Mitsubishi MOTORS Lancer 2004 Workshop Manual Download Page 3

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17-1

GROUP 17

ENGINE AND

EMISSION

CONTROL

CONTENTS

ENGINE CONTROL . . . . . . . . . .

17-2

GENERAL INFORMATION . . . . . .

17-2

SERVICE SPECIFICATIONS. . . . .

17-2

ON-VEHICLE SERVICE. . . . . . . . .

17-2

ACCEL CABLE CHECK AND

ADJUSTMENT. . . . . . . . . . . . . . . . . . . .

17-2

ACCELERATOR CABLE AND
PEDAL . . . . . . . . . . . . . . . . . . . . . .

17-3

REMOVAL AND INSTALLATION . . . . .

17-3

EMISSION CONTROL MPI . . . .

17-5

GENERAL INFORMATION . . . . . .

17-5

EMISSION CONTROL DEVICE
REFERENCE TABLE . . . . . . . . . .

17-5

SERVICE SPECIFICATION(S) . . .

17-5

VACUUM HOSE. . . . . . . . . . . . . . .

17-6

VACUUM HOSE PIPING DIAGRAM . . .

17-6

VACUUM CIRCUIT DIAGRAM . . . . . . .

17-7

VACUUM HOSE CHECK. . . . . . . . . . . .

17-8

VACUUM HOSE INSTALLATION . . . . .

17-8

CRANKCASE EMISSION CONTROL
SYSTEM. . . . . . . . . . . . . . . . . . . . .

17-8

GENERAL INFORMATION (CRANKCASE

EMISSION CONTROL SYSTEM) . . . . .

17-8

COMPONENT LOCATION (CRANKCASE

EMISSION CONTROL SYSTEM) . . . . .

17-9

POSITIVE CRANKCASE VENTILATION

SYSTEM CHECK . . . . . . . . . . . . . . . . . .

17-9

POSITIVE CRANKCASE VENTILATION

(PCV) VALVE CHECK . . . . . . . . . . . . . .

17-9

EVAPORATIVE EMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . .

17-9

GENERAL INFORMATION (EVAPORATIVE

EMISSION CONTROL SYSTEM) . . . . .

17-9

COMPONENT LOCATION (EVAPORATIVE

EMISSION CONTROL SYSTEM) . . . . .

17-10

PURGE CONTROL SYSTEM CHECK. .

17-10

PURGE PORT VACUUM CHECK . . . . .

17-11

PURGE CONTROL SOLENOID VALVE

CHECK . . . . . . . . . . . . . . . . . . . . . . . . . .

17-11

FUEL VAPOUR CANISTER REMOVAL

AND INSTALLATION . . . . . . . . . . . . . . .

17-12

EXHAUST GAS RECIRCULATION
(EGR) SYSTEM . . . . . . . . . . . . . . .

17-13

GENERAL INFORMATION

(EGR SYSTEM) . . . . . . . . . . . . . . . . . . .

17-13

COMPONENT LOCATION

(EGR SYSTEM) . . . . . . . . . . . . . . . . . . .

17-14

EGR SYSTEM CHECK . . . . . . . . . . . . .

17-15

EGR VALVE CHECK . . . . . . . . . . . . . . .

17-15

EGR PORT VACUUM CHECK <4G1>. .

17-16

EGR CONTROL SOLENOID VALVE

CHECK <4G1> . . . . . . . . . . . . . . . . . . . .

17-16

EGR CONTROL SOLENOID VALVE

CHECK <4G6> . . . . . . . . . . . . . . . . . . . .

17-17

EXHAUST GAS RECIRCULATION (EGR)

VALVE REMOVAL AND

INSTALLATION . . . . . . . . . . . . . . . . . . .

17-18

CATALYTIC CONVERTER . . . . . .

17-18

REMOVAL AND INSTALLATION. . . . . .

17-18

Summary of Contents for Lancer 2004

Page 1: ...ANUAL FOREWORD This Workshop manual contains procedures for service mechanics including removal disassembly inspection adjustment reassembly and installation Use the following manuals in combination with this manual as required TECHNICAL INFORMATION MANUAL PYME0302 PYME0302 A WORKSHOP MANUAL CHASSIS GROUP PWME0302 BODY REPAIR MANUAL PBME0302 PBME0302 A PARTS CATALOGUE B606K005A_ All information il...

Page 2: ...dules clock spring side air bag modules and seat belt pre tensioner before drying or baking the vehicle after painting ï SRS ECU air bag module and clock spring 93 C or more ï Seat belt with pre tensioner 90 C or more 3 Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer 4 MITSUBISHI dealer personnel must thoroughly review ...

Page 3: ...CONTROL SYSTEM 17 9 POSITIVE CRANKCASE VENTILATION SYSTEM CHECK 17 9 POSITIVE CRANKCASE VENTILATION PCV VALVE CHECK 17 9 EVAPORATIVE EMISSION CONTROL SYSTEM 17 9 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM 17 9 COMPONENT LOCATION EVAPORATIVE EMISSION CONTROL SYSTEM 17 10 PURGE CONTROL SYSTEM CHECK 17 10 PURGE PORT VACUUM CHECK 17 11 PURGE CONTROL SOLENOID VALVE CHECK 17 11 FUEL VAPOUR ...

Page 4: ...engine ignition switch LOCK OFF position 5 Confirm there are no sharp bends in the accelerator cable 6 Check the inner cable for correct slack Standard value 1 0 2 0 mm 7 If there is too much slack or no slack adjust play by the following procedures 1 Loosen the adjusting bolts to release the cable 2 Move the plate until the inner cable play is at the standard value and then tighten the adjusting ...

Page 5: ... m 9 7 1 2 3 5 0 1 0 N m R H drive vehicles L H drive vehicles N 4 5 7 8 10 11 N 12 13 6 12 2 N m 9 7 Accelerator cable assembly removal steps 1 Inner cable connection Accelerator pedal side 2 Inner cable connection Throttle body side 3 Accelerator cable assembly Accelerator pedal assembly removal steps 1 Inner cable connection Accelerator pedal side 4 Accelerator pedal assembly 5 Accelerator cont...

Page 6: ...embling it NOTE If it is difficult to assemble apply soapy water to the thumb area to enhance the assembling process 7 Accelerator control equip bushing 8 Accelerator pedal arm return spring 9 Accelerator pedal arm stopper Accelerator pedal assembly removal steps Continued 10 Accelerator pedal arm bracket 11 Accelerator pedal arm A 12 Accelerator pedal pad 13 Accelerator pedal arm stopper Accelera...

Page 7: ...le type solenoid 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 EGR valve EGR control solenoid valve Equipped Single type Duty cycle type solenoid valve Purpose NOx reduction Catalytic converter Monolith type Purpose CO HC NOx reduction Related parts Crankca...

Page 8: ...tic converter Oxygen sensor front Oxygen sensor rear EGR valve 4G1 EGR control solenoid valve Purge control solenoid valve Canister Air AB Air cleaner AK204364AC Air cleaner Air Canister Purge control solenoid valve EGR control solenoid valve EGR valve From fuel pump To fuel tank Fuel pressure regulator PCV valve Oxygen sensor front Oxygen sensor rear Catalytic converter Catalytic converter 4G6 ...

Page 9: ...ulator EGR valve EGR control solenoid valve Purge control solenoid valve Canister Vacuum hose colour B Black G Green R Red Y Yellow L Blue 4G1 AK300766 From air cleaner To combustion chamber Throttle body B B AB Intake manifold Y R G W L Fuel pressure regulator EGR valve EGR control solenoid valve Purge control solenoid valve Canister Vacuum hose colour B Black G Green R Red W White Y Yellow L Blu...

Page 10: ...005000237 The crankcase emission control system prevents blow by gases from escaping inside the crankcase into the atmosphere Fresh air is sent from the air cleaner into the crankcase through the breather hose The air becomes mixed with the blow by gases inside the crankcase The blow by gas inside the crankcase is drawn into the intake manifold through the positive crankcase ventilation PCV valve ...

Page 11: ...ing in the PCV valve In this case clean or replace the PCV valve EVAPORATIVE EMISSION CONTROL SYSTEM GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM M1173005100405 The evaporative emission control system prevents fuel vapours generated in the fuel tank from escaping into the atmosphere Fuel vapours from the fuel tank flow through the fuel tank pressure control valve and vapour pipe hose to...

Page 12: ...el tank OFF ON Purge control solenoid valve Control relay Battery Engine ECU 4G1 M T 4G6 Engine A T ECU 4G1 A T Air flow sensor 4G6 Engine coolant temperature sensor Intake air temperature sensor Barometric pressure sensor 4G6 Manifold absolute pressure MAP sensor 4G1 AK300769 4G1 AB Purge control solenoid valve AK300770 4G6 AB Purge control solenoid valve AK300771 4G1 AB Plug Vacuum hose AK300772...

Page 13: ...ly constant negative pressure is generated regardless of the engine speed 5 If no negative pressure is generated the port is probably blocked and should be cleaned PURGE CONTROL SOLENOID VALVE CHECK M1173001700193 NOTE When disconnecting the vacuum hose always make a mark so that it can be reconnected at original position 1 Disconnect the vacuum hose from the solenoid valve 2 Disconnect the harnes...

Page 14: ...INSTALLATION M1173004200153 Battery voltage Normal condition Applied Vacuum leaks Not applied Vacuum maintained Pre removal and Post installation Operation Air Cleaner Assembly Removal and Installation Refer to GROUP 15 P 15 3 AC208253 1 2 3 4 5 6 7 8 AD Removal steps 1 Emission vacuum hose connection 2 Fuel vapour control line hose 3 Fuel vapour control check valve 4 Fuel vapour control line hose...

Page 15: ... 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 exhaust gases The engine coolant temp...

Page 16: ...4G6 EGR control Solenoid valve EGR valve OFF ON Control relay Battery Engine ECU Barometric pressure sensor Air flow sensor Engine coolant temperature sensor Crank angle sensor AK300776 4G1 AB EGR control solenoid valve AK300778 4G6 AB EGR control solenoid valve AK300777 4G1 AB EGR valve AK300779AB 4G6 EGR valve ...

Page 17: ...173002800223 1 Remove the EGR valve and inspect for sticking carbon deposits etc If found clean with a suitable solvent so that the valve seats correctly 2 Connect a hand vacuum pump to the EGR valve 3 Apply 67 kPa of vacuum and check that the vacuum is maintained 4 Apply a vacuum and check the passage of air by blowing through one side of the EGR passage Throttle valve Normal vacuum condition Ope...

Page 18: ...e nipple 2 Plug the vacuum hose White stripe 3 Start the engine 4 Check that a fairly constant negative is generated regardless of the engine speed 5 If no negative pressure is generated the port is probably blocked and should be cleaned EGR CONTROL SOLENOID VALVE CHECK 4G1 M1173003100238 NOTE When disconnecting the vacuum hose always make a mark so that it can be reconnected at original position ...

Page 19: ...ve 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 air tightness by applying a vacuum with voltage applied directly from the battery to the EGR control solenoid valve and without applying voltage 5 Measure the resistance between the terminals of the solenoid valve Standard value 29 35 Ω at 20 C AKX00352 AK2...

Page 20: ...NSTALLATION M1173003900386 Refer to GROUP 15 Exhaust Pipe and Main Muffler P 15 11 Pre removal and Post installation Operation Air Cleaner Assembly Removal and Installation Refer to GROUP 15 P 15 3 AC208130 21 4 N m 2 1 3 N AC 4G1 AC301219 19 3 N m 2 1 3 N AC 4G6 Removal steps 1 Emission vacuum hose connection 2 EGR valve 3 EGR valve gasket Removal steps Continued ...

Page 21: ...13 1 GROUP 13 FUEL CONTENTS MULTIPORT FUEL INJECTION MPI 4G1 13A MULTIPORT FUEL INJECTION MPI 4G6 13B FUEL SUPPLY 13C ...

Page 22: ...NOTES ...

Page 23: ...SERVICE SPECIFICATION 32 3 SPECIAL TOOL 32 3 ENGINE MOUNTING 32 4 REMOVAL AND INSTALLATION 32 4 TRANSMISSION MOUNTING 32 5 REMOVAL AND INSTALLATION 32 5 ENGINE ROLL STOPPER CENTERMEMBER 32 7 REMOVAL AND INSTALLATION 32 7 CROSSMEMBER 32 8 REMOVAL AND INSTALLATION 32 8 ...

Page 24: ...the front and rear roll mounts well distribute their loads thereby reducing engine idling vibrations The fore and aft liquid filled engine mount of cylinder type is adopted to reduce engine shake for improved riding comfort CONSTRUCTION DIAGRAM AC107318 Y0290AU AC303563 Engine front mounting bracket Transmission mounting body side bracket Engine rear roll stopper bracket Engine front roll stopper ...

Page 25: ...0378 Item Standard value Protruding length of stabilizer link thread part mm 22 1 5 Tool Number Name Use MB991897 Ball joint remover Knuckle and tie rod end ball joint disconnection NOTE Steering linkage puller MB990635 or MB991113 is also available to disconnect knuckle and tie rod end ball joint AC106827 ...

Page 26: ...ally and loading the full weight of the engine on the vehicle body Pre removal Operation Raise the engine and transmission assembly until its weight is not applied to the insulator and support it securely AC303999 AC303968 AC304304AB 4G1 4G6 44 10 N m 67 7 N m 2N 3 44 10 N m 67 7 N m 2N 3 12 2 N m 1 Removal steps 1 Pressure hose clamp 4G6 2 Self locking nuts 3 Engine front mounting bracket Removal...

Page 27: ...ght is not applied to the insulator and support it securely Battery and Battery tray Removal Air Cleaner Removal Refer to GROUP 15 Air Cleaner P 15 3 Engine Rear Roll Stopper Bracket Removal Refer to P 32 7 Post installation Operation Engine Rear Roll Stopper Bracket Installation Refer to P 32 7 Air Cleaner Installation Refer to GROUP 15 Air Cleaner P 15 3 Battery and Battery tray Installation AC3...

Page 28: ...2 6 INSTALLATION SERVICE POINT A TRANSMISSION MOUNTING STOPPER INSTALLATION Install the transmission mounting stopper so that its arrow points upward AC200645 Engine side Transmission mounting body side bracket Transmission mounting stopper AB ...

Page 29: ...tion AC303978 AC304309 45 5 N m 45 5 N m 4G1 4G6 52 7 N m 52 7 N m 45 5 N m 52 7 N m 11 1 N m 69 10 N m 69 10 N m 69 10 N m 1 3 2 1 3 4 5 6 7 AB Engine front roll stopper bracket and centermember removal steps 1 Engine front roll stopper bracket connecting bolt Centermember and engine front roll stopper bracket assembly B 2 Engine mounting cushion stopper 4G6 A 3 Engine front roll stopper bracket ...

Page 30: ...hen fully tightened with the vehicle on the earth in the unladen condition AC005918 Front of vehicle Hole AC AC304315AB Front of vehicle Hole Engine mounting cushion stopper Pre removal Operation Centermember Removal Refer to P 32 7 Front Exhaust Pipe Removal Refer to GROUP 15 Exhaust Pipe and Main Muffler P 15 11 Steering Wheel Air Bag Module Assembly Removal Refer to GROUP 37 Steering Wheel P 37...

Page 31: ...arm and knuckle connection B 2 Self locking nut 3 Lower arm assembly 4 Shaft cover 5 Steering shaft assembly and gear box connecting bolt 6 Engine rear roll stopper bracket connection bolt 7 Engine rear roll stopper bracket 8 Return hose connection 9 Eye bolt 10 Pressure hose connection 11 Gasket 12 Clamp 13 Self locking nut A 14 Tie rod end and knuckle connection B Crossmember assembly A 15 Stabi...

Page 32: ... knuckle connection B 2 Self locking nut 3 Lower arm assembly 4 Eye bolt 5 Pressure hose connection 6 Gasket 7 Return hose connection 8 Shaft cover 9 Steering shaft assembly and gear box connecting bolt 10 Self locking nut A 11 Tie rod end and knuckle connection 12 Engine rear roll stopper bracket connection bolt B Crossmember assembly 13 Engine rear roll stopper bracket A 14 Stabilizer bar 15 Ste...

Page 33: ...o disconnect the tie rod end B CROSSMEMBER ASSEMBLY REMOVAL 1 Use a transmission jack to hold the crossmember and then remove the crossmember mounting nuts and bolts 2 Lower the crossmember with the engine rear roll stopper bracket the stabilizer bar the return tube and the steering gear INSTALLATION SERVICE POINTS A STABILIZER BAR BUSHING FIXTURE INSTALLATION Align the stabilizer bar identificati...

Page 34: ...NOTES ...

Page 35: ...LEANER 15 3 REMOVAL AND INSTALLATION 15 3 INLET MANIFOLD 15 5 REMOVAL AND INSTALLATION 4G1 15 5 REMOVAL AND INSTALLATION 4G6 15 6 INSPECTION 15 7 EXHAUST MANIFOLD 15 7 REMOVAL AND INSTALLATION 4G1 15 7 REMOVAL AND INSTALLATION 4G6 15 9 INSPECTION 15 10 EXHAUST PIPE AND MAIN MUFFLER 15 11 REMOVAL AND INSTALLATION 15 11 ...

Page 36: ... is divided into three parts SERVICE SPECIFICATION M1151000300428 SPECIAL TOOL M1151000600399 Item Standard value Limit Manifold distortion of the installation surface mm 0 15 or less 0 20 Tool Number Name Use MD998770 Oxygen sensor wrench Removal and installation of engine control oxygen sensor ...

Page 37: ... precautions Avoid any shock or load to these parts when removing and installing them When installing securely set the air cleaner cover clamp to the air cleaner body NOTE Parts marked by are made of recycled paper mixed plastic material Dispose of according to state and local laws AC303618 4 0 1 0 N m 4 0 1 0 N m 10 9 4 1 5 11 12 1 N m 9 0 1 0 N m 9 0 1 0 N m AB 12 1 N m Clamp 8 3 4G1 ...

Page 38: ...t 2 Air cleaner air flow sensor connector 4G6 3 Air cleaner assembly 4G1 or Air cleaner and air cleaner air flow sensor assembly 4G6 4 Rocker cover breather hose connection 5 Air cleaner to throttle body duct 6 Air cleaner air flow sensor 4G6 7 Air cleaner air flow sensor gasket 4G6 8 Air cleaner cover 9 Air cleaner element 10 Air cleaner body assembly 11 Air cleaner bracket Removal steps Continue...

Page 39: ... to GROUP 42 P 42 9 Engine Coolant Supplying Refer to GROUP 14 On vehicle Service P 14 22 Accelerator Cable Adjustment Refer to GROUP 17 On vehicle Service P 17 2 Fuel Leak Check AC303642AB 15 3 6 5 4 12 10 7 1 2 11 9 13 14 21 4 N m 9 0 1 0 N m 9 0 1 0 N m 18 2 N m 18 2 N m 18 2 N m 5 0 1 0 N m 31 3 N m 49 9 N m N N N 8 Removal steps 1 Inlet manifold absolute pressure sensor 2 Engine control press...

Page 40: ...13B 334 Throttle Body Assembly Installation Refer to GROUP 13B P 13B 336 Strut Tower Bar Installation Refer to GROUP 42 P 42 9 Engine Coolant Supplying Refer to GROUP 14 On vehicle Service P 14 22 Accelerator Cable Adjustment Refer to GROUP 17 On vehicle Service P 17 2 Fuel Leak Check AC303657 9 0 1 0 N m 11 1 N m 20 2 N m 31 3 N m 36 6 N m 20 2 N m 20 2 N m 36 6 N m 36 6 N m 11 9 10 2 12 N 14 13 ...

Page 41: ...nd feeler gauge check for distortion of the cylinder head installation surface Standard value 0 15 mm or less Limit 0 20 mm EXHAUST MANIFOLD REMOVAL AND INSTALLATION 4G1 M1151003300568 8 Battery wiring harness clamp 9 Inlet manifold stay 10 Inlet manifold 11 Inlet manifold gasket 12 Emission vacuum hose pipe and emission solenoid valve assembly 13 EGR valve 14 EGR valve gasket Removal steps Contin...

Page 42: ...tool oxygen sensor wrench MD998770 to install the engine control oxygen sensor front Removal steps 1 Front exhaust pipe connection 2 Exhaust pipe gasket A A 3 Engine control oxygen sensor front 4 Engine oil level gauge and guide assembly 5 Engine oil filler O ring 6 Exhaust manifold cover 7 Exhaust manifold bracket 8 Exhaust manifold 9 Exhaust manifold gasket Removal steps Continued AC212566AC MD9...

Page 43: ... m 14 1 N m 14 1 N m 49 5 N m 29 3 N m 29 3 N m N 3 4 1 2 5 N 8 9 44 5 N m AB 10 49 5 N m 6 7 9 0 2 0 N m 49 9 N m Removal steps 1 Front exhaust pipe connection 2 Exhaust pipe gasket A A 3 Engine control oxygen sensor front 4 Exhaust manifold cover 5 Exhaust manifold bracket 6 Starter cover 7 Starter cover bracket 8 Engine hanger 9 Exhaust manifold 10 Exhaust manifold gasket Removal steps Continue...

Page 44: ... oxygen sensor wrench MD998770 to install the engine control oxygen sensor front INSPECTION M1151003400543 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 feeler gauge check for distortion of the cylinder head installation surface Standard value 0 15 mm or less Limit 0 20 mm AC212566AC...

Page 45: ... N m 2 6 N N 4 5 7 4 N 8 9 59 10 N m 45 5 N m 13 2 N m 45 5 N m 13 2 N m 9 4G6 Exhaust main muffler removal steps 1 Exhaust main muffler 3 Exhaust pipe gasket 4 Exhaust muffler hanger Centre exhaust pipe removal steps 2 Centre exhaust pipe 3 Exhaust pipe gasket 7 Exhaust pipe gasket Front exhaust pipe removal steps A A 5 Engine control oxygen sensor rear 6 Front exhaust pipe 7 Exhaust pipe gasket ...

Page 46: ...nsor wrench MD998770 to remove the engine control oxygen sensor rear INSTALLATION SERVICE POINT A ENGINE CONTROL OXYGEN SENSOR REAR INSTALLATION Use special tool oxygen sensor wrench MD998770 to install the engine control oxygen sensor rear AC212566AD MD998770 Engine control oxygen sensor rear AC212566AD MD998770 Engine control oxygen sensor rear ...

Page 47: ...PENING PRESSURE CHECK 14 22 ENGINE COOLANT REPLACEMENT 14 22 CONCENTRATION MEASUREMENT 14 23 COOLING FAN MOTOR DRIVE CONTROL UNIT CHECK 14 23 FAN CONTROL RELAY CONTINUITY CHECK 14 24 COOLING FAN MOTOR CHECK 14 25 THERMOSTAT 14 26 REMOVAL AND INSTALLATION 14 26 INSPECTION 14 27 WATER PUMP 14 29 REMOVAL AND INSTALLATION 4G1 14 29 REMOVAL AND INSTALLATION 4G6 14 30 WATER HOSE AND WATER PIPE 14 31 REM...

Page 48: ...rive belt from the crankshaft The radiator is the corrugated fin down flow type SERVICE SPECIFICATIONS M1141000300416 LUBRICANT M1141000400338 Item Specification Radiator Performance kJ h 4G13 Standard vehicles 137 720 Vehicles with capacity up radiator option 161 288 4G18 Standard vehicles 161 288 Vehicles with capacity up radiator option 181 800 4G63 181 800 A T oil cooler Performance kJ h 5 651...

Page 49: ...Specified sealant Cylinder block drain plug 3M Nut Locking Part No 4171 or equivalent Water pump 4G1 Thermostat case 4G6 Cooling water outlet hose fitting 4G6 MITSUBISHI GENUINE Part No MD970389 or equivalent Tool Number Name Use MB991502 MUT II sub assembly Reading diagnosis code B991502 ...

Page 50: ... I B MUT III USB cable C MUT III main harness A Vehicles with CAN communication system D MUT III main harness B Vehicles without CAN communication system E MUT III measurement adapter F MUT III trigger harness Checking the A T Diagnosis display using the MUT III Tool Number Name Use MB991910 MB991826 MB991955 MB991911 MB991824 MB991827 MB991825 A B C D E F DO NOT USE ...

Page 51: ...nection MB991871 LLC changer Coolant refilling Tool Number Name Use MB991223 A B C D AC MB991871 Trouble symptom Inspection procedure No Reference page Cooling fan L H and Cooling fan R H 4G1 Vehicles with A C or A C condenser fan 4G6 do not operate 1 P 14 6 Cooling fan L H and Cooling fan R H 4G1 Vehicles with A C or A C condenser fan 4G6 do not change speed or stop 2 P 14 16 Cooling fan L H does...

Page 52: ...16X AC303577 A 18 1 COOLING FAN MOTOR L H COOLING FAN MOTOR R H 4G1 VEHICLES WITH A C OR A C CONDENSER FAN MOTOR 4G6 A 18 2 A 18 COOLING FAN MOTOR DRIVE CONTROL UNIT 1 A 13 LHD 12 C 111 RHD ENGINE ECU M T OR ENGINE A T ECU A T 21 C 123 M T 18 C 122 A T 6 1 5 12 11 7 9 8 10 2 3 4 MU802322 MU801824 C 123 MU803784 C 122 MU802611 A 13 C 111 L L 2 2 2 1 1 1 B L 2 3 4 B W FUSIBLE LINK No 2 B 3 1 R Y R Y...

Page 53: ...water temperature sensor unit and the vehicle speed sensor M T or the output shaft speed sensor A T to the engine ECU M T or engine A T ECU A T The cause could also be a malfunction of the cooling fan motor drive control unit or the engine ECU M T or engine A T ECU A T TROUBLESHOOTING HINTS Malfunction of fusible link 2 Malfunction of fan control relay Malfunction of cooling fan motor L H Vehicles...

Page 54: ... switch to the ON position 3 Measure the voltage between fan control relay connector A 09X terminal 4 and body earth The voltage should measure system voltage 4 Turn the ignition switch to the LOCK OFF position 5 Connect fan control relay connector A 09X install the fan control relay Q Is the measured voltage system voltage YES Go to Step 8 NO Go to Step 6 STEP 6 Check the fan control relay connec...

Page 55: ...relay box Then go to Step 24 STEP 10 Check the harness wire between fan control relay connector A 09X terminal 2 and cooling fan motor drive control unit connector A 18 terminal 3 Q Is the harness wire in good condition YES Go to Step 11 NO Repair the damaged harness wire Then go to Step 24 STEP 11 Measure the terminal voltage at fan control relay connector A 09X 1 Disconnect fan control relay con...

Page 56: ...voltage YES Go to Step 14 NO Go to Step 12 STEP 12 Check the J C No 6 C 12 L H drive vehicles or C 134 R H drive vehicles intermediate connector A 13 L H drive vehicles C 111 R H drive vehicles and fan control relay connector A 09X AC303517AB A 09X Connector Relay box side AC303524 Connector C 12 L H drive vehicles AB C 12 C 12 AC303525 Connector C 134 R H drive vehicles AB C 134 C 134 AC303526 Co...

Page 57: ...d body earth 1 Disconnect fan control relay connector A 09X remove the fan control relay and measure relay box side connector 2 Measure the resistance between fan control relay connector A 09X terminal 3 and body earth Continuity exists 3 Connect fan control relay connector A 09X install the fan control relay Q Does the continuity exists YES An intermittent malfunction is suspected Refer to GROUP ...

Page 58: ...n go to Step 24 STEP 17 Check the continuity between cooling fan motor drive control unit connector A 18 and body earth 1 Disconnect cooling fan motor drive control unit connector A 18 and measure wiring harness side connector 2 Measure the resistance between cooling fan motor drive control unit connector A 18 terminal 1 and body earth Continuity exists 3 Connect cooling fan motor drive control un...

Page 59: ...nction is suspected Refer to GROUP 00 How to use troubleshooting P 00 5 NO Repair the damaged harness wire Then go to Step 24 STEP 20 Check the cooling fan motor drive control unit connector A 18 intermediate connector A 13 L H drive vehicles or C 111 R H drive vehicles and engine ECU connector C 123 M T or engine A T ECU connector C 122 A T AC100293 A 18 3 2 1 Connector A 18 AD AC100293 A 18 3 2 ...

Page 60: ...ector C 123 terminal 21 M T or engine A T ECU connector C 122 terminal 18 A T Q Are these harness wires in good condition YES Go to Step 22 NO Repair the damaged harness wire Then go to Step 24 AC303555AB Connector C 123 M T C 122 A T C 123 M T or C 122 A T C 123 M T Engine ECU M T or engine A T ECU A T C 122 A T AC100293 A 18 3 2 1 Connector A 18 AD AC303555AB Connector C 123 M T C 122 A T C 123 ...

Page 61: ... terminal pin is connected to the body earth does the cooling fan stop YES Go to Step 23 NO Replace the cooling fan motor drive control unit Refer to P 14 35 Then go to Step 24 STEP 23 MUT II III self diag code Check if an MPI system self diag code is set Refer to GROUP 13A Trouble shooting P 13A 9 4G1 or Refer to GROUP 13B Trouble shooting P 13B 9 4G6 Q Diagnosis code set YES Inspection chart for...

Page 62: ...condenser fan motor 4G6 rotate The cause could also be a malfunction of the cooling fan motor L H Vehicles without A C The cause could also be a malfunction of input signal from the A C switch the water temperature sensor unit and the vehicle speed sensor M T or the output shaft speed sensor A T to the engine ECU M T or engine A T ECU A T The cause could also be a malfunction of the cooling fan mo...

Page 63: ...8 STEP 4 Check the cooling fan motor drive control unit connector A 18 intermediate connector A 13 L H drive vehicles or C 111 R H drive vehicles and engine ECU connector C 123 M T or engine A T ECU connector C 122 A T AC303510AB Fan control relay Relay box Connector A 09X A 09X AC100293 A 18 3 2 1 Connector A 18 AD AC100293 A 18 3 2 1 Connector A 18 AD AC303526 Connector A 13 L H drive vehicles A...

Page 64: ...ctor C 123 terminal 21 M T or engine A T ECU connector C 122 terminal 18 A T Q Are these harness wires in good condition YES Go to Step 6 NO Repair the damaged harness wire Then go to Step 8 AC303555AB Connector C 123 M T C 122 A T C 123 M T or C 122 A T C 123 M T Engine ECU M T or engine A T ECU A T C 122 A T AC100293 A 18 3 2 1 Connector A 18 AD AC303555AB Connector C 123 M T C 122 A T C 123 M T...

Page 65: ...or terminal pin is connected to the body earth does the cooling fan stop YES Go to Step 7 NO Replace the cooling fan motor drive control unit Refer to P 14 35 Then go to Step 8 STEP 7 MUT II III self diag code Check if an MPI system self diag code is set Refer to GROUP 13A Trouble shooting P 13A 9 4G1 or Refer to GROUP 13B Trouble shooting P 13B 9 4G6 Q Diagnosis code set YES Inspection chart for ...

Page 66: ... L H Malfunction of cooling fan motor drive control unit DIAGNOSIS STEP 1 Check the cooling fan motor L H Refer to P 14 25 Q Is the cooling fan motor L H in good condition YES Go to Step 2 NO Replace the cooling fan motor L H Refer to P 14 35 Then go to Step 3 STEP 2 Check the cooling fan motor drive control unit Refer to P 14 23 Q Is the cooling fan motor drive control unit in good condition YES ...

Page 67: ...ck the cooling fan motor R H 4G1 or A C condenser fan motor 4G6 Cooling fan motor R H check Refer to P 14 25 4G1 A C condenser fan motor check Refer to GROUP 55 P 55 97 4G6 Q Is the cooling fan motor R H 4G1 or A C condenser fan motor 4G6 in good condition YES Go to Step 2 NO Replace the cooling fan motor R H Refer to P 14 35 4G1 or A C condenser fan motor Refer to GROUP 55 P 55 96 4G6 Then go to ...

Page 68: ...attach the cap to the tester 2 Increase the pressure until the indicator of the gauge stops moving Minimum limit 83 kPa Standard value 93 123 kPa 3 Replace the radiator cap if the reading does not remain at or above the limit ENGINE COOLANT REPLACEMENT M1141001200434 WARNING When removing the radiator cap use care to avoid contact with hot coolant or steam Place a shop towel over the cap and turn ...

Page 69: ...vving the engine up to 3 000 r min several times then stop the engine 12 Remove the radiator cap after the engine has become cold and pour in coolant up to the brim Reinstall the cap CAUTION Do not overfill the radiator condenser tank 13 Add coolant to the radiator condenser tank between the F and L mark if necessary CONCENTRATION MEASUREMENT M1141001100352 Measure the temperature and specific gra...

Page 70: ... cooling fan motor drive control unit side connector terminal 1 and 2 while the fan is running The voltage should repeat the values below Standard value 1 1 V or less 2 8 2 0 7 V 3 System voltage 2 6 V 8 If the voltage does not repeatedly change as indicated replace the cooling fan motor drive control unit Refer to P 14 35 FAN CONTROL RELAY CONTINUITY CHECK M1141006200280 AC303496AB Cooling fan mo...

Page 71: ...r between the connector terminal 1 and 2 of the cooling fan motor Also check to see that there is no abnormal sound coming from the cooling fan motor at this time 3 If the cooling fan motor is defective replace it Refer to P 14 35 1 2 AC303501AB Cooling fan motor drive control unit Cooling fan motor L H connector 1 2 AC303502AB Cooling fan motor drive control unit Cooling fan motor R H connector 4...

Page 72: ...400442 Pre removal and Post installation Operation Engine Coolant Draining and Refilling Refer to P 14 22 Air Cleaner Assembly Removal and Installation Refer to GROUP 15 P 15 3 Battery Removal and Installation AC203409AC 4 3 6 7 22 4 N m 4G1 AC301429 1 2 3 6 7 13 2 N m AD 5 4G6 ...

Page 73: ...f the Cooling water inlet hose fitting 2 Align the mating marks on the radiator lower hose and hose clamp and then connect the radiator lower hose INSPECTION M1141002500427 THERMOSTAT CHECK 1 Immerse the thermostat in water and heat the water while stirring Check the thermostat valve opening temperature Standard value 88 1 5 C 4G1 82 1 5 C 4G6 Removal steps 1 Water temperature gauge unit connector...

Page 74: ... when the water is at the full opening temperature NOTE Measure the valve height when the thermostat is fully closed and use this measurement to compare the valve height when the thermostat is fully open Standard value 100 C 4G1 95 C 4G6 Amount of valve lift 8 5 mm or more ACX00401AC Valve lift ...

Page 75: ... 3 With the sealant still wet within 15 minutes after the sealant is applied install the water pump assembly Do not apply the sealant in an area more than the required Pre removal and Post installation Operation Engine Coolant Draining and Refilling Refer to P 14 22 Valve Timing Belt Removal and Installation Refer to GROUP 11A P 11A 33 AC303372 24 3 N m 23 2 N m 14 1 N m 1 2 Bolt specifications Sc...

Page 76: ...to the water pump assembly Pre removal and Post installation Operation Engine Coolant Draining and Refilling Refer to P 14 22 Valve Timing Belt and Balancer Timing Belt Removal and Installation Refer to GROUP 11C P 11C 35 AC301467 22 4 N m 23 3 N m 14 1 N m 1 2 3 4 N N Bolt specifications Screw diameter length mm 8 70 8 22 8 14 8 22 8 25 2 AB Removal steps 1 Alternator adjusting brace 2 Water pump...

Page 77: ...Refer to P 14 26 AC203411 1 2 3 4 5 6 7 8 10 9 13 2 N m 23 4 N m 13 2 N m N N AC 11 12 13 N Removal steps 1 Water temperature sensor unit connector 2 Water temperature gauge unit connector 3 Control wiring harness and harness bracket A B 4 Radiator upper hose connection 5 Throttle body water feed hose 6 Thermostat case assembly 7 Thermostat case gasket A 8 Cooling water line O ring 9 Control wirin...

Page 78: ...ooling water line O ring to the water pump inlet pipe and coat the outer portion of the cooling water line O ring with water or engine coolant B RADIATOR UPPER HOSE CONNECTION 1 Insert radiator upper hose as far as the projection of the thermostat case assembly 2 Align the mating marks on the radiator upper hose and hose clamp and then connect the radiator upper hose AC200641AC Mating marks AC2006...

Page 79: ...stallation Refer to P 14 26 AC303471 1 2 3 4 5 6 7 8 9 9 13 2 N m 23 4 N m 13 2 N m N N AB 2 Sealant Mitsubishi Genuine Part No MD970389 or equivalent Ø3 mm Ø3 mm 5 Removal steps A C 1 Radiator upper hose connection B 2 Cooling water outlet hose fitting 3 Throttle body water return hose 4 Throttle body water feed hose B 5 Thermostat case assembly 6 Heater water hose connection 7 Control wiring har...

Page 80: ...surface 2 Apply a bead of the specified sealant Specified Sealant MITSUBISHI GENUINE PART No MD970389 or equivalent 3 With the sealant still wet within 15 minutes after the sealant is applied install the thermostat case assembly or cooling water outlet hose fitting Do not apply the sealant in an area more than the required C RADIATOR UPPER HOSE CONNECTION 1 Insert radiator upper hose as far as the...

Page 81: ...500468 Pre removal and Post installation Operation Engine Coolant Draining and Supplying Refer to P 14 22 Air Cleaner Assembly Removal and Installation Refer to GROUP 15 P 15 3 AC303472 18 17 15 20 12 9 14 5 2 9 3 4 1 10 6 10 AB 12 2 N m 12 2 N m 4G1 Vehicles without A C 7 ...

Page 82: ... removal steps 1 Drain plug 2 Radiator cap 3 Radiator condenser tank hose 4 Radiator condenser tank assembly A A 5 Radiator upper hose A A 6 Radiator lower hose 7 Cooling fan motor drive control unit connector 8 T M oil cooler line hose connection A T 9 Radiator support upper insulator Radiator and cooling fan motor shroud assembly 10 Radiator support lower insulator 11 T M oil cooler line hose A ...

Page 83: ...the radiator hose and hose clamp and then connect the radiator hose 12 Cooling fan motor shroud assembly 13 A C condenser fan motor shroud assembly 4G6 14 Radiator assembly Cooling fan motor removal steps 3 Radiator condenser tank hose A A 5 Radiator upper hose 7 Cooling fan motor drive control unit connector Radiator removal steps 12 Cooling fan motor shroud assembly 15 Cooling fan L H 16 Cooling...

Page 84: ...NOTES ...

Page 85: ...ERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING Improper service or maintenance of any component of the SRS or any SRS related component can lead to personal injury or death to service personnel from inadvertent firing of the air bag or to the driver and paassenger from rendering the SRS inoperative Service or maintenance of any SRS component or SRS related component must b...

Page 86: ...24 REMOVAL AND INSTALLATION 37 24 INSPECTION 37 26 DISASSEMBLY AND REASSEMBLY 37 27 TIE ROD END BALL JOINT DUST COVER REPLACEMENT 37 36 POWER STEERING OIL PUMP ASSEMBLY 37 37 REMOVAL AND INSTALLATION 37 37 INSPECTION 37 38 DISASSEMBLY AND REASSEMBLY 37 39 INSPECTION 37 41 POWER STEERING HOSES 37 42 REMOVAL AND INSTALLATION 37 42 ...

Page 87: ...c resin oil reservoir is used to reduce weight and to make the fluid level checking easier SPECIFICATIONS Item Comfort Sport Steering wheel Type 4 spoke type MOMO leather wrapped 3 spoke type Outside diameter mm 380 365 Maximum number of turns 3 19 2 86 L H drive vehicles 3 08 R H drive vehicles Steering column Column mechanism Shock absorbing mechanism and Tilt steering mechanism Power steering t...

Page 88: ... vehicles AC304488AB Steering wheel Steering column shaft assembly Pressure hose assembly Oil reservoir Suction hose Return hose Oil pump assembly Steering gear AC304489AB Steering wheel Steering column shaft assembly Pressure hose assembly Oil reservoir Suction hose Return hose Oil pump assembly Steering gear ...

Page 89: ...86AB Steering wheel Steering column shaft assembly Pressure hose assembly Oil reservoir Suction hose Return hose Oil pump assembly Steering gear AC304487AB Steering wheel Steering column shaft assembly Pressure hose assembly Oil reservoir Suction hose Return hose Oil pump assembly Steering gear ...

Page 90: ...eel 0 03 06 Tie rod end ball joint turning torque N m 0 5 2 5 Tie rod swing resistance N Tie rod swing torque N m 8 27 1 5 4 9 Stationary steering effort N Fluctuation allowance N 29 or less 5 9 or less Oil pump pressure MPa 750 100 r min Oil pump relief pressure 8 8 9 5 Pressure under no load conditions 0 2 0 7 Steering gear retention hydraulic pressure 8 8 9 5 Oil pressure switch operating press...

Page 91: ...l MB991212 MB991213 Pinion and valve assembly seal ring part Bellows Silicon grease As required Tie rod end ball joint Multipurpose grease SAE J310 NLGI No 2 or equivalent As required Oil pump Friction surface of rotor vane cam ring and pump cover ATF DEXRON III or DEXRON II As required O ring Item Specified sealant Steering shaft cover assembly bolt hole on the toeboard 3M ATD Part No 8513 or equ...

Page 92: ...end ball joint MB990326 Preload socket Tie rod end ball joint turning torque check MB991548 Power steering oil pressure gauge adapter Pump side Oil pump pressure test MB991549 Power steering oil pressure gauge adapter Hose side MB990662 Power steering oil pressure gauge MB990784 Ornament remover Cover removal MB990228 or MB991006 Preload socket Steering gear total pinion torque check and adjustmen...

Page 93: ...ion MB990927 MB990938 MB990939 For details refer to GROUP 26 Special Tools P 26 4 MB991120 Needle bearing puller Needle bearing removal MB991202 Oil seal and bearing installer Oil seal installation Comfort Needle bearing installation Lower bearing installation MB991199 Oil seal and bearing installer Oil seal installation Sport MB991197 Bar long type Oil seal installation MB991212 MB991213 Oil seal...

Page 94: ...91317 Seal ring installer Seal rings installation MB990941 Torque tube bearing installer Lower oil seal installation MB991561 Boot band crimping tool Bellows band installation MB990776 Front axle base Tie rod end ball joint dust cover installation Tool Number Name Use MB991203 MB991317 MB990941 MB991561 MB990776 ...

Page 95: ... torque Refer to P 37 27 STEERING ANGLE CHECK M1372001100374 1 Place the front wheel on a turning radius gauge and measure the steering angle Standard value 2 If the steering angle is not within the standard value adjust the toe in as follows Standard value at the centre of tyre tread 1 2 mm Toe angle per wheel 0 03 06 3 Loosen the lock nut and unclip the bellows 4 Adjust the toe in by turning the...

Page 96: ... under the standard value check the ball joint for axial play or ratcheting If no axial play or ratcheting the ball joint can be re used CAUTION Always use a new ball joint nut as it is a self locking nut 7 Install the tie rod end to the knuckle then tighten a new self locking nut to the specified torque Tightening torque 25 5 N m STATIONARY STEERING EFFORT CHECK M1372001700332 1 With the vehicle ...

Page 97: ...Check the fluid in the oil reservoir for foaming or milkiness Check the difference of the fluid level when the engine is stopped and while it is running If the change of the fluid level is 5 mm or more air bleeding should be done FLUID REPLACEMENT M1372002100333 1 Raise and support the front wheels 2 Disconnect the return hose connection and then connect a vinyl hose to the return hose and drain t...

Page 98: ...topped and when it is running 10 If the change of the fluid level is 5 mm or more the air has not been completely bled from the system The air bleeding procedure must be repeated OIL PUMP PRESSURE TEST M1372002300315 1 Disconnect the pressure hose from the oil pump and then connect the following special tools MB990662 Power Steering Oil Pressure Gauge MB991548 Power Steering Oil Pressure Gauge Ada...

Page 99: ...he 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 standard value Standard value 0 7 2 0 MPa 7 Remove the special tools and then tighten the pressure hose to the specified torque Tightening torque 57 ...

Page 100: ... 3 Loosen the two steering column mounting bolts upper by two turns 4 Hold the one way capsules as shown and then try to lock them If there is a slack in either of the capsules replace the steering column shaft assembly NOTE When installing a new steering column shaft assembly place the tilt lever in the lock position if it is not in place CAUTION Be careful that nothing is pinched between the one...

Page 101: ... Clock Spring P 52B 210 When removing and installing the steering wheel do not let it bump against the air bag module NOTE For air bag module removal refer to GROUP 52B Air Bag Module and Clock Spring P 52B 210 Post installation Operation Checking Steering Wheel Position with Wheels Straight Ahead AC107402AB 50 5 N m 1 2 2 1 1 2 A A B B Tab Tab Section A A Section B B Removal steps A 1 Cover B 2 S...

Page 102: ...AL 1 By sliding section A of the clock spring connector shown in the illustration in the arrow direction disconnect the connector 2 Loosen the bolt completely Then remove the steering wheel and air bag module assembly NOTE Use a hexagonal bit socket or a hexagonal wrench having an effective length of 75 mm or more in the hexagonal section and the diameter of 8 mm or more AC006294AB MB990784 AC1058...

Page 103: ...he air bag module NOTE For air bag module removal refer to GROUP 52B Air Bag Module and Clock Spring P 52B 210 REMOVAL SERVICE POINTS A COVER REMOVAL Insert special tool ornament remover MB990784 at the indicated position to remove the cover NOTE The special tool can be inserted through the notch behind the area shown Post installation Operation Checking Steering Wheel Position with Wheels Straigh...

Page 104: ...w direction disconnect the connector 2 Loosen the bolt completely Then remove the steering wheel and airbag module assembly NOTE Use a hexagonal bit socket or a hexagonal wrench having an effective length of 75 mm or more in the hexagonal section and the diameter of 8 mm or more AC105823 AC304700 AC305145AB A Steering wheel Air bag module connector AC211762AC Hexagonal bit socket ...

Page 105: ... the tilt lever is in the lock position and remove the steering column mounting bolts Pre removal Operation Steering Wheel and Air bag Module Assembly Removal Comfort refer to P 37 17 Sport refer to P 37 19 Under Cover Removal Refer to GROUP 52A Instrument Panel P 52A 2 Post installation Operation Under Cover Installation Refer to GROUP 52A Instrument Panel P 52A 2 Steering Wheel and Air bag Modul...

Page 106: ...n installing the steering column do not leave it fixed temporarily at only one point and make sure the column shaft is not shaken strongly If you fail to do the collision absorbing mechanism at the column shaft mounting location may be damaged Ensure that the tilt lever is in the lock position and install the steering column Tighten the four bolts in the order shown by hand and then tighten them t...

Page 107: ...LT INSTALLATION CAUTION The steering lock bracket and bolts must be replaced with new ones when the steering lock is installed 1 When installing the steering lock cylinder assembly and steering lock bracket to the column tube temporarily install the steering lock in alignment with the column boss 2 After checking that the lock works properly tighten the special bolts until the head twists off ACX0...

Page 108: ... by pushing it with your finger Power Steering Fluid Supplying Refer to P 37 13 Power Steering Fluid Line Bleeding Refer to P 37 13 Checking Steering Wheel Position with Wheels Straight Ahead Front Wheel Alignment Adjustment Refer to GROUP 33 On vehicle Service Front Wheel Alignment Check and Adjustment P 33 5 AC304920 AB 57 7 N m 15 3 N m 70 10 N m 7 3 8 5 6 9 10 2 4 1 12 2 N m 12 2 N m L H drive...

Page 109: ...7 N m 15 3 N m 70 10 N m 3 5 2 4 1 R H drive vehicles 6 7 Removal steps 1 Crossmember Refer to GROUP 32 Crossmember P 32 8 A 2 Joint cover grommet 3 Return hose connection 4 Return tube 5 Pressure hose connection 6 Clamp 7 Steering gear and linkage Removal steps Continued ...

Page 110: ...within the standard range first adjust the rack support cover and then check the total pinion torque again If the total pinion torque cannot be adjusted to within the standard range by adjusting the rack support cover check the rack support cover rack support spring rack support and replace any parts if necessary TIE ROD SWING RESISTANCE CHECK 1 Give 10 hard swings to the tie rod 2 Measure the tie...

Page 111: ...using mounting bushing 3 Feed pipe 4 O ring N 5 Lock nut N 6 Tie rod end 7 Clip M 8 Bellows band 9 Bellows L 10 Tie rod L 11 Tab washer K Total pinion torque adjustment J 12 Lock nut A J 13 Rack support cover 14 Support spring 15 Rack support I 16 End plug 17 Lock nut 18 Valve housing assembly B H 19 Lower oil seal B 20 Pinion and valve assembly C G 21 Seal ring D F 22 Upper bearing D F 23 Upper o...

Page 112: ...ng 3 Feed pipe 4 O ring N 5 Lock nut N 6 Tie rod end 7 Clip M 8 Bellows band 9 Bellows L 10 Tie rod L 11 Tab washer K Total pinion torque adjustment J 12 Lock nut A J 13 Rack support cover 14 Support spring 15 Rack support I 16 End plug 17 Lock nut 18 Valve housing assembly B H 19 Lower oil seal B 20 Pinion and valve assembly C G 21 Seal ring D F 22 Upper bearing D F 23 Upper oil seal 24 Valve hou...

Page 113: ... III or DEXRON II Grease Repair kit grease Fluid ATF DXRON III or DEXRON II Sealant 3M ATD Part No 8661 8663 or equivalent Grease Multipurpose grease SAE J310 NLGI No 2 or equivalent Fluid ATF DXRON III or DEXRON II Fluid ATF DXRON III or DEXRON II Fluid ATF DXRON III or DEXRON II Grease Repair kit grease Fluid ATF DXRON III or DEXRON II ...

Page 114: ...SEMBLY REMOVAL Using a plastic hammer gently tap the pinion to remove it C SEAL RING REMOVAL CAUTION When cutting the seal ring be careful not to damage the pinion and valve assembly or the rack Cut the seal ring and remove it from the pinion and valve assembly or the rack D UPPER BEARING UPPER OIL SEAL REMOVAL Using a socket remove the oil seal and the ball bearing from the valve housing simultan...

Page 115: ...artially bend the oil seal and remove it from the rack bushing G LOWER BEARING REMOVAL Use a brass bar or special tool brass bar MB990939 to remove the lower bearing from the valve housing H NEEDLE BEARING REMOVAL CAUTION Do not open special tool excessively to prevent damaging housing interior Use special tool needle bearing puller MB991120 to remove the needle bearing from the valve housing I OI...

Page 116: ...owing special tools MB990938 Bar snap in type MB991202 Oil Seal and Bearing Installer C RACK ASSEMBLY INSTALLATION CAUTION Do not close the vent hole in the rack with grease 1 Apply a coating of repair kit grease to the rack teeth face 2 Cover rack serrations with the following special tool MB991212 Oil Seal Protector Comfort MB991213 Oil Seal Protector Sport 3 Apply ATF DEXRON III or DEXRON II to...

Page 117: ... through cylinder hole Turn the rack stopper clockwise and insert the circlip firmly F UPPER OIL SEAL UPPER BEARING INSTALLATION Apply a coating of ATF DEXRON III or DEXRON II to the outside of the upper oil seal upper bearing Using the following special tools press the upper oil seal upper bearing into the valve housing MB990938 Bar Snap in type MB991203 Oil Seal and Bearing Installer G SEAL RING...

Page 118: ...ivalent 3 Use the following special tool to tighten the rack support cover to 23 2 N m MB990607 Torque Wrench Socket Comfort MB991621 Piston Driver Sport 4 Turn the rack support cover 30 anticlockwise 5 Use the special tool to hold the rack support cover and then tighten the lock nut to 59 10 N m K TOTAL PINION TORQUE ADJUSTMENT CAUTION Be sure there is no ratcheting or catching when operating the...

Page 119: ...y 0 7 mm per one turn NOTE Do not turn the adjusting bolt more than one turn Standard value W 2 9 mm When more than 2 9 mm Screw in the adjusting bolt When less than 2 9 mm Loosen the adjusting bolt CAUTION Hold the rack housing and use special tool to crimp the bellows band securely Crimp the bellows band until special tool touches the stopper 2 Use special tool boot band crimping tool MB991561 t...

Page 120: ...so that the distance is as shown in the illustration TIE ROD END BALL JOINT DUST COVER REPLACEMENT M1372008200327 If the dust cover is damaged accidentally during service work replace the dust cover as follows 1 Apply specified grease to the lip and inside of the dust cover Specified grease Multipurpose grease SAE J310 NLGI No 2 or equivalent 2 Drive in the dust cover with special tool front axle ...

Page 121: ...o P 37 13 Drive Belt Tension Check 1300 1600 refer to GROUP 11A On vehicle Service Drive Belt Tension Check P 11A 7 2000 refer to GROUP 11C On vehicle Service Drive Belt Tension Check P 11C 7 AC209708 8 7 1 2 3 4 5 6 57 7 N m 40 4 N m 22 4 N m N 9 40 5 N m AC Removal steps 1 Pressure switch connector 2 A C compressor harness connector bracket Vehicles with A C 3 Drive belt 4 Suction hose 5 Eye bol...

Page 122: ...t lower side at the pulley side INSPECTION M1372005300187 Check the drive belt for cracks Check the pulley for uneven rotation AC200116AB 22 4 N m 12 2 N m 22 4 N m 49 9 N m 57 7 N m 1 5 4 3 6 2 7 49 9 N m Removal steps 1 Pressure switch connector 2 Drive belt 3 Suction hose 4 Pressure hose A 5 Oil pump assembly 6 A C compressor harness 7 Power steering pump bracket Removal steps Continued ...

Page 123: ... 3 1 18 15 10 2 11 13 10 3 9 8 6 5 7 3 4 3 28 1 N m 16 15 14 59 9 N m 12 28 2 N m 17 12 1 N m 13 Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit ATF DEXRON III or DEXRON II Disassembly steps 1 Pump cover 2 O ring 3 Snap ring 4 Pulley and shaft 5 Vanes C 6 Cam ring 7 Rotor 8 Pin 9 Side plate A 10 O ring B 11 Oil seal 12 Terminal assembly A 13 O ring 14 Plug assembly Disassemb...

Page 124: ...edan Wagon Comfort 12 1 N m Wagon Sport 18 17 5 7 3 9 8 6 3 13 10 2 13 10 15 18 11 4 3 Oil pump seal kit Oil pump cartridge kit Oil pump pulley and shaft kit ATF DEXRON III or DEXRON II Disassembly steps 1 Pump cover 2 O ring 3 Snap ring 4 Pulley and shaft 5 Vanes C 6 Cam ring 7 Rotor 8 Pin 9 Side plate A 10 O ring B 11 Oil seal 12 Terminal assembly A 13 O ring 14 Plug assembly A 15 O ring 16 Flow...

Page 125: ...nstall the cam ring as shown in the illustration INSPECTION M1372005500200 Check the flow control valve of the pump body for clogging Check the pulley and shaft for wear or damage Check the rotor and vane groove for stepped wear Check the contact surface of cam ring and vanes for stepped wear Check the vanes for damage No ID Width mm 1 15 8 2 4 2 21 0 1 9 3 14 8 2 4 4 3 8 1 9 5 14 8 1 9 AC100170AB...

Page 126: ...en fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body LH drive vehicles Pre removal and Post installation Operation Power Steering Fluid Draining and Refilling Refer to P 37 13 and Bleeding Refer to P 37 13 AC304699AB 15 3 N m 18 2 N m 167 9 N m 12 2 N m 49 10 N m 12 2 N m 57 7 N m 57 7 N m 3 1 2 9 13 10 7 11 12 5 6 8 12 2 N m 12 2 ...

Page 127: ...r Centermember P 32 7 A 7 Eye bolt Removal steps Continued 8 Gasket 9 Pressure hose assembly 10 Return tube A 11 Return hose A 12 Return tube 13 O ring Removal steps Continued AC304698AB 15 3 N m 18 2 N m 167 9 N m 12 2 N m 49 10 N m 12 2 N m 57 7 N m 3 1 2 9 10 7 5 6 2 4 8 8 57 7 N m 167 9 N m Crossmember 12 2 N m 1300 1600 2000 7 6 57 7 N m 7 6 57 7 N m 7 6 57 7 N m 12 2 N m Removal steps 1 Oil ...

Page 128: ...URN HOSE INSTALLATION LH DRIVE VEHICLES Install the return hose so that the marking is positioned as shown in the illustration B RETURN HOSE INSTALLATION Install the return hose so that the markings are positioned as shown in the illustration C SUCTION HOSE INSTALLATION Install the suction hose oil pump side so that the marking is positioned forward Centermember Refer to GROUP 32 Engine Roll Stopp...

Page 129: ...CLE SERVICE 36 3 PARKING BRAKE LEVER STROKE CHECK AND ADJUSTMENT 36 3 LINING RUNNING IN 36 3 PARKING BRAKE SWITCH CHECK 36 4 PARKING BRAKE LEVER 36 5 REMOVAL AND INSTALLATION 36 5 PARKING BRAKE CABLE 36 6 REMOVAL AND INSTALLATION 36 6 PARKING BRAKE LINING AND DRUM 36 7 REMOVAL AND INSTALLATION 36 7 INSPECTION 36 9 ...

Page 130: ...r SPECIFICATIONS CONSTRUCTION DIAGRAM SERVICE SPECIFICATIONS M1361000300382 Item Specification Type Drum in disc Clearance adjustment Manual AC211553 AC104333 AC304152 Parking brake lever assembly Parking brake cable AB Drum in disc brake Item Standard value Limit Parking brake lever stroke 5 7 notches Rear brake lining thickness mm 2 8 1 0 Rear drum inside diameter mm 168 0 169 0 ...

Page 131: ...of the arrow 6 Turn the adjusting nut to adjust the parking brake lever stroke to the standard value After adjusting check that there is no space between the adjusting nut and the parking brake lever Check that the adjusting nut is secured with the nut holder CAUTION If the parking brake lever stroke is below the standard value and the braking is too firm the rear brakes may drag 7 Release the par...

Page 132: ...0 minutes 5 Repeat the procedure in steps 2 to 4 four or five times PARKING BRAKE SWITCH CHECK M1361003300381 1 Remove the rear console assembly Refer to GROUP 52A Rear Floor Console P 52A 8 2 Remove the front seat assembly RH Refer to GROUP 52A Front Seat P 52A 24 3 Check for continuity between the parking brake switch terminal and the switch mounting bolt AC212035 AC Spring balance Approximately...

Page 133: ...A 8 Post installation Operation Parking Brake Lever Stroke Adjustment Refer to P 36 3 Rear Console Bracket and Rear Console Assembly Installation Refer to GROUP 52A Rear Floor Console P 52A 8 AC006199 AB 4 5 2 1 3 A A B B Ratchet pawl Section A A Section B B Ratchet pawl Removal steps 1 Adjusting nut 2 Parking brake switch connector 3 Parking brake cable connection 4 Parking brake lever assembly 5...

Page 134: ...st installation Operation Parking Brake Lever Stroke Adjustment Refer to P 36 3 Rear Seat Cushion Assembly Installation Refer to GROUP 52A Rear Seat P 52A 28 Rear Console Bracket and Rear Console Assembly Installation Refer to GROUP 52A Rear Floor Console P 52A 8 AC301226 1 AB 2 3 Removal steps Rear brake shoe assembly Refer to P 36 7 Loosen the parking brake lever stroke adjusting nut 1 Parking b...

Page 135: ... steps A 1 Rear brake assembly 2 Rear brake disc 3 Rear hub assembly Refer to GROUP 27 Rear Hub Assembly P 27 5 D 4 Shoe return spring D 5 Shoe return spring 6 Shoe guide plate 7 Shoe auto adjuster spring C 8 Shoe slack adjuster 9 Parking brake operating lever strut 10 Shoe to strut spring 11 Shoe spring cup 12 Shoe hold down spring 13 Rear brake pin 14 Rear brake primary shoe assembly 15 Rear bra...

Page 136: ...pliers or a similar tool to close the rear brake chamber retainer end onto the pin C SHOE SLACK ADJUSTER INSTALLATION Install the shoe slack adjuster so that the shoe adjusting bolt for the left rear wheel is attached towards the front of the vehicle and the shoe adjusting bolt for the right rear wheel is towards the rear of the vehicle AC000924AG Rear brake secondary shoe assembly pin Rear brake ...

Page 137: ...hat INSPECTION M1361002600248 PARKING BRAKE LINING AND DRUM CHECK 1 Measure the thickness of the brake lining at several places Standard value 2 8 mm Limit 1 0 mm 2 If the thickness of the brake lining is below the limit replace the shoe assemblies on both sides of the vehicle Never replace only one side 3 Measure the inside diameter of the brake disc in two places or more Standard value 168 0 mm ...

Page 138: ...NOTES ...

Page 139: ...35 1 GROUP 35 SERVICE BRAKES CONTENTS BASIC BRAKE SYSTEM 35A ANTI SKID BRAKING SYSTEM ABS 35B ...

Page 140: ...NOTES ...

Page 141: ...4 7 STABILIZER LINK BALL JOINT DUST COVER INSPECTION 34 7 CONTROL LINK UPPER ARM AND LOWER ARM 34 8 REMOVAL AND INSTALLATION 34 8 INSPECTION 34 9 LOWER ARM BUSHING AND LOWER ARM PILLOW BALL BUSHING REPLACEMENT 34 10 TRAILING ARM ASSEMBLY 34 12 REMOVAL AND INSTALLATION 34 12 INSPECTION 34 13 TRAILING ARM BUSHING REPLACEMENT 34 13 SHOCK ABSORBER ASSEMBLY 34 15 REMOVAL AND INSTALLATION 34 15 INSPECTI...

Page 142: ...STRUCTION DIAGRAM AC304024 AB Shock absorber Coil spring Trailing arm bushing Lower arm assembly Control link Trailing arm Upper arm assembly Stabilizer bar Rear shock absorber damper Sedan Wagon Comfort Rear shock absorber damper Rear shock absorber cover AC304025AB Shock absorber Trailing arm bushing Control link Trailing arm Stabilizer bar Sport Coil spring Lower arm assembly Rear shock absorbe...

Page 143: ...in At the centre of tyre tread mm 3 2 Toe angle per wheel 0 08 05 Thrust angle 0 00 0 09 Control link pillow ball bushing rotation starting torque Sport N m 0 5 3 0 Upper arm pillow ball bushing rotation starting torque Sport N m 0 5 3 0 Lower arm pillow ball bushing rotation starting torque N m 0 5 3 0 Protruding length of stabilizer link bolt mm 6 8 Stabilizer link ball joint continuous rotating...

Page 144: ...torque check Stabilizer link ball joint turning torque check MB991447 Bushing remover and installer Lower arm bushing removal and press fitting MB991448 Bushing remover and installer base MB991449 Bushing remover and installer supporter MB990957 A MB990969 B MB990971 Lower arm bushing remover and installer A Guide B Base Lower arm pillow ball bushing removal and press fitting MB990996 Lower arm bu...

Page 145: ...al tool wheel alignment gauge attachment MB991014 are loosened NOTE For vehicles with aluminium wheels attach the camber caster kingpin gauge to the trailing arm spindle by using special tool wheel alignment gauge attachment MB991014 Tighten the special tool to the same torque 175 25 N m as the rear wheel hub nut self locking nut MB990947 Lower arm bushing arbor Trailing arm bushing removal and pr...

Page 146: ...ON To prevent bushings from breakage the control link mounting nut should be temporarily tightened and then fully tightened to 120 10 N m with the vehicle on the earth in the unladen condition Carry out adjustment by turning the toe adjusting bolt control link mounting bolt which is located on the inner side of the body NOTE LH Clockwise viewed from the front Toe in RH Clockwise viewed from the fr...

Page 147: ... your hands to check for an excessive play in the axial direction of the pillow ball bushing If there is an excessive play replace the lower arm pillow ball bushing Refer to P 34 10 4 After inspection install the stabilizer link and shock absorber to the lower arm assembly Refer to P 34 8 STABILIZER LINK BALL JOINT DUST COVER INSPECTION M1341012800274 1 Check stabilizer link ball joint dust covers...

Page 148: ...Post installation Operation Rear Wheel Alignment Check and Adjustment Refer to P 34 5 AC304154 1 2 3 4 5 6 AB 120 10 N m 95 15 N m 120 10 N m 120 10 N m 95 15 N m Sport Sport Comfort Comfort 1 2 90 10 N m 120 10 N m N Control link and upper arm assembly removal steps A B 1 Control link B B 2 Upper arm assembly Lower arm assembly removal steps A 3 Stabilizer link connection B 4 Lower arm assembly a...

Page 149: ...stabilizer link thread part protruding length meets the standard value Standard value A 6 8 mm B UPPER ARM ASSEMBLY CONTROL LINK INSTALLATION Install the upper arm assembly as shown so that its hole is body side Comfort Install the upper arm assembly control link as shown so that its identification colour faces the trailing arm Sport INSPECTION M1341004900157 Check the bushings for wear and deteri...

Page 150: ...it turns smoothly the pillow ball bushing can be reused LOWER ARM BUSHING AND LOWER ARM PILLOW BALL BUSHING REPLACEMENT M1341011800204 Replace the lower arm bushing and lower arm pillow ball bushing as follows LOWER ARM BUSHING REPLACEMENT CAUTION Because the outside diameter of both edges of the bushing are different be careful not to mistake the direction Use following special tools to drive out...

Page 151: ...l tools to drive out and press fit the bushing MB990957 Lower Arm Bushing Remover and Installer MB990969 Guide MB990971 Base MB990996 Lower Arm Bushing Arbor After press fitting the space between the edges of the bushing outer sleeve and of the lower arm should be 3 mm AC102522AC 3 mm MB990996 Lower arm MB990971 MB990969 ...

Page 152: ...icle Service Bleeding P 35A 6 Rear Wheel Alignment Check and Adjustment Refer to P 34 5 Parking Brake Lever Stroke Adjustment Refer to GROUP 36 On vehicle Service Parking Brake Lever Stroke Check and Adjustment P 36 3 AC101449 AC301223 AC304155AB 90 10 N m 120 10 N m 95 15 N m 63 7 N m 6 7 8 1 10 11 2 3 4 120 10 N m 15 2 N m N 9 5 Removal steps A Lifting point 1 Rear ABS Sensor Refer to GROUP 35B ...

Page 153: ...k thread part protruding length meets the standard value Standard value A 6 8 mm INSPECTION M1341002300182 Check the bushings for wear and deterioration Check the trailing arm for bending or damage TRAILING ARM BUSHING REPLACEMENT M1341011300221 1 Use the following special tools to drive out the trailing arm bushing MB990890 Rear Suspension Bushing Base MB990947 Lower Arm Bushing Arbor MB991816 Bu...

Page 154: ...ojection end of the trailing arm bushing inner pipe towards the inside of the vehicle 2 Make sure that the hollow of the trailing arm bushing is located as shown in the illustration 3 Using the special tools press the trailing arm bushing into the position shown AC006173AB AC006172 AF Press fitting MB990890 Trailing arm MB990947 MB991816 16 2 0 5 mm ...

Page 155: ...vehicle on the earth in the unladen condition Pre removal and Post installation Operation Centre Luggage Floor Lid Wagon Removal and Installation Centre Luggage Floor Box Wagon Removal and Installation AC304794 AB 44 5 N m 2 4 1 3 5 95 15 N m 95 15 N m N Removal steps B 1 Stabilizer link connection A 2 Lower arm bolt 3 Coil spring nut 4 Coil spring bolt A 5 Shock absorber assembly Removal steps Co...

Page 156: ...ction so that it points towards the rear side of the vehicle B STABILIZER LINK INSTALLATION Tighten the self locking nut until the stabilizer link thread part protruding length meets the standard value Standard value A 6 8 mm INSPECTION M1341002600150 Check the rubber parts for cracks and wear Check the shock absorber for malfunctions oil leakage or abnormal noise AC107126 AB Piece of wood AC30479...

Page 157: ...spension coil spring washer 3 Rear suspension coil spring bushing 4 Rear suspension coil spring collar D 5 Rear shock absorber insulator 6 Rear suspension coil spring bushing 7 Rear suspension spring damper plate 8 Rear shock absorber damper 9 Rear shock absorber cover Wagon comfort C 10 Rear suspension spring upper pad B 11 Rear suspension coil spring A 12 Rear suspension spring lower pad B 13 Re...

Page 158: ...ill cause special tools MB991237 and MB991239 to slip and cause personal injury 2 While holding the piston rod remove the rear suspension coil spring nut self locking nut B REAR SUSPENSION SHOCK ABSORBER DISPOSAL WARNING Wear goggles when drilling to protect your eyes from flying metal debris The gas must be discharged from the shock absorber before discarding it Place the shock absorber horizonta...

Page 159: ...ON Install the rear shock absorber insulator so that the axis of the lower bushing inner pipe of the shock absorber and the line between the rear shock absorber insulator mounting bolts are straight when looking from above E REAR SUSPENSION COIL SPRING NUT SELF LOCKING NUT INSTALLATION 1 Temporarily tighten the rear suspension coil spring nut self locking nut CAUTION Do not use an impact wrench to...

Page 160: ...to check that there are no cracks or damage in the dust cover AC304232 AC107102 AB 12 2 N m 39 5 N m 4 5 6 7 25 4 N m Specified grease Multipurpose grease SAE J310 NLGI No 2 or equivalent 2 2 3 1 N 3 Removal steps B 1 Self locking nut 2 Stabilizer rubber 3 Stabilizer link A 4 Fixture A 5 Bushing A 6 Stabilizer bar 7 Stabilizer bracket Removal steps Continued ...

Page 161: ...he ball joint Standard value 0 5 1 5 N m 2 If the measured value exceeds the standard value replace the stabilizer link 3 If the measured value is lower than the standard value check that the ball joint turns smoothly without excessive play If so it is possible to re use that ball joint STABILIZER LINK BALL JOINT DUST COVER CHECK 1 Check the dust cover for cracks or damage by pushing it with your ...

Page 162: ... new dust cover Specified grease Multipurpose grease SAE J310 NLGI No 2 or equivalent 3 Wrap plastic tape around the stabilizer link stud and then install the dust cover to the stabilizer link 4 Secure the dust cover by the clip ring 5 Check the dust cover for cracks or damage by pushing it with finger AC006188AB Clip ring ...

Page 163: ... or maintenance of any component of the SRS or any SRS related component can lead to personal injury or death to service personnel from inadvertent firing of the air bag or to the driver and paassenger from rendering the SRS inoperative Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer MITSUBISHI dealer personnel must tho...

Page 164: ...he mark indicates optional item AC304023 AC304022 AC304754 Lower arm assembly Front axle No 1 crossmember Stabilizer bar Strut shock absorber Coil spring AB Comfort Strut cover Strut damper Sport Strut damper Item Sedan Wagon Comfort Sport Comfort Sport Wire diameter mm 13 13 13 1600 M T 14 1600 A T 2000 14 13 1600 14 2000 Average diameter mm 160 160 160 160 Free length mm 330 321 330 1600 M T 338...

Page 165: ...drive vehicles 33 40 1 00 2 00 Sport RH drive vehicles 37 00 1 00 2 00 Outer wheel reference Comfort 32 30 Sport LH drive vehicles 28 46 Sport RH drive vehicles 30 00 Camber Comfort 0 05 30 Sport 0 05 30 Caster Comfort 2 45 30 Sport 2 55 30 Kingpin inclination Comfort 12 30 1 30 Sport 12 40 1 30 Lower arm ball joint rotation starting torque N m 0 3 9 Protruding length of stabilizer link thread par...

Page 166: ...MB991237 B MB991238 A Spring compressor body B Arm set Coil spring compression MB991680 A MB991681 B MB991682 Wrench set A Wrench B Socket Strut assembly disassembly and reassembly MB991006 Preload socket Lower arm ball joint rotation starting torque check MB990800 Ball joint remover and installer Lower arm ball joint cover installation MB991004 MB991237 A B MB991680 A B MB991006 MB990800 ...

Page 167: ...djust the toe in by undoing the clip and lock nut and turning the left and right tie rod turnbuckles by the same amount in opposite directions MB990883 Rear suspension bushing arbor Lower arm bushing rear removal and press fitting MB990972 Torsion bar bushing remover base MB990887 Ring MB990890 Rear suspension bushing base MB991897 Ball joint remover Knuckle and tie rod end ball joint disconnectio...

Page 168: ...the camber caster kingpin gauge to the driveshaft by using special tool wheel alignment gauge attachment MB991004 Tighten the special tool to the same torque 245 29 N m as the driveshaft nut LOWER ARM BALL JOINT AXIAL PLAY CHECK M1332011300074 1 Raise the vehicle 2 Remove the stabilizer link from the lower arm 3 Move the lower arm up and down with your hands to check for an excessive play in the a...

Page 169: ... strut assembly Check the strut assembly for damage or deformation Post installation Operation Front Wheel Alignment Adjustment Refer to P 33 5 AC304153 44 5 N m 1 2 3 4 N AB 167 9 N m 5 Removal steps 1 Front ABS sensor harness bracket 2 Brake hose bracket 3 Knuckle connection 4 Strut nut self locking nut 5 Strut assembly Removal steps Continued ...

Page 170: ...65 9 10 1 2 3 4 5 6 60 10 N m AC 8 7 Sport Comfort Disassembly steps A B 1 Strut nut self locking nut 2 Strut insulator 3 Strut bearing A 4 Spring upper seat 5 Strut damper Sport 6 Strut cover Comfort 7 Strut damper Comfort 8 Coil spring 9 Spring lower pad B 10 Strut Disassembly steps Continued ...

Page 171: ...ll cause special tools MB991237 and MB991238 to slip and cause personal injury 2 Use following special tools to secure the strut and then remove the strut nut self locking nut MB991681 Wrench MB991682 Socket B STRUT DISPOSAL WARNING Wear goggles when drilling to protect your eyes from flying metal debris The gas must be discharged from the strut before discarding it Place the strut horizontally wi...

Page 172: ...ing lower seat with the hole in the spring upper seat NOTE Using a rod as shown facilitates the alignment 5 Align lower end of the coil spring with the groove in the spring lower seat and then loosen the special tools CAUTION Do not use an impact wrench to tighten the self locking nut otherwise the strut nut self locking nut will be damaged 6 Using following special tools tighten the strut nut sel...

Page 173: ...peration Check the lower arm ball joint cover for cracks or damage by pushing it with your finger Front Wheel Alignment Check and Adjustment Refer to P 33 5 AC006097 AD 7 1 3 4 5 108 10 N m 186 10 N m 7 3 6 N Specified grease Multipurpose grease SAE J310 NLGI No 2 or equivalent 167 9 N m 6 2 Removal steps A 1 Self locking nut 2 Bolt 3 Stabilizer rubber 4 Collar 5 Lower arm bolt A 6 Lower arm bolt ...

Page 174: ...not within the standard value or if the ball joint is difficult to turn or does not turn smoothly replace the lower arm assembly LOWER ARM BALL JOINT COVER CHECK 1 Check the lower arm ball joint cover for cracks or damage by pushing it with your finger 2 If the lower arm ball joint cover is cracked or damaged replace the lower arm assembly NOTE Cracks or damage to the dust cover may cause damage t...

Page 175: ...lowing special tools to drive out the lower arm bushing rear MB990883 Rear Suspension Bushing Arbor MB990972 Torsion Bar Bushing Remover Base MB990887 Ring MB990890 Rear Suspension Bushing Base 2 Position the lower arm bushing rear so that its projection is as shown and then use the special tools to press in the bushing 3 Press the lower arm bushing rear until its outer tube is flush with the lowe...

Page 176: ...37 17 Sport refer to GROUP 37 Steering Wheel P 37 19 Clock Spring Removal Refer to GROUP 52B Air Bag Modules and Clock Spring P 52B 210 Centermember Removal Refer to GROUP 32 Engine Roll Stopper Centermember P 32 7 Front Exhaust Pipe Removal Refer to GROUP 15 Exhaust Pipe and Main Muffler P 15 11 Post installation Operation Front Exhaust Pipe Installation Refer to GROUP 15 Exhaust Pipe and Main Mu...

Page 177: ... Removal steps B 1 Self locking nut 2 Stabilizer rubber 3 Collar 4 Lower arm and knuckle connection A 5 Tie rod end and knuckle connection 6 Steering shaft cover 7 Steering gear and joint connecting bolt 8 Engine rear roll stopper bracket connecting bolt B A 9 Stabilizer bar bracket B A 10 Stabilizer bushing B A 11 Stabilizer bar Removal steps Continued ...

Page 178: ...BRACKET STABILIZER BUSHING STABILIZER BAR REMOVAL Carry out the following operations to ensure working space in order to remove the stabilizer bar brackets the stabilizer bushings and the stabilizer bar 1 Use a transmission jack to hold the crossmember and then remove the crossmember mounting nuts and bolts CAUTION Be careful not to lower the crossmember excessively otherwise the power steering re...

Page 179: ...bilizer link thread part protruding length meets the standard value Standard value A 22 1 5 mm INSPECTION M1332002000279 Check the stabilizer rubbers and stabilizer bushings for wear and deterioration Check the stabilizer bar for deterioration or damage Check all bolts for condition and straightness AC101741AC A ...

Page 180: ...NOTES ...

Page 181: ...ION 31 2 SERVICE SPECIFICATIONS 31 2 TROUBLESHOOTING 31 3 DIAGNOSIS 31 3 WHEEL BALANCE ACCURACY 31 4 ON VEHICLE SERVICE 31 7 TYRE INFLATION PRESSURE CHECK 31 7 TYRE WEAR CHECK 31 7 WHEEL RUNOUT CHECK 31 7 WHEEL AND TYRE 31 7 INSTALLATION SERVICE POINT 31 7 ...

Page 182: ...pe Steel type or Aluminium type Aluminium type Size 15 6JJ 16 6JJ Amount of wheel offset mm 46 46 PCD mm 114 3 114 3 Tyre Size 195 60R15 88H 195 50R16 84V Item Comfort Sport Spare wheel Type Steel type Steel type Size 16 4T or 15 6JJ 16 4T or 16 6JJ Amount of wheel offset mm 46 40 or 46 PCD mm 114 3 114 3 Spare tyre Size T125 70D16 96M or 195 60R15 88H T125 70D16 96M or 195 50R16 84V ITEM LIMIT Tr...

Page 183: ...ation Adjust the tyre pressure For tyre inflation pressure refer to the label on the driver s side centre pillar Wear on one side Excessive camber Check the camber Front Refer to GROUP 33 On vehicle service Front wheel alignment check and adjustment P 33 5 Rear Refer to GROUP 34 On vehicle service Rear wheel alignment check and adjustment P 34 5 Feathered edge Incorrect toe in Adjust the toe in Ba...

Page 184: ...this section for zero calibration static balance and dynamic balance checks The wheel balancer calibration checks are also described in the flowchart Refer to P 31 6 PROCEDURE Balancing Tips 1 Confirm that the balancer s cone and the wheel mounting cone are undamaged and free of dirt and rust 2 On this vehicle the wheel s centre hole on the hub side has a chamfered edge Use a back mounting cone on...

Page 185: ...r to the balancer manufacturer s instructions to verify the correct attachments After making the necessary corrections recheck the wheel balance If OK then go to Step 4 If the imbalance is more than 5g the balancer requires calibration Contact the balancer manufacturer for calibration by their repair representative 4 Static Balance Check Attach a 5g weight to the outer rim Recheck the balancer The...

Page 186: ...ppropriate for wheel Make necessary corrections then recheck wheel balance Attach a 5 g 0 18 oz weight to the outer rim Is the imbalance 5 2g 0 18 0 06oz at 170 190 degrees away from the 5 g 0 18 oz weight YES NO Attach a 5 g 0 18 oz weight to the inner rim at 180 degrees opposite the weight on the outer rim Is the imbalance 5 2g 0 18 0 06oz at 170 190 degrees away from both 5 g 0 18 oz weights YE...

Page 187: ...ce the tyre NOTE When the tread depth of the tyres is reduced to 1 6 mm or less wear indicators will appear WHEEL RUNOUT CHECK M1311001100353 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 If wheel runout exceeds the limit replace the wheel WHEEL AND TYRE INSTALLATION SERVICE POINT M1311001300294 Tighten...

Page 188: ...NOTES ...

Page 189: ...VICE SPECIFICATIONS 27 2 SEALANT 27 2 SPECIAL TOOLS 27 3 ON VEHICLE SERVICE 27 4 WHEEL BEARING AXIAL PLAY CHECK 27 4 REAR HUB ROTARY SLIDING RESISTANCE CHECK 27 4 HUB BOLT REPLACEMENT 27 4 REAR AXLE HUB ASSEMBLY 27 5 REMOVAL AND INSTALLATION 27 5 INSPECTION 27 6 ...

Page 190: ...ant to a thrust load ABS rotor for detecting the wheel speeds is press fitted to the rear hub in vehicles with ABS CONSTRUCTION DIAGRAM SERVICE SPECIFICATIONS M1271000300483 SEALANT M1271000500261 AC300617AB Rear hub Oil seal Wheel bearing ABS rotor Trailing arm spindle Item Limit Wheel bearing axial play mm 0 05 Rear hub rotary sliding resistance N 19 Item Specified sealant Remark Hub cap 3M ATD ...

Page 191: ... M1271000600495 Tool Number Name Use MB990767 End yoke holder Hub fixing MB991618 Hub bolt remover Hub bolt removal MD998801 Remover Removal of ABS rotor MD998812 Installer cap MD998813 Installer 100 MD998815 Installer adapter B990767 MB991618 ...

Page 192: ...ope around the hub bolt and turn the hub by pulling at a 90 angle with a spring balance Measure to determine whether or not the rotary sliding resistance of the rear hub is at the limit value Limit 19 N 4 If limit value is exceeded loosen the self locking nut and then tighten it to the specified torque and check the rear hub rotary sliding resistance again Tightening torque 175 25 N m 5 Replace th...

Page 193: ...the system will not function normally The rear hub assembly should not be dismantled When removing the rear hub assembly the wheel bearing inner race may be left at the spindle side In this case always replace the rear hub assembly otherwise the hub will damage the oil seal causing oil leaks or excessive play AC304175 Semi drying sealant 3M ATD Part No 8663 or equivalent 2 3 5 6 4 N 175 25 N m 3 A...

Page 194: ...TS A ABS ROTOR INSTALLATION CAUTION When installing take care not to deform the ABS rotor Press fit the ABS rotor to the rear hub assembly B SELF LOCKING NUT INSTALLATION CAUTION Before securely tightening the self locking nuts make sure there is no load on the wheel bearings Otherwise the wheel bearing will be damaged Tighten the self locking nut to the specified torque INSPECTION M1271002100258 ...

Page 195: ...CE 26 7 WHEEL BEARING AXIAL PLAY CHECK 26 7 HUB BOLT REPLACEMENT 26 7 FRONT AXLE HUB ASSEMBLY 26 8 REMOVAL AND INSTALLATION 26 8 INSPECTION 26 11 DISASSEMBLY AND REASSEMBLY 26 11 INSPECTION 26 13 DRIVE SHAFT ASSEMBLY 26 14 REMOVAL AND INSTALLATION 26 14 DISASSEMBLY AND REASSEMBLY 26 18 INSPECTION 26 21 BJ BOOT RESIN BOOT REPLACEMENT 26 21 ...

Page 196: ...e dynamic damper has been mounted on the driveshaft to reduce differential gear noise ABS rotor for detecting the wheel speed is press fitted to the BJ NOTE TJ Tripod Joint BJ Birfield Joint SPECIFICATIONS CONSTRUCTION DIAGRAM Item 1 3L 1 6L 2 0L Wheel bearing Type Double row angular contact ball bearing Bearing OD x ID mm 80 x 40 80 x 40 Driveshaft Joint type Outer BJ BJ Inner TJ TJ Length joint ...

Page 197: ...oot length mm 1 3L RH 1 6L A T RH 85 3 1 3L LH 1 6L M T 1 6L A T LH 2 0L 90 3 Opening dimension of the special tool MB991561 mm When the BJ boot band small is crimped 2 9 When the BJ boot band large is crimped 2 9 Crimped width of the BJ boot band mm 2 4 2 8 Item Specified lubricant Quantity TJ boot grease Repair kit grease 1 3L LH 1 6L LH 2 0L LH 120 10 g 1 3L RH 1 6L A T RH 110 10 g 1 6L M T RH ...

Page 198: ...t MB990241 A MB990242 B MB990244 Axle shaft puller A Puller shaft B Puller bar Removal of the drive shaft MB991354 Puller body MB991056 or MB991355 Knuckle arm bridge Removal of the hub Removal of the wheel bearing A MB991017 B MB990998 C MB991000 A B Front hub remover and installer C Spacer Removal of the hub Provisional holding of the wheel bearing Measurement of hub starting torque Measurement ...

Page 199: ... objects MB991561 Boot band crimping tool BJ boot resin boot band installation MB990925 Bearing and oil seal installer set Removal of the wheel bearing Removal and installation of the centre bearing Press fitting of the dust seal outer inner MB990890 Rear suspension bushing base Installation of the wheel bearing Press fitting of the dust seal outer inner MB990883 Rear suspension bushing arbor Inst...

Page 200: ...0926 39 0 MB990927 45 0 MB990928 49 5 MB990929 51 0 MB990930 54 0 MB990931 57 0 MB990932 61 0 MB990933 63 5 MB990934 67 5 MB990935 71 5 MB990936 75 5 MB990937 79 0 B MB990938 C MB990939 ACX02372 A B C Brass bar Bar snap in type Tool box MB990925 AC Installer adapter ...

Page 201: ...c caliper assembly and tighten the caliper assembly mounting bolts to the specified torque 100 10 N m HUB BOLT REPLACEMENT M1261001000291 1 Remove the caliper assembly and suspend it with wire so that it does not fall 2 Remove the brake disc 3 Use special tool hub bolt remover MB991618 to remove the hub bolts 4 Install the plain washer to the new hub bolt and install the bolt with a nut while hold...

Page 202: ...uring servicing work Post installation Operation Check the dust cover for cracks or damage by pushing it with your finger AC209505 N N N 5 4 3 1 8 10 9 2 7 6 167 9 N m 25 5 N m 108 10 N m 245 29 N m 100 10 N m AC 7 7 11 12 13 Removal steps 1 Front ABS sensor A 2 Caliper assembly B 3 Brake disc C B 4 Drive shaft nut B 5 Washer A 6 Self locking nut stabilizer bar connection A 7 Stabilizer rubber 8 C...

Page 203: ...G NUT TIE ROD END CONNECTION REMOVAL CAUTION Do not remove the nut from ball joint Loosen it and use the special tool to avoid possible damage to ball joint threads Hang the special tool with cord to prevent it from falling 1 Install special tool ball joint remover MB991897 as shown in the figure 2 Turn the bolt and knob as necessary to make the jaws of special tool parallel tighten the bolt by ha...

Page 204: ... and collar as shown in the figure and tighten the self locking nut so that the protruding length of the stabilizer bar mounting bolt protruding part meets its standard value A Standard value A 22 1 5 mm B WASHER DRIVE SHAFT NUT INSTALLATION CAUTION Before securely tightening the drive shaft nuts make sure there is no load on the wheel bearings Otherwise the wheel bearings will be damaged 1 Be sur...

Page 205: ...er race and the knuckle or of the wheel bearing inner race and the hub is loose replace the bearing or damaged parts DISASSEMBLY AND REASSEMBLY M1261001900205 AC303659 N N 4 1 5 3 2 AB 2 Comfort Sport Disassembly steps 1 Snap ring A 2 Hub 3 Dust cover B 4 Wheel bearing 5 Knuckle Assembly steps 5 Knuckle A 4 Wheel bearing 1 Snap ring 3 Dust cover 2 Hub B Hub starting torque check C Wheel bearing ax...

Page 206: ...he wheel bearing inner race outside CAUTION When removing the inner race outside from the hub be careful not to let the hub drop 2 Remove the wheel bearing inner race outside from the front hub by using special tool side bearing puller MB990810 3 Install the inner race outside that was removed from the hub to the wheel bearing and then use the following special tools to remove the wheel bearing In...

Page 207: ...llowing special tools Torque wrench MB990685 Preload socket MB990326 Limit 1 8 N m 4 The starting torque must be within the limit and the hub rotation must be smooth C WHEEL BEARING AXIAL PLAY CHECK 1 Measure to determine whether the wheel bearing axial play is within the limit or not by using the following special tools Front hub remover and installer MB991017 Spacer MB991000 Limit 0 05 mm 2 If t...

Page 208: ...al Refer to GROUP 15 Exhaust Pipe and Muffler P 15 11 Post installation Operation Front Exhaust Pipe Installation Refer to GROUP 15 Exhaust Pipe and Muffler P 15 11 Check the Ball Joint Dust Cover for cracks or damage by pushing it with your finger Transmission Fluid Filling Refer to GROUP 22A On vehicle Service Transmission Oil Replacement P 22A 8 AC303689AB 9 N N N N 10 7 4 3 2 1 25 5 N m 245 29...

Page 209: ... and knob as necessary to make the jaws of special tool parallel tighten the bolt by hand and confirm that the jaws are still parallel NOTE When adjusting the jaws in parallel make sure the knob is in the position shown in the figure 3 Tighten the bolt with a wrench to disconnect the tie rod end C DRIVE SHAFT REMOVAL 1 Use the following special tools to push out the drive shaft from the hub Axle s...

Page 210: ...ive shaft from the transmission 4 Use special tool plug MB991460 to prevent the entry of foreign material into the transmission case CAUTION Do not apply pressure to the wheel bearing by the vehicle weight to avoid possible damage when the drive shaft is removed If however vehicle weight must be applied to the bearing in moving the vehicle temporarily secure the wheel bearing by using the followin...

Page 211: ...f locking nut so that the protruding length of the stabilizer bar mounting bolt protruding part meets its standard value A Standard value A 22 1 5 mm C WASHER DRIVE SHAFT NUT INSTALLATION 1 Be sure to install the drive shaft washer in the specified direction CAUTION Before securely tightening the drive shaft nuts make sure there is no load on the wheel bearings Otherwise the wheel bearing will be ...

Page 212: ...Tripod Joint BJ Birfield Joint AC303692 2 1 4 12 8 11 10 9 7 13 6 5 N N N 3 N N 2 1 4 13 8 11 12 5 2 1 4 7 6 5 3 2 1 4 7 5 AB N N BJ boot repair kit TJ boot repair kit TJ repair kit Grease for TJ Grease for BJ Disassembly steps D 1 TJ boot band large D 2 TJ boot band small A C 3 TJ case 4 Circlip 5 Snap ring A B 6 Spider assembly B A 7 TJ boot A 8 Damper band A 9 Dynamic damper 10 BJ assembly 11 B...

Page 213: ...OVAL 1 Wipe off grease from the shaft spline 2 When reusing the TJ boot wrap plastic tape around the shaft spline to avoid damaging the boot AC303700 AB Grease repair kit grease Amount used 1 3L LH 1 6L LH 2 0L LH 120 10 g 1 3L RH 1 6L A T RH 110 10 g 1 6L M T RH 120 10 g 2 0L RH 105 10 g The drive shaft joint uses special grease Do not mix old and new or different types of grease CAUTION Grease r...

Page 214: ...pair kit grease 2 Install the spider assembly to the shaft from the direction of the spline chamfered side C TJ CASE INSTALLATION CAUTION The drive shaft joint use special grease Do not mix old and new or different types of grease After applying the specified grease to the TJ case insert the drive shaft and apply grease one more time Specified grease Repair kit grease Amount to use 1 3L LH 1 6 LH ...

Page 215: ...e around the shaft spline and assemble the boot band and BJ boot 4 Align the centre groove on the BJ boot small end with the shaft groove 5 Turn the adjusting bolt on special tool boot band crimping tool MB991561 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...

Page 216: ...mm then W 3 2 mm 9 Check that the boot band is not sticking out past the place where it has been installed If the boot band is sticking out remove it and then repeat steps 6 to 8 using a new boot band CAUTION The drive shaft joint uses special grease Do not mix old and new or different types of grease 10 Fill the inside of the boot with the specified amount of the specified grease Specified grease...

Page 217: ...n W 2 9 mm If the crimping amount is smaller than 2 4 mm Remove the BJ boot band readjust the value of W in step 12 according to the following formula and then repeat the operations in steps 13 and 14 using a new BJ boot band W 5 8 mm F Example If F 2 3 mm then W 3 5 mm 16 Check that the boot band is not sticking out past the place where it has been installed If the boot band is sticking out remov...

Page 218: ...NOTES ...

Page 219: ...ALLATION 42 6 FUEL FILLER LID 42 8 REMOVAL AND INSTALLATION 42 8 STRUT TOWER BAR 42 9 REMOVAL AND INSTALLATION 42 9 WINDOW GLASS 42 9 ADHESIVE 42 9 SPECIAL TOOLS 42 9 WINDOW REPAIR 42 10 WINDSHIELD 42 12 REMOVAL AND INSTALLATION 42 12 REAR WINDOW GLASS 42 16 REMOVAL AND INSTALLATION 42 16 QUARTER WINDOW GLASS 42 19 REMOVAL AND INSTALLATION 42 19 TAILGATE WINDOW GLASS 42 22 REMOVAL AND INSTALLATION...

Page 220: ...LLATION 42 39 TRUNK LID 42 41 SPECIAL TOOL 42 41 ON VEHICLE SERVICE 42 41 TRUNK LID ADJUSTMENT 42 41 ADJUSTMENT OF CLEARANCE AROUND TRUNK LID 42 42 TRUNK LID STRIKER ADJUSTMENT 42 42 TRUNK LID HEIGHT ADJUSTMENT 42 42 TRUNK LID 42 43 REMOVAL AND INSTALLATION 42 43 INSPECTION 42 45 TAILGATE 42 46 SERVICE SPECIFICATIONS 42 46 SEALANTS 42 46 SPECIAL TOOL 42 46 TROUBLESHOOTING 42 46 ON VEHICLE SERVICE ...

Page 221: ... HOOD STRIKER M1421007300126 ADJUSTMENT OF HOOD HEIGHT M1421007400123 Rotate the hood bumper by using arrow mark on the hood bumper as a guide to adjust the hood height If the hood bumper is rotated just one turn the hood height changes by approximately 3 mm AC005945 AC005947 Y0215AU X0424CA AC005948AB Section A A A A Hood Hood bumper 17 mm ...

Page 222: ... of Hood Height Refer to P 42 3 AC304739 1 1 2 2 4 4 5 6 7 3 8 9 10 AD 9 0 2 0 N m 21 4 N m 11 2 N m 21 4 N m Removal 1 Hood bumper 2 Hood latch 3 Hood weatherstrip Hood lock release cable removal steps 4 Hood lock release handle 5 Hood lock release cable Hood and hood hinge removal steps 6 Hood insulator 7 Hood weatherstrip Washer hose Refer to GROUP 51 Windshield wiper and washer P 51 23 8 Hood ...

Page 223: ... BODY 42 5 FENDER SPECIAL TOOL M1421000600256 AC300865 Note Clip positions Section A A AC Clip A A 6 8 6 8 Clip positions Tool Number Name Use MB990784 Ornament remover Side turn signal lamp removal MB990784 ...

Page 224: ... Deck Garnish Removal and Installation Refer to GROUP 51 Windshield Wiper and Washer P 51 23 Side Air Dam Removal and Installation Vehicles with side air dam Refer to GROUP 51 Side Air Dam P 51 15 AC300491 AC304753 AC303863 Clip Section A A AB A A 1 2 3 3 4 Note Clip positions Removal steps 1 Splash shield A A 2 Side turn signal lamp 3 Delta outer garnish 4 Fender Removal steps Continued ...

Page 225: ...tab from the fender and remove the side turn signal light INSTALLATION SERVICE POINT A SIDE TURN SIGNAL LAMP INSTALLATION Engage the claw with the fender panel and install the side turn signal lamp AC005980 AC005980 Front of vehicle Side turn signal light MB990784 AB AC005719 Fender panel Hook Claw Fender panel Front of vehicle AE ...

Page 226: ...cuff Plate Driver s Side Centre Pillar Lower Trim Driver s Side Quarter Trim Driver s Side Removal and Installation Refer to GROUP 52A Trims P 52A 11 18M0109 W0570AQ AC005996 AC005973 3 5 4 3 2 1 5 0 1 0 N m AC Fuel filler lid height and clearance adjustment Removal steps 1 Fuel filler lid panel assembly 2 Clip 3 Fuel filler lid hook assembly 4 Fuel filler lid lock release cable 5 Fuel filler lid ...

Page 227: ...Specified adhesive Windshield 3M ATD Part No 8609 Super Fast Urethane Auto Glass Sealant or equivalent 3M ATD Part No 8608 Super Fast Urethane Primer or equivalent Rear window glass Quarter window glass Tailgate window glass Tool Number Name Use MB990480 Glass holder Removal and installation of window glass MB990784 Ornament remover Removal of rear window lower moulding MB990480 MB990784 ...

Page 228: ...lant for more than 6 months because it will lose its sealing effect BODY PINCH WELD FLANGE SERVICING Before servicing the body pinch weld flange remove old adhesive completely If the flange requires painting bake it after painting is completed Name Remark 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 equiv...

Page 229: ... lock fastener and glass stopper to the glass following the standard position all the way around the inside edge of the glass Application of primer Apply the primer to the adhesion surface of the body and let dry for 3 minutes or more Application of primer Apply sufficient primer evenly to the adhesion surface so that there is no patchiness After application let dry for 3 to 30 minutes Application...

Page 230: ... 11 Headlining Removal and Installation Refer to GROUP 52A Headlining P 52A 21 AC006003 X0111AU X0112AU Y0496AU 1 2 3 4 6 1 1 1 3 N N N N N AC Y0495AU A A B B C C Ceramic line Seal line Seal line Ceramic line Mark Mark Apply the primer and adhesive along the fictitious lines seal line between each of the marks Seal line centre Primer Section A A Section B B Seal line centre Primer Section C C Seal...

Page 231: ...side along the windshield to cut the adhesive CAUTION Inserting the glass adhesive knife too deeply into windshield adhesive may damage windshield 4 Using glass adhesive knife Keep glass adhesive knife at right angles with the windshield edge and put the blade at windshield edge and surface Then cut away adhesive along the windshield edge 5 Use special tool glass holder MB990480 to remove the wind...

Page 232: ...ide in the same way INSTALLATION SERVICE POINTS A WINDSHIELD SPACER SPACER GLASS STOPPER WINDOW DAM WINDSHIELD MOULDING INSTALLATION CAUTION Leave the degreased parts for 3 or more minutes to dry well before starting on the next step Do not touch the degreased parts 1 Use isopropyl alcohol to degrease the inside and outside of the windshield and the body flanges Y0628AU AC006029 10138AU 10139AU Y0...

Page 233: ...e because of the panel replacement on the body side apply evenly to the body side in the specified places 3 Allow the windshield to dry for at least three minutes after applying primer 4 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 appl...

Page 234: ...4AU AC006056 1 1 7 7 AB 6 2 5 4 9 7 3 N 2 N 2 N N 4 N N 3 N 3 N N N 2 N Ceramic line Mark Apply the primer and adhesive along the fictitious lines seal line between each of the marks Section A A Section B B Seal line centre Primer 8 N 10 N Adhesive 3M ATD Part No 8609 Super Fast Urethane Auto Glass Sealant or equivalent and 3M ATD Part No 8608 Super Fast Urethane Primer or equivalent 16 mm A A B B...

Page 235: ... place a mating mark on the rear window glass and body CAUTION Leave the degreased parts for 3 or more minutes to dry well before starting on the next step Do not touch the degreased parts 2 Use isopropyl alcohol to degrease the inside and outside of the rear window glass and the body flanges CAUTION The primer strengthens the adhesive so be sure to apply it evenly around the entire circumference ...

Page 236: ...42 12 B REAR WINDOW LOWER MOULDING INSTALLATION Install the clips to the rear window lower moulding and then fix the rear window moulding to the vehicle body Y0630AU Y0629AU AC006075 Glass stopper and window dam installation position Glass stopper 18 mm Glass end line Align the glass stopper end with the ceramic notch Ceramic line Rear window glass A A Section A A 19 mm Window dam Align the window...

Page 237: ...nd adhesive along the fictitious lines seal line between each of the marks Adhesive 3M ATD Part No 8609 Super Fast Urethane Auto Glass Sealant or equivalent and 3M ATD Part No 8608 Super Fast Urethane Primer or equivalent 1 1 1 Seal line centre Primer Section A A Section B B Seal line centre Primer Section C C Section D D Seal line centre Primer 1 Seal line centre Units mm Primer 16 16 16 16 Ceram...

Page 238: ...Be careful not to remove more adhesive than is necessary Be careful also not to damage the paintwork on the body surface with the knife If the paintwork is damaged repair the damaged area with repair paint or anti rust agent 6 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 7 Finish the flange surfaces so that t...

Page 239: ... step Do not touch the degreased parts 2 Use isopropyl alcohol to degrease the inside and outside of the quarter window glass and the body flanges 3 Assemble the dual lock fastener according to the standard location of the body flange 4 Assemble the dual lock fastener to the quarter window glass relative to the body flange dual lock fastener B QUARTER WINDOW GLASS INSTALLATION Remove the quarter w...

Page 240: ...allation Refer to GROUP 51 Rear Wiper and Washer P 51 29 AC304811 1 2 6 5 5 4 3 3 7 AB N N N N N N N Y1522AU Y1538AU AC304812 Y1537AU Y1537AU AB Units mm Adhesive 3M ATD Part No 8609 Super Fast Urethane Auto Glass Sealant or equivalent and 3M ATD Part No 8608 Super Fast Urethane Primer or equivalent Section A A 13 14 14 Section B B Section C C A A C C B B Ceramic line Mark Apply the primer and adh...

Page 241: ...TION CAUTION Leave the degreased parts for 3 or more minutes to dry well before starting on the next step Do not touch the degreased parts 1 Use isopropyl alcohol to degrease the inside and outside edges of the tailgate window glass and the surface of the tailgate flange Removal steps 1 Connecting the harness connector A B 2 Tailgate window glass A 3 Window lower dam A 4 Window side dam A 5 Dual l...

Page 242: ...nstallation Refer to P 42 12 AC107207 AC107207 Y1484AU Y1484AU AC304816AB Glass stopper Glass spacer Seal line Ceramic line Ceramic line Glass end line Glass end line Window spacer glass stopper and window dam installation position Align the glass spacer and with the tailgate window glass mark Position the window side dam 2 mm inside from the tailgate window glass end Butt the ends of the window l...

Page 243: ...y mm Front door 10 4 9 6 Rear door 10 9 6 Item Specified sealant Door waterproof film 3M ATD Part No 8633 or equivalent Tool Number Name Use MB990480 Window glass holder Removal of power window regulator assembly MB990900 or MB991164 Door hinge adjusting wrench Door alignment MB990925 A MB990939 Bearing and oil seal installer set A Brass bar Door striker adjustment MB990211 Sliding hammer MB990241...

Page 244: ... 54C Troubleshooting P 54C 4 MB991223 A MB991219 B MB991220 C MB991221 D MB991222 Harness set A Test harness B LED harness C LED harness adapter D Probe Terminal voltage measurement A For checking connector pin contact pressure B For checking power supply circuit C For checking power supply circuit D For connecting a locally sourced tester Tool Number Name Use MB991223 A D C B AD ...

Page 245: ...ng bolt washers which are welded to the door hinge 3 On completion paint the affected area with a suitable touch in brush to prevent corrosion 4 Install the door hinge Refer to P 42 31 3 When the door is stiff to lock and unlock 1 Adjustment by using the striker toward the inside of the vehicle and vertical direction Install a temporary bolt instead of the striker mounting bolts and use special to...

Page 246: ...window glass by hand to check the operation force NOTE Insert a cushion or similar object to prevent damage to the glass if it should happen to fall down 4 If the door window glass does not move up and down smoothly check or repair the following points Check the installation condition of the runchannel Repair any twisting in the door sash Check the installation condition of the lower sash or the c...

Page 247: ...nd rear power window sub switches to check that the power windows do not work Turn on the power window lock switch of the power window main switch and operate the power window main switch to check that each power window operates CENTRAL DOOR LOCKING SYSTEM INSPECTION M1427001100133 Check that the central door locking system works by operating the key cylinders driverís and passengerís door and the...

Page 248: ...door inside handle play is outside the standard value range 3 Remove the door trim assembly Refer to GROUP 52A Door trim P 52A 15 4 Remove the waterproof film Refer to P 42 39 5 Adjust the door inside handle play with the outer cable end connecting the door inside handle and inside lock cable AC006114 Y0705AU AB A A B Section A A AC100404AB Clip Inner cable Outer cable end Inside handle rod Door i...

Page 249: ...0 1 2 3 4 5 6 7 8 9 10 1 1 5 0 5 N m 1 5 0 5 N m 11 2 N m 11 2 N m 11 2 N m 11 2 N m 21 4 N m 27 5 N m 21 4 N m 27 5 N m 21 4 N m 27 5 N m 21 4 N m 27 5 N m Removal 1 Damper mail Door assembly removal steps 2 Harness connector 3 Door check connecting bolt 4 Door assembly 5 Door upper hinge 6 Door lower hinge Striker removal steps A 7 Striker 8 Striker shim Door switch removal steps 9 Door switch c...

Page 250: ...ATION M1429001300315 AC305098AB Striker centre Striker Latch centre Latch 1 5 mm 1 5 mm Switch position Tester connection Specified condition Released ON 1 switch body 2 switch body 3 switch body Less than 2 ohms Depressed OFF 1 switch body 2 switch body 3 switch body Open circuit AC211414 1 2 3 AC Post installation Operation Door Window Glass Adjustment Refer to P 42 28 AC212124 AB FRONT DOOR REA...

Page 251: ...l steps Door trim assembly Refer to GROUP 52A Door Trim P 52A 15 Waterproof film Refer to P 42 39 A B 1 Window regulator assembly A B 2 Power window motor assembly Door window glass removal steps Window glass runchannel Refer to P 42 39 3 Door window glass Stationary window glass removal steps Window glass runchannel Refer to P 42 39 Door beltline inner weatherstrip Refer to P 42 39 3 Door window ...

Page 252: ...TS A CENTRE SASH UPPER INSTALLATION Securely insert the centre sash upper into the window rear sash door B WINDOW REGULATOR ASSEMBLY POWER WINDOW REGULATOR MOTOR ASSEMBLY INSTALLATION When installing the window regulator assembly tighten the bolts to the specified torque in the order shown INSPECTION M1429001400282 How to make the power window switch learn the fully closed position of the power wi...

Page 253: ...is operated to open the door window glass while the switch is learning learning will be cancelled If this happens return to step 2 How to make the power window switch learn the fully closed position when the power window switch is replaced with a new one CAUTION The anti trap function does not work until the power window switch completes learning the fully closed position It is because the anti tr...

Page 254: ...rim P 52A 15 AC305110 FRONT DOOR REAR DOOR 5 5 0 1 0 N m 1 4 9 2 AB 4 5 2 3 8 7 5 0 1 0 N m 1 6 9 N N 8 9 0 2 0 N m 9 0 2 0 N m Door handle and door latch assembly removal steps C 1 Door inside handle Waterproof film Refer to P 42 39 2 Door outside handle 3 Door lock key cylinder B 4 Lower sash 5 Door latch assembly 6 Inside lock cable Front door 7 Inside lock rod Rear door 8 Inside handle rod Doo...

Page 255: ...o the door INSPECTION M1423004700392 FRONT DOOR LOCK ACTUATOR CHECK Actuator Operation Check Item Identification mark Front Door Left door 39L Right door 39R Rear Door Left door 40L Right door 40R ACX00541 Identification mark AB AC100404AB Clip Inner cable Outer cable end Inside handle rod Door inside handle Lever position Battery connection Lever operation At the LOCK position Connect terminal No...

Page 256: ... side Right side Lever Lever Lever position Battery connection Lever operation At the LOCK position Connect terminal No 4 and the negative battery terminal Connect terminal No 6 and the positive battery terminal The lever moves from the LOCK position to the UNLOCK position At the UNLOCK position Connect terminal No 6 and the negative battery terminal Connect terminal No 4 and the positive battery ...

Page 257: ...eps Scuff plate centre pillar lower trim and cowl side trim Refer to GROUP 52A Trims P 52A 11 2 Door inner opening weatherstrip Body side Door outer opening weatherstrip removal steps Front door check mounting bolt Door side Refer to P 42 31 A A 3 Door outer opening weatherstrip Door window glass runchannel removal 4 Door window glass runchannel Door beltline inner weatherstrip removal steps Front...

Page 258: ...e trim Refer to GROUP 52A Trims P 52A 11 2 Door inner opening weatherstrip Body side Door outer opening weatherstrip removal steps Rear door check mounting bolt Door side Refer to P 42 31 3 Retainer weatherstrip A A 4 Door outer opening weatherstrip Door window glass runchannel removal 5 Door window glass runchannel Door beltline inner weatherstrip removal steps Rear door trim Refer to GROUP 52A D...

Page 259: ...king of the trunk lid is difficult make adjustments to the trunk lid bumpers refer to P 42 42 and trunk lid hinges refer to P 42 42 2 If the clearance around the trunk lid panel assembly is uniform but locking and unlocking of the trunk lid is difficult make adjustments to the trunk lid bumpers refer to P 42 42 and trunk lid striker refer to P 42 42 ACX00555 15 mm 8 mm AB 4 mm Thickness 1 mm Fabri...

Page 260: ...r checking the trunk lid release cable for proper routing loosen the trunk lid striker mounting bolts Change the position of the trunk lid striker relative to the trunk lid latch assembly so that trunk lid locking and unlocking effort is correct TRUNK LID HEIGHT ADJUSTMENT M1421008300033 Turn each trunk lid bumper until the height shown in the drawing is reached If the trunk lid panel height on on...

Page 261: ...GROUP 52A Trims P 52A 11 Rear seat Refer to GROUP 52A Rear seat assembly P 52A 28 Accelerator pedal stopper Refer to GROUP 17 Accelerator pedal P 17 3 2 Trunk lid release handle 3 Trunk lid release cable Trunk lid striker removal steps Rear end trim Refer to GROUP 52A Trims P 52A 11 4 Trunk lid striker Trunk lid panel removal steps Licence plate garnish Refer to GROUP 51 Garnishes P 51 17 5 Trunk ...

Page 262: ...on bar LH in the same way as the trunk lid torsion bar RH INSTALLATION SERVICE POINTS A TRUNK LID TORSION BAR INSTALLATION Install the trunk lid torsion bars using the following procedure AC305143AB Grease application area 6 2 7 AC205068 AC205068 MB991244 Trunk lid torsion bar RH Trunk lid torsion bar LH AB AC305282 Trunk lid torsion bar RH Trunk lid torsion bar LH Colour mark A B Trunk lid hinge ...

Page 263: ...t B and pressed against point C of the trunk lid hinge RH as shown in View F Then force the portion into point D 5 Twist the portion A of the trunk lid torsion bar LH right end until it reaches point E on the trunk lid hinge RH as shown in View F 6 Attach the trunk lid torsion bar RH to the trunk lid hinge LH using the same method as the trunk lid torsion bar LH B TRUNK LID WEATHERSTRIP INSTALLATI...

Page 264: ...nd backward or to the left and right to adjust after bolt the striker temporarily 3 After adjusting tighten the bolts to the specified torque 24 4 N m Item Standard value Tailgate handle play 2 3 to 5 9 mm Item Specified sealant Tailgate waterproof film 3M ATD Part No 8633 or equivalent Tailgate hinge 3M ATD Part No 8531 Heavy drip check sealer 3M ATD Part No 8646 Automotive joint and seam sealer ...

Page 265: ...E PLAY CHECK M1424002400138 1 Check the tailgate handle play Standard value B 2 3 5 9 mm 2 If it deviates from the standard value remove the lower tailgate trim Refer to GROUP 52A tailgate trim P 52A 19 and waterproof film Refer to P 42 48 3 Remove the holder from the tailgate handle and adjust according to the tailgate latch rod and tailgate handle connection position AC203660AB Grind here AC2015...

Page 266: ...ilgate Trim Assembly Removal Refer to GROUP 52A Tailgate Trim P 52A 19 Rear Wiper Motor Removal Refer to GROUP 51 Rear Wiper and Washer P 51 29 Post installation Operation Tailgate Fit Adjustment Refer to P 42 46 Rear Wiper Motor Installation Refer to GROUP 51 Rear Wiper and Washer P 51 29 Tailgate Trim Assembly Installation Refer to GROUP 52A Tailgate Trim P 52A 19 Tailgate Spoiler Assembly Insta...

Page 267: ...gate assembly removal steps 1 Rear washer hose 2 Tailgate wiring harness 3 Waterproof film 4 Tailgate gas spring 5 Antenna feeder cable 6 Tailgate assembly 7 Tailgate hinge 8 Bumper Rear end trim Refer to GROUP 52A Trims P 52A 11 9 Striker 10 Dynamic damper Tailgate opening weatherstrip removal 4 Tailgate gas spring A 11 Tailgate opening weatherstrip Tailgate assembly removal steps AC305091 Positi...

Page 268: ...lock key cylinder removal steps Lower tailgate trim Refer to GROUP 52A Tailgate Trim P 52A 19 Waterproof film Refer to P 42 48 2 Bolt earth 3 Tailgate latch assembly 4 Tailgate lock key cylinder 5 Tailgate handle Tailgate latch removal steps Lower tailgate trim Refer to GROUP 52A Tailgate Trim P 52A 19 Waterproof film Refer to P 42 48 2 Bolt earth 3 Tailgate latch assembly Tailgate lock actuator r...

Page 269: ...osition Battery connection Lever operation At the LOCK position Connect terminal No 2 and the negative battery terminal Connect terminal No 3 and the positive battery terminal The lever moves from the LOCK position to the UNLOCK position At the UNLOCK position Connect terminal No 3 and the negative battery terminal Connect terminal No 2 and the positive battery terminal The lever moves from the UN...

Page 270: ...e communication interface V C I B MUT III USB cable C MUT III main harness A Vehicles with CAN communication system D MUT III main harness B Vehicles without CAN communication system E MUT III measurement adapter F MUT III trigger harness Encrypted code registration CAUTION MUT III main harness B MB991911 should be used MUT III main harness A should not be used for this vehicle B991502 MB991529 MB...

Page 271: ...NTRY SYSTEM TIMER LOCK FUNCTION INSPECTION M1428004000138 Push the transmitter unlock button and check to see that the doors and tailgate Wagon lock within 30 seconds If it doesn t then execute troubleshooting remedies Refer to GROUP 54B Troubleshooting P 54B 17 refer to GROUP 54C Troubleshooting P 54C 4 ENABLING DISABLING THE ANSWERBACK FUNCTION M1428003200214 If the keyless entry system locks or...

Page 272: ...ound once 1 Turn the ignition switch to ìLOCKî OFF position 2 Turn off the hazard warning lamp switch CAUTION Before connecting or disconnecting the MUT II turn the ignition switch to the LOCK OFF position 3 Connect the MUT II to the diagnosis connector 4 Close the driver s side door 5 Keep the windshield washer switch on for at least ten seconds Then the ETACS ECU buzzer will sound once 2 If the ...

Page 273: ...ds the ETACS ECU buzzer will sound indicating that the hazard answerback function can be enabled or disabled when the doors are unlocked Enable the hazard answerback function when the doors are unlocked The ETACS ECU buzzer will sound once Disable the hazard answerback function when the doors are unlocked The ETACS ECU buzzer will sound twice 4 Exit the hazard answerback customize mode by observin...

Page 274: ...erations 7 If you are using two or more transmitters or have added a second transmitter the same registration procedure should be carried out within one minute after registering the code for the first transmitter 8 Registration mode will be cancelled under the following conditions When the secret code for four transmitters has been registered When one minute has passed after registration mode star...

Page 275: ... the key cylinder 9 After the registration is completed remove the ignition key and close all the doors and then check that the keyless entry system operates normally WHEN THE SPECIAL TOOL V C I MB991824 IS USED 1 Check that the doors lock normally when the key is used 2 Insert the ignition key CAUTION Before connecting or disconnecting the V C I turn the ignition switch to the LOCK OFF position 3...

Page 276: ...te has passed after registration mode started When the V C I is disconnected from the diagnosis connector When the key is removed from the key cylinder 9 After the registration is completed remove the ignition key and close all the doors and then check that the keyless entry system operates normally TRANSMITTER DISASSEMBLY AND REASSEMBLY M1428002800172 Post reassembly operation Transmitter operati...

Page 277: ... of the transmitter assembly when it is open Also do not touch the precision electronic device Install a new battery to the transmitter assembly with its side facing towards the upper cover side Battery required for replacement Coin type battery CR1616 INSPECTION M1428003800067 TRANSMITTER BATTERY CHECK Measure the voltage of the battery If the voltage of the battery is not within the standard val...

Page 278: ...NOTES ...

Page 279: ...AL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES WARNING Improper service or maintenance of any component of the SRS or any SRS related component can lead to personal injury or death to service personnel from inadvertent firing of the air bag or to the driver and paassenger from rendering the SRS inoperative Service or maintenance of any SRS component or SRS related component must be performed only at an...

Page 280: ...ENT 54A 67 BULB REPLACEMENT 54A 68 HEADLAMP 54A 69 REMOVAL AND INSTALLATION 54A 69 HEADLAMP LEVELING SWITCH 54A 70 REMOVAL AND INSTALLATION 54A 70 INSPECTION 54A 70 FOG LAMP 54A 71 SERVICE SPECIFICATION 54A 71 SPECIAL TOOL 54A 71 TROUBLESHOOTING 54A 71 ON VEHICLE SERVICE 54A 71 FRONT FOG LAMP AIMING CHECK 54A 71 FOG LAMP 54A 73 REMOVAL AND INSTALLATION 54A 73 FOG LAMP SWITCH 54A 74 REMOVAL AND INS...

Page 281: ...A 86 INSPECTION 54A 86 COLUMN SWITCH 54A 87 SPECIAL TOOL 54A 87 COLUMN SWITCH 54A 87 REMOVAL AND INSTALLATION 54A 87 INSPECTION 54A 88 HORN 54A 89 REMOVAL AND INSTALLATION 54A 89 HORN RELAY CONTINUITY CHECK 54A 89 CLOCK 54A 90 SPECIAL TOOL 54A 90 CLOCK 54A 90 REMOVAL AND INSTALLATION 54A 90 CIGARETTE LIGHTER 54A 91 INSPECTION 54A 91 RHEOSTAT 54A 91 REMOVAL AND INSTALLATION 54A 91 INSPECTION 54A 92...

Page 282: ...y is brought close to naked flames during charging Be careful to avoid tasks that might produce sparks or other danger while the battery is charging After charging is complete replace the battery plus pour water over the battery to rinse away any sulphuric acid and let the battery stand to dry Charge the battery in a well ventilated location Do not let the battery electrolyte temperature rise abov...

Page 283: ...off for two minutes to allow battery positive voltage to stabilize 3 Disconnect the battery cables 4 Read open circuit voltage Q Is open circuit voltage 12 4 volts or more YES Go to Step 6 NO Go to Step 5 STEP 5 Charge battery Q Charging the battery YES Go to Step 6 NO Charge the battery at 5 amps for 15 hours Then re test go to Step 4 STEP 6 Check the load test 1 Connect a load tester to the batt...

Page 284: ...If the requirements for starting the engine are not satisfied the engine will be immobilized If a registered ignition key is lost all your ignition keys need to be registered again using MUT II III to ensure security Refer to P 54A 20 An additional ignition key can be registered as follows only if no ignition keys are lost Using MUT II III Refer to P 54A 20 OPERATION 1 When the ignition switch is ...

Page 285: ...izer ECU Ignition key When engine A T ECU is replaced Should not be replaced Should not be replaced Should be registered again When engine A T ECU is overwritten Should not be replaced Should not be replaced Should be registered again When immobilizer ECU is replace Should not be replaced Should not be replaced All ignition keys should be registered again When ignition key is added Should not be r...

Page 286: ...991825 F MB991826 MUT III sub assembly A V C I Vehicle communication interface B MUT III USB cable C MUT III Main harness A Vehicles with CAN communication system D MUT III Main harness B Vehicles without CAN communication system E MUT III Measurement adapter F MUT III Trigger harness Immobilizer system check Encrypted code registration B991502 MB991910 MB991826 MB991955 MB991911 MB991824 MB991827...

Page 287: ...is turned on with connector s disconnected On completion confirm all systems for diagnosis code code s If diagnosis code code s are set erase them all Use the following chart to develop proper diagnostic strategy 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 troubleshooti...

Page 288: ...s being started The transponder s encrypted code is not sent to the immobilizer ECU immediately after the ignition switch is turned to ON position NOTE Diagnosis code No 11 is always set together with MPI system diagnosis code No P0513 TROUBLESHOOTING HINTS Radio interference of the encrypted code Malfunction of the transponder Malfunction of the immobilizer ECU HIGH FREQUENCY CIRCUIT IMMOBILIZER ...

Page 289: ...CU connector C 202 1 in good condition YES Replace immobilizer ECU and Then register the password secret cod and encrypted code P 54A 20 Retest the system NO Repair or replace the damage component s Code No 12 Encrypted Codes are Not identical or not Registered DIAGNOSIS CODE SET CONDITION The encrypted code sent by the transponder is not the same encrypted code which is registered in the immobili...

Page 290: ...f the MPI system is normal the engine control relay can be determined as normal In addition if the MPI system and MUT II III can communicate each other the circuits between the diagnosis connector and the engine ECU M T or engine A T ECU A T can determined as normal NOTE If this malfunction appears MPI system diagnosis code No P0513 will be set ENGINE ECU ENGINE CONTROL RELAY ENGINE A T ECU IMMOBI...

Page 291: ... 13B MPI Diagnosis P 13B 15 STEP 2 Voltage measurement at immobilizer ECU connector C 202 1 1 Disconnect immobilizer ECU connector C 202 1 2 Turn the ignition switch to the ON position 3 Measure the voltage between terminal 1 and earth OK System voltage Q Is the check result normal YES Go to Step 5 NO Go to Step 3 STEP 3 Connector check Immobilizer ECU connector C 202 1 and engine control relay co...

Page 292: ...es and key reminder switch connector C 202 and repair if necessary Q Are the harness wires between immobilizer ECU connector C 202 1 terminal 1 and engine control relay connector B 16X terminal 4 in good condition YES There is no action to be taken NO Replace damaged component s Confirm that MUT II III communicates normally AC303806 Connector C 202 1 Harness side AF AC303796 Connector B 16X Harnes...

Page 293: ...s Confirm that MUT II III communicates normally STEP 7 Check the harness wire between immobilizer ECU connector C 202 1 terminal 4 and earth NOTE Prior to the wiring harness inspection check joint connector C 104 LH drive vehicles C 07 RH drive vehicles key reminder switch connector C 202 and repair if necessary AC303806 Connector C 202 1 Harness side AF AC304851AB Connector 202 1 Harness side AC3...

Page 294: ...ent s Confirm that MUT II III communicates normally STEP 9 Check the harness wires between immobilizer ECU connector C 202 1 terminal 3 and engine ECU connector C 127 terminal 51 M T or engine A T ECU connector C 128 terminal 111 A T AC303805 Connector C 127 M T C 128 A T C 128 GR C 127 Y C 127 C 128 58 52 61 55 62 56 60 54 59 53 57 51 101 102 103 104 105 106 107 120 119 118 117116 115 11411311211...

Page 295: ...T or engine A T ECU A T Replace the immobilizer ECU Q Did the communication with MUT II III become possible after replacing the immobilizer ECU YES Register the password secret code and encrypted code P 54A 20 Confirm that MUT II III communicates normally NO Go to Step 11 STEP 11 Recheck for malfunction Q Is a malfunction eliminated YES The procedure is complete If no malfunctions are found in all...

Page 296: ...tors are not operating there might be a problem with the MPI system in addition to a malfunction of the immobilizer system It is normal for this to occur if an attempt is made to start the engine using a key that has not been properly registered TROUBLESHOOTING HINTS Malfunction of MPI system Malfunction of immobilizer ECU DIAGNOSIS PROCEDURE STEP 1 Check the system voltage Measure the system volt...

Page 297: ...nt Malfunction P 00 5 NO Replace the immobilizer ECU DATA LIST REFERENCE TABLE M1543007300314 CHECK IMMOBILIZER ECU M1543007600489 TERMINAL VOLTAGE CHECK TABLE Item No Inspection item Inspection requirement Normal condition 01 Key has been registered Number of registered ignition keys AC304799 Terminal No Signal Inspection condition Terminal voltage 1 Immobilizer ECU power supply Ignition switch L...

Page 298: ... any necessary repairs repeat the operation If an incorrect password is input ten times in a row the immobilizer ECU judges that an unauthorized operation is being attempted Start prevention mode will be set and engine operation will stop and all special functions will be disabled If the ignition switch is turned to ON position Unauthorized operation start prevention mode will be cancelled KEY ID ...

Page 299: ...ess the YES key to accept the password If an incorrect password is input five times in a row this screen is displayed and the immobilizer ECU switches to unauthorized operation start prevention mode NOTE Four separate digits must be input to make up the password 8 Press the YES key to start key ID registration 9 This will be displayed when the key ID registration is successful If an error occurs d...

Page 300: ...code and MPI system diagnosis code did not set 14 Turn the ignition switch to LOCK OFF position 15 Disconnect MUT II Registration of additional keys with the MUT II Additional key s can be registered with the MUT II while keeping all existing key data CAUTION To prevent damage to MUT II always turn the ignition switch to LOCK OFF position before connecting or disconnecting MUT II NOTE To register ...

Page 301: ...t the immobilizer system diagnosis code and MPI system diagnosis code did not set 13 Turn the ignition switch to LOCK OFF position 14 Disconnect MUT II KEY ID ENCRYPTED CODE REGISTRATION MUT III All ignition keys can be registered with MUT III Additional ignition keys can be registered with MUT III Registration with the MUT III CAUTION To prevent damage to MUT III always turn the ignition switch t...

Page 302: ...B991827 MB991824 AB Using the MUT III System select Special function CAN bus diagnosis Function Select Menu Menu AC209666 Maintenance AD MPI GDI DIESEL ELC A T CVT IMMOBILIZER SS4II TCL STARLTY CONTROL AUTO CRUISE CHASSIS BODY System Select Menu POWER TRAIN AC305175 Check Chart For Problem Sy Data List Special Function Self diagnosis SimulatedVehicle Speed Out Resistor Voltmeter POWERTRAIN IMMOBIL...

Page 303: ...e MUT III 14 Turn the ignition switch to LOCK OFF position 15 Disconnect MUT III Registration of additional keys with the MUT III Additional key s can be registered with the MUT III while keeping all existing key data CAUTION To prevent damage to MUT III always turn the ignition switch to LOCK OFF position before connecting or disconnecting MUT III NOTE To register additional keys with the MUT III...

Page 304: ... s to the vehicle NOTE The registered key is the key that allows you to start the engine 1 Turn ON the ignition switch by using the first registered key key A and wait for five seconds 2 Remove the first registered key key A 3 Insert the second registered ignition key key B and turn it to the ON position 4 The immobilizer ECU identifies the new key to accept or reject it and operates the immobiliz...

Page 305: ... let it bump against the air bag module AC304659 2 3 4 6 7 1 5 AB 8 Removal steps 1 Column cover lower 2 Column cover upper 3 Steering wheel and air bag module assembly Refer to GROUP 37 Steering wheel P 37 17 or P 37 19 4 Clock spring and column switch assembly Refer to GROUP 37 Steering shaft P 37 21 A 5 Steering lock cylinder Ignition switch connector 6 Ignition switch 7 Immobilizer ECU Key rem...

Page 306: ...h Then check the continuity KEY REMINDER SWITCH CONTINUITY CHECK Disconnect key reminder switch connector C 202 without removing the ignition switch and key reminder switch Then check the continuity AC304831AB Locking pin AC304833AB Switch position Tester connection Specified condition LOCK OFF 1 2 1 3 1 4 1 5 1 6 2 3 2 4 2 5 2 6 3 4 3 5 3 6 4 5 4 6 5 6 Open circuit ACC 1 6 Less than 2 ohms ON 1 2...

Page 307: ...5 225 3 000 175 300 4 000 225 375 5 000 225 425 6 000 225 475 7 000 200 500 8 000 100 500 Fuel tank gauge unit resistance Ω Float position F highest 3 1 Float position E lowest 110 1 Fuel gauge unit float height mm Float position F A 24 1 2 0 Float position E B 151 6 2 0 Engine coolant temperature gauge unit resistance Ω 104 13 5 at 70 C Item Specified sealant Engine coolant temperature gauge unit...

Page 308: ...mmunication interface B MUT III USB cable C MUT III Main harness A Vehicles with CAN communication system D MUT III Main harness B Vehicles without CAN communication system E MUT III Measurement adapter F MUT III Trigger harness Reading MPI system diagnosis code Tool Number Name Use MB991910 MB991826 MB991955 MB991911 MB991824 MB991827 MB991825 A B C D E F DO NOT USE ...

Page 309: ...nspection C Power circuit inspection D Commercial tester connection Tool Number Name Use MB991223 A B C D AC Symptom Inspection procedure No Reference page Speedometer does not work the other meters work M T 1 P 54A 32 Speedometer does not work the other meters work A T 2 P 54A 37 Tachometer does not work the other meters work 3 P 54A 44 Fuel gauge does not work the other meters work 4 P 54A 48 En...

Page 310: ...her meters work M T Speedometer Circuit IGNITION SWITCH IG1 VEHICLE SPEED SENSOR DIAGNOSIS CONNECTOR COMBINATION METER ENGINE ECU Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Grey R Red P Pink V Violet CONTROL CIRCUIT FRONT SIDE NOTE LH drive vehicles RH drive vehicles ...

Page 311: ...1 Connect the MUT II III to the diagnosis connector 2 Use the MUT II III to enter simulated vehicle speed Q Does the speedometer show that simulated vehicle speed YES Go to Step 6 NO Go to Step 2 STEP 2 Check the vehicle speed sensor MUT II III diagnosis code 1 Connect MUT II III to the diagnosis connector 2 Turn the ignition switch to the ON position 3 Read the MPI system diagnosis code Q Is MPI ...

Page 312: ...sary Q Is the wiring harness between combination meter connector C 04 terminal 12 and diagnosis connector C 11 terminal 14 in good condition YES Go to Step 5 NO Repair or replace the wiring harness AC303798 Connector C 04 L H drive vehicles Harness side AT AC303800 C 11 B Connector C 11 L H drive vehicles Front side AK AC303814 Connector C 04 R H drive vehicles Harness side AT AC303812AD Connector...

Page 313: ...p 7 STEP 7 Connector check Combination meter connector C 04 and engine ECU connector C 127 RH drive vehicles Q Is combination meter connector C 04 and engine ECU connector C 127 in good condition YES Go to Step 8 NO Repair or replace the damage component s STEP 8 Check the wiring harness between combination meter connector C 04 terminal 11 and engine ECU connector C 125 LH drive vehicles C 127 RH ...

Page 314: ...n intermittent malfunction is suspected Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points How to Cope with Intermittent Malfunction P 00 5 NO Go to Step 10 STEP 10 Pulse check Use the MUT II III or a voltmeter to check that the vehicle speed signal is received OK The MUT II III sounds or the voltmeter needle fluctuates Q Is the check result normal YES Replace the combination m...

Page 315: ...ITCH IG1 A T CONTROL RELAY OUTPUT SHAFT SPEED SENSOR DIAGNOSIS CONNECOTR ENGINE A T ECU COMBINATION METER ENGINE A T ECU Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet FRONT SIDE NOTE LH drive vehicles RH drive vehicles CONTROL CIRCUIT Speedometer Circuit ...

Page 316: ... the MUT II III to the diagnosis connector 2 Use the MUT II III to enter simulated vehicle speed Q Does the speedometer show that simulated vehicle speed YES Go to Step 6 NO Go to Step 2 STEP 2 Check the output shaft speed sensor MUT II III diagnosis code 1 Connect MUT II III to the diagnosis connector 2 Turn the ignition switch to the ON position 3 Read the automatic transmission system diagnosis...

Page 317: ...sary Q Is the wiring harness between combination meter connector C 04 terminal 12 and diagnosis connector C 11 terminal 14 in good condition YES Go to Step 5 NO Repair or replace the wiring harness AC303798 Connector C 04 L H drive vehicles Harness side AT AC303800 C 11 B Connector C 11 L H drive vehicles Front side AH AC303814 Connector C 04 R H drive vehicles Harness side AT AC303812AD Connector...

Page 318: ...eck whether the diagnosis code is reset Q Is the MPI related diagnosis code set YES Refer to GROUP 13A Troubleshooting P 13A 15 GROUP 13B Troubleshooting P 13B 15 NO Go to Step 7 STEP 7 Connector check Combination meter connector C 04 and engine A T ECU connector C 124 C 126 AC303798 Connector C 04 L H drive vehicles Harness side AT AC303805 Connector C 124 C 126 L H drive vehicles C 124 GR C 126 ...

Page 319: ...p 8 NO Repair or replace the damage component s AC303814 Connector C 04 R H drive vehicles Harness side AT AC303817 Connector C 124 C 126 R H drive vehicles C 124 C 126 C 126 GR C 124 GR Harness side 41 42 43 44 45 57 56 55 54 53 52 51 50 49 48 47 58 59 60 61 62 63 64 65 66 46 71 72 73 74 75 76 77 89 88 87 86 85 84 83 82 81 80 79 78 90 91 92 93 94 95 96 97 98 AM ...

Page 320: ...126 L H drive vehicles C 124 GR C 126 GR C 124 C 126 Harness side 41 42 43 44 45 57 56 55 54 53 52 51 50 49 48 47 58 59 60 61 62 63 64 65 66 46 71 72 73 74 75 76 77 89 88 87 86 85 84 83 82 81 80 79 78 90 91 92 93 94 95 96 97 98 AK AC303814 Connector C 04 R H drive vehicles Harness side AT AC303817 Connector C 124 C 126 R H drive vehicles C 124 C 126 C 126 GR C 124 GR Harness side 41 42 43 44 45 57...

Page 321: ...mal YES The procedure is complete If no malfunctions are found in all steps an intermittent malfunction is suspected Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points How to Cope with Intermittent Malfunction P 00 5 NO Go to Step 10 STEP 10 Pulse check Use the MUT II III or a voltmeter to check that the vehicle speed signal is received OK The MUT II III sounds or the voltmeter...

Page 322: ...nector s may be defective TROUBLESHOOTING HINTS Malfunction of the combination meter assembly The wiring harness or connectors may have loose corroded or damaged terminals or terminals pushed back in the connector ENGINE ECU Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet ENGINE A T ECU M T A T NOTE LH drive vehicl...

Page 323: ...7 M T or engine A T ECU connector C 124 A T in good condition YES Go to Step 3 NO Repair or replace the damage component s STEP 3 Retest the system Q Is the tachometer normal YES Intermittent Malfunction Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points How to Cope with Intermittent Malfunction P 00 5 NO Go to Step 4 AC303798 Connector C 04 L H drive vehicles Harness side AT A...

Page 324: ...ine A T ECU connector C 124 terminal 43 A T AC303798 Connector C 04 L H drive vehicles Harness side AT AC303805 Connector C 124 A T C 127 M T L H drive vehicles C 124 GR Harness side C 124 C 127 AM C 127 Y Harness side AC303814 Connector C 04 R H drive vehicles Harness side AT AC303817 Connector C 124 A T C 127 M T R H drive vehicles C 127 Y C 124 GR C 124 C 127 Harness side AO Harness side ...

Page 325: ... Q Is the wiring harness between combination meter connector C 04 terminal 11 and engine ECU connector C 127 terminal 58 M T or engine A T ECU connector C 124 terminal 43 A T in good condition YES Replace the combination meter assembly NO Repair or replace the damage component s AC303801 Connector C 12 C 14 L H drive vehicles C 12 C 14 GR C 12 C 14 Harness side AD AC303819 Connector C 134 C 136 R ...

Page 326: ...ING HINTS Malfunction of the fuel gauge unit The wiring harness or connectors may have loose corroded or damaged terminals or terminals pushed back in the connector Malfunction of the combination meter COMBINATION METER CONTROL CIRCUIT FUEL GAUGE UNIT LH drive vehicles SEDAN LH drive vehicles WAGON NOTE LH drive vehicles RH drive vehicles Wire colour code B Black LG Light green G Green L Blue W Wh...

Page 327: ... connector D 13 in good condition YES Go to Step 3 NO Repair or replace the damaged component s STEP 3 Check the wiring harness between combination meter connector C 06 terminal 51 and fuel gauge unit connector D 13 terminal 1 AC305320AB Test lamp 12 V 3 4 W MB991219 Harness side Fuel gauge Earth AC303798 Connector C 04 L H drive vehicles Harness side AT AC303871 Connector D 13 Sedan Harness side ...

Page 328: ...EP 4 Retest the system Q Is the fuel gauge normal YES The procedure is complete If no malfunctions are found in all steps an intermittent malfunction is suspected Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points How to Cope with Intermittent Malfunction P 00 5 NO Replace combination meter AC303871 Connector D 13 Sedan Harness side D 13 B AI AC303917 D 13 B Connector D 13 Wago...

Page 329: ...rminals or terminals pushed back in the connector Malfunction of the combination meter DIAGNOSIS PROCEDURE STEP 1 Check the engine coolant temperature gauge unit Check to see that the engine coolant temperature gauge unit operate normally Refer to P 54A 61 Q Is the engine coolant temperature gauge unit normal YES Go to Step 2 NO Replace the fuel gauge unit Then go to step 4 COMBINATION METER CONTR...

Page 330: ...112 4G1 MPI Harness side B 112 B AF AC303792AE Connector B 112 4G6 MPI B 112 B Harness side AC303798 Connector C 06 L H drive vehicles Harness side C 06 L 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 AV AC303814AU Connector C 06 R H drive vehicles Harness side 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 C 06 L AC303784 Connector B 112 4G1 MPI Harness side B 112...

Page 331: ...al 1 in good condition YES Go to Step 4 NO Repair or replace the damage component s STEP 4 Retest the system Q Is the engine coolant temperature gauge normal YES The procedure is complete If no malfunctions are found in all steps an intermittent malfunction is suspected Refer to GROUP 00 How to Use Troubleshooting Inspection Service Points How to Cope with Intermittent Malfunction P 00 5 NO Replac...

Page 332: ...r earth circuitry or combination meter TROUBLESHOOTING HINTS Malfunction of the combination meter Damaged wiring harness or connectors Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet IGNITION SWITCH IG1 COMBINATION METER CONTROL CIRCUIT BATTERY RELAY BOX NOTE LH drive vehicles RH drive vehicles Combination Meter Po...

Page 333: ...terminal 7 and earth OK System voltage Q IS the check result normal YES Go to Step 4 NO Go to Step 2 STEP 2 Connector check Combination meter connector C 04 Q Is combination meter connector C 04 in good condition YES Go to Step 3 NO Repair or replace the connector Check to see that all meters operate AC303798 Connector C 04 L H drive vehicles Harness side AT AC303814 Connector C 04 R H drive vehic...

Page 334: ...ination meter connector C 04 terminal 7 and battery in good condition YES There is no action to be taken NO Repair or replace the wiring harness Check to see that all meters operate AC303798 Connector C 04 L H drive vehicles Harness side AT AC303814 Connector C 04 R H drive vehicles Harness side AT AC303798AX Connector C 27 L H drive vehicles Harness side AC303802 Connector C 103 L H drive vehicle...

Page 335: ... earth OK System voltage Q Is the check result normal YES Go to Step 7 NO Go to Step 5 STEP 5 Connector check combination meter connector C 04 Q Is combination meter connector C 04 in good condition YES Go to Step 6 NO Repair or replace the connector Check to see that all meters operate AC303798 Connector C 04 L H drive vehicles Harness side AT AC303814 Connector C 04 R H drive vehicles Harness si...

Page 336: ...en combination meter connector C 04 terminal 42 and ignition switch IG1 in good condition YES There is no action to be taken NO Repair or replace the wiring harness Check to see that all meters operate AC303798AU Connector C 03 C 04 L H drive vehicles C 04 C 03 B C 04 C 03 Harness side AC303814 Connector C 04 R H drive vehicles Harness side AT AC303809 Connector C 210 C 212 L H drive vehicles C 21...

Page 337: ...nal 2 and earth OK 2 ohms or less Q Is the check result normal YES Repair or replace the connector NO Go to Step 8 STEP 8 Connector check Combination meter connector C 04 Q Is combination meter connector C 04 in good condition YES Go to Step 9 NO Repair or replace the wiring harness Check to see that all meters operate AC303798 Connector C 04 L H drive vehicles Harness side AT AC303814 Connector C...

Page 338: ...ent the vehicle from moving attach a chain or wire to the rear retraction hook and make sure the end of the chain or wire is secured 4 Check if the speedometer indicator range is within the standard values Standard value 5 If not to the standard value inspect for proper tyre size If not correct replace the tyres with original size tyres and retest If correct replace the speedometer If still not to...

Page 339: ... tank gauge unit float height check If any check is not correct replace the fuel tank gauge unit FUEL TANK GAUGE UNIT FLOAT HEIGHT 1 Move the float and measure height A at position F highest and B at position E lowest with the float arm touching stopper Standard values 2 If all checks are correct go to fuel tank gauge unit float height check If any check is not correct replace the fuel tank gauge ...

Page 340: ...lue Standard value 104 13 5 Ω at 70C Reference value 4 After inspection apply specified sealant at threads of engine coolant temperature gauge unit and tighten to the specified torque Semi drying sealant 3M 1215 or equivalent 5 Add engine coolant Refer to GROUP 14 On vehicle Service P 14 22 Temperature C Resistance Ω 50 230 60 155 80 73 ACX00779 AI Circuit tester Thermometer ACX00780AH 11 1 N m ...

Page 341: ...BLY CHASSIS ELECTRICAL 54A 63 COMBINATION METER ASSEMBLY REMOVAL AND INSTALLATION M1543021300028 AC304803 4 3 2 AB 1 1 Vehicle speed sensor Removal steps 2 Meter bezel 3 Instrument panel ornament 4 Combination meter assembly ...

Page 342: ...n the standard value the vehicle speed sensor is OK If not within the standard value replace the vehicle speed sensor Standard value 0 or Battery Voltage 1turn 4pulses OUTPUT SHAFT SPEED SENSOR CHECK A T Refer to P 23A 38 COMBINATION METER INTERNAL RESISTANCE CHECK Use circuit tester to measure combination meter internal resistance Standard Value AC305188AB Turn Shaft Resistor 3 10 k measurin g te...

Page 343: ...600 COMFORT AC305237 1 2 5 4 AB 3 Disassembly steps 1 Meter glass 2 Meter panel 3 Circuit board cover 4 Bulb 5 Combination meter assembly Disassembly steps Continued AC304664 1 2 5 3 4 AB Disassembly steps 1 Meter glass 2 Meter panel 3 Circuit board cover 4 Bulb 5 Combination meter assembly Disassembly steps Continued ...

Page 344: ...weight of a full tank 0 8 kg per litre 5 There should be no other load in the vehicle other than driver or substituted weight of approximately 75 kg placed in driver s position 6 Thoroughly clean the headlamp lenses 7 Place the vehicle on a level floor perpendicular to a flat screen 10 m away from the bulb centre marks on the headlamp lens 8 Rock vehicle sideways to allow vehicle to assume its nor...

Page 345: ...tion Position at which the stat up point of 15 is crossed with vertical line V Limit Vertical direction 0 29 from the standard value Horizontal direction 0 5 from the standard value LUMINOUS INTENSITY MEASUREMENT M1542001000464 1 Set the headlamps to high beam 2 Using a photometer and following its manufacturer s instruction manual measure the headlamp centre intensity and check to be sure that th...

Page 346: ...ouch the bulb surface bare handed or with dirty gloves If dirt is attached on surface of the bulb immediately use alcohol or thinner to remove dirt and install the bulb after well dried 1 Disconnect the connector 2 Screw out position lamp socket to pull out position lamp bulb Front Turn Signal Lamp Bulb CAUTION Do not touch the bulb surface bare handed or with dirty gloves If dirt is attached on s...

Page 347: ...L 1 Remove the splash shield the radiator grill the front bumper assembly installation clips the screws and the bolts as shown 2 Slide the front bumper assembly and remove the headlamp assembly Post installation Operation Headlamp Aiming Adjustment Refer to P 54A 66 AC304719 1 AB Removal steps A 1 Headlamp assembly AC300690 AC300678 ...

Page 348: ...542013700040 INSPECTION M1542011200908 HEAD LAMP LEVELING SWITCH RESISTANCE CHECK AC304661AB 2 1 Removal steps 1 Switch panel 2 Headlamp leveling switch AC305186AB Terminal No Switch position Resistance 4 6 0 750 ohms 1 1050 ohms 2 1410 ohms 3 1710 ohms 4 2010 ohms 5 6 0 1 2 3 4 2830 ohms ...

Page 349: ...adjust the front fog lamp aiming Check that the tyre inflation pressure is at the value indicated on the tyre pressure labels Set the vehicle to the unladen condition and park it on a level surface Have a single person approximately 75 kg sit in the driver s seat Run the engine at a speed of 2000 r min to fully charge the battery Turn on the front fog lamps and check that the illumination is withi...

Page 350: ...axis does not get shifted when re connecting the connector 2 Insert the screwdriver through the aiming hole on the side under cover By turning the adjusting gear for fog lamp aiming align the cutoff line border line of the shadow temperature with the specified position in the figure NOTE Horizontal adjustment is not possible AC305200AB In the centre of front fog lamps Screen 3 m H V AC305154 Screw...

Page 351: ...nds or dirty gloves If the surface glass section should become dirty clean it immediately with alcohol or thinner and let it dry thoroughly before installing it 1 Remove the bulb cover 2 Remove the bulb installation spring and extract the bulb AC304660 4 9 0 7 N m AB 2 1 Removal steps Side under cover A 1 Front fog lamp bulb 2 Front fog lamp assembly Removal steps Continued AC301335AB Spring ...

Page 352: ...0919 FRONT FOG LAMP SWITCH CONTINUITY CHECK AC304663AB 2 1 Removal steps 1 Instrument panel ornament Refer to GROUP 52A Instrument panel P 52A 2 2 Fog lamp switch front and rear fog lamp switch AC305187 AB Switch position Tester connection Specified condition Pressed 1 2 Less than 2 ohms Released 1 2 Open circuit ...

Page 353: ...led by the Smart Wiring System SWS For Troubleshooting refer to respective Groups below Not using SWS monitor GROUP 54B SWS Troubleshooting P 54B 38 Using SWS monitor GROUP 54C SWS Troubleshooting P 54C 22 SPECIAL TOOL M1542000600902 1 4 3 2 AC305276AB Front fog lamp relay Battery voltage Tester connection Specified condition Not supplied 1 4 Open circuit Connect terminal 2 to the positive battery...

Page 354: ...ON M1542014200015 Refer to P 54A 74 INSPECTION M1542011200942 REAR FOG LAMP SWITCH CONTINUITY CHECK AC305278AB 3 2 1 4 5 Removal steps 1 Bracket 2 Rear fog lamp assembly 3 Bezel 4 Socket 5 Bulb Removal steps Continued AC305187 AB Switch position Tester connection Specified condition Pressed 5 6 Less than 2 ohms Released 5 6 Open circuit ...

Page 355: ...gnal lamp by pushing the fender forward bending the hook and then unclamping the thumb AC305279 1 4 3 2 AB Rear fog lamp relay Battery voltage Tester connection Specified condition Not supplied 1 4 Open circuit Connect terminal 3 to the positive battery terminal Connect terminal 2 to the negative battery terminal 1 4 Less than 2 ohms Tool Number Name Use MB990784 Ornament remover Removal of side t...

Page 356: ...n the ignition key is pulled out the room lamp lights up and then will dim out in 15 seconds The lamp will dim out if the ignition key is inserted again and the door is locked while the timer is activated The room lamp is controlled by the Smart Wiring System SWS For troubleshooting refer to respective Groups below Not using SWS monitor GROUP 54B SWS Troubleshooting P 54B 38 Using SWS monitor GROU...

Page 357: ...tive Groups below Not using SWS monitor GROUP 54B SWS Troubleshooting P 54B 38 Using SWS monitor GROUP 54C SWS Troubleshooting P 54C 22 SPECIAL TOOL M1542000600924 REAR COMBINATION LAMP REMOVAL AND INSTALLATION M1542003900441 Sedan Tool Number Name Use MB990784 Ornament remover Removal of rear combination lamp assembly MB990784 AC304667 4 9 0 7 N m AB 3 4 2 1 Removal steps 1 Rear combination lamp ...

Page 358: ... bare handed or with dirty gloves If dirt is attached on glass surface of the bulb immediately use alcohol or thinner to remove dirt and install the bulb after well dried Remove socket from trunk compartment and replace bulb AC304715AB 3 2 1 4 Removal steps 1 Rear combination lamp assembly 2 Rear combination lamp body 3 Socket assembly 4 Bulb Removal steps Continued AC305292AB High mounted stop la...

Page 359: ...M1542005100452 Sedan AC305293AB 2 3 5 6 7 8 4 1 4 9 0 7 N m With rear shelf Removal steps 1 Socket assembly 2 Socket 3 Bulb 4 High mount stop lamp assembly 5 Socket holder 6 High mounted stop lamp cover front 7 High mounted stop lamp cover rear 8 High mounted stop lamp body Removal steps Continued ...

Page 360: ...HIGH MOUNTED STOP LAMP CHASSIS ELECTRICAL 54A 82 AC304750AB 1 2 With rear spoiler Removal steps 1 Rear spoiler Refer to GROUP 51 Rear spoiler P 51 18 A 2 High mounted stop lamp ...

Page 361: ...ed stop light harness at the connector side 2 Carefully pull out the high mounted stop light AC304722AB 2 1 Removal steps Tailgate trim upper Refer to GROUP 52A Tailgate trim P 52A 19 High mounted stop lamp connector connection Rear washer hose connection Refer to GROUP 51 Rear wiper and washer P 51 29 1 Tailgate spoiler Refer to GROUP 51 Tailgate spoiler P 51 19 Rear washer nozzle Refer to GROUP ...

Page 362: ... CHASSIS ELECTRICAL 54A 84 LICENCE PLATE LAMP REMOVAL AND INSTALLATION M1542004200199 Sedan AC304716AB 3 4 2 1 Removal steps 1 Licence plate lamp lens 2 Packing 3 Socket 4 Licence plate lamp bulb Removal steps Continued ...

Page 363: ... refer to respective Groups below Not using SWS monitor GROUP 54B SWS Troubleshooting P 54B 38 Using SWS monitor GROUP 54C SWS Troubleshooting P 54C 22 SPECIAL TOOL M1542000600935 AC304717AB 2 1 3 4 5 6 Removal steps 1 Licence plate lamp lens 2 Packing 3 Licence plate lamp body 4 Socket 5 Licence plate lamp bulb 6 Harness Removal steps Continued Tool Number Name Use MB990784 Ornament remover Remov...

Page 364: ...ON M1542011200920 HAZARD WARNING LAMP SWITCH CONTINUITY CHECK AC304721AB 3 4 2 1 5 Removal steps 1 Knob 2 Centre panel 3 Meter bezel 4 Centre air outlet panel 5 Hazard warning lamp switch Removal steps Continued AC305304 Switch position Tester connection Specified condition Released 1 2 Open circuit Pressed 1 2 Less than 2 ohms ...

Page 365: ...AND INSTALLATION M1543009100446 Tool Number Name Use MB990784 Ornament remover Removal of column cover MB990784 AC305305AB 2 1 Claw A A A A A A A A 1 4 2 3 Removal steps 1 Lower column cover 2 Upper column cover 3 Turn signal and lighting switch 4 Windshield wiper and washer switch Removal steps Continued ...

Page 366: ...UP 54C SWS Troubleshooting P 54C 22 1 6 8 11 10 9 7 5 4 3 2 1 6 8 11 10 9 7 5 4 3 2 AC005499 At lighting switch side At wiper washer switch side AD Switch position Tester condition Specified condition OFF 3 4 3 6 3 7 3 8 3 9 3 10 3 11 Open circuit Headlamp washer switch 3 4 Less than 2 ohms Headlamp switch 3 6 Less than 2 ohms Tail lamp switch 3 7 Less than 2 ohms Passing switch 3 8 Less than 2 oh...

Page 367: ...K M1543019502418 AC304666AB 1 2 Removal Steps 1 Horn LO 2 Horn HI AC305306 1 4 3 2 AB Horn relay Battery voltage Tester connection Specified condition Not applied 1 4 Open circuit Connect terminal 2 to the positive battery terminal Connect terminal 3 to the negative battery terminal 1 4 Less than 2 ohms ...

Page 368: ...EMOVAL AND INSTALLATION M1543005900224 Tool Number Name Use MB990784 Ornament remover Removal of centre panel and centre air outlet panel MB990784 AC304720AB 3 4 2 5 1 Removal steps 1 Knob 2 Centre panel 3 Meter bezel 4 Centre air outlet panel 5 Clock Removal steps Continued ...

Page 369: ... plug and check for a worn edge on the element spot connection and for shreds of tobacco or other material on the element Using an ohmmeter check that the element resistance value is 1 7 ohms RHEOSTAT REMOVAL AND INSTALLATION M1542006000306 ACX01832AE Element Spot AC304905AB 2 1 Removal steps 1 Switch panel 2 Rheostat switch ...

Page 370: ...TION M1542006100228 RHEOSTAT RESISTANCE CHECK 1 Connect the battery and the test bulb 40 W as shown in the illumination 2 Operate the rheostat and if brightness changes smoothly without switching off rheostat function is normal AC305310AB 40 W ...

Page 371: ...n Wagon Rear speaker Sedan Rear speaker Wagon 5 Front speaker removal steps 1 Front door trim Refer to GROUP 52A Door trim P 52A 15 2 Front speaker Rear speaker Sedan removal steps 3 Rear speaker garnish 4 Rear speaker Rear speaker Wagon removal steps 5 Quarter trim upper Refer to GROUP 52A Trims P 52A 11 6 Rear speaker ...

Page 372: ...m Rear pillar trim Centre pillar trim lower Centre pillar trim upper Refer to GROUP 52A Trims P 52A 11 Headlining Removal and Installation Refer to GROUP 52A Headlining P 52A 21 AC305315AB 1 2 3 1 Roof antenna pole Removal steps 2 Roof antenna base Instrument panel assembly Refer to GROUP 52A Instrument panel assembly P 52A 2 3 Antenna feeder cable ...

Page 373: ...lly turn OFF in about 11 minutes after the defogger switch is turned ON TROUBLESHOOTING M1543000701013 The rear window defogger is controlled by the A C ECU For troubleshooting refer to GROUP 55 Troubleshooting P 55 5 Pre removal and Post installation Operation Front pillar trim Centre pillar trim lower Centre pillar trim upper Quarter trim lower Quarter trim upper Refer to GROUP 52A Trims P 52A 1...

Page 374: ...e terminals from A Defect where the voltage changes suddenly 12 volts in the same method described above REAR WINDOW DEFOGGER SWITCH REMOVAL AND INSTALLATION M1543006200314 Refer to GROUP 55 Heater Control Assembly and A C Switch P 55 77 INSPECTION M1543019502388 DEFOGGER RELAY CHECK ACX00813 Normal characteristic curve Abnormal characteristic curve A Centre point Approximately 6 V Negative termin...

Page 375: ...D WIPER AND WASHER 51 21 GENERAL INFORMATION 51 21 SERVICE SPECIFICATION 51 22 TROUBLESHOOTING 51 22 ON VEHICLE SERVICE 51 22 WINDSHIELD WIPER AND WASHER 51 23 REMOVAL AND INSTALLATION 51 23 INSPECTION 51 25 REAR WIPER AND WASHER 51 28 GENERAL INFORMATION 51 28 SERVICE SPECIFICATION 51 28 TROUBLESHOOTING 51 28 ON VEHICLE SERVICE 51 28 REAR WIPER AND WASHER 51 29 REMOVAL AND INSTALLATION 51 29 INSP...

Page 376: ...1000500426 FRONT BUMPER ASSEMBLY REMOVAL AND INSTALLATION M1511001400444 Item Specification Front three diamond mark Double sided tape 20 mm width and 0 8 mm thickness AC304651 AB 3 2 3 5 2 2 4 5 5 3 1 3 C C B B A A A A A A A A Claw Clip Section A A Section B B Section C C ...

Page 377: ...t bumper fixing clip Removal steps Continued AC304652AC Double sided tape Generic products 20 mm width and 0 8 mm thickness 1 1 8 7 9 6 6 5 5 3 4 3 4 N N 2 Removal steps 1 Front three diamond mark 2 Under duct 3 Air intake bezel Vehicle without fog lamp 4 Fog lamp bezel Vehicle with fog lamp A A 5 Front bumper rivet 6 Front bumper side plate 7 Front bumper centre cover 8 Licence plate garnish 9 Fr...

Page 378: ...by the following procedure 1 Insert the rivet into the base material front bumper side plate assembly 2 Place the recommended tool over section A of the rivet 3 While pushing the flange surface of the rivet with the recommended tool press the handle of the tool 4 The thin part of section A of the rivet will break and the rivet will then be attached AC100411AB Rivet Drill Bumper face AC305178 AB 1 ...

Page 379: ...mbination Light Removal and Installation Sedan Refer to GROUP 54A Rear Combination Lamp P 54A 79 Rear End Trim Removal and Installation Refer to GROUP 52A Trims P 52A 11 Rear Splash Shield Removal and Installation AC300413 AC305045 Clip Rear bumper assembly Rear bumper assembly Section A A Section B B Clip Rear bumper assembly AB B B A A B B Sedan ...

Page 380: ...AR BUMPER ASSEMBLY EXTERIOR 51 6 AC300199 AC305046 A A B B C C Clip Clip Rear bumper assembly Clip Section A A Section B B Section C C Rear bumper assembly Rear bumper assembly Rear bumper assembly Wagon ...

Page 381: ... 2 8 N 3 4 5 6 AB Sedan AC300200 AC304193 1 2 8 N 3 4 5 7 6 AB Wagon Disassembly steps A A 1 Rivets 2 Rear bumper side plate assembly 3 Rear bumper centre reinforcement 4 Rear fog lamp bracket 5 Rear fog lamp assembly 6 Rear fog lamp bezel 7 Extension 8 Rear bumper face Disassembly steps Continued ...

Page 382: ...he following procedure 1 Insert the rivet into the rear bumper face and rear bumper side plate 2 Insert ìAî of the rivet into the rivet tool 3 Pressing the flange surface of the rivet move the handle of the rivet tool 4 The thinnest point of ìAî is cut and the rivet is held in position AC100411AB Rivet Drill Bumper face Y0412AU AC005876 18E0192 AB 1 2 3 4 Section A Rivet Flange Rivet Rear bumper s...

Page 383: ...SIVE M1511000500749 Tool Number Name Application MB990449 Window moulding remover Removal of drip moulding MB990449 Application Specified adhesive Front fender front and rear door mouldings Double sided tape a 6 mm width 1 2 mm thickness b 20 mm width 1 2 mm thickness ...

Page 384: ...REMOVAL AND INSTALLATION M1511004700295 AC304339 Y0622AU Y0624AU Y0623AU Y0729AU W0740AU Section A A Sedan Section B B Section C C Section D D Section E E AB N N N N N C C E E D D B B A A 1 2 6 4 3 5 7 8 9 N N N 1 1 1 9 8 5 1 1 6 7 2 3 4 ...

Page 385: ... 4 3 N 3 N 4 N 6 9 7 N 6 N N 7 N N 9 Wagon Vehicle with roof rail Vehicle without roof rail Removal Front deck garnishes Refer to P 51 23 Roof drip moulding removal steps A C 1 Roof drip moulding B 2 Front drip moulding clip A B 3 Front drip moulding clip B B 4 Front drip moulding clip C B 5 Rear drip moulding clip A 6 Drip moulding clip A A 7 Drip moulding clip B A 8 Drip moulding clip C 9 Roof d...

Page 386: ...DING CLIP A INSTALLATION The front drip moulding clips A B C and rear drip moulding clip differ according to where they are used so check the identification colour before installation C ROOF DRIP MOULDING INSTALLATION Install the clips to the roof drip moulding before installing the moulding to the vehicle body Applicable location Identification colour Drip moulding clip A Yellow Drip moulding cli...

Page 387: ... 2 1 3 Clip Clip AC400840AD Double sided tape Generic products a 6 mm width and 1 2 mm thickness b 20 mm width and 1 2 mm thickness 1 2 3 a b b a Adhesive tape position Door moulding removal steps A A 1 Front fender moulding Door moulding removal steps A A 2 Front door moulding A A 3 Rear door moulding ...

Page 388: ...a resin spatula as possible 2 Wipe the door moulding surface and clean it with a rag moistened with isopropyl alcohol 3 Remove only a small portion of the residual adhesive 4 Adhere the double sided tape as specified on the door moulding INSTALLATION SERVICE POINT A FRONT FENDER FRONT AND REAR DOOR MOULDINGS INSTALLATION 1 Tear off the double sided tape backing paper NOTE If attach the adhesive ta...

Page 389: ...VAL AND INSTALLATION M1511005500238 Item Specification Side air dam Double sided tape 4 mm width and 1 2 mm thickness AC303877 Clip Clip Section A A AD 1 A A Adhesive tape position Double sided tape Generic products 4 mm width and 1 2 mm thickness 1 1 Removal step A A 1 Side air dam ...

Page 390: ...side air dam 1 Scrape off the double sided tape on the side air dam with a resin spatula as possible 2 Wipe the side sill garnish surface and clean it with a rag moistened with isopropyl alcohol 3 Remove only a small portion of the residual adhesive 4 Adhere the double sided tape as specified on the side air dam INSTALLATION SERVICE POINT A SIDE AIR DAM INSTALLATION 1 Tear off the double sided tap...

Page 391: ...17 GARNISHES REMOVAL AND INSTALLATION M1511004100107 AC303863 Clip Delta outer garnish Section A A AB Delta outer garnish A A AC303860 A A Clip Trunk lid panel Licence plate garnish Section A A AB Licence plate garnish Sedan ...

Page 392: ...amp harness in the event of installation CAUTION Ensure that the string is tightly tied 1 Tie string on high mounted stop lamp harness at connector side 2 Carefully pull out high mounted stop lamp AC303713 2 3 4 2 1 AB 1 Removal steps Trunk lid bumper Refer to GROUP 42 Trunk lid P 42 43 1 Cap 2 Gasket 3 Rear spoiler A 4 High mounted stop lamp Removal steps Continued AC303708 Connector String AB ...

Page 393: ... 1 2 3 AB 5 2 1 0 N m Tailgate spoiler removal steps Tailgate trim upper Refer to GROUP 52A Tailgate trim P 52A 19 High mounted stoplight connector connection Rear washer hose connection 1 Tailgate spoiler assembly 2 High mounted stoplight assembly 3 Tailgate spoiler Tailgate spoiler removal steps ...

Page 394: ... C C B D D E F E F AC303828 Section A A Section B B Section C C Section D D Section E E Section F F 1 4 4 1 1 4 3 3 4 4 2 4 Claw Claw Claw Claw Claw Claw Claw Claw Claw Claw Claw AB Removal steps 1 Front roof rail cover 2 Centre roof rail cover 3 Rear roof rail cover 4 Roof rail Removal steps Continued ...

Page 395: ...ains off for the wiper operation interval the relay turns on again causing the wipers to operate in intermittent mode Windshield Mist Wiper Operation If the windshield mist wiper switch is turned to the ON position with the ignition switch at the ACC or ON position the mist wiper high speed operation signal is sent to the front ECU This signal turns on the wiper speed control relay causing the wip...

Page 396: ...ion But if it enters the fail safe mode the wiper can operate only when the ignition switch is at the ON position ON VEHICLE SERVICE M1511000800461 WINDSHIELD INTERMITTENT WIPER INSPECTION 1 If the windshield intermittent wiper interval adjusting knob is operated the wiper interval should change 2 Holding the windshield intermittent wiper interval adjusting knob input the simulated vehicle speed w...

Page 397: ...EMOVAL AND INSTALLATION M1511007600350 Y0597AU Y0616AU Y0599AU AC304408 AB Section B B Section A A View A A A A B B Clip A Clip B 6 7 6 7 6 7 3 2 5 6 7 8 9 10 11 11 12 13 14 27 3 N m 8 9 1 9 N m 11 2 N m Note Clip A positions Clip B positions 11 2 N m 7 4 1 4 N m 2 1 1 4 4 ...

Page 398: ...lade at the specified position standard value Standard value A 34 5 mm Wiper blade assembly removal steps B 1 Wiper blade assembly A 2 Wiper blade Windshield wiper motor and link assembly removal steps 3 Cover 4 Wiper arm 5 Hood weather strip 6 Front deck garnish passenger s side 7 Front deck garnish driver s side A 8 Windshield wiper motor assembly 9 Link assembly Washer hose removal steps Front ...

Page 399: ...ustration A and disconnect the battery during rotation to stop the motor 2 Connect between the terminals and the battery as shown in the illustration B and confirm whether the motor stops at the automatic stop position after rotating in a low speed FRONT WASHER MOTOR CHECK 1 Remove the washer tank assembly with the washer hose attached Then fill the washer tank with water 2 Check to see that the w...

Page 400: ...SHER SWITCH CHECK Check continuity between the switch terminals AC304420 305 70 25 55 140 100 120 115 305 300 600 300 25 25 25 25 25 25 25 55 65 60 50 60 50 AB Windshield washer nozzle perpendicular Windshield washer nozzle perpendicular Windshield washer nozzle Right Left Ceramic line terminal UNITS mm 1 6 8 11 10 9 7 5 4 3 2 AC000417 Switch position Tester connection Specified condition OFF 6 11...

Page 401: ...d from FAST to SLOW by after measuring resistance between connector terminals 3 and 6 at the column switch Windshield mist wiper switch 6 11 Less than 2 ohms Windshield intermittent wiper switch 6 10 Windshield low speed wiper switch 6 9 Windshield high speed wiper switch 6 8 Windshield washer switch 6 7 Switch position Tester connection Specified condition 1 6 8 11 10 9 7 5 4 3 2 AC201004 ...

Page 402: ...ON position the rear washer ON signal is sent to the ETACS ECU causing the rear wiper signal to turn on after 0 3 second After the rear washer switch signal turns off the rear wiper signal turns off in three seconds If the rear washer switch is turned to the ON position while the rear wiper is in intermittent mode the rear washer works for that period when the washer switch remains on Then the rea...

Page 403: ... trim lower Refer to GROUP 52A Tailgate trim P 52A 19 Tailgate waterproof film Refer to GROUP 42 Tailgate P 42 48 3 Rear wiper motor assembly Rear washer nozzle removal steps High mounted stop lamp assembly Refer to GROUP 54A High mounted stop lamp P 54A 81 4 Rear washer nozzle Washer hose removal steps Front scuff plate rear scuff plate cowl side trim and quarter trim Refer to GROUP 52A Trims P 5...

Page 404: ...OTOR CHECK Inspect the rear wiper motor is conducted by removing the harness connector with the motor attached to the vehicle Wiper Motor Operation Connect the battery to the rear wiper motor as shown in the illustration A and check the motor operation Wiper Motor at Stop Position Operation 1 Connect the battery to the rear wiper motor as shown in the illustration A 2 Disconnect the battery cable ...

Page 405: ...serting the flat tipped screwdriver into it For the vertical aiming of washer nozzle insert the flat tipped screwdriver into the nozzle and move it to the arrow direction REAR WIPER AND WASHER SWITCH CHECK Check continuity between the switch terminals 1 2 AC005900 AC304544 AB UNITS mm 57 84 125 6 Section A A A A High mounted stop lamp Rear washer nozzle Flat tipped screwdriver Windshield ceramic l...

Page 406: ...17 or GROUP 54C Troubleshooting P 54C 4 HEADLAMP WASHER REMOVAL AND INSTALLATION M1511009700063 AC304608 AB 10 N 2 4 5 6 8 7 1 9 11 9 1 10 N 4 9 0 7 N m 4 9 0 7 N m 3 Removal steps Washer fluid draining 1 Headlamp washer hose connection 2 Under cover side panel R H 3 Splash shield mounting clip R H 4 Headlamp washer motor connection 5 Headlamp washer joint 6 Headlamp washer hose Removal steps Cont...

Page 407: ... the water is vigorously sprayed when connecting the positive battery terminal to terminal number 1 and terminal number 2 to the negative battery terminal 7 Headlamp washer motor 8 Headlamp washer gasket Front bumper Refer to P 51 2 9 Headlamp washer actuator assembly 10 O ring 11 Headlamp washer hose assembly Removal steps Continued AC304136 AB 1 2 ...

Page 408: ...TALLATION SERVICE POINT A MARK APPLICATION 1 Installation position Attach each mark to the position shown in the illustration AC304202 AC400380 1 1 2 2 3 AB Sedan Wagon 3 Removal A 1 Front three diamond mark A 2 Rear three diamond mark A 3 Lancer mark Removal Continued ...

Page 409: ...r than 20 C the marks and the places on the vehicle body where the marks are to be attached should be heated to 20 38 C 2 Peel off the protection sheet on the back of the marks to paste it on the installation position AC304163 Sedan 2 Three diamond mark Wagon Centre line of vehicle Centre line of vehicle Trunk lid press line Press line 112 mm 53 1 mm AC AC304164 Sedan 3 Lancer mark Rear combinatio...

Page 410: ...rations The defogger comes with a timer function and will automatically turn OFF the switch approximately 11 minutes after the defogger switch is turned ON The heated door mirror operations are also terminated along with the defogger at this time SERVICE SPECIFICATION M1511000300347 SPECIAL TOOL M1511000601103 TROUBLESHOOTING DIAGNOSIS TROUBLESHOOTING FLOW M1511014600169 Refer to GROUP 00 How to U...

Page 411: ...te Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet REAR WINDOW DEFOGGER RELAY REAR WINDOW DEFOGGER REMOTE CONTROLLED MIRROR LH REMOTE CONTROLLED MIRROR RH MIRROR HEATER MIRROR HEATER NOTE LH drive vehicles RH drive vehicles ...

Page 412: ...TEP 1 Check the rear window defogger Check that the rear window defogger system should work normally Q Is the check result normal YES Go to Step 2 NO Troubleshoot the rear window defogger Refer to GROUP 55 TroubleshootingP 55 42 STEP 2 Connector check C 212 junction block connector Q Is the check result normal YES Intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction...

Page 413: ...ire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet REAR WINDOW DEFOGGER RELAY REAR WINDOW DEFOGGER REMOTE CONTROLLED MIRROR LH REMOTE CONTROLLED MIRROR RH MIRROR HEATER MIRROR HEATER NOTE LH drive vehicles RH drive vehicles ...

Page 414: ...ES Go to Step 3 NO Repair the defective connector Step 3 Check the door mirror assembly RH Check that the heater element of the door mirror assembly RH is in good condition Refer to P 51 47 Q Is the check result normal YES Go to Step 4 NO Replace the door mirror assembly RH Step 4 Resistance measurement at the E 11 door mirror assembly RH connector 1 Disconnect the connector and measure at the wir...

Page 415: ...the wiring harness Step 6 Voltage measurement at the E 11 door mirror assembly RH connector 1 Turn the ignition switch to the ON position 2 Rear window defogger switch ON 3 Disconnect the connector and measure at the wiring harness side 4 Voltage between E 11 door mirror assembly connector terminal No 1 and body earth OK System voltage Q Is the check result normal YES Intermittent malfunction Refe...

Page 416: ...NO Repair the wiring harness Step 9 Connector check E 02 door mirror assembly LH connector Q Is the check result normal YES Go to Step 10 NO Repair the defective connector Step 10 Check the door mirror assembly LH Check that the heater element of the door mirror assembly LH is in good condition Refer to P 51 47 Q Is the check result normal YES Go to Step 11 NO Replace the door mirror assembly LH A...

Page 417: ...Prior to the wiring harness inspection check intermediate connector C 29 LHD C 113 RHD and repair if necessary Q Is the check result normal YES Intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness Step 13 Connector check C 212 junction block connector Q Is the check result normal YES Go to Step 14 NO Repair the defective connector...

Page 418: ...ness between E 02 door mirror assembly LH connector terminal No 1 and C 212 junction block connector terminal No 3 Check the power supply line for open circuit NOTE Prior to the wiring harness inspection check intermediate connector C 29 LHD C 113 RHD and repair if necessary Q Is the check result normal YES Intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5...

Page 419: ... 3 4 5 6 7 8 Door mirror removal steps 1 Cover 2 Delta inner cover 3 Harness connector Vehicles with remote controlled mirror 4 Door mirror assembly 5 Door mirror body assembly A A 6 Mirror Remote controlled mirror switch removal steps 7 Instrument panel ornament Refer to GROUP 52A Instrument panel P 52A 2 8 Remote controlled mirror switch ...

Page 420: ...he pivot plate and disengage the bottom of the mirror INSTALLATION SERVICE POINT A MIRROR INSTALLATION While supporting the clip position on the underside of the pivot plate with a flat tipped screwdriver press the clip at the front of the mirror to engage the bottom of the mirror AC000441 00007256 Mirror Flat tipped screwdriver Section A A Pivot plate Notch Protective tape A A A A AE AC000442 000...

Page 421: ...ownward Connect terminal 1 to the negative battery terminal Connect terminal 2 to the positive battery terminal Mirror glass should face to the right Connect terminal 2 to the negative battery terminal Connect terminal 1 to the positive battery terminal Mirror glass should face to the left 3 2 1 AC005969 Battery connection Direction operation Connect terminal 5 to the negative battery terminal Con...

Page 422: ...or terminals 1 and 4 should meet the standard value with the ambient temperature at steady 25 C Standard value 5 9 7 8 Ω Switch position Tester connection Specified condition OFF 9 2 9 3 9 6 9 10 9 11 1 2 1 3 1 6 1 10 1 11 Open circuit Left side OFF 9 6 9 10 9 11 1 6 1 10 1 11 Open circuit Up 1 6 9 11 Less than 2 ohms Down 1 11 6 9 Right 1 6 9 10 Left 1 10 6 9 Right side OFF 9 2 9 3 9 6 1 2 1 3 1 ...

Page 423: ...23 1 GROUP 23 AUTOMATIC TRANSMISSION CONTENTS AUTOMATIC TRANSMISSION FF 23A AUTOMATIC TRANSMISSION OVERHAUL 23B ...

Page 424: ...NOTES ...

Page 425: ...22 1 GROUP 22 MANUAL TRANSMISSION CONTENTS MANUAL TRANSMISSION FF 22A MANUAL TRANSMISSION OVERHAUL 22B ...

Page 426: ...NOTES ...

Page 427: ...21 1 GROUP 21 CLUTCH CONTENTS CLUTCH 21A CLUTCH OVERHAUL 21B ...

Page 428: ...NOTES ...

Page 429: ...ON 16 23 DISASSEMBLY AND REASSEMBLY 16 26 INSPECTION 16 27 IGNITION SYSTEM 16 30 GENERAL INFORMATION 16 30 SERVICE SPECIFICATIONS 16 31 SPECIAL TOOL 16 31 ON VEHICLE SERVICE 16 32 IGNITION COIL WITH BUILT IN POWER TRANSISTOR CHECK 16 32 RESISTIVE CORD CHECK 16 32 SPARK PLUG CHECK AND CLEANING 4G1 16 32 SPARK PLUG CHECK AND CLEANING 4G6 16 33 CAMSHAFT POSITION SENSOR CHECK 16 33 CRANK ANGLE SENSOR ...

Page 430: ...tput 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 approximately 14 4 V the field current is cut off When the battery voltage drops below the regulated voltage the voltage regulator regulates the output voltage to a consta...

Page 431: ...rive belt tension Refer to GROUP 11A On vehicle Service 4G1 P 11A 7 or GROUP 11C On vehicle Service 4G6 P 11C 7 Fusible link Abnormal noise from the alternator while the engine is running Item Standard value Limit Alternator output line voltage drop at 30 A V maximum 0 3 Regulated voltage ambient temperature at voltage regulator V 20 C 14 2 15 4 20 C 13 9 14 9 60 C 13 4 14 6 80 C 13 1 14 5 Output ...

Page 432: ... the headlamps and other lamps on and off to adjust the alternator load so that the value displayed on the ammeter is slightly above 30 A Adjust the engine speed by gradually decreasing it until the value displayed on the ammeter is 30 A Take a reading of the value displayed on the voltmeter at this time Limit maximum 0 3 V NOTE When the alternator output is high and the value displayed on the amm...

Page 433: ...Never use clips but tighten bolts and nuts to connect the line Otherwise loose connections e g using clips will lead to a serious accident because of high current 4 Connect a clamp type DC test ammeter with a range of 0 120 A to the alternator B terminal output wire NOTE The way of disconnecting the alternator output wire and of connecting the ammeter is possibly not found the problem that the out...

Page 434: ... should be carried out as quickly as possible in order to obtain the maximum current output value The current output value will depend on the electrical load and the temperature of the alternator body If the electrical load is small while testing the specified level of current may not be output even though the alternator is normal In such cases increase the electrical load by leaving the headlamps...

Page 435: ... output wire NOTE The way of disconnecting the alternator output wire and of connecting the ammeter is possibly not found the problem that the output current is dropping due to the insufficient connection between terminal B and the output wire 6 Reconnect the negative battery cable 7 Connect a tachometer or the MUT II III Refer to GROUP 11A On vehicle Service Idle speed check 4G1 P 11A 11 or GROUP...

Page 436: ...move the tachometer or the MUT II III 17 Disconnect the negative battery cable 18 Disconnect the ammeter and voltmeter 19 Connect the alternator output wire to the alternator B terminal 20 Remove the special tool and return the connector to the original condition 21 Connect the negative battery cable Voltage Regulation Table Standard value Inspection terminal Voltage regulator ambient temperature ...

Page 437: ...ding to fluctuations in the alternator load current and is normal for the alternator In addition when the voltage waveform reaches an excessively high value approximately 2 V or higher at idle it often indicates an open circuit due to a brown fuse between alternator B terminal and battery but not a defective alternator AK100002 Alternator B terminal CH1 AC Function Special pattern Pattern height V...

Page 438: ...cope 2 Identification of abnormal waveforms is easier when there is a large output current regulator is not operating Waveforms can be observed when the headlamps are illuminated 3 Check the conditions of the charging warning lamp illuminated not illuminated Also check the charging system totally Abnormal waveform Problem cause Example 1 Open diode Example 2 Short in diode AKX00191 AKX00192 ...

Page 439: ...TRICAL 16 11 Example 3 Broken wire in stator coil Example 4 Short in stator coil Example 5 At this time the charging warning lamp is illuminated Open supplementary diode Abnormal waveform Problem cause AKX00193 AKX00194 AKX00195 ...

Page 440: ...val Refer to GROUP 11A Crankshaft Pulley P 11A 16 Post installation Operation Drive Belt Installation Refer to GROUP 11A Crankshaft Pulley P 11A 16 Drive Belt Tension Adjustment Refer to GROUP 11A On vehicle Service P 11A 7 Under Cover Installation AC303729 1 2 4 3 44 10 N m 23 2 N m 24 3 N m 12 2 N m AB Removal steps 1 Power steering pressure hose clamp 2 Alternator connector and terminal 3 Alter...

Page 441: ... 15 3 Post installation Operation Air Cleaner Assembly Installation Refer to GROUP 15 P 15 3 Drive Belt Installation Refer to GROUP 11C Crankshaft Pulley P 11C 16 Strut Tower Bar Installation Refer to GROUP 42 P 42 9 Drive Belt Tension Adjustment Refer to GROUP 11C On vehicle Service P 11C 7 Under Cover Installation AC303826 1 2 3 18 3 N m AB Removal steps 1 Shift cable connection A 2 shift cable ...

Page 442: ...After removing the alternator assembly installation bolts and nut move the alternator assembly to the transmission side and remove the alternator assembly upward the engine room through the clearance between the transmission and the inlet manifold AC303827 6 5 8 4 9 7 22 4 N m 23 3 N m 8 8 1 0 N m 44 10 N m AB Removal steps 4 Battery wiring harness clamp 5 Engine oil pressure switch connection 6 A...

Page 443: ...4 AE 4 4 1 0 N m 3 7 0 7 N m 189 19 N m 3 7 0 7 N m Disassembly steps A 1 Front bracket assembly B 2 Alternator pulley B 3 Rotor 4 Rear bearing 5 Bearing retainer 6 Front bearing 7 Front bracket C 8 Stator 9 Plate C A 10 Regulator assembly 11 Brush 12 Rubber packing 13 Rectifier 14 Rear bracket Disassembly steps Continued ...

Page 444: ...h unsoldering within four seconds Diodes will be damaged by heat if unsoldering time is too long Avoid applying undue force to the diode leads 1 Unsolder the stator leads from the main diode of the rectifier assembly when the stator is removed 2 When removing the rectifier assembly from the regulator assembly undo the soldered points on the rectifier assembly REASSEMBLY SERVICE POINTS A REGULATOR ...

Page 445: ...uity between the slip rings and core 3 If continuity is present replace the rotor STATOR 1 Check the continuity between coil leads If there is no continuity replace the stator 2 Check the continuity between coil and core If there is no continuity replace the stator RECTIFIER ASSEBMLY 1 Check the condition of the heat sink by checking continuity between the heat sink and each of the stator coil lea...

Page 446: ...diode Connect in a polarity and then reverse the polarity for each test If continuity exists or no continuity exists for both polarities the diode is defective Replace the rectifier assembly if any of the diodes is defective BRUSH 1 Measure the length of the protrusion of the brush Replace the brush if the protrusion length is shorter than the limit Limit 2 mm minimum 2 Unsolder the lead of the br...

Page 447: ...the other hand attracting the plunger will turn on the magnetic switch allowing the B terminal and M terminal to conduct Thus current flows to engage the starter motor When the ignition switch is returned to the ON position after starting the engine the starter clutch is disengaged from the ring gear An overrunning clutch is provided between the pinion and the armature shaft to prevent damage to t...

Page 448: ...162000300068 Item 4G1 4G6 Type Reduction drive with planetary gear Reduction drive with planetary gear Rated output kW V 1 2 12 1 4 12 Number of pinion teeth 8 8 Item Standard value Limit Pinion gap mm 0 5 2 0 Commutator run out mm 0 05 Commutator diameter mm 29 4 28 8 Undercut depth mm 0 5 0 2 ...

Page 449: ... the transmission and remove the shift cable assembly from the transmission C STARTER ASSEMBLY REMOVAL Remove the starter assembly from above the vehicle Pre removal and Post installation Operation Air Cleaner Assembly Removal and Installation Refer to GROUP 15 P 15 3 Battery and Battery Tray Removal and Installation AC303962AB 1 1 2 3 5 6 7 4 30 3 N m 18 3 N m 12 2 N m M T A T Removal steps 1 Shi...

Page 450: ...and Post installation Operation Air Cleaner Assembly Removal and Installation Refer to GROUP 15 P 15 3 Under Cover Removal and Installation AC304005 5 2 1 6 49 9 N m 18 3 N m 9 0 2 0 N m 30 3 N m AB 4 3 Removal steps 1 Starter cover 2 Starter connector and terminal 3 Clutch release cylinder connecting bolts 4 Clutch hose clamp A 5 Starter assembly 6 Starter cover bracket Removal steps Continued ...

Page 451: ...s out of specification adjust by adding or removing gasket s between the magnetic switch and front bracket MAGNETIC SWITCH PULL IN TEST 1 Disconnect the field coil wire from the M terminal of the magnetic switch CAUTION This test must be performed quickly in less than 10 seconds to prevent the coil from burning 2 Connect a 12 volt battery between the S terminal and M terminal 3 If the pinion moves...

Page 452: ...as follows 2 Connect a test ammeter 100 ampere scale and carbon pile rheostat in series between the battery terminal and starter motor terminal 3 Connect a voltmeter 15 volt scale across the starter motor 4 Rotate the rheostat to full resistance position 5 Connect the battery cable from the battery terminal to the starter motor body 6 Adjust the rheostat until the battery voltage shown on the volt...

Page 453: ...t the coil from burning 2 Connect a 12 volt battery between the M terminal and body WARNING Be careful not to get your fingers caught when pulling out the pinion 3 Pull the pinion out and release If the pinion quickly returns to its original position everything is operating properly If it doesn t replace the magnetic switch AK300652AB 4G1 S B M Wire Battery Starter motor AKX01248 4G6 S B M Battery...

Page 454: ...9 AG Disassembly steps 1 Screw A 2 Magnetic switch 3 Screw 4 Bolt 5 Rear bracket 6 Brush holder 7 Rear bearing 8 Armature 9 Yoke assembly 10 Packing A 11 Packing B 12 Plate 13 Planetary gear 14 Lever B A 15 Snap ring B A 16 Stop ring 17 Overrunning clutch 18 Internal gear 19 Planetary gear shaft 20 Front bracket Disassembly steps Continued ...

Page 455: ...e parts require cleaning wipe off contamination with cloth 1 Never soak the drive unit in a solvent If it is washed in a solvent the grease having been packed in the overrunning clutch at the factory will be washed out Wipe the drive unit with cloth if it requires cleaning REASSEMBLY SERVICE POINTS A STOP RING SNAP RING INSTALLATION Use a suitable puller to pull the stop ring until it gets over th...

Page 456: ... counterclockwise and can be turned clockwise freely 2 Check the pinion for abnormal ware and damage BRUSHES 1 Check the commutator contacting surface of each brush for abnormal roughness Also check the height of the brush Replace the brush holder if the height is lower than the limit Limit 7 0 mm 2 When the contact surface of the brush is rectified or the brush holder is replaced recondition the ...

Page 457: ...n circuit in the tested coil if there is continuity MAGNETIC SWITCH 1 Coil open circuit test Check that there is continuity between the M terminal and body A If there is no continuity replace the magnetic switch 2 Contact fusion check Check that there is no continuity between the B terminal and M terminal If there is continuity replace the magnetic switch 3 Switch contact check Push the indicated ...

Page 458: ...s in the ignition coils to be alternately interrupted and allowed to flow to fire the cylinders in the order 1 3 4 2 The engine ECU M T or engine A T ECU A T determines which ignition coil should be controlled by means of the signals from the camshaft position sensor which is incorporated in the camshaft and from the crank angle sensor which is incorporated in the crankshaft It also detects the cr...

Page 459: ...0600288 Item Specification Type Molded 2 coil Items 4G1 4G66 NGK BKR6E 11 IGR6A11 DENSO K20PR U11 CHAMPION RC8YC4 Item Standard value Secondary coil resistance kΩ 8 5 11 5 Items Standard value Limit Spark plug gap mm 4G1 1 0 1 1 4G6 1 0 1 1 1 3 Item Standard value Limit Resistance kΩ Maximum 19 Tool Number Name Use MD998773 Detonation sensor wrench Detonation sensor removal and installation ...

Page 460: ...asure resistance Limit Maximum 19 kΩ SPARK PLUG CHECK AND CLEANING 4G1 M1163004300342 CAUTION When pulling off the spark plug cable from the plug always hold the cable cap not the cable 1 Remove the spark plug cables 2 Remove the spark plugs 3 Check for burned out electrode or damaged insulator Check for even burning 4 Remove carbon deposits with wire brush or plug cleaner Remove sand from plug sc...

Page 461: ... code 4G1 P 13A 15 or GROUP 13B Troubleshooting Inspection chart for diagnosis code 4G6 P 13B 15 DETONATION SENSOR CHECK M1163002900047 Check the detonation sensor circuit if self diagnosis code No P0325 is shown Refer to GROUP 13A Troubleshooting Inspection chart for diagnosis code 4G1 P 13A 15 or GROUP 13B Troubleshooting Inspection chart for diagnosis code 4G6 P 13B 15 IGNITION SECONDARY VOLTAG...

Page 462: ... condition is the pattern selector Function Secondary Pattern height High or Low Pattern selector Raster Engine revolutions Curb idle speed Pattern selector Display AKX00278 kV 0 Secondary ignition voltage wave pattern Ignition voltage point D Spark line point A Dwell section Wave dampling reduction section point B Point C Time AD ...

Page 463: ...tion NO 4 cylinder NO 2 cylinder ignition noise Time AC Spark line Plug gap Condition of electrode Compression force Concentration of air mixture Ignition timing Spark plug 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...

Page 464: ...Spark plug gap is too small Example 3 Wave characteristics Spark line is low and long and is sloping However there is almost no spark line distortion Cause of problem Spark plug gap is fouled Example 4 Wave characteristics Spark line is high and short Difficult to distinguish between this and abnormal waveform example 1 Cause of problem Spark plug cable is nearly falling off Causing a dual ignitio...

Page 465: ...500018 AC301727 2 1 3 4 AC304311AB Battery Ignition coil relay Battery voltage Terminal No to be connected to tester Continuity test results Not applied 1 4 Open circuit Connect terminal No 2 and battery terminal Connect terminal No 3 and battery terminal 1 4 Less than 2 ohms ...

Page 466: ...OIL REMOVAL AND INSTALLATION 4G1 M1163004000404 AC303965AB 1 1 5 2 2 10 2 N m 10 2 N m 25 5 N m 3 4 4 Removal steps 1 Ignition coil connector 2 Spark plug cable 3 Accelerator cable support clamp RHD 4 Ignition coil 5 Spark plug Removal steps Continued ...

Page 467: ...REMOVAL AND INSTALLATION 4G6 M1163004000415 AC301786 10 2 N m 25 4 N m 5 4 2 2 3 3 4 AB 1 3 0 0 5 N m Removal steps 1 Rocker cover centre cover 2 Ignition coil connector 3 Spark plug cable 4 Ignition coil 5 Spark plug Removal steps Continued ...

Page 468: ...MSHAFT POSITION SENSOR REMOVAL AND INSTALLATION M1163003400443 AC303970AB 2 3 8 8 1 0 N m N 1 4G1 AC301556 N 1 2 3 8 8 1 0 N m AC 4G6 Removal steps 1 Camshaft position sensor connector 2 Camshaft position sensor 3 O ring Removal steps Continued ...

Page 469: ...OVAL AND INSTALLATION 4G1 M1163003500439 Pre removal and Post installation Operation Valve Timing Belt Removal and Installation Refer to GROUP 11A P 11A 33 AC208380AB 1 2 11 1 N m 8 8 1 0 N m Removal steps 1 Engine crank angle sensor 2 Crank angle sensor connector bracket ...

Page 470: ... wire Pre removal and Post installation Operation Valve Timing Belt Removal and Installation Refer to GROUP 11C P 11C 35 AC301612 8 8 1 0 N m 8 8 8 1 0 N m 9 1 22 4 N m 4 2 3 49 9 N m 49 9 N m 5 22 4 N m 3 0 0 5 N m 6 7 AC Removal steps 1 Power steering pressure switch connector 2 A C compressor connector 3 A C compressor connector clamp A 4 Power steering oil pump assembly 5 Power steering oil pu...

Page 471: ...t the detonation sensor against other components Internal damage may result and the detonation sensor will need to be replaced AC303971 2 1 23 2 N m AB 4G1 Cylinder block Intake side AC303972 2 1 23 2 N m AB 4G6 Inlet manifold Removal steps 1 Engine control detonation sensor connector A A 2 Engine control detonation sensor ...

Page 472: ...998773 to remove the engine control detonation sensor INSTALLATION SERVICE POINT A ENGINE DETONATION SENSOR INSTALLATION Use special tool detonation sensor wrench MD998773 to tighten the engine control detonation sensor to the specified torque AC100807 MD998773 Engine control detonation sensor AD AC100807 MD998773 Engine control detonation sensor AD ...

Page 473: ...TENTS GENERAL INFORMATION 12 2 SERVICE SPECIFICATION 12 2 LUBRICANT 12 2 SEALANT 12 3 SPECIAL TOOLS 12 3 ON VEHICLE SERVICE 12 4 ENGINE OIL CHECK 12 4 ENGINE OIL REPLACEMENT 12 4 ENGINE OIL FILTER REPLACEMENT 12 4 OIL PRESSURE CHECK 12 5 ...

Page 474: ...le Avoid contaminating clothes particularly underpants with oil Do not put oily rags in pockets the use of overalls without pockets will avoid this Do not wear heavily soiled clothing and oil impregnated foot wear Overalls must be cleaned regularly and kept separate from personal clothing Where there is a risk of eye contact eye protection should be worn for example chemical goggles or face shield...

Page 475: ...l and installation of engine oil filter When using the engine oil filter of MD360935 MB991828 Oil filter wrench Removal and installation of engine oil filter When using the engine oil filter of MD348631 and MD365876 MB991610 Oil filter wrench Removal and installation of engine oil filter When using the engine oil filter of MD356000 MD998054 Oil pressure switch wrench Removal and installation of oi...

Page 476: ...ine oil pan drain plug to the specified torque Tightening torque 39 5 N m NOTE Install the engine oil pan drain plug gasket so it faces in the direction shown in the illustration 5 Refill with specified quantity of engine oil Specified Engine Oil ACEA and API classification ACEA A1 A2 or A3 API SG or higher Total quantity Includes volume inside engine oil filter 3 3 L 4G1 4 3 L 4G6 6 Install the e...

Page 477: ...ve the oil pressure switch terminal Number Special tool MD348631 4G1 Oil filter wrench MB991828 or equivalent MD365876 4G1 MD360935 4G1 Oil filter wrench MB991396 or equivalent MD136466 4G6 Commercially available tool MD322508 4G6 MD356000 4G6 Oil filter wrench MB991610 or equivalent AC000093 MB991396 4G1 MB991828 4G1 MB991610 4G6 or commercially available tool AI AC103250AD O ring Number Special ...

Page 478: ...sure is within the standard value Standard value At idle 29 kPa or more At 3 500 r min 294 686 kPa 7 Remove the oil pressure gauge 8 Apply the specified sealant to the thread of oil pressure switch Specified sealant 3M ATD Part No 8660 or equivalent CAUTION Do not start the engine within one hour after the oil pressure switch has been installed 9 Use the special tool Oil pressure switch wrench MD9...

Page 479: ...11 1 GROUP 11 ENGINE CONTENTS ENGINE MECHANICAL 4G1 11A ENGINE OVERHAUL 4G1 11B ENGINE MECHANICAL 4G6 11C ENGINE OVERHAUL 4G6 11D ...

Page 480: ...NOTES ...

Page 481: ...00 1 GROUP 00 GENERAL CONTENTS GENERAL 00 GENERAL ELECTRICAL 00E ...

Page 482: ...NOTES ...

Page 483: ...4G1 MPI LHD 80 8 ENGINE AND TRANSMISSION 4G1 MPI RHD 80 10 ENGINE AND TRANSMISSION 4G6 MPI LHD 80 12 ENGINE AND TRANSMISSION 4G6 MPI RHD 80 14 DASH PANEL 80 16 DASH PANEL LHD 80 16 DASH PANEL RHD 80 19 FLOOR AND ROOF 80 22 FLOOR AND ROOF SEDAN LHD 80 22 FLOOR AND ROOF SEDAN RHD 80 23 FLOOR AND ROOF WAGON LHD 80 24 FLOOR AND ROOF WAGON RHD 80 25 DOOR 80 26 DOOR LHD 80 26 DOOR RHD 80 27 TRUNK LUGGAG...

Page 484: ...iring harnesses 2 also equipped at the right side AC301175AB Front wiring harness RH Control wiring harness Instrument panel wiring harness Roof wiring harness Floor wiring harness RH Battery wiring harness Front wiring harness LH Front door wiring harness Floor wiring harness LH Fuel wiring harness Rear door wiring harness Front bumper wiring harness Rear bumper wiring harness ...

Page 485: ... 2 also equipped at the right side AC301176 AB Front wiring harness RH Control wiring harness Instrument panel wiring harness Roof wiring harness Floor wiring harness RH Battery wiring harness Front wiring harness LH Front door wiring harness Floor wiring harness LH Fuel wiring harness Rear door wiring harness Front bumper wiring harness Rear bumper wiring harness ...

Page 486: ...pped at the right side AC301177AB Front wiring harness RH Control wiring harness Instrument panel wiring harness Roof wiring harness Floor wiring harness RH Battery wiring harness Front wiring harness LH Front door wiring harness Floor wiring harness LH Fuel wiring harness Rear door wiring harness Front bumper wiring harness Rear bumper wiring harness Tailgate wiring harness ...

Page 487: ...pped at the right side AC301178 AB Front wiring harness RH Control wiring harness Instrument panel wiring harness Roof wiring harness Floor wiring harness RH Battery wiring harness Front wiring harness LH Front door wiring harness Floor wiring harness LH Fuel wiring harness Rear door wiring harness Front bumper wiring harness Rear bumper wiring harness Tailgate wiring harness ...

Page 488: ...front fog lamp A 05X 4 Horn relay A 09X 4 Fan control relay A 10X 11 Front ECU A 11X 11 Front ECU A 12 2 B Front wiring harness LH and control wiring harness combination A 13 12 B Front wiring harness LH and control wiring harness combination A 14 3 B Headlamp LH A 15 6 B Front combination lamp LH A 16 2 Front turn signal lamp LH A 17 2 B Front fog lamp LH A 18 3 GR Cooling fan motor drive control...

Page 489: ...relay or spare connector for front fog lamp A 05X 4 Horn relay A 09X 4 Fan control relay A 10X 11 Front ECU A 11X 11 Front ECU A 12 2 B Front wiring harness LH and control wiring harness combination A 14 3 B Headlamp LH A 15 6 B Front combination lamp LH A 16 2 Front turn signal lamp LH A 17 2 B Front fog lamp LH A 18 3 GR Cooling fan motor drive control unit A 19 1 B Horn HI A 20 2 B Front wiring...

Page 490: ... 18 Battery wiring harness B 19 B 20 B 21 B 01 5 GR Windshield wiper motor B 02 2 GR Fuel injector 1 B 03 2 GR Fuel injector 2 B 04 2 GR Fuel injector 3 B 05 2 GR Fuel injector 4 B 06 3 GR Throttle body throttle sensor B 07 3 B Vehicle speed sensor M T B 09 2 GR Brake fluid level indicator switch B 10X 1 Engine speed detection connector B 15X 4 A T control relay B 16X 4 Engine control relay B 17X ...

Page 491: ...wiring harness B 109 B 110 B 111 B 112 B 101 2 BR Emission solenoid valve EGR system B 102 4 GR Inlet manifold absolute pressure sensor B 103 6 B Throttle body idle speed control servo B 104 3 GR Ignition coil 1 B 105 2 B Emission solenoid valve Purge control system B 107 3 B Camshaft position sensor B 108 3 GR Output shaft speed sensor A T B 109 3 B Input shaft speed sensor A T B 110 2 B Back up ...

Page 492: ...ness B 19 B 20 B 21 B 01 5 GR Windshield wiper motor B 02 2 GR Fuel injector 1 B 03 2 GR Fuel injector 2 B 04 2 GR Fuel injector 3 B 05 2 GR Fuel injector 4 B 06 3 GR Throttle body throttle sensor B 07 3 B Vehicle speed sensor M T B 09 2 GR Brake fluid level indicator switch B 10X 1 Engine speed detection connector B 14X 4 Ignition coil relay B 15X 4 A T control relay B 16X 4 Engine control relay ...

Page 493: ...g harness B 109 B 110 B 111 B 112 B 118 B 101 2 BR Emission solenoid valve EGR system B 102 4 GR Inlet manifold absolute pressure sensor B 103 6 B Throttle body idle speed control servo B 104 3 GR Ignition coil 1 B 105 2 B Emission solenoid valve Purge control system B 107 3 B Camshaft position sensor B 108 3 GR Output shaft speed sensor A T B 109 3 B Input shaft speed sensor A T B 110 2 B Back up...

Page 494: ...th cable B 01 5 GR Windshield wiper motor B 02 2 GR Fuel injector 1 B 03 2 GR Fuel injector 2 B 04 2 GR Fuel injector 3 B 05 2 GR Fuel injector 4 B 06 4 B Throttle body throttle sensor B 07 3 B Vehicle speed sensor B 08 7 B Air cleaner air flow sensor B 09 2 GR Brake fluid level indicator switch B 10X 1 Engine speed detection connector B 16X 4 Engine control relay B 17X 4 A C compressor relay B 18...

Page 495: ...iring harness B 111 B 107 Earth cable B 101 2 BR Emission solenoid valve EGR system B 103 6 B Throttle body idle speed control servo B 104 3 GR Ignition coil 1 B 105 2 B Emission solenoid valve Purge control system B 106 1 B Capacitor B 107 3 B Camshaft position sensor B 110 2 B Back up lamp switch B 111 2 B Water temperature sensor unit B 112 1 B Water temperature gauge unit B 113 3 GR Ignition c...

Page 496: ...01 5 GR Windshield wiper motor B 02 2 GR Fuel injector 1 B 03 2 GR Fuel injector 2 B 04 2 GR Fuel injector 3 B 05 2 GR Fuel injector 4 B 06 4 B Throttle body throttle sensor B 07 3 B Vehicle speed sensor B 08 7 B Air cleaner air flow sensor B 09 2 GR Brake fluid level indicator switch B 10X 1 Engine speed detection connector B 14X 4 Ignition coil relay B 16X 4 Engine control relay B 17X 4 A C comp...

Page 497: ... 110 B 111 B 107 B 104 10 Earth cable B 101 2 BR Emission solenoid valve EGR system B 103 6 B Throttle body idle speed control servo B 104 3 GR Ignition coil 1 B 105 2 B Emission solenoid valve Purge control system B 106 1 B Capacitor B 107 3 B Camshaft position sensor B 110 2 B Back up lamp switch B 111 2 B Water temperature sensor unit B 112 1 B Water temperature gauge unit B 113 3 GR Ignition c...

Page 498: ...ss and antenna feeder cable combination C 11 16 B Diagnosis connector C 12 33 J C 6 C 13 25 Instrument panel wiring harness and control wiring harness combination C 14 10 GR Instrument panel wiring harness and control wiring harness combination C 15 22 L Instrument panel wiring harness and control wiring harness combination C 19 12 Diagnosis connector C 21 3 Front wiring harness LH and instrument ...

Page 499: ...panel wiring harness and A C wiring harness combination C 107 7 Outside Inside air selection damper control motor C 108 2 R Air bag module squib Passengerís side C 109 4 Resistor C 110 2 Blower motor C 112 16 Instrument panel wiring harness and front door wiring harness RH combination C 114 25 Front wiring harness RH and instrument panel wiring harness combination C 116 9 GR Instrument panel wirin...

Page 500: ...le squib Driverís side C 208 13 Instrument panel wiring harness and J B combination C 209 14 Instrument panel wiring harness and J B combination C 210 6 Instrument panel wiring harness and J B combination C 211 1 B Instrument panel wiring harness and J B combination C 212 28 Instrument panel wiring harness and J B combination C 213 5 Rear window defogger relay C 214 5 Blower relay C 215 15 Floor w...

Page 501: ...C 10 1 Instrument panel wiring harness and antenna feeder cable combination C 11 16 B Diagnosis connector C 16 20 Y SRS ECU C 17 28 Y SRS ECU C 18 20 Y SRS ECU C 19 12 Diagnosis connector C 20 2 No connection C 23 13 Instrument panel wiring harness and floor wiring harness RH combination C 24 6 L Instrument panel wiring harness and roof wiring harness combination C 26 9 GR Instrument panel wiring ...

Page 502: ...wiring harness combination C 113 16 Instrument panel wiring harness and front door wiring harness LH combination C 115 25 Front wiring harness LH and instrument panel wiring harness combination C 117 11 B Instrument panel wiring harness and floor wiring harness LH combination C 118 6 L Instrument panel wiring harness and floor wiring harness LH combination C 120 13 Instrument panel wiring harness ...

Page 503: ...dule squib Driverís side C 208 13 Instrument panel wiring harness and J B combination C 209 14 Instrument panel wiring harness and J B combination C 210 6 Instrument panel wiring harness and J B combination C 211 1 B Instrument panel wiring harness and J B combination C 212 28 Instrument panel wiring harness and J B combination C 213 5 Rear window defogger relay C 214 5 Blower relay C 216 15 Floor...

Page 504: ...Rear RH D 06 2 GR Rear room lamp D 07 3 Door switch Rear RH D 08 2 Y Side impact sensor Rear RH D 13 3 B Fuel tank gauge unit D 14 2 Y Side impact sensor Rear LH D 15 3 Door switch Rear LH D 16 5 GR Fuel tank pump D 17 2 B Wheel speed sensor Rear LH D 18 8 Floor wiring harness LH and fuel wiring harness combination D 19 8 Floor wiring harness LH and rear door wiring harness LH combination D 20 3 D...

Page 505: ... D 05 2 B Wheel speed sensor Rear RH D 06 2 GR Rear room lamp D 07 3 Door switch Rear RH D 08 2 Y Side impact sensor Rear RH D 13 3 B Fuel tank gauge unit D 14 2 Y Side impact sensor Rear LH D 15 3 Door switch Rear LH D 16 5 GR Fuel tank pump D 17 2 B Wheel speed sensor Rear LH D 18 8 Floor wiring harness LH and fuel wiring harness combination D 19 8 Floor wiring harness LH and rear door wiring ha...

Page 506: ... 2 Y Side impact sensor Rear RH D 09 3 Rear personal lamp RH D 10 3 Luggage room lamp D 11 2 B Diode for luggage room lamp circuit D 12 3 Rear personal lamp LH D 13 3 B Fuel tank gauge unit D 14 2 Y Side impact sensor Rear LH D 15 3 Door switch Rear LH D 16 5 GR Fuel tank pump D 17 2 B Wheel speed sensor Rear LH D 18 8 Floor wiring harness LH and fuel wiring harness combination D 19 8 Floor wiring...

Page 507: ... lamp D 07 3 Door switch Rear RH D 08 2 Y Side impact sensor Rear RH D 09 3 Rear personal lamp RH D 10 3 Luggage room lamp D 11 2 B Diode for luggage room lamp circuit D 12 3 Rear personal lamp LH D 13 3 B Fuel tank gauge unit D 14 2 Y Side impact sensor Rear LH D 15 3 Door switch Rear LH D 16 5 GR Fuel tank pump D 17 2 B Wheel speed sensor Rear LH D 18 8 Floor wiring harness LH and fuel wiring ha...

Page 508: ...eater E 03 2 Front door speaker LH E 04 6 GR Front power window motor LH E 05 14 Power window main switch E 06 6 B Front door lock actuator LH E 07 6 GR Rear power window motor LH E 08 8 Rear power window sub switch LH E 09 6 B Rear door lock actuator LH E 10 3 Remote controlled mirror RH Vehicles without door mirror heater E 11 7 Remote controlled mirror RH Vehicles with door mirror heater E 12 3...

Page 509: ...er E 03 2 Front door speaker LH E 04 6 GR Front power window motor LH E 05 14 Power window main switch E 06 6 B Front door lock actuator LH E 07 6 GR Rear power window motor LH E 08 8 Rear power window sub switch LH E 09 6 B Rear door lock actuator LH E 10 3 Remote controlled mirror RH Vehicles without door mirror heater E 11 7 Remote controlled mirror RH Vehicles with door mirror heater E 12 3 B ...

Page 510: ... L Blue None Milk white O Orange R Red V Violet Y Yellow F 20 Connector symbol F F 01 2 Rear speaker LH F 03 1 Roof antenna F 04 2 Luggage compartment lamp F 05 2 B High mount stop lamp Rear shelf F 06 1 B Rear window defogger F 08 2 Rear speaker RH F 10 2 High mount stop lamp Rear spoiler F 11 6 B Rear combination lamp RH F 15 2 GR Licence plate lamp RH F 16 1 B Trunk lid latch switch F 18 2 GR L...

Page 511: ...k white O Orange R Red V Violet Y Yellow Connector symbol F F 01 2 Rear speaker LH F 03 1 Roof antenna F 04 2 Luggage compartment lamp F 05 2 B High mount stop lamp Rear shelf F 06 1 B Rear window defogger F 07 4 No connection F 08 2 Rear speaker RH F 10 2 High mount stop lamp Rear spoiler F 11 6 B Rear combination lamp RH F 14 2 Rear fog lamp F 15 2 GR Licence plate lamp RH F 16 1 B Trunk lid lat...

Page 512: ...mbol F F 01 2 Rear speaker LH F 02 6 Floor wiring harness LH and Floor wiring harness RH combination F 03 1 Roof antenna F 06 1 Rear window defogger F 07 4 Rear wiper motor F 08 2 Rear speaker RH F 09 2 Accessory socket F 10 2 High mount stop lamp Rear spoiler F 11 6 B Rear combination lamp RH F 12 8 Floor wiring harness RH and tailgate wiring harness combination F 13 2 B Tailgate lock actuator F ...

Page 513: ...r wiring harness Connector symbol F F 01 2 Rear speaker LH F 03 1 Roof antenna F 06 1 Rear window defogger F 07 4 Rear wiper motor F 08 2 Rear speaker RH F 09 2 Accessory socket F 10 2 High mount stop lamp Rear spoiler F 11 6 B Rear combination lamp RH F 12 8 Floor wiring harness RH and tailgate wiring harness combination F 13 2 B Tailgate lock actuator F 14 2 Rear fog lamp F 15 2 GR Licence plate...

Page 514: ...NOTES ...

Page 515: ...GROUP 70 COMPONENT LOCATIONS CONTENTS ECU 70 2 RELAY 70 5 SENSOR 70 6 FUSIBLE LINK AND FUSE 70 10 EARTH CABLE 70 11 SOLENOID VALVE 70 11 DIODE 70 13 EARTH 70 14 INSPECTION CONNECTOR AND SPARE CONNECTOR 70 18 ...

Page 516: ...ive control unit C ABS ECU A Front ECU B Column switch incorporating Column ECU D Immobilizer ECU G Engine A T ECU A T I Power window main switch incorporating ECU K Engine ECU M T I Power window sub switch incorporating ECU J ETACS ECU F SRS ECU H AC301182 D E A B C F G H I AB LHD D E A B C F G H I RHD ...

Page 517: ...AC304537 J K AE AC100209 AC A ABS ECU LHD Hydraulic unit AC206790 A AD ABS ECU Hydraulic unit RHD AC301728 AB B Front ECU Battery AC300571 C AC Radiator fan Cooling fan motor drive control unit AC301746 D Column switch incorporating column ECU AB AC301732 AB E A C ECU ...

Page 518: ...C F ETACS ECU Junction block AC301733 AB Immobilizer ECU G AC301747AB SRS ECU H AC100229 AI Engine ECU M T or engine A T ECU A T I AC301749AB Power window sub switch incorporating ECU J AC301748AB Power window main switch incorporating ECU K ...

Page 519: ...iator fan relay A Front fog lamp relay A Rear fog lamp relay B Fuel pump relay 1 B Rear window defogger relay B Fuel pump relay 2 B AC301758 AB A B AC303951 AB A C compressor relay Engine control relay Horn relay Front fog lamp relay Radiator fan relay A T control relay Ignition coil relay A AC301760 Fuel pump relay 1 Power window relay Rear window defogger relay Blower relay Heated seat relay Fue...

Page 520: ...impact sensor Rear L Engine control detonation sensor B Throttle body throttle sensor C Engine control oxygen sensor Front G Vehicle speed sensor M T E Engine control oxygen sensor Rear N Water temperature sensor unit H Engine crank angle sensor A Wheel speed sensor Front M Inlet manifold absolute pressure sensor incorporating intake air temperature sensor 4G1 C Wheel speed sensor Rear O Input sha...

Page 521: ...Engine crank angle sensor AC301752 B AB Ignition coil 2 4G1 Engine control detonation sensor connector Engine control detonation sensor AC302009 B AB Hydraulic unit 4G6 Alternator Engine control detonation sensor connector Engine control detonation sensor AC208541 C AE 4G1 Throttle body Throttle body throttle sensor Inlet manifold absolute pressure sensor incorporating intake air temperature senso...

Page 522: ...AB F Air cleaner assembly 4G6 Air cleaner air flow sensor AB AC301754 G 4G1 AC Heat protector Engine control oxygen sensor Front Engine control oxygen sensor Front connector AC302482 G AB Heat protector 4G6 Engine control oxygen sensor Front connector Engine control oxygen sensor Front AC206780 AD H Rocker cover 4G1 Water temperature sensor unit AC302483 AC302483 4G6 H AB Rocker cover Water temper...

Page 523: ...K Side impact sensor Front Centre pillar AC300534 AC L Side impact sensor Rear Rear seat belt AC209080 M AG Wheel speed sensor Front connector Coil spring Wheel speed sensor Front AC301753 AB SRS ECU N Engine control oxygen sensor Rear connector Engine control oxygen sensor Rear AC209459 O Wheel speed sensor Rear connector Parking brake cable Coil spring AE Wheel speed sensor Rear ...

Page 524: ...ible links No 1 to 5 Engine compartment B Fuses No 6 to 25 Engine compartment B Fusible link No 26 Battery positive terminal A AC301758AD A B C AC208658 AE A Fusible link No 26 Battery AC301729AD B Fusible link No 1 Relay box Fusible links No 4 5 Fusible links No 2 3 AC301730 B AB Fuses No 6 to 25 Relay box AC301761 C AB Fuses No 1 to 20 Junction block ...

Page 525: ...7 AC302485 AB Timing belt front upper cover Throttle body 4G1 4G6 Name Symbol Name Symbol A T control solenoid valve assembly D Emission solenoid valve Purge control system 4G6 B Emission solenoid valve EGR system B Hydraulic unit incorporating solenoid valve A Emission solenoid valve Purge control system 4G1 C ...

Page 526: ...e manifold AC208527 A AD RHD Hydraulic unit incorporating solenoid valve Air cleaner cover AC206782 4G1 B AC Ignition coil 1 Emission solenoid valve EGR system AC302484 B AB 4G6 Emission solenoid valve EGR system Emission solenoid valve Purge control system AC208529 AD C 4G1 Idle speed control servo Emission solenoid valve Purge control system ...

Page 527: ...PONENT LOCATIONS 70 13 DIODE M1701000900223 AC208684 D AD A T control solenoid valve assembly connector Inhibitor switch A T control solenoid valve assembly Transmission assembly AC300441 AC301240 Diode WAGON AD ...

Page 528: ...ARTH M1701000300362 NOTE Same earth numbers are used in the circuit diagram AC301751 AC301175 AC301176 SEDAN L H drive vehicles 3 2 1 4 5 6 7 9 10 11 12 13 14 15 16 17 SEDAN R H drive vehicles 2 1 4 5 6 7 9 10 11 12 13 14 15 16 17 3 AB ...

Page 529: ... 70 15 NOTE Same earth numbers are used in the circuit diagram AC301756 AC301177 AC301178 WAGON L H drive vehicles 3 2 1 4 5 6 7 9 10 11 12 13 14 15 16 17 WAGON R H drive vehicles AB 8 2 1 4 5 6 7 9 10 11 12 13 14 15 16 17 8 3 ...

Page 530: ...300427 1 AD AC301737AB 2 3 2 3 LHD AC300429AB 2 RHD Junction block AC206768 AD 3 16 3 16 RHD AC301742AB 4 Glove box AC301741AB 5 Diagnosis connector AC100195 6 AC Windshield wiper arm LHD AC212109 AC 6 Steering column shaft assembly RHD ...

Page 531: ...AC SEDAN Rear seatback hook RH AC212111 7 AC WAGON Rear speaker RH AC212112 AC 8 Rear wiper motor AC301744 AB 9 Heat protector AC301743AB 10 Rocker cover AC300437 11 12 11 12 AD Relay box AC301745 13 AB Air cleaner assembly AC301750AB 14 SRS ECU ...

Page 532: ...C Junction block 16 LHD AC301210 17 AC SEDAN Rear seatback hook LH AC300440 17 AC Rear speaker LH WAGON Name Symbol Name Symbol Diagnosis connector E Spare connector for front fog lamp relay A Engine speed detection connector A Spare connector for front fog lamp switch C Spare connector for front fog lamp B Spare connector for audio D AC301758AC B A D C E ...

Page 533: ...AC Spare connector for front fog lamp relay Engine speed detection connector Front ECU AC301740 AB B Spare connector for front fog lamp Heat protector AC301736AB Spare connector for front fog lamp switch C AC301735 AB D Spare connector for audio AC100188 AH Diagnosis connector E ...

Page 534: ...NOTES ...

Page 535: ...inadvertent firing of the air bag or to the driver from rendering the SRS inoperative Service or maintenance of any SRS component or SRS related component must be performed only at an authorized MITSUBISHI dealer M ITSUBISHI 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...

Page 536: ...LY AND EVAPORATOR UNIT 55 81 REMOVAL AND INSTALLATION 55 81 HEATER UNIT 55 82 DISASSEMBLY AND REASSEMBLY L H D 55 82 DISASSEMBLY AND ASSEMBLY R H D 55 83 BLOWER ASSEMBLY 55 84 DISASSEMBLY AND REASSEMBLY 55 84 BLOWERMOTOR RESISTOR AND OUTSIDE INSIDE AIR SELECTION DAMPER CONTROL MOTOR 55 85 REMOVAL AND INSTALLATION 55 85 INSPECTION 55 86 EVAPORATOR ASSEMBLY 55 88 REMOVAL AND INSTALLATION L H D 55 88...

Page 537: ...ue Idle speed r min 750 100 Idle up speed r min 850 100 Resistor for blower motor Ω LO 2 54 ML 1 24 MH 0 6 Air gap magnetic clutch mm 0 3 0 5 Item Specified lubricant Quantity Compressor refrigerant unit lubricant SUN PAG 56 1300 1600 140 mL 2000 120 mL Each connection of refrigerant line SUN PAG 56 As required Refrigerant R134a HFC 134a 480 520 g ...

Page 538: ...lation MB991386 Pin MB991223 A MB991219 B MB991220 C MB991221 D MB991222 Harness set A Test harness B LED harness C LED harness adapter D Probe Continuity check and voltage measurement at harness wire or connector A For checking connector pin contact pressure B For checking power supply circuit C For checking power supply circuit D For connecting a locally sourced tester B991367 MB991223 A B C D A...

Page 539: ...senger compartment does not decrease cool air is not emitted L H D P 55 11 YES R H D Refer to Inspection procedure 4 When the A C is operating temperature inside the passenger compartment does not decrease cool air is not emitted R H D P 55 20 NO Refer to Inspection procedure 5 Blower fan and motor do not turn P 55 29 Symptom Inspection Procedure Reference Page When the ignition switch is ON the A...

Page 540: ...efective TROUBLESHOOTING HINTS Malfunction of the inside outside air selection damper motor Damaged the wiring harness or connectors Malfunction of the manual air conditioner control panel A C ECU IGNITION SWITCH IG2 OUTSIDE INSIDE AIR SELECTION DAMPER CONTROL MOTOR A C ECU HEATER CONTROL PANEL Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR...

Page 541: ...tor Q Is the check result normal YES Go to Step 3 NO Repair the connector STEP 3 Voltage measurement at the C 107 outside inside air selection damper control motor connector 1 Disconnect the connector and measure at the wiring harness side 2 Turn the ignition switch to the ON position 3 Measure the voltage between terminal 7 and body earth OK System voltage Q Is the check result normal YES Go to S...

Page 542: ... H D AD Harness side AC303816 Connector C 107 AI R H D Harness side AC303798 Connector C 35 L H D AJ 2 1 3 13 12 14 21 10 5 4 6 16 15 17 7 8 9 19 18 20 11 22 C 35 L AC303814 Connector C 35 R H D AI C 35 L AC303804 Connector C 106 L H D AC C 106 AC303816 Connector C 106 AH R H D AC303809 Connectors C 209 C 210 AF C 209 C 210 Junction block front view L H D C 209 Harness side 10 1 6 14 5 12 13 4 11 ...

Page 543: ... an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness STEP 5 Connector check C 139 A C ECU connector Q Is the check result normal YES L H D Go to Step 6 YES R H D Go to Step 7 NO Repair the connector AC303823 Connectors C 209 C 210 AE C 210 Junction block front view R H D C 209 C 209 Harness side 10 1 6 14 5 12 13 4 11 7 2 3 8 ...

Page 544: ...inals 10 and 11 NOTE Prior to the wiring harness inspection check intermediate connector C 106 and repair if necessary Check the outside inside air selection damper control motor earth line for open or short circuit Q Is the check result normal YES Go to Step 8 NO Repair the wiring harness STEP 8 Check the outside inside air selection damper control motor Refer to P 55 86 Q Does outside inside air...

Page 545: ...senger Compartment does not Decrease Cool Air is not Emitted L H D ENGINE ECU A C ECU DUAL PRESSURE SWITCH RESISTOR ENGINE A T ECU HEATER CONTROL PANEL Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet AIR THERMO SENSOR NOTE M T A T A C ECU System Circuit ...

Page 546: ... defogger and outside inside air selection damper control motor work normally YES Go to Step 2 NO Refer to Inspection procedure 9 Malfunction of the A C ECU power supply system L H D P 55 53 STEP 2 Check the blower motor operation Q Does the blower motor work normally YES Go to Step 3 NO Refer to Inspection procedure 5 Blower fan and motor do not turn P 55 29 STEP 3 Check the A C compressor Check ...

Page 547: ...earth terminal 20 A T 5 Measure the voltage between terminal 1 and body earth OK System voltage Q Is the check result normal YES Go to Step 6 NO Refer to Inspection procedure 11 A C compressor power supply system P 55 59 AC303782 Connector B 114 4G1 L H D AC Harness side B 114 B AC303790 Connector B 114 4G6 L H D AC Harness side B 114 B AC303805 Connectors C 122 A T C 123 M T L H D C 122 GR C 123 ...

Page 548: ...ctor check C 109 resistor connector Q Is the check result normal YES Go to Step 9 NO Repair the connector STEP 9 Check the wiring harness between C 109 resistor connector terminal No 4 and C 139 A C ECU connector terminal No 8 Q Is the check result normal YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harne...

Page 549: ...C 106 air thermo sensor connector Q Is the check result normal YES Go to Step 13 NO Repair the connector STEP 13 Check the wiring harness between C 106 air thermo sensor connector terminals 4 and 5 and C 139 A C ECU connector terminals 16 and 13 Check the air thermo sensor output and earth line for open or short circuit Q Is the check result normal YES Go to Step 14 NO Repair the wiring harness AC...

Page 550: ...ep 15 NO Repair the wiring harness STEP 15 Connector check C 125 engine ECU connector M T or C 126 engine A T ECU connector A T Q Is the check result normal YES Go to Step 16 NO Repair the connector AC303839 Connector A 31 L H D AH Harness side A 31 BR AC303802 Connector C 139 L H D AE C 139 B Harness side AC303804 Connector C 114 LHD AN 18 3 16 15 14 1 2 17 4 5 8 20 19 6 7 2122 9 10 25 13 24 23 1...

Page 551: ...connector C 114 and C 15 and repair if necessary Check the communication line for open or short circuit Q Is the check result normal YES Go to Step 17 NO Repair the wiring harness AC303839 Connector A 31 L H D AH Harness side A 31 BR AC303805 Connectors C 125 M T C 126 A T AG L H D C 126 GR C 125 Harness side C 125 Y C 126 38 4645444342414039 37363534333231 77 76 75 74737271 78 79 80 81 82 83 84 8...

Page 552: ...nectors terminal No 24 M T or C 124 engine A T ECU connectors terminal No 61 A T and C 139 A C ECU connector terminal No 5 AC303805 Connectors C 123 M T C 124 A T L H D C 124 Harness side C 123 AF C 124 GR C 123 Y 464544 43 42 41 575655545352 515049 48 47 666564 63626160 59 58 AC303805 Connectors C 123 M T C 124 A T L H D C 124 Harness side C 123 AF C 124 GR C 123 Y 464544 43 42 41 575655545352 51...

Page 553: ...nt temperature switch Refer to P 55 95 Q Is the refrigerant temperature switch operating properly YES Go to Step 21 NO Replace the refrigerant temperature switch STEP 21 Check the air thermo sensor Refer to P 55 90 Q Is the air thermo sensor in good condition YES Go to Step 22 NO Replace the air thermo sensor STEP 22 Check the refrigerant level Refer to P 55 69 Q Is the refrigerant level correct Y...

Page 554: ...senger Compartment does not Decrease Cool Air is not Emitted R H D ENGINE ECU A C ECU DUAL PRESSURE SWITCH RESISTOR ENGINE A T ECU HEATER CONTROL PANEL Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet AIR THERMO SENSOR NOTE M T A T A C ECU System Circuit ...

Page 555: ...defogger and outside inside air selection damper control motor work normally YES Go to Step 2 NO Refer to Inspection procedure 10 Malfunction of the A C ECU power supply system R H D P 55 56 STEP 2 Check the blower motor operation Q Does the blower motor work normally YES Go to Step 3 NO Refer to Inspection procedure 5 Blower fan and motor do not turn P 55 29 STEP 3 Check the A C compressor Check ...

Page 556: ...earth terminal 20 A T 5 Measure the voltage between terminal 1 and body earth OK System voltage Q Is the check result normal YES Go to Step 6 NO Refer to Inspection procedure 11 A C compressor power supply system P 55 59 AC303786 Connector B 114 4G1 R H D AB Harness side B 114 B AC303794 Connector B 114 4G6 R H D AB Harness side B 114 B AC303817 Connectors C 122 A T C 123 M T AF R H D C 122 C 122 ...

Page 557: ... Q Is the check result normal YES Go to Step 9 NO Repair the connector STEP 9 Check the wiring harness between C 109 resistor connector terminal No 4 and C 139 A C ECU connector terminal No 8 Q Is the check result normal YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness AC303818 Connector C 139 R H D A...

Page 558: ...air thermo sensor connector Q Is the check result normal YES Go to Step 13 NO Repair the connector STEP 13 Check the wiring harness between C 106 air thermo sensor connector terminals 4 and 5 and C 139 A C ECU connector terminals 4 and 6 Check the air thermo sensor output and earth line for open or short circuit Q Is the check result normal YES Go to Step 14 NO Repair the wiring harness AC303825 C...

Page 559: ...normal YES Go to Step 15 NO Repair the wiring harness STEP 15 Connector check C 125 engine ECU connector M T or C 126 engine A T ECU connector A T Q Is the check result normal YES Go to Step 16 NO Repair the connector AC303825 Connector A 31 R H D AH A 31 BR Harness side AC303818 Connector C 139 R H D AJ Harness side C 139 B 11 12 6 5 7 8 9 10 3 4 2 1 AC303814 Connector C 28 RHD AJ AC303817 Connec...

Page 560: ...diate connector C 28 and C 135 and repair if necessary Check the communication line for open or short circuit Q Is the check result normal YES Go to Step 17 NO Repair the wiring harness AC303825 Connector A 31 R H D AH A 31 BR Harness side AC303817 Connectors C 125 M T C 126 A T AH R H D C 126 GR C 125 Harness side C 125 Y C 126 38 4645444342414039 37363534333231 77 76 75 74737271 78 79 80 81 82 8...

Page 561: ...T and C 139 A C ECU connector terminal No 2 Check the communication line for open or short circuit Q Is the check result normal YES Go to Step 19 NO Repair the wiring harness AC303817 Connectors C 123 M T C 124 A T AG R H D C 123 Y C 123 Harness side C 124 GR 464544 43 42 41 575655545352 515049 48 47 666564 63626160 59 58 C 124 AC303817 Connectors C 123 M T C 124 A T AG R H D C 123 Y C 123 Harness...

Page 562: ...o Step 21 NO Replace the refrigerant temperature switch STEP 21 Check the air thermo sensor Refer to P 55 90 Q Is the air thermo sensor in good condition YES Go to Step 22 NO Replace the air thermo sensor STEP 22 Check the refrigerant level Refer to P 55 69 Q Is the refrigerant level correct YES Go to Step 23 NO Correct the refrigerant level Refer to On vehicle Service P 55 70 STEP 23 Replace the ...

Page 563: ... Blower Fan and Motor do not Turn FUSIBLE LINK 1 IGNITION SWITCH IG2 BLOWER RELAY BLOWER SWITCH BLOWER MOTOR Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet RHD LHD RHD LHD RHD LHD Blower Motor Circuit ...

Page 564: ...r operate when the blower switch is moved to the 4 HI position YES Refer to Inspection procedure 6 Blower air amount cannot be changed P 55 39 NO Go to Step 2 STEP 2 Connector check C 110 blower motor connector Q Is the check result normal YES Go to Step 3 NO Repair the connector STEP 3 Resistance measurement at the C 110 blower motor connector 1 Disconnect the connector and measure at the wiring ...

Page 565: ... STEP 5 Voltage measurement at C 110 blower motor connector 1 Disconnect the connector and measure at the wiring harness side 2 Turn the ignition switch to the ON position 3 Turn the blower switch to the 4 HI position 4 Measure the voltage between terminal 1 and body earth OK System voltage Q Is the check result normal YES Go to Step 20 NO Go to Step 6 AC303804 Connector C 110 L H D AF Harness sid...

Page 566: ...e the relay and measure at the junction block side 2 Turn the ignition switch to the ON position 3 Measure the voltage between terminal 3 and earth OK System voltage Q Is the check result normal YES Go to Step 10 NO Go to Step 9 AC303808 Junction block side Junction block front view Connector C 214 AL L H D AC303822 Junction block side Junction block front view Connector C 214 AM R H D AC303808 Ju...

Page 567: ...ent at C 214 blower relay connector 1 Remove the relay and measure at the junction block side 2 Measure the resistance Continuity between terminal 1 and body earth OK 2 ohms or less Q Is the check result normal YES Go to Step 13 NO L H D Go to Step 11 NO R H D Go to Step 12 AC303809 Connectors C 210 C 214 AL C 214 C 210 Junction block front view L H D C 210 Harness side Junction block side C 214 A...

Page 568: ...ng harness between C 214 blower relay connector terminal No 1 and earth NOTE Prior to the wiring harness inspection check junction block connectors C 212 and joint connectors C 07 and repair if necessary Check the blower relay earth wires for open circuit Q Is the check result normal YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00...

Page 569: ...ck intermediate connectors C 21 and junction block connector C 211 and repair if necessary Check the blower relay power supply line for open circuit Q Is the check result normal YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness AC303808 Junction block side Junction block front view Connector C 214 AL L...

Page 570: ...o GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness STEP 16 Connector check C 140 blower switch connector Q Is the check result normal YES Go to Step 17 NO Repair the connector STEP 17 Check the blower switch continuity Refer to P 55 79 Q Is the blower switch continuity in good condition YES Go to Step 18 NO Replace the blower switch AC303823 Connectors C 211 C...

Page 571: ...ir if necessary Check the blower relay output line for open circuit Q Is the check result normal YES Go to Step 19 NO Repair the wiring harness AC303802 Connector C 140 L H D AF Harness side AC303818 Connector C 140 R H D AK Harness side AC303809 Connectors C 210 C 214 AL C 214 C 210 Junction block front view L H D C 210 Harness side Junction block side C 214 AC303823 Junction block side Junction ...

Page 572: ...ion Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness STEP 20 Check the blower fan and motor operation Refer to P 55 86 Q Is the check result normal YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Replace the blower motor AC303804 Connector C 110 L H D AF Harness side AC303816 Con...

Page 573: ...SIS STEP 1 Check that the blower motor operates when the blower switch is moved to the 4 HI position 1 Turn the ignition switch to the ON position 2 Turn the blower switch to the 4 HI position Q Does the blower motor operate when the blower switch is moved to the 4 HI position YES Go to STEP 2 NO Refer to Inspection procedure 5 Blower fan and motor do not turn P 55 29 BLOWER RELAY BLOWER SWITCH RE...

Page 574: ...h STEP 4 Check the resistor resistance value Refer to P 55 86 Q Is the measured value at the standard value YES Go to Step 5 NO Replace the resistor STEP 5 Check the wiring harness between C 140 blower switch connector terminals 1 4 and 5 and C 109 resistor connector terminals 4 1 and 3 AC303804 Connector C 109 L H D AE Harness side AC303816 Connector C 109 AJ R H D Harness side AC303802 Connector...

Page 575: ...blower motor connector terminal 1 and C 109 resistor connector terminal 2 Check the blower motor power supply line for open circuit Q Is the check result normal YES No action to be taken NO Repair the wiring harness AC303802 Connector C 140 L H D AF Harness side AC303818 Connector C 140 R H D AK Harness side AC303804 Connector C 110 L H D AF Harness side AC303816 Connector C 110 AK R H D Harness s...

Page 576: ...FUSIBLE LINK REAR WINDOW DEFOGGER RELAY A C ECU OR HEATER CONTROL UNIT 1 SEDAN LHD WAGON LHD SEDAN RHD WAGON RHD Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet RHD LHD RHD LHD RHD LHD RHD LHD NOTE REAR WINDOW DEFOGGER REAR WINDOW DEFOGGER Rear Window Defogger Circuit ...

Page 577: ...A C and outside inside air selection damper control motor operation Q Do the A C and outside inside air selection damper control motor work normally YES Go to Step 2 NO L H D Refer to Inspection procedure 9 Malfunction of the A C ECU Power Supply system L H D P 55 53 NO R H D Refer to Inspection procedure 10 Malfunction of the A C ECU Power Supply system R H D P 55 56 STEP 2 Connector check F 22 r...

Page 578: ...position 4 Measure the voltage between terminal 1 and body earth OK System voltage Q Is the check result normal YES Go to Step 14 NO Go to Step 4 AC303954 Connector F 22 WAGON L H D AI Harness side AC303943 Connector F 22 SEDAN L H D Harness side AD AC303956 Connector F 22 Harness side AH WAGON R H D AC303945 Harness side AE Connector F 22 SEDAN R H D AC400965AJ Connector F 22 Harness side 1 SEDAN...

Page 579: ...ar window defogger relay connector 1 Remove the relay and measure at the junction block side 2 Measure the voltage between terminal 5 and body earth OK System voltage Q Is the check result normal YES Go to Step 9 NO L H D Go to Step 7 NO R H D Go to Step 8 AC303808 Junction block side Junction block front view Connector C 213 AK L H D AC303822 Junction block side Junction block front view Connecto...

Page 580: ... YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness STEP 8 Check the wiring harness between C 213 rear window defogger relay connector terminal No 5 and the fusible link 1 NOTE AC303809 Connectors C 211 C 213 AM C 213 C 211 Junction block front view L H D C 211 Harness side Junction block side C 213 AC3...

Page 581: ...lock side 2 Turn the ignition switch to the ON position 3 Measure the voltage between terminal 3 and earth OK System voltage Q Is the check result normal YES Go to Step 11 NO Go to Step 10 STEP 10 Check the wiring harness between C 213 rear window defogger relay connector terminal No 3 and ignition switch IG2 AC303808 Junction block side Junction block front view Connector C 213 AK L H D AC303822 ...

Page 582: ...harness STEP 11 Check the wiring harness between C 213 rear window defogger relay connector terminal No 4 and F 22 rear window defogger connector terminal No 1 AC303809 Connectors C 213 C 215 AR C 213 Junction block front view L H D C 215 C 215 Harness side 7 15 5 6 1413 2 9 12 4 3 10 11 1 8 Junction block side C 213 AC303823 Connectors C 213 C 216 AS C 213 Junction block front view R H D C 216 C ...

Page 583: ...r open circuit Q Is the check result normal YES Go to Step 12 NO Repair the wiring harness STEP 12 Connector check C 139 A C ECU connector or heater control unit connector Q Is the check result normal YES Go to Step 13 NO Repair the connector AC303956 Connector F 22 Harness side AH WAGON R H D AC303945 Harness side AE Connector F 22 SEDAN R H D AC303802 Connector C 139 L H D AE C 139 B Harness sid...

Page 584: ... necessary Check the rear window defogger relay earth line for open or short circuit Q Is the check result normal YES Replace the manual air conditioner control panel A C ECU or the heater control unit NO Repair the wiring harness AC303802 Connector C 139 L H D AE C 139 B Harness side AC303818 Connector C 139 R H D AJ Harness side C 139 B 11 12 6 5 7 8 9 10 3 4 2 1 AC303809 Junction block front vi...

Page 585: ...ring harness side 2 Measure the resistance value between terminal 1 and earth OK 2 ohms or less Q Is the check result normal YES Go to Step 17 NO Go to Step 16 AC303954 Connector F 06 WAGON L H D AH Harness side AC303943 Connector F 06 Harness side AE SEDAN L H D AC303956 Harness side AG Connector F 06 WAGON R H D AC303945 Harness side AF Connector F 06 SEDAN R H D AC303943 Connector F 06 Harness ...

Page 586: ...N PROCEDURE 8 Rear Window Defogger Timer Function does not Operate COMMENTS ON TROUBLE SYMPTOM Turn ON the rear window defogger switch If the rear window defogger does not shut off after roughly 11 minutes then the rear window defogger timer is malfunctioning TROUBLESHOOTING HINTS Malfunction of the manual air conditioner control panel A C ECU or the heater control unit DIAGNOSIS Check the perform...

Page 587: ...ioner defogger and outside inside air selection damper motor all do not operate normally TROUBLESHOOTING HINTS Damaged the wiring harness or connectors Malfunction of the manual air conditioner control panel A C ECU IGNITION SWITCH IG2 A C ECU Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet HEATER CONTROL PANEL A C...

Page 588: ... connector terminal No 10 and the ignition switch IG2 NOTE Prior to the wiring harness inspection check junction block connectors C 210 and C 212 and repair if necessary Check the A C ECU power supply line for open circuit Q Is the check result normal YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness A...

Page 589: ...TEP 5 Check the wiring harness between C 139 A C ECU connector terminal No 12 and the earth NOTE Prior to the wiring harness inspection check joint connector C 104 and repair if necessary Check the A C ECU earth line for open circuit Q Is the check result normal YES Replace the manual air conditioner control panel A C ECU NO Repair the wiring harness AC303802 Connector C 139 L H D AE C 139 B Harne...

Page 590: ...tioner defogger and outside inside air selection damper motor all do not operate normally TROUBLESHOOTING HINTS Damaged the wiring harness or connectors Malfunction of the manual air conditioner control panel A C ECU IGNITION SWITCH IG2 HEATER CONTROL PANEL A C ECU Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet A ...

Page 591: ...en C 139 A C ECU connector terminal No 7 and the ignition switch IG2 NOTE Prior to the wiring harness inspection check junction block connectors C 210 C 212 and joint connector C 35 and repair if necessary Check the A C ECU power supply line for open circuit AC303818 Connector C 139 R H D AJ Harness side C 139 B 11 12 6 5 7 8 9 10 3 4 2 1 AC303818 Connector C 139 R H D AJ Harness side C 139 B 11 1...

Page 592: ... earth OK 2 ohms or less Q Is the check result normal YES Replace the manual air conditioner control panel A C ECU NO Go to Step 5 STEP 5 Check the wiring harness between C 139 A C ECU connector terminal No 3 and the earth Check the A C ECU earth line for open circuit Q Is the check result normal YES Replace the manual air conditioner control panel A C ECU NO Repair the wiring harness AC303818 Con...

Page 593: ...m A C COMPRESSOR RELAY A C COMPRESSOR A C REFRIGERANT TEMPERATURE SWITCH MAGNETIC CLUTCH IGNITION SWITCH IG2 ENGINE ECU BATTERY RELAY BOX ENGINE A T ECU Wire colour code B Black LG Light green G Green L Blue W White Y Yellow SB Sky blue BR Brown O Orange GR Gray R Red P Pink V Violet M T A T NOTE A C Compressor Circuit ...

Page 594: ... relay continuity Refer to P 55 75 Q Is the A C compressor relay in good condition YES Go to Step 3 NO Replace the A C compressor relay STEP 3 Voltage measurement at B 17X A C compressor relay connector 1 Remove the relay and measure at the relay box side 2 Turn the ignition switch to the ON position 3 Measure the voltage between terminal 2 and body earth OK System voltage Q Is the check result no...

Page 595: ... power supply line for open circuit Q Is the check result normal YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness AC304988AB Connector B 17X Front of vehicle 1 3 2 4 Relay box side AC303800 Connector C 15 L H D AE C 15 L AC303798 Connector C 35 L H D AJ 2 1 3 13 12 14 21 10 5 4 6 16 15 17 7 8 9 19 18 ...

Page 596: ...heck the A C compressor relay power supply line for open circuit Q Is the check result normal YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness AC304988AB Connector B 17X Front of vehicle 1 3 2 4 Relay box side AC303814 Connector C 35 R H D AI C 35 L AC303818 Connector C 135 RHD AH C 135 L AC303823 Con...

Page 597: ...e wiring harness inspection check intermediate connector A 13 L H D or C 111 R H D and repair if necessary Check the A C compressor relay power supply line for open circuit Q Is the check result normal YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness AC304988AB Connector B 17X Front of vehicle 1 3 2 4...

Page 598: ...o 4 and B 114 A C compressor connector terminal No 1 AC303782 Connector B 114 4G1 L H D AC Harness side B 114 B AC303790 Connector B 114 4G6 L H D AC Harness side B 114 B AC303786 Connector B 114 4G1 R H D AB Harness side B 114 B AC303794 Connector B 114 4G6 R H D AB Harness side B 114 B AC304988AB Connector B 17X Front of vehicle 1 3 2 4 Relay box side AC303782 Connector B 114 4G1 L H D AC Harnes...

Page 599: ...ector M T or C 122 engine A T ECU connector A T Q Is the check result normal YES M T Go to Step 11 YES A T Go to Step 12 NO Repair the connector AC303786 Connector B 114 4G1 R H D AB Harness side B 114 B AC303794 Connector B 114 4G6 R H D AB Harness side B 114 B AC303805 Connectors C 122 A T C 123 M T L H D C 122 GR C 123 Y C 122 Harness side C 123 AE AC303817 Connectors C 122 A T C 123 M T AF R H...

Page 600: ... ECU connector terminal No 20 and B 17X A C compressor relay connector terminal No 3 Check the A C compressor relay earth line for open or short circuit Q Is the check result normal YES The trouble can be an intermittent malfunction Refer to GROUP 00 How to Cope with Intermittent Malfunction P 00 5 NO Repair the wiring harness AC304988AB Connector B 17X Front of vehicle 1 3 2 4 Relay box side AC30...

Page 601: ... When the damper is moved to the inside air recirculation position System voltage When the damper is moved to the outside air inside air intake position 0 V 4 Output to the engine A T ECU A C1 A C stopped 0 V A C switch ON Blower switch ON System voltage 5 Output to the engine A T ECU A C2 When the A C is under low load System voltage When the A C is under high load 0 V 6 Power supply to the A C i...

Page 602: ...tage 6 Air thermo sensor outlet side Sensor probe temperature 25 C 1 5k ohm 2 2 V 7 Power supply to the ignition switch IG2 Ignition switch ON System voltage 8 Blower switch lo blower switch lo System voltage 9 Rear defogger switch Defogger switch ON 0 V Defogger switch OFF System voltage 10 Inside outside air selection damper motor outside air When the damper is moved to the inside air recirculat...

Page 603: ... DRIVE BELT ADJUSTMENT M1552001000335 1300 1600 Refer to GROUP 11A On vehicle Service Drive Belt Tension Check P 11A 7 2000 Refer to GROUP 11C On vehicle Service Drive Belt Tension Check P 11C 7 DUAL PRESSURE SWITCH CHECK M1552010400320 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 g...

Page 604: ...ower plug of the adapter to a 100 V outlet 6 Install the vacuum pump adaptor to the vacuum pump 7 Connect the charging hose yellow to the R 134a connection port of the vacuum pump adaptor 8 Tighten the adaptor valve handle valve open 9 Open the low pressure valve of the gauge manifold 10 Turn the power switch of the vacuum pump to the ON position NOTE Even if the vacuum pump power switch is turned...

Page 605: ...s state 18 Turn the handle of the charging valve back valve open and tighten the handle of the adaptor valve valve open to charge the system with refrigerant 19 If the refrigerant is not drawn in turn the handle of the adaptor valve back all the way valve closed 20 Check for gas leaks using a leak detector If a gas leak is detected re tighten the connections and then repeat the charging procedure ...

Page 606: ... open and replenish refrigerant while checking the quantity through the sight glass 12 After replenishing is completed turn the handle of the adaptor valve all the way back valve close and remove the quick joint NOTE When there is remainder of refrigerant in the service can keep it for next use with the charge value and the valve of the adaptor valve being closed DISCHARGING SYSTEM M1552013000105 ...

Page 607: ...ct the quick joint for high pressure to the high pressure service valve 6 Start the engine 7 Set the A C controls as follows A C switch A C ON position Mode selection FACE position Temperature control MAXIMUM COOLING position Air selection RECIRCULATION position Blower switch 4 Fast position 8 Keep engine speed to idling speed with A C clutch engaged 9 Engine should be warmed up with doors and all...

Page 608: ...le hose lines is keep the radius of all bends at least 10 times the diameter of the hose Sharper bends will reduce the flow of refrigerant The flexible hose lines should be routed so that they are at least 80 mm from the exhaust manifold It is good practice to inspect all flexible hose lines at least once a year to make sure they are in good condition and properly routed On standard plumbing fitti...

Page 609: ...uit Connect terminal 3 to the positive battery terminal Connect terminal 1 to the negative battery terminal 4 5 Less than 2 ohms AC305308 4 5 1 2 3 5 1 4 3 Blower relay AB Battery voltage Tester connection Specified condition Not applied 1 4 Open circuit Connect terminal 2 to the positive battery terminal Connect terminal 3 to the negative battery terminal 1 4 Less than 2 ohms AC305307 A C compres...

Page 610: ...ng the A C switch to ON and the blower switch to the 3 MH or 4 HI position check to be sure that the idle speed is at the standard value Standard value 850 50 r min NOTE It is not necessary to make an adjustment because the idling speed is automatically adjusted by the ISC system If however a deviation from the standard value occurs for some reason check the ISC system CLEAN AIR FILTER REPLACEMENT...

Page 611: ...R CONTROL ASSEMBLY AND A C SWITCH REMOVAL AND INSTALLATION M1552002400347 AC304650 1 2 3 4 5 AB Removal steps B 1 Air mixing door control cable connection A 2 Mode selection damper cable connection 3 Knob 4 Centre panel 5 Manual air conditioner control panel assembly Removal steps Continued ...

Page 612: ... DOOR CABLE CONNECTION 1 Turn the heater control assemblyís temperature adjustment knob all the way to the HOT side 2 Set the heater unitís air mix door lever to the MAX HOT position turn the damper lever as the left illustration and attach the cable 3 Set the mode locator to the heater unit case and secure with a clip AC304856 DEF position FACE position AB Mode selection damper link Mode locator ...

Page 613: ...FF 1 2 2 4 2 5 2 6 Open circuit 1 LO 1 2 Less than 2 ohms 2 ML 2 4 Less than 2 ohms 3 MH 2 5 Less than 2 ohms 4 HI 2 6 Less than 2 ohms AC100614 1 2 3 4 5 6 7 8 AB Disassembly steps 1 Switch panel 2 Rear window defogger switch 3 Air conditioner switch 4 Inside outside air selection switch A 5 Mode selection damper control cable A 6 Air mixing damper control cable 7 Blower switch assembly 8 Manual ...

Page 614: ... 80 DISASSEMBLY SERVICE POINT A BLOW VENT CHANGEOVER DAMPER CABLE AND AIR MIX DAMPER CABLE REMOVAL Insert a flat tipped screwdriver into the clip through the inside of the control base and prize out the clip claw to disconnect the cables AC100619AB Clip claw flat tipped screwdriver ...

Page 615: ...al and Installation Refer to GROUP 15 Air cleaner P 15 3 Rear console assembly Removal and Installation Refer to GROUP 52A Rear console assembly P 52A 8 Front floor console assembly Removal and Installation Refer to GROUP 52A Front floor console assembly P 52A 6 Front seat assembly Removal and Installation Refer to GROUP 52A Front seat assembly P 52A 24 AC304861 1 2 3 4 5 6 7 8 N 9 AB 12 2 N m 6 7...

Page 616: ... the hose and nipples To prevent the entry of dust or other foreign bodies plug the dismantled hose and the nipples of the expansion valves HEATER UNIT DISASSEMBLY AND REASSEMBLY L H D M1551005400224 AC304862 1 2 3 4 5 6 7 8 9 10 AB 4 7 O ring Pipe coupling A C compressor oil SUN PAG 56 N Disassembly steps 1 Foot duct LH 2 Heater core 3 Expansion valve 4 Joint 5 O ring 6 Evaporator cover 7 Evapora...

Page 617: ...BLY AND ASSEMBLY R H D M1551005400235 AC304863 1 2 3 4 5 N 6 7 8 9 AB 6 O ring Pipe coupling A C compressor oil SUN PAG 56 Disassembly steps 1 Foot duct RH 2 Heater core 3 Expansion valve 4 O ring 5 Evaporator cover 6 Evaporator 7 Air thermo sensor clip 8 Air thermo sensor 9 Heater case Disassembly steps Continued ...

Page 618: ...NER AND VENTILATION 55 84 BLOWER ASSEMBLY DISASSEMBLY AND REASSEMBLY M1551005500179 AC3054131AB 3 4 5 7 6 1 2 Disassembly steps 1 Joint duct 2 Resister 3 Outside inside air selection damper control motor 4 Hose 5 Blower motor 6 Air filter 7 Blower case Disassembly steps Continued ...

Page 619: ...enger s side under cover A 1 Blower motor Resistor removal step Glove box Refer to GROUP 52A Instrument Panel P 52A 2 Engine ECU M T or Engine A T ECU A T Refer to GROUP 13A Engine ECU and Engine A T ECU P 13A 401 2 Resistor Outside inside air selection damper control motor removal step Glove box Refer to GROUP 52A Instrument Panel P 52A 2 Engine ECU M T or Engine A T ECU A T Refer to GROUP 13A En...

Page 620: ... CHECK Use an ohmmeter to measure the resistance between the terminals Check that the measured value is at the standard value Standard value BLOWER FAN AND MOTOR CHECK When battery voltage is applied between the terminals check that the motor operates Also check that there is no abnormal noise AC304916 1 2 3 4 AC304843 Measurement terminal Standard value Ω Between terminals 2 and 4 LO 2 54 Between...

Page 621: ...ever position Battery connection Lever operation At the inside position Connect terminal 7 to the positive battery terminal Connect terminal 4 to the negative battery terminal The lever moves from the inside position to the outside position At the outside position Connect terminal 7 to the positive battery terminal Connect terminal 6 to the negative battery terminal The lever moves from the outsid...

Page 622: ...Charging P 55 70 and Discharging P 55 72 Air cleaner assembly 1300 1600 or Air cleaner and air cleaner air flow sensor assembly 2000 Removal and Installation Refer to GROUP 15 Air cleaner P 15 3 Y2346AU 1 2 4 7 A C compressor oil SUN PAG 56 O ring Pipe coupling 2 10 1 3 4 7 6 5 9 8 8 12 2 N m Removal steps A 1 Flexible suction hose connection A 2 Liquid pipe B connection 3 Expansion valve 4 Joint ...

Page 623: ... Refer to GROUP 15 Air cleaner P 15 3 AC304886AB 12 2 N m 7 7 2 1 9 8 6 5 4 3 1 2 6 A C compressor oil SUN PAG 56 O ring Pipe coupling Removal steps A 1 Flexible suction hose connection A 2 Liquid pipe B connection 3 Expansion valve Glove box Refer to GROUP 52A Instrument Panel P 52A 2 Engine ECU M T or Engine A T ECU A T Refer to GROUP 13A Engine ECU and Engine A T ECU P 13A 401 4 Joint duct Foot...

Page 624: ...o not cut the upper side of the pad 1 When removing the evaporator cut and fold back the dashboard pad as in the diagram The thickness of the pad interferes with the removal of the evaporator 2 Remove the evaporator INSPECTION M1552014300938 AIR THERMO SENSOR INSPECTION Measure the resistance between connector terminals 4 and 5 under at least two different temperatures The resistance values should...

Page 625: ... 11A On vehicles Service Drive Belt Tension Check P 11A 7 2000 Refer to GROUP 11C On vehicles Service Drive Belt Tension Check P 11C 7 Refrigerant Charging Refer to P 55 70 AC304850 1 2 A C compressor oil SUN PAG 56 Pipe coupling O ring 12 2 N m N 1 2 3 5 AB 7 5 4 7 1300 1600 1300 1600 2000 2000 Removal steps A 1 Flexible suction hose connection A 2 Flexible discharge hose connection 3 O ring B 4 ...

Page 626: ...rive belt C DRIVE BELT REMOVAL 2000 The following operations will be needed due to the serpentine drive system with the alternator drive belt auto tensioner 1 Securely insert the spindle handle or ratchet handle with a 12 7 mm insertion angle into the jig hole of the alternator drive belt auto tensioner and turn the alternator drive belt auto tensioner anti clockwise until it hits the stopper CAUT...

Page 627: ...20 mL 2000 140 mL X mL Y mL 1300 1600 120 mL X mL Y mL 2000 NOTE Y mL indicates the amount of oil in the refrigerant line the condenser the evaporator etc NOTE When replacing the following parts at the same times as the compressor subtract the rated oil amount of the each part from Y mL and discharge from the new compressor Quantity Evaporator 60 mL Condenser 15 mL Suction hose 10 mL Receiver 10 m...

Page 628: ...ACHMENT Line up the pin hole on the compressor unit with the field core projection and attach AC100630 N N 16 1 N m 10 4 6 7 8 9 5 1 2 AB 3 11 Cooling temperature switch disassembly steps 1 Snap ring 2 Refrigerant temperature switch 3 O ring Magnetic clutch disassembly D Air gap adjustment A C 4 Self locking nut 5 Armature B 6 Snap ring 7 Rotor 8 Snap ring A 9 Field core 10 Shim 11 A C compressor ...

Page 629: ... CAUTION Do not heat more than necessary 1 Dip the metal part of the cooling temperature switch into engine oil and increase the oil temperature using a gas burner or similar 2 When the oil temperature reaches the standard value check that voltage is supplied between the terminals Standard value NOTE When the oil temperature is 150 C or more and there is no continuity the resistance will not be 2Ω...

Page 630: ...harging P 55 72 Air cleaner cover and air flow sensor assembly Removal and Installation Refer to GROUP 15 Air cleaner P 15 3 AC304889 5 6 A C compressor oil SUN PAG 56 Pipe coupling O ring 2 5 10 10 6 7 9 8 10 3 4 1 N N N AB 4 9 0 9 N m Fan shroud assembly removal steps 1 Fan shroud assembly 2 Fan 3 Fan motor 4 Fan shroud Condenser removal steps A 5 Liquid pipe A connection A 6 Flexible discharge ...

Page 631: ...ent the entry of dust or other foreign bodies plug the dismantled hose and condenser assembly nipples INSTALLATION SERVICE POINT A CONDENSER INSTALLATION When replacing the condenser refill it with a specified amount of compressor oil and install it to the vehicle Compressor oil SUN PAG 56 Quantity 15 mL INSPECTION M1552014300961 CONDENSER FAN MOTOR CHECK Check to be sure that the condenser fan mo...

Page 632: ...Grille Removal and Installation Refer to GROUP 51 Front bumper P 51 2 AC304553 1 2 3 4 5 6 7 8 N N N N N 8 8 8 8 High pressure side service valve Low pressure side service valve 4 9 0 9 N m 13 1 N m 4 9 0 9 N m 12 2 N m AB 6 A C compressor oil SUN PAG 56 Pipe coupling O ring O ring 1 2 3 5 6 Removal steps A 1 Dual pressure switch A 2 Liquid pipe A A 3 Flexible discharge hose 4 Expansion valve cove...

Page 633: ...on hose 10 cm3 REMOVAL AND INSTALLATION R H D M1552006400413 Pre removal and Post installation Operation Refrigerant Draining and Refilling Refer to P 55 70 Air Cleaner Removal and Installation Refer to GROUP 15 Air cleaner P 15 3 Radiator Grille Removal and Installation Refer to GROUP 51 Front bumper P 51 2 AC304554 1 2 3 4 5 6 7 8 N 8 N 8 N N 8 8 N 4 9 0 9 N m Low pressure side service valve 13 ...

Page 634: ...bent use a non porous material to plug the hose and nipples To prevent the entry of other foreign bodies plug the condenser compressor and expansion valve nipples INSTALLATION SERVICE POINT A SUCTION HOSE INSTALLATION When replacing the suction hose refill them with a specified amount of compressor oil and then install them Compressor oil SUN PAG 56 Quantity Suction hose 10 cm3 ...

Page 635: ... duct 5 Defroster nozzle 6 Distribution duct Foot duct Removal steps Console cover and Glove box Refer to GROUP 52A Instrument panel P 52A 2 7 Foot duct RH 8 Rear heater duct A RH upper side Under cover Refer to GROUP 52A Instrument panel P 52A 2 9 Foot duct LH Rear heater duct Removal steps Front floor console Refer to GROUP 52A Front floor console assembly P 52A 6 Front seat Refer to GROUP 52A F...

Page 636: ...ILATORS REMOVAL AND INSTALLATION M1553001600318 AC304949 Cross Section A A Cross Section B B 1 1 1 Claw Claw A A B B A A AB AC304951 1 A A B B A A Rear ventilation duct removal steps Rear bumper assembly Refer to GROUP 51 Rear bumper P 51 5 1 Rear ventilation duct ...

Page 637: ...52 1 GROUP 52 INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM SRS CONTENTS INTERIOR 52A SUPPLEMENTAL RESTRAINT SYSTEM SRS 52B ...

Page 638: ...NOTES ...

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Mitsubishi MOTORS Lancer 2004, Workshop Manual

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