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Mitsubishi MOTORS Colt 2000, Workshop Manual Supplement

The Mitsubishi MOTORS Colt 2000 Workshop Manual Supplement offers comprehensive guidance for maintenance and repair of this remarkable vehicle. This manual is an essential resource for any owner or mechanic seeking in-depth knowledge. Download the free manual now from manualshive.com to ensure smooth and efficient operation of your Colt 2000.

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Summary of Contents for Colt 2000

Page 1: ...ls are also available and should be used in conjunction with this manual TECHNICAL INFORMATION MANUAL PYME9501 PYME9501 1 WORKSHOP MANUAL CHASSIS GROUP PWME9511 Basic PWME9511 A Supplement PWME9511 B Supplement ENGINE GROUP PWEE____ Looseleaf edition ELECTRICAL WIRING PHME9511 Basic PHME9511 A Supplement PHME9511 B Supplement PHME9511 C Supplement BODY REPAIR MANUAL PBME9501 Basic PBME9501 1 Suppl...

Page 2: ...t 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 Rest...

Page 3: ...00 1 GENERAL CONTENTS VEHICLE IDENTIFICATION 2 Models 2 Model Code 2 Chassis Number 3 MAJOR SPECIFICATIONS 4 Hatchback 4 ...

Page 4: ...6 F4A41 INVECS II 4A T MODEL CODE No Items Contents 1 Development CJ MITSUBISHI 2 door 2 Engine type 1 1 298 mL petrol engine 4 1 597 mL petrol engine 3 Sort A Passenger car 4 Body style M 2 door hatchback 5 Transmission type N 5 speed manual transmission R 4 speed automatic transmission 6 Trim level D GL J GLX or GLXi 7 Specification engine feature E SOHC MPI 8 Steering wheel location L Left hand...

Page 5: ...hannel M Japan channel 3 Destination A For Europe right hand drive B For Europe left hand drive 4 Body style M 2 door hatchback 5 Transmission type N 5 speed manual transmission R 4 speed automatic transmission 6 Development order CJ COLT 7 Engine 1 4G13 1 298 mL petrol engine 4 4G92 1 597 mL petrol engine 8 Sort A Passenger car 9 Model year 1 2001 10 Plant U Mizushima Motor Vehicle Works 11 Seria...

Page 6: ...rhang front 7 825 825 825 825 Overhang rear 8 660 660 660 660 Ground clearance unladen 9 150 165 1 3 150 165 1 3 150 165 1 3 150 165 1 3 Vehicle Kerb weight 950 955 975 995 weight kg Max gross vehicle weight rating 1 445 1 445 1 470 1 480 Max axle weight rating front 810 810 810 810 Max axle weight rating rear 705 705 705 705 Seating capacity 5 Engine Model No 4G13 4G92 Total displacement mL 1 298...

Page 7: ...11A 1 ENGINE CONTENTS ENGINE 4G1 11A ENGINE 4G9 11B ...

Page 8: ... of Changes 3 GENERAL INFORMATION 3 SERVICE SPECIFICATIONS 3 SEALANT 3 SPECIAL TOOLS 4 ON VEHICLE SERVICE 5 Compression Pressure Check 5 Lash Adjuster Check 5 CAMSHAFT AND CAMSHAFT OIL SEAL 8 CRANKSHAFT FRONT OIL SEAL 11 CYLINDER HEAD GASKET 12 ...

Page 9: ...t oil seal removal and installation D Crankshaft front oil seal removal and installation D Cylinder head gasket removal and installation GENERAL INFORMATION Items 4G13 Compression ratio 10 0 Combustion chamber Pentroof type Number of valve Intake 8 Exhaust 8 Valve timing Intake Opening BTDC 17_ Closing ABDC 39_ Exhaust Opening BBDC 49_ Closing ATDC 7_ Auto lash adjuster Equipped SERVICE SPECIFICAT...

Page 10: ...pulley holder pin MD998443 Auto lash adjuster holder Supporting of lash adjuster MD998713 Camshaft oil seal installer Press in of the camshaft oil seal MD998304 Crankshaft front oil seal installer Press fitting the crankshaft front oil seal MD998305 Crankshaft front oil seal guide MB991653 Cylinder head bolt wrench Cylinder head bolt removal and installation ...

Page 11: ...e source of the noise is not the lash adjusters 2 If there is a problem with the lash adjusters the noise will almost never disappear even if the engine has been run at idle to let it warm up The only case where the noise might disappear is if the oil in the engine has not been looked after properly and oil sludge has caused the lash adjusters to stick 1 Start the engine 2 Check that the noise occ...

Page 12: ...ituations occur the abnormal noise can be eliminated by bleeding the air from inside the lash adjusters 1 Check the engine oil and replenish or replace the oil if necessary NOTE 1 If there is a only small amount of oil air will be drawn in through the oil screen and will get into the oil passage 2 If the amount of oil is greater than normal then the oil will being mixed by the crankshaft and a lar...

Page 13: ...ions but if there is no change in the noise level after 30 repetitions or more the problem is probably not due to air inside the lash adjusters 4 After the noise has disappeared repeat the drive pattern shown in the illustration at left a further 5 times 5 Run the engine at idle for 1 3 minutes and check that the noise has disappeared Gradually open the throttle valve Drive pattern for air bleedin...

Page 14: ... 34 Nm 10 12 Nm Apply engine oil to all moving parts during installation Removal steps 1 Breather hose connection 2 PCV hose connection 3 Accelerator cable clamp LH drive vehicles 4 Rocker cover 5 Rocker cover gasket 6 Spark plug guide 7 Timing belt front upper cover AA CA 8 Camshaft sprocket BA 9 Camshaft oil seal AB AA 10 Lash adjuster intake rocker arm and shaft assembly AB AA 11 Lash adjuster ...

Page 15: ...rocket with the timing belt attached Caution Do not turn the crankshaft after the camshaft sprocket is removed AB LASH ADJUSTER INTAKE ROCKER ARM AND SHAFT ASSEMBLY LASH ADJUSTER EXHAUST ROCKER ARM AND SHAFT ASSEMBLY REMOVAL Before removing the lash adjuster rocker arm and shaft assembly install the special tools as shown in the illustration so that the lash adjusters will not fall out INSTALLATIO...

Page 16: ...he camshaft oil seal lip 2 Use the special tool to press fit the camshaft oil seal CA CAMSHAFT SPROCKET INSTALLATION Use the special tool to stop the camshaft sprocket from turning in the same way as was done during removal and then tighten the bolts to the specified torque Tightening torque 88 Nm MD998713 ...

Page 17: ...r to GROUP16 5 1 2 3 4 5 Lip Engine oil Removal steps BA 1 Crankshaft sprocket BA 2 Spring pin BA 3 Crankshaft sensing blade BA 4 Crankshaft spacer AA 5 Crankshaft front oil seal INSTALLATION SERVICE POINTS AA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the entire circumference of the oil seal lip 2 Tap the oil seal unit it flushes with the oil seal case Cranksha...

Page 18: ...nkshaft spacer to the crankshaft CYLINDER HEAD GASKET REMOVAL AND INSTALLATION Pre removal and Post installation Operation D Prevention of Fuel Discharge before removal only D Fuel Leak Check after installation only D Under Cover Removal and Installation D Engine Coolant Draining and Supplying D Engine Oil Draining and Supplying D Air Cleaner Removal and Installation Crankshaft sensing blade Crank...

Page 19: ...9 Idle speed control servo connector 10 Purge control solenoid valve connector 11 Engine coolant temperature gauge unit connector 12 Oxygen sensor front connector 13 Engine coolant temperature sensor connector 14 Ignition failure sensor connector 15 Camshaft position sensor connector D Rocker cover Refer to P 11A 8 D Intake manifold Refer to GROUP 15 D Water inlet pipe Refer to GROUP 14 16 Front e...

Page 20: ...revent deviation from the relative positions between the camshaft sprocket and the timing belt 3 Use the special tool to stop the camshaft sprocket from turning 4 Remove the camshaft sprocket with the timing belt attached Caution Do not turn the crankshaft after the camshaft sprocket is removed AB CYLINDER HEAD BOLT REMOVAL Use the special tool to loosen the bolts in 2 or 3 steps in order of the n...

Page 21: ...installing the cylinder head bolts the length below the head of the bolts should be within the limit If it is outside the limit replace the bolts Limit A 103 2 mm 2 Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt 3 Use the special tool to tighten the bolts by the following procedure angle tightening procedure 1 Tighten the cylinder head bolts in th...

Page 22: ...re flush with the paint marks on the cylinder head Caution 1 If the tightening angle is less than 90 the bolt is loose 2 If the tightening angle is more than 90 loosen the bolt and repeat the procedure from step 1 CA CAMSHAFT SPROCKET INSTALLATION Use the special tool to stop the camshaft sprocket from turning in the same way as was done during removal and then tighten the bolts to the specified t...

Page 23: ... 1 ENGINE 4G9 CONTENTS GENERAL 2 Outline of Changes 2 GENERAL INFORMATION 2 SPECIAL TOOL 2 ON VEHICLE SERVICE 2 Ignition Timing Check 2 Lash Adjuster Check 2 CAMSHAFT AND CAMSHAFT OIL SEAL 5 TIMING BELT 6 ...

Page 24: ... Closing ATDC 2_ SPECIAL TOOL Tool Number Name Use MD998443 Auto lash adjuster holder Supporting of lash adjuster ON VEHICLE SERVICE IGNITION TIMING CHECK The ignition timing has been changed Other service procedures are the same as before Standard value Approx 8_BTDC LASH ADJUSTER CHECK If an abnormal noise knocking that seems to be coming from the lash adjuster is heard after starting the engine...

Page 25: ...he lash adjusters are normal 3 While the engine is idling check that the noise level does not change when the engine load is varied for example by shifting from N D If the noise level changes the cause of the noise is probably parts striking because of worn crankshaft bearings or connecting rod bearings In such cases the lash adjusters are normal 4 After the engine has warmed up run it at idle and...

Page 26: ...al noise when the valve closes This is the same effect as if the valve clearance is adjusted to be too large by mistake If the air inside the lash adjusters is then released the operation of the lash adjusters will return to normal 2 Run the engine at idle for 1 3 minutes to let it warm up 3 With no load on the engine repeat the drive pattern shown in the illustration at left and check if the abno...

Page 27: ... AND SHAFT ASSEMBLY LASH ADJUSTER EXHAUST ROCKER ARM AND SHAFT ASSEMBLY REMOVAL Before removing the lash adjuster rocker arm and shaft assembly install the special tools as shown in the illustration so that the lash adjusters will not fall out INSTALLATION SERVICE POINT AA LASH ADJUSTER EXHAUST ROCKER ARM AND SHAFT ASSEMBLY LASH ADJUSTER INTAKE ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION Position t...

Page 28: ...moval steps 1 Crank angle sensor connector AA 2 Timing belt lower cover INSTALLATION SERVICE POINT AA TIMING BELT LOWER COVER INSTALLATION 1 Mount the bolt shown in the illustration M6 20 mm first 2 Mount the other bolts and tighten them to the specified torque Tightening torque 10 Nm ...

Page 29: ...ral On vehicle Service 12 1 GROUP 12 ENGINE LUBRICATION GENERAL OUTLINE OF CHANGE A quality of the engine oil has been changed ON VEHICLE SERVICE Specified Engine Oil ACEA and API classification ACEA A1 A2 A3 API SG or higher ...

Page 30: ...NOTES ...

Page 31: ...le 70 Check at the Engine ECU Terminals 71 Inspection Procedure Using an Analyzer 72 ON VEHICLE SERVICE 78 Basic Idle Speed Adjustment 78 Component Location 79 Intake Air Temperature Sensor Check 80 Oxygen Sensor Check 80 INJECTOR 82 MULTIPOINT FUEL INJECTION MPI 4G9 84 GENERAL 84 Outline of Changes 84 GENERAL INFORMATION 84 Self diagnosis Function 84 General Specifications 84 TROUBLESHOOTING 85 D...

Page 32: ...e sensor has been added D Intake air temperature sensor built in the vacuum sensor manifold absolute pressure sensor has been adopted D Oxygen sensor front rear has been changed D Ignition timing adjustment terminal has been abolished D Delivery pipe has been changed GENERAL INFORMATION SELF DIAGNOSIS FUNCTION The following functions have been added D The engine ECU records the engine operating co...

Page 33: ...ge control solenoid valve l3 Idle speed control valve l4 EGR control servo valve D Fuel pump relay D Engine control relay D A C power relay D Engine warning lamp D Diagnosis signal D Ignition coil power transistor D Fan controller L2 Vacuum sensor L3 Intake air temperature sensor l3 Idle speed control valve Air cleaner To fuel tank Fuel pressure regulator From fuel pump PCV valve l1 Injector EGR v...

Page 34: ...t 4 5 8 0 Rear 11 18 SPECIAL TOOLS Tool Number Name Use MB991536 Throttle position sensor adjustment harness D Measurement of voltage during trouble shooting MB991658 Test harness set D Measurement of voltage during trouble shooting MD998464 Test harness 4 pin square D Measurement of voltage during trouble shooting D Inspection of oxygen sensor front MD998478 Test harness 3 pin triangle D Measurem...

Page 35: ...gine coolant temperature sensor system P0120 Throttle position sensor system P0125 Feedback system P0130 Oxygen sensor front system sensor 1 P0135 Oxygen sensor heater front system sensor 1 P0136 Oxygen sensor rear system sensor 2 P0141 Oxygen sensor heater rear system sensor 2 P0170 Abnormal fuel system P0201 No 1 injector system P0202 No 2 injector system P0203 No 3 injector system P0204 No 4 in...

Page 36: ... 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 METHOD OF READING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points DIAGNOSIS USING DIAGNOSIS 2 MODE 1 Switch the diagnosis mode of the engine control unit to DIAGNOSIS 2 mode using the MUT II 2 Carry out a r...

Page 37: ...ion Closed loop CL Open loop owing to drive condition OL DRV Open loop owing to system malfunction OL SYS Closed loop based on one oxygen sen sor CL H02S Calculation load value Diagnosis code during data recording 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 diag...

Page 38: ...mount during acceleration due to the throttle position sensor signal Engine coolant tem perature sensor Controls as if the engine coolant temperature is 80_C Camshaft position sensor Injects fuelintothe cylinders in the order 1 3 4 2with irregulartiming After the ignitionswitch is turned to ON the No 1 cylinder top dead centre is not detected at all Detonation sensor Switches the ignition timing f...

Page 39: ...re detected 13A 28 P0304 No 4 cylinder misfire detected 13A 28 P0325 Detonation sensor system 13A 29 P0335 Crank angle sensor system 13A 29 P0340 Camshaft position sensor system 13A 31 P0403 EGR control solenoid valve system 13A 32 P0421 Catalyst malfunction 13A 33 P0443 Purge control solenoid valve system 13A 34 P0500 Vehicle speed sensor system 13A 35 P0505 Idle speed control system 13A 36 P1610...

Page 40: ...r B 34 NG Repair MUT II Data list 32 Barometric pressure sensor Refer to P 13A 65 DATA LIST REFERENCE TABLE OK Transient malfunction Refer to GROUP 00 Points to Note for Intermittent Malfunctions NG NG Repair OK Measure at vacuum sensor connector A 54 D Disconnect the connector and measure at the harness side 1 Voltage between terminal 3 and earth Ignition switch ON OK 4 8 5 2 V 2 Resistance betwe...

Page 41: ...easure at engine ECU connector B 34 D Measure the voltage at the engine ECU terminal D Ignition switch ON D Voltage between terminal 85 and earth OK Altitude 0 m 3 7 4 3 V Altitude 1 200 m 3 2 3 8 V NG Check the following connector B 34 NG Repair OK Check the trouble symptoms OK Check the following connector B 34 NG Repair NG Replace the engine ECU ...

Page 42: ...ness between the air flow sensor and the engine ECU and repair if necessary NG Repair OK Check the following connector B 34 2 NG Measure at engine ECU connector B 34 D Measure the voltage at the engine ECU terminal D Disconnect connector A 54 D Ignition switch ON D Voltage between terminal 81 and earth OK 4 8 5 2 V OK Check the trouble symptoms NG Replace the engine ECU OK Check the harness betwee...

Page 43: ...ector B 34 NG Repair From the previous page Code No P0115 Engine coolant temperature sensor system Probable cause Range of Check D Engine Two seconds after the engine has been started Set Conditions D The sensor output voltage is 4 6 V or more for two seconds equivalent to 45_C of engine coolant temperature or D The sensor output voltage is 0 1 V or less for two seconds equivalent to 140_C of engi...

Page 44: ...ne coolant temperature sensor connector A 72 D Disconnect the connector and measure at the harness side 1 Voltage between terminal 1 and earth Ignition switch ON OK 4 8 5 2 V 2 Resistance between terminal 2 and earth OK 2 W or less 1 NG Measure at engine ECU connector B 34 D Measure the voltage at the engine ECU terminal D Disconnect connector A 72 D Ignition switch ON D Voltage between terminal 4...

Page 45: ...A 72 D Use test harness MB991658 to connect the connector and measure at the pick up harness D Ignition switch ON D Voltage between terminal 1 and earth OK At 0_C of engine coolant temperature 3 2 3 8 V At 20_C of engine coolant temperature 2 3 2 9 V At 40_C of engine coolant temperature 1 3 1 9 V At 80_C of engine coolant temperature 0 3 0 9 V NG Check the engine coolant temperature sensor Refer ...

Page 46: ... OK Check the harness wire between the throttle position sensor and the engine ECU NG Repair NG Check the following connector B 34 NG Repair OK Check the harness wire between the throttle position sensor and the engine ECU and repair if necessary NG Repair OK Check the following connector B 34 1 NG Measure at engine ECU connector B 34 D Measure the voltage at the engine ECU connector terminal D Ig...

Page 47: ...5 D Use test harness MB991536 to connect the connector and measure at the pick up harness D Ignition switch ON 1 The voltage between terminal 1 and earth OK 4 8 5 2 V 2 The voltage between terminal 4 and earth OK 0 5 V or less 3 The voltage between terminal 2 and earth OK Accelerator pedal fully re leased 0 3 1 0 V Accelerator pedal fully de pressed 4 5 5 5 V 1 2 NG NG Repair Check the following c...

Page 48: ... warming up D Voltage between terminal 76 and earth OK 0 V and 0 8 V alternate OK Check the harness wire between the oxygen sensor front and the engine ECU and repair if necessary OK NG Repair Check the following connector B 34 OK Check the harness wire between the oxygen sensor front and the engine ECU and repair if necessary NG Replace the engine ECU OK Check the trouble symptoms OK Check the ha...

Page 49: ... Conditions D The oxygen sensor front output voltage is 4 5 V or more when the sensor output voltage is 0 2 V or less and a voltage of 5 V is applied to the oxygen sensor front inside the engine ECU D Malfunction of oxygen sensor front D Open or short circuit in the oxygen sensor front circuit or loose connector contact D Malfunction of engine ECU Range of Check D Engine speed is 2 800 r min or le...

Page 50: ...heck the harness wire between the oxygen sensor front and the engine ECU and repair if necessary NG Replace the engine ECU OK Check the trouble symptoms OK Check the harness wire between the oxygen sensor front and the engine ECU NG Repair Repair OK Measure at oxygen sensor front connector A 106 D Disconnect the connector and measure at the harness side D Resistance between terminal 2 and earth OK...

Page 51: ... and the engine ECU and between the oxygen sensor front and the engine control relay NG Repair OK Check the following connector B 35 NG Repair OK Check the harness wire between the oxygen sensor front and the engine ECU Repair NG Check the following connector B 35 NG OK Measure at engine ECU connector B 35 D Measure the voltage at the engine ECU terminal D Ignition switch ON D Voltage between term...

Page 52: ...the sensor output voltage is 0 2 V or less and a voltage of 5 V is applied to the oxygen sensor rear inside the engine ECU D Malfunction of oxygen sensor rear D Open or short circuit in the oxygen sensor rear circuit or loose connector contact D Malfunction of engine ECU Range of Check D Two seconds have passed after the ECU detected an open circuit D When the oxygen sensor front is in good condit...

Page 53: ...ng connector B 34 OK Check the harness wire between the oxygen sensor rear and the engine ECU and repair if necessary NG Replace the engine ECU OK Check the trouble symptoms OK Check the harness wire between the oxygen sensor rear and the engine ECU NG Repair Repair OK Measure at oxygen sensor rear connector A 108 D Disconnect the connector and measure at the harness side D Resistance between term...

Page 54: ... and between the oxygen sensor rear and the engine control relay NG Repair OK Check the following connector B 35 NG Repair OK Check the harness wire between the oxygen sensor rear and the engine ECU and repair if necessary Repair NG Check the following connector B 35 NG OK Measure at engine ECU connector B 35 D Measure the voltage at the engine ECU terminal D Ignition switch ON D Voltage between t...

Page 55: ...n front pipe etc D Check for entry of foreign matter water kerosene etc into the fuel OK NG Repair NG NG OK MUT II Data list 81 Long term fuel compensation Refer to P 13A 69 D Is fuel trim more or less than zero More than zero Check if air was drawn into the intake system OK Check the fuel pressure Refer to P 13A 78 NG Repair NG NG OK Check the harness wire between the engine ECU and the injector ...

Page 56: ...mal waveform should be displayed as described on P 13A 69 INSPECTION PROCEDURE USING AN ANALYZER OK Check the trouble symptoms NG Measure at the engine ECU connector B 37 D Disconnect the connector and measure at the harness side D Voltage between 1 2 14 15 and earth Ignition switch ON OK System voltage Check the harness wire between the engine ECU and the injector connector and repair if necessar...

Page 57: ...iming belt for jumping teeth D Check the EGR system and EGR valve OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 66 Check the engine coolant temperature sensor system Refer to P 13A 13 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODE P0115 NG NG Check the abnormal fuel system Refer to P 13A 25 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODE P0170 NG OK MUT II Data list 82...

Page 58: ...ctors A 74 A 75 A 76 A 80 B 37 Repair OK NG Check the injector Refer to P 13A 86 Replace OK NG Replace Check the spark plugs Check the ignition coil Refer to GROUP 16 Ignition System OK OK Check the trouble symptoms NG Replace the engine ECU Check the harness wire between the ignition coil and the engine ECU OK NG Repair 2 NG NG Repair Check the following connector B 37 OK Check the harness wire b...

Page 59: ...00 Points to Note for Intermittent Malfunctions OK Check the harness wire between the detonation sensor and the engine ECU NG Repair OK Check the following connector B 34 NG Repair Check the following connector A 64 NG Repair OK Measure at the detonation sensor connector A 64 D Disconnect the connector and measure at the harness side D The resistance between terminal 2 and earth OK 2 W or less NG ...

Page 60: ...the following connector B 13 NG Repair 3 NG OK Check the trouble symptoms NG Replace the engine ECU OK Check the harness wire between the crank angle sensor and the engine ECU NG Repair NG Check the following connector B 34 NG Repair OK Check the harness wire between the crank angle sensor and the engine ECU and repair if necessary NG Repair OK Check the following connector B 34 2 NG Measure at en...

Page 61: ... should be displayed as described on P 13A 72 Inspection Procedure Using an Ana lyzer its maximum value should be 4 8 V or more and its minimum value should be 0 6 V or less with no noise in waveform Check the harness wire between the camshaft position sensor connector and earth and repair if necessary 3 NG OK Check the trouble symptoms NG Replace the engine ECU OK Check the harness wire between t...

Page 62: ...or B 37 NG Repair OK Measure at engine ECU connector B 37 D Measure the voltage at the engine ECU terminal D Ignition switch ON D The voltage between terminal 6 and earth OK System voltage NG Check the harness wire between the EGR control solenoid valve and the engine control relay and repair if necessary NG Check the following connector B 13 NG Repair OK Measure at the EGR control solenoid valve ...

Page 63: ...catalytic converter Check the trouble symptoms OK Replace the oxygen sensor rear OK MUT II Data list 11 Oxygen sensor front D Transmission 2nd OK Changeover between 0 400 mV and 600 1 000 mV occur 15 times in 10 seconds Replace the oxygen sensor front NG MUT II Data list 11 Oxygen sensor front OK 600 1 000 mV when racing suddenly OK NG Check the oxygen sensor front system sensor 1 Refer to P 13A 1...

Page 64: ...d valve and the engine ECU NG Check the following connector B 37 NG Repair OK Measure at engine ECU connector B 37 D Measure the voltage at the engine ECU terminal D Ignition switch ON D The voltage between terminal 9 and earth OK System voltage NG Check the harness wire between the purge control solenoid valve and the engine control relay and repair if necessary NG Check the following connector B...

Page 65: ...gine ECU OK Check the trouble symptoms NG Repair OK Check the harness wire between intermediate connector B 33 and the engine ECU and repair if necessary NO Check the vehicle speed sensor Refer to GROUP 54 Combination Meter YES Use an analyzer to measure the output waveform of the vehicle speed sensor at engine ECU connector B 34 D Driving the vehicle D The voltage between terminal 86 and earth OK...

Page 66: ...or more D Battery voltage is 10 V or more D Intake air temperature is 10_C 14_F or more Judgment Criteria D Actual idle speed has been minimum 200 r min higher than the target idle speed for ten seconds Check Area D During idle speed closed loop control D Engine coolant temperature is about 80_C or higher D Battery voltage is 10 V or higher D Power steering switch is off D Intake air pipe pressure...

Page 67: ...ion 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 NG Check the following connector B 37 OK OK Check the harness wire between the engine control relay and the idle speed control servo and repair if necessary Measure at the idle speed control servo connector A 56 D Disconnect the connector and measure at the ha...

Page 68: ...U D Malfunction of the engine ECU 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 ID code NG Replace the engine ECU Check the trouble symptoms NG Replace the immobilizer ECU OK Check the trouble symptoms OK Check the harness wire between the immobilizer ...

Page 69: ...to start improper starting 7 13A 44 Idling stability Unstable idling Rough idling hunting 8 13A 45 Improper idling Idling speed is high Improper idling speed 9 13A 47 Idling speed is low Improper idling speed 10 13A 47 Idling stability When the engine is cold it stalls at idling Die out 11 13A 48 Engine stalls When the engine becomes hot it stalls at idling Die out 12 13A 49 The engine stalls when...

Page 70: ...agnostic connector 16 pin and earth and repair if necessary OK Replace the MUT II INSPECTION PROCEDURE 2 MUT II communication with engine ECU is impossible Probable cause One of the following causes may be suspected D No power supply to engine ECU D Defective earth circuit of engine ECU D Defective engine ECU D Improper communication line between engine ECU and MUT II D Malfunction of engine ECU p...

Page 71: ...place OK Measure at the combination meter connector B 02 D Disconnect the connector and measure at the harness side D Voltage between 42 and earth Ignition switch ON OK System voltage NG Check the engine warning lamp power supply circuit and repair if necessary OK Check the following connectors B 02 B 32 B 36 B 69 NG Repair OK check the trouble symptom NG Check the harness wire between combination...

Page 72: ...l etc got into fuel D Check the compression pressure D Check the immobilizer system Refer to GROUP 54 Ignition Key and Immobilizer No MUT II Data list 16 Voltage of engine ECU power source Refer to P 13A 66 NG Check the power supply and ignition switch IG system Refer to P 13A 59 INSPECTION PROCEDURE 25 OK Does the camshaft rotate at the engine cranking When oil filler cap is removed No Check timi...

Page 73: ...FOR DIAGNOSIS CODE P0505 OK D Clean the throttle valve area Refer to P 13A 75 No Check the ignition timing when cranking OK Approx 5_BTDC NG Check that the distributor is installed properly OK Check the following items D Check the ignition coil spark plugs spark plug cables Refer to GROUP 16 On vehicle Service D Check if the injectors are clogged D Check the compression pressure Refer to GROUP 11B...

Page 74: ...g when cranking OK Approx 5_BTDC NG Check that the distributor is installed properly OK Check the following items D Check the ignition coil spark plugs spark plug cables Refer to GROUP 16 On vehicle Service D Check if the injectors are clogged D Check the compression pressure Refer to GROUP 11B On vehicle Service D Check if foreign materials water alcohol etc got into fuel OK MUT II Self Diag code...

Page 75: ...anifold gasket D Broken air intake hose D Broken vacuum hose D Positive crankcase ventilation valve does not operate OK MUT II Data list 14 Throttle position sensor Refer to P 13A 65 NG Check the throttle position sensor system Refer to P 13A 16 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE P0120 OK MUT II Data list 13 Intake air temperature sensor Refer to P 13A 65 NG Check the intake air temperature ...

Page 76: ...tch Refer to P 13A 67 NG Check the A C switch and A C relay system Refer to P 13A 62 INSPECTION PROCEDURE 29 OK MUT II Data list 45 ISC servo position Refer to P 13A 68 NG Adjust the basic idle speed Refer to P 13A 78 OK MUT II Data list 11 Oxygen sensor front OK Changes between 0 400 mV and 600 1 000 mV during idling NG Check the fuel pressure Refer to P 13A 78 OK 1 Inspect the intake of air into...

Page 77: ...OK Basic idle adjustment Refer to P 13A 78 check the trouble symptom NG Clean the throttle valve area Refer to P 13A 75 NOTE Refer to the 96 COLT LANCER Workshop Manual Pub No PWME9511 INSPECTION PROCEDURE 10 Idling speed is low Improper idling speed Probable cause In cases such as the above the cause is probably that the intake air volume during idling is too small D Malfunction of the ISC system...

Page 78: ... INSPECTION PROCE DURE FOR DIAGNOSIS CODE P0505 OK Check the injector for operation sound NG Check the injector system Refer to P 13A 26 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE P0201 P0202 P0203 P0204 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 65 NG Check the throttle position sensor system Refer to P 13A 16 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE P0120 OK MUT II Data list 21...

Page 79: ...tent malfunction simulation test Refer to GROUP 00 Points to Note for Intermittent Malfunctions check for sudden changes in the signals shown below D Crank angle sensor signal D Injector drive signal D Primary and secondary ignition signal D Fuel pump drive signal D Engine ECU power supply voltage Yes MUT II Data list 14 Throttle position sensor Refer to P 13A 65 NG Check the throttle position sen...

Page 80: ... P 13A 62 INSPECTION PROCEDURE 29 OK MUT II Data list 45 ISC servo position Refer to P 13A 68 NG Adjust the basic idle speed Refer to P 13A 78 From previous page OK MUT II Data list 11 Oxygen sensor front OK Changes between 0 400 mV and 600 1 000 mV during idling NG Check the fuel pressure Refer to P 13A 78 OK 1 Inspect the intake of air into the air intake system D Broken intake man ifold gasket ...

Page 81: ...ating Probable cause In cases such as the above the cause is probably that theintake airvolume is insufficient due to a defective idle speed control ISC servo system D Malfunction of the ISC system Were the battery terminals disconnected Yes After warming up let the engine run at idling for 10 minutes No MUT II Self Diag code Are diagnosis codes displayed Yes Refer to P 13A 9 INSPECTION CHART FOR ...

Page 82: ...air temperaturesensor system Refer toP 13A 12 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0110 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 66 NG Check the engine coolant temperature sensor system Refer toP 13A 13 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 65 NG Check the throttle position sensor system Refer...

Page 83: ...Check for occurrence of ignition leak INSPECTION PROCEDURE 17 The feeling of impact or vibration when decelerating Probable cause Malfunction of the ISC system is suspected D Malfunction of the ISC system MUT II Self Diag code Are diagnosis codes displayed Yes Refer to P 13A 9 INSPECTION CHART FOR DIAGNOSIS CODES No Check the ISC servo for operation sound Refer to P 13A 88 NG Check the ISC system ...

Page 84: ... 12 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0110 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 66 NG Check the engine coolant temperature sensor system Refer toP 13A 13 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 65 NG Check the throttle position sensor system Refer to P 13A 16 IN SPECTION PROCEDURE FOR DIA...

Page 85: ...t temperature sensor Refer to P 13A 66 NG Check the engine coolant temperature sensor system Refer toP 13A 13 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 65 NG Check the throttle position sensor system Refer to P 13A 16 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE P0120 OK MUT II Actuator test 10 EGR control solenoid valve Refer to P 13A...

Page 86: ...uel MUT II Self Diag code Are diagnosis codes displayed Yes Refer to P 13A 9 INSPECTION CHART FOR DIAGNOSIS CODES No Does knocking occur when driving with the detonation sensor connector disconnected At this time use the MUT II to check if the timing is retarded compared to when the detonation sensor connector is disconnected No Check the detonation sensor system Refer to P 13A 29 INSPEC TION PROC...

Page 87: ...DURE FOR DIAGNOSIS CODE P0110 OK MUT II Data list 59 Oxygen sensor rear D Transmission 2nd gear D Driving with throttle widely open OK 600 1 000 mV NG Check the oxygen sensor rear system Refer to P 13A 22 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0136 OK MUT II Data list 11 Oxygen sensor front OK 600 1 000 mV when racing suddenly NG Check the oxygen sensor front system Refer to P 13A 19 INSPECTION ...

Page 88: ... and A C condenser fan Ignition switch ON OK Fans are stopped D Voltage between 20 and earth 21 and earth Ignition switch ON OK System voltage D Connect a jumper wire between 20 and earth Ignition switch ON OK Radiator fan and condenser fan run at high speed D Connect a jumper wire between 21 and earth Ignition switch ON OK Radiator fan and condenser fan run at low speed NG D Check the radiator fa...

Page 89: ...ors B 34 B 36 B 37 NG Repair OK Check the trouble symptom NG Replace the engine ECU Check the following connectors B 32 B 34 B 48 B 62 B 69 NG Repair OK Check the trouble symptom NG Check the harness wire between engine ECU and battery and repair if necessary INSPECTION PROCEDURE 25 Power supply system and ignition switch IG system Probable cause When an ignition switch ON signal is input to the e...

Page 90: ...nnector and measure at the harness side D Continuity between 2 and earth OK Continuity NG Check the following connectors D 04 D 14 NG Repair OK Check the following connectors B 12 B 33 D 04 D 14 NG Check the harness wire between the fuel pump relay and fuel pump connec tor NG Repair OK Replace the fuel pump Measure at the fuel pump relay connec tor B 12 D Connect the connector D Voltage between 1 ...

Page 91: ... NG Repair OK Check the trouble symptom NG Replace the engine ECU INSPECTION PROCEDURE 28 Power steering fluid pressure switch system Probable cause The presence or absence of power steering load is input to the engine ECU The engine ECU controls the idle speed control ISC servo based on this input D Malfunction of power steering fluid pressure switch D Improper connector contact open circuit or s...

Page 92: ...y Refer to GROUP 55 On vehicle Service NG Replace OK Measure at the engine ECU connectors B 36 B 37 D Disconnect the connectors and measure at the harness side D Voltage between 8 Vehicles with immobilizer system 22 Vehicles without immobilizer system and earth and 45 and earth Ignition switch ON A C switch ON OK System voltage D Short circuit between 8 Vehicles with immobilizer system 22 Vehicles...

Page 93: ...NG Repair Check the following connector A 107 Measure at the ignition coil connectors A 73 A 79 D Disconnect the connector and measure at the harness side 1 Voltage between 1 and earth Ignition switch ON OK Battery positive voltage 2 Voltage between 3 and earth Engine Cranking OK 0 5 4 0 V 3 Continuity between 2 and earth OK Continuity 1 NG OK OK Check the ignition switch Refer to GROUP 54 Ignitio...

Page 94: ...ranking or 3 000 r min OK 0 3 3 0 V 2 NG Check the harness wire between the ignition failure sensor and earth and repair if necessary OK Measure at the ignition failure sensor connector A 107 D Disconnect the connector and measure at the harness side 1 Voltage between 2 and earth Ignition switch ON OK 4 V or more 2 Continuity between 1 and earth OK Continuity 1 NG There is an open or short circuit...

Page 95: ...armed up Air fuel mixture is made leaner when When at 4 000 r min engine is suddenly decelerated 200 mV or less Code No P0130 13A 19 made leaner when decelerating and is made richer when racing When engine is suddenly raced 600 1 000 mV Engine After having warmed up The oxygen sensor signal is used to Engine is idling 400 mV or less Changes 600 1 000 mV check the air fuel mixture ratio and control...

Page 96: ...re is 0_C 0_C When engine coolant temperature is 20_C 20_C When engine coolant temperature is 40_C 40_C When engine coolant temperature is 80_C 80_C 22 Crank angle sensor D Engine Cranking D Tachometer Connected Compare the engine speed readings on the tachometer and the MUT II Accord Code No P0335 13A 29 D Engine Idling D Idle position switch ON When engine coolant temperature is 20_C 1 475 1 675...

Page 97: ...m sensor 1 D Engine coolant temperature 80 Engine Stopped At altitude of 0 m 101 kPa Code No P0105 13A 10 95_C D Lamps electric cooling fan and all Engine Stopped At altitude of 600 m 95 kPa accessories OFF D Transmission Neutral Engine Stopped At altitude of 1 200 m 88 kPa D Ignition switch ON Engine Stopped At altitude of 1 800 m 81 kPa Engine Idling 24 3 37 7 kPa When engine is suddenly raced I...

Page 98: ...iming lamp is set in order to check actual ignition timing 2 500 r min 19 39 _BTDC 45 ISC stepper motor position 4 D Engine coolant temperature 80 95_C D Lamps electric cooling fan and all accessories OFF A C switch OFF 2 25 STEP accessories OFF D Transmission Neutral D Engine Idling D When A C switch is ON A C compressor should be operating A C switch OFF ON Increases by 10 70 steps 49 A C relay ...

Page 99: ...xygen sensor front Engine After having warmed up Air fuel mixture is made leaner when When at 4 000 r min engine is suddenly deceler ated 0 2 V or less Code No P0130 13A 19 decelerating and is made richer when racing When engine is sudden racing 0 6 1 0 V Engine After having warmed up The oxygen sensor signal is used to Engine is idling 0 4 V or less Changes 0 6 1 0 V check the air fuel mixture ra...

Page 100: ...ump Forced driving Inspect Pinch the return hose with fingers to feel the pulse of the fuel being recirculated Pulse is felt Procedure No 26 13A 60 according to boththe above condi tions Listen near the fuel tank for the sound of fuel pump operation Sound of operation is heard 08 Purge control solenoid valve Solenoid valve turns from OFF to ON Ignition switch ON Sound of operation can be heard whe...

Page 101: ...or fan is not operating Engine coolant temperature is 90_C or less System voltage Radiator fan is not operating Engine coolant temperature is 105_C or more 0 3 V 21 Fan motor relay LO Radiator fan and condenser fan are not operating Engine coolant tem perature is 90_C or less System voltage Radiator fan and condenser fan are not operating Engine coolant tem perature is 90 105_C or less 0 3 V 23 Ig...

Page 102: ...arness MD998478 in between 4 Connect the analyzer special patterns pickup to crank angle sensor terminal 2 Alternate Method Test harness not available 1 Connect the analyzer special patterns pickup to engine ECU terminal 88 When checking the camshaft position sensor signal wave pattern 2 Connect the analyzer special patterns pickup to engine ECU terminal 89 When checking the crank angle sensor sig...

Page 103: ...No 1 TDC No 3 TDC No 4 TDC No 2 TDC Time 0 145 35 Wave Pattern Observation Points Check that cycle time T becomes shorter when the engine speed increases Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started D Example 2 Cause of problem Loose timing belt Abnorm...

Page 104: ...inal 5 connection terminal 17 and connection terminal 18 respectively Standard Wave Pattern Observation conditions Function Special patterns Pattern height High Pattern selector Display Engine condition When the engine coolant temperature is 20_C or below turn the ignition switch from OFF to ON without starting the engine While the engine is idling turn the A C switch to ON Immediately after start...

Page 105: ...Probable cause Coil reverse electromotive force does not appear or is extremely small Short in the coil Examples of Abnormal Wave Pattern D Example 1 Cause of problem Motor is malfunctioning Motor is not operating Wave pattern characteristics Induced electromotive force from the motor turning does not appear D Example 2 Cause of problem Open circuit in the line between the ISC servo and the engine...

Page 106: ...e analyzer special patterns pickup to engine ECU terminal 10 No 1 No 4 terminal 23 No 2 No 3 respectively Standard Wave Pattern Observation condition Function Special patterns Pattern height Low Pattern selector Display Engine r min Approx 1 200 r min Standard wave pattern T Revolution time corresponding to a crank angle of 180_ Compression top dead center V 6 4 2 Power transistor control signal w...

Page 107: ...ry circuit Rectangular wave at power voltage Power transistor malfunction Examples of Abnormal Wave Pattern D Example 1 Wave pattern during engine cranking Cause of problem Open circuit in ignition primary circuit Wave pattern characteristics Top right part of the build up section cannot be seen and voltage value is approximately 2 V too low D Example 2 Wave pattern during engine cranking Cause of...

Page 108: ...tion condition 2 Connect the MUT II to the diagnosis connector 16 pin NOTE When the MUT II is connected the diagnosis control terminal should be earthed 3 Start the engine and run at idle 4 Select the item No 30 of the MUT II Actuator test NOTE This holds the ISC servo at the basic step to adjust the basic idle speed 5 Check the idle speed Standard value 750 50 r min NOTE 1 The engine speed may be...

Page 109: ...nition switch 9 Disconnect the MUT II 10 Start the engine again and let it run at idle speed for about 10 minutes check that the idling condition is normal COMPONENT LOCATION Name Symbol Name Symbol Camshaft position sensor D Ignition failure sensor D Crank angle sensor B Oxygen sensor front C Ignition coil A Oxygen sensor rear E C B A D E ...

Page 110: ...l the vacuum sensor and tighten it to the specified torque Tightening torque 4 6 N m OXYGEN SENSOR CHECK Oxygen sensor front 1 Disconnect the oxygen sensor connector and connect the special tool test harness to the connector on the oxygen sensor side 2 Make sure that there is continuity 4 5 8 0 W at 20_C between terminal 1 red clip of special tool and terminal 3 blue clip of special tool on the ox...

Page 111: ... sensor is defective replace the oxygen sensor NOTE For removal and installation of the oxygen sensor refer to GROUP 15 Exhaust Pipe and Main Muffler Oxygen sensor rear 1 Disconnect the oxygen sensor connector and connect the special tool test harness set to the connector on the oxygen sensor side 2 Make sure that there is continuity 11 18 W at 20_C between terminal 1 and terminal 3 on the oxygen ...

Page 112: ...0 12 Nm 10 13 Nm 9 0 Nm Removal steps 1 PCV hose connection 2 Accelerator cable connection 3 Oxygen sensor rear connector 4 Detonation sensor connector 5 Vacuum sensor connector 6 EGR solenoid valve connector 7 Injector connector 8 Vacuum hose connection 9 Fuel return hose connection AA 10 Fuel pressure regulator AA 11 O ring AA 12 High pressure fuel hose connection AA 13 O ring AA 14 Delivery pip...

Page 113: ...engine oil enter the delivery pipe 2 While turning the injector high pressure fuel hose and fuel pressure regulator to the right and left install the delivery pipe while being careful not to damage the O ring After installing check that the hose turns smoothly 3 If it does not turn smoothly the O ring may be trapped remove the injector high pressure fuel hose or fuel pressure regulator and then re...

Page 114: ... with A T D An ignition failure sensor has been adopted GENERAL INFORMATION SELF DIAGNOSIS FUNCTION Following functions have been added D This engine ECU records the engine operating condition when the diagnosis code is set This data is called freeze frame data This data can be read by using the MUT II are can then be used in simulation tests for troubleshooting GENERAL SPECIFICATIONS Items Specif...

Page 115: ...m P0105 Barometric pressure sensor system P0110 Intake air temperature sensor system P0115 Engine coolant temperature sensor system P0120L Throttle position sensor system P0125 Feedback system P0130 Oxygen sensor front system sensor 1 P0135 Oxygen sensor heater front system sensor 1 P0136 Oxygen sensor rear system sensor 2 P0141 Oxygen sensor heater rear system sensor 2 P0170 Abnormal fuel system ...

Page 116: ...d 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 3 After the engine warning lamp illuminates it will be switched off under the following conditions 1 When the engine ECU M T or engine A T ECU A T monitored the power train malfunction three times and met set ...

Page 117: ...ignition switch to OFF the ENGINE ECU will switch the diagnosis mode from DIAGNOSIS 2 mode to DIAGNOSIS 1 mode 5 Erase the diagnosis codes INSPECTION USING MUT II DATA LIST AND ACTUATOR TESTING 1 Carry out inspection by means of the data list and the actuator test function If there is an abnormality check and repair the chassis harnesses and components 2 After repairing re check using the MUT II a...

Page 118: ...losed loop CL Open loop owing to drive condition OL DRV Open loop owing to system malfunction OL SYS Closed loop based on one oxygen sen sor CL H02S Calculation load value Diagnosis code during data recording NOTE If malfunctions have been detected in multiple systems store one malfunction only which has been detected first READINESS TEST STATUS The engine ECU M T or engine A T ECU A T monitors th...

Page 119: ...ls as if the engine coolant temperature is 80_C Camshaft position sensor Injects fuel to all cylinders simultaneously However after the ignition switch is turned to ON the No 1 cylinder top dead centre is not detected at all Barometric pressure sensor Controls as if the barometric pressure is 101 kPa Detonation sensor Switches the ignition timing from ignition timing for super petrol to ignition t...

Page 120: ...l system 13A 109 P0201 No 1 injector system 13A 110 P0202 No 2 injector system 13A 110 P0203 No 3 injector system 13A 110 P0204 No 4 injector system 13A 110 P0300L Ignition coil power transistor system 13A 111 P0301 No 1 cylinder misfire detected 13A 112 P0302 No 2 cylinder misfire detected 13A 112 P0303 No 3 cylinder misfire detected 13A 112 P0304 No 4 cylinder misfire detected 13A 112 P0325 Deto...

Page 121: ...ause of the problem 3 After the engine ECU M T or engine A T ECU A T 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 ind...

Page 122: ...ck the harness between the air flow sensor and the engine ECU M T or engine A T ECU A T NG Repair NG Check the following connector B 34 M T B 94 A T NG Repair OK Check the harness between the air flow sensor and the engine ECU M T or engine A T ECU A T and repair if necessary NG Repair OK Check the following connector B 34 M T B 94 A T 1 NG Measure at engine ECU M T or engine A T ECU A T connector...

Page 123: ... Analyzer and noise should not be displayed in the waveform NG Replace the engine ECU M T or engine A T ECU A T OK Check the trouble symptoms OK Check the harness between the air flow sensor and the engine ECU M T or engine A T ECU A T NG Repair NG Check the following connector A 99 NG Repair OK Measure at air flow sensor connector A 99 D Use test harness MB991709 to connect the connector and meas...

Page 124: ...ness between the air flow sensor and the engine ECU M T or engine A T ECU A T NG Repair OK Check the trouble symptoms NG Replace the engine ECU M T or engine A T ECU A T OK Check the harness between the air flow sensor and the engine ECU M T or engine A T ECU A T and repair if necessary NG Repair MUT II Data list 25 Barometric pressure sensor Refer to P 13A 153 DATA LIST REFERENCE TABLE OK Transie...

Page 125: ... the engine ECU M T or engine A T ECU A T terminal D Ignition switch ON D Voltage between terminal 81 M T 46 A T and earth OK Altitude 0 m 3 7 4 3 V Altitude 1 200 m 3 2 3 8 V NG Check the following connector B 34 M T B 94 A T NG Repair OK Check the trouble symptoms OK Check the following connector B 34 M T B 94 A T NG Repair NG Replace the engine ECU M T or engine A T ECU A T OK Measure at air fl...

Page 126: ...ry MUT II Data list 13 Intake air temperature sensor OK Roughly the same as ambi ent temperature OK Transient malfunction Refer to GROUP 00 Points to Note for Intermittent Malfunctions NG Check the intake air temperature sensor itself Refer to P 13A 25 NG Repair OK Measure at air flow sensor connector A 99 D Disconnect the connector and measure at the harness side 1 Resistance between terminal 5 a...

Page 127: ... 2 3 8 V Ambient temperature 20_C 2 3 2 9 V Ambient temperature 40_C 1 5 2 1 V Ambient temperature 80_C 0 4 1 0 V NG Check the following connectors A 99 B 34 M T B 94 A T NG Repair OK Check the harness between the air flow sensor and the engine ECU M T or engine A T ECU A T and repair if necessary OK Check the trouble symptoms NG Replace the engine ECU M T or engine A T ECU A T From the previous p...

Page 128: ...D Malfunction of engine A T ECU A T Range of Check D Engine After starting Set Conditions D The engine coolant temperature has reduced from over 40_C to less than 40_C and that condition has lasted for five minutes or more OK To the next page MUT II Data list 21 Engine coolant temperature sensor OK When the engine is cold the temperature is roughly the same as ambient tem perature If warm it is 80...

Page 129: ...nt temperature sensor connector A 72 D Disconnect the connector and measure at the harness side 1 Voltage between terminal 1 and earth Ignition switch ON OK 4 8 5 2 V 2 Resistance between terminal 2 and earth OK 2 W or less 1 NG Measure at engine ECU M T or engine A T ECU A T connector B 34 M T B 94 A T D Measure the voltage at the engine ECU M T or engine A T ECU terminal A T D Disconnect connect...

Page 130: ... ECU A T OK OK Check the harness wire between the throttle position sensor and the engine ECU M T or engine A T ECU A T and repair if necessary NG Check throttle position sensor Refer to P 13A 84 NG Replace NG Repair NG Check the following connector B 34 M T B 94 A T NG Repair OK Check the following connector A 05 NG Repair Check the harness wire between the throttle position sensor and the engine...

Page 131: ...n switch ON 1 The voltage between terminal 1 and earth OK 4 8 5 2 V 2 The voltage between terminal 4 and earth OK 0 5 V or less 3 The voltage between terminal 2 and earth OK Accelerator pedal fully re leased 0 3 1 0 V Accelerator pedal fully de pressed 4 5 5 5 V 1 2 NG NG Repair Check the following connector B 34 M T B 94 A T NG Repair From the previous page 3 NG Adjust the throttle position senso...

Page 132: ...B 93 A T 2 NG Check the oxygen sensor front Refer to P 13A 85 NG Replace OK Check the harness wire between the oxygen sensor front and the engine ECU M T or engine A T ECU A T and repair if necessary Repair 1 NG Check the following connectors A 106 B 34 M T B 94 A T NG OK Measure at oxygen sensor front connector A 106 D Use the test harness MD998464 to connect the connector and measure at the pick...

Page 133: ...e is 4 5 V or more when the sensor output voltage is 0 2 V or less and a voltage of 5 V is applied to the oxygen sensor front inside the engine ECU M T or engine A T ECU A T D Malfunction of oxygen sensor front D Open or short circuit in the oxygen sensor front circuit or loose connector contact D Malfunction of engine ECU M T D Malfunction of engine A T ECU A T Range of Check D Engine speed is 3 ...

Page 134: ...B 93 A T OK Check the harness wire between the oxygen sensor front and the engine ECU M T or engine A T ECU A T and repair if necessary Repair 1 NG Check the following connectors A 106 B 34 M T B 94 A T NG NG Replace the engine ECU M T or engine A T ECU A T OK Check the trouble symptoms OK Check the harness wire between the oxygen sensor front and the engine ECU M T or engine A T ECU A T NG Repair...

Page 135: ...sensor front and the engine control relay NG Repair OK Check the following connector B 35 M T B 95 A T NG Repair OK Check the harness wire between the oxygen sensor front and the engine ECU M T or engine A T ECU A T and repair if necessary Repair NG Check the following connectors A 106 B 35 M T B 95 A T NG OK Measure at engine ECU M T or engine A T ECU A T connector B 35 M T B 95 A T D Measure the...

Page 136: ...voltage of 5 V is applied to the oxygen sensor rear inside the engine ECU M T or engine A T ECU A T D Malfunction of oxygen sensor rear D Open or short circuit in the oxygen sensor rear circuit or loose connector contact D Malfunction of engine ECU M T D Malfunction of engine A T ECU A T Range of Check D Two seconds have passed after the engine ECU M T or engine A T ECU A T detected an open circui...

Page 137: ...ng connectors B 34 M T B 93 A T B 108 OK Check the harness wire between the oxygen sensor rear and the engine ECU M T or engine A T ECU A T and repair if necessary NG Replace the engine ECU M T or engine A T ECU A T OK Check the trouble symptoms OK Check the harness wire between the oxygen sensor rear and the engine ECU M T or engine A T ECU A T NG Repair Repair OK Measure at oxygen sensor rear co...

Page 138: ...sensor rear and the engine control relay NG Repair OK Check the following connector B 35 M T B 95 A T NG Repair OK Check the harness wire between the oxygen sensor rear and the engine ECU M T or engine A T ECU A T and repair if necessary Repair NG Check the following connectors B 35 M T B 95 A T B 108 NG OK Measure at engine ECU M T or engine A T ECU A T connector B 35 M T B 95 A T D Measure the v...

Page 139: ...3 D Does the tester indi cate less than the standard value OK No Less than zero MUT II Data list 12 Volume air flow sensor Refer to P 13A 153 D Does the tester indi cate more than the standard value NG Repair OK MUT II Data list 81 Long term fuel compensation Refer to P 13A 156 D Is fuel trim more or less than zero More than zero Check if air was drawn into the intake system OK Check the fuel pres...

Page 140: ...Intermittent malfunction Refer to GROUP 00 Points to Note for Intermittent Malfunctions OK Check the trouble symptoms OK Measure at the engine ECU connector B 37 M T or engine A T ECU connector B 95 A T D Disconnect the connector and measure at the harness side D Voltage between 1 2 14 15 M T or 1 2 9 24 A T and earth Ignition switch ON OK System voltage NG Check the harness wire between the engin...

Page 141: ...r 02 No 2 injector 03 No 3 injector 04 No 4 injector OK The idling condition should change Reference When the cylinder defective cylinder where idling condition does not change is detected after suspending the injector go to 1 and inspect the spark plug the ignition coil the connector and the harness of the defective cylinder When more than one cylinder are detected inspect all of them When all th...

Page 142: ...ure sensor Refer to GROUP 16 Ignition System OK Check the harness wire between the ignition coil and the earth and repair if necessary 3 NG OK Measure at ignition coil connectors A 73 A 79 D Disconnect the connector and measure at the harness side 1 The voltage between terminal 1 and earth Ignition switch ON OK System voltage 2 The voltage between terminal 3 and earth Engine Cranking OK 0 5 4 0 V ...

Page 143: ...erminal 2 and earth OK 2 W or less NG Check the harness wire between the detonation sensor and earth and repair if necessary OK Check the following connector B 34 M T B 93 A T NG Repair OK Check the harness wire between the detonation sensor and the engine ECU M T or engine A T ECU A T NG Repair NG Replace the detonation sensor Check the trouble symptoms NG Replace the engine ECU M T or engine A T...

Page 144: ...ace the crank angle sensor Check the trouble symptoms NG Check the following connectors A 84 B 34 M T B 94 A T NG Repair NG Replace the engine ECU M T or engine A T ECU A T OK Check the harness wire between the crank angle sensor and the engine ECU M T or engine A T ECU A T and repair if necessary OK Measure at the crank angle sensor connector A 84 D Disconnect the connector and measure at the har...

Page 145: ...e engine was started Set Conditions D The sensor output voltage does not change for 4 seconds no pulse signal input D Malfunction of the camshaft position sensor D Open or short circuit in the camshaft position sensor circuit or loose connector contact D Malfunction of engine ECU M T D Malfunction of engine A T ECU A T ...

Page 146: ...The resistance between terminal 1 and earth OK 2 W or less 1 NG Check the following connectors A 10 B 13 NG Repair Replace the camshaft position sensor Check the trouble symptoms OK NG Repair OK Check the harness wires between the camshaft position sensor connector and the engine ECU M T or engine A T ECU A T the camshaft position sensor connector and the engine control relay and the camshaft posi...

Page 147: ...R control solenoid valve and the engine ECU M T or engine A T ECU A T NG Check the following connector A 88 NG Repair OK Measure at engine ECU M T or engine A T ECU A T connector B 37 M T B 95 A T D Measure the voltage at the engine ECU M T or engine A T ECU A T terminal D Ignition switch ON D The voltage between terminal 6 and earth OK System voltage NG Check the harness wire between the EGR cont...

Page 148: ...eplace the catalytic converter Check the trouble symptoms OK Replace the oxygen sensor rear Replace the oxygen sensor front NG OK MUT II Data list 11 Oxygen sensor front D Transmission 2nd gear M T L range A T OK Changeover between 0 400 mV and 600 1 000 mV occur 15 times in 10 seconds NG Check the oxygen sensor front system sensor 1 Refer to P 13A 103 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE C...

Page 149: ...trol solenoid valve and the engine ECU M T or engine A T ECU A T NG Check the following connector A 81 NG Repair OK Measure at engine ECU M T or engine A T ECU A T connector B 37 M T B 95 A T D Measure the voltage at the engine ECU M T or engine A T ECU A T terminal D Ignition switch ON D The voltage between terminal 9 M T 34 A T and earth OK System voltage NG Check the harness wire between the pu...

Page 150: ...he waveform Refer to GROUP 23 Troubleshooting NG Check the following connectors A 60 B 34 M T B 93 A T Does the speedometer operate normally Code No P0505 Idle speed control ISC system Probable cause Check Area D Vehicle speed has reached 1 5 km h at least once D Under the closed loop idle speed control Judgment Criteria D Actual idle speed has continued to be higher than the target idle speed by ...

Page 151: ... When using a circuit tester 5 V and 8 V alternates When using an analyzer 1 V or less and system voltage alternates OK OK Check the harness wire between the engine control relay and the idle speed control servo and repair if necessary OK Measure at the idle speed control servo connector A 56 D Disconnect the connector and measure at the harness side D Ignition switch ON D The voltage between term...

Page 152: ...s to Note for Intermittent Malfunctions OK Check the harness wire between the engine control relay and the idle speed control servo and between the idle speed control servo and the engine ECU M T or engine A T ECU A T NG Repair OK Check the following connector A 56 NG Repair From the previous page NOTE Refer to the 2000 COLT LANCER Workshop Manual Pub No PWME9511 B ...

Page 153: ...air Replace the engine ECU M T or engine A T ECU A T OK NG Check the harness wire between engine ECU M T or engine A T ECU A T and power steering pressure switch connector OK Check the trouble symptom OK Replace the engine ECU M T or engine A T ECU A T OK Check the trouble symptom Repair NG OK Check the following connector A 78 NG Repair NG Check the following connectors A 10 A 78 B 36 M T B 94 A ...

Page 154: ...alfunction of the engine A T ECU A T 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 ID code NG Replace the engine ECU M T or engine A T ECU A T Check the trouble symptoms NG Replace the immobilizer ECU OK Check the trouble symptoms OK Check the harness ...

Page 155: ...rting 7 13A 130 Idling stability Unstable idling Rough idling hunting 8 13A 131 Improper idling Idling speed is high Improper idling speed 9 13A 133 Idling speed is low Improper idling speed 10 13A 133 Idling stability When the engine is cold it stalls at idling Die out 11 13A 134 Engine stalls When the engine becomes hot it stalls at idling Die out 12 13A 135 The engine stalls when starting the c...

Page 156: ... diagnostic connector 16 pin and earth and repair if necessary INSPECTION PROCEDURE 2 MUT II communication with engine ECU M T or engine A T ECU A T is impossible Probable cause One of the following causes may be suspected D No power supply to engine ECU M T or engine A T ECU A T D Defective earth circuit of engine ECU M T or engine A T ECU A T D Defective engine ECU M T or engine A T ECU A T D Im...

Page 157: ...ollowing connector B 36 M T B 95 A T NG Repair OK Measure at the engine ECU connector B 36 M T or the engine A T ECU connector B 95 A T D Disconnect the connector and measure at the harness side D Earth the terminal No 36 M T or No 22 A T OK The engine warning lamp illuminates MUT II Data list 16 engine ECU power supply voltage Refer to P 13A 154 NG Check the engine ECU M T or engine A T ECU A T p...

Page 158: ...E 30 OK Can any sound be heard from the injectors when cranking No Check theinjectorsystem Refer toP 13A 110 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE P0201 P0202 P0203 P0204 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 154 NG Check the engine coolant temperature sensor system Refer toP 13A 98 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Actuator test 07 Fuel p...

Page 159: ...Refer to P 13A 120 INSPECTION PROCE DURE FOR DIAGNOSIS CODE P0505 Yes Check ISC servo for op eration sound Refer to P 13 26 2 OK Is starting good if the engine is cranked with the accelerator pedal slightly depressed OK Can any sound be heard from the injectors when cranking NG Check theinjectorsystem Refer toP 13A 110 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE P0201 P0202 P0203 P0204 OK MUT II Data...

Page 160: ...prox 5_BTDC NG Check that the crank angle sensor is installed properly OK Can any sound be heard from the injectors when cranking NG Check theinjectorsystem Refer toP 13A 110 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE P0201 P0202 P0203 P0204 OK MUT II Data list 18 Ignition switch ST Refer to P 13A 154 NG Check the ignition switch ST system Refer to P 13A 150 INSPECTION PROCEDURE 28 OK MUT II Data li...

Page 161: ...15 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 154 NG Check the barometric pressure sensor system Refer to P 13A 94 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105 OK MUT II Data list 25 Barometric pressure sensor Refer to P 13A 155 NG Check the intake air temperaturesensor system Refer toP 13A 96 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0110 OK MUT II Data list 13 Intake...

Page 162: ... to P 13A 123 INSPECTION PROCE DURE FOR DIAGNOSIS CODE P0551 OK MUT II Data list 27 Power steering fluid pressure switch Refer to P 13A 155 OK 1 Inspect the intake of air into the air intake system D Broken intake manifold gasket D Broken vacuum hose D PCV valve does not operate D Broken air intake hose 2 Check the injector for clog NG Check the fuel pressure Refer to P 13A 78 1 OK MUT II Data lis...

Page 163: ...NOTE 1 Refer to the 96 COLT LANCER Workshop Manual Pub No PWME9511 2 Refer to the 2000 COLT LANCER Workshop Manual Pub No PWME9511 B INSPECTION PROCEDURE 10 Idling speed is low Improper idling speed Probable cause In cases such as the above the cause is probably that the intake air volume during idling is too small D Malfunction of the ISC servo system D Malfunction of the throttle body Check and ...

Page 164: ...gine coolant temperature sensor system Refer toP 13A 98 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 154 NG Check theinjectorsystem Refer toP 13A 110 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE P0201 P0202 P0203 P0204 OK Check the injector for operation sound NG Check theISC system Refer toP 13A 120 INSPECTION PROCE DURE FOR DIA...

Page 165: ...o P 13A 94 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105 OK MUT II Data list 25 Barometric pressure sensor Refer to P 13A 155 NG Check the intake air temperaturesensor system Refer toP 13A 96 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0110 OK MUT II Data list 13 Intake air temperature sensor Refer to P 13A 153 No While carrying out an intermittent malfunction simulation test Refer to GROUP 00 Points...

Page 166: ...t 28 A C switch Refer to P 13A 155 NG Check the power steering fluid pressure switch sys tem Refer to P 13A 123 INSPECTION PROCE DURE FOR DIAGNOSIS CODE P0551 OK MUT II Data list 27 Power steering fluid pressure switch Refer to P 13A 155 OK 1 Inspect the intake of air into the air intake system D Broken intake manifold gasket D Broken vacuum hose D PCV valve does not operate D Broken air intake ho...

Page 167: ...se In cases such as the above the cause is probably that theintake airvolume is insufficient due to a defective idle speed control ISC servo system D Malfunction of the ISC system OK Check the following items D Check the ignition coil spark plugs spark plug cables D Clean the throttle valve area D Check and adjust the fixed SAS NG Check the EGR control solenoid valve system Refer to P 13A 117 INSP...

Page 168: ...he EGR control solenoid valve system Refer to P 13A 117 INSPECTION PROCEDURE FOR DIAGNO SIS CODE P0403 OK MUT II Actuator test 10 EGR control solenoid valve Refer to P 13A 158 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 154 NG Check the engine coolant temperature sensor system Refer toP 13A 98 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Data list 21 Engine coolant te...

Page 169: ...spark plug demand voltage during acceleration D Malfunction of the ignition system No Check the following items D Check the ignition coil spark plugs spark plug cables D Check for occurrence of ignition leak MUT II Self Diag code Are diagnosis codes displayed Yes Refer to P 13A 90 INSPECTION CHART FOR DIAGNOSIS CODES INSPECTION PROCEDURE 17 The feeling of impact or vibration when decelerating Prob...

Page 170: ...ol solenoid valve Refer to P 13A 158 NG Check the throttle position sensor system Refer to P 13A 100 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0120 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 154 NG Check the engine coolant temperature sensor system Refer toP 13A 98 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 1...

Page 171: ...he fuel pressure Refer to P 13A 78 OK 1 Inspect the intake of air into the air intake system D Broken intake manifold gasket D Broken vacuum hose D PCV valve does not operate D Broken air intake hose 2 Check the injector for clog NG Check the fuel pressure Refer to P 13A 78 OK MUT II Data list 11 Oxygen sensor OK Changes between 0 400 mV and 600 1 000 mV during idling From the previous page NOTE R...

Page 172: ... open OK 600 1 000 mV NG Check the EGR control solenoid valve system Refer to P 13A 117 INSPECTION PROCEDURE FOR DIAGNO SIS CODE P0403 OK MUT II Actuator test 10 EGR control solenoid valve Refer to P 13A 158 NG Check the throttle position sensor system Refer to P 13A 100 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0120 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 154 NG Check the en...

Page 173: ... etc got into fuel No Check the detonation sensor system Refer to P 13A 113 INSPEC TION PROCEDURE FOR DIAGNOSIS CODE P0325 No Does knocking occur when driving with the sensor disconnected At this time use the MUT II to check if the timing is retarded compared to when the detonation sensor connector is connected MUT II Self Diag code Are diagnosis codes displayed Yes Refer to P 13A 90 INSPECTION CH...

Page 174: ...ensor OK 600 1 000 mV when racing suddenly NG Check the oxygen sensor rear system Refer to P 13A 106 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136 OK MUT II Data list 59 Oxygen sensor rear D Transmission 2nd gear M T L range A T D Driving with throttle widely open OK 600 1 000 mV NG Check the barometric pressure sensor system Refer to P 13A 94 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105 OK MUT ...

Page 175: ...roper connector contact open circuit or short circuited harness wire D Malfunction of the engine ECU M T or engine A T ECU A T NG Repair NG Replace the engine ECU M T or engine A T ECU A T NG Check the A C system Refer to GROUP 55 On vehicle Service OK Check the trouble symptom Measure at the engine ECU connector B 37 M T or the engine A T ECU connector B 95 A T D Connect the connector D Voltage b...

Page 176: ...oolant temperature sensor OK After the engine has been warmed up the engine coolant temperature during idling is identical to the MUT II reading NG Check the engine coolant temperature sensor system Refer to P 13A 98 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK Check the radiator fan and condenser fan circuit Refer to GROUP 14 Troubleshooting NG Repair Check the harness wire between the engine...

Page 177: ...ire between engine ECU M T or engine A T ECU A T and earth and repair if necessary 2 3 NG Check the harness wire between engine ECU M T or engine A T ECU A T and control relay connector and repair if necessary OK Check the ignition switch Refer to GROUP 54 Ignition Switch OK Check the harness wire between engine ECU M T or engine A T ECU A T and ignition switch connector NG Repair OK Check the tro...

Page 178: ... Check theharnesswirebetweenbattery andcontrol relayconnector and repair if necessary OK Check the trouble symptom NG Check the following connector A 10 NG Repair OK Measure at the control relay connector B 13 D Disconnect the connector and measure at the harness side D Voltage between 3 4 and earth OK System voltage Check the control relay Refer to P 13A 83 NG Replace NOTE Refer to the 96 COLT LA...

Page 179: ... for M T 21 Vehicles with immobilizer system for A T 20 Vehicles without immobilizer system for A T and earth Ignition switch ON OK The fuel pump operates its operation sound can be heard NG Check the harness wire between the fuel pump relay and engine ECU M T or engine A T ECU A T and repair if necessary Check the trouble symptom NG Repair OK NG Check the following connector B 12 OK Measure at th...

Page 180: ... 34 D Disconnect the connector and measure at the harness side D Voltage between 71 and earth Ignition switch START OK 8 V or more A T Measure at the inhibitor switch connector A 27 D Disconnect the connector and measure at the harness side D Voltage between 10 and earth Ignition switch START OK System voltage NG Replace the engine A T ECU OK Check the trouble symptoms NG Repair OK Check the follo...

Page 181: ...obilizersystem for A T 20 Vehicleswithout immobilizer system for A T and earth Ignition switch ON A C switch ON OK A C compressor clutch turns on NG Check the A C system Refer to GROUP 55 Troubleshooting OK Check the following connectors B 37 M T B 95 A T NG Replace OK Check the trouble symptom NG Replace the engine ECU M T or engine A T ECU A T INSPECTION PROCEDURE 30 Ignition circuit system Prob...

Page 182: ... at the harness side 1 Voltage between 2 and earth Ignition switch ON OK 4 V or more 2 Continuity between 1 and earth OK Continuity NG OK Check the trouble symptom OK Check the following connectors A 73 A 79 NG Repair 3 NG Check the harness wire between the ignition coil connector and ground and repair if necessary OK Replace the engine ECU M T or en gine A T ECU A T NG Check the harness wire betw...

Page 183: ... After having warmed up Air fuel mixture is When at 4 000 r min engine is suddenly decelerated 200 mV or less Code No P0130 13A 103 made leaner when de celerating and is made richer when racing When engine is sud denly raced 600 1 000 mV Engine After having warmed up The oxygen sensor signal is used to check Engine is idling 400 mV or less Changes 600 1 000 mV signal is used to check the air fuel ...

Page 184: ...sensor Ignition switch ON or with engine running When engine cool ant temperature is 20_C 20_C Code No P0115 13A 98 When engine cool ant temperature is 0_C 0_C When engine cool ant temperature is 20_C 20_C When engine cool ant temperature is 40_C 40_C When engine cool ant temperature is 80_C 80_C 22 Crank angle sensor D Engine Cranking D Tachometer Connected Compare the engine speed readings on th...

Page 185: ... C compressor should be operating A C switch ON ON No 29 29 Inhibitor Ignition switch ON P or N P or N Procedure 13A 150 switch A T D 2 L or R D 2 L or R No 28 41 Injectors 2 Engine Cranking When engine cool ant temperature is 0_C injection is car ried out for all cylin ders simultaneously 12 19 ms When engine cool ant temperature is 20_C 26 40 ms When engine cool ant temperature is 80_C 6 0 9 1 m...

Page 186: ...tch is operat ing 59 Oxygen sensor rear D Transmission 2nd gear M T L range A T D Drive with throttle widely open 3 500 r min 600 1 000 mV Code No P0136 13A 106 81 Long term fuel com pensation Engine Warm 2 500 r min without any load during closed loop 12 5 12 5 Code No P0170 13A 109 82 Short term fuel com pensation Engine Warm 2 500 r min without any load during closed loop 30 25 Code No P0170 13...

Page 187: ... item 8A Throttle position D Engine coolant temperature Release the acceler ator pedal 6 20 Code No P0120 13A 100 sensor Throttle valve open ing angle 80 95_C D Ignition switch ON Engine Stopped Depress the acceler ator pedal gradually Increase in re sponse to pedal depression stroke Depress the acceler ator pedal fully 80 100 ...

Page 188: ...pump Forced driving Inspect Pinch the return hose with fingers to feel the pulse of the fuel being recirculated Pulse is felt Procedure No 27 13A 148 according to both the above conditions Listen near the fuel tank for the sound of fuel pump operation Sound of opera tion is heard 08 Purge control solenoid valve Solenoid valve turns from OFF to ON Ignition switch ON Sound of opera tion can be heard...

Page 189: ... You may find it convenient to pull out the engine ECU M T or engine A T ECU A T to make it easier to reach the connector terminals 3 The checks can be carried out off the order given in the chart Caution Short circuiting the positive probe between a connector terminal and earth could damage the vehicle wiring the sensor engine ECU M T or engine A T ECU A T or all of them Be careful to prevent thi...

Page 190: ...gine is started System voltage 0 V Changes repeatedly 17 28 Stepper motor coil B 5 15 Stepper motor coil C 18 29 Stepper motor coil D 6 6 EGR control Ignition switch ON System Voltage solenoid valve While engine is idling suddenly depress the accelerator pedal From system voltage momentarily drops 8 or 22 20 or 21 A C relay D Engine Idle speed D A C switch OFF ON A C compressor is operating System...

Page 191: ...ch ON System voltage relay Engine Idle speed 0 3 V 33 8 Alternator G terminal D Engine Warm idle radiator fan OFF D Headlamp OFF to ON D Rear defogger switch OFF to ON D Brake lamp ON Voltage rises by 0 2 3 5 V 41 54 Alternator FR terminal D Engine Warm idle radiator fan OFF D Headlamp OFF to ON D Rear defogger switch OFF to ON D Brake lamp ON Voltage drops by 0 2 3 5 V 36 22 Engine warn ing lamp ...

Page 192: ... intake air temperature is 80_C 0 4 1 0 V 75 73 Oxygen sen sor rear D Transmission 2nd gear M T L range A T D Engine r min 3 500 r min or more D Driving with the throttle valve widely open 0 6 1 0 V 76 71 Oxygen sensor front Engine Running at 2 500 r min after warmed up Check using a digital type voltmeter 0 0 8 V Changes repeatedly 80 66 Backup pow er supply Ignition switch LOCK OFF position Syst...

Page 193: ...gine Idle speed 0 5 2 0 V 89 45 Crank angle Engine Cranking 0 4 4 0 V sensor Engine Idle speed 1 5 2 5 V 90 65 Air flow sen Engine Idle speed 2 2 3 2 V sor Engine r min 2 500 r min CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1 Turn the ignition switch to LOCK OFF position 2 Disconnect the engine ECU M T or engine A T ECU A T connector 3 Measure the resistance and check for continui...

Page 194: ...or Terminal Arrangement Engine A T ECU A T Harness Side Connector Terminal Arrangement Terminal No M T Terminal No A T Inspection item Normal condition Check condition 1 12 1 41 No 1 injector 13 16 W At 20_C 14 12 9 41 No 2 injector 2 12 24 41 No 3 injector 15 12 2 41 No 4 injector 4 12 14 41 Stepper motor coil A 28 33 W At 20_C 17 12 28 41 Stepper motor coil B 5 12 15 41 Stepper motor coil C 18 1...

Page 195: ...temperature is 0_C 2 3 3 0 kW When intake air temperature is 20_C 1 0 1 5 kW When intake air temperature is 40_C 0 30 0 42 kW When intake air temperature is 80_C 83 92 44 57 Engine coolant temperature sensor 5 1 6 5 kW When coolant temperature is 0_C 2 1 2 7 kW When coolant temperature is 20_C 0 9 1 3 kW When coolant temperature is 40_C 0 26 0 36 kW When coolant temperature is 80_C ...

Page 196: ...ng the crank angle sensor signal wave pattern INJECTOR Alternate method Test harness not available 1 Connect the analyzer special patterns pickup to engine A T ECU terminal 1 When checking the No 1 cylinder 2 Connect the analyzer special patterns pickup to engine A T ECU terminal 9 When checking the No 2 cylinder 3 Connect the analyzer special patterns pickup to engine A T ECU terminal 24 When che...

Page 197: ... service procedures are the same as before SERVICE SPECIFICATIONS Items Standard value Thermostat 4G1 Valve opening temperature of thermostat _C 88 1 5 Full opening temperature of thermostat _C 100 Valve lift at 100_C mm 8 5 or more THERMOSTAT REMOVAL AND INSTALLATION 4G1 Pre removal and Post installation Operation Engine Coolant Draining and Supplying 2 4 1 22 Nm 3 Removal steps 1 Oxygen sensor f...

Page 198: ...E CONNECTION 1 Insert each hose as far as the projection of the water inlet fitting 2 Align the mating marks on the radiator hose and hose clamp and then connect the radiator hose 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 88 1 5_C 2 Check that the amount of ...

Page 199: ...Engine coolant temperature sensor connector 2 Oxygen sensor front connector 3 Engine coolant temperature gauge unit connector AA BA 4 Radiator upper hose connection AA BA 5 Radiator lower hose connection 6 Water hose 7 Thermostat case assembly 8 Thermostat case gasket AA 9 O ring 10 Control harness connection 11 Water hose 12 Heater hose connection 13 Water inlet pipe AA 14 O ring REMOVAL SERVICE ...

Page 200: ... engine coolant Caution Do not allow engine oil or other greases to adhere to the O ring BA RADIATOR LOWER HOSE RADIATOR UPPER HOSE CONNECTION 1 Insert each hose as far as the projection of the water inlet fitting or thermostat case assembly 2 Align the mating marks on the radiator hose and hose clamp and then connect the radiator hose Thermostat case assembly or cylinder block O ring Water inlet ...

Page 201: ...ore SPECIAL TOOL Tool Number Name Use MD998770 Oxygen sensor wrench Removal Installation of oxygen sensor INTAKE MANIFOLD REMOVAL AND INSTALLATION 4G1 Pre removal and Post installation Operation D Prevention of Fuel Discharge before removal only D Fuel Leak Check after installation only D Accelerator Cable Adjustment D Engine Coolant Draining and Supplying D Air Cleaner Removal and Installation D ...

Page 202: ...ster vacuum hose connection 4 Purge control solenoid valve connector 5 Vacuum hose connection 6 Detonation sensor connector 7 Vacuum hose connection 8 EGR valve 9 EGR valve gasket 10 Oxygen sensor rear connector 11 Intake manifold stay 12 Engine hanger 13 Intake manifold 14 Intake manifold gasket 15 Purge control solenoid valve assembly 16 EGR solenoid valve assembly 17 Vacuum pipe and hose assemb...

Page 203: ...m Removal steps 1 Oxygen sensor front connector AA AA 2 Oxygen sensor front 3 Exhaust manifold cover 4 Front exhaust pipe connection 5 Front exhaust pipe gasket 6 Exhaust manifold bracket 7 Engine oil level gauge assembly 8 O ring 9 Power steering oil pressure switch connector 10 Air conditioner refrigerant temperature switch and magnetic clutch connector 11 Power steering oil pump and air conditi...

Page 204: ...ion 2 Front exhaust pipe gasket 3 Exhaust manifold bracket 4 Engine oil level gauge assembly 5 O ring 6 Oxygen sensor front connector AA AA 7 Oxygen sensor front 8 Exhaust manifold cover 9 Exhaust manifold 10 Exhaust manifold gasket 11 Exhaust manifold bracket REMOVAL SERVICE POINT AA OXYGEN SENSOR FRONT REMOVAL INSTALLATION SERVICE POINT AA OXYGEN SENSOR FRONT INSTALLATION MD998770 Oxygen sensor ...

Page 205: ...ne of Changes 2 GENERAL INFORMATION 2 SERVICE SPECIFICATIONS 2 SPECIAL TOOL 3 ON VEHICLE SERVICE 3 Ignition Coil with Built in Power Transistor Check 3 Ignition Failure Sensor Check 4 IGNITION COIL 5 CAMSHAFT POSITION SENSOR 6 CRANK ANGLE SENSOR 7 DETONATION SENSOR 8 ...

Page 206: ...pted D The spark plug has been changed D An ignition failure sensor has been added D A detonation sensor has been added 4G9 An ignition failure sensor has been added The crank angle sensor has been changed Other items are the same as before GENERAL INFORMATION IGNITION COIL SPECIFICATIONS Items 4G1 Type Molded 2 coil SPARK PLUG SPECIFICATIONS Items 4G1 NGK BKR6E 11 DENSO K20PR U11 SERVICE SPECIFIC...

Page 207: ...TOR CHECK 4G1 Check by the following procedure and replace if there is a malfunction SECONDARY COIL RESISTANCE CHECK Measure the resistance between the high voltage terminals of the ignition coil Standard value 11 7 14 3 kW PRIMARY COIL AND POWER TRANSISTOR CONTINUITY CHECK NOTE An analog type circuit tester should be used Voltage 1 5V Terminal No 1 2 3 When current is flowing When current is not ...

Page 208: ...TRICAL Ignition System 16 4 IGNITION FAILURE SENSOR CHECK NOTE An analog type circuit tester should be used Check that the resistance between terminals 3 and 4 is at the standard value Standard value 0 1 W or less ...

Page 209: ...LATION 4G1 1 2 1 2 3 3 4 5 6 4 10 Nm 10 Nm 25 Nm 25 Nm 5 0 Nm Ignition coil removal steps 1 Ignition coil connector 2 Spark plug cable assembly 3 Ignition coil 4 Spark plug Ignition failure sensor removal steps 5 Ignition failure sensor connector 6 Ignition failure sensor ...

Page 210: ...ENGINE ELECTRICAL Ignition System 16 6 4G9 1 2 5 0 Nm Removal steps 1 Ignition failure sensor connector 2 Ignition failure sensor CAMSHAFT POSITION SENSOR 4G1 Camshaft position sensor 8 8 Nm ...

Page 211: ...6 7 CRANK ANGLE SENSOR REMOVAL AND INSTALLATION Pre removal and Post installation Operation Timing Belt Cover Removal and Installation 4G1 1 2 10 12 Nm 8 8 Nm 4G9 1 2 9 8 Nm Removal steps 1 Crank angle sensor bracket 2 Crank angle sensor ...

Page 212: ... any shocks REMOVAL AND INSTALLATION 4G1 Pre removal and Post installation Operation Intake Manifold Stay Removal and Installation Refer to GROUP 15 1 20 25 Nm AA AA 1 Detonation sensor REMOVAL SERVICE POINT AA DETONATION SENSOR REMOVAL INSTALLATION SERVICE POINT AA DETONATION SENSOR INSTALLATION MD998773 ...

Page 213: ...acuum Hose Piping Diagram 3 Vacuum Circuit Diagram 4 EVAPORATIVE EMISSION CONTROL SYSTEM 5 System Diagram 5 Component Location 6 Purge Control System Check 6 Purge Port Vacuum Check 7 Purge Control Solenoid Valve Check 7 EXHAUST GAS RECIRCULATION EGR SYSTEM 4G1 8 Component Location 8 Exhaust Gas Recirculation EGR Control System Check 8 EGR Port Vacuum Check 8 ...

Page 214: ... which has an increased flow capacity D The mounting positions for the EGR valve and the EGR control solenoid valve have been changed 4G9 D The purge control solenoid valve has been changed to one which has an increased flow capacity and the layout of the vacuum pipe has been changed D The vacuum hose colour of purge control has been changed D The port position of purge control has been changed GE...

Page 215: ... Air Canister Purge control solenoid valve ON Open EGR control solenoid valve ON Close EGR valve P E A PCV valve Oxygen sensor front Oxygen sensor rear 4G9 Air cleaner Air Canister Purge control solenoid valve ON Open EGR control solenoid valve ON Close EGR valve PCV valve Oxygen sensor front Oxygen sensor rear ...

Page 216: ...ke manifold Fuel pressure regulator White paint mark To combustion chamber EGR valve Red paint mark Vacuum hose colour B Black G Green L Light blue R Red Y Yellow 4G9 From air cleaner Canister Purge control solenoid valve ON Open EGR control solenoid valve ON Close Throttle body Intake manifold Fuel pressure regulator To combustion chamber EGR valve Vacuum hose colour B Black G Green L Light blue ...

Page 217: ...control solenoid valve ON Open Engine ECU Vacuum sensor Engine coolant temperature sensor Intake air temperature sensor Battery 4G9 From fuel tank Throttle body Canister Control relay Purge control solenoid valve ON Open Engine ECU M T or engine A T ECU A T Air flow sensor Engine coolant temperature sensor Intake air temperature sensor Barometric pressure sensor Battery ...

Page 218: ...g the nipple from which the vacuum hose was removed 3 When the engine is cold or hot apply a vacuum of 53 kPa and check the condition of the engine and the vacuum When engine is cold Engine coolant temperature 40_C or less Engine condition Normal condition At idle Vacuum is maintained 3 000 r min When engine is hot Engine coolant temperature 80_C or higher Engine condition Normal condition At idle...

Page 219: ... hose always make a mark so that it can be reconnected at original position 1 Disconnect the vacuum hose from the solenoid valve 2 Disconnect the harness connector 3 Connect a hand vacuum pump to nipple A of the solenoid valve refer to the illustration at left 4 Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without ap...

Page 220: ...alve EGR valve 17 8 EXHAUST GAS RECIRCULATION EGR SYSTEM 4G1 COMPONENT LOCATION EXHAUST GAS RECIRCULATION EGR CONTROL SYSTEM CHECK Inspection procedures have not changed EGR PORT VACUUM CHECK Inspection procedures have not changed Plug Green stripe Plug EGR port vacuum nipple ...

Page 221: ...23 1 AUTOMATIC TRANSMISSION CONTENTS GENERAL 2 Outline of Changes 2 TROUBLESHOOTING 2 ...

Page 222: ...open throttle switch system Short circuit 23 5 26 Stop lamp switch system Short circuit open circuit 23 6 31 Low and reverse solenoid valve system Short circuit open circuit 23 6 32 Underdrive solenoid valve system Short circuit open circuit 23 6 33 Second solenoid valve system Short circuit open circuit 23 6 34 Overdrive solenoid valve system Short circuit open circuit 23 6 36 Damper control clut...

Page 223: ...use If the A T fluid temperature sensor output voltage is 2 6 V or more even after driving for 10 minutes or more if the A T fluid temperature does not increase it is judged that there is an open circuit in the A T fluid temperature sensor and diagnosis code No 15 is output D Malfunction of the A T fluid temperature sensor D Malfunction of connector D Malfunction of the engine A T ECU Refer to 96 ...

Page 224: ...U Check the trouble symptoms NG Eliminate the cause of the noise NG OK Check the trouble symptoms OK NG Repair NG Check the trouble symptoms NG OK Check the trouble symptoms OK Measure output waveform of the input shaft speed sensor using an oscilloscope D Engine 2 000 r min approx 50 km h D Transmission 3rd gear Voltage OK Conforms to the waveform shown at page 23 41 In spection procedure using a...

Page 225: ...ft speed sensor using an oscilloscope D Engine 2 000 r min approx 50 km h D Transmission 3rd gear Voltage OK Conforms to the waveform shown at page 23 41 In spection procedure using an oscilloscope There is no noise in the output waveform NG Replace the output shaft speed sensor Measure at the output shaft speed sen sor connector A 62 D Disconnect the connector and measure at the harness side 1 Vo...

Page 226: ...d reverse solenoid valve system Probable cause Code No 32 Underdrive solenoid valve system Code No 33 Second solenoid valve system Code No 34 Overdrive solenoid valve system If the resistance value for a solenoid valve is too large or too small it is judged that there is a short circuit or an open circuit in the solenoid valve and the respective diagnosis code is output The transmission is locked ...

Page 227: ...e damper clutch control system and diagnosis code No 52 is output When diagnosis code No 36 is output the transmission is locked into 3rd gear as a fail safe measure and the N range lamp flashes at a frequency of 1 Hz D Malfunction of the damper clutch control solenoid valve D Malfunction of connector D Malfunction of the engine A T ECU Refer to 96 COLT LANCER Workshop Manual Pub No PWME9511 Dampe...

Page 228: ... speed sensor system check Refer to P 23 4 NO MUT II Self Diag code Is the diagnosis code No 23 output Code No 23 Output shaft speed sensor system check Refer to P 23 5 NO Measure output waveform from the input shaft speed sensor using an oscilloscope D Connect the connector B 92 B 94 and measure voltage between 57 and 103 at the engine A T ECU D Engine 2 000 r min approx 50 km h D Selector lever ...

Page 229: ... Check the following connectors A 10 B 09 B 93 B 94 NG Repair OK Harness check D Between control relay and body earth D Between control relay and battery D Between control relay and engine A T ECU NG Repair OK Check the trouble symptoms NG Replace the engine A T ECU Code No 56 N range lamp system Probable cause If the N range signal is off after an N range lamp illumination instruction ON instruct...

Page 230: ...function when starting Engine stalling when shifting 6 23 28 Shockswhen changing from N to D and large time lag 7 23 28 Shockswhen changing from N to R and large time lag 8 23 29 Shocks when changing from N to D N to R and large time lag 9 23 30 Malfunction when shifting Shocks and running up 10 23 30 Displaced shifting points All points 11 23 31 Some points 12 23 32 Does not shift No diagnosis co...

Page 231: ...inals Nos 76 88 97 and earth OK Continuity Check the following connectors A 10 B 13 B 93 B 94 Replace the engine A T ECU Check the trouble symptoms Harness check D Between ignition switch and engine A T ECU D Between earth and engine A T ECU INSPECTION PROCEDURE 16 Inhibitor switch system Probable cause The cause is probably a malfunction of the inhibitor switch circuit ignition switch circuit or ...

Page 232: ...gine A T ECU D Malfunction of the vehicle speed sensor D Malfunction of connector D Malfunction of the engine A T ECU Refer to 96 COLT LANCER Workshop Manual Pub No PWME9511 2 NG 3 NG Check the ignition switch Refer to GROUP 54 Ignition switch Replace the engine ECU Replace the engine A T ECU Harness check D Between the vehicle speed sensor and the earth and repair if necessary OK OK 1 NG Check th...

Page 233: ... diagnosis code output 0 5 V flashing 88 Earth Always 0 V 89 Solenoid valve power supply Ignition switch OFF 0 V Ignition switch ON System voltage 97 Earth Always 0 V 101 Inhibitor switch P Selector lever position P System voltage Selector lever position Other than above 0 V 102 Inhibitor switch D Selector lever position D System voltage Selector lever position Other than above 0 V 103 Input shaft...

Page 234: ...ator pedal Depressed Less than 0 4 V 120 Underdrive solenoid valve Selector lever position L 1st gear System voltage Selector lever position P Approx 7 9 V 121 Inhibitor switch N Selector lever position N System voltage Selector lever position Other than above 0 V 122 Inhibitor switch 2 Selector lever position 2 System voltage Selector lever position Other than above 0 V 123 Stop lamp switch Brake...

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