Mitsubishi MOTORS L200 1996 Workshop Manual Download

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DIESEL FUEL <4D5-Step

III

> – Troubleshooting

13I-24

Code No. 48 GE actuator (in the middle of control sleeve
position sensor inoperative) system

Probable cause

Range of Check

Ignition switch: ON

Set Conditions

Target value minus actual value is 1 V or more (duty ratio) for 1 second

Control sleeve position sensor inoperative

GE actuator inoperative

Control sleeve position sensor open circuit, short
circuit, or connector contact inoperative

Engine-ECU inoperative

Check and repair the harness between the
control relay and the injection pump
assembly connector.

GE actuator check (Refer to P.13I-63.)

Replace the engine-ECU.

Repair

Check the following connector: C-49

Check the trouble symptoms.

Check the following connector: A-120

Repair

Check the trouble symptoms.

Measure at C-49 engine-ECU connector

Disconnect the connector and measure at
the harness side.

Voltage between 1 and the earth
(Ignition switch: ON)
OK: 9 V or higher

Measure at A-120 injection pump assembly
connector.

Disconnect the connector and measure at
the harness side.

Voltage between 6 and the earth
(Ignition switch: ON)
OK: System voltage

Replace injection pump assembly.

Check and repair the harness between the
control relay and the injection pump
assembly connector.

Check the following connector: C-95

Repair

Check the trouble symptoms.

Summary of Contents for L200 1996

Page 1: ...Workshop Manual chassis Pub No PWTE96E1 ...

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Page 4: ... ELECTRONIC CONTROL TYPE CARBURETTOR 13B CONVENTIONAL TYPE CARBURETTOR 13C VARIABLE VENTURI TYPE CARBURETTOR 13D DIESEL FUEL 13E FUEL SUPPLY 13F TRACTION CONTROL SYSTEM TCL 13H DIESEL FUEL 4D5 STEP III 13I NOTE THE GROUPS MARKED BY ARE NOT IN THIS MANUAL 13A 1 ...

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Page 7: ...HEATER AIR CONDITIONER AND VENTILATION CONTENTS HEATER AIR CONDITIONER AND VENTILATION 55 AUTOMATIC AIR CONDITIONER 55B 55 1 ...

Page 8: ...GENERAL ...

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Page 10: ...d servicing procedures visual inspections should always be performed as well DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted It is given by tolerance LIMIT Shows the standard for judging the quality of a part or assembly on inspection and mean...

Page 11: ...ndicates the automatic transmission or models equipped with the automatic transmission SOHC Indicates an engine with the single overhead camshaft or a model equipped with such an engine MPI Indicates the multi point injection or engines equipped with the multi point injection DIESEL Indicates a diesel engine or models equipped with such an engine 2WD Indicates the rear wheel drive vehicles 4WD Ind...

Page 12: ...Classifications of Major Maintenance Service Points When there are major points relative to maintenance and servicing procedures such as essential maintenance and service points maintenance and service stan dard values information regarding the use of special tools etc these are ar ranged together as major maintenance and service points and explained in detail AA Indicates that there are essential...

Page 13: ... is applied Indicates the section title Indicates the group num ber Indicates the page number Indicates the group title Denotes non reus able part Repair kit or set parts are shown Only very frequently used parts are shown Operating procedures cau tions etc on removal installa tion disassembly and reas sembly are described The title of the page following the page on which the diagram of component ...

Page 14: ...rmation from the customer Check trouble symptom Reoccurs Does not reoccur Read the diagnosis code No diagnosis code or communication with MUT II not possible Refer to the INSPECTION CHART FOR TROUBLE SYMPTOMS Refer to applicable group Diagnosis code displayed Read the diagnosis code Diagnosis code displayed No diagnosis code After taking note of the malfunction code erase the diagnosis code memory...

Page 15: ...ding to each trouble symptoms classified in the Inspection Chart for Trouble Symptoms Refer to P 00 9 for how to read the inspection procedures 8 SERVICE DATA REFERENCE TABLE Inspection items and normal judgement values have been provided in this chart as reference information 9 CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors inspection items and standard values have been provided i...

Page 16: ...s code by warning lamp When the diagnosis code No 24 is output When no diagnosis code is output On Off 1 5 s 0 5 s 0 5 s Pause time 3 s Tens signal Place division 2 s Units signal On Off 0 5 s NOTE Even if the ABS system is normal removing the valve relay causes the diagnosis code No 51 to be output METHOD OF ERASING DIAGNOSIS CODES WHEN USING THE MUT II Connect the MUT II to the diagnosis connect...

Page 17: ...that there are trouble symptoms If trouble symptoms have disappeared the connector may have been inserted incorrectly and the trouble symptom may have disappeared during inspection If it seems that trouble symptoms still remain proceed to the next page of instructions 7 If trouble symptoms still remain up to this stage there is a possibility that there is an open or short circuit in the harness be...

Page 18: ...te that if the connector control unit etc is too small to permit insertion of the test bar it should not be forced use a special tool the extra thin probe in the harness set for checking for this purpose IF INSPECTING WITH THE CONNECTOR DISCONNECTED When Inspecting a Female Pin Use the special tool inspection harness for connector pin contact pressure in the harness set for inspection The inspecti...

Page 19: ...ed the terminal connections male and female pins will not be perfect even if the connector body is connected and the pins may pull out of the reverse side of the connector Therefore gently pull the harnesses one by one to make sure that no pins pull out of the connector CONNECTOR ENGAGEMENT INSPECTION Use the special tool connector pin connection pressure inspection harness of the inspection harne...

Page 20: ...e becomes simple In order to ascertain the conditions under which an intermittent malfunction occurs first ask the customer for details about the driving conditions weather conditions frequency of occurrence and trouble symptoms and then try to recreate the trouble symptoms Next ascertain whether the reason why the trouble symptom occurred under these conditions is due to vibration temperature or ...

Page 21: ...h are driven through water or which may possibly be driven through water should be subjected to the following inspections and maintenance procedures in advance D Seal the speedometer cable with a water resistant grease or tape D Inspect the dust boots and breather hose for cracks or damage and replace them if cracks or damage are found Joint assembly Clutch release cylinder Speedometer cable ...

Page 22: ...ENERAL Treatment Before After the Fording of a Stream 00 14 D Apply grease to the lubricating points of the front suspension steering linkage and propeller shaft Pitman arm Tie rod ends Upper arm Tie rod ...

Page 23: ...ace or lubricate D Check for water mud sand etc in the rear brake drum clutch housing starter motor brake pipe and fuel pipe D Check for water in the fluid or oil inside the front differential rear differential transmission and transfer D Apply grease to the lubricating points of the front suspension steering linkage and propeller shaft D Check all boots and breather hoses for cracks and damage M ...

Page 24: ...transmission model and body colour code No Item Contents 1 MODEL K62T JERDEL6 K62T Vehicle model JERDEL6 JERDEL6 Model series 2 ENGINE 4G63 Engine model 3 TRANS AXLE R4AW2 4636 R4AW2 Transmission code AXLE 4636 4636 Rear differential reduction 4 COLOR TRIM B60 41H 03V B60 Body colour code TRIM OPT 41H Interior code 03V Equipment code For monotone colour vehicles the body colour code shall be indic...

Page 25: ...WD 4A T MPI ENDEL6 R5M21 2WD 5M T K64T YNDL6 4D56 2 477m R5M21 2WD 5M T Fuel injection ZNDL6 ENDL6 ENDR6 CENDL6 JENDL6 K75T CENDEL6 4G64 SOHC 2 351 m V5M21 4WD 5M T MPI K74T YNDFL6 4D56 Turbocharger with intercooler 2 477 m V5MT1 4WD 5M T Fuel injection ZNDFL6 intercooler 2 477 m ENDFR6 JERDFL6 V4AW2 4WD 4A T GJENXFL6 V5MT1 4WD 5M T CENDFL6 JENDFL6 JENHFL6 ...

Page 26: ... Y Without cargo bed Cab and chassis Single cab Z Without cargo bed Cab and chassis Double cab 6 Cabin shape None Single cab J Double cab C Club cab 7 Rear body shape None Cab and chassis E Smooth surface and low floor 8 Transmission type N 5 speed manual transmission Floor shift R 4 speed automatic transmission Floor shift 9 Vehicle grade D GL H GLX X GLS 10 Specified engine feature None N A E MP...

Page 27: ...ithout rear body Z Double cab without rear body 5 Transmission type N 5 speed manual transmission R 4 speed automatic transmission 6 Vehicle line K Mitsubushi L200 7 Body type 6 Long wheelbase 7 4WD Long wheelbase 8 Engine type 2 4G63 1 997 m petrol engine 4 4D56 2 477 m diesel engine 5 4G64 2 351 m petrol engine 9 International production control code O A B C etc 0 zero No meaning 10 Model year T...

Page 28: ...l number is stamped at the cylinder block as shown in the following Engine model Engine displacement m 4G63 4G64 4D56 1 997 2 351 2 477 2 The engine serial number is stamped near the engine model number Engine serial number AA0201 to YY9999 4G63 4G64 Front of engine Front of engine 4D56 ...

Page 29: ... area length 10 2 245 2 245 2 245 Cargo area width 11 1 470 1 470 1 470 Cargo bed height 12 680 680 680 Vehicle weight kg Kerb weight 1 315 1 365 1 235 1 365 weight kg Max gross vehicle weight rating 2 520 2 570 2 570 2 570 Max axle weight rating front 1 000 1 000 1 000 1 000 Max axle weight rating rear 1 700 1 700 1 700 1 700 Max trailer weight With brake 1 500 1 500 1 500 1 500 weight Without br...

Page 30: ... 10 1 830 1 500 1 500 Cargo area width 11 1 470 1 470 1 470 Cargo bed height 12 695 680 680 Vehicle weight kg Kerb weight 1 440 1 435 1 465 1 335 weight kg Max gross vehicle weight rating 2 570 2 520 2 570 2 570 Max axle weight rating front 1 000 1 000 1 000 1 000 Max axle weight rating rear 1 700 1 700 1 700 1 700 Max trailer weight With brake 1 500 1 500 1 500 1 500 weight Without brake 500 500 ...

Page 31: ... 10 2 245 1 830 1 830 Cargo area width 11 1 470 1 470 1 470 Cargo bed height 12 860 875 875 Vehicle weight kg Kerb weight 1 500 1 630 1 615 1 705 weight kg Max gross vehicle weight rating 2 830 2 830 2 720 2 830 Max axle weight rating front 1 200 1 200 1 200 1 200 Max axle weight rating rear 1 800 1 800 1 800 1 800 Max trailer weight With brake 2 200 2 200 2 200 2 200 weight Without brake 500 500 ...

Page 32: ...area width 11 1 470 1 470 1 470 1 470 Cargo bed height 12 860 860 860 880 Vehicle weight kg Kerb weight 1 730 1 600 1 735 1 735 1 750 weight kg Max gross vehicle weight rating 2 830 2 830 2 830 2 830 2 830 Max axle weight rating front 1 200 1 200 1 200 1 200 1 200 Max axle weight rating rear 1 800 1 800 1 800 1 800 1 750 Max trailer weight With brake 2 200 2 200 2 200 2 200 2 200 weight Without br...

Page 33: ...in the following locations D Hood D Sun visor D Glove box D SRS diagnosis unit D Steering wheel D Air bag module D Clock spring D Frame 6 Store components removed from the SRS in a clean and dry place The air bag module should be stored on a flat surface and placed so that the pad surface is facing upward Do not place anything on top of it 7 Be sure to deploy the air bag before disposing of the ai...

Page 34: ...r the oxygen sensor with a protective cover when applying anti corrosion agents and undercoats PRE INSPECTION CONDITION Pre inspection condition refers to the condition that the vehicle must be in before proper engine inspection can be carried out If you see the words Set the vehicle to the pre inspection condition in this manual it means to set the vehicle to the following condition D Engine cool...

Page 35: ...ed out which involve the electrical or fuel systems MUST be carried out in accordance with MMC s information Instructions ENGINE OILS Health Warning Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin leading to dryness irritation and dermatitits In addition used engine oil contains potentially harmful contaminants which may cause skin cancer Ad...

Page 36: ...is a risk of eye contact eye protection should be worn for example chemical goggles or face shields in addition an eye wash facility should be provided D Obtain First Aid treatment immediately for open cuts and wounds D Wash regularly with soap and water to ensure all oil is removed especially before meals skin cleansers and nail brushes will help After cleaning the application of preparations con...

Page 37: ... safing G sensor The warning lamp on the instrument panel indicates the operational status of the SRS Each front impact sensors are located left and right fender shield panel The clock spring is installed in the steering column Only authorized service personnel should do work on or around the SRS components Those service personnel should read this manual carefully before starting any such work Ext...

Page 38: ...h voltage to deploy the air bag for a short time even after the battery has been disconnected so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected Wind a tape around the disconnected terminal for insulation 5 To unlock the SDU connector place a flat tipped screwdriver against the lock spring at the l...

Page 39: ... L H Refer to GROUP 52B 17 Body wiring harness Front wiring harness Front impact sensor L H 18 Body wiring harness Front wiring harness Front impact sensor R H 19 20 Body wiring harness Earth Correct or replace each wiring harness NOTE The sensor cable marked with is available as service part 7 SRS components should not be subjected to heat over 93_C so remove the SRS diagnosis unit air bag module...

Page 40: ...SUPPORT LOCATIONS FOR LIFTING AND JACKING 00100070058 Caution Do not support the vehicles at locations other than specified supporting points If do so this will cause damage etc SUPPORT POSITIONS FOR A GARAGE JACK AND AXLE STANDS 2WD AXLE STANDS GARAGE JACK ...

Page 41: ...GENERAL Support Locations for Lifting and Jacking 00 33 4WD AXLE STANDS GARAGE JACK ...

Page 42: ... OR DOUBLE POST LIFT AND H BAR LIFT Caution When service procedures require removing rear suspension spare tyre and rear bumper place additional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity changes 2WD DOUBLE POST LIFT SINGLE POST LIFT H BAR LIFT ...

Page 43: ...GENERAL Support Locations for Lifting and Jacking 00 35 4WD DOUBLE POST LIFT SINGLE POST LIFT H BAR LIFT ...

Page 44: ...tened to plastic or die cast inserted nuts 4 If self tapping screws or self locking nuts are used Standard bolt and nut tightening torque Thread size Torque Nm Bolt nominal diameter mm Pitch mm Head mark 4 Head mark 7 Head mark 8 M5 0 8 2 5 4 9 5 9 M6 1 0 4 9 8 8 9 8 M8 1 25 12 22 25 M10 1 25 24 44 52 M12 1 25 41 81 96 M14 1 5 72 137 157 M16 1 5 111 206 235 M18 1 5 167 304 343 M20 1 5 226 412 481 ...

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Page 65: ...CE GENERAL MANAGER QUALITY INFORMATION ANALYSIS EC EXP LANCER CB0A CD0A 1 Description This Service Bulletin informs you of correction to the diagnosis code reading procedure to be followed when using the warning lamp 2 Applicable Manuals Manual Pub No Language Page s 97 GALANT PWDE9611 English 00 8 Workshop Manual CHASSIS PWDW9616 Swedish 96 COLT LANCER PWME9511 English 00 8 Workshop Manual CHASSI...

Page 66: ...gnosis code is output NOTE Even if the ABS system is normal removing the valve relay causes the diagnosis code No 52 to be output METHOD OF ERASING DIAGNOSIS CODES WHEN USING THE MUT II Connect the MUT II to the diagnosis connector and erase the diagnosis code Caution Turn off the ignition switch before connecting or disconnecting the MUT II WHEN NOT USING THE MUT II 1 Turn the ignition switch OFF...

Page 67: ...s output NOTE Even if the ABS system is normal removing the valve relay causes the diagnosis code No 52 to be output METHOD OF ERASING DIAGNOSIS CODES WHEN USING THE MUT II Connect the MUT II to the diagnosis connector and erase the diagnosis code Caution Turn off the ignition switch before connecting or disconnecting the MUT II WHEN NOT USING THE MUT II 1 Turn the ignition switch OFF 2 After disc...

Page 68: ...s output NOTE Even if the ABS system is normal removing the valve relay causes the diagnosis code No 52 to be output METHOD OF ERASING DIAGNOSIS CODES WHEN USING THE MUT II Connect the MUT II to the diagnosis connector and erase the diagnosis code Caution Turn off the ignition switch before connecting or disconnecting the MUT II WHEN NOT USING THE MUT II 1 Turn the ignition switch OFF 2 After disc...

Page 69: ...0 10 Group GENERAL Draft No 00SY0022915 INFORMATION CORRECTION INTERNATIONAL CAR ADMINISTRATIO OFFICE T NITTA PROJECT LEADER AFTER SALES SERVICE CS PROMOTION 1 Description This Service Bulletin informs you of the year model changes for the 2001 L200 2 Applicable Manuals Manual Pub No Language Page s 2000 L200 PWTE96E1 D English Workshop Manual Chassis PWTS96E1 D Spanish PWTF96E1 D French PWTG96E1 ...

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Page 71: ... PWTE96E1 C SUPPLEMENT PWTE96E1 D SUPPLEMENT ELECTRICAL WIRING PHTE96E1 PHTE96E1 A PHTE96E1 B PHTE96E1 D PHTE96E1 D SUPLEMTENT BODY REPAIR MANUAL PARTS CATALOGUE PBTE96E1 T603B00 D All information illustrations and product d e scriptions contained in this manual are current as at the time of publication We however re serve the right to make changes at any time without prior notice or obligation Mi...

Page 72: ... 5M T MPI ENDL6 ENDR6 CENDL6 K64T JENDL6 4D56 2 477mℓ R5M21 2WD M T Fuel injection CENDEL6 K75T GJENXEL6 4G64 SOHC 2 351 mℓ V5M21 4WD 5M T MPI ENDFL6 ENDFR6 V5MT1 4WD 5M T JERDFL6 V4AW2 AWD 4A T GJERXFL6 GJENXFL6 GJENXFR6 CENDFL6 GCENXFL6 JENDFL6 JENDFR6 K74T JENHFL6 4D56 Turbocharger with intercooler 2 477mℓ V5MT1 4WD 5M T Fuel injection 00 1 GENERAL vehicle identification ...

Page 73: ...mission type R 4 speed automatic transmission 6 Vehicle line K Mitsubushi L200 6 Long wheelbase 7 Body type 7 4WD Long wheelbase 2 4G63 1 997mℓ petrol engine 4 4D56 2 477mℓ diesel engine 8 Engine type 5 4G64 2 351 mℓ petrol engine 9 Internal production control code A A B C etc 0 zero No meaning 10 Model year 1 2001 11 Plant A A C LARDKRABANG factory D F LAEMCHABANG factory 12 Serial number NOTE In...

Page 74: ...6 NOTES ...

Page 75: ...oil has been changed ON VEHICLE SERVICE specified engine oil ACEA and API classification 4G6 ACEA A1 A2 A3 API SG or higher 4D5 ACEA B1 B2 B3 B4 API CD or higher ENGINE LUBRICATION General On vehicle Service 12 1 4G6 Barometric temperature Y0042AA Barometric temperature M03B017 4D5 ...

Page 76: ...8 NOTES ...

Page 77: ...ransmitter LOCK UNLOCK NOTE If the MUT II cannot check all the input signals the diagnosis circuit may be defective ETACS FUNCTION ADJUSTMENT PROCEDURE The following functions can be adjusted by operating input switches The adjustments will be stored in th ECU memory even after a battery cable is disconnected Switching of keyless entry answerback function From activation to deactivation or vice ve...

Page 78: ...nd off If the function toggles on the buzzer sounds once default con dition If the function toggles off the buzzer sounds twice Initialisation of all the ETACS func tions From deactivation to activa tion When the tailgate switch remains on for more than 20 seconds th buzzer sounds twice and he answer back function of the keyless entry system is initialised The buzzer will sound in 10 seconds indic...

Page 79: ...ister the encrypted code Refer to P 42 6 OK Replace the transmitter battery Refer to P 42 6 NG Is a commercial equipment equipped No Yes Remove that equipment and then check trouble symptoms NG Check the connection between ETACS ECU and junction block claw NG Repair OK NG Check the following connectors A 56X C 81 C 91 OK NG Measure at the ETACS ECU connector C 91 Disconnect the connector and measu...

Page 80: ...ctuator If either room lamp or turn signal lamp does not flash illuminate the cause may be a malfunction of the room lamp circuit or turn signal lamp Malfunction of ETACS ECU Malfunction of driver s door lock actuator Burnt turn signal lamp bulb Malfunction of connector or wiring harness Carry out the troubleshooting for room lamp circuit Does the room lamp go on go off simultaneous with opening c...

Page 81: ...k No 5 and diagnosis connector OK Replace MUT II Measure at the diagnosis connector C 35 Continuity between 4 and body earth Continuity between 5 and body earth OK System voltage NG NG Repair Check the following connectors C 35 C 86 OK Check trouble symptoms NG Check the harness wire and repair if necessary Between the diagnosis connector and earth NG Check the following connectors A 56X C 81 C 82...

Page 82: ...in the following cases If a second transmitter is to be used If it appears that a problem is occurring because of faulty registration of a code A maximum of two different codes can be stored in the memory area of the EEPROM two different transmit ters can be used When the code for the first transmitter is registered th previously registered codes for two transmitters are cleared Therefore if you a...

Page 83: ...hould be carried out for the second trans mitter and it should be carried out within one min ute after registration of the code for the first trans mitter has been completed After the second regis tration is completed the doors will be automatically locked and unlocked once 7 Registration mode will be terminated under the following conditions When the secret codes for two transmitters hav been reg...

Page 84: ...ACS ECU removal 2 ETACS ECU Keyless entry receiver ECU removal steps Glove box assembly Refer to GROUP 52A 1 Keyless entry receiver ECU NOTE Refer to 97 L200 Workshop Manual Pub No PWTE96E1 42 8 BODY Keyless Entry System AY0014AA A18VO187 Junction block ...

Page 85: ...The service procedures are the same as previous one FRONT SEAT BELT REMOVAL AND INSTALLATION Inner seat belt removal steps Front seat refer to P 52A 5 Inner seat belt Outer seat belt removal steps Center pillar trim lower or quarter trim lower refer to P 52A 1 Sash guide cover 2 Outer seat belt 3 Center pillar trim upper or quarter trim upper refer to P 52A 4 Adjustable seat belt anchor NOTE Refer...

Page 86: ...18 NOTES ...

Page 87: ...ocedure has been added due to the addition of the high stop lamp 4WD HIGH MOUNTED STOP LAMP REMOVAL AND INSTALLATION Removal steps 1 Rear gate panel 2 High mounted stop lamp 3 Lamp bracket 4 Bulb socket assembly 5 Bulb CHASSIS ELECTRICAL High Mounted Stop Lamp 54 1 A16V0088 ...

Page 88: ...00 1 GENERAL CONTENTS HOW TO USE THIS MANUAL 2 VEHICLE IDENTIFICATION 3 Models 3 Chassis Number 4 MAJOR SPECIFICATIONS 5 STANDARD PART TIGHTENING TORQUE TABLE 11 ...

Page 89: ...wable tolerance The central value is the target value and the allowable tolerance provides the checking range for tightening torques If bolts and nuts are not provided with tightening torques refer to P 00 11 EXPLANATION OF MANUAL CONTENTS Denotes tightening torque For bolts and nuts which do not have a tightening torque listed refer to the Standard Parts tightening torque Table ...

Page 90: ...egulation R5M21 2WD 5M T JENDPL6 Emission regulation step II K75T CENDEL6 4G64 SOHC 2 351 mL V5M21 4WD 5M T MPI GJENXEL6 K74T ENDFL6 4D56 Turbocharger with intercooler 2 477 mL V5MT1 4WD 5M T Fuel injection ENDFR6 intercooler 2 477 mL Emission regulation t III JERDFL6 g step III V4A51 4WD 4A T GJERXFL6 GJENXFL6 V5MT1 4WD 5M T GJENXFR6 CENDFL6 GCENXFL6 JENDFL6 JENDFR6 JENHFL6 JERDPL6 4D56 Turbochar...

Page 91: ... Transmission type N 5 speed manual transmission R 4 speed automatic transmission 6 Vehicle line K Mitsubishi L200 7 Body type 6 Long wheelbase 7 4WD Long wheelbase 8 Engine type 4 4D56 2 477 mL diesel engine 5 4G64 2 351 mL petrol engine 9 Internal production control code A A B C etc 0 zero No meaning 10 Model year 2 2002 11 Plant A A C LARDKRABANG factory 11 Plant A A C LARDKRABANG factory D F L...

Page 92: ...2 245 1 830 Cargo area width 11 1 470 1 470 1 470 1 470 Cargo bed height 12 680 680 680 695 Vehicle weight kg Kerb weight 1 410 1 410 1 370 1 485 weight kg Max gross vehicle weight rating 2 570 2 570 2 570 2 570 Max axle weight rating front 1 000 1 000 1 000 1 000 Max axle weight rating rear 1 700 1 700 1 700 1 700 Max trailer weight With brake 1 800 1 800 1 800 1 800 weight Without brake 500 500 ...

Page 93: ...0 1 500 Cargo area width 11 1 470 1 470 1 470 Cargo bed height 12 680 680 680 Vehicle i ht k Kerb weight 1 510 1 520 1 470 weight kg Max gross vehicle weight rating 2 570 2 570 2 570 Max axle weight rating front 1 000 1 000 1 000 Max axle weight rating rear 1 700 1 700 1 700 Max trailer i ht With brake 1 800 1 800 1 800 weight Without brake 500 500 500 Max trailer nose weight 75 75 75 Seating capa...

Page 94: ... width 11 1 470 1 470 1 470 1 470 1 470 Cargo bed height 12 860 860 875 875 895 Vehicle weight kg Kerb weight 1 675 1 675 1 615 1 720 1 740 weight kg Max gross vehicle weight rating 2 830 2 830 2 720 2 830 2 830 Max axle weight rating front 1 200 1 200 1 200 1 200 1 200 Max axle weight rating rear 1 800 1 800 1 800 1 800 1 750 Max trailer weight With brake 2 700 2 700 2 700 2 700 2 700 weight With...

Page 95: ...area width 11 1 470 1 470 1 470 1 470 Cargo bed height 12 860 860 860 860 Vehicle i ht k Kerb weight 1 745 1 745 1 750 1 750 weight kg Max gross vehicle weight rating 2 830 2 830 2 830 2 830 Max axle weight rating front 1 200 1 200 1 200 1 200 Max axle weight rating rear 1 800 1 800 1 800 1 800 Max trailer i ht With brake 2 700 2 700 2 200 2 700 weight Without brake 500 500 500 500 Max trailer nos...

Page 96: ...00 Cargo area width 11 1 470 1 470 1 470 1 470 Cargo bed height 12 880 880 880 880 Vehicle i ht k Kerb weight 1 660 1 765 1 765 1 770 weight kg Max gross vehicle weight rating 2 720 2 830 2 830 2 830 Max axle weight rating front 1 200 1 200 1 200 1 200 Max axle weight rating rear 1 750 1 750 1 750 1 750 Max trailer i ht With brake 2 700 2 700 2 700 2 200 weight Without brake 500 500 500 500 Max tr...

Page 97: ...470 1 470 1 470 1 470 1 470 Cargo bed height 12 860 860 880 880 880 Vehicle weight kg Kerb weight 1 730 1 735 1 750 1 750 1 755 weight kg Max gross vehicle weight rating 2 830 2 830 2 830 2 830 2 830 Max axle weight rating front 1 200 1 200 1 200 1 200 1 200 Max axle weight rating rear 1 800 1 800 1 750 1 750 1 750 Max trailer weight With brake 2 700 2 200 2 700 2 700 2 200 weight Without brake 50...

Page 98: ...mm Head mark 4 Head mark 7 Head mark 8 M5 0 8 2 5 0 5 5 0 1 0 6 0 1 0 M6 1 0 5 0 1 0 9 0 2 0 10 2 M8 1 25 12 2 22 4 25 4 M10 1 25 24 4 44 10 53 7 M12 1 25 41 8 83 12 98 12 M14 1 5 73 12 140 20 155 25 M16 1 5 110 20 210 30 235 35 M18 1 5 165 25 300 40 340 50 M20 1 5 225 35 410 60 480 70 M22 1 5 300 40 555 85 645 95 M24 1 5 395 55 735 105 855 125 Flange bolt and nut tightening torque Thread size Tor...

Page 99: ...NOTES ...

Page 100: ... 4G6 ENGINE ...

Page 101: ...heck and Adjustment 7 Ignition Timing Check and Adjustment 10 Idle Speed Check 11 Idle Mixture Check 11 Compression Pressure Check 12 Manifold Vacuum Check 13 Lash Adjuster Check 14 CAMSHAFT OIL SEAL 16 OIL PAN OIL SCREEN 19 CYLINDER HEAD GASKET 21 TIMING BELT TIMING BELT B 26 CRANKSHAFT FRONT OIL SEAL 32 CRANKSHAFT REAR OIL SEAL 35 ENGINE ASSEMBLY 37 ...

Page 102: ...on Electronic control multipoint fuel injection Rocker arm Roller type Roller type Auto lash adjuster Equipped Equipped SERVICE SPECIFICATIONS 11100030342 Items Standard value Limit Alternator drive belt Tension N When checked 294 490 belt tension When a used belt is installed 343 441 When a new belt is installed 490 686 Deflection Reference When checked 7 0 9 0 Reference value mm When a used belt...

Page 103: ...7 0 When a new belt is installed 4 5 5 5 Basic ignition timing 5_ BTDC 2_ Idle speed r min 750 100 CO contents 0 5 or less HC contents ppm 100 or less Compression pressure 250 400 r min kPa 4G63 1 270 min 960 250 400 r min kPa 4G64 1 320 min 1 000 Compression pressure difference of all cylinder kPa max 100 Intake manifold vacuum kPa min 60 Cylinder head bolt shank length mm 99 4 Auto tensioner pus...

Page 104: ...ly D Checking the idle speed D Erasing of diagnosis code MD998738 Adjusting screw D Holding the auto tensioner D Timing belt tension adjustment MB990767 End yoke holder Holding the camshaft sprocket MD998719 or MD998754 Crankshaft pulley holder pin MD998713 Camshaft oil seal installer Press in of the camshaft oil seal MD998727 Oil pan remover Removal of the oil pan MD998781 Fly wheel stopper Secur...

Page 105: ...he crankshaft rear oil seal MB990938 Handle Press fitting the crankshaft rear oil seal MD998747 Crankshaft pulley holder Supporting of crankshaft sprocket MD998375 Crankshaft front oil seal installer Press fitting the crankshaft front oil seal MD998767 Tension pulley socket wrench Timing belt tension adjustment ...

Page 106: ...tion Reference value mm 7 0 9 0 ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1 Loosen the nut of the alternator pivot bolt 2 Loosen the lock bolt 3 Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values Standard value Items When a used belt is installed When a new belt is installed Tension N 343 441 490 686 Deflection Reference value mm 7 5 8 5 5 5 7 5 4 Tighten t...

Page 107: ... belt is intalled When a new belt is installed Tension N 294 490 343 441 490 686 Deflection Reference value mm 5 5 7 5 6 0 7 0 4 0 6 0 2 If the tension or deflection is outside the standard value adjust by the following procedure 1 Loosen power steering oil pump fixing bolts A and B 2 Move power steering oil pump tension belt moderately and adjust tension 3 Tighten fixing bolts A and B Tightening ...

Page 108: ...When a used belt is intalled When a new belt is installed Tension N 355 445 355 445 530 620 Deflection Reference value mm 6 0 7 0 6 0 7 0 4 5 5 5 2 If the tension or deflection is outside the standard value adjust by the following procedure 1 Loosen tension pulley fixing nut 2 Adjust belt tension with adjusting bolt 3 Tighten fixing nut 4 Check the belt deflection amount and tension and readjust i...

Page 109: ...h the clip to the ignition timing adjustment terminal and earth this to the body as illustrated NOTE Earthing this terminal sets the engine to the basic ignition timing 10 Start the engine and run it at idle 11 Check that basic ignition timing is within the standard value Standard value 5_ BTDC 2_ 12 If not within the standard value loosen distributor fixing bolts and adjust by rotating distributo...

Page 110: ...system 7 If the idle speed is outside the standard value inspect the MPI components by referring to GROUP 13A Troubleshooting IDLE MIXTURE CHECK 11100210265 1 Before inspection set the vehicle to the pre inspection condition 2 Check that the basic ignition timing is within the standard value Standard value 5_ BTDC 2_ 3 Turn the ignition switch to OFF and connect the MUT II to the diagnosis connect...

Page 111: ... connector NOTE Doing this will prevent the engine ECU from carrying out ignition and fuel injection 5 Cover the spark plug hole with a shop towel etc and after the engine has been cranked check that no foreign material is adhering to the shop towel Caution 1 Keep away from the spark plug hole when cranking 2 If compression is measured with water oil fuel etc that has come from cracks inside the c...

Page 112: ...fter oil is added the cause is a burnt or defective valve seat or pressure is leaking from the gasket 10 Connect the distributor connector 11 Install the spark plugs and spark plug cables 12 Use the MUT II to erase the diagnosis codes NOTE This will erase the problem code resulting from the distributor connector being disconnected MANIFOLD VACUUM CHECK 11100270270 1 Start the engine and allow it t...

Page 113: ...hen the valve is closed This is the same phenomenon which occurs when the valve clearance is improperly adjusted to be excessively large However it will return to be normal if the air entrapped in the adjuster is released in this case 2 Start the engine and slowly race it several times 10 times or less If the abnormal noise is eliminated by racing the engine it means that the air is released from ...

Page 114: ...directly above the lash adjuster of the rocker arm is pressed the lash adjuster is defective so replace it Moreover if it is felt to be so hard that the rocker arm is not lowered when it is pressed the lash adjuster is normal Check for other causes of the abnormality For Y formed rocker arm at the exhaust valve side if one lash adjuster is defective and the other is normal it is impossible to pres...

Page 115: ...CA 4 Camshaft sprocket spacer AA BA 5 Camshaft sprocket AB AA 6 Camshaft oil seal REMOVAL SERVICE POINTS AA CAMSHAFT SPROCKET REMOVAL 1 Rotate the crankshaft in the forward right direction and align the timing mark Caution The crankshaft must always be rotated in the forward direction only 2 Tie the camshaft sprocket and timing belt with a cord so that the position of the camshaft sprocket will no...

Page 116: ...h a knife etc 2 Cover the end of a screwdriver with a rag and insert into the notched section of the oil seal and lever out the oil seal to remove it Caution Be careful not to damage the camshaft and the cylinder head INSTALLATION SERVICE POINTS AA CAMSHAFT OIL SEAL INSTALLATION 1 Apply engine oil to the camshaft oil seal lip 2 Use the special tool to press fit the camshaft oil seal BA CAMSHAFT SP...

Page 117: ...ENGINE 4G6 Camshaft Oil Seal 11A 18 CA CAMSHAFT SPROCKET SPACER INSTALLATION Align the mating marks on the camshaft sprocket and the camshaft sprocket spacer groove and then install them Mating marks ...

Page 118: ...moval and Installation D Engine Oil Draining and Refilling Refer to GROUP 12 On vehicle Service 4 0 mm Bolt hole Groove 1 2 3 4 5 4G63 10 12 Nm 18 Nm Frontof engine Sealant MITSUBISHI GENUINE PART No MD970389 or equivalent 39 Nm 9 Nm 7 Nm 4 5 4G64 6 Removal steps 1 Drain plug BA 2 Drain plug gasket 3 Bell housing cover AA AA 4 Oil pan 5 Oil screen 6 Gasket ...

Page 119: ... or equivalent NOTE The sealant should be applied in a continuous bead approximately 4 mm in diameter 4 Assemble oil pan to cylinder block within 15 minutes after applying the sealant Caution After installing the oil pan wait at least 1 hour before starting the engine Be careful when installing as the bolts indicated in the illustration have different lengths from the other bolts BA DRAIN PLUG GAS...

Page 120: ...rottle Cable Adjustment Refer to GROUP 23 On vehicle Service 12 Nm 16 Nm 50 Nm 5 Nm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 17 Removal steps 1 Accelerator cable connection 2 Throttle cable connection A T 3 Brake booster vacuum hose con nection 4 Ignition coil connector 5 Engine coolant temperature sensor connector 6 Noise filter connector 7 Power transistor connector 8 Injector connecto...

Page 121: ...27 28 29 30 Cold engine 78 Nm 0 N m 20 N m 90_ 90_ 21 Power steering pump mount bracket 22 Ignition coil 23 Timing belt upper cover assembly 24 Distributor bracket DA 25 Camshaft sprocket spacer AA CA 26 Camshaft sprocket 27 Rocker cover 28 Intake manifold stay AB BA 29 Cylinder head assembly AA 30 Cylinder head gasket ...

Page 122: ...end of the special tool touch the tensioner arm So the auto tensioner will stop and the timing belt tension will not vary 4 Use the special tool to remove the camshaft sprocket with the timing belt attached Caution After removing the camshaft sprocket be sure not to rotate the crankshaft AB CYLINDER HEAD ASSEMBLY REMOVAL Loosen the bolts in 2 or 3 steps in order of the numbers shown in the illustr...

Page 123: ...arks 1 Tighten to 78 Nm Carry out in the order shown in the illustration 2 Fully loosen Carry out in the reverse order of that shown in the illustration 3 Tighten to 20 Nm Carry out in the order shown in the illustration 4 Tighten 90_ of a turn In the order shown in the illustration Mark the head of the cylinder head bolt and cylinder head by paint 5 Tighten 90_ of a turn In the order shown in the...

Page 124: ...the camshaft sprocket bolt 2 Remove the special tool from the rubber plug hole 3 Remove the cord which binds the camshaft sprocket and timing belt DA CAMSHAFT SPROCKET SPACER INSTALLATION Align the mating marks on the camshaft sprocket and the camshaft sprocket spacer groove and then install them MD998719 or MD998754 MB990767 Camshaft sprocket Mating marks ...

Page 125: ...al and Installation Refer to GROUP 14 D Distributor Removal and Installation 9 Nm 25 Nm 19 Nm 24 Nm 10 12 Nm 10 12 Nm 24 Nm 1 2 3 4 5 6 7 8 9 Removal steps 1 Ignition coil 2 Crankshaft pulley 3 Timing belt upper cover assembly 4 Distributor bracket 5 Timing belt lower cover assembly EA D Timing belt tension adjustment AA DA 6 Auto tensioner AB CA 7 Timing belt BA D Timing belt B tension adjustment...

Page 126: ...sure that crankshaft sprocket B timing marks and the silent shaft sprocket timing marks are aligned 2 Fit timing belt B over crankshaft sprocket B and the silent shaft sprocket Ensure that there is no slack in the belt BA TIMING BELT B TENSION ADJUSTMENT 1 Temporarily fix the timing belt B tensioner such that the centre of the tensioner pulley is to the left and above the centre of the installatio...

Page 127: ...ck that the timing marks of the camshaft sprocket crankshaft sprocket and oil pump sprocket are all aligned 2 After aligning the timing marks on the oil pump sprocket remove the cylinder block plug and insert a Phillips screwdriver with a diameter of 8 mm and check to be sure that the screwdriver goes in 60 mm or more If the screwdriver will only go in 20 25 mm before striking the silent shaft tur...

Page 128: ...press the end of the rod against a metal surface such as the cylinder block with a force of 98 196 Nm and measure how far the rod is pushed in Standard value Within 1 mm A Length when no force is applied B Length when force is applied A B Amount pushed in 2 If it is not within the standard value replace the auto tensioner 3 Place two dolly blocks in a vice as shown in the illustration and then pla...

Page 129: ...e pin will already be inserted into the pin holes 6 Install the auto tensioner to the engine Caution Do not remove the setting pin from the auto tensioner 7 Remove the rubber plug from the timing belt cover assembly rear Then screw in the special tool by hand until the tensioner arm is touching the auto tensioner push rod Caution Do not use a spanner or the similar tool to turn the special tool ot...

Page 130: ...ing pin that has been inserted into the auto tensioner and then remove the special tool 4 Turn the crankshaft two turns clockwise and wait for approximately 15 minutes 5 Insert the special tool again and turn it by hand until the end of the special tool touches the tensioner arm 6 Once the end touches keep turning the special tool until the auto tensioner push rod retracts and the tensioner arm co...

Page 131: ...AL AND INSTALLATION Pre removal and Post installation Operation D Timing Belt Timing Belt B Removal and Installation Refer to P 11A 26 108 127 Nm 1 2 3 4 Crankshaft Engine oil 4 Removal steps AA BA 1 Crankshaft sprocket BA 2 Flange BA 3 Crankshaft sprocket B AA 4 Crankshaft front oil seal ...

Page 132: ...belt 2 Loosen the crankshaft sprocket bolt and then remove the sprocket INSTALLATION SERVICE POINTS AA CRANKSHAFT FRONT OIL SEAL INSTALLATION 1 Apply engine oil to the entire circumference of the oil seal lip 2 Press fit the oil seal until it is flush with the front case BA CRANKSHAFT SPROCKET B FLANGE CRANKSHAFT SPROCKET INSTALLATION 1 Install the crankshaft sprocket B flange and the crankshaft s...

Page 133: ... V ribbed belt and the special tool to stop the crankshaft pulley from turning Caution 1 Do not use the vehicle s V ribbed belt or the belt may be damaged 2 Do not use a damaged V ribbed belt 3 Tighten the crankshaft sprocket bolt to the specified torque Tightening torque 108 127 Nm MD998747 V ribbed belt ...

Page 134: ...stallation 2WD Refer to GROUP 22 23 D Transmission and Transfer Assembly Removal and Installation 4WD Refer to GROUP 22 127 137 Nm M T 1 2 3 4 5 6 127 137 Nm A T Crankshaft Engine oil 4 6 Removal steps M T D Clutch cover and clutch disc AA BA 1 Flywheel bolt 2 Flywheel AA 6 Crankshaft rear oil seal A T AA BA 3 Drive plate bolt 4 Adaptor plate 5 Drive plate AA 6 Crankshaft rear oil seal ...

Page 135: ...ICE POINTS AA CRANKSHAFT REAR OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the entire circumference of the oil seal lip 2 Tap in the oil seal as shown in the illustration BA DRIVE PLATE BOLT A T FLYWHEEL BOLT M T INSTALLATION Use the special tool to install the drive bolt and flywheel bolt MD998781 MB998776 MB990938 ...

Page 136: ...Refer to GROUP 15 D Hood Installation Refer to GROUP 42 D Drive Belt Tension Adjustment Refer to P 11A 7 D Accelerator Cable Adjustment Refer to GROUP 17 On vehicle Service D Throttle Cable Adjustment A T Refer to GROUP 23 On vehicle Service 12 Nm 16 Nm 50 Nm 5 Nm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 15 Removal steps 1 Accelerator cable connection 2 Throttle cable connection A T 3 Brake bo...

Page 137: ...4 25 26 25 15 Drive belt for Power steering AA 16 Power steering oil pump assembly 17 Drive belt for A C AA 18 A C compressor assembly 19 Engine oil pressure switch connec tor 20 Alternator connector 24 Heat protector 25 Engine support front insulator at taching bolt AB AA 26 Engine assembly ...

Page 138: ...no damage will be caused during removal installation of the engine assembly AB ENGINE ASSEMBLY REMOVAL 1 Check that all cables hoses harness connectors etc are disconnected from the engine 2 Lift the chain block slowly to remove the engine assembly upward from the engine compartment INSTALLATION SERVICE POINT AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly When doing so check carefully...

Page 139: ...NOTES ...

Page 140: ...Outline of Change 3 SERVICE SPECIFICATIONS 3 SPECIAL TOOLS 3 ON VEHICLE SERVICE 4 Ignition Timing Check 4 Compression Pressure Check 4 CAMSHAFT OIL SEAL 5 CYLINDER HEAD GASKET 6 TIMING BELT AND TIMING BELT B 8 CRANKSHAFT FRONT OIL SEAL 9 ...

Page 141: ...E SPECIFICATIONS Item Standard value Limit Idle speed r min 750 100 Basic ignition timing 5_ BTDC 2_ Ignition timing Approx 10_BTDC Compression pressure 250 r min kPa 1 324 Min 1 000 Compression pressure difference of all cylinder kPa Max 100 SPECIAL TOOLS Tool Number Name Use MD998747 Crankshaft pulley holder Supporting of crankshaft sprocket MD998375 Crankshaft front oil seal installer Press fit...

Page 142: ...ess the MUT II clear key Select a forced driving cancel mode to release the Actuator test Caution If the test is not cancelled a forced driving will continue for 27 minutes Driving under this condition may damage the engine 10 Check that ignition timing is at the standard value Standard value approx 10_BTDC NOTE 1 Ignition timing is variable within about 7_ even under normal operating 2 And it is ...

Page 143: ... m 10 2 N m 11 1 N m 24 4 N m Removal steps 1 Ignition coil 2 Timing belt upper cover assembly 3 Ignition coil bracket power transis tor and camshaft position sensor assembly 4 Sensing cam position cylinder AA BA 5 Camshaft sprocket AB AA 6 Camshaft oil seal NOTE Follow the conventional procedures for removal and installation service points ...

Page 144: ... 19 20 18 21 22 5 0 1 0 N m Removal steps 1 Accelerator cable connection 2 Throttle cable connection A T 3 Brake booster vacuum hose connection 4 Ignition coil 1 connector 5 Ignition coil 2 connector 6 Engine coolant temperature sensor connector 7 Capacitor connector 8 Camshaft position sensor connector 9 Power transistor connector 10 Injector connectors 11 Throttle position sensor connector 12 Id...

Page 145: ... Power steering pump mount bracket 24 Ignition coil 25 Timing belt upper cover assembly 26 Ignition coil bracket power transistor and camshaft position sensor assembly 27 Sensing cam position cylinder AA CA 28 Camshaft sprocket 29 Rocker cover 30 Intake manifold stay AB BA 31 Cylinder head assembly AA 32 Cylinder head gasket NOTE Follow the conventional procedures for removal and installation serv...

Page 146: ...2 N m 11 1 N m 11 1 N m 9 0 1 0 N m 24 4 N m Removal steps 1 Ignition coil 2 Crankshaft pulley 3 Timing belt upper cover assembly 4 Ignition coil bracket power transis tor and camshaft position sensor assembly 5 Timing belt lower cover assembly EA D Timing belt tension adjustment AA DA 6 Auto tensioner AB CA 7 Timing belt BA D Timing belt B tension adjustment 8 Timing belt B tensioner AB AA 9 Timi...

Page 147: ...ocket BA 2 Crankshaft sensing blade BA 3 Crankshaft sprocket B AA 4 Crankshaft front oil seal REMOVAL SERVICE POINT AA CRANKSHAFT SPROCKET REMOVAL 1 Temporarily install the crankshaft pulley and then use the V ribbed belt and the special tool to stop the crankshaft pulley from turning Caution 1 Do not use the vehicle s V ribbed belt or the belt may be damaged 2 Do not use a damaged V ribbed belt 2...

Page 148: ...he crankshaft sprocket B crankshaft sensing blade and the crankshaft sprocket so that they face as shown in the illustration 2 Temporarily install the crankshaft pulley and then use the V ribbed belt and the special tool to stop the crankshaft pulley from turning Caution 1 Do not use the vehicle s V ribbed belt or the belt may be damaged 2 Do not use a damaged V ribbed belt 3 Tighten the crankshaf...

Page 149: ... 4D5 ENGINE ...

Page 150: ......

Page 151: ...1 x 95 0 Compression ratio 21 Combustion chamber Vortex chamber type Camshaft arrangement SOHC Number of valve Intake 4 Exhaust 4 Valve timing Intake Opening BTDC 20_ Closing ABDC 49_ Exhaust Opening BBDC 55_ Closing ATDC 22_ Fuel system Distribution type injection pump Rocker arm Roller type Adjusting screw Elephant foot type ...

Page 152: ...n a new belt is installed 6 0 8 0 A C compressor drive Tension N When checked 320 400 drive belt tension When a used belt is installed 320 400 When a new belt is installed 480 560 Deflection Reference When checked 6 0 7 0 Reference value mm When a used belt is installed 6 0 7 0 When a new belt is installed 4 5 5 5 Valve clearance at hot mm 0 25 Injection timing Value indicated on dial gauge mm 9_ ...

Page 153: ...B990767 End yoke holder Holding the camshaft sprocket MD998719 Crankshaft pulley holder pin MD998381 Camshaft oil seal installer Installing the camshaft oil seal MD998727 Oil pan remover Removal of oil pan MD998051 Cylinder head bolt wrench Removal and installation of the cylinder head bolt MD998382 Crankshaft front oil seal installer Installing the crankshaft front oil seal MD998383 Crankshaft fr...

Page 154: ...ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Use a belt tension gauge to check that the belt tension is at the standard value at a point half way between the two pulleys as shown in the illustration In addition press this section with a force of 98 N and check that the amount of belt deflection is at the standard value Standard value for each belt Tension N 245 441 Deflection Reference value mm ...

Page 155: ...2 Nm 6 Tighten the adjusting bolt Tightening torque 9 8 Nm POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK AND ADJUSTMENT 11100110152 1 Use a belt tention gauge to check that the belt tension is at the standard value at a point half way between the two pulleys indicated by an arrow in the illustration In addition press this section with a force of 98 N and check that the amount of belt deflection...

Page 156: ...e belt tension is at the standard value at a point half way between the two pulleys indicated by an arrow in the illustration In addition press this section with a force of 98 N and check that the amount of belt deflection is at the standard value Standard value Items When checked When a used belt is intalled When a new belt is installed Tension N 320 400 320 400 480 560 Deflection Reference value...

Page 157: ...ve the timing belt upper cover 3 Remove the rocker cover 4 Align the camshaft sprocket timing marks and set the No 1 cylinder at top dead centre Caution The crankshaft should always be turned in a clockwise direction 5 Measure the valve clearance at the places indicated by arrows in the illustration Standard value 0 25 mm NOTE Insert the thickness gauge from the centre of the cylinder head towards...

Page 158: ...value repeat steps 7 and 8 above 10 Apply specified sealant to the section of the semi circular packing shown in the illustration Specified sealant 3M ATD Part No 8660 or equivalent 11 Install the rocker cover 12 Install the timing belt upper cover INJECTION TIMING CHECK AND ADJUSTMENT 11100180023 1 Warm up the engine and then check to be sure that the fast idle lever is separated from the throttl...

Page 159: ...mately 30_ before compression top dead centre 10 Set the needle of the dial gauge to 0 11 Check that the needle doesn t move even if the crankshaft is turned slightly 2 3_ in both clockwise and anti clockwise direction NOTE If the needle moves the notch is not positioned properly so once again move the No 1 cylinder approximately 30_ before compression top dead centre 12 Turn the crankshaft clockw...

Page 160: ... and bolt of the injection pump 5 Repeat steps 9 13 to check if the adjustment has been made correctly 6 Tighten the mounting nuts and bolts to the specified torque 7 Tighten the injection pump union nuts to the specified torque Caution When tightening the nuts hold the delivery valve holders with a spanner so that they don t turn at the same time 15 Remove the special tool 16 Install a new gasket...

Page 161: ...otating adjusting screw And tighten locking nut IDLE UP MECHANISM CHECK AND ADJUSTMENT FOR A C 11100230032 Refer to GROUP 55 On vehicle Service IDLE UP MECHANISM CHECK AND ADJUSTMENT FOR ABS 11100230025 1 Before inspection set the vehicle to the pre inspection condition 2 Inspect and adjust the idle speed 3 Disconnect the vacuum hose for anti skid brakes blue stripe from the idle up actuator 4 Con...

Page 162: ...ion condition 2 Remove all of the glow plugs Caution Be careful not to subject the glow plugs to any shocks 3 Disconnect the fuel cut solenoid valve connector or fuel cut valve controller NOTE Doing this will prevent carrying out fuel injection 4 Cover the glow plug hole with a shop towel etc and after the engine has been cranked check that no foreign material is adhering to the shop towel Caution...

Page 163: ...ed the cause of the malfunction is a worn or damaged piston ring and or cylinder inner surface 2 If the compression does not rise after oil is added the cause is a burnt or defective valve seat or pressure is leaking from the gasket 9 Connect the fuel cut solenoid valve connector or fuel cut valve controller connector 10 Install the glow plugs Tightening torque 18 Nm TIMING BELT TENSION ADJUSTMENT...

Page 164: ...nger to check that tension of belt is up to standard value Standard value 4 5 mm 9 Mount the timing belt upper cover TIMING BELT B TENSION ADJUSTMENT 11100280143 1 Remove timing belt upper cover 2 Turn the crankshaft in the clockwise direction and check the timing belt around its entire circumference for abnormalities 3 Align the timing marks on the sprockets with the timing mark on the front uppe...

Page 165: ...irst tighten tensioner slot side nut and then tighten pivot side bolt to the specified torque Tightening torque Pivot side bolt 24 Nm Slot side nut 25 Nm 7 Install the access cover while sliding the front lower cover down along the two guides 8 Install the timing belt upper cover Access cover Pivot side bolt Slot side nut Access cover Guide ...

Page 166: ...Tension Adjustment Refer to P 11B 5 D Under Cover Installation 167 186 Nm 1 2 3 4 5 25 Nm Removal steps 1 Drive belt for A C 2 Drive belt for power steering 3 Drive belt for alternator AA AA 4 Crankshaft pulley for power steering or A C 5 Crankshaft pulley REMOVAL SERVICE POINT AA CRANKSHAFT PULLEY REMOVAL INSTALLATION SERVICE POINT AA CRANKSHAFT PULLEY INSTALLATION MD998721 ...

Page 167: ...ivalent Lip Cam section and journal section Engine oil 7 10 6 7 9 8 5 9 Nm 34 39 Nm 19 21 Nm 9 10 9 9 5 4 Camshaft removal steps 1 Timing belt upper cover assembly 2 Breather hose connection 3 Boost hose connection 4WD 4 Rocker cover 5 Semi circular packing AA DA 6 Camshaft sprocket AB CA 7 Camshaft oil seal AC BA 8 Rocker arm and shaft assembly AA 9 Camshaft bearing cap 10 Camshaft Camshaft oil s...

Page 168: ...shaft after removing camshaft sprocket AB CAMSHAFT OIL SEAL REMOVAL 1 Make a notch in the oil seal lip section with a knife etc 2 Cover the end of a screwdriver with a rag and insert into the notched section of the oil seal and lever out the oil seal to remove it Caution Be careful not to damage the camshaft and the cylinder head AC ROCKER ARM AND SHAFT ASSEMBLY REMOVAL Loosen the rocker arm and s...

Page 169: ...e valve clearance and adjust if necessary Refer to P 11B 8 CA CAMSHAFT OIL SEAL INSTALLATION 1 Apply a small amount of engine oil to the entire circumference of the oil seal lip and camshaft 2 Use the special tool to tap in the oil seal NOTE The oil seal should be tapped in until the distance from the end of the camshaft to the end of the oil seal is as shown in the illustration DA CAMSHAFT SPROCK...

Page 170: ... engine Groove φ 4 0 mm Bolt hole Sealant MITSUBISHI GENUINE Part No MD970389 or equivalent 6 39 Nm 6 9 Nm 4 5 2WD 4WD 5 4 2 1 3 19 Nm 6 Removal steps 1 Drain plug BA 2 Drain plug gasket 3 Oil return hose connection AA AA 4 Oil pan 5 Oil screen 6 Gasket REMOVAL SERVICE POINT AA OIL PAN REMOVAL 1 Remove oil pan bolts 2 Tap the special tool in between the oil pan and cylinder block 3 Slide the speci...

Page 171: ...nt MITSUBISHI GENUINE PART No MD970389 or equivalent NOTE The sealant should be applied in a continuous bead approximately 4 mm in diameter 4 Assemble oil pan to cylinder block within 15 minutes after applying the sealant Caution After installing the oil pan wait at least 1 hour before starting the engine BA DRAIN PLUG GASKET INSTALLATION Install a new gasket in the direction so that it faces as s...

Page 172: ...t Filling Refer to GROUP 14 On vehicle Service 29 Nm 29 Nm 29 Nm 4 9 Nm 10 mm 10 mm Sealant 3M ATD Part No 8660 or equivalent 9 11 10 5 9 Nm 4 9 Nm 10 3 2 22 Nm 4 9 Nm 6 4 8 7 1 14 13 12 113 123 Nm 9 5 24 Nm 22 Nm Removal steps 1 Engine coolant temperature switch connector for A C 2 Engine coolant temperature gauge unit and sensor connector 3 Glow plug terminal AA CA 4 Radiator upper hose AB DA 5 ...

Page 173: ... and loosen nut Caution After disconnecting the injection pipe plug the opening so that no foreign particles get inside the pump or into the injection nozzle AC POWER STEERING OIL PUMP REMOVAL Remove the power steering oil pump from the bracket with the hose attached NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine a...

Page 174: ...YLINDER HEAD INSTALLATION Use the special tool to tighten each bolt 2 3 times in the order shown in the illustration Caution The head bolt washer should be installed so that the burred side is facing upwards CA RADIATOR UPPER HOSE CONNECTION To reuse the radiator upper hose align the mating marks that were made during removal and then install the hose clamp DA FUEL INJECTION PIPE INSTALLATION When...

Page 175: ...12 Nm 25 Nm 25 Nm 167 186 Nm 24 Nm 1 6 16 15 14 13 12 11 10 3 4 9 8 7 25 Nm 5 2 25 Nm Removal steps 1 Timing belt front upper cover 2 Tension pulley bracket for A C 3 Crankshaft pulley for power steering and A C AA CA 4 Crankshaft pulley 5 Timing belt front lower cover AB BA 6 Timing belt 7 Tensioner spacer 8 Tensioner spring 9 Timing belt tensioner assembly 10 Crankshaft sprocket 11 Flange AC AA ...

Page 176: ...unting bolt A and B Secure so that tensioner will not move back AC TIMING BELT B REMOVAL 1 When reinstalling timing belt B mark an arrow at the belt to show rotation direction 2 Loosen the tensioner mounting bolt and nut 3 Push timing belt tensioner to water pump side and tighten the tensioner mounting bolt and nut Secure so that tensioner will not move back INSTALLATION SERVICE POINTS AA TIMING B...

Page 177: ...mount of deflection Standard value 4 5 mm BA TIMING BELT INSTALLATION 1 Align the timing marks of the 3 sprockets 2 When reusing timing belt make sure the arrow mark is pointing in the same direction as when the belt was removed 3 Install the timing belt to the crankshaft sprocket to injection pump sprocket to tensioner and to camshaft sprocket in that order Being careful not to allow deflection o...

Page 178: ...re that the part indicated by arrow A does not float upward 7 Tighten the tensioner mounting bolts starting with the bolt in the elongated hole If the lower bolt is tightened first belt tension will become too tight 8 Turn the crankshaft anticlockwise and align the timing mark Next make sure that the timing marks of all sprockets are aligned 9 Press on the centre of the bolt with an index finger t...

Page 179: ... REMOVAL 1 Cut out a portion in the crankshaft oil seal lip 2 Cover the tip of a screwdriver with a cloth and apply it to the cutout in the oil seal to pry off the oil seal Caution Be careful not to damage the crankshaft and front case INSTALLATION SERVICE POINT AA OIL SEAL INSTALLATION Apply engine oil to the outside of the special tool MD998383 and to the oil seal lip and use the special tool to...

Page 180: ...on Refer to GROUP 22 23 6 8 127 137 Nm 127 137 Nm 5 7 4 3 2 1 Removal steps AA CA 1 Flywheel assembly M T AA CA 2 Adaptor plate A T 3 Drive plate A T 4 Crankshaft adaptor A T 5 Oil seal case 6 Gasket BA 7 Oil separator AA 8 Oil seal REMOVAL SERVICE POINT AA FLYWHEEL M T ADAPTOR PLATE A T REMOVAL Use the special tool to secure the flywheel or adaptor plate and remove the bolt INSTALLATION SERVICE P...

Page 181: ...ottom indicated by an arrow in the illustration CA FLYWHEEL M T ADAPTOR PLATE A T INSTALLATION Use the special tool in the same way as during removal to stop the flywheel or adaptor plate assembly from turning and then tighten the bolt to the specified torque Tightening torque 127 137 Nm Oil seal case Oil separator Oil pan mounting surface Oil hole ...

Page 182: ...tion 4WD D Air Cleaner and Air Intake Hose Installation Refer to GROUP 15 D Intercooler Installation 4WD Refer to GROUP 15 D Hood Installation Refer to GROUP 42 D Drive Belt Tension Adjustment Refer to P 11B 5 D Accelerator Cable Adjustment Refer to GROUP 17 On vehicle Service D Throttle Cable Adjustment A T Refer to GROUP 23 On vehicle Service 8 8 Nm 12 Nm 16 Nm 4 9 Nm 1 2 3 14 13 12 11 6 10 5 9 ...

Page 183: ...teering AA 16 Power steering oil pump assembly 17 Drive belt for A C AA 18 A C compressor assembly 19 Engine oil pressure switch connector 20 Alternator connector 21 Engine oil cooler hose connection 22 Fuel hose connections 23 Front exhaust pipe connection 24 Heat protector 25 Engine support front insulator attaching bolt AB AA 26 Engine assembly ...

Page 184: ...no damage will be caused during removal installation of the engine assembly AB ENGINE ASSEMBLY REMOVAL 1 Check that all cables hoses harness connectors etc are disconnected from the engine 2 Lift the chain block slowly to remove the engine assembly upward from the engine compartment INSTALLATION SERVICE POINT AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly When doing so check carefully...

Page 185: ...NOTES ...

Page 186: ...es 2 GENERAL INFORMATION 2 SERVICE SPECIFICATIONS 2 SPECIAL TOOLS 2 ON VEHICLE SERVICE 3 Injection Timing Check and Adjustment 3 Idle Speed Check 3 OIL PAN 4D56 Step III 4 CYLINDER HEAD GASKET 4D56 Step III 5 TIMING BELT AND TIMING BELT B 4D56 Step III 7 ...

Page 187: ...AL INFORMATION Items 4D56 Total displacement mL 2 477 Bore x Stroke mm 91 1 x 95 0 Compression ratio 21 Combustion chamber Vortex chamber type Camshaft arrangement SOHC Number of valve Intake 4 Exhaust 4 Valve timing Intake Opening BTDC 20_ Closing ABDC 49_ Exhaust Opening BBDC 55_ Closing ATDC 22_ Fuel system Electronic controlled injection pump Rocker arm Roller type Adjusting screw Elephant foo...

Page 188: ...ondition 2 Turn the ignition switch to LOCK OFF position and connect the diagnosis connector to the MUT II If the MUT II is not used connect a tachometer to the injection nozzle or the pipe 3 Start the engine and let it run at idle 4 Check the idle speed Standard value 750 30 r min 5 If the idle speed is not within the standard value refer to 13I Troubleshooting to check the electronic controlled ...

Page 189: ...ENGINE 4D5 Oil Pan 4D56 Step III 11B 4 OIL PAN 4D56 Step III REMOVAL AND INSTALLATION 9 0 1 0 N m Oil pan cover ...

Page 190: ...d gasket whose thickness is in size with piston projection is attached So if you replace the piston or the connecting rod the piston projection changes Measure the piston projection select the cylinder head gasket whose thickness is in size with piston projection should be fitted 3 Install the cylinder head gasket in order to fit the cylinder head gasket bore to the cylinder head bore 4 Clean the ...

Page 191: ...cial tool to tighten the cylinder head bolts in the order of the illustrated numbers to 29 2 N m 2 Place the special tool in a wrench to tighten the cylinder head bolt in the order of the illustrated numbers to 120_ 16 9 MD998051 Front of engine 18 17 15 13 12 11 10 8 7 6 5 4 3 2 1 14 16 9 MD998051 Front of engine 18 17 15 13 12 11 10 8 7 6 5 4 3 2 1 14 MB991614 ...

Page 192: ...N m 26 3 N m 26 3 N m 185 5 N m Removal steps 1 Timing belt front upper cover 2 Tension pulley bracket for A C 3 Crankshaft pulley for power steering and A C AA CA 4 Crankshaft pulley 5 Timing belt front lower cover AB BA 6 Timing belt 7 Tensioner spacer 8 Tensioner spring 9 Timing belt tensioner assembly 10 Crankshaft sensing blade 11 Crankshaft sprocket 12 Flange AC AA 13 Timing belt B 14 Gasket...

Page 193: ...NOTES ...

Page 194: ...ENGINE LUBRICATION ...

Page 195: ......

Page 196: ...ore handling them Other precautions D Avoid prolonged and repeated contact with oils particularly used engine oils D Wear protective clothing including impervious gloves where practicable D Avoid contaminating clothes particularly underpants with oil D Do not put oily rags in pockets the use of overalls without pockets will avoid this D Do not wear heavily soiled clothing and oil impregnated foot ...

Page 197: ...ion of engine oil filter When using the oil filter of MD136466 4G6 MH061590 Oil filter wrench Removal and installation of engine oil filter When using the oil filter of MD069782 or MD326489 4D56 ON VEHICLE SERVICE 12100090057 ENGINE OIL CHECK 1 Check the engine oil using the oil level gauge 2 Check that the oil is not excessively dirty that there is no coolant or petrol mixed in and that it has su...

Page 198: ...he coolant reaches 80_C to 90_C 2 Remove the engine oil filler cap 3 Remove the under cover 4 Remove the drain plug to drain oil Caution Use care as oil could be hot 5 Remove the air cleaner and cover the alternator with a rag so that oil will not get on the alternator 4D56 6 Use the following tools to remove the engine oil filter D MB991396 or equivalent when using the oil filter of MD135737 4G6 ...

Page 199: ...he oil filter of MD325714 or MD332687 16 Nm 4G6 When using the oil filter of MD136466 or MD322508 17 Nm 4D56 When using the oil filter of MD069782 or MD184086 20 Nm 4D56 When using the oil filter of MD326489 22 Nm 10 Install the drain plug and refill the engine oil Refer to P 12 3 Engine Oil Replacement 11 Race the engine 2 3 times and check to be sure that no engine oil leaks from installation se...

Page 200: ...ing and Supplying Refer to P 12 3 M T A T 44 Nm 44 Nm 29 34 Nm 29 34 Nm 44 Nm 44 Nm 35 Nm 1 3 4 5 6 7 1 1 2 3 5 6 7 Oil cooler removal steps AA BA 1 Eye bolts for engine oil cooler AA BA 2 Eye bolts for A T oil cooler A T 3 Oil cooler assembly 4 Stay M T Oil cooler tube and hose removal steps AA BA 1 Eye bolts for engine oil cooler 5 Oil return tube 6 Oil feed tube D Engine oil filter Refer to P 1...

Page 201: ...ASSEMBLY ENGINE SIDE INSTALLATION Install the oil cooler hose assembly with the markings facing upwards BA EYE BOLT INSTALLATION 1 Provisionally tighten the eye bolt 2 Align the white markings of the oil feed tube and oil return tube with the clamps and then tighten them provisionally 3 Tighten eye bolt to the specified torque Caution Be sure to hold the weld nut of the oil cooler while tightening...

Page 202: ...NOTES ...

Page 203: ... EC L200 K60 K70 97 99 99 99 99 99 99 99 97 97 1 Description This Service Bulletin informs you that correction has been made of descriptions concerning the oil filter wrench 2 Applicable Manuals Manual Pub No Language Page s 97 GALANT PWDE9611 English 12 3 4 5 Workshop Manual chassis PWDS9612 Spanish PWDF9613 French PWDG9614 German PWDD9615 Dutch PWDW9616 Swedish 99 GALANT PWDE9611 A English Works...

Page 204: ...ch PWDW9808 Swedish 99 SPACE RUNNER SPACE WAGON PWDH9816R English Workshop Manual chassis PWDH9816R Spanish CD ROM PWDH9816R French PWDK9817R German PWDK9817R Dutch PWDK9817R Swedish 12 3 5 99 PAJERO SPORT PWJE9812 English Workshop Manual chassis PWJS9813 Spanish PWJF9814 French PWJG9815 German 99 PAJERO SPORT PWJT9818R English Workshop Manual chassis PWJT9818R Spanish CD ROM PWJT9818R French PWJT...

Page 205: ...ated range 2 Check that the oil is not excessively dirty that there is no coolant or gasoline mixed in and that it has sufficient viscosity ENGINE OIL REPLACEMENT 12100100163 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C 2 Remove the engine oil filler cap 3 Remove the drain plug to drain oil Caution Use care as oil could be hot 00003380 4 Inst...

Page 206: ...6A1 engine the oil which is still inside the oil filter may overflow from the oil guide groove and get onto the starter motor To prevent this the oil inside the filter should be gradually removed while removing the oil filter 5 Clean the filter bracket side mounting surface A02S0003 6 Apply a small amount of engine oil to the O ring of the new oil filter 7 Once the O ring of the oil filter is touc...

Page 207: ...onnector of the oil level relay and measure the voltage of the No 1 terminal on the harness side of the connector while idling the engine in order to confirm that it is the same as the battery voltage NOTE 1 If the voltage at the connector is the same as the battery voltage the problem is probably a malfunction of either the oil level relay or the oil level sensor 2 If the voltage at the connector...

Page 208: ...oil API classification SG or higher Engine oil quantity ℓ Oil filter 0 3 Total 4 3 SPECIAL TOOL Tool Number Name Use B991610 MB991610 Oil filter wrench Removal and installation of engine oil filter When using the oil filter of MD136466 and MD356000 99 GALANT Workshop Manual chassis 12 2 ENGINE LUBRICATION General Lubricants Special Tool Deleted Deleted ...

Page 209: ... flange use the respective tool in the following table to tighten to the specified torque 9 Install the drain plug and refill engine oil Refer to Engine Oil Replacement on P 12 3 10 Race the engine 2 3 times and check to be sure that no engine oil leaks from installation section of the oil filter Number Tool Tightening torque MD136466 MB991610 or equivalent tool Approx 3 4 turns 17 Nm MD322508 Com...

Page 210: ...991610 Oil filter wrench Removal and installation of engine oil filter When using the oil filter of MD136466 01R0340 ON VEHICLE SERVICE 12100090125 ENGINE OIL INSPECTION 1 Pull out the level gauge slowly and check that the oil level is in the illustrated range 2 Check that the oil is not excessively dirty that there is no coolant or gasoline mixed in and that it has sufficient viscosity 99 SPACE S...

Page 211: ...ller cap 7 Check oil level A04Z0002 OIL FILTER REPLACEMENT 12100110241 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C 2 Remove the engine oil filler cap 3 Remove the drain plug to drain oil Caution Use care as oil could be hot 4 Use the following tools to remove the engine oil filter from the underside of the vehicle MB991396 or equivalent When...

Page 212: ...il Refer to Engine Oil Replacement in P 12 4 9 Race the engine 2 3 times and check to be sure that no engine oil leaks from installation section of the oil filter Number Tool Tightening torque MD135737 MB991396 or equivalent tool Approx 1 turn 14 Nm MD136466 MB991610 or equivalent tool Approx 3 4 turn 17 Nm MD322508 Commercially available tool MD325714 and MD332687 Approx 3 4 turn 16 Nm 99 SPACE S...

Page 213: ...ication SG or higher Engine oil quantity ℓ Oil filter 0 3 Total 3 8 SPECIAL TOOLS Tool Number Name Use B991610 MB991610 Oil filter wrench Removal and installation of engine oil filter When using the oil filter of MD136466 and MD356000 MD998054 Oil pressure switch wrench Removal and installation of oil pressure switch 99 SPACE RUNNER SPACE WAGON Workshop Manual chassis ENGINE LUBRICATION Service Sp...

Page 214: ...touching the flange use the respective tool in the following table to tighten to the specified torque 9 Install the drain plug and refill engine oil Refer to Engine Oil Replacement on P 12 3 10 Race the engine 2 3 times and check to be sure that no engine oil leaks from installation section of the oil filter Number Tool Tightening torque MD136466 MB991610 or equivalent tool Approx 3 4 turn 17 Nm M...

Page 215: ...evel gauge 2 Check that the oil is not excessively dirty that there is no coolant or petrol mixed in and that it has sufficient viscosity ENGINE OIL REPLACEMENT 12100100286 1 Start the engine and allow it to warm up until the temperature of the coolant reaches 80 C to 90 C 2 Remove the engine oil filler cap 3 Remove the drain plug to drain oil Caution Use care as oil could be hot 4 Install a new d...

Page 216: ... coolant reaches 80 C to 90 C 2 Remove the engine oil filler cap 3 Remove the under cover 4 Remove the drain plug to drain oil Caution Use care as oil could be hot 5 Remove the air cleaner and cover the alternator with a rag so that oil will not get on the alternator 4D56 A04Z0002 6 Use the respective tool in the following table to remove the engine oil filter 7 Clean the filter bracket side mount...

Page 217: ...STEM CHECK 12100200054 1 Check that the proper amount of oil has been filled 2 When the ignition switch is turned to ON do not start the engine check that the oil level warning lamp illuminates NOTE If the oil level warning lamp does not illuminate the cause is probably a blown lamp or a malfunction in the relay DEN0086 3 When the engine is started check that the oil level warning lamp turns off I...

Page 218: ...ilter wrench Removal and installation of engine oil filter When using the oil filter of MD069782 or MD326489 4D56 ON VEHICLE SERVICE 12100090057 ENGINE OIL CHECK 1 Check the engine oil using the oil level gauge 2 Check that the oil is not excessively dirty that there is no coolant or petrol mixed in and that it has sufficient viscosity A02V0002 ENGINE OIL REPLACEMENT 12100100071 1 Start the engine...

Page 219: ... of the coolant reaches 80 C to 90 C 2 Remove the engine oil filler cap 3 Remove the under cover 4 Remove the drain plug to drain oil Caution Use care as oil could be hot 5 Remove the air cleaner and cover the alternator with a rag so that oil will not get on the alternator 4D56 A04Z0002 6 Use the following tools to remove the engine oil filter MB991396 or equivalent when using the oil filter of M...

Page 220: ...0 10 Group GENERAL Draft No 00SY0022915 INFORMATION CORRECTION INTERNATIONAL CAR ADMINISTRATIO OFFICE T NITTA PROJECT LEADER AFTER SALES SERVICE CS PROMOTION 1 Description This Service Bulletin informs you of the year model changes for the 2001 L200 2 Applicable Manuals Manual Pub No Language Page s 2000 L200 PWTE96E1 D English Workshop Manual Chassis PWTS96E1 D Spanish PWTF96E1 D French PWTG96E1 ...

Page 221: ...2 ...

Page 222: ... PWTE96E1 C SUPPLEMENT PWTE96E1 D SUPPLEMENT ELECTRICAL WIRING PHTE96E1 PHTE96E1 A PHTE96E1 B PHTE96E1 D PHTE96E1 D SUPLEMTENT BODY REPAIR MANUAL PARTS CATALOGUE PBTE96E1 T603B00 D All information illustrations and product d e scriptions contained in this manual are current as at the time of publication We however re serve the right to make changes at any time without prior notice or obligation Mi...

Page 223: ... 5M T MPI ENDL6 ENDR6 CENDL6 K64T JENDL6 4D56 2 477mℓ R5M21 2WD M T Fuel injection CENDEL6 K75T GJENXEL6 4G64 SOHC 2 351 mℓ V5M21 4WD 5M T MPI ENDFL6 ENDFR6 V5MT1 4WD 5M T JERDFL6 V4AW2 AWD 4A T GJERXFL6 GJENXFL6 GJENXFR6 CENDFL6 GCENXFL6 JENDFL6 JENDFR6 K74T JENHFL6 4D56 Turbocharger with intercooler 2 477mℓ V5MT1 4WD 5M T Fuel injection 00 1 GENERAL vehicle identification ...

Page 224: ...mission type R 4 speed automatic transmission 6 Vehicle line K Mitsubushi L200 6 Long wheelbase 7 Body type 7 4WD Long wheelbase 2 4G63 1 997mℓ petrol engine 4 4D56 2 477mℓ diesel engine 8 Engine type 5 4G64 2 351 mℓ petrol engine 9 Internal production control code A A B C etc 0 zero No meaning 10 Model year 1 2001 11 Plant A A C LARDKRABANG factory D F LAEMCHABANG factory 12 Serial number NOTE In...

Page 225: ...6 NOTES ...

Page 226: ...oil has been changed ON VEHICLE SERVICE specified engine oil ACEA and API classification 4G6 ACEA A1 A2 A3 API SG or higher 4D5 ACEA B1 B2 B3 B4 API CD or higher ENGINE LUBRICATION General On vehicle Service 12 1 4G6 Barometric temperature Y0042AA Barometric temperature M03B017 4D5 ...

Page 227: ...8 NOTES ...

Page 228: ...ransmitter LOCK UNLOCK NOTE If the MUT II cannot check all the input signals the diagnosis circuit may be defective ETACS FUNCTION ADJUSTMENT PROCEDURE The following functions can be adjusted by operating input switches The adjustments will be stored in th ECU memory even after a battery cable is disconnected Switching of keyless entry answerback function From activation to deactivation or vice ve...

Page 229: ...nd off If the function toggles on the buzzer sounds once default con dition If the function toggles off the buzzer sounds twice Initialisation of all the ETACS func tions From deactivation to activa tion When the tailgate switch remains on for more than 20 seconds th buzzer sounds twice and he answer back function of the keyless entry system is initialised The buzzer will sound in 10 seconds indic...

Page 230: ...ister the encrypted code Refer to P 42 6 OK Replace the transmitter battery Refer to P 42 6 NG Is a commercial equipment equipped No Yes Remove that equipment and then check trouble symptoms NG Check the connection between ETACS ECU and junction block claw NG Repair OK NG Check the following connectors A 56X C 81 C 91 OK NG Measure at the ETACS ECU connector C 91 Disconnect the connector and measu...

Page 231: ...ctuator If either room lamp or turn signal lamp does not flash illuminate the cause may be a malfunction of the room lamp circuit or turn signal lamp Malfunction of ETACS ECU Malfunction of driver s door lock actuator Burnt turn signal lamp bulb Malfunction of connector or wiring harness Carry out the troubleshooting for room lamp circuit Does the room lamp go on go off simultaneous with opening c...

Page 232: ...k No 5 and diagnosis connector OK Replace MUT II Measure at the diagnosis connector C 35 Continuity between 4 and body earth Continuity between 5 and body earth OK System voltage NG NG Repair Check the following connectors C 35 C 86 OK Check trouble symptoms NG Check the harness wire and repair if necessary Between the diagnosis connector and earth NG Check the following connectors A 56X C 81 C 82...

Page 233: ...in the following cases If a second transmitter is to be used If it appears that a problem is occurring because of faulty registration of a code A maximum of two different codes can be stored in the memory area of the EEPROM two different transmit ters can be used When the code for the first transmitter is registered th previously registered codes for two transmitters are cleared Therefore if you a...

Page 234: ...hould be carried out for the second trans mitter and it should be carried out within one min ute after registration of the code for the first trans mitter has been completed After the second regis tration is completed the doors will be automatically locked and unlocked once 7 Registration mode will be terminated under the following conditions When the secret codes for two transmitters hav been reg...

Page 235: ...ACS ECU removal 2 ETACS ECU Keyless entry receiver ECU removal steps Glove box assembly Refer to GROUP 52A 1 Keyless entry receiver ECU NOTE Refer to 97 L200 Workshop Manual Pub No PWTE96E1 42 8 BODY Keyless Entry System AY0014AA A18VO187 Junction block ...

Page 236: ...The service procedures are the same as previous one FRONT SEAT BELT REMOVAL AND INSTALLATION Inner seat belt removal steps Front seat refer to P 52A 5 Inner seat belt Outer seat belt removal steps Center pillar trim lower or quarter trim lower refer to P 52A 1 Sash guide cover 2 Outer seat belt 3 Center pillar trim upper or quarter trim upper refer to P 52A 4 Adjustable seat belt anchor NOTE Refer...

Page 237: ...18 NOTES ...

Page 238: ...ocedure has been added due to the addition of the high stop lamp 4WD HIGH MOUNTED STOP LAMP REMOVAL AND INSTALLATION Removal steps 1 Rear gate panel 2 High mounted stop lamp 3 Lamp bracket 4 Bulb socket assembly 5 Bulb CHASSIS ELECTRICAL High Mounted Stop Lamp 54 1 A16V0088 ...

Page 239: ... D Due to the adoption of the VG Variable Geometry turbocharger the engine oil quantity has been changed 4WD vehicles with 4D56 Step III engine LUBRICANT Items 4WD vehicles with 4D56 Step III Items 4WD vehicles with 4D56 Ste III engine Engine oil quantity L Oil filter 0 8 Oil cooler 0 4 Total 7 5 ...

Page 240: ...NOTES ...

Page 241: ...MULTIPOINT FUEL INJECTION MPI ...

Page 242: ...Fuel Pressure Test 81 Fuel Pump Connector Disconnection How to Reduce the Fuel Pressure 84 Fuel Pump Operation Check 84 Component Location 85 Control Relay and Fuel Pump Relay Continuity Check 86 Intake Air Temperature Sensor Check 86 Engine Coolant Temperature Sensor Check 86 Throttle Position Sensor Check 87 Idle Position Switch Check 87 Oxygen Sensor Check 88 Injector Check 89 Idle Speed Contro...

Page 243: ...p control in order to obtain the theoretical air fuel mixture ratio that provides the maximum cleaning performance from the three way catalyst IDLE AIR CONTROL The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in accordance with changes in idling conditions and engine load during idling The engine ECU drives the idle speed control ISC mot...

Page 244: ...271 4G63 Vehicles without immobilizer system E2T64277 4G63 Vehicles with immobilizer system E2T64272 4G64 Vehicles without immobilizer system E2T64276 4G64 Vehicles with immobilizer system Sensors Air flow sensor Karman vortex type Barometric pressure sensor Semiconductor type Intake air temperature sensor Thermistor type Engine coolant temperature sensor Thermistor type Oxygen sensor Zirconia typ...

Page 245: ...ic pressure sensor 9 Engine coolant temperature sensor D Power supply voltage D Vehicle speed sensor D A C switch D Inhibitor switch D Power steering fluid pressure switch D Ignition switch ST D Ignition switch IG Engine ECU k3 k1 k2 k4 4 5 8 2 9 Intake air temperature sensor Idle speed control servo Air flow sensor with built in barometric pressure sensor Air cleaner To fuel tank Fuel pressure re...

Page 246: ... 20_C Intake air temperature sensor resistance kΩ 20_C 2 3 3 0 resistance kΩ 80_C 0 30 0 42 Engine coolant temperature sensor resistance kΩ 20_C 2 1 2 7 sensor resistance kΩ 80_C 0 26 0 36 Oxygen sensor output voltage V 0 6 1 0 Fuel pressure kPa Vacuum hose disconnection 324 343 at curb idle Vacuum hose connection Approx 265 at curb idle Injector coil resistance Ω 13 16 at 20_C SEALANT 13100050038...

Page 247: ...rcuit inspection D Commercial tester connection MB991502 MUT II sub assembly D Reading diagnosis code D MPI system inspection MB991348 Test harness set D Adjustment of idle position switch and throttle position sensor D Inspection using an analyzer MD998463 Test harness 6 pin square D Inspection of idle speed control servo D Inspection using an analyzer MD998464 Test harness 4 pin triangle Inspect...

Page 248: ...OOTING FLOW Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points DIAGNOSIS FUNCTION 13100860211 ENGINE WARNING LAMP CHECK ENGINE LAMP If an abnormality occurs in any of the following items related to the Multipoint Fuel Injection MPI system the engine warning lamp will illuminate If the lamp remains illuminated or if the lamp illuminates while the engine is running check the diag...

Page 249: ... ignition timing adjustment is short circuited at the time of ignition timing adjustment METHOD OF READING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points INSPECTION USING MUT II DATA LIST AND ACTUATOR TESTING 1 Carry out inspection by means of the data list and the actuator test function If there is an abnormality check and repair the chassis har...

Page 250: ...coolant temperature sensor Controls as if the engine coolant temperature is 80_C Top dead centre 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 Oxygen sensor Air fuel ratio feedback control closed loop control i...

Page 251: ...re at the oxygen sensor connector B 03 D Disconnect the connector and measure at the harness side 1 Voltage between 1 and earth Ignition switch ON OK System voltage 2 Continuity between 2 and earth OK Continuity OK 1 NG Check the harness wire between the oxygen sensor and the control relay connector and repair if necessary 2 NG Check the following connector C 51 C 60 NG Repair OK Check trouble sym...

Page 252: ...de No 13 Intake air temperature sensor system Probable cause Range of Check D Ignition switch ON D Excluding 60 seconds after the ignition switch is turned to ON or immediately after the engine starts Set conditions D Sensor output voltage is 4 6 V or more corresponding to an intake air temperature of 45_C or less for 4 seconds or D Sensor output voltage is 0 2V or less corresponding to an intake ...

Page 253: ... signal line D Malfunction of the engine ECU MUT II Data list 26 Idle position switch system OK With the throttle valve at the idle position ON With the throttle valve slight ly open OFF NG Check the idle position switch system Refer to P 13A 40 INSPECTION PROCEDURE 25 OK Check the throttle position sensor Refer to P 13A 87 NG Replace OK Measure at the throttle position sensor connector A 47 D Dis...

Page 254: ... Engine speed is approx 50 r min or more Set conditions D The sensor output voltage increases from 1 6 V or less corresponding to an engine coolant temperature of 40_C or more to 1 6 V or more corresponding to an engine coolant temperature of 40_C or less D After this the sensor output voltage is 1 6 V or more for 5 minutes Check the engine coolant temperature sensor Refer to P 13A 86 NG Replace O...

Page 255: ...eplace the engine ECU Measure at the distributor connector A 72 D Disconnect the connector and measure at the harness side 1 Voltage between 3 and earth Ignition switch ON OK System voltage 2 Voltage between 2 and earth Ignition switch ON OK 4 8 5 2 V 3 Continuity between 4 and earth OK Continuity OK Check the following con nector A 72 NG Repair OK Check trouble symptom NG Replace the distributor ...

Page 256: ... idling OK 0 5 2 0 V OK Replace the engine ECU NG Measure at the distributor connector A 72 D Disconnect the connector and measure at the harness side 1 Voltage between 3 and earth Ignition switch ON OK System voltage 2 Voltage between 1 and earth Ignition switch ON OK 4 8 5 2 V 3 Continuity between 4 and earth OK Continuity 1 NG Check the harness wire between the top dead centre sensor and the co...

Page 257: ...heck the vehicle speed sensor Refer to GROUP 54 Combina tion Meters NG Replace OK Measure at the combination meter connector C 06 C 07 D Disconnect the connector and measure st the harness side 1 Voltage between 51 and earth Ignition switch ON OK 4 8 5 2 V 2 Continuity between 34 and earth OK Continuity 1 NG Check the following connectors C 19 C 51 NG Repair OK Check trouble symptom NG Check the h...

Page 258: ...7 4 3V Altitude 0m 3 2 3 8 V Altitude 1 200 m NG Measureattheairflowsensorcon nector A 77 D Disconnect the connector and measure at the harness side D Voltage between 1 and earth Ignition switch ON OK 4 8 5 2 V D Continuitybetween5andearth OK Continuity NG Check the following connector C 51 NG Repair OK Check trouble symptom NG Check the harness wire between the engine ECU and the baromet ric pres...

Page 259: ... cause Range of Check D Engine speed is approx 50 1 000 r min D The throttle position sensor output voltage is 1 15 V or less D Actuator test by MUT II is not carried out Set conditions D Surge voltage of injector coil is not detected for 4 seconds D Malfunction of the injector D Improper connector contact open circuit or short circuited harness wire of the injector circuit D Malfunction of the en...

Page 260: ...nce may cause this code to be displayed 2 This code may be displayed when registering the key ID code No Is there another ignition key near the ignition key that is inserted in the ignition switch Yes Remove the extra ignition key NG Check trouble symptom Is a diagnosis code output from the immobilizer ECU Yes Check the immobilizer system Refer to GROUP 54 Ignition Switch and Immobilizer System No...

Page 261: ...ing impossible 6 13A 27 Long time to start improper starting 7 13A 28 Idling stability Improper idling Unstable idling Rough idling hunting 8 13A 29 Im ro er idling Idling speed is high Improper idling speed 9 13A 30 Idling speed is low Improper idling speed 10 13A 31 Idling stability Engine stalls When the engine is cold it stalls at idling Die out 11 13A 32 Engine stalls When the engine becomes ...

Page 262: ...gine stall Pass out The engine stalls when the accelerator pedal is depressed or while it is being used Driving Hesitation Sag Hesitation is the delay in response of the vehicle speed engine speed that occurs when the accelerator is depressed in order to accelerate from the speed at which the vehicle is now traveling or a temporary drop in vehicle speed engine speed during such acceleration Seriou...

Page 263: ...nector 16 pin C 35 D Voltage between 16 and earth OK Battery voltage NG Check the following connectors A 56X C 79 C 81 NG Repair OK Check trouble symptom NG Check the harness wire between the power supply and diagnosis connector 16 pin and repair if necessary OK Measure at the diagnosis connector 16 pin C 35 D Continuity between 4 and earth D Continuity between 5 and earth OK Continuity NG OK Repl...

Page 264: ... ECU and immobilizer ECU OK Yes NG Vehicles without immobilizer system Check the following connector C 19 NG Repair Check trouble symptom NG Check the harness wire between engine ECU and diagnosis con nector OK Check the harness wire betweenengine ECUand earth NG Repair OK Check the power supply and ignition switch IG system Refer to P 13A 39 INSPECTION PROCEDURE 23 Vehicles with immobilizer syste...

Page 265: ...ace OK Measure at the combination meter connector C 06 D Disconnect the connector and measure at the harness side D Voltage between 43 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 C 04 C 06 C 19 C 50 NG Repair OK Check trouble symptom NG Check the harness wire between combination meter...

Page 266: ...attery OK Is immobilizer ECU diagnosis code displayed only vehicles with immobilizer system Yes Check the immobilizer Refer to GROUP 54 Ignition Key and Immobilizer No MUT II Inspection of no initial combustion Refer to P 13A 47 INSPECTION PROCEDURE 34 OK Can any sound be heard from the injectors when cranking NG Check the injector system Refer to P 13A 19 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE ...

Page 267: ...he injectors when cranking NG Check the injector system Refer to P 13A 19 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE 41 OK Is starting good if the engine is cranked with the accelerator pedal slightly depressed Yes Check ISC servo for op eration sound Refer to P 13A 90 NG Check the ISC servo sys tem Refer to P 13A 45 INSPECTION PROCE DURE 31 OK D Clean the throttle valve area Refer to P 13A 78 D Che...

Page 268: ...igher NG Check the battery Refer to GROUP 54 Battery OK MUT II Check if uncomplete combustion occurs Refer to P 13A 48 INSPECTION PROCEDURE 36 OK Can any sound be heard from the injectors when cranking NG Check the injector system Refer to P 13A 19 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE 41 OK Check the ignition timing when cranking OK Approx 5_BTDC NG Check that the distributor is installed prop...

Page 269: ...ART FOR DIAGNOSIS CODES No Does idling speed fluctuate excessively Yes Check if hunting occurs Refer to P 13A 48 INSPECTION PROCEDURE 37 No Check the ISC servo for operation sound Refer to P 13A 90 NG Check the ISC servo system Refer to P 13A 45 INSPECTION PROCEDURE 31 OK Check the injector for operation sound NG Check the injector system Refer to P 13A 19 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE ...

Page 270: ... P 13A 90 NG Check the ISC servo system Refer to P 13A 45 INSPECTION PROCEDURE 31 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 57 NG Check the engine coolant temperature sensor system RefertoP 13A 14 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 21 OK MUT II Data list 28 A C switch Refer to P 13A 57 NG Check the A C switch and A C relay system Refer to P 13A 43 INSPECTION PROCEDU...

Page 271: ...to P 13A 45 INSPECTION PROCEDURE 31 OK MUT II Data list 26 Idle position switch Refer to P 13A 57 NG Check the idle position switch system Refer to P 13A 40 INSPECTION PROCEDURE 25 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 57 NG Check the engine coolant temperature sensor system RefertoP 13A 14 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 21 OK MUT II Data list 29 Inhibitor s...

Page 272: ...sure Refer to GROUP 11 On vehicle Service D Check the engine oil viscosity OK MUT II Data list 26 Idle position switch Refer to P 13A 57 NG Check the idle position switch system Refer to P 13A 40 INSPECTION PROCEDURE 25 OK Check the injector for operation sound NG Check the injector system Refer to P 13A 19 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE 41 Yes Check the ISC servo for operation sound Ref...

Page 273: ...ystem Refer to P 13A 19 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE 41 OK Does the engine stall right after the accelerator pedal is released Yes Clean the throttle valve area Refer to P 13A 78 Check and adjust the fixed SAS Refer to P 13A 79 No Does the engine stall easily again No While carrying out an intermittent malfunction simulation test Refer to GROUP 00 Points to Note for Intermittent Malfun...

Page 274: ... ISC system No MUT II Data list 26 Idle position switch Refer to P 13A 69 NG Check the idle position switch system Refer to P 13A 49 INSPECTION PROCEDURE 26 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 57 NG Check the throttle position sensor system Refer to P 13A 13 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE 14 OK MUT II Data list 45 ISC servo position D Is the idle speed control ...

Page 275: ...tion sag stumbleorpooraccelerationoccur Refer to P 13A 51 INSPECTION PROCEDURE 40 OK Check the fuel pressure Refer to P 13A 81 OK Check the following items D Check the ignition coil spark plugs spark plug cables Refer to GROUP 16 On vehicle Service D Check the EGR control system Refer to GROUP 17 Emission Control System D Check the compression pressure Refer to GROUP 11 On vehicle Service D Check ...

Page 276: ...ective ignition system abnormal air fuel ratio poor compression pressure etc are suspected D Malfunction of the ignition system D Malfunction of air fuel ratio control system D Malfunction of the fuel supply system D Poor compression pressure D Clogged exhaust system MUT II Self Diag code Are diagnosis codes displayed Yes Refer to P 13A 10 INSPECTION CHART FOR DIAGNOSIS CODES No Check the injector...

Page 277: ...at the distributor is installed properly OK MUT II Check if surge occurs Refer to P 13 52 INSPECTION PROCEDURE 41 OK Check the fuel pressure Refer to P 13A 81 OK Check the following items D Check the ignition coil spark plugs spark plug cables Refer to GROUP 16 On vehicle Service D Check the EGR control system Refer to GROUP 17 Emission Control System INSPECTION PROCEDURE 20 Knocking Probable caus...

Page 278: ...E FOR DIAGNOSIS CODE 25 OK MUT II Data list 11 Oxygen sensor OK 600 1 000mVwhenracingsuddenly RefertoP 13A 57 NG Checktheoxygensensorsystem RefertoP 13A 11 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 11 OK MUT II Data list 11 Oxygen sensor OK Repeat 0 400 mV and 600 1 000 mV alternately when idling Refer to P 13A 57 OK NG Check the fuel pressure Refer to P 13A 81 OK NG Check the following items D Chec...

Page 279: ...ion of the control relay D Improper connector contact open circuit or short circuited harness wire D Disconnected engine ECU earth wire D Malfunction of the engine ECU Check the control relay Refer to P 13A 86 NG Replace OK Measure at the control relay connector C 53 D Disconnect the connector and measure at the harness side D Voltage between 3 4 and earth OK System voltage NG Checktheharnesswireb...

Page 280: ...cessary INSPECTION PROCEDURE 25 Idle position switch system Probable cause The idle position switch inputs the condition of the accelerator pedal i e whether it is depressed or released HIGH LOW to the engine ECU The engine ECU controls the idle speed control servo based on this input D Maladjustment of the accelerator pedal D Maladjustment of the fixed SAS D Maladjustment of the idle position swi...

Page 281: ...e engine ECU connector termi nal No 71 and earth and repair if necessary Measure at the engine ECU connector C 51 D Disconnect the connector and measure at the harness side 1 Voltage between 51 and earth Ignition switch START OK 8V or more 2 Continuity between 71 and earth OK Continuity 1 NG Check the following connector C 51 NG Repair OK Check trouble symptom NG Check harness wire be tween the en...

Page 282: ...ion switch ON OK System voltage 2 Continuity between 5 and earth OK Continuity 3 Voltage between 6 and earth D Ignition switch START D Disconnect engine ECU connector OK System voltage 1 NG Check the following connectors C 01 C 51 C 57 NG Repair OK Check trouble symptom 2 NG 3 NG Check the following connector C 01 C 57 C 70 NG Repair OK Check trouble symptom NG NG Repair Check harness wire be twee...

Page 283: ...ROCEDURE 29 A C switch and A C relay system Probable cause When an A C ON signal is input to the engine ECU the engine ECU carries out control of the idle speed control ISC servo and also operates the A C compressor magnetic clutch D Malfunction of A C control system D Malfunction of A C switch D Improper connector contact open circuit or short circuited harness wire D Malfunction of the engine EC...

Page 284: ...itch connector NG Repair OK Check the ignition switch Refer to GROUP 54 Ignition Switch and Immobilizer System OK Check the following connectors A 65 A 70 NG Repair OK Check trouble symptom NG Check ignition coil and power transistor unit system Refer to P 13A 56 INSPECTION PROCEDURE 48 OK Measure at the power transistor unit connector A 70 D Disconnect the connector and measure at the harness sid...

Page 285: ...y OK Check the following connector C 49 NG Repair OK Check trouble symptom NG Replace the engine ECU INSPECTION PROCEDURE 32 Purge control solenoid valve system Probable cause The purge control solenoid valve controls the purging of air from the canister located inside the intake manifold D Malfunction of solenoid valve D Improper connector contact open circuit or short circuited harness wire D Ma...

Page 286: ... solenoid valve connector A 49 D Disconnect the connector and measure at the harness side D Voltage between 1 and earth Ignition switch ON OK System voltage NG Check the harness wire between control relay and solenoid valve connector and repair if necessary OK Measure at the engine ECU connector C 49 D Disconnect the connector and measure at the harness side D Voltage between 6 and earth Ignition ...

Page 287: ...k the crank angle sensor system RefertoP 13A 15 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 22 OK MUT II Actuator test 07 Fuel pump Refer to P 13A 62 NG Check the fuel pump system Refer to P 13A 40 INSPECTION PROCEDURE 24 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 57 NG Check the engine coolant temperature sensor system RefertoP 13A 14 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 21 ...

Page 288: ...G Check the engine coolant temperature sensor system Refer to P 13A 14 INSPECTION PROCEDURES FOR DIAGNO SIS CODE 21 OK MUT II Data list 18 Ignition switch ST Refer to P 13A 57 NG Check the ignition switch ST system M T Refer to P 13A 41 INSPECTION PROCEDURE 26 INSPECTION PROCEDURE 37 Check if hunting occurs Clean the throttle body Refer to P 13A 78 Check and adjust the fixed SAS Refer to P 13A 79 ...

Page 289: ...ng sudden racing NG Checktheoxygensensorsystem RefertoP 13A 11 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 11 OK MUT II Data list 11 Oxygen sensor OK Changes between 0 400 mV and 600 1 000 mV during idling NG Check the fuel pressure Refer to P 13A 81 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 ...

Page 290: ... 13A 81 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 OK MUT II Data list 27 Power steering fluid pressure switch Refer to P 13A 57 NG Check the power steering fluid pressure switch sys tem Refer to P 13A 43 INSPECTION PROCE DURE 28 OK MUT II Data lis...

Page 291: ...ensor system Refer to P 13A 14 INSPECTION PROCEDURE FOR DIAGNOS TIC CODE 21 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 57 NG Check the throttle position sensor system Refer to P 13A 13 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE 14 OK MUT II Actuator test 10 EGR control solenoid valve Refer to P 13A 62 NG Check the EGR control solenoid valve system Refer to P 13A 46 INSPECTION PRO...

Page 292: ...ertoP 13A 14 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 21 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 57 NG Check the throttle position sensor system Refer to P 13A 13 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE 14 OK MUT II Actuator test 10 EGR control solenoid valve Refer to P 13A 62 NG Check the EGR control solenoid valve system Refer to P s13A 46 INSPECTION PROCEDURE 33 OK MUT II Da...

Page 293: ...asure the engine ECU connectors C 49 C 50 C 51 D Disconnect the connector and measure at the harness side 1 Voltage between 62 and earth Ignition switch ON OK System voltage 2 Voltage between 38 and earth OK System voltage 3 Voltage between 12 25 and earth Ignition switch ON OK System voltage when the terminal 38 is earthed 4 Continuity between 13 26 and earth OK Continuity 5 Voltage between 60 an...

Page 294: ... NG Check the following connector C 54 NG Repair OK Check trouble symptom NG Check the harness wire between engine ECU and fuel pump relay connector and repair if necessary OK Check the following connector C 49 NG Repair OK Check trouble symptom NG Replace the engine ECU INSPECTION PROCEDURE 45 Check air flow sensor AFS control circuit Measure at the air flow sensor connector A 77 D Disconnect the...

Page 295: ...Check trouble symptom NG Check the harness wire between engine ECU and throttle position sensor connector and repair if necessary NG Repair INSPECTION PROCEDURE 47 Check injector control circuit Measure at the engine ECU connector C 49 D Disconnect the connector and measure at the harness side D Voltage between 1 14 and earth Ignition switch ON OK System voltage NG Check the following connectors A...

Page 296: ...k trouble symptom NG Check the harness wire between the engine ECU and the power transistor unit and repair if neces sary NG Repair NG As short circuit occurs between power transistor unit and combina tionmeter tachometer checktheharnesswire andrepairifneces sary OK Check the following connectors and repair if necessary A 65 A 70 NG Check the harness wire between the power transistor unit and igni...

Page 297: ...ve time is sometimes 10 longer than the standard time 5 In a new vehicle driven approximately 500 km or less the step of the stepper motor is sometimes 30 steps greater than the standard value Item No Inspection item Inspection contents Normal condition Inspection procedure No Reference page 11 Oxygen sensor Engine After having warmed up Air fuel mixture is made leaner when de When at 4 000 r min ...

Page 298: ...mV Code No 14 13A 13 osition sensor Gradually open Increases in proportion to throttle opening angle 14 Open fully 4 500 5 500 mV 16 Power supply voltage Ignition switch ON System voltage Procedure No 23 13A 39 18 Cranking signal ignition it h ST Ignition switch ON Engine Stopped OFF Procedure No 26 M T 13A 41 M T 13A 42 switch ST Engine Cranking ON Procedure No 27 A T M T 21 Engine coolant temper...

Page 299: ... 20_C 1 100 1 300 r min When engine coolant temperature is 40_C 950 1 150 r min When engine coolant temperature is 80_C 650 850 r min 25 Barometric pressure Ignition switch ON At altitude of 0 m 101 kPa Code No 25 13A 18 ressure sensor At altitude of 600 m 95 kPa 25 At altitude of 1 200 m 88 kPa At altitude of 1 800 m 81 kPa 26 Idle position switch Ignition switch ON Check by operating accelerator...

Page 300: ...76 ms 4G63 60 90 ms 4G64 When engine coolant temperature is 20_C 26 38 ms 4G63 30 45 ms 4G64 When engine coolant temperature is 80_C 5 7 8 5 ms 4G63 6 7 10 1 ms 4G64 Injectors 4 D Engine coolant temperature 80 95_C D Lamps and all accessories OFF Engine is idling 1 9 3 1 ms 4G63 2 2 3 4 ms 4G64 accessories OFF D Transmission Neutral A T P range 2 500 r min 1 8 3 0 ms 4G63 1 9 3 1 ms 4G64 When engi...

Page 301: ...ccessories OFF D Transmission Neutral A T P range D Idle position A C switch OFF ON Increases by 10 70 steps D Idle osition switch ON D Engine Idling D When A C switch is ON A C compressor should be operating D A C switch OFF D Select lever N range D range Increases by 5 50 steps 49 A C relay Engine After having warmed up Engine is idling A C switch OFF OFF Compressor clutch is not operating Proce...

Page 302: ...Fuel pump Fuel pump operates and fuel is recircu lated D Engine Cranking D Fuel pump Forced driving Inspect accord Pinch the return hose with fingers to feel the pulse of the fuel being recirculated Pulse is felt Procedure No 24 13A 40 accord ing to both the 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 ...

Page 303: ...ed 2 You may find it convenient to pull out the engine ECU to make it easier to reach the connector terminals 3 The checks can be carried out off the order given in the chart Caution Short circuiting the positive probe between a connector terminal and earth could damage the vehicle wiring the sensor engine ECU or all of them Be careful to prevent this 3 If voltmeter shows any division from standar...

Page 304: ...stem Voltage valve While engine is idling suddenly depress the accelerator pedal From system voltage momentarily drops 8 or 22 Fuel pump relay Ignition switch ON System voltage Engine Idle speed 0 3V 9 Purge control solenoid valve Ignition switch ON System voltage valve Running at 3 000r min while engine is warming up after having been started 0 3V 10 Power transistor unit Engine r min 3 000 r min...

Page 305: ...gnition switch ON 0 3V 45 A C switch Engine Idle speed Turn the A C switch OFF 0 3V Turn the A C switch ON A C compressor is operating System voltage 51 Ignition switch ST Engine Cranking 8V or more 52 Intake air temperature sensor Ignition switch ON When intake air temperature is 0_C 3 2 3 8V When intake air temperature is 20_C 2 3 2 9V When intake air temperature is 40_C 1 5 2 1V When intake air...

Page 306: ...e 4 5 5 5V 65 Barometric pressure sensor Ignition switch ON When altitude is 0m 3 7 4 3V When altitude is 1 200m 3 2 3 8V 66 Vehicle speed sensor D Ignition switch ON D Move the vehicle slowly forward 0 5V Changes repeatedly 67 Idle position switch Ignition switch ON Set throttle valve to idle position 0 1V Slightly open throttle valve 4V or more 68 Top dead centre sensor Engine Cranking 0 4 3 0V ...

Page 307: ...ven in the chart Caution If the terminals that should be checked are mistaken or if connector terminals are not correctly shorted to earth damage may be caused to the vehicle wiring sensors engine ECU and or ohmmeter Be careful to prevent this 4 If the ohmmeter shows any deviation from the standard value check the corresponding sensor actuator and related electrical wiring and then repair or repla...

Page 308: ...ensor 5 3 6 7 kΩ When intake air temperature is 0_C 2 3 3 0 kΩ When intake air temperature is 20_C 1 0 1 5 kΩ When intake air temperature is 40_C 0 30 0 42 kΩ When intake air temperature is 80_C 63 72 Engine coolant temperature sensor 5 1 6 5 kΩ When coolant temperature is 0_C 2 1 2 7 kΩ When coolant temperature is 20_C 0 9 1 3 kΩ When coolant temperature is 40_C 0 26 0 36 kΩ When coolant temperat...

Page 309: ... analyzer special patterns pickup to engine ECU terminal 70 Standard Wave Pattern Observation conditions Function Special patterns Pattern height Low Pattern selector Display Engine r min Idle speed Standard wave pattern V 10 0 The time cycle time T is reduced when the amount of intake air increases Times T1 and T2 are equal Time T T1 T2 Observation conditions from conditions above engine speed is...

Page 310: ...ool test harness MB9981348 in between All terminal should be connected 2 Connect the analyzer special patterns pickup to distributor terminal 1 when checking the top dead centre sensor signal wave pattern 3 Connect the analyzer special patterns pickup to distributor terminal 2 when checking the crank angle sensor signal wave pattern Alternate Method Test harness not available 1 Connect the analyze...

Page 311: ...e No 1 TDC No 3 TDC No 4 TDC No 2 TDC Time Wave Pattern Observation Points Check that cycle time T becomes shorter when the engine speed increases Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is not started D Example 2 Cause of problem Loose timing belt Abnormality i...

Page 312: ...lyzer special patterns pickup to engine ECU terminal 1 when checking the No 1 No 3 cylinder 2 Connect the analyzer special patterns pickup to engine ECU terminal 14 when checking the No 2 No 4 cylinder Standard Wave Pattern Observation conditions Function Special patterns Pattern height Variable Variable knob Adjust while viewing the wave pattern Pattern selector Display Engine r min Idle speed St...

Page 313: ... is an abnormality in the engine ECU power transistor that drives the injectors an abnormal wave pattern will be output Wave Pattern Observation Points Point A Height of solenoid back electromotive force Contrast with standard wave pattern Probable cause Solenoid coil back electromotive force is low or doesn t appear at all Short in the injector solenoid Point B Injector drive time D The injector ...

Page 314: ...ction 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 starting the warm...

Page 315: ...n 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 stepper motor and the ...

Page 316: ...r terminal 1 Alternate Method Test harness not available 1 Connect the analyzer special patterns pickup to engine ECU terminal 10 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 Crank angle sensor output wave pattern Power transistor control signal wave pattern V Compression top ...

Page 317: ... circuit Rectangular wave at power voltage Power transistor malfunction Examples of Abnormal Wave Patterns 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 2V too low D Example 2 Wave pattern during engine cranking Cause of p...

Page 318: ...ve deposits are not removed repeat steps 4 and 5 7 Unplug the bypass passage inlet 8 Attach the air intake hose 9 Use the MUT II to erase the self diagnosis code 10 Adjust the basic idle speed Refer to P 13A 79 NOTE If the engine hunts while idling after adjustment of the basic idle speed disconnect the cable from the battery for 10 seconds or more and then reconnect it and run the engine at idle ...

Page 319: ...lock nut 3 Turn the fixed SAS counterclockwise until it is sufficiently backed out and fully close the throttle valve 4 Tighten the fixed SAS until the point where the throttle lever is touched i e the point at which the throttle valve begins to open is found From that point tighten the fixed SAS 1 1 4 turn 5 While holding the fixed SAS so that it doesn t move tighten the lock nut securely 6 Adjus...

Page 320: ...e idle speed Standard value 750 50 r min NOTE 1 The engine speed may be 20 to 100 r min lower than indicated above for a new vehicle driven approximately 500 km or less but no adjustment is necessary 2 If the engine stalls or the engine speed is low even though the vehicle has been driven approximately 500 km or more it is probable that deposits are adhered to the throttle valve so clean it Refer ...

Page 321: ...e fuel pipe line 3 Remove the union joint and bolt from the special tool adapter hose MD998709 and instead attach the special tool hose adapter MD998742 to the adapter hose 4 Install a fuel pressure gauge on the adapter hose that was set up in step 3 Use a suitable O ring or gasket between the fuel pressure gauge and the special tool so as to seal in order to prevent fuel leakage at this time 5 In...

Page 322: ...fuel flow rate is low there will be no fuel pressure in the return hose 13 If any of fuel pressure measured in steps 9 to 12 is out of specification troubleshoot and repair according to the table below Symptom Probable cause Remedy D Fuel pressure too low D Fuel pressure drops after racing Clogged fuel filter Replace fuel filter D Fuel ressure dro s after racing D No fuel pressure in fuel return h...

Page 323: ...ld open Replace fuel pump 15 Release residual pressure from the fuel pipe line Refer to P 13A 84 16 Remove the fuel pressure gauge and special tool from the delivery pipe Caution Cover the hose connection with rags to prevent splash of fuel that could be caused by some residual pressure in the fuel pipe line 17 Replace the O ring at the end of the fuel high pressure hose with a new one Furthermore...

Page 324: ...p connector FUEL PUMP OPERATION CHECK 13100200167 1 Check the operation of the fuel pump by using the MUT II to force drive the fuel pump 2 If the fuel pump will not operate check by using the following procedure and if it is normal check the drive circuit 1 Turn the ignition switch to OFF 2 When the fuel pump drive connector black is attached directly to the battery check if the sound of the fuel...

Page 325: ...er transistor unit J Control relay and fuel pump relay S Inhibitor switch A T L Diagnosis connector R Injectors C Distributor with incorporated crank angle sensor and top dead centre sensor I Oxygen sensor N EGR control solenoid valve F Power steering fluid pressure switch H Engine coolant temperature sensor K Purge control solenoid valve F Engine ECU Q Throttle position sensor with idle position ...

Page 326: ...rd value or the resistance remains unchanged replace the air flow sensor ENGINE COOLANT TEMPERATURE SENSOR CHECK 13100310150 Caution Be careful not to touch the connector resin section with the tool when removing and installing 1 Remove the engine coolant temperature sensor 2 With temperature sensing portion of engine coolant temperature sensor immersed in hot water check resistance Standard value...

Page 327: ...tion Changes smoothly in proportion to the opening angle of the throttle valve 4 If the resistance is outside the standard value or if it doesn t change smoothly replace the throttle position sensor NOTE For the throttle position sensor adjustment procedure refer to P 13A 78 IDLE POSITION SWITCH CHECK 13100330187 1 Disconnect the throttle position sensor connector 2 Check the continuity between th...

Page 328: ...he battery terminal Caution Be very careful when connecting the jumper wire incorrect connection can damage the oxygen sensor 6 Connect a digital voltage meter between terminal 2 black clip and terminal 4 white clip 7 While repeatedly racing the engine measure the oxygen sensor output voltage Standard value Engine Oxygen sensor output voltage Remarks When racing the engine 0 6 1 0 V If you make th...

Page 329: ... bleed out the residual pressure within the fuel pipe line to prevent flow of the fuel Refer to P 13 84 2 Remove the injector 3 Arrange the special tool injector test set adaptor fuel pressure regulator and clips as shown in the illustration below MB991607 High pressure fuel hose MD998741 MD998706 Return hose Battery Injector Pressure regulator MD116395 Clip MB991608 4 Apply battery voltage to the...

Page 330: ...mperature sensor that is at 20_C or below is also okay 2 Check that the operation sound of the stepper motor can be heard after the ignition is switched ON but without starting the motor 3 If the operation sound cannot be heard check the stepper motor s activation circuit If the circuit is normal it is probable that there is a malfunction of the stepper motor or of the engine control unit Checking...

Page 331: ...I On vehicle Service 13A 91 PURGE CONTROL SOLENOID VALVE CHECK 13100560111 Refer to GROUP 17 Emission Control System EGR CONTROL SOLENOID VALVE CHECK 13100570107 Refer to GROUP 17 Emission Control System ...

Page 332: ... vehicle Service Engine oil 12 Nm 12 Nm 16 Nm 9 Nm 4 Nm 5 Nm 12 Nm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 8 11 11 5 4 12 14 16 7 15 Removal steps 1 Accelerator cable connection 2 Throttle cable connection A T 3 Resonance tank AA 4 High pressure fuel hose connection 5 O ring 6 Fuel return hose connection 7 Vacuum hose connection AA 8 Fuel pressure regulator 9 O ring 10 Injector connectors AA 11 Del...

Page 333: ...to let engine oil in the delivery pipe 2 While turning the injector high pressure fuel hose and fuel pressure regulator to the right and left install the delivery pipe while being careful not to damage the O ring After installing check that the hose turns smoothly 3 If it does not turn smoothly the O ring may be trapped remove the fuel pressure regulator and then re insert it into the delivery pip...

Page 334: ...UP 17 On vehicle Service D Throttle Cable Adjustment Refer to GROUP 23 On vehicle Service D Engine Coolant Supplying 12 Nm 16 Nm 18 Nm 4 Nm 1 2 3 4 5 6 7 8 9 6 Removal steps 1 Accelerator cable connection 2 Throttle cable connection 3 Vacuum hose connection 4 Throttle position sensor connector 5 Idle speed control motor connector 6 Water hose connection 7 Resonance tank 8 Throttle body 9 Gasket ...

Page 335: ...d 2 If the fixed SAS should happen to have been removed carry out fixed SAS adjustment Refer to page 13A 79 CLEANING THROTTLE BODY PARTS 1 Clean all throttle body parts Do not use solvent to clean the following parts D Throttle position sensor D Accelerator pedal position sensor D Idle speed control body assembly If these parts are immersed in solvent their insulation will deteriorate Wipe them wi...

Page 336: ...ottle valve is opened slowly to the fully open position 3 Check the continuity between terminal 2 idle position switch and terminal 1 earth of the TPS connector when the throttle valve is fully closed and fully open Normal condition Throttle valve condition Continuity Fully closed Continuity Fully open No continuity If there is no continuity when the throttle valve is fully closed turn the TPS bod...

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Page 402: ...n 4 Fail safe Function Reference Table 8 Inspection Chart for Diagnosis Codes 9 Inspection Procedure Classified by Diagnosis Code 10 Inspection Chart for Trouble Symptoms 42 Inspection Procedure for Trouble Symptoms 43 Data List Reference Table 67 Actuator Test Reference Table 72 Check at the Engine ECU Terminals 73 Inspection Procedure Using an Analyzer 79 ON VEHICLE SERVICE 83 Component Location...

Page 403: ... D Ignition timing adjustment terminal has been abolished GENERAL INFORMATION SELF DIAGNOSIS FUNCTION The functions below have been added D The 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 and can be used in simulation tests for troubleshooting GENERAL SPECIFICATIONS Items Specificat...

Page 404: ...em the engine warning lamp will illuminate or flash If the lamp remains illuminated or if the lamp illuminates while the engine is running check the diagnosis code output However the warning lamp will illuminate as bulb check for five seconds whenever the ignition switch is turned to the ON position Engine warning lamp inspection items Code No Diagnosis item Engine ECU P0100 Air flow sensor system...

Page 405: ...ommunication between MUT II and the engine ECU M T is impossible In this case the diagnosis code cannot be read 2 After the engine ECU has detected a malfunction the engine warning lamp illuminates when the engine is next turned on and the same malfunction is re detected However for items marked with a L in the diagnosis code number column the engine warning lamp illuminates only on the first dete...

Page 406: ...odes INSPECTION USING MUT II DATA LIST AND ACTUATOR TESTING 1 Carry out inspection by means of the data list and the actuator test function If there is an abnormality check and repair the chassis harnesses and components 2 After repairing re check using the MUT II and check that the abnormal input and output have returned to normal as a result of the repairs 3 Erase the diagnosis code memory 4 Rem...

Page 407: ...ad 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 diagnosis items judges if these items are in good condition or not and the stores its history This history can be read out by using MUT II If the ECU has judged an item bef...

Page 408: ...fuel injection amount 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 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 bar...

Page 409: ...cylinder misfire detected 13A 29 P0304 No 4 cylinder misfire detected 13A 29 P0335 Crank angle sensor system 13A 31 P0340 Camshaft position sensor system 13A 32 P0403 EGR valve system 13A 33 P0420 Catalyst malfunction 13A 34 P0443 Purge control solenoid valve system 13A 35 P0500 Vehicle speed sensor system 13A 36 P0505 Idle speed control system 13A 37 P0510 Idle position switch system 13A 39 P0551...

Page 410: ...toms NG Replace the engine ECU OK Check the harness between the air flow sensor and the engine ECU NG Repair NG Check the following connector C 97 NG Repair OK Check the harness between the air flow sensor and the engine ECU and repair if necessary NG Repair OK Check the following connector C 97 1 NG Measure at engine ECU connector C 97 D Measure the voltage at the engine ECU terminal D Ignition s...

Page 411: ... not be displayed in the waveform NG Replace the engine ECU OK Check the trouble symptoms OK Check the harness between the air flow sensor and the engine ECU NG Repair NG Check the following connector C 49 NG Repair OK Measure at air flow sensor connector A 77 D Use test harness MB991348 to connect the connector and measure at the pick up harness D Voltage between terminal 7 and earth OK Engine Id...

Page 412: ... Barometric pressure sensor Refer to P 13A 67 DATA LIST REFERENCE TABLE OK Transient malfunction Refer to GROUP 00 Points to Note for Intermittent Malfunctions NG NG Repair OK Measure at air flow sensor connector A 77 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 5 and earth OK 2 Ω or ...

Page 413: ...ow sensor connector A 77 D Connect connector terminals No 1 No 2 and No 5 only by using test harness MB991348 and measure at the pick up harness D Ignition switch ON 1 Voltage between terminal 1 and earth OK 4 8 5 2 V 2 Voltage between terminal 2 and earth OK Altitude 0 m 3 7 4 3 V Altitude 1 200 m 3 2 3 8 V 3 Voltage between terminal 5 and earth OK 0 5 V or less 1 NG Check the following connector...

Page 414: ...mittent Malfunctions NG Check the intake air temperature sensor itself Refer to P 13A 86 NG Repair OK Measure at air flow sensor connector A 77 D Disconnect the connector and measure at the harness side 1 Resistance between terminal 5 and earth OK 2 Ω or less 2 Voltage between terminal 6 and earth Ignition switch ON OK 4 8 5 2 V 1 NG NG Repair NG Repair NG Check the following connector C 97 NG Rep...

Page 415: ...Voltage between terminal 6 and earth OK Ambient temperature 0_C 3 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 C 94 C 97 NG Repair OK Check the harness between the air flow sensor and the engine ECU and repair if necessary OK Check the trouble symptoms NG Replace the engine ECU From the previous p...

Page 416: ...function of engine ECU 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 80 120_C OK Tra...

Page 417: ...e ECU and repair if necessary OK Measure at engine coolant temperature sensor connector A 64 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 Ω or less 1 NG Measure at engine ECU connector C 97 D Measure the voltage at the engine ECU terminal D Disconnect connector A 64 D...

Page 418: ...C 97 NG Repair OK Check the harness wire between the throttle position sensor and the engine ECU and repair if necessary NG Repair OK Measure at throttle position sensor connector A 47 D Disconnect the connector and measure at the harness side 1 Voltage between terminal 4 and earth Ignition switch ON OK 4 8 5 2 V 2 Resistance between terminal 1 and earth OK 2 Ω or less 1 NG Measure at engine ECU c...

Page 419: ...ion sensor and the engine ECU and repair if necessary Check the following connector C 97 NG Repair 3 NG Adjust the throttle position sensor Refer to P 13A 78 OK Check the harness wire between the throttle position sensor and the engine ECU 1 NG Check the following connector C 97 NG Repair 2 NG OK Measure at throttle position sensor connector A 47 D Use test harness MB991348 to connect the connecto...

Page 420: ...r min after 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 connectors C 60 C 97 2 NG Check the oxygen sensor front Refer to P 13A 84 NG Replace OK Check the harness wire between the oxygen sensor front and the engine ECU and repair if ...

Page 421: ...ygen 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 less D During driving ...

Page 422: ...heck the harness wire between the oxygen sensor front and the engine ECU and repair if necessary Repair 1 NG Check the following connectors C 60 C 94 C 97 NG 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 B 03 D Disconnect the connector and measure at t...

Page 423: ...tween the oxygen sensor front and the engine control relay NG Repair OK Check the following connector C 51 NG Repair OK Check the harness wire between the oxygen sensor front and the engine ECU and repair if necessary Repair NG Check the following connectors B 03 C 51 C 60 NG OK Measure at engine ECU connector C 51 D Measure the voltage at the engine ECU terminal D Ignition switch ON D Voltage bet...

Page 424: ...ine ECU connector C 97 D Measure the voltage at the engine ECU terminal D Engine 2 500 r min after warming up D Voltage between terminal 75 and earth OK 0 V and 0 8 V alternate OK Check the harness wire between the oxygen sensor rear and the engine ECU and repair if necessary OK NG Repair Check the following connectors C 19 C 97 D 02 OK Check the harness wire between the oxygen sensor rear and the...

Page 425: ... the oxygen sensor rear and the engine control relay NG Repair OK Check the following connector C 51 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 connectors C 19 C 51 D 02 NG OK Measure at engine ECU connector C 51 D Measure the voltage at the engine ECU terminal D Ignition switch ON D Voltage between te...

Page 426: ...cate less than the standard value OK No Less than zero MUT II Data list 12 Volume air flow sensor Refer to P 13A 67 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 67 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 81 OK C...

Page 427: ...ent malfunction Refer to GROUP 00 Points to Note for IntermittentMalfunctions OK Check trouble symptoms OK Measure at the engine ECU connector C 49 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 NG Check the harness wire between the engine ECU and the injector connector and repair if necessary OK Check the follo...

Page 428: ...ession pressure D Check the timing belt for missing teeth D Check the EGR system and EGR valve OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 67 NG OK MUT II Data list 81 Long term fuel compensation Refer to P 13A 67 NG Check the abnormal fuel system Refer to P 13A 26 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0170 OK Check the injector Refer to P 13A 89 NG Replace MUT II Da...

Page 429: ...l 1 8 and earth Ignition switch ON OK System voltage 2 Voltage between terminal 2 7 and earth Engine Cranking OK 0 5 4 0 V 1 NG Check the following connectors A 65 A 111 NG Repair OK Check the harness wire between the ignition coil and the power transistor unit connector and repair if necessary NG OK To the next page OK Check the following connector C 88 NG Check the ignition coil Refer to GROUP 1...

Page 430: ...ck the trouble symptoms OK OK Measure at engine ECU connector C 51 D Connect the connector D Voltage between terminal 58 and earth Engine 3 000 r min OK 0 3 3 0 V OK Check the harness wire between the engine ECU and the power transistor unit connector Check the following connector A 70 Check trouble symptom OK Replace the power transistor unit OK Repair Repair From the previous page ...

Page 431: ... NG Check the following connector C 97 NG Repair OK Check the harness wires between the crank angle sensor and the engine ECU crank angle sensor and the engine control relay and the crank angle sensor and earth Then repair if necessary NG Replace the engine ECU OK Check the harness wire between the crank angle sensor and the engine ECU and repair if necessary OK Measure at the crank angle sensor c...

Page 432: ...sconnect the connector and measure at the harness side 1 The voltage between terminal 3 and earth Ignition switch ON OK System voltage 2 The voltage between terminal 2 and earth Ignition switch ON OK 4 8 5 2 V 3 The resistance between terminal 1 and earth OK 2 Ω or less 1 NG Check the following connector C 95 NG Repair Replace the camshaft position sensor Check the trouble symptoms OK NG Repair OK...

Page 433: ... control solenoid valve and the engine ECU NG Check the following connector A 49 NG Repair OK Measure at engine ECU connector C 49 D Measure the voltage at the engine ECU terminal D Ignition switch ON D The voltage between terminal 6 and earth OK System voltage Check the harness wire between the EGR control solenoid valve and the engine control relay and repair if necessary NG OK Measure at the EG...

Page 434: ...ic 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 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 21 INSPECTION PROCEDURE FOR DIAGNOSTIC TROUBLE CODE P0130 MUT II Data list 11 Oxyge...

Page 435: ...rge control solenoid valve and the engine ECU NG Check the following connector C 49 NG Repair OK Measure at engine ECU connector C 49 D Measure the voltage at the engine ECU terminal D Ignition switch ON D The voltage between terminal 9 and earth OK System voltage Check the harness wire between the purge control solenoid valve and the engine control relay and repair if necessary NG OK Measure at t...

Page 436: ...tion meter connector NG Repair OK Replace the engine ECU Check the vehicle speed sensor reed switch Refer to GROUP 54 Combination Meters NG Replace OK Measure at the combination meter connector C 06 C 07 D Disconnect the connector and measure st the harness side 1 Voltage between 51 and earth Ignition switch ON OK 4 8 5 2 V 2 Continuity between 34 and earth OK Continuity 1 NG Check the following c...

Page 437: ...r more D Barometric pressure is 76 kPa or higher D Intake air temperature is 10_C 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 Volumetric efficiency ...

Page 438: ...ltage 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 control servo connector A 50 D Disconnect the connector and measure at the harness side D Ignition switch ON D The voltage between terminal 2 and earth D The voltage between terminal 5 and earth OK System voltage NG Check the following conne...

Page 439: ... two seconds engine speed is 800 rpm or lower and vehicle speed is less than 1 5 km h Judgment Criteria D Idle position switch remains off D Malfunction of idle position switch D Open or shorted idle position switch circuit or loose connector D Malfunction of engine ECU Repair NG Replace the engine ECU OK NG Check the harness wire between engine ECU and throttle position sensor connector OK Check ...

Page 440: ... Malfunction of the engine ECU NG Repair Replace the engine ECU OK NG Check the harness wire between engine ECU and power steering pressure switch connector OK Check trouble symptom OK Replace the engine ECU OK Check trouble symptom Repair NG OK Check the following connector C 50 NG Repair NG Check the following connector C 50 OK Measure at the power steering pressure switch connector A 74 D Disco...

Page 441: ...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 EC...

Page 442: ...ssible 6 13A 46 Long time to start Improper starting 7 13A 47 Idling stability Improper idling Unstable idling Rough idling hunting 8 13A 48 Improper idling Idling speed is high Improper idling speed 9 13A 50 Idling speed is low Improper idling speed 10 13A 50 Idling stability Engine stalls When the engine is cold it stalls at idling Die out 11 13A 51 Engine stalls When the engine becomes hot it s...

Page 443: ...ontinuity between 5 and earth OK Continuity NG OK Replace the MUT II Check the following connector C 86 NG Repair OK Check trouble symptom NG Check the harness wire between the diagnosis connector 16 pin and the earth and repair if necessary 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 eng...

Page 444: ...ulb NG Replace OK Measure at the combination meter connector C 06 D Disconnect the connector and measure at the harness side D Voltage between 43 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 C 04 C 06 C 19 C 50 NG Repair OK Check trouble symptom NG Check the harness wire between combin...

Page 445: ...y sound be heard from the injectors when cranking No Check the injector system Refer to P 13A 27 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE P0201 P0202 P0203 P0204 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 67 NG Check the engine coolant temperature sensor system Refer to P 13A 16 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Actuator test 07 Fuel pump Refer to...

Page 446: ...he ISC servo sys tem Refer to P 13A 37 INSPECTION PROCE DURE FOR DIAGNOSIS CODE P0505 Yes Check ISC servo for op eration sound Refer to P 13A 90 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 the injector system Refer to P 13A 27 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE P0201 P0202 P0203...

Page 447: ...ox 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 the injector system Refer to P 13A 27 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE P0201 P0202 P0203 P0204 OK MUT II Data list 18 Ignition switch ST Refer to P 13A 67 NG Check the ignition switch ST system Refer to P 13A 65 INSPECTION PROCEDURE 26 OK MUT II Data list...

Page 448: ...nsor system Refer to P 13A 12 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105 OK MUT II Data list 25 Barometric pressure sensor Refer to P 13A 67 NG Check the intake air temperature sensor system Refer to P 13A 14 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0110 OK MUT II Data list 13 Intake air temperature sensor Refer to P 13A 67 NG Check the idle position switch system Refer to P 13A 39 INSPEC TION ...

Page 449: ... PROCE DURE FOR DIAGNOSIS CODE P0551 OK MUT II Data list 27 Power steering fluid pressure switch Refer to P 13A 67 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 81 OK MUT II Data list 11 Oxygen sensor OK Chang...

Page 450: ...n sound Refer to P 13A 90 MUT II Self Diag code Are diagnosis codes displayed Yes Refer to P 13A 9 INSPECTION CHART FOR DIAGNOSIS CODES NOTE Refer to the 97 L200 Workshop Manual Pub No PWTE96E1 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 I...

Page 451: ... 13A 16 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 67 NG Check the idle position switch system Refer to P 13A 39 INSPEC TION PROCEDURE FOR DIAGNOSIS CODE P0510 OK MUT II Data list 26 Idle position switch Refer to P 13A 67 NG Check the injector system Refer to P 13A 27 INSPECTION PRO CEDURE FOR DIAGNOSIS CODE P0201 P0202 P02...

Page 452: ...fer to P 13A 67 NG Check the intake air temperature sensor system Refer to P 13A 14 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0110 OK MUT II Data list 13 Intake air temperature sensor Refer to P 13A 67 NG Check the idle position switch system Refer to P 13A 39 INSPEC TION PROCEDURE FOR DIAGNOSIS CODE P0510 Yes MUT II Data list 26 Idle position switch Refer to P 13A 67 No While carrying out an inter...

Page 453: ...67 NG Check the power steering fluid pressure switch sys tem Refer to P 13A 40 INSPECTION PROCE DURE FOR DIAGNOSIS CODE P0551 OK MUT II Data list 27 Power steering fluid pressure switch Refer to P 13A 67 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 N...

Page 454: ...sufficient due to a defective idle speed control ISC 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 33 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0403 No MUT II Actuator test 10 EGR control solenoid...

Page 455: ...DE P0403 OK MUT II Actuator test 10 EGR control solenoid valve Refer to P 13A 72 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 67 NG Check the engine coolant temperature sensor system Refer to P 13A 16 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 67 NG Check the barometric pressure sensor system Refer to P 13...

Page 456: ...function 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 9 INSPECTION CHART FOR DIAGNOSIS CODES INSPECTION PROCEDURE 17 The feeling of impact or vibration when decelerating Probable cause Malfunction of the ISC system is suspecte...

Page 457: ...A 18 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE P0120 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 67 NG Check the engine coolant temperature sensor system Refer to P 13A 16 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0115 OK MUT II Data list 21 Engine coolant temperature sensor Refer to P 13A 67 NG Check the barometric pressure sensor system Refer to P 13A 12 INSPECTION PROCEDURE FOR...

Page 458: ...the fuel pressure Refer to P 13A 81 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 in take hose 2 Check the injector for clog NG Check the fuel pressure Refer to P 13A 81 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...

Page 459: ...3 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0403 OK MUT II Actuator test 10 EGR control solenoid valve Refer to P 13A 72 NG Check the throttle position sensor system Refer to P 13A 18 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE P0120 OK MUT II Data list 14 Throttle position sensor Refer to P 13A 67 NG Check the engine coolant temperature sensor system Refer to P 13A 16 INSPECTION PROCEDURE FOR DIAGNOS...

Page 460: ...e of the spark plug is inappropriate D Inappropriate heat value of the spark plug Check the following items D Spark plugs D Check if foreign materials water alcohol etc got into fuel INSPECTION PROCEDURE 21 Dieseling Probable cause Fuel leakage from injectors is suspected D Fuel leakage from injectors Check the injectors for fuel leakage ...

Page 461: ...Oxygen sensor front OK 600 1 000 mV when racing suddenly NG Check the oxygen sensor rear system Refer to P 13A 24 IN SPECTION PROCEDURE FOR DIAGNOSIS CODE P0136 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 barometric pressure sensor system Refer to P 13A 12 INSPECTION PROCEDURE FOR DIAGNOSIS CODE P0105 OK MUT II ...

Page 462: ...pair if necessary 2 3 NG Check the harness wire between engine ECU and engine control relay connector and repair if necessary OK Check the ignition switch Refer to GROUP 54 Ignition Switch NG Check the harness wire between engine ECU and ignition switch connector NG Repair OK Check trouble symptom Measure at the engine ECU connectors C 49 C 50 C 97 D Disconnect the connector and measure at the har...

Page 463: ...ircuit Refer to P 13A 62 INSPECTION PROCEDURE 23 Check the harness wire between battery and engine control relay connector and repair if necessary NG OK Measure at the engine control relay connector C 53 D Disconnect the connector and measure at the harness side D Voltage between 3 4 and earth OK System voltage Check the engine control relay Refer to P 13A 86 NG Replace NOTE Refer to the 97 L200 W...

Page 464: ...between terminal 22 and earth Ignition switch ON vehicle with immobilizer OK The fuel pump operates its operation sound can be heard NG Check the harness wire between the fuel pump relay and engine ECU and repair if necessary Check trouble symptom NG Repair OK NG Check the following connector C 54 OK Measure at the engine ECU connector C 49 D Disconnect the connector and measure at the harness sid...

Page 465: ...Replace the engine ECU 2 NG INSPECTION PROCEDURE 27 A C switch and A C relay system Probable cause When an A C ON signal is input to the engine ECU the engine ECU carries out control of the idle speed control ISC servo and also operates the A C compressor magnetic clutch D Malfunction of A C control system D Malfunction of A C switch D Improper connector contact open circuit or short circuited har...

Page 466: ...nd earth OK Continuity OK OK Check the power transistor unit Refer to GROUP 16 Ignition System NG Replace Check the ignition coil Refer to GROUP 16 Ignition System NG Replace Check the harness wire between the engine ECU and power transistor unit connector OK 1 NG 2 NG Check the following connector C 88 NG Repair Replace the power transistor unit Replace the engine ECU NG Repair Because an open or...

Page 467: ...ctor drive time is sometimes 10 longer than the standard time 5 In a new vehicle driven approximately 500 km or less the step of the stepper motor is sometimes 30 steps greater than the standard value Item No Inspection item Inspection contents Normal condition Inspection procedure No Reference page 11 Oxygen sensor front Engine After having warmed up Air fuel mixture is made leaner when de When a...

Page 468: ...tion 300 1 000 mV Code No P0120 13A 18 position sensor Gradually open Increases in pro portion to throttle opening angle P0120 Open fully 4 500 5 500 mV 16 Power sup ply voltage Ignition switch ON System voltage Procedure No 23 13A 62 18 Cranking signal Ignition switch ON Engine Stopped OFF Procedure No 26 13A 65 signal ignition switch ST Engine Cranking ON No 26 21 Engine cool ant tempera ture se...

Page 469: ...24 Vehicle speed sen sor Drive at 40 km h Approximately 40 km h Code No P0500 13A 36 25 Barometric pressure Ignition switch ON At altitude of 0 m 101 kPa Code No P0105 13A 12 pressure sensor At altitude of 600 m 95 kPa P0105 At altitude of 1 200 m 88 kPa At altitude of 1 800 m 81 kPa 26 Idle position switch Ignition switch ON Check by operating accelerator pedal re Throttle valve Set to idle posit...

Page 470: ...e is sud denly raced Increases 44 Ignition coils and power transistors D Engine After hav ing warmed up D Timing lamp is set The timing lamp Engine is idling 2 18_BTDC Code No P0300 13A 28 The timing lamp is set in order to check actual igni tion timing 2 500 r min 27 47_BTDC 45 ISC step per motor position 5 D Engine coolant temperature 80 95_C D Lamps electric cooling fan and all accessories OFF ...

Page 471: ...trol condition Engine Warm 2 500 r min Closed loop Code No P0125 13A 20 condition When engine is sud denly raced Open loop drive condition P0125 A1 Oxygen sensor Engine After having warmed up Idling 0 V Code No P0130 13A 21 sensor sensor 1 warmed up Sudden racing 0 6 1 0 V P0130 2 500 r min 0 4 V or less and 0 6 1 0 V alter nates A2 Oxygen sensor sensor 2 D Transmission 2nd gear D Drive with throt...

Page 472: ... 07 Fuel pump Fuel pump operates and fuel is recircu lated D Engine Cranking D Fuel pump Forced driving Inspect according Pinch the return hose with fingers to feel the pulse of the fuel being recirculated Pulse is felt Procedure No 25 13A 63 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 ...

Page 473: ...ou may find it convenient to pull out the engine ECU to make it easier to reach the connector terminals 3 The checks can be carried out off the order given in the chart Caution Short circuiting the positive probe between a connector terminal and earth could damage the vehicle wiring the sensor engine ECU or all of them Be careful to prevent this 3 If voltmeter shows any division from standard valu...

Page 474: ...per motor coil B2 6 EGR control solenoid valve Ignition switch ON System Voltage valve While engine is idling suddenly depress the accelerator pedal From system voltage momentarily drops 8 or 22 Fuel pump relay Ignition switch ON System voltage Engine Idle speed 0 3 V 9 Purge control solenoid valve Ignition switch ON System voltage valve Running at 3 000 r min while engine is warming up after havi...

Page 475: ...r Engine Idling after having warmed up 0 3 V heater Engine r min 5 000 r min System voltage 58 Spark check signal Engine r min 3 000 r min 0 3 3 0 V 60 Oxygen sensor front heater Engine Idling after warming up 0 3 V heater Engine r min 5 000 r min System voltage 71 Ignition switch ST Engine Cranking 8 V or more 72 Intake air temperature sensor Ignition switch ON When intake air temperature is 0_C ...

Page 476: ...0_C 0 3 0 9 V 84 Throttle position sensor Ignition switch ON Set throttle valve to idle position 0 3 1 0 V Fully open throttle valve 4 5 5 5 V 85 Barometric pressure sensor Ignition switch ON When altitude is 0 m 3 7 4 3 V When altitude is 1 200 m 3 2 3 8 V 86 Vehicle speed sensor D Ignition switch ON D Move the vehicle slowly forward 0 5 V Changes repeatedly 87 Idle position switch Ignition switc...

Page 477: ...rt Caution If the terminals that should be checked are mistaken or if connector terminals are not correctly shorted to earth damage may be caused to the vehicle wiring sensors engine ECU and or ohmmeter Be careful to prevent this 4 If the ohmmeter shows any deviation from the standard value check the corresponding sensor actuator and related electrical wiring and then repair or replace 5 After rep...

Page 478: ... At 20_C 60 12 Oxygen sensor front heater 4 5 8 0 Ω At 20_C 72 92 Intake air temperature sensor 5 3 6 7 kΩ When intake air temperature is 0_C 2 3 3 0 kΩ When intake air temperature is 20_C 1 0 1 5 kΩ When intake air temperature is 40_C 0 30 0 42 kΩ When intake air temperature is 80_C 83 92 Engine coolant temperature sensor 5 1 6 5 kΩ When coolant temperature is 0_C 2 1 2 7 kΩ When coolant temperat...

Page 479: ...ness 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 signa...

Page 480: ... 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 Abnormal...

Page 481: ...te Method Test harness not available 1 Connector the analyzer special pattern 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 Crank angle sensor output wave pattern Power transistor control signal wave ...

Page 482: ... circuit Rectangular wave at power voltage Power transistor malfunction Examples of Abnormal Wave Patterns 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 2V too low D Example 2 Wave pattern during engine cranking Cause of p...

Page 483: ...Service 13A 83 ON VEHICLE SERVICE COMPONENT LOCATION Name Symbol Name Symbol Camshaft position sensor A Oxygen sensor front D Crank angle sensor B Oxygen sensor rear E Ignition coil C Power transistor unit A C B A D E ...

Page 484: ... the battery terminal Caution Be very careful when connecting the jumper wire incorrect connection can damage the oxygen sensor 6 Connect a digital voltage meter between terminal 2 black clip and terminal 4 white clip 7 While repeatedly racing the engine measure the oxygen sensor output voltage Standard value Engine Oxygen sensor output voltage Remarks When racing the engine 0 6 1 0 V If you make ...

Page 485: ...3 blue clip of special tool on the oxygen sensor connector 3 If there is no continuity replace the oxygen sensor NOTE 1 If the MUT II does not display the standard value although no abnormality is found by the above mentioned continuity test and harness check replace the oxygen sensor rear 2 For removal and installation of the oxygen sensor refer to GROUP 15 Exhaust Pipe and Main Muffler Oxygen se...

Page 486: ...NOTES ...

Page 487: ...DIESEL FUEL ...

Page 488: ......

Page 489: ...t by a hydraulic timer The hydraulic timer operates by the fuel pressure inside the pump chamber This pressure is controlled by the regulating valve SERVICE SPECIFICATIONS 13300030021 Items Standard value Fuel cut solenoid valve coil resistance Ω 8 10 Fuel injection initial pressure kPa 14 710 15 690 SPECIAL TOOL 13300060020 Tool Number Name Use MD998388 Injection pump sprocket puller Fuel injecti...

Page 490: ...hole Tighten air plug 4 Repeat until hand pump operation becomes stiff FUEL FILTER CARTRIDGE REPLACEMENT 13300320029 Refer to GROUP 13F FUEL INJECTION PUMP CHECK 13300140021 FUEL CUT SOLENOID VALVE OPERATION CHECK Vehicles without immobilizer system When a sound scope is held against the fuel cut solenoid valve and the ignition switch is turned to ON check that the sound of the valve operating can...

Page 491: ...EL INJECTION INITIAL PRESSURE CHECK 1 Install the injection nozzle to a nozzle tester 2 Move the lever of the nozzle tester 2 3 times to inject fuel and to bleed the air 3 Gently press down the lever of the nozzle tester and take a reading of the indication value on the pressure gauge at the point where the needle slowly rises and then suddenly drops Standard value Fuel injection initial pressure ...

Page 492: ... Intermittent fuel injection 2 Check to be sure that no fuel drips after injection is completed 3 If there are any drips disassemble the nozzle clean it and reinspect or replace the nozzle NOZZLE FUEL TIGHT CHECK 1 Gently raise the lever of the nozzle tester until the pressure inside the nozzle value displayed on pressure gauge becomes 12 750 13 730 kPa and after holding this pressure for approxim...

Page 493: ... 12 Nm 16 Nm 4 9 Nm 29 Nm 49 59 Nm 1 2 3 4 5 6 7 8 9 10 11 3 3 3 Removal steps 1 Accelerator cable connection 2 Throttle cable connection A T 3 Injection pipe clamp AA 4 Injection pipe 5 Fuel return hose AB 6 Nut AB 7 Fuel return pipe 8 Fuel return pipe gasket AC 9 Injection nozzle assembly AA 10 Holder gasket AA 11 Nozzle gasket REMOVAL SERVICE POINTS AA INJECTION PIPE DISCONNECTION When loosenin...

Page 494: ...2 Disconnect the fuel return pipe AC INJECTION NOZZLE ASSEMBLY REMOVAL Using a deep socket wrench remove the injection nozzle assembly Caution 1 Make a mark on the removed injection nozzle assembly the cylinder No 2 Use a cap to prevent foreign material etc from entering the injection nozzle hole INSTALLATION SERVICE POINT AA NOZZLE GASKET HOLDER GASKET INSTALLATION Clean the cylinder head s injec...

Page 495: ... REMOVAL 1 Lightly clamp the retaining nut in a vise with soft jaws 2 Hold the retaining nut with a box wrench and loosen the nozzle holder body using a deep socket REASSEMBLY SERVICE POINT AA RETAINING NUT INSTALLATION 1 Finger tighten the nozzle holder body 2 Lightly clamp the retaining nut in a vise with soft jaws 3 While holding the retaining nut with a box wrench tighten the nozzle holder bod...

Page 496: ...le tip is submerged in diesel fuel check that the needle valve slides smoothly If the needle valve does not slide smoothly replace the nozzle tip When replacing the nozzle tip completely wash off the anticorrosive oil from the new nozzle tip with clean diesel fuel before using it 3 Check plunger tip A for deformation and breakage If A is damaged or broken replace it DISTANCE PIECE Check the surfac...

Page 497: ...11B On vehicle Service D Accelerator Cable Adjustment Refer to GROUP 17 On vehicle Service D Throttle Cable Adjustment Refer to GROUP 23 On vehicle Service D Lever Position Switch Adjustment Refer to GROUP 55 4 9 Nm 29 Nm 29 Nm 29 Nm 12 Nm 16 Nm 19 Nm 79 88 Nm 4 9 Nm 1 2 3 4 5 6 7 8 9 10 2 Removal steps 1 Fuel injection pump wiring harness 2 Water hose connection Vehicles with cold start device 3 ...

Page 498: ...de retained by a spanner etc AB FUEL INJECTION PUMP SPROCKET REMOVAL Remove sprocket installing nut and remove sprocket from pump drive shaft with special tool Caution 1 Do not hit pump drive shaft with hammer etc 2 When holding injection pump do not allow to dangle by holding accelerator lever or fast idle lever Do not remove these levers Removal will cause injection pump malfunction Delivery hol...

Page 499: ...NOTES ...

Page 500: ......

Page 501: ......

Page 502: ...FUEL SUPPLY ...

Page 503: ...13F 1 FUEL SUPPLY CONTENTS 13509000111 GENERAL INFORMATION 2 FUEL TANK 3 FUEL FILTER Diesel powered Vehicles 6 ...

Page 504: ... SUPPLY General Information 13F 2 GENERAL INFORMATION 13500010083 The fuel tank is equipped with a valve assembly roll over valve It prevents fuel from leaking out of the fuel tank if the vehicle rolls over ...

Page 505: ... Petrol powered vehicles Double cab Single cab and club cab 4WD 1 2 3 4 5 6 7 9 10 12 13 14 15 16 17 18 36 Nm 22 Nm 24 29 Nm 1 3 2 5 10 8 11 24 29 Nm 2 3 Nm 15 16 2 3 Nm 15 16 17 10 29 Nm 4 11 19 Removal steps 1 Fuel filler cap 2 Filler neck 3 Packing 4 Leveling hose BA 5 Filler hose 6 Fuel gauge unit connector 7 Fuel pump connector 8 Fuel high pressure hose 9 Return hose 10 Vapor hose 11 Fuel tan...

Page 506: ...filler cap 2 Filler neck 3 Packing 4 Leveling hose BA 5 Filler hose 6 Fuel gauge unit connector 7 Return hose 8 Main hose 9 Fuel tank nuts 10 Fuel gauge unit 11 Pipe assembly 12 Fuel filter 13 Packing 14 Valve assembly 15 Vapor hose 16 Breather case AA 17 2 way valve 18 Drain plug 19 Fuel tank INSTALLATION SERVICE POINTS AA 2 WAY VALVE INSTALLATION Install the 2 way valve being careful not to mist...

Page 507: ...he high pressure hose Caution As there will be some pressure remaining in the fuel pipe line cover it with a rag to prevent fuel from spraying out 3 Hold the fuel filter with a spanner and loosen the flare nut Then disconnect the main pipe connection 4 Remove the fuel filter 5 When installing the fuel filter use a new gasket and tighten the flare nut of the high pressure hose and the main pipe to ...

Page 508: ... Drain plug 4 Water level sensor 5 Fuel filter cartridge 6 Fuel filter pump 7 Breather screw 8 Solenoid valve assembly for A C 9 Fuel filter bracket INSTALLATION SERVICE POINT AA FUEL MAIN HOSE INSTALLATION If the pipe has a stepped part connect securely up to the stepped part If the pipe has no stepped part insert so that the inserted portion is 20 25 mm long INSPECTION 13500290012 WATER LEVEL SE...

Page 509: ...3500130093 1 Remove the intercooler assembly 4WD Refer to GROUP 15 2 Remove the fuel tank cap to release the pressure inside the fuel tank 3 Disconnect the water level sensor connector 4 Use an oil filter wrench to remove the fuel filler cartridge from the fuel filter pump body Caution Cover with a rag to prevent fuel from spraying out 5 Install a new filter and bleed the air from fuel line Refer ...

Page 510: ...NOTES ...

Page 511: ...DIESEL FUEL 4D5 Step III ...

Page 512: ... Relay Continuity Check 59 Accelerator Pedal Position Sensor APS Check 59 Idle Switch Check 59 Boost Air Temperature Sensor Intake Air Temperature Sensor Check 60 Engine Coolant Temperature Sensor Check 60 Evacuation of Water from Fuel Filter 61 Evacuation of Air from Fuel Filter 61 Fuel Filter Cartridge Replacement 61 EGR Valve Position Sensor Check 62 Fuel Injection Pump Check 62 Throttle Soleno...

Page 513: ...pressure and when the fuel flow rate reaches the target value for fuel injection the solenoid type spill valve turns off When the solenoid type spill valve turns off the fuel under high pressure inside the plunger is leaked out into the pump chamber and fuel injection is completed FUEL INJECTION TIMING CONTROL The position of the injection pump timer piston is controlled so that fuel injection is ...

Page 514: ...ottle valve is half opened to restrict the amount of intake air in order to prevent the vehicle from running away 3 A C Relay Control Turns the compressor clutch of the A C ON and OFF 4 Condenser Fan Motor Relay Control Controls the condenser fan motor relay based on the A C switch engine coolant temperature and vehicle speed input signals 5 Intercooler Fan Motor Relay Control Controls the interco...

Page 515: ... Throttle solenoid valve l6 Fuel cut solenoid valve l7 Variable geometry solenoid valve D Control relay D A C relay D Condenser fan relay D Intercooler fan relay D Glow indicator lamp D Glow plug relay D Engine warning lamp D Diagnosis output Engine ECU L8 Timer piston position sensor L2 Crank angle sensor L9 EGR valve position sensor L10 Variable geometry control pressure sensor L6 Boost air temp...

Page 516: ...6 Fuel cut solenoid valve resistance Ω 6 8 9 2 Timing control valve resistance Ω 10 8 11 2 Timer piston position sensor resistance Ω Connector terminals No 1 No 2 160 168 Connector terminals No 1 No 3 80 84 Connector terminals No 2 No 3 80 84 Control sleeve position sensor resistance Ω Connector terminals No 4 No 12 11 2 12 4 Connector terminals No 4 No 8 5 6 6 2 Connector terminals No 8 No 12 5 6...

Page 517: ...B991348 Test harness set D Boost pressure sensor check D Variable geometry control pressure sensor check MB991658 Test harness set D APS adjustment D Checking using an analyzer MD998478 Test harness D Crank angle sensor check D Checking using an analyzer MD998388 Injection pump sprocket puller Fuel injection pump sprocket removal MB990767 End yoke holder Holding the fuel injection pump sprocket MD...

Page 518: ...Control sleeve position sensor Timer piston position sensor Main throttle solenoid valve GE actuator Variable geometry control pressure sensor Barometric pressure sensor Timing control valve Idle switch built in Engine ECU METHOD OF ERASING AND ERASING DIAGNOSIS CODES Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points INSPECTION USING MUT II DATA LIST AND ACTUATOR TESTING 1 Car...

Page 519: ...engine coolant temperature at 80_C However at 0_C during engine D Void EGR control Control sleeve position sensor D Engine controlled at low speed D Void EGR control D Void variable geometry turbo control Timer piston position sensor D Injection timing stabilizing control D Void EGR control Barometric pressure sensor ECU built in D Keep the barometric pressure at 101 kPa D Void EGR control D Void ...

Page 520: ...on sensor system 13I 18 26 Control sleeve position sensor system 13I 19 27 Accelerator pedal position sensor sub system 13I 20 41 Main throttle solenoid valve system 13I 21 43 Timing control valve system 13I 22 46 Injection correction ROM system 13I 23 48 GE actuator in the middle of control sleeve position sensor inoperative system 13I 24 49 Over boost variable geometry control pressure sensor sy...

Page 521: ... circuit or connector contact inoperative D Engine ECU inoperative OK Replace the engine ECU Check the harness between the engine ECU and the accelerator pedal position sensor connector NG Repair NG OK Check the trouble symptoms Replace the engine ECU NG OK Replace the engine ECU Repair NG NG Check the harness between the engine ECU and the accelerator pedal position sensor connector OK Check the ...

Page 522: ...vacuum hose between the boost pressure sensor and the intake manifold OK Repair NG NG Repair Check the harness between the engine ECU and the boost pressure sensor connector Check the trouble symptoms OK Replace the engine ECU OK Repair NG NG Check the harness between the engine ECU and the boost pressure sensor connector Check the trouble symptoms OK NG Repair Check the following connector C 97 N...

Page 523: ...ring engine cranking Set Conditions D The sensor output voltage for 3 seconds is 0 2 V or lower the fuel temperature is approximately 125 C or higher or D The sensor output voltage for 3 seconds is 4 6 V or higher the fuel temperature is approximately 47 C or lower D Fuel temperature sensor inoperative D Fuel temperature sensor open circuit short circuit or connector contact inoperative D Engine E...

Page 524: ...ck the harness between the engine ECU and the engine coolant temperature sensor connector Check the trouble symptoms Replace Code No 16 Boost air temperature sensor intake air sensor system Probable cause Range of Check D Ignition switch ON except for during engine cranking Set Conditions D The sensor output voltage for 3 seconds is 4 6 V or higher the intake air temperature is approximately 45_C ...

Page 525: ...trouble symptom NG Repair 2 NG Check the harness wire between the combination meter and the earth and repair if necessary Replace the engine ECU OK Repair NG NG Check the harness wire between the engine ECU and the combination meter connector OK Check the trouble symptoms OK Measure at the combination meter connector C 06 C 07 D Disconnect the connector and measure at the harness side 1 Voltage be...

Page 526: ...ircuit or poor sensor contact D Engine ECU inoperative NG Replace the engine ECU OK Check trouble symptoms NG Repair NG Check the harness between the engine ECU and the pump speed sensor connector and repair if necessary OK Replace the injection pump OK Measure at engine ECU connector C 51 D Connect the connector D Voltage between 51 61 Engine idling and then raced OK Voltage increases from the vo...

Page 527: ...le sensor connector A 121 D Connect the connector Test harness MB998478 used D Voltage between 2 black clip and the earth OK 0 4 4 0 V Engine cranking 1 5 2 5 V Engine idling NG Replace the crank angle sensor Replace the engine ECU Check the following connector C 95 NG NG Check the trouble symptoms OK Repair Check the following connector C 97 NG OK Repair NG Check the harness between the engine EC...

Page 528: ...pedal position sensor open circuit short circuit or connector contact inoperative D Idle switch ON inoperative D Idle switch signal line short circuit D Engine ECU inoperative OK Measure at C 122 accelerator pedal position sensor connector D Disconnect the connector and measure at the harness side D Voltage between 4 and the earth Ignition switch ON OK 4 5 5 5 V D Continuity between 5 and the eart...

Page 529: ... input pulse signal converted in the engine ECU and cannot be measured Replace injection pump assembly timer piston fully closed opened position inoperative etc NG NG OK OK NG Check the following connector C 97 NG Repair OK Repair NG Timer piston position sensor check Refer to P 13I 63 NG NG OK NG Check the trouble symptoms Replace injection pump assembly Check the following connector A 119 OK Rep...

Page 530: ...nput pulse signal converted in the engine ECU and cannot be measured OK NG Check the following connector C 97 NG Repair OK Repair NG Control sleeve position sensor check Refer to P 13I 63 NG NG OK NG Check the trouble symptoms Replace injection pump assembly Check the following connector A 120 OK Replace the engine ECU NG MUT II Data list 17 Control sleeve position sensor target value Refer to P 1...

Page 531: ...in output voltage is 1 875 V or higher D Accelerator pedal position sensor inoperative D Accelerator pedal position sensor open circuit short circuit or connector contact inoperative D Engine ECU inoperative OK Measure at C 122 accelerator pedal position sensor connector D Disconnect the connector and measure at the harness side D Voltage between 8 and the earth Ignition switch ON OK 4 5 5 5 V D C...

Page 532: ...g connector C 95 NG Repair OK Check and repair the harness between the control relay and the solenoid valve connector Check the trouble symptoms NG NG OK Measure at A 115 throttle solenoid valve connector D Disconnect the connector and measure at the harness side D Voltage between 2 and the earth Ignition switch ON OK System voltage OK Replace Throttle body actuator check Refer to P 13I 64 NG OK T...

Page 533: ...Check the following connector C 49 Check the trouble symptoms NG NG NG Check the following connector A 120 NG Repair OK Check the trouble symptoms NG NG Measure at C 49 engine ECU connector D Disconnect the connector and measure at the harness side D Voltage between 3 and the earth Ignition switch ON OK 11 V or higher OK Measure at A 120 injection pump assembly connector D Disconnect the connector...

Page 534: ...e following connector C 51 NG Repair OK Check the trouble symptoms NG Measure at A 117 injection correction ROM connector D Disconnect the connector and measure at the harness side D Voltage between 3 and the earth Ignition switch ON OK 4 5 5 5 V D Continuity between 4 and the earth OK Continuity Check the harness between the engine ECU and the injection correction ROM connector OK Replace the eng...

Page 535: ...tuator check Refer to P 13I 63 Replace the engine ECU OK Repair Check the following connector C 49 Check the trouble symptoms NG NG NG Check the following connector A 120 NG Repair OK Check the trouble symptoms NG NG Measure at C 49 engine ECU connector D Disconnect the connector and measure at the harness side D Voltage between 1 and the earth Ignition switch ON OK 9 V or higher OK Measure at A 1...

Page 536: ...able geometry solenoid valve check Refer to GROUP 15 On vehicle Service Check the trouble symptoms NG NG Check the following connector A 114 NG Repair OK Check the trouble symptoms NG NG Measure at C 49 engine ECU connector D Disconnect the connector and measure at the harness side D Voltage between 17 and earth Ignition switch ON OK System voltage OK Measure at A 114 variable geometry solenoid va...

Page 537: ...CU and the EGR valve position sensor connector EGR valve position sensor check Refer to P 13I 62 OK Replace Check the following connector C 97 Check the trouble symptoms NG NG Check the following connector A 122 NG Repair OK Check the trouble symptoms NG NG Measure at C 97 engine ECU connector D Connect the connector D Voltage between 1 and earth OK 0 4 0 6 V Ignition switch ON 4 1 4 8 V When 60 k...

Page 538: ...ble symptoms OK Replace the engine ECU OK Repair NG NG Check the harness between the engine ECU and the variable geometry control pressure sensor connector Check the trouble symptoms OK NG Repair Check the following connector C 51 NG Repair OK OK OK Check the following connector A 113 NG NG NG Check the following connector A 113 Measure at A 113 variable geometry control pressure sensor connector ...

Page 539: ...the engine radio interference may cause this code to be displayed 2 This code may be displayed when registering the key encrypted code Is there another ignition key near the ignition key that is inserted in the ignition switch Yes Remove the extra ignition key No Check the following connectors C 19 C 36 C 51 NG Repair No Is a diagnosis code output from the immobilizer ECU Yes Check the immobilizer...

Page 540: ... when the engine is cold difficult to start 6 13I 32 Starting performance is bad regardless of when the engine is hot or cold difficult to start 7 13I 33 Idling stability idling inoperative Low idling speed when the engine is cold improper idling speed 8 13I 33 g High idling speed improper idling speed 9 13I 33 Low idling speed improper idling speed 10 13I 34 Idling instable rough idling hunting 1...

Page 541: ...ontinuity between 4 and the earth D Continuity between 5 and the earth OK Continuity NG OK Check the trouble symptoms NG Repair Check the following connector C 86 INSPECTION PROCEDURE 2 No communication can be established between MUT II and the engine ECU Probable cause Probable causes are shown in the following D The power is not supplied to the engine ECU D The earth circuit of the engine ECU in...

Page 542: ... at C 49 engine ECU connector D Disconnect the connector and measure at the harness side D Short circuit between 8 and the earth Ignition switch ON OK The engine warning lamp turns on OK Check the following connector C 49 NG Repair MUT II Data list 11 Engine ECU power supply voltage Refer to P 13I 42 NG The engine ECU power supply and the earth circuit check Refer to P 13I 39 Inspection procedure ...

Page 543: ...pressure D Existence of mixing foreign objects water kerosene with the fuel INSPECTION PROCEDURE 6 Starting performance is bad when the engine is cold unable to start Probable cause Probable causes can be found in troubles with control system injection pump fuel system intake system and glow system D Control system inoperative D Injection pump inoperative D Fuel system inoperative D Intake system ...

Page 544: ...ng speed when the engine is cold improper idling speed Probable cause Probable causes can be found in troubles with control system injection pump and fuel system D Control system inoperative D Injection pump inoperative D Fuel system inoperative D Engine ECU inoperative NG Repair MUT II Self Diag code Is a diagnosis code output YES Inspection chart for diagnosis codes Refer to P 13I 9 NO Conduct M...

Page 545: ... D Glow system inoperative D EGR system inoperative D Engine ECU inoperative NG Repair MUT II Self Diag code Is a diagnosis code output YES Inspection chart for diagnosis codes Refer to P 13I 9 NO Conduct MUT II Data list check and an actuator test Refer to P 13I 42 46 OK Inspect the following items in order D Glow plug glow plug relay D EGR system D Injection nozzle D Compression pressure D Valve...

Page 546: ...l system inoperative D Intake system inoperative D EGR system inoperative D Engine ECU inoperative NG Repair MUT II Self Diag code Is a diagnosis code output YES Inspection chart for diagnosis codes Refer to P 13I 9 NO Conduct MUT II Data list check and an actuator test Refer to P 13I 42 46 OK Inspect the following items in order D Injection nozzle fuel filter D Throttle body assembly D EGR system...

Page 547: ...ystem and glow system D Control system inoperative D Injection pump inoperative D Fuel system inoperative D Intake system inoperative D EGR system inoperative D Glow system inoperative D Engine ECU inoperative NG Repair MUT II Self Diag code Is a diagnosis code output YES Inspection chart for diagnosis codes Refer to P 13I 9 NO Conduct MUT II Data list check and an actuator test Refer to P 13I 42 ...

Page 548: ...nnect the connector and measure at the harness side D Check the A C condenser fan condition Ignition switch ON OK Fan stopped D Voltage between 7 and the earth Ignition switch ON OK System voltage D Short out 7 and the earth Ignition switch ON OK A C condenser fan turns NG A C condenser fan motor circuit check Refer to the wiring harness configuration diagram OK MUT II Data List 02 Engine coolant ...

Page 549: ...erative Check the following connector C 49 NG Measure at C 49 engine ECU connector D Disconnect the connector and measure at the harness side D Check the intercooler fan condition Ignition switch ON OK Fan stopped D Voltage between 6 and earth Ignition switch ON OK System voltage D Short out 6 and the earth Ignition switch ON OK Intercooler fan turns NG Intercooler fan circuit check Refer to the w...

Page 550: ...N OK System voltage 2 Voltage between 46 and the earth Vehicles with immobilizer system Voltage between 38 and the earth Vehicles without immobilizer system OK System voltage 3 Voltage between 12 25 and the earth Ignition switch ON OK System voltage When terminal 38 ve hicles without immobilizer system 46 vehicles with immobilizer system is short circuited to the earth 4 Continuity between 13 26 a...

Page 551: ...ON OK System voltage NG Replace the engine ECU NG Check the trouble symptoms OK Repair Check the following connector C 49 OK INSPECTION PROCEDURE 24 EGR control solenoid valve No 2 circuit inspection NG Check the harness between the engine ECU and the EGR control solenoid valve No 2 connector and repair if necessary OK Check the trouble symptoms OK Measure at EGR control solenoid valve No 2 connec...

Page 552: ...6 Glow System NG Replace Check glow plug relay connector A 88 and repair if necessary OK OK Check the harness between the engine ECU and the glow plug relay connector NG Repair INSPECTION PROCEDURE 26 A C switch and A C relay inspection Replace the engine ECU OK Check the trouble symptoms Measure at engine ECU connector C 49 D Disconnect the connector and measure at the harness side D Voltage betw...

Page 553: ...s 20_C 20_C When the engine coolant temperature is 40_C 40_C When the engine coolant temperature is 80_C 80_C 03 Barometric Ignition switch ON Altitude 0 m 101 kPa Code No 13 13I 12 pressure sensor g Altitude 600 m 95 kPa 13 sensor Altitude 1 200 m 88 kPa Altitude 1 800 m 81 kPa 04 Boost press re D Engine coolant temperat re Altitude 0 m 101 kPa Code No 12 13I 11 pressure sensor temperature 80 95_...

Page 554: ...N System volt age Procedure No 21 13I 39 13 Timing t l Engine After warming th i Idling 70 90 Code No 25 N 13I 18 g control valve 1 g g up the engine When engine is suddenly raced Changes 25 or No 43 13I 22 14 EGR com d l Engine After warming th i Idling 0 100 2 mand value g g up the engine When engine is suddenly raced Momentarily decreases 17 Control sleeve posi Engine After warming up the engin...

Page 555: ... increases NOTE 1 The opening degree of the timing control valve is converted into percentage 0 timer non advanced angle 100 timer maximum advanced angle 2 The opening degree of the EGR solenoid valve is converted into percentage SWITCH Item No Check item Inspection conditions Value to be determined as normal Code No or inspec tion proce dure No Reference page 41 Idle switch Ignition switch ON che...

Page 556: ...sor or actuator is failed ON 41 55 Engine warning l D Ignition switch ON D Select actuator t t it N 16 Engine warning lamp off OFF Procedure No 3 13I 31 g lamp test item No 16 Engine warning lamp is forced on ON 56 Glow lamp D Ignition switch ON D Select actuator Glow lamp off OFF D Select actuator test item No 15 Glow lamp is forced on ON 58 Neutral s itch Ignition switch ON N P range N P switch ...

Page 557: ... from ON to OFF plug relay is ON 03 A C compressor relay Turning the relay from Ignition switch ON The A C compressor clutch makes an Procedure No 26 13I 41 relay relay from OFF to ON or from ON to ON clutch makes an audible sound No 26 from ON to OFF 11 Timing control valve Turn the timing control valve to ON D Ignition switch ON D Engine Idling Makes an audible sound Code No 43 13I 22 12 Turn th...

Page 558: ...or Hold the injection governor in its middle position D Ignition switch ON When the crankshaft is turned clockwise during the adjustment of the injection timing the injection pipes spray out fuel Code No 48 13I 24 35 Variable geometry solenoid valve 4WD Turn the solenoid valve to ON Ignition switch ON Makes an audible sound Code No 49 13I 25 36 4WD Turn the solenoid valve to OFF Engine Idling Oper...

Page 559: ...accelerator pedal is fully depressed D When engine speed is 2 700 r min or higher and vehicle speed is 140 km h or higher D Engine coolant temperature 112_C or higher Accelerator pedal is released during one of the above System voltage 6 Intercooler fan relay Ignition switch ON Boost air temperature at 45_C or lower System voltage Boost air temperature at 60_C or higher 0 1 V 7 Condenser fan relay...

Page 560: ...edal Idling position 0 9 1 1 V Accelerator pedal Fully opened position 3 7 V or higher 60 Sensor power supply Ignition switch ON 4 6 5 4 V 71 Ignition switch ST Engine Cranking 8 V or higher 80 Back up power supply Ignition switch OFF System voltage 81 Power supply to accel erator pedal position sensor 1st channel Ignition switch ON 4 6 5 4 V 82 Ignition switch IG Ignition switch ON System voltage...

Page 561: ...king brake OFF System voltage CHECK CHART FOR RESISTANCE AND CONTINUITY BETWEEN TERMINALS 1 Turn the ignition switch to OFF 2 Disconnect the engine ECU connector 3 Measure the resistance and check for continuity between the terminals of the engine ECU harness side connector while referring to the check chart NOTE 1 When measuring resistance and checking continuity a harness for checking contact pi...

Page 562: ...valve No 2 36 44 Ω at 20_C 9 12 EGR control solenoid valve No 1 36 44 Ω at 20_C 13 Body earth Engine ECU earth Continuity 0 Ω 26 Body earth 14 12 Throttle solenoid valve 29 35 Ω at 20_C 31 61 Idle switch Continuity Replace the foot from the accelerator pedal No continuity when accelerator pedal is fully depressed 51 61 Pump speed sensor 1 36 1 84 kΩ 73 74 Control sleeve position sensor 5 6 6 2 Ω 7...

Page 563: ...0_C 0 26 0 36 kΩ when the engine coolant temperature is 80_C 87 61 Fuel temperature sensor 5 1 6 5 kΩ when the fuel temperature is 0_C 2 1 2 7 kΩ when the fuel temperature is 20_C 0 9 1 3 kΩ when the fuel temperature is 40_C 0 26 0 36 kΩ when the fuel temperature is 80_C 88 61 Boost air temperature sensor 5 3 6 7 kΩ when the intake air temperature is 0_C 2 3 3 0 kΩ when the intake air temperature ...

Page 564: ...nnect the crank angle sensor connector and connect the special tool test harness MD998478 in between 2 Connect the analyzer probe to terminal No 2 of the crank angle sensor connector black clip of special tool NOTE D When measuring at the engine ECU connector connect the analyzer probe to terminal No 89 Standard Wave Pattern Observation conditions Crank angle sensor Probe select switch 1 TIME DIV ...

Page 565: ...n be calculated from the following formula Engine speed r min 2 4T sec 60 30 T sec Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased Examples of Abnormal Wave Patterns D Example 1 Cause of problem Sensor interface malfunction Wave pattern characteristics Rectangular wave pattern is output even when the engine is n...

Page 566: ...tool test harness MD991658 in between All terminals should be connected 2 Connect the analyzer probe to terminal No 1 of the pump speed sensor connector black clip of special tool NOTE D When measuring at the engine ECU connector connect the analyzer probe to terminal No 51 Standard Wave Pattern Observation conditions Pump speed sensor Probe select switch Set according to the probe TIME DIV About ...

Page 567: ...rmula Engine speed 2 4 T sec 60 Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased Examples of Abnormal Wave Patterns D Example 1 Cause of problem Malfunction or open circuit in sensor Wave pattern characteristics No signal is output even when engine is started D Example 2 Cause of problem Incorrect gap between sen...

Page 568: ...njection initial pressure 14 710 15 490 kPa 4 If the fuel injection initial pressure is outside the standard value disassembly the nozzle holder to clean it and then change the thickness of the shim to adjust the fuel injection initial pressure NOTE 1 For disassembly reassembly and adjustment of the nozzle holder refer to P 13B 8 2 There are 10 shims for adjustment with thicknesses in the range of...

Page 569: ...usted in the factory Therefore APS should not be moved carelessly 2 If the adjustment is not done correctly carry out a new adjustment in the following procedure 1 Connect MUT II to the diagnosis connector If MUT II is not used the following operation should be done 1 Disconnect APS connector and connect the special tool test harness MB991658 between two connectors Be careful not to take a wrong t...

Page 570: ...d the terminal No 3 APS main output as well as the resistance between terminal No 8 APS sub power supply and terminal No 6 APS sub output Normal condition Step on the accelerator pedal slowly Resistance smoothly changes in proportion to the travel of the accelerator pedal 4 If the APS is out of the range of the standard value or the resistance does not change smoothly replace APS NOTE Make an adju...

Page 571: ...2 3 3 0 kΩ at 20_C 0 30 0 42 kΩ at 80_C 3 Measure the resistance at the sensor part being warmed up by a hair dryer Normal condition Temperature _C Resistance value kΩ Rising Become smaller 4 If the resistance is not within the range of the standard value or does not change at all replace the boost air temperature sensor NOTE Replace the gasket as well 5 Tighten the boost air temperature sensor to...

Page 572: ...e the engine coolant temperature sensor 4 Apply the sealant to the thread of the engine coolant temperature sensor and tighten it to the specified torque Sealant 3M Nut Locking Part No 4171 or equivalent Tightening torque 36 6 N m EVACUATION OF WATER FROM FUEL FILTER Refer to GROUP 13E of the 97 L200 Workshop Manual Pub No PWTE96E1 EVACUATION OF AIR FROM FUEL FILTER Refer to GROUP 13E of the 97 L2...

Page 573: ...standard value or if it doesn t change smoothly replace the EGR valve position sensor FUEL INJECTION PUMP CHECK FUEL CUT SOLENOID VALVE CHECK Operation noise check 1 Attach the sound scope to the fuel cut solenoid valve to check for running noise when the ignition switch is ON Coil resistance check 1 Disconnect the injection pump connector 12 pin 2 Measure the resistance between terminal No 1 fuel...

Page 574: ...lue Terminal No 4 Terminal No 12 11 2 12 4 Ω Terminal No 4 Terminal No 8 5 6 6 2 Ω Terminal No 8 Terminal No 12 5 6 6 2 Ω TIMER PISTON POSITION SENSOR CHECK 1 Disconnect the timer piston position sensor connector 2 Measure the resistance between the following terminals Standard value Terminal No 1 Terminal No 2 160 168 Ω Terminal No 1 Terminal No 3 80 84 Ω Terminal No 2 Terminal No 3 80 84 Ω PUMP ...

Page 575: ...ve pressure to check the air tightness Standard value Jumper lead Nipple A Normal condition Connected Open Negative pressure leaks Closed Negative pressure maintained Disconnected Open Negative pressure maintained COIL RESISTANCE CHECK 1 Measure the resistance between the solenoid valve terminals Standard value 29 35 Ω at 20_C THROTTLE ACTUATOR CHECK 1 Remove the vacuum hose yellow stripe from the...

Page 576: ...ESEL FUEL 4D5 Step III On vehicle Service 13I 65 VARIABLE GEOMETRY SOLENOID VALVE CHECK Refer to GROUP 15 On vehicle Service EGR CONTROL SOLENOID VALVE CHECK Refer to GROUP 17 Emission Control System 4D5 ...

Page 577: ...nd Battery Installation D Engine Coolant Refilling D Injection Timing Adjustment Refer to GROUP 11B On vehicle Service D Accelerator Cable and Throttle Cable Adjustment Refer to GROUP 23 On vehicle Service 1 11 3 4 5 6 7 8 9 10 2 5 0 1 0 N m 24 3 N m 19 3 N m 12 2 N m 10 2 N m 83 5 N m 5 0 1 0 N m 30 7 N m 30 7 N m 30 7 N m 16 2 N m 10 1 N m 22 3 N m Engine oil Removal steps 1 Accelerator cable co...

Page 578: ...ET REMOVAL 1 Use the special tool to stop the fuel injection pump sprocket from turning and remove the fuel injection pump sprocket mounting bolt 2 Use the special tool to remove the fuel injection pump sprocket Caution 1 Do not hit pump drive shaft with hammer etc 2 When holding injection pump do not allow to dangle by holding accelerator lever or fast idle lever Do not remove these levers Remova...

Page 579: ...NOTES ...

Page 580: ...ENGINE COOLING ...

Page 581: ......

Page 582: ...ted fin down flow type Items Specifications Radiator Performance kJ h 4G63 M T 114 700 4G63 A T 126 800 4G64 4D56 2WD 170 000 4D56 4WD 227 300 Automatic transmission oil cooler Performance kJ h 4G63 A T 6 400 4D56 A T 6 300 SERVICE SPECIFICATIONS 14100030121 Items Standard value Limit High pressure valve opening pressure of radiator cap kPa 75 105 65 Range of coolant antifreeze concentration of ra...

Page 583: ... PRESSURE CHECK 14100130111 1 Use a cap adapter to attach the cap to the tester 2 Increase the pressure until the indicator of the gauge stops moving Limit 65 kPa Standard value 75 105 kPa 3 Replace the radiator cap if the reading does not remain at or above the limit NOTE Be sure that the cap is clean before testing since rust or other foreign material on the cap seal will cause an improper indic...

Page 584: ... until the thermostat opens Touch the radiator hose with your hand to check that warm water is flowing 13 After the thermostat opens race the engine several times and then stop the engine 14 Cool down the engine and then pour engine coolant into the reserve tank until the level reaches the FULL line If the level is low repeat the operation from step 11 CONCENTRATION MEASUREMENT 14100110146 Measure...

Page 585: ...on D Engine Coolant Draining and Supplying Refer to P 14 3 D Radiator Upper Hose Removal and Installation Refer to P 14 14 9 8 12 Nm 1 2 3 4 5 6 9 8 12 Nm 4 9 Nm 12 Nm 4 9 Nm 12 Nm 12 Nm 2 4 3 5 6 4G6 4D56 1 Removal steps 1 Radiator upper shroud 2 Drive belts 3 Cooling fan and fan clutch 4 Pulley 5 Fan Clutch 6 Cooling fan ...

Page 586: ...maged or cracked replace cooling fan FAN CLUTCH CHECK D Check to ensure that fluid in fan clutch is not leaking at case joint and seals If fluid quantity decreases due to leakage fan speed will decrease and engine overheating might result D When a fan attached to an engine is turned by hand it should give a sense of some resistance If fan turns lightly it is faulty D Check bimetal strip for damage...

Page 587: ...ng 5 Water inlet fitting gasket 4D56 AA 6 Thermostat INSTALLATION SERVICE POINTS AA THERMOSTAT INSTALLATION 4G6 Install the thermostat so that the jiggle valve is facing straight up while being careful not to fold over or scratch the rubber ring Caution Make absolutely sure that no oil is adhering to the rubber ring of the thermostat In addition be careful not to fold over or scratch the rubber ri...

Page 588: ...dust etc INSPECTION 14100250190 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 82 1 5_C 2 Check that the amount of valve lift is at the standard value when the water is at the full opening temperature Standard value Items 4G6 and 4D56 4WD 4D56 2WD Full opening temperature _...

Page 589: ...4D56 1 2 3 4 5 6 24 Nm 12 15 Nm 7 4WD 2WD 24 Nm 12 15 Nm 24 Nm 12 15 Nm 12 15 Nm 12 15 Nm 12 15 Nm 3 4 1 2 5 Removal steps 4G6 1 Alternator brace BA 2 Water pump assembly 3 Water pump gasket AA 4 O ring 4D56 D Air intake hose Refer to GROUP 15 Air Cleaner D Thermostat Refer to P 14 7 AA 1 Power steering oil pump 2 Power steering oil pump bracket 3 Thermostat housing 4 Thermostat housing gasket BA ...

Page 590: ...INTS AA O RING INSTALLATION Rinse the mounting location of the O ring and water pipe with water and install the O ring and water pipe Caution 1 Care must be taken not to permit engine oil or other greases to adhere to the O ring 2 When inserting the pipe check to be sure that there is no sand dirt etc on its inner surface BA WATER PUMP ASSEMBLY INSTALLATION No Hardness category Head mark Bolt diam...

Page 591: ... and Supplying Refer to P 14 3 D Thermostat Removal and Installation Refer to P 14 7 D Exhaust Manifold Removal and Installation Refer to GROUP 15 24 Nm 1 2 3 4 5 6 Sealant Mitsubishi Genuine Parts No MD970389 or equivalent 13 Nm 48 Nm 24 Nm 6 6 6 2 1 Removal steps 1 Water bypass fitting 2 Water hose 3 Water pipe assembly 4 Thermostat housing assembly 5 Water inlet pipe AA 6 O ring ...

Page 592: ...Intake Exhaust Manifold Removal and Installation Refer to GROUP 15 42 Nm 2WD 4WD 1 2 3 4 5 6 7 8 9 10 11 12 13 9 8 Nm 12 15 Nm 9 8 12 Nm 42 Nm 12 15 Nm 9 8 12 Nm 13 1 12 4 3 4 1 5 6 Removal steps 1 Heater hose connection 2 Vacuum pipe installation bolt 3 Cable band 4 Water hose 5 Eye bolt 6 Gasket 7 Water pipe assembly A 8 Water hose 9 Water pipe assembly B 10 Water hose 11 Water pipe assembly C 1...

Page 593: ... O ring to pipe and coat the outer circumference of the O ring with water Caution Care must be taken not to permit engine oil or other greases to adhere to the o ring INSPECTION 14100340132 WATER PIPE AND HOSE CHECK Check the water pipe and hose for cracks damage clog and replace them if necessary Pipe O ring ...

Page 594: ...o GROUP 23 On vehicle Service 4G6 4D56 2WD 4D56 4WD 1 2 3 4 5 6 7 8 4 9 Nm 12 Nm 4 9 Nm 4 9 Nm 4 9 Nm 4 9 Nm 4 9 Nm 12 Nm 12 Nm 12 Nm 1 2 5 6 7 8 Radiator removal steps 1 Rubber hose connection 2 Radiator upper hose connection 3 Radiator upper shroud 4 Radiator lower shroud 5 Radiator lower hose connection AA 6 Transmission fluid cooler hose con nection A T 7 Radiator assembly Reserve tank removal...

Page 595: ...NG Radiator 14 15 REMOVAL SERVICE POINT AA TRANSMISSION FLUID COOLER HOSE REMOVAL After removing the hose from the radiator plug the hose and the radiator nipple to prevent dust or foreign particles from getting in ...

Page 596: ...NOTES ...

Page 597: ......

Page 598: ...tline of Change 2 GENERAL SPECIFICATIONS 4D56 Step III 2 SERVICE SPECIFICATION 4D56 Step III 2 COOLING FAN 4D56 Step III 3 THERMOSTAT 4D56 Step III 4 WATER PUMP 4D56 Step III 5 WATER HOSE AND WATER PIPE 4D56 Step III 7 RADIATOR 4D56 Step III 8 ...

Page 599: ...dditional turbocharger the thermostat of vehicle with 2WD has been modified to the thermostat of vehicle with 4WD D With additional or modifiable turbocharger and additional EGR cooler the water hose and pipe have been changed D To improve the cooling performance the radiator has been modified GENERAL SPECIFICATIONS 4D56 Step III Items Specifications Radiator Performance kJ h 2WD M T 201 768 2WD A...

Page 600: ...Engine Coolant Draining Post installation Operation D Engine Coolant Refilling D Drive Belt Tension Adjustment 5 0 1 0 N m 5 0 1 0 N m 1 2 3 4 3 5 6 7 8 2WD 4WD 11 1 N m 11 1 N m Removal steps 1 Radiator upper hose 2 Cover 4WD 3 Radiator Shroud 4 Drive belts 5 Cooling fan and fan clutch 6 Fan clutch 7 Cooling fan 8 Pulley ...

Page 601: ...at the standard value when the water is at the full opening temperature Standard value Items 4D56 Step III Full opening temperature _C 95 Amount of valve lift mm 8 5 or more NOTE Measure the valve height when the thermostat is fully closed and use this measurement to calculate the valve height when the thermostat is fully open Valve lift ...

Page 602: ... N m 22 4 N m Removal steps AA 1 Power steering oil pump 2 Power steering oil pump bracket 3 Water pipe E and hose assembly BA 4 O ring 5 Thermostat housing 6 Thermostat housing gasket AA 7 Water pump assembly 8 Gasket REMOVAL SERVICE POINT AA POWER STEERING OIL PUMP REMOVAL 1 Remove the power steering oil pump from the bracket with the hose still attached 2 Place the power steering oil pump somew...

Page 603: ...8 x 25 3 7T 8 x 70 BA O RING INSTALLATION Rinse the mounting location of the O ring and water pipe with water and install the O ring and water pipe Caution 1 Care must be taken not to permit engine oil or other greases to adhere to the O ring 2 When inserting the pipe check to be sure that there is no sand dirt etc on its inner surface d l 1 1 2 3 Thermostat housing Water pipe O ring ...

Page 604: ...oval and Installation Refer to GROUP 17 D Intake Exhaust Manifold Removal and Installation Refer to GROUP 15 D Injection Pipe Removal and Installation 1 2 3 4 5 6 7 14 1 N m 11 1 N m 14 1 N m 14 1 N m 1 Removal steps 1 Heater hose connection 2 Water hose 3 Water pipe B 4 Water hose turbocharger return AA 5 Water hose EGR cooler return 6 Water pipe C 7 Water pipe D INSTALLATION SERVICE POINT AA WAT...

Page 605: ...5 0 1 0 N m 5 0 1 0 N m 5 0 1 0 N m Radiator removal steps 1 Rubber hose connection 2 Radiator upper hose connection 3 Cover 4WD 4 Radiator shroud 5 Radiator lower hose connection AA 6 Transmission fluid cooler hose connection A T 7 Radiator assembly Reserve tank removal steps 1 Rubber hose connection 8 Reserve tank assembly REMOVAL SERVICE POINT AA TRANSMISSION FLUID COOLER HOSE REMOVAL After rem...

Page 606: ...INTAKE AND EXHAUST ...

Page 607: ......

Page 608: ...at full acceleration can be done with safety Two person should be in the vehicle when the test is conducted the person in the passenger seat should read the indications shown by the pressure meter 1 Remove the boost compensator hose from the fuel injection pump and install a pressure gauge as shown in the illustration 2 Drive at full throttle acceleration in second gear and then measure the superc...

Page 609: ...pprox 1 mm stroke the waste gate actuator rod Standard value Approx 83 kPa Caution In order to avoid damage to the diaphragm do not apply a pressure of 91 kPa or higher 3 If there is a significant deviation from the standard value check the actuator or the waste gate valve replace if necessary POWER RELAY CHECK 15100620011 INTERCOOLER FAN MOTOR RELAY CONTINUITY CHECK Battery voltage Terminal No 1 ...

Page 610: ...ON 4 Nm 4 Nm 8 9 Nm 4G63 4G64 4 Nm 9 Nm 9 Nm 4 Nm 9 Nm 7 6 2 1 4 3 5 9 9 Nm 9 Nm 8 7 6 2 1 4 9 5 Removal steps 1 Breather hose connection 2 Air intake hose 3 Resonator 4G63 4 Resonator 5 Air duct 6 Air flow sensor assembly 7 Air cleaner cover 8 Air cleaner element 9 Air cleaner body ...

Page 611: ...D 4 Nm 7 6 3 4 9 Nm 9 Nm 9 Nm 4 Nm 4 Nm 4 Nm 4 Nm 4 Nm 4 Nm 2 0 Nm 2 1 9 8 7 6 5 2 3 1 9 5 Removal steps 1 Air intake hose A 2 Breather hose connection 3 Air intake hose B 4 Resonator 2WD 5 Air cleaner cover 6 Bolt 7 Air cleaner element 8 Air cleaner body 9 Air cleaner bracket ...

Page 612: ... 9 8 8 7 4 5 9 Nm 9 Nm Intercooler fan ECU removal steps 1 Scuff plate 2 Cowl side trim 3 Intercooler fan ECU Intercooler removal steps 4 Intake air temperature switch connector 5 Intercooler fan motor connector 6 Air hose B connection Intake manifold side 7 Air hose A 2 connection Turbochar ger side 8 Front bracket 9 Intercooler and bracket assembly ...

Page 613: ...bly steps 1 Air hose A 2 2 Blanch tube 3 Blanch tube bracket 4 Intercooler cover 5 Air hose A 1 6 Air hose B 7 Intake air temperature switch 8 Intercooler bracket 9 Fan and motor assembly 10 Intercooler INSPECTION 15100430027 D Check the intercooler fins for bending damage or foreign matter D Check the intercooler hoses for cracking damage or wear ...

Page 614: ...emperature switch in the hot water shown in the figure 2 When changing the water temperature check for continuity between the terminals with the circuit tester Standard value Temperature Continuity Less than 55 _C Temperature at point A OFF No continuity More than 57 _C Temperature at point B ON Continuity ON OFF Water temperature B A ...

Page 615: ...stallation D Air Cleaner Installation Refer to P 15 4 20 Nm 14 Nm O ring Sealant MITSUBISHI GENUINE PART MD970389 or equivalent Engine Oil 5 Nm 12 Nm 20 Nm 22 Nm 6 4 1 8 6 2 3 7 5 13 10 4 11 12 f 3 9 Removal steps 1 Throttle body Refer to GROUP 13A Throttle Body 2 PCV hose 3 Brake booster vacuum hose connection 4 Water outlet fitting 5 Vacuum hose connection AA 6 High pressure fuel hose connection...

Page 616: ... to the O ring and then insert the high pressure fuel hose being careful not to damage the O ring Caution Be careful not to let any engine oil get into the delivery pipe INSPECTION 15100310161 Check the following points replace the part if a problem is found INTAKE MANIFOLD CHECK 1 Check for damage or cracking of any part 2 Check for obstruction of the negative pressure vacuum outlet port and for ...

Page 617: ...18 Nm 18 Nm 18 Nm Removal steps 1 Vacuum pipe attaching bolt 2 Intake manifold 3 Heat protector 4 Exhaust manifold 5 Intake and exhaust manifold gasket INSPECTION 15100370022 Check the following points replace the part if a problem is found INTAKE AND EXHAUST MANIFOLD CHECK 1 Check for damage or cracking of any part 2 Using a straight edge and thickness gauge check for distortion of the cylinder h...

Page 618: ... P 15 4 D Intercooler Removal and Installation Refer to P 15 6 D Brake Master Cylinder Heat Protector Removal and Installation 43 Nm 9 Nm 6 18 Nm 19 Nm 9 Nm 17 Nm 42 Nm 30 Nm 4 2 5 10 12 11 7 1 3 9 18 Nm 9 Nm 18 Nm 8 Removal steps 1 Front exhaust pipe connection 2 Boost hose 3 Waste gate actuator 4 Heat protector A 5 Heat protector 6 Intake manifold 7 Water pipe B 8 Water pipe A 9 Oil pipe 10 Oil ...

Page 619: ...ation 2 Supply clean engine oil from the oil pipe mounting hole of the turbocharger assembly Caution When cleaning take care that no foreign material gets into the engine coolant or oil passages hole INSPECTION 15100640017 TURBOCHARGER ASSEMBLY CHECK D Visually check the turbine wheel and the compressor wheel for cracking or other damage D Check whether the turbine wheel and the compressor wheel c...

Page 620: ...t Manifold 4D56 4WD 15 14 OIL PIPE AND OIL RETURN PIPE CHECK 15100650010 Check the oil pipe and oil return pipe for clogging bending or other damage If there is clogging clean it EXHAUST MANIFOLD CHECK 15100340108 Damage or cracking of any part ...

Page 621: ... AA CA 3 Snap ring AB BA 4 Turbine wheel assembly 5 Compressor cover AA 6 O ring DISASSEMBLY SERVICE POINTS AA SNAP RING REMOVAL Lay the unit with the compressor cover side facing down and using snap ring pliers remove the compressor cover attaching snap ring Caution When removing the snap ring hold it with fingers to prevent it from springing away Snap ring ...

Page 622: ...y a light coat of engine oil to a new O ring and fit in the turbine wheel assembly groove Caution When installing the O ring use care not to damage it A damaged O ring causes oil leaks BA TURBINE WHEEL ASSEMBLY 1 Apply a light coat of engine oil to the periphery of the O ring 2 Install the turbine wheel assembly to the compressor cover in relation to the dowel pin Caution Use care not to damage th...

Page 623: ...osed smoothly COMPRESSOR COVER Check the compressor cover for traces of contact with the compressor wheel and other damage TURBINE WHEEL ASSEMBLY 1 Check the turbine and compressor wheel blades for bend burr damage corrosion and traces of contact on the back side and replace if defective 2 Check the oil passage of the turbine wheel assembly for deposit and clogging 3 In the case of water cooled ty...

Page 624: ... 1 Exhaust Manifold mounting bolt tightening torque 29 Nm 49 Nm 2 3 4 3 Removal steps 1 Heat protector 2 Engine hanger 3 Exhaust manifold 4 Exhaust manifold gasket INSPECTION 15100340115 Check the following points replace the part if a problem is found EXHAUST MANIFOLD CHECK 1 Check for damage or cracking of any part 2 Using a straight edge and a thickness gauge check for distortion of the cylinde...

Page 625: ...44 Nm 50 Nm 13 Nm 25 Nm 12 16 10 13 11 8 7 2 4 3 5 3 6 1 7 8 9 17 15 14 13 Nm 3 7 14 Main muffler removal steps 1 Bolt 2 Main muffler 3 Hanger 4 Heat protector 5 Hanger bracket 6 Rear body floor heat protector Main muffler removal steps 1 Bolt 7 Hanger 8 Heat protector 9 Center exhaust pipe 10 Nut 11 Catalytic converter 12 Front floor heat protector B Front exhaust pipe removal steps 10 Nut 13 Oxy...

Page 626: ...moval steps 1 Bolt 2 Main muffler 3 Hanger 4 Heat protector 5 Hanger bracket Center exhaust pipe removal steps 1 Bolt 6 Hanger 7 Heat protector 8 Center exhaust pipe 9 Bolt 4D56 or nut 4G64 10 Catalytic converter 11 Front floor heat protector B Front exhaust pipe removal steps 9 Bolt 4D56 or nut 4G64 12 Oxygen sensor 13 Hanger 14 Heat protector 15 Exhaust support bracket 16 Front exhaust pipe 17 F...

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Page 628: ......

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Page 632: ...rger Supercharging Pressure Check 3 Supercharging Pressure Control System Check 4 Variable Geometry Actuator Check 5 Variable Geometry Solenoid Valve Check 5 Waste Gate Actuator Check 6 AIR CLEANER 4D56 Step III 6 INTERCOOLER 4D56 Step III 6 INTAKE AND EXHAUST MANIFOLD AND TURBOCHARGER 4D56 Step III 7 EXHAUST PIPE AND MAIN MUFFLER 4G64 11 ...

Page 633: ...ger With additional oxygen sensor by compatible emission regulation step III the service procedure of 4G64 engine that is different from previous service procedure has been established NOTE For description of structure and operation of VG Variable Geometry turbocharger refer to 02 MY PAJERO Workshop Manual SPECIAL TOOL 4G64 Tool Number Name Use MD998770 Oxygen sensor wrench Removal Installation of...

Page 634: ...ot become positive pressure check the following items D Malfunction of the waste gate actuator Step III compatible 4D56 2WD D Malfunction of the boost pressure sensor D Leakage of supercharging pressure D Malfunction of the turbocharger 5 When the indicated supercharging pressure is 133 kPa or more Step III compatible 4D56 4WD or 84 kPa or more Step III compatible 4D56 2WD supercharging control ma...

Page 635: ...Variable geometry actuator vacuum Supercharging pressure OFF 0 kPa Approximately 1 kPa ON Approximately 80 kPa Approximately 3 kPa NOTE 1 If the variable geometry actuator vacuum is not in a normal condition the variable geometry actuator variable geometry solenoid valve variable geometry control pressure sensor vacuum pump or hose may be faulty 2 If the variable geometry actuator vacuum is in a n...

Page 636: ...isconnecting the vacuum hose always make a mark so that it can be reconnected at original position 1 Disconnect the vacuum hose black red stripe from the solenoid valve 2 Disconnect the harness connector 3 Connect a hand vacuum pump to the nipple to which the red striped vacuum hose was connected 4 Check airtightness by applying a vacuum with voltage applied directly from the battery to the variab...

Page 637: ... the standard value check the actuator or the waste gate valve replace if necessary AIR CLEANER 4D56 Step III With additional turbocharger of the vehicle with 2WD the air cleaner is modified to the air cleaner of the vehicle with 4WD The service procedure is same as one of the vehicle with 4WD INTERCOOLER 4D56 Step III With additional air temperature sensor by adopting electronic controlled inject...

Page 638: ...oval and Installation Refer to P 15 6 D Air Cleaner Cover and Air Intake Hose Removal and Installation Refer to P 15 6 D EGR Valve and EGR Cooler Removal and Installation Refer to GROUP 17 2WD 18 2 N m 6 4 2 5 10 12 11 7 1 3 9 8 4 24 4 N m 14 1 N m 18 2 N m 13 18 2 N m 14 9 0 1 0 N m 42 7 N m 17 2 N m 20 4 N m 9 0 1 0 N m 18 2 N m 14 1 N m 42 7 N m 11 1 N m 16 15 17 18 19 20 21 22 23 24 12 1 N m 4...

Page 639: ...tector 15 Water pipe A and water hose assembly 16 Gasket 17 Oil pipe assembly 18 Gasket 19 Intake manifold 20 Exhaust manifold heat protector 21 Water pipe B connection 22 Gasket 23 Boost hose 24 Waste gate actuator 25 Front exhaust pipe connection 26 Gasket 27 Oil return hose connection 28 Exhaust manifold and turbocharger assembly 29 Intake and exhaust manifold gasket 30 Oil return hose 32 33 35...

Page 640: ...ion 6 Solenoid valve assembly 7 VG control pressure sensor connector 8 Vacuum hose connection 9 VG control pressure sensor 10 Air temperature sensor 11 Gasket 12 Air intake fitting 13 Gasket 14 Throttle body assembly 15 Gasket 16 Earth cable connection 17 Engine hanger 18 Turbocharger upper heat protector 19 Oil pipe assembly 20 Gasket 21 Vacuum hose connection 22 Intake manifold 23 Exhaust manifo...

Page 641: ...t manifold 39 Turbocharger gasket AA 40 Turbocharger assembly INSTALLATION SERVICE POINT AA TURBOCHARGER ASSEMBLY INSTALLATION 1 Clean the alignment surfaces shown in the illustration 2 Supply clean engine oil from the oil pipe mounting hole of the turbocharger assembly Caution When cleaning take care that no foreign material gets into the engine coolant or oil passages hole ...

Page 642: ... N m 24 5 N m 44 5 N m 44 5 N m Main muffler removal steps 1 Main muffler 2 Hanger 3 Heat protector Center exhaust pipe removal steps 4 Center exhaust pipe AA AA 5 Oxygen sensor 6 Hanger 7 Heat protector 8 Catalytic converter Front exhaust pipe removal steps AA AA 9 Oxygen sensor 10 Front exhaust pipe 11 Hanger 12 Heat protector 13 Exhaust support bracket REMOVAL SERVICE POINT AA OXYGEN SENSOR REM...

Page 643: ...NOTES ...

Page 644: ...ENGINE ELECTRICAL ...

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Page 646: ...d coil occurs When the stator coil begins to generate power after the engine is started the field coil is excited by the output current of the stator coil The alternator output voltage rises as the field current increases and it falls as the field current decreases When the battery voltage alternator S terminal voltage reaches a regulated voltage of approx 14 4 V the field current is cut off When ...

Page 647: ...0030149 Items Standard value Limit Alternator output line voltage drop at 30A V max 0 3 Regulated voltage ambient temp at voltage regulator V 20_C 14 2 15 4 tem at voltage regulator V 20_C 13 9 4 9 60_C 13 4 14 6 80_C 13 1 14 5 Output current 70 of normal output current Rotor coil resistance Ω Approx 2 5 Maximum vacuum at 3 000 r min 4D56 kPa 80 Protrusion length of brush mm 2 SPECIAL TOOL 1610006...

Page 648: ...egative battery cable 4 Disconnect the alternator output wire from the alternator B terminal and connect a DC test ammeter with a range of 0 100 A in series between the B terminal and the disconnected output wire Connect the lead of the ammeter to the B terminal and then connect the lead of the ammeter to the disconnected output wire NOTE An inductive type ammeter which enables measurements to be ...

Page 649: ...he value displayed on the voltmeter at this time When the value range is 40 A the limit is max 0 4 V 11 If the value displayed on the voltmeter is above the limit value there is probably a malfunction in the alternator output wire so check the wiring between the alternator B terminal and the battery terminal including fusible link If a terminal is not sufficiently tight or if the harness has becom...

Page 650: ...bly an open circuit in the wire or fusible link between the alternator B terminal and the battery terminal 10 Turn the light switch on to turn on headlamps and then start the engine 11 Immediately after setting the headlamps to high beam and turning the heater blower switch to the high revolution position increase the engine speed to 2 500 r min and read the maximum current output value displayed ...

Page 651: ...of the voltmeter to the S terminal and then connect the lead of the voltmeter to a secure earth or to the battery terminal 5 Disconnect the alternator output wire from the alternator B terminal 6 Connect a DC test ammeter with a range of 0 100 A in series between the B terminal and the disconnected output wire Connect the lead of the ammeter to the B terminal Connect the lead of the ammeter to the...

Page 652: ...peed to the idle speed 16 Turn the ignition switch off 17 Remove the tachometer 18 Disconnect the negative battery cable 19 Disconnect the ammeter and voltmeter 20 Connect the alternator output wire to the alternator B terminal 21 Remove the special tool and return the connector to the original condition 22 Connect the negative battery cable Voltage Regulation Table Standard value Inspection termi...

Page 653: ...d Voltage at alternator B terminal 0 4 0 2 0 0 2 0 4 Time NOTE The voltage waveform of the alternator B terminal can undulate as shown at left This waveform is produced when the regulator operates according to fluctuations in the alternator load current and is normal for the alternator In addition when the voltage waveform reaches an excessively high value approx 2 V or higher at idle it often ind...

Page 654: ...s can be observed when the headlamps are illuminated 3 Check the conditions of the charging warning lamp illuminated not illuminated Also check the charging system totally Abnormal waveforms Problem cause Abnormal waveforms Problem cause Example 1 D Open diode Example 4 D Short in stator coil Example 2 D Short in diode Example 5 At this time the charging warning lamp is illuminated D Open supple m...

Page 655: ...ment Refer to GROUP 11 On vehicle Service D Under Cover Installation 4G6 4D56 14 Nm 20 25 Nm 9 8 Nm 12 15 Nm 20 25 Nm 1 2 3 5 7 8 44 Nm 9 8 Nm 12 15 Nm 1 2 3 4 6 7 14 Nm 17 Nm 8 Removal steps 1 Drive bolt for A C 2 Drive belt for power steering 3 Drive belt for alternator 4 Oil pipe connection 5 Oil return hose connection 6 Vacuum hose connection 7 Alternator 8 Alternator brace assembly ...

Page 656: ...9 4G6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Disassembly steps AA 1 Front bracket assembly AB 2 Pulley BA 3 Rotor 4 Rear bearing 5 Bearing retainer 6 Front bearing 7 Front bracket AC 8 Stator 9 Plate AC AA 10 Regulator assembly 11 Brush 12 Slinger 13 Rectifier assembly 14 Rear bracket ...

Page 657: ... steps 1 Check valve 2 Nipple 3 Vacuum pump housing 4 O ring CA 5 Vane CA 6 Rotor 7 Vacuum pump plate 8 O ring AA 9 Front bracket assembly AB 10 Pulley BA 11 Rotor 12 Rear bearing 13 Bearing retainer 14 Front bearing 15 Front bracket AC 16 Stator 17 Plate AC AA 18 Regulator assembly 19 Brush 20 Slinger 21 Rectifier assembly 22 Rear bracket ...

Page 658: ...or unsolder three stator leads soldered to main diodes on rectifier 2 When removing rectifier from brush holder unsolder two soldered points to rectifier Caution 1 When soldering or unsoldering use care to make sure that heat of soldering iron is not transmitted to diodes for a long period Finish soldering or unsoldering in as short a time as possible 2 Use care that no undue force is exerted to l...

Page 659: ...he vanes with the round end facing outward 3 Apply grease to the O ring and fit in the housing groove so that it will not come out from the groove when the bolts are tightened 4 When tightening the housing lightly push it in the direction of arrow so as to minimize the clearance at A and tighten the bolts uniformly NOTE After assembly be sure to conduct a performance test to check to see that the ...

Page 660: ... there is no continuity between slip ring and core If there is continuity replace rotor assembly STATOR 1 Make continuity test on stator coil Check that there is continuity between coil leads If there is no continuity replace stator assembly 2 Check coil for earthing Check that there is no continuity between coil and core If there is continuity replace stator assembly RECTIFIERS 1 Check for contin...

Page 661: ...iode If there is no continuity in both directions diode is faulty and heatsink assembly must be replaced BRUSH 1 Replace the brush if its protrusion length is less than the limit Limit min 2 mm 2 Unsolder pigtail and remove old brush and spring VACUUM PUMP Check the following and replace if defective 1 Check the rotor ends for streaks or damage 2 Check the housing surface in contact with the rotor...

Page 662: ...position after starting the engine the starter clutch is disengaged from the ring gear An overrunning clutch is provided between the pinion and the armature shaft to prevent damage to the starter SYSTEM DIAGRAM Holding coil Pull in coil Lever Over running clutch Ignition switch Pinion shaft Armature Battery Brush Yoke Field coil 4G63 Standard and M T 4D56 Plunger STARTER MOTOR SPECIFICATIONS 4G63 ...

Page 663: ...d coil wire from M terminal of magnetic switch 2 Connect a 12V battery between S terminal and M terminal 3 Set switch to ON and pinion will move out Caution This test must be performed quickly in less than 10 seconds to prevent coil from burning 4 Check pinion to stopper clearance pinion gap with a thickness gauge Pinion gap 0 5 2 0 mm 5 If pinion gap is out of specification adjust by adding or re...

Page 664: ...d in circuit is open Replace magnetic switch FREE RUNNING TEST 1 Place starter motor in a vise equipped with soft jaws and connect a fully charged 12 volt battery to starter motor as follows 2 Connect a test ammeter 100 ampere scale and carbon pile rheostat in series with battery positive post and starter motor terminal 3 Connect a voltmeter 15 volt scale across starter motor 4 Rotate carbon pile ...

Page 665: ...nal and body Caution This test must be performed quickly in less than 10 seconds to prevent coil from burning 3 Pull pinion out and release If pinion quickly returns to its original position everything is in order If it doesn t replace magnetic switch Caution Be careful not to get your fingers caught when pulling out the pinion Field coil wire M Battery B S Starter motor ...

Page 666: ...13 15 12 4 3 2 11 6 16 14 10 9 8 7 5 Disassembly steps 1 Screw AA 2 Magnetic switch 3 Packing 4 Plate 5 Screw 6 Through bolt 7 Rear bracket 8 Rear bearing 9 Brush holder assembly 10 Yoke assembly 11 Armature 12 Lever 13 Washer AC AA 14 Snap ring AC AA 15 Stop ring 16 Overrunning clutch 17 Front bracket ...

Page 667: ... 8 22 Disassembly steps 1 Screw AA 2 Magnetic switch 3 Screw 4 Screw 5 Rear bracket 6 Brush holder 7 Brush 8 Rear bearing AA 9 Armature 10 Yoke assembly AA 11 Ball 12 Packing A 13 Packing B 14 Plate 15 Planetary gear 16 Lever AC AA 17 Snap ring AC AA 18 Stop ring 19 Overrunning clutch 20 Internal gear 21 Planetary gear holder 22 Front bracket ...

Page 668: ...3 9 4 Disassembly steps 1 Screw AA 2 Magnetic switch 3 Screw 4 Screw 5 Rear bracket 6 Brush holder 7 Yoke assembly 8 Brush AB 9 Armature 10 Bearing 11 Packing A 12 Packing B 13 Plate AB 14 Ball 15 Planetary gear 16 Lever AC AA 17 Snap ring AC AA 18 Stop ring 19 Overrunning clutch 20 Internal gear 21 Washer 22 Planetary gear holder 23 Front bracket ...

Page 669: ... overrunning clutch STARTER MOTOR PARTS CLEANING 1 Do not immerse parts in cleaning solvent Immersing the yoke and field coil assembly and or armature will damage insulation Wipe motor assembly with a cloth only 2 Do not immerse drive unit in cleaning solvent Overrunning clutch is pre lubricated at the factory and solvent will wash lubrication from clutch 3 The drive unit may be cleaned with a bru...

Page 670: ...n a pair of V blocks and check the runout with a dial indicator Standard value 0 05 mm Limit 0 1 mm 2 Measure the commutator outer diameter Standard value 32 0 mm Limit 31 0 mm 3 Check the undercut depth between segments Standard value 0 5 mm FIELD COIL OPEN CIRCUIT TEST DIRECT DRIVE TYPE REDUCTION DRIVE TYPE 4D56 Check the continuity between field brushes If there is continuity the field coil is ...

Page 671: ...e in opposite direction If clutch does not function properly replace overrunning clutch assembly 2 Inspect pinion for wear or burrs If pinion is worn or burred replace overrunning clutch assembly If pinion is damaged also inspect ring gear for wear or burrs FRONT AND REAR BRACKET BUSHING CHECK Inspect bushing for wear or burrs If bushing is worn or burred replace front bracket assembly or rear bra...

Page 672: ...he brush from brush holder by prying retainer spring back ARMATURE TEST ARMATURE SHORT CIRCUIT TEST 1 Place armature in a growler 2 Hold a thin steel blade parallel and just above while rotating armature slowly in growler A shorted armature will cause blade to vibrate and be attracted to the core Replace shorted armature ARMATURE COIL EARTH TEST Check the insulation between each commutator segment...

Page 673: ...n timing The engine ECU detects the crankshaft position by the crank angle sensor incorporated in the distributor to provide ignition at the most appropriate timing for the engine operating condition When the engine is cold or operated at a high altitude the ignition timing is slightly advanced to provide optimum performance to the operating condition SYSTEM DIAGRAM Air flow sensor AFS Intake air ...

Page 674: ...R5E 11 NIPPON DENSO K16PR U11 SERVICE SPECIFICATIONS 16300030190 Items Standard value Limit Ignition coil Primary coil resistance Ω 0 67 0 81 Secondary coil resistance kΩ 11 3 15 3 Spark plug gap mm 1 0 1 1 Resistive cord resistance kΩ Max 22 LUBRICANT Items Specified lubricant Quantity Distributor cupping Multipurpose grease SAE J310 NLGI No 3 2 g SPECIAL TOOL 16300060151 Tool Number Name Use MB9...

Page 675: ...en the high voltage terminals and terminal Standard value 11 3 15 3 kΩ POWER TRANSISTOR CONTINUITY CHECK 16300130159 NOTE An analogue type circuit tester should be used Voltage 1 5V Terminal No 1 2 3 Applied Not applied Replace the power transistor if there is a malfunction RESISTIVE CORD CHECK 16300140091 Measure the resistance of the all spark plug cables 1 Check cap and coating for cracks 2 Mea...

Page 676: ...deposits with wire brush or plug cleaner Remove sand from plug screw with compressed air 5 Use a plug gap gauge to check that the plug gap is within the standard value range Standard value 1 0 1 1 mm If the plug gap is not within the standard value range adjust by bending the earth electrode 6 Clean the engine plug holes Caution Be careful not to allow foreign matter in cylinders 7 Install the spa...

Page 677: ...p Basically clamp the spark plug cable of the No 1 cylinder NOTE The waveform of the cylinder clamped to the trigger pickup appears at the left edge of the screen STANDARD WAVEFORM Observation Conditions FUNCTION SECONDARY PATTERN HEIGHT HIGH or LOW PATTERN SELECTOR RASTER Engine Speed Curb idle speed Ignition secondary voltage waveform Dwell section Point C Spark line Point A Vibration damping se...

Page 678: ...ow Rich Advanced Leak Slope Large Plug is fouled Point B Number of vibration in reduction vibration section Refer to abnormal waveform example 5 Number of vibrations Coil and condenser Three or more Normal Except above Abnormal Point C Number of vibrations at beginning of dwell section Refer to abnormal waveform example 5 Number of vibrations Coil 5 6 or higher Normal Except above Abnormal Point D...

Page 679: ... half of the spark line is distorted This could be a result of misfiring Spark plug gap is too small Example 3 Spark line is low and long and is sloping However there is almost no spark line distortion Spark plug gap is fouled Example 4 Spark line is high and short Difficult to distinguish between this and abnormal waveform example 1 Spark plug cable is nearly falling off Causing a dual ignition E...

Page 680: ...ll of the terminals should be connected 2 Connect the analyzer primary pickup to the power transistor connector terminal 3 3 Connect the primary pickup earth terminal 4 Clamp the spark plug cable with the trigger pickup NOTE The waveform of the cylinder clamped to the trigger pickup will appear at the left edge of the screen Power transistor Ignition coil Power transistor connector Analyzer Primar...

Page 681: ...e Speed Curb idle speed Ignition primary voltage waveform V Zener voltage Point C Approx 40 10V Dwell section Spark line Point A Vibration damping section Point B Time 100 0 Observation conditions Only the pattern selector shown below changes from the previous conditions PATTERN SELECTOR DISPLAY V Ignition primary voltage waveform Centre section Time 100 0 ...

Page 682: ... Normal Low Rich Advanced Leak Short Large Large wear High Lean Retarded High resistance Height High Large Large wear High Lean Retarded High resistance Low Small Normal Low Rich Advanced Leak Slope Large Plug is fouled Point B Number of vibration in reduction vibration section Refer to abnormal waveform example 5 Number of vibrations Coil condenser 3 or higher Normal Except above Abnormal Point C...

Page 683: ... and is sloping Also the second half of the spark line is distorted This could be a result of misfiring Spark plug gap is too small Example 3 Spark line is low and long and is sloping However there is almost no spark line distortion Spark plug gap is fouled Example 4 Spark line is high and short Spark plug cable is nearly falling off Causing a dual ignition Example 5 No waves in wave damping secti...

Page 684: ...m 13 Nm 24 Nm 1 2 3 4 5 6 7 8 9 6 9 8 Removal steps 1 Timing belt upper cover 2 Spark plug cable and high tension cable 3 Distributor connector 4 Power transistor connector 5 Ignition coil connector CA 6 Distributor assembly 7 Distributor bracket BA 8 Camshaft sprocket spacer AA 9 Oil seal INSTALLATION SERVICE POINTS AA OIL SEAL INSTALLATION Tap in the oil seal until it is flush with the camshaft ...

Page 685: ...e Multipurpose grease SAE J310 NLGI No 3 2 Turn the crankshaft clockwise to align the timing marks NOTE The No 1 cylinder will be at compression top dead centre if the timing mark on the camshaft sprocket is aligned with the timing mark on the cylinder head 3 Align the mating mark on the distributor housing side with the mating mark on the coupling side 4 Install the distributor to the engine whil...

Page 686: ...ENGINE ELECTRICAL Ignition System 16 42 DISASSEMBLY AND REASSEMBLY 16300220122 1 2 3 4 Disassembly steps 1 Distributor cap 2 Rotor 3 Cover 4 Distributor housing ...

Page 687: ...supplied to the glow plugs after the ignition switch is turned to the ON position and also the glow indicator lamp illumination time in accordance with the engine coolant temperature The resistances of the heating coils which are built into the glow plugs increase as the glow plug temperatures become higher As a result of this the flow of current gradually decreases thus stabilizing the glow plug ...

Page 688: ... switch is turned to ON without starting the engine 9 11 Drops to 0 V after 4 8 seconds have passed While engine is crank ing 6 or more While engine is warm ing up 12 15 Drops to 0 V when the engine coolant temperature increases to 60 _C or more or if 180 seconds have passed since the engine was started Glow plug resistance at 20 _C Ω 0 4 0 6 SEALANT 16400050021 Item Specified sealant Remark Engin...

Page 689: ...arth 5 Measure the voltage immediately after the ignition switch is turned to ON without starting the engine Standard value 9 11 V Drops to 0 V after 4 8 seconds have passed In addition check to be sure that the glow indicator lamp red illuminates immediately after the ignition switch is turned to ON NOTE The time during which the voltage appears energizing time will depend on the engine coolant t...

Page 690: ... plug relay ON OFF Alternator L terminal H L T1 Glow indicator lamp T2 Glow plug relay drive time after ignition switch is turned ON T3 Glow plug relay drive time after engine starts after glow NOTE After glow time T3 becomes longer as the engine coolant temperature drops GLOW CONTROL UNIT CHECK 16400220033 Glow control unit Glow control unit ...

Page 691: ...ture 80 _C 0 5 0 7 V 2 Ignition switch power supply Ignition switch OFF START 8 V or more 7 Glow plug relay glow time control Ignition switch OFF ON Engine coolant temperature 40 _C or less Pre glow function inspection 9 12 V 0 0 5 V after approx 8 sec when engine coolant tempera ture is 20 _C 3 Glow indicator lamp Ignition switch OFF ON Engine coolant temperature 40 _C or less 0 1 V 11 13 V after...

Page 692: ...rnesses must not be shorted to earth 3 When connecting the jumper cables be very careful not to make a mistake in connecting the terminals as this will cause damage to the relay 3 Check the continuity between glow plug relay terminals 2 and 3 while disconnecting and connecting the jumper cable at the battery terminal Jumper cable at battery terminal Continuity between terminals 2 3 Connected Conti...

Page 693: ...re sensor is immersed measure the resistance between B terminal and the body Temperature _C Resistance value kΩ 0 8 6 20 3 25 0 33 40 1 5 80 0 3 3 After applying specified sealant to the threaded portion tighten to the specified torque Specified sealant 3M Nut Locking Part No 4171 or equivalent Tightening torque 35 Nm Engine coolant temperature gauge unit engine coolant temperature sensor A B ...

Page 694: ... connection 2 Glow plug plate AA 3 Glow plug REMOVAL SERVICE POINT AA GLOW PLUG REMOVAL Remove glow plug by hand after loosening with tool as its ceramic part is fragile INSPECTION 16400190044 D Check for rust on glow plug plate D Check glow plug for damage Caution Do not use a plug that has been dropped from a height of 10 cm or more ...

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Page 698: ...2 GENERAL INFORMATION 2 ON VEHICLE SERVICE 3 Ignition Coil Check 3 Power Transistor Continuity Check 3 Waveform Check Using an Analyzer 4 IGNITION COIL AND POWER TRANSISTOR 4G6 11 CRANK ANGLE SENSOR 12 CAMSHAFT POSITION SENSOR 4G6 13 GLOW SYSTEM 13 GENERAL 13 Outline of Change 13 ...

Page 699: ...oltage thus generated is applied to the spark plugs of No 2 and No 3 cylinders The engine ECU controls the two power transistors A and B to turn them alternately ON and OFF This causes the primary currents in the ignition coils A and B to be alternately interrupted and allowed to flow to fire the cylinders in the order 1 3 4 2 The engine ECU determines which ignition coil should be controlled by m...

Page 700: ...dary coil resistance Measure the resistance between the high voltage terminals and terminal Standard value 20 1 27 3 kΩ POWER TRANSISTOR CONTINUITY CHECK NOTE An analogue type circuit tester should be used No 1 No 4 cylinder side Voltage 1 5V Terminal No g 3 7 8 Applied Not applied No 2 No 3 cylinder side Voltage 1 5V Terminal No g 1 2 3 Applied Not applied Replace the power transistor if there is...

Page 701: ...eforms for two cylinders in each group appear during waveform observation No 1 cylinder No 4 cylinder No 2 cylinder No 3 cylinder However waveform observation is only applicable for the cylinder with the spark plug cable clamped by the secondary pickup 3 Identifying which cylinder waveform is displayed can be difficult For reference remember that the waveform of the cylinder attached to the second...

Page 702: ...ry ignition voltage waveform Ignition voltage point D Dwell section Point C Spark line point A Wave damping reduction section point B Time Observation Condition The only change from above condition is the pattern selector Pattern selector Display Secondary ignition voltage waveform kV No 4 cylinder No 2 cylinder ignition noise No 1 cylinder No 3 cylinder ignition noise Neutral section 0 2 Time ...

Page 703: ...ow Rich Advanced Leak Slope Large Plug is fouled Point B Number of vibration in reduction vibration section Refer to abnormal waveform example 5 Number of vibrations Coil and condenser Three or more Normal Except above Abnormal Point C Number of vibrations at beginning of dwell section Refer to abnormal waveform example 5 Number of vibrations Coil 5 6 or higher Normal Except above Abnormal Point D...

Page 704: ... half of the spark line is distorted This could be a result of misfiring Spark plug gap is too small Example 3 Spark line is low and long and is sloping However there is almost no spark line distortion Spark plug gap is fouled Example 4 Spark line is high and short Difficult to distinguish between this and abnormal waveform example 1 Spark plug cable is nearly falling off Causing a dual ignition E...

Page 705: ...the primary pickup earth terminal 4 Clamp the spark plug with the trigger pickup NOTE 1 Clamp the spark plug cable for No 1 and No 3 cylinders of the same group with the cylinder that is connected to the primary pickup 2 The wave pattern of either cylinder in the same group will appear at the left edge of the screen STANDARD WAVEFORM Observation Conditions Function Secondary Pattern height High or...

Page 706: ...ion of electrode Compression force Concentration of air mixture Ignition timing High tension cable Length Long Small Normal Low Rich Advanced Leak Short Large Large wear High Lean Retarded High resistance Height High Large Large wear High Lean Retarded High resistance Low Small Normal Low Rich Advanced Leak Slope Large Plug is fouled Point B Number of vibrations in reduction vibration section Refe...

Page 707: ...ng Also the second half of the spark line is distorted This could be a result of misfiring Spark plug gap is too small Example 3 Spark line is low long and sloping However there is almost no spark line distortion Spark plug gap is fouled Example 4 Spark line is high and short Spark plug cable is not properly connected creating more than one spark from the plug Example 5 No waves in wave damping se...

Page 708: ... AND INSTALLATION 1 2 3 4 5 6 10 2 N m 5 0 1 0 N m Ignition coil removal steps 1 Ignition coil connector connection 2 Spark plug cable connection 3 Ignition coil D Resonance tank 4 Spark plug cable Power transistor removal steps 5 Power transistor connector connection 6 Power transistor ...

Page 709: ...installation Operation D Timing Belt Removal and Installation 4G6 Refer to GROUP 11A D Timing Belt Cover Removal and Installation 4D56 Step III Refer to GROUP 11B 1 2 3 4G6 4D56 Step III 8 8 1 0 N m 9 0 1 0 N m 35 6 N m 3 Removal steps 1 Idler pulley 4G6 2 Timing indicator bracket 4G6 3 Crank angle sensor ...

Page 710: ...OVAL AND INSTALLATION 8 8 1 0 N m Camshaft position sensor GLOW SYSTEM GENERAL OUTLINE OF CHANGE Due to the introduction of the electronic controlled injection system the engine ECU controls the glow system As for the ECU terminal voltage measurement refer to GROUP 13I Troubleshooting ...

Page 711: ...NOTES ...

Page 712: ...ENGINE AND EMISSION CONTROL ...

Page 713: ......

Page 714: ... 14 Operation 14 System Diagram 14 Component Location 14 Exhaust Gas Recirculation EGR Control System Check 15 EGR Valve Check 15 EGR Port Vacuum Check 16 EGR Control Solenoid Valve Check 16 CATALYTIC CONVERTER 17 General Information 17 CANISTER AND TWO WAY VALVE 18 ...

Page 715: ...ust at no load 2 Warm engine until stabilized at idle 3 Confirm idle speed is at prescribed value Standard value 750 100 r min 4 Stop engine ignition switch OFF 5 Confirm there are no sharp bends in accelerator cable 6 Check inner cable for correct slack Standard value 1 2 mm 7 If there is too much slack or no slack adjust play by the following procedures 1 Loosen the lock nut and fully close the ...

Page 716: ...Nm 3 4 Nm 15 12 11 12 3 12 Nm Accelerator cable removal steps 1 Inner cable connection Injection pump side or throttle body side 2 Inner cable connection Accelerator pedal side 3 Accelerator cable Throttle control cable removal steps 4 Wire stopper 5 Bush 6 Knob 7 Nut 8 Cable bracket 9 Throttle cable Accelerator pedal removal steps 2 Inner cable connection Accelerator pedal side 4 Wire stopper 10 ...

Page 717: ...erator cable removal steps 1 Inner cable connection Injection pump side 2 Inner cable connection Accelerator pedal side 3 Accelerator cable Throttle control cable removal steps 4 Wire stopper 5 Bush 6 Knob 7 Nut 8 Throttle control cable Accelerator pedal removal steps 2 Inner cable connection Accelerator pedal side 4 Wire stopper 9 Split pin 10 Spring 11 Accelerator arm 12 Pedal pad 13 Stopper 14 ...

Page 718: ...noid valve Purpose HC reduction Exhaust emission control system Air fuel ratio control device MPI system Oxygen sensor feedback type Purpose CO HC NOx reduction Exhaust gas recirculation system D EGR valve D EGR control solenoid valve Equipped Single type Duty cycle type solenoid valve Purpose NOx reduction Catalytic converter Monolith type Purpose CO HC NOx reduction EMISSION CONTROL DEVICE REFER...

Page 719: ...istance at 20_C Ω 36 44 SPECIAL TOOL 17100060022 Tool Number Name Use MD998770 Oxygen sensor wrench Removal Installation of oxygen sensor VACUUM HOSE 17300090201 VACUUM HOSE PIPING DIAGRAM Canister From fuel tank OFF ON Purge control solenoid valve EGR control solenoid valve EGR valve From fuel pump Fuel pressure regulator PCV valve To fuel tank Oxygen sensor Three way catalytic converter Air clea...

Page 720: ...CIRCUIT DIAGRAM Intake manifold Throttle body To combustion chamber From air cleaner Fuel pressure regulator EGR control solenoid valve ON CLOSE Purge control solenoid valve ON OPEN Canister EGR valve Vacuum hose colour B Black G Green L Light blue R Red Y Yellow M P E A ...

Page 721: ... system prevents blow by gases from escaping inside the crankcase into the atmosphere Fresh air is sent from the air cleaner into the crankcase through the breather hose The air becomes mixed with the blow by gases inside the crankcase The blow by gas inside the crankcase is drawn into the intake manifold through the positive crankcase ventilation valve The positive crankcase ventilation valve lif...

Page 722: ...e ventilation valve and check that vacuum of the intake manifold is felt NOTE At this moment the plunger in the positive crankcase ventilation valve moves back and forth 6 If vacuum is not felt clean the positive crankcase ventilation valve or replace it PCV VALVE CHECK 17300120047 1 Insert a thin rod into the positive crankcase ventilation valve from the side shown in the illustration rocker cove...

Page 723: ...solenoid and purge port and go into the intake manifold to be sent to the combustion chamber When the engine coolant temperature is low or when the intake air quantity is small when the engine is at idle for example the engine control unit turns the purge solenoid off to shut off the fuel vapour flow to the intake manifold This does not only insure the driveability when the engine is cold or runni...

Page 724: ...um is maintained When engine is hot Engine coolant temperature 80_C or higher Vacuum Engine condition Normal condition 53 kPa At idle Vacuum is maintained 3 000 r min Vacuum will leak for approximately 3 minutes after the engine is started After 3 minutes have passed the vacuum will be maintained momentarily after which it will again leak NOTE The vacuum will leak continuously if the atmospheric p...

Page 725: ... it can be reconnected at original position 1 Disconnect the vacuum hose black stripe red stripe from the solenoid valve 2 Disconnect the harness connector 3 Connect a hand vacuum pump to nipple A of the solenoid valve refer to the illustration at left 4 Check airtightness by applying a vacuum with voltage applied directly from the battery to the purge control solenoid valve and without applying v...

Page 726: ... the combustion chamber through the intake manifold to decrease the air fuel mixture combustion temperature resulting in reduction of NOx The EGR flow rate is controlled by the EGR valve so as not to decrease the driveability OPERATION The EGR valve is being closed and does not recirculate exhaust gases under one of the following conditions Otherwise the EGR valve is opened and recirculates exhaus...

Page 727: ...y rise over 13 kPa 3 Disconnect the three way terminal 4 Connect the hand vacuum pump to the EGR valve 5 Check whether the engine stalls or the idling is unstable when a vacuum of 30 kPa or higher is applied during idling EGR VALVE CHECK 17300280042 1 Remove the EGR valve and inspect for sticking carbon deposits etc If found clean with a suitable solvent so that the valve seats correctly 2 Connect...

Page 728: ...can be reconnected at original position 1 Disconnect the vacuum hose yellow stripe white stripe green stripe from the solenoid valve 2 Disconnect the harness connector 3 Connect a hand vacuum pump to the nipple to which the white striped vacuum hose was connected 4 Check airtightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without a...

Page 729: ...ric air fuel ratio the three way catalytic converter provides the highest purification against the three constituents namely CO HC and Nox REMOVAL AND INSTALLATION 17300390141 1 2 3 4 5 6 7 8 9 2 50 Nm 25 Nm 13 Nm 45 Nm 35 Nm 50 Nm 8 Removal steps AA AA 1 Oxygen sensor 2 Center exhaust pipe hanger connection 3 Front exhaust pipe hanger 4 Heat protector 5 Catalytic converter attaching bolt 6 Front ...

Page 730: ...n or fuel system if there are malfunctions otherwise engine misfiring may occur which will damage the catalytic converter 3 Observe manufacturer s specifications when doing service work CANISTER AND TWO WAY VALVE 17300480121 REMOVAL AND INSTALLATION Diesel powered vehicles Petrol powered vehicles 1 2 2 3 4 1 3 4 Canister removal steps 1 Breather hose connection 2 Vapour hose connection 3 Canister ...

Page 731: ...tion of the two way valve INSPECTION 17300490063 TWO WAY VALVE SIMPLE CHECK Attach a clean hose and check the operation of the two way valve Lightly blow from inlet side fuel tank side Air passes through with a slight feeling of resistance Lightly blow from outlet side Air passes through Canister side Tank side Two way valve Inlet side Outlet side Rubber side ...

Page 732: ...NOTES ...

Page 733: ......

Page 734: ......

Page 735: ......

Page 736: ......

Page 737: ......

Page 738: ......

Page 739: ......

Page 740: ...EMISSION CONTROL SYSTEM DIESEL 5 GENERAL 5 Outline of Change 5 SERVICE SPECIFICATION 5 EXHAUST GAS RECIRCULATION EGR SYSTEM 4D56 Step III 5 General Information 5 System Diagram 5 Component Location 6 Function Check 6 EGR Solenoid Valve Operation Check 6 EGR Solenoid Valve Resistance Check 7 Accelerator Pedal Position Sensor APS Engine Coolant Temperature Sensor Boost Air Temperature Sensor Fuel Te...

Page 741: ...to this the service procedures regarding the different description from the previous version have been established D Due to the introduction of the electronic controlled injection pump the accelerator cable has been abolished and the accelerator pedal position sensor has been added SEALANT 4D56 Step III Items Specified sealant Remarks Accelerator arm bracket mounting bolt 3M Nut Locking Part No 41...

Page 742: ...t 3M Nut Locking Part No 4171 or equivalent 3 5 1 0 N m 5 0 1 0 N m 1 2 3 4 5 6 7 8 L H drive vehicles R H drive vehicles 2 3 4 5 6 7 8 9 10 9 10 3 5 1 0 N m 5 0 1 0 N m 1 8 Toe board 7 6 6 8 Removal steps 1 Accelerator cable connection for automatic transmission kickdown A T 2 Accelerator pedal position sensor 3 Accelerator pedal assembly 4 Hysteresis assembly M T 5 Push on spring nut 6 Bushing 7...

Page 743: ...SOLENOID VALVE CHECK NOTE When disconnecting the vacuum hose always make a mark so that it can be reconnected at original position 1 Disconnect the vacuum hoses 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 ba...

Page 744: ...s The EGR valve is controlled by the negative pressure inside the valve which is controlled by EGR solenoid valves No 1 and No 2 In order to obtain EGR amount corresponding to each operating condition the appropriate opening of the EGR valve is calculated based on the input signal from each sensor Feedback control of the EGR solenoid valves No 1 and No 2 operation is carried out based on the signa...

Page 745: ...n check that the EGR valve diaphragm lifts EGR SOLENOID VALVE OPERATION CHECK 1 Remove EGR solenoid valve Nos 1 and 2 connectors and vacuum hoses 2 Attach a vacuum pump to each nipple of the EGR solenoid valve Nos 1 and 2 Then connect the each connector of EGR solenoid valve to battery and apply negative pressure Check that the valves are airtight both when voltage is applied to each terminal of t...

Page 746: ...attery voltage Normal condition When current is flowing Vacuum is maintained When current is not flowing Vacuum leaks EGR SOLENOID VALVE RESISTANCE CHECK Measure terminal resistance of EGR solenoid valves Nos 1 and 2 with a circuit tester Standard value 36 44 Ω at 20 C ACCELERATOR PEDAL POSITION SENSOR APS ENGINE COOLANT TEMPERATURE SENSOR BOOST AIR TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR EGR V...

Page 747: ...m 9 11 22 4 N m 22 4 N m 13 14 17 2 N m 15 Removal steps 1 EGR valve connector 2 Vacuum hose connection 3 EGR valve 4 EGR gasket 5 EGR pipe gasket 6 EGR upper pipe AA 7 EGR pipe gasket CA 8 Water pipe and hose assembly BA 9 O ring 10 Water hose connection 11 EGR cooler and EGR lower pipe assembly AA 12 EGR pipe gasket 13 EGR lower pipe AA 14 EGR pipe gasket 15 EGR cooler ...

Page 748: ...ater pipe Caution 1 Care must be taken not to permit engine oil or other greases to adhere to the O ring 2 When inserting the pipe check to be sure that there is no sand dirt etc on its inner surface CA WATER PIPE AND HOSE ASSEMBLY INSTALLATION When the water hose is separated from the water pipe reconnect the water hose so that its identification mark faces toward the EGR cooler EGR pipe gasket p...

Page 749: ...NOTES ...

Page 750: ...CLUTCH ...

Page 751: ......

Page 752: ...r more LUBRICANTS 21100040078 Items Specified lubricants Quantity Clutch fluid Brake fluid DOT 3 or DOT 4 As required Push rod assembly Rubber grease Boot Release cylinder push rod MITSUBISHI genuine grease Part No 0101011 ON VEHICLE SERVICE 21100090127 CLUTCH PEDAL INSPECTION AND ADJUSTMENT 1 Turn up the carpet etc under the clutch pedal 2 Measure the clutch pedal height Standard value A 176 181 ...

Page 753: ...e ranges Standard value C 6 13 mm Standard value D 56 mm or more 7 If the clutch pedal free play and the distance between the clutch pedal and the toeboard when the clutch is disengaged do not agree with the standard values it is probably the result of either air in the hydraulic system or a faulty master cylinder or clutch Bleed the air or disassembly and inspect the master cylinder or clutch 8 T...

Page 754: ...t ment L H drive vehicles 13 Nm 21 Nm 13 Nm 2WD 4WD 4G64 4WD 4D56 10 29 Nm 3 1 2 11 13 15 14 12 11 5 4 13 Nm 10 5 4 6 7 14 8 9 15 2 1 3 13 Nm 11 12 29 Nm 21 Nm 11 Nm 11 Removal steps 1 Clutch master cylinder installation nut 2 Clevis pin 3 Clutch support member mounting bolt 4 Adjusting bolt 5 Clutch pedal mounting bolt 6 Turnover spring bracket 7 Bushing 8 Turnover spring 9 Bushing 10 Clutch supp...

Page 755: ...r push rod Grease MITSUBISHI Genuine grease Part No 0101011 or equivalent 2WD 4WD 4G64 4WD 4D56 3 4 1 1 4 3 2 7 8 8 7 6 7 5 8 15 Nm 15 Nm 9 9 6 20 25 Nm 36 Nm 36 Nm 36 Nm 36 Nm 13 Nm 5 20 25 Nm Clutch master cylinder removal steps D Hydraulic unit L H drive diesel powered vehicles with ABS 1 Clevis pin 2 Push rod damper L H drive diesel powered vehicles with ABS 3 Clutch master cylinder 4 Sealer C...

Page 756: ...lutch fluid Brake fluid DOT 3 or DOT 4 Grease Rubber grease Piston repair kit 5 4 4 4 8 8 3 1 4 3 2 1 3 Disassembly steps 1 Piston stop ring 2 Damper and push rod 3 Boot 4 Piston assembly 5 Reservoir cap 6 Reservoir 7 Reservoir band 8 Master cylinder body Caution Do not disassemble piston assembly ...

Page 757: ...MANUAL TRANSMISSION ...

Page 758: ......

Page 759: ... 509 4th 1 000 1 000 5th 0 827 0 827 Reverse 4 142 4 142 Speedometer gear ratio driven drive 29 8 26 8 Items Vehicles with 4G64 engine Vehicles with 4D56 engine Transmission model V5M21 9 V5MT1 4 Type 5 speed floor shift 5 speed floor shift Gear ratio 1st 3 967 3 918 2nd 2 136 2 261 3rd 1 360 1 395 4th 1 000 1 000 5th 0 856 0 829 Reverse 3 578 3 925 Transfer type 2 speed 2 speed Gear ratio High 1 ...

Page 760: ...ing sealant Oil drain plug V5MT1 3M ATD Part No 8660 or equivalent Semi drying sealant Control lever gasket 3M ATD Part No 8661 or equivalent Semi drying sealant Control lever assembly mounting bolt 3M Stud Locking No 4170 or equivalent Anaerobic sealant ON VEHICLE SERVICE 22100090193 TRANSMISSION OIL CHECK 1 Remove the oil filler plug 2 Oil level should be at the lower portion of the filler plug ...

Page 761: ...l the level comes to the lower portion of oil filler plug hole Specified transmission oil Hypoid gear oil SAE 75W 90 75W 85W or 80W conforming to API GL 4 Quantity Transmission R5M21 2 3 V5M21 V5MT1 2 2 Transfer 2 3 5 Tighten the oil filler plug to the specified torque Specified torque R5M21 V5M21 32 Nm V5MT1 70 Nm NOTE Only V5MT1 Apply sealant to the oil filler plug threads Specified sealant 3M A...

Page 762: ... between terminals of the black connector indicated in the illustration Transfer lever position Terminal No 1 2 2H 4H HIGH LOW DETECTION SWITCH CONTINUITY CHECK 4WD 22100210025 Check the continuity between terminals of the gray connector indicated in the illustration Transfer lever position Terminal No 1 2 4H 4L 4H 4L ...

Page 763: ...lation Refer to GROUP 52A Caution SRS Be careful not to subject the SRS diagnosis unit to any shocks during removal and installation of the control lever assembly 1 2 3 4 5 6 7 8 Apply the sealant both sides of the gasket Apply the sealant to upper side of the gasket Sealant 3M ATD Part No 8661 or equivalent Control lever assembly mounting bolt Specified adhesive 3M Stud Locking No 4170 or equival...

Page 764: ...lean it by blowing in air 3 Apply specified adhesive to the threads of the control lever assembly mounting bolts Specified adhesive 3M Stud Locking No 4170 or equivalent 4 The dimensions of the mounting bolts vary according to their mounting locations so do not confuse them when installing Bolt Diameter x Length mm A 8 x 23 B 8 x 22 BA DUST COVER INSTALLATION Install the dust cover so that they fa...

Page 765: ...is unit to any shocks during removal and installation of the control lever assembly 1 2 3 4 5 6 7 8 Apply the sealant to both sides of the gasket Apply the sealant to both sides of the gasket Sealant 3M ATD Part No 8661 or equivalent Control lever assembly mounting bolt Specified adhesive 3M Stud Locking No 4170 or equivalent 10 13 Nm 9 10 11 12 13 5 Nm 7 8 10 12 4 6 Transmission control lever ass...

Page 766: ...l housing and clean it by blowing in air 3 Apply specified adhesive to the threads of the control lever assembly mounting bolts Specified adhesive 3M Stud Locking No 4170 or equivalent 4 The dimensions of the mounting bolts vary according to their mounting locations so do not confuse them when installing Bolt Diameter x Length mm A 8 x 18 B 8 x 22 C 8 x 23 CA DUST COVER INSTALLATION Install the du...

Page 767: ... 6 7 8 10 12 Nm 9 10 25 Nm 24 Nm 50 Nm 9 Nm 36 Nm 18 Nm 47 Nm 50 Nm 20 24 Nm Removal steps 1 Back up lamp switch connector 2 Earth cable connection 3 Speedometer cable connection AA 4 Clutch release cylinder 5 Bell housing cover AB 6 Starter motor 7 Exhaust pipe clamp mounting bolt 8 Exhaust pipe clamp mounting bracket D Support the transmission with a transmission jack 9 No 2 crossmember assembly...

Page 768: ...aken not to shake or rock with force because to do so might cause damage to the end of the main drive gear the pilot bearing or the clutch disc etc INSTALLATION SERVICE POINT AA TRANSMISSION ASSEMBLY INSTALLATION The sizes of the mounting bolts are different So be sure not to confuse them Bolt Diameter x Length mm A 8 x 55 B 10 x 44 C 10 x 55 D 10 x 65 A B C D D ...

Page 769: ...ansmission and Transfer Control Lever Operation Check 6 Speedometer Operation Check 24 Nm 25 Nm 26 Nm 50 Nm 2 1 3 4 5 6 7 8 9 10 40 Nm 9 Nm 36 Nm 22 Nm 45 Nm 11 12 13 14 15 16 17 25 Nm 36 Nm 36 Nm 26 Nm 22 Nm 65 Nm 10 12 Nm Removal steps 1 HIGH LOW detection switch con nector 2 4WD detection switch connector 3 Back up lamp switch connector 4D56 4 Back up lamp switch connector 4G64 5 Earth cable 6 ...

Page 770: ...mpartment AC TRANSMISSION ASSEMBLY REMOVAL Caution When removing the transmission assembly from the engine care must be taken not to shake or rock with force because to do so might cause damage to the end of the main drive gear the pilot bearing or the clutch disc etc INSTALLATION SERVICE POINT AA TRANSMISSION ASSEMBLY INSTALLATION The sizes of the mounting bolts are different So be sure not to co...

Page 771: ...nce a between the two are at the shown dimension 4 Check that the right and left clearances b between the stoppers are equal 5 Check that the clearances c between the transfer roll stopper and transfer mounting bracket are equal NOTE When new a transfer roll stopper consists of one part but will separate into outer and inner part during use This is normal Transfer roll stopper outer Transfer roll ...

Page 772: ...LATION 1 2 3 4 Removal steps 1 Front scuff plate attaching screw 2 Cowl side trim 3 Rear differential lock ECU 4 4WD indicator ECU INSPECTION 4WD INDICATOR ECU 1 Measure the voltage with the control unit and harness still connected 2 Earth terminal 8 and then measure terminal voltage View A A ...

Page 773: ...on switch IG1 OFF 0 V ON System voltage 5 Free wheel differen tial indicator lamp ON 2H System voltage tial indicator lam 4H 1 0 V 6 HI LOW detection switch ON Shifting from 4H to 4L or vice versa System voltage 2H 4H 4L 0 V 7 Free wheel clutch changeover solenoid ON 4H 4L 0 V changeover solenoid valve 2H 2 System voltage 10 4WD Indicator lamp ON 2H 0 V 4H 4L System voltage NOTE 1 When vehicle has...

Page 774: ......

Page 775: ...hicles with emission regulation step III compatible 4D5 engine R5M21 type transmission has been changed GENERAL INFORMATION Items Specifications Engine model 4D56 Step III Transmission model R5M21 5 Type 5 speed floor shift Gear ratio 1st 3 967 2nd 2 136 3rd 1 360 4th 1 000 5th 0 856 Reverse 3 578 Speedometer gear ratio driven drive 26 8 ...

Page 776: ...NOTES ...

Page 777: ...AUTOMATIC TRANSMISSION ...

Page 778: ......

Page 779: ...0130 Items Standard value Distance between inner cable stopper and end of outer cable 4G63 mm 0 1 Distance between inner cable stopper and end of outer cable 4D56 mm 34 35 Lock up solenoid valve coil resistance at 20_C Ω Approx 13 Stall speed r min 4G63 2 100 2 400 4D56 2 300 2 600 Governor pressure kPa 1 000 r min 137 166 2 000 r min 245 284 3 200 r min 402 460 Line pressure kPa At idle speed D r...

Page 780: ...t Remarks Automatic transmission fluid temperature switch 3M ATD Part No 8660 or equivalent Semi drying sealant Transfer control lever gasket and spring cover support 3M ATD Part No 8661 or equivalent Semi drying sealant Engine coolant temperature switch 3M Nut Locking Part No 4171 or equivalent Drying sealant SPECIAL TOOLS 23100060139 Tool Number Name Use MD998330 includes MD998331 Oil pressure g...

Page 781: ...ind a defective system A T control component inspection Checkthethrottlecable inhibitorswitch overdrive switch overdrive solenoid valve overdrive control relay defective switch engine coolant temperature switch and vehicle speed sensor Torque converter stall test Inspection of engine performance and mechanical function Check the engine performance torque converter operation and clutch and brake sl...

Page 782: ... TEST 2 again Yes Check the shifting point Incorrect D Line pressure malfunction D Governor malfunction D Detent regulator valve malfunction NG Does the downshift occur No D Shift valves malfunction D Governor malfunction D Overdrive switch or overdrive solenoid malfunction D Overdrive control relay malfunction D Detection switch malfunction TEST 2 Kickdown traveling at 2 speed 3 speed and 4 speed...

Page 783: ...rential tyre torque converter engine etc Extremely thorough inspection is therefore required Yes Carry out TEST 7 again Yes Does lock up go on off No D Lock up signal valve malfunction D Lock up relay valve malfunction D Lock up clutch malfunction No Does the moment when lock up turns ON or OFF conform with the shift pattern No D Governor malfunction D Line pressure malfunction TEST 7 Check that l...

Page 784: ...adjusted throttle cable D 1 2 shift valve malfunction D Line pressure malfunction TEST 2 Kickdown and check that possible kickdown vehicle speed limit at 2 speed 1 speed conforms with shift pattern OK Carry out road test in L range L RANGE TEST No Carry out road test in R range TEST 1 Does the transmission upshift to 2 speed Yes D Low coast modulator valve malfunction D Governor malfunction D Low ...

Page 785: ...haft speed r min Vehicle speed km h 1000 2000 3000 100 80 60 40 20 0 0 20 10 30 40 50 60 70 80 90 100 120 110 2 3 4 1 3 4 2 3 1 1 4D56 engine 3 2 2 2 Throttle opening Lock up ON Lock up OFF Output shaft speed r min Vehicle speed km h 4000 1000 2000 3000 100 80 60 40 20 0 0 20 10 30 40 50 60 70 80 90 100 120 110 2 3 4 1 3 4 2 3 1 1 130 1 ...

Page 786: ...ch OFF 0 V Ignition switch ON System voltage 4 Detection switch Run the vehicle Throttle valve constant opening under 85 System voltage Throttle valve Full opening 0 V 5 Overdrive solenoid valve Run the vehicle at 50 km h Overdrive switch ON Throttle valve constant opening under 85 0 V Throttle valve Full opening 11 V or more 6 Earth Always 0 V 7 Engine coolant temperature Ignition switch ON 30_C ...

Page 787: ...her with fluid leading to various troubles Air trapped in hydraulic circuit forms bubbles which make the fluid spongy This lowers pressure and shows down pressure buildup If the transmission has too much fluid gears churn up foam and cause same conditions as when the fluid level is low resulting in premature deterioration of ATF In either case air bubbles can cause overheating and fluid oxidation ...

Page 788: ... brake and service brake applied move the selector lever through all positions and finally place in the N or P position 6 After the transmission is warmed up to the normal operating temperature recheck the fluid level which must be between the HOT upper limit and HOT lower limit marks 7 Insert the dipstick fully to prevent dirt from entering the transmission TRANSFER OIL LEVEL CHECK 23100110063 In...

Page 789: ...AE 75W 90 75W 85W or 80W conforming to API GL 4 Quantity 2 3 5 Tighten the oil filler plug to the specified torque Specified torque 33 Nm 4WD DETECTION SWITCH CONTINUITY CHECK 4WD 23101110017 Check the continuity between terminals of the black connector indicated in the illustration Transfer lever position Terminal No 1 2 2H 4H HIGH LOW DETECTION SWITCH CONTINUITY CHECK 4WD 23100330025 Check the c...

Page 790: ...rn the adjusting nut 4D56 1 Check throttle lever for defective or bent and the throttle cable bracket for deformation 2 Remove the outer cable side of the boot to expose the inner cable stopper 3 Pull the throttle lever fully open and measure the distance between the inner cable stopper and the end of the outer cable Standard value 34 35 mm 4 If the distance is not within the standard value turn t...

Page 791: ...ed to R 4 When the shift lever malfunctions adjust control cable and selector lever sleeve Check the shift lever assembly sliding parts for worn INHIBITOR SWITCH CONTINUITY CHECK 23100140208 Posi ti Terminal No tion 1 2 3 4 5 6 7 8 9 10 P R N D 2 L INHIBITOR SWITCH AND CONTROL CABLE ADJUSTMENT 23100150126 1 Shift the manual control lever to the N position 2 Loosen the inhibitor switch mounting bol...

Page 792: ...n 3 Use a circuit tester or similar tool to check the continuity The switch can be judged to be good if the conditions are within the following ranges Item Temperature Continuity temperature at point A 143 151 _C No continuity temperature at point B 125 _C or less 4 Apply a small amount of specified sealant to thread of the automatic transmission fluid temperature switch Specified sealant 3M ATD P...

Page 793: ... T CONTROL COMPONENT LOCATION 23100860128 Name Symbol Name Symbol Detection switch E Overdrive solenoid valve F Engine coolant temperature switch 4G6 A Overdrive switch C Inhibitor switch E Vehicle speed sensor B Overdrive control relay D A B C D E F ...

Page 794: ...r and the body earth Standard value Approx 13 Ω 3 If the resistance is not within the standard value replace the overdrive solenoid valve DETECTION SWITCH CHECK 23101140016 1 Remove the detection switch from the transmission case 2 While blowing the low compressed air into the switch check the continuity between terminal and switch body Item Continuity Pressure not applied No continuity Infinite r...

Page 795: ...e Item Temperature On continuity 50 3_C Off no continuity 43_C 3 Replace the engine coolant temperature switch if necessary 4 Apply the specified sealant to the threaded portion and tighten to the specified torque Specified sealant 3M Nut Locking Part No 4171 or equivalent Tightening torque 7 4 Nm VEHICLE SPEED SENSOR CHECK 23100460137 Refer to GROUP 54 On vehicle Service OVERDRIVE SWITCH CHECK 23...

Page 796: ... engine maximum speed Standard value 2 100 2 400 r min 4G63 2 300 2 600 r min 4D56 NOTE When doing so do not keep the engine running with throttle full open for more than 5 seconds If two or more stall tests are needed place the selector lever in the N position and run the engine at about 1 000 r min to allow the transmission fluid to cool before another stall test 7 Place the selector lever in th...

Page 797: ...coolant 80 90_C transmission fluid 70 80_C GOVERNOR PRESSURE TEST 1 Place vehicle on a chassis dynamometer 2 Remove plug from governor pressure take off port 3 Install special tool as shown in figure and place the meter inside vehicles 4 Apply parking brake 5 Start engine 6 Release parking brakes 7 Shift to D and measure governor pressure at each output shaft r min Standard value Output shaft spee...

Page 798: ...or reverse change the oil pressure gauge to 3 000 kPa Standard value Items Line pressure kPa D range R range At idle 4G63 480 558 735 852 4D56 441 500 608 686 At stall 4G63 1019 1195 1519 1911 4D56 1098 1294 1470 1863 JUDGEMENT BY LINE PRESSURE Hydraulic pressure higher than nominal in all ranges 1 Regulator valve faulty 2 Throttle valve faulty 3 Throttle control cable incorrectly adjusted Hydraul...

Page 799: ... 13 Accumulator C2 14 Accumulator C3 15 Lock up relay valve 16 Secondary regulator valve 17 Cut back valve 18 Relief valve 19 Throttle valve 20 Check valve 21 Oil cooler 22 Damping check valve 23 Oil pump 24 Strainer 25 Cooler bypass valve 26 Primary regulator valve 27 1 2 shift valve 28 Low coast shift valve 29 Manual valve 30 Low coast modulator valve 31 Intermediate shift valve 32 Reverse clutc...

Page 800: ... 4WD 11 16 15 12 9 8 10 2 1 7 6 5 4 3 4 3 24 Nm 12 Nm 12 Nm 5 Nm 19 Nm 24 Nm 24 Nm 13 Selector lever assembly removal steps 1 Transmission control cable connection selector lever side 2 Selector lever assembly Transmission control cable assembly removal steps D Rear console assembly Refer to GROUP 52A 1 Transmission control cable connection selector lever side 3 Transmission control upper lever 4 ...

Page 801: ...AUTOMATIC TRANSMISSION Transmission Control 23 24 INSTALLATION SERVICE POINT AA DUST COVER INSTALLATION Install the dust cover as shown in the illustration Front ...

Page 802: ... 8 1 10 11 12 17 12 Nm 11 14 15 16 9 13 12 Nm Removal steps AA 1 Overdrive switch and indicator lamp connector 2 Overdrive switch 3 Button 4 Spring BA 5 Shift knob 6 Indicator panel assembly 7 Bulb 8 Position indicator socket assembly AA 9 Sleeve 10 Lever assembly 11 Shift bushing 12 Collar 13 Pin 14 Spring 15 Ball support 16 Ball 17 Bracket ...

Page 803: ...ssembly end is within the standard value Standard value A 16 0 16 8 mm BA SHIFT KNOB INSTALLATION Shift the selector lever to the N position and then turn the sleeve so that the clearance between the detent plate and pin is within the standard value Standard value A 0 1 0 9 mm INSPECTION 23101100014 POSITION INDICATOR LAMP CHECK Terminal No 1 2 Always OVERDRIVE SWITCH CHECK 23100380129 Switch posi...

Page 804: ...3 11 3 Selector Lever Installation Refer to P 23 23 4 Selector Lever Operation Check Refer to P 23 14 5 Speedometer Operation Check 9 Nm 10 12 Nm 1 13 10 2 9 8 7 6 5 4 11 12 3 45 Nm 50 Nm 25 Nm 26 Nm 24 Nm 24 Nm 36 Nm 16 Nm Removal steps BA 1 Throttle cable connection 2 Filler tube assembly 3 O ring 4 Transmission control cable connection 5 Cable end bracket 6 Speedometer cable connection 7 Earth ...

Page 805: ...Nm 22 Nm 47 Nm 15 16 14 20 19 18 17 14 Breather hose 15 Throttle cable clamp 16 Exhaust pipe clamp bracket AB 17 Torque converter and drive plate con nection bolt D Support the transmission with a transmission jack 18 No 2 crossmember 19 Rear engine support insulator AA 20 Transmission assembly ...

Page 806: ... on the engine side INSTALLATION SERVICE POINTS AA TRANSMISSION ASSEMBLY INSTALLATION The sizes of the mounting bolts are different So be sure not to confuse them Bolt Diameter x Length mm A 10 x 40 B 8 x 55 C 10 x 60 D 10 x 65 BA THROTTLE CABLE INSTALLATION After installing the throttle cable adjust it by the following procedure 1 Open the throttle lever completely and adjust the cable with the a...

Page 807: ... to P 23 11 4 Transfer Case Protector Installation 5 Selector Lever and Transfer Control Lever Installation Refer to P 23 23 6 Selector Lever Operation Check Refer to P 23 14 7 Speedometer Operation Check 1 13 3 12 10 9 8 7 6 5 4 2 14 15 25 Nm 16 Nm 45 Nm 26 Nm 36 Nm 24 Nm 12 Nm 24 Nm 22 Nm 9 Nm 10 12 Nm 11 Removal steps BA 1 Throttle cable connection 2 Filler tube assembly mounting bolt 3 Oil coo...

Page 808: ...m 24 Nm 16 Filler tube assembly 17 O ring 18 Exhaust pipe clamp bracket AB 19 Torque converter and drive plate con nection bolt D Support the transmission with a transmission jack 20 Transfer roll stopper 21 Transfer mount bracket 22 Transfer support bracket 23 No 2 crossmember 24 Stopper 25 Rear engine support insulator AA 26 Transmission assembly ...

Page 809: ...ERTER AND DRIVE PLATE CONNECTION BOLTS REMOVAL 1 Remove the connection bolts 6 places while turning the crankshaft 2 Press in the torque converter to the transmission side so the torque converter does not remain on the engine side INSTALLATION SERVICE POINTS AA TRANSMISSION ASSEMBLY INSTALLATION The sizes of the mounting bolts are different So be sure not to confuse them Bolt Diameter x Length mm ...

Page 810: ...ide until the inner cable stopper can be seen 2 Open the throttle lever completely and adjust the cable with the adjusting nut so that the distance between the inner cable stopper and the outer cable end is at the standard value Standard value A 34 35 mm 3 Tighten the adjusting nut to the specified torque 4WD INDICATOR ECU 23101090014 REMOVAL AND INSTALLATION Refer to GROUP 22 Outer cable Inner ca...

Page 811: ...fer to P 23 11 3 Skid Plate and Front Under Cover Removal and Installation 2WD 4WD 8 12 11 10 1 2 7 3 4 9 12 11 10 8 4 6 5 45 Nm 29 34 Nm 45 Nm 35 Nm 2 5 Removal steps 1 Eye bolt for engine oil cooler 2 Gasket for engine oil cooler 3 Engine oil cooler tube assembly connection 4 Eye bolt for transmission oil cooler 5 Gasket 6 Transmission oil cooler tube assembly connection 7 Oil cooler assembly 8 ...

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Page 813: ......

Page 814: ......

Page 815: ...3 INFORMATION INTERNATIONAL CAR ADMINISTRATION OFFICE T NITTA PROJECT LEADER AFTER SALES SERVICE CS PROMOTION 1 Description In the 99 L200 Workshop Manual a description of abolishment of the ABS idle up solenoid valve has been added 2 Applicable Manuals Manual Pub No Language Page s 99 L200 PWTE96E1 C English 23 3 Workshop Manual chassis PWTS96E1 C Spanish PWTF96E1 C French PWTG96E1 C German 3 Int...

Page 816: ... starting form the nearest one to the transmission assembly 4 Securely tighten the feed tube flare nut and return tube flare nut B FEED HOSE RETURN HOSE B RETURN HOSE A INSTALLATION 1 Connect the feed hose return hose B and return hose A with the mark upwards 2 Insert the hose up to bulge A on the nipple and tube as shown 3 Attach the hose clip at the position being sure that it is not on top of b...

Page 817: ...5B 35C ANTI SKID BRAKING SYSTEM ABS 2WD 4WD GENERAL OUTLINE OF CHANGES The ABS idle up solenoid valve has been abolished 4D56 ABS 2WD 4WD General 35B 35C 1 Added Idle up solenoid valve Abolished 16V0104 16V0202 ...

Page 818: ...vice adjustment procedure of the vehicle with 4D5 engine has been established SERVICE SPECIFICATIONS Items Standard value Play of the accelerator cable inner cable mm 1 2 Dimension of the throttle cable inner cable stopper and outer cable end mm 0 8 1 5 TROUBLESHOOTING SHIFT PATTERN 2WD 1 2 2 1 2 3 2 L 3 2 3 4 4 3 Lock up ON Lock up OFF Throttle opening 100 80 60 40 20 0 1 000 2 000 3 000 4 000 5 ...

Page 819: ...sembly and bracket do not become deformed 3 Check the play of the accelerator cable inner cable Standard value 1 2 mm 4 If the play in inner cable is out of standard value adjust by following the step below 1 Loosen the locking nut and adjusting nut in order to have the A T throttle control cable link assembly to be free 2 Tighten the adjusting nut until the A T throttle control cable link assembl...

Page 820: ...st by following the step below 1 Loosen the locking nut and adjusting nut in order to have the A T throttle control cable link assembly to be free 2 Turn the adjusting nut adjust in order that the dimension A between the inner cable stopper and the outer cable end is in standard value 3 Tighten the lock nut in specified torque Tightening torque 16 2 N m Throttle cable Inner cable Lock nut Adjustin...

Page 821: ...NOTES ...

Page 822: ......

Page 823: ......

Page 824: ...g For 4WD the front propeller shaft is a 2 joint type Rear propeller shaft Center bearing Front propeller shaft Rear propeller shaft Front Rear Center bearing Front propeller shaft SERVICE SPECIFICATIONS 25100030042 Items Standard value Limit Clearance between snap ring and groove wall of yoke mm 0 03 or less Front propeller shaft runout mm 0 6 Rear propeller shaft runout mm 0 6 ...

Page 825: ...Specified lubricant Quantity Sleeve yoke Hypoid gear oil SAE 75W 85W conforming to API GL 4 or higher As required SPECIAL TOOLS 25100060041 Tool Number Name Use MB990840 Universal joint re mover and installer Disassembly and reassembly of the universal joint MB991410 Collar ...

Page 826: ...to GROUP 23 On vehicle Service Post installation Operation 4WD D Transfer Gear Oil Supplying M T Refer to GROUP 22 On vehicle Service A T Refer to GROUP 23 On vehicle Service D Front Under Cover Installation Gear Oil Hypoid gear oil SAE 75W 85W conforming to API GL 4 or higher 2WD 4WD 35 Nm 49 59 Nm 2 35 Nm 49 59 Nm 1 29 34 Nm 49 59 Nm 3 Removal steps AA AA 1 Propeller shaft assembly AA AA 2 Rear ...

Page 827: ...e propeller shaft assembly to the companion flange Caution 1 Tighten installation bolts after removing oil and grease from threads to prevent them from loosening due to lubrication 2 Be careful not to damage the lip section of the transfer case oil seal when installing the propeller shaft INSPECTION 25100110043 D Check the sleeve yoke center yoke and flange yoke for wear damage or cracks D Check t...

Page 828: ...ype 1 External snap ring type Universal joint kit 186 Nm 1 2 3 4 5 6 7 8 9 3 2 1 3 2 8 3 2 1 3 2 1 Disassembly steps AA CA 1 Snap ring AB BA 2 Journal bearing 3 Journal 4 Sleeve yoke 5 Flange yoke 6 Propeller shaft rear AC AA 7 Center yoke AD AA 8 Center bearing assembly 9 Propeller shaft front ...

Page 829: ...opeller shaft Type 2 Internal snap ring type Type 1 Type 2 10 4 3 2 1 4 2 1 3 4 3 2 1 5 1 2 3 4 3 2 4 10 4 3 1 2 2 1 3 4 7 Disassembly steps AA CA 1 Snap ring 2 Grease fitting AB BA 3 Journal bearing 4 Journal 5 Sleeve yoke 6 Flange yoke 7 Front propeller shaft 8 Propeller shaft rear AC AA 9 Center yoke AD AA 10 Center bearing assembly 11 Propeller shaft front ...

Page 830: ...remove the first journal bearing that was pushed Caution Do not tap the journal bearings to remove them as this will upset the balance of the propeller shaft AC CENTER YOKE REMOVAL Place a mating mark on the center yoke and front propeller shaft and then remove the center yoke AD CENTER BEARING ASSEMBLY REMOVAL After removing the rubber mount use a commercially available puller to remove the cente...

Page 831: ...journal bearing into the yoke until the snap ring groove is fully visible 2 Use the special tool to press the opposite side journal bearing into the yoke Caution Be careful when pressing the journal bearings as if they are pressed at an angle the inside of the journal bearings will be damaged by the journal 3 Align the mating marks on the yoke and propeller shaft and install the propeller shaft jo...

Page 832: ...sure the clearance of the snap ring groove with a thickness gauge Standard value A 0 03 mm or less Caution Always use snap rings of equal thicknesses on both sides 4 If the clearance exceeds the standard value adjust by changing the thickness of the snap ring Thickness mm Type 1 Thickness mm Type 2 Identification color 1 28 1 50 1 31 1 55 Yellow 1 34 1 60 Blue 1 37 1 65 Purple Type 1 Type 2 Type 1...

Page 833: ...FRONT AXLE ...

Page 834: ......

Page 835: ...addition a D O J B J type constant velocity ball joint has high power transmission efficiency and reduces vibration and noise D A vacuum type freewheel clutch has been adopted in the freewheel mechanism Its solenoid valve and actuator switch powertrain between 2WD and 4WD D There are two types of differential gear The difference between them is gear ratio 2WD Item Specifications Wheel bearing Type...

Page 836: ...ear x 2 gear ty e type x piece Pinion gear Straight bevel gear x 2 Straight bevel gear x 2 Number of teeth Drive gear 51 39 teeth Drive pinion 11 8 Side gear 14 14 Pinion gear 10 10 Bearing O D x I D Side 80 0 x 45 2 80 0 x 45 2 O D x I D mm Front 64 3 x 30 2 64 3 x 30 2 Rear 76 2 x 36 5 76 2 x 36 5 CONSTRUCTION DIAGRAM 4WD 2WD Drive shaft R H Actuator Freewheel clutch assembly Rotor Front hub ass...

Page 837: ...ing axial play mm 0 05 0 30 Drive gear backlash mm 0 11 0 16 Differential gear backlash mm 0 0 076 Drive pinion rotation torque Nm Without oil seal When replacing with anti rust agent 0 3 0 5 When replacing or reusing with gear oil applied 0 15 0 25 With oil seal When replacing with anti rust agent 0 5 0 7 When replacing or reusing with gear oil applied 0 3 0 4 Drive gear runout mm 0 05 Differenti...

Page 838: ...inner shaft Used together with MB990906 MB990954 Lock nut wrench Removal and adjustment of lock nut 4WD MB990925 Bearing and oil seal installer set D Press out and press fitting of wheel bearing outer race D Press fitting of oil seal front hub D Press fitting of needle bearing Knuckle D Press fitting of bearing freewheel clutch D Press fitting of oil seal freewheel clutch D Press out and press fit...

Page 839: ...al installer Press fitting of knuckle oil seal Used together with MB990938 MB991561 Boot band clipping tool Resin boot band installation MB990906 Drive shaft attachment Removal and installation of inner shaft Used together with MB990211 MB990560 Bearing remover Removal and press fitting of inner shaft bearing MB990799 Ball joint remover and installer Installation of freewheel clutch bearing MB9911...

Page 840: ...11 Differential side bearing cap MB990850 End yoke holder Removal and installation of companion flange MB990339 Bearing puller Removal of drive pinion front bearing inner race MB990648 Bearing remover A B MB990901 A MB990904 B MB990552 Pinion height gauge set A Drive pinion gauge assembly B Cylinder gauge D Inspection of drive pinion rotation starting torque D Measurement of drive pinion height MB...

Page 841: ...99 Drive pinion oil seal installer Press fitting of drive pinion oil seal MB990813 Tap Removal of adhesive MB990925 Brass bar Installer adapter Tool box Bar snap in type A C B Contents of tool MB990925 O D mm Contents of tool MB990925 O D mm A MB990926 39 A MB990933 63 5 MB990927 45 MB990934 67 5 MB990928 49 5 MB990935 71 5 MB990929 51 MB990936 75 5 MB990930 54 MB990937 79 MB990931 57 B MB990938 M...

Page 842: ...in the knuckle turn the nut back within 30_ Then install the split pin 4WD FRONT AXLE TOTAL BACKLASH CHECK 26100130022 Observe the following procedure in order to switch powertrain to 4WD 1 Turn the ignition switch off and then put the transfer shift lever to the 2H position Caution Do not jack up the vehicle 2 Turn the propeller shaft until a click is heard 3 Turn the companion flange clockwise u...

Page 843: ...ls 2 Remove the hub cap 3 Manually push the drive shaft in the direction in which it will closely contact the knuckle 4 As shown in the figure use a thickness gauge to measure the clearance between the drive flange and snap ring Standard value 0 4 0 7 mm 5 If the play is out of standard value adjust by adding or removing shims DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT 26200100026 1 Remove the unde...

Page 844: ...et R H 12 Install the inner shaft and drive shaft R H Caution 1 Do not damage the lip of the oil seal 2 The circlip attached to the B J side of the drive shaft should be replaced with a new clip 13 Install the actuator and secure the harness with the clamp 14 Install the shock absorber 15 Install the hub and knuckle assembly 16 Install the under cover SOLENOID VALVE OPERATION CHECK 26100150028 1 R...

Page 845: ...tery voltage is applied to solenoid valves A and B negative pressure is maintained 4 Connect the hand vacuum pump to solenoid valve A Apply negative pressure and carry out the following inspections 1 With no other operation negative pressure is maintained 2 When battery voltage is applied to solenoid valve B negative pressure disappears 3 When battery voltage is applied to solenoid valve A negativ...

Page 846: ...m 2 Removal steps AA 1 Caliper assembly 2 Hub cap 3 Split pin AA 4 Wheel bearing nut 5 Washer AB 6 Front hub assembly REMOVAL SERVICE POINTS AA CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire so that it does not fall AB FRONT HUB ASSEMBLY REMOVAL Do not drop the outer bearing inner race Outer bearing inner race ...

Page 847: ...ck within 30_ Then install the split pin DISASSEMBLY AND REASSEMBLY 26100190075 1 2 3 4 5 6 7 8 49 59 Nm 4 5 7 8 6 1 Disassembly steps 1 Outer bearing inner race CA 2 Rotor Vehicles with ABS AA 3 Brake disc BA 4 Oil seal 5 Inner bearing inner race AB AA 6 Outer bearing outer race AB AA 7 Inner bearing outer race 8 Front hub DISASSEMBLY SERVICE POINTS AA BRAKE DISC REMOVAL Make the mating marks on ...

Page 848: ...ALLATION SERVICE POINTS AA INNER BEARING OUTER RACE OUTER BEARING OUTER RACE INSTALLATION NOTE Replace the inner race and outer race assembly as a set BA OIL SEAL INSTALLATION CA ROTOR INSTALLATION Outer bearing outer race MB990939 Inner bearing outer race MB990933 Inner bearing outer race MB990938 Outer bearing outer race MB990928 MB990938 MB990936 MB990938 MB990955 Rotor ...

Page 849: ...6 7 8 2 8 Removal steps AA 1 Caliper assembly 2 Hub cap DA D Drive shaft axial play adjustment 3 Snap ring 4 Shim 5 Drive flange CA D Hub rotary sliding resistance and wheel bearing axial movement adjustment BA 6 Lock washer AB AA 7 Lock nut AC 8 Front hub assembly REMOVAL SERVICE POINTS AA CALIPER ASSEMBLY REMOVAL Secure the removed caliper assembly with wire so that it does not fall AB LOCK NUT ...

Page 850: ...lock nut move it within a range of not more than 20_ until the holes are aligned CA HUB ROTARY SLIDING RESISTANCE AND WHEEL BEARING AXIAL MOVEMENT ADJUSTMENT 1 Use a spring balance to measure the hub rotary sliding resistance hub rotation starting torque as shown in the illustration Standard value 7 26 N 0 5 1 8 Nm 2 If the rotary sliding resistance is not within the standard value remove the lock...

Page 851: ...DJUSTMENT 1 Push the drive shaft in by hand towards the knuckle until they touch 2 Measure the clearance between the drive flange and the spacer with a thickness gauge as shown in the illustration Standard value 0 4 0 7 mm 3 If the amount of play is outside the standard value adjust by selecting a shim that will bring the play to the standard value DISASSEMBLY AND REASSEMBLY 26100190082 13 Nm 49 5...

Page 852: ...b and brake disc if necessary Caution Lock disc in vise and grip with copper or aluminium board REASSEMBLY SERVICE POINTS AA INNER BEARING OUTER RACE OUTER BEARING OUTER RACE INSTALLATION NOTE Replace the inner race and outer race assembly as a set BA OIL SEAL INSTALLATION Outer bearing outer race MB990939 Inner bearing outer race Mating marks Inner bearing outer race MB990938 Outer bearing outer ...

Page 853: ... Nm 7 39 Nm 44 Nm 147 Nm Removal steps 1 Dust cover 2 Front speed sensor Vehicles with ABS Refer to GROUP 35B Wheel Speed Sensor AA 3 Tie rod end connection AB 4 Lower arm ball joint connection AA 5 Upper arm ball joint connection 6 Stopper bolt 7 Knuckle REMOVAL SERVICE POINTS AA TIE ROD END UPPER ARM BALL JOINT DISCONNECTION Caution 1 Use the special tool to loosen the nut only do not remove it ...

Page 854: ...nuckle 2WD 26 21 AB LOWER ARM BALL JOINT DISCONNECTION Caution Use the special tool to loosen the nut only do not remove it from the ball joint INSPECTION 26100250049 D Check the knuckle for wear or cracks MB990804 ...

Page 855: ...le Service 1 34 44 Nm 74 Nm 12 Nm 88 103 Nm 118 177 Nm 2 3 4 5 6 7 8 Removal steps 1 Dust cover 2 Front speed sensor Vehicles with ABS Refer to GROUP 35B Wheel Speed Sensor 3 Stabilizer bar connection 4 Shock absorber lower mounting bolt AA 5 Tie rod end connection AA 6 Lower arm ball joint connection AA 7 Upper arm ball joint connection 8 Knuckle Caution Indicates parts which should be temporaril...

Page 856: ... UPPER ARM BALL JOINT DISCONNECTION Caution 1 Use the special tool to loosen the nut only do not remove it from the ball joint 2 Tie the special tool with a cord not to let it fall off INSPECTION 26100250056 D Check the knuckle for wear or cracks Nut Cord Ball joint MB991113 or MB990635 ...

Page 857: ...FRONT AXLE Knuckle 4WD 26 24 DISASSEMBLY AND REASSEMBLY 26100320023 1 2 3 4 3 2 1 Disassembly steps CA 1 Oil seal BA 2 Spacer AA AA 3 Needle bearing 4 Knuckle ...

Page 858: ...POINTS AA NEEDLE BEARING INSTALLATION Caution Use care to prevent driving the needle bearing too far in BA SPACER INSTALLATION Install the spacer to the knuckle with the chamfered side toward the center of vehicle CA OIL SEAL INSTALLATION MB990939 MB990956 MB990938 MB990956 MB990985 MB990938 MB990985 ...

Page 859: ...ront hub shim set Sealant 3M ATD Part No 8661 or equivalent 49 59 Nm 13 12 3 90 Nm Removal steps AA 1 Caliper assembly 2 Front speed sensor Vehicles with ABS Refer to GROUP 35B Wheel Speed Sensor 3 Hub cap CA D Drive shaft axial play adjustment 4 Snap ring 5 Shim 6 Stabilizer bar connection 7 Shock absorber lower mounting bolt AB 8 Tie rod end connection AB 9 Lower arm ball joint connection AB 10 ...

Page 860: ... remove upper knuckle towards you NOTE Pull the D O J side of the drive shaft assembly out slightly from the front differential carrier 2 Slightly back off drive shaft from knuckle Remove lower knuckle holding nut from the lower arm ball joint 3 Disconnect knuckle and lower ball joint 4 Remove knuckle and front hub assembly from drive shaft assembly Caution Do not damage knuckle oil seals with dri...

Page 861: ...and lock upper ball joint onto upper arm 4 Tighten lower ball joint mounting nuts to specified torque Tightening torque 118 177 Nm CA DRIVE SHAFT AXIAL PLAY ADJUSTMENT 1 Push the drive shaft in by hand towards the knuckle until they touch 2 Measure the clearance between the drive flange and the spacer with a thickness gauge as shown in the illustration Standard value 0 4 0 7 mm 3 If the amount of ...

Page 862: ...SPECTION 26100360087 D Check the boot for damage or deterioration D Check the ball joint for operating condition and excessive looseness D Check the splines for wear or damage D Check the differential carrier oil seal L H for damaged ...

Page 863: ...ot band small 3 Circlip 4 D O J outer race 5 Dust cover AA 6 Balls AB 7 D O J cage 8 Snap ring 9 D O J inner race AC 10 D O J boot 11 B J assembly 12 Circlip 13 B J boot band small 14 B J boot band large 15 B J boot Reassembly steps 12 Circlip 11 B J assembly AA 9 D O J inner race AA 8 Snap ring AA 7 D O J cage AA 6 Balls BA 4 D O J outer race 5 Dust cover 3 Circlip CA10 D O J boot CA 2 D O J boot...

Page 864: ...se Repair kit grease Grease Repair kit grease 100 g 60 g inside joint 40 g inside boot Caution Do not mix old and new or different types of grease as a special grease is used in the joint DISASSEMBLY SERVICE POINTS AA BALLS REMOVAL AB D O J CAGE REMOVAL ...

Page 865: ...er race and D O J boot with the specified grease Specified grease Repair kit grease 100 g NOTE The grease in the repair kit should be divided in half for use respectively at the joint and inside the boot Caution The drive shaft joint use special grease Do not mix old and new or different types of grease CA D O J BOOT D O J BOOT BAND INSTALLATION 1 Position the D O J outer race so that the distance...

Page 866: ...eter in a position such that the shaft groove can be seen 4 Turn the adjusting bolt on the special tool so that the size of the opening W is at the standard value Standard value W 2 9 mm If it is larger than 2 9 mm Tighten the adjusting bolt If it is smaller than 2 9 mm Loosen the adjusting bolt NOTE 1 The value of W will change by approximately 0 7 mm for each turn of the adjusting bolt 2 The adj...

Page 867: ... mm Readjust the value of W in step 4 according to the following formula and then repeat the operation in step 6 W 5 5 mm B Example If B 2 9 mm then W 2 6 mm If the crimping amount is smaller than 2 4 mm Remove the B J boot band readjust the value of W in step 4 according to the following formula and then repeat the operations in steps 5 and 6 using a new B J boot band W 5 5 mm B Example If B 2 3 ...

Page 868: ... crimping amount E of the B J boot band is at the standard value Standard value E 2 4 2 8 mm If the crimping amount is larger than 2 8 mm Readjust the value of W in step 11 according to the following formula and then repeat the operation in step 13 W 5 8 mm E Example If E 2 9 mm then W 2 9 mm If the crimping amount is smaller than 2 4 mm Remove the B J boot band readjust the value of W in step 11 ...

Page 869: ...m 88 Nm 8 49 59 Nm 17 Nm 9 10 11 12 88 Nm Removal steps AA 1 Caliper assembly 2 Hub assembly knuckle Refer to P 26 22 3 Drive shaft R H Refer to P 26 26 AB AA 4 Inner shaft 5 Circlip 6 Pin 7 Spacer 8 Rubber 9 Differential mounting bracket R H 10 Pin 11 Actuator assembly 12 Housing tube assembly Caution Indicates parts which should be temporarily tightened and then fully tightened with the vehicle ...

Page 870: ... fall AB INNER SHAFT REMOVAL Caution When pulling the inner shaft out from the front differential carrier be careful that the spline part of the inner shaft does not damage the oil seal INSTALLATION SERVICE POINT AA INNER SHAFT INSTALLATION Caution Be careful not to damage the lip of the dust seal and oil seal MB990906 MB990211 MB990906 MB990211 ...

Page 871: ...ng BA 3 Dust cover 4 Housing tube AA 5 Dust seal DISASSEMBLY SERVICE POINT AA BEARING REMOVAL 1 Bend the outside periphery of dust cover inward with a hammer 2 After the special tool has been installed as shown tighten the nut of the special tool until the portion A of the special tool touches the bearing outer race MB990560 A ...

Page 872: ...new dust seal into the housing tube by using the special tools until it is flush with the housing tube end face BA DUST COVER INSTALLATION Using a steel pipe force a new dust cover onto the inner shaft Steel pipe mm Overall length 50 Outside diameter 75 Wall thickness 4 CA BEARING INSTALLATION MB990560 MB990938 MB990955 Steel pipe MB990560 ...

Page 873: ... shaft Refer to P 26 36 4 Circlip CA 5 Vacuum hose connection 6 Pin 7 Actuator assembly AA BA 8 Front propeller shaft connection 9 Freewheel engage switch connector 10 Front suspension crossmember 11 Differential mount insulator assem bly D Support the differential by a transmission jack 12 Pin 13 Spacer 14 Rubber 15 Differential mounting bracket L H 16 Differential mounting bracket R H 17 Freewhe...

Page 874: ...clutch assembly to the front differential 2 Place a micrometer against the end of the clutch gear and check the axial play of the clutch gear bearing Standard value 0 05 0 30 mm 3 If the play is not within the standard value disassemble the bearing and insert a spacer of the appropriate thickness NOTE The thicknesses of the spacers vary in steps of 0 25 mm BA FRONT PROPELLER SHAFT INSTALLATION Ins...

Page 875: ...drive gear runout at the shoulder on the reverse side of the drive gear Limit 0 05 mm 2 When runout exceeds the limit value check for foreign object between drive gear rear side and differential case or for loose drive gear installation bolts 3 When check 2 gives normal results reposition drive gear and differential case and remeasure 4 If adjustment is impossible replace differential case or repl...

Page 876: ...oth surfaces of the drive gear teeth 2 Insert the brass between the differential carrier and the differential case and then rotate the companion flange by hand once in the normal direction and then once in the reverse direction while applying a load to the drive gear so that the revolution torque approximate 250 300 Ncm is applied to the drive pinion Caution If the drive gear is rotated too much t...

Page 877: ...2 3 4 2 3 4 Tooth contact pattern resulting from insufficient pinion height The drive pinion is positioned too close to the centre of the drive gear 1 2 3 4 Decrease the thickness of the drive pinion rear shim and position the drive pinion farther from the centre of the drive gear Also for backlash adjustment position the drive gear closer to the drive pinion 1 2 3 4 NOTE Checking the tooth contac...

Page 878: ... 8 Lock pin 9 Pinion shaft 10 Pinion gear 11 Pinion washer 12 Side gear 13 Side gear spacer 14 Differential case AE 15 Self locking nut 16 Washer AF 17 Drive pinion assembly 18 Drive pinion 19 Drive pinion front shim for pinion height adjustment AG 20 Drive pinion front bearing inner race 21 Drive pinion spacer 22 Drive pinion rear shim for turning torque adjustment 23 Companion flange 24 Oil seal...

Page 879: ...e so that they do not become mixed at the time of reassembly AB SIDE BEARING INNER RACE REMOVAL NOTE There are two notches provided at the differential case side for the claw part of the special tool use the special tool at that position AC DRIVE GEAR REMOVAL 1 Make the mating marks to the differential case and the drive gear 2 Loosen the drive gear attaching bolts in diagonal sequence to remove t...

Page 880: ...n flange must not be on the coupling surface of the flange yoke and the front propeller shaft 2 Drive out the drive pinion together with the drive pinion spacer and drive pinion shims AG DRIVE PINION FRONT BEARING INNER RACE REMOVAL AH DRIVE PINION REAR BEARING OUTER RACE REMOVAL AI DRIVE PINION FRONT BEARING OUTER RACE REMOVAL Mating marks MB990339 MB990648 MB990939 MB990939 ...

Page 881: ...n front shim for pinion height adjustment 9 Drive pinion front bearing inner race EA D Drive pinion turning torque adjustment 10 Drive pinion rear bearing inner race 11 Oil seal 12 Drive pinion rear shim for turning torque adjustment 13 Drive pinion spacer 14 Drive pinion assembly 15 Companion flange 16 Washer 17 Self locking nut 18 Differential case 19 Side gear spacer 20 Side gear 21 Pinion wash...

Page 882: ...ONT AXLE Differential Carrier 26 49 Lubrication Sealing and Adhesive Points Adhesive 3M Stud Locking 4170 or equivalent Sealant 3M ATD Part No 8661 or equivalent Sealant 3M ATD Part No 8661 or equivalent ...

Page 883: ...e 1 Apply multipurpose grease to the washer of the special tool 2 Install the special tool drive pinion front and rear bearing inner races to the gear carrier 3 Tighten the nut of the special tool while measuring the rotation torque of the drive pinion Gradually keep tightening the nut of the special tool until the rotation torque of the drive pinion without oil seal is at the standard value MB990...

Page 884: ...tch is in the shown position and that the special tools are touching firmly against the side bearing hub 6 Use a thickness gauge to measure the clearance A between the special tools 7 Remove the special tools MB991170 MB990904 8 Use a micrometer to measure the special tool in the places B C shown in the illustration 9 Install the bearing cap and then use a cylinder gauge and micrometer to measure ...

Page 885: ...panion flange to the specified torque by using the special tool 3 Measure the drive pinion rotation torque without the oil seal by using the special tools Standard value Bearing division Bearing lubrication Rotation torque New None With anti rust agent 0 3 0 5 Nm New reusing Gear oil applied 0 15 0 25 Nm 4 If the drive pinion rotation torque is not within the range of the standard value adjust the...

Page 886: ... properly aligned and tighten the companion flange self locking nut to the specified torque by using the special tools 7 Measure the drive pinion rotation torque with the oil seal by using the special tools Standard value Bearing division Bearing lubrication Rotation torque New None With anti rust agent 0 5 0 7 Nm New reusing Gear oil applied 0 3 0 4 Nm 8 If the drive pinion rotation torque is not...

Page 887: ...ust the backlash by installing thicker side gear spacers 6 If adjustment is not possible replace the side gears and pinion gears as a set 7 Measure the differential gear backlash once again and confirm that it is within the limit GALOCK PIN INSTALLATION 1 Align the pinion shaft lock pin hole with the differential case lock pin hole and drive in the lock pin 2 Stake the lock pin with a punch at two...

Page 888: ...ed to the side bearing outer races and then mount the differential case assembly into the gear carrier NOTE Select side bearing spacers with the same thickness for both the drive pinion side and the drive gear side 2 Push the differential case assembly to one side and measure the clearance between the gear carrier and the side bearing adjusting spacer with a thickness gauge 3 Measure the thickness...

Page 889: ...with a dial indicator on the drive gear NOTE Measure at four points or more on the circumference of the drive gear Standard value 0 11 0 16 mm 8 Change the side bearing adjusting spacers as illustrated and then adjust the drive gear backlash between the drive gear and the drive pinion NOTE When increasing the number of side bearing adjusting spacers use the same number for each and as few as possi...

Page 890: ...e reverse side of the drive gear Limit 0 05 mm 11 If the drive gear runout exceeds the limit reinstall by changing the phase of the drive gear and differential case and remeasure 12 If adjustment is not possible replace the differential case or replace the drive gear and drive pinion as a set ...

Page 891: ...removal steps 1 Inner shaft Refer to P 26 36 2 Circlip 3 Freewheel engage switch connector 4 Freewheel engage switch EA 5 Vacuum hose 6 Pin 7 Actuator assembly D Support the differential by a transmission jack 8 Pin 9 Spacer 10 Rubber 11 Differential mounting bracket R H 12 Housing tube assembly 13 Freewheel clutch assembly DA D Clutch gear bearing axial play inspection ...

Page 892: ... Check valve 19 Vacuum pipe 20 Vacuum hose AA 21 Vacuum hose AA 22 Vacuum pipe assembly AA 23 Vacuum hose assembly INSTALLATION SERVICE POINTS AA VACUUM HOSE ASSEMBLY VACUUM PIPE ASSEMBLY VACUUM HOSE INSTALLATION Install the vacuum hoses so that the identification colours of the vacuum pipe assembly match those of the actuators Note that there is no identification colour for the vacuum hose which ...

Page 893: ...ionally install the freewheel clutch assembly to the front differential 2 Place a micrometer against the end of the clutch gear and check the axial play of the clutch gear bearing Standard value 0 05 0 30 mm 3 If the axial play of the clutch gear bearing is not within the standard value disassemble the bearing and insert a spacer of the appropriate thickness NOTE The thickness of the spacers vary ...

Page 894: ...emoval steps AA 1 Main shaft FA 2 Spacer AA EA 3 Bearing 4 Clutch sleeve DA 5 Spring pin 6 Snap ring 7 Shift fork 8 Shift rod CA 9 Oil seal AB BA 10 Clutch gear AB BA 11 Bearing AA 12 Oil seal 13 Clutch housing DISASSEMBLY SERVICE POINTS AA MAINSHAFT BEARING REMOVAL 1 After the special tool has been installed as shown tighten the nut of the special tool until the portion A of the special tool touc...

Page 895: ...d bearing together 2 Use a press to hold the supports against the bearing inner race and separate the clutch gear and bearing REASSEMBLY SERVICE POINTS AA OIL SEAL INSTALLATION Use the special tool to tap the oil seal until it is flush with the clutch housing BA BEARING CLUTCH GEAR INSTALLATION 1 Use the special tool to press fit the bearing to the shoulder of the clutch gear MB990560 Iron MB99116...

Page 896: ... the projection length becomes length shown in the illustration EA BEARING INSTALLATION Press fit the bearing to the shoulder of the mainshaft FA SPACER INSTALLATION 1 After installing the freewheel clutch assembly select a spacer so that the clutch gear axial play bearing looseness is within the standard value Standard value 0 05 0 30 mm 2 If it is outside the standard value disassemble and selec...

Page 897: ...NOTES ...

Page 898: ...K60 70 97 10 Group FRONT SUSPENSION Draft No 98SY070111 CORRECTION OVERSEAS SERVICE DEPT T NITTA VICE GENERAL MANAGER QUALITY INFORMATION ANALYSIS 1 Description This Service Bulletin informs you concerning correction of the part number of the pinion height gauge set s component part 2 Applicable Manuals Manual Pub No Language Page s 97 L200 PWTE96E1 English 26 7 51 Workshop Manual Chassis PWTS96E1...

Page 899: ...Bearing puller Removal of drive pinion front bearing inner race MB990648 Bearing remover MB990901 A MB990904 B MB990552 Pinion height gauge set A Drive pinion gauge assembly B Cylinder gauge Inspection of drive pinion rotation starting torque Measurement of drive pinion height MB990685 Torque wrench Measurement of drive pinion height MB991171 A MB991171 Pinion height gauge set A Cylinder gauge Mea...

Page 900: ...170 MB990904 8 Use a micrometer to measure the special tool in the places B C shown in the illustration 9 Install the bearing cap and then use a cylinder gauge and micrometer to measure the inside diameter D of the bearing cap as shown in the illustration 10 Calculate the thickness E of the required drive pinion front shim by the following formula and then select a shim which most closely matches ...

Page 901: ...E DEPT T NITTA VICE GENERAL MANAGER QUALITY INFORMATION ANALYSIS NOTE This Service Bulletin is a revision of the S B MSB 98E33 501 which contained an error in the pinion height gauge set part number S B MSB 98E33 501 should be discarded 1 Description This Service Bulletin informs you concerning correction of the part number of the pinion height gauge set s component part 2 Applicable Manuals Manua...

Page 902: ...r Removal of drive pinion front bearing inner race MB990648 Bearing remover MB990901 A MB990904 B MB990552 Pinion height gauge set A Drive pinion gauge assembly B Cylinder gauge Inspection of drive pinion rotation starting torque Measurement of drive pinion height MB990685 Torque wrench Measurement of drive pinion height MB991171 A MB991171 Pinion height gauge set A Cylinder gauge Measurement of d...

Page 903: ...icrometer to measure the special tool in the places B C shown in the illustration 9 Install the bearing cap and then use a cylinder gauge and micrometer to measure the inside diameter D of the bearing cap as shown in the illustration 10 Calculate the thickness E of the required drive pinion front shim by the following formula and then select a shim which most closely matches this thickness E A B C...

Page 904: ...REAR AXLE ...

Page 905: ......

Page 906: ...pe Banjo type Axle shaft Support method Semi floating type Semi floating type shaft Shaft O D Bearing part x Centre x Length mm 40 0 x 34 5 x 744 5 40 0 x 34 5 x 723 5 LH 40 0 x 34 5 x 761 0 RH Bearing type Single taper double taper Double taper Bearing O D x I D mm 80 0 x 40 0 80 0 x 40 0 NOTE Vehicles with ABS DIFFERENTIAL 2WD Item 4G63 4D56 Drive gear type Hypoid gear Hypoid gear Reduction rati...

Page 907: ...ear type type x quantity Side gear Straight bevel gear x 2 Straight bevel gear x 2 type x quantity Pinion gear Straight bevel gear x 2 Straight bevel gear x 4 Straight bevel gear x 2 Straight bevel gear x 4 Number of teeth Side gear 39 51 Drive pinion 8 11 Side gear 19 19 Pinion gear 10 10 Bearing O D x I D mm Side 80 0 x 45 2 80 0 x 45 2 mm Front 68 3 x 30 2 68 3 x 30 2 Rear 79 4 x 36 5 79 4 x 36...

Page 908: ...ar differential lock Initial press fitting force 49 000 or more Final press fitting force 98 000 108 000 Clearance between axle shaft retainer and snap ring mm 0 0 166 Rear differential lock air pump pressure kPa 25 40 Drive gear backlash mm 2WD 0 08 0 13 4WD 0 13 0 18 Drive gear runout mm 0 05 Differential gear backlash mm 2WD 0 0 25 0 2 4WD 0 0 076 0 2 Limited slip differential starting torque N...

Page 909: ...ss of the friction surface and the projections mm 0 1 LUBRICANTS 27100040049 Item Specified lubricants Quantity Rear differential gear oil D Conventional differential Hypoid gear oil API classification GL 5 or higher SAE viscosity No 90 80 W D Limited slip differential 2WD 1 6 D Limited sli differential Hypoid gear oil MITSUBISHI Genuine Gear Oil Part No 8149630 EX CASTROL HYPOY LS GL 5 SAE 90 SHE...

Page 910: ...ft puller Removal of axle shaft Use together with MB990211 MB991552 Axle shaft bearing and case remover Removal of the axle shaft bearing and bearing case MB990801 Rear axle bearing outer race remover Removal of bearing case bearing outer race MB990786 Rear axle bearing outer race bridge MB990560 Bearing remover D Removal of bearing inner race D Press fitting of the axle shaft bearing inner race D...

Page 911: ...ial carrier MB990201 Side bearing adjusting special spanner Removal and adjustment of the side bearing nut MB990810 Side bearing puller Removal of the side bearing inner race MB990811 Side bearing cup MB990850 End yoke holder Removal of the companion flange MB990339 Bearing puller Removal of the drive pinion rear bearing inner race MB990648 Bearing remover ...

Page 912: ...l of adhesive MB990728 Bearing installer Press fitting of the drive pinion rear bearing inner race MB990727 Drive pinion oil seal installer Press fitting of the drive pinion oil seal MB990802 Bearing installer Press fitting of the side bearing inner race A B C MB990988 Side gear holding tool set Measurement of the clutch plate preload MB990925 Bearing and oil seal installer set D Press fitting of ...

Page 913: ...ust cover of the companion flange and on the differential carrier 4 Turn the companion flange anti clockwise as far as it will go and measure the amount of distance through which the mating marks moved Limit 5 mm 5 If the backlash exceeds the limit value remove the differential carrier assembly and check the following D Final drive gear backlash Refer to P 27 30 D Differential gear backlash Refer ...

Page 914: ...or shim 4 Measure the clearance between the bearing case and rear axle housing end with a thickness gauge NOTE Confirm that the measurement values no differ in the horizontal and vertical positions 5 Select shims of the thickness which is equal to the sum of the measured clearance and 0 05 0 20 mm Remove the right axle shaft and install shim s and O ring on the right side rear axle housing end 6 A...

Page 915: ...nd lock the front wheels 2 Disconnect the propeller shaft from the differential 3 With the parking brake fully released jack up one rear wheel so that the other is still on the ground 4 Measure the differential preload in the forward direction when using the special tool and when not using the special tool Standard value Using the special tool 13 Nm or more Without using the special tool 25 Nm or ...

Page 916: ...00100047 1 Jack up the vehicle 2 Remove the air pipe and air hose connection 3 Connect a pressure gauge and air regulator to the air pipe 4 Adjust the outside air pressure with the air regulator until the pressure gauge shows approx 25 kPa Caution Do not apply a higher pressure 5 Lock the wheel on one side of the vehicle and slowly turn the wheel on the other side 6 Check for continuity in the rea...

Page 917: ...nnect a pressure gauge and air regulator to the air hose 3 Adjust the outside air pressure with the air regulator until the pressure gauge shows approx 35 kPa Caution Do not apply a higher pressure 4 Shut off the air valve 5 If the pressure has not dropped more than 10 kPa after 10 minutes have passed there can be no air leakage from the air hose etc Pressure gauge Air pressure Air valve Air regul...

Page 918: ... Drum Brake 3 Parking brake cable speed sensor Vehicles with ABS attaching bolt 4 Parking brake cable connection 5 Speed sensor connection Vehicles with ABS 6 Brake tube connection 7 Breather hose connection 8 Spring support 9 Hose connection Vehicles with rear differential lock 10 Rear differential lock position harness connection 11 Rear differential lock position harness AA AA 12 Propeller shaf...

Page 919: ...ent it from falling AB SHOCK ABSORBER REMOVAL Support the axle housing with a jack before removing the shock absorber lower mounting nut AC AXLE ASSEMBLY REMOVAL Take out the axle assembly from the rear of the vehicle Caution Be careful not to drop the axle assembly because it is unstable on the jack INSTALLATION SERVICE POINT AA PROPELLER SHAFT INSTALLATION Align the mating marks on the flange yo...

Page 920: ... Vehicles with ABS or rear differential lock Vehicles without ABS or rear differential lock Sealant 3M ATD Part No 8661 or equivalent 15 Nm 49 59 Nm 9 6 5 3 4 9 7 8 2 6 1 6 Removal steps 1 Brake drum 2 Shoe lining assembly Refer to Group 35A Rear Drum Brake 3 Parking brake cable speed sensor cable Vehicles with ABS attachment bolt 4 Parking brake cable connection 5 Brake tube connection BA D Axle ...

Page 921: ...ed When removing and reinstalling the axle shaft it is not needed and the same thickness and number of shims as previously should be used 1 Insert a 1 mm thick shim and O ring into the left side rear axle housing 2 Apply the specified sealant to the mating surface of the bearing case install the left axle shaft into rear axle housing and tighten the nuts 49 59 Nm Specified sealant 3M ATD Part No 8...

Page 922: ...al to the sum of the measured clearance and 0 05 0 20 mm 6 Remove the right axle shaft and install shim s and O ring on the right side rear axle housing end 7 Apply the specified sealant to the mating surface of bearing case install the right axle shaft into rear axle housing and tighten the nut 49 59 Nm Specified sealant 3M ATD Part No 8661 or equivalent 8 Check to assure that the axle shaft axia...

Page 923: ...ERENTIAL LOCK Apply to entire inside diameter of oil seal lip Sealant 3M ATD Part No 8661 or equivalent 4 1 2 5 6 7 4 8 9 3 9 Disassembly steps GA 1 Snap ring AA EA 2 Retainer AB 3 Axle shaft DA 4 Oil seal CA 5 Bearing inner race AD AA 6 Bearing outer race 7 Bearing case 8 Backing plate 9 Dust cover ...

Page 924: ...Rotor Vehicles with ABS AA 3 Retainer AB 4 Axle shaft 5 Bearing case 6 Backing plate AC 7 Outer bearing inner race 8 Dust cover 9 Inner bearing inner race 10 Oil seal AD 11 Bearing outer race Reassembly steps AA 11 Bearing outer race BA 9 Inner bearing inner race BA 7 Outer bearing inner race DA 10 Oil seal 8 Dust cover 6 Backing plate 5 Bearing case 4 Axle shaft EA 3 Retainer FA 2 Rotor Vehicles ...

Page 925: ...of retainer and the side of bearing become approximately 1 0 1 5 mm and 2 0 mm respectively Caution Be careful not to damage the bearing case and the axle shaft 4 Fix the axle shaft and shave off the remaining 2 0 mm on the side of the bearing of the retainer Caution Be careful not to damage the bearing case and the axle shaft 5 Cut in with a chisel the place where the retainer ring has been shave...

Page 926: ...aring case are parallel 2 Place the end of the bolt against the centre of the axle shaft and then tighten the bolt to remove the axle shaft from the bearing case assembly Caution The hanger and plate should be placed so that they are parallel AC OUTER BEARING INNER RACE REMOVAL Install the special tool as shown in the illustration and then use a press to remove the outer bearing inner race from th...

Page 927: ...R RACE OUTER BEARING INNER RACE INSTALLATION 1 Apply multipurpose grease to the roller surface and ends of the bearing 2 Pass the axle shaft through the bearing case and the inner bearing inner race and outer bearing inner race 3 Use the special tool to press fit the inner bearing inner race and outer bearing inner race to the axle shaft Caution Both bearing inner race outer race sets should be pr...

Page 928: ...cial tools 3 Apply the multipurpose grease to the lips of the oil seal EA RETAINER INSTALLATION Use the special tool to press fit the retainer to the axle shaft while checking that the press fitting force is at the standard value If the initial press fitting force is less that the standard value replace the axle shaft Standard value Item Initial press fitting force N Final press fitting force N Ve...

Page 929: ...he standard value change the snap ring so that the clearance is at the standard value Thickness of snap ring mm Identification colour 2 17 2 01 Yellow 1 85 Blue 1 69 Purple 1 53 Red INSPECTION 27100280014 D Check the dust cover for deformation and damage D Check the inner and outer bearings for seizure discoloration and rough raceway surface D Check the axle shaft for cracks wear and damage MB9907...

Page 930: ...fferential lock switch Rear differential lock ECU removal steps 2 Scuff plate 3 Cowl side trim 4 Rear differential lock ECU Rear differential lock air pump removal steps 5 Hose 6 Rear differential lock air pump 7 Hose 8 Vapor hose 9 Bracket Rear differential lock detection switch removal steps 10 Rear differential lock detection switch 11 Gasket ...

Page 931: ...tch IG1 OFF 0 V ON System voltage 9 Rear differential lock switch ON side Ignition switch ON ON side or OFF side 0 V 1 lock switch OFF side When in neutral System voltage 10 Rear differential lock indicator lamp Ignition switch ON Rear differential is locked 0 V indicator lam Rear differential is free System voltage 2 Vehicle speed reed switch Select D or 1 1st gear and drive forward slowly 5 V 8 ...

Page 932: ... kPa If the pressure is within the standard value the release valve inside the pump is normal 6 Check that the pump does not begin operating for 5 minutes after it has stopped 7 If the inspection for 4 6 is normal then the pump is fully operational REAR DIFFERENTIAL LOCK DETECTION SWITCH CHECK 27200100030 1 Connect an ohmmeter to the detection switch connector 2 The rear differential lock switch i...

Page 933: ... Sealant 3M ATD Part No 8661 or equivalent 59 Nm 49 59 Nm 25 29 Nm 2WD 47 Nm 4WD 49 Nm 1 4 2 3 Removal steps AA AA 1 Propeller shaft connection 2 Rear differential lock detection switch connection 3 Hose connection Vehicles with rear differential lock AB 4 Differential carrier assembly REMOVAL SERVICE POINTS AA PROPELLER SHAFT REMOVAL Make the mating marks on the flange yoke of the propeller shaft...

Page 934: ... install the propeller shaft INSPECTION BEFORE DISASSEMBLY 27200290041 Secure the special tool with a vice and install the differential carrier assembly with the attachment Then carry out the following inspection DRIVE GEAR BACKLASH 1 Place a dial gauge against the end of a drive gear tooth and secure the drive pinion Then turn the drive gear and take measurements at four places or more to check t...

Page 935: ...e or the drive gear and drive pinion as a set DIFFERENTIAL GEAR BACKLASH 1 Tap in a wooden wedge between the side gear and the pinion shaft and secure one side gear Then place a dial gauge with the measuring probe extended against the pinion gear and measure the backlash Standard value 2WD 0 0 076 mm 4WD 0 0 25 mm NOTE Check the other pinion gear by the same procedure Limit 0 2 mm 2 If the backlas...

Page 936: ...usting shim and position the drive pinion closer to the centre of the 1 The drive pinion is positioned too far from the centre of the drive gear drive inion closer to the centre of the drive gear Also for backlash adjustment posi tion the drive gear farther from the drive pinion 2 3 4 Tooth contact pattern resulting from insufficient pinion height The drive pinion is positioned too close to the ce...

Page 937: ... 7 Drive gear AE 8 Lock pin 9 Pinion shaft 10 Thrust block Vehicles without ABS 11 Pinion gear 12 Pinion washer 13 Side gear 14 Side gear thrust spacer 15 Differential case 16 Limited slip differential case assembly AF 17 Self locking nut 18 Washer AG 19 Drive pinion assembly 20 Drive pinion front shim For adjusting preload of drive pinion 21 Drive pinion spacer AH 22 Drive pinion rear bearing inn...

Page 938: ...de bearing outer race AC 13 Side bearing inner race AD 14 Drive gear 15 Differential case AF 16 Self locking nut 17 Washer AG 18 Drive pinion assembly 19 Drive pinion front shim For adjusting preload of drive pinion 20 Drive pinion spacer AH 21 Drive pinion rear bearing inner race 22 Drive pinion rear shim For adjusting drive pinion height 23 Drive pinion 24 Companion flange AI 25 Oil seal AI 26 D...

Page 939: ... NOTE Keep the right and left side bearings and side bearing nuts separate so that they do not become mixed at the time of reassembly AC SIDE BEARING INNER RACE REMOVAL NOTE Attach the prongs of the special tool to the inner race of the side bearing through the openings in the differential case AD DRIVE GEAR REMOVAL 1 Make the mating marks to the differential case and the drive gear 2 Loosen the d...

Page 940: ...shaft 2 Drive out the drive pinion together with the drive pinion spacer and drive pinion front shims AH DRIVE PINION REAR BEARING INNER RACE REMOVAL AI OIL SEAL DRIVE PINION FRONT BEARING INNER RACE DRIVE PINION FRONT BEARING OUTER RACE REMOVAL AJ DRIVE PINION REAR BEARING OUTER RACE REMOVAL MB990850 Mating marks MB990339 MB990648 Drive pinion front bearing inner race Oilseal MB990939 Rear bearin...

Page 941: ...tool to measure the differential preload Standard value When installing a new clutch plate 39 74 Nm When reinstalling the current clutch plate 25 74 Nm 2 If the differential preload is not within the standard value disassemble the differential case assembly and repair or replace the parts MB990992 MB990989 ...

Page 942: ...pinion 5 Drive pinion rear shim For adjusting drive pinion height 6 Drive pinion rear bearing inner race DA D Drive pinion preload adjustment 7 Drive pinion front bearing inner race 8 Oil seal 9 Drive pinion front shim For adjusting drive pinion preload 10 Drive pinion spacer 11 Drive pinion assembly 12 Companion flange 13 Washer 14 Self locking nut 15 Differential case 16 Limited slip differentia...

Page 943: ...ve pinion 7 Drive pinion rear shim For adjusting drive pinion height 8 Drive pinion rear bearing inner race DA D Drive pinion preload adjustment 9 Drive pinion front bearing inner race 10 Oil seal 11 Drive pinion front shim For adjusting drive pinion preload 12 Drive pinion spacer 13 Drive pinion assembly 14 Companion flange 15 Washer 16 Self locking nut 17 Gasket 18 Air pipe assembly B 19 Eye bol...

Page 944: ...ntial Limited slip differential or rear differential lock Adhesive 3M Stud Locking 4170 or equivalent DISASSEMBLY SERVICE POINTS AA DRIVE PINION REAR BEARING OUTER RACE PRESS FITTING BA DRIVE PINION FRONT BEARING OUTER RACE PRESS FITTING MB990938 MB990936 2WD MB990937 4WD MB990938 MB990934 ...

Page 945: ...e is at the standard value Standard value Bearing division Bearing lubrication Rotation torque New None With anti rust agent 0 6 0 9 Nm New or reusing Gear oil applied 0 4 0 5 Nm 4 Clean the side bearing hub 5 Place the special tools between the side bearing hub of the gear carrier and position the notch as shown in the illustration Then tighten side bearing mounting bolt 6 Use a thickness gauge t...

Page 946: ...and drive pinion front bearing inner race companion flange NOTE Do not install the oil seal 2 Tighten the companion flange to the specified torque by using the special tools 3 Measure the drive pinion turning torque without the oil seal Standard value Bearing division Bearing lubrication Rotation torque New None With anti rust agent 0 6 0 9 Nm New or reusing Gear oil applied 0 4 0 5 Nm 4 If the dr...

Page 947: ...ghten the companion flange self locking nut to the specified torque by using the special tools 7 Measure the drive pinion turning torque with oil seal to verify that the drive pinion turning torque complies with the standard value Standard value Bearing division Bearing lubrication Rotation torque New None With anti rust agent 0 8 1 1 Nm New or reusing Gear oil applied 0 6 0 7 Nm 8 If the rotation...

Page 948: ...sure by the same procedure for the other pinion gear Limit 0 2 mm 5 If the backlash exceeds the limit value replace side bearing adjustment spacers 6 If adjustment is not possible replace the side gears and pinion gears as a set 7 Check that the backlash is within the limit value and that the differential gear turns smoothly FA LOCK PIN INSTALLATION 1 Align the pinion shaft lock pin hole with the ...

Page 949: ...onal sequence HA SIDE BEARING INNER RACE INSTALLATION IA BEARING CAP INSTALLATION Align the mating marks on the gear carrier and the bearing cap and then tighten the bearing cap JA DRIVE GEAR BACKLASH ADJUSTMENT Adjust drive gear backlash as follows 1 Using the special tool temporarily tighten the side bearing nut until it is in the state just before preloading of the side bearing 2 Measure the dr...

Page 950: ...entres of two neighbouring holes 5 Choose and install the lock plate two kinds 6 Check the final drive gear tooth contact If poor contact is evident make adjustment Refer to P 27 31 7 Measure the drive gear runout Limit 0 05 mm 8 When drive gear runout exceeds the limit remove the differential case and then the drive gears moving them to different positions and reinstall them 9 If adjustment is no...

Page 951: ...10 12 1 2 3 5 9 10 13 12 15 16 18 22 23 24 25 26 27 14 2 3 4 5 6 7 8 9 10 11 13 12 15 16 17 18 19 20 21 22 27 1 Disassembly steps CA D Differential preload inspection for limited slip differential AA BA 1 Screw 2 Differential case A 3 Thrust washer 4 Spring plate 5 Friction plate 6 Friction disc 7 Friction plate 8 Friction disc 9 Pressure ring 10 Side gear 11 Thrust block 12 Differential pinion ge...

Page 952: ...ential cases for adjustment of the clutch plate friction force and to adjust the end play of the side gear when installing the internal components into the differential case 1 Arrange the two each friction discs and friction plates for each side one on top of another as shown in the figure combining them so that the difference in thickness between the left and the right is the standard value Stand...

Page 953: ...8 Measure the dimension F from the thrust washer end surface to end surface 9 Obtain the dimension G between the thrust washer contact surfaces when differential cases A and B are combined G C D H NOTE Dimension B is the distance between the spring plate contact surfaces when differential cases A and B are combined Refer to P 27 49 10 Check that the clearance G F in the side gear axial direction i...

Page 954: ...nd then insert each part into differential case B in the order shown in the illustration Gear oil MITSUBISHI Genuine Gear Oil part No 8149630EX CASTROL HYPOY LS GL 5 SAE 90 SHELL LSD GL 5 SAE 80W 90 or equivalent NOTE Be particularly sure to apply oil to the contact surfaces and sliding surfaces BA SCREW INSTALLATION 1 Align the mating marks the same numeral on each case of differential case A and...

Page 955: ...aces of the thrust washer and the case E The spring contacting surface of the differential case and spring plate F The contact surfaces of the outer circumference of the pressure ring and the inner circumference of the differential case G The sliding surfaces of the hole in the pressure ring and the outer circumference of the side gear H The projection on the outer circumference of the pressure ri...

Page 956: ...riction surface of the friction disc and pressure ring If there are nicks or scratches repair the part by first grinding with an oil stone and then polishing with rubbing compound on a surface plate NOTE The strong contact on the inner circumference of the friction surface is because of the spring plate this wear is not abnormal WARPING OF THE FRICTION PLATE AND FRICTION DISC Using a dial indicato...

Page 957: ...XP L200 K60 70 97 10 Group REAR AXLE Draft No 98SY070316 CORRECTION OVERSEAS SERVICE DEPT T NITTA VICE GENERAL MANAGER QUALITY INFORMATION ANALYSIS 1 Description This Service Bulletin informs you of correction to the thickness of the differential case friction disc 2 Applicable Manuals Manual Pub No Language Page s 97 L200 PWTE96E1 English 27 48 Workshop Manual Chassis PWTS96E1 Spanish PWTF96E1 Fr...

Page 958: ...st the end play of the side gear when installing the internal components into the differential case 1 Arrange the two each friction discs and friction plates for each side one on top of another as shown in the figure combining them so that the difference in thickness between the left and the right is the standard value Standard value 0 0 05 mm NOTE Two types of replacement parts are available Fric...

Page 959: ...WHEEL AND TYRE ...

Page 960: ......

Page 961: ...type Steel type Aluminium type Size 14 x 6JJ 16 x 6JJ 15 x 7JJ Amount of wheel offset 33 33 10 1 Pitch circle diameter P C D mm 139 7 139 7 139 7 Tyre Size 185R 14C 8PR 205 80 R16 RF 31 x 10 50 R15 LT SERVICE SPECIFICATIONS 31100030036 Items Limit Tread depth of tyre mm 1 6 Wheel runout Radial runout mm Steel wheel 1 2 or less Aluminium wheel 1 0 or less Wheel runout Lateral runout mm Steel wheel ...

Page 962: ...rotation Cracked treads Under inflation Adjust the tyre pressure 31 4 Wear on one side Excessive cam ber Inspect the cam ber Refer to GROUP 33A On ve hicle Service Feathered edge Incorrect toe in Adjust the toe in Bald spots Unbalanced wheel Adjust the imbal anced wheels Scalloped wear Lack of rotation of tyres or worn or out of alignment suspension Rotate the tyres and check the front suspension ...

Page 963: ...hen the tread depth of tyres is reduced to 1 6 mm or less wear indicators will appear WHEEL RUNOUT CHECK 31100110037 Jack up the vehicle so that the wheels are clear of the floor While slowly turning the wheel measure wheel runout with a dial indicator Limit Item Steel wheel Aluminium wheel Radial runout mm 1 2 1 0 Lateral runout mm 1 2 1 0 If wheel runout exceeds the limit replace the wheel WHEEL...

Page 964: ......

Page 965: ......

Page 966: ...HANGE D New 16 inch aluminium wheels has been adopted Vehicles with over fender GENERAL INFORMATION Items Vehicle with over fender Items Vehicle with over fender Wheel Type Aluminium type Size 16 x 7JJ Amount of wheel offset mm 10 Pitch circle diameter P C D mm 139 7 Tyre Size 265 70 R16 112S ...

Page 967: ...NOTES ...

Page 968: ...POWER PLANT MOUNT ...

Page 969: ......

Page 970: ...transmission and 1 place at the transfer has been adopted A differential support method the 3 point support method by which mounting brackets and mounting rubber pieces are used at three places the left side of the differential carrier the part beside the companion flange and via the housing tube at the right side of the differential carrier has been adopted The front suspension crossmember is bol...

Page 971: ...35 Nm 4D56 4WD 1 2 3 1 1 3 Removal steps 1 Heat protector 2 Front insulator stopper AA AA 3 Front engine support insulator REMOVAL SERVICE POINT AA FRONT ENGINE SUPPORT INSULATOR REMOVAL 1 Attach a chain to the engine hangers 2 Using a chain block and tackle hang the engine slightly up so that the insulator is free of engine weight 3 Remove the front engine mounting insulator Caution Do not raise ...

Page 972: ...SULATOR INSTALLATION Make sure that the locating boss and hole are in alignment Caution Do not distort rubber portions and never stain rubber portions with fuel or oil INSPECTION 32100120075 D Check insulators for cracks separation or deformation D Check the front insulator stoppers for deformation ...

Page 973: ...ion 22 Nm 3 2WD M T A T 20 25 Nm 22 Nm 3 1 48 Nm 20 25 Nm 45 Nm 3 1 4WD M T A T 6 45 Nm 40 Nm 65 Nm 2 22 Nm 26 Nm 22 Nm 5 4 45 Nm 3 1 6 45 Nm 40 Nm 65 Nm 2 22 Nm 26 Nm 22 Nm 5 4 3 1 48 Nm 2WD removal steps 1 No 2 crossmember 3 Rear engine support insulator 4WD removal steps AA 1 No 2 crossmember 2 Stopper 3 Rear engine support insulator 4 Transfer support bracket AB AA 5 Transfer roll stopper 6 Tr...

Page 974: ...the engine and transmission assembly rest on the engine mount 3 Tighten the transfer roll stoppers inner and outer finally so that the clearance a between the two are at the shown dimension 4 Check that the right and left clearances b between the stoppers are equal 5 Check that the clearances c between the transfer roll stopper and transfer mounting bracket are equal NOTE When new a transfer roll ...

Page 975: ...ck insulators for cracks separation or deformation D Check transfer mounting bracket for deformation or corrosion D Check transfer support bracket for deformation or corrosion D Check No 2 crossmember for deformation or corrosion 2WD 756 0 5 98 0 5 mm 4WD 760 0 5 90 0 5 mm ...

Page 976: ...5 Nm 95 Nm 90 Nm 2 7 70 Nm 7 9 3 Removal steps 1 Drive shaft Refer to GROUP 26 2 Inner shaft Refer to GROUP 26 3 Pin 4 Spacer 5 Differential mounting rubber B AA 6 Differential mounting bracket 7 Differential mounting rubber A 8 Differential support bracket AA 9 Differential mounting bracket REMOVAL SERVICE POINT AA DIFFERENTIAL MOUNTING BRACKET REMOVAL Remove the differential mounting bracket whi...

Page 977: ... insulators for cracks separation or deformation D Check differential mounting rubber for cracks and damage FRONT SUSPENSION CROSSMEMBER 32100350016 REMOVAL AND INSTALLATION Pre removal and Post installation Operation D Front Under Cover Removal and Installation Front suspension crossmember 36 Nm 110 Nm INSPECTION 32100360019 D Check crossmembers for cracks or damage D Check crossmembers as illust...

Page 978: ...NOTES ...

Page 979: ...FRONT SUSPENSION ...

Page 980: ......

Page 981: ...bined with the torsion bar spring COIL SPRING 2WD Items 4G63 Single cab 4D56 Club cab 4G63 Double cab 4D56 Single cab 4D56 Double cab Wire dia x O D x free length mm 16 99 280 17 100 275 16 100 284 17 100 279 16 100 288 17 100 283 NOTE indicates option TORSION BAR 4WD Items Specification Length x O D mm 1 367 26 1 367 27 NOTE Indicates option CONSTRUCTION DIAGRAM 2WD Upper arm Knuckle Strut bar Sh...

Page 982: ...e between right and left within 30 4WD 1_15 3_15 Difference between right and left within 30 Kingpin inclination 2WD 15_00 4WD 14_50 Shock absorber attaching dimension mm 1 2 Upper arm ball joint starting torque Nm 2WD 0 8 3 4 Strut bar attaching dimension mm 79 Lower arm ball joint end play mm 0 5 Lower arm bush press fitting force kN 9 8 Clearance between bump stopper and bump stopper bracket mm...

Page 983: ...26 Preload socket MB990804 Knuckle arm puller Upper arm ball joint disconnection 2WD MB991639 Bushing remover and installer support Preventing deformation when removing and installing the lower arm bushing 2WD MB990649 Lower arm bushing remover and installer Lower arm bushing removal and press fitting 2WD A MB991071 A MB991072 Lower arm bushing remover and installer A Arbor Lower arm bushing remov...

Page 984: ... MB991522 Torsion bar bushing remover and installer Lower arm bushing A removal and press fitting 4WD MB990883 Rear suspension bushing arbor Lower arm bushing B removal and press fitting 4WD A MB990957 A MB990971 Lower arm bushing remover and installer A Base ...

Page 985: ...d turnbuckles by the same amount in opposite directions NOTE The toe will move out as the left turnbuckle is turned toward the front of the vehicle and the right turnbuckle is turned toward the rear of the vehicle 2 Use a turning radius gauge to check that the steering angle is at the standard value Refer to GROUP 37A On vehicle Service CAMBER AND CASTER 2WD Standard value Camber 0_10 1_10 Differe...

Page 986: ...t number Thickness mm MR132525 1 MR132526 2 MR210107 Front shim integral with rear shim 1 MB932441 Front shim integral with real shim 2 Charts for Shim Increase or Decrease HOW TO USE CHARTS These charts show how shims are added to or removed from existing shims EXAMPLE To decrease camber by 36 and increase caster by 24 increase combined front side shim thickness by 1 mm and increase combined rear...

Page 987: ...ber mounting nut and lock nut compress the shock absorber and loosen the upper arm mounting bolts and nuts 2 Increase or decrease shims between upper arm shaft and crossmember to adjust the camber and caster Refer to Charts for Shim Increase or Decrease Caution 1 Difference in shim thickness between front and rear must be 4 mm or less 2 Do not use 4 or more shims at one location Adjustment of shim...

Page 988: ...er by 30 and caster by 40 increase combined front side shim thickness by 3 mm and increase combined rear side shim thickness by 2 mm Increase in front side shim thickness mm Increase in rear side shim thickness mm Decrease in front side shim thickness mm Decrease in rear side shim thickness mm Camber adjusting angle Caster adjusting angle KINGPIN INCLINATION Standard value 2WD 15_00 4WD 14_50 ...

Page 989: ...ALLATION Post installation Operation D Front Wheel Alignment Check and Adjustment Refer to P 33A 6 Upper arm ball joint Sealant 3M ATD Part No 8661 or equivalent 98 118 Nm 12 Nm 15 Nm 74 Nm 12 Nm 5 3 2 4 1 Removal steps BA 1 Shock absorber AA 2 Upper arm ball joint connection 3 Rebound stopper AB 4 Shims AA 5 Upper arm ...

Page 990: ...ord not lot it fall off AB SHIMS REMOVAL NOTE The camber adjustment shims should be stored for reference at assembly INSTALLATION SERVICE POINTS AA UPPER ARM INSTALLATION When the upper arm assembly is installed to the crossmember insert the upper arm shaft attaching bolts from outside the crossmember and put adjusting shims between the crossmember and upper arm shaft BA SHOCK ABSORBER INSTALLATIO...

Page 991: ...wer than the standard value check that the ball joint turns smoothly without excessive play If so it is possible to use that ball joint UPPER ARM BALL JOINT DUST COVER CHECK When dust cover is cracked or damaged replace the upper arm assembly UPPER ARM BALL JOINT DUST COVER REPLACEMENT 33200800023 Only when dust cover is damaged accidentally during service work replace the dust cover as follows 1 ...

Page 992: ...heel Alignment Check and Adjustment Refer to P 33A 6 9 8 Nm 9 8 Nm Upper arm ball joint assembly 9 7 6 5 8 4 3 1 2 10 25 Nm 44 Nm 74 Nm 88 103 Nm 15 Nm 98 118 Nm Removal Steps CA 1 Shock Absorber D Adjustment of clearance from bump stopper to bump stopper bracket Refer to P 33A 20 AA 2 Anchor arm assembly adjusting nut 3 Brake hose connection 4 Hose clip AB 5 Upper arm ball joint connection 6 Brak...

Page 993: ...ly do not remove it from the ball joint 2 Tie the special tool with a cord not lot it fall off AC SHIMS REMOVAL NOTE The camber and caster adjustment shims should be stored for reference at assembly INSTALLATION SERVICE POINTS AA UPPER ARM INSTALLATION When the upper arm assembly is installed to the crossmember insert the upper arm shaft attaching bolts from outside the crossmember and put adjusti...

Page 994: ... the starting torque exceeds the standard value replace the upper arm ball joint assembly 3 If the starting torque is lower than the standard value check that the ball joint turns smoothly without excessive play If so it is possible to use that ball joint UPPER ARM BALL JOINT DUST COVER CHECK When dust cover is cracked or damaged replace the upper arm ball joint assembly UPPER ARM BALL JOINT DUST ...

Page 995: ... 1 3 8 7 5 6 10 10 Strut bar removal steps 1 Bump stopper CA 2 Strut bar CA 3 Strut bar bushing 4 Strut bar bracket Coil spring removal steps 1 Bump stopper BA 5 Shock absorber AA 6 Lower arm ball joint connection AA 7 Coil spring 8 Spring seat Lower arm removal steps 1 Bump stopper BA 5 Shock absorber AA 6 Lower arm ball joint connection AA 7 Coil spring 8 Spring seat 9 Lower arm assembly 10 Lowe...

Page 996: ...spring with the special tool and assemble the lower ball joint to knuckle NOTE Compression of the coil spring will be facilitated if the lower arm is slightly lifted with a hydraulic jack fitted to the end of the lower arm BA SHOCK ABSORBER INSTALLATION Install the shock absorber so that the distance A shown in the illustration is at the standard value Standard value A 1 2 mm CA STRUT BAR BUSHING ...

Page 997: ...special tool to remove the lower arm bushing 2 Use the special tool to press fit the lower arm bushing until the flange of the bushing touches the lower arm 3 Check that the press fitting force is at the standard value while press fitting the bushing Standard value 9 8 kN 4 If the press fitting force is less than the standard value replace the lower arm LOWER ARM BALL JOINT DUST COVER REPLACEMENT ...

Page 998: ...4 Nm 88 103 Nm 147 Nm 11 7 8 12 6 10 5 3 4 5 2 1 2 5 5 3 9 12 Removal steps CA D Adjustment of clearance from bump stopper to bump stopper bracket BA 1 Anchor arm assembly adjusting nut AA 2 Anchor arm assembly AA 3 Torsion bar 4 Heat cover right side only 5 Dust covers AA 6 Lower arm ball joint connection 7 Stabilizer bar connection 8 Bump stopper 9 Lower arm shaft 10 Anchor arm B 11 Lower arm 12...

Page 999: ...n the white mark on the serrated section of the torsion bar with the mating mark on the anchor arm BA ANCHOR ARM ASSEMBLY ADJUSTING NUT INSTALLATION Tighten the anchor arm assembly adjusting nut so that the distance of the anchor arm bolt shown in the illustration is at the standard value Standard value A 138 mm CA ADJUSTMENT OF CLEARANCE FROM BUMP STOPPER TO BUMP STOPPER BRACKET 1 Tighten the adj...

Page 1000: ...low 1 Measure the lower arm ball joint assembly end play with a dial indicator Limit 0 5 mm 2 If the lower arm ball joint assembly end play exceeds the service limit replace the lower arm ball joint assembly LOWER ARM BALL JOINT DUST COVER CHECK When dust cover is cracked or damaged replace the lower arm ball joint assembly LOWER ARM BUSHING A REPLACEMENT 33200810057 1 Using the special tool remov...

Page 1001: ...l tools and taking care not to twist or tilt the lower arm bushing B NOTE Press fit the lower arm bushing B again from the opposite side to equalize bushing projections at both ends LOWER ARM BALL JOINT DUST COVER REPLACEMENT 33200820043 Only when dust cover is damaged accidentally during service work replace the dust cover as follows 1 Apply multipurpose grease to the interior of the dust cover a...

Page 1002: ...ation 6 5 4 3 2 12 Nm 12 Nm 1 Removal steps AA D Stabilizer link assembly mounting nut adjustment 1 Stabilizer bracket A 2 Bushing 3 Stabilizer bracket 4 Bushing 5 Stabilizer bar 6 Stabilizer link assembly INSTALLATION SERVICE POINT AA STABILIZER LINK ASSEMBLY MOUNTING NUT ADJUSTMENT Tighten the nut so that the dimensions shown in the figure are at standard value Standard value A 16 18 mm A ...

Page 1003: ...NOTES ...

Page 1004: ...REAR SUSPENSION ...

Page 1005: ......

Page 1006: ... noise transmitted to the body during off road driving are reduced by the bump stopper The shock absorbers have a bias arrangement LEAF SPRING Items 2WD 4WD Number of leaf springs 4 5 5 6 Straight span mm 1200 1200 NOTE indicates option CONSTRUCTION DIAGRAM Bump stopper Shock absorber U bolt Leaf spring SERVICE SPECIFICATIONS 34100030129 Items Standard value Toe in mm 0 non adjustable Camber 0_ no...

Page 1007: ...spension assembly must be free of worn loose or damaged parts prior to measurement of rear wheel alignment Standard value Toe in 0 mm Camber 0_ NOTE Toe in and camber are set at the factory and cannot be adjusted If toe in or camber is not within the standard value check and replace bent or damaged parts ...

Page 1008: ... 3 4 5 6 7 8 9 10 22 Nm 52 Nm 157 Nm 98 118 Nm Removal steps 1 Parking brake cable attaching bolt 2 Shock absorber 3 U bolt seat 4 U bolt 5 Bump stopper 6 Shackle plate 7 Shackle assembly 8 Rubber bushings 9 Bushing 10 Rear spring Caution Indicates parts which should be temporarily tightened and then fully tightened with the vehicles on the ground in the unladen condition ...

Page 1009: ...BASIC BRAKE SYSTEM ...

Page 1010: ...er Vacuum Switch Check Diesel powered vehicles 12 Bleeding 12 Brake Fluid Level Sensor Check 13 Load Sensing Spring Length Check and Adjustment 13 Load Sensing Proportioning Valve Function Test 14 Disc Brake Pad Check and Replacement 15 Front Disc Brake Rotor Check 16 Brake Lining Thickness Check 17 Brake Drum Inside Diameter Check 18 Brake Lining and Brake Drum Connection Check 18 BRAKE PEDAL 19 ...

Page 1011: ...4 S60 V5 S60 Rear Leading trailing type drum brake Items 2WD Petrol powered vehicles 2WD Diesel powered vehicles 4WD Petrol powered vehicles 4WD Diesel powered vehicles Master cylinder I D mm 23 8 23 8 23 8 23 8 Brake booster effective dia of power cylinder mm 230 205 230 230 180 205 205 230 180 205 Brake booster boosting ratio 5 0 5 0 7 0 7 0 Load sensing proportioning valve decompression ratio 0...

Page 1012: ...TION DIAGRAM L H drive vehicles Front brake Brake booster Rear brake Load sensing proportioning valve Master cylinder Rear brake R H drive vehicles Master cylinder Brake booster Rear brake Load sensing proportioning valve Front brake Rear brake Front brake ...

Page 1013: ...ad sensing spring length is 215 mm when laden 16 310 17 652 Load sensing spring length mm 189 193 Booster push rod to master cylinder piston clearance mm Single brake booster Petrol powered ve hicles 0 65 1 05 Diesel powered ve hicles 1 00 1 40 Tandem brake booster Vehicle which brake booster of power cylinder is 180 mm and 205 mm in effective diameter 0 90 1 30 Vehicle which brake booster of powe...

Page 1014: ...nner surface Piston cup surface Rear brake shoe and backing plate contact surface Brake grease SAE J310 NLGI No 1 Auto adjuster assembly SEALANTS 35100050108 Items Specified sealant Remarks Vacuum switch 3M ATD Part No 8661 or equivalent Semi drying sealant Shoe hold down pin 3M ATD Part No 8513 or equivalent Drying sealant SPECIAL TOOLS 35100060095 Tool Number Name Use MB990964 MB990520 MB990623 ...

Page 1015: ...ion Clogged brake line Grease or oil on pad or lining surface Replace Load sensing proportioning valve malfunction Auto adjuster malfunction Adjust Increased pedal stroke Reduced pedal to floor Air in brake system Bleed air Reduced edal to floor board clearance Worn lining or pad Replace Broken vacuum hose Faulty master cylinder Brake fluid leaks Correct Auto adjuster malfunction Adjust Excessive ...

Page 1016: ...place brakes are a lied Caliper to wheel interference Correct or replace Dust cover to disc interference Bent brake backing plate Cracked drums or brake disc Squealing groaning or chattering noise when brakes are applied Disc brakes Missing or damaged brake pad anti squeak shim Replace Brake drums and linings discs and pads worn or scored Correct or replace Improper lining parts Disc brake Burred ...

Page 1017: ...ing to caliper body Improper machining of drum causing interference with backing plate or shoe Replace drum Disc brakes Rusted stuck Lubricate or replace Worn damaged or insufficiently lubricated wheel bearings Incorrect brake pedal or booster push rod Adjust Groaning clicking or rattling noise when Stones or foreign material trapped inside wheel covers Remove stones etc rattling noise when brakes...

Page 1018: ...per just before brake pedal is caused to move return the stop lamp switch 1 2 to 1 turn and secure with the lock nut 4 Connect the connector of the stop lamp switch 5 Check to be sure that the stop lamp is not illuminated with the brake pedal released 3 Return the carpet etc BRAKE PEDAL FREE PLAY With the engine stopped depress the brake pedal two or three times After eliminating the vacuum in the...

Page 1019: ...he stop lamp switch is pushed in and when it is released The stop lamp switch is in good condition if there is no continuity when the plunger is pushed in to a depth of within 4 mm from the outer case edge surface and if there is continuity when it is released BRAKE BOOSTER OPERATING TEST 35100100087 For simple checking of the brake booster operation carry out the following tests 1 Run the engine ...

Page 1020: ...t reject criteria Connection at the brake booster side A A negative pressure vacuum is created and held Connection at the intake manifold side B A negative pressure vacuum is not created Caution If the check valve is defective replace it as an assembly unit together with the vacuum hose BRAKE BOOSTER VACUUM SWITCH CHECK DIESEL POWERED VEHICLES 35100920034 1 Connect an ohmmeter to the connector of ...

Page 1021: ...at steps 2 4 three or four times to fill the inside of the master cylinder with brake fluid BRAKE PIPE LINE BLEEDING Start the engine and bleed the air in the sequence shown in the figure BRAKE FLUID LEVEL SENSOR CHECK 35100910086 The brake fluid level sensor is in good condition if there is no continuity when the float surface is above A and if there is continuity when the float surface is below ...

Page 1022: ...he support side 4 Place the spring so that it is in parallel with the load sensing proportioning valve and pull in the direction indicated by the arrow so that its length H shown in the figure the length between its ends is as noted below NOTE At this time the lever is pressed all the way to the load sensing proportioning valve Standard value Items Spring length H mm Input fluid pressure kPa Outpu...

Page 1023: ...rence in the thicknesses of the pads on the left and right sides check the sliding condition of the piston lock pin and guide pin 2 Remove the guide pin 2WD or lock pin 4WD Lift the caliper assembly and retain with wire Caution Do not wipe the special grease from the guide pin 2WD or lock pin 4WD Do not contaminate the guide pin 2WD or lock pin 4WD 3 Remove the following parts from caliper support...

Page 1024: ...s parallelism If the thickness of the disc changes this will cause pedal pulsation shuddering and surging Inset or warping flatness Overheating and improper handling while servicing will cause inset or warping RUN OUT CHECK AND CORRECTION 35100940016 1 Remove the caliper support then raise the caliper assembly upward and secure by using wire 2 Inspect the disc surface for grooves cracks and rust C...

Page 1025: ...5 mm 2 If the disc is beyond the limits for thickness remove it and install a new one If thickness variation exceeds the specification replace the brake disc or turn rotor with on the car type brake lathe MAD DL 8700PF or equivalent BRAKE LINING THICKNESS CHECK 35100300135 1 Remove the brake drum 2 Measure the wear of the brake lining at the place worn the most Standard value 4 7 mm Limit 1 0 mm R...

Page 1026: ...WD 272 0 mm 3 Replace brake drums shoe and lining assembly when wear exceeds the limit value or is badly imbalanced BRAKE LINING AND BRAKE DRUM CONNECTION CHECK 35100310138 1 Remove the brake drum 2 Remove the shoe and lining assembly Refer to P 35A 30 3 Chalk inner surface of brake drum and rub with shoe and lining assembly 4 Replace shoe and lining assembly or brake drums if there are any irregu...

Page 1027: ...stallation Operation D Brake Pedal Adjustment Refer to P 35A 10 1 30 Nm 14 Nm 22 Nm 6 11 8 3 4 7 10 5 2 9 8 Removal steps 1 Stop lamp switch 2 Brake pedal return spring 3 Split pin 4 Washer 5 Clevis pin 6 Brake pedal shaft bolt 7 Brake pedal 8 Bushing 9 Pipe 10 Pedal pad 11 Pedal support member ...

Page 1028: ...les Sealant 3M ATD Part No 8661 or equivalent 15 Nm 15 Nm 14 Nm 15 Nm 6 10 9 1 3 2 1 5 5 5 8 4 11 7 11 Removal steps 1 Brake tube connection 2 Brake fluid level sensor connector 3 Master cylinder assembly BA D Adjustment of clearance between brake booster push rod and primary piston 4 Vacuum switch connector 4D56 AA 5 Vacuum hose with built in check valve 6 Split pin 7 Washer 8 Clevis pin 9 Brake ...

Page 1029: ...ve mm Single brake booster Petrol powered vehicles 0 65 1 05 booster Diesel powered vehicles 1 00 1 40 Tanden brake booster Vehicle which brake booster of power cylinder is 180 mm and 205 mm in effective diameter 0 90 1 30 Vehicle which brake booster of power cylinder is 205 mm and 230 mm in effective diameter 0 70 1 10 NOTE When brake booster negative pressure petrol powered vehicles 66 7 kPa die...

Page 1030: ...bolt 10 Gasket AA 11 Piston stopper ring 12 Primary piston assembly 13 Secondary piston assembly 14 Master cylinder body Caution Do not disassemble the primary piston and secondary piston assembly DISASSEMBLY SERVICE POINT AA PISTON STOPPER BOLT PISTON STOPPER RING DISASSEMBLY Remove the piston stopper bolt and piston stopper ring while depressing the piston INSPECTION 35100430056 D Check the inne...

Page 1031: ...e connection 4 Load sensing spring 5 Load sensing proportioning valve Caution Do not disassemble the load sensing proportioning valve INSTALLATION SERVICE POINT AA SPRING SUPPORT INSTALLATION While the lever of the load sensing proportioning valve is touching the stopper bolt install the spring support so that the distance A from the edge of the spring mounting section of the lever to the place on...

Page 1032: ... Operation D Brake Fluid Draining Post installation Operation D Brake Fluid Supplying D Brake Line Bleeding Refer to P 35A 12 15 Nm 1 2 2WD 4WD 4 3 4 2 3 1 15 Nm 15 Nm 90 Nm 90 Nm 90 Nm Removal steps 1 Brake tube AA 2 Front brake assembly 3 Brake hose bracket 4 Brake disc Refer to GROUP 26 Front Hub Assembly ...

Page 1033: ...oes not become caught when lowering the caliper assembly and install the lock pin 5 Check brake drag torque as follows 1 Start engine and hold brake pedal down for 5 seconds Pedal depression force approx 196 N 2 Stop engine 3 Turn brake disc forward 10 times 4 Check hub torque B with spring balance 5 Calculate drag torque of the disc brake difference between hub torque B and hub torque A Standard ...

Page 1034: ...repair kit Seal and boots repair kit 10 5 9 8 6 4 7 14 13 12 14 3 2 8 9 1 3 5 9 8 7 6 4 2 10 5 13 14 13 11 12 14 12 9 3 5 6 7 5 11 74 Nm Grease Caliper assembly disassembly steps AA 1 Lock pin AA 2 Guide pin 3 Bushing 4 Caliper support pad clip and shim 5 Pin boot 6 Boot ring AA 7 Piston boot AA 8 Piston AB 9 Piston seal 10 Caliper body Pad assembly disassembly steps AA 1 Lock pin AA 2 Guide pin 3...

Page 1035: ...t repair kit 1 2 5 9 8 7 6 5 10 3 4 14 13 12 14 8 9 2 1 3 5 8 7 6 4 9 5 14 12 13 11 13 12 14 9 7 5 6 5 3 Grease 8 Nm 11 Caliper assembly disassembly steps AA 1 Lock pin AA 2 Guide pin 3 Bushing 4 Caliper support pad clip and shim 5 Pin boot 6 Boot ring AA 7 Piston boot AA 8 Piston AB 9 Piston seal 10 Caliper body Pad assembly disassembly steps AA 1 Lock pin AA 2 Guide pin 3 Bushing 4 Caliper suppo...

Page 1036: ...low compressed air gently AB PISTON SEAL REMOVAL 1 Remove piston seal with finger tip Caution Do not use a flat tipped screwdriver or other tool to prevent damage to inner cylinder 2 Clean piston surface and inner cylinder with trichloroethylene alcohol or specified brake fluid Specified brake fluid DOT3 or DOT4 REASSEMBLY SERVICE POINT AA LOCK PIN GUIDE PIN INSTALLATION Install the lock pin and g...

Page 1037: ...e PAD WEAR CHECK Measure the thickness at the thinnest and worn area of the pad Replace the pad assembly if pad thickness is less than the limit value Standard value 10 mm Limit 2 0 mm Caution 1 Replace the pads always at both sides and also the brake pads for the wheels on the opposite side at the same time 2 If there is significant difference in the thicknesses of the pads on the left and right ...

Page 1038: ... J310 NLGI No 1 Sealant 3M ATD Part No 8513 or equivalent 10 8 7 6 9 18 19 2 4 3 15 14 13 12 11 8 7 6 1 16 17 4 17 10 Nm 5 Rear drum brake removal steps 1 Brake drum 2 Shoe to lever spring 3 Adjuster lever 4 Auto adjuster assembly 5 Retainer spring 6 Shoe hold down cup 7 Shoe hold down spring 8 Shoe hold down cup 9 Shoe to shoe spring 10 Shoe and lining assembly 11 Shoe and lever assembly AA BA 12...

Page 1039: ...etainer joint and remove retainer INSTALLATION SERVICE POINTS AA WAVE WASHER INSTALLATION Install the washer in the direction shown in the illustration BA RETAINER INSTALLATION Use pliers or the like to install the retainer or the pin positively Pin of shoe assembly Retainer Washer Shoe assembly Pin Parking lever Pin of shoe assembly Retainer ...

Page 1040: ...0080 DISASSEMBLY AND REASSEMBLY 8 Nm Brake fluid DOT3 or DOT4 Grease Repair kit grease Grease Wheel cylinder repair kit 2 6 2 1 4 1 4 1 2 5 6 4 2 3 1 3 4 Disassembly steps 1 Boots 2 Piston assembly AA 3 Pistons AA 4 Piston cups 5 Bleeder screw 6 Wheel cylinder body ...

Page 1041: ...up on the special tool with the lip of the cup facing up fit the cup onto the special tool and then slide it down the outside of the tool into the piston groove Caution In order to keep the piston cup from becoming twisted or slanted slide the piston cup down the tool slowly and carefully without stopping INSPECTION 35100780069 Check the piston and wheel cylinder walls for rust or damage and if th...

Page 1042: ...NOTES ...

Page 1043: ...les with over fender FRONT DISC BRAKE REMOVAL AND INSTALLATION Pre removal Operation D Brake Fluid Draining Post installation Operation D Brake Fluid Supplying D Brake Line Bleeding 1 4 2 3 88 10 N m 15 2 N m 88 10 N m Removal steps 1 Brake tube AA 2 Front brake assembly 3 Brake hose bracket 4 Brake disc Refer to 97 L200 Workshop Manual GROUP 26 Front Hub Assembly NOTE For service point refer to t...

Page 1044: ... Clip set 12 1 4 2 2 1 4 9 4 3 Grease 27 4 N m Caliper assembly disassembly steps 1 Bolt 2 Pin 3 Bushing 4 Pin boot 5 Caliper support pad clip and shim assembly 6 Caliper support AA 7 Piston boot AA 8 Piston AB 9 Piston seal 10 Caliper body 11 Bleeder screw Pad assembly disassembly steps 1 Bolt 2 Pin 3 Bushing 5 Caliper support pad clip and shim assembly 12 Pad and wear indicator assembly 13 Pad a...

Page 1045: ...on seal inside the seal and boot kit is coated with a special grease so do not wipe this grease off Grease Repair kit grease Grease Repair kit grease 9 DISASSEMBLY SERVICE POINTS Refer to the Basic Manual except for service points described below AC HARNESS CONNECTOR REMOVAL Caution Swivel up the clip as shown to avoid deformation of the clip Clip Caliper support ...

Page 1046: ...NOTES ...

Page 1047: ...ANTI SKID BRAKING SYSTEM ABS 2WD ...

Page 1048: ......

Page 1049: ...A Brake Drum Inside Diameter Check Refer to GROUP 35A Brake Lining and Brake Drum Connection Check Refer to GROUP 35A Wheel Speed Sensor Output Voltage Check 24 Hydraulic Unit Check 26 Solenoid Valve Check 27 Motor Operation Check 27 Motor Relay and Valve Relay Continuity Check 28 Remedy for a Flat Battery 28 BRAKE PEDAL Refer to GROUP 35A MASTER CYLINDER AND BRAKE BOOSTER 29 LOAD SENSING PROPORTI...

Page 1050: ...ttery is disconnected In addition reading of diagnosis codes and data list and actuator testing are possible using the MUT II Items Specifications Speed sensor Magnet coil type Front rotor teeth 47 Rear rotor teeth 47 CONSTRUCTION DIAGRAM 1 2 9 3 9 2 4 1 6 5 6 5 7 8 1 5 6 3 1 NOTE 1 For R H drive vehicles those parts are installed at the right side 2 Diesel powered vehicles L H drive vehicles 3 Ex...

Page 1051: ...NTS 35200040023 Items Specified lubricant Brake fluid DOT3 or DOT4 Brake piston seal Repair kit grease Guide pin boot inner surfaces Lock pin boot inner surfaces Piston boot mounting grooves Brake piston boot inner surfaces Lock pin bush inner surfaces Piston cup surface SEALANTS 35200050057 Items Specified sealant Remarks Vacuum switch 3M ATD Part No 8661 or equivalent Semi drying sealant SPECIAL...

Page 1052: ...es ABS operation Long braking distance For road surfaces such as snow covered roads and gravel roads the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles Accordingly advise the customer to drive safely on such roads by lowering the vehicle speed and not being too overconfident Shock during system operation check Shock may be felt when the brake pedal is d...

Page 1053: ...or 13 Rear right wheel speed sensor 14 Rear left wheel speed sensor 15 Wheel speed sensor Abnormal output signal 35B 8 16 Power supply system 35B 8 21 Front right wheel speed sensor Abnormal 35B 7 22 Front left wheel speed sensor 23 Rear right wheel speed sensor 24 Rear left wheel speed sensor 33 Stop lamp switch system 35B 9 41 Front right solenoid valve 35B 10 42 Front left solenoid valve 43 Rea...

Page 1054: ...fective sensor or a warped rotor D Malfunction of wheel speed sensor D Malfunction of rotor D Malfunction of wheel bearing D Malfunction of wiring harness or connector D Malfunction of ABS ECU NG Replace the ABS ECU OK Check trouble symptoms OK Check the following connector C 62 NG Repair OK Wheelbearingcheck RefertoGROUP 26 and 27 On vehicle Service OK Rotor check Refer to P 35B 40 NG Replace the...

Page 1055: ...eed sensor installation check NG Repair Code No 16 Power supply system Probable cause ThevoltageoftheABS ECUpowersupplydropslowerorriseshigherthanthespecified value If the voltage returns to the specified value this code is no longer output D Malfunction of wiring harness or connector D Malfunction of ABS ECU Caution If battery voltage drops or rises during inspection this code will be output as w...

Page 1056: ... Check the harness between dedicated fuseNo 8andtheABS ECU andrepair if necessary OK Check the harness between dedicated fuseNo 8andtheABS ECU andrepair if necessary OK Stop lamp switch check Refer to GROUP 35A On vehicle Service NG Replace the stop lamp switch OK Check trouble symptom NG Replace the ABS ECU Doesthestoplampilluminateandswitch off normally No Stop lamp switch installation check NG ...

Page 1057: ... 5 OK 2 2 Ω NG Replace the hydraulic unit OK Measure at hydraulic unit connector A 09 and ABS ECU connectors C 62 and C 64 D Disconnect the connector and measure at the harness side D Continuity between the following terminals OK Continuity HU side ABS ECU side C 64 HU side ABS ECU side C 62 NG Check the following connectors A 09 C 62 and C 64 NG Repair OK Measure at hydraulic unit connector A 09 ...

Page 1058: ... is disconnected After repairing all other malfunctions connect the valve relay connector again to check the valve relay Then check that the ABS warning lamp does not illuminate If it illuminates the valve relay may be defective So carry out the following procedure Valve relay check Refer to P 35B 28 NG Replace the valve relay OK Measure at valve relay connector A 39 D Disconnect the connector and...

Page 1059: ...and repair if nec essary No ABS motor relay check Refer to P 35B 28 NG Replace the motor relay OK Measure at motor relay connector A 38 D Disconnect the connector and measure at the harness side D Voltage between 5 body earth OK System voltage NG Check the harness between fusible link No 11 and ABS motor relay and repair if necessary OK Measure at ABS ECU connectors C 62 and C 64 D Disconnect the ...

Page 1060: ...conds and then switches off 4 If the illumination is other than the above check the diagnosis codes NOTE The warning lamp may continue to illuminate until the vehicle speed reaches 8 km h after the ignition switch is turned on If the ABS ECU has stored one of the diagnosis codes Nos 21 to 24 or No 53 as a former malfunction the ECU attempts to detect the malfunction at 8 km h Until the speed reach...

Page 1061: ...when turned to START it illuminates When returned to ON the lamp flashes once and then switches off 6 35B 17 Faulty ABS operation Unequal braking power on both sides 7 35B 18 Insufficient braking power ABS operates under normal braking conditions ABS operates before vehicle stops under normal braking conditions Large brake pedal vibration Caution 2 Caution 1 If steering movements are made when dri...

Page 1062: ...he ABS ECU OK Check the following connectors C 62 and C 64 NG Repair OK Check trouble symptoms NG Check the harness wire between the ignition switch and the ABS ECU and repair if necessary OK Measure at ABS ECU connectors C 62 and C 64 D Disconnect the connector and measure at the harness side D Continuity between 4 15 16 25 C 62 42 C 64 body earth OK Continuity NG OK Measure at ABS ECU connector ...

Page 1063: ...at connector C 02 D Disconnect the connector and measure at the male pin D Ignition switch ON D Does the ABS warning lamp illuminate when terminal 3 is earthed OK Illuminates NG Check whether the ABS warning lamp bulb is burnt out NG Replace the ABS warning lamp bulb Fuseinspection Multi purposefuseNo 11 NG Refer to GROUP 00 Inspection Ser vice Points for a Blown Fuse Inspection Procedure 4 Even a...

Page 1064: ...ir if necessary OK Check the following connector A 39 NG Repair OK Check trouble symptoms NG Check the harness between the valve relay and earth and repair if necessary Inspection Procedure 6 The ABS warning lamp flashes twice after the ignition key is turned to ON The lamp illuminates when the ignition key is turned to START and when the key is returned to ON it flashes once Probable cause The AB...

Page 1065: ...NG Replace the ABS ECU OK Check the following connector C 62 NG Repair NG Measure at ABS ECU connector C 62 D Disconnect the connector and measure at the harness side D Resistancevaluebetweenterminals 10 23 7 20 8 21 and 9 22 OK 1 2 1 4 kΩ The sensor harness and connector should be moved while these inspections are carried out NG Repair OK Check trouble symptom OK Check the following connectors A ...

Page 1066: ...tem stops the ABS ECU the MUT II display data will be unreliable ACTUATOR TEST REFERENCE TABLE 35201160049 The MUT II activates the following actuators for testing NOTE 1 If the ABS ECU runs down actuator testing cannot be carried out 2 Actuator testing is only possible when the vehicle is stationary If the vehicle speed during actuator testing exceeds 10 km h forced actuation will be canceled 3 D...

Page 1067: ...second after engine is started System voltage 26 Output to relay power supply Ignition switch ON System voltage 32 Memory power supply Always System voltage 34 Input from stop lamp switch Ignition switch ON Stop lamp switch ON System voltage Stop lamp switch OFF 1 V or less 36 MUT II Connect the MUT II Serial communication with MUT II Do not connect the MUT II 1 V or less 37 Output to valve relay ...

Page 1068: ...ion Do not connect the MUT II Approx 12 V 48 Input from valve relay monitor Ignition switch ON System voltage 49 Motor monitor Ignition switch ON Approximately 1 second after Motor is on System voltage A roximately 1 second after engine is started Motor is off 0 5 V or less 50 Output to ABS warning lamp Ignition switch ON The lamp is switched off System voltage switch ON The lamp is illuminated 0 ...

Page 1069: ...e OUT side 2 2 Ω 3 Body earth Rear solenoid valve IN side 5 0 Ω 7 20 Front left wheel speed sensor wire 1 2 1 4 kΩ 8 21 Rear right wheel speed sensor wire 1 2 1 4 kΩ 9 22 Rear left wheel speed sensor wire 1 2 1 4 kΩ 10 23 Front right wheel speed sensor wire 1 2 1 4 kΩ 14 Body earth Front left solenoid valve IN side 5 0 Ω 15 Body earth ABS ECU earth Continuity 16 Body earth 25 Body earth 39 43 Idle...

Page 1070: ... with brake fluid BRAKE PIPE LINE BLEEDING Start the engine and bleed the air in the sequence shown in the figure Caution Be sure to install a filter to the master cylinder reservoir tank when supplying brake fluid DISC BRAKE PAD CHECK AND REPLACEMENT 35200280012 NOTE The brake pads have wear indicators that contact the brake disc when the brake pad thickness becomes 2 mm and emit a squealing soun...

Page 1071: ...200160156 1 Lift up the vehicle and release the parking brake 2 Disconnect the ABS ECU connector and then use the special tool inspection harness for connector pin contact pressure to measure the output voltage at the harness side connector 3 Rotate the wheel to be measured at approximately 1 2 1 rotation per second and check the output voltage using a circuit tester or an oscilloscope Wheel speed...

Page 1072: ...tom Probable causes Remedy Too small or zero waveform amplitude Faulty wheel speed sensor Replace sensor Waveform amplitude fluctuates excessively this is no problem if the minimum amplitude is 100 mV or more Axle hub eccentric or with large runout Replace hub Noisy or disturbed waveform Open circuit in sensor Replace sensor Open circuit in harness Correct harness Incorrectly mounted wheel speed s...

Page 1073: ...force drive the actuator NOTE 1 During the actuator test the ABS warning lamp will illuminate and the anti skid control will be cancelled 2 When the ABS has been interrupted by the fail safe function the MUT II actuator testing cannot be used 6 Turn the wheel by hand and check the change in braking force when the brake pedal is depressed When using the braking force tester depress the brake pedal ...

Page 1074: ... 03 wheel manually to check the change of brake force Brake force is not released Incorrect hydraulic unit brake tube connection Connect correctly Hydraulic unit solenoid valve not functioning correctly Replace hydraulic unit assembly SOLENOID VALVE CHECK 35201070120 Measure the resistance between terminals Standard value Solenoid valve Measurement terminals Resistance between terminals Front IN r...

Page 1075: ... engine may misfire and driving might not be possible This happens because ABS consumes a great amount of current for its self check function the remedy is to either allow the battery to recharge sufficiently or to remove the fusible link for ABS circuit thus disabling the anti skid brake system The ABS warning lamp will illuminate when the fusible link for ABS is removed After the battery has suf...

Page 1076: ...r equivalent 4D56 L H drive vehicles 4D56 R H drive vehicles 12 5 5 7 6 10 9 3 2 1 4 11 8 1 15 Nm 14 Nm Removal steps 1 Brake tube connection 2 Brake fluid level sensor connector 3 Master cylinder assembly BA D Adjustment of clearance between brake booster push rod and primary piston 4 Vacuum switch connector 4D56 AA 5 Vacuum hose With built in check valve 6 Split pin 7 Washer 8 Clevis pin 9 Brake...

Page 1077: ...alculate clearance A from the B C and D measurements A B C D Standard value Brake booster size Clearance A standard value mm Petrol powered vehicles 0 90 1 30 Diesel powered vehicles 0 70 1 10 NOTE When brake booster negative pressure petrol powered vehicles 66 7 kPa diesel powered vehicles 93 3 kPa is applied clearance value will become 0 10 0 50 mm If the clearance is not within the standard val...

Page 1078: ...uid level sensor 6 Float 7 Reservoir stopper bolt 8 Reservoir tank 9 Reservoir seal AA 10 Piston stopper bolt 11 Gasket AA 12 Piston stopper ring 13 Primary piston assembly 14 Secondary piston assembly 15 Master cylinder body Caution Do not disassemble the primary and secondary piston assembly DISASSEMBLY SERVICE POINTS AA PISTON STOPPER BOLT PISTON STOPPER RING DISASSEMBLY Remove the piston stopp...

Page 1079: ... scoring wear damage or wear D Check the diaphragm for cracks and wear FRONT DISC BRAKE 35200600016 REMOVAL AND INSTALLATION Pre removal Operation D Brake Fluid draining Post installation Operation D Brake Fluid Supplying D Brake Line Bleeding Refer to P 35B 23 15 Nm 1 90 Nm 15 Nm 2 3 4 Removal steps 1 Brake tube AA 2 Front brake assembly 3 Brake hose bracket 4 Brake disc Refer to GROUP 26 Front H...

Page 1080: ...nstall the lock pin 5 Check brake drag torque as follows 1 Start engine and hold brake pedal down for 5 seconds Pedal depression force approx 196 N 2 Stop engine 3 Turn brake disc forward 10 times 4 Check hub torque B with spring balance 5 Calculate the drag torque of the disc brake difference between hub torque B and hub torque A Standard value 69 N or less 6 If the difference between brake drag ...

Page 1081: ... 12 13 9 8 4 6 7 8 9 5 10 74 Nm 2 8 Nm 1 2 10 5 9 8 7 6 14 12 13 14 12 13 9 7 3 5 6 6 9 5 Grease 11 Caliper assembly disassembly steps AA 1 Lock pin AA 2 Guide pin 3 Bushing 4 Caliper support Pad clip and shim 5 Pin boot 6 Boot ring AA 7 Piston boot AA 8 Piston AB 9 Piston seal 10 Caliper body Pad assembly disassembly steps AA 1 Lock pin AA 2 Guide pin 3 Bushing 4 Caliper support Pad clip and shim...

Page 1082: ...use it will become impossible to remove the second piston AB PISTON SEAL REMOVAL 1 Remove piston seal with finger tip Caution Do not use a screwdriver or other tool to prevent damage to inner cylinder 2 Clean piston surface and inner cylinder with trichloro ethylene alcohol or specified brake fluid Specified brake fluid DOT3 or DOT4 REASSEMBLY SERVICE POINT AA LOCK PIN GUIDE PIN INSTALLATION Insta...

Page 1083: ...e limit value Standard value 10 mm Limit value 2 0 mm Caution 1 When the limit is exceeded replace the pads at both sides and also the brake pads for the wheels on the opposite side at the same time 2 If there is a significant difference in the thicknesses of the pads on the left and right sides check the sliding condition of the piston lock pin and guide pin ...

Page 1084: ...Operation D Brake Fluid Supplying D Brake Lines Bleeding Refer to P 35B 23 D Hydraulic Unit Checking Refer to P 35B 26 Except diesel powered vehicles L H drive vehicles Diesel powered vehicles L H drive vehicles 15 Nm 15 Nm 1 2 15 Nm 4 2 2 3 Removal steps 1 Harness connector AA 2 Brake tube connection AA 3 Hydraulic unit 4 Hydraulic unit bracket ...

Page 1085: ...lts should absolutely not be loosened 3 The hydraulic unit must not be dropped or otherwise subjected to impact shocks 4 The hydraulic unit must not be turned upside down or laid on its side INSTALLATION SERVICE POINT AA BRAKE TUBE CONNECTION Connect the tube to the hydraulic unit as shown in the illustration 1 Master cylinder for front 2 Front brake R H 3 Front brake L H 4 Rear brake 5 Master cyl...

Page 1086: ...ED SENSOR 1 Check whether any metallic foreign material has adhered to the parts shown in the illustration at the speed sensor tip and if so remove it NOTE The section shown in the illustration can become magnetized because of the magnet built into the speed sensor with the result that foreign metallic material easily adheres to it 2 Measure the resistance between the speed sensor terminals Standa...

Page 1087: ... not temporary disconnection occurs Check the connector connection and the terminal insertion SPEED SENSOR INSULATION CHECK 1 Remove all connections from the speed sensor and then measure the resistance between terminals 1 and 2 and the body of the speed sensor Standard value 100 kΩ or more 2 If the speed sensor insulation resistance is outside the standard value range replace with a new speed sen...

Page 1088: ...D INSTALLATION Pre removal and Post installation Operation D Driver s Side Under Cover Removal and Installation Refer to GROUP 52A Instrument Panel D Junction Block Installation Nut Removal and Installation ABS ECU INSPECTION 35200990106 Refer to P 35B 20 ...

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Page 1114: ...diagnostic codes for the cars mentioned below that are equipped with the ABS ECU 2 Applicable Manuals Manual Pub No Language Page s 96 COLT LANCER PWME9511 English 35 6 Workshop Manual Chassis PWMS9512 Spanish PWMF9513 French PWMG9514 German PWMD9515 Dutch PWMW9516 Swedish 95 PAJERO PWJE9086 F English 35 36 4 Workshop Manual Chassis Supplement PWJF9088 F French PWJG9089 F German PWJD9090 F Dutch P...

Page 1115: ...RO MONTERO From September 1998 MR400413 L400 From September 1998 MR400415 PAJERO SPORT MONTERO SPORT From the first production car MR235362 MR307755 MR334886 L200 From September 1998 MR400416 MR400417 MR4469642 Integral Hydraulic unit These part numbers are for the hydraulic unit 4 Details 96 COLT LANCER Workshop Manual Chassis page 3 95 PAJERO Workshop Manual Chassis Supplement page 5 95 L400 Wor...

Page 1116: ...sis due to repeated brake application and release Thump suspension squeak tyres ABS operation Long braking distance For road surfaces such as snow covered roads and gravel roads the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles Accordingly advise the customer to drive safely on suc roads by lowering the vehicle speed and not being too overconfident Dia...

Page 1117: ... 1 and 2 above turn the ignition switch ON After that place the stop lamp switch to OFF with brake pedal released within 3 seconds and cycle the stop lamp switch to ON an OFF ten times consecutively NOTE When ABS ECU stops functioning through the fail safe mechanism erasing of the diagnostic troubl codes cannot be performed Ignition switch Stop lamp switch ABS warning lamp Diagnostic trouble code ...

Page 1118: ...he lamp indicates a malfunction th valve relay system may be detective Refer to P 35 36 14 ERASING DIAGNOSIS CODES Old With the MUT II Connect the MUT II to the diagnosis connector 16 pin and then erase the diagnosis codes Without the MUT II Remove the battery cable from the battery terminal for 10 seconds or more and the reconnect the cable New See next page SERVICEBRAKES ABS Troubleshooting Vehi...

Page 1119: ...with brake pedal depressed 3 Under the condition of 1 and 2 above turn the ignition switch ON After that place the stop lamp switch to OFF with brake pedal released within 3 seconds and cycle the stop lamp switch ON and OFF ten times consecutively NOTE When ABS ECU stops functioning through the fail safe mechanism erasing of the diagnostic troubl codes cannot be performed Ignition switch Stop lamp...

Page 1120: ... lamp Refer to P 35B 19 If the lamp indicates a malfunction the valve relay system may be defective Refer to P 35B 17 ERASING DIAGNOSTIC CODES Old With the MUT II Connect the MUT II to the diagnosis connector 16 pin then erase the diagnostic codes Without the MUT II Removing the battery cable from the battery terminal for 10 seconds or more then reconnect the cable New See next page ABS 2WD Troubl...

Page 1121: ...with brake pedal depressed 3 Under the condition of 1 and 2 above turn the ignition switch ON After that place the stop lamp switch to OFF with brake pedal released within 3 seconds and cycle the stop lamp switch ON and OFF ten times consecutively NOTE When ABS ECU stops functioning through the fail safe mechanism erasing of the diagnostic troubl codes cannot be performed Ignition switch Stop lamp...

Page 1122: ... that for other vehicles Accordingly advise the customer to drive safely on suck roads by lowering the vehicle speed and not being to overconfident Diagnosis detection condition can vary depending on the diagnosis code Make sure that checking requirements listed in the Comment are satisfied when checking the trouble symptom again DIAGNOSIS FUNCTION 35201120351 DIAGNOSIS CODES CHECK Read a diagnosi...

Page 1123: ...pped because of fail sage operation it will not be possible t erase the diagnosis codes Ignition switch Stop lamp switch ABS ECU warming lamp ABS ECU memory Added 5 Ensure that the diagnostic trouble codes have been erased When diagnostic trouble codes Nos 21 to 24 for vehicle wheel speed sensor system failures occur the above procedures may not erase those codes In that case turn the ignition swi...

Page 1124: ...r road surfaces suck as snow covered roads an gravel roads the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles Accordingly advise the customer to drive safely on suck roads by lowering the vehicle speed and not being to overconfident Shock during system operation check Shock may be felt when the brake pedal is depressed slightly at a low driving speed Th...

Page 1125: ...with brake pedal depressed 3 Under the condition of 1 and 2 above turn the ignition switch ON After that place the stop lamp switch to OFF with brake pedal released within 3 seconds and cycle the stop lamp switch ON and OFF ten times consecutively NOTE When ABS ECU stops functioning through the fail safe mechanism erasing of the diagnostic troubl codes cannot be performed Ignition switch Stop lamp...

Page 1126: ...osis control terminal of the diagnosis connector 3 Turn on the stop lamp switch Depress the brake Added When diagnostic trouble codes Nos 21 to 24 for vehicle wheel speed sensor system failures occur normal MUT II operation may not erase those codes In that case erase the diagnostic trouble codes using the following procedures 1 Perform erasing of the diagnostic trouble codes by special operation ...

Page 1127: ...BS warning lamp ABS ECU memory Added 4 Ensure that the diagnostic trouble codes have been erased When diagnostic trouble codes Nos 21 to 24 for vehicle wheel speed sensor system failures occur the above procedures may not erase those codes In that case turn the ignition switch OFF then repeat steps 1 to 3 above 35B 5 ABS 2WD Troubleshooting 3 Changed OFF ON OFF ON OFF ON 9th With in 1s 7th With in...

Page 1128: ...ANTI SKID BRAKING SYSTEM ABS 4WD ...

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Page 1130: ... Disc Brake Rotor Check Brake Lining Thickness Check Brake Drum Inside Diameter Check Brake Lining and Brake Drum Connection Check BRAKE PEDAL LOAD SENSING PROPORTIONING VALVE REAR DRUM BRAKE For the items below refer to GROUP 35B ON VEHICLE SERVICE Bleeding Disc Brake Pad Check and Replacement Wheel Speed Sensor Output Voltage Check Hydraulic Unit Check Solenoid Valve Check Motor Operation Check ...

Page 1131: ...st and actuator of testing are possible using the MUT II Items Specifications Speed sensor Magnet coil type Front rotor teeth 47 Rear rotor teeth 47 CONSTRUCTION DIAGRAM NOTE 1 For R H drive vehicles those parts are installed at the right side 2 Diesel powered vehicles L H drive vehicles 3 Except diesel powered vehicles L H drive vehicles 1 2 3 1 4 1 5 6 7 1 8 1 9 2 10 11 12 13 14 9 3 6 5 6 5 1 AB...

Page 1132: ...seal Repair kit grease Guide pin boot inner surfaces Lock pin boot inner surfaces Piston boot mounting grooves Brake piston boot inner surfaces Lock pin bush inner surfaces Piston cup surface SPECIAL TOOLS 35200060142 Tool Number Name Use MB991502 MUT II sub assembly For checking of ABS Diagnosis code display when using the MUT II MB991529 ABS check harness For checking of ABS Diagnosis code displ...

Page 1133: ...ABS operation Long braking distance For road surfaces such as snow covered roads and gravel roads the braking distance for vehicles with ABS can sometimes be longer than that for other vehicles Accordingly advise the customer to drive safely on such roads by lowering the vehicle speed and not being too overconfident Shock during system operation check Shock may be felt when the brake pedal is depr...

Page 1134: ... Refer to GROUP 35B Troubleshooting 21 Front right wheel speed sensor Abnormal Refer to GROUP 35B Troubleshooting 22 Front left wheel speed sensor 23 Rear right wheel speed sensor 24 Rear left wheel speed sensor 25 Free wheel engage switch 35C 7 26 4WD position detection switch 35C 8 27 Rear differential lock detection switch 35C 9 32 G sensor system 35C 10 33 Stop lamp switch system Refer to GROU...

Page 1135: ...Does the 4WD indicator lamp operate normally No 4WD indicator ECU check Refer to GROUP 22 4WD indicator ECU NG Replace the 4WD indicator ECU Yes Measure at ABS ECU connector C 64 D Disconnect the connector and measure at the harness side D Ignition switch ON D Voltage between 45 and body earth OK System voltage when in 2WD or 0 V when in 4WD NG Check the following connectors C 64 and A 02 NG Repai...

Page 1136: ...dicator ECU and the free wheel engage switch or broken earth wire from the free wheel engage switch Repair the harness Free wheel engage switch is defective Replace the switch Even when the transfer shift lever is in the 4H position the free wheel differential indicator lamp does not illuminate Broken harness wire between the 4WD indicator ECU and the 4WD position detection switch Repair the harne...

Page 1137: ...tection switch and the ABS ECU and repair if necessary OK Check the following connector C 64 NG Repair OK Check trouble symptoms NG Replace the ABS ECU Code No 27 Rear differential lock detection switch Vehicles without rear differential lock Probable cause For vehicles without rear differential lock battery positive voltage is applied to the ABS ECU terminal No 46 This code is output when this li...

Page 1138: ...er to P 35C 20 NG Replace the G sensor OK Measure at ABS ECU connector C 62 D Ignition switch ON D Voltage between 4 and 17 OK 2 4 2 6 V NG Check the following connector C 02 NG Repair OK Check trouble symptom NG Check the harness between the G sen sor and the ABS ECU and repair if nec essary OK Check the following connector C 62 NG Repair OK Check trouble symptom NG Replace the ABS ECU ABS WARNIN...

Page 1139: ...on switch power supply voltage and valve monitor voltage 9 16 V 25 Free wheel engage switch Engage 4WD ON Engage 2WD OFF 26 4WD detection switch Place the transfer lever at 4H ON Place the transfer lever at 2H OFF 27 Rear differential lock detection switch Turn on the switch ON switch Turn off the switch OFF 32 G sensor output voltage Stop the vehicle 2 4 2 6 V Perform a test run Display value flu...

Page 1140: ...nit solenoid valve IN side 4 G sensor signal Ignition switch ON 2 4 2 6 V Horizontal condition 13 ABS ECU power supply Ignition switch ON System voltage Ignition switch START 0 V 14 Output to front left hydraulic unit solenoid valve IN side Ignition switch ON When solenoid valve is off approximately 1 second after engine is started System voltage 17 G sensor earth Always 0 V 26 Output to relay pow...

Page 1141: ... engage switch Ignition switch ON Engage 2WD System voltage switch switch ON Engage 4WD 1 V or less 46 1 Ignition switch Ignition switch ON System voltage Ignition switch START 0 V 46 2 Input from rear differential lock detection switch Ignition switch ON Rear differential lock switch ON 0 V Rear differential lock switch OFF System voltage 47 Input from diagnosis indication selection Connect the M...

Page 1142: ...UT side 2 2 Ω 3 Body earth Rear solenoid valve IN side 5 0 Ω 7 20 Front left wheel speed sensor wire 1 2 1 4 kΩ 8 21 Rear right wheel speed sensor wire 1 2 1 4 kΩ 9 22 Rear left wheel speed sensor wire 1 2 1 4 kΩ 10 23 Front right wheel speed sensor wire 1 2 1 4 kΩ 14 Body earth Front left solenoid valve IN side 5 0 Ω 15 Body earth ABS ECU earth Continuity 16 Body earth 25 Body earth 39 43 Idle up...

Page 1143: ...ake Fluid Draining Post installation Operation D Brake Fluid Supplying D Brake Line Bleeding Refer to GROUP 35B On vehicle Service 90 Nm 90 Nm 15 Nm 1 2 3 4 Removal steps 1 Brake tube 2 Front brake assembly Refer to GROUP 35B Front Disc Brake 3 Brake hose bracket 4 Brake disc Refer to GROUP 26 Front Hub Assembly ...

Page 1144: ...se 8 Nm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 8 9 14 2 1 3 5 9 8 7 6 13 14 11 12 14 12 13 9 7 5 3 5 Caliper assembly disassembly steps AA 1 Lock pin AA 2 Guide pin 3 Bushing 4 Caliper support Pad clip and shim 5 Pin boot 6 Boot ring AA 7 Piston boot AA 8 Piston AB 9 Piston seal 10 Caliper body Pad assembly disassembly steps AA 1 Lock pin AA 2 Guide pin 3 Bushing 4 Caliper support Pad clip and shim 11 P...

Page 1145: ...on because it will become impossible to remove the second piston AB PISTON SEAL REMOVAL 1 Remove piston seal with finger tip Caution Do not use a screwdriver or other tool to prevent damage to inner cylinder 2 Clean piston surface and inner cylinder with trichloro ethylene alcohol or specified brake fluid Specified brake fluid DOT3 or DOT 4 REASSEMBLY SERVICE POINT AA LOCK PIN GUIDE PIN INSTALLATI...

Page 1146: ... the limit value Standard value 10 mm Limit 2 0 mm Caution 1 When the limit is exceeded replace the pads at both sides and also the brake pads for the wheels on the opposite side at the same time 2 If there is a significant difference in the thicknesses of the pads on the left and right sides check the sliding condition of the piston lock pin and guide pin ...

Page 1147: ...TALLATION Post installation Operation D Wheel Speed Sensor Output Voltage Checking Refer to GROUP 35B On vehicle Service 1 2 1 Front speed sensor 2 Front rotor Refer to GROUP 26 Front Hub NOTE The rear wheel speed sensor is the same as 2WD INSPECTION 35200840135 Refer to GROUP 35B ...

Page 1148: ...ON 35201020057 1 Disconnect the G sensor connector and connect the special tool between the terminals of the disconnected connector 2 Turn the ignition switch to ON and take a reading of the following output voltage Between terminals 2 and 3 Standard value 2 4 2 6 V 3 With the special tool still connected secure the G sensor so that the arrow mark on the sensor mounting surface faces straight down...

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Page 1162: ...parking brake is of a mechanical rear wheel brake construction in all vehicles There are two types of parking brake stick type and lever type CONSTRUCTION DIAGRAM SERVICE SPECIFICATIONS 36100030116 Item Standard value Parking brake lever stroke 6 7 notches Parking brake pull rod stroke 11 13 notches ...

Page 1163: ...nging the automatic adjusting mechanism is functioning normally and clearance between the shoe and drum is correct 2 Turn the adjusting nut to adjust the parking brake lever stroke to within the standard value range Caution If the number of brake lever notches engaged is less than the standard value the cable has been pulled excessively Be sure to adjust it to the standard value 3 Check to be sure...

Page 1164: ...d equalizer are at right angles to each other 2 If the number of brake pull rod notches engaged is less than the standard value the cable has been pulled excessively Be sure to adjust it to the standard value 3 Adjust the pull rod stroke Release the parking brake pull rod and jack up the rear of the vehicle 4 Turn the rear wheel to confirm that the rear brakes are not dragging PARKING BRAKE SWITCH...

Page 1165: ... 52A Floor Console Post installation Operation D Rear Floor Console Installation Vehicles with rear floor console Refer to GROUP 52A Floor Console D Parking Brake Lever Stroke Adjustment Refer to P 36 3 1 2 3 4 4 5 Removal steps 1 Parking cover Vehicles without rear floor console 2 Parking lever cable connection 3 Parking brake switch 4 Parking cover bracket Vehicles without rear floor console 5 P...

Page 1166: ... shaft 5 Parking brake pull rod REMOVAL SERVICE POINT AA PARKING BRAKE FRONT CABLE END REMOVAL Remove pawl from ratchet With the parking brake pull rod pushed in disconnect the parking brake front cable end from the parking brake pull rod INSTALLATION SERVICE POINT AA PARKING BRAKE SWITCH INSTALLATION Adjust the parking brake switch position so that the warning lamp will go out when parking brake ...

Page 1167: ...les without rear floor console Refer to 36 5 Post installation Operation D Rear Floor Console Installation Vehicles with rear floor console Refer to GROUP 52A Floor Console D Parking Cover Installation Vehicles without rear floor console Refer to 36 5 D Parking Brake Lever Stroke Adjustment Refer to P 36 3 1 2 3 Removal steps D Shoe and lining assembly Refer to GROUP 35 Rear Drum Brake 1 Front par...

Page 1168: ... 6 4 10 9 Removal steps D Shoe and lining assembly Refer to GROUP 35A Rear Drum Brake 1 Snap ring 2 Clip 3 Parking brake front cable 4 Return spring 5 Adjusting nut 6 Parking brake rear cable end 7 Split pin 8 Plane washer 9 Clevis pin AA 10 Spacer 11 Lever assembly INSTALLATION SERVICE POINT AA SPACER INSTALLATION Install the spacer with its projection located towards rear of the vehicle Forward ...

Page 1169: ...STEERING ...

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Page 1171: ...sm and a tilt steering mechanism A vane type oil pump with a fluid flow control system has been included The steering gear and linkage is ball and nut typ Items Specifications Manual steering gear box Type Ball and nut type Gear ratio 18 5 23 0 Power steering gear box Type Ball and nut type Gear ratio 2WD 18 5 23 0 4WD 16 4 18 0 Oil pump Type Vane type Displacement m rev 9 6 Relief set pressure MP...

Page 1172: ...e idle speed r min 4G6 750 100 4D56 750 100 Stationary steering effort N 39 2 or less Oil pump pressure MPa Oil pump relief pressure 8 3 9 0 ressure MPa Pressure under no load conditions 0 8 1 0 Steering gear retention hydraulic pressure 8 3 9 0 Oil pressure switch operating pressure MPa OFF ON 1 5 2 0 ON OFF 0 7 1 2 Mainshaft starting torque Nm 0 49 0 78 Cross shaft axial play mm 0 05 or less Mai...

Page 1173: ...ole Adjusting bolt seal bolt packing adjusting shim dust cover lip for ball joint 3M ATD Part No 8663 or equivalent Semi drying sealant SPECIAL TOOLS 37100060013 Tool Number Name Use MB990948 Linkage joint gauge Ball joint variation check for shaft direction MB991113 or MB990635 Steering linkage puller Disconnection of ball joint MB990685 MB991151 Torque wrench D Measurement of the ball joint star...

Page 1174: ...Preload socket Measurement of the mainshaft total starting torque MB990776 Front axle base Installation of dust cover for tie rod end ball joint MB990628 Snap ring pliers To remove and install the snap ring of the pulley assembly MB990925 Bearing and oil seal installer set Installation of the oil seal and bearing Refer to GROUP 26 Special Tools MB990915 Pitman arm puller Removal of the pitman arm ...

Page 1175: ... of the lock nut MB991203 Oil seal bearing installer To press in the valve housing oil seal and bearing MB990956 Needle bearing in staller To press in the drive shaft assembly MB991172 Adapter MB990767 End york holder Securing the drive pulley MD998719 or MD998754 Crankshaft pulley holder pin ...

Page 1176: ...et front wheels straight ahead 2 Measure the play on steering wheel circumference before wheels start to move when slightly moving steering wheel in both directions Limit 50 mm 3 When play exceeds the limit check for play on steering shaft connection and steering linkage Correct or replace 4 If the free play still exceeds the limit value set steering wheel straight ahead with engine stopped Load 5...

Page 1177: ...fer to P 37A 49 3 Measure the steering gear backlash at the pitman arm top end with a dial indicator Limit 0 5 mm 4 If the measured value exceeds the limit screw in the steering gear box adjusting bolt until steering wheel free play is within the standard value Caution 1 Be sure to make the adjustment with the steering wheel in the straight ahead position 2 If the adjusting bolt is overtightened m...

Page 1178: ...onnect the ball joint Caution 1 Only loosen tie rod end mounting nut but do not remove it from the ball joint 2 Support the special tool with a cord etc to prevent it from coming off 2 Move the ball joint stud several times and install the nut on stud Measure ball joint starting torque with special tools Standard value 3 0 Nm 3 When the starting torque exceeds the standard value replace the tie ro...

Page 1179: ...eft and right within a range of 1 5 turns Also check to be sure that there is no significant fluctuation of the required steering force Standard value Steering effort 39 2 N or less Fluctuation allowance 5 N or less CHECKING STEERING WHEEL RETURN TO CENTRE POWER STEERING 37200180118 Conduct a road test before this test 1 Make both gradual and sudden turns and check the steering feeling to be sure ...

Page 1180: ...he front wheels on a jack and then support them with rigid racks 2 Disconnect the return hose connection 3 Connect a vinyl hose to the return hose and drain the oil into a container 4 On vehicles with a petrol engine disconnect the high tension cable On vehicles with a diesel engine remove the fuel cut valve connector attached to the injection pump Caution Be careful not to position the high tensi...

Page 1181: ...king 6 On vehicles with a petrol engine connect the high tention cable On vehicles with a diesel engine connect the fuel cut valve connector attached to the injection pump Start the engine idling 7 Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir 8 Confirm that the fluid is not milky and that the level is up to the specified position on the level ga...

Page 1182: ... Check whether or not the hydraulic pressure is the standard value when no load conditions are created by fully opening the shut off valve of the pressure gauge Standard value 0 8 1 0 Mpa 7 If it is not within the standard value the probable cause is a malfunction of the oil line or steering gear box so check these parts and repair as necessary 8 Turn the steering wheel all the way to the left or ...

Page 1183: ...n ohmmeter in position 5 Gradually close the shut off valve of the pressure gauge and increase the hydraulic pressure then check whether or not the hydraulic pressure that activates the switch is the standard value Standard value 1 5 2 0 MPa 6 Gradually open the shut off valve and reduce the hydraulic pressure then check whether or not the hydraulic pressure that deactivates the switch is the stan...

Page 1184: ... 3M ATD Part No 8661 or equivalent 40 Nm 1 3 40 Nm 2 3 7 6 9 5 8 5 Nm 12 Nm 18 Nm 9 4 Vehicles without SRS Vehicles with SRS Removal steps 1 Horn pad Vehicles without SRS 2 Air bag module Refer to GROUP 52B Air Bag Module and Clock Spring AA 3 Steering wheel 4 Upper column cover D Instrument under cover Refer to GROUP 52A Instrument Panel 5 Lower column cover AA 6 Column switch Vehicles without SR...

Page 1185: ...rn pad Vehicles without SRS 2 Air bag module Refer to GROUP 52B Air Bag Module and Clock Spring AA 3 Steering wheel 4 Upper column cover 5 Lower column cover AA 6 Column switch Vehicles without SRS AA 7 Clock spring and column switch Refer to GROUP 52B Air Bag Module and Clock Spring 8 Brake pedal return spring 9 Steering column assembly REMOVAL SERVICE POINT AA STEERING WHEEL REMOVAL MB990803 ...

Page 1186: ...D 4WD 1 4 6 5 3 18 17 11 12 13 16 15 14 10 20 25 Nm 1 2 3 18 17 9 8 7 17 Nm 2 Disassembly steps BA 1 Special bolt AA BA 2 Steering lock bracket AA BA 3 Steering lock cylinder 4 Snap ring 5 Stopper 6 Bearing spacer AA 7 Lower boot 8 Joint assembly AA 9 Upper boot 10 Steering shaft assembly 11 Bearing spacer 12 Stopper 13 Snap ring 14 Yoke 15 Rubber coupling 16 Steering shaft 17 Packing 18 Column su...

Page 1187: ...ws on the upper and lower boots to the slit on the yokes in order to assemble BA STEERING LOCK CYLINDER STEERING LOCK BRACKET SPECIAL BOLT INSTALLATION 1 When installing the steering lock cylinder and steering lock bracket to the column tube temporarily install the steering lock in alignment with the column boss 2 After checking that the lock works properly tighten the special bolts until the head...

Page 1188: ...ght Ahead D Front Wheel Alignment Adjustment Refer to GROUP 33A On vehicle Service 5 1 4 2 18 Nm 60 Nm 40 Nm 3 3 Removal steps 1 Steering gear box and steering shaft connecting bolt 2 Split pin AA 3 Pitman arm and relay rod connec tion 4 Self locking nut 5 Steering gear box REMOVAL SERVICE POINT AA PITMAN ARM AND RELAY ROD DISCONNECTION Use the special tool to disconnect the ball joint Caution 1 U...

Page 1189: ...20 INSPECTION 37100230049 PITMAN ARM DUST COVER CHECK If there are any cracks in or damage to the dust cover replace the pitman arm If the dust cover is damaged accidentally during service work replace the dust cover only Refer to P 37A 25 ...

Page 1190: ... Nm 137 Nm 3 7 9 Lip 14 14 10 2 13 Disassembly steps HA D Steering gear backlash check 1 Jam nut AA GA 2 Pitman arm 3 Breather plug 4 Gasket 5 Seal bolt FA D Mainshaft total starting torque adjustment 6 Lock nut AB 7 Side cover 8 Packing 9 Adjusting bolt EA D Cross shaft axial play adjustment 10 Adjusting spacer AC 11 Cross shaft 12 Bolt DA D Mainshaft starting torque adjustment 13 End cover 14 Ad...

Page 1191: ...ew in the adjusting bolt without turning the side cover and then remove the side cover AC CROSS SHAFT REMOVAL With the mainshaft and cross shaft placed in the straight ahead position tap the bottom of the cross shaft with a plastic hammer to take out the cross shaft together with the top cover REASSEMBLY SERVICE POINTS AA OIL SEAL INSTALLATION BA OIL SEAL INSTALLATION MB990915 MB990939 MB990926 ...

Page 1192: ...stall the adjusting spacer to the adjusting bolt and measure the cross shaft axial play Standard value 0 05 mm or less 2 If the measured value is not within the standard value adjust by changing the adjusting spacer FA MAINSHAFT TOTAL STARTING TORQUE ADJUSTMENT Lubricate the bearings and gear teeth of each shaft 1 Move the ball nut of the mainshaft to the centre position straight ahead position Ca...

Page 1193: ...KLASH CHECK 1 Move the pitman arm to the right and left 3 to 5 times to be sure that the tooth surfaces sufficiently correct with each other 2 Measure the steering gear backlash at the end of the pitman arm with a dial indicator Limit 0 5 mm Caution Measure the steering gear backlash when the mainshaft cross shaft and pitman arm are in the straight ahead position 3 If the reading exceeds the limit...

Page 1194: ...g service work replace the dust cover only as follows 1 Fill inside the dust cover with multipurpose grease 2 Apply specified sealant to the mounting surface of the dust cover at the pitman arm Specified sealant 3M ATD Part No 8661 or equivalent 3 Using the special tool install the dust cover to the pitman arm MB990776 ...

Page 1195: ...ning Refer to P 37A 11 Post installation Operation D Power Steering Fluid Supplying Refer to P 37A 11 D Power Steering Fluid Line Bleeding Refer to P 37A 12 D Checking Steering Wheel Position with Wheels Straight Ahead D Front Wheel Alignment Adjustment Refer to GROUP 33A On vehicle Service 2WD 4WD 5 4 8 1 3 5 4 8 1 7 3 2 2 15 Nm 18 Nm 60 Nm 7 40 Nm 15 Nm 60 Nm 17 Nm 45 Nm 3 6 6 Removal steps 1 Co...

Page 1196: ... the special tool loosen the tie rod end mounting nut Only loosen the nut do not remove it from the ball joint 2 Support the special tool with a cord etc to prevent it from coming off INSPECTION 37200400108 PITMAN ARM DUST COVER CHECK If there are any cracks in or damage to the dust cover replace the pitman arm Refer to P 37A 36 Cord Ball joint Nut MB990635 or MB991113 ...

Page 1197: ... locking nut AB 5 Side cover 6 O ring 7 Y packing 8 Adjusting bolt 9 Adjusting plate AC 10 Cross shaft 11 Mainshaft and valve assembly AD 12 Rack piston 13 Spacer 14 Seal ring 15 Circulator holder 16 Circulator 17 Ball AE 18 Lock nut AF 19 Mainshaft AF 20 Bearing race 21 Cage AF 22 Ball 23 Seal ring 24 Bearing race 25 O ring AG 26 Bearing AG 27 Oil seal 28 Valve housing 29 Oil seal 30 Y packing 31...

Page 1198: ...r and then remove the side cover AC CROSS SHAFT REMOVAL With the mainshaft and cross shaft placed in the straight ahead position tap the bottom of the cross shaft with a plastic hammer to take out the cross shaft together with the side cover AD RACK PISTON REMOVAL Remove the rack piston from the mainshaft by turning it counterclockwise Caution Be careful not to lose the 26 balls inside the rack pi...

Page 1199: ...ING RACE AND BALL REMOVAL Remove the mainshaft while pressing the bearing race so that the balls do not come out AG BEARING AND OIL SEAL REMOVAL Using a socket remove the oil seal and bearing from the valve housing simultaneously Mainshaft Bearing race Socket ...

Page 1200: ...6 Bearing case 7 O ring DA 8 Seal ring EA 9 Cage EA 10 Ball EA 11 Bearing race EA 12 Mainshaft FA 13 Lock nut GA D Mainshaft axial play adjustment 14 Seal ring 15 Spacer HA 16 Rack piston HA 17 Ball 18 Circulator 19 Circulator holder 20 Valve housing 21 Mainshaft and valve assembly 22 Y packing 23 O ring IA D Cross shaft axial play adjustment 24 Adjusting plate 25 Adjusting bolt JA 26 Cross shaft ...

Page 1201: ...luid DEXRON or DEXRON II Sealant 3M ATD Part No 8661 or equivalent Automatic transmission fluid DEXRON or DEXRON II REASSEMBLY SERVICE POINTS AA OIL SEAL INSTALLATION Apply a coating of the specified fluid to the outside of the oil seal Using the special tools press the oil seal into the valve housing Specified fluid Automatic transmission fluid DEXRON or DEXRON II MB990938 MB990926 Oil seal ...

Page 1202: ...g firmly into the valve groove EA CAGE BALLS BEARING RACE AND MAINSHAFT INSTALLATION 1 Apply specified fluid to the mainshaft Specified fluid Automatic transmission fluid DEXRON or DEXRON II 2 Wrap vinyl tape around the serrated part so that the oil seal won t be damaged when the mainshaft is installed to the valve housing 3 Mount the mainshaft to the valve housing 4 Align the cage s hole and the ...

Page 1203: ...e lock nut 3 Check to be sure that the mainshaft rotates smoothly HA RACK PISTON AND BALLS INSTALLATION 1 Install the rack piston until it comes in contact with the edge of the mainshaft 2 Rotate the mainshaft to align the ball race way with the 19 ball insertion hole NOTE The balls must be inserted so that there is no clearance between the balls 3 Set the remaining seven balls in the circulator a...

Page 1204: ... during installation Take care not to damage the cross shaft oil seal KA MAINSHAFT TOTAL STARTING TORQUE ADJUSTMENT 1 While turning the adjusting bolt measure the mainshaft total starting torque by using the special tools Standard value 2WD 0 98 1 47 Nm 4WD 0 69 1 28 Nm Caution Adjust by turning adjusting bolt so that the starting torque at the centre position of the rack piston is approximately 0...

Page 1205: ... BALL JOINT STARTING TORQUE Refer to P 37A 24 DUST COVER REPLACEMENT Only when the dust cover is damaged accidentally during service work replace the dust cover only as follows 1 Fill inside the dust cover with multipurpose grease 2 Apply specified sealant to the mounting surface of the dust cover at the pitman arm Specified sealant 3M ATD Part No 8661 or equivalent 3 Using the special tool instal...

Page 1206: ...Line Bleeding Refer to 37A 12 D Oil Pump Pressure Check Refer to 37A 13 22 Nm 3 5 1 7 6 2 3 1 6 2 7 4 18 Nm 39 Nm 22 Nm 24 Nm 22 Nm 22 Nm 4 4G6 4D56 22 Nm Removal steps 1 Drive belt 2 Suction hose AA 3 Pressure hose 4 O ring 5 Pressure switch connector 4G6 6 Oil pump 7 Oil pump bracket INSTALLATION SERVICE POINTS AA PRESSURE HOSE INSTALLATION Connect the pressure hose so that the notch part contac...

Page 1207: ...5 14 20 Nm 8 Nm 60 Nm 25 30 Nm 26 23 Disassembly steps 1 Pump cover 2 O ring HA 3 Vanes GA 4 Cam ring AA FA 5 Snap ring EA 6 Rotor 7 Pulley assembly DA 8 Side plate BA 9 O ring 10 Connector BA 11 O ring 12 Flow control valve 13 Flow control spring 14 Terminal assembly BA 15 O ring CA 16 Spring 17 Plunger 18 Piston rod 19 Snap ring 20 Terminal 21 Washer 22 Insulator BA 23 O ring 24 Plug 25 Suction ...

Page 1208: ...NSTALLATION No I D x Width mm 1 11 1 9 2 13 1 9 3 17 8 2 4 4 13 5 1 5 5 3 8 1 9 6 16 8 2 4 CA SPRING INSTALLATION Fit the spring to the oil pump body with the larger diameter end at the terminal assembly side MB990628 MB990938 MB990938 MB990926 Suction connector mounting portion of oil pump body Connector Side plate Terminal assembly 1 2 3 4 6 5 2 3 ...

Page 1209: ...NSTALLATION Install the rotor to the pulley assembly so that the rotor s punch mark is at the pump cover side FA SNAP RING INSTALLATION After installation of the snap ring lift the rotor and check that the snap ring has entered the countersunk part GACAM RING INSTALLATION Install the cam ring with the punch mark facing the side plate Dowel pin hole Dowel pin MB990628 Snap ring Punch mark ...

Page 1210: ...tion direction INSPECTION 37200550087 D Check the flow control valve for clogging D Check the pulley assembly for wear or damage D Check the groove of rotor and vane for stepped wear D Check the contact surface of cam ring and vanes for stepped wear D Check the vanes for damage Direct round edge to the cam ring Rotor Vane Cam ring ...

Page 1211: ...Nm 69 78 Nm 61 Nm Disassembly steps AA GA 1 Drive pulley 2 Snap ring 3 Pump cover 4 Lock pin 5 Seal washer FA 6 Vanes EA 7 Cam ring DA 8 Rotor 9 Side plate CA 10 O ring 11 Connector CA 12 O ring 13 Flow control valve 14 Flow control spring 15 Suction connector CA 16 O ring BA 17 Drive shaft assembly AA 18 Oil seal 19 Oil pump body Caution Do not disassemble the flow control valve DISASSEMBLY SERVI...

Page 1212: ...INSTALLATION No I D x Width mm 1 11 1 9 2 13 1 9 3 15 5 2 4 4 14 6 2 4 5 19 4 1 9 DA ROTOR INSTALLATION Install the rotor to the pulley assembly so that the rotor s punch mark is at the pump cover side MB991203 MB990938 Drive shaft assembly MB990956 MB991172 Suction connector mounting portion of oil pump body Side plate Connector 1 2 3 5 4 ...

Page 1213: ... installation direction GADRIVE PULLEY INSTALLATION INSPECTION 37200550087 D Check the flow control valve for clogging D Check the pulley assembly for wear or damage D Check the groove of rotor and vane for stepped wear D Check the contact surface of cam ring and vanes for stepped wear D Check the vanes for damage Punch mark Direct round edge to the cam ring Rotor Vane Cam ring MD998719 or MD99875...

Page 1214: ...eering Fluid Supplying Refer to P 37A 11 D Power Steering Fluid Line Bleeding Refer to P 37A 12 15 4WD 2WD 3 2 1 7 5 9 8 22 Nm 15 Nm 12 Nm 12 Nm 12 Nm 15 18 10 12 14 10 12 17 16 18 14 12 Nm 11 13 13 13 15 17 4G6 11 Removal steps FA 1 Suction hose 2 Return hose 3 Oil reservoir EA 5 Return hose 7 Return tube DA 8 Pressure hose 9 O ring CA 10 Return tube BA 11 Tube stay 12 Return hose AA 13 Return tu...

Page 1215: ...5 13 12 10 11 10 15 13 12 18 14 14 9 12 Nm 12 Nm 12 Nm 12 Nm 22 Nm 13 15 17 15 Nm 18 15 4WD 2WD Removal steps FA 1 Suction hose 2 Return hose 3 Oil reservoir FA 4 Suction hose EA 5 Return hose 6 Suction tube 7 Return tube DA 8 Pressure hose 9 O ring CA 10 Return tube BA 11 Tube stay 12 Return hose AA 13 Return tube 14 O ring 15 Pressure tube 16 O ring 17 Pressure tube 18 O ring ...

Page 1216: ... stay to the positioning hole CA RETURN TUBE INSTALLATION Connect the return tube so that the marking is positioned as shown in the illustration DA PRESSURE HOSE INSTALLATION 1 Connect the pressure hose so that the its notch part contacts the suction connector 2 Align the marks on the pressure hose and pressure tube and install the pressure hose Mating marks Positioning hole Tube stay Return tube ...

Page 1217: ...NSTALLATION Install the return hose so that the marking faces towards front of the vehicle FA SUCTION HOSE INSTALLATION Connect the suction hose so that the marking is positioned as shown in the illustration Return hose Suction hose 4G6 4D56 Suction hose ...

Page 1218: ...tion with Wheels Straight Ahead D Front Wheel Alignment Refer to GROUP 33A On vehicle Service 1 44 Nm 1 44 Nm 59 Nm 95 Nm 1 40 Nm 2WD 4WD 40 Nm 1 4 5 95 Nm 40 Nm 95 Nm 40 Nm 44 Nm 40 Nm 1 1 2 2 4 59 Nm 5 1 1 44 Nm 2 2 3 95 Nm 1 44 Nm 1 3 Removal steps 1 Split pin AA AA 2 Tie rod assembly AA 3 Relay rod 4 Self locking nut AA 5 Idler arm assembly ...

Page 1219: ...a cord etc to prevent it from coming off INSTALLATION SERVICE POINT AA TIE ROD ASSEMBLY INSTALLATION Tighten the tie rod assembly to the specified torque INSPECTION 37100310019 Check the rubber parts for cracks and break DUST COVER CHECK If there are any cracks in or damage to the dust cover replace the tie rod end assembly or idler arm If the dust cover is damaged accidentally during service work...

Page 1220: ... locking nut 2 Washer 3 Idler arm assembly CA 4 Bushing BA 5 Oil seal 6 Idler arm 7 Idler arm support Tie rod disassembly steps AA 8 Tie rod end assembly 9 Pipe REASSEMBLY SERVICE POINTS AA TIE ROD END INSTALLATION 1 Apply multipurpose grease to the threaded section of the tie rod end 2 Screw in the right and left tie rod ends to the pipe by the same amount and then and provisionally tighten the t...

Page 1221: ...ween the bushings Caution Do not apply grease to the outside of the bushings INSPECTION 37100350011 IDLER ARM SLIDING RESISTANCE Standard value 2WD 8 8 30 N 1 0 3 4 Nm 4WD 2 4 16 N 0 3 2 0 Nm DUST COVER REPLACEMENT Only when the dust cover is damaged accidentally during service work replace the dust cover only as follows 1 Fill inside the dust cover with multipurpose grease 2 Apply the specified s...

Page 1222: ...arbox is now available only as an assembly supply of individual components and parts discontinued Accordingly the service procedure for the power steering gearbox is also changed as shown in the attached sheets 2 Applicable Manuals Manual Pub No Language Page s 97 L200 PWTE96E1 English 37A 3 6 28 34 Workshop Manual CHASSIS PWTS96E1 Spanish PWTF96E1 French PWTG96E1 German 95 PAJERO PWJE9086 F Engli...

Page 1223: ...tionairy steering effort N 39 2 or less Oil pump relief pressure 8 3 9 0 Pressure under no load conditions 0 8 1 0 Oil pump pressure MPa Steering gear retention hydraulic pressure 8 3 9 0 OFF ON 1 5 2 0 Oil pressure switch operating pressure Mpa ON OFF 0 7 1 2 Mainshaft starting torque Nm 0 49 0 78 Cross shaft axial play mm 0 05 or less 2WD 0 98 1 47 Mainshaft total starting torque Nm 4WD 0 69 1 2...

Page 1224: ...M ATD Part No 8663 or equivalent Semi drying sealant SPECIAL TOOLS Tools Number Name Use MB990948 Linkage joint gauge Ball joint variation check for shaft direction MB991113 or MB990635 Steering linkage puller Disconnection of ball joint MB990685 MB991151 Torque wrench Measurement of the ball joint starting torque Measurement of the shaft preload Measurement of the mainshaft starting torque MB9903...

Page 1225: ...ue MB990776 Front axle base Installation of dust cover for tie rod end ball joint MB990628 Snap ring pliers To remove and install the snap ring of the pulley asembly MB990925 Bearing and oil seal installer set Installation of the oil seal and bearing Refer to GROUP 26 Special tools MB990915 Pitman arm puller Removal of the pitman arm MB991367 Special spanner Removal and installation of the lock nu...

Page 1226: ...installer To press in the valve housing oil seal and bearing MB990956 Needle bearing installer MB991172 Adapter To press in the drive shaft assembly MB990767 End york holder MB998719 or MD998754 Crankshaft pulley holder pin Securing the drive pulley 37A 6 STEERING Special Tools B991394 B991203 B990956 Deleted ...

Page 1227: ...Y packing 23 Seal ring 08 Adjusting bolt 24 Bearing race 09 Adjusting plate 25 O ring C 10 Cross shaft G 26 Bearing 11 Mainshaft and valve assembly G 27 Oil seal D 12 Rack piston 28 Valve housing 13 Spacer 29 Oil seal 14 Seal ring 30 Y packing 15 Circulator helder 31 Gear box housing 16 Circulator 37A 28 STEERING Power Steering Gear Box 37200420029 A13V0108 Deleted 14 1 O ring Added Deleted New Ol...

Page 1228: ...MOVAL With the mainshaft and cross shaft placed in the straight ahead position tap the bottom of the cross shaft with a plastic hammer to take out the cross shaft together with the side cover D RACK PISTON REMOVAL Remove the rack piston from the mainshaft by turning it counterclockwise Caution Be careful not to lose the 26 balls inside the rack piston E LOCK NUT REMOVAL STEERING Power Steering Gea...

Page 1229: ...e pressing the bearing race so that the balls do not come out G BEARING AND OIL SEAL REMOVAL using a socket remove the oil seal and bearing from the valve housing simultaneously 37A 30 STEERING Power Steering Gear Box Z13W091 Z13W087 Bearing race Mainshaft Socket Deleted ...

Page 1230: ...s shaft E 10 Ball 27 Side cover E 11 Bearing race 28 Side cover and cross shaft E 12 Mainshaft assembly F 13 Lock nut 29 Bolt G Mainshaft axial play adjustment K Mainshaft total staring torque 14 Seal ring Adjustment 15 Spacer 30 Adjusting bolt lock nut H 16 Rack piston L 31 Pitman arm H 17 Ball 32 Jam nut 18 Circulator STEERING Power Steering Gear Box 37A 31 37200430022 A13V0108 Deleted New Old O...

Page 1231: ...omatic transmission fluid DEXRON or DEXRON II 37A 32 STEERING Power Steering Gear Box 00004894 Old Deleted Deleted New 00004895 Automatic transmission fluid DEXRON or DEXRON II Sealant 3M ATD Part No 8661 or equivalent 13W701 13W0035 13V0032 13V0030 13W698 13W706 Automatic transmission fluid DEXRON or DEXRON II Automatic transmission fluid DEXRON or DEXRON II Automatic transmission fluid DEXRON or...

Page 1232: ...S BEARING RACE AND MAINSHAFT INSTALLATION 1 Apply specified fluid to the mainshaft Specified fluid Automatic transmission fluid DEXRON or DEXRON II 2 Wrap vinyl tape around the serrated part so that the oil seal won t be damaged when the mainshaft is installed to the valve housing 3 Mount the mainshaft to the valve housing 4 Align the cage s hole and the channel in the mainshaft and insert two or ...

Page 1233: ...rotates smoothly H RACK PISTON AND BALLS INSTALLATION 1 Install the rack piston until it comes in contact with the edge of the mainshaft 2 Rotate the mainshaft to align the ball race way with the 19 ball insertion hole NOTE The balls must be inserted so that there is no clearance between the balls 3 Set the remaining seven balls in the circulator and install the circulator to the rack piston 4 App...

Page 1234: ... 3 Power steering 0 45 1 25 4 5 12 5 4 11 Ball joint starting torque Nm kgcm in lbs Tie rod end 1 3 10 30 8 9 26 Idler arm 0 5 2 0 5 520 4 17 Idler arm turning torque Nm kgcm in lbs 0 3 2 0 3 20 3 17 Spring balance reading N kg lbs 2 3 15 4 0 23 1 54 0 5 33 9 Limit Steering wheel free play mm in Manual steering 50 1 97 Power steering 50 1 97 Steering gear backlash mm in 0 5 0 020 Ball joint axia p...

Page 1235: ...and pump cover Automatic transmission fluid DEXRON or DEXRON II As required SEALANTS AND ADHESIVES Items Specified sealant and adhesive Remarks Steering column cover assembly installation hole Dash panel cover installed surface Manual steering gear box top cover packing Manual steering gear box cross shaft adjusting and lock nut 3M ATD Part No 861 or equivalent Semi drying sealant Manual steering ...

Page 1236: ... Special spanner MB991394 Pin set Removal and installation of the lock nut MB990326 Preload socket Measurement of the ball joint starting torque MB990778 Ball joint remover Disconnection of idler arm from relay rod SERVICE ADJUSTMENT PROCEDURES STEERING WHEEL FREE PLAY CHECK MANUAL STEERING Standard value Limit 26 6 mm 1 05 in or less 50 mm 1 97 in If the measured value exceeds the repair limit ch...

Page 1237: ...ng race 06 Cross shaft 22 Cage 07 Adjusting bolt 23 Ball 08 Adjusting plate 24 Seal ring 09 O ring 25 Bearing race 10 Y packing 26 O ring 11 Side cover 27 Bearing 12 Main shaft and valve assembly 28 Oil seal 13 Rack piston 29 Valve housing 14 Seal ring 30 Oil seal 15 O ring 31 Y packing 16 Circulation holder 32 Gear box housing STEERING Specifications 37 25 E37NF 13W703 Deleted New Old Deleted ...

Page 1238: ...s there is fluid leakage from the threads of the adjusting bolt If there is leakage replace the Y pacing with a new one 13 REMOVAL OF RACK PISTON Remove the rack piston form the mainshaft by turning it counterclockwise Caution Be careful not to lose the 26 balls inside the rack piston 19 REMOVAL OF LOCK NUT 20 REMOVAL OF MAIN SHAFT 21 BEARING RACE 22 CAGE 23 BALL When removing the main shaft remov...

Page 1239: ...H BETWEEN BALL GROOVE OF RACK PISTON AND BALLS Set the rack piston to the position shown in the figure and then measure the backlash by using a dial gauge Limit 0 05 mm 0 0020 in PITMAN ARM BALL JOINT STARTING TORQUE Standard value 1 3 Nm 10 30 kgcm 9 26 in lbs STEERING Power Steering Gear Box 37 27 13W087 C13156 13W0049 Deleted Socket E37NHAD ...

Page 1240: ...e cover 12 Mainshaft 29 Side cover and cross shaft assembly 13 Lock nut Adjustment of main shaft total staring Adjustment of main shaft axial play torque 14 O ring 30 Dust cover 15 Seal ring 31 Pitman arm 16 Rack piston 32 Jam nut 17 Ball 37 28 STEERING Power Steering Gear Box E37NI A13V0108 Deleted New Old Old New Cross shaft plate set Cross shaft seal kit Gear box seal kit 13B0093 13W699 13W703 ...

Page 1241: ... to the outside of the oil seal Using the special tools press the oil seal into the valve housing Specified fluid Automatic transmission fluid DEXRON or DEXRON II STEERING Power Steering Gear Box 37 29 Old Deleted New 13W701 13E0003 13w0061 13W698 13W706 Automatic transmission fluid DEXRON or DEXRON II Automatic transmission fluid DEXRON or DEXRON II Automatic transmission fluid DEXRON or DEXRON I...

Page 1242: ...ransmission fluid DEXRON or DEXRON II 2 Wrap vinyl tape around the serrated part so that the oil seal won t be damaged when the valve body is installed tot he valve housing 3 Mount the valve body to the valve housing 4 Align the cage s hole and the channel in the main shaft and insert two or three balls 5 Insert the remainder of the balls into the cage s hole while pressing the ball with the beari...

Page 1243: ...the lock nut so as to secure the lock nut 3 Check to be sure that the mainshaft rotates smoothly 16 INSTALLATION OF RACK PISTON 1 Install the rack piston until it comes in contact with the edge of the main shaft 2 Rotate the main shaft to align the ball raceway with the 19 ball insertion hole NOTE The balls must be inserted so that there is no clearance between the balls 3 Set the remaining seven ...

Page 1244: ...he standard value replace with a suitable adjusting plate 26 INSTALLATION OF CROSS SHAFT 27 ADJUSTING BOLT LOCK NUT Install the cross shaft to the side cover and then temporarily tighten the adjusting bolt lock nut 29 INSTALLATION OF SIDE COVER AND CROSS SHAFT ASSEMBLY Install the side cover assembly with the corss shaft to the gear box NOTE Apply specified automatic transmission fluid to the teet...

Page 1245: ...k 2 Applicable Manuals Manual Pub No Language Page s PAJERO Workshop Manual Chassis PWJE9086 English MONTERO Workshop Manual Chassis PWJS9087 Spanish PWJF9088 French PWJG9089 German PWJD9090 Dutch PAJERO Workshop Manual Chassis PWJW9091 Swedish 37 8 99 PAJERO SPORT Workshop Manual Chassis PWJE9812 English 99 MONTERO SPORT Workshop Manual Chassis PWJS9813 Spanish PWJF9814 French 99 PAJERO SPORT Wor...

Page 1246: ...ng wheel in the straight ahead position 2 Set the engine speed to 1 000 r min Caution After checking the engine r min there must be a return to the standard idling r min 3 Measure the tangential force with a spring balance by turning the steering wheel clockwise and counter clock wise one and a half turns Standard value 37N 3 7kg 8 21 Ibs or less 4 If the stationary steering effort exceeds the sta...

Page 1247: ...with engine stopped 10 mm or less If the play exceeds the standard value check the steering gear backlash and ball joint axial play STEERING ANGLE CHECK 37100100029 1 Place the front wheel on a turning radius gauge and measure the steering angle Standard value Items Specifications Inside wheel 29 40 32 40 Outside wheel 29 30 2 If the steering angle is outside the standard value after checking the ...

Page 1248: ...urning radius gauge and measure the steering angle Standard value 2WD vehicles 4WD vehicles 0 Inner wheel 37 3 30 0 Outer wheel 30 20 27 3 2 Adjust the steering angle of each wheel by turning the stop bolt of the knuckle arm NOTE On 4WD vehicles after adjusting the steering angle mount the cap onto the jam bolt so that the edge of the slit side of the cap and the head of the stop volt are flush an...

Page 1249: ...turning steering wheel fully decrease wheel steering angle to touch on stop bolt in advance 4WD Caution When the steering wheel is turned to lock check that the clearance between the knuckle and the stopper is 1 mm or more Added 4WD 12S611 X0520AA Lower arm 1 mm or less Knuckle Flush level Cap slit 13S756 2WD ...

Page 1250: ...ering wheel circumference before wheels start to move when slightly moving steering wheel in both directions Limit 50 mm 3 When play exceeds the limit check for play on steering shaft connection and steering linkage Correct or replace 4 If the free play still exceeds the limit value set steering wheel straight ahead with engine stopped Load 5 N towards steering wheel circumference and check play S...

Page 1251: ...hen turning steering wheel fully decrease wheel steering angle to touch on stop bolt in advance 4WD Caution When the steering wheel is turned to lock check that the clearance between the knuckle and the stopper is 1 mm or more Added A13V0088 Stopper bolt 45 Nm 2WD 4WD X0520AA Lower arm 1 mm or less Knuckle ...

Page 1252: ...BODY ...

Page 1253: ......

Page 1254: ...F FILM 34 DOOR GLASS AND REGULATOR 36 DOOR HANDLE AND LATCH 40 WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP 43 REAR GATE 44 SERVICE SPECIFICATION 44 ON VEHICLE SERVICE 44 Rear Gate Outside Handle Play Check and Adjustment 44 REAR GATE 45 ...

Page 1255: ... 11 A B C D E 47 Nm 24 Nm 47 Nm 47 Nm 47 Nm 47 Nm 24 Nm 24 Nm 24 Nm 1 3 4 5 6 7 10 1 3 4 5 6 7 10 1 3 10 11 9 11 10 11 A B C D E A B C D E A B C D A B C D A B A B 8 1 Special bolt 2 Mounting bolt 3 Plain washer 4 Body mounting rubber A 5 Spacer 6 Body mounting rubber B 7 Washer 8 Body mounting rubber 9 Plate 10 Self locking nut 11 Nut ...

Page 1256: ...ch release cylinder D Speedometer cable D Parking brake cable D Shift lever knob D Idle up vacuum hose D Engine harness D Transmission harness D A C harness D Frame harness D Ground strap D Engine earth D Door opening trim D Floor carpet D Cab body mounting bolt 2 After removing the body mounting bolts and the body shims insert wooden blocks to the body and gently lift with a crane Caution Before ...

Page 1257: ...ub cab Double cab 1 2 3 5 6 A B C F D E G 27 31 Nm H 27 31 Nm 27 31 Nm 27 31 Nm A C D E D F B A 1 2 4 5 1 2 4 5 6 1 2 3 5 D E E F H F H G H A C D E F H D A E F H F B D E G H 1 Mounting bolt 2 Body shim A 3 Plain washer 4 Body shim B assembly 5 Self locking nut 6 Body shim C ...

Page 1258: ... parts D Filler neck Single cab Club cab D Rear body wiring harness connector D Rear body mounting bolts 2 Hook wires onto the rope hocks on the rear body and then use a crane to raise the rear body Caution Make sure that the rear body doesn t hit the cab while it is being raised ...

Page 1259: ...p Vehicles without air conditioner 8 Hood seal Vehicles with air conditioner 9 Hood weatherstrip Petrol powered vehicles 10 Hood silencer Diesel powered vehicles 11 Hood support rod Hood latch and hood lock release cable removal steps D Radiator grille 14 Hood latch 15 Cable protector D Junction block 16 Hood lock release cable Hood and hood hinge removal steps D Washer hose connection 12 Hood D F...

Page 1260: ...oval and Post installation Operation D Front Bumper Removal and Installation Refer to GROUP 51 D Front Deck Garnish Removal and Installation Refer to GROUP 51 Windshield Wiper and Washer Right side only Sealant 3M ATD Part No 8625 or equivalent 1 2 3 4 2 Removal steps 1 Mud guard 2 Splash shield AA 3 Side turn signal lamp 4 Fender REMOVAL SERVICE POINT AA SIDE TURN SIGNAL LAMP REMOVAL Use a flat t...

Page 1261: ...Driver s Seat Removal and Installation Refer to GROUP 52A D Scuff Plate driver s side Removal and Installation Refer to GROUP 52A Trims D Rear Splash Shield L H Removal and Installation 1 2 3 4 L H drive vehicles R H drive vehicles Fuel filler dour height and clearance adjustment 3 2 1 Removal steps 1 Fuel filler door panel assembly 2 Fuel filler door hook assembly 3 Lid lock release handle 4 Fuel...

Page 1262: ... Seat Removal and Installation Refer to GROUP 52A D Scuff Plate driver s side Removal and Installation Refer to GROUP 52A Trims D Rear Splash Shield L H Removal and Installation 1 2 3 4 Fuel filler door height and clearance adjustment 2 1 Removal steps 1 Fuel filler door panel assembly 2 Fuel filler door hook assembly 3 Lid lock release handle 4 Fuel filler door lock release cable ...

Page 1263: ...Plate driver s side Rear Scuff Plate driver s side Center Pillar Lower Trim driver s side Strap Assembly ELR Cover Back Panel Lower Upper Trim Rear Seat Belt ELR L H Rear Pillar Lower Trim Removal and Installation Refer to GROUP 52A Trims 1 2 3 4 5 Fuel filler door height and clearance adjustment 1 Removal steps 1 Fuel filler door panel assembly 2 Lid lock release handle 3 Fuel filler door lock re...

Page 1264: ...emarks Adhesive 3M ATD Part No 8609 Super Fast Urethane Auto Glass Sealant or equivalent Primer 3M ATD Part No 8608 Super Fast Urethane Primer or equivalent Spacers Available as service part Dam Available as service part Anti rust solvent or Tectyl 506T Valvoline Oil Company For rust prevention Isopropyl alcohol For grease removal from bonded surface Steel piano wire Dia length 0 6mm 1m For cuttin...

Page 1265: ...ss side Reusing the glass Replacing the glass Cleaning of adhesion surface Competely cut off all of the residual adhesive Clean the adhesion surface with isopropyl alcohol and let dry for 3 minutes or more Cleaning of adhesion surface Clean off any dirt adhering to the adhe sion surface with isopropyl alcohol and let dry for 3 minutes or more Gluing window spacer and dual lock fastener Glue the wi...

Page 1266: ...ROUP 52A D Headlining 15 15 5 10 5 21 11 5 21 16 16 10 5 Primer Section A A mm Section B B Section C C Primer Primer Adhesive 3M ATD Part No 8609 Super Fast Urethane Auto Glass Sealant or equivalent 1 2 3 4 5 6 A B C C A B Adhesive tape Both side tape 6 mm wide and 0 125 mm thick 100 mm 100 mm 2 6 5 5 Removal steps AA AA 1 Windshield 2 Windshield moulding 3 Windshield protector 4 Window spacer 5 W...

Page 1267: ...7 Use the special tool to remove the windshield glass 8 Use a knife to cut away the remaining adhesive so that the thickness is within 2 mm around the entire circumference of the body flange 9 Finish the flange surfaces so that they are smooth Caution 1 Be careful not to remove more adhesive than is necessary 2 Be careful also not to damage the paintwork on the body surface with the knife If the p...

Page 1268: ...at are corresponding to those on the windshield 7 Fill a sealant gun with adhesive Then apply the adhesive evenly around the windshield within 30 minutes after applying the primer NOTE Cut the tip of the sealant gun nozzle into a V shape to simplify adhesive application 8 Align the mating marks on the glass and the body and lightly press the windshield glass evenly so that it adheres completely 9 ...

Page 1269: ...DOW GLASS REAR WINDOW GLASS WEATHERSTRIP REMOVAL Push the rear window glass out from the inside of the cabin with the lip of the weatherstrip straightened along the entire periphery with a screwdriver INSTALLATION SERVICE POINT AA REAR WINDOW GLASS WEATHERSTRIP REAR WINDOW GLASS INSTALLATION 1 Set round strings in the weatherstrip groove NOTE Make certain that the strings overlap other at both end...

Page 1270: ...strip correctly on the body flange NOTE Pull the strings working from both sides of the rear window glass toward the centre and tapping the glass Caution Tap the rear window glass repeatedly until it is lightly held against the body flange surface QUARTER WINDOW GLASS CLUB CAB 42200250103 REMOVAL AND INSTALLATION Pre removal and Post installation Operation D Quarter Upper Trim Removal and Installa...

Page 1271: ...rs 418 420 Distance C between glass holder and front edge of glass Vehicles without power window 161 165 edge of glass Vehicles with power window 223 227 SEALANT 42300050034 Items Specified sealant Remark Waterproof film 3M ATD Part No 8625 or equivalent Ribbon sealer SPECIAL TOOLS 42300060075 Tool Number Name Use MB991502 MUT II sub assembly ETACS ECU input signal checking MB990784 Ornament remov...

Page 1272: ...power window main switch However they can be operated by the power window sub switches 3 42 23 Passenger s side and rear power windows cannot be operated by the power window sub switches However they can be operated by the power window main switch 4 42 23 Passenger s side and rear power windows cannot be operated by both the power window sub switches and by the power window main switch 5 42 24 Whe...

Page 1273: ...the following connectors C 01 C 78 C 88 C 89 NG Repair OK Check trouble symptoms OK Measureatthepowerwindowrelaycon nector C 78 D Disconnect the connector and measure at the harness side D Continuitybetween2andbodyearth OK Continuity NG Check the following connector C 78 NG Repair OK Check trouble symptoms OK Check the following connectors C 17 C 39 C 78 D 04 D 16 D 22 E 03 E 04 E 13 E 15 OK Check...

Page 1274: ...ness or connector Power window motor driver s side check Refer to P 42 38 NG Replace OK Measure at the power window main switch connector E 03 D Voltage between 1 and body earth When main switch is at UP D Voltage between 5 and body earth When main switch is at DOWN OK System voltage NG Check the following connectors E 03 E 11 NG Repair OK Check trouble symptoms OK Check the following connectors C...

Page 1275: ...window main switch connector E 03 and power win dow sub switch connector E 04 L H or E 15 R H D Disconnect the connector and measure at the harness side D Continuity between 2 main switch side and 8 sub switch side OK Continuity D Continuity between 2 main switch side and the earth OK No continuity NG Check the following connectors L H C 39 D 16 D 22 E 03 E 04 R H C 39 D 04 D 22 E 03 E 15 NG Repai...

Page 1276: ...13 D Disconnect the connector and measure at the harness side D Voltage between 1 and body earth OK System voltage NG Check the following connectors C 17 E 13 NG Repair OK Check trouble symptoms OK Measure at the power window sub switch connector E 13 D Voltage between 3 and body earth When main switch is at DOWN D Voltage between 6 and body earth When main switch is at UP OK System voltage NG Che...

Page 1277: ...e between 3 and body earth When main switch is at DOWN D Voltage between 6 and body earth When main switch is at UP OK System voltage NG Check the following connectors L H D 16 D 22 E 04 R H D 04 D 22 E 15 NG Repair OK Check trouble symptoms NG Check the harness wire between power window sub switch and the earth NG Repair OK Replace the power window sub switch OK Check the following connectors L H...

Page 1278: ...will not be lowered even if something becomes jammed in it D If the limit switch is always off D If there is an open circuit in the harness between the limit switch and the power window main switch or the power window sub switch D If the limit switch turns off before the set value is reached D If the window is within 12 mm of being fully closed normal setting to prevent the window from being lower...

Page 1279: ...e harness between the limit switch and the power window main switch or between the limit switch and the power window sub switch OK Driver s side Replace the power window main switch Passenger s side Replace the power window sub switch NG Repair Inspection Procedure 9 None of the door lock functions operate Probable cause The cause may be a malfunction of the ETACS ECU power supply circuit system o...

Page 1280: ... OK Check the following connectors C 38 C 90 E 09 NG Repair OK Check trouble symptoms OK Replace the ETACS ECU NG Check the harness wire between the front door lock actuator driver s side and ETACS ECU between front door lock actuator and the earth and repair if necessary Inspection Procedure 11 Some doors do not lock or unlock Probable cause The cause may be a malfunction of the door lock actuato...

Page 1281: ... 35 2 Raise the window glass loosen the channel guide mounting bolts and adjust the vertical tilt of the glass ADJUSTMENT AND REPLACEMENT WHEN THERE IS A MALFUNCTION OF THE POWER WINDOWS 42900190048 If the window glass automatically starts moving downwards at the wrong time while it is being raised carry out the following adjustment or replacement procedures 1 Remove the door trim and waterproof f...

Page 1282: ...Check that the door outside handle play is within the standard value range Standard value B 2 8 mm or more 2 If the door outside handle play is not within the standard value range check the door outside handle or the door latch assembly Replace if necessary POWER WINDOW OPERATION CURRENT CHECK 42900110020 1 Remove the power window fuse and connect a circuit analyser as shown in the illustration 2 ...

Page 1283: ... DOWN position The condition of the circuit breaker is good if the power window glass starts to move downwards within 60 seconds DOOR INSIDE HANDLE PLAY CHECK AND ADJUSTMENT 42300150130 1 Check that the door inside handle play is within the standard value range Standard value A 7 3 mm or more 2 If the door inside handle play is outside the standard value range remove the door trim Refer to P 42 33...

Page 1284: ...2 29 Front door 12 Nm Rear door 4 5 6 6 7 8 3 3 9 7 1 1 4 4 2 2 5 5 9 26 Nm 26 Nm 26 Nm 26 Nm 12 Nm 8 Door assembly removal steps 1 Harness connector 2 Spring pin 3 Door assembly AA 4 Door upper hinge AA 5 Door lower hinge Striker removal steps 6 Striker 7 Striker shim Door switch removal steps 8 Door switch cap 9 Door switch ...

Page 1285: ...wer hinge E1 Front right side door Upper hinge E1 Lower hinge F1 Rear left side door Upper hinge A1 Lower hinge B1 Rear right side door Upper hinge B1 Lower hinge L1 INSPECTION 42300600031 DOOR SWITCH CONTINUITY CHECK Driver s door switch Switch iti Terminal No position 1 2 3 Open ON Depressed OFF Passenger s door and rear door switch Switch iti Terminal No position 1 2 Open ON Depressed OFF Front...

Page 1286: ... equivalent 11 Removal steps AA AA 1 Clip Vehicles without power window AA 2 Regulator handle Vehicles without power window AA 3 Escutcheon Vehicles without power window 4 Pull handle box 5 Power window switch Vehicles with power window 6 Cover 7 Inner delta cover 8 Door trim 9 Door inside handle 10 Pull handle bracket 11 Waterproof film 12 Power window switch cover Vehicles with power window 13 D...

Page 1287: ...indow 6 Cover 7 Door trim 8 Door inside handle 9 Pull handle bracket 10 Speaker 11 Speaker cover 12 Waterproof film 13 Power window switch cover Vehicles with power window 14 Ashtray REMOVAL SERVICE POINT AA CLIP REMOVAL Remove the clip by using a rag and then remove the regulator handle INSTALLATION SERVICE POINT AA ESCUTCHEON REGULATOR HANDLE CLIP INSTALLATION 1 Install the escutcheon and the cl...

Page 1288: ...tment Refer to P 42 29 D Power Window Safety Mechanism Check Refer to P 42 30 Door trim Relay box 1 2 3 4 5 6 7 8 9 10 9 7 8 1 Power window switch Vehicles with power window Power window relay removal steps D Driver s side under cover Refer to GROUP 52A Instrument Panel 2 Power window relay Vehicles with power window Front window regulator assembly removal steps 3 Door window inner weatherstrip 4 ...

Page 1289: ...nism Check Refer to P 42 30 Door trim 1 2 3 4 5 6 7 8 9 10 11 12 5 9 Nm 12 1 Power window switch Vehicles with power window Power window regulator assembly removal steps 2 Door lock actuator assembly Vehicles with power window 3 Rear lower sash 4 Latch assembly 5 Door window inner weatherstrip 6 Door beltline moulding assembly 7 Door window glass runchannel AA 8 Rear upper sash 9 Door window glass...

Page 1290: ... cab Double cab A 107 108 mm B 418 420 mm Club cab A 217 218 mm B 418 420 mm Double cab C 161 165 mm Vehicles without power window C 223 227 mm Vehicles with power window INSPECTION 42900180069 POWER WINDOW RELAY CONTINUITY CHECK System lt Terminal No voltage 1 2 3 4 Not applied Applied POWER WINDOW MOTOR CHECK 42900150053 1 Connect a battery directly to the motor terminals and check that the moto...

Page 1291: ...just where the limit switch starts working safety mechanism stops working LIMIT SWITCH CONTINUITY CHECK 42900220020 Switch position Terminal No 1 2 ON OFF Safety mecha nism release angle becomes larger Front door Plate mounting screw Rear door Plate mounting screw Safety mechanism release angle be comes larger Becomes smaller Becomes smaller ON OFF ...

Page 1292: ...r to 42 34 3 Door outside handle 4 Door lock key cylinder 5 Rear lower sash 6 Door latch assembly Rear door handle and door latch assembly removal steps 1 Door inside handle D Waterproof film Refer to 42 35 2 Rear door lock actuator assembly Vehicles with central door locking system 3 Door outside handle 5 Rear lower sash 6 Door latch assembly Door check removal steps 1 Door inside handle D Waterp...

Page 1293: ... door ML INSPECTION 42300610089 FRONT DOOR LOCK ACTUATOR CHECK Vehicles with central door locking system Driver s side Rod position Terminal No Rod operation 1 2 3 4 LOCK LOCK position UNLOCK position UNLOCK UNLOCK position LOCK position LOCK UNLOCK Passenger s side Rod position Terminal No Rod operation 3 4 LOCK LOCK position UNLOCK position UNLOCK UNLOCK position LOCK position Identification mar...

Page 1294: ...068 Rod position Terminal No Rod operation 1 2 B B position C position C C position B position DOOR LOCK KEY CYLINDER SWITCH CONTINUITY CHECK Vehicles with central door locking system 42300630092 Passenger s side only Switch position Terminal No 1 2 3 LOCK Neutral OFF UNLOCK Rear door View A A B C ...

Page 1295: ...ms D Centre pillar lower trim Refer to GROUP 52A Trims D Cowl side trim Refer to GROUP 52A Trims 1 Door inner opening weatherstrip Door outer opening weatherstrip removal 2 Spring pin AA AA 3 Door outer opening weatherstrip Window glass runchannel removal 4 Window glass runchannel Door beltline inner weatherstrip removal steps D Door trim Refer to P 42 34 35 5 Door beltline inner weatherstrip Door...

Page 1296: ...to install correctly Applicable side Identification colour Left door Brown Right door Natural REAR GATE 42500030010 SERVICE SPECIFICATION Item Standard value Tailgate handle play mm 1 3 ON VEHICLE SERVICE 42500090018 REAR GATE OUTSIDE HANDLE PLAY CHECK AND ADJUSTMENT Check that play is within the standard value If not within the standard value adjust as follows 1 Remove the rear gate panel 2 Remov...

Page 1297: ... 11 12 13 14 15 3 2 4 5 3 6 Removal steps 1 Rear gate panel 2 Remote control assembly 3 Latch assembly 4 Cushion 5 Cushion Club cab Double cab 6 Outside handle 7 Rear gate 8 Rear gate hinge 9 Shim 10 Rear gate link assembly 11 Spacer 12 Link hook 13 Rear gate link damper A 14 Rear gate link damper B 15 Cushion rubber ...

Page 1298: ...NOTES ...

Page 1299: ...0 10 Group GENERAL Draft No 00SY0022915 INFORMATION CORRECTION INTERNATIONAL CAR ADMINISTRATIO OFFICE T NITTA PROJECT LEADER AFTER SALES SERVICE CS PROMOTION 1 Description This Service Bulletin informs you of the year model changes for the 2001 L200 2 Applicable Manuals Manual Pub No Language Page s 2000 L200 PWTE96E1 D English Workshop Manual Chassis PWTS96E1 D Spanish PWTF96E1 D French PWTG96E1 ...

Page 1300: ...2 ...

Page 1301: ... PWTE96E1 C SUPPLEMENT PWTE96E1 D SUPPLEMENT ELECTRICAL WIRING PHTE96E1 PHTE96E1 A PHTE96E1 B PHTE96E1 D PHTE96E1 D SUPLEMTENT BODY REPAIR MANUAL PARTS CATALOGUE PBTE96E1 T603B00 D All information illustrations and product d e scriptions contained in this manual are current as at the time of publication We however re serve the right to make changes at any time without prior notice or obligation Mi...

Page 1302: ... 5M T MPI ENDL6 ENDR6 CENDL6 K64T JENDL6 4D56 2 477mℓ R5M21 2WD M T Fuel injection CENDEL6 K75T GJENXEL6 4G64 SOHC 2 351 mℓ V5M21 4WD 5M T MPI ENDFL6 ENDFR6 V5MT1 4WD 5M T JERDFL6 V4AW2 AWD 4A T GJERXFL6 GJENXFL6 GJENXFR6 CENDFL6 GCENXFL6 JENDFL6 JENDFR6 K74T JENHFL6 4D56 Turbocharger with intercooler 2 477mℓ V5MT1 4WD 5M T Fuel injection 00 1 GENERAL vehicle identification ...

Page 1303: ...mission type R 4 speed automatic transmission 6 Vehicle line K Mitsubushi L200 6 Long wheelbase 7 Body type 7 4WD Long wheelbase 2 4G63 1 997mℓ petrol engine 4 4D56 2 477mℓ diesel engine 8 Engine type 5 4G64 2 351 mℓ petrol engine 9 Internal production control code A A B C etc 0 zero No meaning 10 Model year 1 2001 11 Plant A A C LARDKRABANG factory D F LAEMCHABANG factory 12 Serial number NOTE In...

Page 1304: ...6 NOTES ...

Page 1305: ...oil has been changed ON VEHICLE SERVICE specified engine oil ACEA and API classification 4G6 ACEA A1 A2 A3 API SG or higher 4D5 ACEA B1 B2 B3 B4 API CD or higher ENGINE LUBRICATION General On vehicle Service 12 1 4G6 Barometric temperature Y0042AA Barometric temperature M03B017 4D5 ...

Page 1306: ...8 NOTES ...

Page 1307: ...ransmitter LOCK UNLOCK NOTE If the MUT II cannot check all the input signals the diagnosis circuit may be defective ETACS FUNCTION ADJUSTMENT PROCEDURE The following functions can be adjusted by operating input switches The adjustments will be stored in th ECU memory even after a battery cable is disconnected Switching of keyless entry answerback function From activation to deactivation or vice ve...

Page 1308: ...nd off If the function toggles on the buzzer sounds once default con dition If the function toggles off the buzzer sounds twice Initialisation of all the ETACS func tions From deactivation to activa tion When the tailgate switch remains on for more than 20 seconds th buzzer sounds twice and he answer back function of the keyless entry system is initialised The buzzer will sound in 10 seconds indic...

Page 1309: ...ister the encrypted code Refer to P 42 6 OK Replace the transmitter battery Refer to P 42 6 NG Is a commercial equipment equipped No Yes Remove that equipment and then check trouble symptoms NG Check the connection between ETACS ECU and junction block claw NG Repair OK NG Check the following connectors A 56X C 81 C 91 OK NG Measure at the ETACS ECU connector C 91 Disconnect the connector and measu...

Page 1310: ...ctuator If either room lamp or turn signal lamp does not flash illuminate the cause may be a malfunction of the room lamp circuit or turn signal lamp Malfunction of ETACS ECU Malfunction of driver s door lock actuator Burnt turn signal lamp bulb Malfunction of connector or wiring harness Carry out the troubleshooting for room lamp circuit Does the room lamp go on go off simultaneous with opening c...

Page 1311: ...k No 5 and diagnosis connector OK Replace MUT II Measure at the diagnosis connector C 35 Continuity between 4 and body earth Continuity between 5 and body earth OK System voltage NG NG Repair Check the following connectors C 35 C 86 OK Check trouble symptoms NG Check the harness wire and repair if necessary Between the diagnosis connector and earth NG Check the following connectors A 56X C 81 C 82...

Page 1312: ...in the following cases If a second transmitter is to be used If it appears that a problem is occurring because of faulty registration of a code A maximum of two different codes can be stored in the memory area of the EEPROM two different transmit ters can be used When the code for the first transmitter is registered th previously registered codes for two transmitters are cleared Therefore if you a...

Page 1313: ...hould be carried out for the second trans mitter and it should be carried out within one min ute after registration of the code for the first trans mitter has been completed After the second regis tration is completed the doors will be automatically locked and unlocked once 7 Registration mode will be terminated under the following conditions When the secret codes for two transmitters hav been reg...

Page 1314: ...ACS ECU removal 2 ETACS ECU Keyless entry receiver ECU removal steps Glove box assembly Refer to GROUP 52A 1 Keyless entry receiver ECU NOTE Refer to 97 L200 Workshop Manual Pub No PWTE96E1 42 8 BODY Keyless Entry System AY0014AA A18VO187 Junction block ...

Page 1315: ...The service procedures are the same as previous one FRONT SEAT BELT REMOVAL AND INSTALLATION Inner seat belt removal steps Front seat refer to P 52A 5 Inner seat belt Outer seat belt removal steps Center pillar trim lower or quarter trim lower refer to P 52A 1 Sash guide cover 2 Outer seat belt 3 Center pillar trim upper or quarter trim upper refer to P 52A 4 Adjustable seat belt anchor NOTE Refer...

Page 1316: ...18 NOTES ...

Page 1317: ...ocedure has been added due to the addition of the high stop lamp 4WD HIGH MOUNTED STOP LAMP REMOVAL AND INSTALLATION Removal steps 1 Rear gate panel 2 High mounted stop lamp 3 Lamp bracket 4 Bulb socket assembly 5 Bulb CHASSIS ELECTRICAL High Mounted Stop Lamp 54 1 A16V0088 ...

Page 1318: ...EXTERIOR ...

Page 1319: ......

Page 1320: ...050108 Item Specified adhesive Door mirror inner delta cover Adhesive tape double sided tape 5 mm width and 0 5 mm thickness SPECIAL TOOLS 51100060095 Tool Number Name Use MB990784 Ornament remover Front deck garnish front and rear flare remote controlled mirror switch and door mirror inner delta cover removal MB990449 Window moulding remover Roof drip moulding removal MB990528 Stripe tape spatula...

Page 1321: ...REMOVAL AND INSTALLATION 1 2 3 4 5 Removal steps D Radiator grille 1 Front combination lamp assembly 2 Headlamp washer hose connection Vehicles with headlamp washer Refer to P 51 12 3 Front bumper assembly 4 Front bumper support 5 Front bumper side stay ...

Page 1322: ...s with headlamp washer Refer to P 51 12 2 Front bumper beam assembly 3 Front bumper lower reinforcement 4 Front bumper side reinforcement 5 Bumper side corner reinforcement 6 Bumper center corner reinforce ment 7 Licence plate bracket 8 Front bumper center face 9 Front bumper face side extension Vehicles with over fender 10 Front bumper side face ...

Page 1323: ... removal steps 2 Roof drip cover AB 3 Roof drip moulding Front deck garnish removal steps 4 Wiper arm and blade assembly Refer to P 51 9 5 Front deck garnish REMOVAL SERVICE POINTS AA RADIATOR GRILLE REMOVAL Remove the radiator grille by pushing the tab of the radiator grille clips in the direction of the arrows with a flat tipped screwdriver while lightly pulling the radiator grille towards you ...

Page 1324: ...lding OVER FENDER 51101380039 REMOVAL AND INSTALLATION Pre removal and Post installation Operation D Mud Guard Removal and Installation 1 2 3 1 4 4 Removal steps AA AA 1 Rivet 2 Front flare 3 Rear flare 4 Protector REMOVAL SERVICE POINT AA RIVET REMOVAL Use a drill 4 0 5 5 mm to break the rivet by drilling a hole and remove the rivet MB990449 Flare Rivet Drill ...

Page 1325: ...Insert A of the rivet into the riveter 3 Pressing the flange surface of the rivet move the handle of the riveter 4 The thinnest point of A is cut and the rivet is hold in the position SIDE STEP 51101150012 REMOVAL AND INSTALLATION 12 Nm 12 Nm 12 Nm Side step assembly Flange surface Body panel Riveter Flare A Rivet Riveter Rivet 1 2 3 4 ...

Page 1326: ...EXTERIOR Side Step 51 8 DISASSEMBLY AND REASSEMBLY 51101430017 25 Nm 5 Nm 5 Nm 5 Nm 5 Nm 1 2 3 4 1 Disassembly steps 1 Step cover 2 Non slip cover 3 Step plate 4 Side step pipe assembly ...

Page 1327: ...ish AA 3 Wiper motor 4 Wiper link assembly Washer nozzle removal 5 Washer nozzle Washer tank removal steps D Washer fluid draining and supplying 6 Headlamp washer hose connection Vehicles with headlamp washer 7 Washer hose 8 Washer tank assembly 9 Washer motor 10 Headlamp washer motor Vehicles with headlamp washer NOTE For removal and installation of the column switch assembly windshield wiper and...

Page 1328: ...ARM AND BLADE ASSEMBLY INSTALLATION Install the wiper blade in the specified position standard value Standard value Driver s side A 23 33 mm Passenger s side B 25 35 mm INSPECTION 51100770103 COLUMN SWITCH CHECK Wiper and Washer Switch L H drive vehicles Switch position Terminal No 6 7 8 9 10 Wiper switch OFF INT 1 LO 2 HI Washer switch ON R H drive vehicles Switch position Terminal No 8 9 10 11 1...

Page 1329: ... and High Speed Operation Connect a battery to the wiper motor as shown in the illustration and inspect motor operation at low speed and high speed Wiper Motor at Stop Position Operation 1 Run the wiper motor at low speed disconnect the battery and stop the motor 2 Reconnect the battery as shown in the illustration and confirm that after the motor starts turning at low speed it stops at the automa...

Page 1330: ...k valve 4 Washer nozzle NOTE 1 For removal and installation of the column switch assembly built in headlamp washer switch refer to GROUP 37A Steering Wheel and Shaft 2 For removal and installation of the washer tank refer to P 51 9 INSPECTION 51100980070 COLUMN SWITCH HEADLAMP WASHER SWITCH CHECK Check the continuity between terminal 2 of connector A and terminal 1 of connector B with headlamp was...

Page 1331: ... to battery CHECK VALVE CHECK 51101330041 Apply pressure to the inlet of the check valve to check its opening pressure Opening pressure 78 kPa HEADLAMP WASHER MOTOR CHECK 51101340044 1 With the headlamp washer motor installed to the washer tank fill the washer tank with water 2 Check that the water squirts out strongly when battery voltage is applied to terminals 1 and 2 Test lamp Battery Headlamp...

Page 1332: ...marks and decals 2 Peel the backing paper off from the reverse of the marks and decals and attach the marks and decals to the vehicle body 3 Remove the application tape from the decal Caution 1 When installing the marks and decals the surrounding temperature should be 20 38_C and the air should be completely free from dust 2 If the surrounding temperature is lower than 20_C the marks decals and th...

Page 1333: ... be completely free from dust 2 If the surrounding temperature is lower than 20_C the stripe tape and the body surface should be heated to 20 30_C Press line Align tape notch to door opening line Align tape end to press line Single cab Stripe tape Club cab Stripe tape Double cab Stripe tape Point A Press line Align tape notch to press line Point B Door opening line Door end line Align tape notch t...

Page 1334: ...int F Align tape notch to press line Section e e c d e c d e 2 Use the special tool to press on the tape beginning at the centre and moving evenly to both the top and bottom in order to remove any trapped air bubbles Caution 1 If the special tool slides to the side there will be slack at the end of the tape causing wrinkles and the tape may deviate from the correct application position 2 If the ta...

Page 1335: ... 1 Remote controlled mirror switch Door mirror removal steps 2 Inner delta cover 3 Harness connector Vehicles with remote controlled mirror 4 Door mirror assembly AA 5 Mirror Vehicles with remote con trolled mirror REMOVAL SERVICE POINT AA MIRROR REMOVAL Disconnect the parts indicated by the arrows and remove the mirror from the actuator sub assembly ...

Page 1336: ...irror moves as described in the table when each terminal is connected to the battery Battery connection terminal Direction operation 1 2 3 UP DOWN RIGHT LEFT REMOTE CONTROLLED MIRROR SWITCH CONTINUITY CHECK 51101350047 Switch position Terminal No 2 3 4 6 7 8 9 Left side UP DOWN LEFT RIGHT Right side UP DOWN LEFT RIGHT ...

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Page 1338: ......

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Page 1343: ......

Page 1344: ......

Page 1345: ......

Page 1346: ...arate front bumper has been united D The radiator grille design has been changed D The routing of the headlamp washer hoses has been changed FRONT BUMPER REMOVAL AND INSTALLATION 1 3 4 4 5 1 2 6 Removal steps D Radiator grille Refer to P 51 3 D Headlamp 1 Front combination lamp assembly 2 Nut 3 Front bumper assembly 4 Front bumper side stay 5 Front bumper beam assembly 6 Front bumper support assem...

Page 1347: ...ction A A 5 6 1 2 3 4 5 6 4 A A NOTE Clips position 4 Disassembly steps 1 Clip 2 Front bumper reinforcement upper 3 Front bumper reinforcement lower 4 Front bumper reinforcement side 5 Front bumper face side extension Vehicle with over fender 6 Front bumper face ...

Page 1348: ...AA 1 Radiator grille REMOVAL SERVICE POINT AA REMOVAL OF RADIATOR GRILLE 1 Remove the screws on the top side of the radiator grille 2 Remove the radiator grille by pushing its tab clips in the direction of the arrows with a flat tipped screwdriver while lightly pulling the radiator grille toward you ...

Page 1349: ...ADLAMP WASHER REMOVAL AND INSTALLATION 1 2 3 Washer nozzle and check valve removal steps D Washer fluid draining D Front bumper Refer to P 51 1 1 Washer hose 2 Check valve 3 Washer nozzle NOTE For inspection refer to the Basic Manual ...

Page 1350: ...ection Procedure 1 Communication with MUT II is impossible Probable cause The cause is probably that a malfunction of the diagnosis line or the immobilizer ECU is not functioning D Malfunction of diagnosis line D Malfunction of harness or connector D Malfunction of immobilizer ECU Register the password secret code and the encrypted code Check trouble symptoms Check the harness between the immobili...

Page 1351: ...ht be a problem with the fuel injection system in addition to a malfunction of the immobilizer system It is normal for this to occur if an attempt is made to start the engine using a key that has not been properly registered D Malfunction of diesel fuel injection system D Malfunction of immobilizer ECU Check the system voltage during crank ing OK 8 V or more NG Check the battery OK Is a diagnosis ...

Page 1352: ...uble symptom NG Check the harness between the immobi lizer ECU and engine control relay and repair if necessary 2 NG Check the following connector C 36 NG Repair OK Check trouble symptom NG Check the harness between the immobi lizer ECU and body earth and repair if necessary CHECK AT IMMOBILIZER ECU Terminal Voltage Check Chart Terminal No Signal Checking requirements Terminal voltage 3 Immobilize...

Page 1353: ...NOTES ...

Page 1354: ...INTERIOR ...

Page 1355: ...ring the SRS inoperative 2 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 3 MITSUBISHI dealer personnel must thoroughly review this manual and especially its GROUP 52B Supplemental Restraint System SRS before beginning any service or maintenance of any component of the SRS or any SRS related component NOTE The SRS incl...

Page 1356: ...ion heater resistance between terminals Ω Between terminals 2 and 3 Approx 8 Between terminals 1 and 3 0 ADHESIVE 52100050068 Items Specified adhesive Back panel trim lower B to back panel trim lower extension Club cab Adhesive tape double sided tape 8 mm width and 0 16 mm thickness SPECIAL TOOL 52100060146 Tool Number Name Use MB990784 Ornament remover Removal of switch trim etc ...

Page 1357: ...used They are indicated by symbols in the illustration Name Symbol Size mm D x L Colour Shape Tapping screw A 5 x 12 B 5 x 16 C 5 x 12 Black D 5 x 16 E 5 x 20 F 5 x 12 G 5 x 16 H 5 x 16 Black Washer assembled screw I 5 x 12 J 5 x 16 K 5 x 20 Black Washer assembled bolt L 6 x 8 M 6 x 16 N 8 x 16 O 6 x 16 Machine screw P 4 x 8 D Thread diameter L Effective thread length ...

Page 1358: ...osition 4 5 6 10 12 13 14 17 18 18 A B B J B D D 3 1 2 C P B D K 8 J A B K E 11 A 9 16 15 I 19 17 M O K L O 7 Removal steps 1 Hood lock release handle 2 Throttle cable knob Diesel pow ered vehicles 3 Driver side under cover 4 Meter bezel assembly 5 Under cover 6 Glove box assembly 7 Ashtray assembly 8 Center under cover 9 Foot duct 10 Cup holder assembly 11 Radio and tape player 12 Heater control ...

Page 1359: ...remove the adapter DISASSEMBLY AND REASSEMBLY 52100190142 1 2 3 4 5 6 7 8 9 I B N J I B N N N 11 10 J 3 6 J Disassembly steps 1 Defroster nozzle 2 Distribution duct 3 Air outlet assembly 4 Combination meter reinforcement 5 Instrument panel reinforcement 6 Multi meter bracket 7 Instrument pad 8 Instrument panel 9 Center reinforcement 10 Center reinforcement A 11 Center reinforcement B Adapter Lock ...

Page 1360: ...topper 6 Transmission shift lever knob M T 7 Transfer shift lever knob 4WD 8 Front floor console assembly 9 Console panel A 2WD M T 10 Console panel B 2WD A T 11 Console panel C 4WD M T 12 Console panel D 4WD A T 13 Shift lever boots reinforcement M T 14 Transfer lever boots reinforcement 4WD A T 15 Shift lever boots M T 16 Transfer lever boots 4WD A T 17 Console panel 18 Box Vehicles without SRS ...

Page 1361: ...L AND INSTALLATION NOTE Metal clip position Section A A Section B B Section C C Single cab 1 2 3 5 6 A A B B C C 5 1 1 4 1 Front pillar trim 2 Scuff plate 3 Cowl side trim 4 Door opening weatherstrip inner 5 Retractor cover 6 Back panel trim lower ...

Page 1362: ...Adhesive tape double sided tape 8 mm width and 0 16 mm thickness A A B B 6 C C D D 3 5 1 Scuff plate 2 Cowl side trim 3 Front pillar trim 4 Front door opening weatherstrip inner D Rear seat assembly Refer to P 52A 17 5 Back panel trim lower 6 Back panel trim lower extension 7 Back panel trim upper 8 Quarter trim lower 9 Quarter trim upper ...

Page 1363: ... A A B B B B C C 11 10 9 9 1 Front scuff plate 2 Cowl side trim 3 Front pillar trim 4 Front door opening weatherstrip inner 5 Rear scuff plate 6 Center pillar trim lower 7 Center pillar trim upper 8 Rear door opening weatherstrip inner 9 Retractor cover 10 Back panel trim lower 11 Back panel trim upper 12 Rear pillar trim upper 13 Rear pillar trim lower ...

Page 1364: ...clip position 3 3 9 1 2 3 4 5 6 7 8 9 10 C A A B B 9 C 1 Front scuff plate 2 Cowl side trim 3 Front pillar trim 4 Front door opening weatherstrip inner 5 Rear scuff plate 6 Center pillar trim lower 7 Rear door opening weatherstrip inner 8 Trim bracket 9 Retractor cover 10 Back panel trim lower ...

Page 1365: ...5 5 4 4 3 3 SEPARATE TYPE 44 Nm 44 Nm 2 BENCH TYPE 44 Nm 5 2 44 Nm 2 1 Heated seat switch vehicles with heated seat 2 Headrestraint Front seat assembly removal steps 3 Harness connector vehicles with heated seat 4 Seat anchor cover AA 5 Front seat assembly NOTE After provisionally tightening the seat assembly mounting nuts and bolts in every installation location fully tighten them to the specifie...

Page 1366: ...observed the seat adjusters at left and right will not be aligned properly with each other and a locking mechanism will be damaged INSPECTION 52200390026 HEATED SEAT SWITCH CONTINUITY CHECK Switch position Terminal No 1 2 IND 5 6 3 ILL 4 HI OFF LO NOTE To inspect the diode match the polarity of the circuit tester with the polarities in the table SEATBACK HEATER CHECK Measure the resistance between...

Page 1367: ...INTERIOR Front Seat 52A 14 SEAT CUSHION HEATER CHECK Measure the resistance between terminals Standard value Between terminals 2 and 3 Approx 8 Ω Between terminals 1 and 3 0 Ω ...

Page 1368: ...lining adjuster knob 2 Slide adjuster knob 3 Walk in knob Passenger side Club cab 4 Front seat side shield cover 5 Inner seat belt 6 Wire assembly 7 Seat cushion assembly 8 Seat cushion cover 9 Hog ring 10 Seat cushion heater 11 Seat heater wiring harness Vehicles with heated seat 12 Seat inner adjuster 13 Seat outer adjuster 14 Reclining adjuster 15 Seat back assembly 16 Damper Single cab 17 Hog ...

Page 1369: ...ring position Inside 5 1 7 14 12 11 9 13 10 1 12 13 Disassembly steps 1 Seat back assembly 2 Damper 3 Knob 4 Hinge cap 5 Headrestraint guide 6 Hog ring 7 Seat back cover 8 Pull wire 9 Seat adjuster 10 Knob 11 Cover 12 Seat cushion assembly 13 Hog ring 14 Seat cushion cover ...

Page 1370: ...12 1 1 5 5 6 4 3 7 6 10 6 11 11 2 6 6 6 7 3 8 22 Nm 9 2 22 Nm 9 22 Nm 6 22 Nm 9 2 2 8 8 12 12 1 Headrestraint Double cab Removal steps 2 Seat anchor cover Club cab 3 Seatback assembly 4 Damper Double cab 5 Headrestraint guide Double cab 6 Hog ring 7 Seatback cover 8 Shield cap Club cab 9 Rear seat hinge assembly Club cab 10 Seat cushion assembly 11 Hog ring 12 Seat cushion cover ...

Page 1371: ...Nm 44 Nm 2 3 4 1 5 2 44 Nm 3 44 Nm 4 1 Center seat belt Inner outer Outer seat belt removal steps D Retractor cover Single cab Refer to P 52A 8 D Quarter trim lower Club cab Refer to P 52A 9 D Center pillar trim lower Double cab Refer to P 52A 10 11 2 Sash guide cover 3 Outer seat belt 4 Waterproof cover Inner seat belt removal steps D Rear floor console Refer to P 52A 7 5 Inner seat belt ...

Page 1372: ...Club cab 44 Nm 44 Nm 44 Nm 44 Nm 44 Nm 3 4 5 2 2 2 1 Removal steps D Rear seat Double cab Refer to P 52A 17 1 Inner outer seat belt center seat belt 2 Inner seat belt D Quarter trim Club cab Refer to P 52A 9 D Retractor cover Double cab Refer to P 52A 10 3 Sash guide cover 4 Outer seat belt 5 Waterproof cover ...

Page 1373: ...NOTES ...

Page 1374: ......

Page 1375: ......

Page 1376: ......

Page 1377: ......

Page 1378: ...0 10 Group GENERAL Draft No 00SY0022915 INFORMATION CORRECTION INTERNATIONAL CAR ADMINISTRATIO OFFICE T NITTA PROJECT LEADER AFTER SALES SERVICE CS PROMOTION 1 Description This Service Bulletin informs you of the year model changes for the 2001 L200 2 Applicable Manuals Manual Pub No Language Page s 2000 L200 PWTE96E1 D English Workshop Manual Chassis PWTS96E1 D Spanish PWTF96E1 D French PWTG96E1 ...

Page 1379: ...2 ...

Page 1380: ... PWTE96E1 C SUPPLEMENT PWTE96E1 D SUPPLEMENT ELECTRICAL WIRING PHTE96E1 PHTE96E1 A PHTE96E1 B PHTE96E1 D PHTE96E1 D SUPLEMTENT BODY REPAIR MANUAL PARTS CATALOGUE PBTE96E1 T603B00 D All information illustrations and product d e scriptions contained in this manual are current as at the time of publication We however re serve the right to make changes at any time without prior notice or obligation Mi...

Page 1381: ... 5M T MPI ENDL6 ENDR6 CENDL6 K64T JENDL6 4D56 2 477mℓ R5M21 2WD M T Fuel injection CENDEL6 K75T GJENXEL6 4G64 SOHC 2 351 mℓ V5M21 4WD 5M T MPI ENDFL6 ENDFR6 V5MT1 4WD 5M T JERDFL6 V4AW2 AWD 4A T GJERXFL6 GJENXFL6 GJENXFR6 CENDFL6 GCENXFL6 JENDFL6 JENDFR6 K74T JENHFL6 4D56 Turbocharger with intercooler 2 477mℓ V5MT1 4WD 5M T Fuel injection 00 1 GENERAL vehicle identification ...

Page 1382: ...mission type R 4 speed automatic transmission 6 Vehicle line K Mitsubushi L200 6 Long wheelbase 7 Body type 7 4WD Long wheelbase 2 4G63 1 997mℓ petrol engine 4 4D56 2 477mℓ diesel engine 8 Engine type 5 4G64 2 351 mℓ petrol engine 9 Internal production control code A A B C etc 0 zero No meaning 10 Model year 1 2001 11 Plant A A C LARDKRABANG factory D F LAEMCHABANG factory 12 Serial number NOTE In...

Page 1383: ...6 NOTES ...

Page 1384: ...oil has been changed ON VEHICLE SERVICE specified engine oil ACEA and API classification 4G6 ACEA A1 A2 A3 API SG or higher 4D5 ACEA B1 B2 B3 B4 API CD or higher ENGINE LUBRICATION General On vehicle Service 12 1 4G6 Barometric temperature Y0042AA Barometric temperature M03B017 4D5 ...

Page 1385: ...8 NOTES ...

Page 1386: ...ransmitter LOCK UNLOCK NOTE If the MUT II cannot check all the input signals the diagnosis circuit may be defective ETACS FUNCTION ADJUSTMENT PROCEDURE The following functions can be adjusted by operating input switches The adjustments will be stored in th ECU memory even after a battery cable is disconnected Switching of keyless entry answerback function From activation to deactivation or vice ve...

Page 1387: ...nd off If the function toggles on the buzzer sounds once default con dition If the function toggles off the buzzer sounds twice Initialisation of all the ETACS func tions From deactivation to activa tion When the tailgate switch remains on for more than 20 seconds th buzzer sounds twice and he answer back function of the keyless entry system is initialised The buzzer will sound in 10 seconds indic...

Page 1388: ...ister the encrypted code Refer to P 42 6 OK Replace the transmitter battery Refer to P 42 6 NG Is a commercial equipment equipped No Yes Remove that equipment and then check trouble symptoms NG Check the connection between ETACS ECU and junction block claw NG Repair OK NG Check the following connectors A 56X C 81 C 91 OK NG Measure at the ETACS ECU connector C 91 Disconnect the connector and measu...

Page 1389: ...ctuator If either room lamp or turn signal lamp does not flash illuminate the cause may be a malfunction of the room lamp circuit or turn signal lamp Malfunction of ETACS ECU Malfunction of driver s door lock actuator Burnt turn signal lamp bulb Malfunction of connector or wiring harness Carry out the troubleshooting for room lamp circuit Does the room lamp go on go off simultaneous with opening c...

Page 1390: ...k No 5 and diagnosis connector OK Replace MUT II Measure at the diagnosis connector C 35 Continuity between 4 and body earth Continuity between 5 and body earth OK System voltage NG NG Repair Check the following connectors C 35 C 86 OK Check trouble symptoms NG Check the harness wire and repair if necessary Between the diagnosis connector and earth NG Check the following connectors A 56X C 81 C 82...

Page 1391: ...in the following cases If a second transmitter is to be used If it appears that a problem is occurring because of faulty registration of a code A maximum of two different codes can be stored in the memory area of the EEPROM two different transmit ters can be used When the code for the first transmitter is registered th previously registered codes for two transmitters are cleared Therefore if you a...

Page 1392: ...hould be carried out for the second trans mitter and it should be carried out within one min ute after registration of the code for the first trans mitter has been completed After the second regis tration is completed the doors will be automatically locked and unlocked once 7 Registration mode will be terminated under the following conditions When the secret codes for two transmitters hav been reg...

Page 1393: ...ACS ECU removal 2 ETACS ECU Keyless entry receiver ECU removal steps Glove box assembly Refer to GROUP 52A 1 Keyless entry receiver ECU NOTE Refer to 97 L200 Workshop Manual Pub No PWTE96E1 42 8 BODY Keyless Entry System AY0014AA A18VO187 Junction block ...

Page 1394: ...The service procedures are the same as previous one FRONT SEAT BELT REMOVAL AND INSTALLATION Inner seat belt removal steps Front seat refer to P 52A 5 Inner seat belt Outer seat belt removal steps Center pillar trim lower or quarter trim lower refer to P 52A 1 Sash guide cover 2 Outer seat belt 3 Center pillar trim upper or quarter trim upper refer to P 52A 4 Adjustable seat belt anchor NOTE Refer...

Page 1395: ...18 NOTES ...

Page 1396: ...ocedure has been added due to the addition of the high stop lamp 4WD HIGH MOUNTED STOP LAMP REMOVAL AND INSTALLATION Removal steps 1 Rear gate panel 2 High mounted stop lamp 3 Lamp bracket 4 Bulb socket assembly 5 Bulb CHASSIS ELECTRICAL High Mounted Stop Lamp 54 1 A16V0088 ...

Page 1397: ...SUPPLEMENTAL RESTRAINT SYSTEM SRS ...

Page 1398: ......

Page 1399: ...ing lamp on the instrument panel indicates the operational status of the SRS Each front impact sensor is located left and right fender shield panel The clock spring is installed in the steering column Only authorized service personnel should do work on or around the SRS components Those service personnel should read this manual carefully before starting any such work Extreme care must be used when...

Page 1400: ...e to deploy the air bag for a short time even after the battery has been disconnected so serious injury may result from unintended air bag deployment if work is done on the SRS system immediately after the battery cables are disconnected Wind a tape around the disconnected terminal for insulation 5 To unlock the SDU connector place a flat tipped screwdriver against the lock spring at the lock leve...

Page 1401: ...sensor L H P 52B 39 17 Body wiring harness Front wiring harness Front impact sensor L H 18 Body wiring harness Front wiring harness Front impact sensor R H 19 20 Body wiring harness Earth Correct or replace each wiring harness NOTE The sensor cable marked with is available as service part 7 SRS components should not be subjected to heat over 93_C so remove the SRS diagnosis unit air bag module clo...

Page 1402: ...ble period D Reading erase times MB991349 SRS Check harness Checking the SRS electrical circuitry MB990803 Steering wheel puller Steering wheel removal MB686560 SRS air bag adapt er harness A Deployment of air bag module inside the vehicle MB628919 SRS air bag adapt er harness B Deployment of air bag module outside the vehicle TEST EQUIPMENT 52400080035 Tool Name Use Digital multi meter Checking t...

Page 1403: ...inspection chart that is appropriate for the malfunction code Code No Diagnosis item Reference page 11 12 13 Front impact sensor system 52B 7 21 22 Air bag module squib system 52B 8 31 32 SDU capacitor system 52B 9 33 Cranking signal system 52B 10 34 Connector lock system 52B 11 41 IG1 A power circuit system 52B 11 42 IG1 B power circuit system 52B 12 43 SRS warning lamp drive circuit system Lamp ...

Page 1404: ...uib harnesses leading to the power supply 12 D Open circuit in either left or right front impact sensor open harness D Short in front impact sensor or air bag module squib harness leading to the power supply 13 D Open circuit in both left and right front impact sensors or open harness D Short in front impact sensor or air bag module squib harnesses leading to the power supply CHART 2 Item Front im...

Page 1405: ... or connectors D Malfunction of air bag module squib D Malfunction of SDU Chart 1 Code No Trouble Symptom 21 D Short in air bag module squib or harness short D Short in clock spring D Short in air bag module squib or front impact sensor harnesses leading to the power supply 22 D Open circuit in air bag module squib or open harness D Open circuit in clock spring D Malfunction of connector contact D...

Page 1406: ...s code memory Are code Nos 21 and 22 output No Check the harness wire between the SDU and clock spring and repair if necessary Yes Yes Check the front impact sensor system Refer to P 52B 25 OK Replace the SDU Code No 31 or 32 SDU capacitor system Probable cause These diagnosis codes are output if the voltage at the SDU capacitor terminals is higher No 31 or lower No 32 than the specified value for...

Page 1407: ...easure at SRS check harness con nector 5 D Disconnect SDU connector C 27 D Connect SRS check harness connector 3 D Continuity between terminals 19 20 OK Continuity NG Check the following connectors C 27 C 86 NG Repair OK Check trouble symptoms OK Check trouble symptoms OK Measure at SRS check harness connector 5 D Disconnect SDU connector D Connect SRS check harness connector 3 D Ignition switch O...

Page 1408: ... period of 5 seconds or more However if the vehicle condition returns to normal diagnosis code No 41 will be automatically erased and the SRS warning lamp will switch off D Malfunction of wiring harnesses or connectors D Malfunction of SDU Measure at SRS check harness con nectors 5 D Disconnect SDU connector C 27 D Connect SRS check harness connector 3 D Continuity between terminals 19 20 OK Conti...

Page 1409: ... con nector 5 D Disconnect SDU connector C 27 D Connect SRS check harness connector 3 D Continuity between terminals 19 20 OK Continuity NG Check the following connectors C 27 C 86 NG Repair OK Check trouble symptom NG Check the harness between the SDU and earth and repair if necessary OK Measure at SRS check harness connector 5 D Ignition switch ON D Voltage between the terminal 11 and body earth...

Page 1410: ...mbination meter Measure at SRS check harness con nectors 5 D Disconnect SDU connector C 27 D Connect SRS check harness connector 3 D Continuity between terminals 19 20 OK Continuity NG Check the following connectors C 27 C 86 NG Repair OK Check trouble symptom NG Check the harness wire between the SDU and earth and repair if necessary OK Measure at SRS check harness connector 5 D Ignition switch O...

Page 1411: ...cted while the SDU is monitoring the SRS warning lamp drive circuit D Malfunction of wiring harnesses or connectors D Malfunction of SDU Check the SRS warning lamp drive circuit system Refer to P 52B 13 OK Replace the SDU Code No 45 SDU non volatile memory EEPROM and A D converter system Probable cause This diagnosis code is output if there is a malfunction in the SDU non volatile memory EEPROM an...

Page 1412: ... of SDU Measureat SRS check harness connector 5 D Disconnect SDU connector C 27 D Connect SRS check har ness connector 3 D Continuity between termi nals 19 20 OK Continuity NG Check the following connectors C 27 C 86 NG Repair SRS check harness MB991349 OK Check trouble symptoms NG Check the harness wire between the SDU and earth and repair if necessary OK Check trouble symptoms NG Check the harne...

Page 1413: ...er to P 52B 3 SRS DIAGNOSIS UNIT SDU 1 Check SDU case and brackets for dents cracks deformation or rust Caution The SRS may not activate if the SDU is not installed properly which could result in serious injury or death to the vehicle s driver 2 Check connector for damage and terminals for deformation or rust Replace SDU if it fails visual check Refer to P 52B 26 AIR BAG MODULES STEERING WHEEL AND...

Page 1414: ...x 3 4 5 turns counterclockwise to align the mating marks Caution If the clock spring s mating mark is not properly aligned the steering wheel may not be completely rotational during a turn or the flat cable within the clock spring may be severed obstructing normal operation of the SRS and possibly leading to serious injury to the vehicle s driver 9 Install the steering column covers steering wheel...

Page 1415: ...Refer to P 52B 3 Caution The SRS may not activate if SRS harnesses or connectors are damaged or improperly connected which could result in serious injury or death to the vehicle s driver POST INSTALLATION CHECK Reconnect the negative battery terminal Turn the ignition key to the ON position Does the SRS warning lamp illuminate for about 7 seconds turn off and then remain extinguished for at least ...

Page 1416: ... diagnosis unit Inspect and if necessary repair the body wiring harness before proceeding further 3 Read the data list fault duration and how many times memories are erased using the MUT II Data list No Service Data Item Applicability 91 How long a problem has lasted Maximum time to be stored 9999 minutes approximately 7 days 92 Number indicating houw often the memory is cleared Maximum time to be...

Page 1417: ...BAG DOES NOT DEPLOY IN LOW SPEED COLLISION Check the SRS components If the SRS components are showing any visible damage such as dents cracks or deformation replace them with new ones Concerning parts removed for inspection replacement with new parts and cautionary points for working refer to appropriate INDIVIDUAL COMPONENT SERVICE P 52B 21 Front impact sensors 1 Check fender shield panel for def...

Page 1418: ... or alignment with steering wheel 3 Check steering wheel for noise binds or difficult operation and excessive free play Harness connector body and front wiring harness Check harnesses for binding connectors for damage poor connection and terminals for deformation Refer to P 52B 18 INDIVIDUAL COMPONENT SERVICE 52400290148 If the SRS components are to be removed or replaced as a result of maintenanc...

Page 1419: ...on labels relating to the SRS are found in the vehicle as shown in the following illustration Follow label instructions when servicing SRS If labels are dirty or damaged replace them with new ones Steering wheel Air bag module Clock spring Glove box Sun visor SDU Hood Frame 2WD Frame 4WD ...

Page 1420: ...to be dented cracked deformed or rusted replace it with a new one 3 Replace sensor with new ones after the air bag has deployed REMOVAL AND INSTALLATION Pre removal Operation D Turn the ignition key to the LOCK position 1 2 3 4 5 6 4 9 Nm 6 Removal steps CA D Post installation inspection AA 1 Negative Battery cable connec tion BA 2 Front impact sensor R H 3 Battery 4 Windshield washer tank 5 Wirin...

Page 1421: ...Securely connect the connector 2 Set the front impact sensor toward the front of the vehicle as shown by the arrow in the illustration and install it securely Caution The SRS may not activate properly if a front impact sensor is not installed properly which could result in serious injury or death to the vehicle s driver CA POST INSTALLATION INSPECTION 1 Reconnect the negative battery terminal 2 Tu...

Page 1422: ...ure the resistance between terminals and check whether it is within the standard value Standard value 2 000 20Ω Caution Always replace the sensor with a new one if the resistance is not within the standard value 3 Check fender shield panel for deformation or rust 4 Check the continuity between the terminal and bracket If there is a continuity the insulation is malfunctioned and replace the sensor ...

Page 1423: ...vered in the SDU replace it with a new SDU Discard the old one 4 After deployment of an air bag replace the SDU with a new one 5 Never use an ohmmeter on or near the SDU and use only the special test equipment described on P 52B 5 REMOVAL AND INSTALLATION Pre removal Operation D Turn the ignition key to the LOCK position D Front Floor Console Removal Refer to GROUP 52A Post installation Operation ...

Page 1424: ...ERVICE POINTS AA SRS DIAGNOSIS UNIT SDU INSTALLATION Caution The SRS may not activate if SDU is not installed properly which could result in serious injury or death to the vehicle s driver BA HARNESS CONNECTOR CONNECTION After connecting each harness connector securely and correctly to the SDU be sure to press down the lock lever of the SDU CA POST INSTALLATION INSPECTION 1 Reconnect the negative ...

Page 1425: ... terminal should be covered with tape to insulate it Refer to P 52B 3 No 4 2 Never attempt to disassemble or repair the air bag modules or clock spring If faulty replace it 3 Do not drop the air bag modules or clock spring or allow contact with water grease or oil Replace it if a dent crack deformation or rust is detected 4 The air bag modules should be stored on a flat surface and placed so that ...

Page 1426: ...ps DA D Post installation inspection D Negative battery cable connection 1 Air bag module mounting nut AA 2 Air bag module AA D Pre installation inspection Clock spring removal steps DA D Post installation inspection D Negative battery cable connection 1 Air bag module mounting nut AA 2 Air bag module 3 Cover AB CA 4 Steering wheel 5 Throttle cable knob Diesel pow ered vehicles 6 Driver side under...

Page 1427: ...face up AB STEERING WHEEL REMOVAL Caution Do not hammer on the steering wheel Doing so may damage the collapsible column mechanism AC CLOCK SPRING REMOVAL Caution The removed clock spring should be stored in a clean dry place INSTALLATION SERVICE POINTS AA PRE INSTALLATION INSPECTION 1 When installing the new air bag modules and clock spring refer to INSPECTION Caution Dispose of air bag modules o...

Page 1428: ...teering wheel may not be completely rotational during a turn or the flat cable within the clock spring may be severed obstructing normal operation of the SRS and possibly leading to serious injury to the vehicle s driver CA STEERING WHEEL INSTALLATION 1 Before installation the steering wheel be sure to first turn the vehicle s front wheels to the straight ahead position and align the mating marks ...

Page 1429: ...als for deformation and harness for binds 3 Check air bag inflator case for dents cracks or deformation 4 Install the air bag module to steering wheel to check fit or alignment with the wheel Caution If dents cracks deformation or rust are discovered in the air bag module replace it with a new one Dispose of the old one according to the specified procedure Refer to P 52B 34 CLOCK SPRING CHECK If a...

Page 1430: ...connector No 4 and 2 align paint of the No 4 with the portion of the No 2 connector of the clock spring 5 Check for continuity between terminal 21 and terminal 22 of SRS Check harness connector No 5 SRS check harness MB991349 Clock spring connector 2 View A 4 5 A Painted marks ...

Page 1431: ...ince there is a loud noise when the air bag are deployed avoid residential areas whenever possible If anyone is nearby give warning of the impending noise 4 Suitable ear protection should be worn by personnel performing these procedures or by people in the immediate area DEPLOYMENT INSIDE THE VEHICLE when disposing of a vehicle 1 Open all windows and doors of the vehicle Move the vehicle to an iso...

Page 1432: ...onnect the two connected wires from each other and connect them to the two terminals of the battery which has been removed from the vehicle to deploy the air bag Caution 1 Before deploying the air bag in this manner first check to be sure that there is no one in or near the vehicle Wear safety glasses 2 The inflator will be quite hot immediately following the deployment so wait at least 30 minutes...

Page 1433: ...f it 3 Connect two wires each six meters long or more to the two leads of SRS air bag adapter harness B and cover the connections with insulation tape The other ends of the two wires should be connected to each other short circuited to prevent sudden unexpected deployment of the air bag 4 Install nuts that are no longer needed to the four bolts on the rear side of the air bag module and tie on som...

Page 1434: ...tion 1 Before deployment check carefully to be sure that no one is nearby 2 The inflator will be quite hot immediately following deployment so wait at least 30 minutes to allow it to cool before attempting to handle it Although the gas resulting from air bag deployment is not poisonous it should not be inhaled Refer to the Deployed Aid Bag Module Disposal Procedures P 52B 38 for post deployment ha...

Page 1435: ... cool before attempting to handle it 2 Do not put water or oil on the air bag after deployment 3 There may be adhered to the deployed air bag module material that could irritate the eye and or skin so wear gloves and safety glasses when handling a deployed air bag module IF AFTER FOLLOWING THESE PRECAUTIONS ANY MATERIAL DOES GET INTO THE EYES OR ON THE SKIN IMMEDIATELY RINSE THE AFFECTED AREA WITH...

Page 1436: ... cable Refer to P 52B 4 Front wiring harness Sensor cable Frontimpactsensor L H Body wiring harness SDU Front impact sensor R H Grommet Sensor cable Sealant 3M ATD Part No 8625 or equivalent Sensor cable 1 Disconnect the negative battery cable and tape the terminal Caution Wait at least 60 seconds after disconnecting the battery cable before doing any further work Refer to P 52B 3 No 4 Insulating ...

Page 1437: ...fied sealant to the grommet cut portion 5 Connect the sensor cable to the impact sensor and to the body wiring harness POST INSTALLATION INSPECTION 1 Reconnect the negative battery terminal 2 Turn the ignition key to the ON position 3 Does the SRS warning lamp illuminate for about 7 seconds and then remain extinguished for at least 45 seconds after turning OFF 4 If yes SRS system is functioning pr...

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Page 1461: ...module and clock spring has been corrected 2 Applicable Manuals Manual Pub No Language Page s 96 CARISMA Workshop Manual PWDE9502 English 52B 22 chassis PWDS9503 Spanish PWDF9504 French PWDG9505 German PWDD9506 Dutch PWDW9507 Swedish PWDI96E1 Italian 96 ECLIPSE Workshop Manual PWUE95E1 English 52B 24 chassis PWUS95E1 Spanish PWUF95E1 French PWUG95E1 German PWUD95E1 Dutch 52B 25 PWUI95E1 Italian 97...

Page 1462: ...r clock spring If faulty replace it 3 do not drop the air bag modules or clock spring or allow contact with water grease or oil Replace it if a dent crack deformation or rust is detected 4 The air bag modules should be stored on a flat surface and placed so that the pad surface is facing upward Do not place anything on top of it 5 Do not expose the air bag modules to temperatures over 93 C 6 After...

Page 1463: ...andling an air bag that has deployed 8 An undeployed air bag module should only be disposed of in accordance with the specified procedures Refer to P 52B 30 REMOVAL AND INSTALLATION Air bag module Driver s side Clock spring 52B 24 SRS Air Bag Modules and Clock Spring 52400230010 After deployment of an air bag replace the air bag modules Check the clock spring and if faulty replace it with a new pa...

Page 1464: ...lace it 3 do not drop the air bag modules or clock spring or allow contact with water grease or oil 4 Replace it if a dent crack deformation or rust is detected 4 The air bag modules should be stored on a flat surface and placed so that the pad surface is facing upward Do not place anything on top of it 5 Do not expose the air bag modules to temperatures over 93 C 6 After deployment of an air bag ...

Page 1465: ...tic trouble code have been added 2 Applicable Vehicles 91 10 SIGMA 92 10 3000GT 91 10 COLT LANCER 93 10 GALANT 92 10 SPACE RUNNER SPACE WAGON 95 10 L400 91 10 PAJERO MONTERO 97 10 L200 3 Applicable Manuals Manual Pub No Language Page s SIGMA Workshop Manual chassis PWGE9004 G English 52B 14 PWGS9005 F Spanish PWGF9006 F French PWGG9007 F German PWGD9008 F Dutch PWGW900 F Swedish 3000GT Workshop Ma...

Page 1466: ...ch PWMW9516 Swedish GALANT Workshop Manual chassis PWDE9211 B English 52B 13 PWDS9212 B Spanish PWDF9213 B French PWDG9214 B German 52B 11 PWDD9215 B Dutch 52B 13 PWDW9216 B Swedish 96 GALANT Workshop Manual PWDE9211 D English 52B 7 chassis Supplement PWDS9212 D Spanish PWDF9213 D French PWDG9214 D German PWDD9215 D Dutch PWDW9216 D Swedish SPACE RUNNER SPACE WAGON PWDE9104 D English 52B 9 Worksho...

Page 1467: ...glish 52B 10 MONTERO Workshop Manual chassis PWJS9087 F Spanish PAJERO Workshop Manual chassis PWJF9088 F French PWJG9089 F German PWJD9090 F Dutch PWJW9091 F Swedish 96 PAJERO Workshop Manual chassis Supplement PWJE9086 G English 52B 10 96 MONTERO Workshop Manual chassis Supplement PWJS9087 G Spanish 96 PAJERO Workshop Manual PWJF9088 G French chassis Supplement PWJG9089 G German PWJD9090 G Dutch...

Page 1468: ...ssis Supplement Page 13 SPACE RUNNER SPACE WAGON Workshop Manual chassis Page 14 95 SPACE RUNNER SPACE WAGON Workshop Manual chassis Page 15 97 SPACE RUNNER SPACE WAGON Workshop Manual chassis Page 16 95 L400 Workshop Manual chassis Page 17 97 L400 Workshop Manual chassis Supplement Page 18 PAJERO Workshop Manual chassis Page 19 MONTERO Workshop Manual chassis Page 19 96 PAJERO Workshop Manual cha...

Page 1469: ...is open circuit R H drive vehicles refer to P 52B 26 Vehicles with 13 Right and left impact sensor circuits are open or the wires from the sensors to the SDU are open circuit Front passenger s air bag refer to P 52B 32 21 The circuits for the driver s side air bag module squib are shorted together other or the circuit is earthed Perform TEST 6 Vehicles without front passenger s air 22 The driver s...

Page 1470: ...en or the wire from the sensor to the SDU is open circuit passenger s air bag refer to P 52B 24 13 Right and left impact sensor circuits are open or the wires from the sensors to the SDU are open circuit 21 The circuits for the driver s side air bag module squib are shorted together other or the circuit is earthed Perform TEST 6 Vehicles without front passenger s air 22 The driver s side air bag m...

Page 1471: ...RS ECU Code No Trouble symptoms 21 Short in driver s side air bag module squib or harness short Short in clock spring 22 Open circuit in driver s side air bag module squib or open harness Open circuit in clock spring Disconnected connector in the driver s side air bag module squib Open circuit in clock spring due to inappropriate neutral position Malfunction of connector contact 61 Short in driver...

Page 1472: ... Do not attempt to measure the air bag module squib circuit resistance Use of a tester in measuring the circuit resistance will supply current to the squib or erroneous deployment due to static electricity could cause serious injury 3 To unlock the SDU connector place a flat tipped screwdriver against the lock spring at the lock lever notch and push the spring toward the unit In this case do not f...

Page 1473: ...ted connector in the driver s side air bag module squib Open circuit in clock spring due to inappropriate neutral position Connector in loose contact Caution 1 After the ignition switch has been placed at the LOCK position and the negative terminal of the battery has been disconnected wait for more than 60 seconds before starting work Wind a tape around the disconnected terminal for insulation Ref...

Page 1474: ... If the vehicle has a discharged battery it will store the fault codes 41 or 42 When these diagnosis codes are displayed check the battery INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE Code No 21 22 61 or 62 Driver s side air bag module squib system Probable cause These diagnosis codes are output if there is abnormal resistance between the input terminals of the driver s side air bag module sq...

Page 1475: ... No Trouble symptoms 21 Short in driver s side air bag module squib or harness short Short in clock spring 22 Open circuit in driver s side air bag module squib or open harness Open circuit in clock spring Disconnected connector in the driver s side air bag module squib Open circuit in clock spring due to inappropriate neutral position Malfunction of connector contact 61 Short in driver s side air...

Page 1476: ...o notch in the connector lock lever Type 1 Place a screwdriver against the lock spring metal section of the connector lock lever as shown in the illustration and push the spring horizontally toward the inside of the unit 1 Do not use excessive force to raise the lock lever 2 Do not insert the screwdriver into the gap between the lock lever and the lock spring 52B 13 SRS Troubleshooting Code No Tro...

Page 1477: ...g Disconnected connector in the driver s side air bag module squib Open circuit in clock spring due to inappropriate neutral position Malfunction of connector contact 61 Short in air bag module driver s side squib harness leading to the power supply 62 Short in air bag module driver s side squib harness leading to the earth MUT II SELF DIAG CODE Disconnect clock spring connector C 123 Connect SRS ...

Page 1478: ... Analog G sensor does not function or its characteristic is abnormal Replace the SDU Refer to P 52B 34 15 The circuits for the safing impact sensor are shorted together or the circuit is earthed 16 The safing input sensor circuit is open or the wire from the air module to the SDU is open circuit 21 The circuits for the air bag module squib are shorted together other or the circuit is earthed Perfo...

Page 1479: ...tom 15 Short circuit in the safing G sensor 16 Open circuit in the safing G sensor Code No 21 or 22 Driver s side Air bag module squib system Probable cause Comment These diagnosis codes are output if there is abnormal resistance between the input terminals of the air bag module driver s side squib The trouble causes for each code No are as follows Malfunction of clock spring Open circuit in clock...

Page 1480: ...r open harness Open circuit in clock spring Disconnected connector in the driver s side air bag module squib Open circuit in clock spring due to inappropriate neutral position Malfunction of connector contact 61 Short in air bag module driver s side squib harness leading to the power supply MUT II SELF DIAG CODE Disconnect clock spring connector C 77 Connect SRS check harness connector 1 Connect n...

Page 1481: ...ss Open circuit in clock spring Disconnected connector in the driver s side air bag module squib Open circuit in clock spring due to inappropriate neutral position Malfunction of connector contact Chart 2 Item Front impact sensor Short Open circuit 1 sensor Open circuit 2 sensors Air bag module driver s side squib Short 11 or 21 12 or 21 13 or 21 Open circuit 11 or 22 12 or 22 13 or 22 Caution 1 A...

Page 1482: ...ors Malfunction of driver s side air bag module squib Malfunction of SRS ECU Code No Trouble symptoms 21 Short in driver s side air bag module squib or harness short Short in clock spring 22 Open circuit in driver s side air bag module squib or open harness Open circuit in clock spring Disconnected connector in the driver s side air bag module squib Open circuit in clock spring due to inappropriat...

Page 1483: ...ped screwdriver against the lock spring metal portion of the SDU connector lock lever and push the spring horizontally toward the inside of the unit Caution 1 Do not use excessive force to raise the lock lever green 2 do not insert the screwdriver into the gap between the lock lever green and the lock spring metal portion 4 Disconnect the red 14 pin connector from the SDU SRS Troubleshooting 52B 1...

Page 1484: ... s side squib or harness short Short in clock spring Short in driver s side air bag module squib or front impact sensor harnesses leading to the power supply 22 Open circuit in air bag module driver s side squib or open harness Open circuit in clock spring Disconnected connector in the driver s side air bag module squib Open circuit in clock spring due to inappropriate neutral position Malfunction...

Page 1485: ...cuit between the terminals of the safing G sensor inside the SRS ECU The trouble causes for each diagnosis code No Are as follows Malfunction of SRS ECU Code No Trouble Symptom 15 Short circuit in the safing G sensor 16 Open circuit in the safing G sensor Replace the SRS ECU Code No 21 22 or 61 Air bag module driver s side squib system Probable cause These diagnosis codes are output if there is ab...

Page 1486: ...S check harness connector 1 Connect negative battery cable Erase diagnosis code memory Are code Nos 21 22 or 61 output No Check the following connector C 56 and Air bag module connector Check trouble symptom Replace the driver s air bag module NG Repair Yes Check the following connectors C 56 C 128 OK Check trouble symptom NG Check the harness between the SRS ECU and clock spring Disconnect clock ...

Page 1487: ...f air bag module squib Malfunction of SDU Chart 1 Code No Trouble symptom 21 Short in air bag module squib or harness short Short in clock spring Short in air bag module squib or front impact sensor harnesses leading to the power supply 22 Open circuit in air bag module squib or open harness Open circuit in clock spring Disconnected connector in the driver s side air bag module squib Open circuit ...

Page 1488: ... OVERSEAS SERVICE DEPT R USAMI MANAGER QUALITY INFORMATION ANALYSIS 1 Description This Service Bulletin informs you of change in attachment position of the SRS air bag caution label 2 Applicable Manuals Manual Pub No Language Page s L200 Technical Information Manual PYTE96E1 English 6 10 L200 Workshop Manual PWTE96E1 English 52B 22 PWTS96E1 Spanish PWTF96E1 French PWTG96E1 German 3 Effective Date ...

Page 1489: ...eering wheel Air bag module Clock spring Glove box Sun visor SDU Hood Frame 2WD Added Frame 4WD Added Frame 4WD 2 NOTE Label I is attached in position either at Frame 4WD 1 or at Frame 4WD 2 6 10 INTERIOR Supplemental Restraint System SRS 19N0245 19V0059 19X0015 19V0060 19V0061 19V0062 19V0063 19V0064 19V0065 V0205AA Body mounting bracket LH Tyre Front bumper 1 I A B C D E F G H I I ...

Page 1490: ...d replace them with new ones Steering wheel Air bag Clock spring Glove box Sun visor SDU Hood Frame 2WD Added Frame 4WD Added Frame 4WD 2 NOTE The label for Frame 4WD is attached in position either at Frame 4WD 1 or at Frame 4WD 2 52B 22 SRS Warning Caution Labels 19N0245 19V0059 19X0015 19V0060 19V0061 19V0062 19V0063 19V0064 19V0065 V0205AA Body mounting bracket LH Tyre Front bumper 1 I 52400300...

Page 1491: ...cription This Service Bulletin informs you of correction to erasing of the diagnosis codes 2 Applicable Manuals Manual Pub No Language Page s 96 COLT LANCER PWME9511 English 52B 6 Workshop Manual CHASSIS PWMS9512 Spanish PWMF9513 French PWMG9514 German PWMD9515 Dutch PWMW9516 Swedish 98 COLT LANCER PWME9511 A English 52B 5 Workshop Manual CHASSIS PWMS9512 A Spanish PWMF9513 A French PWMG9514 A Ger...

Page 1492: ...nch PWTG95E1 German 98 L300 PWWE8608 Q English 52B 6 Workshop Manual CHASSIS PWWS8613 Q Spanish PWWF8612 Q French PWWG8609 Q German PWWD8610 Q Dutch PWWW8611 Q Swedish 3 Details 96 COLT LANCER Workshop Manual CHASSIS page 3 98 COLT LANCER Workshop Manual CHASSIS page 4 96 ECLIPSE Workshop Manual CHASSIS page 5 97 GALANT Workshop Manual CHASSIS page 6 96 CARISMA Workshop Manual CHASSIS page 7 97 L2...

Page 1493: ...circuitry Use a multi meter for which the maximum test current is 2 mA or less at the minimum range of resistance measurement TROUBLESHOOTING STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points DIAGNOSIS FUNCTION DIAGNOSIS CODE CHECK Connect the MUT II to the diagnosis connector 16 pin under the instrument under cover then check diagno...

Page 1494: ... 32 SRS ECU capacitor system 52B 8 34 Connector lock system 52B 9 35 SRS ECU deployed air bag system 52B 9 41 IG1 A power circuit system 52B 9 42 IG1 B power circuit system 52B 9 Lamp does not illuminate 52B 10 43 SRS warning lamp driver circuit system Lamp does not switch off 52B 10 44 SRS warning lamp drive circuit system 52B 10 45 Internal circuit system of non volatile memory EEPROM inside SRS...

Page 1495: ...er to GROUP 00 How to Use Troubleshooting Inspection Service Points SRS WARNING LAMP INSPECTION 1 Check that the SRS warning lamp illuminates when teh ignition switch is in the ON position 2 Check that it illuminates for approximately 7 seconds and then switches off 3 If the above is not the case check the diagnosis codes 52B 6 SRS Troubleshooting Incorrect WHEN USING THE MUT II Connect the MUT II...

Page 1496: ... Page 14 Analog G sensor system in the SRS ECU 52B 9 15 16 Front impact safing G sensor system inside SRS ECU 52B 9 17 Side impact safing G senosr system insided SRS ECU 52B 10 21 22 61 62 Driver s side air bag module squib system 52B 10 24 25 64 65 Front passenger s side air bag module squib system 52B 11 31 32 SRS ECU capacitor system 52B 11 34 Connector lock system 52B 12 35 SRS ECU deployed ai...

Page 1497: ...age 14 Analog G sensor system 52B 7 15 Safing G sensor system 52B 7 21 22 Driver s side air bag module squib system 52B 7 24 1 25 1 Front passenger s side air bag module squib system 52B 8 26 27 Driver s side pre tensioner squib system 52B 9 28 29 Front passenger s side pre tensioner squib system 52B 9 31 32 SRS ECU capacitor system 52B 10 35 SRS ECU system ignition of the air bag or activation of...

Page 1498: ...8 31 32 SDU capacitor system 52B 9 33 Cranking signal system 52B 10 34 Connector lock system 52B 11 41 IG1 A power circuit system 52B 11 42 IG1 B power circuit system 52B 12 43 SRS warning lamp drive circuit system Lamp does not illuminate 52B 13 SRS warning lamp drive circuit system Lamp does not switch off 52B 14 44 SRS warning lamp drive circuit system 52B 14 45 SDU non volatile memory EEPROM a...

Page 1499: ...ion chart that is appropriate for the malfunction code Code No Diagnosis Item Reference Page 14 Analog G sensor system in the SRS ECU 52B 7 15 16 Safing G sensor system inside SRS ECU 52B 7 21 22 51 54 1 61 64 1 Driver s side air bag module squib system 52B 8 24 25 51 54 61 64 Front passenger s side air bag module squib system 52B 9 31 32 SRS ECU capacitor system 52B 19 34 2 Connector lock system ...

Page 1500: ...ECHNICAL SERVICE PLANNING 1 Description The modified SRS ECU and front impact sensor have been employed 2 Applicable Manuals Manual Pub No Language Page s 97 L200 PWTE96E1 English 52B 5 15 25 Workshop Manual Chassis PWTS96E1 Spanish PWTF96E1 French PWTG96E1 German 99 L200 PWTE96E1 C English 52B 1 2 4 8 9 Workshop Manual Chassis Supplement PWTS96E1 C Spanish PWTF96E1 C French PWTG96E1 C German 3 In...

Page 1501: ...wheel puller Steering wheel removal MB686560 SRS air bag adapter harness A Deployment of air bag module inside the vehicle MB628919 SRS air bag adapter harness B Deployment of air bag module outside the vehicle TEST EQUIPMENT 52400080035 Tool Name Use Digital multi meter Checking the SRS electrical circuitry Use a multi meter for which the maximum test current is 2 mA or less at the minimum range ...

Page 1502: ...uble symptoms NG Check the harness wire between the SDU and earth and repair if necessary Measure at SRS check harness connector 5 Disconnect SDU connector C 27 Connect SRS check harness connector 3 Continuity between terminals 19 20 OK Continuity NG OK Check the following connectors C 27 C 86 C 87 C 88 NG Repair OK Check trouble symptoms Measure at SRS check harness connector 5 Ignition switch ON...

Page 1503: ...on switch ON 1 Voltage between terminal 13 and body earth OK 9 V or more 2 Voltage between terminal 16 and body earth OK 9 V or more 3 Continuity between terminal 7 and body earth OK Continuity 3 NG OK Check the following connectors C 27 C 35 C 86 NG Repair Check the following connectors C 27 C 86 NG Repair OK OK Check trouble symptoms Check trouble symptoms NG NG Check the harness wire between th...

Page 1504: ...ue Standard value 2 000 20 Ω Ω Ω Ω Caution Always replace the sensor with a new one if the resistance is not within the standard value 3 Check fender shield panel for deformation or rust 4 Check the continuity between the terminal and bracket If there is a continuity the insulation is malfunctioned and replace the sensor with a new one 97 L200 Workshop Manual Chassis SRS Front Impact Sensors 52B 2...

Page 1505: ...it SRS ECU Front impact sensors Clock spring Air Bag Modules Driver s and front passenger s sides If these components are diagnosed as faulty just replace in accordance with the INDIVIDUAL COMPONENT SERVICE procedures Refer to P 52B 13 After negative battery cable disconnection wait at least 60 seconds before any further work Also wind the terminal with insulating tape The SRS ECU condenser retain...

Page 1506: ...6 1 2 18 19 Body wiring harness Front wiring harness Front impact sensor R H Sensor cable installation procedures 7 20 21 21 pins yellow Body wiring harness Earth Repair or replace body wiring harness NOTE The sensor cable is available as service part 6 Do not expose the SRS components to heat over 93 C so remove the SRS ECU air bag modules clock spring and front impact sensors before drying or ba...

Page 1507: ...supply 13 Open circuit in both left and right front impact sensors or harness Short circuit in front impact sensors harness leading to the power supply Check the front impact sensors OK Replace NG Check the following connectors A 29 C 20 C 27 NG Repair OK Check trouble symptom NG Check the harness wire between the SRS ECU and front impact sensors and repair if necessary Measure at SRS check harnes...

Page 1508: ... When these diagnosis codes are displayed check the battery Malfunction of wiring harness or connectors Malfunction of SRS ECU NG Check the following connectors C 27 C 86 NG Repair OK Check trouble symptom NG Check the harness wire between the SRS ECU and repair if necessary Measure at SRS check harness connector 5 Disconnect SRS ECU connector C 27 Connect SRS check harness connector 3 Continuity ...

Page 1509: ...N 1 Voltage between terminal 16 and body earth code No 41 OK 9 V or more 2 Voltage between terminal 13 and body earth code No 42 OK 9 V or more 3 Continuity between terminal 7 and body earth OK Continuity 3 NG OK Check the following connectors C 27 C 35 C 86 NG Repair Check the following connectors C 27 C 86 NG Repair OK OK Check trouble symptoms Check trouble symptoms NG NG Check the harness wire...

Page 1510: ...essary Measure at SRS check harness connector 5 Disconnect SRS ECU connector C 27 Connect SRS check harness connector 3 Continuity between terminal 20 and 21 OK Continuity OK Check the bulb for blowing NG Repair OK Check the following connectors C 06 C 79 C 88 NG Repair Measure at SRS check harness connector 5 Disconnect SRS ECU connector C 27 Connect SRS check harness connector 3 Connect the batt...

Page 1511: ...CHASSIS ELECTRICAL ...

Page 1512: ......

Page 1513: ...T COMBINATION LAMP 51 SIDE TURN SIGNAL LAMP 52 REAR COMBINATION LAMP 53 REAR FOG LAMP 54 SPECIAL TOOL 54 REAR FOG LAMP 54 RHEOSTAT 56 SPECIAL TOOL 56 RHEOSTAT 56 HAZARD WARNING LAMP SWITCH 57 SPECIAL TOOL 57 HAZARD WARNING LAMP SWITCH 57 HORN 58 CIGARETTE LIGHTER 59 CLOCK 60 SPECIAL TOOL 60 CLOCK 60 RADIO AND TAPE PLAYER 61 SPECIAL TOOL 61 TROUBLESHOOTING 61 Quick reference Troubleshooting Chart 6...

Page 1514: ...fer to GROUP 27 SERVICE BRAKES ABS Refer to GROUP 35B 35C DOOR GLASS AND REGULATOR POWER WINDOWS Refer to GROUP 42 DOOR HANDLE AND LATCH DOOR LOCKING Refer to GROUP 42 WINDSHIELD WIPER AND WASHER Refer to GROUP 51 HEADLAMP WASHER Refer to GROUP 51 DOOR MIRROR ELECTRONIC CONTROLLED DOOR MIRROR Refer to GROUP 51 FRONT SEAT HEATED SEAT Refer to GROUP 52A SRS AIR BAG Refer to GROUP 52B HEATER Refer to...

Page 1515: ...ydrometer and thermometer to check the specific gravity of the battery fluid Standard value 1 220 1 290 20_C The specific gravity of the battery fluid varies with the temperature so use the following formula to calculate the specific gravity for 20_C Use the calculated value to determine whether or not the specific gravity is satisfactory D20 Dt 0 0007 t 20 D20 Specific gravity of the battery flui...

Page 1516: ...dicated in amperes 4 Determining if charging is completed 1 If the specific gravity of the battery fluid reaches 1 250 1 290 and remains constant for at least one hour 2 If the voltage of each cell reaches 2 5 2 8 V and remains constant for at least one hour Caution 1 Be careful since the battery fluid level may rise during charging 2 Keep all sources of fire away while charging because there is a...

Page 1517: ...ery 2 Loadthebatteryattherecommendeddischargerate seeLOAD TEST RATE CHART for 15 seconds 3 Read voltage after 15 seconds then remove load 4 Compare the measured value with the minimum voltage see LOAD TEST CHART OK Higher than minimum voltage NG Replace battery OK Normal LOAD TEST RATE CHART Battery type 50B24R 55D23R 55B24R 75D26R 80D26R 95D31R Charging time when fully discharged h 5 amp rated cu...

Page 1518: ...CTION POINTS 1 Connect the MUT II to the diagnosis connector 2 If buzzer of the MUT II sounds once when a switch is operated ON OFF the ETACS ECU input signal for that switch circuit system is normal INSPECTION CHART FOR TROUBLE SYMPTOMS 54300720235 Trouble symptoms Inspection procedure Reference page Communication with MUT II is impossible Communication with all systems is impossible 1 54 8 MUT I...

Page 1519: ...G Repair Inspection Procedure 3 Even if the driver s side door is opened the key hole illumination lamp does not illuminate Probable cause Thecauseisprobablyadefectivekeyholeilluminationlampcircuitsystemoradefective driver s side door switch input circuit system D Malfunction of driver s side door switch D Malfunction of key hole illumination lamp D Malfunction of harness or connector D Malfunctio...

Page 1520: ...eminder switch and junction block and repair if necessary Yes Replace the ETACS ECU Inspection Procedure 5 Driver s side door switch input circuit system check Door switch check Refer to GROUP 42 Door Assembly NG Replace OK Door switch earth check NG Repair OK Disconnect the door switch connector D 17 and measure at the harness side D Voltage between the terminal No 2 and body earth OK 5 V NG Chec...

Page 1521: ...W OF DIAGNOSIS TROUBLESHOOTING 54300690024 Refer to GROUP 00 How To Use Troubleshooting Inspection Service Points DIAGNOSIS FUNCTION 54300700116 DIAGNOSIS CODES CHECK Refer to GROUP 00 How To Use Troubleshooting Inspection Service Points ERASING DIAGNOSIS CODES Refer to GROUP 00 How To Use Troubleshooting Inspection Service Points Caution The diagnosis codes which result from disconnecting the bat...

Page 1522: ...om NG Does the engine start using the spare ignition key which has had the ID code registered OK Replace the ignition key that does not work Re register the ID code Refer to P 54 23 NG Diagnosis code check Code No 12 occurs To INSPECTION PROCEDURE FOR DIAGNOSIS CODE No 12 Code No 11 occurs Ignition key ring antenna continuity check Refer to P 54 22 NG Replace OK Check the following connectors C 36...

Page 1523: ...er source and the earth circuit Refer to GROUP 13A Troubleshooting No Check the following connectors C 19 C 36 C 50 NG Repair OK Check trouble symptom NG Check the harness between the engine ECU and immobilizer ECU NG Repair OK Check trouble symptom NG Replace the immobilizer ECU Register the password secret code and ID code Refer to P 54 23 Check trouble symptom NG Replace the engine ECU Code No ...

Page 1524: ... VEHICLES Code No 21 Communication system between fuel cut valve controller and immobilizer ECU Probable cause The confirmation code is not sent from the fuel cut valve controller within the specified time after the ignition key is turned to ON or an incorrect code is sent D Malfunction of harness or connector D Malfunction of fuel cut valve controller D Malfunction of immobilizer ECU Check the fo...

Page 1525: ... II D Malfunction of fuel cut valve controller Use the MUT II to reset the code to the factory setting Refer to P 54 23 Check trouble symptom NG Replace the fuel cut valve controller fuel injection pump assembly Check trouble symptom NG Replace the immobilizer ECU Register the password secret code reset the code to the factory setting and register the ID code Refer to P 54 23 INSPECTION CHART FOR ...

Page 1526: ... 36 Short circuited harness wire between terminal No 14 and No 15 NG Repair Can the MUT II communicate with the engine ECU No Check the following connectors C 35 C 36 NG Repair Inspection Procedure 2 ID code cannot be registered using the MUT II Probable cause The cause is probably that there is no ID code registered in the immobilizer ECU or there is a malfunction of the immobilizer ECU D Malfunc...

Page 1527: ...uble symptom NG Replace the immobilizer ECU Register the password secret code and the ID code Refer to P 54 23 Inspection Procedure 4 Engine does not start Cranking but no initial combus tion Diesel powered vehicles Probable cause If no fuel injection there might be a problem with the fuel injection system in addition to a malfunction of the immobilizer system It is normal for this to occur if an ...

Page 1528: ...hicles Checktheharnessbetweentheimmobi lizer ECU and junction block and repair if necessary 2 NG Check the following connector C 36 NG Repair OK Check trouble symptom NG Checktheharnessbetweentheimmobi lizer ECU and body earth and repair if necessary Inspection Procedure 6 Malfunction of the fuel cut valve controller power source and earth circuit Diesel powered vehicles OK Check trouble symptom N...

Page 1529: ...Checking require ments Terminal voltage 1 Immobilizer ECU power supply Back up Ignition switch ON System voltage 2 Ignition switch IG Petrol powered vehicles Ignition switch OFF 0 V Ignition switch ON System voltage 8 Immobilizer ECU earth Always 0 V 9 Immobilizer ECU power supply Ignition switch ON System voltage 16 Immobilizer ECU earth Always 0 V ...

Page 1530: ...e cable knob Diesel powered vehicles 2 Driver s side under cover 3 Column cover lower 4 Column cover upper AA 5 Steering lock cylinder AB 6 Ignition key cylinder illumination ring 7 Key hole illumination lamp ETACS ECU or buzzer ECU removal steps 1 Throttle cable knob Diesel powered vehicles 2 Driver s side under cover 13 Junction block 14 ETACS ECU or buzzer ECU Ignition switch and key reminder s...

Page 1531: ...S ECU or buzzer ECU removal steps 1 Throttle cable knob Diesel powered vehicles 2 Driver s side under cover 16 Junction block 17 ETACS ECU or buzzer ECU Ignition switch key reminder switch and ignition key ring antenna removal steps 1 Throttle cable knob Diesel powered vehicles 2 Driver s side under cover 3 Column cover lower 4 Column cover upper 7 Steering wheel Refer to GROUP 37A AA 8 Column swi...

Page 1532: ... REMOVAL Turn the ignition key cylinder illumination ring to the left and remove it INSTALLATION SERVICE POINT AA COLUMN SWITCH ASSEMBLY INSTALLATION Tighten the column switch assembly mounting screws to the specified torque in the order of A B and C Tightening torque 25 Nm INSPECTION 54300220124 IGNITION SWITCH CONTINUITY CHECK 1 Remove the driver s side under cover 2 Remove the column cover lowe...

Page 1533: ... the wiring connector from the key reminder switch 4 Check the continuity between the terminal when the ignition key is pulled out of and inserted into the steering lock cylinder Ignition key position Terminal No osition 1 2 4 6 Pulled out Inserted NOTE Vehicles with key hole illumination lamp IGNITION KEY RING ANTENNA CONTINUITY CHECK 54300930027 Use a circuit tester to check the continuity betwe...

Page 1534: ... using an ignition key that has just been newly purchased or if the immobilizer ECU has been replaced you will need to register the ID codes for each ignition key being used into the immobilizer ECU A maximum of eight different ID codes can be registered Moreover when the immobilizer ECU has been replaced you will need to use the MUT II to input the vehicle secret code and to register the password...

Page 1535: ...red vehicles Refer to the MUT II INSTRUCTION MANUAL on handling the MUT II NOTE Resetting the code to the factory setting refers to the process of clearing the identification code which has been recorded in the fuel cut valve controller and switching the controller to learning mode After this resetting is carried out the identification code in the immobilizer ECU will be recorded in the controller...

Page 1536: ...t point F 1 5 Float point E 103 117 Fuel gauge unit float height mm A Float point F 214 1 B Float point E 251 2 Fuel gauge resistance Ω Power supply and earth 192 Power supply and fuel gauge 107 Fuel gauge and earth 85 Engine coolant temperature gauge resistance Ω Power supply and earth 191 resistance Ω Power supply and engine coolant temperature gauge 103 Engine coolant temperature gauge and eart...

Page 1537: ...1 D MB991222 Harness set A Test harness B LED harness C LED harness adapter D Probe D Fuel gauge simple check D Engine coolant temperature gauge simple check Diesel powered vehicles A Connector pin contact pressure check B C Power circuit check D Commercial tester connection MB990784 Ornament remover Removal of meter bezel assembly ...

Page 1538: ...1 and body earth OK Continuity 3 Voltage between the terminal No 43 and body earth OK System voltage 1 NG Check the following connectors Petrol powered vehicles C 04 C 19 Diesel powered vehicles A 91 A 93 C 04 C 19 NG Repair OK Check trouble symptom NG Check the harness wire between the noise filter Petrol powered vehicles or revolution pick up sensor Diesel poweredvehicles andcombinationme ter an...

Page 1539: ... Allowance range km h mph 40 20 40 48 20 25 80 40 80 92 40 47 120 60 120 136 60 69 160 80 160 180 80 91 100 100 114 TACHOMETER CHECK 54300100091 Petrol powered vehicles 1 Insert a paper clip in the noise filter connector from the harness side and attach the engine speedometer NOTE For tachometer inspection use of a fluxmeter type engine speedometer is recommended Because a fluxmeter only needs to ...

Page 1540: ...nit connector Use the special tool to connect a test lamp 12 V 3 4 W to the harness connector Refer to Fig 1 When the ignition switch is turned to ON the test lamp illuminates OK The needle of the fuel gauge moves OK Replace the fuel gauge unit NG Replace the fuel gauge NG Repair the harness FUEL GAUGE UNIT CHECK 54300120158 Remove the fuel gauge unit from the fuel tank FUEL GAUGE UNIT RESISTANCE ...

Page 1541: ...oat arm touching stopper Standard value A 214 1 mm B 251 2 mm THERMISTOR 1 Connect fuel gauge unit thermistor to battery via test lamp 12 V 3 4 W Immerse in water 2 Condition is good if lamp goes off when the thermistor is immersed in water and goes on when it is taken out of water Caution After finishing this test wipe the unit dry and install it in the fuel tank A B Stopper Stopper Point F high ...

Page 1542: ... the engine coolant tempera ture gauge OK Replace the engine coolant tempera ture gauge unit The needle of the engine coolant tem perature gauge moves ENGINE COOLANT TEMPERATURE GAUGE UNIT CHECK 54300150157 1 Bleed the engine coolant Refer to GROUP 14 On vehicle Service 2 Remove the engine coolant temperature gauge unit 3 Immerse the unit in 70_C water to measure the resistance Standard value 104 ...

Page 1543: ...emoval steps 1 Meter bezel assembly 2 Combination meter AA 3 Adapter AB AA 4 Speedometer cable REMOVAL SERVICE POINT AA ADAPTER REMOVAL 1 Disconnect the speedometer cable from the transmission 2 Unlock the adapter and then remove the adapter by pulling it into the passenger compartment along with the speedometer cable Propeller shaft ...

Page 1544: ...NTINUITY CHECK Using a circuit tester check that continuity and discontinuity alternates between terminals 1 and 2 four times at every rotation of the shaft of the speedometer cable connection FUEL GAUGE RESISTANCE CHECK 1 Remove the power supply tightening screw 2 Use a circuit tester to measure the resistance between the terminals NOTE The terminal positions are indicated by FU and Standard valu...

Page 1545: ...ce between the terminals NOTE The terminal positions are indicated by TE and Standard value Power supply Earth 191 Ω Power supply Engine coolant temperature gauge TE 103 Ω Engine coolant temperature gauge TE Earth 88 Ω Caution When inserting the test probe into the power supply terminal be careful not to touch the printed board Engine coolant temperature gauge TE Earth Power supply ...

Page 1546: ...rmometer may be present D Malfunction of outside thermo sensor D Malfunction of harness or connector D Malfunction of thermometer OK Check trouble symptom NG Check the harness between outside thermo sensor and multi meter Repair if necessary OK Replace the thermometer OK Measure at the multi meter connector C 45 D Connecttheconnectorandmeasure voltageofthe sensor atthe following temperature D Volt...

Page 1547: ...tom NG Check the harness between thermome ter and outside thermo sensor Repair if necessary NG Repair OK Replace the thermometer Measure at the multi meter connector C 45 D Disconnect the connector and measure at the harness side 1 Voltage between terminal 11 and earth OK System voltage 2 Continuity between terminal 3 and earth OK Continuity 1 NG Check the following connectors C 44 C 45 C 79 C 88 ...

Page 1548: ...ND INSTALLATION NOTE metal clip position 1 2 Removal steps 1 Multi meter panel 2 Multi meter DISASSEMBLY AND REASSEMBLY 54300410026 1 2 3 4 5 6 7 8 Disassembly steps 1 Bulb 2 Meter garnish 3 Meter glass 4 Window plate 5 Inclinometer 6 Voltmeter 7 Thermometer 8 Meter case ...

Page 1549: ...x 500 OUTSIDE THERMO SENSOR 54300950016 REMOVAL AND INSTALLATION 1 2 3 1 Front combination lamp L H 2 Bracket 3 Outside thermo sensor INSPECTION 54300960019 OUTSIDE THERMO SENSOR INTERNAL RESISTANCE CHECK Check the internal resistance of the outside thermo sensor are at the standard values at temperatures of 20_C and 40_C Standard value Approx 1 200 Ω at 20_C Approx 500 Ω at 40_C Thermometer Dryer...

Page 1550: ...e vertical line V Headlamp intensity cd 30 000 or more SPECIAL TOOLS 54200060327 Tool Number Name Use MB991502 MUT II sub as sembly ETACS ECU input signal checking MB991223 A MB991219 B MB991220 C MB991221 D MB991222 Harness set A Test harness B LED harness C LED harness adapter D Probe Making voltage and resistance measurements during troubleshooting A Connector pin contact pressure inspection B ...

Page 1551: ... one shot pulse input signal only is impossible 2 54 41 The lighting monitor buzzer doesn t sound under the following conditions while tail lamps or headlamps illuminate D When the ignition switch is turned to OFF and the driver s side door is open 3 54 41 Headlamp leveling does not occur when the headlamp leveling switch is operated 5 54 43 The headlamps do not illuminate when the vehicle is in t...

Page 1552: ... between the diagnosis connector and ETACS ECU OK Check the following connectors C 35 C 90 NG Repair NG Repair OK Check trouble symptom NG Replace the ETACS ECU Inspection Procedure 3 The ignition switch is turned to the OFF position and the driver s side door is opened while the tail lamps or headlamps are operating but the light reminder warning buzzer does not sound Probable cause The cause is ...

Page 1553: ...rth check NG Repair OK Disconnect the door switch connector D 17 and measure at the harness side D Voltage between the terminal No 2 and body earth OK 5 V NG Check the following connectors C 87 C 91 D 17 D 21 NG Repair OK Check trouble symptom NG Check the harness wire between the door switch and junction block and re pair if necessary OK Check trouble symptom NG Replace the buzzer ECU or ETACS EC...

Page 1554: ... of the headlamp leveling unit Replace OK Check trouble symptoms NG Check the harness wire between the headlamp leveling unit and body earth Repair if necessary Check the following connectors A 18 A 35 NG Repair Disconnect the headlamp leveling unit LH headlamp leveling unit RH and headlamp leveling switch connectors A 18 A 35 C 32 and measure at the harness side D Continuity between terminal No 3...

Page 1555: ...e OK Disconnect the DRL relay 1 connector A 12 and measure at the harness side D Ignition switch ON 1 Voltage between terminal No 4 and earth OK System voltage 2 Voltage between terminal No 3 and earth OK System voltage when the lighting switch is at HEAD and 0 V when it is at OFF 3 Continuity between terminal No 1 and earth OK Continuity 1 NG Check the following connectors A 12 A 16 C 81 C 88 NG ...

Page 1556: ...nction of the DRL ECU Lighting switch check Refer to P 54 49 NG Replace OK Disconnect DRL ECU connector A 10 and measure at the harness side D Continuity between terminal No 10 and earth OK Continuity NG Check the following connectors A 10 A 19 NG Repair OK Check trouble symptoms NG Check the harness wire between the DRL ECU and the body earth Repair if necessary OK Tail lamp relay check Refer to ...

Page 1557: ...r load in the vehicles other than driver or substituted weight of approximately 75 kg placed in driver s position 2 Set the distance between the screen and the centre of the headlamps as shown in the illustration 3 Check if the beam shining onto the screen is at the standard value Standard value Vertical direction 60 mm below horizontal H Horizontal direction Position where the 15_ sloping section...

Page 1558: ...re to make any adjustments necessary to satisfy such regulations 3 If an illuminometer is used to make the measurements convert its values to photometer values by using the following formula I Er2 Where I intensity cd E illumination lux r distance m from headlamps to illuminometer BULB REPLACEMENT 54200130141 Headlamp Bulb 1 Disconnect the connector 2 Remove the socket cover 3 Unhook the spring wh...

Page 1559: ...tion D Headlamp Aiming Adjustment Refer to P 54 46 6 4 5 1 2 3 7 8 Vehicles with headlamp leveling switch 1 Column switch Lighting switch and dimmer passing switch Refer to GROUP 37A Steering Wheel and Shaft 2 Headlamp leveling switch Headlamp removal steps 3 Radiator grille Refer to GROUP 51 Grille Moulding Garnish 4 Retaining ring 5 Headlamp 6 Adjusting screw 7 Mounting ring or mounting ring and...

Page 1560: ...ING NOTE indicates continuity when the dimmer switch in the lower beam position HEADLAMP LEVELING SWITCH CHECK 54200810038 Check the resistance between the terminals when the headlamp leveling switch is operated Switch position 0 1 2 3 4 Resistance measure ment between termi nal No 3 and 4 Ω 120 300 620 1 100 2 000 HEADLAMP RELAY AND TAIL LAMP RELAY CONTINUITY CHECK 54200820109 Battery voltage Ter...

Page 1561: ...AMP RELAY 1 2 AND 3 CONTINUITY CHECK R H drive vehicles 54200840020 Battery voltage Terminal No 1 2 3 4 Supplied Not supplied RESISTOR RESISTANCE CHECK R H drive vehicles 54200850023 Disconnect the resistor connector and measure the resistance between the terminal No 1 and No 2 Standard value Approx 1 Ω Daytime running lamp relay 1 2 Daytime running lamp ECU Dim dip lamp relay 1 2 3 ...

Page 1562: ...mn switch removal 1 Column switch Lighting switch and turn signal lamp switch Refer to GROUP 37A Steering Wheel and Shaft Front combination lamp removal steps 2 Front combination lamp 3 Bulb For turn signal lamp 4 Bulb For position lamp 5 Bulb socket assembly INSPECTION 54200760074 LIGHTING SWITCH AND TURN SIGNAL LAMP SWITCH CONTINUITY CHECK Switch position Terminal No 3 5 7 8 9 LIGHTING SWITCH OF...

Page 1563: ...tch removal 1 Column switch Turn signal lamp switch Refer to GROUP 37A Steering Wheel and Shaft Side turn signal lamp removal steps AA 2 Side turn signal lamp 3 Bulb socket 4 Bulb 5 Packing 6 Hook REMOVAL SERVICE POINT AA SIDE TURN SIGNAL LAMP REMOVAL Use a flat tipped screw driver or similar tool to remove the lock from the fender panel and then remove the side turn signal lamp INSPECTION 5420076...

Page 1564: ...ng 5 6 4 2 1 3 1 Column switch Lighting switch and turn signal lamp switch Refer to GROUP 37A Steering Wheel and Shaft Rear combination lamp removal steps 2 Rear combination lamp 3 Bulb For tail and stop lamp 4 Bulb For back up lamp 5 Bulb For turn signal lamp 6 Bulb socket assembly INSPECTION 54200760098 LIGHTING SWITCH AND TURN SIGNAL LAMP SWITCH CONTINUITY CHECK Refer to P 54 51 TAIL LAMP RELAY...

Page 1565: ...e MB990784 Ornament remover Fog lamp switch removal REAR FOG LAMP 54200980012 REMOVAL AND INSTALLATION 3 1 2 4 Removal steps 1 Rear fog lamp switch 2 Lens 3 Bulb 4 Rear fog lamp body assembly INSPECTION 54200920014 REAR FOG LAMP SWITCH CONTINUITY CHECK Switch position Terminal No 1 ILL 2 3 6 OFF ON ...

Page 1566: ...CTRICAL Rear Fog Lamp 54 55 REAR FOG LAMP RELAY CONTINUITY CHECK 54200930017 Battery voltage Terminal No 1 2 3 4 Supplied Not supplied L H drive vehicles Rear fog lamp relay R H drive vehicles Rear fog lamp relay ...

Page 1567: ...ame Use MB990784 Ornament remover Rheostat removal RHEOSTAT 54200610096 INSPECTION 1 Connect the battery and the test lamp 40 W as shown in the illustration 2 Operate the rheostat and if the brightness changes smoothly without switching off then the rheostat function is normal 40 W ...

Page 1568: ...remover Meter bezel assembly removal HAZARD WARNING LAMP SWITCH 54200660084 REMOVAL AND INSTALLATION NOTE metal clip position 1 2 3 Removal steps 1 Meter bezel assembly 2 Switch holder 3 Hazard warning lamp switch INSPECTION 54200670100 HAZARD WARNING LAMP SWITCH CONTINUITY CHECK Switch position Terminal No osition 1 2 4 5 6 7 9 ILL 10 OFF ON ...

Page 1569: ...8 REMOVAL AND INSTALLATION 1 2 3 1 Removal steps 1 Front combination lamp 2 Horn High sound 3 Horn Low sound INSPECTION 54200650012 HORN RELAY CONTINUITY CHECK Vehicles with SRS Battery voltage Terminal No 1 2 3 4 Supplied Not supplied Horn relay ...

Page 1570: ...console assembly Refer to GROUP 52A 1 Plug 2 Fixing ring 3 Socket case 4 Socket washer 5 Socket 6 Protector INSPECTION 54300570113 D Take out the plug and check for a worn edge on the element spot connection and for shreds of tobacco or other material on the element D Using a circuit tester check the continuity of the element Element Spot ...

Page 1571: ... REMOVAL AND INSTALLATION NOTE metal clip position 1 2 3 4 5 6 7 8 9 8 Removal steps D Front floor console assembly Refer to GROUP 52A 1 Throttle cable knob Diesel pow ered vehicles 2 Driver s side under cover 3 Meter bezel assembly 4 Glove box assembly 5 Ashtray 6 Ashtray bracket 7 Center under cover 8 Heater control panel assembly mounting screw 9 Clock ...

Page 1572: ...ot of noise A 4 There is more noise either on AM or on FM A 5 There is noise when starting the engine A 6 Some noise appears when there is vibration or shocks during travelling A 7 Noise sometimes appears on FM during travelling A 8 Ever present noise A 9 Radio When switch is set to ON no power is available B 1 No sound from one speaker B 2 There is noise but no reception for both AM and FM or no ...

Page 1573: ... to a different station with a strong signal to boost resistance to interference 2 Suppress high tones to reduce noise 3 Extend antenna completely Yes OK Yes Find out the following information from the user 1 Place 2 Locality conditions valley moun tain etc 3 Name and frequency of stations affected by noise No If due to vehicle noise It may not be possible to prevent noise if the signal is weak If...

Page 1574: ...istance from the station s transmission antenna increases Although this may vary according to the signal strength of the transmitting station and intervening geographical formation or buildings the area of good reception is approx 20 25 km for stereo reception and 30 40 km for monaural reception 2 The signal becomes weak when an area of shadow from the transmitting antenna places where there are o...

Page 1575: ...he appearance of a beating sound may occur Beat sound Two signals close in frequency interfere with each other creating a repetitious high pitched sound This sound is generated not only by sound signals but by electrical waves as well 2 Factors due to vehicle noise Alternator noise may be a cause Is the noise still obvious even with the lamps OFF No Yes Dothefollowingmeasureseliminatethe noise D T...

Page 1576: ... it properly mounted No Clean the antenna plug and earth wire mounting area Mount the antenna se curely Yes If there is more noise than other radios consult a service centre Is the noise eliminated No Yes OK Noise occurs when the engine in running Inspect the vehicle s noise suppressor Refer to A 6 NOTE About noise encountered during FM reception only Due to differences in FM and AM systems FM is ...

Page 1577: ...ther source of electrical noise Yes No Continue to check for static when static is detected check for the conditions listed above Yes Noise prevention on the radio side is difficult If the problem is particularly worse than other radios consult a service centre No If the problem is particularly worse than other radios consult a service centre 2 There is much noise only on FM Due to differences in ...

Page 1578: ...and muffler suspension etc Tighten the mounting bolts securely Cases where the problem is not eliminated by a single response to one area are common due to several body parts being imperfectly earthed Caution 1 Connecting a high tension cable to the noise filter may destroy the noise filter and should never be done 2 Check that there is no external noise Since failure caused by this may result in ...

Page 1579: ...tatic electricity noise Body static electric from the shock absorber rubber bushings used to prevent vibration tyres etc occurs because of separation from the earth causing a buzzing noise Since no measures can be taken on the radio side other steps should be taken to discharge the static electricity of the vehicle body Yes Is the radio correctly earthed Is the mounting screw tightened securely No...

Page 1580: ...city of the vehicle body Yes Istheradiobodycorrectlyearthed Isthemountingscrewtightened securely No Tighten the screw securely Yes Istheantennacorrectlyearthed Ifnoiseappearswhentheantenna is moved this means the earth is not securely connected No If rust is present at the antenna earth screw clean and tighten the earth securely Yes Repair or replace radio No About multipath noise and fading noise...

Page 1581: ...1 No power is supplied when the switch is set to ON Is dedicated fuse No 4 blown or is the circuit open Yes Replace fuse or repair harness No Is the connector at the back of the radio connected properly No Connect connector securely Yes Disconnect and check the connector at the rear of the radio Is the ACC power 12 V being supplied to the radio No Repair harness Yes Repair or replace radio B 2 No ...

Page 1582: ...rradio No Replace the antenna B 4 Insufficient sensitivity No Replace the antenna Yes Repair or replace radio Yes Does the problem disappear when a different radio is con nected OK Isthecheckbeingconductedunderspe cial electrical field conditions Yes Example In an underground garage or inside a building No Does tuning solve the problem Is proper performance obtained when the vehicle is moved Yes O...

Page 1583: ...or replace radio B 6 Distortion on FM only Doesthedistortionpersistwhentheradioistunedtoanotherstation No Due to weak electrical field of radio station Yes Does distortion increase or decrease when the vehicle is moved Yes Due to multipath noise No Repair or replace radio B 7 Too few automatic select stations OK Isthecheckbeingconductedunderspe cial electrical field conditions Yes Example In an un...

Page 1584: ... player may damage the mechanism The player should be taken to a service dealer for repair Does the tape player work if another tape is inserted Yes Replace tape 2 No Repair or replace tape player 2 Ensure that the tape label is not loose that the tape itself is not deformed and that the tape is tightly wound Also tape of C 120 or greater length often get caught in the mechanism and should not be ...

Page 1585: ... that the tape itself is not deformed and that the tape is tightly wound D Tapes of C 120 or greater length often get caught in the mechanism and should not be used Does the player play properly when the tape player head is cleaned Yes OK No Is proper operation obtained when the tape player is replaced Yes Repair or replace tape player No Repair or replace speaker C 5 Cassette tape will not be eje...

Page 1586: ... may damage the mechanism The player should be taken to a service dealer for repair No Is the head or capstan roller dirty Refer to the illustration below Yes Clean Repair or replace tape player C 7 Faulty auto reverse Does the player play OK if the tape is changed Yes OK No D Ensure that the tape label is not loose that the tape itself is not deformed and that the tape is tightly wound D Tapes of...

Page 1587: ... this may damage the tape player mechanism Take the cassette to a service dealer for repair Does the player play OK if the tape 2 is changed Yes Tape used is bad No 2 Ensure that the tape label is not loose that the tape itself is not deformed and that the tape is tightly wound Also tapes of C 120 or greater length often get caught in the mechanism and should not be used Repair or replace tape pla...

Page 1588: ...and then changes into code to wait for the next input No Repair or replace the radio and tape player Yes If the BAND button are pressed after the security code has been input again by means of the memory select buttons do the radio and tape player then work Yes Normal an incorrect code was input the first time No If the security code is not accepted is 2 ERROR displayed for two seconds and then ch...

Page 1589: ...io and tape player does not work for these causes input the security code by the following procedure 1 Using any of the following methods confirm the security code 1 Read the security code indicated on the cards retained by the car 2 If the security code is unknown owing to the user s loss of the card a Remove the radio and tape player referring to P 54 80 b Read the serial No stamped on the radio...

Page 1590: ...nput the correct code 2 The second error is displayed as 2 ERROR When the third error is made 3 ERROR is displayed and then the display changes to OFF If this should occur the unit will not work any more 3 To input the security code again turn the ignition switch to the ACC or ON position and wait for one hour when OFF is displayed After OFF disappears on the display and changes into CODE the secu...

Page 1591: ...al and Post installation Operation D Front Floor Console Assembly Removal and Installation Refer to GROUP 52A D Driver s Side Under Cover Meter Bezel Assembly Glove Box Assembly Center Under Cover Removal and Installation Refer to GROUP 52A Instrument Panel 2 1 1 Removal steps 1 Radio bracket 2 Radio and tape player ...

Page 1592: ...tion 2 1 Driver s side Passenger s side 3 5 4 Removal steps Driver s side 1 Throttle cable knob Diesel powered vehicles 2 Under cover 3 Speaker Passenger s side 4 Glove box assembly 5 Speaker REAR SPEAKER 2 1 Removal steps D Rear door trim Refer to GROUP 42 Door Trim and Waterproof Film 1 Speaker 2 Speaker cover ...

Page 1593: ...installation Operation D Front Floor Console Assembly Removal and Installation Refer to GROUP 52A D Driver s Side Under Cover Meter Bezel Assembly Glove Box Assembly Center Under Cover Removal and Installation Refer to GROUP 52A Instrument Panel 1 2 3 5 4 6 Removal steps 1 Pole 2 Radio and tape player 3 Front scuff plate driver s side 4 Cowl side trim driver s side 5 Cable clipped portion AA 6 Ant...

Page 1594: ...1 Run engine at 2 000 r min Check heater element with battery at full 2 Turn ON rear window defogger switch Measure heater element voltage with circuit tester at rear window glass centre A Condition is good if it indicates about 6V 3 If 12 V is indicated at A there is a break in the negative terminals from A Move test bar slowly to negative terminal to detect where voltage changes suddenly 0V 4 If...

Page 1595: ...s 1 Meter bezel assembly 2 Switch holder 3 Rear window defogger switch INSPECTION 54300630033 DEFOGGER SWITCH CONTINUITY CHECK Switch position Terminal No 1 ILL 5 2 IND 6 3 4 OFF ON REAR WINDOW DEFOGGER RELAY CONTINUITY CHECK 54300680083 Battery voltage Terminal No 1 2 3 5 Power is not supplied Power is supplied Rear window defogger relay Junction block ...

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Page 1614: ...0 10 Group GENERAL Draft No 00SY0022915 INFORMATION CORRECTION INTERNATIONAL CAR ADMINISTRATIO OFFICE T NITTA PROJECT LEADER AFTER SALES SERVICE CS PROMOTION 1 Description This Service Bulletin informs you of the year model changes for the 2001 L200 2 Applicable Manuals Manual Pub No Language Page s 2000 L200 PWTE96E1 D English Workshop Manual Chassis PWTS96E1 D Spanish PWTF96E1 D French PWTG96E1 ...

Page 1615: ...2 ...

Page 1616: ... PWTE96E1 C SUPPLEMENT PWTE96E1 D SUPPLEMENT ELECTRICAL WIRING PHTE96E1 PHTE96E1 A PHTE96E1 B PHTE96E1 D PHTE96E1 D SUPLEMTENT BODY REPAIR MANUAL PARTS CATALOGUE PBTE96E1 T603B00 D All information illustrations and product d e scriptions contained in this manual are current as at the time of publication We however re serve the right to make changes at any time without prior notice or obligation Mi...

Page 1617: ... 5M T MPI ENDL6 ENDR6 CENDL6 K64T JENDL6 4D56 2 477mℓ R5M21 2WD M T Fuel injection CENDEL6 K75T GJENXEL6 4G64 SOHC 2 351 mℓ V5M21 4WD 5M T MPI ENDFL6 ENDFR6 V5MT1 4WD 5M T JERDFL6 V4AW2 AWD 4A T GJERXFL6 GJENXFL6 GJENXFR6 CENDFL6 GCENXFL6 JENDFL6 JENDFR6 K74T JENHFL6 4D56 Turbocharger with intercooler 2 477mℓ V5MT1 4WD 5M T Fuel injection 00 1 GENERAL vehicle identification ...

Page 1618: ...mission type R 4 speed automatic transmission 6 Vehicle line K Mitsubushi L200 6 Long wheelbase 7 Body type 7 4WD Long wheelbase 2 4G63 1 997mℓ petrol engine 4 4D56 2 477mℓ diesel engine 8 Engine type 5 4G64 2 351 mℓ petrol engine 9 Internal production control code A A B C etc 0 zero No meaning 10 Model year 1 2001 11 Plant A A C LARDKRABANG factory D F LAEMCHABANG factory 12 Serial number NOTE In...

Page 1619: ...6 NOTES ...

Page 1620: ...oil has been changed ON VEHICLE SERVICE specified engine oil ACEA and API classification 4G6 ACEA A1 A2 A3 API SG or higher 4D5 ACEA B1 B2 B3 B4 API CD or higher ENGINE LUBRICATION General On vehicle Service 12 1 4G6 Barometric temperature Y0042AA Barometric temperature M03B017 4D5 ...

Page 1621: ...8 NOTES ...

Page 1622: ...ransmitter LOCK UNLOCK NOTE If the MUT II cannot check all the input signals the diagnosis circuit may be defective ETACS FUNCTION ADJUSTMENT PROCEDURE The following functions can be adjusted by operating input switches The adjustments will be stored in th ECU memory even after a battery cable is disconnected Switching of keyless entry answerback function From activation to deactivation or vice ve...

Page 1623: ...nd off If the function toggles on the buzzer sounds once default con dition If the function toggles off the buzzer sounds twice Initialisation of all the ETACS func tions From deactivation to activa tion When the tailgate switch remains on for more than 20 seconds th buzzer sounds twice and he answer back function of the keyless entry system is initialised The buzzer will sound in 10 seconds indic...

Page 1624: ...ister the encrypted code Refer to P 42 6 OK Replace the transmitter battery Refer to P 42 6 NG Is a commercial equipment equipped No Yes Remove that equipment and then check trouble symptoms NG Check the connection between ETACS ECU and junction block claw NG Repair OK NG Check the following connectors A 56X C 81 C 91 OK NG Measure at the ETACS ECU connector C 91 Disconnect the connector and measu...

Page 1625: ...ctuator If either room lamp or turn signal lamp does not flash illuminate the cause may be a malfunction of the room lamp circuit or turn signal lamp Malfunction of ETACS ECU Malfunction of driver s door lock actuator Burnt turn signal lamp bulb Malfunction of connector or wiring harness Carry out the troubleshooting for room lamp circuit Does the room lamp go on go off simultaneous with opening c...

Page 1626: ...k No 5 and diagnosis connector OK Replace MUT II Measure at the diagnosis connector C 35 Continuity between 4 and body earth Continuity between 5 and body earth OK System voltage NG NG Repair Check the following connectors C 35 C 86 OK Check trouble symptoms NG Check the harness wire and repair if necessary Between the diagnosis connector and earth NG Check the following connectors A 56X C 81 C 82...

Page 1627: ...in the following cases If a second transmitter is to be used If it appears that a problem is occurring because of faulty registration of a code A maximum of two different codes can be stored in the memory area of the EEPROM two different transmit ters can be used When the code for the first transmitter is registered th previously registered codes for two transmitters are cleared Therefore if you a...

Page 1628: ...hould be carried out for the second trans mitter and it should be carried out within one min ute after registration of the code for the first trans mitter has been completed After the second regis tration is completed the doors will be automatically locked and unlocked once 7 Registration mode will be terminated under the following conditions When the secret codes for two transmitters hav been reg...

Page 1629: ...ACS ECU removal 2 ETACS ECU Keyless entry receiver ECU removal steps Glove box assembly Refer to GROUP 52A 1 Keyless entry receiver ECU NOTE Refer to 97 L200 Workshop Manual Pub No PWTE96E1 42 8 BODY Keyless Entry System AY0014AA A18VO187 Junction block ...

Page 1630: ...The service procedures are the same as previous one FRONT SEAT BELT REMOVAL AND INSTALLATION Inner seat belt removal steps Front seat refer to P 52A 5 Inner seat belt Outer seat belt removal steps Center pillar trim lower or quarter trim lower refer to P 52A 1 Sash guide cover 2 Outer seat belt 3 Center pillar trim upper or quarter trim upper refer to P 52A 4 Adjustable seat belt anchor NOTE Refer...

Page 1631: ...18 NOTES ...

Page 1632: ...ocedure has been added due to the addition of the high stop lamp 4WD HIGH MOUNTED STOP LAMP REMOVAL AND INSTALLATION Removal steps 1 Rear gate panel 2 High mounted stop lamp 3 Lamp bracket 4 Bulb socket assembly 5 Bulb CHASSIS ELECTRICAL High Mounted Stop Lamp 54 1 A16V0088 ...

Page 1633: ...ection Procedure 1 Communication with MUT II is impossible Probable cause The cause is probably that a malfunction of the diagnosis line or the immobilizer ECU is not functioning D Malfunction of diagnosis line D Malfunction of harness or connector D Malfunction of immobilizer ECU Register the password secret code and the encrypted code Check trouble symptoms Check the harness between the immobili...

Page 1634: ...ht be a problem with the fuel injection system in addition to a malfunction of the immobilizer system It is normal for this to occur if an attempt is made to start the engine using a key that has not been properly registered D Malfunction of diesel fuel injection system D Malfunction of immobilizer ECU Check the system voltage during crank ing OK 8 V or more NG Check the battery OK Is a diagnosis ...

Page 1635: ...uble symptom NG Check the harness between the immobi lizer ECU and engine control relay and repair if necessary 2 NG Check the following connector C 36 NG Repair OK Check trouble symptom NG Check the harness between the immobi lizer ECU and body earth and repair if necessary CHECK AT IMMOBILIZER ECU Terminal Voltage Check Chart Terminal No Signal Checking requirements Terminal voltage 3 Immobilize...

Page 1636: ...NOTES ...

Page 1637: ...HEATER AIR CONDITIONER AND VENTILATION ...

Page 1638: ......

Page 1639: ...L ASSEMBLY AND A C SWITCH 21 HEATER UNIT AND HEATER CORE 24 BLOWER ASSEMBLY AND RESISTOR 26 EVAPORATOR VEHICLES WITH A C 28 COMPRESSOR AND TENSION PULLEY 30 CONDENSER AND CONDENSER FAN MOTOR 33 REFRIGERANT LINE 35 ENGINE COOLANT TEMPERATURE SWITCH Diesel powered Vehicles 37 IDLE UP SYSTEM Diesel powered Vehicles 39 LEVER POSITION SWITCH Diesel powered Vehicles A T 40 VENTILATORS 41 ...

Page 1640: ...ms it will not cause damage to the ozone layer Refrigerant R 134a is transparent and colourless in both the liquid and vapour state Since it has a boiling point of 29 8_C at atmospheric pressure it will be a vapour at all normal temperatures and pressures The vapour is heavier than air non flammable and nonexplosive The following precautions must be observed when handling R 134a Caution Wear safet...

Page 1641: ... R 134a should be used to check for refrigerant gas leaks 2 Do not allow liquid refrigerant to touch bright metal Refrigerant will tarnish bright metal and chrome surfaces and in combination with moisture can severely corrode all metal surfaces SERVICE SPECIFICATIONS 55200030141 Items Standard value Idle speed r min 4G6 750 100 4D5 750 100 Idle up speed r min 900 50 Resistor for blower motor L H d...

Page 1642: ...e refrigerant 55 6 14 Dual pressure switch is defective Replace the dual pressure switch 55 7 35 A C switch is defective Replace the A C switch 55 21 23 Blower switch is defective Replace the blower switch 55 21 23 Thermostat is defective Replace the Thermostat 55 29 Engine coolant temperature switch for A C cut off is defective Diesel powered ve hicles Replace the engine coolant temperature switc...

Page 1643: ...ser fan does not turn Condenser fan relay is defective Replace the condenser fan relay 55 16 ON VEHICLE SERVICE 55200840096 SIGHT GLASS REFRIGERANT LEVEL TEST The sight glass is a refrigerant level indicator To check the refrigerant level clean the sight glass and start the vehicle engine Push the A C button to operate the compressor place the blower switch to high and move the temperature control...

Page 1644: ...ier DUAL PRESSURE SWITCH CHECK 55201040129 1 Remove the dual pressure switch connector and connect the high low pressure side terminals located on the harness side as shown in the illustration 2 Install a gauge manifold to the high pressure side service valve of the refrigerant line Refer to Performance Test 3 When the high low pressure sides of the dual pressure switch are at operation pressure O...

Page 1645: ...ing to ensure that there are no bends in the hose 5 Close the high and low pressure valves of the gauge manifold 6 Install the vacuum pump adaptor to the vacuum pump 7 Connect the vacuum pump plug to the vacuum pump adaptor 8 Connect the charging hose yellow to the R 134a connection port of the vacuum pump adaptor 9 Tighten the adaptor valve handle valve open 10 Open the low pressure valve of the ...

Page 1646: ...y occur 15 Carry out a leak test Good if the negative pressure does not drop Caution If the negative pressure drops increase the tightness of the connections and then repeat the evacuation procedure from step 12 16 With the handle turned back all the way valve open install the charging valve to the service van 17 Turn the handle of the adaptor valve back all the way valve closed remove it from the...

Page 1647: ...leak detector for R 134a should be used 22 Start the engine 23 Operate the A C and set to the lowest temperature MAX COOL 24 Fix the engine speed at 1 500 r min 25 Tighten the handle of the adaptor valve valve open to charge the required volume of refrigerant Caution If the service can is inverted liquid refrigerant may be drawn into the compressor damaging it by liquid compression Keep the servic...

Page 1648: ...r conditioner and set at the lowest temperature MAX COOL 10 Fix the engine speed at 1 500 r min 11 Tighten the handle of the adaptor valve valve open and replenish refrigerant while checking the quantity through the sight glass Caution If the service can is inverted liquid refrigerant may be draw into the compressor damaging it by liquid compression Keep the service can upright to ensure that refr...

Page 1649: ...ends in the hose 6 Place the adaptor valve inside the container and discharge the refrigerant by opening the handle gradually so that oil does not gush out NOTE Any oil remaining in the container should be returned to the A C system REFILLING OF OIL IN THE A C SYSTEM Too little oil will provide inadequate compressor lubrication and cause a compressor failure Too much oil will increase discharge ai...

Page 1650: ...e Caution To connect the quick joint press section A firmly against the service valve until a click is heard When connecting run your hand along the hose while pressing to ensure that there are no bends in the hose 6 Start the engine 7 Set the controls to the A C as follows A C switch A C ON position Mode selection Face position Temperature control Max cooling position Air selection Recirculation ...

Page 1651: ...frigerant system use the procedure for correcting low refrigerant level HANDLING TUBING AND FITTINGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system High pressures are produced in the system when it is operating Extreme care must be exercised to make sure that all connections are pressure tight Dirt and moisture can...

Page 1652: ...l noises that are often mistaken for mechanical problems within the compressor ADJUSTMENT 1 Select a quiet area for testing Duplicate conditions as much as possible Switch compressor on and off several times to clearly identify compressor noise To duplicate high ambient conditions high head pressure restrict air flow through condenser Install manifold gauge set to make sure discharge pressure does...

Page 1653: ...P for vehicles with A T D Steering wheel Straightforward 2 Check whether or not the idling speed is the standard value Standard value 750 100 r min 3 When the A C is running after turning the A C switch to ON and the blower switch to the MH or HI position check to be sure that the idle speed is at the standard value Standard value 900 50 r min NOTE There is no necessity to make an adjustment becau...

Page 1654: ...ed becomes the standard value when the A C switch is switched ON and the A C is activated Standard value 900 50 r min 5 If there is a deviation of the idling speed from the standard value adjust the idling speed by the following the procedures 1 Loosen nuts A and B 2 Adjust by using the adjuster so that the end of the vacuum actuator s rod is at the position indicated in the illustration 3 Securel...

Page 1655: ... full stroke when 12 kPa of negative pressure is applied 4 Disconnect the manual vacuum pump from the vacuum actuator and connect the vacuum hose yellow stripe to the vacuum actuator 5 Start the engine and let it run at idle Then cover the end of the vacuum hose yellow stripe with a finger and check the negative pressure when the A C switch is turned on and off A C switch Negative pressure at hose...

Page 1656: ...nal and without applying voltage Battery voltage Nipple B Vacuum condition Applied Open Vacuum leaks from nipple B Blocked with finger 1 Vacuum is maintained Not applied Open Vacuum is i t i d Blocked with finger 2 maintained NOTE In case of mark 1 a vacuum can be felt but in case of mark 2 a vacuum can not be felt 5 Measure the resistance of the solenoid valve Standard value Approx 40 Ω 6 When di...

Page 1657: ... malfunction adjust the installation position of the lever position switch by the following procedure 1 Check that the idle speed is at the standard value and adjust it if necessary Standard value 750 100 r min 2 Adjust the accelerator cable 3 Depress the accelerator pedal fully to fully open the throttle lever of the fuel injection pump Caution When fully opening the throttle lever of the fuel in...

Page 1658: ... Bezel Assembly Glove Box Assembly Centre Under Cover Removal and Installation Refer to GROUP 52A Instrument Panel Contact surface 2 3 4 5 1 Removal steps 1 Foot duct AA AA 2 Heater control assembly 3 A C switch 4 Knob 5 Blower switch REMOVAL SERVICE POINT AA HEATER CONTROL ASSEMBLY REMOVAL 1 Remove the heater control assembly mounting screws 2 Bend the bosses which are inserted into the centre re...

Page 1659: ...e outer cable in the direction of the arrow so that there is no looseness and then secure it with clip 3 Follow the steps below to install the inside outside air changeover damper link cable 1 Set the inside outside air changeover control knob on the heater control assembly to the inside recirculation position 2 Set the inside outside air changeover damper link of the blower assembly to the inside...

Page 1660: ...ITIONER AND VENTILATION 55 23 INSPECTION 55200220074 A C SWITCH CONTINUITY CHECK Switch iti Terminal No position 1 4 IND 5 3 ILL 6 OFF ON BLOWER SWITCH CONTINUITY CHECK 55200900060 Lever iti Terminal No position 1 ILL 5 2 3 6 7 8 9 10 OFF LO ML MH HI OFF ON ...

Page 1661: ...Refer to GROUP 52A D Joint Duct Removal and Installation Vehicles without A C Refer to P 55 26 Caution SRS When removing and installing the heater unit from vehicles equipped with SRS do not let it bump against the SRS diagnostic unit or the components 1 2 3 5 6 7 8 9 Compressor oil ZXL 100PG Piping connection 5 4 Removal steps 1 Center reinforcement 2 Center ventilation duct 3 Drain hose Vehicles...

Page 1662: ...e and the evaporator nipple not to let foreign matter get into them Caution Seal the hoses completely otherwise the compressor oil and receiver will absorb water vapor easily INSTALLATION SERVICE POINT AA EVAPORATOR INSTALLATION When replacing the evaporator refill with a specified amount of compressor oil and install it to the vehicle Compressor oil ZXL 100PG Quantity 50 m ...

Page 1663: ... without A C NOTE metal clip position 3 5 Resistor blower fan and motor removal steps 1 Under cover 2 Glove box assembly 3 Resistor 4 Blower fan and motor Blower case removal steps D Instrument panel Refer to GROUP 52A 5 Joint duct Vehicles without A C 6 Evaporator Vehicles with A C Refer to P 55 28 AA 7 Inside outside air changeover damper cable connection 8 Blower case assembly ...

Page 1664: ...pplied between the terminals check that the motor operates Also check that there is no abnormal noise RESISTOR CHECK Use a circuit tester to measure the resistance between the terminals as indicated below Check that the measured value is at the standard value Standard value L H drive vehicles Measurement terminal Standard value Ω Between terminals 3 and 2 LO 2 21 Between terminals 3 and 4 ML 0 97 ...

Page 1665: ...s AA 1 Suction pipe or hose connection AA 2 Discharge pipe connection 3 O ring 4 Drain hose 5 Center frame B AA 6 Evaporator REMOVAL SERVICE POINT AA SUCTION PIPE OR HOSE DISCHARGE PIPE DISCONNECTION Plug the disconnected hose and the evaporator nipple not to let foreign matter get into them Caution Seal the hoses completely otherwise the compressor oil and receiver will absorb water vapour easily...

Page 1666: ...INSPECTION 55200370038 THERMOSTAT AIR THERMO SENSOR CHECK 1 Apply battery voltage between the thermostat terminals shown in the illustration and connect a test lamp to terminal 3 2 Blow cool air onto the air thermo sensor and check that the test lamp switches off when the cool air temperature becomes approximately 3 _C or less COMPRESSOR ECU SIMPLE TEST Diesel powered Vehicles A T 1 Check to be su...

Page 1667: ...allation D Refrigerant Charging Refer to P 55 8 CAUTION SRS When removing and installing the compressor from vehicles equipped with SRS do not let it bump against the front impact sensor L H 4G63 4G64 7 1 2 6 3 5 22 Nm 4 Hose connection Compressor oil ZXL 100PG 8 9 45 Nm 22 Nm 4D56 1 2 6 3 5 4 8 45 Nm 22 Nm 7 45 Nm 4 Removal steps AA 1 Drive belt AB 2 Suction hose connection AB 3 Discharge hose co...

Page 1668: ...ICE POINT AA COMPRESSOR INSTALLATION If a new compressor is installed first adjust the amount of oil according to the procedures described below and then install the compressor 1 Measure the amount X m of oil within the removed compressor 2 Drain from the new compressor the amount of oil calculated according to the following formula and then install the new compressor New compressor oil amount 180...

Page 1669: ...l to the compressor side terminal and earth the battery terminal to the body of the compressor The condition is normal if the sound of the magnetic clutch click can be heard COMPRESSOR MAGNETIC CLUTCH AIR GAP CHECK 55201110011 Check whether or not the air gap of the clutch is within the standard value Standard value 0 3 0 6 mm Magnetic clutch connector Thickness gauge ...

Page 1670: ...onnection Compressor oil ZXL 100PG 10 10 10 10 12 9 NOTE L H drive vehicles Condenser fan motor removal steps 1 Hood lock stay 2 Condenser fan motor and shroud assembly 3 Net 4 Condenser fan 5 Condenser fan motor 6 Shroud Condenser removal steps D Refrigerant Discharging and Charging Refer to P 55 8 D Engine oil cooler Diesel powered vehicles Refer to GROUP 12 1 Hood lock stay 2 Condenser fan moto...

Page 1671: ...Seal the hoses completely otherwise the compressor oil and receiver will absorb water vapour easily INSTALLATION SERVICE POINT AA CONDENSER INSTALLATION When replacing the condenser refill it with a specified amount of compressor oil and install it to the vehicle Compressor oil ZXL 100PG Quantity 30 m INSPECTION 55200680094 CONDENSER FAN MOTOR CHECK Check to be sure that the condenser fan motor op...

Page 1672: ...Wiper and Washer CAUTION SRS When removing and installing the suction pipe or discharge pipe C from vehicles equipped with SRS do not let it bump against the front impact sensor R H Compressor oil ZXL 100PG Piping connection 1 2 3 4 5 6 7 8 9 10 9 Nm 11 13 10 10 10 10 10 12 10 10 10 AA AA 1 Suction hose AA 2 Suction pipe D Power steering oil reservoir Refer to GROUP 37A Power Steering Hose AA 3 Su...

Page 1673: ...ection Compressor oil ZXL 100PG 8 2 3 4 5 6 7 8 8 8 1 8 AA AA 1 Suction hose AA 2 Discharge pipe A AA 3 Discharge pipe B AA 4 Discharge hose AA AA 5 Receiver assembly 6 Dual pressure switch 7 Receiver bracket 8 O ring REMOVAL SERVICE POINT AA HOSE PIPE RECEIVER ASSEMBLY DISCONNECTION Plug the disconnected hose the receiver the evaporator and the compressor nipple not to let foreign matter get into...

Page 1674: ...oil ZXL 100PG Quantity Suction hose 10 m Receiver assembly 10 m ENGINE COOLANT TEMPERATURE SWITCH Diesel powered Vehicles 55200730058 REMOVAL AND INSTALLATION Pre removal and Post installation Operation D Coolant Refilling Refer to GROUP 14 On vehicle Service D Intercooler Removal and Installation Vehicles with intercooler Refer to GROUP 15 Threaded portion Sealant 3M Nut Locking Part No 4171 or e...

Page 1675: ...th a circuit tester as the temperature of the oil changes and the condition is normal if the continuity is within the following ranges Standard value Engine coolant temperature switch Temperature Continuity For A C cut off Less than 108 _C Temperature at point A ON Continuity More than 115 _C Temperature at point B OFF No continuity For condenser fan Less than 97 _C Temperature at point A OFF No c...

Page 1676: ...n vehicle Service D Intercooler Installation Vehicles with intercooler Refer to GROUP 15 D Idle up Operation Check Refer to P 55 16 Vehicles with ABS 1 2 3 4 5 9 10 2 10 6 8 7 Idle up solenoid valve removal steps 1 Vacuum hose white stripe connection 2 Vacuum hose yellow stripe connection 3 Idle up solenoid valve 4 Solenoid valve bracket B 5 Solenoid valve bracket A Vacuum actuator assembly remova...

Page 1677: ...p Caution When fully opening the throttle lever of the fuel injection pump always open it by the accelerator pedal not from the injection pump side 4 Adjust the stroke of the lever position switch rod by moving the lever position switch so that the rod is pushed down 4 1 mm from the free position INSPECTION 55200800025 1 Connect a circuit tester as shown in the illustration and check that there is...

Page 1678: ...er grille Air outlet assembly Driver s side and centre outlet assembly removal steps 2 Meter bezel assembly 3 Air outlet assembly Driver s side 4 Centre outlet assembly Foot duct removal steps D Front floor console assembly Refer to GROUP 52A Floor Console 5 Foot duct Defroster nozzle distribution duct air outlet assembly Passenger s side and centre ventilation duct removal steps 6 Instrument pane...

Page 1679: ...1 Air outlet duct assembly Double cab Air outlet duct assembly removal steps D Rear body Refer to GROUP 42 11 Air outlet duct assembly Club cab Air outlet duct assembly removal steps D Rear body Refer to GROUP 42 11 Air outlet duct assembly Rear ventilation duct removal steps D Back panel trim lower Refer to GROUP 52A Trims D Quarter trim lower Refer to GROUP 52A Trims 12 Rear ventilation duct ...

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Page 1686: ...o 99SY060115 CORRECTION INTERNATIONAL CAR ADMINISTRATION OFFICE T NITTA PROJECT LEADER AFTER SALES SERVICE CS PROMOTION 1 Description Omission has been rectified of a description of the disassembly reassembly of the A C compressor assembly under Compressor and Tension Pulley 2 Applicable Manuals Manual Pub No Language Page s PWTE96E1 English 55 5 32 PWTS96E1 Spanish PWTF96E1 French 97 L200 Worksho...

Page 1687: ...ive Replace the Thermostat 55 29 Engine coolant temperature switch for A C cut off is defective Diesel powered vehicles Replace the engine coolant temperature switch 55 37 38 When the ignition switch is ON the A C does not operate Engine ECU is defective Petrol powered vehicles Replace the engine ECU Refrigerant leak Replenish the refrigerant and repair the leak 55 14 Dual pressure switch is defec...

Page 1688: ...is normal if the sound of the magnetic clutch click can be heard COMPRESSOR MAGNETIC CLUTCH AIR GAP CHECK Check whether or not the air gap of the clutch is within the standard value Standard value 0 3 0 6 mm See the Following two pages 55 32 55200850105 HEATER AIR CONDITIONER AND VENTILATION Compressor and Tension Pulley 55201110011 A20G0346 A20V0047 Magnetic clutch connector Thickness gauge ...

Page 1689: ...ing 4 Rotor 5 Snap ring 6 Clutch coil DISASSEMBLY SERVICE POINTS A ARMATURE PLATE REMOVAL REASSEMBLY SERVICE POINTS A SNAP RING INSTALLATION Install the snap ring so that the tapered surface is at the outer side Added HEATER AIR CONDITIONER AND VENTILATION Magnetic clutch AV1021AE AV1079AE Snap ring Rotor Clutch coil Tapered part BWO611AL ...

Page 1690: ...is within the standard value Standard value 0 3 0 6 mm Note If there is a deviation of the air gap from the standard value make the necesarry adjustement by adjusting the number of shims Added HEATER AIR CONDITIONER AND VENTILATION Magnetic clutch A20V0047 Thickness gauge ...

Page 1691: ...AUTOMATIC AIR CONDITIONER ...

Page 1692: ...IAL TOOLS 2 TROUBLESHOOTING 3 ON VEHICLE SERVICE 20 Blower High Speed Relay Continuity Check 20 Idle up Inspection 4D56 20 AUTOMATIC AIR CONDITIONER CONTROL PANEL ASSEMBLY A C ECU 21 MOTOR 22 HEATER UNIT 25 EVAPORATOR 27 PHOTO SENSOR 28 AMBIENCE TEMPERATURE SENSOR 29 REFRIGER LINE 30 THROTTLE CABLE 31 ...

Page 1693: ...meter resistance kΩ DEF position Around 0 18 kΩ FACE position Around 4 82 SPECIAL TOOLS Tool Number Name Use MB991502 MUT II sub assembly Automatic air conditioner inspection MB991529 Diagnosis code check harness Automatic air conditioner inspection when using voltmeter A B C D MB991223 A MB991219 B MB991220 C MB991221 D MB991222 Harness set A Check harness B LED harness C LED harness adapter D Pr...

Page 1694: ...mperature sensor system open circuit 55B 4 14 Ambient temperature sensor system short circuit 55B 4 15 Heater water temperature sensor system open circuit 55B 4 16 Heater water temperature sensor system short circuit 55B 4 21 Air thermo sensor system open circuit 55B 5 22 Air thermo sensor system short circuit 55B 5 31 Potentiometer system for the air mixing damper 55B 5 32 Potentiometer system fo...

Page 1695: ...llowing connectors A 110 A 14 C 111 NG Repair Check the Ambient temperature sensor Refer to P 55B 28 NG Replace Code No 15 16 Heater water temperature sensor system Probable cause Code No 15 is output when the heater water temperature sensor circuit is open Code No 16 is output when that circuit is short D Malfunction of the heater water temperature sensor D Malfunction of connector or harness D M...

Page 1696: ...ector or harness D Malfunction of the A C ECU NG Repair NG Repair NG Check the harness wire between the air mixing damper control potentiometer and the A C ECU and repair if necessary OK Replace the automatic A C control panel assembly A C ECU NG Repair OK Replace the automatic A C control panel assembly A C ECU OK Check the trouble symptoms OK Measure at A C ECU connector C 111 D Connect the conn...

Page 1697: ...tors C 111 C 121 NG Check the harness wire between the mode selection damper control potentiometer and the A C ECU OK Check the trouble symptoms OK Measure at air outlet changeover damper motor connector C 121 D Disconnect the connector and measure at the harness side D Ignition switch ON D Voltage between terminal 2 and body earth OK 5V D Continuity between terminal 6 and body earth OK Continuity...

Page 1698: ... Repair Check the mode selection damper control motor Refer to P 55B 23 NG Replace INSPECTION CHART FOR TROUBLE SYMPTOMS Trouble symptom Inspection pro cedure No Reference page Communication with MUT II is not possible 1 55B 8 The air conditioner does not operate at all 2 55B 9 The air conditioner display does not appear on the display 3 55B 9 A C outlet air temperature can not be set 4 55B 10 The...

Page 1699: ...gnosis connector and the A C ECU may be defective D Malfunction of harness or connector D Malfunction of the A C ECU OK Replace the automatic A C control panel assembly A C ECU NO Check the diagnosis line between the diagnosis connector and the A C ECU and repair if necessary YES NO INSPECTION PROCEDURE FOR TROUBLE SYMPTOM 2 Refer to P 55B 9 YES NG Repair OK NG Check the harness wire between the A...

Page 1700: ...erminals Refer to P 55B 18 OK Check the trouble symptoms Check the following connectors C 112 C 86 4 NG OK Check the trouble symptoms Check the following connectors C 111 C 79 C 81 A 56X 3 NG OK Check the trouble symptoms Check the following connectors C 112 C 79 C 88 2 NG OK Check the trouble symptoms Measure at A C ECU connector C 111 C 112 D Disconnect the connector and measure at the harness s...

Page 1701: ...and the A C ECU OK Check the trouble symptoms OK Check the following connectors C 118 C 111 OK MUT II Data list 25 Photo sensor NG Check the photo sensor Automatic air conditioner Refer to P 55B 27 OK MUT II Data list 15 Heater water temperature sensor NG Check the heater water temperature sensor system Refer to P 55B 4 Code Nos 15 16 OK MUT II Data list 13 Ambient temperature sensor NG Check the ...

Page 1702: ...or connector C 23 D Disconnect the connector and measure at the harness side D Ignition switch ON D Voltage between terminal 1 and body earth OK System voltage Check the following connectors C 83 C 82 OK Check the trouble symptoms Check the following connectors C 83 C 88 2 NG OK Check the trouble symptoms Measure at blower relay connector C 83 D Disconnect the connector and measure at the J B side...

Page 1703: ...s OK Disconnect the A C ECU connector C 111 D Ignition switch ON Does the blower motor operate when A C ECU connector terminal 12 is earthed Check the following connectors C 116 C 86 C 88 OK Check the trouble symptoms Check the following connectors C 116 C 86 2 NG OK Check the trouble symptoms Measure at front blower high speed relay connector C 116 D Disconnect the connector and measure at the ha...

Page 1704: ...Voltage between terminal 2 and body earth OK Approximately 1 3V Check the following connectors C 117 C 23 C 89 1 NG OK Check the trouble symptoms Measure at power transistor connector C 117 D Blower switch ON 1 Continuity between terminal 1 and body earth OK Continuity D Ignition switch ON 2 Voltage between terminal 2 and body earth OK System voltage 2V 3 Voltage between terminal 4 and body earth ...

Page 1705: ...de inside air changeover is not possible Probable cause When inside air cannot be changed to outside air or vice versa even if its changeover switch is on the outside inside air selection damper control system may be defective D Malfunction of the outside inside air selection damper control motor D Malfunction of harness or connector D Malfunction of the A C ECU NG Repair NG NG Repair OK Replace t...

Page 1706: ...onnector A 69 D Disconnect the connector and measure at the harness side D Voltage between terminal 2 and body earth OK System voltage NG OK Check the trouble symptoms Check the following connectors A 59X A 14 2 NG OK Check the trouble symptoms OK Measure at condenser fan relay connector A 59X D Disconnect the connector and measure at the harness side 1 Voltage between terminal 4 and body earth A ...

Page 1707: ... NG Check the trouble symptoms OK Measure at condenser fan relay connector A 59X D Disconnect the connector and measure at the harness side 1 Voltage between terminal 4 and body earth Ignition switch ON A C switch ON OK System voltage 2 Voltage between terminal 3 and body earth OK Continuity 3 Terminal 1 is earthed OK The condenser fan motor operates 1 NG OK Check the condenser fan motor NG Replac...

Page 1708: ...ometer for the air mixing damper control Ignition switch ON Damper position MAX HOT Opening angle Approximately 100 g Ignition switch ON Damper position MAX COOL Opening angle Approximately 0 32 Potentiometer for the mode selection damper control Ignition switch ON Damper position FACE Opening angle Approximately 0 Ignition switch ON Damper position FOOT Opening angle Approximately 50 Ignition swi...

Page 1709: ... from ambient temperature sensor When sensor temperature 25_C 4 kΩ 2 3 2 9 V 8 Input from air thermo sensor Sensor temperature 25_C 4 kΩ 2 3 2 9 V 9 Photo sensor Illuminance 1000 lux 5 0 7 6 mV Illuminance 100 lux 0 5 0 76 mV 10 Sensor power supply At all times 4 8 5 2 V 12 Blower high speed relay Blower switch HI 1 5V or less g y Blower switch except HI System voltage 13 Earth At all times Contin...

Page 1710: ...ng to the FACE position Faint voltage 0 5 V 25 Air mixing damper control motor MAX HOT When the damper flap is moving to the MAX HOT position 10 V When the damper flap is moving to the MAX COOL position Faint voltage 0 5 V 26 Outside inside air selection damper control motor I id When the damper flap is moving to the inside position 10 V Inside When the damper flap is moving to the outside positio...

Page 1711: ... water temperature 80 90 D Lamps electric cooling fan accessories operations OFF D Transmission N range 2 Confirm that the idling speed is set to the typical value Standard value 750 30 rpm NOTE The idling speed does not need adjusting as it is automatically controlled by the ISC system 3 Check that the idling speed conforms with the standard value when the A C switch is turned ON and the air cond...

Page 1712: ...l and Post installation Operations D Driver Side Under Cover Meter Bezel Assembly Glove Box Assembly Center Under Cover Removal and Installation Refer to GROUP 52A Instrument Panel 1 2 3 Removal steps 1 Aspirator hose 2 Automatic air conditioner control panel bracket 3 Automatic air conditioner control panel assembly A C ECU NOTE Refer to the 97 L200 Workshop Manual Pub No PWTE96E1 ...

Page 1713: ... selection damper control motor Mode selection damper control motor removal steps D Driver side under cover Refer to GROUP 52A 3 Mode selection damper control motor Air mixing damper control motor removal steps D Front floor console Glove box assembly Refer to GROUP 52A D Driver side under cover Refer to GROUP 52A D Meter bezel assembly Refer to GROUP 52A D Center reinforcement A Refer to GROUP 52...

Page 1714: ...TROL MOTOR CHECK Battery connection terminal Lever operation 1 3 Turn to DEF side Turn to FACE side NOTE When the lever is in the FACE position or DEF position no power is supplied POTENTIOMETER CHECK When measuring the resistance between connector terminals nos 2 and 5 and between terminals 5 and 6 under the same conditions as the mode selection damper control motor check confirm that the resista...

Page 1715: ...MAX HOT position or MAX COOL position no power is supplied Potentiometer Check When measuring the resistance between connector terminals nos 2 and 5 and between terminals 5 and 6 under the same conditions as the air mixing damper motor check confirm that the resistance gradually fluctuates within the standard value range Standard value 0 18 4 82 kΩ MAX COOL position MAX HOT position Lever ...

Page 1716: ...alling the heater unit from vehicles equipped with SRS do not let it bump against the SRS diagnostic unit or the components 1 2 3 4 5 6 7 8 9 10 12 13 14 11 Removal steps 1 Center reinforcement 2 Center ventilation duct 3 Drain hose AA 4 Liquid pipe B and suction pipe connec tion 5 O ring 6 Heater hose connection 7 Evaporator 8 Heater unit 9 Mode selection damper control motor 10 Air mixing damper...

Page 1717: ...ICE POINTS AAHEATER WATER TEMPERATURE SENSOR CLIP INSTALLATION Insert the heater water temperature sensor into the mounting hole on the side of the heater unit and secure the sensor with the clip NOTE As the compressor oil and receiver are highly moisture absorbent use a non porous material to plug the hoses and nipples INSPECTION HEATER WATER TEMPERATURE SENSOR CHECK Measure the resistance betwee...

Page 1718: ... 5 Evaporator cover lower 6 Lining lower 7 Expansion valve 8 O ring 9 Evaporator INSPECTION AIR THERMO SENSOR CHECK Measure the resistance between the sensor terminals under at least two different temperatures The resistance values should generally match those in the graph NOTE The temperature at the check should not exceed the range in the graph Resistance kΩ Temperature _C 20 15 10 5 0 10 0 10 4...

Page 1719: ... 1 2 Removal steps 1 Defroster nozzle 2 Photo sensor NOTE Refer to the 97 L200 Workshop Manual Pub No PWTE96E1 INSPECTION PHOTO SENSOR CHECK When the full automatic air conditioner is operating cover the insolation sensor photo sensor with your hand If the blower speed drops it is normal If the blower speed does not drop replace the photo sensor ...

Page 1720: ...nt bumper Refer to GROUP 51 Ambience temperature sensor INSPECTION AMBIENCE TEMPERATURE SENSOR CHECK Measure the resistance between the sensor terminals under at least two different temperatures The resistance values should generally match those in the graph Resistance kΩ Temperature _C 40 30 20 10 0 30 0 40 20 60 20 50 ...

Page 1721: ...ndshield Washer Tank Removal and Installation 1 2 3 4 5 6 7 8 9 10 12 11 7 7 7 7 7 7 7 12 9 0 Nm Removal steps AA 1 Suction flexible hose AA 2 Suction pipe A AA 3 Liquid pipe A AA 4 Discharge hose AA 5 Liquid pipe B AA 6 Liquid pipe C 7 O ring 8 Hood latch 9 Hood lock stay 10 Receiver assembly 11 Receiver bracket 12 Suction pipe braclet REMOVAL SERVICE POINTS AA REMOVAL OF HOSES AND PIPES To preve...

Page 1722: ...AUTOMATIC AIR CONDITIONER Throttle Cable 55B 31 THROTTLE CABLE REMOVAL AND INSTALLATION 1 2 3 4 3 4 0 5 N m Removal steps 1 Screw 2 Knob 3 Nut 4 Throttle cable ...

Page 1723: ...NOTES ...

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Mitsubishi MOTORS L200 1996, Workshop Manual

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