Mitsubishi MOTORS Lancer 2005 Workshop Manual Supplement Download Page 1 | Manualshive

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GROUP INDEX

00

General . . . . . . . . . . . . . . . . . . . . . . . .

13

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

LANCER

WORKSHOP MANUAL

SUPPLEMENT

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
PYME0302-B

WORKSHOP MANUAL

CHASSIS GROUP

PWME0302

PWME0302-A
PWME0302-B

BODY REPAIR MANUAL

PBME0302
PBME0302-A
PBME0302-B

PARTS CATALOGUE

B606K006A_

All information, illustrations and product descriptions
contained in this manual are current as at the time of
publication. We, however, reserve the right to make
changes at any time without prior notice or obligation.

©

Mitsubishi Motors Corporation

Oct. 2005

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Summary of Contents for Lancer 2005

Page 1: ...manual as required TECHNICAL INFORMATION MANUAL PYME0302 PYME0302 A PYME0302 B WORKSHOP MANUAL CHASSIS GROUP PWME0302 PWME0302 A PWME0302 B BODY REPAIR MANUAL PBME0302 PBME0302 A PBME0302 B PARTS CATALOGUE B606K006A_ All information illustrations and product descriptions contained in this manual are current as at the time of publication We however reserve the right to make changes at any time with...

Page 2: ...00 1 GROUP 00 GENERAL CONTENTS VEHICLE IDENTIFICATION 00 2 GENERAL DATA AND SPECIFICATIONS 00 3 ...

Page 3: ...ense F4A4B 2WD 4A T MPI MODEL CODE CS 9 W L L N H M 6 AC303950AC 1 2 3 4 5 6 7 8 9 No Item Content 1 Development CS MITSUBISHI LANCER 2 Engine type 9 1 997mL 3 Sort A Passenger car 4 Body style S 4 door sedan 5 Transmission type R 4 speed automatic transmission 6 Trim level H Intense 7 Specification engine feature M MPI DOHC 8 Steering wheel location L Left hand 9 Destination 6 For Europe ...

Page 4: ...ght unladen 8 1 415 Rear track 9 1 470 Vehicle weight kg Kerb weight 1 295 Max gross vehicle weight 1 770 Max axle weight rating front 930 Max axle weight rating rear 840 Max trailer weight With brake 1 000 Without brake 400 Max trailer nose weight 60 Seating capacity 5 Engine Model code 4G63 Total displacement mL 1 997 Maximum output kW r min 99 5 750 Maximum torque N m r min 176 4 500 Transmissi...

Page 5: ...NOTES ...

Page 6: ...Sensor Adjustment 90 Basic Idle Speed Adjustment 91 Fuel Pressure Test 92 Component Location 95 Engine Control Relay Continuity Check 96 Fuel Pump Relay Continuity Check 96 Intake Air Temperature Sensor Check 97 Engine Coolant Temperature Sensor Check 98 Throttle Position Sensor Check 98 Oxygen Sensor Check 99 Injector Check 101 Idle Speed Control ISC Servo Stepper Motor Check 102 Purge Control So...

Page 7: ...MPI 4G63 ï General 13D 2 GENERAL OUTLINE OF CHANGE Following service procedures have been established due to the addition of vehicles with 4G63 MPI engine for Russia ...

Page 8: ...ol in order to obtain the theoretical air fuel mixture ratio that provides the maximum cleaning performance from the three way catalyst IDLE AIR CONTROL The idle speed is kept at the optimum speed by controlling the amount of air that bypasses the throttle valve in accordance with changes in idling conditions and engine load during idling The engine A T ECU drives the idle speed control motor to k...

Page 9: ...dle speed control servo Stepper motor type Engine A T ECU Identification No E6T37983 Sensors Air flow sensor Karman vortex type Barometric pressure sensor Semiconductor type Intake air temperature sensor Thermistor type Engine coolant temperature sensor Thermistor type Oxygen sensor Zirconia type Inhibitor switch Contact switch type Camshaft position sensor Hall element type Crank angle sensor Hal...

Page 10: ...nator FR terminal D Vehicle speed sensor D Engine control relay D Fuel pump relay D A C compressor relay D Ignition coil D Fan controller D Air flow sensor filter reset signal D Engine warning lamp D Diagnosis output D Alternator G terminal D Oxygen sensor front heater D Oxygen sensor rear heater D Tachometer L2 Oxygen sensor rear L3 Air flow sensor L4 Intake air temperature sensor L5 Throttle pos...

Page 11: ...0 30 ï 0 42 Engine coolant temperature sensor resistance k ï20_C 14 ï 17 sensor resistance k 0_C 5 1 ï 6 5 20_C 2 1 ï 2 7 40_C 0 9 ï 1 3 60_C 0 48 ï 0 68 80_C 0 26 ï 0 36 Oxygen sensor output voltage at racing V 0 6 ï 1 0 Oxygen sensor heater resistance at 20_C front 4 5 ï 8 0 resistance at 20_C rear 11 ï 18 Fuel pressure kPa Vacuum hose disconnection 324 ï 343 at kerb idle Vacuum hose connection ...

Page 12: ...6 M U T III sub assembly A Vehicle com munication in terface V C I B M U T III USB cable C M U T III main harness A Vehicles with CAN commu nication system D M U T III main harness B Vehicles with out CAN com munication sys tem E M U T III measurement adapter F M U T III trigger harness M U T III sub assembly D Reading diagnosis code D MPI system inspection D Measurement of fuel pressure MB991348 ...

Page 13: ...t of voltage during Troubleshooting D Adjusting of throttle position sensor MD998464 Test harness 4 pin square D Measurement of voltage during Troubleshooting D Inspection of oxygen sensor front MB991658 Test harness D Measurement of voltage during Troubleshooting D Inspection of oxygen sensor rear B A C D MB991223 A MB991219 B MB991220 C MB991221 D MB991222 Harness set A Test harness B LED harnes...

Page 14: ...rement of fuel pressure MD998742 Hose adaptor MB991637 Fuel pressure gauge set MB991981 Fuel pressure gauge set MB992076 Injector test set Checking the spray condition of injectors MB991607 Injector test harness MD998741 Injector test adaptor MB991976 Injector test holder assembly ...

Page 15: ...s running check the diagnosis code output However the warning lamp will illuminate as bulb check for five seconds whenever the ignition switch is turned to the ON position Engine warning lamp inspection items Engine A T ECU Oxygen sensor front Air flow sensor Intake air temperature sensor Throttle position sensor Engine coolant temperature sensor Crank angle sensor Camshaft position sensor Baromet...

Page 16: ...le position sensor signal and engine speed signal crank angle sensor signal to take reading of the basic injector drive time and basic ignition timing from the pre set mapping 2 Fixes the ISC servo in the appointed position so idle control is not performed Intake air temperature sensor Controls as if the intake air temperature is 25_C Throttle position sensor TPS No increase in fuel injection amou...

Page 17: ...22 23 Camshaft position sensor system 13D 23 24 Vehicle speed signal system 13D 25 25 Barometric pressure sensor system 13D 26 31 Detonation sensor system 13D 28 41 Injector system 13D 29 44 Ignition coil power transistor system 13D 30 54 Immobilizer system 13D 31 59 Oxygen sensor rear system 13D 32 64 Alternator FR terminal system 13D 34 NOTE 1 Do not replace the engine A T ECU until a through te...

Page 18: ...Check the harness between the oxygen sensor front and engine A T ECU NG Repair OK Measure at the B 17 oxygen sensor front connector D Using the test harness MD998464 connect the connector and measure at the pickup harness D Engine After warm up 1 Voltage between terminal No 2 and earth OK Less than 0 5 V 2 Voltage between terminal No 4 and the earth D At rapid deceleration from 4 000 r min OK 200 ...

Page 19: ...ng connectors C 124 C 126 NG Repair OK Check and repair the harness between the oxygen sensor front and engine A T ECU OK Measure at the C 126 engine A T ECU connector D Measure the engine A T ECU terminal voltage D Engine After warm up D Voltage between terminal No 71 and earth D At rapid deceleration from 4 000 r min OK 200 mV or less D During rapid racing OK 600 ï 1 000 mV NG Check the followin...

Page 20: ...r Intermittent Malfunctions OK M U T II III Data list D No 12 Air flow sensor Refer to P 13D 66 NG Replace the engine A T ECU OK Check the harness between the air flow sensor and engine A T ECU NG Repair NG Check the following connector C 124 NG Repair OK Check and repair the harness between the air flow sensor and engine A T ECU NG Repair OK Measure at the B 08 air flow sensor connector D Disconn...

Page 21: ...ngine A T ECU NG Repair OK Measure at the B 08 air flow sensor connector D Using the test harness MB991709 connect the connector and measure at the pickup harness D Voltage between terminal No 7 and earth OK Engine idle 0 ï 1 V Engine 3 000 r min 6 ï 9 V NG Check the following connector C 122 NG Repair OK Replace the air flow sensor OK Check the harness between the air flow sensor and engine A T E...

Page 22: ...ne A T ECU terminal voltage D Disconnect the B 08 air flow sensor connector D Ignition switch ON D Voltage between terminal No 64 and earth OK 4 5 ï 4 9 V OK Check the following connector C 124 OK M U T II III Data list D No 13 Intake air temperature sensor OK Ambient temperature More or less the same as the air temperature NG Replace the engine A T ECU OK Check the harness between the air flow se...

Page 23: ...re 60_C 0 8 ï 1 4 V Ambient temperature 80_C 0 4 ï 1 0 V NG Check the following connectors C 122 C 124 NG Repair From the previous page Code No 14 Throttle position sensor system Probable cause Range of Check D 60 seconds after the ignition switch is set to the ON position or after the completion of start of engine Set Conditions D The sensor output voltage is 4 3 V or more for 4 seconds and volum...

Page 24: ... 5 3 V OK Check the trouble symptoms NG Replace the engine A T ECU OK Check the trouble symptoms NG Replace the engine A T ECU OK Check the harness wire between the throttle position sensor and the engine A T ECU NG Repair NG Check the following connector C 124 NG Repair OK Check the harness wire between the throttle position sensor and the engine A T ECU and repair if necessary NG Repair OK Measu...

Page 25: ...re or D The sensor output voltage is 0 1 V or less for 4 seconds equivalent to 140_C or higher of engine coolant temperature D Malfunction of the engine coolant temperature sensor D Open or short circuit in the engine coolant temperature sensor circuit or loose connector contact D Malfunction of the engine A T ECU Range of Check D Engine After starting Set Condition D The engine coolant temperatur...

Page 26: ...ess D Ignition switch ON D Voltage between terminal 1 and earth OK At 0_C of engine coolant temperature 3 2 ï 3 8 V At 20_C of engine coolant temperature 2 3 ï 2 9 V At 40_C of engine coolant temperature 1 3 ï 1 9 V At 80_C of engine coolant temperature 0 3 ï 0 9 V NG Check the engine coolant temperature sensor Refer to P 13D 98 NG Repair OK Measure at engine coolant temperature sensor connector B...

Page 27: ...nd repair if necessary OK Measure at the crank angle sensor connector B 116 D Disconnect the connector and measure at the harness side 1 The resistance between terminal 1 and earth OK 2 or less 2 The voltage between terminal 2 and earth Ignition switch ON OK 4 9 ï 5 1 V 3 The voltage between terminal 3 and earth Ignition switch ON OK System voltage 1 NG Check the harness between the crank angle se...

Page 28: ...or OK Check the trouble symptoms OK Use an analyzer to measure the output waveform at the crank angle sensor connector B 116 D Use the test harness MD998478 to connect the connector and measure at the pick up harness side D Engine Idling D The voltage between terminal 2 and earth OK A normal waveform should be displayed as described on P 13D 81 Inspection Procedure Using an Ana lyzer Its maximum v...

Page 29: ...connector C 124 D Measure the voltage at the engine A T ECU terminal D Disconnect connector B 107 D Ignition switch ON D The voltage between terminal 56 and earth OK 4 9 ï 5 1 V OK Check the following connector C 124 OK Check the harness wire between the camshaft position sensor connector and the engine control relay and repair if necessary OK Measure at camshaft position sensor connector B 107 D ...

Page 30: ...nds no pulse signal input D Malfunction of the output shaft speed sensor D Open or short circuit in the output shaft speed sensor circuit or loose connector contact D Malfunction of the engine A T ECU NG Replace the engine A T ECU NO Check the trouble symptoms Intermittent malfunction Refer to GROUP 00 ï Points to Note for Intermittent Malfunctions YES D Automatic transmission system check Refer t...

Page 31: ... Repair 2 NG Check the following connector C 122 NG Repair OK Intermittent malfunction Refer to GROUP 00 ï Points to Note for Intermittent Malfunctions OK M U T II III Data list D No 25 Barometric pressure sensor Refer to P 13D 66 NG Replace the engine A T ECU OK Check the harness between the air flow sensor and engine A T ECU NG Repair NG Check the following connector C 124 NG Repair OK Check and...

Page 32: ...lace the air flow sensor OK Check the harness between the air flow sensor and engine A T ECU NG Repair 3 NG Check the following connector C 124 NG Repair OK Check and repair the harness between the air flow sensor and engine A T ECU OK Measure at the B 08 air flow sensor connector D Using the test harness MB991709 connect only connector terminals No 1 No 2 and No 5 and measure at the pickup harnes...

Page 33: ...r circuit or loose connector contact D Malfunction of the engine A T ECU NG Replace the engine A T ECU Check the trouble symptoms NG Replace the detonation sensor OK Check the trouble symptoms OK Intermittent malfunction Refer to GROUP 00 ï Points to Note for Intermittent Malfunctions OK Check the harness wire between the detonation sensor and the engine A T ECU NG Repair OK Check the following co...

Page 34: ...ntermittent malfunction Refer to GROUP 00 ïPoints to Note for Intermittent Malfunctions OK Check the trouble symptoms OK Measure at the engine A T ECU connector C 122 D Disconnect the connector and measure at the harness side D Voltage between 1 2 9 24 and earth Ignition switch ON OK System voltage NG Check the harness wire between the engine A T ECU and the injector connector and repair if necess...

Page 35: ...lace the ignition coil Repair or Replace NG Check the following items in order D Check the spark plug cables spark plugs D Check the compression pressure NG Replace the engine A T ECU OK NG Check the harness wire between the engine A T ECU and ignition coil con nector NG Repair NG OK OK OK Check the trouble symptom Measure at the ignition coil connectors B 104 B 113 D Disconnect the connector and ...

Page 36: ...nction of the engine A T ECU NOTE 1 If the registered ignition keys are close each other when starting the engine radio interference may cause this code to be displayed 2 This code may be displayed when registering the key encrypted code NG Replace the engine A T ECU Check the trouble symptoms NG Replace the immobilizer ECU OK Check the trouble symptoms OK Check the harness wire between the immobi...

Page 37: ...f the oxygen sensor rear D Oxygen sensor rear circuit disconnection short circuit or connector contact defect D Malfunction of the engine A T ECU OK To the next page OK Check the harness between the oxygen sensor rear and engine A T ECU NG Repair NG OK Check the following connector C 126 Repair 2 NG Check the oxygen sensor rear Refer to P 13D 100 NG Replace the oxygen sensor rear OK Check the harn...

Page 38: ...K Check the following connectors C 122 C 124 C 126 NG Repair OK Check and repair the harness between the oxygen sensor rear and engine A T ECU OK Measure at the C 126 engine A T ECU connector D Measure the engine A T ECU terminal voltage D Engine After warm up D Voltage between terminal No 73 and earth D During rapid racing OK 0 and 600 ï 1 000 mV alternate NG Check the following connector C 126 N...

Page 39: ...re at the pick up harness D Engine Idling After warming up D Radiator fan Not operating D The voltage between terminal 4 and earth OK The voltage drops when the headlamps are turned on OK Check the trouble symptoms NG Replace the engine A T ECU OK Check the harness wire between the alternator connector and the engine A T ECU NG Repair NG Check the following connector C 124 NG Repair OK Check the h...

Page 40: ...ility Improper idling Unstable idling Rough idling hunting 8 13D 44 Improper idling Idling speed is high Improper idling speed 9 13D 46 Idling speed is low Improper idling speed 10 13D 46 Idling stability Engine stalls When the engine is cold it stalls at idling Die out 11 13D 47 Engine stalls When the engine is hot it stalls at idling Die out 12 13D 48 The engine stalls when starting the car Pass...

Page 41: ... stall Pass out The engine stalls when the accelerator pedal is depressed or while it is being used Driving Hesitation Sag Hesitation is the delay in response of the vehicle speed engine speed that occurs when the accelerator is depressed in order to accelerate from the speed at which the vehicle is now traveling or a temporary drop in vehicle speed engine speed during such acceleration Serious he...

Page 42: ...hen the engine is cold it stalls at idling Die out 13D 47 12 When the engine is hot it stalls at idling Die out 13D 48 13 The engine stalls when starting the car Pass out 13D 50 14 The engine stalls when decelerating 13D 50 15 Hesitation sag or stumble 13D 51 16 The feeling of impact or vibration when accelerating 13D 52 17 The feeling of impact or vibration when decelerating 13D 52 18 Poor accele...

Page 43: ...ction procedure No Reference page Trouble symptom 31 A C switch and A C relay system 13D 63 32 Idle speed control ISC servo Stepper motor system 13D 64 33 Purge control solenoid valve system 13D 65 34 EGR control solenoid valve system 13D 65 ...

Page 44: ... 5 and earth OK Continuity NG OK Replace the M U T II III Check the harness wire between the diagnosticconnector 16 pin andearth and repair if necessary INSPECTION PROCEDURE 2 M U T II III communication with engine A T ECU is impossible Probable cause One of the following causes may be suspected D No power supply to engine A T ECU D Defective earth circuit of engine A T ECU D Defective engine A T ...

Page 45: ...ion meter connector C 04 D Disconnect the connector and measure at the harness side D Voltage between 9 and earth Ignition switch ON OK System voltage NG Check the engine warning lamp power supply circuit and repair if necessary OK Check the following connectors C 13 C 122 NG Repair OK Check the trouble symptom NG Checktheharnesswirebetweencombinationmeterandengine A T ECU and repair if necessary ...

Page 46: ...bilizer system NO M U T II III Data list 16 Engine A T ECU power supply voltage Refer to P 13D 66 NG Check the power supply system and ignition switch IG system Refer to P 13D 59 INSPECTION PROCEDURE 27 OK Does the camshaft rotate at the engine cranking When oil filler cap is removed NO Check timing belt for breakage YES M U T II III Self Diag code Are diagnosis codes displayed YES Refer to P 13D ...

Page 47: ...y OK Is starting good if the engine is cranked with the accelerator pedal slightly depressed YES Check ISC servo for operation sound Refer to P 13D 102 NG Check the ISC servo sys tem Refer to P 13D 64 INSPECTION PROCE DURE 32 OK Can any sound be heard from the injectors when cranking NG Check theinjectorsystem RefertoP 13D 29 INSPECTIONPRO CEDURE FOR DIAGNOSIS CODE 41 OK M U T II III Data list 18 ...

Page 48: ...ming when cranking OK Approx 5_BTDC NG Check that the crank angle sensor is installed properly OK Check the following items D Check the ignition coil spark plugs spark plug cables D Check if the injectors are clogged D Check the compression pressure D Check if foreign materials water alcohol etc got into fuel OK M U T II III Self Diag code Are diagnosis codes displayed YES Refer to P 13D 12 INSPEC...

Page 49: ...OSIS CODE 21 OK M U T II III Data list 25 Barometric pressure sensor Refer to P 13D 66 NG Check the intake air temperature sensor system RefertoP 13D 16 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 13 OK M U T II III Data list 14 Throttle position sensor Refer to P 13D 66 NG Check the throttle position sensor system Refer to P 13D 18 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14 NG Inspect the intake of air ...

Page 50: ...luid pressure switch Refer to P 13D 66 NG Check the powersteering fluid pressure switch sys tem Refer to P 13D 63 INSPECTION PROCE DURE 30 OK M U T II III Data list 11 Oxygen sensor front OK Changesbetween0 ï400 mV and 600 ï1 000 mV during idling NG Check the fuel pressure Refer to P 13D 92 OK 1 Inspect the intake of air into the air intake system D Broken intake man ifold gasket D Broken vacuum h...

Page 51: ...the A C switch and A C relay system Refer to P 13D 63 INSPECTION PROCEDURE 31 OK Basic idle speed adjustment Refer to P 13D 91 Check the trouble symptom NG Clean the throttle valve area Refer to P 13D 90 INSPECTION PROCEDURE 10 Idling speed is low Improper idling speed Probable cause In cases such as the above the cause is probably that the intake air volume during idling is too small D Malfunctio...

Page 52: ...heck the ISC servo for operation sound Refer to P 13D 102 NG Check the ISC servo system Refer to P 13D 64 INSPECTION PROCEDURE 32 OK Check the injector for operation sound NG Check theinjectorsystem RefertoP 13D 29 INSPECTIONPRO CEDURE FOR DIAGNOSIS CODE 41 OK M U T II III Data list 14 Throttle position sensor Refer to P 13D 66 NG Check the throttle position sensor system Refer to P 13D 18 INSPECT...

Page 53: ...CODE 21 OK M U T II III Data list 13 Intake air temperature sensor Refer to P 13D 66 NG Check the intake air temperature sensor system RefertoP 13D 16 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 13 YES M U T II III Data list 14 Throttle position sensor Refer to P 13D 66 NG Check the throttle position sensor system Refer to P 13D 18 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14 NO Does the engine stall easil...

Page 54: ...K M U T II III Data list 28 A C switch Refer to P 13D 66 NG Check the A C switch and A C relay system Refer to P 13D 63 INSPECTION PROCEDURE 31 OK M U T II III Data list 27 Power steering fluid pressure switch Refer to P 13D 66 NG Check the powersteering fluid pressure switch sys tem Refer to P 13D 63 INSPECTION PROCE DURE 30 OK M U T II III Data list 11 Oxygen sensor front OK Changesbetween0 ï400...

Page 55: ...elerating Probable cause Incasessuchastheabove thecauseisprobablythattheintakeairvolumeisinsufficient due to a defective idle speed control ISC servo system D Malfunction of the ISC system Were the battery terminals disconnected YES After warming up let the engine run at idling for 10 minutes NO M U T II III Self Diag code Are diagnosis codes displayed YES Refer to P 13D 12 INSPECTION CHART FOR DI...

Page 56: ...lve system Refer to P 13D 65 INSPECTION PROCEDURE 34 OK M U T II III Data list 14 Throttle position sensor Refer to P 13D 66 NG Check the throttle position sensor system Refer to P 13D 18 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14 OK M U T II III Data list 21 Engine coolant temperature sensor Refer to P 13D 66 NG Check the engine coolant temperature sensor system RefertoP 13D 20 INSPECTIONPROCEDUR...

Page 57: ...e is an ignition leak accompanying the increase in the spark plug demand voltage during acceleration D Malfunction of the ignition system M U T II III Self Diag code Are diagnosis codes displayed YES Refer to P 13D 12 INSPECTION CHART FOR DIAGNOSIS CODES NO Check the following items D Check the ignition coil spark plugs spark plug cables D Check for occurrence of ignition leak INSPECTION PROCEDURE...

Page 58: ... 13D 66 NG Check the throttle position sensor system Refer to P 13D 18 INSPECTION PROCEDURE FOR DIAGNOSIS CODE 14 OK M U T II III Data list 21 Engine coolant temperature sensor Refer to P 13D 66 NG Check the engine coolant temperature sensor system RefertoP 13D 20 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 21 OK M U T II III Data list 13 Intake air temperature sensor Refer to P 13D 66 NG Check the intak...

Page 59: ...e system OK To the next page OK M U T II III Actuator test 10 EGR control solenoid valve Refer to P 13D 70 NG Check the EGR control solenoid valve system Refer to P 13D 65 INSPECTION PROCEDURE 34 OK M U T II III Data list 14 Throttle position sensor Refer to P 13D 66 NG Check the throttle position sensor system RefertoP 13D 18 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 14 OK M U T II III Data list 21 En...

Page 60: ...G Check the oxygen sensor rear system RefertoP 13D 32 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 59 OK From the previous page INSPECTION PROCEDURE 20 Knocking Probable cause In cases as the above the cause is probably that the detonation control is defective or the heat value of the spark plug is inappropriate D Inappropriate heat value of the spark plug D Defective detonation sensor Check the following...

Page 61: ...ODE 11 OK M U T II III Data list 11 Oxygen sensor front OK 600 ï 1 000 mV when racing suddenly NG Check the oxygen sensor rear system RefertoP 13D 32 INSPECTIONPROCEDUREFORDIAGNOSIS CODE 59 OK M U T II III Data list 59 Oxygen sensor rear D Transmission D range D Driving with throttle widely open OK 600 ï 1 000 mV NG Check the intake air temperature sensor system RefertoP 13D 16 INSPECTIONPROCEDURE...

Page 62: ...uity NG Check the harness wire between the alternatorandtheengine A T ECUcon nector and repair if necessary INSPECTION PROCEDURE 24 Idling speed is improper when A C is operating Probable cause If the engine A T ECU detects that the air conditioner is on it activates the idle speed control ISC servo to control idle up operation The automatic compressor ECU judges if the load caused by air conditio...

Page 63: ...I III Data list 21 Engine coolant temperature sensor OK After the engine has been warmed up the engine coolant temperature during idling is identical to the M U T II III read ing NG Check the engine coolant temperature sensor system Refer to P 13D 20 INSPECTION PROCEDURE FOR DIAGNOSIS DODE 21 OK Check the thermostat NG Replace OK Replace the engine A T ECU NG Repair NG Repair Measure at the engine...

Page 64: ... and repair if necessary 5 NG OK Check the following connectors C 124 C 126 NG Repair OK Check the trouble symptom NG Replace the engine A T ECU Check the harness wire between engine A T ECU and battery and repair if necessary INSPECTION PROCEDURE 27 Power supply system and ignition switch IG system Probable cause Whenan ignition switch ON signal is input to the engine A T ECU the engine A T ECU t...

Page 65: ...re at the harness side D Ignition switch ON 1 Voltage of terminal No 1 ï earth OK System voltage 2 Voltage of terminal No 3 ï earth OK System voltage Check and repair harness from fuel pump relay 1 to earth OK 3 NG Check the following connector C 212 NG Repair Check and repair harness from fuel pump relay 1 to battery OK 2 NG Check the following connectors C 209 C 27 NG Repair OK Check ignitionswi...

Page 66: ...gnition switch ON OK System voltage 2 Continuity of terminal No 4 ï earth OK Continuity NG Replace the engine A T ECU OK Check the trouble symptom OK Check the following connector C 122 NG Repair OK Measure at connector C 122 of engine A T ECU D Disconnect the connector to measure at the harness side D Terminal No 21 ï earth short circuit D Ignition switch ON OK Fuel pump is operated operating noi...

Page 67: ... A T ECU and repair if necessary OK Check the trouble symptom NG Check the following connector B 20 NG Repair OK Measure at the engine A T ECU con nector C 124 D Disconnect the connector and measure at the harness side D Voltage between 58 and earth Selector lever P or N range Ignition switch START OK System voltage NG Repair OK Check the ignition switch Refer to GROUP 54 ï Ignition Switch and Imm...

Page 68: ...epair OK Replace the engine A T ECU OK Check the following connector B 115 NG Repair OK Check the trouble symptom NG Replace the engine A T ECU INSPECTION PROCEDURE 31 A C switch and A C relay system Probable cause When an A C ON signal is input to the engine A T ECU the engine A T ECU carries out control of the idle speed control ISC servo and also operates the A C compressor magnetic clutch D Ma...

Page 69: ...ct the connector and measure at the harness side D Voltage between 2 and earth and 5 and earth Ignition switch ON OK System voltage NG Check the harness wire between control relay and ISC servo con nector and repair if necessary OK Measure at the engine A T ECU connector C 122 D Disconnect the connector measure at the harness side D Voltage between each of 14 15 28 29 and earth Ignition switch ON ...

Page 70: ...ir if necessary OK Checkthe following connector C 122 NG Repair OK Check the trouble symptom NG Replace the engine A T ECU INSPECTION PROCEDURE 34 EGR control solenoid valve system Probable cause The EGR control solenoid valve is controlled by the negative pressure resulting from EGR operation leaking to port A of the throttle body D Malfunction of the solenoid valve D Improper connector contact o...

Page 71: ...ure is made leaner when de When at 4 000 r min engine is suddenly decelerated 200 mV or less Code No 11 13D 13 made leaner when de celerating and is made richer when racing When engine is suddenly raced 600ï1 000 mV Engine After having warmed up The oxygen sensor signal is used to check the air fuel mixture Engine is idling 400 mV or less Changes 600ï1 000 mV the air fuel mixture ratio and control...

Page 72: ...sor Ignition switch ON or with engine running When engine coolant temperature is ï20_C ï20_C Code No 21 13D 20 sensor When engine coolant temperature is 0_C 0_C When engine coolant temperature is 20_C 20_C When engine coolant temperature is 40_C 40_C When engine coolant temperature is 80_C 80_C 22 Crank angle sensor D Engine Cranking D Tachometer Connected Compare the engine speed readings on the ...

Page 73: ...olumetric efficiency D Engine coolant temperature Engine is idling 20 ï 30 ï ï efficiency temperature 85ï95_C D Lamps and all i OFF 2 500 r min 20 ï 30 p accessories OFF D Transmission P range When engine is suddenly raced Increases 41 Injectors 2 Engine Cranking When engine coolant temperature is 0_C injection is carried out for all cylinders simultaneously 14 7 22 1 ms ï ï When engine coolant te...

Page 74: ... Transmission P A C switch OFF o ON Increases by 10ï70 steps P range D Engine Idling D When A C switch is ON A C compressor should be operating D A C switch OFF D Select lever N range o D range Increases by 5ï50 steps 49 A C relay Engine After having warmed up Engine is idling A C switch OFF OFF Compressor clutch is not operating Procedure No 31 13D 63 A C switch ON ON Compressor clutch is operati...

Page 75: ...driving Inspect according Pinch the return hose with fingers to feel the pulse of the fuel being recirculated Pulse is felt Procedure No 28 13D 60 according to both the above condi tions Listen near the fuel tank for the sound of fuel pump operation Sound of operation is heard 08 Purge control solenoid valve Solenoid valve turns from OFF to ON Ignition switch ON Sound of op eration can be heard wh...

Page 76: ... may find it convenient to pull out the engine A T ECU to make it easier to reach the connector terminals 3 The checks can be carried out off the order given in the chart Caution Short circuiting the positive probe between a connector terminal and earth could damage the vehicle wiring the sensor engine A T ECU or all of them Be careful to prevent this 3 If voltmeter shows any division from standar...

Page 77: ...y depress the accelerator pedal From system voltage momentaly drops 8 Alternator G termi nal D Engine Warm idle radiator fan OFF D Headlamp OFF o ON D Stop lamp OFF o ON D Rear defogger switch OFF o ON Voltage increases by 0 2 ï 3 5 V 11 Ignition coil ï No 1 No 4 Engine r min 3 000 r min 0 3 ï 3 0 V 12 Ignition coil ï No 2 12 Ignition coil No 2 No 3 14 Stepper motor coil A D Engine Soon after the ...

Page 78: ...Ignition switch ON System voltage 41 Power supply Ignition switch ON System voltage 47 43 Tachometer signal Engine r min 3 000 r min 0 3 ï 3 0 V 44 Engine coolant temperature sen sor Ignition switch ON When engine coolant temperature is ï20_C 3 9 ï 4 5 V sor When engine coolant temperature is 0_C 3 2 ï 3 8 V When engine coolant temperature is 20_C 2 3 ï 2 9 V When engine coolant temperature is 40_...

Page 79: ...omatic compressor ï ECU terminal 64 Intake air temperature sensor Ignition switch ON When intake air tem perature is ï20_C 3 8 ï 4 4 V sensor When intake air temperature is 0_C 3 2 ï 3 8 V When intake air temperature is 20_C 2 3 ï 2 9 V When intake air temperature is 40_C 1 5 ï 2 1 V When intake air temperature is 60_C 0 8 ï 1 4 V When intake air temperature is 80_C 0 4 ï 1 0 V 65 Air flow sensor ...

Page 80: ...mal condition Check condition Engine condition Check item 83 A C switch Engine Idle speed Turn the A C switch OFF 0 5 V or less Turn the A C switch ON A C compressor is operating System voltage 98 Ignition switch ï IG Ignition switch ON System voltage ...

Page 81: ...sure should be used instead of inserting a test probe 2 Checking need not be carried out in the order given in the chart Caution If the terminals that should be checked are mistaken or if connector terminals are not correctly shorted to earth damage may be caused to the vehicle wiring sensors engine A T ECU and or ohmmeter Be careful to prevent this 4 If the ohmmeter shows any deviation from the s...

Page 82: ... A 28 ï 33 At 20_C 28 ï 41 Stepper motor coil B 15 ï 41 Stepper motor coil C 29 ï 41 Stepper motor coil D 26 ï 41 Oxygen sensor rear heater 11 ï 18 At 20_C 34 ï 41 Purge control solenoid valve 29 ï 35 At 20_C 42 ï Body earth Engine A T ECU earth Continuity 0 48 ï Body earth 44 ï 57 Engine coolant temperature sensor 14 ï 17 k When coolant temperature is ï20_C 5 1 ï 6 5 k When coolant temperature is...

Page 83: ...air temperature sensor 13 ï 17 k When intake air temperature is ï20_C 5 3 ï 6 7 k When intake air temperature is 0_C 2 3 ï 3 0 k When intake air temperature is 20_C 1 0 ï 1 5 k When intake air temperature is 40_C 0 56 ï 0 76 k When intake air temperature is 60_C 0 30 ï 0 42 k When intake air temperature is 80_C ...

Page 84: ...w sensor connector and connect the special tool test harness MB991709 in between All terminals should be connected 2 Connect the oscilloscope special patterns pickup to air flow sensor connector terminal No 3 Alternate Method Test harness not available 1 Connect the oscilloscope special patterns pickup to engine A T ECU terminal No 65 Standard Wave Pattern Observation conditions Function Special p...

Page 85: ...the amount of intake air increases Times T1 and T2 are equal Time T T1 T2 Observation conditions from conditions above engine speed is increased by racing Time V 10 0 T Wave Pattern Observation Points Check that cycle time T becomes shorter and the frequency increases when the engine speed is increased ...

Page 86: ...sor connector and connect the special tool test harness MB991709 in between All terminals should be connected 2 Connect the oscilloscope special pattern pickup to camshaft position sensor terminal No 2 3 Disconnect the crank angle sensor connector and connect the special tool test harness MD998478 in between 4 Connect the oscilloscope special patterns pickup to crank angle sensor terminal No 2 Alt...

Page 87: ...ttern Crank angle sensor output wave pattern V 75_BTDC 2 engine revolutions 1camshaftrevolution 5_BTDC The time cycle time T is reduced when the engine speed increases 0 Camshaft position sensor output wave pattern TDC Top dead centre T No 1 TDC No 3 TDC No 4 TDC No 2 TDC Time 0 Wave Pattern Observation Points Check that cycle time T becomes shorter when the engine speed increases ...

Page 88: ...t MB991348 in between All terminals should be connected 2 Connect the oscilloscope special patterns pickup to terminal No 2 of the injector connector Alternate Method Test harness not available 1 Connect the oscilloscope special patterns pickup to engine A T ECU terminal No 1 When checking the No 1 cylinder 2 Connect the oscilloscope special patterns pickup to engine A T ECU terminal No 9 When che...

Page 89: ...ive signal ON Drive signal OFF Time 50 0 Wave Pattern Observation Points Point A Height of solenoid back electromotive force Contrast with standard wave pattern Probable cause Solenoid coil back electromotive force is low or doesn t appear at all Short in the injector solenoid Point B Injector drive time D The injector drive time will be synchronized with the M U T II III tester display D When the...

Page 90: ...nect the oscilloscope special patterns pickup to engine A T ECU terminal No 14 connection terminal No 15 connection terminal No 28 and connection terminal No 29 respectively Standard wave pattern Observation conditions Function Special patterns Pattern height High Pattern selector Display Engine condition When the engine coolant temperature is 20 C or below turn the ignition switch from LOCK OFF p...

Page 91: ...ck that the standard wave pattern appears when the stepper motor is operating Point A Presence or absence of induced electromotive force from the motor turning Refer to the abnormal wave pattern Contrast with standard wave pattern Probable cause Induced electromotive force does not appear or is extremely small Motor is malfunctioning Point B Height of coil reverse electromotive force Contrast with...

Page 92: ...he motor turning does not appear D Example 2 Cause of problem Open circuit in the line between the stepper motor and the engine A T ECU Wave pattern characteristics Current is not supplied to the motor coil on the open circuit side Voltage does not drop to 0 V Furthermore the induced electromotive force waveform at the normal side is slightly different from the normal waveform Open circuit side No...

Page 93: ...rns pickup to engine A T ECU terminal No 11 No 1 ï No 4 connection terminal No 12 No 2 ï No 3 respectively Standard Wave Pattern Observation condition Function Special patterns Pattern height Low Pattern selector Display Engine r min Approximately 1 200 r min Standard wave pattern Crank angle sensor output wave pattern Power transistor control signal wave pattern V 75_BTDC 5_BTDC T Revolution time...

Page 94: ...ion primary circuit Rectangular wave at power voltage Power transistor malfunction Examples of Abnormal Wave Patterns D Example 1 Wave pattern during engine cranking Cause of problem Open circuit in ignition primary circuit Wave pattern characteristics Topïright part of the buildïup section cannot be seen and voltage value is approximately 2 V too low D Example 2 Wave pattern during engine crankin...

Page 95: ...THROTTLE POSITION SENSOR ADJUSTMENT 1 Connect the M U T II III to the diagnosis connector When not using the M U T II III proceed as follows 1 Disconnect the throttle position sensor connector and connect the special tool test harness MB991536 between the disconnected connector taking care not to confuse the terminal to be connected 2 Connect digital voltmeter between the terminal No 2 special too...

Page 96: ...ng screw SAS by the manufacturer and there should usually be no need for readjustment D If the adjustment has been changed by mistake the idle speed may become too high or the idle speed may drop too low when loads from components such as the A C are placed on the engine If this occurs adjust by the following procedure D The adjustment if made should be made after first confirming that the spark p...

Page 97: ...ess the ISC servo is released the actuator test mode will continue 27 minutes 8 Turn the ignition switch to LOCK OFF position 9 Disconnect the M U T II III 10 Start the engine again and let it run at idle speed for about 10 minutes check that the idling condition is normal FUEL PRESSURE TEST 1 Release residual pressure from the fuel pipe line to prevent fuel gush out Caution Cover the hose connect...

Page 98: ...elect Item No 07 from the M U T II III actuator test to drive the fuel pump Check that there are no fuel leaks from any parts 8 Finish the actuator test or turn the ignition switch to LOCK OFF position 9 Start the engine and run at idle 10 Fuel pressure measurement while the engine is running at idle Standard value Approximately 265 kPa at kerb idle 11 Disconnect the vacuum hose from the fuel pres...

Page 99: ... and check change of fuel pressure gauge reading Normal if the reading does not drop within 2 minutes If it does observe the rate of drop and troubleshoot and repair according to the table below Symptom Probable cause Remedy Fuel pressure drops gradually after engine is stopped Leaky injector Replace injector engine is stopped Leaky fuel regulator valve seat Replace fuel pressure regulator Fuel pr...

Page 100: ...elay 1 and 2 R A C switch U Idle speed control servo E Camshaft position sensor O Ignition coil L Crank angle sensor B Injector C Detonation sensor J Oxygen sensor front K Diagnosis connector T Oxygen sensor rear Q EGR control solenoid valve I Power steering fluid pressure switch A Engine control relay H Purge control solenoid valve I Engine coolant temperature sensor N Throttle position sensor D ...

Page 101: ...of battery to terminal No 3 Continuity FUEL PUMP RELAY CONTINUITY CHECK Tester Connection Terminal Battery Voltage Normal State 1 ï 4 No Voltage Continuity 2 ï 3 No Voltage No continuity Voltage Connect positive terminal of battery to termi nal No 1 and nega tive ï terminal of battery to terminal No 4 Continuity Engine control relay Equipment side connector Relay box s triangle marks Equipment sid...

Page 102: ...k at 60_C 0 30 ï 0 42 k at 80_C 3 Remove the air flow sensor 4 Measure resistance while heating the sensor using a hair drier Normal condition Temperature _C Resistance k Higher Smaller 5 If the value deviates from the standard value or the resistance remains unchanged replace the air flow sensor assembly 6 Install the air flow sensor and tighten it to the specified torque Tightening torque 8 8 r ...

Page 103: ...t temperature sensor and tighten it to the specified torque Tightening torque 29 r 10 N m THROTTLE POSITION SENSOR CHECK 1 Disconnect the throttle position sensor connector 2 Measure the resistance between the throttle position sensor side connector terminal No 1 and terminal No 4 Standard value 3 5 ï 6 5 k 3 Measure the resistance between the throttle position sensor side connector terminal No 2 ...

Page 104: ...u make the air fuel ratio rich by racing the engine repeatedly a normal oxy gen sensor will output a voltage of 0 6 ï 1 0 V Caution D Be very careful when connecting the jumper wire incorrect connection can damage the oxygen sensor D Be careful the heater is broken when voltage of beyond 8V is applied to the oxygen sensor heater NOTE If the sufficiently high temperature of approximate 400 C or mor...

Page 105: ...ich by racing the engine repeatedly a normal oxy gen sensor will output a voltage of 0 6 ï 1 0 V Caution D Be very careful when connecting the jumper wire incorrect connection can damage the oxygen sensor D Be careful the heater is broken when voltage of beyond 12 V is applied to the oxygen sensor heater NOTE If the sufficiently high temperature of approximately 400 C or more is not reached althou...

Page 106: ... between terminals Standard value 10 5 ï 13 5 at 20_C 3 Connect the injector connector Check the Injection Condition 1 Following the steps below bleed out the residual pressure within the fuel pipe line to prevent flow of the fuel 2 Remove the injector 3 Assemble the following special tools as shown in Fig D Injector test set MB992076 D Injector test harness MB991607 D Injector test adaptor MD9987...

Page 107: ...RVO STEPPER MOTOR CHECK Check the Operation Sound 1 Check that the engine coolant temperature is 20 C or below NOTE Disconnecting the engine coolant temperature sensor connector and connecting the harness side of the connector to another engine coolant temperature sensor that is at 20 C or below is also okay 2 Check that the operation sound of the stepper motor can be heard after the ignition is t...

Page 108: ...e terminals No 2 and No 5 5 With the idle speed control servo as shown in the illustration connect the negative ï terminal of the power supply to each clip as described in the following steps and check whether or not a vibrating feeling a feeling of very slight vibration of the stepper motor is generated as a result of the activation of the stepper motor 1 Connect the negative ï terminal of the po...

Page 109: ...MPI 4G63 ï On vehicle Service 13D 104 PURGE CONTROL SOLENOID VALVE CHECK Refer to GROUP 17 ï Emission Control System EGR CONTROL SOLENOID VALVE CHECK Refer to GROUP 17 ï Emission Control System ...

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