AC" "AA 4. Compressor
AB" 2. Discharge flexible hose connection 5. Tension pulley assembly
AB" 3. Suction flexible hose connection 6. Compressor bracket
6
5
3
2 1
7
13.5 2.7 Nm
Groove on the
compressor
Pipe connections
4, 5 O-ring
9.8 2.0 Nm
8
INSPECTION
MOTOR ASSEMBLY CHECK
<Single A/C>
3
Low pressure-side service valve
2
9.8 2.0 Nm
High pressure-side service valve
Pipe connections
4
9.8 2.0 Nm
1 1, 2, 3, 4 O-ring
Removal steps
1. Dual pressure switch AA" 4. Liquid pipe A
AA" 2. Discharge flexible hose 5. Liquid pipe B
AA" 3. Suction flexible hose
<Dual A/C>
9.8 2.0 Nm
33 1 Nm
14 0.5 Nm Low pressure-side service valve
6
33 1 Nm
5 11 3
9.8 2.0 Nm
2
4
9.8 2.0 Nm
Pipe connections
1
9.8 2.0 Nm
7 8
1, 2, 3, 4 O-ring
14 0.5 Nm 33 1 Nm
10
14 0.5 Nm
33 1 Nm
O-ring
33 1 Nm 3, 4, 5, 6,
7,8, 9, 10
<Single A/C>
9.8 2.0 Nm
9.8 2.0 Nm
4 Pipe connections
9.8 2.0 Nm 2
1
1, 2, 3, 4 O-ring
A/C compressor oil:
DENSO OIL 8
Removal steps
1. Dual pressure switch AA" 3. Suction flexible hose
AA" 2. Discharge flexible hose AA" 4. Liquid pipe A
<Dual A/C>
5
14 0.5 Nm
33 1 Nm
9.8 2.0 Nm
3
Pipe connections
9.8 2.0 Nm
1
2 7
8
1, 2, 3, 4 O-ring
33 1 Nm
14 0.5 Nm
9
33 1 Nm
14 0.5 Nm 10
O-ring
33 1 Nm
3, 4, 5, 6,
7,8, 9, 10
Removal steps
1. Dual pressure switch AA" 6. Liquid pipe B
AA" 2. Discharge flexible hose AA" 7. Suction pipe B
AA" 3. Suction flexible hose AA" 8. Liquid pipe C
AA" 4. Liquid pie A AA" 9. Suction pipe C
AA" 5. Suction pipe A AA" 10. Liquid pipe D
(Threaded portion)
2
34.3 4 Nm
INSPECTION
ENGINE COOLANT TEMPERATURE SWITCH
CONTINUITY CHECK
1. Dip the engine coolant temperature switch in oil and heat
Thermometer the oil with a gas burner or similar item.
Caution
Do not heat any more than is necessary.
Oil
2. Check the continuity with a circuit tester as the temperature
of the oil changes, and the condition is normal if the
continuity is within the following ranges.
<For A/C cut-off>
Standard value:
B
Engine coolant Temperature Continuity
temperature
ON switch
OFF
For A/C cut-off Less than 108 _C ON
(Temperature at point (Continuity)
Oil temperature A)
A
More than 115 _C OFF
(Temperature at point B) (No continuity)
For condenser Less than 97 _C OFF
<For condenser fan> fan (Temperature at point A) (No continuity)
B More than 102 _C ON
(Temperature at point B) (Continuity)
ON
OFF
Oil temperature
A
3 2
4
1
2 3
4
DUCTS
FRONT A/C DUCT
REMOVAL AND INSTALLATION
10
8
7
2 6
1 4
2
1 ACX01410
2 4
1 6
1 5
9 8
7
10
Rear roof duct removal steps Rear floor duct removal steps
D Upper quarter trim (R.H.) D Upper quarter trim (R.H.), lower
(Refer to GROUP 52Trims.) quarter trim (R.H.)
1. Air outlet assembly (Refer to GROUP 52 Trims.)
2. Retainer 7. Rear quarter duct
D Head lining 8. Rear floor duct A
3. Roof duct (L.H.) 9. Rear heater grille
4. Roof duct (R.H.) D Floor carpet
5. Rear roof duct 10. Rear floor duct B
6. Pillar duct
VENTILATION
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
Rear Bumper Removal and Installation (Refer to
GROUP 51.)
Section A A
Tab
Body panel
A A
NOTE
: indicates the tab positions.
HEATER, AIR
CONDITIONER AND
VENTILATION
<AUTOMATIC A/C>
Click on the applicable bookmark to selected the required model year.
HEATER, AIR
CONDITIONER AND
VENTILATION
<AUTOMATIC A/C>
CONTENTS
SERVICE SPECIFICATIONS
Item Standard value
Resistance value of the potentiometer for the air mix damper (front A/C) kW Approx. 0.96 - 5.76
Resistance value of the potentiometer for the air outlet changeover damper (front A/C) Approx. 0.96 - 5.76
kW
Resistance of the rear air conditioner switch (temperature control switch) <except rear 0- 3
heater (floor console)> kW
Resistance of the potentiometer for the air mix damper <Rear heater, dual A/C> kW 1.2 - 4.8
Resistance value of the resistor (rear A/C) Between terminals 1 and 6 4.9 7 %
W Between terminals 1 and 3 1.25 7%
Air compressor air gap mm 0.35 - 0.65
Idle speed r/min (N or P range) Petrol 600 50
Idle-up speed r/min (N or P range) Petrol When the A/C is under 700 50
low load
When the A/C is under 800 50
medium load
When the A/C is under 1,000 50
high load
LUBRICANTS
Item Brand Quantity
Compressor oil ml Single A/C <except vehicles with rear DENSO OIL 8 120 20
cooler>
Single air conditioner <vehicles with DENSO OIL 8 140 20
rear cooler>, dual air conditioner
Pipe connections DENSO OIL 8 As required
Refrigerant g Single A/C <except vehicles with rear R134a (HFC-134a) 500 20
cooler>
Single air conditioner <vehicles with R134a (HFC-134a) 780 20
rear cooler>, dual air conditioner
NG
Check the outside air temperature sensor (Refer to P.55B-30). Replace
OK
NG
Check the following connectors: A-30, D-27, D-132 Repair
OK
NG
Check the heater water temperature sensor Replace
(Refer to P.55B-29).
OK
NG
Check the air thermo sensor Replace
(Refer to GROUP 55A - Front A/C).
OK
NG
Check the following connectors: D-129, D-132 Repair
OK
Code No.31 Potentiometer system for the air mix Probable cause
damper
This diagnosis code is set when the potentiometer for the air mix damper does D Malfunction of the potentiometer system for the air
not send any signal to the A/C-ECU due to short or open circuit. mix damper
D Malfunction of connector or harness
D Malfunction of the A/C-ECU
NG
Check the potentiometer system for the air mix damper Replace
(Refer to P.55B-27).
OK
NG
Measure at air mix damper motor connector D-130. Check the following connectors: D-130, D-132
D Disconnect the connector and measure at the harness OK NG
side.
D Ignition switch: ON Check the trouble Repair
D Voltage between terminal 7 and body earth symptoms.
OK: 5V
D Continuity between terminal 5 and body earth NG
OK: Continuity
Check the harness wire between the air mix damper motor
OK and the A/C-ECU.
OK NG
NG
Check the potentiometer for the air outlet changeover damper Replace
(Refer to P.55B-27).
OK
NG
Measure at air outlet changeover damper motor connector Check the following connectors: D-24, D-132
D-24. OK NG
D Disconnect the connector and measure at the harness
side. Check the trouble Repair
D Ignition switch: ON symptoms.
D Voltage between terminal 7 and body earth
OK: 5V NG
D Continuity between terminal 5 and body earth
OK: Continuity Check the harness wire between the air outlet changeover
damper motor and the A/C-ECU.
OK
OK NG
NG
Measure at A/C-ECU connector D-132. Check the following connectors: D-24, D-132
D Connect the connector. OK NG
D Ignition switch: ON
D Air outlet changeover damper: DEF position Check the trouble Repair
D Voltage between terminal 32 and body earth symptoms.
OK: 0.7 - 1.3 V
NG
OK
Check the harness wire between the air outlet changeover
Replace the automatic A/C control panel assembly (A/C-ECU). damper motor and the A/C-ECU, and repair if necessary.
Is communication between MUT-II and other system is NO Check the diagnosis line between the diagnosis connector and
possible? the A/C-ECU, and repair if necessary.
YES
NO
Is the air conditioner operating? INSPECTION PROCEDURE FOR TROUBLE SYMPTOM 2
YES (Refer to P.55B-3.)
NG
Check the following connectors: D-131, D-132, D-222, D-23 Repair
OK
(1) NG
Measure at A/C-ECU connector D-132. Check the following connectors: D-132, D-32, D-210, D-208
D Disconnect the connector and measure at the harness OK NG
side.
D Ignition switch: ON Check the trouble Repair
(1) Voltage between terminal 26 and body earth symptoms.
OK: System voltage
(2) Voltage between terminal 27 and body earth NG
OK: System voltage
Check the harness wire between the A/C-ECU and the ignition
(3) Voltage between terminal 28 and body earth
switch (IG2), and repair if necessary.
OK: System voltage
(4) Continuity between terminal 36 and body earth (2) NG
OK: Continuity Check the following connectors: D-132, D-33, D-210, D-208
OK (4) NG (3) NG OK NG
Check circuit, where the A/C-ECU terminal voltage is Check the harness wire between the A/C-ECU and fusible link
abnormal. (2), and repair if necessary.
OK NG
Check the following connectors: D-132, D-30
Replace the automatic Repair OK NG
A/C control panel
assembly (A/C-ECU). Check the trouble symptoms. Repair
NG
Inspection procedure 3
The air conditioner display does not appear on the Probable cause
center display screen.
Check the harness wires between the A/C-ECU and the center display, and D Malfunction of harness or connector
repair if necessary. D Malfunction of the A/C-ECU
NG
Check the following connectors: D-131, D-06 Repair
OK
Inspection procedure 4
A/C outlet air temperature can not be set. Probable cause
If the air outlet temperature can not be changed after a A/C temperature is set, D Malfunction of the inside air temperature sensor
sensor(s) or the air mix damper may be defective. D Malfunction of the outside air temperature sensor
D Malfunction of the heater water temperature sensor
D Malfunction of the photo sensor
D Malfunction of the electric motor for the air mix
damper
D Malfunction of harness or connector
D Malfunction of the A/C-ECU
YES
MUT-II Self-Diag Code Inspection chart for diagnosis codes (Refer to P.55B-4.)
Are diagnosis codes displayed?
NO
NG
MUT-II Data list Replace the automatic A/C control panel assembly (A/C-ECU).
11 Inside air temperature sensor
OK
NG
MUT-II Data list Check the outside air temperature sensor system.
13 Outside air temperature sensor (Refer to P.55B-4, Code Nos.13, 14.)
OK
NG
MUT-II Data list Check the heater water temperature sensor system.
15 Heater water temperature sensor (Refer to P.55B-5, Code Nos.15, 16.)
OK
NG
MUT-II Data list Check the photo sensor (Automatic air conditioner).
25 Photo sensor (Refer to P.55B-30.)
OK OK NG
Repair
Check the harness wire between the photo sensor and the
A/C-ECU.
OK NG
NG
MUT-II Data list Check the air mix damper potentiometer system
31 Potentiometer for air mix damper (Refer to P.55B-6, Code No.31).
OK
NG
Check the air mix damper motor (Refer to P.55B-27). Replace
OK
NG
Check the following connectors: D-130, D-131 Repair
OK
OK
MUT-II Actuator Test Replace the automatic A/C control panel assembly (A/C-ECU).
01, 02, 03, 04 Blower motor
OK
NG
Check the front blower relay Replace
(Refer to GROUP 55A - On-vehicle Service).
OK
Check the harness wire between the front blower relay and
the ignition switch (IG2), and repair if necessary.
NG
Measure at blower linear controller connector D-126. Check the following connector: D-126
D Disconnect the connector and measure at the harness OK NG
side.
D Continuity between terminal 4 and body earth Check the trouble symptoms. Repair
OK: Continuity
NG
OK
Check the harness wire between the blower linear controller
Check the following connectors: D-220, D-208, D-126, D-17, and body earth, and repair if necessary.
D-131,D-209
OK NG
Check the trouble symptoms. Repair
NG
Check the harness wires between the front blower relay and
the blower linear controller, between the front blower relay and NG
the blower motor, between the blower motor and the blower Repair
linear controller and between the front blower relay and the
A/C-ECU.
OK
Inspection procedure 6
The blower air volume can not be changed. Probable cause
If the air volume can not be controlled, the blower linear controller circuit may be D Malfunction of the blower linear controller
defective. D Malfunction of harness or connector
D Malfunction of the A/C-ECU
OK
MUT-II Actuator Test Replace the automatic A/C control panel assembly (A/C-ECU).
01, 02, 03, 04 Blower motor
NG
NG
Check the following connectors: D-126, D-131 Repair
OK
Inspection procedure 7
Air outlet vent cannot be changed. Probable cause
When the air outlet vents cannot be changed even if the changeover switch is D Malfunction of the electric motor for the air outlet
operated, the air outlet changeover damper motor circuit may be defective. changeover damper
D Malfunction of harness or connector
D Malfunction of the A/C-ECU
OK
MUT-II Actuator Test Replace the automatic A/C control panel assembly (A/C-ECU).
13, 14 Inside/outside air changeover damper motor
NG
NG
Check the inside/outside air changeover damper motor Replace
(Refer to GROUP 55A - Front A/C).
OK
NG
Measure at inside/outside air changeover damper motor Check the following connectors: D-09, D-32, D-210, D-208
connector D-09. OK NG
D Disconnect the connector and measure at the harness
side. Check the trouble Repair
D Ignition switch: ON symptoms.
D Voltage between terminal 1 and body earth
OK: System voltage NG
OK Check the harness wire between the ignition switch (IG2) and
the inside/outside air changeover damper motor, and repair if
Check the following connectors: D-09, D-131 necessary.
OK NG
Inspection procedure 9
The rear defogger does not operate. Probable cause
When the rear defogger does not operate even if the rear defogger switch is on D Malfunction of the defogger relay
(the defogger remains on for twenty minutes due to a timer function), the rear D Malfunction of harness or connector
defogger relay system may be defective. D Malfunction of the A/C-ECU
NG
Check the defogger relay (Refer to GROUP 54A Defogger). Replace
OK
(1) NG
Measure at defogger relay connector D-217. Check the following connectors: D-217, D-208
D Disconnect the connector, and measure at the J/B side. OK NG
D Ignition switch: ON
(1) Voltage between terminal 1 and body earth Check the trouble symptoms. Repair
OK: System voltage
(2) Voltage between terminal 2 and body earth NG
(2) NG
OK: System voltage
Check the harness wire between the defogger relay and the
OK ignition switch (IG2), and repair if necessary.
Check the harness wire between the defogger relay and the
battery, and repair if necessary.
NG
Measure at defogger connector I-01. Check the following connector: I-01
D Disconnect the connector and measure at the harness OK NG
side.
D Continuity between terminal 1 and body earth Check the trouble symptoms. Repair
OK: Continuity NG
OK
Check the harness wire between the defogger and body earth,
Check the following connectors: D-217, D-218, D-124<L.H. and repair if necessary.
drive vehicles>, G-06, I-03, D-131
OK NG
Check the harness wire between the condenser fan relay and
fusible link (1), and repair if necessary.
NG
Measure at condenser fan motor connector A-27. Check the following connector: A-27
D Disconnect the connector and measure at the harness OK NG
side.
D Continuity between terminal 2 and body earth Check the trouble symptoms. Repair
OK: Continuity
NG
OK
Check the harness wire between the condenser fan motor and
Check the following connectors: A-10X, A-27,A-04<L.H. body earth, and repair if necessary.
drive vehicles>, D-143<R.H. drive vehicles>, D-116<M/T>,
D-119<A/T>, D-110<4M41>
OK NG
Check the trouble symptoms. Repair
NG
NG
Check the harness wires between the condenser fan relay Repair
and the condenser fan motor, between the condenser fan
relay and the engine-A/T-ECU <petrol- A/T> or the
engine-ECU<petrol- A/T, diesel>.
OK
Inspection procedure 11
The condenser fan does not operate <4D56>. Probable cause
If the condenser fan does not operate, the condenser fan relay or motor may be D Malfunction of the condenser fan relay
defective. D Malfunction of harness or connector
D Malfunction of the engine-A/T-ECU <petrol> or
engine-ECU <diesel>
NG
Check the condenser fan relay Replace
(Refer to GROUP 55A - On-vehicle Service).
OK
NG
Check the condenser fan motor Replace
(Refer to GROUP 55A - Condenser Fan).
OK
NG
Replace the engine coolant temperature sensor. Replace
OK
(1) NG
Measure at condenser fan relay connector A-10X. Check the following connectors: A-10X, A-15, D-27, D-210,
D Disconnect the connector, and measure at the J/B side. D-208
D Ignition switch: ON OK NG
(1) Voltage between terminal 3 and body earth
OK: System voltage Check the trouble symptoms.
(2) Voltage between terminal 5 and body earth Repair
NG
OK: System voltage
(2) NG Check the harness wire between the condenser fan relay and
the ignition switch (IG2), and repair if necessary.
Check the harness wire between the condenser fan relay and
fusible link (1), and repair if necessary.
NG
Measure at condenser fan motor connector A-27. Check the following connector: A-27
D Disconnect the connector and measure at the harness OK NG
side.
D Continuity between terminal 2 and body earth Check the trouble symptoms. Repair
OK: Continuity
NG
OK
Check the harness wire between the condenser fan motor and
Check the following connectors: A-10X, A-27, A-04<L.H. body earth, and repair if necessary.
drive vehicles>, D-143<R.H. drive vehicles>, B-47
OK NG
NG
Check the rear A/C switch (rear fan switch). Replace
(Refer to GROUP 55A - Rear Heater/Rear Cooler.)
OK
NG
Check the front rear fan switch Replace
(Refer to GROUP 55A - Rear Heater/Rear Cooler).
OK
(1) NG
Measure at rear A/C control unit connector E-23. Check the following connectors: E-23, D-32, D-210, D-208
D Disconnect the connector and measure at the harness OK NG
side.
D Ignition switch: ON Check the trouble symptoms. Repair
(1) Voltage between terminal 5 and body earth
NG
OK: System voltage
(2) Continuity between terminal 2 and body earth
Check the harness wire between the ignition switch (IG2) and
OK: Continuity the rear A/C control unit, and repair if necessary.
(3) Voltage between terminal 13 and body earth
OK: System voltage (rear fan switch or front rear fan (2) NG
switch: OFF), 0 V (rear fan switch or front rear fan Check the following connectors: E-23, D-30
switch: ON) OK NG
(3) NG
Check the trouble symptoms. Repair
OK NG
Check at the rear A/C control unit terminals Check the harness wire between the rear A/C control unit and
(Refer to GROUP 55A - Rear Heater/Rear Cooler). body earth, and repair if necessary.
NG
Check the rear A/C switch (temperature control switch). Replace
(Refer to GROUP 55A - Rear Heater/Rear Cooler.)
OK
NG
Check the air thermo sensor. Replace
(Refer to GROUP 55A - Rear Heater/Rear Cooler.)
OK
NG
Check the air mix damper motor. Replace
(Refer to GROUP 55A - Rear Heater/Rear Cooler.)
OK
Check the magnetic valve. NG
Replace
(Refer to GROUP 55A - Rear Heater/Rear Cooler.)
OK
(1) NG
Measure at rear A/C control unit connector E-23. Check the following connectors: E-23, D-123, E-119
D Connect the connector. OK
D Ignition switch: ON NG
(1) Voltage between terminal 3 and body earth Check the trouble symptoms. Repair
OK: 1 V (Temperature control switch: MAX HOT),
4 V (Temperature control switch: MAX COOL) NG
(2) Voltage between terminal 12 and body earth Check the harness wire between the rear A/C control unit and
OK: 2.2 V [Air thermo sensor temperature: 25_C the rear A/C switch, and repair if necessary.
(1.5 k W)]
(3) Voltage between terminal 7 and body earth (2) NG
OK: 1 V (Air mix damper: MAX HOT), Check the following connectors: E-23, D-123, G-26,
4 V (Air mix damper: MAX COOL) G-24-1, G-24-3
(4) Voltage between terminal 6 and body earth OK NG
OK: 10 V (When the air mix damper flap is moving to the
MAX COOL position), 0.5 V (When the air mix Check the trouble symptoms.
Repair
damper flap is moving to the MAX HOT position) NG
(5) Voltage between terminal 14 and body earth
OK: 0.5 V (When the air mix damper flap is moving to Check the harness wire between the rear A/C control unit and
the MAX COOL position), 10 V (When the air mix the air thermo sensor, and repair if necessary.
damper flap is moving to the MAX HOT position)
(6) Voltage between terminal 1 and body earth (3 - 5) NG
OK: System voltage (magnetic valve: OFF), 0.5 V (mag- Check the following connectors: E-23, D-123, G-24,
netic valve: ON) G-24-1, G-24-2
OK NG
(6) NG Check the harness wire between the rear A/C control unit and
the air mix damper motor, and repair if necessary.
NG
Check the harness wire between the rear A/C control unit and
the magnet valve, and repair if necessary.
Inspection procedure 3
The rear blower does not operate. Probable cause
If no air comes out of the air vents even if the rear fan switch or the front rear D Malfunction of the rear blower relay
fan switch is turned on, the rear blower relay circuit may be defective. D Malfunction of the blower motor
D Malfunction of the rear A/C switch
D Malfunction of harness or connector
OK
Check the blower motor NG
(Refer to GROUP 55A - Rear Heater/Rear Cooler). Replace
OK
NG
Check the rear A/C switch (air volume adjusting switch) Replace
(Refer to GROUP 55A - Rear Heater/Rear Cooler).
OK
(1) NG
Measure at rear blower relay connector D-214. Check the following connectors: D-214, D-32, D-210, D-208
D Disconnect the connector and measure at the harness OK NG
side.
D Ignition switch: ON Check the trouble symptoms.
(1) Voltage between terminal 1 and body earth Repair
OK: System voltage NG
(2) Voltage between terminal 5 and body earth
OK: System voltage Check the harness wire between the rear blower relay and
(3) Voltage between terminal 3 and body earth the ignition switch (IG2), and repair if necessary.
OK: 0 V (Rear fan switch or front rear fan switch: ON)
(2) NG
Check the following connectors: D-214, D-27
OK NG
OK (3) NG
Check the trouble symptoms. Repair
NG
Check the harness wire between the rear blower relay and
fusible link (2), and repair if necessary.
NG
Measure at blower motor connector G-22-1. Check the following connectors: G-22-1, G-22, E-119
D Disconnect the connector and measure at the harness OK NG
side.
D Air volume adjusting switch: 3 Check the trouble symptoms. Repair
D Continuity between terminal 1 and body earth
OK: Continuity NG
OK Check the harness wire between the blower motor and the
rear A/C switch and between the rear A/C switch and body
Check the following connectors: D-214, D-123, G-22, earth, and repair if necessary.
G-22-1
OK NG
Check the harness wire between the rear A/C switch and the
resistor and between the resistor and the blower motor, and
repair if necessary.
Inspection procedure 5
Air outlet vents can not be changed in proportion to the Probable cause
temperature adjusting switch.
If the air outlet temperature can not be changed after a temperature control D Malfunction of the electric motor for the air outlet
switch is operated, the air outlet changeover damper may be defective. changeover damper
D Malfunction of harness or connector
D Malfunction of the rear A/C control unit
NO
Can the air temperature be adjusted by means of the Refer to Inspection Procedure 2 (Refer to P.55-19).
temperature adjusting switch?
YES
(1) NG
Measure at air outlet changeover damper motor connector Check the following connectors: G-22-3, G-22, D-123<L.H>,
G-22-3. D-123<R.H.>, D-32, D-210, D-208
D Disconnect the connector and measure at the harness OK NG
side.
D Ignition switch: ON Check the trouble symptoms. Repair
(1) Voltage between terminal 2 and body earth
OK: System voltage NG
(2) Continuity between terminal 1 and body earth Check the harness wire between the air outlet changeover
OK: Continuity (2) NG
damper motor and the ignition switch (IG2), and repair if
OK necessary.
NG
Check the trouble symptoms. Replace the rear A/C control unit.
ON-VEHICLE SERVICE
MAGNETIC CLUTCH TEST
1. Disconnect the connector (3-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.
FRONT A/C
AUTOMATIC A/C CONTROL PANEL ASSEMBLY (A/C-ECU)
REMOVAL AND INSTALLATION
1
Removal steps
1. Center panel (Refer to GROUP 52A -
Instrument Panel.)
2. Automatic A/C control panel assembly
(A/C-ECU)
INSPECTION
BLOWER LINEAR CONTROLLER INSPECTION
When the connector is connected and the ignition switch
is turned ON, the voltage at terminal 2 should meet the
following table.
Blower switch position Voltage at terminal No.2 V
Low speed 4.0
Medium speed 7.9
High speed 13.7
Removal steps
D Under cover (Refer to GROUP 52A Instrument Panel.)
1. Electric motor for the air mix damper
2. Electric motor for the air outlet changeover damper
INSPECTION
AIR MIX DAMPER MOTOR INSPECTION
Motor check
MAX HOT position
Battery connection terminal Lever operation
1 2
MAX COOL Rotate to the HOT
position position.
Rotate to the COOL
position.
Caution
If the lever reaches the stop position, disconnect the
battery voltage.
Potentiometer check
When the resistances between terminals 3 and 5 as well
as terminals 3 and 7 are measured at the previous check,
the resistance value should change gradually within the
standard value.
Standard value: Approximately 0.96 - 5.76 kW
Caution
If the lever reaches the stop position, disconnect the
battery voltage.
Potentiometer check
When the resistances between terminals 3 and 5 as well
as terminals 3 and 7 are measured at the previous check,
the resistance value should change gradually within the
standard value.
Standard value: Approximately 0.96 - 5.76 kW
Removal steps
D Under cover (Refer to GROUP 52A Instrument Panel.)
"AA 1. Heater water temperature sensor clip
"AA 2. Heater water temperature sensor
INSPECTION
30
HEATER WATER TEMPERATURE SENSOR CHECK
25
20 Measure the resistance between the sensor terminals under
Resist- at least two temperatures. The resistance values should meet
ance 15
(k W)
the left graph.
10
NOTE
5
The temperature should be within the shown range.
0
10 0 20 40 60 80 100
Temperature (_C)
PHOTO SENSOR
REMOVAL AND INSTALLATION
(Refer to GROUP 54A Headlamp.)
INSPECTION
PHOTO SENSOR CHECK
The blower speed should drop when the light-receiving section
of the photo sensor is covered with your hand. If not, replace
the photo sensor.
8
Resist- 6
ance
(k W) 4
2
0
10 0 10 20 30 40
Temperature (_C)
REAR A/C
ELECTRIC MOTOR FOR THE AIR OUTLET CHANGEOVER DAMPER
REMOVAL AND INSTALLATION
9.8 2.0 Nm
14 0.5 Nm 33 1 Nm
Low pressure-side service valve
6
33 1 Nm
5 11 3
9.8 2.0 Nm
Pipe connections
1
9.8 2.0 Nm
7 8
1, 2, 3, 4 O-ring
14 0.5 Nm 33 1 Nm
10
14 0.5 Nm
33 1 Nm
O-ring
33 1 Nm 3, 4, 5, 6,
7,8, 9, 10
Removal steps
1. Dual pressure switch AA" 7. Suction pipe B
AA" 2. Discharge flexible hose AA" 8. Liquid pipe C
AA" 3. Suction flexible hose AA" 9. Suction pipe C
AA" 4. Liquid pipe A AA" 10. Liquid pipe D
AA" 5. Suction pipe A AA" 11. Liquid pipe E
AA" 6. Liquid pipe B
14 0.5 Nm
33 1 Nm
Pipe con-
9.8 2.0 Nm nections
1
2 7
8
1, 2, 3, 4 O-ring
33 1 Nm
14 0.5 Nm
9
33 1 Nm
14 0.5 Nm 10
O-ring
33 1 Nm
3, 4, 5, 6,
7, 8, 9, 10
Removal steps
1. Dual pressure switch AA" 6. Liquid pipe B
AA" 2. Discharge flexible hose AA" 7. Suction pipe B
AA" 3. Suction flexible hose AA" 8. Liquid pipe C
AA" 4. Liquid pipe A AA" 9. Suction pipe C
AA" 5. Suction pipe A AA" 10. Liquid pipe D
9.8 2.0 Nm
5
3
Pipe connections
1
2, 3 O-ring
Removal steps
AA" 1. Drive belt AC" "AA 4. Compressor
AB" 2. Discharge flexible hose connection 5. Compressor bracket
AB" 3. Suction flexible hose connection
INSPECTION
COMPRESSOR MAGNETIC CLUTCH OPERATION
INSPECTION
Connect the positive battery cable to compressor connector
terminal No.3 or No.1 and negative battery cable to the
compressor housing (earth).The magnetic clutch should click.
7
6
4
3 2
8 1
13.5 2.7 Nm
Groove on the
compressor